Subaru Impreza 2004 User manual

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)

LUBRICATION

LU(H4DOTC)

Page

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

2. Oil Pressure System ...................................................................................6

3. Engine Oil....................................................................................................8

4. Oil Pump ...................................................................................................10

5. Oil Pan and Strainer..................................................................................14

6. Oil Pressure Switch...................................................................................18

7. Engine Oil Cooler ......................................................................................19

8. Engine Oil Filter.........................................................................................20

9. Engine Lubrication System Trouble in General.........................................21

LU(H4DOTC)-2

LUBRICATION

General Description

1. General Description

A: SPECIFICATIONS

Lubrication method Forced lubrication

Oil pump

Pump type Trochoid type

Number of teeth Inner rotor 9

Outer rotor 10

Outer rotor diameter ×thickness 78 ×10 mm (3.07 ×0.39 in)

Tip clearance between inner and outer rotor STANDARD 0.04 —0.14 mm (0.0016 —0.0055 in)

LIMIT 0.18 mm (0.0071 in)

Side clearance between inner rotor and pump

case

STANDARD 0.02 —0.07 mm (0.0008 —0.0028 in)

LIMIT 0.12 mm (0.0047 in)

Case clearance between outer rotor and pump

case

STANDARD 0.10 —0.175 mm (0.0039 —0.0069 in)

LIMIT 0.20 mm (0.0079 in)

Capacity at 80°C (176°F)

600 rpm

Discharge

pressure 98 kPa (1.0 kg/cm2, 14 psi)

Discharge

quantity 4.6 2(4.9 US qt, 4.0 Imp qt)/min.

5,000 rpm

Discharge

pressure 294 kPa (3.0 kg/cm2, 43 psi)

Discharge

quantity 47.0 2(49.7 US qt, 41.4 Imp qt)/min.

Relief valve operation pressure 588 kPa (6.0 kg/cm2, 85 psi)

Oil filter

Type Full-flow filter type

Filtration area 800 cm2(124 sq in)

By-pass valve opening pressure 160 kPa (1.63 kg/cm2, 23.2 psi)

Outer diameter ×width 68 ×65 mm (2.68 ×2.56 in)

Oil filter to engine thread size M 20 ×1.5

Oil pressure

switch

Type Immersed contact point type

Working voltage —wattage 12 V —3.4 W or less

Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)

Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)

Oil capacity (at replacement) 4.0 2(4.2 US qt, 3.5 Imp qt)

LU(H4DOTC)-3

LUBRICATION

General Description

B: COMPONENT

(1) Plug (13) Oil cooler (Model with oil cooler) (27) Metal gasket

(2) Gasket (14) O-ring (28) Drain plug

(3) Relief valve spring (15) Oil pump ASSY (29) O-ring

(4) Relief valve (16) Oil pressure switch (30) Oil filler cap

(5) Oil seal (17) Oil filler duct

(6) Oil pump case (18) O-ring Tightening torque: N·m (kgf-m, ft-lb)

(7) Inner rotor (19) Rocker cover T1: 5 (0.5, 3.6)

(8) Outer rotor (20) Baffle plate T2: 6.4 (0.65, 4.7)

(9) Oil pump cover (21) O-ring T3: 10 (1.0, 7.0)

(10) Oil filter (22) Oil strainer T4: 44 (4.5, 32.5)

(11) Oil cooler connector (Model with

oil cooler)

(23) Gasket T5: 69 (7.0, 50.9)

(24) Oil level gauge guide T6: 25 (2.5, 18.1)

(12) Water by-pass pipe (Model with oil

cooler)

(25) Oil pan T7: 54 (5.5, 40)

(26) Oil level gauge

LU-00183

(15)

(14)

T1 T5 T3

T1 T1

(29)

(9)

(8)

(7)

(6)

(13)

(12) (22)

(21)

(23)

(24)

(20)

(19)

(18)

(17)

(16)

(26)

(25)

(11)

(10)

(28) (27)

(5)

(4)

(3)

(2)

(1)

(30)

LU(H4DOTC)-4

LUBRICATION

General Description

C: CAUTION

•Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust or dirt.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly, and replacement.

•Be careful not to burn your hands, because each

part in the vehicle is hot after running.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Place shop jacks or safety stands at the specified

points.

•Before disconnecting electrical connectors of

sensors or units, be sure to disconnect the ground

cable from battery.

D: PREPARATION TOOL

1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977400 CRANKSHAFT

PULLEY

WRENCH

Used for stopping rotation of crankshaft pulley

when loosening and tightening crankshaft pulley

bolt.

498547000 OIL FILTER

WRENCH

•Used for removing and installing oil filter.

•For outer diameter 80 mm (3.15 in) filter.

18332AA000 OIL FILTER

WRENCH

•Used for removing and installing oil filter.

•For outer diameter 68 mm (2.68 in) filter.

ST-499977400

ST-498547000

ST18332AA000

LU(H4DOTC)-5

LUBRICATION

General Description

18332AA010 OIL FILTER

WRENCH

•Used for removing and installing oil filter.

•For outer diameter 65 mm (2.56 in) filter.

499587100 OIL SEAL

INSTALLER

Used for installing oil pump oil seal.

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ST18332AA010

ST-499587100

LU(H4DOTC)-6

LUBRICATION

Oil Pressure System

2. Oil Pressure System

A: WIRING DIAGRAM

LU-00207

B37

B21

E11

i10

1 2 3 4 5 6 7 8 9

10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 21

1234 56

10 11 12 13 14 15

23 30

19 20

22 26 27 28 29

24 31

B21

1 2

5 6 7 8

13 14 15 16

10 11 12

3 4

17 18 19 20

No.14 SBF-4 SBF-1

B72

i10

i11

123456789

BATTERY

IGNITION

SWITCH

COMBINATION

METER

OIL PRESSURE

WARNING LIGHT

OIL PRESSURE

SWITCH

LU(H4DOTC)-7

LUBRICATION

Oil Pressure System

B: INSPECTION

Step Check Yes No

1 CHECK COMBINATION METER.

1)Turn the ignition switch to ON. (engine OFF)

2)Check other warning lights.

Does the warning lights go on? Go to step 2. Repair or replace

the combination

meter. <Ref. to

IDI-3, INSPEC-

TION, Combina-

tion Meter

System.>

2 CHECK HARNESS CONNECTOR BETWEEN

COMBINATION METER AND OIL PRES-

SURE SWITCH.

1)Turn the ignition switch to OFF.

2)Disconnect the connector from oil pressure

switch.

3)Turn the ignition switch ON.

4)Measure the voltage of harness between the

combination meter connector and chassis

ground.

Connector & terminal

(E11) No. 1 (+) —Chassis ground (–):

Is the voltage more than 10 V? Replace the oil

pressure switch.

Go to step 3.

3 CHECK COMBINATION METER.

1)Turn the ignition switch to OFF.

2)Remove the combination meter.

3)Measure the resistance of combination

meter.

Terminals

No. C7 —No. B2:

Is the resistance less than 10

Ω?

Replace the har-

ness connector

between combina-

tion meter and oil

pressure switch.

Repair or replace

the combination

meter.

LU(H4DOTC)-8

LUBRICATION

Engine Oil

3. Engine Oil

A: INSPECTION

1) Park the vehicle on a level surface.

2) Remove the oil level gauge and wipe it clean.

3) Reinsert the level gauge all the way. Be sure that

the level gauge is correctly inserted and in proper

orientation.

4) Remove it again and note the reading. If the en-

gine oil level is below the “L”line, add oil to bring

the level up to “F”line.

5) After turning off the engine, wait a few minutes

for oil to drain back into the oil pan before checking

the level.

6) Just after driving or while the engine is warm, en-

gine oil level may show in the range between the

“F”line and notch mark. This is caused by thermal

expansion of engine oil.

NOTE:

To prevent overfilling the engine oil, do not add oil

above “F”line when the engine is cold.

B: REPLACEMENT

1) Open the engine oil filler cap for quick draining of

engine oil.

2) Remove the clips of service hole cover.

3) Drain the engine oil by loosening the engine oil

drain plug.

4) Replace the drain plug gasket.

5) Tighten the engine oil drain plug after draining

engine oil.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

6) Install the service hole cover.

7) Fill engine oil through the filler pipe up to upper

level on level gauge. Make sure that the vehicle is

placed level when checking oil level. Use the en-

gine oil of proper quality and viscosity, selected in

accordance with the table in figure.

(A) Oil level gauge

(B) Engine oil filler cap

(D) Lower level

(E) Approx. 1.0 2(1.1 US qt, 0.9 Imp qt)

LU-00138

(A) (B)

(C)

(D)

(E)

LU-00185

LU-00186

LU(H4DOTC)-9

LUBRICATION

Engine Oil

Recommended oil

API classification SL, SJ with the “Energy

Conserving”logo is printed, or SH (if you

cannot obtain the oil with SL, SJ or SH

grades, you may use SG grade “ENERGY

CONSERVING”oil.)

ACEA specification, A1, A2 or A3

CCMC specification, G4 or G5

New API certification mark (Star burst mark)

label is on the container.

Engine oil capacity:

Upper level

4.0 2(4.2 US qt, 3.5 Imp qt)

Lower level

3.0 2(3.2 US qt, 2.6 Imp qt)

The proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and

thus increasing cranking speed.

CAUTION:

When replenishing oil, it does not matter if the

oil to be added is a different brand from that in

the engine; however, use oil having the API

classification and SAE viscosity No. designat-

ed by SUBARU.

NOTE:

If the vehicle is used in areas with very high temper-

atures or for other heavy duty applications, the fol-

lowing viscosity oils may be used: API

classification: SL or SJ or SH

SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-

50.

8) Close the engine oil filler cap.

9) Start the engine and warm it up for a time.

10) After the engine stops, recheck the oil level. If

necessary, add engine oil up to the upper level on

level gauge.

(1) SAE Viscosity No. and Applicable Temperature

(2) PREFERRED

LU-00076

4030150-15-20-30( C)

104865932

10W-30,10W-40

5-4-22( F)

5W-30 (2)

SAE (1)

(A) Oil level gauge

(B) Engine oil filler cap

(D) Lower level

(E) Approx. 1.0 2(1.1 US qt, 0.9 lmp qt)

LU-00138

(A) (B)

(C)

(D)

(E)

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