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Subaru Impreza 2003 Service Manual

Subaru Impreza 2003 Service Manual

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2003 Model Year

PDF Service Manual

GENERAL INFORMATION SECTION (Pub.No.G1860GE1)

ENGINE SECTION 1 (Pub.No.G1860GE2)

ENGINE SECTION 2 (Pub.No.G1860GE3)

TRANSMISSION SECTION (Pub.No.G1860GE4)

CHASSIS SECTION (Pub.No.G1860GE5)

BODY SECTION (Pub.No.G1860GE6)

WIRING SYSTEM SECTION (Pub.No.G1860GE7)

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Page 1 2003 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G1860GE1) ENGINE SECTION 1 (Pub.No.G1860GE2) ENGINE SECTION 2 (Pub.No.G1860GE3) TRANSMISSION SECTION (Pub.No.G1860GE4) CHASSIS SECTION (Pub.No.G1860GE5) BODY SECTION (Pub.No.G1860GE6) WIRING SYSTEM SECTION (Pub.No.G1860GE7)
Page 3 SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. IDENTIFICATION This manual includes the procedures...
Page 5 FOREWORD Page Foreword .....................2...
Page 6 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru IMPRE- Applied model: GD*****, GG***** from 2003MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc.
Page 7: How To Use This Manual
HOW TO USE THIS MANUAL Page How to Use This Manual ................2...
Page 8 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 1. How to Use This Manual A: HOW TO USE THIS MANUAL 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
Page 9 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 3. COMPONENTS Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue.
Page 10 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 4. SPECIFICATIONS If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure.
Page 11 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
Page 12 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL HU-6...
Page 13: Specifications
SPECIFICATIONS Page Impreza .......................2...
Page 14 IMPREZA SPECIFICATIONS 1. Impreza A: DIMENSIONS Model Sedan Wagon OUTBACK Overall length mm (in) 4,415 (173.8) Overall width mm (in) 1,740 (68.4) 1,695 (66.7) 1,710 (67.3) 1,740 (68.1) Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,440 (56.7) 1,485 (58.5) 1,495 (58.9)
Page 15 IMPREZA SPECIFICATIONS C: ELECTRICAL Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Ignition timing at BTDC 5°±10° 10°±10° 12°±10° 10°±10° 12°±10° idling Spark Type and Without NGK: BKR6E NGK: BKR6E plug manufacturer (without catalyst) (without catalyst) CHAMPION: CHAMPION: CHAMPION: RC8YC4...
Page 16 IMPREZA SPECIFICATIONS D: TRANSMISSION Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Transmission type Clutch type DSPD DSPD DSPD DSPD DSPD Gear ratio 3.454, 3.454 2.785 3.454 2.785 2.785 3.454 2.785 3.636 3.166 1.947, 2.062 1.545 2.062 1.545 1.545 2.062...
Page 17 IMPREZA SPECIFICATIONS G: BRAKE Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L, STi Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H: TIRE Model...
Page 18 IMPREZA SPECIFICATIONS J: WEIGHT 1. LHD MODEL Sedan Option code Model 1.6 L Base Curb weight (C.W.) Front kgf (lb) (1,587) (1,687) (1,698) (1,609) (1,620) (1,664) (1,654) (1,654) Rear kgf (lb) (1,036) (1,036) (1,036) (1,146) (1,146) (1,146) (1,146) (1,146) Total kgf (lb) 1,190 1,235...
Page 19 IMPREZA SPECIFICATIONS Option code Model 1.6 L 2.0 L Curb weight (C.W.) Front kgf (lb) (1,631) (1,654) (1,644) (1,709) (1,698) (1,698) (1,676) (1,654) Rear kgf (lb) (1,179) (1,146) (1,146) (1,146) (1,146) (1,146) (1,146) (1,179) Total kgf (lb) 1,275 1,270 1,275 1,295 1,290 1,290...
Page 20 IMPREZA SPECIFICATIONS Option code Model 2.0 L Curb weight (C.W.) Front kgf (lb) (1,698) (1,687) (1,698) (1,687) (1,698) (1,687) (1,676) (1,687) Rear kgf (lb) (1,179) (1,179) (1,179) (1,179) (1,179) (1,168) (1,157) (1,235) Total kgf (lb) 1,305 1,300 1,305 1,300 1,305 1,295 1,285 1,325...
Page 21 IMPREZA SPECIFICATIONS Option code Model 2.0 L Curb weight (C.W.) Front kgf (lb) (1,709) (1,753) (1,742) (1,742) (1,742) (1,753) (1,742) (1,753) Rear kgf (lb) (1,168) (1,168) (1,168) (1,168) (1,168) (1,168) (1,157) (1,168) Total kgf (lb) 1,305 1,325 1,320 1,325 1,320 1,325 1,315 1,325...
Page 22 IMPREZA SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,753) (1,841) (1,808) (1,841) (1,841) (1,852) (1,840) (1,852) Rear kgf (lb) (1,224) (1,235) (1,213) (1,224) (1,235) (1,257) (1,246) (1,257) Total kgf (lb) 1,325 1,395 1,370 1,390 1,395...
Page 23 IMPREZA SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,852) (1,852) (1,840) (1,852) (1,852) (1,951) (1,907) (1,951) Rear kgf (lb) (1,257) (1,268) (1,235) (1,268) (1,268) (1,290) (1,290) (1,290) Total kgf (lb) 1,410 1,415 1,395 1,415 1,415 1,470 1,450...
Page 24 IMPREZA SPECIFICATIONS Wagon Option code Model 1.6 L 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,620) (1,631) (1,631) (1,676) (1,664) (1,664) (1,643) (1,654) Rear kgf (lb) (1,202) (1,202) (1,213) (1,202) (1,202) (1,202) (1,235) (1,202) Total kgf (lb) 1,280 1,285 1,290 1,305 1,300...
Page 25 IMPREZA SPECIFICATIONS Option code Model 1.6 L 2.0 L 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,664) (1,664) (1,709) (1,698) (1,698) (1,676) (1,676) (1,731) Rear kgf (lb) (1,202) (1,213) (1,202) (1,202) (1,202) (1,235) (1,257) (1,290) Total kgf (lb) 1,300 1,305 1,320 1,315...
Page 26 IMPREZA SPECIFICATIONS Option code Model 2.0 L 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,720) (1,709) (1,720) (1,720) (1,709) (1,698) (1,709 (1,764) Rear kgf (lb) (1,257) (1,257) (1,257) (1,257) (1,246) (1,300) (1,246) (1,279) Total kgf (lb) 1,350 1,345 1,350 1,350 1,340 1,360...
Page 27 IMPREZA SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,753) (1,742) (1,753) (1,753) (1,742) (1,742) (1,775) (1,819) Rear kgf (lb) (1,246) (1,246) (1,246) (1,246) (1,235) (1,279) (1,290) (1,290) Total kgf (lb) 1,360 1,355 1,360 1,360 1,350...
Page 28 IMPREZA SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,830) (1,830) (1,830) (1,830) Rear kgf (lb) (1,322) (1,322) (1,322) (1,311) Total kgf (lb) 1,430 1,430 1,430 1,425 (3,153) (3,153) (3,153) (3,142) Maximum permissible Front kgf (lb) axle weight (M.P.A.W.) (2,183) (2,183)
Page 29 IMPREZA SPECIFICATIONS 2. RHD MODEL Sedan Option code Model 1.6 L 2.0 L Curb weight (C.W.) Front kgf (lb) (1,631) (1,676) (1,676) (1,654) (1,698) (1,654) (1,687) (1,709) Rear kgf (lb) (1,146) (1,146) (1,146) (1,146) (1,146) (1,179) (1,179) (1,168) Total kgf (lb) 1,260 1,280 1,280...
Page 30 IMPREZA SPECIFICATIONS Option code Model 2.0 L 2.5 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,742) (1,698) (1,753) (1,698) (1,753) (1,720) (1,775) (1,841) Rear kgf (lb) (1,168) (1,179) (1,168) (1,179) (1,168) (1,191) (1,179) (1,246) Total kgf (lb) 1,320 1,305 1,325...
Page 31 IMPREZA SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,841) (1,852) (1,852) (1,852) (1,841) (1,852) (1,896) (1,907) Rear kgf (lb) (1,246) (1,257) (1,268) (1,268) (1,235) (1,257) (1,234) (1,246) Total kgf (lb) 1,395 1,410 1,415 1,415 1,395 1,410 1,415...
Page 32 IMPREZA SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,907) (1,952) (1,952) Rear kgf (lb) (1,257) (1,290) (1,290) Total kgf (lb) 1,435 1,470 1,470 (3,164) (3,241) (3,241) Maximum permissible Front kgf (lb) 1,030 1,030 axle weight (M.P.A.W.) (2,183) (2,271) (2,271)
Page 33 IMPREZA SPECIFICATIONS Wagon Option code Model 1.6 L 2.0 L 5MT D/R 5MT D/R 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,642) (1,687) (1,676) (1,664) (1,698) (1,676) (1,709) (1,709) Rear kgf (lb) (1,202) (1,202) (1,202) (1,202) (1,202) (1,257) (1,257) (1,246) Total kgf (lb)
Page 34 IMPREZA SPECIFICATIONS Option code Model 2.0 L OUTBACK 5MT D/R 5MT D/R 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,742) (1,720) (1,753) (1,720) (1,753) (1,698) (1,731) (1,819) Rear kgf (lb) (1,246) (1,257) (1,246) (1,257) (1,246) (1,257) (1,257) (1,830) Total kgf (lb) 1,355 1,350...
Page 35 IMPREZA SPECIFICATIONS Option code Model 2.0 L Curb weight (C.W.) Front kgf (lb) (1,819) (1,830) (1,830) (1,819) (1,874) Rear kgf (lb) (1,301) (1,323) (1,323) (1,830) (1,830) Total kgf (lb) 1,415 1,430 1,430 1,410 1,435 (3,120) (3,153) (3,153) (3,109) (3,164) Maximum permissible Front kgf (lb) axle weight (M.P.A.W.)
Page 36 IMPREZA SPECIFICATIONS SPC-24...
Page 37 PRECAUTION Page Precaution ....................2...
Page 38 PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handling and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...
Page 39 NOTE Page Note......................2...
Page 40 4. SERVICE PARTS Use authentic service parts for maximum perfor- mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor perfor- mance resulting from the use of parts not specified by a genuine dealer. 5. PROTECTING VEHICLE UNDER MAIN-...
Page 41 NOTE NOTE 7. LIFTS AND JACKS When using a lift or jack 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 42 NOTE NOTE NT-00062 Front Rear Front crossmember Rear differential NT-4...
Page 43 NOTE NOTE 8. TIE-DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. • Tie-down point NT-00063 Hook for tie-down Hook for towing and tie-down •...
Page 44 NOTE NOTE • Vehicle sinking volume at tie-down condition Measure the distance L between tire highest point to arch highest point before tie-down and after tie- down. Difference of measurement value (drop height) shall be within 50.8 mm (1.97 in). Make sure to fix the vehicle securely.
Page 45 NOTE NOTE 9. TOWING Avoid towing vehicles except when the vehicle cannot be driven. For models 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: •...
Page 46 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-8...
Page 47 IDENTIFICATION Page Identification ....................2...
Page 48 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. • POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION ID-00052 ID plate (Europe model) Tire inflation pressure label (Driver Model number plate ADR compliance plate (Australia side) (Australia model)
Page 49 IDENTIFICATION IDENTIFICATION • MANUAL TRANSMISSION • REAR DIFFERENTIAL ID-00055 ID-00056 (1) Transmission serial number (1) Type (white paint) • MODEL NUMBER PLATE Applied model Option CODE Engine type TRIM CODE Transmission type COLOR CODE ID-00057 ID-3...
Page 50 IDENTIFICATION IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1GD5LJ33G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line IMPREZA...
Page 51 IDENTIFICATION IDENTIFICATION 3. MODEL NUMBER PLATE 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. GD9CL5R Digits Code...
Page 52 IDENTIFICATION IDENTIFICATION • Transmission TV1B4VYAAA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V: Full-time AWD AT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: 5MT 85: 6MT 1A: AT 1B: AT Series 4: 5MT...
Page 53 IDENTIFICATION IDENTIFICATION • Option code ECPS Digits Code Meaning Details 1 and 2 Destination EC: EC KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1 E2: E2 3 and 4 Main option of vehicle — ID-7...
Page 54 IDENTIFICATION IDENTIFICATION ID-8...
Page 55 RECOMMENDED MATERIALS Page Recommended Materials ................2...
Page 56 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality. 2. FUEL Always use a gasoline of the same or higher octane value than specified in the owner's manual.
Page 57 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. API Spec. Engine oil SL, SJ Grade “Energy conserving”, or SH G4 or G5 A1, A2 or A3...
Page 58 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil SOHC model (˚C) –30 –20 –10 (˚F) –22 –4 10W-30 or 10W-40 5W-30 0W-20 Recommend RM-00007 DOHC turbo model (˚C) –30 –20 –10 –4 (˚F) –22 10W-30 or 10W-40 5W-30 Recommend RM-00003 RM-4...
Page 59 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Manual transmission oil and rear differential gear oil (˚F) –30 –20 –10 –22 –4 (˚C) 75W-90 RM-00004 AT front differential gear oil (˚C) –30 –20 –10 –22 –4 (˚F) 80W-90 RM-00005 RM-5...
Page 60 Distilled water — Tap water (Soft water) 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any compressor oil except for DH-PR. Air conditioner Recommended Item number...
Page 61 Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary lubricants • O sensor SUBARU CRC 004301003 — • Bolts, etc. Grease MT main shaft FX2200 clutch grease 000040901 — Clutch master cylinder...
Page 62 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • Cylinder block Three Bond 1215 004403007 Dow Corning’s No. 7038 • Torque converter clutch case •...
Page 63 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
Page 64 • Make sure to provide a complete vehicle to the customer. Because of the above reasons, all SUBARU distrib- utor service must always carry out the PDIs before delivering a vehicle. In addition, all franchised shops and PDI centers must check the status of every vehicle received to identify who is responsible for any possible defects.
Page 65 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION B: PDI PROCEDURE 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 66 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Step Check point 24. Seat belt Check the seat belt installation conditions and functionality. 25. Wheel alignment Check that the wheel alignments are properly adjusted. Checks with the Engine Running Step Check point 26. Test mode connector Test mode connector.
Page 67 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER HARNESS • If the vehicle is covered with protective coating, visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har- dents. ness disconnected to protect the air conditioner •...
Page 68 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 2) Close the driver’s door completely, and place the 6. CHECK DOUBLE LOCK OPERATION door lock knob (A) to the lock position. Then pull in- 1) Fully open all the windows. ner remotes (B) to ensure that doors will not open. 2) Remove the key.
Page 69 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 8. CHECK THE TRUNK LID FOR OPEN/ (2) Check that the rear gate is locked correctly when lever is operated using a finger. CLOSE OPERATIONS 1) Operate the trunk lock release lever and verify that the trunk lid opens. 2) Using the key, open the trunk lid several times to check for normal operation.
Page 70 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 12.OPERATION CHECK OF HOOD LOCK 13.BATTERY RELEASE SYSTEM Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found. Operate the hood release knob (A) and check that Check that the battery caps are securely tightened. the hood is unlocked normally.
Page 71 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 16.TRANSMISSION FLUID 19.CLUTCH FLUID Check the transmission fluid amount. If the amount Check the clutch fluid amount. If the amount is in- is insufficient, check that no leaks are found. Then, sufficient, check that no leaks are found. Then, add add the necessary amount of the specified fluid.
Page 72 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION • With OBD MODEL ( A ) PI-00109 PI-00119 • Press the “OPEN” button on the transmitter mo- mentarily once and check that all doors are un- (A) Test mode connector (Green) locked, the hazard light flashes twice and the interior light illuminates.
Page 73 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 32.FRONT ACCESSORY POWER SUPPLY 37.BRAKE TEST SOCKET Check the foot brake for normal operations. Check the front accessory power supply socket op- 38.PARKING BRAKE erations. Check the parking brake for normal operations. 33.LIGHTING SYSTEM 39.AT SHIFT CONTROL •...
Page 74 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 42.CRUISE CONTROL 46.WATER LEAK TEST Operate the cruise control system. Check that the Spray the vehicle with water and check that no wa- system is activated and deactivated correctly. ter enters the passenger compartment. • Before performing the water leakage test, re- 43.ATF LEVEL move anything that may obstruct the operation or Check that the ATF level is normal.
Page 75 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 47.APPEARANCE CHECK 2 • Avoid adhesion of the solvent to resin or rubber components. Do not use coating wax or a solvent • Except paint protection coat wrap guard type while the component surface temperature is high 1) Check the paint after removing the paint protec- due to hot weather, etc.
Page 76 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PI-14...
Page 77: Table Of Contents
PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................8 Engine Oil Filter..................11 Spark Plugs....................12 V-belt......................13 Timing Belt ....................16 Fuel Line ....................20 Fuel Filter ....................21 Air Cleaner Element ..................22 Cooling System ..................23 Coolant......................25 Idle Mixture....................27 Clutch System ...................28 Transmission Gear Oil ................30 Hill-holder System ..................31 ATF ......................32 Front &...
Page 78: General Description
GENERAL DESCRIPTION PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
Page 79: Schedule
SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. FOR EUROPE AREA For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.
Page 80 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring 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 81 SCHEDULE PERIODIC MAINTENANCE SERVICES I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked. PM-5...
Page 82: Engine Oil Filter
SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 1. EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil...
Page 83 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil Replace...
Page 84 ENGINE OIL PERIODIC MAINTENANCE SERVICES 3. Engine Oil • SOHC MODEL A: REPLACEMENT 1) Open the engine oil filler cap for quick draining of the engine oil. LU-00193 4) Replace the drain plug gasket. 5) Tighten the engine oil drain plug after draining engine oil.
Page 85 Recommended oil gine; however, use oil having the API classification API classification and SAE viscosity No. designated by SUBARU. SL or SJ with the words “Energy Conserv- • If vehicle is used in desert areas with very high ing or Energy conserving II”, CCMC speci-...
Page 86 ENGINE OIL PERIODIC MAINTENANCE SERVICES B: INSPECTION 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation.
Page 87 ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT 1) Remove the under cover. 2) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH • SOHC MODEL LU-00194 • DOHC TURBO MODEL LU-00190 3) Get a new oil filter and apply a thin coat of engine oil to the seal rubber.
Page 88: Spark Plugs
SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs 5) Remove the ignition coil. A: REPLACEMENT 1. SOHC MODEL 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench.
Page 89: V-Belt
V-BELT PERIODIC MAINTENANCE SERVICES 6. V-belt 2. WITH USING BELT TENSION GAUGE 1) Replace the belts, if cracks, fraying or wear is A: INSPECTION found. 1. WITHOUT USING BELT TENSION 2) Remove the V-belt cover and radiator reservoir tank. GAUGE 3) Check the belt tension using belt tension gauge.
Page 90 V-BELT PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 2. FRONT SIDE BELT (DRIVING POWER STEERING OIL PUMP AND GENERATOR) 1. V-BELT COVER NOTE: 1) Remove the V-belt cover. Wipe off any oil or water on the belt and pulley. NON-TURBO MODEL 1) Loosen the lock bolt (A). 2) Loosen the slider bolt (B).
Page 91 V-BELT PERIODIC MAINTENANCE SERVICES 3. REAR SIDE BELT (DRIVING AIR CONDI- TIONER) NOTE: Wipe off any oil or water on the belt and pulley. 1) Remove the front side belt. 2) Loosen the lock nut (A). 3) Loosen the slider bolt (B). 4) Remove the rear side belt.
Page 92: Timing Belt
TIMING BELT PERIODIC MAINTENANCE SERVICES 7. Timing Belt 10) Remove the timing belt guide. (MT model) A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove the radiator fan and air conditioner fan. <Ref. to CO(H4SO)-25, Radiator Main Fan and Fan Motor.>, <Ref. to CO(H4SO)-26, Radiator Sub Fan and Fan Motor.>...
Page 93 TIMING BELT PERIODIC MAINTENANCE SERVICES 15) Remove the automatic belt tension adjuster as- 11) Remove the timing belt guide. (MT model) sembly. PM-00008 PM-00011 16) Install in the reverse order of removal. <Ref. to ME(H4SO)-51, INSTALLATION, Timing Belt As- sembly.> 2.
Page 94 TIMING BELT PERIODIC MAINTENANCE SERVICES 12) Turn the crankshaft and align alignment marks 15) Remove the automatic belt tension adjuster as- on crankshaft, and right and left camshaft sprock- sembly. ets with notches of belt cover and cylinder block. To turn the crankshaft, use ST.
Page 95 TIMING BELT PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 1) Remove the timing belt cover (LH). 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed. 3) Measure the timing belt width W.
Page 96: Fuel Line
FUEL LINE PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION 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. SOHC model <Ref.
Page 97: Fuel Filter
FUEL FILTER PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. SOHC model <Ref. to FU(H4SO)-62, Fuel Filter.> DOHC Turbo model <Ref. to FU(H4DOTC)-66, Fuel Filter.> B: INSPECTION 1) If it is clogged, or if replacement interval has been reached, replace it.
Page 98: Air Cleaner Element
AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2. TURBO MODEL 1) Remove the clip (B) above the air cleaner case. A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove the air intake duct from air cleaner case. 2) Remove the bolt (A) which installs air cleaner case to stays.
Page 99: Cooling System
COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 11.Cooling System NOTE: Rust or dirt on the cap may prevent the valve from A: INSPECTION functioning normally: be sure to clean the cap be- 1) Check the radiator for leakage, filling it with cool- fore testing.
Page 100 <Ref. to CO(H4DOTC)-21, Thermostat.> <Ref. to CO(H4DOTC)-23, Radiator.> <Ref. to CO(H4DOTC)-27, Radiator Cap.> 4) Check the electric fan operates using Subaru Select Monitor, when the coolant temperature ex- ceeds 95°C (203°F). If not operate, check the elec- tric fan system.
Page 101: Coolant
NOTE: The SUBARU Genuine Coolant containing anti- A: REPLACEMENT freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- 1. REPLACEMENT OF COOLANT case. Always use SUBARU Genuine Coolant, WARNING: since other coolant may cause corrosion.
Page 102 The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.
Page 103: Idle Mixture
IDLE MIXTURE PERIODIC MAINTENANCE SERVICES 13.Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIXTURE 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 104: Clutch System
CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 14.Clutch System 2) Pedal-to-floor plate gap in disengaged position. (1) With the engine idling, pull the parking brake A: INSPECTION AND ADJUSTMENT lever completely. (2) Slowly depress the clutch pedal while mov- 1. MECHANICAL CLUTCH TYPE ing shift lever into reverse.
Page 105 CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 2) If the fluid level rises, pedal free play is correct. 3) If the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal. <Ref. to CL-40, Clutch Pedal.> 4) Check the fluid level using the scale on the out- side of the clutch master cylinder tank (A).
Page 106: Transmission Gear Oil
TRANSMISSION GEAR OIL PERIODIC MAINTENANCE SERVICES 15.Transmission Gear Oil 3) Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge. A: REPLACEMENT NOTE: Each oil manufacturer has its base oil and addi- 1.
Page 107: Hill-Holder System
HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 16.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm the stopping and starting performance by activating the hill-holder on an uphill road of 3° or higher inclination. (1) When the vehicle does not stop; Tighten the adjusting nut of PHV cable. (2) When the vehicle does not start properly;...
Page 108: 17.Atf
ATF temperature to 70 — 80°C (158 NOTE: — 176°F) on Subaru Select Monitor. <Ref. to 4AT- Before starting work, cool off the ATF well. 21, READ CURRENT DATA, OPERATION, Suba- ru Select Monitor.>...
Page 109 PERIODIC MAINTENANCE SERVICES 4) Check the ATF level. <Ref. to PM-32, INSPEC- TION, ATF.> PI-00105 (A) Level gauge (B) Hot side (C) Upper level (D) Lower level (E) Cold side 2. ATF FILTER NOTE: ATF filter is a maintenance free part. ATF filter needs replacement, when it has physically dam- aged or ATF leaked.
Page 110: Front & Rear Differential Gear Oil
FRONT & REAR DIFFERENTIAL GEAR OIL PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Gear 3) Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge. NOTE: A: REPLACEMENT Each oil manufacturer has its base oil and addi- tives.
Page 111 FRONT & REAR DIFFERENTIAL GEAR OIL PERIODIC MAINTENANCE SERVICES 4) After installing the drain plug onto rear differen- 5) Install the filler plug onto rear differential gear tial gear case firmly, fill oil up fully to the mouth of case firmly. filler plug.
Page 112: Brake Line
BRAKE LINE PERIODIC MAINTENANCE SERVICES 19.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion, traces of Brake pedal free play: fluid leakage on the brake hoses or pipe joints.
Page 113 BRAKE LINE PERIODIC MAINTENANCE SERVICES (4) If there is no free play between clevis pin 4) Check to see if air is in the hydraulic brake line and clevis, turn the brake switch adjusting nut by the feel of pedal operation. If air appears to exist until the clearance between stopper and screw in the line, bleed it from the system.
Page 114: Brake Fluid
BRAKE FLUID PERIODIC MAINTENANCE SERVICES 20.Brake Fluid • During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate en- A: REPLACEMENT try of air. 1) Either jack-up the vehicle and place a safety • The brake pedal operating must be very slow. stand under it, or lift-up the vehicle.
Page 115: Disc Brake Pads And Discs
DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs A: INSPECTION 1. DISC BRAKE PAD AND DISC 1) Jack-up the vehicle and support with rigid racks. Then remove the wheels. 2) Visually check the pad thickness through inspec- tion hole of disc brake assembly.
Page 116: Brake Linings And Drums
BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 22.Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts. A: INSPECTION 1. REAR DRUM BRAKE 1) Remove the brake drum, and check that there is no fluid leakage from wheel cylinder.
Page 117 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2) Check the disk rotor for wear, dents or other B: ADJUSTMENT damage. If the inside surface of disk rotor is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, The main brake is adjusted automatically, and so correct or replace it.
Page 118: Suspension
SUSPENSION PERIODIC MAINTENANCE SERVICES 23.Suspension NOTE: When the transverse link ball joint has been re- A: INSPECTION moved or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, ad- 1. SUSPENSION BALL JOINT just the toe-in.
Page 119 SUSPENSION PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- 7. TIGHTNESS OF BOLTS AND NUTS PENSION Check the bolts and nuts shown in the figure for looseness. Retighten the bolts and nuts to speci- 1) Check the alignment of front suspension to en- fied torque.
Page 120: Wheel Bearing
WHEEL BEARING PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 2. REAR WHEEL BEARING • AWD A: INSPECTION 1) Jack-up the rear of vehicle. 1. FRONT WHEEL BEARING 2) While holding the rear wheel by hand, swing it in and out to check bearing free play. NOTE: 3) Loosen the wheel nuts and remove rear wheel.
Page 121 WHEEL BEARING PERIODIC MAINTENANCE SERVICES 5) Turn the hub unit COMPL with hand to check for noise or binding. If the hub unit COMPL is noisy or binds, replace the hub unit COMPL. PM-00153 (A) Rear housing (B) Tone wheel (C) Hub bolt (D) Hub unit COMPL (E) Socket bolt...
Page 122: Axle Boots & Joints
AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 25.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, re- place them with new ones. <Ref. to DS-33, Front Drive Shaft.>...
Page 123: Steering System (Power Steering)
STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the point of the crossing direction).
Page 124 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (2) Retighten the adjusting screw to 7.4 N·m 3) Check the lock nut on tie-rod end for tightness. If (0.75 kgf-m, 5.4 ft-lb) and back off 25°. it is loose, retighten it to the specified torque. (3) Apply liquid packing to at least 1/3 of entire Tightening torque: perimeter of adjusting screw thread.
Page 125 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary. NOTE: Prevent the hoses from revolving and/or turning when installing hoses.
Page 126 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES PM-50...
Page 127 EC(H4SO) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO) MECHANICAL ME(H4SO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4SO)
Page 128 2003 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SOw/oOBD) SPEED CONTROL SYSTEMS SP(H4SOw/oOBD) IGNITION IG(H4SOw/oOBD) STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD) ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD) G1860GE2...
Page 129 FUEL INJECTION (FUEL SYSTEMS) FU(H4SO) Page General Description ..................2 Throttle Body.....................15 Intake Manifold..................16 Engine Coolant Temperature Sensor............27 Crankshaft Position Sensor...............28 Camshaft Position Sensor.................29 Knock Sensor....................30 Throttle Position Sensor................31 Manifold Absolute Pressure Sensor............33 Intake Air Temperature Sensor ..............34 Idle Air Control Solenoid Valve ..............35 EGR Valve ....................36 Air Assist Injector Solenoid Valve .............37 Fuel Injector ....................38...
Page 130: General Description
GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Item Specification 50 2 (13.2 US gal, 11.0 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
Page 131 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD • 1.6 L MODEL (19) (22) (24) (19) (11) (10) (15) (21) (20) (14) (23) (18) (17) (21) (12) (17) (13) (16) (18) (18) (17) FU-00953 FU(H4SO)-3...
Page 132 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Intake manifold gasket RH (13) Fuel pipe protector LH Tightening torque: N·m (kgf-m, ft-lb) Fuel injector pipe (14) Plug cord holder LH T1: 1.5 (0.15, 1.1) Fuel injector (15) Fuel pipe protector RH T2: 5.0 (0.51, 3.7) O-ring (16) Fuel pipe ASSY...
Page 133 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) • 2.0 L MODEL (19) (21) (23) (19) (15) (10) (20) (11) (22) (14) (18) (17) (20) (12) (17) (13) (16) (18) (18) (17) FU-00954 FU(H4SO)-5...
Page 134 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Intake manifold gasket RH (11) Intake manifold (21) Plug cord holder RH Fuel injector pipe (12) Intake manifold gasket LH (22) Accelerator cable bracket Fuel injector (13) Fuel pipe protector LH (23) EGR valve O-ring (14) Plug cord holder LH...
Page 135 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-00955 Gasket Throttle body Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor Intake air temperature sensor T1: 1.6 (0.16, 1.2) Idle air control solenoid valve Grommet T2: 22 (2.2, 15.9) Manifold absolute pressure sen- Air cleaner case FU(H4SO)-7...
Page 136 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 Crankshaft position sensor Camshaft position sensor support Tightening torque: N·m (kgf-m, ft-lb) Knock sensor T1: 6.4 (0.65, 4.7) Camshaft position sensor T2: 24 (2.4, 17.4) FU(H4SO)-8...
Page 137 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (25) (16) (10) (11) (11) (11) (14) (13) (24) (24) (12) (11) (11) (15) (11) (17) (19) (18) (20) (11) (21) (11) (22) (18) (19) (11) (23) FU-00908 FU(H4SO)-9...
Page 138 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (11) Clip (21) Fuel pipe ASSY Fuel tank band (12) Evaporation hose B (22) Fuel return hose B Protector RH (13) Joint pipe (23) Evaporation hose E Fuel tank (14) Evaporation hose C (24) Evaporation hose F Fuel pump gasket...
Page 139 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) FU-00516 FU(H4SO)-11...
Page 140 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
Page 141 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (11) (10) (12) FU-00956 Fuel filler pipe ASSY Air vent pipe (11) Filler cap tether Evaporation hose holder Air vent pipe holder (12) Filler pipe protector Clip Filler pipe packing Clamp Filler ring Tightening torque: N·m (kgf-m, ft-lb)
Page 142 TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical system. ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 143: Throttle Body
THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 6) Disconnect the air by-pass hose from throttle body. (1.6 L model) A: REMOVAL 1) Disconnect the ground cable from battery. FU-00957 7) Disconnect the engine coolant hoses (A) from FU-00009 throttle body.
Page 144: Intake Manifold
INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold (3) Remove the bolts which hold the power steering pipes onto intake manifold protector. A: REMOVAL NOTE: 1) Release the fuel pressure. <Ref. to FU(H4SO)- Do not disconnect the power steering hose. 51, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.>...
Page 145 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place the power steering pump on the right 12) Remove the air cleaner case stay RH and en- side wheel apron. gine harness bracket, and then disconnect the en- gine harness connectors from the bulkhead harness connectors.
Page 146 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect the connector from the oil pressure 19) Disconnect the fuel hoses from fuel pipes. switch. WARNING: • Do not spill fuel. • Catch fuel from hoses in a container or cloth. FU-00146 17) Disconnect the connector from the camshaft position sensor.
Page 147 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel hoses. 6) Connect the connector to the crankshaft position sensor. FU-00259 FU-00056 (A) Fuel delivery hose 7) Connect the knock sensor connector. (B) Return hose (C) Evaporation hose 3) Connect the EGR pipe to intake manifold. Tightening torque: 34 N·m (3.4 kgf-m, 24.6 ft-lb) FU-00062...
Page 148 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 10) Connect the brake booster hose. (2) Connect the connector to the power steering pump switch. FU-00958 FU-00878 11) Connect the engine coolant hose (A) to throttle body. (3) Tighten the bolts which install the power steering pump bracket.
Page 149 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Connect the cruise control cable (B). (With C: DISASSEMBLY cruise control model) 1) Disconnect the engine ground terminal from in- take manifold. FU-00251 FU-00263 17) Install the air intake duct and air cleaner case. <Ref.
Page 150 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Remove the fuel pipe protector RH. 13) Remove the bolt which installs the fuel injector pipe on the intake manifold as shown in the figure. FU-00267 FU-00959 9) Disconnect the connectors from fuel injectors. •...
Page 151 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) • 2.0 L MODEL 17) Loosen the clamp which holds the fuel injector pipe LH to fuel hose, and then remove the pipe from fuel hose. FU-00170 15) Remove the fuel injectors. FU-00171 (1) Remove the fuel injector securing clip. 18) Loosen the clamp which holds the fuel injector pipe RH to fuel hose, and then remove the pipe from fuel hose.
Page 152 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 5) Connect the air by-pass hose. (1.6 L model) 1) Install the fuel pipe assembly and pressure reg- LH side RH side ulator, etc. to intake manifold. 2) Tighten the bolt which installs the fuel pipes on intake manifold.
Page 153 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 7) Tighten the bolt which installs the injector pipe 8) Tighten the two bolts which install the fuel pipes on intake manifold. on intake manifold. Tightening torque: Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) •...
Page 154 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 12) Install the fuel pipe protector RH. 19) Install the ignition coil and ignitor assembly. <Ref. to IG(H4SO)-8, INSTALLATION, Ignition Coil Tightening torque: & Ignitor ASSY.> 19 N·m (1.9 kgf-m, 13.7 ft-lb) 20) Install the engine ground terminal to intake manifold.
Page 155: Engine Coolant Temperature Sensor
ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Disconnect the ground cable from battery. FU-00288 FU-00009 2) Remove the air intake duct and air cleaner case.
Page 156: Crankshaft Position Sensor
CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SO)-3, COMPONENT, General De- scription.>...
Page 157: Camshaft Position Sensor
CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam- shaft position sensor support as a unit. A: REMOVAL 6) Remove the camshaft position sensor itself. 1) Disconnect the ground cable from battery. FU-00179 FU-00009 B: INSTALLATION...
Page 158: Knock Sensor
KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: • For tightening torque, refer to “COMPONENT”. <Ref.
Page 159: Throttle Position Sensor
THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SO)-3, COMPONENT, General De- scription.>...
Page 160 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) ME-00325 5) Turn the ignition switch to ON, and the Subaru Select Monitor switch to ON. FU-00291 6) Select the {2. Each System Check} in «Main 4) When using Subaru Select Monitor;...
Page 161: Manifold Absolute Pressure Sensor
MANIFOLD ABSOLUTE PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Manifold Absolute Pressure B: INSTALLATION Install in the reverse order of removal. Sensor NOTE: A: REMOVAL • For tightening torque, refer to “COMPONENT”. 1) Disconnect the ground cable from battery. <Ref. to FU(H4SO)-3, COMPONENT, General De- scription.>...
Page 162: Intake Air Temperature Sensor
INTAKE AIR TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Intake Air Temperature Sen- A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector from the intake air temperature sensor. 3) Remove the intake air temperature sensor from the air cleaner case.
Page 163: Idle Air Control Solenoid Valve
IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL • For tightening torque, refer to “COMPONENT”. 1) Disconnect the ground cable from battery. <Ref.
Page 164: Egr Valve
EGR VALVE FUEL INJECTION (FUEL SYSTEMS) 12.EGR Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SO)-3, COMPONENT, General De- scription.> FU-00009 2) Disconnect the connector from EGR valve.
Page 165: Air Assist Injector Solenoid Valve
AIR ASSIST INJECTOR SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 13.Air Assist Injector Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SO)-3, COMPONENT, General De- NOTE: scription.> Air assist injector solenoid valve is equipped in 1.6 L model only.
Page 166: Fuel Injector
FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 14.Fuel Injector 6) Remove the power steering pump and tank from brackets. A: REMOVAL (1) Remove the front side V-belt. <Ref. to ME(H4SO)-44, REMOVAL, V-belt.> 1. RH SIDE (2) Remove the bolts which hold the power 1) Release the fuel pressure.
Page 167 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) (5) Remove the power steering tank from the 9) Remove the bolts which hold the fuel injector bracket by pulling it upwards. pipe to intake manifold. FU-00020 FU-00284 (6) Place the power steering pump and tank on the right side wheel apron.
Page 168 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 8) Move the washer tank, and secure it away from working area. 1) Release the fuel pressure. <Ref. to FU(H4SO)- 51, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Open the fuel flap lid, and then remove the fuel filler cap.
Page 169 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12) Remove the bolt which holds the fuel injector (2) Remove the fuel injector while lifting up the pipe to intake manifold. fuel injector pipe. FU-00309 FU-00313 13) Remove the bolts which hold the fuel pipe on B: INSTALLATION intake manifold.
Page 170 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 2. LH SIDE 19 N·m (1.9 kgf-m, 13.7 ft-lb) Install in the reverse order of removal. NOTE: Replace O-rings with new ones. FU-00284 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00282 (A) O-ring (B) Fuel injector Tightening torque:...
Page 171 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00309 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00266 FU(H4SO)-43...
Page 172: Front Oxygen (A/F) Sensor
21 N·m (2.1 kgf-m, 15.2 ft-lb) EX-00029 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the front oxygen (A/F) sensor.
Page 173 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. FU-00009 FU(H4SO)-45...
Page 174 2) Install the rear oxygen sensor. Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) EX-00030 4) Apply SUBARU CRC or its equivalent to the threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the rear oxygen sensor.
Page 175 REAR OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. FU-00009 FU(H4SO)-47...
Page 176 ENGINE CONTROL MODULE (ECM) FUEL INJECTION (FUEL SYSTEMS) 17.Engine Control Module (ECM) B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. When replacing ECM, be careful not to use the wrong spec.
Page 177 MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 18.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds the main bracket on body. 4) Disconnect the connectors from main relay. FU-00317 B: INSTALLATION Install in the reverse order of removal.
Page 178 FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 19.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds the fuel pump relay bracket on body. 4) Disconnect the connector from fuel pump.
Page 179 FUEL FUEL INJECTION (FUEL SYSTEMS) 20.Fuel 2. DRAINING FUEL WARNING: A: OPERATION • Place “NO FIRE” signs near working area. 1. RELEASING OF FUEL PRESSURE • Be careful not to spill fuel. 1) Set the vehicle on a lift. WARNING: 2) Disconnect the ground cable from battery.
Page 180 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Tank 9) Loosen the clamp, and then disconnect the fuel filler hose and air vent hose from the fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel. 1) Set the vehicle on a lift.
Page 181 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Connect the fuel hoses, and then secure them with clips and quick connector. <Ref. to FU(H4SO)- 1) Support the fuel tank with transmission jack and 66, INSTALLATION, Fuel Delivery, Return and push the fuel tank harness into access hole with Evaporation Lines.>...
Page 182 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 10) Connect the connector to fuel pump relay. FU-00262 C: INSPECTION 1) Make sure there are no cracks, holes, or other damage on fuel tank. 2) Make sure the fuel hoses and fuel pipes are not cracked and the connections are tightened firmly.
Page 183 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un- der the vehicle, and then remove the drain plug A: REMOVAL from fuel tank. WARNING: • Place “NO FIRE” signs near working area. •...
Page 184 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 13) Disconnect the air vent hose from fuel filler 18) Remove the air vent pipe together with clip pipe. from body. FU-00099 FU-00102 14) Remove the bolts which hold the fuel filler pipe B: INSTALLATION bracket on body.
Page 185 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 5) Connect the air vent hose to the fuel filler pipe. 8) Tighten the bolt which holds the fuel filler pipe bracket on body. Tightening torque: 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) FU-00099 6) Insert the fuel filler hose (A) approx.
Page 186 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 12) Lower the vehicle. 13) Tighten the wheel nuts. 14) Connect the connector to fuel pump relay. FU-00262 15) Connect the battery ground cable to battery. FU-00009 FU(H4SO)-58...
Page 187 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Pump 8) Remove the access hole lid. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
Page 188 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION C: INSPECTION Install in the reverse order of removal. Do the fol- Connect the lead harness to connector terminal of lowing: fuel pump, and then apply the battery power supply to check whether the pump operates. NOTE: Replace the gasket with a new one.
Page 189 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Level Sensor A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel. NOTE: Fuel level sensor is built in the fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H4SO)-59, REMOVAL, Fuel Pump.>...
Page 190 FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filter B: INSTALLATION CAUTION: A: REMOVAL • If the fuel hoses are damaged at connecting WARNING: portion, replace them with new ones. • Place “NO FIRE” signs near working area. • If clamps are badly damaged, replace them •...
Page 191 FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Cut Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: WARNING: For tightening torque, refer to “COMPONENT”. • Place “NO FIRE” signs near working area. <Ref. to FU(H4SO)-3, COMPONENT, General De- •...
Page 192 FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Damper Valve A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO)- 51, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Remove the fuel damper valve from the fuel re- turn line. FU-00121 B: INSTALLATION Install in the reverse order of removal.
Page 193 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO)-51, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Open the fuel filler flap lid, and then remove the fuel filler cap. 4) Remove the floor mat.
Page 194 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate the quick connector on fuel delivery B: INSTALLATION line. 1) Connect the quick connector on fuel delivery (1) Clean the pipe and connector, if they are line. covered with dust. NOTE: (2) Hold the connector (A), and then push the •...
Page 195 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 3) Connect the evaporation hose to pipe by approx. CAUTION: 15 to 20 mm (0.59 to 0.79 in) from the hose end. • Pull the connector to ensure it is connected securely.
Page 196 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 29.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten ❍...
Page 197 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................4 EGR Valve ....................5 Canister.......................6 Purge Control Solenoid Valve ..............7 Two-way Valve....................8...
Page 198 GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 199 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal procedures are the same as those for center exhaust pipe. <Ref.
Page 200 REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal procedures are the same as those for center exhaust pipe. <Ref.
Page 201 EGR VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. EGR Valve A: PROCEDURE For EGR valve removal and installation proce- dures, refer to FU section. <Ref. to FU(H4SO)-36, EGR Valve.> EC(H4SO)-5...
Page 202 CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Canister A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the two clamps which hold the two can- ister hoses, and then disconnect the three evapo- ration hoses from canister. EC-00012 3) Remove the canister from body. EC-00013 B: INSTALLATION Install in the reverse order of removal.
Page 203 PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Purge Control Solenoid Valve B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00009 EC-00014 2) Disconnect the connector and hoses from the...
Page 204 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Remove the canister from body. <Ref. to EC(H4SO)-6, REMOVAL, Canister.> 3) Remove the two-way valve with bracket as a sin- gle unit from body. EC-00016 4) Remove the two-way valve from bracket.
Page 205 INTAKE (INDUCTION) IN(H4SO) Page General Description ..................2 Air Cleaner Element ..................4 Air Cleaner Case..................5 Air Intake Duct.....................6 Resonator Chamber..................7...
Page 206 GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: COMPONENT (21) (21) (11) (11) (20) (19) (20) (13) (19) (11) (14) (12) (10) (16) (18) (17) (15) IN-00178 IN(H4SO)-2...
Page 207 GENERAL DESCRIPTION INTAKE (INDUCTION) Spacer (11) Clip (21) Clip Bush (12) Air cleaner element Resonator chamber (13) Air cleaner case B Tightening torque: N·m (kgf-m, ft-lb) Cushion (14) Stay LH (MT model) T1: 33 (3.4, 24.6) Air intake duct A (1.6 L and 2.0 L) (15) Stay LH (AT model) T2: 6.5 (0.66, 4.8)
Page 208 AIR CLEANER ELEMENT INTAKE (INDUCTION) 2. Air Cleaner Element A: REMOVAL 1) Remove the air intake duct from air cleaner case. 2) Remove the bolt (A) which secures the air clean- er case to stay. 3) Remove the clip (B) above the air cleaner case. IN-00039 4) Remove the air cleaner element.
Page 209 AIR CLEANER CASE INTAKE (INDUCTION) 3. Air Cleaner Case B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Refer to “COMPONENT” for tightening torque. <Ref. to IN(H4SO)-2, COMPONENT, General De- scription.>...
Page 210 AIR INTAKE DUCT INTAKE (INDUCTION) 4. Air Intake Duct B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Remove the bolt (A) which installs the air intake Refer to “COMPONENT” for tightening torque. duct A on front side of body. <Ref.
Page 211 RESONATOR CHAMBER INTAKE (INDUCTION) 5. Resonator Chamber A: REMOVAL 1) Remove the air intake duct. <Ref. to IN(H4SO)- 6, REMOVAL, Air Intake Duct.> 2) Remove the resonator chamber. IN-00044 B: INSTALLATION Install in the reverse order of removal. NOTE: Refer to “COMPONENT” for tightening torque. <Ref.
Page 212 RESONATOR CHAMBER INTAKE (INDUCTION) IN(H4SO)-8...
Page 213 MECHANICAL ME(H4SO) Page General Description ..................2 Compression .....................26 Idle Speed ....................27 Ignition Timing...................28 Intake Manifold Vacuum................29 Engine Oil Pressure ..................30 Fuel Pressure....................31 Valve Clearance..................32 Engine Assembly ..................35 Engine Mounting ..................42 Preparation for Overhaul................43 V-belt......................44 Crankshaft Pulley ..................47 Timing Belt Cover..................49 Timing Belt Assembly................50 Camshaft Sprocket..................55 Crankshaft Sprocket..................57...
Page 214 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Model 1.6 L 2.0 L 2.5 L Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline Type engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder 87.9 × 65.8 99.5 × 79.0 Bore × Stroke 92 ×...
Page 215 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) 39.378 — 39.478 mm (1.5503 — 1.5542 in) Intake Limit 39.278 mm (1.5464 in) 1.6 L 39.565 —...
Page 216 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) Standard height 201.0 mm (7.91 in) 87.905 — 87.915 mm (3.4608 — 3.4612 in) 1.6 L 87.895 — 87.905 mm (3.4604 — 3.4608 in) 92.005 —...
Page 217 GENERAL DESCRIPTION MECHANICAL Bend twist per 100 mm (3.94 Limit 0.10 mm (0.0039 in) in) in length Connecting Side clearance 0.070 — 0.330 mm (0.0028 — 0.0130 in) Limit 0.4 mm (0.016 in) 0.010 — 0.038 mm (0.0004 — 0.0015 in) 1.6 L 2.0 L Limit...
Page 218 GENERAL DESCRIPTION MECHANICAL Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.020 mm (0.0008 in) or less Crank pin and crank journal Grinding limit 0.250 mm (0.0098 in) 47.984 — 48.000 mm (1.8891 — 1.8898 in) 0.03 mm (0.0012 in) 47.954 — 47.970 mm (1.8879 — 1.8886 in) 1.6 L 0.05 mm (0.0020 in) 47.934 —...
Page 219 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 220 GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT (12) (10) (13) (11) (15) (14) (16) ME-00376 Timing belt cover No. 2 (RH) (10) Belt idler No. 2 Tightening torque: N·m (kgf-m, ft-lb) Timing belt guide (MT model) (11) Camshaft sprocket No. 2 T1: 5 (0.5, 3.6) Crankshaft sprocket (12)
Page 221 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT (10) (19) (14) (15) (16) (13) (10) (18) (17) (11) (19) (12) ME-00186 Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref.
Page 222 GENERAL DESCRIPTION MECHANICAL 3. VALVE ROCKER ASSEMBLY ME-00187 Intake valve rocker arm Rocker shaft support Tightening torque: N·m (kgf-m, ft-lb) Valve rocker nut Intake rocker shaft T1: 5 (0.5, 3.6) Valve rocker adjust screw Exhaust rocker shaft T2: 10 (1.0, 7.2) Spring Exhaust valve rocker arm T3: 25 (2.5, 18.1)
Page 223 GENERAL DESCRIPTION MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEMBLY ME-00760 Exhaust valve Valve spring seat Retainer Intake valve Intake valve oil seal Retainer key Valve guide Valve spring Exhaust valve oil seal ME(H4SO)-11...
Page 224 GENERAL DESCRIPTION MECHANICAL 5. CYLINDER BLOCK (11) (10) (14) (10) (10) (10) (26) (15) (12) (17) (16) (22) (18) (24) (21) (23) (25) (13) (20) (19) FU-01016 Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb) Cylinder block (RH) (15) Oil filter connector T1: 5 (0.5, 3.6)
Page 225 GENERAL DESCRIPTION MECHANICAL 6. CRANKSHAFT AND PISTON (10) (11) (12) (14) (12) (13) (12) (11) (15) (18) (10) (9) (8) (17) (16) (17) (16) ME-00190 ME(H4SO)-13...
Page 226 GENERAL DESCRIPTION MECHANICAL Flywheel (MT model) Circlip (17) Crankshaft bearing #2, #4 Reinforcement (AT model) (10) Connecting rod bolt (18) Crankshaft bearing #5 Drive plate (AT model) (11) Connecting rod Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb) Second ring (13) Connecting rod cap...
Page 227 GENERAL DESCRIPTION MECHANICAL 7. ENGINE MOUNTING ME-00413 Front cushion rubber Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.3, 31.0) T3: 85 (8.7, 63) ME(H4SO)-15...
Page 228 GENERAL DESCRIPTION MECHANICAL C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to • Wear working clothing, including a cap, protec- assembly. tive goggles, and protective shoes during opera- •...
Page 229 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SUBARU Troubleshooting for electrical systems. SELECT MONI- • English: 22771AA030 (Without printer) TOR KIT • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 498267800 CYLINDER •...
Page 230 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498457100 ENGINE STAND Used with ENGINE STAND (499817000). ADAPTER LH ST-498457100 498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos- STOPPER ening and tightening crankshaft pulley bolt, etc. ST-498497100 498547000 OIL FILTER Used for removing and installing oil filter.
Page 231 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398744300 PISTON GUIDE Used for installing piston in cylinder. (2.0 L model) ST-398744300 498747300 PISTON GUIDE Used for installing piston in cylinder. (2.5 L model) ST-498747300 498857100 VALVE OIL Used for press-fitting of intake and exhaust valve SEAL GUIDE guide oil seals.
Page 232 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499037100 CONNECTING Used for removing and installing connecting rod ROD BUSHING bushing. REMOVER & INSTALLER ST-499037100 499057000 TORX PLUS Used for removing flywheel (Dual mass flywheel). ST-499057000 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL •...
Page 233 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587700 CAMSHAFT OIL Used for installing cylinder head plug. SEAL INSTALLER ST-499587700 499097700 PISTON PIN Used for removing piston pin. REMOVER ASSY ST-499097700 499207400 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket.
Page 234 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587100 OIL SEAL Used for installing oil pump oil seal. INSTALLER ST-499587100 499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal. • Used with CAMSHAFT OIL SEAL INSTALLER (499587500). ST-499597000 499597100 CRANKSHAFT •...
Page 235 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767200 VALVE GUIDE Used for removing valve guides. REMOVER ST-499767200 499767400 VALVE GUIDE Used for reaming valve guides. REAMER ST-499767400 499767700 VALVE GUIDE Used for installing valve guide. (Intake side) ADJUSTER ST-499767700 499767800 VALVE GUIDE Used for installing valve guide.
Page 236 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499817100 ENGINE STAND • Stand used for engine disassembly and assem- bly. • Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100). ST-499817100 499977400 CRANKSHAFT Used for stopping rotation of crankshaft pulley PULLEY when loosening and tightening crankshaft pulley WRENCH...
Page 237 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499897200 PISTON CIR- Used for removing and installing piston pin circlip. CLIP PLIERS ST-499897200 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Compression Gauge Used for measuring compression. Tachometer (Secondary pick-up type) Used for measuring idle speed. Timing Light Used for measuring ignition timing.
Page 238 COMPRESSION MECHANICAL 2. Compression A: INSPECTION CAUTION: After warming up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 1) After warming up the engine, turn the ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Lower the fuel pressure.
Page 239 2) Warm up the engine. 3) Stop the engine, and then turn the ignition switch to OFF. 4) When using the SUBARU SELECT MONITOR, refer to the following. <Ref. to ME(H4SO)-16, SPE- CIAL TOOLS, PREPARATION TOOL, General De- scription.>...
Page 240 IGNITION TIMING MECHANICAL 4. Ignition Timing A: INSPECTION CAUTION: After warming up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 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 timing light.
Page 241 INTAKE MANIFOLD VACUUM MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Warm up the engine. 2) Disconnect the brake vacuum hose, and then in- stall the vacuum gauge to hose fitting on manifold. 3) Keep the engine at idle speed, and then read the vacuum gauge indication.
Page 242 ENGINE OIL PRESSURE MECHANICAL 6. Engine Oil Pressure CAUTION: • If the oil pressure is out of specification, A: INSPECTION check the oil pump, oil filter and lubrication 1) Disconnect the ground cable from battery. line. <Ref. to LU(H4SO)-20, INSPECTION, En- gine Lubrication System Trouble in General.>...
Page 243 FUEL PRESSURE MECHANICAL 7. Fuel Pressure NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 A: INSPECTION to 0.2 kg/cm , 1 to 3 psi) higher than standard val- ues during high-altitude operations. WARNING: Before removing the fuel pressure gauge, lower the fuel pressure.
Page 244 VALVE CLEARANCE MECHANICAL 8. Valve Clearance 9) Set the #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley A: INSPECTION clockwise using a socket wrench. NOTE: NOTE: Inspection and adjustment of the valve clearance When arrow mark (A) on the camshaft sprocket should be performed while engine is cold.
Page 245 VALVE CLEARANCE MECHANICAL 12) Similar to measurement procedures used for B: ADJUSTMENT #1 cylinder, measure the cylinder valve clearances NOTE: in the following sequence: #3, #2 and #4 cylinder. Adjustment of the valve clearance should be per- NOTE: formed while engine is cold. •...
Page 246 VALVE CLEARANCE MECHANICAL 3) Ensure the valve clearances are within specifi- cations. 4) Turn the crankshaft two complete rotations until #1 cylinder piston is again set to the top dead cen- ter on compression stroke. 5) Ensure the valve clearances are within specifi- cations.
Page 247 ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly 11) Remove the air intake chamber stay. • MT MODEL A: REMOVAL 1) Set the vehicle on a lift. 2) Open the front hood fully, and then support with the hood stay. 3) Using the refrigerant recovery system, dis- charge refrigerant.
Page 248 ENGINE ASSEMBLY MECHANICAL (3) Engine ground cable (7) Power steering switch connector ME-00206 FU-00878 (4) Engine harness connectors 13) Disconnect the following hoses. (1) Brake booster vacuum hose FU-00826 FU-00879 (5) Generator connector, terminal and A/C compressor connector (2) Heater inlet outlet hose ( B ) ( A ) ME-00208...
Page 249 ENGINE ASSEMBLY MECHANICAL 14) Remove the power steering pump from brack- (6) Place the power steering pump on right side wheel apron. (1) Remove the resonator chamber. (2) Loosen the lock bolt and slider bolt, and then remove the front side V-belt. <Ref. to ME(H4SO)-44, FRONT SIDE BELT, REMOV- AL, V-belt.>...
Page 250 ENGINE ASSEMBLY MECHANICAL 18) Separate the torque converter clutch from drive 21) Support the engine with a lifting device and plate. (AT model) wire ropes. (1) Lower the vehicle. (2) Remove the service hole plug. (3) Remove the bolts which hold the torque converter clutch to drive plate.
Page 251 ENGINE ASSEMBLY MECHANICAL 24) Install the ST to torque converter clutch case. B: INSTALLATION (AT model) 1) Install the front cushion rubbers. ST 498277200 STOPPER SET Tightening torque: 34 N·m (3.5 kgf-m, 25.3 ft-lb) 2) Install the engine onto transmission. (1) Position the engine in engine compartment and align it with transmission.
Page 252 ENGINE ASSEMBLY MECHANICAL 6) Install the pitching stopper. 10) Install the power steering pump on bracket. (1) Install the power steering tank on bracket. Tightening torque: T1: 50 N·m (5.1 kgf-m, 37 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb) FU-00020 (2) Install the power steering pump on bracket, and then tighten the bolts.
Page 253 ENGINE ASSEMBLY MECHANICAL (5) Install the front side V-belt, and adjust it. 14) Connect the following hoses. <Ref. to ME(H4SO)-44, FRONT SIDE BELT, IN- (1) Fuel delivery hose, return hose and evapo- STALLATION, V-belt.> ration hose (6) Install the resonator chamber. (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose Tightening torque:...
Page 254 ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove engine assembly. <Ref. ME(H4SO)-35, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine as- sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; 35 N·m (3.6 kgf-m, 25.8 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.
Page 255 PREPARATION FOR OVERHAUL MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND ME-00221 2) In this section the procedures described under each index are all connected and stated in order.
Page 256 V-BELT MECHANICAL 12.V-belt 4) Remove the belt tensioner. A: REMOVAL 1. FRONT SIDE BELT NOTE: Perform the following procedures 1) to 4) with the engine installed to body. 1) Remove the V-belt cover. ME-00225 B: INSTALLATION NOTE: Wipe off any oil or water on the belt and pulley. 1.
Page 257 V-BELT MECHANICAL 2. REAR SIDE BELT C: INSPECTION 1) Install the belt tensioner. 1. PROCEDURES WITHOUT BELT TEN- 2) Install the belt, and tighten the slider bolt (B) so SION GAUGE as to obtain the specified belt tension. <Ref. to 1) Replace the belts, if cracks, fraying or wear is ME(H4SO)-45, INSPECTION, V-belt.>...
Page 258 V-BELT MECHANICAL 2. PROCEDURES WITH BELT TENSION GAUGE 1) Replace the belts, if cracks, fraying or wear is found. 2) Remove the V-belt cover and reservoir tank. 3) Check the V-belt tension using belt tension gauge and adjust it if necessary by changing the generator installing position and/or idler pulley in- stalling position.
Page 259 CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley 3) Confirm that the tightening angle of crankshaft pulley bolt is 45 degrees or more. If the tightening A: REMOVAL angle of crankshaft pulley bolt is less than 45 de- grees, conduct the following procedures. 1) Remove the V-belt.
Page 260 CRANKSHAFT PULLEY MECHANICAL 2. 2.5 L MODEL 4) Install the A/C belt tensioner. 1) Install the crankshaft pulley. 2) Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH (1) Clean the crankshaft pulley thread using an air gun.
Page 261 TIMING BELT COVER MECHANICAL 14.Timing Belt Cover B: INSTALLATION 1) Install the front timing belt cover. A: REMOVAL Tightening torque: 1) Remove the V-belt. <Ref. to ME(H4SO)-44, RE- 5 N·m (0.5 kgf-m, 3.6 ft-lb) MOVAL, V-belt.> 2) Install the timing belt cover (LH). 2) Remove crankshaft pulley.
Page 262 TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly A: REMOVAL 1. TIMING BELT 1) Remove the V-belt. <Ref. to ME(H4SO)-44, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-47, REMOVAL, Crankshaft Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO)-49, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt guide.
Page 263 TIMING BELT ASSEMBLY MECHANICAL 7) Remove the belt idler No. 2. B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUST- ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly; CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down.
Page 264 TIMING BELT ASSEMBLY MECHANICAL 2) Install the automatic belt tension adjuster as- 2. TIMING BELT sembly. 1) Preparation for the installation of automatic belt Tightening torque: tension adjuster assembly. <Ref. to ME(H4SO)-51, AUTOMATIC BELT TENSION ADJUSTER AS- 39 N·m (4.0 kgf-m, 28.9 ft-lb) SEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>...
Page 265 TIMING BELT ASSEMBLY MECHANICAL 4) Install the belt idler (No. 2). (2) Check and adjust the clearance between timing belt and timing belt guide by using thick- Tightening torque: ness gauge. 39 N·m (4.0 kgf-m, 28.9 ft-lb) Clearance: 1.0 ± ± ± ± 0.5 mm (0.039 ± ± ± ± 0.020 in) ME-00235 5) After ensuring that the marks on timing belt and ME-00246...
Page 266 TIMING BELT ASSEMBLY MECHANICAL C: INSPECTION • Press the adjuster rod as far as the end sur- face of the cylinder. Do not press the adjuster 1. TIMING BELT rod into the cylinder. Doing so may damage the cylinder. 1) Check the timing belt teeth for breaks, cracks, 4) Measure the extension of rod beyond the body.
Page 267 CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install the camshaft sprocket No. 1. To lock the A: REMOVAL camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET 1. REMOVAL WRENCH 1) Remove the V-belt. <Ref. to ME(H4SO)-44, RE- Tightening torque: MOVAL, V-belt.> 78 N·m (8.0 kgf-m, 57.9 ft-lb) 2) Remove crankshaft...
Page 268 CAMSHAFT SPROCKET MECHANICAL 7) Install the V-belt. <Ref. to ME(H4SO)-44, IN- STALLATION, V-belt.> C: INSPECTION 1) Check the sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprock- et and key. 3) Check the camshaft sprocket notch for sensor for damage and contamination of foreign matter.
Page 269 CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket B: INSTALLATION 1) Install the crankshaft sprocket. A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4SO)-44, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-47, REMOVAL, Crankshaft Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO)-49, REMOVAL, Timing Belt Cover.>...
Page 270 VALVE ROCKER ASSEMBLY MECHANICAL 18.Valve Rocker Assembly B: INSTALLATION 1) Installation of valve rocker assembly A: REMOVAL (1) Temporarily tighten the bolts (a) through (d) 1) Remove the V-belt. <Ref. to ME(H4SO)-44, RE- equally as shown in the figure. MOVAL, V-belt.> NOTE: 2) Remove crankshaft...
Page 271 VALVE ROCKER ASSEMBLY MECHANICAL D: ASSEMBLY 2) If oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows greater 1) Install the adjuster screw and nut to valve rocker. amount of wear. 2) Arrange the valve rocker arms, springs and shaft supports in assembly order and insert valve rocker Rocker arm inside diameter: shaft.
Page 272 CAMSHAFT MECHANICAL 19.Camshaft 13) Remove the camshaft cap. (1) Remove the bolts (a) through (b) in alpha- A: REMOVAL betical sequence. 1) Remove the V-belt. <Ref. to ME(H4SO)-44, IN- STALLATION, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-47, REMOVAL, Crankshaft Pulley.> ( a ) 3) Remove the timing belt cover.
Page 273 CAMSHAFT MECHANICAL 16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly. CAUTION: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when re- moving oil seal. B: INSTALLATION 1) Apply a coat of engine oil to the camshaft jour- nals, and then install the camshaft.
Page 274 CAMSHAFT MECHANICAL (6) Tighten the bolts (o) through (v) in alphabet- 7) Install the oil level gauge guide. (LH side only) ical sequence. 8) Install the camshaft position sensor support. (LH side only) Tightening torque: 9) Install the tensioner bracket. 10 N·m (1.0 kgf-m, 7.2 ft-lb) Tightening torque: ( q )
Page 275 CAMSHAFT MECHANICAL C: INSPECTION Model Item Unit: mm (in) 39.485 — 39.585 1. CAMSHAFT (1.5545 — 1.5585) Intake 1) Measure the bend, and repair or replace if nec- Limit 39.385 (1.5506) 2.5 L essary. 39.257 — 39.357 (1.5455 — 1.5495) Exhaust Limit: Limit...
Page 276 CYLINDER HEAD ASSEMBLY MECHANICAL 20.Cylinder Head Assembly 13) Remove the cylinder head gasket. CAUTION: A: REMOVAL Do not scratch the mating surface of cylinder 1) Remove the V-belt. <Ref. to ME(H4SO)-44, RE- head and cylinder block. MOVAL, V-belt.> 14) Similarly, remove the right side cylinder head. 2) Remove crankshaft pulley.
Page 277 CYLINDER HEAD ASSEMBLY MECHANICAL (7) Further tighten all bolts by 80° to 90° in al- C: DISASSEMBLY phabetical sequence shown in figure below. 1) Place the cylinder head on ST. CAUTION: ST 498267800 CYLINDER HEAD TABLE Ensure that the total “re-tightening angle” [in 2) Set the ST on valve spring.
Page 278 CYLINDER HEAD ASSEMBLY MECHANICAL D: ASSEMBLY (11) (12) (10) (13) ME-00281 Valve Retainer (11) Plug Valve guide Retainer key (12) Camshaft cap Valve spring seat Spark plug gasket (13) Valve rocker ASSY Oil seal Camshaft Valve spring (10) Oil seal 1) Installation of valve spring and valve (4) Set the ST on valve spring.
Page 279 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Compress the valve spring, and then fit the 2. INTAKE AND EXHAUST VALVE OIL valve spring retainer key. SEAL Replace the oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of in- take valve and valve seat are reconditioned or in- take valve guide is replaced.
Page 280 CYLINDER HEAD ASSEMBLY MECHANICAL F: ADJUSTMENT 2. VALVE SEAT Inspect the intake and exhaust valve seats, and 1. CYLINDER HEAD then correct the contact surfaces with valve seat 1) Make sure that no crack or other damage exists. cutter if they are defective or when valve guides are In addition to visual inspection, inspect important replaced.
Page 281 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve 1) Check the clearance between valve guide and guides enter the holes in ST1. stem. The clearance can be checked by measuring (2) Insert the ST2 into valve guide and press it the outside diameter of valve stem and the inside down to remove valve guide.
Page 282 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST. oil, in the cylinder, and then insert the ST1 into Gently rotate the reamer clockwise while press- valve guide. Press in until the valve guide upper ing it lightly into valve guide, and return it also ro- end is flush with the upper surface of ST2.
Page 283 CYLINDER HEAD ASSEMBLY MECHANICAL 4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and re- place 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 284 CYLINDER BLOCK MECHANICAL 21.Cylinder Block 12) Remove the bolts (a) and (c) to remove cylinder head. A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely if applicable. 1) Remove intake manifold. <Ref. FU(H4SO)-16, REMOVAL, Intake Manifold.> or <Ref.
Page 285 CYLINDER BLOCK MECHANICAL 21) Removal of oil pan NOTE: (1) Turn the cylinder block to face the #2 and #4 Using STs, remove the flywheel. (2.5 L MT model) piston sides upward. ST1 498497100 CRANKSHAFT STOPPER (2) Remove the bolts which secure the oil pan ST2 499057000 TORX PLUS to cylinder block.
Page 286 CYLINDER BLOCK MECHANICAL ME-00139 Service hole plug Circlip Service hole cover Gasket Piston pin O-ring 27) Remove the service hole cover and service 28) Rotate the crankshaft to bring #1 and #2 pis- hole plugs using hexagon wrench [14 mm (0.55 tons to bottom dead center position, and then re- in)].
Page 287 CYLINDER BLOCK MECHANICAL 29) Draw out the piston pin from #1 and #2 pistons 30) Similarly remove the piston pins from #3 and #4 using ST. pistons. ST 499097700 PISTON PIN REMOVER 31) Remove the bolts which connect the cylinder block on the side of #2 and #4 cylinders.
Page 288 CYLINDER BLOCK MECHANICAL B: INSTALLATION ME-00144 Crankshaft bearing Cylinder block Rear oil seal Crankshaft NOTE: NOTE: Remove oil in the mating surface of bearing and Do not allow fluid packing to jut into O-ring grooves, cylinder block before installation. Also apply a coat oil passages, bearing grooves, etc.
Page 289 CYLINDER BLOCK MECHANICAL 3) Tighten the 10 mm cylinder block connecting 6) Further tighten the RH side bolts (E — J) to 90° bolts in alphabetical sequence shown in the figure. in alphabetical sequence. (LH side) Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) ME-00399 7) Tighten the 8 mm and 6 mm cylinder block con- necting bolts in alphabetical sequence shown in the...
Page 290 CYLINDER BLOCK MECHANICAL 9) Position the top ring gap at (A) or (B) in the fig- 13) Position the upper rail gap at (G) in the figure. ure. 10) Position the second ring gap at 180° on the re- verse side for top ring gap. 180˚...
Page 291 CYLINDER BLOCK MECHANICAL ME-00155 Piston Gasket Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole plug T: 70 (7.0, 50.6) Circlip 15) Installing piston ST3 499017100 PISTON PIN GUIDE (1) Turn the cylinder block to face the #1 and #2 piston side upward.
Page 292 CYLINDER BLOCK MECHANICAL (5) Apply fluid packing around the service hole (6) Install the service hole plug and gasket. plug. NOTE: Use a new gasket. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent ME-00140 ME-00160 ME-00161 Piston Service hole plug Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole cover...
Page 293 CYLINDER BLOCK MECHANICAL 17) Install the water pipe. 23) Install the flywheel or drive plate. To lock the crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N·m (7.3 kgf-m, 52.8 ft-lb) • MT MODEL ME-00300 18) Install the baffle plate. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 19) Install the oil strainer and O-ring.
Page 294 CYLINDER BLOCK MECHANICAL 25) Installation of oil pump (4) Install the oil pump on cylinder block. Be careful not to damage the oil seal during instal- (1) Discard the front oil seal after removal. Re- place with a new one using the ST. lation.
Page 295 CYLINDER BLOCK MECHANICAL (7) Further tighten all bolts by 80° to 90° in al- 32) Install the crankshaft sprocket. <Ref. to phabetical sequence. ME(H4SO)-57, INSTALLATION, Crankshaft Sprocket.> CAUTION: 33) Install camshaft sprocket. <Ref. Ensure that the total “re-tightening angle” [in the former two steps], do not exceed 180°...
Page 296 CYLINDER BLOCK MECHANICAL D: ASSEMBLY ME-00392 Connecting rod bearing Second ring Tightening torque: N·m (kgf-m, ft-lb) Connecting rod Top ring T: 45 (4.6, 33) Connecting rod cap Circlip Oil ring Side mark 1) Apply oil to the surfaces of the connecting rod E: INSPECTION bearings.
Page 297 CYLINDER BLOCK MECHANICAL 2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cyl- inder 1) The cylinder bore size is stamped on cylinder Measure the inner diameter of each cylinder in both block's front upper surface. the thrust and piston pin directions at the heights NOTE: shown in the figure, using a cylinder bore gauge.
Page 298 CYLINDER BLOCK MECHANICAL 4) How to measure the outer diameter of each pis- 5) Calculate the clearance between cylinder and piston. Measure the outer diameter of each piston at the NOTE: height shown in the figure. (Thrust direction) Measurement should be performed at a tempera- NOTE: ture of 20°C (68°F).
Page 299 CYLINDER BLOCK MECHANICAL 3) Make the sure that piston pin can be inserted 4. PISTON RING into piston pin hole with a thumb at 20°C (68°F). 1) If the piston ring is broken, damaged, or worn, or Replace if defective. if its tension is insufficient, or when the piston is re- Standard clearance between piston pin and placed, replace the piston ring with a new one of...
Page 300 CYLINDER BLOCK MECHANICAL 3) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD inder, and then measure the piston ring gap with a 1) Replace the connecting rod, if the large or small thickness gauge. end thrust surface is damaged. 2) Check for bend or twist using a connecting rod Unit: mm (in) aligner.
Page 301 CYLINDER BLOCK MECHANICAL 4) Inspect the connecting rod bearing for scar, • 2.5 L model peeling, seizure, melting, wear, etc. Standard 5) Measure the oil clearance on individual connect- 0.020 — 0.046 mm (0.0008 — 0.0018 in) ing rod bearings by means of plastigauge. If any oil Limit clearance is not within specification, replace the 0.05 mm (0.0020 in)
Page 302 CYLINDER BLOCK MECHANICAL 7) Replacement procedure is as follows. 6. CRANKSHAFT AND CRANKSHAFT (1) Remove the bushing from connecting rod BEARING with ST and press. 1) Clean the crankshaft completely and check for (2) Press the bushing with ST after applying oil cracks by means of red lead check etc., and re- on the periphery of bushing.
Page 303 CYLINDER BLOCK MECHANICAL Unit: mm (in) Crank journal diameter Crank pin diameter #1, #3 #2, #4, #5 1.6 L 2.0 L 2.5 L Journal 59.992 — 60.008 59.992 — 60.008 47.984 — 48.000 51.984 — 52.000 51.984 — 52.000 O.D. (2.3619 —...
Page 304 ENGINE TROUBLE IN GENERAL MECHANICAL 22.Engine Trouble in General A: INSPECTION A — Very often NOTE: B — Sometimes “RANK” shown in the chart refer to the possibility of C — Rarely reason for the trouble in order (“Very often” to “Rarely”) TROUBLE PROBLEM PARTS, ETC.
Page 305 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 4) Engine stalls after initial • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> or <Ref. to combustion. EN(H4SOw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked intake duct •...
Page 306 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> or <Ref. to poor acceleration EN(H4SOw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked intake duct •...
Page 307 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> or <Ref. to idle. EN(H4SOw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked vacuum hose •...
Page 308 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> or <Ref. to tion EN(H4SOw/oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Dirty air cleaner element •...
Page 309 ENGINE NOISE MECHANICAL 23.Engine Noise A: INSPECTION Type of sound Condition Possible cause • Valve mechanism is defective. • Incorrect valve clearance Sound increases as engine Regular clicking sound • Worn valve rocker speed increases. • Worn camshaft • Broken valve spring •...
Page 310 ENGINE NOISE MECHANICAL ME(H4SO)-98...
Page 311 EXHAUST EX(H4SO) Page General Description ..................2 Front Exhaust Pipe..................6 Center Exhaust Pipe ...................9 Rear Exhaust Pipe ..................10 Muffler .......................12...
Page 312 GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT 1. 1.6 L (16) (15) (13) (14) (16) (11) (10) (12) (16) (27) (26) (17) (28) (22) (18) (25) (24) (23) (31) (30) (19) (29) (21) (20) (31) EX-00123 EX(H4SO)-2...
Page 313 GENERAL DESCRIPTION EXHAUST Front exhaust pipe upper cover (15) Muffler (28) Rear catalytic converter upper cover Front exhaust pipe lower cover (16) Cushion rubber Clamp (17) Lower clamp (29) Rear catalytic converter lower cover Front exhaust pipe upper cover LH (18) Center exhaust pipe upper cover Front exhaust pipe lower cover LH...
Page 314 GENERAL DESCRIPTION EXHAUST 2. 2.0 L (16) (15) (13) (14) (16) (11) (10) (17) (16) (28) (27) (18) (29) (23) (19) (26) (25) (24) (12) (31) (20) (30) (22) (21) (12) EX-00124 EX(H4SO)-4...
Page 315 GENERAL DESCRIPTION EXHAUST Front exhaust pipe upper cover (16) Cushion rubber (29) Rear catalytic converter upper cover Front exhaust pipe lower cover (17) Rear exhaust pipe Clamp (18) Lower clamp (30) Rear catalytic converter lower cover Front exhaust pipe upper cover LH (19) Center exhaust pipe upper cover Front exhaust pipe lower cover LH...
Page 316 FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 4) Lift-up the vehicle. 5) Separate the front and center exhaust pipe as- A: REMOVAL sembly and rear exhaust pipe. 1) Disconnect the ground cable from battery. CAUTION: Be careful, the exhaust pipe is hot. •...
Page 317 FRONT EXHAUST PIPE EXHAUST 8) Remove the bolt which installs the front and cen- B: INSTALLATION ter exhaust pipe assembly to hanger bracket. 1) Install the front oxygen (A/F) sensor and the rear oxygen sensor. <Ref. to FU(H4SO)-44, INSTALLA- TION, Front Oxygen (A/F) Sensor.> and <Ref. to FU(H4SO)-46, INSTALLATION, Rear Oxygen Sensor.>.
Page 318 FRONT EXHAUST PIPE EXHAUST 6) Install the under cover. 10) Connect the rear oxygen sensor connector. 7) Tighten the bolts which install the front and cen- ter exhaust pipe assembly to rear exhaust pipe. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) •...
Page 319 CENTER EXHAUST PIPE EXHAUST 3. Center Exhaust Pipe A: REMOVAL 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(H4SO)-6, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
Page 320 Be careful, the exhaust pipe is hot. • 1.6 L EX-00126 B: INSTALLATION 1) Apply a coat of SUBARU CRC to the mating area of cushion rubbers in advance. SUBARU CRC (Part No. 004301003) 2) Install the rear exhaust pipe bracket to cushion EX-00125 rubber.
Page 321 REAR EXHAUST PIPE EXHAUST 4) Install the rear exhaust pipe to center exhaust pipe. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) • 1.6 L EX-00125 • 2.0 L EX-00031 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds.
Page 322 Be careful, the exhaust pipe is hot. 48 N·m (4.9 kgf-m, 35.4 ft-lb) EX-00024 EX-00024 2) Apply a coat of SUBARU CRC to the mating C: INSPECTION area of cushion rubbers in advance. 1) Make sure there are no exhaust leaks from con- SUBARU CRC (Part No.
Page 323 COOLING CO(H4SO) Page General Description ..................2 Radiator Main Fan System................7 Radiator Sub Fan System .................10 Engine Coolant..................14 Water Pump ....................16 Thermostat ....................19 Radiator.....................21 Radiator Cap .....................24 Radiator Main Fan and Fan Motor ............25 Radiator Sub Fan and Fan Motor..............26 Reservoir Tank..................27 Engine Cooling System Trouble in General ..........28...
Page 324 GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Cooling system Electric fan + Forced engine coolant circulation system 1.6 L AT model: Approx. 7.3 (7.71, 6.42) 1.6 L MT model: Approx. 7.4 (7.82, 6.51) 2 (US qt, Imp qt) Total engine coolant capacity 2.0 L and 2.5 L AT model: Approx.
Page 325 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP CO-00001 Water pump ASSY Gasket Tightening torque: N·m (kgf-m, ft-lb) Gasket Thermostat cover T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Heater by-pass hose Thermostat T2: 6.5 (0.66, 4.8) CO(H4SO)-3...
Page 326 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN (12) (10) (15) (11) (13) (24) (16) (17) (16) (14) (18) (21) (16) (16) (16) (23) (19) (20) (16) (22) CO-00221 Radiator lower cushion (12) Radiator sub fan motor (23) Radiator lower bracket Radiator (13) Radiator main fan shroud...
Page 327 GENERAL DESCRIPTION COOLING C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 328 GENERAL DESCRIPTION COOLING D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977400 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. (1.6 L and 2.0 L model) ST-499977400 499977100 CRANK PULLEY Used for stopping rotation of crankshaft pul- WRENCH ley when loosening and tightening crank-...
Page 329 RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR B225 WITH OBD MODEL : 14 WITUOUT OBD MODEL : 3 WITH OBD MODEL : 13 WITUOUT OBD MODEL : 12...
Page 330 RADIATOR MAIN FAN SYSTEM COOLING B: INSPECTION DETECTING CONDITION: • Engine coolant temperature is above 96°C (205°F). • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. Step Check CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 2.
Page 331 RADIATOR MAIN FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 V? Repair the open Repair the open HOLDER 20 A FUSE TERMINAL. circuit in harness circuit in harness Measure the voltage of harness between A/C between 20 A fuse between main fuse relay holder 20 A fuse terminal and chassis...
Page 332 RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 AIR CONDITIONING No.18 AIR CONDITIONING RELAY HOLDER RELAY HOLDER MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR B225 WITH OBD MODEL : 14 WITUOUT OBD MODEL : 3 WITH OBD MODEL : 13 WITUOUT OBD MODEL : 12...
Page 333 RADIATOR SUB FAN SYSTEM COOLING B: INSPECTION NOTE: System for A/C equipped models only. DETECTING CONDITION: Condition (1): • Engine coolant temperature is below 95°C (203°F). • A/C switch is turned ON. • Vehicle speed is below 19 km/h (12 MPH). Condition (2): •...
Page 334 RADIATOR SUB FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 10. Go to step 9. LAY. 1)Turn the ignition switch to ON. 2)Measure the voltage between sub fan relay terminal and chassis ground.
Page 335 RADIATOR SUB FAN SYSTEM COOLING Step Check CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Verify the DTC. Check poor contact in connector between sub nector between sub fan motor contact connector. Repair the trouble fan and ECM. and ECM? cause.
Page 336 Approx. 7.0 2 (7.4 US qt, 6.2 Imp qt) NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. CO(H4SO)-14...
Page 337 The concentration and safe operating temperature necessary amount of coolant with an undiluted so- of the SUBARU coolant is shown in the diagram. lution of SUBARU genuine coolant (concentration Measuring the temperature and specific gravity of 50%).
Page 338 WATER PUMP COOLING 5. Water Pump 7) Remove the belt cover No. 2 (LH). A: REMOVAL 1) Remove the radiator. <Ref. to CO(H4SO)-21, REMOVAL, Radiator.> 2) Remove the V-belts. <Ref. to ME(H4SO)-44, REMOVAL, V-belt.> 3) Remove the timing belt. <Ref. to ME(H4SO)-50, TIMING BELT, REMOV- AL, Timing Belt Assembly.>...
Page 339 WATER PUMP COOLING B: INSTALLATION 5) Install the camshaft sprockets (LH) by using ST. ST 18231AA010 CAMSHAFT SPROCKET 1) Install the water pump onto cylinder block (LH). WRENCH NOTE: NOTE: • Replace the gasket with a new one. Also the CAMSHAFT SPROCKET WRENCH •...
Page 340 WATER PUMP COOLING C: INSPECTION 1) Check the water pump bearing for smooth rota- tion. 2) Check the water pump pulley for abnormalities. 3) Using a dial gauge, measure the impeller runout in thrust direction while rotating the pulley. “Thrust” runout limit: 0.5 mm (0.020 in) CO-00028 4) Check the clearance between impeller and...
Page 341 THERMOSTAT COOLING 6. Thermostat B: INSTALLATION 1) Install the thermostat in water pump, and then in- A: REMOVAL stall the thermostat cover together with a gasket. 1) Set the vehicle on a lift. NOTE: 2) Lift-up the vehicle. • When reinstalling the thermostat, use a new gas- 3) Remove the under cover.
Page 342 THERMOSTAT COOLING C: INSPECTION Replace the thermostat if the valve does not close completely at an ambient temperature or if the fol- lowing test shows unsatisfactory results. Immerse the thermostat and thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve be- gins to open and when the valve is fully opened.
Page 343 RADIATOR COOLING 7. Radiator 7) Disconnect the radiator outlet hose from water pump. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00076 8) Disconnect the ATF cooler hoses from ATF pipe. (AT model) FU-00009 Plug the openings in the hose and radiator with caps in order to prevent ATF from leaking.
Page 344 RADIATOR COOLING 14) Remove the radiator upper brackets. 3) Install the radiator upper brackets, and then tighten the bolts. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) CO-00090 15) Detach the power steering hose from clip on ra- diator. CO-00090 4) Attach the power steering hose to radiator.
Page 345 RADIATOR COOLING 11) Connect the radiator outlet hose. C: INSPECTION 1) Remove the radiator cap, top off radiator, and then attach the tester to radiator in place of cap. CO-00076 12) Connect the connectors to radiator main fan CO-00094 motor (A) and sub fan motor (B). 2) Apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) to the radiator to check if:...
Page 346 RADIATOR CAP COOLING 8. Radiator Cap A: INSPECTION 1) Attach the radiator cap to tester. CO-00044 2) Increase the pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 to 6 seconds. Standard pressure: 93 —...
Page 347 RADIATOR MAIN FAN AND FAN MOTOR COOLING 9. Radiator Main Fan and Fan B: INSTALLATION Install in the reverse order of removal. Motor NOTE: A: REMOVAL • If it is difficult to install the radiator main fan motor 1) Set the vehicle on a lift. assembly, first loosen the bolts which hold the radi- 2) Disconnect the ground cable from battery.
Page 348 RADIATOR SUB FAN AND FAN MOTOR COOLING 10.Radiator Sub Fan and Fan B: INSTALLATION Install in the reverse order of removal. Motor NOTE: A: REMOVAL Refer to COMPONENT for tightening torque. <Ref. 1) Set the vehicle on a lift. to CO(H4SO)-3, COMPONENT, General Descrip- 2) Disconnect the ground cable from battery.
Page 349 RESERVOIR TANK COOLING 11.Reservoir Tank A: REMOVAL 1) Disconnect the overflow hose from the radiator filler neck position. 2) Pressing the pawl (A), remove the reservoir tank by pulling in the direction indicated by the arrow. CO-00226 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Make sure the engine coolant level is between full and low.
Page 350 ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 12.Engine Cooling System Trouble in General A: INSPECTION Trouble Possible cause Corrective action Replenish the engine coolant, inspect for leakage, and a. Insufficient engine coolant repair. b. Loose timing belt Repair or replace the timing belt tensioner. c.
Page 351 LUBRICATION LU(H4SO) 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 352 GENERAL DESCRIPTION LUBRICATION 1. General Description A: SPECIFICATIONS Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 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 353 GENERAL DESCRIPTION LUBRICATION B: COMPONENT (13) (16) (15) (14) (12) (17) (11) (10) (18) (24) (19) (27) (20) (21) (22) (26) (25) (23) LU-00106 Plug (13) Oil pressure switch (25) Drain plug Gasket (14) Oil filler duct (26) Metal gasket Relief valve spring (15) O-ring...
Page 354 GENERAL DESCRIPTION LUBRICATION C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 355 GENERAL DESCRIPTION LUBRICATION D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977400 CRANKSHAFT • Used for stopping rotation of crankshaft pulley PULLEY when loosening and tightening crankshaft pulley WRENCH bolt. • For 1.6 L and 2.0 L models. ST-499977400 499977100 CRANKSHAFT...
Page 356 OIL PRESSURE SYSTEM LUBRICATION 2. Oil Pressure System A: SCHEMATIC BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH COMBINATION METER : 14 : 31 OIL PRESSURE SWITCH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12...
Page 357 OIL PRESSURE SYSTEM LUBRICATION B: INSPECTION Step Check CHECK COMBINATION METER. Does the warning lights go on? Go to step 2. Repair or replace 1)Turn the ignition switch to ON. (engine OFF) the combination 2)Check other warning lights. meter. <Ref. to IDI-4, INSPEC- TION, Combina- tion Meter...
Page 358 ENGINE OIL LUBRICATION 3. Engine Oil B: REPLACEMENT 1) Open the engine oil filler cap for quick draining of A: INSPECTION the engine oil. 1) Park the vehicle on a level surface. 2) Lift up the vehicle. 2) Remove the oil level gauge and wipe it clean. 3) Drain the engine oil by loosening the engine oil 3) Reinsert the level gauge all the way.
Page 359 API classification and SAE viscosity No. designat- ed by SUBARU. NOTE: If the vehicle is used in areas with very high temper-...
Page 360 OIL PUMP LUBRICATION 4. Oil Pump 9) Remove the crankshaft pulley by using ST. ST 499977400 CRANKSHAFT PULLEY A: REMOVAL WRENCH (1.6 L and 2.0 L 1) Disconnect the ground cable from battery. models) ST 499977100 CRANKSHAFT PULLEY WRENCH (2.5 L model) FU-00009 2) Lift-up the vehicle.
Page 361 OIL PUMP LUBRICATION 13) Remove the bolts which install the oil pump B: INSTALLATION onto cylinder block. Install in the reverse order of removal. NOTE: Do the following: If disassembling or inspecting the oil pump, loosen 1) Apply fluid packing to the matching surfaces of the plug of relief valve before removing the oil oil pump.
Page 362 OIL PUMP LUBRICATION C: DISASSEMBLY D: ASSEMBLY Remove the screws which secure the oil pump cov- 1) Install the front oil seal by using ST. er and disassemble oil pump. Inscribe alignment ST 499587100 OIL SEAL INSTALLER marks on the inner and outer rotors so that they can NOTE: be replaced in their original positions during reas- Use a new oil seal.
Page 363 OIL PUMP LUBRICATION E: INSPECTION 3. SIDE CLEARANCE Measure the clearance between the oil pump inner 1. TIP CLEARANCE rotor and pump cover. If clearance exceeds the lim- Measure the tip clearance of rotors. If clearance ex- it, replace the rotor or pump body. ceeds the limit, replace the rotors as a matched set.
Page 364 OIL PAN AND STRAINER LUBRICATION 5. Oil Pan and Strainer 8) Support the engine with a lifting device and wire ropes. A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the front wheels. 3) Disconnect the ground cable from battery. LU-00028 9) Lift-up the vehicle.
Page 365 OIL PAN AND STRAINER LUBRICATION 15) Insert the oil pan cutter blade between the cyl- B: INSTALLATION inder block to oil pan clearance. CAUTION: CAUTION: Before installing the oil pan, clean the sealant Do not use a screwdriver or similar tool in place from oil pan and engine block.
Page 366 OIL PAN AND STRAINER LUBRICATION 4) Tighten the bolts which install the oil pan onto 10) Remove the lifting device and steel cables. engine block. Tightening torque: 5 N·m (0.5 kgf-m, 3.6 ft-lb) LU-00028 11) Install the pitching stopper. Tightening torque: LU-00031 T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 5) Lower the engine onto front crossmember.
Page 367 OIL PAN AND STRAINER LUBRICATION 16) Connect the battery ground cable to battery. FU-00009 17) Fill engine oil. <Ref. to LU(H4SO)-8, INSPEC- TION, Engine Oil.> C: INSPECTION By visual check make sure the oil pan, oil strainer, oil strainer stay and baffle plate are not damaged. LU(H4SO)-17...
Page 368 OIL PRESSURE SWITCH LUBRICATION 6. Oil Pressure Switch B: INSTALLATION 1) Apply fluid packing to the oil pressure switch A: REMOVAL threads. 1) Remove the generator from bracket. <Ref. to Fluid packing: SC(H4SO)-14, REMOVAL, Generator.> THREE BOND 1324 (Part No. 004403007) or 2) Disconnect the terminal from oil pressure switch.
Page 369 ENGINE OIL FILTER LUBRICATION 7. Engine Oil Filter A: REMOVAL 1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH LU-00194 B: INSTALLATION 1) Get a new oil filter and apply a thin coat of engine oil to the seal rubber.
Page 370 ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION 8. Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure 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 371 SPEED CONTROL SYSTEMS SP(H4SO) Page General Description ..................2 Accelerator Pedal..................4 Accelerator Control Cable ................9...
Page 372 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Free play At pedal pad 0 — 4 mm (0 — 0.16 in) Accelerator pedal Stroke At pedal pad 52 — 57 mm (2.05 — 2.24 in) B: COMPONENT 1. LHD MODEL (13) (11) (10)
Page 373 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 2. RHD MODEL (11) (10) SP-00022 Accelerator bracket Spring pin (11) Kick-down switch (AT model) Stopper Accelerator spring Accelerator pedal lever Bushing Tightening torque: N·m (kgf-m, ft-lb) Accelerator pedal spring Clip T1: 12 (1.2, 9.0) Accelerator pedal (10) Accelerator stopper...
Page 374 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 2. Accelerator Pedal • RHD SOHC MODEL A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lock nut from accelerator cable bracket. 3) Separate the accelerator cable from bracket. 4) Remove the accelerator cable end from throttle cam.
Page 375 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS • LHD MODEL 12) Disconnect the accelerator cable stopper (A) from bracket. SP-00018 SP-00010 • RHD MODEL 13) Separate the accelerator cable and bracket. B: INSTALLATION 1) Install in the reverse order of removal. NOTE: •...
Page 376 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS C: DISASSEMBLY • RHD MODEL 1) Remove the clip, and then remove the accelera- tor pedal from bracket. 2) Pull out the spring pin, and then remove the ac- celerator pedal from accelerator pedal lever. •...
Page 377 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS E: INSPECTION F: ADJUSTMENT 1) Check the pedal stroke and free play by operat- 1. ACCELERATOR PEDAL ing the accelerator pedal by hand. 1) Lightly move the pedal pad in lateral direction to 2) If it is not within specified value, adjust it by turn- ensure that pedal deflection is in specified range.
Page 378 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 3) Ensure the kick-down switch operates at the specified value in relation to the stroke of accelera- tor pedal. If it is not within specified value, adjust it by adjust- ing the position of kick-down switch. CAUTION: Be careful not to rotate the kick-down switch.
Page 379 ACCELERATOR CONTROL CABLE SPEED CONTROL SYSTEMS 3. Accelerator Control Cable A: REMOVAL 1) Remove the accelerator pedal. <Ref. to SP(H4SO)-4, REMOVAL, Accelerator Pedal.> 2) Separate the accelerator cable and accelerator pedal. B: INSTALLATION 1) Install in the reverse order of removal. NOTE: •...
Page 380 ACCELERATOR CONTROL CABLE SPEED CONTROL SYSTEMS SP(H4SO)-10...
Page 381 IGNITION IG(H4SO) Page General Description ..................2 Spark Plug....................5 Ignition Coil & Ignitor ASSY ................8 Spark Plug Cord..................10...
Page 382 GENERAL DESCRIPTION IGNITION 1. General Description A: SPECIFICATIONS Item Designation 1.6 L CM12 — 100C Model 2.0 L FH0137 2.5 L 1.6 L HITACHI Manufacturer 2.0 L DIAMOND 2.5 L 0.7 Ω±10% Ignition coil & ignitor 1.6 L ASSY Primary coil resistance 2.0 L 0.73 Ω±10% 2.5 L...
Page 383 GENERAL DESCRIPTION IGNITION B: COMPONENT 1. 1.6 L MODEL IG-00016 Spark plug Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7) Ignition coil & ignitor ASSY T2: 21 (2.1, 15.5) IG(H4SO)-3...
Page 384 GENERAL DESCRIPTION IGNITION 2. 2.0 L AND 2.5 L MODEL IG-00088 Spark plug Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7) Ignition coil & ignitor ASSY T2: 21 (2.1, 15.5) C: CAUTION •...
Page 385 SPARK PLUG IGNITION 2. Spark Plug 4) Remove the spark plugs using spark plug sock- ets. A: REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug NGK: BKR6E* 1.6 L CHAMPION: RC8YC4** NGK: BKR6E-11** (Alternate) 2.0 L NGK: BKR6E*...
Page 386 SPARK PLUG IGNITION 5) Remove the spark plug cords by pulling the boot, C: INSPECTION not cord itself. Check the electrodes and inner and outer ceramic insulator of plugs, noting the type of deposits and the degree of electrode erosion. IG-00021 6) Remove the spark plugs with spark plug sock- IG-00023...
Page 387 SPARK PLUG IGNITION 3) Oil fouled: D: CLEANING Wet black deposits show excessive oil entrance Clean the spark plugs in a sand blast type cleaner. into combustion chamber through worn rings and Avoid excessive blasting. Clean and remove the pistons or excessive clearance between valve carbon or oxide deposits, but do not wear away ce- guides and stems.
Page 388 IGNITION COIL & IGNITOR ASSY IGNITION 3. Ignition Coil & Ignitor ASSY 4) Remove the ignition coil and ignitor ASSY. • 1.6 L MODEL A: REMOVAL 1) Disconnect the ground cable from battery. IG-00083 • 2.0 L and 2.5 L MODEL FU-00009 2) Disconnect the spark plug cords from ignition coil and ignitor ASSY.
Page 389 IGNITION COIL & IGNITOR ASSY IGNITION C: INSPECTION Specified resistance:(2.0 L and 2.5 L model) Using the accurate tester, inspect the following [Primary side] items, and replace if defective. Between terminal No. 1 and No. 2 1) Primary coil resistance 0.73 Ω±...
Page 390 SPARK PLUG CORD IGNITION 4. Spark Plug Cord A: INSPECTION 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 k Ω Ω Ω Ω #2 cord: 7.3 —...
Page 391 STARTING/CHARGING SYSTEMS SC(H4SO) Page General Description ..................2 Starter ......................7 Generator ....................14 Battery.......................20...
Page 392 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATIONS 1. NON-TURBO MODEL Item Designation Type Reduction type Vehicle type 1.6 L AT 2.0 L AT, 2.5 L AT Model M000T30471 M000T30571 M000T20171 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V —...
Page 393 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 2. TURBO MODEL Item Designation Type Reduction type Vehicle type Model 228000 — 9270 M001T20171 Manufacturer DENSO 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 Voltage 11 V...
Page 394 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS B: COMPONENT 1. STARTER • EXCEPT DOHC TURBO MT MODEL (10) (16) (12) (11) (14) (15) (13) SC-00058 Front bracket Internal gear ASSY (13) Brush holder ASSY Sleeve bearing Shaft ASSY (14) Sleeve bearing Lever set Gear ASSY (15) Rear cover...
Page 395 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS • DOHC TURBO MT MODEL (11) (10) (17) (16) (15) (14) (13) (12) SC-00168 Sleeve bearing Internal gear assembly (13) Armature Front bracket Shaft assembly (14) Brush holder assembly Lever set Gear assembly (15) Brush Magnet switch assembly (10) Ball (16)
Page 396 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 2. GENERATOR (12) (11) (10) SC-00144 Pulley Rotor Brush Front cover Bearing (10) Rectifier Ball bearing Stator coil (11) Rear cover Bearing retainer IC regulator with brush (12) Terminal C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running.
Page 397 STARTER STARTING/CHARGING SYSTEMS 2. Starter 5) Disconnect the connector and terminal from starter. A: REMOVAL 1) Disconnect the ground cable from battery. SC-00006 (A) Terminal FU-00009 (B) Connector 2) Remove the air cleaner case. (Non-turbo model) <Ref. to IN(H4SO)-5, REMOVAL, Air Cleaner 6) Remove the starter from transmission.
Page 398 STARTER STARTING/CHARGING SYSTEMS C: DISASSEMBLY 4) Remove the armature and yoke from front brack- et. The ball used as a bearing will come off from the 1. STARTER ASSEMBLY armature end. NOTE: 1) Loosen the nut which holds the terminal M of Before removal of the yoke, put alignment marks switch assembly, and then disconnect the connec- on the yoke and front bracket.
Page 399 STARTER STARTING/CHARGING SYSTEMS 6) Remove the shaft assembly and overrunning 2. BRUSH HOLDER clutch as a unit. NOTE: NOTE: Only the brush holder of turbo MT model starter Note the direction of the lever before removing. can be disassembled. Slightly open the metal fitting while holding the in- sulating plate against the brush holder.
Page 400 STARTER STARTING/CHARGING SYSTEMS E: INSPECTION 4) Armature short-circuit test Check the armature for short-circuit by placing it on 1. ARMATURE a growler tester. Hold an iron sheet against the ar- mature core while slowly rotating armature. A 1) Check the commutator for any sign of burns of short-circuited armature will cause the iron sheet to rough surfaces or stepped wear.
Page 401 STARTER STARTING/CHARGING SYSTEMS 4. BRUSH AND BRUSH HOLDER 5. SWITCH ASSEMBLY 1) Brush length Using a circuit tester (set in “ohm”), check that there is continuity between terminals S and M, and Measure the brush length, and then replace if it is between terminal S and ground.
Page 402 STARTER STARTING/CHARGING SYSTEMS 7. PINION GAP 8. PERFORMANCE TEST 1) Measure the pinion gap while the pinion is pulled The starter should be submitted to performance out as shown in the figure. tests whenever it has been overhauled, to assure its satisfactory performance when installed on the Pinion gap: engine.
Page 403 STARTER STARTING/CHARGING SYSTEMS 2) Load test Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within the specifications. Load test (standards): Voltage/Load 1.6L MT, 2.0L Non-turbo MT, 2.5L MT and 1.6L 7.5 V/8.84 N·m (0.90 kgf-m, 6.5 ft-lb) 2.0L Non-turbo AT, 2.5L AT 7.7 V/16.7 N·m (1.70 kgf-m, 12.3 ft-lb)
Page 404 GENERATOR STARTING/CHARGING SYSTEMS 3. Generator 5) Remove the bolts which install generator onto bracket. A: REMOVAL 1) Disconnect the ground cable from battery. SC-00032 B: INSTALLATION FU-00009 Install in the reverse order of removal. 2) Disconnect the connector and terminal from Tightening torque: generator.
Page 405 GENERATOR STARTING/CHARGING SYSTEMS C: DISASSEMBLY CAUTION: When holding the rotor with a vise, place alumi- 1) Remove the four through-bolts. num plates or wooden pieces on the vise jaws to prevent rotor from damage. ( A ) ( B ) SC-00078 ( C ) ( D )
Page 406 GENERATOR STARTING/CHARGING SYSTEMS 6) Remove the bearing from rotor using a bearing (2) Unsolder the connection between IC regula- puller. tor and rectifier to remove the IC regulator. SC-00046 SC-00085 7) Unsolder connection between rectifier and stator 9) Remove the brush as follows. coil to remove the stator coil.
Page 407 GENERATOR STARTING/CHARGING SYSTEMS 10) Remove the rectifier as follows. D: ASSEMBLY (1) Remove the bolts which secure the rectifier. Assemble in the reverse order of disassembly. 1) Pulling up brush Before assembling, press the brush down into brush holder, and then fix them in that position by passing a [1 mm (0.08 in) dia.
Page 408 GENERATOR STARTING/CHARGING SYSTEMS E: INSPECTION 2. ROTOR 1) Slip ring surface 1. DIODE Inspect the slip rings for contamination or any CAUTION: roughness on the sliding surface. Repair the slip Never use a mega tester (designed for reading ring surface using a lathe or sand paper. high voltage) or any other similar instrument 2) Slip ring outer diameter for this test;...
Page 409 GENERATOR STARTING/CHARGING SYSTEMS 3. STATOR 4. BRUSH 1) Continuity test 1) Measure the length of each brush. If wear ex- ceeds the service limit, replace the brush. Each Inspect the stator coil for continuity between each brush has the service limit mark (A) on it. end of the lead wires.
Page 410 BATTERY STARTING/CHARGING SYSTEMS 4. Battery 1. EXTERNAL PARTS: Check for the existence of dirt or cracks on battery A: REMOVAL case, top cover, vent plugs, and terminal posts. If 1) Disconnect the positive (+) cable after discon- necessary, clean with water and wipe with a dry necting the ground (−) cable of battery.
Page 411 BATTERY STARTING/CHARGING SYSTEMS D: MEASUREMENT 4. QUICK CHARGING WARNING: Quick charging is a method in which the battery is Do not bring an open flame close to the battery charged in a short period of time with a relatively large current by using a quick charger. at this time.
Page 412 BATTERY STARTING/CHARGING SYSTEMS SC(H4SO)-22...
Page 413 Engine Control Module (ECM) I/O Signal ..........23 Engine Condition Data ................26 Transmission Control Module (TCM) I/O Signal ........27 Data Link Connector .................28 OBD-II General Scan Tool ................29 Subaru Select Monitor................31 Read Diagnostic Trouble Code (DTC) ............38 Inspection Mode..................39 Drive Cycle....................44 Clear Memory Mode..................46 Compulsory Valve Operation Check Mode ..........47...
Page 414 Select Monitor or OBD-II general scan tool (DTC).> Go to function indicator switch to ON. step 4. light illuminates, 4)Read the DTC on the Subaru Select Monitor perform diagnos- or OBD-II general scan tool. tics of malfunction indicator light cir- cuit or combination meter.
Page 415 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. AUTOMATIC TRANSMISSION When the DTC about automatic transmission is shown on display, carry out the following basic check. After that, carry out the replacement or re- pair work. 1) ATF level check <Ref. to 4AT-31, Automatic Transmission Fluid.>...
Page 416 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Engine No. Date of sale Fuel brand Date of repair Odometer reading...
Page 417 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST NO. 2 Check the following items about the vehicle's state when malfunction indicator light turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. ❏ Yes/❏ No ❏...
Page 418 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts at the body side grounding point when measuring voltage and resis- A: CAUTION tance inside the passenger compartment. 1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay.
Page 419 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 12) Observe the following cautions when installing 2) Check the condition of the main and other fuses, a radio in MFI equipped models. and harnesses and connectors. Also check for proper grounding. CAUTION: • The antenna must be kept as far apart as pos- 2.
Page 420 TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical systems. ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 421 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. ENGINE • MODULE EN-01397 EN-01398 Engine control module (ECM) Test mode connector Data link connector Malfunction indicator light EN(H4SO)-9...
Page 422 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01399 EN-00156 EN-01149 EN-01150 EN(H4SO)-10...
Page 423 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SENSOR EN-01400 Intake air temperature sensor Engine coolant temperature sen- Knock sensor Manifold absolute pressure sen- Camshaft position sensor Throttle position sensor Crankshaft position sensor EN(H4SO)-11...
Page 424 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 2) EN-00160 EN-00006 EN-00008 EN-00161 EN-00010 EN-00011 EN-00012 EN(H4SO)-12...
Page 425 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-00162 Front oxygen (A/F) sensor Front catalytic converter Rear catalytic converter Rear oxygen sensor EN-00014 EN-00163 EN-00016 EN-00164 EN(H4SO)-13...
Page 426 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01401 EN-01402 Fuel level sensor EN-01403 EN(H4SO)-14...
Page 427 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS EN-01404 Idle air control solenoid valve Air assisted injector solenoid valve EGR valve (1.6 L model) Purge control solenoid valve Ignition coil & ignitor ASSY EN(H4SO)-15...
Page 428 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) (1 ) EN-00249 EN-00250 EN-01595 EN-00251 EN-01590 EN(H4SO)-16...
Page 429 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01405 EN-01406 Inhibitor switch Fuel pump relay Starter Fuel pump Radiator main fan relay Main relay Radiator sub fan relay EN(H4SO)-17...
Page 430 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-00178 EN-01407 EN-01408 EN-01409 EN-00180 EN-00181 EN(H4SO)-18...
Page 431 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. TRANSMISSION • MODULE EN-01410 EN-01411 Transmission control module AT diagnostic indicator light (AT (TCM) (AT model) model) EN(H4SO)-19...
Page 432 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01413 EN-01412 EN-01414 EN(H4SO)-20...
Page 433 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SENSOR EN-00184 EN-00107 EN-00186 EN-00187 EN-00188 Rear vehicle speed sensor (AT Front vehicle speed sensor (AT ATF temperature sensor (AT model) model) model) Front vehicle speed sensor (MT Torque converter turbine speed Brake light switch model) sensor EN(H4SO)-21...
Page 434 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SOLENOID VALVE AND SWITCH (AT MODELS) AT-00334 AT-00335 EN-01415 Shift solenoid valve 1 Low clutch timing solenoid 2-4 brake timing solenoid Shift solenoid valve 2 Lock up duty solenoid Transfer duty solenoid Line pressure duty solenoid 2-4 brake duty solenoid Inhibitor switch •...
Page 435: Rear Oxygen Sensor
ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 B137 B136 EN-00258 Signal (V) Con- Terminal Content nector Note Ignition SW ON Engine ON (Idling) (Engine OFF) −7 to +7 Signal (+) B135 Sensor output waveform...
Page 436 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Terminal Content nector Note Ignition SW ON Engine ON (Idling) (Engine OFF) ON: 10 — 13 ON: 13 — 14 A/C switch B136 — OFF: 0 OFF: 0 Ignition switch B136 10 —...
Page 437 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Terminal Content nector Note Ignition SW ON Engine ON (Idling) (Engine OFF) ON: 0 ON: 0 Small light switch B137 — OFF: 10 — 13 OFF: 13 — 14 ON: 0 ON: 0 Blower fan switch...
Page 438 ENGINE CONDITION DATA ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Content Specified data 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm racing Measuring condition: • After the engine is warmed-up. • Gear position is in “N” or “P” range. •...
Page 439 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL ENGINE (DIAGNOSTICS) 7. Transmission Control Mod- ule (TCM) I/O Signal A: ELECTRICAL SPECIFICATION For electrical specification of TCM I/O signal, refer to 4AT section. <Ref. to 4AT-13, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM) I/O Signal.> EN(H4SO)-27...
Page 440 Subaru Select Monitor. CAUTION: Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Se- lect Monitor, because the circuit for the Subaru Select Monitor may be damaged. 9 10 11 12 13 EN-00037 Terminal No.
Page 441 OBD-II GENERAL SCAN TOOL ENGINE (DIAGNOSTICS) 9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up DTC and freeze frame data. A: OPERATION OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic 1.
Page 442 OBD-II GENERAL SCAN TOOL ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refers to data denoting the operating condition when trouble is sensed by 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 DTC that caused CARB to require freeze frame data storage...
Page 443 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) 10.Subaru Select Monitor 4) Connect the Subaru Select Monitor to data link connector. A: OPERATION (1) Data link connector located in the lower por- tion of instrument panel (on driver's side). 1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit.
Page 444 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) 4. READ CURRENT DATA FOR ENGINE (NORMAL MODE) 1) On «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On «System Selection Menu» display screen, select the {Engine Control System} and press the [YES] key.
Page 445 ON or OFF Air assisted injector solenoid valve signal Assist Air Sol. Valve ON or OFF AT/MT identification terminal AT model ID Signal ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-33...
Page 446 Short term fuel trim #12 On-board diagnostic system OBD System — A/F sensor check A/F sensor — A/F sensor #11 A/F sensor #11 A/F sensor #11 A/F sensor #11 — NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-34...
Page 447 Intake manifold absolute pressure signal Mani. Absolute Pressure mmHg, kPa, inHg or psi Engine speed signal Engine Speed Vehicle speed signal Vehicle Speed km/h or MPH NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-35...
Page 448 When air assist injector solenoid valve signal Assist Air Sol. Valve ON or OFF signal is input. AT/MT identification terminal AT Vehicle ID Signal ON or OFF ON when vehicle is AT. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-36...
Page 449 ON or OFF Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF Automatic transmission diagnosis indicator light AT Diagnosis light ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-37...
Page 450 DTC. A: OPERATION For details concerning DTC, refer to the List of Di- agnostic Trouble Code (DTC). <Ref. to EN(H4SO)- 1. SUBARU SELECT MONITOR (NORMAL 73, List of Diagnostic Trouble Code (DTC).> MODE) NOTE: 1) On «Main Menu» display screen, select the Refer to OBD-II general scan tool manufacturer's {Each System Check} and press the [YES] key.
Page 451 INSPECTION MODE ENGINE (DIAGNOSTICS) 12.Inspection Mode A: OPERATION Carry out trouble diagnosis shown in the following DTC table. When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle. <Ref. to EN(H4SO)-44, Drive Cycle.> Item P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
Page 452 INSPECTION MODE ENGINE (DIAGNOSTICS) Item P0731 Gear 1 Incorrect Ratio P0732 Gear 2 Incorrect Ratio P0733 Gear 3 Incorrect Ratio P0734 Gear 4 Incorrect Ratio P0741 Torque Converter Clutch Circuit Performance or Stuck Off P0743 Torque Converter Clutch Circuit Electrical P0748 Pressure Control Solenoid “A”...
Page 453 12 V or more. 2) Raise the vehicle using a garage jack and place 3) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO)-8, PREPARATION TOOL, General De- on safety stands or drive the vehicle onto free roll- scription.>...
Page 454 INSPECTION MODE ENGINE (DIAGNOSTICS) 7) Connect the Subaru Select Monitor to data link 14) Perform subsequent procedures as instructed connector. on display screen. (1) Data link connector is located in the lower • If trouble still remains in memory, the corre- portion of the instrument panel (on the driver's sponding DTC appears on display screen.
Page 455 INSPECTION MODE ENGINE (DIAGNOSTICS) 5) Start the engine. NOTE: • Ensure the selector lever is placed in “P” position before starting. (AT models) • Depress the clutch pedal when starting engine. (MT models) 6) Using the selector lever or shift lever, turn the “P” position switch and “N”...
Page 456 DRIVE CYCLE ENGINE (DIAGNOSTICS) 13.Drive Cycle A: OPERATION There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check whether they correctly resume their functions by driving in the required drive pattern. 1.
Page 457 DRIVE CYCLE ENGINE (DIAGNOSTICS) 3. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN Vehicle speed km/h (MPH) 96 (60) 65 (40) (Seconds) EN-00195 Idle engine for 1 minute. Decelerate with fully closed throt- Accelerate to 96 km/h (60 MPH) tle to 65 km/h (40 MPH). within 10 seconds.
Page 458 {Clear Memory} and press the [YES] key. 5) When the ‘Done’ and ‘Turn Ignition Switch OFF’ are shown on display screen, turn the ignition switch to OFF, and then turn the Subaru Select Monitor to OFF. NOTE: • After the memory has been cleared, the idle air control solenoid valve must be initialized.
Page 459 COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 15.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link connector. Check Mode (1) Data link connector is located in the lower portion of instrument panel (on driver’s side). A: OPERATION 1) Prepare the Subaru Select Monitor kit.
Page 460 COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 13) Pressing the [NO] key completes the compul- sory operation check mode. The display will then return to the «Actuator ON/OFF Operation» screen. • A list of support data is shown in the following ta- ble.
Page 461 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) 16.Malfunction indicator light A: PROCEDURE 1. Activation of malfunction indicator light. <Ref. to EN(H4SO)-50, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Mal- function indicator light.> ↓ 2. Malfunction indicator light does not come on. <Ref. to EN(H4SO)-51, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON., Malfunction indicator light.>...
Page 462 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) B: ACTIVATION OF MALFUNCTION 4) When the ignition switch is turned to ON (engine off) or to “START” with test mode connector con- INDICATOR LIGHT nected, the malfunction indicator light blinks at a 1) When the ignition switch is turned to ON (engine cycle of 3 Hz.
Page 463 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON. • DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • TROUBLE SYMPTOM: • When the ignition switch is turned ON (engine OFF), malfunction indicator light does not come on. •...
Page 464: Engine Control Module (Ecm)
MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) Step Check CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair connection Check the ECM connector connection. connected? <Ref. to of ECM connector. FU(H4SO)-48, Engine Control Module (ECM).> CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5.
Page 465 • The malfunction indicator light circuit is shorted. • TROUBLE SYMPTOM: • Although malfunction indicator light comes on when the engine runs, DTC is not shown on Subaru se- lect monitor or OBD-II general scan tool display. • WIRING DIAGRAM:...
Page 466 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK AT A CYCLE OF 3 HZ. • DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • Test mode connector circuit is in open. • TROUBLE SYMPTOM: •...
Page 467 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) Step Check CHECK STATUS OF MALFUNCTION INDI- Dose the malfunction indicator Go to step 2. Repair the mal- CATOR LIGHT. light illuminate? function indicator 1)Turn the ignition switch to OFF. light circuit. <Ref. 2)Disconnect the test mode connector. to EN(H4SO)-51, 3)Turn the ignition switch to ON.
Page 468 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING AT A CYCLE OF 3 • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • Malfunction indicator light blinks at a cycle of 3 Hz when the ignition switch is turned to ON. •...
Page 469 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) Step Check CHECK TEST MODE CONNECTOR. Dose the malfunction indicator Go to step 2. System is in good 1)Disconnect the test mode connector. light blink? order. 2)Turn the ignition switch to ON. NOTE: Malfunction indica- tor light blinks at a cycle of 3 Hz when test mode connec-...
Page 470 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 17.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN(H4SO)-59, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Fail- ure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO)-62, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
Page 471 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-39, OPERATION, Inspec- tion Mode.>. •...
Page 472 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK BATTERY. Is the voltage more than 12 V? Go to step 2. Charge or replace Check the battery voltage. the battery. CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 3. Go to step 4.
Page 473 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH. Is the resistance less than 1 Repair open or Replace the inhibi- Ω? 1)Place the select lever in the “P” or “N” range. ground short cir- tor switch. <Ref. to 2)Measure the resistance between inhibitor cuit in harness 4AT-48, Inhibitor...
Page 474 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-39, OPERATION, Inspec- tion Mode.>.
Page 475 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Repair open circuit Ω? 1)Disconnect the connector from ECM. in harness 2)Measure the resistance of harness between between ECM ECM and chassis ground.
Page 476 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair open or 1)Connect the main relay connector. control system. ground short cir- 2)Turn the ignition switch to ON. <Ref.
Page 477 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-39, OPERATION, Inspec- tion Mode.>. •...
Page 478 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3. Repair harness NITION COIL & IGNITOR ASSY. and connector. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from ignition coil &...
Page 479 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 7. Repair harness Ω? NITION COIL & IGNITOR ASSY CONNEC- and connector. TOR. NOTE: 1)Turn the ignition switch to OFF. In this case, repair 2)Disconnect the connector from ECM.
Page 480 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) E: FUEL PUMP CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-39, OPERATION, Inspec- tion Mode.>. •...
Page 481 CIRCUIT, Diag- nostics for Engine NOTE: Starting Failure.> Fuel pump operation can also be executed us- ing Subaru Select Monitor. For the procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN(H4SO)- 47, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP.
Page 482 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 7. Replace the fuel Ω? 1)Disconnect the connectors from fuel pump pump relay. <Ref. relay and main relay. to FU(H4SO)-50, 2)Remove the fuel pump relay and main relay Fuel Pump...
Page 483 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-39, OPERATION, Inspec- tion Mode.>.
Page 484 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 V? Go to step 3. Repair harness INJECTOR. and connector. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from #1 cylinder In this case, repair fuel injector.
Page 485 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 18.List of Diagnostic Trouble Code (DTC) A: LIST Item Index P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H4SO)-79, DTC P0030 — HO2S HEATER CONTROL CIRCUIT Sensor 1) (BANK 1 SENSOR 1) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
Page 486 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0129 Atmospheric Pressure Sensor Circuit <Ref. to EN(H4SO)-122, DTC P0129 — ATMOSPHERIC PRESSURE SEN- Range/Performance SOR CIRCUIT RANGE/PERFORMANCE —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0130 Sensor Circuit (Bank 1 Sensor 1) <Ref.
Page 487 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0400 Exhaust Gas Recirculation Flow <Ref. to EN(H4SO)-164, DTC P0400 — EXHAUST GAS RECIRCULATION FLOW —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0420 Catalyst System Efficiency Below <Ref. to EN(H4SO)-167, DTC P0420 — CATALYST SYSTEM EFFICIENCY Threshold (Bank 1) BELOW THRESHOLD (BANK 1) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
Page 488 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0703 Torque Converter/Brake Switch “B” <Ref. to EN(H4SO)-213, DTC P0703 — TORQUE CONVERTER/BRAKE Circuit SWITCH “B” CIRCUIT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0705 Transmission Range Sensor Circuit <Ref.
Page 489 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P1111 Atmospheric Pressure Sensor Circuit <Ref. to EN(H4SO)-234, DTC P1111 — ATMOSPHERIC PRESSURE SEN- Malfunction (High Input) SOR CIRCUIT MALFUNCTION (HIGH INPUT) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1134 A/F Sensor Micro-computer Problem <Ref.
Page 490 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P1518 Starter Switch Circuit Low input <Ref. to EN(H4SO)-249, DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1560 Back-up Voltage Circuit Malfunction <Ref.
Page 491 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 19.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0030 — HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 492 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- circuit in harness TOR. between ECM and 1)Start the engine and warm-up engine.
Page 493 13 14 15 16 EN-01421 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Go to step 2. Go to step 5. tor or OBD-II general scan tool display DTC P0031 and P0037 at the same time?
Page 494 Go to step 5. 1)Start the engine. tact in connector. 2)Read the data of front oxygen (A/F) sensor NOTE: heater current using Subaru Select Monitor or In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
Page 495 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 10 Repair harness Replace the front Ω? 1)Turn the ignition switch to OFF. and connector. oxygen (A/F) sen- 2)Measure the resistance between front oxy- sor.
Page 496 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC P0032 — HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 497 Module (ECM).> connector. 3)Turn the ignition switch to ON. 4)Read the data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 498 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) D: DTC P0037 — HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 499 Is the current more than 0.2 A? Repair the con- Go to step 3. 1)Start the engine. nector. 2)Read the data of rear oxygen sensor heater NOTE: current using Subaru Select Monitor or OBD-II In this case, repair general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
Page 500 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 V? Go to step 7. Repair power sup- GEN SENSOR. ply line. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from rear oxygen In this case, repair...
Page 501 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) E: DTC P0038 — HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 502 Engine Control nector. Module (ECM).> 3)Turn the ignition switch to ON. 4)Read the data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 503 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC P0066 — AIR ASSISTED INJECTOR CONTROL CIRCUIT OR CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 504 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair poor con- Go to step 2. 1)Turn ignition switch to ON. tact in ECM con- 2)Measure voltage between ECM and chassis nector.
Page 505 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC P0067 — AIR ASSISTED INJECTOR CONTROL CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 506 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change by Repair battery Contact with your Measure voltage between ECM and chassis shaking the ECM harness and short circuit in har- Subaru distributor ground. connector? ness between service. Connector & terminal ECM and air assist NOTE: (B134) No.
Page 507 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC P0107 — MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRES- SURE CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 508 Go to step 2. 1)Start the engine. than 13.3 kPa (100 mmHg, 2)Read the data of intake manifold absolute 3.94 inHg)? pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 509 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN MANIFOLD Is the voltage more than 4.5 V? Go to step 8. Repair open circuit ABSOLUTE PRESSURE SENSOR AND ECM in harness CONNECTOR. between ECM and 1)Turn the ignition switch to OFF.
Page 510 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC P0108 — MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRES- SURE CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 511 Go to step 2. 1)Start the engine. than 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: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 512 CONNECTOR. 35.29 inHg)? ness between sure sensor. <Ref. 1)Turn the ignition switch to OFF and Subaru ECM and mani- to FU(H4SO)-33, Select Monitor or the OBD-II general scan tool fold absolute pres- Manifold Absolute switch to OFF.
Page 513 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) J: DTC P0111 — INTAKE AIR TEMPERATURE CIRCUIT RANGE/PERFOR- MANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 514 1)Start the engine and warm it up completely. (203°F)? sensor. <Ref. to of Diagnostic 2)Measure the engine coolant temperature FU(H4SO)-34, Trouble Code using Subaru Select Monitor or OBD-II general Intake Air Temper- (DTC)”. <Ref. to scan tool. ature Sensor.> EN(H4SO)-73, List of Diagnostic...
Page 515 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) K: DTC P0112 — INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 516 1)Start the engine. more than 120°C (248°F)? tact. 2)Read the data of intake air temperature sen- NOTE: sor signal using Subaru Select Monitor or the In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
Page 517 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) L: DTC P0113 — INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 518 −40°C (−40°F)? 1)Start the engine. tact. 2)Read the data of intake air temperature sen- NOTE: sor signal using Subaru Select Monitor or the In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
Page 519 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5 Replace the intake Repair harness Ω? TEMPERATURE SENSOR AND ECM CON- air temperature and connector. NECTOR. sensor. <Ref. to NOTE: 1)Turn the ignition switch to OFF.
Page 520 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) M: DTC P0117 — ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Hard to start • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 521 Repair poor con- 1)Start the engine. ture more than 150°C (302°F)? tact. 2)Read the data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor or In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
Page 522 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC P0118 — ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Hard to start • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 523 Repair poor con- ture less than −40°C (−40°F)? 1)Start the engine. tact. 2)Read the data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor or In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
Page 524 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair harness Ω? COOLANT TEMPERATURE SENSOR AND engine coolant and connector. ECM CONNECTOR. temperature sen- NOTE: 1)Turn the ignition switch to OFF. sor.
Page 525 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC P0121 — THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT RANGE/PERFORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 526 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC Replace the throt- P0122 or P0123 tle position sensor. using “List of Diag- <Ref. to nostic Trouble FU(H4SO)-31, Code (DTC)”.
Page 527 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC P0122 — THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIR- CUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 528 1)Start the engine. tion indicator light 2)Read the data of throttle position sensor sig- lights up, the cir- nal using Subaru Select Monitor or OBD-II cuit has returned general scan tool. to a normal condi- tion at this time. A...
Page 529 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair harness THROTTLE POSITION SENSOR CONNEC- and connector. TOR. NOTE: 1)Turn the ignition switch to OFF. In this case, repair 2)Disconnect the connectors from throttle posi- the following:...
Page 530 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0123 — THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 531 1)Start the engine. tion indicator light 2)Read the data of throttle position sensor sig- lights up, the cir- nal using Subaru Select Monitor or OBD-II cuit has returned general scan tool. to a normal condi- tion at this time. A...
Page 532 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) R: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 533 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 534 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) S: DTC P0129 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PER- FORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 535 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) T: DTC P0130 — O SENSOR CIRCUIT (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 536 70°C (160°F). If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3)Read the data of front oxygen (A/F) sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 537 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the front Check exhaust system parts. tem? faulty parts. oxygen (A/F) sen- sor. <Ref. to NOTE: FU(H4SO)-44, Check the following items.
Page 538 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) U: DTC P0131 — O SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 539 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Replace the front Repair ground FRONT OXYGEN (A/F) SENSOR CONNEC- MΩ? oxygen (A/F) sen- short circuit in har- TOR.
Page 540 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) V: DTC P0132 — O SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 541 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 8 V? Replace the front Repair battery FRONT OXYGEN (A/F) SENSOR CONNEC- oxygen (A/F) sen- short circuit in har- TOR.
Page 542 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) W: DTC P0133 — O SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 543 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 544 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) X: DTC P0134 — O SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN- SOR 1) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 545 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair harness Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- and connector. TOR. NOTE: 1)Turn the ignition switch to OFF. In this case, repair 2)Disconnect the connectors from ECM and the following:...
Page 546 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Y: DTC P0137 — O SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 547 1)Warm-up the engine until engine coolant temperature is above 70°C (158°F), and keep the engine speed at 5,000 rpm for two minutes. 2)Read the data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DIS-...
Page 548 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear Check exhaust system parts. tem? faulty parts. oxygen sensor. <Ref. to NOTE: FU(H4SO)-44, Check the following items.
Page 549 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Z: DTC P0138 — O SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 550 70°C (158°F), and imme- diately decrease the engine speed from 5,000 rpm. 2)Read the data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DIS-...
Page 551 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear Check exhaust system parts. tem? faulty parts. oxygen sensor. <Ref. to NOTE: FU(H4SO)-44, Check the following items.
Page 552 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AA:DTC P0139 — O SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 553 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the rear “List of Diagnostic oxygen sensor. Trouble Code <Ref. to (DTC)”. <Ref. to FU(H4SO)-44, EN(H4SO)-73, List Front Oxygen (A/...
Page 554 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AC:DTC P0172 — SYSTEM TOO RICH (BANK 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 555 70 — 100°C (158 — engine coolant 1)Start the engine and warm-up completely. 212°F)? temperature sen- 2)Read the data of engine coolant temperature sor. <Ref. to sensor signal using Subaru Select Monitor or FU(H4SO)-27, OBD-II general scan tool. Engine Coolant Temperature Sen- NOTE: sor.>...
Page 556 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AD:DTC P0301 — CYLINDER 1 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO)-144, DTC P0304 — CYLINDER 4 MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AE:DTC P0302 —...
Page 557 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AG:DTC P0304 — CYLINDER 4 MISFIRE DETECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • Immediately at fault recognition (A misfire which could damage catalyst occurs.) •...
Page 558 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 559 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair poor con- Repair harness 1)Turn the ignition switch to ON. tact in all connec- and connector. 2)Measure the voltage between fuel injector tors in fuel injector NOTE: and engine ground on faulty cylinders.
Page 560 Does the malfunction indicator Go to step 15. Go to step 14. CATOR LIGHT. light illuminate or blink? 1)Clear the memory using Subaru Select Mon- itor. <Ref. to EN(H4SO)-46, Clear Memory Mode.> 2)Start the engine, and drive the vehicle more than 10 minutes.
Page 561 OBD-II general scan tool 2)Read the DTC. display only one DTC? •Subaru Select Monitor <Ref. to EN(H4SO)-31, Subaru Select Moni- tor.> •OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Operation Manual.
Page 562 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and #2 Repair or replace Go to DTC P0171. cylinders? faulty parts. <Ref. to EN(H4SO)-140, NOTE: DTC P0171 — •...
Page 563 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #2 AND #4 CYLINDERS Are there faults in #2 and #4 Repair or replace Go to DTC P0171. cylinders? faulty parts. <Ref. to EN(H4SO)-140, NOTE: DTC P0171 — Check the follow- SYSTEM TOO ing items.
Page 564 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AH:DTC P0327 — KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Poor driving performance •...
Page 565 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than Go to step 2. Repair harness SOR AND ECM CONNECTOR. 700 kΩ? and connector. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from ECM.
Page 566 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0328 — KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Poor driving performance •...
Page 567 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2. Go to step 3. SOR AND ECM CONNECTOR. kΩ? Measure the resistance of harness between ECM connector and chassis ground.
Page 568 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0335 — CRANKSHAFT POSITION SENSOR “A” CIRCUIT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 569 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 CON- 100 kΩ? and connector. NECTOR. NOTE: 1)Turn the ignition switch to OFF. In this case, repair 2)Disconnect the connector from crankshaft the following:...
Page 570 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AK:DTC P0336 — CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/ PERFORMANCE — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 571 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 572 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AL:DTC P0340 — CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 573 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 the ignition switch to OFF. In this case, repair 2)Disconnect the connector from camshaft the following:...
Page 574 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AM:DTC P0341 — CAMSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PER- FORMANCE (BANK 1 OR SINGLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. •...
Page 575 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 576 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 8. Tighten camshaft TION SENSOR. installation bolt tightened position sensor Turn the ignition switch to OFF. securely? installation bolt securely.
Page 577 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AN:DTC P0400 — EXHAUST GAS RECIRCULATION FLOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Poor driving performance on low engine speed • Erroneous idling •...
Page 578 1)Start engine. than 53.3 kPa (400 mmHg, valve, intake mani- 2)Rear the data of intake manifold absolute 15.75 inHg)? fold pressure sen- pressure signal using Subaru Select Monitor or sor and throttle OBD-II general scan tool. body are securely installed. NOTE: •Subaru Select Monitor...
Page 579 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN EGR SOLE- Is the resistance less than 1 Go to step 7. Repair the open Ω? NOID VALVE AND ECM CONNECTOR. circuit in harness 1)Turn the ignition switch to OFF. between ECM and 2)Disconnect the connectors from EGR sole- EGR solenoid...
Page 580 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AO:DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 581 2)Measure the resistance between rear oxy- sor. gen sensor connector and ECM connector. Connector & terminal (B19) No. 3 — (B135) No. 19: CHECK SHIELD HARNESS. Is the shield harness opened? Repair the shield Contact with your harness. Subaru distributor service. EN(H4SO)-169...
Page 582 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AP:DTC P0458 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 583 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if malfunc- Go to step 2. 1)Turn the ignition switch to ON. tion indicator light 2)Measure the voltage between ECM and lights up, the cir- chassis ground.
Page 584 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in purge Repair poor con- Contact with SUB- Check poor contact in purge control solenoid control solenoid valve connec- tact in purge con- ARU distributor valve connector.
Page 585 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AQ:DTC P0459 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 586 ECM chassis ground. connector. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For pro- cedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN(H4SO)-47, Compul- sory Valve Operation Check Mode.> Connector & terminal (B134) No.
Page 587 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AR:DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 588 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 1 2 3 COMBINATION METER 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B135 ECM 1 2 3...
Page 589 •Subaru Select Monitor temporary poor For detailed operation procedure, refer to the contact of the con- “READ CURRENT DATA FOR ENGINE”. nector may be the <Ref. to EN(H4SO)-31, Subaru Select Moni- cause. tor.> NOTE: In this case, repair the following: •...
Page 590 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check Is the resistance 0.5 — 2.5 Ω? Repair poor con- CHECK FUEL LEVEL SENSOR. Replace the fuel 1)Remove the fuel pump assembly. <Ref. to tact in harness level sensor. FU(H4SO)-59, Fuel Pump.>...
Page 591 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AS:DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 592 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 1 2 3 COMBINATION METER 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B135 ECM 1 2 3...
Page 593 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.75 Go to step 3. Even if malfunc- 1)Turn the ignition switch to ON. (Engine OFF) tion indicator light 2)Measure the voltage between ECM connec- lights up, the cir- tor and chassis ground.
Page 594 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace the fuel Replace the com- 54.5 Ω? 1)Remove the fuel pump assembly. <Ref. to level sensor. <Ref. bination meter. FU(H4SO)-59, Fuel Pump.>...
Page 595 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AT:DTC P0483 — COOLING FAN RATIONALITY CHECK — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Occurrence of noise • Overheating CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 596 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH No.17 SBF-4 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR B225 B134 ECM 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 B134 13 14...
Page 597 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele- Check radiator fan vant DTC using and fan motor. “List of Diagnostic <Ref. to Trouble Code CO(H4SO)-25, (DTC)”.
Page 598 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AV:DTC P0503 — VEHICLE SPEED SENSOR INTERMITTENT/ERRATIC/HIGH — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 599 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Moni- Check front vehi- Go to step 3. tor or OBD-II general scan tool cle speed sensor indicate DTC P0720? signal circuit.
Page 600 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AW:DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine is difficult to start. •...
Page 601 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 602 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AX:DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 603 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 604 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AY:DTC P0512 — STARTER REQUEST CIRCUIT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 605 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-4 SBF-1 : AT VEHICLES : MT VEHICLES INHIBITOR SWITCH STARTER MOTOR B136 B136 1 2 3 4 5 6 1 2 3 4 7 8 9 10 11 12 5 6 7 8 10 11 12 13...
Page 606 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Dose the starter motor oper- Repair battery Check starter Turn the ignition switch to ON. ate? short circuit in motor circuit. <Ref. starter motor cir- to EN(H4SO)-59, NOTE: cuit.
Page 607 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AZ:DTC P0519 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 608 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 609 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BA:DTC P0558 — GENERATOR CIRCUIT LOW INPUT — CAUTION: For diagnostic procedure, refer to DTC P0559. <Ref. to EN(H4SO)-197, DTC P0559 — GENERATOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>. EN(H4SO)-197...
Page 610 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BB:DTC P0559 — GENERATOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 611 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN GENERATOR Is the resistance more than 1 Go to step 2. Repair the ground AND ECM CONNECTOR. MΩ? short circuit in har- 1)Turn the ignition switch to OFF. ness between 2)Disconnect the connectors from generator ECM and purge...
Page 612 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BC:DTC P0562 — SYSTEM VOLTAGE LOW — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 613 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage more than 10.8 Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to 2)Idle after warm-up. SC(H4SO)-14, 3)Measure the voltage between generator B Generator.>...
Page 614 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BD: DTC P0563 — SYSTEM VOLTAGE HIGH— • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 615 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage less than 16.2 Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to 2)Idle after warm-up. SC(H4SO)-14, 3)Measure the voltage between generator B Generator.>...
Page 616 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BE:DTC P0565 — CRUISE CONTROL ON SIGNAL — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 617 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN TCM AND Is the resistance more than 1 Go to step 3. Repair short circuit CCM CONNECTOR. MΩ? in harness Measure the resistance of harness between between TCM and TCM and chassis ground.
Page 618 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BF:DTC P0604 — INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 619 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the relevant A temporary poor DTC using the List contact occurs. of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code...
Page 620 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BG:DTC P0691 — COOLING FAN 1 CONTROL CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Radiator fan does not operate properly. •...
Page 621 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH No.17 SBF-4 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR B225 B134 ECM 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 B134 13 14...
Page 622 4)While operating the radiator fan relay, mea- sure voltage between ECM terminal and ground. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN(H4SO)-31, Subaru Select Monitor.> Connector & terminal (B134) No.
Page 623 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BH:DTC P0692 — COOLING FAN 1 CONTROL CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Radiator fan does not operate properly. •...
Page 624 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH No.17 SBF-4 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR B225 B134 ECM 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 B134 13 14...
Page 625 ECM 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(H4SO)-47, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No. 14 (+) — Chassis ground ( − − − − ): (B134) No.
Page 626 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BI: DTC P0703 — TORQUE CONVERTER/BRAKE SWITCH “B” CIRCUIT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 627 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BATTERY No.16 SBF-2 SBF-1 1 : WITH CRUISE CONTROL BRAKE BRAKE LIGHT : WITHOUT CRUISE CONTROL LIGHT SWITCH SWITCH TO STOP LIGHTS 1 2 3 4 10 11 12 14 15 16 17 18 19 20 21 22 23 24...
Page 628 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 3. Repair or replace Ω? BRAKE LIGHT SWITCH CONNECTOR. the harness and 1)Disconnect the connectors from TCM and connector.
Page 629 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BJ:DTC P0731 — GEAR 1 INCORRECT RATIO — NOTE: For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(H4SO)-217, DTC P0734 — GEAR 4 INCOR- RECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> BK:DTC P0732 —...
Page 630 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BM:DTC P0734 — GEAR 4 INCORRECT RATIO — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; excessive tight corner “braking”...
Page 631 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BN:DTC P0741 — TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • No lock-up (after engine warm-up) •...
Page 632 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? the ATF tempera- Check ATF temperature sensor circuit. <Ref. ture sensor circuit.
Page 633 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BO:DTC P0851 — NEUTRAL SWITCH INPUT CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 634 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC Go to step 2. P0705 using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 635 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BP:DTC P0851 — NEUTRAL SWITCH INPUT CIRCUIT LOW (AT VEHICLES) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 636 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Go to step 2. Go to step 4. 1)Turn the ignition switch to ON. 2)Place the shift lever in neutral. 3)Measure the voltage between ECM and chassis ground.
Page 637 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BQ:DTC P0852 — NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT VEHICLES) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 638 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code (DTC).>...
Page 639 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Go to step 8. Repair open circuit Ω? Measure the resistance of harness between in harness inhibitor switch connector and engine ground. between inhibitor Connector &...
Page 640 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BR:DTC P0864 — TCM COMMUNICATION CIRCUIT RANGE/PERFORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 641 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace the TCM. installed on vehicle? line of car phone <Ref. to 4AT-70, or CB system. Transmission Con- trol Module (TCM).>...
Page 642 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BS:DTC P0865 — TCM COMMUNICATION CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 643 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Go to step 2. Even if malfunc- TCM CONNECTOR. tion indicator light 1)Turn the ignition switch to ON. lights up, the cir- 2)Measure the voltage between ECM and cuit has returned...
Page 644 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BT:DTC P0866 — TCM COMMUNICATION CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 645 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 5. Go to step 3. TCM CONNECTOR. Measure the voltage between ECM connector and chassis ground. Connector &...
Page 646 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BU:DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNC- TION (LOW INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 647 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BV:DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNC- TION (HIGH INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 648 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BW:DTC P1134 — A/F SENSOR MICRO-COMPUTER PROBLEM — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 649 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the ECM. the List of Diag- <Ref. to nostic Trouble FU(H4SO)-48, Code (DTC). <Ref. Engine Control to EN(H4SO)-73, Module (ECM).>...
Page 650 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BX: DTC P1137 — O SENSOR CIRCUIT (LAMDA=1) (BANK1 SENSOR1) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 651 If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3)Read the data of front oxygen (A/F) sensor signal during idling using Subaru Select Moni- tor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 652 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BY:DTC P1492 — EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) — NOTE: For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H4SO)-240, DTC P1498 — EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) —, Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
Page 653 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CE:DTC P1498 — EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance. •...
Page 654 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EGR SOLE- Is the voltage more than 10 V? Go to step 2. Repair harness NOID VALVE. and connector. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from EGR sole- In this case, repair...
Page 655 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CF:DTC P1499 — EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance. •...
Page 656 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the DTC Go to step 2. using the List of Diagnostic Trou- ble Code (DTC). <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code...
Page 657 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CG:DTC P1510 — ISC SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) — NOTE: For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(H4SO)-245, DTC P1516 — ISC SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) —, Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
Page 658 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CM:DTC P1516 — ISC SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 659 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2. Repair harness TROL SOLENOID VALVE. and connector. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from idle air con- In this case, repair...
Page 660 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CN:DTC P1517 — ISC SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 661 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the DTC Go to step 2. using the List of Diagnostic Trou- ble Code (DTC). <Ref. to EN(H4SO)-73, List of Diagnostic Trouble Code...
Page 662 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CO:DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 663 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-4 SBF-1 : AT VEHICLES : MT VEHICLES INHIBITOR SWITCH STARTER MOTOR B136 B136 1 2 3 4 5 6 1 2 3 4 7 8 9 10 11 12 5 6 7 8 10 11 12 13...
Page 664 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair harness Check starter Place the inhibitor switch in the “P” or “N” ate when ignition switch is and connector. motor circuit.
Page 665 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CP:DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 666 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 3. Ω? MAIN FUSE BOX CONNECTOR. short circuit in har- 1)Disconnect the connector from ECM. ness between 2)Measure the resistance of harness between ECM connector...
Page 667 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CQ:DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN- PUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 668 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 V? Repair poor con- Go to step 2. 1)Start the engine, and warm-up the engine. tact in ECM con- 2)Turn the ignition switch to OFF.
Page 669 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CR:DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN- PUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO)-46, OP- ERATION, Clear Memory Mode.>...
Page 670 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 V? Go to step 2. Repair battery 1)Start the engine, and warm-up the engine. short circuit in har- 2)Turn the ignition switch to OFF.
Page 671 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CS:DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC- TION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 672 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 2. Go to step 4. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM and chassis ground.
Page 673 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CT:DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC- TION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 674 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 2. Go to step 4. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM and chassis ground.
Page 675 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 20.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO)-92, Engine Trouble in Gen- eral.> Symptom Problem parts 1) Idle air control solenoid valve 2) Manifold absolute pressure sensor 3) Intake air temperature sensor 4) Ignition parts (*1)
Page 676: Automatic Transmission
GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Manifold absolute pressure sensor 4) Engine coolant temperature sensor (*2) 6. Surge 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 8) Throttle position sensor 9) Fuel pump and fuel pump relay...
Page 677 FUEL INJECTION (FUEL SYSTEMS) FU(H4SOw/oOBD) Page General Description ..................2 Throttle Body.....................15 Intake Manifold..................16 Engine Coolant Temperature Sensor............28 Crankshaft Position Sensor...............29 Camshaft Position Sensor.................30 Knock Sensor....................31 Throttle Position Sensor................32 Intake Air Temperature and Manifold Absolute Pressure Sensor .....34 Idle Air Control Solenoid Valve ..............35 Fuel Injector ....................36 Oxygen Sensor ..................41 Engine Control Module (ECM) ..............43...
Page 678 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 1.6 L and 2.0 L 2.5 L 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure...
Page 679 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (20) (23) (22) (13) (20) (14) (16) (10) (21) (15) (19) (18) (21) (11) (18) (12) (17) (19) (19) (18) FU-00906 FU(H4SOw/oOBD)-3...
Page 680 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH Fuel injector pipe (13) Intake air temperature and mani- (23) Accelerator cable bracket fold absolute pressure sensor Fuel injector O-ring (14) O-ring Tightening torque: N·m (kgf-m, ft-lb)
Page 681 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-00907 Gasket Throttle body Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor T1: 1.6 (0.16, 1.2) Idle air control solenoid valve T2: 22 (2.2, 16.2) FU(H4SOw/oOBD)-5...
Page 682 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 Crankshaft position sensor Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) Knock sensor Camshaft position sensor support T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU(H4SOw/oOBD)-6...
Page 683 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK • 1.6 L and 2.0 L MODEL (25) (16) (10) (11) (11) (11) (14) (13) (24) (24) (12) (11) (11) (15) (11) (17) (19) (18) (20) (11) (21) (11) (22) (18) (19) (11) (23)
Page 684 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (11) Clip (21) Fuel pipe ASSY Fuel tank band (12) Evaporation hose B (22) Fuel return hose B Protector RH (13) Joint pipe (23) Evaporation hose E Fuel tank (14) Evaporation hose C (24) Evaporation hose F Fuel pump gasket...
Page 685 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) • 2.5 L MODEL (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (13) (29) (12) (10) (12) (28) (16) (12) (12) (18) (21) (20) (22) (19) (27) (12) (12) (26) (23) (12) (24) (20) (12)
Page 686 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (13) Evaporation hose B (25) Evaporation hose E Fuel tank band (14) Joint pipe (26) Fuel sub level sensor gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
Page 687 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) FU-00910 FU(H4SOw/oOBD)-11...
Page 688 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
Page 689 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (11) (10) (12) FU-00956 Fuel filler pipe ASSY Air vent pipe holder Tightening torque: N·m (kgf-m, ft-lb) Evaporation hose holder Filler pipe packing T: 7.5 (0.76, 5.5) Clip Filler ring Clamp (10) Filler cap...
Page 690 TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical system. ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 691 THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 7) Disconnect the engine coolant hoses from throt- tle body. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00914 8) Remove the bolts which install the throttle body FU-00009 to intake manifold. 2) Remove the air cleaner case.
Page 692 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold NOTE: Do not disconnect the power steering hose. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SOw/ oOBD)-46, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open the fuel flap lid and remove the fuel filler cap.
Page 693 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place the power steering pump and tank on 12) Remove the air cleaner case stay RH and en- right side wheel apron. gine harness bracket, and then disconnect the en- gine harness connectors from bulkhead harness connectors.
Page 694 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect the connector from oil pressure 19) Remove the bolts which hold the intake mani- switch. fold onto cylinder heads. FU-00146 FU-00260 17) Disconnect the connector from camshaft posi- 20) Remove the intake manifold. tion sensor.
Page 695 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3) Connect the connector to camshaft position sen- 7) Connect the connectors to engine coolant tem- sor. perature sensor. FU-00147 FU-00145 4) Connect the connector to oil pressure switch. 8) Install the air cleaner case stay RH and engine harness bracket, and then connect the engine har- ness connectors to bulkhead connectors.
Page 696 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 11) Connect the PCV hose to intake manifold. (3) Tighten the bolts which install the power steering pump on bracket. Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) FU-00141 12) Connect the spark plug cords to the spark plugs.
Page 697 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 17) Connect the connector to the fuel pump relay. C: DISASSEMBLY 1) Disconnect the engine ground cable from intake manifold. FU-00916 18) Connect the battery ground cable to battery. FU-00263 2) Disconnect the connector from ignition coil & ig- nitor ASSY.
Page 698 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 5) Remove the intake air temperature and manifold 10) Remove the fuel pipe protector RH. absolute pressure sensor from intake manifold. FU-00267 FU-00920 11) Disconnect the connectors from fuel injectors. 6) Disconnect the connectors from throttle position sensor and idle air control solenoid valve.
Page 699 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Remove the purge control solenoid valve. 20) Remove the fuel injectors. (1) Remove the fuel injector securing clip. FU-00271 FU-00926 17) Remove the bolt which installs the fuel injector pipe on intake manifold as shown in the figure. (2) Remove the fuel injector while lifting up the fuel injector pipe.
Page 700 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 23) Remove the fuel injector pipe. D: ASSEMBLY 1) Install the fuel pipe assembly (B) and pressure regulator (A), etc. to intake manifold. ( A ) FU-00928 24) Remove the bolt which installs the fuel pipes on ( B ) FU-00930 intake manifold.
Page 701 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 5) Connect the fuel injector pipe LH to fuel hose, 7) Tighten the bolt which installs the fuel injector and then tighten the clamp screw. pipe on intake manifold. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) FU-00927 6) Install the fuel injectors.
Page 702 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 10) Install the purge control solenoid valve. 15) Install the fuel pipe protector RH. Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) FU-00271 11) Connect the hoses to the purge control sole- noid valve. FU-00267 NOTE: 16) Install the fuel pipe protector LH.
Page 703 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 18) Install the throttle body to intake manifold. 23) Install the ignition coil & ignitor ASSY. NOTE: Replace the gasket with a new one. Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) FU-00918 24) Connect the connector to ignition coil & ignitor ASSY.
Page 704 ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Disconnect the ground cable from battery. FU-00288 FU-00009 2) Remove the air intake duct and air cleaner case.
Page 705 CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SOw/oOBD)-3, COMPONENT, General Description.>...
Page 706 CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam- shaft position sensor support as a unit. A: REMOVAL 6) Remove the camshaft position sensor itself. 1) Disconnect the ground cable from battery. FU-00179 FU-00009 B: INSTALLATION...
Page 707 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. • For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SOw/oOBD)-3, COMPONENT, General Description.>...
Page 708 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. For tightening torque, refer to “COMPONENT”. <Ref. to FU(H4SOw/oOBD)-3, COMPONENT, General Description.>...
Page 709 Connector & terminal/Specified voltage (B136) No. 16 — (B136) No. 17/0.45 — 0.55 V [Fully closed.] FU-00933 5) Turn the ignition switch to ON, and Subaru Se- B136 lect Monitor switch to ON. 3 2 1 6) Select the {2. Each System Check} in Main...
Page 710 INTAKE AIR TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Air Temperature and 4) Remove the intake air temperature and manifold absolute pressure sensor. Manifold Absolute Pressure Sensor A: REMOVAL 1) Disconnect the ground cable from battery. FU-00936 B: INSTALLATION Install in the reverse order of removal.
Page 711 IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 10.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL • Always use a new gasket. 1) Disconnect the ground cable from battery. • For tightening torque, refer to “COMPONENT”. <Ref.
Page 712 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 11.Fuel Injector (3) Remove the bolts which install the power steering pump to bracket. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SOw/oOBD)-46, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove the fuel filler cap.
Page 713 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold. (1) Remove the fuel injector securing clip. FU-00267 FU-00939 8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the fuel injector pipe.
Page 714 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 8) Move the washer tank, and secure it away from working area. 1) Release the fuel pressure. <Ref. to FU(H4SOw/ oOBD)-46, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove the fuel filler cap.
Page 715 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12) Remove the bolt which installs the fuel injector (2) Remove the fuel injector while lifting up the pipe to intake manifold. fuel injector pipe. FU-00309 FU-00945 B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Replace the O-rings with new ones.
Page 716 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) FU-00284 FU-00942 Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) FU-00267 FU-00943 2.
Page 717 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) EX-00152 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of oxygen sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the oxygen sensor.
Page 718 OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. FU-00009 FU(H4SOw/oOBD)-42...
Page 719 ENGINE CONTROL MODULE (ECM) FUEL INJECTION (FUEL SYSTEMS) 13.Engine Control Module (ECM) B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. When replacing the ECM, be careful not to use the wrong spec.
Page 720: Main Relay
MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 14.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the front side sill cover of passenger side. 3) Remove the bolt which holds the main relay bracket on body. 4) Disconnect the connectors from main relay.
Page 721: Fuel Pump Relay
FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 15.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the front side sill cover of passenger side . 3) Remove the bolt which holds the fuel pump relay bracket on body.
Page 722: Fuel
FUEL FUEL INJECTION (FUEL SYSTEMS) 16.Fuel 5) Drain fuel from fuel tank. Set a container under the vehicle and remove the A: OPERATION drain plug from fuel tank. • 1.6 L and 2.0 L MODEL 1. RELEASING OF FUEL PRESSURE WARNING: •...
Page 723: Fuel Tank
FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 17.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler hose and air vent hose from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. 1) Set the vehicle on a lift.
Page 724 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Connect the fuel hoses, and then secure them with clips quick connector. <Ref. 1) Support the fuel tank with transmission jack and FU(H4SOw/oOBD)-64, INSTALLATION, Fuel De- push the fuel tank harness into access hole with livery, Return and Evaporation Lines.>...
Page 725 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 10) Connect the connector to the fuel pump relay. FU-00916 C: INSPECTION 1) Make sure there are no cracks, holes, or other damage on fuel tank. 2) Make sure the fuel hoses and fuel pipes are not cracked and the connections are tightened firmly.
Page 726: Fuel Filler Pipe
FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 18.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un- der the vehicle and remove the drain plug from fuel A: REMOVAL tank. • 1.6 L and 2.0 L MODEL WARNING: •...
Page 727 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of ve- fuel filler pipe. hicle. 18) Remove the air vent pipe together with clip from body. FU-00098 13) Disconnect the air vent hose from fuel filler FU-00102...
Page 728 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 6) Insert the fuel filler hose (A) approx. 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe 1) Open the fuel filler flap lid. and tighten the clamp.
Page 729 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 9) Tighten the bolts which hold the evaporation 15) Connect the battery ground cable to battery. hoses onto clip of fuel filler pipe. FU-00009 FU-00098 10) Install the fuel filler pipe protector. FU-00947 11) Install the rear wheel RH.
Page 730: Fuel Pump
FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 19.Fuel Pump 8) Remove the access hole lid. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
Page 731 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 13) Take off the fuel pump assembly from fuel tank. 9) Disconnect the connector from fuel pump. • 2.5 L MODEL 1) Release the fuel pressure. <Ref. to FU(H4SOw/ oOBD)-46, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
Page 732 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION C: INSPECTION Install in the reverse order of removal. Do the fol- Connect the lead harness to connector terminal of lowing: fuel pump and apply battery power supply to check whether the pump operates. NOTE: Always use new gaskets.
Page 733: Fuel Level Sensor
FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Level Sensor • 2.5 L MODEL A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. NOTE: Fuel level sensor is built in the fuel pump assembly. 1) Remove the fuel pump assembly.
Page 734 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Sub Level Sensor 6) Remove the service hole cover. A: REMOVAL NOTE: Fuel sub level sensor is equipped to only 2.5 L model. WARNING: • Place “NO FIRE” signs near working area. •...
Page 735 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) FU-00115 FU(H4SOw/oOBD)-59...
Page 736: Fuel Filter
FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Filter B: INSTALLATION CAUTION: A: REMOVAL • If fuel hoses are damaged at connecting por- WARNING: tion, replace them with new ones. • Place “NO FIRE” signs near working area. • If clamps are badly damaged, replace them •...
Page 737: Fuel Cut Valve
FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Cut Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: WARNING: For tightening torque, refer to “COMPONENT”. • Place “NO FIRE” signs near working area. <Ref. to FU(H4SOw/oOBD)-3, COMPONENT, •...
Page 738: Fuel Damper Valve
FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Damper Valve A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SOw/ oOBD)-46, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Remove the fuel damper valve from fuel return line. FU-00121 B: INSTALLATION Install in the reverse order of removal.
Page 739: Fuel Delivery, Return And Evaporation Lines
FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove the fuel filler cap. Evaporation Lines 4) Remove the floor mat. <Ref. to EI-55, REMOV- AL, Floor Mat.> A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel 1) Set the vehicle on a lift.
Page 740 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate the quick connector on fuel delivery NOTE: line. At this time, two clicking sounds are heard. (1) Clean the pipe and connector, if they are covered with dust. ( A ) (2) Hold the connector (A) and push retainer (B) ( B )
Page 741 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel delivery hose to pipe with an C: INSPECTION overlap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure there are no cracks on fuel pipes and Type A: When the fitting length is specified.
Page 742: Fuel System Trouble In General
FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 26.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to injector Fuel pump will not operate. Inspect connections, especially ground, and tighten ❍ Defective terminal contact. securely.
Page 743 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SOw/oOBD) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................4 Canister.......................5 Purge Control Solenoid Valve ..............6 Two-way Valve....................7...
Page 744: General Description
GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 745: Front Catalytic Converter
FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL The front catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the re- moval procedures are the same as those for center exhaust pipe.
Page 746: Rear Catalytic Converter
REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The rear catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the re- moval procedures are the same as those for center exhaust pipe.
Page 747: Canister
CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Canister B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Lift-up the vehicle. 23 N·m (2.3 kgf-m, 17 ft-lb) 2) Loosen the two clamps which hold the two can- ister hoses, and then disconnect the three evapo- ration hoses from canister.
Page 748: Purge Control Solenoid Valve
PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Purge Control Solenoid Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00009 EC-00014 2) Disconnect the connector and hose of purge...
Page 749: Two-Way Valve
TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Remove the canister from body. <Ref. to EC(H4SOw/oOBD)-5, REMOVAL, Canister.> 3) Remove the two-way valve with bracket as a sin- gle unit from body. EC-00016 4) Remove the two-way valve from bracket.
Page 750 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SOw/oOBD)-8...
Page 751 INTAKE (INDUCTION) IN(H4SOw/oOBD) Page General Description ..................2...
Page 752 GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: SPECIFICATIONS Specification of model without OBD is included in IN(H4SO) section. <Ref. to IN(H4SO)-2, General Description.> IN(H4SOw/oOBD)-2...
Page 753 MECHANICAL ME(H4SOw/oOBD) Page General Description ..................2...
Page 754 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to ME(H4SO)-2, General Description.> ME(H4SOw/oOBD)-2...
Page 755 EXHAUST EX(H4SOw/oOBD) Page General Description ..................2 Front Exhaust Pipe..................6 Center Exhaust Pipe ...................9 Rear Exhaust Pipe ..................10 Muffler .......................11...
Page 756 GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT 1. WITH CATALYTIC CONVERTER (16) (15) (13) (14) (16) (11) (10) (17) (16) (27) (18) (28) (23) (19) (26) (25) (24) (12) (30) (20) (29) (22) (21) (12) EX-00150 EX(H4SOw/oOBD)-2...
Page 757 GENERAL DESCRIPTION EXHAUST Front exhaust pipe upper cover (15) Muffler (28) Rear catalytic converter upper cover Front exhaust pipe lower cover (16) Cushion rubber Clamp (17) Rear exhaust pipe (29) Rear catalytic converter lower cover Front exhaust pipe upper cover (18) Lower clamp Front exhaust pipe lower cover LH...
Page 758 GENERAL DESCRIPTION EXHAUST 2. WITHOUT CATALYTIC CONVERTER (16) (15) (13) (14) (16) (11) (10) (24) (16) (12) (23) (17) (18) (22) (21) (25) (20) (19) (25) EX-00151 EX(H4SOw/oOBD)-4...
Page 759: General Description
GENERAL DESCRIPTION EXHAUST Front exhaust pipe upper cover (12) Rear exhaust pipe cover (23) Center exhaust pipe upper cover Front exhaust pipe lower cover (13) Gasket (24) Rear exhaust pipe Clamp (14) Self-locking nut (25) Gasket Front exhaust pipe upper cover (15) Muffler Front exhaust pipe lower cover LH...
Page 760: Front Exhaust Pipe
FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 5) Remove the under cover. 6) Remove the nuts which hold the front exhaust A: REMOVAL pipe onto cylinder heads. 1) Disconnect the ground cable from battery. CAUTION: Be careful not to pull down the front and center exhaust pipe assembly.
Page 761 FRONT EXHAUST PIPE EXHAUST B: INSTALLATION 7) Tighten the bolts which install the front and cen- ter exhaust pipe assembly to rear exhaust pipe. 1) Install the oxygen sensor. (With catalytic con- verter) <Ref. to FU(H4SOw/oOBD)-41, INSTALLA- Tightening torque: TION, Oxygen Sensor.> 18 N·m (1.8 kgf-m, 13.3 ft-lb) 2) Install the front exhaust pipe to center exhaust pipe.
Page 762 FRONT EXHAUST PIPE EXHAUST 11) Connect the battery ground cable to battery. FU-00009 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EX(H4SOw/oOBD)-8...
Page 763: Center Exhaust Pipe
CENTER EXHAUST PIPE EXHAUST 3. Center Exhaust Pipe A: REMOVAL 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(H4SOw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
Page 764: Rear Exhaust Pipe
EX-00024 Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb) 3) Apply a coat of SUBARU CRC to mating area of cushion rubbers in advance. SUBARU CRC (Part No. 004301003) 4) Remove the rear exhaust pipe bracket from cushion rubber.
Page 765: Muffler
Be careful, the exhaust pipe is hot. 48 N·m (4.9 kgf-m, 35.4 ft-lb) EX-00024 EX-00024 2) Apply a coat of SUBARU CRC to mating area of C: INSPECTION cushion rubbers in advance. 1) Make sure there are no exhaust leaks from con- SUBARU CRC (Part No.
Page 766 MUFFLER EXHAUST EX(H4SOw/oOBD)-12...
Page 767 COOLING CO(H4SOw/oOBD) Page General Description ..................2...
Page 768 GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to CO(H4SO)-2, General Description.> CO(H4SOw/oOBD)-2...
Page 769 LUBRICATION LU(H4SOw/oOBD) Page General Description ..................2...
Page 770 GENERAL DESCRIPTION LUBRICATION 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to LU(H4SO)-2, General Description.> LU(H4SOw/oOBD)-2...
Page 771 SPEED CONTROL SYSTEMS SP(H4SOw/oOBD) Page General Description ..................2...
Page 772 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Specification of model without OBD is the same as that of model with OBD. <Ref. to SP(H4SO)-2, General Description.> SP(H4SOw/oOBD)-2...
Page 773 IGNITION IG(H4SOw/oOBD) Page General Description ..................2...
Page 774 GENERAL DESCRIPTION IGNITION 1. General Description A: SPECIFICATIONS Specifications for model without OBD is included in IG(H4SO) section. <Ref. to IG(H4SO)-2, General Description.> IG(H4SOw/oOBD)-2...
Page 775 STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD) Page General Description ..................2...
Page 776 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATIONS Specification of model without OBD is included in SC(H4SO) section. <Ref. to SC(H4SO)-2, General Description.> SC(H4SOw/oOBD)-2...
Page 777 Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description ..................6 Electrical Components Location..............9 Engine Control Module (ECM) I/O Signal ..........18 Subaru Select Monitor................21 Read Diagnostic Trouble Code (DTC) ............24 Inspection Mode..................26 Clear Memory Mode..................28 Compulsory Valve Operation Check Mode ..........29 Malfunction Indicator Light ................30...
Page 778 Record the DTC. Repair the related 1)Turn the ignition switch to OFF. Monitor indicate DTC? <Ref. to Repair the trouble parts. 2)Connect the SUBARU Select Monitor to data EN(H4SOw/oOBD)-55, LIST, cause. <Ref. to NOTE: link connector. List of Diagnostic Trouble...
Page 779 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. WITHOUT SUBARU SELECT MONITOR CAUTION: • Check the connector while it is connected unless specified otherwise. • Be sure to check again from the beginning in order to prevent secondary trouble caused by repair work.
Page 780 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST No. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer's name Engine No. Date of sale Fuel brand Date of repair Odometer reading...
Page 781 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST No. 2 Check the following items about the vehicle's state when the malfunction indicator light turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. ❏ Yes/❏ No ❏...
Page 782 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use the ECM mounting stud bolt at the body head grounding points when measuring voltage A: CAUTION and resistance inside the passenger compartment. 1) Airbag system wiring harness is routed near en- gine control module (ECM), main relay and fuel pump relay.
Page 783 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 12) Observe the following cautions when installing 2) Check the condition of the main and other fuses, a radio in MFI equipped models. and harnesses and connectors. Also check for proper grounding. CAUTION: • The antenna must be kept as far apart as pos- 2.
Page 784 TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical systems. ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 785 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. MODULE EN-01515 EN-01516 Engine control module (ECM) Read memory connector Data link connector Malfunction indicator light Test mode connector EN(H4SOw/oOBD)-9...
Page 786 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-00156 EN-01517 EN-01518 EN-01519 EN(H4SOw/oOBD)-10...
Page 787 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. SENSOR EN-01520 Engine coolant temperature sen- Throttle position sensor Vehicle speed sensor Knock sensor Intake air temperature and Mani- Crankshaft position sensor fold absolute pressure sensor Camshaft position sensor EN(H4SOw/oOBD)-11...
Page 788 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01521 EN-01522 EN-01523 EN-01524 EN-01526 EN-01525 EN-01527 EN(H4SOw/oOBD)-12...
Page 789 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01528 Oxygen sensor (With catalyst con- verter model) EN-01529 EN(H4SOw/oOBD)-13...
Page 790 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS EN-01530 Purge control solenoid valve Ignition coil and ignitor ASSY CO resistor (Without catalyst con- verter model) Idle air control solenoid valve EN(H4SOw/oOBD)-14...
Page 791 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01531 EN-01532 EN-01534 EN-01533 EN(H4SOw/oOBD)-15...
Page 792 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01535 EN-01536 Fuel pump Main relay Fuel pump relay EN(H4SOw/oOBD)-16...
Page 793 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN-01537 EN-01538 EN-01539 EN(H4SOw/oOBD)-17...
Page 794 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 B136 25 24 26 25 26 25 24 EN-01540 Signal (V) Connec- Terminal Content Ignition SW Note Engine ON tor No. (Idling) ON (Engine OFF) ±6...
Page 795 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) Test mode connector B135 When connected: 0 Read memory connector B135 When connected: 0 Back-up power supply B136 10 —...
Page 796 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note tor No. Engine ON (Idling) ON (Engine OFF) Signal 1 B134 — 1 — 13 Waveform Idle air con- Signal 2 B134 — 1 — 13 Waveform trol sole- Signal 3...
Page 797 1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the SUBARU Select Monitor kit. EN-00040 (A) Power switch 6) Using the SUBARU Select Monitor, call up any DTCs and various data, then record them. EN-00038 2. READ DIAGNOSTIC TROUBLE CODE 2) Connect the diagnosis cable to SUBARU Select (DTC) FOR ENGINE.
Page 798 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) 3. READ CURRENT DATA SHOWN ON DISPLAY. 1) On the «Main Menu» display screen, select the {2. 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 799 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 4. LED OPERATION MODE FOR ENGINE Contents Message LED “ON” requirements Ignition switch signal ON or OFF When ignition switch is turned ON.
Page 800 5) On the «DTC Display» display screen, select the {Current DTC} or {History DTC} and press the [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. • For detailed concerning DTCs, refer to the List of DTC. <Ref. to EN(H4SOw/oOBD)-55, LIST, List of Di- agnostic Trouble Code (DTC).>...
Page 801 READ DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) The malfunction indicator light flashes code corresponding to 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 sec- onds ON) means OK code.
Page 802 (A) Test mode connector this may cause vehicle to jump off free rollers. 2) Connect the SUBARU Select Monitor to data link • In order to prevent the vehicle from slipping connector. <Ref. to EN(H4SOw/oOBD)-9, LOCA- due to vibration, do not place any wooden TION, Electrical Components Location.>...
Page 803 INSPECTION MODE ENGINE (DIAGNOSTICS) NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. • For detailed concerning DTCs, refer to the DTC LIST. <Ref. to EN(H4SOw/oOBD)-55, LIST, List of Diag- nostic Trouble Code (DTC).> • On AWD vehicles, release the parking brake.
Page 804 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 Se- lect Monitor and ignition switch to OFF.
Page 805 COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 10.Compulsory Valve Operation Check Mode A: OPERATION 1) Connect the test mode connector at the lower portion of instrument panel (on the driver’s side). EN-01542 (A) Test mode connector 2) Each valve functions when the ignition switch is turned to ON (engine OFF).
Page 806 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) 11.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. <Ref. to EN(H4SOw/oOBD)-31, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> ↓ 2. Malfunction indicator light does not come on. <Ref. to EN(H4SOw/oOBD)-32, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON., Malfunction Indicator Light.>...
Page 807 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) B: ACTIVATION OF MALFUNCTION 3) When the ignition switch is turned to ON (engine off) or to START with the test mode connector con- INDICATOR LIGHT nected, the malfunction indicator light blinks at a 1) When the ignition switch is turned to ON (engine cycle of 3 Hz.
Page 808 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON. • DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • TROUBLE SYMPTOM: • When the ignition switch is turned ON (engine OFF), the malfunction indicator light does not come on. •...
Page 809 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) Step Check CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair the con- connected? nection of ECM connector. CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5. Repair the har- Ω? TION METER AND ECM CONNECTOR.
Page 810 • The malfunction indicator light circuit is shorted. • TROUBLE SYMPTOM: • Although the malfunction indicator light comes on when engine runs, but DTC is not shown on SUBARU Select Monitor or OBD-II general scan tool display. • WIRING DIAGRAM:...
Page 811 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK AT A CYCLE OF 3 HZ. • DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • Test mode connector circuit is in open. • TROUBLE SYMPTOM: •...
Page 812 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) Step Check CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator Go to step 2. Repair the mal- CATOR LIGHT. light come on? function indicator 1)Turn the ignition switch to OFF. light circuit. <Ref. 2)Disconnect the test mode connector at lower to EN(H4SOw/ portion of instrument panel (on driver’s side).
Page 813 MALFUNCTION INDICATOR LIGHT ENGINE (DIAGNOSTICS) F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING AT A CYCLE OF 3 • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • Even though test mode connector is disconnected, the malfunction indicator light blinks at a cycle of 3 Hz when ignition switch is turned to ON.
Page 814 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 12.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN(H4SOw/oOBD)-39, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(H4SOw/oOBD)-42, ENGINE CONTROL MODULE (ECM) POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
Page 815 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OPER- ATION, Inspection Mode.> •...
Page 816 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4. Go to step 5. TOR. 1)Turn the ignition switch to OFF. 2)Disconnect the connector from starter motor. 3)Turn the ignition switch to START.
Page 817 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than 1 Repair the open Go to step 11. Ω? 1)Turn the ignition switch to OFF. circuit in harness 2)Place the selector lever in the “P” or “N” posi- between starter tion.
Page 818 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: ENGINE CONTROL MODULE (ECM) POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OPER- ATION, Inspection Mode.>...
Page 819 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK MAIN RELAY. Is the resistance less than 10 Go to step 2. Replace the main Ω? 1)Turn the ignition switch to OFF. relay. 2)Remove the main relay. 3)Connect the battery to main relay terminals No.
Page 820 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF MAIN RE- Is the resistance less than 5 Go to step 9. Repair the open Ω? LAY. circuit between 1)Turn the ignition switch to OFF. main relay and 2)Measure the resistance between main relay chassis ground.
Page 821 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of the faulty parts, conduct the Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)- 26, OPERATION, Inspection Mode.> •...
Page 822 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check the fuel Go to step 2. 1)Remove the plug cord cap from each spark inder? pump system. plug. <Ref. to 2)Install new spark plug on the plug cord cap.
Page 823 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 7. Replace the igni- & IGNITOR ASSY. tion coil & ignitor Check if the voltage varies synchronously with ASSY.
Page 824 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 11. Repair the har- Ω? NITION COIL & IGNITOR ASSY CONNEC- ness and connec- TOR. tor. Measure the resistance of harness between NOTE: ECM and ignition coil &...
Page 825 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) E: FUEL PUMP CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OPER- ATION, Inspection Mode.> •...
Page 826 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Go to step 2. PUMP. operating sound? injector circuit. Make sure that the fuel pump is in operation for <Ref.
Page 827 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 7. Replace the fuel Ω? 1)Disconnect the connector from fuel pump pump relay. relay. 2)Remove the fuel pump relay from bracket. 3)Connect the battery to fuel pump relay con- nector terminals No.
Page 828 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only the faulty parts. • After repair or replacement of the faulty parts, conduct the Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)- 26, OPERATION, Inspection Mode.>...
Page 829 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 V? Go to step 4. Repair the har- INJECTOR. ness and connec- 1)Turn the ignition switch to OFF. tor. 2)Disconnect the connector from each cylinder NOTE: fuel injector.
Page 830 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the ground Go to step 8. Ω? FUEL INJECTOR CONNECTOR. short circuit in har- Measure the resistance of harness between ness between ECM and fuel injector connector.
Page 831 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 13.List of Diagnostic Trouble Code (DTC) A: LIST Item Contents of diagnosis Index Crankshaft position sen- • No signal entered from crankshaft <Ref. to EN(H4SOw/oOBD)-57, DTC 11 CRANK- position sensor when starter switch is SHAFT POSITION SENSOR, Diagnostic Proce- dure with Diagnostic Trouble Code (DTC).>...
Page 832 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Contents of diagnosis Index Torque control signal (AT) • Abnormal signal is entered from <Ref. to EN(H4SOw/oOBD)-85, DTC 38 TCM. TORQUE CONTROL SIGNAL, Diagnostic Proce- • Harness connector between ECM dure with Diagnostic Trouble Code (DTC).> and TCM is in short or open.
Page 833 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 14.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11 CRANKSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from crankshaft position sensor when ignition switch is ON. • The harness connector between ECM and crankshaft position sensor is open or shorted. •...
Page 834 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CONDITION OF CRANKSHAFT PO- Are the crankshaft position Go to step 2. Tighten the crank- SITION SENSOR INSTALLATION. sensor installing bolts tight- shaft position sen- ened securely? sor installing bolts securely.
Page 835 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTCs APPEARANCE. Is any other DTC displayed? Proceed with the A temporary poor diagnosis corre- contact. sponding to the DTC. EN(H4SOw/oOBD)-59...
Page 836 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) B: DTC 12 STARTER SWITCH • DIAGNOSIS: • The starter switch signal is abnormal. • The harness connector between ECM and starter switch is open or shorted. • TROUBLE SYMPTOM: • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes.
Page 837 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the voltage more than 10 V? Repair the poor Repair the open or NITION SWITCH CONNECTOR. contact in ECM ground short cir- 1)Turn the ignition switch to OFF.
Page 838 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC 13 CAMSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor. • The harness connector between ECM and camshaft position sensor is open or shorted. •...
Page 839 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CAMSHAFT POSITION SENSOR. Is the resistance 1 — 4 kΩ? Go to step 3. Replace the cam- 1)Remove the camshaft position sensor. shaft position sen- 2)Measure the resistance between connector sor.
Page 840 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR • DIAGNOSIS: • The engine coolant temperature sensor signal is abnormal. • The harness connector between ECM and engine coolant temperature sensor is open or shorted. •...
Page 841 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair the battery Go to step 2. COOLANT TEMPERATURE SENSOR AND short circuit in har- ECM CONNECTOR. ness between 1)Turn the ignition switch to OFF.
Page 842 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Go to step 5. Repair the har- Ω? COOLANT TEMPERATURE SENSOR AND ness and connec- ECM CONNECTOR. tor. 1)Turn the ignition switch to OFF. NOTE: 2)Measure the resistance of harness between In this case, repair...
Page 843 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) E: DTC 22 KNOCK SENSOR • DIAGNOSIS: • The knock sensor signal is abnormal. • The harness connector between ECM and knock sensor is open or shorted. • TROUBLE SYMPTOM: • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes.
Page 844 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 3 V? Go to step 2. Go to step 3. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM connec- tor and chassis ground.
Page 845 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE • DIAGNOSIS: • The idle air control solenoid valve is not in function. • The harness connector between ECM and idle air control solenoid valve is open or shorted. •...
Page 846 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2. Repair the har- TROL SOLENOID VALVE. ness and connec- 1)Turn the ignition switch to OFF. tor.
Page 847 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK AIR BY-PASS LINE. Are foreign particles in the by- Remove the for- Replace the idle 1)Turn the ignition switch to OFF. pass air line? eign particles from air control solenoid 2)Remove the idle air control solenoid valve by-pass air line.
Page 848 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC 26 INTAKE AIR TEMPERATURE SENSOR • DIAGNOSIS: • The intake air temperature sensor signal is abnormal. • The harness connector between ECM and intake air temperature sensor is open or shorted. •...
Page 849 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance 2 — 3 kΩ at Go to step 2. Replace the intake SOR. 20°C (68°F)? air temperature 1)Turn the ignition switch to OFF. sensor.
Page 850 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Contact with your Check poor contact in ECM connector. connector? contact in ECM SUBARU distribu- connector. tor service. NOTE: Inspection by your SUBARU distribu- tor service is re-...
Page 851 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC 31 THROTTLE POSITION SENSOR • DIAGNOSIS: • The throttle position sensor signal is abnormal. • The throttle position sensor is installed abnormally. • The harness connector between ECM and throttle position sensor is open or shorted. •...
Page 852 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? THROTTLE POSITION SENSOR. circuit between 1)Disconnect the connector from ECM and ECM and throttle throttle position sensor.
Page 853 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC 32 OXYGEN SENSOR • DIAGNOSIS: • The oxygen sensor is not in function. • The harness connector between ECM and oxygen sensor is open or shorted. • TROUBLE SYMPTOM: •...
Page 854 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FOR OTHER CAUSES AFFECTING Is CO % more than 2% after Check the fuel Go to step 2. EXHAUST GAS. the engine warm up? system. NOTE: •Check for use of improper fuel. •Check if engine oil or coolant level is extremely low.
Page 855 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR ECM. Do 0.1 and 1 V waveform pat- Go to step 9. Replace the oxy- 1)Turn the ignition switch to OFF. terns alternately appear on the gen sensor.
Page 856 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) J: DTC 33 VEHICLE SPEED SIGNAL • DIAGNOSIS: • The vehicle speed signal is abnormal. • The harness connector between ECM and vehicle speed sensor is open or shorted. • TROUBLE SYMPTOM: •...
Page 857 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 3 V? Go to step 3. Go to step 4. 1)Lift-up the vehicle. 2)Set the oscilloscope probe at ECM connec- tor terminal positive (+) and its ground lead at negative (−).
Page 858 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) K: DTC 35 PURGE CONTROL SOLENOID VALVE • DIAGNOSIS: • The purge control solenoid valve is not in function. • The harness connector between ECM and purge control solenoid valve is open or shorted. •...
Page 859 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION SOUND OF PURGE Does the purge control sole- Go to step 2. Go to step 3. CONTROL SOLENOID VALVE. noid valve produce operating 1)Turn the ignition switch to OFF. sound? 2)Connect the test mode connector at lower portion of instrument panel (on driver’s side).
Page 860 CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Contact with your Check poor contact in purge control solenoid control solenoid valve connec- contact in purge SUBARU distribu- valve connector. tor? control solenoid tor service. valve connector. NOTE:...
Page 861 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) L: DTC 38 TORQUE CONTROL SIGNAL • DIAGNOSIS: • Abnormal signal entered from TCM • The harness connector between ECM and TCM is shorted. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.>...
Page 862 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the ground Go to step 2. Ω? TCM CONNECTOR. short circuit in har- 1)Disconnect the connectors from ECM and ness between TCM.
Page 863 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) M: DTC 45 PRESSURE SENSOR • DIAGNOSIS: • The manifold absolute pressure sensor signal is abnormal. • The harness connector between ECM and manifold absolute pressure sensor is open or shorted. •...
Page 864 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 4.5 — 5.5 V? Go to step 2. Repair the open or MANIFOLD ABSOLUTE PRESSURE SEN- ground short cir- SOR CONNECTOR. cuit in harness 1)Disconnect the connector from manifold between ECM and...
Page 865 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES) • DIAGNOSIS: • The CO resistor signal is abnormal. • The harness connector between ECM and CO resistor is open or shorted. • The CO value is not adjusted to specifications. •...
Page 866 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage 0.5 — 4.5 V? Go to step 3. Go to step 2. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM and chassis ground.
Page 867 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC 51 NEUTRAL POSITION SWITCH (MT MODEL) • DIAGNOSIS: • The neutral position switch signal is abnormal. • The harness connector between ECM and neutral position switch is open or shorted. •...
Page 868 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage 4.5 — 5.5 V in Go to step 3. Go to step 2. 1)Turn the ignition switch to ON. neutral position? 2)Measure the voltage between ECM and chassis ground.
Page 869 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT MODEL) • DIAGNOSIS: • The park/neutral position switch signal is abnormal. • The shift cable is connected abnormally. • The harness connector between ECM/TCM and inhibitor switch is open or shorted. •...
Page 870 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V? Go to step 2. Go to step 3. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM and chassis ground in selector lever “N”...
Page 871 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC 85 CHARGE SYSTEM • DIAGNOSIS: • Power source voltage of the ECM is low or high. • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory and inspection modes. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.>...
Page 872 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage 10.8 V — 16.2 Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to 2)Idle after warm-up. SC(H4SO)-14, 3)Measure the voltage between generator B Generator.>...
Page 873 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 15.General Diagnostic Table A: INSPECTION NOTE: • Malfunction of parts other than those listed is also possible. • The right-hand priority column indicates inspection priority of probable causes of the symptom. Carry out the check starting from A. Symptom Problem parts Priority...
Page 874 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 5. Rough idling 1) Spark plug 2) Manifold absolute 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...
Page 875 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 13. Poor engine revving 1) Pressure regulator 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor 4) Throttle sensor 5) Fuel pump 14. Remarks 1) ECM power supply 2) Manifold absolute pressure sensor 3) Pressure regulator 4) Idle air control solenoid valve 5) Air leak in air intake system...
Page 876 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD)-100...
Page 877 EC(H4DOTC) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4DOTC) MECHANICAL ME(H4DOTC) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4DOTC) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4DOTC)
Page 879 FUEL INJECTION (FUEL SYSTEMS) FU(H4DOTC) Page General Description ..................2 Throttle Body.....................13 Intake Manifold..................14 Engine Coolant Temperature Sensor............28 Crankshaft Position Sensor...............29 Camshaft Position Sensor.................30 AVCS Camshaft Position Sensor..............31 Knock Sensor....................32 Throttle Position Sensor................33 Mass Air Flow and Intake Air Temperature Sensor ........34 Manifold Absolute Pressure Sensor............35 Idle Air Control Solenoid Valve ..............36 Fuel Injector ....................37...
Page 880 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS 60 2 (15.9 US gal, 13.2 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 450 — 677 kPa (4.59 — 6.9 kg/cm , 65.27 — 98.2 psi) Fuel pump More than 130 2 (34.3 US gal, 28.6 Imp gal)/h Discharge flow...
Page 881 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (20) (17) (16) (15) (18) (14) (19) (12) (22) (13) (10) (11) (21) (10) (25) (25) (24) (24) (23) (14) (12) (13) FU-00966 FU(H4DOTC)-3...
Page 882 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Fuel pipe ASSY (13) Insulator (24) Purge hose (Except Australia model) Fuel hose (14) Fuel injector pipe Clip (15) Pressure regulator (25) Tumble generator valve actuator (Except STi model) Purge control solenoid valve (16) Pressure regulator hose Vacuum hose (17)
Page 883 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-00002 Gasket Manifold absolute pressure sensor Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor Gasket T1: 1.6 (0.16, 1.2) Idle air control solenoid valve O-ring T2: 2.8 (0.29, 2.1) Throttle body T3: 22 (2.2, 16.2) FU(H4DOTC)-5...
Page 884 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00003 Crankshaft position sensor AVCS camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) (STi model and Australia model) Knock sensor T1: 6.4 (0.65, 4.7) Camshaft position sensor T2: 24 (2.4, 17.4) FU(H4DOTC)-6...
Page 885 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (29) (13) (12) (10) (12) (28) (16) (12) (12) (18) (21) (20) (22) (19) (27) (12) (12) (26) (23) (12) (24) (20) (12) (25)
Page 886 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (13) Evaporation hose B (25) Evaporation hose E Fuel tank band (14) Joint pipe (26) Fuel sub level sensor gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
Page 887 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) FU-00516 FU(H4DOTC)-9...
Page 888 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
Page 889 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (11) (10) (12) FU-00006 Fuel filler pipe ASSY Air vent pipe (11) Filler cap tether Evaporation hose holder Air vent pipe holder (12) Filler pipe protector Clip Filler pipe packing Clamp Filler ring Tightening torque: N·m (kgf-m, ft-lb)
Page 890 • Be careful not to spill fuel on the floor. moval, installation, disassembly, and replacement. D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical system. ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT ST22771AA030 FU(H4DOTC)-12...
Page 891 THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 5) Disconnect the engine coolant hoses from throt- tle body. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00012 6) Remove the bolts which secure the throttle body FU-00009 to intake manifold. 2) Remove the intercooler.
Page 892 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 11) Remove the coolant filler tank. <Ref. to CO(H4DOTC)-33, REMOVAL, Coolant Filler A: REMOVAL Tank.> 1) Release fuel pressure. <Ref. 12) Remove the power steering pump. FU(H4DOTC)-53, RELEASING OF FUEL PRES- (1) Remove the front side V-belt.
Page 893 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (5) Remove the power steering tank from the 15) Disconnect the brake booster hose. bracket by pulling it upward. FU-00023 FU-00020 16) Disconnect the pressure hose from intake duct. (6) Place the power steering pump on right side wheel apron.
Page 894 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 18) Disconnect the connectors from the engine 22) Disconnect the connector from ignition coil. coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C). FU-00030 23) Disconnect the engine harness fixed by clip (A) FU-00027 from bracket.
Page 895 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 26) Remove the intake manifold. 4) Connect the connector to knock sensor. B: INSTALLATION 1) Install the intake manifold onto cylinder heads. NOTE: Always use new gaskets. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) FU-00028 5) Connect the connector to crankshaft position sensor.
Page 896 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Connect the engine harness with clip (A) to the 11) Connect the engine coolant hoses to throttle bracket. body. FU-00031 FU-00012 9) Connect the engine harness connector to bulk- 12) Connect the emission hose to PCV valve. head harness connectors.
Page 897 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (2) Connect the connector to the power steering 16) Connect the accelerator cable. <Ref. to pump switch. SP(H4SO)-9, INSTALLATION, Accelerator Control Cable.> FU-00017 FU-00011 (3) Install the power steering pump, and then tighten the bolts. 17) Install the intercooler.
Page 898 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) C: DISASSEMBLY 5) Disconnect the engine harness fixed by clip (D) from intake manifold. 1) Remove the fuel pipe protector LH. FU-00038 FU-00968 6) Remove the throttle body from intake manifold. 2) Remove the fuel pipe protector RH. FU-00013 FU-00969 7) Disconnect the connector from fuel injector.
Page 899 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Disconnect the connector from tumble generator 13) Disconnect the evaporation hose from purge valve sensor. (Except STi model) valve. (Except Australia model) FU-00617 FU-00364 10) Disconnect the connector from purge control 14) Remove the two bolts which hold the fuel pipes solenoid valve.
Page 900 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) • RH SIDE 19) Loosen the clamp which holds the front left side fuel hose to injector pipe, and remove the pipe from clamp. FU-00046 FU-00620 20) Remove the fuel injector pipe LH. 21) Remove the bolts which install the fuel pipe on intake manifold.
Page 901 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe, and tighten the clamp screw. NOTE: Replace the gasket with a new one. 1) Install the intake manifold. Tightening torque: 8.25 N·m (0.84 kgf-m, 6.1 ft-lb) FU-00620 6) Install the engine harness to intake manifold.
Page 902 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Tighten the bolts which install the fuel injector 10) Tighten the two bolts which install the fuel pipes pipe onto intake manifold. on the left side of intake manifold. Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 4.9 N·m (0.5 kgf-m, 3.6 ft-lb) •...
Page 903 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 12) Connect the evaporation hose to intake mani- 15) Connect the connector to the purge control so- fold. lenoid valve. FU-00042 FU-00040 13) Install the purge control solenoid valve. 16) Connect the connector to the tumble generator valve sensor.
Page 904 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 19) Install the throttle body to intake manifold. 22) Install the engine ground cable to intake mani- fold. NOTE: Replace the gasket with a new one. Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) FU-00036...
Page 905 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) E: INSPECTION Make sure the fuel pipe and fuel hoses are not cracked and the connections are tightened firmly. FU(H4DOTC)-27...
Page 906 ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 18 N·m (1.8 kgf-m, 13.3 ft-lb) 1) Disconnect the ground cable from battery. FU-00009 2) Remove the generator.
Page 907 CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) FU-00009 FU-00058 2) Remove the bolt which installs the crankshaft position sensor to cylinder block.
Page 908 CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) FU-00009 FU-00060 2) Disconnect the connector from camshaft posi- tion sensor.
Page 909 AVCS CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. AVCS Camshaft Position Sensor A: REMOVAL NOTE: This component is installed to STi and Australia model. 1) Disconnect the ground cable from battery. 2) Remove the intercooler. <Ref. to IN(H4DOTC)- 10, REMOVAL, Intercooler.> 3) Remove intake manifold.
Page 910 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of knock sensor cord must be posi- tioned at a 60°...
Page 911 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 FU-00066 2) Remove the intercooler. <Ref. to IN(H4DOTC)- 10, REMOVAL, Intercooler.>...
Page 912: Mass Air Flow And Intake Air Temperature Sensor
MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Mass Air Flow and Intake Air B: INSTALLATION Install in the reverse order of removal. Temperature Sensor Tightening torque: A: REMOVAL 1.7 N·m (0.17 kgf-m, 1.2 ft-lb) 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector from mass air flow and intake air temperature sensor.
Page 913 MANIFOLD ABSOLUTE PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 11.Manifold Absolute Pressure B: INSTALLATION Install in the reverse order of removal. Sensor NOTE: A: REMOVAL Replace the O-rings for manifold absolute pressure 1) Disconnect the ground cable from battery. sensor with new ones. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009...
Page 914 IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 12.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Replace the gasket with a new one. 1) Disconnect the ground cable from battery. Tightening torque: 2.8 N·m (0.29 kgf-m, 2.1 ft-lb) FU-00009...
Page 915 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13.Fuel Injector 7) Remove the bolts which hold the injector pipe to intake manifold. A: REMOVAL 1. RH SIDE 1) Release fuel pressure. <Ref. FU(H4DOTC)-53, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove the fuel filler cap.
Page 916 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 7) Remove the bolts which hold the injector pipe to intake manifold. 1) Release fuel pressure. <Ref. FU(H4DOTC)-53, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove the fuel filler cap.
Page 917 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 1. RH SIDE Install in the reverse order of removal. NOTE: Replace the O-ring and insulators with new ones. FU-00035 2. LH SIDE Install in the reverse order of removal. NOTE: FU-00073 Replace the O-ring and insulators with new ones.
Page 918 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) FU-00044 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) FU-00618 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) FU-00968 FU(H4DOTC)-40...
Page 919: Tumble Generator Valve Assembly
TUMBLE GENERATOR VALVE ASSEMBLY FUEL INJECTION (FUEL SYSTEMS) 14.Tumble Generator Valve As- 8) Remove the tumble generator valve body from intake manifold. sembly A: REMOVAL NOTE: This component is installed to except STi model. 1) Release fuel pressure. <Ref. FU(H4DOTC)-53, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.>...
Page 920 TUMBLE GENERATOR VALVE ACTUATOR FUEL INJECTION (FUEL SYSTEMS) 15.Tumble Generator Valve Ac- 2. LH SIDE tuator 1) Disconnect the ground cable from battery. A: REMOVAL NOTE: This component is installed to except STi model. 1. RH SIDE 1) Release fuel pressure.
Page 921: Wastegate Control Solenoid Valve
WASTEGATE CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 16.Wastegate Control Solenoid 6) Remove the wastegate control solenoid valve from bracket. Valve A: REMOVAL 1) Disconnect the ground cable from battery. FU-00368 B: INSTALLATION Install in the reverse order of removal. FU-00009 Tightening torque: 2) Disconnect the engine harness connector (A)
Page 922 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) 17.Front Oxygen (A/F) Sensor 7) Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen (A/F) sensor, and A: REMOVAL leave it for 1 minute or more. 1) Disconnect the ground cable from battery.
Page 923 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 7) Connect the connector of front oxygen (A/F) sensor. 1) Before installing the front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make next removal easier.
Page 924 FU-00371 3) Connect the connector to rear oxygen sensor. FU-00082 5) Apply SUBARU CRC or its equivalent to the threaded portion of rear oxygen sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003)
Page 925 REAR OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 4) Connect the clip to crossmember. FU-00082 5) Lower the vehicle. 6) Connect the battery ground cable to battery. FU-00009 FU(H4DOTC)-47...
Page 926 21 N·m (2.1 kgf-m, 15.2 ft-lb) 2) Remove the joint pipe. <Ref. to EX(H4DOTC)- 13, REMOVAL, Joint Pipe.> 3) Apply SUBARU CRC or its equivalent to the threaded portion of exhaust temperature sensor, and leave it for 1 minute or more.
Page 927 ENGINE CONTROL MODULE (ECM) FUEL INJECTION (FUEL SYSTEMS) 20.Engine Control Module (ECM) B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. When replacing the ECM, be careful not to use the wrong spec.
Page 928 MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 21.Main Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the glove box. <Ref. to EI-39, REMOV- AL, Glove Box.> 3) Remove the bolt which holds the main relay bracket on body.
Page 929 FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the glove box.<Ref. to EI-39, REMOV- AL, Glove Box.> 3) Remove the bolt which holds the fuel pump relay bracket on body.
Page 930 FUEL PUMP CONTROL UNIT FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Pump Control Unit B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the rear quarter trim. <Ref. to EI-48, REMOVAL, Rear Quarter Trim.>...
Page 931 FUEL FUEL INJECTION (FUEL SYSTEMS) 24.Fuel 5) Drain fuel from the fuel tank. Set a container under vehicle and remove the drain A: OPERATION plug from fuel tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near working area. •...
Page 932 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler hose and air vent hose from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. 1) Set the vehicle on a lift.
Page 933 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Connect the fuel hoses, and secure them with clips and quick connector. <Ref. to FU(H4DOTC)- 1) Support the fuel tank with transmission jack and 70, INSTALLATION, Fuel Delivery, Return and push the fuel tank harness into access hole with Evaporation Lines.>...
Page 934 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 10) Connect the connector to the fuel pump relay. FU-00871 C: INSPECTION 1) Make sure there are no cracks, holes or other damage on fuel tank. 2) Make sure the fuel hoses and fuel pipes are not cracked and the connections are tightened firmly.
Page 935 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Filler Pipe 9) Drain fuel from fuel tank. Set a container under vehicle and remove the drain plug from fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. •...
Page 936 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 13) Disconnect the air vent hose from fuel filler 18) Remove the air vent pipe together with clip pipe. from body. FU-00099 FU-00102 14) Remove the bolts which hold the fuel filler pipe B: INSTALLATION bracket on body.
Page 937 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 5) Connect the air vent hose to the fuel filler pipe. 8) Tighten the bolt which holds the fuel filler pipe bracket on body. Tightening torque: 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) FU-00099 6) Insert the fuel filler hose (A) approx.
Page 938 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 14) Connect the connector to the fuel pump relay. FU-00871 15) Connect the battery ground cable to battery. FU-00009 FU(H4DOTC)-60...
Page 939 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Pump 7) Raise the rear seat and turn the floor mat up. 8) Remove the access hole lid. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
Page 940 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Do the fol- lowing: NOTE: Replace the gaskets with new ones. (1) Ensure sealing portion is free from fuel or for- eign particles before installation. (2) Tighten the nuts to specified torque in alpha- betical sequence as shown in the figure.
Page 941 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Level Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. NOTE: Fuel level sensor is built in fuel pump assembly.
Page 942 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 29.Fuel Sub Level Sensor 6) Remove the service hole cover. A: REMOVAL WARNING: • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. 1) Disconnect the ground cable from battery. FU-00113 7) Disconnect the connector from fuel sub level sensor.
Page 943 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) FU-00115 FU(H4DOTC)-65...
Page 944 FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 30.Fuel Filter C: INSPECTION 1) Check the inside of fuel filter for dirt and water A: REMOVAL sediment. 2) If it is clogged, or if replacement interval has WARNING: been reached, replace it. • Place “NO FIRE” signs near working area. 3) If water is found in it, shake and expel the water •...
Page 945 FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 31.Fuel Cut Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) • Place “NO FIRE” signs near working area. • Be careful not to spill fuel on floor. 1) Remove the fuel tank.
Page 946 FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 32.Fuel Damper Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Release fuel pressure. <Ref. FU(H4DOTC)-53, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Remove the fuel damper valve from fuel return line.
Page 947 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 33.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4DOTC)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Open the fuel filler flap lid and remove the fuel filler cap. 4) Remove the floor mat.
Page 948 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate the quick connector on fuel delivery (1) Set the new retainer (B) to connector (A). line. (2) Push the pipe into connector completely. (1) Clean the pipe and connector, if they are NOTE: covered with dust.
Page 949 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel delivery hose to pipe with an C: INSPECTION overlap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure there are no cracks on fuel pipes and Type A: When the fitting length is specified.
Page 950 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 34.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to injector Fuel pump will not operate Inspect connections, especially ground, and tighten ❍ Defective terminal contact securely.
Page 951 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4DOTC) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................4 Precatalytic Converter.................5 Canister.......................6 Purge Control Solenoid Valve ..............7 Two-way Valve....................8...
Page 952 GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 953 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL 1) Remove the front catalytic converter and center exhaust pipe as a unit. <Ref. to EX(H4DOTC)-9, REMOVAL, Center Exhaust Pipe.> 2) Separate the front catalytic converter (A) from rear catalytic converter (B).
Page 954 REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL 1) Remove the rear catalytic converter and center exhaust pipe as a unit. <Ref. to EX(H4DOTC)-9, REMOVAL, Center Exhaust Pipe.> 2) Separate the rear catalytic converter (B) from front catalytic converter (A).
Page 955 PRECATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Precatalytic Converter A: REMOVAL NOTE: Precatalytic converter is equipped on models ex- cept for STi and Australia model. Precatalytic converter (A) is built in the joint pipe. Refer to the removal of joint pipe for removal procedure.
Page 956 CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Canister B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Lift-up the vehicle. 23 N·m (2.3 kgf-m, 17 ft-lb) 2) Loosen the two clamps which hold the two can- ister hoses, and then disconnect the three evapo- ration hoses from canister.
Page 957 PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Purge Control Solenoid Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00009 EC-00005 2) Disconnect the connector and hoses from purge...
Page 958 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Remove the canister from body. <Ref. to EC(H4DOTC)-6, REMOVAL, Canister.> 3) Remove the two-way valve with bracket as a unit from body. EC-00007 4) Remove the two-way valve from bracket.
Page 959 INTAKE (INDUCTION) IN(H4DOTC) Page General Description ..................2 Air Cleaner ....................7 Air Intake Duct.....................8 Intake Duct ....................9 Intercooler ....................10 Turbocharger.....................12 Air By-pass Valve..................14 Resonator Chamber..................15...
Page 960 GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: COMPONENT 1. AIR CLEANER (12) (14) (13) (12) (11) (10) IN-00163 Mass air flow and intake air tem- Cushion rubber Tightening torque: N·m (kgf-m, ft-lb) perature sensor Air intake duct T1: 7.5 (0.76, 5.5) Air cleaner upper cover (10) Resonator chamber ASSY...
Page 961 GENERAL DESCRIPTION INTAKE (INDUCTION) 2. INTAKE DUCT IN-00056 Clamp Air by-pass hose C Tightening torque: N·m (kgf-m, ft-lb) PCV hose ASSY Intake duct T1: 19 (1.9, 13.7) Air by-pass hose A Clamp T2: 3 (0.3, 2.2) Air by-pass hose B IN(H4DOTC)-3...
Page 962 GENERAL DESCRIPTION INTAKE (INDUCTION) 3. INTERCOOLER (11) (10) IN-00164 Intercooler Air by-pass valve (11) Clamp Intercooler bracket RH Gasket Intercooler bracket LH Clamp Tightening torque: N·m (kgf-m, ft-lb) Clamp Air by-pass hose A T1: 3 (0.3, 2.2) Air intake duct (10) Intercooler duct T2: 16 (1.6, 11.6)
Page 963 GENERAL DESCRIPTION INTAKE (INDUCTION) 4. TURBOCHARGER (10) (11) (12) IN-00004 Oil inlet pipe Oil outlet pipe Tightening torque: N·m (kgf-m, ft-lb) Metal gasket Clip T1: 4.4 (0.45, 3.3) Turbocharger (10) Oil outlet hose T2: 4.9 (0.50, 3.6) Water pipe (11) Turbocharger bracket RH T3: 29 (3.0, 21.7) Clamp...
Page 964 GENERAL DESCRIPTION INTAKE (INDUCTION) B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 965 AIR CLEANER INTAKE (INDUCTION) 2. Air Cleaner 7) Remove the air cleaner lower case. A: REMOVAL 1) Disconnect the ground cable from battery. IN-00007 B: INSTALLATION Install in the reverse order of removal. FU-00009 Tightening torque: 2) Disconnect the connector from mass air flow 33 N·m (3.4 kgf-m, 24.6 ft-lb) sensor.
Page 966 AIR INTAKE DUCT INTAKE (INDUCTION) 3. Air Intake Duct A: REMOVAL 1) Remove the bolts which install the air intake duct on front side of body. IN-00162 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 7.5 N·m (0.76 kgf-m, 55 ft-lb) IN-00162 C: INSPECTION 1) Inspect for cracks and loose connections.
Page 967 INTAKE DUCT INTAKE (INDUCTION) 4. Intake Duct A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove intake manifold. <Ref. FU(H4DOTC)-14, REMOVAL, Intake Manifold.> 3) Remove the sensor, engine harness and fuel pipe attached to intake manifold. <Ref. to FU(H4DOTC)-20, DISASSEMBLY, Intake Mani- fold.>...
Page 968 INTERCOOLER INTAKE (INDUCTION) 5. Intercooler 5) Separate the intercooler from throttle body. A: REMOVAL 1) Disconnect the air by-pass hoses from intercool- IN-00170 IN-00166 2) Separate the air by-pass valve from intercooler. IN-00167 3) Remove the bolts which secure the intercooler to bracket.
Page 969 INTERCOOLER INTAKE (INDUCTION) B: INSTALLATION C: DISASSEMBLY Install in the reverse order of removal. 1) Remove the intercooler ducts from intercooler. Tightening torque: 16 N·m (1.6 kgf-m, 11.6 ft-lb) IN-00171 D: ASSEMBLY IN-00168 Assemble in the reverse order of disassembly. Tightening torque: 16 N·m (1.6 kgf-m, 11.7 ft-lb) IN-00169...
Page 970 TURBOCHARGER INTAKE (INDUCTION) 6. Turbocharger 7) Loosen the clamp which secures the turbocharg- er to intake duct. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. IN-00074 8) Remove the bolt which secures the bracket of oil pipe to turbocharger.
Page 971 TURBOCHARGER INTAKE (INDUCTION) B: INSTALLATION 4) Install the joint pipe to turbocharger. NOTE: 1) Connect the oil outlet hose to outlet pipe. Replace the gasket with a new one. Tightening torque: 35 N·m (3.6 kgf-m, 25.8 ft-lb) IN-00024 2) Install the turbocharger to intake duct. Tightening torque: IN-00019 3 N·m (0.3 kgf-m, 2.2 ft-lb)
Page 972 AIR BY-PASS VALVE INTAKE (INDUCTION) 7. Air By-pass Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Remove the air by-pass valve from intercooler. 16 N·m (1.6 kgf-m, 11.6 ft-lb) IN-00167 IN-00167 2) Disconnect the air by-pass hoses from air by- pass valve.
Page 973 RESONATOR CHAMBER INTAKE (INDUCTION) 8. Resonator Chamber B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Set the vehicle on a lift. 7.5 N·m (0.76 kgf-m, 5.5 ft-lb) 2) Remove intake duct. <Ref. IN(H4DOTC)-8, REMOVAL, Air Intake Duct.> 3) Remove the air cleaner lower case.
Page 974 RESONATOR CHAMBER INTAKE (INDUCTION) IN(H4DOTC)-16...
Page 975 MECHANICAL ME(H4DOTC) Page General Description ..................2 Compression .....................34 Idle Speed ....................35 Ignition Timing...................36 Intake Manifold Vacuum................37 Engine Oil Pressure ..................38 Fuel Pressure....................39 Valve Clearance..................40 Engine Assembly ..................44 Engine Mounting ..................53 Preparation for Overhaul................54 V-belt......................55 Crankshaft Pulley ..................58 Timing Belt Cover..................59 Timing Belt Assembly................60 Camshaft Sprocket..................69 Crankshaft Sprocket..................71...
Page 976 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS 1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL) Horizontally opposed, liquid cooled, 4-cylinder, Type 4-stroke gasoline engine Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder Bore × Stroke 92 × 75 (3.62 × 2.95) mm (in) Piston displacement 1,994 (121.67)
Page 977 GENERAL DESCRIPTION MECHANICAL Belt tension Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in) adjuster Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in) Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in) 0.025 — 0.125 mm (0.0010 — 0.0049 in) Belt Clearance between spacer and bush tensioner...
Page 978 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) Cylinder bore 91.995 — 92.005 mm (3.6218 — 3.6222 in) 0.015 mm (0.0006 in) Taper Cylinder Limit...
Page 979 GENERAL DESCRIPTION MECHANICAL Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.005 mm (0.0002 in) or less Crank pin and crank jour- Grinding limit 0.25 mm (0.0098 in) 51.984 — 52.000 mm (2.0466 — 2.0472) 0.03 mm (0.0012 51.954 — 51.970 mm (2.0454 — 2.0461) in) US 0.05 mm Crank pin outer diameter...
Page 980 GENERAL DESCRIPTION MECHANICAL 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 2.017 — 2.020 mm (0.0794 — 0.0795 in) in) US 0.05 mm #1, #3 (0.0020 2.027 — 2.030 mm (0.0798 — 0.0799 in) in) US 0.25 mm (0.0098 2.127 —...
Page 981 GENERAL DESCRIPTION MECHANICAL Belt tension Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in) adjuster Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in) Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in) 0.025 — 0.125 mm (0.0010 — 0.0049 in) Belt Clearance between spacer and bush tensioner...
Page 982 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) Cylinder bore 91.995 — 92.005 mm (3.6218 — 3.6222 in) 0.015 mm (0.0006 in) Taper Cylinder Limit...
Page 983 GENERAL DESCRIPTION MECHANICAL Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.005 mm (0.0002 in) or less Crank pin and crank jour- Grinding limit 0.25 mm (0.0098 in) 51.984 — 52.000 mm (2.0466 — 2.0472) 0.03 mm (0.0012 51.954 — 51.970 mm (2.0454 — 2.0461) in) US 0.05 mm Crank pin outer diameter...
Page 984 GENERAL DESCRIPTION MECHANICAL 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 2.017 — 2.020 mm (0.0794 — 0.0795 in) in) US 0.05 mm #1, #3 (0.0020 2.027 — 2.030 mm (0.0798 — 0.0799 in) in) US 0.25 mm (0.0098 2.127 —...
Page 985 GENERAL DESCRIPTION MECHANICAL Belt tension Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in) adjuster Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in) Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in) 0.025 — 0.125 mm (0.0010 — 0.0049 in) Belt Clearance between spacer and bush tensioner...
Page 986 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) Cylinder bore 91.995 — 92.005 mm (3.6218 — 3.6222 in) 0.015 mm (0.0006 in) Taper Cylinder Limit...
Page 987 GENERAL DESCRIPTION MECHANICAL Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.005 mm (0.0002 in) or less Crank pin and crank jour- Grinding limit 0.25 mm (0.0098 in) 51.984 — 52.000 mm (2.0466 — 2.0472) 0.03 mm (0.0012 51.954 — 51.970 mm (2.0454 — 2.0461) in) US 0.05 mm Crank pin outer diameter...
Page 988 GENERAL DESCRIPTION MECHANICAL 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 2.017 — 2.020 mm (0.0794 — 0.0795 in) in) US 0.05 mm #1, #3 (0.0020 2.027 — 2.030 mm (0.0798 — 0.0799 in) in) US 0.25 mm (0.0098 2.127 —...
Page 989 GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT • EXCEPT FOR STi AND AUSTRALIA MODEL (12) (14) (10) (14) (11) (17) (13) (15) (16) (18) ME-00601 Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torque: N·m (kgf-m, ft-lb) Timing belt guide (MT model) (11) Exhaust camshaft sprocket (LH)
Page 990 GENERAL DESCRIPTION MECHANICAL • STi AND AUSTRALIA MODEL (12) (14) (10) (14) (11) (17) (13) (15) (16) (18) ME-00704 Timing belt cover No. 2 (RH) (10) Intake camshaft sprocket (LH) Tightening torque: N·m (kgf-m, ft-lb) Timing belt guide (11) Exhaust camshaft sprocket (LH) T1: 5 (0.5, 3.6) Crankshaft sprocket (12)
Page 991 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT • EXCEPT FOR STi AND AUSTRALIA MODEL (11) (13) (10) (15) (16) (12) (14) (16) (32) (17) (28) (29) (30) (13) (22) (21) (14) (31) (25) (24) (32) (18) (20) (19) (23) (26) (27) ME-00756...
Page 992 GENERAL DESCRIPTION MECHANICAL Rocker cover (RH) (15) Cylinder head (RH) (29) Gasket Rocker cover gasket (RH) (16) Cylinder head gasket (30) Oil filler duct Oil separator cover (17) Cylinder head (LH) (31) O-ring Gasket (18) Intake camshaft (LH) (32) Stud bolt Intake camshaft cap (Front RH) (19) Exhaust camshaft (LH)
Page 993 GENERAL DESCRIPTION MECHANICAL • STi AND AUSTRALIA MODEL (10) (12) (13) (11) (13) (28) (14) (24) (25) (26) (10) (18) (17) (11) (27) (22) (21) (28) (20) (15) (16) (19) (23) ME-00705 ME(H4DOTC)-19...
Page 994 GENERAL DESCRIPTION MECHANICAL Rocker cover (RH) (13) Cylinder head gasket (25) Gasket Rocker cover gasket (RH) (14) Cylinder head (LH) (26) Oil filler duct Variable valve timing solenoid (15) Intake camshaft (LH) (27) O-ring valve assembly (RH) (16) Exhaust camshaft (LH) (28) Stud bolt Intake camshaft cap (RH)
Page 995 GENERAL DESCRIPTION MECHANICAL 3. CYLINDER HEAD AND VALVE ASSEMBLY (11) (11) (12) (10) (12) (10) ME-00003 Exhaust valve Intake valve oil seal Valve lifter Intake valve Valve spring (10) Exhaust valve oil seal Cylinder head Retainer (11) Intake valve guide Valve spring seat Retainer key (12)
Page 996 GENERAL DESCRIPTION MECHANICAL 4. CYLINDER BLOCK (10) (10) (14) (11) (10) (10) (27) (12) (10) (15) (19) (16) (18) (25) (20) (17) (13) (26) (23) (24) (22) (21) ME-00725 Oil pressure switch (16) Water by-pass pipe Tightening torque: N·m (kgf-m, ft-lb) Cylinder block (RH) (17) Connector...
Page 997 GENERAL DESCRIPTION MECHANICAL 5. CRANKSHAFT AND PISTON (10) (11) (12) (13) (10) (15) (14) (13) (14) (13) (10) (13) (16) (12) (11) (19) (17) (18) (18) (17) (10) ME-00005 Flywheel (MT model) Piston pin (17) Crankshaft bearing #1, #3 Ball bearing (MT model) (10) Circlip (18)
Page 998 GENERAL DESCRIPTION MECHANICAL 6. ENGINE MOUNTING ME-00706 Heat shield cover Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) Front cushion rubber T1: 35 (3.6, 25.8) T2: 42 (4.3, 30.9) T3: 85 (8.7, 62.7) ME(H4DOTC)-24...
Page 999 GENERAL DESCRIPTION MECHANICAL C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 1000 GENERAL DESCRIPTION MECHANICAL D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498267600 CYLINDER • Used for replacing valve guides. HEAD TABLE • Used for removing and installing valve springs. ST-498267600 498457000 ENGINE STAND Used with ENGINE STAND (499817000). ADAPTER RH ST-498457000 498457100...
Page 1001 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398744300 PISTON GUIDE Used for installing piston in cylinder for 2.0 L engine. ST-398744300 498857100 VALVE OIL Used for press-fitting of intake and exhaust valve SEAL GUIDE guide oil seals. ST-498857100 499017100 PISTON PIN Used for installing piston pin, piston and connect- GUIDE...
Page 1002 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499097600 PISTON PIN Used for removing piston pin. (Except for Australia REMOVER model) ASSY ST-499097600 499097700 PISTON PIN Used for removing piston pin. (Australia model REMOVER except for STi model) ASSY ST-499097700 499207400 CAMSHAFT Used for removing and installing exhaust cam-...
Page 1003 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977500 CAMSHAFT Used for removing and installing intake camshaft SPROCKET sprocket. (STi and Australia model) WRENCH ST-499977500 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE INSTALLER (499597100).