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
   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


Order of dismantling of the engine by preparation it to capital repairs


1. It is simplest to carry out dismantling of the engine, having installed it on the portable assembly stand. The stand design offered by the Subaru company is presented on illustrations. The such adaptation can always be borrowed rather cheap in a workshop of car service. Before fixing the engine at the stand, it is necessary to remove from it a flywheel / a driving disk and a back epiploon.

2. If opportunity to use the stand is absent, dismantling should be made, having placed the engine on a strong workbench, or having reliably arranged it on a firm floor of garage. During the work without stand watch that the engine incidentally did not overturn.
3. If it is planned to make replacement of the engine on restored, remove with old all hinged units and external components and transfer them to the replaceable block. In number such, subject to shift, components enter:

a) Inlet pipeline;
b) The generator with arms;
c) The steering pump with a basic arm;
d) K/V compressor;
e) Components of system of ignition;
f) Thermostat;
g) Components of system of injection of fuel;
h) Oil filter;
i) Assembly of coupling (RKPP);
j) Engine electrical wiring plaits;
k) Spark plugs;
l) Oil cooler;
m) Flywheel / driving disk.
n) Components of systems of decrease in toxicity of the fulfilled gases.

 At removal from the old engine of external components try to remember characteristics of their installation. Fix landing provisions of laying, epiploons, remote rings and plugs, pins, arms, washers, bolts and other fine details in a notebook.

4. At a scheme choice with use of the reduced set of the block consisting of the block of cylinders with established in it by a cranked shaft and shatunno-piston groups remove from the old unit also a head(s) of cylinders, the pallet of a case and the oil pump (possible alternatives of schemes of performance of capital repairs see in the Section Alternative versions of schemes of recovery repair of the engine).
5. Before carrying out complete capital repairs remove the following components:

a) Inlet pipeline;
b) Generator;
c) K/V compressor;
d) Steering pump;
e) Perepuskna branch pipe/hose of the water pump;
f) Components of system of ignition (including candles);
g) EGR tube;
h) Detonation sensor;
i) Sensors of situation cranked and camshafts (CMP and CKP);
j) Sensor of a detonation (KS);
k) Sensor of temperature of cooling liquid (ECT);
l) Oil pressure sensor switch;
m) Sensor switch of pressure of motive oil;
n) Oil filter and oil cooler.
6. When carrying out complete capital repairs of the old unit, make its dismantling and take all internal components. The optimum order of removal of components when performing procedure of dismantling of the engine is given below:

a) Covers of heads of cylinders;
b) GRM drive covers with bolts;
c) GRM drive components (a gas-distributing belt / chain with gear wheels / asterisks);
d) Assemblies of yokes with camshafts;
e) Heads of cylinders;
f) Water pump;
g) Case pallet;
h) Maslozabornik with the mesh filter;
i) Oil pump;
j) Shatunno-porshnevye assemblies;
k) Back epiploon of a cranked shaft;
l) Cranked shaft and radical bearings;
7. Before starting dismantling of the engine, prepare materials and tools which will be required at service and assembly of the unit:

a) Standard set of the metalwork tool;
b) A set of cardboard or plastic containers / plastic bags for organized storage of small components;
c) A scraper for cleaning of the interfaced surfaces;
d) A vertical drill for removal of step wear in the top part of cylinders;
e) A stripper for dismantle of a pulley of a cranked shaft / a vibration damper;
f) Set of micrometers;
g) Telescopic nutromer;
h) Dial measuring instrument of plunger type (DTI);
i) The tool for compression of valvate springs;
j) Hon for processing of mirrors of cylinders;
k) The tool for a clearing of flutes under installation of piston rings;
l) Electric drill;
m) Set of taps and lerok;
n) Wire brushes;
o) Cylindrical brushes for a clearing of oil galleries;
p) Solvent.