Engine Mechanical (H4DOTC): Removal & Installation Subaru Forester SJ

REMOVAL

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , 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 516

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 air intake duct (rear). < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , 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.

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1. Remove the V-belts. < Ref. to «V-BELT»(ref-662117-S04908089152014101300000) , 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 519

1. Remove the V-belts. < Ref. to «V-BELT»(ref-662117-S04908089152014101300000) , 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 520

Scheme 521

1. Remove the V-belts. < Ref. to «V-BELT»(ref-662117-S04908089152014101300000) , REMOVAL, V-belt. >
2. Remove the radiator main fan & fan motor assembly and radiator sub fan & fan motor assembly. < Ref. to «REMOVAL»(ref-662123-S31829074472014101300000) , Radiator Main Fan and Fan Motor. > < Ref. to «REMOVAL»(ref-662123-S22947873392014101300000) , 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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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: 20 N.m (2.0 kgf-m, 14.8 ft-lb) Use the marker as shown in the figure, draw the reference line (A) on the crank pulley bolt according to the indented line on the crank pulley bolt head, and draw the end line (B) on the crank pulley. NOTE: Four lines are indented by 90° on the crank pulley bolt head. Reference line is drawn for better visibility. Use the ST to lock the crank pulley, and tighten the crank pulley bolt to the angle where reference line (A) and end line (B) are aligned. NOTE: It should be approx. 90° when reference line (A) and end line (B) are aligned. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET Tightening angle: 90°±5°
4. Install the radiator main fan & fan motor assembly and radiator sub fan & fan motor assembly. < Ref. to «INSTALLATION»(ref-662123-S10388759862014101300000) , Radiator Main Fan and Fan Motor. > < Ref. to «INSTALLATION»(ref-662123-S16701728782014101300000) , Radiator Sub Fan and Fan Motor. >
5. Install the V-belts. < Ref. to «V-BELT»(ref-662117-S03871641582014101300000) , INSTALLATION, V-belt. >

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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-662117-S23110950182014101300000) , 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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1. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. > 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. > Remove the radiator. < Ref. to «REMOVAL»(ref-662123-S29070511352014101300000) , Radiator. > Remove the front exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S11833000002014101300000) , Front Exhaust Pipe. >
2. Drain the engine oil. < Ref. to «REPLACEMENT»(ref-662113-S28412402012014101300000) , Engine Oil. >
3. Remove the V-belts. < Ref. to «V-BELT»(ref-662117-S04908089152014101300000) , REMOVAL, V-belt. >
4. Remove the generator. < Ref. to «REMOVAL»(ref-662144-S10599750962014101300000) , Generator. >
5. Remove the water pump pulley. < Ref. to «WATER PUMP»(ref-662123-S41040570792014101300000) , REMOVAL, Water Pump. >
6. Remove the crank pulley. < Ref. to «REMOVAL»(ref-662117-S23110950182014101300000) , Crank Pulley. >
7. Remove the engine oil cooler. < Ref. to «REMOVAL»(ref-662113-S39618861652014101300000) , Engine Oil Cooler. >
8. Remove the front engine oil cooler pipe assembly. < Ref. to «FRONT ENGINE OIL COOLER PIPE»(ref-662113-S28139580632014101300000) , REMOVAL, Engine Oil Cooler Pipe. >
9. When working on the engine unit only NOTE: When working on the engine unit only, also perform the following steps. Remove the PCV hose assembly together with the oil catch tank from the chain cover. NOTE: To disconnect 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 unlock the clamp. ST 18353AA000 CLAMP PLIERS
10. Remove the clip securing the PCV pipe to the intake manifold.
11. Remove the PCV pipe from the clip (A), and move the PCV pipe to the rocker cover RH side.
12. Disconnect the vacuum control hose (A) and vacuum hose (B) from the vacuum pipe assembly, and remove the vacuum pipe assembly from the chain cover.
13. Disconnect the connector (A) from the intake oil control solenoid RH, connector (B) from the exhaust oil control solenoid RH, connector (C) from the intake camshaft position sensor RH, and the connector (D) from the exhaust camshaft position sensor RH, and then remove the clips (E) and (F) securing the engine harness.
14. Disconnect the connector (A) from the exhaust camshaft position sensor LH and the connector (B) from the oil level switch, and remove the engine harness stay from the chain cover.
15. Remove the rubber cap from the oil pressure switch.
16. Disconnect the terminal (A) from the oil pressure switch, connector (B) from the engine oil temperature sensor, connector (C) from the intake oil control solenoid LH, connector (D) from the exhaust oil control solenoid LH, and the connector (E) from the intake camshaft position sensor LH, and then remove the clip (F) securing the engine harness.
17. Pull out the oil level gauge (A), and remove the oil level gauge guide (B), crank pulley boss (C), and idler pulley (D).
18. Remove the bolts securing the chain cover to engine.
19. Pry the points shown in the figure with a crowbar wrapped by protective tape, and then remove the chain cover from the engine.
20. Remove the O-rings from cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
21. Remove the liquid gasket from the chain cover and engine unit.
22. Remove the front oil seal from the chain cover.

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1. 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: Use a new front oil seal. 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
2. 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.
3. 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
4. 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)
5. 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)
6. Install the idler pulley (D), crank pulley boss (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)
7. Connect the terminal (A) to the oil pressure switch, connector (B) to the engine oil temperature sensor, connector (C) to the intake oil control solenoid LH, connector (D) to the exhaust oil control solenoid LH, and the connector (E) to the intake camshaft position sensor LH, and fix the engine harness using the 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)
8. Attach the rubber cap to the oil pressure switch.
9. Connect the connector (A) to the exhaust camshaft position sensor LH and the connector (B) to the oil level switch, and install the engine harness stay to the chain cover. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
10. Connect the connector (A) to the intake oil control solenoid RH, connector (B) to the exhaust oil control solenoid RH, connector (C) to the intake camshaft position sensor RH, and the connector (D) to the exhaust camshaft position sensor RH, and then fix the engine harness using the clips (E) and (F).
11. Install the vacuum pipe assembly to the chain cover, and connect the vacuum control hose (A) and vacuum hose (B) to the vacuum pipe assembly. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
12. Install the PCV pipe to the clip (A).
13. Fix the PCV pipe to the intake manifold using the clip.
14. When worked on the engine unit only NOTE: When work was done on the engine unit only, 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
15. Install the front engine oil cooler pipe assembly. < Ref. to «FRONT ENGINE OIL COOLER PIPE»(ref-662113-S41483713112014101300000) , INSTALLATION, Engine Oil Cooler Pipe. >
16. Attach the engine oil cooler. < Ref. to «INSTALLATION»(ref-662113-S18236659502014101300000) , Engine Oil Cooler. >
17. Install the crank pulley. < Ref. to «INSTALLATION»(ref-662117-S36912952022014101300000) , Crank Pulley. >
18. Install the water pump pulley. < Ref. to «WATER PUMP»(ref-662123-S35099640662014101300000) , INSTALLATION, Water Pump. >
19. Install the generator. < Ref. to «INSTALLATION»(ref-662144-S35090256522014101300000) , Generator. >
20. Install the V-belts. < Ref. to «V-BELT»(ref-662117-S03871641582014101300000) , INSTALLATION, V-belt. >
21. Fill engine oil. < Ref. to «REPLACEMENT»(ref-662113-S28412402012014101300000) , Engine Oil. >
22. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Install the front exhaust pipe. < Ref. to «INSTALLATION»(ref-662147-S39175225412014101300000) , Front Exhaust Pipe. > 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. > Install the radiator. < Ref. to «INSTALLATION»(ref-662123-S35079746222014101300000) , Radiator. >

Scheme 550

Scheme 551

1. When removal work was done on the vehicle NOTE: When removal work was done on the vehicle, also perform the following steps. Remove the PCV hose assembly together with the oil catch tank from the chain cover. NOTE: To disconnect 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 unlock the clamp. ST 18353AA000 CLAMP PLIERS
2. Remove the oil filler cap.
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-662119-S36438559562014101300000) , Engine Oil Temperature Sensor. >
5. Remove the oil control solenoid. < Ref. to «REMOVAL»(ref-662119-S35824647292014101300000) , Oil Control Solenoid. >
6. Remove the camshaft position sensor. < Ref. to «REMOVAL»(ref-662119-S28045415412014101300000) , Camshaft Position Sensor. >

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

Scheme 552

1. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
2. Remove the timing chain. < Ref. to «REMOVAL»(ref-662117-S05711388122014101300000) , 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-662117-S07267539252014101300000) , Timing Chain Assembly. >
3. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >