Subaru Forester

1997-2005 of release

Repair and car operation



Subaru Forester
+ Cars Subaru Forester
+ The maintenance instruction
+ Routine maintenance
- The engine
   Design features and principle of functioning of the engine, - the general information and adjustment клапанных backlashes
   Major repairs and engine service - the general information
   Check of pressure of oil
   Check компрессионного pressure in cylinders
   Diagnostics of a condition of the engine with vacuum gauge application
   Removal of the power unit from the car - preparation and safety measures
   Removal and engine installation
   Alternative variants of schemes of regenerative repair of the engine
   Order of dismantling of the engine by its preparation for major repairs
   Dismantling of drive ГРМ, - removal, check of a condition and installation of components
   Removal, dismantling, check, assemblage and axis installation коромысел, - engines SOHC
   Removal, check of a condition and installation of camshafts
   Service of heads of cylinders
   Service of the block of cylinders
   Greasing system - the general information
   Removal, service and installation
   Removal, check and installation маслоохладителя - only engines DOHC
   Trial start and обкатка the engine after major repairs
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Control systems of the engine
+ Gear change box
+ Coupling, трансмиссионная a line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
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The engine

Specifications

The general parametres

Models without турбокомпрессора

Engine EJ20J model (вып. 98-00), EJ20J2 (вып. 98-01)
Engine type 4-cylinder, 4-taktnyj,
оппозитный petrol engine OHC,
With water cooling
Capacity, kw (h.p.) at rpm
EJ20J 90 (122), at 5600
EJ20J2 92 (125), at 5600
Working volume 1994 sm3
Diameter of cylinders 92.0 mm
Course of pistons 75.0 mm
Compression degree
J20J 9.7: 1
J20J2 10: 1
Pressure of a compression, Bar 9.8-13.0
Ignition order 1-3-2-4
Models with турбокомпрессором
Engine model EJ20, EJ205
Engine type 4-cylinder, 4-taktnyj,
оппозитный petrol engine DOHC
With турбокомпрессором. Cooling – water
Capacity, kw (h.p.) at rpm
EJ20 130 (177), at 5600
EJ205 125 (170), at 5600
Working volume 1994 sm3
Diameter of cylinders 92.0 mm
Course of pistons 75.0 mm
Compression degree
EJ20 8.0: 1
EJ205 8.5: 1
Pressure of a compression, Bar 8.5-11.7
Ignition order 1-3-2-4
Twisting moment, Nanometer / (rpm)
Engines without a turbo-supercharging 164 / (4400)
Engines with a turbo-supercharging 260 / (3600)

Models with турбокомпрессором

Engine model EJ20, EJ205
Engine type 4-cylinder, 4-taktnyj,
оппозитный petrol engine DOHC
With турбокомпрессором. Cooling – water
Capacity, kw (h.p.) at rpm
EJ20 130 (177), at 5600
EJ205 125 (170), at 5600
Working volume 1994 sm3
Diameter of cylinders 92.0 mm
Course of pistons 75.0 mm
Compression degree
EJ20 8.0: 1
EJ205 8.5: 1
Pressure of a compression, Bar 8.5-11.7
Ignition order 1-3-2-4
Twisting moment, Nanometer / (rpm)
Engines without a turbo-supercharging 164 / (4400)
Engines with a turbo-supercharging 260 / (3600)

Adjustments

Klapannyj backlash on the cold engine
The inlet 0.200.02 mm
The final 0.250.02 mm
Pressure of oil, bar 3.0 on 5000 rpm
Idling turns, in mines
Models without a turbo-supercharging
Models with РКПП 650 100
Models with АТ 670 100
Models with a turbo-supercharging 700 100

The maximum admissible depth of depression in the inlet pipeline on single turns, кПа
Engines without a turbo-supercharging 69.3
Engines with a turbo-supercharging 66.7
Pressure of the valve of a cover of a radiator, bar
Models with engines EJ20J 0.8-1.0
Other models 0.95-1.25
Temperature of opening of the thermostat 76-80С
Deflection of a belt of the generator/hydraulic booster of a wheel 9-11 mm
Deflection of a belt of the conditioner of air 9-10 mm

Camshafts
Limiting admissible size of a deflection, mm
Engines SOHC 0.025
Engines DOHC 0.020
Working backlash in bearings, mm
Engines SOHC
Rating value 0.055 0.090
Limiting admissible value 0.10
Engines DOHC
Rating value 0.037 0.072
Limiting admissible value 0.10
Diameter of necks, mm
Engines SOHC 31.928 31.945
Engines DOHC
Forward neck 37.946 37.963
The central and back necks 29.946 29.963
Internal diameter of bearings of support of a camshaft

Engines SOHC, mm 32.000 32.018
Height of cams (), mm
Engines SOHC
Rating value  
The inlet 39.646 39.746
Limiting admissible size of deterioration 0.15
Engines DOHC
Rating value
Inlet camshaft 44.75 44.85
Final camshaft 44.60 44.70
Limiting admissible size of deterioration
Inlet camshaft 42.20
Final camshaft 42.25

The scheme of an arrangement of cams of inlet camshafts of the left and right heads of cylinders on engines DOHC

Axial люфт a camshaft, mm
Engines SOHC
Rating value 0.03 0.09
Limiting admissible value 0.11
Engines DOHC
Rating value 0.015 0.07
Limiting admissible value 0.1

Коромысла a drive of valves (engines SOHC)

Size of a backlash of landing коромысел on axes, mm
Rating value 0.020 0.081
Limiting admissible value 0.10

Head of cylinders and клапанный the mechanism

Head moulding
Limiting admissible неплоскостность
Interfaced surface, mm
0.05
Allowance on polishing, mm 0.1
Standard height, mm
Engines SOHC 98.3
Engines DOHC 127.5

Saddles of valves

Width of a working facet of a saddle of the inlet valve
Engines SOHC
Rating value 1.0
Limiting admissible value 1.7
Engines DOHC
Rating value 1.0
Limiting admissible value 1.7
Width of a working facet of a saddle of the final valve
Engines SOHC
Rating value 1.4
Limiting admissible value 2.1
Engines DOHC
Rating value 1.5
Limiting admissible value 2.2

Directing plugs

Size of a backlash of landing of cores of valves in directing plugs, mm

All engines
Rating value
Final valves 0.040 0.067
Final valves 0.040 0.067
Limiting admissible value 0.15

Internal diameter of the directing plug of the valve, mm

Engines SOHC 6.000 6.012
Engines DOHC 6.000 6.015

Size выступания the directing plug, mm

Engines SOHC
The inlet
20.0 20.5
The final 16.5 17.0
Engines DOHC 12.0 12.4

Valves

Width of a cylindrical part (corbel) of a plate of the valve, mm

Engines SOHC

Inlet valves
Rating value 1.0
Limiting admissible value 0.6
Final valves
Rating value 1.2
Limiting admissible value 0.6

Engines DOHC

Inlet valves
Rating value 1.2
Limiting admissible value 0.8
Final valves
Rating value 1.5
Limiting admissible value 0.8

Valve total length, mm

Engines SOHC
Inlet valves 120.6
Final valves 121.7
Engines DOHC
Inlet valves 104.4
Final valves 104.7

External diameter of a core of the valve, mm

Engines SOHC
Inlet valves 5.950 5.965
Final valves 5.945 5.960
Engines DOHC
Inlet valves 5.950 5.965
Final valves 5.950 5.965

Klapannye springs

Free length, mm
Engines SOHC 54.3
Engines DOHC 44.67

Length under loading, mm

Engines SOHC
Loading of 56.5 kg 34.7
Loading of 56.5 kg 34.7
Engines DOHC
Loading of 22.5 kg 33.0
Loading of 52.1 kg 26.6
Limiting admissible size of infringement торцовки (all engines), hailstones (mm) 2.5 (1.9)

Maslootrazhatelnye caps

Colour marks

Colour of a rubber external face surface
Inlet valves The black
Final valves The brown
Colour of a spring part
Inlet valves The white
Final valves The white

The block of cylinders

Limiting admissible неплоскостность interfaced surfaces, mm 0.05
Allowance on polishing, mm 0.4
Diameter of cylinders, mm
Marks "And" 92.005 92.015
Marks "In" 91.995 91.005
Limiting admissible ovality and
конусность cylinders, mm
0.050
Backlash of landing of the piston in the cylinder at temperature 20С, mm
Rating value 0.010 0.030
Limiting admissible value 0.050
The maximum admissible allowance on расточку cylinders, mm
All engines 0.5  

Pistons and piston fingers

Diameter of pistons, mm
Marks "And" 91.985 91.995
Marks "In" 91.975 91.985
The repair size with increase at 0.25 mm 92.225 92.235
The repair size with increase at 0.25 mm 92.225 92.235
Backlash of landing of a piston finger in the piston, mm 0.04 0.08
Backlash of landing of a piston finger in the plug of the top head of a rod, mm
Rating value 0 0.022
Limiting admissible value 0.030

Backlash in the lock of piston rings

Top компрессионное a ring, SOHC/DOHC
Rating value 0.20 0.35/0.20 0.26
Limiting admissible value 1.0
Average компрессионное a ring
Rating value 0.35 0.50
Limiting admissible value 1.0
Maslosemnoe ring  
Rating value 0.20 0.70
Limiting admissible value 1.5

Landing backlash компрессионных rings in flutes of pistons, mm

The top ring
Rating value 0.04 0.08
Limiting admissible value 0.15
The bottom ring
Rating value 0.03 0.07
Limiting admissible value 0.15

Rods

Limiting admissible values of sizes of a bend and bar twisting at length of 100 mm, mm 0.10
Axial люфт a rod on a pin of a cranked shaft, mm
Rating value 0.70 0.330
Limiting admissible value 0.4
Working backlash in шатунном the bearing, mm
Rating value, SOHC/DOHC 0.010 0.038/0.02 0.046
Limiting admissible value 0.05

Cranked shaft, radical and шатунные bearings bearings

Limiting admissible value
Shaft deflection, mm
0.035
Limiting admissible size
Ovality of a radical neck, mm
0.02
Limiting admissible конусность
Radical neck, mm
0.07
Limiting admissible allowance
On polishing of a radical neck, mm
0.25
Diameter of radical necks, mm
The standard size 59.992 60.008
The repair size (with reduction by 0.03 mm) 59.962 59.978
The repair size
(With reduction by 0.05 mm)
59.942 59.958
The repair size
(With reduction by 0.25 mm)
59.742 59.758

Thickness of loose leaves of radical bearings in an average part, mm

The standard size
Loose leaves of 1st and 5th bearings 1.998 2.011
Loose leaves of 2nd, 3rd and 4th bearings 2.000 2.013
The repair size (with reduction by 0.03 mm)
Loose leaves of 1st and 5th bearings 2.017 2.020
Loose leaves of 2nd, 3rd and 4th bearings 2.019 2.022
The repair size (with reduction by 0.05 mm)
Loose leaves of 1st and 5th bearings 2.027 2.030
Loose leaves of 2nd, 3rd and 4th bearings 2.029 2.032
The repair size (with reduction by 0.25 mm)
Loose leaves of 1st and 5th bearings 2.127 2.130
Loose leaves of 2nd, 3rd and 4th bearings 2.129 2.132
Size axial люфта in the central (persistent) bearing, mm
Rating value 0.030 0.115
Limiting admissible value 0.25
Working backlashes in radical bearings, mm
Rating value 0.010 0.030
Limiting admissible value 0.040
Diameter шатунных necks, SOHC/DOHC, mm
The standard size 51.984 52.000/47.984 48.000
The repair size (with reduction
On 0.03 mm)
51.954 51.970/47.954 47.970
The repair size (with reduction
On 0.05 mm)
51.934 51.950/47.934 47.950
The repair size (with reduction
On 0.25 mm)
51.734 51.750/47.734 47.750

Thickness of loose leaves шатунных bearings in an average part, mm

The standard size
Engines SOHC 1.492 1.501
Engines DOHC 2.000 2.013
The repair size (with reduction by 0.03 mm)
Engines SOHC 1.510 1.513
Engines DOHC 1.505 1.508
The repair size (with reduction by 0.05 mm)
Engines SOHC 1.520 1.523
Engines DOHC 1.515 1.518
The repair size (with reduction by 0.25 mm)
Engines SOHC 1.620 1.623
Engines DOHC 1.615 1.618

Greasing system

The general parametres

Volume at change of impellent oil, l
Engines SOHC 4.5
Engines DOHC 5.2

The oil pump

Type Роторный, трохоидного type,
With internal gearing
Number of teeths
Internal gear wheel (rotor) 9
External gear wheel (rotor) 10
Diameter of an external rotor, mm 78
Thickness of an external rotor, mm
Engines SOHC 9
Engines DOHC 10
Backlash size between tops of teeths of rotors, mm
Rating value 0.04 0.14
Limiting admissible value 0.18
Backlash size between a forming surface of an external rotor and the case, mm
Rating value 0.10 0.175
Limiting admissible value 0.20
Size axial люфта an internal rotor, mm
Rating value 0.02 0.07
Limiting admissible value 0.12

The rashodno-pressure head characteristic of the pump at various turns of the engine and oil temperature 80С

Engines SOHC
600 rpm 4.2 l/mines on 98 кПа
5000 rpm 42.0 l/mines on 294 кПа
Engines DOHC
600 rpm 4.6 l/mines on 98 кПа
5000 rpm 47.0 l/mines on 294 кПа

The oil filter

Type Полнопоточный
Total area of a filtering element, sm2 1000
Pressure of operation перепускного the valve, кПа 156
External diameter, mm 80
Height, mm 70
Diameter of a connecting carving М20 х1.5

Маслоохладитель (only engines DOHC)

Type Water oil
Diameter, mm 10
The size of the heat exchanger, mm 93

The reduktsionnyj valve in a highway of hydraulic proof-readers клапанных backlashes

Pressure of operation, кПа 69
Free length клапанной springs, mm
Engines SOHC 71.8
Engines DOHC 73.7
Length клапанной springs in working order, mm
Engines SOHC 54.7
Engines DOHC 54.7
Effort of preliminary compression at installation, Н
Engines SOHC 77.08
Engines DOHC 93.2

The gauge of pressure of oil

Type Membranno-contact
Pressure of operation, кПа (кГ/см2) 14.7 (0.15)
Limiting pressure, кПа (кГ/см2) More than 981 (10.0)

Efforts of a tightening of carving connections, Nanometer

Are resulted also in the text of the Head on accompanying illustrations.

Bolts of a head of cylinders

In крестовом an order
Stage 1 29 Nanometers
Stage 2 69 Nanometers
Stage 3 To turn on on a turn floor
Stage 4 To turn on on a turn floor
Stage 5 Averages 2 bolts of 34 Nanometers, the others 4 bolts of 15 Nanometers
Stage 6 90
Stage 7 90
Bolts of covers of radical bearings коленвала
10 mm 473 Nanometer
8 mm 252 Nanometer
6 mm 6.4 Nanometers
Bolts of covers of rods
Stage 1 21-23 Nanometers
Stage 2 43-46 Nanometers
Flywheel/privodnoj a disk 69-75
The oil pump to the block of cylinders 6
The pallet картера 5
Pallet stopper картера 44
Coupling basket to a flywheel 14-17
Pulley коленвала 122-137
Cam-shaft gear wheel 73-83

Cover of bed of a cam-shaft

Models without турбокомпрессора
М6 10
М8 18
Models with турбокомпрессором 18-22
Cover of levers of a cam-shaft
Models without турбокомпрессора 4-6
Models with турбокомпрессором 5
The inlet pipeline to a head of cylinders 23-27
The final pipeline to a head of cylinders 34-44
Spark plugs 21
Ljambda-probe
Models without турбокомпрессора 18-24
Models with турбокомпрессором 41-47
The detonation gauge
Models without турбокомпрессора 21-26
Models with турбокомпрессором 6