Engine Mechanical (H6DO): Other Subaru Outback BP

CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part in the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or safety stands at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect ground cable from battery.
9. All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings.
10. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
11. Be careful not to let oil, grease or coolant contact the clutch disc and flywheel.
12. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
13. Bolts, nuts and washers should be replaced with new ones as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
15. Remove or install engine in an area where chain hoists, lifting devices, etc. are available for ready use.
16. Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil. Place a cover over fenders, as required, for protection.
17. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
18. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

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PROCEDURE

It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.

1. Camshaft
2. Cylinder Head

INTAKE AND EXHAUST VALVE STEM SEAL

Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. Use pliers to pinch and remove oil seal from valve.

1. Place cylinder head on ST1.
2. Press-fit oil seal to the specified dimension indicated in the figure using ST2.

ST1 18250AA000 CYLINDER HEAD TABLE

ST2 499585500 VALVE OIL SEAL GUIDE

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1. Check valve lifter visually.
2. Measure outer diameter of valve lifter. Outer diameter: 33.959 - 33.975 mm (1.3370 - 1.3376 in)
3. Measure inner diameter of valve lifter mating part on cylinder head. Inner diameter: 34.006 - 34.016 mm (1.3388 - 1.3392 in) CAUTION: If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the limit, replace cylinder head. Standard: 0.019 - 0.057 mm (0.0007 - 0.0022 in)

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1. Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red lead check. Also make sure that gasket installing surface shows no trace of gas and water leaks.
2. Place cylinder head on ST. ST 18250AA000 CYLINDER HEAD TABLE
3. Measure the warping of the cylinder head surface that mates with crankcase using a straight edge and thickness gauge. If the warping exceeds 0.02 mm (0.0008 in), regrind the surface with a surface grinder. Warping limit: 0.02 mm (0.0008 in) Height after grinding: 123.95 mm (4.88 in) Standard height of cylinder head: 124 mm (4.88 in) CAUTION: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly. Straight edge Thickness gauge

VALVE SEAT

Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.

Valve seat width: W

Intake

1. Standard 1.0 mm (0.039 in)
2. Limit 1.7 mm (0.067 in)

Exhaust

1. Standard 1.5 mm (0.059 in)
2. Limit 2.2 mm (0.087 in)

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1. Check the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively. Clearance between the valve guide and valve stem: Standard Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in)
2. If the clearance between valve guide and stem exceeds the limit, replace valve guide or valve itself whichever shows greater amount of wear. See following procedure for valve guide replacement. Valve guide inner diameter: 5.500 - 5.512 mm (0.2165 - 0.2170 in) Valve stem outer diameter: Intake 5.455 - 5.470 mm (0.2148 - 0.2154 in) Exhaust 5.445 - 5.460 mm (0.2144 - 0.2150 in) Place cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1. Insert ST2 into valve guide and press it down to remove valve guide. ST1 18250AA000 CYLINDER HEAD TABLE ST2 499765700 VALVE GUIDE REMOVER Turn cylinder head upside down and place ST as shown in the figure. ST 18251AA000 VALVE GUIDE ADJUSTER Before installing new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head. Put new valve guide in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499765700 VALVE GUIDE REMOVER ST2 18251AA000 VALVE GUIDE ADJUSTER Check the valve guide protrusion. Valve guide protrusion: L 12.3 - 12.7 mm (0.484 - 0.500 in) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean valve guide to remove chips. ST 499765900 VALVE GUIDE REAMER CAUTION: Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer. Recheck the contact condition between valve and valve seat after replacing valve guide.

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1. Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "H" is less than the specified limit. H: Intake Standard < CA >1.0 mm (0.039 in) Limit 0.8 mm (0.031 in) Exhaust Standard 1.2 mm (0.047 in) Limit 1.0 mm (0.039 in) Valve overall length: Intake 103.5 mm (4.075 in) Exhaust 103.2 mm (4.063 in)
2. Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping.

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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 assembly. Refer to «CYLINDER HEAD ASSEMBLY»(ref-208385-S09361305482005120700000) >
9. Remove drive plate.
10. Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER
11. Remove crankshaft position sensor plate.
12. Remove crankshaft position sensor bracket.
13. Rotate engine until oil pan comes to the top.
14. Remove bolts which secure lower oil pan to upper oil pan.
15. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
16. Remove oil strainer.
17. Remove bolts which secure upper oil pan to cylinder block. Bolt dimension: 8 x 40 8 x 65 8 x 85 8 x 130 8 x 24
18. Remove service hole cover and service hole plugs using hexagon wrench.
19. Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders by using ST. ST 18233AA000 PISTON PIN CIRCLIP PLIER
20. Draw out piston pin from #1 and #2 pistons by using ST. ST 499097500 PISTON PIN REMOVER CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder.
21. Similarly remove piston pins from #3, #4, #5 and #6 pistons.
22. Remove bolts which connect cylinder block.
23. Separate left-hand and right-hand cylinder blocks. CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
24. Remove rear oil seal.
25. Remove crankshaft together with connecting rod.
26. Remove crankshaft bearings from cylinder block using hammer handle. CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
27. Draw out each piston from cylinder block using wooden bar or hammer handle. CAUTION: Do not confuse combination of piston pin and cylinder.

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1. Install ST to cylinder block, then install crankshaft bearing. ST 18232AA000 ENGINE STAND CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
2. Position crankshaft and connecting rod on the #2, #4 and #6 cylinder.
3. Apply fluid gasket to the mating surface of #1, #3 and #5 cylinder block. Fluid gasket: THREE BOND 1215B or equivalent CAUTION: Do not allow fluid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. Fluid gasket application diameter: 1.0+/-0.2 mm (0.039+/-0.008 in)
4. Apply engine oil to washers and threads of cylinder block connecting bolts. Tighten the bolts following the steps below. Tighten all the bolts in the numerical order shown in the figure. TIGHTENING TORQUE: (1) to (11) 25 N.m (2.5 kgf-m, 18 ft-lb) (12) 20 N.m (2.0 kgf-m, 14 ft-lb) (13) 25 N.m (2.5 kgf-m, 18 ft-lb) (14) 20 N.m (2.0 kgf-m, 14 ft-lb) Tighten all the bolts again in the order shown in the figure. TIGHTENING TORQUE: (1) to (11) 25 N.m (2.5 kgf-m, 18 ft-lb) (12) 20 N.m (2.0 kgf-m, 14 ft-lb) (13) 25 N.m (2.5 kgf-m, 18 ft-lb) (14) 20 N.m (2.0 kgf-m, 14 ft-lb)
5. Tighten all the bolts by 90° in the order shown in the figure.
6. Install upper bolts on cylinder block. Tightening torque: 25 N.m (2.5 kgf-m, 18 ft-lb)
7. Install rear oil seal using ST1 and ST2. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
8. Positioning of piston ring. Position the top ring gap at (A) in the figure. Position the second ring gap at (B) in the figure. Position the upper rail gap at (C) in the figure. Position the expander gap at (D) in the figure. Position the lower rail gap at (E) in the figure. CAUTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area. Install circlip. Install circlips in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new circlips.
9. Installing piston. CAUTION: Install piston and piston pin to the same cylinder they were installed before overhaul. Using ST1, rotate crankshaft until each small end of connecting rods #3 and #4 is aligned over service hole (A). ST1 18252AA000 CRANKSHAFT SOCKET Apply a coat of engine oil to piston and cylinders. Install pistons with their front marks (A) facing the front of engine. Insert pistons in their cylinders using ST2. ST2 18254AA000 PISTON GUIDE
10. Installing piston pin. Apply a coat of engine oil to ST3. ST3 18253AA000 PISTON PIN GUIDE Insert ST3 into service hole to align piston pin hole with connecting rod small end. Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod small end through service hole. Using ST4, install circlip. ST4 18233AA000 PISTON PIN CIRCLIP PLIER NOTE: Use a new circlip.
11. Repeat the same steps for pistons #1 and #2, #5 and #6.
12. Install service hole plug and cover.
13. Apply fluid gasket to mating surface of upper oil pan.
14. Install O-ring. Fluid gasket: THREE BOND 1280B
15. Temporarily tighten the upper oil pan. CAUTION: Do not confuse the mounting positions of the bolts. Bolt dimension: 8 x 40 8 x 65 8 x 85 8 x 130 8 x 20
16. Tighten the upper oil pan mounting bolts in the numerical sequence shown in the figure. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
17. Install oil strainer. NOTE: Use a new O-ring.
18. Apply fluid gasket to mating surface of lower oil pan. Fluid gasket: THREE BOND 1280B Fluid gasket application diameter: 5.0+/-1.0 mm (0.097+/-0.039 in)
19. Tighten the lower oil pan mounting bolts in the numerical sequence shown in the figure. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
20. Install crankshaft position sensor bracket. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
21. Install crankshaft position sensor plate.
22. Install drive plate. Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 81 N.m (8.3 kgf-m, 60 ft-lb)
23. Install cylinder head assembly. Refer to «CYLINDER HEAD ASSEMBLY»(ref-208385-S09361305482005120700000) .
24. Install camshafts. Refer to «CAMSHAFT»(ref-208385-S05810713342005120700000) .
25. Install rear chain cover. Refer to «REAR CHAIN COVER»(ref-208385-S13339761462005120700000) .
26. Install crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208385-S37832612542005120700000) .
27. Install camshaft sprockets. Refer to «CAMSHAFT SPROCKET»(ref-208385-S07701704382005120700000) .
28. Install timing chain assembly. Refer to «INSTALLATION»(ref-208385-S24492764732005120700000) , Timing Chain Assembly.
29. Install front chain cover. Refer to «FRONT CHAIN COVER»(ref-208385-S10361917952005120700000) .
30. Install crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208385-S05331601292005120700000)

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1. Remove connecting rod cap.
2. Remove connecting rod bearing. CAUTION: 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. CAUTION: Arrange the removed piston rings in good order to prevent confusion.
5. Remove circlip.

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1. Install connecting rod bearings on connecting rods and connecting rod caps. CAUTION: Apply oil to the surfaces of the connecting rod bearings.
2. Install connecting rod on crankshaft. CAUTION: Position each connecting rod with the side marked facing forward.
3. Install connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: 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.
4. Installation of piston rings and oil ring

CYLINDER BLOCK

1. Visually check for cracks and damage. Especially, inspect important parts by means of red lead check.
2. Check the oil passages for clogging.
3. Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.02 mm (0.0008 in) Height after grinding: 201.95 mm (7.951 in) Standard height of cylinder block: 202 mm (7.95 in) 202 mm (7.95 in)

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1. The cylinder bore size is stamped on the cylinder block's front upper surface. CAUTION: Measurement should be performed at a temperature 20°C (68°F). NOTE: Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line in selecting a standard piston. Standard diameter: A: 89.205 - 89.215 mm (3.5120 - 3.5124 in) B: 89.195 - 89.205 mm (3.5116 - 3.5120 in) Main journal size mark Cylinder bore size mark Cylinder block RH-LH combination mark
2. How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. CAUTION: Measurement should be performed at a temperature 20°C (68°F). Taper: Limit 0.030 mm (0.0012 in) Out-of-roundness: Limit 0.01 mm (0.0004 in) Thrust direction Piston pin direction
3. When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. How to measure the outer diameter of each piston Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) CAUTION: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 39.0 mm (1.535 in) Piston outer diameter: Standard A: 89.185 -89.195 mm (3.5112 -3.5116 in) B: 89.175 -89.185 mm (3.5108 -3.5112 in) 0.25 mm (0.0098 in) oversize 89.425 - 89.435 mm (3.5207 -3.5211 in) 0.50 mm (0.0197 in) oversize 89.675 - 89.685 mm (3.5305 - 3.5309 in)
5. Calculate the clearance between cylinder and piston. CAUTION: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard 0.010 - 0.030 mm (0.0004 - 0.0012 in)
6. Boring and honing If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. CAUTION: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in)

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1. Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective.
2. Measure the piston-to-cylinder clearance at each cylinder. Refer to «ASSEMBLY»(ref-208385-S33021201052005120700000) . If any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston.
3. Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in)
4. Check circlip installation groove on the piston for burr. If necessary, remove burr (A) from the groove so that piston pin can lightly move.
5. Check piston pin circlip for distortion, cracks and wear.

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1. If piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston. CAUTION: Marks are shown on the end of the top and second rings. When installing the rings to the piston, face this mark upward. The oil ring is a combined ring consisting of two rails and a spacer in between. When installing, be careful to assemble correctly.
2. Squarely place piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
3. Measure the clearance between piston ring and piston ring groove with a thickness gauge. CAUTION: Before measuring the clearance, clean the piston ring groove and piston ring.

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1. Replace connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
3. Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in)
4. Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.022 - 0.052 mm (0.0009 - 0.0020 in)
6. Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end. Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 in)
7. Replacement procedure is as follows. Remove bushing from connecting rod with ST and press. Press bushing with ST after applying oil on the periphery of bushing. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. After completion of reaming, clean bushing to remove chips.

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1. Clean crankshaft completely and check for cracks by means of red lead check etc., and replace if defective.
2. Measure the crankshaft bend, and correct or replace if it exceeds the limit. CAUTION: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position crankshaft on these bearings and measure crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
3. Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary. When grinding crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin and crank journal: Out-of-roundness 0.020 mm (0.0008 in) or less Grinding limit 0.250 mm (0.0098 in)
4. Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in)
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
6. Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace defective bearing with an undersize one, and replace recondition crankshaft as necessary.