1994 Subaru Alcyone SVX Service & Repair Manual

MSA5P0631C 6 Cylinder Boxer Engines Series Module 104-H6 December 2009 CERTIFIED TECHNICIAN Technician Reference Booklet Technical Training

© Subaru of America, Inc. 2009 912 to 919 © Copyright 2009 Subaru of America, Inc. All rights reserved. This book may not be reproduced in whole or in part without the express permission of Subaru of America, Inc. Speciﬁcations in this Guide are based on the latest product information available at the time of publication. Some images shown are for illustration purposes only. Subaru of America, Inc. reserves the right at any time to make changes or modiﬁcations to systems, procedures, descriptions, and illustrations contained in this book without necessarily updating this document. Information contained herein is considered current as of December 2009.

6 Cylinder Boxer Engines Series (104-H6)  December 2009 TABLE OF CONTENTS 3.0 LITER ENGINE............................................................................................ 6 General Information .................................................................................. 6 3.0 Liter Engine Features ......................................................................... 6 3.0 Speciﬁcations...................................................................................... 6 3.0 LITER ENGINE DISASSEMBLY ................................................................. 9 Unloading Cam Sprockets ...................................................................... 13 Removal of Oil Pump .............................................................................. 15 O-Ring Placement Inner Cover ..................................................... 18 Removal of Cylinder Head ............................................................ 18 Removal of Oil Pan ....................................................................... 19 Piston Pin Access ......................................................................... 20 Splitting Block Halves ................................................................... 20 Lubrication System ....................................................................... 21 Coolant System............................................................................. 22 Valve Adjustment .......................................................................... 23 Chain Tensioners .......................................................................... 2 3.0 LITER VALVE CLEARANCE ADJUSTMENT- 2001~200 ....................... 25 Adjustment .................................................................................... 25 3.0 LITER ENGINE REASSEMBLY ................................................................ 29 2005 VARIABLE VALVE LIFT SYSTEM ......................................................... 37 VALVE CLEARANCE 3.0 H6 .......................................................................... 39 Inspection...................................................................................... 39 Valve clearance ...................................................................................... 1 ADJUSTMENT........................................................................................ 1 INTAKE SIDE................................................................................ 1 EXHAUST SIDE ..................................................................................... 3 6 CYLINDER AIR BLEED PROCEDURE 05MY AND NEWER ...................... 7 INTRODUCTION 3.6 LITER ENGINE ............................................................. 8 Enhancements / Changes ...................................................................... 9 TIMING CHAINS ............................................................................................. 52 Timing Chain Removal ........................................................................... 5 Right Bank .................................................................................... 5 Left Bank ...................................................................................... 55 TIMING CHAIN INSTALLATION ..................................................................... 56 THE DUAL ACTIVE VALVE TIMING SYSTEM ............................................... 60 OIL PUMP ....................................................................................................... 68 CYLINDER HEAD REMOVAL ......................................................................... 69

6 Cylinder Boxer Engines Series (104-H6) 5 December 2009 CYLINDER BLOCK ......................................................................................... 73 WATER PUMP ................................................................................................ 7 COOLING SYSTEM ........................................................................................ 80 OIL PUMP ....................................................................................................... 81 OIL LEVEL SENSOR ...................................................................................... 82 GENERAL HAND TOOLS AND SUPPLIES .................................................... 85 Reference Materials................................................................................ 85 Special Tools .......................................................................................... 85 SERVICE BULLETINS .................................................................................... 88 SERVICE BULLETINS .................................................................................... 89 WARRANTY BULLETIN .................................................................................. 90 TECH TIPS ...................................................................................................... 92 TECH TIPS ...................................................................................................... 93

6 Cylinder Boxer Engines Series (104-H6) 6 December 2009 3.0 Liter Engine 3.0 LITER ENGINE WITH STANDS General Information The EZ-3.0 is the model name (Engine Designation) for the new 6-cylinder engine 2001-2009 model year Legacy. The design idea for this engine was to create a power plant that could utilize the current body style, provide more power and decreased exhaust emissions. Many of the features refined for the current  cylinder engine are employed on the EZ-3.0 however, new features such as Variable Intake Control and timing chain driven Camshafts give the new engine a look and operation all of its own. SINGLE SERPENTINE BELT BELT WEAR INDICATOR 3.0 Liter Engine Features The front of the engine displays the large front timing chain cover. It is secured to the inner cover with 59 bolts. There are  different lengths used and is sealed to the inner cover with Three Bond (1280B). Special care must be used when servicing the timing chain covers to ensure the proper length bolt and sealing procedures are used. A single serpentine belt provides the power to turn all engine accessories. Tension to the belt is controlled with an automatic tensioner. Replace the serpentine belt when the indicator is at or beyond this line. 3.0 Specifications Bore and stroke 89.2 x 80 millimeters (3.51 x 3.1 inches) Length 65 millimeters (18.3 inches) Height 635 millimeters (2.99) Displacement 3.0 liters (183 cubic inches) Compression Ratio 10.7 to 1 Gasoline for use Unleaded Premium Fuel Injection Type DMPI Maximum Horsepower 212 at 6,000 RPM Maximum torque 210 at ,00 RPM 5 6 7

6 Cylinder Boxer Engines Series (104-H6) 7 December 2009 UPPER RADIATOR HOSE CONNECTIONS Two radiator hose connections are located at the top of the engine block connecting to each of the cylinder heads. OIL COOLER An oil cooler is used to assist with bringing the oil to operating temperature. INDIVIDUAL COILS COIL AND IGNITER ASSEMBLY The view of the left bank side shows the use of new direct ignition coils. The igniter and current control circuits are integrated. LOWER RADIATOR HOSE The lower hose is located on the thermostat housing, connecting to the lower section of the radiator. 8 9 10 11 12

6 Cylinder Boxer Engines Series (104-H6) 8 December 2009 OIL PAN AND EXTENSION CASE The thermostat is housed in the Oil Pan extension case. The Oil Pan itself is much smaller than previous model engines and contains a small magnet to collect metallic debris. CRANKCASE VENTILATION SYSTEM Connections for the crankcase ventilation system are located at the top of the valve cover. Pressure is equalized from the right bank with a cross over tube. CRANK ANGLE SENSOR WITH RELUCTOR The new crank angle sensor, reluctor, and EGR pipe. The crank angle sensor and reluctor have been moved to the rear of the crankshaft. The EGR pipe has a new design and is mounted on the left bank of the engine. 13 14 15

6 Cylinder Boxer Engines Series (104-H6) 9 December 2009 3.0 Liter Engine Disassembly UNLOADING TENSIONER Begin disassembly by unloading and removing the serpentine belt. FUEL RAIL ASSEMBLY Remove the fuel rail protectors from both sides. LOWER ALTERNATOR BOLT The lower alternator bolt must be backed out before the manifold can be removed. Remove the intake manifold. REMOVE ACCESSORIES Remove the alternator, compressor and power steering pump. NOTE: THE COMPRESSOR IS EQUIPPED WITH A SPEED SENSOR THAT SENDS A SIGNAL TO THE ECM. IF THE COMPRESSOR SPEED DROPS MORE THAN 20% COM- PARED TO THE ENGINE SPEED, THE ECM TURNS THE COM- PRESSOR OFF THROUGH THE A/C RELAY. THE REFRIGERANT MUST BE EVACUATED BEFORE REMOVING THE SENSOR. 17 18 19 20

6 Cylinder Boxer Engines Series (104-H6) 10 December 2009 CRANKSHAFT BOLT COVER CRANKSHAFT BOLT SEAL Remove the crankshaft bolt cover, bolt and harmonic balancer. Do not lose the O-Ring that seals the crank shaft bolt cover to the harmonic balancer. Begin removing the outer cover bolts. Keep them organized to ease reassembly. The bolts must be removed in the proper sequence to avoid warping the outer case. OUTER COVER SEALS These two bolts use sealing washers to prevent engine oil from leaking to the outside. The seals are not reusable. OUTER COVER BOLTS The bolts circled in the above picture secure the outer cover to special bolts that have internal threads. These bolts assist with supporting the outer chain cover along the middle where there is no support from the inner case. 21 22 23 24

1994 Subaru Alcyone SVX Service & Repair Manual

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