Subaru Impreza 2002 User Manual

Download

2002 Model Year

PDF Service Manual

Supplement For STi Model

GENERAL INFORMATION SECTION (Pub.No.G1841GE1)

ENGINE 2 SECTION (Pub.No.G1841GE3)

TRANSMISSION SECTION (Pub.No.G1841GE4)

CHASSIS SECTION (Pub.No.G1841GE5)

BODY SECTION (Pub.No.G1841GE6)

WIRING SYSTEM SECTION (Pub.No.G1841GE7)

2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX

GENERAL INFORMATION SECTION

SPECIFICATIONS SPC

IDENTIFICATION ID

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement of parts during repair work is needed, be sure to use SUBARU genuine parts.

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD. G1841GE1

SPECIFICATIONS

1. Impreza .......................................................................................................2

SPC

Page

IMPREZA

SPECIFICATIONS

1. Impreza

A: DIMENSIONS

Model Sedan Wagon OUTBACK STi Overall length mm (in) 4,405 (173.4) Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3) 1,730 (68.1) Overall height (at C.W.) mm (in)

Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6) 1,890 (74.4)

Width mm (in) 1,380 (54.3) Height mm (in) 1,180 (46.5),

Wheelbase mm (in) 2,525 (99.4) Tread Front mm (in)

Rear mm (in) 1,475 (58.1),

Minimum road clearance

Without catalytic converter

With catalytic converter

mm (in) 150 (5.9),

1,440 (56.7)

1,125 (44.3)★5

1,485 (58.5)

1,480 (58.3)★3

155 (6.1)★2

155 (6.1)★3

1,465 (57.7),

1,485 (58.5)★4

1,200 (47.2),

1,150 (45.3)★5

1,460 (57.5)★1,

1,465 (57.7)

1,450 (57.1)★1,

1,455 (57.3)

150 (5.9),

155 (6.1)★2

150 (5.9),

155 (6.1)★3

1,475 (58.1),

1,495 (58.9)★4

1,200 (47.2),

1,150 (45.3)★5

1,460 (57.5) 1,490 (58.7)

1,455 (57.3) 1,480 (58.3)

160 (6.3) —

160 (6.3) 155 (6.1)

1,440 (56.7)

1,180 (46.5)

★1: 1.6 L ★2: 2.0 L ★3: 2.0 L Turbo ★4: With roof rail ★5: With sun roof

B: ENGINE

Model 1.6 L Non-Turbo 2.0 L Turbo 2.0 L 2.5 L STi Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Valve arrangement Overhead camshaft type Bore × Stroke mm (in) 87.9 × 65.8

(3.461 × 2.591)

Displacement

Compression ratio 10.0 ± 0.2 8.0 ± 0.2 10.0 ± 0.2 8.0 ± 0.2 Firing order 1 — 3 — 2 — 4 Idle speed at

Park/Neutral position Maximum output kW (HP)/rpm 70

Maximum torque N·m (kgf-m, ft-lb)

(cu in)

rpm

/rpm

1,597 (97.45) 1,994 (121.67) 2,475 (151.02) 1,994 (121.67)

700 ± 100 750 ± 100 700 ± 100 700 ± 100

(94)/5,200

143

(14.6, 105.5)

/3,600

(123)/5,600

(18.8, 136.0)

/3,600

(3.62 × 2.95)

184

92 × 75

160

(215)/5,600

292

(29.8, 215.4)

/3,600

99.5 × 79

(3.92 × 3.11)

112

(150)/5,600

223

(22.7, 164.5)

/3,600

92 × 75

(3.62 × 2.95)

195

(261)/6,000

343

(35.0, 253.0)

/4,000

SPC-2

IMPREZA

SPECIFICATIONS

C: ELECTRICAL

Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi Ignition timing at

idling speed Spark

plug

Generator 12V — 75A Battery Type and

Type and manufacturer

capacity (5HR)

BTDC/rpm

Without OBD

With OBD CHAMPION:

For Europe and South America

Others 12V — 27AH (34B19L) —

5°±10°/700 10°±10°/700 12°±10°/750

NGK: BKR6E

(without catalyst)

CHAMPION:

RC8YC4

(with catalyst)

NGK: BKR6E-11

(with catalyst)

RC8YC4

Alternate

NGK: BKR6E-11

12V — 48AH

(55D23L)

NGK: BKR6E

(without catalyst)

CHAMPION:

RC10YC4

(with catalyst)

NGK: BKR5E-11

(with catalyst)

CHAMPION:

RC10YC4

Alternate

NGK: BKR5E-11

MT: 12V — 48AH (55D23L)

AT: 12V — 52AH (65D23L)

NGK: PFR6G

—

MT: 10°±10°/700

AT: 15°±10°/700

NGK: BKR6E (with-

out catalyst)

CHAMPION:

RC10YC4 (with cat-

alyst)

NGK: BKR5E-11

(with catalyst)

CHAMPION:

RC10YC4

Alternate

NGK: BKR6E-11

MT: 12V — 48AH

(55D23L)

AT: 12V — 52AH

(75D23L)

12°±10°/700

NGK: PFR6G

12V — 48AH

(55D23L)

—

SPC-3

IMPREZA

SPECIFICATIONS

D: TRANSMISSION

Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 6MT Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD TCC DSPD Gear ratio 1st

2nd

3rd

4th 1.088 0.694 1.088 0.694 0.972 0.694 1.088 0.694 1.346 5th

6th

Reverse 3.333 2.272 3.333 2.272 3.333 2.272 3.333 2.272 3.545 Dual

range

Reduction gear (Front drive)

Reduction gear (Rear drive)

1st reduction

Final reduction

Transfer reduction

Final reduction

Type of gear

Gear ratio

Type of gear

Gear ratio

Type of gear

Gear ratio

Type of gear

Gear ratio

3.454 2.785 3.454 2.785

2.062 1.545 2.062 1.545

1.448 1.000 1.448 1.000

0.825 — 0.825 — 0.738 —

————————

1.447—1.447——————

— Helical — Helical — Helical — Helical —

— 1.000 — 1.000 — 1.000 — 1.000 —

Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid

4.111 4.444 3.900 4.111

Helical — Helical — Helical — Helical — Helical

1.000 — 1.000 —

Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid

4.111 4.444 3.900 4.111

3.454,

3.166★1

1.947,

1.882★1

1.366,

1.296★1

3.900,

4.444★1

1.100,

1.000★1

3.545,

4.444★1

2.785 3.454 2.785 3.636

1.545 2.062 1.545 2.375

1.000 1.448 1.000 1.761

0.871,

0.780★1

4.111

—1.000—

4.111

3.700,

4.111★1

3.700,

4.111★1

—

4.111 3.900

4.111

0.971,

1.062★1

0.756,

0.842★1

1.100,

1.000★1

3.545,

3.900★1

5MT: 5-forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 6MT: 6-forward speeds with synchromesh and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch ★1: Australia spec vehicle

E: STEERING

Model Turbo 2.0 L, 2.5 L OUTBACK OTHERS STi Type Rack and Pinion Turns, lock to lock RHD: 2.7

LHD: 3.0

Minimum turning circle m (ft) Curb to curb 11.0 (36.1) 10.8 (35.4) 10.4 (34.1) 11.0

Wall to wall 12.0 (39.4) 11.6 (38.1) 11.2 (36.7) 12.0

3.0 3.2 2.7

F: SUSPENSION

Front Macpherson strut type, Independent, Coil spring Rear Dual-link type, Independent, Coil spring

SPC-4

IMPREZA

SPECIFICATIONS

G: BRAKE

Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L, STi Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes

H: TIRE

Rim size

Tire size 175/70R14 84T

Type Steel belted radial, Tubeless

14 × 51/2JJ

185/70R14 88H

15 × 6JJ

185/65R15 88H 195/60R15 88H

16 × 61/2JJ

P205/55R16 89V

205/50R16 87V

17 × 7JJ

215/45R17 87W 225/45R17 90W

17 × 71/2JJ

215/45R17 87W

I: CAPACITY

Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi

5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 6MT

Fuel tank 2 (US gal,

Imp gal)

Engine oil

Transmission gear oil

Automatic transmission fluid

AT differential gear oil

AWD rear differential gear oil

Power steering fluid

Engine coolant 2 (US qt,

Total capacity

Engine oil amount for refill

2 (US qt,

Imp qt)

2 (US qt,

Imp qt)

2 (US qt,

Imp qt)

2 (US qt,

Imp qt)

2 (US qt,

Imp qt)

2 (US qt,

Imp qt)

2 (US qt,

Imp qt)

50 (13.2, 11.0) 50 (13.2, 11.0) 60 (15.9, 13.2)

4.0 (4.2, 3.5) 4.5 (4.8, 4.0) 4.0 (4.2, 3.5)

Approx.

4.5 (4.8, 4.0)

3.5

(3.7, 3.1)

—

7.7

(8.1, 6.8)

—

9.3

(9.8, 8.2)

1.2

(1.3, 1.1)

7.7

(8.1, 6.8)

3.5

(3.7, 3.1)

—

7.0

(7.4, 6.2)

3.5

(3.7, 3.1),

4.0

(4.2, 3.5)

★1

—

7.4

(7.8, 6.5)

Approx. 4.0 (4.2, 3.5)

3.5

(3.7, 3.1),

—

8.4

(8.9, 7.4)

1.2

(1.3, 1.1)

7.3

(7.7, 6.4)

4.0

(4.2, 3.5)

★1

—

7.0

(7.4, 6.2)

—

8.4

(8.9, 7.4)

1.2

(1.3, 1.1)

0.8 (0.8, 0.7)

0.7 (0.7, 0.6)

6.9

(7.3, 6.1)

Approx.

4.0 (4.2, 3.5)

9.3

(9.8, 8.2)

1.2

(1.3, 1.1)

6.9

(7.3, 6.1)

—

(4.8, 4.0)

Approx.

(4.8, 4.0)

(4.3, 3.6)

(1.1, 0.9)

(8.1, 6.8)

4.5

4.1

—

1.0

7.7

★1: Dual range

SPC-5

IMPREZA

SPECIFICATIONS

J: WEIGHT

1. LHD VEHICLE

Sedan

Option code★1ECK4K0KS Model 1.6 L

AWD

5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kgf (lb) 730

(1,609)

Rear kgf (lb) 520

(1,146)

Total kgf (lb) 1,250

(2,755)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ——❍❍❍❍❍❍

Front kgf (lb) 890

(1,962)

Rear kgf (lb) 890

(1,962)

Total kgf (lb) 1,700

(3,748)

Cruise control ———————— ABS ———————— Aluminium wheel ———————— Rear spoiler ———————— Spoiler pac ————————

750

(1,654)

520

(1,146)

1,270

(2,800)

890

(1,962)

890

(1,962)

1,700

(3,748)

750

(1,654)

520

(1,146)

1,270

(2,800)

890

(1,962)

890

(1,962)

1,700

(3,748)

770

(1,698)

520

(1,146)

1,290

(2,844)

890

(1,962)

890

(1,962)

1,700

(3,748)

750

(1,654)

520

(1,146)

1,270

(2,800)

890

(1,962)

890

(1,962)

1,700

(3,748)

770

(1,698)

520

(1,146)

1,290

(2,844)

890

(1,962)

890

(1,962)

1,700

(3,748)

740

(1,631)

535

(1,179)

1,275

(2,810)

890

(1,962)

890

(1,962)

1,700

(3,748)

760

(1,676)

535

(1,179)

1,295

(2,855)

890

(1,962)

890

(1,962)

1,700

(3,748)

Option code★1ECK4K0KS Model 2.0 L

AWD

5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kgf (lb) 745

(1,643)

Rear kgf (lb) 535

(1,179)

Total kgf (lb) 1,280

(2,822)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ——❍❍❍❍❍❍

Front kgf (lb) 920

(2,028)

Rear kgf (lb) 910

(2,006)

Total kgf (lb) 1,760

(3,880)

Cruise control ———————— ABS ——❍❍❍❍— ❍ Aluminium wheel ——❍❍——❍❍ Rear spoiler ——————❍❍ Spoiler pac ————————

770

(1,698)

530

(1,168)

1,300

(2,866)

920

(2,028)

910

(2,006)

1,760

(3,880)

765

(1,687)

530

(1,168)

1,295

(2,855)

920

(2,028)

910

(2,006)

1,760

(3,880)

790

(1,742)

525

(1,157)

1,315

(2,899)

920

(2,028)

910

(2,006)

1,760

(3,880)

760

(1,676)

525

(1,157)

1,285

(2,833)

920

(2,028)

910

(2,006)

1,760

(3,880)

795

(1,753)

530

(1,168)

1,325

(2,921)

920

(2,028)

910

(2,006)

1,760

(3,880)

750

(1,653)

550

(1,213)

1,300

(2,866)

920

(2,028)

910

(2,006)

1,760

(3,880)

780

(1,720)

545

(1,202)

1,325

(2,922)

920

(2,028)

910

(2,006)

1,760

(3,880)

★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

SPC-6

IMPREZA

SPECIFICATIONS

Option code★1EC Model 2.5 L 2.0 L Turbo

AWD

RS WRX STi

5MT 4AT 5MT 6MT

Curb weight (C.W.) Front kgf (lb) 760 (1,676) 785 (1,731) 815 (1,797) 875 (1,929)

Rear kgf (lb) 535 (1,179) 530 (1,168) 550 (1,213) 575 (1,268) Total kgf (lb) 1,295 (2,855) 1,315 (2,899) 1,365 (3,009) 1,450 (3,197)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ————

★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

Front kgf (lb) 930 (2,050) 930 (2,050) 970 (2,138) 1,030 (2,271) Rear kgf (lb) 910 (2,006) 910 (2,006) 920 (2,028) 920 (2,028) Total kgf (lb)

Cruise control ———— ABS ❍❍❍❍ Aluminium wheel ———— Rear spoiler ———— Spoiler pac ————

1,780 (3,924) 1,780 (3,924) 1,850 (4,079) 1,880 (4,145)

SPC-7

IMPREZA

SPECIFICATIONS

Wagon

Option code★1ECK4K0KS Model 1.6 L

AWD

D/R 4AT D/R 4AT D/R 4AT D/R 4AT

Curb weight (C.W.) Front kgf (lb) 735

(1,620)

Rear kgf (lb) 545

(1,202)

Total kgf (lb) 1,280

(2,822)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ——❍❍❍❍❍❍

Front kgf (lb) 900

(1,984)

Rear kgf (lb) 910

(2,006)

Total kgf (lb) 1,730

(3,814)

Cruise control ———————— ABS ———————— Aluminium wheel ———————— Rear spoiler ———————— Spoiler pac ————————

750

(1,653)

545

(1,202)

1,295

(2,855)

900

(1,984)

910

(2,006)

1,730

(3,814)

755

(1,664)

545

(1,202)

1,300

(2,866)

900

(1,984)

910

(2,006)

1,730

(3,814)

770

(1,698)

545

(1,202)

1,315

(2,900)

900

(1,984)

910

(2,006)

1,730

(3,814)

755

(1,664)

545

(1,202)

1,300

(2,866)

900

(1,984)

910

(2,006)

1,730

(3,814)

770

(1,698)

545

(1,202)

1,315

(2,900)

900

(1,984)

910

(2,006)

1,730

(3,814)

745

(1,642)

560

(1,235)

1,305

(2,877)

900

(1,984)

910

(2,006)

1,730

(3,814)

760

(1,676)

560

(1,235)

1,320

(2,911)

900

(1,984)

910

(2,006)

1,730

(3,814)

Option code★1ECK4K0KS Model 2.0 L

AWD

D/R 4AT D/R 4AT D/R 4AT D/R 4AT

Curb weight (C.W.) Front kgf (lb) 755

(1,664)

Rear kgf (lb) 570

(1,257)

Total kgf (lb) 1,325

(2,921)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ——❍❍❍❍❍❍

Front kgf (lb) 920

(2,028)

Rear kgf (lb) 960

(2,116)

Total kgf (lb) 1,800

(3,969)

Cruise control ———————— ABS ——❍❍❍❍— ❍ Aluminium wheel ——❍❍——❍❍ Rear spoiler ———————— Spoiler pac ————————

770

(1,698)

565

(1,246)

1,335

(2,944)

920

(2,028)

960

(2,116)

1,800

(3,969)

775

(1,709)

565

(1,246)

1,340

(2,955)

920

(2,028)

960

(2,116)

1,800

(3,969)

790

(1,742)

560

(1,235)

1,350

(2,977)

920

(2,028)

960

(2,116)

1,800

(3,969)

780

(1,720)

570

(1,257)

1,350

(2,977)

920

(2,028)

960

(2,116)

1,800

(3,969)

795

(1,753)

565

(1,246)

1,360

(2,999)

920

(2,028)

960

(2,116)

1,800

(3,969)

760

(1,676)

580

(1,279)

1,340

(2,955)

920

(2,028)

960

(2,116)

1,800

(3,969)

780

(1,720)

575

(1,268)

1,355

(2,988)

920

(2,028)

960

(2,116)

1,800

(3,969)

D/R: Dual range ★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

SPC-8

IMPREZA

SPECIFICATIONS

Option code★1ECK4 Model 2.0 L Turbo

AWD WRX

5MT

Curb weight (C.W.) Front kgf (lb) 805 (1,775) 825 (1,819)

Rear kgf (lb) 585 (1,290) 585 (1,290) Total kgf (lb) 1,390 (3,065) 1,410 (3,109)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner — ❍

D/R: Dual range ★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

Front kgf (lb) 970 (2,138) 970 (2,138) Rear kgf (lb) 950 (2,094) 950 (2,094) Total kgf (lb)

Cruise control —— ABS ❍❍ Aluminium wheel —— Rear spoiler —— Spoiler pac ——

1,860 (4,101) 1,860 (4,101)

SPC-9

IMPREZA

SPECIFICATIONS

2. RHD VEHICLE

Sedan

Option code★1EKK1 Model 1.6 L

AWD

5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kgf (lb) 735 (1,621) 755 (1,665) 750 (1,654) 770 (1,698)

Rear kgf (lb) 520 (1,146) 520 (1,146) 520 (1,146) 520 (1,146) Total kgf (lb) 1,255 (2,767) 1,275 (2,811) 1,270 (2,800) 1,290 (2,844)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ——❍❍

Front kgf (lb) 890 (1,962) 890 (1,962) 890 (1,962) 890 (1,962) Rear kgf (lb) 890 (1,962) 890 (1,962) 890 (1,962) 890 (1,962) Total kgf (lb)

Cruise control ———— ABS ❍❍—— Aluminium wheel ———— Rear spoiler ———— Spoiler pac ❍❍——

1,700 (3,748) 1,700 (3,748) 1,700 (3,748) 1,700 (3,748)

Option code★1EKK1 Model 2.0 L

AWD

5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kgf (lb) 765 (1,687) 790 (1,742) 770 (1,698) 795 (1,753)

Rear kgf (lb) 535 (1,179) 530 (1,168) 535 (1,179) 530 (1,168) Total kgf (lb) 1,300 (2,866) 1,320 (2,910) 1,305 (2,877) 1,325 (2,921)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ❍❍❍❍

★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

Front kgf (lb) 920 (2,028) 920 (2,028) 920 (2,028) 920 (2,028) Rear kgf (lb) 910 (2,006) 910 (2,006) 910 (2,006) 910 (2,006) Total kgf (lb)

Cruise control ———— ABS ❍❍❍❍ Aluminium wheel ❍❍—— Rear spoiler ❍❍—— Spoiler pac ❍❍——

1,760 (3,880) 1,760 (3,880) 1,760 (3,880) 1,760 (3,880)

SPC-10

IMPREZA

SPECIFICATIONS

Option code★1KA Model

Unladen mass (U.M.) Front kgf (lb) 750

Rear kgf (lb) 535

Total kgf (lb) 1,285

Gross vehicle mass (G.V.M.)

Option Air conditioner ——❍❍❍❍❍

Front kgf (lb) 920

Rear kgf (lb) 910

Total kgf (lb) 1,760

Cruise control ❍❍❍❍❍❍❍ ABS ❍❍❍❍❍❍❍ Aluminium wheel ——————— Rear spoiler ——❍❍❍❍— Spoiler pac ———————

2.0 L 2.0 L Turbo 2.5 L

AWD

GX WRX RS STi

5MT 4AT 5MT 4AT 5MT 4AT 6MT

(1,654)

(1,179)

(2,833)

(2,028)

(2,006)

(3,880)

775

(1,709)

530

(1,168)

1,305

(2,877)

920

(2,028)

910

(2,006)

1,760

(3,880)

830

(1,830)

560

(1,235)

1,390

(3,065)

970

(2,138)

920

(2,028)

1,850

(4,079)

855

(1,885)

555

(1,224)

1,410

(3,109)

970

(2,138)

920

(2,028)

1,850

(4,079)

780

(1,720)

540

(1,191)

1,320

(2,910)

930

(2,050)

910

(2,006)

1,780

(3,924)

805

(1,775)

535

(1,179)

1,340

(2,954)

930

(2,050)

910

(2,006)

1,780

(3,924)

2.0 L

Turbo

895

(1,973)

575

(1,268)

1,470

(3,241)

1,030

(2,271)

920

(2,028)

1,880

(4,145)

Option code★1EK Model 2.0 L Turbo

AWD

WRX STi

5MT 6MT

Curb weight (C.W.) Front kgf (lb) 830 (1,830) 895 (1,973)

Rear kgf (lb) 560 (1,235) 575 (1,268) Total kgf (lb) 1,390 (3,065) 1,470 (3,241)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ❍❍

★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

Front kgf (lb) 970 (2,138) 1,030 (2,271) Rear kgf (lb) 920 (2,028) 920 (2,028) Total kgf (lb)

Cruise control —— ABS ❍❍ Aluminium wheel —— Rear spoiler ❍ — Spoiler pac ——

1,850 (4,079) 1,880 (4,145)

SPC-11

IMPREZA

SPECIFICATIONS

Wagon

Option code★1EKK1 Model 1.6 L

AWD

D/R4ATD/R4AT

Curb weight (C.W.) Front kgf (lb) 740 (1,631) 755 (1,664) 755 (1,664) 770 (1,698)

Rear kgf (lb) 545 (1,202) 545 (1,202) 545 (1,202) 545 (1,202) Total kgf (lb) 1,285 (2,833) 1,300 (2,866) 1,300 (2,866) 1,315 (2,900)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ——❍❍

Option code★1EKK1 Model 2.0 L

Curb weight (C.W.) Front kgf (lb) 775 (1,709) 790 (1,742) 780 (1,720) 795 (1,753)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ❍❍❍❍

Front kgf (lb) 900 (1,984) 900 (1,984) 900 (1,984) 900 (1,984) Rear kgf (lb) 910 (2,006) 910 (2,006) 910 (2,006) 910 (2,006) Total kgf (lb)

Cruise control ———— ABS ❍❍—— Aluminium wheel ———— Rear spoiler ———— Spoiler pac ————

Rear kgf (lb) 570 (1,257) 565 (1,246) 570 (1,257) 565 (1,246) Total kgf (lb) 1,345 (2,965) 1,355 (2,987) 1,350 (2,977) 1,360 (2,999) Front kgf (lb) 920 (2,028) 920 (2,028) 920 (2,028) 920 (2,028) Rear kgf (lb) 960 (2,116) 960 (2,116) 960 (2,116) 960 (2,116) Total kgf (lb)

Cruise control ———— ABS ❍❍❍❍ Aluminium wheel ❍❍—— Rear spoiler ———— Spoiler pac ❍❍——

1,730 (3,814) 1,730 (3,814) 1,730 (3,814) 1,730 (3,814)

AWD

D/R4ATD/R4AT

1,800 (3,968) 1,800 (3,968) 1,800 (3,968) 1,800 (3,968)

D/R: Dual range ★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

SPC-12

IMPREZA

SPECIFICATIONS

Option code★1KA Model 2.0 L 2.0 L Turbo

AWD

GX OUTBACK WRX

D/R 4AT D/R 4AT 5MT 4AT

Unladen mass (U.M.) Front kgf (lb) 760 (1,676) 775 (1,709) 750 (1,653) 765 (1,687) 825 (1,819) 850 (1,874)

Rear kgf (lb) 570 (1,257) 565 (1,246) 570 (1,257) 570 (1,257) 585 (1,290) 585 (1,290) Total kgf (lb) 1,330

(2,932)

Gross vehicle mass (G.V.M.)

Option Air conditioner ————❍❍

Front kgf (lb) 920 (2,028) 920 (2,028) 920 (2,028) 920 (2,028) 970 (2,138) 970 (2,138) Rear kgf (lb) 960 (2,116) 960 (2,116) 960 (2,116) 960 (2,116) 950 (2,094) 950 (2,094) Total kgf (lb) 1,800

(3,968)

Cruise control ❍❍❍❍❍❍ ABS ❍❍❍❍❍❍ Aluminium wheel —————— Rear spoiler —————— Spoiler pac ——————

1,340

(2,954)

1,800

(3,968)

1,320

(2,910)

1,800

(3,968)

1,335

(2,943)

1,800

(3,968)

1,410

(3,109)

1,860

(4,101)

1,435

(3,164)

1,860

(4,101)

Option code★1EK Model 2.0 L Turbo

AWD WRX

5MT

Curb weight (C.W.) Front kgf (lb) 825 (1,819)

Rear kgf (lb) 585 (1,290) Total kgf (lb) 1,410 (3,109)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Air conditioner ❍

D/R: Dual range ★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>

Front kgf (lb) 970 (2,138) Rear kgf (lb) 950 (2,094) Total kgf (lb)

Cruise control — ABS ❍ Aluminium wheel — Rear spoiler — Spoiler pac —

1,860 (4,101)

SPC-13

SPECIFICATIONS

IMPREZA

SPC-14

IDENTIFICATION

1. Identification................................................................................................2

Page

IDENTIFICATION

1. Identification

A: IDENTIFICATION

2. MEANING OF V.I.N.

The meaning of the VIN is as follows:

• Europe, Australia and General (Except GCC)

]JF1GD5LJ32G002001[

The starting and ending brackets ( ][ ) are stop marks.

Digits Code Meaning Details 1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made 4 G Car line IMPREZA 5 D Body type D: 4 Door Sedan

G: Wagon

6 5 Displacement 5: 1.6 L AWD

9: 2.0 L AWD A: 2.0 L AWD Turbo B: 2.0 L AWD High-power Turbo E: 2.5 L AWD

7 L Steering position K: RHD (Right-hand drive)

L: LHD (Left-hand drive)

8 J Engine & transmission R: SOHC MPI 4-speed AT

J: SOHC MPI Full-time AWD 5-speed MT K: SOHC MPI Full-time AWD 5-speed MT Dual range D: DOHC Turbo Full-time AWD 5-speed MT H: DOHC Turbo Full-time AWD 6-speed MT P: DOHC Turbo 4-speed AT

9 3 Drive type 3: Full-time AWD Single range

4: Full-time AWD Dual range 5: AWD AT

10 2 Model year 2: 2002MY

3: 2003MY 11 G Factory location G: FHI (Gunma) 12 to 17 002001 Serial number —

• GCC countries (Saudi Arabia, etc.)

]JF1GD45MX2G002001[

The starting and ending brackets ( ][ ) are stop marks.

Digits Code Meaning Details 1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made 4 G Car line IMPREZA 5 D Body type D: 4 Door Sedan

G: Wagon

6 4 Displacement 4: 1.6 L AWD

8: 2.0 L AWD

75 Grade 5: TS

7: GX 8 M Restraint M: Manual belts, dual airbag 9 X Check digit — 10 2 Model year 2: 2002MY

3: 2003MY 11 G Transmission type G: Full-time AWD 5-speed MT single range

H: Full-time AWD 4-speed AT

J: Full-time AWD 5-speed MT dual range 12 to 17 002001 Serial number —

ID-2

IDENTIFICATION

3. MODEL NUMBER PLATE

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts.

GD9BL7R

Digits Code Meaning Details 1 G Series IMPREZA 2 D Body style D: 4 Door Sedan

G: Wagon

3 9 Engine displacement

Drive system Suspension system

4 B Minor change 2002MY 5 L Destination K: Right-hand drive market

67 Grade 4: TS

7 R Transmission, fuel feed

system

5: 1.6 L AWD 9: 2.0 L AWD A: 2.0 L AWD Turbo B: 2.0 L AWD High-power Turbo E: 2.5 L AWD

L: Left-hand drive market

5: GX 6: RS 7: OUTBACK 8: WRX E: STi

R: SOHC MPI 4-speed AT J: SOHC MPI 5-speed MT AWD K: SOHC MPI 5-speed MT Dual range P: DOHC B MPI 4-speed AT D: DOHC B MPI 5-speed MT AWD H: DOHC B MPI 6-speed MT AWD

The engine and transmission type are as follows:

• Engine

EJ161RX3AA

Digits Code Meaning Details 1 and 2 EJ Engine type EJ: 4 cylinders 3 and 4 16 Displacement 16: 1.6 L

20: 2.0 L 25: 2.5 L

5 1 Fuel feed system 1: D-MPI SOHC-A

5: MPI Turbo

7: MPI High-power Turbo 6 R Detailed specifications Used when ordering parts. See the parts catalog for details. 7 X Transmission W: MT

X: AT 8 to 10 3AA Detailed specifications Used when ordering parts. See the parts catalog for details.

ID-3

IDENTIFICATION

• Transmission

TY856WN2AA

Digits Code Meaning Details 1 T Transmission T: Transmission 2 Y Transmission type Y: Full-time AWD MT center differential

V: Full-time AWD AT center differential Z: Full-time AWD AT MPT

3 and 4 85 Classification 75: 5MT

85: 6MT 1B: AT

5 6 Series MT 4: 5MT

6: 6MT

AT 4: AT

6 W Transmission specifica-

tions

7 to 10 N2AA Detailed specifications Used when ordering parts. See the parts catalog for details.

• Rear differential 1

V: Full-time AWD 5-speed MT with viscous coupling center differential single range X: Full-time AWD 5-speed MT with viscous coupling center differential dual range W: Full-time AWD 6-speed MT with viscous coupling center differential single range Z: Full-time AWD 4-speed AT with MPT Y: Full-time AWD 4-speed AT with VTD

VA1REJ

Digits Code Meaning Details 1 V For AWD V: AWD 2 A Type A: A type 3 1 Hypoid gear diameter

mm (in) 4 R Installation position R: Rear 5 E Reduction gear ratio B: 3.900

6 J Specification differ-

ences

1: 152 (6.0) dia. 2: 160 (6.3) dia.

E: 4.111 F: 4.444

J: Case B

• Rear differential 2

Code Reduction gear ratio LSD EG 3.900 No ER 3.700 Viscous

EM 4.444

EJ 4.111 Viscous EF 3.545 Viscous

HG 3.500

HJ 3.545

SURETRAC



ID-4

IDENTIFICATION

• Option code

ECPS

Digits Code Meaning Details

1 to 2 EC Destination EC: EC

KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1

3 to 4 PS Main option of vehicle —

IDENTIFICATION

ID-5

IDENTIFICATION

ID-6

2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE 2 SECTION

FUEL INJECTION (FUEL SYSTEMS) FU(TURBO)

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

INTAKE (INDUCTION) IN(TURBO)

MECHANICAL ME(STi)

ENGINE (DIAGNOSTICS) EN(TURBO)

EC(TURBO)

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD. G1841GE3

FUEL INJECTION (FUEL SYSTEMS)

FU(TURBO)

1. General Description

2. Throttle Body

3. Intake Manifold

4. Engine Coolant Temperature Sensor

5. Crankshaft Position Sensor

6. Camshaft Position Sensor

7. Knock Sensor

8. Throttle Position Sensor

9. Mass Air Flow and Intake Air Temperature Sensor

10. Pressure Sensor

11. Idle Air Control Solenoid Valve

12. Fuel Injector

13. Tumble Generator Valve Assembly ............................................................2

14. Tumble Generator Valve Actuator...............................................................3

15. Wastegate Control Solenoid Valve

16. Front Oxygen (A/F) Sensor

17. Rear Oxygen Sensor

18. Exhaust Temperature Sensor .....................................................................4

19. Engine Control Module

20. Main Relay

21. Fuel Pump Relay

22. Fuel Pump Controller

23. Fuel

24. Fuel Tank

25. Fuel Filler Pipe

26. Fuel Pump

27. Fuel Level Sensor

28. Fuel Sub Level Sensor

29. Fuel Filter

30. Fuel Cut Valve

31. Fuel Damper Valve

32. Fuel Delivery, Return and Evaporation Lines

33. Fuel System Trouble in General

34. Variable Valve Timing Camshaft Positon Sensor .......................................5

35. Variable Valve Timing Solenoid Valve ........................................................6

Page

TUMBLE GENERATOR VALVE ASSEMBLY

FUEL INJECTION (FUEL SYSTEMS)

13.Tumble Generator Valve Assembly

A: REMOVAL

2. STI MODEL

NOTE: Tumble generator valve actuator and sensor are not applied to STi model.

B: INSTALLATION

2. STI MODEL

NOTE: Tumble generator valve actuator and sensor are not applied to STi model.

FU(TURBO)-2

TUMBLE GENERATOR VALVE ACTUATOR

14.Tumble Generator Valve Actuator

A: REMOVAL

3. STI MODEL

NOTE: Tumble generator valve actuator is not applied to STi model.

B: INSTALLATION

3. STI MODEL

NOTE: Tumble generator valve actuator is not applied to STi model.

FUEL INJECTION (FUEL SYSTEMS)

FU(TURBO)-3

EXHAUST TEMPERATURE SENSOR

FUEL INJECTION (FUEL SYSTEMS)

18.Exhaust Temperature Sensor

A: REMOVAL

2. STI MODEL

NOTE: Exhaust temperature sensor is not applied to STi model.

B: INSTALLATION

2. STI MODEL

NOTE: Exhaust temperature sensor is not applied to STi model.

FU(TURBO)-4

VARIABLE VALVE TIMING CAMSHAFT POSITON SENSOR

34.Variable Valve Timing Camshaft Positon Sensor

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the intercooler. <Ref. to IN(TURBO)-

10, REMOVAL, Intercooler.>

3) Remove the intake manifold. <Ref. to FU(TUR-

BO)-15, REMOVAL, Intake Manifold.>

4) Disconnect the variable valve timing camshaft

position sensor connector.

5) Remove the variable valve timing camshaft posi-

tion sensor.

FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

Install in the reverse order of removal.

EN1533

FU(TURBO)-5

VARIABLE VALVE TIMING SOLENOID VALVE

FUEL INJECTION (FUEL SYSTEMS)

35.Variable Valve Timing Solenoid Valve

A: REMOVAL

Refer to following procedure for removal. <Ref. to ME(STi)-59, REMOVAL, Camshaft.>

B: INSTALLATION

Install in the reverse order of removal.

FU(TURBO)-6

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(TURBO)

1. General Description

2. Front Catalytic Converter

3. Rear Catalytic Converter

4. Precatalytic Converter.................................................................................2

5. Canister

6. Purge Control Solenoid Valve

7. Two-way Valve

Page

PRECATALYTIC CONVERTER

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. Precatalytic Converter

A: REMOVAL

2. STI MODEL

NOTE: Precatalytic converter is not applied to STi model.

B: INSTALLATION

2. STI MODEL

NOTE: Precatalytic converter is not applied to STi model.

EC(TURBO)-2

INTAKE (INDUCTION)

IN(TURBO)

1. General Description ....................................................................................2

2. Air Cleaner

3. Air Intake Duct

4. Intake Duct

5. Intercooler

6. Turbocharger

7. Air By-pass Valve

8. Resonator Chamber

9. Intercooler Water Tank................................................................................3

Page

GENERAL DESCRIPTION

INTAKE (INDUCTION)

1. General Description

A: COMPONENT

5. INTERCOOLER WATER TANK

(2)

(1)

EN1545

(1) Water tank assembly (2) Water tank cap Tightening torque: N·m (kgf-m, ft-lb)

T: 6.0 (0.61, 4.4)

IN(TURBO)-2

INTERCOOLER WATER TANK

9. Intercooler Water Tank

A: REMOVAL

1) Disconnect the ground cable from battery.

G6M0095

2) Remove the trunk trim. <Ref. to EI-52, REMOV-

AL, Trunk Trim.>

3) Disconnect the water tank connector.

INTAKE (INDUCTION)

EN1541

4) Remove the two water tank installation bolts.

EN1542

5) Remove the hose between body and water tank,

then remove the water tank.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

6.0 N·m (0.61 kgf-m, 4.4 ft-lb)

C: INSPECTION

1) Make sure the hose is not deformed, damaged,

cracked or clogged.

2) Make sure the water tank is not damaged or

cracked

IN(TURBO)-3

INTAKE (INDUCTION)

INTERCOOLER WATER TANK

IN(TURBO)-4

MECHANICAL

1. General Description ....................................................................................2

2. Compression.............................................................................................22

3. Idle Speed .................................................................................................23

4. Ignition Timing...........................................................................................24

5. Intake Manifold Vacuum............................................................................25

6. Engine Oil Pressure ..................................................................................26

7. Fuel Pressure............................................................................................27

8. Valve Clearance........................................................................................28

9. Engine Assembly ......................................................................................32

10. Engine Mounting .......................................................................................41

11. Preparation for Overhaul...........................................................................42

12. V-belt.........................................................................................................43

13. Crankshaft Pulley ......................................................................................45

14. Belt Cover .................................................................................................46

15. Timing Belt Assembly................................................................................47

16. Camshaft Sprocket....................................................................................56

17. Crankshaft Sprocket..................................................................................58

18. Camshaft ...................................................................................................59

19. Cylinder Head Assembly...........................................................................65

20. Cylinder Block ...........................................................................................73

21. Engine Trouble in General ........................................................................92

22. Engine Noise.............................................................................................97

ME(STi)

Page

MECHANICAL

1. General Description

A: SPECIFICATIONS

GENERAL DESCRIPTION

Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine

1,994 (121.67)

981 — 1,177 (10 — 12, 142 — 171)

700±50 (No load)

750±50 (A/C switch ON)

Engine

Type

Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)

Piston displacement

Compression ratio 8.0 Compression pressure

(at 200 — 300 rpm) kPa (kg/cm Number of piston rings Pressure ring: 2, Oil ring: 1

Opening

Intake valve timing

Closing

Exhaust valve timing

Valve clearance

Idling speed [At neutral position] rpm

Firing order 1 → 3 → 2 → 4 Ignition timing BTDC/rpm 12°±3°/700 rpm

Opening 58° BBDC Closing 10° ATDC Intake mm (in) 0.20±0.02 (0.0079±0.0008) Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)

(cu in)

, psi)

Max. retard ATDC 6° Min. advance BTDC 29° Max. retard ABDC 68° Min. advance ABDC 33°

NOTE: STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize

ME(STi)-2

Belt tension adjuster

Belt tensioner

Camshaft

Cylinder head

Valve seat

Valve guide

Valve

Valve spring

GENERAL DESCRIPTION

MECHANICAL

Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)

Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in) Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in)

Clearance between spacer and bush

Side clearance of spacer

Bend limit 0.020 mm (0.0079 in)

Thrust clearance

Intake

Cam lobe height

Exhaust

Journal O.D. STD

Oil clearance

Surface warpage limit 0.05 mm (0.0020 in) Surface grinding limit 0.1 mm (0.004 in) Standard height 127.5 mm (5.02 in) Refacing angle 90°

Intake

Contacting width

Exhaust

Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in) Protrusion above head 12.0 — 12.4 mm (0.472 — 0.488 in)

Intake

Head edge thickness

Exhaust

Stem diameter

Stem oil clearance

Overall length

Free length 43.89 mm (1.7279 in) Squareness 2.5°, 1.9 mm (0.075 in)

Tension/spring height

STD

Limit — 0.15 mm (0.0059 in)

STD 0.025 — 0.125 mm (0.0010 — 0.0049 in) Limit 0.175 mm (0.0069 in) STD 0.2 — 0.55 mm (0.0079 — 0.0217 in) Limit 0.81 mm (0.0319 in)

STD 0.015 — 0.070 mm (0.0006 — 0.0028 in) Limit 0.10 mm (0.0039 in) STD 45.25 — 45.35 mm (1.781 — 1.785 in) Limit 45.15 mm (1.778 in) STD 45.60 — 45.70 mm (1.795 — 1.799 in) Limit 45.50 mm (1.791 in) Front 37.946 — 37.963 mm (1.4939 — 1.4946 in) Center

rear STD 0.037 — 0.072 mm (0.0015 — 0.0028 in) Limit 0.10 mm (0.0039 in)

STD 1.0 mm (0.039 in) Limit 1.7 mm (0.067 in) STD 1.5 mm (0.059 in) Limit 2.2 mm (0.087 in)

STD 1.2 mm (0.047 in) Limit 0.8 mm (0.031 in) STD 1.5 mm (0.059 in) Limit 0.8 mm (0.031 in) Intake 5.962 — 5.970 mm (0.2347 — 0.2350 in) Exhaust 5.945 — 5.960 mm(0.2341 — 0.2346 in) Intake 0.030 — 0.050 mm (0.0012 — 0.0020 in) Exhaust 0.040 — 0.050 mm (0.0016 — 0.0020 in)

Intake 104.4 mm (4.110 in) Exhaust 104.7 mm (4.122 in)

Set 220.7±15.7 N (22.5±1.6 kgf, 49.6±3.5 lb)/36.0 mm (1.417 in) Lift 582±29 N (59.3±3.0 kgf, 130.8±6.5 lb)/24.65 mm (0.970 in)

29.946 — 29.963 mm (1.1790 — 1.1796 in)

ME(STi)-3

MECHANICAL

Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in) Surface grinding limit 0.1 mm (0.004 in)

Cylinder bore STD

Cylinder block

Piston Outer diameter

Piston pin

Piston ring

Connecting rod

Connecting rod bearing

Connecting rod bushing

Taper

Out-of-roundness

Piston clearance

Enlarging (boring) limit 0.5 mm (0.020 in)

Standard clearance between piston pin and hole in piston

Degree of fit

Piston ring gap

Clearance between piston ring and piston ring groove

Bend twist per 100 mm (3.94 in) in length

Side clearance

Oil clearance

Thickness at center portion

Clearance between piston pin and bushing

GENERAL DESCRIPTION

A 92.005 — 92.015 mm (3.6222 — 3.6226 in) B 91.995 — 92.005 mm (3.6218 — 3.6222 in) STD 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) STD 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in) STD 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.050 mm (0.0020 in)

STD

0.25 mm (0.0098 in) OS

0.50 mm (0.0197 in) OS

Top ring

Second ring

Oil ring

Top ring

Second ring

A 91.985 — 91.995 mm (3.6214 — 3.6218 in) B 91.975 — 91.985 mm (3.6211 — 3.6214 in)

92.225 — 92.235 mm (3.6309 — 3.6313 in)

92.475 — 92.485 mm (3.6407 — 3.6411 in)

STD 0.004 — 0.008 mm (0.0002 — 0.0003 in) Limit 0.020 mm (0.0008 in)

Piston pin must be fitted into position with thumb at 20°C

STD 0.20 — 0.25 mm (0.0079 — 0.0098 in) Limit 1.0 mm (0.039 in) STD 0.35 — 0.50 mm (0.0138 — 0.0197 in) Limit 1.0 mm (0.039 in) STD 0.20 — 0.50 mm (0.0079 — 0.0197 in) Limit 1.5 mm (0.059 in) STD 0.040 — 0.080 mm (0.0016 — 0.0031 in) Limit 0.15 mm (0.0059 in) STD 0.030 — 0.070 mm (0.0012 — 0.0028 in) Limit 0.15 mm (0.0059 in)

Limit 0.10 mm (0.0039 in)

STD 0.070 — 0.330 mm (0.0028 — 0.0130 in) Limit 0.4 mm (0.016 in) STD 0.020 — 0.046 mm (0.0008 — 0.0018 in) Limit 0.05 mm (0.0020 in) STD 1.486 — 1.498 mm (0.0585 — 0.0590 in)

0.03 mm (0.0012 in) US

0.05 mm (0.0020 in) US

0.25 mm (0.0098 in) US

STD 0 — 0.022 mm (0 — 0.0009 in) Limit 0.030 mm (0.0012 in)

1.505 — 1.509 mm (0.0593 — 0.0594 in)

1.515 — 1.519 mm (0.0596 — 0.0598 in)

1.615 — 1.619 mm (0.0636 — 0.0637 in)

(68°F).

ME(STi)-4

Crankshaft

Crankshaft bearing

GENERAL DESCRIPTION

Bend limit 0.035 mm (0.0014 in)

Crank pin and crank journal

Crank pin outer diameter

Crank journal outer diameter

Thrust clearance

Oil clearance

Crankshaft bearing thickness

Out-of-roundness 0.020 mm (0.0008 in) or less Grinding limit 0.25 mm (0.0098 in)

STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)

0.03 mm

#1, #3, #5

#2, #4

#1, #3

#2, #4, #5

(0.0012 in) US

0.05 mm (0.0020 in) US

0.25 mm (0.0098 in) US

STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)

0.03 mm (0.0012 in) US

0.05 mm (0.0020 in) US

0.25 mm (0.0098 in) US

STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)

0.03 mm (0.0012 in) US

0.05 mm (0.0020 in) US

0.25 mm (0.0098 in) US

STD 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) STD 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.040 mm (0.0016 in) STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in) US

0.05 mm (0.0020 in) US

0.25 mm (0.0098 in) US

STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)

0.03 mm (0.0012 in) US

0.05 mm (0.0020 in) US

0.25 mm (0.0098 in) US

51.954 — 51.970 mm (2.0454 — 2.0461 in)

51.934 — 51.950 mm (2.0446 — 2.0453 in)

51.734 — 51.750 mm (2.0368 — 2.0374 in)

59.962 — 59.978 mm (2.3607 — 2.3613 in)

59.942 — 59.958 mm (2.3599 — 2.3605 in)

59.742 — 59.758 mm (2.3520 — 2.3527 in)

59.962 — 59.978 mm (2.3607 — 2.3613 in)

59.942 — 59.958 mm (2.3599 — 2.3605 in)

59.742 — 59.758 mm (2.3520 — 2.3527 in)

2.017 — 2.020 mm (0.0794 — 0.0795 in)

2.027 — 2.030 mm (0.0798 — 0.0799 in)

2.127 — 2.130 mm (0.0837 — 0.0839 in)

2.019 — 2.022 mm (0.0795 — 0.0796 in)

2.029 — 2.032 mm (0.0799 — 0.0800 in)

2.129 — 2.132 mm (0.0838 — 0.0839 in)

MECHANICAL

ME(STi)-5

MECHANICAL

B: COMPONENT

1. TIMING BELT

GENERAL DESCRIPTION

(17)

(12)

(14)

(13)

(8)

(7)

(9)

(2)

(6)

(2)

(11)

(14)

(10)

(1)

(2)

(3)

(4)

(5)

(2)

(15)

(16)

(1) Right-hand belt cover No. 2 (9) Right-hand intake camshaft (2) Timing belt guide (18) Crankshaft pulley

(18)

EN1192

(17) Right-hand belt cover

sprocket

(3) Crankshaft sprocket (10) Left-hand intake camshaft (4) Left-hand belt cover No. 2 Tightening torque: N·m (kgf-m, ft-lb) (5) Tensioner bracket (11) Left-hand exhaust camshaft (6) Automatic belt tension adjuster

ASSY

sprocket

T1: 5 (0.5, 3.6)

sprocket

T2: 10 (1.0, 7)

(12) Timing belt T3: 25 (2.5, 18.1) (7) Belt idler (13) Belt idler No. 2 T4: 39 (4.0, 28.9) (8) Right-hand exhaust camshaft

sprocket

(14) Belt idler T5: 98 (10, 72.4)

(15) Left-hand belt cover T6: <Ref. to ME(STi)-45, Installation,

(16) Front belt cover

Crankshaft Pulley.>

ME(STi)-6

GENERAL DESCRIPTION

MECHANICAL

ME(STi)-7

GENERAL DESCRIPTION

MECHANICAL

2. CYLINDER HEAD AND CAMSHAFT

(2)

(1)

(3)

(7)

(11)

(28)

(6)

(15)

(9)

(16)

(13)

(4)

(14)

(17)

(8)

(5)

(11)

(28)

(10)

(18)

(21)

(20)

(12)

(13)

(24)

(25)

(26)

(27)

(22)

(19)

ME(STi)-8

(23)

EN1193

GENERAL DESCRIPTION

MECHANICAL

(1) Rocker cover (RH) (13) Cylinder head gasket (25) Gasket (2) Rocker cover gasket (RH) (14) Cylinder head (LH) (26) Oil filler duct (3) Variable valve timing solenoid

valve assembly (RH)

(4) Intake camshaft cap (RH) (17) Variable valve timing solenoid (5) Intake camshaft (RH) Tightening torque: N·m (kgf-m, ft-lb) (6) Exhaust camshaft cap (Front RH) (18) Intake camshaft cap (LH) T1: <Ref. to ME(STi)-65, Installation, (7) Exhaust camshaft cap (Center

RH)

(8) Exhaust camshaft cap (Rear RH) T3: 10 (1.0, 7) (9) Exhaust camshaft (RH) (21) Exhaust camshaft cap (Rear LH) T4: 6.4 (0.65, 4.7)

(10) Cylinder head bolt (22) Rocker cover gasket (LH) T5: 20 (2.0, 14.5) (11) Oil seal (23) Rocker cover (LH) (12) Cylinder head (RH) (24) Oil filler cap

(15) Intake camshaft (LH) (27) O-ring

(16) Exhaust camshaft (LH) (28) Stud bolt

valve assembly (LH)

(19) Exhaust camshaft cap (Front LH)

(20) Exhaust camshaft cap (Center

LH)

Cylinder Head Assembly.>

T2: 5 (0.5, 3.6)

ME(STi)-9

GENERAL DESCRIPTION

MECHANICAL

3. CYLINDER HEAD AND VALVE ASSEMBLY

(1)

(2)

(12)

(4)

(3)

(10)

(6)

(11) (4) (5) (6) (7) (8) (9)

(4)

(12)

(11)

(4)

(5) (6)

(10)

(6)

(7)

(8)

(7)

(9)

(8)

(9)

(7)

(8)

(9)

(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter (2) Intake valve (6) Valve spring (10) Exhaust valve oil seal (3) Cylinder head (7) Retainer (11) Intake valve guide (4) Valve spring seat (8) Retainer key (12) Exhaust valve guide

EN1194

ME(STi)-10

4. CYLINDER BLOCK

GENERAL DESCRIPTION

MECHANICAL

EN0144

(1) Oil pressure switch (15) Oil cooler Tightening torque: N·m (kgf-m, ft-lb) (2) Cylinder block (RH) (16) Waster by-pass pipe T1: 5 (0.5, 3.6) (3) Service hole plug (17) Connector T2: 6.4 (0.65, 4.7) (4) Gasket (18) Oil strainer T3: 10 (1.0, 7) (5) Oil separator cover (19) Gasket T4: 25 (2.5, 18.1) (6) Water by-pass pipe (20) Oil pan T5: 47 (4.8, 34.7) (7) Oil pump (21) Drain plug T6: 69 (7.0, 50.6) (8) Front oil seal (22) Metal gasket T7: First 12 (1.2, 8.7) (9) Rear oil seal (23) Oil level gauge guide

(10) O-ring (24) Oil filter T8: 16 (1.6, 11.6) (11) Service hole cover (25) Gasket T9: 44 (4.5, 33) (12) Cylinder block (LH) (26) Water pump hose T10: 25 (2.5, 18.1) (13) Water pump (27) Plug T11: 55 (5.5, 40) (14) Baffle plate

Second 12 (1.2, 8.7)

ME(STi)-11

MECHANICAL

5. CRANKSHAFT AND PISTON

(3)

(4)

(5)

(8)

(6)

(9)

(12)

GENERAL DESCRIPTION

(1)

(8)

(7)

(10)

(11)

(2)

(13)

(11)

(12)

(9)

(6)

(8)

(5)

(4)

(3)

EN1519

(14)

(11)

(10)

(8)

(7)

(17)

(16)

(15)

(16)

(15)

(1) Flywheel (8) Circlip (15) Crankshaft bearing #1, #3 (2) Ball bearing (9) Connecting rod bolt (16) Crankshaft bearing #2, #4 (3) Top ring (10) Connecting rod (17) Crankshaft bearing #5 (4) Second ring (11) Connecting rod bearing (5) Oil ring (12) Connecting rod cap Tightening torque: N·m (kgf-m, ft-lb) (6) Piston (13) Crankshaft T1: 52 (5.3, 38.4) (7) Piston pin (14) Woodruff key T2: 72 (7.3, 52.8)

ME(STi)-12

6. ENGINE MOUNTING

GENERAL DESCRIPTION

MECHANICAL

S2M1783A

(1) Heat shield cover (3) Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) (2) Front cushion rubber T1: 35 (3.6, 25.8)

T2: 42 (4.3, 30.9) T3: 85 (8.7, 62.7)

ME(STi)-13

MECHANICAL

GENERAL DESCRIPTION

C: CAUTION

• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.

• Remove contamination including dirt and corrosion before removal, installation or disassembly.

• Keep the disassembled parts in order and protect them from dust or dirt.

• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.

• Be careful not to burn your hands, because each part in the vehicle is hot after running.

• Be sure to tighten fasteners including bolts and nuts to the specified torque.

• Place shop jacks or safety stands at the specified points.

• Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.

• All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings.

• Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.

• Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.

• All removed parts, if to be reused, should be reinstalled in the original positions and directions.

• Bolts, nuts and washers should be replaced with new ones as required.

• Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.

• Remove or install engine in an area where chain hoists, lifting devices, etc. are available for ready use.

• Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil. Place a cover over fenders, as required, for protection.

• Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.

• Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

D: PREPARATION TOOL

1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

EN0147

498267600 CYLINDER

HEAD TABLE

498457000 ENGINE STAND

ADAPTER RH

• Used for replacing valve guides.

• Used for removing and installing valve springs.

Used with ENGINE STAND (499817000).

B2M3851

ME(STi)-14

GENERAL DESCRIPTION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498457100 ENGINE STAND

ADAPTER LH

B2M3852

498497100 CRANKSHAFT

STOPPER

Used with ENGINE STAND (499817000).

Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.

MECHANICAL

B2M3853

B2M3854

B2M3855

398744300 PISTON GUIDE Used for installing piston in cylinder.

498857100 VALVE OIL

SEAL GUIDE

Used for press-fitting of intake and exhaust valve guide oil seals.

ME(STi)-15

MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

B2M3856

GENERAL DESCRIPTION

499017100 PISTON PIN

GUIDE

499037100 CONNECTING

ROD BUSHING REMOVER & INSTALLER

Used for installing piston pin, piston and connecting rod.

Used for removing and installing connecting rod bushing.

B2M3857

B2M3858

B2M4158

499097700 PISTON PIN

REMOVER ASSY

499207400 CAMSHAFT

SPROCKET WRENCH

Used for removing piston pin.

Used for removing and installing exhaust camshaft sprocket.

ME(STi)-16

GENERAL DESCRIPTION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977500

(Newly adopted

tool)

EN1195

499587700 CAMSHAFT OIL

CAMSHAFT SPROCKET WRENCH

SEAL INSTALLER

Used for removing and installing intake camshaft.

Used for installing camshaft oil seal.

MECHANICAL

B2M3860

B2M3861

B2M3863

499587200 CRANKSHAFT

OIL SEAL INSTALLER

499597100 CRANKSHAFT

OIL SEAL GUIDE

• Used for installing crankshaft oil seal.

• Used with CRANKSHAFT OIL SEAL GUIDE

(499597100).

• Used for installing crankshaft oil seal.

• Used with CRANKSHAFT OIL SEAL

INSTALLER (499587200).

ME(STi)-17

MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

B2M3864

GENERAL DESCRIPTION

499718000 VALVE SPRING

REMOVER

498267700 VALVE GUIDE

ADJUSTER

Used for removing and installing valve spring.

Used for installing intake and exhaust valve guides.

B2M3865

B2M3867

B2M3868

499767200 VALVE GUIDE

REMOVER

499767400 VALVE GUIDE

REAMER

Used for removing valve guides.

Used for reaming valve guides.

ME(STi)-18

GENERAL DESCRIPTION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499817000 ENGINE STAND • Stand used for engine disassembly and assem-

bly.

• Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).

B2M3869

499977300 CRANK PULLEY

WRENCH

Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts.

MECHANICAL

B2M4157

B2M3871

B2M3872

499987500 CRANKSHAFT

SOCKET

498547000 OIL FILTER

WRENCH

Used for rotating crankshaft.

Used for removing and installing oil filter.

ME(STi)-19

MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

B2M3875

GENERAL DESCRIPTION

499587100 OIL SEAL

INSTALLER

499587600 OIL SEAL GUIDE Used for installing camshaft oil seal.

Used for installing oil pump oil seal.

S1H0136

EN0168

EN1196

499597200 OIL SEAL GUIDE Used for installing camshaft oil seal.

Used with OIL SEAL GUIDE (499587600).

499897200 PISTON CIR-

CLIP PLIER

Used for removing and installing piston pin.

ME(STi)-20

GENERAL DESCRIPTION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA190 CARTRIDGE Troubleshooting for electrical systems.

B2M3876

22771AA030 SELECT MONI-

TOR KIT

Troubleshooting for electrical systems.

• English: 22771AA030 (Without printer)

• German: 22771AA070 (Without printer)

• French: 22771AA080 (Without printer)

• Spanish: 22771AA090 (Without printer)

MECHANICAL

B2M3877

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS Compression Gauge Used for measuring compression. Timing Light Used for measuring ignition timing.

E: PROCEDURE

It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.

• V-belt

• Timing Belt

• Camshaft

• Cylinder Head

ME(STi)-21

COMPRESSION

MECHANICAL

2. Compression

A: INSPECTION

CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement.

1) After warming-up the engine, turn the ignition switch to OFF.

2) Make sure that the battery is fully charged.

3) Release fuel pressure. <Ref. to FU(TURBO)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>

4) Remove all the spark plugs. <Ref. to IG(TURBO)-4, REMOVAL, Spark Plug.>

5) Fully open the throttle valve.

6) Check the starter motor for satisfactory performance and operation.

7) Hold the compression gauge tight against the spark plug hole.

CAUTION: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long.

8) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.

EN0172

9) Perform at least two measurements per cylinder, and make sure that the values are correct.

Compression (350 rpm and fully open throttle):

Standard;

951 — 1,147 kPa (9.7 — 11.7 kg/cm

, 138 —

166 psi)

Limit;

883 kPa (9.0 kg/cm

, 128 psi)

Difference between cylinders;

49 kPa (0.5 kg/cm

, 7 psi)

ME(STi)-22

IDLE SPEED

3. Idle Speed

A: INSPECTION

1) Before checking idle speed, check the following: (1) Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are connected properly. (2) Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate.

2) Warm-up the engine.

3) Stop the engine, and turn the ignition switch to

OFF.

4) Insert the cartridge to SUBARU SELECT MONI-

TOR.

5) Connect SUBARU SELECT MONITOR to the

data link connector.

6) Turn the ignition switch to ON, and SUBARU

SELECT MONITOR switch to ON.

7) Select {2. Each System Check} in Main Menu.

8) Select {Engine Control System} in Selection

Menu.

9) Select {1. Current Data Display & Save} in En-

gine Control System Diagnosis.

10) Select {1.12 Data Display} in Data Display

Menu.

11) Start the engine, and read engine idle speed.

12) Check the idle speed when unloaded. (With

headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF)

MECHANICAL

Idle speed (No load and gears in neutral):

±±±±

50 rpm

700

13) Check the idle speed when loaded. (Turn air

conditioning switch to “ON” and operate compressor for at least one minute before measurement.)

Idle speed [A/C “ON”, no load and gears in neutral]:

±±±±

50 rpm

750

CAUTION: Never rotate the idle adjusting screw. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under “Engine Control System”. <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.>

ME(STi)-23

IGNITION TIMING

MECHANICAL

4. Ignition Timing

A: INSPECTION

1) Before checking ignition timing speed, check the

following:

(1) Ensure that air cleaner element is free from clogging, spark plugs are in good condition, and that hoses are connected properly. (2) Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate.

2) Warm-up the engine.

3) Stop the engine, and turn the ignition switch to

OFF.

4) Insert the cartridge to SUBARU SELECT MONI-

TOR.

5) Connect SUBARU SELECT MONITOR to the

data link connector.

6) Turn the ignition switch to ON, and SUBARU

SELECT MONITOR switch to ON.

7) Select {2. Each System Check} in Main Menu.

8) Select {Engine Control System} in Selection

Menu.

9) Select {1. Current Data Display & Save} in En-

gine Control System Diagnosis.

10) Select {1.12 Data Display} in Data Display

Menu.

11) Start the engine, at idle speed and check the ig-

nition timing.

Ignition timing [BTDC/rpm]:

°±

°±3°°°°

°±°±

/700

If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.>

ME(STi)-24

INTAKE MANIFOLD VACUUM

MECHANICAL

5. Intake Manifold Vacuum

A: INSPECTION

1) Warm-up the engine.

2) Disconnect the brake vacuum hose and install

the vacuum gauge to the hose fitting on the manifold.

Diagnosis of engine condition by measurement of manifold vacuum

Vacuum gauge indication Possible engine condition

1. Needle is steady but lower than normal position. This tendency becomes more evident as engine temperature rises.

2. When engine speed is reduced slowly from higher speed, needle stops temporarily when it is lowering or becomes steady above normal position.

3. Needle intermittently drops to position lower than normal position.

4. Needle drops suddenly and intermittently from normal position.

5. When engine speed is gradually increased, needle begins to vibrate rapidly at certain speed, and then vibration increases as engine speed increases.

6. Needle vibrates above and below normal position in narrow range.

3) Keep the engine at the idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below.

H2M1767

Vacuum pressure (at idling, A/C “OFF”):

Less than

−−−−

64.0 kPa (

−−−−

480 mmHg,

−−−−

18.90 in-

Hg)

Leakage around intake manifold gasket or disconnection or damaged vacuum hose

Back pressure too high, or exhaust system clogged

Leakage around cylinder

Sticky valves

Weak or broken valve springs

Defective ignition system or throttle chamber idle adjustment

ME(STi)-25

ENGINE OIL PRESSURE

MECHANICAL

6. Engine Oil Pressure

A: INSPECTION

1) Remove the oil pressure switch from engine cyl-

inder block. <Ref. to LU-21, REMOVAL, Oil Pressure Switch.>

2) Connect the oil pressure gauge hose to cylinder

block.

3) Connect the battery ground cable.

G6M0095

4) Start the engine, and measure the oil pressure.

S2M0242

Oil pressure:

98 kPa (1.0 kg/cm 294 kPa (3.0 kg/cm

, 14 psi) or more at 800 rpm

, 43 psi) or more at 5,000

rpm

CAUTION:

• If the oil pressure is out of specification,

check oil pump, oil filter and lubrication line. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.>

• If the oil pressure warning light is turned ON

and oil pressure is in specification, replace the oil pressure switch. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.>

NOTE: The specified data is based on an engine oil temperature of 80°C (176°F).

5) After measuring the oil pressure, install the oil

pressure switch. <Ref. to LU-21, INSTALLATION, Oil Pressure Switch.>

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

ME(STi)-26

FUEL PRESSURE

MECHANICAL

7. Fuel Pressure

A: INSPECTION

WARNING: Before removing the fuel pressure gauge, release fuel pressure.

NOTE: If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose.

1) Release fuel pressure. <Ref. to FU(TURBO)-53,

RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>

2) Open the fuel flap lid, and remove the fuel filler

cap.

6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold.

Fuel pressure:

Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm

41 — 46 psi)

S2M0554

7) After connecting the pressure regulator vacuum hose, measure the fuel pressure.

Fuel pressure:

Standard; 230 — 260 kPa (2.35 — 2.65 kg/cm

33 — 38 psi)

H2M2535

3) Disconnect the fuel delivery hoses from fuel fil-

ter, and connect the fuel pressure gauge.

S2M0195

4) Connect the connector of fuel pump relay.

S2M0554

NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kg/cm

, 1 to 3 psi) higher than standard val-

ues during high-altitude operations.

5) Start the engine.

EN0344

ME(STi)-27

MECHANICAL

VALVE CLEARANCE

8. Valve Clearance

A: INSPECTION

CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold.

1) Set the vehicle on a lift.

2) Disconnect the battery ground cable.

G6M0095

3) Remove the air intake duct. <Ref. to IN(TUR-

BO)-8, REMOVAL, Air Intake Duct.>

4) Remove one bolt which secures the timing belt

cover (RH).

5) Lift-up the vehicle.

6) Remove the under cover.

7) Loosen the remaining bolts which secure timing

belt cover (RH), then remove the belt cover.

8) Lower the vehicle.

9) When inspecting #1 and #3 cylinders: (1) Pull out the engine harness connector with bracket from air cleaner upper cover.

10) When inspecting #2 and #4 cylinders: (1) Disconnect the battery cables, and then remove the battery and battery carrier.

H6M0426

(2) Remove the bolt which secures engine harness bracket onto body.

H6M0429

(3) Disconnect the washer motor connectors.

H2M1958

(2) Remove the air cleaner case. <Ref. to IN(TURBO)-7, REMOVAL, Air Cleaner.> (3) Disconnect the spark plug cords from spark plugs (#1 and #3 cylinders). (4) Place a suitable container under the vehicle. (5) Disconnect the PCV hose from rocker cover (RH). (6) Remove the bolts, then remove the rocker cover (RH).

ME(STi)-28

H6M0430

(4) Remove the washer tank mounting bolts.

B6M0561

VALVE CLEARANCE

MECHANICAL

(5) Move the washer tank upward.

H6M0431

(6) Disconnect the spark plug cords from spark plugs (#2 and #4 cylinders). (7) Place a suitable container under the vehicle. (8) Disconnect the PCV hose from rocker cover (LH). (9) Remove the bolts, then remove the rocker cover (LH).

11) Turn the crankshaft pulley clockwise until arrow mark on camshaft sprocket is set to position shown in the figure.

NOTE: Turn the crankshaft using ST. ST 499987500 CRANKSHAFT SOCKET

NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.

B2M1234B

13) If necessary, adjust the valve clearance. <Ref.

to ME(STi)-30, ADJUSTMENT, Valve Clearance.>

14) Further turn the crankshaft pulley clockwise.

Using the same procedures described previously, then measure the valve clearances again.

(1) Set the arrow mark on camshaft sprocket to position shown in the figure, and measure #2 cylinder exhaust valve and #3 cylinder intake valve clearances.

EN1197

12) Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A).

CAUTION:

• Insert the thickness gauge in direction as horizontal as possible with respect to the shim.

• Measure the exhaust valve clearances while lifting-up the vehicle.

Valve clearance:

Intake: 0.20

±±±±

Exhaust: 0.25

0.02 mm (0.0079

±±±±

0.02 mm (0.0098

±±±±

0.0008 in)

±±±±

0.0008 in)

ME(STi)-29

EN1198

(2) Set the arrow mark on camshaft sprocket to position shown in the figure, and measure #2 cylinder intake valve and #4 cylinder exhaust valve clearances.

EN1199

MECHANICAL

VALVE CLEARANCE

(3) Set the arrow mark on camshaft sprocket to position shown in the figure, and measure #1 cylinder exhaust valve and #4 cylinder intake valve clearances.

EN1200

15) After inspection, install the related parts in the reverse order of removal.

Tightening torque:

32 N·m (3.3 kgf-m, 24 ft-lb)

B: ADJUSTMENT

CAUTION: Adjustment of valve clearance should be performed while engine is cold.

1) Measure all valve clearances. <Ref. to ME(STi)-

28, INSPECTION, Valve Clearance.>

NOTE: Record each valve clearance after it has been measured.

B2M1234

2) Remove the camshaft. <Ref. to ME(STi)-59, RE-

MOVAL, Camshaft.>

3) Remove the valve lifter.

4) Measure the thickness of valve lifter with mi-

crometer.

EN0191

EN1201

5) Select a valve lifter of suitable thickness using

measured valve clearance and valve lifter thickness, by referring to the following table.

Unit: mm

Intake valve: S =(V + T) - 0.20 Exhaust valve: S =(V + T) - 0.25

S: Valve lifter thickness to be used V: Measured valve clearance T: Removed valve lifter thickness

ME(STi)-30

VALVE CLEARANCE

MECHANICAL

Part No. Thickness mm (in) 13228 AA100 4.68 (0.1843) 13228 AA110 4.69 (0.1846) 13228 AA120 4.70 (0.1850) 13228 AA130 4.71 (0.1854) 13228 AA140 4.72 (0.1858) 13228 AA150 4.73 (0.1862) 13228 AA160 4.74 (0.1866) 13228 AA170 4.75 (0.1870) 13228 AA180 4.76 (0.1874) 13228 AA190 4.77 (0.1878) 13228 AA200 4.78 (0.1882) 13228 AA210 4.79 (0.1886) 13228 AA220 4.80 (0.1890) 13228 AA230 4.81 (0.1894) 13228 AA240 4.82 (0.1898) 13228 AA250 4.83 (0.1902) 13228 AA260 4.84 (0.1906) 13228 AA270 4.85 (0.1909) 13228 AA280 4.86 (0.1913) 13228 AA290 4.87 (0.1917) 13228 AA300 4.88 (0.1921) 13228 AA310 4.89 (0.1925) 13228 AA320 4.90 (0.1929) 13228 AA330 4.91 (0.1933) 13228 AA340 4.92 (0.1937) 13228 AA350 4.93 (0.1941) 13228 AA360 4.94 (0.1945) 13228 AA370 4.95 (0.1949) 13228 AA380 4.96 (0.1953) 13228 AA390 4.97 (0.1957) 13228 AA400 4.98 (0.1961) 13228 AA410 4.99 (0.1965) 13228 AA420 5.00 (0.1969) 13228 AA430 5.01 (0.1972) 13228 AA440 5.02 (0.1976) 13228 AA450 5.03 (0.1980) 13228 AA460 5.04 (0.1984) 13228 AA470 5.05 (0.1988) 13228 AA480 5.06 (0.1992) 13228 AA490 5.07 (0.1996) 13228 AA500 5.08 (0.2000) 13228 AA510 5.09 (0.2004) 13228 AA520 5.10 (0.2008) 13228 AA530 5.11 (0.2012) 13228 AA540 5.12 (0.2016) 13228 AA550 5.13 (0.2020) 13228 AA560 5.14 (0.2024) 13228 AA570 5.15 (0.2028) 13228 AA580 5.16 (0.2031) 13228 AA590 5.17 (0.2035) 13228 AA600 5.18 (0.2039)

Part No. Thickness mm (in) 13228 AA610 5.19 (0.2043) 13228 AA620 5.20 (0.2047) 13228 AA630 5.21 (0.2051) 13228 AA640 5.22 (0.2055) 13228 AA650 5.23 (0.2059) 13228 AA660 5.24 (0.2063) 13228 AA670 5.25 (0.2067) 13228 AA680 5.26 (0.2071) 13228 AA690 5.27 (0.2075) 13228 AA700 4.38 (0.1724) 13228 AA710 4.40 (0.1732) 13228 AA720 4.42 (0.1740) 13228 AA730 4.44 (0.1748) 13228 AA740 4.46 (0.1756) 13228 AA750 4.48 (0.1764) 13228 AA760 4.50 (0.1772) 13228 AA770 4.52 (0.1780) 13228 AA780 4.54 (0.1787) 13228 AA790 4.56 (0.1795) 13228 AA800 4.58 (0.1803) 13228 AA810 4.60 (0.1811) 13228 AA820 4.62 (0.1819) 13228 AA830 4.64 (0.1827) 13228 AA840 4.66 (0.1835) 13228 AA850 5.29 (0.2083) 13228 AA860 5.31 (0.2091) 13228 AA870 5.33 (0.2098) 13228 AA880 5.35 (0.2106) 13228 AA890 5.37 (0.2114) 13228 AA900 5.39 (0.2122) 13228 AA910 5.41 (0.2130) 13228 AA920 5.43 (0.2138) 13228 AA930 5.45 (0.2146) 13228 AA940 5.47 (0.2154) 13228 AA950 5.49 (0.2161) 13228 AA960 5.51 (0.2169) 13228 AA970 5.53 (0.2177) 13228 AA980 5.55 (0.2185) 13228 AA990 5.57 (0.2193) 13228 AB000 5.59 (0.2201) 13228 AB010 5.61 (0.2209) 13228 AB020 5.63 (0.2217) 13228 AB030 5.65 (0.2224)

6) Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step.

7) After inspection, install the related parts in the reverse order of removal.

ME(STi)-31

MECHANICAL

ENGINE ASSEMBLY

9. Engine Assembly

A: REMOVAL

1) Set the vehicle on lift arms.

2) Open the front hood fully and support with stay.

3) Raise the rear seat, and turn floor mat up.

4) Release the fuel pressure. (1) Disconnect the fuel pump relay connector.

EN0344

(2) Start the engine, and run until it stalls. (3) After the engine stalls, crank it for five seconds more. (4) Turn the ignition switch to “OFF”.

5) Remove the filler cap.

6) Disconnect the battery ground terminal.

(3) Disconnect the A/C pressure hoses from A/C compressor.

S2M1584

10) Remove the intercooler. <Ref. to IN(TURBO)10, REMOVAL, Intercooler.>

11) Disconnect the following connectors and cable. (1) Engine harness connector

G6M0095

7) Remove the radiator from vehicle. <Ref. to CO39, REMOVAL, Radiator.>

8) Remove the coolant filler tank. <Ref. to CO-53, REMOVAL, Coolant Filler Tank.>

9) Collect the refrigerant, and remove the pressure hoses.

(1) Place and connect the attachment hose to the refrigerant recycle system. (2) Collect the refrigerant from A/C system.

S2M1929

(2) Engine ground terminal

S2M0731

(3) Engine harness connector

ME(STi)-32

S2M1930

ENGINE ASSEMBLY

MECHANICAL

(4) Generator connector, terminal and A/C compressor connectors

B2M1291I

(A) A/C compressor connector (B) Generator connector and terminal

(5) Accelerator cable

(2) Heater inlet outlet hose

EN0205

13) Remove the power steering pump from brack-

et.

(1) Loosen the lock bolt and slider bolt, and remove the front side V-belt. <Ref. to ME(STi)-43, FRONT SIDE BELT, REMOVAL, V-belt.> (2) Disconnect the power steering switch connector.

(6) Clutch release spring

12) Disconnect the following hoses. (1) Brake booster vacuum hose

S2M1931

EN0360

(3) Remove the pipe with bracket from intake manifold.

S2M1932

EN0206

EN0204

ME(STi)-33

MECHANICAL

ENGINE ASSEMBLY

(4) Remove the power steering pump from engine.

H2M1954

(5) Remove the power steering tank from the bracket by pulling it upward.

16) Remove the nuts which install front cushion rubber onto front crossmember.

S2M1927

17) Separate the clutch release fork from release bearing.

(1) Remove the clutch operating cylinder from transmission. (2) Remove the plug using 10 mm hexagon wrench.

EN0361

(6) Place the power steering pump on the right side wheel apron.

EN0208

14) Remove the center exhaust pipe. <Ref. to

EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>

15) Remove the nuts which hold lower side of

transmission to engine.

S2M1935

B3M2047

ME(STi)-34

ENGINE ASSEMBLY

MECHANICAL

(3) Screw 6 mm dia. bolt into release fork shaft, and remove it.

S2M1936A

19) Disconnect the fuel delivery hose, return hose and evaporation hose.

CAUTION:

• Catch fuel from hose into container.

• Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.

EN0214

20) Remove the fuel filter and bracket.

(A) Shaft (B) Bolt

(4) Raise the release fork and unfasten release bearing tabs to free release fork.

CAUTION: Step (4) is required to prevent interference with engine when removing the engine from transmission.

18) Remove the pitching stopper.

H3M1839

G2M0818

21) Support the engine with a lifting device and wire ropes.

G2M0297

ME(STi)-35

MECHANICAL

ENGINE ASSEMBLY

22) Support the transmission with a garage jack.

CAUTION: Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.

S2M1928

23) Separation of engine and transmission. (1) Remove the starter. <Ref. to SC-5, REMOVAL, Starter.> (2) Remove the bolt which holds right upper side of transmission to engine.

B: INSTALLATION

1) Install the clutch release fork and bearing onto transmission.

(1) Remove the release bearing from clutch cover with flat type screw driver.

S2M1843

(2) Install the release bearing on transmission. (3) Install the release fork into release bearing tab.

B3M2044

24) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. (3) Move the engine horizontally until mainshaft is withdrawn from clutch cover. (4) Slowly move the engine away from engine compartment.

CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.

25) Remove the front cushion rubbers.

S2M1937A

(A) Release fork (B) Release bearing

ME(STi)-36

ENGINE ASSEMBLY

MECHANICAL

(4) Apply grease to the specified points.

• Spline FX2200

• Shaft SUNLIGHT 2

S2M1938A

(A) Spline (FX2200) (B) Shaft (SUNLIGHT 2)

(5) Insert the release fork shaft into release fork.

CAUTION: Be sure to fit groove on clutch release lever shaft into pin located at through-hole.

(6) Tighten the plug.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

S2M1846

2) Install the front cushion rubbers to engine.

Tightening torque:

34 N·m (3.5 kgf-m, 25.3 ft-lb)

3) Install the engine onto transmission. (1) Position the engine in engine compartment and align it with transmission.

CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.

(2) Apply a small amount of grease to splines of mainshaft.

4) Tighten the bolt which holds right upper side of

transmission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

(A) Release fork (B) Release shaft (C) Spring pin

S2M1845A

B2M2791

5) Remove the lifting device and wire ropes.

ME(STi)-37

MECHANICAL

ENGINE ASSEMBLY

6) Remove the garage jack.

7) Install the pitching stopper.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 37 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb)

11) Install the power steering pump on bracket. (1) Install the power steering tank on bracket.

G2M0297

EN0361

(2) Install the power steering pump on bracket, and tighten bolts.

Tightening torque:

20.1 N·m (2.05 kgf-m, 14.8 ft-lb)

H3M1839A

8) Install the starter. <Ref. to SC-6, INSTALLATION, Starter.>

9) Push the clutch release lever to fit bearing into clutch cover.

H2M1818

10) Install the fuel filter and bracket.

H2M1954

(3) Install the power steering pipe bracket on right side intake manifold, and install the spark plug cords.

EN0206

(4) Connect the power steering switch connector.

G2M0818

EN0360

ME(STi)-38

ENGINE ASSEMBLY

MECHANICAL

(5) Install the front side V-belt, and adjust it. <Ref. to ME-44, FRONT SIDE BELT, INSTALLATION, V-belt.>

12) Tighten the nuts which hold lower side of transmission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

B2M2790

13) Tighten the nuts which install front cushion rubber onto crossmember.

Tightening torque:

85 N·m (8.7 kgf-m, 62.7 ft-lb)

CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.

17) Connect the following cables. (1) Accelerator cable (2) Clutch release spring

CAUTION: After connecting each cable, adjust them.

18) Install the air intake system. (1) Install the intercooler. <Ref. to IN(TURBO)11, INSTALLATION, Intercooler.> (2) Install the air cleaner element and air cleaner upper cover. (3) Install the engine harness connector bracket. (4) Install the filler hose to air cleaner case.

H2M1962B

(A) Filler hose (B) Connector bracket

B2M3880A

14) Install the center exhaust pipe. <Ref. to EX(TURBO)-9, INSTALLATION, Center Exhaust Pipe.>

15) Connect the following hoses. (1) Fuel delivery hose, return hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose

16) Connect the following connectors and termi-

nals.

(1) Engine ground terminal (2) Engine harness connectors (3) Generator connector and terminal (4) A/C compressor connectors (With A/C)

19) Install the A/C pressure hoses. (With A/C)

CAUTION: Use new O-rings.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

S2M1584

20) Install the radiator. <Ref. to CO-42, INSTALLATION, Radiator.>

21) Install the coolant filler tank. <Ref. to CO-53, INSTALLATION, Coolant Filler Tank.>

22) Install the window washer tank.

23) Install the battery in vehicle, and connect the cables.

24) Fill coolant. <Ref. to CO-26, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

ME(STi)-39

ENGINE ASSEMBLY

MECHANICAL

25) Charge the A/C system with refrigerant. <Ref.

to AC-22, OPERATION, Refrigerant Charging Procedure.>

26) Remove the front hood stay, and close the front

hood.

27) Take off the vehicle from lift arms.

ME(STi)-40

ENGINE MOUNTING

10.Engine Mounting

A: REMOVAL

1) Remove the engine assembly. <Ref. to ME(STi)-

32, REMOVAL, Engine Assembly.>

2) Remove the engine mounting from engine as-

sembly.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

Engine mounting;

35 N·m (3.6 kgf-m, 25.8 ft-lb)

C: INSPECTION

Make sure there are no cracks or other damage.

MECHANICAL

ME(STi)-41

PREPARATION FOR OVERHAUL

MECHANICAL

11.Preparation for Overhaul

A: PROCEDURE

1) After removing the engine from the body, secure

it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER

ST2 498457100 ENGINE STAND ADAPTER

ST3 499817000 ENGINE STAND

S2M1876A

2) In this section the procedures described under

each index are all connected and stated in order. It will be the complete procedure for overhauling of the engine itself when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

ME(STi)-42

V-BELT

MECHANICAL

12.V-belt

A: REMOVAL

1. FRONT SIDE BELT

NOTE: Perform the following procedures 1) to 4) with the engine installed to the body.

1) Remove the V-belt cover.

EN0048

2) Loosen the lock bolt (A).

3) Loosen the slider bolt (B).

4) Remove the front side belt (C).

(B)

(C)

4) Remove the rear side belt tensioner.

S2M0113

B: INSTALLATION

1. FRONT SIDE BELT

CAUTION: Wipe off any oil or water on the belt and pulley.

1) Install the front side belt (C), and tighten the slider bolt so as to obtain the specified belt tension <Ref. to ME(STi)-44, INSPECTION, V-belt.>

2) Tighten the lock bolt (A)

3) Tighten slider bolt (B).

Tightening torque:

Lock bolt through bolt:

25 N·m (2.5 kgf-m, 18 ft-lb)

Slider bolt:

8 N·m (0.8 kgf-m, 5.5 ft-lb)

2. REAR SIDE BELT

1) Loosen the lock nut (A).

2) Loosen the slider bolt (B).

3) Remove the rear side belt.

(A)

(B)

(C)

EN0225

(A)

EN0225

(B)

(A)

EN0226

ME(STi)-43

V-BELT

MECHANICAL

2. REAR SIDE BELT

1) Install the rear side belt, and tighten the slider

bolt (B) so as to obtain the specified belt tension. <Ref. to ME(STi)-44, INSPECTION, V-belt.>

2) Tighten the lock nut (A).

Tightening torque:

Lock nut (A);

22.6 N·m (2.3 kgf-m, 16.6 ft-lb)

(B)

(A)

EN0226

C: INSPECTION

1) Replace the belts, if cracks, fraying or wear is

found.

2) Check the drive belt tension and adjust it if nec-

essary by changing generator installing position and/or idler pulley installing position.

Belt tension

(A) replaced: 7 — 9 mm (0.276 — 0.354 in) reused: 9 — 11 mm (0.354 — 0.433 in) (B)* replaced: 7.5 — 8.5 mm (0.295 — 0.335 in) reused: 9.0 — 10.0 mm (0.354 — 0.394 in) *: With Air conditioner

98 N (10 kgf, 22 lb)

EN1520

C/P Crankshaft pulley

GEN Generator

P/S Power steering oil pump pulley

A/C Air conditioning compressor pulley

I/P Idler pulley

ME(STi)-44

CRANKSHAFT PULLEY

MECHANICAL

13.Crankshaft Pulley

A: REMOVAL

1) Remove the V-belt. <Ref. to ME(STi)-43, RE-

MOVAL, V-belt.>

2) Remove the crankshaft pulley bolt. To lock the

crankshaft, use ST. ST 499977300 CRANK PULLEY WRENCH

H2M2393C

3) Remove the crankshaft pulley.

B: INSTALLATION

1) Install the crankshaft pulley.

2) Install the pulley bolt.

To lock the crankshaft, use ST. ST 499977300 CRANK PULLEY WRENCH

(1) Clean the crankshaft pulley thread using an air gun. (2) Apply engine oil to the crankshaft pulley bolt seat, thread and washer. (3) Tighten the bolts with tightening torque of 157 N·m (16.0 kgf-m, 116 ft-lb). (4) Loosen the bolts by 180°. (5) Tighten the crankshaft pulley bolts.

3) Confirm that the tightening angle of the crankshaft pulley bolt is 45° or more. If not, conduct the following procedures (1) through (4).

• Replace the crankshaft pulley bolts and clean them.

CAUTION: Conduct the tightening procedures by confirming the turning angle of the crankshaft pulley bolt referring to the gauge indicated on the belt cover.

4) Install the rear side belt tensioner.

S2M0113

5) Install the rear side belt.

(B)

(A)

EN0226

Tightening torque:

157 N·m (16 kgf-m, 116 ft-lb)

(A) Lock nut (B) Slider bolt

C: INSPECTION

1) Make sure the V-belt is not worn or otherwise damaged.

2) Check the tension of the belt. <Ref. to ME(STi)44, INSPECTION, V-belt.>

H2M2393A

ME(STi)-45

BELT COVER

MECHANICAL

14.Belt Cover

A: REMOVAL

1) Remove the V-belt. <Ref. to ME(STi)-43, RE-

MOVAL, V-belt.>

2) Remove the crankshaft pulley. <Ref. to ME(STi)-

45, REMOVAL, Crankshaft Pulley.>

3) Remove the left-hand belt cover (A).

4) Remove the right-hand belt cover (B).

5) Remove the front belt cover (C).

S2M1221A

B: INSTALLATION

1) Install the front belt cover (C).

Tightening torque:

5 N·m (0.5 kgf-m, 3.6 ft-lb)

2) Install the right-hand belt cover (B).

Tightening torque:

5 N·m (0.5 kgf-m, 3.6 ft-lb)

3) Install the left-hand belt cover (A).

Tightening torque:

5 N·m (0.5 kgf-m, 3.6 ft-lb)

S2M1221A

4) Install the crankshaft pulley. <Ref. to ME(STi)-

45, INSTALLATION, Crankshaft Pulley.>

5) Install the V-belt. <Ref. to ME(STi)-43, INSTAL-

LATION, V-belt.>

C: INSPECTION

Make sure the cover is not damaged.

ME(STi)-46

TIMING BELT ASSEMBLY

15.Timing Belt Assembly

A: REMOVAL

1. TIMING BELT

1) Remove the V-belt. <Ref. to ME(STi)-43, RE-

MOVAL, V-belt.>

2) Remove the crankshaft pulley. <Ref. to ME(STi)-

45, REMOVAL, Crankshaft Pulley.>

3) Remove the belt cover. <Ref. to ME(STi)-46,

REMOVAL, Belt Cover.>

4) Remove the timing belt guides.

S2M0294

MECHANICAL

EN0259

5) If the alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as follows:

(1) Turn the crankshaft using ST, and align alignment marks on crankshaft sprocket, lefthand intake camshaft sprocket, left-hand exhaust camshaft sprocket, right-hand intake camshaft sprocket and right hand exhaust camshaft sprocket with notches of belt cover and cylinder block.

ST 499987500 CRANKSHAFT SOCKET

EN1202

EN0258

S2M1878A

ME(STi)-47

MECHANICAL

TIMING BELT ASSEMBLY

(2) Using a white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets.

EN0233

7) Remove the timing belt.

CAUTION: After the timing belt has been removed, never rotate intake and exhaust, camshaft sprocket. If the camshaft sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.

2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY

1) Remove the belt idler (B) and (C).

S2M1226A

2) Remove the belt idler No. 2.

: 54.5 tooth length

: 51 tooth length

: 28 tooth length

6) Remove the belt idler (A).

S2M1225

S2M0411

3) Remove the automatic belt tension adjuster assembly.

S2M1223A

S2M0412

S2M1226A

ME(STi)-48

TIMING BELT ASSEMBLY

MECHANICAL

B: INSTALLATION

1. AUTOMATIC BELT TENSION ADJUST-

ER ASSEMBLY AND BELT IDLER

1) Preparation for installation of automatic belt ten-

sion adjuster assembly:

CAUTION:

• Always use a vertical type pressing tool to

move the adjuster rod down.

• Do not use a lateral type vise.

• Push the adjuster rod vertically.

• Be sure to slowly move the adjuster rod down

applying a pressure of 294 N (30 kgf, 66 lb).

• Press-in the push adjuster rod gradually tak-

ing more than three minutes.

• Do not allow press pressure to exceed 9,807

N (1,000 kgf, 2,205 lb).

• Press the adjuster rod as far as the end sur-

face of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.

• Do not release press pressure until stopper

pin is completely inserted.

(1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool. (2) Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.

2) Install the automatic belt tension adjuster assembly.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

S2M0416

3) Install the belt idler No. 2.

Tightening torque:

39 N·m (4.0 kgf-m, 28.9 ft-lb)

S2M0411

H2M2382

(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.

4) Install the belt idler.

Tightening torque:

39 N·m (4.0 kgf-m, 28.9 ft-lb)

S2M0410

H2M2383

ME(STi)-49

MECHANICAL

TIMING BELT ASSEMBLY

2. TIMING BELT

1) Preparation for installation of automatic belt ten-

sion adjuster assembly. <Ref. to ME(STi)-49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, Timing Belt Assembly.>

2) Crankshaft and camshaft sprocket alignment. (1) Align mark (A) on the crankshaft sprocket with mark on the oil pump cover at cylinder block.

(A)

EN0243

(2) Align single line mark (A) on the right-hand exhaust camshaft sprocket with notch (B) on belt cover.

(4) Align single line mark (A) on the left-hand exhaust camshaft sprocket with notch (B) on belt cover by turning sprocket counterclockwise (as viewed from front of engine).

S2M1229B

(5) Align single line mark (A) on the left-hand intake camshaft sprocket with notch (B) on belt cover by turning sprocket clockwise (as viewed from front of engine). Ensure double lines (C) on the intake and exhaust camshaft sprockets are aligned.

S2M1227B

(3) Align single line mark (A) on the right-hand intake camshaft sprocket with notch (B) on belt cover. (Ensure sure double lines (C) on the intake camshaft and exhaust camshaft sprockets are aligned.)

S2M1228B

S2M1230B

ME(STi)-50

TIMING BELT ASSEMBLY

MECHANICAL

(6) Ensure the camshaft and crankshaft sprockets are positioned properly.

CAUTION:

• Intake and exhaust camshafts for this DOHC

engine can be independently rotated with timing belts removed. As can be seen from the figure, if intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves.

(A)

• Do not allow the camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.

(B)

EN1203

(A) Intake camshaft (B) Exhaust camshaft

• When the timing belts are not installed, four

camshafts are held at the “zero-lift” position, where all cams on camshafts do not push intake and exhaust valves down. (Under this condition, all valves remain unlifted.)

• When the camshafts are rotated to install tim-

ing belts, #2 intake and #4 exhaust cam of lefthand camshafts are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Right-side camshafts are held so that their cams do not push valves down.

• Left-hand camshafts must be rotated from

the “zero-lift” position to the position where timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads.

S2M1231A

ME(STi)-51

TIMING BELT ASSEMBLY

MECHANICAL

3) Installation of timing belt:

S2M0418

Align alignment mark on the timing belt with marks on sprockets in the alphabetical order shown in the figure. While aligning marks, position the timing belt properly.

CAUTION:

• Disengagement of more than three timing belt teeth may result in interference between the valve

and piston.

• Ensure the belt’s rotating direction is correct.

ME(STi)-52

S2M1232A

TIMING BELT ASSEMBLY

4) Install the belt idlers.

Tightening torque:

39 N·m (4.0 kgf-m, 28.9 ft-lb)

CAUTION: Make sure that the marks on timing belt and sprockets are aligned.

H2M2398

5) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin from tensioner adjuster.

6) Install the timing belt guide. (1) Temporarily tighten the remaining bolts. (2) Check and adjust clearance between the timing belt and timing belt guide.

Clearance:

±±±±

0.5 mm (0.039

1.0

±±±±

0.020 in)

MECHANICAL

EN0255

EN0256

(3) Tighten the remaining bolts.

Tightening torque:

9.8 N·m (1.0 kgf-m, 7.2 ft-lb)

S2M0297

EN1204

S2M0294

EN1202

ME(STi)-53

TIMING BELT ASSEMBLY

MECHANICAL

EN0258

EN0259

7) Install the belt cover. <Ref. to ME(STi)-46, IN-

STALLATION, Belt Cover.>

8) Install the crankshaft pulley. <Ref. to ME(STi)-

45, REMOVAL, Crankshaft Pulley.>

9) Install the V-belt. <Ref. to ME(STi)-43, INSTAL-

LATION, V-belt.>

C: INSPECTION

1. TIMING BELT

1) Check the timing belt teeth for breaks, cracks,

and wear. If any fault is found, replace the belt.

2) Check the condition of back side of belt; if any

crack is found, replace the belt.

CAUTION:

• Be careful not to let oil, grease or coolant

contact the belt. Remove quickly and thoroughly if this happens.

• Do not bend the belt sharply.

Bending radius: h

60 mm (2.36 in) or more

2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly.

CAUTION: Slight traces of oil at rod's oil seal does not indicate a problem.

2) Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness.

3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures:

(1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one.

CAUTION:

• Always use a vertical type pressing tool to move the adjuster rod down.

• Do not use a lateral type vise.

• Push the adjuster rod vertically.

• Press-in the push adjuster rod gradually taking more than three minutes.

• Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb).

• Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.

4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one.

Rod extension: H

±±±±

5.7

0.5 mm (0.224

±±±±

0.020 in)

G2M0115

H2M2381A

ME(STi)-54

TIMING BELT ASSEMBLY

3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and

contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty.

2) Check the belt tension pulley for smooth rota-

tion. Replace if noise or excessive play is noted.

3) Check the belt tension pulley for grease leakage.

4. BELT IDLER

1) Check the idler for smooth rotation. Replace if

noise or excessive play is noted.

2) Check the outer contacting surfaces of idler pul-

ley for abnormal wear and scratches.

3) Check the idler for grease leakage.

MECHANICAL

ME(STi)-55

MECHANICAL

CAMSHAFT SPROCKET

16.Camshaft Sprocket

A: REMOVAL

1) Remove the V-belt. <Ref. to ME(STi)-43, RE-

MOVAL, V-belt.>

2) Remove the crankshaft pulley. <Ref. to ME(STi)-

45, REMOVAL, Crankshaft Pulley.>

3) Remove the belt cover. <Ref. to ME(STi)-46,

REMOVAL, Belt Cover.>

4) Remove the timing belt assembly. <Ref. to

ME(STi)-47, REMOVAL, Timing Belt Assembly.>

5) Remove the camshaft position sensor. <Ref. to

FU(TURBO)-31, REMOVAL, Camshaft Position Sensor.>

6) Remove the camshaft sprockets. To lock the

camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET

WRENCH

B: INSTALLATION

1) Install the camshaft sprocket No. 1. and No. 2. To lock the camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET

WRENCH

Tightening torque:

98 N·m (10 kgf-m, 72.4 ft-lb)

CAUTION: Do not confuse right and left side camshaft sprockets during installation. The camshaft sprocket No. 2 is identified by a projection used to monitor camshaft position sensor.

EN1213

ST 499977500 CAMSHAFT SPROCKET

WRENCH

EN1205

ST 499977500 CAMSHAFT SPROCKET

WRENCH

EN1205

2) Install the camshaft position sensor. <Ref. to FU(TURBO)-31, INSTALLATION, Camshaft Position Sensor.>

3) Install the timing belt assembly. <Ref. to ME(STi)-49, INSTALLATION, Timing Belt Assembly.>

4) Install the belt cover. <Ref. to ME(STi)-46, INSTALLATION, Belt Cover.>

5) Install the crankshaft pulley. <Ref. to ME(STi)45, INSTALLATION, Crankshaft Pulley.>

6) Install the V-belt. <Ref. to ME(STi)-43, INSTALLATION, V-belt.>

ME(STi)-56

CAMSHAFT SPROCKET

C: INSPECTION

1) Check the sprocket teeth for abnormal wear and

scratches.

2) Make sure there is no free play between the

sprocket and key.

3) Check the crankshaft sprocket notch for sensor

for damage and contamination of foreign matter.

MECHANICAL

ME(STi)-57

MECHANICAL

CRANKSHAFT SPROCKET

17.Crankshaft Sprocket

A: REMOVAL

1) Remove the V-belt. <Ref. to ME(STi)-43, RE-

MOVAL, V-belt.>

2) Remove the crankshaft pulley. <Ref. to ME(STi)-

45, REMOVAL, Crankshaft Pulley.>

3) Remove the belt cover. <Ref. to ME(STi)-46,

REMOVAL, Belt Cover.>

4) Remove the timing belt assembly. <Ref. to

ME(STi)-47, REMOVAL, Timing Belt Assembly.>

5) Remove the camshaft sprocket. <Ref. to

ME(STi)-56, REMOVAL, Camshaft Sprocket.>

6) Remove the crankshaft sprocket.

EN0263

C: INSPECTION

1) Check the sprocket teeth for abnormal wear and scratches.

2) Make sure there is no free play between the sprocket and key.

3) Check the crankshaft sprocket notch for sensor for damage and contamination of foreign matter.

B: INSTALLATION

1) Install the crankshaft sprocket.

EN0263

2) Install the camshaft sprocket. <Ref. to ME(STi)-

56, INSTALLATION, Camshaft Sprocket.>

3) Install the timing belt assembly. <Ref. to

ME(STi)-49, INSTALLATION, Timing Belt Assembly.>

4) Install the belt cover. <Ref. to ME(STi)-46, IN-

STALLATION, Belt Cover.>

5) Install the crankshaft pulley. <Ref. to ME(STi)-

45, INSTALLATION, Crankshaft Pulley.>

6) Install the V-belt. <Ref. to ME(STi)-43, INSTAL-

LATION, V-belt.>

ME(STi)-58

CAMSHAFT

MECHANICAL

18.Camshaft

A: REMOVAL

1) Remove the V-belt. <Ref. to ME(STi)-43, IN-

STALLATION, V-belt.>

2) Remove the crankshaft pulley. <Ref. to ME(STi)-

45, REMOVAL, Crankshaft Pulley.>

3) Remove the belt cover. <Ref. to ME(STi)-46,

REMOVAL, Belt Cover.>

4) Remove the timing belt assembly. <Ref. to

ME(STi)-47, REMOVAL, Timing Belt Assembly.>

5) Remove the camshaft sprocket. <Ref. to

ME(STi)-56, REMOVAL, Camshaft Sprocket.>

6) Remove the crankshaft sprocket. <Ref. to

ME(STi)-58, REMOVAL, Crankshaft Sprocket.>

7) Disconnect the variable valve timing solenoid

valve assembly connector.

10) Remove the right-hand belt cover No.2.

B2M0738

11) Remove the spark plug cord.

12) Remove the oil level gauge guide. (LH side only)

13) Remove the rocker cover and gasket.

14) Remove the oil pipe.

8) Remove the tensioner bracket.

S2M1163

9) Remove the left-hand belt cover No. 2.

EN1206

EN1207

15) Loosen the variable valve timing solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.

(A)

(B)

(E)

(F) (D)

(C)

EN1208

16) Remove the oil control valve assembly, intake camshaft cap, and camshaft.

S2M1162

ME(STi)-59

MECHANICAL

CAMSHAFT

17) Loosen the exhaust camshaft cap bolts equal-

ly, a little at a time in alphabetical sequence shown in the figure.

(A)

(B)

(E)

(F) (D)

(C)

EN1209

18) Remove the exhaust camshaft cap and cam-

shaft.

CAUTION: Arrange the camshaft caps in order so that they can be installed in their original positions.

19) Similarly, remove the right-hand camshafts and

related parts.

B: INSTALLATION

1) Camshaft installation: Apply engine oil to cylinder head at camshaft bearing location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with “base circle” of cam lobe.

CAUTION:

• When the camshafts are positioned as shown in the figure, camshafts need to be rotated at a minimum to align with the timing belt during installation.

• Right-hand camshaft need not be rotated when set at position shown in the figure. Left-hand intake camshaft: Rotate 80°°°° clockwise. Left-hand exhaust camshaft: Rotate 45°°°° counterclockwise.

(a)

77.5

(b)

A Left side cylinder head

B Right side cylinder head (a) Intake camshaft (b) Exhaust camshaft

77.5

(a)

EN1214

ME(STi)-60

CAMSHAFT

MECHANICAL

2) Camshaft cap and variable valve timing solenoid valve assembly installation:

(1) Apply fluid packing sparingly to cap mating surface.

CAUTION: Do not apply fluid packing excessively. Failure to do so may cause excess packing to come out and flow toward the oil seal, resulting in oil leaks.

Fluid packing:

THREE BOND 1215 or equivalent

S2M1839A

(4) Similarly, tighten cap on the exhaust side. After tightening cap, ensure the camshaft rotates only slightly while holding it at “base” circle.

Tightening torque:

T1: 10 N·m (1.0 kgf-m, 7 ft-lb) T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)

(A)

(B)

(E)

(F) (D)

(C)

EN1532

3) Camshaft oil seal installation: Apply grease to new oil seal lips and press onto front end of camshaft by using ST1 and ST2.

NOTE: Use a new oil seal.

ST1 499587600 OIL SEAL GUIDE ST2 499597200 OIL SEAL GUIDE

EN1210

(2) Apply engine oil to cap bearing surface and install the cap on camshaft as shown by identification mark (A). (3) Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque.

Tightening torque:

T1: 10 N·m (1.0 kgf-m, 7 ft-lb) T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)

(A)

(B)

(E)

(F) (D)

(C)

EN1211

S2M1880A

4) Rocker cover installation: (1) Install the gasket on rocker cover. Install the peripheral gasket and ignition coil gasket. (2) Apply fluid packing to four front open edges of peripheral gasket.

Fluid packing:

THREE BOND 1215 or equivalent

S2M0300B

ME(STi)-61

Subaru Impreza 2002 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION SECTION

1. Impreza

A: DIMENSIONS

B: ENGINE

C: ELECTRICAL

D: TRANSMISSION

E: STEERING

F: SUSPENSION

G: BRAKE

H: TIRE

I: CAPACITY

J: WEIGHT

1. Identification

A: IDENTIFICATION

ENGINE 2 SECTION

TUMBLE GENERATOR VALVE ASSEMBLY

A: REMOVAL

B: INSTALLATION

TUMBLE GENERATOR VALVE ACTUATOR

A: REMOVAL

B: INSTALLATION

18.Exhaust Temperature Sensor

A: REMOVAL

B: INSTALLATION

VARIABLE VALVE TIMING CAMSHAFT POSITON SENSOR

A: REMOVAL

B: INSTALLATION

VARIABLE VALVE TIMING SOLENOID VALVE

A: REMOVAL

B: INSTALLATION

4. Precatalytic Converter

A: REMOVAL

B: INSTALLATION

1. General Description

A: COMPONENT

9. Intercooler Water Tank

A: REMOVAL

B: INSTALLATION

C: INSPECTION

1. General Description

A: SPECIFICATIONS

B: COMPONENT

C: CAUTION

D: PREPARATION TOOL

E: PROCEDURE

2. Compression

A: INSPECTION

3. Idle Speed

A: INSPECTION

4. Ignition Timing

A: INSPECTION

5. Intake Manifold Vacuum

A: INSPECTION

6. Engine Oil Pressure

A: INSPECTION

7. Fuel Pressure

A: INSPECTION

8. Valve Clearance

A: INSPECTION

B: ADJUSTMENT

9. Engine Assembly

A: REMOVAL

B: INSTALLATION

10.Engine Mounting

A: REMOVAL

B: INSTALLATION

C: INSPECTION

11.Preparation for Overhaul

A: PROCEDURE

12.V-belt

A: REMOVAL

B: INSTALLATION

C: INSPECTION

13.Crankshaft Pulley

A: REMOVAL

B: INSTALLATION