Engine Mechanical (H4DO): Removal & Installation Subaru Outback BR рестайлинг

REMOVAL

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 115

1. Remove the V-belt covers.
2. Remove the air intake duct. Refer to «REMOVAL»(ref-565164-S20404975892013071000000) .
3. Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to loosen and remove the V-belt.

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1. Remove the V-belts. Refer to «V-BELT»(ref-565160-S02212680402013071000000) .
2. Remove the bolt securing the V-belt tensioner assembly to the power steering pump bracket, and remove the V-belt tensioner assembly.
3. Remove the bolts which secure the idler pulley to the chain cover, and remove the idler pulley.

Note. When replacing a single part, perform the work with the engine assembly installed to body.

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1. Remove the V-belts. Refer to «REMOVAL»(ref-565160-S05643614912013071000000) .
2. Use the ST to lock the crank pulley, and remove the crank pulley bolt. NOTE: To prevent damaging ST1, attach the ST2 onto the ST1 as shown. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET
3. Remove the crank pulley and remove the crank pulley boss.
4. Remove the front oil seal.

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1. Apply a light coat of engine oil to the front oil seal inner periphery and outer periphery, and install the front oil seal using ST. NOTE: Use a new front oil seal. When tapping the front oil seal in, protect the radiator fin with cardboards etc. so as not to damage the radiator fin by the plastic hammer. ST 398437700 OIL SEAL INSTALLER Front oil seal press-fit position: 1 +0 -1 mm (0.0039 +0 -0.0039 in) position from chain cover end face
2. Clean the crankshaft thread using compressed air.
3. Install the crank pulley boss.
4. Apply engine oil to the crank pulley bolt seat and thread.
5. Install the crank pulley. Install the crank pulley to the crank pulley boss. NOTE: Use new O-rings. Install the crank pulley by aligning the crank pulley knock hole (A) and crank pulley boss knock pin (B). Use the ST to lock the crank pulley, and temporarily tighten the crank pulley bolt. NOTE: To prevent damaging ST1, attach the ST2 onto the ST1 as shown. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb) Draw reference lines (A) and (B) using a marker to set the socket to the crank pulley bolt as shown in the figure. NOTE: Set the socket onto the crank pulley bolt so that reference lines (A) and (B) is visible. Draw end line (C) on crank pulley using a marker at the same position as reference line (B) drawn on the socket in step ( 2 ). Use the ST to lock the crank pulley, and tighten the crank pulley bolt to the angle where reference line (A) and end line (C) are aligned. NOTE: It should be approx. 60° when reference line (A) and end line (C) are aligned. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET Tightening angle: 60°±5°
6. Install the V-belts. Refer to «INSTALLATION»(ref-565160-S15419969042013071000000) .

Note. When replacing a single part, perform the work with the engine assembly installed to body.

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1. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Remove the radiator. Refer to «REMOVAL»(ref-565166-S33959865832013071000000) . Remove the front exhaust pipe. Refer to «REMOVAL»(ref-565184-S34357625012013071000000) . Remove the engine mounting. Refer to «REMOVAL»(ref-565160-S20987039342013071000000) . Remove the bolts which secure the generator cord stay to the chain cover. Remove the power steering pump. Remove the V-belts. Refer to «REMOVAL»(ref-565160-S05643614912013071000000) . Remove the generator. Refer to «REMOVAL»(ref-565187-S26608276672013071000000) . Disconnect the connector from the power steering pump switch. Remove the power steering pump from the engine. Place the power steering pump on the right side wheel apron.
2. Drain the engine oil. Refer to «REPLACEMENT»(ref-565156-S42948795322013071000000) .
3. Remove the water pump pulley. Refer to «WATER PUMP»(ref-565166-S00533035512013071000000) .
4. Remove the crank pulley. Refer to «REMOVAL»(ref-565160-S25761037872013071000000) .
5. Remove the engine harness stay from the chain cover.
6. Disconnect the connector (A) from the oil control solenoid RH, and the connector (B) from the camshaft position sensor RH, and remove the clip (C) and clip (D) which secure the engine harness.
7. Disconnect the connectors from the oil level switch, and remove the clip (A) which secure the oil level switch harness.
8. Disconnect the terminal (A) from the oil pressure switch, and connector (B) from the engine oil temperature sensor, and connector (C) from the oil control solenoid LH, and connector (D) from the camshaft position sensor LH, and remove the clip (E) and clip (F) which secure the engine harness.
9. Pull out the oil level gauge (A), and remove the oil level gauge guide (B) and idler pulley (C).
10. Remove the chain cover.
11. Remove the O-rings from cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
12. Remove the liquid gasket from the chain cover and engine unit.

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1. Install the O-rings to cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper. NOTE: Use new O-rings. Apply a coat of engine oil to the O-rings.
2. Apply liquid gasket if there are gaps between front camshaft cap and cam carrier (A), cam carrier and cylinder head (B), and cylinder head and cylinder block (C) as shown in the figure. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
3. Apply liquid gasket to the chain cover mating surface and center boss (5 places) as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine and chain cover. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 4±0.5 mm (0.1575±0.0197 in)
4. Set the chain cover, and tighten the bolts in numerical order as shown in the figure. Tightening torque: T1: 10 N.m (1.0 kgf-m, 7.4 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
5. Install the idler pulley (C) and oil level gauge guide (B), and insert the oil level gauge (A). NOTE: Use a new O-ring to the oil level gauge guide. Apply a light coat of engine oil to the O-rings of the oil level gauge guide and the oil level gauge. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
6. Connect the terminal (A) to the oil pressure switch, and connector (B) to the engine oil temperature sensor, and connector (C) to the oil control solenoid LH, and connector (D) to the camshaft position sensor LH, and secure the engine harness with clip (E) and clip (F).
7. Secure the oil level switch harness with clips (A), and connect the connectors to the oil level switch.
8. Connect the connector (A) to the oil control solenoid RH, and the connector (B) to the camshaft position sensor RH, and secure the engine harness with clip (C) and clip (D).
9. Install the engine harness stay to the chain cover. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
10. Install the crank pulley. Refer to «INSTALLATION»(ref-565160-S19023894272013071000000) .
11. Install the water pump pulley. Refer to «WATER PUMP»(ref-565166-S37035662032013071000000) .
12. Fill engine oil. Refer to «REPLACEMENT»(ref-565156-S42948795322013071000000) .
13. Install the generator bracket. Set the generator bracket to the engine, and tighten the bolts in numerical order as shown in the figure. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb) Install the generator. Refer to «INSTALLATION»(ref-565187-S33403390092013071000000) . Install the V-belts. Refer to «INSTALLATION»(ref-565160-S15419969042013071000000) .
14. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Install the radiator. Refer to «INSTALLATION»(ref-565166-S00903402992013071000000) . Install the front exhaust pipe. Refer to «INSTALLATION»(ref-565184-S21488111002013071000000) . 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)

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1. Remove the oil filler cap.
2. Remove the engine oil filter and the oil pump union. Refer to «REMOVAL»(ref-565156-S34288620662013071000000) .
3. Remove the oil pressure switch. Refer to «REMOVAL»(ref-565156-S12731432522013071000000) .
4. Remove the engine oil temperature sensor. Refer to «REMOVAL»(ref-565162-S13061703122013071000000) .
5. Remove the oil control solenoid. Refer to «REMOVAL»(ref-565162-S15875048112013071000000) .
6. Remove the camshaft position sensor. Refer to «REMOVAL»(ref-565162-S37698409862013071000000) .
7. Remove the actuator cover from chain cover.

INSTALLATION

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 144

1. Remove the chain cover. Refer to «REMOVAL»(ref-565160-S25461916052013071000000) .
2. Remove the timing chain. Refer to «REMOVAL»(ref-565160-S27521448362013071000000) .
3. Remove the crank sprocket.

1. Install the crank sprocket. NOTE: The direction of installation is not specified for the crank sprocket.
2. Install the timing chain. Refer to «INSTALLATION»(ref-565160-S15049374962013071000000) .
3. Install the chain cover. Refer to «INSTALLATION»(ref-565160-S34689901172013071000000) .