Engine Mechanical (H4SO): Other — Subaru Outback BP рестайлинг (2006-2009)

CAUTION

Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
Remove contamination including dirt and corrosion before removal, installation or disassembly.
Keep the disassembled parts in order and protect them from dust and dirt.
Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
Be sure to tighten fasteners including bolts and nuts to the specified torque.
Place shop jacks or rigid racks at the specified points.
Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings.
Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be reinstalled in the original positions and directions.
Bolts, nuts and washers should be replaced with new parts as required.
Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection.
Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

TOOL NAME	REMARKS
Compression gauge	Used for measuring compression.
Vacuum gauge	Used for vacuum measurement of the intake manifold.
Oil pressure gauge	Used for measuring engine oil pressure.
Fuel pressure gauge	Used for measuring fuel pressure.
Timing light	Used for measuring ignition timing.

GENERAL TOOL DESCRIPTION CHART

PROCEDURE

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

V-belt
Timing belt
Valve rocker ASSY
Camshaft
Cylinder head

FRONT SIDE BELT

Install the front side belt (C), and tighten the slider bolt so as to obtain the specified belt tension. INSPECTION, V-belt .>
Tighten the lock bolt (A).
Tighten the slider bolt (B). Tightening torque: Lock bolt (A) 25 N.m (2.5 kgf-m, 18.1 ft-lb) Slider bolt (B) 8 N.m (0.8 kgf-m, 5.8 ft-lb)

REAR SIDE BELT

Install the belt tensioner.
Install the rear side belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. INSPECTION, V-belt .>
Tighten the lock nut (A). Tightening torque: Lock nut (A) 23 N.m (2.3 kgf-m, 17.0 ft-lb)

Scheme 211

Scheme 211: INSPECTION

Scheme 212

Replace the belts, if crack, fraying or wear is found.
Remove the V-belt cover and reservoir tank, (with belt tension gauge)
Check the V-belt tension and adjust it if necessary by changing the generator installing position or idler pulley installing position. Belt tension (with belt tension gauge): (A) When installing new parts: 640 - 780 N (65 - 80 kgf, 144 - 775 lb) At inspection 490 - 640 N (50 - 65 kgf, 110 - 144 lb) (B) When installing new parts: 650 - 750 N (66 - 76 kgf, 146 - 169 lb) At inspection 350 - 450 N (36 - 46 kgf, 78 - 101 lb) Belt tension (without belt tension gauge): (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 in) At inspection 9 - 11 mm (0.354 - 0.433 in) (B) When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 in) At inspection 9.0 - 10.0 mm (0.354 - 0.394 in)

BELT TENSION PULLEY

Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly if faulty.
Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
Check the belt tension pulley for grease leakage.

BELT IDLER

Check the belt idler for smooth rotation. Replace if noise or excessive play occurs.
Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
Check the belt idler for grease leakage.

VALVE SEAT

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

Valve seat width W

Standard

Intake (A)

0.8 - 1.4 mm (0.03 - 0.055 in)

Exhaust (B)

1.2 - 1.8 mm (0.047 - 0.071 in)

Scheme 213

Scheme 213: VALVE SEAT

Scheme 214

Scheme 215

Scheme 215: VALVE GUIDE

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Scheme 217

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Scheme 221

Check the clearance between valve guide and stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. Clearance between the valve guide and valve stem: Standard: Intake 0.035 - 0.062 mm (0.0014 - 0.0024 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in)
If the clearance between valve guide and stem exceeds the limit, replace the valve guide or valve itself whichever shows greater amount of wear. See the following procedure for valve guide replacement. Valve guide inner diameter: 6.000 - 6.012 mm (0.2362 - 0.2367 in) Valve stem outer diameters: Intake 5.950 - 5.965 mm (0.2343 - 0.2348 in) Exhaust 5.945 - 5.960 mm (0.2341 - 0.2346 in) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267800 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER Turn the cylinder head upside down and place the ST as shown in the figure. Intake side ST 499767700 VALVE GUIDE ADJUSTER Exhaust side ST 499767800 VALVE GUIDE ADJUSTER Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. Put a new valve guide, coated with sufficient oil, in cylinder, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER Intake side ST2 499767700 VALVE GUIDE ADJUSTER Exhaust side ST2 499767800 VALVE GUIDE ADJUSTER Check the valve guide protrusion. Valve guide protrusion L: Intake 20.0 - 21.0 mm (0.787 - 0.827 in) Exhaust 16.5 - 17.5 mm (0.650 - 0.689 in) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. After reaming, clean the valve guide to remove chips. Recheck the contact condition between valve and valve seat after replacing the valve guide. ST 499767400 VALVE GUIDE REAMER

Scheme 222

Scheme 222: INTAKE AND EXHAUST VALVE

Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is outside of the specified limit. H: Intake Standard: 0.8 - 1.2 mm (0.03 - 0.047 in) Exhaust Standard: 1.0 - 1.4 mm (0.039 - 0.055 in)
Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Replace with a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 120.6 mm (4.75 in) Exhaust 121.7 mm (4.79 in)

Scheme 223

Scheme 223: VALVE SPRING

Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table.
To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top of spring using a try square. VALVE SPRING SPECIFICATION Free length mm (in) 55.2 (2.173) Tension/spring height N (kgf, lb)/mm (in) Set 235.3 - 270.7 (24 - 27.6, 52.9 - 60.8)/45.0 (1.772) Lift 578.9 - 639.9 (59.1 - 65.3, 130.3 - 143.9)/34.7 (1.366) Squareness 2.5°, 2.4 mm (0.094 in) or less

Scheme 224

Scheme 224: INTAKE AND EXHAUST VALVE OIL SEAL

For the following, remove the oil seal from the valve guide and replace it with a new part. When the lip is damaged. When the spring is out of the specified position. When readjusting the surfaces of valve and valve seat. When replacing the valve guide.
Place the cylinder head on ST1.
Using the ST2, press in the oil seal. ST1 498267800 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer or strike in. The intake valve oil seal and exhaust valve oil seal can be distinguished by colors. Color of rubber part: Intake [Gray] Exhaust [Green]

CYLINDER BLOCK

Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
Check the oil passages for clogging.
Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

Scheme 225

Scheme 225: CYLINDER AND PISTON

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Scheme 227

The cylinder bore size is stamped on the front upper face of the cylinder block. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston. Standard diameter: A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in)
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 as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Taper: Standard: 0.015 mm (0.0006 in) Out-of-roundness: Standard: 0.010 mm (0.0004 in)
When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
How to measure the outer diameter of each cylinder: Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 38.2 mm (1.504 in) Standard: A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in) 0.25 mm (0.0098 in) oversize: 99.745 - 99.765 mm (3.9270 - 3.9278 in) 0.50 mm (0.0197 in) oversize: 99.995 - 100.015 mm (3.9368 - 3.9376 in)
Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard: -0.010 - 0.010 mm (-0.00039 - 0.00039 in)
Boring and honing If any of the measured value of taper, out-of-roundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston. CAUTION: When any of the cylinders needs reboring, other cylinders must be bored at the same time, and replaced with oversize pistons. Do not perform boring on one cylinder only. Do not replace only a single cylinder for an oversize piston. If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention when measuring the cylinder diameter. Cylinder inner diameter boring limit (diameter): 100.005 mm (3.9372 in)

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Scheme 228: PISTON AND PISTON PIN

Scheme 229

Scheme 230

Check the piston and piston pin for breaks, cracks or wear. Replace if faulty.
Check the piston ring groove for wear and damage. Replace if faulty.
Make sure that the piston pin can be inserted into the piston pin hole with a finger at 20°C (68°F). Replace if faulty. Clearance between piston hole and piston pin: Standard: 0.004 - 0.008 mm (0.0002 - 0.0003 in)
Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
Check the piston pin snap ring for distortion, cracks and wear.

Scheme 231

Scheme 231: PISTON RING

Scheme 232

Scheme 233

If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as the piston. NOTE: The top ring and second ring have the mark to determine the direction to install on them. When installing them to piston, face this mark to the top side. Oil ring consists of the upper rail, expander and lower rail. Be careful about the direction of rail when installing the oil ring to piston.
Clean the piston ring groove and piston ring.
Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge. PISTON RING SPECIFICATION mm (in) Standard Piston ring gap Top ring 0.20 - 0.35 (0.0079 - 0.0138) Second ring 0.37 - 0.52 (0.0144 - 0.0203) Oil ring rail 0.20 - 0.50 (0.0079 - 0.0197)
Measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. PISTON RING SPECIFICATION mm (in) Standard Clearance between piston ring and piston ring groove Top ring 0.040 - 0.080 (0.0016 - 0.0031) Second ring 0.030 - 0.070 (0.0012 - 0.0028)

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Scheme 234: CONNECTING ROD

Scheme 235

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Scheme 237

Replace the connecting rod, if the large or small end thrust surface is damaged.
Check for bend or twist using a connecting rod aligner. Replace the 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)
Install the connecting rod fitted with bearing to crankshaft and measure the thrust clearance. Replace the connecting rod if the thrust clearance exceeds the standard. Connecting rod thrust clearance: Standard: 0.070 - 0.330 mm (0.0028 - 0.0130 in)
Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or under-size as necessary. (See the table below.) Connecting rod oil clearance: Standard: 0.016 - 0.044 mm (0.00063 - 0.0017 in) CONNECTING ROD SPECIFICATION Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.492 - 1.501 (0.0587 - 0.0591) 51.984 - 52.000 (2.0466 - 2.0472) 0.03 (0.0012) Undersize 1.510 - 1.513 (0.0594 - 0.0596) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) Undersize 1.520 - 1.523 (0.0598 - 0.0600) 51.934 - 51.950 (2.0446 - 2.0453) 0.25 (0.0098) Undersize 1.620 - 1.623 (0.0638 - 0.0639) 51.734 - 51.750 (2.0368 - 2.0374)
Inspect the bushing at connecting rod small end, and replace if worn or damaged.
Measure the piston pin clearance at connecting rod small end. If the measured value is not within the standard, replace it with a new part. Clearance between piston pin and bushing: Standard: 0 - 0.022 mm (0 - 0.0009 in)
The replacement procedure for the connecting rod small end bushing is as follows. Remove the bushing from connecting rod with ST and press. Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the premanufactured holes on the connecting rod. Then, ream the inside of bushing. After completion of reaming, clean the bushing to remove chips.

Scheme 238

Scheme 238: CRANKSHAFT AND CRANKSHAFT BEARING

Scheme 239

Scheme 240

Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. Replace if faulty.
Measure the bend of crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or readjust crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin Out-of-roundness: 0.003 mm (0.0001 in) Cylindricality: 0.004 mm (0.0002 in) Grinding limit: To 51.750 mm (2.0374 in) dia. Crank journal Out-of-roundness: 0.005 mm (0.0002 in) Cylindricality: 0.006 mm (0.0002 in) Grinding limit: To 59.758 mm (2.3527 in) dia. CRANK JOURNAL OUTER DIAMETER SPECIFICATION Unit: mm (in) Crank journal outer diameter Crank pin outer diameter #1, #3 #2, #4, #5 Standard Journal O.D. 59.992 - 60.008 (2.3619 - 2.3625) 59.992 - 60.008 (2.3619 - 2.3625) 51.984 - 52.000 (2.0466 - 2.0472) Bearing size (Thickness at center) 1.998 - 2.011 (0.0787 - 0.0792) 2.000 - 2.013 (0.0787 - 0.0793) 1.492 - 1.501 (0.0587 - 0.0591) 0.03 (0.0012) Undersize Journal O.D. 59.962 - 59.978 (2.3607 - 2.3613) 59.962 - 59.978 (2.3607 - 2.3613) 51.954 - 51.970 (2.0454 - 2.0461) Bearing size (Thickness at center) 2.017 - 2.020 (0.0794 - 0.0795) 2.019 - 2.022 (0.0795 - 0.0796) 1.510 - 1.513 (0.0594 - 0.0596) 0.05 (0.0020) Undersize Journal O.D. 59.942 - 59.958 (2.3599 - 2.3605) 59.942 - 59.958 (2.3599 - 2.3605) 51.934 - 51.950 (2.0446 - 2.0453) Bearing size (Thickness at center) 2.027 - 2.030 (0.0798 - 0.0799) 2.029 - 2.032 (0.0799 - 0.0800) 1.520 - 1.523 (0.0598 - 0.0600) 0.25 (0.0098) Undersize Journal O.D. 59.742 - 59.758 (2.3520 - 2.3527) 59.742 - 59.758 (2.3520 - 2.3527) 51.734 - 51.750 (2.0368 - 2.0374) Bearing size (Thickness at center) 2.127 - 2.130 (0.0837 - 0.0839) 2.129 - 2.132 (0.0838 - 0.0839) 1.620 - 1.623 (0.0638 - 0.0639)
Measure the thrust clearance of crankshaft at center bearing by using thickness gauge. If the thrust clearance is not within the standard, replace the bearing. Crankshaft thrust clearance: Standard: 0.030 - 0.115 mm (0.0012 - 0.0045 in)
Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary. Crankshaft oil clearance: Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in)

Scheme 241

Disconnect the ground cable from the battery.
Remove the air intake chamber. REMOVAL , Air Intake Chamber .>
Remove the engine harness connector from the bracket.
Disconnect the connector from the oil switching solenoid valve.
Remove the oil switching solenoid valve.
Remove the variable valve lift diagnosis oil pressure switch. REMOVAL , Variable Valve Lift Diagnosis Oil Pressure Switch .>
Remove the oil temperature sensor. REMOVAL , Oil Temperature Sensor .>
Remove the oil switching solenoid valve holder from the cylinder head.

Scheme 242

Disconnect the ground cable from the battery.
Remove the V-belts. REMOVAL, V-belt .>
Remove the crank pulley. REMOVAL, Crank Pulley .>
Remove the timing belt cover. REMOVAL, Timing Belt Cover .>
Remove the timing belt. REMOVAL, Timing Belt .>
Remove the cam sprocket. REMOVAL, Cam Sprocket .>
Remove the timing belt cover No. 2 (LH).
Disconnect the connector from the oil switching solenoid valve.
Remove the oil switching solenoid valve.
Remove the variable valve lift diagnosis oil pressure switch. REMOVAL , Variable Valve Lift Diagnosis Oil Pressure Switch .>
Remove the oil switching solenoid valve holder from the cylinder head.

RH SIDE

Install in the reverse order of removal.

Note. Use a new gasket. Apply liquid gasket to variable valve lift diagnosis oil pressure switch threads. Install the oil switching solenoid valve to the holder, then install it to the cylinder head.

Tightening torque

8 N.m (0.8 kgf-m, 5.9 ft-lb)

10 N.m (1.0 kgf-m, 7.4 ft-lb)

17 N.m (1.7 kgf-m, 12.5 ft-lb)

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Liquid gasket

THREE BOND 1324 (Part No. 004403042)

Scheme 243

Scheme 243: RH SIDE

LH SIDE