Engine Mechanical (H4SO): Diagnosis Subaru Outback BP

INSPECTION

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1. After warming-up the engine, turn ignition switch to OFF.
2. Make sure that the battery is fully charged.
3. Release fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-208357-S05384786392005120700000) , OPERATION, Fuel.
4. Remove all the spark plugs. Refer to «REMOVAL»(ref-208364-S39204790282005120700000) , Spark Plug.
5. Fully open throttle valve.
6. Check the starter motor for suitable performance and operation.
7. Hold the compression gauge tight against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long.
8. Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.
9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 RPM and fully open throttle): Standard: 1,275 kPa (13.0 kg/cm 2 , 185 psi) Limit: 1,079 kPa (11.0 kg/cm 2 , 156 psi) Difference between cylinders: 49 kPa (0.5 kg/cm 2 , 7 psi), or less

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Scheme 65

1. Before checking idle speed, check the following: Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are connected properly. Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and turn ignition switch to OFF.
4. When using SUBARU SELECT MONITOR, Refer to «SPECIAL TOOLS»(ref-208360-S01786843162005120700000) , PREPARATION TOOL, General Description. Insert the cartridge to SUBARU SELECT MONITOR. Connect SUBARU SELECT MONITOR to the data link connector. Turn ignition switch to ON, and SUBARU SELECT MONITOR switch to ON. Select {2. Each System Check} in Main Menu. Select {Engine Control System} in Selection Menu. Select {1. Current Data Display & Save} in Engine Control System Diagnosis. Select {1.12 Data Display} in Data Display Menu. Start the engine, and read engine idle speed.
5. When using tachometer (Secondary pick-up type). Attach the pick-up clip to No. 1 cylinder spark plug cord. Start the engine, and read engine idle speed. NOTE: When using the OBD-II general scan tool, carefully read its operation manual. This ignition system provides simultaneous ignition for #1 and #2 plugs. It must be noted that some tachometers may register twice that of actual engine speed.
6. Check idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed (No load and gears in neutral (MT), or N or P (AT) position): MT vehicle: 650+/-100 RPM AT vehicle: 700+/-100 RPM
7. Check idle speed when loaded. (Turn air conditioning switch to "ON" and operate compressor for at least one minute before measurement.) Idle speed [A/C "ON", no load and gears in neutral (MT) or N or P (AT) position]: 850+/-100 RPM NOTE: The idle speed is adjusted automatically and manual adjusting cannot be performed. If idle speed is out of specifications, refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-208365-S37816485352005120700000) .

Scheme 66

1. Warm-up the engine.
2. To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light.
3. Start the engine at idle speed and check the ignition timing. Ignition timing [BTDC/RPM]: MT vehicle: 10°+/-8°/650 AT vehicle: 15°+/-8°/700 If the timing is not correct, check the ignition control system. Refer to Engine Control System. Refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-208365-S37816485352005120700000) .

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1. Warm-up the engine.
2. Disconnect the brake vacuum hose and install the vacuum gauge to the hose fitting on the manifold.
3. Keep the engine at the idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below. Vacuum pressure (at idling, A/C "OFF"): Less than -60.0 kPa (-450 mmHg, -17.72 inHg)

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1. Disconnect battery ground cable.
2. Remove generator from bracket. Refer to «REMOVAL»(ref-167690-S02906563862004102000000) , Generator.
3. Disconnect connector from oil pressure switch.
4. Remove oil pressure switch from engine cylinder block. Refer to «REMOVAL»(ref-208363-S23298322492005120700000) , Oil Pressure Switch.
5. Connect oil pressure gauge hose to cylinder block.
6. Connect battery ground cable.
7. Start the engine, and measure oil pressure. Oil pressure: 88 kPa (0.9 kg/cm 2 , 13 psi) or more at 800 RPM 294 kPa (3.0 kg/cm 2 , 43 psi) or more at 5,000 RPM CAUTION: If oil pressure is out of specification, check oil pump, oil filter and lubrication line. Refer to «INSPECTION»(ref-208363-S21344607222005120700000) , Engine Lubrication System Trouble in General. If oil pressure warning light is turned ON and oil pressure is in specification, replace oil pressure switch. Refer to «INSPECTION»(ref-208363-S21344607222005120700000) , Engine Lubrication System Trouble in General. NOTE: The specified data is based on an engine oil temperature of 80°C (176°F).
8. After measuring oil pressure, install oil pressure switch. Refer to «INSTALLATION»(ref-208363-S25852061762005120700000) , Oil Pressure Switch. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
9. Install generator and V-belt in the reverse order of removal, and adjust the V-belt deflection. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000) , V-BELT.

Note. If out of specification, check or replace pressure regulator and pressure regulator vacuum hose.

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1. Release fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-208357-S05384786392005120700000) , OPERATION, Fuel.
2. Open fuel flap lid, and remove fuel filler cap.
3. Disconnect fuel delivery hoses from fuel filter, and connect fuel pressure gauge.
4. Connect connector of fuel pump relay.
5. Start the engine.
6. Measure fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard: 284 -nnn 314 kPa (2.9 - 3.2 kg/cm 2 , 41 - 46 psi)
7. After connecting pressure regulator vacuum hose, measure fuel pressure. Fuel pressure: Standard: 206 - 235 kPa (2.1 - 2.4 kg/cm 2 , 30 - 34 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kg/cm 2 , 1 to 3 psi) higher than standard values during high-altitude operations.

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1. Set the vehicle onto the lift.
2. Lift-up the vehicle.
3. Remove under cover.
4. Lower the vehicle.
5. Disconnect battery ground cable.
6. Remove timing belt cover (LH).
7. When inspecting #1 and #3 cylinders (Except U5); Remove air intake duct as a unit. Remove bolt, and then remove resonator chamber. Disconnect spark plug cords from spark plugs (#1 and #3 cylinders). Disconnect PCV hose from rocker cover (RH). Remove bolts, then remove rocker cover (RH).
8. When inspecting #2 and #4 cylinders; Disconnect battery cables, and then remove battery and battery carrier. Remove the two bolts which hold washer tank. Disconnect washer motor connectors. Move washer tank to forward. Disconnect spark plug cords from spark plugs (#2 and #4 cylinders). Disconnect PCV hose from rocker cover (LH). Remove bolts, then remove rocker cover (LH).
9. 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.
10. Measure #1 cylinder valve clearance by using thickness gauge. NOTE: Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. Measure 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)
11. If necessary, adjust the valve clearance. Refer to «ADJUSTMENT»(ref-208360-S22126397542005120700000) , Valve Clearance.
12. Similar to measurement procedures used for #1 cylinder, measure #2, #3 and #4 cylinder valve clearances. NOTE: Be sure to set cylinder pistons to their respective top dead centers on compression stroke before measuring 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.
13. After inspection, install the related parts in the reverse order of removal. Tightening torque: Resonator chamber: 33 N.m (3.4 kgf-m, 24.6 ft-lb)

1. Make sure pipes and hoses are installed correctly.
2. Make sure the engine coolant and ATF are at specified levels.

Make sure there are no cracks or other damage.

Scheme 90

1. After removing the engine from the body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND
2. In this section the procedures described under each index are all connected and stated in order. It will be the complete procedure for overhauling of the engine itself when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

1. Make sure the V-belt is not worn or otherwise damaged.
2. Check the tension of the belt. Refer to «INSPECTION»(ref-208360-S12723956292005120700000) , V-belt.

Scheme 91

1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000) , CRANKSHAFT PULLEY.
3. Remove belt cover (LH).
4. Remove front belt cover.

Scheme 92

1. Install front belt cover. Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
2. Install belt cover (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
3. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000) , CRANKSHAFT PULLEY.
4. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000) , V-BELT.

Make sure the cover is not damaged.

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1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000) , CRANKSHAFT PULLEY.
3. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000) , BELT COVER.
4. Remove timing belt guide. (MT vehicle only)
5. If alignment mark (a) and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as shown in procedures below. Turn crankshaft using ST. Align mark (a) of sprocket to cylinder block notch (b) and ensure that right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) and/or left side cam sprocket mark (e) and belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET Using white paint, put alignment and/or arrow marks on timing belts in relation to the crank sprocket and cam sprockets. Specified data: Z 1 : 46.8 tooth length Z 2 : 43.7 tooth
6. Remove belt idler (No. 2).
7. Remove belt idler No. 2.
8. Remove timing belt.

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Scheme 101

1. Remove belt idler (No. 1).
2. Remove automatic belt tension adjuster assembly.

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1. Preparation for installation of automatic belt tension adjuster assembly; CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically. Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kgf, 66 lb). Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. Do not release press pressure until stopper pin is completely inserted. Attach the automatic belt tension adjusted assembly to the vertical pressing tool. Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder. With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
2. Install automatic belt tension adjuster assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
3. Install belt idler (No. 1). Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)

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1. Preparation for installation of automatic belt tension adjuster assembly. Refer to «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(ref-208360-S36923269872005120700000) , INSTALLATION, Timing Belt Assembly.
2. Installation of timing belt Turn camshaft sprocket No. 2 using ST1, and turn camshaft sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions. ST1 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE: CAMSHAFT SPROCKET WRENCH (499207100) is also can be used. While aligning alignment mark (B) on timing belt with marks on sprockets (A), position timing belt properly. NOTE: Ensure belt's rotating direction is correct.
3. Install belt idler No. 2. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
4. Install belt idler (No. 2). Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
5. After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper pin from belt tensioner adjuster.
6. Install timing belt guide. (MT vehicles only) Temporarily tighten bolts. Check and adjust clearance between timing belt and timing belt guide by using thickness gauge. Clearance: 1.0+/-0.5 mm (0.039+/-0.020 in) Tighten bolts. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
7. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000) , BELT COVER.
8. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000) , CRANKSHAFT PULLEY.
9. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000) , V-BELT.

Scheme 113

1. Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt.
2. Check the condition of back side of belt; if any crack is found, replace belt. CAUTION: Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Do not bend the belt sharply. Bending radius: h 60 mm (2.36 in) or more

1. Check sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between sprocket and key.
3. Check crankshaft sprocket notch for sensor for damage and contamination of foreign matter.

Scheme 114

1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000) , CRANKSHAFT PULLEY.
3. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000) , BELT COVER.
4. Remove timing belt assembly. Refer to «REMOVAL»(ref-208360-S07939121822005120700000) , TIMING BELT ASSEMBLY.
5. Remove camshaft sprocket. Refer to «REMOVAL»(ref-208360-S34341168092005120700000) , «CAMSHAFT SPROCKET»(ref-208360-S15919221532005120700000) .
6. Remove crankshaft sprocket.

Scheme 115

1. Install crankshaft sprocket.
2. Install camshaft sprocket. Refer to «INSTALLATION»(ref-208360-S23395148232005120700000) , CAMSHAFT SPROCKET.
3. Install timing belt assembly. Refer to «INSTALLATION»(ref-208360-S12148340212005120700000) , Timing Belt Assembly.
4. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000) , BELT COVER.
5. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000) , CRANKSHAFT PULLEY.
6. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000) , V-BELT.

1. Check sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between sprocket and key.
3. Check crankshaft sprocket notch for sensor for damage and contamination of foreign matter.

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1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000) , CRANKSHAFT PULLEY.
3. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000) , BELT COVER.
4. Remove timing belt assembly. Refer to «REMOVAL»(ref-208360-S07939121822005120700000) , TIMING BELT ASSEMBLY.
5. Remove camshaft sprocket. Refer to «REMOVAL»(ref-208360-S34341168092005120700000) , CAMSHAFT SPROCKET.
6. Disconnect PCV hose and remove rocker cover.
7. Removal of valve rocker assembly Remove bolts (a) through (h) in alphabetical sequence. NOTE: Leave two or three threads of bolts (g and h) engaged to retain valve rocker assembly. Remove valve rocker assembly.

Scheme 118

1. Installation of valve rocker assembly Temporarily tighten bolts (a) through (d) alphabetical order equally see scheme 132 NOTE: Do not allow valve rocker assembly to gouge knock pins. Tighten bolts (e) through (h) in alphabetical order to specified torque. Tighten bolts (a) through (d) in alphabetical order to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
2. Adjust the valve clearances. Refer to «ADJUSTMENT»(ref-208360-S22126397542005120700000), Valve Clearance.
3. Install rocker cover and connect PCV hose.
4. Install camshaft sprocket. Refer to «INSTALLATION»(ref-208360-S23395148232005120700000), CAMSHAFT SPROCKET.
5. Install timing belt assembly. Refer to «INSTALLATION»(ref-208360-S12148340212005120700000), Timing Belt Assembly.
6. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000), BELT COVER.
7. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000), CRANKSHAFT PULLEY.
8. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000), V-BELT.

Note. "RANK" shown in the chart refer to the possibility of reason for the trouble in order; (+)"Very often" to "Rarely")

A - Very often

B - Sometimes

C - Rarely

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