Manuale d’uso / di manutenzione del prodotto 2004 del fabbricante Subaru
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FUJI HEAVY INDUSTRIES LTD. G1870GE3 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTI ON 2 This ser vice manu al has bee n prepared to prov ide SUB ARU ser vice pe rsonnel with the nec essary inform ation and data for the corr ect mainte nance and repair of SUBA RU vehicl es.
MECHANICAL ME(H4DOTC) Page 1. General Desc ription ...... ....... .......... ....... ....... ......... ........ ......... ....... ....... .......2 2. C ompre ssio n ..... ...... ..... .... ....... .... ..... .... ....... .... ..... ...... ..... .... .
ME(H4DOTC)-2 MECH ANICAL General Descript ion 1. General Description A: SPECIFICATIONS 1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL) NOTE: STD: Standard I.
ME(H4DOTC)-3 MECHA NIC AL General Descript ion Valve s eat Refaci ng angle 90 ° Cont act ing w idth Intake ST D 1.0 mm (0 .039 in) Limit 1.7 mm (0 .067 in) Exhaust ST D 1.5 mm (0 .059 in) Limit 2.2 mm (0 .087 in) Valve g uide Inner d iameter 6.000 — 6.
ME(H4DOTC)-4 MECH ANICAL General Descript ion Piston ring Pist on ri ng ga p Top ring STD 0.20 — 0.25 mm (0.0079 — 0 .0098 i n) Limit 1.0 mm (0 .039 in) Second ring STD 0.40 — 0.50 mm (0.016 — 0.02 0 in) Limit 1.0 mm (0 .039 in) Oil ring STD 0.
ME(H4DOTC)-5 MECHA NIC AL General Descript ion Crankshaft Bend lim it 0.035 m m (0.0014 in) Crank p in and crank jo ur- nal Out-of-ro undness 0.005 mm (0.000 2 in) or le ss Grindi ng limit 0.25 mm (0.009 8 in) Crank p in oute r diamete r STD 51. 984 — 52.
ME(H4DOTC)-6 MECH ANICAL General Descript ion 2. STi MO DEL NOTE: STD: Standard I.D.: Inner Diameter O.D.: Oute r Diameter OS: Oversize US: Undersize Crankshaft bearing Cranks haft be aring thic k- ness #1, #3 STD 1.998 — 2.011 mm (0.0787 — 0.0 792 in) 0.
ME(H4DOTC)-7 MECHA NIC AL General Descript ion Belt tension adjus ter Protrusion of adjust er rod 5.2 — 6. 2 mm (0.205 — 0.24 4 in ) Belt tension er Spac er O.D . 17. 955 — 17.975 mm (0.70 69 — 0. 7077 in) Tensione r bush I.D . 18.0 — 18 .08 mm (0.
ME(H4DOTC)-8 MECH ANICAL General Descript ion Cylinde r bloc k Surface w arpage li mit (mati ng with c ylinder head) 0.05 mm (0.002 0 in) Surface gri nding limit 0.1 mm (0 .004 in) Cylinder bore STD A 92. 005 — 92.015 m m (3.6222 — 3.6226 i n) B 91.
ME(H4DOTC)-9 MECHA NIC AL General Descript ion Crankshaft Bend lim it 0.035 m m (0.0014 in) Crank p in and crank jo ur- nal Out-of-ro undness 0.005 mm (0.000 2 in) or le ss Grindi ng limit 0.25 mm (0.009 8 in) Crank p in oute r diamete r STD 51. 984 — 52.
ME(H 4D OT C)-1 0 MECH ANICAL General Descript ion 3. DOHC TURBO MODEL (AUSTRALIA MODEL EXCEPT FOR S Ti MODEL) NOTE: STD: Standard I.D.: Inner Diameter O.D.: Oute r Diameter OS: Oversize US: Undersize Crankshaft bearing Cranks haft be aring thic k- ness #1, #3 STD 1.
ME(H 4D OT C)-1 1 MECHA NIC AL General Descript ion Belt tension adjus ter Protrusion of adjust er rod 5.2 — 6. 2 mm (0.205 — 0.24 4 in ) Belt tension er Spac er O.D . 17. 955 — 17.975 mm (0.70 69 — 0. 7077 in) Tensione r bush I.D . 18.0 — 18 .
ME(H 4D OT C)-1 2 MECH ANICAL General Descript ion Cylinde r bloc k Surface w arpage li mit (mati ng with c ylinder head) 0.05 mm (0.002 0 in) Surface gri nding limit 0.1 mm (0 .004 in) Cylinder bore STD A 92. 005 — 92.015 m m (3.6222 — 3.6226 i n) B 91.
ME(H 4D OT C)-1 3 MECHA NIC AL General Descript ion Crankshaft Bend lim it 0.035 m m (0.0014 in) Crank p in and crank jo ur- nal Out-of-ro undness 0.005 mm (0.000 2 in) or le ss Grindi ng limit 0.25 mm (0.009 8 in) Crank p in oute r diamete r STD 51. 984 — 52.
ME(H 4D OT C)-1 4 MECH ANICAL General Descript ion Crankshaft bearing Cranks haft be aring thic k- ness #1, #3 STD 1.998 — 2.011 mm (0.0787 — 0.0 792 in) 0.03 m m (0.0012 in) U S 2.01 7 — 2.020 mm (0 .0794 — 0.0795 in) 0.05 m m (0.0020 in) U S 2.
ME(H 4D OT C)-1 5 MECHA NIC AL General Descript ion B: COMP ONEN T 1. TIMING BELT • EXCEPT FOR STi AND AUSTRALIA MODEL (1) Timing belt cove r No. 2 (RH ) (10) Intake c amshaft spr ocket (LH) Tightening torque: N · m (kgf-m, ft-lb) (2) Timing belt guide (MT mode l) (11) Exhaust camshaf t sprocke t (LH) T1: 5 (0.
ME(H 4D OT C)-1 6 MECH ANICAL General Descript ion • STi AND AUSTRALIA MODEL (1) Timing belt cove r No. 2 (RH ) (10) Intake c amshaft spr ocket (LH) Tightening torque: N · m (kgf-m, ft-lb) (2) Timing belt guide (11) Exhau st cams haft sproc ket (LH) T1: 5 (0.
ME(H 4D OT C)-1 7 MECHA NIC AL General Descript ion 2. CYLINDER HEAD AND CAMSHAFT • EXCEPT FOR STi AND AUSTRALIA MODEL ME-00756 T2 T4 T3 T5 T4 T2 T2 T1 (7) (6) (14) (9) (8) (10) (15) (16) (13) (12) .
ME(H 4D OT C)-1 8 MECH ANICAL General Descript ion (1) Rocker c over (RH) (15) Cylinder hea d (RH) (29) Gasket (2) Rocke r cover gask et (RH) (16) Cylin der head g asket (30) Oil fil ler duct (3) Oil .
ME(H 4D OT C)-1 9 MECHA NIC AL General Descript ion • STi AND AUSTRALIA MODEL ME-00705 T2 T3 T4 T2 T2 T1 (1) (3) (7) (6) (9) (8) (10) (12) (13) (28) (24) (25) (26) (23) (19) (20) (28) (15) (16) (11).
ME(H 4D OT C)-2 0 MECH ANICAL General Descript ion (1) Rocker c over (RH) (13) Cylinder head gask et (25) Gasket (2) Rocker c over gask et (RH) (14) Cylinder head (LH ) (26) Oil filler duc t (3) Oil f.
ME(H 4D OT C)-2 1 MECHA NIC AL General Descript ion 3. CYLINDER HEAD AND VALVE ASSEMBLY (1) Exhau st valve (5) Intak e valve oil seal (9) Valve lifter (2) Inta ke va lve (6) Valv e spr ing (10) Exha u.
ME(H 4D OT C)-2 2 MECH ANICAL General Descript ion 4. CYLINDER BLOCK (1) Oil pressure swit ch (16) Water by-pass pipe Tightening torque: N · m (kgf-m, ft-lb) (2) Cylinder blo ck (RH) (17) Connecto r T1: 5 (0.5, 3.6) (3) Servic e hole p lug (1 8) Oil str ainer T2: 6.
ME(H 4D OT C)-2 3 MECHA NIC AL General Descript ion 5. CRANKSHAFT AND PISTON (1) Flywheel (MT mo del) (10) Circ lip (19) Crankshaft be aring #5 (2) Ball b earing (MT mode l) (11) Connec ting rod b olt.
ME(H 4D OT C)-2 4 MECH ANICAL General Descript ion 6. ENGINE MOUNTING (1) Heat shiel d cov er (3) Fr ont en gin e mou ntin g br acket Tightening torque: N · m (kgf-m, ft-lb) (2) Front cushi on rubb er T1: 35 ( 3.6 , 25 .8) T2: 42 ( 4.3 , 30 .9) T3: 85 ( 8.
ME(H 4D OT C)-2 5 MECHA NIC AL General Descript ion C: CAUT ION • Wear working clot hing, includ ing a cap, protec- tive goggles, a nd protective shoes duri ng opera- tion. • Remove contaminati on includin g dirt and corro- sion before removal, in stallation or di sassembly.
ME(H 4D OT C)-2 6 MECH ANICAL General Descript ion D: PREPARATION T OOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498267600 CYLINDE R HEAD TABLE • Used for r epl acing valv e gu ides. • Used fo r removing a nd ins talling v alve sp rings.
ME(H 4D OT C)-2 7 MECHA NIC AL General Descript ion 398744300 PISTON GUID E Use d for insta lling pi ston i n cylinder fo r 2.0 L engine. 498857100 VALVE OIL SEAL GUIDE Used for pre ss-fit ting of in take and e xhaust v alve guide oil seal s. 499017100 PISTON PIN GUIDE Used for in stall ing pisto n pin, pis ton and c onnect- ing rod.
ME(H 4D OT C)-2 8 MECH ANICAL General Descript ion 499097600 PISTON PIN REMOVER ASSY Used for re movi ng piston pin. (Exc ept for Aus tralia mode l) 499097700 PISTON PIN REMOVER ASSY Used for r emovi ng pi ston pin.
ME(H 4D OT C)-2 9 MECHA NIC AL General Descript ion 499977500 CAMSH AFT SPROCKET WRENCH Used fo r removing a nd inst alling i ntake ca mshaf t sprocke t. (STi and Au strali a model) 499587200 CRANKSHAFT OIL SEAL INSTALLER • Used for i nst alli ng cr anks haft oil s eal .
ME(H 4D OT C)-3 0 MECH ANICAL General Descript ion 18251AA020 VALVE GUI DE ADJUSTER Used for in stall ing intak e and exh aust valve guides. 499767200 VALVE GUI DE REMOVER Used for rem oving v alve gui des. 499767400 VALVE GUI DE REAMER Used for r eam ing valv e guid es.
ME(H 4D OT C)-3 1 MECHA NIC AL General Descript ion 499977400 CRANKSHAFT PULLEY WRENCH Used for s toppin g rotation o f crank shaft pu lley when lo osening and tig htening c rankshaf t pulle y bolts. 499987500 CRANKSHAFT SOCKET Used for rot ating cran kshaft.
ME(H 4D OT C)-3 2 MECH ANICAL General Descript ion 499587100 OIL SEAL INSTALLER Used fo r install ing oil pu mp oi l seal. 499587600 OIL SEAL INSTALLER Used for in stalling camsha ft oil seal fo r DOHC engine. 499597200 OIL SEAL GUIDE Used for install ing camsha ft oil seal fo r DOHC engine.
ME(H 4D OT C)-3 3 MECHA NIC AL General Descript ion 2. GENERAL PU RPOSE TOOLS E: PROCEDURE It is possib le to conduct the foll owing servic e procedures with engi ne on the vehicle , however, the proc edures described in thi s section are based on the conditi on that the engine is r emoved from the vehicle.
ME(H 4D OT C)-3 4 MECH ANICAL Compression 2. Compression A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yo urself duri ng measure- ment. 1) After warmi ng-up the engine, turn t he ignition switch to OFF. 2) Make sure that the batter y is fully charged.
ME(H 4D OT C)-3 5 MECHA NIC AL Idle S peed 3. Idle Speed A: INSPECTION 1. USING SUBARU SELECT MONITOR 1) Before checkin g the idle speed, ch eck the fol - lowing: (1) Ensure the air cl eaner element is free from clogging , ignition ti ming is corr ect, spark plugs are in good condition, and that the hoses are connected properl y.
ME(H 4D OT C)-3 6 MECH ANICAL Ignition Timing 4. Ignition Timing A: INSPECTION 1. USING SUBARU SELECT MONITOR 1) Before checki ng the igni tion timin g speed, c heck the followi ng: (1) Ensure the air cl eaner element is free from clogging , spark plugs are in g ood condi tion, and that hoses are connected pr operly.
ME(H 4D OT C)-3 7 MECHA NIC AL Intake Manifold Vacuum 5. Intake Manifold Vacuum A: INSPECTION 1) Warm-up the engine. 2) Disconnect the brak e vacuum hose, and then install the vacuum gauge to hose fitting on manif old. 3) Keep the engine at the idle speed, and then read the vacuum gauge indicati on.
ME(H 4D OT C)-3 8 MECH ANICAL Engine Oil Pressure 6. Engine Oil Pressure A: INSPECTION 1) Remove the oil pressure swi tch from engine cyl- inder bloc k. <Ref . to LU(H4 DOTC)-18, REMOVAL, Oil Pre ssu re Switc h.> 2) Connect the oil pres sure gauge hose t o cylinder block.
ME(H 4D OT C)-3 9 MECHA NIC AL Fuel Pressure 7. Fuel Pressure A: INSPECTION CAUTION: Before removing the fuel pressur e gauge, re- lease the f uel pressure. NOTE: If out of specif ication, check or replace the press ure regulator and pressure regulator vacuum h ose.
ME(H 4D OT C)-4 0 MECH ANICAL Valve Clearance 8. Valve Clearance A: INSPECTION Inspection and adj ustment of the val ve clearance should be per formed while engin e is col d. 1) Set the vehicle on a lift . 2) Disconnect the grou nd cable from batt ery.
ME(H 4D OT C)-4 1 MECHA NIC AL Valve Clearance (5) Move the washer tank upward. (6) Disconnect the ignition coi l connector. (7) Remove the igniti on coil. (8) Place a suitab le container under t he vehicle. (9) Disconnect t he PCV hose from r ocker cover (LH).
ME(H 4D OT C)-4 2 MECH ANICAL Valve Clearance (3) Set the ar row mark on camshaft sprocket to position shown in the figure, and then measure the #1 cyli nder exhaust val ve and #4 cyli nder in- take valve cleara nces. 15) After inspe ction, inst all the relat ed parts in the reverse order of r emoval.
ME(H 4D OT C)-4 3 MECHA NIC AL Valve Clearance 6) Inspect al l valve s for clearanc e again at this stage. If the valve clear ance is not c orrect, r epeat the procedu re over agai n from t he first step. 7) After inspe ction, inst all the relat ed parts in the reverse or der of r emoval.
ME(H 4D OT C)-4 4 MECH ANICAL Engin e Assemb ly 9. Engine Assem bly A: REM OVA L 1) Set the vehicle on a lift . 2) Open t he front hood full y, and t hen support with the hood stay. 3) Collect the refr igerant from A/C system. 4) Release the fuel pres sure.
ME(H 4D OT C)-4 5 MECHA NIC AL Engin e Assemb ly (5) Accelera tor cabl e (MT model) (6) Clutc h release spring (MT mod el) 12) Disconnect the fo llowing hoses. (1) Brake booster vacuum hose (2) Heater inlet outlet hose 13) Remove the power steering pump from brac k- et.
ME(H 4D OT C)-4 6 MECH ANICAL Engin e Assemb ly (6) Place the power steer ing pump on right side wheel apron. 14) Lift-up the vehic le. 15) Remove the ATF cooler pi pe from frame. (AT mod el) 16) Remove the center exhaust pi pe. <Ref. to EX(H4DOTC)-9, REMOVAL, Center Exhaust Pipe.
ME(H 4D OT C)-4 7 MECHA NIC AL Engin e Assemb ly (4) Remove the other bolt s while rotating the engine using sock et wrench. 22) Remove the pitching stopper . 23) Disconnect th e fuel delive ry hose, retur n hose and evaporati on hose. NOTE: • Catch fuel from the hose into container.
ME(H 4D OT C)-4 8 MECH ANICAL Engin e Assemb ly (3) Remove the bolts which hold the ri ght upper side of t ransmiss ion to eng ine. 28) Remove the engine from vehicle. (1) Slightl y raise the engine. (2) Raise the transmi ssion with garage j ack. (3) Move the engine horizontally unt il the main- shaft is withdr awn from clutch cover.
ME(H 4D OT C)-4 9 MECHA NIC AL Engin e Assemb ly CAUTION: Make sure the cutout portion of rel ease fork shaft contact s spring pi n. (6) Tighten t he plug. Tightening t orque: 44 N · m (4 .5 kg f-m , 32 .5 f t-lb ) 2) Instal l the fr ont cushion rubbers to engine.
ME(H 4D OT C)-5 0 MECH ANICAL Engin e Assemb ly (2) Tighten ot her bolts whi le rotating the engine by using ST. CAUTION: Be careful not to drop bolt s into the torque con- verter clutch housin g. ST 499977300 CRANKSHAFT PULLEY WRENCH Tightening t orque: 25 N · m (2 .
ME(H 4D OT C)-5 1 MECHA NIC AL Engin e Assemb ly Tightening t orque: 50 N · m (5 .1 kg f-m , 36 .9 f t-lb ) 15) Ti ghten the nut s which install the fr ont cushion rubber onto crossmember .
ME(H 4D OT C)-5 2 MECH ANICAL Engine Mounting 10. Engine Mount ing A: REM OVA L 1) Remove the engine assembly. <Ref. to ME(H4DOTC)-44, REMOVAL, Engine Assembly.> 2) Remove the engine mounting fr om engine as- sembly. B: INST ALLA TIO N Install in the reverse order of r emoval.
ME(H 4D OT C)-5 3 MECHA NIC AL Preparation for O verhaul 11. Preparation for Overhaul A: PROCEDURE 1) After removi ng the engin e from body , secure i t in the ST shown b elow.
ME(H 4D OT C)-5 4 MECH ANICAL V-belt 12. V-belt A: REM OVA L 1. FRONT SIDE BELT 1) Remove the V-belt cov er. 2) Loosen t he lock bol t (A). 3) Loosen t he slider bolt (B). 4) Remove the front side belt (C) . 2. REAR SIDE BELT 1) Loosen t he lock nut (A).
ME(H 4D OT C)-5 5 MECHA NIC AL V-belt 3) Tighten the lock nut (A). Tightening t orque: Lock nut ( A): 22.6 N · m (2.3 kgf-m, 16.6 ft-lb) C: INSPECTION 1) Replace the belt s, if cracks, fr aying or wear is found.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Subaru 2004 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Subaru 2004 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Subaru 2004 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Subaru 2004 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Subaru 2004, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Subaru 2004.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Subaru 2004. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Subaru 2004 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
