Subaru 2003 Legacy User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE4
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUEL INJECTION (FUEL SYSTEMS) FU(H4DOSTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4DOSTC)
INTAKE (INDUCTION) IN(H4DOSTC)
MECHANICAL ME(H4DOSTC)
EXHAUST EX(H4DOSTC)
COOLING CO(H4DOSTC)
LUBRICATION LU(H4DOSTC)
SPEED CONTROL SYSTEMS SP(H4DOSTC)
IGNITION IG(H4DOSTC)
STARTING/CHARGING SYSTEMS SC(H4DOSTC)
ENGINE (DIAGNOSTICS) EN(H4DOSTC)

MECHANICAL
ME(H4DOSTC)
Page
1. General Description ....................................................................................2
2. Compression.............................................................................................21
3. Idle Speed.................................................................................................22
4. Ignition Timing...........................................................................................23
5. Intake Manifold Vacuum............................................................................24
6. Engine Oil Pressure..................................................................................25
7. Fuel Pressure............................................................................................26
8. Valve Clearance........................................................................................27
9. Engine Assembly ......................................................................................31
10. Engine Mounting.......................................................................................40
11. Preparation for Overhaul...........................................................................41
12. V-belt.........................................................................................................42
13. Crankshaft Pulley......................................................................................44
14. Belt Cover .................................................................................................46
15. Timing Belt Assembly................................................................................47
16. Camshaft Sprocket....................................................................................55
17. Crankshaft Sprocket..................................................................................56
18. Camshaft...................................................................................................57
19. Cylinder Head Assembly...........................................................................62
20. Cylinder Block...........................................................................................70
21. Engine Trouble in General........................................................................90
22. Engine Noise.............................................................................................95

ME(H4DOSTC)-55
MECHANICAL
CAMSHAFT SPROCKET
16.Camshaft Sprocket
A: REMOVAL
1) Remove the V-belt.
<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>
2) Remove the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-
shaft Pulley.>
3) Remove the belt cover.
<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-
er.>
4) Remove the timing belt assembly.
<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing
Belt Assembly.>
5) Remove the camshaft position sensor.
<Ref. to FU(H4DOSTC)-30, REMOVAL, Camshaft
Position Sensor.>
6) Remove the camshaft sprockets. To lock the
camshaft, use ST.
ST 18231AA010 CAMSHAFT SPROCKET
WRENCH (INTAKE LH)
ST 499207400 CAMSHAFT SPROCKET
WRENCH (Except INTAKE
LH)
B: INSTALLATION
1) Install the camshaft sprocket. To lock the cam-
shaft, use ST.
ST 18231AA010 CAMSHAFT SPROCKET
WRENCH (INTAKE LH)
ST 499207400 CAMSHAFT SPROCKET
WRENCH (Except INTAKE
LH)
Tightening torque:
98 N·m (10 kgf-m, 72.4 ft-lb)
NOTE:
Do not confuse the right and left side camshaft
sprockets intake side during installation. The cam-
shaft sprocket LH is identified by a projection used
to monitor camshaft position sensor.
2) Install the camshaft position sensor.
<Ref. to FU(H4DOSTC)-30, INSTALLATION,
Camshaft Position Sensor.>
3) Install the timing belt assembly.
<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-
ing Belt Assembly.>
4) Install the belt cover.
<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt
Cover.>
5) Install the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, INSTALLATION,
Crankshaft Pulley.>
6) Install the V-belt.
<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-
belt.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME-00368
ST
ME-00368
ST

ME(H4DOSTC)-56
MECHANICAL CRANKSHAFT SPROCKET
17.Crankshaft Sprocket
A: REMOVAL
1) Remove the V-belt.
<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>
2) Remove the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-
shaft Pulley.>
3) Remove the belt cover.
<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-
er.>
4) Remove the timing belt assembly.
<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing
Belt Assembly.>
5) Remove the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, REMOVAL, Camshaft
Sprocket.>
6) Remove the crankshaft sprocket.
B: INSTALLATION
1) Install the crankshaft sprocket.
2) Install the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, INSTALLATION,
Camshaft Sprocket.>
3) Install the timing belt assembly.
<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-
ing Belt Assembly.>
4) Install the belt cover.
<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt
Cover.>
5) Install the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, INSTALLATION,
Crankshaft Pulley.>
6) Install the V-belt.
<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-
belt.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME-00103
ME-00103

ME(H4DOSTC)-57
MECHANICAL
CAMSHAFT
18.Camshaft
A: REMOVAL
1) Remove the V-belt.
<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>
2) Remove the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-
shaft Pulley.>
3) Remove the belt cover.
<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-
er.>
4) Remove the timing belt assembly.
<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing
Belt Assembly.>
5) Remove the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, REMOVAL, Camshaft
Sprocket.>
6) Remove the crankshaft sprocket.
<Ref. to ME(H4DOSTC)-56, REMOVAL, Crank-
shaft Sprocket.>
7) Remove the tensioner bracket.
8) Remove the belt cover No. 2 (LH).
9) Remove the belt cover No. 2 (RH).
10) Disconnect the ignition coil connector.
11) Remove the ignition coil.
12) Remove the rocker cover and gasket.
13) Loosentheintakecamshaftcapbolts equally,a
little at a time in alphabetical sequence shown in
the figure.
14) Remove the camshaft cap and intake cam-
shaft.
15) Loosen the exhaust camshaft cap bolts equal-
ly, a little at a time in alphabetical sequence shown
in the figure.
16) Remove the camshaft caps and exhaust cam-
shaft.
NOTE:
Arrange the camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove the camshafts (RH) and re-
lated parts.
ME-00105
ME-00106
ME-00107
( A )
( B )
( C )
( D )
( E )
( F )
ME-00369
( A )
( B )
( C )
( D )
( E )
( F ) ME-00370

ME(H4DOSTC)-58
MECHANICAL CAMSHAFT
B: INSTALLATION
1) Camshaft installation:
Apply engine oil to the cylinder head at camshaft
bearing location before installing the camshaft. In-
stall the camshaft so that each valves is close to or
in contact with “base circle”of cam lobe.
NOTE:
•When the camshafts are positioned as shown in
the figure, camshafts need to be rotated at a mini-
mum to align with the timing belt during installation.
•Camshaft (RH) need not be rotated when set at
the position shown in the figure.
Intake camshaft (LH): Rotate 80°clockwise.
Exhaust camshaft (LH): Rotate 45°counterclock-
wise.
2) Camshaft cap installation:
(1) Apply fluid packing sparingly to the cap mat-
ing surface.
NOTE:
Do not apply fluid packing excessively. Failure to
do so may cause excess packing to come out and
flow toward oil seal, resulting in oil leaks.
Fluid packing:
Part No. 004403007
THREE BOND 1215 or equivalent
(2) Apply engine oil to cap bearing surface and
install the cap on camshaft as shown by identifi-
cation mark (A).
(3) Gradually tighten the camshaft cap in at
least two stages in alphabetical sequence
shown in the figure, and then tighten to specified
torque.
Tightening torque:
T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
(4) Similarly, tighten the cap on exhaust side.
After tightening the cap, ensure the camshaft ro-
tates only slightly while holding it at“base”circle.
Tightening torque:
T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
A Left side cylinder head
B Right side cylinder head
(a) Intake camshaft
(b) Exhaust camshaft
ME-00111
11
11
77.5
77.5
(a)
(b) (a)
(b)
A
B
L E
L I
R
R
I
E
ME-00112
( A )
ME-00371
(F) (D)
(C)
(A) (E)
(B)
T1
T2
ME-00115
(B)
(A) (E)
(F) (D)
(C)
T1
T2

ME(H4DOSTC)-59
MECHANICAL
CAMSHAFT
3) Camshaft oil seal installation:
Apply grease to the new oil seal lips andpress onto
the front end of camshaft by using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER
ST2 499597200 OIL SEAL GUIDE
4) Rocker cover installation:
(1) Install the gasket on rocker cover.
Install the peripheral gasket and ignition coil
gasket.
(2) Apply fluid packing to the indicated portion
on rocker cover.
Fluid packing:
Part No. 004403007
THREE BOND 1215 or equivalent
(3) Install the rocker cover on cylinder head.
Ensure the gasket is properly positioned during
installation.
5) Install the ignition coil.
6) Connect the ignition coil connector.
7) Similarly, install the parts on right-hand side.
8) Install the belt cover No. 2 (RH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
9) Install the tensioner bracket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
10) Install the belt cover No. 2 (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
11) Install the crankshaft sprockets.
<Ref. to ME(H4DOSTC)-56, INSTALLATION,
Crankshaft Sprocket.>
12) Install the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, INSTALLATION,
Camshaft Sprocket.>
13) Install the timing belt assembly.
<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-
ing Belt Assembly.>
14) Install the belt cover.
ST1 ST2 ME-00116
ME-00604
RH
LH
ME-00107
ME-00105
ME-00106

ME(H4DOSTC)-60
MECHANICAL CAMSHAFT
<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt
Cover.>
15) Install the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, INSTALLATION,
Crankshaft Pulley.>
16) Install the V-belt.
<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-
belt.>
C: INSPECTION
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.020 mm (0.0008 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outside diameter of camshaft jour-
nal. If the jounal diameter is not as specified, check
the oil clearance.
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the cam-
shaft journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Do not turn the camshaft.
Tightening torque:
T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
(5) Remove the bearing caps.
(6) Measure the widest point of plastigauge on
each journal.
If the oil clearance exceeds the limit, replace the
camshaft. If necessary, replace the camshaft
caps and cylinder head as a set.
Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit:
0.10 mm (0.0039 in)
(7) Completely remove the plastigauge.
5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H; replace if the limit has been exceeded.
Cam height: H
Standard:
Intake:
46.25 — 46.35 mm (1.821 — 1.825 in)
Exhaust:
46.15 — 46.25 mm (1.817 — 1.821 in)
Limit:
Intake:
46.15 mm (1.817 in)
Exhaust:
46.65 mm (1.813 in)
Camshaft journal
Front Center, rear
Standard 37.946 —37.963 mm
(1.4939 —1.4946 in) 29.946 —29.963 mm (1.1790 —1.1796 in)
ME-00118
ME-00371
(F) (D)
(C)
(A) (E)
(B)
T1
T2
ME-00119

ME(H4DOSTC)-61
MECHANICAL
CAMSHAFT
Cam base circle diameter A:
37.0 mm (1.457 in)
6) Measure the thrust clearance of camshaft with
dial gauge. If the clearance exceeds the limit, re-
place the caps and cylinder head as a set. If neces-
sary replace the camshaft.
Standard:
0.015 — 0.070 mm (0.0006 — 0.0028 in)
Limit:
0.1 mm (0.004 in)
ME-00120
H
A
ME-00121

ME(H4DOSTC)-62
MECHANICAL CYLINDER HEAD ASSEMBLY
19.Cylinder Head Assembly
A: REMOVAL
1) Remove the V-belt.
<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>
2) Remove the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-
shaft Pulley.>
3) Remove the belt cover.
<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-
er.>
4) Remove the timing belt assembly.
<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing
Belt Assembly.>
5) Remove the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, REMOVAL, Camshaft
Sprocket.>
6) Remove the intake manifold.
<Ref. to FU(H4DOSTC)-15, REMOVAL, Intake
Manifold.>
7) Remove the bolt which installs A/C compressor
bracket on cylinder head.
8) Remove the camshaft. <Ref. to ME(H4DOSTC)-
57, REMOVAL, Camshaft.>
9) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
Leave bolts (A) and (D) engaged by three or four
threads to prevent the cylinder head from falling.
10) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
Remove the bolts (A) and (D) to remove cylinder
head.
11) Remove the cylinder head gasket.
NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
12) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
NOTE:
•Use new cylinder head gaskets.
•Be careful not to scratch the mating surface of
cylinder head and cylinder block.
2) Tighten the cylinder head bolts.
(1) Applyacoatofengine oiltothewashersand
bolt threads.
(2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
(3) Tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence again.
(4) Back off all bolts by 180° first; back them off
by 180×again in reverse order of installation.
(5) Tighten all bolts to 39 N·m (4.0 kgf-m, 29 ft-
lb) in alphabetical sequence.
(6) Tighten all bolts 80 to 90°in alphabetical se-
quence.
(7) Tighten all bolts by 40 to 45°in alphabetical
sequence again.
NOTE:
Do not tighten the bolts by more than 45°.
(8) Further tighten all bolts (A) and (B) by 40 to
45°.
NOTE:
Ensure that the total “re-tightening angle”in the
previous two steps do not exceed 90°.
3) Install the camshaft.
<Ref. to ME(H4DOSTC)-58, INSTALLATION,
Camshaft.>
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold.
<Ref. to FU(H4DOSTC)-18, INSTALLATION, In-
take Manifold.>
ME-00122
( A )
( B ) ( C )
( D )
( E )
( F )
ME-00122
( A )
( B ) ( C )
( D )
( E )
( F )
ME-00123
( A )
( B )
( C )
( D )( E )
( F )

ME(H4DOSTC)-63
MECHANICAL
CYLINDER HEAD ASSEMBLY
6) Install the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, INSTALLATION,
Camshaft Sprocket.>
7) Install the timing belt assembly.
<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-
ing Belt Assembly.>
8) Install the belt cover.
<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt
Cover.>
9) Install the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, INSTALLATION,
Crankshaft Pulley.>
10) Install the V-belt.
<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-
belt.>
C: DISASSEMBLY
1) Remove the valve shims and valve lifters.
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
NOTE:
•Keep the removed parts in order for re-installing
in their original positions.
•Mark each valve to prevent confusion.
•Use extreme care not to damage the lips of the
intake valve oil seals and exhaust valve oil seals.
ME-00124
ST2
ST1

ME(H4DOSTC)-64
MECHANICAL CYLINDER HEAD ASSEMBLY
D: ASSEMBLY
(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter
(2) Intake valve (6) Valve spring (10) Exhaust valve oil seal
(3) Cylinder head (7) Retainer (11) Intake valve guide
(4) Valve spring seat (8) Retainer key (12) Exhaust valve guide
ME-00003
(3)
(1)
(2)
(11) (4) (5) (6) (7) (8) (9)
(11)
(12)
(12)
(10)
(4)
(4)
(5) (6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
(10)
(4)
(6)
(7) (8)
(9)

ME(H4DOSTC)-65
MECHANICAL
CYLINDER HEAD ASSEMBLY
1) Installation of valve spring and valve:
(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
NOTE:
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Be sure to install the valve springs with their close-
coiled end facing the seat on the cylinder head.
(4) Compress the valve spring, and then fit the
valve spring retainer key.
(5) After installing,tap the valve spring retainers
lightly with wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter.
3) Install the valve lifter.
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect the impor-
tant areas by means of red check.
2) Measure the warping of the cylinder head sur-
face that mates with crankcase by using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Standard
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
ME-00124
ST2
ST1
ME-00126
( A )
( B )
ME-00127
w
90˚
150˚

ME(H4DOSTC)-66
MECHANICAL CYLINDER HEAD ASSEMBLY
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit
0.15 mm (0.0059 in)
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.
ST 18251AA020 VALVE GUIDE ADJUSTER
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coatedwith sufficient
oil, in cylinder, and insert ST1 into valve guide.
Press in until the valve guide upper end is flush
with the upper surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 18251AA020 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
15.8 — 16.2 mm (0.622 — 0.638 in)
ME-00128
ST1
ST2
ME-00129
ST
ST1
ST2
ME-00130
ME-00632
L

ME(H4DOSTC)-67
MECHANICAL
CYLINDER HEAD ASSEMBLY
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise. After reaming, clean the
valve guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
NOTE:
•Apply engine oil to the reamer when reaming.
•If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
•If the inner surface of the valve guide becomes
lustrous and the reamer does not chips, use a new
reamer or remedy the reamer.
(8) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and re-
place if damaged, worn, or deformed, or if “H”is
less than the specified limit.
H:
Intake
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake
104.4 mm (4.110 in)
Exhaust
104.7 mm (4.122 in)
2) Put a small amount of grinding compound on the
seat surface and lap the valve and seat surface. In-
stall a new intake valve oil seal after lapping.
ME-00131
90˚+1 -0
H
H
45˚
90˚+1 -0
45˚

ME(H4DOSTC)-68
MECHANICAL CYLINDER HEAD ASSEMBLY
5. VALVE SPRINGS
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within specifications presented in the table.
2) To measure the squareness of valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.
6. INTAKE AND EXHAUST VALVE OIL
SEAL
Replace the oil seal with a new one, if the lip is
damaged or spring out ofplace, or when thesurfac-
es of intake valve and valve seat are reconditioned
or intake valve guide is replaced.
1) Place the cylinder head on ST1.
2) Press in the oil seal as shown in the figure by us-
ing ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
NOTE:
•Apply engine oil to oil seal before force-fitting.
•Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their difference
in color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 — 34.975 mm (1.3763 — 1.3770 in)
3) Measure the inner diameter of valve lifter mating
part on cylinder head.
Inner diameter:
34.994 — 35.016 mm (1.3777 — 1.3786 in)
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the limit, replace the cylinder head.
Valve spring
Free length 44.67 mm (1.7587 in)
Tension/spring
height
206 —236 N
(21.0 —24.1 kgf, 46.2 —53.1 lb)
/36.0 mm (1.417 in)
485 —537 N
(49.5 —54.8 kgf, 109.2 —120.6 lb)
/26.6 mm (1.047 in)
Squareness 2.5°, 2.0 mm (0.079 in)
ME-00132
ME-00133
ST2
ME-00134
ME-00135

ME(H4DOSTC)-69
MECHANICAL
CYLINDER HEAD ASSEMBLY
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Limit:
0.100 mm (0.0039 in)
F: DISPOSAL
CAUTION:
•Metallic sodium is enclosed in the exhaust
valve. Metallic sodium is extremely alkaline and
may produce severe chemical reactions. Full
consideration must therefore be given to the
following points when handing or disposing of
the valve.
•Since metallic sodium may cause blindness if
contacted with the eyes, burns if contacted with
the skin, and fire, do not deliberately take the
valve apart and remove the metallic sodium.
1) If the valve is damaged, remove the valve and
neutralize it by immersing it in water, and dispose
of it in the same way that general steel materials
are disposed of. The disposal method is described
in the following.
(1) Wearing rubber gloves, remove the dam-
aged valve from the cylinder head.
(2) Prepare a large receptacle (bucket or other
container) in a well ventilated location, and fill
the receptacle with water (at least 10 liters).
(3) Immerse the damaged valve in the recepta-
cle.
CAUTION:
A severe reaction mayoccur, sostand at least 2
—3 m from the receptacle. Because the reac-
tionwillproducehydrogengas,moreover,keep
the receptacle away from sparks or flames.
(4) Once the reaction is completed (about 4 —
5 hours have elapsed), carefully remove the
valve using large pincers so that the reaction liq-
uid does not contact your skin, and dispose of it
with other parts that are being disposed of.
(5) The reaction liquid is a strong alkaline solu-
tion, so it must be disposed of in accordance
with local regulations.
CAUTION:
Make sure the reaction liquid does not contact
your skin. If contact with skin occurs, immedi-
ately wash the affected area with large quanti-
ties of water.
ME-00633

ME(H4DOSTC)-70
MECHANICAL CYLINDER BLOCK
20.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold.
<Ref. to FU(H4DOSTC)-15, REMOVAL, Intake
Manifold.>
2) Remove the V-belt. <Ref. to ME(H4DOSTC)-42,
REMOVAL, V-belt.>
3) Remove the crankshaft pulley.
<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-
shaft Pulley.>
4) Remove the belt cover.
<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-
er.>
5) Remove the timing belt assembly.
<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing
Belt Assembly.>
6) Remove the camshaft sprocket.
<Ref. to ME(H4DOSTC)-55, REMOVAL, Camshaft
Sprocket.>
7) Remove the crankshaft sprocket.
<Ref. to ME(H4DOSTC)-56, REMOVAL, Crank-
shaft Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head assembly.
<Ref. to ME(H4DOSTC)-62, REMOVAL, Cylinder
Head Assembly.>
10) Remove the clutch disc and cover. (MT vehi-
cles) <Ref. to CL-15, REMOVAL, Clutch Disc and
Cover.>
11) Remove the flywheel. (MT vehicles)
<Ref. to CL-20, REMOVAL, Flywheel.>
12) Remove the drive plate. (AT vehicles)
Using the ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
13) Remove the oil separator cover.
14) Remove the water by-pass pipe for heater.
15) Remove the oil filter.
16) Remove the oil cooler. (MT vehicles)
17) Removal of oil pan:
(1) Turn the cylinder block with #2and #4piston
sides facing upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance, and then remove
the oil pan.
Do not use a screwdriver or similar tool in place
of oil pan cutter.
18) Remove the oil strainer stay.
19) Remove the oil strainer.
20) Remove the baffle plate.
21) Remove the water pipes.
22) Remove the water pump.
ME-00136
ST
(A) Gasket
(B) Oil cooler
(C) Oil cooler connector
ME-00634
( A )
( B )
( C )
ME-00137

ME(H4DOSTC)-71
MECHANICAL
CYLINDER BLOCK
23) Remove the oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in the fig-
ure when removing the oil pump.
NOTE:
Be careful not to scratch the mating surface of cyl-
inder block and oil pump.
ME-00138
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
ME-00139
( 1 )
( 2 )
( 3 )
( 3 )
( 4 )
( 4 )
( 5 )
( 6 )
( 1 )( 2 )
( 3 )
( 4 )
( 1 ) ( 2 )
( 3 )
( 4 )