MECHANICAL(H4DO)
ME(H4DO)

MECHANICAL(H4DO) > General Description
SPECIFICATION

Engine
Model | 2.5 L
Cylinder arrangement | Horizontally opposed, liquid cooled, 4-cylinder 4-stroke gasoline engine
Valve system mechanism | Chain driven, double overhead camshaft, 4-valve/cylinder
Bore × Stroke | mm (in) | 94.0 × 90.0 (3.70 × 3.54)
Displacement | cm3 (cu in) | 2,498 (152)
Compression ratio | 12.0
Compression pressure (at 200 — 300 r/min) | kPa (kg/cm2, psi) | Standard | 1,050 — 1,400 (11 — 14, 152 — 203)
Number of piston rings | Compression ring: 2 Oil ring: 1
Intake valve timing | Open | Max. retard | ATDC 37°
Min. advance | BTDC 41°
Close | Max. retard | ABDC 105°
Min. advance | ABDC 27°
Exhaust valve timing | Open | Max. retard | BBDC 10°
Min. advance | BBDC 65°
Close | Max. retard | ATDC 46°
Min. advance | BTDC 9°
Cam clearance | mm (in) | Intake | Standard | 0.13+0.02−0.03 (0.0051+0.0008−0.0012)
Exhaust | Standard | 0.22±0.02 (0.0087±0.0008)
Idle rpm (select lever in “P” or “N” range) | r/min | No load | Standard | 675±100
A/C ON | Standard | 800 — 900±50
Ignition order | 1 → 3 → 2 → 4
Ignition timing | BTDC/{r/min} | Standard | 8°±10°/675

OS: Oversize   US: Undersize

Camshaft | Bending | mm (in) | Limit | 0.020 (0.0008)
Cam lobe height | mm (in) | Intake | Valve drive section | Standard | 40.34 — 40.44 (1.5882 — 1.5921)
Fuel pump drive section | Standard | 44.94 — 45.06 (1.7693 — 1.7740)
Exhaust | Standard | 39.66 — 39.76 (1.5614 — 1.5654)
Cam base circle diameter | mm (in) | Standard | 34.0 (1.3386)
Journal outer diameter | mm (in) | Standard | 25.946 — 25.963 (1.0215 — 1.0222)
Thrust clearance | mm (in) | Standard | 0.068 — 0.116 (0.0027 — 0.0047)
Oil clearance | mm (in) | Standard | 0.037 — 0.072 (0.0015 — 0.0028)
Cylinder head | Warpage (mating surface with cylinder block) | mm (in) | Limit | 0.020 (0.0008)
Grinding limit | mm (in) | 98.45 (3.8760) or less
Height | mm (in) | Standard | 98.5 (3.8779)
Valve & valve guide | Valve overall length | mm (in) | Intake | 104.95 (4.1319)
Exhaust | 96.53 (3.8004)
Valve head edge thickness | mm (in) | Intake | Standard | 0.8 — 1.2 (0.0315 — 0.0472)
Exhaust | Standard | 1.0 — 1.4 (0.0394 — 0.0551)
Valve stem outer diameter | mm (in) | Intake | Standard | 5.455 — 5.470 (0.2148 — 0.2154)
Exhaust | Standard | 5.445 — 5.460 (0.2144 — 0.2150)
Valve guide inner diameter | mm (in) | Standard | 5.500 — 5.512 (0.2165 — 0.2170)
Clearance between valve and valve guide | mm (in) | Intake | Standard | 0.030 — 0.057 (0.0012 — 0.0022)
Exhaust | Standard | 0.040 — 0.067 (0.0016 — 0.0026)
Valve guide protrusion amount | mm (in) | Standard | 11.4 — 11.8 (0.4488 — 0.4646)
Valve & valve shim | Valve stem end outer diameter | mm (in) | Intake | Standard | 5.455 — 5.470 (0.2148 — 0.2154)
Exhaust | Standard | 5.445 — 5.460 (0.2144 — 0.2150)
Valve shim inner diameter | mm (in) | Standard | 5.500 — 5.560 (0.2165 — 0.2189)
Clearance between valve and valve shim | mm (in) | Intake | Standard | 0.030 — 0.105 (0.0012 — 0.0041)
Exhaust | Standard | 0.040 — 0.115 (0.0016 — 0.0045)
Valve seat | Seating width between valve and valve seat | mm (in) | Intake | Standard | 0.8 — 1.6 (0.0315 — 0.0630)
Exhaust | Standard | 1.1 — 1.7 (0.0433 — 0.0669)
Seating angle between valve and valve seat | 45°
Seating position between valve and valve seat | Valve face center
Valve spring | Free length (Reference) | mm (in) | Standard | 41.16 (1.6205)
Tension/spring height | N (kgf, lb)/mm (in) | Set | Standard | 182 — 210 (18.56 — 21.41, 40.92 — 47.22)/33.0 (1.2992)
Lift | Standard | 523 — 579 (53.33 — 59.04, 117.59 — 130.18)/22.0 (0.8661)
Squareness (at height of 30 mm (1.1811 in)) | Standard | 2.5°, 1.4 mm (0.0551 in) or less
Cylinder block & piston | Cylinder block warpage (Mating surface with cylinder head) | mm (in) | Limit | 0.025 (0.0010)
Grinding limit of cylinder block | mm (in) | 204.95 (8.0689) or less
Height of cylinder block | mm (in) | Standard | 205.0 (8.0709)
Inner diameter of cylinder liner | mm (in) | Cylinder bore size mark A | Standard | 94.005 — 94.015 (3.7010 — 3.7014)
Cylinder bore size mark B | Standard | 93.995 — 94.005 (3.7006 — 3.7010)
Cylindricality of cylinder liner | mm (in) | Limit | 0.030 (0.0012)
Out-of-roundness of cylinder liner | mm (in) | Limit | 0.030 (0.0012)
Piston grade point | mm (in) | 13.3 (0.5236)
Piston outer diameter | mm (in) | Standard Size | Grade A | Standard | 93.980 — 94.990 (3.7000 — 3.7004)
Grade B | Standard | 93.970 — 93.980 (3.6996 — 3.7000)
0.25 (0.0098) OS | Standard | 94.220 — 94.240 (3.7094 — 3.7102)
0.50 (0.0197) OS | Standard | 94.470 — 94.490 (3.7193 — 3.7201)
Clearance between cylinder liner and piston | mm (in) | Standard | 0.015 — 0.035 (0.0006 — 0.0014)
Inner diameter of cylinder liner boring limit (diameter) | mm (in) | 94.505 (3.7207) or less
Piston and piston pin | Degree of fit | Piston pin must be fitted into position with thumb at 20°C (68°F).
Clearance between piston and piston pin | mm (in) | Standard | 0.004 — 0.008 (0.0002 — 0.0003)
Piston ring | Closed gap | mm (in) | Compression ring | Top ring | Standard | 0.20 — 0.25 (0.0079 — 0.0098)
Second ring | Standard | 0.25 — 0.35 (0.0098 — 0.0138)
Oil ring (upper rail and lower rail) | Standard | 0.10 — 0.35 (0.0039 — 0.0138)
Clearance between compression ring and piston | mm (in) | Top ring | Standard | 0.040 — 0.080 (0.0016 — 0.0031)
Second ring | Standard | 0.030 — 0.070 (0.0012 — 0.0028)
Connecting rod and connecting rod bearing | Bend or twist per 100 mm (3.9370 in) in length | mm (in) | Limit | 0.10 (0.0039)
Thrust clearance | mm (in) | Standard | 0.070 — 0.330 (0.0028 — 0.0130)
Connecting rod bearing thickness (at center) | mm (in) | Connecting rod side | Standard size | Standard | 1.496 — 1.512 (0.0589 — 0.0595)
0.03 (0.0012) US | Standard | 1.515 — 1.519 (0.0596 — 0.0598)
0.05 (0.0020) US | Standard | 1.525 — 1.529 (0.0600 — 0.0602)
0.25 (0.0098) US | Standard | 1.625 — 1.629 (0.0640 — 0.0641)
Connecting rod cap side | Standard size | Standard | 1.492 — 1.508 (0.0587 — 0.0594)
0.03 (0.0012) US | Standard | 1.511 — 1.515 (0.0595 — 0.0596)
0.05 (0.0020) US | Standard | 1.521 — 1.525 (0.0599 — 0.0600)
0.25 (0.0098) US | Standard | 1.621 — 1.625 (0.0638 — 0.0640)
Oil clearance | mm (in) | Standard | 0.017 — 0.047 (0.0007 — 0.0019)
Piston pin & connecting rod bushing | Clearance between piston pin and connecting rod bushing | mm (in) | Standard | 0.004 — 0.026 (0.0002 — 0.0010)
Crankshaft and crankshaft bearing | Bending | mm (in) | Limit | 0.035 (0.0014)
Crankshaft pin | Cylindricality | mm (in) | Limit | 0.006 (0.0002)
Out-of-roundness | mm (in) | Limit | 0.005 (0.0002)
Grinding limit (diameter) | mm (in) | 47.726 (1.8790) or less
Crankshaft journal | Cylindricality | mm (in) | Limit | 0.006 (0.0002)
Out-of-roundness | mm (in) | Limit | 0.005 (0.0002)
Grinding limit (diameter) | mm (in) | 67.735 (2.6667) or less
Crankshaft pin outer diameter | mm (in) | Standard size | Standard | 47.976 — 48.000 (1.8888 — 1.8898)
0.03 (0.0012) US | Standard | 47.946 — 47.970 (1.8876 — 1.8886)
0.05 (0.0020) US | Standard | 47.926 — 47.950 (1.8868 — 1.8878)
0.25 (0.0098) US | Standard | 47.726 — 47.750 (1.8790 — 1.8799)
Crankshaft journal outer diameter | mm (in) | Standard size | Standard | 67.985 — 68.003 (2.6766 — 2.6773)
0.03 (0.0012) US | Standard | 67.955 — 67.979 (2.6754 — 2.6763)
0.05 (0.0020) US | Standard | 67.935 — 67.959 (2.6746 — 2.6755)
0.25 (0.0098) US | Standard | 67.735 — 67.759 (2.6667 — 2.6677)
Crankshaft bearing thickness (at center) | mm (in) | #1, #3 | Standard size | Standard | 2.498 — 2.513 (0.0983 — 0.0989)
0.03 (0.0012) US | Standard | 2.519 — 2.522 (0.0992 — 0.0993)
0.05 (0.0020) US | Standard | 2.529 — 2.532 (0.0996 — 0.0997)
0.25 (0.0098) US | Standard | 2.629 — 2.632 (0.1035 — 0.1036)
#2, #4 | Standard size | Standard | 2.501 — 2.516 (0.0985 — 0.0991)
0.03 (0.0012) US | Standard | 2.519 — 2.522 (0.0992 — 0.0993)
0.05 (0.0020) US | Standard | 2.529 — 2.532 (0.0996 — 0.0997)
0.25 (0.0098) US | Standard | 2.629 — 2.632 (0.1035 — 0.1036)
#5 | Standard size | Standard | 2.499 — 2.514 (0.0984 — 0.0990)
0.03 (0.0012) US | Standard | 2.517 — 2.520 (0.0991 — 0.0992)
0.05 (0.0020) US | Standard | 2.527 — 2.530 (0.0995 — 0.0996)
0.25 (0.0098) US | Standard | 2.627 — 2.630 (0.1034 — 0.1035)
Thrust clearance | mm (in) | Standard | 0.130 — 0.308 (0.0051 — 0.0121)
Oil clearance | mm (in) | Standard | 0.013 — 0.031 (0.0005 — 0.0012)

MECHANICAL(H4DO) > General Description
COMPONENT
1. V-BELT AND V-BELT TENSIONER & IDLER PULLEY

(1) | V-belt | (4) | Idler pulley | Tightening torque: N·m (kgf-m, ft-lb)
(2) | V-belt tensioner | (5) | Idler pulley cover | T1: | 19 (1.9, 14.0)
(3) | V-belt tensioner bracket |  |  | T2: | 36 (3.7, 26.6)

2. VACUUM PUMP

(1) | Vacuum pump |  |  | Tightening torque: N·m (kgf-m, ft-lb)
|  |  |  | T: | 16 (1.6, 11.8)

3. CRANK PULLEY

(1) | Crank pulley | (3) | Crank pulley boss | Tightening torque: N·m (kgf-m, ft-lb)
(2) | O-ring |  |  | T: | MECHANICAL(H4DO)>Crank Pulley>INSTALLATION

4. TIMING CHAIN & CAMSHAFT

(1) | Side chain guide RH | (9) | O-ring | (17) | Side chain guide LH
(2) | Intake camshaft RH | (10) | Chain tensioner RH |
(3) | Exhaust camshaft RH | (11) | Crank sprocket | Tightening torque: N·m (kgf-m, ft-lb)
(4) | Intake cam sprocket RH | (12) | Chain tensioner LH | T1: | 6.4 (0.7, 4.7)
(5) | Exhaust cam sprocket RH | (13) | Intake cam sprocket LH | T2: | 8.5 (0.9, 6.3)
(6) | Timing chain | (14) | Exhaust cam sprocket LH | T3: | 18 (1.8, 13.3)
(7) | Chain guide | (15) | Intake camshaft LH
(8) | Chain tension lever | (16) | Exhaust camshaft LH

5. CHAIN COVER

(1) | Oil level gauge | (6) | Oil filler cap | Tightening torque: N·m (kgf-m, ft-lb)
(2) | O-ring | (7) | Gasket | T1: | 6.4 (0.7, 4.7)
(3) | Oil level gauge guide | (8) | Chain cover | T2: | MECHANICAL(H4DO)>Chain Cover>INSTALLATION
(4) | O-ring | (9) | O-ring
(5) | Front oil seal | (10) | O-ring

6. ROCKER COVER

(1) | Rocker cover RH | (4) | Rocker cover gasket LH | Tightening torque: N·m (kgf-m, ft-lb)
(2) | Rocker cover gasket RH | (5) | Rocker cover LH | T: | MECHANICAL(H4DO)>Rocker Cover>INSTALLATION
(3) | Rocker cover gasket

7. CAM CARRIER

(1) | Cam carrier ASSY RH | (8) | Oil spacer | (15) | Intake rear camshaft cap LH
(2) | Front camshaft cap RH | (9) | Filter | (16) | Exhaust rear camshaft cap LH
(3) | Intake center camshaft cap RH | (10) | Cam carrier ASSY LH
(4) | Exhaust center camshaft cap RH | (11) | Cam carrier LH | Tightening torque: N·m (kgf-m, ft-lb)
(5) | Intake rear camshaft cap RH | (12) | Front camshaft cap LH | T1: | 6.4 (0.7, 4.7)
(6) | Exhaust rear camshaft cap RH | (13) | Intake center camshaft cap LH | T2: | MECHANICAL(H4DO)>Cam Carrier>INSTALLATION
(7) | Cam carrier RH | (14) | Exhaust center camshaft cap LH | T3: | MECHANICAL(H4DO)>Cam Carrier>ASSEMBLY

8. CYLINDER HEAD

(1) | Spark plug pipe gasket | (5) | Cylinder head gasket RH | Tightening torque: N·m (kgf-m, ft-lb)
(2) | O-ring | (6) | Cylinder head gasket LH | T: | MECHANICAL(H4DO)>Cylinder Head>INSTALLATION
(3) | Cylinder head plate | (7) | Cylinder head LH
(4) | Cylinder head RH |  |

9. VALVE ASSEMBLY

(1) | Exhaust valve | (6) | Valve spring | (11) | Roller rocker arm
(2) | Intake valve | (7) | Valve spring retainer | (12) | Exhaust valve guide
(3) | Intake valve guide | (8) | Valve collet | (13) | Exhaust valve oil seal
(4) | Valve spring seat | (9) | Valve shim
(5) | Intake valve oil seal | (10) | Roller rocker arm pivot

10. CYLINDER BLOCK 1

(1) | Engine rear hanger | (5) | O-ring | Tightening torque: N·m (kgf-m, ft-lb)
(2) | Oil separator cover | (6) | Rear oil seal | T1: | 6.4 (0.7, 4.7)
(3) | Cylinder block plug | (7) | Crankshaft position sensor holder | T2: | 16 (1.6, 11.8)
(4) | Main gallery plug | (8) | Cylinder block plate | T3: | 21 (2.1, 15.5)
|  |  |  | T4: | 25 (2.5, 18.4)
|  |  |  | T5: | MECHANICAL(H4DO)>Cylinder Block>ASSEMBLY > CYLINDER BLOCK

11. CYLINDER BLOCK 2

(1) | Cylinder block ASSY | (3) | Cylinder block RH | Tightening torque: N·m (kgf-m, ft-lb)
(2) | Washer | (4) | Cylinder block LH | T: | MECHANICAL(H4DO)>Cylinder Block>INSTALLATION

12. CRANKSHAFT AND PISTON

(1) | Crankshaft position sensor plate | (8) | Connecting rod cap bolt | (15) | Crankshaft bearing #1, #3
(2) | Top ring | (9) | Connecting rod | (16) | Crankshaft bearing #2, #4
(3) | Second ring | (10) | Connecting rod bearing (connecting rod side) | (17) | Crankshaft bearing #5
(4) | Oil ring | (11) | Connecting rod bearing (connecting rod cap side)
(5) | Piston | (12) | Connecting rod cap | Tightening torque: N·m (kgf-m, ft-lb)
(6) | Circlip | (13) | Crankshaft | T: | MECHANICAL(H4DO)>Cylinder Block>INSTALLATION
(7) | Piston pin | (14) | Woodruff key
∗ Tightened together with the drive plate.

13. ENGINE MOUNTING

(1) | Front cushion rubber | (2) | Nut | Tightening torque: N·m (kgf-m, ft-lb)
|  |  |  | T1: | 35 (3.6, 25.8)
|  |  |  | T2: | 90 (9.2, 66.4)

MECHANICAL(H4DO) > General Description
CAUTION

- When performing service operation, refer to “Repair Contents” in “General Description”. REPAIR CONTENTS>Repair Contents

- Prior to starting work, pay special attention to the following:

  1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.

  2. Protect the vehicle using a seat cover, fender cover, etc.

  3. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.

- Prevent scattering of grease and oil. If it scatters, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environmental.

- If the grease and oil is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

- Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

- When performing a repair, identify the cause of trouble and avoid unnecessary work.

- Before disconnecting connectors of sensors or units, be sure to disconnect the ground terminal from the battery sensor.

- Always use the jack-up point when the lifting device, shop jacks or rigid racks are used to support the vehicle.

- Before starting works, remove dirt and corrosion around the target area.

- Keep the removed parts in order and protect them from dust and dirt.

- All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.

- For the parts except for the non-reusable parts, replace then with new parts if necessary.

- Be sure to tighten bolts and nuts to the specified torque.

- Always use new application oil during work.

- Remove or install the engine in an area where lifting devices, chain hoists, etc. are available for ready use.

MECHANICAL(H4DO) > General Description
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION | TOOL NUMBER | DESCRIPTION | REMARKS
| 499267300 | STOPPER PIN | Used for removing and installing the V-belt tensioner assembly.
| 498277200 | STOPPER SET | Used for preventing the torque converter from falling when removing and installing the engine.
| 499765700 | VALVE GUIDE REMOVER AND INSTALLER | Used for removing and installing valve guide.
| 499765900 | VALVE GUIDE REAMER | Used for reaming valve guides.
| 18252AA000 | CRANKSHAFT SOCKET | Used for rotating crankshaft.
| 18261AA010 | VALVE OIL SEAL GUIDE | Used for press-fitting of intake valve oil seals and exhaust valve oil seals.
| 18270AA020 | SOCKET | Used for removing and installing connecting rod.
| 18270KA010 | SOCKET | Used for installing and removing cam sprocket.
| 18334AA000 | PULLEY WRENCH PIN SET | Used for removing and installing the crank pulley. Used together with PULLEY WRENCH (18355AA000).
| 18334AA020 | PULLEY WRENCH PIN SET | Used for rotating the intake cam sprocket LH. Used together with PULLEY WRENCH (18355AA000).
| 18350AA000 | CONNECTING ROD BUSHING REMOVER AND INSTALLER | Used for removing and installing the connecting rod bushing at connecting rod small end.
| 18355AA000 | PULLEY WRENCH | Used for removing and installing the crank pulley. Used for rotating the intake cam sprocket LH. Used together with PULLEY WRENCH PIN SET (18334AA000) or PULLEY WRENCH PIN SET (18334AA020).
| 18360AA040 | HANGER | Used for removing and installing engine. Used for removing and installing rocker cover. Used together with BOLT (18363AA050).
| 18363AA050 | BOLT | Used for removing and installing engine. Used for removing and installing rocker cover. Used together with HANGER (18360AA040).
| 18471AA000 | FUEL PIPE ADAPTER | Used for inspecting the fuel pressure.
| 18632AA030 | STAND ASSY | Used for removing and installing rocker cover.
| 18657AA030 | OIL SEAL INSTALLER | Used for installing the rear oil seal of engine. Used together with OIL SEAL GUIDE (18671AA020).
| 18671AA020 | OIL SEAL GUIDE | Used for installing the rear oil seal of engine. Used together with OIL SEAL INSTALLER (18657AA030).
| 41399FG020 | SPECIAL TOOL B | Used for installing the front oil seal of engine.
| 42075AG690 | FUEL HOSE | Used for inspecting the fuel pressure. This is the SUBARU genuine part.
| 42099AE000 | QUICK CONNECTOR RELEASE | Used for removing FUEL HOSE (42075AG690). FUEL HOSE (42075AG690) is used for checking the fuel pressure.
| — | SUBARU SELECT MONITOR 4 | Used for setting of each function and troubleshooting for electrical system. For detailed operation procedures of Subaru Select Monitor 4, refer to “Help” of application.

2. GENERAL TOOL

TOOL NAME | REMARKS
Compression gauge | Used for measuring compression.
Vacuum gauge | Used for measuring intake manifold vacuum.
Oil pressure gauge | Used for measuring engine oil pressure.
Fuel pressure gauge | Used for measuring fuel pressure.
Thickness gauge | Used for various inspections.
Engine stand | Used for disassembling and assembling engine.
Angle gauge | Used for angle tightening.
Valve spring compressor | Used for removing and installing valve spring.
Piston ring compressor | Used for installing the piston into the cylinder block.
DST-i | Used together with Subaru Select Monitor 4.

MECHANICAL(H4DO) > Compression
INSPECTION

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

- Before checking the compression pressure, the compression condition of each cylinder can be confirmed as a guide by using the compression measurement mode in Subaru Select Monitor. ENGINE (DIAGNOSTICS)(H4DO)>Active Test>OPERATION

- In the compression measurement mode, the compression condition is judged by each cylinder speed. The high speed cylinder has low compression pressure and low speed cylinder has high compression pressure.

1.

After warming-up the engine, turn the ignition switch to OFF.

2.

Make sure that the battery is fully charged.

3.

Check the starter motor for satisfactory performance and operation.

4.

Remove the fuse of fuel pump from main fuse box.

5.

Start the engine and run it until it stalls.

6.

After the engine stalls, crank it for five more seconds.

7.

Turn the ignition switch to OFF.

8.

Remove all spark plugs. IGNITION(H4DO)>Spark Plug>REMOVAL

9.

Install the compression gauge to the spark plug hole.

When using a screw-in type compression gauge, the screw should be less than 25 mm (0.98 in) long.

10.

Install the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSTALLATION

11.

Turn the ignition switch to ON.

12.

Depress the accelerator pedal to full throttle.

13.

Crank the engine by starter motor and read the value when the needle of the compression gauge becomes stable.

- Perform at least two measurements per cylinder, and make sure that the values are correct.

- If the compression pressure is out of the standard value, check or adjust the pistons, valves and cylinders.

Compression pressure:

At 200 — 300 r/min

Standard

1,050 — 1,400 kPa (11 — 14 kg/cm2, 152 — 203 psi)

Difference between cylinders

100 kPa (1 kg/cm2, 14 psi) or less

14.

After inspection, install the related parts in the reverse order of removal.

When compression pressure is checked, the malfunction indicator light illuminates and DTCs may be stored in ECM. When the malfunction indicator light has illuminated, perform the Clear Memory Mode. COMMON(diag)>Clear memory>OPERATION

MECHANICAL(H4DO) > Idle Speed
INSPECTION
1.

Before checking the idle speed, check the following item:

(1)

Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly.

(2)

Check the malfunction indicator light does not illuminate.

2.

Warm up the engine.

3.

Read the engine idle speed using Subaru Select Monitor. ENGINE (DIAGNOSTICS)(H4DO)>Data Monitor>OPERATION

- Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted.

- If idle speed is out of standard, refer to the basic diagnostic procedure of “ENGINE (DIAGNOSTICS)”. ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure

(1)

Check the idle speed when no-loaded. (Headlight, blower fan, rear defroster, radiator fan, A/C etc. are OFF)

Idle rpm (no load and select lever in “P” or “N” range):

Standard

675±100 r/min

(2)

Check the idle speed when loaded. (Turn the A/C switch to ON and operate the compressor for at least one minute before measurement.)

Idle rpm (A/C ON and select lever in “P” or “N” range):

Standard

800 — 900±50 r/min

MECHANICAL(H4DO) > Ignition Timing
INSPECTION

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

1.

Before checking the ignition timing, check the following item:

(1)

Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly.

(2)

Check the malfunction indicator light does not illuminate.

2.

Warm up the engine.

3.

Read the ignition timing using Subaru Select Monitor. ENGINE (DIAGNOSTICS)(H4DO)>Data Monitor>OPERATION

If the ignition timing is out of standard, refer to the basic diagnostic procedure of “ENGINE (DIAGNOSTICS)”. ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure>PROCEDURE

Ignition timing [BTDC/{r/min}]:

Standard

8°±10°/675

MECHANICAL(H4DO) > Intake Manifold Vacuum
INSPECTION
1.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

2.

Warm up the engine.

3.

Disconnect the brake booster vacuum hose from the intake manifold assembly.

4.

Connect the vacuum gauge to the installation area for the brake booster vacuum hose of the intake manifold assembly.

5.

Keep the engine at idle speed and read the vacuum gauge indication.

Condition of engine inside can be diagnosed by observing the behavior of the vacuum gauge needle as described in table below.

Diagnosis of engine condition by inspection of intake manifold vacuum
Vacuum gauge needle behavior | 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 below the standard value. | Leakage around cylinder
3. Needle drops suddenly and intermittently from the 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 the standard value in narrow range. | Defective ignition system

Intake manifold vacuum (A/C is at idling, A/C OFF):

Standard

−60.0 kPa (−450 mmHg, −17.72 inHg) or more

6.

After inspection, install the related parts in the reverse order of removal.

MECHANICAL(H4DO) > Engine Oil Pressure
INSPECTION
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the oil pressure switch. LUBRICATION(H4DO)>Oil Pressure Switch>REMOVAL

3.

Install the oil pressure gauge to the installation area for the oil pressure switch of the chain cover.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Start the engine, and check the oil pressure.

- Standard value is based on an engine oil temperature of 80°C (176°F).

- If the oil pressure is out of the specification, check oil pump, oil filter and lubrication line. LUBRICATION(H4DO)>Symptoms and causes>INSPECTION

- If the oil pressure warning light is ON and oil pressure is within standard, check the oil pressure system. LUBRICATION(H4DO)>Oil Pressure System>INSPECTION

Engine oil pressure:

At 600 r/min

Standard

50 kPa (0.5 kg/cm2, 7 psi) or more

At 3,000 r/min

Standard

230 kPa (2.3 kg/cm2, 33 psi) or more

6.

After inspection, install the related parts in the reverse order of removal.

MECHANICAL(H4DO) > Fuel Pressure
INSPECTION
1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Open the fuel filler lid and remove the fuel filler cap.

This operation is required to release the inner pressure of the fuel tank.

3.

Disconnect the fuel delivery tube from the fuel pipe assembly, and connect the fuel pressure gauge.

- Be careful not to spill fuel.

- Catch the fuel from the tubes using a container or cloth.

(1)

Remove the fuel delivery tube clamp from the fuel delivery tube.

(2)

Disconnect the quick connector on the fuel delivery tube from the fuel pipe assembly.

Disconnect the quick connector as shown in the figure.

(a) | Slider |  |  |  |

(3)

Connect the fuel pressure gauge with ST1 and ST2.

- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

- When connecting the quick connector with slider, make sure to insert it all the way in before locking the slider.

- When it is difficult to lock the slider, check that the connector is fully inserted.

- After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

- ST1 is a SUBARU genuine part.

- When connecting the ST2 to the quick connector on the fuel delivery tube, connect it as shown in the figure.

  (a) | Slider |  |  |  |

Preparation tool:

ST1: FUEL HOSE (42075AG690)

ST2: FUEL PIPE ADAPTER (18471AA000)

(A) | Fuel pipe ASSY side | (B) | Fuel delivery tube side

4.

Start the engine.

5.

Check the fuel pressure after warming up the engine.

- The fuel pressure gauge readings becomes 10 — 20 kPa (0.1 — 0.2 kg/cm2, 1 — 3 psi) higher than standard values during high-altitude operations.

- Check or replace the fuel pump and fuel delivery line if the fuel pressure is out of the standard.

Standard

350 — 450 kPa (3.5 — 4.6 kg/cm2, 50 — 66 psi)

6.

After inspection, install the related parts in the reverse order of removal.

- Before removing the fuel pressure gauge, release the fuel pressure.

- Be careful not to spill fuel.

- Catch the fuel from hoses and tubes using a container or cloth.

- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

- When connecting the quick connector with slider, make sure to insert it all the way in before locking the slider.

- When it is difficult to lock the slider, check that the connector is fully inserted.

- After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

- When disconnecting the ST1, install the ST2 to the fuel pipe assembly, and press the ST2 in the direction of arrow to disconnect the quick connector on the ST1.

  Preparation tool:

  ST2: QUICK CONNECTOR RELEASE (42099AE000)

- Disconnect the quick connector on the fuel delivery tube as shown in the figure.

  (a) | Slider |  |  |  |

- Connect the quick connector on the fuel delivery tube as shown in the figure.

  (a) | Slider |  |  |  |

MECHANICAL(H4DO) > Cam Clearance
INSPECTION
1. WHEN TIMING CHAIN ASSEMBLY IS NOT REMOVED

When working on the vehicle, be careful not to spill engine oil on the exhaust pipe. If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

Inspection of cam clearance should be performed while engine is cold.

1.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL

2.

When inspecting #1 and #3 cylinders

(1)

Remove the rocker cover RH. MECHANICAL(H4DO)>Rocker Cover>REMOVAL > ROCKER COVER RH

When working on the vehicle, place a suitable container under the vehicle.

(2)

Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench.

When the timing mark (B) on crank pulley is aligned to the 0° in timing gauge (A) on chain cover as shown in the figure, the #1 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #1 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #1 cylinder piston at TDC of compression stroke.

(3)

Check the cam clearance for #1 cylinder intake, #1 cylinder exhaust and #3 cylinder exhaust.

- Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A).

- If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

  Cam clearance:

  Intake

  Standard

  0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

  Exhaust

  Standard

  0.22±0.02 mm (0.0087±0.0008 in)

(4)

Turn the crank pulley by 360°.

(5)

Check the cam clearance of #3 cylinder intake.

- Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A).

- If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

  Cam clearance:

  Standard

  0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

3.

When inspecting #2 and #4 cylinders

(1)

Remove the rocker cover LH. MECHANICAL(H4DO)>Rocker Cover>REMOVAL > ROCKER COVER LH

When working on the vehicle, place a suitable container under the vehicle.

(2)

Set #2 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench.

When the timing mark (B) on crank pulley is aligned to the 0° in timing gauge (A) on chain cover as shown in the figure, the #2 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #2 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #2 cylinder piston at TDC of compression stroke.

(3)

Check the cam clearance for #2 cylinder intake, #2 cylinder exhaust and #4 cylinder exhaust.

- Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A).

- If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

  Cam clearance:

  Intake

  Standard

  0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

  Exhaust

  Standard

  0.22±0.02 mm (0.0087±0.0008 in)

(4)

Turn the crank pulley by 360°.

(5)

Check the cam clearance of #4 cylinder intake.

- Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A).

- If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

  Cam clearance:

  Standard

  0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

4.

If necessary, adjust the cam clearance. MECHANICAL(H4DO)>Cam Clearance>ADJUSTMENT

5.

After inspection, install the related parts in the reverse order of removal.

2. WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Inspection of cam clearance should be performed while engine is cold.

1.

When inspecting #1 and #3 cylinders

(1)

Remove the rocker cover RH. MECHANICAL(H4DO)>Rocker Cover>REMOVAL > ROCKER COVER RH

When working on the vehicle, place a suitable container under the vehicle.

(2)

Check the #1 and #3 cylinder cam clearance.

Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand).

- For cam clearance inspection, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the camshaft (cam sprocket) to be measured.

- Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A).

- If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

  Cam clearance:

  Intake

  Standard

  0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

  Exhaust

  Standard

  0.22±0.02 mm (0.0087±0.0008 in)

2.

When inspecting #2 and #4 cylinders

(1)

Remove the rocker cover LH. MECHANICAL(H4DO)>Rocker Cover>REMOVAL > ROCKER COVER LH

When working on the vehicle, place a suitable container under the vehicle.

(2)

Check the #2 and #4 cylinder cam clearance.

Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand).

- Because the intake camshaft is pressurized by the high-pressure fuel pump, it is almost impossible to turn the intake camshaft lightly by hand. Since the zero-lift position is adjusted at the removal of the timing chain LH, measure the cam clearance at that position.

- For cam clearance inspection on exhaust side, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the exhaust camshaft (cam sprocket).

- Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A).

- If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

  Cam clearance:

  Intake

  Standard

  0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

  Exhaust

  Standard

  0.22±0.02 mm (0.0087±0.0008 in)

3.

If necessary, adjust the cam clearance. MECHANICAL(H4DO)>Cam Clearance>ADJUSTMENT

4.

After inspection, install the related parts in the reverse order of removal.

MECHANICAL(H4DO) > Cam Clearance
ADJUSTMENT
1.

Remove the engine from the vehicle. MECHANICAL(H4DO)>Engine Assembly>REMOVAL

2.

Remove the chain cover. MECHANICAL(H4DO)>Chain Cover>REMOVAL

3.

When adjusting #1 and #3 cylinders

(1)

Remove the cam carrier RH. MECHANICAL(H4DO)>Cam Carrier>REMOVAL > CAM CARRIER RH

(2)

Measure the thickness of valve shim using micrometer.

Measurement should be performed at a temperature of 20°C (68°F).

(3)

Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness.

Use a new valve shim.

Intake side: T = T’ +1.69 × (C −0.13 mm (0.0051 in)) Exhaust side: T = T’ +1.87 × (C −0.22 mm (0.0087 in))
T: Valve shim thickness required C: Measured cam clearance T’: Current valve shim thickness

(4)

Install the cam carrier RH. MECHANICAL(H4DO)>Cam Carrier>INSTALLATION > CAM CARRIER RH

(5)

Check all the cam clearance of RH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step (1).

When the removing/installing of cam carrier RH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of RH side is necessary. Refer to INSPECTION of “Cam Clearance” for the cam clearance inspection. MECHANICAL(H4DO)>Cam Clearance>INSPECTION > WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Cam clearance:

Intake

Standard

0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

Exhaust

Standard

0.22±0.02 mm (0.0087±0.0008 in)

4.

When adjusting #2 and #4 cylinders

(1)

Remove the cam carrier LH. MECHANICAL(H4DO)>Cam Carrier>REMOVAL > CAM CARRIER LH

(2)

Measure the thickness of valve shim using micrometer.

Measurement should be performed at a temperature of 20°C (68°F).

(3)

Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness.

Use a new valve shim.

Intake side: T = T’ +1.69 × (C −0.13 mm (0.0051 in)) Exhaust side: T = T’ +1.87 × (C −0.22 mm (0.0087 in))
T: Valve shim thickness required C: Measured cam clearance T’: Current valve shim thickness

(4)

Install the cam carrier LH. MECHANICAL(H4DO)>Cam Carrier>INSTALLATION > CAM CARRIER LH

(5)

Check all the cam clearance of LH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step (1).

When the removing/installing of cam carrier LH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of LH side is necessary. Refer to INSPECTION of “Cam Clearance” for the cam clearance inspection. MECHANICAL(H4DO)>Cam Clearance>INSPECTION > WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Cam clearance:

Intake

Standard

0.13+0.02−0.03 mm (0.0051+0.0008−0.0012 in)

Exhaust

Standard

0.22±0.02 mm (0.0087±0.0008 in)

5.

After adjustment, install the related parts in the reverse order of removal.

MECHANICAL(H4DO) > Engine Assembly
REMOVAL
1.

Remove the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>DISASSEMBLY

2.

Fully open the panel COMPL front hood. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

3.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

4.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

5.

Collect the refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

6.

Open the fuel filler lid and remove the fuel filler cap.

This operation is required to release the inner pressure of the fuel tank.

7.

Disconnect the ground terminal of the battery sensor and the positive terminal of the battery. REPAIR CONTENTS>NOTE > BATTERY

8.

Remove the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>REMOVAL

9.

Remove the air cleaner case (rear). INTAKE (INDUCTION)(H4DO)>Air Cleaner Case>REMOVAL

10.

Remove the radiator. COOLING(H4DO)>Radiator>REMOVAL

11.

Disconnect the connector (A), connector (B) and terminal (C).

12.

Remove the clip (D) and clip (E) that secure the battery cable assembly.

13.

Disconnect the hose pressure suction and the hose pressure discharge from the A/C compressor. AIR CONDITIONER>Hose and Pipe>REMOVAL

14.

Disconnect the brake booster vacuum hose (A).

15.

Disconnect the connector (B), and remove the engine wiring harness from the clip (C).

16.

Remove the clip (D) securing battery cable assembly and release the claw (E).

17.

Disconnect connector (A) from ECM.

In order to prevent damaging the connector (A), check that the lock is released completely when moving the lever.

To disconnect the connector (A), press the portion (a) shown in the figure to release the lock and move the lever in the direction of arrow.

18.

Disconnect the connector (B) from the main fuse box, and remove the engine wiring harness from the clip (C).

19.

Release the claw (A) securing the battery cable to the bracket.

20.

Release the claw (B) securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.

21.

Disconnect the heater inlet hose (A) and the heater outlet hose (B).

22.

Disconnect the transmission harness connector from the engine wiring harness.

23.

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

24.

Disconnect the brake booster vacuum hose (A) from the brake vacuum pump.

Before disconnecting the brake booster vacuum hose, use a marker to put an alignment mark (a) at the position shown in the figure when the clip is slid.

25.

Disconnect the water hose (B) and water hose (C) from the CVTF cooler (with warmer feature) and the EGR cooler.

26.

Lift up the vehicle.

27.

Disconnect the ground cord on the engine side.

28.

Remove the nuts which secure the engine mounting to the crossmember COMPL front.

29.

Remove the crossmember support rear RH. FRONT SUSPENSION>Crossmember Support>REMOVAL

30.

Remove the bolts and nuts which hold the lower side of transmission to the engine.

31.

Lower the vehicle.

32.

Remove the starter. STARTING/CHARGING SYSTEMS(H4DO)>Starter>REMOVAL

33.

Separate the torque converter from drive plate.

(1)

Remove the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>REMOVAL > PCV HOSE NO. 1

(2)

Disconnect the connector (A), and remove the plug (B) from the service hole.

(3)

Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the bolts (4 places) securing the torque converter to the drive plate.

(4)

Attach the ST to the converter case.

Preparation tool:

ST: STOPPER SET (498277200)

34.

Disconnect the fuel delivery tube and evaporation hose.

- Be careful not to spill fuel.

- Catch the fuel from the tubes using a container or cloth.

(1)

Disconnect the purge hose (A) from the purge control solenoid valve, and remove the purge hose (A) from the clip (B).

(2)

Remove the clip (B) from the intake manifold assembly, and disconnect the quick connector of the fuel delivery tube (C) from the fuel pipe.

Disconnect the quick connector as shown in the figure.

(a) | Slider |  |  |  |

35.

Separate the engine and transmission.

Before removing the engine away from transmission, check to be sure no work has been overlooked.

(1)

Using the ST1, install the ST2 to the engine unit.

Preparation tool:

ST1: BOLT (18363AA050)

ST2: HANGER (18360AA040)

Tightening torque:

43 N·m (4.4 kgf-m, 31.7 ft-lb)

(2)

Support the engine with a lifting device and wire ropes.

(A) | To engine rear hanger | (B) | To special tool |  |

(3)

Support the transmission with a garage jack.

Be sure to perform this procedure to prevent the transmission from lowering by its own weight.

(A) | Transmission | (B) | Garage jack |  |

(4)

Remove the bolts which hold the upper side of the transmission to the engine.

36.

Remove the engine from the vehicle.

Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

(1)

Slightly raise the engine.

(2)

Raise the transmission with garage jack.

(3)

Move the engine horizontally until engine is withdrawn from transmission.

(4)

Slowly move the engine away from engine compartment.

37.

Remove the engine mounting from the engine.

38.

Remove the ST1 and ST2 from the engine unit.

MECHANICAL(H4DO) > Engine Assembly
INSTALLATION
1.

Using the ST1, install the ST2 to the engine unit.

Preparation tool:

ST1: BOLT (18363AA050)

ST2: HANGER (18360AA040)

Tightening torque:

43 N·m (4.4 kgf-m, 31.7 ft-lb)

2.

Install the engine mounting onto the engine.

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.

Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

4.

With a lifting device and a garage jack, slowly lower the engine.

5.

Install the bolts which hold upper side of transmission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

6.

Remove the garage jack.

7.

Remove the lifting device and wire ropes.

8.

Remove the ST1 and ST2 from the engine unit.

9.

Install the torque converter to drive plate.

(1)

Remove the ST from converter case.

Be careful not to drop the ST into the converter housing when removing the ST.

(2)

Insert the wrench into the crank pulley bolt, and rotate the crank pulley to attach the four bolts securing the torque converter to the drive plate.

Be careful not to drop bolts into the converter housing.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

(3)

Install the plug (B) to the service hole, and connect the connector (A).

(4)

Attach the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>INSTALLATION > PCV HOSE NO. 1

10.

Install the starter. STARTING/CHARGING SYSTEMS(H4DO)>Starter>INSTALLATION

11.

Lift up the vehicle.

12.

Install 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)

13.

Install the crossmember support rear RH. FRONT SUSPENSION>Crossmember Support>INSTALLATION

14.

Install the nuts which hold the engine mounting to the crossmember COMPL front.

Use new nuts.

Make sure that locators (a) of the engine mounting are securely inserted.

Tightening torque:

90 N·m (9.2 kgf-m, 66.4 ft-lb)

15.

Connect the ground cord.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

16.

Lower the vehicle.

17.

Connect the fuel delivery tube and evaporation hose.

(1)

Connect the quick connector on the fuel delivery tube (C) to the fuel pipe, and install clip (B) to the intake manifold assembly.

- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

- When connecting the quick connector, make sure to insert it all the way in before locking the slider.

- When it is difficult to lock the slider, check that the connector is fully inserted.

- After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

Connect the quick connector as shown in the figure.

(a) | Slider |  |  |  |

(2)

Connect the purge hose (A) to the clip (B), and connect the purge hose (A) to the purge control solenoid valve.

18.

Connect the water hose (C) and water hose (B) to the CVTF cooler (with warmer feature) and the EGR cooler.

19.

Connect the brake booster vacuum hose (A) to the brake vacuum pump.

When connecting the brake booster vacuum hose, align the alignment marks (a) on the brake booster vacuum hose and the vacuum pump.

20.

Install the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>INSTALLATION > PITCHING STOPPER

21.

Connect the transmission harness connector to the engine wiring harness.

22.

Connect the heater inlet hose (A) and the heater outlet hose (B).

Be careful not to mix up the heater inlet hose and the heater outlet hose when connecting them.

(a) | Heater inlet hose | (c) | To water pipe ASSY | (e) | To heater core ASSY
(b) | Heater outlet hose | (d) | To water pipe LH | (f) | Engine coolant flow

23.

Place the engine wiring harness and secure the engine wiring harness to the bracket with the claw (A).

24.

Secure the battery cable assembly to the bracket with the claw (B).

25.

Install the engine wiring harness to the clip (C), and connect the connector (B) to the main fuse box.

26.

Connect connector (A) to ECM.

To prevent damage to the connector (A), when connecting the connector (A), insert the connector (A) straight in until it stops, and while maintaining the position, lock the lever.

When connecting the connector (A), check that the lever is located at the position shown in the figure (position beyond the lock portion (a)).

27.

Secure the battery cable assembly with the claw (E) and clip (D).

28.

Install the engine wiring harness to the clip (C), and connect the connector (B).

29.

Connect the brake booster vacuum hose (A).

30.

Connect the hose pressure suction and the hose pressure discharge to the A/C compressor. AIR CONDITIONER>Hose and Pipe>INSTALLATION

31.

Secure the battery cable assembly with the clip (A) and clip (B).

32.

Connect the connector (C), connector (D), and the terminal (E).

Tightening torque:

15.5 N·m (1.6 kgf-m, 11.4 ft-lb)

33.

Install the radiator. COOLING(H4DO)>Radiator>INSTALLATION

34.

Install the air intake case (rear). INTAKE (INDUCTION)(H4DO)>Air Cleaner Case>INSTALLATION

35.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

36.

Connect the ground terminal of the battery sensor and the positive terminal of the battery. REPAIR CONTENTS>NOTE > BATTERY

37.

Install the fuel filler cap, and close the fuel filler lid.

38.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

39.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

40.

Set the panel COMPL front hood to the normal position. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

41.

Install the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>ASSEMBLY

42.

Close the panel COMPL front hood.

MECHANICAL(H4DO) > Engine Assembly
INSPECTION
1.

Check that pipes, hoses, connectors and clamps are installed firmly.

2.

Check the engine coolant is at specified level.

3.

Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.

MECHANICAL(H4DO) > Engine Mounting
REMOVAL
1.

Remove the crossmember COMPL front. FRONT SUSPENSION>Crossmember>REMOVAL

2.

Remove the engine mounting from the engine.

MECHANICAL(H4DO) > Engine Mounting
INSTALLATION
1.

Install the engine mounting onto the engine.

Tightening torque:

35 N·m (3.6 kgf-m, 25.8 ft-lb)

2.

Install the crossmember COMPL front. FRONT SUSPENSION>Crossmember>INSTALLATION

MECHANICAL(H4DO) > Engine Mounting
INSPECTION

Make sure that there are no cracks or other damages.

MECHANICAL(H4DO) > Preparation for Overhaul
PROCEDURE
1.

After engine has been removed from the vehicle, mount the engine to the engine stand while being careful of the following.

(1)

When mounting the engine stand, follow the instructions of engine stand used.

(2)

When disassembling the cylinder block, remove the crankshaft position sensor plate together with the drive plate first, and then mount the engine stand. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>REMOVAL

(3)

Mount the engine stand using the points shown by the arrows in the figure.

Be sure to mount the engine stand at four points. Otherwise, the engine damage may occur.

- For points (A), either of them can be used for mounting the engine stand.

- The engine stand shown in the figure is just for reference.

2.

In this section the procedures described under each index are all related to each other and described in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process.

Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

MECHANICAL(H4DO) > Vacuum Pump
REMOVAL

When replacing a single part, perform the work with the engine assembly installed to body.

1.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

(2)

Remove the clip from the air intake boot, and loosen the clamp.

(3)

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

(4)

Disconnect the brake booster vacuum hose from the vacuum pump.

Before disconnecting the brake booster vacuum hose, use a marker to put an alignment mark (a) at the position shown in the figure when the clip is slid.

(5)

Remove the crossmember support rear RH. FRONT SUSPENSION>Crossmember Support>REMOVAL

2.

Remove the union bolts (A) securing the oil pipe.

3.

Remove the vacuum pump.

The vacuum pump cannot be disassembled.

4.

Remove liquid gasket from the vacuum pump mounting surface of the engine, and the surface of the vacuum pump.

MECHANICAL(H4DO) > Vacuum Pump
INSTALLATION
1.

Apply liquid gasket to the vacuum pump as shown in the figure.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine where the vacuum pump is mounted on, and the surface of the vacuum pump.

- When applying liquid gasket, the start and the end of application should cross at the point within the range A shown in the figure.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

3±1 mm (0.1181±0.0394 in)

(A) | Range A (range where application can start) | (C) | ⌀3±1 mm (0.1181±0.0394 in) | (E) | Chamfer edge
(B) | Liquid gasket applying position of mating surface | (D) | Within 1 mm (0.0394 in)

2.

Install the vacuum pump.

When installing the vacuum pump, align the slot on the vacuum pump shaft (A) with the protrusion on the intake camshaft RH (B).

Tightening torque:

16 N·m (1.6 kgf-m, 11.8 ft-lb)

3.

Apply engine oil to the threaded portion for the vacuum pump union bolt.

4.

Set a new gasket on the oil pipe, and secure the oil pipe with the union bolt (A).

Tightening torque:

20 N·m (2.0 kgf-m, 14.8 ft-lb)

5.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Install the crossmember support rear RH. FRONT SUSPENSION>Crossmember Support>INSTALLATION

(2)

Connect the brake booster vacuum hose to the vacuum pump.

When connecting the brake booster vacuum hose, align the alignment marks (a) on the brake booster vacuum hose and the vacuum pump.

(3)

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

(4)

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

MECHANICAL(H4DO) > Vacuum Pump
INSPECTION

Check that the vacuum pump has no deformation, cracks or other damages.

MECHANICAL(H4DO) > V-belt
REMOVAL

When replacing a single part, perform the work with the engine assembly installed to body.

1. V-BELT
1.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

2.

Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to loosen and remove the V-belt.

(A) | V-belt | (D) | Crank pulley | (G) | A/C compressor pulley
(B) | Water pump pulley | (E) | V-belt tensioner ASSY |  |
(C) | Idler pulley | (F) | Generator pulley |  |

2. V-BELT TENSIONER ASSY
1.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

2.

Prepare for removing the V-belt tensioner assembly.

(1)

Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise so that the stopper pin hole (A) aligns with the stopper pin hole (B). Insert the ST or 5 mm hex wrench into the holes.

Preparation tool:

ST: STOPPER PIN (499267300)

3.

Remove the V-belt tensioner assembly.

4.

Remove the V-belt tensioner bracket.

3. IDLER PULLEY
1.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

2.

Remove the idler pulley.

MECHANICAL(H4DO) > V-belt
INSTALLATION
1. V-BELT
1.

Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to remove the V-belt as shown in the figure.

- When reusing the V-belt, wipe off dust and water with cloth.

- Do not use the V-belt if there is any oil, grease or coolant on the belt.

- Be careful not to rub the V-belt end surface with bare hands; exposed core may cause injury.

- Wipe off any dust, oil and water on the groove of each pulley with cloth.

(A) | V-belt | (D) | Crank pulley | (G) | A/C compressor pulley
(B) | Water pump pulley | (E) | V-belt tensioner ASSY |  |
(C) | Idler pulley | (F) | Generator pulley |  |

2.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

2. V-BELT TENSIONER ASSY
1.

The V-belt tensioner assembly is replaced.

When replacing the V-belt tensioner assembly, also perform the following steps.

(1)

Set the V-belt tensioner assembly to be discarded on a vice.

(2)

Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to remove the ST or 5 mm hex wrench.

2.

Install the V-belt tensioner bracket.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

3.

Install the V-belt tensioner assembly.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

4.

Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to remove the ST or 5 mm hex wrench.

5.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

3. IDLER PULLEY
1.

Install the idler pulley.

When installing the idler pulley, be careful of the idler pulley cover direction.

(a) | Idler pulley cover | (b) | Protrusion (3 places) |  |

Tightening torque:

36 N·m (3.7 kgf-m, 26.6 ft-lb)

2.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

MECHANICAL(H4DO) > V-belt
INSPECTION
1.

Check the V-belt for cracks, tear or wear.

2.

Check the V-belt tensioner assembly for deformation, cracks and any other damage.

3.

Check that the V-belt ribs are securely placed on the rib grooves for each pulley.

4.

Check that the V-belt tensioner assembly (C) moves in the direction of arrow (D), when the V-belt (A) is pushed and released by the area indicated by the arrow (B).

5.

Start the engine and confirm that the V-belt rotates smoothly and no abnormal noise is emitted.

MECHANICAL(H4DO) > Crank Pulley
REMOVAL

When replacing a single part, perform the work with the engine assembly installed to body.

1.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Remove the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

2.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

3.

Use the ST1 and ST2 to lock the crank pulley, remove the crank pulley bolt.

To prevent damaging ST1, attach the ST2 onto the ST1 as shown in the figure below.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA000)

4.

Remove the crank pulley.

MECHANICAL(H4DO) > Crank Pulley
INSTALLATION
1.

Clean the crankshaft thread using compressed air.

2.

Apply engine oil to the crank pulley bolt seat and thread.

3.

Install the crank pulley.

(1)

Install new O-ring to the crank pulley boss.

(2)

Set the crank pulley to the crank pulley boss.

Install the crank pulley by aligning the flat sides (A) of the crank pulley and the flat sides (B) of the crank pulley boss.

(3)

Use the ST1 and ST2 to lock the crank pulley, and temporarily tighten the crank pulley bolt.

To prevent damaging ST1, attach the ST2 onto the ST1 as shown in the figure below.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA000)

Tightening torque:

95 N·m (9.7 kgf-m, 70.1 ft-lb)

(4)

Draw reference lines (A) and (B) using a marker to set the socket to the crank pulley bolt as shown in the figure.

(a) | When using 6-point socket | (b) | When using 12-point socket |

(5)

Draw reference lines (A) and (B) on the crank pulley bolt using a marker as shown in the figure.

(6)

Draw end line (C) on crank pulley using a marker at the same position as reference line (B) drawn on the crank pulley bolt in step (5).

(7)

Use the ST1 and ST2 to lock the crank pulley, and tighten the crank pulley bolt until the reference line (A) and end line (C) are aligned.

It should be approx. 60° when reference line (A) and end line (C) are aligned.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA000)

Tightening angle:

60°±5°

4.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

5.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Install the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

MECHANICAL(H4DO) > Crank Pulley
INSPECTION
1.

Check that the crank pulley and crank pulley boss have no deformation, cracks or other damages.

2.

Inspect for oil leakage from the front oil seal. If there is an oil leak, replace the front oil seal with a new part according to the following procedures.

(1)

Remove the crank pulley. MECHANICAL(H4DO)>Crank Pulley>REMOVAL

(2)

Remove the crank pulley boss (A) from the chain cover, and remove the front oil seal (B).

(3)

Degrease the press-fit section for the chain cover front oil seal, and install the front oil seal to the chain cover using ST.

Do not apply fluid such as engine oil to the front oil seal and the chain cover; otherwise engine oil leakage may occur.

Preparation tool:

ST: SPECIAL TOOL B (41399FG020)

Front oil seal press-fit position:

1+0−1 mm (0.0394+0−0.0394 in) position from chain cover end face

(A) | Chain cover | (B) | Oil seal | (C) | Front oil seal press-fit position (1+0−1 mm (0.0394+0−0.0394 in) position from chain cover end face)

(4)

Install in the reverse order of removal after replacement.

MECHANICAL(H4DO) > Chain Cover
REMOVAL

When replacing a single part, perform the work with the engine assembly installed to body.

1.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Remove the radiator. COOLING(H4DO)>Radiator>REMOVAL

2.

Drain the engine oil. LUBRICATION(H4DO)>Engine Oil>REPLACEMENT

3.

Remove the V-belt tensioner assembly. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT TENSIONER ASSY

4.

Remove the generator. STARTING/CHARGING SYSTEMS(H4DO)>Generator>REMOVAL

5.

Remove the A/C compressor. AIR CONDITIONER>Compressor>REMOVAL

6.

Remove the idler pulley. MECHANICAL(H4DO)>V-belt>REMOVAL > IDLER PULLEY

7.

Remove the water pump pulley. COOLING(H4DO)>Water Pump>REMOVAL > WATER PUMP

8.

Remove the crank pulley. MECHANICAL(H4DO)>Crank Pulley>REMOVAL

9.

Remove the connector (A) and connector (B).

10.

Remove the clip (C) securing the engine wiring harness, and place it aside so that it does not interfere with work.

11.

Disconnect the connector (A) and disconnect the connector (B) from the chain cover.

12.

Remove the bracket (C) from the water pump.

Do not remove the inlet engine coolant temperature sensor harness from the harness stay (C).

13.

Disconnect the connector (D) and remove the clip (E) securing the oil level switch harness.

14.

Remove the rubber cap (F) from the oil pressure switch.

15.

Disconnect the terminal (G), connector (H), connector (I) and connector (J).

16.

Remove the clip (K) and clip (L) securing the engine wiring harness, and place them aside so that they do not interfere with work.

17.

Pull out the oil level gauge (A), and remove the oil level gauge guide (B) and crank pulley boss (C).

18.

Remove the bolts securing the chain cover to the engine.

19.

Expand the area shown in the figure using a crowbar or a similar tool wrapped in tape for protection, and remove the chain cover from the engine.

The chain cover may contact the protrusion (a) of cam sprocket sensor plate and cause damage. When removing the chain cover, move the chain cover horizontally until it cannot contact with the cam sprocket, and then remove it carefully.

20.

Remove the O-rings from cylinder head RH, cylinder head LH, cylinder block LH and the oil strainer.

21.

Remove the liquid gasket from the chain cover and engine unit.

22.

Remove the front oil seal from the chain cover.

MECHANICAL(H4DO) > Chain Cover
INSTALLATION
1.

Degrease the press-fit section for the chain cover front oil seal, and install new front oil seal using ST.

Do not apply fluid such as engine oil to the front oil seal and the chain cover; otherwise engine oil leakage may occur.

Preparation tool:

ST: SPECIAL TOOL B (41399FG020)

Front oil seal press-fit position:

1+0−1 mm (0.0394+0−0.0394 in) position from chain cover end face

(A) | Chain cover | (B) | Oil seal | (C) | Front oil seal press-fit position (1+0−1 mm (0.0394+0−0.0394 in) position from chain cover end face)

2.

Install new O-rings to cylinder head RH, cylinder head LH, cylinder block LH and oil strainer.

Apply a coat of engine oil to the O-rings.

3.

If there are gaps between head gasket and the chain cover seal surface between the cylinder head and cylinder block (A), apply liquid gasket into the gaps.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

4.

Apply liquid gasket to the chain cover mating surface and center boss (5 places) as shown in the figure.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine and chain cover.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

4±0.5 mm (0.1575±0.0197 in)

(A) | 14.5 mm (0.5709 in) | (G) | 127 mm (5.0000 in) | (M) | ⌀4±0.5 mm (0.1575±0.0197 in)
(B) | 17.5 mm (0.6890 in) | (H) | Range B | (N) | 2.3 mm (0.0906 in)
(C) | Range A | (I) | Liquid gasket applying position of mating surfaces of range A | (O) | ⌀12 mm (0.4724 in)
(D) | 316.2 mm (12.4488 in) | (J) | Liquid gasket applying position of center boss (5 places) | (P) | 2.8 mm (0.1102 in)
(E) | 24.5 mm (0.9646 in) | (K) | Liquid gasket applying position of mating surfaces of range B | (Q) | 1 mm (0.0394 in)
(F) | 18.5 mm (0.7283 in) | (L) | Liquid gasket applying position of mating surfaces other than range A and range B |  |

5.

Set the chain cover, and tighten the bolts in numerical order as shown in the figure.

The chain cover may contact the protrusion (a) of cam sprocket sensor plate and cause damage. When setting the chain cover, move the chain cover horizontally and set it while taking care not to contact with the cam sprocket.

Tightening torque:

T1: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

T2: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

(A) | M6 × 20 | (C) | M8 × 25 | (D) | M8 × 60
(B) | M6 × 50 |  |  |  |

6.

Install the crank pulley boss (C) and oil level gauge guide (B) using a new O-ring, and insert the oil level gauge (A).

Apply a light coat of engine oil to the O-rings of the oil level gauge guide and the oil level gauge.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

7.

Place the engine wiring harness and secure the engine wiring harness with the clip (L) and clip (K).

8.

Connect the connector (J), connector (I), connector (H) and terminal (G).

The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.

(a) | Left side of vehicle |  |  |  |

Tightening torque:

1.5 N·m (0.2 kgf-m, 1.1 ft-lb)

9.

Attach the rubber cap (F) to the oil pressure switch.

10.

Secure the oil level switch harness with clip (E), and connect the connector (D).

11.

Install the bracket (C) to the water pump.

Tightening torque:

8.5 N·m (0.9 kgf-m, 6.3 ft-lb)

12.

Install the connector (B) to the chain cover and connect the connector (A).

- If the clip (a) of the connector (B) is damaged, replace it with a new clip.

- If the installation part for the clip (a) of the connector (B) is damaged, replace it with a new inlet engine coolant temperature sensor.

- If the clip (a) has been replaced, put a marking (b) to ensure that the replacement of clips can be identified.

13.

Place the engine wiring harness and secure the engine wiring harness with the clip (C).

14.

Connect the connector (B) and connector (A).

15.

Install the crank pulley. MECHANICAL(H4DO)>Crank Pulley>INSTALLATION

16.

Install the water pump pulley. COOLING(H4DO)>Water Pump>INSTALLATION > WATER PUMP

17.

Install the idler pulley. MECHANICAL(H4DO)>V-belt>INSTALLATION > IDLER PULLEY

18.

Install the A/C compressor. AIR CONDITIONER>Compressor>INSTALLATION

19.

Install the generator. STARTING/CHARGING SYSTEMS(H4DO)>Generator>INSTALLATION

20.

Install the V-belt tensioner assembly. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT TENSIONER ASSY

21.

Fill engine oil. LUBRICATION(H4DO)>Engine Oil>REPLACEMENT

22.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Install the radiator. COOLING(H4DO)>Radiator>INSTALLATION

MECHANICAL(H4DO) > Chain Cover
DISASSEMBLY
1.

Remove the oil filler cap.

2.

Remove the engine oil filter and the oil pump union. LUBRICATION(H4DO)>Oil Filter>REMOVAL

3.

Remove the oil pressure switch. LUBRICATION(H4DO)>Oil Pressure Switch>REMOVAL

4.

Remove the engine oil temperature sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Oil Temperature Sensor>REMOVAL

5.

Remove the oil control solenoid. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Oil Control Solenoid>REMOVAL

6.

Remove the camshaft position sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Camshaft Position Sensor>REMOVAL

MECHANICAL(H4DO) > Chain Cover
ASSEMBLY
1.

Install the camshaft position sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Camshaft Position Sensor>INSTALLATION

2.

Install the oil control solenoid. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Oil Control Solenoid>INSTALLATION

3.

Install the engine oil temperature sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Oil Temperature Sensor>INSTALLATION

4.

Install the oil pressure switch. LUBRICATION(H4DO)>Oil Pressure Switch>INSTALLATION

5.

Install the engine oil filter and the oil pump union. LUBRICATION(H4DO)>Oil Filter>INSTALLATION

6.

Install the oil filler cap.

MECHANICAL(H4DO) > Chain Cover
INSPECTION

Check that the chain cover does not have deformation, cracks and any other damage.

MECHANICAL(H4DO) > Timing Chain Assembly
REMOVAL
1. TIMING CHAIN RH

When replacing a single part, perform the work with the engine assembly installed to body.

1.

Remove the chain cover. MECHANICAL(H4DO)>Chain Cover>REMOVAL

2.

Using the ST and by turning the crankshaft, align the alignment mark of crank sprocket, the alignment mark (protrusion) of the intake cam sprocket RH and the alignment mark (protrusion) of the exhaust cam sprocket RH to the positions as shown in the figure.

If the alignment marks are aligned to the positions as shown in the figure, the crankshaft key is located at six o’clock position.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

3.

When the cam sprocket RH is removed, and the cam carrier RH is disassembled

Follow also steps below when the cam sprocket RH is removed, and the cam carrier RH is disassembled.

(1)

Using the ST, loosen the bolts which hold the cam sprocket RH.

In order to prevent damage on each component, be careful not to loosen the bolts too much.

Preparation tool:

ST: SOCKET (18270KA010)

4.

Push down the chain tensioner lever RH as shown in the figure, and insert a 2.5 mm (0.0984 in) dia. stopper pin or a 2.5 mm dia. hex wrench into the stopper pin hole in the chain tensioner RH to secure the plunger (A).

5.

Remove the chain tensioner RH, and remove the chain tensioner lever RH (A).

6.

Remove the O-ring from the cylinder block RH.

7.

Remove the chain guide RH, and remove the timing chain RH (A).

- If the timing chain RH is not installed, the intake camshaft RH and exhaust camshaft RH are kept at zero-lift position. All cams on the camshaft are not pressing down the roller rocker arm (intake valve and exhaust valve). (Under this condition, all valves remain unlifted.)

- Intake camshaft RH and exhaust camshaft RH can be independently rotated with the timing chain RH removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero-lift (in range where it can be turned lightly by hand).

To avoid mixing with LH side, keep the removed part in order.

8.

Remove the side chain guide RH from the front camshaft cap RH.

2. TIMING CHAIN LH
1.

Remove the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN RH

2.

Using the ST and by turning the crankshaft, align the key of the crankshaft, the alignment mark (protrusion) of the intake cam sprocket LH and the alignment mark (protrusion) of the exhaust cam sprocket LH to the positions as shown in the figure.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

3.

When the cam sprocket LH is removed, and the cam carrier LH is disassembled

Follow also steps below when the cam sprocket LH is removed, and the cam carrier LH is disassembled.

(1)

Using the ST, loosen the bolts which hold the cam sprocket LH.

In order to prevent damage on each component, be careful not to loosen the bolts too much.

Preparation tool:

ST: SOCKET (18270KA010)

4.

Push up the chain tensioner lever LH as shown in the figure, and insert a stopper pin (clips, etc.) with a diameter of 1.2 mm (0.0472 in) or less or a hex wrench with a diameter of 1.2 mm into the stopper pin hole in the chain tensioner LH to secure the plunger (A).

5.

Remove the chain tensioner LH, and remove the chain tensioner lever LH (A).

6.

Remove the O-ring from the cylinder block LH.

7.

Remove the chain guide LH, and remove the timing chain LH (A).

- If the timing chain LH is not installed, the exhaust camshaft LH is kept at zero-lift position. All cams on the exhaust camshaft LH are not pressing down the roller rocker arm (exhaust valve). (Under this condition, exhaust valves remain unlifted.)

- Intake camshaft LH is kept at lift position. All cams on the intake camshaft LH are pressing down the roller rocker arm (intake valve). (Under this condition, intake valves remain lifted.)

- Intake camshaft LH and exhaust camshaft RH can be independently rotated with the timing chain LH removed. When the exhaust camshaft LH is turned, the valve heads contact each other and valve stem may bend as described in above. Do not turn the exhaust camshaft LH to the outside of range of zero-lift (in range where it can be turned lightly by hand).

- The #4 piston is located near TDC. If the intake camshaft LH is turned, the valve and the piston may contact and valve stem may bend. Do not turn the intake camshaft LH at this time.

To avoid mixing with RH side, keep the removed part in order.

8.

Using the ST and by turning the crankshaft approximately 200° clockwise, align the alignment marks of crank sprocket to the positions as shown in the figure.

- This procedure is required to prevent the valve and piston contacting with each other, by moving the all pistons to the middle of the cylinders.

- Never turn counterclockwise because the valve and piston may contact. Counterclockwise turn is allowed only when adjusting precisely the alignment marks, after turning the crank sprocket alignment mark clockwise near the position as shown in the figure.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

9.

Using ST1 and ST2 by turning the intake cam sprocket LH approximately 210° clockwise, align the alignment marks (protrusion) of intake cam sprocket LH to the positions (zero-lift position) as shown in the figure.

- After this work, when the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn the intake camshaft LH and exhaust camshaft LH to the outside of range of zero-lift (in range where it can be turned lightly by hand).

- Perform the operation carefully since the ST comes off easily.

Intake camshaft LH has four peaks of drive sections for the high-pressure fuel pump. Therefore, there is little range where it can be turned lightly by hand in zero-lift position.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA020)

10.

Remove the side chain guide LH from the front camshaft cap LH.

MECHANICAL(H4DO) > Timing Chain Assembly
INSTALLATION
1. TIMING CHAIN LH

- Be careful that the foreign matter is not into or onto the assembled component during installation.

- Apply engine oil to all component parts of the timing chain.

1.

Install the side chain guide LH to the front camshaft cap LH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2.

Prepare to attach the chain tensioner LH.

(1)

Press the link plate (A) in the direction of arrow to insert the plunger (B).

(2)

In order to secure the plunger, insert a stopper pin (clips, etc.) with a diameter of 1.2 mm (0.0472 in) or less or a hex wrench with a diameter of 1.2 mm into the stopper pin hole.

If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack (A) is engaged with the stopper tooth (B). If not engaged, retract the plunger a little so that the first notch of plunger rack (A) is engaged with the stopper tooth (B).

3.

Check that the alignment mark of the crank sprocket is located at the position shown in the figure. If not aligned, using the ST turn the crankshaft to align the crank sprocket alignment mark to the position shown in the figure.

This procedure is required to prevent the valve and piston contacting with each other in the next step.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

4.

Using ST1 and ST2, by turning the intake cam sprocket LH, align the alignment marks (protrusion) to the positions as shown in the figure.

- When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn the exhaust camshaft LH.

- Perform the operation carefully since the ST comes off easily.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA020)

5.

Using the ST and by turning the crankshaft approximately 200° counterclockwise, align the alignment marks of crankshaft key to the positions as shown in the figure.

Never turn clockwise because the valve and piston may contact. Clockwise turn is allowed only when adjusting the key position precisely, after turning the crankshaft counterclockwise to bring the key near the position as shown in the figure.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

6.

Align the alignment mark (protrusion) of exhaust cam sprocket LH to the position shown in the figure.

To prevent valve damage, turn the exhaust cam sprocket LH only within the range of zero-lift (in range where it can be turned lightly by hand).

7.

Install the timing chain LH and the timing chain guide LH.

(1)

Match the timing chain mark (blue) to the alignment mark of the crank sprocket.

(2)

Match the timing chain mark (pink) to the timing mark position of the intake cam sprocket LH.

(3)

Match the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket LH.

(4)

Install timing chain guide LH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A) | Alignment mark | (C) | Blue | (D) | Pink
(B) | Timing mark |  |  |  |

8.

Install new O-rings to the cylinder block LH.

9.

Install the chain tensioner lever LH (A) and chain tensioner LH.

Tightening torque:

8.5 N·m (0.9 kgf-m, 6.3 ft-lb)

10.

Pull out the stopper pin from the chain tensioner LH.

Confirm the following before pulling out the stopper pin.

- Matching of the timing chain mark (blue) to the alignment mark of the crank sprocket.

- Matching of the timing chain mark (pink) to the timing mark position of the intake cam sprocket LH.

- Matching of the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket LH.

If the stopper pin cannot be removed, lift the chain tension lever LH to remove as shown in the figure.

(A) | Alignment mark | (C) | Blue | (D) | Pink
(B) | Timing mark |  |  |  |

11.

When the cam sprocket LH has been removed, and the cam carrier LH has been disassembled

Follow also steps below when the cam sprocket LH has been removed, and the cam carrier LH has been disassembled.

(1)

Using the ST, tighten the bolts which hold the cam sprocket LH.

Preparation tool:

ST: SOCKET (18270KA010)

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

12.

Using the ST, turn the crankshaft clockwise, and make sure that there are no abnormal conditions.

Always make sure to perform this confirmation.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

13.

Using the ST and by turning the crankshaft, align the alignment mark of crank sprocket, the alignment mark (protrusion) of the intake cam sprocket LH and the alignment mark (protrusion) of the exhaust cam sprocket LH to the positions as shown in the figure.

If the alignment marks are aligned to the positions as shown in the figure, the crankshaft key is located at six o’clock position.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

14.

Install the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN LH

2. TIMING CHAIN RH

- Be careful that the foreign matter is not into or onto the assembled component during installation.

- Apply engine oil to all component parts of the timing chain.

1.

Install timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN RH

2.

Install the side chain guide RH to the front camshaft cap RH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

3.

Prepare to attach the chain tensioner RH.

(1)

Press the link plate (A) in the direction of arrow to insert the plunger (B).

(2)

In order to secure the plunger, insert a stopper pin with a diameter of 2.5 mm (0.0984 in) or a hex wrench with a diameter of 2.5 mm into the stopper pin hole.

If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack (A) is engaged with the stopper tooth (B). If not engaged, retract the plunger a little so that the first notch of plunger rack (A) is engaged with the stopper tooth (B).

4.

Make sure that the alignment mark of the crank sprocket, the alignment mark (protrusion) of the intake cam sprocket LH and the alignment mark (protrusion) of the exhaust cam sprocket LH are aligned to the positions as shown in the figure.

5.

Align the alignment mark (protrusion) of the intake cam sprocket RH and the alignment mark (protrusion) of the exhaust cam sprocket RH to the positions as shown in the figure.

To prevent valve damage, turn the intake cam sprocket RH and exhaust cam sprocket RH only within the range of zero-lift (in range where it can be turned lightly by hand).

6.

Install the timing chain RH and the timing chain guide RH.

(1)

Match the timing chain mark (blue) to the alignment mark of the crank sprocket.

(2)

Match the timing chain mark (pink) to the timing mark position of the intake cam sprocket RH.

(3)

Match the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket RH.

(4)

Install the timing chain guide RH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A) | Alignment mark | (C) | Blue | (D) | Pink
(B) | Timing mark |  |  |  |

7.

Install a new O-ring to the cylinder block RH.

8.

Install the chain tensioner lever RH (A) and chain tensioner RH.

Tightening torque:

8.5 N·m (0.9 kgf-m, 6.3 ft-lb)

9.

Pull out the stopper pin from the chain tensioner RH.

Confirm the following before pulling out the stopper pin.

- Matching of the timing chain mark (blue) to the alignment mark of the crank sprocket.

- Matching of the timing chain mark (pink) to the timing mark position of the intake cam sprocket RH.

- Matching of the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket RH.

(A) | Alignment mark | (C) | Blue | (D) | Pink
(B) | Timing mark |  |  |  |

10.

Make sure that the alignment mark of the cam sprocket and the alignment mark (protrusion) of the crank sprocket are aligned to the positions as shown in the figure.

11.

When the cam sprocket RH has been removed, and the cam carrier RH has been disassembled

Follow also steps below when the exhaust cam sprocket RH has been removed, and the cam carrier RH has been disassembled.

(1)

Using the ST, tighten the bolts which hold the cam sprocket RH.

Preparation tool:

ST: SOCKET (18270KA010)

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

12.

Using the ST, turn the crankshaft clockwise, and make sure that there are no abnormal conditions.

Always make sure to perform this confirmation.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

13.

Install the chain cover. MECHANICAL(H4DO)>Chain Cover>INSTALLATION

MECHANICAL(H4DO) > Timing Chain Assembly
INSPECTION
1.

Check the timing chain, chain guide, chain tensioner lever and chain tensioner for deformation, cracks or other damages.

2.

Check the chain guide and chain tensioner lever for abnormal wear.

MECHANICAL(H4DO) > Cam Sprocket
REMOVAL
1. CAM SPROCKET RH

- When replacing a single part, perform the work with the engine assembly installed to body.

- Be sure to perform the following procedures before removing the timing chain.

- 1. Using the ST, loosen the bolts which hold the cam sprocket RH.

  In order to prevent damage on each component while removing the timing chain, be careful not to loosen the bolts too much.

  Preparation tool:

  ST: SOCKET (18270KA010)

INTAKE CAM SPROCKET RH
1.

Remove the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN RH

2.

Remove the intake cam sprocket RH.

EXHAUST CAM SPROCKET RH
1.

Remove the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN RH

2.

Remove the exhaust cam sprocket RH.

2. CAM SPROCKET LH

- When replacing a single part, perform the work with the engine assembly installed to body.

- Be sure to perform the following procedures before removing the timing chain.

- 1. Using the ST, loosen the bolts which hold the cam sprocket LH.

  In order to prevent damage on each component while removing the timing chain, be careful not to loosen the bolts too much.

  Preparation tool:

  ST: SOCKET (18270KA010)

INTAKE CAM SPROCKET LH
1.

Remove the timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN LH

2.

Remove the intake cam sprocket LH.

EXHAUST CAM SPROCKET LH
1.

Remove the timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN LH

2.

Remove the exhaust cam sprocket LH.

MECHANICAL(H4DO) > Cam Sprocket
INSTALLATION
1. CAM SPROCKET RH
INTAKE CAM SPROCKET RH
1.

Install the intake cam sprocket RH by aligning the knock hole (A) of intake cam sprocket RH and the knock pin (B) of intake camshaft RH.

Before installation, check that there is no foreign matter on the intake cam sprocket RH and intake camshaft RH.

2.

Tighten the bolts securing the intake cam sprocket RH by hand.

- Apply a coat of engine oil to the bolt thread.

- Tighten the bolts until the intake cam sprocket RH contacts the intake camshaft RH by hand.

3.

Install the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN LH

EXHAUST CAM SPROCKET RH
1.

Install the exhaust cam sprocket RH by aligning the knock hole (A) of exhaust cam sprocket RH and the knock pin (B) of exhaust camshaft RH.

Before installation, check that there is no foreign matter on the exhaust cam sprocket RH and exhaust camshaft RH.

2.

Tighten the bolts securing the exhaust cam sprocket RH by hand.

- Apply a coat of engine oil to the bolt thread.

- Tighten the bolts until the exhaust cam sprocket RH contacts the exhaust camshaft RH by hand.

3.

Install the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN LH

2. CAM SPROCKET LH
INTAKE CAM SPROCKET LH
1.

Install the intake cam sprocket LH by aligning the knock hole (A) of intake cam sprocket LH and the knock pin (B) of intake camshaft LH.

Before installation, check that there is no foreign matter on the intake cam sprocket LH and intake camshaft LH.

2.

Tighten the bolts securing the intake cam sprocket LH by hand.

- Apply a coat of engine oil to the bolt thread.

- Tighten the bolts until the intake cam sprocket LH contacts the intake camshaft LH by hand.

3.

Install timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN RH

EXHAUST CAM SPROCKET LH
1.

Install the exhaust cam sprocket LH by aligning the knock hole (A) of exhaust cam sprocket LH and the knock pin (B) of exhaust camshaft LH.

Before installation, check that there is no foreign matter on the exhaust cam sprocket LH and exhaust camshaft LH.

2.

Tighten the bolts securing the exhaust cam sprocket LH by hand.

- Apply a coat of engine oil to the bolt thread.

- Tighten the bolts until the exhaust cam sprocket LH contacts the exhaust camshaft LH by hand.

3.

Install timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN RH

MECHANICAL(H4DO) > Cam Sprocket
INSPECTION

Check the cam sprocket teeth for abnormal wear and scratches.

MECHANICAL(H4DO) > Crank Sprocket
REMOVAL

When replacing a single part, perform the work with the engine assembly installed to body.

1.

Remove the timing chain. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL

2.

Remove the crank sprocket.

MECHANICAL(H4DO) > Crank Sprocket
INSTALLATION
1.

Install the crank sprocket.

The direction of installation is not specified for the crank sprocket.

2.

Install the timing chain. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION

MECHANICAL(H4DO) > Crank Sprocket
INSPECTION
1.

Check the crank sprocket teeth for abnormal wear and scratches.

2.

Make sure there is no free play between crank sprocket and key.

MECHANICAL(H4DO) > Rocker Cover
REMOVAL
1. ROCKER COVER RH

When replacing a single part, perform the work with the engine assembly installed to body.

1.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Remove the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>DISASSEMBLY

(2)

Fully open the panel COMPL front hood. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

(3)

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(4)

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

(5)

Remove the clip from the air intake boot, and loosen the clamp.

(6)

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

(7)

Remove the air cleaner case. INTAKE (INDUCTION)(H4DO)>Air Cleaner Case>REMOVAL

(8)

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

(9)

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

(10)

Remove the nuts which secure the engine mounting to the crossmember COMPL front.

(11)

Lower the vehicle.

(12)

Using the ST1, install the ST2 to the engine unit.

Preparation tool:

ST1: BOLT (18363AA050)

ST2: HANGER (18360AA040)

Tightening torque:

43 N·m (4.4 kgf-m, 31.7 ft-lb)

(13)

Support the engine with a lifting device and wire ropes.

(A) | To engine rear hanger | (B) | To special tool |  |

(14)

While gradually lifting up the engine, set the ST between the engine mount RH and crossmember COMPL front, and then slowly lower the engine.

- When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.

- To avoid damaging the ST, be sure to set the ST as shown in the figure.

  (A) | Direction mark | (B) | Engine mounting side | (C) | Crossmember COMPL front side

- After lowering the engine, rock the engine to check that the ST does not come off.

  Preparation tool:

  ST: STAND ASSY (18632AA030)

(15)

Remove the lifting device and wire ropes.

2.

Remove the #1 ignition coil and the #3 ignition coil. IGNITION(H4DO)>Ignition Coil>REMOVAL

3.

Remove the rocker cover RH.

4.

Remove the rocker cover gasket (ring type) from the cam carrier RH.

5.

Remove the spark plug pipe gasket, and remove the liquid gasket.

- When removing the liquid gasket from engine unit using scraper, use special care not to damage the cam lobe of camshaft RH.

- If the cam lobe of camshaft RH interferes, turn the crankshaft to the position where the scraper does not touch.

6.

Remove the rocker cover gasket RH from the rocker cover RH, and remove the liquid gasket.

2. ROCKER COVER LH

When replacing a single part, perform the work with the engine assembly installed to body.

1.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Remove the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>DISASSEMBLY

(2)

Fully open the panel COMPL front hood. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

(3)

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

(4)

Remove the clip from the air intake boot, and loosen the clamp.

(5)

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

(6)

Remove the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

(7)

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

(8)

Remove the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>REMOVAL

(9)

Disconnect connector (A) from ECM.

In order to prevent damaging the connector (A), check that the lock is released completely when moving the lever.

To disconnect the connector (A), press the portion (a) shown in the figure to release the lock and move the lever in the direction of arrow.

(10)

Disconnect the connector (B) and terminal (C) from the main fuse box, and remove the engine wiring harness from the clip (D).

(11)

Release the claw (A) securing the battery cable assembly to the bracket.

(12)

Release the claw (B) securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.

(13)

Remove the bracket.

(14)

Remove the fuel pipe protector from the high-pressure fuel pump case and intake manifold assembly.

(15)

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

(16)

Remove the nuts which secure the engine mounting to the crossmember COMPL.

(17)

Lower the vehicle.

(18)

Using the ST1, install the ST2 to the engine unit.

Preparation tool:

ST1: BOLT (18363AA050)

ST2: HANGER (18360AA040)

Tightening torque:

43 N·m (4.4 kgf-m, 31.7 ft-lb)

(19)

Support the engine with a lifting device and wire ropes.

(A) | To engine rear hanger | (B) | To special tool |  |

(20)

While gradually lifting up the engine, set the ST between the engine mount LH and crossmember COMPL front, and then slowly lower the engine.

- When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.

- To avoid damaging the ST, be sure to set the ST as shown in the figure.

  (A) | Direction mark | (B) | Engine mounting side | (C) | Crossmember COMPL front side

- After lowering the engine, rock the engine to check that the ST does not come off.

  Preparation tool:

  ST: STAND ASSY (18632AA030)

(21)

Remove the lifting device and wire ropes.

2.

Remove the #2 ignition coil and the #4 ignition coil. IGNITION(H4DO)>Ignition Coil>REMOVAL

3.

Remove the rocker cover LH.

4.

Remove the rocker cover gasket (ring type) from the cam carrier LH.

5.

Remove the spark plug pipe gasket, and remove the liquid gasket.

- When removing the liquid gasket from engine unit using scraper, use special care not to damage the cam lobe of camshaft LH.

- If the cam lobe of camshaft LH interferes, turn the crankshaft to the position where the scraper does not touch.

6.

Remove the rocker cover gasket LH from the rocker cover LH, and remove the liquid gasket.

MECHANICAL(H4DO) > Rocker Cover
INSTALLATION
1. ROCKER COVER RH
1.

Install new spark plug pipe gaskets to the spark plug pipe.

Apply a light coat of engine oil to the spark plug pipe gaskets, and insert them onto the spark plug pipe edge (A).

2.

Install new rocker cover gasket (ring type) to the cam carrier RH.

3.

Install the rocker cover RH.

(1)

Install new rocker cover gasket RH to the rocker cover RH.

(2)

Apply liquid gasket to the mating surface of rocker cover RH as shown in the figure.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine.

- Be careful not to allow liquid gasket to be squeezed out from rocker cover RH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

3±1 mm (0.1181±0.0394 in)

(A) | 10 mm (0.3937 in) or more | (C) | 71 — 73 mm (2.7953 — 2.8740 in) | (D) | Arch starting point
(B) | 74 mm (2.9134 in) or more |  |  |  |

(3)

Set the rocker cover RH on the cam carrier RH, and fasten all bolts until their two full threads engage.

(4)

Tighten all bolts with a torque of 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) in numerical order as shown in the figure.

(5)

Tighten all bolts again with a torque of 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) in numerical order as shown in the figure.

This procedure is necessary to stabilize torque.

4.

Install the #1 ignition coil and the #3 ignition coil. IGNITION(H4DO)>Ignition Coil>INSTALLATION

5.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Support the engine with a lifting device and wire ropes.

(A) | To engine rear hanger | (B) | To special tool |  |

(2)

Lift the engine a little, and remove the ST.

When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.

(3)

Lower the engine and remove the lifting device and wire ropes.

(4)

Remove the ST1 and ST2 from the engine unit.

(5)

Lift up the vehicle.

(6)

Install the nuts which hold the engine mounting to the crossmember COMPL front.

Use new nuts.

Make sure that locators (a) of the engine mounting are securely inserted.

Tightening torque:

90 N·m (9.2 kgf-m, 66.4 ft-lb)

(7)

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

(8)

Lower the vehicle.

(9)

Install the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>INSTALLATION > PITCHING STOPPER

(10)

Install the air cleaner case. INTAKE (INDUCTION)(H4DO)>Air Cleaner Case>INSTALLATION

(11)

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(12)

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

(13)

Set the panel COMPL front hood to the normal position. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

(14)

Install the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>ASSEMBLY

(15)

Close the panel COMPL front hood.

2. ROCKER COVER LH
1.

Install new spark plug pipe gaskets to the spark plug pipe.

Apply a light coat of engine oil to the spark plug pipe gaskets, and insert them onto the spark plug pipe edge (A).

2.

Install new rocker cover gasket (ring type) to the cam carrier LH.

3.

Install the rocker cover LH.

(1)

Install new rocker cover gasket LH to the rocker cover LH.

(2)

Apply liquid gasket to the mating surface of rocker cover LH as shown in the figure.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine.

- Be careful not to allow liquid gasket to be squeezed out from rocker cover LH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

3±1 mm (0.1181±0.0394 in)

(A) | 10 mm (0.3937 in) or more | (C) | 70.7 mm (2.7835 in) or more | (D) | Arch starting point
(B) | 17.3 mm (0.6811 in) or less |  |  |  |

(3)

Set the rocker cover LH on the cam carrier LH, and fasten all bolts until their two full threads engage.

(4)

Tighten all bolts with a torque of 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) in numerical order as shown in the figure.

(5)

Tighten all bolts again with a torque of 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) in numerical order as shown in the figure.

This procedure is necessary to stabilize torque.

4.

Install the #2 ignition coil and the #4 ignition coil. IGNITION(H4DO)>Ignition Coil>INSTALLATION

5.

When working on the vehicle

When working on the vehicle, perform the following steps also.

(1)

Support the engine with a lifting device and wire ropes.

(A) | To engine rear hanger | (B) | To special tool |  |

(2)

Lift the engine a little, and remove the ST.

When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.

(3)

Lower the engine and remove the lifting device and wire ropes.

(4)

Remove the ST1 and ST2 from the engine unit.

(5)

Lift up the vehicle.

(6)

Install the nuts which hold the engine mounting to the crossmember COMPL front.

Use new nuts.

Make sure that locators (a) of the engine mounting are securely inserted.

Tightening torque:

90 N·m (9.2 kgf-m, 66.4 ft-lb)

(7)

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

(8)

Lower the vehicle.

(9)

Install the fuel pipe protector to the high-pressure fuel pump case and intake manifold assembly.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

(10)

Attach the bracket.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(11)

Place the engine wiring harness and secure the engine wiring harness to the bracket with the claw (A).

(12)

Secure the battery cable assembly to the bracket with the claw (B).

(13)

Install the engine wiring harness to the clip (D), and connect the terminal (C) and connector (B) to the main fuse box.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(14)

Connect connector (A) to ECM.

To prevent damage to the connector (A), when connecting the connector (A), insert the connector (A) straight in until it stops, and while maintaining the position, lock the lever.

When connecting the connector (A), check that the lever is located at the position shown in the figure (position beyond the lock portion (a)).

(15)

Install the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSTALLATION

(16)

Install the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>INSTALLATION > PITCHING STOPPER

(17)

Install the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

(18)

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

(19)

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

(20)

Set the front hood to the normal position. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

(21)

Install the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>ASSEMBLY

(22)

Close the panel COMPL front hood.

MECHANICAL(H4DO) > Rocker Cover
INSPECTION

Check that the rocker cover does not have deformation, cracks and any other damage.

MECHANICAL(H4DO) > Camshaft
REMOVAL
1. CAMSHAFT RH

The camshaft RH and cam carrier are designed as removing as a unit. Refer to “Cam Carrier” for removal procedures of camshaft RH.

- MECHANICAL(H4DO)>Cam Carrier>REMOVAL > CAM CARRIER RH

- MECHANICAL(H4DO)>Cam Carrier>DISASSEMBLY > CAM CARRIER RH

2. CAMSHAFT LH

The camshaft LH and cam carrier are designed as removing as a unit. Refer to “Cam Carrier” for removal procedures of camshaft LH.

- MECHANICAL(H4DO)>Cam Carrier>REMOVAL > CAM CARRIER LH

- MECHANICAL(H4DO)>Cam Carrier>DISASSEMBLY > CAM CARRIER LH

MECHANICAL(H4DO) > Camshaft
INSTALLATION
1. CAMSHAFT RH

The camshaft RH and cam carrier are designed as installing as a unit. Refer to “Cam Carrier” for installation procedures of camshaft RH.

- MECHANICAL(H4DO)>Cam Carrier>ASSEMBLY > CAM CARRIER RH

- MECHANICAL(H4DO)>Cam Carrier>INSTALLATION > CAM CARRIER RH

2. CAMSHAFT LH

The camshaft LH and cam carrier are designed as installing as a unit. Refer to “Cam Carrier” for installation procedures of camshaft LH.

- MECHANICAL(H4DO)>Cam Carrier>ASSEMBLY > CAM CARRIER LH

- MECHANICAL(H4DO)>Cam Carrier>INSTALLATION > CAM CARRIER LH

MECHANICAL(H4DO) > Camshaft
INSPECTION

Refer to “Cam Carrier” for inspection procedures of camshaft. MECHANICAL(H4DO)>Cam Carrier>INSPECTION

MECHANICAL(H4DO) > Cam Carrier
REMOVAL
1. CAM CARRIER RH
1.

Remove the engine from the vehicle. MECHANICAL(H4DO)>Engine Assembly>REMOVAL

2.

Remove the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN RH

3.

Remove the rocker cover RH. MECHANICAL(H4DO)>Rocker Cover>REMOVAL > ROCKER COVER RH

4.

Remove the water pipe RH. COOLING(H4DO)>Water Pipe>REMOVAL > WATER PIPE RH

5.

Remove the clip holding the engine wiring harness from cam carrier RH.

6.

When disassembling the cam carrier RH

When disassembling the cam carrier RH, perform the following steps also.

(1)

Remove the oil pipe. LUBRICATION(H4DO)>Oil Pipe>REMOVAL

(2)

Remove the vacuum pump. MECHANICAL(H4DO)>Vacuum Pump>REMOVAL

(3)

Remove the cam sprocket RH. MECHANICAL(H4DO)>Cam Sprocket>REMOVAL > CAM SPROCKET RH

7.

Set the part so that the cam carrier RH is on the upper side.

8.

Loosen the bolts holding the cam carrier RH equally, a little at a time in numerical sequence as shown in the figure and remove the cam carrier RH.

9.

Remove the O-ring and the roller rocker arm from cylinder head RH.

Be careful not to confuse the roller rocker arms.

10.

Remove the valve shim and the roller rocker arm pivot from cylinder head RH.

Be careful not to confuse the valve shim and the roller rocker arm pivot.

11.

Remove the liquid gasket from cam carrier RH and cylinder head RH.

2. CAM CARRIER LH
1.

Remove the engine from the vehicle. MECHANICAL(H4DO)>Engine Assembly>REMOVAL

2.

Remove the timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>REMOVAL > TIMING CHAIN LH

3.

Remove the rocker cover LH. MECHANICAL(H4DO)>Rocker Cover>REMOVAL > ROCKER COVER LH

4.

Remove the water pipe LH. COOLING(H4DO)>Water Pipe>REMOVAL > WATER PIPE LH

5.

Remove the high-pressure fuel delivery pipes. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE

6.

Disconnect the connector from high-pressure fuel pump.

7.

Remove the clip holding the engine wiring harness from cam carrier LH.

8.

When disassembling the cam carrier LH

When disassembling the cam carrier LH, perform the following steps also.

(1)

Remove the high-pressure fuel pump. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Pump>REMOVAL

(2)

Remove the cam sprocket LH. MECHANICAL(H4DO)>Cam Sprocket>REMOVAL > CAM SPROCKET LH

9.

Set the part so that the cam carrier LH is on the upper side.

10.

Loosen the bolts holding the cam carrier LH equally, a little at a time in numerical sequence as shown in the figure and remove the cam carrier LH.

11.

Remove the O-ring and the roller rocker arm from cylinder head LH.

Be careful not to confuse the roller rocker arms.

12.

Remove the valve shim and the roller rocker arm pivot from cylinder head LH.

Be careful not to confuse the valve shim and the roller rocker arm pivot.

13.

Remove the liquid gasket from cam carrier LH and cylinder head LH.

MECHANICAL(H4DO) > Cam Carrier
INSTALLATION
1. CAM CARRIER RH
1.

Set the part so that the cylinder head RH is on the upper side.

2.

Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller rocker arm pivot to the cylinder head RH.

3.

Apply engine oil to new O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to the cylinder head RH.

4.

Install the cam carrier RH.

(1)

Apply liquid gasket to the mating surface of cam carrier RH as shown in the figure.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder head RH and cam carrier RH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

4±0.5 mm (0.1575±0.0197 in)

(A) | Range A | (D) | Liquid gasket applying position of mating surfaces of range A | (G) | 0±0.5 mm (0±0.0197 in)
(B) | ⌀18 mm (0.7087 in) | (E) | ⌀4±0.5 mm (0.1575±0.0197 in) | (H) | Chamfer edge
(C) | Liquid gasket applying position of mating surfaces other than range A | (F) | 1±1 mm (0.0394±0.0394 in)

(2)

Set the cam carrier RH to the cylinder head RH.

Position the intake camshaft RH and the exhaust camshaft RH to the zero-lift position as shown in the figure.

(3)

Tighten all bolts with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure.

(4)

Loosen the bolts (3 places) by 180° in numerical order (3) → (2) → (1) as shown in the figure.

(5)

Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order (1) → (2) → (3) as shown in the figure.

(6)

Loosen the bolts (3 places) by 180° in numerical order (8) → (6) → (4) as shown in the figure.

(7)

Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order (4) → (6) → (8) as shown in the figure.

(8)

Loosen the bolts (3 places) by 180° in numerical order (7) → (9) → (5) as shown in the figure.

(9)

Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order (5) → (9) → (7) as shown in the figure.

After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.

5.

Set the part so that the intake manifold is on the upper side.

6.

When the cam carrier RH has been disassembled

When the cam carrier RH has been disassembled, perform the following steps also.

(1)

Install the cam sprocket RH. MECHANICAL(H4DO)>Cam Sprocket>INSTALLATION > CAM SPROCKET RH

(2)

Install the vacuum pump. MECHANICAL(H4DO)>Vacuum Pump>INSTALLATION

When installing the vacuum pump, do not turn the intake camshaft RH to the outside of range of zero-lift (in range where it can be turned lightly by hand).

(3)

Install the oil pipe. LUBRICATION(H4DO)>Oil Pipe>INSTALLATION

7.

Check the cam clearance. MECHANICAL(H4DO)>Cam Clearance>INSPECTION > WHEN TIMING CHAIN ASSEMBLY IS REMOVED

8.

Secure the engine wiring harness to the cam carrier RH with a clip.

9.

Install the water pipe RH. COOLING(H4DO)>Water Pipe>INSTALLATION > WATER PIPE RH

10.

Install the rocker cover RH. MECHANICAL(H4DO)>Rocker Cover>INSTALLATION > ROCKER COVER RH

11.

Install the timing chain RH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN LH

12.

Install the engine to the vehicle. MECHANICAL(H4DO)>Engine Assembly>INSTALLATION

2. CAM CARRIER LH
1.

Set the part so that the cylinder head LH is on the upper side.

2.

Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller rocker arm pivot to the cylinder head LH.

3.

Apply engine oil to new O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to the cylinder head LH.

4.

Install the cam carrier LH.

(1)

Apply liquid gasket to the mating surface of cam carrier LH as shown in the figure.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder head LH and cam carrier LH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

4±0.5 mm (0.1575±0.0197 in)

(A) | Range A | (D) | Liquid gasket applying position of mating surfaces of range A | (G) | 0±0.5 mm (0±0.0197 in)
(B) | ⌀18 mm (0.7087 in) | (E) | ⌀4±0.5 mm (0.1575±0.0197 in) | (H) | Chamfer edge
(C) | Liquid gasket applying position of mating surfaces other than range A | (F) | 1±1 mm (0.0394±0.0394 in)

(2)

Set the cam carrier LH to the cylinder head LH.

Position the intake camshaft LH and the exhaust camshaft LH to the zero-lift position as shown in the figure.

(3)

Tighten all bolts with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure.

(4)

Loosen the bolts (3 places) by 180° in numerical order (3) → (2) → (1) as shown in the figure.

(5)

Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order (1) → (2) → (3) as shown in the figure.

(6)

Loosen the bolts (3 places) by 180° in numerical order (8) → (6) → (4) as shown in the figure.

(7)

Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order (4) → (6) → (8) as shown in the figure.

(8)

Loosen the bolts (3 places) by 180° in numerical order (7) → (9) → (5) as shown in the figure.

(9)

Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order (5) → (9) → (7) as shown in the figure.

After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.

5.

Set the part so that the installation surface of the intake manifold is on the upper side.

6.

When the cam carrier LH has been disassembled

When the cam carrier LH has been disassembled, perform the following steps also.

(1)

Install the cam sprocket LH. MECHANICAL(H4DO)>Cam Sprocket>INSTALLATION > CAM SPROCKET LH

(2)

Install the high-pressure fuel pump. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Pump>INSTALLATION

Install the high-pressure fuel pump so that the cam lobes on the intake camshaft LH are positioned as shown in the figure. Perform adjustment within the range of zero-lift (in range where it can be turned lightly by hand).

7.

Check the cam clearance. MECHANICAL(H4DO)>Cam Clearance>INSPECTION > WHEN TIMING CHAIN ASSEMBLY IS REMOVED

8.

Secure the engine wiring harness to the cam carrier LH with a clip.

9.

Connect the connector to the high-pressure fuel pump.

10.

Install the high-pressure fuel delivery pipe. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE

11.

Install the water pipe LH. COOLING(H4DO)>Water Pipe>INSTALLATION > WATER PIPE LH

12.

Install the rocker cover LH. MECHANICAL(H4DO)>Rocker Cover>INSTALLATION > ROCKER COVER LH

13.

Install timing chain LH. MECHANICAL(H4DO)>Timing Chain Assembly>INSTALLATION > TIMING CHAIN RH

14.

Install the engine to the vehicle. MECHANICAL(H4DO)>Engine Assembly>INSTALLATION

MECHANICAL(H4DO) > Cam Carrier
DISASSEMBLY
1. CAM CARRIER RH
1.

Remove the oil spacer from cam carrier RH.

2.

Loosen the bolts (front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH, and exhaust rear camshaft cap RH) equally, a little at a time in numerical sequence as shown in the figure, and remove each camshaft cap.

Arrange camshaft caps in order so that they can be installed in their original positions.

3.

Remove the intake camshaft RH and the exhaust camshaft RH from cam carrier RH.

4.

Remove the filter from cam carrier RH.

5.

Remove the liquid gasket from cam carrier RH, front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH.

2. CAM CARRIER LH
1.

Remove the oil spacer from cam carrier LH.

2.

Loosen the bolts (front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH) equally, a little at a time in numerical sequence as shown in the figure, and remove each camshaft cap.

Arrange camshaft caps in order so that they can be installed in their original positions.

3.

Remove the intake camshaft LH and the exhaust camshaft LH from cam carrier LH.

4.

Remove the filter from cam carrier LH.

5.

Remove the liquid gasket from cam carrier LH, front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH.

MECHANICAL(H4DO) > Cam Carrier
ASSEMBLY
1. CAM CARRIER RH
1.

Install new filter to the cam carrier RH.

Filter insert position:

0+0−0.5 mm (+0−0.0197 in) position from cam carrier RH end face

(A) | 0 — 0.5 mm (0 — 0.0197 in) |  |  |  |

2.

Set the intake camshaft RH and the exhaust camshaft RH to the cam carrier RH.

Apply engine oil to the journals of cam carrier RH before setting the intake camshaft RH and exhaust camshaft RH.

3.

Install the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH.

(1)

Apply liquid gasket to the mating surface of front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH as shown in the figure.

- Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward camshaft journal, resulting in engine seizure.

- Do not apply liquid gasket excessively to the intake center camshaft cap RH and exhaust center camshaft cap RH.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap RH, intake rear camshaft cap RH, exhaust rear camshaft cap RH, and cam carrier RH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

Mating surfaces other than range A

2±0.5 mm (0.0787±0.0197 in)

Mating surfaces of range A

3±0.5 mm (0.1181±0.0197 in)

(A) | 29 mm (1.1417 in) | (D) | Liquid gasket applying position of mating surfaces of range A | (G) | ⌀3±0.5 mm (0.1181±0.0197 in)
(B) | 28.5 mm (1.1220 in) | (E) | Liquid gasket applying position of mating surfaces other than range A | (H) | Chamfer edge
(C) | Range A | (F) | Within 1 mm (0.0394 in) | (I) | ⌀2±0.5 mm (0.0787±0.0197 in)

(2)

Apply engine oil to the journals of each camshaft cap before setting the camshaft cap.

(3)

Tighten the bolts which secure front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH in numerical order as shown in the figure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

4.

Install the oil spacer to the cam carrier RH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2. CAM CARRIER LH
1.

Install new filter to the cam carrier LH.

Filter insert position:

0+0−0.5 mm (+0−0.0197 in) position from cam carrier LH end face

(A) | 0 — 0.5 mm (0 — 0.0197 in) |  |  |  |

2.

Set the intake camshaft LH and the exhaust camshaft LH to the cam carrier LH.

Apply engine oil to the journals of cam carrier LH before setting the intake camshaft LH and exhaust camshaft LH.

3.

Install the front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH.

(1)

Apply liquid gasket to the mating surface of front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH as shown in the figure.

- Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward camshaft journal, resulting in engine seizure.

- Do not apply liquid gasket excessively to the intake center camshaft cap LH and exhaust center camshaft cap LH.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap LH, intake rear camshaft cap LH, exhaust rear camshaft cap LH, and cam carrier LH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

Mating surfaces other than range A

2±0.5 mm (0.0787±0.0197 in)

Mating surfaces of range A

3±0.5 mm (0.1181±0.0197 in)

(A) | 28.5 mm (1.1220 in) | (E) | Liquid gasket applying position of mating surfaces of range A | (I) | Chamfer edge
(B) | 8.5 mm (0.3346 in) | (F) | Liquid gasket applying position of mating surfaces other than range A | (J) | ⌀2±0.5 mm (0.0787±0.0197 in)
(C) | 5.5 mm (0.2165 in) | (G) | Within 1 mm (0.0394 in) |  |
(D) | Range A | (H) | ⌀3±0.5 mm (0.1181±0.0197 in) |  |

(2)

Apply engine oil to the journals of each camshaft cap before setting the camshaft cap.

(3)

Tighten the bolts which secure front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH in numerical order as shown in the figure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

4.

Install the oil spacer to the cam carrier LH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

MECHANICAL(H4DO) > Cam Carrier
INSPECTION
1.

Visually check the cam carrier filter, and if clogging is found, replace it with a new part.

2.

Check the camshaft journals for damage and wear. Replace the camshaft if faulty.

3.

Check the cam face condition of camshaft, and remove the minor faults by grinding with oil stone. Replace the camshaft if uneven wear is found.

4.

Using a dial gauge, check the camshaft bend. If it exceeds the limit, replace the camshaft.

Measurement should be performed at a temperature of 20°C (68°F).

Camshaft bend:

Limit

0.020 mm (0.0008 in)

5.

Check the cam lobe height “H” and cam base circle diameter “D” of camshaft as shown in the figure, using micrometer. If it is not within the standard, replace the camshaft.

- Measurement should be performed at a temperature of 20°C (68°F).

- Perform measurement of cam lobe height for fuel pump drive section at two points.

Camshaft cam lobe overall height H:

Intake

Valve drive section

Standard

40.34 — 40.44 mm (1.5882 — 1.5921 in)

Fuel pump drive section

Standard

44.94 — 45.06 mm (1.7693 — 1.7740 in)

Exhaust

Standard

39.66 — 39.76 mm (1.5614 — 1.5654 in)

Camshaft cam base circle diameter D:

Standard

34.0 mm (1.3386 in)

(A) | Valve drive section | (B) | Fuel pump drive section

6.

Check the camshaft journal outer diameter using micrometer. If it is not within the standard, replace the camshaft.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure outer diameter of each journal at several points, and read the value of most worn location.

Camshaft journal outer diameter:

Standard

25.946 — 25.963 mm (1.0215 — 1.0222 in)

7.

Using a dial gauge, check the thrust clearance of the camshaft. If it is not within the standard or if uneven wear is found, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.

- Measurement should be performed at a temperature of 20°C (68°F).

- Set the dial gauge at end surface of camshaft.

Camshaft thrust clearance:

Standard

0.068 — 0.116 mm (0.0027 — 0.0047 in)

8.

Check the oil clearance on the camshaft using a plastigauge.

Measurement should be performed at a temperature of 20°C (68°F).

(1)

Remove the liquid gasket from cam carrier, front camshaft cap, intake rear camshaft cap and exhaust rear camshaft cap.

(2)

Clean each camshaft cap and cam carrier journals.

(3)

Set the camshaft to the cam carrier.

(4)

Place a plastigauge across the camshaft journals of each camshaft and set the camshaft caps.

(5)

Tighten the bolts which secure front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap in numerical order as shown in the figure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

(6)

Loosen the bolts (front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap) equally, a little at a time in numerical sequence as shown in the figure, and remove each camshaft cap.

(7)

Determine camshaft oil clearance by matching the widest point of plastigauge on each journal against scale printed on a package of plastigauge. If it is not within the standard, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.

Camshaft oil clearance:

Standard

0.037 — 0.072 mm (0.0015 — 0.0028 in)

(8)

Completely remove the plastigauge.

MECHANICAL(H4DO) > Cylinder Head
REMOVAL
1. CYLINDER HEAD RH
1.

Remove the engine from the vehicle. MECHANICAL(H4DO)>Engine Assembly>REMOVAL

2.

Remove the engine wiring harness. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Wiring Harness>REMOVAL

3.

Remove the cam carrier RH. MECHANICAL(H4DO)>Cam Carrier>REMOVAL > CAM CARRIER RH

4.

Remove the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

5.

Remove the EGR cooler. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>REMOVAL

6.

When disassembling the cylinder head RH

When disassembling the cylinder head RH, perform the following steps also.

(1)

Remove the spark plug #1 and spark plug #3. IGNITION(H4DO)>Spark Plug>REMOVAL > RH SIDE

(2)

Remove the fuel injector RH. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>REMOVAL > FUEL INJECTOR RH

7.

Set the part so that the cylinder head RH is on the upper side.

8.

Loosen the bolts securing the cylinder head RH equally, a little at a time in numerical sequence as shown in the figure and remove the cylinder head bolt.

9.

While tapping the cylinder head RH with a plastic hammer, separate to remove it from the cylinder block RH.

10.

Remove the cylinder head gasket RH.

Be careful not to scratch the mating surface of cylinder head and cylinder block.

11.

Remove the liquid gasket from the cylinder head RH and cylinder block RH.

2. CYLINDER HEAD LH
1.

Remove the engine from the vehicle. MECHANICAL(H4DO)>Engine Assembly>REMOVAL

2.

Remove the engine wiring harness. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Wiring Harness>REMOVAL

3.

Remove the cam carrier LH. MECHANICAL(H4DO)>Cam Carrier>REMOVAL > CAM CARRIER LH

4.

Remove the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

5.

Remove the heater hose pipe. COOLING(H4DO)>Water Pipe>REMOVAL > HEATER HOSE PIPE

6.

When disassembling the cylinder head LH

When disassembling the cylinder head LH, perform the following steps also.

(1)

Remove the spark plug #2 and spark plug #4. IGNITION(H4DO)>Spark Plug>REMOVAL > LH SIDE

(2)

Remove the fuel injector LH. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>REMOVAL > FUEL INJECTOR LH

7.

Set the part so that the cylinder head LH is on the upper side.

8.

Loosen the bolts securing the cylinder head LH equally, a little at a time in numerical sequence as shown in the figure and remove the cylinder head bolt.

9.

While tapping the cylinder head LH with a plastic hammer, separate to remove it from the cylinder block LH.

10.

Remove the cylinder head gasket LH.

Be careful not to scratch the mating surface of cylinder head and cylinder block.

11.

Remove the liquid gasket from cylinder head LH and cylinder block LH.

MECHANICAL(H4DO) > Cylinder Head
INSTALLATION
1. CYLINDER HEAD RH
1.

Set the part so that the cylinder block RH is on the upper side.

2.

Install the cylinder head RH.

Be careful not to scratch the mating surface of cylinder head RH and cylinder block RH.

(1)

Clean the bolt holes in the cylinder block RH.

To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.

(2)

Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads.

(3)

Apply liquid gasket to both sides of new cylinder head gasket RH as shown in the figure.

- Before applying liquid gasket, degrease the mating surface of cylinder blocks RH and cylinder head RH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

3±1 mm (0.1181±0.0394 in)

(A) | Liquid gasket applying position to the cylinder head side | (C) | Within 1 mm (0.0394 in) | (E) | Cylinder head gasket edge
(B) | Liquid gasket applying position to the cylinder block side | (D) | ⌀3±1 mm (0.1181±0.0394 in) | (F) | Overlap margin of bead end and liquid gasket: 3 — 10 mm (0.1181 — 0.3937 in)

(4)

Attach the cylinder head gasket RH.

Check that liquid gasket RH is squeezed out from the cylinder head gasket.

(5)

Mount the cylinder head RH onto the cylinder block RH, and tighten all cylinder head bolts with a torque of 20 N·m (2.0 kgf-m, 14.8 ft-lb) in numerical order as shown in the figure.

(6)

Tighten all cylinder head bolts further with a torque of 100 N·m (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure.

If the bolt makes stick-slip sound during tightening, repeat the procedure from step (1). In that case, the cylinder head gasket RH can be reused. But it is necessary to remove liquid gasket completely from cylinder block RH, cylinder head RH and cylinder head gasket RH and re-apply to them.

(7)

Loosen all cylinder head bolts by 360° in the reverse order of tightening in step (6).

(8)

Tighten all cylinder head bolts with a torque of 20 N·m (2.0 kgf-m, 14.8 ft-lb) in numerical order as shown in the figure.

(9)

Tighten all cylinder head bolts with a torque of 42 N·m (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure.

(10)

Using an angle gauge, tighten all cylinder head bolts by 98°— 102° in numerical order as shown in the figure.

(11)

Using an angle gauge, tighten the cylinder head bolts (2 places) by 98°— 102° in the order of (1) → (2) as shown in the figure.

(12)

Using an angle gauge, tighten the cylinder head bolts (4 places) by 48°— 52° in the order of (3) → (4) → (5) → (6) as shown in the figure.

3.

Set the part so that the installation surface of the intake manifold is on the upper side.

4.

When the cylinder head RH has been disassembled

When the cylinder head RH has been disassembled, perform the following steps also.

(1)

Install the fuel injector RH. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>INSTALLATION > FUEL INJECTOR RH

(2)

Install the spark plug #1 and spark plug #3. IGNITION(H4DO)>Spark Plug>INSTALLATION > RH SIDE

5.

Install the EGR cooler. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>INSTALLATION

6.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

7.

Install the cam carrier RH. MECHANICAL(H4DO)>Cam Carrier>INSTALLATION > CAM CARRIER RH

8.

Install the engine wiring harness. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Wiring Harness>INSTALLATION

9.

Install the engine to the vehicle. MECHANICAL(H4DO)>Engine Assembly>INSTALLATION

2. CYLINDER HEAD LH
1.

Set the part so that the cylinder block LH is on the upper side.

2.

Install the cylinder head LH.

Be careful not to scratch the mating surface of cylinder head LH and cylinder block LH.

(1)

Clean the bolt holes in the cylinder block LH.

To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.

(2)

Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads.

(3)

Apply liquid gasket to both sides of new cylinder head gasket LH as shown in the figure.

- Before applying liquid gasket, degrease the mating surface of cylinder blocks LH and cylinder head LH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

3±1 mm (0.1181±0.0394 in)

(A) | Liquid gasket applying position to the cylinder head side | (C) | Within 1 mm (0.0394 in) | (E) | Cylinder head gasket edge
(B) | Liquid gasket applying position to the cylinder block side | (D) | ⌀3±1 mm (0.1181±0.0394 in) | (F) | Overlap margin of bead end and liquid gasket: 3 — 10 mm (0.1181 — 0.3937 in)

(4)

Attach the cylinder head gasket LH.

Check that liquid gasket is squeezed out from the cylinder head gasket LH.

(5)

Mount the cylinder head LH onto the cylinder block LH, and tighten all cylinder head bolts with a torque of 20 N·m (2.0 kgf-m, 14.8 ft-lb) in numerical order as shown in the figure.

(6)

Tighten all cylinder head bolts further with a torque of 100 N·m (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure.

If the bolt makes stick-slip sound during tightening, repeat the procedure from step (1). In that case, the cylinder head gasket LH can be reused. But it is necessary to remove liquid gasket completely from cylinder block LH, cylinder head LH and cylinder head gasket LH and re-apply to them.

(7)

Loosen all cylinder head bolts by 360° in the reverse order of tightening in step (6).

(8)

Tighten all cylinder head bolts with a torque of 20 N·m (2.0 kgf-m, 14.8 ft-lb) in numerical order as shown in the figure.

(9)

Tighten all cylinder head bolts with a torque of 42 N·m (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure.

(10)

Using an angle gauge, tighten all cylinder head bolts by 98°— 102° in numerical order as shown in the figure.

(11)

Using an angle gauge, tighten the cylinder head bolts (2 places) by 98°— 102° in the order of (1) → (2) as shown in the figure.

(12)

Using an angle gauge, tighten the cylinder head bolts (4 places) by 48°— 52° in the order of (3) → (4) → (5) → (6) as shown in the figure.

3.

Set the part so that the installation surface of the intake manifold is on the upper side.

4.

When the cylinder head LH has been disassembled

When the cylinder head LH has been disassembled, perform the following steps also.

(1)

Install the fuel injector LH. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>INSTALLATION > FUEL INJECTOR LH

(2)

Install the spark plug #2 and spark plug #4. IGNITION(H4DO)>Spark Plug>INSTALLATION > LH SIDE

5.

Install the heater hose pipe. COOLING(H4DO)>Water Pipe>INSTALLATION > HEATER HOSE PIPE

6.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

7.

Install the cam carrier LH. MECHANICAL(H4DO)>Cam Carrier>INSTALLATION > CAM CARRIER LH

8.

Install the engine wiring harness. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Wiring Harness>INSTALLATION

9.

Install the engine to the vehicle. MECHANICAL(H4DO)>Engine Assembly>INSTALLATION

MECHANICAL(H4DO) > Cylinder Head
DISASSEMBLY
1.

Remove the chain cover securing bolt from the cylinder head LH.

2.

Remove the stud bolts from the cylinder head.

Perform this procedure only when required.

3.

Remove the valve collet, valve, valve spring retainer, valve spring and valve spring seat from the cylinder head RH.

Metallic sodium is encapsulated in the exhaust valve. Metallic sodium is a strong alkaline material and thus prone to serious chemical reaction. When handling or disposing of the valve, be sure to confirm “DISPOSAL”. MECHANICAL(H4DO)>Cylinder Head>DISPOSAL

During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.

- Mark each part to prevent confusion.

- Keep all the removed parts in order for re-installing in their original positions.

(1)

Using valve spring compressor, compress the valve spring and remove the valve collet.

(2)

Remove valve, valve spring retainer, valve spring and valve spring seat.

4.

Remove the valve collet, valve, valve spring retainer, valve spring and valve spring seat from the cylinder head LH.

5.

Remove the valve oil seals from valve guides of cylinder head RH.

- During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.

- Use special care not to damage the cylinder head RH and guide during work.

For removal of valve guide, refer to INSPECTION. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE & VALVE GUIDE

6.

For cylinder head LH, remove the valve oil seal in the same manner.

MECHANICAL(H4DO) > Cylinder Head
ASSEMBLY

(1) | Exhaust valve | (6) | Valve spring | (11) | Roller rocker arm
(2) | Intake valve | (7) | Valve spring retainer | (12) | Exhaust valve guide
(3) | Intake valve guide | (8) | Valve collet | (13) | Exhaust valve oil seal
(4) | Valve spring seat | (9) | Valve shim
(5) | Intake valve oil seal | (10) | Roller rocker arm pivot

1.

Using the ST, install new valve oil seals to valve guides of cylinder head RH.

- During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.

- Use special care not to damage the cylinder head RH and guide during work.

- When installing the valve oil seal, press the ST with hands to install it and never drive the ST with a plastic hammer, otherwise the valve oil seal can be damaged.

- Apply engine oil to valve oil seal before installing.

- The intake valve oil seals and exhaust valve oil seals are distinguished by their colors.

  Identification colors:

  Intake [Gray]

  Exhaust [Light green]

- For installation of valve guide, refer to INSPECTION. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE & VALVE GUIDE

Preparation tool:

ST: VALVE OIL SEAL GUIDE (18261AA010)

2.

For cylinder head LH, install the valve oil seal in the same manner.

3.

Install the valve spring seat, valve spring, valve spring retainer, valve and valve collet to the cylinder head RH.

During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.

(1)

Set the valve spring seat, valve spring and valve spring retainer onto the cylinder head RH.

Be sure to install the valve spring with its larger diameter end facing the cylinder head side.

(2)

Coat the valve stem of each valve with engine oil and insert the valve into valve guide.

When inserting the valve into valve guide, use special care not to damage the oil seal lip.

(3)

Using valve spring compressor, compress the valve spring and install the valve collet.

4.

Install the valve spring seat, valve spring, valve spring retainer, valve and valve collet to the cylinder head LH.

5.

Lightly tap the valve spring retainer with a plastic hammer, and make sure that the valve collet is securely attached.

6.

Install the stud bolts onto cylinder heads.

Tightening torque:

T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

7.

Install the chain cover securing bolt to the cylinder head LH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

MECHANICAL(H4DO) > Cylinder Head
INSPECTION
1. CYLINDER HEAD
1.

Visually inspect to make sure that there are no cracks, scratches or other damage.

2.

Use liquid penetrant tester on the important sections to check for fissures.

3.

Check that there are no marks of gas leaking or water leaking on gasket attachment surface.

4.

Check the warping of the cylinder head mating surface that mates with cylinder block at the locations shown in the figure using a straight edge (A) and thickness gauge (B). If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder head.

- Measurement should be performed at a temperature of 20°C (68°F).

- If there is warpage on the cylinder head mating surface, the cylinder head bolt tightening torque and angle tightening may be improper. When installing the cylinder head, make sure that tightening torque and angle tightening work is performed precisely according to the operation procedures.

- When the cylinder head is replaced, lap each valve. Refer to “VALVE SEAT” for lapping. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

Cylinder head warpage:

Limit

0.020 mm (0.0008 in)

Cylinder head grinding limit:

98.45 mm (3.8760 in) or less

Cylinder head height:

Standard

98.5 mm (3.8779 in)

2. VALVE & VALVE GUIDE

Metallic sodium is encapsulated in the exhaust valve. Metallic sodium is a strong alkaline material and thus prone to serious chemical reaction. When handling or disposing of the valve, be sure to confirm “DISPOSAL”. MECHANICAL(H4DO)>Cylinder Head>DISPOSAL

1.

Check the valve flange and stem for damage, wear or deformation.

2.

Measure the thickness “T” of valve head edge as shown in the figure using a caliper gauge. If it is not within the standard, replace the valve.

- It is possible to differentiate between the intake valve and the exhaust valve by their overall length.

  Valve overall length:

  Intake

  104.95 mm (4.1319 in)

  Exhaust

  96.53 mm (3.8004 in)

- When the valve is replaced, lap the valve. Refer to “VALVE SEAT” for lapping. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

Valve head edge thickness T:

Intake (A)

Standard

0.8 — 1.2 mm (0.0315 — 0.0472 in)

Exhaust (B)

Standard

1.0 — 1.4 mm (0.0394 — 0.0551 in)

3.

Check the clearance between valve and valve guide. Check the clearance between valve and valve guide by measuring the outer diameter of valve stem and the inner diameter of valve guide respectively.

(1)

Measure the outer diameter of valve stem with a micrometer. If it is not within the standard, replace the valve.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the outer diameter of the valve stem at the six locations as shown in the figure, and read the value of most worn location.

- When the valve is replaced, lap the valve. Refer to “VALVE SEAT” for lapping. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

Valve stem outer diameter:

Intake

Standard

5.455 — 5.470 mm (0.2148 — 0.2154 in)

Exhaust

Standard

5.445 — 5.460 mm (0.2144 — 0.2150 in)

(2)

Using a caliper gauge, measure the inner diameter of valve guide. If it is not within the standard, replace the valve guide. For replacement procedure, refer to step 4.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the inner diameter of the valve guide at the six locations as shown in the figure, and read the value of most worn location.

Valve guide inner diameter:

Standard

5.500 — 5.512 mm (0.2165 — 0.2170 in)

(3)

Calculate the clearance between valve and valve guide.

Clearance between valve and valve guide:

Intake

Standard

0.030 — 0.057 mm (0.0012 — 0.0022 in)

Exhaust

Standard

0.040 — 0.067 mm (0.0016 — 0.0026 in)

4.

If the clearance between valve and valve guide exceeds the standard, replace the valve or valve guide, whichever shows the greater amount of wear or damage. For replacement procedure of valve guide, refer to the following.

When the valve is replaced, lap the valve. Refer to “VALVE SEAT” for lapping. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

(1)

Insert ST into the valve guide with the combustion chamber upward and remove the valve guide using plastic hammer.

- Place a wood board wrapped with a waste cloth to stabilize the cylinder head before work.

- Use special care not to damage the cylinder head during work.

- Always strike the ST vertically with a plastic hammer. Otherwise, the ST can be damaged.

Preparation tool:

ST: VALVE GUIDE REMOVER AND INSTALLER (499765700)

(2)

Before installing the valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide installation holes of cylinder head.

(3)

Draw a reference line (A) used for insertion on the valve guide using a marker as shown in the figure.

A reference line for insert is used as a guide when tapping-in the valve guide.

Valve guide inserting reference line position L:

15 mm (0.5906 in)

(4)

Apply a enough coat of engine oil to the valve guide, and set the valve guide on the cylinder head with the combustion chamber downward.

(5)

Insert the ST into the valve guide, and tap-in the valve guide to the reference line (A) for insert using plastic hammer.

- During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head.

- Use special care not to damage the cylinder head during work.

- Always strike the ST vertically with a plastic hammer. Otherwise, the ST can be damaged.

Preparation tool:

ST: VALVE GUIDE REMOVER AND INSTALLER (499765700)

(6)

Measure the valve guide protrusion amount “Q” as shown in the figure using a caliper gauge. Insert the ST into the valve guide again, and tap-in the valve guide so that it is positioned within standard by referring to the measured value using plastic hammer.

- During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head.

- Use special care not to damage the cylinder head during work.

- Always strike the ST vertically with a plastic hammer. Otherwise, the ST can be damaged.

Be careful not to tap-in excessively by repeating the steps of Tapping-in → Measurement → Tapping-in → Measurement … when installing the valve guide.

Preparation tool:

ST: VALVE GUIDE REMOVER AND INSTALLER (499765700)

Valve guide protrusion amount Q:

Standard

11.4 — 11.8 mm (0.4488 — 0.4646 in)

(7)

Ream the inside of valve guide with the combustion chamber upward using the 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.

- Place a wood board wrapped with a waste cloth to stabilize the cylinder head before work.

- Use special care not to damage the cylinder head during work.

- Apply engine oil to the ST.

- 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.

Preparation tool:

ST: VALVE GUIDE REAMER (499765900)

(8)

After reaming, clean the valve guide to remove chips.

(9)

Check the seating width between valve and valve seat. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

3. VALVE & VALVE SHIM

Metallic sodium is encapsulated in the exhaust valve. Metallic sodium is a strong alkaline material and thus prone to serious chemical reaction. When handling or disposing of the valve, be sure to confirm “DISPOSAL”. MECHANICAL(H4DO)>Cylinder Head>DISPOSAL

1.

Visually check the valve shim for damage.

2.

Check the clearance between valve and valve shim. Check the clearance between valve and valve shim by measuring the outer diameter of valve stem end and the inner diameter of valve shim respectively.

(1)

Measure the outer diameter of valve stem end with a micrometer. If it is not within the standard, replace the valve.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the outer diameter of the valve stem end at the two locations as shown in the figure, and read the value of most worn location.

- When the valve is replaced, lap the valve. Refer to “VALVE SEAT” for lapping. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

Valve stem end outer diameter:

Intake

Standard

5.455 — 5.470 mm (0.2148 — 0.2154 in)

Exhaust

Standard

5.445 — 5.460 mm (0.2144 — 0.2150 in)

(2)

Using a caliper gauge, measure the inner diameter of valve shim. If it is not within the standard, replace the valve shim.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the inner diameter of the valve shim at the two locations as shown in the figure, and read the value of most worn location.

- If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. MECHANICAL(H4DO)>Cam Clearance>INSPECTION > WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Valve shim inner diameter:

Standard

5.500 — 5.560 mm (0.2165 — 0.2189 in)

(3)

Calculate the clearance between valve and valve shim. If the clearance exceeds the standard, replace the valve or valve shim, whichever shows the greater amount of wear or damage.

- When the valve is replaced, lap the valve. Refer to “VALVE SEAT” for lapping. MECHANICAL(H4DO)>Cylinder Head>INSPECTION > VALVE SEAT

- If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. MECHANICAL(H4DO)>Cam Clearance>INSPECTION > WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Clearance between valve and valve shim:

Intake

Standard

0.030 — 0.105 mm (0.0012 — 0.0041 in)

Exhaust

Standard

0.040 — 0.115 mm (0.0016 — 0.0045 in)

4. VALVE SEAT
1.

Check the valve seat for damage and deformation.

2.

Check the seating width and seating position between valve and valve seat for the intake valve seat and exhaust valve seat.

(1)

Clean the valve and valve seat.

(2)

Coat the stem (A) of the valve lightly with engine oil and apply red dye evenly on the valve face (B).

(3)

Using the valve lapper, slowly insert the valve with red dye applied into the valve guide. Lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve.

(4)

Check the seating width “W” of valve seat as shown in the figure, using a caliper gauge. Check the seating width “W” between valve and valve seat by measuring the width of red dye on the seating surface of valve seat. If the seating width “W” between valve and valve seat is out of the standard, correct the seating surface of valve seat using the valve seat cutter. For correcting procedures of the valve seat seating surface, refer to step 3.

- When the red dye does not appear seamlessly on the valve seat seating surface, lap the valve. For lapping procedure, refer to step 4.

- When the red dye does not appear seamlessly on the valve seat seating surface even after lapping the valve, correct the valve seat seating surface using the valve seat cutter. For correcting procedures of the valve seat seating surface, refer to step 3.

Seating width W between valve and valve seat:

Intake

Standard

0.8 — 1.6 mm (0.0315 — 0.0630 in)

Exhaust

Standard

1.1 — 1.7 mm (0.0433 — 0.0669 in)

(5)

Wipe off the red dye on the valve and valve seat completely.

(6)

Coat the stem (A) of the valve lightly with engine oil and apply red dye evenly on the seating surface (B) between valve and valve seat.

(7)

Using the valve lapper, slowly insert the valve into the valve guide. Lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve.

(8)

Check the seating position between valve and valve seat. Check the seating position between valve and valve seat by checking the position of red dye on the valve face. If the seating position between valve and valve seat is not at the center of valve face, correct the seating surface of valve seat using the valve seat cutter. For correcting procedures of the valve seat seating surface, refer to step 3.

Seating position between valve and valve seat:

Valve face center

(9)

After inspection, wipe off the red dye completely.

3.

When correcting the seating surfaces of valve seat

(1)

Correct the seating angle between valve and valve seat using the 45° valve seat cutter.

- Select the size of the valve seat cutter by referring to the outer diameters of the intake valve head and exhaust valve head.

  Valve head outer diameter:

  Intake

  Standard

  35.9 — 36.1 mm (1.4134 — 1.4213 in)

  Exhaust

  Standard

  28.9 — 29.1 mm (1.1378 — 1.1457 in)

- Grind the seating surface so that the seating width between valve and valve seat becomes slightly larger than the standard value.

- Gradually reduce pressure at the end of grinding process in order to avoid creating a gap on the valve seat correcting surface.

Seating angle between valve and valve seat:

45°

(2)

Lap the valve. For lapping procedure of the valve, refer to step 4.

(3)

Check the seating position between valve and valve seat. For inspection of the seating position between valve and valve seat, refer to step 2.

This procedure is necessary to select a seat cutter to be used in step (4).

(4)

Using a seat cutter, correct the valve seat so that the seating width between valve and valve seat becomes the standard value.

- Select a proper valve seat cutter according to the following table.

  Seating position between valve and valve seat | Seat cutter selection
  | When the seating position of valve face is high, grind the surface using the 30° seat cutter until seating width between valve and valve seat becomes the standard value.
  | When the seating position of valve face is low, grind the surface using the 70.5° (IN) or 60° (EX) seat cutter until seating width between valve and valve seat reaches the standard value.
  | When the seating position of valve face is at center, grind the surface evenly using the 30° and 70.5° (IN) or 60° (EX) seat cutters until seating width between valve and valve seat reaches the standard value.

- Gradually reduce pressure at the end of grinding process in order to avoid creating a gap on the valve seat correcting surface.

(5)

Lap the valve. For lapping procedure of the valve, refer to step 4.

4.

When lapping the valve

(1)

Coat the stem (A) of the valve lightly with engine oil and put a small amount of valve compound evenly on the valve face (B).

- Be careful not to put the valve compound more than necessary.

- To avoid damaging the valve guide and valve stem, be careful not to let the valve compound contact the valve stem.

(2)

Using the valve lapper, slowly insert the valve with the valve compound applied into the valve guide, and lap the seating surface between valve and valve seat. First, lift the valve and strike it against the valve seat twice, and then slightly turn the valve once. Repeat these steps as one set.

- To prevent the seating width between valve and valve seat from exceeding the standard value, be careful not to keep turning the valve while pressing it against the valve seat during lapping.

- Be careful not to lift the valve too far during lapping in order to prevent the valve from coming off the valve guide.

(3)

Wipe off the valve compound on the valve and valve seat completely after lapping.

Be careful not to leave any valve compound in order to avoid malfunction.

(4)

Check the seating width and seating position between valve and valve seat.

5. VALVE SPRING
1.

Check the valve spring for damage and deformation.

2.

Using a caliper gauge and valve spring tester, check the valve spring free length (reference) and tension/spring height. If it is not within the standard, replace the valve spring.

- Measurement should be performed at a temperature of 20°C (68°F).

- Valve spring free length is described as a reference. If only valve spring free length is out of the standard, it is not necessary to replace the valve spring.

Valve spring free length (reference):

Standard

41.16 mm (1.6205 in)

Valve spring tension/spring height:

Set

Standard

182 — 210 N (18.56 — 21.41 kgf, 40.92 — 47.22 lbf)/33.0 mm (1.2992 in)

Lift

Standard

523 — 579 N (53.33 — 59.04 kgf, 117.59 — 130.18 lbf)/22.0 mm (0.8661 in)

3.

Using thickness gauge, surface plate and try square, check the squareness of the valve spring. If it is not within the standard, replace the valve spring.

Measurement should be performed at a temperature of 20°C (68°F).

(1)

Place the valve spring on the surface plate, with smaller diameter end facing up.

(2)

Using try square and thickness gauge, measure the clearance at the point of 30 mm (1.1811 in) from the bottom, between one coil and the square.

Valve spring squareness (at height of 30 mm (1.1811 in)):

Standard

2.5°, 1.4 mm (0.0551 in) or less

(A) | Surface plate | (B) | Try square | (C) | 30 mm (1.1811 in)

MECHANICAL(H4DO) > Cylinder Head
DISPOSAL

- Metallic sodium is encapsulated in the exhaust valve. Metallic sodium is a strong alkaline material and poses a risk of causing a severe chemical reaction. Use great care when handling and disposing it.

- If the metallic sodium gets into your eyes, you may lose your sight. If it touches the skin, you may get burned severely or if it touches flame, fire may be caused by chemical reaction. Therefore, do not disassemble the exhaust valve.

- It is safe when the metallic sodium encapsulated in the exhaust valve is not exposed to the air.

- When the exhaust valve is broken, remove the broken exhaust valve, and dispose of the metallic sodium.

- Do not intentionally break the exhaust valve and take out the metallic sodium.

- Identify the exhaust valve in which the metallic sodium is encapsulated with the embossed mark.

(a) | Embossed mark (Identification: EC)

- When disposing of the exhaust valve that is not broken, entrust the disposal processing to the industrial waste disposer in charge of dissolution treatment.

- When the exhaust valve is broken, remove it from the cylinder head, perform appropriate processing in the same manner as the general steel material.

- When performing processing, be careful of the following.

  1. Prepare the fire extinguisher nearby.

  2. Wear the protective goggles.

  3. Wear rubber gloves.

1.

Wear rubber gloves and remove the broken exhaust valve from the cylinder head.

2.

Prepare large container (bucket or oil can) in well-ventilated place, and fill the container with water (10 L or more).

3.

Using a pair of large tweezers or pliers, immerse the broken exhaust valve in the water vertically.

- Completely immerse the broken exhaust valve in the water.

- Hydrogen gas is produced by the chemical reaction. Therefore, always keep the container away from open flames such as sparks.

- Because the severe chemical reaction is developed, keep at least 2 to 3 m away from the container.

4.

After completion of chemical reaction (after the elapse of 4 — 5 hours), carefully take out the exhaust valve using a pair of large tweezers or pliers, and dispose of the exhaust valve according to the same disposal procedure the general steel material.

- Concerning the liquid waste disposal of the liquid (sodium hydrate) produced in a chemical reaction, follow all governmental regulations and local regulations related to the liquid waste disposal.

- If the liquid produced in a chemical reaction (sodium hydrate) should touch the skin, immediately wash it away with plenty water.

MECHANICAL(H4DO) > Cylinder Block
REMOVAL
1.

Remove the engine from the vehicle. MECHANICAL(H4DO)>Engine Assembly>REMOVAL

2.

Remove the crankshaft position sensor plate with drive plate. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>REMOVAL

3.

Remove the cylinder head. MECHANICAL(H4DO)>Cylinder Head>REMOVAL

4.

Remove the oil pan upper. LUBRICATION(H4DO)>Oil Pan>REMOVAL > OIL PAN UPPER

5.

Remove the crank sprocket. MECHANICAL(H4DO)>Crank Sprocket>REMOVAL

6.

Remove the water tank pipe assembly. COOLING(H4DO)>Water Pipe>REMOVAL > WATER TANK PIPE ASSEMBLY

7.

Remove the PVC connector. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Connector>REMOVAL

8.

Remove the knock sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Knock Sensor>REMOVAL

9.

Remove the PCV valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Valve>REMOVAL

10.

Remove the engine rear hanger from cylinder block RH.

11.

Remove the bolts securing the crankshaft position sensor holder from the cylinder block LH, and remove the crankshaft position sensor with crankshaft position sensor holder.

12.

Set the part so that the cylinder block RH is on the upper side.

13.

Remove the #1 and #3 connecting rod caps and pistons from the cylinder block.

Mark each connecting rod cap and piston with a cylinder number.

(1)

Using the ST, turn the crankshaft so that the #1 connecting rod cap (A) is located at the position shown in the figure.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(2)

Using the ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.

Preparation tool:

ST: SOCKET (18270AA020)

(3)

Using the ST, turn the crankshaft counterclockwise and separate the positions of the #1 pin (A) of crankshaft and the large end (B) of #1 connecting rod.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(4)

Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block.

(5)

Using the ST, turn the crankshaft so that the #3 connecting rod cap (A) is located at the position shown in the figure.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(6)

Using the ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.

Preparation tool:

ST: SOCKET (18270AA020)

(7)

Using the ST, turn the crankshaft counterclockwise and separate the positions of the #3 pin (A) of crankshaft and the large end (B) of #3 connecting rod.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(8)

Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.

14.

Set the part so that the cylinder block LH is on the upper side.

15.

Remove #2 and #4 connecting rod caps and pistons in the same removal procedure as #1 and #3 connecting rod caps and pistons.

16.

Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block.

(1)

Remove the engine stand from the cylinder block RH.

(2)

Remove the bolt shown in the figure.

(3)

Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and then remove the bolts.

(4)

While tapping the cylinder block RH with a plastic hammer, separate the cylinder block RH from the cylinder block LH.

Lift the cylinder block RH gradually, and confirm that the crankshaft is remaining in the cylinder block LH. Lifting the cylinder block RH carelessly may cause the crankshaft to fall off.

17.

Remove the crankshaft from cylinder block LH, and remove the rear oil seal.

18.

Remove the O-ring from the cylinder block LH.

19.

Remove the crankshaft bearings from the cylinder block.

- Be careful not to confuse the crankshaft bearing combination.

- Press the bearing at the end opposite to locking lip (A).

20.

Remove the liquid gasket from cylinder block.

21.

Remove the cylinder block LH from the engine stand.

MECHANICAL(H4DO) > Cylinder Block
INSTALLATION
1.

Install the cylinder block LH to the engine stand.

2.

Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block.

When performing the operation of the cylinder block RH, be careful of the following.

1. Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.

2. Be careful not to scratch the mating surface of cylinder block during work.

3.

Install new O-rings to the cylinder block LH.

4.

Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.

5.

Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure.

- Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.

- Be careful not to scratch the mating surface of cylinder block during work.

- Do not let the liquid gasket overflow to the oil passage and crankshaft bearing portions, because the engine seizure may result.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block RH and cylinder block LH.

- Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

Mating surfaces other than ranges A, B and C

1±0.5 mm (0.0394±0.0197 in)

Mating surfaces of ranges A and C

4±0.5 mm (0.1575±0.0197 in)

Mating surfaces of range B

3.2±0.5 mm (0.1260±0.0197 in)

(A) | Range A | (F) | Liquid gasket applying position of mating surfaces (the edge) of range C | (K) | 2 mm (0.0787 in)
(B) | Range B | (G) | Within 1 mm (0.0394 in) | (L) | 36 mm (1.4173 in)
(C) | Range C | (H) | ⌀3.2±0.5 mm (0.1260±0.0197 in) | (M) | 2.5 mm (0.0984 in)
(D) | Liquid gasket applying position of mating surfaces of range B | (I) | Chamfer edge |  |
(E) | Liquid gasket applying position of mating surfaces (other than the edge) of range C | (J) | ⌀4±0.5 mm (0.1575±0.0197 in) |  |

6.

Install the cylinder block RH to the cylinder block LH.

7.

Join the cylinder blocks.

When tightening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

(1)

Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.

To prevent mixture of engine oil into the water jacket, do not apply a large amount.

(2)

Tighten all mounting bolts with a torque of 35 N·m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.

(3)

Loosen all mounting bolts by 180° in the reverse order of tightening in step (2).

(4)

Tighten all mounting bolts with a torque of 35 N·m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.

(5)

Loosen the mounting bolts (4 places) by 180° in the order of (6) → (5) → (4) → (3) as shown in the figure.

(6)

Tighten the mounting bolts (4 places) with a torque of 17 N·m (1.7 kgf-m, 12.5 ft-lb) in the order of (3) → (4) → (5) → (6) as shown in the figure.

(7)

Using an angle gauge, tighten the mounting bolts (4 places) with torque of 58°— 62° in the order of (3) → (4) → (5) → (6) as shown in the figure.

(8)

Loosen the mounting bolts (6 places) by 180° in the order of (8) → (7) → (10) → (9) → (2) → (1) as shown in the figure.

(9)

Tighten the mounting bolts (6 places) with a torque of 17 N·m (1.7 kgf-m, 12.5 ft-lb) in the order of (1) → (2) → (9) → (10) → (7) → (8) as shown in the figure.

(10)

Using an angle gauge, tighten the mounting bolts (3 places) with torque of 58°— 62° in the order of (1) → (2) → (9) as shown in the figure.

(11)

Using an angle gauge, tighten the mounting bolt (10) (1 place) shown in the figure to the angle of 78°— 82°.

(12)

Using an angle gauge, tighten the mounting bolt (7) (1 place) shown in the figure to the angle of 58°— 62°.

(13)

Using an angle gauge, tighten the mounting bolt (8) (1 place) shown in the figure to the angle of 78°— 82°.

(14)

Install the bolt shown in the figure.

After tightening, if the liquid gasket is squeezed out onto the seal surfaces of the chain cover and oil pan upper, remove any squeezed-out liquid gasket. Any liquid gasket on the chamfer area, however, should not be removed.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

8.

Set the part so that the installation surface of the oil pan upper is on the upper side.

9.

Check that the piston ring gap for each piston is positioned correctly. MECHANICAL(H4DO)>Cylinder Block>ASSEMBLY > PISTON AND CONNECTING ROD

10.

Install the piston and connecting rod to the cylinder block.

(1)

Apply engine oil to the outer circumference of each piston, crankshaft pin, and in the cylinder block.

(2)

Using the ST, turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(3)

Compress the piston ring using piston ring compressor, and insert the #1 connecting rod with #1 piston into cylinder block.

- Be careful not to damage the cylinder liner and #1 pin of crankshaft by the #1 connecting rod large end.

- Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.

- Face the piston front mark towards the front of the engine.

  (a) | Front mark |  |  |  |

- Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.

(4)

Using the ST, turn the crankshaft counterclockwise so that the #1 pin of crankshaft and the large end (A) of #1 connecting rod are positioned as shown in the figure, while pressing the #1 piston crown, and then set the #1 connecting rod cap and #1 connecting rod cap bolt.

- Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.

- Use a new connecting rod cap bolt.

- Apply a coat of engine oil to the #1 connecting rod cap seat and the connecting rod cap bolt threads.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(5)

Using ST, tighten the #1 connecting rod cap bolts to 10 N·m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N·m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

Preparation tool:

ST: SOCKET (18270AA020)

(6)

Using the ST, turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(7)

Compress the piston ring using piston ring compressor, and insert the #2 connecting rod with #2 piston into cylinder block.

- Be careful not to damage the cylinder liner and #2 pin of crankshaft by the #2 connecting rod large end.

- Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.

- Face the piston front mark towards the front of the engine.

  (a) | Front mark |  |  |  |

- Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.

(8)

Using the ST, turn the crankshaft clockwise so that the #2 pin of crankshaft and the large end (A) of #2 connecting rod are positioned as shown in the figure, while pressing the #2 piston crown, and then set the #2 connecting rod cap and #2 connecting rod cap bolt.

- Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.

- Use a new connecting rod cap bolt.

- Apply a coat of engine oil to the #2 connecting rod cap seat and the connecting rod cap bolt threads.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(9)

Using ST, tighten the #2 connecting rod cap bolts to 10 N·m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N·m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

Preparation tool:

ST: SOCKET (18270AA020)

(10)

Install #3 and #4 pistons and connecting rod caps in the same installation procedure as #1 and #2 pistons and connecting rod caps.

(11)

Using the ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with a torque of 135°— 140° in numerical order as shown in the figure.

Preparation tool:

ST: SOCKET (18270AA020)

(12)

Using the ST, turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure.

Preparation tool:

ST: CRANKSHAFT SOCKET (18252AA000)

(13)

Using the ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with a torque of 135°— 140° in numerical order as shown in the figure.

Preparation tool:

ST: SOCKET (18270AA020)

11.

Set the part so that the installation surface of the intake manifold is on the upper side.

12.

Install the crankshaft position sensor with crankshaft position sensor holder to the cylinder block LH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

13.

Install the engine rear hanger to the cylinder block RH.

Tightening torque:

21 N·m (2.1 kgf-m, 15.5 ft-lb)

14.

Install the PCV valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Valve>INSTALLATION

15.

Install the knock sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Knock Sensor>INSTALLATION

16.

Install the PCV connector. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Connector>INSTALLATION

17.

Install the water tank pipe assembly. COOLING(H4DO)>Water Pipe>INSTALLATION > WATER TANK PIPE ASSEMBLY

18.

Install the crank sprocket. MECHANICAL(H4DO)>Crank Sprocket>INSTALLATION

19.

Install the oil pan upper. LUBRICATION(H4DO)>Oil Pan>INSTALLATION > OIL PAN UPPER

20.

Install the cylinder head. MECHANICAL(H4DO)>Cylinder Head>INSTALLATION

21.

Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install new rear oil seal using ST1 and ST2.

Preparation tool:

ST1: OIL SEAL GUIDE (18671AA020)

ST2: OIL SEAL INSTALLER (18657AA030)

(A) | Rear oil seal | (B) | Drive plate mounting bolt

22.

Install the crankshaft position sensor plate with drive plate. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>INSTALLATION

23.

Install the engine to the vehicle. MECHANICAL(H4DO)>Engine Assembly>INSTALLATION

MECHANICAL(H4DO) > Cylinder Block
DISASSEMBLY
1. CYLINDER BLOCK
1.

Remove the oil separator cover from cylinder block RH.

2.

Remove the liquid gasket from cylinder block RH.

3.

Remove the cylinder block plug (A) and the main gallery plug (B) from cylinder block RH.

- Perform this procedure only when required.

- After removing the parts, remove the liquid gasket from the thread holes of the cylinder block RH, and from the threaded portions of cylinder block plug and main gallery plug.

4.

Remove the cylinder block plate from cylinder block LH.

5.

Remove the main gallery plug from cylinder block LH.

- Perform this procedure only when required.

- After removing the parts, remove the liquid gasket from the thread holes of the cylinder block LH and main gallery plug.

2. PISTON AND CONNECTING ROD

(1) | Connecting rod | (5) | Piston | (9) | Second ring
(2) | Connecting rod bearing (connecting rod side) | (6) | Piston pin | (10) | Top ring
(3) | Connecting rod bearing (connecting rod cap side) | (7) | Circlip |  |
(4) | Connecting rod cap | (8) | Oil ring |  |

To prevent confusion of various parts, mark each part.

1.

Remove the connecting rod bearing from connecting rod and connecting rod cap.

2.

Remove the piston rings from the piston.

Arrange the piston rings in order so that they can be installed in their original positions without confusion.

(1)

Remove the compression rings in the order of top ring and second ring, using piston ring expander.

(2)

Remove the oil rings in the order of upper rail, lower rail and expander by hand.

3.

Remove the connecting rod from piston.

(1)

Remove the circlip on one end from the piston using a flat tip screwdriver.

Be careful not damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape.

(2)

Remove the piston pin from piston, and remove the connecting rod from piston.

(3)

Remove the circlip on other end from the piston using the same procedure as step (1).

MECHANICAL(H4DO) > Cylinder Block
ASSEMBLY
1. CYLINDER BLOCK
1.

Apply liquid gasket to the threaded portion of the main gallery plug, and install the main gallery plug to the cylinder block LH.

Before applying liquid gasket, degrease the thread holes of the cylinder block LH and main gallery plug.

Liquid gasket:

THREE BOND 1105 (Part No. 004403010) or equivalent

Tightening torque:

37 N·m (3.8 kgf-m, 27.3 ft-lb)

2.

Install the cylinder block plate onto cylinder block LH.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

3.

Apply liquid gasket to the threaded portions of cylinder block plug and main gallery plug, and install the cylinder block plug (A) and main gallery plug (B) to cylinder block RH.

Before applying liquid gasket, degrease the thread holes of the cylinder block RH, and the threaded portions of cylinder block plug and main gallery plug.

Liquid gasket:

THREE BOND 1105 (Part No. 004403010) or equivalent

Tightening torque:

T1: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T2: 37 N·m (3.8 kgf-m, 27.3 ft-lb)

4.

Install the oil separator cover to the cylinder block RH.

(1)

Apply liquid gasket to the mating surfaces of oil separator cover.

- Use new oil separator cover.

- Before applying liquid gasket, degrease the old liquid gasket seal surface of cylinder block RH.

- Install within 5 min. after applying liquid gasket.

  Liquid gasket:

  THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

  Liquid gasket applying diameter:

  4±1 mm (0.1772±0.0394 in)

(2)

Install the oil separator cover to the cylinder block RH, and tighten the oil separator cover bolts in numerical order as shown in the figure.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2. PISTON AND CONNECTING ROD

(1) | Connecting rod | (5) | Piston | (9) | Second ring
(2) | Connecting rod bearing (connecting rod side) | (6) | Piston pin | (10) | Top ring
(3) | Connecting rod bearing (connecting rod cap side) | (7) | Circlip |  |
(4) | Connecting rod cap | (8) | Oil ring |  |

1.

Install the connecting rod bearing to the connecting rod and connecting rod cap.

2.

Install a new circlip on one side of the piston using a flat tip screwdriver.

- Be careful not damage the piston, by wrapping the tip of flat tip screwdriver with tape.

- Install the circlip so that its end part (a) does not match the circlip groove cutout portion (b).

- Make sure the circlip is firmly inserted into the circlip groove.

3.

Set the piston to the connecting rod.

Align the front mark of piston and the connecting rod direction correctly as shown in the figure.

(a) | RH side (#1 and #3) | (b) | LH side (#2 and #4) | (c) | Front mark

4.

Apply engine oil to the piston pin, and attach the piston pin.

5.

Install a new circlip on the piston using a flat tip screwdriver.

- Be careful not damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape.

- Install the circlip so that its end part (a) does not match the circlip groove cutout portion (b).

- Make sure the circlip is firmly inserted into the circlip groove.

6.

Install the oil rings to the piston in the order of expander, lower rail and upper rail by hand.

Oil ring consists of the upper rail, expander and lower rail.

(a) | Upper rail | (b) | Expander | (c) | Lower rail

(1)

Set the ring gap of the expander to the position (A).

(2)

Set the ring gap of the lower rail at position (B), located 60° counterclockwise from the position (A) in the figure.

(3)

Set the ring gap of the upper rail at position (C), located 120° counterclockwise from the position (B) in the figure.

(4)

Align the upper rail spin stopper (E) to the side hole (D) on the piston.

7.

Install the compression rings to the piston in the order of second ring and top ring, using piston ring expander.

(1)

Set the ring gap of the second ring to the position (A) in the figure.

The ring mark (2RE) on the second ring should face the piston crown.

(2)

Set the ring gap of top ring at (B) in the figure on the 180° opposite direction of (A).

The ring mark (1RE) of the top ring should face the piston crown.

8.

Check again that the piston rings are installed correctly.

Also check that the ring gaps is not positioned within the range of piston skirt extended line.

MECHANICAL(H4DO) > Cylinder Block
INSPECTION
1. CYLINDER BLOCK & PISTON
1.

Visually inspect to make sure that there are no cracks, scratches or other damage.

2.

Use liquid penetrant tester on the important sections to check for fissures.

3.

Check that there are no traces of gas leaking or water leaking on the gasket attachment surface.

4.

Check the oil passages for clogging.

5.

Check for warpage of mating surfaces of the cylinder block that contacts cylinder head using a straight edge and thickness gauge. If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder block.

Measurement should be performed at a temperature of 20°C (68°F).

Cylinder block warpage:

Limit

0.025 mm (0.0010 in)

Grinding limit of cylinder block:

204.95 mm (8.0689 in) or less

Height of cylinder block:

Standard

205.0 mm (8.0709 in)

6.

Using a cylinder bore gauge, check the cylindricality and out-of-roundness of cylinder liner. If they are not within the standard, perform reboring (including honing), or replace the cylinder block and piston as a set. For reboring and honing procedure, refer to step 8.

- Measure the cylinder liner with cylinder blocks separated (into cylinder block RH and cylinder block LH).

- Measurement should be performed at a temperature of 20°C (68°F).

- Write down all measurement values as the values are used in the next procedure.

- Measure the inner diameter of each cylinder liner in both the thrust and piston pin directions at the heights as shown in the figure.

  (A) | Piston pin direction | (B) | Thrust direction |  |
  H1: | 10 mm (0.3937 in) | H2: | 45 mm (1.7717 in) | H3: | 80 mm (3.1496 in)
  H4: | 105 mm (4.1339 in) |  |  |  |

- Calculate the cylindricality of cylinder liner by using the following formula.

  Calculation formula
  C = The larger value between the calculation values C’ and C’’ C’ = (D (a) − D (b))/2 C’’ = (D (c) − D (d))/2
  C: Cylindricality of cylinder liner D (a): The largest value of all the values obtained by measuring the cylinder liner inner diameter in the direction of the piston pin D (b): The smallest value of all the values obtained by measuring the cylinder liner inner diameter in the direction of the piston pin D (c): The largest value of all the values obtained by measuring the cylinder liner inner diameter in the thrust direction D (d): The smallest value of all the values obtained by measuring the cylinder liner inner diameter in the thrust direction

- Calculate the out-of-roundness of cylinder liner at each measurement height by using the following formula.

  Calculation formula
  R = (D (e) − D (f))/2
  R: Out-of-roundness of cylinder liner D (e): The larger value between the measurement values in the piston pin direction and in the thrust direction of cylinder liner inner diameter D (f): The smaller value between the measurement values in the piston pin direction and in the thrust direction of cylinder liner inner diameter

Cylindricality of cylinder liner:

Limit

0.030 mm (0.0012 in)

Out-of-roundness of cylinder liner:

Limit

0.030 mm (0.0012 in)

7.

Check the clearance between cylinder liner and piston. Check the clearance between cylinder liner and piston by measuring the inner diameter of cylinder liner and the outer diameter of piston respectively.

(1)

Measure the inner diameter of cylinder liner. If they are not within the standard, perform reboring (including honing), or replace the cylinder block and piston as a set. For reboring and honing procedure, refer to step 8.

- Measure the cylinder liner with cylinder blocks separated (into cylinder block RH and cylinder block LH).

- Measurement should be performed at a temperature of 20°C (68°F).

- The cylinder bore size mark is stamped on the upper face of the cylinder block.

  (A) | Main journal size mark | (C) | #1 cylinder bore size mark | (E) | #3 cylinder bore size mark
  (B) | Cylinder block (RH) − (LH) combination mark | (D) | #2 cylinder bore size mark | (F) | #4 cylinder bore size mark

- Measure the inner diameter of each cylinder liner in both the thrust and piston pin directions at the heights as shown in the figure and read the value of the most worn location.

(A) | Piston pin direction | (B) | Thrust direction |  |
H1: | 10 mm (0.3937 in) | H2: | 45 mm (1.7717 in) | H3: | 80 mm (3.1496 in)
H4: | 105 mm (4.1339 in) |  |  |  |

Inner diameter of cylinder liner:

Cylinder bore size mark A

Standard

94.005 — 94.015 mm (3.7010 — 3.7014 in)

Cylinder bore size mark B

Standard

93.995 — 94.005 mm (3.7006 — 3.7010 in)

(2)

Check the outer diameter of piston with a micrometer. If it is not within the standard, replace the piston.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the outer diameter of each piston in thrust direction at the height as shown in the figure.

- Standard sized pistons are classified into two grades, “A” and “B”. These grades should be used as guide lines in selecting a standard piston.

- The grade can be judged by the stamp of cylinder bore size mark on the upper face of the cylinder block.

  (A) | Main journal size mark | (C) | #1 cylinder bore size mark | (E) | #3 cylinder bore size mark
  (B) | Cylinder block (RH) − (LH) combination mark | (D) | #2 cylinder bore size mark | (F) | #4 cylinder bore size mark

- If the piston is replaced, check the clearance between cylinder liner and piston in the step (3), and select a suitable sized piston.

Piston grade point H:

13.3 mm (0.5236 in)

Piston outer diameter:

Standard size (grade A = cylinder bore size mark A)

Standard

93.980 — 94.990 mm (3.7000 — 3.7004 in)

Standard size (grade B = cylinder bore size mark B)

Standard

93.970 — 93.980 mm (3.6996 — 3.7000 in)

(3)

Calculate the clearance between cylinder liner and piston. If they are not within the standard, perform reboring (including honing), or replace the cylinder block and piston as a set. For reboring and honing procedure, refer to step 8.

The clearance between cylinder liner and piston is decided by matching the cylinder block bore size mark and the grade of piston outer diameter (grade A or B).

Clearance between cylinder liner and piston:

Standard

0.015 — 0.035 mm (0.0006 — 0.0014 in)

8.

Reboring and honing

(1)

If any of the cylindricality, out-of-roundness, inner diameter or clearance between cylinder liner and piston is out of standard or if there is any damage on the cylinder liner, perform reboring (including honing).

When any of the cylinder liner needs reboring, all other cylinder liners must be rebored at the same time, and replaced with proper size pistons.

Oversize piston outer diameter:

0.25 mm (0.0098 in) oversize

Standard

94.220 — 94.240 mm (3.7094 — 3.7102 in)

0.50 mm (0.0197 in) oversize

Standard

94.470 — 94.490 mm (3.7193 — 3.7201 in)

(2)

If the inner diameter of cylinder liner exceeds the limit after reboring (including honing), replace the cylinder block and piston as a set.

- Immediately after reboring (including honing), the inner diameter of cylinder liner may differ from its real diameter due to temperature rise. Thus, when measuring the inner diameter of cylinder liner, wait until the temperature has cooled to 20°C (68°F).

- For the measurement of the inner diameter of cylinder liner, refer to step 7.

Inner diameter of cylinder liner boring limit (diameter):

94.505 mm (3.7207 in) or less

2. PISTON AND PISTON PIN
1.

Check the piston and piston pin for wear or crack.

2.

Check the snap ring for distortion or wear.

3.

Check the piston ring groove for damage.

4.

Check the circlip groove (A) for burr.

If the burr is found, remove the burr from groove.

5.

Check that the piston pin can be inserted into the piston with a thumb at 20°C (68°F).

6.

Check the clearance between piston and piston pin. Check the clearance between piston and piston pin by measuring the inner diameter of piston pin hole and the outer diameter of piston pin respectively.

(1)

Using a caliper gauge, measure the inner diameter of piston pin hole.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the inner diameter of the piston pin hole at the four locations as shown in the figure, and read the value of most worn location.

- Record the measured value.

(2)

Measure the outer diameter of piston pin with a micrometer.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the outer diameter of the piston pin at the four locations as shown in the figure, and read the value of most worn location.

- Record the measured value.

(A) | 10 mm (0.3937 in) |  |  |  |

(3)

Calculate the clearance between piston and piston pin. If it is not within the standard, replace the piston and piston pin as a set.

Clearance between piston and piston pin:

Standard

0.004 — 0.008 mm (0.0002 — 0.0003 in)

3. PISTON RING
1.

Make sure the piston ring is not broken or damaged.

2.

Using a cylindrical guide, insert the piston ring into the cylinder liner so that they are perpendicular to the cylinder wall, and check the piston ring gap using a thickness gauge. If it is not within the standard, replace the piston ring.

- Measurement should be performed at a temperature of 20°C (68°F).

- Use piston ring with same size as piston when replacing piston ring.

Piston ring gap:

Compression ring (top ring)

Standard

0.20 — 0.25 mm (0.0079 — 0.0098 in)

Compression ring (second ring)

Standard

0.25 — 0.35 mm (0.0098 — 0.0138 in)

Oil ring (upper rail and lower rail)

Standard

0.10 — 0.35 mm (0.0039 — 0.0138 in)

3.

Fit the compression ring straight into the piston ring groove, then check the clearance between compression ring and piston with a thickness gauge. If it is not within the standard, replace the compression ring.

- Measurement should be performed at a temperature of 20°C (68°F).

- Before inspecting the clearance, clean the piston ring groove and compression ring.

- Use compression ring with same size as piston when replacing compression ring.

Clearance between compression ring and piston:

Top ring

Standard

0.040 — 0.080 mm (0.0016 — 0.0031 in)

Second ring

Standard

0.030 — 0.070 mm (0.0012 — 0.0028 in)

4. CONNECTING ROD AND CONNECTING ROD BEARING
1.

Check for bend or twist using a connecting rod aligner. If it exceeds the limit, replace the connecting rod.

Measurement should be performed at a temperature of 20°C (68°F).

Bend or twist per 100 mm (3.9370 in) in length:

Limit

0.10 mm (0.0039 in)

(A) | Thickness gauge | (B) | Connecting rod |  |

2.

Check that the large or small end thrust surface of each connecting rod is not damaged.

3.

Check each connecting rod bearing for scar, peeling, seizure, melting or wear, etc.

4.

Check the thrust clearance of each connecting rod using a thickness gauge.

Measurement should be performed at a temperature of 20°C (68°F).

(1)

Clean the #1 connecting rod bearing and the #1 pin of crankshaft, and apply engine oil to the #1 pin of crankshaft.

(2)

Set the #1 connecting rod bearing to the #1 connecting rod and #1 connecting rod cap.

(3)

Set the #1 connecting rod, #1 connecting rod cap and #1 connecting rod cap bolt to the #1 pin of crankshaft.

- Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.

- Use a new connecting rod cap bolt.

- Apply a coat of engine oil to the #1 connecting rod cap bolt thread.

(4)

Using ST, tighten the #1 connecting rod cap bolts to 10 N·m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N·m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

- Make sure to hold the crankshaft securely during work.

- When holding the crankshaft, be careful not to damage the crankshaft.

Preparation tool:

ST: SOCKET (18270AA020)

(5)

Using the ST and angle gauge, tighten the #1 connecting rod cap bolts with torque of 135° — 140° in numerical order as shown in the figure.

- Make sure to hold the crankshaft securely during work.

- When holding the crankshaft, be careful not to damage the crankshaft.

Prevent angle gauge from rotating using a V-block, etc.

Preparation tool:

ST: SOCKET (18270AA020)

(6)

In the same manner, install the #2, #3 and #4 connecting rods.

(7)

Check the thrust clearance of each connecting rod using a thickness gauge. If it is not within the standard, replace the connecting rod.

Measure the thrust clearance of each connecting rod at several points, and replace the connecting rod if there is uneven wear.

Connecting rod thrust clearance:

Standard

0.070 — 0.330 mm (0.0028 — 0.0130 in)

5.

Check the oil clearance on each connecting rod bearing using plastigauge.

Measurement should be performed at a temperature of 20°C (68°F).

(1)

Clean the #1 connecting rod bearing and the #1 pin of crankshaft.

(2)

Set the #1 connecting rod bearing to the #1 connecting rod and #1 connecting rod cap.

(3)

Place a plastigauge across the #1 pin of crankshaft, and set the #1 connecting rod, #1 connecting rod cap and #1 connecting rod cap bolt to the #1 pin of crankshaft.

- Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.

- Use a new connecting rod cap bolt.

- Apply a coat of engine oil to the #1 connecting rod cap bolt thread.

(4)

Using ST, tighten the #1 connecting rod cap bolts to 10 N·m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N·m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

- Make sure to hold the crankshaft securely during work.

- When holding the crankshaft, be careful not to damage the crankshaft.

- During tightening, be careful not to move the #1 connecting rod and the #1 connecting rod cap.

Preparation tool:

ST: SOCKET (18270AA020)

(5)

Using the ST and angle gauge, tighten the #1 connecting rod cap bolts with torque of 135° — 140° in numerical order as shown in the figure.

- Make sure to hold the crankshaft securely during work.

- When holding the crankshaft, be careful not to damage the crankshaft.

- During tightening, be careful not to move the #1 connecting rod and the #1 connecting rod cap.

Prevent angle gauge from rotating using a V-block, etc.

Preparation tool:

ST: SOCKET (18270AA020)

(6)

Using the ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.

- Make sure to hold the crankshaft securely during work.

- When holding the crankshaft, be careful not to damage the crankshaft.

- During removal, be careful not to move the #1 connecting rod and the #1 connecting rod cap.

Preparation tool:

ST: SOCKET (18270AA020)

(7)

Determine oil clearance of the #1 connecting rod bearing by matching the widest point of the plastigauge on #1 pin of crankshaft against scale printed on a package of the plastigauge. If it is not within the standard, replace the #1 connecting rod bearing.

Measure the outer diameter of crankshaft pin using micrometer, and select the suitable size connecting rod bearing when replacing the connecting rod bearing.

Unit: mm (in)
Bearing | Connecting rod bearing thickness (at center) | Crankshaft pin outer diameter
Connecting rod side | Connecting rod cap side
Standard | Standard | Standard
Standard size | 1.496 — 1.512 (0.0589 — 0.0595) | 1.492 — 1.508 (0.0587 — 0.0594) | 47.976 — 48.000 (1.8888 — 1.8898)
0.03 (0.0012) Undersize | 1.515 — 1.519 (0.0596 — 0.0598) | 1.511 — 1.515 (0.0595 — 0.0596) | 47.946 — 47.970 (1.8876 — 1.8886)
0.05 (0.0020) Undersize | 1.525 — 1.529 (0.0600 — 0.0602) | 1.521 — 1.525 (0.0599 — 0.0600) | 47.926 — 47.950 (1.8868 — 1.8878)
0.25 (0.0098) Undersize | 1.625 — 1.629 (0.0640 — 0.0641) | 1.621 — 1.625 (0.0638 — 0.0640) | 47.726 — 47.750 (1.8790 — 1.8799)

Connecting rod bearing oil clearance:

Standard

0.017 — 0.047 mm (0.0007 — 0.0019 in)

(8)

Completely remove the plastigauge.

(9)

In the same manner, check oil clearance of the #2, #3 and #4 connecting rod bearings.

5. PISTON PIN & CONNECTING ROD BUSHING
1.

Check that the connecting rod bushing is not damaged.

2.

Check the clearance between piston pin and connecting rod bushing. Check the clearance between piston pin and connecting rod bushing by measuring the outer diameter of piston pin and the inner diameter of connecting rod bushing respectively.

(1)

Measure the outer diameter of piston pin with a micrometer.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the outer diameter of the piston pin at the two locations as shown in the figure, and read the value of most worn location.

- Record the measured value.

(2)

Using a caliper gauge, measure the inner diameter of connecting rod bushing.

- Measurement should be performed at a temperature of 20°C (68°F).

- Measure the inner diameter of the connecting rod bushing at the two locations as shown in the figure, and read the value of most worn location.

- Record the measured value.

(3)

Calculate the clearance between piston pin and connecting rod bushing.

Clearance between piston pin and connecting rod bushing:

Standard

0.004 — 0.026 mm (0.0002 — 0.0010 in)

3.

If the clearance between piston pin and connecting rod bushing is not within the standard, replace the connecting rod bushing and piston pin as a set. For replacement procedure of connecting rod bushing, refer to the following.

(1)

Using the ST and a press, pull out the connecting rod bushing from the small end of the connecting rod.

The direction of ST for pulling out and for press fitting is different. Therefore, attention must be paid to the direction of usage for ST.

Preparation tool:

ST: CONNECTING ROD BUSHING REMOVER AND INSTALLER (18350AA000)

(2)

Press the connecting rod bushing with ST and the press, after applying engine oil on the periphery of connecting rod bushing.

- Clinch area of the connecting rod bushing is as shown in the figure.

  (a) | Clinch area of connecting rod bushing |  |  |  |

- The direction of ST for pulling out and for press fitting is different. Therefore, attention must be paid to the direction of usage for ST.

Preparation tool:

ST: CONNECTING ROD BUSHING REMOVER AND INSTALLER (18350AA000)

(3)

Make two 3 mm (0.1181 in) holes in the pressed connecting rod bushing by aligning with the pre-manufactured holes provided on the small end of the connecting rod.

(4)

Using a reamer, ream the inside surface of the connecting rod bushing. Insert the reamer in the connecting rod bushing, and turn slowly clockwise while pushing lightly. Bring the reamer back while rotating it clockwise.

- Use a reamer with a diameter of ⌀22.

- Apply engine oil to the reamer.

- If the inner surface of connecting rod bushing is damaged, the edge of reamer should be slightly ground with oil stone.

- If the inner surface of connecting rod bushing becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer.

(5)

After completion of reaming, clean the connecting rod bushing to remove chips.

6. CRANKSHAFT AND CRANKSHAFT BEARING
1.

Clean the crankshaft completely, and check it for cracks using liquid penetrant tester.

2.

Using a dial gauge, check the crankshaft bend. If it exceeds the limit, grind to correct the crankshaft journal or replace the crankshaft.

- Measurement should be performed at a temperature of 20°C (68°F).

- If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge.

- When grinding to correct the crankshaft journal, refer to step 3.

Crankshaft bend:

Limit

0.035 mm (0.0014 in)

3.

Using a micrometer, check the outer diameter of crankshaft pin, outer diameter of journal, cylindricality, and out-of-roundness. If it is not within the standard, replace the connecting rod bearing or crankshaft bearing, and grind to correct the crankshaft pin or journal or replace the crankshaft as required.

- Measurement should be performed at a temperature of 20°C (68°F).

- Select the suitable size connecting rod bearing or crankshaft bearing when replacing the connecting rod bearing or crankshaft bearing.

- When grinding to correct the crankshaft pin or journal, finish them to the suitable outer diameter as shown in the table below according to the undersize bearing to be used.

  Crankshaft pin | Unit: mm (in)
  Bearing | Connecting rod bearing thickness (at center) | Crankshaft pin outer diameter
  Connecting rod side | Connecting rod cap side
  Standard | Standard | Standard
  Standard size | 1.496 — 1.512 (0.0589 — 0.0595) | 1.492 — 1.508 (0.0587 — 0.0594) | 47.976 — 48.000 (1.8888 — 1.8898)
  0.03 (0.0012) Undersize | 1.515 — 1.519 (0.0596 — 0.0598) | 1.511 — 1.515 (0.0595 — 0.0596) | 47.946 — 47.970 (1.8876 — 1.8886)
  0.05 (0.0020) Undersize | 1.525 — 1.529 (0.0600 — 0.0602) | 1.521 — 1.525 (0.0599 — 0.0600) | 47.926 — 47.950 (1.8868 — 1.8878)
  0.25 (0.0098) Undersize | 1.625 — 1.629 (0.0640 — 0.0641) | 1.621 — 1.625 (0.0638 — 0.0640) | 47.726 — 47.750 (1.8790 — 1.8799)

  Crankshaft journal | Unit: mm (in)
  Bearing | Crankshaft bearing thickness (at center) | Crankshaft journal outer diameter
  #1, #3 | #2, #4 | #5
  Standard | Standard | Standard | Standard
  Standard size | 2.498 — 2.513 (0.0983 — 0.0989) | 2.501 — 2.516 (0.0985 — 0.0991) | 2.499 — 2.514 (0.0984 — 0.0990) | 67.985 — 68.003 (2.6766 — 2.6773)
  0.03 (0.0012) Undersize | 2.519 — 2.522 (0.0992 — 0.0993) | 2.519 — 2.522 (0.0992 — 0.0993) | 2.517 — 2.520 (0.0991 — 0.0992) | 67.955 — 67.979 (2.6754 — 2.6763)
  0.05 (0.0020) Undersize | 2.529 — 2.532 (0.0996 — 0.0997) | 2.529 — 2.532 (0.0996 — 0.0997) | 2.527 — 2.530 (0.0995 — 0.0996) | 67.935 — 67.959 (2.6746 — 2.6755)
  0.25 (0.0098) Undersize | 2.629 — 2.632 (0.1035 — 0.1036) | 2.629 — 2.632 (0.1035 — 0.1036) | 2.627 — 2.630 (0.1034 — 0.1035) | 67.735 — 67.759 (2.6667 — 2.6677)

Crankshaft pin:

Cylindricality

Limit

0.006 mm (0.0002 in)

Out-of-roundness

Limit

0.005 mm (0.0002 in)

Grinding limit (dia.)

47.726 mm (1.8790 in) or less

Crankshaft journal:

Cylindricality

Limit

0.006 mm (0.0002 in)

Out-of-roundness

Limit

0.005 mm (0.0002 in)

Grinding limit (dia.)

67.735 mm (2.6667 in) or less

4.

Inspect the crankshaft bearing for scar, peeling, seizure, melting or wear, etc.

5.

Use a thickness gauge to check the thrust clearance of crankshaft at thrust of #5 crankshaft bearing. If it is not within the standard, replace the #5 crankshaft bearing.

- Measurement should be performed at a temperature of 20°C (68°F).

- Set all the crankshaft bearings onto the cylinder block, then mount the crankshaft on the cylinder block, and use a thickness gauge to measure the thrust clearance of crankshaft.

- Select the #5 crankshaft bearing of suitable size by referring to step 3 when replacing #5 crankshaft bearing.

Crankshaft thrust clearance:

Standard

0.130 — 0.308 mm (0.0051 — 0.0121 in)

6.

Check the oil clearance on each crankshaft bearing using plastigauge.

Measurement should be performed at a temperature of 20°C (68°F).

(1)

Install the cylinder block LH to the engine stand.

- When the engine stand is not used, place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.

- Be careful not to scratch the mating surface of cylinder block during work.

(2)

Remove the liquid gasket from cylinder block.

(3)

Clean each crankshaft bearing and crankshaft journal.

(4)

Set each crankshaft bearing to the cylinder block.

When performing the operation of the cylinder block RH, be careful of the following.

- 1) Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.

- 2) Be careful not to scratch the mating surface of cylinder block during work.

(5)

Set the crankshaft to the cylinder block LH.

(6)

Place a plastigauge across the crankshaft journals and set the cylinder block RH to the cylinder block LH.

(7)

Join the cylinder blocks.

When tightening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

- 1) Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.

  To prevent mixture of engine oil into the water jacket, do not apply a large amount.

- 2) Tighten all mounting bolts with a torque of 35 N·m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.

- 3) Loosen all mounting bolts by 180° in the reverse order of tightening in step 2).

- 4) Tighten all mounting bolts with a torque of 35 N·m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.

- 5) Loosen the mounting bolts (4 places) by 180° in the order of (6) → (5) → (4) → (3) as shown in the figure.

- 6) Tighten the mounting bolts (4 places) with a torque of 17 N·m (1.7 kgf-m, 12.5 ft-lb) in the order of (3) → (4) → (5) → (6) as shown in the figure.

- 7) Using an angle gauge, tighten the mounting bolts (4 places) with torque of 58° — 62° in the order of (3) → (4) → (5) → (6) as shown in the figure.

- 8) Loosen the mounting bolts (6 places) by 180° in the order of (8) → (7) → (10) → (9) → (2) → (1) as shown in the figure.

- 9) Tighten the mounting bolts (6 places) with a torque of 17 N·m (1.7 kgf-m, 12.5 ft-lb) in the order of (1) → (2) → (9) → (10) → (7) → (8) as shown in the figure.

- 10) Using an angle gauge, tighten the mounting bolts (3 places) with torque of 58° — 62° in the order of (1) → (2) → (9) as shown in the figure.

- 11) Using an angle gauge, tighten the mounting bolt (10) (1 place) shown in the figure to the angle of 78° — 82°.

- 12) Using an angle gauge, tighten the mounting bolt (7) (1 place) shown in the figure to the angle of 58° — 62°.

- 13) Using an angle gauge, tighten the mounting bolt (8) (1 place) shown in the figure to the angle of 78° — 82°.

(8)

Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and then remove the bolts.

(9)

While tapping the cylinder block RH with a plastic hammer, separate the cylinder block RH from the cylinder block LH.

Lift the cylinder block RH gradually, and confirm that the crankshaft is remaining in the cylinder block LH. Lifting the cylinder block RH carelessly may cause the crankshaft to fall off.

(10)

Determine the crankshaft oil clearance by matching the widest point of the plastigauge on each journal against scale printed on a package of the plastigauge. If it is not within the standard, replace the crankshaft bearing, and grind to correct the crankshaft journal or replace the crankshaft as required.

- Select the crankshaft bearing of suitable size by referring to step 3 when replacing crankshaft bearing.

- When grinding to correct the crankshaft journal, finish it to the suitable outer diameter by referring to step 3 according to the undersize bearing to be used.

Crankshaft oil clearance:

Standard

0.013 — 0.031 mm (0.0005 — 0.0012 in)

(11)

Completely remove the plastigauge.

7. REAR OIL SEAL
1.

Check that there is no oil leaking from rear oil seal. If there is any oil leak, replace the rear oil seal with a new part according to the following procedures described below.

(1)

When working on the vehicle

When working on the vehicle, perform the following steps also.

- 1) Remove the transmission main body from the vehicle. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

(2)

Remove the crankshaft position sensor plate with drive plate. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>REMOVAL

(3)

Remove the rear oil seal from cylinder block using the oil seal puller, etc.

Be careful not to damage the crankshaft during work.

(4)

Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install the rear oil seal using ST1 and ST2.

Preparation tool:

ST1: OIL SEAL GUIDE (18671AA020)

ST2: OIL SEAL INSTALLER (18657AA030)

(A) | Rear oil seal | (B) | Drive plate mounting bolt |  |

(5)

Install in the reverse order of removal after replacement.

MECHANICAL(H4DO) > Intake and Exhaust Valve
REMOVAL

Refer to “Cylinder Head” for removal procedures of the intake and exhaust valves.

- MECHANICAL(H4DO)>Cylinder Head>REMOVAL

- MECHANICAL(H4DO)>Cylinder Head>DISASSEMBLY

MECHANICAL(H4DO) > Intake and Exhaust Valve
INSTALLATION

Refer to “Cylinder Head” for installation procedures of the intake and exhaust valves.

- MECHANICAL(H4DO)>Cylinder Head>ASSEMBLY

- MECHANICAL(H4DO)>Cylinder Head>INSTALLATION

MECHANICAL(H4DO) > Intake and Exhaust Valve
INSPECTION

Refer to “Cylinder Head” for inspection procedures of the intake and exhaust valves.

MECHANICAL(H4DO)>Cylinder Head>INSPECTION

MECHANICAL(H4DO) > Piston
REMOVAL

Refer to “Cylinder Block” for removal procedures of pistons.

- MECHANICAL(H4DO)>Cylinder Block>REMOVAL

- MECHANICAL(H4DO)>Cylinder Block>DISASSEMBLY > PISTON AND CONNECTING ROD

MECHANICAL(H4DO) > Piston
INSTALLATION

Refer to “Cylinder Block” for installation procedures of pistons.

- MECHANICAL(H4DO)>Cylinder Block>ASSEMBLY > PISTON AND CONNECTING ROD

- MECHANICAL(H4DO)>Cylinder Block>INSTALLATION

MECHANICAL(H4DO) > Piston
INSPECTION

Refer to “Cylinder Block” for inspection procedures of pistons.

MECHANICAL(H4DO)>Cylinder Block>INSPECTION

MECHANICAL(H4DO) > Connecting Rod
REMOVAL

Refer to “Cylinder Block” for removal procedures of connecting rod.

- MECHANICAL(H4DO)>Cylinder Block>REMOVAL

- MECHANICAL(H4DO)>Cylinder Block>DISASSEMBLY > PISTON AND CONNECTING ROD

MECHANICAL(H4DO) > Connecting Rod
INSTALLATION

Refer to “Cylinder Block” for installation procedures of connecting rod.

- MECHANICAL(H4DO)>Cylinder Block>ASSEMBLY > PISTON AND CONNECTING ROD

- MECHANICAL(H4DO)>Cylinder Block>INSTALLATION

MECHANICAL(H4DO) > Connecting Rod
INSPECTION

Refer to “Cylinder Block” for inspection procedures of connecting rod.

MECHANICAL(H4DO)>Cylinder Block>INSPECTION

MECHANICAL(H4DO) > Crankshaft
REMOVAL

Refer to “Cylinder Block” for removal procedures of the crankshaft.

MECHANICAL(H4DO)>Cylinder Block>REMOVAL

MECHANICAL(H4DO) > Crankshaft
INSTALLATION

Refer to “Cylinder Block” for installation procedures of the crankshaft.

MECHANICAL(H4DO)>Cylinder Block>INSTALLATION

MECHANICAL(H4DO) > Crankshaft
INSPECTION

Refer to “Cylinder Block” for inspection procedures of the crankshaft.

MECHANICAL(H4DO)>Cylinder Block>INSPECTION

MECHANICAL(H4DO) > Symptoms and causes
INSPECTION

The “RANK” shown in the chart shows the possibilities of the cause of trouble in order from “Very often” to “Rarely”.

A — Very often

B — Sometimes

C — Rarely

Symptoms | Problem parts etc. | Possible cause | RANK
1. Engine does not start. |
1) Starter does not turn. | Starter | Defective battery-to-starter harness | B
Defective starter switch | C
Defective relay | C
Defective inhibitor switch | C
Defective starter | B
Battery | Improper connection of terminal | A
Run-down battery | A
Defective charging system | B
Friction | Seizure of crankshaft and connecting rod bearing | C
Seized camshaft | C
Seized or stuck piston and cylinder | C
Immobilizer system IMMOBILIZER (DIAGNOSTICS)>Basic Diagnostic Procedure | A
2) Initial combustion does not occur. | Starter | Defective starter | C
Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Fuel line | Defective fuel pump and relay | A
Clogged fuel line | C
Lack of fuel or insufficient fuel | B
Timing chain | Trouble | B
Defective timing | B
Compression | Incorrect cam clearance | C
Loosened spark plug or defective gasket | C
Loosened cylinder head bolt or defective cylinder head gasket | C
Improper valve sealing | C
Defective valve stem | C
Worn or broken valve spring | B
Worn or stuck piston rings, cylinder liner and piston | C
Incorrect valve timing | B
Improper engine oil (low viscosity) | B
3) Initial combustion occurs. | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Defective intake manifold gasket | B
Defective throttle body gasket | B
Fuel line | Defective fuel pump and relay | C
Clogged fuel line | C
Lack of fuel or insufficient fuel | B
Timing chain | Trouble | B
Defective timing | B
Compression | Incorrect cam clearance | C
Loosened spark plug or defective gasket | C
Loosened cylinder head bolt or defective cylinder head gasket | C
Improper valve sealing | C
Defective valve stem | C
Worn or broken valve spring | B
Worn or stuck piston rings, cylinder liner and piston | C
Incorrect valve timing | B
Improper engine oil (low viscosity) | B
4) Engine stalls after initial combustion. | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened or cracked intake duct | B
Loosened or cracked PCV hose | C
Loosened or cracked vacuum hose | C
Defective intake manifold gasket | B
Defective throttle body gasket | B
Dirty air cleaner element | C
Fuel line | Clogged fuel line | C
Lack of fuel or insufficient fuel | B
Timing chain | Trouble | B
Defective timing | B
Compression | Incorrect cam clearance | C
Loosened spark plug or defective gasket | C
Loosened cylinder head bolt or defective cylinder head gasket | C
Improper valve sealing | C
Defective valve stem | C
Worn or broken valve spring | B
Worn or stuck piston rings, cylinder and piston | C
Incorrect valve timing | B
Improper engine oil (low viscosity) | B
2. Rough idle and engine stall | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened or cracked intake duct | A
Loosened or cracked PCV hose | A
Loosened or cracked vacuum hose | A
Defective intake manifold gasket | B
Defective throttle body gasket | B
Defective PCV valve | C
Loosened oil filler cap | B
Dirty air cleaner element | C
Fuel line | Defective fuel pump and relay | C
Clogged fuel line | C
Lack of fuel or insufficient fuel | B
Timing chain | Defective timing | C
Compression | Incorrect cam clearance | B
Loosened spark plug or defective gasket | B
Loosened cylinder head bolt or defective cylinder head gasket | B
Improper valve sealing | B
Defective valve stem | C
Worn or broken valve spring | B
Worn or stuck piston rings, cylinder and piston | B
Incorrect valve timing | A
Improper engine oil (low viscosity) | B
Lubrication system | Incorrect oil pressure | B
Defective rocker cover gasket | C
Cooling system | Over-heating | C
Other | Evaporative emission control system malfunction | A
Stuck or damaged throttle valve | B
3. Low output, hesitation and poor acceleration | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened or cracked intake duct | A
Loosened or cracked PCV hose | A
Loosened or cracked vacuum hose | B
Defective intake manifold gasket | B
Defective throttle body gasket | B
Defective PCV valve | B
Loosened oil filler cap | B
Dirty air cleaner element | A
Fuel line | Defective fuel pump and relay | B
Clogged fuel line | B
Lack of fuel or insufficient fuel | C
Timing chain | Defective timing | B
Compression | Incorrect cam clearance | B
Loosened spark plug or defective gasket | B
Loosened cylinder head bolt or defective cylinder head gasket | B
Improper valve sealing | B
Defective valve stem | C
Worn or broken valve spring | B
Worn or stuck piston rings, cylinder and piston | C
Incorrect valve timing | A
Improper engine oil (low viscosity) | B
Lubrication system | Incorrect oil pressure | B
Cooling system | Over-heating | C
Over-cooling | C
Other | Evaporative emission control system malfunction | A
4. Surging | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened or cracked intake duct | A
Loosened or cracked PCV hose | A
Loosened or cracked vacuum hose | A
Defective intake manifold gasket | B
Defective throttle body gasket | B
Defective PCV valve | B
Loosened oil filler cap | B
Dirty air cleaner element | B
Fuel line | Defective fuel pump and relay | B
Clogged fuel line | B
Lack of fuel or insufficient fuel | C
Timing chain | Defective timing | B
Compression | Incorrect cam clearance | B
Loosened spark plug or defective gasket | C
Loosened cylinder head bolt or defective cylinder head gasket | C
Improper valve sealing | C
Defective valve stem | C
Worn or broken valve spring | C
Worn or stuck piston rings, cylinder and piston | C
Incorrect valve timing | A
Improper engine oil (low viscosity) | B
Cooling system | Over-heating | B
Other | Evaporative emission control system malfunction | C
5. Engine does not return to idle. | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened or cracked vacuum hose | A
Other | Stuck or damaged throttle valve | A
6. Dieseling (run-on) | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Cooling system | Over-heating | B
Other | Evaporative emission control system malfunction | B
7. After burning in exhaust system | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened or cracked intake duct | C
Loosened or cracked PCV hose | C
Loosened or cracked vacuum hose | B
Defective PCV valve | B
Loosened oil filler cap | C
Timing chain | Defective timing | B
Compression | Incorrect cam clearance | B
Loosened spark plug or defective gasket | C
Loosened cylinder head bolt or defective cylinder head gasket | C
Improper valve sealing | B
Defective valve stem | C
Worn or broken valve spring | C
Worn or stuck piston rings, cylinder and piston | C
Incorrect valve timing | A
Lubrication system | Incorrect oil pressure | C
Cooling system | Over-cooling | C
Other | Evaporative emission control system malfunction | C
8. Knocking | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Loosened oil filler cap | B
Timing chain | Defective timing | B
Compression | Incorrect cam clearance | C
Incorrect valve timing | B
Cooling system | Over-heating | A
9. Excessive engine oil consumption | Intake system | Loosened or cracked PCV hose | A
Defective PCV valve | B
Loosened oil filler cap | C
Compression | Defective valve stem | A
Worn or stuck piston rings, cylinder and piston | A
Lubrication system | Loosened chain cover attaching bolts and defective gasket | B
Defective oil filter gasket | B
Defective crankshaft oil seal | B
Defective rocker cover gasket | B
Loosened oil drain plug or defective gasket | B
Loosened oil pan mounting bolt or defective oil pan | B
10. Excessive fuel consumption | Engine control system ENGINE (DIAGNOSTICS)(H4DO)>Basic Diagnostic Procedure | A
Intake system | Dirty air cleaner element | A
Timing chain | Defective timing | B
Compression | Incorrect cam clearance | B
Loosened spark plug or defective gasket | C
Loosened cylinder head bolt or defective cylinder gasket | C
Improper valve sealing | B
Defective valve stem | C
Worn or broken valve spring | C
Worn or stuck piston rings, cylinder and piston | B
Incorrect valve timing | B
Lubrication system | Incorrect oil pressure | C
Cooling system | Over-cooling | C

MECHANICAL(H4DO) > Engine Noise
INSPECTION

Type of sound | Condition | Possible cause
Regular clicking sound | Sound increases as engine speed increases. | Valve mechanism is defective Incorrect cam clearance Worn camshaft Broken valve spring Defective valve shim
Heavy and dull clank | Oil pressure is low. | Worn crankshaft bearing Worn connecting rod bearing
Oil pressure is normal. | Damaged engine mounting
High-pitched clank | Sound is noticeable when accelerating with an overload condition. | Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong heat range of spark plug Improper octane value gasoline
Clank noise when engine speed is (1,000 — 2,000 r/min) | Sound is reduced when the fuel injector of the noisy cylinder is stopped.∗ | Worn crankshaft bearing Worn connecting rod bearing
Knocking sound when engine is operating under idling speed and engine is warm | Sound is reduced when the fuel injector of the noisy cylinder is stopped.∗ | Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and piton pin hole of piston
Sound is not reduced if each fuel injector is stopped in turn.∗ | Unusually worn valve rocker Unusually worn valve shim Worn cam sprocket Worn journal of cam carrier and camshaft cap
Squeaky sound | — | Insufficient generator lubrication
Rubbing sound | — | Poor contact of generator brush and rotor
Gear scream when starting engine | — | Defective ignition starter switch Worn gear and starter pinion
Sound like polishing glass with a dry cloth | — | Defective V-belt tensioner assembly (loose V-belt) Defective water pump shaft
Hissing sound | — | Insufficient compression Air leakage in air intake system, hose, connection or manifold
Timing chain noise | — | Loose timing chain Timing chain contacting with adjacent part
Valve noise | — | Incorrect cam clearance

∗Fuel injector can be stopped using the Subaru Select Monitor. ENGINE (DIAGNOSTICS)(H4DO)>Active Test>OPERATION