Engine Mechanical (H4DOTC): Removal & Installation Subaru Impreza GD/GC/GG рестайлинг 2

REMOVAL

1. Remove the engine assembly. < Ref. to «REMOVAL»(ref-273767-S32274489892007121100000) , Engine Assembly. >
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

Engine mounting

35 N.m (3.6 kgf-m, 25.8 ft-lb)

Note. Perform the following procedures with the engine installed to the body.

Scheme 379

1. Loosen the lock bolt (A).
2. Loosen the slider bolt (B).
3. Remove the front side belt (C). see scheme 55: Identifying Front Side Belt

Scheme 380

Scheme 381

1. Loosen the lock nut (A).
2. Loosen the slider bolt (B). see scheme 56: Identifying Rear Side Belt
3. Remove the A/C belt.
4. Remove the A/C belt tensioner. see scheme 57: Identifying A/C Belt Tensioner

1. Install the crank pulley.
2. Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH Clean the crank pulley thread using compressed air. Apply engine oil to the crank pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crank pulley bolts. Tightening torque: 180 N.m (18.4 kgf-m, 132.8 ft-lb) see scheme 63: Installing Crank Pulley Bolt Using Crank Pulley Wrench ST 499977100
3. Confirm that the tightening angle of crank pulley bolt is 65 degrees or more. If the tightening angle of crank pulley bolt is less than 65 degrees, conduct the following procedures. CAUTION: If the tightening angle of crank pulley bolt is less than 65 degrees, the bolt should be damaged. In this case, the bolt must be replaced. Replace the crank pulley bolts and clean them. Crank pulley bolt: 12369A A011 Clean the crankshaft thread using compressed air. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crank pulley bolts keeping them in an angle between 65 degrees and 75 degrees. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover.
4. Install the A/C belt tensioner. see scheme 64: Identifying A/C Belt Tensioner
5. Install the V-belt. < Ref. to «INSTALLATION»(ref-273767-S04622586272007121100000), V-belt. >

1. Install the front timing belt cover (C). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
2. Install the timing belt cover (RH) (B). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
3. Install the timing belt cover (LH) (A). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 66: Identifying Front Timing Belt Cover
4. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273767-S39771607392007121100000), Crank Pulley. >
5. Install the V-belt. < Ref. to «INSTALLATION»(ref-273767-S04622586272007121100000), V-belt. >

1. Install the cam sprocket. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.1 kgf-m, 22.1 ft-lb), then further tighten by 45°. NOTE: Do not confuse the cam sprockets (RH) and (LH) intake side during installation. see scheme 105: Installing Cam Sprocket Using Cam Sprocket Wrench ST 499207400 ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.1 kgf-m, 22.1 ft-lb), then further tighten by 45°. see scheme 106: Installing Cam Sprockets Using Cam Sprocket Wrench ST 499977500
2. Install the timing belt. < Ref. to «INSTALLATION»(ref-273767-S26827797762007121100000), Timing Belt. >
3. Install the timing belt cover. < Ref. to «INSTALLATION»(ref-273767-S39364115382007121100000), Timing Belt Cover. >
4. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273767-S39771607392007121100000), Crank Pulley. >
5. Install the V-belt. < Ref. to «INSTALLATION»(ref-273767-S04622586272007121100000), V-belt. >

1. Install the crank sprocket. see scheme 108: Identifying Crank Sprocket
2. Install the timing belt. < Ref. to «INSTALLATION»(ref-273767-S26827797762007121100000), Timing Belt. >
3. Install the timing belt cover. < Ref. to «INSTALLATION»(ref-273767-S39364115382007121100000), Timing Belt Cover. >
4. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273767-S39771607392007121100000), Crank Pulley. >
5. Install the V-belt. < Ref. to «INSTALLATION»(ref-273767-S04622586272007121100000), V-belt. >

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

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

1. Remove the intake manifold. < Ref. to «REMOVAL»(ref-273758-S24504010782007121100000), Intake Manifold. >
2. Remove the V-belt. < Ref. to «REMOVAL»(ref-273767-S32395522102007121100000), V-belt. >
3. Remove the crank pulley. < Ref. to «REMOVAL»(ref-273767-S38262441822007121100000), Crank Pulley. >
4. Remove the timing belt cover. < Ref. to «REMOVAL»(ref-273767-S22372028772007121100000), Timing Belt Cover. >
5. Remove the timing belt. < Ref. to «REMOVAL»(ref-273767-S26187931242007121100000), Timing Belt. >
6. Remove the cam sprockets. < Ref. to «REMOVAL»(ref-273767-S21811062252007121100000), Cam Sprocket. >
7. Remove the crank sprocket. < Ref. to «REMOVAL»(ref-273767-S31944208472007121100000), Crank Sprocket. >
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head. < Ref. to «REMOVAL»(ref-273767-S19163278692007121100000), Cylinder Head. >
10. Remove the clutch disc and cover. (MT model) < Ref. to «REMOVAL»(ref-273763-S16777675632007121100000), Clutch Disc and Cover. >
11. Remove the flywheel. (MT model) < Ref. to «REMOVAL»(ref-273763-S25791942572007121100000), Flywheel. > ST 498497100 CRANKSHAFT STOPPER see scheme 149: Identifying Crankshaft Stopper ST 498497100 On Flywheel
12. Remove the oil separator cover.
13. Remove the water bypass pipe for heater.
14. Remove the oil filter. ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in))
15. Remove the oil cooler. see scheme 150: Exploded View Of Oil Cooler Components
16. Remove the water pump.
17. Remove the oil pump from cylinder block. NOTE: If disassembling or inspecting the oil pump, loosen the plug of relief valve before removing the oil pump. Remove the oil pump from cylinder block. Use a flat tip screwdriver when removing the oil pump. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump. see scheme 151: Identifying 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. CAUTION: 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. see scheme 152: Identifying Service Hole Plug, Service Hole Cover, Piston Pin And O-Ring
23. Remove the service hole cover and service hole plugs using hexagon wrench [14 mm]. see scheme 153: Identifying Service Hole Plugs
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. see scheme 154: Identifying Piston Snap Ring
25. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder. see scheme 155: Removing Piston Pin Using Piston Pin Remover 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 and damage the cylinder block. see scheme 156: Exploded View Of Cylinder Block Components
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 hammer handle. NOTE: Do not confuse the combination of piston and cylinder.

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

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. Install the crankshaft bearing to cylinder block, apply a thin coat of engine oil to crankshaft bearing, and 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: Part No. 004403007 THREE BOND 1215 or equivalent NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. see scheme 158: Applying Liquid Gasket To 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) see scheme 159: Identifying Cylinder Block 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) see scheme 160: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
7. Tighten the LH side bolts (A - D) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) see scheme 161: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
8. Tighten the RH side bolts (E - J) in alphabetical sequence. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) see scheme 162: Identifying Cylinder Block 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). see scheme 163: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
10. Further tighten the RH side bolts (E - J) to 90° in alphabetical sequence. see scheme 164: Identifying Cylinder Block 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) see scheme 165: Identifying Cylinder Block 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 see scheme 166: Installing Rear Oil Seal Using ST1 And ST2 NOTE: Use a new rear oil seal.
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. see scheme 167: Identifying Top Ring Gap Position
15. Position the upper rail gap at (C) in the figure. (Scheme 382): Identifying Upper Rail Gap Position
16. Align upper rail spin stopper (E) with piston side surface hole (D). (Scheme 383): Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
17. Position the expander gap at (F) in the figure. (Scheme 384): Identifying Expander Ring Gap Position
18. Position the lower rail gap at (G) in the figure. (Scheme 385): Identifying Lower Rail Gap Position 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 386): Identifying Snap Rings Installation Position (Scheme 387): Applying Coat Of Engine Oil To Pistons And Cylinders With Torque Specifications Tightening torque: N.m (kgf-m, ft-lb) T: 70(7.1, 51.6)
20. Installing the piston 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 388): Inserting Pistons In Cylinders Using Piston Guide ST2 498747300 NOTE: Piston front mark faces towards the front of the engine. (Scheme 389): Identifying Piston Front Mark
21. Installing piston pin Apply a coat of engine oil to ST3. Insert ST3 into the service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE (Scheme 390): Inserting ST3 Into Service Hole To Aligning Piston Pin Hole With Connecting Rod Small End Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole. Install the snap ring. NOTE: Use new snap rings. (Scheme 391): Identifying Snap Ring Apply liquid gasket around the service hole plug. Liquid gasket: Part No. 004403010 THREE BOND 1105 or equivalent (Scheme 392): Identifying Piston Install the service hole plug and gasket. NOTE: Use a new gasket. (Scheme 393): Identifying Service Hole Plug see scheme 180: Applying Oil To Piston And Cylinder Block With Torque Specifications 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. NOTE: Install it within 20 min. after applying liquid gasket. Liquid gasket: Part No. 004403012 THREE BOND 1207C or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) (Scheme 394): Applying Liquid Gasket To Oil Pan
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 Part No. 004403012 THREE BOND 1207C or equivalent Threaded portion of bolt (A) Part No. 004403042 THREE BOND 1324 or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) see scheme 182: Applying Liquid Gasket To Oil Separator Cover
28. Install the flywheel. < Ref. to «INSTALLATION»(ref-273763-S20641156822007121100000), Flywheel. >
29. Install the clutch disc and cover. < Ref. to «INSTALLATION»(ref-273763-S18265469032007121100000), 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 see scheme 183: Tapping Oil Seal Using ST Oil Seal Installer 499587100 Apply liquid gasket to the matching surface of oil pump. Liquid gasket: Part No. 004403007 THREE BOND 1215 or equivalent (Scheme 395): Applying Liquid Gasket To Oil Pump Apply a coat of engine oil to the inside of the oil seal. (Scheme 396): Applying Engine Oil To Oil Seal Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation. Apply liquid gasket to the threaded portion of three bolts. CAUTION: Do not forget to install the O-ring and seal when installing the oil pump. Align the flat surface of oil pump's inner rotor with crankshaft before installation. 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 397): Identifying Water Pump And Gasket
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 398): Identifying Water Pump Bolts
32. Install the water bypass pipe for heater.
33. Install the oil cooler. CAUTION: Use a new O-ring. Tightening torque: T1:45 N.m (4.6 kgf-m, 33 ft-lb) T2: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) T3: 54 N.m (5.3 kgf-m, 40 ft-lb) T4: 69 N.m (7.0 kgf-m, 50.9 ft-lb) (Scheme 399): Identifying Oil Cooler Components
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))
35. 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, 8.8 ft-lb). CAUTION: Do not tighten excessively, or oil may leak. Be careful not to use the oil filter 80 mm (3.15 in) in diameter to Turbo model.
36. Install the water bypass pipe between oil cooler and water pump.
37. Install the water pipe. NOTE: Always use a new O-ring.
38. Install the cylinder head. < Ref. to «INSTALLATION»(ref-273767-S08960108332007121100000), Cylinder Head. >
39. Install the oil level gauge guide and tighten the attaching bolt (LH side).
40. Install the rocker cover and rocker cover gasket. NOTE: Use a new rocker cover gasket.
41. Install the crank sprocket. < Ref. to «INSTALLATION»(ref-273767-S21179979452007121100000), Crank Sprocket. >
42. Install the cam sprocket. < Ref. to «INSTALLATION»(ref-273767-S27833430412007121100000), Cam Sprocket. >
43. Install the timing belt. < Ref. to «INSTALLATION»(ref-273767-S26827797762007121100000), Timing Belt. >
44. Install the timing belt cover. < Ref. to «INSTALLATION»(ref-273767-S39364115382007121100000), Timing Belt Cover. >
45. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273767-S39771607392007121100000), Crank Pulley. >
46. Install the generator and A/C compressor brackets on cylinder head.
47. Install the V-belt. < Ref. to «INSTALLATION»(ref-273767-S04622586272007121100000), V-belt. >
48. Install the intake manifold. < Ref. to «REMOVAL»(ref-273758-S24504010782007121100000), Intake Manifold. >

Scheme 418

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 419

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. Tighten the connecting rod cap with connecting rod bolt. Ensure the arrow on connecting rod cap faces the front during installation. Tightening torque: 52 N.m (5.3 kgf-m, 38.4 ft-lb) 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 bolts, apply oil on the threads.
4. Install the oil ring upper rail, expander and lower rail in this order by hand. Then install the second ring and top ring using a piston ring expander.