Subaru IMPREZA 2000 Service Manual
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Subaru IMPREZA 2000 Service Manual

Subaru IMPREZA 2000 Service Manual

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Table of Contents

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2000 IMPREZA SERVICE MANUAL
ENGINE SECTION
FOREWORD
This portion of the service manual has been prepared
to provide SUBARU service personnel with the neces-
sary information and data for the correct maintenance
and repair of SUBARU vehicles.
This manual includes the procedures for maintenance,
disassembling, reassembling, inspection and adjust-
ment of components and diagnostics for guidance of
both the fully qualified and the less-experienced
mechanics.
Please peruse and utilize this manual fully to ensure
complete repair work for satisfying our customers by
keeping their vehicle in optimum condition. When
replacement of parts during repair work is needed, be
sure to use SUBARU genuine parts.
All information, illustration and specifications con-
tained in this manual are based on the latest product
information available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
G1810BE2

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Summary of Contents for Subaru IMPREZA 2000

  • Page 1 ENGINE SECTION FOREWORD This portion of the service manual has been prepared to provide SUBARU service personnel with the neces- sary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance,...
  • Page 2 All right reserved. This book may not be reproduced or copied, in whole or in part, without the written per- mission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN. SUBARU, are trademarks of FUJI HEAVY INDUSTRIES LTD. © Copyright 1999 FUJI HEAVY INDUSTRIES LTD.
  • Page 3 ¼ Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance and safe operation, function and performance which the SUBARU vehicle possesses. ¼ In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose parts numbers are designated or their equivalents must be utilized.

  • Page 4: Wservice Procedure

    FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual 2. How to Use this Manual ¼ This Service Manual is divided into six volumes by section so that it can be used with ease at work. Refer to the Table of Contents, select and use the necessary section. ¼...
  • Page 5 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is useful for retrieving the necessary portion. H0M0010...
  • Page 6 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ In this manual, the following symbols are used. Symbol Description Selective part Replacement part Should be lubricated with oil. S0M0001 Should be lubricated with grease. S0M0002 Sealing point S0M0003 Tightening torque S0M0004 Character...
  • Page 7 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ WARNING, CAUTION, NOTE WARNING: Indicates the item which must be observed precisely during performance of maintenance services in order to avoid injury to the mechanics and other persons. CAUTION: Indicates the item which must be followed precisely during performance of maintenance services so as to avoid damage and breakage to the vehicle and its parts and components.
  • Page 8 FOREWORD SERVICE PROCEDURE [W3A0] 3. Basic Checks for Diagnostics ¼ To disconnect a locking connector, first release 3. Basic Checks for the lock, then pull the connector off. Diagnostics <Unlock by pulling the locking tab.> A: DISCONNECTING CONNECTORS ¼ Always hold the connector itself. CAUTION: Don’t pull the harness.
  • Page 9 FOREWORD SERVICE PROCEDURE [W3C1] 3. Basic Checks for Diagnostics ¼ When the connector has a back plate, remove B: INSERTING A PROBE the plate after removing the projection of the plate CAUTION: first. (Be careful not to use excessive force, since Poor contact has been identified as a primary the terminals might brake off.) cause of this problem.
  • Page 10 FOREWORD SERVICE PROCEDURE [W3C2] 4. Diagnosis and Checking Procedure Using Instruments 4. Diagnosis and Checking 2. VISUAL INSPECTION Procedure Using Instruments 1) Disconnect the two connector halves. 2) Check the connector pins for signs of corrosion A: USING A CIRCUIT TESTER or foreign material.
  • Page 11 ¼ Before changing the measurement range the gauge must be reset to zero. B: USING A SUBARU SELECT MONITOR With this testing procedure the defective compo- nent can be determined by directly monitoring input/output signals of the ECM or the trouble codes.
  • Page 12 FOREWORD SERVICE PROCEDURE [W500] 5. Table of Contents 5. Table of Contents 1-1 Specifications 1-2 ########## 1-3 General Information GENERAL INFORMATION SECTION 1-4 Pre-Delivery Inspection 1-5 Periodic Maintenance Services 1-6 Special Tools 2-1 Emission Control System and Vacuum Fitting 2-2 On-Car Services 2-3 Engine 2-4 Engine Lubrication System 2-5 Engine Cooling System...

  • Page 13: Table Of Contents

    EMISSION CONTROL SYSTEM AND VACUUM FITTING Page SERVICE PROCEDURE ...................2 Front Catalytic Converter ................2 Rear Catalytic Converter................4 Canister .......................5 Purge Control Solenoid Valve ..............5 Fuel Temperature Sensor................6 Fuel Tank Pressure Sensor.................8 Pressure Control Solenoid Valve ..............9 Main Fuel Level Sensor ................11 Drain Filter....................12 Fuel Sub Level Sensor................13 Vent Valve ....................15...

  • Page 14: Front Catalytic Converter

    SERVICE PROCEDURE [W1A0] 1. Front Catalytic Converter 1. Front Catalytic Converter 6) Separate front and rear catalytic converter assembly from rear exhaust pipe. A: REMOVAL 1) Disconnect battery ground cable. B2M0055 7) Remove front exhaust pipe from cylinder G6M0095 heads. 2) Disconnect front oxygen (A/F) sensor connec- tor.
  • Page 15 SERVICE PROCEDURE [W1B0] 1. Front Catalytic Converter 9) Separate front and rear catalytic converter 3) Install front exhaust pipe to cylinder heads. assembly from front exhaust pipe. Tightening torque: NOTE: 30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb) The rear catalytic converter is integrated with front catalytic converter.

  • Page 16: Rear Catalytic Converter

    SERVICE PROCEDURE [W2A0] 2. Rear Catalytic Converter 2. Rear Catalytic Converter 6) Connect rear oxygen sensor connector. A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the removal and installation procedures are the same as the those for the front catalytic converter.

  • Page 17: Canister

    SERVICE PROCEDURE [W4A0] 4. Purge Control Solenoid Valve 3. Canister 4. Purge Control Solenoid Valve A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1) Lift-up the vehicle. 2) Disconnect evaporation hoses from canister. 1) Disconnect battery ground cable. S2M0950 G6M0095 3) Remove canister from body.

  • Page 18: Fuel Temperature Sensor

    SERVICE PROCEDURE [W5A0] 5. Fuel Temperature Sensor 5. Fuel Temperature Sensor 4) Take out purge control solenoid valve. 5) Disconnect connector from purge control sole- A: REMOVAL noid valve. 6) Disconnect vacuum hoses from purge control 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> solenoid valve.
  • Page 19 SERVICE PROCEDURE [W5A0] 5. Fuel Temperature Sensor 5) Move clips, and then disconnect fuel delivery 9) Disconnect connector from fuel pump bracket. hose (A), return hose (B) and jet pump hose (C). 6) Disconnect quick connector, and then discon- nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].> S2M0145 10) Remove main fuel level sensor from fuel pump assembly.

  • Page 20: Fuel Tank Pressure Sensor

    SERVICE PROCEDURE [W5B0] 6. Fuel Tank Pressure Sensor 6. Fuel Tank Pressure Sensor B: INSTALLATION CAUTION: A: REMOVAL AND INSTALLATION Leave fuel filler cap open when tightening nuts, 1) Remove fuel tank. <Ref. to 2-8 [W2A0].> to prevent fuel from flowing out through fuel delivery and return pipes.

  • Page 21: Pressure Control Solenoid Valve

    SERVICE PROCEDURE [W7A0] 7. Pressure Control Solenoid Valve 7. Pressure Control Solenoid 5) Move two fuel pipes to upper side, and remove bolt which install fuel tank pressure sensor to Valve bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. H2M3602 6) Move clip, and disconnect pressure hose from fuel tank.
  • Page 22 SERVICE PROCEDURE [W7A0] 7. Pressure Control Solenoid Valve 4) Remove bolt which installs pressure control 9) Disconnect vacuum hose from pressure control solenoid valve holding bracket on body. solenoid valve. H2M2530 B2M1785 5) Disconnect connector from pressure control 10) Installation is in the reverse order of removal. solenoid valve.

  • Page 23: Main Fuel Level Sensor

    SERVICE PROCEDURE [W8A0] 8. Main Fuel Level Sensor 8. Main Fuel Level Sensor 5) Move clips, and then disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C). A: REMOVAL 6) Disconnect quick connector, and then discon- nect fuel delivery hose (A).

  • Page 24: Drain Filter

    SERVICE PROCEDURE [W8B0] 9. Drain Filter 9. Drain Filter B: INSTALLATION CAUTION: A: REMOVAL AND INSTALLATION Leave fuel filler cap open when tightening nuts, 1) Disconnect battery ground cable. to prevent fuel from flowing out through fuel delivery and return pipes. Close fuel filler cap after tightening nuts.

  • Page 25: Fuel Sub Level Sensor

    SERVICE PROCEDURE [W10A0] 10. Fuel Sub Level Sensor 10. Fuel Sub Level Sensor 6) Remove nut which installs drain filter and drain valve brackets on body, and remove them as a A: REMOVAL AND INSTALLATION unit. 1) Release fuel pressure. <Ref. to 2-8 [W1B0].> 2) Open fuel flap lid, and remove fuel filler cap.
  • Page 26 SERVICE PROCEDURE [W10A0] 10. Fuel Sub Level Sensor 6) Remove bolts which install fuel sub level sensor 8) Installation is in the reverse order of removal. on fuel tank. Do the following: (1) Install fuel sub level sensor. Tightening torque: T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) S2M0152...

  • Page 27: Vent Valve

    SERVICE PROCEDURE [W11A0] 11. Vent Valve 11. Vent Valve 5) Installation is in the reverse order of removal. CAUTION: A: REMOVAL AND INSTALLATION Replace rubber seat with a new one. 1) Remove fuel tank. <Ref. to 2-8 [W2A0].> Tightening torque: T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) S2M0169A...

  • Page 28: Shut Valve

    SERVICE PROCEDURE [W12A0] 12. Shut Valve 12. Shut Valve 5) Remove shut valve from fuel filler pipe. A: REMOVAL AND INSTALLATION 1) Drain fuel from fuel tank. <Ref. to 2-8 [W1C0].> B2M1797 6) Installation is in the reverse order of removal. Tightening torque: G2M0345 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)

  • Page 29: Drain Valve

    SERVICE PROCEDURE [W13A0] 13. Drain Valve 13. Drain Valve 6) Remove bolt which installs drain filter and drain valve brackets on body. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. H2M3610 7) Move drain filter to upper side, and remove G6M0095 drain valve with bracket.
  • Page 30 SERVICE PROCEDURE MEMO:...
  • Page 31 ON-CAR SERVICES Page SERVICE PROCEDURE ...................2 Foreword .....................2 Ignition Timing .....................2 Engine Idle Speed..................3 Engine Compression ...................4 Intake Manifold Vacuum................5 Engine Oil Pressure ..................5 Fuel Pressure ....................7 Valve Clearance ..................8...

  • Page 32: Service Procedure

    SERVICE PROCEDURE [W100] 1. Foreword 1. Foreword 2. Ignition Timing This chapter describes major inspection and ser- A: MEASUREMENT vice procedures for the engine mounted on the CAUTION: body. For procedures not found in this chapter, After warming-up, engine becomes very hot. refer to the service procedure section in the appli- Be careful not to burn yourself during mea- cable chapter.

  • Page 33: Engine Idle Speed

    S2M0286A (2) Connect SUBARU SELECT MONITOR to the data link connector. (3) Turn ignition switch to ON, and SUBARU B2M2011 SELECT MONITOR switch to ON. (4) Select {2. Each System Check} in Main Menu.

  • Page 34: Engine Compression

    SERVICE PROCEDURE [W4A0] 4. Engine Compression 4. Engine Compression 6) Check idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, A: MEASUREMENT air conditioning, etc. OFF) Idle speed (No load and gears in neutral (MT), CAUTION: or N or P (AT) position): After warming-up, engine becomes very hot.

  • Page 35: Intake Manifold Vacuum

    SERVICE PROCEDURE [W6A0] 6. Engine Oil Pressure 5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the vacuum gauge indication. A: MEASUREMENT By observing the gauge needle movement, the internal condition of the engine can be diagnosed 1) Warm-up the engine.
  • Page 36 SERVICE PROCEDURE [W6A0] 6. Engine Oil Pressure (2) Remove V-belt cover. 5) Connect oil pressure gauge hose to cylinder block. 6) Connect battery ground cable. S2M0896 (3) Loosen lock bolt and slider bolt, and remove G6M0095 front side V-belt. 7) Start the engine, and measure oil pressure. G2M0286 S2M0242 (4) Remove generator lock bolt.

  • Page 37: Fuel Pressure

    SERVICE PROCEDURE [W7B0] 7. Fuel Pressure 7. Fuel Pressure 6) Measure fuel pressure while disconnecting pressure regulator vacuum hose from collector A: PRECAUTIONS chamber. Fuel pressure: WARNING: ¼ Place “No fire” signs near the working area. Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm , 41 —...

  • Page 38: Valve Clearance

    SERVICE PROCEDURE [W8A0] 8. Valve Clearance 8. Valve Clearance 5) Remove rocker cover. 6) When inspecting #1 and #3 cylinders: A: INSPECTION (1) Remove air intake duct as a unit. CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle onto the lift.
  • Page 39 SERVICE PROCEDURE [W8A0] 8. Valve Clearance (7) Place suitable container under the vehicle. (5) Remove the two bolts which hold washer (8) Lower the vehicle. tank, then secure the tank away from working (9) Remove the timing belt cover (RH) bolt. area.
  • Page 40 SERVICE PROCEDURE [W8A0] 8. Valve Clearance (11) Remove rocker cover bolts, then remove 9) Measure #1 cylinder valve clearance by using rocker cover (LH). thickness gauge. CAUTION: ¼ Insert the thickness gauge in at as horizon- tal a direction as a possible with respect to the valve stem end face.
  • Page 41 SERVICE PROCEDURE [W8B0] 8. Valve Clearance 12) After inspection, install the related parts in the 2) Adjust the #1 cylinder valve clearance. reverse order of removal. (1) Loosen the valve rocker nut and screw. (2) Place suitable thickness gauge. Tightening torque: (3) While noting valve clearance, tighten valve 32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb) rocker adjust screw.
  • Page 42 SERVICE PROCEDURE [W8B0] 8. Valve Clearance 6) Similar to adjustment procedures used for #1 cylinder, adjust #2, #3 and #4 cylinder valve clear- ances. NOTE: ¼ Be sure to set cylinder pistons to their respective top dead centers on the compression stroke before adjusting valve clearances.
  • Page 43 ENGINE Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 Service Data....................3 COMPONENT PARTS ..................7 Timing Belt ....................7 Cylinder Head and Camshaft..............8 Cylinder Head and Valve Assembly............9 Cylinder Block ...................10 Crankshaft and Piston................12 Valve Rocker Assembly................14 SERVICE PROCEDURE .................15 General Precautions..................15 General Procedure ..................15 Timing Belt ....................16 Valve Rocker Assembly................26 Camshaft ....................28...

  • Page 44: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Model 2200 cc 2500 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso- Type line engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder Bore × Stroke 96.9 × 75.0 (3.815 × 2.953) 99.5 ×...

  • Page 45: Service Data

    SPECIFICATIONS AND SERVICE DATA [S200] 2. Service Data 2. Service Data NOTE: STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize Belt ten- sioner Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in) adjuster Spacer O.D.
  • Page 46 SPECIFICATIONS AND SERVICE DATA [S200] 2. Service Data Free length 54.30 mm (2.1378 in) Squareness 2.5°, 2.4 mm (0.094 in) 214.8 — 246.2 N Valve (21.9 — 25.1 kg, 48.3 — 55.3 lb)/45.0 mm (1.772 spring Tension/spring height 526.6 — 581.6 N (53.7 —...
  • Page 47 SPECIFICATIONS AND SERVICE DATA [S200] 2. Service Data 0.010 — 0.038 mm (0.0004 — 0.0015 in) Oil clearance (2200 cc) Limit 0.05 mm (0.0020 in) 0.020 — 0.046 mm (0.0004 — 0.0015 in) Oil clearance (2500 cc) Limit 0.050 mm (0.0020 in) 1.492 —...
  • Page 48 SPECIFICATIONS AND SERVICE DATA [S200] 2. Service Data 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 2.017 — 2.020 mm (0.0794 — 0.0795 in) in) US #1, #3 0.05 mm (0.0020 2.027 — 2.030 mm (0.0798 — 0.0799 in) in) US 0.25 mm (0.0098 2.127 —...
  • Page 49 COMPONENT PARTS [C100] 1. Timing Belt 1. Timing Belt H2M2924A (1) Belt cover No. 2 (RH) (9) Belt idler (No. 2) (17) Crankshaft pulley (2500 cc (2) Timing belt guide (MT vehicles (10) Automatic belt tension adjuster model) only) ASSY (3) Crankshaft sprocket (2500 cc (11) Belt idler No.

  • Page 50: Ccomponent Parts

    COMPONENT PARTS [C200] 2. Cylinder Head and Camshaft 2. Cylinder Head and Camshaft B2M1954D (1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kg-m, ft-lb) (2) Intake valve rocker ASSY (12) Camshaft (LH) <Ref. to 2-3 [W6E1].> (3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) 5±1 (0.5±0.1, 3.6±0.7) (4) Camshaft cap (RH)

  • Page 51: Cylinder Head And Valve Assembly

    COMPONENT PARTS [C300] 3. Cylinder Head and Valve Assembly 3. Cylinder Head and Valve Assembly B2M1955A (1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve guide (2) Intake valve (6) Valve spring (10) Exhaust valve spring seat (3) Intake valve guide (7) Retainer (11) Exhaust valve oil seal (4) Intake valve spring seat...

  • Page 52: Cylinder Block

    COMPONENT PARTS [C400] 4. Cylinder Block 4. Cylinder Block B2M1957G (1) Oil pressure switch (15) Oil filter connector Tightening torque: N·m (kg-m, ft-lb) (2) Cylinder block (RH) (16) Oil strainer 5 (0.5, 3.6) (3) Service hole plug (17) Gasket 6.4 (0.65, 4.7) (4) Gasket (18) Oil pan 10 (1.0, 7)
  • Page 53 COMPONENT PARTS [C400] 4. Cylinder Block MEMO:...

  • Page 54: Crankshaft And Piston

    COMPONENT PARTS [C500] 5. Crankshaft and Piston 5. Crankshaft and Piston B2M3429A...
  • Page 55 COMPONENT PARTS [C500] 5. Crankshaft and Piston (1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4 (2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5 (3) Drive plate (AT) (11) Connecting rod (4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kg-m, ft-lb) (5) Second ring (13) Connecting rod cap...

  • Page 56: Valve Rocker Assembly

    COMPONENT PARTS [C600] 6. Valve Rocker Assembly 6. Valve Rocker Assembly B2M1956A (1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kg-m, ft-lb) (2) Valve rocker nut (7) Exhaust rocker shaft 5±1 (0.5±0.1, 3.6±0.7) (3) Valve rocker adjust screw (8) Exhaust valve rocker arm 10±1 (1.0±0.1, 7.2±0.7) (4) Spring...

  • Page 57: Service Procedure

    SERVICE PROCEDURE [W200] 2. General Procedure 1. General Precautions 2. General Procedure 1) All parts should be thoroughly cleaned, paying 1) For the procedure of removing the engine from special attention to the engine oil passages, pis- the vehicle, refer to 2-11 ENGINE AND TRANS- tons and bearings.

  • Page 58: Timing Belt

    SERVICE PROCEDURE [W3A1] 3. Timing Belt 3. Timing Belt 3) Remove crankshaft pulley bolt. To lock crankshaft, use ST. A: REMOVAL 2200 cc model: ST 499977300 CRANKSHAFT PULLEY 1. CRANKSHAFT PULLEY AND BELT WRENCH COVER 2500 cc model: 1) Remove A/C belt. (With A/C model) ST 499977100 CRANKSHAFT PULLEY WRENCH B2M2584...
  • Page 59 SERVICE PROCEDURE [W3A2] 3. Timing Belt 2. TIMING BELT 2) If alignment mark (a) and/or arrow mark (which indicates rotation direction) on timing belt fade 1) Remove timing belt guide. (MT vehicles only) away, put new marks before removing timing belt as shown in procedures below.
  • Page 60 SERVICE PROCEDURE [W3A3] 3. Timing Belt (2) Using white paint, put alignment and/or 3. BELT IDLER AND AUTOMATIC BELT arrow marks on timing belts in relation to the TENSION ADJUSTER ASSEMBLY crank sprocket and cam sprockets. 1) Remove belt idler (No. 1). B2M2591 B2M2596 Specified data:...
  • Page 61 SERVICE PROCEDURE [W3A4] 3. Timing Belt 2) Remove camshaft sprocket No. 1. To lock 4) Remove belt cover No. 2 (LH). camshaft, use ST. 5) Remove belt cover No. 2 (RH). ST 499207400 CAMSHAFT SPROCKET CAUTION: WRENCH Do not damage or lose the seal rubber when removing belt covers.
  • Page 62 SERVICE PROCEDURE [W3B1] 3. Timing Belt ¼ Press-in the push adjuster rod gradually tak- B: INSPECTION ing more than three minutes. 1. TIMING BELT ¼ Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 lb). 1) Check timing belt teeth for breaks, cracks, and ¼...
  • Page 63 SERVICE PROCEDURE [W3C1] 3. Timing Belt C: INSTALLATION 4) Install crankshaft sprocket. 1. CAMSHAFT AND CRANKSHAFT SPROCKET 1) Install tensioner bracket. Tightening torque: 25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) B2M2600D H2M2380 2) Install belt cover No. 2 (RH). Tightening torque: 5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb) S2M0414D 3) Install belt cover No.
  • Page 64 SERVICE PROCEDURE [W3C2] 3. Timing Belt 6) Install camshaft sprocket No. 2. To lock (2) Slowly move the adjuster rod down with a camshaft, use ST. pressure of 294 N (30 kg, 66 lb) until the ST 499207100 CAMSHAFT SPROCKET adjuster rod is aligned with the stopper pin hole WRENCH in the cylinder.
  • Page 65 SERVICE PROCEDURE [W3C3] 3. Timing Belt 3) Install belt idler (No. 1). 2) Install belt idler No. 2. Tightening torque: Tightening torque: 39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb) 39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb) 3) Install belt idler (No. 2). Tightening torque: 39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb) B2M2596...
  • Page 66 SERVICE PROCEDURE [W3C4] 3. Timing Belt (2) Check and adjust clearance between timing 4) Install pulley bolt. (2200 cc model) belt and timing belt guide by using thickness To lock crankshaft, use ST. gauge. ST 499977000 CRANKSHAFT PULLEY WRENCH Clearance: (1) Clean the crankshaft pulley thread using an 1.0±0.5 mm (0.039±0.020 in) air gun.
  • Page 67 SERVICE PROCEDURE [W3C4] 3. Timing Belt 6) Install pulley bolt. (2500 cc model) 8) Install A/C belt tensioner. (With A/C model) To lock crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH (1) Clean the crankshaft pulley thread using an air gun. (2) Apply engine oil to the crankshaft pulley bolt seat and thread.

  • Page 68: Valve Rocker Assembly

    SERVICE PROCEDURE [W4A0] 4. Valve Rocker Assembly 4. Valve Rocker Assembly CAUTION: Arrange all removed parts in order so that they A: REMOVAL can be installed in their original positions. 3) Remove nut and adjuster screw from valve 1) Disconnect PCV hose and remove rocker cover.
  • Page 69 SERVICE PROCEDURE [W4D0] 4. Valve Rocker Assembly Clearance between support and shaft: 6) Check that valve rocker arm roller rotates Standard smoothly. If not, replace valve rocker arm. 0.005 — 0.039 mm (0.0002 — 0.0015 in) 2. INTAKE AND EXHAUST VALVE Limit ROCKER SHAFT 0.05 mm (0.0020 in)

  • Page 70: Camshaft

    SERVICE PROCEDURE [W4E0] 5. Camshaft 5. Camshaft E: INSTALLATION 1) Installation of valve rocker assembly A: REMOVAL (1) Temporarily tighten bolts (a) through (d) 1. RELATED PARTS equally as shown in figure. CAUTION: Remove timing belt, camshaft sprockets <Ref. to Do not allow valve rocker assembly to gouge 2-3 [W3A0].>...
  • Page 71 SERVICE PROCEDURE [W5B1] 5. Camshaft (4) Remove camshaft cap. (3) Remove bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX PLUS B2M2613 2) Remove camshaft (LH). B2M2612A 3) Remove oil seal. 4) Remove plug from rear side of camshaft (LH). (4) Remove camshaft cap.
  • Page 72 SERVICE PROCEDURE [W5B2] 5. Camshaft 3) Measure outside diameter of camshaft journal clearance). If oil clearance exceeds specifications, and inside diameter of cylinder head journal, and replace camshaft or cylinder head as necessary. determine the difference between the two (= oil Unit: mm (in) Standard 0.055 —...
  • Page 73 SERVICE PROCEDURE [W5C1] 5. Camshaft NOTE: (4) Tighten bolts (a) through (h) in alphabetical Apply a coat of 3 mm (0.12 in) dia. liquid gasket sequence. along edge of cam cap mating surface. Tightening torque: 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb) S2M1199A B2M2621B (2) Temporarily tighten bolts (g) through (j) in...
  • Page 74 SERVICE PROCEDURE [W5C2] 5. Camshaft (7) Tighten bolts (w) through (x) in alphabetical (1) Apply liquid gasket on the around of cam- sequence. shaft cap. Tightening torque: Liquid gasket: 10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb) THREE BOND 1280B B2M2621E B2M2619 3) Apply a coat of grease to oil seal lips and install NOTE: oil seal (A) on camshaft using ST1 and ST2.
  • Page 75 SERVICE PROCEDURE [W5C2] 5. Camshaft (3) Install valve rocker assembly. (6) Tighten bolts (o) through (v) in alphabetical <Ref. to 2-3 [W4E0].> sequence. Tightening torque: 10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb) B2M2615 (4) Tighten bolts (a) through (h) in alphabetical B2M2621D sequence.

  • Page 76: Cylinder Head

    SERVICE PROCEDURE [W5C3] 6. Cylinder Head 6. Cylinder Head 3. RELATED PARTS 1) Adjust the valve clearance. <Ref. to 2-2 A: REMOVAL [W8B1].> 2) Install rocker cover and connect PCV hose. 1. RELATED PARTS 3) Install timing belt. <Ref. to 2-3 [W3C0].> 1) Remove intake manifold.
  • Page 77 SERVICE PROCEDURE [W6C1] 6. Cylinder Head B: DISASSEMBLY C: INSPECTION AND REPLACEMENT 1) Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE 1. CYLINDER HEAD 2) Set ST on valve spring. Compress valve spring 1) Make sure that no crack or other damage and remove the valve spring retainer key.
  • Page 78 SERVICE PROCEDURE [W6C2] 6. Cylinder Head 2. VALVE SEAT 3. VALVE GUIDE Inspect intake and exhaust valve seats, and cor- 1) Check the clearance between valve guide and rect the contact surfaces with valve seat cutter if stem. The clearance can be checked by measur- they are defective or when valve guides are ing the outside diameter of valve stem and the replaced.
  • Page 79 SERVICE PROCEDURE [W6C3] 6. Cylinder Head (2) Insert ST2 into valve guide and press it (5) Put new valve guide, coated with sufficient down to remove valve guide. oil, in cylinder, and insert ST1 into valve guide. ST1 498267800 CYLINDER HEAD TABLE Press in until the valve guide upper end is flush ST2 499767400 VALVE GUIDE REMOVER with the upper surface of ST2.
  • Page 80 SERVICE PROCEDURE [W6C4] 6. Cylinder Head (7) Ream the inside of valve guide with ST. 4. INTAKE AND EXHAUST VALVE Gently rotate the reamer clockwise while press- 1) Inspect the flange and stem of valve, and ing it lightly into valve guide, and return it also replace if damaged, worn, or deformed, or if “H”...
  • Page 81 SERVICE PROCEDURE [W6C6] 6. Cylinder Head 5. VALVE SPRING 6. INTAKE AND EXHAUST VALVE OIL SEAL 1) Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the Replace oil seal with new one, if lip is damaged or specifications presented below.
  • Page 82 SERVICE PROCEDURE [W6D0] 6. Cylinder Head D: ASSEMBLY B2M2629B (1) Valve (6) Retainer (11) Plug (2) Valve guide (7) Retainer key (12) Camshaft cap (3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY (4) Oil seal (9) Camshaft (5) Valve spring (10) Oil seal 1) Installation of valve spring and valve...
  • Page 83 SERVICE PROCEDURE [W6E2] 6. Cylinder Head (5) Compress valve spring and fit valve spring (7) Further tighten all bolts by 80 to 90° in retainer key. alphabetical sequence shown in figure below. CAUTION: Ensure that the total “re-tightening angle” [in the former two steps], do not exceed 180°.

  • Page 84: Cylinder Block

    SERVICE PROCEDURE [W7A1] 7. Cylinder Block 7. Cylinder Block 11) Remove flywheel (MT vehicles only) or drive plate (AT vehicles only). A: REMOVAL Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER 1. RELATED PARTS NOTE: Before conducting this procedure drain engine oil completely if applicable.
  • Page 85 SERVICE PROCEDURE [W7A1] 7. Cylinder Block (3) Insert a oil pan cutter blade between cylin- 21) Remove water pipe. <Ref. to 2-5 [W7A0].> der block-to-oil pan clearance and remove oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
  • Page 86 SERVICE PROCEDURE [W7A2] 7. Cylinder Block 2. CYLINDER BLOCK S2M1590A (1) Service hole plug (3) Circlip (5) Service hole cover (2) Gasket (4) Piston pin 1) Remove service hole cover and service hole 2) Rotate crankshaft to bring #1 and #2 pistons to plugs using hexagon wrench [14 mm (0.55 in)].
  • Page 87 SERVICE PROCEDURE [W7A2] 7. Cylinder Block 3) Draw out piston pin from #1 and #2 pistons 4) Similarly remove piston pins from #3 and #4 using ST. pistons. ST 499097700 PISTON PIN REMOVER 5) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.
  • Page 88 SERVICE PROCEDURE [W7B1] 7. Cylinder Block 12) Draw out each piston from cylinder block using wooden bar or hammer handle. CAUTION: Do not confuse combination of piston and cyl- inder. B: DISASSEMBLY 1. CRANKSHAFT AND PISTON B2M1320I (1) Connecting rod cap (3) Top ring (5) Oil ring (2) Connecting rod bearing...
  • Page 89 SERVICE PROCEDURE [W7C2] 7. Cylinder Block 2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cylinder 1) The cylinder bore size is stamped on the cylin- Measure the inner diameter of each cylinder in der block’s front upper surface. both the thrust and piston pin directions at the CAUTION: heights shown in the figure, using a cylinder bore...
  • Page 90 SERVICE PROCEDURE [W7C3] 7. Cylinder Block 4) How to measure the outer diameter of each 6) Boring and honing piston (1) If the value of taper, out-of-roundness, or Measure the outer diameter of each piston at the cylinder-to-piston clearance measured exceeds height shown in the figure.
  • Page 91 SERVICE PROCEDURE [W7C4] 7. Cylinder Block 3) Make sure that piston pin can be inserted into 4. PISTON RING the piston pin hole with a thumb at 20°C (68°F). 1) If piston ring is broken, damaged, or worn, or if Replace if defective.
  • Page 92 SERVICE PROCEDURE [W7C5] 7. Cylinder Block 2) Squarely place piston ring and oil ring in 5. CONNECTING ROD cylinder, and measure the piston ring gap with a 1) Replace connecting rod, if the large or small thickness gauge. end thrust surface is damaged. 2) Check for bend or twist using a connecting rod Unit: mm (in) aligner.
  • Page 93 SERVICE PROCEDURE [W7C5] 7. Cylinder Block 5) Measure the oil clearance on individual con- 6) Inspect bushing at connecting rod small end, necting rod bearings by means of plastigauge. If and replace if worn or damaged. Also measure the any oil clearance is not within specification, replace piston pin clearance at the connecting rod small the defective bearing with a new one of standard end.
  • Page 94 SERVICE PROCEDURE [W7C6] 7. Cylinder Block 6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, BEARING replace bearing with a suitable (undersize) one, 1) Clean crankshaft completely and check for and replace or recondition crankshaft as neces- cracks by means of red lead check etc., and sary.
  • Page 95 SERVICE PROCEDURE [W7D1] 7. Cylinder Block 4) Measure the thrust clearance of crankshaft at 5) Inspect individual crankshaft bearings for signs center bearing. If the clearance exceeds the limit, of flaking, seizure, melting, and wear. replace bearing. 6) Measure the oil clearance on each crankshaft bearing by means of plastigauge.
  • Page 96 SERVICE PROCEDURE [W7D1] 7. Cylinder Block 3) Install connecting rod cap with connecting rod (4) Position the upper rail gap at (C) or (D) in nut. the figure. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: ¼...
  • Page 97 SERVICE PROCEDURE [W7D1] 7. Cylinder Block (6) Position the lower rail gap at (E) or (F) in the CAUTION: figure. Piston front mark faces towards the front of the engine. CAUTION: ¼ Ensure ring gaps do not face the same direc- tion.
  • Page 98 SERVICE PROCEDURE [W7E1] 7. Cylinder Block E: INSTALLATION 1. CYLINDER BLOCK B2M2407A (1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kg-m, ft-lb) (2) Crankshaft 25±2 (2.5±0.2, 18.1±1.4) (3) Cylinder block 47±3 (4.8±0.3, 34.7±2.2) 1) Install ST to cylinder block, then install crank- 3) Apply fluid packing to the mating surface of #1 shaft bearings.
  • Page 99 SERVICE PROCEDURE [W7E1] 7. Cylinder Block 4) Temporarily tighten 10 mm cylinder block con- 7) Install rear oil seal using ST1 and ST2. necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE figure. ST2 499587200 OIL SEAL INSTALLER B2M0088D G2M0186 5) Tighten 10 mm cylinder block connecting bolts...
  • Page 100 SERVICE PROCEDURE [W7E2] 7. Cylinder Block 2. PISTON AND PISTON PIN (#1 AND #2) B2M1322F (1) Piston (4) Gasket Tightening torque: N·m (kg-m, ft-lb) (2) Piston pin (5) Service hole plug 69±7 (7.0±0.7, 50.6±5.1) (3) Circlip 1) Installing piston 2) Installing piston pin (1) Turn cylinder block so that #1 and #2 cylin- (1) Insert ST3 into service hole to align piston ders face upward.
  • Page 101 SERVICE PROCEDURE [W7E2] 7. Cylinder Block (3) Install circlip. (5) Install service hole plug and gasket. CAUTION: CAUTION: Use new circlips. Use a new gasket. G2M0190 B2M2620 (4) Apply fluid packing around the service hole plug. Fluid packing: THREE BOND 1215 or equivalent B2M2625...
  • Page 102 SERVICE PROCEDURE [W7E3] 7. Cylinder Block 3. PISTON AND PISTON PIN (#3 AND #4) B2M1323F (1) Piston (5) Service hole plug Tightening torque: N·m (kg-m, ft-lb) (2) Piston pin (6) Service hole cover 6.4 (0.65, 4.7) (3) Circlip (7) O-ring 69±7 (7.0±0.7, 50.6±5.1) (4) Gasket Turn cylinder block so that #3 and #4 cylinders face...
  • Page 103 SERVICE PROCEDURE [W7E4] 7. Cylinder Block 6) Apply fluid packing to matching surfaces and 9) Installation of oil pump install oil separator cover. (1) Discard front oil seal after removal. Replace with a new one using ST. Fluid packing: ST 499587100 OIL SEAL INSTALLER THREE BOND 1215 or equivalent S2M0235 G2M0194...
  • Page 104 SERVICE PROCEDURE [W7E4] 7. Cylinder Block 10) Install water pump and gasket. (2) Tighten all bolts to 29 N·m (3.0 kg-m, 22 ft-lb) in alphabetical sequence. Tightening torque: Then tighten all bolts to 69 N·m (7.0 kg-m, 51 First; 12±2 N·m (1.2±0.2 kg-m, 8.7±1.4 ft-lb) in alphabetical sequence.

  • Page 105: Engine Trouble In General

    DIAGNOSTICS [K100] 1. Engine Trouble in General 1. Engine Trouble in General NOTE: “RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C —...
  • Page 106 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 4) Engine stalls after initial Fuel injection system <Ref. to 2-7 [T100].> combustion. ¼ Intake system ¼ Loosened or cracked intake duct ¼ Loosened or cracked PCV hose ¼...
  • Page 107 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Fuel injection system <Ref. to 2-7 [T100].> 3. Low output, hesitation and poor acceleration ¼ Intake system ¼ Loosened or cracked intake duct ¼ Loosened or cracked PCV hose ¼...
  • Page 108 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to Fuel injection system <Ref. to 2-7 [T100].> idle. ¼ Intake system ¼ Loosened or cracked vacuum hose ¼ Others ¼ Stuck or damaged throttle valve ¼...
  • Page 109 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Fuel injection system <Ref. to 2-7 [T100].> 10. Excessive fuel consump- tion ¼ Intake system ¼ Dirty air cleaner element ¼ Belt ¼ Defective timing ¼...

  • Page 110: Engine Noise

    DIAGNOSTICS [K200] 2. Engine Noise 2. Engine Noise Type of sound Condition Possible cause ¼ Valve mechanism is defective. ¼ Incorrect valve clearance Sound increases as engine ¼ Worn valve rocker Regular clicking sound speed increases. ¼ Worn camshaft ¼ Broken valve spring ¼...
  • Page 111 ENGINE LUBRICATION SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 COMPONENT PARTS ..................3 Lubrication System..................3 SERVICE PROCEDURE ...................4 Oil Pump......................4 Oil Pan and Oil Strainer ................8 Oil Pressure Switch...................12 DIAGNOSTICS....................15 Engine Lubrication System Trouble in General ........15...

  • Page 112: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 9 mm (3.07 × 0.35 in) 0.04 — 0.14 mm (0.0016 — 0.0055 STANDARD Tip clearance between inner and outer rotor LIMIT...

  • Page 113: Component Parts

    COMPONENT PARTS [C100] 1. Lubrication System 1. Lubrication System B2M2235A (1) Plug (13) Oil pressure switch (25) Drain plug (2) Washer (14) Oil filler duct (26) Metal gasket (3) Relief valve spring (15) O-ring (4) Relief valve (16) Oil filler cap Tightening torque: N·m (kg-m, ft-lb) (5) Oil seal (17) O-ring...

  • Page 114: Oil Pump

    SERVICE PROCEDURE [W1A0] 1. Oil Pump 1. Oil Pump 7) Remove crankshaft position sensor. A: REMOVAL 1) Disconnect battery ground cable. B2M1252A 8) Remove camshaft position sensor. G6M0095 2) Lift-up the vehicle. 3) Remove under cover. 4) Drain coolant. <Ref. to 2-5 [W1A0].> G2M0417 9) Remove V-belts.
  • Page 115 SERVICE PROCEDURE [W1A0] 1. Oil Pump 11) Remove crankshaft pulley by using ST. 15) Remove bolts which install oil pump onto cyl- 2200 cc model: inder block. ST 499977300 CRANKSHAFT PULLEY WRENCH 2500 cc model: ST 499977100 CRANKSHAFT PULLEY WRENCH S2M0117 16) Remove oil pump by using flat bladed screw- driver.
  • Page 116 SERVICE PROCEDURE [W1B0] 1. Oil Pump B: DISASSEMBLY C: INSPECTION Remove screws which secure oil pump cover and 1. TIP CLEARANCE disassemble oil pump. Measure the tip clearance of rotors. If the clear- Inscribe alignment marks on inner and outer rotors ance exceeds the limit, replace rotors as a so that they can be replaced in their original posi- matched set.
  • Page 117 SERVICE PROCEDURE [W1D0] 1. Oil Pump 3. SIDE CLEARANCE D: ASSEMBLY Measure clearance between oil pump inner rotor 1) Install front oil seal by using ST. and pump cover. If the clearance exceeds the limit, ST 499587100 OIL SEAL INSTALLER replace rotor or pump body.

  • Page 118: Oil Pan And Oil Strainer

    SERVICE PROCEDURE [W1E0] 2. Oil Pan and Oil Strainer 2. Oil Pan and Oil Strainer E: INSTALLATION Installation is in the reverse order of removal. A: REMOVAL Observe the following: 1) Disconnect battery ground cable. 1) Apply fluid packing to matching surfaces of oil pump.
  • Page 119 SERVICE PROCEDURE [W2A0] 2. Oil Pan and Oil Strainer 5) Remove pitching stopper. 9) Remove under cover. 10) Drain engine oil. Set container under the vehicle, and remove drain plug from oil pan. H3M1839 6) Remove radiator upper bracket. G2M0066 11) Disconnect connector from rear oxygen sen- sor.
  • Page 120 SERVICE PROCEDURE [W2B0] 2. Oil Pan and Oil Strainer 14) Remove bolts which install oil pan on cylinder 1) Install baffle plate. block while raising up engine. Tightening torque: 6.4 N·m (0.65 kg-m, 4.7 ft-lb) B2M2687 15) Insert oil pan cutter blade between cylinder S2M0309 block-to-oil pan clearance.
  • Page 121 SERVICE PROCEDURE [W2C0] 2. Oil Pan and Oil Strainer 4) Tighten bolts which install oil pan onto engine 8) Connect connector to rear oxygen sensor. block. Tightening torque: 5 N·m (0.5 kg-m, 3.6 ft-lb) B2M3440 9) Install under cover. 10) Lower the vehicle. B2M2687 CAUTION: 5) Lower engine onto front crossmember.

  • Page 122: Oil Pressure Switch

    SERVICE PROCEDURE [W3A0] 3. Oil Pressure Switch 3. Oil Pressure Switch 13) Install pitching stopper. Tightening torque: A: REMOVAL T1: 49±5 N·m (5.0±0.5 kg-m, 36.2±3.6 ft-lb) T2: 57±10 N·m (5.8±1.0 kg-m, 42±7 ft-lb) 1) Remove alternator from bracket. (1) Disconnect connector and terminal from generator.
  • Page 123 SERVICE PROCEDURE [W3B0] 3. Oil Pressure Switch 2) Disconnect terminal from oil pressure switch. 2) Install oil pressure switch onto engine block. Tightening torque: 25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) G2M0091 3) Remove oil pressure switch. S2M0119 3) Connect terminal of oil pressure switch. S2M0119 B: INSTALLATION G2M0091...
  • Page 124 SERVICE PROCEDURE [W3B0] 3. Oil Pressure Switch 7) Connect connector and terminal to generator. S2M0941...

  • Page 125: Engine Lubrication System Trouble In General

    DIAGNOSTICS [K100] 1. Engine Lubrication System Trouble in General 1. Engine Lubrication System Trouble in General NOTE: Before troubleshooting, make sure that the engine oil level is correct and no oil leakage exists. Trouble Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace. 1) Oil pressure switch failure Broken spring or seized contacts...
  • Page 126 DIAGNOSTICS MEMO:...
  • Page 127 ENGINE COOLING SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 Service Data....................2 COMPONENT PARTS ..................3 Water Pump ....................3 Radiator and Radiator Fan................4 Water Pipe....................5 SERVICE PROCEDURE ...................6 Water Pump ....................6 Thermostat....................11 Radiator .....................12 Radiator Cap .....................15 Radiator Main Fan and Fan Motor............15 Radiator Sub Fan and Fan Motor .............17 Water Pipe....................19 Reservoir Tank ..................21...

  • Page 128: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Electric fan + Forced engine coolant circula- Cooling system tion system Total engine coolant capacity (US qt, Imp qt) 6.2 (6.6, 5.5) Type Centrifugal impeller type Discharge (5.3 US gal, 4.4 Imp gal)/min. Pump speed—total engine Discharge performance I 760 rpm —...

  • Page 129: Component Parts

    COMPONENT PARTS [C100] 1. Water Pump 1. Water Pump H2M2354A (1) Water pump ASSY (6) Thermostat cover Tightening torque: N·m (kg-m, ft-lb) (2) Gasket (3) Heater hose First: (4) Thermostat 12±2 (1.2±0.2, 8.7±1.4) (5) Gasket Second: 12±2 (1.2±0.2, 8.7±1.4) 6.4±0.5 (0.65±0.05, 4.7±0.4)

  • Page 130: Radiator And Radiator Fan

    COMPONENT PARTS [C200] 2. Radiator and Radiator Fan 2. Radiator and Radiator Fan S2M1739A (1) Radiator lower cushion (13) Radiator main fan shroud (21) ATF inlet hose B (AT vehicles (2) Radiator (14) Radiator main fan only) (3) Radiator upper cushion (15) Radiator main fan motor (22) Radiator outlet hose (4) Radiator upper bracket...

  • Page 131: Water Pipe

    COMPONENT PARTS [C300] 3. Water Pipe 3. Water Pipe H2M2355A (1) Engine coolant temperature sen- (3) Water pipe Tightening torque: N·m (kg-m, ft-lb) (4) O-ring 6.4±0.5 (0.65±0.05, 4.7±0.4) (2) Engine coolant temperature (5) By-pass hose gauge...
  • Page 132 SERVICE PROCEDURE [W1A0] 1. Water Pump 1. Water Pump 6) Disconnect connectors from radiator main fan (A) and sub fan (B) motors. A: REMOVAL WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Disconnect ground cable from battery. S2M0893A 7) Detach ATF cooler hose attached to a clip under the radiator main fan shroud.

  • Page 133: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Water Pump 11) Remove radiator main fan and sub fan motor 16) Remove camshaft position sensor. assembly. <Ref. to 2-7 [W10A0].> <Ref. to 2-5 [W5A0].> and <Ref. to 2-5 [W6A0].> B2M2038 S2M0929 17) Remove left-hand camshaft sprocket by using 12) Remove V-belts.
  • Page 134 SERVICE PROCEDURE [W1B0] 1. Water Pump 20) Remove tensioner bracket. 5) After water pump installation, check pulley shaft 21) Disconnect heater hose from water pump. for engine coolant leaks. If leaks are noted, replace 22) Remove water pump. water pump assembly. C: INSTALLATION 1) Install water pump onto left-hand cylinder head.
  • Page 135 SERVICE PROCEDURE [W1C0] 1. Water Pump 3) Install tensioner bracket. 6) Install belt idler No. 2. Tightening torque: Tightening torque: 25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) 39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb) H2M2380 S2M0024 4) Install left-hand camshaft sprockets by using 7) Install automatic belt tension adjuster which tension rod is holded with pin.
  • Page 136 SERVICE PROCEDURE [W1C0] 1. Water Pump 10) Install radiator main fan and sub fan motor 15) Attach ATF cooler hose to a clip under the assemblies. <Ref. to 2-5 [W5A0].> and <Ref. to 2-5 radiator main fan shroud. [W6A0].> H2M3592 S2M0929 16) Connect connectors to radiator main fan (A) and sub fan (B) motors.

  • Page 137: Thermostat

    SERVICE PROCEDURE [W2B0] 2. Thermostat 2. Thermostat 5) Install the thermostat in the water pump, and install the thermostat cover together with a gasket. A: REMOVAL AND INSTALLATION CAUTION: ¼ When reinstalling the thermostat, use a new WARNING: gasket. The radiator is pressurized. Wait until engine ¼...

  • Page 138: Radiator

    SERVICE PROCEDURE [W3A0] 3. Radiator 3. Radiator 6) Disconnect ATF cooler hoses from radiator. (AT vehicles only) A: REMOVAL WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Disconnect battery ground cable. S2M0895 7) Disconnect radiator outlet hose (A) and water by-pass hose (B) (AT vehicles) from thermostat cover.
  • Page 139 SERVICE PROCEDURE [W3B0] 3. Radiator 11) Remove V-belt covers. B: INSTALLATION 1) Attach radiator mounting cushions to pins on the lower side of radiator. S2M0896 12) Disconnect radiator inlet hose from radiator. S2M0944 2) Install radiator while fitting radiator pins to cush- ions.
  • Page 140 SERVICE PROCEDURE [W3B0] 3. Radiator 4) Connect radiator inlet hose. 9) Connect radiator outlet hose (A) and water by- pass hose (B). (AT vehicles) S2M0897 H2M2515A 5) Install reservoir tank. 10) Install under cover. Tightening torque: 11) Lower the vehicle. 4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb) 12) Install V-belt covers.

  • Page 141: Radiator Cap

    SERVICE PROCEDURE [W5A0] 5. Radiator Main Fan and Fan Motor 4. Radiator Cap 5. Radiator Main Fan and Fan Motor A: INSPECTION A: REMOVAL AND INSTALLATION 1) Attach radiator cap to tester. 1) Disconnect battery ground cable. G2M0223 2) Increase pressure until tester gauge pointer G6M0095 stops.
  • Page 142 SERVICE PROCEDURE [W5B0] 5. Radiator Main Fan and Fan Motor 6) Lower the vehicle. 11) Installation is in the reverse order of removal. 7) Remove V-belt covers. NOTE: When the main fan motor assembly cannot be installed as is, loosen the sub fan motor assembly securing bolts to install it.

  • Page 143: Radiator Sub Fan And Fan Motor

    SERVICE PROCEDURE [W6A0] 6. Radiator Sub Fan and Fan Motor 6. Radiator Sub Fan and Fan 2) Remove bolt which install fan itself onto fan motor and shroud assembly. Motor A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0936 3) Remove bolts which install fan motor onto shroud.
  • Page 144 SERVICE PROCEDURE [W6B0] 6. Radiator Sub Fan and Fan Motor 7) Remove bolts which hold sub fan shroud to 2) Remove nut which install fan itself onto fan radiator. motor and shroud assembly. 8) Remove radiator sub fan motor assembly. S2M0939 S2M0935 3) Remove bolts which install fan motor onto...

  • Page 145: Water Pipe

    SERVICE PROCEDURE [W7A0] 7. Water Pipe 7. Water Pipe 7) Lower the vehicle. 8) Remove intake manifold. A: REMOVAL <Ref. to 2-7 [W4A0].> WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Release fuel pressure. <Ref.
  • Page 146 SERVICE PROCEDURE [W7B0] 7. Water Pipe B: INSTALLATION 4) Install intake manifold. <Ref. to 2-7 [W3D0].> 1) Install water pipe on cylinder block. Tightening torque: 6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb) CAUTION: Use a new O-ring. B2M0160 5) Connect connector to fuel pump relay. B2M0141 2) Connect radiator inlet hose.

  • Page 147: Reservoir Tank

    SERVICE PROCEDURE [W8A0] 8. Reservoir Tank 8. Reservoir Tank 4) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb) 1) Disconnect over flow hose from radiator filler neck position. S2M0934 S2M0930 2) Remove bolts which install reservoir tank onto...

  • Page 148: Engine Coolant

    Remove radiator cap so that engine coolant will TEMPERATURE drain faster. The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. B2M0015A...
  • Page 149 B2M3129A of SUBARU genuine coolant (concentration 50). The amount of coolant that should be replaced can be determined using the diagram.
  • Page 150 SERVICE PROCEDURE [W9C0] 9. Engine Coolant C: CHECKING OF COOLING CAUTION: ¼ Engine should be off. SYSTEM ¼ Wipe engine coolant from check points in 1) Remove radiator cap, top off radiator, and advance. attach tester to radiator in place of cap. ¼...
  • Page 151 DIAGNOSTICS [K100] 1. Engine Cooling System Trouble in General 1. Engine Cooling System Trouble in General Trouble Possible cause Corrective action Replenish engine coolant, inspect for leakage, Insufficient engine coolant and repair. Loose timing belt Repair or replace timing belt tensioner. Oil on drive belt Replace.
  • Page 152 DIAGNOSTICS MEMO:...
  • Page 153 ENGINE COOLING SYSTEM Page DIAGNOSTICS ....................2 Wiring Diagram....................2 Radiator Main Fan..................3 Radiator Sub Fan (With A/C model only) ...........7...
  • Page 154 DIAGNOSTICS [T100] 1. Wiring Diagram 1. Wiring Diagram H2M3618...
  • Page 155 DIAGNOSTICS [T2A3] 2. Radiator Main Fan 2. Radiator Main Fan 2A2 : CHECK GROUND CIRCUIT OF MAIN FAN MOTOR. A: OPERATION DETECTING CONDITION: 1) Turn ignition switch to OFF. 2) Measure resistance between main fan motor Condition: ¼ Engine coolant temperature is above 95°C connector and chassis ground.
  • Page 156 DIAGNOSTICS [T2A4] 2. Radiator Main Fan 2A4 : CHECK MAIN FAN MOTOR. 2A6 : CHECK POWER SUPPLY TO MAIN FAN RELAY. Connect battery positive (+) terminal to terminal 1) Turn ignition switch to ON. No. 2, and negative (−) terminal to terminal No. 1 2) Measure voltage between main fan relay termi- of main fan motor connector.
  • Page 157 DIAGNOSTICS [T2A11] 2. Radiator Main Fan 2A8 : CHECK POWER SUPPLY TO A/C 2A10 : CHECK MAIN FAN RELAY. RELAY HOLDER 20 A FUSE TERMI- NAL. 1) Turn ignition switch to OFF. 2) Measure resistance of main fan relay. Measure voltage of harness between A/C relay Terminal holder 20 A fuse terminal and chassis ground.
  • Page 158 : Repair poor contact connector. (F17) No. 2 — (F66) No. 25: : Contact with your Subaru distributor. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. S2M0445A : Is the resistance less than 1 Ω? : Go to step 2A13.
  • Page 159 DIAGNOSTICS [T3A3] 3. Radiator Sub Fan (With A/C model only) 3. Radiator Sub Fan (With A/C 3A2 : CHECK GROUND CIRCUIT OF SUB FAN MOTOR. model only) A: OPERATION 1) Turn ignition switch to OFF. 2) Measure resistance between sub fan motor DETECTING CONDITION: connector and chassis ground.
  • Page 160 DIAGNOSTICS [T3A4] 3. Radiator Sub Fan (With A/C model only) 3A4 : CHECK SUB FAN MOTOR. 3A6 : CHECK POWER SUPPLY TO SUB FAN RELAY. Connect battery positive (+) terminal to terminal 1) Turn ignition switch to ON. No. 2, and negative (−) terminal to terminal No. 1 2) Measure voltage between sub fan relay termi- of sub fan motor connector.
  • Page 161 DIAGNOSTICS [T3A11] 3. Radiator Sub Fan (With A/C model only) 3A8 : CHECK POWER SUPPLY TO A/C 3A10 : CHECK SUB FAN RELAY. RELAY HOLDER 20 A FUSE TERMI- NAL. 1) Turn ignition switch to OFF. 2) Measure resistance of sub fan relay. Measure voltage of harness between A/C relay Terminal holder 20 A fuse terminal and chassis ground.
  • Page 162 (F16) No. 2 — (F28) No. 17: : Repair poor contact connector. : Contact with your Subaru distributor. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. B2M3339A : Is the resistance less than 1 Ω? : Go to step 3A13.
  • Page 163 FUEL INJECTION SYSTEM Page COMPONENT PARTS ..................2 Intake Manifold ....................2 Air Intake System ..................6 Air Cleaner ....................8 Crankshaft Position, Camshaft Position and Knock Sensors.....9 SERVICE PROCEDURE .................10 Air Cleaner Case and Air Intake Duct............10 Throttle Body .....................11 Intake Manifold ..................13 Engine Coolant Temperature Sensor............33 Crankshaft Position Sensor...............34 Camshaft Position Sensor.................35...
  • Page 164 COMPONENT PARTS [C1A0] 1. Intake Manifold 1. Intake Manifold A: 2200 cc MODELS H2M3531A...
  • Page 165 COMPONENT PARTS [C1A0] 1. Intake Manifold (1) Intake manifold gasket RH (11) Nipple Tightening torque: N·m (kg-m, ft-lb) (2) Guide pin (12) Intake manifold 16±1.5 (1.6±0.15, 11.6±1.1) (3) Insulator A (13) Intake manifold gasket LH 23±3 (2.3±0.3, 16.6±2.2) (4) Insulator B (14) Fuel pipe protector LH 25±2 (2.5±0.2, 18.1±1.4) (5) Fuel injector...

  • Page 166: Component Parts

    COMPONENT PARTS [C1B0] 1. Intake Manifold B: 2500 cc MODELS H2M3532A...
  • Page 167 COMPONENT PARTS [C1B0] 1. Intake Manifold (1) Intake manifold gasket RH (15) O-ring Tightening torque: N·m (kg-m, ft-lb) (2) Fuel injector pipe (16) Bracket LH 16±1.5 (1.6±0.15, 11.6±1.1) (3) Fuel injector (17) Bracket RH 25±2 (2.5±0.2, 18.1±1.4) (4) O-ring (18) Fuel pipe ASSY 2.0±0.4 (0.2±0.04, 1.4±0.3) (5) O-ring (19) Fuel hose...

  • Page 168: Air Intake System

    COMPONENT PARTS [C2A0] 2. Air Intake System 2. Air Intake System A: 2200 cc MODELS B2M2278A (1) Gasket (5) Intake manifold pressure sensor Tightening torque: N·m (kg-m, ft-lb) (2) Throttle position sensor (6) Throttle body 2.2±0.2 (0.22±0.02, 1.6±0.1) (3) Gasket 6.0±0.8 (0.61±0.08, 4.4±0.6) (4) Idle air control solenoid valve 22±2 (2.2±0.2, 15.9±1.4)
  • Page 169 COMPONENT PARTS [C2B0] 2. Air Intake System B: 2500 cc MODELS B2M3455A (1) Gasket Tightening torque: N·m (kg-m, ft-lb) (2) Throttle position sensor 2.0±0.4 (0.2±0.04, 1.4±0.3) (3) Idle air control solenoid valve 6.0±0.8 (0.61±0.08, 4.4±0.6) (4) Throttle body 19±5 (1.9±0.5, 13.7±3.6)

  • Page 170: Air Cleaner

    COMPONENT PARTS [C300] 3. Air Cleaner 3. Air Cleaner H2M2940A (1) Spacer (11) Air cleaner case B (19) Bush (2) Bush (12) Air cleaner case stay LH (MT (18) Spacer (3) Air chamber vehicles) (4) Cushion rubber (13) Air cleaner case stay LH (AT Tightening torque: N·m (kg-m, ft-lb) (5) Air intake duct A vehicles)

  • Page 171: Crankshaft Position, Camshaft Position And Knock Sensors

    COMPONENT PARTS [C400] 4. Crankshaft Position, Camshaft Position and Knock Sensors 4. Crankshaft Position, Camshaft Position and Knock Sensors B2M2282B (1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N·m (kg-m, ft-lb) (2) Knock sensor (4) Camshaft position sensor sup- 6.4±0.5 (0.65±0.05, 4.7±0.4) port 23.5±2.9 (2.4±0.3, 17.4±2.2)

  • Page 172: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Air Cleaner Case and Air Intake Duct 1. Air Cleaner Case and Air 4) Remove air intake (A) and (B) as a unit. Intake Duct A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2012 5) Disconnect connector from intake air tempera- ture sensor.

  • Page 173: Throttle Body

    SERVICE PROCEDURE [W2A1] 2. Throttle Body 2. Throttle Body 5) Disconnect connectors from throttle positioin sensor (A), idle air control solenoid valve (B) and A: REMOVAL AND INSTALLATION intake manifold pressure sensor (C). 6) Disconnect air by-pass hose (D) from idle air 1.
  • Page 174 SERVICE PROCEDURE [W2A2] 2. Throttle Body 2. 2500 cc MODELS 5) Disconnect connectors from idle air control solenoid valve, throttle position sensor. 1) Disconnect battery ground cable. 6) Disconnect air by-pass hose from air assist injector solenoid valve. G6M0095 2) Remove air cleaner case. B2M3457A Throttle position sensor Idle air control solenoid valve...

  • Page 175: Intake Manifold

    SERVICE PROCEDURE [W3A0] 3. Intake Manifold 3. Intake Manifold Tightening torque: Air cleaner case; A: REMOVAL 4.9±0.5 N·m (0.5±0.05 kg-m, 3.6±0.4 ft-lb) 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> 2) Open fuel flap lid, and remove fuel filler cap. H2M2947 H2M2535 3) Disconnect battery ground cable.
  • Page 176 SERVICE PROCEDURE [W3A0] 3. Intake Manifold 5) Disconnect accelerator cable (A). (4) Remove bolts which secure power steering 6) Disconnect cruise control cable (B). (With pipe brackets to intake manifold. cruise control model) NOTE: Do not disconnect power steering hose. B2M3365A B2M2309 7) Remove power steering pump and tank from...
  • Page 177 SERVICE PROCEDURE [W3A0] 3. Intake Manifold 9) Disconnect PCV hose from intake manifold. 12) Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness connectors from bulkhead harness connectors. H2M2953 10) Disconnect engine coolant hose from throttle H2M2955 body.
  • Page 178 SERVICE PROCEDURE [W3B1] 3. Intake Manifold 16) Disconnect connector from oil pressure 19) Remove bolts which hold intake manifold onto switch. cylinder heads. B2M1253A B2M2318 17) Disconnect connector from camshaft position 20) Remove intake manifold. sensor. B2M0160 B2M2317C B: DISASSEMBLY 18) Disconnect fuel hoses from fuel pipes.
  • Page 179 SERVICE PROCEDURE [W3B1] 3. Intake Manifold 3) Remove ignition coil and ignitor assembly. 8) Disconnect pressure regulator vacuum hose from intake manifold. B2M3459 B2M3460 4) Disconnect connectors from throttle position sensor (A), idle air control solenoid valve (B) and 9) Remove fuel pipe protector LH. intake manifold pressure sensor (C).
  • Page 180 SERVICE PROCEDURE [W3B1] 3. Intake Manifold 12) Remove harness bands (*) which hold engine 17) Remove two bolts which hold fuel pipes on the harness onto intake manifold. left side of intake manifold. B2M3463A B2M3466 13) Remove engine harness from intake manifold. 18) Remove bolt which installs injector pipe on 14) Remove purge control solenoid valve.
  • Page 181 SERVICE PROCEDURE [W3B2] 3. Intake Manifold 21) Loosen clamp which holds front left side fuel 25) Remove fuel pipe assembly and pressure hose to injector pipe and remove the pipe from regulator, from intake manifold. clamp. 2. 2500 cc MODELS 1) Disconnect engine ground terminal from intake manifold.
  • Page 182 SERVICE PROCEDURE [W3B2] 3. Intake Manifold 4) Disconnect connector from intake air tempera- 8) Remove throttle body. ture and pressure sensor. H2M2951 B2M3474 9) Disconnect connector from air assist injector 5) Remove intake air temperature and pressure solenoid valve. sensor from intake manifold. 10) Disconnect air by-pass hoses from air assist solenoid valve.
  • Page 183 SERVICE PROCEDURE [W3B2] 3. Intake Manifold 13) Remove fuel pipe protector LH. 17) Remove harness bands (*) which hold engine harness onto intake manifold. NOTE: There is no harness band under the fuel protector. B2M3476 14) Disconnect connectors from fuel injectors. B2M3486A 18) Remove engine harness from intake manifold.
  • Page 184 SERVICE PROCEDURE [W3B2] 3. Intake Manifold 21) Remove bolt which installs injector pipe on (2) Remove fuel injector while lifting up fuel intake manifold. injector pipe. H2M2970 H2M2966 25) Disconnect air by-pass hoses from intake 22) Remove two bolts which hold fuel pipes on the manifold.
  • Page 185 SERVICE PROCEDURE [W3C1] 3. Intake Manifold 28) Remove fuel injector pipe. 3) Connect right side fuel hose to injector pipe, and tighten clamp screw. H2M2975 B2M3376 29) Remove bolt which installs fuel pipes on intake manifold. 4) Install fuel injector pipe. B2M3491 H2M2975 30) Remove fuel pipe assembly and pressure...
  • Page 186 SERVICE PROCEDURE [W3C1] 3. Intake Manifold 7) Install fuel injectors. 10) Tighten two bolts which install fuel pipes on the left side of intake manifold. CAUTION: Always use new o-rings and insulators. Tightening torque: 4.9±0.5 N·m (0.5±0.05 kg-m, 3.6±0.4 ft-lb) B2M3516B B2M3466 O-ring...
  • Page 187 SERVICE PROCEDURE [W3C1] 3. Intake Manifold 13) Connect hoses to purge control solenoid 18) Connect pressure regulator vacuum hose to valve. intake manifold. CAUTION: Carefully connect the evaporation hoses. B2M3460 19) Install throttle body to intake manifold. B2M1893A CAUTION: 14) Install engine harness onto intake manifold. Replace gasket with a new one.
  • Page 188 SERVICE PROCEDURE [W3C2] 3. Intake Manifold 23) Install ignition coil and ignitor assembly. 3) Connect right side fuel hose to injector pipe, and tighten clamp screw. B2M3459 B2M3376 24) Connect connector to ignition coil and ignitor assembly. 4) Install fuel injector pipe. 25) Install engine ground terminal to intake mani- fold.
  • Page 189 SERVICE PROCEDURE [W3C2] 3. Intake Manifold 7) Install fuel injectors. 9) Tighten bolt which install injector pipe on intake manifold. CAUTION: Always use new o-rings. Tightening torque: 4.9±0.5 N·m (0.5±0.05 kg-m, 3.6±0.4 ft-lb) B2M3492E H2M2965 O-ring Fuel injector 10) Tighten two bolts which install fuel pipes on the left side of intake manifold.
  • Page 190 SERVICE PROCEDURE [W3C2] 3. Intake Manifold 12) Install purge control solenoid valve. 17) Install fuel pipe protector LH. Tightening torque: 18.6±1.5 N·m (1.9±0.15 kg-m, 13.7±1.1 ft-lb) B2M3487 13) Connect hoses to purge control solenoid valve. B2M3476 CAUTION: Carefully connect the evaporation hoses. 18) Connect pressure regulator vacuum hose to intake manifold.
  • Page 191 SERVICE PROCEDURE [W3C2] 3. Intake Manifold 20) Connect air by-pass hoses to air assist sole- 24) Connect air by-pass hose to throttle body. noid valve. B2M3480 B2M3477 25) Install intake air temperature and pressure 21) Connect connector to air assist solenoid sensor.
  • Page 192 SERVICE PROCEDURE [W3D0] 3. Intake Manifold 26) Connect connector to intake air temperature 2) Connect fuel hoses. and pressure sensor. 27) Install ignition coil and ignitor assembly. S2M0500C 3) Connect connector to camshaft position sensor. B2M3473 28) Connect connector to ignition coil and ignitor assembly.
  • Page 193 SERVICE PROCEDURE [W3D0] 3. Intake Manifold 6) Connect knock sensor connector. 10) Connect engine coolant hose to throttle body. S2M1659 B2M2299B 7) Connect connectors to engine coolant tempera- ture sensor. B2M3458B 11) Connect PCV hose to intake manifold. S2M1658 8) Install air cleaner case stay RH and engine har- ness bracket, and connect engine harness con- nectors to bulkhead connectors.
  • Page 194 SERVICE PROCEDURE [W3D0] 3. Intake Manifold 13) Install power steering pump on bracket. (5) Install V-belt covers. (1) Tighten bolts which install power steering pump on bracket. Tightening torque: 20.1±2.5 N·m (2.05±0.25 kg-m, 14.8±1.8 ft-lb) S2M0896 (6) Install resonator chamber. Tightening torque: 33±10 N·m (3.4±1.0 kg-m, 25±7 ft-lb) S2M0086...

  • Page 195: Engine Coolant Temperature Sensor

    SERVICE PROCEDURE [W4A0] 4. Engine Coolant Temperature Sensor 4. Engine Coolant Temperature 17) Connect connector to fuel pump relay. Sensor A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0093A 18) Connect battery ground cable. G6M0095 2) Remove air intake duct and air cleaner assem- bly.

  • Page 196: Crankshaft Position Sensor

    SERVICE PROCEDURE [W5A0] 5. Crankshaft Position Sensor 5. Crankshaft Position Sensor 4) Remove engine coolant temperature sensor. 5) Installation is in the reverse order of removal. A: REMOVAL AND INSTALLATION Tightening torque: 25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) 1) Disconnect battery ground cable. H2M3503 G6M0095 2) Remove bolt which install crankshaft position...

  • Page 197: Camshaft Position Sensor

    SERVICE PROCEDURE [W6A0] 6. Camshaft Position Sensor 6. Camshaft Position Sensor 4) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION T: 6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb) 1) Disconnect battery ground cable. B2M1252B G6M0095 2) Disconnect connector from camshaft position sensor.

  • Page 198: Knock Sensor

    SERVICE PROCEDURE [W7A0] 7. Knock Sensor 7. Knock Sensor 4) Remove bolt which installs camshaft position sensor support to camshaft cap LH. A: REMOVAL 1) Disconnect battery ground cable from battery ground terminal. B2M2321 5) Remove camshaft position sensor and cam- shaft position sensor support as a unit.
  • Page 199 SERVICE PROCEDURE [W7B0] 7. Knock Sensor B: INSTALLATION 4) Connect battery ground cable. 1) Install knock sensor to cylinder block. Tightening torque: 23.5±2.9 N·m (2.4±0.3 kg-m, 17.4±2.2 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 45° angle relative to the engine rear.

  • Page 200: Front Oxygen (A/F) Sensor

    Tightening torque: 21±3 N·m (2.1±0.3 kg-m, 15.2±2.2 ft-lb) B2M3439 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove front oxygen (A/F) sensor.

  • Page 201: Rear Oxygen Sensor

    B2M1723 2) Disconnect connector from rear oxygen sensor. B2M3440 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor.
  • Page 202 SERVICE PROCEDURE [W9B0] 9. Rear Oxygen Sensor B: INSTALLATION 5) Connect battery ground cable. 1) Before installing rear oxygen sensor, apply anti- seize compound only to threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor.

  • Page 203: Throttle Position Sensor

    SERVICE PROCEDURE [W10A2] 10. Throttle Position Sensor 10. Throttle Position Sensor 4) Installation is in the reverse order of removal. CAUTION: A: REMOVAL AND INSTALLATION When installing throttle position sensor, adjust the position to match with the specified data. 1. 2200 cc MODELS Tightening torque: 1) Disconnect battery ground cable.
  • Page 204 B: ADJUSTMENT 1. 2200 cc MODELS 1) Turn ignition switch to OFF. B2M3660 2) Loosen throttle position sensor holding screws. 4) When using Subaru Select Monitor; NOTE: For detailed operation procedures, refer to the Subaru Select Monitor Operation Manual. B2M3660...
  • Page 205 SERVICE PROCEDURE [W10B2] 10. Throttle Position Sensor (1) Insert the cartridge to Subaru Select Moni- 2. 2500 cc MODELS tor. 1) Turn ignition switch to OFF. <Ref. to 1-6 [G1100].> 2) Loosen throttle position sensor holding screws. S2M0286A B2M3765 (2) Connect Subaru Select Monitor to the data 3) When using voltage meter;...

  • Page 206: Intake Manifold Pressure Sensor (2200 Cc Models)

    (4) Connect Subaru Select Monitor to the data link connector. 5) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. 6) Select {2. Each System Check} in Main Menu. 7) Select {Engine Control System} in Selection Menu.

  • Page 207: Intake Air Temperature Sensor (2200 Cc Models)

    SERVICE PROCEDURE [W12A0] 12. Intake Air Temperature Sensor (2200 cc models) 12. Intake Air Temperature 4) Remove intake manifold pressure sensor from throttle body. Sensor (2200 cc models) A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2373 5) Installation is in the reverse order of removal. CAUTION: Replace gaskets for intake air pressure sensor B2M1723...

  • Page 208: Intake Air Temperature And Pressure Sensor (2500 Cc Models)

    SERVICE PROCEDURE [W13A0] 13. Intake Air Temperature and Pressure Sensor (2500 cc models) 13. Intake Air Temperature and 4) Remove intake air temperature and pressure sensor. Pressure Sensor (2500 cc models) A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M3497 5) Installation is in the reverse order of removal.

  • Page 209: Atmospheric Pressure Sensor (2500 Cc Models)

    SERVICE PROCEDURE [W14A0] 14. Atmospheric Pressure Sensor (2500 cc models) 14. Atmospheric Pressure 4) Installation is in the reverse order of removal. Tightening torque: Sensor (2500 cc models) 6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb) A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M3499 G6M0095 2) Disconnect connector from atmospheric pres-...

  • Page 210: Idle Air Control Solenoid Valve

    SERVICE PROCEDURE [W15A1] 15. Idle Air Control Solenoid Valve 15. Idle Air Control Solenoid 4) Remove idle air control solenoid valve from throttle body. Valve A: REMOVAL AND INSTALLATION 1. 2200 cc MODELS 1) Disconnect battery ground cable. B2M2364 5) Installation is in the reverse order of removal. CAUTION: Replace gasket with a new one.

  • Page 211: Air Assist Injector Solenoid Valve (2500 Cc Models)

    SERVICE PROCEDURE [W16A0] 16. Air Assist Injector Solenoid Valve (2500 cc models) 16. Air Assist Injector Solenoid 2) Disconnect connector from idle air control sole- noid valve. Valve (2500 cc models) A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M3500 3) Remove idle air control solenoid valve from throttle body.

  • Page 212: Purge Control Solenoid Valve

    SERVICE PROCEDURE [W17A0] 17. Purge Control Solenoid Valve 17. Purge Control Solenoid 4) Installation is in the reverse order of removal. Tightening torque: Valve 15.7±1.5 N·m (1.6±0.15 kg-m, 11.6±1.1 A: REMOVAL AND INSTALLATION ft-lb) 1) Disconnect battery ground cable. B2M3503 G6M0095 2) Remove bolt which installs purge control sole- noid valve onto intake manifold.

  • Page 213: Fuel Injector

    SERVICE PROCEDURE [W18A1] 18. Fuel Injector 18. Fuel Injector 5) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 16±1.5 N·m (1.6±0.15 kg-m, 11.6±1.1 ft-lb) 1. RH SIDE 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> 2) Open fuel flap lid, and remove fuel filler cap.
  • Page 214 SERVICE PROCEDURE [W18A1] 18. Fuel Injector 5) Remove resonator chamber. (3) Remove bolts which secure power steering pipes brackets to intake manifold. B2M2306 B2M2309 6) Remove spark plug cords from spark plugs (#1 and #3 cylinders). (4) Remove bolts which install power steering pump to bracket.
  • Page 215 SERVICE PROCEDURE [W18A1] 18. Fuel Injector 9) Remove bolt which install injector pipe to intake 12) Installation is in the reverse order of removal. manifold. CAUTION: Replace O-rings and insulator with new ones. B2M3507 10) Remove bolt which installs injector pipe on B2M3516C intake manifold.
  • Page 216 SERVICE PROCEDURE [W18A2] 18. Fuel Injector Tightening torque: 5) Disconnect connector from front window 3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb) washer motor. 6) Disconnect connector from rear gate glass washer motor. H2M3529 B6M0562B 2. LH SIDE 7) Disconnect rear window glass washer hose 1) Release fuel pressure.
  • Page 217 SERVICE PROCEDURE [W18A2] 18. Fuel Injector 10) Remove fuel pipe protector LH. 14) Remove bolt which holds fuel pipe on the left side intake manifold. H2M3528 H2M2995 11) Disconnect connector from fuel injector. 15) Remove fuel injector from intake manifold. (1) Remove fuel injector securing clip.
  • Page 218 SERVICE PROCEDURE [W18A2] 18. Fuel Injector 16) Installation is in the reverse order of removal. Tightening torque: 4.9±0.5 N·m (0.5±0.05 kg-m, 3.6±0.4 ft-lb) CAUTION: Replace O-rings and insulator with new ones. H2M2995 B2M3516C Tightening torque: 18.6±1.5 N·m (1.9±0.15 kg-m, 13.7±1.1 ft-lb) B2M3492F O-ring...

  • Page 219: Engine Control Module

    SERVICE PROCEDURE [W19A0] 19. Engine Control Module 19. Engine Control Module 5) Remove nuts which hold ECM to bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2368 6) Remove clip from bracket. G6M0095 2) Remove side sill front cover. <Ref.

  • Page 220: Main Relay

    SERVICE PROCEDURE [W20A0] 20. Main Relay 20. Main Relay 4) Remove main relay from mounting bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0137A 5) Installation is in the reverse order of removal. G6M0095 2) Remove bolt which holds bracket of main relay and fuel pump relay.

  • Page 221: Fuel Pump Relay

    SERVICE PROCEDURE [W21A0] 21. Fuel Pump Relay 21. Fuel Pump Relay 3) Remove fuel pump relay from mounting bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0138 4) Installation is in the reverse order of removal. G6M0095 2) Disconnect connector from fuel pump relay. S2M0093A...
  • Page 222 SERVICE PROCEDURE MEMO:...
  • Page 223 ON-BOARD DIAGNOSTICS II SYSTEM Page DIAGNOSTICS ...................2 General......................2 Electrical Components Location..............4 Diagnosis System..................31 Cautions ....................47 Specified Data ...................50 Basic Diagnostic Procedure ..............61 Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) ..64 Diagnostics for Engine Starting Failure ............77 General Diagnostic Table ................107 Diagnostics Chart with Trouble Code for 2200 cc Models .....110 Diagnostics Chart with Trouble Code for 2500 cc Models .....354...

  • Page 224: General

    2-4 brake duty solenoid (a total of eight solenoids). ¼ The OBD-II diagnostics procedure is different from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru Select Monitor or the OBD-II general scan tool to the vehicle. B: ENGINE 1.
  • Page 225 DIAGNOSTICS [T1C1] 1. General MEMO:...

  • Page 226: Electrical Components Location

    2. Electrical Components Location A: ENGINE (2200 cc MODELS) 1. MODULE H2M2431I (1) Engine control module (ECM) (3) Test mode connector (2) Data link connector (for Subaru (4) CHECK ENGINE malfunction Select Monitor and OBD-II gen- indicator lamp (MIL) eral scan tool) B3M0183E...
  • Page 227 DIAGNOSTICS [T2A1] 2. Electrical Components Location MEMO:...
  • Page 228 DIAGNOSTICS [T2A2] 2. Electrical Components Location 2. SENSOR H2M3527A (1) Engine coolant temperature sen- (3) Throttle position sensor (6) Camshaft position sensor (4) Intake manifold pressure sensor (7) Crankshaft position sensor (2) Intake air temperature sensor (5) Knock sensor...
  • Page 229 DIAGNOSTICS [T2A2] 2. Electrical Components Location S2M1248A B2M2250A B2M2251A B2M3702A B2M2241A B2M2242A B2M0213J...
  • Page 230 DIAGNOSTICS [T2A2] 2. Electrical Components Location H2M3230B (1) Front oxygen (A/F) sensor (3) Front catalytic converter (2) Rear oxygen sensor (4) Rear catalytic converter B2M2253A OBD0019I S2M1036B OBD0525G...
  • Page 231 DIAGNOSTICS [T2A2] 2. Electrical Components Location H2M2431B (1) Fuel level sensor (3) Fuel tank pressure sensor (2) Fuel temperature sensor (4) Fuel sub level sensor H2M3207A B2M1807A S2M0270A...
  • Page 232 DIAGNOSTICS [T2A3] 2. Electrical Components Location 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS H2M3527B (1) Purge control solenoid valve (2) Ignition coil & ignitor ASSY (3) Idle air control solenoid valve...
  • Page 233 DIAGNOSTICS [T2A3] 2. Electrical Components Location B2M2254A B2M2255A B2M2256B...
  • Page 234 DIAGNOSTICS [T2A3] 2. Electrical Components Location H2M2431C (1) Pressure control solenoid valve (3) Drain valve (2) Canister (4) Drain filter H2M2443A S2M0949B H2M2444A...
  • Page 235 DIAGNOSTICS [T2A3] 2. Electrical Components Location MEMO:...
  • Page 236 DIAGNOSTICS [T2A3] 2. Electrical Components Location H2M2431D (1) Inhibitor switch (AT vehicles (3) Main relay (6) Radiator sub fan relay only) (4) Fuel pump relay (7) Starter (2) Fuel pump (5) Radiator main fan relay B2M2246A S2M0277A S2M0278A S2M0279A...
  • Page 237 DIAGNOSTICS [T2A3] 2. Electrical Components Location B2M2247B...
  • Page 238 2. Electrical Components Location B: ENGINE (2500 cc MODELS) 1. MODULE H2M2431F (1) Engine control module (ECM) (3) Test mode connector (2) Data link connector (for Subaru (4) CHECK ENGINE malfunction Select Monitor and OBD-II gen- indicator lamp (MIL) eral scan tool) B3M0183E...
  • Page 239 DIAGNOSTICS [T2B1] 2. Electrical Components Location MEMO:...
  • Page 240 DIAGNOSTICS [T2B2] 2. Electrical Components Location 2. SENSOR H2M3526A (1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor (2) Intake air temperature and pres- (6) Camshaft position sensor sure sensor (4) Throttle position sensor (7) Crankshaft position sensor...
  • Page 241 DIAGNOSTICS [T2B2] 2. Electrical Components Location B2M3713A B2M3714A S2M1248B B2M2240A B2M2241A B2M2242A B2M0213J...
  • Page 242 DIAGNOSTICS [T2B2] 2. Electrical Components Location H2M3136B (1) Front oxygen (A/F) sensor (3) Front catalytic converter (2) Rear oxygen sensor (4) Rear catalytic converter S2M0264A OBD0019I S2M1036B OBD0525G...
  • Page 243 DIAGNOSTICS [T2B2] 2. Electrical Components Location H2M2431B (1) Fuel level sensor (3) Fuel tank pressure sensor (2) Fuel temperature sensor (4) Fuel sub level sensor H2M3207A B2M1807A S2M0270A...
  • Page 244 DIAGNOSTICS [T2B3] 2. Electrical Components Location 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS H2M3526B (1) Air assist injector solenoid valve (3) Purge control solenoid valve (2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY...
  • Page 245 DIAGNOSTICS [T2B3] 2. Electrical Components Location B2M3715A H2M3259A H2M3258B B2M3720A...
  • Page 246 DIAGNOSTICS [T2B3] 2. Electrical Components Location H2M2431C (1) Pressure control solenoid valve (3) Drain valve (2) Canister (4) Drain filter H2M2443A S2M0949B H2M2444A...
  • Page 247 DIAGNOSTICS [T2B3] 2. Electrical Components Location MEMO:...
  • Page 248 DIAGNOSTICS [T2B3] 2. Electrical Components Location H2M2431D (1) Inhibitor switch (AT vehicles (3) Main relay (6) Radiator sub fan relay only) (4) Fuel pump relay (7) Starter (2) Fuel pump (5) Radiator main fan relay B2M2246A S2M0277A S2M0278A S2M0279A...
  • Page 249 DIAGNOSTICS [T2B3] 2. Electrical Components Location B2M2247B...
  • Page 250 DIAGNOSTICS [T2C1] 2. Electrical Components Location C: TRANSMISSION 1. MODULE H2M2445E (1) Transmission Control Module (2) AT diagnostic indicator light (for (TCM) (for AT vehicles) AT vehicles) B3M1666D H2M2446E...
  • Page 251 DIAGNOSTICS [T2C2] 2. Electrical Components Location 2. SENSOR B2M2258A B2M2259A B2M2260A B2M2261A OBD0653B (1) Vehicle speed sensor 1 (for AT vehicles) (2) Vehicle speed sensor 2 (for MT vehicles) (3) Vehicle speed sensor 2 (for AT vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles) (6) Brake light switch...
  • Page 252 DIAGNOSTICS [T2C3] 2. Electrical Components Location 3. SOLENOID VALVE AND RELAY ¼ For AT vehicles B3M1670C B2M2246B B2M2263A B2M2264A (1) Dropping resistor (2) Inhibitor switch (3) Shift solenoid valve 1 (4) Shift solenoid valve 2 (5) Line pressure duty solenoid (6) Lock-up duty solenoid (7) Transfer duty solenoid (8) 2-4 brake duty solenoid...

  • Page 253: Diagnosis System

    DIAGNOSTICS [T3B1] 3. Diagnosis System 3. Diagnosis System 4) When ignition switch is turned to ON (engine off) or to “START” with the test mode connector A: CHECK ENGINE MALFUNCTION connected, the MIL blinks at a cycle of 3 Hz. INDICATOR LAMP (MIL) 1.
  • Page 254 MONITOR) 1) This connector is used both for OBD-II general scan tools and the Subaru Select Monitor. 2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal. CAUTION: Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select Monitor, because the circuit for the Subaru Select Monitor may be damaged.
  • Page 255 DIAGNOSTICS [T3B5] 3. Diagnosis System 3. CURRENT POWERTRAIN DIAGNOSTIC DATA (MODE $01) Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure Number of emission-related powertrain trouble codes and MIL status...
  • Page 256 Refer to OBD-II general scan tool manufacturer’s instruction manual to clear or reset emission-related diagnostic information (MODE $04). C: SUBARU SELECT MONITOR 4) Connect Subaru Select Monitor to data link connector. 1. HOW TO USE SUBARU SELECT (1) Data link connector located in the lower por- MONITOR tion of the instrument panel (on the driver’s...
  • Page 257 Display display screen, select the {Current Diagnostic Code(s)} or {History Diagnostic Code(s)} and press the [YES] key. NOTE: ¼ For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. ¼ For detailed concerning diagnostic trouble codes, refer to the DIAGNOSTIC TROUBLE CODE (DTC) LIST.
  • Page 258 DIAGNOSTICS [T3C4] 3. Diagnosis System 4. READ CURRENT DATA SHOWN ON DISPLAY 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 Control System} and press the [YES] key.
  • Page 259 Small light switch signal Small Light Switch ON or OFF Air assist injector solenoid valve signal AAI Solenoid Valve ON or OFF *1: 2500 cc models *2: 2200 cc models NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 260 Rear oxygen sensor output signal Oxygen Sensor #12 Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 On-board diagnostic system OBD System — NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 261 Vehicle Speed km/h or MPH NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA SHOWN ON DISPLAY FOR ENGINE. (OBD MODE) 1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key.
  • Page 262 Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF entered. When camshaft position sensor signal is Camshaft position sensor signal Camshaft Position Sig. ON or OFF entered. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 263 ON or OFF Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 264 5) When the ‘Done’ and ‘Turn Ignition Switch OFF’ ¼ Do not use a pantograph jack in place of a are shown on the display screen, turn the Subaru safety stand. Select Monitor and ignition switch to OFF.
  • Page 265 DIAGNOSTICS [T3E2] 3. Diagnosis System 2. SUBARU SELECT MONITOR 5) Connect Subaru Select Monitor to data link connector. After performing diagnostics and clearing the (1) Connect Subaru Select Monitor to data link memory, check for any remaining unresolved connector located in the lower portion of the trouble data.
  • Page 266 (on the driver’s side). F: COMPULSORY VALVE CAUTION: OPERATION CHECK MODE Do not connect the scan tools except for Subaru Select Monitor and OBD-II general scan 1. SUBARU SELECT MONITOR tool. 1) Prepare Subaru Select Monitor kit. S2M0258B S2M0285 3) Start the engine.
  • Page 267 12) Select the desired compulsory actuator on the Actuator ON/OFF Operation display screen and S2M0259B press the [YES] key. 5) Connect Subaru Select Monitor to data link 13) Pressing the [NO] key completes the compul- connector. sory operation check mode. The display will then...
  • Page 268 ¼ Because ASV solenoid valve, FICD solenoid valve and air injection system diagnosis solenoid valve are not installed, ASV Solenoid Valve, FICD Solenoid Valve and Pressure Switching Sol.2 will be displayed but non-functional. ¼ For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

  • Page 269: Cautions

    1. SUBARU SELECT MONITOR SYSTEM “AIRBAG” 1) Turn ignition switch to OFF. Airbag system wiring harness is routed near the 2) Turn Subaru Select Monitor switch to OFF. engine control module (ECM), main relay and fuel pump relay. CAUTION: ¼ All Airbag system wiring harness and con- nectors are colored yellow.
  • Page 270 DIAGNOSTICS [T4C0] 4. Cautions ¼ The antenna feeder must be placed as far 7) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and apart as possible from the ECM and MFI har- resistance inside the passenger compartment. ness.
  • Page 271 DIAGNOSTICS [T4C2] 4. Cautions 2. ENGINE GROUNDING Make sure the engine grounding terminal is prop- erly connected to the engine. B2M2779...
  • Page 272 DIAGNOSTICS [T5A0] 5. Specified Data 5. Specified Data A: ENGINE CONTROL MODULE (ECM) I/O SIGNAL FOR 2200 cc MODELS B2M2267A Signal (V) Connec- Termi- Content Note Ignition SW ON tor No. nal No. Engine ON (Idling) (Engine OFF) Signal (+) B135 −7 —...
  • Page 273 DIAGNOSTICS [T5A0] 5. Specified Data Signal (V) Connec- Termi- Content Note Ignition SW ON tor No. nal No. Engine ON (Idling) (Engine OFF) ON: 10 — 13 ON: 13 — 14 A/C switch B135 — OFF: 0 OFF: 0 Ignition switch B135 10 —...
  • Page 274 DIAGNOSTICS [T5A0] 5. Specified Data Signal (V) Connec- Termi- Content Note Ignition SW ON tor No. nal No. Engine ON (Idling) (Engine OFF) The value obtained after the Signal B136 2.3 — 2.7 2.3 — 2.7 fuel filler cap was removed once and recapped.

  • Page 275: Specified Data

    DIAGNOSTICS [T5A0] 5. Specified Data MEMO:...
  • Page 276 DIAGNOSTICS [T5B0] 5. Specified Data B: ENGINE CONTROL MODULE (ECM) I/O SIGNAL FOR 2500 cc MODELS B2M2267A Signal (V) Connec- Termi- Content Note Ignition SW ON tor No. nal No. Engine ON (Idling) (Engine OFF) Signal (+) B135 −7 — +7 Sensor output waveform Crankshaft position...
  • Page 277 DIAGNOSTICS [T5B0] 5. Specified Data Signal (V) Connec- Termi- Content Note Ignition SW ON tor No. nal No. Engine ON (Idling) (Engine OFF) Neutral position switch ON: 12±0.5 Switch is ON when gear is in B135 (MT) OFF: 0 neutral position. Neutral position switch ON: 0 Switch is ON when shift is in...
  • Page 278 DIAGNOSTICS [T5B0] 5. Specified Data Signal (V) Connec- Termi- Content Note Ignition SW ON tor No. nal No. Engine ON (Idling) (Engine OFF) The value obtained after the Signal B136 2.3 — 2.7 2.3 — 2.7 fuel filler cap was removed once and recapped.
  • Page 279 DIAGNOSTICS [T5C0] 5. Specified Data C: ENGINE CONDITION DATA Content Specified data 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm racing Measuring condition: ¼ After warm-up the engine. ¼ Gear position is in “N” or “P” position. ¼...
  • Page 280 DIAGNOSTICS [T5D0] 5. Specified Data D: TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL B2M2269A NOTE: Check with ignition switch ON. Connector Terminal Content Measuring conditions Voltage (V) Back-up power supply Ignition switch OFF 10 — 16 Ignition power supply Ignition switch ON (with engine OFF) 10 —...
  • Page 281 DIAGNOSTICS [T5D0] 5. Specified Data Resistance to Connector Terminal Content Measuring conditions Voltage (V) body (ohms) Throttle fully closed. 0.3 — 0.7 Throttle position — sensor Throttle fully open. 4.3 — 4.9 Throttle position Ignition switch ON (with sensor power 4.8 —...
  • Page 282 Less than 1 FWD indicator — Fuse removed from FWD lamp More than 9 switch. Data link signal — — (Subaru Select — — — Monitor) AT diagnosis Less than 1 ←→ More than 4 Ignition switch ON — signal...
  • Page 283 2) Differential gear oil level check <Ref. to 3-2 OBD-II general scan tool to data link connector. [W1B2].> 3) Turn ignition switch to ON and the Subaru 3) ATF leak check <Ref. to 3-2 [W1B3].> Select Monitor or OBD-II general scan tool switch 4) Differential gear oil leak check <Ref.
  • Page 284 DIAGNOSTICS [T6C1] 6. Basic Diagnostic Procedure C: CHECK LIST FOR INTERVIEW 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 285 DIAGNOSTICS [T6C2] 6. Basic Diagnostic Procedure 2. CHECK LIST NO. 2 NOTE: Use copies of this page for interviewing customers. Check the following items about the vehicle’s state when MIL turns on. a) Other warning lights or indicators turn on. „ Yes/„ No „...

  • Page 286: Diagnostics For Check Engine Malfunction Indicator Lamp (Mil)

    DIAGNOSTICS [T7A0] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) A: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON. ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼...
  • Page 287 DIAGNOSTICS [T7A5] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7A1 : CHECK OUTPUT SIGNAL FROM 7A4 : CHECK HARNESS BETWEEN COM- ECM. BINATION METER AND ECM CON- NECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and 2) Remove combination meter.
  • Page 288 DIAGNOSTICS [T7A6] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7A6 : CHECK HARNESS BETWEEN COM- BINATION METER AND IGNITION SWITCH CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between combination meter connector and chassis ground. Connector & terminal (i12) No.
  • Page 289 DIAGNOSTICS [T7A7] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) MEMO:...
  • Page 290 ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD-II general scan tool display. ¼ WIRING DIAGRAM:...
  • Page 291 DIAGNOSTICS [T7B1] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7B1 : CHECK HARNESS BETWEEN COM- BINATION METER AND ECM CON- NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Turn ignition switch to ON. H2M2446C : Does the MIL come on? : Repair short circuit in harness between...
  • Page 292 DIAGNOSTICS [T7C0] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz. ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼...
  • Page 293 DIAGNOSTICS [T7C4] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7C1 : CHECK STATUS OF CHECK ENGINE 7C3 : CHECK HARNESS BETWEEN TEST MALFUNCTION INDICATOR LAMP MODE CONNECTOR AND CHASSIS (MIL). GROUND. 1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF. 2) Disconnect test mode connector.
  • Page 294 DIAGNOSTICS [T7C5] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7C5 : CHECK HARNESS BETWEEN ECM AND TEST MODE CONNECTOR. 1) Connect test mode connector. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B135) No. 14 — Chassis ground: B2M2275A : Is resistance less than 1 Ω? : Go to step 7C6.
  • Page 295 DIAGNOSTICS [T7C6] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) MEMO:...
  • Page 296 DIAGNOSTICS [T7D0] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 Hz. ¼ DIAGNOSIS: ¼ Test mode connector circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON. ¼...
  • Page 297 DIAGNOSTICS [T7D2] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7D2 : CHECK HARNESS BETWEEN ECM CONNECTOR AND ENGINE GROUNDING TERMINAL. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground.
  • Page 298 DIAGNOSTICS [T7D2] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) MEMO:...

  • Page 299: Diagnostics For Engine Starting Failure

    7. Inspection of camshaft position sensor circuit. <Ref. to 2-7 [T8H0].> ↓ 8. Inspection using Subaru Select Monitor or OBD-II general scan tool (2200 cc models: <Ref. to 2-7 [T10A0].>, 2500 cc models: <Ref. to 2-7 [T11A0].>) or inspection using “9. General Diagnostics Table”. <Ref. to 2-7 [T900].>...
  • Page 300 DIAGNOSTICS [T8B0] 8. Diagnostics for Engine Starting Failure B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼ WIRING DIAGRAM: H2M3536 2) Disconnect connector from starter motor. 8B1 : CHECK BATTERY.
  • Page 301 DIAGNOSTICS [T8B5] 8. Diagnostics for Engine Starting Failure 4) Measure power supply voltage between starter 8B4 : CHECK HARNESS BETWEEN BAT- motor connector terminal and engine ground. TERY AND IGNITION SWITCH CON- NECTOR. Connector & terminal (B14) No. 1 (+) — Engine ground (−): 1) Disconnect connector from ignition switch.
  • Page 302 DIAGNOSTICS [T8B6] 8. Diagnostics for Engine Starting Failure 8B6 : CHECK TRANSMISSION TYPE. 8B8 : CHECK INHIBITOR SWITCH. : Is transmission type AT? 1) Place the selector lever in the “P” or “N” posi- tion. : Go to step 8B7. 2) Measure resistance between inhibitor switch : Go to step 8B11.
  • Page 303 DIAGNOSTICS [T8B11] 8. Diagnostics for Engine Starting Failure 8B9 : CHECK INPUT VOLTAGE OF 8B10 : CHECK STARTER INTERLOCK STARTER INTERLOCK RELAY. RELAY. 1) Turn ignition switch to OFF. 1) Connect battery to starter interlock relay termi- 2) Disconnect connector from starter interlock nals No.
  • Page 304 DIAGNOSTICS [T8B12] 8. Diagnostics for Engine Starting Failure 8B12 : CHECK CLUTCH SWITCH. 1) Measure resistance between clutch switch ter- minal while depressing the clutch pedal. Terminals No. 1 — No. 2: B2M3554 : Is the resistance less than 1 Ω? : Go to step 8B13.
  • Page 305 DIAGNOSTICS [T8B13] 8. Diagnostics for Engine Starting Failure MEMO:...
  • Page 306 DIAGNOSTICS [T8C0] 8. Diagnostics for Engine Starting Failure C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE. <Ref. to 2-7 [T3E0].> ¼ WIRING DIAGRAM: H2M3537 8C1 : CHECK MAIN RELAY.
  • Page 307 DIAGNOSTICS [T8C6] 8. Diagnostics for Engine Starting Failure 8C3 : CHECK GROUND CIRCUIT OF ECM. 8C5 : CHECK GROUND CIRCUIT OF ECM. 1) Disconnect connector from ECM. Measure resistance of harness between ECM and 2) Measure resistance of harness between ECM chassis ground.
  • Page 308 DIAGNOSTICS [T8C7] 8. Diagnostics for Engine Starting Failure 8C7 : CHECK GROUND CIRCUIT OF ECM. 8C9 : CHECK INPUT VOLTAGE OF ECM. Measure resistance of harness between ECM and 1) Turn ignition switch to ON. chassis ground. 2) Measure voltage between ECM connector and chassis ground.
  • Page 309 DIAGNOSTICS [T8C14] 8. Diagnostics for Engine Starting Failure 8C11 : CHECK OUTPUT VOLTAGE FROM 8C13 : CHECK GROUND CIRCUIT OF MAIN ECM. RELAY. 1) Connect connector to ECM. 1) Turn ignition switch to OFF. 2) Turn ignition switch to ON. 2) Measure resistance between main relay con- 3) Measure voltage between ECM connector and nector and chassis ground.
  • Page 310 DIAGNOSTICS [T8C15] 8. Diagnostics for Engine Starting Failure 8C15 : CHECK INPUT VOLTAGE OF MAIN 8C17 : CHECK INPUT VOLTAGE OF ECM. RELAY. Measure voltage between ECM connector and chassis ground. Measure voltage between main relay connector and chassis ground. Connector &...
  • Page 311 DIAGNOSTICS [T8C17] 8. Diagnostics for Engine Starting Failure MEMO:...
  • Page 312 DIAGNOSTICS [T8D0] 8. Diagnostics for Engine Starting Failure D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼ WIRING DIAGRAM: B2M3557...
  • Page 313 DIAGNOSTICS [T8D2] 8. Diagnostics for Engine Starting Failure 8D1 : CHECK IGNITION SYSTEM FOR 8D2 : CHECK POWER SUPPLY CIRCUIT SPARKS. FOR IGNITION COIL & IGNITOR ASSEMBLY. 1) Remove plug cord cap from each spark plug. 1) Turn ignition switch to OFF. 2) Install new spark plug on plug cord cap.
  • Page 314 DIAGNOSTICS [T8D3] 8. Diagnostics for Engine Starting Failure 8D3 : CHECK HARNESS OF IGNITION COIL 8D4 : CHECK IGNITION COIL & IGNITOR & IGNITOR ASSEMBLY GROUND ASSEMBLY. CIRCUIT. 1) Remove spark plug cords. 1) Turn ignition switch to OFF. 2) Measure resistance between spark plug cord 2) Measure resistance between ignition coil &...
  • Page 315 DIAGNOSTICS [T8D8] 8. Diagnostics for Engine Starting Failure 8D6 : CHECK INPUT SIGNAL FOR IGNI- 8D8 : CHECK HARNESS BETWEEN ECM TION COIL & IGNITOR ASSEMBLY. AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. 1) Connect connector to ignition coil & ignitor 1) Turn ignition switch to OFF.
  • Page 316 DIAGNOSTICS [T8D9] 8. Diagnostics for Engine Starting Failure 8D9 : CHECK HARNESS BETWEEN ECM 8D10 : CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. ASSEMBLY CONNECTOR. Measure resistance of harness between ECM and Measure resistance of harness between ECM and ignition coil &...
  • Page 317 DIAGNOSTICS [T8D12] 8. Diagnostics for Engine Starting Failure 8D12 : CHECK POOR CONTACT. Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> : Is there poor contact in ECM connec- tor? : Repair poor contact in ECM connector. : Check fuel pump circuit. <Ref. to 2-7 [T8E0].>...
  • Page 318 (Sedan) or NOTE: luggage compartment floor (Wagon). Fuel pump operation can also be executed using Subaru Select Monitor (Function mode: FD01). For the procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 319 DIAGNOSTICS [T8E4] 8. Diagnostics for Engine Starting Failure 4) Measure resistance of harness connector 8E4 : CHECK HARNESS BETWEEN FUEL between fuel pump and chassis ground. PUMP AND FUEL PUMP RELAY CON- NECTOR. Connector & terminal (R58) No. 4 — Chassis ground: 1) Turn ignition switch to OFF.
  • Page 320 DIAGNOSTICS [T8E5] 8. Diagnostics for Engine Starting Failure 8E5 : CHECK HARNESS BETWEEN FUEL 8E6 : CHECK FUEL PUMP RELAY. PUMP AND FUEL PUMP RELAY CON- NECTOR. 1) Disconnect connectors from fuel pump relay and main relay. Measure resistance of harness between fuel pump 2) Remove fuel pump relay and main relay with and fuel pump relay connector.
  • Page 321 DIAGNOSTICS [T8E8] 8. Diagnostics for Engine Starting Failure 8E7 : CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNEC- TOR. 1) Disconnect connectors from ECM. 2) Measure resistance of harness between ECM and fuel pump relay connector. Connector & terminal (B134) No.
  • Page 322 DIAGNOSTICS [T8F0] 8. Diagnostics for Engine Starting Failure F: FUEL INJECTOR CIRCUIT CAUTION: ¼ Check or repair only faulty parts. ¼ After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE. <Ref. to 2-7 [T3E0].> ¼...
  • Page 323 DIAGNOSTICS [T8F3] 8. Diagnostics for Engine Starting Failure 8F2 : CHECK POWER SUPPLY TO EACH 8F3 : CHECK POWER SUPPLY TO EACH FUEL INJECTOR. FUEL INJECTOR. 1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF. 2) Disconnect connector from #1 cylinder fuel 2) Disconnect connector from #2 cylinder fuel injector.
  • Page 324 DIAGNOSTICS [T8F4] 8. Diagnostics for Engine Starting Failure 8F4 : CHECK POWER SUPPLY TO EACH 8F5 : CHECK POWER SUPPLY TO EACH FUEL INJECTOR. FUEL INJECTOR. 1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF. 2) Disconnect connector from #3 cylinder fuel 2) Disconnect connector from #4 cylinder fuel injector.
  • Page 325 DIAGNOSTICS [T8F8] 8. Diagnostics for Engine Starting Failure 8F6 : CHECK HARNESS BETWEEN ECM 8F7 : CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. AND FUEL INJECTOR CONNECTOR. 1) Disconnect connector from ECM. Measure resistance of harness between ECM and 2) Measure resistance of harness between ECM fuel injector connector.
  • Page 326 DIAGNOSTICS [T8F9] 8. Diagnostics for Engine Starting Failure 8F9 : CHECK HARNESS BETWEEN ECM 8F11 : CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and Measure resistance of harness between ECM and fuel injector connector.
  • Page 327 DIAGNOSTICS [T8F15] 8. Diagnostics for Engine Starting Failure 8F13 : CHECK HARNESS BETWEEN ECM 8F15 : CHECK POOR CONTACT. AND FUEL INJECTOR CONNECTOR. Check poor contact in ECM connector. <Ref. to FOREWORD [W3C1].> Measure resistance of harness between ECM and fuel injector connector.
  • Page 328 DIAGNOSTICS [T8G0] 8. Diagnostics for Engine Starting Failure G: CRANKSHAFT POSITION SENSOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. NOTE: Check crankshaft position sensor circuit. ¼...

  • Page 329: General Diagnostic Table

    DIAGNOSTICS [T9A0] 9. General Diagnostic Table 9. General Diagnostic Table A: GENERAL DIAGNOSTICS TABLE WITH NON-CONFORMITY SYMPTOM FOR ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to 2-3 [K100].> Symptom Problem parts 1) Idle air control solenoid valve 2) Intake manifold pressure sensor 3) Intake air temperature sensor 4) Intake air temperature and pressure sensor...
  • Page 330 DIAGNOSTICS [T9B0] 9. General Diagnostic Table Symptom Problem parts 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 4) Engine coolant temperature sensor (*2) 6. Surge 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 8) Throttle position sensor 9) Fuel pump and fuel pump relay...
  • Page 331 DIAGNOSTICS [T9B0] 9. General Diagnostic Table MEMO:...
  • Page 332 DIAGNOSTICS [T10A0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10. Diagnostics Chart with Trouble Code for 2200 cc Models A: DIAGNOSTIC TROUBLE CODE (DTC) LIST Item Index P0106 Intake manifold pressure sensor circuit range/performance problem <Ref. to 2-7 [T10B0].>...
  • Page 333 DIAGNOSTICS [T10A0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models Item Index P0303 Cylinder 3 misfire detected <Ref. to 2-7 [T10AA0].> P0304 Cylinder 4 misfire detected <Ref. to 2-7 [T10AB0].> P0325 Knock sensor circuit malfunction <Ref. to 2-7 [T10AC0].>...
  • Page 334 DIAGNOSTICS [T10A0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models Item Index P0715 Torque converter turbine speed sensor circuit malfunction <Ref. to 2-7 [T10BB0].> P0720 Output speed sensor (vehicle speed sensor 2) circuit malfunction <Ref. to 2-7 [T10BC0].> P0725 Engine speed input circuit malfunction <Ref.
  • Page 335 DIAGNOSTICS [T10A0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models Item Index P1134 Front oxygen (A/F) sensor micro-computer problem <Ref. to 2-7 [T10CC0].> P1139 Front oxygen (A/F) sensor #1 heater circuit range/performance problem <Ref. to 2-7 [T10CD0].> P1142 Throttle position sensor circuit range/performance problem (low input) <Ref.
  • Page 336 DIAGNOSTICS [T10B0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models B: DTC P0106 — INTAKE MANIFOLD PRESSURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 337 P0106. 10B2 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0107 or P0108? : Inspect DTC P0107 or P0108 using “10. Diagnostics Chart with Trouble Code for 2200 cc Models”.
  • Page 338 DIAGNOSTICS [T10C0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models C: DTC P0107 — INTAKE MANIFOLD PRESSURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 339 1) Start engine. Measure voltage between ECM connector and 2) Read the data of intake manifold absolute pres- chassis ground. sure signal using Subaru Select Monitor or OBD-II Connector & terminal general scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 340 : Does the value change more than 3.3 kPa (25 mmHg, 0.98 inHg) by shaking harness and connector of ECM while monitoring the value with Subaru Select Monitor? : Repair poor contact in ECM connector. : Go to step 10C7.
  • Page 341 DIAGNOSTICS [T10C10] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10C9 : CHECK HARNESS BETWEEN ECM AND INTAKE MANIFOLD PRES- SURE SENSOR CONNECTOR. Measure resistance of harness between intake manifold pressure sensor connector and engine ground. Connector & terminal (E21) No.
  • Page 342 DIAGNOSTICS [T10D0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models D: DTC P0108 — INTAKE MANIFOLD PRESSURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 343 1) Start engine. Measure voltage between ECM connector and 2) Read the data of intake manifold absolute pres- chassis ground. sure signal using Subaru Select Monitor or OBD-II Connector & terminal general scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 344 : Does the value change more than 3.3 kPa (25 mmHg, 0.98 inHg) by shaking harness and connector of ECM while monitoring the value with Subaru Select Monitor? : Repair poor contact in ECM connector. : Go to step 10D6.
  • Page 345 NECTOR. Check poor contact in intake manifold pressure sensor connector. <Ref. to FOREWORD [T3C1].> 1) Turn ignition switch to OFF and Subaru Select : Is there poor contact in intake mani- Monitor or the OBD-II general scan tool switch to fold pressure sensor connector? OFF.
  • Page 346 DIAGNOSTICS [T10E0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models E: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 347 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10E1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0112 or P0113? : Inspect DTC P0112 or P0113 using “10.
  • Page 348 DIAGNOSTICS [T10F0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models F: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 349 10F1 : CHECK CURRENT DATA. 1) Start engine. 2) Read data of intake air temperature sensor sig- nal using Subaru Select Monitor or the OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 350 DIAGNOSTICS [T10G0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models G: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 351 1) Turn ignition switch to ON. 3) Read data of intake air temperature sensor sig- 2) Measure voltage between intake air tempera- nal using Subaru Select Monitor or the OBD-II gen- ture sensor connector and engine ground. eral scan tool.
  • Page 352 DIAGNOSTICS [T10G4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10G4 : CHECK HARNESS BETWEEN 10G5 : CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE SEN- INTAKE AIR TEMPERATURE SEN- SOR AND ECM CONNECTOR. SOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure voltage between intake air temperature 2) Measure resistance of harness between intake sensor connector and engine ground.
  • Page 353 DIAGNOSTICS [T10G5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 354 DIAGNOSTICS [T10H0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models H: DTC P0116 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Hard to start ¼...
  • Page 355 ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of engine coolant temperature sen- sor signal using Subaru Select Monitor or OBD-II 1) Turn ignition switch to OFF. general scan tool. 2) Disconnect connector from engine coolant tem- perature sensor.
  • Page 356 DIAGNOSTICS [T10I0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models I: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Hard to start ¼...
  • Page 357 1) Start engine. 2) Read data of engine coolant temperature sen- 1) Turn ignition switch to ON. sor signal using Subaru Select Monitor or OBD-II 2) Measure voltage between engine coolant tem- general scan tool. perature sensor connector and engine ground.
  • Page 358 DIAGNOSTICS [T10I4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10I4 : CHECK HARNESS BETWEEN 10I5 : CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure voltage between engine coolant tempera- 2) Measure resistance of harness between engine ture sensor connector and engine ground.
  • Page 359 DIAGNOSTICS [T10I5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 360 H2M3543 10J1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0107, P0108, P0122 or P0123? : Inspect DTC P0107, P0108, P0122 or P0123 using “10. Diagnostics Chart with Trouble Code for 2200 cc Models”.
  • Page 361 10J2 : CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pres- sure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 362 DIAGNOSTICS [T10K0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models K: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 363 1) Start engine. Measure voltage between ECM connector and 2) Read data of throttle position sensor signal chassis ground. using Subaru Select Monitor or OBD-II general Connector & terminal scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 364 Connector & terminal 0.1 V by shaking harness and con- (B136) No. 17 — (E13) No. 3: nector of ECM while monitoring the value with Subaru Select Monitor? : Repair poor contact in ECM connector. : Go to step 10K6. 10K6 :...
  • Page 365 DIAGNOSTICS [T10K9] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10K8 : CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SEN- SOR CONNECTOR. Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 — Engine ground: B2M2455A : Is the resistance less than 10 Ω? : Repair ground short circuit in harness...
  • Page 366 DIAGNOSTICS [T10L0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models L: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 367 THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of throttle position sensor signal 1) Turn ignition switch to OFF. using Subaru Select Monitor or OBD-II general 2) Disconnect connector from throttle position scan tool. sensor. NOTE: 3) Measure resistance of harness between throttle ¼...
  • Page 368 DIAGNOSTICS [T10L3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10L3 : CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between throttle position sen- sor connector and engine ground. Connector &...
  • Page 369 H2M3542 10M1 : CHECK ANY OTHER DTC ON DIS- 10M2 : CHECK THERMOSTAT. PLAY. : Does thermostat remain opened? : Does the Subaru Select Monitor or : Replace thermostat. <Ref. OBD-II general scan tool indicate [W2A0].> DTC P0116 or P0117? : Replace engine coolant temperature : Inspect DTC P0116 or P0117 using “10.
  • Page 370 DIAGNOSTICS [T10N0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models N: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) — NOTE: For the diagnostic procedure, refer to DTC P0132. <Ref. to 2-7 [T10O0].> O: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —...
  • Page 371 OPERATION MODE FOR ENGINE”. <Ref. to 2-7 [T3C8].> 1) Start engine. : Does the LED of {Rear O2 Rich Sig- 2) While observing the Subaru Select Monitor or nal} blink? OBD-II general scan tool screen, warm-up the : Repair poor contact in front oxygen engine until coolant temperature is above 70°C...
  • Page 372 10P2 : CHECK EXHAUST SYSTEM. PLAY. NOTE: Check the following items. : Does the Subaru Select Monitor or ¼ Loose installation of front portion of exhaust pipe OBD-II general scan tool indicate onto cylinder heads DTC P1130, P1131, P1132, P1133 or ¼...
  • Page 373 DIAGNOSTICS [T10P2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 374 10Q2 : CHECK FAILURE CAUSE OF P1130 PLAY. OR P1131. : Does the Subaru Select Monitor or Inspect DTC P1130 or P1131 using “10. Diagnos- OBD-II general scan tool indicate tics Chart with Trouble Code for 2200 cc Models”. DTC P1130 or P1131? <Ref.
  • Page 375 3) Measure resistance of harness between ECM minutes. and rear oxygen sensor connector. 3) Read data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II general scan tool. Connector & terminal NOTE: (B136) No. 16 — (E25) No. 3: ¼...
  • Page 376 DIAGNOSTICS [T10Q6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10Q6 : CHECK HARNESS BETWEEN REAR 10Q7 : CHECK EXHAUST SYSTEM. OXYGEN SENSOR AND ECM CON- NECTOR. Check exhaust system parts. NOTE: 1) Connect connector to ECM. Check the following items. 2) Turn ignition switch to ON.
  • Page 377 ¼ WIRING DIAGRAM: H2M3545 10R1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0136? : Inspect DTC P0136 using “10. Diagnos- tics Chart with Trouble Code for 2200 cc Models”.
  • Page 378 ¼ WIRING DIAGRAM: H2M3545 10S1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0141 and P0135 at the same time? : Go to step 10S2. : Go to step 10S3.
  • Page 379 DIAGNOSTICS [T10S3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10S2 : CHECK GROUND CIRCUIT OF ECM. 10S3 : CHECK GROUND CIRCUIT OF ECM. 1) Turn ignition switch to OFF. 1) Repair harness and connector. 2) Disconnect connector from ECM. NOTE: 3) Measure resistance of harness between ECM In this case, repair the following:...
  • Page 380 DIAGNOSTICS [T10S4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10S4 : CHECK HARNESS BETWEEN ECM 10S6 : CHECK POWER SUPPLY TO REAR AND REAR OXYGEN SENSOR CON- OXYGEN SENSOR. NECTOR. 1) Connect connector to ECM. Measure resistance of harness between ECM con- 2) Turn ignition switch to ON.
  • Page 381 DIAGNOSTICS [T10S7] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10S7 : CHECK REAR OXYGEN SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between rear oxygen sen- sor connector terminals. Terminals No. 2 — No. 4: B2M2482 : Is the resistance less than 30 Ω? : Repair harness and connector.
  • Page 382 DIAGNOSTICS [T10T0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models T: DTC P0171 — FUEL TRIM MALFUNCTION (A/F TOO LEAN) — NOTE: For the diagnostic procedure, refer to DTC P0172. <Ref. to 2-7 [T10U0].> U: DTC P0172 — FUEL TRIM MALFUNCTION (A/F TOO RICH) — ¼...
  • Page 383 DIAGNOSTICS [T10U4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 5) Start the engine and idle while gear position is 10U4 : CHECK FUEL PRESSURE. neutral. 6) Measure fuel pressure while disconnecting pressure regulator vacuum hose from intake mani- After connecting pressure regulator vacuum hose, fold.
  • Page 384 60°C (140°F). 2) Read data of engine coolant temperature sen- 2) Place the shift lever in neutral position. sor signal using Subaru Select Monitor or OBD-II 3) Turn A/C switch to OFF. general scan tool.
  • Page 385 4) Turn all accessory switches to OFF. 5) Open front hood. 6) Measure ambient temperature. 7) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 386 H2M3014 10V1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0182 or P0183? : Inspect DTC P0182 or P0183 using “10. Diagnostics Chart with Trouble Code for 2200 cc Models”.
  • Page 387 DIAGNOSTICS [T10V1] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 388 DIAGNOSTICS [T10W0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models W: DTC P0182 — FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 389 : Go to step 10W2. 5) Read data of fuel temperature sensor signal : Even if MIL lights up, the circuit has using Subaru Select Monitor or the OBD-II general returned to a normal condition at this scan tool. time.
  • Page 390 DIAGNOSTICS [T10X0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models X: DTC P0183 — FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 391 TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of fuel temperature sensor signal 1) Turn ignition switch to OFF. using Subaru Select Monitor or OBD-II general 2) Remove access hole lid. scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 392 DIAGNOSTICS [T10X3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10X3 : CHECK HARNESS BETWEEN FUEL 10X4 : CHECK HARNESS BETWEEN FUEL TEMPERATURE SENSOR AND ECM TEMPERATURE SENSOR AND ECM CONNECTOR. CONNECTOR. 1) Turn ignition switch to ON. Measure voltage between fuel pump connector 2) Measure voltage between fuel pump connector and chassis ground.
  • Page 393 DIAGNOSTICS [T10X5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10X5 : CHECK HARNESS BETWEEN FUEL TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between fuel pump connector and chassis ground. Connector &...
  • Page 394 DIAGNOSTICS [T10Y0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models Y: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to 2-7 [T10AB0].> Z: DTC P0302 — CYLINDER 2 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304.
  • Page 395 CHECK HARNESS BETWEEN PLAY. FUEL INJECTOR AND ECM CON- NECTOR. : Does the Subaru Select Monitor or 1) Turn ignition switch to OFF. OBD-II general scan tool indicate 2) Disconnect connector from fuel injector on DTC P0106, P0107, P0108, P0116, P0117 or P0125? faulty cylinders.
  • Page 396 DIAGNOSTICS [T10AB4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AB4 : CHECK HARNESS BETWEEN 10AB5 : CHECK FUEL INJECTOR. FUEL INJECTOR AND ECM CON- NECTOR. Measure resistance between fuel injector terminals on faulty cylinder. Measure resistance of harness connector between Terminals ECM connector and fuel injector on faulty cylin- No.
  • Page 397 DIAGNOSTICS [T10AB7] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AB6 : CHECK POWER SUPPLY LINE. 10AB7 : CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CON- NECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between fuel injector and 1) Turn ignition switch to OFF.
  • Page 398 DIAGNOSTICS [T10AB8] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AB8 : CHECK FUEL INJECTOR. 10AB11 : CHECK INSTALLATION CONDI- TION OF TIMING BELT. 1) Turn ignition switch to OFF. Turn crankshaft using ST, and align alignment 2) Measure resistance between fuel injector termi- mark on crankshaft sprocket with alignment mark nals on faulty cylinder.
  • Page 399 ENGINE MALFUNCTION INDICA- TOR LAMP (MIL). : Is there a fault in air intake system? : Repair air intake system. 1) Clear memory using Subaru Select Monitor. NOTE: <Ref. to 2-7 [T3D0].> Check the following items: 2) Start engine, and drive the vehicle more than ¼...
  • Page 400 CHECK DIAGNOSTIC TROUBLE 10AB23 : GROUP OF #3 AND #4 CYLIN- CODE (DTC) ON DISPLAY. DERS : Does the Subaru Select Monitor or : Are there faults in #3 and #4 cylin- OBD-II general scan tool indicate ders? DTC P0301 and P0303? : Repair or replace faulty parts.
  • Page 401 DIAGNOSTICS [T10AB26] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AB26 : CYLINDER AT RANDOM : Is the engine idle rough? : Go to DTC P0171 and P0172. <Ref. to 2-7 [T10U0].> : Repair or replace faulty parts. NOTE: Check the following items.
  • Page 402 DIAGNOSTICS [T10AC0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AC: DTC P0325 — KNOCK SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Poor driving performance ¼ Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 403 DIAGNOSTICS [T10AC4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AC1 : CHECK HARNESS BETWEEN 10AC3 : CHECK KNOCK SENSOR. KNOCK SENSOR AND ECM CON- NECTOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor 1) Turn ignition switch to OFF.
  • Page 404 DIAGNOSTICS [T10AC5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AC5 : CHECK KNOCK SENSOR. 10AC6 : CHECK INPUT SIGNAL FOR ECM. 1) Connect connectors to ECM and knock sensor. 1) Disconnect connector from knock sensor. 2) Turn ignition switch to ON. 2) Measure resistance between knock sensor 3) Measure voltage between ECM and chassis connector terminal and engine ground.
  • Page 405 DIAGNOSTICS [T10AC6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 406 DIAGNOSTICS [T10AD0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AD: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 407 DIAGNOSTICS [T10AD2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AD1 : CHECK HARNESS BETWEEN 10AD2 : CHECK HARNESS BETWEEN CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR AND ECM CONNECTOR. AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure resistance of harness between crank- 2) Disconnect connector from crankshaft position shaft position sensor connector and engine...
  • Page 408 DIAGNOSTICS [T10AD3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AD3 : CHECK HARNESS BETWEEN 10AD5 : CHECK CRANKSHAFT POSITION CRANKSHAFT POSITION SENSOR SENSOR. AND ECM CONNECTOR. 1) Remove crankshaft position sensor. 2) Measure resistance between connector termi- Measure resistance of harness between crank- nals of crankshaft position sensor.
  • Page 409 DIAGNOSTICS [T10AD5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 410 CHECK ANY OTHER DTC ON DIS- 10AE2 : CHECK CONDITION OF CRANK- PLAY. SHAFT POSITION SENSOR. : Does the Subaru Select Monitor or Turn ignition switch to OFF. OBD-II general scan tool indicate : Is the crankshaft position sensor DTC P0335? installation bolt tightened securely? : Inspect DTC P0335 using “10.
  • Page 411 DIAGNOSTICS [T10AE4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AE3 : CHECK CRANKSHAFT SPROCKET. Remove front belt cover. : Are crankshaft sprocket teeth cracked or damaged? : Replace crankshaft sprocket. <Ref. to 2-3 [W3A0].> : Go to step 10AE4. 10AE4 : CHECK INSTALLATION CONDI- TION OF TIMING BELT.
  • Page 412 DIAGNOSTICS [T10AF0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AF: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 413 DIAGNOSTICS [T10AF2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AF1 : CHECK HARNESS BETWEEN 10AF2 : CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR AND ECM CONNECTOR. AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure resistance of harness between camshaft 2) Disconnect connector from camshaft position position sensor connector and engine ground.
  • Page 414 DIAGNOSTICS [T10AF3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AF3 : CHECK HARNESS BETWEEN 10AF5 : CHECK CAMSHAFT POSITION CAMSHAFT POSITION SENSOR SENSOR. AND ECM CONNECTOR. 1) Remove camshaft position sensor. 2) Measure resistance between connector termi- Measure resistance of harness between camshaft nals of camshaft position sensor.
  • Page 415 DIAGNOSTICS [T10AF5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 416 ¼ WIRING DIAGRAM: B2M3562 10AG1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0340? : Inspect DTC P0340 using “10. Diagnos- tics Chart with Trouble Code for 2200 cc Models”.
  • Page 417 DIAGNOSTICS [T10AG3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AG2 : CHECK HARNESS BETWEEN 10AG3 : CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR AND ECM CONNECTOR. AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure resistance of harness between camshaft 2) Disconnect connector from camshaft position position sensor connector and engine ground.
  • Page 418 DIAGNOSTICS [T10AG4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AG4 : CHECK HARNESS BETWEEN 10AG6 : CHECK CAMSHAFT POSITION CAMSHAFT POSITION SENSOR SENSOR. AND ECM CONNECTOR. 1) Remove camshaft position sensor. Measure resistance of harness between camshaft 2) Measure resistance between connector termi- position sensor connector and engine ground.
  • Page 419 DIAGNOSTICS [T10AG9] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AG9 : CHECK INSTALLATION CONDI- TION OF TIMING BELT. Turn camshaft using ST, and align alignment mark on camshaft sprocket with alignment mark on tim- ing belt cover LH. ST 499207100 CAMSHAFT SPROCKET WRENCH H2M3620A...
  • Page 420 DIAGNOSTICS [T10AH0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AH: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 421 10AH3 : CHECK REAR CATALYTIC CON- PLAY. VERTER. Separate rear catalytic converter from rear exhaust : Does the Subaru Select Monitor or pipe. OBD-II general scan tool indicate DTC P0131, P0132, P0133, P0135, P0136, P0139, P0141, P0301, P0302, P0303, P0304, P1130, P1131, P1134, P1139, P1150 and P1151? : Inspect the relevant DTC using “10.
  • Page 422 DIAGNOSTICS [T10AI0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AI: DTC P0440 — EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Gasoline smell ¼ There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 423 3) Operate drain valve. <Ref. to 2-1 [W4A0].> NOTE: Drain valve operation can also be executed using Subaru Select Monitor. For the procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 [T3F0].> B2M1873E : Does drain valve produce operating sound? : Go to step 10AI5.
  • Page 424 1.0 mm (0.04 in) NOTE: dia. in it? Pressure control solenoid valve operation can also be executed using Subaru Select Monitor. For the : Repair or replace fuel tank. <Ref. to 2-8 procedure, refer to “COMPULSORY VALVE [W1C0].>...
  • Page 425 DIAGNOSTICS [T10AI10] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 426 DIAGNOSTICS [T10AJ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AJ: DTC P0443 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼...
  • Page 427 DIAGNOSTICS [T10AJ2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AJ1 : CHECK OUTPUT SIGNAL FROM 10AJ2 : CHECK HARNESS BETWEEN ECM. PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connectors from purge control sole- ground.
  • Page 428 DIAGNOSTICS [T10AJ3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AJ3 : CHECK HARNESS BETWEEN 10AJ4 : CHECK PURGE CONTROL SOLE- PURGE CONTROL SOLENOID NOID VALVE. VALVE AND ECM CONNECTOR. 1) Remove purge control solenoid valve. Measure resistance of harness between ECM and 2) Measure resistance between purge control purge control solenoid valve of harness connector.
  • Page 429 DIAGNOSTICS [T10AJ6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AJ6 : CHECK POOR CONTACT. Check poor contact in purge control solenoid valve connector. <Ref. to FOREWORD [T3C1].> : Is there poor contact in purge control solenoid valve connector? : Repair poor contact in purge control solenoid valve connector.
  • Page 430 DIAGNOSTICS [T10AK0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AK: DTC P0446 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 431 DIAGNOSTICS [T10AK3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AK1 : CHECK OUTPUT SIGNAL FROM 10AK3 : CHECK HARNESS BETWEEN ECM. DRAIN VALVE AND ECM CONNEC- TOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connectors from drain valve and ground.
  • Page 432 DIAGNOSTICS [T10AK4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AK4 : CHECK HARNESS BETWEEN 10AK6 : CHECK POWER SUPPLY TO DRAIN VALVE AND ECM CONNEC- DRAIN VALVE. TOR. 1) Turn ignition switch to ON. 2) Measure voltage between drain valve and Measure resistance of harness between ECM and chassis ground.
  • Page 433 DIAGNOSTICS [T10AL3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AL: DTC P0451 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR RANGE/PERFORMANCE PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 434 DIAGNOSTICS [T10AM0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AM: DTC P0452 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 435 4) Turn ignition switch to ON. Connector & terminal 5) Read the data of fuel tank pressure sensor sig- (B136) No. 15 (+) — Chassis ground (−): nal using Subaru Select Monitor or the OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 436 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AM5 : CHECK INPUT SIGNAL FOR ECM. 10AM7 : CHECK HARNESS BETWEEN (USING SUBARU SELECT MONI- ECM AND COUPLING CONNEC- TOR.) TOR IN REAR WIRING HARNESS. Read data of fuel tank pressure sensor signal 1) Turn ignition switch to OFF.
  • Page 437 DIAGNOSTICS [T10AM11] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AM8 : CHECK HARNESS BETWEEN 10AM10 : CHECK FUEL TANK CORD. ECM AND COUPLING CONNEC- TOR IN REAR WIRING HARNESS. Measure resistance of fuel tank cord. Connector & terminal Measure resistance of harness between rear wir- (R57) No.
  • Page 438 DIAGNOSTICS [T10AM12] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AM12 : CHECK POOR CONTACT. Check poor contact in fuel tank pressure sensor connector. <Ref. to FOREWORD [T3C1].> : Is there poor contact in fuel tank pressure sensor connector? : Repair poor contact in fuel tank pres- sure sensor connector.
  • Page 439 DIAGNOSTICS [T10AM12] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 440 DIAGNOSTICS [T10AN0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AN: DTC P0453 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 441 4) Turn ignition switch to ON. Connector & terminal 5) Read data of fuel tank pressure sensor signal (B136) No. 15 (+) — Chassis ground (−): using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 442 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AN5 : CHECK INPUT SIGNAL FOR ECM. 10AN7 : CHECK HARNESS BETWEEN ECM (USING SUBARU SELECT MONI- AND COUPLING CONNECTOR IN TOR.) REAR WIRING HARNESS. Read data of fuel tank pressure sensor signal 1) Turn ignition switch to OFF.
  • Page 443 DIAGNOSTICS [T10AN11] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AN8 : CHECK HARNESS BETWEEN ECM 10AN10 : CHECK FUEL TANK CORD. AND COUPLING CONNECTOR IN REAR WIRING HARNESS. Measure resistance of fuel tank cord. Connector & terminal Measure resistance of harness between rear wir- (R57) No.
  • Page 444 10AN12 : CHECK HARNESS BETWEEN ECM AND FUEL TANK PRES- SURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF and Subaru Select Monitor or the OBD-II general scan tool switch to OFF. 2) Disconnect connector from fuel tank pressure sensor.
  • Page 445 H2M3558 10AO1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0462 or P0463? : Inspect DTC P0462 or P0463 using “10. Diagnostics Chart with Trouble Code for 2200 cc Models”.
  • Page 446 DIAGNOSTICS [T10AP0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AP: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 447 (USING SUBARU SELECT MONI- TOR.) 10AP5 : CHECK HARNESS BETWEEN ECM AND COMBINATION METER. Read data of fuel level sensor signal using Subaru Select Monitor. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from connector (i10) and ¼ Subaru Select Monitor ECM connector.
  • Page 448 DIAGNOSTICS [T10AP6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AP6 : CHECK HARNESS BETWEEN ECM 10AP8 : CHECK FUEL TANK CORD. AND COMBINATION METER. 1) Disconnect connector from fuel pump assem- Measure resistance between ECM and combina- bly.
  • Page 449 DIAGNOSTICS [T10AP10] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AP10 : CHECK FUEL SUB LEVEL SEN- SOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel sub level sensor. <Ref. to 2-8 [W6A0].>...
  • Page 450 DIAGNOSTICS [T10AQ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AQ: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 451 DIAGNOSTICS [T10AQ4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AQ2 : CHECK INPUT SIGNAL FOR ECM. 10AQ3 : CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to ON. (Engine OFF) 1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and 2) Disconnect combination meter connector (i10) chassis ground.
  • Page 452 DIAGNOSTICS [T10AQ5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AQ5 : CHECK HARNESS BETWEEN 10AQ7 : CHECK FUEL TANK CORD. FUEL TANK CORD AND CHASSIS GROUND. 1) Disconnect connector from fuel sub level sen- sor. Measure resistance between fuel tank cord and 2) Measure resistance between fuel level sensor chassis ground.
  • Page 453 DIAGNOSTICS [T10AQ10] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AQ9 : CHECK FUEL LEVEL SENSOR. 10AQ10 : CHECK FUEL SUB LEVEL SEN- SOR. WARNING: WARNING: During work procedures, if fuel tank is more During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill.
  • Page 454 DIAGNOSTICS [T10AR0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AR: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Radiator fan does not operate properly. ¼...
  • Page 455 : Repair ground short circuit in radiator Radiator fan relay operation can be executed using fan relay control circuit. Subaru Select Monitor. For procedure, refer to : Go to step 10AR3. “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 456 DIAGNOSTICS [T10AR4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AR4 : CHECK MAIN FAN RELAY. 10AR6 : CHECK POOR CONTACT. Check poor contact in ECM or main fan relay con- 1) Turn ignition switch to OFF. nector. <Ref. to FOREWORD [T3C1].> 2) Measure resistance between main fan relay ter- minals.
  • Page 457 DIAGNOSTICS [T10AR6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 458 DIAGNOSTICS [T10AS0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AS: DTC P0483 — COOLING FAN FUNCTION PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Occurrence of noise ¼ Overheating CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 459 DIAGNOSTICS [T10AS1] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AS1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Is there any other DTC on display? : Inspect the relevant DTC using “10. Diagnostics Chart with Trouble Code for 2200 cc Models”.
  • Page 460 : Check speedometer and vehicle speed 10AT2 : CHECK DTC P0720 ON DISPLAY. sensor. <Ref. to 6-2 [K3A0].> : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0720? : Check vehicle speed sensor 2 signal cir- cuit.
  • Page 461 DIAGNOSTICS [T10AT4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AT4 : CHECK HARNESS BETWEEN ECM AND COMBINATION METER CON- NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from combination meter. 3) Measure resistance between ECM and combi- nation meter.
  • Page 462 DIAGNOSTICS [T10AU0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AU: DTC P0505 — IDLE CONTROL SYSTEM CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 463 DIAGNOSTICS [T10AU2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AU1 : CHECK OUTPUT SIGNAL FROM 10AU2 : CHECK POWER SUPPLY TO IDLE ECM. AIR CONTROL SOLENOID VALVE. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connector from idle air control sole- ground.
  • Page 464 DIAGNOSTICS [T10AU3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AU3 : CHECK HARNESS BETWEEN ECM 10AU4 : CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLE- AND IDLE AIR CONTROL SOLE- NOID VALVE CONNECTOR. NOID VALVE CONNECTOR. Measure resistance of harness between ECM and 1) Turn ignition switch to OFF.
  • Page 465 DIAGNOSTICS [T10AU6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AU6 : CHECK POOR CONTACT. Check poor contact in ECM and idle air control solenoid valve connectors. <Ref. to FOREWORD [T3C1].> : Is there poor contact in ECM and idle air control solenoid valve connec- tors? : Repair poor contact in ECM and idle air...
  • Page 466 H2M3569 10AV1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0505 or P1505? : Inspect DTC P0505 or P1505 using “10. Diagnostics Chart with Trouble Code for 2200 cc Models”.
  • Page 467 2) Start engine, and warm-up the engine. 3) Turn all accessory switches to OFF. 4) Read data of idle air control solenoid valve duty ratio using Subaru Select Monitor or OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedures, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 468 CHECK ANY OTHER DTC ON DIS- 10AW2 : CHECK THROTTLE CABLE. PLAY. : Does throttle cable have play for : Does the Subaru Select Monitor or adjustment? OBD-II general scan tool indicate : Go to step 10AW3. DTC P0505 or P1505? : Adjust throttle cable.
  • Page 469 DIAGNOSTICS [T10AW3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AW3 : CHECK AIR INTAKE SYSTEM. 1) Turn ignition switch to ON. 2) Start engine, and idle it. 3) Check the following items. ¼ Loose installation of intake manifold, idle air control solenoid valve and throttle body ¼...
  • Page 470 ¼ WIRING DIAGRAM: H2M3570 10AX1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0601? : Replace ECM. <Ref. to 2-7 [W19A0].> : It is not necessary to inspect DTC...
  • Page 471 DIAGNOSTICS [T10AX1] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 472 DIAGNOSTICS [T10AY0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AY: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 473 DIAGNOSTICS [T10AY4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AY2 : CHECK HARNESS BETWEEN TCM 10AY3 : CHECK HARNESS BETWEEN TCM AND BRAKE LIGHT SWITCH CON- AND BRAKE LIGHT SWITCH CON- NECTOR. NECTOR. 1) Disconnect connectors from TCM and brake Measure resistance of harness between TCM and light switch.
  • Page 474 DIAGNOSTICS [T10AY5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10AY5 : CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 24 (+) — Chassis ground (−): B2M2549A : Is the voltage more than 10 V when depressing the brake pedal? : Go to step 10AY6.
  • Page 475 DIAGNOSTICS [T10BC0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models AZ: DTC P0705 — TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Starter does not rotate when selector lever is in “P” or “N” range. ¼...
  • Page 476 DIAGNOSTICS [T10BD0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BD: DTC P0725 — ENGINE SPEED INPUT CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) ¼...
  • Page 477 DIAGNOSTICS [T10BH6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BH: DTC P0734 — GEAR 4 INCORRECT RATIO — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces- sive tight corner “braking”...
  • Page 478 DIAGNOSTICS [T10BI0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BI: DTC P0740 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) ¼...
  • Page 479 DIAGNOSTICS [T10BI10] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BI7 : CHECK BRAKE LIGHT SWITCH CIRCUIT. Check brake light switch circuit. <Ref. to 2-7 [T11AW0].> : Is there any trouble in brake light switch circuit? : Repair or replace brake light switch cir- cuit.
  • Page 480 DIAGNOSTICS [T10BJ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BJ: DTC P0743 — TORQUE CONVERTER CLUTCH SYSTEM (LOCK-UP DUTY SOLENOID) ELECTRICAL — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 481 DIAGNOSTICS [T10BN1] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BN: DTC P1100 — STARTER SWITCH CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 482 DIAGNOSTICS [T10BO0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BO: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [MT VEHICLES] OR NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [AT VEHICLES]— ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼...
  • Page 483 DIAGNOSTICS [T10BO5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BO1 : CHECK TRANSMISSION TYPE. 10BO4 : CHECK POOR CONTACT. : Is transmission type MT? Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> : Go to step 10BO2. : Is there poor contact in ECM connec- : Go to step 10BO8.
  • Page 484 10BO8 : CHECK DTC P0705 ON DISPLAY. B2M2091A : Does the Subaru Select Monitor or : Is the voltage between 4.5 and 5.5 V? OBD-II general scan tool indicate DTC P0705? : Go to step 10BO11.
  • Page 485 DIAGNOSTICS [T10BO13] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BO11 : CHECK POOR CONTACT. 10BO13 : CHECK HARNESS BETWEEN ECM AND INHIBITOR SWITCH CONNECTOR. Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> 1) Turn ignition switch to OFF. : Is there poor contact in ECM connec- 2) Disconnect connectors from ECM and inhibitor tor?
  • Page 486 DIAGNOSTICS [T10BO14] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BO14 : CHECK INHIBITOR SWITCH 10BO15 : CHECK INHIBITOR SWITCH. GROUND LINE. Measure resistance between inhibitor switch con- nector receptacle’s terminals in selector lever “N” Measure resistance of harness between inhibitor and “P”...
  • Page 487 DIAGNOSTICS [T10BO16] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 488 DIAGNOSTICS [T10BP0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BP: DTC P1103 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 489 DIAGNOSTICS [T10BP6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BP3 : CHECK POOR CONTACT. 10BP5 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Check poor contact in ECM connector. <Ref. to Measure resistance of harness between ECM and FOREWORD [T3C1].>...
  • Page 490 DIAGNOSTICS [T10BQ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BQ: DTC P1106 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 491 DIAGNOSTICS [T10BQ6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BQ3 : CHECK POOR CONTACT. 10BQ5 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Check poor contact in ECM connector. <Ref. to Measure resistance of harness between ECM and FOREWORD [T3C1].>...
  • Page 492 After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. 10BR1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1110? : Replace ECM. <Ref. to 2-7 [W19A0].> NOTE: Atmospheric pressure sensor is built into ECM.
  • Page 493 After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. 10BS1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1111? : Replace ECM. <Ref. to 2-7 [W19A0].> NOTE: Atmospheric pressure sensor is built into ECM.
  • Page 494 INSPECTION MODE <Ref. to 2-7 [T3E0].>. 10BT1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0106, P0107, P0108, P1110 or P1111? : Inspect DTC P0106, P0107, P0108, P1110 or P1111 using “10.
  • Page 495 DIAGNOSTICS [T10BT1] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 496 DIAGNOSTICS [T10BU0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BU: DTC P1115 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 497 DIAGNOSTICS [T10BU2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BU1 : CHECK OUTPUT SIGNAL FROM 10BU2 : CHECK HARNESS BETWEEN ECM ECM. AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 1) Start engine, and warm-up the engine. 2) Measure voltage between ECM and chassis 2) Turn ignition swtich to OFF.
  • Page 498 DIAGNOSTICS [T10BV0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BV: DTC P1116 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 499 DIAGNOSTICS [T10BV3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BV3 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure resistance of harness betwee ECM and TCM connector. Connector & terminal (B134) No. 31 — (B54) No. 2: B2M2714A : Is the resistance less than 1 Ω? : Repair poor contact in ECM or TCM...
  • Page 500 DIAGNOSTICS [T10BW0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BW: DTC P1120 — STARTER SWITCH CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 501 DIAGNOSTICS [T10BW1] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 502 DIAGNOSTICS [T10BX0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BX: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [MT VEHICLES] OR NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [AT VEHICLES] — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼...
  • Page 503 DIAGNOSTICS [T10BX5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BX1 : CHECK TRANSMISSION TYPE. 10BX4 : CHECK POOR CONTACT. : Is transmission type MT? Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> : Go to step 10BX2. : Is there poor contact in ECM connec- : Go to step 10BX9.
  • Page 504 Inspection by DTM is required, because probable cause is deterioration of multiple parts. 10BX9 : CHECK DTC P0705 ON DISPLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0705? : Inspect DTC P0705 using “10. Diagnos- tics Chart with Trouble Code for 2200 cc Models”.
  • Page 505 DIAGNOSTICS [T10BX11] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BX10 : CHECK INPUT SIGNAL FOR 10BX11 : CHECK HARNESS BETWEEN ECM. ECM AND TRANSMISSION HAR- NESS CONNECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connectors from ECM and trans- ground.
  • Page 506 DIAGNOSTICS [T10BX12] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BX12 : CHECK TRANSMISSION HAR- 10BX14 : CHECK SELECTOR CABLE CON- NESS CONNECTOR. NECTION. : Is there any fault in selector cable 1) Disconnect connector from inhibitor switch. connection to inhibitor switch? 2) Measure resistance of harness between trans- mission harness connector and engine ground.
  • Page 507 DIAGNOSTICS [T10BX14] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 508 DIAGNOSTICS [T10BY0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BY: DTC P1130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 509 DIAGNOSTICS [T10BY3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BY1 : CHECK HARNESS BETWEEN ECM 10BY2 : CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SEN- AND FRONT OXYGEN (A/F) SEN- SOR CONNECTOR. SOR CONNECTOR. Measure resistance of harness between ECM and 1) Turn ignition switch to OFF.
  • Page 510 DIAGNOSTICS [T10BZ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models BZ: DTC P1131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 511 DIAGNOSTICS [T10BZ4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BZ1 : CHECK HARNESS BETWEEN ECM 10BZ3 : CHECK OUTPUT SIGNAL FOR AND FRONT OXYGEN (A/F) SEN- ECM. SOR CONNECTOR. 1) Connect connector to ECM. 1) Turn ignition switch to OFF. 2) Turn ignition switch to ON.
  • Page 512 DIAGNOSTICS [T10BZ5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10BZ5 : CHECK OUTPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 20 (+) — Chassis ground (−): B2M2466A : Is the voltage more than 4.95 V? : Go to step 10BZ6.
  • Page 513 DIAGNOSTICS [T10BZ6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 514 ¼ WIRING DIAGRAM: H2M3544 10CA1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1132 and P0141 at the same time? : Go to step 10CA2. : Go to step 10CA5.
  • Page 515 DIAGNOSTICS [T10CA3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CA2 : CHECK GROUND CIRCUIT OF 10CA3 : CHECK GROUND CIRCUIT OF ECM. ECM. Measure resistance of harness between ECM con- 1) Repair harness and connector. nector and chassis ground. NOTE: Connector &...
  • Page 516 1) Start engine 1) Disconnect connectors from ECM. 2) Read data of front oxygen (A/F) sensor heater 2) Turn ignition switch to ON. current using Subaru Select Monitor or OBD-II 3) Measure power supply voltage between ECM general scan tool. connector terminals.
  • Page 517 DIAGNOSTICS [T10CA10] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CA8 : CHECK OUTPUT SIGNAL FROM 10CA10 : CHECK OUTPUT SIGNAL FROM ECM. ECM. Measure voltage between ECM connector and Measure voltage between ECM connector and chassis ground. chassis ground.
  • Page 518 DIAGNOSTICS [T10CA11] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CA11 : CHECK POWER SUPPLY TO 10CA12 : CHECK FRONT OXYGEN (A/F) FRONT OXYGEN (A/F) SENSOR. SENSOR. 1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF. 2) Measure resistance between front oxygen (A/F) 2) Disconnect connector from front oxygen (A/F) sensor connector terminals.
  • Page 519 DIAGNOSTICS [T10CA12] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 520 DIAGNOSTICS [T10CB0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CB: DTC P1133 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 521 3) Turn ignition switch to ON. Connector & terminal 4) Read data of front oxygen (A/F) sensor heater (B134) No. 23 (+) — Chassis ground (−): current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 522 DIAGNOSTICS [T10CB5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CB5 : CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 22 (+) — Chassis ground (−): B2M2468A : Does the voltage change more than 8 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
  • Page 523 ¼ WIRING DIAGRAM: H2M3544 10CC1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1134? : Replace ECM. <Ref. to 2-7 [W19A0].> : It is not necessary to inspect DTC...
  • Page 524 DIAGNOSTICS [T10CD0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CD: DTC P1139 — FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 525 DIAGNOSTICS [T10CD3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CD1 : CHECK HARNESS BETWEEN ECM 10CD2 : CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SEN- AND FRONT OXYGEN (A/F) SEN- SOR CONNECTOR. SOR CONNECTOR. 1) Start engine, and warm-up the engine. Measure resistance of harness between ECM and 2) Turn ignition switch to OFF.
  • Page 526 DIAGNOSTICS [T10CD4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CD4 : CHECK HARNESS BETWEEN ECM 10CD6 : CHECK POOR CONTACT. AND FRONT OXYGEN (A/F) SEN- SOR CONNECTOR. Check poor contact in ECM and front oxygen (A/F) sensor connector. <Ref. to FOREWORD [T3C1].> Measure resistance of harness between ECM and : Is there poor contact in ECM or front front oxygen (A/F) sensor connector.
  • Page 527 DIAGNOSTICS [T10CD6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 528 DIAGNOSTICS [T10CE0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CE: DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 529 10CE2 : CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pres- sure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 530 DIAGNOSTICS [T10CF0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CF: DTC P1151 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 531 3) Operate the INSPECTION MODE. <Ref. to 2-7 Measure voltage between ECM connector and [T3E1].> chassis ground. : Does the Subaru Select Monitor or Connector & terminal OBD-II general scan tool indicate (B134) No. 21 (+) — Chassis ground (−): DTC P1151? : Replace ECM.
  • Page 532 DIAGNOSTICS [T10CF5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CF5 : CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 21 (+) — Chassis ground (−): B2M2483A : Does the voltage change more than 8 V by shaking coupling connector (E2) while monitoring the value with volt- age meter?
  • Page 533 DIAGNOSTICS [T10CF5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 534 DIAGNOSTICS [T10CG0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CG: DTC P1400 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 535 DIAGNOSTICS [T10CG3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CG1 : CHECK OUTPUT SIGNAL FROM 10CG3 : CHECK HARNESS BETWEEN ECM. FUEL TANK PRESSURE CON- TROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis 1) Turn ignition switch to OFF.
  • Page 536 DIAGNOSTICS [T10CG4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CG4 : CHECK HARNESS BETWEEN 10CG5 : CHECK FUEL TANK PRESSURE FUEL TANK PRESSURE CON- CONTROL SOLENOID VALVE. TROL SOLENOID VALVE AND ECM CONNECTOR. Measure resistance between fuel tank pressure control solenoid valve terminals.
  • Page 537 DIAGNOSTICS [T10CG7] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CG6 : CHECK POWER SUPPLY TO FUEL TANK PRESSURE CONTROL SOLENOID VALVE. 1) Turn ignition switch to ON. 2) Measure voltage between fuel tank pressure control solenoid valve and chassis ground. Connector &...
  • Page 538 DIAGNOSTICS [T10CH0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CH: DTC P1420 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 539 : Go to step 10CH4. : Go to step 10CH3. NOTE: Fuel tank pressure control solenoid valve opera- tion can be executed using Subaru Select Monitor. 10CH3 : CHECK POOR CONTACT. For procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 Check poor contact in ECM connector.
  • Page 540 DIAGNOSTICS [T10CH4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CH4 : CHECK HARNESS BETWEEN 10CH5 : CHECK FUEL TANK PRESSURE FUEL TANK PRESSURE CONTROL CONTROL SOLENOID VALVE. SOLENOID VALVE AND ECM CON- NECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between fuel tank pressure control solenoid valve terminals.
  • Page 541 DIAGNOSTICS [T10CH6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 542 DIAGNOSTICS [T10CI0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CI: DTC P1422 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼...
  • Page 543 : Go to step 10CI4. : Go to step 10CI3. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For 10CI3 : CHECK POOR CONTACT. procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 Check poor contact in ECM connector.
  • Page 544 DIAGNOSTICS [T10CI4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CI4 : CHECK HARNESS BETWEEN 10CI5 : CHECK PURGE CONTROL SOLE- PURGE CONTROL SOLENOID NOID VALVE. VALVE AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between purge control 1) Turn ignition switch to OFF.
  • Page 545 DIAGNOSTICS [T10CI6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 546 DIAGNOSTICS [T10CJ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CJ: DTC P1423 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 547 ECM and chassis ground. : Go to step 10CJ4. NOTE: : Go to step 10CJ3. Drain valve operation can be excecuted using Subaru Select Monitor. For procedure, refer to “COMPULSORY VALVE OPERATION CHECK 10CJ3 : CHECK POOR CONTACT. MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 548 DIAGNOSTICS [T10CJ4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CJ4 : CHECK HARNESS BETWEEN 10CJ5 : CHECK DRAIN VALVE. DRAIN VALVE AND ECM CONNEC- TOR. 1) Turn ignition switch to OFF. 2) Measure resistance between drain valve termi- nals.
  • Page 549 DIAGNOSTICS [T10CJ6] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 550 DIAGNOSTICS [T10CK0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CK: DTC P1443 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL FUNCTION PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Immediately after fault occurrence ¼ TROUBLE SYMPTOM: ¼ Improper fuel supply CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 551 3) Turn ignition switch to ON. NOTE: Drain valve operating check can also be executed H2M2482B using Subaru Select Monitor. For the procedure, refer to the “COMPULSORY VALVE OPERATION : Is there a fault in vent line? CHECK MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 552 DIAGNOSTICS [T10CL0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CL: DTC P1505 — IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 553 DIAGNOSTICS [T10CL3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CL2 : CHECK OUTPUT SIGNAL FROM 10CL3 : CHECK OUTPUT SIGNAL FROM ECM. ECM. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connector from idle air control sole- ground.
  • Page 554 DIAGNOSTICS [T10CL4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CL4 : CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 5 (+) — Chassis ground (−): B2M2660A : Does the voltage change more than 10 V by shaking harness and connec- tor of ECM while monitoring the value with voltage meter?
  • Page 555 DIAGNOSTICS [T10CL4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 556 CHECK ANY OTHER DTC ON DIS- 10CM2 : CHECK THROTTLE CABLE. PLAY. : Does throttle cable have play for : Does the Subaru Select Monitor or adjustment? OBD-II general scan tool indicate : Go to step 10CM2. DTC P0116 or P0117 or P0505 or : Adjust throttle cable.
  • Page 557 DIAGNOSTICS [T10CM3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CM3 : CHECK AIR INTAKE SYSTEM. 1) Turn ignition switch to ON. 2) Start engine, and idle it. 3) Check the following items. ¼ Loose installation of intake manifold, idle air control solenoid valve and throttle body ¼...
  • Page 558 DIAGNOSTICS [T10CN0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CN: DTC P1520 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Radiator fan does not operate properly. ¼...
  • Page 559 ECM and chassis ground. NOTE: Radiator fan relay operation can be executed using B2M2654A Subaru Select Monitor. For procedure, refer to “COMPULSORY VALVE OPERATION CHECK : Is the voltage more than 10 V? MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 560 DIAGNOSTICS [T10CN3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CN3 : CHECK MAIN FAN RELAY. 10CN5 : CHECK POOR CONTACT. Check poor contact in ECM connector. <Ref. to 1) Turn ignition switch to OFF. FOREWORD [T3C1].> 2) Remove main fan relay. 3) Measure resistance between main fan relay ter- : Is there poor contact in ECM connec- minals.
  • Page 561 DIAGNOSTICS [T10CN5] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 562 DIAGNOSTICS [T10CO0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CO: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 563 DIAGNOSTICS [T10CO3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CO1 : CHECK INPUT SIGNAL FOR ECM. 10CO3 : CHECK FUSE SBF-5. : Is fuse blown? 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis : Replace fuse.
  • Page 564 DIAGNOSTICS [T10CP0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CP: DTC P1700 — THROTTLE POSITION SENSOR CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces- sive tight corner “braking”...
  • Page 565 DIAGNOSTICS [T10CP0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models MEMO:...
  • Page 566 DIAGNOSTICS [T10CQ0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CQ: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 567 DIAGNOSTICS [T10CQ4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CQ3 : CHECK INPUT SIGNAL FOR TCM. 10CQ4 : CHECK POOR CONTACT. 1) Connect connector to TCM and CCM. Check poor contact in TCM connector. <Ref. to 2) Lift-up the vehicle or set the vehicle on free FOREWORD [T3C1].>...
  • Page 568 DIAGNOSTICS [T10CR0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CR: DTC P1702 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 569 DIAGNOSTICS [T10CR3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CR1 : CHECK HARNESS BETWEEN ECM 10CR2 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. AND TCM CONNECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connector from ECM and TCM.
  • Page 570 DIAGNOSTICS [T10CR4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CR4 : CHECK TROUBLE CODE FOR AUTOMATIC TRANSMISSION. Read trouble code for automatic transmission. <Ref. to 3-2 [T8A0].> : Does trouble code appear for auto- matic transmission? : Inspect trouble code for automatic trans- mission.
  • Page 571 DIAGNOSTICS [T10CU0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CS: DTC P1703 — LOW CLUTCH TIMING CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 572 DIAGNOSTICS [T10CV0] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CV: DTC P1722 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 573 DIAGNOSTICS [T10CV3] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CV1 : CHECK HARNESS BETWEEN ECM 10CV3 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. AND TCM CONNECTOR. 1) Turn ignition switch to ON. Measure voltage between ECM connector and 2) Measure voltage between ECM and chassis chassis ground.
  • Page 574 DIAGNOSTICS [T10CV4] 10. Diagnostics Chart with Trouble Code for 2200 cc Models 10CV4 : CHECK OUTPUT SIGNAL FROM 10CV5 : CHECK HARNESS BETWEEN ECM ECM. AND TCM CONNECTOR. Measure voltage between TCM and chassis Measure voltage between ECM and chassis ground.
  • Page 575 DIAGNOSTICS [T10CW2] 10. Diagnostics Chart with Trouble Code for 2200 cc Models CW: DTC P1742 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 576 DIAGNOSTICS [T11A0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11. Diagnostics Chart with Trouble Code for 2500 cc Models A: DIAGNOSTIC TROUBLE CODE (DTC) LIST Item Index P0106 Pressure sensor circuit range/performance problem <Ref. to 2-7 [T11B0].> P0107 Pressure sensor circuit low input <Ref.
  • Page 577 DIAGNOSTICS [T11A0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models Item Index P0325 Knock sensor circuit high input <Ref. to 2-7 [T11AA0].> P0335 Crankshaft position sensor circuit malfunction <Ref. to 2-7 [T11AB0].> P0336 Crankshaft position sensor circuit range/performance problem <Ref.
  • Page 578 DIAGNOSTICS [T11A0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models Item Index P0725 Engine speed input circuit malfunction <Ref. to 2-7 [T11BB0].> P0731 Gear 1 incorrect ratio <Ref. to 2-7 [T11BC0].> P0732 Gear 2 incorrect ratio <Ref. to 2-7 [T11BD0].>...
  • Page 579 DIAGNOSTICS [T11A0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models Item Index P1207 Air assist injector solenoid valve circuit low input <Ref. to 2-7 [T11CC0].> P1208 Air assist injector solenoid valve circuit high input <Ref. to 2-7 [T11CD0].> P1325 Knock sensor circuit low input <Ref.
  • Page 580 DIAGNOSTICS [T11A0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models Item Index P1704 2-4 brake timing control solenoid valve circuit malfunction <Ref. to 2-7 [T11DD0].> P1705 2-4 brake pressure control solenoid valve (2-4 brake duty solenoid) circuit malfunction <Ref.
  • Page 581 DIAGNOSTICS [T11A0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 582 In this case, it is not necessary to inspect DTC tem? P0106. : Repair air intake system. : Does the Subaru Select Monitor or : Go to step 11B3. OBD-II general scan tool indicate DTC P0107, P0108 or P1112? : Inspect DTC P0107, P0108 or P1112 using “11.
  • Page 583 11B3 : CHECK PRESSURE SENSOR. 11B4 : CHECK THROTTLE POSITION. Read data of throttle position signal using Subaru 1) Start the engine and warm-up engine until cool- Select Monitor or OBD-II general scan tool. ant temperature is greater than 60°C (140°F).
  • Page 584 DIAGNOSTICS [T11C0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models C: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 585 1) Start engine. Measure voltage between ECM connector and 2) Read the data of intake manifold absolute pres- chassis ground. sure signal using Subaru Select Monitor or OBD-II Connector & terminal general scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 586 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11C6 : CHECK INPUT SIGNAL FOR ECM. 11C8 : CHECK HARNESS BETWEEN ECM (USING SUBARU SELECT MONI- AND INTAKE AIR TEMPERATURE TOR.) AND PRESSURE SENSOR CON- NECTOR. Read data of atmospheric absolute pressure signal 1) Turn ignition switch to OFF.
  • Page 587 DIAGNOSTICS [T11C10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11C9 : CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CON- NECTOR. Measure resistance of harness between intake air temperature and pressure sensor connector and engine ground.
  • Page 588 DIAGNOSTICS [T11D0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models D: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 589 1) Start engine. Measure voltage between ECM connector and 2) Read the data of intake manifold absolute pres- chassis ground. sure signal using Subaru Select Monitor or OBD-II Connector & terminal general scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 590 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11D5 : CHECK INPUT SIGNAL FOR ECM. 11D7 : CHECK HARNESS BETWEEN ECM (USING SUBARU SELECT MONI- AND INTAKE AIR TEMPERATURE TOR.) AND PRESSURE SENSOR CON- NECTOR. Read data of atmospheric absolute pressure signal 1) Turn ignition switch to OFF.
  • Page 591 AND PRESSURE SENSOR CON- NECTOR. NECTOR. Measure resistance of harness between ECM and 1) Turn ignition switch to OFF and Subaru Select intake air temperature and pressure sensor con- Monitor or the OBD-II general scan tool switch to nector. OFF.
  • Page 592 DIAGNOSTICS [T11E0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models E: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 593 CHECK ENGINE COOLANT TEM- PERATURE. 1) Start the engine and warm it up completely. 2) Measure engine coolant temperature using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 594 DIAGNOSTICS [T11F0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models F: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 595 11F1 : CHECK CURRENT DATA. 1) Start engine. 2) Read data of intake air temperature sensor sig- nal using Subaru Select Monitor or the OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 596 DIAGNOSTICS [T11G0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models G: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 597 PRESSURE SENSOR AND ECM 1) Start engine. CONNECTOR. 2) Read data of intake air temperature sensor sig- nal using Subaru Select Monitor or the OBD-II gen- 1) Turn ignition switch to OFF. eral scan tool. 2) Disconnect connector from intake air tempera- NOTE: ture and pressure sensor.
  • Page 598 DIAGNOSTICS [T11G3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11G3 : CHECK HARNESS BETWEEN 11G4 : CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM PRESSURE SENSOR AND ECM CONNECTOR. CONNECTOR. 1) Turn ignition switch to ON.
  • Page 599 DIAGNOSTICS [T11G5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11G5 : CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between intake air temperature and pressure sensor connector and engine ground.
  • Page 600 DIAGNOSTICS [T11H0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models H: DTC P0116 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Hard to start ¼...
  • Page 601 ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of engine coolant temperature sen- sor signal using Subaru Select Monitor or OBD-II 1) Turn ignition switch to OFF. general scan tool. 2) Disconnect connector from engine coolant tem- perature sensor.
  • Page 602 DIAGNOSTICS [T11I0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models I: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Hard to start ¼...
  • Page 603 ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of engine coolant temperature sen- sor signal using Subaru Select Monitor or OBD-II 1) Turn ignition switch to OFF. general scan tool. 2) Disconnect connector from engine coolant tem- perature sensor.
  • Page 604 DIAGNOSTICS [T11I3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11I3 : CHECK HARNESS BETWEEN 11I4 : CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. Measure voltage between engine coolant tempera- 2) Measure voltage between engine coolant tem- ture sensor connector and engine ground.
  • Page 605 DIAGNOSTICS [T11I5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11I5 : CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between engine coolant temperature sensor connector and engine ground.
  • Page 606 H2M3577 11J1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0122 or P0123? : Inspect DTC P0122 or P0123 using “11. Diagnostics Chart with Trouble Code for 2500 cc Models”.
  • Page 607 DIAGNOSTICS [T11J1] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 608 DIAGNOSTICS [T11K0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models K: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 609 1) Start engine. Measure voltage between ECM connector and 2) Read data of throttle position sensor signal chassis ground. using Subaru Select Monitor or OBD-II general Connector & terminal scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 610 Connector & terminal 0.1 V by shaking harness and con- (B136) No. 17 — (E13) No. 3: nector of ECM while monitoring the value with Subaru Select Monitor? : Repair poor contact in ECM connector. : Go to step 11K6. 11K6 :...
  • Page 611 DIAGNOSTICS [T11K9] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11K8 : CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 — Engine ground: B2M2706A : Is the resistance less than 10 Ω? : Repair ground short circuit in harness...
  • Page 612 DIAGNOSTICS [T11L0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models L: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 613 THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of throttle position sensor signal 1) Turn ignition switch to OFF. using Subaru Select Monitor or OBD-II general 2) Disconnect connector from throttle position scan tool. sensor. NOTE: 3) Measure resistance of harness between throttle ¼...
  • Page 614 DIAGNOSTICS [T11L3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11L3 : CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between throttle position sen- sor connector and engine ground. Connector &...
  • Page 615 H2M3542 11M1 : CHECK ANY OTHER DTC ON DIS- 11M2 : CHECK THERMOSTAT. PLAY. : Does thermostat remain opened? : Does the Subaru Select Monitor or : Replace thermostat. <Ref. OBD-II general scan tool indicate [W2A0].> DTC P0116 or P0117? : Replace engine coolant temperature : Inspect DTC P0116 or P0117 using “11.
  • Page 616 H2M3578 11N1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1130, P1131, P1132 or P1133? : Inspect DTC P1130, P1131, P1132 or P1133 using “11. Diagnostics Chart with Trouble Code for 2500 cc Models”.
  • Page 617 SOR. 1) Start engine. 1) Turn ignition switch to OFF. 2) While observing the Subaru Select Monitor or 2) Disconnect connector from ECM and front oxy- OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70°C gen (A/F) sensor connector.
  • Page 618 DIAGNOSTICS [T11N5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11N5 : CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SEN- SOR. Measure resistance between ECM and chassis ground. Connector & terminals (B136) No. 6 — Chassis ground: (B136) No.
  • Page 619 CHECK ANY OTHER DTC ON DIS- 11O2 : CHECK EXHAUST SYSTEM. PLAY. NOTE: : Does the Subaru Select Monitor or Check the following items. ¼ Loose installation of front portion of exhaust pipe OBD-II general scan tool indicate DTC P1130, P1131, P1132 or P1133? onto cylinder heads ¼...
  • Page 620 11P2 : CHECK FAILURE CAUSE OF P0130. PLAY. Inspect DTC P1130 or P1131 using “11. Diagnos- : Does the Subaru Select Monitor or tics Chart with Trouble Code for 2500 cc Models”. OBD-II general scan tool indicate <Ref. to 2-7 [T11A0].>...
  • Page 621 3) Measure resistance of harness between ECM 2) Read data of rear oxygen sensor signal using and rear oxygen sensor connector. Subaru Select Monitor or OBD-II general scan tool. Connector & terminal NOTE: ¼ Subaru Select Monitor (B136) No. 16 — (E25) No. 3: For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 622 DIAGNOSTICS [T11P6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11P6 : CHECK HARNESS BETWEEN REAR 11P7 : CHECK EXHAUST SYSTEM. OXYGEN SENSOR AND ECM CON- NECTOR. Check exhaust system parts. NOTE: 1) Turn ignition switch to OFF. Check the following items.
  • Page 623 ¼ WIRING DIAGRAM: H2M3627 11Q1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0136? : Inspect DTC P0136 using “11. Diagnos- tics Chart with Trouble Code for 2500 cc Models”.
  • Page 624 DIAGNOSTICS [T11R0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models R: DTC P0141 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 625 DIAGNOSTICS [T11R2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11R1 : CHECK GROUND CIRCUIT OF ECM. 11R2 : CHECK GROUND CIRCUIT OF ECM. 1) Turn ignition switch to OFF. 1) Repair harness and connector. 2) Disconnect connector from ECM. NOTE: 3) Measure resistance of harness between ECM In this case, repair the following:...
  • Page 626 1) Start engine. Measure voltage between ECM connector and 2) Read data of rear oxygen sensor heater current chassis ground. using Subaru Select Monitor or OBD-II general scan tool. Connector & terminal (B134) No. 21 (+) — Chassis ground (−): NOTE: ¼...
  • Page 627 DIAGNOSTICS [T11R8] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11R7 : CHECK POWER SUPPLY TO REAR 11R8 : CHECK REAR OXYGEN SENSOR. OXYGEN SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between rear oxygen sen- 1) Turn ignition switch to OFF.
  • Page 628 DIAGNOSTICS [T11S0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models S: DTC P0170 — FUEL TRIM MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. ¼...
  • Page 629 DIAGNOSTICS [T11S4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 4) Install fuel filler cap. 11S4 : CHECK FUEL PRESSURE. 5) Start the engine and idle while gear position is neutral. 6) Measure fuel pressure while disconnecting After connecting pressure regulator vacuum hose, pressure regulator vacuum hose from intake mani- measure fuel pressure.
  • Page 630 60°C (140°F). 2) Read data of engine coolant temperature sen- 2) Place the selector lever in “N” or “P” position. sor signal using Subaru Select Monitor or OBD-II 3) Turn A/C switch to OFF. general scan tool.
  • Page 631 H2M3014 11T1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0182 or P0183? : Inspect DTC P0182 or P0183 using “11. Diagnostics Chart with Trouble Code for 2500 cc Models”.
  • Page 632 DIAGNOSTICS [T11U0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models U: DTC P0182 — FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 633 2) Remove access hole lid. 3) Disconnect connector from fuel pump. 4) Turn ignition switch to ON. 5) Read data of fuel temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 634 DIAGNOSTICS [T11V0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models V: DTC P0183 — FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 635 TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Start engine. 2) Read data of fuel temperature sensor signal 1) Turn ignition switch to ON. using Subaru Select Monitor or OBD-II general 2) Measure voltage between fuel pump connector scan tool. and chassis ground. NOTE: ¼...
  • Page 636 DIAGNOSTICS [T11V4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11V4 : CHECK HARNESS BETWEEN FUEL 11V5 : CHECK HARNESS BETWEEN FUEL TEMPERATURE SENSOR AND ECM TEMPERATURE SENSOR AND ECM CONNECTOR. CONNECTOR. 1) Turn ignition switch to OFF. Measure voltage between fuel pump connector 2) Measure resistance of harness between fuel and chassis ground.
  • Page 637 DIAGNOSTICS [T11V5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 638 DIAGNOSTICS [T11W0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models W: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to 2-7 [T11Z0].> X: DTC P0302 — CYLINDER 2 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304.
  • Page 639 11Z3 : CHECK HARNESS BETWEEN FUEL PLAY. INJECTOR AND ECM CONNECTOR. : Does the Subaru Select Monitor or 1) Turn ignition switch to OFF. OBD-II general scan tool indicate 2) Disconnect connector from fuel injector on DTC P0106, P0107, P0108, P0116, faulty cylinders.
  • Page 640 DIAGNOSTICS [T11Z4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11Z4 : CHECK HARNESS BETWEEN FUEL 11Z5 : CHECK FUEL INJECTOR. INJECTOR AND ECM CONNECTOR. Measure resistance between fuel injector terminals Measure resistance of harness connector between on faulty cylinder. ECM connector and fuel injector on faulty cylin- Terminals ders.
  • Page 641 DIAGNOSTICS [T11Z7] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11Z6 : CHECK POWER SUPPLY LINE. 11Z7 : CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between fuel injector and 2) Disconnect connector from fuel injector on engine ground on faulty cylinders.
  • Page 642 DIAGNOSTICS [T11Z8] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11Z8 : CHECK FUEL INJECTOR. 11Z11 : CHECK INSTALLATION CONDITION OF TIMING BELT. 1) Turn ignition switch to OFF. Turn crankshaft using ST, and align alignment 2) Measure resistance between fuel injector termi- mark on crankshaft sprocket with alignment mark nals on faulty cylinder.
  • Page 643 ENGINE MALFUNCTION INDICA- TOR LAMP (MIL). : Is there a fault in air intake system? : Repair air intake system. 1) Clear memory using Subaru Select Monitor. NOTE: <Ref. to 2-7 [T3D0].> Check the following items: 2) Start engine, and drive the vehicle more than ¼...
  • Page 644 11Z23 : GROUP OF #3 AND #4 CYLINDERS CODE (DTC) ON DISPLAY. : Are there faults in #3 and #4 cylin- : Does the Subaru Select Monitor or ders? OBD-II general scan tool indicate : Repair or replace faulty parts.
  • Page 645 DIAGNOSTICS [T11Z26] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11Z26 : CYLINDER AT RANDOM : Is the engine idle rough? : Go to DTC P0170. <Ref. to 2-7 [T11S0].> : Repair or replace faulty parts. NOTE: Check the following items. ¼...
  • Page 646 DIAGNOSTICS [T11AA0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AA: DTC P0325 — KNOCK SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Poor driving performance ¼ Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 647 DIAGNOSTICS [T11AA4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AA1 : CHECK HARNESS BETWEEN 11AA3 : CHECK KNOCK SENSOR. KNOCK SENSOR AND ECM CON- NECTOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor 1) Turn ignition switch to OFF.
  • Page 648 DIAGNOSTICS [T11AA5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AA5 : CHECK KNOCK SENSOR. 11AA6 : CHECK INPUT SIGNAL FOR ECM. 1) Connect connectors to ECM and knock sensor. 1) Disconnect connector from knock sensor. 2) Turn ignition switch to ON. 2) Measure resistance between knock sensor 3) Measure voltage between ECM and chassis connector terminal and engine ground.
  • Page 649 DIAGNOSTICS [T11AA6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 650 DIAGNOSTICS [T11AB0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AB: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 651 DIAGNOSTICS [T11AB2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AB1 : CHECK HARNESS BETWEEN 11AB2 : CHECK HARNESS BETWEEN CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR AND ECM CONNECTOR. AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure resistance of harness between crank- 2) Disconnect connector from crankshaft position shaft position sensor connector and engine...
  • Page 652 DIAGNOSTICS [T11AB3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AB3 : CHECK HARNESS BETWEEN 11AB5 : CHECK CRANKSHAFT POSITION CRANKSHAFT POSITION SENSOR SENSOR. AND ECM CONNECTOR. 1) Remove crankshaft position sensor. 2) Measure resistance between connector termi- Measure resistance of harness between crank- nals of crankshaft position sensor.
  • Page 653 DIAGNOSTICS [T11AB5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 654 CHECK ANY OTHER DTC ON DIS- 11AC2 : CHECK CONDITION OF CRANK- PLAY. SHAFT POSITION SENSOR. : Does the Subaru Select Monitor or Turn ignition switch to OFF. OBD-II general scan tool indicate : Is the crankshaft position sensor DTC P0335? installation bolt tightened securely? : Inspect DTC P0335 using “11.
  • Page 655 DIAGNOSTICS [T11AC4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AC3 : CHECK CRANKSHAFT SPROCKET. Remove front belt cover. : Are crankshaft sprocket teeth cracked or damaged? : Replace crankshaft sprocket. <Ref. to 2-3 [W3A0].> : Go to step 11AC4. 11AC4 : CHECK INSTALLATION CONDI- TION OF TIMING BELT.
  • Page 656 DIAGNOSTICS [T11AD0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AD: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 657 DIAGNOSTICS [T11AD2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AD1 : CHECK HARNESS BETWEEN 11AD2 : CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR AND ECM CONNECTOR. AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure resistance of harness between camshaft 2) Disconnect connector from camshaft position position sensor connector and engine ground.
  • Page 658 DIAGNOSTICS [T11AD3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AD3 : CHECK HARNESS BETWEEN 11AD5 : CHECK CAMSHAFT POSITION CAMSHAFT POSITION SENSOR SENSOR. AND ECM CONNECTOR. 1) Remove camshaft position sensor. 2) Measure resistance between connector termi- Measure resistance of harness between camshaft nals of camshaft position sensor.
  • Page 659 DIAGNOSTICS [T11AD5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 660 ¼ WIRING DIAGRAM: B2M3562 11AE1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0340? : Inspect DTC P0340 using “11. Diagnos- tics Chart with Trouble Code for 2500 cc Models”.
  • Page 661 DIAGNOSTICS [T11AE3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AE2 : CHECK HARNESS BETWEEN 11AE3 : CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR AND ECM CONNECTOR. AND ECM CONNECTOR. 1) Turn ignition switch to OFF. Measure resistance of harness between camshaft 2) Disconnect connector from camshaft position position sensor connector and engine ground.
  • Page 662 DIAGNOSTICS [T11AE4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AE4 : CHECK HARNESS BETWEEN 11AE6 : CHECK CAMSHAFT POSITION CAMSHAFT POSITION SENSOR SENSOR. AND ECM CONNECTOR. 1) Remove camshaft position sensor. Measure resistance of harness between camshaft 2) Measure resistance between connector termi- position sensor connector and engine ground.
  • Page 663 DIAGNOSTICS [T11AE9] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AE9 : CHECK INSTALLATION CONDI- TION OF TIMING BELT. Turn camshaft using ST, and align alignment mark on camshaft sprocket with alignment mark on tim- ing belt cover LH. ST 499207100 CAMSHAFT SPROCKET WRENCH H2M3621A...
  • Page 664 DIAGNOSTICS [T11AF0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AF: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine stalls. ¼ Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 665 11AF3 : CHECK REAR CATALYTIC CON- PLAY. VERTER. Separate rear catalytic converter from rear exhaust : Does the Subaru Select Monitor or pipe. OBD-II general scan tool indicate DTC P0130, P0133, P0136, P0139, P0141, P0301, P0302, P0303, P0304, P1130, P1131, P1132, P1133 and P1151? : Inspect the relevant DTC using “11.
  • Page 666 DIAGNOSTICS [T11AG0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AG: DTC P0440 — EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Gasoline smell ¼ There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 667 3) Operate drain valve. <Ref. to 2-1 [W4A0].> NOTE: Drain valve operation can also be executed using Subaru Select Monitor. For the procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 [T3F0].> B2M1873E : Does drain valve produce operating sound? : Go to step 11AG5.
  • Page 668 1.0 mm (0.04 in) NOTE: dia. in it? Pressure control solenoid valve operation can also be executed using Subaru Select Monitor. For the : Repair or replace fuel tank. <Ref. to 2-8 procedure, refer to “COMPULSORY VALVE [W1C0].>...
  • Page 669 DIAGNOSTICS [T11AG10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 670 DIAGNOSTICS [T11AH0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AH: DTC P0442 — EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Gasoline smell ¼ There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 671 3) Operate drain valve. <Ref. to 2-1 [W4A0].> NOTE: Drain valve operation can also be executed using Subaru Select Monitor. For the procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 [T3F0].> B2M1873E : Does drain valve produce operating sound? : Go to step 11AH5.
  • Page 672 0.5 mm (0.020 in) NOTE: dia. in it? Pressure control solenoid valve operation can also be executed using Subaru Select Monitor. For the : Repair or replace fuel tank. <Ref. to 2-8 procedure, refer to “COMPULSORY VALVE [W1C0].>...
  • Page 673 DIAGNOSTICS [T11AH10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 674 DIAGNOSTICS [T11AI0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AI: DTC P0443 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼...
  • Page 675 DIAGNOSTICS [T11AI2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AI1 : CHECK OUTPUT SIGNAL FROM 11AI2 : CHECK HARNESS BETWEEN ECM. PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connectors from purge control sole- ground.
  • Page 676 DIAGNOSTICS [T11AI3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AI3 : CHECK HARNESS BETWEEN 11AI4 : CHECK PURGE CONTROL SOLE- PURGE CONTROL SOLENOID NOID VALVE. VALVE AND ECM CONNECTOR. 1) Remove purge control solenoid valve. Measure resistance of harness between ECM and 2) Measure resistance between purge control purge control solenoid valve of harness connector.
  • Page 677 DIAGNOSTICS [T11AI6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AI6 : CHECK POOR CONTACT. Check poor contact in purge control solenoid valve connector. <Ref. to FOREWORD [T3C1].> : Is there poor contact in purge control solenoid valve connector? : Repair poor contact in purge control solenoid valve connector.
  • Page 678 DIAGNOSTICS [T11AJ0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AJ: DTC P0446 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 679 DIAGNOSTICS [T11AJ3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AJ1 : CHECK OUTPUT SIGNAL FROM 11AJ3 : CHECK HARNESS BETWEEN ECM. DRAIN VALVE AND ECM CONNEC- TOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connectors from drain valve and ground.
  • Page 680 DIAGNOSTICS [T11AJ4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AJ4 : CHECK HARNESS BETWEEN 11AJ6 : CHECK POWER SUPPLY TO DRAIN VALVE AND ECM CONNEC- DRAIN VALVE. TOR. 1) Turn ignition switch to ON. 2) Measure voltage between drain valve and Measure resistance of harness between ECM and chassis ground.
  • Page 681 DIAGNOSTICS [T11AK3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AK: DTC P0451 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR RANGE/PERFORMANCE PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 682 DIAGNOSTICS [T11AL0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AL: DTC P0452 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 683 4) Turn ignition switch to ON. Connector & terminal 5) Read the data of fuel tank pressure sensor sig- (B136) No. 15 (+) — Chassis ground (−): nal using Subaru Select Monitor or the OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 684 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AL5 : CHECK INPUT SIGNAL FOR ECM. 11AL6 : CHECK HARNESS BETWEEN ECM (USING SUBARU SELECT MONI- AND COUPLING CONNECTOR IN TOR.) REAR WIRING HARNESS. Read data of fuel tank pressure sensor signal 1) Turn ignition switch to OFF.
  • Page 685 DIAGNOSTICS [T11AL9] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AL7 : CHECK HARNESS BETWEEN ECM 11AL8 : CHECK HARNESS BETWEEN ECM AND COUPLING CONNECTOR IN AND COUPLING CONNECTOR IN REAR WIRING HARNESS. REAR WIRING HARNESS. 1) Turn ignition switch to OFF. Measure resistance of harness between rear wir- 2) Disconnect connector from ECM.
  • Page 686 DIAGNOSTICS [T11AL10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AL10 : CHECK FUEL TANK CORD. 11AL12 : CHECK POOR CONTACT. Check poor contact in fuel tank pressure sensor Measure resistance of fuel tank cord. connector. <Ref. to FOREWORD [T3C1].> Connector &...
  • Page 687 DIAGNOSTICS [T11AL12] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 688 DIAGNOSTICS [T11AM0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AM: DTC P0453 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 689 4) Turn ignition switch to ON. Connector & terminal 5) Read data of fuel tank pressure sensor signal (B136) No. 15 (+) — Chassis ground (−): using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 690 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AM5 : CHECK INPUT SIGNAL FOR ECM. 11AM7 : CHECK HARNESS BETWEEN ECM (USING SUBARU SELECT MONI- AND COUPLING CONNECTOR IN TOR.) REAR WIRING HARNESS. Read data of fuel tank pressure sensor signal 1) Turn ignition switch to OFF.
  • Page 691 DIAGNOSTICS [T11AM11] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AM8 : CHECK HARNESS BETWEEN ECM 11AM10 : CHECK FUEL TANK CORD. AND COUPLING CONNECTOR IN REAR WIRING HARNESS. Measure resistance of fuel tank cord. Connector & terminal Measure resistance of harness between rear wir- (R57) No.
  • Page 692 2) Disconnect connector from fuel tank pressure sensor. 3) Turn ignition switch to ON. 4) Read data of fuel tank pressure sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 693 H2M3558 11AN1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0462 or P0463? : Inspect DTC P0462 or P0463 using “11. Diagnostics Chart with Trouble Code for 2500 cc Models”.
  • Page 694 DIAGNOSTICS [T11AO0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AO: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 695 (USING SUBARU SELECT MONI- TOR.) 11AO5 : CHECK HARNESS BETWEEN ECM AND COMBINATION METER. Read data of fuel level sensor signal using Subaru Select Monitor. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from connector (i10) and ¼ Subaru Select Monitor ECM connector.
  • Page 696 DIAGNOSTICS [T11AO6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AO6 : CHECK HARNESS BETWEEN ECM 11AO8 : CHECK FUEL TANK CORD. AND COMBINATION METER. 1) Disconnect connector from fuel pump assem- Measure resistance between ECM and combina- bly.
  • Page 697 DIAGNOSTICS [T11AO10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AO10 : CHECK FUEL SUB LEVEL SEN- SOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel sub level sensor. <Ref. to 2-8 [W6A0].>...
  • Page 698 DIAGNOSTICS [T11AP0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AP: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 699 DIAGNOSTICS [T11AP4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AP2 : CHECK INPUT SIGNAL FOR ECM. 11AP3 : CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to ON. (Engine OFF) 1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and 2) Disconnect combination meter connector (i10) chassis ground.
  • Page 700 DIAGNOSTICS [T11AP5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AP5 : CHECK HARNESS BETWEEN 11AP7 : CHECK FUEL TANK CORD. FUEL TANK CORD AND CHASSIS GROUND. 1) Disconnect connector from fuel sub level sen- sor. Measure resistance between fuel tank cord and 2) Measure resistance between fuel level sensor chassis ground.
  • Page 701 DIAGNOSTICS [T11AP10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AP9 : CHECK FUEL LEVEL SENSOR. 11AP10 : CHECK FUEL SUB LEVEL SEN- SOR. WARNING: WARNING: During work procedures, if fuel tank is more During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill.
  • Page 702 DIAGNOSTICS [T11AQ0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AQ: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Radiator fan does not operate properly. ¼...
  • Page 703 : Is the resistance less than 10 Ω? Radiator fan relay operation can be executed using : Repair ground short circuit in radiator Subaru Select Monitor. For procedure, refer to fan relay 1 control circuit. “COMPULSORY VALVE OPERATION CHECK : Go to step 11AQ3.
  • Page 704 DIAGNOSTICS [T11AQ4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AQ4 : CHECK MAIN FAN RELAY. 11AQ6 : CHECK POOR CONTACT. Check poor contact in ECM or main fan relay con- 1) Turn ignition switch to OFF. nector. <Ref. to FOREWORD [T3C1].> 2) Measure resistance between main fan relay ter- minals.
  • Page 705 DIAGNOSTICS [T11AQ6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 706 DIAGNOSTICS [T11AR0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AR: DTC P0483 — COOLING FAN FUNCTION PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Occurrence of noise ¼ Overheating CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 707 DIAGNOSTICS [T11AR1] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AR1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Is there any other DTC on display? : Inspect the relevant DTC using “11. Diagnostics Chart with Trouble Code for 2500 cc Models”.
  • Page 708 : Check speedometer and vehicle speed 11AS2 : CHECK DTC P0720 ON DISPLAY. sensor. <Ref. to 6-2 [K3A0].> : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0720? : Check vehicle speed sensor 2 signal cir- cuit.
  • Page 709 DIAGNOSTICS [T11AS4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AS4 : CHECK HARNESS BETWEEN ECM AND COMBINATION METER CON- NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from combination meter. 3) Measure resistance between ECM and combi- nation meter.
  • Page 710 DIAGNOSTICS [T11AT0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AT: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Engine is difficult to start. ¼...
  • Page 711 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AT1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517?
  • Page 712 11AU2 : CHECK AIR INTAKE SYSTEM. PLAY. 1) Turn ignition switch to ON. : Does the Subaru Select Monitor or 2) Start engine, and idle it. OBD-II general scan tool indicate 3) Check the following items. ¼ Loose installation of intake manifold, idle air...
  • Page 713 DIAGNOSTICS [T11AU4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AU3 : CHECK THROTTLE CABLE. : Does throttle cable have play for adjustment? : Go to step 11AU4. : Adjust throttle cable. <Ref. to 4-5 [W1A3].> 11AU4 : CHECK AIR BY-PASS LINE.
  • Page 714 ¼ WIRING DIAGRAM: H2M3570 11AV1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0601? : Replace ECM. <Ref. to 2-7 [W19A0].> : It is not necessary to inspect DTC...
  • Page 715 DIAGNOSTICS [T11AV1] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 716 DIAGNOSTICS [T11AW0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AW: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 717 DIAGNOSTICS [T11AW4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AW2 : CHECK HARNESS BETWEEN TCM 11AW3 : CHECK HARNESS BETWEEN TCM AND BRAKE LIGHT SWITCH CON- AND BRAKE LIGHT SWITCH CON- NECTOR. NECTOR. 1) Disconnect connectors from TCM and brake Measure resistance of harness between TCM and light switch.
  • Page 718 DIAGNOSTICS [T11AW5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11AW5 : CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 24 (+) — Chassis ground (−): B2M2549A : Is the voltage more than 10 V when depressing the brake pedal? : Go to step 11AW6.
  • Page 719 DIAGNOSTICS [T11BA0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models AX: DTC P0705 — TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Starter does not rotate when selector lever is in “P” or “N” range. ¼...
  • Page 720 DIAGNOSTICS [T11BB0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BB: DTC P0725 — ENGINE SPEED INPUT CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) ¼...
  • Page 721 DIAGNOSTICS [T11BF6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BF: DTC P0734 — GEAR 4 INCORRECT RATIO — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces- sive tight corner “braking”...
  • Page 722 DIAGNOSTICS [T11BG0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BG: DTC P0740 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) ¼...
  • Page 723 DIAGNOSTICS [T11BG10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BG7 : CHECK BRAKE LIGHT SWITCH CIRCUIT. Check brake light switch circuit. <Ref. to 2-7 [T11AW0].> : Is there any trouble in brake light switch circuit? : Repair or replace brake light switch cir- cuit.
  • Page 724 DIAGNOSTICS [T11BH0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BH: DTC P0743 — TORQUE CONVERTER CLUTCH SYSTEM (LOCK-UP DUTY SOLENOID) ELECTRICAL — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ No lock-up (after engine warm-up) CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 725 DIAGNOSTICS [T11BL1] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BL: DTC P1100 — STARTER SWITCH CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 726 DIAGNOSTICS [T11BM0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BM: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [MT VEHICLES] OR NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [AT VEHICLES]— ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼...
  • Page 727 DIAGNOSTICS [T11BM5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BM1 : CHECK TRANSMISSION TYPE. 11BM4 : CHECK POOR CONTACT. : Is transmission type MT? Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> : Go to step 11BM2. : Is there poor contact in ECM connec- : Go to step 11BM8.
  • Page 728 11BM8 : CHECK DTC P0705 ON DISPLAY. B2M2091A : Does the Subaru Select Monitor or : Is the voltage between 4.5 and 5.5 V? OBD-II general scan tool indicate DTC P0705? : Go to step 11BM11.
  • Page 729 DIAGNOSTICS [T11BM13] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BM11 : CHECK POOR CONTACT. 11BM13 : CHECK HARNESS BETWEEN ECM AND INHIBITOR SWITCH CONNECTOR. Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> 1) Turn ignition switch to OFF. : Is there poor contact in ECM connec- 2) Disconnect connectors from ECM and inhibitor tor?
  • Page 730 DIAGNOSTICS [T11BM14] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BM14 : CHECK INHIBITOR SWITCH 11BM15 : CHECK INHIBITOR SWITCH. GROUND LINE. Measure resistance between inhibitor switch con- nector receptacle’s terminals in selector lever “N” Measure resistance of harness between inhibitor and “P”...
  • Page 731 DIAGNOSTICS [T11BM16] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 732 DIAGNOSTICS [T11BN0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BN: DTC P1103 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 733 DIAGNOSTICS [T11BN6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BN3 : CHECK POOR CONTACT. 11BN5 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Check poor contact in ECM connector. <Ref. to Measure resistance of harness between ECM and FOREWORD [T3C1].>...
  • Page 734 DIAGNOSTICS [T11BO0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BO: DTC P1106 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 735 DIAGNOSTICS [T11BO6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BO3 : CHECK POOR CONTACT. 11BO5 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Check poor contact in ECM connector. <Ref. to Measure resistance of harness between ECM and FOREWORD [T3C1].>...
  • Page 736 DIAGNOSTICS [T11BP0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BP: DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 737 1) Start engine. Measure voltage between ECM connector and 2) Read the data of intake manifold absolute pres- chassis ground. sure signal using Subaru Select Monitor or OBD-II Connector & terminal general scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 738 : Does the value change more than 0 kPa (0 mmHg, 0 inHg) by shaking har- ness and connector of ECM while monitoring the value with Subaru select monitor? : Repair poor contact in ECM connector. : Go to step 11BP7.
  • Page 739 DIAGNOSTICS [T11BP10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BP9 : CHECK HARNESS BETWEEN ECM AND ATMOSPHERIC PRESSURE SENSOR CONNECTOR. Measure resistance of harness between pressure sensor connector and engine ground. Connector & terminal (B2) No. 2 — Engine ground: OBD0695F : Is the resistance more than 500 kΩ? : Go to step 11BP10.
  • Page 740 DIAGNOSTICS [T11BQ0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BQ: DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 741 1) Start engine. Measure voltage between ECM connector and 2) Read the data of intake manifold absolute pres- chassis ground. sure signal using Subaru Select Monitor or OBD-II Connector & terminal general scan tool. (B136) No. 15 (+) — Chassis ground (−): NOTE: ¼...
  • Page 742 : Does the value change more than 0 kPa (0 mmHg, 0 inHg) by shaking har- ness and connector of ECM while monitoring the value with Subaru select monitor? : Repair poor contact in ECM connector. : Go to step 11BQ6.
  • Page 743 3) Turn ignition switch to ON. pressure sensor connector. 4) Read data of intake manifold absolute pressure Connector & terminal signal using Subaru select monitor or OBD-II gen- (B136) No. 16 — (B2) No. 1: eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 744 2) Disconnect connector from atmospheric pres- P0106. sure sensor. 3) Remove atmospheric pressure sensor. : Does the Subaru Select Monitor or 4) Check atmospheric pressure sensor filter. OBD-II general scan tool indicate DTC P0106, P0107, P0108, P1110 or : Is atmospheric pressure sensor filter...
  • Page 745 11BR3 : CHECK CURRENT DATA. 1) Turn ignition switch ON. 2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II gen- eral scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 746 DIAGNOSTICS [T11BS0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BS: DTC P1115 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 747 DIAGNOSTICS [T11BS2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BS1 : CHECK OUTPUT SIGNAL FROM 11BS2 : CHECK HARNESS BETWEEN ECM ECM. AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 1) Start engine, and warm-up the engine. 2) Measure voltage between ECM and chassis 2) Turn ignition swtich to OFF.
  • Page 748 DIAGNOSTICS [T11BT0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BT: DTC P1116 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 749 DIAGNOSTICS [T11BT3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BT3 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure resistance of harness betwee ECM and TCM connector. Connector & terminal (B134) No. 31 — (B54) No. 2: B2M2714A : Is the resistance less than 1 Ω? : Repair poor contact in ECM or TCM...
  • Page 750 DIAGNOSTICS [T11BU0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BU: DTC P1120 — STARTER SWITCH CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 751 DIAGNOSTICS [T11BU1] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 752 DIAGNOSTICS [T11BV0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BV: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [MT VEHICLES] OR NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [AT VEHICLES] — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼...
  • Page 753 DIAGNOSTICS [T11BV5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BV1 : CHECK TRANSMISSION TYPE. 11BV4 : CHECK POOR CONTACT. : Is transmission type MT? Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> : Go to step 11BV2. : Is there poor contact in ECM connec- : Go to step 11BV9.
  • Page 754 Inspection by DTM is required, because probable cause is deterioration of multiple parts. 11BV9 : CHECK DTC P0705 ON DISPLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0705? : Inspect DTC P0705 using “11. Diagnos- tics Chart with Trouble Code for 2500 cc Models”.
  • Page 755 DIAGNOSTICS [T11BV11] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BV10 : CHECK INPUT SIGNAL FOR ECM. 11BV11 : CHECK HARNESS BETWEEN ECM AND TRANSMISSION HAR- NESS CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis 1) Turn ignition switch to OFF.
  • Page 756 DIAGNOSTICS [T11BV12] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BV12 : CHECK TRANSMISSION HAR- 11BV14 : CHECK SELECTOR CABLE CON- NESS CONNECTOR. NECTION. : Is there any fault in selector cable 1) Disconnect connector from inhibitor switch. connection to inhibitor switch? 2) Measure resistance of harness between trans- mission harness connector and engine ground.
  • Page 757 DIAGNOSTICS [T11BV14] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 758 DIAGNOSTICS [T11BW0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BW: DTC P1130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 759 DIAGNOSTICS [T11BW2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BW1 : CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure resistance of harness between ECM and front oxygen (A/F) sensor connector.
  • Page 760 DIAGNOSTICS [T11BX0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BX: DTC P1131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 761 DIAGNOSTICS [T11BX1] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BX1 : CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SEN- SOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground.
  • Page 762 ¼ WIRING DIAGRAM: H2M3578 11BY1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1132 and P0141 at the same time? : Go to step 11BY2. : Go to step 11BY5.
  • Page 763 DIAGNOSTICS [T11BY3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BY2 : CHECK POWER SUPPLY TO 11BY3 : CHECK GROUND CIRCUIT OF FRONT OXYGEN (A/F) SENSOR. ECM. 1) Turn ignition switch to OFF. Measure resistance of harness between ECM con- 2) Disconnect connector from front oxygen (A/F) nector and chassis ground.
  • Page 764 Connector & terminal (B134) No. 22 (+) — Chassis ground (−): 1) Start engine. 2) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 765 DIAGNOSTICS [T11BY10] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BY8 : CHECK OUTPUT SIGNAL FROM 11BY10 : CHECK FRONT OXYGEN (A/F) ECM. SENSOR. Measure voltage between ECM connector and 1) Turn ignition switch to OFF. chassis ground. 2) Measure resistance between front oxygen (A/F) sensor connector terminals.
  • Page 766 DIAGNOSTICS [T11BZ0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models BZ: DTC P1133 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 767 3) Turn ignition switch to ON. Connector & terminal 4) Read data of front oxygen (A/F) sensor heater (B134) No. 23 (+) — Chassis ground (−): current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 768 DIAGNOSTICS [T11BZ5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11BZ5 : CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 22 (+) — Chassis ground (−): B2M2468A : Does the voltage change more than 8 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
  • Page 769 H2M3577 11CA1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0122 or P0123? : Inspect DTC P0122 or P0123 using “11. Diagnostics Chart with Trouble Code for 2500 cc Models”.
  • Page 770 DIAGNOSTICS [T11CB0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CB: DTC P1151 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 771 2) Repair battery short circuit in harness between ECM and rear oxygen sensor connector. 3) Turn ignition switch to ON. 4) Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: ¼ Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DISPLAY...
  • Page 772 DIAGNOSTICS [T11CC0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CC: DTC P1207 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 773 DIAGNOSTICS [T11CC2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CC1 : CHECK OUTPUT SIGNAL FROM 11CC2 : CHECK POWER SUPPLY TO AIR ECM. ASSIST INJECTOR SOLENOID VALVE. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connector from air assist injector ground.
  • Page 774 DIAGNOSTICS [T11CC3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CC3 : CHECK HARNESS BETWEEN ECM 11CC4 : CHECK HARNESS BETWEEN ECM AND AIR ASSIST INJECTOR AND AIR ASSIST INJECTOR SOLENOID VALVE CONNECTOR. SOLENOID VALVE CONNECTOR. Measure resistance of harness between ECM and 1) Turn ignition switch to OFF.
  • Page 775 DIAGNOSTICS [T11CC5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 776 DIAGNOSTICS [T11CD0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CD: DTC P1208 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 777 DIAGNOSTICS [T11CD2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CD1 : CHECK OUTPUT SIGNAL FROM 11CD2 : CHECK OUTPUT SIGNAL FROM ECM. ECM. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connector from air assist injector ground.
  • Page 778 DIAGNOSTICS [T11CD3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CD3 : CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 24 (+) — Chassis ground (−): B2M3805A : Does the voltage change more than 10 V by shaking harness and connec- tor of ECM while monitoring the value with voltage meter?
  • Page 779 DIAGNOSTICS [T11CD3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 780 DIAGNOSTICS [T11CE0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CE: DTC P1325 — KNOCK SENSOR CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Poor driving performance ¼ Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 781 DIAGNOSTICS [T11CE4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CE1 : CHECK HARNESS BETWEEN 11CE3 : CHECK KNOCK SENSOR. KNOCK SENSOR AND ECM CON- NECTOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor 1) Turn ignition switch to OFF.
  • Page 782 DIAGNOSTICS [T11CE5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CE5 : CHECK KNOCK SENSOR. 11CE6 : CHECK INPUT SIGNAL FOR ECM. 1) Connect connectors to ECM and knock sensor. 1) Disconnect connector from knock sensor. 2) Turn ignition switch to ON. 2) Measure resistance between knock sensor 3) Measure voltage between ECM and chassis connector terminal and engine ground.
  • Page 783 DIAGNOSTICS [T11CE6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 784 DIAGNOSTICS [T11CF0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CF: DTC P1400 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 785 DIAGNOSTICS [T11CF3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CF1 : CHECK OUTPUT SIGNAL FROM 11CF3 : CHECK HARNESS BETWEEN ECM. FUEL TANK PRESSURE CONTROL SOLENOID VALVE AND ECM CON- NECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis 1) Turn ignition switch to OFF.
  • Page 786 DIAGNOSTICS [T11CF4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CF4 : CHECK HARNESS BETWEEN 11CF5 : CHECK FUEL TANK PRESSURE FUEL TANK PRESSURE CONTROL CONTROL SOLENOID VALVE. SOLENOID VALVE AND ECM CON- NECTOR. Measure resistance between fuel tank pressure control solenoid valve terminals.
  • Page 787 DIAGNOSTICS [T11CF7] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CF6 : CHECK POWER SUPPLY TO FUEL TANK PRESSURE CONTROL SOLENOID VALVE. 1) Turn ignition switch to ON. 2) Measure voltage between fuel tank pressure control solenoid valve and chassis ground. Connector &...
  • Page 788 DIAGNOSTICS [T11CG0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CG: DTC P1420 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 789 : Go to step 11CG4. : Go to step 11CG3. NOTE: Fuel tank pressure control solenoid valve opera- tion can be executed using Subaru Select Monitor. 11CG3 : CHECK POOR CONTACT. For procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 Check poor contact in ECM connector.
  • Page 790 DIAGNOSTICS [T11CG4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CG4 : CHECK HARNESS BETWEEN 11CG5 : CHECK FUEL TANK PRESSURE FUEL TANK PRESSURE CONTROL CONTROL SOLENOID VALVE. SOLENOID VALVE AND ECM CON- NECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between fuel tank pressure control solenoid valve terminals.
  • Page 791 DIAGNOSTICS [T11CG6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 792 DIAGNOSTICS [T11CH0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CH: DTC P1422 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼...
  • Page 793 : Go to step 11CH4. : Go to step 11CH3. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For 11CH3 : CHECK POOR CONTACT. procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 Check poor contact in ECM connector.
  • Page 794 DIAGNOSTICS [T11CH4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CH4 : CHECK HARNESS BETWEEN 11CH5 : CHECK PURGE CONTROL SOLE- PURGE CONTROL SOLENOID NOID VALVE. VALVE AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between purge control 1) Turn ignition switch to OFF.
  • Page 795 DIAGNOSTICS [T11CH6] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 796 DIAGNOSTICS [T11CI0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CI: DTC P1423 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 797 ECM and chassis ground. : Go to step 11CI4. NOTE: : Go to step 11CI3. Drain valve operation can be excecuted using Subaru Select Monitor. For procedure, refer to “COMPULSORY VALVE OPERATION CHECK 11CI3 : CHECK POOR CONTACT. MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 798 DIAGNOSTICS [T11CI4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CI4 : CHECK HARNESS BETWEEN 11CI5 : CHECK DRAIN VALVE. DRAIN VALVE AND ECM CONNEC- TOR. 1) Turn ignition switch to OFF. 2) Measure resistance between drain valve termi- nals.
  • Page 799 INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼ WIRING DIAGRAM: H2M3558 11CJ1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0461, P0462 or P0463? : Inspect DTC P0461, P0462 or P0463 using “11.
  • Page 800 DIAGNOSTICS [T11CK0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CK: DTC P1443 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL FUNCTION PROBLEM — ¼ DTC DETECTING CONDITION: ¼ Immediately after fault occurrence ¼ TROUBLE SYMPTOM: ¼ Improper fuel supply CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 801 4) Operate drain valve. NOTE: H2M2482B Drain valve operating can also be executed using Subaru Select Monitor. For the procedure, refer to : Is there a fault in vent line? the “COMPULSORY VALVE OPERATION CHECK : Repair or replace the faulty part.
  • Page 802 DIAGNOSTICS [T11CL0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CL: DTC P1445 — AIR ASSIST INJECTOR SOLENOID VALVE MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Immediately after fault occurrence ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼ Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref.
  • Page 803 3) Turn ignition switch to ON. 4) Operate air assist injector solenoid valve. NOTE: Air assist injector solenoid valve operation can also be executed using Subaru Select Monitor. For the procedure, refer to the “COMPULSORY VALVE OPERATION CHECK MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 804 : Go to step 11CM2. 11CM2 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0125, P0301, P0302, P0303 and P0304 at same time? : Go to step 11CM3.
  • Page 805 DIAGNOSTICS [T11CM4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 806 11CN2 : CHECK AIR INTAKE SYSTEM. PLAY. 1) Turn ignition switch to ON. : Does the Subaru Select Monitor or 2) Start engine, and idle it. OBD-II general scan tool indicate 3) Check the following items. ¼ Loose installation of intake manifold, idle air...
  • Page 807 DIAGNOSTICS [T11CN4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CN3 : CHECK THROTTLE CABLE. : Does throttle cable have play for adjustment? : Go to step 11CN4. : Adjust throttle cable. <Ref. to 4-5 [W1A3].> 11CN4 : CHECK AIR BY-PASS LINE.
  • Page 808 DIAGNOSTICS [T11CN4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 809 DIAGNOSTICS [T11CT0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CO: DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT LOW INPUT — NOTE: For the diagnostic procedure, refer to DTC P1516. <Ref. to 2-7 [T11CU0].> CP: DTC P1511 —...
  • Page 810 DIAGNOSTICS [T11CU0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CU: DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Immediately at fault recognition ¼ TROUBLE SYMPTOM: ¼ Erroneous idling ¼...
  • Page 811 DIAGNOSTICS [T11CU2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CU1 : CHECK POWER SUPPLY TO IDLE 11CU2 : CHECK POWER SUPPLY TO IDLE AIR CONTROL SOLENOID VALVE. AIR CONTROL SOLENOID VALVE. 1) Turn ignition switch to OFF. Measure voltage between idle air control solenoid 2) Disconnect connector from idle air control sole- valve connector and engine ground.
  • Page 812 DIAGNOSTICS [T11CU3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CU3 : CHECK HARNESS BETWEEN ECM 11CU4 : CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLE- AND IDLE AIR CONTROL SOLE- NOID VALVE CONNECTOR. NOID VALVE CONNECTOR. 1) Turn ignition switch to OFF.
  • Page 813 DIAGNOSTICS [T11CU5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CU5 : CHECK POOR CONTACT. Check poor contact in ECM connector and idle air control solenoid valve connector. <Ref. to FORE- WORD [T3C1].> : Is there poor contact in ECM connec- tor or idle air control solenoid valve connector? : Repair poor contact in ECM connector...
  • Page 814 ¼ WIRING DIAGRAM: H2M3580 11CV1 : CHECK ANY OTHER DTC ON DIS- PLAY. : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1511, P1513, P1515 and P1517 at same time? : Go to step 11CV2. : Go to step 11CV3.
  • Page 815 DIAGNOSTICS [T11CV3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CV2 : CHECK GROUND CIRCUIT FOR 11CV3 : CHECK HARNESS BETWEEN ECM ECM. AND IDLE AIR CONTROL SOLE- NOID VALVE CONNECTOR. 1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF. 2) Measure resistance between ECM connector 2) Disconnect connector from idle air control sole- and chassis ground.
  • Page 816 DIAGNOSTICS [T11CW0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CW: DTC P1520 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Radiator fan does not operate properly. ¼...
  • Page 817 ECM and chassis ground. NOTE: Radiator fan relay operation can be executed using B2M2654A Subaru Select Monitor. For procedure, refer to “COMPULSORY VALVE OPERATION CHECK : Is the voltage more than 10 V? MODE”. <Ref. to 2-7 [T3F0].>...
  • Page 818 DIAGNOSTICS [T11CW3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CW3 : CHECK MAIN FAN RELAY. 11CW5 : CHECK POOR CONTACT. Check poor contact in ECM connector. <Ref. to 1) Turn ignition switch to OFF. FOREWORD [T3C1].> 2) Remove main fan relay. 3) Measure resistance between main fan relay ter- : Is there poor contact in ECM connec- minals.
  • Page 819 DIAGNOSTICS [T11CW5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 820 : Check speedometer and vehicle speed 11CX2 : CHECK DTC P0720 ON DISPLAY. sensor. <Ref. to 6-2 [K3A0].> : Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0720? : Check vehicle speed sensor 2 signal cir- cuit.
  • Page 821 DIAGNOSTICS [T11CX4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CX4 : CHECK HARNESS BETWEEN ECM AND COMBINATION METER CON- NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from combination meter. 3) Measure resistance between ECM and combi- nation meter.
  • Page 822 DIAGNOSTICS [T11CY0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CY: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 823 DIAGNOSTICS [T11CY3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11CY1 : CHECK INPUT SIGNAL FOR ECM. 11CY3 : CHECK FUSE SBF-5. : Is fuse blown? 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis : Replace fuse.
  • Page 824 DIAGNOSTICS [T11CZ0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models CZ: DTC P1700 — THROTTLE POSITION SENSOR CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault ¼ TROUBLE SYMPTOM: ¼ Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces- sive tight corner “braking”...
  • Page 825 DIAGNOSTICS [T11CZ0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models MEMO:...
  • Page 826 DIAGNOSTICS [T11DA0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models DA: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 827 DIAGNOSTICS [T11DA4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11DA3 : CHECK INPUT SIGNAL FOR TCM. 11DA4 : CHECK POOR CONTACT. 1) Connect connector to TCM and CCM. Check poor contact in TCM connector. <Ref. to 2) Lift-up the vehicle or set the vehicle on free FOREWORD [T3C1].>...
  • Page 828 DIAGNOSTICS [T11DB0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models DB: DTC P1702 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 829 DIAGNOSTICS [T11DB4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11DB2 : CHECK HARNESS BETWEEN ECM 11DB3 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. AND TCM CONNECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis 2) Disconnect connector from ECM and TCM.
  • Page 830 DIAGNOSTICS [T11DB5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11DB5 : CHECK TROUBLE CODE FOR AUTOMATIC TRANSMISSION. Read trouble code for automatic transmission. <Ref. to 3-2 [T8A0].> : Does trouble code appear for auto- matic transmission? : Inspect trouble code for automatic trans- mission.
  • Page 831 DIAGNOSTICS [T11DE0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models DC: DTC P1703 — LOW CLUTCH TIMING CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 832 DIAGNOSTICS [T11DF0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models DF: DTC P1722 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 833 DIAGNOSTICS [T11DF4] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11DF2 : CHECK HARNESS BETWEEN ECM 11DF4 : CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. AND TCM CONNECTOR. 1) Turn ignition switch to ON. Measure voltage between ECM connector and 2) Measure voltage between ECM and chassis chassis ground.
  • Page 834 DIAGNOSTICS [T11DF5] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11DF5 : CHECK OUTPUT SIGNAL FROM 11DF6 : CHECK HARNESS BETWEEN ECM ECM. AND TCM CONNECTOR. Measure voltage between TCM and chassis Measure voltage between ECM and chassis ground.
  • Page 835 DIAGNOSTICS [T11DG3] 11. Diagnostics Chart with Trouble Code for 2500 cc Models DG: DTC P1742 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION — ¼ DTC DETECTING CONDITION: ¼ Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref.
  • Page 836 DIAGNOSTICS [T11DH0] 11. Diagnostics Chart with Trouble Code for 2500 cc Models DH: — AT/MT IDENTIFICATION CIRCUIT MALFUNCTION [MT VEHICLES] — CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼...
  • Page 837 DIAGNOSTICS [T11DH2] 11. Diagnostics Chart with Trouble Code for 2500 cc Models 11DH1 : CHECK HARNESS BETWEEN ECM 11DH2 : CHECK POOR CONTACT. CONNECTOR AND ENGINE GROUNDING TERMINAL. Check poor contact in ECM connector. <Ref. to FOREWORD [T3C1].> 1) Turn ignition switch to ON. : Is there poor contact in ECM connec- 2) Measure voltage between ECM and chassis tor?
  • Page 838 DIAGNOSTICS MEMO:...
  • Page 839 FUEL SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Fuel System ....................2 COMPONENT PARTS ..................4 Fuel Tank.....................4 Fuel Line......................6 SERVICE PROCEDURE ...................8 Fuel Tank.....................8 Fuel Filler Pipe ..................15 Fuel Pump ....................20 Fuel Level Sensor ..................21 Fuel Sub Level Sensor................23 Fuel Cut Valve...................24 Roll Over Valve ..................25 Fuel Filter ....................26 Fuel Delivery, Return and Evaporation Lines ...........27...
  • Page 840 SPECIFICATIONS AND SERVICE DATA [S100] 1. Fuel System 1. Fuel System Capacity (15.9 US gal, 13.2 Imp gal) Fuel tank Location Under rear seat Type Impeller Discharge pressure 299.1 kPa (3.05 kg/cm , 43.4 psi) Fuel pump More than 65 (17.2 US gal, 14.3 Imp gal)/h [12 V at 300 Discharge flow kPa (3.06 kg/cm...

  • Page 841: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Fuel System MEMO:...

  • Page 842: Component Parts

    COMPONENT PARTS [C100] 1. Fuel Tank 1. Fuel Tank H2M3594A...
  • Page 843 COMPONENT PARTS [C100] 1. Fuel Tank (1) Heat sealed cover (15) Evaporation hose C (29) Jet pump filter (2) Fuel tank band (16) Evaporation hose B (30) Fuel sub level sensor (3) Protector LH (17) Evaporation hose D (31) Protector cover (4) Protector RH (18) Evaporation hose E (32) Vent valve hose...

  • Page 844: Fuel Line

    COMPONENT PARTS [C200] 2. Fuel Line 2. Fuel Line H2M3595A...
  • Page 845 COMPONENT PARTS [C200] 2. Fuel Line (1) Clamp (19) Canister hose A (37) Shut valve (2) Fuel delivery hose A (20) Air filter hose A (38) Packing (3) Fuel filter bracket (21) Drain valve hose (39) Ring A (4) Fuel filter holder (22) Air filter hose B (40) Ring B (5) Fuel filter cup...
  • Page 846 SERVICE PROCEDURE [W1A0] 1. Fuel Tank 1. Fuel Tank 4) Remove access hole lid. A: RELEASING OF FUEL PRESSURE WARNING: ¼ Place “No fire” signs near the working area. ¼ Disconnect ground terminal from battery. ¼ Be careful not to spill fuel on the floor. 1) Disconnect connector from fuel pump relay.

  • Page 847: Service Procedure

    SERVICE PROCEDURE [W1B0] 1. Fuel Tank 9) Take off fuel pump from fuel tank. 12) Drain fuel from there. WARNING: Do not use a motor pump when draining fuel. G2M0344 10) Drain fuel from fuel tank by using a hand B2M0049 pump.
  • Page 848 10) Remove rear exhaust pipe. <Ref. to 2-9 5) Remove rear seat cushion. (Sedan model) [W2A0].> NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No. 004301003). H2M2536 6) Move rear seat cushion forward. (Wagon model) S2M0158...
  • Page 849 <Ref. to 2-9 [W3A0].> solenoid valve. 16) Disconnect connector from drain valve. NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No. 004301003). B2M1743 17) Disconnect hoses from roll over valve. G2M0384 12) Remove heat sealed cover.
  • Page 850 SERVICE PROCEDURE [W1D0] 1. Fuel Tank 20) Remove rear crossmember. 24) While holding fuel tank, remove bolts from <Ref. to 4-1 [W10A0].> bands and dismount fuel tank. WARNING: A helper is required to perform this work. G4M0545 21) Loosen clamp, and disconnect fuel filler hose S2M0169A (A) and air vent hose (B) from fuel filler pipe and air vent pipe.
  • Page 851 SERVICE PROCEDURE [W1D0] 1. Fuel Tank 5) Tighten band mounting bolts. 9) Connect connector to pressure control solenoid valve. Tightening torque: 10) Connect hose to joint pipe. 33±10 N·m (3.4±1.0 kg-m, 25±7 ft-lb) S2M0880 S2M0169A 11) Connect evaporation hose to canister, and 6) Install rear crossmember.
  • Page 852 SERVICE PROCEDURE [W1D0] 1. Fuel Tank 14) Install heat sealed cover. 19) Install rear seat cushion. (Sedan model) B2M1736 S2M0166 20) Set rear seat cushion. (Wagon model) 15) Install muffler assembly. <Ref. to 2-9 [W3A0].> B2M1737 G2M0384 21) Install fuel filler cap. 16) Install rear exhaust pipe.

  • Page 853: Fuel Filler Pipe

    SERVICE PROCEDURE [W2A0] 2. Fuel Filler Pipe 2. Fuel Filler Pipe 8) Remove rear right side wheel. A: REMOVAL 1) Set the vehicle on the lift. 2) Release fuel pressure. <Ref. to 2-8 [W1A0].> 3) Open fuel flap lid, and remove fuel filler cap. B2M1748 9) Remove bolts which install protector cover on body.
  • Page 854 SERVICE PROCEDURE [W2B0] 2. Fuel Filler Pipe 12) Remove bolts which hold fuel filler pipe 17) Remove fuel filler pipe to under side of bracket. vehicle. B2M1752 B2M1756 13) Lift-up the vehicle more. B: DISASSEMBLY 14) Remove two evaporation hoses from clip. 1) Move clip, and disconnect evaporation hose from joint pipe.
  • Page 855 SERVICE PROCEDURE [W2C0] 2. Fuel Filler Pipe 3) Disconnect evaporation hose from fuel filler 2) Connect evaporation hoses to shut valve. pipe. B2M1761 B2M1760 3) Connect evaporation hose to fuel filler pipe. 4) Disconnect evaporation hoses from shut valve. B2M1760 B2M1761 4) Connect evaporation hose to evaporation pipe.
  • Page 856 SERVICE PROCEDURE [W2D0] 2. Fuel Filler Pipe D: INSTALLATION 6) Connect evaporation hoses to pipes. 1) Set fuel filler pipe from under side of vehicle, and hold it on fuel filler flap open. B2M1751 7) Lift-up the vehicle. 8) Tighten clamp bolt which holds fuel filler hose. B2M1756 2) Connect fuel filler pipe into fuel filler hose.
  • Page 857 SERVICE PROCEDURE [W2D0] 2. Fuel Filler Pipe 12) While holding the under side of protector 17) Connect connector to fuel pump relay. cover on bracket, install it. S2M0093A B2M1750A 18) Connect battery ground terminal. 13) Tighten bolts which install protector cover on body.

  • Page 858: Fuel Pump

    SERVICE PROCEDURE [W3A0] 3. Fuel Pump 3. Fuel Pump 6) Disconnect quick connector, and then discon- nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].> A: REMOVAL 1) Release fuel pressure. <Ref. to 2-8 [W1B0].> 2) Open fuel flap lid, and remove fuel filler cap. S2M0060A 7) Remove nuts which install fuel pump assembly onto fuel tank.

  • Page 859: Fuel Level Sensor

    SERVICE PROCEDURE [W4A0] 4. Fuel Level Sensor 4. Fuel Level Sensor C: INSTALLATION Installation is in the reverse order of removal. Do A: REMOVAL the following: NOTE: (1) Always use new gaskets. Fuel level sensor is built in fuel pump assembly. (2) Ensure sealing portion is free from fuel or for- eign particles before installation.
  • Page 860 SERVICE PROCEDURE [W4B0] 4. Fuel Level Sensor 5) Move clips, and then disconnect fuel return B: INSTALLATION hose (B) and jet pump hose (C). Installation is in the reverse order of removal. Do 6) Disconnect quick connector, and then discon- the following: nect fuel delivery hose (A).

  • Page 861: Fuel Sub Level Sensor

    SERVICE PROCEDURE [W5A0] 5. Fuel Sub Level Sensor 5. Fuel Sub Level Sensor 5) Remove bolts which install fuel sub level sensor on fuel tank. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0152 6) Remove fuel sub level sensor. G6M0095 2) Remove fuel filler cap.

  • Page 862: Fuel Cut Valve

    SERVICE PROCEDURE [W6A0] 6. Fuel Cut Valve 6. Fuel Cut Valve 5) Installation is in the reverse order of removal procedure. A: REMOVAL AND INSTALLATION Tightening torque: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb) 1) Remove fuel tank. <Ref. to 2-8 [W1C0].> G2M0867 S2M0169A 2) Remove protect cover.

  • Page 863: Roll Over Valve

    SERVICE PROCEDURE [W7B0] 7. Roll Over Valve 7. Roll Over Valve B: INSPECTION 1) Connect hoses to roll over valve as shown in A: REMOVAL AND INSTALLATION Figure. 1) Lift-up the vehicle. 2) Remove roll over valve from bracket. G2M0374 2) While blowing through open end of hose, tilt S2M0174 valve at least 90°...

  • Page 864: Fuel Filter

    SERVICE PROCEDURE [W8A0] 8. Fuel Filter 8. Fuel Filter C: INSTALLATION CAUTION: A: REMOVAL ¼ If fuel hoses are damaged at the connecting 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> portion, replace it with a new one. ¼ If clamps are badly damaged, replace with 2) Disconnect battery ground cable.

  • Page 865: Fuel Delivery, Return And Evaporation Lines

    SERVICE PROCEDURE [W9B0] 9. Fuel Delivery, Return and Evaporation Lines 9. Fuel Delivery, Return and 2) Open fuel flap lid, and remove fuel filler cap. 3) Remove inner trim, insulator and rear seat. Evaporation Lines 4) Remove fuel delivery pipes and hoses, fuel return pipes and hoses, and evaporation pipes and A: REMOVAL hoses.
  • Page 866 SERVICE PROCEDURE [W9B0] 9. Fuel Delivery, Return and Evaporation Lines Type A: When fitting length is specified. Type B: When fitting length is not specified. : 1.0 — 4.0 mm (0.039 — 0.157 in) L: 20 — 25 mm (0.79 — 0.98 in) S2M0229A (1) Set new retainer (B) to connector (A).
  • Page 867 SERVICE PROCEDURE [W9B0] 9. Fuel Delivery, Return and Evaporation Lines 4) Connect connector to fuel pump relay. S2M0093A...

  • Page 868: Fuel System Trouble In General

    DIAGNOSTICS [K100] 1. Fuel System Trouble in General 1. Fuel System Trouble in General Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and Defective terminal contact. tighten securely.
  • Page 869 EXHAUST SYSTEM Page COMPONENT PARTS ..................2 Exhaust System ..................2 SERVICE PROCEDURE ...................5 Front Exhaust Pipe and Center Exhaust Pipe..........5 Rear Exhaust Pipe ..................7 Muffler......................8...

  • Page 870: Component Parts

    COMPONENT PARTS [C1A0] 1. Exhaust System 1. Exhaust System A: 2200 cc MODEL H2M2936B...
  • Page 871 COMPONENT PARTS [C1A0] 1. Exhaust System (1) Upper front exhaust pipe cover (11) Spring (25) Rear oxygen sensor (12) Rear exhaust pipe (26) Front catalytic converter (2) Lower front exhaust pipe cover (13) Self-locking nut (27) Lower front catalytic converter (14) Gasket cover (3) Band RH...
  • Page 872 COMPONENT PARTS [C1B0] 1. Exhaust System B: 2500 cc MODEL S2M0921A (1) Upper front exhaust pipe cover (11) Spring (25) Front catalytic converter (12) Rear exhaust pipe (26) Lower front catalytic converter (2) Lower front exhaust pipe cover (13) Self-locking nut cover (14) Gasket (27) Upper front catalytic converter...

  • Page 873: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Front Exhaust Pipe and Center Exhaust Pipe 1. Front Exhaust Pipe and 5) Separate front and center exhaust pipe assem- bly from rear exhaust pipe. Center Exhaust Pipe WARNING: A: REMOVAL Be careful, exhaust pipe is hot. 1) Disconnect battery ground cable.
  • Page 874 SERVICE PROCEDURE [W1B0] 1. Front Exhaust Pipe and Center Exhaust Pipe 9) Separate front exhaust pipe from front catalytic 4) Tighten bolts which hold front exhaust pipe onto converter and center exhaust pipe assembly. cylinder heads. Tightening torque: 30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb) S2M0923 B: INSTALLATION B2M0054...

  • Page 875: Rear Exhaust Pipe

    B2M3439 10) Connect battery ground cable. G2M0382 3) Remove rear exhaust pipe bracket from rubber cushion. NOTE: To facilitate removal, apply a coat of SUBARU G6M0095 CRC to pipe bracket in advance. SUBARU CRC (Part No. 004301003) G2M0315...

  • Page 876: Muffler

    1) Separate muffler from rear exhaust pipe. 1) Install rear exhaust pipe bracket to rubber cush- ion. NOTE: To facilitate installation, apply a coat of SUBARU CRC to mating area of rubber cushion in advance. SUBARU CRC (Part No. 004301003) G2M0382 2) Remove left and right rubber cushions.
  • Page 877 SERVICE PROCEDURE [W3A0] 3. Muffler 4) Installation is in the reverse order of removal. CAUTION: Replace gasket with a new one. Tightening torque: 48±5 N·m (4.9±0.5 kg-m, 35.4±3.6 ft-lb) G2M0382...
  • Page 878 SERVICE PROCEDURE MEMO:...
  • Page 879 2-10 CLUTCH Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 COMPONENT PARTS ..................3 Clutch System .....................3 Master Cylinder and Reservoir Tank............5 SERVICE PROCEDURE ...................6 General......................6 On-car Service ....................7 Release Bearing and Lever ................8 Clutch Disc and Cover ................12 Operating Cylinder ..................15 Master Cylinder and Reservoir Tank............16 Brake Fluid ....................18 DIAGNOSTICS....................19...

  • Page 880: Specifications And Service Data

    2-10 SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications 2200 cc 2500 cc Clutch cover Diaphragm set load kg (lb) 450 (992) 580 (1,279) Facing material Woven O.D. × I.D. × thickness 225 × 150 × 3.5 (8.86 × 5.91 × 0.138) mm (in) Spline O.D.

  • Page 881: Component Parts

    2-10 COMPONENT PARTS [C1A0] 1. Clutch System 1. Clutch System A: MECHANICAL APPLICATION TYPE H2M2429B (1) Clutch cable bracket (6) Clip (11) Return spring (2) Clutch release lever sealing (7) Clutch release bearing (12) Clutch return spring bracket (3) Pivot (8) Clutch cover (4) Retainer spring (9) Clutch disc...
  • Page 882 2-10 COMPONENT PARTS [C1B0] 1. Clutch System B: HYDRAULIC APPLICATION TYPE S2M0910C (1) Operating cylinder (10) Lever (19) Flywheel (2) Washer (11) Clutch release lever sealing (3) Clutch hose (12) Retainer spring Tightening torque: N·m (kg-m, ft-lb) +0.3 +2.2 (4) Bracket (13) Pivot (1.5 , 10.8...

  • Page 883: Master Cylinder And Reservoir Tank

    2-10 COMPONENT PARTS [C200] 2. Master Cylinder and Reservoir Tank 2. Master Cylinder and Reservoir Tank S2M0911A (1) Reservoir cap (5) Master cylinder (9) Push rod (2) Reservoir tank (6) Seat (10) Piston stop ring (3) Oil sealing (7) Return spring (4) Straight pin (8) Piston...

  • Page 884: Service Procedure

    2-10 SERVICE PROCEDURE [W1A1] 1. General 1. General 4) Check for proper clutch disengagement and clutch pedal return ability. A: PRECAUTION 1. MECHANICAL APPLICATION TYPE When servicing clutch system, pay attention to the following items. 1) Check the routing of clutch cable for smooth- ness.

  • Page 885: On-Car Service

    2-10 SERVICE PROCEDURE [W2A2] 2. On-car Service 2. On-car Service 5) Depress clutch pedal to assure there is no abnormality in the clutch system. A: ADJUSTMENT 1. MECHANICAL APPLICATION TYPE 1) Remove clutch release lever return spring from lever. 2) Adjust spherical nut so that the play is within the specified value at the lever end (center of spheri- cal nut).

  • Page 886: Release Bearing And Lever

    2-10 SERVICE PROCEDURE [W3A1] 3. Release Bearing and Lever 3. Release Bearing and Lever 5) Tighten air bleeder. Tightening torque: A: REMOVAL T: 8±2 N·m (0.8±0.2 kg-m, 5.8±1.4 ft-lb) 1. MECHANICAL APPLICATION TYPE 1) Remove clutch release lever return spring. 2) Remove the two clips from clutch release lever and remove clutch release bearing.
  • Page 887 2-10 SERVICE PROCEDURE [W3B1] 3. Release Bearing and Lever 4) Remove clutch release lever retainer spring 4) Remove clutch release lever retainer spring from clutch release lever pivot with a screwdriver from clutch release lever pivot with a screwdriver by accessing it through clutch housing clutch by accessing it through clutch housing clutch release lever hole.
  • Page 888 2-10 SERVICE PROCEDURE [W3B2] 3. Release Bearing and Lever 2. CLUTCH RELEASE LEVER 3) Install clutch release lever sealing. Check lever pivot portion and the point of contact with clutch release bearing case for wear. H2M3584A C: INSTALLATION 1. MECHANICAL APPLICATION TYPE CAUTION: Before or during assembling, lubricate the fol- lowing points with a light coat of grease.
  • Page 889 2-10 SERVICE PROCEDURE [W3C2] 3. Release Bearing and Lever 2. HYDRAULIC APPLICATION TYPE 5) After remounting engine and transmission on body. CAUTION: <Ref. to 2-11 [W2B0].> Before or during assembling, lubricate the fol- 6) Bleed air from oil line with the help of a co- lowing points with a light coat of grease.

  • Page 890: Clutch Disc And Cover

    2-10 SERVICE PROCEDURE [W4A0] 4. Clutch Disc and Cover 4. Clutch Disc and Cover B: INSPECTION 1. CLUTCH DISC A: REMOVAL 1) Facing wear 1) Install ST on flywheel. Measure the depth of rivet head from the surface ST 498497100 CRANKSHAFT STOPPER of facing.
  • Page 891 2-10 SERVICE PROCEDURE [W4C0] 4. Clutch Disc and Cover 4) Deflection on facing 3) Damaged or worn disc contact surface of pres- If deflection exceeds the specified value at the sure plate. 4) Loose strap plate setting bolt. outer circumference of facing, repair or replace. 5) Worn diaphragm sliding surface.
  • Page 892 2-10 SERVICE PROCEDURE [W4C0] 4. Clutch Disc and Cover 2) Tighten the flywheel attaching bolts to the 4) Install clutch cover on flywheel and tighten bolts specified torque. to the specified torque. NOTE: NOTE: ¼ When installing the clutch cover on the flywheel, Tighten flywheel installing bolts gradually.

  • Page 893: Operating Cylinder

    2-10 SERVICE PROCEDURE [W5A0] 5. Operating Cylinder 5. Operating Cylinder 4) Installation is in the reverse order of removal. NOTE: A: REMOVAL AND INSTALLATION Before installing operating cylinder, apply grease (SUNLIGHT 2: P/N 003602010) to contact point of 1) Remove air cleaner case. clutch release lever and operating cylinder.

  • Page 894: Master Cylinder And Reservoir Tank

    2-10 SERVICE PROCEDURE [W6A0] 6. Master Cylinder and Reservoir Tank 6. Master Cylinder and 2) Remove oil sealing. Reservoir Tank A: REMOVAL 1) Thoroughly drain brake fluid from reservoir tank. 2) Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal. S2M0916A 3) Move the cylinder boot backward.
  • Page 895 2-10 SERVICE PROCEDURE [W6E0] 6. Master Cylinder and Reservoir Tank D: ASSEMBLY 3) After bleeding air from system, ensure that clutch operates properly. CAUTION: <Ref. to 2-10 [W2A2].> Apply a coat of grease to the contacting sur- faces of the push rod and piston before instal- lation.

  • Page 896: Brake Fluid

    2-10 SERVICE PROCEDURE [W7A0] 7. Brake Fluid ¼ The amount of brake fluid required is approxi- 7. Brake Fluid mately 70 m (2.4 US fl oz, 2.5 Imp fl oz) for total A: REPLACEMENT clutch system. CAUTION: 1) Either jack-up vehicle and place a safety stand ¼...

  • Page 897: Clutch Trouble In General

    2-10 DIAGNOSTICS [K100] 1. Clutch Trouble in General 1. Clutch Trouble in General Symptom Possible cause Corrective action 1. Clutch slippage (a) No clutch pedal play Readjust. It is hard to perceive clutch slippage in the early stage, but pay attention to the (b) No clutch release lever end play Readjust.
  • Page 898 2-10 DIAGNOSTICS [K100] 1. Clutch Trouble in General Symptom Possible cause Corrective action 5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc. When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc. partially engaged, the clutch engages (c) Worn or rusted spline of clutch disc Take off rust, apply grease or replace suddenly and the vehicle jumps instead...
  • Page 899 2-10 DIAGNOSTICS [K1A0] 1. Clutch Trouble in General A: DIAGNOSTIC DIAGRAM OF CLUTCH DRAG B2M1012A...
  • Page 900 2-10 DIAGNOSTICS MEMO:...
  • Page 901 ENGINE AND TRANSMISSION 2-11 MOUNTING SYSTEM Page COMPONENT PARTS ..................2 Engine Mounting ..................2 Transmission Mounting ................3 SERVICE PROCEDURE ...................6 Engine ......................6 Transmission .....................18...

  • Page 902: Component Parts

    2-11 COMPONENT PARTS [C100] 1. Engine Mounting 1. Engine Mounting B2M1024A (1) Front cushion rubber Tightening torque: N·m (kg-m, ft-lb) (2) Front engine mounting bracket 34±5 (3.5±0.5, 25.3±3.6) 41±10 (4.2±1.0, 30±7) 83±15 (8.5±1.5, 61±11)

  • Page 903: Transmission Mounting

    2-11 COMPONENT PARTS [C2A0] 2. Transmission Mounting 2. Transmission Mounting A: MT MODEL B2M3383C (1) Pitching stopper (7) Cushion D Tightening torque: N·m (kg-m, ft-lb) (2) Spacer (8) Center crossmember 34±5 (3.5±0.5, 25.3±3.6) (3) Cushion C (9) Rear plate 49±5 (5.0±0.5, 36.2±3.6) (4) Front plate (10) Front crossmember 57±10 (5.8±1.0, 42±7)
  • Page 904 2-11 COMPONENT PARTS [C2B0] 2. Transmission Mounting B: AT MODEL B2M3384A (1) Pitching stopper Tightening torque: N·m (kg-m, ft-lb) (2) Rear cushion rubber 34±5 (3.5±0.5, 25.3±3.6) (3) Crossmember 38±15 (3.9±1.5, 28±11) (4) Stopper 49±5 (5.0±0.5, 36.2±3.6) 57±10 (5.8±1.0, 42±7) 69±15 (7.0±1.5, 51±11)
  • Page 905 2-11 COMPONENT PARTS [C2B0] 2. Transmission Mounting MEMO:...
  • Page 906 2-11 SERVICE PROCEDURE [W1A0] 1. Engine 1. Engine 5) Drain coolant. Set container under the vehicle, and remove drain A: GENERAL PRECAUTION cock from radiator. 1) Remove or install engine in an area where chain hoists, lifting devices, etc. are available for ready use.

  • Page 907: Service Procedure

    2-11 SERVICE PROCEDURE [W1B0] 1. Engine (4) Remove ATF cooler pipe from cylinder (2) Collect refrigerant from A/C system. head. (3) Disconnect A/C flexible hoses from A/C compressor. S2M0744 G2M0270 (5) Remove V-belt cover. 8) Remove air intake system. Remove air intake duct with air cleaner case. <Ref. to 2-7 [W1A0].>...
  • Page 908 2-11 SERVICE PROCEDURE [W1B0] 1. Engine 10) Disconnect connectors, cables and hoses. (1) Disconnect the following connectors and cables. H2M2768E (1) Front oxygen sensor connector (5) A/C compressor connectors (7) Clutch cable (2200 cc MT (2) Engine harness connectors (With A/C) vehicle) (3) Engine ground terminal stay (6) Clutch release spring (2200 cc...
  • Page 909 2-11 SERVICE PROCEDURE [W1B0] 1. Engine B2M3413A B2M0019F S2M0731D B2M1291F B2M1302E B2M1301F...
  • Page 910 2-11 SERVICE PROCEDURE [W1B0] 1. Engine (2) Disconnect the following hoses. H2M2768G (1) Brake booster vacuum hose (3) Cruise control vacuum hose (2) Heater inlet and outlet hoses (With cruise control)
  • Page 911 2-11 SERVICE PROCEDURE [W1B0] 1. Engine B2M2776A S2M0902A S2M0493B 11) Remove power steering pump from bracket. (3) Remove bolts which install power steering (1) Loosen lock bolt and slider bolt, and remove pump from bracket. front side V-belt. S2M0086 G2M0286 (4) Place power steering pump on the right side (2) Remove pipe with bracket from intake mani- wheel apron.
  • Page 912 2-11 SERVICE PROCEDURE [W1B0] 1. Engine (2) Disconnect connector from rear oxygen CAUTION: sensor. Exhaust pipe will drop when all bolts are removed. So, hold it when removing the last bolt. 13) Remove nuts which hold lower side of trans- mission to engine.
  • Page 913 2-11 SERVICE PROCEDURE [W1B0] 1. Engine 16) Remove pitching stopper. 19) Support transmission with a garage jack. CAUTION: Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facili- tate re-installation and because transmission lowers under its own weight.
  • Page 914 2-11 SERVICE PROCEDURE [W1C0] 1. Engine C: INSTALLATION 3) Remove lifting device and wire ropes. 1) Install engine onto transmission. (1) Position engine in engine compartment and align it with transmission. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
  • Page 915 2-11 SERVICE PROCEDURE [W1C0] 1. Engine 6) Install torque converter onto drive plate. (AT (2) Install power steering pipe bracket on right model) side intake manifold, and install spark plug (1) Tighten bolts which hold torque converter to codes. drive plate. (2) Tighten other bolts while rotating the engine by using ST.
  • Page 916 2-11 SERVICE PROCEDURE [W1C0] 1. Engine 9) Tighten nuts which install front cushion rubber 16) Install A/C flexible hoses. (With A/C) onto crossmember. <Ref. to 4-7 [W16A0].> Tightening torque: CAUTION: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb) Use new O-rings. CAUTION: Tightening torque: Be sure to tighten front cushion rubber mount- 25±7 N·m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
  • Page 917 2-11 SERVICE PROCEDURE [W1C0] 1. Engine (3) Install radiator brackets and tighten bolts. (8) Install ATF cooler pipe to cylinder head. (2200 cc AT vehicle) Tightening torque: (9) Install V-belt cover. 13.7±1.5 N·m (1.4±0.15 kg-m, 10.1±1.1 ft-lb) S2M0896 18) Install battery in the vehicle, and connect G2M0218 cables.

  • Page 918: Transmission

    2-11 SERVICE PROCEDURE [W2A0] 2. Transmission 2. Transmission (1) Front oxygen sensor connector A: GENERAL PRECAUTION 1) Remove or install transmission in an area where chain hoists, lifting devices, etc. are avail- able for ready use. 2) Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil.
  • Page 919 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission 6) Disconnect the following cable. (2200 cc MT CAUTION: vehicle) Be careful not to drop bolts into torque con- verter housing. G2M0545 S2M0207 7) Remove starter. (1) Disconnect connectors and terminal from 10) Remove ATF level gauge. (AT vehicles) starter.
  • Page 920 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission 12) Set ST. (3) Remove nuts which install front exhaust ST 41099AA020 ENGINE SUPPORT ASSY pipe onto engine. NOTE: Also is available Part No. 927670000. S2M0205 (4) Separate center exhaust pipe from rear G2M0313 exhaust pipe.
  • Page 921 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (7) Remove rear exhaust pipe. 15) Drain ATF to remove ATF drain plug. (AT vehicles) CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. B3M1036A 16) Disconnect ATF cooler hoses from pipes of S2M0158 transmission side, and remove ATF level gauge guide.
  • Page 922 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (3) Remove bolts which hold center bearing (1) Remove snap pin from range select lever. onto body. CAUTION: Be careful not to drop propeller shaft. B3M1029A (2) Remove select cable from plate assembly. S2M0219 (4) Remove propeller shaft from transmission.
  • Page 923 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (3) Remove spring pins and separate front 24) Remove transmission rear crossmember. ¼ MT vehicles drive shafts from each side of the transmission. CAUTION: Discard removing spring pin. Replace with a new one. G2M0831 ¼...
  • Page 924 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission C: INSTALLATION 3) Install transmission rear crossmember. ¼ MT vehicles 1) Install ST to torque converter clutch case. (AT Tightening torque: vehicles) T1: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb) ST 498277200 STOPPER SET T2: 137±20 N·m (14±2 kg-m, 101±14 ft-lb) H2M1961A G2M0832 2) Install transmission to engine.
  • Page 925 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 6) Tighten bolt which holds right upper side of 8) Install operating cylinder. (2500 cc MT vehicle) transmission to engine. Tightening torque: Tightening torque: 37±3 N·m (3.8±0.3 kg-m, 27.5±2.2 ft-lb) 50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb) B2M1179B B2M2791 9) Remove special tools.
  • Page 926 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 11) Install front drive shafts into transmission. (1) Install gear shift rod onto transmission. (1) Lift-up the vehicle. Tightening torque: (2) Install front drive shaft into transmission. 18±5 N·m (1.8±0.5 kg-m, 13.6±3.6 ft-lb) (3) Drive spring pin into chamfered hole of drive shaft.
  • Page 927 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 15) Install ATF level gauge guide, and ATF cooler (1) Install heat shield cover. hoses onto pipe. (AT vehicles) S2M0215 S2M0909A (2) Install rear exhaust pipe to muffler. 16) Install propeller shaft. Tightening torque: (1) Install propeller shaft into transmission.
  • Page 928 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission (5) Install center exhaust pipe to rear exhaust 18) Install ATF level gauge. (AT vehicles) pipe. Tightening torque: 18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb) S2M0908A 19) Connect the following connectors. (1) Transmission harness connectors B2M0055 (6) Tighten bolt which installs center exhaust pipe to hanger bracket.
  • Page 929 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission (5) Neutral position and back-up light switch 21) Install air cleaner case stay. ¼ MT vehicles connector (MT vehicles) S2M0900 B2M0337 ¼ AT vehicles 20) Install starter. (1) Install starter onto transmission case, and connect connectors and terminals.
  • Page 930 2-11 SERVICE PROCEDURE MEMO:...
  • Page 931 TRANSMISSION AND DIFFERENTIAL SECTION FOREWORD This portion of the service manual has been prepared to provide SUBARU service personnel with the neces- sary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance,...
  • Page 932 All right reserved. This book may not be reproduced or copied, in whole or in part, without the written per- mission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN. SUBARU, are trademarks of FUJI HEAVY INDUSTRIES LTD. © Copyright 1999 FUJI HEAVY INDUSTRIES LTD.
  • Page 933 ¼ Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance and safe operation, function and performance which the SUBARU vehicle possesses. ¼ In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose parts numbers are designated or their equivalents must be utilized.
  • Page 934 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual 2. How to Use this Manual ¼ This Service Manual is divided into six volumes by section so that it can be used with ease at work. Refer to the Table of Contents, select and use the necessary section. ¼...
  • Page 935 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is useful for retrieving the necessary portion. H0M0010...
  • Page 936 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ In this manual, the following symbols are used. Symbol Description Selective part Replacement part Should be lubricated with oil. S0M0001 Should be lubricated with grease. S0M0002 Sealing point S0M0003 Tightening torque S0M0004 Character...
  • Page 937 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ WARNING, CAUTION, NOTE WARNING: Indicates the item which must be observed precisely during performance of maintenance services in order to avoid injury to the mechanics and other persons. CAUTION: Indicates the item which must be followed precisely during performance of maintenance services so as to avoid damage and breakage to the vehicle and its parts and components.
  • Page 938 FOREWORD SERVICE PROCEDURE [W3A0] 3. Basic Checks for Diagnostics ¼ To disconnect a locking connector, first release 3. Basic Checks for the lock, then pull the connector off. Diagnostics <Unlock by pulling the locking tab.> A: DISCONNECTING CONNECTORS ¼ Always hold the connector itself. CAUTION: Don’t pull the harness.
  • Page 939 FOREWORD SERVICE PROCEDURE [W3C1] 3. Basic Checks for Diagnostics ¼ When the connector has a back plate, remove B: INSERTING A PROBE the plate after removing the projection of the plate CAUTION: first. (Be careful not to use excessive force, since Poor contact has been identified as a primary the terminals might brake off.) cause of this problem.
  • Page 940 FOREWORD SERVICE PROCEDURE [W3C2] 4. Diagnosis and Checking Procedure Using Instruments 4. Diagnosis and Checking 2. VISUAL INSPECTION Procedure Using Instruments 1) Disconnect the two connector halves. 2) Check the connector pins for signs of corrosion A: USING A CIRCUIT TESTER or foreign material.
  • Page 941 ¼ Before changing the measurement range the gauge must be reset to zero. B: USING A SUBARU SELECT MONITOR With this testing procedure the defective compo- nent can be determined by directly monitoring input/output signals of the ECM or the trouble codes.
  • Page 942 FOREWORD SERVICE PROCEDURE [W500] 5. Table of Contents 5. Table of Contents 1-1 Specifications 1-2 ########## 1-3 General Information GENERAL INFORMATION SECTION 1-4 Pre-Delivery Inspection 1-5 Periodic Maintenance Services 1-6 Special Tools 2-1 Emission Control System and Vacuum Fitting 2-2 On-Car Services 2-3 Engine 2-4 Engine Lubrication System 2-5 Engine Cooling System...
  • Page 943 MANUAL TRANSMISSION AND DIFFERENTIAL Page SPECIFICATIONS AND SERVICE DATA............2 Manual Transmission and Differential............2 Transmission Gear Oil ................2 Transmission Case Assembly ..............2 Drive Pinion Assembly ................3 Reverse Idler Gear..................3 Shifter Fork and Rod...................4 Transfer Case....................4 Extension Assembly ..................5 Front Differential..................5 COMPONENT PARTS ..................6 Transmission Case..................6 Drive Pinion Assembly ................7 Main Shaft Assembly...................9...

  • Page 944: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Manual Transmission and Differential 1. Manual Transmission and Differential Model Item 2200 cc 2500 cc Type 5-forward speeds with synchromesh and 1-reverse 3.545 2.111 1.448 Transmission gear ratio 1.088 0.780 Reverse 3.333 Type of gear Hypoid Front reduction Final...

  • Page 945: Drive Pinion Assembly

    SPECIFICATIONS AND SERVICE DATA [S500] 5. Reverse Idler Gear 4. Drive Pinion Assembly 5. Reverse Idler Gear Preload adjustment of thrust bearing Adjustment of reverse idler gear position Starting torque Reverse idler gear to transmission case (LH) wall 0.3 — 0.8 N·m clearance (0.03 —...

  • Page 946: Shifter Fork And Rod

    SPECIFICATIONS AND SERVICE DATA [S600] 6. Shifter Fork and Rod 6. Shifter Fork and Rod 7. Transfer Case Select suitable shifter forks so that both coupling Neutral position adjustment sleeve and reverse driven gear are positioned in Adjustment shim the center of their synchromesh mechanisms. Part No.

  • Page 947: Extension Assembly

    SPECIFICATIONS AND SERVICE DATA [S900] 9. Front Differential 8. Extension Assembly 9. Front Differential Thrust washer (52 × 61 × t) to ball bearing side Bevel gear to pinion backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) clearance 0.05 — 0.30 mm (0.0020 — 0.0118 in) Washer (38.1 ×...

  • Page 948: Component Parts

    COMPONENT PARTS [C100] 1. Transmission Case 1. Transmission Case B3M1356A (1) Transmission case ASSY (7) Speedometer shaft (13) Clip (2) Gasket (8) Snap ring (Outer) (3) Drain plug (9) Oil seal Tightening torque: N·m (kg-m, ft-lb) (4) Snap ring (Outer) (10) Oil level gauge 44±3 (4.5±0.3, 32.5±2.2) (5) Speedometer driven gear...

  • Page 949: Drive Pinion Assembly

    COMPONENT PARTS [C2A0] 2. Drive Pinion Assembly 2. Drive Pinion Assembly A: 2200 cc MODEL H3M1778A (1) Drive pinion shaft (14) 1st driven gear (27) Lock nut (2) Roller bearing (15) Baulk ring (28) Washer (3) Washer (16) 1st-2nd synchronizer hub (29) Thrust bearing (4) Thrust bearing (17) Insert key...
  • Page 950 COMPONENT PARTS [C2B0] 2. Drive Pinion Assembly B: 2500 cc MODEL S3M0423A (1) Drive pinion shaft (15) Baulk ring (29) Lock nut (2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer (3) Washer (17) Insert key (31) Thrust bearing (4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve (19) Outer baulk ring...

  • Page 951: Main Shaft Assembly

    COMPONENT PARTS [C3A0] 3. Main Shaft Assembly 3. Main Shaft Assembly A: 2200 cc MODEL H3M1832A (1) Oil seal (13) Needle bearing (25) Insert stopper plate (2) Needle bearing (14) 4th gear thrust washer (26) Lock washer (3) Transmission main shaft (15) Ball bearing (27) Lock nut (4) Needle bearing...
  • Page 952 COMPONENT PARTS [C3B0] 3. Main Shaft Assembly B: 2500 cc MODEL B3M1357A (1) Oil seal (15) Needle bearing (29) Ball bearing (2) Needle bearing (16) 4th gear thrust washer (30) Synchro cone stopper (3) Transmission main shaft (17) Ball bearing (31) Snap ring (4) Needle bearing (18) 5th gear thrust washer...

  • Page 953: Shifter Fork And Shifter Rod

    COMPONENT PARTS [C400] 4. Shifter Fork and Shifter Rod 4. Shifter Fork and Shifter Rod H3M1966A (1) Shifter arm (9) 3rd-4th fork rod (17) Reverse fork rod arm (2) 5th shifter fork (10) Interlock plunger (18) Reverse shifter lever (3) Straight pin (11) 1st-2nd fork rod Tightening torque: N·m (kg-m, ft-lb) (4) Reverse fork rod...

  • Page 954: Transfer Case And Extension

    COMPONENT PARTS [C500] 5. Transfer Case and Extension 5. Transfer Case and Extension B3M1358A (1) Oil guide (16) O-ring (31) Ball bearing (2) Gasket (17) Adjusting select shim (32) Gasket (3) Transfer case (18) Reverse check sleeve (33) Extension (34) Oil seal (4) Ball (19) Gasket (5) Reverse accent spring...

  • Page 955: Front Differential

    COMPONENT PARTS [C600] 6. Front Differential 6. Front Differential H3M1967A (1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate (2) Hypoid driven gear (9) Roller bearing Tightening torque: N·m (kg-m, ft-lb) (3) Pinion shaft (10) Differential case (4) Straight pin (11) Oil seal 25±3 (2.5±0.3, 18.1±2.2)
  • Page 956 SERVICE PROCEDURE [W1A0] 1. General 1. General B: INSPECTION Disassembled parts should be washed clean first A: PRECAUTIONS and then inspected carefully. 1) The following job should be followed before dis- 1) Bearings assembly: Replace bearings in the following cases: (1) Clean oil, grease, dirt and dust from trans- ¼...

  • Page 957: Service Procedure

    SERVICE PROCEDURE [W1B0] 1. General ¼ If the gap between the end faces of the ring and 9) Differential gear the gear splined part is excessively small when the Repair or replace the differential gear in the follow- ing cases: ring is pressed against the cone.

  • Page 958: Transmission Case

    SERVICE PROCEDURE [W2A1] 2. Transmission Case 2. Transmission Case A: DISASSEMBLY 1. SEPARATION OF TRANSMISSION B3M0614G (1) Operating cylinder (2500 cc (4) Release bearing (8) Transmission case model) (5) Release lever sealing (9) Drive pinion ASSY (2) Release lever (2200 cc model) (6) Bolt (10) Main shaft ASSY (3) Release lever (2500 cc model)
  • Page 959 SERVICE PROCEDURE [W2A1] 2. Transmission Case 4) Remove main shaft rear plate. 7) Remove drive pinion shaft assembly from left side transmission case. NOTE: Use a hammer handle, etc. to remove if too tight. S3M0100B 5) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals.
  • Page 960 SERVICE PROCEDURE [W2A2] 2. Transmission Case 2. TRANSMISSION CASE S3M0104A (1) Straight pin (7) 3rd-4th fork rod (13) Reverse idler gear (2) 5th shifter fork (8) 3rd-4th shifter fork (14) Washer (3) Checking ball plug (9) 1st-2nd fork rod (15) Snap ring (4) Gasket (10) 1st-2nd shifter fork (16) Reverse fork rod arm...
  • Page 961 SERVICE PROCEDURE [W2A2] 2. Transmission Case 3) Drive out straight pin, and pull out 3-4 fork rod 6) Remove outer snap ring, and pull out reverse and shifter fork. shifter rod arm from reverse fork rod. Then take out ball, spring and interlock plunger from rod. NOTE: And then remove rod.
  • Page 962 SERVICE PROCEDURE [W2B1] 2. Transmission Case B: ASSEMBLY 1. TRANSMISSION CASE S3M0104B (1) Reverse shifter lever (9) Checking ball spring (17) 3rd-4th shifter fork (2) Reverse idler gear (10) Gasket (18) 5th shifter fork (3) Reverse idler gear shaft (11) Checking ball plug (4) Straight pin (12) Washer Tightening torque: N·m (kg-m, ft-lb)
  • Page 963 SERVICE PROCEDURE [W2B1] 2. Transmission Case 2) Install reverse shifter lever, reverse idler gear 5) Move reverse shifter rod toward REV side. and reverse idler gear shaft, and secure with Adjust clearance between reverse idler gear and straight pin. transmission case wall, using reverse shifter lever. NOTE: Clearance A: Be sure to install reverse idler shaft from the rear...
  • Page 964 SERVICE PROCEDURE [W2B1] 2. Transmission Case CAUTION: 13) Position balls, checking ball springs and gas- kets into 3-4 and 1-2 rod holes, and install plugs. Replace straight pin with a new one. CAUTION: NOTE: Replace gasket with a new one. ¼...
  • Page 965 SERVICE PROCEDURE [W2B2] 2. Transmission Case 2. COMBINATION OF TRANSMISSION CASE B3M0614E (1) Differential ASSY (9) O-ring (15) Operating cylinder (2500 cc (2) Drive pinion shim (10) Oil seal model) (3) Drive pinion ASSY (11) Retainer lock plate Tightening torque: N·m (kg-m, ft-lb) (4) Main shaft ASSY (12) Clutch release lever (2200 cc (5) Main shaft rear plate...
  • Page 966 SERVICE PROCEDURE [W2B2] 2. Transmission Case 3) Inspection and adjustment of ST Drive pinion shim NOTE: Part No. Thickness mm (in) ¼ Loosen the two bolts and adjust so that the scale 32295AA031 0.150 (0.0059) indicates 0.5 correctly when the plate end and the 32295AA041 0.175 (0.0069) scale end are on the same level...
  • Page 967 SERVICE PROCEDURE [W2B2] 2. Transmission Case ¼ Be careful not to drop oil seal when installing 1st driven gear to reverse driven gear right side transmission main case. Clearance (a): 9.5 mm (0.374 in) ¼ Make sure straight pin is positioned in hole in Reverse driven gear to 2nd driven gear needle bearing’s outer race.
  • Page 968 SERVICE PROCEDURE [W2B2] 2. Transmission Case 5th driven gear to coupling sleeve 14) Tighten 17 bolts with bracket, clip, etc. as Clearance (a): 9.3 mm (0.366 in) shown in the figure. NOTE: ¼ Insert bolts from the bottom and tighten nuts at the top.
  • Page 969 SERVICE PROCEDURE [W2B2] 2. Transmission Case 16) Backlash adjustment of hypoid gear and pre- 19) Remove weight and screw in retainer without load adjustment of roller bearing O-ring on the upper side and stop at the point where slight resistance is felt. NOTE: NOTE: Support drive pinion assembly with ST.
  • Page 970 SERVICE PROCEDURE [W2B2] 2. Transmission Case ¼ Backlash is excessive. NOTE: ¼ If backlash is outside specified range, adjust it To reduce backlash, loosen holder on the upper by turning holder in right side case. side (case right side) and turn in the holder on the ¼...
  • Page 971 SERVICE PROCEDURE [W2B2] 2. Transmission Case ¼ The drive pinion shim selected before is too thin. Increase its thickness. B3M0531A 28) Install clutch release lever and bearing. <Ref. to 2-10 [W3C0].> B3M0074 26) After checking the tooth contact of hypoid gears, remove the lock plate.

  • Page 972: Drive Pinion Assembly

    SERVICE PROCEDURE [W3A1] 3. Drive Pinion Assembly 3) Remove roller bearing and washer (33 × 50 × 3. Drive Pinion Assembly 5) using ST and press. A: DISASSEMBLY CAUTION: Do not reuse roller bearing. 1. DRIVE PINION SHAFT ST 498077000 REMOVER 1) Straighten lock nut at staked portion.
  • Page 973 SERVICE PROCEDURE [W3A3] 3. Drive Pinion Assembly 4) Remove roller bearing (42 × 74 × 40), 3rd and 1) Straighten lock nut at staked portion. Remove 4th driven gear using ST1 and ST2. the lock nut using ST1 and ST2. ST1 499757002 SNAP RING PRESS ST1 499987300 SOCKET WRENCH (50) ST2 899714110 REMOVER...
  • Page 974 SERVICE PROCEDURE [W3B0] 3. Drive Pinion Assembly 6) Remove 2nd driven gear, inner baulk ring, syn- B: ASSEMBLY chro cone and outer baulk ring. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton) during installation. 1.
  • Page 975 SERVICE PROCEDURE [W3B3] 3. Drive Pinion Assembly 6) Install lock washer (42 × 53 × 2). Install lock nut 3) Install 2nd driven gear, 1st-2nd baulk ring and (42 × 13) and tighten to the specified torque using insert onto driven shaft. After installing key on driven shaft, install 3rd-4th driven gear using ST and press.
  • Page 976 SERVICE PROCEDURE [W3B3] 3. Drive Pinion Assembly 3) Install 2nd driven gear bushing onto driven 5) After installing key on driven shaft, install 3rd- shaft using ST1, ST2 and press. 4th driven gear using ST and press. ST1 499277200 INSTALLER NOTE: ST2 499587000 INSTALLER Align groove in baulk ring with insert.
  • Page 977 SERVICE PROCEDURE [W3B4] 3. Drive Pinion Assembly 8) Install lock washer (42 × 53 × 2). Install lock nut 4. DRIVE PINION SHAFT (42 × 13) and tighten to the specified torque using 1) Install roller bearing onto drive pinion. Install washer (33 ×...
  • Page 978 SERVICE PROCEDURE [W3C1] 3. Drive Pinion Assembly 3) Install drive pinion collar, needle bearing, C: ADJUSTMENT adjusting washer No. 2, thrust bearing, adjusting 1. THRUST BEARING PRELOAD washer No. 1 and differential bevel gear sleeve in that order. 1) After completing the preceding steps 1) through 3), select adjusting washer No.
  • Page 979 SERVICE PROCEDURE [W3C1] 3. Drive Pinion Assembly 3) After removing ST2, measure starting torque 5) If specified starting torque range cannot be using torque driver. obtained when a No. 1 adjusting washer is used, then select a suitable No. 2 adjusting washer from ST1 899884100 HOLDER those listed in the following table.

  • Page 980: Main Shaft Assembly

    SERVICE PROCEDURE [W4A1] 4. Main Shaft Assembly 4. Main Shaft Assembly 4) Using ST1 and ST2, remove the rest of parts. NOTE: A: DISASSEMBLY Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage 1.
  • Page 981 SERVICE PROCEDURE [W4A2] 4. Main Shaft Assembly 3) Remove 5th-Rev sleeve and hub assembly, 5) Using ST1, ST2 and a press, remove ball baulk ring, 5th drive gear and needle bearing (32 bearing, synchro cone and baulk ring (Rev). × 36 × 25.7). NOTE: ¼...
  • Page 982 SERVICE PROCEDURE [W4B0] 4. Main Shaft Assembly 6) Using ST1 and ST2, remove the rest of parts. 1. 2200 cc MODEL NOTE: 1) Assemble sleeve and hub assembly for 3rd-4th Replace sleeve and hub with new ones. Do not and, 5th synchronizing. attempt to disassemble because they must engage NOTE: specified...
  • Page 983 SERVICE PROCEDURE [W4B1] 4. Main Shaft Assembly 4) Install baulk ring, needle bearing (32 × 30 × 7) Install the following parts to the rear section of 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft. transmission main shaft.
  • Page 984 SERVICE PROCEDURE [W4B2] 4. Main Shaft Assembly 2. 2500 cc MODEL 3) Install 4th needle bearing race onto transmis- sion main shaft using ST1, ST2 and a press. 1) Assemble sleeve and hub assembly for 3rd-4th ST1 899714110 REMOVER and, 5th synchronizing. ST2 499877000 RACE 4-5 INSTALLER NOTE: Position open ends of spring 120°...
  • Page 985 SERVICE PROCEDURE [W4B2] 4. Main Shaft Assembly 6) Using ST1 and ST2, install the 5th gear thrust 9) Install synchro cone stopper and snap ring to washer and 5th needle bearing race onto the rear 5th-Rev sleeve and hub assembly. section of transmission main shaft.

  • Page 986: Transfer Case And Extension

    SERVICE PROCEDURE [W5A0] 5. Transfer Case and Extension 5. Transfer Case and Extension 2) Remove transfer driven gear and center differ- ential as a set. A: REMOVAL 1) Remove back-up light switch and neutral switch. B3M1375A 3) Remove thrust washer. 2.
  • Page 987 SERVICE PROCEDURE [W5B4] 5. Transfer Case and Extension 3. EXTENSION 4. REVERSE CHECK SLEEVE 1) Remove transfer drive gear assembly. 1) Using a standard screwdriver, remove snap ring. NOTE: Replace snap ring with a new one if deformed or weakened. B3M1380 2) Remove shift bracket.
  • Page 988 SERVICE PROCEDURE [W5B5] 5. Transfer Case and Extension 5. TRANSFER DRIVEN GEAR 1) Using ST, remove ball bearing from transfer driven gear. ST 498077000 REMOVER B3M1385A 2) Using ST, remove ball bearing from transfer driven gear. ST 899864100 REMOVER B3M1386A...
  • Page 989 SERVICE PROCEDURE [W5C2] 5. Transfer Case and Extension C: ASSEMBLY 2. REVERSE CHECK SLEEVE 1) Install return spring (1st-2nd), return spring cap, CAUTION: reverse accent shaft, check cam, return spring and Do not apply pressure in excess of 10 kN (1 ton, check spring onto reverse check sleeve.
  • Page 990 SERVICE PROCEDURE [W5C3] 5. Transfer Case and Extension ¼ Move cam and shaft all the way toward plate 2) Install reverse check sleeve assembly to trans- and release. fer case. If cam does not return properly, replace reverse Tightening torque: check spring;...
  • Page 991 SERVICE PROCEDURE [W5C5] 5. Transfer Case and Extension 2) Install ball bearing to transfer driven gear. 4) Calculate space “Y” using the following equa- tion: Y = X − W + 0.24 mm (0.0094 in) [Thickness of gasket] 5) Select suitable washer in the following table: Standard clearance between thrust washer and ball bearing: 0.05 —...
  • Page 992 SERVICE PROCEDURE [W5D0] 5. Transfer Case and Extension 3) Install transfer case with extension assembly to Thrust washer transmission case. Part No. Thickness mm (in) Tightening torque: 803036050 0.9 (0.035) 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb) 803036054 1.0 (0.039) 803036051 1.1 (0.043) 803036055 1.2 (0.047)

  • Page 993: Front Differential

    SERVICE PROCEDURE [W6A0] 6. Front Differential 6. Front Differential 2. REVERSE CHECK PLATE ADJUSTMENT A: DISASSEMBLY 1) Shift shifter arm to “5th” and then to reverse to see if reverse check mechanism operates properly. 1) Remove right and left snap rings from 2) Also check to see if arm returns to neutral when differential, and then remove two axle drive shafts.
  • Page 994 SERVICE PROCEDURE [W6B0] 6. Front Differential 4) Pull out pinion shaft, and remove differential 2) Measure backlash between bevel gear and pin- bevel pinion and gear and washer. ion. If it is not within specifications, install a suitable washer to adjust it. NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.
  • Page 995 SERVICE PROCEDURE [W6B0] 6. Front Differential 4) Install roller bearing (40 × 80 × 19.75) to differ- 7) If it is not within specifications, replace snap ential case. ring with a suitable one. NOTE: Snap ring (Outer-28) Be careful because roller bearing outer races are Part No.

  • Page 996: Center Differential

    SERVICE PROCEDURE [W7A0] 7. Center Differential 7. Center Differential 2) Install ball bearing to center differential assem- bly. A: DISASSEMBLY AND ASSEMBLY NOTE: 1) Remove ball bearing using ST. Do not disassemble center differential because it is a non-disassemble part. CAUTION: Do not reuse ball bearing.

  • Page 997: Manual Transmission

    DIAGNOSTICS [K200] 2. Differential 1. Manual Transmission Symptom and possible cause Remedy 1. Gears are difficult to intermesh. The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the other is malfunction of the transmission.
  • Page 998 DIAGNOSTICS [K200] 2. Differential Symptom and possible cause Remedy (f) Loose hypoid driven gear clamping bolts Tighten. 5. Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of the trouble.
  • Page 999 AUTOMATIC TRANSMISSION AND DIFFERENTIAL Page SPECIFICATIONS AND SERVICE DATA............3 Torque Converter Clutch ................3 Oil Pump......................3 Transmission Control Element ..............4 Transmission Gear Ratio ................4 Planetary Gear and Plate................5 Selector Position ..................5 Hydraulic Control and Lubrication...............6 Cooling and Harness...................6 Transfer .......................7 Final Reduction ...................7 Adjusting Parts ....................9 Location and Installing Direction of Thrust Needle Bearing .....13 Fluid Passages..................15...
  • Page 1000 Transfer Valve Body ................107 Transmission Control Module (TCM) ............108 Dropping Resistor..................109...

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