Engine Mechanical (SOHC): Removal & Installation Subaru Forester SG

REMOVAL

1. Remove the engine assembly. Refer to «REMOVAL»(ref-200788-S26422196292005102300000) , Engine Assembly.
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

1. Engine mounting; 34 N.m (3.5 kgf-m, 25.3 ft-lb)

Note. Before conducting this procedure, drain the engine oil completely if applicable.

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1. Remove the intake manifold. Refer to «REMOVAL»(ref-200785-S18758421022005102300000) , Intake Manifold.
2. Remove the V-belt. Refer to «REMOVAL»(ref-200788-S33926247212005102300000) , V-belt.
3. Remove the crankshaft pulley. Refer to «REMOVAL»(ref-200788-S02022350792005102300000) , Crankshaft Pulley.
4. Remove the belt cover. Refer to «REMOVAL»(ref-200788-S33590109302005102300000) , Belt Cover.
5. Remove the timing belt assembly. Refer to «REMOVAL»(ref-200788-S26728354622005102300000) , Timing Belt Assembly.
6. Remove the camshaft sprocket. Refer to «REMOVAL»(ref-200788-S15205751072005102300000) , Camshaft Sprocket.
7. Remove the crankshaft sprocket. Refer to «REMOVAL»(ref-200788-S02022350792005102300000) , Crankshaft Pulley.
8. Remove the generator and A/C compressor with their brackets.
9. Remove the rocker cover.
10. Remove the cylinder head bolts in alphabetical sequence shown in the figure. NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent cylinder head from falling.
11. While tapping the cylinder head with a plastic hammer, separate it from cylinder block.
12. Remove the bolts (a) and (c) to remove cylinder head.
13. Remove the cylinder head gasket. NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
14. Similarly, remove the right side cylinder head.
15. Remove the clutch housing cover. (MT vehicles)
16. Remove the flywheel (MT vehicles) or drive plate (AT vehicles). Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER MT VEHICLES AT VEHICLES
17. Remove the oil separator cover.
18. Remove the water by-pass pipe for heater.
19. Loosen the bolts in alphabetical sequence as shown in the figure, and then remove water pump.
20. Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing oil pump. NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump.
21. Removal of oil pan Turn the cylinder block to face the #2 and #4 piston sides upward. Remove the bolts which secure oil pan to cylinder block. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance, and then remove the oil pan. NOTE: Do not use a screwdriver or similar tool in place of oil pan cutter.
22. Remove the oil strainer stay.
23. Remove the oil strainer.
24. Remove the baffle plate.
25. Remove the oil filter using ST. ST 498547000 OIL FILTER WRENCH
26. Remove the oil cooler. (AT vehicles)
27. Remove the water pipe.
28. Remove the service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
29. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston circlip through service hole of #1 and #2 cylinders. ST 499897200 PISTON SNAP RING PLIER
30. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
31. Similarly remove the piston pins from #3 and #4 pistons.
32. Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
33. Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
34. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, and then remove the cylinder block connecting bolts.
35. Separate the cylinder blocks (RH) and (LH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
36. Remove the rear oil seal.
37. Remove the crankshaft together with connecting rod.
38. Remove the crankshaft bearings from cylinder } block using hammer handle. NOTE: Do not confuse the combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
39. Draw out each piston from cylinder block using wooden bar or hammer handle. NOTE: Do not confuse the combination of piston and cylinder.

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Note. Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

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1. Position the crankshaft on #2 and #4 cylinder block.
2. Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent NOTE: Do not allow fluid packing to jut into O-ring grooves oil passages, bearing grooves, etc.
3. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side) Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb)
4. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side) Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb)
5. Further tighten LH side bolts (A) - (D) by 90° in alphabetical sequence.
6. Further tighten RH side bolts (E) - (J) by 90° in alphabetical sequence.
7. Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
8. Install the rear oil seal using ST1 and ST2 ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
9. Position the top ring gap at (A) or (B) in the figure.
10. Position the second ring gap at 180° on the reverse side for top ring gap.
11. Position the expander gap at (C) in the figure.
12. Position the lower rail gap at (D) in the figure. NOTE: Align the lower rail stopper (F) to the lateral hole (E) on the piston.
13. Position the upper rail gap within (G) in the figure. CAUTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.
14. Install circlip. Install circlips in the piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new circlips. CAUTION: Piston front mark faces towards the front of the engine.
15. Installing piston Turn the cylinder block to face the #1 and #2 piston side upward. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Apply a coat of engine oil to pistons and cylinders, and then insert the pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE
16. Installing piston pin Apply a coat of engine oil to the ST3 before insertion. Insert the ST3 into service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to the piston pin, and then insert the piston pin into piston and connecting rod through service hole. Install the circlip. NOTE: Use new circlips. ST3 499897200 PISTON SNAP RING PLIER Apply fluid packing around the service hole plug. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Install the service hole plug and gasket. NOTE: Use a new gasket. Turn the cylinder block to face the #3 and #4 piston side upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
17. Install the water pipe.
18. Install the baffle plate. Tightening torque: 6.4 N.m (0.kfg.m, 4.7 ft-lb)
19. Install the oil strainer and O-ring. Tightening torque: 10 N.m (1.0 kgf-m, 7ft-lb)
20. Install the oil strainer stay.
21. Apply fluid packing to the matching surfaces, and then install the oil pan. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent
22. Apply fluid packing to the matching surfaces, and then install the oil separator cover. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent
23. Install the flywheel or drive plate. To lock the crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb) MT VEHICLES AT VEHICLES
24. Install the housing cover.
25. Installation of oil pump Discard the front oil seal after removal. Replace with a new one using the ST. ST 499587100 OIL SEAL INSTALLER Apply fluid packing to the matching surface of oil pump. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Apply a coat of engine oil to the inside of oil seal. Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) CAUTION: Do not forget to the install the O-ring and seal when installing oil pump. Align flat surface of oil pump's inner rotor with crankshaft before installation.
26. Install the water pump and gasket. Tightening torque: First; 12 N.m (1.2 kgf-m, 8.7 ft-lb) Second; 12 N.m (1.2 kgf-m, 8.7 ft-lb) CAUTION: Be sure to use a new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure.
27. Install the water by-pass pipe for heater.
28. Apply fluid packing to the nipple (D), and then install the oil cooler. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Tightening torque: T1: 54 N.m (5.5 kgf-m, 40 ft-lb) T2: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
29. Install the oil filter using ST. ST 498547000 OIL FILTER WRENCH
30. Tighten the cylinder head bolts. Apply a coat of engine oil to the washers and bolt threads. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. Back off all bolts by 180° first; back them off by 180° again. Tighten the bolts (a) and (b) to 34 N.m (3.5 kgf-m, 25 ft-lb). Tighten the bolts (c), (d), (e) and (f) to 15 N.m (1.5 kgf-m, 11 ft-lb). Tighten all bolts by 80 to 90° in alphabetical sequence. CAUTION: Do not tighten bolts more than 90°. Further tighten all bolts by 80 to 90° in alphabetical sequence. CAUTION: Ensure that the total "re-tightening angle" [in the former two steps], do not exceed 180°.
31. Install the oil level gauge guide, and then tighten the attaching bolt (left side only).
32. Install the rocker cover.
33. Install the crankshaft sprocket. Refer to «INSTALLATION»(ref-200788-S33116162442005102300000) , Crankshaft Sprocket.
34. Install the camshaft sprocket. Refer to «INSTALLATION»(ref-200788-S00049029912005102300000) , Camshaft Sprocket.
35. Install the timing belt assembly. Refer to «INSTALLATION»(ref-200788-S22789107912005102300000) , Timing Belt Assembly.
36. Install the belt cover. Refer to «INSTALLATION»(ref-200788-S41837229032005102300000) , Belt Cover.
37. Install the crankshaft pulley. Refer to «INSTALLATION»(ref-200788-S33531086162005102300000) , Crankshaft Pulley.
38. Install the generator and A/C compressor brackets on cylinder head.
39. Install the V-belt. Refer to «INSTALLATION»(ref-200788-S14994437452005102300000) , V-belt.
40. Install the intake manifold. Refer to «INSTALLATION»(ref-200785-S13124992952005102300000) , Intake Manifold.

Scheme 171

1. Remove the connecting rod cap.
2. Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order to prevent confusion.
3. Remove the piston rings using the piston ring expander.
4. Remove the oil ring by hand. NOTE: Arrange the removed piston rings in good order to prevent confusion.
5. Remove the circlip.

Scheme 172

1. Apply oil to the surfaces of the connecting rod bearings.
2. Install the connecting rod bearings on connecting rods and connecting rod caps.
3. Position each connecting rod with the marked side facing forward, and then install them.
4. Install the connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads.
5. Install the expander, lower rail and upper rail in this order by hand. Then install the second ring and top ring with a piston ring expander.