Engine Mechanical (H6DO): Diagnosis Subaru Outback BR рестайлинг

INSPECTION

Scheme 479

Scheme 480

1. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
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. Refer to «REMOVAL»(ref-565159-S12872483052013071000000) .
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 - 1, 471 kPa (13.0 - 15.0 kgf/cm 2 , 185 - 213 psi) 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. Refer to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-565198-S08829121112013071000000) . NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If idle speed is out of standard, refer to the «BASIC DIAGNOSTIC PROCEDURE»(ref-565198-S31331816802013071000000) . 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

1. Disconnect the ground cable from battery.
2. Remove the oil pressure switch from the oil pan upper. Refer to «REMOVAL»(ref-565157-S36502971202013071000000) .
3. Attach the oil pressure gauge to the oil pan upper.
4. Connect the battery ground terminal.
5. Start the engine, and check the oil pressure. NOTE: If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. Refer to «ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL»(ref-565157-S42932991842013071000000) . If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. Refer to «OIL PRESSURE SYSTEM»(ref-565157-S00767948492013071000000) and «OIL PRESSURE SWITCH»(ref-565157-S25923518682013071000000) . Engine oil pressure (at oil temperature of 120°C (248°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.

Scheme 481

Scheme 482

1. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
2. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-565163-S24691353262013071000000) .
3. Open the fuel filler lid and remove the fuel filler cap.
4. Disconnect the fuel delivery hose from fuel damper, and connect fuel pressure gauge. 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 Connect the fuel pressure gauge with ST1 and ST2. NOTE: ST1 is a SUBARU genuine part. ST1 42075AG690 FUEL HOSE ST2 18471AA000 FUEL PIPE ADAPTER
5. Start the engine.
6. Check 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 340 - 400 kPa (3.5 - 4.1 kgf/cm 2 , 49.3 - 58 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.

Scheme 483

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Scheme 488

Scheme 489

Scheme 490

Scheme 491

1. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
2. Disconnect the ground cable from battery.
3. Lift up the vehicle.
4. Remove the under cover. Refer to «REMOVAL»(ref-565181-S28182960572013071000000) .
5. Lower the vehicle.
6. When inspecting valve clearances for #1, #3 and #5
7. Loosen the clamp (A) which connects the air intake boot assembly.
8. Loosen the bolt (B) which secures the air intake boot assembly to the collector cover bracket. Remove the air intake boot assembly, and move it to the left side wheel apron. Remove the air intake duct and air cleaner case. Refer to «REMOVAL»(ref-565165-S00196848762013071000000) and «REMOVAL»(ref-565165-S02004603892013071000000) . Remove the fuel pipe protector (RH). Disconnect the connector of oil pressure switch. Remove the ignition coil. Refer to «REMOVAL»(ref-565159-S34853286892013071000000) . Remove the rocker cover (RH). Refer to «REMOVAL»(ref-565161-S07435264002013071000000) .
9. When inspecting valve clearances for #2, #4 and #6 Remove the battery and battery carrier. Refer to «REMOVAL»(ref-565199-S16388899782013071000000) . 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 from rocker cover (LH). Remove the fuel pipe protector (LH). Remove the ignition coil. Refer to «REMOVAL»(ref-565159-S34853286892013071000000) . Remove the rocker cover (LH). Refer to «REMOVAL»(ref-565161-S07435264002013071000000) .
10. Turn the crankshaft clockwise until the camshaft is set to position shown in the figure.
11. 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.
12. If necessary, adjust the valve clearance. Refer to «ADJUSTMENT»(ref-565161-S36822164342013071000000) .
13. Further turn the crank pulley clockwise and then measure the valve clearances again.
14. After inspection, install the related parts in the reverse order of removal. Refer to «INSTALLATION»(ref-565161-S35809709142013071000000) .

Scheme 492

1. Remove the engine from vehicle. Refer to «REMOVAL»(ref-565161-S41933007102013071000000) .
2. Measure all the valve clearances. Refer to «INSPECTION»(ref-565161-S31647162322013071000000) . NOTE: Record each valve clearance after measurement.
3. Remove the timing chain assembly. Refer to «REMOVAL»(ref-565161-S16020200682013071000000) .
4. Remove the cam sprocket. Refer to «REMOVAL»(ref-565161-S27908761212013071000000) .
5. Remove the camshaft. Refer to «REMOVAL»(ref-565161-S07435264002013071000000) .
6. Remove the valve lifter.
7. Measure the thickness of valve lifter using micrometer.
8. 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. Unit: mm (in) S = (V + T) - 0.20 (0.0079) S: Valve lifter thickness required V: Measured valve clearance T: Current valve lifter thickness
9. Install the camshaft. Refer to «INSTALLATION»(ref-565161-S35809709142013071000000) .
10. Install the cam sprocket. Refer to «INSTALLATION»(ref-565161-S34826815772013071000000) .
11. Install the timing chain assembly. Refer to «INSTALLATION»(ref-565161-S03866533742013071000000) .
12. Measure all valve clearance again at this time. If the valve clearance is not within the adjustment value, repeat the procedure from step 3 ). Valve clearance (adjustment value): 0.20 +0.04 -0.06 mm (0.0079 +0.0016 -0.0024 in)
13. After adjustment, install the related parts in the reverse order of removal. NOTE: Refer to «INSTALLATION»(ref-565161-S35809709142013071000000) when installing the rocker cover. .

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.

Scheme 493

Scheme 494

Scheme 495

Scheme 496

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 the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
3. Loosen the clamp (A) which connects the air intake boot assembly.
4. Loosen the bolt (B) which secures the air intake boot assembly to the collector cover bracket.
5. Remove the air intake boot assembly, and move it to the left side wheel apron.
6. Remove the air intake duct and air cleaner case. Refer to «REMOVAL»(ref-565165-S00196848762013071000000) and «REMOVAL»(ref-565165-S02004603892013071000000) .
7. Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.
8. Lift up the vehicle.
9. Remove the under cover. Refer to «REMOVAL»(ref-565181-S28182960572013071000000) .
10. Drain engine coolant completely. Refer to «DRAINING OF ENGINE COOLANT»(ref-565167-S19351012342013071000000) .
11. Lower the vehicle.
12. Remove the radiator main fan & fan motor and radiator sub fan & fan motor. Refer to «REMOVAL»(ref-565167-S11463109162013071000000) and «REMOVAL»(ref-565167-S21296041312013071000000) .
13. Disconnect the engine harness.
14. Disconnect the connector from the throttle body.
15. Remove the engine harness connector from the engine hanger bracket.
16. Remove the engine hanger bracket.
17. Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant.
18. Attach the ST. ST 18360AA020 HANGER Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
19. Support the engine with a lifting device and wire ropes.
20. Remove the front mount.
21. Remove the front mounting bracket from the cradle.
22. Remove the bracket from the cradle.

Scheme 497

1. Install the bracket to the cradle. Tightening torque: 65 N.m (6.6 kgf-m, 47.9 ft-lb)
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. Remove the lifting device and wire ropes.
5. Install the radiator main fan & fan motor and radiator sub fan & fan motor. Refer to «INSTALLATION»(ref-565167-S13254392552013071000000) and «INSTALLATION»(ref-565167-S33283941762013071000000) .
6. Lift up the vehicle.
7. Install the under cover. Refer to «INSTALLATION»(ref-565181-S36610771312013071000000) .
8. Lower the vehicle.
9. Remove the ST.
10. 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)
11. Install the engine hanger bracket. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
12. Install the engine harness connector to the engine hanger bracket.
13. Connect the connector to the throttle body.
14. Connect the engine harness.
15. Attach the grille bracket.
16. Install the air intake duct and air cleaner case. Refer to «INSTALLATION»(ref-565165-S37221606252013071000000) and «INSTALLATION»(ref-565165-S04574179012013071000000) .
17. Install the air intake boot assembly. Tightening torque: Clamp (A) 3 N.m (0.3 kgf-m, 2.2 ft-lb) Bolt (B) 6.5 N.m (0.7 kgf-m, 4.8 ft-lb)
18. Connect the ground cable to battery.
19. Fill engine coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-565167-S04263119292013071000000) .
20. Install the collector cover.
21. 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)

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

Scheme 498

1. Remove the engine from vehicle. Refer to «REMOVAL»(ref-565161-S41933007102013071000000) .
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. Refer to «REMOVAL»(ref-565163-S22406632202013071000000) . Remove the generator. Refer to «REMOVAL»(ref-565199-S21079726502013071000000) . Remove the A/C compressor. Refer to «REMOVAL»(ref-565180-S28623040862013071000000) . Disconnect the water pipe and hose. Disconnect the engine harness. Remove the spark plug. Refer to «REMOVAL»(ref-565159-S12872483052013071000000) . Remove the camshaft position sensor. Refer to «REMOVAL»(ref-565163-S29731556922013071000000) . Remove the crankshaft position sensor. Refer to «REMOVAL»(ref-565163-S21979173062013071000000) . Remove the knock sensor. Refer to «REMOVAL»(ref-565163-S34765604832013071000000) . Remove the engine coolant temperature sensor. Refer to «REMOVAL»(ref-565163-S27111508802013071000000) . Remove the oil temperature sensor. Refer to «REMOVAL»(ref-565163-S03583801722013071000000) . Remove the oil flow control solenoid valve. Refer to «REMOVAL»(ref-565163-S15153236632013071000000) . Remove the oil pressure switch. Refer to «REMOVAL»(ref-565157-S36502971202013071000000) . Remove the oil filter. Refer to «REMOVAL»(ref-565157-S06527211262013071000000) . Remove the oil cooler. Refer to «REMOVAL»(ref-565157-S00715069172013071000000) .

Scheme 499

1. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
2. Remove the air intake duct. Refer to «REMOVAL»(ref-565165-S00196848762013071000000) .
3. Install the tool to the pulley bolt of the belt tension adjuster assembly.
4. Rotate the tool clockwise and loosen the V-belt to remove.

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

Scheme 500

Scheme 501

1. Drain the engine oil. Refer to «REPLACEMENT»(ref-565157-S20989681072013071000000) .
2. Lift up the vehicle.
3. Remove the under cover. Refer to «REMOVAL»(ref-565181-S28182960572013071000000) .
4. Drain engine coolant. Refer to «DRAINING OF ENGINE COOLANT»(ref-565167-S19351012342013071000000) .
5. Remove the front exhaust pipe. Refer to «REMOVAL»(ref-565201-S03342601172013071000000) .
6. Lower the vehicle.
7. Change the 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)
8. Loosen the clamp (A) which connects the air intake boot assembly.
9. Loosen the bolt (B) which secures the air intake boot assembly to the collector cover bracket.
10. Remove the air intake boot assembly, and move it to the left side wheel apron.
11. Remove the air intake duct. Refer to «REMOVAL»(ref-565165-S00196848762013071000000) .
12. Disconnect the engine harness connector.
13. Disconnect the connector from the throttle body.
14. Remove the engine harness connector from the engine hanger bracket.
15. Remove the engine hanger bracket.
16. Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant.
17. Attach the ST. ST 18360AA020 HANGER Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
18. Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.
19. Remove the V-belts. Refer to «REMOVAL»(ref-565161-S04819945492013071000000) .
20. Remove the reservoir tank. Refer to «REMOVAL»(ref-565167-S25209266492013071000000) .
21. Remove the radiator main fan & fan motor and radiator sub fan & fan motor. Refer to «REMOVAL»(ref-565167-S11463109162013071000000) .
22. Remove the radiator. Refer to «REMOVAL»(ref-565167-S05791119462013071000000) .
23. Remove the crank pulley. Refer to «REMOVAL»(ref-565161-S07305427412013071000000) .
24. Support the engine with a lifting device and wire ropes.
25. Remove the front mount from the chain cover.
26. Remove the front mounting bracket from the cradle.
27. Remove the oil cooler pipe from the chain cover.
28. Remove the chain cover. NOTE: Chain cover installation bolt has three different sizes. To prevent the confusion in installation, keep these bolts on container individually.

Scheme 502

Scheme 503

Scheme 504

Scheme 505

1. Apply liquid gasket to the mating surfaces of the cylinder block, cylinder head and oil pan upper as shown in the figure. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
2. Apply liquid gasket to the mating surface of the chain cover. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±0.5 mm (0.138±0.020 in)
3. Attach the chain cover and temporarily tighten the chain cover installation bolts. CAUTION: Do not install the chain cover installation bolts in wrong place.
4. Tighten the chain cover installing bolts in the numerical order as shown in the figure. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
5. Install the oil cooler pipe to the chain cover. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
6. Install front mounting bracket to the cradle. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
7. 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)
8. Remove the lifting device and wire ropes.
9. Install the crank pulley. Refer to «INSTALLATION»(ref-565161-S26224654262013071000000) .
10. Install the radiator. Refer to «INSTALLATION»(ref-565167-S09229691332013071000000) .
11. Install the radiator main & fan motor and radiator sub fan & fan motor. Refer to «INSTALLATION»(ref-565167-S13254392552013071000000) .
12. Install the reservoir tank. Refer to «REMOVAL»(ref-565167-S25209266492013071000000) .
13. Install the V-belts. Refer to «INSTALLATION»(ref-565161-S02167665892013071000000) .
14. Attach the grille bracket.
15. 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)
16. Remove the ST (HANGER) and install the engine hanger bracket. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
17. Install the engine harness connector to the engine hanger bracket.
18. Connect the connector to the throttle body.
19. Connect the engine harness connector.
20. Install the V-belts. Refer to «INSTALLATION»(ref-565161-S02167665892013071000000) .
21. Install the air intake boot assembly. Tightening torque: Clamp (A) 3 N.m (0.3 kgf-m, 2.2 ft-lb) Bolt (B) 6.5 N.m (0.7 kgf-m, 4.8 ft-lb)
22. Install the air intake duct. Refer to «INSTALLATION»(ref-565165-S37221606252013071000000) .
23. Install the front exhaust pipe. Refer to «INSTALLATION»(ref-565201-S28862029152013071000000) .
24. Fill engine coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-565167-S04263119292013071000000) .
25. Fill engine oil. Refer to «REPLACEMENT»(ref-565157-S20989681072013071000000) .
26. Make sure there is no oil leaks in the chain cover mating surface.
27. Install the under cover. Refer to «INSTALLATION»(ref-565181-S36610771312013071000000) .
28. Install the collector cover.
29. Change the 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)

Scheme 506

1. Check the chain cover surface for scratches or dents.
2. Check for oil leakage on the chain cover mating surface and installation part of crank pulley. If there is an oil leak from the oil seal, perform replacement with a new oil seal. ST 499585700 OIL SEAL GUIDE Oil seal press-fit position: Chain cover end face - Position -1 mm (-0.039 in) from the chain cover end face.

Scheme 507

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

Scheme 508

1. Remove the V-belts. Refer to «REMOVAL»(ref-565161-S04819945492013071000000) .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-565161-S07305427412013071000000) .
3. Remove the chain cover. Refer to «REMOVAL»(ref-565161-S05362704272013071000000) .
4. Remove the timing chain assembly. Refer to «REMOVAL»(ref-565161-S16020200682013071000000) .
5. Remove the crank sprocket (A).

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

Scheme 509

Scheme 510

Scheme 511

1. Remove the engine from vehicle. Refer to «REMOVAL»(ref-565161-S41933007102013071000000) .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-565161-S07305427412013071000000) .
3. Remove the chain cover. Refer to «REMOVAL»(ref-565161-S05362704272013071000000) .
4. Remove the timing chain assembly. Refer to «REMOVAL»(ref-565161-S16020200682013071000000) .
5. Remove the cam sprocket. Refer to «REMOVAL»(ref-565161-S27908761212013071000000) .
6. Remove the crank sprocket. Refer to «REMOVAL»(ref-565161-S05626316712013071000000) .
7. Remove the exhaust oil flow control solenoid valve. Refer to «REMOVAL»(ref-565163-S15153236632013071000000) .
8. Remove the camshaft position sensor. Refer to «REMOVAL»(ref-565163-S29731556922013071000000) .
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.

Scheme 512

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

Scheme 518

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) Install the O-ring to the front camshaft cap. NOTE: Use new O-rings. 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. Refer to «INSTALLATION»(ref-565161-S03021229472013071000000) .
5. Install the cam sprocket. Refer to «INSTALLATION»(ref-565161-S34826815772013071000000) .
6. Install the timing chain assembly. Refer to «INSTALLATION»(ref-565161-S03866533742013071000000) .
7. Install the chain cover. Refer to «INSTALLATION»(ref-565161-S16896700402013071000000) .
8. Install the crank pulley. Refer to «INSTALLATION»(ref-565161-S26224654262013071000000) .
9. Install the engine to the vehicle. Refer to «INSTALLATION»(ref-565161-S28513021132013071000000) .

Scheme 519

Scheme 520

Scheme 521

1. Measure the bend, and 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 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. 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) 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 with setting the dial gauge at end surface of camshaft. If the thrust 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)

Scheme 522

Scheme 523

1. Remove the engine from vehicle. Refer to «REMOVAL»(ref-565161-S41933007102013071000000) .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-565161-S07305427412013071000000) .
3. Remove the chain cover. Refer to «REMOVAL»(ref-565161-S05362704272013071000000) .
4. Remove the timing chain assembly. Refer to «REMOVAL»(ref-565161-S16020200682013071000000) .
5. Remove the cam sprocket. Refer to «REMOVAL»(ref-565161-S27908761212013071000000) .
6. Remove the crank sprocket. Refer to «REMOVAL»(ref-565161-S05626316712013071000000) .
7. Remove the camshaft. Refer to «REMOVAL»(ref-565161-S07435264002013071000000) .
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).

Scheme 524

Scheme 525

Scheme 526

Scheme 527

Scheme 528

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 the 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. Refer to «INSTALLATION»(ref-565161-S35809709142013071000000) .
8. Install the crank sprocket. Refer to «INSTALLATION»(ref-565161-S03021229472013071000000) .
9. Install the cam sprocket. Refer to «INSTALLATION»(ref-565161-S34826815772013071000000) .
10. Install the timing chain assembly. Refer to «INSTALLATION»(ref-565161-S03866533742013071000000) .
11. Install the chain cover. Refer to «INSTALLATION»(ref-565161-S16896700402013071000000) .
12. Install the crank pulley. Refer to «INSTALLATION»(ref-565161-S26224654262013071000000) .
13. Install the engine to the vehicle. Refer to «INSTALLATION»(ref-565161-S28513021132013071000000) .

Scheme 529

Scheme 530

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 «VALVE GUIDE»(ref-565161-S29306917172013071000000) and «INTAKE AND EXHAUST VALVE OIL SEAL»(ref-565161-S26223990832013071000000) .
4. Remove the plug and filter from the front camshaft cap as necessary.

Scheme 531

Scheme 532

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.
4. Install the plug and filter to the front camshaft cap as necessary. Tightening torque: T1: 9 N.m (0.9 kgf-m, 6.6 ft-lb) T2: 17 N.m (1.7 kgf-m, 12.5 ft-lb) T3: 23 N.m (2.3 kgf-m, 17.0 ft-lb)

Scheme 533

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