Subaru Legacy 2002 Service Manual
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Subaru Legacy 2002 Service Manual

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Table of Contents

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Download this manual See also: Owner's Manual
2002 Model Year
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G2290GE1)
ENGINE 1 SECTION (Pub.No.G2290GE2)
ENGINE 2 SECTION (Pub.No.G2290GE3)
TRANSMISSION SECTION (Pub.No.G2290GE4)
CHASSIS SECTION (Pub.No.G2290GE5)
BODY SECTION (Pub.No.G2290GE6)
WIRING SYSTEM SECTION (Pub.No.G2290GE7)

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Summary of Contents for Subaru Legacy 2002

  • Page 1 2002 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G2290GE1) ENGINE 1 SECTION (Pub.No.G2290GE2) ENGINE 2 SECTION (Pub.No.G2290GE3) TRANSMISSION SECTION (Pub.No.G2290GE4) CHASSIS SECTION (Pub.No.G2290GE5) BODY SECTION (Pub.No.G2290GE6) WIRING SYSTEM SECTION (Pub.No.G2290GE7)
  • Page 2 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 3 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 4 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 5 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 6 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.

  • Page 7: Body Section

    When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 8 2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION G2290GE6...
  • Page 9 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 10 FOREWORD Page Foreword .....................2...
  • Page 11 FOREWORD Foreword 1. Foreword SA01674 A: FOREWORD SA01674G21 These manuals are used when performing maintenance, repair, or diagnosis of the Subaru Legacy. Applied model: BE***** and BH***** from 2002MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0864ZE) The manuals contain the latest information at the time of publication.

  • Page 12: How To Use This Manual

    HOW TO USE THIS MANUAL Page How to Use This Manual................2...

  • Page 13: Table Of Contents

    HOW TO USE THIS MANUAL How to Use This Manual 1. How to Use This Manual SA02675 A: HOW TO USE THIS MANUAL SA02675F69 1. STRUCTURE SA02675F6901 Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
  • Page 14 SPECIFICATIONS Page Legacy ......................2 OUTBACK ....................10...
  • Page 15 LEGACY Specifications 1. Legacy SA08704 A: DIMENSIONS SA08704G28 Model Sedan Wagon Overall length mm (in) 4,605 (181.3) 4,680 (184.3) Overall width mm (in) 1,695 (66.7) 1,695 (66.7) Overall height (at CW) mm (in) 1,415 (55.7) 1,515 (59.6) Compartment Length mm (in) 1,965 (77.4) 1,925 (75.8) Width...
  • Page 16 LEGACY Specifications C: ELECTRICAL SA08704G30 Model Sedan/Wagon 2.0 L 2.5 L Ignition timing at idling speed BTDC/rpm 10°±10°/700 Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst) CHAMPION: RC10YC4 (with catalyst) NGK: BKR5E-11 (with catalyst) With OBD RC10YC4 ..CHAMPION Alternate RC8YC4 ..
  • Page 17 LEGACY Specifications E: STEERING SA08704G32 Model Models with Models with Models with 185/70R14 tires 195/60R15 tires 205/50R16 tires Type Rack and Pinion Turns, lock to lock Minimum turning circle m (ft) Curb to curb: 10.8±1.0 (35.4±3.3) Wall to wall: 11.5±1.0 (37.7±3.3) F: SUSPENSION SA08704G33 Model...
  • Page 18 LEGACY Specifications J: WEIGHT SA08704G37 1. SEDAN SA08704G3708 ¼ LHD Vehicle Option code *1 KO, KS Model 2.0 L Curb weight (C.W.) Front kg (lb) (1,730) (1,785) (1,710) (1,765) (1,740) (1,795) Rear kg (lb) (1,335) (1,335) (1,345) (1,345) (1,345) (1,345) Total kg (lb) 1,390...
  • Page 19 LEGACY Specifications ¼ RHD Vehicle Option code *1 Model 2.0 L 2.5 L Curb weight (C.W.) Front kg (lb) 800 (1,765) 785 (1,730) 810 (1,785) 795 (1,755) 820 (1,810) Rear kg (lb) 605 (1,335) 605 (1,335) 605 (1,335) 605 (1,335) 610 (1,345) Total kg (lb) 1,405 (3,100)
  • Page 20 LEGACY Specifications 2. WAGON SA08704G3709 ¼ LHD Vehicle Option code *1 KO, KS Model 2.0 L Curb weight (C.W.) Front kg (lb) (1,720) (1,765) (1,710) (1,740) (1,740) (1,775) Rear kg (lb) (1,435) (1,435) (1,445) (1,445) (1,445) (1,445) Total kg (lb) 1,430 1,450 1,430...
  • Page 21 LEGACY Specifications ¼ RHD Vehicle Option code *1 Model 2.0 L 2.5 L Curb weight (C.W.) Front kg (lb) (1,710) (1,740) (1,731) (1,765) (1,740) (1,775) Rear kg (lb) (1,445) (1,445) (1,435) (1,435) (1,445) (1,445) Total kg (lb) 1,430 1,445 1,435 1,450 1,445 1,460...
  • Page 22 LEGACY Specifications NOTE: When any of the following optional parts are installed, add the weight to the curb weight. Weight of optional Cruise control Air conditioner Sunroof Leather interior SRS Airbag parts (Side) Front kg (lb) 6.5 (14.33) 2.1 (4.6) 13.9 (30.6) 10.9 (24.0) 1.8 (4.0)
  • Page 23 OUTBACK Specifications 2. OUTBACK SA08705 A: DIMENSIONS SA08705G28 Model OUTBACK Overall length mm (in) 4,720 (185.8) Overall width mm (in) 1,745 (68.7) Overall height (at CW) mm (in) 1,580 (62.2), 1,590 (62.6)*3 Compartment Length mm (in) 1,925 (75.8) Width mm (in) 1,440 (56.7), 1,420 (55.9)*1 Height mm (in)
  • Page 24 OUTBACK Specifications C: ELECTRICAL SA08705G30 Model OUTBACK 2.5 L 3.0 L Ignition timing at idling BTDC/rpm 10°±10°/700 10°±8°/600 speed Spark plug Type and manufacturer RC10YC4 ..CHAMPION PLFR6A ..NGK Alternate RC8YC4 ..CHAMPION BKR6E-11 ..NGK K20PR-U11 ..NIPPONDENSO Generator 12V —...
  • Page 25 OUTBACK Specifications E: STEERING SA08705G32 Model OUTBACK Type Rack and Pinion Turns, lock to lock Minimum turning circle m (ft) Curb to curb: 11.2±1.0 (36.7±3.3) Wall to wall: 12.0±1.0 (39.4±3.3) F: SUSPENSION SA08705G33 Model OUTBACK Front Macpherson strut type, Independent, Coil spring Rear Multi-link type, Independent, Coil spring G: BRAKE...
  • Page 26 OUTBACK Specifications J: WEIGHT SA08705G37 1. OUTBACK SA08705G3707 ¼ LHD vehicle Option code *1 Model 2.5 L Curb weight (C.W.) Front kg (lb) 810 (1,785) 825 (1,820) 815 (1,795) 830 (1,830) 785 (1,730) Rear kg (lb) 670 (1,475) 670 (1,475) 670 (1,475) 670 (1,475) 650 (1,435)
  • Page 27 OUTBACK Specifications ¼ RHD vehicle Option code *1 Model 2.5 L 3.0 L Curb weight (C.W.) Front kg (lb) 800 (1,765) 815 (1,795) 915 (2,020) Rear kg (lb) 670 (1,475) 670 (1,475) 695 (1,530) Total kg (lb) 1,470 (3,240) 1,485 (3,275) 1,610 (3,550) Maximum permissible Front...
  • Page 28 PRECAUTION Page Precaution ....................2...
  • Page 29 PRECAUTION Precaution 1. Precaution 7. AIRBAG MODULE SA04677F5907 SA04677 Adhere to the following when handing and storing A: PRECAUTION SA04677F59 the airbag module to prevent bodily injury from Please clearly understand and adhere to the fol- unexpected deployment: ¼ Do not hold harnesses or connectors to carry lowing general precautions.
  • Page 30 NOTE Page Note ......................2...
  • Page 31 ECM from rush current. 4. SERVICE PARTS SA03676A1504 Use authentic service parts for maximum perfor- mance maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer. NT-2...
  • Page 32 NOTE Note 5. LIFTS AND JACKS SA03676A1505 When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
  • Page 33 NOTE Note GI0101B NT-4...
  • Page 34 NOTE Note 6. TIE DOWNS SA03676A1506 Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. B1M0489A NT-5...
  • Page 35 NOTE Note 7. TOWING SA03676A1507 Avoid towing vehicles except when the vehicle cannot be driven. For vehicles with AWD, AT, or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or vehicle: ¼...
  • Page 36 For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-7...
  • Page 37 NOTE Note MEMO: NT-8...
  • Page 38 IDENTIFICATION Page Identification ....................2...
  • Page 39 IDENTIFICATION Identification 1. Identification SA06679 A: IDENTIFICATION SA06679F70 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001 The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification GI0112A GI0007A GI0008A GI0009A ID-2...
  • Page 40 IDENTIFICATION Identification GI0010A GI0011A ID-3...
  • Page 41 IDENTIFICATION Identification 2. MEANING OF V.I.N. SA06679F7002 The meaning of the VIN is as follows: ¼ Europe, Australia and General (Except GCC) ]JF1BE5LJ32G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made JF2: MPV, FHI made Car line...
  • Page 42 IDENTIFICATION Identification 3. MODEL NUMBER PLATE SA06679F7003 The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. BE9CL7R Digits Code...
  • Page 43 IDENTIFICATION Identification ¼ Transmission TV1A4YCAAA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V: Full-time AWD AT VTD Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1A, 1B: AT Series 4: 4th Generation Legacy Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center...
  • Page 44 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 45 RECOMMENDED MATERIALS Recommended Materials 1. Recommended Materials SA05678 A: RECOMMENDED MATERIALS SA05678G22 1. GENERAL SA05678G2201 To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality. 2. FUEL SA05678G2202 Always use a gasoline of the same or higher octane value than specified in the owner’s manual.
  • Page 46 RECOMMENDED MATERIALS Recommended Materials 3. LUBRICANTS SA05678G2203 Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the cor- rect SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SL or SJ Grade “Energy conserving”...
  • Page 47 RECOMMENDED MATERIALS Recommended Materials SAE viscosity SAE viscosity No. and applicable temperature SAE J300 Engine oil GI0003A Manual transmission oil Rear differential GI0004A Front differential GI0005A RM-4...
  • Page 48 Tap water 6. REFRIGERANT SA05678G2206 Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refriger- ants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9. Air conditioner Recommended...
  • Page 49 RECOMMENDED MATERIALS Recommended Materials 8. ADHESIVES SA05678G2210 Use the adhesives shown in the table below, or equivalent. Adhesive Application point Recommended Item number Alternative Adhesive Windshield and body Essex Chemical Crop’s — Sunstar 580 Urethane E Soft vinyl Cemedine 540 —...
  • Page 50 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 51 PRE-DELIVERY INSPECTION Pre-delivery Inspection 1. Pre-delivery Inspection SA09719 A: GENERAL SA09719G23 The purposes of the pre-delivery inspection (PDI) are as follows. ¼ Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. ¼...
  • Page 52 PRE-DELIVERY INSPECTION Pre-delivery Inspection B: PDI PROCEDURE SA09719G50 Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
  • Page 53 PRE-DELIVERY INSPECTION Pre-delivery Inspection Step Check point 21. Seat (1) Check the seat surfaces for smears or dirt. (2) Check the seat installation conditions and functionality. 22. Seat belt (1) Check the seat belt installation conditions and functionality. 23. Wheel alignment (1) Check that the wheel alignments are properly adjusted.
  • Page 54 PRE-DELIVERY INSPECTION Pre-delivery Inspection 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER SA09719G5001 CUT CONNECTOR ¼ If the vehicle is covered with protective coating, SA09719G5051 visually check the vehicle body for damage and A vehicle just delivered has its air conditioner cut dents.
  • Page 55 PRE-DELIVERY INSPECTION Pre-delivery Inspection ¼ Vehicles with power door locks: 7. CHECK THE REAR GATE OPERATIONS, LOCK/UNLOCK AND Sit in the driver seat, close the driver’s door OPEN/CLOSE, AS FOLLOWS. completely, and place the power door locking SA09719G5053 ¼ Using the key, lock and unlock the rear gate switch (A) to the lock position.
  • Page 56 PRE-DELIVERY INSPECTION Pre-delivery Inspection 9. ACCESSORY CHECK 10. OPERATION CHECK OF HOOD LOCK SA09719G5008 RELEASE SYSTEM Check that the following accessories are provided SA09719G5009 in the luggage compartment or cargo area. Unlatch and open the hood while checking that no ¼...
  • Page 57 PRE-DELIVERY INSPECTION Pre-delivery Inspection 13. ENGINE OIL 16. COOLANT SA09719G5014 SA09719G5017 Check the engine oil amount. If the amount is Check the coolant amount on the reservoir. If the insufficient, check that no leaks are found. Then, amount is insufficient, check that no leaks are add the necessary amount of the specified engine found.
  • Page 58 PRE-DELIVERY INSPECTION Pre-delivery Inspection 20. KEYLESS ENTRY SYSTEM 24. READ MEMORY AND TEST MODE SA09719G5021 CONNECTORS Check the keyless entry system operations as fol- SA09719G5050 lows. Turn the ignition switch to ON and check that the ¼ Remove the key from the ignition switch and check-engine light starts blinking.
  • Page 59 PRE-DELIVERY INSPECTION Pre-delivery Inspection 29. RADIO 37. AT SHIFT CONTROL SA09719G5033 SA09719G5041 Check the radio for full functionality and normal Set the AT select lever to each gear position while noise level. Also check the CD unit operations. checking that the demanded gear position is cor- rectly attained.
  • Page 60 PRE-DELIVERY INSPECTION Pre-delivery Inspection 42. POWER STEERING FLUID LEVEL check all areas that may have possibly contributed to the leak. SA09719G5046 Check that the power steering fluid level is normal. 45. APPEARANCE CHECK 2 SA09719G5049 If insufficient, check that no leaks are found. Then Check the vehicle body paints, plated faces, glass, add the necessary amount of the specified power and lenses for any dirt or damage.
  • Page 61 PRE-DELIVERY INSPECTION Pre-delivery Inspection MEMO: PI-12...
  • Page 62 PERIODIC MAINTENANCE SERVICES Page General Description..................2 Schedule......................3 Engine Oil....................6 Engine Oil Filter...................8 Spark Plugs ....................9 Drive Belt(s)....................10 Camshaft Drive Belt ..................13 Fuel Line....................15 Fuel Filter ....................16 Air Cleaner Element ..................17 Cooling System ..................18 Coolant ......................19 Idle Mixture....................21 Clutch System ...................22 Hill-holder System ..................23 Transmission Oil..................24 ATF ......................25...

  • Page 63: General Description

    GENERAL DESCRIPTION Periodic Maintenance Services 1. General Description SA07001 A: GENERAL SA07001G23 Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...

  • Page 64: Schedule

    SCHEDULE Periodic Maintenance Services 2. Schedule SA07682 A: MAINTENANCE SCHEDULE 1 SA07682G24 1. MAINTENANCE SCHEDULE 1 – (1) SA07682G2401 For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by refer- ring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
  • Page 65 SCHEDULE Periodic Maintenance Services Maintenance Interval [Number of months or km (miles), whichever occurs first] Months Remarks × 1,000 km × 1,000 miles Axle boots & joints Steering system (Power steering) Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) Periodic inspection and replacement of the camshaft drive chains on the 3.0 liter models are not required.
  • Page 66 SCHEDULE Periodic Maintenance Services B: MAINTENANCE SCHEDULE 2 SA07682G25 Item Every Repeat short Repeat Extremely Salt or other High humidity Repeat tow- distance drive rough/muddy cold weather corrosive or mountain ing trailer road drive area used or area coastal area Engine oil Replace more Replace more...

  • Page 67: Engine Oil

    ENGINE OIL Periodic Maintenance Services 3. Engine Oil 3.0 L model SA07077 A: REPLACEMENT SA07077A20 1) Drain engine oil by loosening engine oil drain plug. Except 3.0 L model B2M4534A 3) Replace drain plug gasket. 4) Tighten engine oil drain plug after draining engine oil.
  • Page 68 3) Reinsert the level gauge all the way. Be sure tion and SAE viscosity No. designated by that the level gauge is correctly inserted and in the SUBARU. proper orientation. ¼ If vehicle is used in desert areas with very high 4) Remove it again and note the reading.

  • Page 69: Engine Oil Filter

    ENGINE OIL FILTER Periodic Maintenance Services 4. Engine Oil Filter SA07585 A: REPLACEMENT SA07585A20 1. EXCEPT 3.0 L MODEL SA07585A2003 1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH B2M3887 3) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH GI0012A 2) Get a new oil filter and apply a thin coat of engine oil to the rubber seal.

  • Page 70: Spark Plugs

    SPARK PLUGS Periodic Maintenance Services 5. Spark Plugs 2. 3.0 L MODEL SA07683A2002 SA07683 1) Disconnect battery cables and then remove A: REPLACEMENT SA07683A20 battery and battery carrier. 1. 2.5 L MODEL 2) Remove washer tank and put it aside. SA07683A2001 3) Remove air cleaner lower case.

  • Page 71: Drive Belt(S)

    DRIVE BELT(S) Periodic Maintenance Services 6. Drive Belt(s) 2. 3.0 L MODEL SA07684A1002 SA07684 1) Replace belts, if cracks, fraying or wear is A: INSPECTION SA07684A10 found. 1. EXCEPT 3.0 L MODEL 2) Check that the V-belt automatic tensioner indi- SA07684A1003 cator is within the range (D).
  • Page 72 DRIVE BELT(S) Periodic Maintenance Services 8) Install a new belt, and tighten the slider bolt so B: REPLACEMENT SA07684A20 as to obtain the specified belt tension. 1. EXCEPT 3.0 L MODEL 9) Tighten the slider bolt (B). SA07684A2006 10) Tighten the lock nut (A). 1) Remove V-belt cover.
  • Page 73 DRIVE BELT(S) Periodic Maintenance Services 3) Install in the reverse order of removal. B2M4013A Power steering oil pump Belt tension adjuster Crankshaft pulley A/C compressor Belt idler Generator PM-12...

  • Page 74: Camshaft Drive Belt

    CAMSHAFT DRIVE BELT Periodic Maintenance Services 7. Camshaft Drive Belt 10) Turn crankshaft and align alignment marks on SA07685 crankshaft, and left and right camshaft sprockets A: REPLACEMENT with notches of belt cover and cylinder block: SA07685A20 ST 499987500 CRANKSHAFT SOCKET 1.
  • Page 75 CAMSHAFT DRIVE BELT Periodic Maintenance Services B: INSTALLATION C: INSPECTION SA07685A11 SA07685A10 1. SOHC MODEL 1. SOHC MODEL SA07685A1101 SA07685A1001 To install, reverse order of removal procedures. 1) Remove left and right timing belt covers. <Ref. to ME-51, INSTALLATION, Timing Belt 2) While cranking engine at least four rotations, Assembly.>...

  • Page 76: Fuel Line

    FUEL LINE Periodic Maintenance Services 8. Fuel Line SA07686 A: INSPECTION SA07686A10 The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU-78, Fuel Delivery, Return and Evaporation Lines.>...

  • Page 77: Fuel Filter

    FUEL FILTER Periodic Maintenance Services 9. Fuel Filter SA07027 A: REPLACEMENT SA07027A20 For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU-75, Fuel Filter.> or <Ref. to FU(w/oOBD)-69, Fuel Filter.> or <Ref. to FU(H6)- 70, Fuel Filter.> PM-16...

  • Page 78: Air Cleaner Element

    AIR CLEANER ELEMENT Periodic Maintenance Services 10. Air Cleaner Element 2. 3.0 L MODEL SA07687A2006 SA07687 1) Remove the clip (A) above the air cleaner upper A: REPLACEMENT SA07687A20 cover. NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a special non-flammable slow-evaporating viscous liquid.

  • Page 79: Cooling System

    COOLING SYSTEM Periodic Maintenance Services 11. Cooling System SA07688 A: INSPECTION SA07688A10 1) Check radiator for leakage, filling it with coolant and attach radiator cap tester (A) to the filler neck. Then apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) and check the following points: ¼...

  • Page 80: Coolant

    2. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE SA07689A2002 The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. GI0036A [Example] If the coolant temperature is 25°C (77°F) and its...
  • Page 81 SUBARU genuine coolant (concentration 50). The amount of coolant that should be replaced can be determined using the diagram.

  • Page 82: Idle Mixture

    IDLE MIXTURE Periodic Maintenance Services 13. Idle Mixture SA07734 A: INSPECTION AND ADJUSTMENT SA07734G26 1. IDLE MIXTURE SA07734G2601 Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”...

  • Page 83: Clutch System

    CLUTCH SYSTEM Periodic Maintenance Services 14. Clutch System SA07690 A: INSPECTION AND ADJUSTMENT SA07690G26 1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not. GI0039A 2) If the fluid level rises, pedal free play is correct.

  • Page 84: Hill-Holder System

    HILL-HOLDER SYSTEM Periodic Maintenance Services 15. Hill-holder System SA07735 A: INSPECTION AND ADJUSTMENT SA07735G26 1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or higher inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly;...

  • Page 85: Transmission Oil

    TRANSMISSION OIL Periodic Maintenance Services 16. Transmission Oil SA07691 A: REPLACEMENT SA07691A20 1. MANUAL TRANSMISSION SA07691A2001 1) Drain gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0041 2) Reinstall drain plug after draining gear oil and tighten it to the specified torque.

  • Page 86: Atf

    Periodic Maintenance Services 17. ATF 4) Fluid temperature rising speed SA07692 ¼ By idling the engine A: INSPECTION Time for temperature rise to 60°C (140°F) with SA07692A10 atmospheric temperature of 0°C (32°F): More than 1) Raise ATF temperature to 60 to 80°C (140 to 25 minutes 176°F) from 40 to 60°C (104 to 140°F) (when cold) <Reference>...
  • Page 87 Periodic Maintenance Services B: REPLACEMENT SA07692A20 1. AUTOMATIC TRANSMISSION FLUID SA07692A2001 1) Drain ATF (Automatic Transmission Fluid) by removing drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0043A 2) Reinstall drain plug after draining ATF, and tighten it to the specified torque.

  • Page 88: Front & Rear Differential Oil

    FRONT & REAR DIFFERENTIAL OIL Periodic Maintenance Services 18. Front & Rear Differential Oil SA07693 A: REPLACEMENT SA07693A20 1. FRONT DIFFERENTIAL (MANUAL TRANSMISSION) SA07693A2001 For M/T vehicle, manual transmission oil works as differential oil to lubricate differential. Refer to “Transmission Oil”. <Ref. to PM-24, MANUAL GI0046A TRANSMISSION, REPLACEMENT, Transmission Oil.>...
  • Page 89 FRONT & REAR DIFFERENTIAL OIL Periodic Maintenance Services 5) Install filler plug onto rear differential gear case firmly. NOTE: ¼ Apply fluid packing to filler plug before installa- tion in T-type. ¼ VA-type uses a new aluminum gasket. Fluid packing: Three Bond 1105 Tightening torque: T-type:...

  • Page 90: Brake Line

    BRAKE LINE Periodic Maintenance Services 19. Brake Line B: CHECKING SA07694G27 SA07694 1. SERVICE BRAKE A: INSPECTION SA07694G2701 SA07694A10 1) Check the free play of brake pedal with a force 1. BRAKE LINE SA07694A1001 of less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on brake hoses or pipe...
  • Page 91 BRAKE LINE Periodic Maintenance Services 3) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between the pedal and steering wheel again.

  • Page 92: Brake Fluid

    BRAKE FLUID Periodic Maintenance Services 20. Brake Fluid NOTE: SA07162 ¼ Cover bleeder with waste cloth, when loosening A: REPLACEMENT it, to prevent brake fluid from being splashed over SA07162A20 surrounding parts. 1) Either jack up vehicle and place a safety stand ¼...

  • Page 93: Disc Brake Pads And Discs

    DISC BRAKE PADS AND DISCS Periodic Maintenance Services 21. Disc Brake Pads and Discs NOTE: When replacing a pad, always replace the pads for SA07695 both the left and right wheels at the same time. A: INSPECTION Also replace pad clips if they are twisted or worn. SA07695A10 1.

  • Page 94: Parking Brake

    PARKING BRAKE Periodic Maintenance Services 22. Parking Brake B: ADJUSTMENT SA07813A01 SA07813 For rear disc brake, adjust parking brake after A: INSPECTION SA07813A10 bleeding the air. Inspect brake linings and drums of both sides of 1) Remove rear cover (rubber) installed at back the rear brake at the same time by removing brake plate.

  • Page 95: Suspension

    SUSPENSION Periodic Maintenance Services 23. Suspension SA07697 A: INSPECTION SA07697A10 1. SUSPENSION BALL JOINT SA07697A1001 1) Jack up vehicle until front wheels are off ground. 2) Next, grasp bottom of tire and move it in and out. If relative movement is observed between brake disc cover and end of transverse link, ball GI0066A joint may be excessively worn.
  • Page 96 SUSPENSION Periodic Maintenance Services 4. WHEEL ALIGNMENT OF FRONT 8. DAMAGE TO SUSPENSION PARTS SUSPENSION SA07697A1008 SA07697A1004 1) Check the following parts and the fastening por- 1) Check alignment of front suspension to ensure tion of the vehicle body for deformation or exces- that following items conform to standard values.

  • Page 97: Wheel Bearing

    WHEEL BEARING Periodic Maintenance Services 24. Wheel Bearing 6) While supporting rear drive shaft horizontally SA07698 with one hand, turn hub assembly with the other to A: INSPECTION check for noise or binding. SA07698A10 If hub assembly is noisy or binds, disassemble rear 1.

  • Page 98: Axle Boots & Joints

    AXLE BOOTS & JOINTS Periodic Maintenance Services 25. Axle Boots & Joints SA07699 A: INSPECTION SA07699A10 1. FRONT AND REAR AXLE BOOTS SA07699A1001 Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones.
  • Page 99 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 26. Steering System (Power 2. STEERING SHAFT JOINT SA07701A1002 Steering) 1) When steering wheel free play is excessive, SA07701 disconnect universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the SA07701A10 point of the crossing direction).

  • Page 100: Steering System (Power Steering)

    STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 3) With vehicle on a level surface, quickly turn Tightening torque: 83 N·m (8.5 kgf-m, 61.5 ft-lb) steering wheel to the left and right. While steering wheel is being rotated, check the 5. POWER STEERING FLUID LEVEL gear backlash.
  • Page 101 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 7. HOSES OF OIL PUMP FOR DAMAGES 10. FITTING BOLTS AND NUTS SA07701A1010 SA07701A1007 Inspect fitting bolts and nuts of oil pump and Check pressure hose and return hose of oil pump bracket for looseness, and retighten them if neces- for crack, swell or damage.

  • Page 102: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM Periodic Maintenance Services 27. Supplemental Restraint System SA07702 A: INSPECTION SA07702A10 Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnos- tic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect (also double lock the connector). When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
  • Page 103 SUPPLEMENTAL RESTRAINT SYSTEM Periodic Maintenance Services MEMO: PM-42...
  • Page 104 FUEL INJECTION (FUEL SYSTEMS) Page General Description..................2 Throttle Body .....................14 Intake Manifold ..................15 Engine Coolant Temperature Sensor............29 Crankshaft Position Sensor...............30 Camshaft Position Sensor.................31 Knock Sensor ....................32 Throttle Position Sensor................34 Intake Air Temperature and Pressure Sensor...........37 Atmospheric Pressure Sensor ..............38 Idle Air Control Solenoid Valve ..............39 Air Assist Injector Solenoid Valve .............40 Fuel Injector....................41 Front Oxygen (A/F) Sensor...............47...
  • Page 105 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 1. General Description S175001 A: SPECIFICATIONS S175001E49 Model Capacity (16.9 US gal, 14.1 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
  • Page 106 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) MEMO: FU-3...
  • Page 107 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) B: COMPONENT S175001A05 1. INTAKE MANIFOLD S175001A0501 B2M4252B FU-4...
  • Page 108 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Intake manifold gasket RH (15) O-ring Tightening torque: N·m (kgf-m, ft-lb) (2) Fuel injector pipe (16) Plug cord holder LH 15 (0.15, 1.1) (3) Fuel injector (17) Fuel pipe protector RH 3.4 (0.35, 2.5) (4) O-ring (18) Fuel pipe ASSY 5.0 (0.51, 3.7)
  • Page 109 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 2. AIR INTAKE SYSTEM S175001A0502 B2M3455C (1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor 1.6 (0.16, 1.2) (3) Idle air control solenoid valve 22 (2.2, 16) FU-6...
  • Page 110 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS S175001A0503 B2M2282B (1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor (4) Camshaft position sensor sup- 6.4 (0.65, 4.7) port 24 (2.4, 17.4) FU-7...
  • Page 111 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 4. FUEL TANK S175001A0504 B2M3837A FU-8...
  • Page 112 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Heat sealed cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...
  • Page 113 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 5. FUEL LINE S175001A0505 B2M4171B FU-10...
  • Page 114 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Clamp (14) Fuel delivery hose C (27) Canister (2) Fuel return hose A (15) Fuel pipe ASSY (28) Front canister bracket (3) Dumper valve (Return) (16) Evaporation hose B (29) Rear canister bracket (4) Fuel return hose B (17) Two-way valve hose (30) Canister bracket spacer...
  • Page 115 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 6. FUEL FILLER PIPE S175001A0506 B2M4253B (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap 7.4 (0.75, 5.4) (3) Clamp (7) Filler pipe protector (4) Filler pipe packing FU-12...
  • Page 116 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) ¼ Be careful not to burn your hands, because each C: CAUTION S175001A03 part on the vehicle is hot after running. ¼ Wear working clothing, including a cap, protec- ¼ Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
  • Page 117 THROTTLE BODY Fuel Injection (Fuel Systems) 2. Throttle Body 5) Disconnect connectors from idle air control S175010 solenoid valve, throttle position sensor. A: REMOVAL 6) Disconnect air by-pass hose from air assist S175010A18 injector solenoid valve. 1) Disconnect battery ground cable. B2M3457A G6M0095 Throttle position sensor...
  • Page 118 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 3. Intake Manifold 7) Remove power steering pump and tank from S175034 brackets. A: REMOVAL (1) Remove resonator chamber. S175034A18 1) Release fuel pressure. <Ref. to FU-54, RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. B6M1237 (2) Remove V-belt covers.
  • Page 119 INTAKE MANIFOLD Fuel Injection (Fuel Systems) (4) Remove bolts which hold power steering (7) Remove power steering tank from the pipes onto intake manifold protector. bracket by pulling it upwards. NOTE: Do not disconnect power steering hose. B2M3153 (8) Place power steering pump and tank on the B2M4126 right side wheel apron.
  • Page 120 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 11) Disconnect brake booster hose. 15) Disconnect connector from crankshaft position sensor. B2M4259 B2M1252 12) Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness 16) Disconnect connector from oil pressure connectors from bulkhead harness connectors.
  • Page 121 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 18) Disconnect fuel hoses from fuel pipes. B: INSTALLATION S175034A11 WARNING: 1) Install intake manifold onto cylinder heads. ¼ Do not spill fuel. NOTE: ¼ Catch fuel from hoses in a container or cloth. Always use new gaskets.
  • Page 122 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 4) Connect connector to oil pressure switch. 8) Install air cleaner case stay RH and engine har- ness bracket, and connect engine harness con- nectors to bulkhead connectors. B2M1253 5) Connect connector to crankshaft position sen- B2M4260 sor.
  • Page 123 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 13) Install power steering pump and tank on (4) Install power steering pipes onto right side brackets. intake manifold protector. (1) Install power steering tank on bracket. B2M4126 B2M3153 (5) Install power steering pump drive V-belt. (2) Connect connector to power steering pump switch.
  • Page 124 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 14) Connect accelerator cable (A). C: DISASSEMBLY S175034A06 15) Connect cruise control cable (B). (With cruise 1) Disconnect engine ground terminal from intake control models) manifold. B2M4254A B2M4265 16) Install air intake duct and air cleaner assem- 2) Disconnect connector from ignition coil and bly.
  • Page 125 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 5) Remove intake air temperature and pressure 9) Disconnect connector from air assist injector sensor from intake manifold. solenoid valve. 10) Disconnect air by-pass hoses from air assist solenoid valve. B2M3475 6) Disconnect connectors from throttle position B2M4266 sensor and idle air control solenoid valve.
  • Page 126 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 14) Remove fuel pipe protector RH. 19) Remove engine harness from intake manifold. 20) Remove purge control solenoid valve. B2M4130 B2M3487 15) Disconnect connectors from fuel injectors. 21) Remove bolt which installs injector pipe on intake manifold as shown in figure.
  • Page 127 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 24) Remove fuel injectors. 27) Loosen clamp which holds front right side fuel (1) Remove fuel injector securing clip. hose to injector pipe and remove the pipe from fuel hose. B2M3488 B2M4274 (2) Remove fuel injector while lifting up fuel injector pipe.
  • Page 128 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 2) Tighten bolt which installs fuel pipes on intake 6) Connect air assist hoses. manifold. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M4149A 7) Install fuel injectors. NOTE: B2M3491 Always use new O-rings. 3) Connect right side fuel hose to injector pipe, and tighten clamp screw.
  • Page 129 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 8) Tighten bolt which installs injector pipe on 11) Install purge control solenoid valve. intake manifold. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3487 12) Connect hoses to purge control solenoid valve. H2M2965 CAUTION: 9) Tighten two bolts which install fuel pipes on the Carefully connect the evaporation hoses.
  • Page 130 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 16) Install fuel pipe protector RH. 19) Install air assist injector solenoid valve to bracket. Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M4130 B2M3478 17) Install fuel pipe protector LH. 20) Connect air by-pass hoses to air assist sole- Tightening torque: noid valve.
  • Page 131 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 23) Connect connector to throttle position sensor 26) Connect connector to intake air temperature and pressure sensor. and idle air control solenoid valve. 27) Install ignition coil and ignitor assembly. B2M3479 B2M3473 24) Connect air by-pass hose to throttle body. 28) Connect connector to ignition coil and ignitor assembly.
  • Page 132 ENGINE COOLANT TEMPERATURE SENSOR Fuel Injection (Fuel Systems) 4. Engine Coolant Temperature B: INSTALLATION S175047A11 Sensor Install in the reverse order of removal. S175047 Tightening torque: A: REMOVAL S175047A18 16 N·m (0.16 kgf-m, 1.2 ft-lb) 1) Disconnect battery ground cable. B2M4275 G6M0095 2) Remove air intake duct and air cleaner assem-...
  • Page 133 CRANKSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 5. Crankshaft Position Sensor B: INSTALLATION S175043A11 Install in the reverse order of removal. S175043 A: REMOVAL Tightening torque: S175043A18 T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. B2M1252B G6M0095 2) Remove bolt which installs crankshaft position sensor to cylinder block.
  • Page 134 CAMSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 6. Camshaft Position Sensor 4) Remove bolt which installs camshaft position sensor support to camshaft cap LH. S175041 A: REMOVAL S175041A18 1) Disconnect battery ground cable. B2M2321 5) Remove camshaft position sensor and cam- shaft position sensor support as a unit.
  • Page 135 KNOCK SENSOR Fuel Injection (Fuel Systems) 7. Knock Sensor B: INSTALLATION S175042A11 S175042 1) Install knock sensor to cylinder block. A: REMOVAL S175042A18 Tightening torque: 1) Disconnect battery ground cable. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...
  • Page 136 KNOCK SENSOR Fuel Injection (Fuel Systems) 4) Connect battery ground cable. G6M0095 FU-33...
  • Page 137 THROTTLE POSITION SENSOR Fuel Injection (Fuel Systems) 8. Throttle Position Sensor B: INSTALLATION S175039A11 S175039 Install in the reverse order of removal. A: REMOVAL S175039A18 Tightening torque: 1) Disconnect battery ground cable. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.
  • Page 138 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3148A 5) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. 6) Select {2. Each System Check} in Main Menu. 7) Select {Engine Control System} in Selection Menu.
  • Page 139 THROTTLE POSITION SENSOR Fuel Injection (Fuel Systems) Condition: Throttle fully closed Throttle opening angle 0.00% Throttle sensor voltage 0.50 V 11) Tighten throttle position sensor holding screws. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3765 FU-36...
  • Page 140 INTAKE AIR TEMPERATURE AND PRESSURE SENSOR Fuel Injection (Fuel Systems) 9. Intake Air Temperature and 4) Remove intake air temperature and pressure sensor. Pressure Sensor S175044 A: REMOVAL S175044A18 1) Disconnect battery ground cable. B2M3497 B: INSTALLATION S175044A11 Install in the reverse order of removal. G6M0095 Tightening torque: 2) Disconnect spark plug cord from ignition coil...

  • Page 141: Atmospheric Pressure Sensor

    ATMOSPHERIC PRESSURE SENSOR Fuel Injection (Fuel Systems) 10. Atmospheric Pressure B: INSTALLATION S175045A11 Sensor Install in the reverse order of removal. S175045 Tightening torque: A: REMOVAL S175045A18 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. B2M3499 G6M0095 2) Disconnect connector from atmospheric pres- sure sensor.
  • Page 142 IDLE AIR CONTROL SOLENOID VALVE Fuel Injection (Fuel Systems) 11. Idle Air Control Solenoid B: INSTALLATION S175056A11 Valve Install in the reverse order of removal. S175056 NOTE: A: REMOVAL S175056A18 Always use new gasket. 1) Disconnect battery ground cable. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 B2M3501...

  • Page 143: Air Assist Injector Solenoid Valve

    AIR ASSIST INJECTOR SOLENOID VALVE Fuel Injection (Fuel Systems) 12. Air Assist Injector Solenoid B: INSTALLATION S175570A11 Valve Install in the reverse order of removal. S175570 Tightening torque: A: REMOVAL S175570A18 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. B2M3503 G6M0095 2) Disconnect connector from air assist injector...
  • Page 144 FUEL INJECTOR Fuel Injection (Fuel Systems) 13. Fuel Injector 7) Remove power steering pump and tank from S175051 brackets. A: REMOVAL (1) Remove V-belt covers. S175051A18 1. RH SIDE S175051A1801 1) Release fuel pressure. <Ref. FU-54, RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap.
  • Page 145 FUEL INJECTOR Fuel Injection (Fuel Systems) (5) Disconnect connector from power steering 9) Disconnect connector from fuel injector. pump switch. B2M4280 B2M4257 10) Remove bolt which holds injector pipe to (6) Remove power steering tank from the intake manifold. bracket by pulling it upwards. B2M4281 B2M3153 11) Remove bolt which install injector pipe to...
  • Page 146 FUEL INJECTOR Fuel Injection (Fuel Systems) (2) Remove fuel injector while lifting up fuel 4) Remove two bolts which install washer tank on injector pipe. body. B2M3509 B2M3139 5) Disconnect connector from front window 2. LH SIDE washer motor. S175051A1802 6) Disconnect connector from rear gate glass 1) Release fuel pressure.
  • Page 147 FUEL INJECTOR Fuel Injection (Fuel Systems) 9) Remove spark plug cords from spark plugs (#2 13) Remove bolt which installs injector pipe to intake manifold. and #4 cylinders). H2M2994 B2M4287 14) Remove bolt which holds fuel pipe on the left 10) Remove fuel pipe protector LH.
  • Page 148 FUEL INJECTOR Fuel Injection (Fuel Systems) Tightening torque: B: INSTALLATION S175051A11 19 N·m (0.19 kgf-m, 1.4 ft-lb) 1. RH SIDE S175051A1101 Install in the reverse order of removal. NOTE: Replace O-rings and insulators with new ones. B2M4130 2. LH SIDE S175051A1102 Install in the reverse order of removal.
  • Page 149 FUEL INJECTOR Fuel Injection (Fuel Systems) Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) H2M2995 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) B2M4133 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) B2M4129 FU-46...
  • Page 150 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) B2M4243 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove front oxygen (A/F) sensor.
  • Page 151 FRONT OXYGEN (A/F) SENSOR Fuel Injection (Fuel Systems) 5) Connect battery ground cable. G6M0095 FU-48...
  • Page 152 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) S2M0128 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor.
  • Page 153 REAR OXYGEN SENSOR Fuel Injection (Fuel Systems) 5) Connect battery ground cable. B2M1723 FU-50...
  • Page 154 ENGINE CONTROL MODULE Fuel Injection (Fuel Systems) 16. Engine Control Module 5) Remove nuts which hold ECM to bracket. S175049 A: REMOVAL S175049A18 1) Disconnect battery ground cable. B2M3162 6) Remove clip from bracket. G6M0095 2) Remove lower inner trim of passenger side. <Ref.
  • Page 155 MAIN RELAY Fuel Injection (Fuel Systems) 17. Main Relay S175050 A: REMOVAL S175050A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower inner trim of passenger side. <Ref. to EI-41, REMOVAL, Lower Inner Trim.> B2M0672 3) Disconnect connectors from main relay. 4) Remove bolt which holds main relay bracket on body.
  • Page 156 FUEL PUMP RELAY Fuel Injection (Fuel Systems) 18. Fuel Pump Relay S175048 A: REMOVAL S175048A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower cover. <Ref. EI-35, REMOVAL, Instrument Panel Assembly.> 3) Disconnect connector from fuel pump relay. B2M3159 4) Remove fuel pump relay from mounting bracket.
  • Page 157 FUEL Fuel Injection (Fuel Systems) 19. Fuel 3) Lift-up the vehicle. S175052 4) Remove front right side fuel tank cover. A: OPERATION S175052A16 1. RELEASING OF FUEL PRESSURE S175052A1601 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Disconnect connector from fuel pump relay.
  • Page 158 FUEL Fuel Injection (Fuel Systems) Tightening torque: 11) Remove fuel sub level sensor. 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M3178 B2M3173 12) Drain fuel from fuel tank by using hand pump. 7) Lower the vehicle. WARNING: 8) Remove sub service hole cover. Do not use a motor pump when draining fuel.
  • Page 159 FUEL Fuel Injection (Fuel Systems) (2) Connect connector from fuel sub level sen- sor. B2M3176 (3) Install sub service hole cover. B2M3175 (4) Set rear seat and floor mat. FU-56...
  • Page 160 6) Push grommet which holds fuel tank cord on service hole cover into body side. B2M3173 13) Remove rear exhaust pipe and muffler. B2M3179 NOTE: To facilitate removal, apply a coat of SUBARU CRC to matching area of rubber cushions in advance. SUBARU CRC (Part No. 004301003) FU-57...
  • Page 161 FUEL TANK Fuel Injection (Fuel Systems) (1) Separate rear exhaust pipe from center 14) Remove propeller shaft. <Ref. to DS-13 exhaust pipe. REMOVAL, Propeller Shaft.> 15) Disconnect connector from ABS sensor. B2M3109 B2M3184 (2) Remove left and right rubber cushions. 16) Remove bolts which hold parking brake cable CAUTION: holding bracket.
  • Page 162 FUEL TANK Fuel Injection (Fuel Systems) 19) Remove bolts which hold rear brake hoses (3) Remove bolt which secure rear suspension holding bracket. assembly to body. B2M3187 20) Remove rear brake caliper, then tie it up to the body side of the vehicle as shown in figure. B2M3190 (4) Remove rear suspension assembly.
  • Page 163 FUEL TANK Fuel Injection (Fuel Systems) 24) Loosen clamp and disconnect fuel filler hose B: INSTALLATION S175053A11 (A) and air vent hose (B) from fuel filler pipe. 1) Support fuel tank with transmission jack and push fuel tank harness into access hole with grom- met.
  • Page 164 FUEL TANK Fuel Injection (Fuel Systems) 5) Tighten band mounting bolts. (1) Support rear suspension assembly and then tighten bolts which secure rear suspension Tightening torque: assembly. 33 N·m (3.4 kgf-m, 25 ft-lb) Tightening torque: T1: 172 N·m (17.5 kgf-m, 127 ft-lb) T2: 108 N·m (11.0 kgf-m, 80 ft-lb) T3: 66 N·m (6.7 kgf-m, 48 ft-lb) B2M3194...
  • Page 165 NOTE: pushing it forward. To facilitate the procedure, apply a coat of 11) Tighten bolts which hold parking brake cable SUBARU CRC to matching area of rubber cush- holding bracket. ions in advance. Tightening torque: SUBARU CRC (Part No. 004301003) 18 N·m (1.8 kgf-m, 13.0 ft-lb)
  • Page 166 FUEL TANK Fuel Injection (Fuel Systems) (2) Install front rubber cushion and attach muf- 16) Install rear wheel. fler assembly. 17) Lower the vehicle. 18) Tighten wheel nuts to rear wheel. 19) Install parking brake cable. <Ref. to PB-4, INSTALLATION, Parking Brake Lever.> B2M3118 (3) Install rear exhaust pipe to center exhaust pipe.
  • Page 167 FUEL TANK Fuel Injection (Fuel Systems) 23) Connect connector to fuel sub level sensor. 28) Connect connector to fuel pump relay. B2M3159 B2M3176 29) Adjust parking brake lever stroke. <Ref. to 24) Install sub service hole cover. PB-4, ADJUSTMENT, Parking Brake Lever.> 30) Check wheel alignment and adjust if neces- sary.
  • Page 168 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 21. Fuel Filler Pipe 6) Remove rear right side wheel nuts. S175022 7) Lift-up the vehicle. A: REMOVAL 8) Remove rear right side wheel. S175022A18 1) Set the vehicle on the lift. 2) Release fuel pressure. <Ref. to FU-54, RELEASING FUEL PRESSURE,...
  • Page 169 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 11) Tighten fuel drain plug and then install front 13) Remove bolts which hold evaporation pipe right side tank cover. bracket on fuel filler pipe. Tightening torque: 26 N·m (2.65 kgf-m, 19.2 ft-lb) B2M3174 Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
  • Page 170 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 5) Insert air vent hose approximately 25 to 30 mm B: INSTALLATION S175022A11 (0.98 to 1.18 in) into the lower end of air vent pipe 1) Hold fuel filler flap open. and hold clip. 2) Set fuel saucer (A) with rubber packing (C) and L = 27.5±2.5 mm (1.083±0.098 in) insert fuel filler pipe into hole from the inner side of...
  • Page 171 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 7) Tighten bolts which hold evaporation pipe 12) Connect connector to fuel pump relay. bracket on fuel pipe. B2M3159 13) Connect battery ground cable. B2M4174 G6M0095 8) Install fuel filler pipe protector. B2M3198 9) Install rear right wheel.
  • Page 172 FUEL PUMP Fuel Injection (Fuel Systems) 22. Fuel Pump 6) Drain fuel from fuel tank. Set a container under S175025 the vehicle and remove drain plug from fuel tank. A: REMOVAL S175025A18 WARNING: ¼ Place “NO FIRE” signs near the working area.
  • Page 173 FUEL PUMP Fuel Injection (Fuel Systems) 9) Remove access hole lid. 14) Take off fuel pump assembly from fuel tank. B: INSTALLATION S175025A11 Install in the reverse order of removal. Do the fol- lowing: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or for- eign particles before installation.
  • Page 174 FUEL PUMP Fuel Injection (Fuel Systems) D: ASSEMBLY S175025A02 Assemble in the reverse order of disassembly. E: INSPECTION S175025A10 Connect lead harness to connector terminal of fuel pump and apply battery power supply to check whether the pump operate. WARNING: ¼...
  • Page 175 FUEL LEVEL SENSOR Fuel Injection (Fuel Systems) 23. Fuel Level Sensor B: INSTALLATION S175026A11 S175026 Install in the reverse order of removal. A: REMOVAL S175026A18 WARNING: WARNING: ¼ Ground cable must be connected. ¼ Place “NO FIRE” signs near the working ¼...
  • Page 176 FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 24. Fuel Sub Level Sensor 5) Tighten fuel drain plug and install front right side S175023 fuel tank cover. A: REMOVAL S175023A18 Tightening torque: 26 N·m (2.65 kgf-m, 19.2 ft-lb) WARNING: ¼ Place “NO FIRE” signs near the working area.
  • Page 177 FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 9) Disconnect connector from fuel sub level sen- B: INSTALLATION S175023A11 sor. Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3176 10) Disconnect fuel jet pump hose. B2M3178 B2M3177 11) Remove bolts which install fuel sub level sen-...
  • Page 178 FUEL FILTER Fuel Injection (Fuel Systems) 25. Fuel Filter 1) Set O-ring on the filter holder and install by S175027 turning to the right. A: REMOVAL S175027A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. NOTE: Fuel filter is built in fuel pump assembly.
  • Page 179 FUEL CUT VALVE Fuel Injection (Fuel Systems) 26. Fuel Cut Valve S175021 A: REMOVAL S175021A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Remove fuel tank. <Ref. to FU-57, REMOVAL, Fuel Tank.>...
  • Page 180 FUEL DUMPER VALVE Fuel Injection (Fuel Systems) 27. Fuel Dumper Valve S175708 A: REMOVAL S175708A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU-54, RELEASING FUEL PRESSURE,...
  • Page 181 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 28. Fuel Delivery, Return and 3) Open fuel filler flap lid and remove fuel filler cap. Evaporation Lines S175019 4) Remove floor mat. <Ref. to EI-51, REMOVAL, Floor Mat.> A: REMOVAL S175019A18 5) Remove fuel delivery pipes and hoses, fuel 1) Set vehicle on the lift.
  • Page 182 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 9) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are cov- ered with dust. (2) Hold connector (A) and push retainer (B) down.
  • Page 183 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 2) Connect fuel delivery hose to pipe with an over- lap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. : 2.5±1.5 mm (0.098±0.059 in) L: 22.5±2.5 mm (0.886±0.098 in) B2M1194B...
  • Page 184 FUEL SYSTEM TROUBLE IN GENERAL Fuel Injection (Fuel Systems) 29. Fuel System Trouble in General S175571 A: INSPECTION S175571A10 Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten Defective terminal contact.
  • Page 185 FUEL SYSTEM TROUBLE IN GENERAL Fuel Injection (Fuel Systems) MEMO: FU-82...
  • Page 186 FUEL INJECTION (FUEL SYSTEMS) FU(w/oOBD) Page General Description..................2 Throttle Body .....................12 Intake Manifold ..................13 Engine Coolant Temperature Sensor............27 Crankshaft Position Sensor...............28 Camshaft Position Sensor.................29 Knock Sensor ....................30 Throttle Position Sensor................32 Intake Air Temperature and Pressure Sensor...........35 Idle Air Control Solenoid Valve ..............36 Fuel Injector....................37 Oxygen Sensor..................43 Engine Control Module................45...

  • Page 187: General Description

    GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 1. General Description S135001 A: SPECIFICATIONS S135001E49 Model Capacity (16.9 US gal, 14.1 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
  • Page 188 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) B: COMPONENT S135001A05 1. INTAKE MANIFOLD S135001A0501 B2M4290B FU(w/oOBD)-3...
  • Page 189 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH (2) Fuel injector pipe (13) Intake air temperature and pres- (3) Fuel injector sure sensor Tightening torque: N·m (kgf-m, ft-lb) (4) O-ring (14) O-ring 1.5 (0.15, 1.1)
  • Page 190 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 2. AIR INTAKE SYSTEM S135001A0502 H2M2945C (1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor 1.6 (0.16, 1.2) (3) Idle air control solenoid valve 22 (2.2, 15.9) FU(w/oOBD)-5...
  • Page 191 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS S135001A0503 B2M2282B (1) Crank angle position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor (4) Camshaft position sensor sup- 6.4 (0.65, 4.7) port 24 (2.4, 17.4) FU(w/oOBD)-6...
  • Page 192 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 4. FUEL TANK S135001A0504 B2M3837A FU(w/oOBD)-7...
  • Page 193 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Heat sealed cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...
  • Page 194 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 5. FUEL LINE S135001A0505 B2M3838B (1) Clamp (10) Two-way valve (19) Dumper valve (Delivery) (2) Fuel delivery hose A (11) Canister hose B (20) Bracket (3) Evaporation hose A (12) Canister hose C (21) Dumber valve (Return) (4) Clip (13) Canister bracket (22) Fuel return hose B...
  • Page 195 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 6. FUEL FILLER PIPE S135001A0506 B2M4253B (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap 7.4 (0.75, 5.4) (3) Clamp (7) Filler pipe protector (4) Filler pipe packing FU(w/oOBD)-10...
  • Page 196 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) ¼ Be careful not to burn your hands, because each C: CAUTION S135001A03 part on the vehicle is hot after running. ¼ Wear working clothing, including a cap, protec- ¼ Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.

  • Page 197: Throttle Body

    THROTTLE BODY Fuel Injection (Fuel Systems) 2. Throttle Body 5) Disconnect connectors from idle air control S135010 solenoid valve, throttle position sensor. A: REMOVAL 6) Disconnect air by-pass hose from purge control S135010A18 solenoid valve. 1) Disconnect battery ground cable. H2M2949A G6M0095 Throttle position sensor...

  • Page 198: Intake Manifold

    INTAKE MANIFOLD Fuel Injection (Fuel Systems) 3. Intake Manifold 7) Remove power steering pump and tank from S135034 brackets. A: REMOVAL (1) Remove resonator chamber. S135034A18 1) Release fuel pressure. <Ref. to FU(w/oOBD)- RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. B6M1237 (2) Remove V-belt covers.
  • Page 199 INTAKE MANIFOLD Fuel Injection (Fuel Systems) (4) Remove bolts which hold power steering (7) Remove power steering tank from the pipes onto intake manifold protector. bracket by pulling it upwards. NOTE: Do not disconnect power steering hose. B2M3153 (8) Place power steering pump and tank on the B2M4126 right side wheel apron.
  • Page 200 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 11) Disconnect brake booster hose. 15) Disconnect connector from crankshaft position sensor. B2M4259 B2M1252 12) Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness 16) Disconnect connector from oil pressure connectors from bulkhead harness connectors.
  • Page 201 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 18) Disconnect fuel hoses from fuel pipes. B: INSTALLATION S135034A11 WARNING: 1) Install intake manifold onto cylinder heads. ¼ Do not spill fuel. NOTE: ¼ Catch fuel from hoses in a container or cloth. Always use new gaskets.
  • Page 202 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 4) Connect connector to oil pressure switch. 8) Install air cleaner case stay RH and engine har- ness bracket, and connect engine harness con- nectors to bulkhead connectors. B2M1253 5) Connect connector to crankshaft position sen- B2M4260 sor.
  • Page 203 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 13) Install power steering pump and tank on (4) Install power steering pipes onto right side brackets. intake manifold protector. (1) Install power steering tank on bracket. B2M4126 B2M3153 (5) Install power steering pump drive V-belt. (2) Connect connector to power steering pump switch.
  • Page 204 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 14) Connect accelerator cable (A). C: DISASSEMBLY S135034A06 15) Connect cruise control cable (B). (With cruise 1) Disconnect engine ground terminal from intake control models) manifold. B2M4254A B2M4265 16) Install air intake duct and air cleaner assem- 2) Disconnect connector from ignition coil and bly.
  • Page 205 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 5) Remove intake air temperature and pressure 10) Remove fuel pipe protector RH. sensor from intake manifold. B2M4130 H2M2960 11) Disconnect connectors from fuel injectors. 6) Disconnect connectors from throttle position sensor and idle air control solenoid valve. 7) Remove throttle body.
  • Page 206 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 13) Disconnect air by-pass hose from purge con- 17) Remove bolt which installs injector pipe on trol solenoid valve. intake manifold as shown in figure. H2M2949A H2M2965 18) Remove bolt which installs injector pipe on Throttle position sensor Idle air control solenoid valve intake manifold.
  • Page 207 INTAKE MANIFOLD Fuel Injection (Fuel Systems) (2) Remove fuel injector while lifting up fuel 24) Remove bolt which installs fuel pipes on injector pipe. intake manifold. H2M2970 H2M2974 21) Loosen clamp which holds front left side fuel 25) Remove fuel pipe assembly and pressure hose to injector pipe and remove the pipe from regulator, from intake manifold.
  • Page 208 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 2) Tighten bolt which installs fuel pipes on intake 6) Install fuel injectors. manifold. NOTE: Tightening torque: Always use new O-rings and insulators. 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3372A H2M2974 O-ring 3) Connect right side fuel hose to injector pipe, Fuel injector and tighten clamp screw.
  • Page 209 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 8) Tighten two bolts which install fuel pipes on the 11) Connect hoses to purge control solenoid left side of intake manifold. valve. Tightening torque: CAUTION: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) Carefully connect the evaporation hoses. B2M4272 B2M1893D 9) Tighten bolt which install injector pipe on intake...
  • Page 210 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 16) Install intake manifold protector LH. 19) Connect air by-pass hose from purge control solenoid valve to intake manifold. Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) H2M2949A B2M4129 20) Install intake air temperature and pressure sensor.
  • Page 211 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 21) Connect connector to intake air temperature and pressure sensor. 22) Connect connectors to throttle position sensor and idle air control solenoid valve. 23) Install ignition coil and ignitor assembly. H2M2958 24) Connect connector to ignition coil and ignitor assembly.

  • Page 212: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR Fuel Injection (Fuel Systems) 4. Engine Coolant Temperature B: INSTALLATION S135047A11 Sensor Install in the reverse order of removal. S135047 Tightening torque: A: REMOVAL S135047A18 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Disconnect battery ground cable. B2M4275 G6M0095 2) Remove air intake duct and air cleaner assem-...

  • Page 213: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 5. Crankshaft Position Sensor B: INSTALLATION S135043A11 Install in the reverse order of removal. S135043 A: REMOVAL Tightening torque: S135043A18 T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. B2M1252B G6M0095 2) Remove bolt which install crankshaft position sensor to cylinder block.

  • Page 214: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 6. Camshaft Position Sensor 4) Remove bolt which installs camshaft position sensor support to camshaft cap LH. S135041 A: REMOVAL S135041A18 1) Disconnect battery ground cable. B2M2321 5) Remove camshaft position sensor and cam- shaft position sensor support as a unit.

  • Page 215: Knock Sensor

    KNOCK SENSOR Fuel Injection (Fuel Systems) 7. Knock Sensor B: INSTALLATION S135042A11 S135042 1) Install knock sensor to cylinder block. A: REMOVAL S135042A18 Tightening torque: 1) Disconnect battery ground cable from battery 24 N·m (2.4 kgf-m, 17.4 ft-lb) ground terminal. NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...
  • Page 216 KNOCK SENSOR Fuel Injection (Fuel Systems) 4) Connect battery ground cable. G6M0095 FU(w/oOBD)-31...

  • Page 217: Throttle Position Sensor

    THROTTLE POSITION SENSOR Fuel Injection (Fuel Systems) 8. Throttle Position Sensor B: INSTALLATION S135039A11 S135039 Install in the reverse order of removal. A: REMOVAL S135039A18 Tightening torque: 1) Disconnect battery ground cable. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.
  • Page 218 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3148A 5) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. 6) Select {2. Each System Check} in Main Menu. 7) Select {Engine Control System} in Selection Menu.
  • Page 219 THROTTLE POSITION SENSOR Fuel Injection (Fuel Systems) Condition: Throttle fully closed Throttle opening angle 0.00% Throttle sensor voltage 0.50 V 11) Tighten throttle position sensor holding screws. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3765 FU(w/oOBD)-34...

  • Page 220: Intake Air Temperature And Pressure Sensor

    INTAKE AIR TEMPERATURE AND PRESSURE SENSOR Fuel Injection (Fuel Systems) 9. Intake Air Temperature and 4) Remove intake air temperature and pressure sensor. Pressure Sensor S135044 A: REMOVAL S135044A18 NOTE: This sensor is installed on AT vehicles only. 1) Disconnect battery ground cable. H2M2982 B: INSTALLATION S135044A11...

  • Page 221: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE Fuel Injection (Fuel Systems) 10. Idle Air Control Solenoid B: INSTALLATION S135056A11 Valve Install in the reverse order of removal. S135056 NOTE: A: REMOVAL S135056A18 Always use new gasket. 1) Disconnect battery ground cable. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 H2M2984...
  • Page 222 FUEL INJECTOR Fuel Injection (Fuel Systems) 11. Fuel Injector 7) Remove power steering pump and tank from S135051 brackets. A: REMOVAL (1) Remove V-belt covers. S135051A18 1. RH SIDE S135051A1801 1) Release fuel pressure. <Ref. to FU(w/oOBD)-48, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>...

  • Page 223: Fuel Injector

    FUEL INJECTOR Fuel Injection (Fuel Systems) (5) Disconnect connector from power steering 9) Disconnect connector from fuel injector. pump switch. B2M4280 B2M4257 10) Remove bolt which holds injector pipe to (6) Remove power steering tank from the intake manifold. bracket by pulling it upwards. B2M4281 B2M3153 11) Remove bolt which install injector pipe to...
  • Page 224 FUEL INJECTOR Fuel Injection (Fuel Systems) (2) Remove fuel injector while lifting up fuel 4) Remove two bolts which install washer tank on injector pipe. body. H2M2992 B2M3139 5) Disconnect connector from front window 2. LH SIDE washer motor. S135051A1802 6) Disconnect connector from rear gate glass 1) Release fuel pressure.
  • Page 225 FUEL INJECTOR Fuel Injection (Fuel Systems) 9) Remove spark plug cords from spark plugs (#2 13) Remove bolt which installs injector pipe to intake manifold. and #4 cylinders). H2M2994 B2M4287 14) Remove bolt which holds fuel pipe on the left 10) Remove fuel pipe protector LH.
  • Page 226 FUEL INJECTOR Fuel Injection (Fuel Systems) Tightening torque: B: INSTALLATION S135051A11 19 N·m (1.9 kgf-m, 13.7 ft-lb) 1. RH SIDE S135051A1101 Install in the reverse order of removal. NOTE: Replace O-rings with new ones. B2M4130 Tightening torque: 32 N·m (3.3 kgf-m, 23.9 ft-lb) B2M3372A O-ring Fuel injector...
  • Page 227 FUEL INJECTOR Fuel Injection (Fuel Systems) Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) H2M2994 Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) H2M2995 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) B2M4133 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) B2M4129 FU(w/oOBD)-42...
  • Page 228 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) H2M2977 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove oxygen sensor.
  • Page 229 OXYGEN SENSOR Fuel Injection (Fuel Systems) 5) Connect battery ground cable. G6M0095 FU(w/oOBD)-44...

  • Page 230: Engine Control Module

    ENGINE CONTROL MODULE Fuel Injection (Fuel Systems) 13. Engine Control Module 5) Remove nuts which hold ECM to bracket. S135049 A: REMOVAL S135049A18 1) Disconnect battery ground cable. B2M3162 6) Remove clip from bracket. G6M0095 2) Remove lower inner trim of passenger side. <Ref.

  • Page 231: Main Relay

    MAIN RELAY Fuel Injection (Fuel Systems) 14. Main Relay S135050 A: REMOVAL S135050A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower inner trim of passenger side. <Ref. to EI-41, REMOVAL, Lower Inner Trim.> B2M0672 3) Disconnect connectors from main relay. 4) Remove bolt which holds main relay bracket on body.

  • Page 232: Fuel Pump Relay

    FUEL PUMP RELAY Fuel Injection (Fuel Systems) 15. Fuel Pump Relay S135048 A: REMOVAL S135048A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower cover. <Ref. EI-35, REMOVAL, Instrument Panel Assembly.> 3) Disconnect connector from fuel pump relay. B2M3159 4) Remove fuel pump relay from mounting bracket.

  • Page 233: Fuel

    FUEL Fuel Injection (Fuel Systems) 16. Fuel 3) Lift-up the vehicle. S135052 4) Remove front right side fuel tank cover. A: OPERATION S135052A16 1. RELEASING OF FUEL PRESSURE S135052A1601 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Disconnect connector from fuel pump relay.
  • Page 234 FUEL Fuel Injection (Fuel Systems) Tightening torque: 11) Remove fuel sub level sensor. 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M3178 B2M3173 12) Drain fuel from fuel tank by using hand pump. 7) Lower the vehicle. WARNING: 8) Remove sub service hole cover. Do not use a motor pump when draining fuel.
  • Page 235 FUEL Fuel Injection (Fuel Systems) (2) Connect connector from fuel sub level sen- sor. B2M3176 (3) Install sub service hole cover. B2M3175 (4) Set rear seat and floor mat. FU(w/oOBD)-50...

  • Page 236: Fuel Tank

    6) Push grommet which holds fuel tank cord on service hole cover into body side. B2M3173 B2M3179 13) Remove rear exhaust pipe and muffler. NOTE: To facilitate removal, apply a coat of SUBARU CRC to matching area of rubber cushions in advance. SUBARU CRC (Part No. 004301003) FU(w/oOBD)-51...
  • Page 237 FUEL TANK Fuel Injection (Fuel Systems) (1) Separate rear exhaust pipe from center 14) Remove propeller shaft. <Ref. to DS-13, exhaust pipe. REMOVAL, Propeller Shaft.> 15) Disconnect connector from ABS sensor. B2M3109 B2M3184 (2) Remove left and right rubber cushions. 16) Remove bolts which hold parking brake cable CAUTION: holding bracket.
  • Page 238 FUEL TANK Fuel Injection (Fuel Systems) 19) Remove bolts which hold rear brake hoses (3) Remove bolt which secure rear suspension holding bracket. assembly to body. B2M3187 20) Remove rear brake caliper, then tie it up to the body side of the vehicle as shown in figure. B2M3190 (4) Remove rear suspension assembly.
  • Page 239 FUEL TANK Fuel Injection (Fuel Systems) 24) Loosen clamp and disconnect fuel filler hose B: INSTALLATION S135053A11 (A) and air vent hose (B) from fuel filler pipe. 1) Support fuel tank with transmission jack and push fuel tank harness into access hole with grom- met.
  • Page 240 FUEL TANK Fuel Injection (Fuel Systems) 5) Tighten band mounting bolts. (1) Support rear suspension assembly and then tighten bolts which secure rear suspension Tightening torque: assembly. 33 N·m (3.4 kgf-m, 25 ft-lb) Tightening torque: T1: 172 N·m (17.5 kgf-m, 127 ft-lb) T2: 108 N·m (11.0 kgf-m, 80 ft-lb) T3: 66 N·m (6.7 kgf-m, 48 ft-lb) B2M3194...
  • Page 241 NOTE: pushing it forward. To facilitate the procedure, apply a coat of 11) Tighten bolts which hold parking brake cable SUBARU CRC to matching area of rubber cush- holding bracket. ions in advance. Tightening torque: SUBARU CRC (Part No. 004301003) 18 N·m (1.8 kgf-m, 13.0 ft-lb)
  • Page 242 FUEL TANK Fuel Injection (Fuel Systems) (2) Install front rubber cushion and attach muf- 16) Install rear wheel. fler assembly. 17) Lower the vehicle. 18) Tighten wheel nuts to rear wheel. 19) Install parking brake cable. <Ref. to PB-6, INSTALLATION, Parking Brake Cable.> B2M3118 (3) Install rear exhaust pipe to center exhaust pipe.
  • Page 243 FUEL TANK Fuel Injection (Fuel Systems) 23) Connect connector to fuel sub level sensor. B2M3159 29) Adjust parking brake lever stroke. <Ref. to B2M3176 PB-4, ADJUSTMENT, Parking Brake Lever.> 24) Install sub service hole cover. 30) Check wheel alignment and adjust if neces- sary.

  • Page 244: Fuel Filler Pipe

    FUEL FILLER PIPE Fuel Injection (Fuel Systems) 18. Fuel Filler Pipe 6) Remove rear right side wheel nuts. S135022 7) Lift-up the vehicle. A: REMOVAL 8) Remove rear right side wheel. S135022A18 1) Set the vehicle on the lift. 2) Release fuel pressure. <Ref. to FU(w/oOBD)- RELEASING FUEL PRESSURE,...
  • Page 245 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 11) Tighten fuel drain plug and then install front 13) Remove bolts which hold evaporation pipe right side tank cover. bracket on fuel filler pipe. Tightening torque: 26 N·m (2.65 kgf-m, 19.2 ft-lb) B2M3174 Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
  • Page 246 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 5) Insert air vent hose approximately 25 to 30 mm B: INSTALLATION S135022A11 (0.98 to 1.18 in) into the lower end of air vent pipe 1) Hold fuel filler flap open. and hold clip. 2) Set fuel saucer (A) with rubber packing (C) and L = 27.5±2.5 mm (1.083±0.098 in) insert fuel filler pipe into hole from the inner side of...
  • Page 247 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 7) Tighten bolts which hold evaporation pipe 12) Connect connector to fuel pump relay. bracket on fuel pipe. B2M3159 13) Connect battery ground terminal. B2M4174 G6M0095 8) Install fuel filler pipe protector. B2M3198 9) Install rear right wheel.

  • Page 248: Fuel Pump

    FUEL PUMP Fuel Injection (Fuel Systems) 19. Fuel Pump 6) Drain fuel from fuel tank. Set a container under S135025 the vehicle and remove drain plug from fuel tank. A: REMOVAL S135025A18 WARNING: ¼ Place “NO FIRE” signs near the working area.
  • Page 249 FUEL PUMP Fuel Injection (Fuel Systems) 9) Remove access hole lid. 14) Take off fuel pump assembly from fuel tank. B: INSTALLATION S135025A11 Install in the reverse order of removal. Do the fol- lowing: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or for- eign particles before installation.
  • Page 250 FUEL PUMP Fuel Injection (Fuel Systems) D: ASSEMBLY S135025A02 Assemble in the reverse order of disassembly. E: INSPECTION S135025A10 Connect lead harness to connector terminal of fuel pump and apply battery power supply to check whether the pump operate. WARNING: ¼...

  • Page 251: Fuel Level Sensor

    FUEL LEVEL SENSOR Fuel Injection (Fuel Systems) 20. Fuel Level Sensor B: INSTALLATION S135026A11 S135026 Install in the reverse order of removal. A: REMOVAL S135026A18 WARNING: WARNING: ¼ Ground cable must be connected. ¼ Place “NO FIRE” signs near the working ¼...

  • Page 252: Fuel Sub Level Sensor

    FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 21. Fuel Sub Level Sensor 5) Tighten fuel drain plug and install front right side S135023 fuel tank cover. A: REMOVAL S135023A18 Tightening torque: 26 N·m (2.65 kgf-m, 19.2 ft-lb) WARNING: ¼ Place “NO FIRE” signs near the working area.
  • Page 253 FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 9) Disconnect connector from fuel sub level sen- B: INSTALLATION S135023A11 sor. Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3176 10) Disconnect fuel jet pump hose. B2M3178 B2M3177 11) Remove bolts which install fuel sub level sen-...

  • Page 254: Fuel Filter

    FUEL FILTER Fuel Injection (Fuel Systems) 22. Fuel Filter 1) Set O-ring on the filter holder and install by S135027 turning to the right. A: REMOVAL S135027A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. NOTE: Fuel filter is built in fuel pump assembly.

  • Page 255: Fuel Cut Valve

    FUEL CUT VALVE Fuel Injection (Fuel Systems) 23. Fuel Cut Valve S135021 A: REMOVAL S135021A18 1) Remove fuel tank. <Ref. to FU(w/oOBD)-51, REMOVAL, Fuel Tank.> 2) Move clip and disconnect evaporation hose from fuel cut valve. B2M3201 3) Remove bolts which install fuel cut valve. B: INSTALLATION S135021A11 Install in the reverse order of removal.
  • Page 256 FUEL DUMPER VALVE Fuel Injection (Fuel Systems) 24. Fuel Dumper Valve S135708 A: REMOVAL S135708A18 1) Release fuel pressure. <Ref. to FU(w/oOBD)- RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Remove fuel damper valve from fuel delivery line (A) and return line (B). B2M3404A B: INSTALLATION S135708A11...
  • Page 257 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 25. Fuel Delivery, Return and 3) Open fuel filler flap lid and remove fuel filler cap. Evaporation Lines S135019 4) Remove floor mat. <Ref. to EI-51, REMOVAL, Floor Mat.> A: REMOVAL S135019A18 5) Remove fuel delivery pipes and hoses, fuel 1) Set vehicle on the lift.
  • Page 258 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 9) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are cov- ered with dust. (2) Hold connector (A) and push retainer (B) down.
  • Page 259 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 2) Connect fuel delivery hose to pipe with an over- lap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. : 2.5±1.5 mm (0.098±0.059 in) L: 22.5±2.5 mm (0.886±0.098 in) B2M1194B...
  • Page 260 FUEL SYSTEM TROUBLE IN GENERAL Fuel Injection (Fuel Systems) 26. Fuel System Trouble in General S135571 A: INSPECTION S135571A10 Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten Defective terminal contact.
  • Page 261 FUEL SYSTEM TROUBLE IN GENERAL Fuel Injection (Fuel Systems) MEMO: FU(w/oOBD)-76...
  • Page 262 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) Page General Description..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister .......................7 Purge Control Solenoid Valve ..............8 Two-way Valve ....................9...
  • Page 263 GENERAL DESCRIPTION Emission Control (AUX. Emission Control Devices) 1. General Description S170001 A: CAUTION S170001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼...
  • Page 264 FRONT CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 2. Front Catalytic Converter 7) Separate front and center exhaust pipe from S170017 rear exhaust pipe. A: REMOVAL S170017A18 CAUTION: Be careful, exhaust pipe is hot. 1) Set the vehicle on the lift. 2) Disconnect battery ground cable.
  • Page 265 FRONT CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 10) Separate front catalytic converter from front 3) Tighten nuts which hold front exhaust pipe onto exhaust pipe. cylinder heads. NOTE: Tightening torque: The rear catalytic converter is integrated with front 30 N·m (3.1 kgf-m, 22.4 ft-lb) catalytic converter.
  • Page 266 FRONT CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 7) Lower the vehicle. 8) Connect front oxygen (A/F) sensor connector. B2M4243 9) Connect connector to rear oxygen sensor con- nector. B2M4244 10) Connect battery ground cable. G6M0095 C: INSPECTION S170017A10 1) Make sure there are no exhaust leaks from con- nections and welds.
  • Page 267 REAR CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 3. Rear Catalytic Converter S170036 A: REMOVAL S170036A18 The front and rear catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the removal and installation procedures are the same as the those for the front catalytic converter.
  • Page 268 CANISTER Emission Control (AUX. Emission Control Devices) 4. Canister S170037 A: REMOVAL S170037A18 1) Lift-up the vehicle. 2) Loosen two clamps which hold two canister hoses, and disconnect evaporation hose from can- ister. B2M4165 3) Remove canister from body. B2M4166 B: INSTALLATION S170037A11 1) Install in the reverse order of removal.
  • Page 269 PURGE CONTROL SOLENOID VALVE Emission Control (AUX. Emission Control Devices) 5. Purge Control Solenoid B: INSTALLATION S170035A11 Valve 1) Install in the reverse order of removal. S170035 Tightening torque: A: REMOVAL S170035A18 16 N·m (1.6 kgf-m, 11.6 ft-lb) 1) Disconnect battery ground cable. H2M2985 G6M0095 CAUTION:...
  • Page 270 TWO-WAY VALVE Emission Control (AUX. Emission Control Devices) 6. Two-way Valve S170707 A: REMOVAL S170707A18 1) Lift-up the vehicle. 2) Disconnect hoses from two-way valve. B2M4167 3) Remove two-way valve with bracket as a single unit from body. B2M4168 4) Remove two-way valve from bracket. B: INSTALLTION S170707A11 1) Install in the reverse order of removal.
  • Page 271 TWO-WAY VALVE Emission Control (AUX. Emission Control Devices) MEMO: EC-10...
  • Page 272 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(w/oOBD) Page General Description..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister .......................7 Purge Control Solenoid Valve ..............8 Two-way Valve ....................9...

  • Page 273: General Description

    GENERAL DESCRIPTION Emission Control (AUX. Emission Control Devices) 1. General Description S130001 A: CAUTION S130001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼...

  • Page 274: Front Catalytic Converter

    FRONT CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 2. Front Catalytic Converter 7) Remove nuts which hold front exhaust pipe S130017 onto cylinder heads. A: REMOVAL S130017A18 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. B2M3200 8) Remove front and center exhaust pipe from hanger bracket.
  • Page 275 FRONT CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 4) Tighten bolts which secure front and center B: INSTALLATION S130017A11 exhaust pipe assembly to rear exhaust pipe. NOTE: Tightening torque: Replace gaskets with new ones. 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Install front catalytic converter to front exhaust pipe.
  • Page 276 FRONT CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 9) Connect battery ground cable. G6M0095 C: INSPECTION S130017A10 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EC(w/oOBD)-5...

  • Page 277: Rear Catalytic Converter

    REAR CATALYTIC CONVERTER Emission Control (AUX. Emission Control Devices) 3. Rear Catalytic Converter S130036 A: REMOVAL S130036A18 The front and rear catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the removal and installation procedures are the same as the those for the front catalytic converter.

  • Page 278: Canister

    CANISTER Emission Control (AUX. Emission Control Devices) 4. Canister B: INSTALLATION S130037A11 S130037 Install in the reverse order of removal. A: REMOVAL S130037A18 Tightening torque: 1) Lift-up the vehicle. 7.4±2.0 N·m (0.75±0.2 kgf-m, 5.4±1.4 ft-lb) 2) Disconnect canister hoses from canister. B2M3115 B2M3840 CAUTION:...

  • Page 279: Purge Control Solenoid Valve

    PURGE CONTROL SOLENOID VALVE Emission Control (AUX. Emission Control Devices) 5. Purge Control Solenoid B: INSTALLATION S130035A11 Valve Install in the reverse order of removal. S130035 Tightening torque: A: REMOVAL S130035A18 16 N·m (1.6 kgf-m, 11.6 ft-lb) 1) Disconnect battery ground cable. H2M2985 G6M0095 CAUTION:...

  • Page 280: Two-Way Valve

    TWO-WAY VALVE Emission Control (AUX. Emission Control Devices) 6. Two-way Valve S130707 A: REMOVAL S130707A18 1) Lift-up the vehicle. 2) Disconnect hoses from two-way valve, and remove it. B2M3399B From fuel tank To canister Pressure valve Valve Body Seat B2M3116 Pressure valve Spring B: INSTALLATION...
  • Page 281 TWO-WAY VALVE Emission Control (AUX. Emission Control Devices) MEMO: EC(w/oOBD)-10...
  • Page 282 INTAKE (INDUCTION) Page General Description..................2 Air Cleaner Element ..................5 Air Cleaner Case..................6 Air Intake Duct.....................7 Resonator Chamber ..................8...
  • Page 283 GENERAL DESCRIPTION Intake (Induction) 1. General Description S174001 A: COMPONENT S174001A05 B2M4250A IN-2...
  • Page 284 GENERAL DESCRIPTION Intake (Induction) (1) Spacer (12) Air cleaner case B Tightening torque: N·m (kgf-m, ft-lb) (2) Bushing (13) Air cleaner case stay LH (MT 32.4 (3.3, 23.9) (3) Resonator chamber vehicles) 6.5 (0.66, 4.8) (4) Cushion rubber (14) Air cleaner case stay LH (AT 7.5 (0.76, 5.5) (5) Air intake duct A vehicles)

  • Page 285: General Description

    GENERAL DESCRIPTION Intake (Induction) B: CAUTION S174001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼ Keep the disassembled parts in order and pro- tect them from dust or dirt.

  • Page 286: Air Cleaner Element

    AIR CLEANER ELEMENT Intake (Induction) 2. Air Cleaner Element S174687 A: REMOVAL S174687A18 1) Remove the clip (A) above the air cleaner case. H2M2947B 2) Remove air cleaner element. B: INSTALLATION S174687A11 Install in the reverse order of removal. CAUTION: Fasten with a clip after inserting the lower tab of the case.

  • Page 287: Air Cleaner Case

    AIR CLEANER CASE Intake (Induction) 3. Air Cleaner Case S174089 A: REMOVAL S174089A18 1) Loosen clamp which connects air cleaner case to throttle body. H2M2946 2) Disconnect hoses and intake duct from air cleaner case. 3) Remove bolts which install air cleaner case to stays.

  • Page 288: Air Intake Duct

    AIR INTAKE DUCT Intake (Induction) 4. Air Intake Duct S174566 A: REMOVAL S174566A18 1) Remove bolts which install air intake duct on the front side of body. B6M1222 2) Remove bolt which installs air intake duct on body. B6M1302 3) Remove air intake ducts as a unit. B6M1224 B: INSTALLATION S174566A11...

  • Page 289: Resonator Chamber

    RESONATOR CHAMBER Intake (Induction) 5. Resonator Chamber B: INSTALLATION S174639A11 S174639 Install in the reverse order of removal. A: REMOVAL S174639A18 Tightening torque: 1) Remove air intake duct. <Ref. to IN-7, 32.4 N·m (3.3 kgf-m, 23.9 ft-lb) REMOVAL, Air Intake Duct.> 2) Remove resonator chamber.
  • Page 290 MECHANICAL Page General Description..................2 Compression .....................24 Idle Speed ....................25 Ignition Timing ...................26 Intake Manifold Vacuum................27 Engine Oil Pressure ..................28 Fuel Pressure ....................29 Valve Clearance ..................30 Engine Assembly..................34 Engine Mounting ..................43 Preparation for Overhaul................44 V-belt ......................45 Crankshaft Pulley ..................47 Belt Cover....................49 Timing Belt Assembly ................50 Camshaft Sprocket..................55 Crankshaft Sprocket..................57...

  • Page 291: General Description

    GENERAL DESCRIPTION Mechanical 1. General Description S173001 A: SPECIFICATIONS S173001E49 Model 2000 cc 2500 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso- Type line engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95) 99.5 x 79.0 (3.917 x 3.110) Displacement (cu in)
  • Page 292 GENERAL DESCRIPTION Mechanical Bend limit 0.025 mm (0.0010 in) 0.030 — 0.090 mm (0.0012 — 0.0035 in) Thrust clearance Limit 0.10 mm (0.0039 in) 38.732 — 38.832 mm (1.5249 — 1.5288 in) Intake Limit 38.632 mm (1.5209 in) 2000 cc 39.257 —...
  • Page 293 GENERAL DESCRIPTION Mechanical Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in) Surface grinding limit 0.1 mm (0.004 in) 92.005 — 92.015 mm (3.6222 — 3.6226 in) 2000 cc 91.995 — 92.005 mm (3.6218 — 3.6222 in) Cylinder bore 99.505 —...
  • Page 294 GENERAL DESCRIPTION Mechanical 0.010 — 0.038 mm (0.0004 — 0.0015 in) 2000 cc Limit 0.05 mm (0.0020 in) Oil clearance 0.012 — 0.037 mm (0.0005 — 0.0015 in) 2500 cc Limit 0.05 mm (0.0020 in) 1.492 — 1.501 mm (0.0587 — 0.0591 in) 0.03 mm (0.0012 in) 1.510 —...
  • Page 295 GENERAL DESCRIPTION Mechanical 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 in) 2.017 — 2.020 mm (0.0794 — 0.0795 in) #1, #3 0.05 mm (0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in) 0.25 mm (0.0098 in) 2.127 —...
  • Page 296 GENERAL DESCRIPTION Mechanical B: COMPONENT S173001A05 1. TIMING BELT S173001A0501 B2M3122A (1) Belt cover No. 2 (RH) (11) Camshaft sprocket No. 2 Tightening torque: N·m (kgf-m, ft-lb) (2) Timing belt guide (MT vehicles (12) Timing belt 5 (0.5, 3.6) only) (13) Front belt cover 9.8 (1.0, 7.2) (3) Crankshaft sprocket...
  • Page 297 GENERAL DESCRIPTION Mechanical 2. CYLINDER HEAD AND CAMSHAFT S173001A0502 B2M1954D (1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb) (2) Intake valve rocker ASSY (12) Camshaft (LH) <Ref. to ME-65, (3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) INSTALLATION, Cylinder (4) Camshaft cap (RH) (14) Oil filler cap...
  • Page 298 GENERAL DESCRIPTION Mechanical 3. VALVE ROCKER ASSEMBLY S173001A0503 B2M1956A (1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb) (2) Valve rocker nut (7) Exhaust rocker shaft 5 (0.5, 3.6) (3) Valve rocker adjust screw (8) Exhaust valve rocker arm 10 (1.0, 7.2) (4) Spring 25 (2.5, 18.1)
  • Page 299 GENERAL DESCRIPTION Mechanical 4. CYLINDER HEAD AND VALVE ASSEMBLY S173001A0504 B2M1955D (1) Exhaust valve (4) Valve spring seat (7) Retainer (2) Intake valve (5) Intake valve oil seal (8) Retainer key (3) Valve guide (6) Valve spring (9) Exhaust valve oil seal ME-10...
  • Page 300 GENERAL DESCRIPTION Mechanical 5. CYLINDER BLOCK S173001A0505 B2M4154B (1) Oil pressure switch (15) Oil filter connector Tightening torque: N·m (kgf-m, ft-lb) (2) Cylinder block (RH) (16) Oil strainer 5 (0.5, 3.6) (3) Service hole plug (17) Gasket 6.4 (0.65, 4.7) (4) Gasket (18) Oil pan 10 (1.0, 7)
  • Page 301 GENERAL DESCRIPTION Mechanical 6. CRANKSHAFT AND PISTON S173001A0506 B2M3429A ME-12...
  • Page 302 GENERAL DESCRIPTION Mechanical (1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4 (2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5 (3) Drive plate (AT) (11) Connecting rod (4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb) (5) Second ring (13) Connecting rod cap 44.6 (4.55, 32.9)
  • Page 303 GENERAL DESCRIPTION Mechanical 7. ENGINE MOUNTING S173001A0507 B2M3382A (1) Front cushion rubber (3) Front cushion rubber (2500 cc Tightening torque: N·m (kgf-m, ft-lb) (2000 cc model) model) 34 (3.5, 25.3) (2) Front engine mounting bracket 41 (4.2, 30) (2000 cc model) 85 (8.7, 63) C: CAUTION removal, installation, disassembly, and replace-...
  • Page 304 GENERAL DESCRIPTION Mechanical ¼ All parts should be thoroughly cleaned, paying ¼ Remove or install engine in an area where chain special attention to the engine oil passages, pis- hoists, lifting devices, etc. are available for ready tons and bearings. use.
  • Page 305 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498497100 CRANKSHAFT Used for stopping rotation of flywheel when STOPPER loosening and tightening crankshaft pulley bolt, etc. B2M3853 498747100 PISTON GUIDE Used for installing piston in cylinder. (2000 cc model) 498747300 (2500 cc model) B2M3854 498857100 VALVE OIL SEAL...
  • Page 306 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499037100 CONNECTING ROD Used for removing and installing connecting rod BUSHING bushing. REMOVER & INSTALLER B2M3857 499097700 PISTON PIN Used for removing piston pin. REMOVER ASSY B2M3858 499207100 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket.
  • Page 307 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587700 CAMSHAFT OIL Used for installing cylinder head plug. SEAL INSTALLER B2M3860 ¼ Used for installing crankshaft oil seal. 499587200 CRANKSHAFT OIL ¼ Used with CRANKSHAFT OIL SEAL GUIDE SEAL INSTALLER (499597100). B2M3861 ¼...
  • Page 308 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499718000 VALVE SPRING Used for removing and installing valve spring. REMOVER B2M3864 499767700 VALVE GUIDE Used for installing valve guides. (Intake side) ADJUSTER 499767800 (Exhaust side) B2M3865 499767200 VALVE GUIDE Used for removing valve guides. REMOVER B2M3867 499767400...
  • Page 309 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Stand used for engine disassembly and 499817100 ENGINE STAND assembly. ¼ Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100). B2M3869 499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolts.
  • Page 310 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498547000 OIL FILTER Used for removing and installing oil filter. WRENCH B2M3872 499497000 TORX PLUS Used for removing and installing camshaft cap. B2M3873 499587500 OIL SEAL Used for installing front camshaft oil seal. INSTALLER B2M3874 499587100...
  • Page 311 GENERAL DESCRIPTION Mechanical ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498277200 STOPPER SET Used for installing automatic transmission assembly to engine. B3M2043 499057000 TORX PLUS Used for removing flywheel (Dual mass fly- wheel). B2M4159 24082AA190 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) B2M3876 22771AA030 SELECT MONITOR...
  • Page 312 GENERAL DESCRIPTION Mechanical E: PROCEDURE S173001E45 It is possible to conduct the following service pro- cedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.

  • Page 313: Compression

    COMPRESSION Mechanical 2. Compression S173081 A: INSPECTION S173081A10 CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during mea- surement. 1) After warming-up the engine, turn ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release fuel pressure.

  • Page 314: Idle Speed

    7) Check idle speed when loaded. (Turn air con- B2M3148 ditioning switch to “ON” and operate compressor (3) Turn ignition switch to ON, and SUBARU for at least one minute before measurement.) SELECT MONITOR switch to ON. Idle speed [A/C “ON”, no load and gears in (4) Select {2.

  • Page 315: Ignition Timing

    IGNITION TIMING Mechanical 4. Ignition Timing S173086 A: INSPECTION S173086A10 CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during mea- surement. 1) Warm-up the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light.

  • Page 316: Intake Manifold Vacuum

    INTAKE MANIFOLD VACUUM Mechanical 5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the S173654 vacuum gauge indication. A: INSPECTION By observing the gauge needle movement, the S173654A10 internal condition of the engine can be diagnosed 1) Warm-up the engine.

  • Page 317: Engine Oil Pressure

    ENGINE OIL PRESSURE Mechanical 6. Engine Oil Pressure 7) Start the engine, and measure oil pressure. S173655 A: INSPECTION S173655A10 1) Disconnect battery ground cable. S2M0242 Oil pressure: 98 kPa (1.0 kg/cm , 14 psi) or more at 800 G6M0095 294 kPa (3.0 kg/cm , 43 psi) or more at 2) Remove generator from bracket.

  • Page 318: Fuel Pressure

    FUEL PRESSURE Mechanical 7. Fuel Pressure 5) Start the engine. S173656 6) Measure fuel pressure while disconnecting A: INSPECTION pressure regulator vacuum hose from intake mani- S173656A10 fold. WARNING: Fuel pressure: Before removing fuel pressure gauge, release Standard; 284 — 314 kPa (2.9 — 3.2 fuel pressure.

  • Page 319: Valve Clearance

    VALVE CLEARANCE Mechanical 8. Valve Clearance 7) Remove rocker cover. S173083 8) When inspecting #1 and #3 cylinders; A: INSPECTION (1) Remove bolt which secures air intake duct S173083A10 to radiator panel side. CAUTION: (2) Remove air intake duct as a unit. Inspection and adjustment of valve clearance should be performed while engine is cold.
  • Page 320 VALVE CLEARANCE Mechanical 9) When inspecting #2 and #4 cylinders; (6) Disconnect PCV hose from rocker cover (1) Disconnect battery cables, then (LH). remove battery and battery carrier. (7) Remove bolts, then remove rocker cover (LH). 10) Set #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise using ST.
  • Page 321 VALVE CLEARANCE Mechanical 12) If necessary, adjust the valve clearance. <Ref. B: ADJUSTMENT S173083A01 to ME-32, ADJUSTMENT, Valve Clearance.> CAUTION: 13) Similar to measurement procedures used for Adjustment of valve clearance should be per- #1 cylinder, measure #2, #3 and #4 cylinder valve formed while engine is cold.
  • Page 322 VALVE CLEARANCE Mechanical 2) Adjust the #1 cylinder valve clearance. 6) Similar to adjustment procedures used for #1 cylinder, adjust #2, #3 and #4 cylinder valve clear- (1) Loosen the valve rocker nut and screw. ances. (2) Place suitable thickness gauge. (3) While noting valve clearance, tighten valve NOTE: rocker adjust screw.

  • Page 323: Engine Assembly

    ENGINE ASSEMBLY Mechanical 9. Engine Assembly (1) Place and connect the attachment hose to S173079 the refrigerant recycle system. A: REMOVAL (2) Collect refrigerant from A/C system. S173079A18 (3) Disconnect A/C pressure hoses from A/C 1) Set the vehicle on lift arms. compressor.
  • Page 324 ENGINE ASSEMBLY Mechanical 12) Disconnect the following connectors and (4) Engine harness connectors cables. (1) Front oxygen (A/F) sensor connector (With OBD) B2M4243 (2) Front oxygen sensor connector (Without OBD) B2M4292 (5) Alternator connector, terminal and A/C com- pressor connector H2M2977 (3) Engine ground terminal B2M3386B...
  • Page 325 ENGINE ASSEMBLY Mechanical (7) Pressure switch (4) Remove bolts which install power steering pump bracket. B2M4257 B2M3151 13) Disconnect the following hoses. (1) Brake booster vacuum hose (5) Remove power steering tank from the bracket by pulling it upward. B2M3419 B2M3153 (2) Heater inlet outlet hose (6) Place power steering pump on the right side...
  • Page 326 ENGINE ASSEMBLY Mechanical 16) Remove nuts which hold lower side of trans- 19) Remove pitching stopper. mission to engine. H3M1839 B3M2047 20) Disconnect fuel delivery hose, return hose and 17) Remove nuts which install front cushion rub- evaporation hose. ber onto front crossmember. CAUTION: ¼...
  • Page 327 ENGINE ASSEMBLY Mechanical 22) Support transmission with a garage jack. withdrawn from clutch cover. (4) Slowly move engine away from engine CAUTION: compartment. Before moving engine away from transmission, check to be sure no work has been overlooked. CAUTION: Doing this is very important in order to facili- Be careful not to damage adjacent parts or tate re-installation and because transmission body panels with crank pulley, oil level gauge,...
  • Page 328 ENGINE ASSEMBLY Mechanical 6) Install pitching stopper. B: INSTALLATION S173079A11 Tightening torque: 1) Install front cushion rubbers. T1: 50 N·m (5.1 kgf-m, 37 ft-lb) Tightening torque: T2: 58 N·m (5.9 kgf-m, 43 ft-lb) 34 N·m (3.5 kgf-m, 25.3 ft-lb) 2) Install engine onto transmission. (1) Position engine in engine compartment and align it with transmission.
  • Page 329 ENGINE ASSEMBLY Mechanical (1) Install power steering tank on bracket. (4) Install front side V-belt, and adjust it. <Ref. to ME-45, FRONT SIDE BELT, INSTALLATION, V-belt.> B2M3153 (2) Install power steering pump on bracket, and G2M0286 tighten bolts. (5) Install resonator chamber. Tightening torque: 20.1 N·m (2.05 kgf-m, 14.8 ft-lb) Tightening torque:...
  • Page 330 ENGINE ASSEMBLY Mechanical 12) Tighten nuts which install front cushion rubber 18) Install A/C pressure hoses. onto crossmember. <Ref. to AC-42, INSTALLATION, Flexible Hose.> Tightening torque: NOTE: 85 N·m (8.7 kgf-m, 63 ft-lb) Use new O-rings. CAUTION: Tightening torque: Make sure the front cushion rubber mounting 25 N·m (2.5 kgf-m, 18.1 ft-lb) bolts (A) and locator (B) are securely installed.
  • Page 331 ENGINE ASSEMBLY Mechanical 2) Make sure the engine coolant and ATF are at specified levels. ME-42...

  • Page 332: Engine Mounting

    ENGINE MOUNTING Mechanical 10. Engine Mounting S173085 A: REMOVAL S173085A18 1) Remove engine assembly. <Ref. to ME-34 REMOVAL, Engine Assembly.> 2) Remove engine mounting from engine assem- bly. B: INSTALLATION S173085A11 Install in the reverse order of removal. Tightening torque: Engine mounting;...

  • Page 333: Preparation For Overhaul

    PREPARATION FOR OVERHAUL Mechanical 11. Preparation for Overhaul S173091 A: PROCEDURE S173091E45 1) After removing the engine from the body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND B2M2582A 2) In this section the procedures described under each index are all connected and stated in order.

  • Page 334: V-Belt

    V-BELT Mechanical 12. V-belt 3) Remove the A/C belt. S173080 4) Remove the A/C belt tensioner. A: REMOVAL S173080A18 1. FRONT SIDE BELT S173080A1801 NOTE: Perform the following procedures 1) to 4) with the engine installed to the body. 1) Remove V-belt cover. B2M2585 B: INSTALLATION S173080A11...
  • Page 335 V-BELT Mechanical 2. REAR SIDE BELT C: INSPECTION S173080A1102 S173080A10 1) Install a belt, and tighten the slider bolt (B) so 1) Replace belts, if cracks, fraying or wear is as to obtain the specified belt tension. <Ref. to found. ME-46, INSPECTION, V-belt.>...

  • Page 336: Crankshaft Pulley

    CRANKSHAFT PULLEY Mechanical 13. Crankshaft Pulley (4) Tighten the crankshaft pulley bolts. S173098 Tightening torque: A: REMOVAL S173098A18 127 N·m (13.0 kgf-m, 94.0 ft-lb) 1) Remove V-belt. <Ref. to ME-45, REMOVAL, V-belt.> 2) Remove crankshaft pulley bolt. To lock crankshaft, use ST. ST 499977300 (2000 cc model) ST 499977100 (2500 cc model) CRANKSHAFT PULLEY WRENCH...
  • Page 337 CRANKSHAFT PULLEY Mechanical (4) Tighten the crankshaft pulley bolts. 7) Install A/C belt. Tightening torque: 177 N·m (18.0 kgf-m, 130.2 ft-lb) B2M2584 C: INSPECTION H2M2393A S173098A10 1) Make sure the V-belt is not worn or otherwise 5) Confirm that the tightening angle of the crank- damaged.

  • Page 338: Belt Cover

    BELT COVER Mechanical 14. Belt Cover S173582 A: REMOVAL S173582A18 1) Remove V-belt. <Ref. to ME-45, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME-47, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover (LH). 4) Remove front belt cover. B2M2587B Belt cover (LH) Front belt cover B: INSTALLATION S173582A11...

  • Page 339: Timing Belt Assembly

    TIMING BELT ASSEMBLY Mechanical 15. Timing Belt Assembly S173099 A: REMOVAL S173099A18 1. TIMING BELT S173099A1801 1) Remove V-belt. <Ref. to ME-45, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME-47, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. ME-49, REMOVAL, Belt Cover.>...
  • Page 340 TIMING BELT ASSEMBLY Mechanical 6) Remove belt idler (No. 2). B: INSTALLATION S173099A11 7) Remove belt idler No. 2. 1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER S173099A1101 1) Preparation for installation of automatic belt tension adjuster assembly; CAUTION: ¼...
  • Page 341 TIMING BELT ASSEMBLY Mechanical (3) With a 2 mm (0.08 in) dia. stopper pin or a (1) Turn camshaft sprocket No. 2 using ST1, 2 mm (0.08 in) (nominal) dia. hex bar wrench and turn camshaft sprocket No. 1 using ST2 so inserted into the stopper pin hole in the cylinder, that their alignment marks (A) come to top posi- secure the adjuster rod.
  • Page 342 TIMING BELT ASSEMBLY Mechanical 5) After ensuring that the marks on timing belt and (3) Tighten remaining bolts. camshaft sprockets are aligned, remove stopper Tightening torque: pin from belt tensioner adjuster. 9.8 N·m (1.0 kgf-m, 7.2 ft-lb) CAUTION: After properly installing timing belt, remove rocker cover and ensure that the valve lash adjuster contains no air.
  • Page 343 TIMING BELT ASSEMBLY Mechanical CAUTION: 3) Check tension pulley for grease leakage. Slight traces of oil at rod’s oil seal does not 4. BELT IDLER indicate a problem. S173099A1004 1) Check belt idler for smooth rotation. Replace if 2) Check that the adjuster rod does not move noise or excessive play is noted.

  • Page 344: Camshaft Sprocket

    CAMSHAFT SPROCKET Mechanical 16. Camshaft Sprocket B: INSTALLATION S173097A11 S173097 1) Install camshaft sprocket No. 1. To lock A: REMOVAL S173097A18 camshaft, use ST. 1) Remove V-belt. <Ref. to ME-45, REMOVAL, ST 499207400 CAMSHAFT SPROCKET V-belt.> WRENCH 2) Remove crankshaft pulley. <Ref. to ME-47, Tightening torque: REMOVAL, Crankshaft Pulley.>...
  • Page 345 CAMSHAFT SPROCKET Mechanical C: INSPECTION S173097A10 1) Check sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprocket and key. 3) Check crankshaft sprocket notch for sensor for damage and contamination of foreign matter. ME-56...

  • Page 346: Crankshaft Sprocket

    CRANKSHAFT SPROCKET Mechanical 17. Crankshaft Sprocket B: INSTALLATION S173101A11 S173101 1) Install crankshaft sprocket. A: REMOVAL S173101A18 1) Remove V-belt. <Ref. to ME-45, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME-47, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. ME-49, REMOVAL, Belt Cover.>...

  • Page 347: Valve Rocker Assembly

    VALVE ROCKER ASSEMBLY Mechanical 18. Valve Rocker Assembly (2) Tighten bolts (e) through (h) to specified S173094 torque. A: REMOVAL (3) Tighten bolts (a) through (d) to specified S173094A18 torque. 1) Remove V-belt. <Ref. to ME-45, REMOVAL, Tightening torque: V-belt.> 25 N·m (2.5 kgf-m, 18.1 ft-lb) 2) Remove crankshaft pulley.
  • Page 348 VALVE ROCKER ASSEMBLY Mechanical 3) Install valve rocker shaft securing bolts. 4) If oil clearance exceeds the limit, replace rocker shaft support or shaft, whichever shows greater E: INSPECTION amount of wear. S173094A10 Rocker shaft support inside diameter: 1. VALVE ROCKER ARM S173094A1001 22.005 —...

  • Page 349: Camshaft

    CAMSHAFT Mechanical 19. Camshaft (1) Remove bolts (a) through (b) in alphabetical S173092 sequence. A: REMOVAL S173092A18 1) Remove V-belt. <Ref. to ME-45, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME-47, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. ME-49, REMOVAL, Belt Cover.>...
  • Page 350 CAMSHAFT Mechanical 16) Remove plug from rear side of camshaft. (2) Temporarily tighten bolts (g) through (j) in alphabetical sequence. CAUTION: ¼ Do not remove oil seal unless necessary. ¼ Do not scratch journal surface when remov- ing oil seal. B: INSTALLATION S173092A11 1) Apply a coat of engine oil to camshaft journals...
  • Page 351 CAMSHAFT Mechanical (5) Tighten TORX bolts (i) through (n) in alpha- 3) Apply a coat of grease to oil seal lips and install betical sequence using ST. oil seal (A) on camshaft using ST1 and ST2. ST 499427000 TORX PLUS CAUTION: Tightening torque: Use a new oil seal.
  • Page 352 CAMSHAFT Mechanical 11) Install belt cover No. 2 (LH). Unit: mm (in) Tightening torque: Standard 0.055 — 0.090 (0.0022 — 0.0035) Clearance 5 N·m (0.5 kgf-m, 3.6 ft-lb) at journal Limit 0.10 (0.0039) 31.928 — 31.945 (1.2570 — Camshaft journal O.D. 1.2577) 32.000 —...
  • Page 353 CAMSHAFT Mechanical 2. CAMSHAFT SUPPORT S173092A1002 Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace camshaft support. Standard: 0.030 — 0.090 mm (0.0012 — 0.0035 in) Limit: 0.10 mm (0.0039 in) B2M2618 ME-64...

  • Page 354: Cylinder Head Assembly

    CYLINDER HEAD ASSEMBLY Mechanical 20. Cylinder Head Assembly CAUTION: S173093 Do not scratch the mating surface of cylinder A: REMOVAL head and cylinder block. S173093A18 14) Similarly, remove right side cylinder head. 1) Remove V-belt. <Ref. to ME-45, REMOVAL, V-belt.> B: INSTALLATION 2) Remove crankshaft pulley.
  • Page 355 CYLINDER HEAD ASSEMBLY Mechanical 6) Install intake manifold. <Ref. FU-18, INSTALLATION, Intake Manifold.> or <Ref. to FU(w/oOBD)-16, INSTALLATION, Intake Mani- fold.> 7) Install camshaft sprocket. <Ref. to ME-55, INSTALLATION, Camshaft Sprocket.> 8) Install timing belt assembly. <Ref. to ME-51, INSTALLATION, Timing Belt Assembly.> 9) Install belt cover.
  • Page 356 CYLINDER HEAD ASSEMBLY Mechanical D: ASSEMBLY S173093A02 B2M2629B (1) Valve (6) Retainer (11) Plug (2) Valve guide (7) Retainer key (12) Camshaft cap (3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY (4) Oil seal (9) Camshaft (5) Valve spring (10) Oil seal 1) Installation of valve spring and valve...
  • Page 357 CYLINDER HEAD ASSEMBLY Mechanical (5) Compress valve spring and fit valve spring 2. INTAKE AND EXHAUST VALVE OIL retainer key. SEAL S173093A1002 Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.
  • Page 358 CYLINDER HEAD ASSEMBLY Mechanical Warping limit: 2. VALVE SEAT S173093A0102 0.05 mm (0.0020 in) Inspect intake and exhaust valve seats, and cor- Grinding limit: rect the contact surfaces with valve seat cutter if 0.1 mm (0.004 in) they are defective or when valve guides are replaced.
  • Page 359 CYLINDER HEAD ASSEMBLY Mechanical Clearance between the valve guide and valve (2) Insert ST2 into valve guide and press it stem: down to remove valve guide. Standard ST1 498267800 CYLINDER HEAD TABLE Intake 0.035 — 0.062 mm (0.0014 — ST2 499767200 VALVE GUIDE REMOVER 0.0024 in) Exhaust 0.040 —...
  • Page 360 CYLINDER HEAD ASSEMBLY Mechanical (5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST. oil, in cylinder, and insert ST1 into valve guide. Gently rotate the reamer clockwise while press- Press in until the valve guide upper end is flush ing it lightly into valve guide, and return it also with the upper surface of ST2.
  • Page 361 CYLINDER HEAD ASSEMBLY Mechanical 4. INTAKE AND EXHAUST VALVE S173093A0104 1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if “H” is less than the specified limit. Intake Standard 1.0 mm (0.039 in) Limit 0.6 mm (0.024 in) Exhaust Standard 1.2 mm (0.047 in)

  • Page 362: Cylinder Block

    CYLINDER BLOCK Mechanical 21. Cylinder Block 12) Remove bolts (a) and (b) to remove cylinder S173090 head. A: REMOVAL S173090A18 NOTE: Before conducting this procedure, drain engine oil completely if applicable. 1) Remove intake manifold. <Ref. to FU-15, REMOVAL, Intake Manifold.> or <Ref. to FU(w/ oOBD)-13, REMOVAL, Intake Manifold.>...
  • Page 363 CYLINDER BLOCK Mechanical ST1 498497100 CRANKSHAFT STOPPER 22) Remove oil strainer stay. ST2 499057000 TORX PLUS 23) Remove oil strainer. 24) Remove baffle plate. 25) Remove oil filter using ST. ST 498547000 OIL FILTER WRENCH B2M3347A 17) Remove oil separator cover. 18) Remove water by-pass pipe for heater.
  • Page 364 CYLINDER BLOCK Mechanical S2M1590B (1) Service hole plug (3) Circlip (5) Service hole cover (2) Gasket (4) Piston pin (6) O-ring 27) Remove service hole cover and service hole 28) Rotate crankshaft to bring #1 and #2 pistons plugs using hexagon wrench [14 mm (0.55 in)]. to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
  • Page 365 CYLINDER BLOCK Mechanical 29) Draw out piston pin from #1 and #2 pistons 30) Similarly remove piston pins from #3 and #4 using ST. pistons. ST 499097700 PISTON PIN REMOVER 31) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders. CAUTION: 32) Back off bolts which connect cylinder block on Be careful not to confuse original combination...
  • Page 366 CYLINDER BLOCK Mechanical CAUTION: Do not confuse combination of piston and cyl- inder. B: INSTALLATION S173090A11 B2M2407A (1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb) (2) Crankshaft 25 (2.5, 18.1) (3) Cylinder block 47 (4.8, 34.7) CAUTION: CAUTION: Remove oil in the mating surface of bearing...
  • Page 367 CYLINDER BLOCK Mechanical 3) Temporarily tighten 10 mm cylinder block con- 6) Install rear oil seal using ST1 and ST2. necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE figure. ST2 499587200 OIL SEAL INSTALLER B2M0088D S2M1827A 4) Tighten 10 mm cylinder block connecting bolts Rear oil seal in alphabetical sequence.
  • Page 368 CYLINDER BLOCK Mechanical ¼ 2000 cc model NOTE: Align the lower rail stopper (F) to the lateral hole (E) on the piston. B2M4619A ¼ 2500 cc model B2M4601A 11) Position the upper rail gap at (G) in the figure. ¼ 2000 cc model B2M4620A 10) Position the lower rail gap at (D) in the figure.
  • Page 369 CYLINDER BLOCK Mechanical ¼ 2500 cc model B2M1403A B2M4626A CAUTION: Piston front mark faces towards the front of the Front mark engine. ¼ 2000 cc model B2M4625A B2M1322J (1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb) (2) Piston pin (5) Service hole plug 69 (7.0, 50.6) (3) Circlip...
  • Page 370 CYLINDER BLOCK Mechanical (3) Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747100 PISTON GUIDE (2000 cc model) ST2 498747300 PISTON GUIDE (2500 cc model) S2M1828 (4) Apply fluid packing around the service hole plug.
  • Page 371 CYLINDER BLOCK Mechanical B2M1323K (1) Piston (5) Service hole plug Tightening torque: N·m (kgf-m, ft-lb) (2) Piston pin (6) Service hole cover 6.4 (0.65, 4.7) (3) Circlip (7) O-ring 69 (7.0, 50.6) (4) Gasket (6) Turn cylinder block so that #3 and #4 cylin- ders face upward.
  • Page 372 CYLINDER BLOCK Mechanical 15) Install water pipe. Tightening torque: 72 N·m (7.3 kgf-m, 52.8 ft-lb) B2M2638 B2M3361A 16) Install baffle plate. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 17) Install oil strainer and O-ring Tightening torque: 10 N·m (1.0 kgf-m, 7 ft-lb) 18) Install oil strainer stay.
  • Page 373 CYLINDER BLOCK Mechanical ST 499587100 OIL SEAL INSTALLER 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) CAUTION: ¼ Be sure to use a new gasket. ¼ When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
  • Page 374 CYLINDER BLOCK Mechanical CAUTION: Ensure that the total “re-tightening angle” [in the former two steps], do not exceed 180°. B2M2628B 28) Install oil level gauge guide and tighten attach- ing bolt (left side only). 29) Install rocker cover. 30) Install crankshaft sprocket. <Ref. to ME-57, INSTALLATION, Crankshaft Sprocket.>...
  • Page 375 CYLINDER BLOCK Mechanical C: DISASSEMBLY S173090A06 B2M1320I (1) Connecting rod cap (3) Top ring (5) Oil ring (2) Connecting rod bearing (4) Second ring (6) Circlip 1) Remove connecting rod cap. 2) Remove connecting rod bearing. CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confu- sion.
  • Page 376 CYLINDER BLOCK Mechanical D: ASSEMBLY S173090A02 B2M1320J (1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb) (2) Connecting rod (6) Top ring 44.6 (4.55, 32.9) (3) Connecting rod cap (7) Circlip (4) Oil ring 1) Install connecting rod bearings on connecting E: INSPECTION S173090A10 rods and connecting rod caps.
  • Page 377 CYLINDER BLOCK Mechanical 2. CYLINDER AND PISTON 2) How to measure the inner diameter of each S173090A1002 cylinder 1) The cylinder bore size is stamped on the cylin- Measure the inner diameter of each cylinder in der block’s front upper surface. both the thrust and piston pin directions at the CAUTION: heights shown in the figure, using a cylinder bore...
  • Page 378 CYLINDER BLOCK Mechanical 4) How to measure the outer diameter of each Cylinder to piston clearance at 20°C (68°F): piston Standard Measure the outer diameter of each piston at the 0.010 — 0.030 mm (0.0004 — 0.0012 in) height shown in the figure. (Thrust direction) Limit 0.050 mm (0.0020 in) CAUTION:...
  • Page 379 CYLINDER BLOCK Mechanical 3) Make sure that piston pin can be inserted into 4. PISTON RING S173090A1004 the piston pin hole with a thumb at 20°C (68°F). 1) If piston ring is broken, damaged, or worn, or if Replace if defective. its tension is insufficient, or when the piston is Standard clearance between piston pin and replaced, replace piston ring with a new one of the...
  • Page 380 CYLINDER BLOCK Mechanical 5. CONNECTING ROD S173090A1005 1) Replace connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace connecting rod if the bend or twist exceeds the limit.
  • Page 381 CYLINDER BLOCK Mechanical 4) Inspect connecting rod bearing for scar, 6) Inspect bushing at connecting rod small end, peeling, seizure, melting, wear, etc. and replace if worn or damaged. Also measure the 5) Measure the oil clearance on individual con- piston pin clearance at the connecting rod small necting rod bearings by means of plastigauge.
  • Page 382 CYLINDER BLOCK Mechanical 6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for BEARING wear. If they are not within the specifications, S173090A1006 replace bearing with a suitable (undersize) one, 1) Clean crankshaft completely and check for and replace or recondition crankshaft as neces- cracks by means of red lead check etc., and sary.
  • Page 383 CYLINDER BLOCK Mechanical 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) EN0341 5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.

  • Page 384: Engine Trouble In General

    ENGINE TROUBLE IN GENERAL Mechanical 22. Engine Trouble in General S173095 A: INSPECTION S173095A10 NOTE: “RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C —...
  • Page 385 ENGINE TROUBLE IN GENERAL Mechanical TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to 3) Initial combustion occur. EN(w/oOBD)-2, Basic Diagnostic Procedure.> ¼ Intake system ¼ Defective intake manifold gasket ¼...
  • Page 386 ENGINE TROUBLE IN GENERAL Mechanical TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to 2. Rough idle and engine stall EN(w/oOBD)-2, Basic Diagnostic Procedure.> ¼ Intake system ¼ Loosened or cracked intake duct ¼...
  • Page 387 ENGINE TROUBLE IN GENERAL Mechanical TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to 3. Low output, hesitation and poor acceleration EN(w/oOBD)-2, Basic Diagnostic Procedure.> ¼ Intake system ¼ Loosened or cracked intake duct ¼...
  • Page 388 ENGINE TROUBLE IN GENERAL Mechanical TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to 4. Surging EN(w/oOBD)-2, Basic Diagnostic Procedure.> ¼ Intake system ¼ Loosened or cracked intake duct ¼...
  • Page 389 ENGINE TROUBLE IN GENERAL Mechanical TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to 7. After burning in exhaust system EN(w/oOBD)-2, Basic Diagnostic Procedure.> ¼ Intake system ¼ Loosened or cracked intake duct ¼...
  • Page 390 ENGINE TROUBLE IN GENERAL Mechanical TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to 10. Excessive fuel consump- tion EN(w/oOBD)-2, Basic Diagnostic Procedure.> ¼ Intake system ¼ Dirty air cleaner element ¼...

  • Page 391: Engine Noise

    ENGINE NOISE Mechanical 23. Engine Noise S173096 A: INSPECTION S173096A10 Type of sound Condition Possible cause ¼ Valve mechanism is defective. ¼ Incorrect valve clearance Sound increases as engine ¼ Worn valve rocker Regular clicking sound speed increases. ¼ Worn camshaft ¼...
  • Page 392 EXHAUST Page General Description..................2 Front Exhaust Pipe..................5 Center Exhaust Pipe ...................8 Rear Exhaust Pipe ..................9 Muffler......................10...

  • Page 393: Components

    GENERAL DESCRIPTION Exhaust 1. General Description S172001 A: COMPONENT S172001A05 B2M4612A EX-2...

  • Page 394: General Description

    GENERAL DESCRIPTION Exhaust (1) Upper front exhaust pipe cover (10) Lower center exhaust pipe cover (21) Self-locking nut (11) Gasket (22) Protector (2) Lower front exhaust pipe cover (12) Upper rear catalytic converter (23) Rear oxygen sensor cover (24) Gasket (3) Front exhaust pipe (13) Lower rear catalytic converter (4) Front oxygen (A/F) sensor...
  • Page 395 GENERAL DESCRIPTION Exhaust B: CAUTION S172001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼ Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 396 FRONT EXHAUST PIPE Exhaust 2. Front Exhaust Pipe 4) Lift-up the vehicle. S172065 5) Separate front and center exhaust pipe assem- A: REMOVAL bly from rear exhaust pipe. S172065A18 WARNING: 1) Disconnect battery ground cable. Be careful, exhaust pipe is hot. G6M0095 B2M3109 2) Disconnect front oxygen (A/F) sensor connec-...
  • Page 397 FRONT EXHAUST PIPE Exhaust ¼ After removing front and center exhaust B: INSTALLATION S172065A11 assembly, do not apply excessive pulling force 1) Install front exhaust pipe to center exhaust on rear exhaust pipe. pipe. 10) Separate front exhaust pipe from center NOTE: exhaust pipe.
  • Page 398 FRONT EXHAUST PIPE Exhaust 5) Tighten bolts which install front and center 10) Connect front oxygen (A/F) sensor connector. exhaust pipe assembly to rear exhaust pipe. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M4243 11) Connect battery ground cable. B2M3109 6) Tighten bolt which holds front and center exhaust pipe assembly to hanger bracket.
  • Page 399 CENTER EXHAUST PIPE Exhaust 3. Center Exhaust Pipe S172067 A: REMOVAL S172067A18 After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX-5, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION S172067A11 Install the center exhaust pipe and front exhaust...
  • Page 400 REAR EXHAUST PIPE Exhaust 4. Rear Exhaust Pipe 2) Install rear exhaust pipe to center exhaust pipe. S172068 Tightening torque: A: REMOVAL S172068A18 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Separate rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, exhaust pipe is hot. B2M3109 C: INSPECTION S172068A10...
  • Page 401 S172066 fler assembly. A: REMOVAL S172066A18 NOTE: To facilitate removal, apply a coat of SUBARU 1) Separate muffler from rear exhaust pipe. CRC to mating area of rubber cushion in advance. CAUTION: SUBARU CRC (Part No. 004301003) Be careful, exhaust pipe is hot.
  • Page 402 EXHAUST EX(w/oOBD) Page General Description..................2 Front Exhaust Pipe..................9 Center Exhaust Pipe .................12 Rear Exhaust Pipe ..................13 Muffler......................14...
  • Page 403 GENERAL DESCRIPTION Exhaust 1. General Description S132001 A: COMPONENT S132001A05 1. WITH CATALYTIC CONVERTER (EXCEPT AUSTRALIA OUTBACK MODEL) S132001A0501 B2M4609A EX(w/oOBD)-2...
  • Page 404 GENERAL DESCRIPTION Exhaust (1) Upper front exhaust pipe cover (10) Lower center exhaust pipe cover (21) Self-locking nut (11) Gasket (22) Protector (2) Lower front exhaust pipe cover (12) Upper rear catalytic converter (23) Gasket cover Tightening torque: N·m (kgf-m, ft-lb) (3) Front exhaust pipe (13) Lower rear catalytic converter (4) Oxygen sensor...
  • Page 405 GENERAL DESCRIPTION Exhaust 2. AUSTRALIA OUTBACK MODEL S132001A0502 B2M4610A EX(w/oOBD)-4...
  • Page 406 GENERAL DESCRIPTION Exhaust (1) Upper front exhaust pipe cover (8) Clamp (19) Protector (9) Upper center exhaust pipe cover (20) Gasket (2) Lower front exhaust pipe cover (10) Lower center exhaust pipe cover (11) Gasket Tightening torque: N·m (kgf-m, ft-lb) (3) Front exhaust pipe (12) Center exhaust pipe 8 (0.8, 5.8)
  • Page 407 GENERAL DESCRIPTION Exhaust 3. WITHOUT CATALYTIC CONVERTER S132001A0503 B2M4611A EX(w/oOBD)-6...
  • Page 408 GENERAL DESCRIPTION Exhaust (1) Upper front exhaust pipe cover (8) Rear exhaust pipe Tightening torque: N·m (kgf-m, ft-lb) (9) Self-locking nut 8 (0.8, 5.8) (2) Lower front exhaust pipe cover (10) Gasket 13 (1.3, 9.4) (11) Cushion rubber 18 (1.8, 13.0) (3) Front exhaust pipe (12) Muffler 30 (3.1, 22.4)
  • Page 409 GENERAL DESCRIPTION Exhaust B: CAUTION S132001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼ Keep the disassembled parts in order and pro- tect them from dust or dirt.

  • Page 410: Front Exhaust Pipe

    FRONT EXHAUST PIPE Exhaust 2. Front Exhaust Pipe 6) Remove nuts which hold front exhaust pipe S132065 onto cylinder heads. A: REMOVAL S132065A18 CAUTION: Be careful not to pull down front and center 1) Disconnect battery ground cable. exhaust pipe assembly. G6M0095 B2M3200 2) Disconnect front oxygen sensor connector.
  • Page 411 FRONT EXHAUST PIPE Exhaust 5) Tighten bolts which install front and center B: INSTALLATION S132065A11 exhaust pipe assembly to rear exhaust pipe. 1) Install front exhaust pipe to center exhaust Tightening torque: pipe. 18 N·m (1.8 kgf-m, 13.0 ft-lb) NOTE: Replace gaskets with new ones.
  • Page 412 FRONT EXHAUST PIPE Exhaust 10) Connect battery ground cable. G6M0095 C: INSPECTION S132065A10 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EX(w/oOBD)-11...

  • Page 413: Center Exhaust Pipe

    CENTER EXHAUST PIPE Exhaust 3. Center Exhaust Pipe S132067 A: REMOVAL S132067A18 After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX(w/ oOBD)-9, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION S132067A11 Install the center exhaust pipe and front exhaust...

  • Page 414: Rear Exhaust Pipe

    REAR EXHAUST PIPE Exhaust 4. Rear Exhaust Pipe 2) Install rear exhaust pipe to center exhaust pipe. S132068 Tightening torque: A: REMOVAL S132068A18 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Separate rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, exhaust pipe is hot. B2M3109 C: INSPECTION S132068A10...

  • Page 415: Muffler

    S132066 fler assembly. A: REMOVAL S132066A18 NOTE: To facilitate removal, apply a coat of SUBARU 1) Separate muffler from rear exhaust pipe. CRC to mating area of rubber cushion in advance. CAUTION: SUBARU CRC (Part No. 004301003) Be careful, exhaust pipe is hot.
  • Page 416 COOLING Page General Description..................2 Radiator Main Fan System .................7 Radiator Sub Fan System.................10 Engine Coolant..................13 Water Pump ....................15 Thermostat ....................20 Radiator .....................21 Radiator Cap .....................25 Radiator Main Fan and Fan Motor............26 Radiator Sub Fan and Fan Motor .............29 Reservoir Tank ..................31 Engine Cooling System Trouble in General..........32...

  • Page 417: Specifications

    GENERAL DESCRIPTION Cooling 1. General Description S176001 A: SPECIFICATIONS S176001E49 Electric fan + Forced engine coolant circula- Cooling system tion system MT: Approx. 6.8 (7.2, 6.0) Total engine coolant capacity (US qt, Imp qt) AT: Approx. 6.7 (7.1, 5.9) Type Centrifugal impeller type Discharge (5.3 US gal, 4.4 Imp gal)/min.

  • Page 418: General Description

    GENERAL DESCRIPTION Cooling B: COMPONENT S176001A05 1. WATER PUMP S176001A0501 H2M2354A (1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb) (2) Gasket (6) Thermostat cover First 12 (1.2, 8.7) (3) Heater by-pass hose Second 12 (1.2, 8.7) (4) Thermostat 6.4 (0.65, 4.7) CO-3...
  • Page 419 GENERAL DESCRIPTION Cooling 2. RADIATOR AND RADIATOR FAN S176001A0502 B2M3700A (1) Radiator lower cushion (12) Main fan shroud (19) ATF inlet hose B (AT vehicles (2) Radiator (13) Radiator main fan and main fan only) (3) Radiator upper cushion motor ASSY (20) Radiator outlet hose (4) Radiator upper bracket (14) ATF hose clamp (AT vehicles...
  • Page 420 GENERAL DESCRIPTION Cooling C: CAUTION S176001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼ Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 421 GENERAL DESCRIPTION Cooling D: PREPARATION TOOL S176001A17 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. (2500 cc model) B2M3870 499977300 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts.
  • Page 422 RADIATOR MAIN FAN SYSTEM Cooling 2. Radiator Main Fan System S176732 A: SCHEMATIC S176732A21 B2M4761 CO-7...

  • Page 423: Radiator Main Fan System

    RADIATOR MAIN FAN SYSTEM Cooling ¼ Vehicle speed is below 19 km/h (12 MPH). B: INSPECTION S176732A10 TROUBLE SYMPTOM: DETECTING CONDITION: ¼ Radiator main fan does not rotate under the Condition: above conditions. ¼ Engine coolant temperature is above 95°C (203°F).
  • Page 424 Contact with your Check poor contact in connector between connector between main tact connector. Subaru distributor main fan and ECM. fan motor and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-9...
  • Page 425 RADIATOR SUB FAN SYSTEM Cooling 3. Radiator Sub Fan System S176733 A: SCHEMATIC S176733A21 B2M4761 CO-10...

  • Page 426: Radiator Sub Fan System

    RADIATOR SUB FAN SYSTEM Cooling ¼ Vehicle speed is below 19 km/h (12 MPH). B: INSPECTION S176733A10 Condition (2): NOTE: ¼ Engine coolant temperature is above 100°C Radiator sub fan system is for model with A/C. (212°F). DETECTING CONDITION: ¼ A/C switch is turned OFF. ¼...
  • Page 427 Contact with your Check poor contact in connector between sub connector between sub fan tact connector. Subaru distributor fan and ECM. motor and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-12...

  • Page 428: Engine Coolant

    1. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE S176060A1001 The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. B2M2921 2. FILLING OF ENGINE COOLANT...
  • Page 429 B2M3129A sary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50). The amount of coolant that should be replaced can be determined using the diagram. CO-14...

  • Page 430: Water Pump

    WATER PUMP Cooling 5. Water Pump 6) Disconnect radiator outlet hose and heater S176061 hose from water pump. A: REMOVAL S176061A18 1) Disconnect ground cable from the battery. B2M2924 7) Lower the vehicle. 8) Remove air intake duct. G6M0095 2) Lift-up the vehicle. 3) Remove under cover.
  • Page 431 WATER PUMP Cooling 12) Remove V-belts. 17) Remove left-hand belt cover No. 2. <Ref. to ME-45, REMOVAL, V-belt.> 13) Remove timing belt. <Ref. to ME-50, TIMING BELT, REMOVAL, Timing Belt Assembly.> 14) Remove automatic belt tension adjuster. B2M2040 18) Remove tensioner bracket. H2M2375 15) Remove belt idler No.
  • Page 432 WATER PUMP Cooling Tightening torque: 4) Install left-hand camshaft sprockets by using First: 12 N·m (1.2 kgf-m, 8.7 ft-lb) ST 4992707100 CAMSHAFT SPROCKET Second: WRENCH 12 N·m (1.2 kgf-m, 8.7 ft-lb) Tightening torque: 78 N·m (8.0 kgf-m, 57.9 ft-lb) S2M0760A 2) Install left-hand belt cover No.
  • Page 433 WATER PUMP Cooling 10) Install reservoir tank. 15) Connect connectors to radiator main fan (A) and sub fan (B) motors. B2M2926 B2M2923A 11) Connect over flow hose. 16) Install under cover. B2M2925 B2M2920 12) Install air intake duct. 17) Lower the vehicle. 18) Connect battery ground cable.
  • Page 434 WATER PUMP Cooling 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley. “Thrust” runout limit: 0.5 mm (0.020 in) G2M0211 4) Check clearance between impeller and pump case. Clearance between impeller and pump case: Standard 0.5 —...

  • Page 435: Thermostat

    THERMOSTAT Cooling ¼ The thermostat must be installed with the 6. Thermostat S176062 jiggle pin (A) facing to front side. ¼ At this time, set the jiggle pin of thermostat A: REMOVAL S176062A18 for front side. 1) Lift-up the vehicle. Tightening torque: 2) Remove under cover.

  • Page 436: Radiator

    RADIATOR Cooling 7. Radiator 6) Disconnect radiator outlet hose from thermostat S176058 cover. A: REMOVAL S176058A18 1) Disconnect battery ground cable. B2M2929 7) Disconnect ATF cooler hoses from radiator. (AT G6M0095 vehicles only) 2) Lift-up the vehicle. 3) Remove under cover. B2M2928B Clip B2M2920...
  • Page 437 RADIATOR Cooling 11) Remove reservoir tank. 16) Lift radiator up and away from vehicle. B2M2926 B2M2933 12) Disconnect radiator inlet hose from engine. B: INSTALLATION S176058A11 1) Attach radiator mounting cushions to holes on the vehicle. B2M2930 13) Remove radiator upper brackets. B2M2934 2) Install radiator while fitting radiator pins to cush- ions.
  • Page 438 RADIATOR Cooling 3) Install radiator brackets and tighten bolts. 7) Install air intake duct. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M2922 8) Lift-up the vehicle. B2M2931 9) Connect ATF cooler hoses. (AT vehicles only) 4) Attach power steering hose to the radiator. B2M2928B B2M2932 Clip...
  • Page 439 RADIATOR Cooling 12) Install under cover. C: INSPECTION S176058A10 1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. B2M2920 13) Lower the vehicle. 14) Connect battery ground cable. B2M3127 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 440: Radiator Cap

    RADIATOR CAP Cooling 8. Radiator Cap S176064 A: INSPECTION S176064A10 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 sec- onds.

  • Page 441: Radiator Main Fan And Fan Motor

    RADIATOR MAIN FAN AND FAN MOTOR Cooling 9. Radiator Main Fan and Fan 5) Lower the vehicle. 6) Remove air intake duct. Motor S176059 A: REMOVAL S176059A18 1) Disconnect battery ground cable. B2M2922 7) Disconnect over flow hose. G6M0095 2) Lift-up the vehicle. 3) Remove under cover.
  • Page 442 RADIATOR MAIN FAN AND FAN MOTOR Cooling 2) Remove nut which holds fan itself onto fan B: INSTALLATION S176059A11 motor and shroud assembly. Install in the reverse order of removal. NOTE: When the main fan motor assembly cannot be installed as is, loosen the sub fan motor assembly securing bolts to install it.
  • Page 443 RADIATOR MAIN FAN AND FAN MOTOR Cooling Tightening torque: 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) S2M0936 E: INSPECTION S176059A10 1) Connect battery positive (+) terminal to terminal No. 2, and negative (−) terminal to terminal No. 1 of main fan motor connector. 2) Make sure the main fan motor operates prop- erly.

  • Page 444: Radiator Sub Fan And Fan Motor

    RADIATOR SUB FAN AND FAN MOTOR Cooling 10. Radiator Sub Fan and Fan 5) Lower the vehicle. 6) Remove air intake duct. Motor S176074 A: REMOVAL S176074A18 1) Disconnect battery ground cable. B2M2922 7) Remove bolts which hold sub fan shroud to radiator.
  • Page 445 RADIATOR SUB FAN AND FAN MOTOR Cooling C: DISASSEMBLY D: ASSEMBLY S176074A06 S176074A02 1) Remove clip which holds motor harness onto Assemble in the reverse order of disasssembly. shroud. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) S2M0937 2) Remove nut which holds fan itself onto fan B2M3169 motor and shroud assembly.

  • Page 446: Reservoir Tank

    RESERVOIR TANK Cooling 11. Reservoir Tank S176075 A: REMOVAL S176075A18 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 S176075A11 Install in the reverse order of removal.

  • Page 447: Engine Cooling System Trouble In General

    ENGINE COOLING SYSTEM TROUBLE IN GENERAL Cooling 12. Engine Cooling System Trouble in General S176078 A: INSPECTION S176078A10 Trouble 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.
  • Page 448 LUBRICATION 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 Filter..................19 Engine Lubrication System Trouble in General ........20...

  • Page 449: General Description

    GENERAL DESCRIPTION Lubrication 1. General Description S178001 A: SPECIFICATIONS S178001E49 Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 7 mm (3.07 × 0.28 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 450 GENERAL DESCRIPTION Lubrication B: COMPONENT S178001A05 B2M2235D (1) Plug (14) Oil filler duct (27) Gasket (2) Washer (15) O-ring (3) Relief valve spring (16) Oil filler cap Tightening torque: N·m (kgf-m, ft-lb) (4) Relief valve (17) O-ring 5 (0.5, 3.6) (5) Oil seal (18) Baffle plate 5 (0.5, 3.6)
  • Page 451 GENERAL DESCRIPTION Lubrication C: CAUTION S178001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼ Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 452 GENERAL DESCRIPTION Lubrication D: PREPARATION TOOL S178001A17 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolt. (2500 cc model) B2M3870 499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolt.
  • Page 453 OIL PRESSURE SYSTEM Lubrication 2. Oil Pressure System A: SCHEMATIC S178076A21 S178076 B2M4735 LU-6...

  • Page 454: Oil Pressure System

    OIL PRESSURE SYSTEM Lubrication B: INSPECTION S178076A10 Step Check CHECK COMBINATION METER. Do the warning lights go Go to step 2. Repair or replace 1) Turn ignition switch to ON. (engine OFF) the combination 2) Check other warning lights. meter. <Ref. to IDI-6, INSPECTION, Combination...

  • Page 455: Engine Oil

    ENGINE OIL Lubrication 3. Engine Oil 2) Open engine oil filler cap for quick draining of S178077 the engine oil. A: INSPECTION S178077A10 1) Park vehicle on a level surface. 2) Remove 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 the proper orientation.
  • Page 456 API classification and SAE viscosity No. desig- nated by SUBARU. NOTE: If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,...

  • Page 457: Oil Pump

    OIL PUMP Lubrication 4. Oil Pump 9) Remove rear side V-belt tensioner. S178070 A: REMOVAL S178070A18 1) Disconnect battery ground cable. S2M0113 10) Remove crankshaft pulley by using ST. 2000 cc model: G6M0095 ST 499977300 CRANKSHAFT PULLEY WRENCH 2) Lift-up the vehicle. 2500 cc model: 3) Remove under...
  • Page 458 OIL PUMP Lubrication 12) Remove timing belt guide. (MT vehicles only) B: INSTALLATION S178070A11 Install in the reverse order of removal. Do the following: 1) Apply fluid packing to matching surfaces of oil pump. Fluid packing: THREE BOND 1215 or equivalent 2) Replace O-ring (A) with a new one.
  • Page 459 OIL PUMP Lubrication C: DISASSEMBLY D: ASSEMBLY S178070A06 S178070A02 Remove screws which secure oil pump cover and 1) Install front oil seal by using ST. ST 499587100 OIL SEAL INSTALLER disassemble oil pump. Inscribe alignment marks on inner and outer rotors so that they can be NOTE: replaced in their original positions during reassem- Use a new oil seal.
  • Page 460 OIL PUMP Lubrication 3. SIDE CLEARANCE E: INSPECTION S178070A1003 S178070A10 Measure clearance between oil pump inner rotor 1. TIP CLEARANCE S178070A1001 and pump cover. If the clearance exceeds the limit, Measure the tip clearance of rotors. If the clear- replace rotor or pump body. ance exceeds the limit, replace rotors as a Side clearance: matched set.

  • Page 461: Oil Pan And Strainer

    OIL PAN AND STRAINER Lubrication 5. Oil Pan and Strainer 7) Support engine with a lifting device and wire S178071 ropes. A: REMOVAL S178071A18 1) Set the vehicle on lift arms. 2) Remove front wheels. 3) Disconnect battery ground cable. G2M0297 8) Lift-up the vehicle.
  • Page 462 OIL PAN AND STRAINER Lubrication 12) Remove nuts which install front cushion rub- 16) Remove baffle plate. ber onto front crossmember. S2M0309 S2M1831 B: INSTALLATION 13) Remove bolts which install oil pan on cylinder S178071A11 block while raising up engine. CAUTION: 14) Insert oil pan cutter blade between cylinder Before installing oil pan, clean sealant from oil...
  • Page 463 OIL PAN AND STRAINER Lubrication 3) Apply fluid packing to mating surfaces and 7) Install front and center exhaust pipes. install oil pan. <Ref. to EX-6, INSTALLATION, Front Exhaust Pipe.> <Ref. EX(w/oOBD)-10, Fluid packing: INSTALLATION, Front Exhaust Pipe.> THREE BOND 1215 or equivalent NOTE: Always use the new gaskets.
  • Page 464 OIL PAN AND STRAINER Lubrication 12) Install radiator upper brackets. B2M2931 13) Install air intake duct and air cleaner case. <Ref. to IN-7, INSTALLATION, Air Intake Duct.> and <Ref. to IN-6, INSTALLATION, Air Cleaner Case.> 14) Install front wheels. 15) Connect battery ground cable. G6M0095 16) Fill engine oil.

  • Page 465: Oil Pressure Switch

    OIL PRESSURE SWITCH Lubrication 6. Oil Pressure Switch B: INSTALLATION S178069A11 S178069 1) Apply fluid packing to oil pressure switch A: REMOVAL S178069A18 threads. 1) Remove generator from bracket. <Ref. to Fluid packing: SC-13, REMOVAL, Generator.> THREE BOND 1215 or equivalent 2) Disconnect terminal from oil pressure switch.

  • Page 466: Engine Oil Filter

    ENGINE OIL FILTER Lubrication 7. Engine Oil Filter S178585 A: REMOVAL S178585A18 1) Remove access lid. B2M3887 2) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH B2M3888A B: INSTALLATION S178585A11 1) Get a new oil filter and apply a thin coat of engine oil to the seal rubber.

  • Page 467: Engine Lubrication System Trouble In General

    ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL Lubrication 8. Engine Lubrication System Trouble in General S178100 A: INSPECTION S178100A10 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 468 SPEED CONTROL SYSTEMS Page General Description..................2 Accelerator Pedal ..................4 Accelerator Control Cable ................9...
  • Page 469 GENERAL DESCRIPTION Speed Control Systems 1. General Description S177001 A: SPECIFICATION S177001A22 Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in) Accelerator pedal Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in) B: COMPONENT S177001A05 1.
  • Page 470 GENERAL DESCRIPTION Speed Control Systems 2. RHD MODEL S177001A0502 B2M4177B (1) Accelerator bracket (7) Accelerator spring Tightening torque: N·m (kgf-m, ft-lb) (2) Stopper (8) Bushing 12 (1.2, 8.7) (3) Accelerator pedal lever (9) Clip 18 (1.8, 13.0) (4) Accelerator pedal spring (10) Accelerator stopper (5) Accelerator pedal (11) Kick-down switch (AT model)
  • Page 471 ACCELERATOR PEDAL Speed Control Systems 2. Accelerator Pedal 6) Remove clip inside engine compartment. S177005 ¼ LHD model A: REMOVAL S177005A18 1) Disconnect ground cable from battery. 2) Remove lock nut from accelerator cable bracket. 3) Separate accelerator cable from bracket. 4) Remove accelerator cable end from throttle cam.
  • Page 472 ACCELERATOR PEDAL Speed Control Systems 10) Remove accelerator pedal connecting bolt from accelerator pedal bracket. ¼ LHD model B4M1741B Slot type screwdriver 14) Disconnect accelerator cable stopper (A) from B2M4178 bracket. ¼ RHD model B4M1742B B4M1746 15) Separate accelerator cable and bracket. 11) Disconnect grommet (A) from toe board.
  • Page 473 ACCELERATOR PEDAL Speed Control Systems ¼ RHD model C: DISASSEMBLY S177005A06 1) Remove the clip, and then remove the accel- erator pedal from the bracket. 2) Pull out the spring pin, and then remove the accelerator pedal from the accelerator pedal lever. ¼...
  • Page 474 ACCELERATOR PEDAL Speed Control Systems Deflection of accelerator pedal: F: ADJUSTMENT S177005A01 Service limit 1) Check pedal stroke and free play by operating 5.0 mm (0.197 in) or less accelerator pedal by hand. If it is not within specified value, adjust it by turn- ing nut connecting accelerator cable to throttle body.
  • Page 475 ACCELERATOR PEDAL Speed Control Systems 2) Check to ensure the kick-down switch operates at the specified value in relation to the stroke of the accelerator pedal. If it is not in specified value, adjust it by adjusting position of kick-down switch. CAUTION: Be careful not to rotate kick-down switch.
  • Page 476 ACCELERATOR CONTROL CABLE Speed Control Systems 3. Accelerator Control Cable S177007 A: REMOVAL S177007A18 1) Remove accelerator pedal. <Ref to SP-4, REMOVAL, Accelerator Pedal.> 2) Separate accelerator cable and accelerator pedal. B: INSTALLATION S177007A11 1) Install in the reverse order of removal. CAUTION: ¼...
  • Page 477 ACCELERATOR CONTROL CABLE Speed Control Systems MEMO: SP-10...
  • Page 478 IGNITION Page General Description..................2 Spark Plug....................4 Ignition Coil and Ignitor Assembly...............7 Spark Plug Cord..................9...
  • Page 479 GENERAL DESCRIPTION Ignition 1. General Description S171001 A: SPECIFICATIONS S171001E49 Item Designation Model FH0137 Manufacturer DIAMOND Ignition coil 0.73 Ω±10% Primary coil resistance and ignitor Secondary coil resistance 12.8 kΩ±15% assembly Insulation resistance between primary More than 100 MΩ terminal and case RC10YC4 ..

  • Page 480: General Description

    GENERAL DESCRIPTION Ignition B: COMPONENT S171001A05 S6M0329B (1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) (2) Spark plug cord (#1, #3) 21 (2.1, 15) (3) Ignition coil and ignitor ASSY 6.4 (0.65, 4.7) removal, installation, disassembly, and replace- C: CAUTION S171001A03 ment.
  • Page 481 SPARK PLUG Ignition 2. Spark Plug 2. LH SIDE S171003A1806 S171003 1) Disconnect battery ground cable. A: REMOVAL S171003A18 CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: CHAMPION: RC10YC4 (Alternate) NGK: BKR5E-11 1.
  • Page 482 SPARK PLUG Ignition 5) Remove spark plugs cord by pulling boot, not C: INSPECTION S171003A10 cord itself. Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion. B2M4287 6) Remove spark plug with the spark plugs socket. S6M0420A Electrode gap Carbon accumulation or wear...
  • Page 483 SPARK PLUG Ignition 3) Oil fouled E: ADJUSTMENT S171003A01 Wet black deposits show excessive oil entrance Correct it if the spark plug gap is measured with a into combustion chamber through worn rings and gap gauge, and it is necessary. pistons or excessive clearance between valve guides and stems.
  • Page 484 IGNITION COIL AND IGNITOR ASSEMBLY Ignition 3. Ignition Coil and Ignitor 4) Remove ignition coil and ignitor assembly. Assembly S171015 A: REMOVAL S171015A18 1) Disconnect battery ground cable. B6M0930 B: INSTALLATION S171015A11 Install in the reverse order of removal. G6M0095 Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 2) Disconnect spark plug cords from ignition coil...
  • Page 485 IGNITION COIL AND IGNITOR ASSEMBLY Ignition C: INSPECTION S171015A10 Using accurate tester, inspect the following items, and replace if defective. 1) Primary resistance 2) Secondary coil resistance CAUTION: If the resistance is extremely low, this indicates the presence of a short-circuit. Specified resistance: [Primary side] Between terminal No.
  • Page 486 SPARK PLUG CORD Ignition 4. Spark Plug Cord S171014 A: INSPECTION S171014A10 Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 — 10.6 #2 cord: 7.3 — 13.7 #3 cord: 5.9 —...
  • Page 487 SPARK PLUG CORD Ignition MEMO: IG-10...
  • Page 488 IGNITION IG(w/oOBD) Page General Description..................2 Spark Plug....................4 Ignition Coil and Ignitor Assembly...............7 Spark Plug Cord..................9...
  • Page 489 GENERAL DESCRIPTION Ignition 1. General Description S131001 A: SPECIFICATIONS S131001E49 Item Designation Model FH0137 Manufacturer DIAMOND 0.73 Ω±10% Ignition coil and ignitor Primary coil resistance assembly Secondary coil resistance 12.8 kΩ±15% Insulation resistance between primary terminal and More than 100 MΩ case Without catalytic con- BKR6E ..
  • Page 490 GENERAL DESCRIPTION Ignition B: COMPONENT S131001A05 S6M0329B (1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) (2) Spark plug cord (#1, #3) 21 (2.1, 15) (3) Ignition coil and ignitor ASSY 6.4 (0.65, 4.7) removal, installation, disassembly, and replace- C: CAUTION S131001A03 ment.

  • Page 491: Spark Plug

    SPARK PLUG Ignition 2. Spark Plug 2. LH SIDE S131003A1806 S131003 1) Disconnect battery ground cable. A: REMOVAL S131003A18 CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: With catalytic converter CHAMPION: RC10YC4 NGK: BKR5E-11 (Alternate) Without catalytic converter NGK: BKR6E...
  • Page 492 SPARK PLUG Ignition 5) Remove spark plugs cord by pulling boot, not C: INSPECTION S131003A10 cord itself. Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion. B2M4287 6) Remove spark plug with the spark plugs socket. S6M0420A Electrode gap Carbon accumulation or wear...
  • Page 493 SPARK PLUG Ignition 3) Oil fouled E: ADJUSTMENT S131003A01 Wet black deposits show excessive oil entrance Correct it if the spark plug gap is measured with a into combustion chamber through worn rings and gap gauge, and it is necessary. pistons or excessive clearance between valve guides and stems.
  • Page 494 IGNITION COIL AND IGNITOR ASSEMBLY Ignition 3. Ignition Coil and Ignitor 4) Remove ignition coil and ignitor assembly. Assembly S131015 A: REMOVAL S131015A18 1) Disconnect battery ground cable. B6M0930 B: INSTALLATION S131015A11 Install in the reverse order of removal. G6M0095 Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 2) Disconnect spark plug cords from ignition coil...

  • Page 495: Ignition Coil And Ignitor Assembly

    IGNITION COIL AND IGNITOR ASSEMBLY Ignition C: INSPECTION S131015A10 Using accurate tester, inspect the following items, and replace if defective. 1) Primary resistance 2) Secondary coil resistance CAUTION: If the resistance is extremely low, this indicates the presence of a short-circuit. Specified resistance: [Primary side] Between terminal No.
  • Page 496 SPARK PLUG CORD Ignition 4. Spark Plug Cord S131014 A: INSPECTION S131014A10 Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 — 10.6 #2 cord: 7.3 — 13.7 #3 cord: 5.9 —...

  • Page 497: Spark Plug Cord

    SPARK PLUG CORD Ignition MEMO: IG(w/oOBD)-10...
  • Page 498 STARTING/CHARGING SYSTEMS Page General Description..................2 Starter......................5 Generator ....................13 Battery .......................18...

  • Page 499: General Description

    GENERAL DESCRIPTION Starting/Charging Systems 1. General Description S179001 A: SPECIFICATIONS S179001E49 Item Designation Type Reduction type Vehicle type MT vehicles AT vehicles Model M000T83981 M001T86381 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Direction of rotation Counterclockwise (when observed from pinion) Number of pinion teeth...
  • Page 500 GENERAL DESCRIPTION Starting/Charging Systems B: COMPONENT S179001A05 1. STARTER S179001A0501 H6M0492C (1) Sleeve bearing (7) Internal gear ASSY (13) Armature (2) Front bracket (8) Shaft ASSY (14) Brush holder (3) Lever set (9) Gear ASSY (15) Brush (4) Magnet switch ASSY (10) Ball (16) Sleeve bearing (5) Stopper set...
  • Page 501 GENERAL DESCRIPTION Starting/Charging Systems 2. GENERATOR S179001A0502 H6M0493C (1) Pulley (5) Rotor (9) Brush (2) Front cover (6) Bearing (10) Rectifier (3) Ball bearing (7) Stator coil (11) Rear cover (4) Bearing retainer (8) IC regulator with brush (12) Terminal C: CAUTION removal, installation, disassembly, and replace- S179001A03...

  • Page 502: Starter

    STARTER Starting/Charging Systems 2. Starter 4) Disconnect connector and terminal from starter. S179012 A: REMOVAL S179012A18 1) Disconnect battery ground cable. S6M0002A Terminal Connector G6M0095 5) Remove starter from transmission. 2) Remove air cleaner case. G2M0309 B6M1221 3) Remove air cleaner case stay. ¼...
  • Page 503 STARTER Starting/Charging Systems 2) Remove bolts which hold switch assembly, and B: INSTALLATION S179012A11 remove switch assembly, plunger and plunger Install in the reverse order of removal. spring from starter as a unit. Tightening torque: CAUTION: 50 N·m (5.1 kgf-m, 37 ft-lb) Be careful because pinion gap adjustment washer may sometimes be used on the mount- ing surface of switch assembly.
  • Page 504 STARTER Starting/Charging Systems 4) Remove armature and yoke. Ball used as a 6) Remove shaft assembly and overrunning clutch bearing will then be removed from the end of arma- as a unit. ture. CAUTION: CAUTION: Before removal, confirm the following: ¼...
  • Page 505 STARTER Starting/Charging Systems 2. BRUSH HOLDER D: ASSEMBLY S179012A0602 S179012A02 Slightly open the metal fitting holding the insulating Assemble in the reverse order of disassembly. Do plate to the brush holder. Remove the insulating the following: plate. 1) Carefully assemble all parts in the order of assembly and occasionally inspect nothing has NOTE: been overlooked.
  • Page 506 STARTER Starting/Charging Systems 3) When installing yoke to the front bracket, match 2) Run-out test bolt hole. Check the commutator run-out and replace if it exceeds the limit. Commutator run-out: Standard 0.05 mm (0.0020 in) Service limit Less than 0.10 mm (0.0039 in) B2M4773A Bolt hole 4) When installing rear bracket, match brush...
  • Page 507 STARTER Starting/Charging Systems 4) Armature short-circuit test 4. BRUSH AND BRUSH HOLDER S179012A1004 Check armature for short-circuit by placing it on 1) Brush length growler tester. Hold a hacksaw blade against Measure the brush length and replace if it exceeds armature core while slowly rotating armature.
  • Page 508 STARTER Starting/Charging Systems 5. SWITCH ASSEMBLY 7. PINION GAP S179012A1005 S179012A1007 Be sure there is continuity between terminals S 1) Measure pinion gap while the pinion is pulled and M, and between terminal S and ground. Use out as shown in the figure. a circuit tester (set in “ohm”).
  • Page 509 STARTER Starting/Charging Systems 8. PERFORMANCE TEST 3) Lock test S179012A1008 With starter stalled, or not rotating, measure the The starter should be submitted to performance torque developed and current draw when the volt- tests whenever it has been overhauled, to assure age is adjusted to the specified voltage.

  • Page 510: Generator

    GENERATOR Starting/Charging Systems 3. Generator 5) Remove bolts which install generator onto S179008 bracket. A: REMOVAL S179008A18 1) Disconnect battery ground cable. S6M0352 B: INSTALLATION G6M0095 S179008A11 2) Disconnect connector and terminal from gen- Install in the reverse order of removal. erator.
  • Page 511 GENERATOR Starting/Charging Systems 2) Remove the four through-bolts. Then insert the 4) Unsolder connection between rectifier and sta- tip of a flat-head screwdriver into the gap between tor coil to remove stator coil. the stator core and front bracket. Pry then apart to CAUTION: disassemble.
  • Page 512 GENERATOR Starting/Charging Systems 7) Remove the nut and insulating bushing at ter- E: INSPECTION S179008A10 minal B, and remove rectifier. 1. DIODE S179008A1001 CAUTION: Never use a megatester (measuring use for high voltage) or any other similar measure for this test; otherwise, the diodes may be dam- aged.
  • Page 513 GENERATOR Starting/Charging Systems Measure slip ring outer diameter. If slip ring is worn 5) Ball bearing (rear side) replace rotor assembly. (1) Check rear ball bearing. Replace if it is noisy or if rotor does not turn smoothly. Slip ring outer diameter: (2) The rear bearing can be removed by using Standard common bearing puller.
  • Page 514 GENERATOR Starting/Charging Systems 4. BRUSH 2) Replacing front bearing S179008A1004 (1) Remove front bearing retainer. 1) Measure the length of each brush. If wear (2) Closely install a fit tool on the bearing inner exceeds the service limit, replace the brush. Each race.

  • Page 515: Battery

    BATTERY Starting/Charging Systems 4. Battery C: INSPECTION S179011A10 S179011 WARNING: A: REMOVAL S179011A18 ¼ Electrolyte has toxicity; be careful handling 1) Remove battery cable holder (A) from battery the fluid. rod. ¼ Avoid contact with skin, eyes or clothing. Especially at contact with eyes, flush with water for 15 minutes and get prompt medical attention.
  • Page 516 BATTERY Starting/Charging Systems = St + 0.0007 × (t − 20) 2. CHECK HYDROMETER FOR STATE OF : Specific gravity corrected at electro- CHARGE S179011A1402 lyte temperature of 20°C Hydrometer St : Measured specific gravity State of charge Required action indicator t : Measured temperature (°C) Green dot...
  • Page 517 BATTERY Starting/Charging Systems MEMO: SC-20...
  • Page 518 Engine Condition Data ................27 Transmission Control Module (TCM) I/O Signal ........28 Data Link Connector .................31 OBD-II General Scan Tool ................32 Subaru Select Monitor................34 Read Diagnostic Trouble Code (DTC) ............41 Inspection Mode ..................42 Clear Memory Mode..................45 Compulsory Valve Operation Check Mode..........46 Engine Malfunction Indicator Lamp (MIL) ..........48...

  • Page 519: Basic Diagnostic Procedure

    OBD-II general scan tool to data link connec- EN-82, List of If DTC is not tor. Diagnostic shown on display 3) Turn ignition switch to ON and the Subaru Trouble Code although the MIL Select Monitor or OBD-II general scan tool (DTC).> Go to illuminates, per- switch to ON.
  • Page 520 BASIC DIAGNOSTIC PROCEDURE Engine (Diagnostics) 2. AUTOMATIC TRANSMISSION S078501E4502 When trouble code about automatic transmission is shown on display, carry out the following basic check. After that, carry out the replacement or repair work. 1) ATF level check <Ref. to AT-9, Automatic Trans- mission Fluid.>...

  • Page 521: Check List For Interview

    CHECK LIST FOR INTERVIEW Engine (Diagnostics) 2. Check List for Interview Check the following items when problem has S078502 occurred. A: CHECK S078502A04 NOTE: 1. CHECK LIST NO. 1 Use copies of this page for interviewing customers. S078502A0401 Customer’s name Engine no.
  • Page 522 CHECK LIST FOR INTERVIEW Engine (Diagnostics) 2. CHECK LIST NO. 2 NOTE: S078502A0402 Use copies of this page for interviewing customers. Check the following items about the vehicle’s state when MIL turns on. a) Other warning lights or indicators turn on. „ Yes/„ No „...

  • Page 523: General Description

    GENERAL DESCRIPTION Engine (Diagnostics) 3. General Description 8) Use ECM mounting stud bolts at the body head S078001 grounding point when measuring voltage and A: CAUTION resistance inside the passenger compartment. S078001A03 1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay.
  • Page 524 ¼ The OBD-II system is capable of communication for proper grounding. with a general scan tool (OBD-II general scan tool) formed by ISO 9141 CARB. ¼ The OBD-II diagnostics procedure is different from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru EN-7...
  • Page 525 GENERAL DESCRIPTION Engine (Diagnostics) ¼ Reduced emission of harmful exhaust gases. Select Monitor or the OBD-II general scan tool to ¼ Reduced in fuel consumption. the vehicle. ¼ Increased engine output. 2. ENGINE AND EMISSION CONTROL ¼ Superior acceleration and deceleration. SYSTEM ¼...
  • Page 526 GENERAL DESCRIPTION Engine (Diagnostics) MEMO: EN-9...
  • Page 527 S078507A13 1. ENGINE S078507A1301 ¼ MODULE S078507A130101 B2M4181C B2M4182C (1) Engine control module (ECM) (3) Test mode connector (4) Data link connector (for Subaru (2) CHECK ENGINE malfunction Select Monitor and OBD-II gen- indicator lamp (MIL) eral scan tool) EN-10...

  • Page 528: Electrical Components Location

    ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B3M1575A B2M4704A B2M2238D B2M2960H EN-11...
  • Page 529 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) ¼ SENSOR S078507A130102 B2M3427A (1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor (2) Intake air temperature and pres- (6) Camshaft position sensor sure sensor (4) Throttle position sensor (7) Crankshaft position sensor EN-12...
  • Page 530 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M3713A B2M3714A S2M1248B B2M2240A B2M2241A B2M2242A B2M0213J EN-13...
  • Page 531 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M4231A (1) Front oxygen (A/F) sensor (3) Front catalytic converter (2) Rear oxygen sensor (4) Rear catalytic converter S2M0264A S2M0265A OBD0524G OBD0525G EN-14...
  • Page 532 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M4181D B2M4182D (1) Fuel level sensor (2) Fuel sub level sensor B2M2966B B2M3706B EN-15...
  • Page 533 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) ¼ SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS S078507A130103 B2M3427B (1) Air assist injector solenoid valve (3) Purge control solenoid valve (2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY EN-16...
  • Page 534 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M3715A H2M3259A H2M3258B B2M3720A EN-17...
  • Page 535 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M4181E B2M4182E (1) Inhibitor switch (4) Fuel pump relay (7) Starter (2) Fuel pump (5) Radiator main fan relay (3) Main relay (6) Radiator sub fan relay EN-18...
  • Page 536 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M2246A B2M2966C B2M3833B B2M3834B B2M2967C B2M2968C B2M3711B B2M2247E EN-19...
  • Page 537 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) 2. TRANSMISSION S078507A1302 ¼ MODULE S078507A130201 B2M4181F B2M4182F (1) Transmission Control Module (2) AT diagnostic indicator light (for (TCM) (for AT vehicles) AT vehicles) EN-20...
  • Page 538 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B3M1592D B3M1652B B2M4704B EN-21...
  • Page 539 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) ¼ SENSOR S078507A130202 B2M2258A B2M2259A B2M2260A B2M2261A OBD0653B (1) Rear vehicle speed sensor (for AT vehicles) (2) Front vehicle speed sensor (for MT vehicles) (3) Front vehicle speed sensor (for AT vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles) (6) Brake light switch EN-22...
  • Page 540 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) ¼ SOLENOID VALVE AND SWITCH (AT VEHICLES) S078507A130203 B2M2246F B2M2263K B2M2264F (1) Inhibitor switch (2) Shift solenoid valve 1 (3) Shift solenoid valve 2 (4) Line pressure duty solenoid (5) Lock-up duty solenoid (6) Transfer duty solenoid (7) 2-4 brake duty solenoid (8) Low clutch timing solenoid valve (9) 2-4 brake timing solenoid valve...
  • Page 541 ENGINE CONTROL MODULE (ECM) I/O SIGNAL Engine (Diagnostics) 5. Engine Control Module (ECM) I/O Signal S078526 A: ELECTRICAL SPECIFICATION S078526A08 B2M2267A Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) Signal (+) B135 −7 —...

  • Page 542: Engine Control Module (Ecm) I/O Signal

    ENGINE CONTROL MODULE (ECM) I/O SIGNAL Engine (Diagnostics) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) ON: 10 — 13 ON: 13 — 14 A/C switch B135 — OFF: 0 OFF: 0 Ignition switch B135 10 —...
  • Page 543 ENGINE CONTROL MODULE (ECM) I/O SIGNAL Engine (Diagnostics) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) Less than 1 ←→ More Less than 1 ←→ More AT diagnosis input sig- B135 Waveform than 4 than 4...

  • Page 544: Engine Condition Data

    ENGINE CONDITION DATA Engine (Diagnostics) 6. Engine Condition Data S078530 A: ELECTRICAL SPECIFICATION S078530A08 Content Specified data 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm racing Measuring condition: ¼ After warm-up the engine. ¼ Gear position is in “N” or “P” position. ¼...
  • Page 545 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL Engine (Diagnostics) 7. Transmission Control Module (TCM) I/O Signal S078506 A: ELECTRICAL SPECIFICATION S078506A08 S3M0244A Check with ignition switch ON. Connec- Terminal Resistance to Content Measuring conditions Voltage (V) tor No. body (ohms) Back-up power supply Ignition switch OFF 10 —...

  • Page 546: Transmission Control Module (Tcm) I/O Signal

    TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL Engine (Diagnostics) Check with ignition switch ON. Connec- Terminal Resistance to Content Measuring conditions Voltage (V) tor No. body (ohms) VDC communication signal + (+) — (–) — (With VDC model) Plus signal Ignition ON VDC communication signal –...
  • Page 547 FWD switch (Without VDC — model) Fuse installed. Less than 1 Fuse ON FWD switch Less than 1 FWD indicator light (Without — Fuse removed from FWD VDC model) More than 9 switch Data link signal (Subaru — — — Select Monitor) EN-30...

  • Page 548: Data Link Connector

    S078505A15 1) This connector is used both for OBD-II general scan tools and the Subaru Select Monitor. 2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal. CAUTION: Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select Monitor, because the circuit for the Subaru Select Monitor may be damaged.

  • Page 549: Obd-Ii General Scan Tool

    OBD-II GENERAL SCAN TOOL Engine (Diagnostics) 9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up S078527 DTC(s) and freeze frame data. A: OPERATION OBD-II general scan tool functions consist of: S078527A16 (1) MODE $01: Current powertrain diagnostic 1.
  • Page 550 OBD-II GENERAL SCAN TOOL Engine (Diagnostics) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) S078527A1603 Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure Trouble code that caused CARB required freeze frame data storage...

  • Page 551: Subaru Select Monitor

    1) Prepare Subaru Select Monitor kit. <Ref. to EN-8, PREPARATION TOOL, General Descrip- tion.> S2M0288A 6) Using Subaru Select Monitor, call up DTC and various data, then record them. S2M0285 2. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. (NORMAL MODE) 2) Connect diagnosis cable to Subaru Select Monitor.
  • Page 552 SUBARU SELECT MONITOR Engine (Diagnostics) 4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) S078503A1604 1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key.
  • Page 553 ON or OFF Air assist injector solenoid valve signal Assist Air Sol. Valve ON or OFF AT vehicle ID signal AT Vehicle ID Signal ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-36...
  • Page 554 Rear oxygen sensor output signal Oxygen Sensor #12 Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 On-board diagnostic system OBD System — NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-37...
  • Page 555 Engine Speed Vehicle speed signal Vehicle Speed km/h or MPH NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD MODE) S078503A1607 1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key.
  • Page 556 Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF entered. When camshaft position sensor signal is Camshaft position sensor signal Camshaft Position Sig. ON or OFF entered. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-39...
  • Page 557 ON or OFF Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-40...

  • Page 558: Read Diagnostic Trouble Code (Dtc)

    A: OPERATION For details concerning diagnostic trouble codes, S078792A16 refer to the List of Diagnostic Trouble Code (DTC). 1. SUBARU SELECT MONITOR (NORMAL <Ref. to EN-82, List of Diagnostic Trouble Code MODE) S078792A1601 (DTC).> 1) On the...

  • Page 559: Inspection Mode

    INSPECTION MODE Engine (Diagnostics) 12. Inspection Mode 1) Prepare Subaru Select Monitor kit. <Ref. to S078510 EN-8, PREPARATION TOOL, General Descrip- A: OPERATION tion.> S078510A16 1. PREPARATION FOR THE INSPECTION MODE S078510A1601 Raise the vehicle using a garage jack and place on safety stands or drive the vehicle onto free rollers.
  • Page 560 INSPECTION MODE Engine (Diagnostics) 5) Connect Subaru Select Monitor to data link NOTE: ¼ For detailed operation procedure, refer to the connector. (1) Connect Subaru Select Monitor to data link SUBARU SELECT MONITOR OPERATION connector located in the lower portion of the MANUAL.
  • Page 561 INSPECTION MODE Engine (Diagnostics) 3) Start the engine. NOTE: ¼ Ensure the selector lever is placed in the “P” position before starting. (AT vehicles) ¼ Depress clutch pedal when starting the engine. (MT vehicles) 4) Using the selector lever or shift lever, turn the “P”...

  • Page 562: Clear Memory Mode

    {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. NOTE: ¼ After the memory has been cleared, the idle air control solenoid valve must be initialized.
  • Page 563 COMPULSORY VALVE OPERATION CHECK MODE Engine (Diagnostics) 14. Compulsory Valve 5) Connect Subaru Select Monitor to data link connector. Operation Check Mode (1) Connect Subaru Select Monitor to data link S078528 connector located in the lower portion of the A: OPERATION S078528A16 instrument panel (on the driver’s side).

  • Page 564: Compulsory Valve Operation Check Mode

    EGR Solenoid Valve ASV Solenoid Valve PCV Solenoid Valve Vent Control Solenoid Valve FICD Solenoid Pressure Switching Sol. 1 Pressure Switching Sol. 2 Fuel Tank Sensor Control Valve ¼ For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-47...

  • Page 565: Engine Malfunction

    ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) 15. Engine Malfunction Indicator Lamp (MIL) S078653 A: PROCEDURE S078653E45 1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN-49, ACTIVATION OF CHECK ENGINE MAL- FUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> ↓...

  • Page 566: Engine Malfunction Indicator Lamp (Mil)

    ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) 3) If the diagnosis system senses a misfire which B: ACTIVATION OF CHECK ENGINE could damage the catalyzer, the MIL will blink at a MALFUNCTION INDICATOR LAMP cycle of 1 Hz. (MIL) S078653E89 1) When ignition switch is turned to ON (engine off), the CHECK ENGINE malfunction indicator lamp (MIL) in the combination meter illuminates.
  • Page 567 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON. S078653E90 ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼ TROUBLE SYMPTOM: ¼ When ignition switch is turned ON (engine OFF), MIL does not come on. ¼...
  • Page 568 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK POOR CONTACT. Does the MIL come on Repair poor con- Go to step 3. when shaking or pulling tact in ECM con- ECM connector and har- nector. ness? CHECK ECM CONNECTOR. Is ECM connector correctly Replace ECM.
  • Page 569 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK LAMP BULB. Is lamp bulb condition OK? Repair combina- Replace lamp Remove engine malfunction indicator lamp tion meter con- bulb. bulb. nector. EN-52...
  • Page 570 ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD-II general scan tool display. ¼ WIRING DIAGRAM:...
  • Page 571 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz. S078653E92 ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼ Test mode connector circuit is in open. ¼...
  • Page 572 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) ¼ WIRING DIAGRAM: B2M4706 Step Check CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL FUNCTION INDICATOR LAMP (MIL). circuit. <Ref. to 1) Turn ignition switch to OFF. EN-50, CHECK 2) Disconnect test mode connector.
  • Page 573 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN TEST MODE Is resistance less than 1 Go to step 4. Repair harness Ω? CONNECTOR AND CHASSIS GROUND. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from ECM. In this case, 3) Measure resistance of harness between repair the follow-...
  • Page 574 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) MEMO: EN-57...
  • Page 575 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 Hz. S078653E93 ¼ DIAGNOSIS: ¼ Test mode connector circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON. ¼...
  • Page 576 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM CON- Is resistance less than 5 Repair short cir- Replace ECM. Ω? NECTOR AND ENGINE GROUNDING TER- cuit in harness <Ref. to FU-51, MINAL. between ECM Engine Control 1) Turn ignition switch to OFF.
  • Page 577 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) MEMO: EN-60...
  • Page 578 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) 16. Diagnostics for Engine Starting Failure S078533 A: PROCEDURE S078533E45 1. Inspection of starter motor circuit. <Ref. to EN-62, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN-66, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
  • Page 579 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) B: STARTER MOTOR CIRCUIT S078533E94 CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.>. ¼...
  • Page 580 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Go to step 2. Go to step 3. when the switch starts? Go to step 3. CHECK DTC. Is the trouble code stored Record DTC.
  • Page 581 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK TRANSMISSION TYPE. Is the vehicle AT? Go to step 10. Repair open cir- cuit between igni- tion switch and starter motor cir- cuit. CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than Repair open cir- Go to step 11.
  • Page 582 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN-65...
  • Page 583 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE S078533E37 CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.> and Inspection Mode. <Ref. to EN-42, OPERATION, Inspection Mode.> ¼...
  • Page 584 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 3. Repair open cir- 5 Ω? 1) Disconnect connector from ECM. cuit in harness 2) Measure resistance of harness between between ECM ECM and chassis ground.

  • Page 585: Diagnostics For Engine Starting Failure

    DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 Check ignition Repair open or 1) Connect main relay connector. control system. ground short cir- 2) Turn ignition switch to ON. <Ref.
  • Page 586 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN-69...
  • Page 587 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) D: IGNITION CONTROL SYSTEM S078533E95 CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.>. ¼...
  • Page 588 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK POWER SUPPLY CIRCUIT FOR Is the voltage more than 10 Go to step 3. Repair harness IGNITION COIL & IGNITOR ASSEMBLY. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from ignition coil &...
  • Page 589 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 9. Repair harness 1 Ω? IGNITION COIL & IGNITOR ASSEMBLY and connector. CONNECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Disconnect connector from ECM.
  • Page 590 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN-73...
  • Page 591 CIRCUIT, Diag- NOTE: nostics for Engine Fuel pump operation can also be executed Starting Failure.> using Subaru Select Monitor (Function mode: FD01). For the procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN-46, Compulsory Valve Operation Check Mode.>...
  • Page 592 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than Go to step 3. Repair harness 5 Ω? 1) Turn ignition switch to OFF. and connector. 2) Remove fuel pump access hole lid located NOTE: on the right rear of trunk compartment floor In this case,...
  • Page 593 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 8. Repair open cir- 1 Ω? FUEL PUMP RELAY CONNECTOR. cuit in harness 1) Disconnect connectors from ECM. between ECM 2) Measure resistance of harness between and fuel pump...
  • Page 594 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN-77...
  • Page 595 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) F: FUEL INJECTOR CIRCUIT S078533E97 CAUTION: ¼ Check or repair only faulty parts. ¼ After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.> and Inspection Mode. <Ref. to EN-42, OPERATION, Inspection Mode.>...
  • Page 596 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 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, injector.
  • Page 597 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 8. Repair harness and 20 Ω? FUEL INJECTOR CONNECTOR. and connector. Measure resistance of harness between ECM NOTE: and fuel injector connector.
  • Page 598 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN-81...

  • Page 599: List Of Diagnostic Trouble Code (Dtc)

    LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) 17. List of Diagnostic Trouble Code (DTC) S078525 A: LIST S078525A12 Item Index P0031 Front oxygen (A/F) sensor heater <Ref. to EN-88, DTC P0031 — FRONT OXYGEN (A/F) SENSOR circuit low input HEATER CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...

  • Page 600: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Item Index P0125 Insufficient coolant temperature for <Ref. to EN-136, DTC P0125 — INSUFFICIENT COOLANT TEMPERA- closed loop fuel control TURE FOR CLOSED LOOP FUEL CONTROL —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0130 Front oxygen (A/F) sensor circuit <Ref.
  • Page 601 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Item Index P0445 Evaporative emission control system <Ref. to EN-186, DTC P0445 — EVAPORATIVE EMISSION CONTROL purge control valve circuit high input SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT —, Diagnos- tic Procedure with Diagnostic Trouble Code (DTC).> P0461 Fuel level sensor circuit range/ <Ref.
  • Page 602 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Item Index P0741 Torque converter clutch system mal- <Ref. to EN-226, DTC P0741 — TORQUE CONVERTER CLUTCH SYS- function TEM MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0743 Torque converter clutch system <Ref.
  • Page 603 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Item Index P1515 Idle air control solenoid valve signal <Ref. to EN-254, DTC P1515 — IDLE AIR CONTROL SOLENOID VALVE 3 circuit high input SIGNAL 3 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 604 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Item Index P1701 Cruise control set signal circuit mal- <Ref. to EN-286, DTC P1701 — CRUISE CONTROL SET SIGNAL CIR- function for automatic transmission CUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1703 Low clutch timing control solenoid <Ref.
  • Page 605 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) 18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) S078521 A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT — S078521F83 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 606 Repair poor con- Go to step 5. 1) Start engine tact in connector. 2) Read data of front oxygen (A/F) sensor NOTE: heater current using Subaru Select Monitor or In this case, OBD-II general scan tool. repair the follow- NOTE: ing: ¼...
  • Page 607 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair poor con- Go to step 7. Measure voltage between ECM connector less than 1.0 V by shaking tact in ECM con- and chassis ground.
  • Page 608 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-91...
  • Page 609 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT — S078521F84 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 610 ECM and front oxygen (A/F) sensor connector. 3) Turn ignition switch to ON. 4) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 611 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION — S078521F85 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 612 Repair connector. Go to step 4. 1) Start engine. NOTE: 2) Read data of rear oxygen sensor heater In this case, current using Subaru Select Monitor or OBD-II repair the follow- general scan tool. ing: ¼ Poor contact in NOTE: ¼...
  • Page 613 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 Go to step 8. Repair power sup- GEN SENSOR. ply line. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from rear oxygen In this case,...
  • Page 614 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-97...
  • Page 615 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT — S078521F86 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 616 ECM and rear oxygen sensor con- Module.> nector. 3) Turn ignition switch to ON. 4) Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 617 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) E: DTC P0066 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW INPUT — S078521F88 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 618 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Repair poor con- Go to step 2. 1) Turn ignition switch to ON. tact in ECM con- 2) Measure voltage between ECM and chas- nector.
  • Page 619 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) F: DTC P0067 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH INPUT — S078521G72 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 620 Does the voltage change Repair battery Contact with your Measure voltage between ECM and chassis more than 10 V by shaking short circuit in Subaru distributor ground. harness and connector of harness between service. Connector & terminal ECM while monitoring the...
  • Page 621 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) G: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) — S078521F90 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 622 3) Turn A/C switch to OFF. Pressure Sensor.> 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sen- sor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 623 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) H: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT — S078521B12 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 624 Go to step 2. 1) Start engine. kPa (100 mmHg, 3.94 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 625 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 9. Repair open cir- 1 Ω? INTAKE AIR TEMPERATURE AND PRES- cuit in harness SURE SENSOR CONNECTOR. between ECM 1) Turn ignition switch to OFF.
  • Page 626 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-109...
  • Page 627 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) I: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT — S078521B13 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 628 1) Start engine. 119.5 kPa (896.5 mmHg, 2) Read the data of intake manifold absolute 35.29 inHg)? pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 629 SURE SENSOR CONNECTOR. 35.29 inHg)? harness between pressure sensor. 1) Turn ignition switch to OFF and Subaru ECM and intake <Ref. to FU-37, Select Monitor or the OBD-II general scan air temperature Intake Air Tem- tool switch to OFF.
  • Page 630 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-113...
  • Page 631 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) J: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM — S078521B14 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 632 (167°F) and 95°C (203°F)? pressure sensor. List of Diagnostic 2) Measure engine coolant temperature using <Ref. to FU-37, Trouble Code Subaru Select Monitor or OBD-II general scan Intake Air Tem- (DTC)”. <Ref. to tool. perature and EN-82, List of NOTE: Pressure Sensor.>...
  • Page 633 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) K: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT — S078521B15 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 634 Repair poor con- 1) Start engine. 120°C (248°F)? tact. 2) Read data of intake air temperature sensor NOTE: signal using Subaru Select Monitor or the In this case, OBD-II general scan tool. repair the follow- NOTE: ing: ¼ Subaru Select Monitor ¼...
  • Page 635 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) L: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT — S078521B16 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 636 Repair poor con- 1) Start engine. −40°C (−40°F)? tact. 2) Read data of intake air temperature sensor NOTE: signal using Subaru Select Monitor or the In this case, OBD-II general scan tool. repair the follow- NOTE: ing: ¼ Subaru Select Monitor ¼...
  • Page 637 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 Go to step 5. Repair harness TEMPERATURE AND PRESSURE SENSOR and connector. AND ECM CONNECTOR. NOTE: Measure voltage between intake air tempera- In this case, ture and pressure sensor connector and repair the follow-...
  • Page 638 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-121...
  • Page 639 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) M: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT — S078521F91 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Hard to start ¼ Erroneous idling ¼...
  • Page 640 Repair poor con- 1) Start engine. 150°C (302°F)? tact. 2) Read data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor or In this case, OBD-II general scan tool. repair the follow- NOTE: ing: ¼ Subaru Select Monitor ¼...
  • Page 641 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) N: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT — S078521F92 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Hard to start ¼ Erroneous idling ¼...
  • Page 642 Repair poor con- 1) Start engine. −40°C (−40°F)? tact. 2) Read data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor or In this case, OBD-II general scan tool. repair the follow- NOTE: ing: ¼ Subaru Select Monitor ¼...
  • Page 643 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 Go to step 5. Repair harness COOLANT TEMPERATURE SENSOR AND and connector. ECM CONNECTOR. NOTE: Measure voltage between engine coolant tem- In this case, perature sensor connector and engine repair the follow-...
  • Page 644 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-127...
  • Page 645 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) O: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) — S078521B19 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 646 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace throttle Monitor or OBD-II general P0122 or P0123 position sensor. scan tool indicate DTC using “17. List of <Ref.
  • Page 647 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) P: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT — S078521B20 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 648 Even if MIL lights 1) Start engine. up, the circuit has 2) Read data of throttle position sensor signal returned to a nor- using Subaru Select Monitor or OBD-II gen- mal condition at eral scan tool. this time. A tem- NOTE: porary poor con- ¼...
  • Page 649 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than Go to step 7. Repair harness THROTTLE POSITION SENSOR CONNEC- 4.5 V? and connector. TOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Disconnect connectors from throttle posi- repair the follow-...
  • Page 650 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-133...
  • Page 651 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Q: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — S078521B21 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 652 Even if MIL lights 1) Start engine. up, the circuit has 2) Read data of throttle position sensor signal returned to a nor- using Subaru Select Monitor or OBD-II gen- mal condition at eral scan tool. this time. A tem- NOTE: porary poor con- ¼...
  • Page 653 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) R: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL — S078521B22 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 654 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0117 or P0118 scan tool indicate DTC using “17. List of...
  • Page 655 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) S: DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LEAN) — S078521G44 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 656 DATA. more than 0.85 and equal 1) Start engine. to less than 1.15 in idling? 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70°C (158°F). If the engine is already warmed-up, operate at idle speed for at least 1 minute.
  • Page 657 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than Go to step 6. Repair ground FRONT OXYGEN (A/F) SENSOR. 1 MΩ? short circuit Measure resistance between ECM and chas- between ECM sis ground.
  • Page 658 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-141...
  • Page 659 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) — S078521G45 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 660 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 2. Repair harness 1 Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- and connector. TOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Disconnect connectors from ECM and front repair the follow-...
  • Page 661 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) — S078521G46 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 662 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than Replace front oxy- Repair ground 10 Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- gen (A/F) sensor. short circuit in TOR. <Ref.
  • Page 663 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE — S078521B26 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 664 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0131, P0132, scan tool indicate DTC P0031 or P0032 P0131, P0132, P0031 or using “17.
  • Page 665 Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.>. ¼ WIRING DIAGRAM: B2M4711 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Go to step 2. Go to step 3. Monitor or OBD-II general scan tool indicate DTC P0131 or P0132?
  • Page 666 70°C (158°F), and keep the engine speed at 2,000 rpm to 3,000 rpm for two minutes. 2) Read data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DIS-...
  • Page 667 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace rear oxy- Check exhaust system parts. system? faulty parts. gen sensor. <Ref. NOTE: to FU-49, Rear Check the following items.
  • Page 668 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-151...
  • Page 669 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) X: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE — S078521B29 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 670 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace rear oxy- Monitor or OBD-II general P0136 using “17. gen sensor. <Ref. scan tool indicate DTC...
  • Page 671 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Y: DTC P0170 — FUEL TRIM MALFUNCTION — S078521B31 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 672 1) Start the engine and warm-up completely. (212°F)? ture sensor. <Ref. 2) Read data of engine coolant temperature to FU-29, Engine sensor signal using Subaru Select Monitor or Coolant Tempera- OBD-II general scan tool. ture Sensor.> NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 673 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Z: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — S078521B37 NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN-158, DTC P0304 — CYLINDER 4 MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AA: DTC P0302 —...
  • Page 674 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-157...
  • Page 675 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AC: DTC P0304 — CYLINDER 4 MISFIRE DETECTED — S078521B40 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ Immediately at fault recognition (A misfire which could damage catalyst occurs.) ¼...
  • Page 676 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) B2M4713 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0106, P0107, scan tool indicate DTC P0108, P0117,...
  • Page 677 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Go to step 7. Go to step 3. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground on faulty cylinders.
  • Page 678 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK POWER SUPPLY LINE. Is the voltage more than 10 Repair poor con- Repair harness 1) Turn ignition switch to ON. tact in all connec- and connector. 2) Measure voltage between fuel injector and tors in fuel injector NOTE: engine ground on faulty cylinders.
  • Page 679 Is the MIL coming on or Go to step 15. Go to step 14. FUNCTION INDICATOR LAMP (MIL). blinking? 1) Clear memory using Subaru Select Moni- tor. <Ref. to EN-45, Clear Memory Mode.> 2) Start engine, and drive the vehicle more than 10 minutes.
  • Page 680 Monitor or OBD-II general 2) Read DTC. scan tool indicate only one ¼ Subaru Select Monitor DTC? <Ref. to EN-34, Subaru Select Monitor.> ¼ OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Operation Manual. NOTE: Perform diagnosis according to the items listed below.
  • Page 681 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check GROUP OF #3 AND #4 CYLINDERS Are there faults in #3 and Repair or replace Go to DTC #4 cylinders? faulty parts. P0170. <Ref. to NOTE: EN-154, DTC ¼ Check the fol- P0170 —...
  • Page 682 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-165...
  • Page 683 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AD: DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT — S078521F94 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Poor driving performance ¼ Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 684 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN KNOCK Is the resistance more than Go to step 2. Repair harness SENSOR AND ECM CONNECTOR. 700 kΩ? and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from ECM.
  • Page 685 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AE: DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT — S078521F95 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Poor driving performance ¼ Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 686 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN KNOCK Is the resistance less than Go to step 2. Go to step 3. SENSOR AND ECM CONNECTOR. 400 kΩ? Measure resistance of harness between ECM connector and chassis ground.
  • Page 687 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AF: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — S078521B42 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 688 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair harness Go to step 2. SHAFT POSITION SENSOR AND ECM 100 kΩ? and connector. CONNECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Disconnect connector from crankshaft posi- repair the follow-...
  • Page 689 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AG: DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM — S078521B43 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 690 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0335 using “17. scan tool indicate DTC List of Diagnostic...
  • Page 691 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AH: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — S078521B44 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 692 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair harness Go to step 2. POSITION SENSOR AND ECM CONNEC- 100 kΩ? and connector. TOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Disconnect connector from camshaft posi- repair the follow-...
  • Page 693 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AI: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM — S078521B45 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 694 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0340 using “17. scan tool indicate DTC List of Diagnostic...
  • Page 695 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace camshaft 1) Remove camshaft position sensor. and 4 kΩ? position sensor. 2) Measure resistance between connector <Ref.
  • Page 696 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-179...
  • Page 697 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AJ: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD — S078521B46 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 698 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect the rel- Go to step 2. Monitor or OBD-II general evant DTC using scan tool indicate DTC “17. List of Diag-...
  • Page 699 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AK: DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT — S078521G47 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 700 2) Measure voltage between ECM and chas- returned to a nor- sis ground. mal condition at Connector & terminal this time. Contact (B134) No. 2 (+) — Chassis ground (−): with your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterio- ration of multiple parts.
  • Page 701 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Contact with your Check poor contact in purge control solenoid purge control solenoid tact in purge con- Subaru distributor. valve connector. valve connector? trol solenoid valve NOTE: connector. Inspection by...
  • Page 702 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-185...
  • Page 703 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AL: DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT — S078521G48 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 704 ECM and connector. chassis ground. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For procedure, refer to “Compulsory Valve Opera- tion Check Mode”. <Ref. to EN-46, Compul- sory Valve Operation Check Mode.> Connector & terminal (B134) No.
  • Page 705 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AM: DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM — S078521B54 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 706 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace fuel level Monitor or OBD-II general P0462 or P0463 sensor <Ref. to scan tool indicate DTC using “17.
  • Page 707 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AN: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — S078521B55 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 708 Select Monitor? porary poor con- For detailed operation procedure, refer to the tact of the con- “READ CURRENT DATA FOR ENGINE”. nector may be the <Ref. to EN-34, Subaru Select Monitor.> cause. NOTE: In this case, repair the follow- ing: ¼...
  • Page 709 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK FUEL TANK CORD. Is the resistance more than Go to step 8. Repair ground 1) Turn ignition switch to OFF. 1 MΩ? short circuit in fuel 2) Disconnect connector from fuel sub level tank cord.
  • Page 710 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-193...
  • Page 711 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AO: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — S078521B56 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 712 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 3. Even if MIL lights 1) Turn ignition switch to ON. (Engine OFF) 4.75 V? up, the circuit has 2) Measure voltage between ECM connector returned to a nor- and chassis ground.
  • Page 713 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK FUEL TANK CORD. Is the resistance less than Go to step 8. Repair open cir- 10 Ω? 1) Disconnect connector from fuel sub level cuit between fuel sensor. level sensor and 2) Measure resistance between fuel level sen- fuel sub level sen-...
  • Page 714 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-197...
  • Page 715 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AP: DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT— S078521G01 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 716 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0462 or P0463 scan tool indicate DTC using “17. List of...
  • Page 717 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AQ: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — S078521B57 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Radiator fan does not operate properly. ¼...
  • Page 718 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) ¼ WIRING DIAGRAM: B2M4761 EN-201...
  • Page 719 NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN-34, Subaru Select Moni- tor.> Connector & terminal (B134) No. 3 (+) — Chassis ground (−): CHECK GROUND SHORT CIRCUIT IN...
  • Page 720 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-203...
  • Page 721 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AR: DTC P0483 — COOLING FAN FUNCTION PROBLEM — S078521B58 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Occurrence of noise ¼ Overheating CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 722 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) ¼ WIRING DIAGRAM: B2M4761 EN-205...
  • Page 723 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Check radiator fan display? evant DTC using and fan motor. “17. List of Diag- <Ref.
  • Page 724 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-207...
  • Page 725 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AS: DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION — S078521B59 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 726 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Check front Go to step 3. Monitor or OBD-II general vehicle speed scan tool indicate DTC sensor signal cir- P0720? cuit.
  • Page 727 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AT: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED — S078521B61 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine is difficult to start. ¼...
  • Page 728 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P1510, P1511, scan tool indicate DTC P1512, P1513, P1510, P1511, P1512,...
  • Page 729 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AU: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED — S078521B62 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 730 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P1510, P1511, scan tool indicate DTC P1512, P1513, P1510, P1511, P1512,...
  • Page 731 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AV: DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT — S078521G02 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 732 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair battery Check starter NOTE: when ignition switch to short circuit in motor circuit. Place the inhibitor switch in each position. “ON”? starter motor cir- <Ref.
  • Page 733 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AW: DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT — S078521G81 ¼ DTC DETECTING CONDITION: ¼ Power source voltage of the ECM is low. ¼ TROUBLE SYMPTOM: ¼ Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 734 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK GENERATOR. Is the voltage less than Go to step 2. Repair generator. 1) Start engine. 10.8 V? <Ref. to SC-13, 2) Idling after warm-up. Generator.> 3) Measure voltage between generator B ter- minal and chassis ground.
  • Page 735 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AX: DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT — S078521G82 ¼ DTC DETECTING CONDITION: ¼ Power source voltage of the ECM is high. ¼ TROUBLE SYMPTOM: ¼ Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 736 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK GENERATOR. Is the voltage more than Go to step 2. Repair generator. 1) Start engine. 16.2 V? <Ref. to SC-13, 2) Idling after warm-up. Generator.> 3) Measure voltage between generator B ter- minal and chassis ground.
  • Page 737 Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.>. ¼ WIRING DIAGRAM: B2M4708 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Replace ECM. It is not necessary Monitor or OBD-II general <Ref. to FU-51, to inspect DTC...
  • Page 738 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-221...
  • Page 739 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) AZ: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — S078521B64 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 740 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 3. Repair or replace 1 Ω? BRAKE LIGHT SWITCH CONNECTOR. harness and con- 1) Disconnect connectors from TCM and nector.
  • Page 741 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BA: DTC P0731 — GEAR 1 INCORRECT RATIO — S078521B70 NOTE: For the diagnostic procedure, refer to DTC P0734. <Ref. to EN-225, DTC P0734 — GEAR 4 INCORRECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> BB: DTC P0732 —...
  • Page 742 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BD: DTC P0734 — GEAR 4 INCORRECT RATIO — S078521B73 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces- sive tight corner “braking”...
  • Page 743 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BE: DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION — S078521G04 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) ¼...
  • Page 744 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9. CUIT. temperature sensor circuit? ATF temperature Check ATF temperature sensor circuit. <Ref. sensor circuit.
  • Page 745 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BF: DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT — S078521B84 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 746 Go to step 2. 1) Start engine. kPa (0 mmHg, 0 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 747 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than Go to step 8. Repair harness ATMOSPHERIC PRESSURE SENSOR CON- 4.5 V? and connector. NECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Disconnect connector from atmospheric repair the follow-...
  • Page 748 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-231...
  • Page 749 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BG: DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT — S078521B85 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 750 Go to step 2. 1) Start engine. kPa (1,050 mmHg, 41.34 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 751 Pressure 4) Read data of intake manifold absolute sensor connector. Sensor.> pressure signal using Subaru select monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 752 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-235...
  • Page 753 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BH: DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM — S078521B86 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 754 2) Read data of intake manifold absolute inHg) and 106.6 kPa (800 sensor. <Ref. to pressure sensor. pressure signal using Subaru Select Monitor mmHg, 31.50 inHg)? FU-38, Atmo- <Ref. to FU-37, or OBD-II general scan tool. spheric Pressure...
  • Page 755 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BI: DTC P1137 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM — S078521G49 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 756 DATA. more than 0.85 and equal 1) Start engine. to less than 1.15 in idling? 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70°C (158°F). If the engine is already warmed-up, operate at idle speed for at least 1 minute.
  • Page 757 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than Go to step 6. Repair ground FRONT OXYGEN (A/F) SENSOR. 1 MΩ? short circuit Measure resistance between ECM and chas- between ECM sis ground.
  • Page 758 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-241...
  • Page 759 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BJ: DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) — S078521B99 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 760 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace throttle Monitor or OBD-II general P0122 or P0123 position sensor. scan tool indicate DTC using “17. List of <Ref.
  • Page 761 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BK: DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) — S078521G07 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 762 3) Turn A/C switch to OFF. Pressure Sensor.> 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sen- sor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 763 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BL: DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM 2 — S078521C11 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 764 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace fuel level Monitor or OBD-II general P0461, P0462 or sensor <Ref. to scan tool indicate DTC P0463 using “17.
  • Page 765 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BM: DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — S078521G08 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Radiator fan does not operate properly. ¼...
  • Page 766 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) ¼ WIRING DIAGRAM: B2M4761 EN-249...
  • Page 767 ECM voltage between ECM and chassis ground. connector. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN-46, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No.
  • Page 768 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-251...
  • Page 769 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BN: DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) — S078521C16 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 770 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P1510, P1511, scan tool indicate DTC P1512, P1513, P1510, P1511, P1512,...
  • Page 771 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BO: DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT LOW INPUT — S078521C17 NOTE: For the diagnostic procedure, refer to DTC P1516. <Ref. to EN-256, DTC 1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 772 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-255...
  • Page 773 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BU: DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT — S078521C23 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 774 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK POWER SUPPLY TO IDLE AIR Is the voltage more than 10 Go to step 2. Repair harness CONTROL SOLENOID VALVE. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from idle air control In this case,...
  • Page 775 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace idle air Check poor contact in ECM connector and ECM connector or idle air tact in ECM con- control solenoid idle air control solenoid valve connector.
  • Page 776 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-259...
  • Page 777 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BV: DTC P1517 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT — S078521C24 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 778 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Go to step 2. Go to step 3. Monitor or OBD-II general scan tool indicate DTC P1511, P1513, P1515 and P1517 at same time? CHECK GROUND CIRCUIT FOR ECM.
  • Page 779 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BW: DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT — S078521G09 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 780 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair harness Check starter NOTE: when ignition switch to and connector. motor circuit. Place the inhibitor switch in the “P” or “N” “ST”? NOTE: <Ref.
  • Page 781 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BX: DTC P1540 — VEHICLE SPEED SENSOR MALFUNCTION 2 — S078521C26 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 782 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Check front Go to step 2. Monitor or OBD-II general vehicle speed scan tool indicate DTC sensor signal cir- P0720? cuit.
  • Page 783 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BY: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — S078521C27 ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 784 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair ground Go to step 3. 10 Ω? MAIN FUSE BOX CONNECTOR. short circuit in 1) Disconnect connector from ECM. harness between 2) Measure resistance of harness between ECM connector...
  • Page 785 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) BZ: DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT MODEL) — S078521G83 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 786 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0705 using “17. scan tool indicate DTC List of Diagnostic...
  • Page 787 No. 7 — No. 12: CHECK SELECTOR CABLE CONNECTION. Is there any fault in selec- Repair selector Contact with your tor cable connection to cable connection. Subaru distributor inhibitor switch? <Ref. to CS-11, service. INSPECTION, NOTE: Select Cable.> Inspection by...
  • Page 788 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN-271...
  • Page 789 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CA: DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MODEL) — S078521G84 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 790 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2. Monitor or OBD-II general P0705 using “17. scan tool indicate DTC List of Diagnostic...
  • Page 791 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CB: DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT MODEL) — S078521G85 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 792 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 2. Go to step 4. 1) Turn ignition switch to ON. 10V in neutral position? 2) Measure voltage between ECM and chas- sis ground.
  • Page 793 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CC: DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION — S078521G12 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 794 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace TCM. installed on vehicle? line of car phone <Ref. to AT-49, or CB system. Transmission Control Module (TCM).> EN-277...
  • Page 795 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CD: DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT — S078521G13 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 796 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Go to step 2. Even if MIL lights TCM CONNECTOR. up, the circuit has 1) Turn ignition switch to ON. returned to a nor- 2) Measure voltage between ECM and chas- mal condition at...
  • Page 797 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CE: DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT — S078521G14 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 798 Even if MIL lights Contact with your Measure voltage between ECM and chassis from 1 V to 4 V while moni- up, the circuit has Subaru distributor ground. toring the value with volt- returned to a nor- service. Connector & terminal...
  • Page 799 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CF: DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT — S078521G15 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 800 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 Repair poor con- Go to step 2. 1) Start engine, and warm-up the engine. tact in ECM con- 2) Turn ignition switch to OFF.
  • Page 801 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CG: DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT — S078521G16 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 802 Does the voltage change Repair battery Contact with your TCM CONNECTOR. more than 10 V by shaking short circuit in Subaru distributor 1) Turn ignition switch to OFF. harness and connector of harness between service. 2) Measure voltage between ECM and chas-...
  • Page 803 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CH: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION — S078521C29 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-45, OPERATION, Clear Memory Mode.>...
  • Page 804 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 2. Repair open cir- 1 Ω? CCM CONNECTOR. cuit in harness 1) Turn ignition switch to OFF. between TCM and 2) Disconnect connectors from TCM and CCM connector.
  • Page 805 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CI: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION — S078521G17 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 806 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 2. Go to step 4. 1) Turn ignition switch to ON. 4.5 V? 2) Measure voltage between ECM and chas- sis ground.
  • Page 807 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) CJ: DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION — S078521G18 ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 808 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 2. Go to step 4. 1) Turn ignition switch to ON. 4.5 V? 2) Measure voltage between ECM and chas- sis ground.
  • Page 809 GENERAL DIAGNOSTIC TABLE Engine (Diagnostics) 19. General Diagnostic Table S078257 A: INSPECTION S078257A10 1. ENGINE S078257A1001 NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME-95, Engine Trouble in General.> Symptom Problem parts 1) Idle air control solenoid valve 2) Intake air temperature and pressure sensor 3) Ignition parts (*1) 1.
  • Page 810 GENERAL DIAGNOSTIC TABLE Engine (Diagnostics) Symptom Problem parts 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 7. Spark knock 4) Engine coolant temperature sensor 5) Knock sensor 6) Fuel injection parts (*4) 7) Fuel pump and fuel pump relay 1) Intake manifold pressure sensor 2) Intake air temperature sensor...
  • Page 811 GENERAL DIAGNOSTIC TABLE Engine (Diagnostics) MEMO: EN-294...
  • Page 812 Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description..................6 Electrical Components Location..............10 Engine Control Module (ECM) I/O Signal..........20 Subaru Select Monitor................23 Read Diagnostic Trouble Code (DTC) ............26 Inspection Mode ..................28 Clear Memory Mode..................30 Compulsory Valve Operation Check Mode..........31 Engine Malfunction Indicator Lamp (MIL) ..........33 Diagnostics for Engine Starting Failure ............45...

  • Page 813: Basic Diagnostic Procedure

    Repair the trouble NOTE: link connector. LIST, List of Diagnostic cause. <Ref. to If DTC is not 3) Turn ignition switch to ON and the Subaru Trouble Code (DTC).> EN(w/oOBD)-68, shown on display Select Monitor switch to ON. Diagnostic Proce- although the MIL 4) Read DTC on the Subaru Select Monitor.
  • Page 814 BASIC DIAGNOSTIC PROCEDURE Engine (Diagnostics) ¼ Be sure to check again from the beginning in 2. WITHOUT SUBARU SELECT MONITOR order to prevent secondary trouble caused by S038501E4502 repair work. CAUTION: ¼ Check the connector while it is connected unless specified otherwise.

  • Page 815: Check List For Interview

    CHECK LIST FOR INTERVIEW Engine (Diagnostics) 2. Check List for Interview S038502 A: CHECK S038502A04 1. CHECK LIST NO. 1 S038502A0401 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Engine no.
  • Page 816 CHECK LIST FOR INTERVIEW Engine (Diagnostics) 2. CHECK LIST NO. 2 S038502A0402 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 „...

  • Page 817: General Description

    GENERAL DESCRIPTION Engine (Diagnostics) 3. General Description 8) Use ECM mounting stud bolts at the body head S038001 grounding point when measuring voltage and A: CAUTION resistance inside the passenger compartment. S038001A03 1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay.
  • Page 818 GENERAL DESCRIPTION Engine (Diagnostics) ¼ The antenna feeder must be placed as far 2. ENGINE GROUNDING S038001A1002 apart as possible from the ECM and MFI har- Make sure the engine grounding terminal is prop- ness. erly connected to the engine. ¼...
  • Page 819 GENERAL DESCRIPTION Engine (Diagnostics) D: PREPARATION TOOL S038001A17 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA190 CARTRIDGE Troubleshooting for electrical (Newly adopted tool) systems. B2M3876 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems. ¼ English: 22771AA030 (Without printer) ¼ German: 22771AA070 (Without printer) ¼...
  • Page 820 GENERAL DESCRIPTION Engine (Diagnostics) MEMO: EN(w/oOBD)-9...

  • Page 821: Electrical Components Location

    ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) 4. Electrical Components Location S038507 A: LOCATION S038507A13 1. MODULE S038507A1301 B2M4181A B2M4182A (1) Engine control module (ECM) (3) Read memory connector (2) CHECK ENGINE malfunction (4) Test mode connector indicator lamp (MIL) (5) Data link connector EN(w/oOBD)-10...
  • Page 822 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) S2M0256A B2M4704A B2M2958B B2M2959B B2M2960C B2M2961B EN(w/oOBD)-11...
  • Page 823 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) 2. SENSOR S038507A1302 B2M2962A (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 sure sensor (6) Camshaft position sensor EN(w/oOBD)-12...
  • Page 824 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) S2M1248A H2M3255A H2M3256A S2M1406B B2M0213M B2M0212F S2M0907C EN(w/oOBD)-13...
  • Page 825 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M2963B (8) Oxygen sensor (With catalyst model) S2M0264B EN(w/oOBD)-14...
  • Page 826 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) MEMO: EN(w/oOBD)-15...
  • Page 827 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS S038507A1303 B2M2962B (1) Purge control solenoid valve (3) Ignition coil and ignitor ASSY (4) CO resistor (Without catalyst (2) Idle air control solenoid valve model) EN(w/oOBD)-16...
  • Page 828 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) H2M3258A H2M3259A H2M3261A S2M1764B EN(w/oOBD)-17...
  • Page 829 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M4181B B2M4182B (1) Fuel pump (2) Main relay (3) Fuel pump relay EN(w/oOBD)-18...
  • Page 830 ELECTRICAL COMPONENTS LOCATION Engine (Diagnostics) B2M2966A B2M3833A B2M3834A B2M2967B B2M2968B EN(w/oOBD)-19...
  • Page 831 ENGINE CONTROL MODULE (ECM) I/O SIGNAL Engine (Diagnostics) 5. Engine Control Module (ECM) I/O Signal S038526 A: ELECTRICAL SPECIFICATION S038526A08 H2M3262A EN(w/oOBD)-20...

  • Page 832: Engine Control Module (Ecm) I/O Signal

    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 sen- Signal (−) B135 — Shield B135 —...
  • Page 833 ENGINE CONTROL MODULE (ECM) I/O SIGNAL Engine (Diagnostics) Signal (V) Connec- Content Terminal No. Ignition SW Note tor No. Engine ON (Idling) ON (Engine OFF) Signal 1 B134 — 1 — 13 Waveform Idle air con- Signal 2 B134 — 1 —...

  • Page 834: Subaru Select Monitor

    1. HOW TO USE SUBARU SELECT MONITOR S038503A1601 1) Prepare Subaru Select Monitor kit. S2M0288A 6) Using Subaru Select Monitor, call up diagnostic trouble code(s) and various data, then record them. 2. READ DIAGNOSTIC TROUBLE CODE S2M0285 (DTC) FOR ENGINE.
  • Page 835 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(w/oOBD)-24...
  • Page 836 *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(w/oOBD)-25...
  • Page 837 Diagnostic Code(s)} and press the [YES] key. NOTE: ¼ For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. ¼ For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(w/oOBD)-66, LIST, LIST of Diagnostic Trouble Code (DTC).>...

  • Page 838: Read Diagnostic Trouble Code (Dtc)

    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: ¼...

  • Page 839: Inspection Mode

    B2M2970A or accelerator pedal during works even when 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(w/oOBD)-10, LOCATION, ¼ In order to prevent the vehicle from slipping Electrical Components Location.>...
  • Page 840 DIAGNOSTIC TROUBLE trol diagnosis is finished, perform the ABS memory CODE (DTC) LIST. <Ref. to EN(w/oOBD)-66, LIST, clearance procedure of self-diagnosis system. 3. WITHOUT SUBARU SELECT MONITOR S038510A1603 Step Check CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2.

  • Page 841: 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. NOTE: ¼...
  • Page 842 COMPULSORY VALVE OPERATION CHECK MODE Engine (Diagnostics) 10. Compulsory Valve Operation Check Mode S038528 A: OPERATION S038528A16 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. B2M2970A 2) Each valve functions when ignition switch is turned to ON (engine OFF).

  • Page 843: Compulsory Valve Operation Check Mode

    COMPULSORY VALVE OPERATION CHECK MODE Engine (Diagnostics) MEMO: EN(w/oOBD)-32...
  • Page 844 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) 11. Engine Malfunction Indicator Lamp (MIL) S038653 A: PROCEDURE S038653E45 1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(w/oOBD)-33, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> ↓...

  • Page 845: Engine Malfunction Indicator Lamp (Mil)

    ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON. S038653E90 ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼ TROUBLE SYMPTOM: ¼ When ignition switch is turned ON (engine OFF), MIL does not come on. ¼...
  • Page 846 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 Go to step 4. Go to step 2. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground.
  • Page 847 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN COMBINA- Is voltage more than 10 V? Go to step 7. Check the follow- TION METER AND IGNITION SWITCH CON- ing and repair if NECTOR. necessary. 1) Turn ignition switch to ON. NOTE: ¼...
  • Page 848 ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD-II general scan tool display. ¼ WIRING DIAGRAM:...
  • Page 849 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz. S038653E92 ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼ Test mode connector circuit is in open. ¼...
  • Page 850 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) ¼ WIRING DIAGRAM: B2M4725 Step Check CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL FUNCTION INDICATOR LAMP (MIL). circuit. <Ref. to 1) Turn ignition switch to OFF. EN(w/oOBD)-34, 2) Disconnect test mode connector.
  • Page 851 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 4. Repair harness Ω? TEST MODE CONNECTOR. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from ECM. In this case, 3) Measure resistance of harness between repair the follow-...
  • Page 852 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) MEMO: EN(w/oOBD)-41...
  • Page 853 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 Hz. S038653E93 ¼ DIAGNOSIS: ¼ Test mode connector circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
  • Page 854 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM CON- Is resistance less than 5 Repair short cir- Replace ECM. Ω? NECTOR AND ENGINE GROUNDING TER- cuit in harness <Ref. to FU(w/ MINAL. between ECM oOBD)-45, Engine 1) Turn ignition switch to OFF.
  • Page 855 ENGINE MALFUNCTION INDICATOR LAMP (MIL) Engine (Diagnostics) MEMO: EN(w/oOBD)-44...
  • Page 856 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) 12. Diagnostics for Engine Starting Failure S038533 A: PROCEDURE S038533E45 1. Inspection of starter motor circuit. <Ref. to EN(w/oOBD)-46, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(w/oOBD)-50, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...

  • Page 857: Diagnostics For Engine Starting Failure

    DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) B: STARTER MOTOR CIRCUIT S038533E94 CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> ¼...
  • Page 858 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR STARTER Is the voltage more than 10 Go to step 4. Go to step 5. MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from starter motor. 3) Turn ignition switch to ST.
  • Page 859 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than Repair open cir- Go to step 11. 1 Ω? 1) Turn ignition switch to OFF. cuit in harness 2) Place the selector lever in the “P” or “N” between starter position.
  • Page 860 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN(w/oOBD)-49...
  • Page 861 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE S038533E37 CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.>...
  • Page 862 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 3. Repair open cir- 5 Ω? 1) Disconnect connector from ECM. cuit in harness 2) Measure resistance of harness between between ECM ECM and chassis ground.
  • Page 863 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 Check ignition Repair open or 1) Connect main relay connector. control system. ground short cir- 2) Turn ignition switch to ON. <Ref.
  • Page 864 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN(w/oOBD)-53...
  • Page 865 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) D: IGNITION CONTROL SYSTEM S038533E95 CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> ¼...
  • Page 866 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each Check fuel pump Go to step 2. 1) Remove plug cord cap from each spark cylinder? system. <Ref. to plug. EN(w/oOBD)-58, 2) Install new spark plug on plug cord cap.
  • Page 867 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR IGNITION Is the voltage more than 10 Go to step 7. Replace ignition COIL & IGNITOR ASSEMBLY. coil & ignitor Check if voltage varies synchronously with assembly. engine speed when cranking, while monitoring voltage between ignition coil &...
  • Page 868 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 11. Repair harness 1 Ω? IGNITION COIL & IGNITOR ASSEMBLY and connector. CONNECTOR. NOTE: Measure resistance of harness between ECM In this case, and ignition coil &...
  • Page 869 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) E: FUEL PUMP CIRCUIT S038533E96 CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> ¼...
  • Page 870 CIRCUIT, Diag- NOTE: nostics for Engine Fuel pump operation check can also be Starting Failure.> executed using Subaru Select Monitor. For the procedure, refer to the “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to EN(w/oOBD)-31, OPERATION, Compulsory Valve Operation Check Mode.>...
  • Page 871 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK FUEL PUMP RELAY. Is the resistance less than Go to step 7. Replace fuel 10 Ω? 1) Disconnect connector from fuel pump relay. pump relay. 2) Remove fuel pump relay from bracket. 3) Connect battery to fuel pump relay connec- tor terminals No.
  • Page 872 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) MEMO: EN(w/oOBD)-61...
  • Page 873 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) F: FUEL INJECTOR CIRCUIT S038533E97 CAUTION: ¼ Check or repair only faulty parts. ¼ After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.>...
  • Page 874 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 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, injector.
  • Page 875 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 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, injector.
  • Page 876 DIAGNOSTICS FOR ENGINE STARTING FAILURE Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance between Go to step 11. Repair harness 11 and 12 Ω? FUEL INJECTOR CONNECTOR. and connector. Measure resistance of harness between ECM NOTE: and fuel injector connector.
  • Page 877 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) 13. List of Diagnostic Trouble Code (DTC) S038525 A: LIST S038525A12 Trouble Item Contents of diagnosis Index code Crankshaft position sensor ¼ No signal entered from crankshaft <Ref. to EN(w/oOBD)-68, DTC 11 CRANK- position sensor when starter switch SHAFT POSITION SENSOR, Diagnostic Proce- is ON.

  • Page 878: List Of Diagnostic Trouble Code (Dtc)

    LIST OF DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Trouble Item Contents of diagnosis Index code ¼ The purge control solenoid valve Purge control solenoid <Ref. to EN(w/oOBD)-96, DTC 35 PURGE valve is not in function. CONTROL SOLENOID VALVE, Diagnostic Pro- ¼...
  • Page 879 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) 14. Diagnostic Procedure with Diagnostic Trouble Code (DTC) S038521 A: DTC 11 CRANKSHAFT POSITION SENSOR S038521G55 ¼ DIAGNOSIS: ¼ No signal entered from crankshaft position sensor when ignition switch is ON. ¼...

  • Page 880: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK CONDITION OF CRANKSHAFT Are the crankshaft position Go to step 2. Tighten crankshaft POSITION SENSOR INSTALLATION. sensor installing bolts tight- position sensor ened securely? installing bolts securely. CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 3.
  • Page 881 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) B: DTC 12 STARTER SWITCH S038521G56 ¼ DIAGNOSIS: ¼ The starter switch signal is abnormal. ¼ The harness connector between ECM and starter switch is in short or open. ¼ TROUBLE SYMPTOM: ¼...
  • Page 882 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 Repair poor con- Repair open or IGNITION SWITCH CONNECTOR. tact in ECM con- ground short cir- 1) Turn ignition switch to OFF. nector.
  • Page 883 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) C: DTC 13 CAMSHAFT POSITION SENSOR S038521G57 ¼ DIAGNOSIS: ¼ No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor. ¼ The harness connector between ECM and camshaft position sensor is in short or open. ¼...
  • Page 884 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK CONDITION OF CAMSHAFT POSI- Are the camshaft position Go to step 2. Tighten camshaft TION SENSOR INSTALLATION. sensor installing bolts tight- position sensor ened securely? installing bolts securely. CHECK CAMSHAFT POSITION SENSOR.
  • Page 885 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR S038521G58 ¼ DIAGNOSIS: ¼ The engine coolant temperature sensor signal is abnormal. ¼ The harness connector between ECM and engine coolant temperature sensor is in short or open. ¼...
  • Page 886 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 Repair battery Go to step 2. COOLANT TEMPERATURE SENSOR AND short circuit in ECM CONNECTOR. harness between 1) Turn ignition switch to OFF. ECM and engine 2) Remove generator.
  • Page 887 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ENGINE Is the resistance less than Go to step 5. Repair harness 5 Ω? COOLANT TEMPERATURE SENSOR AND and connector. ECM CONNECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, 2) Measure resistance of harness between repair the follow-...
  • Page 888 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN(w/oOBD)-77...
  • Page 889 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) E: DTC 22 KNOCK SENSOR S038521G59 ¼ DIAGNOSIS: ¼ The knock sensor signal is abnormal. ¼ The harness connector between ECM and knock sensor is in short or open. ¼ TROUBLE SYMPTOM: ¼...
  • Page 890 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 3 Go to step 2. Go to step 3. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground.
  • Page 891 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE S038521G60 ¼ DIAGNOSIS: ¼ The idle air control solenoid valve is not in function. ¼ The harness connector between ECM and idle air control solenoid valve is in short or open. ¼...
  • Page 892 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK POWER SUPPLY TO IDLE AIR Is the voltage more than 10 Go to step 2. Repair harness CONTROL SOLENOID VALVE. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from idle air control In this case,...
  • Page 893 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK AIR BY-PASS LINE. Are foreign particles in by- Remove foreign Replace idle air 1) Turn ignition switch to OFF. pass air line? particles from by- control solenoid 2) Remove idle air control solenoid valve from pass air line.
  • Page 894 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN(w/oOBD)-83...
  • Page 895 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) G: DTC 26 INTAKE AIR TEMPERATURE SENSOR S038521G61 ¼ DIAGNOSIS: ¼ The intake air temperature sensor signal is abnormal. ¼ The harness connector between ECM and intake air temperature sensor is in short or open. ¼...
  • Page 896 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance between 2 Go to step 2. Replace intake air SOR. and 3 kΩ at 20°C (68°F)? temperature sen- 1) Turn ignition switch to OFF. sor.
  • Page 897 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Contact with your Check poor contact in ECM connector. ECM connector? tact in ECM con- Subaru distributor. nector. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterio- ration of multiple parts.
  • Page 898 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN(w/oOBD)-87...
  • Page 899 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) H: DTC 31 THROTTLE POSITION SENSOR S038521G62 ¼ DIAGNOSIS: ¼ The throttle position sensor signal is abnormal. ¼ The throttle position sensor is installed abnormally. ¼ The harness connector between ECM and throttle position sensor is in short or open. ¼...
  • Page 900 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 2. Repair open cir- 1 Ω? THROTTLE POSITION SENSOR. cuit between ECM 1) Disconnect connector from ECM and and throttle posi- throttle position sensor.
  • Page 901 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) I: DTC 32 OXYGEN SENSOR S038521G63 ¼ DIAGNOSIS: ¼ The oxygen sensor is not in function. ¼ The harness connector between ECM and oxygen sensor is in short or open. ¼ TROUBLE SYMPTOM: ¼...
  • Page 902 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK FOR OTHER CAUSES AFFECTING Is CO% more than 2% Check fuel sys- Go to step 2. EXHAUST GAS. after engine warm up? tem. NOTE: ¼ Check for use of improper fuel. ¼...
  • Page 903 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT VOLTAGE FOR ECM. Do 0.1 and 1 V waveform Go to step 9. Replace oxygen 1) Connect connector to ECM and oxygen patterns alternately appear sensor. sensor. on the oscilloscope 2) Measure voltage between ECM and chas- screen?
  • Page 904 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN(w/oOBD)-93...
  • Page 905 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) J: DTC 33 VEHICLE SPEED SIGNAL S038521G64 ¼ DIAGNOSIS: ¼ The vehicle speed signal is abnormal. ¼ The harness connector between ECM and vehicle speed sensor is in short or open. ¼...
  • Page 906 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK SPEEDOMETER OPERATION IN Does speedometer operate Go to step 2. Check speedom- COMBINATION METER. normally? eter and vehicle speed sensor. CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 3 Go to step 3.
  • Page 907 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) K: DTC 35 PURGE CONTROL SOLENOID VALVE S038521G65 ¼ DIAGNOSIS: ¼ The purge control solenoid valve is not in function. ¼ The harness connector between ECM and purge control solenoid valve is in short or open. ¼...
  • Page 908 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK OPERATION SOUND OF PURGE Does purge control sole- Go to step 2. Go to step 3. CONTROL SOLENOID VALVE. noid valve produce operat- 1) Turn ignition switch to OFF. ing sound? 2) Connect test mode connector.
  • Page 909 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Contact with your Check poor contact in purge control solenoid purge control solenoid tact in purge con- Subaru distributor. valve connector. valve connector? trol solenoid valve NOTE: connector. Inspection by your...
  • Page 910 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) MEMO: EN(w/oOBD)-99...
  • Page 911 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) L: DTC 38 TORQUE CONTROL SIGNAL S038521G66 ¼ DIAGNOSIS: ¼ Abnormal signal entered from TCM ¼ 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.
  • Page 912 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair ground Go to step 2. 10 Ω? TCM CONNECTOR. short circuit in 1) Disconnect connectors from ECM and harness between TCM.
  • Page 913 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) M: DTC 45 PRESSURE SENSOR S038521G67 ¼ DIAGNOSIS: ¼ The pressure sensor signal is abnormal. ¼ The harness connector between ECM and pressure sensor is in short or open. ¼ TROUBLE SYMPTOM: ¼...
  • Page 914 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage between 4.5 Go to step 2. Repair open or PRESSURE SENSOR CONNECTOR. and 5.5 V? ground short cir- 1) Disconnect connector from pressure sen- cuit in harness sor.
  • Page 915 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES) S038521G68 ¼ DIAGNOSIS: ¼ The CO resistor signal is abnormal. ¼ The harness connector between ECM and CO resistor is in short or open. ¼...
  • Page 916 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage between 0.5 Go to step 3. Go to step 2. 1) Turn ignition switch to ON. and 4.5 V? 2) Measure voltage between ECM and chas- sis ground.
  • Page 917 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) O: DTC 51 NEUTRAL POSITION SWITCH (MT VEHICLE) S038521G69 ¼ DIAGNOSIS: ¼ The neutral position switch signal is abnormal. ¼ The harness connector between ECM and neutral position switch is in short or open. ¼...
  • Page 918 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 Go to step 3. Go to step 2. 1) Turn ignition switch to ON. and 5.5 V in neutral posi- 2) Measure voltage between ECM and chas- tion? sis ground.
  • Page 919 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE) S038521G70 ¼ DIAGNOSIS: ¼ The park/neutral position switch signal is abnormal. ¼ The shift cable is connected abnormally. ¼ The harness connector between ECM/TCM and inhibitor switch is in short or open. ¼...
  • Page 920 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 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”...
  • Page 921 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Q: DTC 85 CHARGE SYSTEM S038521G71 ¼ DIAGNOSIS: ¼ Power source voltage of the ECM is low or high. ¼ TROUBLE SYMPTOM: ¼ Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref.
  • Page 922 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Engine (Diagnostics) Step Check CHECK GENERATOR. Is the voltage between 10.8 Go to step 2. Repair generator. 1) Start engine. V and 16.2 V? <Ref. to SC-13, 2) Idling after warm-up. Generator.> 3) Measure voltage between generator B ter- minal and chassis ground.
  • Page 923 GENERAL DIAGNOSTIC TABLE Engine (Diagnostics) 15. General Diagnostic Table S038257 A: INSPECTION S038257A10 NOTE: ¼ Malfunction of parts other than those listed is also possible. ¼ The right-hand priority column indicates the inspection priority of probable causes of the symptom. Carry out the check starting from A.

  • Page 924: General Diagnostic Table

    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 925 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(w/oOBD)-114...
  • Page 926 FUEL INJECTION (FUEL SYSTEMS) FU(H6) Page General Description..................2 Throttle Body .....................16 Intake Manifold ..................17 Engine Coolant Temperature Sensor............29 Crankshaft Position Sensor...............30 Camshaft Position Sensor.................31 Knock Sensor ....................32 Throttle Position Sensor................33 Intake Manifold Pressure Sensor..............34 Intake Air Temperature Sensor ..............35 Idle Air Control Solenoid Valve ..............36 Induction Valve ..................37 Induction Valve Control Solenoid ..............38 Fuel Injector....................39...
  • Page 927 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 1. General Description S145001 A: SPECIFICATIONS S145001E49 Model Capacity (16.9 US gal, 14.1 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...

  • Page 928: General Description

    GENERAL DESCRIPTION Fuel Injection (Fuel Systems) MEMO: FU(H6)-3...
  • Page 929 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) B: COMPONENT S145001A05 1. INTAKE MANIFOLD S145001A0501 B2M4476A FU(H6)-4...
  • Page 930 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Fuel damper valve (10) Nipple (19) Gasket (2) Clamp (11) Plug (3) Fuel pipe ASSY (12) Intake manifold Tightening torque: N·m (kgf-m, ft-lb) (4) Air assist hose (13) Induction valve control solenoid 6.4 (0.65, 4.7) (5) Air assist and purge pipe ASSY (14) EGR valve 5.0 (0.51, 3.7)
  • Page 931 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 2. FUEL INJECTOR S145001A0502 B2M4477A (1) Fuel injector pipe LH (5) Insulator Tightening torque: N·m (kgf-m, ft-lb) (2) Pressure regulator (6) Fuel injector 6.4 (0.65, 4.7) (3) O-ring (7) Fuel injector pipe RH 19 (1.9, 14) (4) Injection rubber FU(H6)-6...

  • Page 932: Throttle Body

    GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 3. AIR INTAKE SYSTEM S145001A0503 B2M4478A (1) Gasket (5) O-ring Tightening torque: N·m (kgf-m, ft-lb) (2) Intake manifold pressure sensor (6) Throttle body 1.6 (0.16, 1.2) (3) Idle air control solenoid valve 2.8 (0.29, 2.1) (4) Throttle position sensor 22 (2.2, 15.9) FU(H6)-7...
  • Page 933 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 4. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS S145001A0504 B2M4479A (1) Crankshaft position sensor (3) Knock sensor RH Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor LH (4) Camshaft position sensor 6.4 (0.65, 4.7) 25 (2.5, 18) FU(H6)-8...
  • Page 934 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) MEMO: FU(H6)-9...
  • Page 935 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 5. FUEL TANK S145001A0505 B2M3837A FU(H6)-10...
  • Page 936 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Heat sealed cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...
  • Page 937 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 6. FUEL LINE S145001A0506 B2M4585B FU(H6)-12...
  • Page 938 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Clamp (12) Two-way valve hose (23) Front canister bracket (2) Fuel return hose A (13) Two-way valve (24) Rear canister bracket (3) Fuel return hose B (14) Two-way valve bracket (25) Canister bracket spacer (4) Clip (15) Two-way valve drain hose (26) Cushion...
  • Page 939 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 7. FUEL FILLER PIPE S145001A0507 B2M4253B (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap 7.4 (0.75, 5.4) (3) Clamp (7) Filler pipe protector (4) Filler pipe packing FU(H6)-14...
  • Page 940 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) ¼ Be careful not to burn your hands, because each C: CAUTION S145001A03 part on the vehicle is hot after running. ¼ Wear working clothing, including a cap, protec- ¼ Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
  • Page 941 THROTTLE BODY Fuel Injection (Fuel Systems) 2. Throttle Body 7) Disconnect throttle position sensor connector. S145010 A: REMOVAL S145010A18 1) Disconnect battery ground cable. B2M4482 8) Disconnect engine coolant hoses from throttle body. 9) Remove bolts which secure throttle body to B2M1723 intake manifold.

  • Page 942: Intake Manifold

    INTAKE MANIFOLD Fuel Injection (Fuel Systems) 3. Intake Manifold (2) Remove power steering oil pipe with S145034 bracket. A: REMOVAL S145034A18 1) Release fuel pressure. <Ref. to FU(H6)-50, RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. B2M4020 (3) Remove bolts which install power steering pump bracket.
  • Page 943 INTAKE MANIFOLD Fuel Injection (Fuel Systems) (5) Remove power steering tank from the 11) Disconnect rear window glass washer hose bracket by pulling it upward. from washer motor, then plug connection with a suitable cap. 12) Move washer tank upward. B2M3153 (6) Place power steering pump on the right side H6M0431...
  • Page 944 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 16) Remove EGR pipe from EGR valve. 19) Disconnect fuel hoses from fuel pipes. NOTE: WARNING: ¼ Do not spill fuel. Be careful not to drop gaskets. ¼ Catch fuel from hoses in a container or cloth. B2M4487 B2M4490 17) Disconnect engine harness connectors from...
  • Page 945 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 22) Disconnect air assist hose (A). 27) Remove bolts which holds intake manifold 23) Remove the bolt (B), which holds fuel injector onto cylinder heads. pipe LH onto cylinder head. B2M4497 B2M4493A 24) Remove ground cable from fuel pipe protector B2M4498 28) Remove intake manifold.
  • Page 946 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 4) Install fuel pipe protector RH. B: INSTALLATION S145034A11 Tightening torque: 1) Install intake manifold onto cylinder heads. 19 N·m (1.9 kgf-m, 14 ft-lb) NOTE: Always use new gaskets. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) B2M4495 5) Install ground cable to fuel pipe protector RH.
  • Page 947 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 8) Install fuel pipe protector LH. 11) Connect fuel hoses. Tightening torque: 19 N·m (1.9 kgf-m, 14 ft-lb) B2M4490 12) Connect engine ground terminal to intake B2M4492 manifold. 9) Install ground cable to fuel pipe protector LH. B2M4489 B2M4491 13) Connect engine harness connectors to bulk-...
  • Page 948 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 15) Connect engine coolant hose to throttle body. (3) Tighten bolts which install power steering pump on bracket. Tightening torque: 20.1 N·m (2.05 kgf-m, 14.8 ft-lb) B2M4485 16) Connect PCV hose to cylinder head cover. B2M4021A Power steering pump Generator...
  • Page 949 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 21) Install washer tank on body. 26) Connect battery ground cable. B2M3139 G6M0095 22) Connect accelerator cable (A). C: DISASSEMBLY 23) Connect cruise control cable (B). (With cruise S145034A06 control models) 1) Disconnect connectors from throttle position sensor.
  • Page 950 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 4) Remove throttle body. 11) Remove EGR valve. B2M4499 B2M4503 5) Remove induction valve. 12) Remove engine harness assembly from intake manifold. B2M4500 B2M4504 6) Disconnect connector from induction valve con- trol solenoid. 13) Remove PCV pipe from intake manifold. 7) Remove induction valve control solenoid.
  • Page 951 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 16) Remove fuel pipe and injector pipe assembly. 2) Install fuel pipe and injector pipe assembly. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) 3) Connect pressure regulator vacuum hose (A) to intake manifold. B2M4507A B2M4508 B2M4508...
  • Page 952 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 5) Install PCV pipe to intake manifold. 10) Connect connector to purge control solenoid valve. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) B2M4502 B2M4505 11) Connect hoses to purge control solenoid valve. 6) Install engine harness assembly to intake mani- fold.
  • Page 953 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 14) Install induction valve. 17) Connect connectors to throttle position sensor. Tightening torque: 19 N·m (1.9 kgf-m, 14 ft-lb) B2M4482 18) Connect connectors to intake manifold pres- sure sensor (A) and idle air control solenoid valve B2M4500 (B).

  • Page 954: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR Fuel Injection (Fuel Systems) 4. Engine Coolant Temperature B: INSTALLATION S145047A11 Sensor Install in the reverse order of removal. S145047 Tightening torque: A: REMOVAL S145047A18 16 N·m (0.16 kgf-m, 1.2 ft-lb) 1) Disconnect battery ground cable. B2M4512 G6M0095 2) Disconnect connector from engine coolant tem-...

  • Page 955: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 5. Crankshaft Position Sensor 6) Remove crankshaft position sensor, and dis- connect connector from it. S145043 A: REMOVAL S145043A18 1) Disconnect battery ground cable. B2M4515 B: INSTALLATION S145043A11 G6M0095 Install in the reverse order of removal. 2) Remove air intake chamber.

  • Page 956: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 6. Camshaft Position Sensor 6) Remove camshaft position sensor. S145041 A: REMOVAL S145041A18 1) Disconnect battery ground cable. B2M4516 B: INSTALLATION S145041A11 Install in the reverse order of removal. G6M0095 Tightening torque: ¼ Camshaft position sensor; 2) Remove air cleaner.

  • Page 957: Knock Sensor

    KNOCK SENSOR Fuel Injection (Fuel Systems) 7. Knock Sensor 4) Connect battery ground cable. S145042 A: REMOVAL S145042A18 1) Disconnect battery ground cable from battery ground terminal. G6M0095 G6M0095 2) Remove intake manifold. <Ref. to FU(H6)-17, REMOVAL, Intake Manifold.> 3) Disconnect knock sensor connector. 4) Remove knock sensor from cylinder block.

  • Page 958: Throttle Position Sensor

    THROTTLE POSITION SENSOR Fuel Injection (Fuel Systems) 8. Throttle Position Sensor S145039 A: REMOVAL S145039A18 1) Disconnect battery ground cable. B2M1723 Remove air intake chamber. <Ref. to IN(H6)-6, REMOVAL, Air Intake Chamber.> 2) Disconnect connector from throttle position sensor. 3) Remove throttle position sensor...

  • Page 959: Intake Manifold Pressure Sensor

    INTAKE MANIFOLD PRESSURE SENSOR Fuel Injection (Fuel Systems) 9. Intake Manifold Pressure Sensor S145568 A: REMOVAL S145568A18 1) Disconnect battery ground cable. B2M1723 2) Disconnect connector from intake manifold pressure sensor. 3) Remove intake manifold pressure sensor from throttle body. B2M4519 B: INSTALLATION S145568A11...

  • Page 960: Intake Air Temperature Sensor

    INTAKE AIR TEMPERATURE SENSOR Fuel Injection (Fuel Systems) 10. Intake Air Temperature Sensor S145569 A: REMOVAL S145569A18 1) Disconnect battery ground cable. B2M1723 2) Disconnect connector from intake air tempera- ture sensor. 3) Remove intake air temperature sensor from air intake chamber.

  • Page 961: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE Fuel Injection (Fuel Systems) 11. Idle Air Control Solenoid Valve S145056 A: REMOVAL S145056A18 1) Disconnect battery ground cable. B2M1723 2) Disconnect connector (A) from idle air control solenoid valve. 3) Disconnect air by-pass hose (B) from idle air control solenoid valve.

  • Page 962: Induction Valve

    INDUCTION VALVE Fuel Injection (Fuel Systems) 12. Induction Valve S145742 A: REMOVAL S145742A18 1) Disconnect battery ground cable. 2) Remove intake manifold. <Ref. to FU(H6)-17, REMOVAL, Intake Manifold.> 3) Remove induction valve from intake manifold. B2M4500 B: INSTALLATION S145742A11 Install in the reverse order of removal. NOTE: Always use a new gasket.

  • Page 963: Induction Valve Control Solenoid

    INDUCTION VALVE CONTROL SOLENOID Fuel Injection (Fuel Systems) 13. Induction Valve Control Solenoid S145743 A: REMOVAL S145743A18 1) Disconnect battery ground cable. 2) Remove intake manifold. <Ref. to FU(H6)-17, REMOVAL, Intake Manifold.> 3) Disconnect connector from induction valve con- trol solenoid. 4) Remove induction valve control solenoid from intake manifold.

  • Page 964: Fuel Injector

    FUEL INJECTOR Fuel Injection (Fuel Systems) 14. Fuel Injector (3) Remove bolts which install power steering S145051 pump bracket. A: REMOVAL S145051A18 CAUTION: Do not separate hose and pipe from the main 1. RH SIDE S145051A1801 pump. 1) Release fuel pressure. <Ref.
  • Page 965 FUEL INJECTOR Fuel Injection (Fuel Systems) (6) Place power steering pump on the right side 2. LH SIDE S145051A1802 wheel apron. 1) Release fuel pressure. <Ref. to FU(H6)-50, RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. B2M4321 6) Remove ground cable from fuel pipe protector B2M3135...
  • Page 966 FUEL INJECTOR Fuel Injection (Fuel Systems) 5) Disconnect connector from front window 10) Remove fuel pipe protector LH. washer motor. 6) Disconnect connector from rear gate glass washer motor. B2M4492 11) Disconnect connector (A) from fuel injector. 12) Remove bolt (B) which holds injector pipe onto B6M0562 cylinder head.
  • Page 967 FUEL INJECTOR Fuel Injection (Fuel Systems) 2. LH SIDE B: INSTALLATION S145051A1102 S145051A11 Install in the reverse order of removal. 1. RH SIDE S145051A1101 NOTE: Install in the reverse order of removal. Replace O-rings and insulators with new ones. NOTE: Replace O-rings and insulators with new ones.

  • Page 968: Front Oxygen (A/F) Sensor

    ¼ RH side G6M0095 2) Disconnect connector from front oxygen (A/F) sensor. B2M4606A 6) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) B2M4407A 3) Lift-up the vehicle.
  • Page 969 FRONT OXYGEN (A/F) SENSOR Fuel Injection (Fuel Systems) 7) Remove front oxygen (A/F) sensor. B: INSTALLATION S145642A11 CAUTION: 1) Before installing front oxygen (A/F) sensor, When removing front oxygen (A/F) sensor, do apply anti-seize compound only to threaded por- not force front oxygen (A/F) sensor especially tion of front oxygen (A/F) sensor to make the next when exhaust pipe is cold, otherwise it will removal easier.
  • Page 970 FRONT OXYGEN (A/F) SENSOR Fuel Injection (Fuel Systems) 3) Secure harness to clip (A). 7) Connect battery ground cable. ¼ LH side G6M0095 B2M4607A ¼ RH side B2M4606A 4) Install under cover. 5) Lower the vehicle. 6) Connect connector of front oxygen (A/F) sen- sor.

  • Page 971: Rear Oxygen Sensor

    B2M4526 3) Connect connector to rear oxygen sensor. B2M4408 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor.

  • Page 972: Engine Control Module

    ENGINE CONTROL MODULE Fuel Injection (Fuel Systems) 17. Engine Control Module 6) Remove clip from bracket. S145049 A: REMOVAL S145049A18 1) Disconnect battery ground cable. B2M4527 7) Disconnect ECM connectors and take out ECM. G6M0095 B: INSTALLATION S145049A11 2) Remove lower inner trim of passenger side. Install in the reverse order of removal.

  • Page 973: Main Relay

    MAIN RELAY Fuel Injection (Fuel Systems) 18. Main Relay S145050 A: REMOVAL S145050A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower inner trim of passenger side. <Ref. to EI-41, REMOVAL, Lower Inner Trim.> 3) Disconnect connectors from main relay. 4) Remove bolt which holds main relay bracket on body.

  • Page 974: Fuel Pump Relay

    FUEL PUMP RELAY Fuel Injection (Fuel Systems) 19. Fuel Pump Relay S145048 A: REMOVAL S145048A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower cover. <Ref. EI-35, REMOVAL, Instrument Panel Assembly.> 3) Disconnect connector from fuel pump relay. B2M3159 4) Remove fuel pump relay from mounting bracket.

  • Page 975: Fuel

    FUEL Fuel Injection (Fuel Systems) 20. Fuel 3) Lift-up the vehicle. S145052 4) Remove front right side fuel tank cover. A: OPERATION S145052A16 1. RELEASING OF FUEL PRESSURE S145052A1601 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Disconnect connector from fuel pump relay.
  • Page 976 FUEL Fuel Injection (Fuel Systems) Tightening torque: 11) Remove fuel sub level sensor. 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M3178 B2M3173 12) Drain fuel from fuel tank by using hand pump. 7) Lower the vehicle. WARNING: 8) Remove sub service hole cover. Do not use a motor pump when draining fuel.
  • Page 977 FUEL Fuel Injection (Fuel Systems) (2) Connect connector from fuel sub level sen- sor. B2M3176 (3) Install sub service hole cover. B2M3175 (4) Set rear seat and floor mat. FU(H6)-52...

  • Page 978: Fuel Tank

    FUEL TANK Fuel Injection (Fuel Systems) 21. Fuel Tank 7) Separate quick connector of fuel delivery (A) S145053 and return hose (B). <Ref. to FU(H6)-73, A: REMOVAL REMOVAL, Fuel Delivery, Return and Evaporation S145053A18 Lines.> 1) Set vehicle on the lift. 2) Release fuel pressure.
  • Page 979 FUEL TANK Fuel Injection (Fuel Systems) 15) Disconnect connector from ABS sensor. 20) Remove rear brake caliper, then tie it up to the body side of the vehicle as shown in figure. B2M3184 B2M3188 16) Remove bolts which hold parking brake cable holding bracket.
  • Page 980 FUEL TANK Fuel Injection (Fuel Systems) (3) Remove bolts which secure rear suspen- 24) Loosen clamp and disconnect fuel filler hose sion assembly to body. (A) and air vent hose (B) from fuel filler pipe. B2M4173A 25) Support fuel tank with transmission jack, remove bolts from bands and dismount fuel tank from the vehicle.
  • Page 981 FUEL TANK Fuel Injection (Fuel Systems) 3) Connect two-way valve hose (A) to two-way 6) Install rear side fuel tank cover. valve and connect evaporation hose (B) to evapo- Tightening torque: ration pipe. 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M4172A B2M3191A 4) Connect fuel filler hose (A) and air vent hose 7) Install rear suspension assembly.
  • Page 982 FUEL TANK Fuel Injection (Fuel Systems) (2) Tighten bolt which holds rear shock 11) Tighten bolts which hold parking brake cable absorber to rear suspension arm. <Ref. to holding bracket. RS-14, INSTALLATION, Link Upper.> Tightening torque: Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) 157 N·m (16 kgf-m, 116 ft-lb) B2M3185 B2M3189...
  • Page 983 FUEL TANK Fuel Injection (Fuel Systems) 15) Install front side fuel tank cover. 22) Connect fuel jet pump hose. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) B2M3177 23) Connect connector to fuel sub level sensor. B2M3173 16) Install rear wheel. 17) Lower the vehicle.
  • Page 984 FUEL TANK Fuel Injection (Fuel Systems) 26) Install holder clip which secures fuel tank cord on bracket. B2M3408 27) Set rear seat and floor mat. 28) Connect connector to fuel pump relay. B2M3159 29) Adjust parking brake lever stroke. <Ref. to PB-4, ADJUSTMENT, Parking Brake Lever.>...

  • Page 985: Fuel Filler Pipe

    FUEL FILLER PIPE Fuel Injection (Fuel Systems) 22. Fuel Filler Pipe 5) Lift-up the vehicle. S145022 6) Remove rear right side wheel nuts. A: REMOVAL 7) Remove rear right side wheel. S145022A18 1) Release fuel pressure. <Ref. to FU(H6)-50 RELEASING FUEL PRESSURE, OPERATION, Fuel.>...
  • Page 986 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 10) Tighten fuel drain plug and then install front 12) Remove bolts which hold evaporation pipe right side tank cover. bracket on fuel filler pipe. Tightening torque: 26 N·m (2.65 kgf-m, 19.2 ft-lb) B2M3174 Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
  • Page 987 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 5) Insert air vent hose approximately 25 to 30 mm B: INSTALLATION S145022A11 (0.98 to 1.18 in) into the lower end of air vent pipe 1) Hold fuel filler flap open. and hold clip. 2) Set fuel saucer (A) with rubber packing (C) and L = 27.5±2.5 mm (1.083±0.098 in) insert fuel filler pipe into hole from the inner side of...
  • Page 988 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 7) Tighten bolts which hold evaporation pipe 12) Connect connector to fuel pump relay. bracket on fuel pipe B2M3159 13) Connect battery ground cable. B2M4174 G6M0095 8) Install fuel filler pipe protector. B2M3198 9) Install rear right wheel.

  • Page 989: Fuel Pump

    FUEL PUMP Fuel Injection (Fuel Systems) 23. Fuel Pump 6) Drain fuel from fuel tank. Set a container under S145025 the vehicle and remove drain plug from fuel tank. A: REMOVAL S145025A18 WARNING: ¼ Place “NO FIRE” signs near the working area.
  • Page 990 FUEL PUMP Fuel Injection (Fuel Systems) 9) Remove access hole lid. 14) Take off fuel pump assembly from fuel tank. B: INSTALLATION S145025A11 Install in the reverse order of removal. Do the fol- lowing: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or for- eign particles before installation.
  • Page 991 FUEL PUMP Fuel Injection (Fuel Systems) D: ASSEMBLY S145025A02 Assemble in the reverse order of disassembly. E: INSPECTION S145025A10 Connect lead harness to connector terminal of fuel pump and apply battery power supply to check whether the pump operates. WARNING: ¼...

  • Page 992: Fuel Level Sensor

    FUEL LEVEL SENSOR Fuel Injection (Fuel Systems) 24. Fuel Level Sensor B: INSTALLATION S145026A11 S145026 Install in the reverse order of removal. A: REMOVAL S145026A18 WARNING: WARNING: ¼ Ground cable must be connected. ¼ Place “NO FIRE” signs near the working ¼...

  • Page 993: Fuel Sub Level Sensor

    FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 25. Fuel Sub Level Sensor 5) Tighten fuel drain plug and install front right side S145023 fuel tank cover. A: REMOVAL S145023A18 Tightening torque: 26 N·m (2.65 kgf-m, 19.2 ft-lb) WARNING: ¼ Place “NO FIRE” signs near the working area.
  • Page 994 FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 9) Disconnect connector from fuel sub level sen- B: INSTALLATION S145023A11 sor. Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3176 10) Disconnect fuel jet pump hose. B2M3178 B2M3177 11) Remove bolts which install fuel sub level sen-...

  • Page 995: Fuel Filter

    FUEL FILTER Fuel Injection (Fuel Systems) 26. Fuel Filter 1) Set O-ring on the filter holder and install by S145027 turning to the right. A: REMOVAL S145027A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. NOTE: Fuel filter is built in fuel pump assembly.

  • Page 996: Fuel Cut Valve

    FUEL CUT VALVE Fuel Injection (Fuel Systems) 27. Fuel Cut Valve S145021 A: REMOVAL S145021A18 1) Remove fuel tank. <Ref. to FU(H6)-53, REMOVAL, Fuel Tank.> 2) Move clip and disconnect evaporation hose from fuel cut valve. B2M3678 3) Remove bolts which install fuel cut valve. B: INSTALLATION S145021A11 Install in the reverse order of removal.

  • Page 997: Fuel Damper Valve

    FUEL DAMPER VALVE Fuel Injection (Fuel Systems) 28. Fuel Damper Valve S145708 A: REMOVAL S145708A18 1) Release fuel pressure. <Ref. to FU(H6)-50, RELEASING FUEL PRESSURE, OPERATION, Fuel.> 2) Remove fuel damper valve from return line. B2M4562 B: INSTALLATION S145708A11 Install in the reverse order of removal. FU(H6)-72...
  • Page 998 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 29. Fuel Delivery, Return and 3) Open fuel filler flap lid and remove fuel filler cap. Evaporation Lines S145019 4) Remove floor mat. <Ref. to EI-51, REMOVAL, Floor Mat.> A: REMOVAL S145019A18 5) Remove fuel delivery pipes and hoses, fuel 1) Set vehicle on the lift.

  • Page 999: Fuel Delivery, Return And Evaporation Lines

    FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 9) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are cov- ered with dust. (2) Hold connector (A) and push retainer (B) down.
  • Page 1000 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 2) Connect fuel delivery hose to pipe with an over- lap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. : 2.5±1.5 mm (0.098±0.059 in) L: 22.5±2.5 mm (0.886±0.098 in) B2M1194B...

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