Subaru Legacy/Outback

1999-2003 of release

Repair and car operation



Subaru Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ The operation manual
+ Routine maintenance
- The engine
   Specifications
   Check компрессионного pressure in cylinders and tightness of the block
   Diagnostics of a condition of the engine with vacuum gauge application
   System of greasing of the engine - the general information
   + The procedures of the repair which has been not connected with extraction of the engine from the car, - four-cylinder engines
   + The procedures of the repair which has been not connected with extraction of the engine from the car, - six-cylinder engines
   - The general and major repairs of engines
      Removal of the power unit from the car - performance and safety measure methods
      Removal and installation of the power unit - an order of performance of procedure
      Alternative variants of schemes of regenerative repair of the engine
      Order of dismantling of the engine by its preparation for major repairs
      Service of a head of cylinders
      Dismantling of the block of cylinders
      Service of shatunno-piston assemblages
      Service of the block of cylinders
      Assemblage of the block of cylinders
      Trial start and обкатка the engine after major repairs
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Manual box and differential
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Service of the block of cylinders

Site and the scheme of drawing of dimensional marks of radical bearings and cylinders of the 4-cylinder engine

A — Marks of the size of radical bearings
B — Marks of a combination of the left and right semiblocks
C — Marks of the size of the cylinder № 1

D — Marks of the size of the cylinder № 2
E — Marks of the size of the cylinder № 3
F — Marks of the size of the cylinder № 4


Cleaning and check of a condition of the block

Cleaning

 PERFORMANCE ORDER

1. Remove covers of radical bearings and take from the beds in covers and the block loose leaves of bearings. Mark loose leaves by means of an adhesive tape on conformity to the beds (№ the bearing, the block/cover) and will put them aside.
2. Scratch out from an interfaced surface of the block all traces of a material of an old lining. Try not to leave задиров.
3. Remove from the block all covers and carving заглушки oil galleries. Заглушки are usually tightened very hardly, therefore, quite probably, they should be drilled with the subsequent restoration of a carving in an aperture. At block assemblage заглушки it is necessary to replace new.
4. At strong external pollution of the engine it is necessary to deliver it in a workshop of car-care centre for steam cleaning or heat treatment.
5. After return of the block from a workshop once again carefully clean all oil apertures and galleries - for this purpose special cylindrical brushes of the special form (ask in shops of automobile accessories) are issued. Wash out cavities and channels warm water, - continue washing until from an opposite side of the block pure water will not start to follow. Carefully dry up the block, then slightly grease all pierced surfaces with liquid oil for their protection against corrosion. In the presence of access to a source of compressed air take advantage of it for acceleration of process of drying of the block and a purge of remote cavities and channels.

 At work with compressed air do not forget to put on goggles!

6. At strong pollution or зашлаковывании the block it is necessary to resort to щеточной to cleaning by hot water with soap. It is not necessary to try to save time at the expense of the negligent relation to block cleaning. Without dependence from the chosen way, track carefulness of procleaning of remote cavities, channels and apertures. In summary dry the block and grease the pierced surfaces with liquid oil for their protection against corrosion.
7. Banish all carving apertures in the block a tap of the corresponding size for the purpose of a guarantee of conformity of indications of the indicator динамометрического a key to really developed efforts of a tightening of fixture at engine assemblage. Then, whenever possible, blow the banished apertures the compressed air, having removed from them all small dust and a shaving. Having finished processing of apertures, walk леркой by a carving part of bolts.
8. Establish to the place of a cover of radical bearings, by hand having tightened their fixture.
9. Grease with not stiffening hermetic a carving new заглушек and закупорьте them apertures of oil galleries. Track durability of a tightening заглушек.
10. If be not going to start immediately engine assemblage, place the block in the big polyethylene package for protection of its pollution.

CHECK

 PERFORMANCE ORDER

1. Preliminary the block should be carefully cleared.
2. Make external survey of semiblocks about revealing of traces of corrosion, cracks and other damages. Check up a carving condition болтовых apertures. It will be reasonable to make also testing of semiblocks for presence of the latent cracks in the conditions of a workshop of car-care centre with application of the special diagnostic equipment. In case of revealing of defects the block is subject to regenerative repair or replacement.
3. Check up passableness маслотоков.
4. Estimate degree неплоскостности interfaced surfaces of semiblocks. Compare results of measurements to requirements of Specifications, in case of need give the block in проточку.
5. Check up a condition of mirrors of cylinders.
6. Estimate sizes taking place конусности and ovality of cylinders:

a) Measure diameter of each of cylinders in top (directly under border of step deterioration), the central and bottom sections in a plane of a parallel axis of a cranked shaft;
b) Measure diameters at the same three levels, but in a plane, a perpendicular axis of the block;
c) the Size конусности the cylinder is defined by a difference between results of measurements in the top and bottom sections. As ovality is called the difference of diameters in a parallel and perpendicular axis of a cranked shaft in each of planes.
d) Compare results of check to rating values (Specifications see).
7. Operating in a similar manner, serially check up all cylinders.
8. At revealing of appreciable defects or a deviation of results of measurements from standard requirements, the block of cylinders is subject to regenerative machining in the conditions of a car-care centre workshop. If in the course of regenerative repair has been made расточка cylinders, the engine should be completed by new pistons corresponding repair (with excess) the size.
9. If the condition of mirrors of cylinders during check performance is found satisfactory at simultaneous observance of standard requirements to the form of cylinders and landing backlashes in them of pistons, necessity in проточке cylinders disappears. Will execute only хонингование their mirrors enough.


Cylinders and pistons

Condition check

 PERFORMANCE ORDER

1. Dimensional marks of cylinders are beaten out from above in a forward part of the block. Pistons of the standard sizes share on two dimensional groups (And and) and should be established in the cylinders marked in appropriate way.

2. At replacement of the worn out pistons replaceable elements steal up proceeding from size of a backlash of landing of the piston in the cylinder. Measure internal diameter of each of cylinders in four sections of perpendicularly axis of a piston finger (in 10, 45, 80 and 115 (115 - only for engines SOHC) mm from an axis of a piston finger).

 Measurements should be made at temperature 20°С.


A — the Direction of an axis of a piston finger
B — the Persistent direction

A — the Direction of an axis of a piston finger
B — the Persistent direction

3. Having prepared the complete set of pistons of the repair size, measure diameters of their skirts in a plane of a perpendicular axis of a piston finger on distance H = 40.0 mm (models 2.0/37.0) mm (models 2.5) / 39.0 mm (models 3.0) from the piston bottom.

 Measurement make at temperature 20°С.

4. Having compared results of measurements to requirements of Specifications, define sizes of landing backlashes of pistons, estimate конусность and ovality of cylinders, in case of need give the block in проточку. Pay attention that measured at once after проточки diameter of the cylinder can not correspond to real received diameter because of the raised temperature.

 All cylinders should be pierced till the identical repair size! If растачивание without excess of the maximum permissible size it is not obviously possible, the block is subject to replacement!

5. Before engine assemblage it is without fail spent хонингование mirrors of cylinders for the purpose of achievement of correct landing to them of the piston rings, providing due tightness of chambers of combustion.

 At absence near at hand necessary tools or unwillingness independently to carry out хонингование, work for quite moderate payment can be charged experts of a workshop of car-care centre.


Хонингование cylinders

 PERFORMANCE ORDER

1. Before to start to хонингованию, establish to the place of a cover of radical bearings and tighten fixing bolts with demanded effort.
2. Two types хонов for processing of mirrors of cylinders are issued: хон type «bottle ершик» and, more traditional, superficial хон in the form of a nozzle with подпружиненными grinding stones. Both tools provide necessary quality of processing of mirrors of cylinders though use of the first is more preferable to not skilled mechanic. Enough of the rags, special хонинговочного or simply liquid lubricating oil, and also an electrodrill as a drive for хонинговочных nozzles Is required also. Operate in a following order:

a) Clamp хон in an electrodrill cartridge, reduce подпружиненные grinding stones/rods ершика nozzles and fill last in the cylinder.

 Do not forget to put on goggles or an obverse guard!

b) Plentifully moisten a mirror of the processed cylinder oil, include a drill and start to make a nozzle back and forth motions in the cylinder. Speed of vertical moving хона should provide drawing on a surface of a mirror of the cylinder of a mesh pattern with a corner of crossing of the parties ячеи nearby 60 °. Do not feel sorry some oil and try not to remove from a surface of walls of the cylinder of more material, than it is really necessary for achievement of demanded result.

 Manufacturers of piston rings can make own demands to a corner of crossing of the parties ячеи a mesh pattern, - attentively familiarise with the instruction on packing ремнабора;

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 will not stop to rotate. After a drill stop compress grinding stones and take хон from the cylinder. At using хоном type «bottle ершик» wait a full stop of a drill, then take a nozzle, continuing to rotate manually a cartridge in a normal direction;
d) Wipe rags a mirror of the cylinder and pass to хонингованию the following.
3. On termination of processing, take advantage надфилем for removal of facets from upper edges of cylinders, - the given processing is made so that there were no difficulties with refuelling in cylinders of pistons with the rings put on them. Observe extreme care, - do not scratch надфилем a cylinder mirror.
4. In summary all block should be washed carefully out a warm solution of soap water.

 It is possible to consider cylinders washed out when after carrying out on a mirror the white rags moistened with oil on it does not remain a grey touch. Do not forget to clean a cylindrical brush all oil apertures and channels, then wash out the block a water stream under a pressure.

5. After washing carefully dry the block and oil the pierced surfaces for their protection against corrosion. Prior to the beginning of engine assemblage wrap the block in a pure polyethylene package.


Pistons and piston fingers

 PERFORMANCE ORDER

1. In considered engines pistons facilitated юбочной designs with thermal flutes under installation маслосъемных rings are used.
2. Fingers of pistons are displaced or upwards (even numbers of cylinders), or downwards (odd numbers of cylinders).
3. Attentively examine each of pistons on presence of cracks in a skirt, round ledges under installation of piston fingers and around an arrangement of rings.
4. Check up persistent surfaces of a skirt of the piston on presence of scratches, the bottom - on presence of through apertures and прогаров 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 an air-fuel mix, - check up serviceability of functioning of system of cooling. Прогары along the edges of the bottom are the detonation certificate. In any case, the reason of the revealed infringement should be eliminated in order to avoid relapses. As the possible reasons of formation of the listed defects leaks of soaked up air, wrong configuration of an air-fuel mix, infringement of installation of a corner of an advancing of ignition, wrong functioning of systems of ignition and EGR can act also.
5. Dot corrosion of pistons in the form of cavities speaks about hit in chambers of combustion and-or картер the engine of a cooling liquid. Besides, take care, that the reason of internal leaks has been eliminated.
6. Check up landing freedom in pistons of fingers of the top heads of rods. At temperature 20°С fingers should refuel in landing apertures in pistons effort of a thumb, - if the given condition is not carried out, make replacement of corresponding fingers.
7. Measure a backlash of landing of a piston finger in the piston. If the measured size does not correspond to Specifications, replace a finger.
8. Check up, whether there are no agnails in a flute of the ring spring lock of a piston finger. If the lock does not move freely, remove agnails.


Details of installation and a design of piston rings of 4-cylinder engines

1 — Adjusting marks (forward on the engine)
2 — the Identification code (the size of the piston)
3 — the Code of volume of the engine
A — Top компрессионное a ring
B — the Second компрессионное a ring
C — Maslosemnoe a ring

a — the Internal facet
b — Sample
c — the Top working section маслосъемного rings
d — the Dilator маслосъемного rings
e — the Bottom working section маслосъемного rings


Details of installation and a design of piston rings of 6-cylinder engines

1 — Adjusting marks (forward on the engine)
A — Top компрессионное a ring
B — the Second компрессионное a ring
C — Maslosemnoe a ring
a — the Internal facet

b — Sample
c — the Top working section маслосъемного rings
d — the Dilator маслосъемного rings
e — the Bottom working section маслосъемного rings


Piston rings

 PERFORMANCE ORDER

1. On each piston it is established on three rings: two компрессионных (top and the second) and one маслосъемное. On top компрессионном a ring there is an internal facet; on the second компрессионном a ring – providing decrease in the expense of impellent oil sample from external edge of the bottom surface.
2. Preliminary pistons and rods should be carefully cleared. Rings are necessary for removing from pistons.

 Piston rings are subject to replacement without fail.

3. By means of the special adaptation remove rings from pistons, - try not to damage a wall of the last casually.
4. Scratch out from the bottoms of pistons traces of coal adjournment. After removal of the basic layer of adjournment smooth out a surface manually a wire brush or a piece of a fine-grained emery paper.

 At all do not use for зачистки made of a soft material and pistons easily subject to erosion wire nozzles to an electrodrill!

5. By means of the special adaptation clean flutes under installation of rings on pistons. It is alternatively possible to take advantage for this purpose of a fragment of an old piston ring, however be careful, - do not scratch a bottom and walls of a flute and do not cut fingers.
6. Having removed the basic adjournment, wash out шатунные assemblages by solvent and carefully dry them, whenever possible with application of compressed air.

 At using the compressed air do not forget to put on goggles! Check up passableness масловозвратных apertures in back walls of flutes under installation of piston rings, and also oil apertures in the bottom heads of rods.

7. If walls of pistons and a mirror of cylinders are not damaged and excessively are not worn out, and the engine block was not pierced and not replaced, necessity for replacement of pistons disappears. Normal deterioration of pistons is shown in the form of vertical traces of development on a persistent surface and a small weak point of landing top компрессионного rings in the flute. Do not forget that replacement of piston rings is made without fail, without dependence from their condition.

8. Estimate size of a lateral backlash of landing of piston rings in the flutes for what enclose a new ring outside in the flute on the piston and probeом лезвийного type measure a remaining backlash. Repeat measurement in two-three points on flute perimetre. Remember that top компрессионное the ring differs from second (bottom). If the backlash size exceeds admissible value (Specifications see), pistons are subject to replacement.

9. Execute check of backlashes 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 made with the help probeа лезвийного type. Serially define backlashes 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 rings outside!


Rods and шатунные bearings

 PERFORMANCE ORDER

 If the engine is under repair for the purpose of elimination of knock of fingers, replace шатунные assemblages.

1. If pushing surfaces of any of rod heads are damaged, it is necessary to replace it.

2. At the special stand estimate size of a residual bend and rod twisting.

A — ShChup лезвийного type
B — the Rod

3. Establish a rod with loose leaves on a corresponding neck of a cranked shaft and with the help probeа лезвийного type define size axial люфта assemblages. Compare results of measurements to requirements of Specifications, in case of need replace the worn out rod.

4. Estimate a condition of loose leaves шатунных bearings. Make sure of absence задиров, agnails, выщерблин, signs of an overheat and other defects, - excessively worn out loose leaves are subject to replacement.
5. Measure size of working backlashes of each of шатунных bearings by means of the calibrated plastic thread from set Plastigage, - follow instructions of manufacturers. Compare results of measurements to requirements of Specifications, in case of need replace loose leaves standard or repair the corresponding size.

6. Estimate a condition of plugs in the top heads of rods. Make sure of landing density in plugs of piston fingers.

7. The worn out or damaged plugs are subject to replacement: выпрессовывание plugs it is made by means of special tool ST 5990337100 or ST 18350АА000. Before landing the new plug is greased with pure impellent oil. Drill in the plug two apertures in diameter of 3 mm and develop an internal surface of the plug. Having finished procedure, carefully clear the plug of a shaving.


Cranked shaft and radical bearings

 PERFORMANCE ORDER

1. Carefully wipe a cranked shaft and attentively examine it on presence of cracks, in case of need give a shaft to a workshop of car-care centre for carrying out дефектоскопии with application of the special equipment. In case of revealing of defects the shaft is subject to replacement.

2. Having laid a cranked shaft pins on prisms with V-shaped samples, with the help циферблатного a measuring instrument плунжерного type define size of radial palpation of a shaft to a neck of the central radical bearing.

 At absence near at hand special prisms, plant in one of semiblocks loose leaves of 1st and 5th radical bearings, and lower in them a shaft. Compare result of measurement to requirements of Specifications. In case of need give a shaft in проточку, or make its replacement.

3. Check up radical and шатунные shaft necks on presence of signs of deterioration and damages. By measurement of diameters of necks in various sections and planes define sizes конусности and ovality. Compare results of measurements to requirements of Specifications. In case of need give a shaft in проточку, - after проточки the sizes of necks should correspond to one of standard repair types (Specifications see).

4. Attentively examine loose leaves of radical bearings on presence of traces of an overheat, выщерблин, estimate degree of deterioration of working surfaces. Define size axial люфта a shaft on the central (persistent) bearing. If the measured size does not meet requirements of Specifications, replace the bearing.

5. By means of the calibrated wire from measuring set Plastigage define sizes of working backlashes in radical bearings. Compare results of measurements to requirements of Specifications. In case of need replace loose leaves repair, or give a shaft in проточку.

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