Мануал на субару легаси 1995

1. Front Catalytic Converter

A: REMOVAL

1) Disconnect front oxygen sensor connector.

G2M0544

2)Lift-up the vehicle.

3)Disconnect rear oxygen sensor connector.

B2M0312

4) Separate center exhaust pipe from rear exhaust pipe.

B2M0055

5) Remove bolts which hold front exhaust pipe onto cylinder heads.

B2M0054

6) 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

7) 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 cylinder heads.

Tightening torque:

30±5 N m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0054

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

1.Front Catalytic Converter — 2. Rear Catalytic Converter

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.

B2M0312

7)Lower the vehicle.

Connect front oxygen sensor connector.

G2M0544

2. Rear Catalytic Converter

A: REMOVAL

1)Lift-up the vehicle.

2)Disconnect rear oxygen sensor connector.

B2M0312

3) Separate center exhaust pipe and rear catalytic converter assembly from rear exhaust pipe.

B2M0055

1.Front Catalytic Converter — 2. Rear Catalytic Converter

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.

B2M0312

7)Lower the vehicle.

Connect front oxygen sensor connector.

G2M0544

2. Rear Catalytic Converter

A: REMOVAL

1)Lift-up the vehicle.

2)Disconnect rear oxygen sensor connector.

B2M0312

3) Separate center exhaust pipe and rear catalytic converter assembly from rear exhaust pipe.

B2M0055

4) Separate center exhaust pipe and rear catalytic converter assembly from front catalytic converter.

B2M0421

5) Remove center exhaust pipe and rear catalytic converter assembly from hanger bracket.

CAUTION:

!Be careful not to pull down center exhaust pipe.

!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

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

2.Rear Catalytic Converter — 4. Purge Control Solenoid Valve

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.

B2M0312

3. Canister

A: REMOVAL AND INSTALLATION

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.

4. Purge Control Solenoid Valve

A: REMOVAL AND INSTALLATION

1) Remove bolt which installs purge control solenoid valve onto intake manifold.

NOTE:

This figure shows the rear side of intake manifold.

B2M0422A

2.Rear Catalytic Converter — 4. Purge Control Solenoid Valve

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.

B2M0312

3. Canister

A: REMOVAL AND INSTALLATION

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.

4. Purge Control Solenoid Valve

A: REMOVAL AND INSTALLATION

1) Remove bolt which installs purge control solenoid valve onto intake manifold.

NOTE:

This figure shows the rear side of intake manifold.

B2M0422A

2.Rear Catalytic Converter — 4. Purge Control Solenoid Valve

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.

B2M0312

3. Canister

A: REMOVAL AND INSTALLATION

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.

4. Purge Control Solenoid Valve

A: REMOVAL AND INSTALLATION

1) Remove bolt which installs purge control solenoid valve onto intake manifold.

NOTE:

This figure shows the rear side of intake manifold.

B2M0422A

4.Purge Control Solenoid Valve — 6. Back-Pressure Transducer (BPT)

2)Take out purge control solenoid valve through the bottom of the intake manifold.

3)Disconnect connector and hoses from purge control solenoid valve.

B2M0168

4) 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 manifold.

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 hoses from BPT.

2)Remove BPT from bracket.

3)Installation is in the reverse order of removal.

B2M0424

4.Purge Control Solenoid Valve — 6. Back-Pressure Transducer (BPT)

2)Take out purge control solenoid valve through the bottom of the intake manifold.

3)Disconnect connector and hoses from purge control solenoid valve.

B2M0168

4) 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 manifold.

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 hoses from BPT.

2)Remove BPT from bracket.

3)Installation is in the reverse order of removal.

B2M0424

4.Purge Control Solenoid Valve — 6. Back-Pressure Transducer (BPT)

2)Take out purge control solenoid valve through the bottom of the intake manifold.

3)Disconnect connector and hoses from purge control solenoid valve.

B2M0168

4) 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 manifold.

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 hoses from BPT.

2)Remove BPT from bracket.

3)Installation is in the reverse order of removal.

B2M0424

7. EGR Solenoid Valve

A: REMOVAL AND INSTALLATION

1)Remove bolt which installs EGR solenoid valve onto intake manifold.

2)Disconnect hoses and connector from EGR solenoid valve.

NOTE:

This figure shows the rear side of intake manifold.

B2M0425A

3) Installation is in the reverse order of removal.

Tightening torque:

19±5 N m (1.9±0.5 kg-m, 13.7±3.6 ft-lb)

2-2

1. Foreword — 2. Ignition Timing

1. Foreword

This chapter describes major inspection and service procedures for the engine mounted on the body. For procedures not found in this chapter, refer to the service procedure section in the applicable chapter.

2. Ignition Timing

A: MEASUREMENT

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 system. <Ref. to 2-7 On-Board Diagnostics II System.>

Ignition timing [BTDC/rpm]: 14°±8°/700 (MT)

G2M0094 20°±8°/700 (AT)

2-2

1. Foreword — 2. Ignition Timing

1. Foreword

This chapter describes major inspection and service procedures for the engine mounted on the body. For procedures not found in this chapter, refer to the service procedure section in the applicable chapter.

2. Ignition Timing

A: MEASUREMENT

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 system. <Ref. to 2-7 On-Board Diagnostics II System.>

Ignition timing [BTDC/rpm]: 14°±8°/700 (MT)

G2M0094 20°±8°/700 (AT)

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:

!When using the OBD-II general scan tool, carefully read its operation manual.

!When Subaru Select Monitor is not used, attach the pickup sensor on tachometer (Secondary pickup type) to #1 cylinder spark plug cord.

!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

2-2

3. Engine Idle Speed

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”.

2-2

4. Engine Compression

4. Engine Compression

A: 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.

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.

Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.

G2M0098

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

Compression (200 — 300 rpm and fully open throttle): Standard

1,079 — 1,275 kPa

(11.0 — 13.0 kg/cm2, 156 — 185 psi) Limit

883 kPa (9.0 kg/cm2, 128 psi) Difference between cylinders

196 kPa (2.0 kg/cm2, 28 psi)

2-2

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

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

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:

! If oil pressure is out of specification, check oil pump, oil filter and lubrication line.

<Ref. to 2-4 [K100].>

G2M0093 ! 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.

1. Engine

A: SPECIFICATIONS

1. Timing Belt

B2M0102A

2. Cylinder Head and Camshaft

B2M0103A

3. Cylinder Head and Valve Assembly

B2M0380A

4. Cylinder Block

B2M0381A

5. Crankshaft and Piston

G2M0105

1.General Precautions — 2. Hydraulic Lash Adjuster

1.General Precautions

1) Before disassembling engine, place it on ST3.

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.

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

1.General Precautions — 2. Hydraulic Lash Adjuster

1.General Precautions

1) Before disassembling engine, place it on ST3.

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.

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

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

2) Manually remove lash adjusters where air is trapped.

CAUTION:

If lash adjuster is difficult to remove manually, use pliers. Be careful not to scratch 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

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 interval of one second.

(3)Move plunger up and down until air bubbles are no longer emitted from lash adjuster.

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.

6) Fill rocker arm’s oil reservoir with engine oil and install lash adjuster.

CAUTION:

«Do not rotate lash adjuster during installation.

«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 !1 through !4 . Do not allow knock pin to catch valve rocker assembly.

Tighten bolts !5 through !8 to specified torque.

9)Tighten bolts !1 through !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 positions.

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

B2M0415A

1) If alignment mark !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 !2 on crankshaft sprocket, and left and right camshaft

sprockets with notches !1 of belt cover and cylinder block.

ST 499987500 CRANKSHAFT SOCKET

B2M0064A

(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.

G2M0112

1)Remove belt idler.

2)Remove belt tensioner and spacer.

3)Remove belt tensioner adjuster.

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.

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:

» Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens.

» 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 tension 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 projectionally acting force and should not sink within 8.5 seconds.

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.

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 camshaft 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.

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:

«Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 lb).

«Do not release press pressure until stopper pin is completely inserted.

«Push tension adjuster rod vertically.

«Press-in the push rod gradually taking three minutes or more.

B2M0109A

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)

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 camshaft 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

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: 108−+105 (11+1−0..05 , 79.6+7−3..26 )

1)Install front belt cover.

2)Install right side belt cover.

3)Install left side belt cover.

4)Install crankshaft pulley.

G2M0108

4. Valve Rocker Assembly

A: REMOVAL

B2M0418A

1)Disconnect PCV hose and remove rocker cover.

2)Removal of valve rocker assembly

(1) Remove bolts !1 through !4 in numerical sequence.

CAUTION:

Leave two or three threads of bolt !1 engaged to retain valve rocker assembly.

(2) Equally loosen bolts !5 through !8 all the way, being careful that knock pin is not gouged.

B2M0382A

(3) Remove valve rocker assembly.

CAUTION:

Locate valve rocker assembly with air vent (on rocker arm) facing upward or dip it in engine oil after removal.

B2M0414

B: DISASSEMBLY

B2M0383A

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.

«Locate rocker arms with air vents facing upward.

3) Remove valve lash adjuster from valve rocker.

CAUTION:

«Do not remove valve lash adjuster unless it requires air bleeding or replacement.

«If valve lash adjuster is hard to remove by hand, use pliers. Be careful not to scratch valve lash adjuster.

«Dip lash adjuster in engine oil after removal.

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

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.

2. VALVE ROCKER ARM

1) Measure inside diameter of valve rocker arm and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).

Clearance between arm and shaft: Standard

0.020 — 0.054 mm (0.0008 — 0.0021 in) Limit

0.10 mm (0.0039 in)

If oil clearance exceeds specifications, replace valve rocker arm or shaft.

NOTE:

Replace valve rocker arm or shaft, whichever shows greater amount of wear.

Rocker arm inside diameter:

22.020 — 22.041 mm (0.8669 — 0.8678 in)

Rocker shaft diameter:

21.987 — 22.000 mm (0.8656 — 0.8661 in)

2) Measure inside diameter of rocker shaft support and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).

Clearance between support and shaft: Standard

0.005 — 0.039 mm (0.0002 — 0.0015 in) Limit

0.05 mm (0.0020 in)

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.

«Breaks in check ball body

«Foreign particles caught in valve spring

«Oil leakage at check ball

CAUTION:

Repair or replace valve rocker shaft as necessary.