Subaru Impreza 2004 User Manual

FUJI HEAVY INDUSTRIES LTD. G1870GE32004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEXENGINE SECTION 2This service manual has been preparedto provide SU

ME(H4DOTC)-9MECHANICALGeneral DescriptionCrankshaftBend limit 0.035 mm (0.0014 in)Crank pin and crank jour-nalOut-of-roundness 0.005 mm (0.0002 in) or

ME(H4DOTC)-10MECHANICALGeneral Description3. DOHC TURBO MODEL (AUSTRALIA MODEL EXCEPT FOR STi MODEL)NOTE:STD: Standard I.D.: Inner Diameter O.D.: Oute

ME(H4DOTC)-11MECHANICALGeneral DescriptionBelt tension adjusterProtrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)Belt tensionerSpacer O.D. 17.

ME(H4DOTC)-12MECHANICALGeneral DescriptionCylinder blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)Surface grinding limit 0.

ME(H4DOTC)-13MECHANICALGeneral DescriptionCrankshaftBend limit 0.035 mm (0.0014 in)Crank pin and crank jour-nalOut-of-roundness 0.005 mm (0.0002 in) o

ME(H4DOTC)-14MECHANICALGeneral DescriptionCrankshaft bearingCrankshaft bearing thick-ness#1, #3STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)0.03 mm (0.001

ME(H4DOTC)-15MECHANICALGeneral DescriptionB: COMPONENT1. TIMING BELT• EXCEPT FOR STi AND AUSTRALIA MODEL(1) Timing belt cover No. 2 (RH) (10) Intake c

ME(H4DOTC)-16MECHANICALGeneral Description• STi AND AUSTRALIA MODEL(1) Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torq

ME(H4DOTC)-17MECHANICALGeneral Description2. CYLINDER HEAD AND CAMSHAFT• EXCEPT FOR STi AND AUSTRALIA MODELME-00756T2T4T3T5T4T2T2T1(7)(6)(14)(9)(8)(10

ME(H4DOTC)-18MECHANICALGeneral Description(1) Rocker cover (RH) (15) Cylinder head (RH) (29) Gasket(2) Rocker cover gasket (RH) (16) Cylinder head gas

MECHANICALME(H4DOTC)Page1. General Description ...22. Compression ...

ME(H4DOTC)-19MECHANICALGeneral Description• STi AND AUSTRALIA MODELME-00705T2T3T4T2T2T1(1)(3)(7)(6)(9)(8)(10)(12)(13)(28)(24)(25)(26)(23)(19)(20)(28)(

ME(H4DOTC)-20MECHANICALGeneral Description(1) Rocker cover (RH) (13) Cylinder head gasket (25) Gasket(2) Rocker cover gasket (RH) (14) Cylinder head (

ME(H4DOTC)-21MECHANICALGeneral Description3. CYLINDER HEAD AND VALVE ASSEMBLY(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter(2) Intake va

ME(H4DOTC)-22MECHANICALGeneral Description4. CYLINDER BLOCK(1) Oil pressure switch (16) Water by-pass pipe Tightening torque: N·m (kgf-m, ft-lb)(2) C

ME(H4DOTC)-23MECHANICALGeneral Description5. CRANKSHAFT AND PISTON(1) Flywheel (MT model) (10) Circlip (19) Crankshaft bearing #5(2) Ball bearing (MT

ME(H4DOTC)-24MECHANICALGeneral Description6. ENGINE MOUNTING(1) Heat shield cover (3) Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-

ME(H4DOTC)-25MECHANICALGeneral DescriptionC: CAUTION• Wear working clothing, including a cap, protec-tive goggles, and protective shoes during opera-t

ME(H4DOTC)-26MECHANICALGeneral DescriptionD: PREPARATION TOOL1. SPECIAL TOOLSILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS498267600 CYLINDER HEAD TABLE

ME(H4DOTC)-27MECHANICALGeneral Description398744300 PISTON GUIDE Used for installing piston in cylinder for 2.0 L engine.498857100 VALVE OIL SEAL GUID

ME(H4DOTC)-28MECHANICALGeneral Description499097600 PISTON PIN REMOVER ASSYUsed for removing piston pin. (Except for Australia model)499097700 PISTON

ME(H4DOTC)-2MECHANICALGeneral Description1. General DescriptionA: SPECIFICATIONS1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL)NOTE:STD: Stan

ME(H4DOTC)-29MECHANICALGeneral Description499977500 CAMSHAFT SPROCKET WRENCHUsed for removing and installing intake camshaft sprocket. (STi and Austra

ME(H4DOTC)-30MECHANICALGeneral Description18251AA020 VALVE GUIDE ADJUSTERUsed for installing intake and exhaust valve guides.499767200 VALVE GUIDE REM

ME(H4DOTC)-31MECHANICALGeneral Description499977400 CRANKSHAFT PULLEY WRENCHUsed for stopping rotation of crankshaft pulley when loosening and tighten

ME(H4DOTC)-32MECHANICALGeneral Description499587100 OIL SEAL INSTALLERUsed for installing oil pump oil seal.499587600 OIL SEAL INSTALLERUsed for insta

ME(H4DOTC)-33MECHANICALGeneral Description2. GENERAL PURPOSE TOOLSE: PROCEDUREIt is possible to conduct the following service procedures with engine o

ME(H4DOTC)-34MECHANICALCompression2. CompressionA: INSPECTIONCAUTION:After warming-up, engine becomes very hot. Be careful not to burn yourself during

ME(H4DOTC)-35MECHANICALIdle Speed3. Idle SpeedA: INSPECTION1. USING SUBARU SELECT MONITOR 1) Before checking the idle speed, check the fol-lowing:(1)

ME(H4DOTC)-36MECHANICALIgnition Timing4. Ignition TimingA: INSPECTION1. USING SUBARU SELECT MONITOR1) Before checking the ignition timing speed, check

ME(H4DOTC)-37MECHANICALIntake Manifold Vacuum5. Intake Manifold VacuumA: INSPECTION1) Warm-up the engine.2) Disconnect the brake vacuum hose, and then

ME(H4DOTC)-38MECHANICALEngine Oil Pressure6. Engine Oil PressureA: INSPECTION1) Remove the oil pressure switch from engine cyl-inder block. <Ref. t

ME(H4DOTC)-3MECHANICALGeneral DescriptionValve seatRefacing angle 90°Contacting widthIntakeSTD 1.0 mm (0.039 in)Limit 1.7 mm (0.067 in)ExhaustSTD 1.5

ME(H4DOTC)-39MECHANICALFuel Pressure7. Fuel PressureA: INSPECTIONCAUTION:Before removing the fuel pressure gauge, re-lease the fuel pressure.NOTE:If o

ME(H4DOTC)-40MECHANICALValve Clearance8. Valve ClearanceA: INSPECTIONInspection and adjustment of the valve clearanceshould be performed while engine

ME(H4DOTC)-41MECHANICALValve Clearance(5) Move the washer tank upward.(6) Disconnect the ignition coil connector.(7) Remove the ignition coil.(8) Plac

ME(H4DOTC)-42MECHANICALValve Clearance(3) Set the arrow mark on camshaft sprocket toposition shown in the figure, and then measurethe #1 cylinder exha

ME(H4DOTC)-43MECHANICALValve Clearance6) Inspect all valves for clearance again at thisstage. If the valve clearance is not correct, repeatthe procedu

ME(H4DOTC)-44MECHANICALEngine Assembly9. Engine AssemblyA: REMOVAL1) Set the vehicle on a lift.2) Open the front hood fully, and then support withthe

ME(H4DOTC)-45MECHANICALEngine Assembly(5) Accelerator cable (MT model)(6) Clutch release spring (MT model)12) Disconnect the following hoses.(1) Brake

ME(H4DOTC)-46MECHANICALEngine Assembly(6) Place the power steering pump on right sidewheel apron.14) Lift-up the vehicle.15) Remove the ATF cooler pip

ME(H4DOTC)-47MECHANICALEngine Assembly(4) Remove the other bolts while rotating theengine using socket wrench.22) Remove the pitching stopper.23) Disc

ME(H4DOTC)-48MECHANICALEngine Assembly(3) Remove the bolts which hold the right upperside of transmission to engine.28) Remove the engine from vehicle

ME(H4DOTC)-4MECHANICALGeneral DescriptionPiston ringPiston ring gapTop ringSTD 0.20 — 0.25 mm (0.0079 — 0.0098 in)Limit 1.0 mm (0.039 in)Second ringST

ME(H4DOTC)-49MECHANICALEngine AssemblyCAUTION:Make sure the cutout portion of release fork shaft contacts spring pin.(6) Tighten the plug.Tightening t

ME(H4DOTC)-50MECHANICALEngine Assembly(2) Tighten other bolts while rotating the engineby using ST.CAUTION:Be careful not to drop bolts into the torqu

ME(H4DOTC)-51MECHANICALEngine AssemblyTightening torque:50 N·m (5.1 kgf-m, 36.9 ft-lb)15) Tighten the nuts which install the front cushionrubber onto

ME(H4DOTC)-52MECHANICALEngine Mounting10.Engine MountingA: REMOVAL1) Remove the engine assembly. <Ref. toME(H4DOTC)-44, REMOVAL, Engine Assembly.&g

ME(H4DOTC)-53MECHANICALPreparation for Overhaul11.Preparation for OverhaulA: PROCEDURE1) After removing the engine from body, secure it inthe ST shown

ME(H4DOTC)-54MECHANICALV-belt12.V-beltA: REMOVAL1. FRONT SIDE BELT1) Remove the V-belt cover.2) Loosen the lock bolt (A).3) Loosen the slider bolt (B)

ME(H4DOTC)-55MECHANICALV-belt3) Tighten the lock nut (A).Tightening torque:Lock nut (A): 22.6 N·m (2.3 kgf-m, 16.6 ft-lb)C: INSPECTION1) Replace the b

ME(H4DOTC)-5MECHANICALGeneral DescriptionCrankshaftBend limit 0.035 mm (0.0014 in)Crank pin and crank jour-nalOut-of-roundness 0.005 mm (0.0002 in) or

ME(H4DOTC)-6MECHANICALGeneral Description2. STi MODELNOTE:STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: UndersizeCrankshaft

ME(H4DOTC)-7MECHANICALGeneral DescriptionBelt tension adjusterProtrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)Belt tensionerSpacer O.D. 17.9

ME(H4DOTC)-8MECHANICALGeneral DescriptionCylinder blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)Surface grinding limit 0.1