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Subaru 2001 IMPREZA Service Manual

Subaru 2001 impreza
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2001 IMPREZA SERVICE MANUAL
ENGINE 1 SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
LUBRICATION
SPEED CONTROL SYSTEMS
IGNITION
STARTING/CHARGING SYSTEMS
ENGINE (DIAGNOSTICS)
FU(SOHC)
EC(SOHC)
IN(SOHC)
ME(SOHC)
EX(SOHC)
CO
LU
SP
IG(SOHC)
SC
EN(SOHC)
G1830GE2

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  • Page 1 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 1 SECTION FUEL INJECTION (FUEL SYSTEMS) FU(SOHC) EMISSION CONTROL EC(SOHC) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(SOHC) MECHANICAL ME(SOHC) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(SOHC)

  • Page 2: Table Of Contents

    MECHANICAL ME(SOHC) Page General Description ..................2 Compression .....................23 Idle Speed ....................24 Ignition Timing...................25 Intake Manifold Vacuum................26 Engine Oil Pressure ..................27 Fuel Pressure....................28 Valve Clearance..................29 Engine Assembly ..................32 Engine Mounting ..................40 Preparation for Overhaul................41 V-belt......................42 Crankshaft Pulley ..................44 Belt Cover ....................45 Timing Belt Assembly................46 Camshaft Sprocket..................51 Crankshaft Sprocket..................53...

  • Page 3: General Description

    GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Model 1600 cc 2000 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline Type engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder Bore x Stroke mm (in) 87.9 x 65.8 (3.46 x 2.591) 92 x 75 (3.62 x 2.95) Displacement 1,597 (97.45)
  • Page 4 GENERAL DESCRIPTION MECHANICAL Bend limit 0.020 mm (0.0008 in) 0.030 — 0.090 mm (0.0012 — 0.0035 in) Thrust clearance Limit 0.11 mm (0.0043 in) 39.378 — 39.478 mm (1.5503 — 1.5542 in) Intake Limit 39.278 mm (1.5464 in) 1600 cc 39.565 —...
  • Page 5 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) 87.905 — 87.915 mm (3.4608 — 3.4612 in) 1600 cc 87.895 — 87.905 mm (3.4604 — 3.4608 in) Cylinder bore 92.005 —...
  • Page 6 GENERAL DESCRIPTION MECHANICAL 0 — 0.022 mm (0 — 0.0009 in) Connecting Clearance between piston pin rod bushing and bushing Limit 0.030 mm (0.0012 in) Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.020 mm (0.0008 in) or less Crank pin and crank journal Grinding limit 0.250 mm (0.0098 in)

  • Page 7: Timing Belt

    GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT (12) (10) (13) (15) (11) (14) EN0581 Belt cover No. 2 (RH) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb) ASSY Timing belt guide (MT vehicles T1: 5 (0.5, 3.6) only) (10) Belt idler No.
  • Page 8 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT B2M1954D Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref. to ME(SOHC)-60, Installation, Cylinder Head Exhaust valve rocker ASSY (13) Camshaft cap (LH) Assembly.>...

  • Page 9: Valve Rocker Assembly

    GENERAL DESCRIPTION MECHANICAL 3. VALVE ROCKER ASSEMBLY B2M1956A Intake valve rocker arm Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb) Valve rocker nut Exhaust rocker shaft T1: 5 (0.5, 3.6) Valve rocker adjust screw Exhaust valve rocker arm T2: 10 (1.0, 7.2) Spring T3: 25 (2.5, 18.1) Rocker shaft support...
  • Page 10 GENERAL DESCRIPTION MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEM- B2M1955A Exhaust valve Intake valve oil seal Exhaust valve guide Intake valve Valve spring (10) Exhaust valve spring seat Intake valve guide Retainer (11) Exhaust valve oil seal Intake valve spring seat Retainer key ME(SOHC)-9...

  • Page 11: Cylinder Block

    GENERAL DESCRIPTION MECHANICAL 5. CYLINDER BLOCK B2M4154A Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb) Cylinder block (RH) (15) Oil filter connector T1: 5 (0.5, 3.6) Service hole plug (16) Oil strainer T2: 6.4 (0.65, 4.7) Gasket (17) Gasket T3: 10 (1.0, 7)
  • Page 12 GENERAL DESCRIPTION MECHANICAL ME(SOHC)-11...
  • Page 13 GENERAL DESCRIPTION MECHANICAL 6. CRANKSHAFT AND PISTON B2M3429A ME(SOHC)-12...
  • Page 14 GENERAL DESCRIPTION MECHANICAL Flywheel (MT) Circlip (17) Crankshaft bearing #2, #4 Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5 Drive plate (AT) (11) Connecting rod Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)
  • Page 15 GENERAL DESCRIPTION MECHANICAL 7. ENGINE MOUNTING EN1005 Front cushion rubber Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.3, 31.0) T3: 85 (8.7, 63) C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to •...

  • Page 16: Special Tools

    GENERAL DESCRIPTION MECHANICAL • 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 498267800 CYLINDER • Used for replacing valve guides. HEAD TABLE • Used for removing and installing valve springs. B2M3850 498457000 ENGINE STAND...
  • Page 17 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498747100 PISTON GUIDE Used for installing piston in cylinder. (2000 cc model) 498747000 (1600 cc model) B2M3854 498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve GUIDE guide oil seals. B2M3855 499017100 PISTON PIN...
  • Page 18 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499097700 PISTON PIN Used for removing piston pin. REMOVER ASSY B2M3858 499207100 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket. (LH side) WRENCH B2M3859 499207400 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket.
  • Page 19 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE INSTALLER (499597100). B2M3861 499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal. •...
  • Page 20 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767700 VALVE GUIDE Used for installing valve guides. (Intake side) ADJUSTER 499767800 (Exhaust side) B2M3865 499767200 VALVE GUIDE Used for removing valve guides. REMOVER B2M3867 499767400 VALVE GUIDE Used for reaming valve guides. REAMER B2M3868 499817100...
  • Page 21 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 499497000...
  • Page 22 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587500 OIL SEAL Used for installing front camshaft oil seal. INSTALLER B2M3874 499587100 OIL SEAL Used for installing oil pump oil seal. INSTALLER B2M3875 498277200 STOPPER SET Used for installing automatic transmission assem- bly to engine.
  • Page 23 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.

  • Page 24: Compression

    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.

  • Page 25: Idle Speed

    N or P (AT) position): B2M3148A 700 ± ± ± ± 100 rpm (3) Turn igintion switch to ON, and SUBARU 7) Check idle speed when loaded. (Turn air condi- SELECT MONITOR switch to ON. tioning switch to “ON” and operate compressor for (4) Select {2.

  • Page 26: Ignition Timing

    IGNITION TIMING MECHANICAL 4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 1) Warm-up the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light.

  • Page 27: Intake Manifold Vacuum

    INTAKE MANIFOLD VACUUM MECHANICAL 5. Intake Manifold Vacuum By observing the gauge needle movement, the in- ternal condition of the engine can be diagnosed as A: INSPECTION described below. 1) Warm-up the engine. 2) Disconnect the brake vacuum hose and install the vacuum gauge to the hose fitting on the mani- fold.

  • Page 28: Engine Oil Pressure

    ENGINE OIL PRESSURE MECHANICAL 6. Engine Oil Pressure 7) Start the engine, and measure oil pressure. A: INSPECTION 1) Disconnect battery ground cable. S2M0242 Oil pressure: 98 kPa (1.0 kg/cm , 14 psi) or more at 800 rpm G6M0095 294 kPa (3.0 kg/cm , 43 psi) or more at 5,000 2) Remove generator from bracket.

  • Page 29: Fuel Pressure

    FUEL PRESSURE MECHANICAL 7. Fuel Pressure 6) Measure fuel pressure while disconnecting pres- sure regulator vacuum hose from intake manifold. A: INSPECTION Fuel pressure: WARNING: Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm Before removing fuel pressure gauge, release 41 —...

  • Page 30: Valve Clearance

    VALVE CLEARANCE MECHANICAL 8. Valve Clearance 8) When inspecting #2 and #4 cylinders; (1) Disconnect spark plug cords from spark A: INSPECTION plugs (LH Side) <Ref. to IG(SOHC)-5, LH SIDE, REMOVAL, Spark Plug.> or <Ref. to IG(SO- CAUTION: HCw/oOBD)-5, LH SIDE, REMOVAL, Spark Inspection and adjustment of valve clearance Plug.>.
  • Page 31 VALVE CLEARANCE MECHANICAL 11) If necessary, adjust the valve clearance. <Ref. B: ADJUSTMENT to ME(SOHC)-30, ADJUSTMENT, Valve Clear- CAUTION: ance.> Adjustment of valve clearance should be per- 12) Similar to measurement procedures used for formed while engine is cold. #1 cylinder, measure #2, #3 and #4 cylinder valve 1) Set #1 cylinder piston to top dead center of com- clearances.
  • Page 32 VALVE CLEARANCE MECHANICAL 2) Adjust the #1 cylinder valve clearance. 6) Similar to adjustment procedures used for #1 (1) Loosen the valve rocker nut and screw. cylinder, adjust #2, #3 and #4 cylinder valve clear- ances. (2) Place suitable thickness gauge. (3) While noting valve clearance, tighten valve NOTE: rocker adjust screw.

  • Page 33: Engine Assembly

    ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly 10) Remove air cleaner case stay. • MT model A: REMOVAL 1) Set the vehicle on lift arms. 2) Open front hood fully and support with stay. 3) Release fuel pressure. <Ref. to FU(SOHC)-51, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.>...
  • Page 34 ENGINE ASSEMBLY MECHANICAL (3) Engine ground terminal (6) Accelerator cable and cruise control cable S2M0731 B2M3415A (4) Engine harness connectors (A) Accelerator cable (B) Cruise control cable (7) Pressure switch EN0360 12) Disconnect the following hoses. (1) Brake booster vacuum hose B2M4292 (5) Generator connector, terminal and A/C compressor connector...
  • Page 35 ENGINE ASSEMBLY MECHANICAL 13) Remove power steering pump from bracket. 14) Remove front and center exhaust pipe. (1) Remove resonator chamber. <Ref. to EX(SOHC)-7, REMOVAL, Front Exhaust Pipe.> or <Ref. to EX(SOHCw/oOBD)-9, REMOV- (2) Loosen lock bolt and slider bolt, and remove AL, Front Exhaust Pipe.>...
  • Page 36 ENGINE ASSEMBLY MECHANICAL 18) Remove pitching stopper. 21) 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.
  • Page 37 ENGINE ASSEMBLY MECHANICAL 24) Remove engine from vehicle. B: INSTALLATION (1) Slightly raise engine. 1) Install front cushion rubbers. (2) Raise transmission with garage jack. Tightening torque: (3) Move engine horizontally until main shaft is 34 N·m (3.5 kgf-m, 25.3 ft-lb) withdrawn from clutch cover.
  • Page 38 ENGINE ASSEMBLY MECHANICAL 6) Install pitching stopper. 10) Install power steering pump on bracket. (1) Install power steering tank on bracket. Tightening torque: T1: 49 N·m (5.0 kgf-m, 36.2 ft-lb) T2: 57 N·m (5.8 kgf-m, 42 ft-lb) EN0361 (2) Install power steering pump on bracket, and tighten bolts.
  • Page 39 ENGINE ASSEMBLY MECHANICAL (6) Install resonator chamber. (3) Brake booster vacuum hose 15) Connect the following connectors. Tightening torque: (1) Engine ground terminals 33 N·m (3.4 kgf-m, 24.6 ft-lb) Tightening torque: 14 N·m (1.4 kgf-m, 10.1 ft-lb) (2) Engine harness connectors (3) Generator connector and terminal (4) A/C compressor connectors (5) Power steering pressure switch...
  • Page 40 ENGINE ASSEMBLY MECHANICAL C: INSPECTION 1) Make sure pipes and hoses are installed correct- 2) Make sure the engine coolant and ATF are at specified levels. ME(SOHC)-39...

  • Page 41: Engine Mounting

    ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove engine assembly. <Ref. to ME(SOHC)- 32, REMOVAL, Engine Assembly.> 2) Remove engine mounting from engine assem- bly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; 34 N·m (3.5 kgf-m, 25.3 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.

  • Page 42: Preparation For Overhaul

    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 ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND B2M2582A 2) In this section the procedures described under each index are all connected and stated in order.

  • Page 43: V-Belt

    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. B2M2585 B: INSTALLATION 1.
  • Page 44 V-BELT MECHANICAL 2. REAR SIDE BELT C: INSPECTION 1) Replace belts, if cracks, fraying or wear is found. 1) Install a belt, and tighten the slider bolt (B) so as 2) Check drive belt tension and adjust it if neces- to obtain the specified belt tension.

  • Page 45: Crankshaft Pulley

    CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley 3) Confirm that the tightening angle of the crank- shaft pulley bolt is 45 degrees or more. If not, con- A: REMOVAL duct the following procedures. 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- CAUTION: MOVAL, V-belt.> If the tightening angle of crankshaft pulley bolt 2) Remove crankshaft pulley bolt.

  • Page 46: Belt Cover

    BELT COVER MECHANICAL 14.Belt Cover A: REMOVAL 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)- 44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover (LH). 4) Remove front belt cover. B2M2587A B: INSTALLATION 1) Install front belt cover.

  • Page 47: Timing Belt Assembly

    TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly A: REMOVAL 1. TIMING BELT 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)- 44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, RE- MOVAL, Belt Cover.>...
  • Page 48 TIMING BELT ASSEMBLY MECHANICAL 7) Remove belt idler No. 2. B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUST- ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly; CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down.
  • Page 49 TIMING BELT ASSEMBLY MECHANICAL 2) Install automatic belt tension adjuster assembly. (2) While aligning alignment mark on timing belt with marks on sprockets, position timing belt Tightening torque: properly. 25 N·m (2.5 kgf-m, 18.4 ft-lb) CAUTION: Ensure belt's rotating direction is correct. H2M2384 3) Install belt idler (No.
  • Page 50 TIMING BELT ASSEMBLY MECHANICAL 6) Install timing belt guide. (MT vehicles only) C: INSPECTION (1) Temporarily tighten remaining bolts. 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.
  • Page 51 TIMING BELT ASSEMBLY MECHANICAL 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. • Press-in the push adjuster rod gradually tak- ing more than three minutes.

  • Page 52: Camshaft Sprocket

    CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install camshaft sprocket No. 1. To lock cam- A: REMOVAL shaft, use ST. ST 499207400 CAMSHAFT SPROCKET 1. REMOVAL WRENCH 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- Tightening torque: MOVAL, V-belt.> 78 N·m (8.0 kgf-m, 57.9 ft-lb) 2) Remove crankshaft pulley.
  • Page 53 CAMSHAFT SPROCKET MECHANICAL 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 camshaft sprocket notch for sensor for damage and contamination of foreign matter. ME(SOHC)-52...

  • Page 54: Crankshaft Sprocket

    CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket B: INSTALLATION 1) Install crankshaft sprocket. A: REMOVAL 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)- 44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, RE- MOVAL, Belt Cover.>...

  • Page 55: Valve Rocker Assembly

    VALVE ROCKER ASSEMBLY MECHANICAL 18.Valve Rocker Assembly (2) Tighten bolts (e) through (h) to specified torque. A: REMOVAL (3) Tighten bolts (a) through (d) to specified torque. 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- MOVAL, V-belt.> Tightening torque: 2) Remove crankshaft pulley. <Ref. to ME(SOHC)- 25 N·m (2.5 kgf-m, 18.1 ft-lb) 44, REMOVAL, Crankshaft Pulley.>...
  • Page 56 VALVE ROCKER ASSEMBLY MECHANICAL E: INSPECTION Rocker shaft support inside diameter: 22.005 — 22.026 mm (0.8663 — 0.8672 in) 1. VALVE ROCKER ARM Rocker shaft diameter: 1) Measure inside diameter of valve rocker arm and 21.987 — 22.000 mm (0.8656 — 0.8661 in) outside diameter of valve rocker shaft, and deter- 5) If cam or valve contact surface of valve rocker mine the difference between the two (= oil clear-...

  • Page 57: Camshaft

    CAMSHAFT MECHANICAL 19.Camshaft 13) Remove camshaft cap. (1) Remove bolts (a) through (b) in alphabetical A: REMOVAL sequence. 1) Remove V-belt. <Ref. to ME(SOHC)-42, IN- STALLATION, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)- 44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, RE- MOVAL, Belt Cover.>...
  • Page 58 CAMSHAFT MECHANICAL 16) Remove plug from rear side of camshaft. (3) Install valve rocker assembly. CAUTION: • Do not remove oil seal unless necessary. • Do not scratch journal surface when remov- ing oil seal. B: INSTALLATION 1) Apply a coat of engine oil to camshaft journals and install camshaft.
  • Page 59 CAMSHAFT MECHANICAL (6) Tighten bolts (o) through (v) in alphabetical 9) Install tensioner bracket. sequence. Tightening torque: Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) 10 N·m (1.0 kgf-m, 7.2 ft-lb) H2M2380 10) Install belt cover No. 2 (RH). B2M2621D (7) Tighten bolts (w) through (x) in alphabetical Tightening torque: sequence.
  • Page 60 CAMSHAFT MECHANICAL C: INSPECTION Cam base circle diameter A: IN: 34.00 mm (1.3386 in) 1. CAMSHAFT EX: 34.00 mm (1.3386 in) 1) Measure the bend, and repair or replace if nec- essary. Limit: 0.025 mm (0.0010 in) B2M1209A 2. CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial gauge.

  • Page 61: Cylinder Head Assembly

    CYLINDER HEAD ASSEMBLY MECHANICAL 20.Cylinder Head Assembly 13) Remove cylinder head gasket. CAUTION: A: REMOVAL Do not scratch the mating surface of cylinder 1) Remove V-belt. <Ref. to ME(SOHC)-42, RE- head and cylinder block. MOVAL, V-belt.> 14) Similarly, remove right side cylinder head. 2) Remove crankshaft pulley.
  • Page 62 CYLINDER HEAD ASSEMBLY MECHANICAL 6) Install intake manifold. <Ref. to FU(SOHC)-17, CAUTION: INSTALLATION, Intake Manifold.> or <Ref. to • Mark each valve to prevent confusion. FU(SOHCw/oOBD)-17, INSTALLATION, Intake • Use extreme care not to damage the lips of Manifold.> the intake valve oil seals and exhaust valve oil 7) Install camshaft sprocket.
  • Page 63 CYLINDER HEAD ASSEMBLY MECHANICAL D: ASSEMBLY B2M2629B Valve Retainer (11) Plug Valve guide Retainer key (12) Camshaft cap Valve spring seat Spark plug gasket (13) Valve rocker ASSY Oil seal Camshaft Valve spring (10) Oil seal 1) Installation of valve spring and valve (4) Set ST on valve spring.
  • Page 64 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Compress valve spring and fit valve spring 2. INTAKE AND EXHAUST VALVE OIL retainer key. SEAL Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.
  • Page 65 CYLINDER HEAD ASSEMBLY MECHANICAL Warping limit: 2. VALVE SEAT 0.05 mm (0.0020 in) Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they Grinding limit: are defective or when valve guides are replaced. 0.1 mm (0.004 in) Valve seat width: W Standard height of cylinder head:...
  • Page 66 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (2) Insert ST2 into valve guide and press it down to remove valve guide. 1) Check the clearance between valve guide and ST1 498267800 CYLINDER HEAD TABLE stem. The clearance can be checked by measuring ST2 499767200 VALVE GUIDE REMOVER the outside diameter of valve stem and the inside...
  • Page 67 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST. oil, in cylinder, and insert ST1 into valve guide. Gently rotate the reamer clockwise while press- Press in until the valve guide upper end is flush ing it lightly into valve guide, and return it also ro- with the upper surface of ST2.
  • Page 68 CYLINDER HEAD ASSEMBLY MECHANICAL 4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and re- place if damaged, worn, or deformed, or if “H” is less than the specified limit. Intake Standard 1.0 mm (0.039 in) Limit 0.6 mm (0.024 in) Exhaust Standard 1.2 mm (0.047 in)

  • Page 69: Cylinder Block

    CYLINDER BLOCK MECHANICAL 21.Cylinder Block 12) Remove bolts (a) and (b) to remove cylinder head. A: REMOVAL NOTE: Before conducting this procedure, drain engine oil completely if applicable. 1) Remove intake manifold. <Ref. to FU(SOHC)- 15, REMOVAL, Intake Manifold.> or <Ref.
  • Page 70 CYLINDER BLOCK MECHANICAL 26) Remove water pipe. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump. B2M2638 G2M0162 21) Removal of oil pan (1) Turn cylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylin- der block.
  • Page 71 CYLINDER BLOCK MECHANICAL S2M1590A Service hole plug Circlip Service hole cover Gasket Piston pin 27) Remove service hole cover and service hole 28) 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.
  • Page 72 CYLINDER BLOCK MECHANICAL 29) Draw out piston pin from #1 and #2 pistons us- 30) Similarly remove piston pins from #3 and #4 ing ST. pistons. ST 499097700 PISTON PIN REMOVER 31) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders. CAUTION: 32) Back off bolts which connect cylinder block on Be careful not to confuse original combination...
  • Page 73 CYLINDER BLOCK MECHANICAL B: INSTALLATION B2M2407A Crankshaft bearing Rear oil seal Tightening torque: N·m (kgf-m, ft-lb) Crankshaft T1: 25 (2.5, 18.1) 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.
  • Page 74 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-...
  • Page 75 CYLINDER BLOCK MECHANICAL 9) Position the upper rail gap at (C) or (D) in the fig- 12) Install circlip. ure. Install circlips in piston holes located opposite ser- vice holes in cylinder block, when positioning all pistons in the corresponding cylinders. CAUTION: Use new circlips.
  • Page 76 CYLINDER BLOCK MECHANICAL B2M1322J Piston Gasket Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole plug T: 69 (7.0, 50.6) Circlip 13) Installing piston ST3 499017100 PISTON PIN GUIDE (1) Turn cylinder block so that #1 and #2 cylin- ders face upward. (2) Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead cen- ter.
  • Page 77 CYLINDER BLOCK MECHANICAL (4) Apply fluid packing around the service hole (5) Install service hole plug and gasket. plug. CAUTION: Use a new gasket. Fluid packing: THREE BOND 1215 or equivalent B2M2620 B2M2625 B2M1323K Piston Service hole plug Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7)
  • Page 78 CYLINDER BLOCK MECHANICAL 15) Install water pipe. Tightening torque: 72 N·m (7.3 kgf-m, 52.8 ft-lb) B2M2638 16) Install baffle plate. B2M3361A 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.
  • Page 79 CYLINDER BLOCK MECHANICAL (3) Apply a coat of engine oil to the inside of the 27) Tighten cylinder head bolts. oil seal. (1) Apply a coat of engine oil to washers and bolt threads. (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft- lb) in alphabetical sequence.
  • Page 80 CYLINDER BLOCK MECHANICAL C: DISASSEMBLY B2M1320I Connecting rod cap Top ring Oil ring Connecting rod bearing Second ring 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.
  • Page 81 CYLINDER BLOCK MECHANICAL D: ASSEMBLY B2M1320J Connecting rod bearing Second ring Tightening torque: N·m (kgf-m, ft-lb) Connecting rod Top ring T: 44.6 (4.55, 32.9) Connecting rod cap Circlip Oil ring 1) Install connecting rod bearings on connecting E: INSPECTION rods and connecting rod caps. 1.
  • Page 82 CYLINDER BLOCK MECHANICAL 2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cyl- inder 1) The cylinder bore size is stamped on the cylinder Measure the inner diameter of each cylinder in both block's front upper surface. the thrust and piston pin directions at the heights CAUTION: shown in the figure, using a cylinder bore gauge.
  • Page 83 CYLINDER BLOCK MECHANICAL Piston grade point H: CAUTION: 40.0 mm (1.575 in) When any of the cylinders needs reboring, all other cylinders must be bored at the same time, Piston outer diameter: and use oversize pistons. Do not perform bor- 1600 cc model ing on one cylinder only, nor use an oversize Standard...
  • Page 84 CYLINDER BLOCK MECHANICAL 3) Make sure that piston pin can be inserted into the 4. PISTON RING piston pin hole with a thumb at 20°C (68°F). Re- 1) If piston ring is broken, damaged, or worn, or if its place if defective. tension is insufficient, or when the piston is re- Standard clearance between piston pin and placed, replace piston ring with a new one of the...
  • Page 85 CYLINDER BLOCK MECHANICAL 3) Measure the clearance between piston ring and 5. CONNECTING ROD piston ring groove with a thickness gauge. 1) Replace connecting rod, if the large or small end CAUTION: thrust surface is damaged. Before measuring the clearance, clean the pis- 2) Check for bend or twist using a connecting rod ton ring groove and piston ring.
  • Page 86 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 piston pin clearance at the connecting rod small 5) Measure the oil clearance on individual connect- end.
  • Page 87 CYLINDER BLOCK MECHANICAL 6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace BEARING bearing with a suitable (undersize) one, and re- 1) Clean crankshaft completely and check for place or recondition crankshaft as necessary.
  • Page 88 CYLINDER BLOCK MECHANICAL 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) EN0341 5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.

  • Page 89: Engine Trouble In General

    ENGINE TROUBLE IN GENERAL MECHANICAL 22.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely TROUBLE PROBLEM PARTS, ETC.
  • Page 90 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3) Initial combustion occur. • Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Defective intake manifold gasket •...
  • Page 91 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 2. Rough idle and engine • Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. stall to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked intake duct •...
  • Page 92 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and • Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. poor acceleration to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked intake duct •...
  • Page 93 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to • Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. idle. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked vacuum hose •...
  • Page 94 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- • Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. tion to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Dirty air cleaner element •...

  • Page 95: Engine Noise

    ENGINE NOISE MECHANICAL 23.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 •...

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