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Subaru LEGACY 2003 Service Manual

Engine section 1
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2003 LEGACY SERVICE MANUAL

ENGINE SECTION 1

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)
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
FU(H4SO)
EC(H4SO)
IN(H4SO)
ME(H4SO)
EX(H4SO)
CO(H4SO)
LU(H4SO)
SP(H4SO)
IG(H4SO)
SC(H4SO)
EN(H4SO)
FU(H4SOw/oOBD)
EC(H4SOw/oOBD)
IN(H4SOw/oOBD)
ME(H4SOw/oOBD)
EX(H4SOw/oOBD)
CO(H4SOw/oOBD)
G2300GE2

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Summary of Contents for Subaru LEGACY 2003

  • Page 1: Engine Section

    EC(H4SO) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO) MECHANICAL ME(H4SO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4SO)
  • Page 2 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SOw/oOBD) SPEED CONTROL SYSTEMS SP(H4SOw/oOBD) IGNITION IG(H4SOw/oOBD) STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD) ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD) G2300GE2...

  • Page 3: Table Of Contents

    Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description ..................6 Electrical Components Location..............9 Engine Control Module (ECM) I/O Signal ..........18 Subaru Select Monitor................21 Read Diagnostic Trouble Code (DTC) ............24 Inspection Mode..................26 Clear Memory Mode..................28 Compulsory Valve Operation Check Mode ..........29 Engine Malfunction Indicator Lamp (MIL) ..........30...

  • Page 4: Basic Diagnostic Procedure

    2) Connect the Subaru Select Monitor to data Repair the trouble NOTE: link connector. cause. <Ref. to 3) Turn ignition switch to ON and the Subaru EN(H4SOw/ shown on display Select Monitor switch to ON. oOBD)-59, Diag- although the MIL il- 4) Read DTC on the Subaru Select Monitor.
  • Page 5 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. WITHOUT SUBARU SELECT MONITOR • Be sure to check again from the beginning in order to prevent secondary trouble caused by CAUTION: repair work. • Check the connector while it is connected un- less specified otherwise.

  • Page 6: Check List For Interview

    CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer's name Engine no. Date of sale Fuel brand Date of repair Odometer reading...
  • Page 7 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST NO. 2 Check the following items about the vehicle's state when MIL turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. Yes/ No Low fuel warning light Charge indicator light...

  • Page 8: General Description

    GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and resis- A: CAUTION tance inside the passenger compartment. 1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay.
  • Page 9 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) • The antenna feeder must be placed as far 2. ENGINE GROUNDING apart as possible from the ECM and MFI har- Make sure the engine grounding terminal is proper- ness. ly connected to the engine. • Carefully adjust the antenna for correct matching.
  • Page 10 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) ST24082AA210 22771AA030 SELECT MONI- Troubleshooting for electrical systems. TOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) •...

  • Page 11: Electrical Components Location

    ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. MODULE • LHD model ( 1 ) ( 4 ) ( 3 ) ( 5 ) ( 2 ) EN-01013 • RHD model ( 4 ) ( 3 ) ( 5 ) ( 2 ) ( 1 )
  • Page 12 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 2 ) ( 1 ) EN-00845 EN-01016 ( 3 ) ( 5 ) ( 4 ) EN-01015 EN-01017 EN(H4SOw/oOBD)-10...
  • Page 13 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. SENSOR ( 7 ) ( 3 ) ( 2 ) ( 4 ) ( 1 ) ( 6 ) ( 5 ) EN-01018 (1) Engine coolant temperature sen- (3) Throttle position sensor (7) Vehicle speed sensor (4) Knock sensor (2) Intake air temperature and pres- (5) Crankshaft position sensor...
  • Page 14 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01019 EN-01023 ( 3 ) ( 4 ) EN-01020 EN-01024 ( 6 ) ( 5 ) EN-01021 EN-01025 ( 7 ) EN-01022 EN(H4SOw/oOBD)-12...
  • Page 15 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 8 ) EN-01026 (8) Oxygen sensor (With catalyst model) ( 8 ) EN-01027 EN(H4SOw/oOBD)-13...
  • Page 16 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS ( 2 ) ( 1 ) ( 4 ) ( 3 ) EN-01028 (1) Purge control solenoid valve (3) Ignition coil and ignitor ASSY (4) CO resistor (Without catalyst (2) Idle air control solenoid valve model)
  • Page 17 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01031 EN-01029 ( 4 ) ( 3 ) EN-01030 EN-01032 EN(H4SOw/oOBD)-15...
  • Page 18 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • LHD model ( 1 ) ( 4 ) ( 3 ) ( 5 ) ( 2 ) EN-01033 • RHD model ( 4 ) ( 3 ) ( 5 ) ( 2 ) ( 1 ) EN-01034 (1) Fuel pump (2) Main relay...
  • Page 19 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01035 EN-01037 ( 3 ) EN-01036 EN(H4SOw/oOBD)-17...

  • Page 20: Engine Control Module (Ecm) I/O Signal

    ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 B136 25 24 26 25 24 EN-01038 EN(H4SOw/oOBD)-18...
  • Page 21 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note Engine ON tor No. (Idling) ON (Engine OFF) ±6 Signal (+) B135 Sensor output waveform Crankshaft position Signal (−) B135 — sensor Shield B135 —...
  • Page 22 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note tor No. Engine ON (Idling) ON (Engine OFF) Signal 1 B134 — 1 — 13 Waveform Idle air con- Signal 2 B134 — 1 — 13 Waveform trol sole- Signal 3...

  • Page 23: Subaru Select Monitor

    {Engine Control System} and EN-00039 press the [YES] key. 3) Press the [YES] key after displayed the informa- 4) Connect Subaru Select Monitor to data link con- tion of engine type. nector. 4) On the «Engine Diagnosis» display screen, se- (1) Data link connector (A) located in the lower lect the {1.
  • Page 24 Blower fan switch ON or OFF Light switch ON or OFF Idle switch signal ON or OFF *1: With catalyst model only *2: Without catalyst model only NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SOw/oOBD)-22...
  • Page 25 *1: On MT model, switch is turned ON when gear position is in neutral position. On AT model, switch is turned ON when shift position is in “P” or “N” position. *2: With catalyst model only NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SOw/oOBD)-23...

  • Page 26: Read Diagnostic Trouble Code (Dtc)

    Diagnostic Code(s)} and press the [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. • For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SOw/oOBD)-57, LIST, List of Diagnostic Trouble Code (DTC).>...
  • Page 27 READ DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) The CHECK ENGINE malfunction indicator lamp (MIL) flashes the code corresponding to the faulty parts. The long segment (1.3 seconds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies “one”. And middle segment (0.5 seconds ON) means OK code. NOTE: •...

  • Page 28: Inspection Mode

    (A) Test mode connector engine is operating at low speeds since this 2) Connect Subaru select monitor to data link con- may cause vehicle to jump off free rollers. nector. <Ref. to EN(H4SOw/oOBD)-9, LOCATION, •...
  • Page 29 ABS warning light, but • For detailed operation procedure, refer to the this indicates no malfunctions. When engine con- SUBARU SELECT MONITOR OPERATION MAN- trol diagnosis is finished, perform the ABS memory UAL. clearance procedure of self-diagnosis system.

  • Page 30: Clear Memory Mode

    4) On the «Engine Diagnosis» display screen, select the {Clear Memory} and press the [YES] key. 5) When the `Done' and `Turn Ignition Switch OFF' are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF.

  • Page 31: Compulsory Valve Operation Check Mode

    COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 10.Compulsory Valve Operation Check Mode A: OPERATION 1) Connect test mode connector at the lower por- tion of instrument panel (on the driver's side), to the side of the center console box. ( A ) EN-01040 (A) Test mode connector 2) Each valve functions when ignition switch is...

  • Page 32: Engine Malfunction Indicator Lamp (Mil)

    ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) 11.Engine Malfunction Indicator Lamp (MIL) A: PROCEDURE 1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(H4SOw/oOBD)-30, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> ↓ 2.
  • Page 33 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • TROUBLE SYMPTOM: • When ignition switch is turned ON (engine OFF), MIL does not come on. •...
  • Page 34 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. MIL illuminates. Repair poor con- Go to step 3. Does the MIL come on when shaking or pulling tact in ECM con- ECM connector and harness? nector. CHECK ECM CONNECTOR. ECM connector is connected Replace ECM.
  • Page 35 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. There is poor contact. Repair poor con- Replace bulb or Check poor contact in combination meter con- tact in combination combination nector. <Ref. to IDI-14, Combination Meter meter connector. meter.
  • Page 36 • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. • TROUBLE SYMPTOM: • Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD- II general scan tool display. • WIRING DIAGRAM: BATTERY No.
  • Page 37 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz. • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • Test mode connector circuit is in open. •...
  • Page 38 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value CHECK STATUS OF CHECK ENGINE MAL- MIL illuminates. Go to step 2. Repair the MIL cir- FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to 1) Turn ignition switch to OFF. EN(H4SOw/ 2) Disconnect test mode connector. oOBD)-31, 3) Turn ignition switch to ON.
  • Page 39 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK- ING AT A CYCLE OF 3 Hz. • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
  • Page 40 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value 5 Ω CHECK HARNESS BETWEEN ECM CON- Repair short circuit Replace ECM. NECTOR AND ENGINE GROUNDING TER- in harness <Ref. to MINAL. between ECM and FU(H4SOw/ 1) Turn ignition switch to OFF. test mode connec- oOBD)-42, Engine 2) Disconnect connector from ECM.

  • Page 41: Diagnostics For Engine Starting Failure

    DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 12.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN(H4SOw/oOBD)-40, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(H4SOw/oOBD)-43, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
  • Page 42 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.> •...
  • Page 43 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK DTC. Trouble code is stored in mem- Record DTC. Go to step 3. <Ref. to EN(H4SOw/oOBD)-24, OPERATION, ory. Repair the trouble Read Diagnostic Trouble Code (DTC).> cause. <Ref. to Is the trouble code stored in memory? <Ref. to EN(H4SOw/ EN(H4SOw/oOBD)-57, LIST, List of Diagnostic oOBD)-59, Diag-...
  • Page 44 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN BATTERY 10 V Go to step 8. Repair open circuit AND IGNITION SWITCH CONNECTOR. in harness 1) Ignition switch to OFF. between ignition 2) Disconnect connector from ignition switch. switch and battery.
  • Page 45 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.>...
  • Page 46 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK MAIN RELAY. Go to step 2. Replace main 1) Turn the ignition switch to OFF. relay. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No.
  • Page 47 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT VOLTAGE FROM ECM. 10 V Go to step 7. Replace ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector &...
  • Page 48 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.> •...
  • Page 49 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK IGNITION SYSTEM FOR SPARKS. Spark occurs. Check fuel pump Go to step 2. 1) Remove plug cord cap from each spark system. <Ref. to plug. EN(H4SOw/ 2) Install new spark plug on plug cord cap. oOBD)-50, FUEL PUMP CIRCUIT, CAUTION:...
  • Page 50 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR IGNITION COIL 10 V Go to step 7. Replace ignition & IGNITOR ASSEMBLY. coil & ignitor Check if voltage varies synchronously with assembly. engine speed when cranking, while monitoring voltage between ignition coil &...
  • Page 51 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND IG- 1 MΩ Go to step 12. Repair ground NITION COIL & IGNITOR ASSEMBLY CON- short circuit in har- NECTOR. ness between Measure resistance of harness between ECM ECM and ignition and chassis ground.
  • Page 52 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) E: FUEL PUMP CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.> •...
  • Page 53 INJECTOR CIR- CUIT, Diagnostics NOTE: for Engine Start- Fuel pump operation check can also be execut- ing Failure.> ed using Subaru Select Monitor. For the proce- dure, refer to the “COMPULSORY VALVE OPERATION CHECK MODE”.<Ref. EN(H4SOw/oOBD)-29, OPERATION, Compul- sory Valve Operation Check Mode.>...
  • Page 54 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK FUEL PUMP RELAY. Go to step 7. Replace fuel pump 1) Disconnect connector from fuel pump relay. relay. 2) Remove fuel pump relay from bracket. 3) Connect battery to fuel pump relay connec- tor terminals No.
  • Page 55 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)- 26, OPERATION, Inspection Mode.>...
  • Page 56 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO EACH FUEL 10 V Go to step 3. Repair harness INJECTOR. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from #1 cylinder fuel In this case, repair injector.
  • Page 57 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO EACH FUEL 10 V Go to step 6. Repair harness INJECTOR. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from #4 cylinder fuel In this case, repair injector.
  • Page 58 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 1 Ω CHECK HARNESS BETWEEN ECM AND Repair ground Go to step 11. FUEL INJECTOR CONNECTOR. short circuit in har- Measure resistance of harness between ECM ness between and fuel injector connector. ECM and fuel Connector &...

  • Page 59: List Of Diagnostic Trouble Code (Dtc)

    LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 13.List of Diagnostic Trouble Code (DTC) A: LIST Trouble Item Contents of diagnosis Index code Crankshaft position sen- • No signal entered from crankshaft <Ref. to EN(H4SOw/oOBD)-59, DTC 11 CRANK- position sensor when starter switch is SHAFT POSITION SENSOR, Diagnostic Proce- dure with Diagnostic Trouble Code (DTC).>...
  • Page 60 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Trouble Item Contents of diagnosis Index code Purge control solenoid • The purge control solenoid valve is <Ref. to EN(H4SOw/oOBD)-86, DTC 35 PURGE valve not in function. CONTROL SOLENOID VALVE, Diagnostic Pro- •...

  • Page 61: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 14.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11 CRANKSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from crankshaft position sensor when ignition switch is ON. • The harness connector between ECM and crankshaft position sensor is in short or open. •...
  • Page 62 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CONDITION OF CRANKSHAFT PO- Installing bolts are securely Go to step 2. Tighten crank- SITION SENSOR INSTALLATION. tightened. shaft position sen- Are the crankshaft position sensor installing sor installing bolts bolts tightened securely? securely.
  • Page 63 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ECM. DTC is displayed. Replace genera- Go to step 8. 1) Connect all connectors. tor. 2) Erase the memory. <Ref. to EN(H4SOw/ oOBD)-28, OPERATION, Clear Memory Mode.> 3) Perform inspection mode. <Ref. to EN(H4SOw/oOBD)-26, OPERATION, Inspection Mode.>...
  • Page 64 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) B: DTC 12 STARTER SWITCH • DIAGNOSIS: • The starter switch signal is abnormal. • The harness connector between ECM and starter switch is in short or open. • TROUBLE SYMPTOM: •...
  • Page 65 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND IG- 10 V Repair poor con- Repair open or NITION SWITCH CONNECTOR. tact in ECM con- ground short cir- 1) Turn ignition switch to OFF. nector.
  • Page 66 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC 13 CAMSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor. • The harness connector between ECM and camshaft position sensor is in short or open. •...
  • Page 67 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CONDITION OF CAMSHAFT POSI- Bolts are securely tightened. Go to step 2. Tighten camshaft TION SENSOR INSTALLATION. position sensor Are the camshaft position sensor installing installing bolts bolts tightened securely? securely.
  • Page 68 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ECM. DTC is indicated. Replace ECM. Go to step 8. 1) Connect all connectors. 2) Erase the memory. <Ref. to EN(H4SOw/ oOBD)-28, OPERATION, Clear Memory Mode.> 3) Perform inspection mode. <Ref. to EN(H4SOw/oOBD)-26, OPERATION, Inspection Mode.>...
  • Page 69 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR • DIAGNOSIS: • The engine coolant temperature sensor signal is abnormal. • The harness connector between ECM and engine coolant temperature sensor is in short or open. •...
  • Page 70 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ENGINE 10 V Repair battery Go to step 2. COOLANT TEMPERATURE SENSOR AND short circuit in har- ECM CONNECTOR. ness between 1) Turn ignition switch to OFF. ECM and engine 2) Remove generator.
  • Page 71 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 5 Ω CHECK HARNESS BETWEEN ENGINE Go to step 5. Repair harness COOLANT TEMPERATURE SENSOR AND and connector. ECM CONNECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, repair 2) Measure resistance of harness between the following: engine coolant temperature sensor connec-...
  • Page 72 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ENGINE COOLANT TEMPERATURE 0.2 — 0.3 kΩ Replace ECM. Replace engine SENSOR. coolant tempera- 1) Raise temperature up to approx. 90°C ture sensor. (194°F). CAUTION: Be careful not to burn yourself. 2) Measure resistance between engine cool- ant temperature sensor terminals.
  • Page 73 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) E: DTC 22 KNOCK SENSOR • DIAGNOSIS: • The knock sensor signal is abnormal. • The harness connector between ECM and knock sensor is in short or open. • TROUBLE SYMPTOM: •...
  • Page 74 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. Go to step 2. Go to step 3. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No.
  • Page 75 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE • DIAGNOSIS: • The idle air control solenoid valve is not in function. • The harness connector between ECM and idle air control solenoid valve is in short or open. •...
  • Page 76 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO IDLE AIR CON- 10 V Go to step 2. Repair harness TROL SOLENOID VALVE. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from idle air control In this case, repair solenoid valve.
  • Page 77 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK AIR INTAKE SYSTEM. The system is faulty. Repair air suction Go to step 9. 1) Turn ignition switch to ON. and leaks. 2) Start engine, and idle it. 3) Check the following items.
  • Page 78 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC 26 INTAKE AIR TEMPERATURE SENSOR • DIAGNOSIS: • The intake air temperature sensor signal is abnormal. • The harness connector between ECM and intake air temperature sensor is in short or open. •...
  • Page 79 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INTAKE AIR TEMPERATURE SEN- 2 — 3 kΩ Go to step 2. Replace intake air SOR. temperature sen- 1) Turn ignition switch to OFF. sor. <Ref. to 2) Disconnect connector from intake air tem- FU(H4SOw/ perature sensor.
  • Page 80 CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact with your Check poor contact in ECM connector. tact in ECM con- Subaru distributor. Is there poor contact in ECM connector? nector. NOTE: Inspection by your Subaru distributor required,...
  • Page 81 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC 31 THROTTLE POSITION SENSOR • DIAGNOSIS: • The throttle position sensor signal is abnormal. • The throttle position sensor is installed abnormally. • The harness connector between ECM and throttle position sensor is in short or open. •...
  • Page 82 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CONDITION OF THROTTLE POSI- Installing screw is securely Go to step 2. Adjust throttle TION SENSOR INSTALLATION. tightened. position sensor Are the throttle position sensor installing screw and tighten throt- tightened securely? tle position sensor installing screws...
  • Page 83 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC 32 OXYGEN SENSOR • DIAGNOSIS: • The oxygen sensor is not in function. • The harness connector between ECM and oxygen sensor is in short or open. • TROUBLE SYMPTOM: •...
  • Page 84 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK FOR OTHER CAUSES AFFECTING Check fuel sys- Go to step 2. EXHAUST GAS. tem. 1) Check for use of improper fuel. 2) Check if engine oil or coolant level is extremely low.
  • Page 85 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND OX- 0.2 V Go to step 8. Repair battery YGEN SENSOR. short circuit 1) Ignition switch to ON. between ECM and 2) Measure voltage between ECM and chas- oxygen sensor.
  • Page 86 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) J: DTC 33 VEHICLE SPEED SIGNAL • DIAGNOSIS: • The vehicle speed signal is abnormal. • The harness connector between ECM and vehicle speed sensor is in short or open. • TROUBLE SYMPTOM: •...
  • Page 87 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK SPEEDOMETER OPERATION IN Speedometer operates nor- Go to step 2. Check speedome- COMBINATION METER. mally. ter and vehicle Does speedometer operate normally? speed sensor. CHECK INPUT SIGNAL FOR ECM. Go to step 3.
  • Page 88 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) K: DTC 35 PURGE CONTROL SOLENOID VALVE • DIAGNOSIS: • The purge control solenoid valve is not in function. • The harness connector between ECM and purge control solenoid valve is in short or open. •...
  • Page 89 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OPERATION SOUND OF PURGE The valve produces operating Go to step 2. Go to step 3. CONTROL SOLENOID VALVE. sound. 1) Turn ignition switch to OFF. 2) Connect test mode connector. 3) Turn ignition switch to ON.
  • Page 90 CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact with your Check poor contact in purge control solenoid tact in purge con- Subaru distributor. valve connector. trol solenoid valve NOTE: Is there poor contact in purge control solenoid connector.
  • Page 91 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) L: DTC 38 TORQUE CONTROL SIGNAL • DIAGNOSIS: • Abnormal signal entered from TCM • The harness connector between ECM and TCM is in short. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.>...
  • Page 92 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK HARNESS BETWEEN ECM AND Repair ground Go to step 2. TCM CONNECTOR. short circuit in har- 1) Disconnect connectors from ECM and ness between TCM. ECM and TCM 2) Measure resistance of harness between connector.
  • Page 93 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) M: DTC 45 PRESSURE SENSOR • DIAGNOSIS: • The pressure sensor signal is abnormal. • The harness connector between ECM and pressure sensor is in short or open. • TROUBLE SYMPTOM: •...
  • Page 94 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 4.5 — 5.5 V Go to step 2. Repair open or PRESSURE SENSOR CONNECTOR. ground short cir- 1) Disconnect connector from pressure sen- cuit in harness sor.
  • Page 95 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES) • DIAGNOSIS: • The CO resistor signal is abnormal. • The harness connector between ECM and CO resistor is in short or open. •...
  • Page 96 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. 0.5 — 4.5 V Go to step 3. Go to step 2. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chas- sis ground.
  • Page 97 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC 51 NEUTRAL POSITION SWITCH (MT VEHICLE) • DIAGNOSIS: • The neutral position switch signal is abnormal. • The harness connector between ECM and neutral position switch is in short or open. •...
  • Page 98 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. 4.5 — 5.5 V Go to step 3. Go to step 2. 1) Select MT shift lever to neutral position. 2) Turn ignition switch to ON. 3) Measure voltage between ECM and chas- sis ground.
  • Page 99 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK HARNESS BETWEEN ECM AND Repair ground Go to step 8. NEUTRAL POSITION SWITCH CONNEC- short circuit in har- TOR. ness between Measure resistance between ECM and chas- ECM and trans- sis ground.
  • Page 100 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE) • DIAGNOSIS: • The park/neutral position switch signal is abnormal. • The shift cable is connected abnormally. • The harness connector between ECM and inhibitor switch is in short or open. •...
  • Page 101 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. Go to step 2. Go to step 3. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chas- sis ground in selector lever “N” and “P” positions.
  • Page 102 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC 85 CHARGE SYSTEM • DIAGNOSIS: • Power source voltage of the ECM is low or high. • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.>...
  • Page 103 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK GENERATOR. 10.8 V — 16.2 V Go to step 2. Repair generator. 1) Start engine. <Ref. to 2) Idling after warm-up. SC(H4SO)-14, 3) Measure voltage between generator B ter- Generator.>...

  • Page 104: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 15.General Diagnostic Table A: INSPECTION NOTE: • Malfunction of parts other than those listed is also possible. • The right-hand priority column indicates the inspection priority of probable causes of the symptom. Carry out the check starting from A. Symptom Problem parts Priority...
  • Page 105 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 5. Rough idling 1) Spark plug 2) Pressure sensor 3) Engine coolant temperature sensor 4) Pressure regulator 5) Idle air control solenoid valve 6) Air leak in air intake system 7) ECM power supply 8) Throttle position sensor 9) Camshaft position sensor 10) Crankshaft position sensor...
  • Page 106 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 14. Remarks 1) ECM power supply 2) Pressure sensor 3) Pressure regulator 4) Idle air control solenoid valve 5) Air leak in air intake system A*: Including ECM ground circuit B*: Check hoses. EN(H4SOw/oOBD)-104...

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