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Engine Mechanical (H4DOTC): Overhaul Subaru Forester SJ

Mechanical 45 illustrations ~3623 words

WHEN TIMING CHAIN ASSEMBLY IS NOT REMOVED

CAUTIONWhen working on the vehicle, if engine oil is spilled onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

Note. Inspection of cam clearance should be performed while engine is cold. If the engine is removed from vehicle, performing the step 1) is not necessary.

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  1. Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover.
  2. Remove the V-belts. < Ref. to «REMOVAL»(ref-662117-S32960985752014101300000) , V-belt. >
  3. When inspecting #1 and #3 cylinders Remove the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662117-S21007045862014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the timing mark (A) on crank pulley is aligned to the 0° in timing gauge (B) on chain cover as shown in the figure, the #1 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #1 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #1 cylinder piston at TDC of compression stroke. Check the cam clearance for #1 cylinder intake, #1 cylinder exhaust and #3 cylinder exhaust. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in) Turn the crank pulley by 360°. Check the clearance of #3 cylinder intake. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in)
  4. When inspecting #2 and #4 cylinders Remove the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662117-S07706327262014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Set #2 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the timing mark (A) on crank pulley is aligned to the 0° in timing gauge (B) on chain cover as shown in the figure, the #2 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #2 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #2 cylinder piston at TDC of compression stroke. Check the cam clearance for #2 cylinder intake, #2 cylinder exhaust and #4 cylinder exhaust. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in) Turn the crank pulley by 360°. Check the clearance of #4 cylinder intake. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in)
  5. If necessary, adjust the cam clearance. < Ref. to «ADJUSTMENT»(ref-662117-S01095940792014101300000) , Cam Clearance. >
  6. After inspection, install the related parts in the reverse order of removal.

WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Note. Inspection of cam clearance should be performed while engine is cold.

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Scheme 560: WHEN TIMING CHAIN ASSEMBLY IS REMOVED
Scheme 560: WHEN TIMING CHAIN ASSEMBLY IS REMOVED

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  1. When inspecting #1 and #3 cylinders Remove the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662117-S21007045862014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Check the #1 and #3 cylinder cam clearance. CAUTION: Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand). NOTE: For cam clearance inspection, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the camshaft (cam sprocket) to be measured. Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
  2. When inspecting #2 and #4 cylinders Remove the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662117-S07706327262014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Check the #2 and #4 cylinder cam clearance. CAUTION: Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand). NOTE: Because the intake camshaft is pressurized by the high-pressure fuel pump, it is almost impossible to turn the intake camshaft lightly by hand. Since the zero-lift position is adjusted at the removal of the timing chain LH, measure the cam clearance at that position. For cam clearance inspection on exhaust side, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the exhaust camshaft (cam sprocket). Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
  3. If necessary, adjust the cam clearance. < Ref. to «ADJUSTMENT»(ref-662117-S01095940792014101300000) , Cam Clearance. >
  4. After inspection, install the related parts in the reverse order of removal.

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Scheme 562: ADJUSTMENT
Scheme 562: ADJUSTMENT
  1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , Engine Assembly. >
  2. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
  3. When adjusting #1 and #3 cylinders Remove the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S23766873962014101300000) , REMOVAL, Timing Chain Assembly. > Remove the cam carrier RH. < Ref. to «CAM CARRIER RH»(ref-662117-S08845425352014101300000) , REMOVAL, Cam Carrier. > Measure the thickness of valve shim using micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness. NOTE: Use a new valve shim. Intake side: S = T + 1.54 x (V - 0.13 mm (0.0051 in)) Exhaust side: S = T + 1.69 x (V - 0.22 mm (0.0087 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Install the cam carrier RH. < Ref. to «CAM CARRIER RH»(ref-662117-S18154004902014101300000) , INSTALLATION, Cam Carrier. > Check all the cam clearance of RH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step 2 ). NOTE: When the removing/installing of cam carrier RH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of RH side is necessary. Refer to INSPECTION of " «CAM CLEARANCE»(ref-662117-S37692034152014101300000) " for the cam clearance inspection. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662117-S31430679392014101300000) , INSPECTION, Cam Clearance. > Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
  4. When adjusting #2 and #4 cylinders Remove the timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S18193102732014101300000) , REMOVAL, Timing Chain Assembly. > Remove the intake manifold. < Ref. to «REMOVAL»(ref-662119-S34762705842014101300000) , Intake Manifold. > Remove the cam carrier LH. < Ref. to «CAM CARRIER LH»(ref-662117-S14538972082014101300000) , REMOVAL, Cam Carrier. > Measure the thickness of valve shim using micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness. NOTE: Use a new valve shim. Intake side: S = T + 1.54 x (V - 0.13 mm (0.0051 in)) Exhaust side: S = T + 1.69 x (V - 0.22 mm (0.0087 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Install the cam carrier LH. < Ref. to «CAM CARRIER LH»(ref-662117-S39311653762014101300000) , INSTALLATION, Cam Carrier. > Check all the cam clearance of LH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step 3 ). NOTE: When the removing/installing of cam carrier LH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of LH side is necessary. Refer to INSPECTION of " «CAM CLEARANCE»(ref-662117-S37692034152014101300000) " for the cam clearance inspection. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662117-S31430679392014101300000) , INSPECTION, Cam Clearance. > Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
  5. After adjustment, install the related parts in the reverse order of removal.

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Scheme 563: REMOVAL
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  1. Open the front hood, and remove the upper grille bracket from the front hood.
  2. Using a marker pen, make alignment marks (A) on both the front hood and the front hood striker.
  3. Remove the front hood striker from the front hood.
  4. Remove the front center grille assembly from the front hood.
  5. Change the front hood damper mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
  6. Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover.
  7. Collect the refrigerant from A/C system. < Ref. to «REFRIGERANT RECOVERY PROCEDURE»(ref-662134-S41814187102014101300000) . >
  8. Release the fuel pressure. < Ref. to «RELEASING OF FUEL PRESSURE»(ref-662119-S23335610212014101300000) , PROCEDURE, Fuel. >
  9. Disconnect the ground cable from battery.
  10. Remove the air intake duct. < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , Air Intake Duct. >
  11. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. >
  12. Remove the intake duct No. 1 and intake duct No. 2. < Ref. to «INTAKE DUCT NO. 1»(ref-662121-S27614790662014101300000) , REMOVAL, Intake Duct. > < Ref. to «INTAKE DUCT NO. 2»(ref-662121-S10441269482014101300000) , REMOVAL, Intake Duct. >
  13. Remove the radiator. < Ref. to «REMOVAL»(ref-662123-S29070511352014101300000) , Radiator. >
  14. Disconnect sections (A) and (B) of the brake booster vacuum hose from the brake vacuum pump and intake manifold, and remove the brake booster vacuum hose from the clip (C).
  15. Remove the clip (D) securing the brake booster vacuum hose to the intake manifold, and move the brake booster vacuum hose at the locations that do not interfere operation.
  16. Disconnect the bulkhead harness connectors from the engine harness connectors.
  17. Disconnect the connector (A) from the brake vacuum pump.
  18. Disconnect connector (B) and terminal (C) from the generator, and remove the clip (D) securing the generator cord to the intake manifold.
  19. Disconnect connector (A) from A/C compressor, and remove the generator cord from clip (B).
  20. Remove the clip (C) securing the generator cord to the fuel pipe protector, and move the generator cord to the left side wheel apron.
  21. Disconnect the A/C pressure hoses from A/C compressor. < Ref. to «REMOVAL»(ref-662134-S35863784852014101300000) , Hose and Pipe. >
  22. Disconnect the heater inlet hose (A) from the water pipe assembly, and disconnect the heater outlet hose (B) from the water pipe LH.
  23. Disconnect the engine coolant inlet hose and engine coolant outlet hose from the CVTF cooler (with warmer feature) and EGR cooler.
  24. Remove the front exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S11833000002014101300000) , Front Exhaust Pipe. >
  25. Lift up the vehicle.
  26. Disconnect the ground cable from the oil pipe assembly.
  27. Remove the lower bolt securing the CVTF cooler (with warmer feature) to the CVT.
  28. Remove the bolts and nuts which hold the lower side of transmission to the engine.
  29. Remove the nuts which secure the engine mounting to the front crossmember.
  30. Lower the vehicle.
  31. Remove the pitching stopper.
  32. Separate the torque converter clutch from the drive plate. Remove the starter. < Ref. to «REMOVAL»(ref-662144-S29498763952014101300000) , Starter. > Remove the service hole plug. Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate. Attach the ST to the torque converter clutch case. ST 498277200 STOPPER SET
  33. Remove the clip (A) securing the bulkhead harness to the CVTF cooler (with warmer feature).
  34. Remove the upper bolt securing the CVTF cooler (with warmer feature) to the CVT, and move the CVTF cooler (with warmer feature) at the locations that do not interfere operation.
  35. Remove the bolt securing the transmission harness stay to the CVT. NOTE: This procedure is required to prevent the transmission connector from touching the A/C pressure hose during engine removal/installation.
  36. Disconnect the fuel delivery tube and evaporation hose. CAUTION: Be careful not to spill fuel. Catch the fuel from the tubes using a container or cloth. Disconnect the quick connector on the fuel delivery tube from the fuel pipe assembly, and remove the clip (A) securing the fuel delivery tube. NOTE: Disconnect the quick connector as shown in the figure. Disconnect the evaporation hose from the fuel pipe assembly.
  37. Separate the engine and transmission. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Support the engine with a lifting device and wire ropes. Support the transmission with a garage jack. CAUTION: Be sure to perform this procedure to prevent the transmission from lowering by its own weight. Remove the bolts which hold the upper side of the transmission to the engine.
  38. Remove the engine from the vehicle. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. Move the engine horizontally until engine is withdrawn from transmission. Slowly move the engine away from engine compartment.
  39. Remove the engine mounting from the engine.

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  1. Install the engine mounting onto the engine. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
  2. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  3. Install the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  4. Remove the lifting device and wire ropes.
  5. Remove the garage jack.
  6. Install the bolt which secures the transmission harness stay to the CVT. Tightening torque: 15 N.m (1.6 kgf-m, 11.8 ft-lb)
  7. Install the CVTF cooler (with warmer feature) to the CVT. Temporarily tighten the upper bolt which secures the CVTF cooler (with warmer feature) to the CVT. Using clip (A), fix the bulkhead harness to the CVTF cooler (with warmer feature). Lift up the vehicle. Install the lower bolt which secures CVTF cooler (with warmer feature) to the CVT. Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb) Lower the vehicle. Tighten the upper bolt which secures the CVTF cooler (with warmer feature) to the CVT. Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
  8. Install the torque converter clutch to drive plate. Remove the ST from torque converter clutch case. NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Fit the plug to service hole. Install the starter. < Ref. to «INSTALLATION»(ref-662144-S10832284602014101300000) , Starter. >
  9. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
  10. Lift up the vehicle.
  11. Install the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  12. Install the nuts which hold the engine mounting to the crossmember. NOTE: Make sure that locators (A) of the engine mounting are securely inserted. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
  13. Connect the ground cable to the oil pipe assembly. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  14. Install the front exhaust pipe. < Ref. to «INSTALLATION»(ref-662147-S39175225412014101300000) , Front Exhaust Pipe. >
  15. Connect the fuel delivery tube and evaporation hose. Connect the evaporation hose to fuel pipe assembly. Connect the quick connector on the fuel delivery tube to the fuel pipe assembly, and fix the fuel delivery tube using clip (A). CAUTION: Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe. When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider. When it is difficult to lock the slider, check that the pipe is fully inserted. Make sure that the quick connector is securely connected. NOTE: Connect the quick connector as shown in the figure.
  16. Connect the engine coolant inlet hose and engine coolant outlet hose to the CVTF cooler (with warmer feature) and EGR cooler.
  17. Connect the heater inlet hose (A) to the water pipe assembly, and connect the heater outlet hose (B) to the water pipe LH. NOTE: Be careful not to mix up the heater inlet hose and the heater outlet hose when connecting them.
  18. Connect the A/C pressure hose to A/C compressor. < Ref. to «INSTALLATION»(ref-662134-S07956159822014101300000) , Hose and Pipe. >
  19. Set the generator cord, and fix the generator cord to the fuel pipe protector using clip (C).
  20. Install the generator cord to clip (B), and connect the connector (A) to A/C compressor.
  21. Using clip (D), fix the generator cord to the generator cord stay, and connect the connector (B) and the terminal (C) to the generator. Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb)
  22. Connect the connector (A) to the brake vacuum pump.
  23. Connect the bulkhead harness connector to the engine harness connector.
  24. Using clip (D), fix the brake booster vacuum hose to the intake manifold.
  25. Connect sections (A) and (B) of the brake booster vacuum hose to the brake vacuum pump and intake manifold, and install the brake booster vacuum hose to the clip (C).
  26. Install the radiator. < Ref. to «INSTALLATION»(ref-662123-S35079746222014101300000) , Radiator. >
  27. Install the intake duct No. 1 and intake duct No. 2. < Ref. to «INTAKE DUCT NO. 1»(ref-662121-S33249425962014101300000) , INSTALLATION, Intake Duct. > < Ref. to «INTAKE DUCT NO. 2»(ref-662121-S20049375172014101300000) , INSTALLATION, Intake Duct. >
  28. Install the intercooler. < Ref. to «INSTALLATION»(ref-662121-S02050373282014101300000) , Intercooler. >
  29. Install the air intake duct. < Ref. to «INSTALLATION»(ref-662121-S35607443062014101300000) , Air Intake Duct. >
  30. Connect the battery ground terminal.
  31. Fill engine coolant. < Ref. to «FILLING OF ENGINE COOLANT»(ref-662123-S39370784392014101300000) , REPLACEMENT, Engine Coolant. >
  32. Check the CVTF level and replenish it if necessary. < Ref. to «ADJUSTMENT»(ref-662126-S25388033382014101300000) , CVTF. >
  33. Charge the A/C system with refrigerant. < Ref. to «PROCEDURE»(ref-662134-S39973495562014101300000) , Refrigerant Charging Procedure. >
  34. Install the collector cover.
  35. Change the installation position of the front hood damper from (B) to (A). Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
  36. Install the front center grille assembly to the front hood. Tightening torque: 4.5 N.m (0.5 kgf-m, 3.3 ft-lb)
  37. Align the alignment marks (A), and install the front hood striker to the front hood. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)
  38. Install the upper grille bracket to the front hood, and close the front hood. Tightening torque: 4.5 N.m (0.5 kgf-m, 3.3 ft-lb)

ASSEMBLY

  1. Install the camshaft position sensor. < Ref. to «INSTALLATION»(ref-662119-S39092150022014101300000) , Camshaft Position Sensor. >
  2. Install the oil control solenoid. < Ref. to «INSTALLATION»(ref-662119-S27743563592014101300000) , Oil Control Solenoid. >
  3. Install the engine oil temperature sensor. < Ref. to «INSTALLATION»(ref-662119-S05843037742014101300000) , Engine Oil Temperature Sensor. >
  4. Install the oil pressure switch. < Ref. to «INSTALLATION»(ref-662113-S36092070782014101300000) , Oil Pressure Switch. >
  5. Install the oil filler cap.
  6. When installation work is done on the vehicle NOTE: When installation work is done on the vehicle, also perform the following steps. Install the PCV hose assembly together with the oil catch tank to the chain cover. NOTE: Use a new clamp. To connect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the clamp as shown in the figure, squeeze the ST's handles together and lock the clamp. ST 18353AA000 CLAMP PLIERS

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