Subaru Impreza 2004 User Manual

2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 2

FUEL INJECTION (FUEL SYSTEMS) FU(H4DOTC)

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.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

INTAKE (INDUCTION) IN(H4DOTC)

MECHANICAL ME(H4DOTC)

EXHAUST EX(H4DOTC)

COOLING CO(H4DOTC)

LUBRICATION LU(H4DOTC)

SPEED CONTROL SYSTEMS SP(H4DOTC)

IGNITION IG(H4DOTC)

STARTING/CHARGING SYSTEMS SC(H4DOTC)

EC(H4DOTC)

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. G1870GE3

ENGINE (DIAGNOSTICS) EN(H4DOTC)(diag)

MECHANICAL

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

2. Compression .............................................................................................34

3. Idle Speed .................................................................................................35

4. Ignition Timing ...........................................................................................36

5. Intake Manifold Vacuum............................................................................37

6. Engine Oil Pressure ..................................................................................38

7. Fuel Pressure............................................................................................39

8. Valve Clearance ........................................................................................40

9. Engine Assembly ......................................................................................44

10. Engine Mounting .......................................................................................52

11. Preparation for Overhaul...........................................................................53

12. V-belt .........................................................................................................54

13. Crankshaft Pulley ......................................................................................56

14. Timing Belt Cover......................................................................................57

15. Timing Belt Assembly................................................................................58

16. Camshaft Sprocket....................................................................................66

17. Crankshaft Sprocket..................................................................................68

18. Camshaft...................................................................................................69

19. Cylinder Head Assembly...........................................................................78

20. Cylinder Block ...........................................................................................85

21. Intake and Exhaust Valve .......................................................................105

22. Piston ......................................................................................................106

23. Connecting Rod ......................................................................................107

24. Crankshaft...............................................................................................108

25. Engine Trouble in General ......................................................................109

26. Engine Noise...........................................................................................114

ME(H4DOTC)

Page

General Description

MECHANICAL

1. General Description

A: SPECIFICATIONS

1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL)

Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine

1,994 (121.67)

981 — 1,177 (10 — 12, 142 — 171)

700±100 (No load)

800±150 (A/C switch ON)

Engine

Type

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

Piston displacement

Compression ratio 8.0 Compression pres-

sure (at 200 — 300 rpm)

Number of piston rings Pressure ring: 2, Oil ring: 1

Intake valve timing

Exhaust valve timing

Valve clearance

Idling speed [At neutral position on MT or “P” or “N” range on AT]

Firing order 1 → 3 → 2 → 4 Ignition timing BTDC/rpm 12°±10°/700

Opening BTDC 10° Closing ABDC 50° Opening BBDC 53° Closing ATDC 7° Intake mm (in) 0.20±0.02 (0.0079±0.0008) Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)

kPa (kgf/cm

(cu in)

, psi)

rpm

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

Belt tension adjuster

Belt tensioner

Camshaft

Cylinder head

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 0.3 mm (0.012 in) Standard height 127.5 mm (5.02 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 0.040 — 0.080 mm (0.0016 — 0.0031 in) Limit 0.10 mm (0.0039 in) STD 46.25 — 46.35 mm (1.821 — 1.825 in) Limit 46.15 mm (1.817 in) STD 46.15 — 46.25 mm (1.817 — 1.821 in) Limit 46.05 mm (1.813 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)

29.946 — 29.963 mm (1.1790 — 1.1796 in)

ME(H4DOTC)-2

Refacing angle 90°

Valve seat

Valve guide

Valve

Valve spring

Cylinder block

Piston Outer diameter

Piston pin

Contacting width

Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in) Protrusion above head 15.8 — 16.2 mm (0.622 — 0.638 in)

Head edge thickness

Stem diameter

Stem oil clearance

Overall length

Free length 47.32 mm (1.8630 in) Squareness 2.5°, 2.1 mm (0.083 in)

Tension/spring height

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

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

General Description

Intake

Exhaust

Intake

Exhaust

STD

Limit — 0.15 mm (0.0059 in)

STD

0.25 mm (0.0098 in) OS

0.50 mm (0.0197 in) OS

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 5.955 — 5.970 mm (0.2344 — 0.2350 in) Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in) Intake 0.030 — 0.057 mm (0.0012 — 0.0022 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)

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

Set

Lift

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)

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

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

205 — 235 N (20.9 — 24.0 kgf, 46.1 — 52.8 lb)/

36.0 mm (1.417 in)

426 — 490 N (43.4 — 50.0 kgf, 95.8 — 110 lb)/

26.5 mm (1.043 in)

92.225 — 92.235 mm (3.6309 — 3.6313 in)

92.475 — 92.485 mm (3.6407 — 3.6411 in)

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

(68°F).

MECHANICAL

ME(H4DOTC)-3

MECHANICAL

General Description

Piston ring

Connecting rod

Connecting rod bearing

Connecting rod bushing

Top ring

Piston ring gap

Clearance between piston ring and piston ring groove

Bend or twist per 100 mm (3.94 in) in length

Side clearance

Oil clearance

Thickness at center portion

Clearance between piston pin and bushing

Second ring

Oil ring

Top ring

Second ring

STD 0.20 — 0.25 mm (0.0079 — 0.0098 in) Limit 1.0 mm (0.039 in) STD 0.40 — 0.50 mm (0.016 — 0.020 in) Limit 1.0 mm (0.039 in) STD 0.20 — 0.50 mm (0.0079 — 0.020 in) Limit 1.5 mm (0.059 in) STD 0.04 — 0.08 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)

1.504 — 1.512 mm (0.0592 — 0.0595 in)

1.514 — 1.522 mm (0.0596 — 0.0599 in)

1.614 — 1.622 mm (0.0635 — 0.0639 in)

ME(H4DOTC)-4

Crankshaft

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

Out-of-roundness 0.005 mm (0.0002 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

(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 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.045 mm (0.0018 in) STD 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.040 mm (0.0016 in) STD 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.045 mm (0.0018 in) STD 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.040 mm (0.0016 in)

51.954 — 51.970 mm (2.0454 — 2.0461 in)

51.934 — 51.950 mm (2.0447 — 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)

MECHANICAL

ME(H4DOTC)-5

MECHANICAL

Crankshaft bearing

Crankshaft bearing thickness

2. STi MODEL

General Description

STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in) US

#1, #3

#2, #4, #5

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

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)

Engine

Type

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

Piston displacement

Compression ratio 8.0 Compression pres-

sure (at 200 — 300 rpm)

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 on MT]

Firing order 1 → 3 → 2 → 4 Ignition timing BTDC/rpm 12°±10°/700

Opening BBDC 58° Closing ATDC 10° Intake mm (in) 0.20±0.02 (0.0079±0.0008) Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)

kPa (kgf/cm

Max. retard ATDC 6° Min. advance BTDC 24° Max. retard ABDC 68° Min. advance ABDC 38°

(cu in)

, psi)

rpm

Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine

1,994 (121.67)

981 — 1,177 (10 — 12, 142 — 171)

700±100 (No load)

800±150 (A/C switch ON)

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

ME(H4DOTC)-6

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 0.3 mm (0.012 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 15.8 — 16.2 mm (0.622 — 0.638 in)

Intake

Head edge thickness

Exhaust

Stem diameter

Stem oil clearance

Overall length

Free length 43.89 mm (1.728 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 0.040 — 0.080 mm (0.0016 — 0.0031 in) Limit 0.10 mm (0.0039 in) STD 45.25 — 45.35 mm (1.781 — 1.785 in) Limit 45.15 mm (1.758 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)

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

Set

Lift

29.946 — 29.963 mm (1.1790 — 1.1796 in)

205 — 237 N (20.9 — 24.2 kgf, 46.1 — 53.3 lb)/

36.0 mm (1.417 in)

553 — 611 N (56.4 — 62.3 kgf, 124 — 137 lb)/

26.45 mm (1.041 in)

ME(H4DOTC)-7

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 or 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

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)

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

STD 0.20 — 0.25 mm (0.0079 — 0.0098 in) Limit 1.0 mm (0.039 in) STD 0.40 — 0.50 mm (0.016 — 0.020 in) Limit 1.0 mm (0.039 in) STD 0.20 — 0.50 mm (0.0079 — 0.020 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)

92.225 — 92.235 mm (3.6309 — 3.6313 in)

92.475 — 92.485 mm (3.6407 — 3.6411 in)

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

(68°F).

1.504 — 1.512 mm (0.0592 — 0.0595 in)

1.514 — 1.522 mm (0.0596 — 0.0599 in)

1.614 — 1.622 mm (0.0635 — 0.0639 in)

ME(H4DOTC)-8

Crankshaft

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

Out-of-roundness 0.005 mm (0.0002 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

(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

51.954 — 51.970 mm (2.0454 — 2.0461 in)

51.934 — 51.950 mm (2.0447 — 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)

MECHANICAL

ME(H4DOTC)-9

General Description

MECHANICAL

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

Crankshaft bearing

#1, #3

Crankshaft bearing thickness

#2, #4, #5

3. DOHC TURBO MODEL (AUSTRALIA MODEL EXCEPT FOR STi MODEL)

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)

Engine

Type

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

Piston displacement

Compression ratio 9.0 Compression pres-

sure (at 200 — 300 rpm)

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 on MT, or “P” or “N” position on AT]

Firing order 1 → 3 → 2 → 4

Ignition timing BTDC/rpm

Opening BBDC 53° Closing ATDC 7° Intake mm (in) 0.20±0.02 (0.0079±0.0008) Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)

kPa (kgf/cm

rpm

(cu in)

, psi)

Max. retard ATDC 7° Min. advance BTDC 27° Max. retard ABDC 67° Min. advance ABDC 33°

MT 12°±3°/650 AT 12°±3°/700

Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine

1,994 (121.67)

1,108 — 1,304 (11 — 13, 161 — 189)

650±50 (No load)

800±50 (A/C switch ON)

700±50 (No load)

820±50 (A/C switch ON)

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

ME(H4DOTC)-10

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 0.3 mm (0.012 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 15.8 — 16.2 mm (0.622 — 0.638 in)

Intake

Head edge thickness

Exhaust

Stem diameter

Stem oil clearance

Overall length

Free length 47.32 mm (1.8630 in) Squareness 2.5°, 2.1 mm (0.083 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)

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)

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

Set

Lift

29.946 — 29.963 mm (1.1790 — 1.1796 in)

205 — 235 N (20.9 — 24.0 kgf, 46.1 — 52.8 lb)/

36.0 mm (1.417 in)

426 — 490 N (43.4 — 50.0 kgf, 95.8 — 110 lb)/

26.5 mm (1.043 in)

ME(H4DOTC)-11

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 or 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

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)

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

STD 0.20 — 0.25 mm (0.0079 — 0.0098 in) Limit 1.0 mm (0.039 in) STD 0.40 — 0.50 mm (0.016 — 0.020 in) Limit 1.0 mm (0.039 in) STD 0.20 — 0.50 mm (0.0079 — 0.020 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)

92.225 — 92.235 mm (3.6309 — 3.6313 in)

92.475 — 92.485 mm (3.6407 — 3.6411 in)

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

(68°F).

1.504 — 1.512 mm (0.0592 — 0.0595 in)

1.514 — 1.522 mm (0.0596 — 0.0599 in)

1.614 — 1.622 mm (0.0635 — 0.0639 in)

ME(H4DOTC)-12

Crankshaft

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

Out-of-roundness 0.005 mm (0.0002 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

(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

51.954 — 51.970 mm (2.0454 — 2.0461 in)

51.934 — 51.950 mm (2.0447 — 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)

MECHANICAL

ME(H4DOTC)-13

MECHANICAL

Crankshaft bearing

Crankshaft bearing thickness

General Description

STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in) US

#1, #3

#2, #4, #5

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

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)

ME(H4DOTC)-14

General Description

B: COMPONENT

1. TIMING BELT

• EXCEPT FOR STi AND AUSTRALIA MODEL

MECHANICAL

(17)

(12)

(14)

(13)

(9)

(8)

(7)

(2)

(6)

(2)

(10)

(11)

(1)

(2)

(3)

(4)

(5)

(14)

(2)

(15)

(16)

(18)

ME-00601

(1) Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torque: N·m (kgf-m, ft-lb) (2) Timing belt guide (MT model) (11) Exhaust camshaft sprocket (LH) T1: 5 (0.5, 3.6) (3) Crankshaft sprocket (12) Timing belt T2: 6.4 (0.65, 4.7) (4) Timing belt cover No. 2 (LH) (13) Belt idler No. 2 T3: 25 (2.5, 18.1) (5) Tensioner bracket (14) Belt idler T4: 39 (4.0, 28.9) (6) Automatic belt tension adjuster

ASSY

(7) Belt idler (17) Timing belt cover (RH) (8) Exhaust camshaft sprocket (RH) (18) Crankshaft pulley

(15) Timing belt cover (LH) T5: 98 (10, 72.4) (16) Front belt cover T6: <Ref. to ME(H4DOTC)-56,

INSTALLATION, CRANKSHAFT PULLEY.>

(9) Intake camshaft sprocket (RH) T7: 10 (1.0, 7.2)

ME(H4DOTC)-15

MECHANICAL

• STi AND AUSTRALIA MODEL

General Description

(17)

(12)

(14)

(13)

(8)

(7)

(9)

(2)

(6)

(2)

(11)

(14)

(10)

(1)

(2)

(3)

(4)

(5)

(2)

(15)

(16)

(18)

ME-00704

(1) Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torque: N·m (kgf-m, ft-lb) (2) Timing belt guide (11) Exhaust camshaft sprocket (LH) T1: 5 (0.5, 3.6) (3) Crankshaft sprocket (12) Timing belt T2: 6.4 (0.65, 4.7) (4) Timing belt cover No. 2 (LH) (13) Belt idler No. 2 T3: 25 (2.5, 18.1) (5) Tensioner bracket (14) Belt idler T4: 39 (4.0, 28.9) (6) Automatic belt tension adjuster

ASSY

(7) Belt idler (17) Timing belt cover (RH) (8) Exhaust camshaft sprocket (RH) (18) Crankshaft pulley

(15) Timing belt cover (LH) T5: 98 (10, 72.4) (16) Front belt cover T6: <Ref. to ME(H4DOTC)-56,

INSTALLATION, CRANKSHAFT PULLEY.>

(9) Intake camshaft sprocket (RH)

ME(H4DOTC)-16

General Description

2. CYLINDER HEAD AND CAMSHAFT

• EXCEPT FOR STi AND AUSTRALIA MODEL

(3)

(4)

(2)

MECHANICAL

(1)

(5)

(14)

(32)

(9)

(18)

(19)

(6)

(16)

(7)

(10)

(17)

(11)

(20)

(8)

(14)

(21)

(12)

(32)

(13)

(24)

(13)

(22)

(25)

(31)

(15)

(16)

(28)

(29)

(30)

(3)

(4)

(23)

ME(H4DOTC)-17

(26)

(27)

ME-00756

General Description

MECHANICAL

(1) Rocker cover (RH) (15) Cylinder head (RH) (29) Gasket (2) Rocker cover gasket (RH) (16) Cylinder head gasket (30) Oil filler duct (3) Oil separator cover (17) Cylinder head (LH) (31) O-ring (4) Gasket (18) Intake camshaft (LH) (32) Stud bolt (5) Intake camshaft cap (Front RH) (19) Exhaust camshaft (LH) (6) Intake camshaft cap (Center RH) (20) Intake camshaft cap (Front LH) Tightening torque: N·m (kgf-m, ft-lb) (7) Intake camshaft cap (Rear RH) (21) Intake camshaft cap (Center LH) T1: <Ref. to ME(H4DOTC)-78, (8) Intake camshaft cap (RH) (22) Intake camshaft cap (Rear LH) (9) Exhaust camshaft cap (Front RH) (23) Exhaust camshaft cap (Front LH)

(10) Exhaust camshaft cap (Center

RH)

(11) Exhaust camshaft cap (Rear RH) (25) Exhaust camshaft cap (Rear LH) T4: 6.4 (0.65, 4.7) (12) Exhaust camshaft (RH) (26) Rocker cover gasket (LH) T5: 10 (1.0, 7.2) (13) Cylinder head bolt (27) Rocker cover (LH) (14) Oil seal (28) Oil filler cap

(24) Exhaust camshaft cap (Center

LH)

INSTALLATION, CYLINDER HEAD ASSEMBLY.>

T2: 5 (0.5, 3.6) T3: 20 (2.0, 14.5)

ME(H4DOTC)-18

• STi AND AUSTRALIA MODEL

General Description

MECHANICAL

(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(H4DOTC)-19

(23)

ME-00705

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) Oil flow control solenoid valve

assembly (RH)

(4) Intake camshaft cap (RH) (17) Oil flow control solenoid valve (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(H4DOTC)-78, (7) Exhaust camshaft cap (Center

RH)

(9) Exhaust camshaft (RH) (21) Exhaust camshaft cap (Rear LH) T3: 10 (1.0, 7) (10) Cylinder head bolt (22) Rocker cover gasket (LH) T4: 6.4 (0.65, 4.7) (11) Oil seal (23) Rocker cover (LH) T5: 20 (2.0, 14.5) (12) Cylinder head (RH) (24) Oil filler cap

(15) Intake camshaft (LH) (27) O-ring (16) Exhaust camshaft (LH) (28) Stud bolt

assembly (LH)

(19) Exhaust camshaft cap (Front LH) (20) Exhaust camshaft cap (Center

LH)(8) Exhaust camshaft cap (Rear RH) T2: 5 (0.5, 3.6)

INSTALLATION, CYLINDER HEAD ASSEMBLY.>

ME(H4DOTC)-20

General Description

3. CYLINDER HEAD AND VALVE ASSEMBLY

MECHANICAL

(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

ME-00003

ME(H4DOTC)-21

MECHANICAL

4. CYLINDER BLOCK

General Description

(10)

(18)

(8)

(19)

(14)

(7)

(2)

(3)

(10)

(4)

T10

(27)

(16)

(10)

(15)

(1)

(3)

(10)

(4)

(3)

(9)

(25)

(5)

(6)

(10)

(11)

(12)

(23)

T11

(24)

(17)

(13)

(26)

ME-00725

(21)

(22)

(20)

(1) Oil pressure switch (16) Water by-pass pipe Tightening torque: N·m (kgf-m, ft-lb)

(2) Cylinder block (RH) (17) Connector T1: 5 (0.5, 3.6)

(3) Service hole plug (18) Oil strainer T2: 6.4 (0.65, 4.7)

(4) Gasket (19) Gasket T3: 10 (1.0, 7.2)

(5) Oil separator cover (20) Oil pan T4: 25 (2.5, 18.1)

(6) Water by-pass pipe (21) Drain plug T5: <Ref. to ME(H4DOTC)-89,

(7) Oil pump (22) Metal gasket

(8) Front oil seal (23) Oil level gauge guide

INSTALLATION, CYLINDER BLOCK.>

(9) Rear oil seal (24) Oil filter T6: 69 (7.0, 50.6) (10) O-ring (25) Gasket T7: First 12 (1.2, 8.7) (11) Service hole cover (26) Water pump hose

Second 12 (1.2, 8.7)

(12) Cylinder block (LH) (27) Plug T8: 16 (1.6, 11.6) (13) Water pump T9: 44 (4.5, 33) (14) Baffle plate T10: 25 (2.5, 18.1) (15) Oil cooler T11: 54 (5.5, 40)

ME(H4DOTC)-22

5. CRANKSHAFT AND PISTON

(1)

(2)

General Description

MECHANICAL

(4)

(5)

(6)

(7)

(10)

(8)

(14)

(17)

(13)

(16)

(18)

(10)

(9)

(17)

(11)

(12)

(13)

(12)

(18)

(13)

(19)

(11)

(10)

(9)

(15)

(13)

(7)

(6)

(3)

(14)

(10)

(8)

(5)

ME-00005

(1) Flywheel (MT model) (10) Circlip (19) Crankshaft bearing #5

(2) Ball bearing (MT model) (11) Connecting rod bolt

(3) Reinforcement (AT model) (12) Connecting rod Tightening torque: N·m (kgf-m, ft-lb)

(4) Drive plate (AT model) (13) Connecting rod bearing T1: 45 (4.6, 33.3) (Except for STi

(5) Top ring (14) Connecting rod cap

model)

(6) Second ring (15) Crankshaft T1: 52 (5.3, 38.4) (STi model)

(7) Oil ring (16) Woodruff key T2: 72 (7.3, 52.8) (Except for STi

(8) Piston (17) Crankshaft bearing #1, #3

model)

(9) Piston pin (18) Crankshaft bearing #2, #4 T2: 77 (7.9, 56.8) (STi model)

ME(H4DOTC)-23

MECHANICAL

6. ENGINE MOUNTING

General Description

(3)

(2)

(1)

(3)

(2)

ME-00706

(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(H4DOTC)-24

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 the ground cable 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 the 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.

MECHANICAL

ME(H4DOTC)-25

MECHANICAL

D: PREPARATION TOOL

1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ST-498267600

General Description

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).

ST-498457000

ST-498457100

ST-498497100

498457100 ENGINE STAND

ADAPTER LH

498497100 CRANKSHAFT

STOPPER

Used with ENGINE STAND (499817000).

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

ME(H4DOTC)-26

General Description

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398744300 PISTON GUIDE Used for installing piston in cylinder for 2.0 L

engine.

ST-398744300

498857100 VALVE OIL SEAL

GUIDE

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

MECHANICAL

ST-498857100

ST-499017100

ST-499037100

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.

ME(H4DOTC)-27

MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ST-499097600

General Description

499097600 PISTON PIN

REMOVER ASSY

499097700 PISTON PIN

REMOVER ASSY

Used for removing piston pin. (Except for Australia model)

Used for removing piston pin. (Australia model except for STi model)

ST-499097700

ST-499207400

ST18231AA010

499207400 CAMSHAFT

SPROCKET WRENCH

18231AA010 CAMSHAFT

SPROCKET WRENCH

Used for removing and installing exhaust camshaft sprocket and intake camshaft sprocket (RH). (Except for STi and Australia model)

Used for removing and installing intake camshaft sprocket (LH). (Except for STi and Australia model)

ME(H4DOTC)-28

General Description

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977500 CAMSHAFT

SPROCKET WRENCH

ST-499977500

499587200 CRANKSHAFT

OIL SEAL INSTALLER

Used for removing and installing intake camshaft sprocket. (STi and Australia model)

• Used for installing crankshaft oil seal.

• Used with CRANKSHAFT OIL SEAL GUIDE

(499597100).

MECHANICAL

ST-499587200

ST-499597100

ST-499718000

499597100 CRANKSHAFT

OIL SEAL GUIDE

499718000 VALVE SPRING

REMOVER

• Used for installing crankshaft oil seal.

• Used with CRANKSHAFT OIL SEAL

INSTALLER (499587200).

Used for removing and installing valve spring.

ME(H4DOTC)-29

MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ST18251AA020

General Description

18251AA020 VALVE GUIDE

ADJUSTER

499767200 VALVE GUIDE

REMOVER

Used for installing intake and exhaust valve guides.

Used for removing valve guides.

ST-499767200

ST-499767400

ST-499817000

499767400 VALVE GUIDE

REAMER

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

Used for reaming valve guides.

bly.

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

ME(H4DOTC)-30

General Description

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977400 CRANKSHAFT

PULLEY WRENCH

ST-499977400

499987500 CRANKSHAFT

SOCKET

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

Used for rotating crankshaft.

MECHANICAL

ST-499987500

ST-498547000

ST18332AA000

498547000 OIL FILTER

WRENCH

18332AA000 OIL FILTER

WRENCH

• Used for removing and installing oil filter.

• For oil filter (Outer diameter: 80 mm (3.15 in))

• Used for removing and installing oil filter.

• For oil filter (Outer diameter: 68 mm (2.68 in))

ME(H4DOTC)-31

MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ST-499587100

General Description

499587100 OIL SEAL

INSTALLER

499587600 OIL SEAL

INSTALLER

Used for installing oil pump oil seal.

Used for installing camshaft oil seal for DOHC engine.

ST-499587600

ST-499597200

ST-498277200

499597200 OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC

engine. Used with OIL SEAL GUIDE (499587600).

498277200 STOPPER SET Used for installing automatic transmission assem-

bly to engine.

ME(H4DOTC)-32

General Description

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA230 CARTRIDGE Troubleshooting for electrical systems.

ST24082AA230

22771AA030 SUBARU

SELECT MONITOR KIT

Troubleshooting for electrical systems.

• English: 22771AA030 (Without printer)

• German: 22771AA070 (Without printer)

• French: 22771AA080 (Without printer)

• Spanish: 22771AA090 (Without printer)

MECHANICAL

ST22771AA030

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Compression Gauge Used for measuring compression.

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(H4DOTC)-33

MECHANICAL

Compression

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 the fuel pressure. <Ref. to FU(H4DOTC)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>

4) Remove all the spark plugs. <Ref. to IG(H4DOTC)-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 spark plug hole.

NOTE: 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 starter motor, and then read the maximum value on the gauge when the pointer is steady.

Australia model (Except for STi model)

Standard

1.108 — 1,304 kPa (11 — 13 kgf/cm 189 psi)

Limit

951 kPa (10 kgf/cm

, 138 psi)

Difference between cylinders

Less than 49 kPa (0.5 kgf/cm

, 7 psi)

, 161 —

ME-00007

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

Compression (350 rpm and fully open throttle):

Except for Australia model

Standard

981 — 1,177 kPa (10 — 12 kgf/cm

, 142 —

171 psi)

Limit

882 kPa (9.0 kgf/cm

, 128 psi)

Difference between cylinders

Less than 49 kPa (0.5 kgf/cm

, 7 psi)

ME(H4DOTC)-34

Idle Speed

MECHANICAL

3. Idle Speed

A: INSPECTION

1. USING SUBARU SELECT MONITOR

1) Before checking the idle speed, check the following:

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

2) Warm-up the engine.

3) Stop the engine, and then turn the ignition switch to OFF.

4) Insert the cartridge to SUBARU SELECT MONITOR.

5) Connect the SUBARU SELECT MONITOR to data link connector.

6) Turn the ignition switch to ON, and SUBARU SELECT MONITOR switch to ON.

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

8) Select the {Engine Control System} in Selection Menu.

9) Select the {1. Current Data Display & Save} in Engine Control System Diagnosis.

10) Select the {1.12 Data Display} in Data Display Menu.

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

12) Check the idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF)

NOTE: As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under “Engine Control System”. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>

Idle speed [No load and gears in neutral]:

Except for Australia model

100 rpm

±±±±

700

Australia model (Except for STi model)

650

50 rpm (MT model)

±±±±

50 rpm (AT model)

700

±±±±

13) Check the idle speed when loaded. (Turn the air conditioning switch to “ON” and operate the compressor for at least 1 minute before measurement.)

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

Except for Australia model

150 rpm

±±±±

800

Australia model (Except for STi model)

800

50 rpm (MT model)

±±±±

50 rpm (AT model)

±±±±

820

ME(H4DOTC)-35

Ignition Timing

MECHANICAL

4. Ignition Timing

A: INSPECTION

1. USING SUBARU SELECT MONITOR

1) Before checking the ignition timing speed, check the following:

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

2) Warm-up the engine.

3) Stop the engine, and then turn the ignition switch to OFF.

4) Insert the cartridge to SUBARU SELECT MONITOR.

5) Connect the SUBARU SELECT MONITOR to data link connector.

6) Turn the ignition switch to ON, and SUBARU SELECT MONITOR switch to ON.

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

8) Select the {Engine Control System} in Selection Menu.

9) Select the {1. Current Data Display & Save} in Engine Control System Diagnosis.

10) Select the {1.12 Data Display} in Data Display Menu.

11) Start the engine and check the ignition timing at idle speed.

Ignition timing [BTDC/rpm]:

Except for Australia model

/700

°±

°±10°°°°

°±°±

Australia model (Except for STi model)

/650 (MT model)

°±

°±3°°°°

°±°±

If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>

/700 (AT model)

°±

°±3°°°°

°±°±

ME(H4DOTC)-36

Intake Manifold Vacuum

MECHANICAL

5. Intake Manifold Vacuum

A: INSPECTION

1) Warm-up the engine.

2) Disconnect the brake vacuum hose, and then install the vacuum gauge to hose fitting on manifold.

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

ME-00008

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

Less than

60.0 kPa (

−−−−

450 mmHg,

−−−−

17.72 inHg)

−−−−

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.

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(H4DOTC)-37

Engine Oil Pressure

MECHANICAL

6. Engine Oil Pressure

A: INSPECTION

1) Remove the oil pressure switch from engine cylinder block. <Ref. to LU(H4DOTC)-18, REMOVAL, Oil Pressure Switch.>

2) Connect the oil pressure gauge hose to cylinder block.

3) Connect the battery ground cable to battery.

FU-00009

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

ME-00009

Oil pressure:

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

• If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to LU(H4DOTC)-21, 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(H4DOTC)-21, 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(H4DOTC)-18, INSTALLATION, Oil Pressure Switch.>

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

, 14 psi) or more at 800 rpm

, 43 psi) or more at 5,000

ME(H4DOTC)-38

Fuel Pressure

MECHANICAL

7. Fuel Pressure

A: INSPECTION

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

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

1) Release the fuel pressure. <Ref. to FU(H4DOTC)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>

2) Open the fuel flap lid, and then remove the fuel filler cap.

3) Disconnect the fuel delivery hoses from fuel filter, and then connect the fuel pressure gauge.

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

Fuel pressure:

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

41 — 46 psi)

ME-00011

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

Fuel pressure:

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

, 33 — 38 psi)

ME-00010

4) Connect the connector of fuel pump relay.

FU-00871

5) Start the engine.

ME-00011

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

, 1 to 3 psi) higher than standard val-

ues during high-altitude operations.

ME(H4DOTC)-39

MECHANICAL

Valve Clearance

8. Valve Clearance

A: INSPECTION

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

1) Set the vehicle on a lift.

2) Disconnect the ground cable from battery.

FU-00009

3) Remove the air intake duct. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>

4) Remove the bolts which secure the timing belt cover (RH).

5) Lift-up the vehicle.

6) Remove the under cover.

7) Loosen the remaining bolts which secure the timing belt cover (RH), and then remove the timing belt cover.

8) Lower the vehicle.

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

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

ME-00013

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

ME-00014

(3) Disconnect the washer motor connectors.

ME-00012

(2) Remove the air cleaner case. <Ref. to IN(H4DOTC)-7, REMOVAL, Air Cleaner.> (3) Disconnect the ignition coil connector. (4) Remove the ignition coil. (5) Place a suitable container under the vehicle. (6) Disconnect the PCV hose from rocker cover (RH). (7) Remove the bolts, and then remove the rocker cover (RH).

ME(H4DOTC)-40

ME-00015

(4) Remove the washer tank mounting bolts.

ME-00016

Valve Clearance

MECHANICAL

(5) Move the washer tank upward.

ME-00017

(6) Disconnect the ignition coil connector. (7) Remove the ignition coil. (8) Place a suitable container under the vehicle. (9) Disconnect the PCV hose from rocker cover (LH). (10)Remove the bolts, and then remove the rocker cover (LH).

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

NOTE: Turn the crankshaft using socket wrench.

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

(A)

ME-00019

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

to ME(H4DOTC)-42, ADJUSTMENT, Valve Clearance.>

14) Further turn the crankshaft pulley clockwise.

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

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

ME-00733

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

NOTE:

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

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

Valve clearance:

Intake: 0.20 Exhaust: 0.35

0.02 mm (0.0079

±±±±

0.02 mm (0.0138

±±±±

0.0008 in)

±±±±

0.0008 in)

±±±±

ME(H4DOTC)-41

ME-00734

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

ME-00735

MECHANICAL

Valve Clearance

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

ME-00736

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

Tightening torque:

33 N·m (3.4 kgf-m, 25 ft-lb)

3) Remove the valve lifter.

4) Measure the thickness of valve lifter with a mi-

crometer.

ME-00025

5) Select a shim of suitable thickness using mea-

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

Unit: mm

Intake valve: S = V – 0.20 Exhaust valve: S = V – 0.25

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

ME-00023

B: ADJUSTMENT

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

1) Measure all valve clearances. <Ref. to ME(H4DOTC)-40, INSPECTION, Valve Clearance.>

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

ME-00024

2) Remove the camshaft. <Ref. to ME(H4DOTC)69, REMOVAL, Camshaft.>

Part No. Thickness mm (in) 13228 AB101 4.68 (0.1843) 13228 AB111 4.69 (0.1846) 13228 AB121 4.70 (0.1850) 13228 AB131 4.71 (0.1854) 13228 AB141 4.72 (0.1858) 13228 AB151 4.73 (0.1862) 13228 AB161 4.74 (0.1866) 13228 AB171 4.75 (0.1870) 13228 AB181 4.76 (0.1874) 13228 AB191 4.77 (0.1878) 13228 AB201 4.78 (0.1882) 13228 AB211 4.79 (0.1886) 13228 AB221 4.80 (0.1890) 13228 AB231 4.81 (0.1894) 13228 AB241 4.82 (0.1898) 13228 AB251 4.83 (0.1902) 13228 AB261 4.84 (0.1906) 13228 AB271 4.85 (0.1909) 13228 AB281 4.86 (0.1913) 13228 AB291 4.87 (0.1917) 13228 AB301 4.88 (0.1921) 13228 AB311 4.89 (0.1925) 13228 AB321 4.90 (0.1929) 13228 AB331 4.91 (0.1933) 13228 AB341 4.92 (0.1937) 13228 AB351 4.93 (0.1941) 13228 AB361 4.94 (0.1945) 13228 AB371 4.95 (0.1949) 13228 AB381 4.96 (0.1953)

ME(H4DOTC)-42

Valve Clearance

MECHANICAL

Part No. Thickness mm (in) 13228 AB391 4.97 (0.1957) 13228 AB401 4.98 (0.1961) 13228 AB411 4.99 (0.1965) 13228 AB421 5.00 (0.1969) 13228 AB431 5.01 (0.1972) 13228 AB441 5.02 (0.1976) 13228 AB451 5.03 (0.1980) 13228 AB461 5.04 (0.1984) 13228 AB471 5.05 (0.1988) 13228 AB481 5.06 (0.1992) 13228 AB491 5.07 (0.1996) 13228 AB501 5.08 (0.2000) 13228 AB511 5.09 (0.2004) 13228 AB521 5.10 (0.2008) 13228 AB531 5.11 (0.2012) 13228 AB541 5.12 (0.2016) 13228 AB551 5.13 (0.2020) 13228 AB561 5.14 (0.2024) 13228 AB571 5.15 (0.2028) 13228 AB581 5.16 (0.2031) 13228 AB591 5.17 (0.2035) 13228 AB601 5.18 (0.2039) 13228 AB611 5.19 (0.2043) 13228 AB621 5.20 (0.2047) 13228 AB631 5.21 (0.2051) 13228 AB641 5.22 (0.2055) 13228 AB651 5.23 (0.2059) 13228 AB661 5.24 (0.2063) 13228 AB671 5.25 (0.2067) 13228 AB681 5.26 (0.2071) 13228 AB691 5.27 (0.2075) 13228 AB701 4.38 (0.1724) 13228 AB711 4.40 (0.1732) 13228 AB721 4.42 (0.1740) 13228 AB731 4.44 (0.1748) 13228 AB741 4.46 (0.1756) 13228 AB751 4.48 (0.1764) 13228 AB761 4.50 (0.1771) 13228 AB771 4.52 (0.1780) 13228 AB781 4.54 (0.1787) 13228 AB791 4.56 (0.1795) 13228 AB801 4.58 (0.1803) 13228 AB811 4.60 (0.1811) 13228 AB821 4.62 (0.1819) 13228 AB831 4.64 (0.1827) 13228 AB841 4.66 (0.1835) 13228 AB851 5.29 (0.2083) 13228 AB861 5.31 (0.2091) 13228 AB871 5.33 (0.2098) 13228 AB881 5.35 (0.2106) 13228 AB891 5.37 (0.2114)

Part No. Thickness mm (in) 13228 AB901 5.39 (0.2122) 13228 AB911 5.41 (0.2123) 13228 AB921 5.43 (0.2138) 13228 AB931 5.45 (0.2146) 13228 AB941 5.47 (0.2154) 13228 AB951 5.49 (0.2161) 13228 AB961 5.51 (0.2169) 13228 AB971 5.53 (0.2177) 13228 AB981 5.55 (0.2185) 13228 AB991 5.57 (0.2193) 13228 AC001 5.59 (0.2201) 13228 AC011 5.61 (0.2209) 13228 AC021 5.63 (0.2217) 13228 AC031 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(H4DOTC)-43

MECHANICAL

Engine Assembly

9. Engine Assembly

A: REMOVAL

1) Set the vehicle on a lift.

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

3) Collect the refrigerant from A/C system.

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

FU-00871

(2) Start the engine, and run until stalls. (3) After the engine stalls, crank it for 5 seconds more. (4) Turn the ignition switch to OFF.

5) Remove the filler cap.

6) Disconnect the ground cable from battery.

10) Remove the intercooler. <Ref. to IN(H4DOTC)10, REMOVAL, Intercooler.>

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

ME-00027

(2) Engine ground terminal

ME-00028

FU-00009

7) Remove the radiator from vehicle. <Ref. to CO(H4DOTC)-23, REMOVAL, Radiator.>

8) Remove the coolant filler tank. <Ref. to CO(H4DOTC)-33, REMOVAL, Coolant Filler Tank.>

9) Disconnect the A/C pressure hoses from A/C compressor.

(3) Engine harness connector

ME-00029

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

(B)

(A)

ME-00030

ME-00707

ME(H4DOTC)-44

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

Engine Assembly

MECHANICAL

(5) Accelerator cable (MT model)

(6) Clutch release spring (MT model)

(2) Disconnect the power steering switch connector.

ME-00031

ME-00035

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

ME-00032

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

(2) Heater inlet outlet hose

ME-00036

(4) Remove the power steering pump from engine.

ME-00033

ME-00037

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

ME-00034

13) Remove the power steering pump from brack-

et.

(1) Loosen the lock bolt and slider bolt, and then remove the front side V-belt. <Ref. to ME(H4DOTC)-54, FRONT SIDE BELT, REMOVAL, V-belt.>

ME(H4DOTC)-45

ME-00038

MECHANICAL

Engine Assembly

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

ME-00039

14) Lift-up the vehicle.

15) Remove the ATF cooler pipe from frame. (AT

model)

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

EX(H4DOTC)-9, REMOVAL, Center Exhaust Pipe.>

17) Remove the nuts which hold the lower side of

transmission to engine.

(2) Remove the plug using a 10 mm hexagon wrench.

ME-00042

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

(A)

ME-00040

18) Remove the nuts which install the front cushion

rubber onto front crossmember.

ME-00041

19) Lower the vehicle.

20) Separate the clutch release fork from release

bearing. (MT model)

(1) Remove the clutch operating cylinder from transmission.

(B)

ME-00043

(A) Shaft (B) Bolt

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

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

21) Separate the torque converter clutch from drive plate. (AT model)

(1) Lower the vehicle. (2) Remove the service hole plug. (3) Remove the bolts which hold the torque converter clutch to drive plate.

ME(H4DOTC)-46

Engine Assembly

MECHANICAL

(4) Remove the other bolts while rotating the engine using socket wrench.

ME-00044

22) Remove the pitching stopper.

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

ME-00047

26) Support the transmission with a garage jack. NOTE:

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.

MT-00069

23) Disconnect the fuel delivery hose, return hose

and evaporation hose. NOTE:

• Catch fuel from the hose into container.

• Disconnect the hose with its end wrapped with

cloth to prevent fuel from splashing.

ME-00045

24) Remove the fuel filter and bracket.

ME-00048

27) Separation of the engine and transmission. (1) Remove the starter. <Ref. to SC(H4SO)-7, REMOVAL, Starter.> (2) Install the ST to torque converter clutch case. (AT model)

ST 498277200 STOPPER SET

ME-00046

ME(H4DOTC)-47

ME-00049

MECHANICAL

Engine Assembly

(3) Remove the bolts which hold the right upper side of transmission to engine.

ME-00050

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

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

29) Remove the front cushion rubbers.

(3) Install the release fork into release bearing tab.

(A)

(B)

(A) Release fork (B) Release bearing

ME-00052

(4) Apply grease to the specified points.

• Spline: FX2200

• Shaft: SUNLIGHT 2

B: INSTALLATION

1) Install the clutch release fork and bearing onto

transmission. (MT model)

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

ME-00051

(2) Install the release bearing on transmission.

(A)

(B)

ME-00053

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

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

ME(H4DOTC)-48

Engine Assembly

MECHANICAL

CAUTION: Make sure the cutout portion of release fork shaft contacts spring pin.

(B)

(C)

(A) Release fork (B) Release shaft

(A)

ME-00054

(6) Tighten the plug.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

ME-00050

5) Remove the lifting device and wire ropes.

6) Remove the garage jack.

ME-00055

2) Install the front cushion rubbers to engine.

Tightening torque:

35 N·m (3.6 kgf-m, 25.8 ft-lb)

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

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

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

4) Tighten the bolts which hold the right upper side

of transmission to engine.

ME-00047

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)

MT-00085

8) Remove the ST from torque converter clutch case. (AT model)

NOTE: Be careful not to drop the ST into torque converter clutch case when removing ST. ST 498277200 STOPPER SET

9) Install the starter. <Ref. to SC(H4SO)-7, INSTALLATION, Starter.>

10) Install the torque converter clutch onto drive plate. (AT model)

(1) Tighten the bolts which hold the torque converter clutch to drive plate.

ME(H4DOTC)-49

MECHANICAL

Engine Assembly

(2) Tighten other bolts while rotating the engine by using ST.

CAUTION: Be careful not to drop bolts into the torque converter clutch housing.

ST 499977300 CRANKSHAFT PULLEY

WRENCH

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

ME-00044

(3) Clog the service hole with plug.

11) Install the fuel filter and bracket.

(2) Install the power steering pump.

Tightening torque:

20.1 N·m (2.05 kgf-m, 14.8 ft-lb)

ME-00037

(3) Install the power steering pipe bracket on intake manifold RH.

ME-00046

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

ME-00038

ME-00036

(4) Connect the power steering switch connector.

ME-00035

(5) Install the front side V-belt, and adjust it. <Ref. to ME(H4DOTC)-54, FRONT SIDE BELT, INSTALLATION, V-belt.>

13) Lift-up the vehicle.

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

ME(H4DOTC)-50

Engine Assembly

MECHANICAL

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

ME-00040

15) Tighten the nuts which install the front cushion

rubber onto crossmember.

Tightening torque:

85 N·m (8.7 kgf-m, 62.7 ft-lb)

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

(A)

(B)

(A)

(B)

ME-00056

16) Install the ATF cooler pipe to frame. (AT model)

17) Install the center exhaust pipe.

<Ref. to EX(H4DOTC)-10, INSTALLATION, Center Exhaust Pipe.>

18) Lower the vehicle.

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

20) 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

21) Connect the following cables: (1) Accelerator cable (2) Clutch release spring

22) After connecting each cable, adjust them.

23) Install the air intake system. (1) Install the intercooler. <Ref. to IN(H4DOTC)-10, 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.

24) Install the A/C pressure hoses. NOTE:

Use new O-rings.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

ME-00707

25) Install the radiator. <Ref. to CO(H4DOTC)-24, INSTALLATION, Radiator.>

26) Install the coolant filler tank. <Ref. to CO(H4DOTC)-33, INSTALLATION, Coolant Filler Tank.>

27) Install the window washer tank.

28) Install the battery in the vehicle, and then connect the cables.

29) Fill coolant. <Ref. to CO(H4DOTC)-18, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

30) Charge the A/C system with refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>

31) Remove the front hood stay, and close the front hood.

32) Take off the vehicle from lift arms.

ME(H4DOTC)-51

Engine Mounting

MECHANICAL

10.Engine Mounting

A: REMOVAL

1) Remove the engine assembly. <Ref. to

ME(H4DOTC)-44, 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.

ME(H4DOTC)-52

Preparation for Overhaul

11.Preparation for Overhaul

A: PROCEDURE

1) After removing the engine from body, secure it in

the ST shown below. ST1 498457000 ENGINE STAND ADAPTER

ST2 498457100 ENGINE STAND ADAPTER

ST3 499817000 ENGINE STAND

ST2

ST1

ST3

ME-00057

MECHANICAL

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(H4DOTC)-53

MECHANICAL

V-belt

12.V-belt

A: REMOVAL

1. FRONT SIDE BELT

1) Remove the V-belt cover.

2) Loosen the lock bolt (A).

3) Loosen the slider bolt (B).

4) Remove the front side belt (C).

(B)

(A)

ME-00708

(C)

4) Remove the A/C belt tensioner.

ME-00061

B: INSTALLATION

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

1. FRONT SIDE BELT

1) Install a V-belt (C), and tighten the slider bolt so as to obtain the specified belt tension. <Ref. to ME(H4DOTC)-55, INSPECTION, V-belt.>

2) Tighten the lock bolt (A).

3) Tighten the slider bolt (B).

Tightening torque:

Lock bolt (A):

25 N·m (2.5 kgf-m, 18.1 ft-lb)

Slider bolt (B):

8 N·m (0.8 kgf-m, 5.9 ft-lb)

2. REAR SIDE BELT

1) Loosen the lock nut (A).

2) Loosen the slider bolt (B).

3) Remove the A/C belt.

(B)

ME-00059

(A)

ME-00060

(B)

(C)

(A)

ME-00059

2. REAR SIDE BELT

1) Remove the A/C belt tensioner.

2) Install a V-belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(H4DOTC)-55, INSPECTION, V-belt.>

ME(H4DOTC)-54

V-belt

MECHANICAL

3) Tighten the lock nut (A).

Tightening torque:

Lock nut (A):

22.6 N·m (2.3 kgf-m, 16.6 ft-lb)

(B)

(A)

ME-00060

C: INSPECTION

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

found.

2) Check the V-belt tension and adjust it if neces-

sary by changing the generator installing position and idler pulley installing position.

Belt tension (with belt tension gauge)

(A)

When installing new parts:

618 — 755 N (63 — 77 kgf, 139 — 170 lb)

At inspection:

490 — 640 N (50 — 65 kgf, 110 — 144 lb)

Belt tension (without belt tension gauge)

(A)

When installing new parts:

7 — 9 mm (0.276 — 0.354 in)

At inspection:

9 — 11 mm (0.354 — 0.433 in)

(B)

When installing new parts:

7.5 — 8.5 mm (0.295 — 0.335 in)

At inspection:

9.0 — 10.0 mm (0.354 — 0.394 in)

98 N (10 kgf, 22 lb)

P/S

C/P Crank pulley

GEN Generator

P/S Power steering oil pump pulley A/C A/C compressor pulley

I/P Idler pulley

GEN

(A)

C/P

(B)

A/C

I/P

ME-00062

(B)

When installing new parts:

740 — 880 N (75 — 90 kgf, 166 — 198 lb)

At inspection:

350 — 450 N (36 — 46 kgf, 78 — 101 lb)

(A)

P/S

(A) Front side belt (B) Rear side belt

C/P Crank pulley

GEN Generator

P/S Power steering oil pump pulley A/C A/C compressor pulley

I/P Idler pulley

GEN

C/P

A/C

(B)

I/P

PM-00154

ME(H4DOTC)-55

Subaru Impreza 2004 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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