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

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
9. All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings.
10. Before applying liquid gasket, completely remove the old liquid gasket and degrease it.
11. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
12. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
13. Bolts, nuts and washers should be replaced with new parts as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making re-checks.
15. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
16. Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection.
17. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
18. Lift up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

GENERAL TOOL DESCRIPTION CHART

PROCEDURE

It is possible to conduct the following service procedures with engine on vehicle, however, the procedures described in this article are based on the condition that the engine is removed from vehicle.

1. V-belt
2. Timing chain

INTAKE SIDE

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

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1. Measure all the valve clearances. Ref. to «INSPECTION»(ref-371890-S20486289882010091900000) , Valve Clearance. NOTE: Record each valve clearance after measurement.
2. Remove the timing chain assembly. Ref. to «REMOVAL»(ref-371890-S10281519252010091900000) , Timing Chain Assembly.
3. Remove the cam sprocket. Ref. to «REMOVAL»(ref-371890-S35346914062010091900000) , Cam Sprocket.
4. Remove the camshaft. Ref. to «REMOVAL»(ref-371890-S04918135372010091900000) , Camshaft.
5. Remove the valve lifter.
6. Measure the thickness of valve lifter using micrometer.
7. Select a valve lifter of suitable thickness using the measured valve clearance and valve lifter thickness, and install it. NOTE: Use a new valve lifter. VALVE LIFTER THICKNESS CHART Unit: mm (in) S = (V + T) - 0.20 (0.0079) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used
8. Install the camshaft. Ref. to «INSTALLATION»(ref-371890-S15615319062010091900000) , Camshaft.
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. Measure all valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step. Valve clearance (adjustment value): 0.20 +0.04 -0.03 mm (0.0079 +0.0016 -0.0024 in)
12. After measuring, install the related parts in the reverse order of removal.

Note. Use a new rocker cover gasket.

EXHAUST SIDE

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

1. Measure all the valve clearances. Ref. to «INSPECTION»(ref-371890-S20486289882010091900000) , Valve Clearance. NOTE: Record each valve clearance after measurement.
2. Remove the camshaft. Ref. to «REMOVAL»(ref-371890-S04918135372010091900000) , Camshaft.
3. Remove the valve lifter.
4. Measure the thickness of valve lifter using micrometer.
5. Select a valve lifter of suitable thickness using the measured valve clearance and valve lifter thickness, and install it. NOTE: Use a new valve lifter. VALVE LIFTER THICKNESS CHART Unit: mm (in) S = (V + T)-0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used
6. Install the camshaft. Ref. to «INSTALLATION»(ref-371890-S15615319062010091900000) , Camshaft.
7. Install the cam sprocket. Ref. to «INSTALLATION»(ref-371890-S02283279292010091900000) , Cam Sprocket.
8. Install the timing chain assembly. Ref. to «INSTALLATION»(ref-371890-S27655773222010091900000) , Timing Chain Assembly.
9. Measure all valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step. Valve clearance (adjustment value): 0.35±0.05 mm (0.0138±0.0020 in)
10. After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

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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. Collect the refrigerant from A/C system. Ref. to «PROCEDURE»(ref-371912-S26476577802010091900000) , Refrigerant Recovery Procedure.
4. Release the fuel pressure. Ref. to «PROCEDURE»(ref-371893-S10358926402010091900000) , Fuel.
5. Disconnect the ground cable from battery.
6. Open the fuel filler lid and remove the fuel filler cap.
7. 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.
8. Remove the V-belts. Ref. to «REMOVAL»(ref-371890-S42424743962010091900000) , V-belt.
9. Disconnect the following connector. 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.
10. Remove the power steering pump together with the bracket. NOTE: Do not disconnect the hose and pipe from the power steering pump. Disconnect the manifold absolute pressure sensor connector (A) and power steering pump connector (B). Remove the securing bolts of collector cover bracket and power steering pump bracket. Use a cloth to protect the power steering pump and place it on the RH front strut using a wire.
11. Remove the brake booster vacuum hose.
12. Remove the engine ground.
13. Remove the starter harness and engine ground from bracket.
14. Remove the starter. Ref. to «REMOVAL»(ref-371915-S27522616522010091900000) , Starter.
15. Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.
16. Lift up the vehicle.
17. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
18. Drain engine coolant completely. Ref. to «DRAINING OF ENGINE COOLANT»(ref-371899-S23258697372010091900000) , REPLACEMENT, Engine Coolant.
19. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe.
20. Remove the ground cable from the underside of chain cover.
21. Remove the connecting bolts and nuts (lower side) between the engine and transmission.
22. Lower the vehicle.
23. 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.
24. Remove the radiator. Ref. to «REMOVAL»(ref-371899-S41079586492010091900000) , Radiator.
25. Remove the heater inlet hose and heater outlet hose.
26. Disconnect the engine harness connector.
27. Disconnect the connector from the throttle body.
28. Remove the engine harness connector from the engine hanger bracket.
29. Remove the engine hanger bracket.
30. Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant.
31. Attach the ST. ST 18360AA020 HANGER Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
32. Separate the torque converter clutch from drive plate. Remove the service hole plug. Rotate the clank pulley to align the drive plate to the service hole, and remove four bolts.
33. Disconnect the fuel delivery hose and evaporation hose. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE Remove the clip and disconnect the evaporation hose.
34. Disconnect the A/C pressure hoses from A/C compressor. Ref. to «REMOVAL»(ref-371912-S20198905942010091900000) , Hose and Pipe.
35. Remove the connecting bolts (upper side) between engine and transmission.
36. Set the ST to torque converter clutch case. ST 498277200 STOPPER SET
37. Support the engine with a lifting device and wire ropes.
38. Remove the front mount.
39. Remove the front mounting bracket from the cradle.
40. Remove the engine from the engine compartment. Operate the lifter to set the engine horizontally. Move the engine towards the front of the vehicle to disconnect it from the torque converter clutch case. Operate the lifter to take out the engine from the engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

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1. Install the engine to the vehicle. Operate the lifter to place the engine in the engine compartment. Operate the lifter to set the engine horizontally. Move the engine towards the rear of the vehicle to connect it to the torque converter clutch case. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
2. Install front mounting bracket to the cradle. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
3. Install the front mount. Tightening torque: T1:25 N.m (2.5 kgf-m, 18.4 ft-lb) T2:45 N.m (4.6 kgf-m, 33.2 ft-lb)
4. Install the connecting bolts (upper side) between engine and transmission. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) NOTE: Make sure there are no gaps in the mating surfaces between engine and transmission. If there are gaps, loosen the connecting bolts, and adjust the position while retightening the bolts.
5. Remove the lifting device and wire ropes.
6. Remove the ST from torque converter clutch case. NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST.
7. Install the radiator. Ref. to «INSTALLATION»(ref-371899-S10711893152010091900000) , Radiator.
8. Install the radiator main fan & fan motor and radiator sub fan & fan motor. Ref. to «INSTALLATION»(ref-371899-S04472265882010091900000) , Radiator Main Fan and Fan Motor. Ref. to «INSTALLATION»(ref-371899-S08760544642010091900000) , Radiator Sub Fan and Fan Motor.
9. Lift up the vehicle.
10. Attach the connecting bolts and nuts (lower side) between the engine and transmission. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
11. Install the ground cable to the underside of chain cover. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
12. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe.
13. Install the undercover. Ref. to «INSTALLATION»(ref-371913-S15712020302010091900000) , Front Under Cover.
14. Lower the vehicle.
15. Install the A/C pressure hoses to A/C compressor. Ref. to «INSTALLATION»(ref-371912-S00821492682010091900000) , Hose and Pipe.
16. Connect the fuel delivery hose (A) and evaporation hose (B). NOTE: If fuel hoses or clamps are damaged, replace them with new parts.
17. Connect the torque converter clutch to the drive plate. Rotate the clank pulley to align the drive plate to the service hole, and tighten four bolts. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Install the service hole plug.
18. Remove the ST.
19. Install the throttle body to intake manifold. NOTE: Use a new gasket. Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)
20. Install the engine hanger bracket. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
21. Install the engine harness connector to the engine hanger bracket.
22. Connect the connector to the throttle body.
23. Connect the engine harness.
24. Install the heater inlet hose and heater outlet hose.
25. Attach the grille bracket.
26. Install the starter. Ref. to «INSTALLATION»(ref-371915-S06872456192010091900000) , Starter.
27. Install the starter harness and engine ground to the bracket.
28. Install the engine ground.
29. Install the brake booster vacuum hose.
30. Install the power steering pump together with the bracket. Install the power steering pump and power steering pump bracket to the cylinder block. Install the collector cover bracket and power steering pump bracket. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T3: 33 N.m (3.4 kgf-m, 24.3 ft-lb) Connect the manifold absolute pressure sensor connector (A) and power steering pump connector (B).
31. Connect the following connectors. Generator connector Generator terminal B Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb) Install the harness cover to the collector cover bracket. A/C compressor solenoid connector Flow sensor connector Install with the securing clips to the two locations on the fuel pipe protector (LH).
32. Install the V-belts. Ref. to «INSTALLATION»(ref-371890-S32448109492010091900000) , V-belt.
33. Install the air intake duct, air cleaner case and air intake boot assembly. Ref. to «INSTALLATION»(ref-371896-S14011537962010091900000) , Air Intake Duct. Ref. to «INSTALLATION»(ref-371896-S17810390872010091900000) , Air Cleaner Case. Ref. to «INSTALLATION»(ref-371896-S02881003482010091900000) , Air Intake Boot.
34. Connect the ground cable to battery.
35. Fill engine coolant. Ref. to «FILLING OF ENGINE COOLANT»(ref-371899-S36348928632010091900000) , REPLACEMENT, Engine Coolant.
36. Charge the A/C system with refrigerant. Ref. to «PROCEDURE»(ref-371912-S05881540232010091900000) , Refrigerant Charging Procedure.
37. Check the ATF level and replenish it if necessary. Ref. to «INSPECTION»(ref-371902-S33705940982010091900000) , Automatic Transmission Fluid.
38. Install the collector cover.
39. Change the front hood damper bolt mounting position from (B) to (A), and completely close the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)

VALVE SEAT

Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.

Contacting width of valve seat W

Standard Intake

1.0 mm (0.039 in)

Exhaust

1.5 mm (0.059 in)

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1. Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. Clearance between the valve guide and valve stem: Standard Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in)
2. If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve itself, whichever shows the greater amount of wear or damage. See the following procedure for valve guide replacement. Valve guide inner diameter: 5.500 - 5.512 mm (0.2165 - 0.2170 in) Valve stem outer diameters: Intake 5.455 - 5.470 mm (0.2148 - 0.2154 in) Exhaust 5.445 - 5.460 mm (0.2144 - 0.2150 in) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499765700 VALVE GUIDE REMOVER
3. Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA050 VALVE GUIDE ADJUSTER (INTAKE SIDE) ST 18251AA060 VALVE GUIDE ADJUSTER (EXHAUST SIDE)
4. Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head.
5. Coat a new valve guide with sufficient oil, put it into the cylinder, and insert the ST1 into the valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499765700 VALVE GUIDE REMOVER ST2 18251AA050 VALVE GUIDE ADJUSTER (INTAKE SIDE) ST2 18251AA060 VALVE GUIDE ADJUSTER (EXHAUST SIDE)
6. Check the valve guide protrusion amount Valve guide protrusion amount L: Intake 8.6 - 9.0 mm (0.3386 - 0.3543 in) Exhaust 10.7-11.1 mm (0.4213 - 0.4370 in)
7. Ream the inside of valve guide using ST. Put the reamer in valve guide, and slowly rotate the reamer clockwise while pushing it lightly. Bring the reamer back while rotating it clockwise. ST 499765900 VALVE GUIDE REAMER NOTE: Apply engine oil to the reamer when reaming. If the inner surface of valve guide is damaged, the edge of reamer should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer.
8. After reaming, clean the valve guide to remove chips.
9. Recheck the contact condition between valve and valve seat after replacing the valve guide.

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1. Inspect the flange and stem of valve, and replace if damaged, worn or deformed, "H" exceeds the standard, or if there is uneven wear. Head edge thickness H: Standard Intake (A) 1.0 mm (0.039 in) Exhaust (B) 1.2 mm (0.047 in)
2. Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Install a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 103.5 mm (4.075 in) Exhaust 103.2 mm (4.063 in)

VALVE SPRING

1. Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table.
2. To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of the spring using a try square.

VALVE SPRING SPECIFICATION CHART

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1. For the following, replace the oil seal with a new part. When the lip is damaged. When the spring is out of the specified position. When readjusting the surfaces of valve and valve seat. When replacing the valve guide.
2. Set the cylinder head on ST1.
3. Using the ST2, press in the oil seal. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499585500 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer or strike in.

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1. Perform visual check on the valve lifter.
2. Measure the valve lifter outer diameter. Outer diameter of valve lifter: 32.959 - 32.975 mm (1.2976 - 1.2982 in)
3. Measure the inner diameter of valve lifter hole of cylinder head. Inner diameter of valve lifter mating surface: 32.994 - 33.016 mm (1.2990 - 1.2998 in)
4. Check the clearance between valve lifter and valve lifter mating surface. The clearance can be determined from the measured value of the valve lifter outer diameter and valve lifter mating surface inner diameter. If it is not within the standard or there is uneven wear in the inner surface, replace the cylinder head. Clearance between valve lifter and valve lifter mating surface: Standard 0.019 - 0.057 mm (0.0007 - 0.0022 in)

CYLINDER BLOCK

1. Visually check for cracks or damage. Use liquid penetrant tester on the important sections.
2. Check the oil passages for clogging.
3. Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge If the warpage exceeds limit, replace the cylinder block. Warping limit: 0.020 mm (0.0008 in) Standard height of cylinder block: 202 mm (7.95 in) 2. CYLINDER AND PISTON

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1. The cylinder bore size is stamped on the front upper face of the cylinder block. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston. Standard diameter: A: 92.005 - 92.015 mm (3.6222 - 3.6226 in) B: 91.995 - 92.005 mm (3.6218 - 3.6222 in)
2. Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Taper: Standard 0.030 mm (0.0012 in) Out-of-roundness: Standard 0.010 mm (0.0004 in)
3. When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance.
4. Measure outer diameter of each piston. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 37.3 mm (1.4685 in) Piston outer diameter: Standard A: 92.005 - 92.015 mm (3.6222 - 3.6226 in) B: 91.995 - 92.005 mm (3.6218 - 3.6222 in) 0.25 mm (0.0098 in) oversize 92.245 - 92.265 mm (3.6317-3.6325 in) 0.50 mm (0.0197 in) oversize 92.495 - 92.515 mm (3.6415 - 3.6423 in)
5. Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard -0.010 - 0.010 mm (-0.0004 - 0.0004 in)
6. Boring and honing: If any of the measured value of taper, out-of-roundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature. Cylinder inner diameter boring limit (diameter): To 92.515 mm (3.6717 in)

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1. Check the piston and piston pin for damage, cracks or wear. And check the piston ring groove for wear or damage. Replace if faulty.
2. Measure the clearance between piston and cylinder in each cylinder. Ref. to «CYLINDER AND PISTON»(ref-371890-S29153382782010091900000) , INSPECTION, Cylinder Block. If the clearance exceeds the standard, replace the piston, or rebore the cylinder so that an oversize piston can be used.
3. Make sure the piston pin can be inserted into the piston pin hole by a thumb at 20°C (68°F). Replace if faulty. Clearance between piston pin hole and piston pin: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in)
4. Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
5. Check the piston pin snap ring for distortion, cracks and wear.

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1. If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: The top ring and second ring have the mark to determine the direction for installing. When attaching the ring to the piston, face these marks towards the top side. Oil ring consists of the upper rail, expander and lower rail. When installing to the piston, be careful of the direction of each rail.
2. Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge. PISTON RING SPECIFICATION CHART Standard mm (in) Piston ring gap Top ring 0.20 - 0.25 (0.0079 - 0.0098) Second ring 0.40 - 0.50 (0.0157 - 0.0197) Oil ring 0.20 - 0.50 (0.0079 - 0.0197)
3. Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. PISTON RING SPECIFICATION CHART Standard mm (in) Clearance between piston ring and piston ring groove Top ring 0.040 - 0.080 (0.0016 - 0.0031) Second ring 0.030 - 0.070 (0.0012 - 0.0028) Clearance between oil ring and oil ring groove 0.065 - 0.165 (0.0026 - 0.0065)

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1. Replace the connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
3. Install the connecting rod with bearings attached to the crankshaft, and using a thickness gauge, measure the thrust clearance. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod. Connecting rod thrust clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in)
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.016 - 0.043 mm (0.0006 - 0.0017 in) CONNECTING ROD SPECIFICATION CHART Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.489-1.505 (0.0586 - 0.0593) 51.976 - 52.000 (2.0463 - 2.0472) 0.03 (0.0012) Undersize 1.507-1.515 (0.0593 - 0.0596) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) Undersize 1.517-1.525 (0.0597 - 0.0600) 51.934 - 51.950 (2.0446-2.0453) 0.25 (0.0098) Undersize 1.617-1.625 (0.0637 - 0.0640) 51.734 - 51.750 (2.0368 - 2.0374)
6. Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged.
7. Measure the piston pin clearance at connecting rod small end. Replace it with a new part if the value is not within the standard, Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 in)
8. The replacement procedure for the connecting rod small end bushing is as follows. Remove the bushing from connecting rod with ST and press. Apply oil on the periphery of the new bushing, and press the bushing in with the ST. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in the pressed bushing to match the pre-manufactured holes on the connecting rod, then ream the inside of the bushing. After completion of reaming, clean the bushing to remove chips.

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Scheme 420

1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft.
2. Check the crankshaft for bend, and repair or replace if needed. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using the #1 and #7 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
3. Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 51.734 mm (2.0368 in) Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 63.742 mm (2.5095 in) CRANK JOURNAL SPECIFICATION CHART Unit: mm (in) Crank journal diameter Crank pin outer diameter #1,#3, #5 #7 #2, #4, #6 Standard Journal O.D. 63.992 - 64.016 (2.5194 - 2.5203) 51.976 - 52.000 (2.0463 - 2.0472) Bearing size (Thickness at center) 1.996 - 2.013 (0.0786 - 0.0793) 1.992 - 2.009 (0.0784 - 0.0791) 1.996 - 2.013 (0.0786 - 0.0793) 1.489 - 1.505 (0.0586 - 0.0593) 0.03 (0.0012) Undersize Journal O.D. 63.962 - 63.978 (2.5182 - 2.5188) 51.954 - 51.970 (2.0454 - 2.0461) Bearing size (Thickness at center) 2.011 -2.014 (0.0792 - 0.0793) 2.011 -2.014 (0.0792 - 0.0793) 2.015 - 2.018 (0.0793 - 0.0794) 1.507 - 1.515 (0.0593 - 0.0596) 0.05 (0.0020) Undersize Journal O.D. 63.942 - 63.958 (2.5174 - 2.5180) 51.934 - 51.950 (2.0446 - 2.0453) Bearing size (Thickness at center) 2.021 - 2.024 (0.0796 - 0.0797) 2.021 - 2.024 (0.0796 - 0.0797) 2.025 - 2.028 (0.0797 - 0.0798) 1.517-1.525 (0.0597 - 0.0600) 0.25 (0.0098) Undersize Journal O.D. 63.742 - 63.758 (2.5095 - 2.5102) 51.734 - 51.750 (2.0368 - 2.0374) Bearing size (Thickness at center) 2.121-2.124 (0.0835 - 0.0836) 2.121-2.124 (0.0835 - 0.0836) 2.125 - 2.128 (0.0837 - 0.0838) 1.617-1.625 (0.0637 - 0.0640)
4. Use a thickness gauge to measure the thrust clearance of crankshaft at center bearing. If clearance exceeds the standard, replace the bearing. Crankshaft thrust clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in)
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
6. Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 - 0.030 mm (0.0004 - 0.0012 in)