Engine Mechanical (H4DOTC): Removal & Installation Subaru Forester SG рестайлинг

REMOVAL

1. Remove the engine unit. REMOVAL ENGINE ASSEMBLY.>
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

Engine mounting

35 N.m (3.6 kgf-m, 25.8 ft-lb)

1. Install the crank pulley.
2. Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH Clean the crank pulley thread using compressed air. Apply engine oil to the crank pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crank pulley bolts. Tightening torque: 180 N.m (18.3 kgf-m, 132.7 ft-lb) see scheme 69: Locking Crankshaft Using Crank Pulley Wrench ST 499977100
3. Check that the tightening angle of the clamp pulley bolt is a minimum of 65°. Perform the following procedure when less than 65°. CAUTION: If the tightening angle of crank pulley bolt is less than 65°, the bolt is damaged. In this case, the bolt must be replaced. Replace the crank pulley bolts and clean them. Crank pulley bolt: 12369A A011 Clean the crankshaft thread using compressed air. Apply engine oil to the crank pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crank pulley bolts 65° to 75°. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover.
4. Install the belt tensioner. see scheme 70: Identifying A/C Belt Tensioner
5. Install the V-belts. INSTALLATION V-BELT.>

1. Remove the V-belts. REMOVAL V-BELT.>
2. Remove the crank pulley. REMOVAL CRANK PULLEY.>
3. Remove the timing belt cover (LH) (A).
4. Remove the timing belt cover (RH) (B).
5. Remove the front timing belt cover (C).

Scheme 377

1. Install the front timing belt cover (C). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
2. Install the timing belt cover (RH) (B). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
3. Install the timing belt cover (LH) (A). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 72: Identifying Front Timing Belt Covers
4. Install the crank pulley. INSTALLATION CRANK PULLEY.>
5. Install the V-belts. INSTALLATION V-BELT.>

1. Fasten the cam sprocket and install to the cam shaft using ST. NOTE: Do not confuse left and right side cam sprockets during installation. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.0 kgf-m, 21.8 ft-lb) of torque, and then tighten further by 45°. see scheme 111: Locating Cam Sprocket Wrench ST 499207400 ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.0 kgf-m, 21.8 ft-lb) of torque, and then tighten further by 45°. see scheme 112: Locating Cam Sprocket Wrench ST 499977500
2. Install the timing belt. INSTALLATION TIMING BELT.>
3. Install the timing belt cover. INSTALLATION TIMING BELT COVER.>
4. Install the crank pulley. INSTALLATION CRANK PULLEY.>
5. Install the V-belts. INSTALLATION V-BELT.>

1. Remove the V-belts. REMOVAL V-BELT.>
2. Remove the crank pulley. REMOVAL CRANK PULLEY.>
3. Remove the timing belt cover. REMOVAL TIMING BELT COVER.>
4. Remove the timing belt. REMOVAL TIMING BELT.>
5. Remove the crank sprocket.

Scheme 378

1. Install the crank sprocket. see scheme 114: Identifying Crank Sprocket Timing Mark
2. Install the timing belt. INSTALLATION TIMING BELT.>
3. Install the timing belt cover. INSTALLATION TIMING BELT COVER.>
4. Install the crank pulley. INSTALLATION CRANK PULLEY.>
5. Install the V-belts. INSTALLATION V-BELT.>

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

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

1. Remove the intake manifold. REMOVAL, Intake Manifold.>
2. Remove the V-belts. REMOVAL, V-BELT.>
3. Remove the crank pulley. REMOVAL, CRANK PULLEY.>
4. Remove the timing belt cover. REMOVAL, TIMING BELT COVER.>
5. Remove the timing belt. REMOVAL, TIMING BELT.>
6. Remove the cam sprocket. REMOVAL, CAM SPROCKET.>
7. Remove the crank sprocket. REMOVAL, CRANK SPROCKET.>
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head. REMOVAL, CYLINDER HEAD.>
10. Remove the clutch disc and cover. REMOVAL, Clutch Disc and Cover.>
11. Remove the flywheel. REMOVAL, Flywheel.> ST 498497100 CRANKSHAFT STOPPER see scheme 155: Identifying Crankshaft Stopper ST 498497100 On Flywheel
12. Remove the oil separator cover.
13. Remove the water by-pass pipe for heater.
14. Remove the oil filter. REMOVAL, Engine Oil Filter.>
15. Remove the oil cooler. see scheme 156: Exploded View Of Oil Cooler
16. Remove the water pump.
17. Remove the oil pump from cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump. Remove the oil pump from cylinder block using a flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump. see scheme 157: Removing Oil Pump From Cylinder Block Using Screwdriver
18. Removal of oil pan: Turn the cylinder block with #2 and #4 piston sides facing upward. Remove the bolts which secure oil pan to cylinder block. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
19. Remove the oil strainer stay.
20. Remove the oil strainer.
21. Remove the baffle plate.
22. Remove the water pipe. see scheme 158: Exploded View Of Oil Pan Components
23. Remove the service hole cover and service hole plugs using a hexagon wrench [14 mm]. see scheme 159: Removing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench
24. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring by inserted the radio pincers into the service hole of #1 and #2 cylinders. see scheme 160: Removing Piston Snap Ring
25. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER CAUTION: Be careful not to confuse the original combination of piston, piston pin and cylinder. 26) Similarly remove the piston pins from #3 and #4 pistons. see scheme 161: Drawing Out Piston Pin From Pistons Using Piston Pin Remover ST 499097700
26. Similarly remove the piston pins from #3 and #4 pistons.
27. Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
28. Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
29. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
30. Separate the cylinder block to the left and right. NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block. see scheme 162: Exploded View Of Piston, Crankshaft Bearing And Oil Seal
31. Remove the rear oil seal.
32. Remove the crankshaft together with connecting rod.
33. Remove the crankshaft bearings from cylinder block using a hammer handle. CAUTION: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
34. Remove each piston from cylinder block using wooden bar or hammer handle. CAUTION: Do not confuse the combination of piston and cylinder.

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

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Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

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Scheme 408

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Scheme 412

Scheme 413

1. Install the crankshaft bearings on the cylinder block, apply a coat of engine oil to crankshaft bearings, and position the crankshaft on the #2 and #4 cylinder block.
2. Apply liquid gasket to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Liquid gasket: Three Bond 1215 (Part No. 004403007) or equivalent CAUTION: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. see scheme 164: Identifying Liquid Gasket Applying Surfaces
3. Apply a coat of engine oil to the washer and bolt thread.
4. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side) Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 165: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
5. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side) Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 166: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
6. Further tighten the LH side bolts (A - D) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) see scheme 167: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
7. Further tighten the RH side bolts (E - J) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) see scheme 168: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
8. Further tighten the LH side bolts (A - D) in alphabetical sequence. (A), (C): Angle tightening Tightening angle: 90° (B), (D): Torque tightening Tightening torque: 40 N.m (4.1 kgf-m, 29.6 ft-lb) see scheme 169: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
9. Further tighten the RH side bolts (E - J) in alphabetical sequence another 90°. see scheme 170: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
10. 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) see scheme 171: Identifying Cylinder Block Connecting Bolts Tightening Sequence In Alphabetical Order
11. Install the rear oil seal using ST1 and ST2. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER see scheme 172: Installing Rear Oil Seal Using Crankshaft Oil Seal Guide ST1 499597100 And Crankshaft Oil Seal Installer ST2 499587200 NOTE: Use a new rear oil seal.
12. Position the top ring gap at (A) or (B) in the figure.
13. Position the second ring gap at 180° on the reverse side the top ring gap. see scheme 173: Identifying Top Ring Gap Position
14. Position the upper rail gap at (C) in the figure. (Scheme 379): Identifying Upper Rail Gap Position
15. Align the upper rail spin stopper (E) to the side hole (D) on the piston. (Scheme 380): Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
16. Position the expander gap at (F) in the figure. (Scheme 381): Identifying Expander Ring Gap Position
17. Position the lower rail gap at (G) in the figure. (Scheme 382): Identifying Lower Rail Gap Position CAUTION: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
18. Install the snap ring. Install the snap rings in the piston holes located opposite to the service holes in cylinder block before positioning all pistons in corresponding cylinders. NOTE: Use new snap rings. (Scheme 383): Identifying Piston With Snap Rings (Scheme 384): Exploded View Of Piston Tightening torque: N.m (kgf-m, ft-lb) T: 70(7.1,51.4)
19. Installing piston: Place the cylinder block to face the #1 and #2 cylinder 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 the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE (Scheme 385): Inserting Pistons In Cylinders Using Piston Guide ST2 498747300 CAUTION: Piston front mark faces towards the front of engine. (Scheme 386): Identifying Piston Front Mark
20. Installing piston pin: Apply a coat of engine oil to ST3. Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end. ST3 499017100 PISTON PIN GUIDE (Scheme 387): Inserting Piston Pin Guide ST3 499017100 Into Service Hole Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. Using radio pincers, install the snap ring. NOTE: Use new snap rings. (Scheme 388): Installing Snap Ring Apply liquid gasket around the service hole plug. Liquid gasket: Three Bond 1105 (Part No. 004403010) or equivalent (Scheme 389): Applying Liquid Gasket Around Service Hole Plug Install the service hole plug and gasket. NOTE: Use a new gasket. (Scheme 390): Removing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench see scheme 186: Exploded View Of Piston With Torque Specification Tightening torque: N.m (kgf-m, ft-lb) T1: 6.4(0.65,4.7) T2: 70(7.1,51.4) Place the cylinder block to face the #3 and #4 cylinder side upward. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
21. Install the water pipe.
22. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
23. Install the oil strainer and O-ring. Tightening torque: 10 N.m (1.0 kgf-m, 7 ft-lb)
24. Install the oil strainer stay.
25. Apply liquid gasket to the mating surfaces, and install the oil pan. NOTE: Install within 20 min. after applying liquid gasket. Liquid gasket: Three Bond 1207C (Part No. 004403012) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 187: Identifying Liquid Gasket Applying Area On Mating Surfaces Of Oil Pan
26. Apply liquid gasket to the mating surfaces and the threaded portion of bolt (A) shown in the figure, and then install the oil separator cover. NOTE: Install within 20 min. after applying liquid gasket. Liquid gasket: Mating surface Three Bond 1207C (Part No. 004403012) or equivalent Bolt thread (A) Three Bond 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) see scheme 188: Identifying Liquid Gasket Applying Area On Mating Surfaces And Threaded Portion Of Bolt (A)
27. Install the flywheel. INSTALLATION Flywheel.>
28. Install the clutch disc and cover. INSTALLATION Clutch Disc and Cover.>
29. Installation of oil pump: After removing, discard the front oil seal and install a new oil seal using ST. ST 499587100 OIL SEAL INSTALLER see scheme 189: Installing Oil Seal Using Oil Seal Installer ST 499587100 Apply liquid gasket to the matching surface of oil pump. Liquid gasket: Three Bond 1215 (Part No. 004403007) or equivalent (Scheme 391): Identifying Liquid Gasket Applying Area On Matching Surface Of Oil Pump Apply a coat of engine oil to the inside of oil seal. (Scheme 392): Identifying Engine Oil Applying Area Inside Of Oil Seal Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation. Apply liquid gasket to the three bolts thread. CAUTION: Do not forget to install the O-ring and seal when installing the oil pump. Align the flat surface of oil pump's inner rotor with crankshaft before installation. Liquid gasket: Three Bond 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 393): Identifying Liquid Gasket Applying Area On Threads Of Bolts
30. Install the service hole plug 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 bolts in two stages in alphabetical sequence as shown in the figure. (Scheme 394): Identifying Water Pump Bolts Tightening Sequence
31. Install the water by-pass pipe for heater.
32. Install the oil cooler. Tightening torque: T1: 45 N.m (4.6 kgf-m, 33 ft-lb) T2: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) T3: 54 N.m (5.3 kgf-m, 39 ft-lb) (Scheme 395): Exploded View Of Oil Cooler
33. Install the oil filter. INSTALLATION Engine Oil Filter.>
34. Install the water by-pass pipe between oil cooler and water pump.
35. Install the water pipe. NOTE: Use new O-rings.
36. Install the cylinder head. INSTALLATION CYLINDER HEAD.>
37. Install the oil level gauge guide and tighten the attaching bolt (left side).
38. Install the rocker cover and rocker cover gasket. NOTE: Use a new gasket.
39. Install the crank sprocket. INSTALLATION, CRANK SPROCKET.>
40. Install the cam sprocket. INSTALLATION CAM SPROCKET.>
41. Install the timing belt. INSTALLATION TIMING BELT.>
42. Install the timing belt cover. INSTALLATION, TIMING BELT COVER.>
43. Install the crank pulley. INSTALLATION, CRANK PULLEY.>
44. Install the generator and A/C compressor brackets on cylinder head.
45. Install the V-belts. INSTALLATION, V-BELT.>
46. Install the intake manifold. INSTALLATION, Intake Manifold.>

Scheme 414

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 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 snap ring.

Scheme 415

Tightening torque: N.m (kgf-m, ft-lb)

T: 52(5.3,38.4)

1. Apply oil to the surface of the connecting rod bearings, and install the connecting rod bearings on connecting rods and connecting rod caps.
2. Install the connecting rod on crankshaft.
3. Position each connecting rod with the marking side facing forward.
4. Tighten the connecting rod cap with the connecting rod bolt. Make sure the arrow on connecting rod cap faces the front during installation. Tightening torque: 52 N.m (5.3 kgf-m, 38.4 ft-lb) 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 oil ring upper rail, expander and lower rail in this order by hand.
6. Install the second ring and top ring using piston ring expander.

REMOVAL AND INSTALLATION

Refer to "19. Cylinder Head" for work relating to the intake and the exhaust valves.

REMOVAL CYLINDER HEAD.> INSTALLATION CYLINDER HEAD.>

Refer to "20. Cylinder Block" for work relating to the piston.

REMOVAL CYLINDER BLOCK.> INSTALLATION CYLINDER BLOCK.>

Refer to "20. Cylinder Block" for work relating to the connecting rods.

REMOVAL CYLINDER BLOCK.> INSTALLATION CYLINDER BLOCK.>

Refer to "20. Cylinder Block" for work relating to the crankshaft.

REMOVAL CYLINDER BLOCK.> INSTALLATION CYLINDER BLOCK.>