Subaru Legacy/Outback

1999-2003 of release

Repair and operation of the car



Subaru of Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ Operation manual
+ Routine maintenance
- Engine
   Specifications
   Check of compression pressure in cylinders and tightness of the block
   Diagnostics of a condition of the engine with use of the vacuum gage
   The engine lubrication system - the general information
   + the repair Procedures which are not connected with extraction of the engine from the car - four-cylinder engines
   + the repair Procedures which are not connected with extraction of the engine from the car - six-cylinder engines
   - General and capital repairs of engines
      Removal of the power unit from the car - methods of performance and a precautionary measure
      Removal and installation of the power unit - a procedure performance order
      Alternative versions of schemes of recovery repair of the engine
      Order of dismantling of the engine by preparation it to capital repairs
      Service of a head of cylinders
      Dismantling of the block of cylinders
      Service of shatunno-piston assemblies
      Service of the block of cylinders
      Assembly of the block of cylinders
      Trial start and running in of the engine after capital repairs
+ Cooling systems, heating
+ Power supply system and release
+ Electric equipment of the engine
+ Manual box and differential
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment




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Removal and installation of the power unit - a procedure performance order

4-cylinder models

REMOVAL

 PERFORMANCE ORDER

1. The car also establish to Poddomkratta it on props.
2. Completely open a cowl and record it by means of an emphasis.
3. Dump pressure in a power supply system (see the Head of the Power supply system and release).
4. Uncover a jellied mouth.
5. Disconnect a negative wire from the battery.

6. Remove assembly of the air cleaner with an inlet sleeve.

7. Remove protection of a case.

8. Remove a radiator complete with ventilatory assembly.

9. Uncover the GRM drive (see the Section Removal and installation of forward covers of the GRM drive).
10. Uncover a belt of the V-shaped drive of auxiliary units (see the Head Routine maintenance).
11. On models with To/in bring a connecting hose to system of recirculation of coolant.
12. Merge coolant from the highway K/V.

13. Disconnect pressure head hoses from the K/V compressor.

14. Remove a basic arm of fastening of the air cleaner.

15. Disconnect an electrical wiring from forward a lambda probe.

16. Disconnect the plug of grounding of the power unit.

17. Disunite sockets of a braid of an electrical wiring of the engine.

18. Disconnect an electrical wiring from the generator and the К/В compressor.

And — the Contact socket and the plug of the generator
B — the K/V compressor electrical wiring Socket

19. Disconnect cables driving cables of a butterfly valve (gas and tempostat).

And — a gas Cable
B — the Cable of a tempostat

20. Disconnect an electrical wiring from pressure sensor switch.

21. Disconnect a vacuum hose of the brake amplifier.

22. Disconnect heater hoses.

23. Make removal from a basic arm of the steering pump:

a) Remove a rezonatorny chamber;
b) Release fixing and adjusting bolts and take off a forward V-shaped belt;
c) Release fixture of basic arms of hydraulic lines;
d) Turn out bolts of fastening of a basic arm of the steering pump.
e) Having pulled up, remove the GUR liquid tank from an arm, having pressured him towards a car front;
f) Without disconnecting hydraulic lines from the pump, take assembly aside and, having enclosed rags, lay it on a mudguard of the right wing.

24. Remove receptions and central sections of system of production of the fulfilled gases.

25. Give nuts of fastening of the lower part of transmission to the engine.

26. Turn off nuts of fastening of pillows of forward support of a suspension bracket of the power unit to a cross beam.

And engine Support

27. On models with AT lower the car on the earth and turn out a service stopper of AT. Turn out fixing bolts and separate the hydrotransformer coupling from a driving disk, - for the purpose of serial ensuring access to bolts turn a cranked shaft of the engine for a pulley by means of a special key of ST 499977300 (model of 2.0 l) / ST 499977100 (model of 2.5 l).

28. Remove the limiter of raskachivaniye of the power unit.

Efforts of a tightening of threaded connections, Nanometer
T1: 50
T2: 58

29. Disconnect hoses of lines of giving and return of fuel, and also a hose of branch of fuel evaporations.

 Attention: Before a detachment of a fuel hose wrap up its end rags for the purpose of prevention of spraying of fuel. In advance prepare drain capacity!



And — a fuel supply Hose
In — a fuel return Hose
With — the Hose of the vaporizing line

30. Hang out the engine on the winch.

31. Prop up transmission by a cart jack.

 Before separation of the engine from transmission, make sure that all preparatory procedures are complete. Remember that after office of the engine the jack can give a little under the weight of transmission assembly!

32. Remove a starter (see the Head Elektrooborudovaniye of the engine), then turn out bolts of fastening of the top part of transmission to the engine.

33. On models with AT install the lock of the driving disk ST 498277200 on a hydrotransformer dome.

34. Start taking slowly the engine at the top, at the same time raising transmission on a jack. Displace the engine in the horizontal direction (for release from it entrance/primary shaft of transmission) a little, then take it from a motor compartment, - try not to damage the acting engine elements (a pulley of a cranked shaft, the directing tube of the measuring probe, etc.) surrounding body panels and components established in a motor compartment.
35. Remove rubber pillows of forward support of a suspension bracket of the power unit.

INSTALLATION

 PERFORMANCE ORDER

1. Establish rubber pillows of support of an engine mount and tighten fixture with the demanded effort (34 Nanometers).
2. Bring the engine to a motor compartment and join it with transmission - try not to damage the acting engine elements (a pulley of a cranked shaft, the directing tube of the measuring probe, etc.) surrounding body panels and components established in a motor compartment.
3. On models with RKPP slightly grease vents of the leading shaft of a box.
4. Tighten with the demanded effort (50 Nanometers) the top bolts of fastening of transmission to the engine.
5. Disconnect lifting slings and clean the jack which is propping up transmission.
6. Install the limiter of raskachivaniye of the engine and tighten boats of its fastening with the demanded effort.
7. On models with AT remove the lock of a driving disk (ST 498177200) from the hydrotransformer case, - try not to drop the adaptation in a transmission case.
8. Establish a starter (see the Head Elektrooborudovaniye of the engine).
9. Connect the hydrotransformer coupling to a driving disk and tighten fixing bolts of fastening with the demanded effort (25 Nanometers), - for a provorachivaniye of a cranked shaft use a special key of ST 499977300 (model of 2.0 l) / ST 499977100 (model of 2.5 l). Establish into place a stopper of a service opening of AT.
10. Working as it should be, the return to an order of dismantle of components, install the steering pump on the regular place. The effort of a tightening of bolts of fastening of pump assembly makes 20.1 Nanometer, a rezonatorny chamber - 33 Nanometers. Adjust a tension of a V-shaped driving belt (see the Head Routine maintenance).
11. Tighten with the demanded effort (50 Nanometers) of a nut of fastening of the lower part of transmission to the engine.

12. Tighten nuts of fastening of pillows of forward support of an engine mount to a cross beam with effort of 85 Nanometers. Make sure of reliability of durability of fixing of fixing and adjusting bolts of support.

13. Further installation is made as it should be, the return to an order of dismantle of components. Track observance of efforts of a tightening of the corresponding fixture, do not forget to replace sealing rings of nipple knots of lines of the refrigerator highway K/V. Execute adjustment of cables of the drive of a butterfly valve. Make sure of correctness of laying and reliability of fixing of hoses, then fill in in the relevant systems working liquids (see the Head Routine maintenance).
14. Start the engine and check it for serviceability of functioning and existence of signs of development of leaks, then muffle and check levels of working liquids.


6-cylinder models

REMOVAL

 PERFORMANCE ORDER

1. The car also establish to Poddomkratta it on props.
2. Open a cowl and record it an emphasis.
3. Lift a back seat and unbend a floor carpet.
4. Dump pressure in a power supply system (see the Head of the Power supply system and release).
5. Uncover a jellied mouth.
6. Disconnect a negative wire from the battery.
7. Remove assembly of the air cleaner with an inlet sleeve.
8. Remove protection of a case.
9. Remove a radiator (see the Head of the Cooling system, heating).
10. Take off a V-shaped driving belt (see the Head Routine maintenance).
11. Disconnect a hose of the pressure head line of a refrigerator path from the K/V compressor.

12. Disconnect the plug of the tire of grounding of the engine.

13. Separate sockets of a braid of an electrical wiring of a motive compartment.

14. Disconnect an electrical wiring from the generator and the К/В compressor.

And — the K/V compressor Socket
B — the Socket and the plug of the generator

15. Disconnect cables of the drive of a butterfly valve (gas and tempostat).

A — a gas Cable
B — the Cable of a tempostat

16. Disconnect a vacuum hose of the brake amplifier.

17. Disconnect hoses of a heating path.

18. Disconnect system of production of the fulfilled gases from the engine.

19. Remove the steering pump:

a) Remove tubes with basic arms;
b) Turn out bolts of fastening of a basic arm of the steering pump;
c) Having wrung out forward, release the tank of the GUR hydraulic liquid from an arm;
d) Without disconnecting hydraulic lines from assembly, take the pump aside and, having enclosed rags, lay it on a mudguard of the right wing.

A — the Steering pump
B — the Generator
With — the K/V Compressor

20. Give nuts of fastening of the lower part of transmission to the engine.

21. Turn off nuts of fastening of pillows of forward support of an engine mount to a cross beam.

22. Lower the car on the earth and remove a stopper (A) of a service opening of AT, having Serially released fixing bolts, separate the hydrotransformer coupling from a driving disk. For the purpose of ensuring access to the next bolt turn the engine for a bolt of a pulley of a cranked shaft by means of ST 499977100 key.

23. Remove the limiter of raskachivaniye of the engine.

Efforts of a tightening of threaded connections, Nanometer
T1: 49
T2: 57

24. Disconnect hoses of giving and return, and also a hose of branch of fuel evaporations.

 Before a detachment of a fuel hose wrap the union the end in rags for the purpose of prevention of spraying of fuel. In advance prepare drain capacity!

25. Hang out the engine on the winch.
26. Prop up transmission by a cart jack.
27. Remove a starter and turn out bolts of fastening of the top part of transmission to the engine.
28. On models with AT block a driving disk by means of the ST 498277200 adaptation.
29. Separate the engine from transmission and take it a motor compartment.
30. Remove rubber pillows of forward support of a suspension bracket of the power unit.

INSTALLATION

 PERFORMANCE ORDER

1. Installation is made as it should be, the return to an order of dismantle of components. Attentively check a condition of all established components, replace worn-out details. Track that all fixture was tightened with the demanded effort (pillows of support: 34/74 Nanometers, limiter of raskachivaniye of the engine: 49 Nanometers and 57 Nanometers, bolts of fastening of the coupling of the hydrotransformer to a driving disk: 25 Nanometers, bolts of fastening of the steering pump: 20.1 Nanometer, bolts and nuts of fastening of transmission to the engine: 50 Nanometers, plug of the tire of grounding of the engine: 14 Nanometers).
2. In summary start the engine and check it for serviceability of functioning and existence of signs of development of leaks, then muffle and check levels of working liquids.