Subaru Forester
+ Subaru Forester cars
+ Maintenance instruction
+ Routine maintenance
- Engine
Design features and the principle of functioning of the engine, - the general information and adjustment of valvate gaps
Capital repairs and service of the engine - the general information
Check of pressure of oil
Check of compression pressure in cylinders
Diagnostics of a condition of the engine with use of the vacuum gage
Removal of the power unit from the car - preparation and precautionary measures
Removal and installation of the engine
Alternative versions of schemes of recovery repair of the engine
Order of dismantling of the engine by preparation it to capital repairs
Dismantling of the GRM drive, - removal, check of a state and installation of components
Removal, dismantling, check, assembly and installation of an axis of yokes, - SOHC engines
Removal, check of a state and installation of camshafts
Service of heads of cylinders
Service of the block of cylinders
The lubrication system - the general information
Removal, service and installation
Removal, check and installation of the oil cooler - only DOHC engines
Trial start and running in of the engine after capital repairs
+ Cooling systems, heating
+ Power supply system and release
+ Engine electric equipment
+ Control systems of the engine
+ Gear shifting box
+ Coupling, transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
|
Engine
Specifications
General parameters
Models without turbocompressor
| Model of the EJ20J engine (issue 98-00), EJ20J2 (issue 98-01) |
| Engine type |
4-cylinder, 4-stroke,
opposite petrol OHC engine,
with water cooling |
| Power, kW (h.p.) at rpm |
| EJ20J |
90 (122), at 5600 |
| EJ20J2 |
92 (125), at 5600 |
| Working volume |
1994 cm3 |
| Diameter of cylinders |
92.0 mm |
| Course of pistons |
75.0 mm |
| Extent of compression |
| J20J |
9.7: 1 |
| J20J2 |
10: 1 |
| Pressure of a compression, Bar |
9.8-13.0 |
| Ignition order |
1-3-2-4 |
| Models with a turbocompressor |
| Engine model |
EJ20, EJ205 |
| Engine type |
4-cylinder, 4-stroke,
opposite petrol DOHC engine
with a turbocompressor. Cooling – water |
| Power, kW (h.p.) at rpm |
| EJ20 |
130 (177), at 5600 |
| EJ205 |
125 (170), at 5600 |
| Working volume |
1994 cm3 |
| Diameter of cylinders |
92.0 mm |
| Course of pistons |
75.0 mm |
| Extent of compression |
| EJ20 |
8.0: 1 |
| EJ205 |
8.5: 1 |
| Pressure of a compression, Bar |
8.5-11.7 |
| Ignition order |
1-3-2-4 |
| Torque, Nanometer/(rpm) |
| Engines without turbo-supercharging |
164/(4400) |
| Engines with a turbo-supercharging |
260/(3600) |
Models with a turbocompressor
| Engine model |
EJ20, EJ205 |
| Engine type |
4-cylinder, 4-stroke,
opposite petrol DOHC engine
with a turbocompressor. Cooling – water |
| Power, kW (h.p.) at rpm |
| EJ20 |
130 (177), at 5600 |
| EJ205 |
125 (170), at 5600 |
| Working volume |
1994 cm3 |
| Diameter of cylinders |
92.0 mm |
| Course of pistons |
75.0 mm |
| Extent of compression |
| EJ20 |
8.0: 1 |
| EJ205 |
8.5: 1 |
| Pressure of a compression, Bar |
8.5-11.7 |
| Ignition order |
1-3-2-4 |
| Torque, Nanometer/(rpm) |
| Engines without turbo-supercharging |
164/(4400) |
| Engines with a turbo-supercharging |
260/(3600) |
Adjustments
Valvate gap on the cold engine
| Inlet |
0.20±0.02 mm |
| Final |
0.25±0.02 mm |
| Pressure of oil, bar |
3.0 on 5000 rpm |
| Idling turns, in min. |
| Models without turbo-supercharging |
| Models with RKPP |
650 ± 100 |
| Models with AT |
670 ± 100 |
| Models with a turbo-supercharging |
700 ± 100 |
The maximum admissible depth of depression in the inlet pipeline on single turns, kPa
| Engines without turbo-supercharging |
69.3 |
| Engines with a turbo-supercharging |
66.7 |
| Pressure of the valve of a cover of a radiator, bar |
| Models with EJ20J engines |
0.8-1.0 |
| Other models |
0.95-1.25 |
| Temperature of opening of the thermostat |
76-80 °C |
| Deflection of a belt of the generator/power steering |
9-11 mm |
| Air conditioner belt deflection |
9-10 mm |
Camshafts
| Extreme admissible size of a deflection, mm |
| SOHC engines |
0.025 |
| DOHC engines |
0.020 |
| Working gap in bearings, mm |
| SOHC engines |
| Nominal rate |
0.055 ÷ 0.090 |
| Extreme admissible value |
0.10 |
| DOHC engines |
| Nominal rate |
0.037 ÷ 0.072 |
| Extreme admissible value |
0.10 |
| Diameter of necks, mm |
| SOHC engines |
31.928 ÷ 31.945 |
| DOHC engines |
| Forward neck |
37.946 ÷ 37.963 |
| Central and back necks |
29.946 ÷ 29.963 |
| Internal diameter of bearings of support of the camshaft
|
| SOHC engines, mm |
32.000 ÷ 32.018 |
| Height of cams (N), mm |
| SOHC engines |
| Nominal rate |
|
| Inlet |
39.646 ÷ 39.746 |
| Extreme admissible size of wear |
0.15 |
| DOHC engines |
| Nominal rate |
| Inlet camshaft |
44.75 ÷ 44.85 |
| Final camshaft |
44.60 ÷ 44.70 |
| Extreme admissible size of wear |
| Inlet camshaft |
42.20 |
| Final camshaft |
42.25 |
The scheme of an arrangement of cams of inlet camshafts of the left and right heads of cylinders on DOHC engines
| Axial side play of the camshaft, mm |
| SOHC engines |
| Nominal rate |
0.03 ÷ 0.09 |
| Extreme admissible value |
0.11 |
| DOHC engines |
| Nominal rate |
0.015 ÷ 0.07 |
| Extreme admissible value |
0.1 |
Yokes of the drive of valves (SOHC engines)
| Size of a gap of landing of yokes to axes, mm |
| Nominal rate |
0.020 ÷ 0.081 |
| Extreme admissible value |
0.10 |
Head of cylinders and valvate mechanism
| Casting of a head |
Extreme admissible not planeness
the interfaced surface, mm |
0.05 |
| Allowance for grinding, mm |
0.1 |
| Standard height, mm |
| SOHC engines |
98.3 |
| DOHC engines |
127.5 |
Saddles of valves
| Width of a working facet of a saddle of the inlet valve |
| SOHC engines |
| Nominal rate |
1.0 |
| Extreme admissible value |
1.7 |
| DOHC engines |
| Nominal rate |
1.0 |
| Extreme admissible value |
1.7 |
| Width of a working facet of a saddle of the final valve |
| SOHC engines |
| Nominal rate |
1.4 |
| Extreme admissible value |
2.1 |
| DOHC engines |
| Nominal rate |
1.5 |
| Extreme admissible value |
2.2 |
The directing plugs
The size of a gap of landing of cores of valves in the directing plugs, mm |
| All engines |
| Nominal rate |
| Final valves |
0.040 ÷ 0.067 |
| Final valves |
0.040 ÷ 0.067 |
| Extreme admissible value |
0.15 |
Internal diameter of the directing plug of the valve, mm |
| SOHC engines |
6.000 ÷ 6.012 |
| DOHC engines |
6.000 ÷ 6.015 |
The size of a vystupaniye of the directing plug, mm |
| SOHC engines |
Inlet
|
20.0 ÷ 20.5 |
| Final |
16.5 ÷ 17.0 |
| DOHC engines |
12.0 ÷ 12.4 |
Valves
Width of a cylindrical part (corbel) of a plate of the valve, mm
SOHC engines |
| Inlet valves |
| Nominal rate |
1.0 |
| Extreme admissible value |
0.6 |
| Final valves |
| Nominal rate |
1.2 |
| Extreme admissible value |
0.6 |
DOHC engines |
| Inlet valves |
| Nominal rate |
1.2 |
| Extreme admissible value |
0.8 |
| Final valves |
| Nominal rate |
1.5 |
| Extreme admissible value |
0.8 |
Total length of the valve, mm |
| SOHC engines |
| Inlet valves |
120.6 |
| Final valves |
121.7 |
| DOHC engines |
| Inlet valves |
104.4 |
| Final valves |
104.7 |
Outer diameter of a core of the valve, mm |
| SOHC engines |
| Inlet valves |
5.950 ÷ 5.965 |
| Final valves |
5.945 ÷ 5.960 |
| DOHC engines |
| Inlet valves |
5.950 ÷ 5.965 |
| Final valves |
5.950 ÷ 5.965 |
Valvate springs
| Free length, mm |
| SOHC engines |
54.3 |
| DOHC engines |
44.67 |
Length under loading, mm |
| SOHC engines |
| Loading of 56.5 kg |
34.7 |
| Loading of 56.5 kg |
34.7 |
| DOHC engines |
| Loading of 22.5 kg |
33.0 |
| Loading of 52.1 kg |
26.6 |
| Extreme admissible size of violation of a tortsovka (all engines), hail (mm) |
2.5 (1.9) |
Maslootrazhatelny caps
Color marking |
| Color of a rubber external face surface |
| Inlet valves |
Black |
| Final valves |
Brown |
| Color of a spring part |
| Inlet valves |
White |
| Final valves |
White |
Block of cylinders
| Extreme admissible not planeness of the interfaced surfaces, mm |
0.05 |
| Allowance for grinding, mm |
0.4 |
| Diameter of cylinders, mm |
| Marking "And" |
92.005 ÷ 92.015 |
| Marking "In" |
91.995 ÷ 91.005 |
Limit admissible ovality and
conicity of cylinders, mm |
0.050 |
| Gap of landing of the piston in the cylinder at a temperature of 20 °C, mm |
| Nominal rate |
0.010 ÷ 0.030 |
| Extreme admissible value |
0.050 |
| Maximum admissible allowance for boring of cylinders, mm |
| All engines 0.5 |
|
Pistons and piston fingers
| Diameter of pistons, mm |
| Marking "And" |
91.985 ÷ 91.995 |
| Marking "In" |
91.975 ÷ 91.985 |
| The repair size with increase by 0:25 mm |
92.225 ÷ 92.235 |
| The repair size with increase by 0:25 mm |
92.225 ÷ 92.235 |
| Gap of landing of a piston finger in the piston, mm |
0.04 ÷ 0.08 |
| Gap of landing of a piston finger in the plug of the top head of a rod, mm |
| Nominal rate |
0 ÷ 0.022 |
| Extreme admissible value |
0.030 |
Gap in the lock of piston rings |
| Top compression ring, SOHC/DOHC |
| Nominal rate |
0.20 ÷ 0.35/0.20 ÷ 0.26 |
| Extreme admissible value |
1.0 |
| Average compression ring |
| Nominal rate |
0.35 ÷ 0.50 |
| Extreme admissible value |
1.0 |
| Oil scraper ring |
|
| Nominal rate |
0.20 ÷ 0.70 |
| Extreme admissible value |
1.5 |
Gap of landing of compression rings in flutes of pistons, mm |
| Top ring |
| Nominal rate |
0.04 ÷ 0.08 |
| Extreme admissible value |
0.15 |
| Lower ring |
| Nominal rate |
0.03 ÷ 0.07 |
| Extreme admissible value |
0.15 |
Rods
| Extreme admissible values of sizes of a bend and twisting of a bar on length of 100 mm, mm |
0.10 |
| Axial side play of a rod on a pin of a bent shaft, mm |
| Nominal rate |
0.70 ÷ 0.330 |
| Extreme admissible value |
0.4 |
| Working gap in the conrod bearing, mm |
| Nominal rate, SOHC/DOHC |
0.010 ÷ 0.038/0.02 ÷ 0.046 |
| Extreme admissible value |
0.05 |
Bent shaft, radical and conrod bearings bearings
Extreme admissible value
deflection of a shaft, mm |
0.035 |
Extreme admissible size
ovality of a radical neck, mm |
0.02 |
Extreme admissible conicity
radical neck, mm |
0.07 |
Limit admissible allowance
on grinding of a radical neck, mm |
0.25 |
| Diameter of radical necks, mm |
| Standard size |
59.992 ÷ 60.008 |
| The repair size (with reduction by 0:03 mm) |
59.962 ÷ 59.978 |
Repair size
(with reduction by 0:05 mm) |
59.942 ÷ 59.958 |
Repair size
(with reduction by 0:25 mm) |
59.742 ÷ 59.758 |
Thickness of inserts of radical bearings in a middle part, mm |
| Standard size |
| Inserts of the 1st and 5th bearings |
1.998 ÷ 2.011 |
| Inserts of the 2nd, 3rd and 4th bearings |
2.000 ÷ 2.013 |
| The repair size (with reduction by 0:03 mm) |
| Inserts of the 1st and 5th bearings |
2.017 ÷ 2.020 |
| Inserts of the 2nd, 3rd and 4th bearings |
2.019 ÷ 2.022 |
| The repair size (with reduction by 0:05 mm) |
| Inserts of the 1st and 5th bearings |
2.027 ÷ 2.030 |
| Inserts of the 2nd, 3rd and 4th bearings |
2.029 ÷ 2.032 |
| The repair size (with reduction by 0:25 mm) |
| Inserts of the 1st and 5th bearings |
2.127 ÷ 2.130 |
| Inserts of the 2nd, 3rd and 4th bearings |
2.129 ÷ 2.132 |
| The size of an axial side play in the central (persistent) bearing, mm |
| Nominal rate |
0.030 ÷ 0.115 |
| Extreme admissible value |
0.25 |
| Working gaps in radical bearings, mm |
| Nominal rate |
0.010 ÷ 0.030 |
| Extreme admissible value |
0.040 |
| Diameter of conrod necks, SOHC/DOHC, mm |
| Standard size |
51.984 ÷ 52.000/47.984 ÷ 48.000 |
The repair size (with reduction
on 0:03 mm) |
51.954 ÷ 51.970/47.954 ÷ 47.970 |
The repair size (with reduction
on 0:05 mm) |
51.934 ÷ 51.950/47.934 ÷ 47.950 |
The repair size (with reduction
on 0:25 mm) |
51.734 ÷ 51.750/47.734 ÷ 47.750 |
Thickness of inserts of conrod bearings in a middle part, mm |
| Standard size |
| SOHC engines |
1.492 ÷ 1.501 |
| DOHC engines |
2.000 ÷ 2.013 |
| The repair size (with reduction by 0:03 mm) |
| SOHC engines |
1.510 ÷ 1.513 |
| DOHC engines |
1.505 ÷ 1.508 |
| The repair size (with reduction by 0:05 mm) |
| SOHC engines |
1.520 ÷ 1.523 |
| DOHC engines |
1.515 ÷ 1.518 |
| The repair size (with reduction by 0:25 mm) |
| SOHC engines |
1.620 ÷ 1.623 |
| DOHC engines |
1.615 ÷ 1.618 |
Lubrication system
General parameters |
| Volume during the changing of motive oil, l |
| SOHC engines |
4.5 |
| DOHC engines |
5.2 |
Oil pump |
| Type |
Rotor, trokhoidny type,
with internal gearing |
| Number of teeths |
| Internal gear wheel (rotor) |
9 |
| External gear wheel (rotor) |
10 |
| Diameter of an external rotor, mm |
78 |
| Thickness of an external rotor, mm |
| SOHC engines |
9 |
| DOHC engines |
10 |
| Gap size between tops of teeths of rotors, mm |
| Nominal rate |
0.04 ÷ 0.14 |
| Extreme admissible value |
0.18 |
| Gap size between the forming surface of an external rotor and the case, mm |
| Nominal rate |
0.10 ÷ 0.175 |
| Extreme admissible value |
0.20 |
| Size of an axial side play of an internal rotor, mm |
| Nominal rate |
0.02 ÷ 0.07 |
| Extreme admissible value |
0.12 |
The account and pressure head characteristic of the pump at various turns of the engine and temperature of oil of 80 °C |
| SOHC engines |
| 600 rpm |
4.2 l/min on 98 kPa |
| 5000 rpm |
42.0 l/min on 294 kPa |
| DOHC engines |
| 600 rpm |
4.6 l/min on 98 kPa |
| 5000 rpm |
47.0 l/min on 294 kPa |
Oil filter
| Type |
Full-line |
| The total area of the filtering element, cm2 |
1000 |
| Pressure of operation of the perepuskny valve, kPa |
156 |
| Outer diameter, mm |
80 |
| Height, mm |
70 |
| Diameter of a connecting carving |
M20 h1.5 |
Oil cooler (only DOHC engines)
| Type |
Water oil |
| Diameter, mm |
10 |
| Size of the heat exchanger, mm |
93 |
The reducing valve in the highway of hydraulic proofreaders of valvate gaps
| Pressure of operation, kPa |
69 |
| Free length of a valvate spring, mm |
| SOHC engines |
71.8 |
| DOHC engines |
73.7 |
| Length of a valvate spring in working order, mm |
| SOHC engines |
54.7 |
| DOHC engines |
54.7 |
| Effort of preliminary compression at installation, N |
| SOHC engines |
77.08 |
| DOHC engines |
93.2 |
Oil pressure sensor
| Type |
Membrane and contact |
| Pressure of operation, kPa (kg/cm2) |
14.7 (0.15) |
| Extreme pressure, kPa (kg/cm2) |
more than 981 (10.0) |
Efforts of tightening of threaded connections, Nanometer
Are provided also in the text of the Head on accompanying illustrations.
Bolts of a head of cylinders |
| In a cross order |
| Stage |
1 29 Nanometer |
| Stage |
2 69 Nanometer |
| Stage 3 |
to turn off on a turn floor |
| Stage 4 |
to turn off on a turn floor |
| Stage 5 |
average 2 bolts of 34 Nanometers, other 4 bolts of 15 Nanometers |
| Stage 6 |
90 ° |
| Stage 7 |
90 ° |
| Bolts of covers of radical bearings of the crankshaft |
| 10 mm |
47±3 Nanometer |
| 8 mm |
25±2 Nanometer |
| 6 mm |
6.4 Nanometer |
| Bolts of covers of rods |
| Stage 1 |
21-23 Nanometer |
| Stage 2 |
43-46 Nanometer |
| Flywheel / driving disk |
69-75 |
| The oil pump to the block of cylinders |
6 |
| Case pallet |
5 |
| Case pallet stopper |
44 |
| Coupling basket to a flywheel |
14-17 |
| Crankshaft pulley |
122-137 |
| Cam-shaft gear wheel |
73-83 |
Cam-shaft bed cover |
| models without turbocompressor |
| M6 |
10 |
| M8 |
18 |
| models with a turbocompressor |
18-22 |
| Cover of levers of a cam-shaft |
| models without turbocompressor |
4-6 |
| models with a turbocompressor |
5 |
| The inlet pipeline to a head of cylinders |
23-27 |
| The final pipeline to a head of cylinders |
34-44 |
| Spark plugs |
21 |
| Lambda probe |
| models without turbocompressor |
18-24 |
| models with a turbocompressor |
41-47 |
| Detonation sensor |
| models without turbocompressor |
21-26 |
| models with a turbocompressor |
6 |
|
|