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Engine Mechanical (H4SO - 2.5L SOHC): Adjustments Subaru Outback BR

Mechanical 23 illustrations ~1462 words

ADJUSTMENT

CAUTIONIf engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

Note. Adjustment of valve clearance should be performed while engine is cold.

Scheme 9

Scheme 9
Scheme 9
  1. Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke.
  2. Adjust the #1 cylinder valve clearance. Loosen the valve rocker nut and screw. Set a suitable thickness gauge. While noting the valve clearance, tighten the valve rocker adjusting screw. When the specified valve clearance is obtained, tighten the valve rocker nut. NOTE: Insert a thickness gauge in a direction as horizontal as possible with respect to the valve stem end face. Lift up the vehicle and adjust the exhaust valve clearances. Valve clearance (adjustment value): Intake 0.20±0.04 mm (0.0079±0.0016 in) Exhaust 0.25±0.04 mm (0.0098±0.0016 in) Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb)
  3. Adjust the valve clearance in #3, #2 and #4 cylinder in the same adjustment procedure as #1 cylinder in this order. NOTE: Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. By rotating the crank pulley clockwise every 180° from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order.
  4. Ensure the valve clearances of each cylinder are within specifications. If necessary, readjust the valve clearances.
  5. After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

Scheme 10

Scheme 10: REMOVAL
Scheme 10: REMOVAL

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Scheme 29
  1. Change the front hood damper mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
  2. Remove the V-belt covers.
  3. Collect the refrigerant from A/C system. Ref. to «REFRIGERANT RECOVERY PROCEDURE»(ref-371912-S27381168332010091900000) .
  4. Release the fuel pressure. Ref. to «RELEASING OF FUEL PRESSURE»(ref-371892-S35824116682010091900000) , PROCEDURE, Fuel.
  5. Disconnect the ground cable from battery.
  6. Open the fuel filler lid and remove the fuel filler cap.
  7. Remove the air intake duct. Ref. to «REMOVAL»(ref-371894-S28286124812010091900000) , Air Intake Duct.
  8. Remove the air intake boot assembly. Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
  9. Remove the radiator. Ref. to «REMOVAL»(ref-371897-S36238138202010091900000) , Radiator.
  10. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371916-S00119671682010091900000) , Front Exhaust Pipe.
  11. Lower the vehicle.
  12. Remove the bolt, and disconnect the bulkhead harness connector from the engine harness connector and rear engine hanger.
  13. Slide the engine harness connector in the direction of the arrow and remove it from the rear engine hanger.
  14. Disconnect connector (A) and terminal (B) from the generator, and remove the generator cord from clip (C).
  15. Disconnect connector (D) from the A/C compressor.
  16. Remove the clip which secure the generator cord to the intake manifold protector LH.
  17. Disconnect the following hoses. A/C pressure hose Ref. to «REMOVAL»(ref-371912-S20198905942010091900000) , Hose and Pipe. Brake booster vacuum hose Heater inlet hose and heater outlet hose
  18. Lift up the vehicle.
  19. Disconnect the ground cable on the engine side.
  20. Lower the vehicle.
  21. Separate the torque converter clutch from the drive plate. (CVT model) Remove the service hole plug. Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the four bolts which hold torque converter clutch to the drive plate.
  22. Disconnect the fuel delivery hose (A) and evaporation hose (B). CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose (A). ST 42099AE000 QUICK CONNECTOR RELEASE Remove the clip and disconnect the evaporation hose (B) from the evaporation pipe.
  23. Support the engine with a lifting device and wire ropes.
  24. Remove the stopper rod.
  25. Remove the bolt and nut which secure engine mounting to the cradle.
  26. Lift up the vehicle. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time.
  27. Remove the bolts which secure the engine mounting onto the engine, and remove the engine mounting.
  28. Remove the bolts and nuts which hold the lower side of transmission to the engine. CVT model MT model
  29. Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time.
  30. Support the transmission with a garage jack. NOTE: Fine adjustment of the transmission height can be performed with this operation.
  31. Separation of engine and transmission CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. Ref. to «REMOVAL»(ref-371915-S27522616522010091900000) , Starter. Attach the ST to the torque converter clutch case. (CVT model) ST 498277200 STOPPER SET
  32. Remove the bolts which hold the upper side of the transmission to the engine. CVT model MT model
  33. Remove the engine from vehicle. Slightly raise the engine. Adjust the height of the transmission with garage jack. Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) Move the engine from engine compartment slowly. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31
  1. Apply a small amount of grease to splines of main shaft. (MT model) Grease: NICHIMOLY N-130 or equivalent
  2. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  3. Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) CVT model MT model
  4. Remove the garage jack.
  5. Remove the ST from torque converter clutch case. (CVT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
  6. Install the starter. Ref. to «INSTALLATION»(ref-371915-S06872456192010091900000) , Starter.
  7. Lift up the vehicle. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time.
  8. Attach the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) CVT model MT model
  9. Set the engine mounting, and tighten the bolts which hold engine mounting to the engine. Tightening torque: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
  10. Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time.
  11. Attach the bolts and nuts which secure engine mounting to the cradle. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
  12. Install the stopper rod. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
  13. Remove the lifting device and wire ropes.
  14. Install the torque converter clutch to drive plate. (CVT model) Insert the wrench into the crank pulley bolt, and rotate the crank pulley to attach the four bolts which hold torque converter clutch to the drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Fit the plug to service hole.
  15. Lift up the vehicle.
  16. Install the engine harness cover, and connect the ground cable. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
  17. Lower the vehicle.
  18. Connect the following hoses. Fuel delivery hose Evaporation hose Heater inlet hose and heater outlet hose Brake booster vacuum hose A/C pressure hose Ref. to «INSTALLATION»(ref-371912-S00821492682010091900000) , Hose and Pipe.
  19. Install the clip which secure the generator cord to the intake manifold protector LH.
  20. Connect connector (D) to the A/C compressor.
  21. Install the generator cord to clip (C), and connect connector (A) and terminal (B) to the generator. Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb)
  22. Connect the engine harness connector to the bulkhead harness connector, attach it to the rear engine hanger, and fasten with bolt. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
  23. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371916-S33619852892010091900000) , Front Exhaust Pipe.
  24. Install the radiator. Ref. to «INSTALLATION»(ref-371897-S40246255102010091900000) , Radiator.
  25. Install the air intake boot assembly. Ref. to «INSTALLATION»(ref-371894-S23105748052010091900000) , Air Intake Boot.
  26. Install the air intake duct. Ref. to «INSTALLATION»(ref-371894-S07613473472010091900000) , Air Intake Duct.
  27. Connect the ground cable to battery.
  28. Fill engine coolant. Ref. to «FILLING OF ENGINE COOLANT»(ref-371897-S13253157322010091900000) , REPLACEMENT, Engine Coolant.
  29. Charge the A/C system with refrigerant. Ref. to «PROCEDURE»(ref-371912-S05881540232010091900000) , Refrigerant Charging Procedure.
  30. Check the CVTF level and replenish it if necessary. (CVT model) Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.
  31. Install the V-belt cover.
  32. Change the front hood damper mounting position from (B) to (A), and close the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)

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