SUBARU TRIBECA 2009 1.G Service Workshop Manual

ME(H6DO)-65
Cylinder Block
MECHANICAL
9) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
NOTE:
Apply engine oil to the pressing-in portion.
10) Position the top ring gap at (A) in the figure.
11) Position the second ring gap at (B).
12) Position the upper rail gap at (C) in the figure.
13) Position the expander gap at (D) in the figure.
14) Position the lower rail gap at (E) in the figure.
CAUTION:
•Make sure ring gaps do not face the same di-
rection.
•Make sure ring gaps are not within the piston
skirt area.
•Assemble it so that R mark faces to top side
of piston.
15) Install the snap ring.
Install the snap rings in the piston holes located op-
posite to the service holes in cylinder block when
positioning all pistons in corresponding cylinders.
NOTE:
Use new snap rings.
16) Installation of piston:
(1) Using the ST1, turn the crankshaft so that #3
and #4 connecting rod small ends are set on the
service hole (A).
ST1 18252AA000 CRANKSHAFT SOCKET
(2) Apply a thin coat of engine oil to piston and
cylinder.
(3) Using the ST2, press-fit the piston into cylin-
der.
ST2 18254AA000 PISTON GUIDE
(A) Rear oil seal
(B) Drive plate installation bolt
ST2ST1
(A)
(B)
ME-00570
180˚
(A)(B)
ME-02066
25˚35˚(C)
(D)
(E)
ME-02067
(A) Front side of vehicle
(A)
#1
#2
#3
#4
#5
#6
ME-00573
ST1(A)
(A)
ME-00574
ST2
ME-00576

ME(H6DO)-66
Cylinder Block
MECHANICAL
NOTE:
Let the piston front mark (A) face towards the front
of engine.
17) Installing piston pin:
(1) Apply a coat of engine oil to ST3 before in-
sertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 18253AA000 PISTON GUIDE
(2) Apply a coat of engine oil to piston pin, and
insert the piston pin into piston and connecting
rod through service hole.
(3) Using the ST4, install the snap ring.
ST4 18233AA000 PISTON PIN SNAP RING PLI-
ERS
NOTE:
Use new snap rings.
(4) Similarly install the #1, #2, #5 and #6 pis-
tons.
18) Install the service hole plug and O-ring.
NOTE:
Use new O-rings.
19) Apply liquid gasket to the mating surface of oil
pan upper.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
Applying liquid gasket diameter:
Full line part
3.0±1.0 mm (0.12±0.04 in)
Broken line part
1.0 mm (0.04 in)
NOTE:
Use new O-rings.
20) Temporarily tighten the oil pan upper.
NOTE:
Do not install the bolts in wrong place.
(A)
ME-02076
ST3
ME-00577
ST4
ME-00564
(A) O-ring
(A) M8 × 40
(B) M8 × 65
(C) M8 × 85
(D) M8 × 130
(E) M8 × 24
*: Coating
ME-02068
(A)(A)
(A)
(A)
ME-02069
(D)(E)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(E)
(A)(A)(A)
(C)(B)
(A)
(D)
(A)
(A)
(A)
(A)
(A)
(B)

ME(H6DO)-67
Cylinder Block
MECHANICAL
21) Tighten the oil pan upper installing bolts in the
numerical order as shown in the figure.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
22) Install the oil strainer.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
23) Apply liquid gasket to the matching surface of
oil pan lower.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
Applying liquid gasket diameter:
5.0±1.0 mm (0.20±0.04 in)
24) Tighten the oil pan lower installing bolts in the
numerical order as shown in the figure.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
25) Install the crankshaft sensor bracket.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
ME-02070
(19)
(14)
(12)
(16)
(24)(22)
(27)
(25)
(21)
(17)
(13)
(11)
(15)
(23)
(26)
(20)
(18)
(7)(6)(9)
(8) (10)
(5)
(3)
(4)
(1)
(2)
LU-02108
ME-00581
(1)(2)
(3)
(4)
(5)
(6)
(7)(8)(9)
(10)
(11)
(12)
(13)(14)
(15)
ME-00582
ME-00559

ME(H6DO)-68
Cylinder Block
MECHANICAL
26) Install the crankshaft sensor plate.
27) Install the drive plate.
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
81 N·m (8.3 kgf-m, 60 ft-lb)
28) Install the cylinder head. 57, INSTALLATION, Cylinder Head.>
29) Install the camshaft. INSTALLATION, Camshaft.>
30) Install the rear chain cover. ME(H6DO)-51, INSTALLATION, Rear Chain Cov-
er.>
31) Install the crank sprocket.
Sprocket.>
32) Install the cam sprocket. 49, INSTALLATION, Cam Sprocket.>
33) Install the timing chain assembly.
Chain Assembly.>
34) Install the front chain cover.
Chain Cover.>
35) Install the crank pulley.
Pulley.>
ME-00558
ME-02664
ST

ME(H6DO)-69
Cylinder Block
MECHANICAL
C: DISASSEMBLY
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using piston ring ex-
pander.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Snap ring
(1)
(1)
(2)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
ME-02097

ME(H6DO)-70
Cylinder Block
MECHANICAL
D: ASSEMBLY
1) Apply oil to the surfaces of the connecting rod
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
NOTE:
Position each connecting rod with the marking side
facing forward.
3) Install the connecting rod cap.
Make sure the arrow mark on connecting rod cap
facing front during installation.
CAUTION:
•Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
•When tightening the connecting rod bolts,
apply oil on the threads and flange end.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Install the second ring and top
ring using piston ring expander.
(1) Connecting rod cap (5) Oil ringTightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod bearing (6) Snap ringT: 53 (5.4, 39)
(3) Top ring (7) Connecting rod
(4) Second ring
(1)
(1)
(2)
(2)
(2)
(7)
(3)
(4)(5)
(7)
(3)
(4)
(5)
(6)
(6)T
T
ME-02459

ME(H6DO)-71
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especial-
ly, inspect the important parts using liquid pene-
trant tester.
2) Check the oil passages for clogging.
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge.
Standard height of cylinder block:
202 mm (7.95 in)
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the front
upper face of the cylinder block.
NOTE:
•Measurement should be performed at a temper-
ature of 20°C (68°F).
•Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as guide lines in selecting a standard piston.
Standard diameter:
A: 89.205 — 89.215 mm (3.5120 — 3.5124 in)
B: 89.195 — 89.205 mm (3.5116 — 3.5120 in)
2) How to measure the inner diameter of each cyl-
inder:
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights as
shown in the figure, using a cylinder bore gauge.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Cylindricality:
Standard
0.030 mm (0.0012 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
(A) Main journal size mark
(B) Cylinder bore size mark
(C) Cylinder block (RH) – (LH) combination mark
#7 #6#5
#2#1
#4#3#6#5#4#3#2#1
BBB 2
42BAB4
(A)
(B)
(C)
ME-00585
(A) Piston pin direction
(B) Thrust direction
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
ME-00586
H1
H2
H3
Unit: mm (in)
(B)
(A)

ME(H6DO)-72
Cylinder Block
MECHANICAL
4) How to measure the outer diameter of each pis-
ton:
Measure the outer diameter of each piston at the
height as shown in the figure. (Thrust direction)
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Piston grade point H:
37.3 mm (1.4865 in)
Piston outer diameter:
Standard
A: 89.205 — 89.215 mm (3.5120 — 3.5124
in)
B: 89.195 — 89.205 mm (3.5116 — 3.5120
in)
0.25 mm (0.0098 in) oversize
89.445 — 89.465 mm (3.5215 — 3.5222 in)
0.50 mm (0.0197 in) oversize
89.695 — 89.715 mm (3.5313 — 3.5321 in)
5) Calculate the clearance between cylinder and
piston.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
20 Cylinder to piston clearance at 20°C (68°F):
Standard
–0.010 — 0.010 mm (–0.00039 — 0.00039 in)
6) Boring and honing:
(1) If the value of cylindricality, out-of-round-
ness, or cylinder-to-piston clearance measured
is out of standard or if there is any damage on
the cylinder wall, rebore it to use an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform bor-
ing on one cylinder only. Nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds
89.715 mm (3.5321 in) after boring and honing,
replace the crankcase.
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter.
3. PISTON AND PISTON PIN
1) Check the pistons and piston pins for damage,
cracks and wear, and the piston ring grooves for
wear and damage. Replace if faulty.
2) Measure the piston-to-cylinder clearance at
each cylinder. AND PISTON, INSPECTION, Cylinder Block.>If
any of the clearances is not within standard, re-
place the piston or bore the cylinder to use an over-
size piston.
3) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20°C (68°F).
Replace if faulty.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
ME-00172
H
ME-00173
ME-00174

ME(H6DO)-73
Cylinder Block
MECHANICAL
4) Check the snap ring installation groove (A) on
the piston for burr. If necessary, remove burr from
the groove so that the piston pin can lightly move.
5) Check the piston pin snap ring for distortion,
cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or
if its tension is insufficient, or when the piston is re-
placed, replace the piston ring with a new one of
the same size as piston.
CAUTION:
•Marks are displayed on the end of top and
second rings. When installing the ring to pis-
ton, face this mark upward.
•Oil ring consists of the upper rail, expander
and lower rail. When installing on the piston, be
careful of the direction of each rail
2) Squarely place the piston ring and oil ring in cyl-
inder, and measure the piston ring gap with a thick-
ness gauge.
3) Measure the clearance between piston ring and
piston ring groove with a thickness gauge.
NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
(A) Top ring
(B) Second ring
(C) Oil ring
(a) Upper rail
(b) Expander
(c) Lower rail
ME-00175
(A)
(a)
(c)
(b)
(A)
(B)
(C)
ME-00591
Standard
mm (in)
Piston ring gap
To p r i n g0.20 — 0.35
(0.0079 — 0.0138)
Second ring0.35 — 0.50
(0.0138 — 0.0197)
Oil ring0.20 — 0.60
(0.0079 — 0.0236)
Standard
mm (in)
Clearance
between piston
ring and piston
ring groove
To p r i n g0.040 — 0.080
(0.0016 — 0.0031)
Second ring0.030 — 0.070
(0.0012 — 0.0028)
Clearance between oil ring and oil
ring groove
0.045 — 0.125
(0.0018 — 0.0049)
ME-00592
ME-00178

ME(H6DO)-74
Cylinder Block
MECHANICAL
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small
end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if it has the
bend or twist.
3) Install the connecting rod fitted with bearing to
crankshaft and measure the thrust clearance. If the
clearance exceeds the standard or offset wear oc-
curs, replace the connecting rod.
Connecting rod thrust clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
4) Inspect the connecting rod bearing for scar,
peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on each connecting
rod bearing using plastigauge. If any oil clearance
is not within the standard, replace the defective
bearing with a new one of standard size or under-
size as necessary. (See the table below.)
Connecting rod oil clearance:
Standard
0.016 — 0.043 mm (0.0006 — 0.0017 in)
6) Inspect the bushing at connecting rod small end,
and replace if worn or damaged. Also measure the
piston pin clearance at connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 — 0.022 mm (0 — 0.0009 in)(A) Thickness gauge
(B) Connecting rod
(A)
(A)
(B)
(B)
ME-00179
ME-00180
Unit: mm (in)
Bearing
Bearing size
(Thickness at cen-
ter)
Outer diameter of
crank pin
Standard1.490 — 1.506
(0.0587 — 0.0593)
51.984 — 52.000
(2.0466 — 2.0472)
0.03
(0.0012)
undersize
1.509 — 1.513
(0.0594 — 0.0596)
51.954 — 51.970
(2.0454 — 2.0461)
0.05
(0.0020)
undersize
1.519 — 1.523
(0.0598 — 0.0600)
51.934 — 51.950
(2.0446 — 2.0453)
0.25
(0.0098)
undersize
1.619 — 1.623
(0.0637 — 0.0639)
51.734 — 51.750
(2.0368 — 2.0374)
ME-00181
ME-00174