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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Dismantling of drive ГРМ, - removal, check of a condition and installation of components

Dismantling

 PERFORMANCE ORDER

1. Remove a belt of a drive of the generator (Routine maintenance see the Head).
2. Having blocked a pulley of a cranked shaft from проворачивания by means of the special adaptation, release a bolt of its fastening. Remove a pulley.
3. Remove the left, right and central covers of drive ГРМ.

Details of installation of covers of drive ГРМ on engines SOHC


1  — the  Belt of a drive of the generator
2  — the  Bolt of fastening of a pulley
3  — the  Pulley of a cranked shaft
4  — the  Left cover of drive ГРМ
5  — the  Right cover of drive ГРМ
6  — the  Central cover of drive ГРМ

 


Details of installation of covers of drive ГРМ on engines DOHC

1  — the  Belt of a drive of the generator
2  — the  Bolt of fastening of a pulley
3  — the  Pulley of a cranked shaft
4  — the  Left cover of drive ГРМ
5  — the  Central cover of drive ГРМ
6  — the  Right cover of drive ГРМ

 


Removal газораспределительного a belt

Details of installation of components of drive ГРМ on engines SOHC

1 — the  Cogwheel of a cranked shaft
2  — the  Right back cover of drive ГРМ (№ 2)
3  — the  Left back cover of drive ГРМ (№ 2)
4  — the  Cogwheel of the right camshaft
5  — the  Intermediate roller
6  — the  Arm натяжителя a belt
7  — the  Intermediate roller
8  — the  Tension roller

9  —  Natjazhitel of a belt
10  — the  Intermediate cogwheel № 2
11  — the  Cogwheel of the left camshaft
12  —  Gazoraspredelitelnyj a belt
13  — the  Right cover of drive ГРМ
14  — the  Central cover of drive ГРМ
15  — the  Left cover of drive ГРМ
16  — the  Pulley of a cranked shaft


Details of installation of components of drive ГРМ on engines DOHC

1  — the  Cogwheel of a cranked shaft
2  — the  Right back cover of drive ГРМ (№ 2)
3  — the  Left back cover of drive ГРМ (№ 2)
4  — the  Cogwheel of the right inlet camshaft
5  — the  Cogwheel of the right final camshaft
6  — the  Intermediate roller
7  — the  Tension roller
8  —  Natjazhitel of a belt
9  — the  Arm натяжителя a belt

10  — the  Cogwheel of the left inlet camshaft
11  — the  Cogwheel of the left final camshaft
12  — the  Intermediate cogwheel № 2
13  — the  Intermediate roller
14  —  Gazoraspredelitelnyj a belt
15  — the  Right cover of drive ГРМ
16  — the  Central cover of drive ГРМ
17  — the  Left cover of drive ГРМ
18  — the  Pulley of a cranked shaft


Combination of adjusting labels of cogwheels cranked and camshafts on engines SOHC

1  — the  Adjusting label
2  —  Reciprocal risk

 


Combination of adjusting labels of cogwheels cranked and camshafts on engines DOHC

1  — the  Cover of drive ГРМ
2  —  Reciprocal risk
3  — the  Adjusting label (an unary strip)
4  — the  Gear belt of an inlet camshaft

5  — the  Adjusting label (a double strip)
6  — the  Cogwheel of a final camshaft
7  — the  Cogwheel of a cranked shaft
8  — the  Adjusting label


Marks are put on the back party of a belt (engine SOHC)

1  —  44 teeth
2  —  40.5 teeths

 


Marks are put on the back party of a belt (engine DOHC)

1  —  28 teeths
2  —  54.5 teeth
3  —  51 tooth

 


 PERFORMANCE ORDER

1. Check up gear газораспределительный a belt on presence of adjusting labels and a rotation directional marker. In case of need put corresponding marks independently on the back party of a tape:

  • Turn a cranked shaft before combination of adjusting labels of cogwheels cranked and camshafts with reciprocal risks on back covers of drive ГРМ (№ 2) and the block of cylinders;
  • White paint put position labels (opposite to labels on зубатых wheels of shaft) and directions of rotation of a belt.
  • 2. Loosen the fastening bolts натяжителя a belt.
    3. Remove an intermediate roller.
    4. On engines DOHC remove an intermediate cogwheel № 2.
    5. Remove газораспределительный a belt.

    Assemblage removal натяжителя and intermediate rollers

    Installation details натяжителя and intermediate rollers газораспределительного a belt on engines SOHC

    1  —  Natjazhitel
    2  — the  Tension roller
    3  — the  Intermediate roller

     


    Installation details натяжителя and intermediate rollers газораспределительного a belt on engines DOHC

    1  —  Natjazhitel
    2  — the  Tension roller
    3  — the  Intermediate roller
    4  — the  Intermediate cogwheel

     


     PERFORMANCE ORDER

    1. Remove an intermediate roller.
    2. On engines DOHC remove intermediate зубчаток a wheel № 2.
    3. Remove натяжитель a belt.


    Removal of cogwheels and back covers of drive ГРМ

     PERFORMANCE ORDER

    Keeping of a cogwheel from проворачивания at release a fixing bolt is made by means of the special adaptation.

    Engines SOHC

    Details of installation of cogwheels cranked and camshafts on engines SOHC

    1  — the  Right back cover of drive ГРМ (№ 2)
    2  — the  Left back cover of drive ГРМ (№ 2)
    3  — the  Arm натяжителя a belt
    4  — the  Cogwheel of a cranked shaft
    5  — the  Cogwheel of the right camshaft
    6  — the  Cogwheel of the left camshaft

     


     PERFORMANCE ORDER

    1. Turn out a fixing bolt and remove a cogwheel of the left camshaft.
    2. Operating in a similar manner, remove a cogwheel of the right camshaft.
    3. Remove a cogwheel of a cranked shaft.
    4. Remove the left and right back covers (№ 2) drive ГРМ.
    5. Remove an arm натяжителя a belt.


    Engines DOHC

    Keeping of a cogwheel from проворачивания at release a fixing bolt is made by means of the special adaptation


    On engines DOHC casual проворачивание camshafts at removed газораспределительном a belt it is fraught with damage of valves at blow their friend about the friend!

    Details of installation of cogwheels cranked and camshafts on engines DOHC

    1  — the  Right back cover of drive ГРМ (№ 2)
    2  — the  Left back cover of drive ГРМ (№ 2)
    3  — the  Arm натяжителя a belt
    4  — the  Cogwheel of a cranked shaft

    5  — the  Cogwheel of the right final camshaft
    6  — the  Cogwheel of the right inlet camshaft
    7  — the  Cogwheel of the left final camshaft
    8  — the  Cogwheel of the left inlet camshaft


     PERFORMANCE ORDER

    1. Having blocked a cogwheel left inlet from проворачивания by means of a special key, release a fixing bolt. Remove a cogwheel.
    2. Operating in a similar manner, remove cogwheels left final, right inlet and right final camshafts.
    3. Remove a cogwheel of a cranked shaft.
    4. Remove an arm натяжителя a belt.
    5. Remove left and right back (№ 2) covers of drive ГРМ.


    Check

    Gazoraspredelitelnyj belt

    Do not suppose hit on a surface газораспределительного a belt of oils, greasing or a cooling liquid, - in case of need carefully remove the slightest traces of pollution. In order to avoid breaks, try not to bend excessively a belt tape, - the bend radius should not exceed 30 mm.


     PERFORMANCE ORDER

    1. Check up a gear surface of a belt on presence of ruptures, cracks and signs of deterioration of a tape. Turn a belt and attentively study a condition of its back party.
    2. In case of revealing of defects the belt is subject to replacement.


    Натяжитель a belt

     PERFORMANCE ORDER

    1. Check up assemblage натяжителя on presence of signs of development of leaks through sealing rings. Estimate a condition and degree of deterioration of a rod натяжителя. Replace defective components.

    Presence on a rod surface натяжителя insignificant traces of greasing is admissible.

    2. Keeping assemblage натяжителя both hands, rest a rod against a floor or a wall of garage and press on it with effort 15 50 кГс, - if the rod begins заглубляться in the assemblage case, replace натяжитель.
    3. Measure size выступания a rod over a face surface of assemblage. If the result of measurement falls outside the limits an admissible range (15.4 16.4 mm), replace натяжитель.
    Н = 15.4 16.4 mm

    Assemblage

    Installation of cogwheels

     PERFORMANCE ORDER

    1. Establish right and left back (№ 2) covers of drive ГРМ.
    2. Establish an arm натяжителя a belt.
    3. Establish gear wheels of a cranked shaft.


    Engines SOHC

    The cogwheel of the left camshaft differs from right a ledge intended for work of gauge CMP.


     PERFORMANCE ORDER

    1. Establish a cogwheel of the right camshaft, - keep a shaft from проворачивания by means of the special adaptation.
    2. Establish a gear pulley of the left camshaft.

    Engines DOHC

     PERFORMANCE ORDER

    1. Establish a cogwheel of the right final camshaft, - keep a shaft from проворачивания by means of the special adaptation.
    2. Establish a cogwheel of the right inlet camshaft.
    3. Establish a cogwheel of the left final camshaft.
    4. Establish a cogwheel of the left inlet camshaft.

    Installation натяжителя a belt and intermediate rollers

    Rod fixing натяжителя in the drowned position

    1  —  to Drown before combination of apertures
    2  — the  Lock core

     


    Press wring out a rod натяжителя in the case before combination of lock apertures. Fix a rod in the drowned position, having passed in apertures a metal core in diameter about 1.5 mm.

    Watch, that the effort was put strictly in parallel an axis of a rod and did not exceed value 1 т! Before to dump pressure in a press, make sure of reliability of fixing of a rod a core.


     PERFORMANCE ORDER

    1. Establish натяжитель on the regular place, shift it to the right against the stop and temporarily fix.
    2. Establish a tension roller.
    3. Establish an intermediate pulley.
    4. On engines DOHC establish an intermediate cogwheel № 2.


    Installation газораспределительного a belt

    Engines SOHC

     PERFORMANCE ORDER

    1. The help of the special tool, develop cogwheels cranked and both camshafts adjusting labels upwards.
    2. Having achieved combination of the labels put on the back party of a belt with adjusting labels, accurately put on a belt cogwheels, - track observance of an initial direction of rotation of a belt.
    3. Establish an intermediate cogwheel № 2.
    4. Establish an intermediate roller.
    5. Release fastening bolts натяжителя, displace assemblage of the last against the stop to the left, then again tighten bolts.
    6. Once again make sure of correctness of combination of labels of a belt then take the core keeping a rod натяжителя in drowned position.
    7. Having finished belt installation, remove covers of a head of cylinders and make sure of absence of air in hydroproof-readers клапанных backlashes.

    Inlet and final camshafts on engines DOHC at removed газораспределительном a belt can are turned independently from each other.

    If thus there will be a simultaneous moving of inlet and final valves they can appear are damaged as a result of contact with each other.

    In view of told, at the removed belt it is necessary to fix all shaft in position of zero lifting at which all valves are closed.

    When at installation газораспределительного a belt shaft are turned, inlet valves of 2nd cylinder and final 4th fall under the influence of corresponding cams of camshafts of the left head of cylinders.

    Camshafts of the right head of cylinders thus do not render influence on valves. At installation of a belt camshafts of the left head of cylinders should be deduced from position of zero lifting in a starting position by поворачивания their cogwheels on the minimum possible corner for the purpose of prevention of dangerous contact of valves.


    Combination of adjusting labels of a cogwheel of a cranked shaft

    1  —  Correct image the combined adjusting labels

     


    Combination of adjusting labels of a cogwheel of the right final camshaft

    1  — the  Adjusting label in the form of an unary strip
    2  —  Reciprocal risk (cut)
    3  — the  Cogwheel of the right final camshaft

     


    Combination of adjusting labels of a cogwheel of the right inlet camshaft

    1  — the  Adjusting label in the form of an unary strip
    2  —  Reciprocal risk (cut)
    3  —  Adjusting labels in the form of a double strip
    4  — the  Cogwheel of the right inlet camshaft

     


    Combination of adjusting labels of a cogwheel of the left final camshaft

    1  —  Reciprocal risk (cut)
    2  — the  Adjusting label in the form of an unary strip
    3  — the  Cogwheel of the left final camshaft

     


    Combination of adjusting labels of a cogwheel of the left inlet camshaft

    1  —  Reciprocal risk (cut)
    2  — the  Adjusting label in the form of an unary strip
    3  — the  Cogwheel of the right inlet camshaft
    4  —  Adjusting labels in the form of a double strip

     


    Make preliminary installation of cogwheels:
  • Achieve combination of an adjusting label of a cogwheel of a cranked shaft with reciprocal риской on a cover of the oil pump on the block of cylinders;
  • Achieve combination of a label in the form of an unary strip on a cogwheel of the right final camshaft with reciprocal риской on a cover of drive ГРМ;
  • Achieve combination of a label in the form of an unary strip on a cogwheel of the right inlet camshaft with reciprocal риской on cover ГРМ. Make sure of combination of labels in the form of a double strip of cogwheels of inlet and final camshafts;
  • Operating in a similar manner, achieve combination of adjusting labels of cogwheels of the left camshafts;
  • Check up, that cogwheels of all shaft have been located as is shown in an illustration.
  • Cogwheels cranked and camshafts should appear established as it is shown on the scheme

    RH-IN  —  Right inlet
    RH-EX  —  Right final
    LH-IN  —  Left inlet
    LH-EX  —  Left final

     


    At all do not turn camshafts in the directions specified in the top part of an illustration

    1  — a  rotation Direction
    2  — the  Starting position of cogwheels at installation газораспределительного a belt

     

    At all do not turn camshafts in the directions specified in the top part of an accompanying illustration, - the Prevention in the subsection beginning see!


    Correct combination of landing labels at installation газораспределительного a belt on engine DOHC

    1  —  Marks of a direction of rotation of a belt
    2  — the  Landing label
    3  —  28 teeths
    4  —  54.5 teeth
    5  —  51 tooth
    6  —  to Establish in last turn

     


     PERFORMANCE ORDER

    1. Having achieved combination of the labels put on the back party of a belt with adjusting labels, put on a belt cogwheels of shaft. Track preservation of a correct direction of rotation of a belt.
    2. Establish an intermediate roller. Once again make sure in correctness of combination of all labels.
    3. Release fastening bolts натяжителя, shift last to the left against the stop, then again tighten fixture.
    4. Once again make sure of correctness of combination of labels, then take a lock core from the case натяжителя.
    5. Having finished belt installation, remove covers of a head of cylinders and make sure of absence of signs of hit of air in hydroproof-readers клапанных backlashes.


    Installation of a pulley of a cranked shaft and covers of drive ГРМ

     PERFORMANCE ORDER

    1. Establish the central, left and right covers of drive ГРМ.
    2. Establish a pulley of a cranked shaft.
    3. Screw fixing and tighten it with demanded effort.
    4. Establish a belt of a drive of the generator.