Subaru Legacy 1998 Workshop Manual

Page 1
2-1 [W1A0] SERVICE PROCEDURE
1. Front Catalytic Converter
1. Front Catalytic Converter
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Disconnect front oxygen sensor connector.
4) Lift-up the vehicle.
5) Disconnect rear oxygen sensor connector. (Except California spec. vehicles)
B2M0312
6) Separate center exhaust pipe from front cata­lytic converter.
S2M0127
3) Disconnect rear oxygen sensor connector. (California spec. vehicles)
S2M0128
S2M0052
7) Remove bolts which hold front exhaust pipe onto cylinder heads.
CAUTION: Be careful not to pull down front exhaust pipe and center exhaust pipe.
S2M0236
2
Page 2
[W1B0] 2-1SERVICE PROCEDURE
1. Front Catalytic Converter
8) Separate front catalytic converter from front exhaust pipe.
S2M0053
B: INSTALLATION
CAUTION: Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust pipe and center exhaust pipe.
Tightening torque:
±
5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
30
3) Install center exhaustpipe to frontcatalytic con­verter.
Tightening torque:
±
5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
35
S2M0052
4) Connect rear oxygen sensorconnector. (Except California spec. vehicles)
S2M0053
2) Tightenbolts which holdfront exhaust pipe onto cylinder heads.
Tightening torque:
±
5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
30
S2M0236
B2M0312
5) Lower the vehicle.
6) Connect rear oxygen sensor connector. (Cali­fornia spec. vehicles)
S2M0128
3
Page 3
2-1 [W2A0] SERVICE PROCEDURE
2. Rear Catalytic Converter
7) Connect front oxygen sensor connector.
S2M0127
8) Connect battery ground cable.
2. Rear Catalytic Converter
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Disconnect rear oxygen sensor connector. (Except California spec. vehicles)
B2M1723
B2M0312
4) Separate center exhaust pipe and rear catalytic converter assembly from rear exhaust pipe.
B2M0055
4
Page 4
2-1 [W2A0] SERVICE PROCEDURE
2. Rear Catalytic Converter
7) Connect front oxygen sensor connector.
S2M0127
8) Connect battery ground cable.
2. Rear Catalytic Converter
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Disconnect rear oxygen sensor connector. (Except California spec. vehicles)
B2M1723
B2M0312
4) Separate center exhaust pipe and rear catalytic converter assembly from rear exhaust pipe.
B2M0055
4
Page 5
[W2B0] 2-1SERVICE PROCEDURE
2. Rear Catalytic Converter
5) Separate center exhaust pipe and rear catalytic converter assembly from front catalytic converter.
S2M0052
6) Remove center exhaust pipe and rear catalytic converter assembly from hanger bracket.
CAUTION: I Be careful not to pull down center exhaust pipe. I After removing center exhaust pipe, do not apply excessive pulling force on front catalytic converter and front exhaust pipe.
2) Install center exhaust pipe to front catalytic con­verter.
Tightening torque:
±
5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
35
S2M0052
3) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
±
5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
18
B2M0313
B: INSTALLATION
CAUTION: Replace gaskets with new ones.
1) Install center exhaust pipe and rear catalytic converter assembly. Temporarily tighten bolt which installs center exhaust pipe to hanger bracket.
B2M0313
B2M0055
4) Tighten bolt which holds center exhaust pipe to hanger bracket.
Tightening torque:
±
5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
35
B2M0313
5
Page 6
2-1 [W3A1] SERVICE PROCEDURE
3. Canister
5) Connect rear oxygen sensor connector. (Except California spec. vehicles)
B2M0312
6) Lower the vehicle.
7) Connect battery ground cable.
B2M1723
3. Canister
A: REMOVAL AND INSTALLATION
1. 2200 cc FWD AND TAIWAN SPEC. VEHICLES
1) Disconnect canister hoses from evaporation pipes.
2) Remove canister with bracket.
S2M0574
3) Installation is in the reverse order of removal.
CAUTION: Insert air vent hose of canister into the hole on body.
2. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES AND 2500 cc MODEL
1) Lift-up the vehicle.
2) Disconnect evaporation hoses from canister.
B2M0952
3) Remove canister from body.
S2M0142
6
Page 7
2-1 [W3A1] SERVICE PROCEDURE
3. Canister
5) Connect rear oxygen sensor connector. (Except California spec. vehicles)
B2M0312
6) Lower the vehicle.
7) Connect battery ground cable.
B2M1723
3. Canister
A: REMOVAL AND INSTALLATION
1. 2200 cc FWD AND TAIWAN SPEC. VEHICLES
1) Disconnect canister hoses from evaporation pipes.
2) Remove canister with bracket.
S2M0574
3) Installation is in the reverse order of removal.
CAUTION: Insert air vent hose of canister into the hole on body.
2. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES AND 2500 cc MODEL
1) Lift-up the vehicle.
2) Disconnect evaporation hoses from canister.
B2M0952
3) Remove canister from body.
S2M0142
6
Page 8
[W4A0] 2-1SERVICE PROCEDURE
4. Purge Control Solenoid Valve
4) Installation is in the reverse order of removal.
Tightening torque:
±
7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)
22.5
S2M0143A
4. Purge Control Solenoid Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Remove air intake chamber and air intake duct as a unit. <Ref. to 2-7 [W18A0].>
S6M0007
3) Remove bolt which installs purge control sole­noid valve to intake manifold.
S2M0055
7
Page 9
[W4A0] 2-1SERVICE PROCEDURE
4. Purge Control Solenoid Valve
4) Installation is in the reverse order of removal.
Tightening torque:
±
7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)
22.5
S2M0143A
4. Purge Control Solenoid Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Remove air intake chamber and air intake duct as a unit. <Ref. to 2-7 [W18A0].>
S6M0007
3) Remove bolt which installs purge control sole­noid valve to intake manifold.
S2M0055
7
Page 10
2-1 [W5A0] SERVICE PROCEDURE
5. EGR Valve (Except 2200 cc MT Vehicles)
4) Take out purge control solenoid valve.
5) Disconnect connector from purge control sole­noid valve.
6) Disconnect vacuum hoses from purge control solenoid valve.
S2M0056
7) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
15.7 ft-lb)
5. EGR Valve (Except 2200 cc MT Vehicles)
A: REMOVAL AND INSTALLATION
1) Remove air intake chamber.
B2M1679
2) Disconnect vacuum hose from EGR valve.
3) Remove bolts which install EGR valve onto intake manifold.
B2M1201A
CAUTION: Carefully connect the evaporation hoses.
B2M1893A
B2M0423
4) Installation is in the reverse order of removal.
CAUTION: Replace gasket with a new one.
Tightening torque:
±
1.5 N·m (1.9±1.5 kg-m, 13.7±1.1 ft-lb)
18.6
8
Page 11
2-1 [W5A0] SERVICE PROCEDURE
5. EGR Valve (Except 2200 cc MT Vehicles)
4) Take out purge control solenoid valve.
5) Disconnect connector from purge control sole­noid valve.
6) Disconnect vacuum hoses from purge control solenoid valve.
S2M0056
7) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
15.7 ft-lb)
5. EGR Valve (Except 2200 cc MT Vehicles)
A: REMOVAL AND INSTALLATION
1) Remove air intake chamber.
B2M1679
2) Disconnect vacuum hose from EGR valve.
3) Remove bolts which install EGR valve onto intake manifold.
B2M1201A
CAUTION: Carefully connect the evaporation hoses.
B2M1893A
B2M0423
4) Installation is in the reverse order of removal.
CAUTION: Replace gasket with a new one.
Tightening torque:
±
1.5 N·m (1.9±1.5 kg-m, 13.7±1.1 ft-lb)
18.6
8
Page 12
[W7A2] 2-1SERVICE PROCEDURE
7. EGR Solenoid Valve (Except 2200 cc MT Vehicles)
6. Back-Pressure Transducer (BPT) (Except 2200 cc MT Vehicles)
A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hoses from BPT.
2) Remove BPT from bracket.
S2M0057
3) Installation is in the reverse order of removal.
7. EGR Solenoid Valve (Except 2200 cc MT Vehicles)
A: REMOVAL AND INSTALLATION
1. 2200 cc AT VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Disconnect connector from EGR solenoid valve.
3) Disconnect vacuum hoses from EGR solenoid valve.
4) Remove bolt which installs EGR solenoid valve onto intake manifold.
B2M1202C
5) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
15.7 ft-lb)
2. 2500 cc MODEL
1) Disconnect battery ground cable.
B2M1723
9
Page 13
[W7A2] 2-1SERVICE PROCEDURE
7. EGR Solenoid Valve (Except 2200 cc MT Vehicles)
6. Back-Pressure Transducer (BPT) (Except 2200 cc MT Vehicles)
A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hoses from BPT.
2) Remove BPT from bracket.
S2M0057
3) Installation is in the reverse order of removal.
7. EGR Solenoid Valve (Except 2200 cc MT Vehicles)
A: REMOVAL AND INSTALLATION
1. 2200 cc AT VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Disconnect connector from EGR solenoid valve.
3) Disconnect vacuum hoses from EGR solenoid valve.
4) Remove bolt which installs EGR solenoid valve onto intake manifold.
B2M1202C
5) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
15.7 ft-lb)
2. 2500 cc MODEL
1) Disconnect battery ground cable.
B2M1723
9
Page 14
2-1 [W8A0] SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
2) Remove air intake chamber. <Ref. to 2-7 [W18A0].>
B2M1679
3) Disconnect vacuum hoses from EGR solenoid valve.
4) Disconnect connector from EGR solenoid valve.
8. Fuel Temperature Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
S2M0058A
5) Remove bolt which installs EGR solenoid valve onto intake manifold.
S2M0059
6) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
15.7 ft-lb)
B2M1723
4) Disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C).
B2M0954E
10
Page 15
2-1 [W8A0] SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
2) Remove air intake chamber. <Ref. to 2-7 [W18A0].>
B2M1679
3) Disconnect vacuum hoses from EGR solenoid valve.
4) Disconnect connector from EGR solenoid valve.
8. Fuel Temperature Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
S2M0058A
5) Remove bolt which installs EGR solenoid valve onto intake manifold.
S2M0059
6) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
15.7 ft-lb)
B2M1723
4) Disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C).
B2M0954E
10
Page 16
[W8B0] 2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
5) Remove nuts which install fuel pump assembly onto fuel tank.
B2M0955
6) Take off fuel pump assembly from fuel tank.
B: INSTALLATION
CAUTION: Leave fuel filler cap open when tightening nuts, to prevent fuel from flowing out through fuel delivery and return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the following: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or for­eign particles before installation. (3) Tighten nuts in alphabetical sequence shown in figure to specified torque.
Tightening torque:
4.4
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
B2M0956
7) Disconnect connector from fuel pump bracket.
S2M0145
8) Remove main fuel level sensor from fuel pump assembly. <Ref. to 2-1 [W12A0].>
NOTE: Fuel temperature sensor is a unit with fuel pump. If replacing it, replace as a fuel pump.
B2M0955C
S2M0149
11
Page 17
2-1 [W9A1] SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
9. Fuel Tank Pressure Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL AND INSTALLATION
1. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
5) Remove fuel tank. <Ref. to 2-8 [W2A0].>
S2M0169A
6) Remove protector cover.
3) Disconnect battery ground cable.
B2M1723
4) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].>
B2M1773
7) Disconnect connector from fuel tank pressure sensor.
B2M1774
8) Release clips which hold fuel pipes onto fuel tank.
G2M0345
B2M1775A
12
Page 18
[W9A2] 2-1SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
9) Move two fuel pipes to upper side, and remove bolt which install fuel tank pressure sensor to bracket.
B2M1776
10) Move clip, and disconnect pressure hose from fuel tank.
12) Installation is in the reverse order of removal.
Tightening torque:
±
1.96 N·m (0.75±0.20 kg-m, 5.4±1.4
7.35 ft-lb)
B2M1776
2. 2500 cc MODEL
1) Disconnect battery ground cable.
B2M1778
11) Disconnect pressure hose from fuel tank pres­sure sensor.
B2M1779
B2M1723
2) Remove trims. I 4 door model: Remove right trunk side trim.
H2M1122
13
Page 19
2-1 [W10A1] SERVICE PROCEDURE
10. Pressure Control Solenoid Valve (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
I Wagon model:
(1) Remove right rear quarter upper rear trim. (2) Remove right strut cap. (3) Remove right rear quarter pillar lower trim.
B2M0927
3) Disconnect connector from fuel tank pressure sensor.
4) Remove bolts which install fuel tank pressure sensor bracket on body.
10. Pressure Control Solenoid Valve (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL AND INSTALLATION
1. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Remove canister. <Ref. to 2-1 [W3A2].>
B2M0960
5) Disconnect hose from fuel tank pressure sen­sor.
6) Remove fuel tank pressure sensor from bracket.
B2M0961
7) Installation is in the reverse order of removal.
B2M1780
3) Remove bolt which installs pressure control solenoid valve holding bracket on body.
B2M1781
14
Page 20
2-1 [W10A1] SERVICE PROCEDURE
10. Pressure Control Solenoid Valve (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
I Wagon model:
(1) Remove right rear quarter upper rear trim. (2) Remove right strut cap. (3) Remove right rear quarter pillar lower trim.
B2M0927
3) Disconnect connector from fuel tank pressure sensor.
4) Remove bolts which install fuel tank pressure sensor bracket on body.
10. Pressure Control Solenoid Valve (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL AND INSTALLATION
1. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Remove canister. <Ref. to 2-1 [W3A2].>
B2M0960
5) Disconnect hose from fuel tank pressure sen­sor.
6) Remove fuel tank pressure sensor from bracket.
B2M0961
7) Installation is in the reverse order of removal.
B2M1780
3) Remove bolt which installs pressure control solenoid valve holding bracket on body.
B2M1781
14
Page 21
[W10A2] 2-1SERVICE PROCEDURE
10. Pressure Control Solenoid Valve (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
4) Disconnect connector from pressure control solenoid valve.
B2M1782
5) Disconnect two evaporation hoses from pres­sure control solenoid valve.
6) Remove pressure control solenoid valve with bracket.
9) Installation is in the reverse order of removal.
Tightening torque:
±
5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
17.6
B2M1781
2. 2500 cc MODEL
1) Disconnect battery ground cable.
B2M1783
7) Remove pressure control solenoid valve from bracket.
B2M1786
8) Disconnect vacuum hose from pressure control solenoid valve.
B2M1723
2) Lift-up the vehicle.
3) Disconnect evaporation hoses from pressure control valve.
S2M0075
B2M1785
15
Page 22
2-1 [W11A0] SERVICE PROCEDURE
11. Vent Control Solenoid Valve (2500 cc Model)
4) Disconnect connector from pressure control valve.
S2M0076
5) Remove pressure control valve from bracket.
11. Vent Control Solenoid Valve (2500 cc Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A2].>
B2M0963
6) Installation is in the reverse order of removal.
B2M1780
4) Disconnect two hoses from air filter.
B2M1888A
16
Page 23
2-1 [W11A0] SERVICE PROCEDURE
11. Vent Control Solenoid Valve (2500 cc Model)
4) Disconnect connector from pressure control valve.
S2M0076
5) Remove pressure control valve from bracket.
11. Vent Control Solenoid Valve (2500 cc Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A2].>
B2M0963
6) Installation is in the reverse order of removal.
B2M1780
4) Disconnect two hoses from air filter.
B2M1888A
16
Page 24
[W11B0] 2-1SERVICE PROCEDURE
11. Vent Control Solenoid Valve (2500 cc Model)
5) Disconnect connector from vent control sole­noid valve.
B2M0964
6) Remove one bolt fixing bracket on the body.
B: INSTALLATION
1) Install the bolt fixing vent control solenoid valve on bracket.
B2M0966
2) Install two vacuum hoses to vent control sole­noid valve.
H2M1469
7) Remove two vacuum hoses from vent control solenoid valve.
B2M0965A
8) Remove one bolt fixing vent control solenoid valve on bracket.
B2M0965A
3) Install the bolt fixing bracket on the body.
Tightening torque:
±
7 N·m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
25
H2M1469
9) Remove vent control solenoid valve.
B2M0966
17
Page 25
2-1 [W12A0] SERVICE PROCEDURE
12. Main Fuel Level Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
4) Connect connector to vent control solenoid valve.
B2M0964
5) Connect two hoses to air filter.
12. Main Fuel Level Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1888A
6) Install canister. <Ref. to 2-1 [W3A2].>
7) Lower the vehicle.
8) Connect battery ground cable.
B2M1723
4) Disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C).
B2M1780
B2M0954E
B2M1723
18
Page 26
2-1 [W12A0] SERVICE PROCEDURE
12. Main Fuel Level Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
4) Connect connector to vent control solenoid valve.
B2M0964
5) Connect two hoses to air filter.
12. Main Fuel Level Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1888A
6) Install canister. <Ref. to 2-1 [W3A2].>
7) Lower the vehicle.
8) Connect battery ground cable.
B2M1723
4) Disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C).
B2M1780
B2M0954E
B2M1723
18
Page 27
[W12B0] 2-1SERVICE PROCEDURE
12. Main Fuel Level Sensor (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
5) Remove nuts which install fuel pump assembly onto fuel tank.
B2M0955
6) Take off fuel pump assembly from fuel tank.
9) Remove No. 2 and No. 3 terminals from sensor connector.
S2M0147A
10) Separate harness.
B2M0956
7) Disconnect connector from fuel pump bracket.
S2M0145
8) Remove spiral cable from wire harness.
S2M0146
S2M0148A
11) Remove screw which installs fuel level sensor on mounting bracket.
S2M0149
B: INSTALLATION
CAUTION: Leave fuel filler cap open when tightening nuts, to prevent fuel from flowing out through fuel delivery and return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the following:
19
Page 28
2-1 [W13A1] SERVICE PROCEDURE
13. Air Filter (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
(1) Install the fuel level sensor by inserting its pawl into the cutout area of the mounting bracket.
S2M0150A
(2) Always use new gaskets. (3) Ensure sealing portion is free from fuel or for­eign particles before installation. (4) Tighten nuts in alphabetical sequence shown in figure to specified torque.
Tightening torque:
4.4
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
13. Air Filter (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL AND INSTALLATION
1. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A2].>
B2M0955C
B2M1780
4) Disconnect connector from drain valve.
B2M1788
20
Page 29
2-1 [W13A1] SERVICE PROCEDURE
13. Air Filter (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
(1) Install the fuel level sensor by inserting its pawl into the cutout area of the mounting bracket.
S2M0150A
(2) Always use new gaskets. (3) Ensure sealing portion is free from fuel or for­eign particles before installation. (4) Tighten nuts in alphabetical sequence shown in figure to specified torque.
Tightening torque:
4.4
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
13. Air Filter (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
A: REMOVAL AND INSTALLATION
1. 2200 cc AWD EXCEPT TAIWAN SPEC. VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A2].>
B2M0955C
B2M1780
4) Disconnect connector from drain valve.
B2M1788
20
Page 30
[W13A2] 2-1SERVICE PROCEDURE
13. Air Filter (2200 cc AWD except Taiwan Spec. Vehicles and 2500 cc Model)
5) Disconnect evaporation hoses from joint pipes.
B2M1789
6) Remove nut which installs air filter and drain valve brackets on body, and remove them as a unit.
2. 2500 cc MODEL
1) Remove canister. <Ref. to 2-1 [W3A2].>
B2M1780
2) Disconnect two hoses from air filter.
3) Remove flange nut from bracket.
B2M1790
7) Disconnect evaporation hoses, and remove air filter.
B2M1791A
8) Installation is in the reverse order of removal.
Tightening torque:
22.5
±
7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)
B2M1889
4) Installation is in the reverse order of removal.
Tightening torque:
±
7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)
22.5
B2M1790
21
Page 31
2-1 [W14A0] SERVICE PROCEDURE
14. Sub Fuel Level Sensor (AWD Model)
14. Sub Fuel Level Sensor (AWD Model)
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
5) Disconnect connector from fuel sub meter, and disconnect jet pump hose.
S2M0151
6) Remove bolts which install sub fuel level sensor on fuel tank.
4) Remove service hole cover.
B2M1723
G2M0863
S2M0152
7) Remove sub fuel level sensor.
S2M0153
8) Installation is in the reverse order of removal.
Tightening torque:
±
T: 4.4
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)
22
S2M0152A
Page 32
[W15A0] 2-1SERVICE PROCEDURE
15. Vent Valve (2200 cc AWD except Taiwan Spec. Vehicles)
15. Vent Valve (2200 cc AWD except Taiwan Spec. Vehicles)
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filer cap.
B2M1746
3) Disconnect battery ground cable.
6) Remove protector cover.
B2M1773
7) Move clips, and disconnect hoses from vent valve.
B2M1723
4) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].>
G2M0345
5) Remove fuel tank. <Ref. to 2-8 [W2A0].>
B2M1792
8) Remove nuts which install vent valve on fuel tank.
B2M1793
S2M0169A
23
Page 33
2-1 [W16A0] SERVICE PROCEDURE
16. Shut Valve (2200 cc AWD except Taiwan Spec. Vehicles)
9) Installation is in the reverse order of removal.
CAUTION: Replace rubber seat with a new one.
Tightening torque:
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
4.4
B2M1794A
16. Shut Valve (2200 cc AWD except Taiwan Spec. Vehicles)
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filer cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].>
G2M0345
5) Remove fuel filler pipe. <Ref. to 2-8 [W3A2].>
24
B2M1756
Page 34
2-1 [W16A0] SERVICE PROCEDURE
16. Shut Valve (2200 cc AWD except Taiwan Spec. Vehicles)
9) Installation is in the reverse order of removal.
CAUTION: Replace rubber seat with a new one.
Tightening torque:
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
4.4
B2M1794A
16. Shut Valve (2200 cc AWD except Taiwan Spec. Vehicles)
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filer cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].>
G2M0345
5) Remove fuel filler pipe. <Ref. to 2-8 [W3A2].>
24
B2M1756
Page 35
[W17A0] 2-1SERVICE PROCEDURE
17. Drain Valve (2200 cc AWD except Taiwan Spec. Vehicles)
6) Disconnect evaporation hoses from shut valve.
B2M1796
7) Remove shut valve from fuel filler pipe.
17. Drain Valve (2200 cc AWD except Taiwan Spec. Vehicles)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A2].>
B2M1797
8) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
4.4
B2M1797
B2M1780
4) Disconnect connector from drain valve.
B2M1788
5) Disconnect evaporation hoses from drain valve.
25
B2M1798A
Page 36
[W17A0] 2-1SERVICE PROCEDURE
17. Drain Valve (2200 cc AWD except Taiwan Spec. Vehicles)
6) Disconnect evaporation hoses from shut valve.
B2M1796
7) Remove shut valve from fuel filler pipe.
17. Drain Valve (2200 cc AWD except Taiwan Spec. Vehicles)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A2].>
B2M1797
8) Installation is in the reverse order of removal.
Tightening torque:
±
1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
4.4
B2M1797
B2M1780
4) Disconnect connector from drain valve.
B2M1788
5) Disconnect evaporation hoses from drain valve.
25
B2M1798A
Page 37
2-1 [W17A0] SERVICE PROCEDURE
17. Drain Valve (2200 cc AWD except Taiwan Spec. Vehicles)
6) Remove bolt which installs air filter and drain valve brackets on body.
B2M1790
7) Move air filter to upper side, and remove drain valve with bracket.
8) Installation is in the reverse order of removal.
Tightening torque:
±
7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)
22.5
B2M1790
B2M1799
26
Page 38
2-2 [W1A0] SERVICE PROCEDURE
1. Foreword
1. Foreword
A: GENERAL
This chapter describes major inspection and ser­vice procedures for the engine mounted on the body. For procedures not found in this chapter, refer to the service procedure section in the appli­cable chapter.
2. Ignition Timing
A: MEASUREMENT
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during mea­surement.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light.
3) Start the engine at idle speed and check the ignition timing.
Ignition timing [BTDC/rpm]:
±
8°/700 (2200 cc MT model)
14° 20°
±
8°/700 (2200 cc AT model)
±
8°/700 (2500 cc model)
15°
B2M0750A
If the timing is not correct, check the ignition con­trol system. <Ref. to 2-7 On-Board Diagnostics II System.>
2
Page 39
2-2 [W1A0] SERVICE PROCEDURE
1. Foreword
1. Foreword
A: GENERAL
This chapter describes major inspection and ser­vice procedures for the engine mounted on the body. For procedures not found in this chapter, refer to the service procedure section in the appli­cable chapter.
2. Ignition Timing
A: MEASUREMENT
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during mea­surement.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light.
3) Start the engine at idle speed and check the ignition timing.
Ignition timing [BTDC/rpm]:
±
8°/700 (2200 cc MT model)
14° 20°
±
8°/700 (2200 cc AT model)
±
8°/700 (2500 cc model)
15°
B2M0750A
If the timing is not correct, check the ignition con­trol system. <Ref. to 2-7 On-Board Diagnostics II System.>
2
Page 40
[W3A0] 2-2SERVICE PROCEDURE
3. Engine Idle Speed
3. Engine Idle Speed
A: MEASUREMENT
1) Before checking idle speed, check the follow­ing:
(1) Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are con­nected properly. (2) Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn igintion switch to OFF.
4) When using SUBARU SELECT MONITOR; (1) Insert the cartridge to SUBARU SELECT MONITOR. (2) Connect SUBARU SELECT MONITOR to the data link connector. (3) Turn igintion switch to ON, and SUBARU SELECT MONITOR switch to ON. (4) Select {2. Each System Check} in Main Menu. (5) Select {EGI/EMPI} in Selection Menu. (6) Select {1. Current Data Display & Save} in EGI/EMPI Diagnosis. (7) Select {1.12 Data Display} in Data Display Menu. (8) Start the engine, and read engine idle speed.
5) When using tachometer (Secondary pick-up
type).
(1) Attach the pick-up clip to No. 1 cylinder spark plug cord. (2) Start the engine, and read engine idle speed.
6) Check idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF)
Idle speed (No load and gears in neutral (MT), or N or P (AT) position):
±
100 rpm
700
7) Check idle speed when loaded. (Turn air con­ditioning switch to “ON” and operate compressor for at least one minute before measurement.)
Idle speed [A/C “ON”, no load and gears in neutral (MT) or N or P (AT) position]:
±
50 rpm
850
CAUTION: Never rotate idle adjusting screw. If idle speed is out of specifications, refer to General On­board Diagnosis Table under “2-7 On-Board Diagnostics II System”.
G2M0097
NOTE: I When using the OBD-II general scan tool, care­fully read its operation manual. I This ignition system provides simultaneous igni­tion for #1 and #2 plugs. It must be noted that some tachometers may register twice that of actual engine speed.
3
Page 41
2-2 [W4A1] SERVICE PROCEDURE
4. Engine Compression
4. Engine Compression
A: MEASUREMENT
1. 2200 cc MODEL
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs.
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when the pointer is steady.
2. 2500 cc MODEL
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during mea­surement.
1) After warming-up the engine, turn ignition switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs. <Ref. to 6-1 [W3B0].> and <Ref. to 6-1 [W3C0].>
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor­mance and operation.
7) Hold the compression gauge tight against the spark plug hole.
CAUTION: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long.
8) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.
G2M0098
9) Perform at least two measurements per
cylinder,and make sure that the values are correct.
Compression (200 — 300 rpm and fully open throttle):
Standard;
1,079 — 1,275 kPa (11.0 — 13.0 kg/cm
2
,
156 — 185 psi)
Limit;
883 kPa (9.0 kg/cm
Difference between cylinders;
196 kPa (2.0 kg/cm
2
, 128 psi)
2
, 28 psi)
B2M0752A
9) Perform at least two measurements per cylinder,and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
1,216 kPa (12.4 kg/cm
Limit;
941 kPa (9.6 kg/cm
Difference between cylinders;
49 kPa (0.5 kg/cm
2
, 176 psi)
2
, 137 psi)
2
, 7 psi), or less
4
Page 42
[W5A0] 2-2SERVICE PROCEDURE
5. Intake Manifold Vacuum
5. Intake Manifold Vacuum
A: MEASUREMENT
1) Warm-up the engine.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani­fold.
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten­dency becomes more evident as engine temperature rises.
2. When engine speed is reduced slowly from higher speed, needle stops temporarily when it is lowering or becomes steady above normal position.
3. Needle intermittently drops to position lower than normal position.
4. Needle drops suddenly and intermittently from normal posi­tion.
5. When engine speed is gradually increased, needle begins to vibrate rapidly at certain speed, and then vibration increases as engine speed increases.
6. Needle vibrates above and below normal position in narrow range.
3) Keep the engine at the idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below.
H2M1601
Vacuum pressure (at idling, A/C “OFF”):
Less than −60.0 kPa (−450 mmHg, −17.72 inHg)
Leakage around intake manifold gasket or disconnection or damaged vacuum hose
Back pressure too high, or exhaust system clogged
Leakage around cylinder
Sticky valves
Weak or broken valve springs
Defective ignition system or throttle chamber idle adjustment
5
Page 43
2-2 [W6A0] SERVICE PROCEDURE
6. Engine Oil Pressure
6. Engine Oil Pressure
A: MEASUREMENT
1) Disconnect battery ground cable.
2) Remove generator from bracket. (1) Disconnect connector and terminal from generator.
G2M0088
(2) Remove V-belt cover
3) Disconnect connector from oil pressure switch.
4) Remove oil pressure switch from engine cylin­der block.
G2M0091
5) Connect oil pressure gauge hose to cylinder block.
6) Connect battery ground cable.
7) Start the engine, and measure oil pressure.
G2M0089
(3) Loosen lock bolt and slider bolt, and remove V-belt for generator. (4) Remove generator lock bolt. (5) Remove bolt which install generator on bracket.
G2M0090
S2M0242
Oil pressure:
98 kPa (1.0 kg/cm rpm 294 kPa (3.0 kg/cm
2
,14 psi) or more at 800
2
, 43 psi) or more at
5,000 rpm
CAUTION: I If oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to 2-4 ENGINE LUBRICATION SYSTEM.> I If oil pressure warning light is turned ON and oil pressure is in specification, replace oil pres­sure switch. <Ref. to 2-4 ENGINE LUBRICA­TION SYSTEM.>
NOTE: The specified data is based on an engine oil tem­perature of 80°C (176°F).
8) After measuring oil pressure, install oil pressure switch.
Tightening torque:
±
3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
25
9) Install generator and V-belt in the reverse order of removal, and adjust the V-belt deflection.
6
Page 44
[W7A1] 2-2SERVICE PROCEDURE
7. Valve Clearance
7. Valve Clearance
A: INSPECTION
1. 2200 cc MODEL
CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Disconnect battery ground cable.
3) Remove timing belt cover (RH).
4) Remove rocker cover.
I When inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow sensor.
B2M1225A
(2) Loosen clamp which connects air intake duct to air intake chamber.
B2M1226A
(3) Remove the two clips from air cleaner upper cover.
(5) Remove air intake duct and air cleaner upper cover as a unit.
B2M1227
(6) Remove air cleaner element. (7) Disconnect spark plug cords from spark plugs (#1 and #3 cylinders). (8) Remove under cover (RH). (9) Place suitable container under the vehicle. (10) Disconnect PCV hose from rocker cover (RH). (11) Remove bolts, then remove rocker cover (RH).
I When inspecting #2 and #4 cylinders;
(1) Disconnect battery cables, and then remove battery and battery carrier. (2) Disconnect washer motor connectors. (3) Disconnect rear window glass washer hose from washer motor, then plug connection with a suitable cap. (4) Remove the two bolts which holds washer tank, then secure the tank away from working area. (5) Disconnect spark plug cords from spark plugs (#2 and #4 cylinders). (6) Remove under cover (LH). (7) Place suitable container under the vehicle. (8) Disconnect PCV hose from rocker cover (LH). (9) Remove bolts, then remove rocker cover (LH).
CAUTION: Before installing air cleaner upper cover, align hole(s) with protruding portions of air cleaner lower case, then secure upper cover.
(4) Disconnect blow-by hose from air intake duct.
7
Page 45
2-2 [W7A2] SERVICE PROCEDURE
7. Valve Clearance
5) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley clockwise.
NOTE: When arrow mark on camshaft sprocket (RH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke.
B2M1228A
6) Measure #1 cylinder valve clearance by using
thickness gauge.
CAUTION: I Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. I Measure exhaust valve clearances while lift­ing-up the vehicle.
Valve clearance:
±
Intake: 0.20 Exhaust: 0.25
0.02 mm (0.0079±0.0008 in)
±
0.02 mm (0.0098±0.0008 in)
B2M1229A
7) If necessary, adjust the valve clearance. <Ref.
to 2-2 [W7B1].>
8) Similar to measurement procedures used for #1 cylinder, measure #2, #3 and #4 cylinder valve clearances.
NOTE: I Be sure to set cylinder pistons to their respective top dead centers on compression stroke before measuring valve clearances. I To set #3, #2 and #4 cylinder pistons to their top dead centers on compression stroke, turn crank­shaft pulley clockwise 90° at a time starting with arrow mark on right- hand camshaft sprocket fac­ing up.
B2M1230A
9) After inspection, install the related parts in the reverse order of removal.
2. 2500 cc MODEL
CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Disconnect battery ground cable.
3) Remove canister (Taiwan spec. vehicles only).
4) Remove two bolts on the upper side which secure timing belt cover (RH).
5) Lift-up the vehicle.
6) Remove under cover (RH).
7) Remove canister bracket (Taiwan spec. vehicles only).
8) Loosen remaining bolt on under side which secures timing belt cover (RH), then remove belt cover.
9) Lower the vehicle.
10) Remove rocker cover.
8
Page 46
[W7A2] 2-2SERVICE PROCEDURE
7. Valve Clearance
I When inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow sensor.
B2M1225A
(2) Loosen clamp which connects air intake duct to air intake chamber.
B2M1226A
(3) Remove the two clips from air cleaner upper cover.
CAUTION: Before installing air cleaner upper cover, align hole(s) with protruding portions of air cleaner lower case, then secure upper cover.
(4) Disconnect blow-by hose from air intake duct. (5) Remove air intake duct and air cleaner upper cover as a unit.
(7) Remove air cleaner lower case.
S2M0179
(8) Disconnect spark plug cords from spark plugs (#1 and #3 cylinders). (9) Place suitable container under the vehicle. (10) Disconnect PCV hose from rocker cover (RH). (11) Remove bolts, then remove rocker cover (RH).
I When inspecting # 2 and #4 cylinders;
(1) Disconnect battery cables, and then remove battery and battery carrier. (2) Disconnect washer motor connectors. (3) Disconnect washer hoses from washer motors, then plug connections with suitable caps. (4) Remove washer tank. (5) Disconnect spark plug cords from spark plugs (#2 and #4 cylinders). (6) Remove under cover (LH). (7) Place suitable container under the vehicle. (8) Disconnect PCV hose from rocker cover (LH). (9) Remove bolts, then remove rocker cover (LH).
11) Turn crankshaft pulley clockwise until arrow mark on camshaft sprocket is set to position shown in figure.
(6) Remove air cleaner element.
B2M1227
B2M1233A
9
Page 47
2-2 [W7A2] SERVICE PROCEDURE
7. Valve Clearance
12) Measure #1 cylinder intake valve and #3 cyl-
inder exhaust valve clearances by using thickness gauge.
CAUTION: I Insert the thickness gauge in as horizontal a direction as possible with respect to the shim. I Measure exhaust valve clearances while lift­ing-up the vehicle.
Valve clearance:
±
Intake: 0.20 Exhaust: 0.25
0.02 mm (0.0079±0.0008 in)
±
0.02 mm (0.0098±0.0008 in)
B2M1234A
(2) Set arrow mark on camshaft sprocket to position shown in figure, and measure #2 cylin­der intake valve and #4 cylinder exhaust valve clearances.
B2M1236A
(3) Set arrow mark on camshaft sprocket to position shown in figure, and measure #1 cylin­der exhaust valve and #4 cylinder intake valve clearances.
13) If necessary, adjust the valve clearance. <Ref.
to 2-2 [W7B2].>
14) Further turn crankshaft pulley clockwise.
Using the same procedures as in step 12) above, measure valve clearances.
(1) Set arrow mark on camshaft sprocket to position shown in figure, and measure #2 cylin­der exhaust valve and #3 cylinder intake valve clearances.
B2M1235A
B2M1237A
15) After inspection, install the related parts in the reverse order of removal.
10
Page 48
[W7B1] 2-2SERVICE PROCEDURE
7. Valve Clearance
B: ADJUSTMENT
1. 2200 cc MODEL
CAUTION: Adjustment of valve clearance should be per­formed while engine is cold.
1) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley clockwise.
NOTE: When arrow mark on camshaft sprocket (RH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke.
2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. (2) Place suitable thickness gauge. (3) While noting valve clearance, tighten valve rocker adjust screw. (4) When specified valve clearance is obtained, tighten valve rocker nut.
Tightening torque:
±
1 N·m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
10
CAUTION: I Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. I Adjust exhaust valve clearances while lift­ing-up the vehicle.
Valve clearance:
±
Intake: 0.20 Exhaust: 0.25
0.02 mm (0.0079±0.0008 in)
±
0.02 mm (0.0098±0.0008 in)
B2M1228A
B2M1238A
3) Ensure that valve clearances are within speci-
fications.
4) Turn crankshaft two complete rotations until #1
cylinder piston is again set to top dead center on compression stroke.
5) Ensure that valve clearances are within speci-
fications. If necessary, re-adjust valve clearances.
11
Page 49
2-2 [W7B2] SERVICE PROCEDURE
7. Valve Clearance
6) Similar to adjustment procedures used for #1 cylinder, adjust #2, #3 and #4 cylinder valve clear­ances.
NOTE: I Be sure to set cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. I To set #3, #2 and #4 cylinder pistons to their top dead centers on compression stroke, turn crank­shaft pulley clockwise 90° at a time starting with arrow mark on right-hand camshaft sprocket facing up.
B2M1230A
2) Remove shim of intake side. (1) Prepare the ST.
ST 498187100 SHIM REPLACER KIT
H1H0491
(2) Rotate the notch of the valve lifter outward by 45°.
2. 2500 cc MODEL
CAUTION: Adjustment of valve clearance should be per­formed while engine is cold.
1) Measure all valve clearances. <Ref. to 2-2 [W7A2].>
NOTE: Record each valve clearance after it has been measured.
B2M1234A
H2M1771A
(3) Set REPLACER No. 1 (A) to intake cam­shaft.
H2M1772B
(4) Set REPLACER No. 2 (B).
12
H2M1773B
Page 50
[W7B2] 2-2SERVICE PROCEDURE
7. Valve Clearance
(5) Set REPLACER No. 3 (C) to hole of REPLACER No. 1.
H2M1774B
(6) Rotate REPLACER No. 3 (C) until REPLACER No. 2 (B) pushes away valve lifter.
(2) Rotate the notch of the valve lifter outward by 45°.
H2M1777A
(3) Set REPLACER No. 1 (A) to exhaust cam­shaft.
H2M1775B
(7) Insert tweezers into the notch of the valve lifter, and take the shim out.
H2M1776A
3) Remove shim of exhaust side. (1) Prepare the ST.
ST 498187100 SHIM REPLACER KIT
H2M1778B
(4) Set REPLACER No. 2 (B).
H2M1779B
(5) Set REPLACER No. 3 (C) to hole of REPLACER No. 1.
H1H0491
H2M1780B
13
Page 51
2-2 [W7B2] SERVICE PROCEDURE
7. Valve Clearance
(6) Rotate REPLACER No. 3 until REPLACER No. 2 pushes away valve lifter.
H2M1781
(7) Insert tweezers into the notch of the valve lifter, and take the shim out.
NOTE: By using a magnet, the shim can be taken out without dropping it.
H2M1782A
4) Measure thickness of shim with micrometer.
B2M1240A
14
Page 52
[W7B2] 2-2SERVICE PROCEDURE
7. Valve Clearance
5) Select a shim of suitable thickness using measured valve clearance and shim thickness, using the fol-
lowing table.
Intake valve (mm):S=(V+T)−0.20 Exhaust valve (mm):S=(V+T)−0.25
S: Shim thickness to be used V: Measured valve clearance T: Shim thickness required
Part No. Thickness mm (in) Part No. Thickness mm (in)
13218AC230 2.22 (0.0874) 13218AC480 2.52 (0.0992)
13218AE000 2.23 (0.0878) 13218AC490 2.53 (0.0996)
13218AC240 2.24 (0.0882) 13218AC500 2.54 (0.1000)
13218AE010 2.25 (0.0886) 13218AC510 2.55 (0.1004)
13218AC250 2.26 (0.0890) 13218AC520 2.56 (0.1008)
13218AE020 2.27 (0.0894) 13218AC530 2.57 (0.1012)
13218AC260 2.28 (0.0898) 13218AC540 2.58 (0.1016)
13218AE030 2.29 (0.0902) 13218AC550 2.59 (0.1020)
13218AC270 2.30 (0.0906) 13218AC560 2.60 (0.1024)
13218AE040 2.31 (0.0909) 13218AC570 2.61 (0.1028) 13218AC280 2.32 (0.0913) 13218AC580 2.62 (0.1031) 13218AC290 2.33 (0.0917) 13218AC590 2.63 (0.1035) 13218AC300 2.34 (0.0921) 13218AC600 2.64 (0.1039) 13218AC310 2.35 (0.0925) 13218AC610 2.65 (0.1043) 13218AC320 2.36 (0.0929) 13218AC620 2.66 (0.1047) 13218AC330 2.37 (0.0933) 13218AC630 2.67 (0.1051) 13218AC340 2.38 (0.0937) 13218AC640 2.68 (0.1055) 13218AC350 2.39 (0.0941) 13218AC650 2.69 (0.1059) 13218AC360 2.40 (0.0945) 13218AC660 2.70 (0.1063) 13218AC370 2.41 (0.0949) 13218AE050 2.71 (0.1067) 13218AC380 2.42 (0.0953) 13218AC670 2.72 (0.1071) 13218AC390 2.43 (0.0957) 13218AE060 2.73 (0.1075) 13218AC400 2.44 (0.0961) 13218AC680 2.74 (0.1079) 13218AC410 2.45 (0.0965) 13218AE070 2.75 (0.1083) 13218AC420 2.46 (0.0969) 13218AC690 2.76 (0.1087) 13218AC430 2.47 (0.0972) 13218AE080 2.77 (0.1091) 13218AC440 2.48 (0.0976) 13218AC700 2.78 (0.1094) 13218AC450 2.49 (0.0980) 13218AE090 2.79 (0.1098) 13218AC460 2.50 (0.0984) 13218AC710 2.80 (0.1102) 13218AC470 2.51 (0.0988) 13218AE100 2.81 (0.1106)
6) Set suitable shim selected in one step before, to valve lifter.
15
Page 53
2-2 [W7B2] SERVICE PROCEDURE
7. Valve Clearance
7) Turn crankshaft pulley clockwise until arrow mark on camshaft sprocket is set to position shown in figure.
B2M1233A
8) Ensure that #1 cylinder intake valve and #3 cyl­inder exhaust valve are adjusted to specifications.
CAUTION: I Insert the thickness gauge in as horizontal a direction as possible with respect to the shim. I Adjust exhaust valve clearances while lift­ing-up the vehicle.
Valve clearance:
±
Intake: 0.20 Exhaust: 0.25
0.02 mm (0.0079±0.0008 in)
±
0.02 mm (0.0098±0.0008 in)
(1) Set arrow mark on camshaft sprocket to position shown in figure, and check #2 cylinder exhaust valve and #3 cylinder intake valve clearances.
B2M1235A
(2) Set arrow mark on camshaft sprocket to position shown in figure, and check #2 cylinder intake valve and #4 cylinder exhaust valve clearances.
B2M1234A
9) Turn crankshaft two complete rotations. Check again to ensure that #1 cylinder intake valve and #3 cylinder exhaust valve clearances are within specifications. If necessary, re-adjust valve clear­ances.
10) Further turn crankshaft pulley clockwise. Using the same procedures as in two steps before, measure valve clearances.
B2M1236A
(3) Set arrow mark on camshaft sprocket to position shown in figure, and check #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
B2M1237A
16
Page 54
2-3a [S1A0] SPECIFICATION AND SERVICE DATA
1. Engine
1. Engine
A: SPECIFICATIONS
Model 2200 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
, psi) 1,079 — 1,275 (11.0 — 13.0, 156 — 185)
rpm
700±100 (No load)
850±50 (A/C switch ON)
Engine
Type Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore × Stroke mm (in) 96.9 × 75.0 (3.815 × 2.953) Displacement cm Compression ratio 9.7 Compression pressure
(at 200 — 300 rpm) Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timing
Exhaust valve timing
Valve clearance Idling speed
[At neutral position on MT, or “P” or “N” position on AT]
Firing order 1 3 2 4 Ignition timing BTDC/rpm 14°±8°/700 (MT), 20°±8°/700 (AT)
Opening 4° BTDC Closing 52° ABDC Opening 48° BBDC Closing 12° ATDC Intake mm (in) 0.20±0.02 (0.0079±0.0008) Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
kPa (kg/cm
3
(cu in) 2,212 (135.0)
2
B: SERVICE DATA
NOTE: STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize
Belt ten­sioner adjuster
Belt ten­sioner
Valve rocker arm
Protrusion of adjuster rod 15.4 — 16.4 mm (0.606 — 0.646 in)
Spacer O.D. 16 mm (0.63 in) Tensioner bush I.D. 16.16 mm (0.6362 in)
Clearance between spacer and bush
Side clearance of spacer
Clearance between shaft and arm
STD 0.117 — 0.180 mm (0.0046 — 0.0071 in) Limit 0.230 mm (0.0091 in) STD 0.37 — 0.54 mm (0.0146 — 0.0213 in) Limit 0.8 mm (0.031 in)
STD 0.020 — 0.054 mm (0.0008 — 0.0021 in) Limit 0.10 mm (0.0039 in)
2
Page 55
Cam­shaft
Cylinder head
Valve set
Valve guide
Valve
Valve spring
[S1B0] 2-3aSPECIFICATION AND SERVICE DATA
1. Engine
Bend limit 0.025 mm (0.0010 in) Thrust clearance
Intake
Cam lobe height
Exhaust
Front
Camshaft journal O.D.
Camshaft journal hole I.D.
Oil clearance Surface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in) Standard height 98.3 mm (3.870 in) Refacing angle 90°
Contacting width
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in) Protrusion above head 17.5 — 18.0 mm (0.689 — 0.709 in)
Head edge thickness
Stem diameter
Stem oil clearance
Overall length Free length 44.05 mm (1.7342 in)
Squareness 2.5°, 1.9 mm (0.075 in)
Tension/spring height
RH
RH
Cen­ter
Rear Front 37.935 — 37.950 mm (1.4935 — 1.4941 in) Front Cen-
ter Rear Front 38.005 — 38.025 mm (1.4963 — 1.4970 in)
LH
LH
Intake
Exhaust
Intake
Exhaust
STD Limit 0.15 mm (0.0059 in)
STD 0.030 — 0.260 mm (0.0012 — 0.0102 in) Limit 0.35 mm (0.0138 in) STD 32.244 — 32.344 mm (1.2694 — 1.2734 in) Limit 32.094 mm (1.2635 in) STD 31.964 — 32.064 mm (1.2584 — 1.2624 in) Limit 31.814 mm (1.2525 in) Rear 31.935 — 31.950 mm (1.2573 — 1.2579 in)
Center 37.435 — 37.450 mm (1.4738 — 1.4744 in)
Rear 32.005 — 32.025 mm (1.2600— 1.2608 in) Center 37.505 — 37.525 mm (1.4766 — 1.4774 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in) Limit 0.10 mm (0.0039 in)
STD 0.7 mm (0.028 in) Limit 1.4 mm (0.055 in) STD 1.4 mm (0.055 in) Limit 1.8 mm (0.071 in)
STD 1.0 mm (0.039 in) Limit 0.8 mm (0.031 in) STD 1.2 mm (0.047 in) Limit 0.8 mm (0.031 in) Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in) Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in) Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Intake 101.0 mm (3.976 in) Exhaust 101.2 mm (3.984 in)
174.6 — 200.1 N (17.8 — 20.4 kg, 39.2 — 45.0 lb)/36.0 mm (1.417 in)
405.0 — 458.0 N (41.3 — 46.7 kg, 91.1 — 103.0 lb)/28.2 mm (1.110 in)
3
Page 56
2-3a [S1B0] SPECIFICATION AND SERVICE DATA
1. Engine
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in) Surface grinding limit 0.1 mm (0.004 in)
Cylinder bore STD
Cylinder block
Piston Outer diameter
Piston pin
Piston ring
Con­necting rod
Con­necting rod bearing
Con­necting rod bushing
Taper
Out-of-roundness
Piston clearance Enlarging (boring) limit 0.5 mm (0.020 in)
Standard clearance between piston pin and hole in piston
Degree of fit
Piston ring gap
Clearance between piston ring and pis­ton ring groove
Bend twist per 100 mm (3.94 in) in length
Side clearance
Oil clearance
Thickness at center portion
Clearance between piston pin and bushing
Top ring
Second ring
Oil ring
Top ring
Second ring
STD
0.25 mm (0.0098 in) OS
0.50 mm (0.0197 in) OS
STD 0.004 — 0.010 mm (0.0002 — 0.0004 in) Limit 0.020 mm (0.0008 in)
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in) Limit 1.0 mm (0.039 in) STD 0.20 — 0.50 mm (0.0079 — 0.0197 in) Limit 1.0 mm (0.039 in) STD 0.20 — 0.70 mm (0.0079 — 0.0276 in) Limit 1.5 mm (0.059 in) STD 0.040 — 0.080 mm (0.0016 — 0.0031 in) Limit 0.15 mm (0.0059 in) STD 0.030 — 0.070 mm (0.0012 — 0.0028 in) Limit 0.15 mm (0.0059 in)
Limit 0.10 mm (0.0039 in) STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit 0.4 mm (0.016 in) STD 0.015 — 0.045 mm (0.0006 — 0.0018 in) Limit 0.05 mm (0.0020 in) STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
STD 0 — 0.022 mm (0 — 0.0009 in)
Limit 0.030 mm (0.0012 in)
A 96.905 — 96.915 mm (3.8151 — 3.8155 in) B 96.895 — 96.905 mm (3.8148 — 3.8151 in) STD 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) STD 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in) STD 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.050 mm (0.0020 in)
A 96.885 — 96.895 mm (3.8144 — 3.8148 in) B 96.875 — 96.885 mm (3.8140 — 3.8144 in)
97.115 — 97.145 mm (3.8234 — 3.8246 in)
97.365 — 97.395 mm (3.8333 — 3.8344 in)
Piston pin must be fitted into position with thumb at 20°C (68°F).
1.510 — 1.513 mm (0.0594 — 0.0596 in)
1.520 — 1.523 mm (0.0598 — 0.0600 in)
1.620 — 1.623 mm (0.0638 — 0.0639 in)
4
Page 57
Crank­shaft
Crank­shaft bearing
Bend limit 0.035 mm (0.0014 in) Crankpin and crank journal
Crankpin outer diameter
Crank journal outer diameter
Thrust clearance
Oil clearance
Crankshaft bearing thickness
#1, #5
#2, #3, #4
#1, #5 STD 0.003 — 0.030 mm (0.0001 — 0.0012 in) #2,
#3, #4 #1,
#3, #5 #2, #4 Limit 0.035 mm (0.0014 in)
#1, #5
#2, #3, #4
Out-of-roundness 0.030 mm (0.0012 in) or less Grinding limit 0.250 mm (0.0098 in) STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.033 mm (0.0004 — 0.0013 in)
Limit 0.040 mm (0.0016 in)
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
51.954 — 51.970 mm (2.0454 — 2.0461 in)
51.934 — 51.950 mm (2.0446 — 2.0453 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.934 — 59.950 mm (2.3596 — 2.3602 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
59.954 — 59.970 mm (2.3604 — 2.3610 in)
59.934 — 59.950 mm (2.3596 — 2.3602 in)
59.734 — 59.750 mm (2.3517 — 2.3524 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
[S1B0] 2-3aSPECIFICATION AND SERVICE DATA
1. Engine
5
Page 58
2-3a [C100] COMPONENT PARTS
1. Timing Belt
1. Timing Belt
(1) Belt cover No. 2 (RH) (2) Timing belt guide (MT vehicles
only) (3) Crankshaft sprocket (4) Belt cover No. 2 (LH) (5) Camshaft sprocket No. 1 (6) Belt idler (No. 1) (7) Tensioner bracket (8) Belt idler (No. 2) (9) Automatic belt tension adjuster
ASSY
(10) Belt idler No. 2 (11) Camshaft sprocket No. 2 (12) Timing belt (13) Belt cover (RH) (14) Front belt cover (15) Belt cover (LH) (16) Crankshaft pulley
6
B2M1729B
Tightening torque: N·m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:
9.8±1.0 (1.0±0.1, 7.2±0.7)
T3:
25±3 (2.5±0.3, 18.1±2.2)
T4:
39±4 (4.0±0.4, 28.9±2.9)
T5:
78±5 (8.0±0.5, 57.9±3.6)
T6:
127 94
+10
+7.2
/−5(13.0
/
−3.6
+1.0
/
,
−0.5
)
Page 59
2. Cylinder Head and Camshaft
[C200] 2-3aCOMPONENT PARTS
2. Cylinder Head and Camshaft
(1) Rocker cover (RH) (2) Rocker cover gasket (3) Camshaft support (RH) (4) O-ring (5) Camshaft (RH) (6) Intake valve guide (7) Exhaust valve guide (8) Oil seal (9) Cylinder head (RH) (10) Cylinder head gasket
(11) Cylinder head (LH) (12) Plug (13) Camshaft (LH) (14) O-ring (15) Camshaft support (LH) (16) Oil seal (17) Oil filler cap (18) Gasket (19) Oil filler pipe (20) O-ring
7
H2M1540B
(21) Rocker cover gasket (22) Rocker cover (LH)
Tightening torque: N·m (kg-m, ft-lb)
T1:
Refer to 2–3a [W5E1].
T2:
5±1 (0.5±0.1, 3.6±0.7)
T3:
10 (1.0, 7)
T4:
16 (1.6, 12)
Page 60
2-3a [C300] COMPONENT PARTS
3. Cylinder Head and Valve Assembly
3. Cylinder Head and Valve Assembly
(1) Exhaust valve (2) Intake valve (3) Intake valve oil seal (4) Valve spring (5) Retainer (6) Retainer key (7) Exhaust valve oil seal (8) Rocker shaft support
(9) Rocker shaft support (10) Rocker shaft support (11) Rocker shaft (12) Valve rocker adjust screw (13) Valve rocker nut (14) Intake valve rocker arm (15) Exhaust valve rocker arm (16) Spring
8
B2M1001C
(17) Plate
Tightening torque: N·m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:
10±1 (1.0±0.1, 7.2±0.7)
T3:
12±1 (1.2±0.1, 8.7±0.7)
Page 61
4. Cylinder Block
[C400] 2-3aCOMPONENT PARTS
4. Cylinder Block
(1) Oil pressure switch (2) Cylinder block (RH) (3) Service hole plug (4) Gasket (5) Oil separator cover (6) Water by-pass pipe (7) Oil pump (8) Front oil sea (9) Rear oil seal (10) O-ring (11) Service hole cover
(12) Cylinder block (LH) (13) Water pump (14) Baffle plate (15) Oil filter connector (16) Oil strainer (17) Gasket (18) Oil pan (19) Drain plug (20) Metal gasket (21) Oil level gauge guide
9
B2M1766A
Tightening torque: N·m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:
6.4 (0.65, 4.7)
T3:
10 (1.0, 7)
T4:
25±2 (2.5±0.2, 18.1±1.4)
T5:
47±3 (4.8±0.3, 34.7±2.2)
T6:
69±7 (7.0±0.7, 50.6±5.1)
T7:
First 12±2 (1.2±0.2, 8.7±1.4) Second 12
8.7
±
1.4)
±
2 (1.2±0.2,
Page 62
2-3a [C500] COMPONENT PARTS
5. Crankshaft and Piston
5. Crankshaft and Piston
(1) Drive plate (AT) (2) Reinforcement (AT) (3) Flywheel (MT) (4) Bell bearing (MT) (5) Top ring (6) Second ring (7) Oil ring (8) Piston
(9) Piston pin (10) Circlip (11) Connecting rod bolt (12) Connecting rod (13) Connecting rod bearing (14) Connecting rod cap (15) Crankshaft (16) Woodruff key
10
B2M1317C
(17) Crankshaft bearing #1, #5 (18) Crankshaft bearing #2, #4 (19) Crankshaft bearing #3
Tightening torque: N·m (kg-m, ft-lb)
T1:
44±2 (4.5±0.2, 32.5±1.4)
T2:
72±3 (7.3±0.3, 52.8±2.2)
Page 63
[W1A0] 2-3aSERVICE PROCEDURE
1. Precautions
1. Precautions
A: GENERAL PRECAUTIONS
1) Before disassembling engine, place it on ST3. ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
G2M0106
2) All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pis­tons and bearings.
3) Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
4) Be careful not to let oil, grease or coolant con­tact the timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be reinstalled in the original positions and directions.
6) All removed parts, if to be reused, should be reinstalled in the original positions and directions.
7) Bolts, nuts and washers should be replaced with new ones as required.
8) Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
11
Page 64
2-3a [W2A1] SERVICE PROCEDURE
2. Timing Belt
2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
(1) V-belt (2) Crankshaft pulley bolt
(3) Crankshaft Pulley (4) Belt cover (LH)
1) Remove V-belt and A/C belt tensioner.
H2M2364
2) Remove crankshaft pulley bolt. To lock crank­shaft use ST. ST 499977000 CRANKSHAFT PULLEY
WRENCH
H2M2363C
(5) Belt cover (RH) (6) Front belt cover
3) Remove crankshaft pulley.
4) Remove belt cover (LH).
5) Remove belt cover (RH).
6) Remove front belt cover.
H2M2365
G2M0108
12
Page 65
2. TIMING BELT
[W2A2] 2-3aSERVICE PROCEDURE
2. Timing Belt
H2M2414E
(a) Alignment mark (1) Timing belt guide (MT vehicles
only)
(2) Belt idler (No. 2) (3) Belt idler No. 2 (4) Timing belt
1) Remove timing belt guide. (MT vehicles only)
S2M0294
2) If alignment mark (a) and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as shown in Figure:
13
B2M0993B
Page 66
2-3a [W2A2] SERVICE PROCEDURE
2. Timing Belt
(1) Turn crankshaft using ST, and align align­ment marks (c) on crankshaft sprocket, and left and right camshaft sprockets with notches (c) of belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
H2M2368A
(2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets.
3) Remove belt idler (No. 2).
4) Remove belt idler No. 2.
H2M2371
5) Remove timing belt.
Specified data:
: 44 tooth length
Z
1
Z
: 40.5 tooth
2
H2M2372
H2M2369
H2M2370A
14
Page 67
3. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY
[W2A3] 2-3aSERVICE PROCEDURE
2. Timing Belt
H2M2373D
(1) Belt idler (No. 1) (2) Automatic belt tension adjuster
ASSY
1) Remove belt idler (No. 1).
2) Remove automatic belt tension adjuster assem­bly.
H2M2374
H2M2375
15
Page 68
2-3a [W2A4] SERVICE PROCEDURE
2. Timing Belt
4. CAMSHAFT AND CRANKSHAFT SPROCKET
H2M2376E
(1) Camshaft sprocket No. 2 (2) Camshaft sprocket No. 1
(3) Crankshaft sprocket (4) Belt cover No. 2 (LH)
1) Remove camshaft sprocket No. 1 and No. 2. To lock camshaft use ST. ST 499207100 CAMSHAFT SPROCKET
WRENCH
H2M2377A
2) Remove crankshaft sprocket.
(5) Belt cover No. 2 (RH) (6) Tensioner bracket
3) Remove belt cover No. 2 (LH).
4) Remove belt cover No. 2 (RH).
CAUTION: Do not damage or lose the seal rubber when removing belt covers.
H2M2379
5) Remove tensioner bracket.
S2M0414
H2M2380
16
Page 69
[W2B5] 2-3aSERVICE PROCEDURE
2. Timing Belt
B: INSPECTION
1. TIMING BELT
1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt.
2) Check the condition of back side of belt; if any crack is found, replace belt.
CAUTION: I Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thor­oughly if this happens. I Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
I Do not use a lateral type vise. I Push adjuster rod vertically. I Press-in the push adjuster rod gradually tak-
ing more than three minutes. I Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 lb). I Press the adjuster rod as far as the end sur­face of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one.
Rod extension: H
±
0.5 mm (0.224±0.020 in)
5.7
G2M0115
2. AUTOMATIC BELT TENSION ADJUSTER
1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace faulty parts.
CAUTION: Slight traces of oil at rod’s oil seal does not indicate a problem.
2) Check that the adjuster rod does not move when a pressure of 294 N (30 kg, 66 lb) is applied to it. This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kg, 66 lb), check it using the following procedures:
(1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kg, 66 lb) to it. Check adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one.
CAUTION: I Always use a vertical type pressing tool to move the adjuster rod down.
H2M2381A
3. BELT TENSION PULLEY
1) Check mating surfaces of timing belt and con­tact point of adjuster rod for abnormal wear or scratches. Replace automatic belt tension adjuster assembly if faulty.
2) Check tension pulley for smooth rotation. Replace if noise or excessive play is noted.
3) Check tension pulley for grease leakage.
4. BELT IDLER
1) Check belt idler for smooth rotation. Replace if noise or excessive play is noted.
2) Check belt outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check belt idler for grease leakage.
5. CAMSHAFT AND CRANKSHAFT SPROCKET
1) Check sprocket teeth for abnormal wear and scratches.
2) Make sure there is no free play between sprocket and key.
3) Check crankshaft sprocket notch for sensor for damage and contamination of foreign matter.
17
Page 70
2-3a [W2C1] SERVICE PROCEDURE
2. Timing Belt
C: INSTALLATION
1. CAMSHAFT AND CRANKSHAFT SPROCKET
(1) Tensioner bracket (2) Belt cover No. 2 (RH) (3) Belt cover No. 2 (LH) (4) Crankshaft sprocket
1) Install tensioner bracket.
2) Install belt cover No. 2 (RH).
3) Install belt cover No. 2 (LH).
(5) Camshaft sprocket No. 1 (6) Camshaft sprocket No. 2
4) Install crankshaft sprocket.
H2M2380
H2M2376F
Tightening torque: N·m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:
25±3 (2.5±0.3, 18.1±2.2)
T3:
78±5 (8.0±0.5, 57.9±3.6)
S2M0414
H2M2379
18
Page 71
5) Install camshaft sprocket No. 1 and camshaft sprocket No. 2. To lock camshaft use ST. ST 499207100 CAMSHAFT SPROCKET
WRENCH
CAUTION: Do not confuse left and right side camshaft sprockets during installation. The camshaft sprocket No. 2 is identified by a projection used to monitor camshaft position sensor.
H2M2377A
[W2C2] 2-3aSERVICE PROCEDURE
2. Timing Belt
2. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
(1) Automatic belt tension adjuster
ASSY
(2) Belt idler (No. 1)
Tightening torque: N·m (kg-m, ft-lb)
T:
39±4 (4.0±0.4, 28.9±2.9)
H2M2373E
19
Page 72
2-3a [W2C2] SERVICE PROCEDURE
2. Timing Belt
1) Preparation for installation of automatic belt tension adjuster assembly;
CAUTION: I Always use a vertical type pressing tool to move the adjuster rod down.
I Do not use a lateral type vise. I Push adjuster rod vertically. I Be sure to slowly move the adjuster rod
down applying a pressure of 294 N (30 kg, 66 lb). I Press-in the push adjuster rod gradually tak­ing more than three minutes. I Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 lb). I Press the adjuster rod as far as the end sur­face of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. I Do not release press pressure until stopper pin is completely inserted.
(1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool. (2) Slowly move the adjuster rod down with a pressure of 294 N (30 kg, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
2) Install automatic belt tension adjuster assem­bly.
H2M2384
3) Install belt idler (No. 1).
H2M2374
H2M2382
(3) Witha2mm(0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
H2M2383A
20
Page 73
3. TIMING BELT
[W2C3] 2-3aSERVICE PROCEDURE
2. Timing Belt
H2M2414F
(a) Alignment mark (1) Timing belt (2) Belt idler No. 2 (3) Belt idler (No. 2)
(4) Timing belt guide (MT vehicles
only)
1) Installation of timing belt
(1) Using ST, turn left and right camshaft sprockets so that their alignment marks come to top positions.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
H2M2385A
Tightening torque: N·m (kg-m, ft-lb)
T1:
9.8±1.0 (1.0±0.1, 7.2±0.7)
T2:
39±4 (4.0±0.4, 28.9±2.9)
(2) While aligning alignment mark on timing belt with marks on sprockets, position timing belt properly.
CAUTION: Ensure belt’s rotating direction is correct.
H2M2386A
21
Page 74
2-3a [W2C3] SERVICE PROCEDURE
2. Timing Belt
2) Install belt idler No. 2.
3) Install belt idler (No. 2).
H2M2371
4) After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper pin from belt tensioner adjuster.
CAUTION: After properly installing timing belt, remove rocker cover and ensure that the valve lash adjuster contains no air.
(2) Check and adjust clearance between timing belt and timing belt guide.
Clearance:
±
0.5 mm (0.039±0.020 in)
1.0
S2M0297
(3) Tighten remaining bolts.
H2M2387A
5) Install timing belt guide. (MT vehicles only)
(1) Temporarily tighten remaining bolts.
S2M0294
H2M2415
22
Page 75
4. CRANKSHAFT PULLEY AND BELT COVER
[W2C4] 2-3aSERVICE PROCEDURE
2. Timing Belt
H2M2363D
(1) Front belt cover (2) Belt cover (RH) (3) Belt cover (LH) (4) Crankshaft pulley
1) Install front belt cover.
2) Install belt cover (RH).
3) Install belt cover (LH).
(5) Crankshaft pulley bolt (6) V-belt
4) Install crankshaft pulley.
5) Install pulley bolt. To lock crankshaft, use ST. ST 499977000 CRANKSHAFT PULLEY
H2M2365
6) Install V-belt.
Tightening torque: N·m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:
127 94
+10
+7.2
/−5(13.0
/
−3.6
+1.0
/
,
−0.5
)
WRENCH
G2M0108
23
H2M2364
Page 76
2-3a [W3A0] SERVICE PROCEDURE
3. Valve Rocker Assembly
3. Valve Rocker Assembly
A: REMOVAL
(1) Rocker cover (2) Rocker cover gasket
(3) Valve rocker ASSY (4) Knock pin
1) Disconnect PCV hose and remove rocker cover.
2) Removal of valve rocker assembly
(1) Remove bolts (a) through (b) in alpfabetical sequence.
CAUTION: Leave two or three threads of bolt (a) engaged to retain valve rocker assembly.
B2M0382D
B2M1206E
(2) Equally loosen bolts (e) through (h) all the way, being careful that knock pin is not gouged.
B2M0382D
(3) Remove valve rocker assembly.
24
Page 77
B: DISASSEMBLY
[W3B0] 2-3aSERVICE PROCEDURE
3. Valve Rocker Assembly
B2M1264F
(1) Bolt (2) Rocker shaft (3) Rocker shaft support
(4) Intake valve rocker arm (5) Plate (6) Exhaust valve rocker arm
1) Remove bolts which secure rocker shaft.
2) Extract rocker shaft. Remove valve rocker arms, springs, plates and shaft supports from rocker shaft.
CAUTION: Arrange all removed parts in order so that they can be installed in their original positions.
3) Remove nut and adjuster screw from valve rocker.
(7) Spring (8) Valve rocker nut (9) Valve rocker adjust screw
25
Page 78
2-3a [W3C1] SERVICE PROCEDURE
3. Valve Rocker Assembly
C: INSPECTION
1. VALVE ROCKER ARM
1) Measure inside diameter of valve rocker arm and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).
Clearance between arm and shaft:
Standard
0.020 — 0.054 mm (0.0008 — 0.0021 in)
Limit
0.10 mm (0.0039 in)
I If oil clearance exceeds specifications, replace valve rocker arm or shaft.
NOTE: Replace valve rocker arm or shaft, whichever shows greater amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
2) Measure inside diameter of rocker shaft sup­port and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).
Clearance between support and shaft:
Standard
0.005 — 0.039 mm (0.0002 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
I If oil clearance exceeds specifications, replace rocker shaft support or shaft.
NOTE: Replace rocker shaft support or shaft, whichever shows greater amount of wear.
Rocker shaft support inside diameter:
22.005 — 22.026 mm (0.8663 — 0.8672 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) If cam or valve contact surface of valve rocker arm is worn or dented excessively, replace valve rocker arm.
4) Check that valve rocker arm roller rotates smoothly. If not, replace valve rocker arm.
B2M0072
B2M0073
2. VALVE ROCKER SHAFT
Visually check oil relief valve of shaft end for any of the following abnormalities.
I Breaks in check ball body I Foreign particles caught in valve spring I Oil leakage at check ball
CAUTION: Repair or replace valve rocker shaft as neces­sary.
26
Page 79
D: ASSEMBLY
[W3D0] 2-3aSERVICE PROCEDURE
3. Valve Rocker Assembly
B2M1264G
(1) Valve rocker adjust screw (2) Valve rocker nut (3) Intake valve rocker arm (4) Exhaust valve roker arm (5) Spring
(6) Plate (7) Rocker shaft (8) Rocker shaft support (9) Bolt (A) Oil hole
1) Install adjuster screw and nut to valve rocker.
2) Arrange valve rocker arms, springs and shaft supports in assembly order and insert valve rocker shaft. Ensure that cutout portion of rocker shaft faces oil holes (A) in shaft supports.
CAUTION: Valve rocker arms, rocker shaft and shaft sup­ports have identification marks. Ensure parts with same markings are properly assembled.
3) Install valve rocker shaft securing bolts while aligning shaft “lock” holes (B) with bolts.
(B) Lock hole
Tightening torque: N·m (kg-m, ft-lb)
T:
5±1 (0.5±0.1, 3.6±0.7)
27
Page 80
2-3a [W3E0] SERVICE PROCEDURE
3. Valve Rocker Assembly
E: INSTALLATION
B2M1206F
(1) Valve rocker ASSY (2) Knock pin (3) Rocker cover gasket
(4) Rocker cover
1) Installation of valve rocker assembly
(1) Temporarily tighten bolts (a) through (d) equally as shown in Figure.
CAUTION: Do not allow valve rocker assembly to gouge knock pins.
(2) Tighten bolts (e) through (h) to specified torque. (3) Tighten bolts (a) through (d) to specified torque.
Tightening torque:
±
1N·m (1.2±0.1kg-m, 8.7±0.7ft-lb)
12
Tightening torque: N·m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:
12±1 (1.2±0.1, 8.7±0.7)
2) Adjust the valve clearances. <Ref. to 2-2 [W7B1].>
3) Install rocker cover and connect PCV hose.
B2M0382C
28
Page 81
[W4A2] 2-3aSERVICE PROCEDURE
4. Camshaft
4. Camshaft
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and related parts. <Ref. to 2-3a [W2A0].>
2. CAMSHAFT (LH)
2) Remove valve rocker assembly. <Ref. to 2-3a [W3A0].>
(1) Camshaft position sensor (2) Bolt
(3) Camshaft support (LH) (4) O-ring
1) Remove camshaft position sensor.
CAUTION: Do not damage the camshaft position sensor.
2) Remove oil level gauge guide attaching bolt.
3) Remove camshaft support (LH).
4) Remove camshaft support LH.Remove O-ring.
H2M2358A
(5) Camshaft (LH) (6) Oil seal
5) Remove camshaft (LH).
6) Remove oil seal.
CAUTION:
I Do not remove oil seal unless necessary. I Do not scratch journal surface when remov-
ing oil seal.
29
Page 82
2-3a [W4A3] SERVICE PROCEDURE
4. Camshaft
3. CAMSHAFT (RH)
B2M0385C
(1) Camshaft support (RH) (2) O-ring
(3) Camshaft (RH) (4) Oil seal
1) Remove camshaft support (RH).
2) Remove O-ring.
3) Remove camshaft (RH).
4) Remove oil seal.
CAUTION:
I Do not remove oil seal unless necessary. I Do not scratch journal surface when remov-
ing oil seal.
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec­essary.
Limit:
0.025 mm (0.0010 in)
2) Check journal for damage and wear. Replace if faulty.
3) Measure outside diameter of camshaft journal and inside diameter of cylinder head journal, and determine the difference between the two (= oil clearance). If oil clearance exceeds specifications, replace camshaft or cylinder head as necessary.
G2M0137
30
Page 83
Item
Clearance at journal
Camshaft journal O.D.
Journal hole I.D.
[W4B2] 2-3aSERVICE PROCEDURE
4. Camshaft
Unit: mm (in) Right-hand camshaft Front Center Rear Left-hand camshaft Rear Center Front Standard 0.055 — 0.090 (0.0022 — 0.0035) Limit 0.10 (0.0039)
31.935 — 31.950
(1.2573 — 1.2579)
32.005 — 32.025
(1.2600 — 1.2608)
37.435 — 37.450
(1.4738 — 1.4744)
37.505 — 37.525
(1.4766 — 1.4774)
37.935 — 37.950
(1.4935 — 1.4941)
38.005 — 38.025
(1.4963 — 1.4970)
4) Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded.
Cam height: H
Standard
IN: 32.244 — 32.344 mm (1.2694 — 1.2734 in) EX: 31.964 — 32.064 mm (1.2584 —
1.2624 in)
Limit
IN: 32.094 mm (1.2635 in) EX: 31.814 mm (1.2525 in)
Cam base circle diameter A:
IN: 27.5 mm (1.083 in) EX: 27.0 mm (1.063 in)
2. CAMSHAFT SUPPORT
Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace camshaft support.
Standard:
0.030— 0.260 mm (0.0012 — 0.0102 in)
Limit:
0.35 mm (0.0138 in)
G2M0139
B2M1209A
31
Page 84
2-3a [W4C1] SERVICE PROCEDURE
4. Camshaft
C: INSTALLATION
1. CAMSHAFT (LH)
(1) Camshaft (LH) (2) O-ring (3) Camshaft support (LH) (4) Oil seal
(5) Bolt (6) Camshaft position sensor
1) Apply a coat of engine oil to camshaft journals and install camshaft (LH).
2) Apply a coat of engine oil or grease to O-ring.
3) Install O-ring to camshaft support.
CAUTION: Use a new O-ring.
4) Install camshaft support.
5) Apply a coat of grease to oil seal lips and install oil seal on camshaft support by using ST1 and ST2.
CAUTION: Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE ST2 499587100 OIL SEAL INSTALLER
Tightening torque: N·m (kg-m, ft-lb)
T1:
10 (1.0, 7)
T2:
16 (1.6, 12)
6) Install oil level gauge guide bolt.
7) Install camshaft position sensor.
H2M1565B
G2M0141
32
Page 85
2. CAMSHAFT (RH)
[W4C3] 2-3aSERVICE PROCEDURE
4. Camshaft
B2M0385D
(1) Camshaft (RH) (2) O-ring (3) Camshaft support (RH)
(4) Oil seal
1) Apply a coat of engine oil to camshaft journals and install camshaft (RH).
2) Apply a coat of engine oil or grease to O-ring.
3) Install O-ring to camshaft support.
CAUTION: Use a new O-ring.
4) Install camshaft support.
5) Install oil seal by using ST1 and ST2.
CAUTION: Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE ST2 499587100 OIL SEAL INSTALLER
Tightening torque: N·m (kg-m, ft-lb)
T:
16 (1.6, 12)
3. RELATED PARTS
1) Install valve rocker assembly. <Ref. to 2-3a [W3E0].>
2) Install timing belt, camshaft sprockets and related parts. <Ref. to 2-3a [W2C0].>
G2M0143
33
Page 86
2-3a [W5A1] SERVICE PROCEDURE
5. Cylinder Head
5. Cylinder Head
A: REMOVAL
1. RELATED PARTS
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Drain engine coolant. <Ref. to 2-5 [W1A0].>
3) Remove V-belt.
4) Remove alternator and bracket.
5) Disconnect spark plug cords.
2. CYLINDER HEAD
6) Remove connector bracket attaching bolt.
7) Remove crankshaft position sensor and cam­shaft position sensor.
8) Disconnect oil pressure switch connector.
9) Disconnect blow-by hose.
10) Remove EGR pipe. (AT vehicles only)
11) Remove intake manifold. <Ref. to 2-7 [W4A0].>
12) Remove engine coolant pipe.
(1) Cylinder head bolt (2) Cylinder head (3) Cylinder head gasket
1) Remove timing belt, camshaft sprocket and related parts. <Ref. to 2-3a [W2A0].>
2) Remove oil level gauge guide attaching bolt (left hand only) and oil level gauge guide.
34
B2M0119G
Page 87
[W5A2] 2-3aSERVICE PROCEDURE
5. Cylinder Head
3) Remove cylinder head bolts in alphabetical sequence shown in Figure.
CAUTION: Leave bolts (a) and (c) engaged by three or four threads to prevent cylinder head from falling.
B2M0120D
4) While tapping cylinder head with a plastic hammer, separate it from cylinder block.
5) Remove bolts (a) and (b) to remove cylinder head.
6) Remove cylinder head gasket.
CAUTION: Do not scratch the mating surface of cylinder head and cylinder block.
7) Similarly, remove right side cylinder head.
B2M0120D
35
Page 88
2-3a [W5B0] SERVICE PROCEDURE
5. Cylinder Head
B: DISASSEMBLY
(1) Rocker cover (2) Valve rocker ASSY
(3) Camshaft support (4) Camshaft
1) Remove rocker cover.
2) Remove valve rocker assembly. <Ref. to 2-3a [W3A0].>
3) Remove camshaft and support. <Ref. to 2-3a [W4A0].>
4) Place cylinder head on ST. ST 498267200 CYLINDER HEAD TABLE
H2M1541E
(5) Oil seal
5) Set ST on valve spring. Compress valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER
CAUTION:
I Mark each valve to prevent confusion. I Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil seals.
6) Removal of plug (cylinder head LH)
CAUTION: Do not remove plug unless necessary.
36
B2M0386A
Page 89
[W5C2] 2-3aSERVICE PROCEDURE
5. Cylinder Head
C: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red lead check. Also make sure that gasket installing surface shows no trace of gas and water leaks.
2) Place cylinder head on ST. ST 498267200 CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head sur­face that mates with crankcase by using a straight edge and thickness gauge. If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
98.3 mm (3.870 in)
CAUTION: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay spe­cial attention to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect intake and exhaust valve seats, and cor­rect the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.
Valve seat width: W
Intake
Standard 0.7 mm (0.028 in) Limit 1.4 mm (0.055 in)
Exhaust
Standard 1.4 mm (0.055 in) Limit 1.8 mm (0.071 in)
G2M0149
G2M0148
B2M0074
37
Page 90
2-3a [W5C3] SERVICE PROCEDURE
5. Cylinder Head
3. VALVE GUIDE
1) Check the clearance between valve guide and stem. The clearance can be checked by measur­ing the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve stem:
Standard
Intake 0.035 — 0.062 mm (0.0014 —
0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 —
0.0026 in)
Limit
0.15 mm (0.0059 in)
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
2) If the clearance between valve guide and stem exceeds the specification, replace guide as fol­lows:
(1) Place cylinder head on ST1 with the com­bustion chamber upward so that valve guides enter the holes in ST1. (2) Insert ST2 into valve guide and press it
down to remove valve guide. ST1 498267200 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
G2M0150
(3) Turn cylinder head upside down and place
ST as shown in the Figure. ST 499767000 VALVE GUIDE ADJUSTER
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
B2M0387A
B2M0077B
(4) Before installing new oversize valve guide,
make sure that neither scratches nor damages
exist on the inside surface of the valve guide
holes in cylinder head.
B2M0076A
38
Page 91
[W5C3] 2-3aSERVICE PROCEDURE
5. Cylinder Head
(5) Put new valve guide, coated with sufficient oil, in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush
with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 499767000 VALVE GUIDE ADJUSTER
B2M0388A
(6) Check the valve guide protrusion.
Valve guide protrusion: L
17.5 — 18.0 mm (0.689 — 0.709 in)
(7) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while press­ing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean valve guide to remove chips.
CAUTION: I Apply engine oil to the reamer when ream­ing. I If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. I If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
B2M0077A
B2M0078
(8) Recheck the contact condition between valve and valve seat after replacing valve guide.
39
Page 92
2-3a [W5C4] SERVICE PROCEDURE
5. Cylinder Head
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if “H” is less than the specified limit.
H:
Intake
Standard 1.0 mm (0.039 in) Limit 0.8 mm (0.031 in)
Exhaust
Standard 1.2 mm (0.047 in) Limit 0.8 mm (0.031 in)
Valve overall length:
Intake
101.0 mm (3.976 in)
Exhaust
101.2 mm (3.984 in)
5. VALVE SPRING
1) Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifications presented below.
2) To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.
Free length 44.05 mm (1.7342 in) Squareness 2.5°, 1.9 mm (0.075 in)
174.6 — 200.1 N (17.8 — 20.4 kg, 39.2 — 45.0 lb)
Tension/spring height
/ 36.0 mm (1.417 in)
405.0 — 458.0 N (41.3 — 46.7 kg, 91.1 — 103.0 lb) / 28.2 mm (1.110 in)
G2M0153
2) Put a small amount of grinding compound on the seat surface and lap the valve and seat sur­face. <Ref. to 2-3a [W5C2].> Install a new intake valve oil seal after lapping.
G2M0154
40
Page 93
6. INTAKE AND EXHAUST VALVE OIL SEAL
Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.
1) Place cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi­cated in the Figure by using ST2.
CAUTION: I Apply engine oil to oil seal before press-fit­ting. I When press-fitting oil seal, do not use ham­mer or strike in. I Differentiate between intake valve oil seal and exhaust valve oil seal by noting their dif­ference in color.
ST1 498267200 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black] Exhaust [Brown]
Color of spring part:
Intake [Silver] Exhaust [Silver]
[W5C6] 2-3aSERVICE PROCEDURE
5. Cylinder Head
B2M0389A
41
Page 94
2-3a [W5D0] SERVICE PROCEDURE
5. Cylinder Head
D: ASSEMBLY
(1) Oil seal (2) Camshaft (3) Camshaft support (4) Valve rocker ASSY
(5) Rocker cover
1) Install plug (cylinder head LH) by using ST. ST 499587100 OIL SEAL INSTALLER
2) Installation of valve spring and valve
(1) Place cylinder head on ST. ST 498267200 CYLINDER HEAD TABLE
(2) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION: When inserting valve into valve guide, use spe­cial care not to damage the oil seal lip.
(3) Install valve spring and retainer.
CAUTION: Be sure to install the valve springs with their close-coiled end facing the seat on the cylinder head.
B2M0121D
Tightening torque: N·m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:
10 (1.0, 7)
T3:
12±1 (1.2±0.1, 8.7±0.7)
T4:
16 (1.6, 12)
(4) Set ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
B2M0386A
42
Page 95
[W5E1] 2-3aSERVICE PROCEDURE
5. Cylinder Head
(5) Compress valve spring and fit valve spring
retainer key.
B2M1210B
E: INSTALLATION
1. CYLINDER HEAD
(6) After installing, tap valve spring retainers lightly with wooden hammer for better seating.
3) Install camshaft and support. <Ref. to 2-3a [W4C0].>
4) Install valve rocker assembly. <Ref. to 2-3a [W3E0].>
5) Install rocker cover.
(1) Cylinder head gasket (2) Cylinder head (3) Cylinder head bolt
1) Install cylinder head and gaskets on cylinder block.
CAUTION: Use new cylinder head gaskets.
43
B2M0119C
Page 96
2-3a [W5E2] SERVICE PROCEDURE
5. Cylinder Head
2) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N·m (3.0 kg-m, 22
ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 N·m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180° first; back them off
by 180° again.
(4) Tighten bolts (a) and (b) to 34 N·m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
(1.5 kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90° in alphabetical
sequence.
CAUTION: Do not tighten bolts more than 90°.
(7) Further tighten all bolts by 80 to 90° in
alphabetical sequence.
CAUTION: Ensure that the total “re-tightening angle” [in the former two steps], do not exceed 180°.
2. RELATED PARTS
CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
1) Install engine coolant pipe.
2) Install intake manifold. <Ref. to 2-7 [W4D0].>
3) Connect blow-by hose.
4) Install EGR pipe. (AT vehicles only)
5) Connect oil pressure switch connector.
6) Install crankshaft position sensor and camshaft position sensor.
7) Install connector bracket attaching bolt.
8) Connect spark plug cords.
9) Install alternator and bracket.
10) Install V-belt.
11) Remove ENGINE STAND (ST).
B2M0120C
3) Install oil level gauge guide attaching bolt (left side only).
4) Install timing belt, camshaft sprocket and related parts. <Ref. to 2-3a [W2C0].>
44
Page 97
[W6A2] 2-3aSERVICE PROCEDURE
6. Cylinder Block
6. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprocket and related parts.
2. OIL PUMP AND WATER PUMP
<Ref. to 2-3a [W2A0].>
2) Remove intake manifold and cylinder head. <Ref. to 2-3a [W5A0].>
(1) Clutch housing cover (MT
vehicles only) (2) Flywheel (MT vehicles only) (3) Drive plate (AT vehicles only)
(4) Oil separator cover (5) Water by-pass pipe (6) Water pump (7) Oil pump
1) Remove clutch housing cover. (MT vehicles only)
B2M1767A
(8) Oil pan (9) Oil strainer (10) Baffle plate (11) Oil filter
45
Page 98
2-3a [W6A2] SERVICE PROCEDURE
6. Cylinder Block
2) Remove flywheel or drive plate. To lock crankshaft use ST. ST 498497100 CRANKSHAFT STOPPER
G2M0161
3) Remove oil separator cover.
4) Remove water by-pass pipe.
5) Remove water pump.
6) Remove oil pump from cylinder block. Use a flat-bladed screwdriver as shown in Figure when removing oil pump.
CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
7) Removal of oil pan (1) Turn cylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylin­der block. (3) Insert a oil pan cutter blade between cylin­der block-to-oil pan clearance and remove oil pan.
CAUTION: Do not use a screwdriver or similar tool in place of oil- pan cutter.
G2M0163
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.
S2M0722A
46
Page 99
B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT
[W6B1] 2-3aSERVICE PROCEDURE
6. Cylinder Block
(1) Service hole plug (2) Service hole cover
(3) Gasket (4) Circlip
1) Remove service hole cover and service hole plugs using hexagon wrench (14 mm).
2) Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
G2M0165
B2M1002A
(5) Piston pin
3) Draw out piston pin from #1 and #2 pistons by
using ST. ST 499097500 PISTON PIN REMOVER
CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder.
G2M0166
47
Page 100
2-3a [W6B2] SERVICE PROCEDURE
6. Cylinder Block
4) Similarly remove piston pins from #3 and #4 pistons by using ST. ST 499097500 PISTON PIN REMOVER
G2M0166
2. CYLINDER BLOCK
5) Remove bolts which connect cylinder block on
the side of #2 and #4 cylinders.
6) Back off bolts which connect cylinder block on
the side of #1 and #3 cylinders two or three turns.
(1) Bolt (2) Cylinder block (RH) (3) Cylinder block (LH)
(4) Rear oil seal (5) Crankshaft (6) Connecting rod
1) Set up cylinder block so that #1 and #3 cylin­ders are on the upper side, then remove cylinder block connecting bolts.
2) Separate left-hand and right-hand cylinder blocks.
CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cyl­inder block.
B2M1319D
(7) Crankshaft bearing (8) Piston
3) Remove rear oil seal.
4) Remove crankshaft together with connecting
rod.
5) Remove crankshaft bearings from cylinder
block using hammer handle.
CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
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