Engine Mechanical (H6DO - 3.6L DOHC): Diagnosis Subaru Outback BR

INSPECTION

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1. Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. Lift up the rear side holding two positions (A). Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.
2. After warming-up the engine, turn the ignition switch to OFF.
3. Make sure that the battery is fully charged.
4. Remove the fuse of fuel pump from main fuse box.
5. Start the engine and run it until it stalls.
6. After the engine stalls, crank it for five more seconds.
7. Turn the ignition switch to OFF.
8. Remove all spark plugs. Ref. to «REMOVAL»(ref-371887-S28029716962010091900000) , Spark Plug.
9. Fully open the throttle valve.
10. Check the starter motor for satisfactory performance and operation.
11. Secure the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long.
12. Crank the engine by the starter motor, and read the maximum value on the gauge when the needle of gauge is steady. NOTE: Perform at least two measurements per cylinder, and make sure that the values are correct. If the compression pressure is out of standard, check or adjust the pistons, valves and cylinders. Compression (350 RPM and fully open throttle): Standard 1,275 - 7,477 kPa (13.0 - 15.0 kgf/cm 2 , 185 - 213 psi) Service limit 1,128 kPa (11.5 kgf/cm 2 , 164 psi) Difference between cylinders 49 kPa (0.5 kgf/cm 2 , 7 psi) or less
13. After inspection, install the related parts in the reverse order of removal.

1. Before checking the idle speed, check the following item: Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm up the engine.
3. Read the engine idle speed using Subaru Select Monitor. Ref. to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-371924-S22277518732010091900000) , OPERATION, Subaru Select Monitor. NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If idle speed is out of standard, refer to the General Diagnosis Table under "Engine Control System". Ref. to «BASIC DIAGNOSTIC PROCEDURE»(ref-371924-S17215283042010091900000) . Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF) Idle speed (No load and gears in "P" or "N" range): Standard 700±100 RPM Check the idle speed when loaded. (Turn the A/C switch to "ON" and operate the compressor for at least one minute before measurement.) Idle speed (A/C ON and gear in "P" or "N" range): Standard 700 - 910±100 RPM

Scheme 227

1. METHOD WITH SUBARU SELECT MONITOR Before checking the ignition timing, check the following item: Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate. Warm up the engine. Read the ignition timing using Subaru Select Monitor. Ref. to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-371924-S22277518732010091900000) , OPERATION, Subaru Select Monitor. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to "Engine Control System". Ref. to «BASIC DIAGNOSTIC PROCEDURE»(ref-371924-S17215283042010091900000) . Ignition timing [BTDC/RPM]: Standard 15°±8°/700
2. METHOD WITH TIMING LIGHT Before checking the ignition timing, check the following item: Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate. Warm up the engine. Stop the engine, and turn the ignition switch to OFF. Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. Lift up the rear side holding two positions (A). Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle. Disconnect the ground cable from battery. Remove the air intake duct. Ref. to «REMOVAL»(ref-371896-S20541353172010091900000) , Air Intake Duct. Disconnect the connector from mass air flow and intake air temperature sensor. Remove the air cleaner case and element. Connect the timing light to the power wire of #1 ignition coil. Install the connectors of air cleaner case, element, and the mass air flow and intake air temperature sensor. Connect the ground cable to battery. Start the engine, turn the timing light to the crank pulley, and check the ignition timing through the chain cover gauge. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to "Engine Control System". Ref. to «BASIC DIAGNOSTIC PROCEDURE»(ref-371924-S17215283042010091900000) . Ignition timing [BTDC/RPM]: Standard 15°±8°/700 After inspection, install the related parts in the reverse order of removal.

Scheme 228

1. Warm up the engine.
2. Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. Lift up the rear side holding two positions (A). Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.
3. Remove the air intake boot. Ref. to «REMOVAL»(ref-371896-S05520593882010091900000) , Air Intake Boot.
4. Disconnect the brake booster vacuum hose from the intake manifold, and attach the vacuum gauge.
5. Install the air intake boot. Ref. to «INSTALLATION»(ref-371896-S02881003482010091900000) , Air Intake Boot.
6. Keep the engine at idle speed and read the vacuum gauge indication. NOTE: Condition of engine inside can be diagnosed by observing the behavior of the vacuum gauge needle as described in table below. Intake manifold vacuum (at idling, A/C OFF): Standard Less than -60.0 kPa (-450 mmHg, -17.72 inHg) INTAKE MANIFOLD VACUUM SPECIFICATION CHART Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than standard value. This tendency becomes more evident as engine temperature rises. Leakage around intake manifold gasket, disconnection or damage of vacuum hose 2. Needle intermittently drops to position lower than standard value. Leakage around cylinder 3. Needle drops suddenly and intermittently from standard value. Sticky valve 4. When engine speed is gradually increased, needle begins to vibrate rapidly at certain speed, and then vibration increases as engine speed increases. Weak or broken valve springs 5. Needle vibrates above and below standard value in narrow range. Defective ignition system

1. Disconnect the ground cable from battery.
2. Remove the oil pressure switch from the oil pan upper. Ref. to «REMOVAL»(ref-371884-S00655437822010091900000) , Oil Pressure Switch.
3. Attach the oil pressure gauge to the oil pan upper.
4. Connect the ground cable to battery.
5. Start the engine, and measure the oil pressure. NOTE: If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. Ref. to «ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL»(ref-371884-S01746844972010091900000) . If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. Ref. to «OIL PRESSURE SYSTEM»(ref-371884-S05165488452010091900000) . Ref. to «OIL PRESSURE SWITCH»(ref-371884-S06721534032010091900000) . Engine oil pressure (at oil temperature of 80°C (176°F)): Standard 100 kPa (1.0 kgf/cm 2 , 15 psi) or more (at 700 RPM) 500 kPa (5.1 kgf/cm 2 , 73 psi) or more (at 5,000 RPM)
6. After inspection, install the related parts in the reverse order of removal.

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1. Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. Lift up the rear side holding two positions (A). Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.
2. Release the fuel pressure. Ref. to «RELEASING OF FUEL PRESSURE»(ref-371893-S25881329662010091900000) , PROCEDURE, Fuel.
3. Open the fuel filler lid and remove the fuel filler cap.
4. Disconnect the fuel delivery hose from the fuel damper, and connect the fuel pressure gauge.
5. Start the engine.
6. Measure the fuel pressure after warming up the engine. NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm 2 , 1 to 3 psi) higher than standard values during high-altitude operations. Check or replace the fuel pump and fuel delivery line if the fuel pressure is out of the standard. Fuel pressure: Standard 338 - 348 kPa (3.4 - 3.5 kgf/cm 2 , 49 - 50.5 psi)
7. After inspection, install the related parts in the reverse order of removal.

Note. Inspection of valve clearance should be performed while engine is cold.

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1. Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. Lift up the rear side holding two positions (A). Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.
2. Disconnect the ground cable from battery.
3. Lift up the vehicle.
4. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
5. Lower the vehicle.
6. When inspecting #1, #3 and #5 cylinders Remove the air intake duct, air cleaner case and air intake boot assembly. Ref. to «REMOVAL»(ref-371896-S20541353172010091900000) , Air Intake Duct. Ref. to «REMOVAL»(ref-371896-S07012520272010091900000) , Air Cleaner Case. Ref. to «REMOVAL»(ref-371896-S05520593882010091900000) , Air Intake Boot. Remove the fuel pipe protector (RH). Disconnect the connector of oil pressure switch. Remove the ignition coil. Ref. to «REMOVAL»(ref-371887-S12927384972010091900000) , Ignition Coil. Remove the rocker cover (RH). Ref. to «REMOVAL»(ref-371890-S04918135372010091900000) , Camshaft.
7. When inspecting #2, #4 and #6 cylinders Disconnect the battery cable, and then remove the battery and battery carrier. Ref. to «REMOVAL»(ref-371915-S38323050542010091900000) , Battery. Remove two fixing clips on the fuel pipe protector (LH). Generator connector Generator terminal B Remove the harness cover from collector cover bracket. A/C compressor solenoid connector Flow sensor connector Slide the harness and connector to the battery side. Disconnect the PCV hose and blow-by hose from the rocker cover (LH). Remove the fuel pipe protector (LH). Remove the ignition coil. Ref. to «REMOVAL»(ref-371887-S12927384972010091900000) , Ignition Coil. Remove the rocker cover (LH). Ref. to «REMOVAL»(ref-371890-S04918135372010091900000) , Camshaft.
8. Turn the crankshaft clockwise until the camshaft is set to position shown in the figure.
9. Measure the clearance of intake valve and exhaust valve using thickness gauge (A). NOTE: Measure it within the range of ±30° from specified position shown in the figure. Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter. Valve clearance (inspection value): Intake 0.20 +0.04 -0.06 mm (0.0079 +0.0016 -0.0024 in) Exhaust 0.35±0.05 mm (0.0138±0.0020 in) If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.
10. If necessary, adjust the valve clearance. Ref. to «ADJUSTMENT»(ref-371890-S42196502612010091900000) , Valve Clearance.
11. Further turn the crank pulley clockwise and then measure the valve clearances again.
12. After inspection, install the related parts in the reverse order of removal. Ref. to «INSTALLATION»(ref-371890-S15615319062010091900000) , Camshaft.

1. Check that the pipes, hoses, connectors and clips are securely connected.
2. Check that the engine coolant is up to specified level.
3. Check that the ATF is up to specified level.
4. Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.

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1. Change the front hood damper bolt mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
2. Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. Lift up the rear side holding two positions (A). Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.
3. Remove the air intake duct, air cleaner case and air intake boot assembly. Ref. to «REMOVAL»(ref-371896-S20541353172010091900000) , Air Intake Duct. Ref. to «REMOVAL»(ref-371896-S07012520272010091900000) , Air Cleaner Case. Ref. to «REMOVAL»(ref-371896-S05520593882010091900000) , Air Intake Boot.
4. Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.
5. Lift up the vehicle.
6. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
7. Drain engine coolant completely. Ref. to «DRAINING OF ENGINE COOLANT»(ref-371899-S23258697372010091900000) , REPLACEMENT, Engine Coolant.
8. Lower the vehicle.
9. Remove the radiator main fan & fan motor and radiator sub fan & fan motor. Ref. to «REMOVAL»(ref-371899-S35640087102010091900000) , Radiator Main Fan and Fan Motor. Ref. to «REMOVAL»(ref-371899-S04293189452010091900000) , Radiator Sub Fan and Fan Motor.
10. Disconnect the engine harness.
11. Disconnect the connector from the throttle body.
12. Remove the engine harness connector from the engine hanger bracket.
13. Remove the engine hanger bracket.
14. Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant.
15. Attach the ST. ST 18360AA020 HANGER Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
16. Support the engine with a lifting device and wire ropes.
17. Remove the front mount.
18. Remove the front mounting bracket from the cradle.

Scheme 240

Check that the front mount and front mount bracket have no deformation, cracks and other damages.

Scheme 241

1. Remove the engine assembly from the body. Ref. to «REMOVAL»(ref-371890-S35280511132010091900000) , Engine Assembly.
2. Set the engine on ST. ST 18232AA000 ENGINE STAND
3. Before servicing overhaul, remove the sensor, pipe and hose that installed to engine. Remove the intake manifold. Ref. to «REMOVAL»(ref-371893-S33188599982010091900000) , Intake Manifold. Remove the generator. Ref. to «REMOVAL»(ref-371915-S37254385682010091900000) , Generator. Remove the A/C compressor. Ref. to «REMOVAL»(ref-371912-S14509447212010091900000) , Compressor. Disconnect the water pipe and hose. Disconnect the engine harness. Remove the spark plug. Ref. to «REMOVAL»(ref-371887-S28029716962010091900000) , Spark Plug. Remove the camshaft position sensor. Ref. to «REMOVAL»(ref-371893-S08336571192010091900000) , Camshaft Position Sensor. Remove the crankshaft position sensor. Ref. to «REMOVAL»(ref-371893-S34186513042010091900000) , Crankshaft Position Sensor. Remove the knock sensor. Ref. to «REMOVAL»(ref-371893-S29745430592010091900000) , Knock Sensor. Remove the engine coolant temperature sensor. Ref. to «REMOVAL»(ref-371893-S05195677782010091900000) , Engine Coolant Temperature Sensor. Remove the oil temperature sensor. Ref. to «REMOVAL»(ref-371893-S09550547442010091900000) , Oil Temperature Sensor. Remove the oil flow control solenoid valve. Ref. to «REMOVAL»(ref-371893-S26097011772010091900000) , Oil Flow Control Solenoid Valve. Remove the oil pressure switch. Ref. to «REMOVAL»(ref-371884-S00655437822010091900000) , Oil Pressure Switch. Remove the oil filter. Ref. to «REMOVAL»(ref-371884-S25652592312010091900000) , Engine Oil Filter. Remove the oil cooler. Ref. to «REMOVAL»(ref-371884-S40189439112010091900000) , Oil Cooler.

1. Check for oil leaks in the crank pulley cover.
2. Check the crank pulley for looseness.

1. Check the cam sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between cam sprocket and key.

1. Check the crank sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between crank sprocket and key.

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1. Remove the engine from vehicle. Ref. to «REMOVAL»(ref-371890-S35280511132010091900000) , Engine Assembly.
2. Remove the crank pulley. Ref. to «REMOVAL»(ref-371890-S11461836852010091900000) , Crank Pulley.
3. Remove the chain cover. Ref. to «REMOVAL»(ref-371890-S03614994732010091900000) , Chain Cover.
4. Remove the timing chain assembly. Ref. to «REMOVAL»(ref-371890-S10281519252010091900000) , Timing Chain Assembly.
5. Remove the cam sprocket. Ref. to «REMOVAL»(ref-371890-S35346914062010091900000) , Cam Sprocket.
6. Remove the crank sprocket. Ref. to «REMOVAL»(ref-371890-S25481745322010091900000) , Crank Sprocket.
7. Remove the exhaust oil flow control solenoid valve. Ref. to «REMOVAL»(ref-371893-S26097011772010091900000) , Oil Flow Control Solenoid Valve.
8. Remove the camshaft position sensor. Ref. to «REMOVAL»(ref-371893-S08336571192010091900000) , Camshaft Position Sensor.
9. Loosen the rocker cover bolts in the order indicated in the figure, and remove the rocker cover. LH side RH side
10. Loosen the camshaft cap bolts equally, a little at a time in numerical sequence, as shown in the figure.
11. Remove the camshaft caps and camshaft (RH). NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
12. Similarly, remove the camshaft (LH) and related parts.

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1. Apply engine oil to camshaft journals, and install the camshaft.
2. Install the camshaft cap. Apply liquid gasket sparingly to back side of the front camshaft cap as shown in the figure. NOTE: Install within 5 min. after applying liquid gasket. Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward cam journal, resulting in engine seizure. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 2.0±0.5 mm (0.079±0.020 in) Apply a thin coat of engine oil to the cap journal surface, and install the camshaft cap to the camshaft. Gradually tighten the camshaft cap in at least two stages in the numerical order shown in the figure, then tighten to specified torque. Tightening torque: (1) - (12): 16 N.m (1.6 kgf-m, 11.8 ft-lb) (13) - (17): 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle.
3. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Apply liquid gasket sparingly to the mating surface of cylinder head and rocker cover as shown in the figure. NOTE: Install within 5 min. after applying liquid gasket. Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward cam journal, resulting in engine seizure. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±0.5 mm (0.138±0.020 in) LH side RH side Tighten the rocker cover bolts in the numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) LH side RH side
4. Install the crank sprocket. Ref. to «INSTALLATION»(ref-371890-S37450556162010091900000) , Crank Sprocket.
5. Install the cam sprocket. Ref. to «INSTALLATION»(ref-371890-S02283279292010091900000) , Cam Sprocket.
6. Install the timing chain assembly. Ref. to «INSTALLATION»(ref-371890-S27655773222010091900000) , Timing Chain Assembly.
7. Install the chain cover. Ref. to «INSTALLATION»(ref-371890-S20199785232010091900000) , Chain Cover.
8. Install the crank pulley. Ref. to «INSTALLATION»(ref-371890-S23260494852010091900000) , Crank Pulley.
9. Install the engine to the vehicle. Ref. to «INSTALLATION»(ref-371890-S12809169672010091900000) , Engine Assembly.

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1. Measure and inspect the degree of bending. Repair or replace if necessary. Camshaft bend limit: 0.020 mm (0.00079 in)
2. Check the journal for damage and wear. Replace if faulty.
3. Check the cutout portion used for camshaft sensor for damage. Replace if faulty.
4. Check the cam face condition; remove the minor faults by grinding with oil stone. Replace if there is uneven wear or others.
5. Measure the cam lobe height "H" and cam base circle diameter "A". If it exceeds the standard or offset wear occurs, replace it. Cam lobe height H: Standard Intake 45.90 - 46.00 mm (1.8071 - 1.8110 in) Exhaust 44.65 - 44.75 mm (1.7579 - 1.7618 in) Cam base circle diameter A: Standard Intake 36.00 mm (1.4173 in) Exhaust 36.00 mm (1.4137 in)
6. Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance. CAMSHAFT JOURNAL SPECIFICATION CHART Camshaft journal Front Except for front Standard mm (in) 37.946 - 37.963 (1.4939-1.4946) 25.946 - 25.963 (1.0215-1.0222)
7. Measure the oil clearance of camshaft journal. Clean the camshaft cap and cylinder head camshaft journal. Place the camshaft on cylinder head. (Without installing the valve lifter) Place a plastigauge across each camshaft journals. Gradually tighten the camshaft cap in at least two stages in the numerical order shown in the figure, then tighten to specified torque. Do not turn the camshaft. Remove the camshaft cap. Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Camshaft oil clearance: Standard 0.037 - 0.072 mm (0.0015 - 0.0028 in) Completely remove the plastigauge.
8. Measure the thrust clearance of camshaft with the dial gauge set at end of camshaft. If the clearance is not within the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft. Camshaft thrust clearance: Standard Intake 0.075 - 0.135 mm (0.0030 - 0.0053 in) Exhaust 0.075 - 0.135 mm (0.0030 - 0.0053 in)

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1. Remove the engine from vehicle. Ref. to «REMOVAL»(ref-371890-S35280511132010091900000) , Engine Assembly.
2. Remove the crank pulley. Ref. to «REMOVAL»(ref-371890-S11461836852010091900000) , Crank Pulley.
3. Remove the chain cover. Ref. to «REMOVAL»(ref-371890-S03614994732010091900000) , Chain Cover.
4. Remove the timing chain assembly. Ref. to «REMOVAL»(ref-371890-S10281519252010091900000) , Timing Chain Assembly.
5. Remove the cam sprocket. Ref. to «REMOVAL»(ref-371890-S35346914062010091900000) , Cam Sprocket.
6. Remove the crank sprocket. Ref. to «REMOVAL»(ref-371890-S25481745322010091900000) , Crank Sprocket.
7. Remove the camshaft. Ref. to «REMOVAL»(ref-371890-S04918135372010091900000) , Camshaft.
8. Remove the seal bolt shown in the figure.
9. Remove the cylinder head bolts in the numerical order as shown in the figure. NOTE: Leave bolts (2) and (4) engaged by three or four threads to prevent the cylinder head from falling.
10. While tapping the cylinder head with a plastic hammer, separate it from cylinder block.
11. Remove the bolts (2) and (4) to remove cylinder head.
12. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
13. Similarly, remove the cylinder head (RH).

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1. Apply liquid gasket to the mating surface of cylinder block shown in the figure. NOTE: Install within 5 min. after applying liquid gasket. Do not apply liquid gasket excessively. If too much is applied, remove any liquid gasket that is squeezed out. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±1.0 mm (0.138±0.039 in) LH side RH side
2. Install the cylinder head gaskets LH and RH onto the cylinder block. NOTE: Use a new cylinder head gasket.
3. Apply liquid gasket to the mating surface of cylinder head gasket shown in the figure. NOTE: Install within 5 min. after applying liquid gasket. Do not apply liquid gasket excessively. If too much is applied, remove any liquid gasket that is squeezed out. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±1.0 mm (0.138±0.039 in) LH side RH side
4. Attach the cylinder head to the cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
5. Tighten the cylinder head bolts. Apply a thin coat of engine oil to washers and cylinder head bolt threads. Mount the cylinder head onto the cylinder block, then tighten the bolts with a torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in the order indicated in the figure. Tighten the bolts with a torque of 50 N.m (5.1 kgf-m, 36.9 ft-lb) in the order indicated in the figure. Loosen all bolts by 180° in the reverse order of installing, and loosen them further by 180°. Tighten the bolts with torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical sequence as shown in the figure. Tighten the bolts (1) - (4) in the order indicated with a torque of 48 N.m (4.9 kgf-m, 35.4 ft-lb). Tighten the bolts (5) - (8) in the order indicated with a torque of 44 N.m (4.5 kgf-m, 32.5 ft-lb). Tighten all bolts 90° in the numerical order as shown in the figure. Tighten the bolt (1) - (4) by 45° in the numerical order.
6. Install the seal bolt shown in the figure. NOTE: Before installing seal bolts, apply a sealing material to bolt threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
7. Install the camshaft. Ref. to «INSTALLATION»(ref-371890-S15615319062010091900000) , Camshaft.
8. Install the crank sprocket. Ref. to «INSTALLATION»(ref-371890-S37450556162010091900000) , Crank Sprocket.
9. Install the cam sprocket. Ref. to «INSTALLATION»(ref-371890-S02283279292010091900000) , Cam Sprocket.
10. Install the timing chain assembly. Ref. to «INSTALLATION»(ref-371890-S27655773222010091900000) , Timing Chain Assembly.
11. Install the chain cover. Ref. to «INSTALLATION»(ref-371890-S20199785232010091900000) , Chain Cover.
12. Install the crank pulley. Ref. to «INSTALLATION»(ref-371890-S23260494852010091900000) , Crank Pulley.
13. Install the engine to the vehicle. Ref. to «INSTALLATION»(ref-371890-S12809169672010091900000) , Engine Assembly.

Scheme 261

1. Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE
2. Remove the valve lifter.
3. Compress the valve spring using ST, and remove the valve spring retainer key, each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. Keep all the removed parts in order for re-installing in their original positions. For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to "INSPECTION". Ref. to «VALVE GUIDE»(ref-371890-S16122298842010091900000) , INSPECTION, Cylinder Head. Ref. to «INTAKE AND EXHAUST VALVE OIL SEAL»(ref-371890-S01453015112010091900000) , INSPECTION, Cylinder Head.

Scheme 262

1. Install the valve spring and valve. Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE Coat the stem of each valve with engine oil and insert the valve into valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its close-coiled end facing the seat on cylinder head. Install the valve spring with the painted side facing to retainer. Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER Compress the valve spring and fit the valve spring retainer key. After installing, tap the valve spring retainers lightly with a wooden hammer for better seating.
2. Apply oil to the surface of valve lifter.
3. Install the valve lifter.

Scheme 263

1. Make sure that there are no cracks or other damages. Perform visual check, and use liquid penetrant tester on the important sections. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
2. Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE
3. Check for warpage at mating surface between the cylinder block and cylinder head using a straight edge (A) and thickness gauge (B). If the warpage exceeds limit, replace the cylinder head. Warping limit: 0.020 mm (0.0008 in) Standard height of cylinder head: 124±0.05 mm (4.88±0.0020 in) NOTE: Uneven torque for the cylinder head bolts can cause warpage. When reinstalling, pay special attention to the torque so as to tighten evenly.

Note. The "RANK" shown in the chart shows the possibilities of the cause of trouble in order from "Very often" to "Rarely".

A - Very often

B - Sometimes

C - Rarely

ENGINE TROUBLE INSPECTION CHART

ENGINE NOISE INSPECTION CHART