Page 2 - MECHANICAL; Page
MECHANICAL ME(H4DOTC) Page 1. General Description ....................................................................................2 2. Compression .............................................................................................34 3. Idle Speed ..........................................
Page 3 - General Description
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 ...
Page 16 - • EXCEPT FOR STi AND AUSTRALIA MODEL
ME(H4DOTC)-15 MECHANICAL General Description B: COMPONENT 1. TIMING BELT • EXCEPT FOR STi AND AUSTRALIA MODEL (1) Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torque: N·m (kgf-m, ft-lb) (2) Timing belt guide (MT model) (11) Exhaust camshaft sprocket (LH) T1: 5 (0.5, 3.6...
Page 17 - • STi AND AUSTRALIA MODEL
ME(H4DOTC)-16 MECHANICAL General Description • STi AND AUSTRALIA MODEL (1) Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torque: N·m (kgf-m, ft-lb) (2) Timing belt guide (11) Exhaust camshaft sprocket (LH) T1: 5 (0.5, 3.6) (3) Crankshaft sprocket (12) Timing belt T2: 6.4...
Page 18 - CYLINDER HEAD AND CAMSHAFT
ME(H4DOTC)-17 MECHANICAL General Description 2. CYLINDER HEAD AND CAMSHAFT • EXCEPT FOR STi AND AUSTRALIA MODEL ME-00756 T 2 T 4 T 3 T 5 T 4 T 2 T 2 T 1 ( 7 ) ( 6 ) ( 1 4 ) ( 9 ) ( 8 ) ( 1 0 ) ( 1 5 ) ( 1 6 ) ( 1 3 ) ( 1 2 ) ( 3 2 ) ( 2 9 ) ( 3 0 ) ( 3 1 ) ( 3 ) ( 4 ) ( 2 7 ) ( 2 3 ) ( 2 4 ) ( 2 1 )...
Page 22 - CYLINDER HEAD AND VALVE ASSEMBLY
ME(H4DOTC)-21 MECHANICAL General Description 3. CYLINDER HEAD AND VALVE ASSEMBLY (1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter (2) Intake valve (6) Valve spring (10) Exhaust valve oil seal (3) Cylinder head (7) Retainer (11) Intake valve guide (4) Valve spring seat (8) Retainer key (1...
Page 24 - CRANKSHAFT AND PISTON
ME(H4DOTC)-23 MECHANICAL General Description 5. CRANKSHAFT AND PISTON (1) Flywheel (MT model) (10) Circlip (19) Crankshaft bearing #5 (2) Ball bearing (MT model) (11) Connecting rod bolt (3) Reinforcement (AT model) (12) Connecting rod Tightening torque: N·m (kgf-m, ft-lb) (4) Drive plate (AT model)...
Page 34 - GENERAL PURPOSE TOOLS
ME(H4DOTC)-33 MECHANICAL General Description 2. GENERAL PURPOSE TOOLS E: PROCEDURE It is possible to conduct the following service procedures with engine on the vehicle, however, the proceduresdescribed in this section are based on the condition that the engine is removed from the vehicle.• V-belt• ...
Page 35 - Compression
ME(H4DOTC)-34 MECHANICAL Compression 2. Compression A: INSPECTION CAUTION:After warming-up, engine becomes very hot. Be careful not to burn yourself during measure-ment. 1) After warming-up the engine, turn the ignitionswitch to OFF.2) Make sure that the battery is fully charged.3) Release the fuel ...
Page 36 - Idle Speed; USING SUBARU SELECT MONITOR; Except for Australia model
ME(H4DOTC)-35 MECHANICAL Idle Speed 3. Idle Speed A: INSPECTION 1. USING SUBARU SELECT MONITOR 1) Before checking the idle speed, check the fol-lowing: (1) Ensure the air cleaner element is free fromclogging, ignition timing is correct, spark plugsare in good condition, and that the hoses areconnect...
Page 37 - Ignition Timing
ME(H4DOTC)-36 MECHANICAL Ignition Timing 4. Ignition Timing A: INSPECTION 1. USING SUBARU SELECT MONITOR 1) Before checking the ignition timing speed, checkthe following: (1) Ensure the air cleaner element is free fromclogging, spark plugs are in good condition, andthat hoses are connected properly....
Page 38 - Intake Manifold Vacuum; Less than
ME(H4DOTC)-37 MECHANICAL Intake Manifold Vacuum 5. Intake Manifold Vacuum A: INSPECTION 1) Warm-up the engine.2) Disconnect the brake vacuum hose, and then install the vacuum gauge to hose fitting on manifold.3) Keep the engine at the idle speed, and then read the vacuum gauge indication.By observin...
Page 39 - Engine Oil Pressure; rpm
ME(H4DOTC)-38 MECHANICAL Engine Oil Pressure 6. Engine Oil Pressure A: INSPECTION 1) Remove the oil pressure switch from engine cyl-inder block. <Ref. to LU(H4DOTC)-18, REMOVAL,Oil Pressure Switch.>2) Connect the oil pressure gauge hose to cylinderblock.3) Connect the battery ground cable to b...
Page 40 - Fuel Pressure; ) Connect the connector of fuel pump relay.
ME(H4DOTC)-39 MECHANICAL Fuel Pressure 7. Fuel Pressure A: INSPECTION CAUTION:Before removing the fuel pressure gauge, re-lease the fuel pressure. NOTE:If out of specification, check or replace the pressureregulator and pressure regulator vacuum hose.1) Release the fuel pressure. <Ref. toFU(H4DOT...
Page 41 - Valve Clearance
ME(H4DOTC)-40 MECHANICAL Valve Clearance 8. Valve Clearance A: INSPECTION Inspection and adjustment of the valve clearanceshould be performed while engine is cold.1) Set the vehicle on a lift.2) Disconnect the ground cable from battery. 3) Remove the air intake duct. <Ref. toIN(H4DOTC)-8, REMOVAL...
Page 45 - Engine Assembly
ME(H4DOTC)-44 MECHANICAL Engine Assembly 9. Engine Assembly A: REMOVAL 1) Set the vehicle on a lift.2) Open the front hood fully, and then support withthe hood stay.3) Collect the refrigerant from A/C system.4) Release the fuel pressure. (1) Disconnect the fuel pump relay connector. (2) Start the en...
Page 48 - 6) Support the transmission with a garage jack.
ME(H4DOTC)-47 MECHANICAL Engine Assembly (4) Remove the other bolts while rotating theengine using socket wrench. 22) Remove the pitching stopper. 23) Disconnect the fuel delivery hose, return hoseand evaporation hose. NOTE:• Catch fuel from the hose into container.• Disconnect the hose with its end...
Page 50 - ) Install the front cushion rubbers to engine.
ME(H4DOTC)-49 MECHANICAL Engine Assembly CAUTION:Make sure the cutout portion of release fork shaft contacts spring pin. (6) 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: 35 N·m (3.6 kgf-m, 25.8 ft-lb) 3) Instal...
Page 51 - ST
ME(H4DOTC)-50 MECHANICAL Engine Assembly (2) Tighten other bolts while rotating the engineby using ST. CAUTION:Be careful not to drop bolts into the torque con-verter clutch housing. ST 499977300 CRANKSHAFT PULLEY WRENCH Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) (3) Clog the service hole wit...
Page 53 - Engine Mounting; Install in the reverse order of removal.
ME(H4DOTC)-52 MECHANICAL Engine Mounting 10.Engine Mounting A: REMOVAL 1) Remove the engine assembly. <Ref. toME(H4DOTC)-44, REMOVAL, Engine Assembly.>2) Remove the engine mounting from engine as-sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mountin...
Page 54 - Preparation for Overhaul; ENGINE STAND
ME(H4DOTC)-53 MECHANICAL Preparation for Overhaul 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it inthe ST shown below.ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817000 ENGINE STAND 2) In this section the procedures d...
Page 56 - When installing new parts:
ME(H4DOTC)-55 MECHANICAL V-belt 3) Tighten the lock nut (A). Tightening torque: Lock nut (A): 22.6 N·m (2.3 kgf-m, 16.6 ft-lb) C: INSPECTION 1) Replace the belts, if cracks, fraying or wear isfound.2) Check the V-belt tension and adjust it if neces-sary by changing the generator installing positiona...