Important safety notice

쐌 Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance
and safe operation, function and performance which the SUBARU vehicle possesses.

쐌 In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose
parts numbers are designated or their equivalents must be utilized.

쐌 It must be made well known that the safety of the serviceman and the safe operation of the vehicle would be
jeopardized if the used any service parts, consumables, special tools and work procedure manuals which are
not approved or designated by SUBARU.

All right reserved. This book may not be reproduced

or copied, in whole or in part, without the written
permission of FUJI HEAVY INDUSTRIES LTD.,
TOKYO JAPAN.

SUBARU, and are trademarks of

FUJI HEAVY INDUSTRIES LTD.

© Copyright 1996 FUJI HEAVY INDUSTRIES LTD.

2
 How to use this manual

쐌 This Service Manual is divided into four volumes by section so that it can be used with ease at work. Refer to
the Table of Contents, select and use the necessary section.

쐌 GENERAL INFORMATION SECTION

쐌 REPAIR SECTION
쐌 DIAGNOSTICS SECTION
쐌 WIRING DIAGRAM SECTION
쐌 Each chapter in the manual is basically made of the following four types of areas.

S SPECIFICATIONS AND SERVICE DATA

C COMPONENT PARTS
W SERVICE PROCEDURE
(X SERVICE PROCEDURE)
(Y SERVICE PROCEDURE)
K DIAGNOSTICS

쐌 The description of each area is provided with four types of titles different in size as shown below. The Title No.
or Symbol prefixes each title in order that the construction of the article and the flow of explanation can be eas-
ily understood.

[Example of each title]

쐌 Area title: W SERVICE PROCEDURE (one of the four types of areas)
쐌 Large title (Heading): 1. Oil Pump (to denote the main item of explanation)
쐌 Medium title (Section): A: REMOVAL (to denote the type of work in principle)
쐌 Small title (Sub-section): 1. INNER ROTATOR (to denote a derivative item of explanation)

3
쐌 The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is useful
for retrieving the necessary portion.

(Example of usage)

Refer to 4 - 1 [ W 1 A 0 ]

Small title (Sub-section)

Medium title (Section)

Large title (Heading)

Area title

Chapter No.

4
쐌 In this manual, the following symbols are used.

* : Selective part

★ : Replacement part

: Should be lubricated with oil.

: Should be lubricated with grease.

: Sealing point

: Tightening torque

쐌 WARNING, CAUTION, NOTE

쐌 WARNING: Indicates the item which must be observed precisely during performance of maintenance ser-
vices in order to avoid injury to the mechanics and other persons.
쐌 CAUTION: Indicates the item which must be followed precisely during performance of maintenance ser-
vices so as to avoid damage and breakage to the vehicle and its parts and components.
쐌 NOTE: Indicates the hints, knacks, etc. which make the maintenance job easier.

쐌 SPECIAL TOOLS
When any special tool is required to perform the job, it is identified by “ST” in the applicable illustration and its
part number is shown in the manual.

1. Procedures for adjusting backlash

1) Set steering wheel to the straight-ahead position.
2) Remove the exhaust pipe
3) Loosen the lock nut with ST. 䊴

䊳
{ ST1
ST2
921650000
921550000
STEERING GEARBOX WRENCH
STEERING GEARBOX WRENCH
䊱 䊱

Description
(of job method)
M1H0120
Shows the part name

Shows the part number

Tells that two kinds of special tools are required.

When two or more kinds of special tools are required to do
a job, they are identified by ST1, ST2,......respectively.

5
2-1 SERVICE PROCEDURE
1. Front Catalytic Converter

1. Front Catalytic Converter

A: REMOVAL
1) Disconnect front oxygen sensor connector.

B2M0724

2) Disconnect rear oxygen sensor connector. (California

2200 cc model)

B2M0725

3) Lift-up the vehicle.

4) Disconnect rear oxygen sensor connector. (Except Cali-
fornia 2200 cc model)

B2M0312

5) Separate center exhaust pipe from rear exhaust pipe.

B2M0055

6) Remove bolts which hold front exhaust pipe onto cylin-

der heads.

B2M0054

2
 SERVICE PROCEDURE 2-1
1. Front Catalytic Converter

7) Remove front exhaust pipe and center exhaust pipe

from hanger bracket.
CAUTION:
Be careful not to pull down front exhaust pipe and
center exhaust pipe.

B2M0313

8) Separate front catalytic converter from front exhaust

pipe and center exhaust pipe.

B2M0060

B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust pipe and
center exhaust pipe.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0060

2) Install front exhaust pipe and center exhaust pipe.

And temporarily tighten bolt which installs center exhaust
pipe to hanger bracket.

B2M0313

3) Tighten bolts which hold front exhaust pipe onto cylin-

der heads.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0054

3
2-1 SERVICE PROCEDURE
1. Front Catalytic Converter

4) Install center exhaust pipe to rear exhaust pipe.

Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

B2M0055

5) Tighten bolt which holds center exhaust pipe to hanger

bracket.
Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)

B2M0313

6) Connect rear oxygen sensor connector. (Except Califor-

nia 2200 cc model)

B2M0312

7) Lower the vehicle.

8) Connect rear oxygen sensor connector. (California
2200 cc model)

B2M0725

9) Connect front oxygen sensor connector.

B2M0724

4
 SERVICE PROCEDURE 2-1
2. Rear Catalytic Converter

2. Rear Catalytic Converter

A: REMOVAL
1) Lift-up the vehicle.
2) Disconnect rear oxygen sensor connector. (Except Cali-
fornia 2200 cc model)

B2M0312

3) Separate center exhaust pipe and rear catalytic con-

verter assembly from rear exhaust pipe.

B2M0055

4) Separate center exhaust pipe and rear catalytic con-

verter assembly from front catalytic converter.

B2M0421

5) Remove center exhaust pipe and rear catalytic con-

verter assembly from hanger bracket.
CAUTION:
쐌 Be careful not to pull down center exhaust pipe.
쐌 After removing center exhaust pipe, do not apply
excessive pulling force on front catalytic converter
and front exhaust pipe.

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

5
2-1 SERVICE PROCEDURE
2. Rear Catalytic Converter

2) Install center exhaust pipe to front catalytic converter.

Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)

B2M0421

3) Install center exhaust pipe to rear exhaust pipe.

Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

B2M0055

4) Tighten bolt which holds center exhaust pipe to hanger

bracket.
Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)

B2M0313

5) Connect rear oxygen sensor connector. (Except Califor-

nia 2200 cc model)

B2M0312

6
 SERVICE PROCEDURE 2-1
3. Canister - 4. Purge Control Solenoid Valve

3. Canister
A: REMOVAL AND INSTALLATION
1. 2200 cc FWD AND 2500 cc MODEL
1) Disconnect canister hoses from evaporation pipes.
2) Remove canister with bracket.

G2M0375

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 MODEL

1) Lift-up the vehicle.
2) Disconnect evaporation hoses from canister.

B2M0952

3) Remove canister from body.

4) Installation is in the reverse order of removal.
Tightening torque:
25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)

B2M0953

4. Purge Control Solenoid Valve

A: REMOVAL AND INSTALLATION
1) Disconnect connector from purge control solenoid
valve.
2) Disconnect vacuum hoses from purge control solenoid
valve.
3) Remove bolt which installs purge control solenoid valve
to intake manifold.
B2M1201A
4) Take out purge control solenoid valve.

7
 SERVICE PROCEDURE 2-1
3. Canister - 4. Purge Control Solenoid Valve

3. Canister
A: REMOVAL AND INSTALLATION
1. 2200 cc FWD AND 2500 cc MODEL
1) Disconnect canister hoses from evaporation pipes.
2) Remove canister with bracket.

G2M0375

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 MODEL

1) Lift-up the vehicle.
2) Disconnect evaporation hoses from canister.

B2M0952

3) Remove canister from body.

4) Installation is in the reverse order of removal.
Tightening torque:
25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)

B2M0953

4. Purge Control Solenoid Valve

A: REMOVAL AND INSTALLATION
1) Disconnect connector from purge control solenoid
valve.
2) Disconnect vacuum hoses from purge control solenoid
valve.
3) Remove bolt which installs purge control solenoid valve
to intake manifold.
B2M1201A
4) Take out purge control solenoid valve.

7
2-1 SERVICE PROCEDURE
4. Purge Control Solenoid Valve - 6. Back-Pressure Transducer (BPT)

5) Installation is in the reverse order of removal.

Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)

5. EGR Valve
A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from EGR valve.
2) Remove bolts which install EGR valve onto intake mani-
fold.

B2M0423

3) Installation is in the reverse order of removal.

CAUTION:
Replace gasket with a new one.
Tightening torque:
17.1 — 20.1 N⋅m (1.74 — 2.05 kg-m, 12.6 — 14.8
ft-lb)

6. Back-Pressure Transducer (BPT)

A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from BPT.
2) Remove BPT from bracket.
3) Installation is in the reverse order of removal.

B2M0424

8
2-1 SERVICE PROCEDURE
4. Purge Control Solenoid Valve - 6. Back-Pressure Transducer (BPT)

5) Installation is in the reverse order of removal.

Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)

5. EGR Valve
A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from EGR valve.
2) Remove bolts which install EGR valve onto intake mani-
fold.

B2M0423

3) Installation is in the reverse order of removal.

CAUTION:
Replace gasket with a new one.
Tightening torque:
17.1 — 20.1 N⋅m (1.74 — 2.05 kg-m, 12.6 — 14.8
ft-lb)

6. Back-Pressure Transducer (BPT)

A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from BPT.
2) Remove BPT from bracket.
3) Installation is in the reverse order of removal.

B2M0424

8
2-1 SERVICE PROCEDURE
4. Purge Control Solenoid Valve - 6. Back-Pressure Transducer (BPT)

5) Installation is in the reverse order of removal.

Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)

5. EGR Valve
A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from EGR valve.
2) Remove bolts which install EGR valve onto intake mani-
fold.

B2M0423

3) Installation is in the reverse order of removal.

CAUTION:
Replace gasket with a new one.
Tightening torque:
17.1 — 20.1 N⋅m (1.74 — 2.05 kg-m, 12.6 — 14.8
ft-lb)

6. Back-Pressure Transducer (BPT)

A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from BPT.
2) Remove BPT from bracket.
3) Installation is in the reverse order of removal.

B2M0424

8
 SERVICE PROCEDURE 2-1
7. EGR Solenoid Valve - 8. Fuel Temperature Sensor (2200 cc AWD Model)

7. EGR Solenoid Valve

A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect connector from EGR solenoid valve.
2) Disconnect vacuum hoses from EGR solenoid valve.
3) Remove bolt which installs EGR solenoid valve.
4) Take out EGR solenoid valve.
5) Installation is in the reverse order of removal.
B2M1202A Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
2. 2500 cc MODEL
1) Remove bolt which installs EGR solenoid valve onto
intake manifold.
2) Take out EGR solenoid valve.
3) Disconnect connector from EGR solenoid valve.
4) Disconnect vacuum hoses from EGR solenoid valve.
5) Remove EGR solenoid valve.
NOTE:
B2M0425B This figure shows the under side of intake manifold.
6) Installation is in the reverse order of removal.
Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)

8. Fuel Temperature Sensor (2200 cc

AWD Model)
A: REMOVAL
1) Disconnect battery ground cable.

G6M0095

2) Release fuel pressure. <Ref. to 2-8 [W1A0].>

1 , return hose 쎻
3) Disconnect fuel delivery hose 쎻 2 and jet
pump hose 쎻 3 .

B2M0954A

9
 SERVICE PROCEDURE 2-1
7. EGR Solenoid Valve - 8. Fuel Temperature Sensor (2200 cc AWD Model)

7. EGR Solenoid Valve

A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect connector from EGR solenoid valve.
2) Disconnect vacuum hoses from EGR solenoid valve.
3) Remove bolt which installs EGR solenoid valve.
4) Take out EGR solenoid valve.
5) Installation is in the reverse order of removal.
B2M1202A Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
2. 2500 cc MODEL
1) Remove bolt which installs EGR solenoid valve onto
intake manifold.
2) Take out EGR solenoid valve.
3) Disconnect connector from EGR solenoid valve.
4) Disconnect vacuum hoses from EGR solenoid valve.
5) Remove EGR solenoid valve.
NOTE:
B2M0425B This figure shows the under side of intake manifold.
6) Installation is in the reverse order of removal.
Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)

8. Fuel Temperature Sensor (2200 cc

AWD Model)
A: REMOVAL
1) Disconnect battery ground cable.

G6M0095

2) Release fuel pressure. <Ref. to 2-8 [W1A0].>

1 , return hose 쎻
3) Disconnect fuel delivery hose 쎻 2 and jet
pump hose 쎻 3 .

B2M0954A

9
2-1 SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD Model)

4) Remove nuts which install fuel pump assembly onto

fuel tank.

B2M0955

5) Take off fuel pump assembly from fuel tank.

B2M0956

6) Remove two screws fixing terminals on fuel pump

assembly.

H2M1456

7) Disconnect connector from fuel pump.

H2M1457

8) Remove fuel temperature sensor from fuel pump

assembly.

H2M1458A

10
 SERVICE PROCEDURE 2-1
8. Fuel Temperature Sensor (2200 cc AWD Model) - 9. Fuel Tank Pressure Sensor (2200 cc AWD Model)

B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent 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 fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
B2M0955A
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

9. Fuel Tank Pressure Sensor (2200 cc

AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove trims.
쐌 4 door model:
Remove right trunk side trim.

H2M1122B

쐌 Wagon model:
(1) Remove right rear quarter upper rear trim.
(2) Remove right strut cap.
(3) Remove right rear quarter pillar lower trim.

B2M0927A

11
 SERVICE PROCEDURE 2-1
8. Fuel Temperature Sensor (2200 cc AWD Model) - 9. Fuel Tank Pressure Sensor (2200 cc AWD Model)

B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent 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 fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
B2M0955A
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

9. Fuel Tank Pressure Sensor (2200 cc

AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove trims.
쐌 4 door model:
Remove right trunk side trim.

H2M1122B

쐌 Wagon model:
(1) Remove right rear quarter upper rear trim.
(2) Remove right strut cap.
(3) Remove right rear quarter pillar lower trim.

B2M0927A

11
2-1 SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD Model) - 10. Pressure Control Solenoid Valve (2200 cc AWD Model)

3) Disconnect connector from fuel tank pressure sensor.

4) Remove bolts which install fuel tank pressure sensor
bracket on body.

B2M0960

5) Disconnect hose from fuel tank pressure sensor.

6) Remove fuel tank pressure sensor from bracket.
7) Installation is in the reverse order of removal.

B2M0961

10. Pressure Control Solenoid Valve

(2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Lift-up the vehicle.

G6M0095

3) Disconnect evaporation hoses from pressure control

valve.
4) Disconnect connector from pressure control valve.

B2M0962

5) Remove pressure control valve from bracket.

6) Installation is in the reverse order of removal.

B2M0963

12
2-1 SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD Model) - 10. Pressure Control Solenoid Valve (2200 cc AWD Model)

3) Disconnect connector from fuel tank pressure sensor.

4) Remove bolts which install fuel tank pressure sensor
bracket on body.

B2M0960

5) Disconnect hose from fuel tank pressure sensor.

6) Remove fuel tank pressure sensor from bracket.
7) Installation is in the reverse order of removal.

B2M0961

10. Pressure Control Solenoid Valve

(2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Lift-up the vehicle.

G6M0095

3) Disconnect evaporation hoses from pressure control

valve.
4) Disconnect connector from pressure control valve.

B2M0962

5) Remove pressure control valve from bracket.

6) Installation is in the reverse order of removal.

B2M0963

12
 SERVICE PROCEDURE 2-1
11. Vent Control Solenoid Valve (2200 cc AWD Model)

11. Vent Control Solenoid Valve (2200

cc AWD Model)
A: REMOVAL
1) Disconnect battery ground cable.

G6M0095

2) Lift-up the vehicle.

3) Remove canister. <Ref. to 2-1 [W3A2].>
4) Disconnect two hoses from air filter.
5) Disconnect connector from vent control solenoid valve.

B2M0964

6) Remove one bolt fixing bracket on the body.

H2M1469

7) Remove two vacuum hoses from vent control solenoid

valve.

B2M0965A

8) Remove one bolt fixing vent control solenoid valve on

bracket.
9) Remove vent control solenoid valve.

B2M0966

13
2-1 SERVICE PROCEDURE
11. Vent Control Solenoid Valve (2200 cc AWD Model)

B: INSTALLATION
1) Install the bolt fixing vent control solenoid valve on
bracket.

B2M0966

2) Install two vacuum hoses to vent control solenoid valve.

B2M0965A

3) Install the bolt fixing bracket on the body.

Tightening torque:
25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)

H2M1469

4) Connect connector to vent control solenoid valve.

5) Connect two hoses to air filter.
6) Install canister. <Ref. to 2-1 [W3A2].>
7) Let down the vehicle.

B2M0964

8) Connect battery ground cable.

G6M0095

14
 SERVICE PROCEDURE 2-1
12. Fuel Level Sensor (2200 cc AWD Model)

12. Fuel Level Sensor (2200 cc AWD

Model)
A: REMOVAL
1) Disconnect battery ground cable.

G6M0095

2) Release fuel pressure. <Ref. to 2-8 [W1A0].>

1 , return hose 쎻
3) Disconnect fuel delivery hose 쎻 2 and jet
pump hose 쎻 3 .

B2M0954A

4) Remove nuts which install fuel pump assembly onto

fuel tank.

B2M0955

5) Take off fuel pump assembly from fuel tank.

B2M0956

6) Disconnect connector from fuel pump.

H2M1459

15
2-1 SERVICE PROCEDURE
12. Fuel Level Sensor (2200 cc AWD Model) - 13. Air Filter (2200 cc AWD Model)

7) Remove two screws fixing bracket on fuel pump assem-

bly.

H2M1460

8) Remove one screw fixing fuel level sensor on bracket.

9) Remove fuel level sensor from fuel pump assembly.

H2M1461A

B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent 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 fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
B2M0955A
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure 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 Model)

A: REMOVAL AND INSTALLATION
1) Remove canister. <Ref. to 2-1 [W3A2].>
2) Remove two hoses from air filter.
3) Remove flange nut from bracket.
4) Installation is in the reverse order of removal.

B2M0968

16
2-1 SERVICE PROCEDURE
12. Fuel Level Sensor (2200 cc AWD Model) - 13. Air Filter (2200 cc AWD Model)

7) Remove two screws fixing bracket on fuel pump assem-

bly.

H2M1460

8) Remove one screw fixing fuel level sensor on bracket.

9) Remove fuel level sensor from fuel pump assembly.

H2M1461A

B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent 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 fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
B2M0955A
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure 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 Model)

A: REMOVAL AND INSTALLATION
1) Remove canister. <Ref. to 2-1 [W3A2].>
2) Remove two hoses from air filter.
3) Remove flange nut from bracket.
4) Installation is in the reverse order of removal.

B2M0968

16
2-2
1. Foreword - 2. Ignition Timing

1. Foreword
This chapter describes major inspection and service pro-
cedures for the engine mounted on the body. For proce-
dures not found in this chapter, refer to the service proce-
dure section in the applicable chapter.

2. Ignition Timing
A: MEASUREMENT
1. 2200 cc MODEL
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.
If the timing is not correct, check the ignition control sys-
tem. <Ref. to 2-7 On-Board Diagnostics II System.>
Ignition timing [BTDC/rpm]:
14°±8°/700 (MT)
G2M0094 20°±8°/700 (AT)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful 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.
If the timing is not correct, check the ignition control sys-
tem. <Ref. to 2-7 On-Board Diagnostics II System.>
Ignition timing [BTDC/rpm]:
15°±8°/700
B2M0750A

2
2-2
1. Foreword - 2. Ignition Timing

1. Foreword
This chapter describes major inspection and service pro-
cedures for the engine mounted on the body. For proce-
dures not found in this chapter, refer to the service proce-
dure section in the applicable chapter.

2. Ignition Timing
A: MEASUREMENT
1. 2200 cc MODEL
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.
If the timing is not correct, check the ignition control sys-
tem. <Ref. to 2-7 On-Board Diagnostics II System.>
Ignition timing [BTDC/rpm]:
14°±8°/700 (MT)
G2M0094 20°±8°/700 (AT)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful 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.
If the timing is not correct, check the ignition control sys-
tem. <Ref. to 2-7 On-Board Diagnostics II System.>
Ignition timing [BTDC/rpm]:
15°±8°/700
B2M0750A

2
 2-2
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) Connect Subaru Select Monitor or the OBD-II general
scan tool to data link connector.
CAUTION:
When connecting Subaru Select Monitor, turn ignition
switch to OFF.
4) Start the engine and measure engine speed.
NOTE:
Engine speed is indicated on Subaru Select Monitor by
selecting “MODE F04”.
G2M0096

NOTE:
쐌 When using the OBD-II general scan tool, carefully read
its operation manual.
쐌 When Subaru Select Monitor is not used, attach the
pickup sensor on tachometer (Secondary pickup type) to
#1 cylinder spark plug cord.
쐌 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.
G2M0097

5) 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):
700±100 rpm
6) 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]:
850±50 rpm
CAUTION:
Never rotate idle adjusting screw. If idle speed is out
of specifications, refer to General On-board Diagnosis
Table under “2-7 On-Board Diagnostics II System”.

3
2-2
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 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
G2M0098
steady.

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/cm2, 156 — 185 psi)
Limit
883 kPa (9.0 kg/cm2, 128 psi)
Difference between cylinders
196 kPa (2.0 kg/cm2, 28 psi)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful 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 [W3D0],
[W3E0].>
4) Disconnect connectors from fuel injectors.

4
 2-2
4. Engine Compression

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.
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/cm2, 176 psi)
Limit
941 kPa (9.6 kg/cm2, 137 psi)
Difference between cylinders
49 kPa (0.5 kg/cm2, 7 psi), or less

5
2-2
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.

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.
Vacuum pressure (at idling, A/C “OFF”):
Less than −60.0 kPa
(−450 mmHg, −17.72 inHg)

G2M0099

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 Leakage around intake manifold gasket or disconnection or
tendency becomes more evident as engine temperature damaged vacuum hose
rises.
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes
steady above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal Sticky valves
position.
5. When engine speed is gradually increased, needle begins Weak or broken valve springs
to vibrate rapidly at certain speed, and then vibration
increases as engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.

6
 2-2
6. Engine Oil Pressure

6. Engine Oil Pressure

A: MEASUREMENT
1) Remove generator from bracket.
(1) Disconnect connector and terminal from generator.

G2M0088

(2) Remove V-belt cover.

(3) Loosen lock bolt and slider bolt, and remove V-belt
for generator.

G2M0089

(4) Remove generator lock bolt.

(5) Remove bolt which install generator on bracket.

G2M0090

2) Disconnect connector from oil pressure switch.

3) Remove oil pressure switch from engine cylinder block.

G2M0091

7
2-2
6. Engine Oil Pressure

4) Connect oil pressure gauge hose to cylinder block.

5) Start the engine, and measure oil pressure.
Oil pressure:
98 kPa (1.0 kg/cm2,14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000 rpm
CAUTION:
쐌 If oil pressure is out of specification, check oil
pump, oil filter and lubrication line.
<Ref. to 2-4 [K100].>
G2M0093
쐌 If oil pressure warning light is turned ON and oil
pressure is in specification, replace oil pressure
switch.
<Ref. to 2-4 [W3A0].>
NOTE:
The specified data is based on an engine oil temperature
of 80°C (176°F).
6) After measuring oil pressure, install oil pressure switch.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
7) Install generator and V-belt in the reverse order of
removal, and adjust the V-belt deflection.

8
 2-2
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.
쐌 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.
(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.
B2M1226A

(5) Remove air intake duct and air cleaner upper cover
as a unit.
(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).
B2M1227

9
2-2
7. Valve Clearance

쐌 When inspecting #2 and #4 cylinders;

(1) Disconnect battery cables, and then remove bat-
tery 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).

5) Set #1 cylinder piston to top dead center of compres-

sion 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:
쐌 Insert the thickness gauge in as horizontal a direc-
tion as possible with respect to the valve stem end
face.
쐌 Measure exhaust valve clearances while lifting-up
the vehicle.
Valve clearance:
B2M1229A
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
7) If necessary, adjust the valve clearance. <Ref. to 2-2
[07B1].>

10
 2-2
7. Valve Clearance

8) Similar to measurement procedures used for #1

cylinder, measure #2, #3 and #4 cylinder valve clearances.
NOTE:
쐌 Be sure to set cylinder pistons to their respective top
dead centers on compression stroke before measuring
valve clearances.
쐌 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-
B2M1230A hand camshaft sprocket facing up.
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.
4) Remove one bolt which secures timing belt cover (RH).
5) Lift-up the vehicle.
6) Remove under cover (RH).
7) Remove canister bracket.
8) Loosen remaining bolts which secure timing belt cover
(RH), then remove belt cover.
9) Lower the vehicle.

10) Remove rocker cover.

쐌 When inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow sensor.

B2M1225A

11
2-2
7. Valve Clearance

(2) Loosen clamp which connects air intake duct to air

intake chamber.
(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.
B2M1226A

(5) Remove air intake duct and air cleaner upper cover
as a unit.
(6) Remove air cleaner element.

B2M1227

(7) Remove air cleaner lower case.

B2M1232A

(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).

쐌 When inspecting # 2 and #4 cylinders;

(1) Disconnect battery cables, and then remove bat-
tery 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).

12
 2-2
7. Valve Clearance

11) Turn crankshaft pulley clockwise until arrow mark on

camshaft sprocket is set to position shown in figure.
12) Measure #1 cylinder intake valve and #3 cylinder
exhaust valve clearances by using thickness gauge.
CAUTION:
쐌 Insert the thickness gauge in as horizontal a direc-
tion as possible with respect to the shim.
쐌 Measure exhaust valve clearances while lifting-up
the vehicle.
B2M1233A
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
13) If necessary, adjust the valve clearance. <Ref. to 2-2
[07B2].>

B2M1234A

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

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

B2M1237A

13
2-2
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 compres-
sion stroke by rotating crankshaft pulley clockwise.
NOTE:
B2M1228A 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:
10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
B2M1238A
CAUTION:
쐌 Insert the thickness gauge in as horizontal a direc-
tion as possible with respect to the valve stem end
face.
쐌 Adjust exhaust valve clearances while lifting-up the
vehicle.
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
3) Ensure that valve clearances are within specifications.
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 specifications.
If necessary, re-adjust valve clearances.

14
 2-2
7. Valve Clearance

6) Similar to adjustment procedures used for #1 cylinder,

adjust #2, #3 and #4 cylinder valve clearances.
NOTE:
쐌 Be sure to set cylinder pistons to their respective top
dead centers on compression stroke before adjusting valve
clearances.
쐌 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-
B2M1230A hand camshaft sprocket facing up.
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 [07A2].>
NOTE:
Record each valve clearance after it has been measured.
2) Remove timing belt, camshaft sprockets, and related
parts. <Ref. to 2-3b [W2A0].>
B2M1234A
3) Remove camshaft. <Ref. to 2-3b [W3A0].>
4) Remove shim from valve lifter.
5) Measure thickness of shim with micrometer.

B2M1240A

15
2-2
7. Valve Clearance

6) Select a shim of suitable thickness using measured

valve clearance and shim thickness, using the following
table.
Unit: mm
Intake valve: S = (V + T) − 0.20
Exhaust valve: 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)

13218AC290 2.33 (0.0917) 13218AC480 2.52 (0.0992)
13218AC300 2.34 (0.0921) 13218AC490 2.53 (0.0996)
13218AC310 2.35 (0.0925) 13218AC500 2.54 (0.1000)
13218AC320 2.36 (0.0929) 13218AC510 2.55 (0.1004)
13218AC330 2.37 (0.0933) 13218AC520 2.56 (0.1008)
13218AC340 2.38 (0.0937) 13218AC530 2.57 (0.1012)
13218AC350 2.39 (0.0941) 13218AC540 2.58 (0.1016)
13218AC360 2.40 (0.0945) 13218AC550 2.59 (0.1020)
13218AC370 2.41 (0.0949) 13218AC560 2.60 (0.1024)
13218AC380 2.42 (0.0953) 13218AC570 2.61 (0.1028)
13218AC390 2.43 (0.0957) 13218AC580 2.62 (0.1031)
13218AC400 2.44 (0.0961) 13218AC590 2.63 (0.1035)
13218AC410 2.45 (0.0965) 13218AC600 2.64 (0.1039)
13218AC420 2.46 (0.0969) 13218AC610 2.65 (0.1043)
13218AC430 2.47 (0.0972) 13218AC620 2.66 (0.1047)
13218AC440 2.48 (0.0976) 13218AC630 2.67 (0.1051)
13218AC450 2.49 (0.0980) 13218AC640 2.68 (0.1055)
13218AC460 2.50 (0.0984) 13218AC650 2.69 (0.1059)
13218AC470 2.51 (0.0988)

7) Set suitable shim selected in step 6) to valve lifter.

8) Install camshaft. <Ref. to 2-3b [W3C0].>
9) Install camshaft sprockets, timing belt and related parts.
<Ref. to 2-3b [W2C0].>
NOTE:
At this point, do not install rocker cover.

16
 2-2
7. Valve Clearance

10) Turn crankshaft pulley clockwise until arrow mark on

camshaft sprocket is set to position shown in figure.
11) Ensure that #1 cylinder intake valve and #3 cylinder
exhaust valve are adjusted to specifications.
CAUTION:
쐌 Insert the thickness gauge in as horizontal a direc-
tion as possible with respect to the shim.
쐌 Adjust exhaust valve clearances while lifting-up the
vehicle.
B2M1233A
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
12) 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.

B2M1234A

13) Further turn crankshaft pulley clockwise. Using the

same procedures as in step 11) above, measure valve
clearances.
(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.

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

17
2-3 SPECIFICATIONS AND SERVICE DATA
1. Engine

1. Engine
A: SPECIFICATIONS
Model 2200 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke
Type
gasoline engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953)
3
Displacement cm (cu in) 2,212 (135.0)
Compression ratio 9.7
Compression pressure 1,079 — 1,275
(at 200 — 300 rpm) kPa (kg/cm2, psi) (11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Engine Opening 4° BTDC
Intake valve timing
Closing 52° ABDC
Opening 48° BBDC
Exhaust valve timing
Closing 12° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
700±100 (No load)
[At neutral position on MT, or
850±50 (A/C switch ON)
“P” or “N” position on AT] rpm
Firing order 1,3,2,4
Ignition timing BTDC/rpm 14°±8°/700 (MT), 20°±8°/700 (AT)

2
 SPECIFICATIONS AND SERVICE DATA 2-3
1. Engine

B: SERVICE DATA
Belt
tension Protrusion of adjuster rod 15.4 — 16.4 mm (0.606 — 0.646 in)
adjuster
Spacer O.D. 16 mm (0.63 in)
Tensioner bush I.D. 16.16 mm (0.6362 in)
Belt ten- STD 0.117 — 0.180 mm (0.0046 — 0.0071 in)
Clearance between spacer and bush
sioner Limit 0.230 mm (0.0091 in)
STD 0.37 — 0.54 mm (0.0146 — 0.0213 in)
Side clearance of spacer
Limit 0.8 mm (0.031 in)
Valve STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
Clearance between shaft and arm
rocker arm Limit 0.10 mm (0.0039 in)
Bend limit 0.025 mm (0.0010 in)
STD 0.030 — 0.260 mm (0.0012 — 0.0102 in)
Thrust clearance
Limit 0.35 mm (0.0138 in)
STD 32.244 — 32.344 mm (1.2694 — 1.2734 in)
Intake
Limit 32.094 mm (1.2635 in)
Cam lobe height
STD 31.964 — 32.064 mm (1.2584 — 1.2624 in)
Exhaust
Limit 31.814 mm (1.2525 in)
Camshaft Front Rear 31.935 — 31.950 mm (1.2573 — 1.2579 in)
Camshaft journal O.D. RH Center LH Center 37.435 — 37.450 mm (1.4738 — 1.4744 in)
Rear Front 37.935 — 37.950 mm (1.4935 — 1.4941 in)
Front Rear 32.005 — 32.025 mm (1.2600 — 1.2608 in)
Camshaft journal hole
RH Center LH Center 37.505 — 37.525 mm (1.4766 — 1.4774 in)
I.D.
Rear Front 38.005 — 38.025 mm (1.4963 — 1.4970 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.1 mm (0.004 in)
head
Standard height 98.3 mm (3.870 in)
Refacing angle 90°
STD 0.7 mm (0.028 in)
Intake
Valve set Limit 1.4 mm (0.055 in)
Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 1.8 mm (0.071 in)
Valve Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
guide Protrusion above head 17.5 — 18.0 mm (0.689 — 0.709 in)
STD 1.0 mm (0.039 in)
Intake
Limit 0.8 mm (0.031 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.8 mm (0.031 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 101.0 mm (3.976 in)
Overall length
Exhaust 101.2 mm (3.984 in)
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter

3
2-3 SPECIFICATIONS AND SERVICE DATA
1. Engine

Free length 44.05 mm (1.7342 in)

Squareness 2.5°, 1.9 mm (0.075 in)
Valve spring 174.6 — 200.1 N
Tension/spring height (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)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 96.905 — 96.915 mm (3.8151 — 3.8155 in)
Cylinder bore STD
B 96.895 — 96.905 mm (3.8148 — 3.8151 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
block Limit 0.050 mm (0.0020 in)
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 96.885 — 96.895 mm (3.8144 — 3.8148 in)
STD
B 96.875 — 96.885 mm (3.8140 — 3.8144 in)
Piston Outer diameter 0.25 mm (0.0098 in) 97.115 — 97.145 mm (3.8234 — 3.8246 in)
OS
0.50 mm (0.0197 in) 97.365 — 97.395 mm (3.8333 — 3.8344 in)
OS
Standard clearance between piston STD 0.004 — 0.010 mm (0.0002 — 0.0004 in)
pin and hole in piston Limit 0.020 mm (0.0008 in)
Piston pin
Degree of fit Piston pin must be fitted into position with thumb at 20°C
(68°F).
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.20 — 0.50 mm (0.0079 — 0.0197 in)
Piston ring gap ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.70 mm (0.0079 — 0.0276 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
STD 0.040 — 0.080mm (0.0016 — 0.0031 in)
Top ring
Clearance between piston Limit 0.15 mm (0.0059 in)
ring and piston ring groove Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94 in) in Limit 0.10 mm (0.0039 in)
Connecting length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.015 — 0.045 mm (0.0006 — 0.0018 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm
(0.0012 in) 1.510 — 1.513 mm (0.0594 — 0.0596 in)
Connecting US
rod bearing
Thickness at center portion 0.05 mm
(0.0020 in) 1.520 — 1.523 mm (0.0598 — 0.0600 in)
US
0.25 mm
(0.0098 in) 1.620 — 1.623 mm (0.0638 — 0.0639 in)
US
Connecting Clearance between piston pin and STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing bushing Limit 0.030 mm (0.0012 in)
STD: Standard OS: Oversize US: Undersize

4
 SPECIFICATIONS AND SERVICE DATA 2-3
1. Engine

Bend limit 0.035 mm (0.0014 in)

Out-of-roundness 0.030 mm (0.0012 in) or less
Crank pin and crank journal
Grinding limit 0.25 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm
(0.0012 in) 51.954 — 51.970 mm (2.0454 — 2.0461 in)
US
Crank pin outer diameter 0.05 mm
(0.0020 in) 51.934 — 51.950 mm (2.0446 — 2.0453 in)
US
0.25 mm
(0.0098 in) 51.734 — 51.750 mm (2.0368 — 2.0374 in)
US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 in) 59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #5 0.05 mm
(0.0020 in) 59.934 — 59.950 mm (2.3596 — 2.3602 in)
US
Crankshaft
0.25 mm
(0.0098 in) 59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
Crank journal outer diameter
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 in) 59.954 — 59.970 mm (2.3604 — 2.3610 in)
US
#2, #3, #4 0.05 mm
(0.0020 in) 59.934 — 59.950 mm (2.3596 — 2.3602 in)
US
0.25 mm
(0.0098 in) 59.734 — 59.750 mm (2.3517 — 2.3524 in)
US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
#1, #5 STD 0.003 — 0.030 mm (0.0001 — 0.0012 in)
#2, #3, #4 STD 0.010 — 0.033 mm (0.0004 — 0.0013 in)
Oil clearance
#1, #3, #5 Limit 0.040 mm (0.0016 in)
#2, #4 Limit 0.035 mm (0.0014 in)
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm
(0.0012 in) 2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
#1, #5 0.05 mm
(0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm
(0.0098 in) 2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft US
bearing Crankshaft bearing thickness
STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm
(0.0012 in) 2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #3, #4 0.05 mm
(0.0020 in) 2.029 — 2.032 mm (0.0799 — 0.0800 in)
US
0.25 mm
(0.0098 in) 2.129 — 2.132 mm (0.0838 — 0.0839 in)
US
STD: Standard US: Undersize

5
2-3 COMPONENT PARTS
1. Timing Belt

1. Timing Belt

B2M0102A

쎻
1 Crankshaft sprocket 쎻
13 Belt cover (RH)
쎻
2 Belt cover No. 2 (RH) 쎻
14 Front belt cover
쎻
3 Belt cover No. 2 (LH) 쎻
15 Belt cover (LH)
쎻
4 Camshaft sprocket (RH) 쎻
16 Crankshaft pulley
쎻
5 Belt idler
쎻
6 Tensioner bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
7 Belt idler T1: 5±1 (0.5±0.1, 3.6±0.7)
쎻
8 Belt tensioner T2: 25±2 (2.5±0.2, 18.1±1.4)
T3: 39±4 (4.0±0.4, 28.9±2.9)
쎻
9 Tensioner adjuster
T4: 78±5 (8.0±0.5, 57.9±3.6)
쎻
10 Belt idler No. 2 T5: 127±10 (13.0±1.0, 94±7)
쎻
11 Camshaft sprocket (LH)
쎻
12 Timing belt

6
 COMPONENT PARTS 2-3
2. Cylinder Head and Camshaft

2. Cylinder Head and Camshaft

B2M0103A

쎻
1 Rocker cover (RH) 쎻
16 Oil seal
쎻
2 Rocker cover gasket 쎻
17 Oil filler cap
쎻
3 Camshaft support (RH) 쎻
18 Gasket
쎻
4 O-ring 쎻
19 Oil filler pipe
쎻
5 Camshaft (RH) 쎻
20 O-ring
쎻
6 Intake valve guide 쎻
21 Rocker cover gasket
쎻
7 Exhaust valve guide 쎻
22 Rocker cover (LH)
쎻
8 Oil seal
쎻
9 Cylinder head (RH) Tightening torque: N⋅m (kg-m, ft-lb)
쎻
10 Cylinder head gasket T1: Refer to 2-3 [W6E1].
쎻
11 Cylinder head (LH) T2: 5±1 (0.5±0.1, 3.6±0.7)
쎻
12 Plug T3: 10 (1.0, 7)
쎻
13 Camshaft (LH) T4: 16 (1.6, 12)
쎻
14 O-ring
쎻
15 Camshaft support (LH)

7
2-3 COMPONENT PARTS
3. Cylinder Head and Valve Assembly

3. Cylinder Head and Valve Assembly

B2M1001A

쎻
1 Exhaust valve 쎻
12 Valve rocker adjust screw
쎻
2 Intake valve 쎻
13 Valve rocker nut
쎻
3 Intake valve oil seal 쎻
14 Intake valve rocker arm
쎻
4 Valve spring 쎻
15 Exhaust valve rocker arm
쎻
5 Retainer 쎻
16 Spring
쎻
6 Retainer key
쎻
7 Exhaust valve oil seal Tightening torque: N⋅m (kg-m, ft-lb)
쎻
8 Rocker shaft support T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 10±1 (1.0±0.1, 7.2±0.7)
쎻
9 Rocker shaft support
T3: 12±1 (1.2±0.1, 8.7±0.7)
쎻
10 Rocker shaft support
쎻
11 Rocker shaft

8
 COMPONENT PARTS 2-3
4. Cylinder Block

4. Cylinder Block

B2M0381A

쎻
1 Oil pressure switch 쎻
17 Gasket
쎻
2 Cylinder block (RH) 쎻
18 Oil pan
쎻
3 Service hole plug 쎻
19 Oil drain plug
쎻
4 Gasket 쎻
20 Gasket
쎻
5 Oil separator cover 쎻
21 Oil filler pipe
쎻
6 Water pipe
쎻
7 Oil pump Tightening torque: N⋅m (kg-m, ft-lb)
쎻
8 Front oil seal T1: 5 (0.5, 3.6)
쎻
9 Rear oil seal T2: 6.4 (0.65, 4.7)
쎻
10 O-ring T3: 10 (1.0, 7)
T4: 25±2 (2.5±0.2, 18.1±1.4)
쎻
11 Service hole cover
T5: 47±3 (4.8±0.3, 34.7±2.2)
쎻
12 Cylinder block (LH) T6: 69±7 (7.0±0.7, 50.6±5.1)
쎻
13 Water pump T7: First 12±2 (1.2±0.2, 8.7±1.4)
쎻
14 Baffle plate Second 12±2 (1.2±0.2, 8.7±1.4)
쎻
15 Oil strainer stay
쎻
16 Oil strainer

9
2-3 COMPONENT PARTS
5. Crankshaft and Piston

5. Crankshaft and Piston

G2M0105

쎻
1 Drive plate (AT) 쎻
13 Connecting rod bearing
쎻
2 Reinforcement (AT) 쎻
14 Connecting rod cap
쎻
3 Flywheel (MT) 쎻
15 Crankshaft
쎻
4 Bell bearing (MT) 쎻
16 Woodruff key
쎻
5 Top ring 쎻
17 Crankshaft bearing #1, #5
쎻
6 Second ring 쎻
18 Crankshaft bearing #2, #4
쎻
7 Oil ring 쎻
19 Crankshaft bearing #3
쎻
8 Piston
쎻
9 Piston pin Tightening torque: N⋅m (kg-m, ft-lb)
T1: 44±2 (4.5±0.2, 32.5±1.4)
쎻
10 Circlip
T2: 72±3 (7.3±0.3, 52.8±2.2)
쎻
11 Connecting rod bolt
쎻
12 Connecting rod

10
 SERVICE PROCEDURE 2-3
1. General Precautions - 2. Hydraulic Lash Adjuster

1. 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) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
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.

2. Hydraulic Lash Adjuster

A: INSPECTION
1) Disconnect blow-by hose from rocker cover.
2) Remove spark plug cap.

3) Remove left and right rocker covers.

CAUTION:
Before removing left rocker cover, disconnect battery
cables and generator cable.

B2M0413A

11
 SERVICE PROCEDURE 2-3
1. General Precautions - 2. Hydraulic Lash Adjuster

1. 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) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
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.

2. Hydraulic Lash Adjuster

A: INSPECTION
1) Disconnect blow-by hose from rocker cover.
2) Remove spark plug cap.

3) Remove left and right rocker covers.

CAUTION:
Before removing left rocker cover, disconnect battery
cables and generator cable.

B2M0413A

11
2-3 SERVICE PROCEDURE
2. Hydraulic Lash Adjuster

4) Manually push valve rocker (at lash adjuster location) to

check that there is no air in it.
NOTE:
When air is in lash adjuster, valve rocker moves when
pushed with fingers.

G2M0198

5) If air is in lash adjuster, remove valve rocker assembly

from engine and bleed air completely.

G2M0199

B: AIR BLEEDING
1) Remove valve rocker assembly.
(1) Remove bolts 쎻 1 through 쎻4 in numerical
sequence.
CAUTION:
Leave two or three threads of bolt 쎻 1 engaged to retain
valve rocker assembly.
(2) Equally loosen bolts 쎻 5 through 쎻 8 all the way,
B2M0382A
being careful that knock pin is not gouged.

2) Manually remove lash adjusters where air is trapped.

CAUTION:
If lash adjuster is difficult to remove manually, use pli-
ers. Be careful not to scratch lash adjuster.

12
 SERVICE PROCEDURE 2-3
2. Hydraulic Lash Adjuster

3) Bleed air from hydraulic lash adjuster as described

below:
(1) While dipping hydraulic lash adjuster in engine oil,
as shown in Figure, push check ball in using a 2 mm
(0.08 in) diameter round bar.
(2) With check ball pushed in, manually move plunger
up and down at one second intervals until air bubbles
disappear.
(3) After air bubbles disappear, remove round bar and
G2M0131 quickly push plunger in to ensure it is locked. If plunger
does not lock properly, replace hydraulic lash adjuster.
CAUTION:
Leave hydraulic lash adjuster (after air is bled) in
engine oil until it is ready for installation.

4) Using ST;
(1) Insert lash adjuster into ST, and fill ST with engine
oil. Using a 2 mm (0.08 in) diameter rod, push check
ball in.
ST 499597000 OIL SEAL GUIDE
(2) With check ball pushed in, push plunger at an inter-
val of one second.
(3) Move plunger up and down until air bubbles are no
longer emitted from lash adjuster.
G2M0200
NOTE:
Hold hydraulic lash adjusters vertically during air bleeding.

5) Remove the rod. Push plunger to ensure that air is

completely bled out.
CAUTION:
If plunger does not properly lock (when pushed),
replace lash adjuster with a new one.

13
2-3 SERVICE PROCEDURE
2. Hydraulic Lash Adjuster

6) Fill rocker arm’s oil reservoir with engine oil and install
lash adjuster.
CAUTION:
쐌 Do not rotate lash adjuster during installation.
쐌 Be careful not to scratch the oil seal.

CAUTION:
When removing valve rocker assembly, keep the
assembly soaked in engine oil, or position it with air
bleeding orifice on rocker arm facing upward as
shown. This prevents oil leakage from and air entering
into the hydraulic lash adjuster. Failure to do so may
cause air to enter the hydraulic lash adjuster, causing
loss in performance.

B2M0414

7) Temporarily and equally tighten bolts 쎻

1 through 쎻4 . Do
not allow knock pin to catch valve rocker assembly.
5 through 쎻
8) Tighten bolts 쎻 8 to specified torque.
1 through 쎻
9) Tighten bolts 쎻 4 to specified torque.
Tightening torque:
12±1 N⋅m (1.2±0.1 kg-m, 8.7±0.7 ft-lb)

B2M0382B

10) Install rocker covers.

Tightening torque:
5±1 N⋅m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)

11) Connect harness connectors, hoses, etc. to their posi-

tions.

14
 SERVICE PROCEDURE 2-3
3. Timing Belt

3. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER

G2M0107

1) Remove V-belt and A/C belt tensioner.

2) Remove pulley bolt. To lock crankshaft use ST.
ST 499977000 CRANKSHAFT PULLEY WRENCH
3) Remove crankshaft pulley.
4) Remove left side belt cover.
5) Remove right side belt cover.
6) Remove front belt cover.

G2M0108

15
2-3 SERVICE PROCEDURE
3. Timing Belt

2. TIMING BELT

B2M0415A

1) If alignment mark 쎻 2 and/or arrow mark (which indicates

rotation direction) on timing belt fade away, put new marks
before removing timing belt as follows:

G2M0616

(1) Turn crankshaft, and align alignment marks 쎻 2 on

crankshaft sprocket, and left and right camshaft
sprockets with notches 쎻 1 of belt cover and cylinder
block.
ST 499987500 CRANKSHAFT SOCKET

B2M0064A

16
 SERVICE PROCEDURE 2-3
3. Timing Belt

(2) Using white paint, put alignment and/or arrow

marks on timing belts in relation to the sprockets.
Z1: 44 tooth length
Z2: 40.5 tooth length

G2M0111

2) Loosen tensioner adjuster mounting bolts.

B2M0065

3) Remove belt idler.

4) Remove belt idler No. 2.
5) Remove timing belt.
6) Remove tensioner adjuster.

17
2-3 SERVICE PROCEDURE
3. Timing Belt

3. BELT TENSIONER AND IDLER

G2M0112

1) Remove belt idler.

2) Remove belt tensioner and spacer.
3) Remove belt tensioner adjuster.

18
 SERVICE PROCEDURE 2-3
3. Timing Belt

4. SPROCKET

B2M0416A

1) Remove left side camshaft sprocket.

2) Remove right side camshaft sprocket. To lock camshaft
use ST.
ST 499207100 CAMSHAFT SPROCKET WRENCH

G2M0114

3) Remove crankshaft sprocket.

4) Remove left side belt cover No. 2.
5) Remove right side belt cover No. 2.
CAUTION:
Do not damage or lose the seal rubber when removing
belt covers.
6) Remove tensioner bracket.

19
2-3 SERVICE PROCEDURE
3. 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:
쐌 Be careful not to let oil, grease or coolant contact
the belt. Remove quickly and thoroughly if this hap-
pens.

쐌 Do not bend the belt sharply.

Bending radius: h
60 mm (2.36 in) or more

G2M0115

2. BELT TENSION ADJUSTER

1) Visually check oil seals for leaks, and rod ends for
abnormal wear or scratches. If necessary, replace belt ten-
sion adjuster.
CAUTION:
Slight traces of oil at rod’s oil seal does not indicate a
problem.
2) While holding tensioner with both hands, push the rod
section against floor or wall ensuring the rod section will
react as follows:
(1) When applying a force of 147 N (15 kg, 33 lb), the
rod section should not sink.
(2) When applying a force of 147 to 490 N (15 to 50 kg,
33 to 110 lb), the rod section should maintain a projec-
tionally acting force and should not sink within 8.5 sec-
onds.

20
 SERVICE PROCEDURE 2-3
3. Timing Belt

3) Measure the extension of rod beyond the body. If it is

not within specifications, replace with a new one.
Rod extension: H
15.4 — 16.4 mm (0.606 — 0.646 in)

B2M0108A

3. BELT TENSIONER
1) Check mating surfaces of timing belt and contact point
of tension adjuster rod for abnormal wear or scratches.
Replace belt tensioner if faulty.
2) Check spacer and tensioner bushing for wear.
3) Check tensioner for smooth rotation. Replace if noise or
excessive play is noted.
4) Check tensioner for grease leakage.

4. BELT IDLER
1) Check idler for smooth rotation. Replace if noise or
excessive play is noted.
2) Check outer contacting surfaces of idler pulley for
abnormal wear and scratches.
3) Check idler for grease leakage.

5. 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.

21
2-3 SERVICE PROCEDURE
3. Timing Belt

C: INSTALLATION
1. SPROCKET

B2M0416B

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 25±2 (2.5±0.2, 18.1±1.4)
T3: 78±5 (8.0±0.5, 57.9±3.6)

1) Install right side belt cover No. 2.

2) Install tensioner bracket.
3) Install left side belt cover No. 2.
4) Install crankshaft sprocket.
5) Install right side camshaft sprocket and left side cam-
shaft sprocket. To lock camshaft use ST.
ST 499207100 CAMSHAFT SPROCKET WRENCH
CAUTION:
Do not confuse left and right side camshaft sprockets
G2M0114
during installation. The left side camshaft sprocket is
identified by a projection used to monitor cam angle
sensor.

22
 SERVICE PROCEDURE 2-3
3. Timing Belt

2. BELT TENSIONER AND IDLER

B2M0070A

Tightening torque: N⋅m (kg-m, ft-lb)

T: 39±4 (4.0±0.4, 28.9±2.9)

1) Installation of belt tension adjuster

Insert stopper pin 1.5 mm (0.059 in) diameter into place
while pushing tension adjuster rod into body using a press.
CAUTION:
쐌 Do not allow press pressure to exceed 9,807 N (1,000
kg, 2,205 lb).
쐌 Do not release press pressure until stopper pin is
completely inserted.
쐌 Push tension adjuster rod vertically.
쐌 Press-in the push rod gradually taking three minutes
or more.

B2M0109A

23
2-3 SERVICE PROCEDURE
3. Timing Belt

2) Install belt tensioner and spacer.

3) Install belt idler.

4) Temporarily tighten bolts while belt tension adjuster is

pushed all the way to the right.

B2M0110

3. TIMING BELT

B2M0071A

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 25±2 (2.5±0.2, 18.1±1.4)
T2: 39±4 (4.0±0.4, 28.9±2.9)

24
 SERVICE PROCEDURE 2-3
3. Timing Belt

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

G2M0122

(2) While aligning alignment mark on timing belt with

marks on sprockets, position timing belt properly.
CAUTION:
Ensure belt’s rotating direction is correct.

B2M0417A

2) Install belt idler No. 2.

3) Install belt idler.

4) Loosen belt tension adjuster attaching bolts and move

adjuster all the way to the left. Tighten the bolts.

B2M0111

5) After ensuring that the marks on timing belt and cam-

shaft sprockets are aligned, remove stopper pin from belt
tension adjuster.
CAUTION:
After properly installing timing belt, remove rocker
cover and ensure that the valve lash adjuster contains
no air.

G2M0125

25
2-3 SERVICE PROCEDURE
3. Timing Belt

4. CRANKSHAFT PULLEY AND BELT COVER

G2M0126

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 127±10 (13.0±1.0, 94±7)

1) Install front belt cover.

2) Install right side belt cover.
3) Install left side belt cover.
4) Install crankshaft pulley.

5) Install pulley bolt.

To lock crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY WRENCH
6) Install V-belt.

G2M0108

26
 SERVICE PROCEDURE 2-3
4. Valve Rocker Assembly

4. Valve Rocker Assembly

A: REMOVAL

B2M1206A

1) Disconnect PCV hose and remove rocker cover.

2) Removal of valve rocker assembly
(1) Remove bolts 쎻 1 through 쎻 4 in numerical sequence.
CAUTION:
Leave two or three threads of bolt 쎻 1 engaged to retain
valve rocker assembly.
(2) Equally loosen bolts 쎻5 through 쎻8 all the way, being
careful that knock pin is not gouged.
B2M1207A (3) Remove valve rocker assembly.

27
2-3 SERVICE PROCEDURE
4. Valve Rocker Assembly

B: DISASSEMBLY

B2M1264A

1) Remove bolts which secure rocker shaft.

2) Extract rocker shaft. Remove valve rocker arms,
springs and shaft supports from rocker shaft.
CAUTION:
Arrange all removed parts in order so that they can be
installed in their original positions.

3) Loosen rocker nut, and then remove rocker screw and

nut from rocker arm.
CAUTION:
Do not remove rocker screw and nut unless necessary.

28
 SERVICE PROCEDURE 2-3
4. Valve Rocker Assembly

C: INSPECTION
1. HYDRAULIC LASH ADJUSTER
1) Bleed air from hydraulic lash adjuster as described
below:
(1) While dipping hydraulic lash adjuster in engine oil,
as shown in Figure, push check ball in using a 2 mm
(0.08 in) diameter round bar.
(2) With check ball pushed in, manually move plunger
up and down at one second intervals until air bubbles
G2M0131
disappear.
(3) After air bubbles disappear, remove round bar and
quickly push plunger in to ensure it is locked. If plunger
does not lock properly, replace hydraulic lash adjuster.
CAUTION:
Leave hydraulic lash adjuster (after air is bled) in
engine oil until it is ready for installation.

2) Replace hydraulic lash adjuster with a new one if valve

contact surface is scratched.

29
2-3 SERVICE PROCEDURE
4. Valve Rocker Assembly

2. VALVE ROCKER ARM

1) Measure inside diameter of valve rocker arm and out-
side diameter of valve rocker shaft, and determine the dif-
ference 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)
B2M0072
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
B2M0073 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)
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.

3. VALVE ROCKER SHAFT

Visually check oil relief valve of shaft end for any of the
following abnormalities.
쐌 Breaks in check ball body
쐌 Foreign particles caught in valve spring
쐌 Oil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as necessary.

30
SERVICE PROCEDURE 2-3
4. Valve Rocker Assembly

D: ASSEMBLY

B2M1264B

Tightening torque: N⋅m (kg-m, ft-lb)

T: 5±1 (0.5±0.1, 3.6±0.7)

1) Install rocker adjust screw and nut to rocker arm, and

loosely tighten nut.

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 쎻
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 쎻
B with bolts.

31
2-3 SERVICE PROCEDURE
4. Valve Rocker Assembly

E: INSTALLATION

B2M1206B

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)

1) Installation of valve rocker assembly

(1) Temporarily tighten bolts 쎻 1 through 쎻 4 equally as
shown in Figure.
CAUTION:
Do not allow valve rocker assembly to gouge knock
pins.
(2) Tighten bolts 쎻 5 through 쎻 8 to specified torque.
(3) Tighten bolts 쎻 1 through 쎻 4 to specified torque.

B2M1207B

2) Adjust the valve clearances. <Ref. to 2-2 [07B1].>

3) Install rocker cover and connect PCV hose.

32
SERVICE PROCEDURE 2-3
5. Camshaft

5. Camshaft
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and related
parts.
<Ref. to 2-3 [W3A0].>
2) Remove valve rocker assembly.
<Ref. to 2-3 [W4A0].>

2. CAMSHAFT LH

B2M0384A

1) Remove oil level gauge guide attaching bolt.

2) Remove camshaft support LH.
CAUTION:
Do not damage the camshaft position sensor.
3) Remove O-ring.
4) Remove camshaft LH.
5) Remove oil seal.
CAUTION:
쐌 Do not remove oil seal unless necessary.
쐌 Do not scratch journal surface when removing oil
seal.

33
2-3 SERVICE PROCEDURE
5. Camshaft

3. CAMSHAFT RH

B2M0385A

1) Remove camshaft support RH.

2) Remove O-ring.
3) Remove camshaft.
4) Remove oil seal.
CAUTION:
쐌 Do not remove oil seal unless necessary.
쐌 Do not scratch journal surface when removing oil
seal.

B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Limit:
0.025 mm (0.0010 in)

G2M0137

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 clear-
ance exceeds specifications, replace camshaft or cylinder
head as necessary.

34
 SERVICE PROCEDURE 2-3
5. Camshaft

Unit: mm (in)
Right-hand camshaft Front Center Rear
Item
Left-hand camshaft Rear Center Front
Standard 0.055 — 0.090 (0.0022 — 0.0035)
Clearance at journal
Limit 0.10 (0.0039 )
31.935 — 31.950 37.435 — 37.450 37.935 — 37.950
Camshaft journal O.D.
(1.2573 — 1.2579) (1.4738 — 1.4744) (1.4935 — 1.4941)
32.005 — 32.025 37.505 — 37.525 38.005 — 38.025
Journal hole I.D.
(1.2600 — 1.2608) (1.4766 — 1.4774) (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)
B2M1209A 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 sup-
port.
Standard:
0.030 — 0.260 mm (0.0012 — 0.0102 in)
Limit:
0.35 mm (0.0138 in)
G2M0139

35
2-3 SERVICE PROCEDURE
5. Camshaft

C: INSTALLATION
1. CAMSHAFT LH

B2M0384B

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 10 (1.0, 7)
T2: 16 (1.6, 12)

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
6) Install oil level gauge guide bolt.

G2M0141

36
 SERVICE PROCEDURE 2-3
5. Camshaft

2. CAMSHAFT RH

B2M0385B

Tightening torque: N⋅m (kg-m, ft-lb)

T: 16 (1.6, 12)

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

G2M0143

37
2-3 SERVICE PROCEDURE
5. Camshaft - 6. Cylinder Head

3. RELATED PARTS
1) Install valve rocker assembly.
<Ref. to 2-3 [W4E0].>

B2M0418B

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) Install timing belt, camshaft sprockets and related parts.

<Ref. to 2-3 [W3C0].>

6. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain engine coolant. <Ref. to 2-5 [W1A0].>
3) Remove intake manifold. <Ref. to 2-7 [W4A0].>
4) Remove engine coolant pipe.

38
2-3 SERVICE PROCEDURE
5. Camshaft - 6. Cylinder Head

3. RELATED PARTS
1) Install valve rocker assembly.
<Ref. to 2-3 [W4E0].>

B2M0418B

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) Install timing belt, camshaft sprockets and related parts.

<Ref. to 2-3 [W3C0].>

6. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain engine coolant. <Ref. to 2-5 [W1A0].>
3) Remove intake manifold. <Ref. to 2-7 [W4A0].>
4) Remove engine coolant pipe.

38
 SERVICE PROCEDURE 2-3
6. Cylinder Head

2. CYLINDER HEAD

B2M0119A

1) Remove timing belt, camshaft sprocket and related

parts.
<Ref. to 2-3 [W3A0].>
2) Remove oil level gauge guide attaching bolt (left hand
only) and oil level gauge guide.

3) Remove cylinder head bolts in numerical sequence

shown in Figure.
CAUTION:
Leave bolts 쎻 1 and 쎻3 engaged by three or four threads
to prevent cylinder head from falling.
4) While tapping cylinder head with a plastic hammer,
separate it from cylinder block.
Remove bolts 쎻 1 and 쎻3 to remove cylinder head.
5) Remove cylinder head gasket.
B2M0120A
CAUTION:
Do not scratch the mating surface of cylinder head and
cylinder block.
6) Similarly, remove right side cylinder head.

39
2-3 SERVICE PROCEDURE
6. Cylinder Head

B: DISASSEMBLY

B2M0121A

1) Remove rocker cover.

2) Remove valve rocker assembly.
<Ref. to 2-3 [W4A0].>
3) Remove camshaft and support.
<Ref. to 2-3 [W5A0].>
4) Place cylinder head on ST.
ST 498267200 CYLINDER HEAD TABLE

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:
쐌 Mark each valve to prevent confusion.
쐌 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:
B2M0386A Do not remove plug unless necessary.

40
 SERVICE PROCEDURE 2-3
6. 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 thick-
ness 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)
G2M0148
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
G2M0149 1.4 mm (0.055 in)
Exhaust
Standard
1.4 mm (0.055 in)
Limit
1.8 mm (0.071 in)

B2M0074

41
2-3 SERVICE PROCEDURE
6. 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)
B2M0387A 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)
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)
B2M0076A

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

G2M0151

(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.
(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 sur-
face of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 499767000 VALVE GUIDE ADJUSTER
B2M0388A

42
 SERVICE PROCEDURE 2-3
6. Cylinder Head

(6) Check the valve guide protrusion.

Valve guide protrusion: L
17.5 — 18.0 mm (0.689 — 0.709 in)

B2M0077A

(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.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
쐌 Apply engine oil to the reamer when reaming.
쐌 If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with an
B2M0078
oil stone.
쐌 If the inner surface of the valve guide becomes lus-
trous and the reamer does not chips, use a new reamer
or remedy the reamer.

(8) Recheck the contact condition between valve and

valve seat after replacing valve guide.

43
2-3 SERVICE PROCEDURE
6. 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)
G2M0153
2) Put a small amount of grinding compound on the seat
surface and lap the valve and seat surface. Also refer to 2.
VALVE SEAT 2-3 [W6C2] at this time. Install a new intake
valve oil seal after lapping.

5. VALVE SPRINGS
1) Check valve springs for damage, free length, and ten-
sion. 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)
G2M0154
174.6 — 200.1 N
(17.8 — 20.4 kg, 39.2 — 45.0 lb)/ 36.0 mm
(1.417 in)
Tension/spring height
405.0 — 458.0 N
(41.3 — 46.7 kg, 91.1 — 103.0 lb)/
28.2 mm (1.110 in)

44
 SERVICE PROCEDURE 2-3
6. Cylinder Head

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.
ST1 498267200 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
B2M0389A
CAUTION:
쐌 Apply engine oil to oil seal before press-fitting.
쐌 When press-fitting oil seal, do not use hammer or
strike in.
쐌 Differentiate between intake valve oil seal and
exhaust valve oil seal by noting their difference in
color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [White]
Exhaust [White]

45
2-3 SERVICE PROCEDURE
6. Cylinder Head

D: ASSEMBLY

B2M0121B

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)

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.

46
 SERVICE PROCEDURE 2-3
6. Cylinder Head

(3) Install valve spring and retainer.

CAUTION:
Be sure to install the valve springs with their painted
facing towards the valve spring retainer.
(4) Set ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
(5) Compress valve spring and fit valve spring retainer
key.
B2M0386A

(6) After installing, tap valve spring retainers lightly

with wooden hammer for better seating.

B2M1210A

3) Install camshaft and support.

<Ref. to 2-3 [W5C0].>
4) Install valve rocker assembly.
<Ref. to 2-3 [W4E0].>
5) Install rocker cover.

47
2-3 SERVICE PROCEDURE
6. Cylinder Head

E: INSTALLATION
1. CYLINDER HEAD

B2M0119B

1) Install cylinder head and gaskets on cylinder block.

CAUTION:
Use new cylinder head gaskets.

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
numerical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kg-m, 51 ft-lb) in
numerical sequence.
(3) Back off all bolts by 180° first; back them off by 180°
again.
B2M0120B (4) Tighten bolts 쎻 1 and 쎻 2 to 34 N⋅m (3.5 kg-m, 25 ft-
lb).
(5) Tighten bolts 쎻 3 ,쎻4 ,쎻5 and 쎻 6 to 15 N⋅m (1.5 kg-m,
11 ft-lb).
(6) Tighten all bolts by 80 to 90° in numerical
sequence.
CAUTION:
Do not tighten bolts more than 90°.

48
SERVICE PROCEDURE 2-3
6. Cylinder Head

(7) Further tighten all bolts by 80 to 90° in numerical

sequence.
CAUTION:
Ensure that the total “re-tightening angle” [steps (6)
and (7) above] do not exceed 180°.

3) Install oil level gauge guide attaching bolt (left side

only).
4) Install timing belt, camshaft sprocket and related parts.
<Ref. to 2-3 [W3C0].>

2. INTAKE MANIFOLD
CAUTION:
Use dry compressed air to remove foreign particles
before installing each solenoid valve and sensor.
1) Install engine coolant pipe.
2) Install intake manifold. <Ref. to 2-7 [W4D0].>
3) Remove ENGINE STAND (ST).

49
2-3 SERVICE PROCEDURE
7. Cylinder Block

7. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprocket and related
parts.
<Ref. to 2-3 [W3A0].>
2) Remove intake manifold and cylinder head.
<Ref. to 2-3 [W6A0].>

2. OIL PUMP AND ENGINE COOLANT PUMP

B2M0124A

50
 SERVICE PROCEDURE 2-3
7. Cylinder Block

1) Remove housing cover.

2) Remove flywheel or drive plate.

To lock crankshaft use ST.
ST 498497100 CRANKSHAFT STOPPER

G2M0161

3) Remove oil separator cover.

4) Remove engine coolant pipe.
5) Remove engine coolant 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 cylin-
der block and oil pump.

G2M0162

51
2-3 SERVICE PROCEDURE
7. Cylinder Block

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-
G2M0163
pan cutter.
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.

B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK
CONNECTING BOLT

G2M0164

52
 SERVICE PROCEDURE 2-3
7. Cylinder Block

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

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.
4) Similarly remove piston pins from #3 and #4 pistons by
using ST.

G2M0166

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.

53
2-3 SERVICE PROCEDURE
7. Cylinder Block

2. CYLINDER BLOCK
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 con-
necting rod to fall and damage the cylinder block.
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.
6) Draw out each piston from cylinder block using wooden
bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cylinder.

G2M0167

54
SERVICE PROCEDURE 2-3
7. Cylinder Block

3. CRANKSHAFT AND PISTON

G2M0168

1) Remove connecting rod cap.

2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting rod cap
and bearing in order to prevent confusion.

3) Remove piston rings using the piston ring expander.

4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good order to
prevent confusion.
5) Remove circlip.

55
2-3 SERVICE PROCEDURE
7. Cylinder Block

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)

2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades, “A”
and “B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 96.905 — 96.915 mm (3.8151 — 3.8155 in)
B: 96.895 — 96.905 mm (3.8148 — 3.8151 in)

B2M0082A

56
 SERVICE PROCEDURE 2-3
7. Cylinder Block

2) How to measure the inner diameter of each cylinder

Measure the inner diameter of each cylinder in both the
thrust and piston pin directions at the heights shown in the
Figure, using a cylinder bore gauge.
CAUTION:
Measurement should be performed at a temperature
20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When piston is to be replaced due to general or cylin-
der wear, determine a suitable sized piston by measuring
G2M0170
the piston clearance.

4) How to measure the outer diameter of each piston

Measure the outer diameter of each piston at the height
shown in the Figure. (Thrust direction)
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Piston grade point H:
40.0 mm (1.575 in)
Piston outer diameter:
B2M1305A
Standard
A: 96.885 — 96.895 mm (3.8144 — 3.8148 in)
B: 96.875 — 96.885 mm (3.8140 — 3.8144 in)
0.25 mm (0.0098 in) oversize
97.115 — 97.145 mm (3.8234 — 3.8246 in)
0.50 mm (0.0197 in) oversize
97.365 — 97.395 mm (3.8333 — 3.8344 in)
5) Calculate the clearance between cylinder and piston.
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)

57
2-3 SERVICE PROCEDURE
7. Cylinder Block

6) Boring and honing

(1) If the value of taper, out-of-roundness, or cylinder-
to-piston clearance measured exceeds the specified
limit or if there is any damage on the cylinder wall,
rebore it to use an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all other
cylinders must be bored at the same time, and use
oversize pistons. Do not perform boring on one cylin-
der only, nor use an oversize piston for one cylinder
only.
(2) If the cylinder inner diameter exceeds the limit after
boring and honing, replace the crankcase.
CAUTION:
Immediately after reboring, the cylinder diameter may
differ from its real diameter due to temperature rise.
Thus, pay attention to this when measuring the cylin-
der diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1) Check pistons and piston pins for damage, cracks, and
wear and the piston ring grooves for wear and damage.
Replace if defective.

2) Measure the piston-to-cylinder clearance at each cylin-

der as instructed in 2. CYLINDER AND PISTON 2-3
[W7C2]. If any of the clearances is not to specification,
replace the piston or bore the cylinder to use an oversize
piston.

3) Make sure that piston pin can be inserted into the pis-
ton pin hole with a thumb at 20°C (68°F). Replace if defec-
tive.
Standard clearance between piston pin and hole in
piston:
Standard
0.004 — 0.010 mm (0.0002 — 0.0004 in)
Limit
0.020 mm (0.0008 in)
B2M0083

58
 SERVICE PROCEDURE 2-3
7. Cylinder Block

B2M0084A

4) Check circlip installation groove on the piston for burr.

If necessary, remove burr from the groove so that piston
pin can lightly move.
5) Check piston pin circlip for distortion, cracks and wear.

B2M0420A

4. PISTON RING
1) If piston ring is broken, damaged, or worn, or if its ten-
sion is insufficient, or when the piston is replaced, replace
piston ring with a new one of the same size as the piston.
CAUTION:
쐌 “R” is marked on the end of the top and second
rings. When installing the rings to the piston, face this
mark upward.

G2M0623

쐌 The oil ring is a combined ring consisting of two

rails and a spacer in between. When installing, be care-
ful to assemble correctly.

G2M0624

2) Squarely place piston ring and oil ring in cylinder, and

measure the piston ring gap with a thickness gauge.
Unit: mm (in)
Standard Limit
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston 0.20 — 0.50
Second ring 1.0 (0.039)
ring gap (0.0079 — 0.0197)
0.20 — 0.70
Oil ring rail 1.5 (0.059)
(0.0079 — 0.0276)
G2M0174

59
2-3 SERVICE PROCEDURE
7. Cylinder Block

3) Measure the clearance between piston ring and piston

ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the piston ring
groove and piston ring.
Unit: mm (in)
Standard Limit
0.040 — 0.080
Clearance Top ring (0.0016 — 0.15 (0.0059)
G2M0175
between piston 0.0031)
ring and piston 0.030 — 0.070
ring groove Second ring (0.0012 — 0.15 (0.0059)
0.0028)

5. CONNECTING ROD
1) Replace connecting rod, if the large or small end thrust
surface is damaged.

2) Check for bend or twist using a connecting rod aligner.

Replace connecting rod if the bend or twist exceeds the
limit.
Limit of bend or twist per 100 mm (3.94 in) in length:
0.10 mm (0.0039 in)
쎻1 Thickness gauge
쎻2 Connecting rod

G2M0196

60
 SERVICE PROCEDURE 2-3
7. Cylinder Block

3) Install connecting rod fitted with bearing to crankshaft

and measure the side clearance (thrust clearance).
Replace connecting rod if the side clearance exceeds the
specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
G2M0176

4) Inspect connecting rod bearing for scar, peeling,

seizure, melting, wear, etc.

5) Measure the oil clearance on individual connecting rod

bearings by means of plastigauge. If any oil clearance is
not within specification, replace the defective bearing with
a new one of standard size or undersize as necessary.
(See the table below.)
Connecting rod oil clearance:
Standard
0.015 — 0.045 mm (0.0006 — 0.0018 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size Outer diameter of
Bearing
(Thickness at center) crank pin
1.492 — 1.501 51.984 — 52.000
Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.03 (0.0012) 1.510 — 1.513 51.954 — 51.970
undersize (0.0594 — 0.0596) (2.0454 — 2.0461)
0.05 (0.0020) 1.520 — 1.523 51.934 — 51.950
undersize (0.0598 — 0.0600) (2.0446 — 2.0453)
0.25 (0.0098) 1.620 — 1.623 51.734 — 51.750
undersize (0.0638 — 0.0639) (2.0368 — 2.0374)

61
2-3 SERVICE PROCEDURE
7. Cylinder Block

6) Inspect bushing at connecting rod small end, and

replace if worn or damaged. Also measure the piston pin
clearance at the connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 — 0.022 mm (0 — 0.0009 in)
Limit
0.030 mm (0.0012 in)

B2M0085

B2M0084A

7) Replacement procedure is as follows.

(1) Remove bushing from connecting rod with ST and
press.
(2) Press bushing with ST after applying oil on the
periphery of bushing.
ST 499037100 CONNECTING ROD BUSHING
REMOVER AND INSTALLER
(3) Make two 3 mm (0.12 in) holes in bushing. Ream
the inside of bushing.
G2M0177
(4) After completion of reaming, clean bushing to
remove chips.

6. CRANKSHAFT AND CRANKSHAFT BEARING

1) Clean crankshaft completely and check for cracks by
means of red lead check etc., and replace if defective.

62
 SERVICE PROCEDURE 2-3
7. Cylinder Block

2) Measure the crankshaft bend, and correct or replace if

it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1 and #5
crankshaft bearing on cylinder block, position crank-
shaft on these bearings and measure crankshaft bend
using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0178

3) Inspect the crank journal and crank pin for wear. If not
to specifications, replace bearing with an undersize one,
and replace or recondition crankshaft as necessary. When
grinding crank journal or crank pin, finish them to the speci-
fied dimensions according to the undersize bearing to be
used.
Crank pin and crank journal:
Out-of-roundness
0.030 mm (0.0012 in) or less
G2M0179 Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)
Unit: mm (in)

Crank journal diameter

Crank pin diameter
#1, #5 #2, #3, #4
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
center)
59.962 — 59.978 59.954 — 59.970 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3604 — 2.3610) (2.0454 — 2.0461)
0.03 (0.0012)
undersize Bearing size
2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
center)
59.934 — 59.950 59.934 — 59.950 51.934 — 51.950
Journal O.D.
(2.3596 — 2.3602) (2.3596 — 2.3602) (2.0446 — 2.0453)
0.05 (0.0020)
undersize Bearing size
2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
center)
59.742 — 59.758 59.734 — 59.750 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3517 — 2.3524) (2.0368 — 2.0374)
0.25 (0.0098)
undersize Bearing size
2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
center)
O.D. ... Outer Diameter

63
2-3 SERVICE PROCEDURE
7. Cylinder Block

4) Measure the thrust clearance of crankshaft at center

bearing. If the clearance exceeds the limit, replace bearing.
Crankshaft thrust clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)

G2M0180

5) Inspect individual crankshaft bearings for signs of

flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft bearing
by means of plastigauge. If the measurement is not within
the specification, replace defective bearing with an under-
size one, and replace or recondition crankshaft as neces-
sary.
Unit: mm (in)
Crankshaft oil clearance
0.003 — 0.030
#1, #5
(0.0001 — 0.0012)
Standard
0.010 — 0.033
#2, #3, #4
(0.0004 — 0.0013)
#1, #3, #5 0.040 (0.0016)
Limit
#2, #4 0.035 (0.0014)

64
SERVICE PROCEDURE 2-3
7. Cylinder Block

D: ASSEMBLY
1. CRANKSHAFT AND PISTON

B2M0127A

Tightening torque: N⋅m (kg-m, ft-lb)

T: 44±2 (4.5±0.2, 32.5±1.4)

1) Install connecting rod bearings on connecting rods and

connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod bear-
ings.
2) Install connecting rod on crankshaft.
CAUTION:
Position each connecting rod with the side marked
facing forward.
3) Install connecting rod cap with connecting rod nut.
Ensure the arrow on connecting rod cap faces the front
during installation.
CAUTION:
쐌 Each connecting rod has its own mating cap. Make
sure that they are assembled correctly by checking
their matching number.
쐌 When tightening the connecting rod nuts, apply oil
on the threads.

65
2-3 SERVICE PROCEDURE
7. Cylinder Block

4) Installation of piston rings and oil ring

(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180° on the reverse
side for the top ring gap.

B2M1211A

(4) Position the upper rail gap at C or D in the Figure.

(5) Position the expander gap at 180° of the reverse
side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
쐌 Ensure ring gaps do not face the same direction.
쐌 Ensure ring gaps are not within the piston skirt area.

B2M1212A

5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark “쎻” facer toward front of engine.
G2M0183

66
 SERVICE PROCEDURE 2-3
7. Cylinder Block

2. CYLINDER BLOCK
1) Install ST to cylinder block, then install crankshaft bear-
ings.
ST 499817000 ENGINE STAND
CAUTION:
Remove oil the mating surface of bearing and cylinder
block before installation. Also apply a coat of engine
oil to crankshaft pins.
2) Position crankshaft on the #2 and #4 cylinder block.
Tightening torque:
T1: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
T2: 47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)

B2M0087A

67
2-3 SERVICE PROCEDURE
7. Cylinder Block

3) Apply fluid packing to the mating surface of #1 and #3

cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring grooves,
oil passages, bearing grooves, etc.

G2M0185

4) Temporarily tighten 10 mm cylinder block connecting

bolts in numerical order shown in Figure.
5) Tighten 10 mm cylinder block connecting bolts in
numerical order.
Tightening torque:
47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)

B2M0088A

6) Tighten 8 mm and 6 mm cylinder block connecting bolts

in numerical order shown in Figure.
Tightening torque:
1 — 쎻
쎻 7 : 25±2 N⋅m
(2.5±0.2 kg-m, 18.1±1.4 ft-lb)
쎻8 : 6.4 N⋅m (0.65 kg-m, 4.7 ft-lb)

B2M0089A

7) Install rear oil seal by using ST1 and ST2.

ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER

G2M0186

68
 SERVICE PROCEDURE 2-3
7. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)

B2M0128A

Tightening torque: N⋅m (kg-m, ft-lb)

T: 69±7 (7.0±0.7, 50.6±5.1)

1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylinders face
upward.
(2) Using ST1, turn crankshaft so that #1 and #2 con-
necting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cylinders
and insert pistons in their cylinders by using ST2.
ST2 498747100 PISTON GUIDE
G2M0188

2) Installing piston pin

(1) Insert ST3 into service hole to align piston pin hole
with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE

G2M0189

69
2-3 SERVICE PROCEDURE
7. Cylinder Block

(2) Apply a coat of engine oil to piston pin and insert

piston pin into piston and connecting rod through ser-
vice hole.

(3) Install circlip.

CAUTION:
Use new circlips.

G2M0190

(4) Install service hole plug and gasket.

CAUTION:
Use a new gasket and apply a coat of fluid packing to
it before installation.
Fluid packing:
THREE BOND 1215 or equivalent

70
SERVICE PROCEDURE 2-3
7. Cylinder Block

4. PISTON AND PISTON PIN (#3 AND #4)

B2M0129A

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 6.4 (0.65, 4.7)
T2: 69±7 (7.0±0.7, 50.6±5.1)

Turn cylinder block so that #3 and #4 cylinders face

upward. Using the same procedures as used for #1 and #2
cylinders, install pistons and piston pins.

71
2-3 SERVICE PROCEDURE
7. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP

B2M0124B

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: 72±3 (7.3±0.3, 52.8±2.2)
T5: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)

72
 SERVICE PROCEDURE 2-3
7. Cylinder Block

1) Install baffle plate.

2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent

G2M0084

5) Apply fluid packing to matching surfaces and install oil

separator cover.
Fluid packing:
THREE BOND 1215 or equivalent

G2M0194

6) Install flywheel or drive plate.

To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.

G2M0161

8) Installation of oil pump

(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER

G2M0076

73
2-3 SERVICE PROCEDURE
7. Cylinder Block

(2) Apply fluid packing to matching surface of oil pump.

Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
쐌 Do not forget to install O-ring and seal when install-
ing oil pump.
쐌 Align flat surface of oil pump’s inner rotor with
B2M0390A
crankshaft before installation.
9) Install engine coolant pump and gasket.
CAUTION:
쐌 Be sure to use a new gasket.
쐌 When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.

G2M0628

10) Install engine coolant pipe.

11) Install oil filter.

2. RELATED PARTS
1) Install cylinder head and intake manifold.
<Ref. to 2-3 [W6E0].>
2) Install timing belt, camshaft sprocket and related parts.
<Ref. to 2-3 [W3C0].>

74
 DIAGNOSTICS 2-3
1. Engine Trouble in General

1. Engine Trouble in General

Numbers shown in the chart refer to the possibility of reason for the
trouble in order (“Very often” to “Rarely”)
1 — Very often
2 — Sometimes
3 — Rarely

TROUBLE

Engine will not start. Low output, hesitation and poor acceleration
Engine stalls after initial combustion.

Excessive engine oil consumption

Initial combustion does not occur.

After burning in exhaust system

Engine does not return to idle.

Excessive fuel consumption

Rough idle and engine stall
Initial combustion occurs.
Starter does not turn.

Dieseling (Run-on)

Knocking
Surging

POSSIBLE CAUSE
STARTER
2 쐌 Defective battery-to-starter harness
3 쐌 Defective starter switch
3 쐌 Defective inhibitor switch
2 3 쐌 Defective starter
BATTERY
1 쐌 Poor terminal connection
1 쐌 Run-down battery
2 쐌 Defective charging system
Fuel injection system <Ref. to 2-7 On-Board
1 1 1 1 1 1 1 1 1 1 1
Diagnostics II System.>

75
2-3 DIAGNOSTICS
1. Engine Trouble in General

TROUBLE

Low output, hesitation and poor acceleration

Engine will not start.

Engine stalls after initial combustion.

Excessive engine oil consumption

Initial combustion does not occur.

After burning in exhaust system

Engine does not return to idle.

Excessive fuel consumption

Rough idle and engine stall
Initial combustion occurs.
Starter does not turn.

Dieseling (Run-on)

Knocking
Surging

INTAKE SYSTEM
2 1 1 1 3 쐌 Loosened or cracked intake air pipe
3 1 1 1 3 1 쐌 Loosened or cracked blow-by hose
3 1 2 1 1 2 쐌 Loosened or cracked vacuum hose
2 2 2 2 2 쐌 Defective intake manifold gasket
2 2 2 2 2 쐌 Defective throttle body gasket
3 2 2 2 2 쐌 Defective PCV valve
2 2 2 3 2 3 쐌 Loosened oil filler cap
3 3 1 2 1 쐌 Dirty air cleaner element
FUEL LINE
1 3 3 2 2 쐌 Defective fuel pump and relay
3 3 3 2 2 쐌 Clogged fuel line
2 2 2 2 3 3 쐌 Lack of or insufficient fuel
BELT
2 2 2 쐌 Defective
2 2 2 3 2 2 2 2 2 쐌 Defective timing
FRICTION
3 쐌 Seizure of crankshaft and connecting rod bearing
3 쐌 Seized camshaft
3 쐌 Seized or stuck piston and cylinder
COMPRESSION
3 3 3 2 2 2 2 3 2 쐌 Incorrect valve clearance
3 3 3 2 2 3 3 3 쐌 Loosened spark plugs or defective gasket
3 3 3 2 2 3 3 3 쐌 Loosened cylinder head bolts or defective gasket
3 3 3 2 2 3 2 2 쐌 Improper valve seating
3 3 3 3 3 3 3 1 3 쐌 Defective valve stem
2 2 2 2 2 3 3 3 쐌 Worn or broken valve spring
3 3 3 2 3 3 3 1 2 쐌 Worn or stuck piston rings, cylinder and piston
2 2 2 1 1 1 1 2 2 쐌 Incorrect valve timing
2 2 2 2 2 2 쐌 Improper engine oil (low viscosity)

76
 DIAGNOSTICS 2-3
1. Engine Trouble in General

TROUBLE

Low output, hesitation and poor acceleration

Engine will not start.

Engine stalls after initial combustion.

Excessive engine oil consumption

Initial combustion does not occur.

After burning in exhaust system

Engine does not return to idle.

Excessive fuel consumption

Rough idle and engine stall
Initial combustion occurs.
Starter does not turn.

Dieseling (Run-on)

Knocking
Surging

LUBRICATION SYSTEM
2 2 3 3 쐌 Incorrect oil pressure
쐌 Loosened oil pump attaching bolts and defective
2
gasket
2 쐌 Defective oil filter seal
2 쐌 Defective crankshaft oil seal
3 2 쐌 Defective rocker cover gasket
2 쐌 Loosened oil drain plug or defective gasket
2 쐌 Loosened oil pan fitting bolts or defective oil pan
COOLING SYSTEM
3 3 2 2 1 쐌 Overheating
3 3 3 쐌 Over cooling
OTHERS
쐌 Malfunction of Evaporative Emission Control
1 1 3 3
System
2 1 쐌 Stuck or damaged throttle valve
3 2 2 2 쐌 Accelerator cable out of adjustment

77
2-3 DIAGNOSTICS
2. Engine Noise

2. Engine Noise
Type of sound Condition Possible cause
Valve mechanism is defective.
쐌 Incorrect valve clearance
Sound increases as engine
Regular clicking sound 쐌 Worn valve rocker
speed increases.
쐌 Worn camshaft
쐌 Broken valve spring
쐌 Worn crankshaft main bearing
Oil pressure is low.
쐌 Worn connecting rod bearing (big end)
Heavy and dull clank
쐌 Loose flywheel mounting bolts
Oil pressure is normal.
쐌 Damaged engine mounting
쐌 Ignition timing advanced
High-pitched clank Sound is noticeable when 쐌 Accumulation of carbon inside combustion chamber
(Spark knock) accelerating with an overload. 쐌 Wrong spark plug
쐌 Improper gasoline
Sound is reduced when fuel
Clank when engine speed is injector connector of noisy 쐌 Worn crankshaft main bearing
medium (1,000 to 2,000 rpm). cylinder is disconnected. 쐌 Worn bearing at crankshaft end of connecting rod
(NOTE*)
Sound is reduced when fuel
쐌 Worn cylinder liner and piston ring
injector connector of noisy
쐌 Broken or stuck piston ring
Knocking sound when engine cylinder is disconnected.
쐌 Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm. Sound is not reduced if each
fuel injector connector is 쐌 Worn camshaft journal bore in crankcase
disconnected in turn. (NOTE*)
Squeaky sound — 쐌 Insufficient generator lubrication
Rubbing sound — 쐌 Defective generator brush and rotor contact
Gear scream when starting 쐌 Defective ignition starter switch
—
engine 쐌 Worn gear and starter pinion
Sound like polishing glass with 쐌 Loose drive belt
—
a dry cloth 쐌 Defective engine coolant pump shaft
쐌 Loss of compression
Hissing sound — 쐌 Air leakage in air intake system, hoses, connections or
manifolds
쐌 Loose timing belt
Timing belt noise —
쐌 Belt contacting case/adjacent part
Valve tappet noise — 쐌 Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. (Ref. to 2-7 On-Board
Diagnostics II System.)

78
DIAGNOSTICS 2-3
2. Engine Noise

79
2-3b SPECIFICATIONS AND SERVICE DATA
1. Engine

1. Engine
A: SPECIFICATIONS
Model 2500 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke
Type
gasoline engine
Valve arrangement Belt driven, double over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 99.5 x 79.0 (3.917 x 3.110)
3
Displacement cm (cu in) 2,457 (149.93)
Compression ratio 9.5
Compression pressure Standard 1,216 (12.4, 176) − 350
(at 200 — 300 rpm)
kPa (kg/cm2, psi) − rpm Limit 941 (9.6, 137) − 350

Engine Number of piston rings Pressure ring: 2, Oil ring: 1

Opening 6° BTDC
Intake valve timing
Closing 50° ABDC
Opening Front: 54° BBDC, Rear: 30° BBDC (Position in degrees)
Exhaust valve timing
Closing Front: 10° ATDC, Rear: 10° ATDC (Position in degrees)
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
700±100 (No load)
[At neutral position on MT, or
850±50 (A/C switch ON)
“P” or “N” position on AT] rpm
Firing order 1,3,2,4
Ignition timing BTDC/rpm 15°±8°/700 rpm

2
 SPECIFICATIONS AND SERVICE DATA 2-3b
1. Engine

B: SERVICE DATA
Belt
tension Protrusion of adjuster rod 15.4 — 16.4 mm (0.606 — 0.646 in)
adjuster
Spacer O.D. 16 mm (0.63 in)
Tensioner bush I.D. 16.16 mm (0.6362 in)
Belt ten- STD 0.117 — 0.180 mm (0.0046 — 0.0071 in)
Clearance between spacer and bush
sioner Limit 0.230 mm (0.0091 in)
STD 0.37 — 0.54 mm (0.0146 — 0.0213 in)
Side clearance of spacer
Limit 0.8 mm (0.031 in)
Bend limit 0.020 mm (0.0008 in)
STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Thrust clearance
Limit 0.10 mm (0.0039 in)
STD 42.20 — 42.30 mm (1.6614 — 1.6654 in)
Intake
Limit 42.04 mm (1.6551 in)

Cam lobe height Front: 42.50 — 42.60 mm (1.6732 — 1.6772 in)

STD
Rear: 41.40 — 41.50 mm (1.6299 — 1.6339 in)
Exhaust
Front: 42.34 mm (1.6669 in)
Limit
Camshaft Rear: 41.24 mm (1.6236 in)
Front 31.946 — 31.963 mm (1.2577 — 1.2584 in)
Camshaft journal O.D. Center 27.946 — 27.963 mm (1.1002 — 1.1009 in)
Rear 27.946 — 27.963 mm (1.1002 — 1.1009 in)
Front 32.000 — 32.018 mm (1.2598 — 1.2605 in)
Camshaft journal hole I.D. Center 28.000 — 28.018 mm (1.1024 — 1.1031 in)
Rear 28.000 — 28.018 mm (1.1024 — 1.1031 in)
STD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.3 mm (0.012 in)
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve seat Limit 1.7 mm (0.067 in)
Contacting width
STD 1.5 mm (0.059 in)
Exhaust
Limit 2.2 mm (0.087 in)
Valve Inner diameter 6.000 — 6.015 mm (0.2362 — 0.2368 in)
guide Protrusion above head 12.0 — 12.4 mm (0.472 — 0.488 in)
STD 1.2 mm (0.047 in)
Intake
Limit 0.8 mm (0.031 in)
Head edge thickness
STD 1.5 mm (0.059 in)
Exhaust
Limit 0.8 mm (0.031 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 105.9 mm (4.169 in)
Overall length
Exhaust 106.2 mm (4.181 in)
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter

3
2-3b SPECIFICATIONS AND SERVICE DATA
1. Engine

Free length 48.04 mm (1.8913 in)

Squareness 2.5°, 2.1 mm (0.083 in)
Valve spring 146.1 — 167.7 N
Tension/spring height (14.9 — 17.1 kg, 32.9 — 37.7 lb)/42.0 mm (1.654 in)
455.0 — 523.7 N
(46.4 — 53.4 kg, 102.3 — 117.7 lb)/33.4 mm (1.315 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 99.505 — 99.515 mm (3.9175 — 3.9179 in)
Cylinder bore STD
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
block Limit 0.050 mm (0.0020 in)
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 99.485 — 99.495 mm (3.9167 — 3.9171 in)
STD
B 99.475 — 99.485 mm (3.9163 — 3.9167 in)
Piston Outer diameter 0.25 mm (0.0098 in) 99.725 — 99.735 mm (3.9262 — 3.9266 in)
OS
0.50 mm (0.0197 in) 99.975 — 99.985 mm (3.9360 — 3.9364 in)
OS
Standard clearance between piston STD 0.004 — 0.010 mm (0.0002 — 0.0004 in)
pin and hole in piston Limit 0.020 mm (0.0008 in)
Piston pin
Degree of fit Piston pin must be fitted into position with thumb at 20°C
(68°F).
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.37 — 0.52 mm (0.0146 — 0.0205 in)
Piston ring gap ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.60 mm (0.0079 — 0.0236 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
STD 0.040 — 0.080mm (0.0016 — 0.0031 in)
Top ring
Clearance between piston Limit 0.15 mm (0.0059 in)
ring and piston ring groove Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94 in) in Limit 0.10 mm (0.0039 in)
Connecting length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.010 — 0.038 mm (0.0004 — 0.0015 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm
(0.0012 in) 1.510 — 1.513 mm (0.0594 — 0.0596 in)
Connecting US
rod bearing
Thickness at center portion 0.05 mm
(0.0020 in) 1.520 — 1.523 mm (0.0598 — 0.0600 in)
US
0.25 mm
(0.0098 in) 1.620 — 1.623 mm (0.0638 — 0.0639 in)
US
Connecting Clearance between piston pin and STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing bushing Limit 0.030 mm (0.0012 in)
STD: Standard OS: Oversize US: Undersize

4
 SPECIFICATIONS AND SERVICE DATA 2-3b
1. Engine

Bend limit 0.035 mm (0.0014 in)

Out-of-roundness 0.020 mm (0.0008 in) or less
Crank pin and crank journal
Grinding limit 0.25 mm (0.0098 in)
STD 47.984 — 48.000 mm (1.8891 — 1.8898 in)
0.03 mm
(0.0012 in) 47.954 — 47.970 mm (1.8879 — 1.8886 in)
US
Crank pin outer diameter 0.05 mm
(0.0020 in) 47.934 — 47.950 mm (1.8872 — 1.8878 in)
US
0.25 mm
(0.0098 in) 47.734 — 47.750 mm (1.8793 — 1.8799 in)
US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 in) 59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #5 0.05 mm
(0.0020 in) 59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
Crankshaft
0.25 mm
(0.0098 in) 59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
Crank journal outer diameter
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 in) 59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#2, #3, #4 0.05 mm
(0.0020 in) 59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm
(0.0098 in) 59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
#1, #5 STD 0.003 — 0.030 mm (0.0001 — 0.0012 in)
#2, #3, #4 STD 0.010 — 0.033 mm (0.0004 — 0.0013 in)
Oil clearance
#1, #3, #5 Limit 0.040 mm (0.0016 in)
#2, #4 Limit 0.045 mm (0.0018 in)
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm
(0.0012 in) 2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
#1, #5 0.05 mm
(0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm
(0.0098 in) 2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft US
bearing Crankshaft bearing thickness
STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm
(0.0012 in) 2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #3, #4 0.05 mm
(0.0020 in) 2.029 — 2.032 mm (0.0799 — 0.0800 in)
US
0.25 mm
(0.0098 in) 2.129 — 2.132 mm (0.0838 — 0.0839 in)
US
STD: Standard US: Undersize

5
2-3b COMPONENT PARTS
1. Timing Belt

1. Timing Belt

B2M1244A

쎻
1 Right-hand belt cover No. 2 쎻
14 Belt idler
쎻
2 Crankshaft sprocket 쎻
15 Left-hand belt cover
쎻
3 Left-hand belt cover No. 2 쎻
16 Front belt cover
쎻
4 Tensioner bracket 쎻
17 Right-hand belt cover
쎻
5 Tensioner adjuster 쎻
18 Crankshaft pulley
쎻
6 Belt tensioner
쎻
7 Belt idler Tightening torque: N⋅m (kg-m, ft-lb)
쎻
8 Right-hand exhaust camshaft sprocket T1: 4.9±0.5 (0.5±0.05, 3.6±0.4)
쎻
9 Right-hand intake camshaft sprocket T2: 25±2 (2.5±0.2, 18.1±1.4)
쎻
10 Left-hand intake camshaft sprocket T3: 39±4 (4.0±0.4, 28.9±2.9)
T4: 78±5 (8.0±0.5, 57.9±3.6)
쎻
11 Left-hand exhaust camshaft sprocket
T5: 177±10 (18.0±1.0, 130±7)
쎻
12 Timing belt
쎻
13 Belt idler No. 2

6
 COMPONENT PARTS 2-3b
2. Cylinder Head and Camshaft

2. Cylinder Head and Camshaft

B2M0681A

쎻
1 Rocker cover (RH) 쎻
14 Exhaust valve guide 쎻
27 Exhaust camshaft cap (Center LH)
쎻
2 Rocker cover gasket (RH) 쎻
15 Cylinder head bolt 쎻
28 Exhaust camshaft cap (Rear LH)
쎻
3 Oil separator cover 쎻
16 Oil seal 쎻
29 Rocker cover gasket (LH)
쎻
4 Gasket 쎻
17 Cylinder head (RH) 쎻
30 Rocker cover (LH)
쎻
5 Intake camshaft cap (Front RH) 쎻
18 Cylinder head gasket (RH) 쎻
31 Oil filler cap
쎻
6 Intake camshaft cap (Center RH) 쎻
19 Cylinder head gasket (LH) 쎻
32 Gasket
쎻
7 Intake camshaft cap (Rear RH) 쎻
20 Cylinder head (LH) 쎻
33 Oil filler duct
쎻
8 Intake camshaft (RH) 쎻
21 Intake camshaft (LH) 쎻
34 Gasket
쎻
9 Exhaust camshaft cap (Front RH) 쎻
22 Exhaust camshaft (LH) Tightening torque: N⋅m (kg-m, ft-lb)
쎻
10 Exhaust camshaft cap (Center RH) 쎻
23 Intake camshaft cap (Front LH) T1: Refer to 2-3b [W4E1].
쎻
11 Exhaust camshaft cap (Rear RH) 쎻
24 Intake camshaft cap (Center LH) T2: 5 (0.5, 3.6)
쎻
12 Exhaust camshaft (RH) 쎻
25 Intake camshaft cap (Rear LH) T3: 10 (1.0, 7)
쎻
13 Intake valve guide 쎻
26 Exhaust camshaft (Front LH)

7
2-3b COMPONENT PARTS
3. Cylinder Head and Valve Assembly

3. Cylinder Head and Valve Assembly

B2M1007A

쎻
1 Exhaust valve 쎻
7 Retainer
쎻
2 Intake valve 쎻
8 Retainer key
쎻
3 Cylinder head 쎻
9 Valve lifter
쎻
4 Valve spring seat 쎻
10 Shim
쎻
5 Intake valve oil seal 쎻
11 Exhaust valve oil seal
쎻
6 Valve spring

8
 COMPONENT PARTS 2-3b
4. Cylinder Block

4. Cylinder Block

B2M0381A

쎻
1 Oil pressure switch 쎻
17 Gasket
쎻
2 Cylinder block (RH) 쎻
18 Oil pan
쎻
3 Service hole plug 쎻
19 Oil drain plug
쎻
4 Gasket 쎻
20 Gasket
쎻
5 Oil separator cover 쎻
21 Oil filler pipe
쎻
6 Water pipe
쎻
7 Oil pump Tightening torque: N⋅m (kg-m, ft-lb)
쎻
8 Front oil seal T1: 5 (0.5, 3.6)
쎻
9 Rear oil seal T2: 6.4 (0.65, 4.7)
쎻
10 O-ring T3: 10 (1.0, 7)
T4: 25±2 (2.5±0.2, 18.1±1.4)
쎻
11 Service hole cover
T5: 47±3 (4.8±0.3, 34.7±2.2)
쎻
12 Cylinder block (LH) T6: 69±7 (7.0±0.7, 50.6±5.1)
쎻
13 Engine coolant pump T7: First 12±2 (1.2±0.2, 8.7±1.4)
쎻
14 Baffle plate Second 12±2 (1.2±0.2, 8.7±1.4)
쎻
15 Oil strainer stay
쎻
16 Oil strainer

9
2-3b COMPONENT PARTS
5. Crankshaft and Piston

5. Crankshaft and Piston

B2M0683A

쎻
1 Drive plate 쎻
12 Connecting rod cap
쎻
2 Reinforcement 쎻
13 Crankshaft
쎻
3 Top ring 쎻
14 Woodruff key
쎻
4 Second ring 쎻
15 Crankshaft bearing #1, #5
쎻
5 Oil ring 쎻
16 Crankshaft bearing #2, #4
쎻
6 Piston 쎻
17 Crankshaft bearing #3
쎻
7 Piston pin
쎻
8 Circlip Tightening torque: N⋅m (kg-m, ft-lb)
T1: 44±2 (4.5±0.2, 32.5±1.4)
쎻
9 Connecting rod bolt
T2: 72±3 (7.3±0.3, 52.8±2.2)
쎻
10 Connecting rod
쎻
11 Connecting rod bearing

10
 SERVICE PROCEDURE 2-3b
1. General Precautions

1. 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

G2M0709

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) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
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
2-3b SERVICE PROCEDURE
2. Timing Belt

2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER

B2M1215A

1) Remove V-belt cover, V-belt and air conditioning com-

pressor drive belt tensioner. <Ref. to 1-5 [01A0].>
2) Remove pulley bolt. To lock crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY WRENCH
3) Remove crankshaft pulley.

G2M0711

4) Remove left-hand belt cover.

B2M0729

12
 SERVICE PROCEDURE 2-3b
2. Timing Belt

5) Remove right-hand belt cover.

B2M0730

6) Remove front belt cover.

B2M0731

13
2-3b SERVICE PROCEDURE
2. Timing Belt

2. TIMING BELT

B2M0685A

G2M0713

1) If alignment mark and/or arrow mark (which indicates

rotation direction) on timing belt fade away, put new marks
before removing timing belt as follows:
(1) Turn crankshaft using ST, and align alignment
marks on crankshaft sprocket, left-hand intake cam-
shaft sprocket, left-hand exhaust camshaft sprocket,
right-hand intake camshaft sprocket and right hand
exhaust camshaft sprocket with notches of belt cover
and cylinder block.
B2M0686A
ST 499987500 CRANKSHAFT SOCKET

14
 SERVICE PROCEDURE 2-3b
2. Timing Belt

(2) Using white paint, put alignment and/or arrow

marks on timing belts in relation to the sprockets.
Z1: 54.5 tooth length
Z2: 51 tooth length
Z3: 28 tooth length

B2M0687A

B2M0688

B2M0689

2) Loosen tensioner adjuster mounting bolts.

3) Remove belt idler.

G2M0739

4) Remove timing belt.

5) Remove belt idler No. 2.
CAUTION:
After timing belt has been removed, never rotate intake
and exhaust, camshaft sprocket.
If camshaft sprocket is rotated, the intake and exhaust
valve heads strike together and valve stems are bent.

B2M0733

15
2-3b SERVICE PROCEDURE
2. Timing Belt

3. BELT TENSIONER AND IDLER

B2M0690A

1) Remove belt idler.

B2M0732

2) Remove belt idler No. 2.

B2M0733

3) Remove belt tensioner and spacer.

B2M0734

16
 SERVICE PROCEDURE 2-3b
2. Timing Belt

4) Remove belt tension adjuster.

B2M0735

4. SPROCKET

B2M0691A

1) Remove left-hand intake camshaft sprocket.

2) Remove left-hand exhaust camshaft sprocket.
3) Remove right-hand intake camshaft sprocket.
4) Remove right-hand exhaust camshaft sprocket.
ST 499207300 CAMSHAFT SPROCKET WRENCH
5) Remove crankshaft sprocket.

H2M1294A

6) Remove tensioner bracket.

B2M0736

17
2-3b SERVICE PROCEDURE
2. Timing Belt

7) Remove left-hand belt cover No. 2.

B2M0737

8) Remove right-hand belt cover No. 2.

B2M0738

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:
쐌 Be careful not to let oil, grease or coolant contact
the belt. Remove quickly and thoroughly if this hap-
pens.

쐌 Do not bend the belt sharply.

Bending radius: h
60 mm (2.36 in) or more

G2M0115

18
 SERVICE PROCEDURE 2-3b
2. Timing Belt

2. BELT TENSION ADJUSTER

1) Visually check oil seals for leaks, and rod ends for
abnormal wear or scratches. If necessary, replace belt ten-
sion adjuster.
CAUTION:
Slight traces of oil at rod’s oil seal does not indicate a
problem.
2) While holding tensioner with both hands, push the rod
section against floor or wall ensuring the rod section will
react as follows:
(1) When applying a force of 147 N (15 kg, 33 lb), the
rod section should not sink.
(2) When applying a force of 147 to 490 N (15 to 50 kg,
33 to 110 lb), the rod section should maintain a projec-
tionally acting force and should not sink within 8.5 sec-
onds.

3) Measure the extension of rod beyond the body. If it is

not within specifications, replace with a new one.
Rod extension: H
15.4 — 16.4 mm (0.606 — 0.646 in)

B2M0108A

3. BELT TENSIONER
1) Check mating surfaces of timing belt and contact point
of tension adjuster rod for abnormal wear or scratches.
Replace belt tensioner if faulty.
2) Check spacer and tensioner bushing for wear.
3) Check tensioner for smooth rotation. Replace if noise or
excessive play is noted.
4) Check tensioner for grease leakage.

4. BELT IDLER
1) Check idler for smooth rotation. Replace if noise or
excessive play is noted.
2) Check outer contacting surfaces of idler pulley for
abnormal wear and scratches.
3) Check idler for grease leakage.

19
2-3b SERVICE PROCEDURE
2. Timing Belt

5. 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.

C: INSTALLATION
1. SPROCKET

B2M0691B

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T2: 25±2 (2.5±0.2, 18±1.4)
T3: 78±5 (8.0±0.5, 58±3.6)

1) Install right-hand belt cover No. 2.

B2M0738

20
 SERVICE PROCEDURE 2-3b
2. Timing Belt

2) Install left-hand belt cover No. 2.

B2M0737

3) Install tensioner bracket.

4) Install crankshaft sprocket.

B2M0736

5) Install right-hand exhaust camshaft sprocket. To lock

camshaft, use ST.
6) Install right-hand intake camshaft sprocket using ST.
7) Install left-hand exhaust camshaft sprocket using ST.
8) Install left-hand intake camshaft sprocket using ST.
ST 499207300 CAMSHAFT SPROCKET WRENCH

H2M1294A

21
2-3b SERVICE PROCEDURE
2. Timing Belt

2. BELT TENSIONER AND IDLER

B2M0690B

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 25±2 (2.5±0.2, 18±1.4)
T2: 39±4 (4.0±0.4, 29±2.9)

1) Installation of belt tensioner adjuster

(1) Insert stopper pin 1.5 mm (0.059 in) dia. into place
while pushing tension adjuster rod into body using a
press.
CAUTION:
쐌 Do not allow press pressure to exceed 9,807 N (1,000
kg, 2,205 lb).
쐌 Do not release press pressure until stopper pin is
completely inserted.
쐌 Push tension adjuster rod vertically.
쐌 Press-in the push rod gradually, taking three min-
utes or more.

G2M0119

22
 SERVICE PROCEDURE 2-3b
2. Timing Belt

(2) Temporarily tighten bolts while tension adjuster is

pushed all the way to the right.

G2M0725

2) Install belt tensioner.

3) Install belt idler.
4) Install belt idler No. 2.

G2M0726

3. TIMING BELT

B2M0693A

Tightening torque: N⋅m (kg-m, ft-lb)

T: 39±4 (4.0±0.4, 29±2.9)

23
2-3b SERVICE PROCEDURE
2. Timing Belt

1) Crankshaft and camshaft sprocket alignment

(1) Align mark on crankshaft sprocket with mark on the
oil pump cover at cylinder block.

G2M0728

(2) Align single line mark on right-hand exhaust cam-

shaft sprocket with notch on belt cover.

B2M0694A

(3) Align single line mark on right-hand exhaust cam-

shaft sprocket with notch on belt cover.
(Make sure double lines on intake camshaft and
exhaust camshaft sprockets are aligned.)

B2M0695A

(4) Align single line mark on left-hand exhaust cam-

shaft sprocket with notch on belt cover by turning
sprocket counter-clockwise (as viewed from front of
engine).

B2M0696A

(5) Align single line mark on left-hand intake camshaft

sprocket with notch on belt cover by turning sprocket
clockwise (as viewed from front of engine).
Ensure double lines on intake and exhaust camshaft
sprockets are aligned.

B2M0697A

24
 SERVICE PROCEDURE 2-3b
2. Timing Belt

(6) Ensure camshaft and crankshaft sprockets are

positioned as shown.

G2M0734

CAUTION:
쐌 Intake and exhaust camshafts for this DOHC engine
can be independently rotated with timing belts
removed. As can be seen from the figure, if intake and
exhaust valves are lifted simultaneously, their heads
will interfere with each other, resulting in bent valves.

G2M0735

25
2-3b SERVICE PROCEDURE
2. Timing Belt

쐌 When timing belts are not installed, four camshafts

are held at the “zero-lift” position, where all cams on
camshafts do not push intake and exhaust valves
down. (Under this condition, all valves remain
unlifted.)
쐌 When camshafts are rotated to install timing belts,
#2 intake and #4 exhaust cam of left-hand camshafts
are held to push their corresponding valves down.
(Under this condition, these valves are held lifted.)
Right-side camshafts are held so that their cams do
not push valves down.
쐌 Left-hand camshafts must be rotated from the “zero-
lift” position to the position where timing belt is to be
installed at as small an angle as possible, in order to
prevent mutual interference of intake and exhaust
valve heads.
쐌 Do not allow camshafts to rotate in the direction
shown in the upper of figure as this causes both intake
and exhaust valves to lift simultaneously, resulting in
interference with their heads.
B2M0698A

2) Installation of timing belt

Align alignment mark on timing belt with marks on sprock-
ets in the numerical order shown in figure. While aligning
marks, position timing belt properly.
CAUTION:
Ensure belt’s rotating direction is correct.

B2M0699

G2M0738

26
 SERVICE PROCEDURE 2-3b
2. Timing Belt

3) Install belt idler.

CAUTION:
Make sure that the marks on timing belt and sprockets
are aligned.

G2M0739

4) Loosen tension adjuster attaching bolts and move

adjuster all the way to the left. Tighten the bolts.

B2M0700

5) After ensuring that the marks on timing belt and sprock-

ets are aligned, remove stopper pin from tension adjuster.

G2M0741

27
2-3b SERVICE PROCEDURE
2. Timing Belt

4. CRANKSHAFT PULLEY AND BELT COVER

B2M1215B

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 5±0.5 (0.5±0.05, 3.6±0.4)
T2: 177±10 (18.0±1.0, 130±7)

1) Install front belt cover.

B2M0731

2) Install right-hand belt cover.

B2M0730

3) Install left-hand belt cover.

4) Install crankshaft pulley.

B2M0729
28
 SERVICE PROCEDURE 2-3b
2. Timing Belt

5) Install pulley bolt by using ST.

ST 499977100 CRANKSHAFT PULLEY WRENCH
6) Install V-belt.
CAUTION:
After installing V-belt, check and adjust V-belt tension.

G2M0711

29
2-3b SERVICE PROCEDURE
3. Camshaft

3. Camshaft
A: REMOVAL
1. RELATED PARTS
Remove timing belt, camshaft sprockets and related parts.
<Ref. to 2-3b [W2A0].>

2. CAMSHAFT LH

G2M0743

1) Remove camshaft position sensor.

2) Remove ignition coils.
3) Remove rocker cover and gasket.

4) Loosen intake camshaft cap bolts equally, a little at a

time in the numerical sequence shown in figure.
5) Remove camshaft caps and intake camshaft.

G2M0744

30
 SERVICE PROCEDURE 2-3b
3. Camshaft

6) Loosen exhaust camshaft cap bolts equally, a little at a

time in the numerical sequence shown in figure.
7) Remove camshaft caps and exhaust camshaft.
CAUTION:
Arrange camshaft caps in order so that they can be
installed in their original positions.
8) Similarly, remove right-hand camshafts and related
parts.
G2M0745

B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Limit:
0.020 mm (0.0008 in)
2) Check journal for damage and wear. Replace if faulty.
3) Measure outside diameter of camshaft journal. If the
journal diameter is not as specified, check the oil clear-
G2M0746 ance.
Camshaft journal
Front Center, rear
31.946 — 31.963 mm 27.946 — 27.963 mm
Standard
(1.2577 — 1.2584 in) (1.1002 — 1.1009 in)

4) Measurement of the camshaft journal oil clearance

(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head. (Without
installing valve rocker.)
(3) Place plastigauge across each of the camshaft
journals.
(4) Install the bearing caps.
<Ref. to 2-3b [W3B1].>
CAUTION:
B2M1216 Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge on
each journal.
If the oil clearance exceeds the limit, replace the cam-
shaft. If necessary, replace the camshaft caps and cyl-
inder head as a set.
Standard oil clearance:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit:
0.10 mm (0.0039 in)
(7) Completely remove the plastigauge.

31
2-3b SERVICE PROCEDURE
3. Camshaft

5) 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:
Intake:
42.20 — 42.30 mm (1.6614 — 1.6654 in)
Exhaust:
Front: 42.50 — 42.60 mm (1.6732 — 1.6772 in)
B2M1209A
Rear: 41.40 — 41.50 mm (1.6299 — 1.6339 in)
Limit:
Intake:
42.04 mm (1.6551 in)
Exhaust:
Front: 42.34 mm (1.6669 in)
Rear: 41.24 mm (1.6236 in)
Cam base circle diameter A:
28.0 mm (1.102 in)

6) Measure the thrust clearance of camshaft with dial

gauge. If the clearance exceeds the limit, replace caps and
cylinder head as a set. If necessary replace camshaft.
Standard:
0.040 — 0.080 mm (0.0016 — 0.0031 in)
Limit:
0.1 mm (0.004 in)

B2M1217

32
 SERVICE PROCEDURE 2-3b
3. Camshaft

C: INSTALLATION
1. CAMSHAFT

B2M1304F

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 5±0.5 (0.5±0.05, 3.6±0.4)
T2: 10±0.7 (1.0±0.07, 7.2±0.5)
T3: 20±2 (2.0±0.2, 14.5±1.4)

1) Camshaft installation
Apply engine oil to cylinder head at camshaft bearing loca-
tion before installing camshaft. Install camshaft so that
rocker arm is close to or in contact with “base circle” of cam
lobe.
CAUTION:
쐌 When camshafts are positioned as shown in figure,
camshafts need to be rotated at a minimum to align
with timing belt during installation.
쐌 Right-hand camshaft need not be rotated when set
at position shown in figure.
Left-hand intake camshaft: Rotate 80° clockwise.
Left-hand exhaust camshaft: Rotate 45° counter-clock-
wise.

B2M1200A

33
2-3b SERVICE PROCEDURE
3. Camshaft

2) Camshaft cap installation

(1) Apply fluid packing sparingly to cap mating surface.
CAUTION:
Do not apply fluid packing excessively. Failure to do so
may cause excess packing to come out and flow
toward oil seal, resulting in oil leaks.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0752

(2) Apply engine oil to cap bearing surface and install

cap on camshaft as shown by identification mark.
(3) Gradually tighten cap in at least two stages in the
numerical order shown in figure, and then tighten to
specified torque.
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates only
slightly while holding it at “base” circle.

G2M0753

3) Inspect for valve clearance.

Measure valve clearances using thickness gauge. <Ref. to
2-2 [07A2].>
If necessary, adjust valve clearances. <Ref. to 2-2 [07B2].>

B2M1219A

4) Camshaft oil seal installation

Apply grease to new oil seal lips and press onto front end
of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587100 OIL SEAL INSTALLER
ST2 499597000 OIL SEAL GUIDE

G2M0754

5) Rocker cover installation

(1) Install gaskets on rocker cover.
Install peripheral rocker cover gaskets.
(2) Apply fluid packing to four front open edges of
peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install rocker cover on cylinder head. Ensure gas-
ket is properly positioned during installation.
G2M0755

34
SERVICE PROCEDURE 2-3b
3. Camshaft

6) Install spark plug cords.

7) Install camshaft position sensor.
8) Similarly, install parts on right-hand side.

2. RELATED PARTS
Install timing belt, camshaft sprockets and related parts.
<Ref. to 2-3b [W2C0].>

35
2-3b SERVICE PROCEDURE
4. Cylinder Head

4. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Remove V-belt.
2) Remove generator, air conditioner compressor and
brackets.
3) Remove hoses and tubes from cylinder block.
4) Disconnect each connector and/or remove connector
bracket.
5) Remove coolant filler tank.
6) Remove intake manifold assembly and gasket.
7) Remove water pipe.
8) Remove crank angle sensor, cam angle sensor and
knock sensor.
9) Remove timing belt, camshaft sprockets and related
parts.
<Ref. to 2-3b [W2A0].>
10) Remove rocker cover, camshafts and related parts.
<Ref. to 2-3b [W3A0].>

2. CYLINDER HEAD

B2M0770A

36
 SERVICE PROCEDURE 2-3b
4. Cylinder Head

1) Remove oil level gauge guide attaching bolt (left-hand

only).
2) Remove cylinder head bolts in numerical sequence
shown in figure.
CAUTION:
Leave bolts 쎻 1 and 쎻 4 engaged by three or four threads
to prevent cylinder head from falling.
3) While tapping cylinder head with a plastic hammer,
separate it from cylinder block.
G2M0757
Remove bolts 쎻 1 and 쎻4 to remove cylinder head.
4) Remove cylinder head gasket.
5) Similarly, remove right-hand cylinder head.

B: DISASSEMBLY

B2M1220A

37
2-3b SERVICE PROCEDURE
4. Cylinder Head

1) Remove shims and valve lifters.

2) Compress the valve spring and remove the valve spring
retainer key. Remove each valve and valve spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
쐌 Keep removed parts in order for re-installing in their
original positions.
쐌 Mark each valve to prevent confusion.
B2M1221A
쐌 Use extreme care not to damage the lips of the
intake valve oil seals and exhaust valve oil seals.

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 check.
2) Measure the warping of the cylinder head surface that
mates with crankcase by using a straight edge and thick-
ness gauge.
If the warping exceeds 0.05 mm (0.0020 in), regrind the
G2M0760
surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
CAUTION:
Uneven torque for the cylinder head nuts can cause
warping. When reassembling, pay special attention to
the torque so as to tighten evenly.

38
 SERVICE PROCEDURE 2-3b
4. Cylinder Head

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
1.0 mm (0.039 in)
Limit
G2M0761 1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
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 — 6.015 mm (0.2362 — 0.2368 in)
Valve stem outer diameter:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.950 — 5.965 mm (0.2343 — 0.2348 in)

39
2-3b SERVICE PROCEDURE
4. Cylinder Head

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 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
G2M0762

(3) Turn cylinder head upside down and place ST as

shown in the figure.
ST 498267700 VALVE GUIDE ADJUSTER

G2M0763

(4) Before installing new valve guide, make sure that

neither scratches nor damages exist on the inside sur-
face of the valve guide holes in 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 sur-
face of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 498267700 VALVE GUIDE ADJUSTER
G2M0764

(6) Check the valve guide protrusion.

Valve guide protrusion: L
12.0 — 12.4 mm (0.472 — 0.488 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.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
쐌 Apply engine oil to the reamer when reaming.
쐌 If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with an
oil stone.
쐌 If the inner surface of the valve guide becomes lus-
trous and the reamer does not chips, use a new reamer
or remedy the reamer.
(8) Recheck the contact condition between valve and
valve seat after replacing valve guide.

40
 SERVICE PROCEDURE 2-3b
4. 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
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake 105.9 mm (4.169 in)
Exhaust 106.2 mm (4.181 in)
2) Put a small amount of grinding compound on the seat
surface and lap the valve and seat surface. Install a new
G2M0153 intake valve oil seal after lapping.
5. VALVE SPRINGS
1) Check valve springs for damage, free length, and ten-
sion. 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.
Valve spring
Free length 48.04 mm (1.8913 in)
G2M0154
146.1 — 167.7 N
(14.9 — 17.1 kg, 32.9 — 37.7 lb)/42.0 mm
(1.654 in)
Tension/spring height
455.0 — 523.7 N
(46.4 — 53.4 kg, 102.3 — 117.7 lb)/33.4 mm
(1.315 in)
Squareness 2.5°, 2.1 mm (0.083 in)

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 in oil seal to the specified dimension indicated in
the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
G2M0765

41
2-3b SERVICE PROCEDURE
4. Cylinder Head

CAUTION:
쐌 Apply engine oil to oil seal before force-fitting.
쐌 Differentiate between intake valve oil seal and
exhaust valve oil seal by noting their difference in
color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Black]
Exhaust [Black]

7. VALVE LASH ADJUSTER

1) Check valve lash adjuster visually.
2) Measure outer diameter of valve lash adjuster.
Outer diameter:
29.959 — 29.975 mm (1.1795 — 1.1801 in)

G2M0766

3) Measure inner diameter of bush on cylinder head.

Inner diameter:
29.994 — 30.016 mm (1.1809 — 1.1817 in)
CAUTION:
If difference between outer diameter of valve lash
adjuster and inner diameter of bush is over the limit,
replace cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
G2M0767
Limit:
0.100 mm (0.0039 in)

42
 SERVICE PROCEDURE 2-3b
4. Cylinder Head

8. VALVE LIFTER
1) Check valve lifter for scratch or uneven wear.
2) Measure outer diameter of valve lifter.
Outer diameter:
32.959 — 32.975 mm (1.2976 — 1.2982 in)

B2M1222

3) Measure inner diameter of valve lifter mating part on

cylinder head.
Inner diameter:
32.994 — 33.016 mm (1.2990 — 1.2998 in)
CAUTION:
If difference between outer diameter of valve lifter and
inner diameter of valve lifter mating part is over the
limit, replace cylinder head.
Standard:
G2M0767
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Limit:
0.100 mm (0.0039 in)

43
2-3b SERVICE PROCEDURE
4. Cylinder Head

D: ASSEMBLY

B2M1220B

1) Installation of valve spring and valve

(1) 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.
(2) Set cylinder head on ST1.
(3) Install valve spring and retainer using ST2.
B2M1221A ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their painted
facing towards the valve spring retainer.
(4) Compress valve spring and fit valve spring retainer
key.
(5) After installing, tap valve spring retainers lightly
with wooden hammer for better seating.
2) Install valve lifter and shim.

44
 SERVICE PROCEDURE 2-3b
4. Cylinder Head

E: INSTALLATION
1. CYLINDER HEAD

B2M0771A

1) Install cylinder head and gaskets on cylinder block.

CAUTION:
Use new cylinder head gaskets.

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
numerical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kg-m, 51 ft-lb) in
numerical sequence.
(3) Back off all bolts by 180° first; back them off by 180°
again.
G2M0771 (4) Tighten bolts 쎻 1 and 쎻 2 to 34 N⋅m (3.5 kg-m, 25 ft-
lb).
(5) Tighten bolts 쎻 3 ,쎻4 ,쎻5 and 쎻 6 to 15 N⋅m (1.5 kg-m,
11 ft-lb).
(6) Tighten all bolts by 80 to 90° in numerical
sequence.
CAUTION:
Do not tighten bolts more than 90°.

45
2-3b SERVICE PROCEDURE
4. Cylinder Head

(7) Further tighten all bolts by 80 to 90° in numerical

sequence.
CAUTION:
Ensure that the total “re-tightening angle” [steps (6)
and (7) above] do not exceed 180°.
3) Install oil level gauge guide attaching bolt (left side
only).

2. INTAKE MANIFOLD
1) Install camshafts, rocker cover and related parts.
<Ref. to 2-3b [W3C0].>

G2M0750

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 10±0.7 (1.0±0.07, 7.2±0.5)
T2: 20±2 (2.0±0.2, 14.5±1.4)

46
 SERVICE PROCEDURE 2-3b
4. Cylinder Head

2) Install camshaft sprockets, timing belt and related parts.

<Ref. to 2-3b [W2C0].>

B2M0702

3) Install engine coolant pipe.

CAUTION:
Use new gaskets.

B2M0703

47
2-3b SERVICE PROCEDURE
4. Cylinder Head

4) Install intake manifold.

CAUTION:
Use new gaskets.
5) Install coolant filler tank.
6) Install crankshaft position sensor, camshaft position
sensor and knock sensor. Use dry compressed air to
remove foreign particles before installing sensors.
7) Connect each connector and/or install connector
bracket.
G2M0774
8) Connect hoses and tubes to cylinder block.
9) Install brackets, generator and air conditioner compres-
sor.
10) Install V-belt.

48
SERVICE PROCEDURE 2-3b
5. Cylinder Block

5. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and related
parts.
<Ref. to 2-3b [W2A0].>

B2M0702

49
2-3b SERVICE PROCEDURE
5. Cylinder Block

2) Remove rocker cover, camshafts and related parts.

<Ref. to 2-3b [W3A0].>

G2M0743

50
SERVICE PROCEDURE 2-3b
5. Cylinder Block

3) Remove cylinder heads.

<Ref. to 2-3b [W4A0].>

B2M0770A

51
2-3b SERVICE PROCEDURE
5. Cylinder Block

2. OIL PUMP AND ENGINE COOLANT PUMP

B2M0705A

1) Remove housing cover.

52
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

2) Remove drive plate.

To lock crankshaft use ST.
ST 498497100 CRANKSHAFT STOPPER

B2M0706A

3) Remove oil separator cover.

4) Remove engine coolant pipe.
5) Remove engine coolant 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 cylin-
der block and oil pump.

G2M0162

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-
G2M0163
pan cutter.
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.

53
2-3b SERVICE PROCEDURE
5. Cylinder Block

B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK
CONNECTING BOLT

G2M0164

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

54
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

3) Draw out piston pin from #1 and #2 pistons by using ST.

ST 499097700 PISTON PIN REMOVER
CAUTION:
Be careful not to confuse original combination of
piston, piston pin and cylinder.
4) Similarly remove piston pins from #3 and #4 pistons by
using ST.

G2M0166

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.

55
2-3b SERVICE PROCEDURE
5. Cylinder Block

2. CYLINDER BLOCK
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 con-
necting rod to fall and damage the cylinder block.
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.
6) Draw out each piston from cylinder block using wooden
bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cylinder.

G2M0167

56
SERVICE PROCEDURE 2-3b
5. Cylinder Block

3. CRANKSHAFT AND PISTON

G2M0168

1) Remove connecting rod cap.

2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting rod cap
and bearing in order to prevent confusion.

3) Remove piston rings using the piston ring expander.

4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good order to
prevent confusion.
5) Remove circlip.

57
2-3b SERVICE PROCEDURE
5. Cylinder Block

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)

2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades, “A”
and “B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175 in)

B2M0082A

58
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

2) How to measure the inner diameter of each cylinder

Measure the inner diameter of each cylinder in both the
thrust and piston pin directions at the heights shown in the
Figure, using a cylinder bore gauge.
CAUTION:
Measurement should be performed at a temperature
20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When piston is to be replaced due to general or cylin-
der wear, determine a suitable sized piston by measuring
G2M0170
the piston clearance.

4) How to measure the outer diameter of each piston

Measure the outer diameter of each piston at the height
shown in the Figure. (Thrust direction)
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Piston grade point H:
37.0 mm (1.457 in)
Piston outer diameter:
B2M1305A
Standard
A: 99.485 — 99.495 mm (3.9167 — 3.9171 in)
B: 99.475 — 99.485 mm (3.9163 — 3.9167 in)
0.25 mm (0.0098 in) oversize
99.725 — 99.735 mm (3.9262 — 3.9266 in)
0.50 mm (0.0197 in) oversize
99.975 — 99.985 mm (3.9360 — 3.9364 in)
5) Calculate the clearance between cylinder and piston.
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)

59
2-3b SERVICE PROCEDURE
5. Cylinder Block

6) Boring and honing

(1) If the value of taper, out-of-roundness, or cylinder-
to-piston clearance measured exceeds the specified
limit or if there is any damage on the cylinder wall,
rebore it to use an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all other
cylinders must be bored at the same time, and use
oversize pistons. Do not perform boring on one cylin-
der only, nor use an oversize piston for one cylinder
only.
(2) If the cylinder inner diameter exceeds the limit after
boring and honing, replace the crankcase.
CAUTION:
Immediately after reboring, the cylinder diameter may
differ from its real diameter due to temperature rise.
Thus, pay attention to this when measuring the cylin-
der diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1) Check pistons and piston pins for damage, cracks, and
wear and the piston ring grooves for wear and damage.
Replace if defective.

2) Measure the piston-to-cylinder clearance at each cylin-

der as instructed in 2. CYLINDER AND PISTON 2-3b
[W5C2]. If any of the clearances is not to specification,
replace the piston or bore the cylinder to use an oversize
piston.

3) Make sure that piston pin can be inserted into the pis-
ton pin hole with a thumb at 20°C (68°F). Replace if defec-
tive.
Standard clearance between piston pin and hole in
piston:
Standard
0.004 — 0.010 mm (0.0002 — 0.0004 in)
Limit
0.020 mm (0.0008 in)
B2M0083

60
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

B2M0084A

4) Check circlip installation groove on the piston for burr.

If necessary, remove burr from the groove so that piston
pin can lightly move.
5) Check piston pin circlip for distortion, cracks and wear.

B2M0420A

4. PISTON RING
1) If piston ring is broken, damaged, or worn, or if its ten-
sion is insufficient, or when the piston is replaced, replace
piston ring with a new one of the same size as the piston.
CAUTION:
쐌 “R” or “N” is marked on the end of the top and sec-
ond rings. When installing the rings to the piston, face
this mark upward.

G2M0172

쐌 The oil ring is a combined ring consisting of two

rails and a spacer in between. When installing, be care-
ful to assemble correctly.

G2M0624

2) Squarely place piston ring and oil ring in cylinder, and

measure the piston ring gap with a thickness gauge.
Unit: mm (in)
Standard Limit
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston 0.37 — 0.52
Second ring 1.0 (0.039)
ring gap (0.0146 — 0.0205)
0.20 — 0.60
Oil ring rail 1.5 (0.059)
(0.0079 — 0.0236)
G2M0174

61
2-3b SERVICE PROCEDURE
5. Cylinder Block

3) Measure the clearance between piston ring and piston

ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the piston ring
groove and piston ring.
Unit: mm (in)
Standard Limit
0.040 — 0.080
Clearance Top ring (0.0016 — 0.15 (0.0059)
G2M0175
between piston 0.0031)
ring and piston 0.030 — 0.070
ring groove Second ring (0.0012 — 0.15 (0.0059)
0.0028)

5. CONNECTING ROD
1) Replace connecting rod, if the large or small end thrust
surface is damaged.

2) Check for bend or twist using a connecting rod aligner.

Replace connecting rod if the bend or twist exceeds the
limit.
Limit of bend or twist per 100 mm (3.94 in) in length:
0.10 mm (0.0039 in)
쎻1 Thickness gauge
쎻2 Connecting rod

G2M0196

62
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

3) Install connecting rod fitted with bearing to crankshaft

and measure the side clearance (thrust clearance).
Replace connecting rod if the side clearance exceeds the
specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
G2M0176

4) Inspect connecting rod bearing for scar, peeling,

seizure, melting, wear, etc.

5) Measure the oil clearance on individual connecting rod

bearings by means of plastigauge. If any oil clearance is
not within specification, replace the defective bearing with
a new one of standard size or undersize as necessary.
(See the table below.)
Connecting rod oil clearance:
Standard
0.010 — 0.038 mm (0.0004 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size Outer diameter of
Bearing
(Thickness at center) crank pin
1.492 — 1.501 47.984 — 48.000
Standard
(0.0587 — 0.0591) (1.8891 — 1.8898)
0.03 (0.0012) 1.510 — 1.513 47.954 — 47.970
undersize (0.0594 — 0.0596) (1.8879 — 1.8886)
0.05 (0.0020) 1.520 — 1.523 47.934 — 47.950
undersize (0.0598 — 0.0600) (1.8872 — 1.8878)
0.25 (0.0098) 1.620 — 1.623 47.734 — 47.750
undersize (0.0638 — 0.0639) (1.8793 — 1.8799)

63
2-3b SERVICE PROCEDURE
5. Cylinder Block

6) Inspect bushing at connecting rod small end, and

replace if worn or damaged. Also measure the piston pin
clearance at the connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 — 0.022 mm (0 — 0.0009 in)
Limit
0.030 mm (0.0012 in)

B2M0085

B2M0084A

7) Replacement procedure is as follows.

(1) Remove bushing from connecting rod with ST and
press.
(2) Press bushing with ST after applying oil on the
periphery of bushing.
ST 499037100 CONNECTING ROD BUSHING
REMOVER AND INSTALLER
(3) Make two 3 mm (0.12 in) holes in bushing. Ream
the inside of bushing.
G2M0177
(4) After completion of reaming, clean bushing to
remove chips.

6. CRANKSHAFT AND CRANKSHAFT BEARING

1) Clean crankshaft completely and check for cracks by
means of red lead check etc., and replace if defective.

64
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

2) Measure the crankshaft bend, and correct or replace if

it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1 and #5
crankshaft bearing on cylinder block, position crank-
shaft on these bearings and measure crankshaft bend
using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0178

3) Inspect the crank journal and crank pin for wear. If not
to specifications, replace bearing with an undersize one,
and replace or recondition crankshaft as necessary. When
grinding crank journal or crank pin, finish them to the speci-
fied dimensions according to the undersize bearing to be
used.
Crank pin and crank journal:
Out-of-roundness
0.020 mm (0.0008 in) or less
G2M0179 Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)
Unit: mm (in)

Crank journal diameter

Crank pin diameter
#1, #5 #2, #3, #4
59.992 — 60.008 59.992 — 60.008 47.984 — 48.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (1.8891 — 1.8898)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
center)
59.962 — 59.978 59.962 — 59.978 47.954 — 47.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (1.8879 — 1.8886)
0.03 (0.0012)
undersize Bearing size
2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
center)
59.942— 59.958 59.942 — 59.958 47.934 — 47.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (1.8872 — 1.8878)
0.05 (0.0020)
undersize Bearing size
2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
center)
59.742 — 59.758 59.742 — 59.758 47.734 — 47.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (1.8793 — 1.8799)
0.25 (0.0098)
undersize Bearing size
2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
center)
O.D. ... Outer Diameter

65
2-3b SERVICE PROCEDURE
5. Cylinder Block

4) Measure the thrust clearance of crankshaft at center

bearing. If the clearance exceeds the limit, replace bearing.
Crankshaft thrust clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)

G2M0180

5) Inspect individual crankshaft bearings for signs of

flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft bearing
by means of plastigauge. If the measurement is not within
the specification, replace defective bearing with an under-
size one, and replace or recondition crankshaft as neces-
sary.
Unit: mm (in)
Crankshaft oil clearance
0.003 — 0.030
#1, #5
(0.0001 — 0.0012)
Standard
0.010 — 0.033
#2, #3, #4
(0.0004 — 0.0013)
#1, #3, #5 0.040 (0.0016)
Limit
#2, #4 0.045 (0.0018)

66
SERVICE PROCEDURE 2-3b
5. Cylinder Block

D: ASSEMBLY
1. CRANKSHAFT AND PISTON

B2M0127A

Tightening torque: N⋅m (kg-m, ft-lb)

T: 44±2 (4.5±0.2, 32.5±1.4)

1) Install connecting rod bearings on connecting rods and

connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod bear-
ings.
2) Install connecting rod on crankshaft.
CAUTION:
Position each connecting rod with the side marked
facing forward.
3) Install connecting rod cap with connecting rod nut.
Ensure the arrow on connecting rod cap faces the front
during installation.
CAUTION:
쐌 Each connecting rod has its own mating cap. Make
sure that they are assembled correctly by checking
their matching number.
쐌 When tightening the connecting rod nuts, apply oil
on the threads.

67
2-3b SERVICE PROCEDURE
5. Cylinder Block

4) Installation of piston rings and oil ring

(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180° on the reverse
side for the top ring gap.

B2M1223A

(4) Position the upper rail gap at C or D in the Figure.

(5) Position the expander gap the at 180° of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
쐌 Ensure ring gaps do not face the same direction.
쐌 Ensure ring gaps are not within the piston skirt area.

B2M1224A

5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark “쎻” faces toward front of engine.
G2M0183

68
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

2. CYLINDER BLOCK
1) Install ST to cylinder block, then install crankshaft bear-
ings.
ST 499817000 ENGINE STAND
CAUTION:
Remove oil the mating surface of bearing and cylinder
block before installation. Also apply a coat of engine
oil to crankshaft pins.
2) Position crankshaft on the #2 and #4 cylinder block.
Tightening torque:
T1: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
T2: 47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)

B2M0087A

69
2-3b SERVICE PROCEDURE
5. Cylinder Block

3) Apply fluid packing to the mating surface of #1 and #3

cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring grooves,
oil passages, bearing grooves, etc.

G2M0185

4) Temporarily tighten 10 mm cylinder block connecting

bolts in numerical order shown in Figure.
5) Tighten 10 mm cylinder block connecting bolts in
numerical order.
Tightening torque:
47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)

B2M0088A

6) Tighten 8 mm and 6 mm cylinder block connecting bolts

in numerical order shown in Figure.
Tightening torque:
1 — 쎻
쎻 7 : 25±2 N⋅m
(2.5±0.2 kg-m, 18.1±1.4 ft-lb)
쎻8 : 6.4 N⋅m (0.65 kg-m, 4.7 ft-lb)

B2M0089A

7) Install rear oil seal by using ST1 and ST2.

ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER

G2M0186

70
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)

B2M0128A

Tightening torque: N⋅m (kg-m, ft-lb)

T: 69±7 (7.0±0.7, 50.6±5.1)

1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylinders face
upward.
(2) Using ST1, turn crankshaft so that #1 and #2 con-
necting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cylinders
and insert pistons in their cylinders by using ST2.
ST2 498747300 PISTON GUIDE
G2M0188

2) Installing piston pin

(1) Insert ST3 into service hole to align piston pin hole
with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE

G2M0189

71
2-3b SERVICE PROCEDURE
5. Cylinder Block

(2) Apply a coat of engine oil to piston pin and insert

piston pin into piston and connecting rod through ser-
vice hole.

(3) Install circlip.

CAUTION:
Use new circlips.

G2M0190

(4) Install service hole plug and gasket.

CAUTION:
Use a new gasket and apply a coat of fluid packing to
it before installation.
Fluid packing:
THREE BOND 1215 or equivalent

72
SERVICE PROCEDURE 2-3b
5. Cylinder Block

4. PISTON AND PISTON PIN (#3 AND #4)

B2M0129A

Tightening torque: N⋅m (kg-m, ft-lb)

T1: 6.4 (0.65, 4.7)
T2: 69±7 (7.0±0.7, 50.6±5.1)

Turn cylinder block so that #3 and #4 cylinders face

upward. Using the same procedures as used for #1 and #2
cylinders, install pistons and piston pins.

73
2-3b SERVICE PROCEDURE
5. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP

B2M0705B

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: 72±3 (7.3±0.3, 52.8±2.2)
T5: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)

74
 SERVICE PROCEDURE 2-3b
5. Cylinder Block

1) Install baffle plate.

2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent

G2M0084

5) Apply fluid packing to matching surfaces and install oil

separator cover.
Fluid packing:
THREE BOND 1215 or equivalent

G2M0194

6) Install drive plate.

To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.

B2M0706A

8) Installation of oil pump

(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER

G2M0076

(2) Apply fluid packing to matching surface of oil pump.

Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
쐌 Do not forget to install O-ring and seal when install-
ing oil pump.
쐌 Align flat surface of oil pump’s inner rotor with
B2M0390A
crankshaft before installation.

75
2-3b SERVICE PROCEDURE
5. Cylinder Block

9) Install engine coolant pump and gasket.

CAUTION:
쐌 Be sure to use a new gasket.
쐌 When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.

G2M0628

10) Install engine coolant pipe.

11) Install oil filter.

2. RELATED PARTS
1) Install cylinder heads.
<Ref. to 2-3b [W4E0].>
2) Install camshafts, rocker cover and related parts.
<Ref. to 2-3b [W3C0].>
3) Install camshaft sprockets, timing belt and related parts.
<Ref. to 2-3b [W2C0].>

76
 DIAGNOSTICS 2-3b
1. Engine Trouble in General

1. Engine Trouble in General

Numbers shown in the chart refer to the possibility of reason for the
trouble in order (“Very often” to “Rarely”)
1 — Very often
2 — Sometimes
3 — Rarely

TROUBLE

Engine will not start. Low output, hesitation and poor acceleration
Engine stalls after initial combustion.

Excessive engine oil consumption

Initial combustion does not occur.

After burning in exhaust system

Engine does not return to idle.

Excessive fuel consumption

Rough idle and engine stall
Initial combustion occurs.
Starter does not turn.

Dieseling (Run-on)

Knocking
Surging

POSSIBLE CAUSE
STARTER
2 쐌 Defective battery-to-starter harness
3 쐌 Defective starter switch
3 쐌 Defective inhibitor switch
2 3 쐌 Defective starter
BATTERY
1 쐌 Poor terminal connection
1 쐌 Run-down battery
2 쐌 Defective charging system
Fuel injection system <Ref. to 2-7 On-Board
1 1 1 1 1 1 1 1 1 1 1
Diagnostics II System.>

77
2-3b DIAGNOSTICS
1. Engine Trouble in General

TROUBLE

Low output, hesitation and poor acceleration

Engine will not start.

Engine stalls after initial combustion.

Excessive engine oil consumption

Initial combustion does not occur.

After burning in exhaust system

Engine does not return to idle.

Excessive fuel consumption

Rough idle and engine stall
Initial combustion occurs.
Starter does not turn.

Dieseling (Run-on)

Knocking
Surging

INTAKE SYSTEM
2 1 1 1 3 쐌 Loosened or cracked intake air pipe
3 1 1 1 3 1 쐌 Loosened or cracked blow-by hose
3 1 2 1 1 2 쐌 Loosened or cracked vacuum hose
2 2 2 2 2 쐌 Defective intake manifold gasket
2 2 2 2 2 쐌 Defective throttle body gasket
3 2 2 2 2 쐌 Defective PCV valve
2 2 2 3 2 3 쐌 Loosened oil filler cap
3 3 1 2 1 쐌 Dirty air cleaner element
FUEL LINE
1 3 3 2 2 쐌 Defective fuel pump and relay
3 3 3 2 2 쐌 Clogged fuel line
2 2 2 2 3 3 쐌 Lack of or insufficient fuel
BELT
2 2 2 쐌 Defective
2 2 2 3 2 2 2 2 2 쐌 Defective timing
FRICTION
3 쐌 Seizure of crankshaft and connecting rod bearing
3 쐌 Seized camshaft
3 쐌 Seized or stuck piston and cylinder
COMPRESSION
3 3 3 2 2 2 2 3 2 쐌 Incorrect valve clearance
3 3 3 2 2 3 3 3 쐌 Loosened spark plugs or defective gasket
3 3 3 2 2 3 3 3 쐌 Loosened cylinder head bolts or defective gasket
3 3 3 2 2 3 2 2 쐌 Improper valve seating
3 3 3 3 3 3 3 1 3 쐌 Defective valve stem
2 2 2 2 2 3 3 3 쐌 Worn or broken valve spring
3 3 3 2 3 3 3 1 2 쐌 Worn or stuck piston rings, cylinder and piston
2 2 2 1 1 1 1 2 2 쐌 Incorrect valve timing
2 2 2 2 2 2 쐌 Improper engine oil (low viscosity)

78
 DIAGNOSTICS 2-3b
1. Engine Trouble in General

TROUBLE

Low output, hesitation and poor acceleration

Engine will not start.

Engine stalls after initial combustion.

Excessive engine oil consumption

Initial combustion does not occur.

After burning in exhaust system

Engine does not return to idle.

Excessive fuel consumption

Rough idle and engine stall
Initial combustion occurs.
Starter does not turn.

Dieseling (Run-on)

Knocking
Surging

LUBRICATION SYSTEM
2 2 3 3 쐌 Incorrect oil pressure
쐌 Loosened oil pump attaching bolts and defective
2
gasket
2 쐌 Defective oil filter seal
2 쐌 Defective crankshaft oil seal
3 2 쐌 Defective rocker cover gasket
2 쐌 Loosened oil drain plug or defective gasket
2 쐌 Loosened oil pan fitting bolts or defective oil pan
COOLING SYSTEM
3 3 2 2 1 쐌 Overheating
3 3 3 쐌 Over cooling
OTHERS
쐌 Malfunction of Evaporative Emission Control
1 1 3 3
System
2 1 쐌 Stuck or damaged throttle valve
3 2 2 2 쐌 Accelerator cable out of adjustment

79
2-3b DIAGNOSTICS
2. Engine Noise

2. Engine Noise
Type of sound Condition Possible cause
Valve mechanism is defective.
Sound increases as engine 쐌 Incorrect valve clearance
Regular clicking sound
speed increases. 쐌 Worn camshaft
쐌 Broken valve spring
쐌 Worn crankshaft main bearing
Oil pressure is low.
쐌 Worn connecting rod bearing (big end)
Heavy and dull clank
쐌 Loose flywheel mounting bolts
Oil pressure is normal.
쐌 Damaged engine mounting
쐌 Ignition timing advanced
High-pitched clank Sound is noticeable when 쐌 Accumulation of carbon inside combustion chamber
(Spark knock) accelerating with an overload. 쐌 Wrong spark plug
쐌 Improper gasoline
Sound is reduced when fuel
Clank when engine speed is injector connector of noisy 쐌 Worn crankshaft main bearing
medium (1,000 to 2,000 rpm). cylinder is disconnected. 쐌 Worn bearing at crankshaft end of connecting rod
(NOTE*)
Sound is reduced when fuel
쐌 Worn cylinder liner and piston ring
injector connector of noisy
쐌 Broken or stuck piston ring
Knocking sound when engine cylinder is disconnected.
쐌 Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm. Sound is not reduced if each
쐌 Unusually worn valve lifter
fuel injector connector is
쐌 Worn camshaft journal bore in crankcase
disconnected in turn. (NOTE*)
Squeaky sound — 쐌 Insufficient generator lubrication
Rubbing sound — 쐌 Defective generator brush and rotor contact
Gear scream when starting 쐌 Defective ignition starter switch
—
engine 쐌 Worn gear and starter pinion
Sound like polishing glass with 쐌 Loose drive belt
—
a dry cloth 쐌 Defective engine coolant pump shaft
쐌 Loss of compression
Hissing sound — 쐌 Air leakage in air intake system, hoses, connections or
manifolds
쐌 Loose timing belt
Timing belt noise —
쐌 Belt contacting case/adjacent part
Valve tappet noise — 쐌 Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. (Ref. to 2-7 On-Board
Diagnostics II System.)

80
2-4 SPECIFICATIONS AND SERVICE DATA
1. Lubrication System

1. Lubrication System
A: SPECIFICATIONS
1. 2200 cc MODEL
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter x thickness 78 x 9 mm (3.07 x 0.35 in)
STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Tip clearance between inner and outer rotor
LIMIT 0.18 mm (0.0071 in)

Side clearance between inner rotor and pump STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Oil pump case LIMIT 0.15 mm (0.0059 in)

Case clearance between outer rotor and pump STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi) or more
700 rpm Discharge
Capacity at - quantity 4.2
(4.4 US qt, 3.7 Imp qt)/min.
80°C (176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi) or more
5,000 rpm Discharge
- quantity 42.0
(11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm2, 71 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm2, 10 psi)
Type Immersed contact point type

Oil pressure Working voltage — wattage 12 V — 3.4 W or less

switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity 4.0
(4.2 US qt, 3.5 Imp qt)

2
 SPECIFICATIONS AND SERVICE DATA 2-4
1. Lubrication System

2. 2500 cc MODEL
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter x thickness 78 x 10 mm (3.07 x 0.39 in)
STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Tip clearance between inner and outer rotor
LIMIT 0.18 mm (0.0071 in)

Side clearance between inner rotor and pump STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Oil pump case LIMIT 0.15 mm (0.0059 in)

Case clearance between outer rotor and pump STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi) or more
600 rpm Discharge
Capacity at - quantity 4.6
(4.9 US qt, 4.0 Imp qt)/min.
80°C (176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi) or more
5,000 rpm Discharge
- quantity 47.0
(12.4 US gal, 10.3 Imp gal)/min.
Relief valve operation pressure 588 kPa (6.0 kg/cm2, 85 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Type Immersed contact point type

Oil pressure Working voltage — wattage 12 V — 3.4 W or less

switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity 4.5
(4.8 US qt, 4.0 Imp qt)

3
2-4 COMPONENT PARTS
1. Lubrication System

1. Lubrication System

B2M0314A

쎻
1 Plug 쎻
15 Baffle plate
쎻
2 Washer 쎻
16 Oil strainer stay
쎻
3 Relief valve spring 쎻
17 O-ring
쎻
4 Relief valve 쎻
18 Oil strainer
쎻
5 Oil seal 쎻
19 Oil level gauge guide
쎻
20 Oil pan
쎻
6 Oil pump case
쎻
21 Oil level gauge
쎻
7 Inner rotor
쎻
22 Washer
쎻
8 Outer rotor 쎻
23 Drain plug
쎻
9 Oil pump cover
쎻
10 Oil filter Tightening torque: N⋅m (kg-m, ft-lb)
쎻
11 O-ring T1: 5 (0.5, 3.6)
+1
T2: 5−0 (0.5+0.1 , 3.6+0.7
−0 )
쎻
12 Oil pump ASSY −0
T3: 6.4 (0.65, 4.7)
쎻
13 Oil pressure switch T4: 9.8 (1.0, 7.0)
쎻
14 Oil filler duct T5: 44.1±3.4 (4.5±0.35, 32.5±2.5)

4
 SERVICE PROCEDURE 2-4
1. Oil Pump

1. Oil Pump
A: REMOVAL
1) Drain engine oil.
Set container under the vehicle, and remove drain plug
from oil pan.

G2M0066

2) Drain coolant.
Set container under the vehicle, and remove drain cock
from radiator.

B2M0051A

3) Remove belt covers, timing belt and related parts.

<Ref. to 1-5 [02A0].>

B2M0302

4) Remove belt tensioner bracket.

B2M0303

5) Remove left cam sprocket and left belt cover No. 2.

6) Remove water pump.

G2M0210

5
2-4 SERVICE PROCEDURE
1. Oil Pump

7) Remove oil pump by using flat-bladed screwdriver.

CAUTION:
Be careful not to scratch mating surfaces of cylinder
block and oil pump.

G2M0071

B: DISASSEMBLY
Remove screws which secure oil pump cover and disas-
semble oil pump.
Inscribe alignment marks on inner and outer rotors so that
they can be replaced in their original positions during reas-
sembly.
CAUTION:
Before removing relief valve, loosen plug when remov-
ing oil pump from cylinder block.
쎻1 Oil seal
쎻2 Pump case
쎻3 Inner rotor
쎻4 Outer rotor
쎻5 Pump cover
쎻6 Relief valve
쎻7 Relief spring
쎻8 Plug
쎻9 Washer
쎻10 O-ring

B2M0315A

C: INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clearance
exceeds the limit, replace rotors as a matched set.
Tip clearance:
Standard
0.04 — 0.14 mm (0.0016 — 0.0055 in)
Limit
0.18 mm (0.0071 in)
B2M0316A

2. CASE CLEARANCE
Measure the clearance between the outer rotor and the
cylinder block rotor housing. If the clearance exceeds the
limit, replace the rotor.
Case clearance:
Standard
0.10 — 0.175 mm (0.0039 — 0.0069 in)
Limit
0.20 mm (0.0079 in)
B2M0317A

6
 SERVICE PROCEDURE 2-4
1. Oil Pump

3. SIDE CLEARANCE
Measure clearance between oil pump inner rotor and pump
cover. If the clearance exceeds the limit, replace rotor or
pump body.
Side clearance:
Standard
0.02 — 0.07 mm (0.0008 — 0.0028 in)
Limit
0.15 mm (0.0059 in)
B2M0318

4. OIL RELIEF VALVE

Check the valve for fitting condition and damage, and the
relief valve spring for damage and deterioration. Replace
the parts if defective.
Relief valve spring:
Free length; 71.8 mm (2.827 in)
Installed length; 54.7 mm (2.154 in)
Load when installed; 77.08 N (7.86 kg, 17.33 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole, clogged oil
passage, worn rotor chamber, cracks, and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening, wear,
etc. and replace if defective.

D: ASSEMBLY
1) Install front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER
CAUTION:
Use a new oil seal.

G2M0076

7
2-4 SERVICE PROCEDURE
1. Oil Pump

2) Install inner and outer rotors in their original positions.

3) Install oil relief valve and relief spring.
4) Install oil pump cover.
Tightening torque:
T1: 5+1 +0.1
−0 N⋅m (0.5 −0 kg-m, 3.6−0
+0.7
ft-lb)
T2: 44.1±3.4 N⋅m (4.5±0.35 kg-m, 32.5±2.5 ft-lb)

B2M0315B

E: INSTALLATION
Installation is in the reverse order of removal.
Do the following:
1) Apply fluid packing to matching surfaces of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent

B2M0319A

2) Replace O-ring with a new one.

3) Be careful not to scratch oil seal when installing oil
pump on cylinder block.
CAUTION:
Apply fluid packing to oil pressure switch threads
before installation.
Fluid packing:
THREE BOND 1215 or equivalent

8
 SERVICE PROCEDURE 2-4
2. Oil Pan and Oil Strainer

2. Oil Pan and Oil Strainer

A: REMOVAL
1) Remove front wheels.
2) Remove air intake duct.
3) Disconnect connector from front oxygen sensor.

B2M0724

4) Disconnect connector from rear oxygen sensor. (Cali-

fornia 2200 cc model only)

B2M0725

5) Remove pitching stopper.

G2M0295

6) Remove radiator upper brackets.

B2M0320

7) Support engine with a lifting device and wire ropes.

8) Lift-up the vehicle.
CAUTION:
At this time, raise up wire ropes.

B2M0053

9
2-4 SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

9) Drain engine oil.

Set container under the vehicle, and remove drain plug
from oil pan.

G2M0066

10) Disconnect connector from rear oxygen sensor.

(Except California 2200 cc model)

B2M0312

11) Remove front exhaust pipe.

(1) Separate front catalytic converter from center
exhaust pipe.
(2) Remove front exhaust pipe from engine.
(3) Remove bolt which installs front exhaust pipe on
bracket.

B2M0054

12) Remove nuts which install front cushion rubber onto

front crossmember.

B2M0743A

13) Remove bolts which install oil pan on cylinder block

while raising up engine.
14) Insert oil pan cutter blade between cylinder block-to-oil
pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in place of oil
pan cutter.

G2M0081

10
 SERVICE PROCEDURE 2-4
2. Oil Pan and Oil Strainer

15) Separate oil strainer from oil strainer stay.

G2M0082

16) Remove oil strainer.

G2M0376

17) Remove baffle plate and oil strainer stay.

G2M0377

B: INSPECTION
By visual check make sure oil pan, oil strainer, oil strainer
stay and baffle plate are not damaged.

C: INSTALLATION
CAUTION:
Before installing oil pan, clean sealant from oil and
engine block.
1) Install baffle plate and oil strainer stay.
Tightening torque:
5 N⋅m (0.5 kg-m, 3.6 ft-lb)

G2M0377

11
2-4 SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

2) Install oil strainer onto baffle plate.

CAUTION:
Replace O-ring with a new one.
Tightening torque:
9.8 N⋅m (1.0 kg-m, 7 ft-lb)

G2M0376

3) Hold oil strainer to oil strainer stay.

Tightening torque:
9.8 N⋅m (1.0 kg-m, 7 ft-lb)

G2M0082

4) Apply fluid packing to mating surfaces and install oil

pan.
Fluid packing:
THREE BOND 1207C or equivalent

G2M0084

5) Tighten bolts which install oil pan onto engine block.

Tightening torque:
9.8 N⋅m (1.0 kg-m, 7 ft-lb)
6) Tighten drain plug.
Tightening torque:
44 +4.8
0 N⋅m (4.5
+0.5
0 kg-m, 33
+3.6
0 ft-lb)
CAUTION:
Replace drain plug gasket with new one.
G2M0081

7) Lower engine onto front crossmember.

8) Tighten nuts which install front cushion rubber onto front
crossmember.
Tightening torque:
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)

B2M0743A

12
 SERVICE PROCEDURE 2-4
2. Oil Pan and Oil Strainer

9) Install front exhaust pipe.

CAUTION:
Always use the new gaskets.
(1) Place front exhaust pipe on bracket.
(2) Tighten nuts which install front exhaust pipe on
engine.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0054

(3) Tighten nuts which install front catalytic converter to

center exhaust pipe.
Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)

B2M0055

(4) Tighten bolt which installs front exhaust pipe on

bracket.
Tightening torque:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)

B2M0056

10) Connect connector to rear oxygen sensor. (Except

California 2200 cc model)

B2M0312

11) Lower the vehicle.

CAUTION:
At this time, lower lifting device and release steel
cables.
12) Remove lifting device and steel cables.

B2M0053

13
2-4 SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

13) Connect connector to front oxygen sensor.

B2M0724

14) Connect connector to rear oxygen sensor. (California

2200 cc model only)

B2M0725

15) Install pitching stopper.

Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)

G2M0302

16) Install radiator upper brackets.

Tightening torque:
12±3 N⋅m (1.2±0.3 kg-m, 8.7±2.2 ft-lb)

B2M0320

17) Install air intake duct.

18) Fill engine oil through filler pipe up to upper point of
level gauge. <Ref. to 1-5 [03A0].>
Engine oil capacity:
2200 cc ; Upper level
4.0
(4.2 US qt, 3.5 Imp qt)
Lower level
3.0
(3.2 US qt, 2.6 Imp qt)
2500 cc ; Upper level
B2M0321
4.5
(4.8 US qt, 4.0 Imp qt)

14
 SERVICE PROCEDURE 2-4
2. Oil Pan and Oil Strainer

Lower level
3.5
(3.7 US qt, 3.1 Imp qt)

3. Oil Pressure Switch

A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from generator.

G2M0088

(2) Remove V-belt cover.

(3) Loosen lock bolt and slider bolt, and remove front
side V-belt.

B2M0017

(4) Remove bolts which install generator on bracket.

G2M0090

2) Disconnect terminal from oil pressure switch.

3) Remove oil pressure switch.

G2M0091

15
 SERVICE PROCEDURE 2-4
2. Oil Pan and Oil Strainer

Lower level
3.5
(3.7 US qt, 3.1 Imp qt)

3. Oil Pressure Switch

A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from generator.

G2M0088

(2) Remove V-belt cover.

(3) Loosen lock bolt and slider bolt, and remove front
side V-belt.

B2M0017

(4) Remove bolts which install generator on bracket.

G2M0090

2) Disconnect terminal from oil pressure switch.

3) Remove oil pressure switch.

G2M0091

15
2-4 SERVICE PROCEDURE
3. Oil Pressure Switch

B: INSTALLATION
1) Install oil pressure switch onto engine block.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
2) Connect terminal of oil pressure switch.

G2M0091

3) Install generator on bracket and temporary tighten

installing bolts.

G2M0090

4) Install front side V-belt and adjust it.

<Ref. to 1-5 [01A0].>
5) Install V-belt cover.

B2M0017

6) Connect connector and terminal to generator.

G2M0088

16
 DIAGNOSTICS 2-4
1. Engine Lubrication System

1. Engine Lubrication System

Before troubleshooting, make sure that the engine oil level
is correct and no oil leakage exists.
Trouble Possible cause Corrective action

1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
1. Warning light remains 2) Low oil pressure Clogged oil passage Clean.
on.
Excessive tip clearance and side clearance of oil
Replace.
pump rotor and gear
Clogged oil strainer or broken pipe Clean or replace.
Insufficient engine oil Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
1) Burn-out bulb Replace.
2. Warning light does not
2) Poor contact of switch contact points Replace.
go on.
3) Disconnection of wiring Repair.
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3. Warning light flickers
momentarily. Check for the same pos-
3) Low oil pressure sible causes as listed in
1.—2)

17
2-5 SPECIFICATIONS AND SERVICE DATA
1. Engine Cooling System

1. Engine Cooling System

A: SPECIFICATIONS
1. 2200 cc MODEL
Electric fan + Forced engine coolant circulation
Cooling system
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Type Centrifugal impeller type
Discharge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
Discharge performance I 760 rpm — 0.3 mAq (1.0 ftAq)
ant head
Engine coolant temperature 85°C (185°F)
Discharge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
Engine ant head
coolant
Engine coolant temperature 85°C (185°F)
pump
Discharge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
ant head
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Motor 120 W
Radiator fan
Fan diameter x Blade 320 mm (12.60 in) x 5
Type Cross flow, pressure type
670 x 361 x 16 mm
Core dimensions
(26.38 x 14.21 x 0.63 in)

Radiator Above: 88±10 kPa

(0.9±0.1 kg/cm2, 12.8±1.4 psi)
Pressure range in which cap valve is open
Below: −4.9 to −9.8 kPa
(−0.05 to −0.1 kg/cm2, −0.7 to −1.4 psi)
Fins Corrugated fin type
Reservoir
Capacity 0.5
(0.5 US qt, 0.4 Imp qt)
tank

2
 SPECIFICATIONS AND SERVICE DATA 2-5
1. Engine Cooling System

2. 2500 cc MODEL
Electric fan + Forced engine coolant circulation
Cooling system
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Type Centrifugal impeller type
Discharge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
Discharge performance I 760 rpm — 0.3 mAq (1.0 ftAq)
ant head
Engine coolant temperature 85°C (185°F)
Discharge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
Engine ant head
coolant
Engine coolant temperature 85°C (185°F)
pump
Discharge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
ant head
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
120 W (main fan)
Motor
140 W (sub fan)
Radiator fan
340 mm (13.39 in) x 5 (main fan)
Fan diameter x Blade
280 mm (11.02 in) x 4 (sub fan)
Type Cross flow, pressure type
670 x 361 x 25 mm
Core dimensions
(26.38 x 14.21 x 0.98 in)

Radiator Above: 88±10 kPa

(0.9±0.1 kg/cm2, 12.8±1.4 psi)
Pressure range in which cap valve is open
Below: −4.9 to −9.8 kPa
(−0.05 to −0.1 kg/cm2, −0.7 to −1.4 psi)
Fins Corrugated fin type
Reservoir
Capacity 0.5
(0.5 US qt, 0.4 Imp qt)
tank

B: SERVICE DATA
Engine Standard 0.5 — 0.7 mm (0.020 — 0.028 in)
Clearance between impeller and case
coolant Limit 1.0 mm (0.039 in)
pump “Thrust” runout of impeller end 0.5 mm (0.020 in)

3
2-5 COMPONENT PARTS
1. Engine Coolant Pump

1. Engine Coolant Pump

G2M0201

쎻
1 Engine coolant pump ASSY Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Gasket T1: First +4
10−0 +0.4
(1.0−0 , 7.2+2.9 )
−0
쎻
3 Heater hose Second 10−0+4 +0.4
(1.0−0 , 7.2+2.9
−0 )
쎻
4 Thermostat T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
쎻
5 Gasket
쎻
6 Thermostat case

4
 COMPONENT PARTS 2-5
2. Radiator and Radiator Fan

2. Radiator and Radiator Fan

B2M0300A

쎻
1 Radiator lower cushion 쎻
15 Radiator drain pipe
쎻
2 Radiator 쎻
16 Gasket
쎻
3 O-ring 쎻
17 Radiator drain plug
쎻
4 Air vent plug 쎻
18 ATF hose clamp
쎻
5 Radiator upper cushion 쎻
19 ATF inlet hose A
쎻
6 Radiator upper bracket 쎻
20 ATF outlet hose A
쎻
7 Clamp 쎻
21 ATF pipe
쎻
8 Radiator inlet hose 쎻
22 ATF outlet hose B
쎻
9 Engine coolant reservoir tank cap 쎻
23 ATF inlet hose B
쎻
10 Over flow hose
쎻
11 Engine coolant reservoir tank Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.9±1.5 (0.7±0.15, 5.1±1.1)
쎻
12 Shroud
T2: 12±3 (1.2±0.3, 8.7±2.2)
쎻
13 Radiator main fan motor ASSY
쎻
14 Radiator outlet hose

5
2-5 COMPONENT PARTS
3. Engine Coolant Pipe

3. Engine Coolant Pipe

G2M0203

쎻
1 Engine coolant temperature sensor Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Engine coolant temperature gauge T: 6.4±0.5 (0.65±0.05, 4.7±0.4)
쎻
3 Engine coolant pipe
쎻
4 O-ring
쎻
5 By-pass hose

6
 SERVICE PROCEDURE 2-5
1. On-Car Service

1. On-Car Service
A: DRAINING OF ENGINE COOLANT
1) Lift-up the vehicle.

2) Fit vinyl tube to drain pipe.

B2M0133A

3) Loosen drain cock to drain engine coolant into con-

tainer.
NOTE:
Remove radiator cap so that engine coolant will drain
faster.

B2M0015A

B: FILLING OF ENGINE COOLANT

1) Remove air vent plug from radiator.

B2M0301

2) Fill engine coolant into radiator up to filler neck position.

B2M0135

7
2-5 SERVICE PROCEDURE
1. On-Car Service

3) Fill engine coolant into reservoir tank up to upper level.

B2M0140

4) Attach radiator cap and reservoir tank cap properly.

5) Install air vent plug.
6) Warm-up engine completely for more than five minutes
at 2,000 to 3,000 rpm.
7) Stop engine and wait until temperature drops to a safe
level.
8) If engine coolant level drops in radiator, add engine
coolant to filler neck position.
9) If engine coolant level drops from upper level of reser-
voir tank, add engine coolant to upper level.
10) Attach radiator cap and reservoir tank cap properly.

C: CHECKING OF COOLING SYSTEM

1) Remove radiator cap, top off radiator, and attach tester
to radiator in place of cap.
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi) to
radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or connec-
tions.
CAUTION:
B2M0136
쐌 Engine should be off.
쐌 Wipe engine coolant from check points in advance.
쐌 Be careful to prevent engine coolant from spurting
out when removing tester.
쐌 Be careful also not to deform filler neck of radiator
when installing or removing tester.

8
 SERVICE PROCEDURE 2-5
2. Engine Coolant Pump

2. Engine Coolant Pump

A: REMOVAL
1) Open engine hood.
2) Disconnect ground cable from the battery.

G6M0095

3) Drain engine coolant completely.

<Ref. to 2-5 [W1A0].>

B2M0015A

4) Disconnect radiator outlet hose from engine coolant

pump.

B2M0137

5) Remove radiator fan motor assembly.

<Ref. to 2-5 [W6A0].>

B2M0323

6) Remove V-belt(s).
<Ref. to 1-5 [01B0].>

G2M0286

9
2-5 SERVICE PROCEDURE
2. Engine Coolant Pump

7) Remove timing belt.

<Ref. to 1-5 [02A0].>

B2M0302

8) Remove belt tension adjuster.

B2M0303

9) Remove camshaft position sensor.

<Ref. to 2-7 [W10A0].>

G2M0417

10) Remove left side camshaft pulley by using ST.

ST 499207100 CAMSHAFT SPROCKET WRENCH

G2M0207

11) Remove left side rear timing belt cover.

G2M0208

10
 SERVICE PROCEDURE 2-5
2. Engine Coolant Pump

12) Remove tensioner bracket.

13) Disconnect heater hose from engine coolant pump.
14) Remove engine coolant pump.

G2M0210

B: INSPECTION
1) Check engine coolant pump bearing for smooth rota-
tion.
2) Check engine coolant pump pulley for abnormalities.

3) Using a dial gauge, measure impeller runout in thrust

direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)

G2M0211

4) Check clearance between impeller and pump case.

Clearance between impeller and pump case:
Standard
0.5 — 0.7 mm (0.020 — 0.028 in)
Limit
1.0 mm (0.039 in)

G2M0212

5) After engine coolant pump installation, check pulley

shaft for engine coolant leaks. If leaks are noted, replace
engine coolant pump assembly.

11
2-5 SERVICE PROCEDURE
2. Engine Coolant Pump - 3. Thermostat

C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
쐌 Replace gasket with a new one.
쐌 When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in fig-
ure.
Tightening torque:
+4
10−0 N⋅m (1.0+0.4
−0 kg-m, 7.2+2.9
−0 ft-lb)
G2M0213

3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
2) Disconnect radiator outlet hose from thermostat cover.
3) Remove thermostat cover and gasket, and pull out the
thermostat.
G2M0214

4) Install the thermostat in the intake manifold, and install

the thermostat cover together with a gasket.
CAUTION:
쐌 When reinstalling the thermostat, use a new gasket.
쐌 The thermostat must be installed with the jiggle pin
upward.
쐌 In this time, set the jiggle pin of thermostat for front
side.

G2M0227

B: INSPECTION
Replace the thermostat if the valve does not close com-
pletely at an ambient temperature or if the following test
shows unsatisfactory results.
Immerse the thermostat and a thermometer in water. Raise
water temperature gradually, and measure the temperature
and valve lift when the valve begins to open and when the
valve is fully opened. During the test, agitate the water for
even temperature distribution. The measurement should
G2M0215 be to the specification.
Starts to open:
76.0 — 80.0°C (169 — 176°F)
Fully opens:
91°C (196°F)

12
2-5 SERVICE PROCEDURE
2. Engine Coolant Pump - 3. Thermostat

C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
쐌 Replace gasket with a new one.
쐌 When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in fig-
ure.
Tightening torque:
+4
10−0 N⋅m (1.0+0.4
−0 kg-m, 7.2+2.9
−0 ft-lb)
G2M0213

3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
2) Disconnect radiator outlet hose from thermostat cover.
3) Remove thermostat cover and gasket, and pull out the
thermostat.
G2M0214

4) Install the thermostat in the intake manifold, and install

the thermostat cover together with a gasket.
CAUTION:
쐌 When reinstalling the thermostat, use a new gasket.
쐌 The thermostat must be installed with the jiggle pin
upward.
쐌 In this time, set the jiggle pin of thermostat for front
side.

G2M0227

B: INSPECTION
Replace the thermostat if the valve does not close com-
pletely at an ambient temperature or if the following test
shows unsatisfactory results.
Immerse the thermostat and a thermometer in water. Raise
water temperature gradually, and measure the temperature
and valve lift when the valve begins to open and when the
valve is fully opened. During the test, agitate the water for
even temperature distribution. The measurement should
G2M0215 be to the specification.
Starts to open:
76.0 — 80.0°C (169 — 176°F)
Fully opens:
91°C (196°F)

12
 SERVICE PROCEDURE 2-5
4. Radiator

4. Radiator
A: REMOVAL
1) Disconnect battery cables and remove battery from
body.
2) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.

B2M0015A

3) Disconnect radiator outlet hose from thermostat cover.

4) Disconnect ATF cooler hoses from radiator. (AT model)

B2M0304

5) Remove V-belt cover.

B2M0017

6) Disconnect inlet hose from radiator.

B2M0305

7) Disconnect connectors of radiator main fan and sub fan

motor.

G2M0263

13
2-5 SERVICE PROCEDURE
4. Radiator

8) Remove radiator upper brackets.

NOTE:
Place left upper radiator bracket between grille and body.

B2M0320

9) While slightly lifting radiator, slide it to left.

10) Lift radiator up and away from vehicle.

G2M0220

B: INSTALLATION
1) Attach radiator mounting cushions to body.

B2M0307A

2) Install radiator while fitting radiator pins to cushions.

G2M0220

14
 SERVICE PROCEDURE 2-5
4. Radiator

3) Install radiator brackets and tighten bolts.

4) Connect radiator main fan motor and sub fan motor
connectors.

B2M0320

5) Connect radiator inlet and outlet hoses.

6) Connect ATF cooler hoses. (AT model)

B2M0137

7) Install V-belt cover.

B2M0017

8) Connect ground cable to battery terminal.

G6M0095

15
2-5 SERVICE PROCEDURE
5. Radiator Cap - 6. Radiator Fan and Fan Motor

5. Radiator Cap
A: INSPECTION
1) Attach radiator cap to tester.
2) Increase pressure until tester gauge pointer stops.
Radiator cap is functioning properly if it holds the service
limit pressure for five to six seconds.
Standard pressure:
78 — 98 kPa (0.8 — 1.0 kg/cm2, 11 — 14 psi)
G2M0223 Service limit pressure:
69 kPa (0.7 kg/cm2, 10 psi)
CAUTION:
Be sure to remove foreign matter and rust from the cap
in advance; otherwise, results of pressure test will be
incorrect.

6. Radiator Fan and Fan Motor

A: REMOVAL
1) Disconnect ground cable from battery terminal.
2) Disconnect connector of fan motor.

G2M0263

3) Remove reservoir tank.

G2M0224

4) Remove four bolts holding shroud to radiator.

B2M0308

16
2-5 SERVICE PROCEDURE
5. Radiator Cap - 6. Radiator Fan and Fan Motor

5. Radiator Cap
A: INSPECTION
1) Attach radiator cap to tester.
2) Increase pressure until tester gauge pointer stops.
Radiator cap is functioning properly if it holds the service
limit pressure for five to six seconds.
Standard pressure:
78 — 98 kPa (0.8 — 1.0 kg/cm2, 11 — 14 psi)
G2M0223 Service limit pressure:
69 kPa (0.7 kg/cm2, 10 psi)
CAUTION:
Be sure to remove foreign matter and rust from the cap
in advance; otherwise, results of pressure test will be
incorrect.

6. Radiator Fan and Fan Motor

A: REMOVAL
1) Disconnect ground cable from battery terminal.
2) Disconnect connector of fan motor.

G2M0263

3) Remove reservoir tank.

G2M0224

4) Remove four bolts holding shroud to radiator.

B2M0308

16
 SERVICE PROCEDURE 2-5
6. Radiator Fan and Fan Motor - 7. Engine Coolant Pipe

5) Remove radiator fan motor assembly.

6) Remove fan motor from shroud.

B2M0323

B: INSTALLATION
Installation is in the reverse order of removal procedures.
Do the following:
1) Before installing radiator fan motor, apply a coat of seal-
ant to threads and tighten nuts.
2) Make sure radiator fan does not come into contact with
shroud when installed.
3) After installation, make sure there is no unusual noise
or vibration when fan is rotated.

7. Engine Coolant Pipe

A: REMOVAL
1) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
2) Disconnect ground cable from the battery.

G6M0095

3) Drain engine coolant completely.

<Ref. to 2-5 [W1A0].>

B2M0015A

4) Remove intake manifold.

<Ref. to 2-7 [W4A0].>

B2M0160

17
 SERVICE PROCEDURE 2-5
6. Radiator Fan and Fan Motor - 7. Engine Coolant Pipe

5) Remove radiator fan motor assembly.

6) Remove fan motor from shroud.

B2M0323

B: INSTALLATION
Installation is in the reverse order of removal procedures.
Do the following:
1) Before installing radiator fan motor, apply a coat of seal-
ant to threads and tighten nuts.
2) Make sure radiator fan does not come into contact with
shroud when installed.
3) After installation, make sure there is no unusual noise
or vibration when fan is rotated.

7. Engine Coolant Pipe

A: REMOVAL
1) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
2) Disconnect ground cable from the battery.

G6M0095

3) Drain engine coolant completely.

<Ref. to 2-5 [W1A0].>

B2M0015A

4) Remove intake manifold.

<Ref. to 2-7 [W4A0].>

B2M0160

17
2-5 SERVICE PROCEDURE
7. Engine Coolant Pipe

5) Disconnect heater inlet hose.

B2M0138

6) Disconnect radiator inlet hose from engine coolant pipe.

B2M0139

7) Remove bolts which install engine coolant pipe on cyl-

inder block.

B2M0141

B: INSTALLATION
1) Install engine coolant pipe on cylinder block.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
CAUTION:
Use a new O-ring.

B2M0141

2) Connect radiator inlet hose.

B2M0139

18
 SERVICE PROCEDURE 2-5
7. Engine Coolant Pipe

3) Connect heater inlet hose.

B2M0138

4) Install intake manifold.

<Ref. to 2-7 [W4D0].>

B2M0160

5) Connect ground cable to battery terminal.

G6M0095

19
2-5 DIAGNOSTICS
1. Engine Cooling System

1. Engine Cooling System

Trouble Possible cause Corrective action
Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair ignition control system.
g. Improper ignition timing
<Ref. to 2-7 On-Board Diagnostics II System.>
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in engine coolant Replace engine coolant.
Inspect and repair fuel injection system.
j. Air/fuel mixture ratio too lean
<Ref. to 2-7 On-Board Diagnostics II System.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
Inspect radiator fan relay, engine coolant temperature
q. Malfunction of electric fan
sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low Partly cover radiator front area.
Over-cooling
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
Engine coolant
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
leaks.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
a. Defective drive belt Replace.
b. Defective radiator fan Replace.
Noise
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.

20
DIAGNOSTICS 2-5
2. Radiator Main Fan

2. Radiator Main Fan

B2M1306

21
2-5 DIAGNOSTICS
2. Radiator Main Fan

A: OPERATION (WITHOUT A/C MODEL)

CONDITION:
쐌 Engine coolant temperature is above 95°C (203°F).
TROUBLE SYMPTOM:
쐌 Radiator main fan does not operate under the above
condition.

1. Check fuse and power supply. Not OK Melted fuse , repair the shorted part of the circuit
왘
, replace fuse.
OK
왔
2. Check harness connector between fuse and Not OK Repair or replace wiring harness.
왘
relay box, and A/C relay holder.

OK
왔
3. Check A/C relay holder. Not OK Repair or replace A/C relay holder.
왘
OK
왔
4. Check harness connector between A/C relay Not OK
왘
Repair or replace wiring harness.
holder and main fan motor.

OK
왔
5. Check ground circuit of main fan motor. Not OK
왘
Repair or replace wiring harness.

OK
왔
Not OK
6. Check main fan motor. 왘
Replace main fan motor.

OK
왔
Refer to 2-7 On-Board Diagnostics II System.

1. CHECK FUSE AND POWER SUPPLY.

1) Check fuse No. 13.
2) Turn ignition switch to ACC.
3) Measure voltage between fuse and relay box, and body.
Connector & terminal / Specified voltage:
(F40) No. 3 — Body / 10 V, or more

B2M0427A

22
 DIAGNOSTICS 2-5
2. Radiator Main Fan

2. CHECK HARNESS CONNECTOR BETWEEN FUSE

AND RELAY BOX, AND A/C RELAY HOLDER.
1) Turn ignition switch to OFF.
2) Disconnect connectors from fuse and relay box, and
A/C relay holder.
3) Measure resistance of harness connector between fuse
and relay box, and A/C relay holder.
Connector & terminal / Specified resistance:
(F40) No. 3 — (F29) No. 2 / 10 Ω, max.
B2M0325A

3. CHECK A/C RELAY HOLDER.

1) Disconnect connector from A/C relay holder.
2) Measure resistance between terminals of A/C relay
holder.
Connector & terminal / Specified resistance:
(F29) No. 2 — (F28) No. 4 / 10 Ω, max.
(F29) No. 2 — (F30) No. 4 / 10 Ω, max.

B2M0428A

4. CHECK HARNESS CONNECTOR BETWEEN A/C

RELAY HOLDER AND MAIN FAN MOTOR.
1) Disconnect connectors from A/C relay holder and main
fan motor.
2) Measure resistance of harness connector between A/C
relay holder and main fan motor.
Connector & terminal / Specified resistance:
(F28) No. 4 — (F17) No. 2 / 10 Ω, max.
(F30) No. 4 — (F17) No. 3 / 10 Ω, max.
B2M0366A

5. CHECK GROUND CIRCUIT OF MAIN FAN MOTOR.

Measure resistance between main fan motor connector
and body.
Connector & terminal / Specified resistance:
(F17) No. 1 — Body / 10 Ω, max.

B2M0367A

6. CHECK MAIN FAN MOTOR.

1) Disconnect connector from main fan motor.
2) Connect battery positive (+) terminal to terminals No. 2
and No. 3, and connect terminal No. 1 to ground. Ensure
that fan rotates.

B2M0368A

23
2-5 DIAGNOSTICS
2. Radiator Main Fan

B: LO MODE OPERATION (WITH A/C MODEL)

CONDITION:
Condition (1) :
쐌 Engine coolant temperature is below 89°C (192°F).
쐌 A/C switch is turned ON.
쐌 Vehicle speed is below 10 km/h (6 MPH).
Condition (2) :
쐌 Engine coolant temperature is above 95°C (203°F).
쐌 A/C switch is turned OFF.
쐌 Vehicle speed is below 10 km/h (6 MPH).
TROUBLE SYMPTOM:
쐌 Radiator main fan does not rotate at LO speed under
conditions (1) and (2) above.

1. Check power supply to main fan relay-1. Not OK Melted fuse (in A/C relay holder) , repair the
왘
shorted part of the circuit , replace fuse.
OK
왔
2. Check main fan relay-1. Not OK
왘
Replace main fan relay-1.

OK
왔
Not OK
3. Check harness connector between main fan 왘
Repair or replace wiring harness.
relay-1 and main fan motor.

OK
왔
4. Check ground circuit of main fan motor. Not OK
왘
Repair or replace wiring harness.

OK
왔
Not OK
5. Check main fan motor. 왘
Replace main fan motor.

OK
왔
Refer to 2-7 On-Board Diagnostics II System.

24
 DIAGNOSTICS 2-5
2. Radiator Main Fan

1. CHECK POWER SUPPLY TO MAIN FAN RELAY-1.

1) Turn ignition switch to OFF.
2) Disconnect connector from A/C relay holder.
3) Measure voltage between A/C relay holder connector
and body.
Connector & terminal / Specified voltage:
(F28) No. 2 — Body / 10 V, or more
(F28) No. 1 — Body / 1 V, max.

B2M0369A

4) Turn ignition switch to ON.

5) Measure voltage between A/C relay holder connector
and body.
Connector & terminal / Specified voltage:
(F28) No. 1 — Body / 10 V, or more

2. CHECK MAIN FAN RELAY-1.

1) Turn ignition switch to OFF.
2) Remove main fan relay-1 from A/C relay holder.
3) Check continuity between terminals (indicated in table
below) when terminal (1) is connected to battery and ter-
minal (3) is grounded.
Between terminals (2)
When current flows. Continuity exists.
and (4)
Between terminals (2) Continuity does not
When current does not and (4) exist.
flow. Between terminals (1)
Continuity exists.
and (3)

B2M0370A

3. CHECK HARNESS CONNECTOR BETWEEN MAIN

FAN RELAY-1 AND MAIN FAN MOTOR.
1) Disconnect connectors from main fan relay-1 and main
fan motor.
2) Measure resistance of harness connector between
main fan relay-1 and main fan motor.
Connector & terminal / Specified resistance:
(F28) No. 4 — (F17) No.2 / 10 Ω, max.

B2M0371A

25
2-5 DIAGNOSTICS
2. Radiator Main Fan

4. CHECK GROUND CIRCUIT OF MAIN FAN MOTOR.

Measure resistance between main fan motor connector
and body.
Connector & terminal / Specified resistance:
(F17) No. 1 — Body / 10 Ω, max.

B2M0367A

5. CHECK MAIN FAN MOTOR.

1) Disconnect connector from main fan motor.
2) Connect battery positive (+) terminal to terminal No. 2
and connect terminal No. 1 to ground. Ensure that fan
rotates at LO speed.

B2M0372A

26
 DIAGNOSTICS 2-5
2. Radiator Main Fan

C: HI MODE OPERATION (WITH A/C MODEL)

CONDITION:
Condition (1) :
쐌 Engine coolant temperature is below 89°C (192°F).
쐌 A/C switch is turned ON.
쐌 Vehicle speed is over 20 km/h (12 MPH).
Condition (2) :
쐌 Engine coolant temperature is above 95°C (203°F).
쐌 A/C switch is turned OFF.
쐌 Vehicle speed is over 20 km/h (12 MPH).
Condition (3) :
쐌 Engine coolant temperature is above 95°C (203°F).
쐌 A/C switch is turned ON.
TROUBLE SYMPTOM:
쐌 Radiator main fan does not rotate at HI speed under
conditions (1), (2) and (3) above.
Not OK
1. Check operation of main fan motor LO mode. 왘
Check LO mode operation. <Ref. to 2-5 [K2B0].>

OK
왔
Not OK
2. Check power supply to main fan relay-2. 왘
Melted fuse (in A/C relay holder) , repair the
shorted part of the circuit , replace fuse.
OK
왔
3. Check main fan relay-2. Not OK
왘
Replace main fan relay-2.

OK
왔
4. Check harness connector between main fan Not OK
왘
Repair or replace wiring harness.
relay-2 and main fan motor.

OK
왔
Not OK
5. Check ground circuit of main fan motor. 왘
Repair or replace wiring harness.

OK
왔
6. Check main fan motor. Not OK Replace main fan motor.
왘
OK
왔
Refer to 2-7 On-Board Diagnostics II System.

27
2-5 DIAGNOSTICS
2. Radiator Main Fan

1. CHECK OPERATION OF MAIN FAN MOTOR LO

MODE.
Check that radiator main fan rotates at LO speed under
each condition described under LO mode operation. <Ref.
to 2-5 [K2B0].>

2. CHECK POWER SUPPLY TO MAIN FAN RELAY-2.

1) Turn ignition switch to OFF.
2) Disconnect connector from A/C relay holder.
3) Measure voltage between A/C relay holder connector
and body.
Connector & terminal / Specified voltage:
(F30) No. 2 — Body / 10 V, or more
(F30) No. 1 — Body / 1 V, max.

B2M0374A

4) Turn ignition switch to ON.

5) Measure voltage between A/C relay holder connector
and body.
Connector & terminal / Specified voltage:
(F30) No. 1 — Body / 10 V, or more

3. CHECK MAIN FAN RELAY-2.

1) Turn ignition switch to OFF.
2) Remove main fan relay-2 from A/C relay holder.
3) Check continuity between terminals (indicated in table
below) when terminal (1) is connected to battery and ter-
minal (3) is grounded.
Between terminals (2)
When current flows. Continuity exists.
and (4)
Between terminals (2) Continuity does not
When current does not and (4) exist.
flow. Between terminals (1)
Continuity exists.
and (3)

B2M0370A

28
 DIAGNOSTICS 2-5
2. Radiator Main Fan

4. CHECK HARNESS CONNECTOR BETWEEN MAIN

FAN RELAY-2 AND MAIN FAN MOTOR.
1) Disconnect connectors from main fan relay-2 and main
fan motor.
2) Measure resistance of harness connector between
main fan relay-2 and main fan motor.
Connector & terminal / Specified resistance:
(F30) No. 4 — (F17) No. 3 / 10 Ω, max.

B2M0375A

5. CHECK GROUND CIRCUIT OF MAIN FAN MOTOR.

Measure resistance between main fan motor connector
and body.
Connector & terminal / Specified resistance:
(F17) No. 1 — Body / 10 Ω, max.

B2M0367A

6. CHECK MAIN FAN MOTOR.

1) Disconnect connector from main fan motor.
2) Connect battery positive (+) terminal to terminals No. 2
and No. 3, and connect terminal No. 1 to ground. Ensure
that fan rotates at HI speed.

B2M0368A

29
2-7 COMPONENT PARTS
1. Intake Manifold

1. Intake Manifold
1. 2200 cc MODEL

B2M1031A

2
 COMPONENT PARTS 2-7
1. Intake Manifold

쎻
1 Intake manifold gasket LH 쎻
26 EGR vacuum hose B (Except 2200 cc MT model)
쎻
2 Intake manifold gasket RH 쎻
27 EGR valve (Except 2200 cc MT model)
쎻
3 Fuel injector pipe insulator 쎻
28 Gasket (Except 2200 cc MT model)
쎻
4 Fuel injector pipe 쎻
29 EGR solenoid valve (Except 2200 cc MT model)
쎻
5 O-ring A 쎻
30 EGR pipe (Except 2200 cc MT model)
쎻
6 O-ring B 쎻
31 Pressure sensor
쎻
7 Fuel injector 쎻
32 Pressure sources switching solenoid valve
쎻
8 Insulator 쎻
33 Vacuum hose A
쎻
9 Fuel injector cap 쎻
34 Vacuum hose B
쎻
10 Plate
쎻
35 Vacuum hose C
쎻
11 Sealing
쎻
36 Bracket (Except Canada spec. vehicles)
쎻
12 Gasket
쎻
37 Bracket (For Canada spec. vehicles)
쎻
13 Engine coolant hose B
쎻
38 Intake manifold
쎻
14 Air by-pass hose
쎻
15 Idle air control solenoid valve Tightening torque: N⋅m (kg-m, ft-lb)
쎻
16 Engine coolant hose A T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
쎻
17 Nipple (AT model) T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
쎻
18 Plug T3: 6.4±0.5 (0.65±0.05, 4.7±0.4)
쎻
19 PCV valve T4: 16±1.5 (1.6±0.15, 11.6±1.1)
쎻
20 Purge control solenoid valve T5: 19±1.5 (1.9±0.15, 13.7±1.1)
쎻
21 Nipple T6: 19±2 (1.9±0.2, 13.7±1.4)
쎻
22 BPT (Except 2200 cc MT model) T7: 23±3 (2.3±0.3, 16.6±2.2)
T8: 25±2 (2.5±0.2, 18.1±1.4)
쎻
23 BPT holder bracket (Except 2200 cc MT model)
T9: 34±2 (3.5±0.2, 25.3±1.4)
쎻
24 Back pressure hose (Except 2200 cc MT model)
쎻
25 EGR vacuum hose A (Except 2200 cc MT model)

3
2-7 COMPONENT PARTS
1. Intake Manifold

2. 2500 cc MODEL

B2M1198A

쎻
1 Intake manifold gasket LH 쎻
20 Purge control solenoid valve 쎻
38 Bracket
쎻
2 Intake manifold gasket RH 쎻
21 Nipple (Except Canada spec. vehicles)
쎻
3 Fuel injector pipe insulator 쎻
22 BPT 쎻
39 Bracket
쎻
4 Fuel injector pipe 쎻
23 BPT holder bracket (For Canada spec. vehicles)
쎻
5 O-ring A 쎻
24 Back pressure hose 쎻
40 Collar
쎻
6 O-ring B 쎻
25 EGR vacuum hose A 쎻
41 Intake manifold
쎻
7 Fuel injector 쎻
26 EGR vacuum pipe
쎻
8 Insulator 쎻
27 EGR vacuum hose C Tightening torque: N⋅m (kg-m, ft-lb)
쎻
9 Fuel injector cap 쎻
28 EGR valve T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
쎻
10 Plate 쎻
29 Gasket T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
쎻
11 Sealing 쎻
30 EGR vacuum hose B T3: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T4: 16±1.5 (1.6±0.15, 11.6±1.1)
쎻
12 Gasket 쎻
31 EGR solenoid valve
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
쎻
13 Engine coolant hose B 쎻
32 EGR pipe T6: 19±2 (1.9±0.2, 13.7±1.4)
쎻
14 Air by-pass hose 쎻
33 Pressure sensor T7: 23±3 (2.3±0.3, 16.6±2.2)
쎻
15 Idle air control solenoid valve 쎻
34 Pressure sources switching solenoid T8: 25±2 (2.5±0.2, 18.1±1.4)
쎻
16 Engine coolant hose A valve T9: 34±2 (3.5±0.2, 25.3±1.4)
쎻
17 Nipple (AT model) 쎻
35 Vacuum hose A
쎻
18 Plug 쎻
36 Vacuum hose B
쎻
19 PCV valve 쎻
37 Vacuum hose C

4
 COMPONENT PARTS 2-7
2. Air Intake System

2. Air Intake System

B2M1166A

쎻
1 Gasket 쎻
8 Stay A Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Throttle position sensor 쎻
9 Stay B (AT model) T1: 2.2±0.2 (0.22±0.02, 1.6±0.1)
쎻
3 Throttle body 쎻
10 Stay C (MT model) T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
쎻
4 Clamp 쎻
11 Stay D (MT model) T3: 22±2 (2.2±0.2, 15.9±1.4)
쎻
5 Air intake duct 쎻
12 Spacer
쎻
6 By-pass hose 쎻
13 Bush
쎻
7 Air intake chamber

5
2-7 COMPONENT PARTS
3. Air Cleaner

3. Air Cleaner

B2M1245A

쎻
1 Mass air flow sensor bracket 쎻
7 Clip Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Mass air flow sensor ASSY 쎻
8 Air cleaner case T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
3 Air cleaner upper cover 쎻
9 Cushion rubber T2: 33±10 (3.4±1.0, 25±7)
쎻
4 Air cleaner element 쎻
10 Air intake duct
쎻
5 Spacer 쎻
11 Resonator chamber ASSY
쎻
6 Bush 쎻
12 Clip

6
 SERVICE PROCEDURE 2-7
1. Air Cleaner and Air Intake Duct

1. Air Cleaner and Air Intake Duct

A: REMOVAL AND INSTALLATION
1) Disconnect connector from mass air flow sensor.

B2M1225A

2) Loosen clamp which connects air intake duct to air

intake chamber.
3) Remove two clips of air cleaner upper cover.
4) Disconnect blow-by hose from air intake duct.

B2M1226A

5) Remove air intake duct and air cleaner upper cover as

a unit.
6) Remove air cleaner element.

B2M1227

7) Remove air cleaner lower case.

B2M1232A

8) Installation is in the reverse order of removal.

CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.

B2M1213

7
2-7 SERVICE PROCEDURE
2. Mass Air Flow Sensor

2. Mass Air Flow Sensor

A: REMOVAL AND INSTALLATION
1) Loosen clamps which connect air intake duct to air
intake chamber and mass air flow sensor.
2) Disconnect blow-by hose from air intake duct.
3) Remove air intake duct.

B2M1214A

4) Disconnect connector from mass air flow sensor.

B2M1246A

5) Remove two clips, then remove air cleaner upper cover.

G2M0390

6) Remove mass air flow sensor from air cleaner upper

cover.
7) Installation is in the reverse order of removal.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
G2M0393

8
 SERVICE PROCEDURE 2-7
3. Throttle Body

3. Throttle Body
A: REMOVAL AND INSTALLATION
1) Loosen clamps which connect air intake duct to air
intake chamber and mass air flow sensor.
2) Disconnect blow-by hose from air intake duct.
3) Remove air intake duct.

B2M1214A

4) Loosen clamp which connects air intake chamber to

throttle body.
5) Disconnect air hoses, and remove air intake chamber.

B2M1218

6) Disconnect accelerator cable 쎻1 .

7) Disconnect cruise control cable 쎻2 . (With cruise control
model)

G2M0280

8) Disconnect connector from throttle position sensor.

B2M1247

9) Disconnect engine coolant hoses from throttle body.

B2M1248

9
2-7 SERVICE PROCEDURE
3. Throttle Body - 4. Intake Manifold

10) Remove bolts which install throttle body to intake

manifold.
11) Installation is in the reverse order of removal.
CAUTION:
쐌 Always use a new gasket.
쐌 Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
Tightening torque:
B2M1249
Throttle body:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
Air intake chamber:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

4. Intake Manifold
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect connector from mass air flow sensor.

B2M1225A

3) Loosen clamp which connects air intake duct to air

intake chamber.
4) Remove two clips of air cleaner upper cover.
5) Disconnect blow-by hose from air intake duct.

B2M1226A

6) Remove air intake duct and air cleaner upper cover as

a unit.
7) Remove air cleaner element.

B2M1227

10
2-7 SERVICE PROCEDURE
3. Throttle Body - 4. Intake Manifold

10) Remove bolts which install throttle body to intake

manifold.
11) Installation is in the reverse order of removal.
CAUTION:
쐌 Always use a new gasket.
쐌 Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
Tightening torque:
B2M1249
Throttle body:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
Air intake chamber:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

4. Intake Manifold
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect connector from mass air flow sensor.

B2M1225A

3) Loosen clamp which connects air intake duct to air

intake chamber.
4) Remove two clips of air cleaner upper cover.
5) Disconnect blow-by hose from air intake duct.

B2M1226A

6) Remove air intake duct and air cleaner upper cover as

a unit.
7) Remove air cleaner element.

B2M1227

10
 SERVICE PROCEDURE 2-7
4. Intake Manifold

8) Loosen clamp which connects air intake chamber to

throttle body.
9) Disconnect air hoses, and remove air intake chamber.

B2M1218

10) Disconnect accelerator cable 쎻 1 .

11) Disconnect cruise control cable 쎻2 . (With cruise control
model)

G2M0280

12) Disconnect vacuum hoses from pressure sources

switching solenoid valve.

B2M1231A

13) Remove power steering pump from bracket.

(1) Remove V-belt cover.

B2M0017

(2) Loosen lock bolt and slider bolt, and remove power
steering pump drive V-belt.

G2M0286

11
2-7 SERVICE PROCEDURE
4. Intake Manifold

(3) Remove bolts which secure power steering pipe

brackets to intake manifold.
NOTE:
Do not disconnect power steering hose.

B2M0340

(4) Remove bolts which install power steering pump to

bracket.

B2M0334

(5) Place power steering pump on the right side wheel

apron.

B2M0029

14) Disconnect spark plug cords from ignition coil.

B6M0772

15) Disconnect PCV hose from intake manifold.

B2M1239

12
 SERVICE PROCEDURE 2-7
4. Intake Manifold

16) Disconnect engine coolant hose from throttle body.

B2M1241

17) Disconnect engine coolant hose 쎻

1 from idle air con-
trol solenoid valve.
18) Disconnect air by-pass hose 쎻2 from idle air control
solenoid valve.

H2M1259A

19) Disconnect brake booster hose.

B2M0342

20) Remove EGR pipe.

B2M1242

21) Disconnect canister hoses from pipes. (2500 cc, 2200

cc FWD and Taiwan spec. vehicles)

G2M0370

13
2-7 SERVICE PROCEDURE
4. Intake Manifold

22) Disconnect engine harness connectors from bulkhead

harness connectors, and remove engine harness connec-
tors from bracket.

B2M0019

23) Disconnect connectors from engine coolant tempera-

1 and thermometer 쎻
ture sensor 쎻 2 .

B2M0345A

24) Disconnect knock sensor connector.

B2M1243A

25) Disconnect connector from camshaft position sensor.

B2M1251A

26) Disconnect connector from crankshaft position sensor.

B2M1252A

14
 SERVICE PROCEDURE 2-7
4. Intake Manifold

27) Disconnect connector from oil pressure switch.

B2M1253A

28) Disconnect fuel hoses from fuel pipes.

WARNING:
Catch fuel from hoses in a container.

G2M0296

29) Remove bolts which hold intake manifold onto cylinder

heads.

B2M0159

30) Remove intake manifold.

B2M0160

B: DISASSEMBLY
1) Disconnect engine ground terminal from intake mani-
fold.

B2M0757A

15
2-7 SERVICE PROCEDURE
4. Intake Manifold

2) Disconnect connectors from throttle position sensor,

ignition coil, fuel injectors, idle air control solenoid valve,
purge control solenoid valve and EGR solenoid valve.
3) Remove engine harness from intake manifold.
쎻1 EGR solenoid valve
쎻2 Throttle position sensor
쎻3 Idle air control solenoid valve
쎻4 Purge control solenoid valve
쎻5 Harness band
B2M0347A

4) Remove idle air control solenoid valve from intake

manifold.

H2M1247

5) Remove throttle body from intake manifold.

B2M0157

6) Remove fuel pipes, etc. from intake manifold.

쎻1 Pressure regulator
쎻2 Fuel pipe ASSY
7) Remove EGR solenoid valve and purge control sole-
noid valve.

B2M0161B

C: ASSEMBLY
1) Install EGR solenoid valve and purge control solenoid
valve.
2) Assemble fuel pipes, etc. to intake manifold.
쎻1 Pressure regulator
쎻2 Fuel pipe ASSY

B2M0161B

16
 SERVICE PROCEDURE 2-7
4. Intake Manifold

3) Assemble throttle body to intake manifold.

CAUTION:
Replace gasket with a new one.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)

B2M0157

4) Install idle air control solenoid valve to intake manifold.

CAUTION:
Replace gasket with a new one.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

H2M1247

5) Install engine harness onto intake manifold.

6) Connect connectors to throttle position sensor, ignition
coil, fuel injectors, idle air control solenoid valve, purge
control solenoid valve and EGR solenoid valve.
쎻1 EGR solenoid valve
쎻2 Throttle position sensor
쎻3 Idle air control solenoid valve
쎻4 Purge control solenoid valve
쎻5 Harness band
B2M0347A

7) Connect engine ground terminal to intake manifold.

B2M0757A

D: INSTALLATION
1) Install intake manifold onto cylinder heads.
CAUTION:
Always use new gaskets.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)

B2M0159

17
2-7 SERVICE PROCEDURE
4. Intake Manifold

2) Connect fuel hoses.

G2M0296

3) Connect connector to oil pressure switch.

B2M1253A

4) Connect connector to crankshaft position sensor.

B2M1252A

5) Connect connector to camshaft position sensor.

B2M1251A

6) Connect knock sensor connector.

B2M1243A

18
 SERVICE PROCEDURE 2-7
4. Intake Manifold

7) Connect connectors to engine coolant temperature sen-

1 and thermometer 쎻
sor 쎻 2 .

B2M0345A

8) Install engine harness connectors to bracket, and con-

nect engine harness connectors to bulkhead connectors.

B2M0019

9) Connect canister hoses. (2500 cc, 2200 cc FWD and

Taiwan spec. vehicles)

G2M0370

10) Install EGR pipe.

Tightening torque:
34±2 N⋅m (3.5±0.2 kg-m, 25.3±1.4 ft-lb)

B2M1242

11) Connect brake booster hose.

B2M0342

19
2-7 SERVICE PROCEDURE
4. Intake Manifold

12) Connect engine coolant hose 쎻1 to idle air control sole-

noid valve.
13) Connect air by-pass hose 쎻
2 to idle air control solenoid
valve.

H2M1259A

14) Connect engine coolant hose to throttle body.

B2M1241

15) Connect PCV hose to intake manifold.

B2M1239

16) Connect spark plug cords to ignition coil.

B6M0772

17) Install power steering pump on bracket.

(1) Install power steering pump on bracket, and tighten
bolts.
Tightening torque:
20.1±2.5 N⋅m (2.05±0.25 kg-m, 14.8±1.8 ft-lb)

B2M0334

20
 SERVICE PROCEDURE 2-7
4. Intake Manifold

(2) Install power steering pipe brackets on right side

intake manifold.

B2M0340

(3) Install power steering pump drive V-belt.

(4) Adjust V-belt. <Ref. to 1-5 [01A0].>

G2M0286

(5) Install V-belt cover.

B2M0017

18) Connect vacuum hoses to pressure sources switching

solenoid valve.

B2M1231A

19) Connect accelerator cable 쎻1 .

20) Connect cruise control cable 쎻 2 . (With cruise control
model)

G2M0280

21
2-7 SERVICE PROCEDURE
4. Intake Manifold - 5. Engine Coolant Temperature Sensor

21) Install air intake chamber and connect air hoses.

Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

B2M1218

22) Install air cleaner element.

23) Install air cleaner upper cover and air intake duct as a
unit.
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.

B2M1213

24) Connect connector to mass air flow sensor.

B2M1225A

5. Engine Coolant Temperature Sensor

A: REMOVAL AND INSTALLATION
1) Remove air intake duct.

B2M0154

2) Disconnect connector from engine coolant temperature

sensor.
3) Remove engine coolant temperature sensor.

G2M0407

22
2-7 SERVICE PROCEDURE
4. Intake Manifold - 5. Engine Coolant Temperature Sensor

21) Install air intake chamber and connect air hoses.

Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

B2M1218

22) Install air cleaner element.

23) Install air cleaner upper cover and air intake duct as a
unit.
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.

B2M1213

24) Connect connector to mass air flow sensor.

B2M1225A

5. Engine Coolant Temperature Sensor

A: REMOVAL AND INSTALLATION
1) Remove air intake duct.

B2M0154

2) Disconnect connector from engine coolant temperature

sensor.
3) Remove engine coolant temperature sensor.

G2M0407

22
 SERVICE PROCEDURE 2-7
5. Engine Coolant Temperature Sensor - 7. Front Oxygen Sensor

4) Installation is in the reverse order of removal.

Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)

G2M0407

6. Crankshaft Position Sensor

A: REMOVAL AND INSTALLATION
1) Remove bolt which install crankshaft position sensor to
cylinder block.

G2M0408

2) Remove crankshaft position sensor, and disconnect

connector from it.

G2M0409

3) Installation is in the reverse order of removal.

Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

G2M0408

7. Front Oxygen Sensor

A: REMOVAL
1) Remove air intake duct.

B2M0154

23
 SERVICE PROCEDURE 2-7
5. Engine Coolant Temperature Sensor - 7. Front Oxygen Sensor

4) Installation is in the reverse order of removal.

Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)

G2M0407

6. Crankshaft Position Sensor

A: REMOVAL AND INSTALLATION
1) Remove bolt which install crankshaft position sensor to
cylinder block.

G2M0408

2) Remove crankshaft position sensor, and disconnect

connector from it.

G2M0409

3) Installation is in the reverse order of removal.

Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

G2M0408

7. Front Oxygen Sensor

A: REMOVAL
1) Remove air intake duct.

B2M0154

23
 SERVICE PROCEDURE 2-7
5. Engine Coolant Temperature Sensor - 7. Front Oxygen Sensor

4) Installation is in the reverse order of removal.

Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)

G2M0407

6. Crankshaft Position Sensor

A: REMOVAL AND INSTALLATION
1) Remove bolt which install crankshaft position sensor to
cylinder block.

G2M0408

2) Remove crankshaft position sensor, and disconnect

connector from it.

G2M0409

3) Installation is in the reverse order of removal.

Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

G2M0408

7. Front Oxygen Sensor

A: REMOVAL
1) Remove air intake duct.

B2M0154

23
2-7 SERVICE PROCEDURE
7. Front Oxygen Sensor

2) Disconnect connector from front oxygen sensor.

G2M0544

3) Lift-up the vehicle.

4) Apply SUBARU CRC or its equivalent to threaded por-
tion of front oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)

5) Remove front oxygen sensor.

CAUTION:
When removing oxygen sensor, do not force oxygen
sensor especially when exhaust pipe is cold, other-
wise it will damage exhaust pipe.

G2M0411

B: INSTALLATION
1) Before installing front oxygen sensor, apply anti-seize
compound only to threaded portion of front oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of front
oxygen sensor.
G2M0412

2) Install front oxygen sensor.

Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector of front oxygen sensor.
5) Install air intake duct.

G2M0411

24
 SERVICE PROCEDURE 2-7
8. Rear Oxygen Sensor

8. Rear Oxygen Sensor

A: REMOVAL
1. EXCEPT CALIFORNIA 2200 cc MODEL
1) Lift-up the vehicle.
2) Disconnect connector from rear oxygen sensor.

B2M0335

3) Apply SUBARU CRC or its equivalent to threaded por-

tion of rear oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)

4) Remove rear oxygen sensor.

CAUTION:
When removing rear oxygen sensor, do not force rear
oxygen sensor especially when exhaust pipe is cold,
otherwise it will damage exhaust pipe.

B2M0351

2. CALIFORNIA 2200 cc MODEL

1) Disconnect connector from rear oxygen sensor.
2) Lift-up the vehicle.

B2M0740

3) Apply SUBARU CRC or its equivalent to threaded por-

tion of rear oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)

25
2-7 SERVICE PROCEDURE
8. Rear Oxygen Sensor

4) Remove rear oxygen sensor.

CAUTION:
When removing rear oxygen sensor, do not force rear
oxygen sensor especially when exhaust pipe is cold,
otherwise it will damage exhaust pipe.

B2M0741

B: INSTALLATION
1. EXCEPT CALIFORNIA 2200 cc MODEL
1) Before installing rear oxygen sensor, apply anti-seize
compound only to threaded portion of rear oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
B2M0352A Never apply anti-seize compound to protector of rear
oxygen sensor.

2) Install rear oxygen sensor.

Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Connect connector of rear oxygen sensor.
4) Lower the vehicle.

B2M0351

2. CALIFORNIA 2200 cc MODEL

1) Before installing rear oxygen sensor, apply anti-seize
compound only to threaded portion of rear oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of rear
oxygen sensor.
B2M0742A

26
 SERVICE PROCEDURE 2-7
8. Rear Oxygen Sensor - 9. Throttle Position Sensor

2) Install rear oxygen sensor.

Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector to rear oxygen sensor.

B2M0741

9. Throttle Position Sensor

A: REMOVAL AND INSTALLATION
1) Disconnect connector from throttle position sensor.
2) Remove throttle position sensor holding screws, and
remove it.
3) Installation is in the reverse order of removal.
Tightening torque:
2.2±0.2 N⋅m (0.22±0.02 kg-m, 1.6±0.1 ft-lb)
B2M0162 CAUTION:
When installing throttle position sensor, adjust to the
specified data.

B: ADJUSTMENT
1) Turn ignition switch to OFF.
2) Loosen throttle position sensor holding screws.

B2M0163

3) When using voltage meter;

(1) Take out ECM.
(2) Turn ignition switch to ON.
(3) Adjust throttle position sensor so that signal voltage
to ECM may be in specification.
Connector & Terminal / Specified voltage
(B84) No. 24 — (B84) No. 25 / 0.45 — 0.55 V
[Fully closed.]
(4) Tighten throttle position sensor holding screws.
G2M0415

27
 SERVICE PROCEDURE 2-7
8. Rear Oxygen Sensor - 9. Throttle Position Sensor

2) Install rear oxygen sensor.

Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector to rear oxygen sensor.

B2M0741

9. Throttle Position Sensor

A: REMOVAL AND INSTALLATION
1) Disconnect connector from throttle position sensor.
2) Remove throttle position sensor holding screws, and
remove it.
3) Installation is in the reverse order of removal.
Tightening torque:
2.2±0.2 N⋅m (0.22±0.02 kg-m, 1.6±0.1 ft-lb)
B2M0162 CAUTION:
When installing throttle position sensor, adjust to the
specified data.

B: ADJUSTMENT
1) Turn ignition switch to OFF.
2) Loosen throttle position sensor holding screws.

B2M0163

3) When using voltage meter;

(1) Take out ECM.
(2) Turn ignition switch to ON.
(3) Adjust throttle position sensor so that signal voltage
to ECM may be in specification.
Connector & Terminal / Specified voltage
(B84) No. 24 — (B84) No. 25 / 0.45 — 0.55 V
[Fully closed.]
(4) Tighten throttle position sensor holding screws.
G2M0415

27
2-7 SERVICE PROCEDURE
9. Throttle Position Sensor - 11. Pressure Sensor (AT model)

4) When using Subaru Select Monitor;

(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Turn ignition switch to ON and SSM switch to ON.
(3) Select mode “F10”.
(4) Adjust throttle position sensor to specified data.
Condition / Specified data.
Throttle fully closed / 0.50 V
(5) Tighten throttle position sensor holding screws.
G2M0096

10. Camshaft Position Sensor

A: REMOVAL AND INSTALLATION
1) Disconnect connector from camshaft position sensor.

G2M0416

2) Remove camshaft position sensor from camshaft sup-

port LH.
3) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

G2M0417

11. Pressure Sensor (AT model)

A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sensor.
2) Disconnect hose from pressure sensor.

B2M0355

3) Remove pressure sensor from bracket.

4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0356

28
2-7 SERVICE PROCEDURE
9. Throttle Position Sensor - 11. Pressure Sensor (AT model)

4) When using Subaru Select Monitor;

(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Turn ignition switch to ON and SSM switch to ON.
(3) Select mode “F10”.
(4) Adjust throttle position sensor to specified data.
Condition / Specified data.
Throttle fully closed / 0.50 V
(5) Tighten throttle position sensor holding screws.
G2M0096

10. Camshaft Position Sensor

A: REMOVAL AND INSTALLATION
1) Disconnect connector from camshaft position sensor.

G2M0416

2) Remove camshaft position sensor from camshaft sup-

port LH.
3) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

G2M0417

11. Pressure Sensor (AT model)

A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sensor.
2) Disconnect hose from pressure sensor.

B2M0355

3) Remove pressure sensor from bracket.

4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0356

28
2-7 SERVICE PROCEDURE
9. Throttle Position Sensor - 11. Pressure Sensor (AT model)

4) When using Subaru Select Monitor;

(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Turn ignition switch to ON and SSM switch to ON.
(3) Select mode “F10”.
(4) Adjust throttle position sensor to specified data.
Condition / Specified data.
Throttle fully closed / 0.50 V
(5) Tighten throttle position sensor holding screws.
G2M0096

10. Camshaft Position Sensor

A: REMOVAL AND INSTALLATION
1) Disconnect connector from camshaft position sensor.

G2M0416

2) Remove camshaft position sensor from camshaft sup-

port LH.
3) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

G2M0417

11. Pressure Sensor (AT model)

A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sensor.
2) Disconnect hose from pressure sensor.

B2M0355

3) Remove pressure sensor from bracket.

4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0356

28
 SERVICE PROCEDURE 2-7
12. Idle Air Control Solenoid Valve

12. Idle Air Control Solenoid Valve

A: REMOVAL AND INSTALLATION
1) Disconnect connector from idle air control solenoid
valve.

B2M0164

2) Disconnect engine coolant hoses 쎻

1 from idle air con-
trol solenoid valve.
3) Disconnect air by-pass hose 쎻2 from idle air control
solenoid valve.

B2M0165A

4) Remove idle air control solenoid valve from throttle

body.
5) Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0166

B: CLEANING
1) Start and warm-up the engine until radiator fan oper-
ates.
2) Hold throttle valve so that engine speed is at 2,000 rpm.

B2M0357

3) Disconnect by-pass hose from idle air control solenoid

valve.

B2M0359

29
2-7 SERVICE PROCEDURE
12. Idle Air Control Solenoid Valve - 13. Pressure Sources Switching Solenoid Valve (AT model)

4) Slowly pour one can (16 oz) of cleaner into by-pass air
hole.
Cleaner:
쐌 Part No. 1050002 GM Top Engine Cleaner
쐌 Part No. X66-A AC Delco Carburetor Tune-up
Conditioner
5) Leave the engine running for five minutes.
NOTE:
White smoke comes out of the muffler until the cleaner is
B2M0358
used up.
6) Stop the engine.

7) Release the throttle valve.

8) Connect by-pass hose to idle air control solenoid valve.

B2M0359

9) Check duty ratio of idle air control solenoid valve with

Subaru Select Monitor.
(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Start the engine and turn Subaru Select Monitor
switch to ON.
(3) Select mode “F12”.
(4) Make sure duty ratio on radiator fan and electric
load is OFF.
G2M0096
Specified data: 25 — 40%
13. Pressure Sources Switching
Solenoid Valve (AT model)
A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sources switching
solenoid valve.
2) Disconnect hoses from pressure sources switching
solenoid valve.

B2M0361

30
2-7 SERVICE PROCEDURE
12. Idle Air Control Solenoid Valve - 13. Pressure Sources Switching Solenoid Valve (AT model)

4) Slowly pour one can (16 oz) of cleaner into by-pass air
hole.
Cleaner:
쐌 Part No. 1050002 GM Top Engine Cleaner
쐌 Part No. X66-A AC Delco Carburetor Tune-up
Conditioner
5) Leave the engine running for five minutes.
NOTE:
White smoke comes out of the muffler until the cleaner is
B2M0358
used up.
6) Stop the engine.

7) Release the throttle valve.

8) Connect by-pass hose to idle air control solenoid valve.

B2M0359

9) Check duty ratio of idle air control solenoid valve with

Subaru Select Monitor.
(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Start the engine and turn Subaru Select Monitor
switch to ON.
(3) Select mode “F12”.
(4) Make sure duty ratio on radiator fan and electric
load is OFF.
G2M0096
Specified data: 25 — 40%
13. Pressure Sources Switching
Solenoid Valve (AT model)
A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sources switching
solenoid valve.
2) Disconnect hoses from pressure sources switching
solenoid valve.

B2M0361

30
 SERVICE PROCEDURE 2-7
13. Pressure Sources Switching Solenoid Valve (AT model) - 15. Engine Control Module

3) Remove pressure sources switching solenoid valve

from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0362

14. Fuel Injector

A: REMOVAL AND INSTALLATION
1) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
2) Disconnect connector from fuel injector.

G2M0398

3) Remove fuel injector from fuel pipe assembly.

G2M0431

4) Installation is in the reverse order of removal.

CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
쎻1 O-ring B
쎻2 O-ring A
쎻3 Fuel injector
쎻4 Insulator
B2M0169A
쎻5 Fuel injector cup
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

31
 SERVICE PROCEDURE 2-7
13. Pressure Sources Switching Solenoid Valve (AT model) - 15. Engine Control Module

3) Remove pressure sources switching solenoid valve

from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0362

14. Fuel Injector

A: REMOVAL AND INSTALLATION
1) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
2) Disconnect connector from fuel injector.

G2M0398

3) Remove fuel injector from fuel pipe assembly.

G2M0431

4) Installation is in the reverse order of removal.

CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
쎻1 O-ring B
쎻2 O-ring A
쎻3 Fuel injector
쎻4 Insulator
B2M0169A
쎻5 Fuel injector cup
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

31
 SERVICE PROCEDURE 2-7
13. Pressure Sources Switching Solenoid Valve (AT model) - 15. Engine Control Module

3) Remove pressure sources switching solenoid valve

from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)

B2M0362

14. Fuel Injector

A: REMOVAL AND INSTALLATION
1) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
2) Disconnect connector from fuel injector.

G2M0398

3) Remove fuel injector from fuel pipe assembly.

G2M0431

4) Installation is in the reverse order of removal.

CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
쎻1 O-ring B
쎻2 O-ring A
쎻3 Fuel injector
쎻4 Insulator
B2M0169A
쎻5 Fuel injector cup
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

31
2-7 SERVICE PROCEDURE
15. Engine Control Module - 16. Main Relay

2) Detach floor mat of front passenger seat.

3) Remove protect cover.

G2M0434

4) Release the lock of ECM connector and disconnect it.

5) Remove nuts which install ECM onto body.
6) Take out ECM.

B2M0363

7) Connect ECM connector and lock it.

8) Installation is in the reverse order of removal.

B2M0364

16. Main Relay

A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove lower cover and then disconnect connectors.

3) Lower transmission control module.
4) Remove the front pillar lower trim.
<Ref. to 5-3 [W5A1].>
5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.

B5M0024A

32
2-7 SERVICE PROCEDURE
15. Engine Control Module - 16. Main Relay

2) Detach floor mat of front passenger seat.

3) Remove protect cover.

G2M0434

4) Release the lock of ECM connector and disconnect it.

5) Remove nuts which install ECM onto body.
6) Take out ECM.

B2M0363

7) Connect ECM connector and lock it.

8) Installation is in the reverse order of removal.

B2M0364

16. Main Relay

A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove lower cover and then disconnect connectors.

3) Lower transmission control module.
4) Remove the front pillar lower trim.
<Ref. to 5-3 [W5A1].>
5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.

B5M0024A

32
 SERVICE PROCEDURE 2-7
16. Main Relay - 17. Fuel Pump Relay

8) Remove screw which retains bracket of main relay 쎻

1
and fuel pump relay 쎻
2 .
9) Disconnect connector from main relay.

G2M0438

10) Installation is in the reverse order of removal.

쎻1 Main relay
쎻2 Fuel pump relay

G2M0438

17. Fuel Pump Relay

A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove lower cover and then disconnect connectors.

3) Lower transmission control module.
4) Remove the front pillar lower trim.
<Ref. to 5-3 [W5A1].>
5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.

B5M0024A

8) Remove fuel pump relay from main relay and fuel pump
relay mounting bracket.
9) Disconnect connector from fuel pump relay.

G2M0438

33
 SERVICE PROCEDURE 2-7
16. Main Relay - 17. Fuel Pump Relay

8) Remove screw which retains bracket of main relay 쎻

1
and fuel pump relay 쎻
2 .
9) Disconnect connector from main relay.

G2M0438

10) Installation is in the reverse order of removal.

쎻1 Main relay
쎻2 Fuel pump relay

G2M0438

17. Fuel Pump Relay

A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove lower cover and then disconnect connectors.

3) Lower transmission control module.
4) Remove the front pillar lower trim.
<Ref. to 5-3 [W5A1].>
5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.

B5M0024A

8) Remove fuel pump relay from main relay and fuel pump
relay mounting bracket.
9) Disconnect connector from fuel pump relay.

G2M0438

33
2-7 SERVICE PROCEDURE
17. Fuel Pump Relay - 19. Knock Sensor

10) Installation is in the reverse order of removal.

쎻1 Main relay
쎻2 Fuel pump relay

G2M0438

18. Air Intake Chamber

A: REMOVAL AND INSTALLATION
1) Loosen clamps which connect air intake chamber to
throttle body and air intake duct.
2) Disconnect air hoses from air intake chamber.
3) Remove bolts which secure air intake chamber to stays.
4) Remove air intake chamber.
5) Installation is in the reverse order of removal.
B2M1254 Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

19. Knock Sensor

A: REMOVAL
1. 2200 cc MODEL
1) Disconnect battery ground cable from battery ground
terminal.

G6M0095

2) Remove air intake chamber.

<Ref. to 2-7 [W18A0].>

B2M1679

34
2-7 SERVICE PROCEDURE
17. Fuel Pump Relay - 19. Knock Sensor

10) Installation is in the reverse order of removal.

쎻1 Main relay
쎻2 Fuel pump relay

G2M0438

18. Air Intake Chamber

A: REMOVAL AND INSTALLATION
1) Loosen clamps which connect air intake chamber to
throttle body and air intake duct.
2) Disconnect air hoses from air intake chamber.
3) Remove bolts which secure air intake chamber to stays.
4) Remove air intake chamber.
5) Installation is in the reverse order of removal.
B2M1254 Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

19. Knock Sensor

A: REMOVAL
1. 2200 cc MODEL
1) Disconnect battery ground cable from battery ground
terminal.

G6M0095

2) Remove air intake chamber.

<Ref. to 2-7 [W18A0].>

B2M1679

34
2-7 SERVICE PROCEDURE
17. Fuel Pump Relay - 19. Knock Sensor

10) Installation is in the reverse order of removal.

쎻1 Main relay
쎻2 Fuel pump relay

G2M0438

18. Air Intake Chamber

A: REMOVAL AND INSTALLATION
1) Loosen clamps which connect air intake chamber to
throttle body and air intake duct.
2) Disconnect air hoses from air intake chamber.
3) Remove bolts which secure air intake chamber to stays.
4) Remove air intake chamber.
5) Installation is in the reverse order of removal.
B2M1254 Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)

19. Knock Sensor

A: REMOVAL
1. 2200 cc MODEL
1) Disconnect battery ground cable from battery ground
terminal.

G6M0095

2) Remove air intake chamber.

<Ref. to 2-7 [W18A0].>

B2M1679

34
 SERVICE PROCEDURE 2-7
19. Knock Sensor

3) Remove band clip which fastens engine harness to

engine coolant hose.

B2M1680A

4) Disconnect knock sensor connector.

B2M1681

5) Remove knock sensor from cylinder block.

B2M1682

2. 2500 cc MODEL
1) Disconnect battery ground cable from battery ground
terminal.

G6M0095

2) Remove air intake chamber.

<Ref. to 2-7 [W18A0].>

B2M1683

35
2-7 SERVICE PROCEDURE
19. Knock Sensor

3) Remove operating cylinder. (MT vehicle only)

B2M1179D

NOTE:
Place the operating cylinder where it will not interfere with
the work in process.

B2M1684

4) Remove band clip which fastens engine harness to

engine coolant hose.

B2M1685A

5) Disconnect knock sensor connector.

B2M1686

6) Remove knock sensor from cylinder block.

B2M1682

36
 SERVICE PROCEDURE 2-7
19. Knock Sensor

B: INSTALLATION
1. 2200 cc MODEL
1) Install knock sensor to cylinder block.
Tightening torque:
23.5±2.9 N⋅m (2.4±0.3 kg-m, 17.3±2.1 ft-lb)
NOTE:
The extraction area of the knock sensor cord must be posi-
tioned at a 45° angle relative to the engine rear.
B2M1682A

2) Connect knock sensor connector.

B2M1681

NOTE:
The knock sensor cord must pass between the engine
harness and engine coolant hose.

B2M1687A

3) Fasten engine harness to engine coolant hose with

band clip.
NOTE:
Make sure that the throttle linkage does not interfere with
other parts in the operating area.

B2M1680A

4) Install air intake chamber. <Ref. to 2-7 [W18A0].>

B2M1679

37
2-7 SERVICE PROCEDURE
19. Knock Sensor

5) Connect battery ground cable to battery ground termi-

nal.

G6M0095

2. 2500 cc MODEL
1) Install knock sensor to cylinder block.
Tightening torque:
23.5±2.9 N⋅m (2.4±0.3 kg-m, 17.3±2.1 ft-lb)
NOTE:
The extraction area of the knock sensor cord must be posi-
tioned at a 45° angle relative to the engine rear.

B2M1682A

2) Connect knock sensor connector.

B2M1686

NOTE:
The connector must be connected to the engine front end
of the engine coolant hose.

B2M1688A

B2M1689A

38
 SERVICE PROCEDURE 2-7
19. Knock Sensor

3) Fasten engine harness to engine coolant hose with

band clip.
NOTE:
Make sure that the throttle linkage does not interfere with
other parts in the operating area.

B2M1685A

4) Install operating cylinder. (MT vehicle only)

Tightening torque:
37±3 N⋅m (3.8±0.3 kg-m, 27.3±2.2 ft-lb)
NOTE:
Apply grease to contact point of release lever and operat-
ing cylinder rod. <Ref. to 2-10 [W5A0].>

B2M1179E

5) Install air intake chamber. <Ref. to 2-7 [W18A0].>

B2M1683

6) Connect battery ground cable to battery ground termi-

nal.

G6M0095

39
2-8 SPECIFICATIONS AND SERVICE DATA
1. Fuel System

1. Fuel System
A: SPECIFICATIONS
Capacity 60
(15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Discharge pressure 250.1 kPa (2.55 kg/cm2, 36.3 psi)
Fuel pump
AWD: More than 80
(21.1 US gal, 17.6 Imp gal)/h
Discharge flow FWD: More than 65
(17.2 US gal, 14.3 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type

2
 COMPONENT PARTS 2-8
1. Fuel Tank

1. Fuel Tank
1. 2500 cc AWD MODEL

B2M0630A

쎻
1 Heat sealed cover 쎻
12 Clip 쎻
23 Fuel delivery hose B
쎻
2 Fuel tank band 쎻
13 Joint pipe 쎻
24 Fuel return hose B
쎻
3 Protector LH 쎻
14 Evaporation hose B 쎻
25 Evaporation hose E
쎻
4 Protector RH 쎻
15 Evaporation pipe ASSY 쎻
26 Fuel sub meter gasket
쎻
5 Fuel tank 쎻
16 Evaporation hose D 쎻
27 Jet pump filter
쎻
6 Fuel pump gasket 쎻
17 Clamp 쎻
28 Fuel sub meter unit
쎻
7 Fuel pump ASSY 쎻
18 Jet pump hose A 쎻
29 Roll over valve
쎻
8 Fuel cut valve gasket 쎻
19 Fuel delivery hose A
쎻
9 Fuel cut valve 쎻
20 Fuel return hose A Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
쎻
10 Evaporation hose C 쎻
21 Fuel pipe ASSY
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
11 Evaporation hose A 쎻
22 Jet pump hose B T3: 33±10 (3.4±1.0, 25±7)

3
2-8 COMPONENT PARTS
1. Fuel Tank

2. FWD MODEL

B2M0631A

쎻
1 Heat seated cover 쎻
14 Fuel delivery hose B
쎻
2 Fuel tank band 쎻
15 Fuel return hose B
쎻
3 Protector 쎻
16 Evaporation hose B
쎻
4 Protector bracket 쎻
17 Plate
쎻
5 Fuel tank 쎻
18 Roll over valve
쎻
6 Fuel pump gasket
쎻
7 Fuel pump ASSY Tightening torque: N⋅m (kg-m, ft-lb)
쎻
8 Clamp T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
쎻
9 Clip T2: 7.4±0.2 (0.75±0.2, 5.4±1.4)
쎻
10 Fuel delivery hose A T3: 18±5 (1.8±0.5, 13.0±3.6)
T4: 33±10 (3.4±1.0, 25±7)
쎻
11 Fuel return hose A
쎻
12 Evaporation hose A
쎻
13 Fuel pipe ASSY

4
COMPONENT PARTS 2-8
1. Fuel Tank

3. 2200 cc AWD MODEL

B2M0975A

5
2-8 COMPONENT PARTS
1. Fuel Tank

쎻
1 Heat sealed cover 쎻
20 Evaporation hose D
쎻
2 Fuel tank band 쎻
21 Evaporation hose E
쎻
3 Protector LH 쎻
22 Clamp
쎻
4 Protector RH 쎻
23 Jet pump hose A
쎻
5 Fuel tank 쎻
24 Fuel delivery hose A
쎻
6 Pressure control solenoid valve bracket 쎻
25 Fuel return hose A
쎻
7 Pressure control solenoid valve 쎻
26 Fuel pipe ASSY
쎻
8 Evaporation hose G 쎻
27 Jet pump hose B
쎻
9 Evaporation pipe A 쎻
28 Fuel delivery hose B
쎻
10 Fuel pump gasket 쎻
29 Fuel return hose B
쎻
11 Fuel pump ASSY 쎻
30 Evaporation hose F
쎻
12 Fuel cut valve gasket 쎻
31 Fuel sub meter gasket
쎻
13 Fuel cut valve 쎻
32 Jet pump filter
쎻
14 Evaporation hose C 쎻
33 Fuel sub meter unit
쎻
15 Evaporation hose A
쎻
16 Clip Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
쎻
17 Joint pipe
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
18 Evaporation hose B T3: 33±10 (3.4±1.0, 25±7)
쎻
19 Evaporation pipe ASSY

6
 COMPONENT PARTS 2-8
2. Fuel Line

2. Fuel Line
1. 2200 cc FWD AND 2500 cc MODEL

B2M0046A

쎻
1 Clamp 쎻
10 Fuel return hose
쎻
2 Fuel delivery hose A 쎻
11 Air vent hose
쎻
3 Fuel filter bracket 쎻
12 Canister
쎻
4 Fuel filter holder 쎻
13 Canister hose A
쎻
5 Fuel filter cup 쎻
14 Two-way valve
쎻
6 Fuel filter 쎻
15 Canister hose B
쎻
7 Evaporation hose 쎻
16 Canister hose C
쎻
8 Clip 쎻
17 Canister bracket
쎻
9 Fuel delivery hose B 쎻
18 Fuel pipe ASSY

7
2-8 COMPONENT PARTS
2. Fuel Line

2. 2200 cc AWD MODEL

B2M0974A

8
 COMPONENT PARTS 2-8
2. Fuel Line

쎻
1 Clamp 쎻
27 Ring A
쎻
2 Fuel delivery hose A 쎻
28 Ring B
쎻
3 Fuel filter bracket 쎻
29 Fuel filler cap
쎻
4 Fuel filter holder 쎻
30 Fuel filler pipe protector
쎻
5 Fuel filter cup 쎻
31 Fuel tank pressure sensor
쎻
6 Fuel filter 쎻
32 Fuel tank pressure sensor hose A
쎻
7 Evaporation hose 쎻
33 Fuel tank pressure sensor bracket
쎻
8 Clip 쎻
34 Grommet
쎻
9 Fuel delivery hose B 쎻
35 Fuel tank pressure sensor hose B
쎻
10 Fuel return hose
쎻
36 Air ventilator hose A
쎻
11 Roll over valve
쎻
37 Air ventilator pipe A
쎻
12 Roll over valve bracket
쎻
38 Air ventilator hose B
쎻
13 Evaporation hose H
쎻
39 Air ventilator pipe B
쎻
14 Evaporation hose I
쎻
15 Evaporation pipe B 쎻
40 Air ventilator pipe protector
쎻
16 Canister hose A 쎻
41 Vent control solenoid valve
쎻
17 Canister hose B 쎻
42 Vent control solenoid valve hose
쎻
18 Canister holder 쎻
43 Air filter hose A
쎻
19 Canister upper bracket 쎻
44 Air filter hose B
쎻
20 Cushion rubber 쎻
45 Air filter
쎻
21 Canister lower bracket 쎻
46 Tapping screw
쎻
22 Canister
쎻
23 Fuel pipe ASSY Tightening torque: N⋅m (kg-m, ft-lb)
T1: 23±7 (2.3±0.7, 17±5.1)
쎻
24 Fuel filler valve
T2: 25±7 (2.5±0.7, 18±5.1)
쎻
25 Fuel filler pipe
쎻
26 Packing

9
2-8 SERVICE PROCEDURE
1. Precautions

1. Precautions
WARNING:
쐌 Place “No fire” signs near the working area.
쐌 Disconnect ground terminal from battery.
쐌 Be careful not to spill fuel on the floor.

A: RELEASING OF FUEL PRESSURE

1) Take off floor mat.
2) Remove access hole lid.

G2M0340

3) Disconnect connector from fuel pump.

4) Start the engine, and run it until it stalls.
5) After the engine stalls, crank it for five more seconds.
6) Turn ignition switch OFF.

B2M0047

B: DRAINING OF FUEL
1) Remove rear seat and seat back.
2) Remove access hole lid.

G2M0340

3) Disconnect connector from fuel pump.

4) Release fuel pressure. <Ref. to 2-8 [W1A0].>

B2M0047

10
 SERVICE PROCEDURE 2-8
1. Precautions

5) Disconnect fuel delivery hose 쎻1 and return hose 쎻

2 .
6) Disconnect jet pump hose 쎻 3 . (AWD model)

B2M0048A

7) Remove nuts which install fuel pump assembly onto

fuel tank.

G2M0343

8) Take off fuel pump from fuel tank.

G2M0344

9) Drain fuel from fuel tank by using a hand pump.

WARNING:
Do not use a motor pump when draining fuel.

G2M0345

10) After draining fuel, reinstall fuel pump.

Tighten nuts in numerical 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)

G2M0346

11
2-8 SERVICE PROCEDURE
1. Precautions - 2. On-Car Services

11) On AWD model, after removing fuel sub meter unit,

drain fuel from there.
WARNING:
Do not use a motor pump when draining fuel.

B2M0049

2. On-Car Services
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Connect connector to fuel pump.

3) Disconnect fuel delivery hoses from fuel filter, and con-

nect fuel pressure gauge.

G2M0347

4) Start the engine.

5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from collector chamber.
Fuel pressure:
235 — 265 kPa (2.4 — 2.7 kg/cm2, 34 — 38 psi)
6) After connecting pressure regulator vacuum hose, mea-
sure fuel pressure.
Fuel pressure:
177 — 206 kPa (1.8 — 2.1 kg/cm2, 26 — 30 psi)
G2M0348
WARNING:
Before removing fuel pressure gauge, release fuel
pressure.
NOTE:
If out of specification as measured at step 6), check or
replace pressure regulator and pressure regulator vacuum
hose.

12
2-8 SERVICE PROCEDURE
1. Precautions - 2. On-Car Services

11) On AWD model, after removing fuel sub meter unit,

drain fuel from there.
WARNING:
Do not use a motor pump when draining fuel.

B2M0049

2. On-Car Services
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Connect connector to fuel pump.

3) Disconnect fuel delivery hoses from fuel filter, and con-

nect fuel pressure gauge.

G2M0347

4) Start the engine.

5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from collector chamber.
Fuel pressure:
235 — 265 kPa (2.4 — 2.7 kg/cm2, 34 — 38 psi)
6) After connecting pressure regulator vacuum hose, mea-
sure fuel pressure.
Fuel pressure:
177 — 206 kPa (1.8 — 2.1 kg/cm2, 26 — 30 psi)
G2M0348
WARNING:
Before removing fuel pressure gauge, release fuel
pressure.
NOTE:
If out of specification as measured at step 6), check or
replace pressure regulator and pressure regulator vacuum
hose.

12
 SERVICE PROCEDURE 2-8
3. Fuel Tank

3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>

G2M0345

3) Remove rear exhaust pipe.

(1) Lift-up the vehicle.
(2) Separate rear exhaust pipe from center exhaust
pipe.
(3) Separate rear exhaust pipe from muffler.
(4) Remove bracket from rubber cushion, and remove
exhaust pipe.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
G2M0382
CRC5-56 (Part No. 004301003)
<Ref. to 2-9 [W2A0].>

4) Remove muffler assembly.

NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
<Ref. to 2-9 [W3A0].>

G2M0384

5) Remove rear differential assembly. (AWD model)

(1) Remove rear axle shafts from rear differential
assembly.
(2) Remove rear differential front cover.
(3) Remove propeller shaft.
(4) Remove lower differential bracket.
(5) Set transmission jack under rear differential.
(6) Remove bolts which install rear differential onto
rear crossmember.
G3M0059
<Ref. to 3-4 [W2B0].>

13
2-8 SERVICE PROCEDURE
3. Fuel Tank

6) Remove rear crossmember. (AWD model)

<Ref. to 4-1 [W11A0].>

G4M0545

7) Loosen clamp, and disconnect fuel filler hose from pipe.

8) Loosen clamp, and disconnect air vent hose from air
vent pipe.
쎻1 Fuel filler hose
쎻2 Air vent hose

G2M0353

9) Loosen clip and clamps, and disconnect fuel delivery

1 , return hose 쎻
hose 쎻 2 and evaporation hose 쎻
3 .

B2M0310A

10) While holding fuel tank, remove bolts from bands and
dismount fuel tank.
WARNING:
A helper is required to perform step 10).

G2M0356

B: INSTALLATION
Installation is in the reverse order of removal. Do the fol-
lowing:
1) When installing fuel tank, have a helper hold fuel tank
while installing bands.
2) Before tightening band mounting bolts, connect fuel
system hoses.

14
 SERVICE PROCEDURE 2-8
3. Fuel Tank

3) Install hose and hold down clips at positions indicated

in Figure.
Tightening torque:
1.0 +0.5
−0 N⋅m (0.1 +0.05
−0 kg-m, 0.7 +0.4
−0 ft-lb)
Type A: When fitting length is specified.
Type B: When fitting length is not specified.
쎻1 Fitting
쎻2 Clamp
쎻3 Hose
G2M0357

: 1.0 — 4.0 mm (0.039 — 0.157 in)
L: 20 — 25 mm (0.79 — 0.98 in)

쎻1 Hose
쎻2 Clip
쎻3 Pipe
Fuel return hose:
L = 20 — 25 mm (0.79 — 0.98 in)
Evaporation hose:
L = 15 — 20 mm (0.59 — 0.79 in)

G2M0358

4) Tighten band mounting bolts.

Tightening torque:
33±10 N⋅m (3.4±1.0 kg-m, 25±7 ft-lb)

G2M0356

5) Install rear crossmember. <Ref. to 4-1 [W11C0].>

G4M0545

15
2-8 SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe

6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>

G3M0059

7) Install muffler assembly.

G2M0384

8) Install heat sealed cover.

9) Install rear exhaust pipe.

G2M0382

10) Lower the vehicle, and connect connector to fuel

pump.
11) Install access hole lid.

G2M0340

4. Fuel Filler Pipe

A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>

G2M0345

16
2-8 SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe

6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>

G3M0059

7) Install muffler assembly.

G2M0384

8) Install heat sealed cover.

9) Install rear exhaust pipe.

G2M0382

10) Lower the vehicle, and connect connector to fuel

pump.
11) Install access hole lid.

G2M0340

4. Fuel Filler Pipe

A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>

G2M0345

16
 SERVICE PROCEDURE 2-8
4. Fuel Filler Pipe

3) Remove right rear wheel.

4) Open fuel filler flap and remove filler cap.
5) Remove screws holding packing in place.

G2M0360

6) Lift-up the vehicle.

7) Remove fuel filler pipe protector.

G2M0361

8) Remove clip, and separate air vent hose from pipe.

9) Loosen clamp, and separate fuel filler hose from pipe.
쎻1 Fuel filler hose
쎻2 Air vent hose
10) Remove fuel filler pipe to under side of the vehicle.

G2M0353

B: INSTALLATION
1) Hold fuel filler flap open.
2) Set fuel saucer 쎻 1 with rubber packing 쎻3 , and insert fuel
filler pipe into hole from the inner side of apron.
3) Align holes in fuel filler pipe neck and set cup 쎻 2 , and
tighten screws.
NOTE:
If edges of rubber packing are folded toward the inside,
straighten it with a screwdriver.
G2M0364

4) Insert fuel filler hose approximately 25 to 30 mm (0.98

to 1.18 in) over the lower end of fuel filler pipe and tighten
clamp.
쎻1 Fuel filler hose
쎻2 Air vent hose
CAUTION:
Do not allow clips to touch air vent hose and rear sus-
pension crossmember.
G2M0353

17
2-8 SERVICE PROCEDURE
4. Fuel Filler Pipe - 5. Fuel Filter

5) Insert air vent hose approximately 25 to 30 mm (0.98 to

1.18 in) into the lower end of air vent pipe and hold clip.
쎻1 Hose
쎻2 Clip
쎻3 Pipe
L = 25 — 30 mm (0.98 — 1.18 in)

G2M0358

6) Install fuel filler pipe protector.

7) Install right rear wheel.

G2M0361

5. Fuel Filter
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>

2) Disconnect fuel delivery hoses from fuel filter.

3) Remove filter from holder.

G2M0347

B: INSPECTION
1) Check the inside of fuel filter for dirt and water sedi-
ment.
2) If it is clogged, or if replacement interval has been
reached, replace it.
3) If water is found in it, shake and expel the water from
inlet port.

18
2-8 SERVICE PROCEDURE
4. Fuel Filler Pipe - 5. Fuel Filter

5) Insert air vent hose approximately 25 to 30 mm (0.98 to

1.18 in) into the lower end of air vent pipe and hold clip.
쎻1 Hose
쎻2 Clip
쎻3 Pipe
L = 25 — 30 mm (0.98 — 1.18 in)

G2M0358

6) Install fuel filler pipe protector.

7) Install right rear wheel.

G2M0361

5. Fuel Filter
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>

2) Disconnect fuel delivery hoses from fuel filter.

3) Remove filter from holder.

G2M0347

B: INSPECTION
1) Check the inside of fuel filter for dirt and water sedi-
ment.
2) If it is clogged, or if replacement interval has been
reached, replace it.
3) If water is found in it, shake and expel the water from
inlet port.

18
 SERVICE PROCEDURE 2-8
5. Fuel Filter - 6. Fuel Pump

C: INSTALLATION
CAUTION:
쐌 If fuel hoses are damaged at the connecting portion,
replace it with a new one.
쐌 If clamps are badly damaged, replace with new ones.

1) Installation is in the reverse order of removal.

2) Tighten hose clamp screws.
Tightening torque:
1.0 +0.5
−0 N⋅m (0.1 +0.05
−0 kg-m, 0.7 +0.4
−0 ft-lb)

G2M0347

6. Fuel Pump
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect fuel delivery hose 쎻1 and return hose 쎻
2 .
3) Disconnect jet pump hose 쎻 3 . (AWD model)

B2M0048A

4) Remove nuts which install fuel pump assembly onto

fuel tank.

G2M0343

5) Take off fuel pump from fuel tank.

G2M0344

19
 SERVICE PROCEDURE 2-8
5. Fuel Filter - 6. Fuel Pump

C: INSTALLATION
CAUTION:
쐌 If fuel hoses are damaged at the connecting portion,
replace it with a new one.
쐌 If clamps are badly damaged, replace with new ones.

1) Installation is in the reverse order of removal.

2) Tighten hose clamp screws.
Tightening torque:
1.0 +0.5
−0 N⋅m (0.1 +0.05
−0 kg-m, 0.7 +0.4
−0 ft-lb)

G2M0347

6. Fuel Pump
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect fuel delivery hose 쎻1 and return hose 쎻
2 .
3) Disconnect jet pump hose 쎻 3 . (AWD model)

B2M0048A

4) Remove nuts which install fuel pump assembly onto

fuel tank.

G2M0343

5) Take off fuel pump from fuel tank.

G2M0344

19
2-8 SERVICE PROCEDURE
6. Fuel Pump - 7. Fuel Meter Unit

B: INSPECTION
Connect lead harness to connector terminal of fuel pump,
and apply battery power supply to check whether the pump
operate.
WARNING:
쐌 Wipe off the fuel completely.
쐌 Keep battery as far apart from fuel pump as pos-
sible.
쐌 Be sure to turn the battery supply ON and OFF on
G2M0366 the battery side.
쐌 Do not run fuel pump for a long time under non-load
condition.

C: INSTALLATION
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
G2M0346
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
7. Fuel Meter Unit
A: REMOVAL
NOTE:
Fuel meter unit is built in fuel pump assembly.
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect fuel delivery hose 쎻 1 and return hose 쎻
2 .
3) Disconnect jet pump hose 쎻 3 . (AWD model)

B2M0048A

20
2-8 SERVICE PROCEDURE
6. Fuel Pump - 7. Fuel Meter Unit

B: INSPECTION
Connect lead harness to connector terminal of fuel pump,
and apply battery power supply to check whether the pump
operate.
WARNING:
쐌 Wipe off the fuel completely.
쐌 Keep battery as far apart from fuel pump as pos-
sible.
쐌 Be sure to turn the battery supply ON and OFF on
G2M0366 the battery side.
쐌 Do not run fuel pump for a long time under non-load
condition.

C: INSTALLATION
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
G2M0346
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
7. Fuel Meter Unit
A: REMOVAL
NOTE:
Fuel meter unit is built in fuel pump assembly.
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect fuel delivery hose 쎻 1 and return hose 쎻
2 .
3) Disconnect jet pump hose 쎻 3 . (AWD model)

B2M0048A

20
 SERVICE PROCEDURE 2-8
7. Fuel Meter Unit

4) Remove nuts which install fuel pump assembly onto

fuel tank.
5) Take off fuel pump assembly.

G2M0344

B: INSTALLATION
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
G2M0346
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

21
2-8 SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

8. Fuel Delivery, Return and

Evaporation Lines
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Remove inner trim, insulator and rear seat.
3) Remove fuel delivery pipes and hoses, fuel return pipes
and hoses, and evaporation pipes and hoses.

B2M0971A

B2M0972A

22
 SERVICE PROCEDURE 2-8
8. Fuel Delivery, Return and Evaporation Lines

B2M0973A

4) In engine compartment, detach fuel delivery hose,

return hose and evaporation hose.

G2M0296

5) In engine compartment, detach canister hoses from

canister. (Except 2200 cc AWD model)

G2M0370

23
2-8 SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

B: INSTALLATION
Installation is in the reverse order of removal.
1) Connect fuel delivery hose to pipe with an overlap of 20
to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
Type B: When fitting length is not specified.
쎻1 Fitting
쎻2 Clamp
쎻3 Hose
G2M0357

: 1.0 — 4.0 mm (0.039 — 0.157 in)
L: 20 — 25 mm (0.79 — 0.98 in)

2) Connect evaporation hose to pipe by approx. 15 mm

(0.59 in) from hose end.
쎻1 Hose
쎻2 Clip
쎻3 Pipe
L = 15 — 20 mm (0.59 — 0.79 in)
CAUTION:
Be sure to inspect hoses and their connections for any
leakage of fuel.
G2M0358

24
 SERVICE PROCEDURE 2-8
9. Roll Over Valve - 10. Fuel Sub Meter Unit (Turbo model only)

9. Roll Over Valve

A: REMOVAL
1) Lift up the vehicle.
2) Remove roll over valve with bracket.
3) Disconnect hoses from roll over valve, and remove it
from bracket.

G2M0373

B: INSPECTION
1) Connect hoses to roll over valve as shown in Figure.
2) While blowing through open end of hose, tilt valve at
least 90° left and right from normal position.
3) Ensure that there is no air flow when hose is tilted
greater than 90°.

G2M0374

C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
쐌 Do not install top side of valve down.
쐌 Before installing bracket on body, securely fit con-
cave part of bracket to hole in body.

G2M0373

10. Fuel Sub Meter Unit (AWD model

only)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove rear seat.

3) Remove service hole cover.

G2M0863

25
 SERVICE PROCEDURE 2-8
9. Roll Over Valve - 10. Fuel Sub Meter Unit (Turbo model only)

9. Roll Over Valve

A: REMOVAL
1) Lift up the vehicle.
2) Remove roll over valve with bracket.
3) Disconnect hoses from roll over valve, and remove it
from bracket.

G2M0373

B: INSPECTION
1) Connect hoses to roll over valve as shown in Figure.
2) While blowing through open end of hose, tilt valve at
least 90° left and right from normal position.
3) Ensure that there is no air flow when hose is tilted
greater than 90°.

G2M0374

C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
쐌 Do not install top side of valve down.
쐌 Before installing bracket on body, securely fit con-
cave part of bracket to hole in body.

G2M0373

10. Fuel Sub Meter Unit (AWD model

only)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

G6M0095

2) Remove rear seat.

3) Remove service hole cover.

G2M0863

25
2-8 SERVICE PROCEDURE
10. Fuel Sub Meter Unit (AWD model only) - 11. Fuel Cut Valve (AWD model only)

4) Disconnect connector from fuel sub meter.

5) Disconnect jet pump hose.

G2M0864

6) Remove fuel sub meter unit.

G2M0865

7) Installation is in the reverse order of removal procedure.

Tightening torque:
T: 3 — 6 N⋅m (0.3 — 0.6 kg-m, 2.2 — 4.3 ft-lb)

G2M0866

11. Fuel Cut Valve (AWD model only)

A: REMOVAL AND INSTALLATION
1) Remove fuel tank. <Ref. to 2-8 [W3A0].>

G2M0356

2) Disconnect evaporation hose from fuel cut valve.

3) Remove fuel cut valve.
4) Installation is in the reverse order of removal procedure.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

G2M0867

26
2-8 SERVICE PROCEDURE
10. Fuel Sub Meter Unit (AWD model only) - 11. Fuel Cut Valve (AWD model only)

4) Disconnect connector from fuel sub meter.

5) Disconnect jet pump hose.

G2M0864

6) Remove fuel sub meter unit.

G2M0865

7) Installation is in the reverse order of removal procedure.

Tightening torque:
T: 3 — 6 N⋅m (0.3 — 0.6 kg-m, 2.2 — 4.3 ft-lb)

G2M0866

11. Fuel Cut Valve (AWD model only)

A: REMOVAL AND INSTALLATION
1) Remove fuel tank. <Ref. to 2-8 [W3A0].>

G2M0356

2) Disconnect evaporation hose from fuel cut valve.

3) Remove fuel cut valve.
4) Installation is in the reverse order of removal procedure.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

G2M0867

26
 DIAGNOSTICS 2-8
1. Fuel System

1. Fuel System
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
쎻 Defective terminal contact.
securely.
쎻 Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube. Clean, correct or replace air breather tube or air vent tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel filler
1) Retightening.
pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.

NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel
tank.
쐌 To prevent water condensation:
1) Top off the fuel tank or drain the fuel completely.
2) Drain water condensation from the fuel filter.
쐌 Refilling the fuel tank:
Refill the fuel tank while there is still some fuel left in the tank.
쐌 Protecting the fuel system against freezing and water condensation:
1) Cold areas
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop
below 0°C (32°F) throughout the winter season, use an anti-freeze solution in the cooling system.
Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about
one-half. After the winter season, drain water which may have accumulated in the fuel filter and fuel
tank in the manner same as that described under affected areas as below.
2) Affected areas
When water condensation is notched in the fuel filter, drain water from both the fuel filter and fuel tank
or use a water removing agent (or anti-freeze solution) in the fuel tank.
쐌 Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water
removing agent) container before use.

27
2-9 COMPONENT PARTS
1. Exhaust System

1. Exhaust System
1. 2500 cc MODEL

B2M0311A

쎻
1 Upper front exhaust pipe cover CTR 쎻
13 Self-locking nut 쎻
25 Rear oxygen sensor
쎻
2 Lower front exhaust pipe cover CTR 쎻
14 Gasket 쎻
26 Front catalytic converter
쎻
3 Band RH 쎻
15 Muffler 쎻
27 Lower front catalytic converter cover
쎻
4 Band LH 쎻
16 Cushion rubber 쎻
28 Upper front catalytic converter cover
쎻
5 Upper front exhaust pipe cover LH 쎻
17 Clamp
쎻
6 Lower front exhaust pipe cover LH 쎻
18 Upper center exhaust pipe cover Tightening torque: N⋅m (kg-m, ft-lb)
쎻
7 Front exhaust pipe 쎻
19 Center exhaust pipe T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
8 Lower front exhaust pipe cover RH 쎻
20 Clamp B T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 30±5 (3.1±0.5, 22.4±3.6)
쎻
9 Upper front exhaust pipe cover RH 쎻
21 Upper rear catalytic converter cover
T4: 35±5 (3.6±0.5, 26.0±3.6)
쎻
10 Gasket 쎻
22 Lower rear catalytic converter cover T5: 48±5 (4.9±0.5, 35.4±3.6)
쎻
11 Spring 쎻
23 Gasket
쎻
12 Rear exhaust pipe 쎻
24 Front oxygen sensor

2
 COMPONENT PARTS 2-9
1. Exhaust System

2. 2200 cc MODEL

B2M0723A

쎻
1 Upper front exhaust pipe cover CTR 쎻
14 Gasket 쎻
26 Rear oxygen sensor (Except Califor-
쎻
2 Lower front exhaust pipe cover CTR 쎻
15 Muffler nia 2200 cc model)
쎻
3 Band RH 쎻
16 Cushion rubber 쎻
27 Front catalytic converter
쎻
4 Band LH 쎻
17 Clamp 쎻
28 Lower front catalytic converter cover
쎻
5 Upper front exhaust pipe cover LH 쎻
18 Upper center exhaust pipe cover 쎻
29 Upper front catalytic converter cover
쎻
6 Lower front exhaust pipe cover LH 쎻
19 Center exhaust pipe
쎻
7 Front exhaust pipe 쎻
20 Clamp B Tightening torque: N⋅m (kg-m, ft-lb)
쎻
8 Lower front exhaust pipe cover RH 쎻
21 Upper rear catalytic converter cover T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
9 Upper front exhaust pipe cover RH 쎻
22 Lower rear catalytic converter cover T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
10 Gasket 쎻
23 Gasket T3: 30±5 (3.1±0.5, 22.4±3.6)
T4: 35±5 (3.6±0.5, 26.0±3.6)
쎻
11 Spring 쎻
24 Front oxygen sensor
T5: 48±5 (4.9±0.5, 35.4±3.6)
쎻
12 Rear exhaust pipe 쎻
25 Rear oxygen sensor (California 2200
쎻
13 Self-locking nut cc model)

3
2-9 SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

1. Front Exhaust Pipe and Center

Exhaust Pipe
A: REMOVAL
1) Disconnect front oxygen sensor connector.

B2M0724

2) Disconnect rear oxygen sensor connector. (California

2200 cc model)

B2M0725

3) Lift-up the vehicle.

4) Disconnect rear oxygen sensor connector. (Except Cali-
fornia 2200 cc model)

B2M0312

5) Separate center exhaust pipe from rear exhaust pipe.

B2M0055

6) Remove bolts which hold front exhaust pipe onto cylin-

der heads.

B2M0054

4
 SERVICE PROCEDURE 2-9
1. Front Exhaust Pipe and Center Exhaust Pipe

7) Remove front exhaust pipe and center exhaust pipe

from hanger bracket.
CAUTION:
Be careful not to pull down front exhaust pipe and
center exhaust pipe.

B2M0313

8) Separate front exhaust pipe from front catalytic con-

verter.

B2M0060

B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust pipe.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0060

2) Install front exhaust pipe and center exhaust pipe.

And temporarily tighten bolt which installs center exhaust
pipe to hanger bracket.

B2M0313

3) Tighten bolts which hold front exhaust pipe onto cylin-

der heads.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0054

5
2-9 SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

4) Install center exhaust pipe to rear exhaust pipe.

Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

B2M0055

5) Tighten bolt which holds center exhaust pipe to hanger

bracket.
Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)

B2M0313

6) Connect rear oxygen sensor connector. (Except Califor-

nia 2200 cc model)

B2M0312

7) Lower the vehicle.

8) Connect rear oxygen sensor connector. (California
2200 cc model)

B2M0725

9) Connect front oxygen sensor connector.

B2M0724

6
 SERVICE PROCEDURE 2-9
2. Rear Exhaust Pipe

2. Rear Exhaust Pipe

A: REMOVAL
1) Separate rear exhaust pipe from center exhaust pipe.

B2M0055

2) Separate rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down rear exhaust pipe.

B2M0061

3) Remove rear exhaust pipe bracket from rubber cushion.

NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to pipe bracket in advance.
SUBARU CRC (Part No. 004301003)

G2M0315

B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install rear exhaust pipe bracket to rubber cushion.
NOTE:
To facilitate installation, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
G2M0315

2) Install rear exhaust pipe to muffler.

Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)

B2M0061

7
2-9 SERVICE PROCEDURE
2. Rear Exhaust Pipe

3) Install rear exhaust pipe to center exhaust pipe.

Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

B2M0055

8
 SERVICE PROCEDURE 2-9
3. Muffler

3. Muffler
A: REMOVAL AND INSTALLATION
1) Separate muffler from rear exhaust pipe.

B2M0061

2) Remove left and right rubber cushions.

CAUTION:
Be careful not to pull down muffler.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushions in advance.
SUBARU CRC (Part No. 004301003)

B2M0062

3) Remove front rubber cushion, and detach muffler

assembly.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)

B2M0063

4) Installation is in the reverse order of removal.

CAUTION:
Replace gasket with a new one.
Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)

B2M0061

9
2-10 SPECIFICATIONS AND SERVICE DATA
1. Clutch System

1. Clutch System
A: SPECIFICATIONS
2200 cc 2500 cc
Clutch cover Diaphragm set load kg (lb) 450 (992) 550 (1,213)
Facing material Woven
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
Clutch disc
Spline O.D. mm (in) 25.2 (0.992)
(No. of teeth) (24)
Clutch release lever ratio 3.0 1.6
Release bearing Grease-packed self-aligning

B: SERVICE DATA
2200 cc 2500 cc
Clutch pedal Full stroke mm (in) 140 — 150 (5.51 — 5.91)
Stroke mm (in) 24 — 26 (0.94 — 1.02)
Release lever
Play at release lever center mm (in) 3 — 4 (0.12 — 0.16)

Depth of rivet head Standard 1.3 — 1.9 (0.051 — 0.075)

Clutch disc mm (in) Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)

2
 COMPONENT PARTS 2-10
1. Clutch System

1. Clutch System
1. MECHANICAL APPLICATION TYPE

B2M0632A

쎻
1 Clutch cable bracket 쎻
9 Clutch disc
쎻
2 Clutch release lever sealing 쎻
10 Return spring (Models without hill holder only)
쎻
3 Retainer spring 쎻
11 Clutch return spring bracket
쎻
4 Pivot
쎻
5 Clutch release lever Tightening torque: N⋅m (kg-m, ft-lb)
쎻
6 Clip T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
쎻
7 Clutch release bearing
쎻
8 Clutch cover

3
2-10 COMPONENT PARTS
1. Clutch System

2. HYDRAULIC APPLICATION TYPE

B2M1009B

쎻
1 Snap pin 쎻
10 Clutch release lever sealing 쎻
19 Spacer
쎻
2 Clevis pin 쎻
11 Retainer spring
쎻
3 Master cylinder ASSY 쎻
12 Pivot Tightening torque: N⋅m (kg-m, ft-lb)
쎻
4 Bracket 쎻
13 Release lever T1: 15.7±1.5
(1.6±0.15, 11.6±1.1)
쎻
5 Clutch hose B 쎻
14 Clip
T2: 18±3 (1.8±0.3, 13.0±2.2)
쎻
6 Clutch damper 쎻
15 Release bearing T3: 25±7 (2.5±0.7, 18.1±5.1)
쎻
7 Damper bracket 쎻
16 Clutch cover T4: 37±3 (3.8±0.3, 27.5±2.2)
쎻
8 Clutch hose A 쎻
17 Clutch disc
쎻
9 Operating cylinder 쎻
18 Flywheel

4
 COMPONENT PARTS 2-10
2. Master Cylinder and Reservoir Tank

2. Master Cylinder and Reservoir Tank

G2M0976

쎻
1 Reservoir cap 쎻
5 Master cylinder
쎻
2 Reservoir tank 쎻
6 Piston
쎻
3 Reservoir band 쎻
7 Push rod
쎻
4 Seat 쎻
8 Piston stop ring

5
2-10 SERVICE PROCEDURE
1. General - 2. On-Car Service

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the follow-
ing items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smoothness.
2) Excessive tightness or looseness of clutch cable have
a bad influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of
clutch pedal.
4) Apply grease sufficiently to the release lever portion.
5) Position clutch cable through the center of toe board
hole and route it smoothly. Adjustment is done by moving
the outer cable.
6) Make sure not to let the clutch chatter when starting
forward or rearward. If clutch chattering occurs, readjust so
that the bend of clutch outer cable becomes flatter.

2. HYDRAULIC APPLICATION TYPE

1) Check fluid level using a scale on outside of reservoir
tank. If the level is below “MIN”, add clutch fluid to bring it
up to “MAX”.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
CAUTION:
쐌 Avoid mixing different brakes of brake fluid to pre-
vent degradation of the fluid.
B2M1177A
쐌 Be careful not to allow dirt or dust to get into the
reservoir tank.
쐌 Use fresh DOT3 or DOT4 brake fluid when refilling
fluid.
2) Make sure that clutch fluid does not leak from master
cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever pinion.
4) Check for proper clutch disengagement and clutch
pedal return ability.

2. On-Car Service
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever (Models
without hill holder only).
2) Adjust spherical nut so that the play is within the speci-
fied value at the lever end (center of spherical nut).
CAUTION:
Take care not to twist the cable during adjustment
G2M0234 Play: 3 — 4 mm (0.12 — 0.16 in)
Full stroke: 24 — 26 mm (0.94 — 1.02 in)

6
2-10 SERVICE PROCEDURE
1. General - 2. On-Car Service

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the follow-
ing items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smoothness.
2) Excessive tightness or looseness of clutch cable have
a bad influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of
clutch pedal.
4) Apply grease sufficiently to the release lever portion.
5) Position clutch cable through the center of toe board
hole and route it smoothly. Adjustment is done by moving
the outer cable.
6) Make sure not to let the clutch chatter when starting
forward or rearward. If clutch chattering occurs, readjust so
that the bend of clutch outer cable becomes flatter.

2. HYDRAULIC APPLICATION TYPE

1) Check fluid level using a scale on outside of reservoir
tank. If the level is below “MIN”, add clutch fluid to bring it
up to “MAX”.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
CAUTION:
쐌 Avoid mixing different brakes of brake fluid to pre-
vent degradation of the fluid.
B2M1177A
쐌 Be careful not to allow dirt or dust to get into the
reservoir tank.
쐌 Use fresh DOT3 or DOT4 brake fluid when refilling
fluid.
2) Make sure that clutch fluid does not leak from master
cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever pinion.
4) Check for proper clutch disengagement and clutch
pedal return ability.

2. On-Car Service
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever (Models
without hill holder only).
2) Adjust spherical nut so that the play is within the speci-
fied value at the lever end (center of spherical nut).
CAUTION:
Take care not to twist the cable during adjustment
G2M0234 Play: 3 — 4 mm (0.12 — 0.16 in)
Full stroke: 24 — 26 mm (0.94 — 1.02 in)

6
 SERVICE PROCEDURE 2-10
2. On-Car Service

3) Upon completion of adjustment, securely lock spherical

nut with lock nut.
Install return spring on lever (Models without hill holder
only).
NOTE:
Hook the long hook side of the return spring with the lever
(Models without hill holder only).

G2M0235

4) Depress clutch pedal to assure there is no abnormality

in the clutch system.

G2M0236

2. HYDRAULIC APPLICATION TYPE

Bleed air from oil line with the help of a co-worker.
1) Fit one end of a vinyl tube into the air bleeder of clutch
damper and put the other end into a clutch fluid container.

G2M0970

2) Slowly depress the clutch pedal and keep it depressed.

Then open the air bleeder to discharge air together with the
fluid.
Release the air bleeder for 1 or 2 seconds. Next, with the
bleeder closed, slowly release the clutch pedal.

G2M0971

3) Repeat these steps until there are no more air bubbles

in the vinyl tube.
CAUTION:
Cover bleeder with waste cloth when loosening it, to
prevent clutch fluid from being splashed over sur-
rounding parts.

7
2-10 SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever

4) Tighten air bleeder.

Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)

G2M0972

5) Remove air chamber.

<Ref. to 2-7 [W18A0].>
6) Repeat steps 1) through 3) using air bleeder on oper-
ating cylinder.

B2M1178A

7) Tighten air bleeder.

Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
8) After depressing the clutch pedal, make sure that there
are no leaks evident in the entire system.
9) After bleeding air from system, ensure that clutch oper-
ates properly.

B2M1179A

3. Release Bearing and Lever

A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring 쎻
1 (Models without
hill holder only).
2) Remove the two clips 쎻2 from clutch release lever 쎻
3
and remove release bearing 쎻6 .
CAUTION:
Be careful not to deform clips.
3) Remove release lever seal 쎻4 .

B2M0633A

8
2-10 SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever

4) Tighten air bleeder.

Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)

G2M0972

5) Remove air chamber.

<Ref. to 2-7 [W18A0].>
6) Repeat steps 1) through 3) using air bleeder on oper-
ating cylinder.

B2M1178A

7) Tighten air bleeder.

Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
8) After depressing the clutch pedal, make sure that there
are no leaks evident in the entire system.
9) After bleeding air from system, ensure that clutch oper-
ates properly.

B2M1179A

3. Release Bearing and Lever

A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring 쎻
1 (Models without
hill holder only).
2) Remove the two clips 쎻2 from clutch release lever 쎻
3
and remove release bearing 쎻6 .
CAUTION:
Be careful not to deform clips.
3) Remove release lever seal 쎻4 .

B2M0633A

8
 SERVICE PROCEDURE 2-10
3. Release Bearing and Lever

4) Remove release lever retainer spring from release lever

pivot with a screwdriver by accessing it through clutch
housing release lever hole. Then remove release lever.

B2M0174A

2. HYDRAULIC APPLICATION TYPE

1) Remove transmission assembly from vehicle body.
<Ref. to 2-11 [W3A0].>
2) Remove operating cylinder 쎻1 .
<Ref. to 2-10 [W5A0].>
3) Remove the two clips 쎻2 from clutch release lever 쎻
3
and remove release bearing 쎻6 .
CAUTION:
Be careful not to deform clips.
4) Remove release lever seal 쎻4 .

B2M1257A

5) Remove release lever retainer spring from release lever

pivot with a screwdriver by accessing it through clutch
housing release lever hole. Then remove release lever.

B2M1258A

9
2-10 SERVICE PROCEDURE
3. Release Bearing and Lever

B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent when servicing the clutch.
1) Check the bearing for smooth movement by applying
force in the radial direction.
B2M0173A Radial direction stroke:
FWD; Approx.
1.0 mm (0.039 in)
AWD; Approx.
1.4 mm (0.055 in)

2) Check the bearing for smooth rotation by applying pres-

sure in the thrust direction.
3) Check wear and damage of bearing case surface con-
tacting with lever.

G2M0240

2. RELEASE LEVER
Check lever pivot portion and the point of contact with
release bearing case for wear.

G2M0241

C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the following
points with a light coat of grease.
쐌 Inner groove of release bearing
쐌 Contact surface of lever and pivot
쐌 Contact surface of lever and bearing
쐌 Transmission main shaft spline (Use grease contain-
ing molybdenum disulphide.)

10
 SERVICE PROCEDURE 2-10
3. Release Bearing and Lever

1. MECHANICAL APPLICATION TYPE

1) While pushing release lever 쎻 3 to pivot and twisting it to
both sides, fit retainer spring 쎻
5 onto the constricted portion
of pivot.
NOTE:
Confirm that retainer spring is securely fitted by observing
it through the main case hole.
2) Install release bearing 쎻 6 and fasten it with two clips 쎻 2 .
3) Install release lever seal 쎻 4 .

B2M0633A

4) After remounting engine and transmission on body,

make adjustment of the clutch release lever end play.
CAUTION:
Take care not to twist the cable during adjustment.
5) Install release lever return spring (Models without hill
holder only).
NOTE:
Hook up the return spring to right side hole of the release
lever.
G2M0235

2. HYDRAULIC APPLICATION TYPE

1) While pushing release lever 쎻 1 to pivot and twisting it to
both sides, fit retainer spring 쎻
2 onto the constricted portion
of pivot.
NOTE:
쐌 Apply grease (SUNLIGHT 2: P/N 003602010) to contact
point of release lever and operating cylinder.
쐌 Confirm that retainer spring is securely fitted by observ-
ing it through the main case hole.
2) Install release bearing 쎻 3 and fasten it with two clips 쎻 4 .
3) Install release lever seal 쎻 5 .
4) Install operating cylinder 쎻 6 .
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)

B2M1257C

11
2-10 SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover

5) After remounting engine and transmission on body;

<Ref. to 2-11 [W3B0].>
6) Bleed air from oil line with the help of a co-worker.
<Ref. to 2-10 [W202].>

4. Clutch Disc and Cover

A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
쐌 Take care not to allow oil on the clutch disc facing.
쐌 Do not disassemble either clutch cover or clutch
G2M0242
disc.
3) Remove flywheel.

G2M0243

B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3 — 1.9 mm (0.051 — 0.075 in)
B2M0328
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.

12
2-10 SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover

5) After remounting engine and transmission on body;

<Ref. to 2-11 [W3B0].>
6) Bleed air from oil line with the help of a co-worker.
<Ref. to 2-10 [W202].>

4. Clutch Disc and Cover

A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
쐌 Take care not to allow oil on the clutch disc facing.
쐌 Do not disassemble either clutch cover or clutch
G2M0242
disc.
3) Remove flywheel.

G2M0243

B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3 — 1.9 mm (0.051 — 0.075 in)
B2M0328
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.

12
 SERVICE PROCEDURE 2-10
4. Clutch Disc and Cover

2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace clutch disc and inspect transmission front oil seal,
transmission case mating surface, engine rear oil seal and
other points for oil leakage.

B2M0329A

4) Deflection on facing
If deflection exceeds the specified value at the outer cir-
cumference of facing, repair or replace.
Limit for deflection:
1.0 mm (0.039 in) at R = 107 mm (4.21 in)

B2M0330A

5) Worn spline, loose rivets and torsion spring failure

Replace defective parts.

B2M0333A

2. CLUTCH COVER
Visually check for the following items without
disassembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at center of
diaphragm spring.

G2M0248

3) Damaged or worn disc contact surface of pressure

plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.

G2M0249

13
2-10 SERVICE PROCEDURE
4. Clutch Disc and Cover

3. FLYWHEEL
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent.
1) Damage of facing and ring gear
If defective, replace flywheel.

G2M0250

2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust direction.
If noise or excessive play is noted, replace ball bearing as
follows:
(1) Drive out ball bearing from flywheel.
(2) Press bearing into flywheel until bearing end sur-
face is flush with clutch disc contact surface of flywheel.
Do not press inner race.
ST 899754112 SNAP RING PRESS
G2M0251

C: INSTALLATION
1) Install flywheel.
2) Install ST, and tighten the flywheel attaching bolts to the
specified torque.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72±3 N⋅m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)
NOTE:
B2M0331A Tighten flywheel installing bolts gradually. Each bolt should
be tightened to the specified torque in a crisscross fashion.

B2M0332A

3) Insert ST into the clutch disc and install them on the

flywheel by inserting the ST end into the pilot bearing.
ST 499747100 CLUTCH DISC GUIDE

G2M0253

14
 SERVICE PROCEDURE 2-10
4. Clutch Disc and Cover - 5. Operating Cylinder

4) Install clutch cover on flywheel and tighten bolts to the

specified torque.
NOTE:
쐌 When installing the clutch cover on the flywheel, position
the clutch cover so that there is a gap of 120° or more
between “0” marks on the flywheel and clutch cover. (“0”
marks indicate the directions of residual unbalance.)
쐌 Note the front and rear of the clutch disc when installing.
쐌 Tighten clutch cover installing bolts gradually. Each bolt
should be tightened to the specified torque in a crisscross
fashion.
Tightening torque:
15.7±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
5) Remove ST.
ST 499747100 CLUTCH DISC GUIDE

G2M0254

5. Operating Cylinder
A: REMOVAL AND INSTALLATION
1) Remove air chamber.
<Ref. to 2-7 [W18A0].>

B2M1265

2) Remove clutch hose from operating cylinder.

CAUTION:
Cover hose joint to prevent clutch fluid from flowing
out.

B2M1179B

3) Remove operating cylinder from transmission.

B2M1263

15
 SERVICE PROCEDURE 2-10
4. Clutch Disc and Cover - 5. Operating Cylinder

4) Install clutch cover on flywheel and tighten bolts to the

specified torque.
NOTE:
쐌 When installing the clutch cover on the flywheel, position
the clutch cover so that there is a gap of 120° or more
between “0” marks on the flywheel and clutch cover. (“0”
marks indicate the directions of residual unbalance.)
쐌 Note the front and rear of the clutch disc when installing.
쐌 Tighten clutch cover installing bolts gradually. Each bolt
should be tightened to the specified torque in a crisscross
fashion.
Tightening torque:
15.7±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
5) Remove ST.
ST 499747100 CLUTCH DISC GUIDE

G2M0254

5. Operating Cylinder
A: REMOVAL AND INSTALLATION
1) Remove air chamber.
<Ref. to 2-7 [W18A0].>

B2M1265

2) Remove clutch hose from operating cylinder.

CAUTION:
Cover hose joint to prevent clutch fluid from flowing
out.

B2M1179B

3) Remove operating cylinder from transmission.

B2M1263

15
2-10 SERVICE PROCEDURE
5. Operating Cylinder - 6. Master Cylinder and Reservoir Tank

4) Installation is in the reverse order of removal.

NOTE:
Before installing operating cylinder, apply grease (SUN-
LIGHT 2: P/N 003602010) to contact point of release lever
and operating cylinder.
Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1179C

5) After bleeding air from operating cylinder, ensure that

clutch operates properly.
<Ref. to 2-10 [W202].>

6. Master Cylinder and Reservoir Tank

A: REMOVAL
1) Remove snap pin 쎻 2 , clevis pin 쎻
1 and separate push
rod 쎻
3 of master cylinder from clutch pedal.

G2M0979

2) Remove clutch hose from master cylinder.

CAUTION:
Plug up hose connection to prevent clutch fluid from
spilling out.

B2M1260A

3) Remove master cylinder with reservoir tank.

B2M1261A

16
2-10 SERVICE PROCEDURE
5. Operating Cylinder - 6. Master Cylinder and Reservoir Tank

4) Installation is in the reverse order of removal.

NOTE:
Before installing operating cylinder, apply grease (SUN-
LIGHT 2: P/N 003602010) to contact point of release lever
and operating cylinder.
Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1179C

5) After bleeding air from operating cylinder, ensure that

clutch operates properly.
<Ref. to 2-10 [W202].>

6. Master Cylinder and Reservoir Tank

A: REMOVAL
1) Remove snap pin 쎻 2 , clevis pin 쎻
1 and separate push
rod 쎻
3 of master cylinder from clutch pedal.

G2M0979

2) Remove clutch hose from master cylinder.

CAUTION:
Plug up hose connection to prevent clutch fluid from
spilling out.

B2M1260A

3) Remove master cylinder with reservoir tank.

B2M1261A

16
 SERVICE PROCEDURE 2-10
6. Master Cylinder and Reservoir Tank

B: INSPECTION
If any damage, deformation, wear, swelling, rust or other
faults are found on the cylinder, piston, push rod, fluid
reservoir, seat and gasket, replace the faulty part.

G2M0987

C: INSTALLATION
1) Install master cylinder to body.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)

B2M1261A

2) Install clutch hose to master cylinder.

CAUTION:
Check that hose is routed properly.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)

B2M1260A

3) Connect push rod 쎻 3 of master cylinder to clutch pedal,

1 and snap pin 쎻
and install clevis pin 쎻 2 .
NOTE:
Apply grease to clevis pin.
4) After bleeding air from system, ensure that clutch oper-
ates properly.
<Ref. to 2-10 [W202].>

B4M1189B

17
2-10 SERVICE PROCEDURE
7. Clutch Damper - 8. Clutch Fluid

7. Clutch Damper
A: REMOVAL AND INSTALLATION
1) Remove clutch hoses from clutch damper.
CAUTION:
Cover hose joint to prevent clutch fluid from flowing
out.
2) Remove clutch damper with bracket.
G2M0970

3) Installation is in the reverse order of removal.

Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
4) After bleeding air from system, ensure that clutch oper-
ates properly.
<Ref. to 2-10 [W202].>

G2M0991

8. Clutch Fluid
A: REPLACEMENT
CAUTION:
쐌 The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.
쐌 Cover bleeder with waste cloth, when loosening it,
to prevent clutch fluid from being splashed over sur-
rounding parts.
쐌 Avoid mixing different brands of clutch fluid to pre-
vent degrading the quality of the fluid.
쐌 Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
쐌 During bleeding operation, keep the clutch reserve tank
filled with clutch fluid to eliminate entry of air.
쐌 Clutch pedal operating must be very slow.
쐌 For convenience and safety, it is advisable to have two
man working.
쐌 The amount of clutch fluid required is approximately 70
m
(2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the clutch fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended clutch fluid.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
5) Bleed air from oil line with the help of a co-worker.
<Ref. to 2-10 [W202].>

18
2-10 SERVICE PROCEDURE
7. Clutch Damper - 8. Clutch Fluid

7. Clutch Damper
A: REMOVAL AND INSTALLATION
1) Remove clutch hoses from clutch damper.
CAUTION:
Cover hose joint to prevent clutch fluid from flowing
out.
2) Remove clutch damper with bracket.
G2M0970

3) Installation is in the reverse order of removal.

Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
4) After bleeding air from system, ensure that clutch oper-
ates properly.
<Ref. to 2-10 [W202].>

G2M0991

8. Clutch Fluid
A: REPLACEMENT
CAUTION:
쐌 The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.
쐌 Cover bleeder with waste cloth, when loosening it,
to prevent clutch fluid from being splashed over sur-
rounding parts.
쐌 Avoid mixing different brands of clutch fluid to pre-
vent degrading the quality of the fluid.
쐌 Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
쐌 During bleeding operation, keep the clutch reserve tank
filled with clutch fluid to eliminate entry of air.
쐌 Clutch pedal operating must be very slow.
쐌 For convenience and safety, it is advisable to have two
man working.
쐌 The amount of clutch fluid required is approximately 70
m
(2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the clutch fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended clutch fluid.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
5) Bleed air from oil line with the help of a co-worker.
<Ref. to 2-10 [W202].>

18
 DIAGNOSTICS 2-10
1. Clutch System

1. Clutch System
Condition Possible cause and testing Corrective action
1. Clutch slip- It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
page
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in
proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing.
쐌 Method of testing: Put the vehicle in stationary condition with parking brake fully applied. Disengage the clutch and
shift the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing the engine
speed. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not
start off and the engine does not stall.
(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f ) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult when shifting
drags. gears. The symptom becomes more apparent when shifting into the first gear. However, because much trouble of the
this sort is due to defective synchronization mechanism, carry out the test as described after.
쐌 Method of testing: Refer to DIAGNOSTIC DIAGRAM on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f ) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
3. Clutch chat- Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially
ters. engaged.

(a) Improper clutch cable routing Correct.

(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc defection.
(e) Warped pressure plate or flywheel Correct or replace.
(f ) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.

19
2-10 DIAGNOSTICS
1. Clutch System

Condition Possible cause and testing Corrective action

4. Noisy Examine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged.
clutch
(a) Broken, worn or unlubricated release bearing Replace release bearing.
(b) Insufficient lubrication of pilot bearing Apply grease.
(c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch When starting the vehicle with the clutch partially engaged, the clutch engages suddenly and the vehicle jumps
grabs. instead of making a smooth start.
(a) Grease or oil on facing Replace clutch disc.
(b) Deteriorated cushioning spring Replace clutch disc.
Take off rust, apply grease or replace clutch shaft disc or
(c) Worn or rusted spline of clutch disc or main
mainshaft.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f ) Deteriorated diaphragm spring Replace.

20
 DIAGNOSTICS 2-10
1. Clutch System

1. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

Test (1) Disengage the clutch and shift quickly from neutral to reverse in idling condition.

왔
Gear noise No Sufficient disengagement of clutch
왘
Yes
왔
Test (2) Shift to reverse after 0.5 to 1.0 sec of clutch disengagement.

왔
Gear noise No Defective transmission
왘
or excessive clutch drag torque
Yes

[Cause]
1. Defective pilot bearing
2. Excessive disc deflection
3. Defective transmission
4. Defective clutch disc hub spline
왔
Test (3) Shift the gear N , R several times during disengaging clutch as test (2).

왔
Gear noise No
왘
Sticked clutch disc

Yes

[Cause]
1. Clutch disc smeared by oil
2. Clutch disc smeared by rust
3. Defective clutch disc hub spline
왔
Clutch drags.

[Cause]
1. Cracked clutch disc facing
2. Damaged or worn clutch cover
3. Malfunction of clutch release system
4. Insufficient clutch release amount
5. Excessive clutch pedal play

21
2-10 DIAGNOSTICS
1. Clutch System

22
2-11 COMPONENT PARTS
1. Engine Mounting

1. Engine Mounting

G2M0258

쎻
1 Front cushion rubber Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Front engine mounting bracket T1: 26±7 (2.7±0.7, 19.5±5.1)
T2: 41±10 (4.2±1.0, 30±7)
T3: 79±15 (8.0±1.5, 58±11)

2
 COMPONENT PARTS 2-11
2. Transmission Mounting

2. Transmission Mounting
1. MT MODEL

B2M0013A

쎻
1 Pitching stopper Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Rear cushion rubber (AWD) T1: 33±5 (3.4±0.5, 24.6±3.6)
쎻
3 Rear cushion rubber (FWD) T2: 37±10 (3.8±1.0, 27±7)
쎻
4 Rear crossmember T3: 49±5 (5.0±0.5, 36.2±3.6)
쎻
5 Center crossmember T4: 57±10 (5.8±1.0, 42±7)
쎻
6 Cushion C T5: 69±15 (7.0±1.5, 51±11)
쎻
7 Rear plate T6: 137±20 (14±2, 101±14)
쎻
8 Front crossmember
쎻
9 Cushion D
쎻
10 Spacer
쎻
11 Front plate

3
2-11 COMPONENT PARTS
2. Transmission Mounting

2. AT MODEL

B2M1159A

쎻
1 Pitching stopper Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Rear cushion rubber (FWD) T1: 25±7 (2.5±0.7, 18.1±5.1)
쎻
3 Rear cushion rubber (AWD) T2: 26±7 (2.7±0.7, 19.5±5.1)
쎻
4 Stopper T3: 37±10 (3.8±1.0, 27±7)
쎻
5 Crossmember T4: 49±5 (5.0±0.5, 36.2±3.6)
T5: 57±10 (5.8±1.0, 42±7)
T6: 69±15 (7.0±1.5, 51±11)

4
 COMPONENT PARTS 2-11
2. Transmission Mounting

3. MT MODEL (OUTBACK WITH STEP ROOF)

B2M0714A

쎻
1 Pitching stopper Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Rear cushion rubber T1: 33±5 (3.4±0.5, 24.6±3.6)
쎻
3 Rear crossmember T2: 37±10 (3.8±1.0, 27±7)
쎻
4 Center crossmember T3: 49±5 (5.0±0.5, 36.2±3.6)
쎻
5 Cushion C T4: 57±10 (5.8±1.0, 42±7)
쎻
6 Rear plate T5: 69±15 (7.0±1.5, 51±11)
쎻
7 Front crossmember T6: 137±20 (14±2, 101±14)
쎻
8 Cushion D
쎻
9 Spacer
쎻
10 Front plate
쎻
11 Spacer

5
2-11 COMPONENT PARTS
2. Transmission Mounting

4. AT MODEL (OUTBACK WITH STEP ROOF)

B2M1158A

쎻
1 Pitching stopper Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Rear cushion rubber T1: 25±7 (2.5±0.7, 18.1±5.1)
쎻
3 Crossmember T2: 37±10 (3.8±1.0, 27±7)
쎻
4 Stopper T3: 49±5 (5.0±0.5, 36.2±3.6)
T4: 57±10 (5.8±1.0, 42±7)
T5: 69±15 (7.0±1.5, 51±11)

6
SERVICE PROCEDURE 2-11
1. General Precaution

1. General Precaution
1) Remove or install engine and transmission in an area
where chain hoists, lifting devices, etc. are available for
ready use.
2) Be sure not to damage coated surfaces of body panels
with tools or stain seats and windows with coolant or oil.
Place a cover over fenders, as required, for protection.
3) Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and
oil, wire ropes, chain hoist, transmission jacks, etc.
4) Lift-up or lower the vehicle when necessary. Make sure
to support the correct positions. (Refer to Chapter 1-3
“General Information”.)

7
2-11 SERVICE PROCEDURE
2. Engine

2. Engine
A: REMOVAL
1. Set the vehicle on lift arms.
2. Open front hood and support with a stay.

왔
3. Release fuel pressure.
4. Disconnect battery cable and remove battery from vehicle.
5. Drain coolant.

왔
6. Remove cooling system.

With A/C
왔
7. Collect refrigerant, and remove pressure hoses.

왔
8. Remove air intake system.

왔
9. Remove canister and bracket.

왔
10. Disconnect connectors, cables and hoses.

왔
11. Remove power steering pump from bracket.

왔
12. Remove front exhaust pipe and center exhaust pipe.

왔
13. Remove nuts which hold lower side of transmission to
engine.
14. Remove nuts which install front cushion rubber onto front
crossmember.

AT model
왔
15. Separate torque converter from drive plate.

왔
16. Remove pitching stopper.

왔
17. Disconnect fuel delivery hose, return hose and evaporation
hoses.

왔
18. Support engine with a lifting device and wire ropes.
19. Support transmission with a garage jack.

왔
20. Remove bolts which hold upper side of transmission to
engine.

왔
21. Remove engine from vehicle.

8
 SERVICE PROCEDURE 2-11
2. Engine

1) Set the vehicle on lift arms.

2) Open front hood fully and support with stay.

3) Release fuel pressure.

(1) Disconnect fuel tank connector.
(2) Start the engine, and run until it stalls.
(3) After the engine stalls, crank it for five seconds
more.
(4) Turn ignition switch to “OFF”.
<Ref. to 2-8 [W1A0].>

G2M0341

4) Disconnect battery cables and remove battery from

vehicle.

G6M0095

5) Drain coolant.
Set container under the vehicle, and remove drain cock
from radiator.

B2M0015A

6) Remove cooling system.

(1) Disconnect radiator fan motor connector.
(2) Disconnect radiator outlet hose from thermostat
cover.

G2M0263

9
2-11 SERVICE PROCEDURE
2. Engine

(3) Disconnect ATF cooler hoses from pipes. (AT

model)

B2M0016A

(4) Remove V-belt cover.

B2M0017

(5) Disconnect radiator inlet hose from radiator.

G2M0267

(6) Remove radiator upper bracket, and remove radia-

tor assembly from vehicle.

G2M0220

7) Collect refrigerant, and remove pressure hoses. (With

A/C)
(1) Place and connect the attachment hose to the
refrigerant recycle system.
(2) Collect refrigerant from A/C system.

10
 SERVICE PROCEDURE 2-11
2. Engine

(3) Disconnect A/C pressure hoses from A/C compres-

sor.

G2M0270

8) Remove air intake system.

(1) Disconnect connector from mass air flow sensor.
(2) Remove air intake duct with air cleaner upper
cover, and remove air cleaner element.

B2M1168

9) Remove canister and bracket. (2500 cc, 2200 cc FWD

and Taiwan spec. vehicles)

G2M0272

11
2-11 SERVICE PROCEDURE
2. Engine

10) Disconnect connectors, cables and hoses.

(1) Disconnect the following connectors.
쎻
1 Front oxygen sensor connector
쎻
2 Engine harness connectors
쎻
3 Engine ground terminal stay
쎻
4 Alternator connector and terminal
쎻
5 A/C compressor connectors (With A/C)

B2M1169A

12
SERVICE PROCEDURE 2-11
2. Engine

B2M0020A B2M0019A

B2M0021C B2M1291A

13
2-11 SERVICE PROCEDURE
2. Engine

(2) Disconnect the following cables.

쎻1 Clutch release spring (MT model except
2500 cc)
쎻2 Clutch cable (MT model except 2500 cc)
쎻3 Accelerator cable
쎻4 Cruise control cable (With cruise control)

B2M1169B

B2M1301A B2M1302A

14
SERVICE PROCEDURE 2-11
2. Engine

(3) Disconnect the following hoses.

쎻1 Brake booster vacuum hose
쎻2 Heater inlet and outlet hoses

B2M1169C

B2M0026A B2M0027

15
2-11 SERVICE PROCEDURE
2. Engine

11) Remove power steering pump from bracket.

(1) Loosen lock bolt and slider bolt, and remove front
side V-belt.

G2M0286

(2) Remove pipe with bracket from intake manifold.

B2M0340

(3) Remove bolts which install power steering pump

from bracket.

B2M0334

(4) Place power steering pump on the right side wheel

apron.

B2M0029

12) Remove front exhaust pipe and center exhaust pipe.

(1) Lift-up the vehicle.
(2) Remove nuts which install front exhaust pipe onto
engine.

G2M0290

16
 SERVICE PROCEDURE 2-11
2. Engine

(3) Disconnect connector from rear oxygen sensor.

B2M0335

(4) Separate center exhaust pipe from rear exhaust

pipe.

G2M0291

(5) Remove bolt which installs center exhaust pipe on

hunger bracket.
(6) Take off front and center exhaust pipes.
CAUTION:
Exhaust pipe will drop when all bolts are removed. So,
hold it when removing the last bolt.

B2M0313

13) Remove nuts which hold lower side of transmission to

engine.

G2M0292

14) Remove nuts which install front cushion rubber onto

front crossmember.

G2M0293

17
2-11 SERVICE PROCEDURE
2. Engine

15) Separate torque converter from drive plate. (AT model)

(1) Lower the vehicle.
(2) Remove service hole plug.
(3) Remove bolts which hold torque converter to drive
plate.
(4) Remove other bolts while rotating the engine using
ST.
ST 499977000 CRANK PULLEY WRENCH
G2M0294

16) Remove pitching stopper.

G2M0295

17) Disconnect fuel delivery hose, return hose and evapo-

ration hose.
CAUTION:
쐌 Disconnect hose with its end wrapped with cloth to
prevent fuel from splashing.
쐌 Catch fuel from hose into container.

B2M0336

18) Support engine with a lifting device and wire ropes.

G2M0297

19) Support transmission with a garage jack.

CAUTION:
Before moving engine away from transmission, check
to be sure no work has been overlooked. Doing this is
very important in order to facilitate re-installation and
because transmission lowers under its own weight.

G2M0298

18
 SERVICE PROCEDURE 2-11
2. Engine

20) Remove bolts which hold upper side of transmission to

engine.

G2M0299

21) Remove engine from vehicle.

(1) Slightly raise engine.
(2) Raise transmission with garage jack.
(3) Move engine horizontally until mainshaft is with-
drawn from clutch cover.
(4) Slowly move engine away from engine compart-
ment.
CAUTION:
Be careful not to damage adjacent parts or body pan-
G2M0300
els with crank pulley, oil pressure gauge, etc.

19
2-11 SERVICE PROCEDURE
2. Engine

B: INSTALLATION
1. Install engine to transmission.

왔
2. Tighten bolts which hold upper side of transmission to engine.

왔
3. Remove lifting device and wire rope.
4. Remove garage jack.

왔
5. Install pitching stopper.

AT model 왔
6. Install torque converter onto drive plate.

왔
7. Install canister and bracket.
8. Install power steering pump on bracket.

왔
9. Tighten nuts which hold lower side of transmission to engine.
10. Tighten nuts which install front cushion rubber onto cross-
member.

왔
11. Install front exhaust pipe and center exhaust pipe.

왔
12. Connect hoses, connectors and cables.

왔
13. Install air intake system.
쐌 Air intake duct
쐌 Air cleaner element and upper cover.

With A/C 왔
14. Install A/C pressure hoses.

왔
15. Install cooling system.

왔
16. Install battery onto the vehicle, and connect cables.
17. Fill coolant.
18. Check ATF level, and connect if necessary. [AT]
19. Correct power steering oil, and bleed air.
20. Remove front hood stay, and close front hood.
21. Take off the vehicle from lift arms.

20
 SERVICE PROCEDURE 2-11
2. Engine

1) Install engine onto transmission.

(1) Position engine in engine compartment and align it
with transmission.
CAUTION:
Be careful not to damage adjacent parts or body pan-
els with crank pulley, oil pressure gauge, etc.

G2M0301

(2) Apply a small amount of grease to spline of main-

shaft.

2) Tighten bolts which hold upper side of transmission to

engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

G2M0299

3) Remove lifting device and wire ropes.

4) Remove garage jack.

G2M0297

21
2-11 SERVICE PROCEDURE
2. Engine

5) Install pitching stopper.

Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)

G2M0302

6) Install torque converter onto drive plate. (AT model)

(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
G2M0294
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.

7) Install canister and bracket. (2500 cc, 2200 cc FWD and

Taiwan spec. vehicles)

G2M0272

8) Install power steering pump on bracket.

(1) Install power steering pump on bracket, and tighten
bolts.
Tightening torque:
39±10 N⋅m (4.0±1.0 kg-m, 29±7 ft-lb)

B2M0334

22
 SERVICE PROCEDURE 2-11
2. Engine

(2) Install power steering pipe bracket on right side

intake manifold, and install spark plug codes.

B2M0340

(3) Install front side V-belt, and adjust it.

<Ref. to 1-5 [01A0].>

G2M0286

9) Tighten nuts which hold lower side of transmission to

engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

G2M0292

10) Tighten nuts which install front cushion rubber onto

crossmember.
Tightening torque:
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
CAUTION:
Be sure to tighten front cushion rubber mounting bolts
in the innermost elliptical hole in the front crossmem-
ber.
G2M0303

23
2-11 SERVICE PROCEDURE
2. Engine

11) Install front exhaust pipe and center exhaust pipe.

12) Connect hoses, connectors and cables.
(1) Connect the following hoses.
쐌 Fuel delivery hose, return hose and evaporation
hose
쐌 Heater inlet and outlet hoses
쐌 Brake booster vacuum hose
(2) Connect the following connectors.
쐌 Engine ground terminal
쐌 Engine harness connectors
쐌 Front oxygen sensor connector
쐌 Rear oxygen sensor connector
쐌 Alternator connector and terminal
쐌 A/C compressor connectors (With A/C)
(3) Connect the following cables.
쐌 Accelerator cable
쐌 Cruise control cables (With cruise control)
쐌 Clutch cable
쐌 Clutch release spring
CAUTION:
After connecting each cable, adjust them.
13) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake duct with air cleaner upper cover.

B2M1168

(3) Connect connector to mass air flow sensor.

B2M0030

14) Install A/C pressure hoses. (With A/C)

<Ref. to 4-7 [W16A0].>
CAUTION:
Use new O-rings.
Tightening torque:
25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)

G2M0270

24
 SERVICE PROCEDURE 2-11
2. Engine

15) Install cooling system.

(1) Attach radiator mounting cushions to body.

B2M0307A

(2) Install radiator while fitting radiator pins to cush-

ions.

G2M0220

(3) Install radiator brackets and tighten bolts.

Tightening torque:
13.7±1.5 N⋅m (1.4±0.15 kg-m, 10.1±1.1 ft-lb)

B2M0320

(4) Connect radiator fan motor connector.

G2M0263

(5) Connect radiator inlet hose.

G2M0267

25
2-11 SERVICE PROCEDURE
2. Engine

(6) Connect radiator outlet hose.

(7) Connect ATF cooler hoses. (AT model)

B2M0016A

(8) Install V-belt cover.

B2M0017

16) Install battery in the vehicle, and connect cables.

17) Fill coolant.
<Ref. to 2-5 [W1B0].>
18) Check ATF level and correct if necessary. (AT model)
<Ref. to 3-2 [W2A1].>
19) Charge A/C system with refrigerant.
<Ref. to 4-7 [W700].>
20) Remove front hood stay, and close front hood.
21) Take off the vehicle from lift arms.

26
 SERVICE PROCEDURE 2-11
3. Transmission

3. Transmission
A: REMOVAL
1. Open front hood fully, and support it with stay.
2. Disconnect battery ground terminal.

왔
3. Remove air intake duct and chamber.

왔
4. Disconnect connectors and cables.

왔
5. Remove starter.

왔
6. Remove pitching stopper.

AT model 왔
7. Separate torque converter from drive plate.
8. Remove ATF level gauge.

왔
9. Remove transmission connector bracket.

Hydraulic clutch model 왔

10. Remove operating cylinder.

왔
11. Set special tools.

왔
12. Remove bolt which holds right upper side of transmission to
engine.

Hydraulic clutch model 왔

13. Remove clutch damper.

왔
14. Remove exhaust system.
쐌 Front exhaust pipe
쐌 Center exhaust pipe
쐌 Rear exhaust pipe [AWD]

AT model 왔
15. Drain ATF to remove ATF drain plug.
16. Disconnect ATF cooler hose from pipe on transmission side,
and remove ATF level gauge guide.

AWD model 왔
17. Remove propeller shaft.
왔
쎻
A

27
2-11 SERVICE PROCEDURE
3. Transmission

쎻
A

왔
18. Remove gear shift rod and stay from transmission.

왔
19. Remove shift selector cable.

왔
20. Remove bolts which install stabilizer clamp onto
crossmember.

왔
21. Remove front drive shaft from transmission.

왔
22. Remove nuts which hold lower side of transmission to
engine.

왔
23. Place transmission jack under transmission.

왔
24. Remove transmission rear crossmember.

왔
25. Remove transmission.

28
 SERVICE PROCEDURE 2-11
3. Transmission

1) Open front hood fully, and support with stay.

2) Disconnect battery ground terminal.
3) Remove air intake duct and chamber.

B2M1170

4) Disconnect connectors and cables.

(1) Disconnect the following connectors.
쐌 Front oxygen sensor connector

G2M0544

쐌 Transmission harness connector

쐌 Transmission ground terminal

G2M0307

쐌 Neutral position switch connector (MT model)

쐌 Back-up light switch connector (MT model)

B2M0337

쐌 Vehicle speed sensor 2

G2M0827

29
2-11 SERVICE PROCEDURE
3. Transmission

(2) Disconnect the following cables.

쐌 Clutch release spring (MT model)
쐌 Clutch cable (MT mechanical clutch model)

G2M0545

5) Remove starter.
(1) Disconnect connectors and terminal from starter.
(2) Remove bolt which installs upper side of starter.
(3) Remove nut which installs lower side of starter, and
remove starter from transmission.

G2M0309

6) Remove pitching stopper.

G2M0295

7) Separate torque converter from drive plate. (AT model)

(1) Remove service hole plug.
(2) Remove bolts which hold torque converter to drive
plate.
(3) While rotating the engine, remove other bolts using
ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
G2M0294 housing.

8) Remove ATF level gauge. (AT model)

CAUTION:
Plug opening to prevent entry of foreign particles into
transmission fluid.

B2M0031

30
 SERVICE PROCEDURE 2-11
3. Transmission

9) Remove transmission connector holder bracket.

G2M0312

10) Remove operating cylinder. (MT hydraulic clutch

model)

B2M1179B

11) Set ST.

ST 41099AA020 ENGINE SUPPORT ASSY
NOTE:
Also is available Part No. 927670000.

G2M0313

12) Remove bolt which holds right upper side of transmis-

sion to engine.

G2M0299

13) Remove clutch damper. (MT hydraulic clutch model)

(1) Lift-up the vehicle.
(2) Remove tightening bolts.

B2M1300A

31
2-11 SERVICE PROCEDURE
3. Transmission

14) Remove exhaust system.

(1) Remove nuts which install front exhaust pipe onto
engine.

G2M0290

(2) Disconnect connector from rear oxygen sensor.

B2M0335

(3) Separate center exhaust pipe from rear exhaust

pipe.

G2M0291

(4) Remove bolt which installs center exhaust pipe to

hanger bracket.
(5) Take off front and center exhaust pipes.

B2M0313

(6) Remove rear exhaust pipe. (AWD model)

CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.

G2M0315

32
 SERVICE PROCEDURE 2-11
3. Transmission

(7) Remove heat shield cover of rear exhaust pipe.

(AWD model)

G2M0830

(8) Remove hanger bracket from right side of transmis-

sion. (AWD model)

B2M0032

15) Drain ATF to remove ATF drain plug. (AT model)

쎻1 Front differential oil drain plug
쎻2 ATF drain plug

G2M0316

16) Disconnect ATF cooler hoses from pipes of transmis-

sion side, and remove ATF level gauge guide. (AT model)

G2M0317

17) Remove propeller shaft. (AWD model)

(1) Remove front cover of rear differential mount.
(2) Separate propeller shaft from rear differential.

G3M0023

33
2-11 SERVICE PROCEDURE
3. Transmission

(3) Remove bolts which hold center bearing onto body.

CAUTION:
Be careful not to drop propeller shaft.

G3M0024

(4) Remove propeller shaft from transmission.

CAUTION:
쐌 Be sure to use an empty container to catch oil flow-
ing out when removing propeller shaft.
쐌 Be sure not to damage oil seals and the frictional
surface of sleeve yoke.
쐌 Be sure to plug the opening in transmission after
removal of propeller shaft.

G3M0025

18) Remove gear shift rod and stay from transmission.

(MT model)
(1) Remove spring.
(2) Disconnect stay from transmission.
(3) Disconnect rod from transmission.

G3M0697

19) Remove shift selector cable. (AT model)

(1) Disconnect shift selector cable from selector
lever.
(2) Remove cable bracket from body.

B2M0033A

20) Remove bolts which install stabilizer clamps onto

crossmember.

G2M0323

34
 SERVICE PROCEDURE 2-11
3. Transmission

21) Remove front drive shafts from transmission.

(1) Remove transverse link from housing.
(2) Lower transverse link.

G2M0324

(3) Remove spring pins and separate front drive shafts

from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a new one.

G2M0325

22) Remove nuts which hold lower side of transmission to

engine.

G2M0292

23) Place transmission jack under transmission.

CAUTION:
쐌 Always support transmission case with a transmis-
sion jack.
쐌 On AT model, make sure that the support plates of
transmission jack don’t touch the oil pan.

G2M0326

24) Remove transmission rear crossmember.

쐌 MT model

G2M0831

35
2-11 SERVICE PROCEDURE
3. Transmission

쐌 AT model

B2M1171

25) Remove transmission.

CAUTION:
쐌 Move transmission jack toward rear until mainshaft
is withdrawn from clutch cover. (MT model)
쐌 Move transmission and torque converter as a unit
away from engine. (AT model)

B2M0035

36
 SERVICE PROCEDURE 2-11
3. Transmission

B: INSTALLATION
1. Install transmission to engine.

왔
2. Install transmission rear crossmember.

왔
3. Take off transmission jack.

왔
4. Tighten nuts which hold lower side of transmission to engine.

왔
5. Tighten bolt which holds right upper side of transmission to
engine.

AT model 왔
6. Install torque converter to drive plate.

Hydraulic clutch model 왔

7. Install operating cylinder.

왔
8. Remove special tools.
9. Install pitching stopper.

왔
10. Install front drive shafts into transmission.

왔
11. Install stabilizer clamps onto front crossmember.

왔
12. Install gear shift rod and stay.

왔
쎻
B

37
2-11 SERVICE PROCEDURE
3. Transmission

쎻
B

AT model 왔
13. Install shift selector cable to selector lever.
14. Install ATF level gauge guide, and connect ATF cooler hose
to pipe.

AWD model 왔
15. Install propeller shaft.

왔
16. Install exhaust system.
쐌 Heat shield cover [AWD]
쐌 Rear exhaust pipe [AWD]
쐌 Front exhaust pipe
쐌 Center exhaust pipe

Hydraulic clutch model 왔

17. Install clutch damper.

왔
18. Install transmission connector holder bracket.

AT model 왔
19. Install ATF level gauge.

왔
20. Connect connectors and cables.

왔
21. Install starter.

왔
22. Install air intake duct and chamber.

왔
23. Connect battery ground cable.
24. Fill ATF. [AT]
25. Check selector lever operation. [AT]
26. Take off the vehicle from lift arm.
27. Check the vehicle on the road tester. [AT]

38
 SERVICE PROCEDURE 2-11
3. Transmission

1) Install transmission onto engine.

(1) Gradually raise transmission with transmission
jack.
(2) Engage them at splines.
CAUTION:
Be careful not to strike mainshaft against clutch cover.
(MT model)

B2M0035

2) Install transmission rear crossmember.

쐌 MT model
Tightening torque:
T1: 69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
T2: 137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)

G2M0832

쐌 AT model
Tightening torque:
T1: 37±10 N⋅m (3.8±1.0 kg-m, 27±7 ft-lb)
T2: 69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)

B2M1172A

3) Take off transmission jack.

4) Tighten nuts which hold lower side of transmission to
engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

G2M0292

5) Tighten bolt which holds right upper side of transmis-

sion to engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

G2M0299

39
2-11 SERVICE PROCEDURE
3. Transmission

6) Install torque converter to drive plate. (AT model)

(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
G2M0294
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.

(4) Install V-belt cover.

B2M0017

7) Install operating cylinder. (Hydraulic clutch model)

Tightening torque:
37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)

B2M1179B

8) Remove special tools.

G2M0313

40
 SERVICE PROCEDURE 2-11
3. Transmission

9) Install pitching stopper.

Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)

G2M0302

10) Install front drive shafts into transmission.

(1) Lift-up the vehicle.
(2) Install front drive shaft into transmission.
(3) Drive spring pin into chamfered hole of drive shaft.
CAUTION:
Always use a new spring pin.

G2M0325

(4) Install ball joints of lower arm into knuckle arm of

housing, and tighten installing bolts.
Tightening torque:
49±10 N⋅m (5.0±1.0 kg-m, 36±7 ft-lb)

G2M0324

11) Install stabilizer clamps onto front crossmember.

Tightening torque:
25±4 N⋅m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)

G2M0323

12) Install gear shift rod and stay. (MT model)

(1) Install gear shift rod onto transmission.
(2) Install stay onto transmission.
(3) Install spring.

G3M0697

41
2-11 SERVICE PROCEDURE
3. Transmission

13) Install shift selector cable onto selector lever. (AT

model)
(1) Install selector cable into selector lever.
(2) Install cable bracket onto body.
NOTE:
Tighten selector cable adjusting and lock nut after check-
ing selector lever operation.

B2M0033A

14) Install ATF level gauge guide, and ATF cooler hoses
onto pipe. (AT model)

G2M0317

15) Install propeller shaft. (AWD model)

(1) Install propeller shaft into transmission.
(2) Tighten bolts which install propeller shaft onto com-
panion flange of rear differential.
Tightening torque:
31±8 N⋅m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)

G3M0023

(3) Install center bearing bracket on body.

Tightening torque:
52±5 N⋅m (5.3±0.5 kg-m, 38.3±3.6 ft-lb)

G3M0024

16) Install exhaust system.

(1) Install heat shield cover. (AWD model)

G2M0830

42
 SERVICE PROCEDURE 2-11
3. Transmission

(2) Install rear exhaust pipe to muffler. (AWD model)

Tightening torque:
48±9 N⋅m (4.9±0.9 kg-m, 35.4±6.5 ft-lb)

G2M0382

(3) Install hanger bracket on right side of transmission.

(AWD model)

B2M0032

(4) Install front exhaust pipe onto engine.

Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

G2M0290

(5) Install center exhaust pipe to rear exhaust pipe.

Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

G2M0291

(6) Tighten bolt which installs center exhaust pipe to

hanger bracket.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0313

43
2-11 SERVICE PROCEDURE
3. Transmission

(7) Connect connector to rear oxygen sensor.

B2M0335

17) Install clutch damper. (Hydraulic clutch model)

Tightening torque:
25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)

B2M1300A

18) Install transmission connector holder bracket.

G2M0312

19) Install ATF level gauge. (AT model)

B2M0031

44
 SERVICE PROCEDURE 2-11
3. Transmission

20) Connect connectors and cables.

(1) Connect the following connectors.
쐌 Transmission harness connectors
쐌 Transmission ground terminal
쐌 Front oxygen sensor connector
쐌 Vehicle speed sensor 2
쐌 Neutral position switch connector (MT model)
쐌 Back-up light switch connector (MT model)
(2) Connect the following cables.
쐌 Cruise control cable
(With cruise control model)
쐌 Clutch cable

21) Install starter.

(1) Install starter onto transmission case, and connect
connectors and terminals.
(2) Tighten bolt and nut which install starter onto trans-
mission.
Tightening torque:
40±4 N⋅m (4.1±0.4 kg-m, 29.7±2.9 ft-lb)

G2M0309

22) Install air intake duct and chamber.

B2M1170

23) Connect battery ground cable.

24) Fill ATF. (AT model)
<Ref. to 3-2 [W2A1].>
25) Check selector lever operation. (AT model)
<Ref. to 3-3 [W2E0].>
26) Take off vehicle from lift arms.
27) Check the vehicle on road tester. (AT model)
<Ref. to 3-2 [W3E0].>

45