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Subaru Legacy 2004 Service Manual

Subaru Legacy 2004 Service Manual

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2004 Model Year

PDF S e rvi c e M a n u a l

GENERAL INFORMATION SECTION (Pub.No.G2320GE1)

ENGINE SECTION 1 (Pub.No.G2320GE2)

ENGINE SECTION 2 (Pub.No.G2320GE3)

ENGINE SECTION 3 (Pub.No.G2320GE4)

TRANSMISSION SECTION (Pub.No.G2320GE5)

CHASSIS SECTION (Pub.No.G2320GE6)

BODY SECTION (Pub.No.G2320GE7)

WIRING SYSTEM SECTION (Pub.No.G2320GE8)

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Page 1 2004 Model Year PDF S e rvi c e M a n u a l GENERAL INFORMATION SECTION (Pub.No.G2320GE1) ENGINE SECTION 1 (Pub.No.G2320GE2) ENGINE SECTION 2 (Pub.No.G2320GE3) ENGINE SECTION 3 (Pub.No.G2320GE4) TRANSMISSION SECTION (Pub.No.G2320GE5) CHASSIS SECTION (Pub.No.G2320GE6) BODY SECTION (Pub.No.G2320GE7) WIRING SYSTEM SECTION (Pub.No.G2320GE8)
Page 2 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 4 FOREWORD Page Foreword....................2...
Page 5 Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of Subaru LEGACY. Applied model: BL*****, BP***** from 2004MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc.
Page 6: How To Use This Manuals
HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
Page 7 How to Use This Manuals HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
Page 8 How to Use This Manuals HOW TO USE THIS MANUALS 3. COMPONENT Illustrations are provided 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 parts, refer to parts catalogue.
Page 9 How to Use This Manuals HOW TO USE THIS MANUALS 4. SPECIFICATION If necessary, specifications are also included. 5. INSPECTION Inspections to be carried out before and after maintenance are included. 6. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure.
Page 10 How to Use This Manuals HOW TO USE THIS MANUALS 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 11 : Exhaust Gas Recirculation SOHC : Single Overhead Camshaft : Emergency Locking Retractor : Supplemental Restraint System : Exhaust : Subaru Select Monitor : Fuse & Joint Box : Special Tool : Fusible Link : Switch : Full-time AWD : Traction Control System...
Page 12: Specifications
SPECIFICATIONS Page LEGACY......................2...
Page 13 LEGACY SPECIFICATIONS 1. LEGACY A: DIMENSION 1. SEDAN MODEL Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC Overall length mm (in) 4,665 (183.7) Overall width mm (in) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,425 (56.1) Length mm (in)
Page 14 LEGACY SPECIFICATIONS B: ENGINE Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC Horizontally opposed, liquid Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gas- Engine type cooled, 6-cylin- oline engine der, 4-stroke gas- oline engine Valve arrangement Overhead camshaft 99.5 "...
Page 15 LEGACY SPECIFICATIONS D: TRANSMISSION SEDAN, WAGON 2.0 L Model 3.0 L 2.0 L SOHC DOHC 2.5 L SOHC DOHC turbo Transmission type Clutch type DSPD DSPD 2.785 3.454 3.540 2.785 3.454 3.540 1.545 1.947 2.264 1.545 2.062 2.264 1.000 1.366 1.471 1.000 1.448...
Page 16 LEGACY SPECIFICATIONS 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch : KA, K4 model : Dual range model only E: STEERING SEDAN, WAGON Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC Type...
Page 17 LEGACY SPECIFICATIONS I: CAPACITY 2.0 L SOHC 2.0 L DOHC turbo Model Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1) Capacity (at 2 (US qt, Imp qt) 4.5 (4.8, 4.0) 5.0 (5.3, 4.4) overhaul) Filling Engine oil amount of 2 (US qt, Imp qt) 4.0 (4.2, 3.5) engine oil...
Page 18 LEGACY SPECIFICATIONS J: WEIGHT 1. SEDAN MODEL • LHD model Option code 2.0 L SOHC Model 2.0 i 5MT (Single range) Front kgf (lb) 740 (1,631) 755 (1,664) 760 (1,676) 760 (1,676) 765 (1,686) 775 (1,709) Curb weight Rear kgf (lb) 590 (1,301) 590 (1,301) 590 (1,301)
Page 19 LEGACY SPECIFICATIONS Option code 2.0 L SOHC Model 2.0 i Front kgf (lb) 760 (1,676) 775 (1,709) 780 (1,720) 780 (1,720) 785 (1,731) 795 (1,753) Curb weight Rear kgf (lb) 590 (1,301) 590 (1,301) 590 (1,301) 590 (1,301) 605 (1,334) 615 (1,356) (C.W.) Total...
Page 20 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Single range) Front kgf (lb) 760 (1,676) 770 (1,698) 765 (1,686) 770 (1,698) 765 (1,686) 775 (1,709) Curb weight Rear kgf (lb) 600 (1,323) 605 (1,334) 600 (1,323) 605 (1,334) 605 (1,334) 610 (1,345) (C.W.)
Page 21 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Single range) Front kgf (lb) 775 (1,709) 780 (1,720) 785 (1,731) 780 (1,720) 790 (1,742) 785 (1,731) Curb weight Rear kgf (lb) 615 (1,356) 625 (1,378) 625 (1,378) 600 (1,323) 605 (1,334) 600 (1,323) (C.W.)
Page 22 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i Front kgf (lb) 790 (1,742) 785 (1,731) 795 (1,753) 800 (1,764) 805 (1,774) 805 (1,774) Curb weight Rear kgf (lb) 605 (1,334) 605 (1,334) 610 (1,345) 615 (1,356) 625 (1,378) 625 (1,378) (C.W.) Total...
Page 23 LEGACY SPECIFICATIONS Option code 3.0 L DOHC Model 3.0 R, 3.0 R-A Front kgf (lb) 875 (1,929) 880 (1,940) 890 (1,962) 890 (1,962) Curb weight Rear kgf (lb) 625 (1,378) 630 (1,389) 635 (1,400) 635 (1,400) (C.W.) Total kgf (lb) 1,495 (3,296) 1,510 (3,329) 1,525 (3,362) 1,525 (3,362) Maximum Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Page 24 LEGACY SPECIFICATIONS Option code 2.0 L SOHC Model 2.0 i 5MT (Single range) Front kgf (lb) 750 (1,653) 740 (1,631) 755 (1,664) 750 (1,653) 760 (1,676) 770 (1,698) Curb weight Rear kgf (lb) 590 (1,301) 590 (1,301) 590 (1,301) 590 (1,301) 600 (1,323) 590 (1,301) (C.W.)
Page 25 LEGACY SPECIFICATIONS Option code 2.0 L SOHC 2.5 L SOHC Model 2.0 i 2.5 i 5MT (Single range) Front kgf (lb) 775 (1,709) 770 (1,698) 780 (1,720) 770 (1,698) 775 (1,709) 760 (1,676) Curb weight Rear kgf (lb) 590 (1,301) 590 (1,301) 595 (1,312) 610 (1,345)
Page 26 LEGACY SPECIFICATIONS Option code 2.5 L SOHC 2.5 L SOHC Model 2.5 i 5MT (Single range) Front kgf (lb) 770 (1,698) 770 (1,698) 790 (1,742) 795 (1,753) 795 (1,753) 800 (1,764) Curb weight Rear kgf (lb) 605 (1,334) 610 (1,345) 610 (1,345) 620 (1,367) 615 (1,356)
Page 27 LEGACY SPECIFICATIONS Option code 2.5 L SOHC 3.0 L DOHC Model 2.5 i 3.0 R, 3.0 R-A Front kgf (lb) 780 (1,720) 790 (1,742) 790 (1,742) 890 (1,962) 880 (1,940) Curb weight Rear kgf (lb) 595 (1,312) 605 (1,334) 610 (1,345) 635 (1,400) 635 (1,400) (C.W.)
Page 28 LEGACY SPECIFICATIONS • RHD model Option code 2.0 L SOHC Model 2.0 i 5MT (Single range) Front kgf (lb) 755 (1,664) 760 (1,676) 770 (1,698) 775 (1,709) 775 (1,709) 780 (1,720) Curb weight Rear kgf (lb) 590 (1,301) 590 (1,301) 605 (1,334) 610 (1,345) 590 (1,301)
Page 29 LEGACY SPECIFICATIONS Option code 2.0 L SOHC 2.5 L SOHC Model 2.0 i 2.5 i 5MT (Single range) Front kgf (lb) 790 (1,742) 795 (1,753) 760 (1,676) 765 (1,686) 770 (1,698) 775 (1,709) Curb weight Rear kgf (lb) 605 (1,334) 610 (1,345) 600 (1,323) 600 (1,323)
Page 30 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Single range) Front kgf (lb) 785 (1,731) 785 (1,731) 780 (1,720) 785 (1,731) 790 (1,742) 805 (1,774) Curb weight Rear kgf (lb) 625 (1,378) 625 (1,378) 600 (1,323) 600 (1,323) 610 (1,345) 615 (1,356) (C.W.)
Page 31 LEGACY SPECIFICATIONS Option code 2.5 L SOHC 3.0 L DOHC Model 2.5 i 3.0 R, 3.0 R-A Front kgf (lb) 810 (1,785) 805 (1,774) 810 (1,785) 890 (1,962) 890 (1,962) Curb weight Rear kgf (lb) 620 (1,367) 620 (1,367) 620 (1,367) 635 (1,400) 635 (1,400) (C.W.)
Page 32 LEGACY SPECIFICATIONS Option code 2.0 L SOHC Model 2.0 i 5MT (Single range) Front kgf (lb) 755 (1,664) 760 (1,676) 765 (1,687) 780 (1,720) 775 (1,709) 780 (1,720) Curb weight Rear kgf (lb) 590 (1,301) 590 (1,301) 595 (1,312) 610 (1,345) 590 (1,301) 590 (1,301) (C.W.)
Page 33 LEGACY SPECIFICATIONS Option code 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC Model 2.0 i 2.0 GT 2.5 i 5MT (Single range) Front kgf (lb) 785 (1,731) 800 (1,764) 845 (1,863) 860 (1,896) 765 (1,687) 770 (1,698) Curb weight Rear kgf (lb) 595 (1,312)
Page 34 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Single range) Front kgf (lb) 775 (1,709) 780 (1,720) 785 (1,731) 785 (1,731) 790 (1,742) 795 (1,753) Curb weight Rear kgf (lb) 615 (1,356) 620 (1,367) 625 (1,378) 595 (1,312) 605 (1,334) 615 (1,356) (C.W.)
Page 35 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i Front kgf (lb) 800 (1,764) 785 (1,731) 795 (1,753) 805 (1,774) 810 (1,786) 815 (1,797) Curb weight Rear kgf (lb) 625 (1,378) 605 (1,334) 610 (1,345) 615 (1,356) 625 (1,378) 625 (1,378) (C.W.) Total...
Page 36 LEGACY SPECIFICATIONS 2. WAGON MODEL • LHD model Option code 2.0 L SOHC Model 2.0 i 5MT (Dual range) Front kgf (lb) 750 (1,653) 765 (1,686) 770 (1,698) 770 (1,698) 775 (1,709) 785 (1,731) Curb weight Rear kgf (lb) 610 (1,345) 610 (1,345) 610 (1,345) 610 (1,345)
Page 37 LEGACY SPECIFICATIONS Option code 2.0 L SOHC Model 2.0 i Front kgf (lb) 760 (1,676) 775 (1,709) 780 (1,720) 780 (1,720) 785 (1,731) 790 (1,742) Curb weight Rear kgf (lb) 610 (1,345) 610 (1,345) 610 (1,345) 610 (1,345) 635 (1,400) 640 (1,410) (C.W.) Total...
Page 38 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Dual range) Front kgf (lb) 770 (1,698) 780 (1,720) 775 (1,709) 780 (1,720) 780 (1,720) 785 (1,731) Curb weight Rear kgf (lb) 620 (1,367) 625 (1,378) 620 (1,367) 625 (1,378) 620 (1,367) 630 (1,389) (C.W.)
Page 39 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Dual range) Front kgf (lb) 785 (1,731) 790 (1,742) 800 (1,764) 780 (1,720) 790 (1,742) 785 (1,731) Curb weight Rear kgf (lb) 645 (1,422) 655 (1,444) 660 (1,455) 620 (1,367) 625 (1,378) 620 (1,367) (C.W.)
Page 40 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i Front kgf (lb) 790 (1,742) 785 (1,731) 795 (1,753) 800 (1,764) 805 (1,775) 815 (1,797) Curb weight Rear kgf (lb) 625 (1,378) 625 (1,378) 630 (1,389) 645 (1,422) 655 (1,444) 660 (1,455) (C.W.) Total...
Page 41 LEGACY SPECIFICATIONS Option code 3.0 L DOHC 2.0 L SOHC Model 3.0 R 2.0 i 5MT (Dual range) Front kgf (lb) 880 (1,940) 890 (1,962) 890 (1,962) 760 (1,676) 750 (1,653) 765 (1,686) Curb weight Rear kgf (lb) 640 (1,410) 665 (1,466) 665 (1,466) 610 (1,345)
Page 42 LEGACY SPECIFICATIONS Option code 2.0 L SOHC Model 2.0 i (Dual range) Front kgf (lb) 760 (1,676) 770 (1,698) 775 (1,709) 785 (1,731) 770 (1,698) Curb weight Rear kgf (lb) 610 (1,345) 610 (1,345) 610 (1,345) 635 (1,400) 610 (1,345) (C.W.) Total kgf (lb) 1,370 (3,020) 1,380 (3,042) 1,385 (3,053) 1,420 (3,131) 1,380 (3,042)
Page 43 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Dual range) Front kgf (lb) 780 (1,720) 780 (1,720) 790 (1,742) 790 (1,742) 790 (1,742) 790 (1,742) Curb weight Rear kgf (lb) 635 (1,400) 645 (1,422) 650 (1,433) 655 (1,444) 635 (1,400) 645 (1,422) (C.W.)
Page 44 LEGACY SPECIFICATIONS Option code 2.5 L SOHC 3.0 L DOHC Model 3.0 R, 2.5 i 3.0 R-A Front kgf (lb) 800 (1,764) 795 (1,753) 800 (1,764) 810 (1,785) 890 (1,962) Curb weight Rear kgf (lb) 650 (1,433) 645 (1,422) 650 (1,433) 650 (1,433) 665 (1,466) (C.W.)
Page 45 LEGACY SPECIFICATIONS Option code 2.0 L SOHC Model 2.0 i 5MT (Dual range) Front kgf (lb) 770 (1,698) 775 (1,709) 790 (1,742) 780 (1,720) 785 (1,731) 800 (1,764) Curb weight Rear kgf (lb) 610 (1,345) 615 (1,356) 640 (1,410) 610 (1,345) 615 (1,356) 640 (1,410) (C.W.)
Page 46 LEGACY SPECIFICATIONS Option code 2.0 L DOHC turbo 2.5 L SOHC Model 2.0 GT 2.5 i 5MT (Dual range) Front kgf (lb) 845 (1,863) 850 (1,874) 860 (1,896) 775 (1,709) 780 (1,720) 785 (1,731) Curb weight Rear kgf (lb) 635 (1,400) 645 (1,422) 665 (1,466) 620 (1,367)
Page 47 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i 5MT (Dual range) Front kgf (lb) 795 (1,753) 805 (1,774) 780 (1,720) 790 (1,742) 795 (1,753) 800 (1,764) Curb weight Rear kgf (lb) 650 (1,433) 660 (1,455) 620 (1,667) 625 (1,378) 640 (1,410) 650 (1,433) (C.W.)
Page 48 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model 2.5 i Front kgf (lb) 785 (1,731) 790 (1,742) 800 (1,764) 810 (1,786) 815 (1,797) Curb weight Rear kgf (lb) 620 (1,367) 630 (1,389) 645 (1,422) 650 (1,433) 660 (1,455) (C.W.) Total kgf (lb) 1,405 (3,097) 1,420 (3,131) 1,445 (3,186) 1,460 (3,219) 1,470 (3,241) Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Page 49 LEGACY SPECIFICATIONS 3. OUTBACK • LHD model Option code 2.5 L SOHC Model OBK 2.5 i 5MT (Dual range) Front kgf (lb) 785 (1,731) 795 (1,753) 800 (1,764) 795 (1,753) 805 (1,774) 810 (1,785) Curb weight Rear kgf (lb) 645 (1,422) 670 (1,477) 675 (1,488) 645 (1,422)
Page 50 LEGACY SPECIFICATIONS Option code 3.0 L DOHC 2.5 L SOHC Model OBK 3.0 R, OBK 3.0 R-A OBK 2.5 i 5MT (Dual range) Front kgf (lb) 885 (1,951) 890 (1,962) 900 (1,984) 900 (1,984) 785 (1,731) 795 (1,753) Curb weight Rear kgf (lb) 660 (1,455)
Page 51 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model OBK 2.5 i 5MT (Dual range) Front kgf (lb) 785 (1,731) 795 (1,753) 795 (1,753) 795 (1,753) 805 (1,774) 810 (1,785) Curb weight Rear kgf (lb) 640 (1,410) 655 (1,444) 660 (1,455) 645 (1,422) 670 (1,477) 670 (1,477)
Page 52 LEGACY SPECIFICATIONS Option code 2.5 L SOHC 3.0 L DOHC Model OBK 2.5 i OBK 3.0 R, OBK 3.0 R-A Front kgf (lb) 795 (1,753) 805 (1,774) 805 (1,774) 900 (1,984) 890 (1,962) Curb weight Rear kgf (lb) 640 (1,410) 655 (1,444) 660 (1,455) 685 (1,510)
Page 53 LEGACY SPECIFICATIONS • RHD model Option code 2.5 L SOHC 3.0 L DOHC Model OBK 3.0 R, OBK 2.5 i OBK 3.0 R-A 5MT (Dual range) Front kgf (lb) 800 (1,764) 790 (1,742) 810 (1,785) 800 (1,764) 815 (1,797) 895 (1,973) Curb weight Rear kgf (lb)
Page 54 LEGACY SPECIFICATIONS Option code 3.0 L DOHC Model OBK 3.0 R, OBK 3.0 R-A Front kgf (lb) 905 (1,995) 905 (1,995) Curb weight Rear kgf (lb) 685 (1,510) 685 (1,510) (C.W.) Total kgf (lb) 1,590 (1,301) 1,590 (1,301) Maximum Front kgf (lb) 1,040 (2,293) 1,040 (2,293) permissible axle weight...
Page 55 LEGACY SPECIFICATIONS Option code 2.5 L SOHC Model OBK 2.5 i 5MT (Dual range) Front kgf (lb) 790 (1,742) 800 (1,764) 800 (1,764) 805 (1,774) 800 (1,764) 810 (1,785) Curb weight Rear kgf (lb) 640 (1,410) 665 (1,466) 670 (1,477) 670 (1,477) 640 (1,410) 665 (1,466)
Page 56 LEGACY SPECIFICATIONS Option code 2.5 L SOHC 3.0 L DOHC Model OBK 2.5 i OBK 3.0 R, OBK 3.0 R-A Front kgf (lb) 810 (1,785) 810 (1,785) 885 (1,951) 900 (1,984) 905 (1,995) Curb weight Rear kgf (lb) 670 (1,477) 675 (1,488) 655 (1,444) 685 (1,510)
Page 57 LEGACY SPECIFICATIONS SPC-46...
Page 58 PRECAUTION Page Precaution ....................2...
Page 59 Precaution PRECAUTION 1. Precaution 7. AIRBAG DISPOSAL To prevent bodily injury from unexpected airbag A: CAUTION deployment, do not dispose airbag modules in the Please clearly understand and adhere to the follow- same way as other refuse. Follow the special in- ing general precautions.
Page 60 NOTE Page Note......................2...
Page 61 4. SERVICE PARTS not reach the supporting locations. Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance result- ing from the use of parts except for genuine parts. 5. PROTECTING VEHICLE UNDER MAIN-...
Page 62 Note NOTE NT-00086 Supporting locations Swing arm lift Plate lift Pantograph jack Rigid rack Attachment NT-3...
Page 63 Note NOTE NT-00072 Front Rear Front crossmember Rear differential NT-4...
Page 64 Note NOTE 8. TIE DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to the specified locations on the vehicle. • TIE-DOWN LOCATION NT-00073 Hook for tie-down NT-5...
Page 65 Note NOTE • CHAIN DIRECTION AT TIE-DOWN CONDI- • VEHICLE SINKING VOLUME AT TIE-DOWN TION CONDITION Measure the distance between the highest tire point and highest arch point before and after tie- down. Difference of measurement value (sinking volume) shall be within 50 mm (1.97 in) and make sure to fix the vehicle securely.
Page 66 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, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight.
Page 67 Note NOTE • NOTES Towing Notes Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. NT-00023 Rope • Check if both front and rear wheels are rotated nor- mally.
Page 68 Note NOTE CAUTION: • Check ATF, gear oil and rear differential oil before driving. • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. •...
Page 69 Fix the vehicle using a pulling metal (chain or Subaru Select Monitor can be used to diagnose the wire) to the front and rear towing hooks or tie- engine, ABS, air conditioner and other parts.
Page 70 Note NOTE 14.BRAKE TEST Specifications: 1) Full-time AWD MT model Braking force (1) Perform this test after driving the vehicle 2 to Rear wheel total More than 10% of load on front or rear 3 km (1.24 to 1.86 miles) on road in order to sta- wheels bilize the viscous torque of viscous coupling.
Page 71 Note NOTE NT-12...
Page 72 IDENTIFICATION Page Identification ....................2...
Page 73 Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. • POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION ID-00072 ID plate (EC and EK model) Tire inflation pressure label (Driver Saudi Arabia plate (Saudi Arabia ADR compliance plate (KA model) side) (KA model)
Page 74 Identification IDENTIFICATION • MANUAL TRANSMISSION VA1-TYPE ID-00068 DI-00396 (1) Transmission serial No. (1) Type (label) (2) MT type label VA2-TYPE • REAR DIFFERENTIAL T-TYPE DI-00397 (1) Type (label) ID-00056 (1) Type (white paint) • MODEL NUMBER PLATE ID-00073 ID-3...
Page 75 Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: • EC, EK, KA AND K4 MODEL ]JF1BL5LJ34G002001[ The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 — 3 Manufacturer body area JF1: Passenger car, FHI made (Except for KA OUTBACK model) JF2: Passenger car, FHI made (KA OUTBACK model)
Page 76 Identification IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates the type, V.I.N. <Ref. to ID-4, MEANING OF V.I.N., IDENTIFICATION, Identification.>, applied model, option code, trim code, engine type, transmission type and the exterior color code. This information is helpful when placing orders for parts. •...
Page 77 Identification IDENTIFICATION • TRANSMISSION TY757VRAAB Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V, G: Full-time AWD AT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: 5MT 1B: 4AT 5C: 5AT Series LEGACY...
Page 78 Identification IDENTIFICATION • OPTION ECXV Digits Code Meaning Details 1 — 2 Destination EC: For Europe (LHD model) EK: For Europe (RHD model) KS: For GCC counties K4: For Middle and South America KA: For Australia Nothing: For Hong Kong Option equipment A: Vehicle dynamics control, Cruise control, Power pack, 17 inch tire...
Page 79 Identification IDENTIFICATION ID-8...
Page 80 RECOMMENDED MATERIALS Page Recommended Materials ................2...
Page 81 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 gasoline of the same or higher octane value than specified in the owner’s manual.
Page 82 Recommended Materials RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent. See the table below to choose the correct SAE vis- cosity. 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 83 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 3.0 L and DOHC turbo model –20 –10 (˚C) –30 –22 –4 (˚F) 10W-30 or 10W-40 5W-30 Recommend...
Page 84 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 other than DENSO OIL 8. Air conditioner Recommended...
Page 85 Recommended Materials RECOMMENDED MATERIALS 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary • Oxygen sensor Spray type lubricant — — lubricants • Bolts, etc. Grease MT main shaft CLUTCH GREASE K0879Y0501 —...
Page 86 Recommended Materials RECOMMENDED MATERIALS 9. SEAL MATERIAL Use the seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • MT transmission case • Cylinder block • Converter case THREE BOND 1215 004403007 DOW CORNING’s No.
Page 87 Recommended Materials RECOMMENDED MATERIALS RM-8...
Page 88 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
Page 89 • Check if the vehicle after repair is in a normal state. • Make sure to provide a complete vehicle to the customer. For the above reasons, all SUBARU dealers (dealerships) carry out the PDIs before delivering a vehicle. Refer to this manual unless otherwise specified.
Page 90 Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE Check point 15. Engine oil Check that the oil level is normal. 16. Transmission gear oil Check that the transmission gear oil level is normal. 17. AT front differential oil Check that the AT front differential oil level is normal. 18.
Page 91 Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE Check point 53. Fluid leak check Check for fluid/oil leaks. 54. Water leak test Spray the vehicle with water and check for water leaks. 55. Appearance check 2 (1) Remove the protective coating (if any). (2) Check the body paints for damage and stain.
Page 92 Pre-delivery Inspection PRE-DELIVERY INSPECTION For other doors, place the door lock knob (A) to lock 6. CHECK DOUBLE LOCK OPERATION position and then pull the inner remote (B) to en- 1) Fully open all the windows. sure that doors will not open. 2) Remove the key.
Page 93 Pre-delivery Inspection PRE-DELIVERY INSPECTION 3) Put the lever (A) in the cancel lever of trunk lid to 11.ACCESSORY CHECK cancel position, and close the trunk lid. Check that Check that the following accessories are provided. the trunk lid will not open even when the trunk lock •...
Page 94 Pre-delivery Inspection PRE-DELIVERY INSPECTION Operate the lever (B) and check that the front hood 14.BRAKE FLUID is opened normally. Support the front hood with Check that the brake fluid level is normal. If the hood stay. amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake oper- ation.
Page 95 Pre-delivery Inspection PRE-DELIVERY INSPECTION • 3.0 L model 17.AT FRONT DIFFERENTIAL OIL Check that the AT front differential oil level is nor- mal. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil.
Page 96 NOTE: The following inspections show the initial settings. When the settings are different from the initial set- tings, use Subaru Select Monitor to check the de- tails of each setting for inspections. <Ref. to LAN(diag)-26, OPERATION, Read Current Data.> 1) Fully open all the door windows.
Page 97 Pre-delivery Inspection PRE-DELIVERY INSPECTION 7) Press the “UNLOCK” button momentarily on the 26.TEST MODE CONNECTOR keyless transmitter. Check that the driver’s door is Turn the ignition switch to ON and check that the unlocked and hazard light blinks twice and room malfunction indicator light starts blinking.
Page 98 Pre-delivery Inspection PRE-DELIVERY INSPECTION 28.STARTING CONDITION 39.WINDOW WASHER Start the engine and check that the engine starts Check that the window washer system injects smoothly. If the battery voltage is low, recharge or washer fluid to the specified area of the windshield replace the battery.
Page 99 Pre-delivery Inspection PRE-DELIVERY INSPECTION 45.BRAKE TEST 50.CRUISE CONTROL Check the foot brake for normal operations. Operate the cruise control system. Check that the system is activated and deactivated correctly. 46.PARKING BRAKE 51.ATF LEVEL Check the parking brake for normal operations. When applying the parking brake with force of 200 While engine is idling, check that the ATF level is N (20.4 kgf, 45.0 lb), check that the lever stroke of...
Page 100 Pre-delivery Inspection PRE-DELIVERY INSPECTION 52.POWER STEERING FLUID LEVEL 55.APPEARANCE CHECK 2 Check that the power steering fluid level is normal. 1) When vehicle body is covered with protective If the amount is insufficient, check that no leaks are film, peel it off. found.
Page 101 Pre-delivery Inspection PRE-DELIVERY INSPECTION 6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. • Seat • Door trim • Floor carpet • Side sill • Front hood lock release lever • Edge rear • Rear wiper •...
Page 102: Table Of Contents
PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................7 Engine Oil Filter...................9 Spark Plug....................10 V-belt......................11 Timing Belt ....................14 Fuel Line ....................17 Air Cleaner Element ..................18 Cooling System ..................20 Engine Coolant..................22 Clutch System ...................24 Transmission Gear Oil ................25 Automatic Transmission Fluid ..............26 Front and Rear Differential Gear Oil ............28 Brake Line ....................30 Brake Fluid ....................32...
Page 103: General Description
General Description PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur. PM-2...
Page 104: Schedule
Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. 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 105 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 106 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 107 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 108: Engine Oil
Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil • 2.0 L non-turbo and 2.5 L model A: REPLACEMENT 1) Open the engine oil filter cap for quick draining of engine oil. • Except for 3.0 L model LU-00218 • 3.0 L model PM-00161 (A) Oil level gauge (B) Oil filler cap...
Page 109 API (A) Oil level gauge classification and SAE viscosity No. designat- (B) Oil filler cap ed by SUBARU. (C) Upper level (D) Lower level NOTE: If the vehicle is used in areas with very high temper-...
Page 110: Engine Oil Filter
Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter 6) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. A: REPLACEMENT NOTE: 1) Remove the under cover. The filter element and filter case are permanently 2) Remove the oil filter using ST.
Page 111: Spark Plug
Spark Plug PERIODIC MAINTENANCE SERVICES 5. Spark Plug • 3.0 L model A: REPLACEMENT 1. SOHC MODEL 1) Remove the intake duct and intake chamber. 2) Remove the battery. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a spark plug socket. IG-02004 (A) Bracket (B) Connector...
Page 112: V-Belt
V-belt PERIODIC MAINTENANCE SERVICES 6. V-belt Belt tension (with belt tension gauge): A: INSPECTION When installing new one: 640 — 785 N (65.3 — 80.0 kgf, 144 — 176 lb) 1. EXCEPT FOR 3.0 L MODEL At inspection: 490 — 640 N (50 — 65 kgf, 1) Replace the belts if crack, fraying or wear is 110 —...
Page 113 V-belt PERIODIC MAINTENANCE SERVICES 2. 3.0 L MODEL • Turbo model 1) Replace the belts if crack, fraying or wear is found. 2) Check that the V-belt automatic tensioner indica- tor (A) is within the range (D). ME-00807 3) Loosen the lock bolt (A). 4) Loosen the slider bolt (B).
Page 114 V-belt PERIODIC MAINTENANCE SERVICES Tightening torque: 23 N m (2.3 kgf-m, 17.0 ft-lb) PM-00005 7) Install the front side belt. • Non-turbo model <Ref. to ME(H4SO 2.0)-38, FRONT SIDE BELT, INSTALLATION, V-belt.> • Turbo model <Ref. to ME(H4DOTC)-39, FRONT SIDE BELT, INSTALLATION, V-belt.> 3.
Page 115: Timing Belt
Timing Belt PERIODIC MAINTENANCE SERVICES 7. Timing Belt ST 499987500 CRANKSHAFT SOCKET A: REPLACEMENT 1. SOHC MODEL 1) Protect the radiator with cardboard and blanket. 2) Remove the V-belt covers. PM-00003 3) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, V-belt.> 4) Remove the A/C compressor V-belt tensioner.
Page 116 Timing Belt PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 9) Remove the timing belt guide. (Except for non- turbo AT model) 1) Protect the radiator with cardboard and blanket. 2) Remove the V-belts. <Ref. to ME(H4DOTC)-39, V-belt.> 3) Remove the A/C compressor V-belt tensioner. 4) Remove the pulley bolt.
Page 117 Timing Belt PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corre- sponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur. B: INSPECTION 1.
Page 118: 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 band, etc. If faulty parts are found, repair or replace them. •...
Page 119: Air Cleaner Element
Air Cleaner Element PERIODIC MAINTENANCE SERVICES 9. Air Cleaner Element • Non-turbo model A: REPLACEMENT 1) Disconnect the ground cable from battery. PM-00182 • Turbo model IN-00203 2) Disconnect the connector from mass air flow sensor. (2.0 L turbo, 3.0 L and 2.5 L EC, EK, K4 model) •...
Page 120 Air Cleaner Element PERIODIC MAINTENANCE SERVICES • Refer to “COMPONENT” for tightening torque. 2.0 L non-turbo and 2.5 L model <Ref. to IN(H4SO 2.0)-2, COMPONENT, Gen- eral Description.> Turbo model <Ref. to IN(H4DOTC)-2, COMPONENT, Gener- al Description.> 3.0 L model <Ref.
Page 121: Cooling System
Cooling System PERIODIC MAINTENANCE SERVICES 10.Cooling System NOTE: Rust or dirt on the cap may prevent valve from func- A: INSPECTION tioning normally: be sure to clean the cap before 1) To check the radiator for leakage, fill it with en- testing.
Page 122 CO(H6DO)-12, Thermostat.> <Ref. to CO(H6DO)- 13, Radiator.> <Ref. to CO(H6DO)-16, Radiator Cap.> 4) Check the radiator fan operates using Subaru Select Monitor, when the coolant temperature ex- ceeds 95#C (203#F). If it does not operate, check the radiator fan system.
Page 123: Engine Coolant
9) Pour the coolant from radiator filler port to neck freeze and anti-rust agents is especially made for of filler. Then, pour the coolant into reservoir tank SUBARU engine, which has an aluminum crank- up to “FULL” level. case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
Page 124 CONCENTRATION AND FREEZING TEM- only. PERTAURE Concentration and safe operating temperature of SUBARU coolant is shown in the diagram. Measur- ing the temperature and specific gravity of the cool- ant will provide this information. [Example] If the coolant temperature is 25#C (77#F), its specif- Necessary Concentration ic gravity is 1.054 and the concentration is 45%...
Page 125: Clutch System
Clutch System PERIODIC MAINTENANCE SERVICES 12.Clutch System • Be careful not to allow dirt or dust to get into the reservoir tank. A: INSPECTION AND ADJUSTMENT 1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not.
Page 126: Transmission Gear Oil
Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 13.Transmission Gear Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug. NOTE: • Before starting work, cool off the transmission gear oil well. • If transmission gear oil adheres to the exhaust pipe, wipe it off completely.
Page 127: Automatic Transmission Fluid
5 to 10 km (3 to 6 miles). Otherwise, idle the en- gine to raise ATF temperature to 70 — 80#C (158 PI-00190 — 176#F) on Subaru Select Monitor. <Ref. to (A) Level gauge 4AT(diag)-17, READ CURRENT DATA, OPERA- TION, Subaru Select Monitor.>...
Page 128 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES B: REPLACEMENT • 4AT model 1. AUTOMATIC TRANSMISSION FLUID 1) Drain the ATF by removing drain plug. NOTE: Before starting work, cool off the ATF well. • 4AT model PI-00189 (A) Level gauge (B) ATF level range at “HOT” [70 — 80#C (158 — 176#F)] (C) Upper level (D) Lower level...
Page 129: Front And Rear Differential Gear Oil
Front and Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 15.Front and Rear Differential NOTE: Each oil manufacturer has its base oil and addi- Gear Oil tives. Thus, do not mix two or more brands. A: REPLACEMENT Differential gear oil capacity: 4AT model 1.
Page 130 Front and Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES Tightening torque: Liquid gasket: T-type THREE BOND 1105 (Part No. 004403010) 49.0 N m (5.0 kgf-m, 36.2 ft-lb) Tightening torque: VA1-type T-type 34 N m (3.5 kgf-m, 25.3 ft-lb) 49.0 N m (5.0 kgf-m, 36.2 ft-lb) VA2-type VA1-type...
Page 131: Brake Line
Brake Line PERIODIC MAINTENANCE SERVICES 16.Brake Line Brake pedal free play (Pulling up direction of pedal) A: INSPECTION 0.5 — 2.0 mm (0.02 — 0.08 in) 1. BRAKE LINE 1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps.
Page 132 Brake Line PERIODIC MAINTENANCE SERVICES 3) Check the pedal stroke. Replace the both check valve and vacuum hose if the check valve is faulty. Engine side of vacuum While the engine is idling, depress the brake pedal hose is indicated by marking “ENG” as shown. with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel.
Page 133: Brake Fluid
Brake Fluid PERIODIC MAINTENANCE SERVICES 17.Brake Fluid NOTE: • Cover the bleeder with cloth, when loosening it, A: REPLACEMENT to prevent brake fluid from being splashed over sur- 1) Either jack-up the vehicle and place a rigid rack rounding parts. under it, or lift-up the vehicle.
Page 134: Disc Brake Pad And Disc
Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 18.Disc Brake Pad and Disc A: INSPECTION 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. Replace the pad if necessary.
Page 135: Parking Brake
Parking Brake PERIODIC MAINTENANCE SERVICES 19.Parking Brake 4) When the shoe return spring tension is exces- sively weakened, replace it. A: INSPECTION B: ADJUSTMENT Inspect the brake linings and disc rotor of both For rear disc brake, adjust the parking brake after sides of the rear brake at the same time by remov- bleeding air.
Page 136: Suspension
Suspension PERIODIC MAINTENANCE SERVICES 20.Suspension NOTE: When the front arm ball joint has been removed or A: INSPECTION replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, adjust the 1. SUSPENSION BALL JOINT toe-in.
Page 137 Suspension PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- • Rear suspension PENSION <Ref. to RS-2, General Description.> 1) Check the alignment of front suspension to en- 8. DAMAGE TO SUSPENSION PARTS sure that following items conform to standard val- Check the following parts and the fastening portion ues.
Page 138: Wheel Bearing
Wheel Bearing PERIODIC MAINTENANCE SERVICES 21.Wheel Bearing If the hub is noisy or binds, replace the rear axle. A: INSPECTION 1. FRONT WHEEL BEARING NOTE: Inspect the condition of front wheel bearing grease. 1) Jack-up the front side of vehicle. 2) While holding the front wheel by hand, swing it in and out to check bearing free play.
Page 139: Axle Boots And Joints
Axle Boots and Joints PERIODIC MAINTENANCE SERVICES 22.Axle Boots and 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-22, Front Drive Shaft.>...
Page 140: Steering System (Power Steering)
Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 23.Steering System (Power 2. STEERING SHAFT JOINT Steering) 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 141 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 3) With the vehicle placed on a level surface, quick- 4. TIE-ROD ly turn the steering wheel to the left and right. 1) Check the tie-rod and tie-rod ends for bends, While steering wheel is being rotated, check the scratches or other damage.
Page 142 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 2) Clips are fitted outside of positions (A) and (B) of NOTE: boot. If fluid level is at MAX level or above, drain fluid to 3) Boot does not have crack and hole. keep the level in the specified range of indicator by using a syringe or the like.
Page 143 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES PM-42...
Page 144 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 145 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 146 FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.0) Page General Description ..................2 Throttle Body.....................10 Intake Manifold..................11 Engine Coolant Temperature Sensor............20 Crankshaft Position Sensor...............21 Camshaft Position Sensor.................22 Knock Sensor....................23 Throttle Position Sensor................25 Manifold Absolute Pressure Sensor............26 Intake Air Temperature Sensor ..............27 EGR Valve ....................28 Fuel Injector ....................29 Front Oxygen (A/F) Sensor ...............32 Rear Oxygen Sensor.................33...
Page 147: General Description
General Description FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATION Capacity 64 2(16.9 US gal, 14.1 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 441 — 686 kPa (4.50 — 7.00 kg/cm , 64.0 — 99.5 psi) Fuel pump 75 2 (19.8 US gal, 16.5 Imp gal)/h or more Discharge...
Page 148 General Description FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (17) (19) (11) (10) (17) (14) (12) (12) (10) (13) (12) (16) (18) (16) (18) (15) (16) (18) FU-02056 FU(H4SO 2.0)-3...
Page 149: Air Intake System
General Description FUEL INJECTION (FUEL SYSTEMS) Intake manifold (10) O-ring (19) PCV valve Gasket (11) Purge control solenoid valve Guide pin (12) Plug cord holder Tightening torque: N m (kgf-m, ft-lb) EGR valve (EC, EK, K4 model) (13) Nipple (LHD model) T1: 1.5 (0.15, 1.1) Fuel pipe protector RH (14)
Page 150 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 2.0)-5...
Page 151 General Description FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (19) (17) (18) (15) (16) (17) (14) (15) (10) (12) (11) (13) (22) (22) (20) (21) (23) (24) (25) FU-01080 FU(H4SO 2.0)-6...
Page 152 General Description FUEL INJECTION (FUEL SYSTEMS) Fuel tank (12) Fuel sub level sensor upper plate (22) Retainer Fuel tank band RH (13) Fuel sub level sensor gasket (23) Heat shield cover Fuel tank band LH (14) Fuel filler hose (24) Fuel tank protector RH (Front) Delivery tube (15)
Page 153 General Description FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (28) (18) (26) (23) (15) (19) (17) (25) (27) (20) (22) (14) (13) (24) (21) (16) (22) (34) (11) (29) (10) (12) (33) (32) (30) (31) FU-01081 FU(H4SO 2.0)-8...
Page 154 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 155: Throttle Body
Throttle Body FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the air intake chamber. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> 3) Disconnect the connectors from the throttle posi- tion sensor and manifold absolute pressure sensor.
Page 156: Intake Manifold
Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 9) Disconnect the engine harness connectors from bulkhead harness connectors. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
Page 157 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 14) Disconnect the connector from oil pressure • Catch the fuel from hoses using a container switch (B). or cloth. FU-01087 FU-02062 15) Disconnect the connector from camshaft posi- (A) Fuel delivery hose tion sensor. (B) Return hose (C) Evaporation hose 18) Remove the bolts which secure intake manifold...
Page 158 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 6) Connect the connector to oil pressure switch (B). NOTE: If fuel hoses or clamps are damaged, replace them with new ones. Tightening torque (Hose clamp screw): 1.25 N m (0.13 kgf-m, 0.94 ft-lb) FU-01087 7) Connect the connector to crankshaft position sensor.
Page 159 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 11) Connect the brake booster hose. C: DISASSEMBLY 1) Disconnect the engine ground terminal from in- take manifold. FU-02089 12) Connect the engine harness connectors to bulkhead harness connectors. FU-02063 2) Remove the ignition coil & ignitor ASSY. <Ref. to IG(H4SO 2.0)-8, REMOVAL, Ignition Coil &...
Page 160 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. • RH side FU-02066 FU-02070 8) Disconnect the connectors from fuel injector. FU-02071 FU-02067 • LH side 9) Remove the purge control solenoid valve. <Ref. to EC(H4SO 2.0)-7, REMOVAL, Purge Control So- lenoid Valve.>...
Page 161 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) (1) Remove the clip which secures fuel injector 17) Remove the bolt which installs fuel pipes on in- from injector pipe. take manifold. FU-02074 FU-02077 (2) Remove the fuel injector with lifting up the 18) Remove the fuel pipe assembly and pressure fuel injector pipe.
Page 162 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 4) Connect the fuel injector pipe LH to fuel hose, • LH side and tighten the clamp screw. Tightening torque: 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02075 5) Install the fuel injectors. FU-02078 6) Install the clip which secures fuel injector.
Page 163 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 9) Secure the engine harness with harness band 12) Install the fuel pipe protector RH. (A) and bolts (B), (C). Tightening torque: Tightening torque: 19 N m (1.9 kgf-m, 13.7 ft-lb) (B): 16 N m (1.6 kgf-m, 11.8 ft-lb) (C): 6.4 N m (0.65 kgf-m, 4.7 ft-lb)
Page 164 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02063 E: INSPECTION Make sure the fuel pipe and fuel hoses are not damaged and the connections are tightened firmly. FU(H4SO 2.0)-19...
Page 165: Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the generator. <Ref. to SC(H4SO 2.0)- 14, REMOVAL, Generator.> 3) Disconnect the connectors from engine coolant temperature sensor.
Page 166: 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 Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) IN-00203 FU-00058 2) Remove the bolt which installs crankshaft posi- tion sensor to cylinder block.
Page 167: Camshaft Position Sensor
Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00179 B: INSTALLATION Install in the reverse order of removal. IN-00203 Tightening torque: 2) Disconnect the connector from camshaft posi- Camshaft position sensor support tion sensor.
Page 168: Knock Sensor
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. Extraction area of knock sensor cord must be posi- tioned at a 60" angle relative to the engine rear. Tightening torque: 24 N m (2.4 kgf-m, 17.4 ft-lb)
Page 169 Knock Sensor FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. IN-00203 FU(H4SO 2.0)-24...
Page 170: Throttle Position Sensor
Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure. <Ref. to FU(H4SO 2.0)-10, REMOVAL, Throttle Body.>...
Page 171: Manifold Absolute Pressure Sensor
Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS) 9. Manifold Absolute Pressure Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from manifold abso- lute pressure sensor. FU-02079 3) Remove the manifold absolute pressure sensor from throttle body.
Page 172: 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. IN-00203 2) Disconnect the connector from intake air tem- perature sensor. 3) Remove the intake air temperature sensor. FU-02080 B: INSTALLATION Install in the reverse order of removal.
Page 173: Egr Valve
EGR Valve FUEL INJECTION (FUEL SYSTEMS) 11.EGR Valve A: REMOVAL NOTE: EGR valve is equipped to EC, EK and K4 model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from EGR valve. 3) Remove the EGR valve from intake manifold. FU-02082 B: INSTALLATION Install in the reverse order of removal.
Page 174: Fuel Injector
Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 12.Fuel Injector 8) Remove the clip which secure fuel injector. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
Page 175 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 5) Remove the fuel pipe protector LH. 8) Remove the bolts which hold fuel injector pipe onto intake manifold. FU-02065 FU-02072 6) Disconnect the connector from fuel injector. FU-02073 FU-02067 9) Remove the fuel injector while lifting up the fuel 7) Remove the clips which secure fuel injector.
Page 176 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02071 FU-02072 Tightening torque: Tightening torque: 19 N m (1.9 kgf-m, 13.7 ft-lb) 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02066 FU-02065 2.
Page 177: Front Oxygen (A/F) Sensor
Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS) 13.Front Oxygen (A/F) Sensor B: INSTALLATION 1) Before installing front oxygen (A/F) sensor, ap- A: REMOVAL ply anti-seize compound only to the threaded por- 1) Disconnect the ground cable from battery. tion of front oxygen (A/F) sensor to make the next removal easier.
Page 178: Rear Oxygen Sensor
Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS) 14.Rear Oxygen Sensor B: INSTALLATION 1) Before installing rear oxygen sensor, apply anti- A: REMOVAL seize compound only to the threaded portion of 1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas- ier.
Page 179: Engine Control Module (Ecm)
Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS) 15.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 180: Main Relay
Main Relay FUEL INJECTION (FUEL SYSTEMS) 16.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from main relay. FU-02093 B: INSTALLATION Install in the reverse order of removal.
Page 181: Fuel Pump Relay
Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS) 17.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from fuel pump relay. FU-02094 B: INSTALLATION Install in the reverse order of removal.
Page 182: Electronic Throttle Control Relay
Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS) 18.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from electric control throttle relay.
Page 183: Fuel
Fuel FUEL INJECTION (FUEL SYSTEMS) 19.Fuel 6) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from the A: PROCEDURE fuel tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...
Page 184: Fuel Tank
Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Tank (2) Push the grommet (B) down under the body and remove the service hole cover. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
Page 185 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 12) Remove the rear brake caliper and tie it to the 19) Remove the bolts which install parking brake side of vehicle body. cable clamp. FU-00462 FU-01130 13) Remove the parking brake cable from parking brake assembly.
Page 186 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) (3) Remove the bolts which secure rear sus- 23) Support the fuel tank with transmission jack, re- pension assembly to body. move the bolts from fuel tank bands and dismount the fuel tank from vehicle. WARNING: A helper is required to perform this work.
Page 187 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 2) Correctly insert the fuel filler hose (A) and vent Tightening torque: hose (B) to specified position, and then tighten the T1: 125 N m (12.7 kgf-m, 92.2 ft-lb) clamp. T2: 65 N m (6.2 kgf-m, 48 ft-lb) T3: 175 N m (17.8 kgf-m, 129 ft-lb) FU-01136...
Page 188 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: 18 N m (1.8 kgf-m, 13.0 ft-lb) 33 N m (3.4 kgf-m, 25 ft-lb) FU-01130 FU-01128 Tightening torque: 15) Install the rear wheels. 32 N m (3.3 kgf-m, 23.9 ft-lb) 16) Lower the vehicle.
Page 189 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 20) Connect the connector to fuel pump. FU-01125 21) Install the service hole cover of fuel pump. FU-01124 (A) Bolt (B) Grommet 22) Install the rear seat. 23) Install the fuse of fuel pump to main fuse box. C: INSPECTION 1) Check that the fuel tank is not holed, cracked, or otherwise damaged.
Page 190: Fuel Filler Pipe
Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Filler Pipe 7) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from the A: REMOVAL fuel tank. WARNING: • Place “NO FIRE” signs near the working area. •...
Page 191 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Tighten the bolts which hold fuel filler pipe brack- et on the body. 1) Open the fuel filler flap lid. 2) Set the fuel saucer (A) with rubber packing (C) Tightening torque: and insert the fuel filler pipe into hole from the inner 7.5 N...
Page 192: Fuel Pump
Fuel Pump FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump 7) Remove the nuts which install fuel pump assem- bly onto fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. •...
Page 193 Fuel Pump FUEL INJECTION (FUEL SYSTEMS) • Do not run fuel pump for a long time under non-load condition. FU-01330 FU(H4SO 2.0)-48...
Page 194: Fuel Level Sensor
Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Level Sensor A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly.
Page 195: Fuel Sub Level Sensor
Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Sub Level Sensor 6) Remove the bolts which install the fuel sub level sensor on fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. •...
Page 196: Fuel Filter
Fuel Filter FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filter A: SPECIFICATION Fuel filter forms a unit with fuel pump. Refer to Fuel Pump for removal and installation. <Ref. to FU(H4SO 2.0)-47, REMOVAL, Fuel Pump.> <Ref. to FU(H4SO 2.0)-47, INSTALLATION, Fuel Pump.> FU(H4SO 2.0)-51...
Page 197: Fuel Damper Valve
Fuel Damper Valve FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Damper Valve A: REMOVAL 1. DELIVERY SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper valve from fuel delivery line. FU-01147 2.
Page 198: Fuel Delivery, Return And Evaporation Lines
Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCE- DURE, Fuel.> 3) Open the fuel filler flap lid, and remove the fuel filler cap.
Page 199 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) CAUTION: CAUTION: Always use a new retainer. • Pull the connector to ensure it is connected securely. • Ensure the two retainer pawls are engaged in their mating positions in the connector. •...
Page 200 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) CAUTION: Be sure to inspect the hoses and their connec- tions for fuel leakage. FU-00129 (1) Hose (2) Clip (3) Pipe C: INSPECTION 1) Make sure that there are no cracks on the fuel pipes and fuel hoses.
Page 201: Fuel System Trouble In General
Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS) 28.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to injector Fuel pump does not operate. Inspect contact, especially ground, and tighten it H Defective terminal contact.
Page 202 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 203 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 204 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.0) 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...................9 PCV Valve ....................10...
Page 205: General Description
General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear work clothing, including a cap, protective goggles and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 206: Front Catalytic Converter
Front Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrat- ed into center exhaust pipe as a unit; therefore, re- fer to “Center Exhaust Pipe” for removal procedure. <Ref.
Page 207: Rear Catalytic Converter
Rear Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrat- ed into center exhaust pipe as a unit; therefore, re- fer to “Center Exhaust Pipe” for removal procedure. <Ref.
Page 208: Egr Valve
EGR Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. EGR Valve A: SPECIFICATION Refer to “EGR Valve” for removal and installation. <Ref. to FU(H4SO 2.0)-28, EGR Valve.> or <Ref. to FU(H4SO 2.5)-30, EGR Valve.> EC(H4SO 2.0)-5...
Page 209: Canister
Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Canister Tightening torque: 8.3 N m (0.85 kgf-m, 6.1 ft-lb) A: REMOVAL 1) Lift-up the vehicle. 2) Remove the rear wheel LH. 3) Remove the mud guard LH. 4) Remove the protector. (Sedan model) 5) Disconnect the quick connector (A).
Page 210: Purge Control Solenoid Valve
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, 14.0 ft-lb) •...
Page 211 Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) • 2.5 L model EC-00224 (A) To fuel pipe (Evaporation line) (B) To intake manifold C: INSPECTION Make sure the hoses are not cracked or loose. EC(H4SO 2.0)-8...
Page 212: Two-Way Valve
Two-way Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Disconnect the evaporation hoses from two-way valve. 3) Remove the two-way valve as a unit with bracket from body. EC-00221 4) Remove the two-way valve from bracket. B: INSTALLATION Install in the reverse order of removal.
Page 213: Pcv Valve
PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 8. PCV Valve A: REMOVAL Disconnect the PCV hose and remove the PCV valve. • 2.0 L model EC-02029 • 2.5 L model EC-00225 B: INSTALLATION Install in the reverse order of removal. NOTE: Apply liquid gasket to the bolt threads of PCV valve.
Page 214 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 215 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 216 INTAKE (INDUCTION) IN(H4SO 2.0) Page General Description ..................2 Air Cleaner Element ..................5 Air Cleaner Case..................6 Air Intake Chamber ..................8 Air Intake Duct.....................9 Resonator Chamber..................10...
Page 217: General Description
General Description INTAKE (INDUCTION) 1. General Description A: COMPONENT (15) (14) (14) (13) (13) (11) (12) (10) (22) (16) (23) (19) (18) (17) (21) (20) IN-02004 IN(H4SO 2.0)-2...
Page 218 General Description INTAKE (INDUCTION) Air intake duct (14) Spacer (23) Intake air temperature sensor (Except for 2.5 L EC, EK, K4 Clip (15) Air intake chamber model) Resonator chamber (16) Stay LH (MT model) Air cleaner case (front) (17) Stay LH (AT model) Spacer (18) Clamp...
Page 219 General Description INTAKE (INDUCTION) B: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust and dirt.
Page 220: Air Cleaner Element
Air Cleaner Element INTAKE (INDUCTION) 2. Air Cleaner Element B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Fasten the air cleaner case (rear) with a clip after inserting the lower tab of the case. IN-00203 2) Disconnect the connector from mass air flow and IN-00207...
Page 221: Air Cleaner Case
Air Cleaner Case INTAKE (INDUCTION) 3. Air Cleaner Case 6) Remove the air cleaner case (rear) and air cleaner element. A: REMOVAL 1) Disconnect the ground cable from battery. IN-00206 7) Remove the bolt (A) and nut (B) which hold the IN-00203 air cleaner case on body.
Page 222 Air Cleaner Case INTAKE (INDUCTION) B: INSTALLATION Install in the reverse order of removal. Tightening torque: Bolt (A): 6.0 N m (0.6 kgf-m, 4.4 ft-lb) Nut (B): 7.5 N m (0.76 kgf-m, 5.5 ft-lb) IN-00208 NOTE: Fasten with a clip after inserting the lower tab of the case.
Page 223: Air Intake Chamber
Air Intake Chamber INTAKE (INDUCTION) 4. Air Intake Chamber B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. Clamp (A), (B) (Except for EC, EK, K4 model) 3.0 N m (0.3 kgf-m, 2.2 ft-lb) Bolt (C) 6.5 N...
Page 224: Air Intake Duct
Air Intake Duct INTAKE (INDUCTION) 5. Air Intake Duct A: REMOVAL 1) Remove the clips which install the air intake duct on the front side of body. 2) Remove the air intake duct. IN-00210 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Check for cracks or loose connections.
Page 225: Resonator Chamber
Resonator Chamber INTAKE (INDUCTION) 6. Resonator Chamber A: REMOVAL Refer to “Air Cleaner Case” for removal procedure because the resonator chamber forms a single unit with air cleaner case. <Ref. to IN(H4SO 2.0)-6, RE- MOVAL, Air Cleaner Case.> B: INSTALLATION Refer to “Air Cleaner Case”...
Page 226 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 227 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 228 MECHANICAL ME(H4SO 2.0) Page General Description ..................2 Compression .....................22 Idle Speed ....................23 Ignition Timing...................24 Intake Manifold Vacuum................25 Engine Oil Pressure ..................26 Fuel Pressure....................27 Valve Clearance..................28 Engine Assembly ..................30 Engine Mounting ..................36 Preparation for Overhaul................37 V-belt......................38 Crank Pulley....................40 Timing Belt Cover..................42 Timing Belt ....................43 Cam Sprocket ...................48 Crank Sprocket ..................50...
Page 229: General Description
General Description MECHANICAL 1. General Description A: SPECIFICATION Model 2.0 L 2.5 L Horizontally opposed, liquid cooled, 4-cylinder, Cylinder arrangement 4-stroke gasoline engine Belt driven, single over-head camshaft, 4-valve/ Valve system mechanism cylinder 99.5 ! 79.0 Bore ! Stroke 92 ! 75 (3.62 ! 2.95) mm (in) (3.917 ! 3.110) Displacement...
Page 230 General Description MECHANICAL Refacing angle 90" Valve seat Intake Standard 0.8 — 1.4 (0.03 — 0.055) Contacting width mm (in) Exhaust Standard 1.2 — 1.8 (0.047 — 0.071) Inside diameter mm (in) 6.000 — 6.012 (0.2362 — 0.2367) Valve guide Intake 20.0 —...
Page 231 General Description MECHANICAL Bend twist per 100 mm (3.94 in) in mm (in) Limit 0.10 (0.0039) Connecting length Side clearance of mm (in) Standard 0.070 — 0.330 (0.0028 — 0.0130) large end Oil clearance mm (in) Standard 0.016 — 0.044 (0.00063 — 0.0017) Standard 1.492 —...
Page 232 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.
Page 233 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 234 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 235 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 2.0)-8...
Page 236 General Description MECHANICAL 5. CYLINDER BLOCK (10) (11) (10) (14) (15) (10) (10) (26) (17) (16) (23) (12) (22) (18) (24) (21) (13) (20) (25) (19) ME-00810 & Oil pressure switch (14) Baffle plate Tightening torque: N m (kgf-m, ft-lb) Cylinder block (RH) (15) Oil filter connector...
Page 237 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 Flywheel (MT model) Piston pin (15) Woodruff key Reinforcement (AT model) Snap ring (16) Crankshaft bearing #1, #3 Drive plate (AT model) (10) Connecting rod bolt...
Page 238 General Description MECHANICAL 7. ENGINE MOUNTING • 2.0 L model 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 2.0)-11...
Page 239 General Description MECHANICAL • 2.5 L model ME-02090 & Front cushion rubber Tightening torque: N m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 85 (8.7, 62.7) ME(H4SO 2.0)-12...
Page 240 General Description MECHANICAL C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to • Wear work clothing, including a cap, protective assembly. goggles and protective shoes during operation. • Be careful not to let oil, grease or coolant contact •...
Page 241 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SUBARU Troubleshooting for electrical system. SELECT MONI- • English: 22771AA030 (Without printer) TOR KIT • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 498267800 CYLINDER •...
Page 242 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498457100 ENGINE STAND Used with ENGINE STAND (499817100). ADAPTER LH ST-498457100 498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos- STOPPER ening/tightening crank pulley bolt. ST-498497100 398744300 PISTON GUIDE Used for installing piston in cylinder. (2.0 L model) ST-398744300 498747300 PISTON GUIDE...
Page 243 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve GUIDE guide oil seals. ST-498857100 499017100 PISTON PIN Used for installing piston pin, piston and connect- GUIDE ing rod. ST-499017100 499037100 CONNECTING Used for removing and installing connecting rod...
Page 244 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587500 OIL SEAL • Used for installing camshaft oil seal. INSTALLER • Used with OIL SEAL GUIDE (499597000). ST-499587500 499587700 CAMSHAFT OIL Used for installing cylinder head plug. SEAL INSTALLER ST-499587700 499097700 PISTON PIN Used for removing piston pin.
Page 245 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499497000 Used for removing and installing camshaft cap. ® TORX PLUS ST-499497000 499587100 OIL SEAL Used for installing oil pump oil seal. INSTALLER ST-499587100 499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal. •...
Page 246 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499718000 VALVE SPRING Used for removing and installing valve spring. REMOVER ST-499718000 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 guides.
Page 247 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767800 VALVE GUIDE Used for installing valve guides. (Exhaust side) ADJUSTER ST-499767800 499817100 ENGINE STAND • Stand used for engine disassembly and assem- bly. • Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100). ST-499817100 499977400 CRANK PULLEY...
Page 248 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18332AA000 OIL FILTER Used for removing and installing oil filter. (Outer WRENCH diameter: 68 mm (2.68 in)) ST18332AA000 18332AA010 OIL FILTER Used for removing and installing oil filter. (Outer WRENCH diameter: 65 mm (2.56 in)) ST18332AA010 499987500 CRANKSHAFT...
Page 249: Compression
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) Release the fuel pressure.
Page 250: Idle Speed
3) Stop the engine, and turn the ignition switch to OFF. NOTE: 4) When using Subaru Select Monitor, refer to the This ignition system provides simultaneous ignition following. <Ref. to ME(H4SO 2.0)-13, SPECIAL for #1 and #2 plugs. It must be noted that some ta-...
Page 251: Ignition Timing
Ignition Timing MECHANICAL 4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement. 1) Idle the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light.
Page 252: Intake Manifold Vacuum
Intake Manifold Vacuum MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Idle the engine. 2) Disconnect the brake vacuum hose from the in- take manifold, and then install the vacuum gauge. 3) Keep the engine at the idle speed and read the vacuum gauge indication.
Page 253: Engine Oil Pressure
Engine Oil Pressure MECHANICAL 6. Engine Oil Pressure CAUTION: • If the oil pressure is out of specification, A: INSPECTION check oil pump, oil filter and lubrication line. 1) Disconnect the ground cable from battery. <Ref. to LU(H4SO 2.0)-19, INSPECTION, Gener- al Diagnostic Table.>...
Page 254: Fuel Pressure
Fuel Pressure MECHANICAL 7. Fuel Pressure A: INSPECTION WARNING: Before removing the fuel pressure gauge, re- lease fuel pressure. NOTE: When the fuel pressure is out of specification, check or replace the pressure regulator and pres- sure regulator vacuum hose. 1) Release the fuel pressure.
Page 255: Valve Clearance
Valve Clearance MECHANICAL 8. Valve Clearance NOTE: When the arrow mark (A) on cam sprocket (LH) A: INSPECTION comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression NOTE: stroke. Inspection and adjustment of valve clearance should be performed while engine is cold.
Page 256 Valve Clearance MECHANICAL Valve clearance NOTE: Intake: • Be sure to set the cylinder pistons to their re- 0.20 0.04 mm (0.0079 0.0016 in) spective top dead centers on compression stroke Exhaust: before measuring valve clearances. 0.25 0.04 mm (0.0098 0.0016 in) •...
Page 257: Engine Assembly
Engine Assembly MECHANICAL 9. Engine Assembly (1) Front oxygen (A/F) sensor connector A: REMOVAL 1) Set the vehicle on a lift. 2) Open the front hood fully and support with the front food stay. 3) Collect the refrigerant from A/C system. <Ref. to AC-20, PROCEDURE, Refrigerant Recovery Pro- cedure.>...
Page 258 Engine Assembly MECHANICAL (5) Generator connector and terminal 14) Remove the power steering pump from brack- (1) Loosen the lock bolt and slider bolt, and re- move the front side belt. <Ref. to ME(H4SO 2.0)-38, FRONT SIDE BELT, REMOVAL, V- belt.>...
Page 259 Engine Assembly MECHANICAL (4) Remove other bolts while rotating the en- 22) Support the transmission with a garage jack. gine using a socket wrench. CAUTION: • Doing this is very important because the transmission lowers for its own weight. This work is also of great importance for facilitating reinstallation.
Page 260 Engine Assembly MECHANICAL (3) Move the engine horizontally until main Tightening torque: & shaft is withdrawn from clutch cover. T1: 50 N m (5.1 kgf-m, 36.9 ft-lb) & (4) Slowly move the engine away from engine T2: 58 N m (5.9 kgf-m, 42.8 ft-lb) compartment.
Page 261 Engine Assembly MECHANICAL Tightening torque: NOTE: & 22 N m (2.2 kgf-m, 16 ft-lb) Make sure the front cushion rubber mounting bolts are securely installed. FU-00139 LU-00223 (2) Connect the power steering switch connec- tor. 15) Install the front and center exhaust pipe. <Ref.
Page 262 Engine Assembly MECHANICAL <Ref. to 4AT-31, INSPECTION, Automatic Trans- mission Fluid.> 27) Charge the A/C system with refrigerant. <Ref. to AC-21, PROCEDURE, Refrigerant Charging Procedure.> 28) Remove the front hood stay, and close the front hood. 29) Take off the vehicle from a lift. C: INSPECTION 1) Check pipes and hoses are installed firmly.
Page 263: Engine Mounting
Engine Mounting MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove engine assembly. <Ref. ME(H4SO 2.0)-30, 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...
Page 264: Preparation For Overhaul
Preparation for Overhaul MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from the body, secure it in the ST shown below. 498457000 ENGINE STAND ADAPTER 498457100 ENGINE STAND ADAPTER 499817100 ENGINE STAND ME-00221 2) In this section the procedures described under each index are all connected and stated in order.
Page 265: V-Belt
V-belt MECHANICAL 12.V-belt 4) Remove the belt tensioner. A: REMOVAL NOTE: Perform the following procedures with the engine installed to the body. 1. FRONT SIDE BELT 1) Remove the V-belt covers. ME-00225 B: INSTALLATION NOTE: Wipe off any oil or water on the belt and pulley. 1.
Page 266 V-belt MECHANICAL Tightening torque: Belt tension (without belt tension gauge) Lock nut (A); & 23 N m (2.3 kgf-m, 17.0 ft-lb) When installing new parts: 7 — 9 mm (0.276 — 0.354 in) At inspection: 9 — 11 mm (0.354 — 0.433 in) When installing new parts: 7.5 —...
Page 267: Crank Pulley
Crank Pulley MECHANICAL 13.Crank Pulley CAUTION: If the tightening angle of crank pulley bolt is A: REMOVAL less than 45", the bolt should be damaged. In 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, this case, the bolt must be replaced. REMOVAL, V-belt.>...
Page 268 Crank Pulley MECHANICAL Tightening torque: & 180 N m (18.4 kgf-m, 132.8 ft-lb) ME-00227 3) Confirm that the tightening angle of crank pulley bolt is 65 degrees or more. If the tightening angle of crank pulley bolt is less than 65 degrees, conduct the following procedures.
Page 269: Timing Belt Cover
Timing Belt Cover MECHANICAL 14.Timing Belt Cover A: REMOVAL 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO 2.0)-40, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover (LH). 4) Remove the front timing belt cover. ME-00821 (A) Timing belt cover (LH) (B) Front timing belt cover...
Page 270 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 271 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 272 MECHANICAL ME(H4SO 2.0) Page General Description ..................2 Compression .....................22 Idle Speed ....................23 Ignition Timing...................24 Intake Manifold Vacuum................25 Engine Oil Pressure ..................26 Fuel Pressure....................27 Valve Clearance..................28 Engine Assembly ..................30 Engine Mounting ..................36 Preparation for Overhaul................37 V-belt......................38 Crank Pulley....................40 Timing Belt Cover..................42 Timing Belt ....................43 Cam Sprocket ...................48 Crank Sprocket ..................50...
Page 273: Timing Belt
Timing Belt MECHANICAL 15.Timing Belt A: REMOVAL 1. TIMING BELT 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO 2.0)-40, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov- er.>...
Page 274 Timing Belt 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 275 Timing Belt MECHANICAL 2) Install the automatic belt tension adjuster as- 499207400 CAM SPROCKET WRENCH sembly. Tightening torque: 39 N m (4.0 kgf-m, 28.9 ft-lb) ME-00243 (2) While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, posi- tion the timing belt properly.
Page 276 Timing Belt MECHANICAL 5) After ensuring the marks on timing belt and cam Tightening torque: sprockets are aligned, remove the stopper pin from 10 N m (1.0 kgf-m, 7.2 ft-lb) belt tension adjuster. ME-00247 ME-00245 7) Install the timing belt cover. 6) Install the timing belt guide.
Page 277 Timing Belt MECHANICAL 2. AUTOMATIC BELT TENSION ADJUST- 3. BELT TENSION PULLEY 1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or 1) Visually check the oil seals for leaks, and rod scratches.
Page 278: Cam Sprocket
Cam Sprocket MECHANICAL 16.Cam Sprocket NOTE: Do not confuse left and right side cam sprockets A: REMOVAL during installation. Cam sprocket No. 2 is identified 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, by a protrusion used to monitor the camshaft posi- REMOVAL, V-belt.>...
Page 279 Cam Sprocket MECHANICAL 3) Check the cam sprocket protrusion used for sen- sor for damage and contamination of foreign mat- ter. ME(H4SO 2.0)-49...
Page 280: Crank Sprocket
Crank Sprocket MECHANICAL 17.Crank Sprocket 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign A: REMOVAL matter. 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO 2.0)-40, REMOVAL, Crank Pulley.>...
Page 281: Valve Rocker Assembly
Valve Rocker Assembly MECHANICAL 18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified torque. A: REMOVAL Tightening torque: 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, 25 N m (2.5 kgf-m, 18.1 ft-lb) REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO ( g ) ( e ) ( a )
Page 282 Valve Rocker Assembly MECHANICAL E: INSPECTION 1. VALVE ROCKER ARM AND ROCKER SHAFT 1) Measure the inner diameter of valve rocker arm and outer diameter of valve rocker shaft, and deter- mine the difference (oil clearance) between the two values. Clearance between arm and shaft: Standard: 0.020 —...
Page 283: Camshaft
Camshaft MECHANICAL 19.Camshaft (1) Remove the bolts (a) and (b) in alphabetical sequence. A: REMOVAL 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO ( a ) 2.0)-40, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover.
Page 284 Camshaft MECHANICAL (3) Install the valve rocker assembly. CAUTION: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when re- moving the oil seal. B: INSTALLATION 1) Apply a coat of engine oil to camshaft journals and install the camshaft.
Page 285 Camshaft MECHANICAL Tightening torque: 9) Install the tensioner bracket. 10 N m (1.0 kgf-m, 7.2 ft-lb) Tightening torque: 25 N m (2.5 kgf-m, 18.1 ft-lb) ( q ) ( o ) ( u ) ( s ) ( t ) ( v ) ( p ) ( r )
Page 286 Camshaft MECHANICAL C: INSPECTION Cam base circle diameter A: Intake: 34.00 mm (1.3386 in) 1. CAMSHAFT Exhaust: 34.00 mm (1.3386 in) 1) Measure the bend, and repair or replace if nec- essary. Service limit: 0.020 mm (0.00079 in) ME-00276 2. CAMSHAFT SUPPORT Measure the side clearance of camshaft with set- ting the dial gauge at end of camshaft.
Page 287: Cylinder Head
Cylinder Head MECHANICAL 20.Cylinder Head CAUTION: Be careful not to scratch the mating surface of A: REMOVAL cylinder head and cylinder block. 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, 14) Similarly, remove the right side cylinder head. REMOVAL, V-belt.> B: INSTALLATION 2) Remove the crank pulley.
Page 288 Cylinder Head MECHANICAL 7) Install the cam sprocket. <Ref. to ME(H4SO NOTE: 2.0)-48, INSTALLATION, Cam Sprocket.> Keep all the removed parts in order for re-installing 8) Install the timing belt. <Ref. to ME(H4SO 2.0)- in their original positions. 44, INSTALLATION, Timing Belt.> CAUTION: 9) Install the timing belt cover.
Page 289 Cylinder Head MECHANICAL 1) Installation of valve spring and valve: E: INSPECTION (1) Place the cylinder head on the ST. 1. VALVE SPRING ST 498267800 CYLINDER HEAD TABLE (2) Coat the stem of each valve with engine oil 1) Check the valve springs for damage, free length, and insert the valve into valve guide.
Page 290 Cylinder Head MECHANICAL Color of spring part: 2. VALVE SEAT Intake [Silver] Inspect the intake and exhaust valve seats, and Exhaust [Silver] correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are re- placed.
Page 291 Cylinder Head MECHANICAL Clearance between the valve guide and valve 498267800 CYLINDER HEAD TABLE stem: 499767200 VALVE GUIDE REMOVER Standard Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in) ME-00290 (3) Turn the cylinder head upside down and place the ST as shown in the figure.
Page 292 Cylinder Head MECHANICAL (6) Check the valve guide protrusion. 4. INTAKE AND EXHAUST VALVE Valve guide protrusion L: 1) Inspect the flange and stem of valve, and re- place if damaged, worn or deformed, or if “H” ex- Intake ceed the standard value. 20.0 —...
Page 293: Cylinder Block
Cylinder Block MECHANICAL 21.Cylinder Block 12) Remove the bolts (a) and (c) to remove the cyl- inder head. A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the intake manifold. <Ref. to FU(H4SO 2.0)-11, REMOVAL, Intake Manifold.> 2) Remove the V-belts.
Page 294 Cylinder Block MECHANICAL 19) Remove the water pump after loosening the 25) Remove the oil filter. bolts in alphabetical sequence as shown in the fig- ure. ME-00299 26) Remove the water pipe. ME-00847 20) Remove the oil pump from cylinder block. Use a flat tip screwdriver as shown in the figure when removing the oil pump.
Page 295 Cylinder Block MECHANICAL ME-00139 Service hole plug Snap ring 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 a hexagon wrench (14 mm). tons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
Page 296 Cylinder Block MECHANICAL 30) Similarly remove the piston pins from #3 and #4 NOTE: pistons. Be careful not to confuse the original combination 31) Remove the bolts which connect cylinder block of piston, piston pin and cylinder. on the side of #2 and #4 cylinders. 32) Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
Page 297 Cylinder Block MECHANICAL B: INSTALLATION ME-00144 Crankshaft bearing Cylinder block Rear oil seal Crankshaft NOTE: NOTE: Remove oil on the mating surface of bearing and Do not allow liquid gasket to flow into O-ring cylinder block before installation. Apply a coat of grooves, oil passages, bearing grooves, etc.
Page 298 Cylinder Block MECHANICAL Tightening torque: Tightening torque: 10 N m (1.0 kgf-m, 7.4 ft-lb) (E), (F), (G), (I): 20 N m (2.0 kgf-m, 14.8 ft-lb) (H), (J): 18 N m (1.8 kgf-m, 13.3 ft-lb) ME-00398 ME-00399 4) Tighten the 10 mm cylinder block connecting bolts on RH side (E —...
Page 299 Cylinder Block MECHANICAL Tightening torque: 13) Position the upper rail gap at (C) in the figure. (A) — (G): 25 N m (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 N m (0.65 kgf-m, 4.7 ft-lb) ME-02087 14) Align the upper rail spin stopper (E) to the side hole (D) on the piston.
Page 300 Cylinder Block MECHANICAL 17) Install the snap ring. CAUTION: Install snap rings in the piston holes located oppo- Piston front mark faces towards the front of en- site to the service holes in cylinder block, when po- gine. sitioning all pistons in the corresponding cylinders. NOTE: Use new snap rings.
Page 301 Cylinder Block MECHANICAL 19) Install the piston pin. (6) Install the service hole plug and gasket. (1) Apply a coat of engine oil to ST3. NOTE: (2) Insert ST3 into the service hole to align pis- Use a new gasket. ton pin hole with connecting rod small end.
Page 302 Cylinder Block MECHANICAL ME-00161 Piston Service hole plug Tightening torque: N m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7) Snap ring O-ring T2: 70 (7.1, 50.6) Gasket (7) Place the cylinder block to face the #3 and 24) Apply liquid gasket to mating surfaces and in- #4 cylinder side upward.
Page 303 Cylinder Block MECHANICAL 25) Apply liquid gasket to mating surfaces and in- ST 499587100 OIL SEAL INSTALLER stall the oil separator cover. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent ME-00164 (2) Apply liquid gasket to the matching surface of oil pump.
Page 304 Cylinder Block MECHANICAL Tightening torque: CAUTION: First: 12 N m (1.2 kgf-m, 8.7 ft-lb) Ensure the total “re-tightening angle” of the Second: 12 N m (1.2 kgf-m, 8.7 ft-lb) step (6) and (7) does not exceed 180#. CAUTION: • Be sure to use a new gasket. •...
Page 305 Cylinder Block MECHANICAL C: DISASSEMBLY ME-00168 Connecting rod cap Top ring Oil ring Connecting rod bearing Second ring Snap ring 1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion. 3) Remove the piston rings using the piston ring ex- pander.
Page 306 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, 33.3) Connecting rod cap Snap ring Oil ring Side mark 1) Apply oil to the surfaces of the connecting rod E: INSPECTION bearings.
Page 307 Cylinder Block MECHANICAL Standard diameter: Out-of-roundness: 2.0 L model Standard A: 92.005 — 92.015 mm (3.6222 — 3.6226 0.010 mm (0.0004 in) B: 91.995 — 92.005 mm (3.6218 — 3.6222 2.5 L model A: 99.505 — 99.515 mm (3.9175 — 3.9179 B: 99.495 —...
Page 308 Cylinder Block MECHANICAL Standard (2) If the cylinder inner diameter exceeds limit* after boring and honing, replace the cylinder 2.0 L model block. A: 92.005 — 92.015 mm (3.6222 — 3.6226 *: 2.0 L model B: 91.995 — 92.005 mm (3.6219 — 3.6222 92.515 mm (3.6423 in) 2.5 L model 2.5 L model...
Page 309 Cylinder Block MECHANICAL 4) Check the snap ring installation groove (A) on 2) Clean the piston ring groove and piston ring. the piston for burr. If necessary, remove burr from 3) Squarely place the piston ring and oil ring in cyl- the groove so that the piston pin can lightly move.
Page 310 Cylinder Block MECHANICAL Limit of bend or twist per 100 mm (3.94 in) in Connecting rod oil clearance: length: Standard 0.10 mm (0.0039 in) 0.016 — 0.044 mm (0.00063 — 0.0017 in) Unit: mm (in) Bearing size ( A ) Outer diameter of Bearings (Thickness at cen-...
Page 311 Cylinder Block MECHANICAL ST 499037100 CONNECTING ROD BUSH- Crank pin: ING REMOVER AND IN- 2.0 L model STALLER Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit To 51.750 mm (2.0374 in) dia. 2.5 L model Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in)
Page 312 Cylinder Block MECHANICAL Unit: mm (in) Crank journal outer diameter Crank pin outer diameter #1, #3 #2, #4, #5 59.992 — 60.008 59.992 — 60.008 51.984 — 52.000 Journal O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472) Standard Bearing size 1.998 —...
Page 313: Engine Trouble In General
Engine Trouble in General MECHANICAL 22.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely Symptom Problem parts, etc.
Page 314 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 4) Engine stalls after initial Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> combustion. Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket...
Page 315 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 3. Low output, hesitation and Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> poor acceleration Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket...
Page 316 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 5. Engine does not return to Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> idle. Intake system Loosened or cracked vacuum hose Other Stuck or damaged throttle valve 6.
Page 317 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 10. Excessive fuel consump- Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> tion Intake system Dirty air cleaner element Belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing...
Page 318: Engine Noise
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 319 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 320 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 321 EXHAUST EX(H4SO 2.0) Page General Description ..................2 Front Exhaust Pipe..................7 Center Exhaust Pipe .................10 Rear Exhaust Pipe ..................11 Muffler .......................13...
Page 322: General Description
General Description EXHAUST 1. General Description A: COMPONENT • 2.0 L model (19) (22) (20) (21) (19) (16) (19) (15) (18) (17) (23) (24) (12) (11) (14) (10) (13) EX-02020 EX(H4SO 2.0)-2...
Page 323 General Description EXHAUST Front catalytic converter upper (11) Center exhaust pipe lower cover (23) Rear exhaust pipe upper cover cover (12) Gasket (24) Rear exhaust pipe lower cover Front catalytic converter (13) Front catalytic converter lower cover Center exhaust pipe Tightening torque: N m (kgf-m, ft-lb) Center exhaust pipe upper cover...
Page 324 General Description EXHAUST • 2.5 L model (22) (19) (23) (19) (21) (19) (21) (20) (19) (16) (19) (20) (15) (18) (17) (24) (25) (12) (11) (14) (10) (13) EX-02012 EX(H4SO 2.0)-4...
Page 325 General Description EXHAUST Front catalytic converter upper (11) Center exhaust pipe lower cover (23) Muffler (LH) cover (12) Gasket (24) Rear exhaust pipe upper cover Front catalytic converter (13) Front catalytic converter lower (25) Rear exhaust pipe lower cover cover Center exhaust pipe Center exhaust pipe upper cover (14)
Page 326 General Description EXHAUST B: CAUTION • Wear work clothing, including a cap, protective goggles and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust and dirt.
Page 327: Front Exhaust Pipe
Front Exhaust Pipe EXHAUST 2. Front Exhaust Pipe 7) Remove the nuts which hold front exhaust pipe onto cylinder heads. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. Be careful not to pull down the front and center exhaust pipe assembly.
Page 328 Front Exhaust Pipe EXHAUST 11) Remove the front oxygen (A/F) sensor and rear 5) Install the nuts to cylinder head which hold front oxygen sensor. <Ref. to FU(H4SO 2.0)-32, RE- exhaust pipe. MOVAL, Front Oxygen (A/F) Sensor.> <Ref. to Tightening torque: FU(H4SO 2.0)-33, REMOVAL, Rear Oxygen Sen- 30 N m (3.1 kgf-m, 22.4 ft-lb)
Page 329 Front Exhaust Pipe EXHAUST 9) Connect the rear oxygen sensor connector. FU-01116 10) Lower the vehicle. 11) Connect the front oxygen (A/F) sensor connec- tor. ME-00859 12) Connect the battery ground cable to battery. IN-00203 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds.
Page 330: 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 “Front Exhaust Pipe” for removal procedure. <Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
Page 331: Rear Exhaust Pipe
Rear Exhaust Pipe EXHAUST 4. Rear Exhaust Pipe 4) Remove the rear exhaust pipe bracket from cushion rubber. A: REMOVAL 1) Separate the rear exhaust pipe from center ex- haust pipe. EX-00219 B: INSTALLATION 1) Apply a coat of spray type lubricant to mating EX-00214 area of cushion rubber.
Page 332 Rear Exhaust Pipe EXHAUST • RH side (2.5 L model) EX-00218 4) Install the rear exhaust pipe to center exhaust pipe. Tightening torque: 18 N m (1.8 kgf-m, 13.0 ft-lb) EX-00214 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds.
Page 333: Muffler
Muffler EXHAUST 5. Muffler B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Separate the muffler from rear exhaust pipe. Use a new gasket and self-locking nut. • LH side Tightening torque: 48 N m (4.9 kgf-m, 35.4 ft-lb) •...
Page 334 Muffler EXHAUST EX(H4SO 2.0)-14...
Page 335 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 336 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 337 COOLING CO(H4SO 2.0) Page General Description ..................2 Radiator Fan System ..................7 Engine Coolant..................13 Water Pump ....................15 Thermostat ....................18 Radiator.....................20 Radiator Cap .....................24 Radiator Main Fan and Fan Motor ............25 Radiator Sub Fan and Fan Motor..............27 Reservoir Tank..................29 Engine Cooling System Trouble in General ..........30...
Page 338: General Description
General Description COOLING 1. General Description A: SPECIFICATION Cooling system Electric fan + Forced engine coolant circulation system MT: approx. 6.5 (6.9, 5.7) Total engine coolant capacity 2 (US qt, Imp qt) AT: approx. 6.4 (6.8, 5.6) (Model without ATF warmer) AT: approx.
Page 339 General Description COOLING Engine coolant temperature 96 — 99!C 95!C (203!F) or less 100!C (212!F) or more Vehicle speed A/C compressor load (203 — 210!F) Operation of radiator Operation of radiator Operation of radiator Low-Speed High-Speed 19 km/h (12 MPH) or less Low-Speed Low-Speed High-Speed...
Page 340 General Description COOLING B: COMPONENT 1. WATER PUMP CO-02031 Water pump ASSY Thermostat Tightening torque: N m (kgf-m, ft-lb) Gasket Gasket T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Heater by-pass hose Thermostat cover ATF warmer by-pass hose (Model T2: 12 (1.2, 8.7) with ATF warmer) CO(H4SO 2.0)-4...
Page 341 General Description COOLING 2. RADIATOR AND RADIATOR FAN (10) (14) (27) (11) (26) (24) (12) (14) (28) (13) (14) (15) (20) (14) (22) (14) (21) (16) (14) (25) (23) (14) (17) (18) (14) (19) CO-02010 Radiator lower cushion (14) ATF hose clamp (AT model) (24) Radiator cap Radiator...
Page 342 General Description COOLING C: CAUTION • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Wear work clothing, including a cap, protective • Be sure to tighten fasteners including bolts and goggles, and protective shoes during operation. nuts to the specified torque.
Page 343 Radiator Fan System COOLING 2. Radiator Fan System A: WIRING DIAGRAM SBF-1 SBF-7 No.3 IGNITION SWITCH No.2 No.26 No.22 MAIN FUSE BOX (M/B) MAIN B143 RELAY 1 THROUGH JOINT CONNECTOR F109 B360 A/C RELAY HOLDER MAIN RELAY 2 RELAY MAIN FAN MOTOR THROUGH JOINT CONNECTOR...
Page 344: Radiator Fan System
Subaru Select Monitor. NOTE: • When performing the compulsory operation check for the radiator fan relay using Subaru Select Monitor, the radiator main fan and sub fan will repeat such a operation as low speed revolution &'high speed revolution &'OFF in this order.
Page 345 Radiator Fan System COOLING Step Check CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 7. Go to step 6. LAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between sub fan relay terminal and chassis ground.
Page 346 Radiator Fan System COOLING Step Check CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 15. Repair the open RELAY 2 TERMINAL AND MAIN FAN MO- circuit of harness TOR CONNECTOR. between main fan 1) Disconnect the connector from main fan relay 2 terminal motor.
Page 347 Radiator Fan System COOLING Step Check CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 23. Repair the open RELAY 1 TERMINAL AND MAIN FAN MO- circuit of harness TOR CONNECTOR. between main fan 1) Disconnect the connector from main fan relay 1 terminal motor.
Page 348 Radiator Fan System COOLING Step Check CHECK MAIN FAN RELAY 2. Is the resistance more than 1 Go to step 31. Replace the main 1) Turn the ignition switch to OFF. fan relay 2. 2) Remove the main fan relay 2. 3) Measure the resistance of main fan relay 2.
Page 349: Engine Coolant
6.8 2(7.2 US qt, 6.0 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 2.0)-13...
Page 350 The concentration and safe operating temperature amount of coolant with an undiluted solution of of SUBARU coolant is shown in the diagram. Mea- SUBARU genuine coolant (concentration 50%). suring the temperature and specific gravity of the The amount of coolant that should be replaced can coolant will provide this information.
Page 351: Water Pump
Water Pump COOLING 4. Water Pump 7) Remove the belt cover No. 2 (LH). A: REMOVAL 1) Remove the radiator. <Ref. to CO(H4SO 2.0)- 20, REMOVAL, Radiator.> 2) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 3) Remove the timing belt. <Ref. to ME(H4SO 2.0)- 43, TIMING BELT, REMOVAL, Timing Belt.>...
Page 352 Water Pump COOLING Tightening torque: Tightening torque: First: 78 N m (8.0 kgf-m, 57.9 ft-lb) 12 N m (1.2 kgf-m, 8.7 ft-lb) Second: 12 N m (1.2 kgf-m, 8.7 ft-lb) CO-00018 6) Install the belt idler No. 2. Tightening torque: ME-00847 39 N m (4.0 kgf-m, 28.9 ft-lb)
Page 353 Water Pump COOLING Clearance between impeller and pump case: Standard value 0.5 — 1.5 mm (0.020 — 0.060 in) CO-00293 5) After water pump installation, check the pulley shaft for engine coolant leaks and noise. If leaks or noise are noted, replace the water pump assembly. CO(H4SO 2.0)-17...
Page 354: Thermostat
Thermostat COOLING 5. Thermostat 6) Remove the thermostat cover and gasket, and then remove the thermostat. A: REMOVAL 1) Set the vehicle on a lift. 2) Lift-up the vehicle. 3) Remove the under cover. 4) Drain engine coolant completely. <Ref. to CO(H4SO 2.0)-13, DRAINING OF EN- GINE COOLANT, REPLACEMENT, Engine Cool- ant.>...
Page 355 Thermostat COOLING Tightening torque: Valve lift: 12 N m (1.2 kgf-m, 8.7 ft-lb) 9.0 mm (0.354 in) or more ( A ) ( B ) CO-00033 (A) Thermometer (B) Thermostat CO-00155 (A) Thermostat cover (B) Gasket (C) Thermostat (D) Jiggle pin 2) Connect the radiator outlet hose to thermostat cover.
Page 356: Radiator
Radiator COOLING 6. Radiator 7) Disconnect the connector (A) of radiator main fan motor and connector (B) of sub fan motor. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00274 IN-00203 3) Lift-up the vehicle. 4) Remove the under cover.
Page 357 Radiator COOLING 13) Remove the hood stay holder. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side. 3) Install the radiator upper brackets and tighten the bolts. Tightening torque: 18 N m (1.8 kgf-m, 13.0 ft-lb) CO-00276 14) Remove the air intake duct.
Page 358 Radiator COOLING 10) Connect the ATF cooler hoses. (Model without 13) Install the heat shield cover. (Model without ATF warmer) ATF warmer) CO-00253 CO-00273 11) Connect the radiator outlet hose. 14) Install the under cover. 15) Lower the vehicle. 16) Connect the battery ground cable to battery. CO-00270 12) Connect the connector (A) to radiator main fan IN-00203...
Page 359 Radiator COOLING • Be careful to prevent engine coolant from spurting out when removing tester. • Be careful not to deform the filler neck of ra- diator when installing or removing the tester. CO(H4SO 2.0)-23...
Page 360: Radiator Cap
Radiator Cap COOLING 7. Radiator Cap A: INSPECTION 1) Attach the radiator cap to tester. CO-00044 2) Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Standard pressure: 93 —...
Page 361: Radiator Main Fan And Fan Motor
Radiator Main Fan and Fan Motor COOLING 8. Radiator Main Fan and Fan 11) Remove the bolts which hold the radiator main fan shroud to radiator. Motor A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00096 12) Remove the radiator main fan motor assembly.
Page 362 Radiator Main Fan and Fan Motor COOLING 3) Remove the bolts which install fan motor onto the shroud. CO-00098 D: ASSEMBLY Assemble in the reverse order of disassembly. Tightening torque: 4.4 N m (0.45 kgf-m, 3.3 ft-lb) CO-00098 Tightening torque: 3.4 N m (0.35 kgf-m, 2.5 ft-lb) CO-00102...
Page 363: Radiator Sub Fan And Fan Motor
Radiator Sub Fan and Fan Motor COOLING 9. Radiator Sub Fan and Fan 10) Remove the bolts which hold the radiator sub fan shroud to radiator. Motor A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00101 11) Remove the radiator sub fan motor assembly from the lower side of vehicle.
Page 364 Radiator Sub Fan and Fan Motor COOLING 3) Remove the bolts which install fan motor onto the shroud. CO-00098 D: ASSEMBLY Assemble in the reverse order of disassembly. Tightening torque: 4.4 N m (0.45 kgf-m, 3.3 ft-lb) CO-00098 Tightening torque: 3.4 N m (0.35 kgf-m, 2.5 ft-lb) CO-00097...
Page 365: Reservoir Tank
Reservoir Tank COOLING 10.Reservoir Tank A: REMOVAL 1) Disconnect the over flow hose. 2) Pull out the reservoir tank to the direction of ar- row while pushing the pawl (A). CO-00279 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Make sure the engine coolant level is between “FULL”...
Page 366: Engine Cooling System Trouble In General
Engine Cooling System Trouble in General COOLING 11.Engine Cooling System Trouble in General A: INSPECTION Trouble Possible cause Corrective action Replenish engine coolant, inspect for leakage, and a. Insufficient engine coolant repair it if necessary. b. Loose timing belt Repair or replace timing belt tensioner. c.
Page 367 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 368 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 369 LUBRICATION LU(H4SO 2.0) Page General Description ..................2 Oil Pressure System ...................6 Engine Oil....................8 Oil Pump ....................10 Oil Pan and Strainer..................14 Oil Pressure Switch...................17 Engine Oil Filter..................18 General Diagnostic Table................19...
Page 370: General Description
5W-30,0W-20 (2) CCMC specification, G4 or G5 New API certification mark (Star burst mark) label is on the container. LU-00071 (1) SAE viscosity No. and applicable temperature (2) Recommend CAUTION: When replacing oil, use only SUBARU genuine engine oil. LU(H4SO 2.0)-2...
Page 371 General Description LUBRICATION B: COMPONENT (13) (16) (15) (14) (12) (17) (11) (18) (10) (19) (23) (20) (26) (21) (22) (25) (24) LU-00228 Plug (13) Oil pressure switch (24) Drain plug Gasket (14) Oil filler duct (25) Metal gasket Relief valve spring (15) O-ring (26)
Page 372 General Description LUBRICATION C: CAUTION • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Wear work clothing, including a cap, protective • Be sure to tighten fasteners including bolts and goggles and protective shoes during operation. nuts to the specified torque.
Page 373 General Description LUBRICATION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18332AA010 OIL FILTER Used for removing and installing oil filter. (Outer WRENCH diameter: 65 mm (2.56 in)) ST18332AA010 499587100 OIL SEAL Used for installing oil seal into oil pump. INSTALLER ST-499587100 LU(H4SO 2.0)-5...
Page 374: Oil Pressure System
Oil Pressure System LUBRICATION 2. Oil Pressure System A: WIRING DIAGRAM BATTERY No.5 SBF-7 SBF-1 IGNITION SWITCH COMBINATION METER OIL PRESSURE SWITCH 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 4 5 6...
Page 375 Oil Pressure System LUBRICATION B: INSPECTION Step Check CHECK COMBINATION METER. Does the warning light illumi- Go to step 2. Repair or replace 1)Turn the ignition switch to ON (engine OFF). nate? the combination 2)Check the warning light of combination meter.
Page 376: Engine Oil
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 engine oil by loosening the engine oil drain 3) Reinsert the level gauge all the way.
Page 377 Engine Oil LUBRICATION 8) After the engine stops, recheck the oil level. If necessary, add engine oil up to the upper level on level gauge. LU-00213 (A) Oil level gauge (B) Engine oil filler cap (C) Upper level (D) Lower level (E) Approx.
Page 378: Oil Pump
Oil Pump LUBRICATION 4. Oil Pump 9) Remove the crank pulley using ST. ST 499977400 CRANK PULLEY WRENCH A: REMOVAL (2.0 L model) 1) Disconnect the ground cable from battery. ST 499977100 CRANK PULLEY WRENCH (2.5 L model) IN-00203 LU-00012 2) Lift-up the vehicle.
Page 379 Oil Pump LUBRICATION 13) Remove the bolts which install oil pump onto 3) Apply a coat of engine oil to the inside of oil seal. cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
Page 380 Oil Pump LUBRICATION C: DISASSEMBLY D: ASSEMBLY Remove the screws which secure oil pump cover 1) Install the front oil seal using ST. and then 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 381 Oil Pump LUBRICATION E: INSPECTION 3. SIDE CLEARANCE Measure the clearance between oil pump inner ro- 1. TIP CLEARANCE tor and pump cover. If the clearance is out of the Measure the tip clearance of rotors. If the clearance standard value, replace the rotor or oil pump case. is out of the standard value, replace the rotors as a Side clearance: matched set.
Page 382: Oil Pan And Strainer
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-00222 9) Lift-up the vehicle.
Page 383 Oil Pan and Strainer LUBRICATION 17) Remove the baffle plate. 3) Apply liquid gasket to the mating surfaces and install the oil pan. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent LU-00034 4) Tighten the bolts which install oil pan onto cylin- der block.
Page 384 Oil Pan and Strainer LUBRICATION 6) Tighten the nuts which install front cushion rub- 12) Install the hood stay holder (A) and radiator up- ber onto front crossmember. per brackets (B). Tightening torque: 69 N m (7.0 kgf-m, 50.9 ft-lb) LU-00232 13) Install the air intake chamber.
Page 385: Oil Pressure Switch
Oil Pressure Switch LUBRICATION 6. Oil Pressure Switch 2) Install the oil pressure switch onto engine block. Tightening torque: A: REMOVAL 25 N m (2.5 kgf-m, 18.1 ft-lb) 1) Remove the generator from bracket. <Ref. to SC(H4SO 2.0)-14, REMOVAL, Genera- tor.>...
Page 386: Engine Oil Filter
Engine Oil Filter LUBRICATION 7. Engine Oil Filter A: REMOVAL 1) Lift-up the vehicle. 2) Remove the oil filter using ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) LU-00234 B: INSTALLATION 1) Clean the oil filter installing surface on cylinder...
Page 387: General Diagnostic Table
General Diagnostic Table LUBRICATION 8. General Diagnostic Table A: INSPECTION Before performing diagnosis, make sure that the engine oil level is correct and no oil leakage exists. Symptom Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace. 1) Oil pressure switch failure Broken spring or seized contacts...
Page 388 General Diagnostic Table LUBRICATION LU(H4SO 2.0)-20...
Page 389 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 390 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 391 SPEED CONTROL SYSTEMS SP(H4SO 2.0) Page General Description ..................2 Accelerator Pedal..................4...
Page 392 General Description SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION LHD model 50 — 63 mm (1.97 — 2.48 in) Accelerator pedal Stroke At pedal pad RHD model 53 — 65 mm (2.09 — 2.56 in) B: COMPONENT • LHD model SP-02002 Accelerator pedal ASSY Clip...
Page 393 General Description SPEED CONTROL SYSTEMS • RHD model SP-02003 Accelerator pedal ASSY Tightening torque: N m (kgf-m, ft-lb) Stopper T: 18 (1.8, 13.0) C: CAUTION • Wear work clothing, including a cap, protective goggles and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly.
Page 394 Accelerator Pedal SPEED CONTROL SYSTEMS 2. Accelerator Pedal A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector. 3) Remove the nut securing accelerator pedal as- sembly. • LHD model SP-02001 • RHD model SP-00052 B: INSTALLATION Install in the reverse order of removal.
Page 395 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 396 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 397 IGNITION IG(H4SO 2.0) Page General Description ..................2 Spark Plug....................5 Ignition Coil & Ignitor ASSY ................8 Spark Plug Cord..................10...
Page 398: General Description
General Description IGNITION 1. General Description A: SPECIFICATION 1. 2.0 L MODEL Item Designation Model CM12-100C Ignition coil & ignitor Manufacturer HITACHI ASSY Secondary coil resistance 18.0 k!" 20% Manufacturer and Type CHAMPION: RC10YC4 Thread size (diameter, pitch, length) 14, 1.25, 19 Spark plug Spark plug gap mm (in)
Page 399 General Description IGNITION B: COMPONENT • 2.0 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, 15.2) IG(H4SO 2.0)-3...
Page 400 General Description IGNITION • 2.5 L model IG-00094 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, 15.2) C: CAUTION •...
Page 401: Spark Plug
Spark Plug IGNITION 2. Spark Plug 2. LH SIDE 1) Remove the battery. A: REMOVAL 2) Remove the spark plug cords by pulling the boot. CAUTION: (Do not pull the cord itself.) All spark plugs installed on an engine must be of the same heat range.
Page 402 Spark Plug IGNITION C: INSPECTION 3) Oil fouled: Wet black deposits show excessive oil entrance Check the electrodes and inner and outer ceramic into combustion chamber through worn rings and insulator of plugs, noting the type of deposits and pistons or excessive clearance between valve the degree of electrode erosion.
Page 403 Spark Plug IGNITION NOTE: Replace with a new spark plug if the area (A) is worn to spherical shape. IG(H4SO 2.0)-7...
Page 404: Ignition Coil & Ignitor Assy
Ignition Coil & Ignitor ASSY IGNITION 3. Ignition Coil & Ignitor ASSY 4) Remove the bolt (B) which secures the ignition coil & ignitor ASSY to intake manifold. A: REMOVAL • 2.0 L model 1) Disconnect the ground cable from battery. IG-02002 IN-00203 •...
Page 405 Ignition Coil & Ignitor ASSY IGNITION Specified resistance (2.0 L model): [Secondary side] Between (A) and (B) !" 18.0 k Between (C) and (D) !" 18.0 k IG-02003 Specified resistance (2.5 L model): [Secondary side] Between (A) and (B) !" 11.2 k Between (C) and (D) !"...
Page 406: Spark Plug Cord
Spark Plug Cord IGNITION 4. Spark Plug Cord A: INSPECTION Check the following items: • Damage to cords, deformation, burning or rust formation of terminals • Resistance values of cords Resistance value (2.0 L model): #1 cord: 5.9 — 11.1 k #2 cord: 8.8 —...
Page 407 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 408 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 409 STARTING/CHARGING SYSTEMS SC(H4SO 2.0) Page General Description ..................2 Starter ......................6 Generator ....................14 Battery.......................20...
Page 410: General Description
General Description STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATION Item Specification Vehicle model Type Reduction type Model M000T30471 M000T20171 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Revolving direction Counterclockwise (when observed from pinion) Number of pinion teeth Voltage 11 V...
Page 411 General Description STARTING/CHARGING SYSTEMS B: COMPONENT 1. STARTER (10) (16) (12) (11) (14) (15) (13) SC-02005 Front bracket Internal gear ASSY (13) Brush holder ASSY Sleeve bearing Shaft ASSY (14) Sleeve bearing Lever set Gear ASSY (15) Rear cover Magnet switch ASSY (10) Packing (16)
Page 412 General Description STARTING/CHARGING SYSTEMS 2. GENERATOR (13) (12) (11) (10) SC-00163 Pulley nut Bearing (13) Terminal Pulley Stator coil Front cover IC regulator with brush Tightening torque: N m (kgf-m, ft-lb) Ball bearing (10) Brush T1: 4.7 (0.48, 3.5) Bearing retainer (11) Rectifier T2: 108 (11.0, 80)
Page 413 General Description STARTING/CHARGING SYSTEMS C: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust and dirt.
Page 414: Starter
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) Terminals IN-00203 (B) Connector 2) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air In- 6) Remove the starter from transmission.
Page 415 Starter STARTING/CHARGING SYSTEMS C: DISASSEMBLY 4) Remove the through-bolts and brush holder screws of both sides, and then detach the rear cov- 1. STARTER ASSEMBLY er and brush holder assembly. 1) Loosen the nut which holds terminal M of switch assembly, and then disconnect the connector.
Page 416 Starter STARTING/CHARGING SYSTEMS 7) Remove the plate. (2) Remove the ring, stopper and clutch from shaft. SC-00065 (A) Plate 8) Remove the shaft assembly and overrunning clutch from front bracket as a unit. NOTE: Check the following points before removal. •...
Page 417 Starter STARTING/CHARGING SYSTEMS (1) Insert the ring into the shaft groove by lightly (2) Internal gear position tapping it with an appropriate tool (such as a fit socket wrench). SC-00070 4) Install the plate. SC-00067 (A) Ring (B) Stopper (2) Install the stopper to ring using a press. SC-00065 (A) Plate 5) Install the planetary gear.
Page 418 Starter STARTING/CHARGING SYSTEMS 8) Install the yoke to front bracket matching front 10) Install the rear cover matching it’s groove to bracket to the groove of yoke assembly. brush holder assembly. SC-00072 SC-00062 9) Install the brush holder to yoke assembly as fol- (A) Brush holder ASSY lows.
Page 419 Starter STARTING/CHARGING SYSTEMS 13) Connect the connector to terminal M of switch Depth of segment mold: assembly. 0.5 mm (0.020 in) SC-00059 SC-00022 (A) Terminal M (A) Depth of mold (B) Segment E: INSPECTION (C) Mold 1. ARMATURE 4) Armature short-circuit test 1) Check the commutator for any sign of burns of Check the armature for short-circuit by placing it on rough surfaces or stepped wear.
Page 420 Starter STARTING/CHARGING SYSTEMS 2. YOKE 5. SWITCH ASSEMBLY Make sure the pole is set in position. Be sure there is continuity between the terminals S and M, and between terminal S and ground. Use a 3. OVERRUNNING CLUTCH circuit tester (set in “ohm”). Inspect the teeth of pinion for wear and damage.
Page 421 Starter STARTING/CHARGING SYSTEMS 7. PERFORMANCE TEST Current / Speed MT model The starter should be submitted to performance 300 A / 870 rpm or more tests whenever it has been overhauled, to assure AT model its satisfactory performance when installed on the 400 A / 710 rpm or more engine.
Page 422: Generator
Generator STARTING/CHARGING SYSTEMS 3. Generator 5) Remove the bolts which install the generator onto bracket. A: REMOVAL 1) Disconnect the ground cable from battery. SC-00179 B: INSTALLATION IN-00203 Install in the reverse order of removal. 2) Disconnect the connector and terminal from Tightening torque: generator.
Page 423 Generator STARTING/CHARGING SYSTEMS 2) Heat portion (A) of rear cover to 50"C (122"F) CAUTION: with a heater drier. When holding the rotor with a vise, place alumi- num plates or wooden pieces on the vise jaws to prevent rotor from damage. SC-00079 3) Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover.
Page 424 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 425 Generator STARTING/CHARGING SYSTEMS 10) Remove the rectifier as follows. CAUTION: (1) Remove the bolt which secures the rectifier. Be sure to remove the wire after reassembly. SC-00089 SC-00092 (2) Remove the cover of terminal B. (A) Wire 2) Install the ball bearing. (1) Set the ball bearing on the front cover, and then securely install an appropriate tool (such as a fit socket wrench) to the bearing outer race.
Page 426 Generator STARTING/CHARGING SYSTEMS E: INSPECTION Slip ring outer diameter: Standard 1. DIODE 22.7 mm (0.894 in) Limit CAUTION: 22.1 mm (0.870 in) Never use a mega tester (designed for reading 3) Continuity test high voltage) or any other similar instrument Check the resistance between slip rings using cir- for this test;...
Page 427 Generator STARTING/CHARGING SYSTEMS 3. STATOR Brush length: Service limit (1) 1) Continuity test 5.0 mm (0.197 in) Inspect the stator coil for continuity between each Standard (2) end of the lead wires. If resistance is 1 M# or more, 18.5 mm (0.728 in) the lead wire is broken, and so replace the stator assembly.
Page 428: Battery
Battery STARTING/CHARGING SYSTEMS 4. Battery • To lessen the risk of sparks, remove rings, metal watch-bands, and other metal jewelry. A: REMOVAL Never allow metal tools to contact the positive 1) Disconnect the positive (+) terminal after discon- battery terminal and anything connected to it necting the negative ($) terminal of battery.
Page 429 Battery STARTING/CHARGING SYSTEMS D: MEASUREMENT 4. QUICK CHARGING Quick charging is a method that the battery is WARNING: charged in a short period of time with a relatively Do not bring an open flame close to the battery large current by using a quick charger. at this time.
Page 430 Battery STARTING/CHARGING SYSTEMS SC(H4SO 2.0)-22...
Page 431 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 432 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 433 Electrical Component Location ..............8 Engine Control Module (ECM) I/O Signal ..........17 Engine Condition Data ................21 Data Link Connector .................22 OBD-II General Scan Tool ................23 Subaru Select Monitor................25 Read Diagnostic Trouble Code (DTC) ............31 Inspection Mode..................32 Drive Cycle....................36 Clear Memory Mode..................38 Compulsory Valve Operation Check Mode ..........39...
Page 434: Basic Diagnostic Procedure
Repair the related 1) Turn the ignition switch to OFF. aru Select Monitor? Repair the trouble parts. 2) Connect the Subaru Select Monitor to data cause. <Ref. to NOTE: link connector. EN(H4SO 3) Turn the ignition switch to ON, and the Sub- 2.0)(diag)-66, List...
Page 435: Check List For Interview
Check List for Interview ENGINE (DIAGNOSTICS) 2. Check List for Interview 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 436 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. J Yes / J No J Low fuel warning light J Charge indicator light J AT diagnostic indicator light...
Page 437: General Description
General Description ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts as the grounding point to body 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 438 Calling the self-diagnosis result is performed by the performing diagnostics. Subaru Select Monitor. 15) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most impor- tant thing in diagnostics is to understand the cus- tomer’s complaint, and distinguish between the...
Page 439 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 440: Electrical Component Location
Electrical Component Location ENGINE (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION 1. ENGINE • Control module EN-02413 EN-02451 Engine control module (ECM) Test mode connector Data link connector Malfunction indicator light EN(H4SO 2.0)(diag)-8...
Page 441 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01966 EN-01147 AT-01877 EN-02414 EN(H4SO 2.0)(diag)-9...
Page 442 Electrical Component Location ENGINE (DIAGNOSTICS) • Sensor EN-02415 Intake air temperature sensor Electronic throttle control Camshaft position sensor Manifold absolute pressure sensor Knock sensor Crankshaft position sensor Engine coolant temperature sen- EN(H4SO 2.0)(diag)-10...
Page 443 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02416 EN-02417 EN-02418 EN-02179 EN-00010 EN-00011 EN-00012 EN(H4SO 2.0)(diag)-11...
Page 444 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01973 Front oxygen (A/F) sensor Front catalytic converter Rear catalytic converter Rear oxygen sensor EN-02091 EN-02092 EN(H4SO 2.0)(diag)-12...
Page 445 Electrical Component Location ENGINE (DIAGNOSTICS) • Solenoid valve, actuator, emission control system parts and ignition system parts EN-02419 Purge control solenoid valve EGR Valve (EC, EK, K4 model) Ignition coil & ignitor ASSY EN(H4SO 2.0)(diag)-13...
Page 446 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02420 EN-02421 EN-02422 EN(H4SO 2.0)(diag)-14...
Page 447 Electrical Component Location ENGINE (DIAGNOSTICS) (4) (3) (6) (9) EN-02423 (8) (7) EN-01979 Inhibitor switch Fuel pump relay Radiator sub fan relay Fuel pump Electronic throttle control relay Radiator main fan relay 2 Main relay Radiator main fan relay 1 Starter EN(H4SO 2.0)(diag)-15...
Page 448 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02093 EN-00178 EN-02094 EN-02095 EN-02096 EN(H4SO 2.0)(diag)-16...
Page 449 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 18 19 20 21 22 23 26 27 20 21...
Page 450 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Connector Terminal DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) Electronic throttle control B137 Duty waveform Duty waveform Drive frequency: 1 kHz motor 2 (") Electronic throttle control B137 10 —...
Page 451 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Connector Terminal DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) ON: 0.5 or less ON: 0.5 or less A/C relay control B135 — OFF: 10 — 13 OFF: 13 — 14 ON: 0.5 or less ON: 0.5 or less Radiator fan relay 1 control...
Page 452 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Connector Terminal DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) GND (sensor 2) B137 — GND (injector) B134 — B134 — GND (power supply) B137 — B136 — GND (control system) B136 —...
Page 453: Engine Condition Data
Engine Condition Data ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Remarks SPECIFICATION 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm Racing Measuring condition: • After engine is warmed-up. • Gear position is in “N” or “P” range. •...
Page 454: Data Link Connector
This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools except for OBD-II general scan tool and Subaru Select Monitor, be- cause the circuit for Subaru Select Monitor may be damaged. 9 10 11 12 13 EN-00037 Terminal No.
Page 455: Obd-Ii General Scan Tool
OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 8. 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 456 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is detected 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 457: Subaru Select Monitor
5) Turn the ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON. A: OPERATION 1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION TOOL, General Description.> EN-00040...
Page 458 Subaru Select Monitor ENGINE (DIAGNOSTICS) 4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
Page 459 Main switch signal Main Switch — OFF (At OFF) Integrated unit data reception Body Int. Unit Data — Integrated unit data update Body Int. Unit Count — NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.0)(diag)-27...
Page 460 EGR system incomplete NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. 6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
Page 461 Subaru Select Monitor ENGINE (DIAGNOSTICS) 7. LED OPERATION MODE FOR ENGINE 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
Page 462 Data reception signal Body Int. Unit Data ON or OFF entered. When counter update signal is Counter update signal Body Int. Unit Count ON or OFF entered. NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.0)(diag)-30...
Page 463: Read Diagnostic Trouble Code (Dtc)
Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
Page 464: Inspection Mode
Inspection Mode ENGINE (DIAGNOSTICS) 11.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 2.0)(diag)-36, Drive Cycle.> Item P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
Page 465: Pantograph
Inspection Mode ENGINE (DIAGNOSTICS) Item P1570 Antenna P1571 Reference Code Incompatibility P1572 IMM Circuit Failure (Except Antenna Circuit) P1574 Key Communication Failure P1576 EGI Control Module EEPROM P1577 IMM Control Module EEPROM P1578 Meter Failure P2101 Throttle Actuator Control Motor Circuit Range/Performance P2102 Throttle Actuator Control Motor Circuit Low P2103...
Page 466 Inspection Mode ENGINE (DIAGNOSTICS) 2. SUBARU SELECT MONITOR 7) Connect the Subaru Select Monitor to data link connector located in the lower portion of the instru- 1) After clearing the memory, check for any remain- ment panel (on the driver’s side).
Page 467 Inspection Mode ENGINE (DIAGNOSTICS) • The speed difference between front and rear 9) Place the select lever or shift lever in “D” position wheels may light the ABS warning light, but this in- (AT model) or “1st” gear (MT model) and drive the dicates no malfunctions.
Page 468: Drive Cycle
Drive Cycle ENGINE (DIAGNOSTICS) 12.Drive Cycle A: PROCEDURE 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 469 Drive Cycle ENGINE (DIAGNOSTICS) 3. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN 96 (60) 65 (40) EN-00195 Idle engine for 1 minute. Decelerate with throttle fully Accelerate to 96 km/h (60 MPH) closed to 65 km/h (40 MPH). within 10 seconds. Accelerate to 96 km/h (60 MPH) within 20 seconds.
Page 470: Clear Memory Mode
{Memory Clear} and press the [YES] key. 5) When the “Done” and “Turn Ignition Switch OFF” are shown on the display screen, turn the ignition switch to OFF and then Subaru Select Monitor switch to OFF. NOTE: • Initial diagnosis of electronic control throttle is performed after memory clearance.
Page 471: Compulsory Valve Operation Check Mode
Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) 14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link connector located in the lower portion of instrument Check Mode panel (on the driver’s side). A: PROCEDURE 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION TOOL,...
Page 472 Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) • A list of the support data is shown in the following table. DESCRIPTION Display Compulsory fuel pump relay oper- Fuel Pump ation check Compulsory radiator fan relay Radiator Fan Relay operation check Compulsory air conditioning relay A/C Compressor Relay operation check...
Page 473: Malfunction Indicator Light
Malfunction Indicator Light ENGINE (DIAGNOSTICS) 15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.0)(diag)-42, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> 2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.0)(diag)-43, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>...
Page 474 Malfunction Indicator Light ENGINE (DIAGNOSTICS) B: ACTIVATION OF MALFUNCTION (3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Mal- INDICATOR LIGHT function indicator light illuminates if faulty. 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the com- bination meter illuminates.
Page 475 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 to ON (engine OFF), malfunction indicator light does not come on. WIRING DIAGRAM: IGNITION SWITCH...
Page 476 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 4. Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM con- nector and chassis ground.
Page 477 D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF. DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor display. WIRING DIAGRAM: IGNITION...
Page 478 Malfunction Indicator Light ENGINE (DIAGNOSTICS) E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK. DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • Test mode connector circuit is in open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during inspection mode. WIRING DIAGRAM: •...
Page 479 Malfunction Indicator Light ENGINE (DIAGNOSTICS) • RHD model IGNITION BATTERY SWITCH SBF-7 SBF-1 No.5 COMBINATION METER B135 1 2 3 4 5 6 7 8 9 6 7 8 9 10 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 4 5 6 B135...
Page 480 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 illuminate? function indictor 1) Turn the ignition switch to OFF. light circuit. <Ref. 2) Disconnect the test mode connectors. to EN(H4SO 3) Turn the ignition switch to ON.
Page 481 Malfunction Indicator Light ENGINE (DIAGNOSTICS) F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING. DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when test mode connector is not connected. WIRING DIAGRAM: • LHD model IGNITION BATTERY SWITCH SBF-7 SBF-1 No.5 COMBINATION...
Page 482 Malfunction Indicator Light ENGINE (DIAGNOSTICS) • RHD model IGNITION BATTERY SWITCH SBF-7 SBF-1 No.5 COMBINATION METER B135 1 2 3 4 5 6 7 8 9 6 7 8 9 10 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 4 5 6 B135...
Page 483 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) 16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check for fuel amount. 2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.0)(diag)-52, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start- ing Failure.> 3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO 2.0)(diag)-55, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>...
Page 484 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
Page 485 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 OPERATION OF STARTER MOTOR. Does the starter motor oper- Go to step 3.
Page 486 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF STARTER RE- Is the voltage more than 10 V? Go to step 9. Repair the open LAY. circuit in harness 1) Turn the ignition switch to OFF. between starter 2) Disconnect the connector from starter relay.
Page 487 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MOD- ULE (ECM) CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
Page 488 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 &? 1) Turn the ignition switch to OFF. relay. 2) Remove the main relay. 3) Connect the battery to main relay terminals No.
Page 489: Diagnostics For Engine Starting Failure
Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair the open or 1) Turn the ignition switch to ON. control system. ground short cir- 2) Measure the voltage between ECM con- <Ref.
Page 490 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
Page 491 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check fuel pump Go to step 2. 1) Remove the plug cord cap from each spark inder? system. <Ref. to plug.
Page 492 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 the har- &? NITION COIL & IGNITOR ASSY CONNEC- ness and connec- TOR. tor. 1) Turn the ignition switch to OFF.
Page 493 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
Page 494 CIRCUIT, Diag- NOTE: nostics for Engine Fuel pump operation can also be executed us- Starting Failure.> ing Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.0)(diag)-39, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP.
Page 495 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair the open &? FUEL PUMP RELAY CONNECTOR. circuit in harness 1) Disconnect the connector from ECM. between ECM and 2) Measure the resistance of harness fuel pump relay...
Page 496 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 2.0)(di- ag)-38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OP- ERATION, Inspection Mode.>.
Page 497 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit oper- Check the fuel Go to step 2. TOR. ating sound? pressure. <Ref. to While cranking the engine, check each fuel ME(H4SO 2.0)-27, injector emits operating sound.
Page 498: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 17.List of Diagnostic Trouble Code (DTC) A: LIST Item NOTE P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H4SO 2.0)(diag)-71, DTC P0030 HO2S HEATER CONTROL Sensor 1) CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
Page 499: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0134 O2 Sensor Circuit No Activity <Ref. to EN(H4SO 2.0)(diag)-116, DTC P0134 O2 SENSOR CIRCUIT NO Detected (Bank 1 Sensor 1) ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
Page 500 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0463 Fuel Level Sensor Circuit High Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0463 FUEL LEVEL SENSOR CIR- CUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0500 Vehicle Speed Sensor <Ref.
Page 501 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1494 EGR Solenoid Valve Signal #2 Cir- <Ref. to EN(H4SO 2.0)(diag)-181, DTC P1494 EGR SOLENOID VALVE cuit Malfunction (Low Input) SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1495 EGR Solenoid Valve Signal #2 Cir- <Ref.
Page 502 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P2111 Throttle Actuator Control System - <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2111 THROTTLE ACTUATOR Stuck Open CONTROL SYSTEM - STUCK OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P2122 Throttle/Pedal Position Sensor/ <Ref.
Page 503 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 18.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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 504 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 &? FRONT OXYGEN (A/F) SENSOR CONNEC- circuit in harness TOR. between ECM and 1) Start and warm-up the engine.
Page 505 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 506 Go to step 5. 1) Start the engine. contact connector. 2) Read the data of front oxygen (A/F) sensor NOTE: heater current using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”.
Page 507 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 10 Repair the har- Replace the front &? 1) Turn the ignition switch to OFF. ness and connec- oxygen (A/F) sen- 2) Measure the resistance between front oxy- tor.
Page 508 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 509 (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. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.>...
Page 510 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 511 NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”. <Ref. rear oxygen sen- to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- sor connector itor.> • Poor contact in rear oxygen sen- sor connecting harness connector •...
Page 512 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 the power GEN SENSOR. supply line. 1) Turn the ignition switch to OFF. NOTE: 2) Disconnect the connector from rear oxygen In this case, repair...
Page 513 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 514 4) Read the data of rear oxygen sensor heater current using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.> CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END.
Page 515 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) F: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 516 Go to step 2. 1) Start the engine. (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.>...
Page 517 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 9. Repair the open &? MANIFOLD ABSOLUTE PRESSURE SEN- circuit in harness SOR CONNECTOR. between ECM and 1) Turn the ignition switch to OFF.
Page 518 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) G: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 519 1) Start the engine. kPa (896.5 mmHg, 35.29 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.>...
Page 520 ECM and sure sensor. <Ref. 1) Turn the ignition switch to OFF, and the manifold absolute to FU(H4SO 2.0)- Subaru Select Monitor switch to OFF. pressure sensor 26, Manifold Abso- 2) Disconnect the connector from manifold connector. lute Pressure Sen- absolute pressure sensor.
Page 521 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) H: 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 522 1) Start the engine. more than 120!C (248!F)? contact. 2) Read the data of intake air temperature NOTE: sensor signal using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”.
Page 523 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) I: 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 524 "40!C ("40!F)? 1) Start the engine. contact. 2) Read the data of intake air temperature NOTE: sensor signal using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”.
Page 525 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 the har- &? TEMPERATURE SENSOR AND ECM CON- air temperature ness and connec- NECTOR. sensor.
Page 526 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) J: 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 527 Repair the poor 1) Start the engine. ture more than 150!C (302!F)? contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
Page 528 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) K: 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 529 Repair the poor ture less than "40!C ("40!F)? 1) Start the engine. contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
Page 530 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair the har- &? COOLANT TEMPERATURE SENSOR AND engine coolant ness and connec- ECM CONNECTOR. temperature sen- tor.
Page 531 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) L: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 532 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 533 Is the voltage more than 0.4 V? Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
Page 534 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) M: 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 535 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 536 Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
Page 537 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) N: 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 538 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 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
Page 539 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) O: DTC P0130 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 540 Is the voltage 0.85 — 1.15 V? Go to step 3. Go to step 4. 1) Start the engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70!C (160!F).
Page 541 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the front Check exhaust system parts. system? faulty parts. oxygen (A/F) sen- sor. <Ref. to NOTE: FU(H4SO 2.0)-32, Check the following items.
Page 542 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) P: DTC P0131 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 543 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 the ground FRONT OXYGEN (A/F) SENSOR CONNEC- M&? oxygen (A/F) sen- short circuit in har- TOR.
Page 544 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0132 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 545 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 the battery FRONT OXYGEN (A/F) SENSOR CONNEC- oxygen (A/F) sen- short circuit in har- TOR.
Page 546 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) R: DTC P0133 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 547 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 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
Page 548 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) S: DTC P0134 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 549 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 har- &? FRONT OXYGEN (A/F) SENSOR CONNEC- ness and connec- TOR. tor. 1) Turn the ignition switch to OFF.
Page 550 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) T: DTC P0137 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 551 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 4.
Page 552 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the rear Check exhaust system parts. system? the faulty part. oxygen sensor. <Ref. to FU(H4SO NOTE: 2.0)-33, Rear Oxy- Check the following items: gen Sensor.>...
Page 553 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) U: DTC P0138 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 554 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 4.
Page 555 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the rear Check exhaust system parts. system? the faulty part. oxygen sensor. <Ref. to FU(H4SO NOTE: 2.0)-33, Rear Oxy- Check the following items: gen Sensor.>...
Page 556 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) V: DTC P0139 O2 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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 557 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 FU(H4SO (DTC)”. <Ref. to 2.0)-33, Rear Oxy- EN(H4SO gen Sensor.>...
Page 558 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) W: DTC P0171 SYSTEM TOO LEAN (BANK 1) Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO 2.0)(diag)-126, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> X: DTC P0172 SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault...
Page 559 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 tempera- sor. <Ref. to ture sensor signal using Subaru Select Moni- FU(H4SO 2.0)-20, tor. Engine Coolant Temperature Sen- NOTE: sor.>...
Page 560 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Y: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 561 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 562 Is the voltage more than 0.8 V? Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor...
Page 563 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Z: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 564 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 565 Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
Page 566 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AA:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO 2.0)(diag)-135, DTC P0304 CYLIN- DER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AB:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.
Page 567 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AD: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.) TROUBLE SYMPTOM: • Engine stalls. •...
Page 568 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 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
Page 569 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair the poor Repair the har- 1) Turn the ignition switch to ON. contact in all con- ness and connec- 2) Measure the voltage between fuel injector nectors in fuel tor.
Page 570 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 Monitor. <Ref. to EN(H4SO 2.0)(diag)-38, Clear Mem- ory Mode.> 2) Start the engine, and drive the vehicle more than 10 minutes.
Page 571 • Are there cracks or any disconnec- tion of hoses? CHECK MISFIRE SYMPTOM. Does the Subaru Select Moni- Go to step 21. Go to step 17. 1) Turn the ignition switch to ON. tor or OBD-II general scan tool 2) Read the DTC.
Page 572 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #1 AND #2 CYLINDERS Are there any faults in #1 and Repair or replace Go to DTC P0171. #2 cylinders? faulty parts. <Ref. to EN(H4SO 2.0)(diag)-126, NOTE: DTC P0171 SYS- •...
Page 573 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #2 AND #4 CYLINDERS Are there any faults in #2 and Repair or replace Go to DTC P0171. #4 cylinders? faulty parts. <Ref. to EN(H4SO 2.0)(diag)-126, NOTE: DTC P0171 SYS- Check the follow- TEM TOO LEAN...
Page 574 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AE: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 • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 575 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 the har- SOR AND ECM CONNECTOR. 700 k&? ness and connec- 1) Turn the ignition switch to OFF. tor.
Page 576 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AF: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 • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 577 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. k&? Measure the resistance of harness between ECM connector and chassis ground.
Page 578 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AG: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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 579 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair the har- Go to step 2. SHAFT POSITION SENSOR AND ECM CON- 100 k&? ness and connec- NECTOR. tor. 1) Turn the ignition switch to OFF.
Page 580 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AH:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN- GLE 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 581 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair the har- Go to step 2. POSITION SENSOR AND ECM CONNEC- 100 k&? ness and connec- TOR. tor. 1) Turn the ignition switch to OFF. NOTE: 2) Disconnect the connector from camshaft In this case, repair...
Page 582 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0400 EXHAUST GAS RECIRCULATION FLOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Movement performance problem when engine is low speed. • Erroneous idling • Movement performance problem CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 583 1) Start the engine. kPa (400 mmHg, 15.75 inHg)? EGR valve, mani- 2) Read the data of intake manifold absolute fold absolute pres- pressure signal using Subaru Select Monitor. sure sensor and throttle body are NOTE: installed securely. For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”.
Page 584 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 &? NOID VALVE AND ECM CONNECTOR. circuit in harness 1) Turn the ignition switch to OFF. between ECM and 2) Detach the connector from EGR solenoid EGR solenoid...
Page 585 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 586 2) Measure the resistance between rear oxy- sor. gen sensor connector and ECM connector. Connector & terminals (B19) No. 3 — (B136) No. 18: CHECK SHIELD HARNESS. Is the shield harness opened? Repair the shield Contact with your harness. Subaru distributor service. EN(H4SO 2.0)(diag)-154...
Page 587 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AK: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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 588 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 the mal- Go to step 2. 1) Turn the ignition switch to ON. function indicator 2) Measure the voltage between ECM and light illuminates, chassis ground.
Page 589 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AL: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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 590 ECM connector. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.0)(diag)-39, Compulsory Valve Operation Check Mode.> Connector & terminal "...
Page 591 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0462 appear on Check the combi- Temporary poor the Subaru Select Monitor? nation meter. contact occurs. <Ref. to IDI-3, Combination Meter System.> AN:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT...
Page 592 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AP: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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 593 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY B225 STARTER MOTOR B135 B225 B135 1 2 3 4 1 2 3 4 5 6 5 6 7 8 7 8 9 10 11 12 4 5 6 10 11 12 13 14 15 16 17...
Page 594 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check starter Turn the ignition switch to ON. ate? short circuit in motor circuit. <Ref. starter motor cir- to EN(H4SO NOTE: cuit.
Page 595 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AQ: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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 596 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AS:DTC P0559 GENERATOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
Page 597 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. M&? short circuit in har- 1) Turn the ignition switch to OFF. ness between 2) Disconnect the connectors from generator ECM and purge...
Page 598 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AU:DTC P0604 INTERNAL CONTROL MODULE READ 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 599 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- Temporary poor vant DTC using contact occurs. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou-...
Page 600 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AW:DTC P0607 CONTROL MODULE PERFORMANCE 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 601 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 — 13 V? Go to step 2. Repair the open or 1) Turn the ignition switch to ON. ground short cir- 2) Measure the voltage between ECM con- cuit of power sup- nector and chassis ground.
Page 602 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0691 appear on Check the radiator Temporary poor the Subaru Select Monitor? fan system. <Ref. contact occurs. to CO(H4SO 2.0)- 7, Radiator Fan System.> AZ:DTC P0692 COOLING FAN 1 CONTROL CIRCUIT HIGH...
Page 603 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BB: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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 604 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
Page 605 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BC:DTC P0852 NEUTRAL SWITCH INPUT 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 606 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
Page 607 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 the open &? Measure the resistance of harness between circuit in harness inhibitor switch connector and engine ground. between inhibitor Connector &...
Page 608 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BD: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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, Inspec- tion Mode.>.
Page 609 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 FU(H4SO nostic Trouble 2.0)-34, Engine Code (DTC). <Ref. Control Module to EN(H4SO (ECM).>...
Page 610 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BE: DTC P1137 O2 SENSOR CIRCUIT (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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 611 Is the voltage 0.85 — 1.15 V? Go to step 3. Go to step 4. 1) Start the engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70!C (160!F).
Page 612 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the front Check exhaust system parts. system? faulty parts. oxygen (A/F) sen- sor. <Ref. to NOTE: FU(H4SO 2.0)-32, Check the following items.
Page 613 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BF:DTC P1160 RETURN SPRING FAILURE NOTE: For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos- tic Trouble Code (DTC).> BG:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) NOTE:...
Page 614 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BM: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 • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 615 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 the har- NOID VALVE. ness and connec- 1) Turn the ignition switch to OFF. tor.
Page 616 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BN: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 • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 617 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
Page 618 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BO: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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 619 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY B225 STARTER MOTOR B135 B225 B135 1 2 3 4 1 2 3 4 5 6 5 6 7 8 7 8 9 10 11 12 4 5 6 10 11 12 13 14 15 16 17...
Page 620 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check starter Place the inhibitor switch in the “P” or “N” when ignition switch to ness and connec- motor circuit.
Page 621 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BP:DTC P1521 BRAKE SWITCH CIRCUIT RANGE/PERFORMANCE PROBLEM (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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 622 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 2. Go to step 3. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground.
Page 623 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BQ: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 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
Page 624 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the poor Go to step 2. 1) Turn the ignition switch to OFF. contact in ECM 2) Measure the voltage between ECM and connector.
Page 625 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BS:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 626 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 627 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Go to step 2. Replace the elec- &? TROL RELAY. tronic throttle con- 1) Turn the ignition switch to OFF. trol relay.
Page 628 Go to step 16. 1) Connect all the connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 15.
Page 629 3) Turn the ignition switch to ON. Replace the elec- 4) Read the data of main throttle sensor signal tronic throttle con- using Subaru Select Monitor. trol if defective. CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 23.
Page 630 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 24. Repair the open &? ELECTRONIC THROTTLE CONTROL MO- circuit of harness TOR. connector. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM.
Page 631 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Does the valve return to the Repair the poor Replace the elec- TROL. specified position? contact in ECM tronic throttle con- Move the throttle valve to the fully open and Standard value: 3 mm (0.12 in) connector.
Page 632 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BT:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 633 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 634 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Go to step 2. Replace the elec- &? TROL RELAY. tronic throttle con- 1) Turn the ignition switch to OFF. trol relay.
Page 635 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BU:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 636 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 637 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Is the resistance more than 1 Go to step 2. Replace the elec- TROL RELAY. M&? tronic throttle con- 1) Turn the ignition switch to OFF. trol relay.
Page 638 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BX:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 639 Is the voltage more than 0.4 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
Page 640 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCELERATOR POSITION SEN- Is the resistance 0.5 — 2.5 Repair the poor Replace the accel- SOR. k&? contact in ECM erator position Measure the resistance of accelerator position connector.
Page 641 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BY:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 642 Is the voltage less than 4.8 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
Page 643 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BZ:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 644 Is the voltage more than 0.4 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
Page 645 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCELERATOR POSITION SEN- Is the resistance 0.28 — 1.68 Repair the poor Replace the accel- SOR. k&? contact in ECM erator position 1) Measure the resistance of accelerator posi- connector.
Page 646 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CA:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 647 Is the voltage less than 4.8 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
Page 648 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CB:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” / “B” VOLTAGE RATIONALITY 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 649 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
Page 650 Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage more than 0.8 V? Go to step 3. Go to step 4.
Page 651 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact. contact occurred, ECM and electronic throttle control. but it is normal at present.
Page 652 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CC:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY 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. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
Page 653 SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal and sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 12.
Page 654 2) Connect all the connectors. 3) Turn the ignition switch to ON. 4) Read the data of main throttle sensor signal and sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 18.
Page 655 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1 Go to step 18. Repair the short CELERATOR POSITION SENSOR. M&? circuit to sensor 1) Turn the ignition switch to OFF. power supply.
Page 656 General Diagnostic Table ENGINE (DIAGNOSTICS) 19.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in General.> Symptom Problem parts 1) Manifold absolute pressure sensor 2) Intake air temperature sensor 3) Ignition parts (*1) 1.
Page 657: General Diagnostic Table
General Diagnostic Table ENGINE (DIAGNOSTICS) Symptom Problem parts 1) Intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 6. Surge 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay 9) EGR valve...
Page 658 General Diagnostic Table ENGINE (DIAGNOSTICS) EN(H4SO 2.0)(diag)-226...
Page 659 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 660 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 661 FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.5) Page General Description ..................2 Throttle Body...................11 Intake Manifold ..................12 Engine Coolant Temperature Sensor............20 Crankshaft Position Sensor ..............21 Camshaft Position Sensor ..............22 Knock Sensor ..................23 Throttle Position Sensor ................24 Manifold Absolute Pressure Sensor .............25 Mass Air Flow and Intake Air Temperature Sensor ......26 Intake Air Temperature Sensor..............27 Tumble Generator Valve Assembly............28 Tumble Generator Valve Actuator ............29...
Page 662: General Description
General Description FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATION Capacity 64 2(16.9 US gal, 14.1 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 441 — 686 kPa (4.50 — 7.00 kg/cm , 64.0 — 99.5 psi) Fuel pump 75 2 (19.8 US gal, 16.5 Imp gal)/h or more Discharge...
Page 663 General Description FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (18) (17) (10) (17) (24) (11) (23) (15) (25) (13) (12) (15) (14) (11) (13) (16) (12) (14) (15) (15) (13) (13) (12) (12) (14) (14) (22) (20) (21) (21) (19) (21)
Page 664 General Description FUEL INJECTION (FUEL SYSTEMS) Intake manifold (11) Fuel injector pipe (24) Nipple (RHD model) Gasket (EC, EK and K4 model) (12) Fuel injector (25) Nipple (LHD model) Tumble generator valve ASSY (13) O-ring (EC, EK and K4 model) (14) O-ring Tightening torque: N...
Page 665 General Description FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-01079 Gasket O-ring Tightening torque: N m (kgf-m, ft-lb) Throttle body T1: 2.0 (0.2, 1.5) Manifold absolute pressure sensor T2: 8 (0.8, 5.8) FU(H4SO 2.5)-5...
Page 666 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 2.5)-6...
Page 667 General Description FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (19) (17) (18) (15) (16) (17) (14) (15) (10) (12) (11) (13) (22) (22) (20) (21) (23) (24) (25) FU-01080 FU(H4SO 2.5)-7...
Page 668 General Description FUEL INJECTION (FUEL SYSTEMS) Fuel tank (12) Fuel sub level sensor upper plate (22) Retainer Fuel tank band RH (13) Fuel sub level sensor gasket (23) Heat shield cover Fuel tank band LH (14) Fuel filler hose (24) Fuel tank protector RH (Front) Delivery tube (15)
Page 669 General Description FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (28) (18) (26) (23) (15) (19) (17) (25) (27) (20) (22) (14) (13) (24) (21) (16) (22) (34) (11) (29) (10) (12) (33) (32) (30) (31) FU-01081 FU(H4SO 2.5)-9...
Page 670 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 671: Throttle Body
Throttle Body FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the air intake chamber. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> 3) Disconnect the connectors from the throttle posi- tion sensor and manifold absolute pressure sensor.
Page 672: Intake Manifold
Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 10) Disconnect the connectors from engine coolant temperature sensor. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
Page 673 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 15) Disconnect the connector from camshaft posi- 18) Remove the bolts which secure intake manifold tion sensor. to cylinder head. FU-01335 FU-01089 16) Remove the EGR pipe from intake manifold. 19) Remove the intake manifold. (EC, EK and K4 model) B: INSTALLATION 1) Install the intake manifold onto cylinder heads.
Page 674 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3) Install the EGR pipe to intake manifold. (EC, EK 8) Connect the knock sensor connector. and K4 model) Tightening torque: 34 N m (3.4 kgf-m, 24.6 ft-lb) FU-01334 9) Connect the connectors to engine coolant tem- perature sensor.
Page 675 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 15) Install the air cleaner case and air intake cham- 6) Disconnect the pressure regulator vacuum hose ber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air (A) from intake manifold. Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTAL- LATION, Air Intake Chamber.>...
Page 676 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 12) Remove the purge control solenoid valve. • LH side <Ref. to EC(H4SO 2.0)-7, REMOVAL, Purge Con- trol Solenoid Valve.> 13) Remove the harness band clips which install the engine harness. FU-01099 FU-01096 14) Remove the bolts which hold the engine har- ness to intake manifold.
Page 677 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 22) Remove the bolt which installs the fuel pipes on 2) Tighten the bolt which installs the fuel pipes on intake manifold. intake manifold. Tightening torque: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) FU-01337 23) Remove the fuel pipe assembly and pressure regulator, from intake manifold.
Page 678 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 8) Tighten the bolts which install injector pipe on in- 11) Tighten the bolts which install engine harness take manifold. on intake manifold. • RH side Tightening torque: Tightening torque: 16 N m (1.6 kgf-m, 11.8 ft-lb) 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-01097...
Page 679 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 17) Install the fuel pipe protector RH. 21) Install the EGR valve. (EC, EK and K4 model) <Ref. to FU(H4SO 2.5)-30, INSTALLATION, EGR Tightening torque: Valve.> 19 N m (1.9 kgf-m, 13.7 ft-lb) 22) Install the throttle body to intake manifold. <Ref.
Page 680: Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the generator. <Ref. to SC(H4SO 2.0)- 14, REMOVAL, Generator.> 3) Disconnect the connectors from engine coolant temperature sensor.
Page 681: 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 Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) IN-00203 FU-00058 2) Remove the bolt which installs crankshaft posi- tion sensor to cylinder block.
Page 682: Camshaft Position Sensor
Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00179 B: INSTALLATION Install in the reverse order of removal. IN-00203 Tightening torque: 2) Disconnect the connector from camshaft posi- Camshaft position sensor support tion sensor.
Page 683: Knock Sensor
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. Extraction area of knock sensor cord must be posi- tioned at a 60" angle relative to the engine rear. Tightening torque: 24 N m (2.4 kgf-m, 17.4 ft-lb)
Page 684: Throttle Position Sensor
Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure. <Ref. to FU(H4SO 2.5)-11, REMOVAL, Throttle Body.>...
Page 685 Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS) 9. Manifold Absolute Pressure Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from manifold abso- lute pressure sensor. FU-01105 3) Remove the manifold absolute pressure sensor from throttle body.
Page 686 Mass Air Flow and Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 10.Mass Air Flow and Intake Air Temperature Sensor A: REMOVAL NOTE: Mass air flow and intake air temperature sensor is installed to EC, EK and K4 model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from mass air flow and intake air temperature sensor.
Page 687 Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 11.Intake Air Temperature Sen- A: REMOVAL NOTE: Intake air temperature sensor is installed to models except for EC, EK and K4. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from intake air tem- perature sensor.
Page 688: Tumble Generator Valve Assembly
Tumble Generator Valve Assembly FUEL INJECTION (FUEL SYSTEMS) 12.Tumble Generator Valve As- 7) Remove the tumble generator valve body from intake manifold. sembly A: REMOVAL NOTE: This component is installed to EC, EK and K4 mod- 1) Release the fuel pressure. <Ref.
Page 689 Tumble Generator Valve Actuator FUEL INJECTION (FUEL SYSTEMS) 13.Tumble Generator Valve Ac- 3) Disconnect the ground cable from battery. tuator A: REMOVAL 1. RH SIDE NOTE: This component is installed to EC, EK and K4 mod- 1) Release the fuel pressure. <Ref.
Page 690 EGR Valve FUEL INJECTION (FUEL SYSTEMS) 14.EGR Valve A: REMOVAL NOTE: EGR valve is installed to EC, EK and K4 model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from EGR valve. FU-01152 3) Remove the EGR valve from intake manifold. FU-01153 B: INSTALLATION Install in the reverse order of removal.
Page 691 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 15.Fuel Injector 9) Remove the bolts which hold fuel injector pipe onto intake manifold. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
Page 692 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 7) Remove the harness band (B) which holds en- B: INSTALLATION gine harness to injector pipe. 1. RH SIDE Install in the reverse order of removal. NOTE: • Use new O-rings. • O-ring (B) is used for EC, EK and K4 model. FU-01338 8) Remove the bolts which hold fuel injector pipe onto intake manifold.
Page 693 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE Tightening torque: 19 N m (1.9 kgf-m, 13.7 ft-lb) Install in the reverse order of removal. NOTE: • Use new O-rings. • O-ring (B) is used for EC, EK and K4 model. FU-01093 FU-02157 (A) O-ring...
Page 694 Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS) 16.Front Oxygen (A/F) Sensor B: INSTALLATION 1) Before installing front oxygen (A/F) sensor, ap- A: REMOVAL ply anti-seize compound only to the threaded por- 1) Disconnect the ground cable from battery. tion of front oxygen (A/F) sensor to make the next removal easier.
Page 695 Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS) 17.Rear Oxygen Sensor B: INSTALLATION 1) Before installing rear oxygen sensor, apply anti- A: REMOVAL seize compound only to the threaded portion of 1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas- ier.
Page 696 Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS) 18.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 697 Main Relay FUEL INJECTION (FUEL SYSTEMS) 19.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from main relay. FU-02093 B: INSTALLATION Install in the reverse order of removal.
Page 698 Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from fuel pump relay. FU-02094 B: INSTALLATION Install in the reverse order of removal.
Page 699 Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS) 21.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from electric throttle control relay.
Page 700 Fuel FUEL INJECTION (FUEL SYSTEMS) 22.Fuel 6) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from fuel A: PROCEDURE tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...
Page 701 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Tank (2) Push the grommet (B) down under the body and remove service hole cover. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
Page 702 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 12) Remove the rear brake caliper and tie it to the 19) Remove the bolts which install the parking vehicle body side. brake cable clamp. FU-00462 FU-01130 13) Remove the parking brake cable from parking brake assembly.
Page 703 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) (3) Remove the bolts which secure the rear 23) Support the fuel tank with transmission jack, re- suspension assembly to body. move the bolts from fuel tank bands, and dismount the fuel tank from vehicle. WARNING: A helper is required to perform this work.
Page 704 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 2) Correctly insert the fuel filler hose (A) and vent Tightening torque: hose (B) to specified position, and then tighten the T1: 125 N m (12.7 kgf-m, 92.2 ft-lb) clamp. T2: 65 N m (6.2 kgf-m, 48 ft-lb) T3: 175 N m (17.8 kgf-m, 129 ft-lb) FU-01136...
Page 705 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 6) Tighten the bolts which install the parking brake 14) Tighten the bolt which secures rear brake hose cable clamp. installation bracket. Tightening torque: Tightening torque: 18 N m (1.8 kgf-m, 13.0 ft-lb) 33 N m (3.4 kgf-m, 25 ft-lb) FU-01130 FU-01128...
Page 706 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 20) Connect the connector to fuel pump. FU-01125 21) Install the service hole cover of fuel pump. FU-01124 (A) Bolt (B) Grommet 22) Install the rear seat. 23) Install the fuse of fuel pump to main fuse box. C: INSPECTION 1) Check that the fuel tank is not holed, cracked or otherwise damaged.
Page 707 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Filler Pipe 7) Set a container under the vehicle, and remove the drain plug from the fuel tank to drain fuel from A: REMOVAL fuel tank. WARNING: • Place “NO FIRE” signs near the working area. •...
Page 708 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Tighten the bolts which hold the fuel filler pipe bracket on the body. 1) Open the fuel filler flap lid. 2) Set the fuel saucer (A) with rubber packing (C) Tightening torque: and insert the fuel filler pipe into hole from the inner 7.5 N...
Page 709 Fuel Pump FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Pump 7) Remove the nuts which install the fuel pump as- sembly onto fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. •...
Page 710 Fuel Pump FUEL INJECTION (FUEL SYSTEMS) • Do not run fuel pump for a long time under non-load condition. FU-01330 FU(H4SO 2.5)-50...
Page 711 Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Level Sensor A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly.
Page 712 Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Sub Level Sensor 6) Remove the nuts and bolts which install the fuel sub level sensor on fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. •...
Page 713 Fuel Filter FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Filter A: SPECIFICATION Fuel filter forms a unit with fuel pump. Refer to Fuel Pump for removal and installation. <Ref. to FU(H4SO 2.5)-49, REMOVAL, Fuel Pump.> <Ref. to FU(H4SO 2.5)-49, INSTALLATION, Fuel Pump.> FU(H4SO 2.5)-53...
Page 714 Fuel Damper Valve FUEL INJECTION (FUEL SYSTEMS) 29.Fuel Damper Valve A: REMOVAL 1. DELIVERY SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper valve from fuel delivery line. FU-01147 2.
Page 715 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) 30.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCE- DURE, Fuel.> 3) Open the fuel filler flap lid, and remove the fuel filler cap.
Page 716 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) (3) Hold the connector (A) and push retainer (B) (2) Push the pipe into the connector completely. down. ( A ) (4) Pull out the connector (A) from retainer (B). CAUTION: ( B ) Always use a new retainer.
Page 717 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) 2: 2.5 1.5 mm (0.098 0.059 in) L: 22.5 2.5 mm (0.886 0.098 in) ( 3 ) ( 1 ) ( 2 ) Type A Type B FU-00128 (1) Pipe (2) Clamp (3) Hose 3) Connect the return hose and evaporation hose...
Page 718 Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS) 31.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to injector Fuel pump does not operate. Inspect contact, especially ground, and tighten it H Defective terminal contact securely.
Page 719 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 720 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 721 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.5) Page General Description ..................2...
Page 722 General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in EC(H4SO 2.0) section. <Ref. to EC(H4SO 2.0)-2, General Description.> EC(H4SO 2.5)-2...
Page 723 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 724 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 725 INTAKE (INDUCTION) IN(H4SO 2.5) Page General Description ..................2...
Page 726 General Description INTAKE (INDUCTION) 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in IN(H4SO 2.0) section. <Ref. to IN(H4SO 2.0)-2, General Description.> IN(H4SO 2.5)-2...
Page 727 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 728 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 729 MECHANICAL ME(H4SO 2.5) Page General Description ..................2...
Page 730 General Description MECHANICAL 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in ME(H4SO 2.0) section. <Ref. to ME(H4SO 2.0)-2, General Description.> ME(H4SO 2.5)-2...
Page 731 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 732 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 733 EXHAUST EX(H4SO 2.5) Page General Description ..................2...
Page 734 General Description EXHAUST 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in EX(H4SO 2.0) section. <Ref. to EX(H4SO 2.0)-2, General Description.> EX(H4SO 2.5)-2...
Page 735 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 736 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 737 COOLING CO(H4SO 2.5) Page General Description ..................2...
Page 738 General Description COOLING 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to CO(H4SO 2.0)-2, General De- scription.> CO(H4SO 2.5)-2...
Page 739 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 740 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 741 LUBRICATION LU(H4SO 2.5) Page General Description ..................2...
Page 742 General Description LUBRICATION 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to LU(H4SO 2.0)-2, General De- scription.> LU(H4SO 2.5)-2...
Page 743 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 744 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 745 SPEED CONTROL SYSTEMS SP(H4SO 2.5) Page General Description ..................2...
Page 746 General Description SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to SP(H4SO 2.0)-2, General De- scription.> SP(H4SO 2.5)-2...
Page 747 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 748 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 749 IGNITION IG(H4SO 2.5) Page General Description ..................2...
Page 750 General Description IGNITION 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in IG(H4SO 2.0) section. <Ref. to IG(H4SO 2.0)-2, General Description.> IG(H4SO 2.5)-2...
Page 751 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 752 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 753 STARTING/CHARGING SYSTEMS SC(H4SO 2.5) Page General Description ..................2...
Page 754 General Description STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to SC(H4SO 2.0)-2, General De- scription.> SC(H4SO 2.5)-2...
Page 755 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 756 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 757 Electrical Component Location ..............8 Engine Control Module (ECM) I/O Signal ..........17 Engine Condition Data ................21 Data Link Connector .................22 OBD-II General Scan Tool ................23 Subaru Select Monitor................26 Read Diagnostic Trouble Code (DTC) ............33 Inspection Mode..................34 Drive Cycle....................39 Clear Memory Mode..................41 Compulsory Valve Operation Check Mode ..........42...
Page 758 Repair the related 1) Turn the ignition switch to OFF. aru Select Monitor? Repair the trouble parts. 2) Connect the Subaru Select Monitor to data cause. <Ref. to NOTE: link connector. EN(H4SO 3) Turn the ignition switch to ON, and the Sub- 2.5)(diag)-70, List...
Page 759 Check List for Interview ENGINE (DIAGNOSTICS) 2. Check List for Interview 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 760 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. J Yes / J No J Low fuel warning light J Charge indicator light J AT diagnostic indicator light...
Page 761 General Description ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts as the grounding point to chassis 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 762 Calling the self-diagnosis result is performed by the performing diagnostics. Subaru Select Monitor. 15) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most impor- tant thing in diagnostics is to understand the cus- tomer’s complaint, and distinguish between the...
Page 763 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 764 Electrical Component Location ENGINE (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION 1. ENGINE • Control module • LHD model EN-02413 • RHD model EN-02451 Engine control module (ECM) Test mode connector Data link connector Malfunction indicator light EN(H4SO 2.5)(diag)-8...
Page 765 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01966 EN-01147 AT-01877 EN-02414 EN(H4SO 2.5)(diag)-9...
Page 766 Electrical Component Location ENGINE (DIAGNOSTICS) • Sensor EN-02530 Mass air flow and intake air tem- Electronic throttle control Intake air temperature sensor (KA perature sensor (EC, EK and K4 and KS model) Knock sensor model) Camshaft position sensor Manifold absolute pressure sensor Crankshaft position sensor Engine coolant temperature sen- Tumble generator valve position...
Page 767 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01970 EN-01971 EN-01972 EN-02179 EN-00010 EN-00011 EN-02531 EN-00012 EN(H4SO 2.5)(diag)-11...
Page 768 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02547 EN-01973 Front oxygen (A/F) sensor Front catalytic converter Rear catalytic converter Rear oxygen sensor EN-02091 EN-02092 EN(H4SO 2.5)(diag)-12...
Page 769 Electrical Component Location ENGINE (DIAGNOSTICS) • Solenoid valve, actuator, emission control system parts and ignition system parts EN-02452 Purge control solenoid valve Tumble generator valve actuator Fuel injector EGR Valve (EC, EK and K4 Ignition coil & ignitor ASSY model) EN(H4SO 2.5)(diag)-13...
Page 770 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01975 EN-01976 EN-01977 EN-01978 EN-02453 EN(H4SO 2.5)(diag)-14...
Page 771 Electrical Component Location ENGINE (DIAGNOSTICS) • LHD model (4) (3) (6) (9) EN-02423 • RHD model (8) (7) EN-01979 Inhibitor switch Fuel pump relay Radiator sub fan relay Fuel pump Electronic throttle control relay Radiator main fan relay 2 Main relay Radiator main fan relay 1 Starter EN(H4SO 2.5)(diag)-15...
Page 772 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02093 EN-00178 EN-02094 EN-02095 EN-02096 EN(H4SO 2.5)(diag)-16...
Page 773 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 18 19 20 21 22 23 26 27 20 21...
Page 774 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Termi- Connector DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) Front oxygen Signal 1 B134 0 — 1.0 0 — 1.0 — (A/F) sensor Signal 2 B134 0 — 1.0 0 —...
Page 775 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Termi- Connector DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) Fuel pump relay control ON: 0.5 or less B135 0.5 or less — (Model without immobilizer) OFF: 10 — 13 ON: 0.5 or less ON: 0.5 or less A/C relay control...
Page 776 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Termi- Connector DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) GND (oxygen sensor heater B134 — GND (Electronic throttle B137 — control) ON: 0 ON: 0 Main switch B137 —...
Page 777 Engine Condition Data ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Remarks SPECIFICATION 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm Racing Measuring condition: • After engine is warmed-up. • Gear position is in “N” or “P” range. •...
Page 778 This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools except for Subaru Select Monitor or OBD-II general scan tool, because the circuit for Subaru Select Monitor may be damaged. 9 10 11 12 13 EN-00037 Terminal No.
Page 779 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 8. OBD-II General Scan Tool OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic A: OPERATION data (2) MODE $02: Powertrain freeze frame data 1. HOW TO USE OBD-II GENERAL SCAN (3) MODE $03: Emission-related powertrain TOOL 1) Prepare a general scan tool (OBD-II general...
Page 780 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is detected by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure DTC that caused CARB required freeze frame data storage...
Page 781 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) Test value & Test limit Unit sensor heater circuit (Bank 1 Sensor 2) <$81 or $02> Coolant thermostat (Coolant temperature below thermostat regulating tempera- ture) Evaporative emission control system vent control circuit range/performance 7. MODE $07 Refer to the data of DTC (pending code) for troubleshooting result about emission in first time.
Page 782 5) Turn ignition switch to ON (engine OFF) and turn Subaru Select Monitor switch to ON. A: OPERATION 1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.5)(diag)-7, PREPARATION TOOL, General Description.> EN-00040...
Page 783 Subaru Select Monitor ENGINE (DIAGNOSTICS) 4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
Page 784 Cancel switch signal Cancel Switch — OFF (At OFF) Integrated unit data reception Body Int. Unit Data — Integrated unit data update Body Int. Unit Count — NOTE: For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.5)(diag)-28...
Page 785 A/C system refrigerant no support Test of oxygen sensor Oxygen sensor complete Test of oxygen sensor heater O2 Heater Diagnosis complete Test of EGR system EGR system incomplete NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.5)(diag)-29...
Page 786 MPH Ignition timing signal Ignition Timing Intake air volume Mass Air Flow g/sec Intake air temperature signal Intake Air Temp Throttle position signal Throttle Opening Angle NOTE: For detailed operation procedure, refer to SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO 2.5)(diag)-30...
Page 787 Subaru Select Monitor ENGINE (DIAGNOSTICS) 7. LED OPERATION MODE FOR ENGINE 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
Page 788 Data reception signal Body Int. Unit Data ON or OFF entered. When counter update signal is Counter update signal Body Int. Unit Count ON or OFF entered. NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.5)(diag)-32...
Page 789 Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
Page 790 Inspection Mode ENGINE (DIAGNOSTICS) 11.Inspection Mode A: PROCEDURE 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 2.5)(diag)-39, Drive Cycle.> Item Condition P0031...
Page 791 Inspection Mode ENGINE (DIAGNOSTICS) Item Condition P0852 Neutral Switch Input Circuit High — P1086 Tumble Generated Valve Position Sensor 2 Circuit Low — P1087 Tumble Generated Valve Position Sensor 2 Circuit High — P1088 Tumble Generated Valve Position Sensor 1 Circuit Low —...
Page 792 [20 — 40 2 (5.3 — 10.6 US 2) Idle the engine. gal, 4.4 — 8.8 Imp gal)]. 3) Prepare the Subaru Select Monitor kit. <Ref. to 2) Lift-up the vehicle using a garage jack and place EN(H4SO 2.5)(diag)-7, PREPARATION TOOL, it on rigid racks, or drive the vehicle onto free roll- General Description.>...
Page 793 Inspection Mode ENGINE (DIAGNOSTICS) 7) Connect the Subaru Select Monitor to data link • The speed difference between front and rear connector located in the lower portion of the instru- wheels may light the ABS warning light, but this in- ment panel (on the driver’s side).
Page 794 Inspection Mode ENGINE (DIAGNOSTICS) 9) Place the select lever or shift lever in “D” range (AT model) or “1st” gear (MT model) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: • On AWD model, release the parking brake. •...
Page 795 Drive Cycle ENGINE (DIAGNOSTICS) 12.Drive Cycle A: PROCEDURE 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 796 Drive Cycle ENGINE (DIAGNOSTICS) 4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN (60) 64 (40) EN-00842 Idle engine for 10 seconds or Decelerate with throttle fully Stop vehicle with throttle fully more. closed to 64 km/h (40 MPH). closed. Accelerate to 97 km/h (60 MPH) Drive vehicle at 64 km/h (40 MPH) Vehicle speed km/h (MPH) within 20 seconds.
Page 797 {Memory Clear} and press the [YES] key. 5) When the “Done” and “Turn Ignition Switch OFF” are shown on the display screen, turn the ignition switch to OFF and then Subaru Select Monitor switch to OFF. NOTE: • Initial diagnosis of electronic control throttle is performed after memory clearance.
Page 798 Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) 14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link connector located in the lower portion of instrument Check Mode panel (on the driver’s side). A: OPERATION 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.5)(diag)-7, PREPARATION TOOL,...
Page 799 Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) • A list of the support data is shown in the following table. DESCRIPTION Display Compulsory fuel pump relay oper- Fuel Pump ation check Compulsory radiator fan relay Radiator Fan Relay operation check Compulsory air conditioning relay A/C Compressor Relay operation check...
Page 800 Malfunction Indicator Light ENGINE (DIAGNOSTICS) 15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.5)(diag)-45, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> 2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.5)(diag)-46, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>...
Page 801 Malfunction Indicator Light ENGINE (DIAGNOSTICS) B: ACTIVATION OF MALFUNCTION (3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Mal- INDICATOR LIGHT function indicator light illuminates if faulty. 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the com- bination meter illuminates.
Page 802 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 to ON (engine OFF), malfunction indicator light does not come on. WIRING DIAGRAM: •...
Page 803 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
Page 804 D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF. DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor display. WIRING DIAGRAM: • EC, EK and K4 model...
Page 805 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
Page 806 Malfunction Indicator Light ENGINE (DIAGNOSTICS) E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK. DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • Test mode connector circuit is in open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during inspection mode. WIRING DIAGRAM: •...
Page 807 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
Page 808 Malfunction Indicator Light ENGINE (DIAGNOSTICS) F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING. DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when test mode connector is not connected. WIRING DIAGRAM: • EC, EK and K4 model IGNITION BATTERY SWITCH SBF-7...
Page 809 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
Page 810 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) 16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check for fuel amount. 2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.5)(diag)-55, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start- ing Failure.> 3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO 2.5)(diag)-58, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>...
Page 811 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 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
Page 812 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) • KA and KS model NOTE: Fuel injection system for KA and KS model is the same as 2.0 L model. Refer to EN(H4SO 2.0) section. Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2.
Page 813 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK IGNITION SWITCH. Is the resistance less than 5 Go to step 9. Replace the igni- 1) Disconnect the connector from ignition tion switch. switch. 2) Measure the resistance between ignition switch terminals after turning the ignition switch to START position.
Page 814 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MOD- ULE (ECM) CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
Page 815 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same...
Page 816 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Go to step 8. Repair the open or 1) Connect the connectors to ECM and main ground short cir- relay.
Page 817 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 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
Page 818 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same...
Page 819 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR IGNITION COIL Does the voltage vary more Go to step 7. Replace the igni- & IGNITOR ASSY. than 10 V? tion coil & ignitor 1) Connect the connector to ignition coil & ASSY.
Page 820 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 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
Page 821 CIRCUIT, Diag- NOTE: nostics for Engine Fuel pump operation can also be executed us- Starting Failure.> ing Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.5)(diag)-42, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP.
Page 822 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 8. Replace the fuel 1) Disconnect the connectors from fuel pump pump relay. <Ref. relay and main relay. to FU(H4SO 2.5)- 2) Remove the fuel pump relay and main relay 49, Fuel Pump.>...
Page 823 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 2.5)(di- ag)-41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>.
Page 824 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same...
Page 825 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check Is the resistance 5 — 20 '? CHECK EACH FUEL INJECTOR. Go to step 7. Replace the faulty 1) Turn the ignition switch to OFF. fuel injector. 2) Measure the resistance between each fuel injector terminals.
Page 826 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 17.List of Diagnostic Trouble Code (DTC) A: LIST 1. EC, EK AND K4 MODEL Item NOTE P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H4SO 2.5)(diag)-80, DTC P0030 HO2S HEATER CONTROL Sensor 1) CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
Page 827 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0132 O2 Sensor Circuit High Voltage <Ref. to EN(H4SO 2.5)(diag)-123, DTC P0132 O2 SENSOR CIRCUIT HIGH (Bank 1 Sensor 1) VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0133 O2 Sensor Circuit Slow Response <Ref.
Page 828 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0459 Evaporative Emission Control Sys- <Ref. to EN(H4SO 2.5)(diag)-169, DTC P0459 EVAPORATIVE EMISSION tem Purge Control Valve Circuit High CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnos- tic Procedure with Diagnostic Trouble Code (DTC).> P0462 Fuel Level Sensor Circuit Low Input <Ref.
Page 829 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1089 Tumble Generated Valve Position <Ref. to EN(H4SO 2.5)(diag)-200, DTC P1089 TUMBLE GENERATED Sensor 1 Circuit High VALVE POSITION SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1090 Tumble Generated Valve System 1 <Ref.
Page 830 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1497 EGR Solenoid Valve Signal #3 Cir- <Ref. to EN(H4SO 2.5)(diag)-221, DTC P1497 EGR SOLENOID VALVE cuit Malfunction (High Input) SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1498 EGR Solenoid Valve Signal #4 Cir- <Ref.
Page 831 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P2138 Throttle/Pedal Position Sensor/ <Ref. to EN(H4SO 2.5)(diag)-257, DTC P2138 THROTTLE/PEDAL POSI- Switch “D”/“E” Voltage Rationality TION SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> 2.
Page 832 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0133 O2 Sensor Circuit Slow Response <Ref. to EN(H4SO 2.0)(diag)-114, DTC P0133 O2 SENSOR CIRCUIT (Bank 1 Sensor 1) SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diag- nostic Trouble Code (DTC).> P0134 O2 Sensor Circuit No Activity <Ref.
Page 833 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0462 Fuel Level Sensor Circuit Low Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0462 FUEL LEVEL SENSOR CIR- CUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0463 Fuel Level Sensor Circuit High Input <Ref.
Page 834 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1493 EGR Solenoid Valve Signal #1 Cir- <Ref. to EN(H4SO 2.0)(diag)-181, DTC P1493 EGR SOLENOID VALVE cuit Malfunction (High Input) SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1494 EGR Solenoid Valve Signal #2 Cir- <Ref.
Page 835 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P2109 Throttle/Pedal Position Sensor A <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2109 THROTTLE ANGLE Minimum Stop Performance CLOSED POSITION ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P2111 Throttle Actuator Control System - <Ref.
Page 836 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
Page 837 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
Page 838 Electrical Component Location ..............8 Engine Control Module (ECM) I/O Signal ..........17 Engine Condition Data ................21 Data Link Connector .................22 OBD-II General Scan Tool ................23 Subaru Select Monitor................26 Read Diagnostic Trouble Code (DTC) ............33 Inspection Mode..................34 Drive Cycle....................39 Clear Memory Mode..................41 Compulsory Valve Operation Check Mode ..........42...
Page 839 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 18.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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 840 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 841 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 842 Go to step 6. 1) Start the engine. contact connector. 2) Read the data of front oxygen (A/F) sensor NOTE: heater current using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to the •...
Page 843 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 8. Go to step 7. 1) Start and idle the engine. 2) Measure the voltage between ECM con- nector and chassis ground.
Page 844 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 845 (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. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.>...
Page 846 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 847 NOTE: For detailed operation procedure, refer to the • Poor contact in “READ CURRENT DATA FOR ENGINE”. <Ref. rear oxygen sen- to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- sor connector itor.> • Poor contact in rear oxygen sen- sor connecting harness connector •...
Page 848 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Replace the ECM. Repair the battery 1) Disconnect the connector from rear oxygen <Ref. to FU(H4SO short circuit in har- sensor.
Page 849 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 850 4) Read the data of rear oxygen sensor heater current using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END.
Page 851 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) F: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW 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 852 SELECT MONITOR. function indicator 1) Turn the ignition switch to OFF. light illuminates, 2) Connect the Subaru Select Monitor to data the circuit has link connector. returned to a nor- 3) Turn the ignition switch to ON, and the Sub- mal condition at aru Select Monitor switch to ON.
Page 853 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 7. Repair the open MASS AIR FLOW SENSOR CONNECTOR. circuit between 1) Turn the ignition switch to OFF. ECM and mass air 2) Disconnect the connector from ECM.
Page 854 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) G: DTC P0103 MASS OR VOLUME AIR FLOW 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 855 SELECT MONITOR. function indicator 1) Turn the ignition switch to OFF. light illuminates, 2) Connect the Subaru Select Monitor to data the circuit has link connector. returned to a nor- 3) Turn the ignition switch to ON, and the Sub- mal condition at aru Select Monitor switch to ON.
Page 856 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) H: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 857 Go to step 3. 1) Start the engine. (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref.
Page 858 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 9. Repair the open MANIFOLD ABSOLUTE PRESSURE SEN- circuit in harness SOR CONNECTOR. between ECM and 1) Turn the ignition switch to OFF.
Page 859 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) I: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 860 1) Start the engine. kPa (896.5 mmHg, 35.29 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.>...
Page 861 ECM and sure sensor. <Ref. 1) Turn the ignition switch to OFF, and the manifold absolute to FU(H4SO 2.5)- Subaru Select Monitor switch to OFF. pressure sensor 25, Manifold Abso- 2) Disconnect the connector from manifold connector. lute Pressure Sen- absolute pressure sensor.
Page 862 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) J: 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 863 Repair the poor 1) Start the engine. more than 120#C (248#F)? contact. 2) Read the data of mass air flow and intake NOTE: air temperature sensor signal using Subaru In this case, repair Select Monitor. the following: • Poor contact in NOTE:...
Page 864 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) K: 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 865 Repair the poor less than "40#C ("40#F)? 1) Start the engine. contact. 2) Read the data of air flow and intake air tem- NOTE: perature sensor signal using Subaru Select In this case, repair Monitor. the following: • Poor contact in NOTE:...
Page 866 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 3 V? Go to step 6. Repair the har- FLOW AND INTAKE AIR TEMPERATURE ness and connec- SENSOR AND ECM CONNECTOR. tor.
Page 867 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) L: 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 868 Repair the poor 1) Start the engine. ture more than 150#C (302#F)? contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
Page 869 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) M: 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 870 Repair the poor ture less than "40#C ("40#F)? 1) Start the engine. contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
Page 871 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 6. Repair the har- COOLANT TEMPERATURE SENSOR AND ness and connec- ECM CONNECTOR. tor. Measure the voltage between engine coolant NOTE: temperature sensor connector and engine In this case, repair...
Page 872 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) N: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 873 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
Page 874 Is the voltage more than 0.4 V? Go to step 3. Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
Page 875 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) O: 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 876 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
Page 877 Go to step 3. Go to step 4. 1)Turn the ignition switch to ON. 2)Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Temporary poor...
Page 878 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) P: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine will not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 879 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 880 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0131 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 881 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 882 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) R: DTC P0132 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 883 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 884 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) S: DTC P0133 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 885 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 886 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) T: DTC P0134 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 887 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 888 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) U: DTC P0137 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 889 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 5.
Page 890 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 — 0.5 V? Replace the rear Repair the har- GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec- 1) Turn the ignition switch to OFF. <Ref.
Page 891 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) V: DTC P0138 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 892 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 5.
Page 893 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 — 0.5 V? Replace the rear Repair the har- GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec- 1) Turn the ignition switch to OFF. <Ref.
Page 894 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) W: DTC P0139 O2 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 895 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 896 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Y: 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 897 1) Start the engine and warm-up completely. 100#C (212#F)? temperature sen- 2) Read the data of engine coolant tempera- sor. <Ref. to ture sensor signal using Subaru Select Moni- FU(H4SO 2.5)-20, tor. Engine Coolant Temperature Sen- NOTE: sor.>...
Page 898 ON? 5) Read the data of manifold pressure sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> EN(H4SO 2.5)(diag)-139...
Page 899 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Z: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 900 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
Page 901 Is the voltage more than 0.8 V? Go to step 3. Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor...
Page 902 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AA:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 903 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
Page 904 Go to step 3. Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
Page 905 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AB:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO 2.5)(diag)-147, DTC P0304 CYLIN- DER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AC:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.
Page 906 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AE: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.) TROUBLE SYMPTOM: • Engine stalls. •...
Page 907 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 908 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair the poor Repair the har- 1) Turn the ignition switch to ON. contact in all con- ness and connec- 2) Measure the voltage between fuel injector nectors in fuel tor.
Page 909 Go to step 16. Go to step 15. CATOR LIGHT. light come on or blink? 1) Clear the memory using Subaru Select Monitor. <Ref. to EN(H4SO 2.5)(diag)-41, Clear Memory Mode.> 2) Start the engine, and drive the vehicle more than 10 minutes.
Page 910 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AF: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 • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 911 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 912 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AG: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 • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 913 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 914 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AH: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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 915 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 916 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 6. Tighten the crank- SITION SENSOR. sor installation bolt tightened shaft position sen- securely? sor installation bolt securely.
Page 917 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN- GLE 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 918 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 919 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CAMSHAFT POSITION SENSOR. Is the resistance 1 — 4 k!? Repair the poor Replace the cam- 1) Remove the camshaft position sensor. contact in cam- shaft position sen- 2) Measure the resistance between connector shaft position sen- sor.
Page 920 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0400 EXHAUST GAS RECIRCULATION FLOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Movement performance problem when engine is low speed. • Erroneous idling • Movement performance problem CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 921 1) Start the engine. kPa (400 mmHg, 15.75 inHg)? EGR valve, mani- 2) Read the data of intake manifold absolute fold absolute pres- pressure signal using Subaru Select Monitor. sure sensor and throttle body are NOTE: installed securely. For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 922 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 NOID VALVE AND ECM CONNECTOR. circuit in harness 1) Turn the ignition switch to OFF. between ECM and 2) Detach the connector from EGR solenoid EGR solenoid...
Page 923 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AK:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 924 <Ref. to EC(H4SO 2.0)-4, Rear Catalytic Converter.> CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front Contact Subaru Remove the front catalytic converter. front face of front catalyst? catalytic con- distributor service. verter. <Ref. to NOTE: EC(H4SO 2.0)-3,...
Page 925 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AL: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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 926 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 927 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Replace the ECM. Check poor contact in purge control solenoid control solenoid valve connec- contact in purge <Ref.
Page 928 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AM: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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 929 NOTE: ECM connector. Purge control solenoid valve operation can be executed using Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.5)(diag)-42, Compulsory Valve Operation Check Mode.> Connector & terminal "...
Page 930 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the ECM. Check poor contact in ECM connector. connector? contact in ECM <Ref. to FU(H4SO connector. 2.5)-36, Engine Control Module (ECM).>...
Page 931 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0462 displayed on the Check the combi- Temporary poor Subaru Select Monitor? nation meter sys- contact occurs. tem. <Ref. to IDI-3, Combination Meter System.>...
Page 932 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0463 displayed on the Check the combi- Temporary poor Subaru Select Monitor? nation meter sys- contact occurs. tem. <Ref. to IDI-3, Combination Meter System.>...
Page 933 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AP:DTC P0500 VEHICLE SPEED SENSOR DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. Step Check CHECK OPTION CODE.
Page 934 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AQ: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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 935 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY STARTER MOTOR B225 B135 B137 B225 B135 B137 4 5 6 11 12 15 16 19 20 23 24 10 11 12 13 14 15 16 17...
Page 936 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 937 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AR: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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 938 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AT:DTC P0559 GENERATOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
Page 939 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 940 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AV:DTC P0604 INTERNAL CONTROL MODULE READ 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 941 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 942 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AX:DTC P0607 CONTROL MODULE PERFORMANCE 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 943 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 944 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0691 displayed on the Check the radiator Temporary poor Subaru Select Monitor? fan system. <Ref. contact occurs. to CO(H4SO 2.0)- 7, Radiator Fan System.>...
Page 945 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0692 displayed on the Check the radiator Temporary poor Subaru Select Monitor? fan system. <Ref. contact occurs. to CO(H4SO 2.0)- 7, Radiator Fan System.>...
Page 946 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BC: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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 947 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 948 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BD:DTC P0852 NEUTRAL SWITCH INPUT 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 949 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 950 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 9. Repair the open Measure the resistance of harness between circuit in harness inhibitor switch connector and engine ground. between inhibitor Connector &...
Page 951 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BE:DTC P1086 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 952 1) Start the engine. indicator light 2) Read the data of throttle position sensor lights up, the cir- signal using Subaru Select Monitor or OBD-II cuit has returned general scan tool. to a normal condi- tion at this time. A...
Page 953 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 the har- TUMBLE GENERATOR VALVE POSITION ness and connec- SENSOR CONNECTOR. tor. 1) Turn the ignition switch to OFF.
Page 954 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BF:DTC P1087 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT HIGH 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 955 1) Start the engine. indicator light 2) Read the data of throttle position sensor lights up, the cir- signal using Subaru Select Monitor or OBD-II cuit has returned general scan tool. to a normal condi- tion at this time. A...
Page 956 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BG:DTC P1088 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 957 1) Start the engine. indicator light 2) Read the data of tumble generator valve lights up, the cir- position sensor signal using Subaru Select cuit has returned Monitor or OBD-II general scan tool. to a normal condi- tion at this time. A...
Page 958 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 the har- TUMBLE GENERATOR VALVE POSITION ness and connec- SENSOR CONNECTOR. tor. 1) Turn the ignition switch to OFF.
Page 959 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BH:DTC P1089 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT HIGH 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 960 1) Start the engine. indicator light 2) Read the data of tumble generator valve lights up, the cir- position sensor signal using Subaru Select cuit has returned Monitor or OBD-II general scan tool. to a normal condi- tion at this time. A...
Page 961 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BI: DTC P1090 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE OPEN) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 962 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BJ:DTC P1091 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE CLOSE) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 963 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BK:DTC P1092 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE OPEN) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 964 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BL:DTC P1093 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE CLOSE) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 965 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BM:DTC P1094 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNC- TION (OPEN) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 966 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 TUMBLE GENERATOR VALVE ACTUATOR circuit between CONNECTOR. ECM and tumble 1) Turn the ignition switch to OFF. generator valve 2) Disconnect the connector from tumble gen- connector.
Page 967 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BN:DTC P1095 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNC- TION (SHORT) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 968 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit CONNECTOR. assembly. <Ref. to between ECM and 1) Turn the ignition switch to OFF.
Page 969 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BO:DTC P1096 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNC- TION (OPEN) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 970 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 TUMBLE GENERATOR VALVE ACTUATOR circuit between CONNECTOR. ECM and tumble 1) Turn the ignition switch to OFF. generator valve 2) Disconnect the connector from tumble gen- connector.
Page 971 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BP:DTC P1097 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNC- TION (SHORT) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 972 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit CONNECTOR. assembly. <Ref. to between ECM and 1) Turn the ignition switch to OFF.
Page 973 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BQ:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION (LOW INPUT) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 974 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BR:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION (HIGH INPUT) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 975 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BS:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1) 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 976 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 977 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BT:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) 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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 978 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 979 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Repair the poor Measure the voltage between ECM connector short circuit in har- contact in ECM and chassis ground.
Page 980 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BU:DTC P1160 RETURN SPRING FAILURE NOTE: For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO 2.5)(diag)-231, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos- tic Trouble Code (DTC).> BV:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) NOTE:...
Page 981 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CB: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 • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 982 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 the har- NOID VALVE. ness and connec- 1) Turn the ignition switch to OFF. tor.
Page 983 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CC: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 • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 984 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.5)(diag)-70, List of Diagnostic Trou- ble Code (DTC).>...
Page 985 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CD: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 2.5)(diag)- 41, Clear Memory Mode.>...
Page 986 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY STARTER MOTOR B225 B135 B137 B225 B135 B137 4 5 6 11 12 15 16 19 20 23 24 10 11 12 13 14 15 16 17...
Page 987 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 988 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CE: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 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
Page 989 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 990 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CF:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 991 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
Page 992 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 993 1) Connect all the connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage more than 0.8 V? Go to step 9. Go to step 10.
Page 994 3) Turn the ignition switch to ON. Replace the elec- 4) Read the data of main throttle sensor signal tronic throttle con- using Subaru Select Monitor. trol if defective. CHECK SENSOR OUTPUT. Is the voltage 1.64 — 1.70 V? Go to step 24.
Page 995 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 25. Repair the open ELECTRONIC THROTTLE CONTROL MO- circuit of harness TOR. connector. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM.
Page 996 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CG:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 997 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
Page 998 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
Page 999 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CH:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
Page 1000 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) • KA and KS model NOTE: Fuel injection system for KA and KS model is the same as 2.0 L model. Refer to EN(H4SO 2.0) section. Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2.
Page 1001 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CJ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” 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. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...

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