Engine Mechanical (H4SO): Removal & Installation Subaru Impreza GD/GC/GG рестайлинг 2

REMOVAL

1. Remove the engine assembly. < Ref. to «REMOVAL»(ref-273755-S13057663922007121100000) , 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 115

Scheme 116

1. Remove the V-belt covers. see scheme 53: Identifying V-Belt Covers
2. Loosen the lock bolt (A).
3. Loosen the slider bolt (B).
4. Remove the front side belt (C). see scheme 54: Locating Lock Bolt And Slider Bolt

Scheme 117

Scheme 118

1. Loosen the lock nut (A).
2. Loosen the slider bolt (B). see scheme 55: Identifying Rear Side Belt Slider Bolt And Lock Nut
3. Remove the rear side belt.
4. Remove the belt tensioner. see scheme 56: Identifying Belt Tensioner

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

1. Install the crank pulley.
2. Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH Clean the crankshaft 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 62: Removing Crank Pulley Bolt Using Crank Pulley Wrench (ST 499977100)
3. Confirm that the tightening angle of crank pulley bolt is 65° or more. If the tightening angle of crank pulley bolt is less than 65°, conduct the following procedures. Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 Clean the crankshaft 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 keeping them in an angle between 65° and 75°. 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 belt tensioner. see scheme 63: Identifying Belt Tensioner
5. Install the V-belts. < Ref. to «INSTALLATION»(ref-273755-S16958100522007121100000), V-belt. >

1. Install the cam sprocket No. 1. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH Tightening torque: 78 N.m (8.0 kgf-m, 57.9 ft-lb) NOTE: Do not confuse left and right side cam sprockets during installation. Identify by indication of L or R. see scheme 90: Installing Cam Sprocket No. 1 Using Cam Sprocket Wrench ST (499207400)
2. Install the cam sprocket No. 2. To lock the camshaft, use ST. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. Tightening torque: 78 N.m (8.0 kgf-m, 57.9 ft-lb) see scheme 91: Installing Cam Sprocket No. 2 Using Cam Sprocket Wrench ST (18231AA010)
3. Install the camshaft position sensor. < Ref. to «INSTALLATION»(ref-273750-S42540989292007121100000), Camshaft Position Sensor. >
4. Install the timing belt. < Ref. to «INSTALLATION»(ref-273755-S29109239632007121100000), Timing Belt. >
5. Install the timing belt cover. < Ref. to «INSTALLATION»(ref-273755-S17196946692007121100000), Timing Belt Cover. >
6. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273755-S32428409802007121100000), Crank Pulley. >
7. Install the V-belts. < Ref. to «INSTALLATION»(ref-273755-S16958100522007121100000), V-belt. >

1. Install the crank sprocket. see scheme 93: Identifying Crank Sprocket
2. Install the timing belt. < Ref. to «INSTALLATION»(ref-273755-S29109239632007121100000), Timing Belt. >
3. Install the timing belt cover. < Ref. to «INSTALLATION»(ref-273755-S17196946692007121100000), Timing Belt Cover. >
4. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273755-S32428409802007121100000), Crank Pulley. >
5. Install the V-belts. < Ref. to «INSTALLATION»(ref-273755-S16958100522007121100000), V-belt. >

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

Scheme 119

Scheme 120

Scheme 121

Scheme 122

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Scheme 124

Scheme 125

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Scheme 128

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Scheme 130

Scheme 131

Scheme 132

1. Remove the intake manifold. < Ref. to «REMOVAL»(ref-273750-S07281051152007121100000), Intake Manifold. >
2. Remove the V-belts. < Ref. to «REMOVAL»(ref-273755-S11716697212007121100000), V-belt. >
3. Remove the crank pulley. < Ref. to «REMOVAL»(ref-273755-S25781489702007121100000), Crank Pulley. >
4. Remove the timing belt cover. < Ref. to «REMOVAL»(ref-273755-S32994864712007121100000), Timing Belt Cover. >
5. Remove the timing belt. < Ref. to «REMOVAL»(ref-273755-S36343847212007121100000), Timing Belt. >
6. Remove the cam sprocket. < Ref. to «REMOVAL»(ref-273755-S21919957302007121100000), Cam Sprocket. >
7. Remove the crank sprocket. < Ref. to «REMOVAL»(ref-273755-S25781489702007121100000), Crank Pulley. >
8. Remove the generator and A/C compressor with their brackets.
9. Remove the rocker cover.
10. Remove the cylinder head bolts in alphabetical sequence as shown in the figure. NOTE: Leave bolts (a) and (d) engaged by three or four threads to prevent the cylinder head from falling. see scheme 145: Identifying Cylinder Head Bolts In Alphabetical Sequence
11. While tapping the cylinder head with a plastic hammer, separate it from cylinder block.
12. Remove the bolts (a) and (d) to remove the cylinder head. see scheme 146: Identifying Cylinder Head Bolts In Alphabetical Sequence
13. Remove the cylinder head gasket. NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
14. Similarly, remove the right side cylinder head.
15. Remove the clutch housing cover. (MT model)
16. Remove the flywheel (MT model) or drive plate (AT model). Lock the crankshaft using ST. ST 498497100 CRANKSHAFT STOPPER MT model see scheme 147: Locking Crankshaft Using Crankshaft Stopper ST (498497100)- MT Model AT model see scheme 148: Locking Crankshaft Using Crankshaft Stopper ST (498497100)- AT Model
17. Remove the oil separator cover.
18. Remove the water bypass pipe for heater.
19. Remove the water pump after loosening the bolts in alphabetical sequence as shown in the figure. see scheme 149: Identifying Water Pump Bolts Loosening Sequence In Alphabetical Order
20. Remove the bolts which install the oil pump onto cylinder block. NOTE: If disassembling or inspecting the oil pump, loosen the plug of relief valve before removing the oil pump. see scheme 150: Identifying Oil Pump Relief Valve
21. 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: Removing Oil Pump From Cylinder Block Using Screwdriver
22. Remove the oil pan. Place the cylinder block to face the #2 and #4 piston side upward. Remove the bolts which secure oil pan to cylinder block. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. NOTE: Do not use a screwdriver or similar tools in place of oil pan cutter.
23. Remove the oil strainer stay.
24. Remove the oil strainer.
25. Remove the baffle plate.
26. Remove 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. see scheme 152: Removing Oil Filter
27. Remove the water pipe. see scheme 153: Identifying Water Pipe see scheme 154: Identifying Cylinder Block Components
28. Remove the service hole cover and service hole plugs using a hexagon wrench (14 mm). see scheme 155: Removing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench
29. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders. see scheme 156: Removing Piston Snap Ring
30. 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 157: Drawing Out Piston Pin From Pistons
31. Similarly remove the piston pins from #3 and #4 pistons.
32. Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
33. Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
34. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
35. Separate the cylinder block (RH) and (LH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block. see scheme 158: Identifying Cylinder Block Components
36. Remove the rear oil seal.
37. Remove the crankshaft together with connecting rod.
38. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip.
39. 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 133

Note. Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.

Scheme 134

Scheme 135

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Scheme 156

Scheme 157

1. Position the crankshaft on the #2 and #4 cylinder block.
2. 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 NOTE: Do not allow liquid gasket to flow into O-ring grooves, oil passages, bearing grooves, etc. see scheme 160: Applying Liquid Gasket To Mating Surface Of Cylinder Block
3. Apply engine oil to washers and thread of bolts.
4. Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) see scheme 161: Identifying Cylinder Block Connecting Bolt Alphabetical Sequence
5. Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) see scheme 162: Identifying Cylinder Block Connecting Bolts Tightening Sequence In Alphabetical Order
6. Further 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 163: Identifying Cylinder Block Connecting Bolt Alphabetical Sequence
7. Further 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 164: Identifying Cylinder Block Connecting Bolts Tightening Sequence In Alphabetical Order
8. Further tighten the LH side bolts (A), (C) to 90°, (B), (D) to 40 N.m (4.1 kgf-m, 29.5 ft-lb) in alphabetical sequence. see scheme 165: Identifying Cylinder Block Connecting Bolt Alphabetical Sequence
9. Further tighten the RH side bolts (E - J) to 90° in alphabetical sequence. see scheme 166: Identifying Cylinder Block Connecting Bolts Tightening Sequence In Alphabetical Order
10. Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence. 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 167: Identifying Cylinder Block Connecting Bolts Tightening Sequence In Alphabetical Order
11. Install the rear oil seal using ST1 and ST2. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER see scheme 168: Installing Rear Oil Seal Using ST1 And ST2 NOTE: Use a new rear oil seal.
12. Position the top ring gap at (A) or (B) in the figure. NOTE: Assemble the piston ring with stamped mark "R" facing toward upside of piston.
13. Position the second ring gap at 180° on the reverse side of the top ring gap. NOTE: Assemble the piston ring with stamped mark "R" facing toward upside of piston. (Scheme 119): Identifying Ring Gap Position
14. Position the upper rail gap at (C) in the figure. (Scheme 120): Positioning Upper Rail Gap At (C)
15. Align upper rail spin stopper (E) with piston side surface hole (D). (Scheme 121): Identifying Upper Rail Spin Stopper (E) And Piston Side Surface Hole (D)
16. Position the expander gap on the opposite side position (F) 180° away from upper rail gap position (C). (Scheme 122): Identifying Upper Rail Gap Position
17. Position the lower rail gap on the position (G) 120° away from upper rail gap position (C). (Scheme 123): 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.
18. Install the snap ring. Install snap rings in the piston holes located opposite to the service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new snap rings. (Scheme 124): Identifying Snap Ring In Piston Holes CAUTION: Piston front mark faces towards the front of engine. (Scheme 125): Identifying Piston Front Mark (Scheme 126): Identifying Cylinder Block Components With Torque Specification
19. Install the piston. Place the cylinder block to face the #1 and #2 cylinder side upward. Using 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 127): Inserting Pistons In Cylinders Using ST2
20. Install the 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 128): Inserting ST3 Into Service Hole To Align Piston Pin Hole With Connecting Rod Small End Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. Install the snap ring. NOTE: Use new snap rings. (Scheme 129): Installing Snap Ring Apply liquid gasket around the service hole plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent (Scheme 130): Applying Liquid Gasket Around Service Hole Plug Install the service hole plug and gasket. NOTE: Use a new gasket. (Scheme 131): Installing Service Hole Plug And Gasket (Scheme 132): Identifying Cylinder Block Components With Torque Specification Tightening torque: N.m (kgf-m, ft-lb) T1: 6.4 (0.65,4.7) T2: 70 (7.1, 50.6) Place the cylinder block to face the #3 and #4 cylinder sides upward. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
21. Install the water pipe. (Scheme 133): Identifying Water Pipe
22. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
23. Install the oil strainer and O-ring. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
24. Install the oil strainer stay.
25. Apply liquid gasket to mating surfaces and install the oil pan. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent (Scheme 134): Applying Liquid Gasket To Mating Surfaces Of Oil Pan
26. 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 Thread 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) (Scheme 135): Applying Liquid Gasket To Mating Surfaces And Threaded Portion Of Bolt (A)
27. Install the flywheel. (MT model) < Ref. to «INSTALLATION»(ref-273763-S20641156822007121100000), Flywheel. > To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb) (Scheme 136): Locking Crankshaft Using ST
28. Install the drive plate. To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb) see scheme 187: Locking Crankshaft Using ST
29. Install the housing cover.
30. Installation of oil pump: Discard the front oil seal after removal. Replace with a new one using ST. ST 499587100 OIL SEAL INSTALLER see scheme 188: Installing Oil Seal Using ST Apply liquid gasket to the matching surface of oil pump. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent see scheme 189: Applying Liquid Gasket To Matching Surface Of Oil Pump Apply a coat of engine oil to the inside of oil seal. see scheme 190: 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. CAUTION: Make sure the oil seal lip is not folded. Do not forget to install the O-ring and seal when installing 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: T: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 137): Applying Liquid Gasket To Threaded Portion Of Three Bolts
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 bolts in two stages in alphabetical sequence as shown in the figure. (Scheme 138): Identifying Tightening Sequence Of Water Pump Bolts In Alphabetical Order
32. Install the water bypass pipe for heater.
33. 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 cylinder block or 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 cylinder block or 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.
34. Tighten the cylinder head bolts. Apply a coat of engine oil to washers and bolt threads. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. Back off all bolts by 180° in reverse order of installation, and back them off again by 180°. Tighten all bolts to 42 N.m (4.3 kgf-m, 31 ft-lb) in alphabetical sequence. Tighten all bolts by 80 - 90° in alphabetical sequence. Tighten all bolts by 40 - 45° in alphabetical sequence. CAUTION: Tightening angle of the bolt must not exceed 45°. Further tighten the bolts (a) and (b) by 40 - 45°. CAUTION: Total "re-tightening angle" of the step (6) and (7) must not exceed 90°. (Scheme 139): Identifying Tightening Sequence Of Cylinder Head Bolts In Alphabetical Order
35. Install the oil level gauge guide and tighten the bolt. (LH side)
36. Install the rocker cover and rocker cover gasket. NOTE: Use new rocker cover gasket.
37. Install the crank sprocket. < Ref. to «INSTALLATION»(ref-273755-S16866396162007121100000), Crank Sprocket. >
38. Install the cam sprocket. < Ref. to «INSTALLATION»(ref-273755-S34082838472007121100000), Cam Sprocket. >
39. Install the timing belt. < Ref. to «INSTALLATION»(ref-273755-S29109239632007121100000), Timing Belt. >
40. Install the timing belt cover. < Ref. to «INSTALLATION»(ref-273755-S17196946692007121100000), Timing Belt Cover. >
41. Install the crank pulley. < Ref. to «INSTALLATION»(ref-273755-S32428409802007121100000), Crank Pulley. >
42. Install the generator and A/C compressor brackets on cylinder head.
43. Install the V-belts. < Ref. to «INSTALLATION»(ref-273755-S16958100522007121100000), V-belt. >
44. Install the intake manifold. < Ref. to «INSTALLATION»(ref-273750-S41727741592007121100000), Intake Manifold. >

Scheme 158

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 159

1. Apply oil to the surfaces of the connecting rod bearings.
2. Install the connecting rod bearings on connecting rods and connecting rod caps.
3. Position each connecting rod with the marked side facing forward, and install it.
4. Install the connecting rod cap with connecting rod nut. Ensure the connecting rod side mark faces toward 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.
5. Install the expander, lower rail and upper rail in this order by hand. Install the second ring and top ring with a piston ring expander.