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Engine Mechanical (H4SO): Removal & Installation Subaru Outback BP

Mechanical 53 illustrations ~1928 words

REMOVAL

  1. Remove engine assembly. Refer to «ENGINE ASSEMBLY»(ref-208360-S26597180952005120700000) .
  2. Remove engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

  1. Tightening torque: Engine mounting: 35 N.m (3.6 kgf-m, 26.0 ft-lb)

Note. Before conducting this procedure, drain engine oil completely.

Scheme 125

Scheme 125: REMOVAL
Scheme 125: REMOVAL

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Scheme 138
  1. Remove intake manifold. Refer to «REMOVAL»(ref-208357-S02061872362005120700000), Intake Manifold.
  2. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000), V-BELT.
  3. Remove crankshaft Pulley.
  4. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000), BELT COVER.
  5. Remove timing belt assembly. Refer to «REMOVAL»(ref-208360-S07939121822005120700000), TIMING BELT ASSEMBLY.
  6. Remove camshaft sprocket. Refer to «REMOVAL»(ref-208360-S34341168092005120700000), CAMSHAFT SPROCKET.
  7. Remove crankshaft sprocket. Refer to «REMOVAL»(ref-208360-S21251795552005120700000), CRANKSHAFT PULLEY.
  8. Remove generator and A/C compressor with their brackets.
  9. Remove rocker cover.
  10. Remove cylinder head bolts in alphabetical sequence (Scheme 126) NOTE: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
  11. While tapping cylinder head with a plastic hammer, separate it from cylinder block.
  12. Remove bolts (a) through (c) to remove cylinder head.
  13. Remove cylinder head gasket. NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
  14. Similarly, remove right side cylinder head.
  15. Remove clutch housing cover (MT vehicles only).
  16. Remove flywheel (MT vehicles only) or drive plate (AT vehicles only). Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER
  17. Remove oil separator cover.
  18. Remove water by-pass pipe for heater.
  19. Loosen bolts in alphabetical sequence (Scheme 130)and remove water pump.
  20. Remove oil pump from cylinder block. Use a flat-bladed screwdriver (Scheme 131)when removing oil pump. NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump.
  21. Removal of oil pan Turn cylinder block with #2 and #4 piston sides facing upward. Remove bolts which secure oil pan to cylinder block. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan. NOTE: Do not use a screwdriver or similar tool in place of oil pan cutter.
  22. Remove oil strainer stay.
  23. Remove oil strainer.
  24. Remove baffle plate.
  25. Remove oil filter using ST. ST 498547000 OIL FILTER WRENCH [outer diameter 80 mm (3.15 in) for oil filter] ST 18332AA000 OIL FILTER WRENCH [outer diameter 68 mm (2.68 in) for oil filter] ST 18332AA010 OIL FILTER WRENCH [outer diameter 65 mm (2.56 in) for oil filter]
  26. Remove water pipe.
  27. Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
  28. Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston snap ring through service hole of #1 and #2 cylinders.
  29. Draw out piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse original combination of piston, piston pin and cylinder.
  30. Similarly remove piston pins from #3 and #4 pistons.
  31. Remove bolts which connect cylinder block of the side of #2 and #4 cylinders.
  32. Loosen bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  33. Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts.
  34. Separate left-hand and right-hand cylinder blocks. NOTE: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
  35. Remove rear oil seal.
  36. Remove crankshaft together with connecting rod.
  37. Remove crankshaft bearings from cylinder block using hammer handle. NOTE: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
  38. Remove pistons from cylinder block using hammer handle. NOTE: Do not confuse combination of pistons and cylinders.

Note. Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

Scheme 139

Scheme 139: INSTALLATION
Scheme 139: INSTALLATION

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Scheme 175
  1. Position crankshaft on the #2 and #4 cylinder block.
  2. Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: Part number 004403007 THREE BOND 1215 or equivalent NOTE: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
  3. Tighten 10 mm cylinder block connecting bolts in alphabetical sequence (Scheme 142) (LH side) Tightening torque: 15 N.m (1.5 kgf-m, 11 ft-lb)
  4. Tighten 10 mm cylinder block connecting bolts in alphabetical sequence (Scheme 143) (RH side) Tightening torque: 15 N.m (1.5 kgf-m, 11 ft-lb)
  5. Tighten bolts (A to D) on left side of cylinder block more 90° in alphabetical sequence.
  6. Tighten bolts (E to J) on right side of cylinder block more 90° in alphabetical sequence.
  7. Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence (Scheme 146) Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
  8. Install rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
  9. Position the top ring gap at (A) or (B) in (Scheme 148).
  10. Position the second ring gap at 180° on the reverse side for the top ring gap.
  11. Position the expander gap at (C) in (Scheme 149) or (Scheme 150).
  12. Position the lower rail gap at (D) in (Scheme 151) or (Scheme 152). NOTE: Align lower rail spin stopper (F) with piston side surface hole (E).
  13. Position the upper rail gap at (G) in (Scheme 154) or (Scheme 155). CAUTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.
  14. Install snap ring. Install snap rings in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new snap rings. NOTE: Piston front mark (A) faces towards the front of the engine.
  15. Installing piston Turn cylinder block so that #1 and #2 cylinders face upward. Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE
  16. Installing piston pin Apply a coat of engine oil to ST3. Insert ST3 into service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole. Install snap ring. NOTE: Use new snap rings. Apply fluid packing around the service hole plug. Fluid packing: Part number 004403007 THREE BOND 1215 or equivalent Install service hole plug and gasket. NOTE: Use a new gasket. Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.
  17. Install water pipe.
  18. Install baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb
  19. Install oil strainer and O-ring. Tightening torque: 10 N.m (1.0 kgf-m, 7 ft-lb
  20. Install oil strainer stay.
  21. Apply fluid packing to matching surfaces and install oil pan. Fluid packing: Part number 004403007 THREE BOND 1215 or equivalent
  22. Apply fluid packing to matching surfaces and install oil separator cover. Fluid packing: Part number 004403007 THREE BOND 1215 or equivalent
  23. Install flywheel or drive plate. To lock crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
  24. Install housing cover.
  25. Installation of oil pump Discard front oil seal after removal. Replace with a new one using ST. ST 499587100 OIL SEAL INSTALLER Apply fluid packing to matching surface of oil pump. Fluid packing: Part number 004403007 THREE BOND 1215 or equivalent Apply a coat of engine oil to the inside of the oil seal. Install oil pump on cylinder block. Be careful not to damage oil seal during installation. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) NOTE: Do not forget to install O-ring and seal when installing oil pump. Align flat surface of oil pump's inner rotor with crankshaft before installation.
  26. Install water pump and gasket. Tightening torque: First: 12 N.m (1.2 kgf-m, 8.7 ft-lb) Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb) NOTE: Be sure to use a new gasket. When installing water pump, tighten bolts in two stages in alphabetical sequence (Scheme 174)
  27. Install water by-pass pipe for heater.
  28. Install oil filter by turning it by hand, being careful not to damage seal rubber. Further tighten (approximately 2/3 to 3/4 turn) the oil filter with outer diameter of 80 mm (3.15 in) after the seal rubber contacts the cylinder block or the oil cooler. Further tighten (approximately 1 turn) the oil filter with outer diameter of 68 mm (2.68 in) or 65 mm (2.56 in) after the seal rubber contacts the cylinder block. CAUTION: Oil filter with outer diameter of 80 mm (3.15 in) is not available for turbo model. Do not tighten excessively, or oil may leak.
  29. Tighten cylinder head bolts. Apply a coat of engine oil to washers and bolt threads. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. Back off all bolts by 180° first; back them off by 180° again. Tighten bolts (a) and (b) to 34 N.m (3.5 kgf-m, 25 ft-lb). Tighten bolts (c), (d), (e) and (f) to 15 N.m (1.5 kgf-m, 11 ft-lb). Tighten all bolts by 80 to 90° in alphabetical sequence. CAUTION: Do not tighten bolts more than 90°. Further tighten all bolts by 80 to 90° in alphabetical sequence. CAUTION: Ensure that the total "re-tightening angle" [in the former two steps], do not exceed 180°.
  30. Install oil level gauge guide and tighten attaching bolt (left side only).
  31. Install rocker cover.
  32. Install crankshaft sprocket. Refer to «INSTALLATION»(ref-208360-S37321035592005120700000), CRANKSHAFT SPROCKET.
  33. Install camshaft sprocket. Refer to «INSTALLATION»(ref-208360-S23395148232005120700000), CAMSHAFT SPROCKET.
  34. Install timing belt assembly. Refer to «INSTALLATION»(ref-208360-S12148340212005120700000), Timing Belt Assembly.
  35. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000), BELT COVER.
  36. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000), CRANKSHAFT PULLEY.
  37. Install generator and A/C compressor brackets on cylinder head.
  38. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000), V-BELT.
  39. Install intake manifold. Refer to «INSTALLATION»(ref-208357-S23219009012005120700000), Intake Manifold.

Scheme 176

Scheme 176: DISASSEMBLY
Scheme 176: DISASSEMBLY
  1. Remove connecting rod cap.
  2. Remove connecting rod bearing. NOTE: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion.
  3. Remove piston rings using the piston ring expander.
  4. Remove the oil ring by hand. NOTE: Arrange the removed piston rings in good order to prevent confusion.
  5. Remove snap ring.

Scheme 177

Scheme 177: ASSEMBLY
Scheme 177: ASSEMBLY
  1. Apply oil to the surfaces of the connecting rod bearings.
  2. Install connecting rod bearings on connecting rods and connecting rod caps.
  3. Position each connecting rod with the side marked facing forward, and install connecting rod on crankshaft.
  4. Install connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads.
  5. Install oil ring spacer, lower rail and upper rail in this order by hand. Then install second ring and top ring with a piston ring expander.

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