Engine Mechanical - 2.0L Dohc/tc: Adjustments Subaru Impreza GD/GC/GG рестайлинг

ADJUSTMENT

Scheme 496

Scheme 497

1. Measure all valve clearances, see «INSPECTION»(ref-179854-S10136660412005071500000) , Valve Clearance. NOTE: Record each valve clearance after it has been measured.
2. Remove the camshaft, see «REMOVAL»(ref-179854-S05125307182005071500000) , Camshaft.
3. Remove the valve lifter.
4. Measure the thickness of valve lifter with a micrometer.
5. Based on the measured valve clearance and valve lifter thickness, obtain the correct amount of shims from the following table.
6. Set the correct amount of shims to the valve lifter. Selecting Valve Clearance Shims Unit: mm Intake valve: S =(V + T) - 0.20 Exhaust valve: S =(V + T) - 0.25 S: Thickness of valve lifter V: Measured valve clearance T: Thickness of shims AVAILABLE SHIMS Part No. Thickness mm (in) 13228 AB101 4.68 (0.1843) 13228 AB111 4.69 (0.1846) 13228 AB121 4.70 (0.1850) 13228 AB131 4.71 (0.1854) 13228 AB141 4.72 (0.1858) 13228 AB151 4.73 (0.1862) 13228 AB161 4.74 (0.1866) 13228 AB171 4.75 (0.1870) 13228 AB181 4.76 (0.1874) 13228 AB191 4.77 (0.1878) 13228 AB201 4.78 (0.1882) 13228 AB211 4.79 (0.1886) 13228 AB221 4.80 (0.1890) 13228 AB231 4.81 (0.1894) 13228 AB241 4.82 (0.1898) 13228 AB251 4.83 (0.1902) 13228 AB261 4.84 (0.1906) 13228 AB271 4.85 (0.1909) 13228 AB281 4.86 (0.1913) 13228 AB291 4.87 (0.1917) 13228 AB301 4.88 (0.1921) 13228 AB311 4.89 (0.1925) 13228 AB321 4.90 (0.1929) 13228 AB331 4.91 (0.1933) 13228 AB341 4.92 (0.1937) 13228 AB351 4.93 (0.1941) 13228 AB361 4.94 (0.1945) 13228 AB371 4.95 (0.1949) 13228 AB381 4.96 (0.1953) 13228 AB391 4.97 (0.1957) 13228 AB401 4.98 (0.1961) 13228 AB411 4.99 (0.1965) 13228 AB421 5.00 (0.1969) 13228 AB431 5.01 (0.1972) 13228 AB441 5.02 (0.1976) 13228 AB451 5.03 (0.1980) 13228 AB461 5.04 (0.1984) 13228 AB471 5.05 (0.1988) 13228 AB481 5.06 (0.1992) 13228 AB491 5.07 (0.1996) 13228 AB501 5.08 (0.2000) 13228 AB511 5.09 (0.2004) 13228 AB521 5.10 (0.2008) 13228 AB531 5.11 (0.2012) 13228 AB541 5.12 (0.2016) 13228 AB551 5.13 (0.2020) 13228 AB561 5.14 (0.2024) 13228 AB571 5.15 (0.2028) 13228 AB581 5.16 (0.2031) 13228 AB591 5.17 (0.2035) 13228 AB601 5.18 (0.2039) 13228 AB611 5.19 (0.2043) 13228 AB621 5.20 (0.2047) 13228 AB631 5.21 (0.2051) 13228 AB641 5.22 (0.2055) 13228 AB651 5.23 (0.2059) 13228 AB661 5.24 (0.2063) 13228 AB671 5.25 (0.2067) 13228 AB681 5.26 (0.2071) 13228 AB691 5.27 (0.2075) 13228 AB701 4.38 (0.1724) 13228 AB711 4.40 (0.1732) 13228 AB721 4.42 (0.1740) 13228 AB731 4.44 (0.1748) 13228 AB741 4.46 (0.1756) 13228 AB751 4.48 (0.1764) 13228 AB761 4.50 (0.1771) 13228 AB771 4.52 (0.1780) 13228 AB781 4.54 (0.1787) 13228 AB791 4.56 (0.1795) 13228 AB801 4.58 (0.1803) 13228 AB811 4.60 (0.1811) 13228 AB821 4.62 (0.1819) 13228 AB831 4.64 (0.1827) 13228 AB841 4.66 (0.1835) 13228 AB851 5.29 (0.2083) 13228 AB861 5.31 (0.2091) 13228 AB871 5.33 (0.2098) 13228 AB881 5.35 (0.2106) 13228 AB891 5.37 (0.2114) 13228 AB901 5.39 (0.2122) 13228 AB911 5.41 (0.2126) 13228 AB921 5.43 (0.2138) 13228 AB931 5.45 (0.2146) 13228 AB941 5.47 (0.2154) 13228 AB951 5.49 (0.2161) 13228 AB961 5.51 (0.2169) 13228 AB971 5.53 (0.2177) 13228 AB981 5.55 (0.2185) 13228 AB991 5.57 (0.2193) 13228 AC001 5.59 (0.2201) 13228 AC011 5.61 (0.2209) 13228 AC021 5.63 (0.2217) 13228 AC031 5.65 (0.2224)
7. Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step.
8. After inspection, install the related parts in the reverse order of removal.

Scheme 498

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

Scheme 525

1. Set the vehicle on lift arms.
2. Open the front hood fully and support with stay.
3. Raise the rear seat, and turn the floor mat up.
4. Release fuel pressure, see «RELEASING OF FUEL PRESSURE»(ref-180569-S10774078772005072700000) , Operation, Fuel. Disconnect the fuel pump relay connector. Start the engine, and run until stalls. After the engine stalls, crank it for five seconds more. Turn the ignition switch to "OFF".
5. Remove the filler cap.
6. Disconnect the ground cable from battery.
7. Remove the radiator from vehicle, see «REMOVAL»(ref-180110-S09738665852005072100000) , Radiator.
8. Remove the coolant filler tank, see «REMOVAL»(ref-180110-S23016645702005072100000) , Coolant Filler Tank.
9. Collect refrigerant, and remove the pressure hoses. Place and connect the attachment hose to the refrigerant recycle system. Collect the refrigerant from A/C system. Disconnect the A/C pressure hoses from A/C compressor.
10. Remove the intercooler, see «REMOVAL»(ref-178630-S40256432242005061700000) , Intercooler.
11. Disconnect the following connectors and cable. Engine harness connector Engine ground terminal Engine harness connector Generator connector, terminal and A/C compressor connectors Accelerator cable Clutch release spring
12. Disconnect the following hoses. Brake booster vacuum hose Heater inlet outlet hose
13. Remove the power steering pump from bracket. Loosen lock bolt and slider bolt, and remove the front side V-belt. See «FRONT SIDE BELT»(ref-179854-S40389376652005071500000) , Removal, V-belt. Disconnect the power steering switch connector. Remove the pipe with bracket from intake manifold. Remove the power steering pump from engine. Remove the power steering tank from the bracket by pulling it upward. Place the power steering pump on the right side wheel apron.
14. Lift-up the vehicle.
15. Remove the ATF cooler pipe from frame (AT vehicles)
16. Remove the center exhaust pipe, see «REMOVAL»(ref-178516-S22847674342005061600000) , Center Exhaust Pipe.
17. Remove the nuts which hold lower side of transmission to engine.
18. Remove the nuts which install the front cushion rubber onto front crossmember.
19. Lower the vehicle.
20. Separate the clutch release fork from release bearing (MT vehicles) Remove the clutch operating cylinder from transmission. Remove the plug using a 10 mm hexagon wrench. Screw the 6 mm diameter bolt into release fork shaft, and remove it. Raise the release fork and unfasten the release bearing tabs to free release fork. CAUTION: Step (4) is required to prevent interference with engine when removing the engine from transmission.
21. Separate the torque converter clutch from drive plate (AT vehicles) Lower the vehicle. Remove the service hole plug. Remove the bolts which hold torque converter clutch to drive plate. Remove the other bolts while rotating the engine using ST. ST 499977400 CRANK PULLEY WRENCH
22. Remove the pitching stopper.
23. Disconnect the fuel delivery hose, return hose and evaporation hose. CAUTION: Catch fuel from hose into container. Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.
24. Remove the fuel filter and bracket.
25. Support the engine with a lifting device and wire ropes.
26. Support the transmission with a floor jack. CAUTION: Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.
27. Separation of engine and transmission. Remove the starter, see «REMOVAL»(ref-167795-S32898263682004102100000) , Starter. Install the ST to torque converter clutch case (AT vehicles) ST 498277200 STOPPER SET Remove the bolts which hold right upper side of transmission to engine.
28. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with floor jack. Move the engine horizontally until the mainshaft is withdrawn from clutch cover. Slowly move the engine away from engine compartment. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
29. Remove the front cushion rubbers.

Scheme 526

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

1. Install the clutch release fork and bearing onto transmission (MT vehicles) Remove the release bearing from clutch cover with flat type screw driver. Install the release bearing on transmission. Install the release fork into release bearing tab. Apply grease to the specified points. Spline; FX2200 Shaft; SUNLIGHT 2 Insert the release fork shaft into release fork. CAUTION: Make sure the cutout portion of release fork shaft contacts spring pin. Tighten the plug. Tightening torque: 44 N.m (4.5 kgf-m, 32.5 ft-lb)
2. Install the front cushion rubbers to engine. Tightening torque: 34 N.m (3.5 kgf-m, 25.3 ft-lb)
3. Install the engine onto transmission. Position the engine in engine compartment and align it with transmission. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc. Apply a small amount of grease to splines of mainshaft (MT vehicles)
4. Tighten the bolts which hold right upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
5. Remove the lifting device and wire ropes.
6. Remove the floor jack.
7. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 37 ft-lb) T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
8. Remove the ST from torque converter clutch case (AT vehicles). NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST. ST 498277200 STOPPER SET
9. Install the starter, see «INSTALLATION»(ref-167795-S01805040782004102100000) , Starter.
10. Install the torque converter clutch onto drive plate (AT vehicles). Tighten the bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the engine by using ST. CAUTION: Be careful not to drop bolts into the torque converter clutch housing. ST 499977300 CRANK PULLEY WRENCH Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) Clog the service hole with plug.
11. Install the fuel filter and bracket.
12. Install the power steering pump on bracket. Install the power steering tank on bracket. Install the power steering pump. Tightening torque: 20.1 N.m (2.05 kgf-m, 14.8 ft-lb) Install the power steering pipe bracket on right side intake manifold, and install the spark plug codes. Connect the power steering switch connector. Install the front side V-belt, and adjust it. See «FRONT SIDE BELT»(ref-179854-S06072564312005071500000) , Installation, V-belt.
13. Lift-up the vehicle.
14. Tighten the nuts which hold lower side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
15. Tighten the nuts which install the front cushion rubber onto crossmember. Tightening torque: 83 N.m (8.5 kgf-m, 61 ft-lb) CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
16. Install the ATF cooler pipe to frame (AT vehicles).
17. Install the center exhaust pipe, see «INSTALLATION»(ref-178516-S11937377122005061600000) , Center Exhaust Pipe.
18. Lower the vehicle.
19. Connect the following hoses: Fuel delivery hose, return hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose
20. Connect the following connectors and terminals: Engine ground terminal Engine harness connectors Generator connector Generator terminal Tightening torque: 5.88 N.m (0.60 kgf-m, 4.34 ft-lb) A/C compressor connectors
21. Connect the following cables: Accelerator cable Clutch release spring CAUTION: After connecting each cable, adjust them.
22. Install the air intake system. Install the intercooler, see «INSTALLATION»(ref-178630-S18428907492005061700000) , Intercooler. Install the air cleaner element and air cleaner upper cover. Install the engine harness connector bracket. Install the filler hose to air cleaner case.
23. Install the A/C pressure hoses. CAUTION: Use new O-rings. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
24. Install the radiator, see «INSTALLATION»(ref-180110-S15042483712005072100000) , Radiator.
25. Install the coolant filler tank, see «INSTALLATION»(ref-180110-S04275405452005072100000) , Coolant Filler Tank.
26. Install the window washer tank.
27. Install the battery in the vehicle, and connect cables.
28. Fill coolant, see «FILLING OF ENGINE COOLANT»(ref-180110-S07004686282005072100000) , Replacement, Engine Coolant.
29. Charge the A/C system with refrigerant. See «REFRIGERANT CHARGING PROCEDURE»(ref-179689-S04664630082005071200000) , HVAC.
30. Remove the front hood stay, and close the front hood.
31. Take off the vehicle from lift arms.