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Subaru 2004 manual

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Table of contents for the manual

  • Page 1

    FUJI HEAVY INDUSTRIES LTD. G1870GE3 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTI ON 2 This ser vice manu al has bee n prepared to prov ide SUB ARU ser vice pe rsonnel with the nec essary inform ation and data for the corr ect mainte nance and repair of SUBA RU vehicl es. This man ual in clude s the proc edures for mai ntenan ce, d[...]

  • Page 2

    MECHANICAL ME(H4DOTC) Page 1. General Desc ription ...... ....... .......... ....... ....... ......... ........ ......... ....... ....... .......2 2. C ompre ssio n ..... ...... ..... .... ....... .... ..... .... ....... .... ..... ...... ..... .... .... ....... .... ..... .. 34 3. Id le Spe ed ....... .... .... ....... .... ..... .... ....... ....[...]

  • Page 3

    ME(H4DOTC)-2 MECH ANICAL General Descript ion 1. General Description A: SPECIFICATIONS 1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL) NOTE: STD: Standard I.D.: Inner Diameter O.D.: Oute r Diameter OS: Oversize US: Undersize Engine Typ e Horizontall y opposed, liq uid cooled, 4-cylinder, 4-st roke gaso line e ngine Valve a rrangement Belt [...]

  • Page 4

    ME(H4DOTC)-3 MECHA NIC AL General Descript ion Valve s eat Refaci ng angle 90 ° Cont act ing w idth Intake ST D 1.0 mm (0 .039 in) Limit 1.7 mm (0 .067 in) Exhaust ST D 1.5 mm (0 .059 in) Limit 2.2 mm (0 .087 in) Valve g uide Inner d iameter 6.000 — 6. 012 mm (0.2362 — 0.2 367 in) Protrusion above head 15.8 — 1 6.2 mm (0 .622 — 0.63 8 in) [...]

  • Page 5

    ME(H4DOTC)-4 MECH ANICAL General Descript ion Piston ring Pist on ri ng ga p Top ring STD 0.20 — 0.25 mm (0.0079 — 0 .0098 i n) Limit 1.0 mm (0 .039 in) Second ring STD 0.40 — 0.50 mm (0.016 — 0.02 0 in) Limit 1.0 mm (0 .039 in) Oil ring STD 0.20 — 0 .50 mm (0. 0079 — 0 .020 in) Limit 1.5 mm (0 .059 in) Clea ranc e bet ween pist on ring[...]

  • Page 6

    ME(H4DOTC)-5 MECHA NIC AL General Descript ion Crankshaft Bend lim it 0.035 m m (0.0014 in) Crank p in and crank jo ur- nal Out-of-ro undness 0.005 mm (0.000 2 in) or le ss Grindi ng limit 0.25 mm (0.009 8 in) Crank p in oute r diamete r STD 51. 984 — 52.000 m m (2.0466 — 2.0472 i n) 0.03 m m (0.0012 in) U S 51. 954 — 51.970 m m (2.0454 — 2[...]

  • Page 7

    ME(H4DOTC)-6 MECH ANICAL General Descript ion 2. STi MO DEL NOTE: STD: Standard I.D.: Inner Diameter O.D.: Oute r Diameter OS: Oversize US: Undersize Crankshaft bearing Cranks haft be aring thic k- ness #1, #3 STD 1.998 — 2.011 mm (0.0787 — 0.0 792 in) 0.03 m m (0.0012 in) U S 2.01 7 — 2.020 mm (0 .0794 — 0.0795 in) 0.05 m m (0.0020 in) U S[...]

  • Page 8

    ME(H4DOTC)-7 MECHA NIC AL General Descript ion Belt tension adjus ter Protrusion of adjust er rod 5.2 — 6. 2 mm (0.205 — 0.24 4 in ) Belt tension er Spac er O.D . 17. 955 — 17.975 mm (0.70 69 — 0. 7077 in) Tensione r bush I.D . 18.0 — 18 .08 mm (0.7087 — 0 .7118 in) Clearan ce between spac er and bus h STD 0.025 — 0.125 mm (0.0010 —[...]

  • Page 9

    ME(H4DOTC)-8 MECH ANICAL General Descript ion Cylinde r bloc k Surface w arpage li mit (mati ng with c ylinder head) 0.05 mm (0.002 0 in) Surface gri nding limit 0.1 mm (0 .004 in) Cylinder bore STD A 92. 005 — 92.015 m m (3.6222 — 3.6226 i n) B 91. 995 — 92.005 m m (3.6218 — 3.6222 i n) Taper STD 0.015 m m (0.0006 in) Limit 0.050 m m (0.00[...]

  • Page 10

    ME(H4DOTC)-9 MECHA NIC AL General Descript ion Crankshaft Bend lim it 0.035 m m (0.0014 in) Crank p in and crank jo ur- nal Out-of-ro undness 0.005 mm (0.000 2 in) or le ss Grindi ng limit 0.25 mm (0.009 8 in) Crank p in oute r diamete r STD 51. 984 — 52.000 m m (2.0466 — 2.0472 i n) 0.03 m m (0.0012 in) U S 51. 954 — 51.970 m m (2.0454 — 2[...]

  • Page 11

    ME(H 4D OT C)-1 0 MECH ANICAL General Descript ion 3. DOHC TURBO MODEL (AUSTRALIA MODEL EXCEPT FOR S Ti MODEL) NOTE: STD: Standard I.D.: Inner Diameter O.D.: Oute r Diameter OS: Oversize US: Undersize Crankshaft bearing Cranks haft be aring thic k- ness #1, #3 STD 1.998 — 2.011 mm (0.0787 — 0.0 792 in) 0.03 m m (0.0012 in) U S 2.01 7 — 2.020 [...]

  • Page 12

    ME(H 4D OT C)-1 1 MECHA NIC AL General Descript ion Belt tension adjus ter Protrusion of adjust er rod 5.2 — 6. 2 mm (0.205 — 0.24 4 in ) Belt tension er Spac er O.D . 17. 955 — 17.975 mm (0.70 69 — 0. 7077 in) Tensione r bush I.D . 18.0 — 18 .08 mm (0.7087 — 0 .7118 in) Clearan ce between spac er and bus h STD 0.025 — 0.125 mm (0.001[...]

  • Page 13

    ME(H 4D OT C)-1 2 MECH ANICAL General Descript ion Cylinde r bloc k Surface w arpage li mit (mati ng with c ylinder head) 0.05 mm (0.002 0 in) Surface gri nding limit 0.1 mm (0 .004 in) Cylinder bore STD A 92. 005 — 92.015 m m (3.6222 — 3.6226 i n) B 91. 995 — 92.005 m m (3.6218 — 3.6222 i n) Taper STD 0.015 m m (0.0006 in) Limit 0.050 m m [...]

  • Page 14

    ME(H 4D OT C)-1 3 MECHA NIC AL General Descript ion Crankshaft Bend lim it 0.035 m m (0.0014 in) Crank p in and crank jo ur- nal Out-of-ro undness 0.005 mm (0.000 2 in) or le ss Grindi ng limit 0.25 mm (0.009 8 in) Crank p in oute r diamete r STD 51. 984 — 52.000 m m (2.0466 — 2.0472 i n) 0.03 m m (0.0012 in) U S 51. 954 — 51.970 m m (2.0454 [...]

  • Page 15

    ME(H 4D OT C)-1 4 MECH ANICAL General Descript ion Crankshaft bearing Cranks haft be aring thic k- ness #1, #3 STD 1.998 — 2.011 mm (0.0787 — 0.0 792 in) 0.03 m m (0.0012 in) U S 2.01 7 — 2.020 mm (0 .0794 — 0.0795 in) 0.05 m m (0.0020 in) U S 2.02 7 — 2.030 mm (0 .0798 — 0.0799 in) 0.25 m m (0.0098 in) U S 2.12 7 — 2.130 mm (0 .0837 [...]

  • Page 16

    ME(H 4D OT C)-1 5 MECHA NIC AL General Descript ion B: COMP ONEN T 1. TIMING BELT • EXCEPT FOR STi AND AUSTRALIA MODEL (1) Timing belt cove r No. 2 (RH ) (10) Intake c amshaft spr ocket (LH) Tightening torque: N · m (kgf-m, ft-lb) (2) Timing belt guide (MT mode l) (11) Exhaust camshaf t sprocke t (LH) T1: 5 (0.5, 3.6) (3) Crank shaf t spr ocket [...]

  • Page 17

    ME(H 4D OT C)-1 6 MECH ANICAL General Descript ion • STi AND AUSTRALIA MODEL (1) Timing belt cove r No. 2 (RH ) (10) Intake c amshaft spr ocket (LH) Tightening torque: N · m (kgf-m, ft-lb) (2) Timing belt guide (11) Exhau st cams haft sproc ket (LH) T1: 5 (0.5, 3.6) (3) Crank shaf t spr ocket (12) T imin g belt T2: 6.4 (0.65, 4.7 ) (4) Timing be[...]

  • Page 18

    ME(H 4D OT C)-1 7 MECHA NIC AL General Descript ion 2. CYLINDER HEAD AND CAMSHAFT • EXCEPT FOR STi AND AUSTRALIA MODEL ME-00756 T2 T4 T3 T5 T4 T2 T2 T1 (7) (6) (14) (9) (8) (10) (15) (16) (13) (12) (32) (29) (30) (31) (3) (4) (27) (23) (24) (21) (32) (18) (19) (14) (26) (28) (25) (20) (22) (17) (16) (11) (5) (4) (1) (3) (2) T1 T3 T3 T5 T5 T3 T4 T[...]

  • Page 19

    ME(H 4D OT C)-1 8 MECH ANICAL General Descript ion (1) Rocker c over (RH) (15) Cylinder hea d (RH) (29) Gasket (2) Rocke r cover gask et (RH) (16) Cylin der head g asket (30) Oil fil ler duct (3) Oil separa tor cover (17) Cylin der head (LH) (31) O-ring (4) Gask et (18) Intake cams haf t (LH) (32) Stud bolt (5) Intake c amshaft cap (Front RH ) (19)[...]

  • Page 20

    ME(H 4D OT C)-1 9 MECHA NIC AL General Descript ion • STi AND AUSTRALIA MODEL ME-00705 T2 T3 T4 T2 T2 T1 (1) (3) (7) (6) (9) (8) (10) (12) (13) (28) (24) (25) (26) (23) (19) (20) (28) (15) (16) (11) (17) (22) (27) (21) (18) (10) (14) (13) (11) (5) (4) T3 T3 T5 (2) T3 T5 T5 T5[...]

  • Page 21

    ME(H 4D OT C)-2 0 MECH ANICAL General Descript ion (1) Rocker c over (RH) (13) Cylinder head gask et (25) Gasket (2) Rocker c over gask et (RH) (14) Cylinder head (LH ) (26) Oil filler duc t (3) Oil flo w contro l soleno id valve assembl y (RH) (15) Intake camsh aft (LH) (27) O-ring (16) Exhaust camshaf t (LH) (28) Stud bolt (4) Intake c amshaft ca[...]

  • Page 22

    ME(H 4D OT C)-2 1 MECHA NIC AL General Descript ion 3. CYLINDER HEAD AND VALVE ASSEMBLY (1) Exhau st valve (5) Intak e valve oil seal (9) Valve lifter (2) Inta ke va lve (6) Valv e spr ing (10) Exha ust valv e oil se al (3) Cylin der head (7) Retain er (11) Intak e valve guide (4) Valve spring s eat (8) Retain er key (12) Exhau st valve guide ME-00[...]

  • Page 23

    ME(H 4D OT C)-2 2 MECH ANICAL General Descript ion 4. CYLINDER BLOCK (1) Oil pressure swit ch (16) Water by-pass pipe Tightening torque: N · m (kgf-m, ft-lb) (2) Cylinder blo ck (RH) (17) Connecto r T1: 5 (0.5, 3.6) (3) Servic e hole p lug (1 8) Oil str ainer T2: 6.4 (0.65, 4.7) (4) Gaske t ( 19) Gas ket T3: 10 ( 1.0 , 7.2 ) (5) Oil se parator cov[...]

  • Page 24

    ME(H 4D OT C)-2 3 MECHA NIC AL General Descript ion 5. CRANKSHAFT AND PISTON (1) Flywheel (MT mo del) (10) Circ lip (19) Crankshaft be aring #5 (2) Ball b earing (MT mode l) (11) Connec ting rod b olt (3) Reinfo rcement (AT model ) (12) Connec ting rod Tightening torque: N · m (kgf-m, ft-lb) (4) Drive plate (AT mo del) (13) Connecti ng rod b earin[...]

  • Page 25

    ME(H 4D OT C)-2 4 MECH ANICAL General Descript ion 6. ENGINE MOUNTING (1) Heat shiel d cov er (3) Fr ont en gin e mou ntin g br acket Tightening torque: N · m (kgf-m, ft-lb) (2) Front cushi on rubb er T1: 35 ( 3.6 , 25 .8) T2: 42 ( 4.3 , 30 .9) T3: 85 ( 8.7 , 62 .7) ME-00706 (3) T3 T1 (2) (1) (3) (2) T3 T1 T2 T2[...]

  • Page 26

    ME(H 4D OT C)-2 5 MECHA NIC AL General Descript ion C: CAUT ION • Wear working clot hing, includ ing a cap, protec- tive goggles, a nd protective shoes duri ng opera- tion. • Remove contaminati on includin g dirt and corro- sion before removal, in stallation or di sassembly. • Keep the disassemble d parts in order and pr o- tect them from dus[...]

  • Page 27

    ME(H 4D OT C)-2 6 MECH ANICAL General Descript ion D: PREPARATION T OOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498267600 CYLINDE R HEAD TABLE • Used for r epl acing valv e gu ides. • Used fo r removing a nd ins talling v alve sp rings. 498457000 ENGINE STAND ADAPTER RH Used with EN GINE STAND (49981700 0). 498457100 ENGIN[...]

  • Page 28

    ME(H 4D OT C)-2 7 MECHA NIC AL General Descript ion 398744300 PISTON GUID E Use d for insta lling pi ston i n cylinder fo r 2.0 L engine. 498857100 VALVE OIL SEAL GUIDE Used for pre ss-fit ting of in take and e xhaust v alve guide oil seal s. 499017100 PISTON PIN GUIDE Used for in stall ing pisto n pin, pis ton and c onnect- ing rod. 499037100 CONN[...]

  • Page 29

    ME(H 4D OT C)-2 8 MECH ANICAL General Descript ion 499097600 PISTON PIN REMOVER ASSY Used for re movi ng piston pin. (Exc ept for Aus tralia mode l) 499097700 PISTON PIN REMOVER ASSY Used for r emovi ng pi ston pin. (Aus tral ia mod el except f or STi mode l) 499207400 CAMSH AFT SPROCKET WRENCH Used for rem oving a nd instal ling exh aust cam- shaf[...]

  • Page 30

    ME(H 4D OT C)-2 9 MECHA NIC AL General Descript ion 499977500 CAMSH AFT SPROCKET WRENCH Used fo r removing a nd inst alling i ntake ca mshaf t sprocke t. (STi and Au strali a model) 499587200 CRANKSHAFT OIL SEAL INSTALLER • Used for i nst alli ng cr anks haft oil s eal . • Used with CRANKSHAFT OIL SEAL GUIDE (49959710 0). 499597100 CRANKSHAFT O[...]

  • Page 31

    ME(H 4D OT C)-3 0 MECH ANICAL General Descript ion 18251AA020 VALVE GUI DE ADJUSTER Used for in stall ing intak e and exh aust valve guides. 499767200 VALVE GUI DE REMOVER Used for rem oving v alve gui des. 499767400 VALVE GUI DE REAMER Used for r eam ing valv e guid es. 499817000 ENGINE STAND • Stand use d for en gine dis assembl y and as sem- b[...]

  • Page 32

    ME(H 4D OT C)-3 1 MECHA NIC AL General Descript ion 499977400 CRANKSHAFT PULLEY WRENCH Used for s toppin g rotation o f crank shaft pu lley when lo osening and tig htening c rankshaf t pulle y bolts. 499987500 CRANKSHAFT SOCKET Used for rot ating cran kshaft. 498547000 OIL FILTER WRENCH • Used for rem oving a nd instal ling oil filter. • For oi[...]

  • Page 33

    ME(H 4D OT C)-3 2 MECH ANICAL General Descript ion 499587100 OIL SEAL INSTALLER Used fo r install ing oil pu mp oi l seal. 499587600 OIL SEAL INSTALLER Used for in stalling camsha ft oil seal fo r DOHC engine. 499597200 OIL SEAL GUIDE Used for install ing camsha ft oil seal fo r DOHC engine. Used with OIL SEAL GUIDE (4 99587600 ). 498277200 STOPPER[...]

  • Page 34

    ME(H 4D OT C)-3 3 MECHA NIC AL General Descript ion 2. GENERAL PU RPOSE TOOLS E: PROCEDURE It is possib le to conduct the foll owing servic e procedures with engi ne on the vehicle , however, the proc edures described in thi s section are based on the conditi on that the engine is r emoved from the vehicle. • V-belt • Timing Belt • Camshaft ?[...]

  • Page 35

    ME(H 4D OT C)-3 4 MECH ANICAL Compression 2. Compression A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yo urself duri ng measure- ment. 1) After warmi ng-up the engine, turn t he ignition switch to OFF. 2) Make sure that the batter y is fully charged. 3) Release the fuel pressure. <Ref. to FU(H4DOTC)-53[...]

  • Page 36

    ME(H 4D OT C)-3 5 MECHA NIC AL Idle S peed 3. Idle Speed A: INSPECTION 1. USING SUBARU SELECT MONITOR 1) Before checkin g the idle speed, ch eck the fol - lowing: (1) Ensure the air cl eaner element is free from clogging , ignition ti ming is corr ect, spark plugs are in good condition, and that the hoses are connected properl y. (2) Ensure the mal[...]

  • Page 37

    ME(H 4D OT C)-3 6 MECH ANICAL Ignition Timing 4. Ignition Timing A: INSPECTION 1. USING SUBARU SELECT MONITOR 1) Before checki ng the igni tion timin g speed, c heck the followi ng: (1) Ensure the air cl eaner element is free from clogging , spark plugs are in g ood condi tion, and that hoses are connected pr operly. (2) Ensure the malfunct ion ind[...]

  • Page 38

    ME(H 4D OT C)-3 7 MECHA NIC AL Intake Manifold Vacuum 5. Intake Manifold Vacuum A: INSPECTION 1) Warm-up the engine. 2) Disconnect the brak e vacuum hose, and then install the vacuum gauge to hose fitting on manif old. 3) Keep the engine at the idle speed, and then read the vacuum gauge indicati on. By observing the gauge needle movement, the inter[...]

  • Page 39

    ME(H 4D OT C)-3 8 MECH ANICAL Engine Oil Pressure 6. Engine Oil Pressure A: INSPECTION 1) Remove the oil pressure swi tch from engine cyl- inder bloc k. <Ref . to LU(H4 DOTC)-18, REMOVAL, Oil Pre ssu re Switc h.> 2) Connect the oil pres sure gauge hose t o cylinder block. 3) Connect the battery ground cable to bat tery. 4) Start the engine, a[...]

  • Page 40

    ME(H 4D OT C)-3 9 MECHA NIC AL Fuel Pressure 7. Fuel Pressure A: INSPECTION CAUTION: Before removing the fuel pressur e gauge, re- lease the f uel pressure. NOTE: If out of specif ication, check or replace the press ure regulator and pressure regulator vacuum h ose. 1) Release the fuel pressure. <Ref. to FU(H4DOTC)-53, RELEASING OF FUEL PRES- SU[...]

  • Page 41

    ME(H 4D OT C)-4 0 MECH ANICAL Valve Clearance 8. Valve Clearance A: INSPECTION Inspection and adj ustment of the val ve clearance should be per formed while engin e is col d. 1) Set the vehicle on a lift . 2) Disconnect the grou nd cable from batt ery. 3) Remove the air intake duct. <Ref. to IN(H 4D OTC)- 8, RE MOVA L, Ai r Intak e Duct .> 4)[...]

  • Page 42

    ME(H 4D OT C)-4 1 MECHA NIC AL Valve Clearance (5) Move the washer tank upward. (6) Disconnect the ignition coi l connector. (7) Remove the igniti on coil. (8) Place a suitab le container under t he vehicle. (9) Disconnect t he PCV hose from r ocker cover (LH). (10)Remo ve the bolts, and then remove the rocker cover (LH). 11) Turn the cranks haft p[...]

  • Page 43

    ME(H 4D OT C)-4 2 MECH ANICAL Valve Clearance (3) Set the ar row mark on camshaft sprocket to position shown in the figure, and then measure the #1 cyli nder exhaust val ve and #4 cyli nder in- take valve cleara nces. 15) After inspe ction, inst all the relat ed parts in the reverse order of r emoval. Tightening t orque: 33 N · m (3 .4 kg f-m , 25[...]

  • Page 44

    ME(H 4D OT C)-4 3 MECHA NIC AL Valve Clearance 6) Inspect al l valve s for clearanc e again at this stage. If the valve clear ance is not c orrect, r epeat the procedu re over agai n from t he first step. 7) After inspe ction, inst all the relat ed parts in the reverse or der of r emoval. 13228 AB3 91 4.97 (0.195 7) 13228 AB4 01 4.98 (0.196 1) 1322[...]

  • Page 45

    ME(H 4D OT C)-4 4 MECH ANICAL Engin e Assemb ly 9. Engine Assem bly A: REM OVA L 1) Set the vehicle on a lift . 2) Open t he front hood full y, and t hen support with the hood stay. 3) Collect the refr igerant from A/C system. 4) Release the fuel pres sure. (1) Disconnect the fuel pump relay connector . (2) Start the engi ne, and run until stal ls.[...]

  • Page 46

    ME(H 4D OT C)-4 5 MECHA NIC AL Engin e Assemb ly (5) Accelera tor cabl e (MT model) (6) Clutc h release spring (MT mod el) 12) Disconnect the fo llowing hoses. (1) Brake booster vacuum hose (2) Heater inlet outlet hose 13) Remove the power steering pump from brac k- et. (1) Loosen the lock bolt and sli der bolt, and then remove the fr ont side V-be[...]

  • Page 47

    ME(H 4D OT C)-4 6 MECH ANICAL Engin e Assemb ly (6) Place the power steer ing pump on right side wheel apron. 14) Lift-up the vehic le. 15) Remove the ATF cooler pi pe from frame. (AT mod el) 16) Remove the center exhaust pi pe. <Ref. to EX(H4DOTC)-9, REMOVAL, Center Exhaust Pipe.> 17) Remove the nuts which hol d the lower s ide of transmissi[...]

  • Page 48

    ME(H 4D OT C)-4 7 MECHA NIC AL Engin e Assemb ly (4) Remove the other bolt s while rotating the engine using sock et wrench. 22) Remove the pitching stopper . 23) Disconnect th e fuel delive ry hose, retur n hose and evaporati on hose. NOTE: • Catch fuel from the hose into container. • Disconnect t he hose with it s end wrapped with cloth to pr[...]

  • Page 49

    ME(H 4D OT C)-4 8 MECH ANICAL Engin e Assemb ly (3) Remove the bolts which hold the ri ght upper side of t ransmiss ion to eng ine. 28) Remove the engine from vehicle. (1) Slightl y raise the engine. (2) Raise the transmi ssion with garage j ack. (3) Move the engine horizontally unt il the main- shaft is withdr awn from clutch cover. (4) Slowly mov[...]

  • Page 50

    ME(H 4D OT C)-4 9 MECHA NIC AL Engin e Assemb ly CAUTION: Make sure the cutout portion of rel ease fork shaft contact s spring pi n. (6) Tighten t he plug. Tightening t orque: 44 N · m (4 .5 kg f-m , 32 .5 f t-lb ) 2) Instal l the fr ont cushion rubbers to engine. Tightening t orque: 35 N · m (3 .6 kg f-m , 25 .8 f t-lb ) 3) Instal l the e ngine [...]

  • Page 51

    ME(H 4D OT C)-5 0 MECH ANICAL Engin e Assemb ly (2) Tighten ot her bolts whi le rotating the engine by using ST. CAUTION: Be careful not to drop bolt s into the torque con- verter clutch housin g. ST 499977300 CRANKSHAFT PULLEY WRENCH Tightening t orque: 25 N · m (2 .5 kg f-m , 18 .1 f t-lb ) (3) Clog the servic e hole with plug. 11) Install the f[...]

  • Page 52

    ME(H 4D OT C)-5 1 MECHA NIC AL Engin e Assemb ly Tightening t orque: 50 N · m (5 .1 kg f-m , 36 .9 f t-lb ) 15) Ti ghten the nut s which install the fr ont cushion rubber onto crossmember . Tightening t orque: 85 N · m (8 .7 kg f-m , 62 .7 f t-lb ) NOTE: Make sure the fr ont cushion r ubber mounting bolts (A) and locator (B) are securely inst all[...]

  • Page 53

    ME(H 4D OT C)-5 2 MECH ANICAL Engine Mounting 10. Engine Mount ing A: REM OVA L 1) Remove the engine assembly. <Ref. to ME(H4DOTC)-44, REMOVAL, Engine Assembly.> 2) Remove the engine mounting fr om engine as- sembly. B: INST ALLA TIO N Install in the reverse order of r emoval. Tightening t orque: Engine mounting; 35 N · m (3. 6 kgf- m, 25.8 [...]

  • Page 54

    ME(H 4D OT C)-5 3 MECHA NIC AL Preparation for O verhaul 11. Preparation for Overhaul A: PROCEDURE 1) After removi ng the engin e from body , secure i t in the ST shown b elow. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817000 ENGINE STAND 2) In this sect ion the procedure s described under each index are al [...]

  • Page 55

    ME(H 4D OT C)-5 4 MECH ANICAL V-belt 12. V-belt A: REM OVA L 1. FRONT SIDE BELT 1) Remove the V-belt cov er. 2) Loosen t he lock bol t (A). 3) Loosen t he slider bolt (B). 4) Remove the front side belt (C) . 2. REAR SIDE BELT 1) Loosen t he lock nut (A). 2) Loosen t he slider bolt (B). 3) Remove the A/C belt. 4) Remove th e A/C belt tensioner. B: I[...]

  • Page 56

    ME(H 4D OT C)-5 5 MECHA NIC AL V-belt 3) Tighten the lock nut (A). Tightening t orque: Lock nut ( A): 22.6 N · m (2.3 kgf-m, 16.6 ft-lb) C: INSPECTION 1) Replace the belt s, if cracks, fr aying or wear is found. 2) Check the V-belt t ension and a djust it if nece s- sary by changing the generator inst alling posi tion and idler pulley inst alling [...]