DISPOSAL Subaru Impreza WRX GD/GG рестайлинг 2

DISPOSAL

If the valve is damaged, remove the valve and neutralize it by immersing it in water, and dispose of it in the same way that general steel materials are disposed of. The disposal method is described in the following.

Scheme 640

1. Wearing rubber gloves, remove the damaged valve from the cylinder head.
2. Prepare a large receptacle (bucket or other container) in a well ventilated location, and fill the receptacle with water (at least 10 l (21.14 US qt, 17.6 Imp qt)).
3. Immerse the damaged valve in the receptacle. CAUTION: A severe reaction may occur, so stand at least 2 - 3 m from the receptacle. Because the reaction will produce hydrogen gas, moreover, keep the receptacle away from sparks or flames.
4. Once the reaction is completed (about 4 - 5 hours have elapsed), carefully remove the valve using large pincers so that the reaction liquid does not contact your skin, and dispose of it with other parts that are being disposed of.
5. The reaction liquid is a strong alkaline solution, so it must be disposed of in accordance with local regulations. CAUTION: Make sure the reaction liquid does not contact your skin. If contact with skin occurs, immediately wash the affected area with large quantities of water. (Scheme 624): Immersion Of Damaged Valve In The Receptacle

Note. Before conducting this procedure, drain the engine oil completely if applicable.

Scheme 641

Scheme 642

Scheme 643

Scheme 644

Scheme 645

Scheme 646

Scheme 647

Scheme 648

1. Remove the intake manifold. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/fuel-system/#fuel-injection-fuel-systems-sti), Intake Manifold. >
2. Remove the V-belt. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), V-belt. >
3. Remove the crank pulley. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Crank Pulley. >
4. Remove the timing belt cover. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Timing Belt Cover. >
5. Remove the timing belt. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Timing Belt. >
6. Remove the cam sprocket. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Cam Sprocket. >
7. Remove the crank sprocket. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Crank Sprocket. >
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Cylinder Head. >
10. Remove the clutch disc and cover. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/clutches-manual-hydraulic/#clutch-system__removal), Clutch Disc and Cover. >
11. Remove the flywheel. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/clutches-manual-hydraulic/#clutch-system), Flywheel. > ST 498497100 CRANKSHAFT STOPPER (Scheme 625): Removing Flywheel Using Crankshaft Stopper ST 498497100
12. Remove the oil separator cover.
13. Remove the water by-pass pipe for heater.
14. Remove the oil filter using ST. ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) NOTE: Standard oil filter is outer diameter of 65 mm (2.56 in). However, SUBARU genuine oil filter having outer diameter of 68 mm (2.68 in) can also be used.
15. Remove the oil cooler. (Scheme 626): Identifying Gasket, Oil Cooler And Connector
16. Remove the water pump.
17. Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing the oil pump. NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump. see scheme 157: Removing Oil Pump From Cylinder Block
18. Removal of oil pan: Turn the cylinder block with #2 and #4 piston sides facing upward. Remove the bolts which secure oil pan to cylinder block. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance, and then remove the oil pan. Do not use a screwdriver or similar tool in place of oil pan cutter.
19. Remove the oil strainer stay.
20. Remove the oil strainer.
21. Remove the baffle plate.
22. Remove the water pipes. (Scheme 627): Identifying Piston Pin, Snap Ring, Gasket, Service Hole Plug And Cover
23. Remove the service hole cover and service hole plugs using hexagon wrench (14 mm). (Scheme 628): Removing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench
24. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston snap ring through service hole of #1 and #2 cylinders. (Scheme 629): Removing Piston Snap Ring
25. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER ASSY NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder. see scheme 161: Identifying Piston Pin Remover Assembly ST 499097700
26. Similarly remove the piston pins from #3 and #4 pistons.
27. Remove the bolts which connect the cylinder block on the side of #2 and #4 cylinders.
28. Back off the bolts which connect the cylinder block on the side of #1 and #3 cylinders two or three turns.
29. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
30. Separate the cylinder blocks (LH) and (RH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block. (Scheme 630): Exploded View Of Cylinder Block
31. Remove the rear oil seal.
32. Remove the crankshaft together with connecting rod.
33. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
34. Draw out each piston from cylinder block using a wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

1. Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
2. Position the crankshaft on #2 and #4 cylinder block.
3. Apply liquid gasket to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent (Scheme 632): Applying Liquid Gasket To Mating Surface Of Cylinder Block
4. Apply engine oil to washers and thread of bolts.
5. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side) Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) (Scheme 633): Identifying Cylinder Block Connecting Bolts Tightening Sequence (LH Side)
6. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side) Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) (Scheme 634): Identifying Cylinder Block Connecting Bolts Tightening Sequence (RH Side)
7. Further tighten the LH side bolts (A) - (D) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) (Scheme 635): Identifying Cylinder Block Connecting Bolts Tightening Sequence (LH Side)
8. Further tighten the RH side bolts (E) - (J) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) (Scheme 636): Identifying Cylinder Block Connecting Bolts Tightening Sequence (RH Side)
9. Further tighten the LH side bolts (A) - (D) in alphabetical sequence, by 90° for (A) and (C), and to 40 N.m (4.1 kgf-m, 29.5 ft-lb) for (B) and (D). (Scheme 637): Identifying Cylinder Block Connecting Bolts Tightening Sequence (LH Side)
10. Further tighten the RH side bolts (E) - (J) by 90° in alphabetical sequence. (Scheme 638): Identifying Cylinder Block Connecting Bolts Tightening Sequence (RH Side)
11. Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 639): Identifying Cylinder Block Connecting Bolts Tightening Sequence
12. Install the rear oil seal using ST1 and ST2. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER (Scheme 640): Installing Rear Oil Seal Using Special Tools ST1 499597100, ST2 499587200
13. Position the top ring gap at (A) or (B) in the figure.
14. Position the second ring gap at 180° on the reverse side for the top ring gap. (Scheme 641): Identifying Second Ring Gap
15. Position the upper rail gap at (C) in the figure. (Scheme 642): Identifying Upper Rail Gap
16. Align upper rail spin stopper (D) with piston side surface hole (E). (Scheme 643): Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
17. Position the expander gap at (F) in the figure. (Scheme 644): Identifying Expander Ring Gap
18. Position the lower rail gap at (G) in the figure. (Scheme 645): Identifying Lower Rail Gap CAUTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.
19. Install the snap ring. Install the snap rings in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new snap rings. (Scheme 646): Installing Snap Rings In Piston Holes (Scheme 647): Identifying Cylinder Block Components With Torque Specification
20. Piston installation: Turn the cylinder block so that #1 and #2 cylinders face upward. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE (Scheme 648): Installing Piston Using Special Tools ST1 499987500, ST2 498747300 NOTE: Piston front mark faces towards the front of the engine. see scheme 181: Identifying Piston Front Mark
21. Piston pin installation: Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE (Scheme 649): Installing Piston Pin Using Special Tools ST1 499987500, ST3 499017100 Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole. Using the ST, install the snap ring. NOTE: Use new snap rings. (Scheme 650): Installing Snap Ring Apply liquid gasket around the service hole plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent (Scheme 651): Applying Liquid Gasket On Service Hole Plug Install the service hole plug and gasket. NOTE: Use a new gasket. see scheme 185: Installing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench see scheme 186: Identifying Cylinder Block Components With Torque Specification Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
22. Install the water pipe.
23. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
24. Install the oil strainer and O-ring Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
25. Install the oil strainer stay.
26. Apply liquid gasket to the matching surfaces, and then install the oil pan. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 187: Applying Liquid Gasket To Oil Pan Matching Surfaces
27. Apply liquid gasket to the mating surfaces and threaded portion of bolt (A) as shown in the figure, and then install the oil separator cover. Liquid gasket: Mating surface THREE BOND 1207C (Part No. 004403012) or equivalent Threaded portion of bolt (A) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) see scheme 188: Applying Liquid Gasket To Oil Separator Cover Mating Surfaces
28. Install the flywheel. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/clutches-manual-hydraulic/#clutch-system), Flywheel. >
29. Install the clutch disc and cover. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/clutches-manual-hydraulic/#clutch-system__installation), Clutch Disc and Cover. >
30. Installation of oil pump: Discard the front oil seal after removal. Replace with a new one using the ST. ST 499587100 OIL SEAL INSTALLER (Scheme 652): Installing Front Oil Seal Using Oil Seal Installer ST 499587100 Apply liquid gasket to the matching surface of oil pump. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent (Scheme 653): Applying Liquid Gasket To Matching Surface Of Oil Pump Apply a coat of engine oil to the inside of the oil seal. (Scheme 654): Applying Coat Of Engine Oil To Inside Of Oil Seal Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation. Position the oil pump, aligning the notched area with crankshaft, and push the oil pump straight. CAUTION: Make sure the oil seal lip is not folded. Install the oil pump. Apply liquid gasket to the threaded portion of three bolts. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 655): Applying Liquid Gasket To Oil Pump Bolts CAUTION: Use new O-ring and seal. Do not forget to install the O-ring and seal when installing the oil pump.
31. Install the water pump and gasket. Tightening torque: First; 12 N.m (1.2 kgf-m, 8.7 ft-lb) Second; 12 N.m (1.2 kgf-m, 8.7 ft-lb) CAUTION: Be sure to use a new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure. (Scheme 656): Identifying Water Pump Bolts Tightening Sequence
32. Install the water by-pass pipe for heater.
33. Install the oil cooler. CAUTION: Always use a new O-ring. Tightening torque: T1: 54 N.m (5.5 kgf-m, 40 ft-lb) T2: 69 N.m (7.0 kgf-m, 50.9 ft-lb) T3: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 657): Identifying Oil Cooler Components With Torque Specification
34. Install the oil filter using ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) NOTE: Standard oil filter is outer diameter of 68 mm (2.68 in). However, SUBARU genuine oil filter having outer diameter of 65 mm (2.56 in) can also be used. Install the oil filter by turning it by hand, being careful not to damage the seal rubber. Tighten the oil filter 68 mm (2.68 in) in diameter by approx. 1 rotation more after the seal rubber of oil filter comes in contact with oil cooler. If using a torque wrench, tighten it to 14 N.m (1.4 kgf-m, 10.3 ft-lb). Tighten the oil filter 65 mm (2.56 in) in diameter by approx. 2/3 - 3/4 rotation more after the seal rubber of oil filter comes in contact with oil cooler. If using a torque wrench, tighten it to 12 N.m (1.2 kgf-m, 8.7 ft-lb). CAUTION: Do not tighten excessively, or oil may leak.
35. Install the water by-pass pipe between oil cooler and water pump.
36. Install the water pipe. NOTE: Always use a new O-ring.
37. Install the cylinder head. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Cylinder Head. >
38. Install the oil level gauge guide and tighten the attaching bolt (LH side).
39. Install the rocker cover. NOTE: Be sure to use a new gasket of rocker cover.
40. Install the crank sprocket. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Crank Sprocket. >
41. Install the cam sprocket. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Cam Sprocket. >
42. Install the timing belt. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Timing Belt. >
43. Install the timing belt cover. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Timing Belt Cover. >
44. Install the crank pulley. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), Crank Pulley. >
45. Install the generator and A/C compressor brackets on cylinder head.
46. Install the V-belt. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-sti), V-belt. >
47. Install the intake manifold. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/fuel-system/#fuel-injection-fuel-systems-sti), Intake Manifold. >

Scheme 675

1. Remove the connecting rod cap.
2. Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order to prevent confusion.
3. Remove the piston rings using the piston ring expander.
4. Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order to prevent confusion.
5. Remove the snap ring.

Scheme 676

1. Apply oil to the surfaces of the connecting rod bearings. Install the connecting rod bearings on connecting rods and connecting rod caps.
2. Install the connecting rod on crankshaft. NOTE: Position each connecting rod with the side marked facing forward.
3. Install the connecting rod cap. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads.
4. Install the oil ring spacer, upper rail and lower rail in this order by hand. Then install the second ring and top ring with a piston ring expander.