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Subaru impreza 2001 Service Manual

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2001 IMPREZA SERVICE MANUAL
ENGINE 1 SECTION
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(SOHC)
EC(SOHC)
IN(SOHC)
ME(SOHC)
EX(SOHC)
CO
LU
SP
IG(SOHC)
SC
EN(SOHC)
G1830GE2

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  • Page 1 EC(SOHC) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(SOHC) MECHANICAL ME(SOHC) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(SOHC) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING This manual includes the procedures...

  • Page 2: Table Of Contents

    COOLING Page General Description ..................2 Radiator Main Fan System................9 Radiator Sub Fan System .................17 Engine Coolant..................25 Water Pump ....................27 Thermostat ....................35 Radiator.....................37 Radiator Cap .....................45 Radiator Main Fan and Fan Motor ............46 Radiator Sub Fan and Fan Motor..............48 Reservoir Tank..................50 Coolant Filler Tank ..................51 Engine Cooling System Trouble in General ..........52...

  • Page 3: General Description

    GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Model Non-turbo Turbo Electric fan + Forced engine coolant circulation sys- Cooling system 1.6AT: Approx. 7.3 (7.71, 6.42) 1.6MT: Approx. 7.4 (7.82, 6.51) Approx. 7.7 2 (US qt, Imp qt) Total engine coolant capacity 2.0AT: Approx.
  • Page 4 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP • NON-TURBO MODEL H2M2354A Water pump ASSY Gasket Tightening torque: N·m (kgf-m, ft-lb) Gasket Thermostat cover T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Heater by-pass hose Thermostat T2: 6.4 (0.65, 4.7) CO-3...
  • Page 5 GENERAL DESCRIPTION COOLING • TURBO MODEL H2M1785B Thermostat case Header by-pass hose Tightening torque: N·m (kgf-m, ft-lb) Gasket Coolant filler tank by-pass hose T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Thermostat Water by-pass pipe Water pump ASSY T2: 6.4 (0.65, 4.7) Gasket CO-4...
  • Page 6 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN • NON-TURBO MODEL (12) (10) (15) (11) (13) (24) (16) (17) (16) (14) (18) (21) (16) (16) (16) (23) (19) (20) (16) (22) EN0068 Radiator lower cushion (13) Main fan shroud (23) Radiator lower bracket Radiator (14)
  • Page 7 GENERAL DESCRIPTION COOLING • TURBO MODEL (21) (20) (19) (11) (10) (13) (16) (12) (14) (18) (15) (17) (23) EN0069 Radiator lower cushion (10) Over flow pipe (19) Engine coolant filler tank Radiator (11) Sub fan shroud (20) Engine coolant filler tank cap Radiator upper cushion (12) Radiator sub fan...
  • Page 8 GENERAL DESCRIPTION COOLING 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.
  • Page 9 GENERAL DESCRIPTION COOLING D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977300 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. B2M4157 499207100 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket. (Non-turbo LH side only) WRENCH B2M3859 499207400...

  • Page 10: Radiator Main Fan System

    RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY SBF-1 No.3 IGNITION SWITCH SBF-4 No.17 AIR CONDITIONING No.18 AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR...
  • Page 11 RADIATOR MAIN FAN SYSTEM COOLING 2. TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.18 No.17 LHD : 2 RHD : 7 LHD : 12 RHD : 17 B137 ECM SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 SUB FAN MAIN FAN...
  • Page 12 RADIATOR MAIN FAN SYSTEM COOLING B: INSPECTION 1. NON-TURBO MODEL DETECTING CONDITION: • Vehicle speed is below 19 km/h (12 MPH). Condition: TROUBLE SYMPTOM: • Engine coolant temperature is above 95°C • Radiator main fan does not rotate under the (203°F).
  • Page 13 Contact with your Check poor contact in connector between main nector between main fan motor tact connector. Subaru distributor. fan and ECM. and ECM? NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-12...
  • Page 14 RADIATOR MAIN FAN SYSTEM COOLING 2. TURBO MODEL TROUBLE SYMPTOM: • Radiator main fan does not rotate under the DETECTING CONDITION: above conditions. Condition: • Radiator main fan does not rotate at high speed • Engine coolant temperature is above 96°C when the following conditions are both met: (205°F).
  • Page 15 (F66) No. 28 — (B137) No. 17: CHECK POOR CONTACT. Is there poor contact in con- Repair poor con- Contact with your Check poor contact in connector between main nector between main fan motor tact connector. Subaru distributor. fan and ECM. and ECM? CO-14...
  • Page 16 RADIATOR MAIN FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 18. Go to step 20. TOR. CAUTION: Be careful not to overheat engine during re- pair. 1)Turn ignition switch to OFF.
  • Page 17 Contact with your Check poor contact in connector between main nector between main fan motor tact connector. Subaru distributor. fan and ECM. and ECM? NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-16...

  • Page 18: Radiator Sub Fan System

    RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY SBF-1 No.3 IGNITION SWITCH SBF-4 No.17 AIR CONDITIONING No.18 AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR...
  • Page 19 RADIATOR SUB FAN SYSTEM COOLING 2. TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.18 No.17 LHD : 2 RHD : 7 LHD : 12 RHD : 17 B137 ECM SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 SUB FAN MAIN FAN...
  • Page 20 RADIATOR SUB FAN SYSTEM COOLING B: INSPECTION • A/C switch is turned ON. • Vehicle speed is below 19 km/h (12 MPH). 1. NON-TURBO MODEL Condition (2): • Engine coolant temperature is above 100°C NOTE: (212°F). System for A/C equipped vehicles only. •...
  • Page 21 Contact with your Check poor contact in connnector between sub nector between sub fan motor tact connector. Subaru distributor. fan and ECM. and ECM? NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-20...
  • Page 22 RADIATOR SUB FAN SYSTEM COOLING 2. TURBO MODEL TROUBLE SYMPTOM: • Radiator sub fan does not rotate under the above DETECTING CONDITION: conditions. Condition: • Radiator sub fan does not rotate at high speed • Engine coolant temperature is above 96°C when the following conditions are both met: (205°F).
  • Page 23 (F28) No. 6 — (B137) No. 17: CHECK POOR CONTACT. Is there poor contact in con- Repair poor con- Contact with your Check poor contact in connector between sub nector between sub fan motor tact connector. Subaru distributor. fan and ECM. and ECM? CO-22...
  • Page 24 RADIATOR SUB FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? Go to step 18. Go to step 20. TOR. CAUTION: Be careful not to overheat engine during re- pair. 1)Turn ignition switch to OFF.
  • Page 25 Contact with your Check poor contact in connector between sub nector between sub fan motor tact connector. Subaru distributor. fan and ECM. and ECM? NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-24...

  • Page 26: Engine Coolant

    1) Fill engine coolant into radiator up to filler neck position. The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Coolant capacity (fill up to “FULL” level): Measuring the temperature and specific gravity of 1.62 AT model...
  • Page 27 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU cool- ant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

  • Page 28: Water Pump

    WATER PUMP COOLING 5. Water Pump 6) Disconnect radiator outlet hose and heater hose from water pump. A: REMOVAL 1. NON-TURBO MODEL 1) Disconnect ground cable from the battery. EN0112 7) Lower the vehicle. 8) Remove air intake duct. G6M0095 2) Lift-up the vehicle.
  • Page 29 WATER PUMP COOLING 13) Remove timing belt. 18) Remove tensioner bracket. <Ref. to ME(SOHC)-46, TIMING BELT, REMOV- AL, Timing Belt Assembly.> 14) Remove automatic belt tension adjuster. H2M2380 19) Disconnect heater hose from water pump. 20) Remove water pump. H2M2375 15) Remove belt idler No.
  • Page 30 WATER PUMP COOLING 2. TURBO MODEL 12) Remove reservoir tank. WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on the lift. 2) Disconnect ground cable from the battery. S2M0931 13) Remove radiator main fan and sub fan assem- blies.
  • Page 31 WATER PUMP COOLING 21) Remove left-hand belt cover No. 2. Tightening torque: First: 12 N·m (1.2 kgf-m, 8.7 ft-lb) Second: 12 N·m (1.2 kgf-m, 8.7 ft-lb) S2M1162 22) Remove tensioner bracket. S2M0760A 2) Install left-hand belt cover No. 2. Tightening torque: 5 N·m (0.5 kgf-m, 3.6 ft-lb) S2M1163 23) Disconnect heater hose from water pump.
  • Page 32 WATER PUMP COOLING 4) Install left-hand camshaft sprockets by using ST. 11) Connect over flow hose. ST 4992707100 CAMSHAFT SPROCKET WRENCH Tightening torque: 78 N·m (8.0 kgf-m, 57.9 ft-lb) B2M2925 12) Install air intake duct. B2M2039A 5) Install belt idler No. 2. Tightening torque: 39 N·m (4.0 kgf-m, 28.9 ft-lb) EN0063...
  • Page 33 WATER PUMP COOLING 15) Connect connectors to radiator main fan (A) 2. TURBO MODEL and sub fan (B) motors. 1) Install water pump onto left-hand cylinder head. CAUTION: • Replace gasket with a new one. • When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
  • Page 34 WATER PUMP COOLING 4) Install left-hand camshaft sprockets by using ST. 12) Install reservoir tank. ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque: 98 N·m (10.0 kgf-m, 72.4 ft-lb) S2M0931 13) Connect over flow hose. 14) Lift-up the vehicle. 15) Connect radiator outlet hose (A) and heater hose (B) to water pump.
  • Page 35 WATER PUMP COOLING 22) Fill coolant. <Ref. to CO-25, FILLING OF EN- GINE COOLANT, REPLACEMENT, Engine Cool- ant.> C: INSPECTION 1) Check water pump bearing for smooth rotation. 2) Check water pump pulley for abnormalities. 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley.

  • Page 36: Thermostat

    THERMOSTAT COOLING 6. Thermostat 6) Remove thermostat cover and gasket, and pull out the thermostat. A: REMOVAL 1) Lift-up the vehicle. 2) Remove under cover. 3) Drain engine coolant completely. <Ref. to CO- 25, DRAINING OF ENGINE COOLANT, RE- PLACEMENT, Engine Coolant.> G2M0214 B: INSTALLATION 1) Install the thermostat in the water pump, and in-...
  • Page 37 THERMOSTAT COOLING C: INSPECTION Replace the thermostat if the valve does not close completely at an ambient temperature or if the fol- lowing test shows unsatisfactory results. Immerse the thermostat and a thermometer in wa- ter. Raise water temperature gradually, and mea- sure the temperature and valve lift when the valve begins to open and when the valve is fully opened.

  • Page 38: Radiator

    RADIATOR COOLING 7. Radiator 5) Disconnect radiator outlet hose from thermostat cover. A: REMOVAL 1. NON-TURBO MODEL 1) Disconnect battery ground cable. EN0112 6) Disconnect ATF cooler hoses from radiator. (AT vehicles only) G6M0095 2) Lift-up the vehicle. 3) Drain engine coolant completely. <Ref. to CO- 25, DRAINING OF ENGINE COOLANT, RE- PLACEMENT, Engine Coolant.>...
  • Page 39 RADIATOR COOLING 10) Remove reservoir tank. 15) Lift radiator up and away from vehicle. B2M2926 B2M2933 11) Disconnect radiator inlet hose from engine. B2M2930 12) Remove radiator upper brackets. B2M2931 13) Detach power steering hose from the clip on the radiator. B2M2932 14) While slightly lifting radiator, slide it to left.
  • Page 40 RADIATOR COOLING 2. TURBO MODEL 7) Disconnect oil cooler hoses from oil cooler pipes. (if equipped) WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. S2M1743 8) Disconnect radiator outlet hose from thermostat cover.
  • Page 41 RADIATOR COOLING 13) Remove V-belt covers. B: INSTALLATION 1. NON-TURBO MODEL 1) Attach radiator mounting cushions to holes on the vehicle. EN0048 14) Disconnect radiator inlet hose (A) and water tank hose (B) from radiator. B2M2934 2) Install radiator while fitting radiator pins to cush- ions.
  • Page 42 RADIATOR COOLING 4) Attach power steering hose to the radiator. 9) Connect ATF cooler hoses. (AT vehicles only) EN0102 B2M2932 5) Connect radiator inlet hose. 10) Connect connectors to radiator main fan motor (A) and sub fan motor (B). B2M2930 6) Install reservoir tank.
  • Page 43 RADIATOR COOLING 14) Connect battery ground cable. 2. TURBO MODEL 1) Attach radiator mounting cushions to holes on the vehicle. G6M0095 15) Fill coolant. <Ref. to CO-25, FILLING OF EN- GINE COOLANT, REPLACEMENT, Engine Cool- B2M2934 ant.> 2) Install radiator brackets and tighten bolts. 16) Check ATF level.
  • Page 44 RADIATOR COOLING 4) Install reservoir tank. 9) Connect radiator outlet hose. Tightening torque: 4.9±1.5 N·m (0.50±0.15 kgf-m, 3.6±1.1 ft-lb) EN0107 10) Install under cover. 11) Lower the vehicle. S2M0934 12) Install V-belt covers. 5) Connect over flow hose. 6) Lift-up the vehicle. 7) Connect connectors to radiator main fan mo- tor(A) and sub fan motor(B).
  • Page 45 RADIATOR COOLING C: INSPECTION 1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. • Non-Turbo model B2M3127 • Turbo model EN0116 2) Apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) to radiator to check if: (1) Engine coolant leaks at/around radiator.

  • Page 46: Radiator Cap

    RADIATOR CAP COOLING 8. Radiator Cap A: INSPECTION 1) Attach radiator cap to tester. G2M0223 2) Increase pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Standard pressure: 93 —...

  • Page 47: Radiator Main Fan And Fan Motor

    RADIATOR MAIN FAN AND FAN MOTOR COOLING 9. Radiator Main Fan and Fan 7) Disconnect over flow hose. Motor A: REMOVAL 1) Disconnect battery ground cable. B2M2925 8) Remove over flow pipe. (Turbo model) 9) Remove reservoir tank. G6M0095 2) Lift-up the vehicle. 3) Remove under cover.
  • Page 48 RADIATOR MAIN FAN AND FAN MOTOR COOLING B: INSTALLATION 3) Remove bolts which install fan motor onto shroud. Install in the reverse order of removal. NOTE: When the main fan motor assembly cannot be in- stalled as is, loosen the sub fan motor assembly securing bolts to install it.

  • Page 49: Radiator Sub Fan And Fan Motor

    RADIATOR SUB FAN AND FAN MOTOR COOLING 10.Radiator Sub Fan and Fan 8) Remove over flow pipe. (Turbo model) 9) Remove radiator sub fan shroud through the un- Motor der side of vehicle. A: REMOVAL 1) Disconnect battery ground cable. B2M2937 B: INSTALLATION Install in the reverse order of removal.
  • Page 50 RADIATOR SUB FAN AND FAN MOTOR COOLING 3) Remove bolts which install fan motor onto shroud. EN0121 D: ASSEMBLY Assemble in the reverse order of disasssembly. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) EN0121 Tightening torque: 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) EN0123 CO-49...

  • Page 51: Reservoir Tank

    RESERVOIR TANK COOLING 11.Reservoir Tank A: REMOVAL 1) Disconnect over flow hose from radiator filler neck position. 2) Remove bolts which install reservoir tank onto radiator main fan shroud. 3) Remove reservoir tank. B2M2926 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.9N·m (0.50 kgf-m, 3.6 ft-lb) B2M2926...

  • Page 52: Coolant Filler Tank

    COOLANT FILLER TANK COOLING 12.Coolant Filler Tank B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) The radiator is pressurized. Wait until engine T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) cools down before working on the radiator.

  • Page 53: Engine Cooling System Trouble In General

    ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 13.Engine Cooling System Trouble in General A: INSPECTION Trouble Possible cause Corrective action Replenish engine coolant, inspect for leakage, and a. Insufficient engine coolant repair. b. Loose timing belt Repair or replace timing belt tensioner. c.

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