Contents Section: Mechanical All sections

Engine Mechanical (H6DO): Diagnosis Subaru Tribeca WX рестайлинг

Mechanical 33 illustrations ~3396 words

INSPECTION

CAUTIONAfter warming-up, engine becomes very hot. Be careful not to burn yourself during measurement.

Scheme 30

Scheme 30
  1. Remove the collector cover.
  2. After warming-up the engine, turn the ignition switch to OFF.
  3. Make sure that the battery is fully charged.
  4. Release the fuel pressure. Ref. to «RELEASING OF FUEL PRESSURE»(ref-356685-S39418415252010022700000) , PROCEDURE, Fuel.
  5. Remove all the spark plugs. Ref. to «REMOVAL»(ref-356703-S10884482542010022700000) , Spark Plug.
  6. Fully open the throttle valve.
  7. Check the starter motor for satisfactory performance and operation.
  8. Hold 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.
  9. Crank the engine by the starter motor, and read the maximum value on the gauge when the needle of gauge is steady.
  10. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 rpm and fully open throttle): Standard: 1,275 - 1,471 kPa (13.0 - 15.0 kgf/cm 2 , 185 - 213 psi) Service limit: 1,128 kPa (11.5 kgf/cm 2 , 164 psi)
  11. 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. Idle the engine.
  3. Read the engine idle speed using Subaru Select Monitor. Ref. to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-356699-S29602494512010022700000) , OPERATION, Subaru Select Monitor.
  4. 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]: 700±100 rpm
  5. Check the idle speed when loaded. (Turn the air conditioning switch "ON" and operate the compressor for at least one minute before measurement.) Idle speed [A/C "ON" and gears in "P" or "N" range]: 805±100 rpm NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to General Diagnosis Table under "Engine Control System". Ref. to «BASIC DIAGNOSTIC PROCEDURE»(ref-356699-S41068277322010022700000) .
CAUTIONAfter warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.
  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. Idle the engine.
  3. Read the ignition timing using the Subaru Select Monitor. Ref. to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-356699-S29602494512010022700000) , OPERATION, Subaru Select Monitor. Ignition timing [BTDC/rpm]: 15° ±8°/700 If the timing is not correct, check the ignition control system. Refer to "Engine Control System". Ref. to «BASIC DIAGNOSTIC PROCEDURE»(ref-356699-S41068277322010022700000) .

Scheme 31

Scheme 31: INSPECTION
  1. Idle the engine.
  2. Disconnect the brake booster vacuum hose from the intake manifold, and install the vacuum gauge.
  3. Keep the engine at idle speed and read the vacuum gauge indication. By observing the vacuum gauge needle movement, internal condition of the engine can be diagnosed as described below. Vacuum pressure (at idling, A/C OFF): -60.0 kPa (-450 mmHg, -17.72 inHg) or less POSSIBLE ENGINE CONDITION CHART Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tendency becomes more evident as engine temperature rises. Air leakage around intake manifold gasket, disconnection or damage of vacuum hose 2. Needle intermittently drops to position lower than normal position. Leakage around cylinder 3. Needle drops suddenly and intermittently from normal position. 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 normal position in narrow range. Defective ignition system
  1. Remove the oil pressure switch from the oil pan, upper. Ref. to «REMOVAL»(ref-356684-S35927391132010022700000) , Oil Pressure Switch.
  2. Connect the oil pressure gauge hose to the oil pan upper.
  3. Connect the ground cable to battery.
  4. Start the engine, and measure the oil pressure. Oil pressure (at oil temperature of 80°C (176°F)): Standard: 100 kPa (1.0 kgf/cm 2 , 15 psi) or more (at 700 rpm) 500 kPa (5.1 kgf/cm 2 , 73 psi) or more (at 5,000 rpm) If the oil pressure is out of specification, check the oil pump, oil filter and lubrication line. Ref. to «INSPECTION»(ref-356684-S09309601452010022700000) , General Diagnostic Table. If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. Ref. to «INSPECTION»(ref-356684-S09309601452010022700000) , General Diagnostic Table.
  5. After measuring the oil pressure, install the oil pressure switch. Ref. to «INSTALLATION»(ref-356684-S14904814472010022700000) , Oil Pressure Switch.
CAUTIONBefore removing the fuel pressure gauge, release the fuel pressure. Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.

Note. If the fuel pressure is out of specification, check or replace the fuel pump and fuel delivery line.

Scheme 32

Scheme 32

Scheme 33

Scheme 33

Scheme 34

Scheme 34
  1. Remove the collector cover.
  2. Release the fuel pressure. Ref. to «RELEASING OF FUEL PRESSURE»(ref-356685-S39418415252010022700000) , PROCEDURE, Fuel.
  3. Open the fuel filler lid, and remove the fuel filler cap.
  4. Disconnect the fuel delivery hose and connect fuel pressure gauge. Disconnect the fuel delivery hose using the ST1. ST1 42099AE000 QUICK CONNECTOR RELEASE Connect the fuel pressure meter using the ST2 and ST3. NOTE: ST2 is a genuine Subaru part. ST2 42075AG690 FUEL HOSE ST3 18471AA000 FUEL PIPE ADAPTER
  5. Install the fuse of fuel pump to the main fuse box.
  6. Start the engine.
  7. Measure the fuel pressure after warming up the engine. Fuel pressure: Standard: 338 - 348 kPa (3.4 - 3.5 kgf/cm 2 , 49 - 50.5 psi) 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.

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

Scheme 35

Scheme 35: INSPECTION

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Scheme 39

Scheme 39
  1. Set the vehicle on a lift.
  2. Remove the collector cover.
  3. Disconnect the ground cable from battery.
  4. Lift up the vehicle.
  5. Remove the under cover.
  6. Lower the vehicle.
  7. When inspecting RH side cylinders: Remove the air intake duct and air cleaner case. Ref. to «REMOVAL»(ref-356695-S28116802952010022700000) , Air Intake Duct. Ref. to «REMOVAL»(ref-356695-S25477935752010022700000) , Air Cleaner Case. Remove the fuel pipe protector (RH). Disconnect the connector of oil pressure switch. Remove the ignition coil. Ref. to «REMOVAL»(ref-356703-S42469484542010022700000) , Ignition Coil. Remove the rocker cover (RH). Ref. to «REMOVAL»(ref-356702-S27252641172010022700000) , Camshaft.
  8. When inspecting LH side cylinders: Disconnect the battery cable, and then remove the battery and battery carrier. Disconnect the PCV hose and blow-by hose from the rocker cover (LH). Remove the fuel pipe protector (LH). Remove the ignition coil. Ref. to «REMOVAL»(ref-356703-S42469484542010022700000) , Ignition Coil. Remove the rocker cover (LH). Ref. to «REMOVAL»(ref-356702-S27252641172010022700000) , Camshaft.
  9. Turn the crankshaft clockwise until the cam is set to position shown in the figure.
  10. 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: 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.
  11. If necessary, adjust the valve clearance. Ref. to «ADJUSTMENT»(ref-356702-S03997986792010022700000) , Valve Clearance.
  12. Further turn the crank pulley clockwise and then measure the valve clearances again.
  13. After inspection, install the related parts in the reverse order of removal. Ref. to «INSTALLATION»(ref-356702-S18940478422010022700000) , Camshaft.
  1. Check the pipes and hoses are installed firmly.
  2. Check the engine coolant and ATF are at specified levels.
  3. Start the engine and check for leaks of fuel, exhaust gas, engine coolant, etc. Also check for noise and vibrations.

Make sure that no crack or other damages do not exist.

Scheme 40

Scheme 40: REMOVAL
  1. Remove the engine from the body. Ref. to «REMOVAL»(ref-356702-S24470607562010022700000) , Engine Assembly.
  2. Set the engine on ST. ST 18232AA000 ENGINE STAND
  3. Before servicing overhaul, remove the sensor, pipe and hose that installed to engine. Remove the intake manifold. Ref. to «REMOVAL»(ref-356685-S33880319142010022700000) , Intake Manifold. Remove the generator. Ref. to «REMOVAL»(ref-356696-S18200835812010022700000) , Generator. Remove the A/C compressor. Ref. to «REMOVAL»(ref-356694-S10286735352010022700000) , Compressor. Disconnect the water pipe and hose. Disconnect the engine harness. Remove the spark plug. Ref. to «REMOVAL»(ref-356703-S10884482542010022700000) , Spark Plug. Remove the camshaft position sensor. Ref. to «REMOVAL»(ref-356685-S42237314662010022700000) , Camshaft Position Sensor. Remove the crankshaft position sensor. Ref. to «REMOVAL»(ref-356685-S42363846892010022700000) , Crankshaft Position Sensor. Remove the knock sensor. Ref. to «REMOVAL»(ref-356685-S04849343042010022700000) , Knock Sensor. Remove the engine coolant temperature sensor. Ref. to «REMOVAL»(ref-356685-S36611441722010022700000) , Engine Coolant Temperature Sensor. Remove the oil temperature sensor. Ref. to «REMOVAL»(ref-356685-S06744740522010022700000) , Oil Temperature Sensor. Remove the oil flow control solenoid valve. Ref. to «REMOVAL»(ref-356685-S26694208412010022700000) , Oil Flow Control Solenoid Valve. Remove the oil pressure switch. Ref. to «REMOVAL»(ref-356684-S35927391132010022700000) , Oil Pressure Switch. Remove the oil filter. Ref. to «REMOVAL»(ref-356684-S04825968892010022700000) , Engine Oil Filter. Remove the oil cooler. Ref. to «REMOVAL»(ref-356684-S24803275462010022700000) , Oil Cooler.
  1. Check the crank pulley cover for oil and air leakage.
  2. Check the crank pulley for looseness.
  1. Check the cam sprocket teeth for abnormal wear and scratches.
  2. Make sure there is no free play between cam sprocket and key.
  1. Check the crank sprocket teeth for abnormal wear and scratches.
  2. Make sure there is no free play between crank sprocket and key.

Scheme 41

Scheme 41: REMOVAL

Scheme 42

Scheme 42

Scheme 43

Scheme 43
  1. Remove the engine from vehicle. Ref. to «REMOVAL»(ref-356702-S24470607562010022700000) , Engine Assembly.
  2. Remove the crank pulley. Ref. to «REMOVAL»(ref-356702-S02998419892010022700000) , Crank Pulley.
  3. Remove the chain cover. Ref. to «REMOVAL»(ref-356702-S00863908562010022700000) , Chain Cover.
  4. Remove the timing chain assembly. Ref. to «REMOVAL»(ref-356702-S25228579272010022700000) , Timing Chain Assembly.
  5. Remove the cam sprocket. Ref. to «REMOVAL»(ref-356702-S17672293192010022700000) , Cam Sprocket.
  6. Remove the crank sprocket. Ref. to «REMOVAL»(ref-356702-S19005087832010022700000) , Crank Sprocket.
  7. Remove the exhaust oil flow control solenoid valve. Ref. to «REMOVAL»(ref-356685-S26694208412010022700000) , Oil Flow Control Solenoid Valve.
  8. Remove the camshaft position sensor. Ref. to «REMOVAL»(ref-356685-S42237314662010022700000) , Camshaft Position Sensor.
  9. Loosen the rocker cover bolt in the numerical order as shown in the figure, then remove the rocker cover. LH side RH side
  10. Loosen the camshaft cap bolts equally, a little at a time in numerical sequence 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 camshafts (LH) and related parts.

Scheme 44

Scheme 44: INSTALLATION

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Scheme 48

Scheme 49

Scheme 49
  1. Apply engine oil to camshaft journals, and install the camshaft.
  2. Install the camshaft cap. Apply liquid gasket sparingly to back side of front camshaft cap as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure. NOTE: Install the oil pan lower within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 2.0±0.5 mm (0.079 ±0.020 in) Apply engine oil to cap bearing surface, and install the cap to camshaft. Tighten the camshaft cap bolts in the numerical order as shown in the figure. Tightening torque: (1) - (12): 16 N.m (1.6 kgf-m, 11.8 ft-lb) (13) - (16): 9.75 N.m (1.0 kgf-m, 7.2 ft-lb)
  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. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure. NOTE: Install the oil pan lower within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 3.5±0.5 mm (0.138 ±0.020 in) LH side RH side Tighten the rocker cover bolts in the numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) LH side RH side
  4. Install the crank sprocket. Ref. to «INSTALLATION»(ref-356702-S10473554702010022700000) , Crank Sprocket.
  5. Install the cam sprocket. Ref. to «INSTALLATION»(ref-356702-S40103196722010022700000) , Cam Sprocket.
  6. Install the timing chain assembly. Ref. to «INSTALLATION»(ref-356702-S11926965042010022700000) , Timing Chain Assembly.
  7. Install the chain cover. Ref. to «INSTALLATION»(ref-356702-S27091003422010022700000) , Chain Cover.
  8. Install the crank pulley. Ref. to «INSTALLATION»(ref-356702-S19937659232010022700000) , Crank Pulley.
  9. Install the engine to the vehicle. Ref. to «INSTALLATION»(ref-356702-S14364150742010022700000) , Engine Assembly.

Scheme 50

Scheme 50: INSPECTION

Scheme 51

Scheme 51

Scheme 52

Scheme 52
  1. Measure the bend of camshaft. Repair or replace if bended. Service 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. Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance. CAMSHAFT JOURNAL CHART Camshaft Journal Front Except for front Standard mm (in) 37.946 - 37.963 (1.4939 - 1.4946) 25.946 - 25.963 (1.0215 - 1.0222)
  5. Measurement of the camshaft journal oil clearance: Clean the camshaft cap and cylinder head camshaft journal. Place the camshafts on the cylinder head. (Without installing the valve rocker.) Place a plastigage across each camshaft journals. Install the camshaft cap. NOTE: Do not turn the camshaft. Remove the camshaft cap. Measure the widest point of the plastigage on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard: 0.037 - 0.072 mm (0.0015 - 0.0028 in) Completely remove the plastigage.
  6. Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard or offset wear occurs, replace it. Cam 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: Intake: 36.00 mm (1.4173 in) Exhaust: 36.00 mm (1.4173 in)
  7. Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the standard or offset wear occurs, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft. Standard: Intake 0.075 - 0.135 mm (0.0030 - 0.0053 in) Exhaust 0.075 - 0.135 mm (0.0030 - 0.0053 in)

Scheme 53

Scheme 53: REMOVAL

Scheme 54

Scheme 54
  1. Remove the engine from vehicle. Ref. to «REMOVAL»(ref-356702-S24470607562010022700000) , Engine Assembly.
  2. Remove the crank pulley. Ref. to «REMOVAL»(ref-356702-S02998419892010022700000) , Crank Pulley.
  3. Remove the chain cover. Ref. to «REMOVAL»(ref-356702-S00863908562010022700000) , Chain Cover.
  4. Remove the timing chain assembly. Ref. to «REMOVAL»(ref-356702-S25228579272010022700000) , Timing Chain Assembly.
  5. Remove the cam sprocket. Ref. to «REMOVAL»(ref-356702-S17672293192010022700000) , Cam Sprocket.
  6. Remove the crank sprocket. Ref. to «REMOVAL»(ref-356702-S19005087832010022700000) , Crank Sprocket.
  7. Remove the camshaft. Ref. to «REMOVAL»(ref-356702-S27252641172010022700000) , Camshaft.
  8. Remove the seal bolts as shown in the figure.
  9. Remove the cylinder head bolts in the numerical order as shown in the figure. 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 surfaces of the cylinder head and cylinder block.
  13. Similarly, remove the cylinder head (RH).

Scheme 55

Scheme 55: INSTALLATION

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Scheme 59

Scheme 59
  1. Apply liquid gasket to the mating surface of cylinder block as shown in the figure. CAUTION: Do not apply liquid gasket excessively. If applying excessively, remove the excess liquid gasket that flowed out. NOTE: Install the oil pan lower within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 3.5±1.0 mm (0.138 ±0.039 in) LH side RH side
  2. Install the cylinder head gaskets (LH and RH) on cylinder blocks. NOTE: Use a new cylinder head gasket.
  3. Apply liquid gasket to the mating surface of cylinder head gasket as shown in the figure. CAUTION: Do not apply liquid gasket excessively. If applying excessively, remove the excess liquid gasket that flowed out. NOTE: Install the oil pan lower within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 3.5±1.0 mm (0.138 ±0.039 in) LH side RH side
  4. Install the cylinder head to cylinder block. CAUTION: Be careful not to scratch the mating surfaces of the cylinder head and cylinder block.
  5. Tighten the cylinder head bolts. Apply a coat of engine oil to washers and cylinder head bolt threads. Install the cylinder head to cylinder block, and then 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 with torque of 50 N.m (5.1 kgf-m, 36.9 ft-lb) in numerical sequence as shown 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) with torque of 48 N.m (4.9 kgf-m, 35.4 ft-lb) in numerical sequence. Tighten the bolts (5) - (8) with torque of 44 N.m (4.5 kgf-m, 32.5 ft-lb) in numerical sequence. 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 bolts as shown in the figure. NOTE: Apply seal material on the bolt threads before installing the seal bolts. Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
  7. Install the camshaft. Ref. to «INSTALLATION»(ref-356702-S18940478422010022700000) , Camshaft.
  8. Install the crank sprocket. Ref. to «INSTALLATION»(ref-356702-S10473554702010022700000) , Crank Sprocket.
  9. Install the cam sprocket. Ref. to «INSTALLATION»(ref-356702-S40103196722010022700000) , Cam Sprocket.
  10. Install the timing chain assembly. Ref. to «INSTALLATION»(ref-356702-S11926965042010022700000) , Timing Chain Assembly.
  11. Install the chain cover. Ref. to «INSTALLATION»(ref-356702-S27091003422010022700000) , Chain Cover.
  12. Install the crank pulley. Ref. to «INSTALLATION»(ref-356702-S19937659232010022700000) , Crank Pulley.
  13. Install the engine to the vehicle. Ref. to «INSTALLATION»(ref-356702-S14364150742010022700000) , Engine Assembly.

Scheme 60

Scheme 60: DISASSEMBLY
  1. Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE
  2. Remove the valve lifter.
  3. Set the ST on valve spring retainer. Compress the valve spring and remove the valve spring retainer key. Remove 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. Refer to INSPECTION for removal and installation procedures of valve guide, intake valve oil seal and exhaust valve oil seal. Ref. to «VALVE GUIDE»(ref-356702-S26797112222010022700000) , INSPECTION, Cylinder Head. Ref. to «INTAKE AND EXHAUST VALVE OIL SEAL»(ref-356702-S24043661112010022700000) , INSPECTION, Cylinder Head.

Scheme 61

Scheme 61: ASSEMBLY
  1. Installation of valve spring and valve: Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE Coat the stem of each valve with engine oil and insert the valve into valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its close-coiled end facing the seat on cylinder head. Install the valve spring with the painted side facing to retainer. Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER Compress the valve spring and fit the valve spring retainer key. After installing, tap the valve spring retainers lightly with a wooden hammer for better seating.
  2. Apply oil to the surface of valve lifter.
  3. Install the valve lifter.

Scheme 62

Scheme 62: CYLINDER HEAD
  1. Make sure that no crack or other damages do not exist. In addition to visual inspection, inspect important areas using liquid penetrant tester. 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. Surface warpage limit: 0.02 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 warping. 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 "most likely" to "rarely".

A - Most likely

B - Sometimes

C - Rarely

SymptomsProblem parts etc.Possible causeRANK
1. Engine does not start.
1) Starter does not turn.StarterDefective battery-to-starter harnessB
Defective starter switchC
Defective inhibitor switchC
Defective starterB
BatteryImproper connection of terminalA
Run-down batteryA
Defective charging systemB
FrictionSeizure of crankshaft and connecting rod bearingC
Seized camshaftC
Seized or stuck piston and cylinderC
2) Initial combustion does not occur.StarterDefective starterC
Engine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Fuel lineDefective fuel pump and relayA
Clogged fuel lineC
Lack of or insufficient fuelB
Timing chainTroubleB
Defective timingB
CompressionIncorrect valve clearanceC
Loosened spark plug or defective gasketC
Loosened cylinder head bolt or defective gasketC
Improper valve sealingC
Defective valve stemC
Worn or broken valve springB
Worn or stuck piston rings, cylinder and pistonC
Incorrect valve timingB
Improper engine oil (low viscosity)B
3) Initial combustion occurs.Engine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemDefective intake manifold gasketB
Defective throttle body gasketB
Fuel lineDefective fuel pump and relayC
Clogged fuel lineC
Lack of or insufficient fuelB
Timing chainTroubleB
Defective timingB
CompressionIncorrect valve clearanceC
Loosened spark plug or defective gasketC
Loosened cylinder head bolt or defective gasketC
Improper valve sealingC
Defective valve stemC
Worn or broken valve springB
Worn or stuck piston rings, cylinder and pistonC
Incorrect valve timingB
Improper engine oil (low viscosity)B
4) Engine stalls after initial combustion.Engine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened or cracked intake ductB
Loosened or cracked PCV hoseC
Loosened or cracked vacuum hoseC
Defective intake manifold gasketB
Defective throttle body gasketB
Dirty air cleaner elementC
Fuel lineClogged fuel lineC
Lack of or insufficient fuelB
Timing chainTroubleB
Defective timingB
CompressionIncorrect valve clearanceC
Loosened spark plug or defective gasketC
Loosened cylinder head bolt or defective gasketC
Improper valve sealingC
Defective valve stemC
Worn or broken valve springB
Worn or stuck piston rings, cylinder and pistonC
Incorrect valve timingB
Improper engine oil (low viscosity)B
2. Rough idle and engine stallEngine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened or cracked intake ductA
Loosened or cracked PCV hoseA
Loosened or cracked vacuum hoseA
Defective intake manifold gasketB
Defective throttle body gasketB
Defective PCV valveC
Loosened oil filler capB
Dirty air cleaner elementC
Fuel lineDefective fuel pump and relayC
Clogged fuel lineC
Lack of or insufficient fuelB
Timing chainDefective timingC
CompressionIncorrect valve clearanceB
Loosened spark plug or defective gasketB
Loosened cylinder head bolt or defective gasketB
Improper valve sealingB
Defective valve stemC
Worn or broken valve springB
Worn or stuck piston rings, cylinder and pistonB
Incorrect valve timingA
Improper engine oil (low viscosity)B
Lubrication systemIncorrect oil pressureB
Defective rocker cover gasketC
Cooling systemOver-heatingC
OthersEvaporative emission control system malfunctionA
Stuck or damaged throttle valveB
3. Low output, hesitation and poor accelerationEngine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened or cracked intake ductA
Loosened or cracked PCV hoseA
Loosened or cracked vacuum hoseB
Defective intake manifold gasketB
Defective throttle body gasketB
Defective PCV valveB
Loosened oil filler capB
Dirty air cleaner elementA
Fuel lineDefective fuel pump and relayB
Clogged fuel lineB
Lack of or insufficient fuelC
Timing chainDefective timingB
CompressionIncorrect valve clearanceB
Loosened spark plug or defective gasketB
Loosened cylinder head bolt or defective gasketB
Improper valve sealingB
Defective valve stemC
Worn or broken valve springB
Worn or stuck piston rings, cylinder and pistonC
Incorrect valve timingA
Improper engine oil (low viscosity)B
Lubrication systemIncorrect oil pressureB
Cooling systemOver-heatingC
Over-coolingC
OthersEvaporative emission control system malfunctionA
4. SurgingEngine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened or cracked intake ductA
Loosened or cracked PCV hoseA
Loosened or cracked vacuum hoseA
Defective intake manifold gasketB
Defective throttle body gasketB
Defective PCV valveB
Loosened oil filler capB
Dirty air cleaner elementB
Fuel lineDefective fuel pump and relayB
Clogged fuel lineB
Lack of or insufficient fuelC
Timing chainDefective timingB
CompressionIncorrect valve clearanceB
Loosened spark plug or defective gasketC
Loosened cylinder head bolt or defective gasketC
Improper valve sealingC
Defective valve stemC
Worn or broken valve springC
Worn or stuck piston rings, cylinder and pistonC
Incorrect valve timingA
Improper engine oil (low viscosity)B
Cooling systemOver-heatingB
OthersEvaporative emission control system malfunctionC
5. Engine does not return to idle.Engine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened or cracked vacuum hoseA
OthersStuck or damaged throttle valveA
6. Dieseling (Run-on)Engine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Cooling systemOver-heatingB
OthersEvaporative emission control system malfunctionB
7. After burning in exhaust systemEngine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened or cracked intake ductC
Loosened or cracked PCV hoseC
Loosened or cracked vacuum hoseB
Defective PCV valveB
Loosened oil filler capC
Timing chainDefective timingB
CompressionIncorrect valve clearanceB
Loosened spark plug or defective gasketC
Loosened cylinder head bolt or defective gasketC
Improper valve sealingB
Defective valve stemC
Worn or broken valve springC
Worn or stuck piston rings, cylinder and pistonC
Incorrect valve timingA
Lubrication systemIncorrect oil pressureC
Cooling systemOver-coolingC
OthersEvaporative emission control system malfunctionC
8. KnockingEngine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemLoosened oil filler capB
Timing chainDefective timingB
CompressionIncorrect valve clearanceC
Incorrect valve timingB
Cooling systemOver-heatingA
9. Excessive engine oil consumptionIntake systemLoosened or cracked PCV hoseA
Defective PCV valveB
Loosened oil filler capC
CompressionDefective valve stemA
Worn or stuck piston rings, cylinder and pistonA
Lubrication systemLoosened oil pump attaching bolts and defective gasketB
Defective oil filter O-ringB
Defective crankshaft oil sealB
Defective rocker cover gasketB
Loosened oil drain plug or defective gasketB
Loosened oil pan fitting bolts or defective oil panB
10. Excessive fuel consumptionEngine control system, Ref. to BASIC DIAGNOSTIC PROCEDURE .A
Intake systemDirty air cleaner elementA
Timing chainDefective timingB
CompressionIncorrect valve clearanceB
Loosened spark plug or defective gasketC
Loosened cylinder head bolt or defective gasketC
Improper valve sealingB
Defective valve stemC
Worn or broken valve springC
Worn or stuck piston rings, cylinder and pistonB
Incorrect valve timingB
Lubrication systemIncorrect oil pressureC
Cooling systemOver-coolingC

SYMPTOM CHART

Type of soundConditionPossible cause
Regular clicking soundSound increases as engine speed increases.Valve mechanism is defective. Incorrect valve clearance Worn camshaft Broken valve spring Trouble of valve lifter
Heavy and dull clankOil pressure is low.Worn camshaft main bearing Worn connecting rod bearing (large end)
Oil pressure is normal.Damaged engine mounting
High-pitched clankSound is noticeable when accelerating with an overload condition.Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong thermal value spark plug Gasoline of improper octane number
Clank when engine speed is between 1,000 and 2,000 rpm.Sound is reduced when fuel injector connector of noisy cylinder is disconnected. (1)Worn crankshaft main bearing Worn connecting rod bearing (large end)
Knocking sound when engine is operating under idling speed and engine is warmSound is reduced when fuel injector connector of noisy cylinder is disconnected. (1)Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each fuel injector connector is disconnected in turn. (1)Unusually worn valve lifter Worn cam gear Worn camshaft journal bore in cylinder head
Squeaky soundInsufficient generator lubrication
Rubbing soundPoor contact of generator brush and rotor
Gear scream when starting engineDefective ignition starter switch Worn gear and starter pinion
Sound like polishing glass with a dry clothLoose drive belt Defective water pump shaft
Hissing soundInsufficient compression Air leakage in air intake system, hose, connection or manifold
Timing chain noiseLoose timing chain Contact of timing chain with adjacent part
Valve lifter noiseIncorrect valve clearance
(1) When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode, Ref. to OPERATION , Clear Memory Mode. and Inspection Mode, Ref. to PROCEDURE , Inspection Mode. after connecting the fuel injector connector.
(1)When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode, Ref. to OPERATION , Clear Memory Mode. and Inspection Mode, Ref. to PROCEDURE , Inspection Mode. after connecting the fuel injector connector.

POSSIBLE CAUSE SYMPTOM