Engine Mechanical - 2.0L Dohc/tc: Removal & Installation Subaru Impreza GD/GC/GG рестайлинг

REMOVAL

1. Remove the engine assembly, see «REMOVAL»(ref-179854-S38031340382005071500000) , Engine Assembly.
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

1. Engine mounting: 34 N.m (3.5 kgf-m, 25.3 ft-lb)

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

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Scheme 650

1. Remove the intake manifold, see «REMOVAL»(ref-178630-S02153573902005061700000) , Intake Manifold.
2. Remove the V-belt, see «REMOVAL»(ref-179854-S23601933212005071500000) , V-Belt.
3. Remove the crankshaft pulley, see «REMOVAL»(ref-179854-S28920813252005071500000) , Crankshaft Pulley.
4. Remove the belt cover, see «REMOVAL»(ref-179854-S32597685712005071500000) , Belt Cover.
5. Remove the timing belt assembly, see «REMOVAL»(ref-179854-S33820595882005071500000) , Timing Belt Assembly.
6. Remove the camshaft sprocket, see «REMOVAL»(ref-179854-S25751931102005071500000) , Camshaft Sprocket.
7. Remove the crankshaft sprocket, see «REMOVAL»(ref-179854-S19211323802005071500000) , Crankshaft Sprocket.
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head assembly, see «REMOVAL»(ref-179854-S25115318432005071500000) , Cylinder Head Assembly.
10. Remove the clutch disc and cover (MT vehicles). See «REMOVAL»(ref-175715-S08788529072005042600000) , Clutch Disc and Cover.
11. Remove the flywheel (MT vehicles). See «REMOVAL»(ref-175715-S08260766212005042600000) , Flywheel.
12. Remove the drive plate (AT vehicles). Using the ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER
13. Remove the oil separator cover.
14. Remove the water by-pass pipe for heater.
15. Remove the oil filter.
16. Remove the oil cooler.
17. Removal of oil pan: Turn the cylinder block with No. 2 and No. 4 piston sides facing 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. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
18. Remove the oil strainer stay.
19. Remove the oil strainer.
20. Remove the baffle plate.
21. Remove the water pipes.
22. Remove the water pump.
23. Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing the oil pump. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
24. Remove the service hole cover and service hole plugs using the hexagon wrench [14 mm (0.55 in)].
25. Rotate the crankshaft to bring No. 1 and No. 2 pistons to bottom dead center position, then remove the piston circlip through service hole of No. 1 and No. 2 cylinders.
26. Draw out the piston pin from No. 1 and No. 2 pistons using ST. ST 499097600 PISTON PIN REMOVER CAUTION: Be careful not to confuse the original combination of piston, piston pin and cylinder.
27. Similarly remove the piston pins from No. 3 and No. 4 pistons.
28. Remove the bolts which connect cylinder block on the side of No. 2 and No. 4 cylinders.
29. Back off the bolts which connect cylinder block on the side of No. 1 and No. 3 cylinders two or three turns.
30. Set up the cylinder block so that No. 1 and No. 3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
31. Separate the left-hand and right-hand cylinder blocks. CAUTION: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
32. Remove the rear oil seal.
33. Remove the crankshaft together with connecting rod.
34. Remove the crankshaft bearings from cylinder block using a hammer handle. CAUTION: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
35. Draw out each piston from cylinder block using a wooden bar or hammer handle. CAUTION: Do not confuse the combination of piston and cylinder.

Scheme 651

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Scheme 681

1. Position the crankshaft on the No. 2 and No. 4 cylinder block.
2. Apply fluid packing to the mating surface of No. 1 and No. 3 cylinder block, and position it on No. 2 and No. 4 cylinder block. Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
3. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure (LH side). Tightening torque: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
4. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure (RH side). Tightening torque: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
5. Tighten LH side bolts (A)-(D) for a further 90° in alphabetical order.
6. Tighten RH side bolts (E)-(J) for a further 90° in alphabetical order.
7. 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, 18.1 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
8. Install the rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
9. Position the top ring gap at (A) or (B) in the figure.
10. Position the second ring gap at 180° apart from the top ring gap.
11. Position the expander gap at (C) in the figure.
12. Position the lower rail gap at (D) in the figure.
13. Align the lower rail rotation stopper (F) with the hole (E) in the side of piston.
14. Position the upper rail gap at (G) in the figure. NOTE: Ensure the ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.
15. Installing the circlip: Install the circlips in piston holes located opposite of the service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new circlips. CAUTION: Piston front mark faces towards the front of the engine.
16. Installing the piston: Turn the cylinder block so that No. 1 and No. 2 cylinders face upward. Using ST1, turn the crankshaft so that No. 1 and No. 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 398744300 PISTON GUIDE
17. Installing piston pin: Insert ST3 into service hole to align piston pin hole with connecting rod small end. CAUTION: Apply a coat of engine oil to ST3 before insertion. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole. Install the circlip using ST. ST 499897200 PISTON SNAP RING PLIERS CAUTION: Use new circlips. Apply fluid packing around the service hole plug. Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent Install the service hole plug and gasket. CAUTION: Use a new gasket. Turn the cylinder block so that No. 3 and No. 4 cylinders face upward. Using the same procedures as used for No. 1 and No. 2 cylinders, install the pistons and piston pins.
18. Install the water pipe.
19. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
20. Install the oil strainer and O-ring Tightening torque: 10 N.m (1.0 kgf-m, 7 ft-lb)
21. Install the oil strainer stay.
22. Apply fluid packing to matching surfaces and install the oil pan. Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent
23. Apply fluid packing to matching surfaces and install the oil separator cover. Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent
24. Install the drive plate (AT vehicles) To lock the crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
25. Install the flywheel (MT vehicles), see «INSTALLATION»(ref-175715-S15767170702005042600000) , Flywheel.
26. Install the clutch disc and cover (MT vehicles), see «INSTALLATION»(ref-175715-S28478136882005042600000) , Clutch Disc and Cover.
27. Installation of oil pump: Discard the front oil seal after removal. Replace with a new one using ST. ST 499587100 OIL SEAL INSTALLER Apply fluid packing to the matching surface of oil pump. Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent Apply a coat of engine oil to the inside of the oil seal. Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 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.
28. 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.
29. Install the water by-pass pipe for heater.
30. Install the oil cooler. Tightening torque: T1: 55 N.m (5.5 kgf-m, 40 ft-lb) T2: 70 N.m (7.0 kgf-m, 50.6 ft-lb) T3: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
31. Install the oil filter using ST. ST 498547000 OIL FILTER WRENCH
32. Install the water by-pass pipe between oil cooler and water pump.
33. Install the water pipe. NOTE: Always use a new O-ring.
34. Install the cylinder head assembly, see «INSTALLATION»(ref-179854-S25541956562005071500000) , Cylinder Head Assembly.
35. Install the oil level gauge guide and tighten the attaching bolt (left side only).
36. Install the rocker cover.
37. Install the crankshaft sprocket, see «INSTALLATION»(ref-179854-S16635414262005071500000) , Crankshaft Sprocket.
38. Install the camshaft sprockets, see «INSTALLATION»(ref-179854-S11577067612005071500000) , Camshaft Sprocket.
39. Install the timing belt assembly, see «INSTALLATION»(ref-179854-S39203199362005071500000) , Timing Belt Assembly.
40. Install the belt cover, see «INSTALLATION»(ref-179854-S41674705122005071500000) , Belt Cover.
41. Install the crankshaft pulley, see «INSTALLATION»(ref-179854-S19082087232005071500000) , Crankshaft Pulley.
42. Install the generator and A/C compressor brackets on cylinder head.
43. Install the V-belt, see «INSTALLATION»(ref-179854-S40545159892005071500000) , V-belt.
44. Install the intake manifold, see «INSTALLATION»(ref-178630-S18479996802005061700000) , Intake Manifold.

Scheme 682

1. Remove the connecting rod cap.
2. Remove the connecting rod bearing. CAUTION: 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. CAUTION: Arrange the removed piston rings in proper order to prevent confusion.
5. Remove the circlip.

Scheme 683

1. Install the connecting rod bearings on connecting rods and connecting rod caps. CAUTION: Apply oil to the surfaces of the connecting rod bearings.
2. Install the connecting rod on crankshaft. CAUTION: Position each connecting rod with the side marked facing forward.
3. Install the connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: Each the 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.