2001 СУБАРУ ФОРЕСТЕР. Руководство по обслуживанию

CYLINDER BLOCK

Mechanical

20) Remove oil pump from cylinder block.

Use a flat-bladed screwdriver as shown in figure

when removing oil pump.

CAUTION:

Be careful not to scratch the mating surface of

cylinder block and oil pump.

22) Remove oil strainer stay.

23) Remove oil strainer.

24) Remove baffle plate.

25) Remove oil filter using ST.

ST 498547000 OIL FILTER WRENCH

26) Remove water pipe.

21) Removal of oil pan

(1) Turn cylinder block with #2 and #4 piston sides facing upward.

(2) Remove bolts which secure oil pan to cylinВder block.

(3) Insert a oil pan cutter blade between cylinВder block-to-oil pan clearance and remove oil pan.

CAUTION:

Do not use a screwdriver or similar tool in

place of oil pan cutter.

ME(SOHC)-68

CYLINDER BLOCK

Mechanical

(1) Service hole plug

(2) Gasket

(3) Circlip

(4) Piston pin

(5) Service hole cover

(6) O-ring

28) 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.

27) Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].

ME(SOHC)-69

CYLINDER BLOCK

Mechanical

29) Draw out piston pin from #1 and #2 pistons

using ST.

ST 499097700 PISTON PIN REMOVER

CAUTION:

Be careful not to confuse original combination

of piston, piston pin and cylinder.

30) Similarly remove piston pins from #3 and #4 pistons.

31) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.

32) Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.

33) Set up cylinder block so that #1 and #3 cylinВders are on the upper side, then remove cylinder block connecting bolts.

34) Separate left-hand and right-hand cylinder blocks.

CAUTION:

When separating cylinder block, do not allow the connecting rod to fall and damage the cylВinder block.

(1) Cylinder block

(2) Rear oil seal

(3) Crankshaft

(4) Crankshaft bearing

(5) Piston

35) Remove rear oil seal.

36) Remove crankshaft together with connecting rod.

37) 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.

38) Draw out each piston from cylinder block using wooden bar or hammer handle.

ME(SOHC)-70

CYLINDER BLOCK

Mechanical

CAUTION:

Do not confuse combination of piston and cylВinder.

B: INSTALLATION

S153090A11

(1) Crankshaft bearing

(2) Crankshaft

(3) Cylinder block

(4) Rear oil seal

Tightening torque: N-m (kgf-m, ft-lb) T1: 25 (2.5, 18.1) T2: 47 (4.8, 34.7)

CAUTION:

Do not allow fluid packing to jut into O-ring

grooves, oil passages, bearing grooves, etc.

CAUTION:

Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

1) Position crankshaft on the #2 and #4 cylinder block.

2) 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

ME(SOHC)-71

CYLINDER BLOCK

Mechanical

3) Temporarily tighten 10 mm cylinder block conВnecting bolts in alphabetical sequence shown in figure.

6) Install rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER

4) Tighten 10 mm cylinder block connecting bolts in alphabetical sequence.

Tightening torque:

47 Nm (4.8 kgf-m, 34.7 ft-lb)

(A) Rear oil seal

(B) Flywheel attaching bolt

7) Position the top ring gap at (A) or (B) in the figВure.

5) Tighten 8 mm and 6 mm cylinder block connectВing bolts in alphabetical sequence shown in figure.

Tightening torque:

(A) - (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

8) Position the second ring gap at 180° on the reverse side for the top ring gap.

9) Position the upper rail gap at (C) or (D) in the figure.

10) Position the expander gap at 180° of the reverse side for the upper rail gap.

ME(SOHC)-72

CYLINDER BLOCK

Mechanical

11) Position the lower rail gap at (E) or (F) in the figure.

CAUTION:

- Ensure ring gaps do not face the same direcВtion.

- Ensure ring gaps are not within the piston skirt area.

CAUTION:

Use new circlips.

CAUTION:

Piston front mark faces towards the front of the

engine.

12) Install circlip.

Install circlips in piston holes located opposite serВvice holes in cylinder block, when positioning all pistons in the corresponding cylinders.

(1) Piston

(2) Piston pin

(3) Circlip

(4) Gasket

(5) Service hole plug

Tightening torque: N-m (kgf-m, ft-lb) T: 69 (7.0, 50.6)

ME(SOHC)-73

CYLINDER BLOCK

Mechanical

13) Installing piston

(1) Turn cylinder block so that #1 and #2 cylinВders face upward.

(2) Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead cenВter.

ST1 499987500 CRANKSHAFT SOCKET

(3) Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2.

ST2 498747100 PISTON GUIDE

CAUTION:

Use new circlips.

(4) Apply fluid packing around the service hole plug.

Fluid packing:

THREE BOND 1215 or equivalent

14) 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 inserВtion.

ST3 499017100 PISTON PIN GUIDE

(5) Install service hole plug and gasket.

CAUTION:

Use a new gasket.

(2) Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole.

(3) Install circlip.

ME(SOHC)-74

CYLINDER BLOCK

Mechanical

(1) Piston

(2) Piston pin

(3) Circlip

(4) Gasket

(5) Service hole plug

(6) Service hole cover

(7) O-ring

Tightening torque: N-m (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 69 (7.0, 50.6)

(6) Turn cylinder block so that #3 and #4 cylinВders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.

ME(SOHC)-75

CYLINDER BLOCK

Mechanical

15) Install water pipe.

Tightening torque:

72 Nm (7.3 kgf-m, 52.8 ft-lb)

16) Install baffle plate.

Tightening torque:

6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

17) Install oil strainer and O-ring

Tightening torque:

10 Nm (1.0 kgf-m, 7 ft-lb)

18) Install oil strainer stay.

19) Apply fluid packing to matching surfaces and install oil pan.

Fluid packing:

THREE BOND 1215 or equivalent

22) Install housing cover.

23) Installation of oil pump.

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

20) Apply fluid packing to matching surfaces and install oil separator cover.

Fluid packing:

THREE BOND 1215 or equivalent

21) Install flywheel or drive plate.

To lock crankshaft, use ST.

ST 498497100 CRANKSHAFT STOPPER

ME(SOHC)-76

CYLINDER BLOCK

Mechanical

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

Fluid packing:

THREE BOND 1215 or equivalent

CAUTION:

- Be sure to use a new gasket.

- When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.

(3) Apply a coat of engine oil to the inside of the oil seal.

25) Install water by-pass pipe for heater.

26) Install oil filter using ST.

ST 498547000 OIL FILTER WRENCH

(4) Install oil pump on cylinder block. Be careВful not to damage oil seal during installation.

Tightening torque:

6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

CAUTION:

- Do not forget to install O-ring and seal when installing oil pump.

- Align flat surface of oil pump's inner rotor with crankshaft before installation.

24) Install water pump and gasket.

Tightening torque:

First; 12 Nm (1.2 kgf-m, 8.7 ft-lb) Second; 12 Nm (1.2 kgf-m, 8.7 ft-lb)

27) Tighten cylinder head bolts.

(1) Apply a coat of engine oil to washers and bolt threads.

(2) Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence.

Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.

(3) Back off all bolts by 180° first; back them off by 180° again.

(4) Tighten bolts (a) and (b) to 34 Nm (3.5 kgf-m, 25 ft-lb).

(5) Tighten bolts (c), (d), (e) and (f) to 15 Nm (1.5 kgf-m, 11 ft-lb).

(6) Tighten all bolts by 80 to 90° in alphabetical sequence.

CAUTION:

Do not tighten bolts more than 90°.

(7) Further tighten all bolts by 80 to 90° in alphabetical sequence.

ME(SOHC)-77

CYLINDER BLOCK

Mechanical

CAUTION:

Ensure that the total "re-tightening angle" [in

the former two steps], do not exceed 180°.

28) Install oil level gauge guide and tighten attachВing bolt (left side only).

29) Install rocker cover.

30) Install crankshaft sprocket. <Ref. to ME(SOHC)-53, INSTALLATION, Crankshaft Sprocket.>

31) Install camshaft sprocket. <Ref. to ME(SOHC)-51, INSTALLATION, Camshaft Sprocket.>

32) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.>

33) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.>

34) Install crankshaft pulley. <Ref. to ME(SOHC)-44, INSTALLATION, Crankshaft Pulley.>

35) Install generator and A/C compressor brackets on cylinder head.

36) Install V-belt. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>

37) Install intake manifold. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-15, INSTALLATION, Intake Manifold.>

ME(SOHC)-78

CYLINDER BLOCK

Mechanical

C: DISASSEMBLY

S153090A06

(1) Connecting rod cap

(2) Connecting rod bearing

(3) Top ring

(4) Second ring

(5) Oil ring

(6) Circlip

1) Remove connecting rod cap.

2) Remove connecting rod bearing.

CAUTION:

Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confuВsion.

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.

ME(SOHC)-79

CYLINDER BLOCK

Mechanical

D: ASSEMBLY

S153090A02

(1) Connecting rod bearing

(2) Connecting rod

(3) Connecting rod cap

(4) Oil ring

(5) Second ring

(6) Top ring

(7) Circlip

Tightening torque: N-m (kgf-m, ft-lb) T: 44.6 (4.55, 32.9)

1) Install connecting rod bearings on connecting rods and connecting rod caps.

CAUTION:

Apply oil to the surfaces of the connecting rod

bearings.

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:

- Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number.

- When tightening the connecting rod nuts, apply oil on the threads.

4) 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.

E: INSPECTION

S153090A10

1. CYLINDER BLOCK

S153090A1001

1) Visually check for cracks and damage. Especially, inspect important parts by means of red lead check.

2) Check the oil passages for clogging.

3) Inspect crankcase surface that mates with cylВinder 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)

ME(SOHC)-80

CYLINDER BLOCK

Mechanical

2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinВder block's front upper surface.

CAUTION:

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

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: 92.005 - 92.015 mm (3.6222 - 3.6226

in)

B: 91.995 - 92.005 mm (3.6218 - 3.6222

in)

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 temВperature 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)

(A) Main jourual size mark

(B) Cylinder block RH-LH combination mark

(D) #2 cylinder bore size mark

(E) #3 cylinder bore size mark

(F) #4 cylinder bore size mark

(A) Piston pin direction

(B) Thrust direction

3) When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.

ME(SOHC)-81

CYLINDER BLOCK

Mechanical

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 temВperature of 20°C (68°F).

Piston grade point H: 40.0 mm (1.575 in)

Piston outer diameter: Standard

A: 91.985-91.995mm

(3.6214 -3.6218 in)

B: 91.975- 91.985 mm

(3.6211 - 3.6214 in) 0.25 mm (0.0098 in) oversize

92.225 - 92.235 mm

(3.6309 -3.6313 in) 0.50 mm (0.0197 in) oversize

92.475 - 92.485 mm

(3.6407-3.6411 in)

(2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crank-case.

CAUTION:

Immediately after reboring, the cylinder diamВeter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder 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 cylinder. <Ref. to ME(SOHC)-81, CYLINDER AND PISTON, INSPECTION, Cylinder Block.> 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 piston pin hole with a thumb at 20°C (68°F). Replace if defective.

Standard clearance between piston pin and hole in piston: Standard

0.004 - 0.008 mm (0.0002 - 0.0003 in) Limit

0.020 mm (0.0008 in)

5) Calculate the clearance between cylinder and piston.

CAUTION:

Measurement should be performed at a temВperature 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)

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 cylinder only, nor use an overВsize piston for one cylinder only.

ME(SOHC)-82

CYLINDER BLOCK

Mechanical

4) Check circlip installation groove on the piston for burr (A). If necessary, remove burr from the groove so that piston pin can lightly move.

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
Piston ring gap	Top ring	0.20 - 0.35 (0.0079 - 0.0138)	1.0 (0.039)
	Second ring	0.35 - 0.50 (0.0138 - 0.0197)	1.0 (0.039)
	Oil ring rail	0.20 - 0.70 (0.0079 - 0.0276)	1.5 (0.059)

5) Check piston pin circlip for distortion, cracks and wear.

4. PISTON RING

S153090A1004

1) If piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston.

CAUTION:

- Marks are shown on the end of the top and second rings. When installing the rings to the piston, face these marks upward.

- The oil ring is a combined ring consisting of two rails and a spacer in between. When installing, be careful to assemble correctly.

3) Measure the clearance between piston ring and piston ring groove with a thickness gauge.

CAUTION:

Before measuring the clearance, clean the pisВton ring groove and piston ring.


Unit: mm (in)
		Standard	Limit
Clearance between pisВton ring and piston ring groove	Top ring	0.040 - 0.080 (0.0016 - 0.0031)	0.15(0.0059)
Clearance between pisВton ring and piston ring groove	Second ring	0.030 - 0.070 (0.0012 - 0.0028)	0.15(0.0059)


	(A)	Top ring
	(B)	Second ring
	(C)	Oil ring
	(a)	Upper rail
	(b)	Spacer
	(c)	Lower rail

5. CONNECTING ROD

S153090A1005

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.

ME(SOHC)-83

CYLINDER BLOCK

Mechanical

Limit of bend or twist per 100 mm (3.94 in) in length:

0.10 mm (0.0039 in)

4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc.

5) Measure the oil clearance on individual conВnecting 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	Bearing size (Thickness at center)	Outer diameter of crank pin
Standard	1.492 - 1.501 (0.0587 - 0.0591)	51.984 - 52.000 (2.0466 - 2.0472)
0.03 (0.0012) undersize	1.510 - 1.513 (0.0594 - 0.0596)	51.954 - 51.970 (2.0454 - 2.0461)
0.05 (0.0020) undersize	1.520 - 1.523 (0.0598 - 0.0600)	51.934 - 51.950 (2.0446 - 2.0453)
0.25 (0.0098) undersize	1.620 - 1.623 (0.0638 - 0.0639)	51.734 - 51.750 (2.0368 - 2.0374)

(A) Thickness gauge

(B) Connecting rod

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)

ME(SOHC)-84

CYLINDER BLOCK

Mechanical

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)

6. CRANKSHAFT AND CRANKSHAFT

S153090A1006

BEARING

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

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 crankshaft on these bearings and measure crankshaft bend using a dial gauge.

Crankshaft bend limit: 0.035 mm (0.0014 in)

3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace bearing with a suitable (undersize) one, and replace or recondition crankshaft as necesВsary. When grinding crank journal or crank pin, finВish them to the specified 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 Taper limit

0.07 mm (0.0028 in) Grinding limit

0.250 mm (0.0098 in)

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 BUSHВING REMOVER AND INSTALLER

(3) Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing.

(4) After completion of reaming, clean bushing to remove chips.

ME(SOHC)-85

CYLINDER BLOCK

Mechanical


Unit: mm (in)
		Crank journal diameter		Crank pin diameter
		#1, #3	#2, #4, #5	Crank pin diameter
Standard	Journal O.D.	59.992 - 60.008 (2.3619 - 2.3625)	59.992 - 60.008 (2.3619 - 2.3625)	51.984 - 52.000 (2.0466 - 2.0472)
Standard	Bearing size (Thickness at cenВter)	1.998 - 2.011 (0.0787 - 0.0792)	2.000 - 2.013 (0.0787 - 0.0793)	1.492- 1.501 (0.0587 - 0.0591)
0.03 (0.0012) undersize	Journal O.D.	59.962 - 59.978 (2.3607 - 2.3613)	59.962 - 59.978 (2.3607 - 2.3613)	51.954 - 51.970 (2.0454 - 2.0461)
0.03 (0.0012) undersize	Bearing size (Thickness at cenВter)	2.017 - 2.020 (0.0794 - 0.0795)	2.019 - 2.022 (0.0795 - 0.0796)	1.510- 1.513 (0.0594 - 0.0596)
0.05 (0.0020) undersize	Journal O.D.	59.942 - 59.958 (2.3599 - 2.3605)	59.942 - 59.958 (2.3599 - 2.3605)	51.934 - 51.950 (2.0446 - 2.0453)
0.05 (0.0020) undersize	Bearing size (Thickness at cenВter)	2.027 - 2.030 (0.0798 - 0.0799)	2.029 - 2.032 (0.0799 - 0.0800)	1.520- 1.523 (0.0598 - 0.0600)
0.25 (0.0098) undersize	Journal O.D.	59.742 - 59.758 (2.3520 - 2.3527)	59.742 - 59.758 (2.3520 - 2.3527)	51.734 - 51.750 (2.0368 - 2.0374)
0.25 (0.0098) undersize	Bearing size (Thickness at cenВter)	2.127 - 2.130 (0.0837 - 0.0839)	2.129 - 2.132 (0.0838 - 0.0839)	1.620- 1.623 (0.0638 - 0.0639)

O.D. ... Outer Diameter

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)

6) Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measureВment is not within the specification, replace defecВtive bearing with an undersize one, and replace or recondition crankshaft as necessary.


	Unit: mm (in)
	Crankshaft oil clearance
	Standard	0.010 - 0.030(0.0004 - 0.0012)
	Limit	0.040 (0.0016)

5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.

ME(SOHC)-86

CYLINDER BLOCK

Mechanical

21. Cylinder Block		S153090	12) Remove bolts (a) and (b) to remove cylinder head.

A: REMOVAL	S153090A18

NOTE: Before conducting this procedure, drain engine oil completely if applicable. 1) Remove intake manifold. <Ref. to FU(SOHC)-15, REMOVAL, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-12, REMOVAL, Intake ManiВfold.> 2) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 3) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 4) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 5) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt AssemВbly. > 6) Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 7) Remove crankshaft sprocket. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 8) Remove generator and A/C compressor with their brackets. 9) Remove rocker cover. 10) Remove cylinder head bolts in alphabetical sequence shown in figure. CAUTION: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
			13) Remove cylinder head gasket. CAUTION: Do not scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove right side cylinder head. 15) Remove clutch housing cover (MT vehicles only). 16) Remove flywheel (MT vehicles only) or drive plate (AT vehicles only). Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER


11) While tapping cylinder head with a plastic hammer, separate it from cylinder block.

17) Remove oil separator cover. 18) Remove water by-pass pipe for heater. 19) Remove water pump.

ME(SOHC)-67



CYLINDER BLOCK

Mechanical



(1) Service hole plug (2) Gasket	(3) Circlip (4) Piston pin	(5) Service hole cover (6) O-ring 28) 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.
27) Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].



ME(SOHC)-69



CYLINDER BLOCK

Mechanical

CAUTION: Do not confuse combination of piston and cylВinder.

B: INSTALLATION	S153090A11



(1) Crankshaft bearing (2) Crankshaft (3) Cylinder block	(4) Rear oil seal	*Tightening torque: N-m (kgf-m, ft-lb) T1: 25 (2.5, 18.1) T2: 47 (4.8, 34.7)* CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins. 1) Position crankshaft on the #2 and #4 cylinder block. 2) 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*


ME(SOHC)-71



	CYLINDER BLOCK

	Mechanical

	13) Installing piston (1) Turn cylinder block so that #1 and #2 cylinВders face upward. (2) Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead cenВter. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747100 PISTON GUIDE	CAUTION: Use new circlips.


		(4) Apply fluid packing around the service hole plug. *Fluid packing:* *THREE BOND 1215 or equivalent*

	14) 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 inserВtion. ST3 499017100 PISTON PIN GUIDE

		(5) Install service hole plug and gasket. CAUTION: Use a new gasket.

	(2) Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole. (3) Install circlip.

	ME(SOHC)-74



CYLINDER BLOCK

Mechanical



(1) Piston (2) Piston pin (3) Circlip (4) Gasket	(5) Service hole plug (6) Service hole cover (7) O-ring	*Tightening torque: N-m (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 69 (7.0, 50.6)*

(6) Turn cylinder block so that #3 and #4 cylinВders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.

ME(SOHC)-75



	CYLINDER BLOCK

	Mechanical

	CAUTION: Ensure that the total "re-tightening angle" [in the former two steps], do not exceed 180°.



	28) Install oil level gauge guide and tighten attachВing bolt (left side only). 29) Install rocker cover. 30) Install crankshaft sprocket. <Ref. to ME(SOHC)-53, INSTALLATION, Crankshaft Sprocket.> 31) Install camshaft sprocket. <Ref. to ME(SOHC)-51, INSTALLATION, Camshaft Sprocket.> 32) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 33) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 34) Install crankshaft pulley. <Ref. to ME(SOHC)-44, INSTALLATION, Crankshaft Pulley.> 35) Install generator and A/C compressor brackets on cylinder head. 36) Install V-belt. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.> 37) Install intake manifold. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-15, INSTALLATION, Intake Manifold.>

	ME(SOHC)-78



	CYLINDER BLOCK

	Mechanical

	2. CYLINDER AND PISTON 1) The cylinder bore size is stamped on the cylinВder block's front upper surface. CAUTION: Measurement should be performed at a temВperature 20°C (68°F). 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: 92.005 - 92.015 mm (3.6222 - 3.6226 in) B: 91.995 - 92.005 mm (3.6218 - 3.6222 in)	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 temВperature 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)


	(A) Main jourual size mark (B) Cylinder block RH-LH combination mark (C) #1 cylinder bore size mark (D) #2 cylinder bore size mark (E) #3 cylinder bore size mark (F) #4 cylinder bore size mark
		(A) Piston pin direction (B) Thrust direction 3) When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.

	ME(SOHC)-81