Subaru IMPREZA 2004 Service Manual
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Subaru IMPREZA 2004 Service Manual

Subaru IMPREZA 2004 Service Manual

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2004 IMPREZA SERVICE MANUAL

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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
LUBRICATION
SPEED CONTROL SYSTEMS
IGNITION
STARTING/CHARGING SYSTEMS
ENGINE (DIAGNOSTICS)
FU(H4DOTC)
EC(H4DOTC)
IN(H4DOTC)
ME(H4DOTC)
EX(H4DOTC)
CO(H4DOTC)
LU(H4DOTC)
SP(H4DOTC)
IG(H4DOTC)
SC(H4DOTC)
EN(H4DOTC)(diag)
G1870GE3

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Summary of Contents for Subaru IMPREZA 2004

  • Page 1: Engine Section

    EC(H4DOTC) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4DOTC) MECHANICAL ME(H4DOTC) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4DOTC) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4DOTC)

  • Page 2: Table Of Contents

    LUBRICATION LU(H4DOTC) Page General Description ..................2 Oil Pressure System ...................6 Engine Oil....................8 Oil Pump ....................10 Oil Pan and Strainer..................14 Oil Pressure Switch...................18 Engine Oil Cooler ..................19 Engine Oil Filter..................20 Engine Lubrication System Trouble in General.........21...

  • Page 3: General Description

    General Description LUBRICATION 1. General Description A: SPECIFICATIONS Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 10 mm (3.07 × 0.39 in) STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in) Tip clearance between inner and outer rotor LIMIT 0.18 mm (0.0071 in)
  • Page 4 General Description LUBRICATION B: COMPONENT (16) (17) (30) (15) (18) (14) (19) (20) (29) (21) (13) (23) (26) (12) (22) (24) (11) (10) (25) (27) (28) LU-00183 Plug (13) Oil cooler (Model with oil cooler) (27) Metal gasket Gasket (14) O-ring (28) Drain plug...
  • Page 5 General Description LUBRICATION C: CAUTION • Be careful not to burn your hands, because each part in the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
  • Page 6 General Description LUBRICATION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18332AA010 OIL FILTER • Used for removing and installing oil filter. WRENCH • For outer diameter 65 mm (2.56 in) filter. ST18332AA010 499587100 OIL SEAL Used for installing oil pump oil seal. INSTALLER ST-499587100 LU(H4DOTC)-5...

  • Page 7: Oil Pressure System

    Oil Pressure System LUBRICATION 2. Oil Pressure System A: WIRING DIAGRAM IGNITION BATTERY SWITCH No.14 SBF-4 SBF-1 COMBINATION METER OIL PRESSURE SWITCH 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 19 20...
  • Page 8 Oil Pressure System LUBRICATION B: INSPECTION Step Check CHECK COMBINATION METER. Does the warning lights go on? Go to step 2. Repair or replace 1)Turn the ignition switch to ON. (engine OFF) the combination 2)Check other warning lights. meter. <Ref. to IDI-3, INSPEC- TION, Combina- tion Meter...

  • Page 9: Engine Oil

    Engine Oil LUBRICATION 3. Engine Oil B: REPLACEMENT 1) Open the engine oil filler cap for quick draining of A: INSPECTION engine oil. 1) Park the vehicle on a level surface. 2) Remove the clips of service hole cover. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way.
  • Page 10 API classification and SAE viscosity No. designat- ed by SUBARU. NOTE: If the vehicle is used in areas with very high temper-...

  • Page 11: Oil Pump

    Oil Pump LUBRICATION 4. Oil Pump 7) Remove the crankshaft position sensor. A: REMOVAL 1) Disconnect the ground cable from battery. LU-00046 8) Remove the V-belts. <Ref. to ME(H4DOTC)-54, REMOVAL, V-belt.> FU-00009 9) Remove the rear side V-belt tensioner. 2) Lift-up the vehicle. 3) Remove the under cover.
  • Page 12 Oil Pump LUBRICATION 13) Remove the crankshaft sprocket. Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent ( A ) LU-00014 14) Remove the bolts which install the oil pump LU-00017 onto cylinder block. 2) Replace the O-ring (A) with a new one. 3) Apply a coat of engine oil to the inside of oil seal.
  • Page 13 Oil Pump LUBRICATION D: ASSEMBLY CAUTION: Before disassembling the oil pump, remove the 1) Install the front oil seal by using ST. relief valve. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new oil seal. LU-00021 2) Apply a coat of engine oil to the inner and outer rotors.
  • Page 14 Oil Pump LUBRICATION E: INSPECTION 3. SIDE CLEARANCE Measure the clearance between the oil pump inner 1. TIP CLEARANCE rotor and pump cover. If clearance exceeds the lim- Measure the tip clearance of rotors. If clearance ex- it, replace the rotor or pump body. ceeds the limit, replace the rotors as a matched set.

  • Page 15: Oil Pan And Strainer

    Oil Pan and Strainer LUBRICATION 5. Oil Pan and Strainer 7) Remove the pitching stopper. A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the front wheels. 3) Disconnect the ground cable from battery. ME-00213 8) Remove the radiator upper brackets. FU-00009 4) Disconnect the connector from mass air flow sensor.
  • Page 16 Oil Pan and Strainer LUBRICATION 13) Remove the nuts which install the front cushion B: INSTALLATION rubber onto front crossmember. CAUTION: Before installing the oil pan, clean sealant from oil pan and engine block. 1) Install the baffle plate. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) LU-00030 14) Remove the bolts which install the oil pan on...
  • Page 17 Oil Pan and Strainer LUBRICATION 4) Tighten the bolts which install the oil pan onto 10) Install the pitching stopper. engine block. Tightening torque: Tightening torque: T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 5 N·m (0.5 kgf-m, 3.6 ft-lb) T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb) LU-00031 ME-00218 5) Lower the engine onto front crossmember.
  • Page 18 Oil Pan and Strainer LUBRICATION 15) Install the front wheels. 16) Connect the battery ground cable to battery. FU-00009 17) Fill engine oil. <Ref. to LU(H4DOTC)-8, IN- SPECTION, Engine Oil.> C: INSPECTION By visual check, make sure the oil pan, oil strainer, oil strainer stay and baffle plate are not damaged.

  • Page 19: Oil Pressure Switch

    Oil Pressure Switch LUBRICATION 6. Oil Pressure Switch 2) Install the oil pressure switch onto engine block. Tightening torque: A: REMOVAL 25 N·m (2.5 kgf-m, 18.1 ft-lb) 1) Remove the generator from bracket. <Ref. to SC(H4SO)-13, REMOVAL, Generator.> 2) Disconnect the terminal from oil pressure switch. LU-00037 3) Connect the terminal of oil pressure switch.

  • Page 20: Engine Oil Cooler

    Engine Oil Cooler LUBRICATION 7. Engine Oil Cooler B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Lift-up the vehicle. T1: 54 N·m (5.5 kgf-m, 40 ft-lb) 2) Remove the under cover. T2: 69 N·m (7.0 kgf-m, 50.6 ft-lb) 3) Drain the engine oil.

  • Page 21: Engine Oil Filter

    Engine Oil Filter LUBRICATION 8. Engine Oil Filter A: REMOVAL 1) Remove the under cover. 2) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH (Outer diameter: 80 mm (3.15 in)) ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) LU-00190...

  • Page 22: Engine Lubrication System Trouble In General

    Engine Lubrication System Trouble in General LUBRICATION 9. Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists. Trouble Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace.
  • Page 23 Engine Lubrication System Trouble in General LUBRICATION LU(H4DOTC)-22...

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