Engine Mechanical (H4DO): Removal & Installation Subaru Forester SJ

REMOVAL

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662116-S04219794502014101300000) , Engine Assembly. >
2. Remove the engine mounting from the engine.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

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

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 89

1. Remove the V-belt covers.
2. Remove the air intake duct (rear). < Ref. to «REMOVAL»(ref-662120-S42382818082014101300000) , Air Intake Duct. >
3. Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to loosen and remove the V-belt.

Scheme 90

Scheme 91

1. Remove the V-belts. < Ref. to «V-BELT»(ref-662116-S26119621172014101300000) , REMOVAL, V-belt. >
2. Remove the cap from V-belt tensioner assembly.
3. Remove the bolt securing the V-belt tensioner assembly to the generator bracket, and remove the V-belt tensioner assembly.

Scheme 92

1. Remove the V-belts. < Ref. to «V-BELT»(ref-662116-S26119621172014101300000) , REMOVAL, V-belt. >
2. Remove the bolts which secure the idler pulley to the chain cover, and remove the idler pulley.

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 93

Scheme 94

1. Remove the V-belts. < Ref. to «REMOVAL»(ref-662116-S07347334572014101300000) , V-belt. >
2. Remove the radiator main fan & fan motor assembly and radiator sub fan & fan motor assembly. < Ref. to «REMOVAL»(ref-662122-S25494677872014101300000) , Radiator Main Fan and Fan Motor. > < Ref. to «REMOVAL»(ref-662122-S01461362072014101300000) , Radiator Sub Fan and Fan Motor. >
3. Use the ST to lock the crank pulley, and remove the crank pulley bolt. NOTE: To prevent damaging ST1, attach the ST2 onto the ST1 as shown. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET
4. Remove the crank pulley.

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Scheme 100

1. Clean the crankshaft thread using compressed air.
2. Apply engine oil to the crank pulley bolt seat and thread.
3. Install the crank pulley. Install the crank pulley to the crank pulley boss. NOTE: Use new O-rings. Install the crank pulley by aligning the crank pulley knock hole (A) and crank pulley boss knock pin (B). Use the ST to lock the crank pulley, and temporarily tighten the crank pulley bolt. NOTE: To prevent damaging ST1, attach the ST2 onto the ST1 as shown. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb) Draw reference lines (A) and (B) using a marker to set the socket to the crank pulley bolt as shown in the figure. Draw reference lines (A) and (B) on the crank pulley bolt using a marker as shown in the figure. Draw end line (C) on crank pulley using a marker at the same position as reference line (B) drawn on the crank pulley bolt in step ( 4 ). Use the ST to lock the crank pulley, and tighten the crank pulley bolt to the angle where reference line (A) and end line (C) are aligned. NOTE: It should be approx. 60° when reference line (A) and end line (C) are aligned. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET Tightening angle: 60°±5°
4. Install the radiator main fan & fan motor assembly and radiator sub fan & fan motor assembly. < Ref. to «INSTALLATION»(ref-662122-S05023192002014101300000) , Radiator Main Fan and Fan Motor. > < Ref. to «INSTALLATION»(ref-662122-S15714431392014101300000) , Radiator Sub Fan and Fan Motor. >
5. Install the V-belts. < Ref. to «INSTALLATION»(ref-662116-S24922850782014101300000) , V-belt. >

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Scheme 103

1. Check that the crank pulley and crank pulley boss have no deformation, cracks or other damages.
2. Inspect for oil leakage from the front oil seal. If there is an oil leak, replace the front oil seal with a new part according to the following procedures. Remove the crank pulley. < Ref. to «REMOVAL»(ref-662116-S25634263832014101300000) , Crank Pulley. > Remove the crank pulley boss from the chain cover. Remove the front oil seal from the chain cover. Apply a light coat of engine oil to the front oil seal inner periphery and outer periphery, and install the front oil seal to the chain cover using ST. NOTE: When tapping the front oil seal in, protect the radiator fin with cardboards etc. so as not to damage the radiator fin by the plastic hammer. ST 398437700 OIL SEAL INSTALLER Front oil seal press-fit position: 1+0 -1 mm (0.0039+0 -0.0039 in) position from chain cover end face
3. Install in the reverse order of removal after replacement.

Note. When replacing a single part, perform the work with the engine assembly installed to body.

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Scheme 112

1. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Remove the radiator. < Ref. to «REMOVAL»(ref-662122-S05365879092014101300000) , Radiator. > Remove the front exhaust pipe. < Ref. to «REMOVAL»(ref-662139-S23483353282014101300000) , Front Exhaust Pipe. > Remove the bolts which secure the generator cord stay to the chain cover.
2. Remove the generator. < Ref. to «REMOVAL»(ref-662144-S10599750962014101300000) , Generator. >
3. Drain the engine oil. < Ref. to «REPLACEMENT»(ref-662113-S28412402012014101300000) , Engine Oil. >
4. Remove the water pump pulley. < Ref. to «WATER PUMP»(ref-662122-S14294039212014101300000) , REMOVAL, Water Pump. >
5. Remove the crank pulley. < Ref. to «REMOVAL»(ref-662116-S25634263832014101300000) , Crank Pulley. >
6. Remove the engine harness stay from the chain cover.
7. Disconnect the connector (A) from the oil control solenoid RH, and the connector (B) from the camshaft position sensor RH, and remove the clip (C) and clip (D) which secure the engine harness.
8. Disconnect the connectors from the oil level switch, and remove the clip (A) which secure the oil level switch harness.
9. Remove the rubber cap from the oil pressure switch.
10. Disconnect the terminal (A) from the oil pressure switch, and connector (B) from the engine oil temperature sensor, and connector (C) from the oil control solenoid LH, and connector (D) from the camshaft position sensor LH, and remove the clip (E) and clip (F) which secure the engine harness.
11. Pull out the oil level gauge (A), and remove the oil level gauge guide (B) and idler pulley (C).
12. Remove the bolts securing the chain cover to engine.
13. Expand the area shown in the figure using a crowbar or a similar tool wrapped in tape for protection, and remove the chain cover from the engine.
14. Remove the O-rings from cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
15. Remove the liquid gasket from the chain cover and engine unit.

Scheme 113

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Scheme 117

1. Install the O-rings to cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper. NOTE: Use new O-rings. Apply a coat of engine oil to the O-rings.
2. Apply liquid gasket if there are gaps between front camshaft cap and cam carrier (A), cam carrier and cylinder head (B), and cylinder head and cylinder block (C) as shown in the figure. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
3. Apply liquid gasket to the chain cover mating surface and center boss (5 places) as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine and chain cover. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 4±0.5 mm (0.1575±0.0197 in)
4. Set the chain cover, and tighten the bolts in numerical order as shown in the figure. Tightening torque: T1: 10 N.m (1.0 kgf-m, 7.4 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
5. Install the idler pulley (C) and oil level gauge guide (B), and insert the oil level gauge (A). NOTE: Use a new O-ring to the oil level gauge guide. Apply a light coat of engine oil to the O-rings of the oil level gauge guide and the oil level gauge. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
6. Connect the terminal (A) to the oil pressure switch, and connector (B) to the engine oil temperature sensor, and connector (C) to the oil control solenoid LH, and connector (D) to the camshaft position sensor LH, and secure the engine harness with clip (E) and clip (F). NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°. Tightening torque: 1.5 N.m (0.2 kgf-m, 1.1 ft-lb)
7. Attach the rubber cap to the oil pressure switch.
8. Secure the oil level switch harness with clips (A), and connect the connectors to the oil level switch.
9. Connect the connector (A) to the oil control solenoid RH, and the connector (B) to the camshaft position sensor RH, and secure the engine harness with clip (C) and clip (D).
10. Install the engine harness stay to the chain cover. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
11. Install the crank pulley. < Ref. to «INSTALLATION»(ref-662116-S23810439092014101300000) , Crank Pulley. >
12. Install the water pump pulley. < Ref. to «WATER PUMP»(ref-662122-S07348095152014101300000) , INSTALLATION, Water Pump. >
13. Fill engine oil. < Ref. to «REPLACEMENT»(ref-662113-S28412402012014101300000) , Engine Oil. >
14. Install the generator. < Ref. to «INSTALLATION»(ref-662144-S35090256522014101300000) , Generator. >
15. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Install the radiator. < Ref. to «INSTALLATION»(ref-662122-S21112920992014101300000) , Radiator. > Install the front exhaust pipe. < Ref. to «INSTALLATION»(ref-662139-S42712300302014101300000) , Front Exhaust Pipe. > Install the generator cord stay to the chain cover. NOTE: Install the generator cord stay so that the folded end (A) touches at the chain cover boss. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Scheme 118

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Scheme 120

1. Remove the oil filler cap.
2. Remove the engine oil filter and the oil pump union. < Ref. to «REMOVAL»(ref-662113-S38018409412014101300000) , Engine Oil Filter. >
3. Remove the oil pressure switch. < Ref. to «REMOVAL»(ref-662113-S34653955542014101300000) , Oil Pressure Switch. >
4. Remove the engine oil temperature sensor. < Ref. to «REMOVAL»(ref-662118-S09677875222014101300000) , Engine Oil Temperature Sensor. >
5. Remove the oil control solenoid. < Ref. to «REMOVAL»(ref-662118-S21573395922014101300000) , Oil Control Solenoid. >
6. Remove the camshaft position sensor. < Ref. to «REMOVAL»(ref-662118-S26160077182014101300000) , Camshaft Position Sensor. >
7. Remove the actuator cover from chain cover.
8. Remove the sensor cover from chain cover.

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 121

1. Remove the chain cover. < Ref. to «REMOVAL»(ref-662116-S23929380932014101300000) , Chain Cover. >
2. Remove the timing chain. < Ref. to «REMOVAL»(ref-662116-S30370856772014101300000) , Timing Chain Assembly. >
3. Remove the crank sprocket.

1. Install the crank sprocket. NOTE: The direction of installation is not specified for the crank sprocket.
2. Install the timing chain. < Ref. to «INSTALLATION»(ref-662116-S36358219502014101300000) , Timing Chain Assembly. >
3. Install the chain cover. < Ref. to «INSTALLATION»(ref-662116-S06464170222014101300000) , Chain Cover. >