Engine Mechanical (H6DO): Other Subaru Outback BR рестайлинг

CAUTION

1. Prior to starting work, pay special attention to the following: Always wear work clothes, a safety cap, protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary. Protect the vehicle using a seat cover, fender cover, etc. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
2. Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
3. When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement.
4. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
5. Always use the jack-up point when the shop jacks or rigid racks are used to support the vehicle.
6. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. When lifting up the vehicle, make sure to support the vehicle at the jack-up points.
7. Be careful not to let any oil or grease contact the clutch disc or flywheel.
8. Remove contamination including dirt and corrosion before removal, installation, disassembly or assembly.
9. Keep the removed parts in order and protect them from dust and dirt.
10. All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
11. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil when being assembled.
12. Bolts, nuts and washers should be replaced with new parts as required.
13. Be sure to tighten the fasteners including bolts and nuts to the specified torque.

GENERAL TOOL

METHOD WITH SUBARU SELECT MONITOR

1. 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.
2. Warm up the engine.
3. Read the ignition timing using Subaru Select Monitor. Refer to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-565198-S08829121112013071000000) . NOTE: If ignition timing is out of standard, check the ignition control system. Refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-565198-S31331816802013071000000) . Ignition timing [BTDC/rpm]: Standard 15°±8°/700

Scheme 623

1. 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.
2. Warm up the engine.
3. Stop the engine, and turn the ignition switch to OFF.
4. 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.
5. Disconnect the ground cable from battery.
6. Remove the air intake duct. Refer to «REMOVAL»(ref-565165-S00196848762013071000000) .
7. Disconnect the connector from mass air flow and intake air temperature sensor.
8. Remove the air cleaner case and element.
9. Connect the timing light to the power wire of #1 ignition coil.
10. Install the connectors of air cleaner case, element, and the mass air flow and intake air temperature sensor.
11. Connect the ground cable to battery.
12. 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 «BASIC DIAGNOSTIC PROCEDURE»(ref-565198-S31331816802013071000000) . Ignition timing [BTDC/rpm]: Standard 15°±8°/700
13. After inspection, install the related parts in the reverse order of removal.

Scheme 624

1. Warm up the engine.
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. Disconnect the brake booster vacuum hose from the intake manifold, and attach the vacuum gauge.
4. 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)
5. After inspection, install the related parts in the reverse order of removal. 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

EXHAUST SIDE

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 camshaft. Refer to «REMOVAL»(ref-565161-S07435264002013071000000) .
4. Remove the valve lifter.
5. Measure the thickness of valve lifter using micrometer.
6. 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) - 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Current valve lifter thickness
7. Install the camshaft. Refer to «INSTALLATION»(ref-565161-S35809709142013071000000) .
8. Install the cam sprocket. Refer to «INSTALLATION»(ref-565161-S34826815772013071000000) .
9. Install the timing chain assembly. Refer to «INSTALLATION»(ref-565161-S03866533742013071000000) .
10. 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): 0.35±0.05 mm (0.0138±0.0020 in)
11. After adjustment, install the related parts in the reverse order of removal. NOTE: Refer to «INSTALLATION»(ref-565161-S35809709142013071000000) when installing the rocker cover. .

Scheme 625

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Scheme 648

Scheme 649

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. Collect the refrigerant from A/C system. Refer to «PROCEDURE»(ref-565180-S26395196252013071000000) .
4. Release the fuel pressure. Refer to «PROCEDURE»(ref-565163-S40104667132013071000000) .
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. Refer to «REMOVAL»(ref-565165-S00196848762013071000000) , Air Intake Duct, «REMOVAL»(ref-565165-S02004603892013071000000) , Air Cleaner Case, and «REMOVAL»(ref-565165-S25915665572013071000000) , Air Intake Boot.
8. Remove the V-belts. Refer to «REMOVAL»(ref-565161-S04819945492013071000000) .
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. Refer to «REMOVAL»(ref-565199-S32337342902013071000000) .
15. Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.
16. Lift up the vehicle.
17. Remove the under cover. Refer to «REMOVAL»(ref-565181-S28182960572013071000000) .
18. Drain engine coolant completely. Refer to «DRAINING OF ENGINE COOLANT»(ref-565167-S19351012342013071000000) .
19. Remove the front exhaust pipe. Refer to «REMOVAL»(ref-565201-S03342601172013071000000) .
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. Refer to «REMOVAL»(ref-565167-S11463109162013071000000) and «REMOVAL»(ref-565167-S21296041312013071000000) .
24. Remove the radiator. Refer to «REMOVAL»(ref-565167-S05791119462013071000000) .
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. Refer to «REMOVAL»(ref-565180-S08675238322013071000000) .
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.

Scheme 650

Scheme 651

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Scheme 654

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. Refer to «INSTALLATION»(ref-565167-S09229691332013071000000) .
8. Install the radiator main fan & fan motor and radiator sub fan & fan motor. Refer to «INSTALLATION»(ref-565167-S13254392552013071000000) and «INSTALLATION»(ref-565167-S33283941762013071000000) .
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. Refer to «INSTALLATION»(ref-565201-S28862029152013071000000) .
13. Install the under cover. Refer to «INSTALLATION»(ref-565181-S36610771312013071000000) .
14. Lower the vehicle.
15. Install the A/C pressure hoses to A/C compressor. Refer to «INSTALLATION»(ref-565180-S02271563392013071000000) .
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. Refer to «INSTALLATION»(ref-565199-S24945347732013071000000) .
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. Refer to «INSTALLATION»(ref-565161-S02167665892013071000000) .
33. Install the air intake duct, air cleaner case and air intake boot assembly. Refer to «INSTALLATION»(ref-565165-S37221606252013071000000) , Air Intake Duct, Refer to «INSTALLATION»(ref-565165-S04574179012013071000000) , Air Cleaner Case, and.Refer to «INSTALLATION»(ref-565165-S19209019292013071000000) , Air Intake Boot.
34. Connect the ground cable to battery.
35. Fill engine coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-565167-S04263119292013071000000) .
36. Charge the A/C system with refrigerant. Refer to «PROCEDURE»(ref-565180-S21933146242013071000000) .
37. Check the ATF level and replenish it if necessary. Refer to «INSPECTION»(ref-565170-S12832332002013071000000) .
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)

Scheme 655

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Scheme 658

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 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) 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. Put a new valve guide, coated with sufficient oil, in the cylinder head, and insert the ST1 into 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) Check the valve guide protrusion amount "L". 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) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. ST 499765900 VALVE GUIDE REAMER NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. After reaming, clean the valve guide to remove chips. Recheck the contact condition between valve and valve seat after replacing the valve guide.

Scheme 659

1. Check the flange and stem of the valve, and replace the valve with new one 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 valve seat surface, and lap the valve and valve 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)

Scheme 660

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. Free length mm (in) 49.06 (1.9315) Tension/spring height N (kgf, lb)/mm (in) Set 182 - 210 (18.6 - 21.4, 40.9 - 47.2)/31.0 (1.220 in) Lift 316 - 350 (32.2 - 35.7, 71.0 - 78.7)/21.0 (0.827 in) Squareness 2.5°, 2.1 mm (0.083 in) or less

Scheme 661

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 18261AA010 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 to strike in.

Scheme 662

Scheme 663

1. Check the valve lifter visually.
2. Measure the outer diameter of valve lifter. Outer diameter of valve lifter: 32.959 - 32.975 mm (1.2976 - 1.2982 in)
3. Measure the inner diameter of valve lifter mating surface on 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 checked by measuring the outer diameter of valve lifter and the inner diameter of valve lifter. If it exceeds the standard or offset wear occurs, replace the cylinder head. Valve lifter and valve lifter mating surface clearance: 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 for checking. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
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)

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Scheme 666

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). Cylindricality: Limit 0.030 mm (0.0012 in) Out-of-roundness: Limit 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). Clearance between cylinder and piston 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 cylindricality, 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. If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. 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)

Scheme 667

Scheme 668

Scheme 669

1. Check the piston and piston pin for damage, cracks or wear. Replace if faulty.
2. Check the piston ring groove for wear or damage. Replace if faulty.
3. Make sure that the piston pin can be inserted into the piston pin hole with 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.

Scheme 670

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Scheme 672

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 installing the ring to piston, face marks to 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. Standard mm (in) Piston ring gap Top ring 0.20 - 0.35 (0.0079 - 0.0138) 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. 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)

Scheme 673

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Scheme 676

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 the bend or twist exceeds the limit. 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. Connecting rod oil clearance: Standard 0.016 - 0.043 mm (0.0006 - 0.0017 in) 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. If the measured value is not within the standard, replace it with a new part. 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. Press the bushing with the ST after applying oil on the periphery of new bushing. 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.

Scheme 677

Scheme 678

Scheme 679

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 Limit 0.005 mm (0.0002 in) Cylindricality Limit 0.006 mm (0.0002 in) Grinding limit (dia.) To 51.734 mm (2.0368 in) Crank journal: Out-of-roundness Limit 0.005 mm (0.0002 in) Cylindricality Limit 0.006 mm (0.0002 in) Grinding limit (dia.) To 63.742 mm (2.5095 in) 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)