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Engine Mechanical (H4SO): Overhaul Subaru Forester SG рестайлинг

Mechanical 25 illustrations ~2095 words

DISASSEMBLY

Note. Intake valve rocker assembly cannot be disassembled.

  1. Remove the exhaust valve rocker arm from the rocker shaft. NOTE: Keep all the removed parts in order for re-installing in their original positions.
  2. Remove the nut and adjusting screw from exhaust valve rocker.

ASSEMBLY

Note. Intake valve rocker assembly cannot be disassembled.

  1. Install the adjusting screw and nut to the exhaust valve rocker.
  2. Insert the exhaust valve rocker arm to rocker shaft. NOTE: Valve rocker arms, and rocker shaft have identification marks. Make sure the parts with same markings are properly assembled.

INTAKE VALVE ROCKER ASSEMBLY

  1. If the roller or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker assembly.
  2. Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker assembly.

Scheme 188

Scheme 188: EXHAUST VALVE ROCKER ASSEMBLY
Scheme 188: EXHAUST VALVE ROCKER ASSEMBLY

Scheme 189

Scheme 189
Scheme 189
  1. Measure the inner diameter of valve rocker arm and outer diameter of valve rocker shaft, and confirm the difference (oil clearance) between the two values. Clearance between arm and shaft: Standard: 0.020 - 0.054 mm (0.0008 - 0.0021 in) Service limit: 0.10 mm (0.0039 in) see scheme 104: Measuring Inner Diameter Of Valve Rocker Arm see scheme 105: Measuring Outer Diameter Of Valve Rocker Shaft
  2. If the oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows greater amount of wear. Rocker arm inside diameter: 22.020 - 22.041 mm (0.8669 - 0.8678 in) Rocker shaft diameter: 21.987 - 22.000 mm (0.8656 - 0.8661 in)
  3. If the roller or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker arm.
  4. Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker arm.

Scheme 190

Scheme 190: REMOVAL
Scheme 190: REMOVAL

Scheme 191

Scheme 191
Scheme 191

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Scheme 193

Scheme 194

Scheme 194
Scheme 194
  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 cam sprocket. REMOVAL, CAM SPROCKET. >
  6. Remove the timing belt cover No. 2 (LH).
  7. Remove the timing belt cover No. 2 (RH). NOTE: Do not damage or lose the seal rubber when removing the timing belt covers. see scheme 106: Identifying Belt Cover
  8. Remove the tensioner bracket. see scheme 107: Identifying Tensioner Bracket
  9. Remove the camshaft position sensor support. (LH side only)
  10. Remove the oil level gauge guide. (LH side only)
  11. Remove the valve rocker assembly. REMOVAL, VALVE ROCKER ASSEMBLY. >
  12. Remove the camshaft cap. Remove the bolts (a) and (b) in alphabetical sequence. see scheme 108: Identifying Removal Sequence Of Bolts Equally loosen the bolts (c) through (j) all the way in alphabetical sequence. see scheme 109: Identifying Loosening Sequence Of Bolts Remove the bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX® plus see scheme 110: Identifying Removal Sequence Of Bolts Remove the camshaft cap.
  13. Remove the camshaft.
  14. Remove the oil seal.
  15. Remove the plug from rear side of camshaft. CAUTION: Do not remove the oil seal unless necessary. Do not scratch the journal surface when removing the oil seal.

Scheme 195

Scheme 195: INSTALLATION
Scheme 195: INSTALLATION

Scheme 196

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Scheme 198

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Scheme 199

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Scheme 204

Scheme 204
Scheme 204
  1. Apply a thin coat of engine oil to camshaft journals, and install the camshaft.
  2. Install the camshaft cap. Apply liquid gasket to the mating surfaces of camshaft cap. Liquid gasket: Three bond 1280B (Part Number K0877YA018) see scheme 111: Identifying Camshaft Cap NOTE: Apply a coat of liquid gasket of 3 mm (0.12 in) in diameter (A) along the edge (B) of camshaft cap (C) mating surface. Install within 20 min. after applying liquid gasket. see scheme 112: Identifying Liquid Gasket Applying Area Temporarily tighten the bolts (a) through (d) in alphabetical sequence. see scheme 113: Identifying Tightening Sequence Of Bolts Install the valve rocker assembly. INSTALLATION, VALVE ROCKER ASSEMBLY. > Tighten the TORX® bolts (e) through (j) in alphabetical sequence using ST. ST 499497000 TORX® plus Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) see scheme 114: Identifying Tightening Sequence Of Bolts Tighten the bolts (k) through (r) in alphabetical sequence. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 115: Identifying Tightening Sequence Of Bolts Tighten the bolts (s) and (t) in alphabetical sequence. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 116: Identifying Tightening Sequence Of Bolts
  3. Apply a coat of grease to oil seal lips and install the oil seal (A) on camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499597000 OIL SEAL GUIDE ST2 499587500 OIL SEAL INSTALLER see scheme 117: Installing Oil Seal Using Oil Seal Guide ST1 499597000 And Oil Seal Installer ST2 499587500
  4. Install the plug (A) using ST. ST 499587700 CAMSHAFT OIL SEAL INSTALLER see scheme 118: Installing Plug Using Camshaft Oil Seal Installer ST499587700
  5. Adjust the valve clearance. ADJUSTMENT, VALVE CLEARANCE. >
  6. Install the rocker cover and rocker cover gasket, and then connect PCV hose. NOTE: Use a new rocker cover gasket. Tighten the bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First time 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Second time 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) RH side see scheme 119: Identifying Tightening Sequence Of Rocker Cover Bolts - RH Side LH side see scheme 120: Identifying Tightening Sequence Of Rocker Cover Bolts - LH Side
  7. Install the oil level gauge guide. (LH side only)
  8. Install the camshaft position sensor support. (LH side only)
  9. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb) see scheme 121: Identifying Tensioner Bracket
  10. Install the timing belt cover No. 2 (RH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
  11. Install the timing belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 122: Identifying Timing Belt Cover
  12. Install the cam sprocket. INSTALLATION, CAM SPROCKET. >
  13. Install the timing belt. INSTALLATION, TIMING BELT. >
  14. Install the timing belt cover. INSTALLATION, TIMING BELT COVER. >
  15. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
  16. Install the V-belts. INSTALLATION, V-BELT. >

Scheme 205

Scheme 205: CAMSHAFT
Scheme 205: CAMSHAFT

Scheme 206

Scheme 206
Scheme 206
  1. Measure the bend, and repair or replace if necessary. Service limit: 0.025 mm (0.00098 in) see scheme 123: Measuring Camshaft For Bend
  2. Check the journal for damage and wear. Replace if faulty.
  3. Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal, and confirm the difference (oil clearance) between the two values. If the oil clearance exceeds standard, replace the camshaft or cylinder head as necessary. OIL CLEARANCE AND CAMSHAFT JOURNAL OUTER DIAMETER SPECIFICATION Unit: mm (in) Oil clearance Standard 0.055 - 0.090 (0.0022 - 0.0035) Limit 0.10 (0.0039) Camshaft journal O.D. 31.928 - 31.945 (1.2570 - 1.2577) Journal hole I.D. 32.000 - 32.018 (1.2598 - 1.2605)
  4. Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the limit, replace it. Cam height H: CAM HEIGHT SPECIFICATION Part Unit: mm (in) Intake Constant Standard 40.075 - 40.175 (1.5778 - 1.5817) Limit 39.975 (1.5738) Low speed Standard 35.182 - 35.282 (1.3851 - 1.3891) Limit 35.082 (1.3812) High speed Standard 40.315 - 40.415 (1.5872 - 1.5911) Limit 40.215 (1.5833) Exhaust Standard 40.149 - 40.249 (1.5807 - 1.5846) Limit 40.049 (1.5767) Cam base circle diameter A: Intake 34.00 mm (1.3386 in) Exhaust 34.00 mm (1.3386 in) Base circle step of adjacent intake cams (low speed and high speed): 0.03 mm (0.001 in) or less see scheme 124: Identifying Cam Height And Cam Base Circle Diameter
  5. Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust clearance exceeds the limit, replace the camshaft caps and cylinder head as a set. If necessary, replace the camshaft. Standard: 0.030 - 0.090 mm (0.0012 - 0.0035 in) Service limit: 0.10 mm (0.0039 in)

Scheme 207

Scheme 207: REMOVAL
Scheme 207: REMOVAL
  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 cam sprocket. REMOVAL, CAM SPROCKET. >
  6. Remove the intake manifold. REMOVAL, Intake Manifold. >
  7. Remove the bolt which installs the A/C compressor bracket on cylinder head.
  8. Remove the valve rocker assembly. REMOVAL, VALVE ROCKER ASSEMBLY. >
  9. Remove the camshaft. REMOVAL, CAMSHAFT. >
  10. Remove the cylinder head bolts in alphabetical sequence as shown in the figure. NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling. see scheme 125: Identifying Removal Sequence Of Cylinder Head Bolts
  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. see scheme 126: Identifying Removal Sequence Of Cylinder Head Bolts
  13. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder block and cylinder head.
  14. Similarly, remove the right side cylinder head.

Scheme 208

Scheme 208: INSTALLATION
Scheme 208: INSTALLATION
  1. Install the cylinder head and gaskets on cylinder block. CAUTION: Use new cylinder head gaskets. Be careful not to scratch the mating surface of cylinder block and cylinder head.
  2. Tighten the cylinder head bolts. Apply a thin coat of engine oil to washer and bolt thread. 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 the bolts by 180° in reverse order of installation, and back them off again by 180°. Tighten all bolts to 42 N.m (3.9 kgf-m, 31 ft-lb) in alphabetical sequence. Tighten all bolts by 80 to 90° in alphabetical sequence. Tighten all bolts by 40 to 45° in alphabetical sequence. CAUTION: The tightening angle of the bolt should not exceed 45°. Further tighten the bolts (a) and (b) by 40 - 45°. CAUTION: Make sure the total "re-tightening angle" of the step (6) and (7) does not exceed 90°. see scheme 127: Identifying Tightening Sequence Of Cylinder Head Bolts
  3. Install the camshaft. INSTALLATION, CAMSHAFT. >
  4. Install the valve rocker assembly. INSTALLATION, VALVE ROCKER ASSEMBLY. >
  5. Install the A/C compressor bracket on cylinder head.
  6. Install the intake manifold. INSTALLATION, Intake Manifold. >
  7. Install the cam sprocket. INSTALLATION, CAM SPROCKET. >
  8. Install the timing belt. INSTALLATION, TIMING BELT. >
  9. Install the timing belt cover. INSTALLATION, TIMING BELT COVER. >
  10. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
  11. Install the V-belts. INSTALLATION, V-BELT. >

Scheme 209

Scheme 209: DISASSEMBLY
Scheme 209: DISASSEMBLY
  1. Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE
  2. Set the ST on valve spring. Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Keep all the removed parts in order for re-installing in their original positions. Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. see scheme 128: Identifying Valve Spring Remover ST 499718000

Scheme 210

Fig. 129: Identifying Cylinder Head Assembly Components
Scheme 129: Identifying Cylinder Head Assembly Components

Scheme 211

Scheme 211
Scheme 211
  1. Installation of valve spring and valve: Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE Coat the stem of each valve with engine oil and insert the valve into valve guide. CAUTION: Use extreme care not to damage the oil seal lips when inserting the valve into valve guide. Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its close-coiled end facing the seat on cylinder head. Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER (Scheme 189): Identifying Valve Spring Remover ST 499718000 Compress the valve spring and fit the valve spring retainer key. (Scheme 190): Identifying Valve Spring And Valve Spring Retainer Key After installing, tap the valve spring retainers lightly with a plastic hammer for better seating.

Scheme 212

Scheme 212: CYLINDER HEAD
Scheme 212: CYLINDER HEAD
  1. Make sure that no crack or other damage do not exists. In addition to visual inspection, inspect important areas using liquid penetrant tester. Also make sure the gasket installing surface shows no trace of gas and water leaks.
  2. Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE
  3. Measure the warping of the cylinder head surface that mates with crankcase using a straight edge and thickness gauge. If the warping exceeds the limit, regrind the surface with a surface grinder. Warping limit: 0.03 mm (0.0012 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.839 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly. (Scheme 191): Measuring Warping Of Cylinder Head Surface

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