Engine Mechanical (H6DO): Diagnosis Subaru Outback BP

INSPECTION

Scheme 357

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-208382-S24241737122005120700000) , OPERATION, Fuel.
4. Remove all the spark plugs. Refer to «REMOVAL»(ref-208389-S30056766502005120700000) , Spark Plug.
5. Check the starter motor for satisfactory performance and operation.
6. Hold the compression gauge tight against the spark plug hole. CAUTION: 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.
7. Fully open throttle valve.
8. Crank the engine by means of the starter motor, and read the maximum value on the gauge when he 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. 1,275 -1,471 kPa (13.0 -15.0 kg/cm 2 , 185 - 213 psi) Limit
2. 1,128 kPa (11.5 kg/cm 2 , 164 psi)

Scheme 358

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 «PREPARATION TOOL»(ref-208385-S36328703352005120700000) , 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. NOTE: When using the OBD-II general scan tool, carefully read its operation manual.
5. Check idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed (No load and gears in N or P position): 600+/-50 RPM
6. 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 N or P position]: 700+/-50 RPM CAUTION: Idle speed cannot be adjusted manually because it is controlled automatically. If idle speed is out of specifications, refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-208390-S29837623122005120700000) .

Scheme 359

1. Before checking ignition timing, check the following: Ensure that air cleaner element is free from clogging, 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 «PREPARATION TOOL»(ref-208385-S36328703352005120700000) , 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 engine at idle speed and check the ignition timing. Ignition timing [BTDC/RPM]: 10°+/-3°/600+/-50 If the timing is not correct, check the ignition control system. Refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-208390-S29837623122005120700000) .

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1. Set the vehicle on the lift.
2. Disconnect battery ground cable.
3. Lift up the vehicle.
4. Remove under cover.
5. Lower the vehicle.
6. Place suitable container under the vehicle.
7. When inspecting RH side cylinder. Remove air intake duct and air cleaner case. Refer to «REMOVAL»(ref-208384-S10767206552005120700000) , Air Intake Duct «REMOVAL»(ref-208384-S32437817092005120700000) , Air Cleaner. Remove V-belt. Refer to «V-BELT»(ref-208385-S23620638772005120700000) . Remove power steering hose from 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. Remove fuel pipe protector RH. Disconnect fuel injector connectors. Disconnect front oxygen (A/F) sensor connector. Disconnect oil pressure switch connector. Remove ignition coils. Refer to «REMOVAL»(ref-208389-S26533706192005120700000) , Ignition Coil and Ignitor Assembly. Remove rocker cover RH. Refer to «CAMSHAFT»(ref-208385-S05810713342005120700000) .
8. When inspecting LH side cylinder. Set the vehicle on the lift. Remove battery. Remove washer tank mounting bolts. Disconnect washer motor connectors. Move washer tank upward. Disconnect PCV hose and blow-by hose from rocker cover LH. Remove fuel pipe protector LH. Disconnect fuel injector connectors. (A) Disconnect front oxygen (A/F) sensor connector. (B) Remove ignition coils. Refer to «REMOVAL»(ref-208389-S26533706192005120700000) , Ignition Coil and Ignitor Assembly. Remove rocker cover LH. Refer to «CAMSHAFT»(ref-208385-S05810713342005120700000) .
9. Turn the crankshaft clockwise using the ST. Move the camshaft position so that the adjusting cam is perpendicular to the shim as shown in the figure. ST 18252AA000 CRANKSHAFT SOCKET
10. Measure intake valve and exhaust valve clearances by using thickness gauge (A). CAUTION: Insert the thickness gauge in as horizontal a direction as possible with respect to the shim. Valve clearance: Intake: 0.20 +0.04 / -0.06 mm (0.0079 +0.0016 / -0.0024 in) Exhaust: 0.25+/-0.05 mm (0.0098+/-0.0020 in) NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.
11. If necessary, adjust the valve clearance. Refer to «ADJUSTMENT»(ref-208385-S31116572502005120700000) , Valve Clearance.
12. Further turn crankshaft pulley clockwise. Using the same procedure described previously, then measure valve clearances again.
13. After inspection, install the related parts in the reverse order of removal.

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

C: INSPECTION

Make sure there are no cracks or other damage.

Scheme 378

1. Remove engine from body. Refer to «ENGINE ASSEMBLY»(ref-208385-S40718943072005120700000) .
2. Drain engine oil. Refer to «REPLACEMENT»(ref-208388-S11978859622005120700000) , Engine Oil.
3. After removing engine from body, install ST onto engine. ST 18232AA000 ENGINE STAND
4. Remove sensors, pipes, and hoses installed on engine before starting overhaul. Remove intake manifold. Refer to «REMOVAL»(ref-208382-S39770035642005120700000) , Intake Manifold. Remove generator. Refer to «REMOVAL»(ref-167690-S02906563862004102000000) , Generator. Remove A/C compressor. Refer to «REMOVAL»(ref-216290-S35125235682006011800000) , Compressor. Remove EGR pipe. Refer to «REMOVAL»(ref-208383-S07715850022005120700000) , EGR Valve. Remove water pipe and hoses. Remove engine harness. Remove spark plugs. Refer to «REMOVAL»(ref-208389-S30056766502005120700000) , Spark Plug. Remove camshaft position sensor. Refer to «REMOVAL»(ref-208382-S05401792592005120700000) , Camshaft Position Sensor. Remove crankshaft position sensor. Refer to «REMOVAL»(ref-208382-S20742466062005120700000) , Crankshaft Position Sensors. Remove knock sensor. Refer to «REMOVAL»(ref-208382-S13073400002005120700000) , Knock Sensor. Remove engine coolant temperature sensor. Refer to «REMOVAL»(ref-208382-S10352221142005120700000) , Engine Coolant Temperature Sensor. Remove oil pressure switch. Refer to «REMOVAL»(ref-208388-S24156927402005120700000) , Oil Pressure Switch. Remove oil filter. Refer to «REMOVAL»(ref-208388-S22484218592005120700000) , Engine Oil Filter. Remove oil cooler. Refer to «REMOVAL»(ref-208388-S40482215352005120700000) , Oil Cooler.

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Scheme 380

1. Remove crankshaft pulley cover.
2. Remove crankshaft pulley bolt. To lock crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH
3. Remove crankshaft pulley.

Scheme 381

1. Install crankshaft pulley.
2. Install crankshaft pulley bolt. To lock crankshaft use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH Clean the crankshaft pulley thread using an air gun. Apply engine oil to the crankshaft pulley bolt seat and thread. Tighten the crankshaft pulley bolts. Tightening torque: 178 N.m (18.1 kgf-m, 131 ft-lb)
3. Install the crankshaft pulley cover. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Scheme 382

1. Check crankshaft pulley cover for oil leaks and bleeding.
2. Check crankshaft pulley for looseness.

Scheme 383

1. Remove crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .
2. Remove front chain cover. NOTE: There are four different types of chain cover mounting bolts. Sort them into separate containers to avoid confusion at installation. Bolt dimension: 6 x 45 6 x 16 6 x 30 6 x 50 Sealing washer

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1. Remove old fluid gasket on the matching surface, and degrease it.
2. Apply fluid gasket to the mating surface of front chain cover. Fluid gasket: THREE BOND 1280B Fluid gasket application diameter: 2.5+/-0.5 mm (0.098+/-0.020 in)
3. Install front chain cover. Temporarily tighten the bolts. CAUTION: Do not confuse the mounting positions of the bolts.
4. Tighten the bolts in the numerical sequence shown in figure. Tightening torque: 6.6 N.m (0.67 kgf-m, 4.8 ft-lb)
5. Install crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .

Check the cover surface for flaws and dents.

Check the cover mating surface and the mounting point of crankshaft pulley for oil leaks.

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1. Remove crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .
2. Remove front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
3. Remove chain tensioner (RH). NOTE: Make sure plunger (A) does not come out.
4. Remove chain guide. (Right-hand between cams)
5. Remove chain guide (RH).
6. Remove chain tensioner (LH). Remove timing chain (RH).
7. Remove chain tensioner (LH). NOTE: Make sure plunger (A) does not come out.
8. Remove chain tensioner lever (LH). Remove chain guide. (Left-hand between cams)
9. Remove chain guide (LH).
10. Remove chain guide. (Center)
11. Remove idler sprocket. (Upper)
12. Remove timing chain (LH).
13. Remove idler sprocket. (Lower)

1. Check sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between sprocket and key.

Scheme 397

1. Remove crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .
2. Remove front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
3. Remove timing chain assembly. Refer to «TIMING CHAIN ASSEMBLY»(ref-208385-S22290053572005120700000) .
4. Remove camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
5. Remove crankshaft sprocket (A).

Scheme 398

1. Install crankshaft sprocket (A).
2. Install camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
3. Install timing chain assembly. Refer to «INSTALLATION»(ref-208385-S24492764732005120700000) , Timing Chain Assembly.
4. Install front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
5. Install crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .

1. Check sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between sprocket and key.

Scheme 399

1. Remove crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .
2. Remove front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
3. Remove timing chain. Refer to «TIMING CHAIN ASSEMBLY»(ref-208385-S22290053572005120700000) .
4. Remove camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
5. Remove crankshaft sprocket.
6. Remove oil pump. Refer to «REMOVAL»(ref-208388-S39954639622005120700000) , Oil Pump.
7. Remove oil pump relief valve. Refer to «REMOVAL»(ref-208388-S07273003132005120700000) , Oil Pump Relief Valve.
8. Remove water pump. Refer to «REMOVAL»(ref-208387-S37518214312005120700000) , Water Pump.
9. Remove rear chain cover. NOTE: There are seven different types of mounting bolts. Sort them into separate containers to avoid confusion at installation. Bolt dimension: 6 x 14 6 x 18 (Silver) 6 x 30 6 x 18 6 x 40 6 x 30 6 x 22

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1. Remove old fluid gasket on the matching surface, and degrease it.
2. Apply fluid gasket to the mating surface of rear chain cover. Fluid gasket: THREE BOND 1280B Fluid gasket application diameter: 1.0+/-0.5 mm (0.039+/-0.020 in) 3.0+/-1.0 mm (0.118+/-0.039 in)
3. Install O-ring. NOTE: Do not reuse the O-ring.
4. Temporarily tighten rear chain cover. CAUTION: Do not confuse the mounting positions of the bolts. NOTE: Replace mounting bolts (G) with new ones. Bolt dimension: 6 x 14 6 x 18 (Silver) 6 x 30 6 x 18 8 x 40 8 x 30 6 x 22
5. Tighten the bolts in the numerical sequence shown in figure. TIGHTENING TORQUE: (1) to (11) 9 N.m (0.9 kgf-m, 6.5 ft-lb) (12) to (19) 20 N.m (2.0 kgf-m, 14 ft-lb) (20) to (31) 9 N.m (0.9 kgf-m, 6.5 ft-lb) (32) to (39) 12 N.m (1.2 kgf-m, 8.7 ft-lb) (40) to (46) 9 N.m (0.9 kgf-m, 6.5 ft-lb)
6. Install water pump. Refer to «REMOVAL»(ref-208387-S37518214312005120700000) , Water Pump.
7. Install oil pump relief valve. Refer to «INSTALLATION»(ref-208388-S15378962952005120700000) , Oil Pump Relief Valve.
8. Install oil pump. Refer to «INSTALLATION»(ref-208388-S25309653162005120700000) , Oil Pump.
9. Install crankshaft sprocket.
10. Install camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
11. Install timing chain. Refer to «INSTALLATION»(ref-208385-S24492764732005120700000) , Timing Chain Assembly.
12. Install front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
13. Install crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .

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1. Remove crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .
2. Remove front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
3. Remove timing chain assembly. Refer to «TIMING CHAIN ASSEMBLY»(ref-208385-S22290053572005120700000) .
4. Remove camshaft sprockets. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
5. Remove crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208385-S37832612542005120700000) .
6. Remove rear chain cover. Refer to «REAR CHAIN COVER»(ref-208385-S13339761462005120700000) .
7. Remove rocker cover (RH).
8. Loosen front camshaft cap bolts equally, a little at a time in numerical sequence shown in the figure (RH).
9. Remove camshaft cap and intake camshaft (RH).
10. Loosen camshaft cap bolts equally, a little at a time in the numerical sequence shown in the figure.
11. Remove camshaft cap and exhaust camshaft (RH). CAUTION: Arrange camshaft caps in order so that they can be installed in their original position.
12. Remove plug (LH).
13. Similarly, remove left-hand camshafts and related parts.

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1. Apply a coat of engine oil to camshaft journals and install camshaft. CAUTION: When installing camshaft, adjust camshaft front flange knock pin (A) position as follows: LH side: 12 o'clock RH side: 10 o'clock
2. Install camshaft cap. Apply fluid packing sparingly to back of front camshaft cap shown in the figure. CAUTION: Do not apply fluid gasket excessively. Failure to do so may cause excess fluid gasket to come out and flow toward camshaft journal, resulting burning stuck of engine. Fluid gasket: THREE BOND 1280B Fluid gasket application diameter: 2.0+/-0.5 mm (0.079+/-0.020 in) Apply engine oil to cap bearing surface and install cap on camshaft. Tighten the camshaft cap bolts in the numerical sequence shown in the figure. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb) Tighten the front camshaft cap bolts in the numerical sequence shown in the figure. Tightening torque: 9.8 N.m (1.0 kgf-m, 7.2 ft-lb)
3. Install rocker cover. Apply fluid gasket sparingly to matching surface of cylinder heads and rocker covers shown in the figure. CAUTION: Do not apply fluid gasket excessively. Doing so may cause excess fluid gasket to come out and flow toward camshaft journal, resulting burning stuck of engine. Fluid gasket: THREE BOND 1280B Tighten the rocker cover bolts in the numerical order shown in the figure. Tightening torque: 6.4 N.m (0.64 kgf-m, 4.6 ft-lb)
4. Install rear chain cover. Refer to «REAR CHAIN COVER»(ref-208385-S13339761462005120700000) .
5. Install crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208385-S37832612542005120700000) .
6. Install camshaft sprockets. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
7. Install timing chain assembly. Refer to «INSTALLATION»(ref-208385-S24492764732005120700000) , Timing Chain Assembly.
8. Install front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
9. Install crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .

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1. Measure the bend, and repair or replace if necessary. Limit: 0.020 mm (0.0008 in)
2. Check journal for damage and wear. Replace if faulty.
3. Measure outside diameter of camshaft journal. If the journal diameter is not as specified, check the oil clearance.
4. Measurement of the camshaft journal oil clearance Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Place plastigauge across each of the camshaft journals. Install the bearing caps. CAUTION: Do not turn the camshaft. Remove the bearing caps. Measure the widest point of the plastigauge on each journal. If the oil clearance exceeds the limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard oil clearance: 0.037 - 0.072 mm (0.0015 - 0.0028 in) Completely remove the plastigauge.
5. Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded. Cam height: H Standard: Intake: 45.75 - 45.85 mm (1.8012 - 1.8051 in) Exhaust: 45.25 - 45.35 mm (1.7815 - 1.7854 in) Cam base circle diameter A: 36.0 mm (1.4173 in)
6. Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace caps and cylinder head as a set. If necessary replace camshaft. Standard: Intake: 0.075 - 0.135 mm (0.0030 - 0.0053 in) Exhaust: 0.048 - 0.108 mm (0.0019 - 0.0043 in)

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1. Remove crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .
2. Remove front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
3. Remove timing chain assembly. Refer to «TIMING CHAIN ASSEMBLY»(ref-208385-S22290053572005120700000) .
4. Remove camshaft sprockets. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
5. Remove crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208385-S37832612542005120700000) .
6. Remove rear chain cover. Refer to «REAR CHAIN COVER»(ref-208385-S13339761462005120700000) .
7. Remove camshafts. Refer to «CAMSHAFT»(ref-208385-S05810713342005120700000) .
8. Remove cylinder head bolts in numerical sequence shown in figure. CAUTION: Leave bolts (2) and (4) engaged by three or four threads to prevent cylinder head from falling.
9. Tap cylinder head with a plastic hammer to separate it from cylinder block.
10. Remove bolts (2) and (4) to remove cylinder head.
11. Remove cylinder head gasket. CAUTION: Do not scratch the mating surface of cylinder head and cylinder block.
12. Similarly, remove right side cylinder head.

Scheme 422

1. Install cylinder head and gaskets on cylinder block. CAUTION: Use new cylinder head gaskets. Be careful not to scratch the mating surface of cylinder block and oil pump.
2. Tighten cylinder head bolts. Coat the washers and threaded parts of the cylinder head bolts with engine oil. Install the cylinder head on the cylinder block and tighten the bolts in the numerical order shown in the figure to a tightening torque of 20 N.m (2.0 kgf-m, 14 ft-lb). Tighten the bolts in the numerical order shown in the figure to a tightening torque of 50 N.m (5.1 kgf-m, 37 ft-lb). Loosen all the bolts in 2 stages, 180° at a time, in the reverse order of tightening. Tighten the bolts in the numerical order shown in the figure to a tightening torque of 25 N.m (2.5 kgf-m, 18 ft-lb). Tighten the bolts in the numerical order shown in the figure to a tightening torque of 25 N.m (2.5 kgf-m, 18 ft-lb). Tighten all the bolts 90° in the numerical order shown in the figure. Tighten the (1) to (4) bolts 90° again in the numerical order shown in the figure. Tighten the (5) to (8) bolts 45° again in the numerical order shown in the figure.
3. Install camshafts. Refer to «CAMSHAFT»(ref-208385-S05810713342005120700000) .
4. Install rear chain cover. Refer to «REAR CHAIN COVER»(ref-208385-S13339761462005120700000) .
5. Install crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208385-S37832612542005120700000) .
6. Install camshaft sprockets. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
7. Install timing chain assembly. Refer to «INSTALLATION»(ref-208385-S24492764732005120700000) , Timing Chain Assembly.
8. Install front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
9. Install crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000) .

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

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1. A - Very often
2. B - Sometimes
3. C - Rarely

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