2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE 2 SECTION

FUEL INJECTION (FUEL SYSTEMS) FU(SOHCw/oOBD)

EMISSION CONTROL EC(SOHCw/oOBD)

(AUX. EMISSION CONTROL DEVICES)

EXHAUST EX(SOHCw/oOBD)

IGNITION IG(SOHCw/oOBD)
This service manual has been prepared
to provide SUBARU service personnel
ENGINE(DIAGNOSTICS) EN(SOHCw/oOBD)
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. FUEL INJECTION (FUEL SYSTEMS) FU(DOHC TURBO)
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of EMISSION CONTROL EC(DOHC TURBO)
components and diagnostics for guid- (AUX. EMISSION CONTROL DEVICES)
ance of experienced mechanics.
Please peruse and utilize this manual INTAKE (INDUCTION) IN(DOHC TURBO)
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. MECHANICAL ME(DOHC TURBO)
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. EXHAUST EX(DOHC TURBO)

IGNITION IG(DOHC TURBO)

ENGINE (DIAGNOSTICS) EN(DOHC TURBO)

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830GE3

MECHANICAL

ME(DOHC TURBO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................22
3. Idle Speed .................................................................................................23
4. Ignition Timing...........................................................................................24
5. Intake Manifold Vacuum............................................................................25
6. Engine Oil Pressure ..................................................................................26
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. Engine Assembly ......................................................................................33
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul...........................................................................42
12. V-belt.........................................................................................................43
13. Crankshaft Pulley ......................................................................................45
14. Belt Cover .................................................................................................46
15. Timing Belt Assembly................................................................................47
16. Camshaft Sprocket....................................................................................56
17. Crankshaft Sprocket..................................................................................57
18. Camshaft...................................................................................................58
19. Cylinder Head Assembly...........................................................................63
20. Cylinder Block ...........................................................................................70
21. Engine Trouble in General ........................................................................89
22. Engine Noise.............................................................................................94
 GENERAL DESCRIPTION
MECHANICAL

1. General Description
A: SPECIFICATIONS
Horizontally opposed, liquid cooled, 4-cylinder,
Type
4-stroke gasoline engine
Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)
Piston displacement cm3 (cu in) 1,994 (121.67)
Compression ratio 8.0
Compression pres-
sure (at 200 — 300 kPa (kgf/cm2, psi) 981 — 1,177 (10 — 12, 142 — 171)
rpm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Engine
Opening 10° BTDC
Intake valve timing
Closing 50° ABDC
Opening 53° BBDC
Exhaust valve timing
Closing 7° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
750±100 (No load)
Idling speed [At neutral position] rpm
800±150 (A/C switch ON)
Firing order 1→3→2→4
Ignition timing BTDC/rpm 12°±3°/750 rpm
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize

ME(DOHC TURBO)-2
 GENERAL DESCRIPTION
MECHANICAL

Belt ten-
sion Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)
adjuster
Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in)
Belt ten- STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
sioner Limit 0.175 mm (0.0069 in)
STD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Bend limit 0.020 mm (0.0079 in)
STD 0.015 — 0.070 mm (0.0006 — 0.0028 in)
Thrust clearance
Limit 0.10 mm (0.0039 in)
STD 46.25 — 46.35 mm (1.821 — 1.825 in)
Intake
Limit 46.15 mm (1.817 in)
Cam lobe height
STD 46.15 — 46.25 mm (1.817 — 1.821 in)
Camshaft Exhaust
Limit 46.05 mm (1.813 in)
Front 37.946 — 37.963 mm (1.4939 — 1.4946 in)
Jounal O.D. STD Center
29.946 — 29.963 mm (1.1790 — 1.1796 in)
rear
STD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.3 mm (0.012 in)
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve seat Limit 1.7 mm (0.067 in)
Contacting width
STD 1.5 mm (0.059 in)
Exhaust
Limit 2.2 mm (0.087 in)
Inner diameter 6.000 — 6.015 mm (0.2362 — 0.2368 in)
Valve guide
Protrusion above head 12.0 — 12.4 mm (0.472 — 0.488 in)
STD 1.2 mm (0.047 in)
Intake
Limit 0.8 mm (0.031 in)
Head edge thickness
STD 1.5 mm (0.059 in)
Exhaust
Limit 0.8 mm (0.031 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.950 — 5.965 mm(0.2343 — 0.2348 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 104.4 mm (4.110 in)
Overall length
Exhaust 104.7 mm (4.122 in)
Free length 44.67 mm (1.7587 in)
Valve Squareness 2.5°, 2.0 mm (0.079 in)
spring 220.7±15.7 N (22.5±1.6 kgf, 49.6±3.5 lb)/36.0 mm (1.417 in)
Tension/spring height
510.9±25.5 N (52.1±2.6 kgf, 114.9±5.7 lb)/26.6 mm (1.0.47 in)

ME(DOHC TURBO)-3
 GENERAL DESCRIPTION
MECHANICAL

Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 92.005 — 92.015 mm (3.6222 — 3.6226 in)
Cylinder bore STD
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
Limit 0.050 mm (0.0020 in)
block
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 91.985 — 91.995 mm (3.6214 — 3.6218 in)
STD
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
Piston Outer diameter 0.25 mm (0.0098 in)
92.225 — 92.235 mm (3.6309 — 3.6313 in)
OS
0.50 mm (0.0197 in)
92.475 — 92.485 mm (3.6407 — 3.6411 in)
OS
Standard clearance between piston STD 0.004 — 0.008 mm (0.0002 — 0.0003 in)
pin and hole in piston Limit 0.020 mm (0.0008 in)
Piston pin
Piston pin must be fitted into position with thumb at 20°C
Degree of fit
(68°F).
STD 0.20 — 0.26 mm (0.0079 — 0.0102 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.70 mm (0.0079 — 0.0276 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Clearance between piston Top ring
Limit 0.15 mm (0.0059 in)
ring and piston ring
groove Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94 in) in
Limit 0.10 mm (0.0039 in)
Connecting length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.020 — 0.046 mm (0.0008 — 0.0018 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm
(0.0012 1.510 — 1.513 mm (0.0594 — 0.0596 in)
Connecting in) US
rod bearing 0.05 mm
Thickness at center portion
(0.0020 1.520 — 1.523 mm (0.0598 — 0.0600 in)
in) US
0.25 mm
(0.0098 1.620 — 1.623 mm (0.0638 — 0.0639 in)
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)

ME(DOHC TURBO)-4
 GENERAL DESCRIPTION
MECHANICAL

Bend limit 0.035 mm (0.0014 in)

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

ME(DOHC TURBO)-5
 GENERAL DESCRIPTION
MECHANICAL

B: COMPONENT
1. TIMING BELT

S2M1725A

(1) Right-hand belt cover No. 2 (9) Right-hand intake camshaft (17) Right-hand belt cover
(2) Timing belt guide (MT vehicles sprocket (18) Crankshaft pulley
only) (10) Left-hand intake camshaft
(3) Crankshaft sprocket sprocket Tightening torque: N·m (kgf-m, ft-lb)
(4) Left-hand belt cover No. 2 (11) Left-hand exhaust camshaft T1: 5 (0.5, 3.6)
(5) Tensioner bracket sprocket T2: 10 (1.0, 7)
(6) Automatic belt tension adjuster (12) Timing belt T3: 25 (2.5, 18.1)
ASSY (13) Belt idler No. 2 T4: 39 (4.0, 28.9)
(7) Belt idler (14) Belt idler T5: 98 (10, 72.4)
(8) Right-hand exhaust camshaft (15) Left-hand belt cover T6: 127 (13, 94.0)
sprocket (16) Front belt cover

ME(DOHC TURBO)-6
GENERAL DESCRIPTION
MECHANICAL

ME(DOHC TURBO)-7
 GENERAL DESCRIPTION
MECHANICAL

2. CYLINDER HEAD AND CAMSHAFT

S2M1188A

ME(DOHC TURBO)-8
 GENERAL DESCRIPTION
MECHANICAL

(1) Rocker cover (RH) (15) Cylinder head (RH) (29) Oil filler cap
(2) Rocker cover gasket (RH) (16) Cylinder head gasket (RH) (30) Gasket
(3) Oil separator cover (17) Cylinder head gasket (LH) (31) Oil filler duct
(4) Gasket (18) Cylinder head (LH) (32) O-ring
(5) Intake camshaft cap (Front RH) (19) Intake camshaft (LH) (33) Stud bolt
(6) Intake camshaft cap (Center RH) (20) Exhaust camshaft (LH)
(7) Intake camshaft cap (Rear RH) (21) Intake camshaft cap (Front LH) Tightening torque: N·m (kgf-m, ft-lb)
(8) Intake camshaft (RH) (22) Intake camshaft cap (Center LH) T1: <Ref. to ME(DOHC TURBO)-63,
(9) Exhaust camshaft cap (Front RH) (23) Intake camshaft cap (Rear LH) Installation, Cylinder Head
(10) Exhaust camshaft cap (Center (24) Exhaust camshaft (Front LH) Assembly.>
RH) (25) Exhaust camshaft cap (Center T2: 5 (0.5, 3.6)
(11) Exhaust camshaft cap (Rear RH) LH) T3: 10 (1.0, 7)
(12) Exhaust camshaft (RH) (26) Exhaust camshaft cap (Rear LH) T4: 6.4 (0.65, 4.7)
(13) Cylinder head bolt (27) Rocker cover gasket (LH)
(14) Oil seal (28) Rocker cover (LH)

ME(DOHC TURBO)-9
 GENERAL DESCRIPTION
MECHANICAL

3. CYLINDER HEAD AND VALVE ASSEM-

BLY

S2M1197A

(1) Exhaust valve (6) Valve spring (11) Exhaust valve oil seal
(2) Intake valve (7) Retainer (12) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (10) Shim

ME(DOHC TURBO)-10
 GENERAL DESCRIPTION
MECHANICAL

4. CYLINDER BLOCK

EN0144

(1) Oil pressure switch (15) Oil cooler Tightening torque: N·m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Waster by-pass pipe T1: 5 (0.5, 3.6)
(3) Service hole plug (17) Connector T2: 6.4 (0.65, 4.7)
(4) Gasket (18) Oil strainer T3: 10 (1.0, 7)
(5) Oil separator cover (19) Gasket T4: 25 (2.5, 18.1)
(6) Water by-pass pipe (20) Oil pan T5: 47 (4.8, 34.7)
(7) Oil pump (21) Drain plug T6: 69 (7.0, 50.6)
(8) Front oil seal (22) Metal gasket T7: First 12 (1.2, 8.7)
(9) Rear oil seal (23) Oil level gauge guide Second 12 (1.2, 8.7)
(10) O-ring (24) Oil filter T8: 16 (1.6, 11.6)
(11) Service hole cover (25) Gasket T9: 44 (4.5, 33)
(12) Cylinder block (LH) (26) Water pump hose T10: 25 (2.5, 18.1)
(13) Water pump (27) Plug T11: 55 (5.5, 40)
(14) Baffle plate

ME(DOHC TURBO)-11
 GENERAL DESCRIPTION
MECHANICAL

5. CRANKSHAFT AND PISTON

EN0415

(1) Flywheel (MT vehicles only) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT vehicles only) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT vehicles only) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT vehicles only) (12) Connecting rod
(5) Top ring (13) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod cap T1: 44.6 (4.55, 32.9)
(7) Oil ring (15) Crankshaft T2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key

ME(DOHC TURBO)-12
 GENERAL DESCRIPTION
MECHANICAL

6. ENGINE MOUNTING

S2M1783A

(1) Hear shield cover (3) Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Front cushion rubber T1: 35 (3.6, 25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)

ME(DOHC TURBO)-13
 GENERAL DESCRIPTION
MECHANICAL

C: CAUTION • Rotating parts and sliding parts such as piston,

• Wear working clothing, including a cap, protec- bearing and gear should be coated with oil prior to
tive goggles, and protective shoes during opera- assembly.
tion. • Be careful not to let oil, grease or coolant contact
• Remove contamination including dirt and corro- the timing belt, clutch disc and flywheel.
sion before removal, installation or disassembly. • All removed parts, if to be reused, should be re-
• Keep the disassembled parts in order and pro- installed in the original positions and directions.
tect them from dust or dirt. • Bolts, nuts and washers should be replaced with
• Before removal, installation or disassembly, be new ones as required.
sure to clarify the failure. Avoid unnecessary re- • Even if necessary inspections have been made
moval, installation, disassembly, and replacement. in advance, proceed with assembly work while
• Be careful not to burn your hands, because each making rechecks.
part in the vehicle is hot after running. • Remove or install engine in an area where chain
• Be sure to tighten fasteners including bolts and hoists, lifting devices, etc. are available for ready
nuts to the specified torque. use.
• Place shop jacks or safety stands at the specified • Be sure not to damage coated surfaces of body
points. panels with tools or stain seats and windows with
• Before disconnecting electrical connectors of coolant or oil. Place a cover over fenders, as re-
sensors or units, be sure to disconnect negative quired, for protection.
terminal from battery. • Prior to starting work, prepare the following:
• All parts should be thoroughly cleaned, paying Service tools, clean cloth, containers to catch cool-
special attention to the engine oil passages, pis- ant and oil, wire ropes, chain hoist, transmission
tons and bearings. jacks, etc.
• Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.

D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498267600 CYLINDER • Used for replacing valve guides.
HEAD TABLE • Used for removing and installing valve springs.

EN0147
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH

B2M3851

ME(DOHC TURBO)-14
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498457100 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER LH

B2M3852
498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-
STOPPER ening and tightening crankshaft pulley bolt, etc.

B2M3853
398744300 PISTON GUIDE Used for installing piston in cylinder.

B2M3854
498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve
GUIDE guide oil seals.

B2M3855

ME(DOHC TURBO)-15
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.

B2M3856
499037100 CONNECTING Used for removing and installing connecting rod
ROD BUSHING bushing.
REMOVER &
INSTALLER

B2M3857
499097700 PISTON PIN Used for removing piston pin.
REMOVER
ASSY

B2M3858
499207400 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket.
WRENCH

B2M4158

ME(DOHC TURBO)-16
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL
INSTALLER

B2M3860
499587200 CRANKSHAFT • Used for installing crankshaft oil seal.
OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).

B2M3861
499597100 CRANKSHAFT • Used for installing crankshaft oil seal.
OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).

B2M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER

B2M3864

ME(DOHC TURBO)-17
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498267700 VALVE GUIDE Used for installing intake and exhaust valve
ADJUSTER guides.

B2M3865
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER

B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER

B2M3868
499817000 ENGINE STAND • Stand used for engine disassembly and assem-
bly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).

B2M3869

ME(DOHC TURBO)-18
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolts.

B2M4157
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET

B2M3871
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH

B2M3872
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER

B2M3875

ME(DOHC TURBO)-19
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499587600 OIL SEAL GUIDE Used for installing camshaft oil seal.

S1H0136
499597200 OIL SEAL GUIDE • Used for installing camshaft oil seal.
• Used with OIL SEAL GUIDE (499587600).

EN0168
49818200 SHIM Used for correct valve clearance.
REPLACER

EN0169

ME(DOHC TURBO)-20
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA150 CARTRIDGE Troubleshooting for electrical systems.

B2M3876
22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)

B2M3877

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Compression Gauge Used for measuring compression.
Timing Light Used for measuring ignition timing.

E: PROCEDURE
It is possible to conduct the following service proce-
dures with engine on the vehicle, however, the pro-
cedures described in this section are based on the
condition that the engine is removed from the vehi-
cle.
• V-belt
• Timing Belt
• Camshaft
• Cylinder Head

ME(DOHC TURBO)-21
 COMPRESSION
MECHANICAL

2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn ignition switch
to OFF.
2) Make sure that the battery is fully charged.
3) Release fuel pressure. <Ref. to FU(DOHC TUR-
BO)-49, RELEASING OF FUEL PRESSURE, OP-
ERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(DOHC
TURBO)-4, REMOVAL, Spark Plug.>
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance 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.

EN0172
9) Perform at least two measurements per cylinder,
and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
951 — 1,147 kPa (9.7 — 11.7 kgf/cm2, 138 —
166 psi)
Limit;
834 kPa (8.5 kgf/cm2, 121 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm2, 7 psi)

ME(DOHC TURBO)-22
 IDLE SPEED
MECHANICAL

3. Idle Speed
A: INSPECTION
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 con-
nected properly.
(2) Ensure that malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn igintion switch to OFF.
4) Insert the cartridge to SUBARU SELECT MONI-
TOR.
5) Connect SUBARU SELECT MONITOR to the
data link connector.
6) Turn igintion switch to ON, and SUBARU SE-
LECT MONITOR switch to ON.
7) Select {2. Each System Check} in Main Menu.
8) Select {Engine Control System} in Selection
Menu.
9) Select {1. Current Data Display & Save} in En-
gine Control System Diagnosis.
10) Select {1.12 Data Display} in Data Display
Menu.
11) Start the engine, and read engine idle speed.
12) Check idle speed when unloaded. (With head-
lights, heater fan, rear defroster, radiator fan, air
conditioning, etc. OFF)
Idle speed (No load and gears in neutral:
750±100 rpm
13) Check idle speed when loaded. (Turn air condi-
tioning switch to “ON” and operate compressor for
at least one minute before measurement.)
Idle speed [A/C “ON”, no load and gears in neu-
tral]:
800±150 rpm
CAUTION:
Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On-
board Diagnosis Table under “Engine Control
System”. <Ref. to EN(DOHC TURBO)-2, Basic
Diagnostic Procedure.>

ME(DOHC TURBO)-23
 IGNITION TIMING
MECHANICAL

4. Ignition Timing
A: INSPECTION
1) Before checking ignition timing speed, check the
following:
(1) Ensure that air cleaner element is free from
clogging, 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) Stop the engine, and turn igintion switch to OFF.
4) Insert the cartridge to SUBARU SELECT MONI-
TOR.
5) Connect SUBARU SELECT MONITOR to the
data link connector.
6) Turn igintion switch to ON, and SUBARU SE-
LECT MONITOR switch to ON.
7) Select {2. Each System Check} in Main Menu.
8) Select {Engine Control System} in Selection
Menu.
9) Select {1. Current Data Display & Save} in En-
gine Control System Diagnosis.
10) Select {1.12 Data Display} in Data Display
Menu.
11) Start the engine, at idle speed and check the ig-
nition timing.
Ignition timing [BTDC/rpm]:
12°±3°/750
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. <Ref. to
EN(DOHC TURBO)-2, Basic Diagnostic Proce-
dure.>

ME(DOHC TURBO)-24
 INTAKE MANIFOLD VACUUM
MECHANICAL

5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: INSPECTION By observing the gauge needle movement, the in-
1) Warm-up the engine. ternal condition of the engine can be diagnosed as
2) Disconnect the brake vacuum hose and install described below.
the vacuum gauge to the hose fitting on the mani-
fold.

H2M1767

Vacuum pressure (at idling, A/C “OFF”):

Less than −60.0 kPa (−450 mmHg, −17.72 in-
Hg)

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 ten- Leakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises. damaged vacuum hose
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 posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
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.

ME(DOHC TURBO)-25
 ENGINE OIL PRESSURE
MECHANICAL

6. Engine Oil Pressure

A: INSPECTION
1) Remove oil pressure switch from engine cylinder
block. <Ref. to LU-21, REMOVAL, Oil Pressure
Switch.>
2) Connect oil pressure gauge hose to cylinder
block.
3) Connect battery ground cable.

G6M0095
4) Start the engine, and measure oil pressure.

S2M0242

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
LU-26, INSPECTION, Engine Lubrication Sys-
tem Trouble in General.>
• If oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch. <Ref. to LU-26, INSPECTION, En-
gine Lubrication System Trouble in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
5) After measuring oil pressure, install oil pressure
switch. <Ref. to LU-22, INSTALLATION, Oil Pres-
sure Switch.>
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)

ME(DOHC TURBO)-26
 FUEL PRESSURE
MECHANICAL

7. Fuel Pressure 4) Connect connector of fuel pump relay.

A: INSPECTION
WARNING:
Before removing fuel pressure gauge, release
fuel pressure.
NOTE:
If out of specification, check or replace pressure
regulator and pressure regulator vacuum hose.
1) Release fuel pressure. <Ref. to FU(DOHC TUR- EN0344
BO)-49, RELEASING OF FUEL PRESSURE, OP- 5) Start the engine.
ERATION, Fuel.> 6) Measure fuel pressure while disconnecting pres-
2) Open fuel flap lid, and remove fuel filler cap. sure regulator vacuum hose from intake manifold.
Fuel pressure:
Standard; 284 — 314 kPa (2.9 — 3.2 kgf/cm2,
41 — 46 psi)

H2M2535
3) Disconnect fuel delivery hoses from fuel filter,
and connect fuel pressure gauge.

S2M0554
7) After connecting pressure regulator vacuum
hose, measure fuel pressure.
Fuel pressure:
Standard; 230 — 260 kPa (2.35 — 2.65 kgf/
cm2, 33 — 38 psi)

S2M0195

S2M0554

NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.

ME(DOHC TURBO)-27
 VALVE CLEARANCE
MECHANICAL

8. Valve Clearance 10) When inspecting #2 and #4 cylinders;

(1) Disconnect battery cables, and then remove
A: INSPECTION battery and battery carrier.
CAUTION:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Disconnect battery ground cable.

H6M0426
(2) Remove bolt which secures engine harness
bracket onto body.

G6M0095
3) Remove air intake duct. <Ref. to IN(DOHC TUR-
BO)-8, REMOVAL, Air Intake Duct.>
4) Remove one bolt which secures timing belt cov-
er (RH).
5) Lift-up the vehicle.
6) Remove under cover.
7) Loosen remaining bolts which secure timing belt H6M0429
cover (RH), then remove belt cover. (3) Disconnect washer motor connectors.
8) Lower the vehicle.
9) When inspecting #1 and #3 cylinders:
(1) Pull out engine harness connector with
bracket from air cleaner upper cover.

H6M0430
(4) Remove washer tank mounting bolts.

H2M1958
(2) Remove air cleaner case. <Ref. to
IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.>
(3) Disconnect spark plug cords from spark
plugs (#1 and #3 cylinders).
(4) Place suitable container under the vehicle.
(5) Disconnect PCV hose from rocker cover
(RH). B6M0561
(6) Remove bolts, then remove rocker cover
(RH).

ME(DOHC TURBO)-28
 VALVE CLEARANCE
MECHANICAL

(5) Move washer tank upward. NOTE:

If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.

H6M0431
(6) Disconnect spark plug cords from spark
plugs (#2 and #4 cylinders).
(7) Place suitable container under the vehicle. B2M1234B
(8) Disconnect PCV hose from rocker cover 13) If necessary, adjust the valve clearance. <Ref.
(LH). to ME(DOHC TURBO)-30, ADJUSTMENT, Valve
(9) Remove bolts, then remove rocker cover Clearance.>
(LH). 14) Further turn crankshaft pulley clockwise.
11) Turn crankshaft pulley clockwise until arrow Using the same procedures described previously,
mark on camshaft sprocket is set to position shown then measure valve clearances again.
in figure. (1) Set arrow mark on camshaft sprocket to po-
NOTE: sition shown in figure, and measure #2 cylinder
Turn crankshaft using ST. exhaust valve and #3 cylinder intake valve clear-
ST 499987500 CRANKSHAFT SOCKET ances.

S2M1194B
S2M1192B
12) Measure #1 cylinder intake valve and #3 cylin- (2) Set arrow mark on camshaft sprocket to po-
der exhaust valve clearance by using thickness sition shown in figure, and measure #2 cylinder
gauge (A). intake valve and #4 cylinder exhaust valve clear-
ances.
CAUTION:
• Insert the thickness gauge in as horizontal a
direction as possible with respect to the shim.
• Measure exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)

S2M1195B

ME(DOHC TURBO)-29
 VALVE CLEARANCE
MECHANICAL

(3) Set arrow mark on camshaft sprocket to po- B: ADJUSTMENT

sition shown in figure, and measure #1 cylinder
exhaust valve and #4 cylinder intake valve clear- CAUTION:
ances. Adjustment of valve clearance should be per-
formed while engine is cold.
1) Measure all valve clearances. <Ref. to
ME(DOHC TURBO)-28, INSPECTION, Valve
Clearance.>
NOTE:
Record each valve clearance after it has been
measured.

S2M1196B
15) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)

B2M1234
2) Remove shim from valve lifter.
(1) Prepare the ST.
ST 498187200 SHIM REPLACER

EN0191

H2M3622
(2) Rotate the notch of the valve lifter outward
by 45°.

H2M1777A

ME(DOHC TURBO)-30
 VALVE CLEARANCE
MECHANICAL

(3) Adjust SHIM REPLACER notch to valve lift- 3) Measure thickness of shim with micrometer.
er and set it.

B2M1240
H2M3628 4) Select a shim of suitable thickness using mea-
NOTE: sured valve clearance and shim thickness, by refer-
When setting, be careful SHIM REPLACER edge ring to the following table.
does not touch shim. 5) Set suitable shim selected in step 4) to valve lift-
er.
(4) Tighten bolt (A) and install it to the cylinder
head. Unit: mm
(5) Tighten bolt (B) and insert the valve lifter. Intake valve:S =(V + T) - 0.20
Exhaust valve:S =(V + T) - 0.25
S: Shim thickness to be used
V: Measured valve clearance
T: Shim thickness required

H2M3623A
(6) Insert tweezers into the notch of the valve
lifter, and take the shim out.

H2M3629

NOTE:
By using a magnet (A), the shim (B) can be taken
out without dropping it.

H2M3624A

ME(DOHC TURBO)-31
 VALVE CLEARANCE
MECHANICAL

Part No. Thickness mm (in)

13218 AK010 2.00 (0.0787)
13218 AK020 2.02 (0.0795)
13218 AK030 2.04 (0.0803)
13218 AK040 2.06 (0.0811)
13218 AK050 2.08 (0.0819)
13218 AK060 2.10 (0.0827)
13218 AK070 2.12 (0.0835)
13218 AK080 2.14 (0.0843)
13218 AK090 2.16 (0.0850)
13218 AK100 2.18 (0.0858)
13218 AK110 2.20 (0.0866)
13218 AE710 2.22 (0.0874)
13218 AE730 2.24 (0.0882)
13218 AE750 2.26 (0.0890)
13218 AE770 2.28 (0.0898)
13218 AE790 2.30 (0.0906)
13218 AE810 2.32 (0.0913)
13218 AE830 2.34 (0.0921)
13218 AE850 2.36 (0.0929)
13218 AE870 2.38 (0.0937)
13218 AE890 2.40 (0.0945)
13218 AE910 2.42 (0.0953)
13218 AE920 2.43 (0.0957)
13218 AE930 2.44 (0.0961)
13218 AE940 2.45 (0.0965)
13218 AE950 2.46 (0.0969)
13218 AE960 2.47 (0.0972)
13218 AE970 2.48 (0.0976)
13218 AE980 2.49 (0.0980)
13218 AE990 2.50 (0.0984)
13218 AF000 2.51 (0.0988)
13218 AF010 2.52 (0.0992)
13218 AF020 2.53 (0.0996)
13218 AF030 2.54 (0.1000)
13218 AF040 2.55 (0.1004)
13218 AF050 2.56 (0.1008)
13218 AF060 2.57 (0.1012)
13218 AF070 2.58 (0.1016)
13218 AF090 2.60 (0.1024)
13218 AF110 2.62 (0.1031)
13218 AF130 2.64 (0.1039)
13218 AF150 2.66 (0.1047)
13218 AF170 2.68 (0.1055)
13218 AF190 2.70 (0.1063)

6) Inspect all valves for clearance again at this

stage. If the valve clearance is not correct, repeat
the procedure over again from the first step.
7) After inspection, install the related parts in the re-
verse order of removal.

ME(DOHC TURBO)-32
 ENGINE ASSEMBLY
MECHANICAL

9. Engine Assembly 10) Remove intercooler. <Ref. to IN(DOHC TUR-

BO)-10, REMOVAL, Intercooler.>
A: REMOVAL 11) Disconnect the following connectors and cable.
1) Set the vehicle on lift arms. (1) Engine harness connector
2) Open front hood fully and support with stay.
3) Raise rear seat, and turn floor mat up.
4) Release fuel pressure.
(1) Disconnect fuel pump relay connector.

S2M1929
(2) Engine ground terminal

EN0344
(2) Start th enjine, and run until stalls.
(3) After the engine stalls, crank it for five sec-
onds more.
(4) Turn ignition switch to “OFF”.
5) Remove filler cap.
6) Disconnect battery ground terminal.
S2M0731
(3) Engine harness connector

G6M0095
7) Remove radiator from vehicle. <Ref. to CO-37,
REMOVAL, Radiator.> S2M1930
8) Remove coolant filler tank. <Ref. to CO-51, RE-
MOVAL, Coolant Filler Tank.>
9) Collect refrigerant, and remove pressure hoses.
(1) Place and connect the attachment hose to
the refrigerant recycle system.
(2) Collect refrigerant from A/C system.
(3) Disconnect A/C pressure hoses from A/C
compressor.

S2M1584

ME(DOHC TURBO)-33
 ENGINE ASSEMBLY
MECHANICAL

(4) Generator connector, terminal and A/C (2) Heater inlet outlet hose
compressor connectors

EN0205
13) Remove power steering pump from bracket.
B2M1291I
(1) Loosen lock bolt and slider bolt, and remove
(A) A/C compressor connector front side V-belt. <Ref. to ME(DOHC TURBO)-
(B) Generator connector and terminal 43, FRONT SIDE BELT, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
(5) Accelerator cable nector.

S2M1931 EN0360
(6) Clutch release spring (3) Remove pipe with bracket from intake mani-
fold.

S2M1932
12) Disconnect the following hoses EN0206
(1) Brake booster vacuum hose (4) Remove power steering pump from engine.

EN0204
H2M1954

ME(DOHC TURBO)-34
 ENGINE ASSEMBLY
MECHANICAL

(5) Remove power steering tank from the (1) Remove clutch operating cylinder from
bracket by pulling it upward. transmission.
(2) Remove plug using 10 mm hexagon
wrench.

EN0361
(6) Place power steering pump on the right side
wheel apron. S2M1935
(3) Screw 6 mm dia. bolt into release fork shaft,
and remove it.

EN0208
14) Remove center exhaust pipe. <Ref. to
EX(DOHC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>
15) Remove nuts which hold lower side of trans-
mission to engine.

S2M1936A

B3M2047 (A) Shaft

16) Remove nuts which install front cushion rubber (B) Bolt
onto front crossmember.
(4) Raise release fork and unfasten release
bearing tabs to free release fork.
CAUTION:
Step (4) is required to prevent interference with
engine when removing engine from transmis-
sion.

S2M1927
17) Separate clutch release fork from release bear-
ing.

ME(DOHC TURBO)-35
 ENGINE ASSEMBLY
MECHANICAL

18) Remove pitching stopper. 22) Support transmission with a garage jack.
CAUTION:
Before moving engine away from transmission,
check to be sure no work has been overlooked.
Doing this is very important in order to facilitate
re-installation and because transmission low-
ers under its own weight.

H3M1839
19) Disconnect fuel delivery hose, return hose and
evaporation hose.
CAUTION:
• Catch fuel from hose into container.
• Disconnect hose with its end wrapped with
cloth to prevent fuel from splashing. S2M1928
23) Separation of engine and transmission.
(1) Remove starter. <Ref. to SC-5, REMOVAL,
Starter.>
(2) Remove bolt which holds right upper side of
transmission to engine.

EN0214

20) Remove fuel filter and bracket.

B3M2044
24) Remove engine from vehicle.
(1) Slightly raise engine.
(2) Raise transmission with garage jack.
(3) Move engine horizontally until mainshaft is
withdrawn from clutch cover.
G2M0818
(4) Slowly move engine away from engine com-
21) Support engine with a lifting device and wire partment.
ropes. CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
25) Remove front cushion rubbers.

G2M0297

ME(DOHC TURBO)-36
 ENGINE ASSEMBLY
MECHANICAL

B: INSTALLATION (4) Apply grease to specified points.

1) Install clutch release fork and bearing onto trans- • Spline FX2200
mission. • Shaft SUNLIGHT 2
(1) Remove release bearing from clutch cover
with flat type screw driver.

S2M1843
(2) Install release bearing on transmission.
(3) Install release fork into release bearing tab.

S2M1938A

(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
S2M1937A
(5) Insert release fork shaft into release fork.
(A) Release fork
(B) Release bearing CAUTION:
Make sure the cutout portion of release fork
shaft contasts spring pin.

S2M1845A

(A) Release fork

(B) Release shaft
(C) Spring pin

ME(DOHC TURBO)-37
 ENGINE ASSEMBLY
MECHANICAL

(6) Tighten plug. 7) Install pitching stopper.

Tightening torque: Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) T1: 49 N·m (5.0 kgf-m, 36.2 ft-lb)
T2: 57 N·m (5.8 kgf-m, 42 ft-lb)

S2M1846
2) Install front cushion rubbers to engine. H3M1839A
8) Install starter. <Ref. to SC-6, INSTALLATION,
Tightening torque:
Starter.>
34 N·m (3.5 kgf-m, 25.3 ft-lb)
9) Install fuel filter and bracket.
3) Install engine onto tarnsmission.
(1) Position engine in engine compartment and
align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
(2) Apply a small amount of grease to splines of
mainshaft.
4) Tighten bolt which hold right upper side of trans-
G2M0818
mission to engine.
10) Install power steering pump on bracket.
Tightening torque: (1) Install the power steering tank on bracket.
50 N·m (5.1 kgf-m, 36.9 ft-lb)

EN0361
B2M2791 (2) Install power steering pump on bracket, and
5) Remove lifting device and wire ropes. tighten bolts.
6) Remove garage jack. Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)

G2M0297

H2M1954

ME(DOHC TURBO)-38
 ENGINE ASSEMBLY
MECHANICAL

(3) Install power steering pipe bracket on right CAUTION:

side intake manifold, and install spark plug Make sure the front cushion rubber mounting
codes. bolts (A) and locator (B) are securely installed.

EN0206
B2M3880A
(4) Connect power steering switch connector. 13) Install center exhaust pipe.
<Ref. to EX(DOHC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>
14) Connect the following hoses.
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
15) Connect the following connectors and termi-
nals.
EN0360 (1) Engine ground terminal
(5) Install front side V-belt, and adjust it. <Ref. (2) Engine harness connectors
to ME(SOHC)-42, FRONT SIDE BELT, IN- (3) Generator connector and terminal
STALLATION, V-belt.> (4) A/C compressor connectors (With A/C)
11) Tighten nuts which hold lower side of transmis- 16) Connect the following cables.
sion to engine. (1) Accelerator cable
Tightening torque: (2) Clutch release spring
50 N·m (5.1 kgf-m, 36.9 ft-lb) CAUTION:
After connecting each cable, adjust them.
17) Install air intake system.
(1) Install intercooler. <Ref. to IN(DOHC TUR-
BO)-11, INSTALLATION, Intercooler.>
(2) Install air cleaner element and air cleaner
upper cover.
(3) Install engine harness connector bracket.
(4) Install filler hose to air cleaner case.

B2M2790
12) Tighten nuts which install front cushion rubber
onto crossmember.
Tightening torque:
83 N·m (8.5 kgf-m, 61 ft-lb)

H2M1962B

(A) Filler hose

(B) Connector bracket

ME(DOHC TURBO)-39
 ENGINE ASSEMBLY
MECHANICAL

18) Install A/C pressure hoses. (With A/C)

CAUTION:
Use new O-rings.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)

S2M1584
19) Install radiator. <Ref. to CO-40, INSTALLA-
TION, Radiator.>
20) Install coolant filler tank. <Ref. to CO-51, IN-
STALLATION, Coolant Filler Tank.>
21) Install window washer tank.
22) Install battery in the vehicle, and connect ca-
bles.
23) Fill coolant.
<Ref. to CO-25, FILLING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
24) Charge A/C system with refrigerant.
<Ref. to AC-17, OPERATION, Refrigerant Charg-
ing Procedure.>
25) Remove front hood stay, and close front hood.
26) Take off the vehicle from lift arms.

ME(DOHC TURBO)-40
 ENGINE MOUNTING
MECHANICAL

10.Engine Mounting
A: REMOVAL
1) Remove engine assembly. <Ref. to ME(DOHC
TURBO)-33, REMOVAL, Engine Assembly.>
2) Remove engine mounting from engine assem-
bly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Engine mounting;
35 N·m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.

ME(DOHC TURBO)-41
 PREPARATION FOR OVERHAUL
MECHANICAL

11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from the body, secure
it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND

S2M1876A
2) In this section the procedures described under
each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.

ME(DOHC TURBO)-42
 V-BELT
MECHANICAL

12.V-belt 3) Remove the A/C belt.

4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to the body.
1) Remove V-belt cover.

S2M0113

B: INSTALLATION
1. FRONT SIDE BELT
CAUTION:
Wipe off any oil or water on the belt and pulley.
EN0048 1) Install a belt, and tighten the slider bolt so as to
2) Loosen the lock bolt (A). obtain the specified belt tension <Ref. to
3) Loosen the slider bolt (B). ME(DOHC TURBO)-44, INSPECTION, V-belt.>
4) Remove the front side belt (C). 2) Tighten the lock bolt (A)
3) Tighten slider bolt (B).

(B)
Tightening torque:
Lock bolt through bolt:
(C)
25 N·m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N·m (0.8 kgf-m, 5.5 ft-lb)

(A) (B)

(C)
EN0225

2. REAR SIDE BELT

1) Loosen the lock nut (A).
2) Loosen the slider bolt (B). (A)

EN0225

(B)

(A)

EN0226

ME(DOHC TURBO)-43
 V-BELT
MECHANICAL

2. REAR SIDE BELT C: INSPECTION

1) Install a belt, and tighten the slider bolt (B) so as 1) Replace belts, if cracks, fraying or wear is found.
to obtain the specified belt tension. <Ref. to 2) Check drive belt tension and adjust it if neces-
ME(DOHC TURBO)-44, INSPECTION, V-belt.> sary by changing generator installing position and/
2) Tighten the lock nut (A). or idler pulley installing position.
Tightening torque: Belt tension
Lock nut (A); (A)
22.6 N·m (2.3 kgf-m, 16.6 ft-lb) replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
(B) reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: With Air conditioner

(A)

EN0226

B2M4123A

C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley

ME(DOHC TURBO)-44
 CRANKSHAFT PULLEY
MECHANICAL

13.Crankshaft Pulley Crankshaft pulley bolt:

12369AA011
A: REMOVAL (2) Clean the crankshaft thread using an air
1) Remove V-belt. <Ref. to ME(DOHC TURBO)- gun.
43, REMOVAL, V-belt.> (3) Tighten the bolts temporarily with tightening
2) Remove crankshaft pulley bolt. To lock crank- torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
shaft, use ST. (4) Tighten the crankshaft pulley bolts keeping
ST 499977100 them in an angle between 65 degrees and 75
CRANKSHAFT PULLEY WRENCH degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
4) Install A/C belt tensioner.

H2M2393C
3) Remove crankshaft pulley.
B: INSTALLATION
1) Install crankshaft pulley.
2) Install pulley bolt.
To lock crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY S2M0113

WRENCH 5) Install A/C belt.

(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread. (B)

(3) Tighten the bolts temporarily with tightening

torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts. (A)
Tightening torque:
177 N·m (18.0 kgf-m, 130.2 ft-lb)
EN0226

C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to
ME(DOHC TURBO)-44, INSPECTION, V-belt.>

H2M2393A
3) Confirm that the tightening angle of the crank-
shaft pulley bolt is 65 degrees or more. If not, con-
duct the following procedures (1) through (4).
(1) Replace the crankshaft pulley bolts and
clean them.

ME(DOHC TURBO)-45
 BELT COVER
MECHANICAL

14.Belt Cover
A: REMOVAL
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-
43, REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.>
3) Remove left-hand belt cover (A).
4) Remove right-hand belt cover (B).
5) Remove front belt cover (C).

S2M1221A

B: INSTALLATION
1) Install front belt cover (C).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
2) Install right-hand belt cover (B).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
3) Install left-hand belt cover (A).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)

S2M1221A
4) Install crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, INSTALLATION, Crankshaft Pulley.>
5) Install V-belt. <Ref. to ME(DOHC TURBO)-43,
INSTALLATION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.

ME(DOHC TURBO)-46
 TIMING BELT ASSEMBLY
MECHANICAL

15.Timing Belt Assembly (2) Using white paint, put alignment and/or ar-
row marks on timing belts in relation to the
A: REMOVAL sprockets.
1. TIMING BELT
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-
43, REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.>
3) Remove belt cover. <Ref. to ME(DOHC TUR-
BO)-46, REMOVAL, Belt Cover.>
4) Remove timing belt guides.
EN0233

S2M0294
5) If alignment mark and/or arrow mark (which indi-
cates rotation direction) on timing belt fade away, S2M1225
put new marks before removing timing belt as fol- Z1: 54.5 tooth length
lows: Z2: 51 tooth length
(1) Turn crankshaft using ST, and align align- Z3: 28 tooth length
ment marks on crankshaft sprocket, left-hand in-
take camshaft sprocket, left-hand exhaust
camshaft sprocket, right-hand intake camshaft
sprocket and right hand exhaust camshaft
sprocket with notches of belt cover and sylinder
block.
ST 499987500 CRANKSHAFT SOCKET

S2M1223A
6) Remove belt idler (A).

S2M1878A

S2M1226A
7) Remove timing belt.

ME(DOHC TURBO)-47
 TIMING BELT ASSEMBLY
MECHANICAL

CAUTION: B: INSTALLATION
After timing belt has been removed, never ro-
tate intake and exhaust, camshaft sprocket. If 1. AUTOMATIC BELT TENSION ADJUST-
camshaft sprocket is rotated, the intake and ex- ER ASSEMBLY AND BELT IDLER
haust valve heads strike together and valve 1) Preparation for installation of automatic belt ten-
stems are bent. sion adjuster assembly:
2. BELT IDLER AND AUTOMATIC BELT CAUTION:
TENSION ADJUSTER ASSEMBLY • Always use a vertical type pressing tool to
move the adjuster rod down.
1) Remove belt idler (B) and (C).
• Do not use a lateral type vise.
• Push adjuster rod vertically.
• Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30 kgf, 66 lb).
• Press-in the push adjuster rod gradually tak-
ing more than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
S2M1226A rod into the cylinder. Doing so may damage the
2) Remove belt idler No. 2. cylinder.
• Do not release press pressure until stopper
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.

S2M0411
3) Remove automatic belt tension adjuster assem-
bly.

H2M2382
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
S2M0412 secure the adjuster rod.

H2M2383

ME(DOHC TURBO)-48
 TIMING BELT ASSEMBLY
MECHANICAL

2) Install automatic belt tension adjuster assembly. 2. TIMING BELT

Tightening torque: 1) Preparation for installation of automatic belt ten-
39 N·m (4.0 kgf-m, 28.9 ft-lb) sion adjuster assembly. <Ref. to ME(DOHC TUR-
BO)-48, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, Tim-
ing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on crankshaft sprocket with
mark on the oil pump cover at cylinder block.

(A)

S2M0416
3) Install belt idler No. 2.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)

EN0243
(2) Align single line mark (A) on right-hand ex-
haust camshaft sprocket with notch (B) on belt
cover.

S2M0411
4) Install belt idler.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
S2M1227B
(3) Align single line mark (A) on right-hand in-
take camshaft sprocket with notch (B) on belt
cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)

S2M0410

S2M1228B

ME(DOHC TURBO)-49
 TIMING BELT ASSEMBLY
MECHANICAL

(4) Align single line mark (A) on left-hand ex-

haust camshaft sprocket with notch (B) on belt
cover by turning sprocket counterclockwise (as
viewed from front of engine).

S2M1229B
(5) Align single line mark (A) on left-hand intake
camshaft sprocket with notch (B) on belt cover
by turning sprocket clockwise (as viewed from
front of engine).
Ensure double lines (C) on intake and exhaust
camshaft sprockets are aligned.

S2M1230B
(6) Ensure camshaft and crankshaft sprockets
are positioned properly.

ME(DOHC TURBO)-50
 TIMING BELT ASSEMBLY
MECHANICAL

CAUTION: • When timing belts are not installed, four cam-

• Intake and exhaust camshafts for this DOHC shafts are held at the “zero-lift” position, where
engine can be independently rotated with tim- all cams on camshafts do not push intake and
ing belts removed. As can be seen from the fig- exhaust valves down. (Under this condition, all
ure, if intake and exhaust valves are lifted si- valves remain unlifted.)
multaneously, their heads will interfere with • When camshafts are rotated to install timing
each other, resulting in bent valves. belts, #2 intake and #4 exhaust cam of left-hand
camshafts are held to push their correspond-
ing valves down. (Under this condition, these
valves are held lifted.) Right-side camshafts are
held so that their cams do not push valves
down.
• Left-hand camshafts must be rotated from
the “zero-lift” position to the position where
timing belt is to be installed at as small an angle
as possible, in order to prevent mutual interfer-
ence of intake and exhaust valve heads.
• Do not allow camshafts to rotate in the direc-
tion shown in the figure as this causes both in-
take and exhaust valves to lift simultaneously,
resulting in interference with their heads.

B2M1392B

(A) Intake camshaft

(B) Exhaust camshaft

S2M1231A

ME(DOHC TURBO)-51
 TIMING BELT ASSEMBLY
MECHANICAL

3) Installation of timing belt

S2M0418
Align alignment mark on timing belt with marks on sprockets in the alphabetical order shown in figure. While
aligning marks, position timing belt properly.
CAUTION:
• Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
• Ensure belt’s rotating direction is correct.

S2M1232A

ME(DOHC TURBO)-52
 TIMING BELT ASSEMBLY
MECHANICAL

4) Install belt idlers.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
Make sure that the marks on timing belt and
sprockets are aligned.

EN0255

H2M2398
5) After ensuring that the marks on timing belt and
sprockets are aligned, remove stopper pin from
tensioner adjuster.
6) Install timing belt guide.
(1) Temporarily tighten remaining bolts. EN0256
(2) Check and adjust clearance between timing (3) Tighten remaining bolts.
belt and timing belt guide.
Tightening torque:
Clearance:
9.8 N·m (1.0 kgf-m, 7.2 ft-lb)
1.0±0.5 mm (0.039±0.020 in)

S2M0294
S2M0297

EN0257
EN0254

ME(DOHC TURBO)-53
 TIMING BELT ASSEMBLY
MECHANICAL

C: 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 thorough-
EN0258 ly if this happens.
• Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more

EN0259
7) Install belt cover. <Ref. to ME(DOHC TURBO)-
46, INSTALLATION, Belt Cover.>
G2M0115
8) Install crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.> 2. AUTOMATIC BELT TENSION ADJUST-
9) Install V-belt. <Ref. to ME(DOHC TURBO)-43, ER
INSTALLATION, V-belt.>
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary, re-
place automatic belt tension adjuster assembly.
CAUTION:
Slight traces of oil at rod's oil seal does not in-
dicate a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
• Push adjuster rod vertically.

ME(DOHC TURBO)-54
 TIMING BELT ASSEMBLY
MECHANICAL

• Press-in the push adjuster rod gradually tak-

ing more than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body. If
it is not within specifications, replace with a new
one.
Rod extension: H
5.7±0.5 mm (0.224±0.020 in)

H2M2381A

3. BELT TENSION PULLEY

1) Check mating surfaces of timing belt and contact
point of adjuster rod for abnormal wear or scratch-
es. Replace belt tension pulley if faulty.
2) Check belt tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
3) Check belt tension pulley 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.

ME(DOHC TURBO)-55
 CAMSHAFT SPROCKET
MECHANICAL

16.Camshaft Sprocket B: INSTALLATION

1) Install camshaft sprocket No. 1. and No. 2. To
A: REMOVAL lock camshaft, use ST.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)- ST 499207100 CAMSHAFT SPROCKET
43, REMOVAL, V-belt.> WRENCH
2) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.> Tightening torque:
3) Remove belt cover. <Ref. to ME(DOHC TUR- 98 N·m (10 kgf-m, 72.4 ft-lb)
BO)-46, REMOVAL, Belt Cover.> CAUTION:
4) Remove timing belt assembly. <Ref. to Do not confuse left and right side camshaft
ME(DOHC TURBO)-47, REMOVAL, Timing Belt sprockets during installation. The camshaft
Assembly.> sprocket No. 2 is identified by a projection used
5) Remove camshaft position sensor. <Ref. to to monitor camshaft position sensor.
FU(DOHC TURBO)-29, REMOVAL, Camshaft Po-
sition Sensor.>
6) Remove camshaft sprockets. To lock camshaft,
use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH

S2M1879A
2) Install camshaft position sensor. <Ref. to
FU(DOHC TURBO)-29, INSTALLATION, Cam-
shaft Position Sensor.>
3) Install timing belt assembly. <Ref. to ME(DOHC
TURBO)-48, INSTALLATION, Timing Belt Assem-
S2M1879A bly.>
4) Install belt cover. <Ref. to ME(DOHC TURBO)-
46, INSTALLATION, Belt Cover.>
5) Install crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, INSTALLATION, Crankshaft Pulley.>
6) Install V-belt. <Ref. to ME(DOHC TURBO)-43,
INSTALLATION, V-belt.>
C: INSPECTION
1) Check sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check crankshaft sprocket notch for sensor for
damage and contamination of foreign matter.

ME(DOHC TURBO)-56
 CRANKSHAFT SPROCKET
MECHANICAL

17.Crankshaft Sprocket B: INSTALLATION

1) Install crankshaft sprocket.
A: REMOVAL
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-
43, REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.>
3) Remove belt cover. <Ref. to ME(DOHC TUR-
BO)-46, REMOVAL, Belt Cover.>
4) Remove timing belt assembly. <Ref. to
ME(DOHC TURBO)-47, REMOVAL, Timing Belt
Assembly.> EN0263
5) Remove camshaft sprocket. <Ref. to ME(DOHC
TURBO)-56, REMOVAL, Camshaft Sprocket.> 2) Install camshaft sprocket. <Ref. to ME(DOHC
6) Remove crankshaft sprocket. TURBO)-56, INSTALLATION, Camshaft Sprock-
et.>
3) Install timing belt assembly. <Ref. to ME(DOHC
TURBO)-48, INSTALLATION, Timing Belt Assem-
bly.>
4) Install belt cover. <Ref. to ME(DOHC TURBO)-
46, INSTALLATION, Belt Cover.>
5) Install crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, INSTALLATION, Crankshaft Pulley.>
6) Install V-belt. <Ref. to ME(DOHC TURBO)-43,
INSTALLATION, V-belt.>
EN0263
C: INSPECTION
1) Check sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check crankshaft sprocket notch for sensor for
damage and contamination of foreign matter.

ME(DOHC TURBO)-57
 CAMSHAFT
MECHANICAL

18.Camshaft 13) Loosen intake camshaft cap bolts equally, a lit-

tle at a time in alphabetical sequence shown in fig-
A: REMOVAL ure.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-
43, INSTALLATION, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.>
3) Remove belt cover. <Ref. to ME(DOHC TUR-
BO)-46, REMOVAL, Belt Cover.>
4) Remove timing belt assembly. <Ref. to
ME(DOHC TURBO)-47, REMOVAL, Timing Belt
Assembly.>
5) Remove camshaft sprocket. <Ref. to ME(DOHC S2M1233A
TURBO)-56, REMOVAL, Camshaft Sprocket.> 14) Remove camshaft caps and intake camshaft.
6) Remove crankshaft sprocket. <Ref. to 15) Loosen exhaust camshaft cap bolts equally, a
ME(DOHC TURBO)-57, REMOVAL, Crankshaft little at a time in alphabetical sequence shown in
Sprocket.> figure.
7) Remove left-hand belt cover No. 2.

S2M1234A
S2M1162 16) Remove camshaft caps and exhaust camshaft.
8) Remove right-hand belt cover No.2.
CAUTION:
Arrange camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove right-hand camshafts and re-
lated parts.

B2M0738
9) Remove tensioner bracket.

S2M1163
10) Remove oil level gauge guide. (LH side only)
11) Remove spark plug cord.
12) Remove rocker cover and gasket.

ME(DOHC TURBO)-58
 CAMSHAFT
MECHANICAL

B: INSTALLATION Fluid packing:

1) Camshaft installation THREE BOND 1215 or equivalent
Apply engine oil to cylinder head at camshaft bear-
ing location before installing camshaft. Install cam-
shaft so that each valves is close to or in contact
with “base circle” of cam lobe.
CAUTION:
• When camshafts are positioned as shown in
figure, camshafts need to be rotated at a mini-
mum to align with timing belt during installa-
tion.
• Right-hand camshaft need not be rotated S2M1839A
when set at position shown in figure. (2) Apply engine oil to cap bearing surface and
Left-hand intake camshaft: Rotate 80°° clock- install cap on camshaft as shown by identifica-
wise. tion mark (A).
Left-hand exhaust camshaft: Rotate 45°° coun- (3) Gradually tighten cap in at least two stages
terclockwise. in alphabetical sequence shown in figure, and
then tighten to specified torque.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)

S2M1233A
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates
only slightly while holding it at “base” circle.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
3) Camshaft oil seal installation
B2M1200B
Apply grease to new oil seal lips and press onto
front end of camshaft by using ST1 and ST2.
A Left side cylinder head CAUTION:
B Right side cylinder head Use a new oil seal.
(a) Intake camshaft ST1 499587600 OIL SEAL INSTALLER
(b) Exhaust camshaft ST2 499597200 OIL SEAL GUIDE
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating
surface.
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess packing to come out
and flow toward oil seal, resulting in oil leaks.

S2M1880A

ME(DOHC TURBO)-59
 CAMSHAFT
MECHANICAL

4) Rocker cover installation 9) Install tensioner bracket.

(1) Install gasket on rocker cover.
Tightening torque:
Install peripheral gasket and ignition coil gasket.
25± 3 N·m (2.5± 0.3 kg-m, 18.1± 2.2 ft-lb)
(2) Apply fluid packing to four front open edges
of peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent

S2M1163
10) Install crankshaft sprocket. <Ref. to ME(DOHC
TURBO)-56, INSTALLATION, Camshaft Sprock-
et.>
S2M0300B 11) Install camshaft sprockets. <Ref. to ME(DOHC
(3) Install rocker cover on cylinder head. TURBO)-56, INSTALLATION, Camshaft Sprock-
Ensure gasket is properly positioned during in- et.>
stallation. 12) Install timing belt assembly. <Ref. to
5) Install spark plug cord. ME(DOHC TURBO)-48, INSTALLATION, Timing
6) Similarly, install parts on right-hand side. Belt Assembly.>
7) Install right-hand belt cover No. 2. 13) Install belt cover. <Ref. to ME(DOHC TURBO)-
46, INSTALLATION, Belt Cover.>
Tightening torque: 14) Install crackshaft pulley. <Ref. to ME(DOHC
5 N·m (0.5 kgf-m, 3.6 ft-lb) TURBO)-45, INSTALLATION, Crankshaft Pulley.>
15) Install V-belt. <Ref. to ME(DOHC TURBO)-43,
INSTALLATION, V-belt.>

B2M0738
8) Install left-hand belt cover No. 2.
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)

S2M1162

ME(DOHC TURBO)-60
 CAMSHAFT
MECHANICAL

C: INSPECTION (6) Measure the widest point of the plastigauge

1) Measure the bend, and repair or replace if nec- on each journal.
essary. If the oil clearance exceeds the limit, replace the
camshaft. If necessary, replace the camshaft
Limit: caps and cylinder head as a set.
0.020 mm (0.0008 in)
Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit:
0.10 mm (0.0039 in)

G2M0746
2) Check journal for damage and wear. Replace if
faulty.
3) Measure outside diameter of camshaft journal. If
the jounal diameter is not as specified, check the oil B2M1216
clearance. (7) Completely remove the plastigauge.
Camshaft journal 5) Check cam face condition; remove minor faults
Front Center, rear
by grinding with oil stone. Measure the cam height
H; replace if the limit has been exceeded.
37.946 — 37.9635 29.946 — 29.963
Standard
(1.4939 — 1.4946 in) (1.1790 — 1.1796 in) Cam height: H
Standard:
4) Measurement of the camshaft journal oil clear- Intake:
ance
46.25 — 46.35 mm (1.821 — 1.825 in)
(1) Clean the bearing caps and camshaft jour-
Exhaust:
nals.
46.15 — 46.25 mm (1.817 — 1.821 in)
(2) Place the camshafts on the cylinder head.
(Without installing valve rocker.) Limit:
(3) Place plastigauge across each of the cam- Intake:
shaft jounals. 46.15 mm (1.817 in)
(4) Gradually tighten cap in at least two stages Exhaust:
in alphabetical sequence shown in figure, and 46.05 mm (1.813 in)
then tighten to specified torque.
Cam base circle diameter A:
Tightening torque: 37.0 mm (1.457 in)
20 N·m (2.0 kgf-m, 14.5 ft-lb)

B2M1209A
S2M1233A

CAUTION:
Do not turn the camshaft.
(5) Remove the bearing caps.

ME(DOHC TURBO)-61
 CAMSHAFT
MECHANICAL

6) Measure the thrust clearance of camshaft with

dial gauge. If the clearance exceeds the limit, re-
place caps and cylinder head as a set. If neces-
sary replace camshaft.
Standard:
0.015 — 0.070 mm (0.0006 — 0.0028 in)
Limit:
0.1 mm (0.004 in)

B2M1217

ME(DOHC TURBO)-62
 CYLINDER HEAD ASSEMBLY
MECHANICAL

19.Cylinder Head Assembly B: INSTALLATION

1) Install cylinder head and gaskets on cylinder
A: REMOVAL block.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-
CAUTION:
43, REMOVAL, V-belt.>
• Use new cylinder head gaskets.
2) Remove crankshaft pulley. <Ref. to ME(DOHC
• Be careful not to scratch the mating surface
TURBO)-45, REMOVAL, Crankshaft Pulley.>
of cylinder head and cylinder block.
3) Remove belt cover. <Ref. to ME(DOHC TUR-
BO)-46, REMOVAL, Belt Cover.> 2) Tighten cylinder head bolts.
4) Remove timing belt assembly. <Ref. to (1) Apply a coat of engine oil to washers and
ME(DOHC TURBO)-47, REMOVAL, Timing Belt bolt threads.
Assembly.> (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
5) Remove camshaft sprocket. <Ref. to ME(DOHC lb) in alphabetical sequence.
TURBO)-56, REMOVAL, Camshaft Sprocket.> Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
6) Remove intake manifold. <Ref. to FU(DOHC lb) in alphabetical sequence.
TURBO)-15, REMOVAL, Intake Manifold.> (3) Back off all bolts by 180° first; back them off
7) Remove bolt which installs A/C compressor by 180° again.
bracket on cylinder head. (4) Tighten bolts (A) and (B) to 34 N·m (3.5 kgf-
8) Remove camshaft. <Ref. to ME(DOHC TUR- m, 25 ft-lb).
BO)-58, REMOVAL, Camshaft.>
9) Remove cylinder head bolts in alphabetical se-
quence shown in figure.
CAUTION:
Leave bolts (A) and (D) engaged by three or
four threads to prevent cylinder head from fall-
ing.

B2M1397D
(5) Tighten bolts (C), (D), (E) and (F) to 15 N·m
(1.5 kgf-m, 11 ft-lb).

B2M1397C
10) While tapping cylinder head with a plastic ham-
mer, separate it from cylinder block.
Remove bolts (A) and (D) to remove cylinder head.
B2M1397D
(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 al-
phabetical sequence.
CAUTION:
B2M1397C Ensure that the total “re-tightening angle” [in
11) Remove cylinder head gasket. the two previous steps] do not exceed 180°°.
CAUTION: 3) Install camshaft. <Ref. to ME(DOHC TURBO)-
Do not scratch the mating surface of cylinder 59, INSTALLATION, Camshaft.>
head and cylinder block. 4) Install A/C compressor bracket on cylinder head.
12) Similarly, remove right side cylinder head.

ME(DOHC TURBO)-63
 CYLINDER HEAD ASSEMBLY
MECHANICAL

5) Install intake manifold. <Ref. to FU(DOHC TUR-

BO)-17, INSTALLATION, Intake Manifold.>
6) Install camshaft sprocket. <Ref. to ME(DOHC
TURBO)-56, INSTALLATION, Camshaft Sprock-
et.>
7) Install timing belt assembly. <Ref. to ME(DOHC
TURBO)-48, INSTALLATION, Timing Belt Assem-
bly.>
8) Install belt cover. <Ref. to ME(DOHC TURBO)-
46, INSTALLATION, Belt Cover.>
9) Install crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, INSTALLATION, Crankshaft Pulley.>
10) Install V-belt. <Ref. to ME(DOHC TURBO)-43,
INSTALLATION, V-belt.>
C: DISASSEMBLY
1) Remove valve shims and valve lifters.
2) Compress the valve spring and remove the valve
spring retainer key. Remove each valve and valve
spring.
ST 498267600 CYLINDER HEAD TABLE
ST 499718000 VALVE SPRING REMOVER
CAUTION:
• Keep 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.

S2M1881A

ME(DOHC TURBO)-64
 CYLINDER HEAD ASSEMBLY
MECHANICAL

D: ASSEMBLY

S2M1197A

(1) Exhaust valve (6) Valve spring (11) Exhaust valve oil seal
(2) Intake valve (7) Retainer (12) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (10) Shim

ME(DOHC TURBO)-65
 CYLINDER HEAD ASSEMBLY
MECHANICAL

1) Installation of valve spring and valve CAUTION:

(1) Coat stem of each valve with engine oil and Uneven torque for the cylinder head nuts can
insert valve into valve guide. cause warping. When reassembling, pay spe-
CAUTION: cial attention to the torque so as to tighten
When inserting valve into valve guide, use spe- evenly.
cial care not to damage the oil seal lip.
(2) Set cylinder head on ST1.
(3) Install valve spring and retainer using ST2.
ST 498267600 CYLINDER HEAD TABLE
ST 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
S2M1840A

2. VALVE SEAT
Inspect intake and exhaust valve seats, and correct
the contact surfaces with valve seat cutter if they
are defective or when valve guides are replaced.
Valve seat width: W
Intake
Standard
S2M1881A
1.0 mm (0.039 in)
Limit
(4) Compress valve spring and fit valve spring 1.7 mm (0.067 in)
retainer key.
Exhaust
(5) After installing, tap valve spring retainers
Standard
lightly with wooden hammer for better seating.
1.5 mm (0.059 in)
2) Apply oil to the surface of the valve lifter and
Limit
valve shim.
2.2 mm (0.087 in)
3) Install valve lifter and valve shim.
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect important
areas by means of red check.
2) Measure the warping of the cylinder head sur-
face that mates with crankcase by using a straight
edge (A) and thickness gauge (B). G2M0761
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)

ME(DOHC TURBO)-66
 CYLINDER HEAD ASSEMBLY
MECHANICAL

3. VALVE GUIDE (3) Turn cylinder head upside down and place
ST as shown in the figure.
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring ST 498767700 VALVE GUIDE ADJUSTER
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
0.035 — 0.062 mm (0.0014 — 0.0024 in)
Exhaust
G2M0763
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit (4) Before installing new valve guide, make
sure that neither scratches nor damages exist
0.15 mm (0.0059 in)
on the inside surface of the valve guide holes in
2) If the clearance between valve guide and stem cylinder head.
exceeds the limit, replace valve guide or valve itself (5) Put new valve guide, coated with sufficient
whichever shows greater amount of wear. See fol- oil, in cylinder, and insert ST1 into valve guide.
lowing procedure for valve guide replacement. Press in until the valve guide upper end is flush
Valve guide inner diameter: with the upper surface of ST2.
6.000 — 6.012 mm (0.2362 — 0.2367 in) ST1 499767200 VALVE GUIDE REMOVER
ST2 498267700 VALVE GUIDE ADJUSTER
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
enter the holes in ST1.
(2) Insert ST2 into valve guide and press it
down to remove valve guide.
S2M1883A
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER (6) Check the valve guide protrusion.
Valve guide protrusion: L
12.0 — 12.4 mm (0.472 — 0.488 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into valve guide, and return it also ro-
tating clockwise. After reaming, clean valve
guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
S2M1882A • 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 be-
comes 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 valve guide.

ME(DOHC TURBO)-67
 CYLINDER HEAD ASSEMBLY
MECHANICAL

4. INTAKE AND EXHAUST VALVE 5. VALVE SPRINGS

1) Inspect the flange and stem of valve, and re- 1) Check valve springs for damage, free length,
place if damaged, worn, or deformed, or if “H” is and tension. Replace valve spring if it is not to the
less than the specified limit. specifications presented in the table.
2) To measure the squareness of the valve spring,
H:
stand the spring on a surface plate and measure its
Intake
deflection at the top using a try square.
Standard
1.2 mm (0.047 in) Valve spring
Limit Free length 44.67 mm (1.7587 in)
0.8 mm (0.031 in) 220.7±15.7 N
Exhaust (22.5 ± 1.6 kgf, 49.6±3.5 lb)/36.0 mm
Standard Tension/spring (1.417 in)
1.5 mm (0.059 in) height 510.9±25.5 N
Limit (52.1±2.6 kgf, 114.9±5.7 lb)/26.6
0.8 mm (0.031 in) mm (1.047 in)
Squareness 2.5°, 2.0 mm (0.079 in)
Valve overall length:
Intake
104.4 mm (4.110 in)
Exhaust
104.7 mm (4.122 in)

G2M0154

G2M0153
2) Put a small amount of grinding compound on the
seat surface and lap the valve and seat surface.
Install a new intake valve oil seal after lapping.

ME(DOHC TURBO)-68
 CYLINDER HEAD ASSEMBLY
MECHANICAL

6. INTAKE AND EXHAUST VALVE OIL 3) Measure inner diameter of valve lifter mating
SEAL part on cylinder head.
Replace oil seal with new one, if lip is damaged or Inner diameter:
spring out of place, or when the surfaces of intake 34.994 — 35.016 mm (1.3777 — 1.3786 in)
valve and valve seat are reconditioned or intake
valve guide is replaced.
1) Place cylinder head on ST1.
2) Press in oil seal to the specified dimension indi-
cated in the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 498857100 VALVE GUIDE REMOVER
CAUTION:
• Apply engine oil to oil seal before force-fit-
ting. B2M1400
• Differentiate between intake valve oil seal CAUTION:
and exhaust valve oil seal by noting their dif- If difference between outer diameter of valve
ference in color. lifter and inner diameter of valve lifter mating
Color of rubber part: part is over the limit, replace cylinder head.
Intake [Black] Standard:
Exhaust [Brown] 0.019 — 0.057 mm (0.0007 — 0.0022 in)
Color of spring part: Limit:
Intake [Silver] 0.100 mm (0.0039 in)
Exhaust [Silver]

S2M1924A

7. VALVE LIFTER
1) Check valve lifter visually.
2) Measure outer diameter of valve lifter.
Outer diameter:
34.959 — 34.975 mm (1.3763 — 1.3770 in)

B2M1222

ME(DOHC TURBO)-69
 CYLINDER BLOCK
MECHANICAL

20.Cylinder Block CAUTION:

Do not use a screwdriver or similar tool in place
A: REMOVAL of oil pan cutter.
NOTE:
Before conducting this procedure, drain engine oil
completely if applicable.
1) Remove intake manifold. <Ref. to FU(DOHC
TURBO)-15, REMOVAL, Intake Manifold.>
2) Remove V-belt. <Ref. to ME(DOHC TURBO)-
43, REMOVAL, V-belt.>
3) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, REMOVAL, Crankshaft Pulley.>
4) Remove belt cover. <Ref. to ME(DOHC TUR- G2M0163
BO)-46, REMOVAL, Belt Cover.> 15) Remove oil strainer stay.
5) Remove timing belt assembly. <Ref. to 16) Remove oil strainer.
ME(DOHC TURBO)-47, REMOVAL, Timing Belt 17) Remove baffle plate.
Assembly.> 18) Remove water pips.
6) Remove camshaft sprocket. <Ref. to ME(DOHC 19) Remove water pump.
TURBO)-56, REMOVAL, Camshaft Sprocket.> 20) Remove oil pump from cylinder block.
7) Remove crankshaft sprocket. <Ref. to Use a flat-bladed screwdriver as shown in figure
ME(DOHC TURBO)-57, REMOVAL, Crankshaft when removing oil pump.
Sprocket.>
8) Remove generator and A/C compressor with CAUTION:
their brackets. Be careful not to scratch the mating surface of
9) Remove cylinder head assembly. <Ref. to cylinder block and oil pump.
ME(DOHC TURBO)-63, REMOVAL, Cylinder
Head Assembly.>
10) Remove clutch housing cover.
11) Remove flywheel.
Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER

G2M0162

G2M0776
12) Remove oil separator cover.
13) Remove water by-pass pipe for heater.
14) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove bolts which secure oil pan to cylin-
der block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.

ME(DOHC TURBO)-70
 CYLINDER BLOCK
MECHANICAL

EN0294

(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
21) Remove service hole cover and service hole 22) Rotate crankshaft to bring #1 and #2 pistons to
plugs using hexagon wrench [14 mm (0.55 in)]. bottom dead center position, then remove piston
circlip through service hole of #1 and #2 cylinders.

B2M2620
G2M0165

ME(DOHC TURBO)-71
 CYLINDER BLOCK
MECHANICAL

23) Draw out piston pin from #1 and #2 pistons us- 24) Similarly remove piston pins from #3 and #4
ing ST. pistons.
ST 499097700 PISTON PIN REMOVER 25) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 26) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder. the side of #1 and #3 cylinders two or three turns.
27) Set up cylinder block so that #1 and #3 cylin-
ders are on the upper side, then remove cylinder
block connecting bolts.
28) Separate left-hand and right-hand cylinder
blocks.
CAUTION:
When separating cylinder block, do not allow
the connecting rod to fall and damage the cylin-
der block.
G2M0166

B2M2408A

(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
29) Remove rear oil seal. 32) Draw out each piston from cylinder block using
30) Remove crankshaft together with connecting wooden bar or hammer handle.
rod. CAUTION:
31) Remove crankshaft bearings from cylinder Do not confuse combination of piston and cyl-
block using hammer handle. inder.
CAUTION:
Do not confuse combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.

ME(DOHC TURBO)-72
 CYLINDER BLOCK
MECHANICAL

B: INSTALLATION

B2M2407A

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

S2M1826A

ME(DOHC TURBO)-73
 CYLINDER BLOCK
MECHANICAL

3) Temporarily tighten 10 mm cylinder block con- 6) Install rear oil seal using ST1 and ST2.
necting bolts in alphabetical sequence shown in fig- ST1 499597100 OIL SEAL GUIDE
ure. ST2 499587200 OIL SEAL INSTALLER

B2M0088D G2M0186
4) Tighten 10 mm cylinder block connecting bolts in 7) Position the top ring gap at (A) or (B) in the fig-
alphabetical sequence. ure.
Tightening torque: 180
47±3 N·m (4.8±0.3 kgf-m, 34.7±2.2 ft-lb)

(A) (B)

EN0304
8) Position the second ring gap at 180° on the re-
B2M0088D
verse side for the top ring gap.
9) Position the upper rail gap at (C) or (D) in the fig-
5) Tighten 8 mm and 6 mm cylinder block connect- ure.
ing bolts in alphabetical sequence shown in figure.
Tightening torque: (E)
(A) — (G): 25±2 N·m (2.5±0.2 kgf-m, 18.1±1.4
(C)
ft-lb) 35
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 25

(D)

(F)
EN0305
10) Position the expander gap at 180° of the re-
verse side for the upper rail gap.
11) Position the lower rail gap at (E) or (F) in the fig-
ure.
B2M0089F

ME(DOHC TURBO)-74
 CYLINDER BLOCK
MECHANICAL

CAUTION: CAUTION:
• Ensure ring gaps do not face the same direc- Use new circlips.
tion.
• Ensure ring gaps are not within the piston
skirt area.

(E)

(C)
35
25

B2M1403A
(D)

(F)
CAUTION:
Piston front mark faces towards the front of the
EN0305
engine.
12) Install circlip.
Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
pistons in the corresponding cylinders.

(A)

EN0307

(A) Front mark

B2M1322J

(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug T: 69 (7.0, 50.6)
(3) Circlip

ME(DOHC TURBO)-75
 CYLINDER BLOCK
MECHANICAL

13) Installing piston (4) Apply fluid packing around the service hole
(1) Turn cylinder block so that #1 and #2 cylin- plug.
ders face upward.
Fluid packing:
(2) Using ST1, turn crankshaft so that #1 and THREE BOND 1215 or equivalent
#2 connecting rods are set at bottom dead cen-
ter.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cyl-
inders and insert pistons in their cylinders using
ST2.
ST2 498744300 PISTON GUIDE

B2M2625
(5) Install service hole plug and gasket.
CAUTION:
Use a new gasket.

S2M0306A
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 inser-
tion.
ST3 499017100 PISTON PIN GUIDE B2M2620

G2M0189
(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.
CAUTION:
Use new circlips.

G2M0190

ME(DOHC TURBO)-76
 CYLINDER BLOCK
MECHANICAL

B2M1323K

(1) Piston (5) Service hole plug Tightening torque: N·m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring T2: 69 (7.0, 50.6)
(4) Gasket
(6) Turn cylinder block so that #3 and #4 cylin- 19) Apply fluid packing to matching surfaces and
ders face upward. Using the same procedures install oil pan.
as used for #1 and #2 cylinders, install pistons
Fluid packing:
and piston pins.
THREE BOND 1215 or equivalent
15) Install water pipe.
16) Install baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
17) Install oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install oil strainer stay.
S2M1833A

ME(DOHC TURBO)-77
 CYLINDER BLOCK
MECHANICAL

20) Apply fluid packing to matching surfaces and

install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent

B2M0390B

(A) O-ring

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

S2M1834A oil seal.
21) Install flywheel.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N·m (7.3 kgf-m, 52.8 ft-lb)

S2M0118B
(4) Install oil pump on cylinder block. Be careful
not to damage oil seal during installation.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M3361A CAUTION:
22) Install housing cover. • Do not forget to install O-ring and seal when
23) Installation of oil pump installing oil pump.
(1) Discard front oil seal after removal. Replace • Align flat surface of oil pump's inner rotor
with a new one using ST. with crankshaft before installation.
ST 499587100 OIL SEAL INSTALLER 24) Install water pump and gasket.
Tightening torque:
First; 12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second; 12 N·m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
• Be sure to use a new gasket.
• When installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
S2M0235
(2) Apply fluid packing to matching surface of oil
pump.
Fluid packing:
THREE BOND 1215 or equivalent

H2M1846D

ME(DOHC TURBO)-78
 CYLINDER BLOCK
MECHANICAL

25) Install water by-pass pipe for heater. 33) Install crankshaft sprocket. <Ref. to ME(DOHC
26) Install oil cooler. TURBO)-57, INSTALLATION, Crankshaft Sprock-
et.>
Tightening torque:
34) Install camshaft sprocket. <Ref. to ME(DOHC
T1: 55 N·m (5.5 kgf-m, 40 ft-lb) TURBO)-56, INSTALLATION, Camshaft Sprock-
T2: 69 N·m (7.0 kgf-m, 50.6 ft-lb) et.>
35) Install timing belt assembly. <Ref. to
ME(DOHC TURBO)-48, INSTALLATION, Timing
Belt Assembly.>
36) Install belt cover. <Ref. to ME(DOHC TURBO)-
46, INSTALLATION, Belt Cover.>
37) Install crankshaft pulley. <Ref. to ME(DOHC
TURBO)-45, INSTALLATION, Crankshaft Pulley.>
38) Install generator and A/C compressor brackets
on cylinder head.
39) Install V-belt. <Ref. to ME(DOHC TURBO)-43,
INSTALLATION, V-belt.>
40) Install intake manifold. <Ref. to FU(DOHC
TURBO)-15, REMOVAL, Intake Manifold.>

EN0320

(A) O-ring
(B) Oil cooler
(C) Connector

27) Install oil filter using ST.

ST 498547000 OIL FILTER WRENCH
28) Install water by-pass pipe between oil cooler
and water pump.

EN0321
29) Install water pipe.
CAUTION:
Always use a new O-ring.
30) Install cylinder head assembly. <Ref. to
ME(DOHC TURBO)-63, INSTALLATION, Cylinder
Head Assembly.>
31) Install oil level gauge guide and tighten attach-
ing bolt (left side only).
32) Install rocker cover.

ME(DOHC TURBO)-79
 CYLINDER BLOCK
MECHANICAL

C: DISASSEMBLY

B2M1320I

(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second 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 confu-
sion.
3) Remove piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good order
to prevent confusion.
5) Remove circlip.

ME(DOHC TURBO)-80
 CYLINDER BLOCK
MECHANICAL

D: ASSEMBLY

B2M1320J

(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install connecting rod bearings on connecting E: INSPECTION
rods and connecting rod caps.
1. CYLINDER BLOCK
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage. Especial-
bearings. ly, inspect important parts by means of red lead
2) Install connecting rod on crankshaft. check.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect crankcase surface that mates with cylin-
Position each connecting rod with the side der head for warping by using a straight edge, and
marked facing forward. correct by grinding if necessary.
3) Install connecting rod cap with connecting rod
nut. Warping limit:
Ensure the arrow on connecting rod cap faces the 0.05 mm (0.0020 in)
front during installation. Grinding limit:
CAUTION: 0.1 mm (0.004 in)
• Each connecting rod has its own mating cap. Standard height of cylinder block:
Make sure that they are assembled correctly by 201.0 mm (7.91 in)
checking their matching number.
• When tightening the connecting rod nuts, ap-
ply 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.

ME(DOHC TURBO)-81
 CYLINDER BLOCK
MECHANICAL

2. CYLINDER AND PISTON CAUTION:

1) The cylinder bore size is stamped on the cylinder Measurement should be performed at a temper-
block's front upper surface. ature 20°°C (68°°F).
CAUTION: Taper:
Measurement should be performed at a temper- Standard
ature 20°°C (68°°F). 0.015 mm (0.0006 in)
Limit
NOTE:
Standard sized pistons are classified into two 0.050 mm (0.0020 in)
grades, “A” and “B”. These grades should be used Out-of-roundness:
as a guide line in selecting a standard piston. Standard
Standard diameter: 0.010 mm (0.0004 in)
A: 92.005 — 92.015 mm (3.6222 — 3.6226 Limit
in) 0.050 mm (0.0020 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222
in)

S2M1821A

(A) Thrust direction

H2M1732C
(B) Piston pin direction
(A) Main jourual size mark
3) When piston is to be replaced due to general or
(B) Cylinder block RH-LH combination mark
cylinder wear, determine a suitable sized piston by
(C) #1 cylinder bore size mark measuring the piston clearance.
(D) #2 cylinder bore size mark 4) How to measure the outer diameter of each pis-
(E) #3 cylinder bore size mark ton
(F) #4 cylinder bore size mark Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
2) How to measure the inner diameter of each cyl-
inder CAUTION:
Measure the inner diameter of each cylinder in both Measurement should be performed at a temper-
the thrust and piston pin directions at the heights ature of 20°°C (68°°F).
shown in the figure, using a cylinder bore gauge.

ME(DOHC TURBO)-82
 CYLINDER BLOCK
MECHANICAL

Piston grade point H: perature rise. Thus, pay attention to this when
37.0 mm (1.457 in) measuring the cylinder diameter.
Piston outer diameter: Limit of cylinder enlarging (boring):
Standard 0.5 mm (0.020 in)
A: 91.985 — 91.995 mm
3. PISTON AND PISTON PIN
(3.6214 — 3.6218 in)
B: 91.975 — 91.985 mm 1) Check pistons and piston pins for damage,
(3.6211 — 3.6214 in) cracks, and wear and the piston ring grooves for
0.25 mm (0.0098 in) oversize wear and damage. Replace if defective.
92.225 — 92.235 mm 2) Measure the piston-to-cylinder clearance at
(3.6309 — 3.6313 in) each cylinder. <Ref. to ME(DOHC TURBO)-82,
0.50 mm (0.0197 in) oversize CYLINDER AND PISTON, INSPECTION, Cylinder
92.475 — 92.485 mm Block.> If any of the clearances is not to specifica-
(3.6407 — 3.6411 in) tion, 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). Re-
place if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
B2M1305A
0.020 mm (0.0008 in)
5) Calculate the clearance between cylinder and
piston.
CAUTION:
Measurement should be performed at a temper-
ature 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 B2M1401
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 pis-
ton.
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 bor- B2M0084A
ing on one cylinder only, nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crank-
case.
CAUTION:
Immediately after reboring, the cylinder diame-
ter may differ from its real diameter due to tem-

ME(DOHC TURBO)-83
 CYLINDER BLOCK
MECHANICAL

4) Check circlip installation groove on the piston for 4. PISTON RING

burr (A). If necessary, remove burr from the groove
1) If piston ring is broken, damaged, or worn, or if its
so that piston pin can lightly move.
tension is insufficient, or when the piston is re-
placed, replace piston ring with a new one of the
same size as the piston.
CAUTION:
• “N” is marked on the end of the top and sec-
ond rings. When installing the rings to the pis-
ton, face this mark upward.

B2M0420B
5) Check piston pin circlip for distortion, cracks and
wear.

EN0330
• The oil ring is a combined ring consisting of
two rails and a spacer in between. When install-
ing, be careful to assemble correctly.

EN0331

(A) Top ring

(B) Second ring
(C) Oil ring
(D) Upper rail
(E) Spacer
(F) Lower rail

ME(DOHC TURBO)-84
 CYLINDER BLOCK
MECHANICAL

2) Squarely place piston ring and oil ring in cylinder, 5. CONNECTING ROD
and measure the piston ring gap with a thickness
1) Replace connecting rod, if the large or small end
gauge.
thrust surface is damaged.
Unit: mm (in) 2) Check for bend or twist using a connecting rod
Standard Limit aligner. Replace connecting rod if the bend or twist
0.20 — 0.35 exceeds the limit.
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Limit of bend or twist per 100 mm (3.94 in) in
Piston Second 0.35 — 0.50 length:
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
0.10 mm (0.0039 in)
Oil ring 0.20 — 0.70
1.5 (0.059)
rail (0.0079 — 0.0276)

G2M0174
3) Measure the clearance between piston ring and
piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the pis-
ton ring groove and piston ring.
Unit: mm (in)
Standard Limit
0.040 — 0.080 B2M1184B
Clearance Top ring (0.0016 — 0.15 (0.0059)
between pis- 0.0031) (A) Thickness gauge
ton ring and
0.030 — 0.070 (B) Connecting rod
piston ring Second
groove (0.0012 — 0.15 (0.0059)
ring 3) Install connecting rod fitted with bearing to
0.0028)
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)

B2M1402A

EN0335

ME(DOHC TURBO)-85
 CYLINDER BLOCK
MECHANICAL

4) Inspect connecting rod bearing for scar, peeling, 6) Inspect bushing at connecting rod small end,
seizure, melting, wear, etc. and replace if worn or damaged. Also measure the
5) Measure the oil clearance on individual connect- piston pin clearance at the connecting rod small
ing rod bearings by means of plastigauge. If any oil end.
clearance is not within specification, replace the
Clearance between piston pin and bushing:
defective bearing with a new one of standard size
Standard
or undersize as necessary. (See the table below.)
0 — 0.022 mm (0 — 0.0009 in)
Connecting rod oil clearance: Limit
Standard 0.030 mm (0.0012 in)
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size
Outer diameter of
Bearing (Thickness at cen-
crank pin
ter)
1.492 — 1.501 47.984 — 48.000
Standard
(0.0587 — 0.0591) (4.8891 — 1.8898)
0.03 B2M0085
1.510 — 1.513 47.954 — 47.970
(0.0012)
(0.0594 — 0.0596) (1.8879 — 1.8886)
undersize
0.05
1.520 — 1.523 47.934 — 47.950
(0.0020)
(0.0598 — 0.0600) (1.8872 — 1.8878)
undersize
0.25
1.620 — 1.623 47.734 — 47.750
(0.0098)
(0.0638 — 0.0639) (1.8793 — 1.8799)
undersize

B2M0084
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 BUSH-
ING REMOVER AND IN-
STALLER

G2M0177
(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(DOHC TURBO)-86
 CYLINDER BLOCK
MECHANICAL

6. CRANKSHAFT AND CRANKSHAFT

BEARING
1) Clean crankshaft completely and check for
cracks by means of red lead check etc., and re-
place if defective.
2) Measure the crankshaft bend, and correct or re-
place 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 mea-
sure crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)

EN0339
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 re-
place or recondition crankshaft as necessary.
When grinding crank journal or crank pin, finish
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)

G2M0179

ME(DOHC TURBO)-87
 CYLINDER BLOCK
MECHANICAL

Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5 #2, #4
59.992 — 60.008 59.992 — 60.008 47.984 — 48.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (1.8891 — 1.8898)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.510
(Thickness at cen-
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
ter)
59.962 — 59.978 59.962 — 59.978 47.954 — 47.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (1.8879 — 1.8886)
0.03 (0.0012)
undersize Bearing size
2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at cen-
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
ter)
59.942 — 59.958 59.942 — 59.958 47.934 — 47.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (1.8872 — 1.8878)
0.05 (0.0020)
Bearing size
undersize 2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at cen-
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
ter)
59.742 — 59.758 59.742 — 59.758 47.734 — 47.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (1.8793 — 1.8799)
0.25 (0.0098)
Bearing size
undersize 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at cen-
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
ter)
O.D. ... Outer Diameter
4) Measure the thrust clearance of crankshaft at 6) Measure the oil clearance on each crankshaft
center bearing. If the clearance exceeds the limit, bearing by means of plastigauge. If the measure-
replace bearing. ment is not within the specification, replace defec-
tive bearing with an undersize one, and replace or
Crankshaft thrust clearance:
recondition crankshaft as necessary.
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in) Unit: mm (in)
Limit Crankshaft oil clearance
0.25 mm (0.0098 in) Standard 0.010 — 0.030 (0.0004 —
0.0012)
Limit 0.040 (0.0016)

EN0341
5) Inspect individual crankshaft bearings for signs
of flaking, seizure, melting, and wear.

ME(DOHC TURBO)-88
 ENGINE TROUBLE IN GENERAL
MECHANICAL

21.Engine Trouble in General

A: INSPECTION
NOTE: A — Very often
“RANK” shown in the chart refer to the possibility of B — Sometimes
reason for the trouble in order (“Very often” to C — Rarely
“Rarely”)
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. • Starter • Defective battery-to-starter harness B
• Defective starter switch C
• Defective inhibitor switch or neutral switch C
• Defective starter B
• Battery • Poor terminal connection A
• Run-down battery A
• Defective charging system B
• Friction • Seizure of crankshaft and connecting rod bearing C
• Seized camshaft C
• Seized or stuck piston and cylinder C
2) Initial combustion does • Starter • Defective starter C
not occur. • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
• Fuel line • Defective fuel pump and relay A
• Lack of or insufficient fuel B
• Belt • Defective B
• Defective timing B
• Compression • Incorrect valve clearance C
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating C
• Defective valve stem C
• Worn or broken valve spring B
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing B
• Improper engine oil (low viscosity) B
3) Initial combustion occur. • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
• Intake system • Defective intake manifold gasket B
• Defective throttle body gasket B
• Fuel line • Defective fuel pump and relay C
• Clogged fuel line C
• Lack of or insufficient fuel B
• Belt • Defective B
• Defective timing B
• Compression • Incorrect valve clearance C
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating C
• Defective valve stem C
• Worn or broken valve spring B
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing B
• Improper engine oil (low viscosity) B

ME(DOHC TURBO)-89
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

4) Engine stalls after initial • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
combustion. • Intake system • Loosened or cracked intake duct B
• Loosened or cracked PCV hose C
• Loosened or cracked vacuum hose C
• Defective intake manifold gasket B
• Defective throttle body gasket B
• Dirty air cleaner element C
• Fuel line • Clogged fuel line C
• Lack of or insufficient fuel B
• Belt • Defective B
• Defective timing B
• Compression • Incorrect valve clearance C
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating C
• Defective valve stem C
• Worn or broken valve spring B
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing B
• Improper engine oil (low viscosity) B
2. Rough idle and engine • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
stall • Intake system • Loosened or cracked intake duct A
• Loosened or cracked PCV hose A
• Loosened or cracked vacuum hose A
• Defective intake manifold gasket B
• Defective throttle body gasket B
• Defective PCV valve C
• Loosened oil filter cap B
• Dirty air cleaner element C
• Fuel line • Defective fuel pump and relay C
• Clogged fuel line C
• Lack of or insufficient fuel B
• Belt • Defective timing C
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket B
• Loosened cylinder head bolts or defective gasket B
• Improper valve seating B
• Defective valve stem C
• Worn or broken valve spring B
• Worn or stuck piston rings, cylinder and piston B
• Incorrect valve timing A
• Improper engine oil (low viscosity) B
• Lubrication system • Incorrect oil pressure B
• Defective rocker cover gasket C
• Cooling system • Overheating C
• Others • Malfunction of evaporative emission control system A
• Stuck or damaged throttle valve B
• Accelerator cable out of adjustment C

ME(DOHC TURBO)-90
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

3. Low output, hesitation and • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
poor acceleration • Intake system • Loosened or cracked intake duct A
• Loosened or cracked PCV hose A
• Loosened or cracked vacuum hose B
• Defective intake manifold gasket B
• Defective throttle body gasket B
• Defective PCV valve B
• Loosened oil filter cap B
• Dirty air cleaner element A
• Fuel line • Defective fuel pump and relay B
• Clogged fuel line B
• Lack of or insufficient fuel C
• Belt • Defective timing B
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket B
• Loosened cylinder head bolts or defective gasket B
• Improper valve seating B
• Defective valve stem C
• Worn or broken valve spring B
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing A
• Improper engine oil (low viscosity) B
• Lubrication system • Incorrect oil pressure B
• Cooling system • Overheating C
• Over cooling C
• Others • Malfunction of evaporative emission control system A
4. Surging • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
• Intake system • Loosened or cracked intake duct A
• Loosened or cracked PCV hose A
• Loosened or cracked vacuum hose A
• Defective intake manifold gasket B
• Defective throttle body gasket B
• Defective PCV valve B
• Loosened oil filter cap B
• Dirty air cleaner element B
• Fuel line • Defective fuel pump and relay B
• Clogged fuel line B
• Lack of or insufficient fuel C
• Belt • Defective timing B
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating C
• Defective valve stem C
• Worn or broken valve spring C
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing A
• Improper engine oil (low viscosity) B
• Cooling system • Overheating B
• Others • Malfunction of evaporative emission control system C

ME(DOHC TURBO)-91
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

5. Engine does not return to • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
idle. • Intake system • Loosened or cracked vacuum hose A
• Others • Stuck or damaged throttle valve A
• Accelerator cable out of adjustment B
6. Dieseling (Run-on) • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
• Cooling system • Overheating B
• Others • Malfunction of evaporative emission control system B
7. After burning in exhaust • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
system • Intake system • Loosened or cracked intake duct C
• Loosened or cracked PCV hose C
• Loosened or cracked vacuum hose B
• Defective PCV valve B
• Loosened oil filler cap C
• Belt • Defective timing B
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating B
• Defective valve stem C
• Worn or broken valve spring C
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing A
• Lubrication system • Incorrect oil pressure C
• Cooling system • Over cooling C
• Others • Malfunction of evaporative emission control system C
8. Knocking • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
• Intake system • Loosened oil filter cap B
• Belt • Defective timing B
• Compression • Incorrect valve clearance C
• Incorrect valve timing B
• Cooling system • Overheating A
9. Excessive engine oil con- • Intake system • Loosened or cracked PCV hose A
sumption • Defective PCV valve B
• Loosened oil filter cap C
• Compression • Defective valve stem A
• Worn or stuck piston rings, cylinder and piston A
• Lubrication system • Loosened oil pump attaching bolts and defective B
gasket
• Defective oil filter seal B
• Defective crankshaft oil seal B
• Defective rocker cover gasket B
• Loosened oil drain plug or defective gasket B
• Loosened oil pan fitting bolts or defective oil pan B

ME(DOHC TURBO)-92
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

10. Excessive fuel consump- • Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> A
tion • Intake system • Dirty air cleaner element A
• Belt • Defective timing B
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating B
• Defective valve stem C
• Worn or broken valve spring C
• Worn or stuck piston rings, cylinder and piston B
• Incorrect valve timing B
• Lubrication system • Incorrect oil pressure C
• Cooling system • Over cooling C
• Others • Accelerator cable out of adjustment B

ME(DOHC TURBO)-93
 ENGINE NOISE
MECHANICAL

22.Engine Noise
A: INSPECTION
Type of sound Condition Possible cause
• Valve mechanism is defective.
• Incorrect valve clearance
Sound increases as engine
Regular clicking sound • Worn valve rocker
speed increases.
• Worn camshaft
• Broken valve spring
• Worn crankshaft main bearing
Oil pressure is low.
• Worn connecting rod bearing (big end)
Heavy and dull clank
• Loose flywheel mounting bolts
Oil pressure is normal.
• Damaged engine mounting
• Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when • Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. • Wrong spark plug
• Improper gasoline
Sound is reduced when fuel • Worn crankshaft main bearing
Clank when engine speed is injector connector of noisy cyl- • Worn bearing at crankshaft end of connecting rod
medium (1,000 to 2,000 rpm). inder is disconnected.
(NOTE*)
Sound is reduced when fuel • Worn cylinder liner and piston ring
injector connector of noisy cyl- • Broken or stuck piston ring
Knocking sound when engine inder is disconnected. • Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm Sound is not reduced if each • Unusually worn valve lifter
fuel injector connector is dis- • Worn cam gear
connected in turn. (NOTE*) • Worn camshaft journal bore in crankcase
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Defective generator brush and rotor contact
Gear scream when starting • Defective ignition starter switch
—
engine • Worn gear and starter pinion
Sound like polishing glass with • Loose drive belt
—
a dry cloth • Defective water pump shaft
• Loss of compression
Hissing sound — • Air leakage in air intake system, hoses, connections or mani-
folds
• Loose timing belt
Timing belt noise —
• Belt contacting case/adjacent part
Valve tappet noise — • Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-38, OPERATION, Clear Memory Mode.> and
INSPECTION MODE <Ref. to EN(DOHC TURBO)-35, OPERATION, Inspection Mode.> after connecting fuel injector connector.

ME(DOHC TURBO)-94