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Engine Mechanical (H6DO): Other Subaru Tribeca WX рестайлинг

Mechanical 56 illustrations ~5031 words

CAUTION

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

GENERAL TOOL

TOOL NAMEREMARKS
Compression gaugeUsed for measuring compression.
Vacuum gaugeUsed for measuring intake manifold vacuum.
Oil pressure gaugeUsed for measuring engine oil pressure.
Fuel pressure gaugeUsed for measuring fuel pressure.
TORX® socket (E12)Used for removing and installing connecting rod cap.

GENERAL TOOL REFERENCE

PROCEDURE

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

  1. V-belt
  2. Timing chain

INTAKE SIDE

Note. Adjustment of valve clearance should be performed while engine is cold. Do not wear gloves during removal and installation of valve lifter. Do not use valve lifters that were dropped or otherwise exposed to strong impacts.

Scheme 163

Scheme 163: INTAKE SIDE
Scheme 163: INTAKE SIDE
  1. Measure all valve clearances. Ref. to «INSPECTION»(ref-356702-S04935507882010022700000) , Valve Clearance. NOTE: Record each valve clearance after measurement.
  2. Remove the timing chain assembly. Ref. to «REMOVAL»(ref-356702-S25228579272010022700000) , Timing Chain Assembly.
  3. Remove the cam sprocket. Ref. to «REMOVAL»(ref-356702-S17672293192010022700000) , Cam Sprocket.
  4. Remove the camshaft. Ref. to «REMOVAL»(ref-356702-S27252641172010022700000) , Camshaft.
  5. Remove the valve lifter.
  6. Measure the thickness of valve lifter using micrometer.
  7. Select and install a valve lifter of suitable thickness from the following table using the measured valve clearance and valve lifter thickness. VALVE CLEARANCE REFERENCE Unit: mm (in) S = (V + T)-0.20 (0.0079) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used PART THICKNESS CHART Part number Thickness mm (in) 13228AD181 4.32 (0.1701) 13228AD191 4.34 (0.1709) 13228AD201 4.36 (0.1717) 13228AD211 4.38 (0.1724) 13228AD221 4.40 (0.1732) 13228AD231 4.42 (0.1740) 13228AD241 4.44 (0.1748) 13228AD251 4.46 (0.1756) 13228AD261 4.48 (0.1764) 13228AD271 4.50 (0.1772) 13228AD281 4.52 (0.1780) 13228AD291 4.54 (0.1787) 13228AD301 4.56 (0.1795) 13228AD311 4.58 (0.1803) 13228AD321 4.60 (0.1811) 13228AC581 4.62 (0.1819) 13228AC591 4.63 (0.1823) 13228AC601 4.64 (0.1827) 13228AC611 4.65 (0.1831) 13228AC621 4.66 (0.1835) 13228AC631 4.67 (0.1839) 13228AC641 4.68 (0.1843) 13228AC651 4.69 (0.1846) 13228AC661 4.70 (0.1850) 13228AC671 4.71 (0.1854) 13228AC681 4.72 (0.1858) 13228AC691 4.73 (0.1862) 13228AC701 4.74 (0.1866) 13228AC711 4.75 (0.1870) 13228AC721 4.76 (0.1874) 13228AC731 4.77 (0.1878) 13228AC741 4.78 (0.1882) 13228AC751 4.79 (0.1886) 13228AC761 4.80 (0.1890) 13228AC771 4.81 (0.1894) 13228AC781 4.82 (0.1898) 13228AC791 4.83 (0.1902) 13228AC801 4.84 (0.1906) 13228AC811 4.85 (0.1909) 13228AC821 4.86 (0.1913) 13228AC831 4.87 (0.1917) 13228AC841 4.88 (0.1921) 13228AC851 4.89 (0.1925) 13228AC861 4.90 (0.1929) 13228AC871 4.91 (0.1933) 13228AC881 4.92 (0.1937) 13228AC891 4.93 (0.1941) 13228AC901 4.94 (0.1945) 13228AC911 4.95 (0.1949) 13228AC921 4.96 (0.1953) 13228AC931 4.97 (0.1957) 13228AC941 4.98 (0.1961) 13228AC951 4.99 (0.1965) 13228AC961 5.00 (0.1969) 13228AC971 5.01 (0.1972) 13228AC981 5.02 (0.1976) 13228AC991 5.03 (0.1980) 13228AD001 5.04 (0.1984) 13228AD011 5.05 (0.1988) 13228AD021 5.06 (0.1992) 13228AD031 5.07 (0.1996) 13228AD041 5.08 (0.2000) 13228AD051 5.09 (0.2004) 13228AD061 5.10 (0.2008) 13228AD071 5.11 (0.2012) 13228AD081 5.12 (0.2016) 13228AD091 5.13 (0.2020) 13228AD101 5.14 (0.2024) 13228AD111 5.15 (0.2028) 13228AD121 5.16 (0.2032) 13228AD131 5.17 (0.2035) 13228AD141 5.18 (0.2039) 13228AD151 5.19 (0.2043) 13228AD161 5.20 (0.2047) 13228AD171 5.21 (0.2051) 13228AD331 5.23 (0.2059) 13228AD341 5.25 (0.2067) 13228AD351 5.27 (0.2075) 13228AD361 5.29 (0.2083) 13228AD371 5.31 (0.2091) 13228AD381 5.33 (0.2098) 13228AD391 5.35 (0.2106) 13228AD401 5.37 (0.2114) 13228AD411 5.39 (0.2122) 13228AD421 5.41 (0.2130) 13228AD431 5.43 (0.2138) 13228AD441 5.45 (0.2146) 13228AD451 5.47 (0.2154) 13228AD461 5.49 (0.2161) 13228AD471 5.51 (0.2169) 13228AD481 5.53 (0.2177) 13228AD491 5.55 (0.2185) 13228AD501 5.57 (0.2193) 13228AD511 5.59 (0.2201)
  8. Install the camshaft. Ref. to «INSTALLATION»(ref-356702-S18940478422010022700000) , Camshaft.
  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. Re-measure all valve clearance at this time. If the valve clearance is not appropriate, repeat from the first step.
  12. After measurement, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

EXHAUST SIDE

Note. Adjustment of valve clearance should be performed while engine is cold. Do not wear gloves during removal and installation of valve lifter. Do not use valve lifters that were dropped or otherwise exposed to strong impacts.

  1. Measure all valve clearances. Ref. to «INSPECTION»(ref-356702-S04935507882010022700000) , Valve Clearance. NOTE: Record each valve clearance after measurement.
  2. Remove the camshaft. Ref. to «REMOVAL»(ref-356702-S27252641172010022700000) , Camshaft.
  3. Remove the valve lifter.
  4. Measure the thickness of valve lifter using micrometer.
  5. Select and install a valve lifter of suitable thickness from the following table using the measured valve clearance and valve lifter thickness. VALVE LIFTER THICKNESS CHART Unit: mm (in) S = (V + T)-0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used PART THICKNESS CHART Part number Thickness mm (in) 13228AD181 4.32(0.1701) 13228AD191 4.34(0.1709) 13228AD201 4.36 (0.1717) 13228AD211 4.38 (0.1724) 13228AD221 4.40(0.1732) 13228AD231 4.42 (0.1740) 13228AD241 4.44(0.1748) 13228AD251 4.46(0.1756) 13228AD261 4.48 (0.1764) 13228AD271 4.50(0.1772) 13228AD281 4.52 (0.1780) 13228AD291 4.54(0.1787) 13228AD301 4.56(0.1795) 13228AD311 4.58 (0.1803) 13228AD321 4.60(0.1811) 13228AC581 4.62(0.1819) 13228AC591 4.63(0.1823) 13228AC601 4.64(0.1827) 13228AC611 4.65(0.1831) 13228AC621 4.66(0.1835) 13228AC631 4.67(0.1839) 13228AC641 4.68(0.1843) 13228AC651 4.69(0.1846) 13228AC661 4.70(0.1850) 13228AC671 4.71 (0.1854) 13228AC681 4.72(0.1858) 13228AC691 4.73(0.1862) 13228AC701 4.74(0.1866) 13228AC711 4.75(0.1870) 13228AC721 4.76(0.1874) 13228AC731 4.77(0.1878) 13228AC741 4.78(0.1882) 13228AC751 4.79(0.1886) 13228AC761 4.80(0.1890) 13228AC771 4.81 (0.1894) 13228AC781 4.82(0.1898) 13228AC791 4.83(0.1902) 13228AC801 4.84(0.1906) 13228AC811 4.85(0.1909) 13228AC821 4.86(0.1913) 13228AC831 4.87(0.1917) 13228AC841 4.88(0.1921) 13228AC851 4.89(0.1925) 13228AC861 4.90(0.1929) 13228AC871 4.91 (0.1933) 13228AC881 4.92(0.1937) 13228AC891 4.93(0.1941) 13228AC901 4.94(0.1945) 13228AC911 4.95(0.1949) 13228AC921 4.96(0.1953) 13228AC931 4.97(0.1957) 13228AC941 4.98(0.1961) 13228AC951 4.99(0.1965) 13228AC961 5.00(0.1969) 13228AC971 5.01 (0.1972) 13228AC981 5.02(0.1976) 13228AC991 5.03(0.1980) 13228AD001 5.04(0.1984) 13228AD011 5.05(0.1988) 13228AD021 5.06(0.1992) 13228AD031 5.07(0.1996) 13228AD041 5.08 (0.2000) 13228AD051 5.09 (0.2004) 13228AD061 5.10(0.2008) 13228AD071 5.11 (0.2012) 13228AD081 5.12(0.2016) 13228AD091 5.13(0.2020) 13228AD101 5.14(0.2024) 13228AD111 5.15(0.2028) 13228AD121 5.16(0.2032) 13228AD131 5.17(0.2035) 13228AD141 5.18(0.2039) 13228AD151 5.19(0.2043) 13228AD161 5.20 (0.2047) 13228AD171 5.21 (0.2051) 13228AD331 5.23 (0.2059) 13228AD341 5.25 (0.2067) 13228AD351 5.27 (0.2075) 13228AD361 5.29 (0.2083) 13228AD371 5.31 (0.2091) 13228AD381 5.33 (0.2098) 13228AD391 5.35(0.2106) 13228AD401 5.37(0.2114) 13228AD411 5.39(0.2122) 13228AD421 5.41 (0.2130) 13228AD431 5.43(0.2138) 13228AD441 5.45(0.2146) 13228AD451 5.47(0.2154) 13228AD461 5.49(0.2161) 13228AD471 5.51 (0.2169) 13228AD481 5.53(0.2177) 13228AD491 5.55(0.2185) 13228AD501 5.57(0.2193) 13228AD511 5.59(0.2201)
  6. Install the camshaft. Ref. to «INSTALLATION»(ref-356702-S18940478422010022700000) , Camshaft.
  7. Install the cam sprocket. Ref. to «INSTALLATION»(ref-356702-S40103196722010022700000) , Cam Sprocket.
  8. Install the timing chain assembly. Ref. to «INSTALLATION»(ref-356702-S11926965042010022700000) , Timing Chain Assembly.
  9. Re-measure all valve clearance at this time. If the valve clearance is not appropriate, repeat from the first step.
  10. After measurement, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

Scheme 164

Scheme 164: REMOVAL
Scheme 164: REMOVAL

Scheme 165

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Scheme 184

Scheme 185

Scheme 185
Scheme 185
  1. Set the vehicle on a lift.
  2. Change the bolt mounting position from (A) to (B), then completely open the front hood.
  3. Remove the collector cover.
  4. Collect the refrigerant from A/C system. Ref. to «PROCEDURE»(ref-356694-S08537380652010022700000) , Refrigerant Recovery Procedure.
  5. Release the fuel pressure. Ref. to «RELEASING OF FUEL PRESSURE»(ref-356685-S39418415252010022700000) , PROCEDURE, Fuel.
  6. Remove the battery from vehicle. Ref. to «REMOVAL»(ref-356696-S38431336602010022700000) , Battery.
  7. Remove the air intake duct, air cleaner case and air intake chamber. Ref. to «REMOVAL»(ref-356695-S28116802952010022700000) , Air Intake Duct. Ref. to «REMOVAL»(ref-356695-S25477935752010022700000) , Air Cleaner Case. Ref. to «REMOVAL»(ref-356695-S35903837162010022700000) , Air Intake Chamber.
  8. Remove the front upper cover.
  9. Remove the front bumper. Ref. to «FRONT BUMPER FACE»(ref-356698-S18076064042010022700000) , REMOVAL, Front Bumper.
  10. Remove the radiator from vehicle. Ref. to «REMOVAL»(ref-356686-S07060985392010022700000) , Radiator. NOTE: Protect the condenser so that it will not be damaged.
  11. Remove the fuel hose bracket.
  12. Remove the V-belts. Ref. to «REMOVAL»(ref-356702-S00140377892010022700000) , V-belt.
  13. Disconnect the A/C pressure hoses from A/C compressor. Ref. to «REMOVAL»(ref-356694-S04335591122010022700000) , Hose and Pipe.
  14. Remove the engine ground terminal.
  15. Disconnect the following connector. Engine harness connectors Generator connector, terminal and A/C compressor connector Power steering switch connector
  16. Disconnect the following hoses. Brake booster vacuum hose Heater inlet and outlet hoses
  17. Remove the power steering pump together with the bracket. NOTE: Do not disconnect the hose and pipe from the power steering pump body.
  18. Remove the power reserve tank together with the bracket. NOTE: Do not disconnect the hose from the reservoir tank body.
  19. Suspend the power steering pump using wire, etc.
  20. Remove the bolts which hold the vacuum pump bracket to the engine. Ref. to «BRAKE VACUUM PUMP»(ref-356689-S37392138992010022700000) , COMPONENT, General Description.
  21. Lift up the vehicle.
  22. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-356700-S41167135532010022700000) , Front Exhaust Pipe. NOTE: Be careful not to let the front exhaust pipe interfere with water pipes on engine side.
  23. Remove the ground cable from the chain cover lower (left and right).
  24. Remove the bolts which hold the vacuum pump bracket to the transmission, then remove the vacuum pump together with the bracket. Ref. to «BRAKE VACUUM PUMP»(ref-356689-S37392138992010022700000) , COMPONENT, General Description.
  25. Remove the bolts and nuts which hold lower side of transmission to engine.
  26. Remove the nuts which install front cushion rubber onto front crossmember.
  27. Remove the two clutch housing securing bolts.
  28. Lower the vehicle.
  29. Separate the torque converter clutch from drive plate. Remove the throttle body securing bolts to and slide the throttle body over. Remove the service hole plug. Remove the bolts which hold torque converter clutch to drive plate. Remove other bolts while rotating the crankshaft using socket wrench.
  30. Remove the pitching stopper.
  31. Disconnect the fuel delivery hose and evaporation hose. Disconnect the connector of fuel pipe by pushing the ST in the direction of arrow. ST 42099AE000 QUICK CONNECTOR RELEASE Remove the clamp, and disconnect the evaporation hose from the pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
  32. Remove the radiator center bracket.
  33. Support the engine with a lifting device and wire ropes.
  34. Support the transmission with a garage jack. CAUTION: Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
  35. Separate the engine and transmission. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. Ref. to «REMOVAL»(ref-356696-S27246888992010022700000) , Starter. Remove the bolts which hold upper side of transmission to engine.
  36. Attach the ST to converter case. ST 498277200 STOPPER SET
  37. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with garage jack. Move the engine horizontally until main shaft is withdrawn from clutch cover. Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  38. Remove the engine mount.
  39. Remove the clutch housing cover from vehicle.

Scheme 186

Scheme 186: INSTALLATION
Scheme 186: INSTALLATION

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Scheme 193
Scheme 193
  1. Set the clutch housing cover to the vehicle.
  2. Install the engine mount. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
  3. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  4. Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  5. Remove the lifting device and wire ropes.
  6. Remove the garage jack.
  7. Install the radiator center bracket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  8. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
  9. Remove the ST from converter case. NOTE: Be careful not to drop the ST into the converter case when removing the ST. ST 498277200 STOPPER SET
  10. Install the starter. Ref. to «INSTALLATION»(ref-356696-S04615633472010022700000) , Starter.
  11. Install the torque converter clutch to drive plate. Tighten the bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the crankshaft using socket wrench. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Install the service hole plug to prevent foreign matter from being mixed. Install the throttle body to intake manifold. Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)
  12. Lift up the vehicle.
  13. Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  14. Tighten the bolts which holds the vacuum pump bracket to the transmission. Ref. to «BRAKE VACUUM PUMP»(ref-356689-S37392138992010022700000) , COMPONENT, General Description. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
  15. Tighten the nuts which install the front cushion rubber onto crossmember. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb) NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
  16. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-356700-S37596940432010022700000) , Front Exhaust Pipe. NOTE: Be care not to let the front exhaust pipe interfere with water pipes and crossmember on engine side. Be care not to scratch the flange surface of front exhaust pipe with stud bolt on engine.
  17. Connect the ground cable to the chain cover lower (left and right).
  18. Lower the vehicle.
  19. Install the fuel hose bracket. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
  20. Tighten the bolts which holds the vacuum pump bracket to the engine. Ref. to «BRAKE VACUUM PUMP»(ref-356689-S37392138992010022700000) , COMPONENT, General Description. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
  21. Install the power steering pump. Tightening torque: (A) 25 N.m (2.5 kgf-m, 18.4 ft-lb) (B) 33 N.m (3.4 kgf-m, 24.3 ft-lb)
  22. Install the reservoir tank. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)
  23. Connect the following hoses. Fuel delivery hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose
  24. Connect the following connectors. Engine harness connectors Generator connector and terminal A/C compressor connector Power steering switch connector
  25. Connect the engine ground terminal. Tightening torque: 14 N.m (1.4 kgf-m, 10.3 ft-lb)
  26. Install the A/C pressure hoses. Ref. to «INSTALLATION»(ref-356694-S36941251232010022700000) , Hose and Pipe.
  27. Install the V-belts. Ref. to «INSTALLATION»(ref-356702-S21173229552010022700000) , V-belt.
  28. Install the radiator to vehicle. Ref. to «INSTALLATION»(ref-356686-S01138712392010022700000) , Radiator.
  29. Install the front bumper. Ref. to «FRONT BUMPER FACE»(ref-356698-S09854344242010022700000) , INSTALLATION, Front Bumper.
  30. Install the fuse of fuel pump to the main fuse box.
  31. Install the battery to the vehicle. Ref. to «INSTALLATION»(ref-356696-S10502434862010022700000) , Battery.
  32. Fill engine coolant. Ref. to «FILLING OF ENGINE COOLANT»(ref-356686-S03353205592010022700000) , REPLACEMENT, Engine Coolant.
  33. Check the ATF level and replenish it if necessary. Ref. to «INSPECTION»(ref-356688-S29187960972010022700000) , Automatic Transmission Fluid.
  34. Charge the A/C system with refrigerant. Ref. to «PROCEDURE»(ref-356694-S17298669492010022700000) , Refrigerant Charging Procedure.
  35. Install the front upper cover.
  36. Install the air intake duct, air cleaner case and air intake chamber. Ref. to «INSTALLATION»(ref-356695-S13782467052010022700000) , Air Intake Duct. Ref. to «INSTALLATION»(ref-356695-S26742152722010022700000) , Air Cleaner Case. Ref. to «INSTALLATION»(ref-356695-S22112747372010022700000) , Air Intake Chamber.
  37. Install the collector cover.
  38. Change the bolt mounting position from (B) to (A), then close the front hood.
  39. Lower the vehicle from lift.

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.

Valve seat width W: Intake: Standard: 1.0 mm (0.039 in)

Exhaust: Standard: 1.5 mm (0.059 in)

Scheme 194

Scheme 194: VALVE SEAT
Scheme 194: VALVE SEAT

Scheme 195

Scheme 195: VALVE GUIDE
Scheme 195: VALVE GUIDE

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Scheme 197
Scheme 197
  1. Check the clearance between valve guide and stem. The clearance can be checked by measuring the valve stem outer diameter with a micrometer and valve guide inner diameter with a caliper gauge respectively. 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 stem exceeds the standard, replace the valve guide or valve itself whichever shows greater amount of wear or damaged and etc. 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 cylinder, 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. Valve guide protrusion 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 reamer in valve guide, and rotate the reamer slowly clockwise while pushing it lightly. Bring the reamer back while rotating it clockwise. ST 499765900 VALVE GUIDE REAMER NOTE: Apply engine oil to the reamer when reaming. If the inner surface of valve guide is damaged, the edge of reamer should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer. After reaming, clean the valve guide to remove chips. Recheck the contact condition between valve and valve seat after replacing the valve guide.

Scheme 198

Scheme 198: INTAKE AND EXHAUST VALVE
Scheme 198: INTAKE AND EXHAUST VALVE
  1. Inspect the flange and stem of valve, and replace if damaged, worn or deformed, or if dimension of "H" in the figure exceeds the standard, or if offset wear occurs. Head edge thickness H: Intake (A): Standard 1.0 mm (0.039 in) Exhaust (B): Standard 1.2 mm (0.047 in) Valve overall length: Intake (A): 103.5 mm (4.075 in) Exhaust (B): 103.2 mm (4.063 in)
  2. Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Install a new valve oil seal after lapping.

Scheme 199

Scheme 199: VALVE SPRING
Scheme 199: VALVE SPRING
  1. Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table. VALVE SPRING LENGTH CHART Free length mm (in) Intake 41.51 (1.6342) Exhaust 41.51 (1.6342) Squareness Intake 2.5°, 1.8 mm (0.071 in) Exhaust 2.5°, 1.8 mm (0.071 in)
  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 valve spring using a try square.

INTAKE AND EXHAUST VALVE OIL SEAL

For the following, replace the oil seal with a new part.

  1. When the lip is damaged.
  2. When the spring is out of the specified position.
  3. When readjusting the surfaces of intake valve and valve seat.
  4. When replacing the intake valve guide.

Scheme 200

Scheme 200
Scheme 200
  1. Set the cylinder head on ST1.
  2. Using the ST2, press in the oil seal. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499585500 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer to strike in.

Scheme 201

Scheme 201: VALVE LIFTER
Scheme 201: VALVE LIFTER

Scheme 202

Scheme 202
Scheme 202
  1. Check the valve lifter visually.
  2. Measure the outer diameter of valve lifter. Outer diameter: 32.959 - 32.975 mm (1.2976 - 1.2982 in)
  3. Measure the inner diameter of valve lifter hole of cylinder head. Inner diameter: 32.994 - 33.016 mm (1.2990 - 1.2998 in) NOTE: If difference between outer diameter of valve lifter and inner diameter of valve lifter hole is out of the standard or offset wearing exists, replace the cylinder head. Standard: 0.019 - 0.057 mm (0.0007 - 0.0022 in)

CYLINDER BLOCK

  1. Visually check for cracks and damage. Especially, inspect the important parts using liquid penetrant tester.
  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. Surface warpage limit: 0.02 mm (0.0008 in) Standard height of cylinder block: 202 mm (7.95 in)

Scheme 203

Scheme 203: CYLINDER AND PISTON
Scheme 203: CYLINDER AND PISTON

Scheme 204

Scheme 204
Scheme 204

Scheme 205

Scheme 205
Scheme 205
  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. How to measure the 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: Standard: 0.030 mm (0.0012 in) Out-of-roundness: Standard: 0.010 mm (0.0004 in)
  3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
  4. How to measure the outer diameter of each piston: Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 37.3 mm (1.4685 in) Piston outer diameter: Standard: A: 92.005 - 92.015 mm (3.6222 - 3.6226 in) B: 91.995 - 92.005 mm (3.6218 - 3.6222 in) 0.25 mm (0.0098 in) oversize: 92.245 - 92.265 mm (3.6317 - 3.6325 in) 0.50 mm (0.0197 in) oversize: 92.495 - 92.515 mm (3.6415 - 3.6423 in)
  5. Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard: -0.010 - 0.010 mm (-0.0004 - 0.0004 in)
  6. Boring and honing: If the value of cylindricality, out-of-round-ness, or cylinder-to-piston clearance measured is out of standard or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only. Nor use an oversize piston for one cylinder only. If the cylinder inner diameter exceeds 92.515 mm (3.6317 in) 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, pay attention to this when measuring the cylinder diameter.

Scheme 206

Scheme 206: PISTON AND PISTON PIN
Scheme 206: PISTON AND PISTON PIN

Scheme 207

Scheme 207
Scheme 207

Scheme 208

Scheme 208
Scheme 208
  1. Check the pistons and piston pins for damage, cracks and wear, and the piston ring grooves for wear and damage. Replace if faulty.
  2. Measure the clearance between each cylinder piston and cylinders. Ref. to «CYLINDER AND PISTON»(ref-356702-S40946341802010022700000) , INSPECTION, Cylinder Block. If any of the clearances is not within standard, replace the piston, or bore the cylinder to use an oversize piston.
  3. Check that the piston pin can be inserted into the piston pin hole just by using your thumb at 20°C (68°F). Replace if faulty. Standard clearance between piston pin and hole in piston: 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 209

Scheme 209: PISTON RING
Scheme 209: PISTON RING

Scheme 210

Scheme 210
Scheme 210

Scheme 211

Scheme 211
Scheme 211
  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. CAUTION: Marks are displayed on the end of top and second rings. When installing the ring to piston, face this mark upward. Oil ring consists of the upper rail, expander and lower rail. When installing on 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 SPECIFICATION Standard mm (in) Piston ring gap Top ring 0.20 - 0.25 (0.0079 - 0.0098) Second ring 0.40 - 0.50 (0.0157 - 0.0197) Oil ring 0.20 - 0.50 (0.0079 - 0.0197)
  3. 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 SPECIFICATION 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 212

Scheme 212: CONNECTING ROD
Scheme 212: CONNECTING ROD

Scheme 213

Scheme 213
Scheme 213

Scheme 214

Scheme 214
Scheme 214

Scheme 215

Scheme 215
Scheme 215
  1. Replace the connecting rod, if the large or small end thrust surface is damaged.
  2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist.
  3. Install the connecting rod fitted with bearing to crankshaft and measure the thrust clearance. If the clearance exceeds the standard or offset wear occurs, 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 plastigage. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard: 0.016 - 0.043 mm (0.0006 - 0.0017 in) BEARING SIZE THICKNESS CHART Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.489 - 1.505 (0.0586 - 0.0593) 51.976 - 52.000 (2.0463 - 2.0472) 0.03 (0.0012) Undersize 1.507 - 1.515 (0.0593 - 0.0596) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) Undersize 1.517 - 1.525 (0.0597 - 0.0600) 51.934 - 51.950 (2.0446 - 2.0453) 0.25 (0.0098) Undersize 1.617 - 1.625 (0.0637 - 0.0640) 51.734 - 51.750 (2.0368 - 2.0374)
  6. Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance on the smaller end of the connecting rod. Clearance between piston pin and bushing: Standard: 0 - 0.022 mm (0 - 0.0009 in)
  7. Replacement procedure is as follows. Remove the bushing from connecting rod with ST and press. Press the bushing with ST after applying oil on the periphery of the new bushing. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the pre-manufactured holes on the connecting rod. Ream the inside of bushing. After completion of reaming, clean the bushing to remove chips.

Scheme 216

Scheme 216: CRANKSHAFT AND CRANKSHAFT BEARING
Scheme 216: CRANKSHAFT AND CRANKSHAFT BEARING

Scheme 217

Scheme 217
Scheme 217

Scheme 218

Scheme 218
Scheme 218
  1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. Replace if defective.
  2. Check the crankshaft for bend, and repair or replace if needed. Repair or replace if bended. NOTE: If a suitable V-block is not available, install #1 and #7 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then check the crankshaft bend using a dial gauge.
  3. Inspect the crank journal and crank pin for wear. If they are not within the specification, replace the bearing with a suitable (undersize) one, and replace or readjust 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 and crank journal: Out-of-roundness: 0.005 mm (0.0002 in) Cylindricality: 0.006 mm (0.0002 in) CRANK JOURNAL DIAMETER CHART Unit: mm (in) Crank journal diameter Crank pin outer diameter #1,#3, #5 #7 #2, #4, #6 Standard Journal O.D. 63.992 - 64.016 (2.5194 - 2.5203) 51.976 - 52.000 (2.0463 - 2.0472) Bearing size (Thickness at center) 1.996 - 2.013 (0.0786 - 0.0793) 1.992 - 2.009 (0.0784 - 0.0791) 1.996 - 2.013 (0.0786 - 0.0793) 1.489 - 1.501 (0.0586 - 0.0591) 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) 2.015 - 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) 2.025 - 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) 2.125 - 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 plastigage. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary. Crankshaft oil clearance: Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in)

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