Subaru SVX (1992) manual

ENGINE SUBARU SVX 1992 2-3 Page M MECHANISM AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 . Timing Belt . . . . . . . . . . . . . . . . .[...]

2-3 JIV11001 ENGINE M MECHANISM AND FUNCTION 1 . General The Subaru 3300cc, 6-cylinders engine is made from aluminum alloy and is horizontally opposed . It is a 4-stroke cycle, water-cooled, DOW 24-valve engine . The fuel system utilizes an MPFI (multiple fuel injection) design . A summary of the major construction and function features is given be[...]

ENGINE [nn2ool 2-3 2 . Timing Belt A single timing belt drives two exhaust camshafts (one in the left bank and one in the right bank) . The back of the belt also drives the water pump . The timing belt teeth have a specially designed round profile to provide quiet operation . The timing belt is composed of a strong and inflexible core wire, a wear-[...]

2-3 [M3001 ENGINE 3 . Belt Tension Adjuster The belt tension adjuster provides a constant value of tension for the timing belt . Proper belt tension is main- tained using a rod to push the tension pulley . The location of the tensioner pulley shaft center is offset in relation to the center of the pulley's outside diameter . The tensioner adju[...]

ENGINE [M500] 2-3 4 . Belt Cover The belt cover is made of synthetic resin molding which is lightweight and heat resistant . It has a totally enclosed design that utilizes rubber packing at the mating surface of the cylinder block . This eliminates the chance of dust and water from entering the interior . A floating design is utilized by placing ru[...]

2-3 [M600] ENGINE 6 . Hydraulic Lash Adjuster The hydraulic lash adjuster is located between the camshaft and valve stem . The top surface of the hydrau- lic lash adjuster is always in contact with the cam face . The cam directly pushes the lash adjuster to open or close the valve . The engine oil flows through the cylinder head and goes into the l[...]

ENGINE [Wool 2-3 7 . Cylinder Head Combustion chambers in the cylinder head are com- pact, center plug, pentroof types which feature a wide "squish" area for increased combustion efficiency . Four valves (two intake and two exhaust), which are arranged in a cross-flow design, are used per cylinder . The cylinder head gasket is made from c[...]

2-3 [M8001 ENGINE 8 . Cylinder Block The cylinder block is made from aluminum diecast . The cylinder perimeter has an open-deck design which is lightweight, highly rigid and has superb cooling effi- ciency . The cylinder liners are made from cast iron and are dry types which are totally cast with aluminum cylinder block . Seven main journal block d[...]

ENGINE [nn1ooo1 2-3 9 . Crankshaft The crankshaft is supported by seven bearings to pro- vide high rigidity and strength . The corners of the crankshaft journals and webs, as well as the crank pins and webs, are finished with fillet-roll work to increase strength . The seven crankshaft bearings are made from aluminum alloy and the No . 5 bearing is[...]

2-3 [SOA01 ENGINE S SPECIFICATIONS AND SERVICE DATA f A : SPECIFICATIONS Type Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine Valve arrangement Belt driven, double over-head camshaft, 4-valve/cylinder Bore x Stroke mm (in) 96 .9 x 75 (3 .815 x 2 .95) Piston displacement cm3 (cu in) 3,318 (202 .46) Compression ratio 10 .0 C[...]

ENGINE [SOSO] 2-3 ~B : SERVICE DATA Unit : mm (in) Belt tension adjuster Adjuster rod protrusion 15 .4 - 16 .4 (0 .606 - 0 .646) Spacer O .D . 16 (0 .63) Tensioner bush I .D . 16 .16 (0 .6362) STD 0 . 117 - 0 .180 (0 .0046 - 0 .0071) Belt tensioner Clearance between spacer and bush Limit 0 .230 (0 .0091) STD 0 .37 - 0 .54 (0 .0146 - 0 .0213) Side c[...]

2-3 [SOBO1 ENGINE Unit : mm (in) STD 0 .030 - 0 .057 (0 .0012 - 0 .0022) S il l Intake Limit 0 .10 (0 .0039) V l tem o c earance E h STD 0 .040 - 0 .067 (0 .0016 - 0 .0026) ve a x aust Limit 0 .10 - (0 .0039) O ll l th Intake 90 .00 (3 .5433) vera eng Exhaust 90 .85 (3 .5768) F l h Outer spring 36 .4 (1 .433) ree engt Inner spring 34 .9 (1 .374) S [...]

ENGINE ISOBOI 2-3 Unit : mm (in) Standard clearance between piston pin and hole in piston 0 .004 - 0 .008 (0 .0002 - 0 .0003) Piston pin Degree of fit Piston pin must be fitted into position with thumb at 20°C (68°F) . STD 0 .20 - 0 .30 (0 .0079 - 0 .0118) Top ring Limit 0 .5 (0 .020) Second LTD 0 .37 - 0 .52 (0 .0146 - 0 .0205) Piston ring gap r[...]

2-3 [SOB01 ENGINE Unit : mm (in) STD 0 .030 - 0 .115 (0 .0012 - 0 .0045) Thrust clearance Limit 0 .25 (0 .0098) #1, #3, #7 0 .005 - 0 .035 (0 .0002 - 0 .0014) Crankshaft STD #2, #4, #6 0 .013 - 0 .038 (0 .0005 - 0 .0015) Oil clearance #5 0 .013 - 0 .034 (0 .0005 - 0 .0013) #1, #2, #6, #7 0 .045 (0 .0018) Limit #3, #4, #5 0 .040 (0 .0016) STD 1 .998[...]

ENGINE [Clool 2-3 C COMPONENT PARTS 1 . Timing Belt Crank shaft sprocket Right-hand belt cover No . 2 Left-hand belt cover No . 2 Right-hand camshaft sprocket Belt idler Belt tensioner bracket Belt tensioner Belt idler No . 2 Belt tension adjuster Left-hand camshaft sprocket Timing belt Right-hand belt cover Front belt cover Left-hand belt cover Cr[...]

2-3 [C200] ENGINE 2 . Cylinder Head and Camshaft Tightening torque : N .m (kg-m, ft-Ib) T1 : Refer to [W4E1 ] . T2 :9 .1-10 .5(0 .93-1 .07,6 .7-7 .7) T3 :4 .4-5 .4(0 .45-0 .55,3 .3-4 .0) T3 T~ i t i i i T2 -~ ' 1 Cylinder head cover (RH) 2 Cylinder head cover gasket (R H) 3 Intake camshaft cap 4 Exhaust camshaft cap 5 Front camshaft cap (R H[...]

ENGINE (C3001 2-3 3 . Cylinder Head and Valve ASSY " p , , 1 Exhaust valve 2 Intake valve 3 Valve spring seat 4 Intake valve oil seal 5 Inner valve spring 6 Outer valve spring 7 Retainer 8 Retainer key 9 Hydraulic lash adjuster 10 Exhaust valve oil seal C2-195 Fig . 12 17[...]

2-3 [C4001 ENGINE 4 . Cylinder Block Fig . 13 1 Water pipe 2 Oil pressure switch "' Cylinder block (RH) Service hole plug Gasket Oil separator cover Oil pump Front oil seal ear oil seal -ring Service hole cover Cylinder block (LH) 13 Water pump uffle plate Oil strainer Gasket Oil pan Oil drain plug Gasket Oil level gauge guide Oil level g[...]

ENGINE [C5001 2-3 5 . Crankshaft and Piston T1 2 e 0 ® e 00 Fig . 14 1 Drive plate 2 Reinforcement 3 Top ring 4 Second ring 5 Oil ring 6 Piston 7 Piston pin 8 Circlip 9 Connecting rod bolt 10 Connecting rod 11 Connecting rod bearing 12 Connecting rod cap 13 Crank shaft 14 Woodruff key 15 Crank shaft bearing #1, #3, #7 16 Crank shaft bearing #2, #4[...]

2-3 [w100) ENGINE W SERVICE PROCEDURE 1 . General Precautions 1) Before disassembling engine, install on ENGINE STAND . rig . 10 2) Since the engine is very heavy, be sure to use more than four persons when lifting the engine . Never hold ENGINE STAND REINFORCEMENT when lifting the engine . 3) All parts should be thoroughly cleaned, paying spe- cia[...]

ENGINE [w2A2] 2-3 2 . Timing Belt A : REMOVAL 1 . RELATED PARTS 1) Remove V-belts . (Refer to 1-5 Drive Belts [01B1] .) 2) Remove power steering pump . 3) Remove alternator and V-belt cover bracket . 2 . CRANKSHAFT PULLEY AND BELT COVER 4) Remove power steering pump bracket . 5) Remove A/C belt tensioner bracket . 6) Remove A/C compressor . 7) Remo[...]

2-3 [W2A3] ENGINE 3 . TIMING BELT O - ;,, ;,/ ice .~ r( C ~ - . r ~i . , , ~ ~" C ~ > e r o o C2-202 Fig . 19 1) If alignment mark and/or arrow mark (which indi- cates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows : (1) Turn crankshaft, and align alignment marks on crankshaft s[...]

ENGINE [w2A4] 2-3 (2) Using white paint, put alignment and/or arrow 2) marks on timing belts in relation to the sprockets . 3) 4) 5) Fig . 2 7 4 . BELT TENSIONER AND IDLER Loosen tensioner adjuster mounting bolts . Remove belt idler . Remove belt idler No . 2 Remove timing belt . J 10 0 0 0 c2_208 Fig . 22 1) Remove belt idlers . 2) Remove belt ten[...]

2-3 [W2A5] ENGINE 3) Remove belt tension adjuster . 5 . SPROCKET OO © ~~f'I / ~k / U t~ J 0 ~ ( t C2-2o9 Fig . 23 1) Remove left-hand camshaft sprocket . If unable to remove crankshaft sprocket, tap two holes in crankshaft sprocket, and remove using PULLER and BOLT . But this PULLER has no holes to fit crank shaft sprocket holes . Therefore[...]

ENGINE [W2B4] 2-3 Cut thread using tap . ®O D i PULLER (89952 1421) M8 bolt Crankshaft sprocket Crankshaft BOLT (49952 5500) -- C2-211 Fig . 25 4) Remove left-hand belt cover No . 2 . 5) Remove right-hand belt cover No . 2 . 6) Remove tensioner bracket . B : INSPECTION 1 . TIMING BELT 1) Check timing belt teeth for breaks, cracks, and wear . If an[...]

2-3 [W2C1] ENGINE C : INSTALLATION 1 . SPROCKET T 4 .4 - 5 .4 (0 .45-0 .55, 3 .3 - 4 .0) ~I 05 /~ it 1'~L ~ ~kT o T 23 - 26 ® (2 .3-2 .7, 17-20) ~, 3O T 4 .4 - 5 .4 (0 .45 - 0 .55, 3 .3 - 4 .0) T : N-m (kg-m, ft-Ib) T 108 - 127 (11 - 13,80 - 94) C2-213 Fig . 28 1) Install tensioner bracket . 2) Install right-hand belt cover No . 2 . 3) Inst[...]

ENGINE 2 . BELT TENSIONER AND IDLER o T 35-43 "' (3 .6-4 .4,26-32) 11 T 35-43 O (3 .6-4 .4,26-32) O T 23-26(2 .3-2 .7,17-20) T 35- 43 O (3 .6-4 .4,26-32) [w2C2] 2-3 T : N -m (kg-m, ft-Ib) C2-214 Fig . 29 1) Installation of belt tension adjuster . (1) Insert stopper pin 1 .5 mm (0 .059 in) dia . into place while pushing tension adjuster ro[...]

2-3 IW2C3I ENGINE 3 . TIMING BELT /- T 35-43 V T N-m (kg-m, ft-Ib) (3 .6-4 .4,26-32) C2-217 Fig . 32 1) Installation of timing belt (1) Using SPROCKET WRENCH, turn sprockets and align their alignment marks with marks of belt covers and oil oumn . 28[...]

ENGINE IW2C3I 2-3 (2) While aligning alignment mark on timing belt with Ensure belts rotating direction is correct . marks on sprockets, position timing belt properly . 53 tooth length 53 tooth length ~ ),~c/ © OO Alignment mark Alignment mark Alignment mark - _ .o ICI C C2-223 Fig . 34 2) Install belt idler No . 2 . 5) After ensuring tha[...]

2-3 [W2C4] ENGINE 4 . CRANKSHAFT PULLEY AND BELT COVER 1 i ~h I OO ~ I I° T 147 - 167 (15-17,108-123) / T 4 .4 - 5 .4 T : N-m (kg-m, ft-Ib) , (0 .45 - 0 .55, 3 .3-4 .0) C2-226 Fig . 37 1) Install front belt cover . 2) Install right-hand belt cover . 3) Install left-hand belt cover . 4) Install crankshaft pulley . 5) Install pulley bolt . To lock [...]

ENGINE [w3A2I 2-3 3 . Camshaft A : REMOVAL 1 . RELATED PARTS 1) Remove timing belt, camshaft sprockets and related parts (Refer to Timing Belt [MAO] .) 2) Disconnect cam angle sensor connector . 3) Disconnect ignition coil connectors . 2 . CAMSHAFTS LH ~~7 '1 C~`h c2-227 Fig . 38 1) Remove cam angle sensor with bracket . 2) Remove ignition coi[...]

2-3 [W3A2] ENGINE (1) Rotate the intake camshaft (upper) and exhaust camshaft (lower) so that the notch at the front end of each camshaft faces directly downward, by applying a wrench to the hexagonal portion of the camshafts . O O v l~ ® o O 0 v Face the notch downward . /- ( - ®I 0 C2-22s Fig . 39 (2) See the rear side of the camshaft gears, an[...]

ENGINE When removing camshafts, make certain that the tor- sional spring force of the sub-gear has been eliminated by the above operation . (4) Loosen six bolts on three intake camshaft caps equally, a little at a time, in the numerical sequence as illustrated . v o c~ uou e~ ~ I 0 ~~ C2-231 Fig . 42 Make sure that, as the bolts are loosened, the c[...]

2-3 [W3A3) ENGINE 7) Remove hydraulic lash adjusters . Arrange the hydraulic lash adjusters in order so that they can be installed in their original positions . C2-235 Fig . 46 3 . CAMSHAFTS RH Operation precautions are the same as those for the LH camshafts, except the method for aligning the cam- shaft gear match marks before removing camshafts .[...]

ENGINE [W3A3] 2-3 (2) Seethe rear side of the camshaft gears, and make sure that the match marks of the intake camshaft gear (driven gear) and exhaust camshaft gear (drive gear) are aligned . 0 C o Math I mark -v C J % ~` Match ' mark I C2-237 Fig . 48 (3) Install a service bolt to the sub-gear mounting bolt hole of the intake camshaft gear to[...]

2-3 [W3B1I ENGINE B : DISASSEMBLY 1 . INTAKE CAMSHAFT Fig . 51 1) Removal of snap ring (1) Secure the shaft portion of the camshaft in a vice using a rag . a . Never attempt to hold the cam lobe or journal in the vice . b . Pay attention not to damage the cam lobe and journal . Fig . 53 (3) Remove snap ring using CAMSHAFT GEAR PLI- ERS . Fig . 52 ([...]

ENGINE [W3C1] 2-3 2) Remove wave washer . 3) Remove camshaft sub-gear . 4) Remove camshaft gear spring . , Arrange the camshaft sub-gears and gear springs . C : INSPECTION 1 . CAMSHAFT 1) Visually check the camshafts for scratches flaking and wear . 2) Measurement of the camshaft bend . (1) Place the camshaft on V-blocks at the No . 2 and No .4 jou[...]

2-3 [W3C2] ENGINE Standard camshaft thrust clearance : Intake :0 .03 - 0 .09 mm (0 .0012 - 0 .0035 in) Wear limit 0 .13 mm (0 .0051 in) Exhaust :0 .02 - 0 .08 mm (0 .0008 - 0 .0031 in) Wear limit 0 .12 mm (0 .0047 in) (3) If the thrust clearance exceeds the limit, replace the camshaft caps and cylinder head as a set . If necessary, replace the cams[...]

ENGINE [W3D11 2-3 D : ASSEMBLY 1 . INTAKE CAMSHAFTS Fig . 61 1) Install camshaft gear spring . 2) Install camshaft sub-gear . 3) Install wave washer . 4) Install snap ring using CAMSHAFT GEAR PLIERS . r-1g . Uz 5) Installation of service bolt (1) Secure the shaft portion of the camshaft in a vice using a rag . a . Never attempt to hold the cam lobe[...]

2-3 [W3E1I ENGINE [ E : INSTALLATION 1 . CAMSHAFTS LH n y1 c-it T 9 .1 - 10 .5 (0 .93-1 .07,6 .7-7 .7) O ~_//-T T 9 .1 - 10 .5 (0 .93 - 1 .07, 6 .7 - 7 .7) 4 .4 - 5 .4 (0 .45 - 0 .55, 3 .3 -4 .0) T : N-m (kg-m, ft-Ib) C2-251 Fig . 65 Since the camshaft thrust clearance is small, the cam- shaft must be installed by holding it parallel to the cylinde[...]

ENGINE [w3E1] 2-3 Fig . 67 (5) Tighten each bolt to the specified torque in the sequence explained in step (4) . 2) Installation of intake camshaft Each intake and exhaust camshaft gear has match marks at two places . Accordingly, if the match marks are incorrectly aligned, the cam timing will be mis- aligned by 180° between the intake side and ex[...]

2-3 [W3E1] ENGINE Match C / mark I C , v C Match mark `1' i C2-229 Fig . 69 (5) Tighten six bolts of three intake camshaft caps equally, a little at a time, in the numerical sequence as illustrated . Fig . 70 Make sure that, as the bolts are tightened, the clear- ance between the camshaft journal and the cylinder head journal decreases even[...]

ENGINE [w3E2] 2-3 Fluid packing C2-257 Fig . 73 Fig . 76 (2) Install front camshaft cover . (3) Install cylinder head cover and gasket . 4) Apply a coat of grease to oil seal lips and install oil (4) Connect blow-by hose . seal . 7) Install ignition coils . Use a new oil seal . 8) Install cam angle sensor . Fig . 74 5) Install camshaft plug . c o ~[...]

2-3 [W3E2] ENGINE Make sure that, as the bolts are tightened, the clear- ance between the camshaft journal and the cylinder head journal decreases evenly at three places . If not, loosen the bolts by reversing the illustrated numerical sequence, and then repeat step (4) above . (5) Tighten each bolt to the specified torque in the sequence explained[...]

ENGINE [W4A1] 2-3 C Match I mark C Match ' mark C2-237 Fig . 79 (5) Tighten six bolts of three intake camshaft caps equally, a little at a time, in the numerical sequence as illustrated . Fig . 80 Make sure that, as the bolts are tightened, the clear- ance between the camshaft journal and the cylinder head journal bearing decreases evenly at t[...]

2-3 [w4A1] ENGINE 46 Fig . 82 9) Remove exhaust manifold and gasket . 10) Remove cylinder head covers, camshafts and re- lated parts . (Refer to 3 Camshafts [W3A0] .j[...]

ENGINE [W4A21 2-3 2 . CYLINDER HEAD C2-263 Fig . 83 1) Remove oil level gauge guide . 2) Remove heater pipe . 3) Remove cylinder head bolts in numerical sequence shown in Figure . Leave bolts 5@ or ® engaged by three or four threads to prevent cylinder head from falling . 4) While tapping cylinder head with a plastic hammer, separate it from cylin[...]

2-3 [w4BO] ENGINE B : DISASSEMBLY ,~ ~-rlnl 6~RN~ C2-2s5 Fig . 85 1) Remove hydraulic lash adjusters . a . Mark each valve to prevent confusion . Arrange the hydraulic lash adjusters in order so that b . Use extreme care not to damage the lips of the they can be installed in their original positions . intake valve oil seals and exhaust valve oil se[...]

ENGINE [W4C3] 2-3 C : 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 . tive or when valve guides are replaced . W : Intake Standard 1 .0 mm (0 .039 in) Limit 1 .7 mm (0 .067 in) 2) Measure the warping of the cylinder head surface Exhaus[...]

2-3 [W4C3] ENGINE (2) Insert VALVE GUIDE REMOVER into valve guide and press it down to remove valve guide . VALVE GUIDE REMOVER (49976 7200) Fig . 90 (3) Turn cylinder head upside down and place VALVE GUIDE ADJUSTER as shown in the figure . VALVE GUIDE ADJUSTER (79976 7600) CYLINDER HEAD TABLE (49826 7500) C2-273 Fig . 92 (6) Check the valve guide [...]

ENGINE Iw4C5l 2-3 VALVE GUIDE REAMER (49976 7400) C2-274 Fig . 93 (8) Coat the face of the valve with talcum powder, and lightly rotate the valve against the seat to inspect for proper valve seating . 4 . INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "H" is less than the[...]

2-3 Iw4C6] ENGINE Outer spring Inner spring Free length 36 .4 mm (1 .433 in) 34 .9 mm (1 .374 in) 124 .5-142 .2N (12 .7- 58 .8-66 .7N(6- 14 .5 kg, 28 .0 - 32 .0 6 .8 kg, 13 .2 - 15 .6Nor- Tension/ Ib)/29 mm (1 .14 in) mal Control Ib)/ spring 27 .5 mm (1 .083 in) height 308 .9 - 356 .0 N (31 .5 - 147 .1 - 168 .7 N (15 - 36 .3 kg, 69 .5 - 80 .0 lb)/ [...]

ENGINE IW4Do] 2-3 4) Subtract the hydraulic lash adjuster diameter from the hydraulic lash adjuster bush inner diameter mea- surement . The oil clearance can be calculated . If the oil clearance exceeds the limit, replace cylinder head . Standard oil clearance : 0 .028 - 0 .078 mm (0 .0011 - 0 .0031 in) Limit : 0 .110 mm (0 .0043 in) ~ D : ASSEMBLY[...]

2-3 IW4E1] ENGINE f E : INSTALLATION 1 . CYLINDER HEAD T 14 .2 - 17 .2 (1 .45-1 .75,10 .5-12 .7) /~ T 14 .2 - 17 .2 ® I 3 s~ (1 .45-1 .75,10 .5-12 .7) v I " U J 11 J ~ 7 L ~G ~~ I ' ~ 'I ( ~ n fl - V Mark (S) O Mark (L T : N-m (kg-m, ft-1b) ~ Mark (L) Mark (S) C2-280 Fig . 102 1) Install cylinder head and gaskets on cylinder blo[...]

ENGINE [W4E21 2-3 2 . INTAKE MANIFOLD Use dry compressed air to remove foreign particles before installing sensors . 1) Install camshafts, cylinder head covers and related pa rts . (Refer to 3 Camshafts [W3E0] .) 2? Install exhaust manifold and gasket . 3) Install collector and intake manifold ASSY and gas- kets . T 23 - 26 N-m Collector and intake[...]

2-3 [W5A1) ENGINE 5 . Cylinder Block A : REMOVAL 1 . RELATED PARTS 1) Remove timing belt, camshaft sprockets and related parts . (Refer to 2 Timing belt [MAO] .) 2) Remove cylinder head covers and camshafts and related parts . (Refer to 3 Camshafts CW3A0] .) 3) Remove intake manifold, cylinder head and related parts . (Refer to 4 Cylinder head CW4A[...]

ENGINE 1) Remove drive plate . To lock crankshaft, use CRANKSHAFT STOPPER CJ o o s o ' sc ® . o D CRANKSHAFT STOPPER (49849 7200) C2-284 Fig . 106 2) Remove oil separator cover . 3) Remove water by-pass pipe . 4) Remove water pipe . 5) Remove water pump and gasket . 6) Remove oil pump from cylinder block . Use a stan- dard screwdriver as sh[...]

2-3 [W5B1/ ENGINE B : DISASSEMBLY 1 . PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT 2 O C2-287 Fig . 109 1) Remove service hole cover and service hole plugs using hexagon wrench (14 mm) . 2) Rotate crankshaft to bring # 1 and #2 pistons to BDC position, then remove piston circlip through service hole of #1 and #2 cvlinders . .ly . ~ n r, ~f C I l I[...]

ENGINE Iw5B1) 2-3 4) Rotate crankshaft to bring #3 and #4 piston to BDC position, then remove piston circlip through service hole of #1 and #2 cylinders with PISTON CIRCLIP PLIERS . Fig . 112 5) Draw out piston pin from #3 and #4 pistons through service hole of #1 and #2 cylinders . 6) Rotate crankshaft to bring #5 and #6 pistons BDC position, then[...]

2-3 [W5B2] ENGINE 2 . CYLINDER BLOCK J 2 o o a I 4 l a . . ~ I o I I I I ' /,, ~r 2 ~~ l~a . 5,~~`~ll" .r I J I C2-291 Fig . 113 1) Set up cylinder block so that #2, #4 and #6 cylin- ders are on the upper side, then remove cylinder block connecting bolts . Be sure to remove small connecting bolt in the crank- case . Fig . 114 2) Se[...]

ENGINE [W5C21 2-3 3 . CRANKSHAFT AND PISTON C2-293 Fig . 115 1 ) Remove connecting rod cap . 2) Remove connecting rod bearing . Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion . 3) Remove the piston rings using the piston ring ex- pander . 4) Remove the oil ring by hand . Arrange the removed piston rings[...]

2-3 [W5C2] ENGINE (3) Proper combination of pistons and cylinders Cylinder Piston Piston clearance Bore size symbol Cylinder bore dia . Piston grade symbol Standard piston dia . 20°C (68° F) 96 .905 - 96 .915 mm A 96 .885 - 96 .895 mm (3 .8151 - 3 .8155 in) (3 .8144 - 3 .8148 in) B 96 .895 -96 .905 mm B 96 .875 - 96 .885 mm 0 .01 - 0 .03 mm (3 .8[...]

ENGINE [W5C4] 2-3 (3) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase . Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise . Thus, pay attention to this when measuring the cylin- der diameter . Limit of cylinder enlarging (boring) : 0 .3 mm (0 .[...]

2-3 [w5C5] ENGINE 3) Measure the clearance between piston ring and piston ring groove with a thickness gauge . Before measuring the clearance, clean the piston ring groove and piston ring . Unit :mm (in) Standard Limit 0 .04-0 .09 Clearance be- Top ring (0 .0016 - 0 .15 (0 .0059) tween piston 0 .003 5) ring and piston 0 .03-0 .07 ring groove Second[...]

ENGINE [W5C61 2-3 4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc . 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge . If any oil clear- ance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary, necessary . (Se[...]

2-3 (w5C6] ENGINE Unit : mm (in) Crank journal Crank pin O .D . #1, #3, #7 #2, #4, #6 #5 Journal O .D . 59 .992 - 60 .008 f 51 .984 - 52 .000 S d d 2 .3619 - 2 .3625 2 .0466 - 2 .0472 tan ar Bearing size 1 .998 - 2 .011 2 .000 - 2 .013 2 .000 - 2 .013 1 .492 - 1 .510 Thickness at center 0 .0787 - 0 .0792 0 .0787 - 0 .0793 0 .0787 - 0 .0793 0 .0587 [...]

ENGINE [W5D1] 2-3 D : ASSEMBLY 1 . CRANKSHAFT AND PISTON O T 43 - 46 (4 .4 - 4 .7, 32 - :734 ® I / ~- T : N-m (kg-m, ft-1b) Side mark O C2-300 Fig . 129 1) Install connecting rod bearings on connecting rods and connecting rod caps . 2) Install connecting rod on crankshaft . a . Apply oil to the surfaces of the connecting rod bearings . b . Positio[...]

2-3 [W5D2] ENGINE 2 . CYLINDER BLOCK J r S o 0 O "' ~T6 - 7 N-m ( tC l . 0 .6 - 0 .7 kg-m, r 4 .3 - 5 .1 ft-Ib) - J 2 ` q c Fs 411 ` 3 v -( _ ~ ~-- r  , I ~?I ~l 1 =/ C2-302 Fig . 132 1) Install ENGINE STAND to cylinder block, then install crankshaft bearings . Remove oil the mating surface of bearing and cylinder block before in[...]

ENGINE [ W5D3] 2-3 3 . CYLINDER BLOCK CONNECTING BOLT T 23 - 26N-m (2 .3 - 2 .7 kg-m, 17 - 20 ft-Ib) C2-304 Fig . 135 1) Turn cylinder block so that it is horizontal . 2) To confirm tightening torque on the #2, #4 and #6 Tighten cylinder block connecting bolts to 15 N " m (1 .5 cylinder block side connecting bolts re-tighten connect- kg-m, 11 [...]

2-3 [w5D4] ENGINE 4) Re-tighten connecting bolts by 90°- 110° on the #1, #3 and #5 cylinder block side in the numerical se- quence shown in figure . 5) Tighten other cylinder block connecting bolts to specified torque . 6) Install rear oil seal . Flywheel attaching bolt ' Re a oil seal OIL SEAL INSTALLE t S ~~ (499587200)/ o o OIL SEAL GU[...]

ENGINE [W5D4] 2-3 1) Installing piston . (1) Turn cylinder block so that #1 and #2 cylinders face upward . (2) Turn crankshaft so that #3 and #4 connecting rods are set at bottom dead center . (3) Apply a coat of engine oil to pistons and cylinders and insert #3 and #4 pistons in their cylinders . CRANKSHAFT SOCKET (49998 7500) PISTON GUIDE (49874 [...]

2-3 [W5D5] ENGINE 5 . PISTON AND PISTON PIN (#1 and #2) T 62 - 76 N-m (6 .3 - 7 .7 kg-m, 46 - 56 ft-Ib) 4 O 0 O ~ U ~ ~ I" I I C2-310 Fig . 143 1 ) Installing piston (1) Turn cylinder block so that #1 and #2 cylinders face upward . (2) Turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center . (3) Apply a coat of engine[...]

ENGINE [w5D61 2-3 6 . PISTON AND PISTON PIN (#5 and #6) T 62-76 (6 .3-7 .7,46-56) 4 e T 6-7 (0 .6-0 .7,4 .3-5 .1) ° 4 ~ '41 " 1 0-1 T : N .m (kg-m, ft-Ib) C2-312 Fig . 146 Turn cylinder block so that #5 and #6 cylinders face upward . Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins . 73[...]

2-3 IW5E1I ENGINE E : INSTALLATION 1 . OIL PUMP AND WATER PUMP T 6-7 (0 .6-0 .7, 4 .3 -5 .1), S'* © r, (('' QQ ,0 -~ ,lll ! F, 4 T 10 - 14 - (1 .0-1 .4,7-10) T 12-16 O (1 .2-1 .6,9-12) T 9-11 (0 .9-1 .1, 6 .5-an) ~T 6-7(0 .6-0 .7,4 .3-5 .1) T 69 - 75 (7 .0-7 .6,51-55) ) o ~ o ooh o o T 6-7 (0 .6 - 0 .7, 4 .3 - 5 .1) T 4 .4 - 5 .4 (0[...]

ENGINE [W5E2] 2- 3 (2) Apply fluid packing to matching surface of oil pump . t -1g . 7 4d 4) Apply fluid packing to matching surfaces and install oil separator cover . Fluid packing : Three-bond 1215B or equivalent U o Fluid packing 0 U o O 0 B2-037 Fig . 149 5) Install drive plate . 6) Installation of oil pump . (1) Discard front oil seal after re[...]

2-3 [T100] ENGINE T TROUBLESHOOTING 1 . Engine Trouble in General Symbols shown in the chart refer to No . TROUBLE the possibility of reason for the trouble in order ("Ver often" to "Rare l ") 1 Starter does not turn . -- O- Very often y y 2 Engine will Initial combustion does not occur . 0- Sometimes D R l 3 not start . Initial[...]

ENGINE ITioo] 2-3 TROUBLE No . POSSIBLE CAUSE 1 2 3 4 5 6 7 8 9 10 11 12 13 INTAKE SYSTEM 0 0 O 0 0 O 0 0 O 0 Improper idle adjustment . 0 O O O L O * Loosened or cracked intake boot . 0 O O O L O e Loosened or cracked intake duct . O O O L O 0 e Loosened or cracked blow-by hose . O 0 O O 0 O 0 Loosened or cracked vacuum hose . 0 0 O O 0 Defective [...]

2-3 [Tioo1 ENGINE TROUBLE No . E CAUSE 1 2 3 4 5 6 7 8 9 10 11 12 13 POSSIBL LUBRICATION SYSTEM 0 0 9 Incorrect oil pressure . 0 0 Loosened oil pump attaching bolts and defective gasket . 0 0 Defective oil filter seal . 0 0 Defective crankshaft oil seal . d 0 0 Defective rocker cover gasket . 0 0 Loosened oil drain plug or defective gasket . 0 * Lo[...]

ENGINE [T200) 2-3 2 . Engine Noise Valve lash adjusters may make clicking noise once engine starts . It is normal if clicking noise ceases after a few minutes . If clicking noise continues after a few minutes, check engine oil level and add oil if necessary . Warm up engine for five minutes, then drive it at approximately 3,000 rpm for twenty minut[...]