Engine Mechanical (H4DO): Overhaul Subaru Outback BR рестайлинг

WHEN TIMING CHAIN ASSEMBLY IS NOT REMOVED

Note. Inspection of cam clearance should be performed while engine is cold. If the engine is removed from vehicle, performing the step 1 ) and 2 ) is not necessary.

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1. Disconnect the ground cable from battery.
2. Remove the air intake duct. Refer to «REMOVAL»(ref-565164-S20404975892013071000000) .
3. When inspecting #1 and #3 cylinders Remove the rocker cover RH. Refer to «ROCKER COVER RH»(ref-565160-S07123621472013071000000) . NOTE: When working on the vehicle, place a suitable container under the vehicle. Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the timing mark (A) on crank pulley is aligned to the 0° in timing gauge (B) on chain cover as shown in the figure, the #1 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #1 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #1 cylinder piston at TDC of compression stroke. Check the cam clearance for #1 cylinder intake, #1 cylinder exhaust and #3 cylinder exhaust. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13±0.03 mm (0.0051±0.0012 in) Exhaust Standard 0.24±0.03 mm (0.0094±0.0012 in) Turn the crank pulley by 360°. Check the clearance of #3 cylinder intake. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Standard 0.13±0.03 mm (0.0051±0.0012 in)
4. When inspecting #2 and #4 cylinders Remove the rocker cover LH. Refer to «ROCKER COVER LH»(ref-565160-S22277919802013071000000) . NOTE: When working on the vehicle, place a suitable container under the vehicle. Set #2 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the timing mark (A) on crank pulley is aligned to the 0° in timing gauge (B) on chain cover as shown in the figure, the #2 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #2 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #2 cylinder piston at TDC of compression stroke. Check the cam clearance for #2 cylinder intake, #2 cylinder exhaust and #4 cylinder exhaust. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13±0.03 mm (0.0051±0.0012 in) Exhaust Standard 0.24±0.03 mm (0.0094±0.0012 in) Turn the crank pulley by 360°. Check the clearance of #4 cylinder intake. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Standard 0.13±0.03 mm (0.0051±0.0012 in)
5. If necessary, adjust the cam clearance. Refer to «ADJUSTMENT»(ref-565160-S26573401182013071000000) .
6. After inspection, install the related parts in the reverse order of removal.

WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Note. Inspection of cam clearance should be performed while engine is cold.

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1. When inspecting #1 and #3 cylinders Remove the rocker cover RH. Refer to «ROCKER COVER RH»(ref-565160-S07123621472013071000000) . NOTE: When working on the vehicle, place a suitable container under the vehicle. Check the #1 and #3 cylinder cam clearance. CAUTION: Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand). NOTE: For cam clearance inspection, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the camshaft (cam sprocket) to be measured. Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13±0.03 mm (0.0051±0.0012 in) Exhaust Standard 0.24±0.03 mm (0.0094±0.0012 in)
2. When inspecting #2 and #4 cylinders Remove the rocker cover LH. Refer to «ROCKER COVER LH»(ref-565160-S22277919802013071000000) . NOTE: When working on the vehicle, place a suitable container under the vehicle. Check the #2 and #4 cylinder cam clearance. CAUTION: Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand). NOTE: For cam clearance inspection, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the camshaft (cam sprocket) to be measured. Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13±0.03 mm (0.0051±0.0012 in) Exhaust Standard 0.24±0.03 mm (0.0094±0.0012 in)
3. If necessary, adjust the cam clearance. Refer to «ADJUSTMENT»(ref-565160-S26573401182013071000000) .
4. After inspection, install the related parts in the reverse order of removal.

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1. Remove the engine from the vehicle. Refer to «REMOVAL»(ref-565160-S20320245162013071000000) .
2. Remove the chain cover. Refer to «REMOVAL»(ref-565160-S25461916052013071000000) .
3. When adjusting #1 and #3 cylinders Remove the timing chain RH. Refer to «TIMING CHAIN RH»(ref-565160-S15965613732013071000000) . Remove the cam carrier RH. Refer to «CAM CARRIER RH»(ref-565160-S35054171542013071000000) . Measure the thickness of valve shim using micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness. NOTE: Use a new valve shim. Intake side: S = T+1.54 x (V-0.13 mm (0.0051 in)) Exhaust side: S = T+1.69 x (V-0.24 mm (0.0094 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Install the cam carrier RH. Refer to «CAM CARRIER RH»(ref-565160-S42795824172013071000000) . Check all the cam clearance of RH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step 2 ). NOTE: When the removing/installing of cam carrier RH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of RH side is necessary. Refer to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-565160-S09545514952013071000000) for the cam clearance inspection. Cam clearance: Intake Standard 0.13±0.03 mm (0.0051±0.0012 in) Exhaust Standard 0.24±0.03 mm (0.0094±0.0012 in)
4. When adjusting #2 and #4 cylinders Remove the timing chain LH. Refer to «TIMING CHAIN LH»(ref-565160-S00647957182013071000000) . Remove the cam carrier LH. Refer to «CAM CARRIER LH»(ref-565160-S16806117752013071000000) . Measure the thickness of valve shim using micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness. NOTE: Use a new valve shim. Intake side: S = T+1.54 x (V-0.13 mm (0.0051 in)) Exhaust side: S = T+1.69 x (V-0.24 mm (0.0094 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Install the cam carrier LH. Refer to «CAM CARRIER LH»(ref-565160-S20085707152013071000000) . Check all the cam clearance of LH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step 2 ). NOTE: When the removing/installing of cam carrier LH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of LH side is necessary. Refer to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-565160-S09545514952013071000000) for the cam clearance inspection. Cam clearance: Intake Standard 0.13±0.03 mm (0.0051±0.0012 in) Exhaust Standard 0.24±0.03 mm (0.0094±0.0012 in)
5. After adjustment, install the related parts in the reverse order of removal.

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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. Refer to «REFRIGERANT RECOVERY PROCEDURE»(ref-565180-S07266244962013071000000) .
4. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-565162-S41045262652013071000000) .
5. Disconnect the ground cable from battery.
6. Remove the air intake duct. Refer to «REMOVAL»(ref-565164-S20404975892013071000000) .
7. Remove the air intake boot. Refer to «REMOVAL»(ref-565164-S05274062402013071000000) .
8. Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) which holds the mass air flow and intake air temperature sensor harness.
9. Remove the suction hose (C) from the air cleaner case (rear).
10. Remove the air cleaner case (rear).
11. Remove the radiator. Refer to «REMOVAL»(ref-565166-S33959865832013071000000) .
12. Disconnect the brake booster vacuum hose from the intake manifold.
13. Disconnect the engine harness connector. Remove the bolt securing the bulkhead harness connector bracket. Disconnect the bulkhead harness connector from the engine harness connector (black) and engine harness connector (brown).
14. Remove the bolts which secure the generator cord stay to the chain cover.
15. Disconnect the connectors (A) and (B) from the A/C compressor.
16. Disconnect the connector (A) and the terminal (B) from the generator, and disconnect the clip (C) which secures to the stay of the A/C compressor.
17. Remove the generator cord from the clip (D) and move the generator cord to the left side wheel apron.
18. Disconnect the following hoses. A/C pressure hose Refer to «REMOVAL»(ref-565180-S08675238322013071000000) . Heater inlet hose and heater outlet hose
19. Remove the V-belts. Refer to «REMOVAL»(ref-565160-S05643614912013071000000) .
20. Remove the generator. Refer to «REMOVAL»(ref-565187-S26608276672013071000000) .
21. Remove the power steering pump. Disconnect the connector from power steering pump. Remove the power steering pump together with the power steering pump bracket from the engine. Mount the power steering pump together with the power steering pump bracket on RH side wheel apron.
22. Lift up the vehicle.
23. Remove the front exhaust pipe. Refer to «REMOVAL»(ref-565184-S34357625012013071000000) .
24. Disconnect the ground cable on the engine side.
25. Remove the bolts and nuts which hold the lower side of transmission to the engine. CVT model MT model
26. Remove the starter. Refer to «REMOVAL»(ref-565187-S23832579102013071000000) .
27. 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 bolts which hold torque converter clutch to drive plate.
28. Disconnect the fuel delivery hose and evaporation hose. 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. ST 42099AE000 QUICK CONNECTOR RELEASE Remove the clip and disconnect the evaporation hose from the evaporation pipe.
29. Support the engine with a lifting device and wire ropes.
30. Remove the bolt and nut which secure engine mounting to the cradle.
31. Remove the bolts which hold the engine mounting to the engine mounting bracket.
32. Separate the engine and transmission. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. Refer to «REMOVAL»(ref-565187-S23832579102013071000000) . Attach the ST to the torque converter clutch case. (CVT model) ST 498277200 STOPPER SET Remove the bolts which hold the upper side of the transmission to the engine. CVT model MT model
33. Remove the engine from the vehicle. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. Slightly raise the engine. Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) Slowly move the engine away from engine compartment.
34. Remove the engine mounting bracket from the engine.

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1. Install the engine mounting bracket onto the engine. Tightening torque: 30 N.m (3.1 kgf-m, 22.1 ft-lb)
2. Apply a small amount of grease to splines of main shaft. (MT model) Grease: NICHIMOLY N-130 or equivalent
3. 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.
4. 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
5. Attach the bolts which secure the engine mounting to the engine mounting bracket. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
6. 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)
7. Remove the lifting device and wire ropes.
8. 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
9. Install the torque converter clutch to drive plate. (CVT model) Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to 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.
10. Install the starter. Refer to «INSTALLATION»(ref-565187-S27231661562013071000000) .
11. Lift up the vehicle.
12. Install 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
13. Connect the ground cable. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
14. Install the front exhaust pipe. Refer to «INSTALLATION»(ref-565184-S21488111002013071000000) .
15. Lower the vehicle.
16. Connect the following hoses. Fuel delivery hose and evaporation hose Heater inlet hose and heater outlet hose Brake booster vacuum hose A/C pressure hose Refer to «INSTALLATION»(ref-565180-S02271563392013071000000) .
17. Install the power steering pump. Install the power steering pump together with the power steering pump bracket onto the engine. Tightening torque: Refer to «GENERATOR BRACKET»(ref-565187-S41943908852013071000000) . Connect the connector to the power steering pump. Install the generator. Refer to «INSTALLATION»(ref-565187-S33403390092013071000000) . Install the V-belts. Refer to «INSTALLATION»(ref-565160-S15419969042013071000000) .
18. Place the generator code and install the generator cord to the clip (D).
19. Connect connector (A) and terminal (B) to the generator, and secure them to the stay of the A/C compressor with the clip (C). Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb)
20. Connect the connectors (A) and (B) to the A/C compressor.
21. Install the generator cord stay to the chain cover. NOTE: Install the generator cord stay so that the folded end (A) touches at the chain cover boss. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
22. Connect the engine harness connector. Connect the bulkhead harness connector to the engine harness connector (black) and engine harness connector (brown). Install the bolt which secures the bulkhead harness connector bracket. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
23. Install the radiator. Refer to «INSTALLATION»(ref-565166-S00903402992013071000000) .
24. Install the air intake case (rear).
25. Install the suction hose (C) to the air cleaner case.
26. Install the clip (B) which secures the air flow and intake air temperature sensor harness, and connect the connector (A) to the air flow and intake air temperature sensor.
27. Install the air intake boot. Refer to «INSTALLATION»(ref-565164-S07668311112013071000000) .
28. Install the air intake duct. Refer to «INSTALLATION»(ref-565164-S36764007252013071000000) .
29. Connect the battery ground terminal.
30. Fill engine coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-565166-S19560019672013071000000) .
31. Check the CVTF level and replenish it if necessary. (CVT model) Refer to «ADJUSTMENT»(ref-565171-S15048869762013071000000) .
32. Charge the A/C system with refrigerant. Refer to «PROCEDURE»(ref-565180-S21933146242013071000000) .
33. Install the V-belt cover. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
34. 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)

ASSEMBLY

1. Install the actuator cover to chain cover. NOTE: Use new O-rings. Apply a coat of engine oil to the O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
2. Install the camshaft position sensor. Refer to «INSTALLATION»(ref-565162-S25372439912013071000000) .
3. Install the oil control solenoid. Refer to «INSTALLATION»(ref-565162-S37030785192013071000000) .
4. Install the engine oil temperature sensor. Refer to «INSTALLATION»(ref-565162-S05814078512013071000000) .
5. Install the oil pressure switch. Refer to «INSTALLATION»(ref-565156-S39549447752013071000000) .
6. Install the engine oil filter and the oil pump union. Refer to «INSTALLATION»(ref-565156-S28167184002013071000000) .
7. Install the oil filler cap.