SUBARU TRIBECA 2009 1.G Service Workshop Manual
Manufacturer: SUBARU, Model Year: 2009, Model line: TRIBECA, Model: SUBARU TRIBECA 2009 1.GPages: 2453, PDF Size: 46.32 MB
Page 1921 of 2453
ME(H6DO)-55
Camshaft
MECHANICAL
(2) Tighten the rocker cover bolts in the numer-
ical order as shown in the figure.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
•LH side
•RH side
5) Connect the oil pipe.
CAUTION:
•Be careful not to mistake the location of (A)
and (B).
•Be sure to use a new gasket.
Tightening torque:
(A), (B)
29 N·m (3.0 kgf-m, 652.27 cm-lb)
(C)
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
6) Install the rear chain cover.
7) Install the crank sprocket.
8) Install the cam sprocket.
9) Install the timing chain assembly.
10) Install the front chain cover.
11) Install the crank pulley.
C: INSPECTION
1) Measure the bend of camshaft. Repair or re-
place if bended.
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outside diameter of camshaft jour-
nal. If the journal diameter is not within specifica-
tion, check the oil clearance.
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each camshaft
journals.
(4) Install the bearing cap.
NOTE:
Do not turn the camshaft.
(5) Remove the bearing caps.
(A) Bolt without filter (with white mark)
(B) Bolt with filter (without white mark)
(C) Oil pipe bolt
ME-02061(2)
(7)(3)(1)(10)
(6)
(8)(4)
(5)
(9)
ME-02566
(8)(4)(1)
(5)
(7)
(9)(3)(2)
(6)
(10)
ME-02567
(A)
(C)
(B)
Camshaft journal
Front Except for front
Standard
mm (in)
37.946 — 37.963
(1.4939 — 1.4946)
25.946 — 25.963
(1.0215 — 1.0222)
ME-00539
Page 1922 of 2453
ME(H6DO)-56
Camshaft
MECHANICAL
(6) Measure the widest point of the plastigauge
on each journal. If oil clearance exceeds the
standard, replace the camshaft. If necessary,
replace the camshaft caps and cylinder head as
a set.
Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
(7) Completely remove the plastigauge.
5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H. If it exceeds the standard or offset wear
occurs, replace it.
Cam height H:
Standard
Intake
HIGH 42.09 — 42.19 mm (1.6571 — 1.6610
in)
LOW1 38.14 — 38.24 mm (1.5016 — 1.5055
in)
LOW2 35.44 — 35.54 mm (1.3953 — 1.3992
in)
Exhaust
41.65 — 41.75 mm (1.6398 — 1.6437 in)
Cam base circle diameter A:
Intake
HIGH 32.0 mm (1.2598 in)
LOW1 31.84 mm (1.2535 in)
LOW2 31.84 mm (1.2535 in)
Exhaust
32.0 mm (1.2598 in)
6) Measure the thrust clearance of camshaft with
dial gauge. If the clearance exceeds the standard
or offset wear occurs, replace the caps and cylinder
head as a set. If necessary replace the camshaft.
Standard
Intake
0.075 — 0.135 mm (0.0030 — 0.053 in)
Exhaust
0.030 — 0.090 mm (0.0012 — 0.035 in)
ME-00119
ME-00120
H
A
Page 1923 of 2453
ME(H6DO)-57
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
1) Remove the crank pulley.
2) Remove the front chain cover.
3) Remove the timing chain assembly.
4) Remove the cam sprocket.
5) Remove the crank sprocket.
6) Remove the rear chain cover.
7) Remove the camshaft.
8) Remove the cylinder head bolts in the numerical
order as shown in the figure.
Leave bolts (2) and (4) engaged by three or four
threads to prevent the cylinder head from falling.
9) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
10) Remove the bolts (2) and (4) to remove cylin-
der head.
11) Remove the cylinder head gasket.
CAUTION:
Be careful not to scratch the mating surface of
cylinder head and cylinder block.
12) Similarly, remove the cylinder head (RH).
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
•Use new cylinder head gaskets.
•Be careful not to scratch the mating surface
of cylinder head and cylinder block.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
cylinder head bolt threads.
(2) Install the cylinder head to cylinder block,
and then tighten the bolts with torque of 20 N·m
(2.0 kgf-m, 14 ft-lb) in numerical sequence as
shown in the figure.
(3) Tighten the bolts with torque of 50 N·m (5.1
kgf-m, 37 ft-lb) in numerical sequence as shown
in the figure.
(4) Back off all the bolts by 180° in reverse order
of installation, and back them off again by 180°.
(5) Tighten the bolts with torque of 20 N·m (2.0
kgf-m, 14 ft-lb) in numerical sequence as shown
in the figure.
(6) Tighten the bolts (1) — (4) with torque of 48
N·m (4.9 kgf-m, 35.4 ft-lb) in numerical se-
quence.
(7) Tighten the bolts (5) — (8) with torque of 44
N·m (4.5 kgf-m, 33 ft-lb) in numerical sequence.
(8) Tighten all bolts 90° in the numerical order
as shown in the figure.
(9) Tighten the bolt (1) — (4) by 45° in the nu-
merical order.
3) Install the camshaft.
4) Install the rear chain cover.
5) Install the crank sprocket.
6) Install the cam sprocket.
7) Install the timing chain assembly.
(2)
(8) (6)
(5) (7)
(4)
(1)(3)
ME-02063
(2)
(8) (6)
(5) (7)
(4)
(1)(3)
ME-02063
(7)
(1) (3)
(4) (2)
(5)
(8)(6)
ME-02064
Page 1924 of 2453
ME(H6DO)-58
Cylinder Head
MECHANICAL
8) Install the front chain cover.
9) Install the crank pulley.
C: DISASSEMBLY
1) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE
2) Remove the valve lifter.
3) Set the ST on valve spring retainer. Compress
the valve spring and remove the valve spring re-
tainer key. Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
CAUTION:
•Mark each valve to prevent confusion.
•Pay careful attention not to damage the lips
of intake valve oil seals and exhaust valve oil
seals.
D: ASSEMBLY
1) Installation of valve spring and valve:
(1) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
NOTE:
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
NOTE:
•Be sure to install the valve spring with its close-
coiled end facing the seat on cylinder head.
•For the valve spring on intake side, install two of
them (inner and outer).
•Install the valve spring with the painted side fac-
ing to retainer.
(4) Set the ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
(5) Compress the valve spring and fit the valve
spring retainer key.
(6) After installing, tap the valve spring retainers
lightly with a wooden hammer for better seating.
2) Apply oil to the surface of valve lifter and valve
shim.
3) Install the valve lifter and valve shim.
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damages do
not exist. In addition to visual inspection, inspect
important areas using liquid penetrant tester.
Check that there are no marks of gas leaking or wa-
ter leaking on gasket installing surface.
2) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE
ST
ME-00545
(1) Seat
(2) Valve spring
(3) Retainer
(4) Painted face
(1)
(2)(3)
(4)
ME-00546
ST
ME-00545
Page 1925 of 2453
ME(H6DO)-59
Cylinder Head
MECHANICAL
3) Measure the flatness of the cylinder head sur-
face that mates with crankcase using a straight
edge (A) and thickness gauge (B).
Flatness:
Standard
0.02 mm (0.0008 in)
Standard height of cylinder head:
124±0.05 mm (4.88±0.0020 in)
NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reinstalling, pay special at-
tention to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
correct the contact surfaces with a valve seat cutter
if they are defective or when valve guides are re-
placed.
Valve seat width W:
Intake
Standard
1.0 mm (0.039 in)
Exhaust
Standard
1.5 mm (0.059 in)
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
respectively the outer diameter of valve stem and
inner diameter of valve guide with a micrometer.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
2) If the clearance between valve guide and stem
exceeds the standard, replace the valve guide or
valve itself whichever shows greater amount of
wear or damaged and etc. See the following proce-
dure for valve guide replacement.
Valve guide inner diameter:
5.500 — 5.512 mm (0.2165 — 0.2170 in
Valve stem outer diameters:
Intake
5.455 — 5.470 mm (0.2148 — 0.2154 in)
Exhaust
5.445 — 5.460 mm (0.2144 — 0.2150 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides fit the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 18250AA010 CYLINDER HEAD TABLE
ST2 499765700 VALVE GUIDE REMOVER
(A)
(B)
ME-00551
ME-00127
WME-00553
Page 1926 of 2453
ME(H6DO)-60
Cylinder Head
MECHANICAL
(3) Turn the cylinder head upside down and
place the ST as shown in the figure.
ST 18251AA040 VALVE GUIDE ADJUSTER
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inner surface of valve guide holes in cyl-
inder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder, and insert the ST1 into valve
guide. Press in until the valve guide upper end
is flush with the upper surface of ST2.
ST1 499765700 VALVE GUIDE REMOVER
ST2 18251AA040 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion L:
11.4 — 11.8 mm (0.449 — 0.465 in)
(7) Ream the inside of valve guide using ST.
Put the reamer in valve guide, and rotate the
reamer slowly clockwise while pushing it lightly.
Bring the reamer back while rotating it clock-
wise. After reaming, clean the valve guide to re-
move chips.
ST 499765900 VALVE GUIDE REAMER
NOTE:
•Apply engine oil to the reamer when reaming.
•If the inner surface of valve guide is damaged,
the edge of reamer should be slightly ground with
oil stone.
•If the inner surface of valve guide becomes lus-
trous and the reamer does not chip, use a new
reamer or remedy the reamer.
(8) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and re-
place if damaged, worn or deformed, or if “H” ex-
ceeds the standard, or offset wear occurs.
H:
Intake (A)
Standard
1.0 mm (0.039 in)
Exhaust (B)
Standard
1.2 mm (0.047 in)
Valve overall length:
Intake (A)
99.7 mm (3.925 in)
Exhaust (B)
105.2 mm (4.142 in)
2) Put a small amount of grinding compound on the
seat surface, and lap the valve and seat surface.
Install a new intake valve oil seal after lapping.
ME-00757
ST
L
ME-00130
ST1
ST2
ME-02096
H
H
(B)
(A)
90 0+1
90 0+1
Page 1927 of 2453
ME(H6DO)-61
Cylinder Head
MECHANICAL
5. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within the standard value presented in the table.
2) To measure the squareness of the valve spring,
stand the spring on a surface plate and measure its
deflection at the top of spring using a try square.
6. INTAKE AND EXHAUST VALVE OIL
SEAL
In the following case, pinch and remove the oil seal
from valve using pliers, and then replace it with a
new one.
•When the lip is damaged.
•When the spring is out of the specified position.
•When readjusting the surfaces of intake valve
and valve sheet.
•When replacing the intake valve guide.
1) Set the cylinder head on ST1.
2) Press-fit the oil seal to the specified dimension
indicated in the figure using ST2.
ST1 18250AA010 CYLINDER HEAD TABLE
ST2 499585500 VALVE OIL SEAL GUIDE
NOTE:
•Apply engine oil to oil seal before press-fitting.
•When press-fitting the oil seal, do not use a ham-
mer or strike in.
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
32.959 — 32.975 mm (1.2976 — 1.2982 in)
3) Measure the inner diameter of valve lifter hole of
cylinder head.
Inner diameter:
32.994 — 33.016 mm (1.2990 — 1.2998 in)
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter hole is out of the
standard or offset wearing is emitted, replace the
cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Fr e e
lengthmm (in)
Intake
Inner39.55
(1.5571)
Outer41.18
(1.6213)
Exhaust46.32
(1.8236)
Squareness
Intake
Inner2.5°1.7 mm
(0.067 in)
Outer2.5°1.8 mm
(0.071 in)
Exhaust2.5°2.0 mm
(0.079 in)
ME-00132
ME-00548
ME-00134
ME-00550
Page 1928 of 2453
ME(H6DO)-62
Cylinder Block
MECHANICAL
21.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
1) Remove the crank pulley.
2) Remove the front chain cover.
3) Remove the timing chain assembly.
4) Remove the cam sprocket.
5) Remove the crank sprocket.
6) Remove the rear chain cover.
7) Remove the camshaft.
8) Remove the cylinder head.
9) Remove the drive plate.
Using the ST, lock the crankshaft.
ST 498497100 CRANKSHAFT STOPPER
10) Remove the crankshaft position sensor plate.
11) Remove the crankshaft position sensor brack-
et.
12) Rotate the engine to set oil pan upper.
13) Remove the bolts which secure oil pan lower to
oil pan upper.
14) Insert an oil pan cutter blade between cylinder
block-to-oil pan clearance and remove the oil pan.
CAUTION:
Do not use a screwdriver or similar tools in
place of oil pan cutter.
15) Remove the oil strainer.
ME-02664
ST
ME-00558
ME-00559
ME-00560
LU-02108
Page 1929 of 2453
ME(H6DO)-63
Cylinder Block
MECHANICAL
16) Remove the bolts which install oil pan upper
onto cylinder block.
NOTE:
Installation bolt has five different sizes. To prevent
the confusion in installation, keep these bolts on
container individually.
17) Remove the service hole cover and service
hole plugs using a hexagon wrench.
18) Rotate the crankshaft to bring #1 and #2 pis-
tons to bottom dead center position, then, using the
ST, remove the piston snap ring through service
hole of #1 and #2 cylinders.
ST 18233AA000 PISTON PIN SNAP RING PLI-
ERS
19) Draw out the piston pin from #1 and #2 pistons
using ST.
ST 499097700 PISTON PIN REMOVER
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.
20) Similarly remove the piston pins from #3, #4,
#5, and #6 pistons.
21) Remove the bolts which secure cylinder block.
22) Separate the cylinder block (LH) and (RH).
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall and damage the cylinder
block.
23) Remove the rear oil seal.
24) Remove the crankshaft together with connect-
ing rod.
25) Remove the crankshaft bearings from cylinder
block using a hammer handle.
NOTE:
•Do not confuse the combination of crankshaft
bearings.
•Press the bearing at the end opposite to locking
lip.
26) Draw out each piston from cylinder block using
wooden bar or hammer handle.
NOTE:
Be careful not to confuse the original combination
of piston and cylinder.
(A) M8 × 40
(B) M8 × 65
(C) M8 × 85
(D) M8 × 130
(E) M8 × 24
ME-02065
(D)(E)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(E)
(A)(A)(A)
(C)(B)
(A)
(D)
(A)
(A)
(A)
(A)
(A)
(B)
ME-00563
ST4
ME-00564
ME-00565
ME-00566
Page 1930 of 2453
ME(H6DO)-64
Cylinder Block
MECHANICAL
B: INSTALLATION
1) After setting the cylinder block to ST, install the
crankshaft bearing.
ST 18232AA000 ENGINE STAND
NOTE:
Remove oil on the mating surface of bearing and
cylinder block before installation. Apply a coat of
engine oil to crankshaft pins.
2) Position the crankshaft and connecting rod on
#2, #4 and #6 cylinder block.
3) Apply liquid gasket to the mating surface of the
#1, #3 and #5 cylinder blocks, and position it on #2,
#4 and #6 cylinder blocks.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007)
NOTE:
Do not allow liquid gasket to run over to O-ring
grooves, oil passages, bearing grooves, etc.
Applying liquid gasket diameter:
1.0±0.2 mm (0.039±0.008 in)
4) Apply a coat of engine oil to the washer and bolt
thread.
5) Tighten all bolts in the numerical order as shown
in the figure.
Tightening torque:
(1) — (11), (13): 25 N·m (2.5 kgf-m, 18 ft-lb)
(12), (14): 20 N·m (2.0 kgf-m, 14 ft-lb)
6) Retighten all bolts in the numerical order as
shown in the figure.
Tightening torque:
(1) — (11), (13): 25 N·m (2.5 kgf-m, 18 ft-lb)
(12), (14): 20 N·m (2.0 kgf-m, 14 ft-lb)
7) Tighten all bolts 90° in the numerical order as
shown in the figure.
8) Install the upper bolt to cylinder block.
Tightening torque:
25 N·m (2.5 kgf-m, 18 ft-lb)
NOTE:
Remove the liquid gasket which is running over to
sealing surface between cylinder block and rear
chain cover, cylinder block and oil pan upper, after
tightening the bolts which combine the cylinder
block.
ME-00567
(1)(6)(8)(3)(9)
(2)(4)(5)(7)(10)
(11)
(12)
(13)
(14)
ME-00568
(1)(6)(8)(3)(9)
(2)(4)(5)(7)(10)
(11)
(12)
(13)
(14)
ME-00568
(1)(6)(8)(3)(9)
(2)(4)(5)(7)(10)
(11)
(12)
(13)
(14)
ME-00568
ME-00569