Subaru Impreza 2004 Bedienungsanleitung

FUJI HEAVY INDUSTRIES LTD. G1870GE3

2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 2

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FUEL INJECTION (FUEL SYSTEMS) FU(H4DOTC)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H4DOTC)

INTAKE (INDUCTION) IN(H4DOTC)

MECHANICAL ME(H4DOTC)

EXHAUST EX(H4DOTC)

COOLING CO(H4DOTC)

LUBRICATION LU(H4DOTC)

SPEED CONTROL SYSTEMS SP(H4DOTC)

IGNITION IG(H4DOTC)

STARTING/CHARGING SYSTEMS SC(H4DOTC)

ENGINE (DIAGNOSTICS) EN(H4DOTC)(diag)

MECHANICAL

ME(H4DOTC)

Page

1. General Description ....................................................................................2

2. Compression .............................................................................................34

3. Idle Speed .................................................................................................35

4. Ignition Timing...........................................................................................36

5. Intake Manifold Vacuum............................................................................37

6. Engine Oil Pressure ..................................................................................38

7. Fuel Pressure............................................................................................39

8. Valve Clearance........................................................................................40

9. Engine Assembly ......................................................................................44

10. Engine Mounting .......................................................................................52

11. Preparation for Overhaul...........................................................................53

12. V-belt.........................................................................................................54

13. Crankshaft Pulley ......................................................................................56

14. Timing Belt Cover......................................................................................57

15. Timing Belt Assembly................................................................................58

16. Camshaft Sprocket....................................................................................66

17. Crankshaft Sprocket..................................................................................68

18. Camshaft...................................................................................................69

19. Cylinder Head Assembly...........................................................................78

20. Cylinder Block ...........................................................................................85

21. Intake and Exhaust Valve .......................................................................105

22. Piston ......................................................................................................106

23. Connecting Rod ......................................................................................107

24. Crankshaft...............................................................................................108

25. Engine Trouble in General ......................................................................109

26. Engine Noise...........................................................................................114

ME(H4DOTC)-2

MECHANICAL

General Description

1. General Description

A: SPECIFICATIONS

1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL)

NOTE:

STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize

Engine

Type Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine

Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder

Bore ×Stroke mm (in) 92 ×75 (3.62 ×2.95)

Piston displacement cm3(cu in) 1,994 (121.67)

Compression ratio 8.0

Compression pres-

sure (at 200 —300

rpm)

kPa (kgf/cm2, psi) 981 —1,177 (10 —12, 142 —171)

Number of piston rings Pressure ring: 2, Oil ring: 1

Intake valve timing Opening BTDC 10°

Closing ABDC 50°

Exhaust valve timing Opening BBDC 53°

Closing ATDC 7°

Valve clearance Intake mm (in) 0.20±0.02 (0.0079±0.0008)

Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)

Idling speed

[At neutral position on MT or “P”or

“N”range on AT]

rpm 700±100 (No load)

800±150 (A/C switch ON)

Firing order 1 →3 →2 →4

Ignition timing BTDC/rpm 12°±10°/700

Belt

tension

adjuster

Protrusion of adjuster rod 5.2 —6.2 mm (0.205 —0.244 in)

Belt

tensioner

Spacer O.D. 17.955 —17.975 mm (0.7069 —0.7077 in)

Tensioner bush I.D. 18.0 —18.08 mm (0.7087 —0.7118 in)

Clearance between spacer and bush STD 0.025 —0.125 mm (0.0010 —0.0049 in)

Limit 0.175 mm (0.0069 in)

Side clearance of spacer STD 0.2 —0.55 mm (0.0079 —0.0217 in)

Limit 0.81 mm (0.0319 in)

Camshaft

Bend limit 0.020 mm (0.0079 in)

Thrust clearance STD 0.040 —0.080 mm (0.0016 —0.0031 in)

Limit 0.10 mm (0.0039 in)

Cam lobe height

Intake STD 46.25 —46.35 mm (1.821 —1.825 in)

Limit 46.15 mm (1.817 in)

Exhaust STD 46.15 —46.25 mm (1.817 —1.821 in)

Limit 46.05 mm (1.813 in)

Journal O.D. STD

Front 37.946 —37.963 mm (1.4939 —1.4946 in)

Center

rear 29.946 —29.963 mm (1.1790 —1.1796 in)

Oil clearance STD 0.037 —0.072 mm (0.0015 —0.0028 in)

Limit 0.10 mm (0.0039 in)

Cylinder

head

Surface warpage limit 0.05 mm (0.0020 in)

Surface grinding limit 0.3 mm (0.012 in)

Standard height 127.5 mm (5.02 in)

ME(H4DOTC)-3

MECHANICAL

General Description

Valve seat

Refacing angle 90°

Contacting width

Intake STD 1.0 mm (0.039 in)

Limit 1.7 mm (0.067 in)

Exhaust STD 1.5 mm (0.059 in)

Limit 2.2 mm (0.087 in)

Valve guide Inner diameter 6.000 —6.012 mm (0.2362 —0.2367 in)

Protrusion above head 15.8 —16.2 mm (0.622 —0.638 in)

Valve

Head edge thickness

Intake STD 1.2 mm (0.047 in)

Limit 0.8 mm (0.031 in)

Exhaust STD 1.5 mm (0.059 in)

Limit 0.8 mm (0.031 in)

Stem diameter Intake 5.955 —5.970 mm (0.2344 —0.2350 in)

Exhaust 5.945 —5.960 mm (0.2341 —0.2346 in)

Stem oil clearance STD Intake 0.030 —0.057 mm (0.0012 —0.0022 in)

Exhaust 0.040 —0.067 mm (0.0016 —0.0026 in)

Limit —0.15 mm (0.0059 in)

Overall length Intake 104.4 mm (4.110 in)

Exhaust 104.7 mm (4.122 in)

Valve

spring

Free length 47.32 mm (1.8630 in)

Squareness 2.5°, 2.1 mm (0.083 in)

Tension/spring height

Set 205 —235 N (20.9 —24.0 kgf, 46.1 —52.8 lb)/

36.0 mm (1.417 in)

Lift 426 —490 N (43.4 —50.0 kgf, 95.8 —110 lb)/

26.5 mm (1.043 in)

Cylinder

block

Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)

Surface grinding limit 0.1 mm (0.004 in)

Cylinder bore STD A 92.005 —92.015 mm (3.6222 —3.6226 in)

B 91.995 —92.005 mm (3.6218 —3.6222 in)

Taper STD 0.015 mm (0.0006 in)

Limit 0.050 mm (0.0020 in)

Out-of-roundness STD 0.010 mm (0.0004 in)

Limit 0.050 mm (0.0020 in)

Piston clearance STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.050 mm (0.0020 in)

Enlarging (boring) limit 0.5 mm (0.020 in)

Piston Outer diameter

STD A 91.985 —91.995 mm (3.6214 —3.6218 in)

B 91.975 —91.985 mm (3.6211 —3.6214 in)

0.25 mm (0.0098 in)

OS 92.225 —92.235 mm (3.6309 —3.6313 in)

0.50 mm (0.0197 in)

OS 92.475 —92.485 mm (3.6407 —3.6411 in)

Piston pin

Standard clearance between piston

pin and hole in piston

STD 0.004 —0.008 mm (0.0002 —0.0003 in)

Limit 0.020 mm (0.0008 in)

Degree of fit Piston pin must be fitted into position with thumb at 20°C

(68°F).

ME(H4DOTC)-4

MECHANICAL

General Description

Piston ring

Piston ring gap

Top ring STD 0.20 —0.25 mm (0.0079 —0.0098 in)

Limit 1.0 mm (0.039 in)

Second

ring

STD 0.40 —0.50 mm (0.016 —0.020 in)

Limit 1.0 mm (0.039 in)

Oil ring STD 0.20 —0.50 mm (0.0079 —0.020 in)

Limit 1.5 mm (0.059 in)

Clearance between piston

ring and piston ring

groove

Top ring STD 0.04 —0.08 mm (0.0016 —0.0031 in)

Limit 0.15 mm (0.0059 in)

Second

ring

STD 0.030 —0.070 mm (0.0012 —0.0028 in)

Limit 0.15 mm (0.0059 in)

Connecting

rod

Bend or twist per 100 mm (3.94 in) in

length Limit 0.10 mm (0.0039 in)

Side clearance STD 0.070 —0.330 mm (0.0028 —0.0130 in)

Limit 0.4 mm (0.016 in)

Connecting

rod bearing

Oil clearance STD 0.020 —0.046 mm (0.0008 —0.0018 in)

Limit 0.05 mm (0.0020 in)

Thickness at center portion

STD 1.486 —1.498 mm (0.0585 —0.0590 in)

0.03 mm

(0.0012

in) US

1.504 —1.512 mm (0.0592 —0.0595 in)

0.05 mm

(0.0020

in) US

1.514 —1.522 mm (0.0596 —0.0599 in)

0.25 mm

(0.0098

in) US

1.614 —1.622 mm (0.0635 —0.0639 in)

Connecting

rod bushing

Clearance between piston pin and

bushing

STD 0 —0.022 mm (0 —0.0009 in)

Limit 0.030 mm (0.0012 in)

ME(H4DOTC)-5

MECHANICAL

General Description

Crankshaft

Bend limit 0.035 mm (0.0014 in)

Crank pin and crank jour-

nal

Out-of-roundness 0.005 mm (0.0002 in) or less

Grinding limit 0.25 mm (0.0098 in)

Crank pin outer diameter

STD 51.984 —52.000 mm (2.0466 —2.0472 in)

0.03 mm

(0.0012

in) US

51.954 —51.970 mm (2.0454 —2.0461 in)

0.05 mm

(0.0020

in) US

51.934 —51.950 mm (2.0447 —2.0453 in)

0.25 mm

(0.0098

in) US

51.734 —51.750 mm (2.0368 —2.0374 in)

Crank journal outer diam-

eter

#1, #3, #5

STD 59.992 —60.008 mm (2.3619 —2.3625 in)

0.03 mm

(0.0012

in) US

59.962 —59.978 mm (2.3607 —2.3613 in)

0.05 mm

(0.0020

in) US

59.942 —59.958 mm (2.3599 —2.3605 in)

0.25 mm

(0.0098

in) US

59.742 —59.758 mm (2.3520 —2.3527 in)

#2, #4

STD 59.992 —60.008 mm (2.3619 —2.3625 in)

0.03 mm

(0.0012

in) US

59.962 —59.978 mm (2.3607 —2.3613 in)

0.05 mm

(0.0020

in) US

59.942 —59.958 mm (2.3599 —2.3605 in)

0.25 mm

(0.0098

in) US

59.742 —59.758 mm (2.3520 —2.3527 in)

Thrust clearance STD 0.030 —0.115 mm (0.0012 —0.0045 in)

Limit 0.25 mm (0.0098 in)

Oil clearance

#1 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.040 mm (0.0016 in)

#2 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.045 mm (0.0018 in)

#3 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.040 mm (0.0016 in)

#4 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.045 mm (0.0018 in)

#5 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.040 mm (0.0016 in)

ME(H4DOTC)-6

MECHANICAL

General Description

2. STi MODEL

NOTE:

STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize

Crankshaft

bearing

Crankshaft bearing thick-

ness

#1, #3

STD 1.998 —2.011 mm (0.0787 —0.0792 in)

0.03 mm

(0.0012

in) US

2.017 —2.020 mm (0.0794 —0.0795 in)

0.05 mm

(0.0020

in) US

2.027 —2.030 mm (0.0798 —0.0799 in)

0.25 mm

(0.0098

in) US

2.127 —2.130 mm (0.0837 —0.0839 in)

#2, #4, #5

STD 2.000 —2.013 mm (0.0787 —0.0793 in)

0.03 mm

(0.0012

in) US

2.019 —2.022 mm (0.0795 —0.0796 in)

0.05 mm

(0.0020

in) US

2.029 —2.032 mm (0.0799 —0.0800 in)

0.25 mm

(0.0098

in) US

2.129 —2.132 mm (0.0838 —0.0839 in)

Engine

Type Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine

Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder

Bore ×Stroke mm (in) 92 ×75 (3.62 ×2.95)

Piston displacement cm3(cu in) 1,994 (121.67)

Compression ratio 8.0

Compression pres-

sure (at 200 —300

rpm)

kPa (kgf/cm2, psi) 981 —1,177 (10 —12, 142 —171)

Number of piston rings Pressure ring: 2, Oil ring: 1

Intake valve timing

Opening Max. retard ATDC 6°

Min. advance BTDC 24°

Closing Max. retard ABDC 68°

Min. advance ABDC 38°

Exhaust valve timing Opening BBDC 58°

Closing ATDC 10°

Valve clearance Intake mm (in) 0.20±0.02 (0.0079±0.0008)

Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)

Idling speed

[At neutral position on MT] rpm 700±100 (No load)

800±150 (A/C switch ON)

Firing order 1 →3 →2 →4

Ignition timing BTDC/rpm 12°±10°/700

ME(H4DOTC)-7

MECHANICAL

General Description

Belt

tension

adjuster

Protrusion of adjuster rod 5.2 —6.2 mm (0.205 —0.244 in)

Belt

tensioner

Spacer O.D. 17.955 —17.975 mm (0.7069 —0.7077 in)

Tensioner bush I.D. 18.0 —18.08 mm (0.7087 —0.7118 in)

Clearance between spacer and bush STD 0.025 —0.125 mm (0.0010 —0.0049 in)

Limit 0.175 mm (0.0069 in)

Side clearance of spacer STD 0.2 —0.55 mm (0.0079 —0.0217 in)

Limit 0.81 mm (0.0319 in)

Camshaft

Bend limit 0.020 mm (0.0079 in)

Thrust clearance STD 0.040 —0.080 mm (0.0016 —0.0031 in)

Limit 0.10 mm (0.0039 in)

Cam lobe height

Intake STD 45.25 —45.35 mm (1.781 —1.785 in)

Limit 45.15 mm (1.758 in)

Exhaust STD 45.60 —45.70 mm (1.795 —1.799 in)

Limit 45.50 mm (1.791 in)

Journal O.D. STD

Front 37.946 —37.963 mm (1.4939 —1.4946 in)

Center

rear 29.946 —29.963 mm (1.1790 —1.1796 in)

Oil clearance STD 0.037 —0.072 mm (0.0015 —0.0028 in)

Limit 0.10 mm (0.0039 in)

Cylinder

head

Surface warpage limit 0.05 mm (0.0020 in)

Surface grinding limit 0.3 mm (0.012 in)

Standard height 127.5 mm (5.02 in)

Valve seat

Refacing angle 90°

Contacting width

Intake STD 1.0 mm (0.039 in)

Limit 1.7 mm (0.067 in)

Exhaust STD 1.5 mm (0.059 in)

Limit 2.2 mm (0.087 in)

Valve guide Inner diameter 6.000 —6.012 mm (0.2362 —0.2367 in)

Protrusion above head 15.8 —16.2 mm (0.622 —0.638 in)

Valve

Head edge thickness

Intake STD 1.2 mm (0.047 in)

Limit 0.8 mm (0.031 in)

Exhaust STD 1.5 mm (0.059 in)

Limit 0.8 mm (0.031 in)

Stem diameter Intake 5.955 —5.970 mm (0.2344 —0.2350 in)

Exhaust 5.945 —5.960 mm (0.2341 —0.2346 in)

Stem oil clearance STD Intake 0.030 —0.057 mm (0.0012 —0.0022 in)

Exhaust 0.040 —0.067 mm (0.0016 —0.0026 in)

Limit —0.15 mm (0.0059 in)

Overall length Intake 104.4 mm (4.110 in)

Exhaust 104.7 mm (4.122 in)

Valve

spring

Free length 43.89 mm (1.728 in)

Squareness 2.5°, 1.9 mm (0.075 in)

Tension/spring height

Set 205 —237 N (20.9 —24.2 kgf, 46.1 —53.3 lb)/

36.0 mm (1.417 in)

Lift 553 —611 N (56.4 —62.3 kgf, 124 —137 lb)/

26.45 mm (1.041 in)

ME(H4DOTC)-8

MECHANICAL

General Description

Cylinder

block

Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)

Surface grinding limit 0.1 mm (0.004 in)

Cylinder bore STD A 92.005 —92.015 mm (3.6222 —3.6226 in)

B 91.995 —92.005 mm (3.6218 —3.6222 in)

Taper STD 0.015 mm (0.0006 in)

Limit 0.050 mm (0.0020 in)

Out-of-roundness STD 0.010 mm (0.0004 in)

Limit 0.050 mm (0.0020 in)

Piston clearance STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.050 mm (0.0020 in)

Enlarging (boring) limit 0.5 mm (0.020 in)

Piston Outer diameter

STD A 91.985 —91.995 mm (3.6214 —3.6218 in)

B 91.975 —91.985 mm (3.6211 —3.6214 in)

0.25 mm (0.0098 in)

OS 92.225 —92.235 mm (3.6309 —3.6313 in)

0.50 mm (0.0197 in)

OS 92.475 —92.485 mm (3.6407 —3.6411 in)

Piston pin

Standard clearance between piston

pin and hole in piston

STD 0.004 —0.008 mm (0.0002 —0.0003 in)

Limit 0.020 mm (0.0008 in)

Degree of fit Piston pin must be fitted into position with thumb at 20°C

(68°F).

Piston ring

Piston ring gap

Top ring STD 0.20 —0.25 mm (0.0079 —0.0098 in)

Limit 1.0 mm (0.039 in)

Second

ring

STD 0.40 —0.50 mm (0.016 —0.020 in)

Limit 1.0 mm (0.039 in)

Oil ring STD 0.20 —0.50 mm (0.0079 —0.020 in)

Limit 1.5 mm (0.059 in)

Clearance between piston

ring and piston ring

groove

Top ring STD 0.040 —0.080 mm (0.0016 —0.0031 in)

Limit 0.15 mm (0.0059 in)

Second

ring

STD 0.030 —0.070 mm (0.0012 —0.0028 in)

Limit 0.15 mm (0.0059 in)

Connecting

rod

Bend or twist per 100 mm (3.94 in) in

length Limit 0.10 mm (0.0039 in)

Side clearance STD 0.070 —0.330 mm (0.0028 —0.0130 in)

Limit 0.4 mm (0.016 in)

Connecting

rod bearing

Oil clearance STD 0.020 —0.046 mm (0.0008 —0.0018 in)

Limit 0.05 mm (0.0020 in)

Thickness at center portion

STD 1.486 —1.498 mm (0.0585 —0.0590 in)

0.03 mm

(0.0012

in) US

1.504 —1.512 mm (0.0592 —0.0595 in)

0.05 mm

(0.0020

in) US

1.514 —1.522 mm (0.0596 —0.0599 in)

0.25 mm

(0.0098

in) US

1.614 —1.622 mm (0.0635 —0.0639 in)

Connecting

rod bushing

Clearance between piston pin and

bushing

STD 0 —0.022 mm (0 —0.0009 in)

Limit 0.030 mm (0.0012 in)

ME(H4DOTC)-9

MECHANICAL

General Description

Crankshaft

Bend limit 0.035 mm (0.0014 in)

Crank pin and crank jour-

nal

Out-of-roundness 0.005 mm (0.0002 in) or less

Grinding limit 0.25 mm (0.0098 in)

Crank pin outer diameter

STD 51.984 —52.000 mm (2.0466 —2.0472 in)

0.03 mm

(0.0012

in) US

51.954 —51.970 mm (2.0454 —2.0461 in)

0.05 mm

(0.0020

in) US

51.934 —51.950 mm (2.0447 —2.0453 in)

0.25 mm

(0.0098

in) US

51.734 —51.750 mm (2.0368 —2.0374 in)

Crank journal outer diam-

eter

#1, #3, #5

STD 59.992 —60.008 mm (2.3619 —2.3625 in)

0.03 mm

(0.0012

in) US

59.962 —59.978 mm (2.3607 —2.3613 in)

0.05 mm

(0.0020

in) US

59.942 —59.958 mm (2.3599 —2.3605 in)

0.25 mm

(0.0098

in) US

59.742 —59.758 mm (2.3520 —2.3527 in)

#2, #4

STD 59.992 —60.008 mm (2.3619 —2.3625 in)

0.03 mm

(0.0012

in) US

59.962 —59.978 mm (2.3607 —2.3613 in)

0.05 mm

(0.0020

in) US

59.942 —59.958 mm (2.3599 —2.3605 in)

0.25 mm

(0.0098

in) US

59.742 —59.758 mm (2.3520 —2.3527 in)

Thrust clearance STD 0.030 —0.115 mm (0.0012 —0.0045 in)

Limit 0.25 mm (0.0098 in)

Oil clearance

#1 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.040 mm (0.0016 in)

#2 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.045 mm (0.0018 in)

#3 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.040 mm (0.0016 in)

#4 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.045 mm (0.0018 in)

#5 STD 0.010 —0.030 mm (0.0004 —0.0012 in)

Limit 0.040 mm (0.0016 in)

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