Engine Mechanical (H4DOTC): Other Subaru Impreza GD/GC/GG рестайлинг 2

CAUTION

1. Wear work clothing, including a cap, protective goggles and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn yourself, because each part in the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery.
9. All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings.
10. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
11. Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.
12. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
13. Bolts, nuts and washers should be replaced with new ones as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
15. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
16. 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.
17. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
18. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

GENERAL TOOL

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.

1. V-belt
2. Timing Belt
3. Camshaft
4. Cylinder Head

FRONT SIDE BELT

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

1. Install the V-belt (C), and tighten the slider bolt so as to obtain the specified belt tension. < Ref. to «INSPECTION»(ref-273767-S03556740342007121100000), V-belt. >
2. Tighten the lock bolt (A).
3. Tighten the slider bolt (B). Tightening torque: Lock bolt through bolt 25 N.m (2.5 kgf-m, 18.4 ft-lb) Slider bolt: 8 N.m (0.8 kgf-m, 5.9 ft-lb) see scheme 58: Identifying Front Side Belt

REAR SIDE BELT

1. Install the belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. < Ref. to «INSPECTION»(ref-273767-S03556740342007121100000), V-belt. >
2. Tighten the lock nut (A). Tightening torque: Lock nut (A) 23 N.m (2.3 kgf-m, 17.0 ft-lb) see scheme 59: Identifying Rear Side Belt

BELT TENSION PULLEY

1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty.
2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted.
3. Check the belt tension pulley for grease leakage.

BELT IDLER

1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted.
2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check the belt idler for grease leakage.

Scheme 439

Scheme 440

1. Remove the V-belt. < Ref. to «REMOVAL»(ref-273767-S32395522102007121100000), V-belt. >
2. Remove the crank pulley. < Ref. to «REMOVAL»(ref-273767-S38262441822007121100000), Crank Pulley. >
3. Remove the timing belt cover. < Ref. to «REMOVAL»(ref-273767-S22372028772007121100000), Timing Belt Cover. >
4. Remove the timing belt. < Ref. to «REMOVAL»(ref-273767-S26187931242007121100000), Timing Belt. >
5. Remove the cam sprockets. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH see scheme 103: Removing Cam Sprockets Using Cam Sprocket Wrench ST 499207400 ST 499977500 CAM SPROCKET WRENCH see scheme 104: Installing Cam Sprockets Using Cam Sprocket Wrench ST 499977500

VALVE SEAT

Inspect the intake and exhaust valve seats, and then correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.

Valve seat contact width W

Intake

Standard 0.6 - 1.4 mm (0.024 - 0.055 in) Limit 1.7 mm (0.067 in)

Exhaust

Standard 1.2 - 1.8 mm (0.047-0.071 in)

Limit 2.2 mm (0.087 in)

Scheme 441

Scheme 442

Scheme 443

Scheme 444

1. Check the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively. Clearance between the valve guide and valve stem: Standard Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in) Limit 0.15 mm (0.0059 in)
2. If the clearance between valve guide and stem exceeds the standard value, replace the valve guide or valve itself whichever shows greater amount of wear. See the following procedure for valve guide replacement. Valve guide inner diameter: 6,000 - 6.012 mm (0.2362 - 0.2367 in) Valve stem outer diameters: Intake 5.955 - 5.970 mm (0.2344 - 0.2350 in) Exhaust 5.945 - 5.960 mm (0.2341 - 0.2346 in) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1. Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER see scheme 140: Inserting ST2 Into Valve Guide Turn the cylinder head upside down and place ST as shown in the figure. ST 18251AA020 VALVE GUIDE ADJUSTER see scheme 141: Identifying Valve Guide Adjuster ST 18251AA020 On Cylinder Head Before installing a new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head. Put a new valve guide, coated with sufficient oil, in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 18251AA020 VALVE GUIDE ADJUSTER see scheme 142: Inserting ST1 Into Valve Guide Check the valve guide protrusion. Valve guide protrusion L: 15.8 - 16.2 mm (0.622 - 0.638 in) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into the valve guide, and return it also rotating clockwise. After reaming, clean the valve guide to remove chips. ST 499767400 VALVE GUIDE REAMER NOTE: Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer. Recheck the contact condition between valve and valve seat after replacing the valve guide.

Scheme 445

1. Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "H" is exceeds the standard value. H: Intake (A) Standard 1.0 - 1.4 mm (0.039 - 0.055 in) Limit 0.8 mm (0.031 in) Exhaust (B) Standard 1.3 -1.7 mm (0.051 - 0.067 in) Limit 0.8 mm (0.031 in) see scheme 143: Inspecting Intake And Exhaust Valve Flange And Stem
2. Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping. NOTE: Replace the valve oil seal with new one after lapping. Intake valve and exhaust valve can be identified by their overall length. Valve overall length: Intake (A) 104.4 mm (4.110 in) Exhaust (B) 104.65 mm (4.120 in)

VALVE SPRINGS

1. Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within specifications presented in the table.
2. To measure the squareness of valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.

VALVE SPRINGS LENGTH

Scheme 446

INTAKE AND EXHAUST VALVE OIL SEAL

In the following case, pinch and remove the oil seal from valve using pliers, and then replace it with a new one.

1. When the lip is damaged.
2. When the spring is out of the specified position.
3. When readjusting the surfaces of intake valve and valve sheet.
4. When replacing the intake valve guide.

1. Place the cylinder head on ST1.
2. Using ST2, press-fit the oil seal.

ST1 498267600 CYLINDER HEAD TABLE

ST2 498857100 VALVE OIL SEAL GUIDE

Color of rubber part

Intake [Gray] Exhaust [Green]

Scheme 447

Scheme 448

1. Visually check the valve lifter.
2. Measure the outer diameter of valve lifter. Outer diameter: 34.959 - 34.975 mm (1.3763 - 1.3770 in) see scheme 146: Measuring Outer Diameter Of Valve Lifter
3. Measure the inner diameter of valve lifter mating part on cylinder head.

Inner diameter

34.994 - 35.016 mm (1.3777 - 1.3786 in)

Scheme 449

Note. If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the standard, replace the cylinder head.

Standard

0.019 - 0.057 mm (0.0007 - 0.0022 in)

Limit

0.100 mm (0.0039 in)

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 450

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 liters).
3. Immerse the damaged valve in the receptacle. CAUTION: A severe reaction may occur, so stand at least 2 - 3m 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. see scheme 148: Disposing Of Valve

CYLINDER BLOCK

1. Visually check for cracks and damage. Especially, inspect the important parts by means of liquid penetrant tester.
2. Check the oil passages for clogging.
3. Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

Scheme 451

Scheme 452

Scheme 453

1. The cylinder bore size is stamped on cylinder block's front upper surface. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line in selecting a standard piston. Standard diameter: A: 99.505 - 99.515 mm (3.9175 - 3.9779 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in) see scheme 191: Identifying Cylinder Bore Size Is Stamped On Cylinder Block'S Front Upper Surface
2. How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Taper: Standard 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) Out-of-roundness: Standard 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in) see scheme 192: Measuring Inner Diameter Of Cylinder Bore
3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. How to measure the outer diameter of each piston: Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 38.2 mm (1.50 in) Piston outer diameter: Standard A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in) 0.25 mm (0.0098 in) oversize 99.745 - 99.765 mm (3.9270 - 3.9278 in) 0.50 mm (0.0197 in) oversize 99.995 - 100.015 mm (3.9368 - 3.9376 in) see scheme 193: Measuring Outer Diameter Of Piston
5. Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard -0.010 - 0.010 mm (-0.0004 - 0.0004 in) Limit 0.030 mm (0.0012 in)
6. Boring and honing If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the limit or if there is any damage on the cylinder wall, reboring it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. If the cylinder inner diameter exceeds the limit after boring and honing, replace the crank-case. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Cylinder enlarging (boring) limit (dia.): To 100.005 mm (3.937 In)

Scheme 454

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Scheme 456

1. Check the pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective.
2. Measure the piston-to-cylinder clearance at each cylinder. < Ref. to «CYLINDER AND PISTON»(ref-273767-S13115888112007121100000), INSPECTION, Cylinder Block. > If any of the clearances is not within specification, replace the piston or bore the cylinder to use an oversize piston.
3. Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in) Limit 0.020 mm (0.0008 in) see scheme 194: Measuring Inner Diameter Piston see scheme 195: Measuring Outer Diameter Piston Pin
4. Check the snap ring installation groove (A) on piston for burr. If necessary, remove the burr from groove so that the piston pin can lightly move. see scheme 196: Identifying Snap Ring Installation Position
5. Check the piston pin snap ring for distortion, cracks and wear.

Scheme 457

Scheme 458

Scheme 459

1. If the piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of the same size as the piston. CAUTION: Marks are shown on the end of top and second rings. When installing the rings to piston, face this mark upward. Oil ring consists of upper rail, expander and lower rail. When installing on piston, be careful of each rail's direction. see scheme 197: Identifying Upper Rail, Expander And Lower Rail Gap Position
2. Squarely place the piston ring and oil ring in cylinder, and then measure the piston ring closed gap with a thickness gauge. PISTON RING CLEARANCE Unit: mm (in) Standard Limit Piston ring closed gap Top ring 0.20 - 0.25 (0.0079 - 0.0098) 1.0 (0.039) Second ring 0.37 - 0.52 (0.015 - 0.020) 1.0 (0.039) Oil ring rail 0.20 - 0.50 (0.0079 - 0.0197) 1.5 (0.059) see scheme 198: Measuring Piston Ring Closed Gap
3. Measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. PISTON RING CLEARANCE Unit: mm (in) Standard Limit Clearance between piston ring and piston ring groove Top ring 0.040 - 0.080 (0.0016 - 0.0031) 0.15 (0.0059) Second ring 0.030 - 0.070 (0.0012 - 0.0028) 0.15 (0.0059) see scheme 199: Measuring Clearance Between Piston Ring And Piston Ring Groove

Scheme 460

Scheme 461

Scheme 462

Scheme 463

1. Replace the connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in) see scheme 200: Checking For Bend Or Twist
3. Install the connecting rod fitted with bearing to crankshaft, and then measure the side clearance (thrust clearance). Replace the connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in) Limit 0.4 mm (0.016 in) see scheme 201: Measuring Connecting Rod Side Clearance
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on individual connecting rod bearings by means of plastigage. If any oil clearance is not within the specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the «BEARING SPECIFICATION»(ref-273767-S28977223762007121100000) below.) Connecting rod oil clearance: Standard 0.017 - 0.045 mm (0.0007 - 0.0018 in) Limit 0.05 mm (0.0020 in) BEARING SPECIFICATIONS Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.490 - 1.502 (0.0587 - 0.0591) 51.984 - 52.000 (2.0466 - 2.0472) 0.03 (0.0012) undersize 1.504 - 1.512 (0.0592 - 0.0595) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) undersize 1.514-1.522 (0.0596 - 0.0599) 51.934 - 51.950 (2.0447 - 2.0453) 0.25 (0.0098) undersize 1.614 - 1.622 (0.0635 - 0.0639) 51.734 - 51.750 (2.0368 - 2.0374)
6. Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at connecting rod small end. Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 in) Limit 0.030 mm (0.0012 in) see scheme 202: Measuring Piston Pin Clearance At Connecting Rod Small End see scheme 203: Measuring Outer Diameter Piston Pin
7. Replacement procedure is as follows. Remove the bushing from connecting rod with ST and press. Press the bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER see scheme 204: Pressing Bushing With Connecting Rod Bushing Remover And Installer ST 499037100 Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. After the completion of reaming, clean the bushing to remove chips.

Scheme 464

Scheme 465

Scheme 466

1. Clean the crankshaft completely and check for cracks by means of liquid penetrant tester etc., and replace if defective.
2. Measure the crankshaft bend, and correct or replace if it exceeds the limit. NOTE: If a suitable V-block is not available, install the #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings and measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in) see scheme 205: Measuring Crankshaft Runout
3. Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and then replace or recondition the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 in) Cylindrically 0.004 mm (0.0002 in) Grinding limit To 51.750 mm (2.0374 in) dia. Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindrically 0.006 mm (0.0002 in) Grinding limit To 59.750 mm (2.3524 in) dia. see scheme 206: Inspecting Crank Journal And Crank Pin For Wear CRANK JOURNAL DIAMETER Unit: mm (in) Crank journal diameter Crank pin diameter #1, #3 #2, #4, #5 Standard Journal O.D. 59.992 - 60.008 (2.3619 - 2.3625) 59.992 - 60.008 (2.3619 - 2.3625) 51.984 - 52.000 (2.0466 - 2.0472) Bearing size (Thickness at center) 1.998 - 2.011 (0.0787 - 0.0792) 2.000 - 2.013 (0.0787 - 0.0793) 1.490 - 1.502 (0.0587 - 0.0591) 0.03(0.0012) undersize Journal O.D. 59.962 - 59.978 (2.3607 - 2.3613) 59.962 - 59.978 (2.3607 - 2.3613) 51.954 - 51.970 (2.0454 - 2.0461) Bearing size (Thickness at center) 2.017 - 2.020 (0.0794 - 0.0795) 2.019 - 2.022 (0.0795 - 0.0796) 1.504 - 1.512 (0.0592 - 0.0595) 0.05 (0.0020) undersize Journal O.D. 59.942 - 59.958 (2.3599 - 2.3605) 59.942 - 59.958 (2.3599 - 2.3605) 51.934 - 51.950 (2.0447 - 2.0453) Bearing size (Thickness at center) 2.027 - 2.030 (0.0798 - 0.0799) 2.029 - 2.032 (0.0799 - 0.0800) 1.514-1.522 (0.0596 - 0.0599) 0.25 (0.0098) undersize Journal O.D. 59.742 - 59.758 (2.3520 - 2.3527) 59.742 - 59.758 (2.3520 - 2.3527) 51.734 - 51.750 (2.0368 - 2.0374) Bearing size (Thickness at center) 2.127 - 2.130 (0.0837 - 0.0839) 2.129 - 2.132 (0.0838 - 0.0839) 1.614 - 1.622 (0.0635 - 0.0639) O.D.: Outer Diameter
4. Measure the side clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace the bearing. Crankshaft side clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in) Limit 0.25 mm (0.0098 in) see scheme 207: Measuring Side Clearance Of Crankshaft Center Bearing
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
6. Measure the oil clearance on each crankshaft bearing by means of plastigage. If the measurement is not within the specification, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 - 0.030 mm (0.0004 - 0.0012 in) Limit 0.040 mm (0.0016 in)