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Engine Mechanical (H4DOTC) (Except Sti): Adjustments Subaru Impreza GH

Mechanical 32 illustrations ~1975 words

ADJUSTMENT

CAUTIONIf engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

Note. Adjustment of valve clearance should be performed while engine is cold.

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  1. Measure all the valve clearances. Ref. to «INSPECTION»(ref-357237-S33761826512010031100000) , Valve Clearance. NOTE: Record each valve clearance after measurement.
  2. Remove the camshaft. Ref. to «REMOVAL»(ref-357237-S39472170562010031100000) , Camshaft.
  3. Remove the valve lifter.
  4. Measure the thickness of valve lifter using micrometer.
  5. Select a valve lifter of suitable thickness from the following table using the measured valve clearance and valve lifter thickness, and install it. NOTE: Use a new valve lifter. VALVE LIFTER THICKNESS REFERENCE Unit: mm (in) Intake valve: S = (V + T) - 0.19 (0.0075) Exhaust valve: S = (V + T) - 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used VALVE LIFTER THICKNESS REFERENCE Part No. Thickness mm (in) 13228 AB102 4.68 (0.1843) 13228 AB112 4.69 (0.1846) 13228 AB122 4.70 (0.1850) 13228 AB132 4.71 (0.1854) 13228 AB142 4.72 (0.1858) 13228 AB152 4.73 (0.1862) 13228 AB162 4.74 (0.1866) 13228 AB172 4.75 (0.1870) 13228 AB182 4.76 (0.1874) 13228 AB192 4.77 (0.1878) 13228 AB202 4.78 (0.1882) 13228 AB212 4.79 (0.1886) 13228 AB222 4.80 (0.1890) 13228 AB232 4.81 (0.1894) 13228 AB242 4.82 (0.1898) 13228 AB252 4.83 (0.1902) 13228 AB262 4.84 (0.1906) 13228 AB272 4.85 (0.1909) 13228 AB282 4.86 (0.1913) 13228 AB292 4.87 (0.1917) 13228 AB302 4.88 (0.1921) 13228 AB312 4.89 (0.1925) 13228 AB322 4.90 (0.1929) 13228 AB332 4.91 (0.1933) 13228 AB342 4.92 (0.1937) 13228 AB352 4.93 (0.1941) 13228 AB362 4.94 (0.1945) 13228 AB372 4.95 (0.1949) 13228 AB382 4.96 (0.1953) 13228 AB392 4.97 (0.1957) 13228 AB402 4.98 (0.1961) 13228 AB412 4.99 (0.1965) 13228 AB422 5.00 (0.1969) 13228 AB432 5.01 (0.1972) 13228 AB442 5.02 (0.1976) 13228 AB452 5.03 (0.1980) 13228 AB462 5.04 (0.1984) 13228 AB472 5.05 (0.1988) 13228 AB482 5.06 (0.1992) 13228 AB492 5.07 (0.1996) 13228 AB502 5.08 (0.2000) 13228 AB512 5.09 (0.2004) 13228 AB522 5.10 (0.2008) 13228 AB532 5.11 (0.2012) 13228 AB542 5.12 (0.2016) 13228 AB552 5.13 (0.2020) 13228 AB562 5.14 (0.2024) 13228 AB572 5.15 (0.2028) 13228 AB582 5.16 (0.2031) 13228 AB592 5.17 (0.2035) 13228 AB602 5.18 (0.2039) 13228 AB612 5.19 (0.2043) 13228 AB622 5.20 (0.2047) 13228 AB632 5.21 (0.2051) 13228 AB642 5.22 (0.2055) 13228 AB652 5.23 (0.2059) 13228 AB662 5.24 (0.2063) 13228 AB672 5.25 (0.2067) 13228 AB682 5.26 (0.2071) 13228 AB692 5.27 (0.2075) 13228 AB702 4.38 (0.1724) 13228 AB712 4.40 (0.1732) 13228 AB722 4.42 (0.1740) 13228 AB732 4.44 (0.1748) 13228 AB742 4.46 (0.1756) 13228 AB752 4.48 (0.1764) 13228 AB762 4.50 (0.1771) 13228 AB772 4.52 (0.1780) 13228 AB782 4.54 (0.1787) 13228 AB792 4.56 (0.1795) 13228 AB802 4.58 (0.1803) 13228 AB812 4.60 (0.1811) 13228 AB822 4.62 (0.1819) 13228 AB832 4.64 (0.1827) 13228 AB842 4.66 (0.1835) 13228 AB852 5.29 (0.2083) 13228 AB862 5.31 (0.2091) 13228 AB872 5.33 (0.2098) 13228 AB882 5.35 (0.2106) 13228 AB892 5.37 (0.2114) 13228 AB902 5.39 (0.2122) 13228 AB912 5.41 (0.2123) 13228 AB922 5.43 (0.2138) 13228 AB932 5.45 (0.2146) 13228 AB942 5.47 (0.2154) 13228 AB952 5.49 (0.2161) 13228 AB962 5.51 (0.2169) 13228 AB972 5.53 (0.2177) 13228 AB982 5.55 (0.2185) 13228 AB992 5.57 (0.2193) 13228 AC002 5.59 (0.2201) 13228 AC012 5.61 (0.2209) 13228 AC022 5.63 (0.2217) 13228 AC032 5.65 (0.2224)
  6. Install the camshaft. Ref. to «INSTALLATION»(ref-357237-S35193641722010031100000) , Camshaft.
  7. Install the cam sprocket. Ref. to «INSTALLATION»(ref-357237-S32810246052010031100000) , Cam Sprocket.
  8. Install the timing belt. Ref. to «TIMING BELT»(ref-357237-S08053995022010031100000) , INSTALLATION, Timing Belt.
  9. Measure all valves for valve clearance again at this time. If the valve clearance is not within the adjustment value, repeat the procedure over again from the first step. Valve clearance (adjustment value): Intake 0.20 +001 -0.03 mm (0.0079 +00004 -0.0012 in) Exhaust 0.35±0.02 mm (0.0138±0.0008 in)
  10. After measurement, install the related parts in the reverse order of removal.

Note. Use a new rocker cover gasket. Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS

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Scheme 570: REMOVAL
Scheme 570: REMOVAL

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  1. Set the vehicle on a lift.
  2. Change the bolt installation position from (A) to (B), then open the front hood completely. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
  3. Remove the V-belt covers.
  4. Collect the refrigerant from A/C system. Ref. to «REFRIGERANT RECOVERY PROCEDURE»(ref-357257-S01739646982010031100000) .
  5. Release the fuel pressure. Ref. to «RELEASING OF FUEL PRESSURE»(ref-357241-S05249623012010031100000) , PROCEDURE, Fuel.
  6. Remove the battery. Ref. to «REMOVAL»(ref-357234-S21509179942010031100000) , Battery.
  7. Open the fuel filler lid and remove the fuel filler cap.
  8. Remove the air intake duct and air cleaner case. Ref. to «REMOVAL»(ref-357235-S10313590332010031100000) , Air Intake Duct. Ref. to «REMOVAL»(ref-357235-S04762520242010031100000) , Air Cleaner Case.
  9. Remove the intercooler. Ref. to «REMOVAL»(ref-357235-S29312200482010031100000) , Intercooler.
  10. Remove the radiator. Ref. to «REMOVAL»(ref-357239-S26125994232010031100000) , Radiator.
  11. Remove the coolant filler tank. Ref. to «REMOVAL»(ref-357239-S05624852022010031100000) , Coolant Filler Tank.
  12. Disconnect the A/C pressure hoses from A/C compressor. Ref. to «REMOVAL»(ref-357257-S33730063252010031100000) , Hose and Pipe.
  13. Disconnect the bulkhead harness connectors from the engine harness connectors.
  14. Remove the engine harness connector from the engine harness bracket.
  15. Disconnect the following connectors and terminals. Generator connector and terminal A/C compressor connector Secondary air pump connector
  16. Disconnect the following hoses. Brake booster vacuum hose Heater inlet and outlet hoses
  17. Remove the power steering pump. Remove the front side belts. Ref. to «FRONT SIDE BELT»(ref-357237-S02797211002010031100000) , REMOVAL, V-belt. Disconnect the power steering pump switch connector. Remove the power steering pump from the engine. Place the power steering pump on the right side wheel apron.
  18. Remove the center exhaust pipe. Ref. to «REMOVAL»(ref-357260-S26748740802010031100000) , Center Exhaust Pipe.
  19. Remove the turbocharger. Ref. to «REMOVAL»(ref-357235-S36049160272010031100000) , Turbocharger.
  20. Remove the joint pipe and front exhaust pipe. Ref. to «REMOVAL»(ref-357260-S25313241422010031100000) , Joint Pipe. Ref. to «REMOVAL»(ref-357260-S13721512082010031100000) , Front Exhaust Pipe.
  21. Disconnect the ground cable on the engine side.
  22. Remove the bolts and nuts which hold the lower side of transmission to the engine. AT MODEL MT MODEL
  23. Remove the nuts which secure the engine mounting to the front crossmember.
  24. Lower the vehicle.
  25. Separate the torque converter clutch from the drive plate. (AT model) Remove the service hole plug. Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate.
  26. Remove the pitching stopper.
  27. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
  28. Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. Attach ST to the fuel return pipe as shown in the figure. Insert the front side of ST into the quick connector. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
  29. Remove the clip and disconnect the evaporation hose from the fuel pipe.
  30. Support the engine with a lifting device and wire ropes.
  31. Support the transmission with a garage jack. CAUTION: Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
  32. Separation of engine and transmission CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. Ref. to «REMOVAL»(ref-357234-S14658303492010031100000) , Starter. Attach the ST to the torque converter clutch case. (AT model) ST 498277200 STOPPER SET Remove the bolts which hold the upper side of the transmission to the engine. AT MODEL MT MODEL
  33. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with garage jack. Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  34. Remove the engine mounting from the engine.

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  1. Install the engine mounting onto the engine. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
  2. Apply a small amount of grease to splines of main shaft. (MT model) Grease: NICHIMOLY N-130 or equivalent
  3. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  4. Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) AT MODEL MT MODEL
  5. Remove the lifting device and wire ropes.
  6. Remove the garage jack.
  7. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
  8. Remove the ST from torque converter clutch case. (AT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
  9. Install the starter. Ref. to «INSTALLATION»(ref-357234-S36592124982010031100000) , Starter.
  10. Install the torque converter clutch to drive plate. (AT model) Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Fit the plug to service hole.
  11. Install the power steering pump. Install the power steering pump onto the engine. Tightening torque: Refer to "COMPONENT" of "Power Steering" for the tightening torque. Ref. to «COMPONENT»(ref-357258-S12059879692010031100000) , General Description. Connect the power steering pump switch connector. Install and adjust the front side belt. Ref. to «FRONT SIDE BELT»(ref-357237-S02797211002010031100000) , INSTALLATION, V-belt.
  12. Lift up the vehicle.
  13. Install the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) AT MODEL MT MODEL
  14. Install the nuts which hold the engine mounting to the crossmember. NOTE: Make sure that the engine mounting nuts (A) and locator (B) are securely installed. Tightening torque: 85 N.m (8.7 kgf-m, 62.7 ft-lb)
  15. Install the joint pipe and front exhaust pipe. Ref. to «INSTALLATION»(ref-357260-S13802090782010031100000) , Front Exhaust Pipe. Ref. to «INSTALLATION»(ref-357260-S25565108272010031100000) , Joint Pipe.
  16. Install the turbocharger. Ref. to «INSTALLATION»(ref-357235-S36678181012010031100000) , Turbocharger.
  17. Install the center exhaust pipe. Ref. to «INSTALLATION»(ref-357260-S05562151172010031100000) , Center Exhaust Pipe.
  18. Connect the ground cable. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
  19. Lower the vehicle.
  20. Connect the following hoses. Fuel delivery hose, fuel return hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose
  21. Connect the following connectors and terminals. Generator connector and terminal Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb) A/C compressor connector Secondary air pump connector
  22. Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
  23. Install the intercooler. Ref. to «INSTALLATION»(ref-357235-S05398122832010031100000) , Intercooler.
  24. Install the A/C pressure hoses to A/C compressor. Ref. to «INSTALLATION»(ref-357257-S30210735142010031100000) , Hose and Pipe.
  25. Install the radiator. Ref. to «INSTALLATION»(ref-357239-S29225592222010031100000) , Radiator.
  26. Install the coolant filler tank. Ref. to «INSTALLATION»(ref-357239-S29793624972010031100000) , Coolant Filler Tank.
  27. Install the air cleaner case and air intake duct. Ref. to «INSTALLATION»(ref-357235-S38224274812010031100000) , Air Cleaner Case. Ref. to «INSTALLATION»(ref-357235-S12040137862010031100000) , Air Intake Duct.
  28. Install the battery. Ref. to «INSTALLATION»(ref-357234-S20300629692010031100000) , Battery.
  29. Fill engine coolant. Ref. to «FILLING OF ENGINE COOLANT»(ref-357239-S07197404722010031100000) , REPLACEMENT, Engine Coolant.
  30. Charge the A/C system with refrigerant. Ref. to «PROCEDURE»(ref-357257-S32465084432010031100000) , Refrigerant Charging Procedure.
  31. Check the ATF level and replenish it if necessary. (AT model) Ref. to «INSPECTION»(ref-357244-S25560399872010031100000) , Automatic Transmission Fluid.
  32. Install the V-belt cover. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
  33. Change the bolt installation position from (B) to (A), then close the front hood.

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

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