Мануал на субару легаси 1995

  1. Руководства по ремонту
  2. Руководство по ремонту Субару Легаси 1990-1998 г.в.

Руководство по ремонту Subaru Legacy / Субару Легаси 1990-

Общая информация об автомобиле.

Subaru Legacy 1990-1998

Полтора десятка лет назад автомобили Subaru имели репутацию неприхотливых фермерских «лошадок». Желая изменить сложившийся имидж и сделать из Subaru культовую марку, руководство японской компании в конце 80х годов приняло решение начать программу участия в чемпионате мира по ралли, вести которую было доверено британской фирме Prodrive.

Начало было положено в 1990 году, когда Subaru вышла на сцену с моделью Legacy. Её не слишком успешная карьера в чемпионате мира продолжалась три года, однако стараниями Колина Макрея она завершилась на победной ноте — в 1993 году молодой шотландец выиграл за рулем Legacy ралли Новая Зеландия, после которого наступила эра Subaru Impreza, дебют которой состоялся в Финляндии.

Последним же значительным успехом Legacy перед отправкой на пенсию стал завоеванный Ричардом Бёрнсом титул чемпиона Великобритании.

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1. Идентификационные номера

1.0 Идентификационные номера
1.2 Органы управления и контрольные приборы
1.3 Переключатели освещения, поворотов, омывателя и очистителя стекла
1.3. Переключатель освещения, поворотов и яркости освещения
1.4 Каталитический нейтрализатор
1.5 Система вентиляции и кондиционирования воздуха
1.6 Система климат-контроля
1.7 Система круиз-контроля
1.8 Механическая коробка передач
1.9 Автоматическая коробка передач
1.10. Передние сиденья
1.11 Расположение и мощность лампочек
1.12. Предохранители и электрические цепи
1.13 Основы безопасной эксплуатации автомобиля
1.14 Колеса и шины
1.15 Углы установки колес

2. Техническое обслуживание

2.0 Техническое обслуживание
2.2 Технические характеристики
2.3 Периодичность обслуживания
2.4 Проверка уровня моторного масла
2.5 Уровень охлаждающей жидкости
2.6 Уровень тормозной жидкости и жидкости привода сцепления
2.7 Жидкость для омывателя ветрового стекла
2.8 Проверка аккумулятора
2.9 Шины и проверка давления в шинах
2.10 Проверка уровня масла в автоматической коробке передач
2.11 Проверка уровня жидкости в усилителе рулевого управления
2.12 Замена масла и масляного фильтра
2.13 Проверка и обслуживание аккумулятора
2.14 Зарядка аккумулятора
2.15 Проверка системы охлаждения
2.16 Проверка шлангов, трубок и их замена
2.17 Проверка и замена щеток стеклоочистителей
2.18 Перестановка шин
2.19 Проверка подвески и рулевого управления
2.20 Проверка выхлопной системы
2.21 Проверка уровня масла в коробке передач и главной передаче
2.22 Проверка уровня масла в дифференциале (главной передаче)
2.23 Проверка тормозной системы
2.24 Проверка вакуумного усилителя тормозов
2.25 Проверка ручного тормоза
2.26 Проверка топливной системы
2.27 Замена топливного фильтра
2.28 Проверка и замена приводного ремня
2.29 Проверка свободного хода педали тормоза
2.30 Проверка свободного хода педали сцепления
2.31 Проверка и замена свечей зажигания
2.32 Проверка высоковольтных проводов
2.33 Проверка и регулировка оборотов холостого хода
2.34 Замена воздушного фильтра
2.35 Проверка и замена клапана вентиляции картера (PCV)
2.36 Проверка системы улавливания паров топлива
2.37 Проверка системы повторного сжигания отработанных газов (EGR)
2.38 Обслуживание системы охлаждения
2.39 Замена тормозной жидкости
2.40 Замена масла в автоматической коробке передач
2.41 Замена масла в механической коробке передач
2.42 Проверка и регулировка зазоров клапанов
2.43. Основные неисправности

3. Двигатели

3.0 Двигатели
3.2 Операции по ремонту двигателя, установленного в автомобиле
3.3 Верхняя мертвая точка первого цилиндра
3.4 Крышка головки блока цилиндров
3.5 Впускной коллектор
3.6. Зубчатый ремень и шкивы
3.7 Замена переднего уплотнительного кольца коленчатого вала
3.8 Замена уплотнительных колец распределительных валов
3.9 Распределительные валы и толкатели
3.10 Головки блока цилиндров
3.11 Масляный поддон
3.12 Масляный насос
3.13 Маховик/ пластина привода
3.14 Замена заднего уплотнительного кольца коленчатого вала
3.15 Подвеска силового агрегата
3.16. Капитальный ремонт двигателя

4. Отопление, вентиляция

4.0 Отопление, вентиляция
4.1. Технические характеристики
4.2. Система отопления
4.3. Система кондиционирования воздуха
4.4 Система климат-контроля

5. Топливная система

5.0 Топливная система
5.2 Технические характеристики
5.3 Снятие давления в топливной системе
5.4 Проверка топливного насоса
5.5 Топливный насос
5.6 Сепаратор топлива (только модели 4WD)
5.7 Датчик уровня топлива
5.8 Топливный бак
5.9 Кожух воздушного фильтра
5.10 Трос акселератора
5.11 Электронная система впрыска топлива
5.12 Топливная система
5.13 Система подачи воздуха
5.14 Система электронного управления
5.15 Проверка системы впрыска топлива
5.16. Проверка и замена элементов системы впрыска топлива
5.17 Турбонагнетатель
5.18 Проверка исполнительного механизма заслонки турбонагнетателя
5.19 Общая проверка турбонагнетателя
5.20 Снятие и установка турбонагнетателя

6. Выхлопная система

6.0 Выхлопная система
6.2. Уменьшение токсичности выхлопных газов и управление работой двигателя

7. Системы запуска, зажигания

7.0 Системы запуска, зажигания
7.2 Технические характеристики
7.3 Проверка аккумулятора
7.4 Зарядка аккумулятора
7.5 Аккумулятор
7.6. Система зажигания
7.7. Система зарядки
7.8. Система запуска двигателя

8. Коробки передач

8.0 Коробки передач
8.1. Технические характеристики
8.2. Автоматическая коробка передач

9. Сцепление, валы

9.0 Сцепление, валы
9.2. Сцепление
9.3. Карданный вал
9.4. Приводные валы

10. Тормозная система

10.0 Тормозная система
10.2 Технические характеристики
10.3 Замена тормозных колодок на дисковых тормозах
10.4 Суппорт дисковых тормозов
10.5 Тормозной диск
10.6 Замена тормозных колодок барабанных тормозов
10.7 Рабочий тормозной цилиндр
10.8 Главный тормозной цилиндр
10.9 Тормозные трубопроводы и шланги
10.10 Замена регулятора давления
10.11 Прокачка гидравлической тормозной системы
10.12 Регулировка ручного тормоза
10.13 Замена троса ручного тормоза
10.14 Замена тормозных колодок ручного тормоза на задних дисковых тормозах
10.15 Дополнительная тормозная система
10.16 Вакуумный усилитель тормозов
10.17 Выключатель стоп-сигнала
10.18 Антиблокировочная система тормозов (ABS)

11. Подвеска

11.0 Подвеска
11.2 Технические характеристики
11.3. Передняя стойка
11.4. Стойка задней подвески
11.5 Воздушная самовыравнивающаяся подвеска

12. Рулевое управление

12.0 Рулевое управление
12.2 Технические характеристики
12.3 Рулевое колесо
12.4 Наконечники рулевой тяги
12.5 Замена защитных чехлов рулевой передачи
12.6 Рулевая передача
12.7 Насос усилителя рулевого управления
12.8 Удаление воздуха из системы рулевого управления с усилителем

13. Кузов

13.0 Кузов
13.2 Уход за кузовом
13.3 Уход за обивкой и ковриками
13.4 Ремонт незначительных повреждений кузова
13.5 Ремонт сильных повреждений кузова
13.6 Капот
13.7 Замена замка капота
13.8 Замена троса замка капота
13.9 Решетка радиатора
13.10 Передний бампер
13.11 Задний бампер
13.12 Переднее крыло
13.13 Обивка двери
13.14 Замок, цилиндр замка и ручки открытия двери
13.15 Стекло двери
13.16 Стеклоподъемник
13.17 Наружное зеркало
13.18 Двери
13.19 Крышка багажника
13.20 Замок багажника
13.21 Трос открытия замка багажника
13.22 Замена стоек поддержки задней двери
13.23 Задняя дверь
13.24 Замок задней двери, наружная ручка и цилиндр замка
13.25 Кожухи рулевой колонки
13.26 Центральная консоль
13.27 Элементы панели приборов
13.28 Панель приборов
13.29 Решетка воздухозаборника
13.30 Передние сиденья

14. Электрооборудование

14.0 Электрооборудование
14.1. Электрические цепи
14.2. Электросхемы

Service Manual Subaru Legacy 2012 г.

Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Subaru Legacy 2012 модельного года.

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  • Издательство: Fuji Heavy Industries Ltd.
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  • Размер: 138,2 Mb

Service Manual Subaru Legacy II.

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Subaru Legacy второго поколения 1995-1999 годов выпуска.

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  • Издательство: Fuji Heavy Industries Ltd.
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  • Размер: 373,6 Mb

Service Manual Subaru Legacy III.

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Subaru Legacy третьего поколения 2000-2003 годов выпуска.

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  • Издательство: Fuji Heavy Industries Ltd.
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  • Размер: 420,2 Mb

Service Manual Subaru Legacy IV.

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Subaru Legacy четвертого поколения 2003-2009 годов выпуска.

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  • Размер: 219,0 Mb

Service Manual Subaru Legacy.

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Subaru Legacy 1989-1994 годов выпуска.

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  • Издательство: Fuji Heavy Industries Ltd.
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  • Размер: 70,5 Mb

Ремонт и эксплуатация Subaru Legacy 1990-1998 г.

Мультимедийное руководство по эксплуатации и ремонту автомобиля Subaru Legacy 1990-1998 годов выпуска.

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Руководство по обслуживанию Subaru Legacy 2008 г.

Руководство по техническому обслуживанию и ремонту автомобиля Subaru Legacy 2008 года выпуска.

  • Автор:
  • Издательство: Fuji Heavy Industries Ltd.
  • Год издания:
  • Страниц: 5228
  • Формат: PDF
  • Размер: 80,1 Mb

Руководство по ремонту и ТО Subaru Legacy 1990-1998 г.

Руководство по техническому обслуживанию и ремонту автомобиля Subaru Legacy 1990-1998 годов выпуска с бензиновыми двигателями объемом 1,8/2,0/2,2/2,5 л.

  • Автор:
  • Издательство: Техно-ВООК
  • Год издания: 1999
  • Страниц: 272
  • Формат: PDF
  • Размер: 864,0 Mb

Руководство по эксплуатации, техническому обслуживанию и ремонту автомобилей Subaru Legacy/Legacy Outback 1989-1998 годов выпуска с бензиновыми двигателями.

  • Автор:
  • Издательство: Легион-Автодата
  • Год издания:
  • Страниц: 384
  • Формат:
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Руководство по ремонту и ТО Subaru Legacy 1998-2003 г.

Руководство по эксплуатации, техническому обслуживанию и ремонту + каталог расходных запчастей автомобилей Subaru Legacy/Outback/Wagon/B4/Lancaster 1998-2003 годов выпуска с двигателями объемом 2,0/2,5/3,0 л.

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  • Издательство: Легион-Автодата
  • Год издания:
  • Страниц: 680
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Руководство по ремонту и ТО Subaru Legacy 2003-2009 г.

Руководство по эксплуатации, техническому обслуживанию и ремонту + каталог расходных запчастей автомобилей Subaru Legacy/Outback/Wagon/B4 2003-2009 годов выпуска с двигателями объемом 2,0/2,5/3,0 л.

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  • Издательство: Легион-Автодата
  • Год издания:
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Руководство по ремонту и эксплуатации Subaru Legacy с 2000 г.

Руководство по эксплуатации и ремонту автомобилей Subaru Baja/Forester/Legacy/Outback с 2000 года выпуска с бензиновыми двигателями объемом 2,5 л.

  • Автор:
  • Издательство: Монолит
  • Год издания:
  • Страниц: 468
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Руководство по ремонту и эксплуатации Subaru Legacy с 2009 г.

Руководство по эксплуатации и ремонту автомобилей Subaru Legacy и Subaru Outback с 2009 года выпуска с бензиновыми двигателями объемом 2,0/2,5/3,6 литра.

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Руководство по эксплуатации Subaru Legacy 2005-2007 г.

Сборник руководств по эксплуатации и техническому обслуживанию автомобилей Subaru Legacy и Subaru Outback 2005-2007 годов выпуска.

  • Автор:
  • Издательство: Fuji Heavy Industries Ltd.
  • Год издания: 2004/2006
  • Страниц: 600/528
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Руководство по эксплуатации Subaru Legacy IV с 2003 г.

Руководство по эксплуатации и техническому обслуживанию автомобиля Subaru Legacy с 2003 года выпуска.

  • Автор:
  • Издательство: MoToR
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Руководство по эксплуатации и ремонту Subaru Legacy 1999-2003 г.

Руководство по эксплуатации и ремонту автомобилей Subaru Forester с 1997 и Subaru Legacy/Outback 1999-2003 годов выпуска.

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Устройство, обслуживание, ремонт Subaru Legacy 1999-2003 г.

Мультимедийное руководство по эксплуатации и ремонту автомобилей Subaru Legacy и Subaru Outback 1999-2003 годов выпуска.

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Доп информация

Фото в бортжурнале Subaru Legacy (BD/BG/BK)

Всем привет, долго искал книгу по ремонту и эксплуатации авто.
Просто выложу её здесь вдруг кому пригодится.

Subaru Legacy 1990-98г.в: Ремонт и эксплуатация

Ремонт и эксплуатация SUBARU Legacy 1990-98г.в
Язык интерфейса: русский
Формат: (.iso)
Описание: Руководство «Устройство Обслуживание Ремонт» составленное для автомобиля SUBARU представляет собой мультимедийный вариант популярного печатного издания
В ссылке архив без пароля, в нем файл открывается через любой эмулятор Windows.
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Manufacturer: SUBARU, Model Year: 1995,
Model line: LEGACY,
Model: SUBARU LEGACY 1995
Pages: 2248, PDF Size: 48.81 MB

Trending: ECU, Safety switch, charging, warning light, Cv axle, Fuel pump

Page 1 of 2248

SUBARU LEGACY 1995  Service Repair Manual G2M0544
1. Front Catalytic Converter
A: REMOVAL
1) Disconnect front oxygen sensor connector.
B2M0312
2) Lift-up the vehicle.
3) Disconnect rear oxygen sensor connector.
B2M0055
4) Separate center exha

Page 2 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0060
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 f

Page 3 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0313
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)
B2M0312
6) Connect rear oxygen sensor connector.
G2M0544
7) L

Page 4 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0313
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)
B2M0312
6) Connect rear oxygen sensor connector.
G2M0544
7) L

Page 5 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0421
4) Separate center exhaust pipe and rear catalytic con-
verter assembly from front catalytic converter.
B2M0313
5) Remove center exhaust pipe and rear catalytic con-
verter assembly from hange

Page 6 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0313
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)
B2M0312
5) Connect rear oxygen sensor connector.
G2M0375
3. C

Page 7 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0313
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)
B2M0312
5) Connect rear oxygen sensor connector.
G2M0375
3. C

Page 8 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0313
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)
B2M0312
5) Connect rear oxygen sensor connector.
G2M0375
3. C

Page 9 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0168
2) Take out purge control solenoid valve through the bot-
tom of the intake manifold.
3) Disconnect connector and hoses from purge control
solenoid valve.
4) Installation is in the reverse ord

Page 10 of 2248

SUBARU LEGACY 1995  Service Repair Manual B2M0168
2) Take out purge control solenoid valve through the bot-
tom of the intake manifold.
3) Disconnect connector and hoses from purge control
solenoid valve.
4) Installation is in the reverse ord

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2-1

SERVICE PROCEDURE

1. Front Catalytic Converter

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

2

SERVICE PROCEDURE

2-1

1. Front Catalytic Converter

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

3

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.

8) 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

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.

8) 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

SERVICE PROCEDURE

2-1

2. Rear Catalytic Converter

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

5

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

6

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

6

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

6

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

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

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

2-1

SERVICE PROCEDURE

7. EGR Solenoid Valve

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)

8

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

2-2

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

2-2

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

3

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”.

4

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.

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

G2M0098

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

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

1,079 — 1,275 kPa

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

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

196 kPa (2.0 kg/cm2, 28 psi)

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:

! 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.

8

2-3

SPECIFICATIONS AND SERVICE DATA

1. Engine

1. Engine

A: SPECIFICATIONS

Model

2200 cc

Type

Horizontally

opposed, liquid cooled, 4-cylinder, 4-stroke

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)

Displacement

cm3 (cu in)

2,212 (135.0)

Compression ratio

9.5

Compression pressure

kPa (kg/cm2, psi)

1,079 — 1,275

(at 200 — 300 rpm)

(11.0 — 13.0, 156 — 185)

Engine

Number of piston rings

Pressure ring: 2, Oil ring: 1

Intake valve timing

Opening

1° BTDC

Closing

55° ABDC

Exhaust valve timing

Opening

48° BBDC

Closing

12° ATDC

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

Protrusion of adjuster rod

15.4 — 16.4 mm

(0.606 — 0.646 in)

tension

adjuster

Spacer O.D.

16 mm

(0.63 in)

Tensioner bush I.D.

16.16 mm

(0.6362 in)

Belt ten-

Clearance between spacer and bush

STD

0.117 — 0.180 mm

(0.0046 — 0.0071 in)

sioner

Limit

0.230 mm

(0.0091 in)

Side clearance of spacer

STD

0.37 — 0.54 mm

(0.0146 — 0.0213 in)

Limit

0.8 mm

(0.031 in)

Valve

Clearance between shaft and arm

STD

0.020 — 0.054 mm

(0.0008 — 0.0021 in)

rocker arm

Limit

0.10 mm

(0.0039 in)

Bend limit

0.025 mm

(0.0010 in)

Thrust clearance

STD

0.030 — 0.260 mm

(0.0012 — 0.0102 in)

Limit

0.35 mm

(0.0138 in)

Intake

STD

31.994 — 32.094 mm

(1.2596 — 1.2635 in)

Cam lobe height

Limit

31.844 mm

(1.2537 in)

Exhaust

STD

32.624 — 32.724 mm

(1.2844 — 1.2883 in)

Camshaft

Limit

32.474 mm

(1.2785 in)

Camshaft journal O.D.

RH

Front

LH

Rear

31.935 — 31.950 mm

(1.2573 — 1.2579 in)

Center

Center

37.435 — 37.450 mm

(1.4738 — 1.4744 in)

Rear

Front

37.935 — 37.950 mm

(1.4935 — 1.4941 in)

Camshaft journal hole

Front

Rear

32.005 — 32.025 mm

(1.2600 — 1.2608 in)

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)

Oil clearance

STD

0.055 — 0.090 mm

(0.0022 — 0.0035 in)

Limit

0.10 mm

(0.0039 in)

Cylinder

Surface warpage limit

0.05 mm

(0.0020 in)

Surface grinding limit

0.1 mm

(0.004 in)

head

Standard height

98.3 mm

(3.870 in)

Refacing angle

90°

Intake

STD

0.7 mm

(0.028 in)

Valve set

Contacting width

Limit

1.4 mm

(0.055 in)

Exhaust

STD

1.4 mm

(0.055 in)

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)

Intake

STD

1.0 mm

(0.039 in)

Head edge thickness

Limit

0.8 mm

(0.031 in)

Exhaust

STD

1.2 mm

(0.047 in)

Limit

0.8 mm

(0.031 in)

Stem diameter

Intake

5.950 — 5.965 mm

(0.2343 — 0.2348 in)

Valve

Exhaust

5.945 — 5.960 mm

(0.2341 — 0.2346 in)

STD

Intake

0.035 — 0.062 mm

(0.0014 — 0.0024 in)

Stem oil clearance

Exhaust

0.040 — 0.067 mm

(0.0016 — 0.0026 in)

Limit

0.15 mm

(0.0059 in)

Overall length

Intake

101.0 mm

(3.976 in)

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)

Valve spring

Squareness

2.5°, 1.9 mm

(0.075 in)

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)

Cylinder bore

STD

A

96.905 — 96.915 mm

(3.8151 — 3.8155 in)

B

96.895 — 96.905 mm

(3.8148 — 3.8151 in)

Cylinder

Taper

STD

0.015 mm

(0.0006 in)

Limit

0.050 mm

(0.0020 in)

block

Out-of-roundness

STD

0.010 mm

(0.0004 in)

Limit

0.050 mm

(0.0020 in)

Piston clearance

STD

0.010 — 0.030 mm

(0.0004 — 0.0012 in)

Limit

0.050 mm

(0.0020 in)

Enlarging (boring) limit

0.5 mm

(0.020 in)

STD

A

96.885 — 96.895 mm

(3.8144 — 3.8148 in)

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)

Piston pin

pin and hole in piston

Limit

0.020 mm

(0.0008 in)

Degree of fit

Piston pin must be fitted into position with thumb at 20°C

(68°F).

Top ring

STD

0.20 — 0.35 mm

(0.0079 — 0.0138 in)

Limit

1.0 mm

(0.039 in)

Piston ring gap

Second

STD

0.20 — 0.50 mm

(0.0079 — 0.0197 in)

ring

Limit

1.0 mm

(0.039 in)

Piston ring

Oil ring

STD

0.20 — 0.70 mm

(0.0079 — 0.0276 in)

Limit

1.5 mm

(0.059 in)

Top ring

STD

0.040 — 0.080mm

(0.0016 — 0.0031 in)

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

Side clearance

STD

0.070 — 0.330 mm

(0.0028 — 0.0130 in)

Limit

0.4 mm

(0.016 in)

Oil clearance

STD

0.015 — 0.045 mm

(0.0006 — 0.0018 in)

Limit

0.05 mm

(0.0020 in)

STD

1.492 — 1.501 mm

(0.0587 — 0.0591 in)

0.03 mm

1.510 — 1.513 mm

(0.0594 — 0.0596 in)

Connecting

(0.0012 in)

US

rod bearing

Thickness at center portion

0.05 mm

1.520 — 1.523 mm

(0.0598 — 0.0600 in)

(0.0020 in)

US

0.25 mm

1.620 — 1.623 mm

(0.0638 — 0.0639 in)

(0.0098 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)

Crank pin and crank journal

Out-of-roundness

0.030 mm (0.0012 in) or less

Grinding limit

0.25 mm

(0.0098 in)

STD

51.984 — 52.000 mm

(2.0466 — 2.0472 in)

0.03 mm

51.954 — 51.970 mm

(2.0454 — 2.0461 in)

(0.0012 in)

US

Crank pin outer diameter

0.05 mm

51.934 — 51.950 mm

(2.0446 — 2.0453 in)

(0.0020 in)

US

0.25 mm

51.734 — 51.750 mm

(2.0368 — 2.0374 in)

(0.0098 in)

US

STD

59.992 — 60.008 mm

(2.3619 — 2.3625 in)

0.03 mm

59.962 — 59.978 mm

(2.3607 — 2.3613 in)

(0.0012 in)

US

#1, #5

0.05 mm

59.934 — 59.950 mm

(2.3596 — 2.3602 in)

(0.0020 in)

Crankshaft

US

0.25 mm

59.742 — 59.758 mm

(2.3520 — 2.3527 in)

(0.0098 in)

Crank journal outer diameter

US

STD

59.992 — 60.008 mm

(2.3619 — 2.3625 in)

0.03 mm

59.954 — 59.970 mm

(2.3604 — 2.3610 in)

(0.0012 in)

US

#2, #3, #4

0.05 mm

59.934 — 59.950 mm

(2.3596 — 2.3602 in)

(0.0020 in)

US

0.25 mm

59.734 — 59.750 mm

(2.3517 — 2.3524 in)

(0.0098 in)

US

Thrust clearance

STD

0.030 — 0.115 mm

(0.0012 — 0.0045 in)

Limit

0.25 mm

(0.0098 in)

#1, #5

STD

0.003 — 0.030 mm

(0.0001 — 0.0012 in)

Oil clearance

#2, #3, #4

STD

0.010 — 0.033 mm

(0.0004 — 0.0013 in)

#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

2.017 — 2.020 mm

(0.0794 — 0.0795 in)

(0.0012 in)

US

#1, #5

0.05 mm

2.027 — 2.030 mm

(0.0798 — 0.0799 in)

(0.0020 in)

US

0.25 mm

2.127 — 2.130 mm

(0.0837 — 0.0839 in)

Crankshaft

(0.0098 in)

Crankshaft bearing thickness

US

bearing

STD

2.000 — 2.013 mm

(0.0787 — 0.0793 in)

0.03 mm

2.019 — 2.022 mm

(0.0795 — 0.0796 in)

(0.0012 in)

US

#2, #3, #4

0.05 mm

2.029 — 2.032 mm

(0.0799 — 0.0800 in)

(0.0020 in)

US

0.25 mm

2.129 — 2.132 mm

(0.0838 — 0.0839 in)

(0.0098 in)

US

STD: Standard US: Undersize

5

2-3

COMPONENT PARTS

1. Timing Belt

1. Timing Belt

B2M0102A

!1 Crankshaft sprocket !2 Belt cover No. 2 (RH) !3 Belt cover No. 2 (LH)

!4 Camshaft sprocket (RH) !5 Belt idler

!6 Tensioner bracket !7 Belt idler

!8 Belt tensioner

!9 Tensioner adjuster !10 Belt idler No. 2

!11 Camshaft sprocket (LH) !12 Timing belt

!13 Belt cover (RH) !14 Front belt cover !15 Belt cover (LH)

!16 Crankshaft pulley

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: 39±4 (4.0±0.4, 28.9±2.9)

T4: 78±5 (8.0±0.5, 57.9±3.6)

T5: 108+10−5 (11+1.0−0.5 , 79.6+7.2−3.6 )

6

COMPONENT PARTS

2-3

2. Cylinder Head and Camshaft

2. Cylinder Head and Camshaft

B2M0103A

!1 Rocker cover (RH) !2 Rocker cover gasket

!3 Camshaft support (RH) !4 O-ring

!5 Camshaft (RH) !6 Intake valve guide

!7 Exhaust valve guide !8 Oil seal

!9 Cylinder head (RH) !10 Cylinder head gasket !11 Cylinder head (LH) !12 Plug

!13 Camshaft (LH) !14 O-ring

!15 Camshaft support (LH)

!16 Oil seal

!17 Oil filler cap !18 Gasket

!19 Oil filler pipe !20 O-ring

!21 Rocker cover gasket !22 Rocker cover (LH)

Tightening torque: N m (kg-m, ft-lb)

T1: Refer to [W6E1].

T2: 5±1 (0.5±0.1, 3.6±0.7) T3: 10 (1.0, 7)

T4: 16 (1.6, 12)

7

2-3

COMPONENT PARTS

3. Cylinder Head and Valve Assembly

3. Cylinder Head and Valve Assembly

B2M0380A

!1 Exhaust valve !2 Intake valve

!3 Intake valve oil seal !4 Valve spring

!5 Retainer

!6 Retainer key

!7 Exhaust valve oil seal !8 Rocker shaft support !9 Rocker shaft support !10 Rocker shaft support

!11 Rocker shaft

!12 Hydraulic lash adjuster !13 Intake valve rocker arm !14 Exhaust valve rocker arm !15 Spring

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)

8

Subaru Legacy 1995 User Manual

COMPONENT PARTS

2-3

4. Cylinder Block

4. Cylinder Block

B2M0381A

!1 Oil pressure switch !2 Cylinder block (RH) !3 Service hole plug !4 Gasket

!5 Oil separator cover !6 Water pipe

!7 Oil pump

!8 Front oil seal !9 Rear oil seal !10 O-ring

!11 Service hole cover !12 Cylinder block (LH) !13 Water pump

!14 Baffle plate

!15 Oil strainer stay !16 Oil strainer

!17 Gasket !18 Oil pan

!19 Oil drain plug !20 Gasket

!21 Oil filler pipe

Tightening torque: N m (kg-m, ft-lb)

T1: 5 (0.5, 3.6) T2: 6.4 (0.65, 4.7) T3: 10 (1.0, 7)

T4: 25±2 (2.5±0.2, 18.1±1.4)

T5: 47±3 (4.8±0.3, 34.7±2.2)

T6: 69±7 (7.0±0.7, 50.6±5.1)

T7: First 12±2 (1.2±0.2, 8.7±1.4) Second 12±2 (1.2±0.2, 8.7±1.4)

9

2-3

COMPONENT PARTS

5. Crankshaft and Piston

5. Crankshaft and Piston

G2M0105

!1 Drive plate (AT)

!2 Reinforcement (AT) !3 Flywheel (MT)

!4 Bell bearing (MT) !5 Top ring

!6 Second ring !7 Oil ring

!8 Piston

!9 Piston pin !10 Circlip

!11 Connecting rod bolt !12 Connecting rod

!13 Connecting rod bearing !14 Connecting rod cap

!15 Crankshaft !16 Woodruff key

!17 Crankshaft bearing #1, #5 !18 Crankshaft bearing #2, #4 !19 Crankshaft bearing #3

Tightening torque: N m (kg-m, ft-lb)

T1: 44±2 (4.5±0.2, 32.5±1.4) T2: 72±3 (7.3±0.3, 52.8±2.2)

10

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

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 !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,

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 pliers. 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

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.

13

2-3

SERVICE PROCEDURE

2. Hydraulic Lash Adjuster

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.

8) 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.

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 !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

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:

» 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.

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 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.

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:

«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

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 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

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: 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.

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

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

27

2-3

SERVICE PROCEDURE

4. Valve Rocker Assembly

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.

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

G2M0131

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.

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 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.

30

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