Engine Mechanical (H4SO): Adjustments Subaru Outback BP

ADJUSTMENT

Note. Adjustment of valve clearance should be performed while engine is c

Scheme 23

Scheme 24

Scheme 25

1. Set #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise. NOTE: When arrow mark (A) on camshaft sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke.
2. Adjust the #1 cylinder valve clearance. Loosen the valve rocker nut and screw. Place suitable thickness gauge. While noting valve clearance, tighten valve rocker adjust screw. When specified valve clearance is obtained, tighten valve rocker nut. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) NOTE: Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. Adjust exhaust valve clearances while lifting-up the vehicle. Valve clearance: Intake: 0.20+/-0.02 mm (0.0079+/-0.0008 in) Exhaust: 0.25+/-0.02 mm (0.0098+/-0.0008 in)
3. Ensure that valve clearances are within specifications.
4. Turn crankshaft two complete rotations unit #1 cylinder piston is again set to top dead center on compression stroke.
5. Ensure that valve clearances are within specifications. If necessary, readjust valve clearances.
6. Similar to adjustment procedures used for #1 cylinder, adjust #2, #3 and #4 cylinder valve clearances. NOTE: Be sure to set cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. To set #3, #2 and #4 cylinder pistons to their top dead centers on compression stroke, turn crankshaft pulley clockwise 90° at a time starting with arrow mark on left-hand camshaft sprocket facing up.

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Set the vehicle on lift arms.
2. Open front hood fully and support with stay.
3. Raise rear seat, and turn floor mat up.
4. Release fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-208357-S05384786392005120700000) , OPERATION, Fuel.
5. Remove filler cap.
6. Collect refrigerant, and remove pressure hoses. (With A/C) Refer to «REMOVAL»(ref-216290-S30449531042006011800000) , Flexible Hose.
7. Disconnect battery ground cable.
8. Remove air intake duct and air cleaner case. Refer to «REMOVAL»(ref-208359-S04615035932005120700000) , Air Intake Duct and «REMOVAL»(ref-208359-S22811893822005120700000) , Air Cleaner Case.
9. Remove under cover.
10. Remove radiator from vehicle. Refer to «REMOVAL»(ref-208362-S23728764862005120700000) , Radiator.
11. Remove ATF cooler pipe from body, Refer to «REMOVAL»(ref-208395-S15919917352005120700000) , ATF Cooler Pipe and Hose.
12. Remove air cleaner case stay. MT model AT model
13. Disconnect the following connectors and cables. Engine ground terminal Engine harness connectors Alternator connector, terminal and A/C compressor connector Accelerator cable and cruise control cable Pressure switch
14. Disconnect the following hoses. Brake booster vacuum hose Heater inlet/outlet hose
15. Remove power steering pump from bracket. Remove resonator chamber (Except U5). Loosen lock bolt and slider bolt, and remove front side V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT. Remove pipe with bracket. Remove bolts which install power steering pump bracket. Remove power steering tank from the bracket by pulling it upward. Place power steering pump on the right side wheel apron.
16. Remove front and center exhaust pipe. Refer to «REMOVAL»(ref-208361-S23577908762005120700000) , Front Exhaust Pipe and «REMOVAL»(ref-208361-S36449104472005120700000) , Center Exhaust Pipe.
17. Remove nuts which hold lower side of transmission to engine.
18. Remove nuts which install front cushion rubber onto front crossmember.
19. Separate torque converter clutch from drive plate. (AT model) Lower the vehicle. Remove service hole plug. Remove bolts which hold torque converter clutch to drive plate. Remove other bolts while rotating the crankshaft pulley using ST. ST 499977100 CRANK PULLEY WRENCH
20. Remove pitching stopper.
21. Disconnect fuel delivery hose, return hose and evaporation hose. CAUTION: Disconnect hose with its end wrapped with cloth to prevent fuel from splashing. Catch fuel from hose into container.
22. Support engine with a lifting device and wire ropes.
23. Support transmission with a garage jack. CAUTION: Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.
24. Separation of engine and transmission. Remove starter. Refer to «REMOVAL»(ref-167805-S27941158102004102100000) , Starter. Remove bolts which hold upper side of transmission to engine.
25. Install ST to torque converter clutch case. (AT model) ST 498277200 STOPPER SET
26. Remove engine from vehicle. Slightly raise engine. Raise transmission with garage jack. Move engine horizontally until main shaft is withdrawn from clutch cover. Slowly move engine away from engine room. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
27. Remove front cushion rubbers.

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. Install front cushion rubbers. Tightening torque: 35 N.m (3.6 kgf-m, 26.0 ft-lb)
2. Install engine onto transmission. Position engine in engine room and align it with transmission. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. Apply a small amount of grease to spline of main shaft. (MT model)
3. Tighten bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
4. Remove lifting device and wire ropes.
5. Remove garage jack.
6. Install pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
7. Remove ST from torque converter clutch case. (AT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST. ST 498277200 STOPPER SET
8. Install starter. Refer to «INSTALLATION»(ref-167805-S28872000082004102100000) , Starter.
9. Install torque converter clutch onto drive plate. (AT model) Tighten bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the crankshaft pulley by using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977100 CRANK PULLEY WRENCH Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) Clog plug onto service hole.
10. Install power steering pump on bracket. Install power steering tank on bracket. Install power steering pump on bracket, and tighten bolts. Tightening torque: 20.1 N.m (2.05 kgf-m, 14.8 ft-lb) Tighten bolt which installs power steering pump bracket, and install spark plug codes. Connect power steering switch connector. Front side V-belt Install and adjust it. Refer to «V-BELT»(ref-208360-S19262472212005120700000) . Install resonator chamber (Except U5). Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)
11. Tighten nuts which hold lower side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
12. Tighten nuts which install front cushion rubber onto crossmember. Tightening torque: 85 N.m (8.7 kgf-m, 63 ft-lb) CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
13. Install front and center exhaust pipe. Refer to «INSTALLATION»(ref-208361-S07815720742005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208361-S24437987872005120700000) , Center Exhaust Pipe.
14. Connect the following hoses. Fuel delivery hose, return hose and evaporation hose. Refer to «INSTALLATION»(ref-208357-S07150466082005120700000) , Fuel Delivery, Return and Evaporation Lines. Heater inlet and outlet hoses Brake booster vacuum hose
15. Connect the following connectors. Engine ground terminals Tightening torque: 14 N.m (1.4 kgf-m, 10.1 ft-lb) Engine harness connectors Alternator connector and terminal A/C compressor connectors Power steering pressure switch
16. Connect the following cables. Accelerator cable Cruise control cables (With cruise control)
17. After connecting each cable, adjust them.
18. Install air cleaner case stay. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb)
19. Install A/C pressure hoses. Refer to «INSTALLATION»(ref-216290-S22085764632006011800000) , Flexible Hose.
20. Install radiator to vehicle. Refer to «INSTALLATION»(ref-208362-S04081329412005120700000) , Radiator.
21. Install ATF cooler pipe to body. Refer to «INSTALLATION»(ref-208395-S40307278202005120700000) , ATF Cooler Pipe and Hose.
22. Install air intake duct and cleaner case. Refer to «INSTALLATION»(ref-208359-S30669962782005120700000) , Air Intake Duct and «INSTALLATION»(ref-208359-S26990629822005120700000) , Air Cleaner Case.
23. Install under cover.
24. Install battery in the vehicle, and connect cables.
25. Fill coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-208362-S19587309232005120700000) , REPLACEMENT, Engine Coolant.
26. Check ATF level and correct if necessary. (AT model) Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .
27. Charge A/C system with refrigerant. Refer to «OPERATION»(ref-216290-S42421627722006011800000) , Refrigerant Charging Procedure.
28. Remove front hood stay, and close front hood.
29. Take off the vehicle from lift arms.