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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Service of a head of cylinders

Design of a head of cylinders of 4-cylinder engines

1 — Final valves
2 — Inlet valves
3 — the Directing plugs of valves
4 — Saddles of valvate springs
5 — Maslootrazhatelny caps of inlet valves

6 — Valvate springs
7 — Plates of valvate springs
8 — Crackers of cutting locks
9 — Maslootrazhatelny caps of final valves

Design of a head of cylinders of 6-cylinder engines

1 — Final valves
2 — Inlet valves
3 — the Directing plugs of inlet valves
4 — Saddles of valvate springs
5 — Maslootrazhatelny caps of inlet valves
6 — Valvate springs
7 — Plates of valvate springs

8 — Crackers of cutting locks
9 — Pushers of valves
10 — Adjusting washers
11 — the Directing plugs of final valves
12 — Maslootrazhatelny caps of final valves
13 — Caps
14 — the Head of cylinders

Components of assembly of a head of cylinders

1 — the Valve
2 — Directing a valve core
3 — the Support of a valvate spring
4 — the Maslootrazhatelny cap
5 — the Valvate spring
6 — the Stopper
7 — Crackers of the cutting lock

8 — Consolidation of a spark plug
9 — the Camshaft
10 — the Epiploon
11 — the Cap
12 — the Cover of a head of cylinders
13 — Assembly of yokes


Details of installation of valvate components

1 — a valve Saddle
2 — the Valvate spring

3 — the Plate of a spring
4 — the Painted surface

DISMANTLING

4-cylinder engine

 PERFORMANCE ORDER

1. The design of a head of cylinders of 4-cylinder engines is presented on an illustration.
2. Establish a head of cylinders on the ST 498267800 stand (see the Section Order of Dismantling of the Engine by preparation it to capital repairs).

3. By means of the special adaptation (ST 799718000) squeeze a spring of the first of valves and take crackers of the cutting lock. Remove a plate, a spring and a saddle of a spring, then take the valve. Working in a similar manner, remove all valvate assemblies, - try not to damage working edges of maslootrazhatelny caps. Put the removed components in an organized order in appropriately inscribed capacities (for example, small plastic bags).


6-cylinder engine

 PERFORMANCE ORDER

1. The design of a head of cylinders of 6-cylinder engines is presented on an illustration.
2. Establish a head of cylinders on the ST 18250AA00 stand.
3. Remove adjusting washers and pushers of valves.

4. By means of the special ST 499718000 adaptation serially wring out valvate springs and take crackers of cutting locks. Take valves and valvate springs, - try not to damage working edges of maslootrazhatelny caps. For simplification of the subsequent assembly, the removed components should be put in an organized order, - use appropriately marked small plastic bags or other capacities.


Cleaning of a head of cylinders

 PERFORMANCE ORDER

1. Careful cleaning of a head of cylinders and components of the valvate mechanism with the subsequent detailed check of their state will help to determine the approximate volume of the forthcoming recovery work.

 Strong overheats of the engine can lead to deformation of a head of cylinders and violation of planeness of its interfaced surfaces.

2. Scratch out all traces of material of old laying and sealant from the interfaced surfaces of a head of cylinders, the inlet pipeline and a final collector - try not to damage surfaces. Application of a special razmyagchitel which should impregnate previously stuck deposits will significantly facilitate work.
3. Remove all traces of a scum from walls of water channels.
4. A rigid wire brush carefully clean all available cavities and openings. At strong pollution of canals the clearing of a head should be charged to experts.
5. "Banish" the tap suitable by the size each of bolted openings, having removed corrosion products, traces of old sealant from a carving and having restored the damaged rounds. In the presence of access to a source of compressed air, blow openings, having removed from them shaving and small garbage.

 When using compressed air do not forget to put on goggles!

6. A wire brush smooth out a carving of hairpins of fastening of the inlet pipeline and a final collector.
7. Wash out a head solvent and carefully dry it. Use of compressed air will allow to reduce significantly the term of drying and will give a quality assurance of a clearing of badly available cavities and openings.

 Different structures for removal of traces of a deposit significantly facilitating performance of cleaning procedure can be got in many shops of automobile accessories. Remember that such means usually are chemically aggressive and have to be applied with observance of the appropriate measures of precaution, - strictly adhere to instructions of the manufacturers who are usually given on a container label.

8. On models 2.0 and 2.5 of l wash out solvent of a yoke of the drive of valves, then carefully dry them. Use of compressed air will significantly facilitate procedure performance (do not forget to put on goggles).
9. Wash out in solvent and carefully dry valvate springs, their plates and crackers of cutting locks. Try not to mix components.
10. Scratch out bulk of the valves of deposits created on surfaces, then a wire nozzle to the electric drill finally smooth out surfaces of cores and plates of valves - watch that valves were not mixed.
11. On models of 3.0 l take and carefully clean hydraulic pushers and adjusting washers.
12. Put the cleared components in an organized order.


Check of a state and service of components

4-cylinder engine

Valvate springs

 PERFORMANCE ORDER

1. Check valvate springs for existence of mechanical damages.
2. Measure length of springs in a free state and under loading. Compare results of measurements to requirements of Specifications. Replace the defective and given springs.
3. For check of a tortsovka of a spring it should be established vertically on a flat surface and to measure deviation size from a vertical by means of a square. Springs with violation of a tortsovka are also subject to replacement.

Maslootrazhatelny caps

 PERFORMANCE ORDER

1. Replacement of maslootrazhatelny caps is made at wear of their working edges, at shift or loss of rasporny springs, and also after restoration of working surfaces of valves and replacement of the directing plugs.
2. Landing of new caps to the acting parts of the directing plugs is made by means of a special mandrel of ST 498857100 after preliminary greasing by their pure motive oil.

 Caps of inlet and final valves differ on a standard size and can be identified on color marking. So, the rubber basis of caps of inlet valves has black color, final - brown. The spring part of all caps is painted in silvery color. It is not allowed to make landing of caps by a zastukivaniye at all!

Molding of a head of cylinders

 PERFORMANCE ORDER

1. Check molding of a head for existence of cracks, cavities and other damages.

2. By means of the planeness measuring instrument (the steel ruler put on an edge) and the probe of lezviyny type determine the size of not planeness of the interfaced surface of a head of cylinders. If the result of measurement exceeds limit admissible value (see Specifications), the head should be given to a pro-point.

 Remember that unevenness of a tightening of bolts of fastening of a head can be the reason of development of not planeness of the interfaced surface!



A — the planeness Measuring instrument (a steel ruler)
B — the Probe of lezviyny type

Saddles of valves

 PERFORMANCE ORDER

Estimate a condition of facets of valvate saddles. In case of need make restoration of working surfaces by a pro-point, or processings of facets a grinding stone.

 When replacing of the directing plugs of valves processing of facets is made without fail. Geometrical parameters of saddles of valves are shown on an illustration, compare the actual characteristics to requirements of Specifications, in case of need make the corresponding recovery repair.

The directing plugs of valves

 PERFORMANCE ORDER

1. Determine the size of a gap of landing of the valve in the directing plug. The gap can be calculated by subtraction of outer diameter of a core of the valve from the internal diameter of the plug, - measurements perform by means of a micrometer.
2. At an exit of results of measurements out of limits of admissible range (see Specifications) plugs are subject to replacement.

3. Develop a head combustion chambers up and establish it on the special ST1 498267800 stand so that the directing plugs got to openings in it. Plugs vypressovyvatsya from a head by means of the ST2 499767200 adaptation.

4. Turn a head the interfaced surface down and install the calibrated limiter of size of a vystupaniye of ST 499767700 plugs (for plugs of inlet valves) / to ST 499767800 (for plugs of final valves). Make sure of lack of cracks in walls of nests under landing of plugs.

A — the Directing valve plug

5. Previously having oiled pure motive, enclose the new directing plug in a mandrel of the special tool. Fill a tool core in the plug and press the last aflush with a face surface of the limiter. Make sure that the size of a vystupaniye of the new plug does not exceed the limit of admissible range (see Specifications).
6. By means of development of ST 499767400 develop an opening of the directing plug, - carefully rotating the development oiled motive clockwise and slightly pressing, enter it in the plug. At extraction of development it is necessary to continue to rotate it in the former direction (clockwise). Having finished development, remove from shaving plugs. If during development of the plug its internal surface remains brilliant and there is no shaving, replace development or make its editing.

 If on an internal surface of the directing plug there are teases, they can be removed by means of grinding whetstone.

7. In summary double-check a form of working facets of saddles of valves.

Inlet and final valves

 PERFORMANCE ORDER

1. Attentively examine plates and cores of valves. In case of detection of defects, deformations or wear replace the valve.

2. The valve is also subject to replacement if width of cylindrical part of its plate, - the corbel, - is lower than the limit admissible value stipulated in Specifications.

N — the Corbel

3. If valves are in a satisfactory condition, it is necessary to make their grinding in to the saddles. Grinding in is carried out with use of special abrasive paste. Also it is made before emergence on a surface of a facet of an equal continuous ring of opaque coloring.
4. Having finished grinding in, carefully remove all traces of an abrasive and establish new maslootrazhatelny caps.

 After grinding in each valve "is attached" to a concrete saddle!

6-cylinder engine

 PERFORMANCE ORDER

1. Check of a state and service of valvate springs, maslootrazhatelny caps, molding of a head of cylinders, saddles and the directing plugs of valves, and also valves on 6-cylinder engines is made to similarly corresponding procedures described above for 4-cylinder engines taking into account the listed below differences.
2. The directing plugs vypressovyvatsya from a head by means of the special ST 499765700 adaptation. For all valves the calibrated limiter of size of a vystupaniye of ST 18251AA000 plugs is used. Development of openings of the directing plugs is made by means of development of ST 499765900.

Pushers of valves

 PERFORMANCE ORDER

1. Attentively examine pushers of valves.
2. Measure the outer diameter of a pusher and internal diameter of a nest under its landing in a head of cylinders.
3. Determine the size of a gap of landing of a pusher of the valve in a nest and compare results of calculations to admissible values (see Specifications), - at their exit out of limits of admissible range a head are subject to replacement.

ASSEMBLY

4-cylinder engine

 PERFORMANCE ORDER

1. Components of assembly of a head of cylinders are presented on an illustration.
2. Establish a head of cylinders on the assembly ST 498267800 stand.
3. Oil cores pure and install valves in their directing plugs, - try not to damage working edges of maslootrazhatelny caps.
4. Establish valvate springs with plates.

 Springs are established by the party with the reduced step of rounds down (to a head), and the painted end up (to a plate)!

5. By means of the special ST 499718000 adaptation serially squeeze valvate springs and establish crackers of cutting locks. After installation slightly knock with a wooden hammer on valvate springs for their best landing.

6-cylinder engine

 PERFORMANCE ORDER

1. Assembly of a head is also made at the ST 18250AA000 stand.
2. Oiling cores pure motive, also install valves in the directing plugs, - try not to damage working edges of maslootrazhatelny caps.
3. Establish valvate springs with plates.

 Springs are established by the party with the reduced step of rounds down (to a head), and the painted end up.

4. By means of the special ST 499718000 adaptation serially squeeze valvate springs and establish crackers of cutting locks. After installation slightly knock valvate assemblies with a hammer with soft brisk for the purpose of shrinkage of components.
5. Grease and establish adjusting washers and pushers of valves.