Engine Mechanical (Except Wrx): Removal & Installation Subaru XV GP

REMOVAL

1. Remove the engine from the vehicle. < Refer to «REMOVAL»(ref-560356-S11535048802013061300000) , Engine Assembly. >
2. Remove the engine mounting from the engine.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

35 N.m (3.6 kgf-m, 25.8 ft-lb)

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

Scheme 62

1. Remove the V-belt covers.
2. Remove the air intake duct. < Refer to «REMOVAL»(ref-560358-S09391633272013061300000) , Air Intake Duct. >
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-560356-S00082257512013061300000) , REMOVAL, V-belt. >
2. Remove the cap from V-belt tensioner assembly.
3. Remove the bolt securing the V-belt tensioner assembly to the generator bracket, and remove the V-belt tensioner assembly.
4. Remove the bolts which secure the idler pulley to the generator bracket and 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-560356-S39091804112013061300000) , V-belt. >
2. Remove the radiator sub fan and fan motor. < Refer to «REMOVAL»(ref-560359-S37328944852013061300000) , Radiator Sub Fan and Fan Motor. >
3. 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
4. Remove the crank pulley and remove the crank pulley boss.
5. 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 radiator sub fan and fan motor. < Refer to «INSTALLATION»(ref-560359-S36079977462013061300000) , Radiator Sub Fan and Fan Motor. >
7. Install the V-belts. < Refer to «INSTALLATION»(ref-560356-S41858146502013061300000) , V-belt. >

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-560359-S03301069572013061300000) , Radiator. > Remove the front exhaust pipe. < Refer to «REMOVAL»(ref-560376-S32386970822013061300000) , Front Exhaust Pipe. > Remove the bolts which secure the generator cord stay to the chain cover.
2. Remove the generator bracket. Remove the V-belts. < Refer to «REMOVAL»(ref-560356-S39091804112013061300000) , V-belt. > Remove the generator. < Refer to «REMOVAL»(ref-560379-S04163940592013061300000) , Generator. > Remove the generator bracket from the engine.
3. Drain the engine oil. < Refer to «REPLACEMENT»(ref-560354-S15960665222013061300000) , Engine Oil. >
4. Remove the water pump pulley. < Refer to «REMOVAL»(ref-560359-S25956835212013061300000) , Water Pump. >
5. Remove the crank pulley. < Refer to «REMOVAL»(ref-560356-S33499382622013061300000) , Crank Pulley. >
6. Disconnect the connector (A) from the exhaust camshaft position sensor RH, and remove the engine harness stay from the chain cover.
7. Disconnect the connector (A) from the intake oil control solenoid RH, connector (B) from the exhaust oil control solenoid RH, and the connector (C) from the intake camshaft position sensor RH, and then remove the clips (D) and (E) which secure the engine harness.
8. Disconnect the connectors from the oil level switch, and remove the clip (A) which secure the oil level switch harness.
9. Remove the rubber cap from the oil pressure switch.
10. Disconnect the terminal (A) from the oil pressure switch, connector (B) from the engine oil temperature sensor, connector (C) from the intake oil control solenoid LH, connector (D) from the exhaust oil control solenoid LH, connector (E) from the intake camshaft position sensor LH, and connector (F) from the exhaust camshaft position sensor LH, and remove the clips (G) and (H) which secure the engine harness.
11. Pull out the oil level gauge (A), and remove the oil level gauge guide (B) and idler pulley (C).
12. Remove the chain cover.
13. Remove the O-rings from cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
14. 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), between cam carrier and cylinder head (B), and between cylinder head and cylinder block (C) as shown. 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, connector (B) to the engine oil temperature sensor, connector (C) to the intake oil control solenoid LH, connector (D) to the exhaust oil control solenoid LH, connector (E) to the intake camshaft position sensor LH, and connector (F) to the exhaust camshaft position sensor LH, and secure the engine harness with the clips (G) and (H). NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°. Tightening torque: 1.5 N.m (0.2 kgf-m, 1.1 ft-lb)
7. Attach the rubber cap to the oil pressure switch.
8. Secure the oil level switch harness with clips (A), and connect the connectors to the oil level switch.
9. Connect the connector (A) to the intake oil control solenoid RH, connector (B) to the exhaust oil control solenoid RH, and connector (C) to the intake camshaft position sensor RH, and then secure the engine harness with the clips (D) and (E).
10. Connect the connector (A) to the exhaust camshaft position sensor RH, and install the engine harness stay to the chain cover. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
11. Install the crank pulley. < Refer to «INSTALLATION»(ref-560356-S33738184832013061300000) , Crank Pulley. >
12. Install the water pump pulley. < Refer to «INSTALLATION»(ref-560359-S02037421512013061300000) , Water Pump. >
13. Fill engine oil. < Refer to «REPLACEMENT»(ref-560354-S15960665222013061300000) , Engine Oil. >
14. 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-560379-S05534648942013061300000) , Generator. > Install the V-belts. < Refer to «INSTALLATION»(ref-560356-S41858146502013061300000) , V-belt. >
15. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Install the radiator. < Refer to «INSTALLATION»(ref-560359-S42851209242013061300000) , Radiator. > Install the front exhaust pipe. < Refer to «INSTALLATION»(ref-560376-S08119204982013061300000) , Front Exhaust Pipe. > 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)

Scheme 91

1. Remove the oil filler cap.
2. Remove the engine oil filter and the oil pump union. < Refer to «REMOVAL»(ref-560354-S21094449692013061300000) , Engine Oil Filter. >
3. Remove the oil pressure switch. < Refer to «REMOVAL»(ref-560354-S16441789112013061300000) , Oil Pressure Switch. >
4. Remove the engine oil temperature sensor. < Refer to «REMOVAL»(ref-560357-S34321704842013061300000) , Engine Oil Temperature Sensor. >
5. Remove the oil control solenoid. < Refer to «REMOVAL»(ref-560357-S38477421562013061300000) , Oil Control Solenoid. >
6. Remove the camshaft position sensor. < Refer to «REMOVAL»(ref-560357-S22931000792013061300000) , Camshaft Position Sensor. >

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

Scheme 92

1. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
2. Remove the timing chain. < Refer to «REMOVAL»(ref-560356-S16868345932013061300000) , Timing Chain Assembly. >
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-560356-S42943023022013061300000) , Timing Chain Assembly. >
3. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >