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
|
Service of the block of cylinders
Preparation, removal of external components
The block of cylinders and the accompanying components. SOHC engines
The block of cylinders and the accompanying components. DOHC engines
Blocking of a bent shaft at an otpuskaniye of bolts of fastening of a flywheel / a driving disk by means of a special bracket
Separation of assembly of the oil pump from the block of cylinders by means of the screw-driver with a flat sting
|
|
|
|
1. Remove a flywheel / a driving disk, - blocking of a bent shaft is made by means of a special bracket.
2. Uncover an oil separator.
3. Remove perepuskny a branch pipe of a cooling path.
4. Remove assembly of the water pump.
5. Remove assembly of the oil pump from the block of cylinders, - for office of the pump use the screw-driver with a flat sting, - try not to damage the interfaced surfaces.
6. Turn the block upside down and turn out bolts of fastening of the pallet of a case. |
| 7. The office of the pallet, in order to avoid damage of the interfaced surfaces, is made by a poddevaniye by his special shovel. |
|
8. Remove a basic arm of a maslozabornik.
9. Remove a maslozabornik.
10. Remove a maslootrazhatelny partition.
11. Remove an oil filter.
12. On DOHC engines disconnect an U-shaped tube from the block, then turn out bolts of fastening of a branch pipe of a cooling path, pick up the connecting phone, the oil cooler and a tube of supply of cooling liquid from the oil cooler. |
|
Dismantling
Piston fingers and coupling bolts of semi-blocks
The reversing of traffic jams of technological openings is made by means of a six-sided prutkovy key on 14 mm
|
|
|
|
| 1. By means of a six-sided prutkovy key on 14 mm turn out traffic jams of technological openings. |
| 2. Having turned a bent shaft, transfer pistons of the first and second cylinders to provisions of NMT, then through technological openings in sidewalls of the block take spring lock rings and by means of special adaptation remove piston fingers. |
|
3. Working in a similar manner, take fingers of pistons No. No. 3 and 4.
|
|
At assembly all components have to be installed strictly as their initial installation! |
4. Turn out the bolts which are pulling together semi-blocks from the 2nd and 4th then on two-three turns weaken the bolts which are pulling together semi-blocks from the 1st and 3rd cylinders. |
|
Extraction of internal components of the block
Scheme of installation of internal components of the block of cylinders
Components of conrod and piston groups
|
|
1. Turn the block cylinders No. No. 1 and 3 up, then turn out the weakened earlier coupling bolts.
2. Separate the right semi-block from left, - track that rods did not damage the top heads a mirror of cylinders.
3. Remove a back epiploon of a bent shaft.
4. Take a bent shaft assembled with rods.
5. Take from beds in the block inserts of radical bearings, - press off inserts from outside, opposite to the lock lock.
|
|
At assembly inserts have to be established strictly on the former places! |
6. The wooden handle of the hammer push out pistons from cylinders, - at assembly pistons have to be installed strictly on the former places.
7. Uncover the lower heads of rods, take inserts of conrod bearings.
|
|
At assembly all components have to be installed strictly on the former places! |
8. From openings under installation of piston fingers take the remained lock rings. |
|
Check of a condition of components
Block of cylinders
|
|
| 1. Attentively examine semi-blocks on existence of cracks and mechanical damages. In case of need give the block to a workshop of car service for performing defectoscopy by means of the special equipment.
2. Check passability of maslotok.
3. Estimate degree of not planeness of the interfaced surfaces of semi-blocks. Compare results of measurements to requirements of Specifications in case of need give the block to a pro-point. |
|
Cylinders and pistons
Dimensional marking is applied on a forward wall of the block
|
|
|
|
1. Dimensional marking is beaten out on the forward party of the block. Pistons of the standard sizes are divided into three dimensional groups (And, In and C) and have to be established in the cylinders marked as appropriate.
2. When replacing worn-out pistons replaceable elements are selected proceeding from the size of a landing gap in the cylinder. Measure the internal diameter of each of cylinders in four sections perpendicular to an axis of a piston finger (in 10, 45, 80 and 115 mm from an axis of a piston finger).
|
|
Measurements should be performed at a temperature of 20 °C. |
3. Having prepared a set of pistons of the repair size, measure diameters of their skirts in the plane of a perpendicular axis of a piston finger at h distance = 52.0 mm from the bottom.
|
|
You perform measurement at a temperature of 20 °C. |
4. Having compared results of measurements to requirements of Specifications determine sizes of landing gaps of pistons, estimate conicity and ovality of cylinders, in case of need give the block to a pro-point.
|
|
All cylinders have to be pierced to the identical repair size! If boring without excess of the maximum permissible size is not possible, the block is subject to replacement! |
5. Before assembly of the engine the honingovaniye of mirrors of cylinders for the purpose of achievement of the correct landing to them of piston rings providing due tightness of combustion chambers is without fail carried out.
|
|
In the absence of near at hand necessary tools or unwillingness to independently carry out a honingovaniye, work for quite moderate payment can be charged to experts of a workshop of car service. |
6. Two types of khans for processing of mirrors of cylinders are issued: хон like "the bottle brush" and, more traditional, superficial хон in the form of a nozzle with the sprung grinding stones. Both tools provide necessary quality of processing of mirrors of cylinders though use of the first is more preferable to the inexperienced mechanic. Also enough rags, special honingovochny or just liquid lubricating oil, and also the electric drill as the drive for honingovochny nozzles will be required. Act in the following order:
a) Clamp хон in an electric drill cartridge, reduce the sprung grinding stones / rods of the brush of a nozzle and fill the last in the cylinder.
|
|
Do not forget to put on goggles or a front guard! |
|
| b) Plentifully moisten a mirror of the processed cylinder with oil, include a drill and begin to make a nozzle back and forth motions in the cylinder. Speed of vertical movement of a hon has to provide drawing on a surface of a mirror of the cylinder of a mesh pattern with the angle of crossing of the parties of a cell about 60 °. Do not feel sorry for oil and try not to remove more material from a surface of walls of the cylinder, than it is really necessary for achievement of the required result. |
|
|
|
Manufacturers of piston rings can impose own requirements to the angle of crossing of the parties of a cell of a mesh pattern, - attentively study the instruction on packing of a remnabor. |
c) Do not take хон from the cylinder to a full stop of a drill! Continue to make back and forth motions by a nozzle until it does not stop rotating. After a stop of a drill squeeze grinding stones and take хон from the cylinder. When using of the khan like "bottle brush" wait for a full stop of a drill, then take a nozzle, continuing to rotate manually a cartridge in the normal direction.
d) Wipe with rags a mirror of the cylinder and you pass to a following honingovaniye.
7. Upon completion of processing, use a file for removal of facets from the upper edges of cylinders, - this processing is made with the purpose there were no difficulties with gas station in cylinders of pistons with the rings which are put on them. Observe extreme care, - do not scratch a file a cylinder mirror.
8. In conclusion all block has to be washed carefully out by warm solution of soap water.
|
|
Cylinders can be considered washed out when after carrying out on a mirror the gray raid does not remain the white rags moistened with oil on it. Do not forget to clean a cylindrical brush all oil openings and channels, then wash out the block a water stream under a pressure. |
9. After washing carefully dry the block and oil the pierced surfaces for protection them from corrosion. Prior to assembly of the engine wrap the block in a pure plastic bag.
10. Previously pistons and rods have to be carefully cleared. Rings need to be removed from pistons.
|
|
Piston rings are subject to replacement without fail. |
11. By means of special adaptation remove rings from pistons, - try not to damage walls of the last incidentally.
12. Scratch out traces of coal deposits from the bottoms of pistons. After removal of the main layer of deposits smooth out a surface manually a wire brush or a piece of a fine-grained emery paper.
|
|
Do not use for cleaning made of soft material and pistons easily subject to an erosion wire nozzles to the electric drill at all! |
|
| 13. By means of special adaptation clean flutes under installation of rings on pistons. It is alternatively possible to use a fragment of an old piston ring for this purpose, however be careful, - do not scratch a bottom and walls of a flute and do not cut fingers. |
|
14. Having removed the main deposits, wash out conrod assemblies by solvent and carefully dry them, whenever possible with use of compressed air.
|
|
When using compressed air do not forget to put on goggles! Check passability of maslovozvratny openings in back walls of flutes under installation of piston rings, and also oil openings in the lower heads of rods. |
15. If walls of pistons and a mirror of cylinders are not damaged and excessively are not worn-out, and the block of the engine was not pierced and not replaced, need for replacement of pistons also disappears. Normal wear of pistons is shown in the form of vertical traces of development on a persistent surface and a small weak point of landing of the top compression ring in the flute. Do not forget that replacement of piston rings is made without fail, regardless of their state.
16. Attentively examine each of pistons on existence of cracks in a skirt, around ledges under installation of piston fingers and around an arrangement of rings.
17. Check persistent surfaces of a skirt of the piston for existence of scratches, the bottom - on existence of through openings and progar on edge. Presence of scratches on a skirt can be regarded as a sign of long overheats of the engine, or too early ignition of air-fuel mix, - check serviceability of functioning of the cooling system. Progara at the edges of the bottom are the certificate of a detonation. Anyway, the cause of the revealed violation has to be removed in order to avoid a recurrence. Also leak of the soaked-up air, the wrong configuration of air-fuel mix, violation of installation of a corner of an advancing of ignition, the wrong functioning of systems of ignition and EGR can act as the possible reasons of education listed defects.
18. Pointed corrosion of pistons in the form of cavities speaks about hit in combustion chambers and/or a case of the engine of cooling liquid. Besides, take care that the cause of internal leaks was removed. |
|
Check of a gap of landing of a piston ring in a flute
Design of piston rings
|
|
|
|
| 1. Estimate the size of a side gap of landing of piston rings in the flutes for what enclose a new ring outside in the flute on the piston and the probe of lezviyny type measure the remaining gap. Repeat measurement in two-three points on flute perimeter. Remember that the top compression ring differs from the second (lower), - pay attention to marking in the form of letters of R and N. If the size of a gap exceeds admissible value (see Specifications) pistons are subject to replacement. |
| 2. Execute check of gaps in locks of piston rings: fill a ring in the cylinder and level it perpendicularly, the piston bottom, having drowned on depth about 15 mm. Measurement is performed by means of the probe of lezviyny type. Serially define gaps in locks of all rings. Compare results of measurements to requirements of Specifications in case of need chisel locks a file, having clamped a ring in a vice, - pull a file only from within a ring outside! |
|
| 3. Check freedom of landing in pistons of fingers of the top heads of rods. At a temperature of 20 °C fingers have to refuel in landing openings in pistons by effort of a thumb, - if this condition is not satisfied, make replacement of the corresponding fingers. |
|
Rods
|
|
If the engine is under repair for the purpose of elimination of knock of fingers, replace conrod assemblies. |
Determination of sizes of a bend and twisting of a rod at the special stand
Replacement of plugs of the top heads of a rod is made by means of a press and a special mandrel
|
|
| 1. Check rods for existence of cracks and other mechanical damages. In case of detection of this sort of defects make replacement.
2. By means of special measuring set estimate the size of a residual bend and twisting of a rod.
3. Establish a rod with inserts on the corresponding neck of a bent shaft and by means of the probe of lezviyny type determine the size of an axial side play of assembly. Compare results of measurements to requirements of Specifications in case of need replace a worn-out rod.
4. Estimate a condition of inserts of conrod bearings. Make sure of lack of zadir, agnails, it is erose, signs of an overheat and other defects, - excessively worn-out inserts are subject to replacement.
5. Measure the size of working gaps of each of conrod bearings by means of the calibrated wire from the Plastigage set, - follow instructions of manufacturers. Compare results of measurements to requirements of Specifications in case of need replace inserts standard or repair the corresponding size.
6. Estimate a condition of plugs in the top heads of rods. Make sure of density of landing of plugs in rods.
7. The worn-out or damaged plugs are subject to replacement: the vypressovyvaniye of plugs is made by means of a special drift and a press. Before landing the new plug is oiled by pure motive. Drill two openings with a diameter of 3 mm in the plug and develop the internal surface of the plug. Having finished the procedure, carefully clear the plug of shaving. |
|
Bent shaft and radical bearings
|
|
|
|
| 1. Carefully wipe a bent shaft and attentively examine it on existence of cracks, in case of need give a shaft to a workshop of car service for performing defectoscopy with use of the special equipment. In case of detection of defects the shaft is subject to replacement. |
| 2. By means of the dial measuring instrument of plunger type determine a shaft deflection by the size of a beating of an average radical neck. |
|
|
|
In the absence of near at hand special V-shaped measuring support, put inserts of the 1st and 5th radical bearings in one of semi-blocks, and lower in them a shaft. Compare result of measurement to requirements of Specifications. In case of need give a shaft to a pro-point, or make its replacement. |
3. Check radical and conrod necks of a shaft for existence of signs of wear and damages. By measurement of diameters of necks in various sections and the planes determine sizes of conicity and ovality. Compare results of measurements to requirements of Specifications. In case of need give a shaft to a pro-point, - after a pro-point the sizes of necks have to correspond to one of standard repair types (see Specifications).
4. Attentively examine inserts of radical bearings on existence of traces of an overheat, it is erose, estimate degree of wear of working surfaces.
5. By means of the calibrated wire from the measuring Plastigage set determine sizes working gaps in radical bearings. Compare results of measurements to requirements of the Specification. In case of need replace inserts repair, or give a shaft to a pro-point. |
|
Assembly
Bent shaft and conrod and piston groups
Assembly of a bent shaft and conrod and piston group
|
|
|
|
1. Establish inserts of bearings in the lower heads of rods and their cover. Oil surfaces of inserts pure motive.
2. Establish rods on the corresponding necks of a bent shaft by side tags to a pin.
3. Establish covers of the lower heads and tighten fixture with the required effort. Track that tags in the form of arrows on covers specified on a shaft forward.
|
|
Each cover has to be established strictly on the rod. Before tightening of fixing nuts a carving part of hairpins should be oiled pure motive. |
|
| 4. Manually put working sections and a spring dilator of an oil scraper ring in the lower flute of the piston, then, by means of special adaptation put in the flutes the second and first (top) compression rings. |
|
|
Before installation of pistons of their ring it is necessary to develop locks as it is shown on an illustration
The scheme of installation on pistons of internal lock rings of piston fingers
|
|
|
1. Develop rings locks as shown in an illustration.
2. Put on one spring lock ring in openings under installation of a finger in each of pistons. |
|
|
|
Rings should be installed from outside, opposite to an arrangement corresponding technological in the semi-block. |
Block of cylinders
The scheme of putting sealant on the interfaced surface of semi-blocks
Install semi-blocks on the assembly stand and enclose inserts of radical bearings in their beds.
|
|
Before installation of inserts of their back and bed in semi-blocks it is necessary to clear carefully of oil and any other pollution! |
|
|
1. Oil radical necks of a shaft pure motive.
2. Lay a shaft in a bed of the semi-block of the 1st and 3rd cylinders.
3. Grease the interfaced surface sealant like Tree-bond 1215 and install on it the semi-block of the 2nd and 4th cylinders.
|
|
Do not allow hit of sealant in flutes under landing of sealing rings, bearings and maslotok! |
4. Screw the coupling bolts established from the semi-block of the 2nd and 4th cylinders and tighten them previously with effort of 20 Nanometers.
5. Deploy the block horizontally, screw opposite coupling bolts, then tighten all bolts with the required effort. |
|
Details of assembly of the block of cylinders
Pistons and piston fingers
|
|
|
|
1. Turn assembly of the block the first and second cylinder up.
2. You will check a bent shaft so that rods of the 1st and 2nd cylinders fell into NMT state.
3. Grease the surfaces of pistons and a mirror of cylinders with pure motive oil, press out piston rings a mandrel of the special tool and fill pistons in cylinders, - in order to avoid a vyskakivaniye of rings you watch density of pressing of a mandrel to the surface of the semi-block.
4. Oil motive a special mandrel and fill it in a technological opening in a sidewall of the corresponding cylinder. Achieve combination of an opening with an opening in the top head of a rod. |
| 5. Oil motive the corresponding piston finger and through a technological opening pass it throughout the piston and a head of a rod. |
|
6. Through a technological opening record a finger the second lock ring. Muffle an opening a special stopper.
|
|
Do not forget to replace laying of caps and to grease them before installation by liquid sealant like Three-bond 1105. |
7. Working in a similar manner, establish a piston finger of the second cylinder, then turn assembly and establish fingers of pistons of the second semi-block. |
|
Installation of external components
Details of installation of external components of the block of cylinders on the example of the SOHC engine, places of putting sealant
Water and oil pumps
|
|
1. Establish a maslootrazhatelny partition.
2. Establish a sealing ring and a maslozabornik. Tighten fixture with the required effort (10 Nanometers).
3. Establish an arm of a maslozabornik. |
| 4. Grease the surface of the pallet of a case interfaced to the block with liquid sealant like Three-bond 1207. Press the pallet to the block, screw fixture and tighten it with the required effort (5 Nanometers). |
|
| 5. Apply liquid sealant like Three-bond 1215 on the interfaced oil separator cover surface. Establish a cover, screw fixture and tighten it with the required effort (6.4 Nanometers). |
|
6. Establish a flywheel / a driving disk and tighten its fixture with the required effort (69 ÷ 75 Nanometers: for SOHC engines and 78 ÷ 84 Nanometers: for DOHC engines).
7. Establish a transmission dome.
8. Establish a new forward epiploon of a bent shaft. |
| 9. Apply sealant like Three-bond 1215 on the surface of the oil pump interfaced to the block. |
|
10. Press assembly of the pump to the block, screw fixture and tighten it with the required effort (6.4 Nanometers). Be careful, - try not to damage an epiploon.
|
|
Do not forget to establish a sealing ring and an epiploon before installation of the oil pump. Before installation track combination лысок a rotor of the pump and a bent shaft. |
|
| 11. Establish assembly of the water pump, - do not forget to replace sealing laying. Screw fixture and tighten it in strictly certain order with the required effort (10 ÷ 14 Nanometers: for SOHC engines and 12 Nanometers: for DOHC engines). |
|
12. Establish a branch pipe of a cooling path.
13. On SOHC engines establish an oil filter.
14. On DOHC engines install the oil cooler (effort of tightening of fixture: 49 ÷ 59 Nanometers), a connecting tube, a branch pipe of a cooling path, then - an oil filter.
15. Establish heads of the block of cylinders and the inlet pipeline (see above).
16. On SOHC engines install GRM drive components (see above).
17. On DOHC engines install camshafts and covers of valvate mechanisms, then - GRM drive components. |
|
|
|