2-5 [T100] DIAGNOSTICS

1. Wiring Diagram

1. Wiring Diagram

S2M1808

2
 DIAGNOSTICS [T2A3] 2-5
2. Radiator Main Fan

2. Radiator Main Fan 2A2 : CHECK GROUND CIRCUIT OF MAIN

FAN MOTOR.
A: OPERATION
DETECTING CONDITION: 1) Turn ignition switch to OFF.
Condition: 2) Measure resistance between main fan motor
I Engine coolant temperature is above 95°C connector and chassis ground.
(203°F). Connector & terminal
I Vehicle speed is below 19 km/h (12 MPH). (F17) No. 1 — Chassis ground:
TROUBLE SYMPTOM:
I Radiator main fan does not rotate under the
above conditions.

2A1 : CHECK POWER SUPPLY TO MAIN

FAN MOTOR.

CAUTION:
Be careful not to overheat engine during repair.
1) Turn ignition switch to OFF. H2M1715B
2) Disconnect connector from main fan motor.
3) Start the engine, and warm it up until engine : Is the resistance less than 5 Ω?
coolant temperature increases over 95°C (203°F).
: Go to step 2A3.
4) Stop the engine and turn ignition switch to ON.
5) Measure voltage between main fan motor con- : Repair open circuit in harness between
nector and chassis ground. main fan motor connector and chassis
ground.
Connector & terminal
(F17) No. 2 (+) — Chassis ground (−):
2A3 : CHECK POOR CONTACT.

Check poor contact in main fan motor connector.

<Ref. to FOREWORD [W3C1].>
: Is there poor contact in main fan
motor connector?
: Repair poor contact in main fan motor
connector.
: Go to step 2A4.
H2M1709A

: Is the voltage more than 10 V?

: Go to step 2A2.
: Go to step 2A5.

3
2-5 [T2A4] DIAGNOSTICS
2. Radiator Main Fan

2A4 : CHECK MAIN FAN MOTOR. 2A6 : CHECK POWER SUPPLY TO MAIN
FAN RELAY.
Connect battery positive (+) terminal to terminal
No. 2, and negative (−) terminal to terminal No. 1 1) Turn ignition switch to ON.
of main fan motor connector. 2) Measure voltage between main fan relay termi-
nal and chassis ground.
Connector & terminal
(F66) No. 28 (+) — Chassis ground (−):

S2M1003B

: Does the main fan rotate?

: Repair poor contact in main fan motor S2M0438A
connector.
: Replace main fan motor with a new one. : Is the voltage more than 10 V?
: Go to step 2A10.
2A5 : CHECK POWER SUPPLY TO MAIN : Go to step 2A9.
FAN RELAY.
2A7 : CHECK 20 A FUSE.
1) Turn ignition switch to OFF.
2) Remove main fan relay from A/C relay holder. 1) Remove 20 A fuse from A/C relay holder.
3) Measure voltage between main fan relay termi- 2) Check condition of fuse.
nal and chassis ground.
Connector & terminal
(F66) No. 26 (+) — Chassis ground (−):

S2M0439A

: Is the fuse blown-out?

S2M0437A
: Replace fuse.
: Go to step 2A8.
: Is the voltage more than 10 V?
: Go to step 2A6.
: Go to step 2A7.

4
 DIAGNOSTICS [T2A11] 2-5
2. Radiator Main Fan

2A8 : CHECK POWER SUPPLY TO A/C 2A10 : CHECK MAIN FAN RELAY.
RELAY HOLDER 20 A FUSE TERMI-
NAL. 1) Turn ignition switch to OFF.
2) Measure resistance of main fan relay.
Measure voltage of harness between A/C relay
Terminal
holder 20 A fuse terminal and chassis ground.
No. 25 — No. 26:
Connector & terminal
(F27) No. 1 (+) — Chassis ground (−):

S2M0468A

B2M3740A : Is the resistance more than 1 MΩ?

: Go to step 2A11.
: Is the voltage more than 10 V?
: Replace main fan relay.
: Repair open circuit in harness between
20 A fuse and main fan relay terminal.
2A11 : CHECK MAIN FAN RELAY.
: Repair open circuit in harness between
main fuse box connector and 20 A fuse
terminal. 1) Connect battery to terminals No. 27 and No. 28
of main fan relay.
2) Measure resistance of main fan relay.
2A9 : CHECK FUSE.
Terminal
No. 25 — No. 26:
1) Turn ignition switch to OFF.
2) Remove fuse No. 18 from joint box.
3) Check condition of fuse.

S2M0469A

: Is the resistance less than 1 Ω?

S2M0442A
: Go to step 2A12.
: Is the fuse blown-out? : Replace main fan relay.
: Replace fuse.
: Repair open circuit in harness between
main fan relay and ignition switch.

5
2-5 [T2A12] DIAGNOSTICS
2. Radiator Main Fan

2A12 : CHECK HARNESS BETWEEN MAIN 2A14 : CHECK POOR CONTACT.

FAN RELAY TERMINAL AND MAIN
FAN MOTOR CONNECTOR. Check poor contact in connector between main fan
and ECM. <Ref. to FOREWORD [W3C1].>
Measure resistance of harness between main fan : Is there poor contact in connector
motor connector and main fan relay terminal. between main fan motor and ECM?
Connector & terminal : Repair poor contact connector.
(F17) No. 2 — (F66) No. 25: : Contact with your Subaru distributor.
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.

S2M0445A

: Is the resistance less than 1 Ω?

: Go to step 2A13.
: Repair open circuit in harness between
main fan motor connector and main fan
relay terminal.

2A13 : CHECK HARNESS BETWEEN MAIN

FAN RELAY AND ECM.

1) Turn ignition switch to OFF.

2) Disconnect connector from ECM.
3) Measure resistance of harness between main
fan relay connector and ECM connector.
Connector & terminal
(F66) No. 27 — (B134) No. 3:

H2M3617A

: Is the resistance less than 1 Ω?

: Go to step 2A14.
: Repair open circuit in harness between
main fan relay and ECM.

6
 DIAGNOSTICS [T3A3] 2-5
3. Radiator Sub Fan (With A/C model only)

3. Radiator Sub Fan (With A/C 3A2 : CHECK GROUND CIRCUIT OF SUB
model only) FAN MOTOR.

A: OPERATION 1) Turn ignition switch to OFF.

DETECTING CONDITION: 2) Measure resistance between sub fan motor
connector and chassis ground.
Condition (1):
I Engine coolant temperature is below 95°C Connector & terminal
(203°F). (F16) No. 1 — Chassis ground:
I A/C switch is turned ON.
I Vehicle speed is below 19 km/h (12 MPH).
Condition (2):
I Engine coolant temperature is above 100°C
(212°F).
I A/C switch is turned OFF.
I Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
I Radiator sub fan does not rotate under condi-
tions (1) and (2) above.
H2M1715A

3A1 : CHECK POWER SUPPLY TO SUB : Is the resistance less than 5 Ω?

FAN MOTOR.
: Go to step 3A3.
: Repair open circuit in harness between
CAUTION: sub fan motor connector and chassis
Be careful not to overheat engine during repair. ground.
1) Turn ignition switch to OFF.
2) Disconnect connector from sub fan motor and 3A3 : CHECK POOR CONTACT.
main fan motor.
3) Start the engine, and warm it up until engine
coolant temperature increases over 100°C Check poor contact in sub fan motor connector.
(212°F). <Ref. to FOREWORD [W3C1].>
4) Stop the engine and turn ignition switch to ON. : Is there poor contact in sub fan motor
5) Measure voltage between sub fan motor con- connector?
nector and chassis ground. : Repair poor contact in sub fan motor
Connector & terminal connector.
(F16) No. 2 (+) — Chassis ground (−): : Go to step 3A4.

H2M1714A

: Is the voltage more than 10 V?

: Go to step 3A2.
: Go to step 3A5.

7
2-5 [T3A4] DIAGNOSTICS
3. Radiator Sub Fan (With A/C model only)

3A4 : CHECK SUB FAN MOTOR. 3A6 : CHECK POWER SUPPLY TO SUB
FAN RELAY.
Connect battery positive (+) terminal to terminal
No. 2, and negative (−) terminal to terminal No. 1 1) Turn ignition switch to ON.
of sub fan motor connector. 2) Measure voltage between sub fan relay termi-
nal and chassis ground.
Connector & terminal
(F28) No. 21 (+) — Chassis ground (−):

S2M1003A

: Does the sub fan rotate?

: Repair poor contact in sub fan motor S2M0448A
connector.
: Replace sub fan motor with a new one. : Is the voltage more than 10 V?
: Go to step 3A10.
3A5 : CHECK POWER SUPPLY TO SUB : Go to step 3A9.
FAN RELAY.
3A7 : CHECK 20 A FUSE.
1) Turn ignition switch to OFF.
2) Remove sub fan relay from A/C relay holder. 1) Remove 20 A fuse from A/C relay holder.
3) Measure voltage between sub fan relay termi- 2) Check condition of fuse.
nal and chassis ground.
Connector & terminal
(F28) No. 23 (+) — Chassis ground (−):

S2M0439B

: Is the fuse blown-out?

S2M0447A
: Replace fuse.
: Go to step 3A8.
: Is the voltage more than 10 V?
: Go to step 3A6.
: Go to step 3A7.

8
 DIAGNOSTICS [T3A11] 2-5
3. Radiator Sub Fan (With A/C model only)

3A8 : CHECK POWER SUPPLY TO A/C 3A10 : CHECK SUB FAN RELAY.
RELAY HOLDER 20 A FUSE TERMI-
NAL. 1) Turn ignition switch to OFF.
2) Measure resistance of sub fan relay.
Measure voltage of harness between A/C relay
Terminal
holder 20 A fuse terminal and chassis ground.
No. 23 — No. 24:
Connector & terminal
(F27) No. 3 (+) — Chassis ground (−):

S2M0470A

B2M3741A : Is the resistance more than 1 MΩ?

: Go to step 3A11.
: Is the voltage more than 10 V?
: Replace sub fan relay.
: Repair open circuit in harness between
20 A fuse and sub fan relay terminal.
3A11 : CHECK SUB FAN RELAY.
: Repair open circuit in harness between
main fuse box connector and 20 A fuse
terminal. 1) Connect battery to terminals No. 21 and No. 22
of sub fan relay.
2) Measure resistance of sub fan relay.
3A9 : CHECK FUSE.
Terminal
No. 23 — No. 24:
1) Turn ignition switch to OFF.
2) Remove fuse No. 17 from joint box.
3) Check condition of fuse.

S2M0471A

: Is the resistance less than 1 Ω?

S2M0442B
: Go to step 3A12.
: Is the fuse blown-out? : Replace sub fan relay.
: Replace fuse.
: Repair open circuit in harness between
sub fan relay and ignition switch.

9
2-5 [T3A12] DIAGNOSTICS
3. Radiator Sub Fan (With A/C model only)

3A12 : CHECK HARNESS BETWEEN SUB 3A14 : CHECK POOR CONTACT.

FAN RELAY TERMINAL AND SUB
FAN MOTOR CONNECTOR. Check poor contact in connnector between sub fan
and ECM. <Ref. to FOREWORD [W3C1].>
Measure resistance of harness between sub fan : Is there poor contact in connector
motor connector and sub fan relay terminal. between sub fan motor and ECM?
Connector & terminal : Repair poor contact connector.
(F16) No. 2 — (F28) No. 24: : Contact with your Subaru distributor.
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.

S2M1810A

: Is the resistance less than 1 Ω?

: Go to step 3A13.
: Repair open circuit in harness between
sub fan motor and sub fan relay connec-
tor.

3A13 : CHECK HARNESS BETWEEN SUB

FAN RELAY AND ECM.

1) Turn ignition switch to OFF.

2) Disconnect connector from ECM.
3) Measure resistance of harness between sub
fan relay connector and ECM connector.
Connector & terminal
(F28) No. 22 — (B134) No. 12:

S2M1809A

: Is the resistance less than 1 Ω?

: Go to step 3A14.
: Repair open circuit in harness between
sub fan relay and ECM.

10
2-5 DIAGNOSTICS

MEMO:

11
2-1 [W1A0] SERVICE PROCEDURE
1. Front Catalytic Converter

1. Front Catalytic Converter 6) Separate front and rear catalytic converter

assembly from rear exhaust pipe.
A: REMOVAL
1) Disconnect battery ground cable.

B2M0055

7) Remove front exhaust pipe from cylinder

G6M0095 heads.
2) Disconnect front oxygen (A/F) sensor connec-
tor.

B2M0054

8) Remove front and rear catalytic converter

B2M3439 assembly from hanger bracket.
3) Lift-up the vehicle. CAUTION:
4) Remove under cover. I Be careful not to pull down center exhaust
5) Disconnect rear oxygen sensor connector. pipe.
I After removing center exhaust pipe, do not
apply excessive pulling force on rear exhaust
pipe.

B2M3440

B2M0313

2
 SERVICE PROCEDURE [W1B0] 2-1
1. Front Catalytic Converter

9) Separate front and rear catalytic converter 3) Install front exhaust pipe to cylinder heads.
assembly from front exhaust pipe. Tightening torque:
NOTE: 30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
The rear catalytic converter is integrated with front
catalytic converter. Therefore, the procedure for
removing rear catalytic converter is the same as
the description above.

B2M0054

4) Install front and rear catalytic converter assem-

bly to rear exhaust pipe.
S2M0923 Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install front and rear catalytic converter assem-
bly to front exhaust pipe.

B2M0055

5) Tighten bolt which holds front and rear catalytic

converter assembly to hanger bracket.
Tightening torque:
35±5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
S2M0923

2) Install front and rear catalytic converter assem-

bly.
Temporarily tighten bolt which installs center
exhaust pipe to hanger bracket.

B2M0313

B2M0313

3
2-1 [W2A0] SERVICE PROCEDURE
2. Rear Catalytic Converter

6) Connect rear oxygen sensor connector. 2. Rear Catalytic Converter

A: REMOVAL
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit.
Therefore, the removal and installation procedures
are the same as the those for the front catalytic
converter. <Ref. to 2-1 [W1A0].>

B: INSTALLATION
B2M3440
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit.
7) Install under cover. Therefore, the removal and installation procedures
8) Lower the vehicle. are the same as the ones described under front
9) Connect connector to front oxygen (A/F) sen- catalytic converter. <Ref. to 2-1 [W1B0].>
sor.

B2M3439

10) Connect battery ground cable.

G6M0095

4
2-1 [W2A0] SERVICE PROCEDURE
2. Rear Catalytic Converter

6) Connect rear oxygen sensor connector. 2. Rear Catalytic Converter

A: REMOVAL
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit.
Therefore, the removal and installation procedures
are the same as the those for the front catalytic
converter. <Ref. to 2-1 [W1A0].>

B: INSTALLATION
B2M3440
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit.
7) Install under cover. Therefore, the removal and installation procedures
8) Lower the vehicle. are the same as the ones described under front
9) Connect connector to front oxygen (A/F) sen- catalytic converter. <Ref. to 2-1 [W1B0].>
sor.

B2M3439

10) Connect battery ground cable.

G6M0095

4
 SERVICE PROCEDURE [W4A0] 2-1
4. Purge Control Solenoid Valve

3. Canister 4. Purge Control Solenoid

A: REMOVAL AND INSTALLATION Valve
1) Lift-up the vehicle. A: REMOVAL AND INSTALLATION
2) Disconnect evaporation hoses from canister.
1) Disconnect battery ground cable.

S2M0950
G6M0095
3) Remove canister from body.
2) Remove air cleaner case and air intake duct.
<Ref. to 2-7 [W1A0].>

S2M0142

4) Install in the reverse order of removal. H2M2929

Tightening torque:
22.5±7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb) 3) Remove bolt which installs purge control sole-
noid valve to intake manifold.

S2M0142
S2M0055

5
 SERVICE PROCEDURE [W4A0] 2-1
4. Purge Control Solenoid Valve

3. Canister 4. Purge Control Solenoid

A: REMOVAL AND INSTALLATION Valve
1) Lift-up the vehicle. A: REMOVAL AND INSTALLATION
2) Disconnect evaporation hoses from canister.
1) Disconnect battery ground cable.

S2M0950
G6M0095
3) Remove canister from body.
2) Remove air cleaner case and air intake duct.
<Ref. to 2-7 [W1A0].>

S2M0142

4) Install in the reverse order of removal. H2M2929

Tightening torque:
22.5±7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb) 3) Remove bolt which installs purge control sole-
noid valve to intake manifold.

S2M0142
S2M0055

5
2-1 [W5A0] SERVICE PROCEDURE
5. Fuel Temperature Sensor

4) Take out purge control solenoid valve. 5. Fuel Temperature Sensor

5) Disconnect connector from purge control sole-
noid valve. A: REMOVAL
6) Disconnect vacuum hoses from purge control
solenoid valve. 1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Open fuel filler lid, and remove fuel filler cap.

S2M0056
B2M3197
7) Install in the reverse order of removal.
3) Disconnect battery ground cable.
Tightening torque:
15.7±1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
ft-lb)

G6M0095

4) Remove the floor box located just behind the

B2M2384 rear seat.
5) Remove service hole cover.
CAUTION:
Carefully connect the evaporation hoses.

S2M0246

B2M1893B

(A) To fuel pipe

(B) To intake manifold

6
2-1 [W5A0] SERVICE PROCEDURE
5. Fuel Temperature Sensor

4) Take out purge control solenoid valve. 5. Fuel Temperature Sensor

5) Disconnect connector from purge control sole-
noid valve. A: REMOVAL
6) Disconnect vacuum hoses from purge control
solenoid valve. 1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Open fuel filler lid, and remove fuel filler cap.

S2M0056
B2M3197
7) Install in the reverse order of removal.
3) Disconnect battery ground cable.
Tightening torque:
15.7±1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
ft-lb)

G6M0095

4) Remove the floor box located just behind the

B2M2384 rear seat.
5) Remove service hole cover.
CAUTION:
Carefully connect the evaporation hoses.

S2M0246

B2M1893B

(A) To fuel pipe

(B) To intake manifold

6
 SERVICE PROCEDURE [W5A0] 2-1
5. Fuel Temperature Sensor

6) Disconnect connector from fuel pump. 11) Disconnect connector from fuel pump bracket.

S2M0172 S2M0145

7) Move clips, and then disconnect fuel delivery 12) Remove main fuel level sensor from fuel pump
hose (A), return hose (B) and jet pump hose (C). assembly. <Ref. to 2-1 [W8A0].>
8) Disconnect quick connector, and then discon-
nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].>

H2M3206

S2M0060A NOTE:
Fuel temperature sensor is a unit with fuel pump.
9) Remove nuts which install fuel pump assembly If replacing it, replace as a fuel pump.
onto fuel tank.

S2M0061

10) Take off fuel pump assembly from fuel tank.

B2M0956

7
2-1 [W5B0] SERVICE PROCEDURE
6. Fuel Tank Pressure Sensor

B: INSTALLATION 6. Fuel Tank Pressure Sensor

CAUTION: A: REMOVAL AND INSTALLATION
Leave fuel filler cap open when tightening nuts,
to prevent fuel from flowing out through fuel 1) Remove fuel tank. <Ref. to 2-8 [W2A0].>
delivery and return pipes. Close fuel filler cap
after tightening nuts.
Install in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten nuts in alphabetical sequence shown
in figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) S2M0169A

2) Remove protector cover.

S2M0063A

(4) Connect connector to fuel pump relay. H2M3601

3) Disconnect connector from fuel tank pressure

sensor.

S2M0093

H2M3603

4) Release clips which hold fuel pipes onto fuel

tank.

H2M3604

8
2-1 [W5B0] SERVICE PROCEDURE
6. Fuel Tank Pressure Sensor

B: INSTALLATION 6. Fuel Tank Pressure Sensor

CAUTION: A: REMOVAL AND INSTALLATION
Leave fuel filler cap open when tightening nuts,
to prevent fuel from flowing out through fuel 1) Remove fuel tank. <Ref. to 2-8 [W2A0].>
delivery and return pipes. Close fuel filler cap
after tightening nuts.
Install in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten nuts in alphabetical sequence shown
in figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) S2M0169A

2) Remove protector cover.

S2M0063A

(4) Connect connector to fuel pump relay. H2M3601

3) Disconnect connector from fuel tank pressure

sensor.

S2M0093

H2M3603

4) Release clips which hold fuel pipes onto fuel

tank.

H2M3604

8
 SERVICE PROCEDURE [W7A0] 2-1
7. Pressure Control Solenoid Valve

5) Move the two fuel pipes to upper side, and 7. Pressure Control Solenoid
remove bolt which install fuel tank pressure sensor
to bracket. Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

H2M3602

6) Move clip, and disconnect pressure hose from

fuel tank.
G6M0095
7) Disconnect pressure hose from fuel tank pres-
sure sensor. 2) Remove canister. <Ref. to 2-1 [W3A0].>

B2M1779
B2M1780

8) Install in the reverse order of removal. 3) Disconnect evaporation hoses (A) from joint
Tightening torque: pipes.
7.35±1.96 N·m (0.75±0.20 kg-m, 5.4±1.4
ft-lb)

S2M0876A

H2M3602

9
 SERVICE PROCEDURE [W7A0] 2-1
7. Pressure Control Solenoid Valve

5) Move the two fuel pipes to upper side, and 7. Pressure Control Solenoid
remove bolt which install fuel tank pressure sensor
to bracket. Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

H2M3602

6) Move clip, and disconnect pressure hose from

fuel tank.
G6M0095
7) Disconnect pressure hose from fuel tank pres-
sure sensor. 2) Remove canister. <Ref. to 2-1 [W3A0].>

B2M1779
B2M1780

8) Install in the reverse order of removal. 3) Disconnect evaporation hoses (A) from joint
Tightening torque: pipes.
7.35±1.96 N·m (0.75±0.20 kg-m, 5.4±1.4
ft-lb)

S2M0876A

H2M3602

9
2-1 [W7A0] SERVICE PROCEDURE
7. Pressure Control Solenoid Valve

4) Remove bolt which installs pressure control 9) Disconnect vacuum hose from pressure control
solenoid valve holding bracket on body. solenoid valve.

H2M2530 B2M1785

5) Disconnect connector from pressure control 10) Install in the reverse order of removal.
solenoid valve. Tightening torque:
17.6±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

S2M1998

6) Disconnect two evaporation hoses from pres- H2M2530

sure control solenoid valve.

7) Remove pressure control solenoid valve with
bracket.

S2M1999

8) Remove pressure control solenoid valve from

bracket.

B2M1786

10
 SERVICE PROCEDURE [W8A0] 2-1
8. Main Fuel Level Sensor

8. Main Fuel Level Sensor 6) Disconnect connector from fuel pump.

A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Open fuel flap lid, and remove fuel filler cap.

S2M0172

7) Move clips, and then disconnect fuel delivery

hose (A), return hose (B) and jet pump hose (C).
8) Disconnect quick connector, and then discon-
B2M3197 nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].>
3) Disconnect battery ground cable.

S2M0060A

G6M0095 9) Remove nuts which install fuel pump assembly

4) Remove the floor box located just behind the onto fuel tank.
rear seat.
5) Remove service hole cover.

S2M0061

10) Take off fuel pump assembly from fuel tank.

S2M0246 11) Disconnect connector from fuel pump bracket.

S2M0145

11
2-1 [W8B0] SERVICE PROCEDURE
8. Main Fuel Level Sensor

12) Remove bolt which installs fuel level sensor 5) Connect connector to fuel pump relay.
on mounting bracket.

S2M0093
H2M3206

B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts,
to prevent fuel from flowing out through fuel
delivery and return pipes. Close fuel filler cap
after tightening nuts.
Install in the reverse order of removal. Do the fol-
lowing:
1) Install the fuel level sensor onto the mounting
bracket.

H2M3206

2) Always use new gaskets.

3) Ensure sealing portion is free from fuel or for-
eign particles before installation.
4) Tighten nuts in alphabetical sequence shown in
figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

S2M0063A

12
 SERVICE PROCEDURE [W9A0] 2-1
9. Drain Filter

9. Drain Filter 6) Remove nut which installs drain filter and drain
valve brackets on body, and remove them as a
A: REMOVAL AND INSTALLATION unit.
1) Disconnect battery ground cable.

H2M3611

G6M0095 7) Disconnect evaporation hoses, and remove

drain filter.
2) Lift-up the vehicle.
3) Remove canister. <Ref. to 2-1 [W3A0].>

B2M1791

B2M1780
8) Install in the reverse order of removal.
Tightening torque:
4) Disconnect connector from drain valve. 22.5±7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)

H2M3611
H2M3611

5) Disconnect evaporation hoses (A) from joint

pipes.

S2M0876A

13
2-1 [W10A0] SERVICE PROCEDURE
10. Fuel Sub Level Sensor

10. Fuel Sub Level Sensor 6) Remove bolts which install fuel sub level sensor
on fuel tank.
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.

S2M0152

7) Remove fuel sub level sensor.

B2M3197

3) Disconnect battery ground cable.

S2M0153

G6M0095

4) Remove service hole cover.

G2M0863

5) Disconnect connector from fuel sub level

sensor, and disconnect jet pump hose.

S2M0151

14
 SERVICE PROCEDURE [W11A0] 2-1
11. Vent Valve

8) Installation is in the reverse order of removal. 11. Vent Valve

Do the following:
(1) Install fuel sub level sensor. A: REMOVAL AND INSTALLATION
Tightening torque: 1) Remove fuel tank. <Ref. to 2-8 [W2A0].>
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)

S2M0169

S2M0152B 2) Remove protector cover.

(2) Connect connector to fuel pump relay.

H2M3601

S2M0093 3) Move clips, and disconnect hoses from vent

valve.

H2M3606

4) Remove nuts which install vent valve on fuel

tank.

H2M3607

15
 SERVICE PROCEDURE [W11A0] 2-1
11. Vent Valve

8) Installation is in the reverse order of removal. 11. Vent Valve

Do the following:
(1) Install fuel sub level sensor. A: REMOVAL AND INSTALLATION
Tightening torque: 1) Remove fuel tank. <Ref. to 2-8 [W2A0].>
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)

S2M0169

S2M0152B 2) Remove protector cover.

(2) Connect connector to fuel pump relay.

H2M3601

S2M0093 3) Move clips, and disconnect hoses from vent

valve.

H2M3606

4) Remove nuts which install vent valve on fuel

tank.

H2M3607

15
2-1 [W12A0] SERVICE PROCEDURE
12. Shut Valve

5) Installation is in the reverse order of removal. 12. Shut Valve

CAUTION:
Replace rubber seat with a new one. A: REMOVAL AND INSTALLATION
Tightening torque: 1) Disconnect battery ground cable.
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)

G6M0095

B2M1794B
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].>

S2M0163

3) Remove fuel filler pipe. <Ref. to 2-8 [W3A1].>

B2M1756

4) Disconnect evaporation hoses from shut valve.

B2M1796

16
2-1 [W12A0] SERVICE PROCEDURE
12. Shut Valve

5) Installation is in the reverse order of removal. 12. Shut Valve

CAUTION:
Replace rubber seat with a new one. A: REMOVAL AND INSTALLATION
Tightening torque: 1) Disconnect battery ground cable.
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)

G6M0095

B2M1794B
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].>

S2M0163

3) Remove fuel filler pipe. <Ref. to 2-8 [W3A1].>

B2M1756

4) Disconnect evaporation hoses from shut valve.

B2M1796

16
 SERVICE PROCEDURE [W13A0] 2-1
13. Drain Valve

5) Remove shut valve from fuel filler pipe. 13. Drain Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

B2M1797

6) Install in the reverse order of removal.

Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) G6M0095

2) Lift-up the vehicle.

3) Remove canister. <Ref. to 2-1 [W3A0].>

B2M1797

B2M1780

4) Disconnect connector from drain valve.

H2M3611

5) Disconnect evaporation hoses from drain valve.

H2M3612

17
 SERVICE PROCEDURE [W13A0] 2-1
13. Drain Valve

5) Remove shut valve from fuel filler pipe. 13. Drain Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

B2M1797

6) Install in the reverse order of removal.

Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) G6M0095

2) Lift-up the vehicle.

3) Remove canister. <Ref. to 2-1 [W3A0].>

B2M1797

B2M1780

4) Disconnect connector from drain valve.

H2M3611

5) Disconnect evaporation hoses from drain valve.

H2M3612

17
2-1 [W13A0] SERVICE PROCEDURE
13. Drain Valve

6) Remove bolt which installs drain filter and drain 8) Install in the reverse order of removal.
valve brackets on body. Tightening torque:
22.5±7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)

H2M3611

7) Move drain filter to upper side, and remove H2M3611

drain valve with bracket.

H2M3613

18
2-10 [S100] SPECIFICATIONS AND SERVICE DATA
1. Clutch System

1. Clutch System
2500 cc
Clutch cover Diaphragm set load kg (lb) 580 (1,279)
Facing material Woven
O.D. × I.D. × thickness mm (in) 225 × 150 × 3.5 (8.86 × 5.91 × 0.138)
Spline O.D. (No. of teeth) mm (in) 25.2 (0.992) (24)
Clutch disc
Depth of rivet head mm
Limit of sinking 0.3 (0.012)
(in)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
Clutch release lever ratio 1.6
Clutch release bearing Grease-packed self-aligning
Clutch release lever Stroke mm (in) 12 — 13.6 (0.472 — 0.535)
Clutch pedal Full stroke mm (in) 130 — 135 (5.12 — 5.31)

2
 COMPONENT PARTS [C100] 2-10
1. Clutch System

1. Clutch System

S2M0910C

(1) Operating cylinder (10) Lever (19) Flywheel

(2) Washer (11) Clutch release lever sealing
(3) Clutch hose (12) Retainer spring Tightening torque: N·m (kg-m, ft-lb)
(4) Bracket (13) Pivot T1: 15+3/−2 (1.5+0.3/−0.2, 10.8+2.2/
(5) Clip (14) Clutch release lever −1.4 )
(6) Pipe (15) Clip T2: 15.7±1.5 (1.6±0.15, 11.6±1.1)
(7) Master cylinder ASSY (16) Clutch release bearing T3: 18±3 (1.8±0.3, 13.0±2.2)
(8) Clevis pin (17) Clutch cover T4: 37±3 (3.8±0.3, 27.5±2.2)
(9) Snap pin (18) Clutch disc

3
2-10 [C200] COMPONENT PARTS
2. Master Cylinder and Reservoir Tank

2. Master Cylinder and Reservoir Tank

S2M0911A

(1) Reservoir cap (5) Master cylinder (9) Push rod

(2) Reservoir tank (6) Seat (10) Piston stop ring
(3) Oil seal (7) Return spring
(4) Straight pin (8) Piston

4
 SERVICE PROCEDURE [W2A0] 2-10
2. On-car Service

1. General 2. On-car Service

A: PRECAUTION A: ADJUSTMENT
When servicing clutch system, pay attention to the NOTE:
following items. Bleed air from oil line with the help of a co-worker.
1) Check fluid level using a scale on outside of
reservoir tank. If the level is below “MIN”, add 1) Remove air cleaner case.
brake fluid to bring it up to “MAX”. 2) Fit one end of a vinyl tube into the air bleeder
of operating cylinder and put the other end into a
Recommended brake fluid: brake fluid container.
FMVSS No. 116, fresh DOT3 or DOT4
brake fluid
CAUTION:
I Avoid mixing different brakes of brake fluid
to prevent degradation of the fluid.
I Be careful not to allow dirt or dust to get into
the reservoir tank.
I Use fresh DOT3 or DOT4 brake fluid when
refilling fluid.

B2M1179K

(A) Clutch hose

(B) Air bleeder

3) Slowly depress the clutch pedal and keep it

depressed. Then open the air bleeder to discharge
air together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
S2M0912B
pedal.
(A) Reservoir tank

2) Make sure that brake fluid does not leak from

master cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the clutch release
lever pinion.
4) Check for proper clutch disengagement and
clutch pedal return ability.

B2M1178C

(A) Operating cylinder

(B) Vinyl tube

4) Repeat these steps until there are no more air

bubbles in the vinyl tube.
CAUTION:
Cover bleeder with waste cloth when loosening
it, to prevent brake fluid from being splashed
over surrounding parts.

5
 SERVICE PROCEDURE [W2A0] 2-10
2. On-car Service

1. General 2. On-car Service

A: PRECAUTION A: ADJUSTMENT
When servicing clutch system, pay attention to the NOTE:
following items. Bleed air from oil line with the help of a co-worker.
1) Check fluid level using a scale on outside of
reservoir tank. If the level is below “MIN”, add 1) Remove air cleaner case.
brake fluid to bring it up to “MAX”. 2) Fit one end of a vinyl tube into the air bleeder
of operating cylinder and put the other end into a
Recommended brake fluid: brake fluid container.
FMVSS No. 116, fresh DOT3 or DOT4
brake fluid
CAUTION:
I Avoid mixing different brakes of brake fluid
to prevent degradation of the fluid.
I Be careful not to allow dirt or dust to get into
the reservoir tank.
I Use fresh DOT3 or DOT4 brake fluid when
refilling fluid.

B2M1179K

(A) Clutch hose

(B) Air bleeder

3) Slowly depress the clutch pedal and keep it

depressed. Then open the air bleeder to discharge
air together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
S2M0912B
pedal.
(A) Reservoir tank

2) Make sure that brake fluid does not leak from

master cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the clutch release
lever pinion.
4) Check for proper clutch disengagement and
clutch pedal return ability.

B2M1178C

(A) Operating cylinder

(B) Vinyl tube

4) Repeat these steps until there are no more air

bubbles in the vinyl tube.
CAUTION:
Cover bleeder with waste cloth when loosening
it, to prevent brake fluid from being splashed
over surrounding parts.

5
2-10 [W3A0] SERVICE PROCEDURE
3. Clutch Release Bearing and Lever

5) Tighten air bleeder. 3. Clutch Release Bearing and

Tightening torque: Lever
T: 8±2 N·m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
A: REMOVAL
1) Remove transmission assembly from vehicle
body.
<Ref. to 2-11 [W2B0].>
2) Remove operating cylinder.
<Ref. to 2-10 [W5A0].>
3) Remove the two clips from clutch release lever
and remove clutch release bearing.
CAUTION:
B2M1179A Be careful not to deform clips.
6) After depressing the clutch pedal, make sure 4) Remove clutch release lever sealing.
that there are no leaks evident in the entire system.
7) After bleeding air from system, ensure that
clutch operates properly.

B2M1257G

(A) Operating cylinder

(B) Clip
(C) Clutch release lever
(D) Clutch release bearing
(E) Clutch release lever sealing

6
2-10 [W3A0] SERVICE PROCEDURE
3. Clutch Release Bearing and Lever

5) Tighten air bleeder. 3. Clutch Release Bearing and

Tightening torque: Lever
T: 8±2 N·m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
A: REMOVAL
1) Remove transmission assembly from vehicle
body.
<Ref. to 2-11 [W2B0].>
2) Remove operating cylinder.
<Ref. to 2-10 [W5A0].>
3) Remove the two clips from clutch release lever
and remove clutch release bearing.
CAUTION:
B2M1179A Be careful not to deform clips.
6) After depressing the clutch pedal, make sure 4) Remove clutch release lever sealing.
that there are no leaks evident in the entire system.
7) After bleeding air from system, ensure that
clutch operates properly.

B2M1257G

(A) Operating cylinder

(B) Clip
(C) Clutch release lever
(D) Clutch release bearing
(E) Clutch release lever sealing

6
 SERVICE PROCEDURE [W3C0] 2-10
3. Clutch Release Bearing and Lever

5) Remove clutch release lever retainer spring 2) Check the bearing for smooth rotation by apply-
from clutch release lever pivot with a screwdriver ing pressure in the thrust direction.
by accessing it through clutch housing clutch
release lever hole. Then remove clutch release
lever.

S2M1844A

(A) Bearing case

B2M1258B 3) Check wear and damage of bearing case sur-
(A) Clutch release lever sealing face contacting with lever.
(B) Clutch release lever
2. CLUTCH RELEASE LEVER
B: INSPECTION 1) Check lever pivot portion and the point of con-
tact with release bearing case for wear.
1. CLUTCH RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gaso-
line or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by
applying force in the radial direction.
Radial direction stroke:
1.4 mm (0.055 in)
S2M1102E

(A) Clutch release lever

(B) Pivot
(C) Clutch release bearing

C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the fol-
lowing points with a light coat of grease.
B2M0173B I Contact surface of lever and pivot
I Contact surface of lever and bearing
(A) Bearing case
I Transmission main shaft spline (Use grease
containing molybdenum disulphide.)

7
2-10 [W4A0] SERVICE PROCEDURE
4. Clutch Disc and Cover

1) While pushing clutch release lever to pivot and 4. Clutch Disc and Cover
twisting it to both sides, fit retainer spring onto the
constricted portion of pivot. A: REMOVAL
NOTE: 1) Install ST on flywheel.
I Apply grease (SUNLIGHT 2: P/N 003602010) to ST 498497100 CRANKSHAFT STOPPER
contact point of clutch release lever and operating
cylinder.
I Confirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install clutch release bearing and fasten it with
two clips.
3) Install clutch release lever sealing.
4) Install operating cylinder.
Tightening torque:
T: 37±3 N·m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
S2M1847A

(A) Clutch cover

2) Remove clutch cover and clutch disc.

CAUTION:
I Take care not to allow oil on the clutch disc
facing.
I Do not disassemble either clutch cover or
clutch disc.
3) Remove flywheel.

B2M1257L S2M1848A

(A) Clutch release lever (A) Flywheel

(B) Retainer spring
(C) Clutch release bearing
(D) Clip
(E) Clutch release lever sealing
(F) Operating cylinder

5) After remounting engine and transmission on

body.
<Ref. to 2-11 [W2C0].>
6) Bleed air from oil line with the help of a co-
worker.
<Ref. to 2-10 [W2A0].>

8
2-10 [W4A0] SERVICE PROCEDURE
4. Clutch Disc and Cover

1) While pushing clutch release lever to pivot and 4. Clutch Disc and Cover
twisting it to both sides, fit retainer spring onto the
constricted portion of pivot. A: REMOVAL
NOTE: 1) Install ST on flywheel.
I Apply grease (SUNLIGHT 2: P/N 003602010) to ST 498497100 CRANKSHAFT STOPPER
contact point of clutch release lever and operating
cylinder.
I Confirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install clutch release bearing and fasten it with
two clips.
3) Install clutch release lever sealing.
4) Install operating cylinder.
Tightening torque:
T: 37±3 N·m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
S2M1847A

(A) Clutch cover

2) Remove clutch cover and clutch disc.

CAUTION:
I Take care not to allow oil on the clutch disc
facing.
I Do not disassemble either clutch cover or
clutch disc.
3) Remove flywheel.

B2M1257L S2M1848A

(A) Clutch release lever (A) Flywheel

(B) Retainer spring
(C) Clutch release bearing
(D) Clip
(E) Clutch release lever sealing
(F) Operating cylinder

5) After remounting engine and transmission on

body.
<Ref. to 2-11 [W2C0].>
6) Bleed air from oil line with the help of a co-
worker.
<Ref. to 2-10 [W2A0].>

8
 SERVICE PROCEDURE [W4B2] 2-10
4. Clutch Disc and Cover

B: INSPECTION 4) Deflection on facing

If deflection exceeds the specified value at the
1. CLUTCH DISC outer circumference of facing, repair or replace.
1) Facing wear Limit for runout:
Measure the depth of rivet head from the surface 1.0 mm (0.039 in) at R = 107 mm (4.21 in)
of facing. Replace if facings are worn locally or
worn down to less than the specified value.
Depth of rivet head:
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning
fluid.

B2M0330B

(A) Dial gauge

(B) Facing

5) Worn spline, loose rivets and torsion spring fail-

ure
Replace defective parts.

B2M0328

2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace clutch disc and inspect transmission front
oil sealing, transmission case mating surface,
engine rear oil sealing and other points for oil leak-
age.
B2M0333B

(A) Torsion spring

(B) Rivet
(C) Spline

2. CLUTCH COVER
NOTE:
Visually check for the following items without
disassembling, and replace or repair if defective.
B2M0329B

(A) Facing

9
2-10 [W4B3] SERVICE PROCEDURE
4. Clutch Disc and Cover

1) Loose thrust rivet. 1) Damage of facing and ring gear

2) Damaged or worn bearing contact area at cen- If defective, replace flywheel.
ter of diaphragm spring.

S2M1851A
S2M1849A
(A) Flywheel
(A) Thrust rivet (B) Ring gear
(B) Diaphragm spring
2) Smoothness of rotation
3) Damaged or worn disc contact surface of pres- Rotate ball bearing applying pressure in thrust
sure plate. direction.
4) Loose strap plate setting bolt. 3) If noise or excessive play is noted, replace fly-
5) Worn diaphragm sliding surface. wheel.

C: INSTALLATION
1) Install flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER

S2M1850A

(A) Pressure plate

(B) Strap plate

3. FLYWHEEL B2M0332B

CAUTION: (A) Flywheel

Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gaso-
line or any solvent.

10
 SERVICE PROCEDURE [W4C0] 2-10
4. Clutch Disc and Cover

2) Tighten the flywheel attaching bolts to the 4) Install clutch cover on flywheel and tighten bolts
specified torque. to the specified torque.
NOTE: NOTE:
Tighten flywheel installing bolts gradually. Each I When installing the clutch cover on the flywheel,
bolt should be tightened to the specified torque in position the clutch cover so that there is a gap of
a crisscross fashion. 120° or more between “0” marks on the flywheel
and clutch cover. (“0” marks indicate the directions
Tightening torque: of residual unbalance.)
72±3 N·m (7.3±0.3 kg-m, 52.8±2.2 ft-lb) I Note the front and rear of the clutch disc when
installing.
I Tighten clutch cover installing bolts gradually.
Each bolt should be tightened to the specified
torque in a crisscross fashion.
Tightening torque:
15.7±1.5 N·m (1.6±0.15 kg-m, 11.6±1.1
ft-lb)
5) Remove ST.
ST 499747100 CLUTCH DISC GUIDE
B2M0331B

3) Insert ST into the clutch disc and install them on

the flywheel by inserting the ST end into the pilot
bearing.
ST 499747100 CLUTCH DISC GUIDE

G2M0253

B2M1011B

(A) “0” marks

11
2-10 [W5A0] SERVICE PROCEDURE
5. Operating Cylinder

5. Operating Cylinder 4) Install in the reverse order of removal.

NOTE:
A: REMOVAL AND INSTALLATION Before installing operating cylinder, apply grease
1) Remove air cleaner case. (SUNLIGHT 2: P/N 003602010) to contact point of
clutch release lever and operating cylinder.
Tightening torque:
T1: 18±3 N·m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 37±3 N·m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)

S2M0913

2) Remove clutch hose from operating cylinder.

CAUTION:
Cover hose joint to prevent clutch fluid from B2M1179C
flowing out.
5) After bleeding air from operating cylinder,
ensure that clutch operates properly.
<Ref. to 2-10 [W2A0].>

B2M1179J

(A) Clutch hose

(B) Operating cylinder

3) Remove operating cylinder from transmission.

B2M1263

12
 SERVICE PROCEDURE [W6B0] 2-10
6. Master Cylinder and Reservoir Tank

6. Master Cylinder and B: DISASSEMBLY

Reservoir Tank 1) Remove straight pin and reservoir tank.
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir
tank.
2) Remove snap pin, clevis pin and separate push
rod of master cylinder from clutch pedal.

S2M0915A

(A) Reservoir tank

(B) Straight pin

2) Remove oil sealing.

B4M1189E

(A) Clevis pin

(B) Snap pin
(C) Push rod
(D) Lock nut

3) Remove clutch pipe from master cylinder.

4) Remove master cylinder with reservoir tank.
CAUTION:
S2M0916B
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm (A) Oil seal
the paint surface; wipe it off quickly if spilt. (B) Master cylinder

3) Move the cylinder boot backward.

S2M0914B

(A) Master cylinder S2M0917B

(B) Clutch pipe
(A) Cylinder boot
(B) Master cylinder

4) Remove snap ring.

CAUTION:
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring
from flying out.

13
2-10 [W6C0] SERVICE PROCEDURE
6. Master Cylinder and Reservoir Tank

C: INSPECTION E: INSTALLATION
If any damage, deformation, wear, swelling, rust or 1) Install master cylinder to body, and install clutch
other faults are found on the cylinder, piston, push pipe to master cylinder.
rod, fluid reservoir, return spring and gasket, CAUTION:
replace the faulty part. Check that pipe is routed properly.
Tightening torque:
T1: 15+3/−2 N·m (1.5+0.3/−0.2 kg-m, 10.8+2.2/
−1.4 ft-lb)
T2: 18±3 N·m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)

S2M0918A

(A) Master cylinder body

(B) Return spring
(C) Piston
(D) Snap ring S2M0919C
(E) Rod ASSY
2) Connect push rod of master cylinder to clutch
D: ASSEMBLY pedal, and install clevis pin and snap pin.
NOTE:
1) Apply a coat of grease to the contacting sur-
Apply grease to clevis pin.
faces of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)

B4M1189C

(A) Clevis pin

(B) Snap pin
(C) Push rod
S2M0918B
3) After bleeding air from system, ensure that
2) To assemble the master cylinder reverse the clutch operates properly.
sequence of disassembly procedure. <Ref. to 2-10 [W2A0].>

14
 SERVICE PROCEDURE [W7A0] 2-10
7. Brake Fluid

7. Brake Fluid I The amount of brake fluid required is approxi-

mately 70 m (2.4 US fl oz, 2.5 Imp fl oz) for total
A: REPLACEMENT clutch system.
CAUTION: 1) Either jack-up vehicle and place a safety stand
I The FMVSS No. 116, fresh DOT3 or 4 brake under it, or lift-up vehicle.
fluid must be used. 2) Remove both front and rear wheels.
I Cover bleeder with waste cloth, when loos- 3) Draw out the brake fluid from reservoir tank with
ening it, to prevent brake fluid from being syringe.
splashed over surrounding parts. 4) Refill reservoir tank with recommended brake
I Avoid mixing different brands of brake fluid fluid.
to prevent degrading the quality of the fluid.
I Be careful not to allow dirt or dust to get into Recommended brake fluid:
the reservoir tank. FMVSS No. 116, fresh DOT3 or 4 brake
fluid
NOTE:
I During bleeding operation, keep the clutch res- 5) Bleed air from oil line with the help of a co-
ervoir tank filled with brake fluid to eliminate entry worker.
of air. <Ref. to 2-10 [W2A0].>
I Clutch pedal operating must be very slow.
I For convenience and safety, it is advisable to
have two men working.

15
2-10 [K100] DIAGNOSTICS
1. Clutch System

1. Clutch System
Symptom Possible cause Corrective
1. Clutch slippage. (a) Clutch facing smeared by oil Replace.
It is hard to perceive clutch slippage in
the early stage, but pay attention to the
following symptoms
I Engine speed up when shifting.
(b) Worn clutch facing Replace.
I High speed driving is impossible;
especially rapid acceleration impossible
and vehicle speed does not increase in
proportion to an increase in engine
speed. (c) Deteriorated diaphragm spring Replace.
I Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
I Method of testing: Put the vehicle in (d) Distorted pressure plate or flywheel Correct or replace.
stationary condition with parking brake
fully applied. Disengage the clutch and
shift the transmission gear into the first.
Gradually allow the clutch to engage
while gradually increasing the engine (e) Defective clutch release bearing Correct or replace.
speed. The clutch function is satisfactory holder
if the engine stalls. However, the clutch
is slipping if the vehicle does not start off
and the engine does not stall.
2. Clutch drags. (a) Worn or rusty clutch disc hub spline Replace clutch disc.
As a symptom of this trouble, a harsh
scratching noise develops and control
(b) Excessive deflection of clutch disc Correct or replace.
becomes quite difficult when shifting
facing
gears. The symptom becomes more
apparent when shifting into the first gear.
However, because much trouble of this (c) Seized crankshaft pilot needle bear- Replace.
sort is due to defective synchronization ing
mechanism, carry out the test as
described after. (d) Cracked clutch disc facing Replace.
I Method of testing: <Ref. to 2-10
[K1A0].>
It may be judged as insufficient disen- (e) Sticked clutch disc (smeared by oil or Replace.
gagement of clutch if any noise occurs water)
during this test.
3. Clutch chatters. (a) Adhesion of oil on the facing Replace clutch disc.
Clutch chattering is an unpleasant vibra-
(b) Weak or broken torsion spring Replace clutch disc.
tion to the whole body when the vehicle (c) Defective facing contact or excessive Replace clutch disc defection.
is just started with clutch partially disc
engaged.
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace clutch disc.
(f) Loose engine mounting Retighten or replace mounting.
(g) Improper adjustment of pitching stop- Adjustment.
per
4. Noisy clutch (a) Broken, worn or unlubricated clutch Replace clutch release bearing.
Examine whether the noise is generated release bearing
when the clutch is disengaged, engaged, (b) Insufficient lubrication of pilot bearing Apply grease.
or partially engaged. (c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.

16
 DIAGNOSTICS [K100] 2-10
1. Clutch System

Symptom Possible cause Corrective

5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc.
partially engaged, the clutch engages (c) Worn or rusted spline of clutch disc Take off rust, apply grease or replace
suddenly and the vehicle jumps instead or main shaft clutch disc or main shaft.
of making a smooth start.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.

17
2-10 [K1A0] DIAGNOSTICS
1. Clutch System

A: DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

B2M1012B

18
2-11 [C100] COMPONENT PARTS
1. Engine Mounting

1. Engine Mounting

B2M1024A

(1) Front cushion rubber Tightening torque: N·m (kg-m, ft-lb)

(2) Front engine mounting bracket
T1: 34±5 (3.5±0.5, 25.3±3.6)
T2: 41±10 (4.2±1.0, 30±7)
T3: 83±15 (8.5±1.5, 61±11)

2
 COMPONENT PARTS [C2A0] 2-11
2. Transmission Mounting

2. Transmission Mounting
A: MT MODEL

S2M0196C

(1) Pitching stopper (7) Cushion D Tightening torque: N·m (kg-m, ft-lb)
(2) Spacer (8) Center crossmember
T1: 34±5 (3.5±0.5, 25.3±3.6)
(3) Cushion C (9) Rear plate
T2: 49±5 (5.0±0.5, 36.2±3.6)
(4) Front plate (10) Front crossmember
T3: 57±10 (5.8±1.0, 42±7)
(5) Rear cushion rubber
(6) Rear crossmember T4: 69±15 (7.0±1.5, 51±11)
T5: 137±20 (14±2, 101±14)

3
2-11 [C2B0] COMPONENT PARTS
2. Transmission Mounting

B: AT MODEL

S2M0197A

(1) Pitching stopper Tightening torque: N·m (kg-m, ft-lb)

(2) Rear cushion rubber
T1: 34±5 (3.5±0.5, 25.3±3.6)
(3) Crossmember
T2: 38±15 (3.9±1.5, 28±11)
(4) Stopper
T3: 49±5 (5.0±0.5, 36.2±3.6)
T4: 57±10 (5.8±1.0, 42±7)
T5: 69±15 (7.0±1.5, 51±11)

4
 SERVICE PROCEDURE [W1B0] 2-11
1. Engine

1. Engine 5) Remove under cover.

A: GENERAL PRECAUTION
(1) Remove or install engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
(2) Be sure not to damage coated surfaces of
body panels with tools or stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
(3) Prior to starting work, prepare the following:
S2M0012
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission 6) Drain coolant.
jacks, etc. Set container under the vehicle, and loose drain
(4) Lift-up or lower the vehicle when necessary. cock from radiator.
Make sure to support the correct positions. <Ref.
to 1-3 [G7B0].>

B: REMOVAL
1) Set the vehicle on lift arms.
2) Open front hood and support with a stay.
3) Release fuel pressure.
(1) Disconnect fuel pump relay connector.

S2M0892

7) Remove cooling system.

(1) Disconnect connectors from radiator main
fan and sub fan motors.

S2M0093B

(A) Fuel pump relay connector

(2) Start the engine, and run until it stalls.

(3) After the engine stalls, crank it for five sec-
onds more.
(4) Turn ignition switch to “OFF”. S2M0893
(5) Remove filler cap.
4) Disconnect battery ground terminal.

G6M0095

5
2-11 [W1B0] SERVICE PROCEDURE
1. Engine

(2) Disconnect radiator outlet hose from ther- (6) Disconnect radiator inlet hose from radiator.
mostat cover, and remove ATF cooler hose from
clip of radiator.

S2M0897

S2M0894B
(7) Remove radiator upper bracket, and
remove radiator assembly from vehicle.
(A) Radiator outlet hose
(B) ATF cooler hose

(3) Disconnect ATF cooler hoses from radiator.

(AT vehicles)

G2M0220

8) Collect refrigerant, and remove flexible hoses.

(With A/C)
(1) Place and connect the attachment hose to
S2M0895 the refrigerant recycle system.
(2) Collect refrigerant from A/C system.
(4) Lower the vehicle.
(3) Disconnect A/C flexible hoses from A/C
(5) Remove V-belt covers.
compressor.

S2M0896
G2M0270

6
 SERVICE PROCEDURE [W1B0] 2-11
1. Engine

9) Remove air intake system. (2) Engine ground terminal

Remove air intake duct with air cleaner case.

S2M0201
S2M1172
(3) Engine harness connector
10) Remove air cleaner case stay.
I MT vehicles

S2M0900

I AT vehicles

B2M3414

(4) Generator connector, terminal and A/C

compressor connectors (With A/C)
S2M0901

11) Disconnect the following connectors and

cables.
(1) Front oxygen sensor connector

B2M1291I

(A) A/C compressor connectors

(B) Generator connector and terminal

B2M3413

7
2-11 [W1B0] SERVICE PROCEDURE
1. Engine

(5) Accelerator cable and cruise control cable 13) Remove power steering pump.
(1) Loosen lock bolt and slider bolt, and remove
front side V-belt.

B2M3365A

(A) Accelerator cable

G2M0286
(B) Cruise control cable
(2) Remove power steering pipe bracket.
12) Disconnect the following hoses.
(1) Brake booster vacuum hose

S2M0903

B2M2776 (3) Remove bolts which install power steering

pump from bracket.
(2) Heater inlet and outlet hoses

S2M0086
S2M0902
(4) Place power steering pump on the right side
(3) Cruise control vacuum hose
wheel apron.

S2M0203
S2M0087

8
 SERVICE PROCEDURE [W1B0] 2-11
1. Engine

14) Remove front exhaust pipe and center (5) Remove bolt which installs center exhaust
exhaust pipe. pipe on hunger bracket.
(1) Lift-up the vehicle.
(2) Disconnect connector from rear oxygen
sensor.

S2M0206

(6) Take off front and center exhaust pipes.

B2M3421 CAUTION:
Exhaust pipe will drop when all bolts are
(3) Remove nuts which install front exhaust removed. So, hold it when removing the last
pipe onto engine. bolt.
15) Remove nuts which hold lower side of trans-
mission to engine.

S2M0205

(4) Separate center exhaust pipe from rear

exhaust pipe. B2M2790

16) Remove nuts which install front cushion rub-

ber onto front crossmember.

B2M0055

S2M1927

17) Separate torque converter from drive plate.

(AT vehicles)
(1) Lower the vehicle.
(2) Remove service hole plug.

9
2-11 [W1B0] SERVICE PROCEDURE
1. Engine

(3) Remove bolts which hold torque converter 20) Support engine with a lifting device and wire
to drive plate. ropes.

S2M0207 G2M0297

(4) Remove other bolts while rotating the 21) Support transmission with a garage jack.
engine using ST. CAUTION:
ST 499977100 CRANK PULLEY WRENCH Before moving engine away from transmission,
18) Remove pitching stopper. check to be sure no work has been overlooked.
Doing this is very important in order to facili-
tate re-installation and because transmission
lowers under its own weight.

S2M0126

19) Disconnect fuel delivery hose, return hose and

evaporation hose.
S2M1928
CAUTION:
I Disconnect hose with its end wrapped with 22) Separation of engine and transmission.
cloth to prevent fuel from splashing. (1) Remove starter. <Ref. to 6-1 [W1A0].>
I Catch fuel from hose into container. (2) Install ST to torque converter clutch case.
(AT model)
ST 498277200 STOPPER SET

S2M0904

H2M1961A

10
 SERVICE PROCEDURE [W1C0] 2-11
1. Engine

(3) Remove bolts which hold upper side of (1) Position engine in engine compartment and
transmission to engine. align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.

B2M2791

23) Remove engine from vehicle

(1) Slightly raise engine.
(2) Raise transmission with garage jack.
(3) Move engine horizontally until mainshaft is S2M0222

withdrawn from clutch cover. (2) Apply a small amount of grease to spline of
(4) Slowly move engine away from engine mainshaft.
compartment. 2) Connect engine and transmission.
CAUTION: (1) Remove ST from torque converter clutch
Be careful not to damage adjacent parts or case. (AT vehicles)
body panels with crank pulley, oil pressure NOTE:
gauge, etc. Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
ST 498277200 STOPPER SET
(2) Install starter.
<Ref. to 6-1 [W1A0].>
(3) Tighten bolt which holds right upper side of
transmission to engine.
Tightening torque:
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

S2M0222

C: INSTALLATION
1) Install engine onto transmission.

B2M2791

11
2-11 [W1C0] SERVICE PROCEDURE
1. Engine

3) Remove lifting device and wire ropes. 7) Install power steering pump on bracket.
(1) Install power steering pump on bracket, and
tighten bolts.
Tightening torque:
39±10 N·m (4.0±1.0 kg-m, 29±7 ft-lb)

G2M0297

4) Remove garage jack.

5) Install pitching stopper.
Tightening torque: S2M0086
T1: 49±5 N·m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N·m (5.8±1.0 kg-m, 42±7 ft-lb) (2) Install power steering pipe bracket on right
side intake manifold, and install spark plug
codes.

S2M0126C

6) Install torque converter onto drive plate. (AT S2M0903

vehicles)
(1) Tighten bolts which hold torque converter to (3) Install front side V-belt, and adjust it.
drive plate. <Ref. to 1-5 [G200].>
(2) Tighten other bolts while rotating the engine
by using ST.
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
Tightening torque:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)

G2M0286

S2M0207

(3) Clog plug onto service hole.

12
 SERVICE PROCEDURE [W1C0] 2-11
1. Engine

8) Tighten nuts which hold lower side of transmis- 15) Install air intake system.
sion to engine. (1) Install air cleaner case stay.
Tightening torque: (2) Install air intake duct with air cleaner case.
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

S2M1172

B2M2790 16) Install A/C flexible hoses. (With A/C)

9) Tighten nuts which install front cushion rubber <Ref. to 4-7 [W16A0].>
onto crossmember. CAUTION:
Tightening torque: Use new O-rings.
83±15 N·m (8.5±1.5 kg-m, 61±11 ft-lb) Tightening torque:
CAUTION: 25±7 N·m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
Be sure to tighten front cushion rubber mount-
ing bolts in the innermost elliptical hole in the
front crossmember.

G2M0270

17) Install cooling system.

(1) Attach radiator lower cushions to radiator.
G2M0303

10) Install front exhaust pipe and center exhaust

pipe. <Ref. to 2-9 [W1B0].>
11) Connect rear oxygen sensor connector.
12) 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
(4) Cruise control vacuum hose
13) Connect the following connectors. S2M0034
(1) Engine ground terminal
(2) Engine harness connectors
(3) Front oxygen sensor connector
(4) Generator connector and terminal
(5) A/C compressor connectors (With A/C)
14) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cables (With cruise control)
CAUTION:
After connecting each cable, adjust them.

13
2-11 [W1C0] SERVICE PROCEDURE
1. Engine

(2) Install radiator while fitting radiator pins to (6) Connect radiator outlet hose to thermostat
cushions. cover.

G2M0220 S2M0894C

(3) Install radiator brackets and tighten bolts. (A) Radiator outlet hose
(B) ATF cooler hose
Tightening torque:
12±3 N·m (1.2±0.3 kg-m, 8.7±2.2 ft-lb) (7) Connect radiator fan motor connector.

S2M0905 S2M0893

(4) Connect radiator inlet hose. (8) Install V-belt covers.

S2M0896
S2M0897

18) Install battery in the vehicle, and connect ter-

(5) Connect ATF cooler hoses. (AT vehicles)
minal.
19) Fill coolant.
<Ref. to 2-5 [W9B0].>
20) Check ATF level and correct if necessary. (AT
vehicles)
<Ref. to 3-2 [W1B1].>
21) Charge A/C system with refrigerant.
<Ref. to 4-7 [W7H0].>
22) Remove front hood stay, and close front hood.
23) Take off the vehicle from lift arms.

S2M0895

14
 SERVICE PROCEDURE [W2B0] 2-11
2. Transmission

2. Transmission 4) Remove air cleaner case stay.

I MT vehicles
A: GENERAL PRECAUTION
(1) Remove or install transmission in an area
where chain hoists, lifting devices, etc. are avail-
able for ready use.
(2) Be sure not to damage coated surfaces of
body panels with tools or stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
(3) Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
S2M0900
ant and oil, wire ropes, chain hoist, transmission
jacks, etc. I AT vehicles
(4) Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions. <Ref.
to 1-3 [G7B0].>

B: REMOVAL
1) Open front hood fully, and support with stay.
2) Disconnect battery ground terminal.
3) Remove air intake duct and air cleaner case.

S2M0901

5) Disconnect the following connectors.

(1) Front oxygen sensor connector

S2M1172

B2M3413

(2) Transmission harness connector (AT

vehicles)

S2M0212

(3) Transmission ground terminal

15
2-11 [W2B0] SERVICE PROCEDURE
2. Transmission

(4) Neutral position switch connector (MT 8) Separate torque converter from drive plate. (AT
vehicles) vehicles)
(5) Back-up light switch connector (MT (1) Remove service hole plug.
vehicles) (2) Remove bolts which hold torque converter
to drive plate.
(3) While rotating the engine, remove other
bolts using ST.
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.

B2M0337

(6) Vehicle speed sensor (MT vehicles)

S2M0207

9) Remove ATF level gauge. (AT vehicles)

CAUTION:
Plug opening to prevent entry of foreign par-
S2M0907 ticles into transmission fluid.

6) Disconnect connectors and terminal from

starter.
7) Remove pitching stopper.

S2M0908

10) Remove operating cylinder. (MT vehicles)

S2M0126

B2M1179J

(A) Clutch hose

(B) Operating cylinder

16
 SERVICE PROCEDURE [W2B0] 2-11
2. Transmission

11) Set ST. (3) Disconnect connector from rear oxygen

ST 41099AA020 ENGINE SUPPORT ASSY sensor.
NOTE:
Also is available Part No. 927670000.

B2M3421

(4) Separate center exhaust pipe from rear

G2M0313 exhaust pipe.
12) Remove bolt which holds right upper side of
transmission to engine.

B2M0055

(5) Remove bolt which installs center exhaust

B2M2791 pipe to hanger bracket.
13) Remove exhaust system.
(1) Lift-up the vehicle.
(2) Remove nuts which install front exhaust
pipe onto engine.

S2M0206

(6) Take off front and center exhaust pipes.

S2M0205

17
2-11 [W2B0] SERVICE PROCEDURE
2. Transmission

(7) Remove rear exhaust pipe. 14) Drain ATF to remove ATF drain plug. (AT
CAUTION: vehicles)
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.

B3M1036B

(A) Oil pan

S2M0158 (B) ATF drain plug
(C) Differential oil drain plug
(8) Remove heat shield cover of rear exhaust
pipe. 15) Disconnect ATF cooler hoses from pipes of
transmission side, and remove ATF level gauge
guide. (AT vehicles)

S2M0215

(9) Remove hanger bracket from right side of

S2M0909A
transmission.
16) Remove propeller shaft.
(1) Remove front cover of rear differential
mount.
(2) Separate propeller shaft from rear differen-
tial.

B2M0032

S2M0218

18
 SERVICE PROCEDURE [W2B0] 2-11
2. Transmission

(3) Remove bolts which hold center bearing (1) Disconnect stay from transmission.
onto body. (2) Disconnect rod from transmission.
CAUTION:
Be careful not to drop propeller shaft.

B3M0616B

(A) Joint
S2M0219
18) Remove shift select cable. (AT vehicles)
(4) Remove propeller shaft from transmission. (1) Remove snap pin from range select lever.
CAUTION:
I Be sure to use an empty container to catch
oil flowing out when removing propeller shaft.
I Be sure not to damage oil seals and the fric-
tional surface of sleeve yoke.
I Be sure to plug the opening in transmission
after removal of propeller shaft.

B3M1029B

(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp

(2) Remove select cable from plate assembly.

S2M0220

(5) Install the extension cap to transmission.

NOTE:
If extension cap is not available, place vinyl bag
over opening and faster with string to prevent gear
oil or ATF from leaking.

B3M1030E

(A) Select cable

(B) Plate ASSY
(C) Clamp

19) Remove front drive shafts from transmission.

S3M0498A

(A) Extension cap

17) Remove gear shift rod and stay from transmis-

sion. (MT vehicles)

19
2-11 [W2B0] SERVICE PROCEDURE
2. Transmission

(1) Remove transverse link from housing. 21) Remove nuts which hold lower side of trans-
mission to engine.

S2M1940A
B2M2790
(A) Transverse link
(B) Ball joint 22) Place transmission jack under transmission.
(2) Lower transverse link. CAUTION:
(3) Remove spring pins and separate front I Always support transmission case with a
drive shafts from each side of the transmission. transmission jack.
I On AT vehicles, make sure that the support
CAUTION:
plates of transmission jack don’t touch the oil
Discard removing spring pin. Replace with a
pan.
new one.

G2M0326
G2M0325
23) Remove transmission rear crossmember.
20) Remove starter.
I MT vehicles
(1) Remove bolt which installs upper side of
starter.
(2) Remove nut which installs lower side of
starter, and remove starter form transmission.
(3) Install ST to torque converter clutch case.
(AT model)
ST 498277200 STOPPER SET

G2M0831

H2M1961A

20
 SERVICE PROCEDURE [W2C0] 2-11
2. Transmission

I AT vehicles 2) Install transmission to engine.

(1) Gradually raise transmission with transmis-
sion jack.

S2M0221

24) Remove transmission. B2M0035

CAUTION:
I Move transmission jack toward rear until (2) Engage them at splines.
mainshaft is withdrawn from clutch cover. (MT CAUTION:
vehicles) Be careful not to strike mainshaft against
I Move transmission and torque converter as clutch cover. (MT vehicles)
a unit away from engine. (AT vehicles) 3) Install transmission rear crossmember.
I MT vehicles
Tightening torque:
T1: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb)
T2: 137±20 N·m (14±2 kg-m, 101±14 ft-lb)

B2M0035

C: INSTALLATION
1) Install ST to torque converter clutch case. (AT
G2M0832
vehicles)
ST 498277200 STOPPER SET I AT vehicles
Tightening torque:
T1: 34±5 N·m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
T2: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb)

H2M1961A

S2M0221A

4) Take off transmission jack.

21
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission

5) Tighten nuts which hold lower side of transmis- 7) Install torque converter to drive plate. (AT
sion to engine. vehicles)
Tightening torque: (1) Tighten bolts which hold torque converter to
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb) drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
Tightening torque:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)

B2M2790

6) Connect engine and transmission.

(1) Remove ST from torque converter clutch
case. (AT vehicles)
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
ST 498277200 STOPPER SET S2M0207
(2) Install starter.
<Ref. to 6-1 [W1A0].> (3) Clog plug onto service hole.
(3) Tightening bolt which holds right upper side 8) Install operating cylinder. (MT vehicles)
of transmission to engine. Tightening torque:
Tightening torque: 37±3 N·m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

B2M1179

B2M2791 9) Remove special tools.

G2M0313

22
 SERVICE PROCEDURE [W2C0] 2-11
2. Transmission

10) Install pitching stopper. (1) Install gear shift rod onto transmission.
Tightening torque: Tightening torque:
T1: 49±5 N·m (5.0±0.5 kg-m, 36.2±3.6 ft-lb) 18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
T2: 57±10 N·m (5.8±1.0 kg-m, 42±7 ft-lb)

B3M0616B
S2M0126C
(A) Joint
11) Install front drive shafts into transmission.
(1) Lift-up the vehicle. (2) Install stay onto transmission.
(2) Install front drive shaft into transmission. Tightening torque:
(3) Drive spring pin into chamfered hole of drive 18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
shaft. 13) Install shift select cable onto select lever. (AT
CAUTION: vehicles)
Always use a new spring pin. (1) Install select cable to plate assembly.
Tightening torque:
T: 33±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)

G2M0325

(4) Install ball joints of lower arm into knuckle

arm of housing, and tighten installing bolts. B3M1030G

Tightening torque: (A) Select cable

49±10 N·m (5.0±1.0 kg-m, 36±7 ft-lb) (B) Plate ASSY

S2M1940A

(A) Transverse link

(B) Ball joint

12) Install gear shift rod and stay. (MT vehicles)

23
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission

(2) Install snap pin to range select lever. (3) Install center bearing bracket on body.
Tightening torque:
T: 52±5 N·m (5.3±0.5 kg-m, 38.3±3.6 ft-lb)

B3M1029B

(A) Range select lever

(B) Snap pin S2M0219A

(C) Select cable

(D) Clamp
16) Install exhaust system.
(1) Install heat shield cover.
14) Install ATF level gauge guide, and ATF cooler
hoses onto pipe. (AT vehicles)

S2M0215

S2M0909
(2) Install rear exhaust pipe to muffler.
Tightening torque:
15) Install propeller shaft. 48±5 N·m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
(1) Install propeller shaft into transmission.
(2) Tighten bolts which install propeller shaft
onto companion flange of rear differential.
Tightening torque:
T: 31±8 N·m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)

S2M0157

S2M0218A

24
 SERVICE PROCEDURE [W2C0] 2-11
2. Transmission

(3) Install hanger bracket on right side of trans- (6) Tighten bolt which installs center exhaust
mission. pipe to hanger bracket.
Tightening torque:
35±5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)

B2M0032

(4) Install front exhaust pipe onto engine.

S2M0206
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb) (7) Connect connector to rear oxygen sensor.

S2M0205 B2M3421

(5) Install center exhaust pipe to rear exhaust 17) Install ATF level gauge. (AT vehicles)
pipe.
Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

S2M0908

18) Connect the following connectors.

(1) Transmission harness connectors
B2M0055

B2M0019

25
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission

(2) Transmission ground terminal 19) Install air cleaner case stay.
(3) Front oxygen sensor connector I MT vehicles

B2M3413 S2M0900

(4) Vehicle speed sensor (MT vehicles) I AT vehicles

S2M0907 S2M0901

(5) Neutral position switch and back-up light 20) Install air intake duct and air cleaner case.
switch connector (MT vehicles)

S2M1172
B2M0337
21) Connect battery ground terminal.
22) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole. (AT vehicles)
Recommended fluid:
Dexron IIE or Dexron III type automatic
transmission fluid
Fluid capacity:
9.3 — 9.6  (9.8 — 10.1 US qt, 8.2 — 8.4
Imp qt)
23) Check select lever operation. (AT vehicles)
<Ref. to 3-2 [T2C0].>
24) Take off vehicle from lift arms.
25) Run the vehicle until ATF temperature rises
from 60 to 80°C (140 to 176°F) and check the ATF
level of the “HOT” side on level gauge. (AT
vehicles)

26
 SERVICE PROCEDURE [W2C0] 2-11
2. Transmission

26) Check the vehicle on road tester. (AT vehicles) <Ref. to 3-2 [W7A0].>

27
2-11 SERVICE PROCEDURE

MEMO:

28
2-2 [W100] SERVICE PROCEDURE
1. Foreword

1. Foreword 2. Ignition Timing

This chapter describes major inspection and ser- A: MEASUREMENT
vice procedures for the engine mounted on the
body. For procedures not found in this chapter, CAUTION:
refer to the service procedure section in the appli- After warming-up, engine becomes very hot.
cable chapter. Be careful not to burn yourself during mea-
surement.
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.
3) Start the engine at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
10°±8°/650 (MT model)
15°±8°/700 (AT model)

B2M3130

If the timing is not correct, check the ignition con-

trol system.
Refer to 2-7 On-Board Diagnostics II System.
<Ref. to 2-7 [T100].>

2
2-2 [W100] SERVICE PROCEDURE
1. Foreword

1. Foreword 2. Ignition Timing

This chapter describes major inspection and ser- A: MEASUREMENT
vice procedures for the engine mounted on the
body. For procedures not found in this chapter, CAUTION:
refer to the service procedure section in the appli- After warming-up, engine becomes very hot.
cable chapter. Be careful not to burn yourself during mea-
surement.
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.
3) Start the engine at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
10°±8°/650 (MT model)
15°±8°/700 (AT model)

B2M3130

If the timing is not correct, check the ignition con-

trol system.
Refer to 2-7 On-Board Diagnostics II System.
<Ref. to 2-7 [T100].>

2
 SERVICE PROCEDURE [W3A0] 2-2
3. Engine Idle Speed

3. Engine Idle Speed (8) Start the engine, and read engine idle
speed.
A: MEASUREMENT
1) Before checking idle speed, check the follow-
ing:
(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.
S2M0098
3) Stop the engine, and turn ignition switch to
OFF. 5) When using tachometer (Secondary pick-up
4) When using SUBARU SELECT MONITOR; type);
NOTE: (1) Attach the pick-up clip to No. 1 cylinder
For detailed operation procedures, refer to the spark plug cord.
SUBARU SELECT MONITOR OPERATION (2) Start the engine, and read engine idle
MANUAL. speed.
(1) Insert the cartridge to SUBARU SELECT NOTE:
MONITOR. <Ref. to 1-6 [G1100].> I When using the OBD-II general scan tool, care-
fully read its operation manual.
I This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that
some tachometers may register twice that of actual
engine speed.

S2M0286A

(2) Connect SUBARU SELECT MONITOR to

the data link connector.
(3) Turn ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON. B2M2011
(4) Select {2. Each System Check} in Main
Menu. 6) Check idle speed when unloaded. (With
(5) Select {Engine Control System} in Selection headlights, heater fan, rear defroster, radiator fan,
Menu. air conditioning, etc. OFF)
(6) Select {1. Current Data Display & Save} in Idle speed (No load and gears in neutral (MT),
EGI/EMPI Diagnosis. or N or P (AT) position):
(7) Select {1.12 Data Display} in Data Display 650±100 rpm (MT model)
Menu. 700±100 rpm (AT model)
7) Check idle speed when loaded. (Turn air con-
ditioning switch to “ON” and operate compressor
for at least one minute before measurement.)
Idle speed [A/C “ON”, no load and gears in
neutral (MT) or N or P (AT) position]:
850±50 rpm

3
2-2 [W4A0] SERVICE PROCEDURE
4. Engine Compression

CAUTION: 4. Engine Compression

Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On- A: MEASUREMENT
board Diagnosis Table under “2-7 On-Board
CAUTION:
Diagnostics II System”. <Ref. to 2-7 [T100].>
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Disconnect battery ground cable.
4) Remove all the spark plugs. <Ref. to 6-1
[W3A0].>
5) Disconnect connectors from fuel injectors.
6) Connect battery ground cable.
7) Fully open throttle valve.
8) Check the starter motor for satisfactory perfor-
mance and operation.
9) 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.
10) Crank the engine by means of the starter
motor, and read the maximum value on the gauge
when the pointer is steady.

S2M0539

11) Perform at least two measurements per

cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,079 — 1,275 kPa (11.0 — 13.0 kg/cm2,
156 — 185 psi)
Limit;
1,020 kPa (10.4 kg/cm2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm2, 7 psi), or less

4
2-2 [W4A0] SERVICE PROCEDURE
4. Engine Compression

CAUTION: 4. Engine Compression

Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On- A: MEASUREMENT
board Diagnosis Table under “2-7 On-Board
CAUTION:
Diagnostics II System”. <Ref. to 2-7 [T100].>
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Disconnect battery ground cable.
4) Remove all the spark plugs. <Ref. to 6-1
[W3A0].>
5) Disconnect connectors from fuel injectors.
6) Connect battery ground cable.
7) Fully open throttle valve.
8) Check the starter motor for satisfactory perfor-
mance and operation.
9) 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.
10) Crank the engine by means of the starter
motor, and read the maximum value on the gauge
when the pointer is steady.

S2M0539

11) Perform at least two measurements per

cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,079 — 1,275 kPa (11.0 — 13.0 kg/cm2,
156 — 185 psi)
Limit;
1,020 kPa (10.4 kg/cm2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm2, 7 psi), or less

4
 SERVICE PROCEDURE [W6A0] 2-2
6. Engine Oil Pressure

5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: MEASUREMENT By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
1) Warm-up the engine. as described below.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the intake Vacuum pressure (at idling, A/C “OFF”):
manifold. Less than −60.0 kPa (−450 mmHg, −17.72
inHg)

B2M3134

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 Weak or broken valve springs
to 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.

6. Engine Oil Pressure 2) Remove generator from bracket.

(1) Disconnect connector and terminal from
A: MEASUREMENT generator.
1) Disconnect battery ground cable.

S2M0941

G6M0095

5
 SERVICE PROCEDURE [W6A0] 2-2
6. Engine Oil Pressure

5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: MEASUREMENT By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
1) Warm-up the engine. as described below.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the intake Vacuum pressure (at idling, A/C “OFF”):
manifold. Less than −60.0 kPa (−450 mmHg, −17.72
inHg)

B2M3134

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 Weak or broken valve springs
to 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.

6. Engine Oil Pressure 2) Remove generator from bracket.

(1) Disconnect connector and terminal from
A: MEASUREMENT generator.
1) Disconnect battery ground cable.

S2M0941

G6M0095

5
2-2 [W6A0] SERVICE PROCEDURE
6. Engine Oil Pressure

(2) Remove V-belt cover. 5) Connect oil pressure gauge hose to cylinder
block.
6) Connect battery ground cable.

S2M0896

(3) Loosen lock bolt and slider bolt, and remove G6M0095
front side V-belt.
7) Start the engine, and measure oil pressure.

G2M0286
S2M0242
(4) Remove generator lock bolt.
(5) Remove bolt which install generator on Oil pressure:
bracket. 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:
I If oil pressure is out of specification, check
oil pump, oil filter and lubrication line. Refer to
2-4 ENGINE LUBRICATION SYSTEM. <Ref. to
2-4 [W100].>
I If oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
S2M0942 sure switch. Ref. to 2-4 ENGINE LUBRICATION
SYSTEM. <Ref. to 2-4 [W300].>
3) Disconnect connector from oil pressure switch.
NOTE:
4) Remove oil pressure switch from engine cylin- The specified data is based on an engine oil tem-
der block. <Ref. to 2-4 [W3A0].> perature of 80°C (176°F).
8) After measuring oil pressure, install oil pressure
switch. <Ref. to 2-4 [W3B0].>
Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
9) Install generator and V-belt in the reverse order
of removal, and adjust the V-belt deflection. <Ref.
to 1-5 [G2A0].>

G2M0091

6
 SERVICE PROCEDURE [W7B0] 2-2
7. Fuel Pressure

7. Fuel Pressure 6) Measure fuel pressure while disconnecting

pressure regulator vacuum hose from collector
A: PRECAUTIONS chamber.
WARNING: Fuel pressure:
I Place “No fire” signs near the working area. Standard; 284 — 314 kPa (2.9 — 3.2
I Disconnect ground terminal from battery. kg/cm2, 41 — 46 psi)
I Be careful not to spill fuel on the floor.
B: MEASUREMENT OF FUEL
PRESSURE
WARNING:
Before removing fuel pressure gauge, release
fuel pressure.
NOTE:
If out of specification, check or replace pressure
regulator and pressure regulator vacuum hose. S2M0248

1) Release fuel pressure. <Ref. to 2-8 [W1A0].> 7) After connecting pressure regulator vacuum
2) Remove fuel filler cap. hose, measure fuel pressure.
3) Disconnect fuel delivery hoses from fuel filter,
Fuel pressure:
and connect fuel pressure gauge.
Standard; 206 — 235 kPa (2.1 — 2.4
kg/cm2, 30 — 34 psi)

B2M2484

S2M0248
4) Connect connector to fuel pump relay.
NOTE:
The fuel pressure gauge registers 10 to 20 kPa
(0.1 to 0.2 kg/cm2, 1.4 to 2.8 psi) higher than stan-
dard values during high-altitude operations.

S2M0093

5) Start the engine.

7
2-2 [W8A0] SERVICE PROCEDURE
8. Valve Clearance

8. Valve Clearance 5) Remove rocker cover.

6) When inspecting #1 and #3 cylinders:
A: INSPECTION (1) Remove air intake duct as a unit.
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.

B2M2012

(2) Remove resonator chamber.

G6M0095

3) Remove engine coolant reservoir tank.

<Ref. to 2-5 [W8A0].>

B2M2013

(3) Disconnect spark plug cords from spark

plugs (#1 and #3 cylinders).

S2M0931

4) Remove timing belt cover (LH).

B2M2014

(4) Disconnect blow-by hose from rocker cover

(RH).

B2M2031

B2M2015

(5) Lift-up the vehicle.

(6) Remove under cover.

8
 SERVICE PROCEDURE [W8A0] 2-2
8. Valve Clearance

(7) Place suitable container under the vehicle. (5) Remove the two bolts which hold washer
(8) Lower the vehicle. tank, then secure the tank away from working
(9) Remove the timing belt cover (RH) bolt. area.

B2M2016 H6M0431

(10) Remove rocker cover bolts, then remove (6) Disconnect spark plug cords from spark
rocker cover (RH). plugs (#2 and #4 cylinders).

B2M2017 B2M2024

7) When inspecting #2 and #4 cylinders: (7) Disconnect blow-by hose form rocker cover.
(1) Disconnect battery cables, and then
remove battery and battery carrier.
(2) Disconnect front window washer motor con-
nector.
(3) Disconnect rear gate glass washer motor
connector.

B2M2025

(8) Lift-up the vehicle.

(9) Remove under cover.
(10) Place suitable container under the vehicle.

S2M0546

(4) Disconnect rear gate glass washer hose

from washer motor, then plug connection with a
suitable cap.

9
2-2 [W8A0] SERVICE PROCEDURE
8. Valve Clearance

(11) Remove rocker cover bolts, then remove 9) Measure #1 cylinder valve clearance by using
rocker cover (LH). thickness gauge (A).
CAUTION:
I Insert the thickness gauge (A) in at as hori-
zontal a direction as a possible with respect to
the valve stem end face.
I 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)
B2M2026

8) Set #1 cylinder piston to top dead center of

compression stroke by rotating crankshaft pulley
clockwise.
NOTE:
When arrow mark (A) on camshaft sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of the compression
stroke.
B2M2028B

10) If necessary, adjust the valve clearance. <Ref.

to 2-2 [W7B0].>
11) Similar to measurement procedures used for
#1 cylinder, measure #2, #3 and #4 cylinder valve
clearances.
NOTE:
I Be sure to set cylinder pistons to their respective
top dead centers on the compression stroke before
B2M2027B measuring valve clearances.
I To set #3, #2 and #4 cylinder pistons to their top
dead centers on the compression stroke, turn
crankshaft pulley clockwise 90° at a time starting
with arrow mark on left-hand camshaft sprocket
facing up.

B2M2029B

10
 SERVICE PROCEDURE [W8B0] 2-2
8. Valve Clearance

12) After inspection, install the related parts in the 2) Adjust the #1 cylinder valve clearance.
reverse order of removal. (1) Loosen the valve rocker nut and screw.
Tightening torque: (2) Place suitable thickness gauge.
33±10 N·m (3.4±1.0 kg-m, 25±7 ft-lb) (3) While noting valve clearance, tighten valve
rocker adjust screw.
(4) When specified valve clearance is obtained,
tighten valve rocker nut.
Tightening torque:
10±1 N·m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
CAUTION:
I Insert the thickness gauge in at as horizon-
tal a direction as possible with respect to the
valve stem end face.
I Adjust exhaust valve clearances while lift-
B2M2013
ing-up the vehicle.
Valve clearance:
B: ADJUSTMENT Intake: 0.20±0.02 mm (0.0079±0.0008 in)
CAUTION: Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise.
NOTE:
When arrow mark (A) on camshaft sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of the compression
stroke. B2M2030C

(A) Thickness gauge

(B) Valve rocker nut
(C) Valve rocker screw

3) Ensure that valve clearances are within speci-

fications.
4) Turn crankshaft two complete rotations until #1
cylinder piston is again set to top dead center on
compression stroke.
5) Ensure that valve clearances are within speci-
B2M2027B fications. If necessary, re-adjust valve clearances.

11
2-2 [W8B0] SERVICE PROCEDURE
8. Valve Clearance

6) Similar to adjustment procedures used for #1

cylinder, adjust #2, #3 and #4 cylinder valve clear-
ances.
NOTE:
I Be sure to set cylinder pistons to their respective
top dead centers on the compression stroke before
adjusting valve clearances.
I To set #3, #2 and #4 cylinder pistons to their top
dead centers on the compression stroke, turn
crankshaft pulley clockwise 90° at a time starting
with arrow mark on left-hand camshaft sprocket
facing up.

B2M2029B

12
2-3 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Engine

1. Engine
A: SPECIFICATIONS
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-
Type
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm3 (cu in) 2,457 (150)
Compression ratio 10.0
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 1,079 — 1,275 (11.0 — 13.0, 156 — 185)
rpm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Engine Opening 1° BTDC
Intake valve timing
Closing 51° ABDC
Opening 50° BBDC
Exhaust valve timing
Closing 6° 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)
Idling speed [At neutral position
700±100 (No load)
on MT, or “P” or “N” position on rpm
850±100 (A/C switch ON)
AT]
Firing order 1→3→2→4
Ignition timing BTDC/rpm 10°±10°/700

B: SERVICE DATA
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
Belt ten-
sioner 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. 18.00 — 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 0.20 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Valve rocker STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
Clearance between shaft and arm
arm Limit 0.10 mm (0.0039 in)
Bend limit 0.020 mm (0.0008 in)
STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.11 mm (0.0043 in)
STD 39.485 — 39.585 mm (1.5545 — 1.5585 in)
Intake
Limit 39.385 mm (1.5506 in)
Cam lobe height
Camshaft STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Camshaft journal O.D. 31.928 — 31.945 mm (1.2570 — 1.2577 in)
Camshaft journal hole I.D. 32.000 — 32.018 mm (1.2598 — 1.2605 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.1 mm (0.004 in)
head
Standard height 98.3 mm (3.870 in)

2
 SPECIFICATIONS AND SERVICE DATA [S1B0] 2-3
1. Engine

Refacing angle 90°

STD 1.0 mm (0.039 in)
Intake
Valve set Limit 1.7 mm (0.067 in)
Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 2.1 mm (0.083 in)
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve guide Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)
STD 1.0 mm (0.039 in)
Intake
Limit 0.6 mm (0.024 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.6 mm (0.024 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 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 120.6 mm (4.75 in)
Overall length
Exhaust 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Valve spring 214.8 — 246.2 N (21.9 — 25.1 kg, 48.3 — 55.3 lb)/45.0
Tension/spring height mm (1.772 in) 526.6 — 581.6 N (53.7 — 59.3 kg, 118.4
— 130.8 lb)/34.7 mm (1.366 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 99.505 — 99.515 mm (3.9175 — 3.9179 in)
Cylinder bore STD
B 99.495 — 99.505 mm (3.9171 — 3.9175 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 99.485 — 99.495 mm (3.9167 — 3.9171 in)
STD
B 99.475 — 99.485 mm (3.9163 — 3.9167 in)
0.25 mm (0.0098 in)
Outer diameter 99.725 — 99.735 mm (3.9262 — 3.9266 in)
Piston OS
0.50 mm (0.0197 in)
99.975 — 99.985 mm (3.9360 — 3.9364 in)
OS
Standard inner diameter of piston pin hole 23.000 — 23.006 mm (0.9055 — 0.9057 in)
Outer diameter 22.994 — 23.000 mm (0.9053 — 0.9055 in)
Standard clearance between piston pin and hole in
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Piston pin piston
Piston pin must be fitted into position with thumb at
Degree of fit
20°C (68°F).

3
2-3 [S1B0] SPECIFICATIONS AND SERVICE DATA
1. Engine

STD 0.20 — 0.35 mm (0.0079 — 0.0138 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)
Clearance STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Top ring
between piston Limit 0.15 mm (0.0059 in)
ring and piston Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring groove ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94
Limit 0.10 mm (0.0039 in)
Connecting in) in 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 1.486 — 1.498 mm (0.0585 — 0.0590 in)
0.03 mm (0.0012 in)
Connecting 1.504 — 1.512 mm (0.0592 — 0.0595 in)
US
rod bearing
Thickness at center portion 0.05 mm (0.0020 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
US
0.25 mm (0.0098 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
US
Connecting Clearance between piston STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing pin and bushing Limit 0.030 mm (0.0012 in)
Bend limit 0.035 mm (0.0014 in)
Crank pin and Out-of-roundness 0.020 mm (0.0008 in) or less
crank journal Grinding limit 0.250 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
US
Crank pin outer diameter 0.05 mm (0.0020 in)
51.934 — 51.950 mm (2.0446 — 2.0453 in)
US
0.25 mm (0.0098 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #5, #3 0.05 mm (0.0020 in)
Crankshaft 59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal US
outer diameter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#2, #4 0.05 mm (0.0020 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 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)

4
 SPECIFICATIONS AND SERVICE DATA [S1B0] 2-3
1. Engine

STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
#1, #5 0.05 mm (0.0020 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm (0.0098 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft Crankshaft bear- US
bearing ing thickness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #3, #4 0.05 mm (0.0020 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
US
0.25 mm (0.0098 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
US

5
2-3 [C100] COMPONENT PARTS
1. Timing Belt

1. Timing Belt

S2M1786A

(1) Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N·m (kg-m, ft-lb)
(2) Timing belt guide (MT vehicles ASSY
T1: 5±1 (0.5±0.1, 3.6±0.7)
only) (10) Belt idler No. 2
T2: 9.8±1.0 (1.0±0.1, 7.2±0.7)
(3) Crankshaft sprocket (11) Camshaft sprocket No. 2
T3: 25±3 (2.5±0.3, 18.1±2.2)
(4) Belt cover No. 2 (LH) (12) Timing belt
(5) Camshaft sprocket No. 1 (13) Front belt cover T4: 39±4 (4.0±0.4, 28.9±2.9)
(6) Belt idler (No. 1) (14) Belt cover (LH) T5: 78±5 (8.0±0.5, 57.9±3.6)
(7) Tensioner bracket (15) Crankshaft pulley T6: 177±5 (18.0±0.5, 130.2±3.6)
(8) Belt idler (No. 2)

6
 COMPONENT PARTS [C200] 2-3
2. Cylinder Head and Camshaft

2. Cylinder Head and Camshaft

B2M1954D

(1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kg-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH)
T1: Refer to [W6E1].
(3) Exhaust valve rocker ASSY (13) Camshaft cap (LH)
T2: 5±1 (0.5±0.1, 3.6±0.7)
(4) Camshaft cap (RH) (14) Oil filler cap
T3: 10±2 (1.0±0.2, 7.2±1.4)
(5) Oil seal (15) Gasket
(6) Camshaft (RH) (16) Oil filler pipe T4: 18±2 (1.8±0.2, 13.0±1.4)
(7) Plug (17) O-ring T5: 25±2 (2.5±0.2, 18.1±1.4)
(8) Spark plug pipe gasket (18) Rocker cover (LH) T6: 6.4±0.5 (0.65±0.05, 4.7±0.4)
(9) Cylinder head (RH) (19) Stud bolt
(10) Cylinder head gasket

7
2-3 [C300] COMPONENT PARTS
3. Cylinder Head and Valve Assembly

3. Cylinder Head and Valve Assembly

B2M1955A

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

8
 COMPONENT PARTS [C400] 2-3
4. Cylinder Block

4. Cylinder Block

S2M1787B

(1) Oil pressure switch (18) Oil pan Tightening torque: N·m (kg-m, ft-lb)
(2) Cylinder block (RH) (19) Drain plug
T1: 5 (0.5, 3.6)
(3) Service hole plug (20) Metal gasket
T2: 6.4 (0.65, 4.7)
(4) Gasket (21) Oil level gauge guide
T3: 10 (1.0, 7)
(5) Oil separator cover (22) Water pump sealing
(6) Water by-pass pipe (23) Oil filter T4: 25±2 (2.5±0.2, 18.1±1.4)
(7) Oil pump (24) Gasket T5: 47±3 (4.8±0.3, 34.7±2.2)
(8) Front oil seal (25) Water pump hose T6: 69±7 (7.0±0.7, 50.6±5.1)
(9) Rear oil seal (26) Connector (AT vehicles) T7: First 12±2 (1.2±0.2, 8.7±1.4)
(10) O-ring (27) Water by-pass pipe (AT vehicles) Second 12±2 (1.2±0.2,
(11) Service hole cover (28) Oil cooler (AT vehicles) 8.7±1.4)
(12) Cylinder block (LH) (29) Nipple (AT vehicles) T8: 16±1.5 (1.6±0.15, 11.6±1.1)
(13) Water pump (30) Plug (MT vehicles) T9: 44 (4.5, 33)
(14) Baffle plate (31) Gasket (MT vehicles) T10: 25±3 (2.5±0.3, 18.1±2.2)
(15) Oil filter connector (32) Gasket (AT vehicles) T11: 54±5 (5.5±0.5, 39.8±3.6)
(16) Oil strainer (33) O-ring
(17) Gasket

9
2-3 [C500] COMPONENT PARTS
5. Crankshaft and Piston

5. Crankshaft and Piston

B2M3429A

10
 COMPONENT PARTS [C500] 2-3
5. Crankshaft and Piston

(1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4

(2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT) (11) Connecting rod
(4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kg-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 44.6±1.5 (4.55±0.15, 32.9±1.1)
(6) Oil ring (14) Crankshaft T2: 72±3 (7.3±0.3, 52.8±2.2)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3

11
2-3 [C600] COMPONENT PARTS
6. Valve Rocker Assembly

6. Valve Rocker Assembly

B2M1956A

(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kg-m, ft-lb)
(2) Valve rocker nut (7) Exhaust rocker shaft
T1: 5±1 (0.5±0.1, 3.6±0.7)
(3) Valve rocker adjust screw (8) Exhaust valve rocker arm
T2: 10±1 (1.0±0.1, 7.2±0.7)
(4) Spring
T3: 25±2 (2.5±0.2, 18.1±1.4)
(5) Rocker shaft support

12
 SERVICE PROCEDURE [W200] 2-3
2. General Procedure

1. General Precautions 2. General Procedure

1) All parts should be thoroughly cleaned, paying 1) For the procedure of removing the engine from
special attention to the engine oil passages, pis- the vehicle, refer to 2-11 ENGINE AND TRANS-
tons and bearings. MISSION MOUNTING SYSTEM. <Ref. to 2-11
2) Rotating parts and sliding parts such as piston, [W2A0].> However, before going into the
bearing and gear should be coated with oil prior to procedure, it is necessary to do the following.
assembly. I Before disassembling engine, place it on ST3.
3) Be careful not to let oil, grease or coolant con- ST1 498457000 ENGINE STAND ADAPTER
tact the timing belt, clutch disc and flywheel. RH
4) All removed parts, if to be reused, should be ST2 498457100 ENGINE STAND ADAPTER
reinstalled in the original positions and directions. LH
5) Bolts, nuts and washers should be replaced ST3 499817000 ENGINE STAND
with new ones as required.
6) Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.

S2M1859A

2) It is possible to conduct the following service

procedures with engine on the vehicle, however,
the procedures described in this section are based
on the condition that the engine is removed from
the vehicle.
I Timing Belt
I Valve Rocker Assembly
I Camshaft
I Cylinder Head
3) In this section the procedures described under
each index are all connected and stated in order.
It will be the complete procedure for over hauling
of the engine it-self 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.

13
 SERVICE PROCEDURE [W200] 2-3
2. General Procedure

1. General Precautions 2. General Procedure

1) All parts should be thoroughly cleaned, paying 1) For the procedure of removing the engine from
special attention to the engine oil passages, pis- the vehicle, refer to 2-11 ENGINE AND TRANS-
tons and bearings. MISSION MOUNTING SYSTEM. <Ref. to 2-11
2) Rotating parts and sliding parts such as piston, [W2A0].> However, before going into the
bearing and gear should be coated with oil prior to procedure, it is necessary to do the following.
assembly. I Before disassembling engine, place it on ST3.
3) Be careful not to let oil, grease or coolant con- ST1 498457000 ENGINE STAND ADAPTER
tact the timing belt, clutch disc and flywheel. RH
4) All removed parts, if to be reused, should be ST2 498457100 ENGINE STAND ADAPTER
reinstalled in the original positions and directions. LH
5) Bolts, nuts and washers should be replaced ST3 499817000 ENGINE STAND
with new ones as required.
6) Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.

S2M1859A

2) It is possible to conduct the following service

procedures with engine on the vehicle, however,
the procedures described in this section are based
on the condition that the engine is removed from
the vehicle.
I Timing Belt
I Valve Rocker Assembly
I Camshaft
I Cylinder Head
3) In this section the procedures described under
each index are all connected and stated in order.
It will be the complete procedure for over hauling
of the engine it-self 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.

13
2-3 [W3A1] SERVICE PROCEDURE
3. Timing Belt

3. Timing Belt 6) Remove front belt cover.

A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT
COVER
1) Remove A/C belt. (With A/C model)

B2M2587

2. TIMING BELT
1) Remove timing belt guide. (MT vehicles only)

B2M2584

2) Remove A/C belt tensioner. (With A/C model)

S2M0294

B2M2585

3) Remove crankshaft pulley bolt. To lock

crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH

S2M1860A

4) Remove crankshaft pulley.

5) Remove belt cover (LH).

14
 SERVICE PROCEDURE [W3A2] 2-3
3. Timing Belt

2) If alignment mark (a) and/or arrow mark (which (2) Using white paint, put alignment and/or
indicates rotation direction) on timing belt fade arrow marks on timing belts in relation to the
away, put new marks before removing timing belt crank sprocket and cam sprockets.
as shown in procedures below.
(1) Turn crankshaft using ST. Align mark (a) of
sprocket to cylinder block notch (b) and ensure
that right side cam sprocket mark (c), cam cap
and cylinder head matching surface (d) and/or
left side cam sprocket mark (e) and belt cover
notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET

B2M2591

Specified data:
Z1: 44 tooth length
Z2: 40.5 tooth

S2M1861A

B2M2592A

3) Remove belt idler (No. 2).

4) Remove belt idler No. 2.

S2M1008

5) Remove timing belt.

S2M1007C

B2M2594

15
2-3 [W3A3] SERVICE PROCEDURE
3. Timing Belt

3. BELT IDLER AND AUTOMATIC BELT 3) Remove camshaft sprocket No. 1. To lock
TENSION ADJUSTER ASSEMBLY camshaft, using ST.
ST 499207400 CAMSHAFT SPROCKET
1) Remove belt idler (No. 1).
WRENCH

B2M2596
S2M1863A

2) Remove automatic belt tension adjuster assem- 4) Remove crankshaft sprocket.

bly.

S2M0414
H2M2375
5) Remove belt cover No. 2 (LH).
4. CAMSHAFT AND CRANKSHAFT 6) Remove belt cover No. 2 (RH).
SPROCKET CAUTION:
1) Remove camshaft position sensor. Do not damage or lose the seal rubber when
2) Remove camshaft sprocket No. 2. To lock removing belt covers.
camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH

B2M2601

S2M1862A

16
 SERVICE PROCEDURE [W3B4] 2-3
3. Timing Belt

7) Remove tensioner bracket. (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 kg, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension
adjuster assembly with a new one.
CAUTION:
I Always use a vertical type pressing tool to
H2M2380
move the adjuster rod down.
I Do not use a lateral type vise.
B: INSPECTION I Push adjuster rod vertically.
I Press-in the push adjuster rod gradually tak-
1. TIMING BELT ing more than three minutes.
1) Check timing belt teeth for breaks, cracks, and I Do not allow press pressure to exceed 9,807
wear. If any fault is found, replace belt. N (1,000 kg, 2,205 lb).
2) Check the condition of back side of belt; if any I Press the adjuster rod as far as the end sur-
crack is found, replace belt. face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
CAUTION: cylinder.
I Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thor- 4) Measure the extension of rod beyond the body.
oughly if this happens. If it is not within specifications, replace with a new
I Do not bend the belt sharply. one.
Bending radius h: Rod extension H:
60 mm (2.36 in) or more 5.7±0.5 mm (0.224±0.020 in)

G2M0115 H2M2381A

2. AUTOMATIC BELT TENSION 3. BELT TENSION PULLEY

ADJUSTER 1) Check mating surfaces of timing belt and con-
1) Visually check oil seals for leaks, and rod ends tact point of adjuster rod for abnormal wear or
for abnormal wear or scratches. If necessary, scratches. Replace automatic belt tension adjuster
replace faulty parts. assembly if faulty.
2) Check tension pulley for smooth rotation.
CAUTION: Replace if noise or excessive play is noted.
Slight traces of oil at rod’s oil seal does not 3) Check tension pulley for grease leakage.
indicate a problem.
2) Check that the adjuster rod does not move 4. BELT IDLER
when a pressure of 294 N (30 kg, 66 lb) is applied 1) Check belt idler for smooth rotation. Replace if
to it. This is to check adjuster rod stiffness. noise or excessive play is noted.
3) If the adjuster rod is not stiff and moves freely 2) Check belt outer contacting surfaces of idler
when applying 294 N (30 kg, 66 lb), check it using pulley for abnormal wear and scratches.
the following procedures: 3) Check belt idler for grease leakage.

17
2-3 [W3B5] SERVICE PROCEDURE
3. Timing Belt

5. CAMSHAFT AND CRANKSHAFT 4) Install crankshaft sprocket.

SPROCKET
1) Check sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between
sprocket and key.
3) Check crankshaft sprocket notch for sensor for
damage and contamination of foreign matter.

C: INSTALLATION
1. CAMSHAFT AND CRANKSHAFT S2M0414
SPROCKET
5) Install camshaft sprocket No. 1. To lock
1) Install tensioner bracket. camshaft, use ST.
Tightening torque: ST 499207400 CAMSHAFT SPROCKET
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) WRENCH
Tightening torque:
78±5 N·m (8.0±0.5 kg-m, 57.9±3.6 ft-lb)
CAUTION:
Do not confuse left and right side camshaft
sprockets during installation.

H2M2380

2) Install belt cover No. 2 (RH).

Tightening torque:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)
3) Install belt cover No. 2 (LH). S2M1863A

Tightening torque:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)

B2M2601

18
 SERVICE PROCEDURE [W3C2] 2-3
3. Timing Belt

6) Install camshaft sprocket No. 2. To lock 2. AUTOMATIC BELT TENSION

camshaft, use ST. ADJUSTER ASSEMBLY AND BELT IDLER
ST 499207100 CAMSHAFT SPROCKET
WRENCH 1) Preparation for installation of automatic belt
tension adjuster assembly;
Tightening torque:
78±5 N·m (8.0±0.5 kg-m, 57.9±3.6 ft-lb) CAUTION:
I Always use a vertical type pressing tool to
CAUTION: move the adjuster rod down.
Do not confuse left and right side camshaft
I Do not use a lateral type vise.
sprockets during installation. The camshaft
I Push adjuster rod vertically.
sprocket No. 2 is identified by a projection
used to monitor camshaft position sensor. I Be sure to slowly move the adjuster rod
down applying a pressure of 294 N (30 kg, 66
lb).
I Press-in the push adjuster rod gradually tak-
ing more than three minutes.
I Do not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
I 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.
I Do not release press pressure until stopper
S2M1862A
pin is completely inserted.
7) Install camshaft position sensor. (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 kg, 66 lb) until the
adjuster rod is aligned with the stopper pin hole
in the cylinder.

H2M2382

(3) With a 2 mm (0.08 in) dia. stopper pin or a

2 mm (0.08 in) (nominal) dia. hex bar wrench
inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.

H2M2383

19
2-3 [W3C3] SERVICE PROCEDURE
3. Timing Belt

2) Install automatic belt tension adjuster assem- (2) While aligning alignment mark (A) on timing
bly. belt with marks on sprockets, position timing
Tightening torque: belt properly.
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb) CAUTION:
Ensure belt’s rotating direction is correct.

H2M2384
B2M2603B
3) Install belt idler (No. 1).
Tightening torque: 2) Install belt idler No. 2.
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb) Tightening torque:
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)
3) Install belt idler (No. 2).
Tightening torque:
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)

B2M2596

3. TIMING BELT
1) Installation of timing belt
(1) Turn camshaft sprocket No. 2 using ST1, S2M1008
and turn camshaft sprocket No. 1 using ST2 so
that their alignment marks (A) come to top posi- 4) After ensuring that the marks on timing belt and
tions. camshaft sprockets are aligned, remove stopper
ST1 499207100 CAMSHAFT SPROCKET pin from belt tensioner adjuster.
WRENCH CAUTION:
ST2 499207400 CAMSHAFT SPROCKET After properly installing timing belt, remove
WRENCH rocker cover and ensure that the valve lash
adjuster contains no air.

B2M2602B
H2M2387

20
 SERVICE PROCEDURE [W3C4] 2-3
3. Timing Belt

5) Install timing belt guide. (MT vehicles only) 4. CRANKSHAFT PULLEY AND BELT
(1) Temporarily tighten remaining bolts. COVER
1) Install front belt cover.
Tightening torque:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)
2) Install belt cover (LH).
Tightening torque:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)

S2M0294

(2) Check and adjust clearance between timing

belt and timing belt guide by using thickness
gauge.
Clearance:
1.0±0.5 mm (0.039±0.020 in)
B2M2587

3) Install crankshaft pulley.

4) Install pulley bolt.
To lock crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
S2M0297
seat and thread.
(3) Tighten remaining bolts. (3) Tighten the bolts temporarily with tightening
torque of 44 N·m (4.5 kg-m, 33 ft-lb).
Tightening torque: (4) Tighten the crankshaft pulley bolts.
9.8±1.0 N·m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
Tightening torque:
177±5 N·m (18.0±0.5 kg-m, 130.2±3.6 ft-lb)

H2M2415

S2M1860A

5) 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).
CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be
damaged. In this case, the bolt must be
replaced.

21
2-3 [W4A0] SERVICE PROCEDURE
4. Valve Rocker Assembly

(1) Replace the crankshaft pulley bolts and 4. Valve Rocker Assembly
clean them.
Crankshaft pulley bolt: A: REMOVAL
12369AA011 1) Disconnect PCV hose and remove rocker
(2) Clean the crankshaft thread using an air cover.
gun. 2) Loosen bolt which secures rocker shaft sup-
(3) Tighten the bolts temporarily with tightening port.
torque of 44 N·m (4.5 kg-m, 33 ft-lb). 3) Removal of valve rocker assembly
(4) Tighten the crankshaft pulley bolts keeping (1) Remove bolts (a) through (d) in alphabetical
them in an angle between 65 degrees and 75 sequence.
degrees. CAUTION:
CAUTION: Leave two or three threads of bolt (a) engaged
Conduct the tightening procedures by confirm- to retain valve rocker assembly.
ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
6) Install A/C belt tensioner. (With A/C model)

B2M2605B

(2) Equally loosen bolts (e) through (h) all the

way, being careful that knock pin is not gouged.

B2M2585

7) Install A/C belt. (With A/C model)

B2M2605C

(3) Remove valve rocker assembly.

B2M2584

B2M2606

22
2-3 [W4A0] SERVICE PROCEDURE
4. Valve Rocker Assembly

(1) Replace the crankshaft pulley bolts and 4. Valve Rocker Assembly
clean them.
Crankshaft pulley bolt: A: REMOVAL
12369AA011 1) Disconnect PCV hose and remove rocker
(2) Clean the crankshaft thread using an air cover.
gun. 2) Loosen bolt which secures rocker shaft sup-
(3) Tighten the bolts temporarily with tightening port.
torque of 44 N·m (4.5 kg-m, 33 ft-lb). 3) Removal of valve rocker assembly
(4) Tighten the crankshaft pulley bolts keeping (1) Remove bolts (a) through (d) in alphabetical
them in an angle between 65 degrees and 75 sequence.
degrees. CAUTION:
CAUTION: Leave two or three threads of bolt (a) engaged
Conduct the tightening procedures by confirm- to retain valve rocker assembly.
ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
6) Install A/C belt tensioner. (With A/C model)

B2M2605B

(2) Equally loosen bolts (e) through (h) all the

way, being careful that knock pin is not gouged.

B2M2585

7) Install A/C belt. (With A/C model)

B2M2605C

(3) Remove valve rocker assembly.

B2M2584

B2M2606

22
 SERVICE PROCEDURE [W4C2] 2-3
4. Valve Rocker Assembly

B: DISASSEMBLY 2) If oil clearance exceeds the limit, replace valve

rocker arm or shaft, whichever shows greater
1) Remove bolts which secure rocker shaft. amount of wear.
2) Extract rocker shaft. Remove valve rocker
arms, springs, plates and shaft supports from Rocker arm inside diameter:
rocker shaft. 22.020 — 22.041 mm (0.8669 — 0.8678 in)
CAUTION: Rocker shaft diameter:
Arrange all removed parts in order so that they 21.987 — 22.000 mm (0.8656 — 0.8661 in)
can be installed in their original positions. 3) Measure inside diameter of rocker shaft sup-
3) Remove nut and adjuster screw from valve port and outside diameter of valve rocker shaft,
rocker. and determine the difference between the two (=
oil clearance).
C: INSPECTION
Clearance between support and shaft:
1. VALVE ROCKER ARM Standard
1) Measure inside diameter of valve rocker arm 0.005 — 0.039 mm (0.0002 — 0.0015 in)
and outside diameter of valve rocker shaft, and Limit
determine the difference between the two (= oil 0.05 mm (0.0020 in)
clearance). 4) If oil clearance exceeds the limit, replace rocker
Clearance between arm and shaft: shaft support or shaft, whichever shows greater
Standard amount of wear.
0.020 — 0.054 mm (0.0008 — 0.0021 in) Rocker shaft support inside diameter:
Limit 22.005 — 22.026 mm (0.8663 — 0.8672 in)
0.10 mm (0.0039 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
5) If cam or valve contact surface of valve rocker
arm is worn or dented excessively, replace valve
rocker arm.
6) Check that valve rocker arm roller rotates
smoothly. If not, replace valve rocker arm.
2. INTAKE AND EXHAUST VALVE
ROCKER SHAFT
B2M0072
Visually check oil relief valve of shaft end for any
of the following abnormalities.
I Breaks in check ball body
I Foreign particles caught in valve spring
I Oil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as neces-
sary.

B2M0073

23
2-3 [W4D0] SERVICE PROCEDURE
4. Valve Rocker Assembly

D: ASSEMBLY

B2M2607B

(1) Valve rocker adjust screw (5) Rocker shaft support Tightening torque: N·m (kg-m, ft-lb)
(2) Valve rocker nut (6) Intake valve rocker shaft
T: 5±1 (0.5±0.1, 3.6±0.7)
(3) Intake valve rocker arm (7) Exhaust valve rocker arm
(4) Spring (8) Exhaust valve rocker shaft

1) Install adjuster screw and nut to valve rocker. E: INSTALLATION

2) Arrange valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker 1) Installation of valve rocker assembly
shaft. (1) Temporarily tighten bolts (a) through (d)
equally as shown in figure.
Tightening torque (Shaft supports installing
bolts): CAUTION:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb) Do not allow valve rocker assembly to gouge
knock pins.
CAUTION:
Valve rocker arms, rocker shaft and shaft sup- (2) Tighten bolts (e) through (h) to specified
ports have identification marks. Ensure parts torque.
with same markings are properly assembled. (3) Tighten bolts (a) through (d) to specified
torque.
3) Install valve rocker shaft securing bolts.
Tightening torque:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)

B2M2605A

2) Adjust the valve clearances. <Ref. to 2-2

[W8B1].>
3) Install rocker cover and connect PCV hose.

24
 SERVICE PROCEDURE [W5A3] 2-3
5. Camshaft

5. Camshaft (4) Remove camshaft cap.

A: REMOVAL
1. RELATED PARTS
Remove camshaft sprockets, belt cover No. 2
<Ref. to 2-3 [W3A4].> and valve rocker assembly.
<Ref. to 2-3 [W4A0].>
2. CAMSHAFT (LH)
1) Remove camshaft cap.
(1) Remove bolts (a) and (b). B2M2613

2) Remove camshaft (LH).

3) Remove oil seal.
4) Remove plug from rear side of camshaft (LH).
CAUTION:
I Do not remove oil seal unless necessary.
I Do not scratch journal surface when remov-
ing oil seal.
3. CAMSHAFT (RH)
B2M2612B 1) Remove camshaft cap.
(1) Remove bolts (a) and (b).
(2) Equally loosen bolts (c) through (j) all the
way in alphabetical sequence.

B2M2612B

B2M2612C (2) Equally loosen bolts (c) through (j) all the
way in alphabetical sequence.
(3) Remove bolts (k) through (p) in alphabetical
sequence using ST.
ST 499497000 TORX PLUS

B2M2612C

B2M2612D

25
2-3 [W5B1] SERVICE PROCEDURE
5. Camshaft

(3) Remove bolts (k) through (p) in alphabetical 3) Measure outside diameter of camshaft journal
sequence using ST. and inside diameter of cylinder head journal, and
ST 499497000 TORX PLUS determine the difference between the two (oil
clearance). If oil clearance exceeds specifications,
replace camshaft or cylinder head as necessary.
Unit: mm (in)
Clearance Standard 0.055 — 0.090 (0.0022 — 0.0035)
at journal Limit 0.10 (0.0039)
31.928 — 31.945 (1.2570 —
Camshaft journal O.D.
1.2577)
32.000 — 32.018 (1.2598 —
Journal hole I.D.
1.2605)
B2M2612D 4) Check cam face condition; remove minor faults
by grinding with oil stone. Measure the cam height
(4) Remove camshaft cap.
H; replace if the limit has been exceeded.
Cam height H:
Item Unit: mm (in)
39.485 — 39.585
STD
Intake (1.5545 — 1.5585)
Limit 39.385 (1.5506)
39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit 39.157 (1.5416)

B2M2613 Cam base circle diameter A:

IN: 34.00 mm (1.3386 in)
2) Remove camshaft (RH). EX: 34.00 mm (1.3386 in)
3) Remove oil seal.
4) Remove plug from rear side of camshaft (RH).
CAUTION:
I Do not remove oil seal unless necessary.
I Do not scratch journal surface when remov-
ing oil seal.
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec-
B2M1209A
essary.
Limit:
0.025 mm (0.0010 in)

B2M2617

2) Check journal for damage and wear. Replace if

faulty.

26
 SERVICE PROCEDURE [W5C1] 2-3
5. Camshaft

2. CAMSHAFT SUPPORT NOTE:

Apply a coat of 3 mm (0.12 in) dia. (A) liquid gas-
Measure the thrust clearance of camshaft with dial
ket along edge (B) of camshaft cap (C) mating
gauge. If the clearance exceeds the limit, replace
surface.
camshaft support.
Standard:
0.030 — 0.090 mm (0.0012 — 0.0035 in)
Limit:
0.10 mm (0.0039 in)

S2M1199B

(2) Temporarily tighten bolts (g) through (j) in

alphabetical sequence.

B2M2618

C: INSTALLATION
1. CAMSHAFT (LH)
1) Apply a coat of engine oil to camshaft journals
and install camshaft (LH).
2) Install camshaft cap.
(1) Apply liquid gasket on the around of cam- B2M2612E

shaft cap.
(3) Install valve rocker assembly.
Liquid gasket: <Ref. to 2-3 [W4E0].>
THREE BOND 1280B

B2M2606
B2M2619A

27
2-3 [W5C2] SERVICE PROCEDURE
5. Camshaft

(4) Tighten bolts (a) through (h) in alphabetical (7) Tighten bolts (w) and (x).
sequence. Tightening torque:
Tightening torque: 10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)

B2M2621E
B2M2621B
3) Apply a coat of grease to oil seal lips and install
(5) Tighten TORX bolts (i) through (n) in alpha- oil seal (A) on camshaft using ST1 and ST2.
betical sequence using ST. CAUTION:
ST 499497000 TORX PLUS Use a new oil seal.
Tightening torque: ST1 499597000 OIL SEAL GUIDE
18±2 N·m (1.8±0.2 kg-m, 13.0±1.4 ft-lb) ST2 499587500 OIL SEAL INSTALLER

B2M2621C
S2M1865A

(6) Tighten bolts (o) through (v) in alphabetical 4) Install plug using ST.
sequence. ST 499587700 OIL SEAL INSTALLER
Tightening torque: 5) Install oil level gauge guide.
10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb) 6) Install camshaft position sensor support.
2. CAMSHAFT (RH)
1) Apply a coat of engine oil to camshaft journals
and install camshaft (RH).
2) Install camshaft cap.

B2M2621D

28
 SERVICE PROCEDURE [W5C2] 2-3
5. Camshaft

(1) Apply liquid gasket on the around of cam- (3) Install valve rocker assembly.
shaft cap. <Ref. to 2-3 [W4E0].>
Liquid gasket:
THREE BOND 1280B

B2M2615

(4) Tighten bolts (a) through (h) in alphabetical

B2M2619A sequence.

NOTE: Tightening torque:

Apply a coat of 3 mm (0.12 in) dia. (A) liquid gas- 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
ket along edge (B) of camshaft cap (C) mating
surface.

B2M2621B

(5) Tighten TORX bolts (i) through (n) in alpha-

S2M1199B betical sequence using ST.
(2) Temporarily tighten bolts (g) through (j) in ST 499427000 TORX PLUS
alphabetical sequence. Tightening torque:
18±2 N·m (1.8±0.2 kg-m, 13.0±1.4 ft-lb)

B2M2612E
B2M2621C

29
2-3 [W5C3] SERVICE PROCEDURE
5. Camshaft

(6) Tighten bolts (o) through (v) in alphabetical 3. RELATED PARTS

sequence. 1) Adjust the valve clearance. <Ref. to 2-2
Tightening torque: [W8B1].>
10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb) 2) Install rocker cover and connect PCV hose.
3) Install timing belt. <Ref. to 2-3 [W3C0].>

B2M2621D

(7) Tighten bolts (w) and (x).

Tightening torque:
10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)

B2M2621E

3) Apply a coat of grease to oil seal lips and install

oil seal (A) on camshaft using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER

S2M1864A

4) Install plug using ST.

ST 499587700 OIL SEAL INSTALLER

30
 SERVICE PROCEDURE [W6B0] 2-3
6. Cylinder Head

6. Cylinder Head B: DISASSEMBLY

A: REMOVAL 1) Place cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
1. RELATED PARTS 2) Set ST on valve spring. Compress valve spring
1) Remove intake manifold. <Ref. to 2-7 [W3A0].> and remove the valve spring retainer key. Remove
2) Remove bolt which installs A/C compressor each valve and valve spring.
bracket on cylinder head. (With A/C model) ST 499718000 VALVE SPRING REMOVER
3) Remove camshafts. <Ref. to 2-3 [W5A2].> CAUTION:
I Mark each valve to prevent confusion.
2. CYLINDER HEAD I Use extreme care not to damage the lips of
1) Remove oil level gauge guide attaching bolt the intake valve oil seals and exhaust valve oil
(left hand only) and oil level gauge guide. seals.
2) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.

S2M1866A

S2M1589A

3) While tapping cylinder head with a plastic

hammer, separate it from cylinder block.
4) Remove bolts (a) and (b) to remove cylinder
head.

S2M1589A

5) Remove cylinder head gasket.

CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
6) Similarly, remove right side cylinder head.

31
2-3 [W6C1] SERVICE PROCEDURE
6. Cylinder Head

C: INSPECTION AND 2. VALVE SEAT

REPLACEMENT Inspect intake and exhaust valve seats, and cor-
rect the contact surfaces with valve seat cutter if
1. CYLINDER HEAD
they are defective or when valve guides are
1) Make sure that no crack or other damage replaced.
exists. In addition to visual inspection, inspect
Valve seat width: W
important areas by means of red lead check.
Intake
Also make sure that gasket installing surface
Standard 1.0 mm (0.039 in)
shows no trace of gas and water leaks.
Limit 1.7 mm (0.067 in)
2) Place cylinder head on ST.
Exhaust
ST 498267800 CYLINDER HEAD TABLE
Standard 1.4 mm (0.055 in)
3) Measure the warping of the cylinder head sur-
Limit 2.1 mm (0.083 in)
face that mates with crankcase using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in),
regrind 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:
97.5 mm (3.839 in) G2M0149
CAUTION:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.

B2M0074

S2M1817A

32
 SERVICE PROCEDURE [W6C3] 2-3
6. Cylinder Head

3. VALVE GUIDE (1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
1) Check the clearance between valve guide and
enter the holes in ST1.
stem. The clearance can be checked by measur-
(2) Insert ST2 into valve guide and press it
ing the outside diameter of valve stem and the
down to remove valve guide.
inside diameter of valve guide with outside and
ST1 498267800 CYLINDER HEAD TABLE
inside micrometers respectively.
ST2 499767200 VALVE GUIDE REMOVER
Clearance between the valve guide and valve
stem:
Standard
Intake 0.035 — 0.062 mm (0.0014 —
0.0024 in)
Exhaust 0.040 — 0.067 mm (0.0016 —
0.0026 in)
Limit
0.15 mm (0.0059 in)
NOTE:
Measure the top, center, and bottom diameters of S2M1867A

valve and valve guide respectively to check each (3) Turn cylinder head upside down and place
clearance. ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER

B2M0387

B2M0077C

(A) Valve guide

(4) Before installing new oversize valve guide,

make sure that neither scratches nor damages
exist on the inside surface of the valve guide
holes in cylinder head.
B2M0076B

2) If the clearance between valve guide and stem

exceeds the limit, replace valve guide or valve
itself whichever shows greater amount of wear.
See following procedure for valve guide replace-
ment.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
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)

33
2-3 [W6C3] SERVICE PROCEDURE
6. Cylinder Head

(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
with the upper surface of ST2. rotating clockwise. After reaming, clean valve
ST1 499767200 VALVE GUIDE REMOVER guide to remove chips.
Intake side: CAUTION:
ST2 499767700 VALVE GUIDE ADJUSTER I Apply engine oil to the reamer when ream-
Exhaust side: ing.
ST2 499767800 VALVE GUIDE ADJUSTER I If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
I If the inner surface of the valve guide
becomes lustrous and the reamer does not
chips, use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER

S2M1868A

(6) Check the valve guide protrusion.

Valve guide protrusion: L
Intake
20.0 — 20.5 mm (0.787 — 0.807 in)
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in) S2M1962A

(8) Recheck the contact condition between

valve and valve seat after replacing valve guide.

B2M0077C

(A) Valve guide

34
 SERVICE PROCEDURE [W6C5] 2-3
6. Cylinder Head

4. INTAKE AND EXHAUST VALVE 5. VALVE SPRING

1) Inspect the flange and stem of valve, and 1) Check valve springs for damage, free length,
replace 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 below.
H: 2) To measure the squareness of the valve spring,
Intake stand the spring on a surface plate and measure
Standard 1.0 mm (0.039 in) its deflection at the top using a try square.
Limit 0.6 mm (0.024 in) Free length 54.30 mm (2.1378 in)
Exhaust Squareness 2.5°, 2.4 mm (0.094 in)
Standard 1.2 mm (0.047 in) 214.8 — 246.2 N
Limit 0.6 mm (0.024 in) (21.9 — 25.1 kg, 48.3 — 55.3 lb)/
Valve overall length: 45.0 mm (1.772 in)
Tension/spring height
Intake 526.6 — 581.6 N
120.6 mm (4.75 in) (53.7 — 59.3 kg, 118.4 — 130.8
lb)/34.7 mm (1.366 in)
Exhaust
121.7 mm (4.79 in)

G2M0154

G2M0153

2) Put a small amount of grinding compound on

the seat surface and lap the valve and seat sur-
face. <Ref. to 2-3 [W6C2].> Install a new intake
valve oil seal after lapping.

35
2-3 [W6C6] SERVICE PROCEDURE
6. Cylinder Head

6. INTAKE AND EXHAUST VALVE OIL

SEAL
Replace oil seal with a 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. Use pliers to pinch
and remove oil seal from valve.
1) Place cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
CAUTION:
I Apply engine oil to oil seal before press-fit-
ting.
I When press-fitting oil seal, do not use ham-
mer or strike in.
I Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif-
ference in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]

S2M1869A

36
 SERVICE PROCEDURE [W6D0] 2-3
6. Cylinder Head

D: ASSEMBLY

B2M2629B

(1) Valve (6) Retainer (11) Plug

(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve spring (10) Oil seal

1) Installation of valve spring and valve (4) Set ST on valve spring.

(1) Place cylinder head on ST. ST 499718000 VALVE SPRING REMOVER
ST 498267800 CYLINDER HEAD TABLE
(2) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder S2M1866A

head.

37
2-3 [W6E1] SERVICE PROCEDURE
6. Cylinder Head

(5) Compress valve spring and fit valve spring (7) Further tighten all bolts by 80 to 90° in
retainer key. alphabetical sequence shown in figure below.
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°.

B2M2634B

(A) Retainer key

(B) Painted face
S2M1589B
(6) After installing, tap valve spring retainers
3) Install oil level gauge guide and tighten attach-
lightly with wooden hammer for better seating. ing bolt (left side only).
E: INSTALLATION 2. RELATED PARTS
1. CYLINDER HEAD CAUTION:
Be careful not to scratch the mating surface of
1) Install cylinder head and gaskets on cylinder
cylinder block and oil pump.
block.
1) Install camshafts. <Ref. to 2-3 [W5C0].>
CAUTION: 2) Install intake manifold. <Ref. to 2-7 [W3D0].>
Use new cylinder head gaskets. 3) Tighten bolt which installs A/C compressor
2) Tighten cylinder head bolts. bracket on cylinder head. (With A/C model)
(1) Apply a coat of engine oil to washers and
bolt threads.
NOTE:
Bolts with pink marks on their bolts heads must be
used for (c) through (f).
(2) Tighten all bolts to 29 N·m (3.0 kg-m, 22
ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 N·m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180° first; back them off
by 180° again.
(4) Tighten bolts (a) and (b) to 34 N·m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
(1.5 kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90° in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90°.

38
 SERVICE PROCEDURE [W7A1] 2-3
7. Cylinder Block

7. Cylinder Block 11) Remove flywheel (MT vehicles only) or drive

plate (AT vehicles only).
A: REMOVAL Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
1. RELATED PARTS
NOTE:
Before conducting this procedure drain engine oil
completely if applicable.
1) Remove intake manifold. <Ref. to 2-7 [W3A0].>
2) Remove timing belt. <Ref. to 2-3 [W3A0].>
3) Remove A/C compressor bracket. (With A/C
model)
4) Remove generator and A/C compressor with
their brackets.
S2M1818A
5) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.

S2M1870A

12) Remove oil separator cover.

13) Remove water by-pass pipe for heater.
B2M2628A
14) Remove water by-pass pipe between oil
cooler and water pump (AT vehicles only).
6) While tapping cylinder head with a plastic
hammer, separate it from cylinder block.
7) Remove bolts (a) and (b) to remove cylinder
head.

S2M0305

15) Remove water pump.

B2M2628A

8) Remove cylinder head gasket.

CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
9) Similarly, remove right side cylinder head.
10) Remove clutch housing cover (MT vehicles
only).

39
2-3 [W7A1] SERVICE PROCEDURE
7. Cylinder Block

16) Remove oil pump from cylinder block. 22) Remove oil cooler (AT vehicles only).
Use a flat-bladed screwdriver as shown in figure
when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.

S2M1819

17) 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.
S2M0123C
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil (A) Gasket
pan. (B) Oil cooler
CAUTION: (C) Connector
Do not use a screwdriver or similar tool in
place of oil pan cutter. 23) Remove water pipe. <Ref. to 2-5 [W7A0].>

S2M1820 B2M2638

18) Remove oil strainer stay.

19) Remove oil strainer.
20) Remove baffle plate.
21) Remove oil filter using ST.
ST 498187000 OIL FILTER WRENCH

S2M1871A

40
 SERVICE PROCEDURE [W7A2] 2-3
7. Cylinder Block

2. CYLINDER BLOCK

S2M1590A

(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin

1) Remove service hole cover and service hole 2) 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

41
2-3 [W7A2] SERVICE PROCEDURE
7. Cylinder Block

3) Draw out piston pin from #1 and #2 pistons 4) Similarly remove piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 5) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 6) 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.
7) Set up cylinder block so that #1 and #3 cylin-
ders are on the upper side, then remove cylinder
block connecting bolts.
8) Separate left-hand and right-hand cylinder
blocks.
CAUTION:
When separating cylinder block, do not allow
the connecting rod to fall and damage the cyl-
inder block.
S2M1872A

B2M2408A

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

(2) Rear oil seal (4) Crankshaft bearing

9) Remove rear oil seal. CAUTION:

10) Remove crankshaft together with connecting Do not confuse combination of crankshaft
rod. bearings. Press bearing at the end opposite to
11) Remove crankshaft bearings from cylinder locking lip.
block using hammer handle.

42
 SERVICE PROCEDURE [W7C1] 2-3
7. Cylinder Block

12) Draw out each piston from cylinder block

using wooden bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cyl-
inder.
B: DISASSEMBLY
1. CRANKSHAFT AND PISTON

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. Warping limit:

2) Remove connecting rod bearing. 0.05 mm (0.0020 in)
CAUTION: Grinding limit:
Arrange removed connecting rod, connecting 0.1 mm (0.004 in)
rod cap and bearing in order to prevent confu-
sion. Standard height of cylinder block:
201.0 mm (7.91 in)
3) Remove piston rings using the piston ring
expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.

C: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage.
Especially, inspect important parts by means of red
lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cyl-
inder head for warping by using a straight edge,
and correct by grinding if necessary.

43
2-3 [W7C2] SERVICE PROCEDURE
7. Cylinder Block

2. CYLINDER AND PISTON 2) How to measure the inner diameter of each

cylinder
1) The cylinder bore size is stamped on the cylin-
Measure the inner diameter of each cylinder in
der block’s front upper surface.
both the thrust and piston pin directions at the
CAUTION: heights shown in the figure, using a cylinder bore
Measurement should be performed at a tem- gauge.
perature 20°C (68°F).
CAUTION:
NOTE: Measurement should be performed at a tem-
Standard sized pistons are classified into two perature 20°C (68°F).
grades, “A” and “B”. These grades should be used
Taper:
as a guide line in selecting a standard piston.
Standard
Standard diameter: 0.015 mm (0.0006 in)
A: 99.505 — 99.515 mm (3.9175 — 3.9179 Limit
in) 0.050 mm (0.0020 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175
Out-of-roundness:
in)
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)

H2M1732C

(A) Main journal size mark

(B) Cylinder block RH-LH combination mark
(C) #1 cylinder bore size mark S2M1821A
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark (A) Thrust direction
(F) #4 cylinder bore size mark (B) Piston direction

3) When piston is to be replaced due to general or

cylinder wear, determine a suitable sized piston by
measuring the piston clearance.

44
 SERVICE PROCEDURE [W7C3] 2-3
7. Cylinder Block

4) How to measure the outer diameter of each (2) If the cylinder inner diameter exceeds the
piston limit after boring and honing, replace the crank-
Measure the outer diameter of each piston at the case.
height shown in the figure. (Thrust direction) CAUTION:
CAUTION: Immediately after reboring, the cylinder diam-
Measurement should be performed at a tem- eter may differ from its real diameter due to
perature of 20°C (68°F). temperature rise. Thus, pay attention to this
Piston grade point H: when measuring the cylinder diameter.
37.0 mm (1.457 in) Limit of cylinder enlarging (boring):
Piston outer diameter: 0.5 mm (0.020 in)
Standard 3. PISTON AND PISTON PIN
A: 99.485 — 99.495 mm
(3.9167 — 3.9171 in) 1) Check pistons and piston pins for damage,
B: 99.475 — 99.485 mm cracks, and wear and the piston ring grooves for
(3.9163 — 3.9167 in) wear and damage. Replace if defective.
0.25 mm (0.0098 in) oversize 2) Measure the piston-to-cylinder clearance at
99.725 — 99.735 mm each cylinder. <Ref. to 2-3 [W7C2].> If any of the
(3.9262 — 3.9266 in) clearances is not to specification, replace the pis-
0.50 mm (0.0197 in) oversize ton or bore the cylinder to use an oversize piston.
99.975 — 99.985 mm 3) Make sure that piston pin can be inserted into
(3.9360 — 3.9364 in) the piston pin hole with a thumb at 20°C (68°F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)

B2M1305A

5) Calculate the clearance between cylinder and

piston.
CAUTION:
Measurement should be performed at a tem-
perature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68°F): B2M1401
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
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
piston.
CAUTION:
When any of the cylinders needs reboring, all B2M0084

other cylinders must be bored at the same

time, and use oversize pistons. Do not perform
boring on one cylinder only, nor use an over-
size piston for one cylinder only.

45
2-3 [W7C4] SERVICE PROCEDURE
7. Cylinder Block

4) Check circlip installation groove on the piston I The oil ring is a combined ring consisting of
for burr (A). If necessary, remove burr from the two rails and a spacer in between. When
groove so that piston pin can lightly move. installing, be careful to assemble correctly.

B2M0420C S2M1825A

5) Check piston pin circlip for distortion, cracks (A) Top ring
and wear. (B) Second ring
(C) Oil ring
4. PISTON RING (a) Upper rail
1) If piston ring is broken, damaged, or worn, or if (b) Spacer
(c) Lower rail
its tension is insufficient, or when the piston is
replaced, replace piston ring with a new one of the 2) Squarely place piston ring and oil ring in
same size as the piston. cylinder, and measure the piston ring gap with a
CAUTION: thickness gauge.
I “R” is marked on the end of the top and sec-
Unit: mm (in)
ond rings. When installing the rings to the
Standard Limit
piston, face this mark upward.
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston Second 0.35 — 0.50
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
Oil ring 0.20 — 0.70
1.5 (0.059)
rail (0.0079 — 0.0276)

S2M1822A

S2M1823

46
 SERVICE PROCEDURE [W7C5] 2-3
7. Cylinder Block

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
CAUTION: end 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. aligner. Replace connecting rod if the bend or twist
exceeds the limit.
Unit: mm (in)
Standard Limit Limit of bend or twist per 100 mm (3.94 in) in
0.040 — 0.080 length:
Clearance Top ring (0.0016 — 0.15 (0.0059) 0.10 mm (0.0039 in)
between pis- 0.0031)
ton ring and
0.030 — 0.070
piston ring Second
(0.0012 — 0.15 (0.0059)
groove ring
0.0028)

B2M1402

B2M1005B

(A) Thickness gauge

(B) Connecting rod

3) Install connecting rod fitted with bearing to

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)

S2M1824

47
2-3 [W7C5] SERVICE PROCEDURE
7. Cylinder Block

4) Inspect connecting rod bearing for scar, 6) Inspect bushing at connecting rod small end,
peeling, seizure, melting, wear, etc. and replace if worn or damaged. Also measure the
5) Measure the oil clearance on individual con- piston pin clearance at the connecting rod small
necting rod bearings by means of plastigauge. If end.
any oil clearance is not within specification, replace Clearance between piston pin and bushing:
the defective bearing with a new one of standard Standard
size or undersize as necessary. (See the table 0 — 0.022 mm (0 — 0.0009 in)
below.) Limit
Connecting rod oil clearance: 0.030 mm (0.0012 in)
Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.050 mm (0.0020 in)
Unit: mm (in)
Bearing size Outer diameter of
Bearing
(Thickness at center) crank pin
1.486 — 1.498 51.984 — 52.000
Standard
(0.0585 — 0.0590) (2.0466 — 2.0472)
0.03
1.504 — 1.512 51.954 — 51.970 B2M0085
(0.0012)
(0.0592 — 0.0595) (2.0454 — 2.0461)
undersize
0.05
1.514 — 1.522 51.934 — 51.950
(0.0020)
(0.0596 — 0.0599) (2.0446 — 2.0453)
undersize
0.25
1.614 — 1.622 51.734 — 51.750
(0.0098)
(0.0635 — 0.0639) (2.0368 — 2.0374)
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
INSTALLER

S2M1873A

(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.

48
 SERVICE PROCEDURE [W7C6] 2-3
7. Cylinder Block

6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for
BEARING wear. If they are not within the specifications,
replace bearing with a suitable (undersize) one,
1) Clean crankshaft completely and check for
cracks by means of red lead check etc., and and replace or recondition crankshaft as neces-
replace if defective. sary. When grinding crank journal or crank pin, fin-
2) Measure the crankshaft bend, and correct or ish them to the specified dimensions according to
replace if it exceeds the limit. the undersize bearing to be used.
CAUTION: Crank pin and crank journal:
If a suitable V-block is not available, install #1 Out-of-roundness
and #5 crankshaft bearing on cylinder block, 0.020 mm (0.0008 in) or less
position crankshaft on these bearings and Taper limit
measure crankshaft bend using a dial gauge. 0.07 mm (0.0028 in)
Grinding limit
Crankshaft bend limit:
0.035 mm (0.0014 in) 0.250 mm (0.0098 in)

G2M0179
S2M1944

Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3 #2, #4, #5
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at cen-
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
ter)
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
0.03 (0.0012)
Bearing size
undersize 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 51.934 — 51.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (2.0446 — 2.0453)
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 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
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

49
2-3 [W7D1] SERVICE PROCEDURE
7. Cylinder Block

4) Measure the thrust clearance of crankshaft at 5) Inspect individual crankshaft bearings for signs
center bearing. If the clearance exceeds the limit, of flaking, seizure, melting, and wear.
replace bearing. 6) Measure the oil clearance on each crankshaft
Crankshaft thrust clearance: bearing by means of plastigauge. If the measure-
Standard ment is not within the specification, replace defec-
0.030 — 0.115 mm (0.0012 — 0.0045 in) tive bearing with an undersize one, and replace or
Limit recondition crankshaft as necessary.
0.25 mm (0.0098 in)
Unit: mm (in)
Crankshaft oil clearance
Standard 0.010 — 0.030 (0.0004 —
0.0012)
Limit 0.040 (0.0016)

H2M2939

D: ASSEMBLY
1. CRANKSHAFT AND PISTON

B2M1320J

(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kg-m, ft-lb)
(2) Connecting rod (6) Top ring
T: 44.6±1.5 (4.55±0.15, 32.9±1.1)
(3) Connecting rod cap (7) Circlip
(4) Oil ring

1) Install connecting rod bearings on connecting 2) Install connecting rod on crankshaft.

rods and connecting rod caps. CAUTION:
CAUTION: Position each connecting rod with the side
Apply oil to the surfaces of the connecting rod marked facing forward.
bearings.

50
 SERVICE PROCEDURE [W7D1] 2-3
7. Cylinder Block

3) Install connecting rod cap with connecting rod (5) Position the expander gap at 180° of the
nut. reverse side for the upper rail gap.
Ensure the arrow on connecting rod cap faces the (6) Position the lower rail gap at (E) or (F) in the
front during installation. figure.
CAUTION: CAUTION:
I Each connecting rod has its own mating cap. I Ensure ring gaps do not face the same direc-
tion.
Make sure that they are assembled correctly by
I Ensure ring gaps are not within the piston
checking their matching number. skirt area.
I When tightening the connecting rod nuts,
apply oil on the threads.
4) Installation of piston rings and oil ring
(1) 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.
(2) Position the top ring gap at (A) or (B) in the
figure.

B2M3723D

5) Install circlip.
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.
B2M3722D

(3) Position the second ring gap at 180° on the

reverse side for the top ring gap.
(4) Position the upper rail gap at (C) or (D) in
the figure.

B2M1403A

CAUTION:
Piston front mark (A) faces towards the front of
the engine.

B2M3723D

B2M3724E

51
2-3 [W7E1] SERVICE PROCEDURE
7. Cylinder Block

E: INSTALLATION
1. CYLINDER BLOCK

B2M2407A

(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kg-m, ft-lb)
(2) Crankshaft
T1: 25±2 (2.5±0.2, 18.1±1.4)
(3) Cylinder block
T2: 47±3 (4.8±0.3, 34.7±2.2)

1) Install ST to cylinder block, then install crank- 3) Apply fluid packing to the mating surface of #1
shaft bearings. and #3 cylinder block, and put #2 and #4 cylinder
ST 499817000 ENGINE STAND blocks on, and align to #1 and #3.
CAUTION: Fluid packing:
Remove oil in the mating surface of bearing THREE BOND 1215 or equivalent
and cylinder block before installation. Also CAUTION:
apply a coat of engine oil to crankshaft pins. Do not allow fluid packing to jut into O-ring
2) Position crankshaft on the #1 and #3 cylinder grooves, oil passages, bearing grooves, etc.
block.

S2M1826A

52
 SERVICE PROCEDURE [W7E1] 2-3
7. Cylinder Block

4) Temporarily tighten 10 mm cylinder block con- 7) Install rear oil seal using ST1 and ST2.
necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
figure. ST2 499587200 OIL SEAL INSTALLER

B2M0088D S2M1827A

5) Tighten 10 mm cylinder block connecting bolts (A) Rear oil seal

in alphabetical sequence. (B) Flywheel attaching bolt
Tightening torque:
47±3 N·m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)

B2M0088D

6) Tighten 8 mm and 6 mm cylinder block connect-

ing bolts in alphabetical sequence shown in figure.
Tightening torque:
(A) — (G): 25±2 N·m (2.5±0.2 kg-m,
18.1±1.4 ft-lb)
(H): 6.4 N·m (0.65 kg-m, 4.7 ft-lb)

B2M0089F

53
2-3 [W7E2] SERVICE PROCEDURE
7. Cylinder Block

2. PISTON AND PISTON PIN (#1 AND #2)

B2M1322I

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

(2) Piston pin (5) Service hole plug
T: 69±7 (7.0±0.7, 50.6±5.1)
(3) Circlip

1) Installing piston 2) Installing piston pin

(1) Turn cylinder block so that #1 and #2 cylin- (1) Insert ST3 into service hole to align piston
ders face upward. pin hole with connecting rod small end.
(2) Using ST1, turn crankshaft so that #1 and CAUTION:
#2 connecting rods are set at bottom dead cen- Apply a coat of engine oil to ST3 before inser-
ter. tion.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and ST3 499017100 PISTON PIN GUIDE
cylinders and insert pistons in their cylinders
using ST2.
ST2 498747300 PISTON GUIDE

S2M1875A

(2) Apply a coat of engine oil to piston pin and

insert piston pin into piston and connecting rod
S2M1874A
through service hole.

54
 SERVICE PROCEDURE [W7E3] 2-3
7. Cylinder Block

(3) Install circlip. (4) Install service hole plug and gasket.
CAUTION: CAUTION:
Use new circlips. Use a new gasket.

S2M1828 B2M2620

3. PISTON AND PISTON PIN (#3 AND #4)

B2M1323J

(1) Piston (5) Service hole plug Tightening torque: N·m (kg-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 (7.0±0.7, 50.6±5.1)
(4) Gasket

Turn cylinder block so that #3 and #4 cylinders face

upward. Using the same procedures as used for #1
and #2 cylinders, install pistons and piston pins.

55
2-3 [W7E4] SERVICE PROCEDURE
7. Cylinder Block

4. RELATED PARTS 7) Install flywheel or drive plate.

To lock crankshaft, use ST.
1) Install water pipe. <Ref. to 2-5 [W7B0].>
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72±3 N·m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)

B2M2638

2) Install baffle plate.

Tightening torque: S2M1818A

6.4 N·m (0.65 kg-m, 4.7 ft-lb)

3) Install oil strainer and O-ring.
Tightening torque:
10 N·m (1.0 kg-m, 7 ft-lb)
4) Install oil strainer stay.
5) Apply fluid packing to matching surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
S2M1870A

8) Install housing cover.

9) Installation of oil pump
(1) Discard front oil seal after removal. Replace
with a new one using ST.
ST 499587100 OIL SEAL INSTALLER

S2M1833A

6) Apply fluid packing to matching surfaces and

install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
S2M1925

S2M1834A

56
 SERVICE PROCEDURE [W7E4] 2-3
7. Cylinder Block

(2) Apply fluid packing to matching surface of 10) Install water pump and gasket.
oil pump. Tightening torque:
Fluid packing: First; 12±2 N·m (1.2±0.2 kg-m, 8.7±1.4
THREE BOND 1215 or equivalent ft-lb)
Second; 12±2 N·m (1.2±0.2 kg-m, 8.7±1.4
ft-lb)
CAUTION:
I Be sure to use a new gasket.
I When installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.

S2M0739B

(A) O-ring

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

oil seal.

H2M1568B

11) Install water by-pass pipe for heater.

12) Install oil cooler (AT vehicles only).
Tightening torque:
54±5 N·m (5.5±0.5 kg-m, 39.8±3.6 ft-lb)
CAUTION:
Always use a new gasket.
S2M0118B

(4) Install oil pump on cylinder block. Be care-

ful not to damage oil seal during installation.
Tightening torque:
6.4 N·m (0.65 kg-m, 4.7 ft-lb)
CAUTION:
I Do not forget to install O-ring and seal when
installing oil pump.
I Align flat surface of oil pump’s inner rotor
with crankshaft before installation.

S2M0123C

(A) Gasket
(B) Oil cooler
(C) Connector

57
2-3 [W7E4] SERVICE PROCEDURE
7. Cylinder Block

13) Install oil filter using ST. (3) Back off all bolts by 180° first; back them off
ST 498547000 OIL FILTER WRENCH by 180° again.
(4) Tighten bolts (a) and (b) to 34 N·m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
(1.5 kg-m, 11 ft-lb).
(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
S2M1871A alphabetical sequence.
14) Install water by-pass pipe between oil cooler CAUTION:
and water pump (AT vehicles only). Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°.

S2M0305
B2M2628B
15) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and 16) Install oil level gauge guide and tighten attach-
bolt threads. ing bolt (left side only).
NOTE: 17) Install timing belt, camshaft sprocket and
Bolts with pink marks on their bolt heads must be related parts.
used for (c) through (f). <Ref. to 2-3 [W3C0].>
18) Install generator and A/C compressor brackets
(2) Tighten all bolts to 29 N·m (3.0 kg-m, 22 on cylinder head.
ft-lb) in alphabetical sequence.
19) Install drive belts. <Ref. to 1-5 [G2A0].>
Then tighten all bolts to 69 N·m (7.0 kg-m, 51
20) Install intake manifold. <Ref. to 2-7 [W3D0].>
ft-lb) in alphabetical sequence.

58
 DIAGNOSTICS [K100] 2-3
1. Engine Trouble in General

1. Engine Trouble in General

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. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. I Starter I Defective battery-to-starter harness B
I Defective starter switch C
I Defective inhibitor switch or neutral switch C
I Defective starter B
I Battery I Poor terminal connection A
I Run-down battery A
I Defective charging system B
I Friction I Seizure of crankshaft and connecting rod bearing C
I Seized camshaft C
I Seized or stuck piston and cylinder C
2) Initial combustion does I Starter I Defective starter C
not occur. I Fuel injection system <Ref. to 2-7 [T100].> A
I Fuel line I Defective fuel pump and relay A
I Lack of or insufficient fuel B
I Belt I Defective B
I Defective timing B
I Compression I Incorrect valve clearance C
I Loosened spark plugs or defective gasket C
I Loosened cylinder head bolts or defective gasket C
I Improper valve seating C
I Defective valve stem C
I Worn or broken valve spring B
I Worn or stuck piston rings, cylinder and piston C
I Incorrect valve timing B
I Improper engine oil (low viscosity) B
3) Initial combustion occur. I Fuel injection system <Ref. to 2-7 [T100].> A
I Intake system I Defective intake manifold gasket B
I Defective throttle body gasket B
I Fuel line I Defective fuel pump and relay C
I Clogged fuel line C
I Lack of or insufficient fuel B
I Belt I Defective B
I Defective timing B
I Compression I Incorrect valve clearance C
I Loosened spark plugs or defective gasket C
I Loosened cylinder head bolts or defective gasket C
I Improper valve seating C
I Defective valve stem C
I Worn or broken valve spring B
I Worn or stuck piston rings, cylinder and piston C
I Incorrect valve timing B
I Improper engine oil (low viscosity) B

59
2-3 [K100] DIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

4) Engine stalls after initial Fuel injection system <Ref. to 2-7 [T100].> A
combustion. I Intake system I Loosened or cracked intake duct B
I Loosened or cracked PCV hose C
I Loosened or cracked vacuum hose C
I Defective intake manifold gasket B
I Defective throttle body gasket B
I Dirty air cleaner element C
I Fuel line I Clogged fuel line C
I Lack of or insufficient fuel B
I Belt I Defective B
I Defective timing B
I Compression I Incorrect valve clearance C
I Loosened spark plugs or defective gasket C
I Loosened cylinder head bolts or defective gasket C
I Improper valve seating C
I Defective valve stem C
I Worn or broken valve spring B
I Worn or stuck piston rings, cylinder and piston C
I Incorrect valve timing B
I Improper engine oil (low viscosity) B
2. Rough idle and engine Fuel injection system <Ref. to 2-7 [T100].> A
stall I Intake system I Loosened or cracked intake duct A
I Loosened or cracked PCV hose A
I Loosened or cracked vacuum hose A
I Defective intake manifold gasket B
I Defective throttle body gasket B
I Defective PCV valve C
I Loosened oil filter cap B
I Dirty air cleaner element C
I Fuel line I Defective fuel pump and relay C
I Clogged fuel line C
I Lack of or insufficient fuel B
I Belt I Defective timing C
I Compression I Incorrect valve clearance B
I Loosened spark plugs or defective gasket B
I Loosened cylinder head bolts or defective gasket B
I Improper valve seating B
I Defective valve stem C
I Worn or broken valve spring B
I Worn or stuck piston rings, cylinder and piston B
I Incorrect valve timing A
I Improper engine oil (low viscosity) B
I Lubrication system I Incorrect oil pressure B
I Defective rocker cover gasket C
I Cooling system I Overheating C
I Others I Malfunction of evaporative emission control system A
I Stuck or damaged throttle valve B
I Accelerator cable out of adjustment C

60
 DIAGNOSTICS [K100] 2-3
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

3. Low output, hesitation I Fuel injection system <Ref. to 2-7 [T100].> A
and poor acceleration I Intake system I Loosened or cracked intake duct A
I Loosened or cracked PCV hose A
I Loosened or cracked vacuum hose B
I Defective intake manifold gasket B
I Defective throttle body gasket B
I Defective PCV valve B
I Loosened oil filter cap B
I Dirty air cleaner element A
I Fuel line I Defective fuel pump and relay B
I Clogged fuel line B
I Lack of or insufficient fuel C
I Belt I Defective timing B
I Compression I Incorrect valve clearance B
I Loosened spark plugs or defective gasket B
I Loosened cylinder head bolts or defective gasket B
I Improper valve seating B
I Defective valve stem C
I Worn or broken valve spring B
I Worn or stuck piston rings, cylinder and piston C
I Incorrect valve timing A
I Improper engine oil (low viscosity) B
I Lubrication system I Incorrect oil pressure B
I Cooling system I Overheating C
I Over cooling C
I Others I Malfunction of evaporative emission control system A
4. Surging I Fuel injection system <Ref. to 2-7 [T100].> A
I Intake system I Loosened or cracked intake duct A
I Loosened or cracked PCV hose A
I Loosened or cracked vacuum hose A
I Defective intake manifold gasket B
I Defective throttle body gasket B
I Defective PCV valve B
I Loosened oil filter cap B
I Dirty air cleaner element B
I Fuel line I Defective fuel pump and relay B
I Clogged fuel line B
I Lack of or insufficient fuel C
I Belt I Defective timing B
I Compression I Incorrect valve clearance B
I Loosened spark plugs or defective gasket C
I Loosened cylinder head bolts or defective gasket C
I Improper valve seating C
I Defective valve stem C
I Worn or broken valve spring C
I Worn or stuck piston rings, cylinder and piston C
I Incorrect valve timing A
I Improper engine oil (low viscosity) B
I Cooling system I Overheating B
I Others I Malfunction of evaporative emission control system C

61
2-3 [K100] DIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

5. Engine does not return to Fuel injection system <Ref. to 2-7 [T100].> A
idle. I Intake system I Loosened or cracked vacuum hose A
I Others I Stuck or damaged throttle valve A
I Accelerator cable out of adjustment B
6. Dieseling (Run-on) I Fuel injection system <Ref. to 2-7 [T100].> A
I Cooling system I Overheating B
I Others I Malfunction of evaporative emission control system B
7. After burning in exhaust I Fuel injection system <Ref. to 2-7 [T100].> A
system I Intake system I Loosened or cracked intake duct C
I Loosened or cracked PCV hose C
I Loosened or cracked vacuum hose B
I Defective PCV valve B
I Loosened oil filler cap C
I Belt I Defective timing B
I Compression I Incorrect valve clearance B
I Loosened spark plugs or defective gasket C
I Loosened cylinder head bolts or defective gasket C
I Improper valve seating B
I Defective valve stem C
I Worn or broken valve spring C
I Worn or stuck piston rings, cylinder and piston C
I Incorrect valve timing A
I Lubrication system I Incorrect oil pressure C
I Cooling system I Over cooling C
I Others I Malfunction of evaporative emission control system C
8. Knocking I Fuel injection system <Ref. to 2-7 [T100].> A
I Intake system I Loosened oil filter cap B
I Belt I Defective timing B
I Compression I Incorrect valve clearance C
I Incorrect valve timing B
I Cooling system I Overheating A
9. Excessive engine oil con- I Intake system I Loosened or cracked PCV hose A
sumption I Defective PCV valve B
I Loosened oil filter cap C
I Compression I Defective valve stem A
I Worn or stuck piston rings, cylinder and piston A
I Lubrication system I Loosened oil pump attaching bolts and defective B
gasket
I Defective oil filter seal B
I Defective crankshaft oil seal B
I Defective rocker cover gasket B
I Loosened oil drain plug or defective gasket B
I Loosened oil pan fitting bolts or defective oil pan B

62
 DIAGNOSTICS [K100] 2-3
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

10. Excessive fuel consump- I Fuel injection system <Ref. to 2-7 [T100].> A
tion I Intake system I Dirty air cleaner element A
I Belt I Defective timing B
I Compression I Incorrect valve clearance B
I Loosened spark plugs or defective gasket C
I Loosened cylinder head bolts or defective gasket C
I Improper valve seating B
I Defective valve stem C
I Worn or broken valve spring C
I Worn or stuck piston rings, cylinder and piston B
I Incorrect valve timing B
I Lubrication system I Incorrect oil pressure C
I Cooling system I Over cooling C
I Others I Accelerator cable out of adjustment B

63
2-3 [K200] DIAGNOSTICS
2. Engine Noise

2. Engine Noise
Type of sound Condition Possible cause
I Valve mechanism is defective.
I Incorrect valve clearance
Sound increases as engine
Regular clicking sound I Worn valve rocker
speed increases.
I Worn camshaft
I Broken valve spring
I Worn crankshaft main bearing
Oil pressure is low.
I Worn connecting rod bearing (big end)
Heavy and dull clank
I Loose flywheel mounting bolts
Oil pressure is normal.
I Damaged engine mounting
I Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when I Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. I Wrong spark plug
I Improper gasoline
Sound is reduced when fuel
Clank when engine speed is injector connector of noisy cyl- I Worn crankshaft main bearing
medium (1,000 to 2,000 rpm). inder is disconnected. I Worn bearing at crankshaft end of connecting rod
(NOTE*)
Sound is reduced when fuel
I Worn cylinder liner and piston ring
injector connector of noisy cyl-
I Broken or stuck piston ring
Knocking sound when engine inder is disconnected. I 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 I Unusually worn valve lifter
fuel injector connector is dis- I Worn cam gear
connected in turn. (NOTE*) I Worn camshaft journal bore in crankcase
Squeaky sound — I Insufficient generator lubrication
Rubbing sound — I Defective generator brush and rotor contact
Gear scream when starting I Defective ignition starter switch
—
engine I Worn gear and starter pinion
Sound like polishing glass with I Loose drive belt
—
a dry cloth I Defective engine coolant pump shaft
I Loss of compression
Hissing sound — I Air leakage in air intake system, hoses, connections or
manifolds
I Loose timing belt
Timing belt noise —
I Belt contacting case/adjacent part
Valve tappet noise — I 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 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].> after con-
necting fuel injector connector.

64
2-4 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications

1. Specifications
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter × thickness 78 × 9 mm (3.07 × 0.35 in)
STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Tip clearance between inner and outer rotor
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Oil pump pump case LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
pump case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi) or more
600 rpm Discharge
Capacity at 80°C - quantity 4.6  (4.9 US qt, 4.0 Imp qt)/min.
(176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi) or more
5,000 rpm Discharge
- quantity 47.0  (12.4 US gal, 10.3 Imp gal)/min.
Relief valve operation pressure 588 kPa (6.0 kg/cm2, 85 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter × width 80 × 70 mm (3.15 × 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7 kg/cm2, 10 psi)
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity 4.0  (4.2 US qt, 3.5 Imp qt)

2
 COMPONENT PARTS [C100] 2-4
1. Lubrication System

1. Lubrication System

S2M1793B

3
2-4 [C100] COMPONENT PARTS
1. Lubrication System

(1) Plug (17) Plug (MT vehicles) (34) Oil level gauge
(2) Washer (18) Gasket (MT vehicles) (35) Metal gasket
(3) Relief valve spring (19) Oil filter connector (MT vehicles) (36) Drain plug
(4) Relief valve (20) O-ring
(5) Oil seal (21) Oil pump ASSY Tightening torque: N·m (kg-m, ft-lb)
(6) Oil pump case (22) Oil pressure switch T1: 5 (0.5, 3.6)
(7) Inner rotor (23) Oil filler duct T2: 5+1/−0 (0.5+0.1/−0, 3.6+0.7/−0)
(8) Outer rotor (24) O-ring T3: 6.4 (0.65, 4.7)
(9) Oil pump cover (25) Cylinder head cover T4: 10 (1.0, 7.0)
(10) Oil filter (26) Oil filler cap T5: 44.1±3.4 (4.5±0.35, 32.5±2.5)
(11) Oil cooler pipe and hose ASSY (27) O-ring
T6: 6.4±0.5 (0.65±0.05, 4.7±0.4)
(AT vehicles) (28) Baffle plate
T7: 54±5 (5.5±0.5, 39.8±3.6)
(12) Connector (AT vehicles) (29) O-ring
T8: 69±7 (7.0±0.7, 50.6±5.1)
(13) Oil cooler (AT vehicles) (30) Oil strainer
(14) Gasket (AT vehicles) (31) Gasket T9: 25±3 (2.5±0.3, 18.1±2.2)
(15) Nipple (AT vehicles) (32) Oil level gauge guide T10: 44 (4.5, 33)
(16) Gasket (AT vehicles) (33) Oil pan

4
 SERVICE PROCEDURE [W1A0] 2-4
1. Oil Pump

1. Oil Pump 7) Remove water pipe and hoses between oil

cooler and water pump. (AT vehicles only)
A: REMOVAL
1) Set the vehicle on the lift.
2) Disconnect battery ground cable.

S2M0112

8) Lower the vehicle.

9) Remove radiator. <Ref. to 2-5 [W3A0].>
G6M0095

3) Lift-up the vehicle.

4) Remove under cover.
5) Drain coolant. <Ref. to 2-5 [W1A0].>

S2M0033

10) Remove crankshaft position sensor.

B2M0015

6) Remove bolts which install water pipe of oil

cooler to oil pump. (AT vehicles only)

B2M1252

11) Remove camshaft position sensor. <Ref. to

2-7 [W10A0].>

S2M0027

B2M2317

5
2-4 [W1A0] SERVICE PROCEDURE
1. Oil Pump

12) Remove V-belts. <Ref. to 1-5 [G2A0].> 16) Remove timing belt guide. (MT vehicles only)

G2M0286 S2M0115

13) Remove rear side V-belt tensioner. 17) Remove crankshaft sprocket.

S2M0113 S2M0116

14) Remove crankshaft pulley using ST. 18) Remove bolts which install oil pump onto cyl-
ST 499977100 CRANKSHAFT PULLEY inder block.
WRENCH

S2M0117
S2M0114
19) Remove oil pump using flat bladed screw-
15) Remove water pump. <Ref. to 2-5 [W1A0].> driver.
CAUTION:
Be careful not to scratch mating surfaces of
cylinder block and oil pump.

S2M0022

S2M1819

6
 SERVICE PROCEDURE [W1C2] 2-4
1. Oil Pump

B: DISASSEMBLY C: INSPECTION
Remove screws which secure oil pump cover and 1. TIP CLEARANCE
disassemble oil pump.
Measure the tip clearance of rotors. If the clear-
Inscribe alignment marks on inner and outer rotors
ance exceeds the limit, replace rotors as a
so that they can be replaced in their original posi-
matched set.
tions during reassembly.
Tip clearance:
CAUTION:
Standard
Before removing relief valve, loosen plug when
0.04 — 0.14 mm (0.0016 — 0.0055 in)
removing oil pump from cylinder block.
Limit
0.18 mm (0.0071 in)

S2M0736

2. CASE CLEARANCE
Measure the clearance between the outer rotor
and the cylinder block rotor housing. If the clear-
ance exceeds the limit, replace the rotor.
Case clearance:
Standard
S2M0121A
0.10 — 0.175 mm (0.0039 — 0.0069 in)
Limit
(A) Oil seal 0.20 mm (0.0079 in)
(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief spring
(H) Plug
(I) Washer

S2M0737

7
2-4 [W1C3] SERVICE PROCEDURE
1. Oil Pump

3. SIDE CLEARANCE D: ASSEMBLY

Measure clearance between oil pump inner rotor 1) Install front oil seal using ST.
and pump cover. If the clearance exceeds the limit, ST 499587100 OIL SEAL INSTALLER
replace rotor or pump body.
CAUTION:
Side clearance: Use a new oil seal.
Standard
0.02 — 0.07 mm (0.0008 — 0.0028 in)
Limit
0.15 mm (0.0059 in)

S2M0235A

2) Install inner and outer rotors in their original

positions.
G2M0075 3) Install oil relief valve and relief spring.
4) Install oil pump cover.
4. OIL RELIEF VALVE Tightening torque:
T1: 5 — 6 N·m (0.5 — 0.6 kg-m, 3.6 — 4.3
Check the valve for fitting condition and damage,
ft-lb)
and the relief valve spring for damage and deterio-
T2: 40.7 — 47.5 N·m (4.15 — 4.84 kg-m,
ration. Replace the parts if defective.
30.0 — 35.0 ft-lb)
Relief valve spring:
Free length; 71.8 mm (2.827 in)
Installed length; 54.7 mm (2.154 in)
Load when installed; 77.08 N (7.86 kg,
17.33 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.

S2M0121B

8
 SERVICE PROCEDURE [W2A0] 2-4
2. Oil Pan and Oil Strainer

E: INSTALLATION 2. Oil Pan and Oil Strainer

Install in the reverse order of removal. A: REMOVAL
Observe the following:
1) Apply fluid packing to matching surfaces of oil 1) Set the vehicle on the lift.
pump. 2) Disconnect battery ground cable.
Fluid packing:
THREE BOND 1215 or equivalent
2) Replace O-ring (A) with a new one.

G6M0095

3) Remove air intake duct and air cleaner assem-

bly. <Ref. to 2-7 [W1A0].>
S2M0739B

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

seal.

H2M2929

4) Disconnect front oxygen (A/F) sensor connec-

tor.
S2M0118B

4) Be careful not to scratch oil seal when installing

oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
B2M3439
T: 6.4 N·m (0.65 kg-m, 4.7 ft-lb)

S2M0740B

9
 SERVICE PROCEDURE [W2A0] 2-4
2. Oil Pan and Oil Strainer

E: INSTALLATION 2. Oil Pan and Oil Strainer

Install in the reverse order of removal. A: REMOVAL
Observe the following:
1) Apply fluid packing to matching surfaces of oil 1) Set the vehicle on the lift.
pump. 2) Disconnect battery ground cable.
Fluid packing:
THREE BOND 1215 or equivalent
2) Replace O-ring (A) with a new one.

G6M0095

3) Remove air intake duct and air cleaner assem-

bly. <Ref. to 2-7 [W1A0].>
S2M0739B

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

seal.

H2M2929

4) Disconnect front oxygen (A/F) sensor connec-

tor.
S2M0118B

4) Be careful not to scratch oil seal when installing

oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
B2M3439
T: 6.4 N·m (0.65 kg-m, 4.7 ft-lb)

S2M0740B

9
2-4 [W2A0] SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

5) Remove pitching stopper. 10) Drain engine oil.

Set container under the vehicle, and remove drain
plug from oil pan.

S2M0126

6) Remove radiator upper bracket. S2M1830A

(A) Washer
(B) Drain plug

11) Disconnect connector from rear oxygen sen-

sor.

S2M0932

7) Support engine with a lifting device and wire

ropes.

B2M3440

12) Remove front and center exhaust pipe assem-

bly. <Ref. to 2-9 [W1A0].>

S2M0222

8) Lift-up the vehicle.

CAUTION:
At this time, raise up wire ropes.
9) Remove under cover. B2M0054

10
 SERVICE PROCEDURE [W2C0] 2-4
2. Oil Pan and Oil Strainer

13) Remove nuts which install front cushion rub- 17) Remove baffle plate.
ber onto front crossmember.

S2M0309
S2M1831

14) Remove bolts which install oil pan on cylinder B: INSPECTION

block while raising up engine. By visual check make sure oil pan, oil strainer and
baffle plate are not damaged.

C: INSTALLATION
CAUTION:
Before installing oil pan, clean sealant from oil
pan and engine block.
1) Install baffle plate.
Tightening torque:
B2M2687
6.4 N·m (0.65 kg-m, 4.7 ft-lb)

15) Insert oil pan cutter blade between cylinder

block-to-oil pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
16) Remove oil strainer.

S2M0309

2) Install oil strainer onto baffle plate.

CAUTION:
Replace O-ring with a new one.
Tightening torque:
10 N·m (1.0 kg-m, 7 ft-lb)
S2M0238

S2M0238

11
2-4 [W2C0] SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

3) Apply fluid packing to mating surfaces and 7) Install front and center exhaust pipe assembly.
install oil pan. <Ref. to 2-9 [W1A0].>
Fluid packing: CAUTION:
THREE BOND 1215 or equivalent Always use new gaskets.

S2M1833A B2M0054

4) Tighten bolts which install oil pan onto engine 8) Connect connector to rear oxygen sensor.
block.
Tightening torque:
5 N·m (0.5 kg-m, 3.6 ft-lb)

B2M3440

9) Install under cover.

B2M2687
10) Lower the vehicle.
CAUTION:
5) Lower engine onto front crossmember. At this time, lower lifting device and release
6) Tighten nuts which install front cushion rubber steel cables.
onto front crossmember.
11) Remove lifting device and steel cables.
Tightening torque:
69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb)

S2M0222

S2M1831

12
 SERVICE PROCEDURE [W2C0] 2-4
2. Oil Pan and Oil Strainer

12) Connect connector to front oxygen (A/F) sen- 15) Install air intake duct and air cleaner assem-
sor. bly. <Ref. to 2-7 [W1A0].>

B2M3439 H2M2929

13) Install pitching stopper. 16) Fill engine oil through filler pipe up to upper
point of level gauge. <Ref. to 1-5 [G4A0].>
Tightening torque:
T1: 49±5 N·m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N·m (5.8±1.0 kg-m, 42±7 ft-lb)

S2M0126D

14) Install radiator upper brackets.

Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13±4 ft-lb)

S2M0932

13
2-4 [W3A0] SERVICE PROCEDURE
3. Oil Pressure Switch

3. Oil Pressure Switch 2) Disconnect terminal from oil pressure switch.

A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from
generator.

G2M0091

3) Remove oil pressure switch.

S2M0941

(2) Remove V-belt cover.

S2M0119

B: INSTALLATION
1) Apply fluid packing to oil pressure switch
S2M0896
threads before installation.
Fluid packing:
(3) Loosen lock bolt and slider bolt, and remove THREE BOND 1215 or equivalent
front side V-belt.
(4) Remove bolts which install generator on
bracket.

S2M0124B

S2M0942

14
 SERVICE PROCEDURE [W3B0] 2-4
3. Oil Pressure Switch

2) Install oil pressure switch onto engine block. 7) Connect connector and terminal to generator.
Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)

S2M0941

S2M0119

3) Connect terminal of oil pressure switch.

G2M0091

4) Install generator on bracket and temporary

tighten installing bolts.

S2M0942

5) Install front side V-belt and adjust it. <Ref. to

1-5 [G2A0].>
6) Install V-belt cover.

S2M0896

15
2-4 [W4A0] SERVICE PROCEDURE
4. Oil Cooler (AT Vehicles Only)

4. Oil Cooler (AT Vehicles 6) Remove oil filter using ST.

ST 498547000 OIL FILTER WRENCH
Only)
NOTE:
A: REMOVAL Set container under the vehicle.
1) Lift-up the vehicle.
2) Remove under cover.
3) Drain engine coolant completely. <Ref. to 2-2
[W8A0].>

S2M0125

7) Remove connector and remove oil cooler.

B2M0015

4) Remove bolt which installs water pipe to

engine.

S2M0027

5) Disconnect water hose from oil cooler.

S2M0123C

(A) Gasket
(B) Oil cooler
(C) Connector

B: INSPECTION
S2M0112 1) Check that coolant passages are not clogged
using air blow method.
2) Check mating surfaces of cylinder block, O-ring
groove and oil filter for damage.

16
 SERVICE PROCEDURE [W4C0] 2-4
4. Oil Cooler (AT Vehicles Only)

C: INSTALLATION 2) Install oil filter using ST.

ST 498547000 OIL FILTER WRENCH
1) Install oil cooler on cylinder block with connec-
tor pipe.
Tightening torque:
T: 54±5 N·m (5.5±0.5 kg-m, 39.8±3.6 ft-lb)
CAUTION:
Always use a new O-ring.

S2M0125

3) Install water hose to oil cooler.

S2M0112

4) Check the amount of engine oil. If necessary, fill

engine oil. <Ref. to 1-5 [G4A0].>
5) Fill engine coolant. <Ref. to 2-5 [W9B0].>
S2M0123B

17
2-4 [K100] DIAGNOSTICS
1. Engine Lubrication System Trouble in General

1. Engine Lubrication System Trouble in General

NOTE:
Before troubleshooting, make sure that the engine oil level is correct and no oil leakage exists.
Trouble Possible cause Corrective action
1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
1. Warning light 2) Low oil pressure Clogged oil passage Clean.
remains on. Excessive tip clearance and side clearance of
Replace.
oil pump rotor and gear
Clogged oil strainer or broken pipe Clean or replace.
Insufficient engine oil Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
1) Burn-out bulb Replace.
2. Warning light does
2) Poor contact of switch contact points Replace.
not go on.
3) Disconnection of wiring Repair.
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3. Warning light flickers
momentarily. Check for the same pos-
3) Low oil pressure sible causes as listed in
1.—2).

18
2-5 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications

1. Specifications
Electric fan + Forced engine coolant circula-
Cooling system
tion system
MT: Approx. 6.0 (6.3, 5.3)
Total engine coolant capacity  (US qt, Imp qt)
AT: Approx. 6.2 (6.6, 5.5)
Type Centrifugal impeller type
Discharge 20  (5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine
Discharge performance I 760 rpm — 0.3 mAq (1.0 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100  (26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
coolant head
Water pump
Engine coolant temperature 85°C (185°F)
Discharge 200  (52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
70 W (main fan)
Motor
70 W (sub fan)
Radiator fan
320 mm (12.60 in) × 5 (main fan)
Fan diameter × Blade
320 mm (12.60 in) × 7 (sub fan)
Type Down flow, pressure type
691.5 × 340 × 16 mm
Core dimensions
(27.22 × 13.39 × 0.63 in)
Radiator Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Pressure range in which cap valve is open
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir tank Capacity 0.45  (0.5 US qt, 0.4 Imp qt)

2. Service Data
Water pump 0.5 — 0.7 mm (0.020 — 0.028
Standard
Clearance between impeller and case in)
Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)

2
2-5 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications

1. Specifications
Electric fan + Forced engine coolant circula-
Cooling system
tion system
MT: Approx. 6.0 (6.3, 5.3)
Total engine coolant capacity  (US qt, Imp qt)
AT: Approx. 6.2 (6.6, 5.5)
Type Centrifugal impeller type
Discharge 20  (5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine
Discharge performance I 760 rpm — 0.3 mAq (1.0 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100  (26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
coolant head
Water pump
Engine coolant temperature 85°C (185°F)
Discharge 200  (52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
70 W (main fan)
Motor
70 W (sub fan)
Radiator fan
320 mm (12.60 in) × 5 (main fan)
Fan diameter × Blade
320 mm (12.60 in) × 7 (sub fan)
Type Down flow, pressure type
691.5 × 340 × 16 mm
Core dimensions
(27.22 × 13.39 × 0.63 in)
Radiator Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Pressure range in which cap valve is open
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir tank Capacity 0.45  (0.5 US qt, 0.4 Imp qt)

2. Service Data
Water pump 0.5 — 0.7 mm (0.020 — 0.028
Standard
Clearance between impeller and case in)
Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)

2
 COMPONENT PARTS [C100] 2-5
1. Water Pump

1. Water Pump

S2M0010A

(1) Water by-pass hose A (AT (6) Heater hose Tightening torque: N·m (kg-m, ft-lb)
vehicles) (7) Thermostat
T1:
(2) Water by-pass pipe (AT vehicles) (8) Gasket
First:
(3) Water by-pass hose B (AT (9) Thermostat cover
12±2 (1.2±0.2, 8.7±1.4)
vehicles) Second:
(4) Water pump ASSY 12±2 (1.2±0.2, 8.7±1.4)
(5) Gasket T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)

3
 COMPONENT PARTS [C100] 2-5
1. Water Pump

1. Water Pump

S2M0010A

(1) Water by-pass hose A (AT (6) Heater hose Tightening torque: N·m (kg-m, ft-lb)
vehicles) (7) Thermostat
T1:
(2) Water by-pass pipe (AT vehicles) (8) Gasket
First:
(3) Water by-pass hose B (AT (9) Thermostat cover
12±2 (1.2±0.2, 8.7±1.4)
vehicles) Second:
(4) Water pump ASSY 12±2 (1.2±0.2, 8.7±1.4)
(5) Gasket T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)

3
2-5 [C200] COMPONENT PARTS
2. Radiator and Radiator Fan

2. Radiator and Radiator Fan

S2M1739A

(1) Radiator lower cushion (13) Main fan shroud (21) ATF inlet hose B (AT vehicles
(2) Radiator (14) Radiator main fan only)
(3) Radiator upper cushion (15) Radiator main fan motor (22) Radiator outlet hose
(4) Radiator upper bracket (16) ATF hose clamp (AT vehicles (23) Radiator drain plug
(5) Clamp only)
(6) Radiator inlet hose (17) ATF inlet hose A (AT vehicles Tightening torque: N·m (kg-m, ft-lb)
(7) Engine coolant reservoir tank only) T1: 4.4±0.5 (0.45±0.05, 3.3±0.4)
cap (18) ATF outlet hose A (AT vehicles T2: 12±3 (1.2±0.3, 8.7±2.2)
(8) Over flow hose only) T3: 18±5 (1.8±0.5, 13.0±3.6)
(9) Engine coolant reservoir tank (19) ATF pipe (AT vehicles only) T4: 3.4±0.5 (0.35±0.05, 2.5±0.4)
(10) Sub fan shroud (20) ATF outlet hose B (AT vehicles T5: 4.9±1.5 (0.50±0.15, 3.6±1.1)
(11) Radiator sub fan only)
(12) Radiator sub fan motor

4
 COMPONENT PARTS [C300] 2-5
3. Water Pipe

3. Water Pipe

S2M1164A

(1) Engine coolant temperature sen- (3) O-ring Tightening torque: N·m (kg-m, ft-lb)
sor (4) By-pass hose
T: 6.4±0.5 (0.65±0.05, 4.7±0.4)
(2) Water pipe

5
2-5 [W1A0] SERVICE PROCEDURE
1. Water Pump

1. Water Pump 7) Detach ATF cooler hose attached to a clip

under the radiator main fan shroud. (AT vehicles
A: REMOVAL only)
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Set the vehicle on the lift.
2) Disconnect ground cable from the battery.

H2M3592

8) Remove bolt which installs water by-pass pipe

of oil cooler onto oil pump. (AT vehicles only)

G6M0095

3) Lift-up the vehicle.

4) Remove under cover.
5) Drain engine coolant completely.
<Ref. to 2-5 [W9A0].>

S2M0027

9) Disconnect radiator outlet hose (A) and heater

hose (B) from water pump.
10) Disconnect water by-pass hose (C). (AT
vehicles only)

B2M0015

6) Disconnect connectors from radiator main fan

and sub fan motors.

S2M0015A

11) Lower the vehicle.

S2M0893

6
 SERVICE PROCEDURE [W1A0] 2-5
1. Water Pump

12) Disconnect over flow hose. 17) Remove automatic belt tension adjuster.

S2M0930 H2M2375

13) Remove reservoir tank. 18) Remove belt idler No. 2.

S2M0931 S2M0024

14) Remove radiator main fan and sub fan assem- 19) Remove camshaft position sensor.
blies. <Ref. to 2-5 [W5A0].> and <Ref. to 2-5 <Ref. to 2-7 [W6A0].>
[W6A0].>

B2M2038
S2M0929
20) Remove left-hand camshaft sprocket by using
15) Remove V-belts. ST.
<Ref. to 1-5 [G2B0].> ST 499207100 CAMSHAFT SPROCKET
WRENCH

G2M0286
B2M2039A
16) Remove timing belt.
<Ref. to 2-3 [W3A0].>

7
2-5 [W1B0] SERVICE PROCEDURE
1. Water Pump

21) Remove left-hand belt cover No. 2. 3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)

B2M2040

22) Remove tensioner bracket.

G2M0211

4) Check clearance between impeller and pump

case.
Clearance between impeller and pump case:
Standard
0.5 — 0.7 mm (0.020 — 0.028 in)
Limit
1.0 mm (0.039 in)
H2M2380

23) Remove tensioner bracket.

24) Disconnect heater hose from water pump.
25) Remove water pump.

G2M0212

5) After water pump installation, check pulley shaft

for engine coolant leaks. If leaks are noted, replace
water pump assembly.
S2M1829

B: INSPECTION
1) Check water pump bearing for smooth rotation.
2) Check water pump pulley for abnormalities.

8
 SERVICE PROCEDURE [W1C0] 2-5
1. Water Pump

C: INSTALLATION 4) Install left-hand camshaft sprockets by using

ST.
1) Install water pump onto left-hand cylinder head. ST 4992707100 CAMSHAFT SPROCKET
CAUTION: WRENCH
I Replace gasket with a new one. Tightening torque:
I When installing water pump, tighten bolts in 78±5 N·m (8.0±0.5 kg-m, 57.9±3.6 ft-lb)
two stages in alphabetical sequence as shown
in figure.
Tightening torque:
First:
12±2 N·m (1.2±0.2 kg-m, 8.7±1.4 ft-lb)
Second:
12±2 N·m (1.2±0.2 kg-m, 8.7±1.4 ft-lb)

B2M2039A

5) Install camshaft position sensor. <Ref. to 2-7

[W6A0].>

S2M0023A

2) Install left-hand belt cover No. 2.

Tightening torque:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)

B2M2038

6) Install belt idler No. 2.

Tightening torque:
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)

B2M2040

3) Install tensioner bracket.

Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)

S2M0024

H2M2380

9
2-5 [W1C0] SERVICE PROCEDURE
1. Water Pump

7) Install automatic belt tension adjuster which 11) Install reservoir tank.
tension rod is holded with pin. <Ref. to 2-3
[W3C2].>

S2M0931

H2M2384
12) Connect over flow hose.

8) Install timing belt. <Ref. to 2-3 [W2C0].>

S2M0930

S2M0017
13) Lift-up the vehicle.
14) Connect radiator outlet hose (A) and heater
9) Install V-belts. <Ref. to 1-5 [G2B0].> hose (B) to water pump.
15) Connect water by-pass hose (C). (AT vehicles
only)

G2M0286

10) Install radiator main fan and sub fan motor S2M0015A
assemblies. <Ref. to 2-5 [W5A0].> and <Ref. to 2-5
[W6A0].> 16) Install bolt which installs water by-pass pipe
onto oil pump. (AT vehicles only)

S2M0929
S2M0027

10
 SERVICE PROCEDURE [W2A0] 2-5
2. Thermostat

17) Attach ATF cooler hose to a clip under the 2. Thermostat

radiator main fan shroud. (AT vehicles only)
A: REMOVAL AND INSTALLATION
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Lift-up the vehicle.
2) Remove under cover.
3) Drain engine coolant completely. <Ref. to 2-5
[W9A0].>

H2M3592

18) Connect connectors to radiator main fan and

sub fan motors.

B2M0015

4) Remove bolt which installs water by-pass pipe

of oil cooler onto oil pump. (AT vehicles only)

S2M0893

19) Install under cover.

20) Lower the vehicle.
21) Connect battery ground cable.

S2M0027

5) Disconnect radiator outlet hose and water by-

pass hose B (AT vehicles) from thermostat cover.

G6M0095

22) Fill coolant. <Ref. to 2-5 [W9B0].>

S2M0015

11
 SERVICE PROCEDURE [W2A0] 2-5
2. Thermostat

17) Attach ATF cooler hose to a clip under the 2. Thermostat

radiator main fan shroud. (AT vehicles only)
A: REMOVAL AND INSTALLATION
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Lift-up the vehicle.
2) Remove under cover.
3) Drain engine coolant completely. <Ref. to 2-5
[W9A0].>

H2M3592

18) Connect connectors to radiator main fan and

sub fan motors.

B2M0015

4) Remove bolt which installs water by-pass pipe

of oil cooler onto oil pump. (AT vehicles only)

S2M0893

19) Install under cover.

20) Lower the vehicle.
21) Connect battery ground cable.

S2M0027

5) Disconnect radiator outlet hose and water by-

pass hose B (AT vehicles) from thermostat cover.

G6M0095

22) Fill coolant. <Ref. to 2-5 [W9B0].>

S2M0015

11
2-5 [W2B0] SERVICE PROCEDURE
2. Thermostat

6) Remove thermostat cover and gasket, and pull B: INSPECTION

out the thermostat.
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
Immerse the thermostat and a thermometer in
water. Raise water temperature gradually, and
measure the temperature and valve lift when the
valve begins to open and when the valve is fully
opened. During the test, agitate the water for even
temperature distribution. The measurement should
be to the specification.

G2M0214
Starts to open:
76.0 — 80.0°C (169 — 176°F)
7) Install the thermostat in the water pump, and Fully opens:
install the thermostat cover together with a gasket. 91°C (196°F)
CAUTION:
I When reinstalling the thermostat, use a new
gasket.
I The thermostat must be installed with the
jiggle pin facing to front side.
I At this time, set the jiggle pin (A) of thermo-
stat for front side.
Tightening torque:
6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
H2M2357A

(A) Thermometer
(B) Thermostat

S2M0026B

8) Fill coolant. <Ref. to 2-5 [W9B0].>

12
 SERVICE PROCEDURE [W3A0] 2-5
3. Radiator

3. Radiator 7) Detach ATF cooler hose attached to a clip

under the radiator main fan shroud. (AT vehicles
A: REMOVAL only)
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Set the vehicle on the lift.
2) Disconnect battery ground cable.

H2M3592

8) Disconnect ATF cooler hoses from radiator. (AT

vehicles only)

G6M0095

3) Lift-up the vehicle.

4) Remove under cover.
5) Drain engine coolant completely. <Ref. to 2-5
[W9A0].>

S2M0895

9) Disconnect radiator outlet hose from thermostat

cover.

B2M0015

6) Disconnect connectors of radiator main fan and

sub fan motor.

S2M0015

10) Lower the vehicle.

11) Disconnect over flow hose.

S2M0893

S2M0930

13
2-5 [W3B0] SERVICE PROCEDURE
3. Radiator

12) Remove reservoir tank. 17) Lift radiator up and away from vehicle.

S2M0931 S2M0033

13) Remove V-belt covers.

B: INSTALLATION
1) Attach radiator mounting cushions to pins on
the lower side of radiator.

S2M0896

14) Disconnect radiator inlet hose from radiator.

S2M0944

2) Install radiator while fitting radiator pins to cush-

ions.
NOTE:
Fit cushion on lower side of radiator into holes on
body side.

S2M0897

15) Remove radiator upper brackets.

S2M0033

S2M0932

16) While slightly lifting radiator, slide it to left.

14
 SERVICE PROCEDURE [W3B0] 2-5
3. Radiator

3) Install radiator brackets and tighten bolts. 7) Attach ATF cooler hose to a clip under the
Tightening torque: radiator main fan shroud. (AT vehicles only)
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

H2M3592

S2M0932 8) Connect ATF cooler hoses. (AT vehicles only)

4) Connect radiator inlet hose.

S2M0895

S2M0897 9) Connect connectors to radiator main fan motor

5) Install reservoir tank. and sub fan motor.

Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb)

S2M0893

10) Connect radiator outlet hose.

S2M0934

6) Lift-up the vehicle.

S2M0015

11) Install under cover.

12) Lower the vehicle.

15
2-5 [W4A0] SERVICE PROCEDURE
4. Radiator Cap

13) Install V-belt covers. 4. Radiator Cap

A: INSPECTION
1) Attach radiator cap to tester.

S2M0896

14) Connect battery ground cable.

G2M0223

2) Increase pressure until tester gauge pointer

stops. Radiator cap is functioning properly if it
holds the service limit pressure for five to six sec-
onds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 —
18 psi)
G6M0095 Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
15) Fill coolant. <Ref. to 2-2 [W9B0].>
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance; otherwise, results of pres-
sure test will be incorrect.

16
2-5 [W4A0] SERVICE PROCEDURE
4. Radiator Cap

13) Install V-belt covers. 4. Radiator Cap

A: INSPECTION
1) Attach radiator cap to tester.

S2M0896

14) Connect battery ground cable.

G2M0223

2) Increase pressure until tester gauge pointer

stops. Radiator cap is functioning properly if it
holds the service limit pressure for five to six sec-
onds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 —
18 psi)
G6M0095 Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
15) Fill coolant. <Ref. to 2-2 [W9B0].>
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance; otherwise, results of pres-
sure test will be incorrect.

16
 SERVICE PROCEDURE [W5A0] 2-5
5. Radiator Main Fan and Fan Motor

5. Radiator Main Fan and Fan 8) Remove V-belt covers.

Motor
A: REMOVAL AND INSTALLATION
1) Set the vehicle on the lift.
2) Disconnect battery ground cable.

S2M0896

9) Disconnect over flow hose.

G6M0095

3) Lift-up the vehicle.

4) Remove under cover.
5) Disconnect connector of main fan motor.

S2M0930

10) Remove reservoir tank.

S2M0591

6) Detach ATF cooler hose attached to a clip

under the radiator main fan shroud. (AT vehicles
only)
S2M0931

11) Remove radiator main fan motor assembly.

H2M3592

7) Lower the vehicle.

S2M0929

17
2-5 [W5B0] SERVICE PROCEDURE
5. Radiator Main Fan and Fan Motor

12) Install in the reverse order of removal. 2) Remove nut which holds fan itself onto fan
NOTE: motor and shroud assembly.
When the main fan motor assembly cannot be
installed as is, loosen the sub fan motor assembly
securing bolts to install it. <Ref. to 2-5 [W6A0].>
Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb)

S2M0936

3) Remove bolts which install fan motor onto

shroud.

S2M0933

Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb)

H2M3593

4) Install in the reverse order of removal.

Tightening torque:
4.4±0.5 N·m (0.45±0.05 kg-m, 3.3±0.4 ft-lb)

S2M0934

B: DISASSEMBLY AND ASSEMBLY

1) Remove clip which holds motor connector onto
shroud.

H2M3593

Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)

S2M0937A

S2M0936

18
 SERVICE PROCEDURE [W6B0] 2-5
6. Radiator Sub Fan and Fan Motor

6. Radiator Sub Fan and Fan 9) Remove radiator sub fan motor assembly.
Motor
A: REMOVAL AND INSTALLATION
1) Set the vehicle on the lift.
2) Disconnect battery ground cable.

S2M0935

10) Install in the reverse order of removal.

Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb)
G6M0095

3) Lift-up the vehicle.

4) Remove under cover.
5) Disconnect connector of sub fan motor.

S2M0935

B: DISASSEMBLY AND ASSEMBLY

1) Remove clip which holds motor harness onto
S2M0597
shroud.

6) Lower the vehicle.

7) Remove V-belt covers.

S2M0937A

S2M0896

8) Remove bolts which hold sub fan shroud to

radiator.

19
2-5 [W7A0] SERVICE PROCEDURE
7. Water Pipe

2) Remove nut which holds fan itself onto fan 7. Water Pipe
motor and shroud assembly.
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Set the vehicle on the lift.
2) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
3) Disconnect ground cable from the battery.

S2M0939

3) Remove bolts which install fan motor onto

shroud.

G6M0095

4) Drain engine coolant completely.

<Ref. to 2-5 [W9A0].>

H2M3593

4) Install in the reverse order of removal.

Tightening torque:
4.4±0.5 N·m (0.45±0.05 kg-m, 3.3±0.4 ft-lb)

B2M0015

5) Lower the vehicle.

6) Remove intake manifold.
<Ref. to 2-7 [W3A0].>

H2M3593

Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)

B2M0160

S2M0939

20
2-5 [W7A0] SERVICE PROCEDURE
7. Water Pipe

2) Remove nut which holds fan itself onto fan 7. Water Pipe
motor and shroud assembly.
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Set the vehicle on the lift.
2) Release fuel pressure.
<Ref. to 2-8 [W1A0].>
3) Disconnect ground cable from the battery.

S2M0939

3) Remove bolts which install fan motor onto

shroud.

G6M0095

4) Drain engine coolant completely.

<Ref. to 2-5 [W9A0].>

H2M3593

4) Install in the reverse order of removal.

Tightening torque:
4.4±0.5 N·m (0.45±0.05 kg-m, 3.3±0.4 ft-lb)

B2M0015

5) Lower the vehicle.

6) Remove intake manifold.
<Ref. to 2-7 [W3A0].>

H2M3593

Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)

B2M0160

S2M0939

20
 SERVICE PROCEDURE [W7B0] 2-5
7. Water Pipe

7) Disconnect heater inlet hose. B: INSTALLATION

1) Install water pipe on cylinder block.
Tightening torque:
6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
CAUTION:
Use a new O-ring.

B2M0138

8) Disconnect radiator inlet hose from water pipe.

B2M0141

2) Connect radiator inlet hose.

B2M0139

9) Remove bolts which install water pipe on cylin-

der block.

B2M0139

3) Connect heater inlet hose.

B2M0141

B2M0138

21
2-5 [W8A0] SERVICE PROCEDURE
8. Reservoir Tank

4) Install intake manifold. 8. Reservoir Tank

<Ref. to 2-7 [W3D0].>
A: REMOVAL AND INSTALLATION
1) Disconnect over flow hose from radiator filler
neck position.

B2M0160

5) Connect connector to fuel pump relay.

S2M0930

2) Remove bolts which install reservoir tank onto

radiator main fan shroud.

S2M0093

6) Connect ground cable to battery.

S2M0934

3) Remove reservoir tank.

G6M0095

7) Lift-up the vehicle.

8) Install under cover.
9) Lower the vehicle.
10) Fill coolant.
S2M0931
<Ref. to 2-5 [W9B0].>

22
2-5 [W8A0] SERVICE PROCEDURE
8. Reservoir Tank

4) Install intake manifold. 8. Reservoir Tank

<Ref. to 2-7 [W3D0].>
A: REMOVAL AND INSTALLATION
1) Disconnect over flow hose from radiator filler
neck position.

B2M0160

5) Connect connector to fuel pump relay.

S2M0930

2) Remove bolts which install reservoir tank onto

radiator main fan shroud.

S2M0093

6) Connect ground cable to battery.

S2M0934

3) Remove reservoir tank.

G6M0095

7) Lift-up the vehicle.

8) Install under cover.
9) Lower the vehicle.
10) Fill coolant.
S2M0931
<Ref. to 2-5 [W9B0].>

22
 SERVICE PROCEDURE [W9A0] 2-5
9. Engine Coolant

4) Install in the reverse order of removal. 9. Engine Coolant

Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb) A: DRAINING OF ENGINE
COOLANT
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Lift-up the vehicle.
2) Remove under cover.
3) Fit vinyl tube to drain pipe.

S2M0934

H2M2927B

(A) Drain pipe

(B) Vinyl tube
(C) Drain cock

4) Loosen drain cock to drain engine coolant into

container.
NOTE:
Remove radiator cap so that engine coolant will
drain faster.

B2M0015

23
 SERVICE PROCEDURE [W9A0] 2-5
9. Engine Coolant

4) Install in the reverse order of removal. 9. Engine Coolant

Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb) A: DRAINING OF ENGINE
COOLANT
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Lift-up the vehicle.
2) Remove under cover.
3) Fit vinyl tube to drain pipe.

S2M0934

H2M2927B

(A) Drain pipe

(B) Vinyl tube
(C) Drain cock

4) Loosen drain cock to drain engine coolant into

container.
NOTE:
Remove radiator cap so that engine coolant will
drain faster.

B2M0015

23
2-5 [W9B0] SERVICE PROCEDURE
9. Engine Coolant

B: FILLING OF ENGINE COOLANT 1. RELATIONSHIP OF SUBARU COOLANT

CONCENTRATION AND FREEZING
1) Fill engine coolant into radiator up to filler neck
position. TEMPERATURE
Coolant capacity (fill up to “FULL” level): The concentration and safe operating temperature
MT model; of the SUBARU coolant is shown in the diagram.
Approx. 6.0  (6.3 US qt, 5.3 Imp qt) Measuring the temperature and specific gravity of
AT model; the coolant will provide this information.
Approx. 6.2  (6.6 US qt, 5.5 Imp qt) [Example]
If the coolant temperature is 25°C (77°F) and its
CAUTION: specific gravity is 1.054, the concentration is 35%
The SUBARU Genuine Coolant containing anti- (point A), the safe operating temperature is −14°C
freeze and anti-rust agents is especially made (7°F) (point B), and the freezing temperature is
for SUBARU engine, which has an aluminum −20°C (−4°F) (point C).
crankcase. Always use SUBARU Genuine
Coolant, since other coolant may cause corro-
sion.
2) Fill engine coolant into reservoir tank up to full
level.

S2M0552B

(A) Full level

(B) Low level

3) Attach radiator cap and reservoir tank cap prop-

erly.
B2M3128A
4) Warm-up engine completely for more than five
minutes at 2,000 to 3,000 rpm.
5) If engine coolant level drops in radiator, add
engine coolant to filler neck position.
6) If engine coolant level drops from upper level of
reservoir tank, add engine coolant to upper level.
7) Attach radiator cap and reservoir tank cap prop-
erly.

24
 SERVICE PROCEDURE [W9C0] 2-5
9. Engine Coolant

2. PROCEDURE TO ADJUST THE C: CHECKING OF COOLING

CONCENTRATION OF THE COOLANT SYSTEM
To adjust the concentration of the coolant accord- 1) Remove radiator cap, top off radiator, and
ing to temperature, find the proper fluid concentra-
attach tester to radiator in place of cap.
tion in the above diagram and replace the neces-
sary amount of coolant with an undiluted solution
of SUBARU genuine coolant (concentration 50).
The amount of coolant that should be replaced can
be determined using the diagram.
[Example]
Assume that the coolant concentration must be
increased form 25% to 40%. Find point A, where
the 25% line of coolant concentration intersects
with the 40% curve of the necessary coolant
concentration, and read the scale on the vertical
axis of the graph at height A. The quantity of cool- S2M0948
ant to be drained is 2.1 liters (2.2 US qt, 1.8 Imp
qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of cool- 2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23
ant from the cooling system and add 2.1 liters (2.2 psi) to radiator to check if:
US qt, 1.8 Imp qt) of the undiluted solution of (1) Engine coolant leaks at/around radiator.
SUBARU coolant. (2) Engine coolant leaks at/around hoses or
If a coolant concentration of 50% is needed, drain connections.
all the coolant and refill with the undiluted solution CAUTION:
only. I Engine should be off.
I Wipe engine coolant from check points in
advance.
I Be careful to prevent engine coolant from
spurting out when removing tester.
I Be careful also not to deform filler neck of
radiator when installing or removing tester.

B2M3129A

25
2-5 [K100] DIAGNOSTICS
1. Engine Cooling System Trouble in General

1. Engine Cooling System Trouble in General

Trouble Corrective action
Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair ignition control system.
g. Improper ignition timing
<Ref. to 2-7 [T100].> On-Board Diagnostics II System
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in engine coolant Replace engine coolant.
Inspect and repair fuel injection system.
j. Air/fuel mixture ratio too lean
<Ref. to 2-7 [T100].> On-Board Diagnostics II System
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
Inspect radiator fan relay, engine coolant temperature
q. Malfunction of electric fan
sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low Partly cover radiator front area.
Over-cooling
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on
Repair or replace.
hoses
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
Engine coolant
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
leaks.
e. Damaged or cracked cylinder head and crank-
Repair or replace.
case
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
a. Defective drive belt Replace.
b. Defective radiator fan Replace.
Noise
c. Defective water pump bearing Replace water pump.
d. Defective water pump mechanical seal Replace water pump.

26
2-8 [S100] SPECIFICATIONS AND SERVICE DATA
1. Fuel System

1. Fuel System
Capacity 60  (15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Discharge pressure 299.1 kPa (3.05 kg/cm2, 43.4 psi)
Fuel pump
More than 65  (17.2 US gal, 14.3 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type

2
 SPECIFICATIONS AND SERVICE DATA [S100] 2-8
1. Fuel System

MEMO:

3
2-8 [C100] COMPONENT PARTS
1. Fuel Tank

1. Fuel Tank

S2M2001A

4
 COMPONENT PARTS [C100] 2-8
1. Fuel Tank

(1) Heat sealed cover (15) Evaporation hose C (29) Jet pump filter
(2) Fuel tank band (16) Evaporation hose B (30) Fuel sub level sensor
(3) Protector LH (17) Evaporation hose D (31) Protector cover
(4) Protector RH (18) Evaporation hose E (32) Vent valve hose
(5) Fuel tank (19) Evaporation pipe ASSY (33) Vent valve
(6) Canister hose A (20) Retainer (34) Fuel tank pressure sensor
(7) Clamp (21) Quick connector (35) Fuel tank pressure sensor hose
(8) Fuel pump gasket (22) Jet pump hose A (36) Vent valve gasket
(9) Fuel pump ASSY (23) Fuel return hose A
(10) Fuel cut valve gasket (24) Fuel pipe ASSY Tightening torque: N·m (kg-m, ft-lb)
(11) Fuel cut valve (25) Jet pump hose B T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
(12) Evaporation hose A (26) Fuel return hose B T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(13) Clip (27) Evaporation hose F T3: 33±10 (3.4±1.0, 25±7)
(14) Joint pipe (28) Fuel sub level sensor gasket

5
2-8 [C200] COMPONENT PARTS
2. Fuel Line

2. Fuel Line

S2M2002A

6
 COMPONENT PARTS [C200] 2-8
2. Fuel Line

(1) Clamp (19) Canister hose A (37) Shut valve

(2) Fuel delivery hose A (20) Air filter hose A (38) Packing
(3) Fuel filter bracket (21) Drain valve hose (39) Ring A
(4) Fuel filter holder (22) Air filter hose B (40) Ring B
(5) Fuel filter cup (23) Drain filter (41) Fuel filler cap
(6) Fuel filter (24) Drain valve (42) Fuel filler pipe protector
(7) Evaporation hose (25) Canister upper bracket (43) Tapping screw
(8) Clip (26) Cushion rubber (44) Evaporation hose O
(9) Fuel delivery hose B (27) Canister lower bracket (45) Joint pipe
(10) Fuel return hose (28) Canister holder (46) Evaporation hose P
(11) Roll over valve (29) Evaporation hose L (47) Evaporation hose Q
(12) Roll over valve bracket (30) Pressure control solenoid valve (48) Evaporation pipe
(13) Evaporation hose H (31) Canister hose B (49) Clip
(14) Evaporation hose I (32) Canister
(15) Evaporation pipe B (33) Fuel pipe ASSY Tightening torque: N·m (kg-m, ft-lb)
(16) Evaporation hose J (34) Fuel filler pipe T1: 17.7±5 (1.8±0.5, 13.0±3.6)
(17) Evaporation hose K (35) Evaporation hose M T2: 23±7 (2.3±0.7, 16.6±5.1)
(18) Joint pipe (36) Evaporation hose N

7
2-8 [W1A0] SERVICE PROCEDURE
1. Fuel Tank

1. Fuel Tank 3) Disconnect battery ground cable.

A: RELEASING OF FUEL
PRESSURE
WARNING:
I Place “No fire” signs near the working area.
I Disconnect ground terminal from battery.
I Be careful not to spill fuel on the floor.
1) Disconnect connector from fuel pump relay.

G6M0095

4) Remove access hole lid.

S2M0093

2) Start the engine, and run it until it stalls.

3) After the engine stalls, crank it for five more
seconds. S2M0246
4) Turn ignition switch OFF.
5) Disconnect connector from fuel pump.
B: DRAINING OF FUEL
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Open fuel flap lid, and remove fuel filler cap.

S2M0172

6) Disconnect quick connector, and then discon-

nect fuel delivery hose (A). <Ref. to 2-8 [W9A0].>
7) Move clips, and then disconnect fuel return
hose (B) and jet pump hose (C).

B2M3363

S2M0060A

8
 SERVICE PROCEDURE [W1C0] 2-8
1. Fuel Tank

8) Remove nuts which install fuel pump assembly 12) Drain fuel from there.
onto fuel tank. WARNING:
Do not use a motor pump when draining fuel.

S2M0061

9) Take off fuel pump from fuel tank. B2M0049

10) Drain fuel from fuel tank by using a hand 13) After draining fuel, reinstall fuel pump and fuel
pump. sub level sensor.
WARNING: Tighten nuts of fuel pump in alphabetical sequence
Do not use a motor pump when draining fuel. shown in figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

S2M0163

11) Remove fuel sub level sensor. <Ref. to 2-8

[W5A0].> S2M0063A

S2M0153
S2M0152B

C: REMOVAL
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Set the vehicle on the lift.

9
2-8 [W1C0] SERVICE PROCEDURE
1. Fuel Tank

2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].> 7) Remove rear exhaust pipe. <Ref. to 2-9
[W2A0].>
NOTE:
To facilitate the removal of parts, apply a coat of
SUBARU CRC5-56 (Part No. 004301003).

S2M0163

3) Remove rear seat cushion and turn up cover.

S2M0157

8) Remove muffler assembly.

<Ref. to 2-9 [W3A0].>
NOTE:
To facilitate the removal of parts, apply a coat of
SUBARU CRC5-56 (Part No. 004301003).

S2M0064

4) Disconnect connector of fuel tank cord from

rear harness.

S2M0159

9) Remove heat sealed cover.

S2M0164

5) Push grommet which holds fuel tank cord on

floor panel into the body side.

S2M0166

S2M0165

6) Lift-up the vehicle.

10
 SERVICE PROCEDURE [W1C0] 2-8
1. Fuel Tank

10) Move clamp, and disconnect evaporation 15) Remove bolts which hold parking brake cable
hose from canister. holding bracket.

S2M0949 S2M0191

11) Disconnect hose from joint pipe. 16) Remove rear differential assembly.
<Ref. to 3-4 [W2B0].>

S2M0880
G3M1030
12) Disconnect connector from pressure control
solenoid valve. 17) Remove rear crossmember.
13) Disconnect connector from drain valve. <Ref. to 4-1 [W10A0].>

B2M1743 G4M0545

14) Disconnect hoses from roll over valve. 18) Loosen clamp, and disconnect fuel filler hose
(A) and air vent hose (B) from fuel filler pipe and
air vent pipe.

H2M2538

S2M0193A

11
2-8 [W1D0] SERVICE PROCEDURE
1. Fuel Tank

19) Move clips, and disconnect fuel return hose 3) Connect fuel filler hose, and tighten clamp.
(B) and evaporation hose (C).
20) Disconnect quick connector, and then discon-
nect fuel delivery hose (A).

B2M1745

4) Connect fuel hoses, and hold then with clips

S2M0168A
and quick connector. <Ref. to 2-8 [W9A0].>
5) Tighten band mounting bolts.
21) While holding fuel tank, remove bolts from Tightening torque:
bands and dismount fuel tank. 33±10 N·m (3.4±1.0 kg-m, 25±7 ft-lb)
WARNING:
A helper is required to perform this work.

S2M0169

S2M0169
6) Install rear crossmember. <Ref. to 4-1
[W10C0].>

D: INSTALLATION
1) While a helper holds fuel tank, push fuel tank
harness into access hole with grommet.

G4M0545

S2M0169

2) Set fuel tank, and temporary tighten bolts in

order to install fuel tank bands.

12
 SERVICE PROCEDURE [W1D0] 2-8
1. Fuel Tank

7) Install rear differential assembly. <Ref. to 3-4 12) Connect hoses to roll over valve.
[W2F0].>

H2M2538
G3M1030
13) Install bolts which hold parking brake holding
8) Connect connector to drain valve. bracket.

B2M1743 S2M0191

9) Connect connector to pressure control solenoid 14) Install heat sealed cover.
valve.
10) Connect hose to joint pipe.

S2M0166

S2M0880
15) Install muffler assembly. <Ref. to 2-9 [W3A0].>

11) Connect evaporation hose to canister, and

hold them with clamp.

G2M0384

S2M0949

13
2-8 [W1D0] SERVICE PROCEDURE
1. Fuel Tank

16) Install rear exhaust pipe. <Ref. to 2-9 22) Connect battery ground cable.
[W2B0].>

G6M0095
S2M0158

17) Lower the vehicle.

18) Connect connectors to fuel tank harness, and
plug access hole with grommet.

S2M0164

19) Install rear seat cushion.

S2M0064

20) Install fuel filler cap.

21) Connect connector to fuel pump relay.

S2M0093

14
 SERVICE PROCEDURE [W2A0] 2-8
2. Fuel Filler Pipe

2. Fuel Filler Pipe 7) Remove bolts which install protector cover on

body.
A: REMOVAL
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Set the vehicle on the lift.
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>

B2M1749

8) While releasing the under side of protector

cover from hook, remove it.

S2M0163

3) Remove screws which install fuel filler pipe on

filler lid open.

B2M1750A

9) Disconnect evaporation hoses from pipes.

B2M3363

4) Remove wheel nuts of rear right side.

5) Lift-up the vehicle.
6) Remove rear right side wheel.
S2M0881

10) Lift-up the vehicle more.

11) Remove the two evaporation hoses from clip.

B2M1748

B2M1753

15
2-8 [W2B0] SERVICE PROCEDURE
2. Fuel Filler Pipe

12) Disconnect evaporation hose from joint pipe. 2) Remove bolt which installs joint pipe on fuel
filler pipe.

B2M1754
B2M1759
13) Loosen clamp, and disconnect fuel filler hose
from fuel filler pipe. 3) Disconnect evaporation hose from fuel filler
pipe.

B2M1745
B2M1760
14) Remove fuel filler pipe to under side of
vehicle. 4) Disconnect evaporation hoses from shut valve.

B2M1756 B2M1761

5) Remove shut valve from fuel filler pipe.

B: DISASSEMBLY
1) Move clip, and disconnect evaporation hose
from joint pipe.

B2M1762

S2M0882

16
 SERVICE PROCEDURE [W2D0] 2-8
2. Fuel Filler Pipe

C: ASSEMBLY 5) Install evaporation pipe to fuel filler pipe.

1) Install shut valve on fuel filler pipe.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

B2M1759

D: INSTALLATION
B2M1762 1) Set fuel filler pipe from under side of vehicle,
and hold it on fuel filler flap open.
2) Connect evaporation hoses to shut valve.

B2M1756
B2M1761
2) Connect fuel filler pipe into fuel filler hose.
3) Connect evaporation hose to fuel filler pipe.

B2M1757
B2M1760
3) Lower the vehicle.
4) Connect evaporation hose to evaporation pipe. 4) Temporarily tighten screws which install fuel
filler pipe on filler lid open.

S2M0882
B2M3363

17
2-8 [W2D0] SERVICE PROCEDURE
2. Fuel Filler Pipe

5) Connect evaporation hoses to pipes. 11) While holding the under side of protector cover
on bracket, install it.

S2M0881
B2M1750B
6) Lift-up the vehicle.
7) Tighten clamp bolt which holds fuel filler hose. (A) Hook

12) Tighten bolts which install protector cover on

body.

B2M1745

8) Install the two evaporation hoses to clip.

B2M1749

13) Tighten screws which install fuel filler pipe on

filler lid open.

B2M1753

9) Connect evaporation hose to joint pipe.

B2M3363

14) Install rear right wheel.

B2M1754

10) Lower the vehicle.

B2M1748

15) Install fuel filler cap.

18
 SERVICE PROCEDURE [W3A0] 2-8
3. Fuel Pump

16) Connect connector to fuel pump relay. 3. Fuel Pump

A: REMOVAL
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.

S2M0093

17) Connect battery ground terminal.

B2M3363

3) Disconnect battery ground cable.

G6M0095

G6M0095

4) Disconnect connector from fuel pump.

S2M0172

5) Move clips, and then disconnect fuel delivery

hose (A), return hose (B) and jet pump hose (C).

19
 SERVICE PROCEDURE [W3A0] 2-8
3. Fuel Pump

16) Connect connector to fuel pump relay. 3. Fuel Pump

A: REMOVAL
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.

S2M0093

17) Connect battery ground terminal.

B2M3363

3) Disconnect battery ground cable.

G6M0095

G6M0095

4) Disconnect connector from fuel pump.

S2M0172

5) Move clips, and then disconnect fuel delivery

hose (A), return hose (B) and jet pump hose (C).

19
2-8 [W3B0] SERVICE PROCEDURE
3. Fuel Pump

6) Disconnect quick connector, and then discon- (1) Always use new gaskets.
nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].> (2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten nuts in alphabetical sequence shown
in Figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

S2M0060A

7) Remove nuts which install fuel pump assembly

onto fuel tank.
8) Take off fuel pump from fuel tank.
S2M0063A

(4) Connect connector to fuel pump relay.

S2M0061

B: INSPECTION S2M0093

Connect lead harness to connector terminal of fuel

pump, and apply battery power supply to check
whether the pump operate.
WARNING:
I Wipe off the fuel completely.
I Be sure to turn the battery supply ON and
OFF on the battery side.
I Do not run fuel pump for a long time under
non-load condition.

G2M0366

C: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:

20
 SERVICE PROCEDURE [W4A0] 2-8
4. Fuel Level Sensor

4. Fuel Level Sensor 5) Move clips, and then disconnect fuel return
hose (B) and jet pump hose (C).
A: REMOVAL 6) Disconnect quick connector, and then discon-
WARNING: nect fuel delivery hose (A). <Ref. to 2-8 [W9A0].>
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Open fuel flap lid, and remove fuel filler cap.

S2M0060A

7) Remove nuts which install fuel pump assembly

onto fuel tank.
8) Take off fuel pump assembly.
9) Disconnect connector from fuel pump bracket.

B2M3363

3) Disconnect battery ground cable.

S2M0145

10) Remove bolt which installs fuel level sensor

on mounting bracket.

G6M0095

4) Disconnect connector from fuel pump.

H2M3206

S2M0172

21
2-8 [W4B0] SERVICE PROCEDURE
5. Fuel Sub Level Sensor

B: INSTALLATION 5. Fuel Sub Level Sensor

Install in the reverse order of removal. Do the fol- A: REMOVAL AND INSTALLATION
lowing:
(1) Install the fuel level sensor on mounting WARNING:
bracket. I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Disconnect battery ground cable.

H2M3206

(2) Always use new gaskets.

(3) Ensure sealing portion is free from fuel or for-
eign particles before installation. G6M0095
(4) Tighten nuts in alphabetical sequence shown
in Figure to specified torque. 2) Remove fuel filler cap.
3) Remove service hole cover.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

G2M0863

S2M0063A 4) Disconnect connector from fuel sub level

(5) Connect connector to fuel pump relay. sensor, and disconnect jet pump hose.

S2M0151
S2M0093

22
2-8 [W4B0] SERVICE PROCEDURE
5. Fuel Sub Level Sensor

B: INSTALLATION 5. Fuel Sub Level Sensor

Install in the reverse order of removal. Do the fol- A: REMOVAL AND INSTALLATION
lowing:
(1) Install the fuel level sensor on mounting WARNING:
bracket. I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Disconnect battery ground cable.

H2M3206

(2) Always use new gaskets.

(3) Ensure sealing portion is free from fuel or for-
eign particles before installation. G6M0095
(4) Tighten nuts in alphabetical sequence shown
in Figure to specified torque. 2) Remove fuel filler cap.
3) Remove service hole cover.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

G2M0863

S2M0063A 4) Disconnect connector from fuel sub level

(5) Connect connector to fuel pump relay. sensor, and disconnect jet pump hose.

S2M0151
S2M0093

22
 SERVICE PROCEDURE [W6A0] 2-8
6. Fuel Cut Valve

5) Remove bolts which install fuel sub level sensor 6. Fuel Cut Valve
on fuel tank.
A: REMOVAL AND INSTALLATION
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Remove fuel tank. <Ref. to 2-8 [W1C0].>

S2M0152

6) Remove fuel sub level sensor.

S2M0169A

2) Remove protect cover.

S2M0153

7) Install in the reverse order of removal.

Tightening torque:
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)

H2M3601

3) Disconnect evaporation hose from fuel cut

valve.
4) Remove fuel cut valve.

S2M0152B

G2M0867

23
 SERVICE PROCEDURE [W6A0] 2-8
6. Fuel Cut Valve

5) Remove bolts which install fuel sub level sensor 6. Fuel Cut Valve
on fuel tank.
A: REMOVAL AND INSTALLATION
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Remove fuel tank. <Ref. to 2-8 [W1C0].>

S2M0152

6) Remove fuel sub level sensor.

S2M0169A

2) Remove protect cover.

S2M0153

7) Install in the reverse order of removal.

Tightening torque:
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)

H2M3601

3) Disconnect evaporation hose from fuel cut

valve.
4) Remove fuel cut valve.

S2M0152B

G2M0867

23
2-8 [W7A0] SERVICE PROCEDURE
7. Roll Over Valve

5) Install in the reverse order of removal. 7. Roll Over Valve

Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) A: REMOVAL AND INSTALLATION
1) Lift-up the vehicle.
2) Remove roll over valve from bracket.

G2M0867

S2M0174

3) Disconnect hoses from roll over valve, and

remove it from bracket.

S2M0175

4) Install in the reverse order of removal.

CAUTION:
I Do not install top side of valve down.
I Before installing bracket on body, securely
fit concave part of bracket to hole in body.

S2M0174

24
2-8 [W7A0] SERVICE PROCEDURE
7. Roll Over Valve

5) Install in the reverse order of removal. 7. Roll Over Valve

Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) A: REMOVAL AND INSTALLATION
1) Lift-up the vehicle.
2) Remove roll over valve from bracket.

G2M0867

S2M0174

3) Disconnect hoses from roll over valve, and

remove it from bracket.

S2M0175

4) Install in the reverse order of removal.

CAUTION:
I Do not install top side of valve down.
I Before installing bracket on body, securely
fit concave part of bracket to hole in body.

S2M0174

24
 SERVICE PROCEDURE [W8B0] 2-8
8. Fuel Filter

B: INSPECTION 8. Fuel Filter

1) Connect hoses to roll over valve as shown in A: REMOVAL
Figure.
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect battery ground cable.

G2M0374

2) While blowing through open end of hose, tilt

valve at least 90° left and right from normal posi-
tion.
3) Ensure that there is no air flow when hose is
tilted greater than 90°.
G6M0095

3) Disconnect fuel delivery hoses from fuel filter.

S2M0195

4) Remove filter from holder.

B: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.

25
 SERVICE PROCEDURE [W8B0] 2-8
8. Fuel Filter

B: INSPECTION 8. Fuel Filter

1) Connect hoses to roll over valve as shown in A: REMOVAL
Figure.
WARNING:
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Disconnect battery ground cable.

G2M0374

2) While blowing through open end of hose, tilt

valve at least 90° left and right from normal posi-
tion.
3) Ensure that there is no air flow when hose is
tilted greater than 90°.
G6M0095

3) Disconnect fuel delivery hoses from fuel filter.

S2M0195

4) Remove filter from holder.

B: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.

25
2-8 [W8C0] SERVICE PROCEDURE
8. Fuel Filter

C: INSTALLATION 3) Connect connector to fuel pump relay.

CAUTION:
I If fuel hoses are damaged at the connecting
portion, replace it with a new one.
I If clamps are badly damaged, replace with
new ones.
1) Install in the reverse order of removal.
2) Tighten hose clamp screws.
Tightening torque:
1.0 +0.5/−0 N·m (0.1+0.05/−0 kg-m, 0.7+0.4/−0
ft-lb) S2M0093

S2M0195

26
 SERVICE PROCEDURE [W9A0] 2-8
9. Fuel Delivery, Return and Evaporation Lines

9. Fuel Delivery, Return and 1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Remove fuel filler cap.
Evaporation Lines 3) Remove inner trim, insulator and rear seat.
A: REMOVAL 4) Remove fuel delivery pipes and hoses, fuel
return pipes and hoses, and evaporation pipes and
WARNING: hoses.
I Place “NO FIRE” signs near the working
area.
I Be careful not to spill fuel on the floor.

S2M0863A

(1) Purge control solenoid valve (6) Pressure control solenoid valve (11) Fuel sub level sensor
(2) Roll over valve (7) Drain valve (12) Fuel tank pressure sensor
(3) Quick connector (8) Drain filter (13) Fuel tank
(4) Fuel pump (9) Canister (14) Fuel filter
(5) Shut valve (10) Fuel cut valve

5) In engine compartment, detach fuel delivery

hose, return hose and evaporation hose.

S2M0500

27
2-8 [W9B0] SERVICE PROCEDURE
9. Fuel Delivery, Return and Evaporation Lines

6) Separate quick connector on fuel delivery line. (1) Set new retainer (B) to connector (A).
(1) Clean pipe and connector, if they are cov- (2) Push pipe into connector completely.
ered with dust.
NOTE:
(2) Hold connector (A) and push retainer (B)
down. At this time, two clicking sounds are heard.
(3) Pull out connector (A) from retainer (B).
CAUTION:
Replace retainer with new ones.

S2M0230A

(A) Connector
(B) Retainer
S2M0228A (C) Pipe

(A) Connector CAUTION:

(B) Retainer I Pull the connector to ensure it is connected
(C) Pipe securely.
I Ensure the two retainer pawls are engaged in
B: INSTALLATION their mating positions in the connector.
Install in the reverse order of removal. I Be sure to inspect hoses and their connec-
1) Connect quick connector on fuel delivery line. tions for any leakage of fuel.
CAUTION:
I Always use a new retainer.
I Make sure that the connected portion is not
damaged or has dust. If necessary, clean seal
surface of pipe.

S2M0231A

(A) Connector
(B) Retainer
(C) Pipe

S2M0229

28
 SERVICE PROCEDURE [W9B0] 2-8
9. Fuel Delivery, Return and Evaporation Lines

2) Connect fuel delivery hose to pipe in engine 3) Connect return hose and evaporation hose to
compartment with an overlap of 20 to 25 mm (0.79 pipe by approx. 15 mm (0.59 in) from hose end.
to 0.98 in). Fuel return hose:
A: When fitting length is specified. L = 20 — 25 mm (0.79 — 0.98 in)
B: When fitting length is not specified.
Fuel evaporation hose:
 : 1.0 — 4.0 mm (0.039 — 0.157 in) L = 15 — 20 mm (0.59 — 0.79 in)
L: 20 — 25 mm (0.79 — 0.98 in) CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.

B2M1194D

(1) Fitting
B2M1195A
(2) Clamp
(3) Hose (1) Hose
(2) Clip
(3) Pipe

4) Connect connector to fuel pump relay.

S2M0093

29
2-8 [K100] DIAGNOSTICS
1. Fuel System Trouble in General

1. Fuel System Trouble in General

Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and
q Defective terminal contact.
tighten securely.
Trouble in electromagnetic or electronic circuit
q Replace fuel pump.
parts.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
Clean, correct or replace air breather tube or
6) Clogged or bent breather tube or pipe.
pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
Clogged or bent air breather tube or air vent Clean, correct or replace air breather tube or air
5)
tube. vent tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube
1) Retightening.
and fuel filler pipe.
Defective packing air tightness on the fuel sau-
2) Correct or replace packing.
cer.
3) Cracked fuel separator. Replace separator.
4) Inoperable fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
(1) To prevent water condensation:
I Top off the fuel tank or drain the fuel completely.
I Drain water condensation from the fuel filter.
(2) Refilling the fuel tank:
Refill the fuel tank while there is still some fuel left in the tank.
(3) Protecting the fuel system against freezing and water condensation:
I Cold areas
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0°C (32°F) throughout the winter season, use an anti-freeze solution in the cooling system. Refueling
will also complement the effect of anti-freeze solution each time the fuel level drops to about one-half.
After the winter season, drain water which may have accumulated in the fuel filter and fuel tank in the
manner same as that described under Affected areas below.
I Affected areas
When water condensation is notched in the fuel filter, drain water from both the fuel filter and fuel tank
or use a water removing agent (or anti-freeze solution) in the fuel tank.
(4) Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water
removing agent) container before use.

30
2-9 [C100] COMPONENT PARTS
1. Exhaust System

1. Exhaust System

S2M0921A

(1) Upper front exhaust pipe cover (11) Spring (25) Front catalytic converter
CTR (12) Rear exhaust pipe (26) Lower front catalytic converter
(2) Lower front exhaust pipe cover (13) Self-locking nut cover
CTR (14) Gasket (27) Upper front catalytic converter
(3) Band RH (15) Muffler cover
(4) Band LH (16) Cushion rubber (28) Gasket
(5) Upper front exhaust pipe cover (17) Clamp (29) Rear catalytic converter
LH (18) Upper center exhaust pipe cover (30) Gasket
(6) Lower front exhaust pipe cover (19) Center exhaust pipe
LH (20) Clamp B Tightening torque: N·m (kg-m, ft-lb)
(7) Front exhaust pipe (21) Upper rear catalytic converter T1: 13±3 (1.3±0.3, 9.4±2.2)
(8) Lower front exhaust pipe cover cover T2: 18±5 (1.8±0.5, 13.0±3.6)
RH (22) Lower rear catalytic converter T3: 30±5 (3.1±0.5, 22.4±3.6)
(9) Upper front exhaust pipe cover cover T4: 35±5 (3.6±0.5, 26.0±3.6)
RH (23) Front oxygen (A/F) sensor T5: 48±5 (4.9±0.5, 35.4±3.6)
(10) Gasket (24) Rear oxygen sensor

2
 SERVICE PROCEDURE [W1A0] 2-9
1. Front and Center Exhaust Pipe Assembly

1. Front and Center Exhaust 7) Separate front and center exhaust pipe assem-
bly from rear exhaust pipe.
Pipe Assembly
WARNING:
A: REMOVAL Be careful, exhaust pipe is hot.
1) Set the vehicle on the lift.
2) Disconnect battery ground cable.

B2M0055

8) Remove bolts which hold front exhaust pipe

G6M0095 onto cylinder heads.
3) Disconnect front oxygen (A/F) sensor connec- CAUTION:
tor. Be careful not to pull down front and center
exhaust pipe assembly.

B2M3439
B2M0054
4) Lift-up the vehicle.
5) Remove under cover. 9) Remove bolt which installs front and center
6) Disconnect rear oxygen sensor connector. exhaust pipe assembly to hanger bracket.

B2M3440 B2M0313

10) Remove front and center exhaust pipe assem-

bly from the vehicle.
CAUTION:
I Be careful not to let front and center exhaust
pipe assembly fall off when removing as it is
quite heavy.
I After removing front and center exhaust
assembly, do not apply excessive pulling force
on rear exhaust pipe.

3
2-9 [W1B0] SERVICE PROCEDURE
1. Front and Center Exhaust Pipe Assembly

11) Separate front exhaust pipe from front cata- 4) Tighten bolts which hold front exhaust pipe onto
lytic converter and center exhaust pipe assembly. cylinder heads.
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

S2M0923

B: INSTALLATION B2M0054

1) Install front exhaust pipe to front catalytic con- 5) Tighten bolts which install front and center
verter and center exhaust pipe assembly. exhaust pipe assembly to rear exhaust pipe.
CAUTION: Tightening torque:
Replace gaskets with new ones. 18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)

B2M0055

6) Tighten bolt which holds front and center

S2M0923 exhaust pipe assembly to hanger bracket.
2) Install front and center exhaust pipe assembly Tightening torque:
to the vehicle. 35±5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
3) Temporarily tighten bolt which installs front and
center exhaust pipe assembly to hanger bracket.

B2M0313

B2M0313

4
 SERVICE PROCEDURE [W2A0] 2-9
2. Rear Exhaust Pipe

7) Connect rear oxygen sensor connector. 2. Rear Exhaust Pipe

A: REMOVAL
1) Lift-up the vehicle.
2) Separate rear exhaust pipe from center
exhaust pipe.
WARNING:
Be careful, exhaust pipe is hot.

B2M3440

8) Install under cover.

9) Lower the vehicle.
10) Connect front oxygen (A/F) sensor connector.

B2M0055

3) Separate rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down rear exhaust pipe.

B2M3439

11) Connect battery ground cable.

S2M0157

4) Remove rear exhaust pipe bracket from rubber

cushion.
G6M0095 NOTE:
To facilitate removal, apply a coat of SUBARU
CRC or equivalent to pipe bracket in advance.
SUBARU CRC (Part No. 004301003)

S2M0158

5
 SERVICE PROCEDURE [W2A0] 2-9
2. Rear Exhaust Pipe

7) Connect rear oxygen sensor connector. 2. Rear Exhaust Pipe

A: REMOVAL
1) Lift-up the vehicle.
2) Separate rear exhaust pipe from center
exhaust pipe.
WARNING:
Be careful, exhaust pipe is hot.

B2M3440

8) Install under cover.

9) Lower the vehicle.
10) Connect front oxygen (A/F) sensor connector.

B2M0055

3) Separate rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down rear exhaust pipe.

B2M3439

11) Connect battery ground cable.

S2M0157

4) Remove rear exhaust pipe bracket from rubber

cushion.
G6M0095 NOTE:
To facilitate removal, apply a coat of SUBARU
CRC or equivalent to pipe bracket in advance.
SUBARU CRC (Part No. 004301003)

S2M0158

5
2-9 [W2B0] SERVICE PROCEDURE
3. Muffler

B: INSTALLATION 3. Muffler
CAUTION: A: REMOVAL AND INSTALLATION
Replace gaskets with new ones.
WARNING:
1) Install rear exhaust pipe bracket to rubber cush-
Be careful, exhaust pipe is hot.
ion.
NOTE: 1) Lift-up the vehicle.
To facilitate installation, apply a coat of SUBARU 2) Separate muffler from rear exhaust pipe.
CRC or equivalent to mating area of rubber cush-
ion in advance.
SUBARU CRC (Part No. 004301003)

S2M0157

3) Remove left and right rubber cushions.

CAUTION:
S2M0158
Be careful not to pull down muffler.
2) Install rear exhaust pipe to muffler. NOTE:
Tightening torque: To facilitate removal, apply a coat of SUBARU
48±5 N·m (4.9±0.5 kg-m, 35.4±3.6 ft-lb) CRC or equivalent to mating area of rubber cush-
ions in advance.
SUBARU CRC (Part No. 004301003)

S2M0157

3) Install rear exhaust pipe to center exhaust pipe.

S2M1101
Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

B2M0055

6
2-9 [W2B0] SERVICE PROCEDURE
3. Muffler

B: INSTALLATION 3. Muffler
CAUTION: A: REMOVAL AND INSTALLATION
Replace gaskets with new ones.
WARNING:
1) Install rear exhaust pipe bracket to rubber cush-
Be careful, exhaust pipe is hot.
ion.
NOTE: 1) Lift-up the vehicle.
To facilitate installation, apply a coat of SUBARU 2) Separate muffler from rear exhaust pipe.
CRC or equivalent to mating area of rubber cush-
ion in advance.
SUBARU CRC (Part No. 004301003)

S2M0157

3) Remove left and right rubber cushions.

CAUTION:
S2M0158
Be careful not to pull down muffler.
2) Install rear exhaust pipe to muffler. NOTE:
Tightening torque: To facilitate removal, apply a coat of SUBARU
48±5 N·m (4.9±0.5 kg-m, 35.4±3.6 ft-lb) CRC or equivalent to mating area of rubber cush-
ions in advance.
SUBARU CRC (Part No. 004301003)

S2M0157

3) Install rear exhaust pipe to center exhaust pipe.

S2M1101
Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

B2M0055

6
 SERVICE PROCEDURE [W3A0] 2-9
3. Muffler

4) Remove front rubber cushion, and detach muf- 5) Install in the reverse order of removal.
fler assembly. CAUTION:
NOTE: Replace gasket with a new one.
To facilitate removal, apply a coat of SUBARU
CRC or equivalent to mating area of rubber cush-
Tightening torque:
ion in advance. 48±5 N·m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
SUBARU CRC (Part No. 004301003)

S2M0157

S2M0160

7
2-9 SERVICE PROCEDURE

MEMO: