Engine Mechanical (H4SO): 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)

Note. Perform the following procedures with the engine installed to body.

Scheme 144

1. Remove the V-belt covers. see scheme 54: Identifying V-Belt Cover
2. Loosen the lock bolt (A).
3. Loosen the slider bolt (B).
4. Remove the front side belt (C).

Scheme 145

Scheme 146

Scheme 147

1. Loosen the lock nut (A).
2. Loosen the slider bolt (B). see scheme 56: Identifying Slider Bolt And Lock Bolt
3. Remove the rear side belt.
4. Remove the belt tensioner. see scheme 57: Identifying Belt Tensioner

Note. Wipe off any oil or water on the belt and pulley.

1. Install the crank pulley.
2. Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH Clean the crank shaft 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 (18.4 kgf-m, 132.8 ft-lb) see scheme 63: Tightening Crank Pulley Bolt Using Crank Pulley Wrench ST499977100
3. Check that the tightening angle of the clamp pulley bolt is a minimum of 65°. Perform the following procedures when less than 65°. Replace the crank pulley bolts and clean them. Crank pulley bolt: 12369AA011 Clean the crank shaft 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 bolt keeping them in an angle between 65° and 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 64: Identifying Belt Tensioner
5. Install the V-belts. INSTALLATION, V-BELT. >

1. Install the cam sprocket No. 1. To lock the camshaft, use the ST. ST 499207400 CAM SPROCKET WRENCH Tightening torque: 78 N.m (8.0 kgf-m, 57.9 ft-lb) NOTE: Do not confuse left and right side cam sprockets during installation. Identify by L or R markings. see scheme 90: Installing Cam Sprocket No 1 Using Cam Sprocket Wrench ST499207400
2. Install the cam sprocket No. 2. To lock the camshaft, use the ST. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. Tightening torque: 78 N.m (8.0 kgf-m, 57.9 ft-lb) see scheme 91: Installing Cam Sprocket No 2 Using Cam Sprocket Wrench ST18231AA010
3. Install the camshaft position sensor. INSTALLATION, Camshaft Position Sensor. >
4. Install the timing belt. INSTALLATION, TIMING BELT. >
5. Install the timing belt cover. INSTALLATION, TIMING BELT COVER. >
6. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
7. Install the V-belts. INSTALLATION, V-BELT. >

1. Install the crank sprocket. see scheme 93: Identifying Crank Sprocket
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.

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Scheme 160

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 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 (d) engaged by three or four threads to prevent the cylinder head from falling. see scheme 145: 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 (d) to remove cylinder head. see scheme 146: Identifying Removal Sequence Of Cylinder Head Bolts
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 model)
16. Remove the flywheel (MT model) or drive plate (AT model). Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER MT model see scheme 147: Locking Crankshaft Using Crankshaft Stopper ST498497100 - MT Model AT model see scheme 148: Locking Crankshaft Using Crankshaft Stopper ST498497100 - AT Model
17. Remove the oil separator cover.
18. Remove the water by-pass pipe for heater.
19. Remove the water pump after loosening the bolts in alphabetical sequence as shown in the figure. see scheme 149: Identifying Loosening Sequence Of Water Pump Bolts
20. Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump. see scheme 150: Locating Oil Pump Bolts
21. Remove the oil pump from cylinder block using flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump. see scheme 151: Locating Oil Pump
22. Remove the oil pan. Place the cylinder block to face the #2 and #4 piston side 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. NOTE: Do not use a screwdriver or similar tools in place of oil pan cutter.
23. Remove the oil strainer stay.
24. Remove the oil strainer.
25. Remove the baffle plate.
26. Remove the oil filter. REMOVAL, Engine Oil Filter. >
27. Remove the water pipe. see scheme 152: Identifying Water Pipe see scheme 153: Identifying Service Hole Plug, Snap Ring, Piston Pin And Service Hole Cover
28. Remove the service hole cover and service hole plugs using a hexagon wrench [14 mm]. see scheme 154: Locating Service Hole Plug
29. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders. see scheme 155: Locating Piston Snap Ring
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. see scheme 156: Removing Piston Pin Using Piston Pin Remover ST 499097700
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, then remove the cylinder block connecting bolts.
35. Separate the cylinder block (RH) and (LH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block. see scheme 157: Identifying Rear Oil Seal, Crankshaft, Crankshaft Bearing And Piston
36. Remove the rear oil seal.
37. Remove the crankshaft together with connecting rod.
38. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip.
39. Draw out each piston from cylinder block using wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.

Identifying Rear Oil Seal, Crankshaft, Crankshaft Bearing And O-Ring. Scheme 161

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

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Scheme 185

1. 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 Number004403007) or equivalent NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. see scheme 159: Identifying Liquid Gasket Applying Area Of Cylinder Block
3. Apply a coat of engine oil to the washer and bolt thread.
4. Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 160: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
5. Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 161: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
6. Further tighten the LH side bolts (A - D) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13 ft-lb) see scheme 162: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
7. Further tighten the RH side bolts (E - J) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13 ft-lb) see scheme 163: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
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 164: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
9. Tighten the RH side bolts (E - J) 90° further in alphabetical sequence. see scheme 165: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
10. Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence. 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 166: Identifying Tightening Sequence Of Cylinder Block Connecting Bolts
11. Install the rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER see scheme 167: Installing Rear Oil Seal Using 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. NOTE: Assemble so that the piston ring mark "R" faces the upper side of the piston.
13. Position the second ring gap at 180° on the reverse side the top ring gap. NOTE: Assemble so that the piston ring mark "R" faces the upper side of the piston. see scheme 168: Identifying Second Ring Gap
14. Position the upper rail gap at (C) in the figure. see scheme 169: Identifying Upper Rail Gap
15. Align the upper rail spin stopper (E) to the side hole (D) on the piston. (Scheme 148): Identifying Upper Rail Spin Stopper
16. Position the expander gap at (F) in the figure. (Scheme 149): Identifying Expander Gap
17. Position the lower rail gap at (G) in the figure. (Scheme 150): Identifying Lower Rail Gap 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 when positioning all pistons in corresponding cylinders. NOTE: Use new snap rings. (Scheme 151): Identifying Piston Position CAUTION: Piston front mark faces towards the front of engine. (Scheme 152): Identifying Front Mark On Piston (Scheme 153): Identifying Piston, Piston Pin, Piston Ring And Service Hole Plug
19. Install the 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 154): Inserting Pistons In Cylinder Using Piston Guide ST2 498747300
20. Install the piston pin. Apply a coat of engine oil to ST3. Insert ST3 into the service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE (Scheme 155): Inserting ST3 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. Install the snap ring. NOTE: Use new snap rings. (Scheme 156): Installing Snap Ring Apply liquid gasket around the service hole plug. Liquid gasket: Three bond 1215 (Part Number004403007) or equivalent (Scheme 157): Applying Liquid Gasket Around Service Hole Plug Install the service hole plug and gasket. NOTE: Use a new gasket. (Scheme 158): Installing Service Hole Plug (Scheme 159): Identifying Piston, Piston Pin, Piston Ring And Service Hole Plug 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. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 160): Identifying 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, 7.2 ft-lb)
24. Install the oil strainer stay.
25. Apply liquid gasket to the mating surfaces, and install the oil pan. Liquid gasket: Three bond 1207C (Part No.004403012) or equivalent see scheme 183: Identifying Liquid Gasket Applying Area 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. Liquid gasket: Mating surface Three bond 1207C (Part No.004403012) or equivalent (A) bolt threads Three bond 1324 (Part Number004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 162): Identifying Liquid Gasket Applying Area Of Bolt
27. Install the flywheel. (MT model) INSTALLATION, Flywheel. > To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb) (Scheme 163): Locking Crankshaft Using Crankshaft Stopper ST498497100 - MT Model
28. Install the drive plate. To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb) (Scheme 164): Locking Crankshaft Using Crankshaft Stopper ST498497100 - AT Model
29. Install the housing cover.
30. Installation of oil pump: Discard the front oil seal after removal. Replace with a new one using ST. ST 499587100 OIL SEAL INSTALLER see scheme 187: Installing Oil Seal Using Oil Seal Installer ST499587100 Apply liquid gasket to the matching surface of oil pump. Liquid gasket: Three bond 1215 (Part Number004403007) or equivalent see scheme 188: Identifying Liquid Gasket Applying Area Of Oil Pump Apply a coat of engine oil to the inside of oil seal. see scheme 189: Identifying Liquid Gasket Applying Area Of Oil Seal Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation. CAUTION: Make sure the oil seal lip is not folded. Do not forget to install the O-ring and seal when installing oil pump. Apply liquid gasket to the three bolts thread shown in figure. Liquid gasket: Three bond 1324 (Part Number004403042) or equivalent Tightening torque: T: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) see scheme 190: Identifying Liquid Gasket Applying Area Of Bolts
31. 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 165): Identifying Tightening Sequence Of Water Pump Bolts
32. Install the water by-pass pipe for heater.
33. Install the oil filter. INSTALLATION, Engine Oil Filter. >
34. Tighten the cylinder head bolts. INSTALLATION, CYLINDER HEAD. >
35. Install the oil level gauge guide and tighten the bolts. (LH side only)
36. Install the rocker cover and rocker cover gasket. NOTE: Use a new rocker cover gasket.
37. Install the crank sprocket. INSTALLATION, CRANK SPROCKET. >
38. Install the cam sprocket. INSTALLATION, CAM SPROCKET. >
39. Install the timing belt. INSTALLATION, TIMING BELT. >
40. Install the timing belt cover.
41. INSTALLATION, TIMING BELT COVER. >
42. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
43. Install the generator and A/C compressor brackets on cylinder head.
44. Install the V-belts. INSTALLATION, V-BELT. >
45. Install the intake manifold. INSTALLATION, Intake Manifold. >

Identifying Oil Switching Solenoid Valve Holder And Oil Switching Solenoid Valve. Scheme 186

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 proper order, to prevent confusion.
5. Remove the snap ring.

Scheme 187

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 marking side facing forward, and install it.
4. Install the connecting rod cap with connecting rod nut. Make sure the arrow on connecting rod cap faces toward 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. Install the second ring and top ring along with the piston ring expander.