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

cm

3

(cu in)

2

, 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

#1

#2

#3

#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 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°

cm

3

(cu in)

2

, 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)

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

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

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)

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

#1

#2

#3

#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 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)-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

3

(cu in)

cm

2

, psi)

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

MT

AT

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)

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)

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

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

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)

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

#1

#2

#3

#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 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)-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)

T1

T5

(12)

(14)

T4

(13)

(9)

(8)

T2

(7)

T4

(2)

T2

T1

(6)

T5

(2)

T4

T3

(10)

(11)

T1

T4

(1)

(2)

T7

(3)

(4)

(5)

(14)

T1

(2)

T2

(15)

(16)

T6

(18)

T1

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)

T1

T5

(12)

(14)

T4

T5

(13)

(8)

(7)

T2

(9)

T4

(2)

T5

T2

T1

T5

(6)

T3

(2)

T3

(11)

T1

T4

(14)

(10)

(1)

(2)

T2

(3)

(4)

(5)

T1

(2)

T2

(15)

(16)

T6

(18)

T1

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