Subaru 2002 IMPREZA Service Manual
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Subaru 2002 IMPREZA Service Manual

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Summary of Contents for Subaru 2002 IMPREZA

  • Page 2 2002 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G1840GE1) ENGINE 1 SECTION (Pub.No.G1840GE2) ENGINE 2 SECTION (Pub.No.G1840GE3) TRANSMISSION SECTION (Pub.No.G1840GE4) CHASSIS SECTION (Pub.No.G1840GE5) BODY SECTION (Pub.No.G1840GE6) WIRING SYSTEM SECTION (Pub.No.G1840GE7)
  • Page 3 2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 5 FOREWORD Page Foreword .....................2...
  • Page 6 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru IMPRE- Applied model: GG***** and GD***** from 2002MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANU- AL (Pub. No. G0864ZE) The manuals contain the latest information at the time of publication.

  • Page 7: How To Use This Manuals

    HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
  • Page 8 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.

  • Page 9: Specifications

    SPECIFICATIONS Page Impreza SA08731 ..................2...
  • Page 10 IMPREZA SPECIFICATIONS 1. Impreza SA08731 A: DIMENSIONS SA08731G28 Model Sedan Wagon OUTBACK Overall length mm (in) 4,405 (173.4) Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3) Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,485 (58.5)#4 1,495 (58.9)#4 Compartment...
  • Page 11 IMPREZA SPECIFICATIONS C: ELECTRICAL SA08731G30 Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Ignition timing at BTDC/rpm MT: 10°±10°/700 5°±10°/700 10°±10°/700 12°±10°/750 idling speed AT: 15°±10°/700 Spark Type and Without NGK: BKR6E NGK: BKR6E NGK: BKR6E (without plug manufacturer (without catalyst)
  • Page 12 IMPREZA SPECIFICATIONS E: STEERING SA08731G32 Model Turbo 2.0 L, 2.5 L OUTBACK OTHERS Type Rack and Pinion Turns, lock to lock RHD: 2.7 LHD: 3.0 Minimum turning circle m (ft) Curb to curb 11.0 (36.1) 10.8 (35.4) 10.4 (34.1) Wall to wall 12.0 (39.4) 11.6 (38.1) 11.2 (36.7)
  • Page 13 IMPREZA SPECIFICATIONS J: WEIGHT SA08731G37 1. LHD VEHICLE SA08731G3703 Sedan Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) (1,609) (1,654) (1,654) (1,698) (1,654) (1,698) (1,631) (1,676) Rear kgf (lb) (1,146) (1,146) (1,146) (1,146) (1,146) (1,146) (1,179) (1,179) Total kgf (lb) 1,250...
  • Page 14 IMPREZA SPECIFICATIONS Option code#1 Model 2.5 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) 760 (1,676) 785 (1,731) 815 (1,797) Rear kgf (lb) 535 (1,179) 530 (1,168) 550 (1,213) Total kgf (lb) 1,295 (2,855) 1,315 (2,899) 1,365 (3,009) Maximum permissible Front kgf (lb)
  • Page 15 IMPREZA SPECIFICATIONS Wagon Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) (1,620) (1,653) (1,664) (1,698) (1,664) (1,698) (1,642) (1,676) Rear kgf (lb) (1,202) (1,202) (1,202) (1,202) (1,202) (1,202) (1,235) (1,235) Total kgf (lb) 1,280 1,295 1,300 1,315 1,300 1,315 1,305...
  • Page 16 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) 805 (1,775) 825 (1,819) Rear kgf (lb) 585 (1,290) 585 (1,290) Total kgf (lb) 1,390 (3,065) 1,410 (3,109) Maximum permissible Front kgf (lb) 970 (2,138) 970 (2,138) axle weight (M.P.A.W.) Rear kgf (lb)
  • Page 17 IMPREZA SPECIFICATIONS 2. RHD VEHICLE SA08731G3704 Sedan Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) 735 (1,621) 755 (1,665) 750 (1,654) 770 (1,698) Rear kgf (lb) 520 (1,146) 520 (1,146) 520 (1,146) 520 (1,146) Total kgf (lb) 1,255 (2,767) 1,275 (2,811) 1,270 (2,800)
  • Page 18 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L 2.5 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,653) (1,709) (1,720) (1,775) (1,830) (1,885) (1,830) Rear kgf (lb) (1,179) (1,168) (1,191) (1,179) (1,235) (1,224) (1,235) Total kgf (lb) 1,285 1,305 1,320 1,340 1,390...
  • Page 19 IMPREZA SPECIFICATIONS Wagon Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) 740 (1,631) 755 (1,664) 755 (1,664) 770 (1,698) Rear kgf (lb) 545 (1,202) 545 (1,202) 545 (1,202) 545 (1,202) Total kgf (lb) 1,285 (2,833) 1,300 (2,866) 1,300 (2,866) 1,315 (2,900) Maximum permissible...
  • Page 20 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L OUT BACK Curb weight (C.W.) Front kgf (lb) 760 (1,676) 775 (1,709) 750 (1,653) 765 (1,687) Rear kgf (lb) 570 (1,257) 565 (1,246) 570 (1,257) 570 (1,257) Total kgf (lb) 1,330 (2,932) 1,340 (2,954) 1,320 (2,910) 1,335 (2,943) Maximum permissible...
  • Page 21 PRECAUTION Page Precaution ....................2...
  • Page 22 PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handing and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...
  • Page 23 NOTE Page Note......................2...
  • Page 24 ECM from rush current. 4. SERVICE PARTS Use authentic service parts for maximum perfor- mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor perfor- mance resulting from the use of parts not specified by a genuine dealer. NT-2...
  • Page 25 NOTE NOTE 5. LIFTS AND JACKS When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
  • Page 26 NOTE NOTE Front Front crossmember Rear Rear differential GI0121 NT-4...
  • Page 27 NOTE NOTE 6. TIE DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. Hook for tie-down Hook for towing Hook for towing Hook for tie-down and tie-down GI0122 NT-5...
  • Page 28 NOTE NOTE GI0103 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 45˚ 45˚ 45˚ 45˚ : Tie-down range GI0123 7. TOWING Avoid towing vehicles except when the vehicle can- not be driven. For vehicles with AWD, AT, or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damag- ing the hook or vehicle: •...
  • Page 29 For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-7...
  • Page 30 NOTE NOTE NT-8...
  • Page 31 IDENTIFICATION Page Identification ....................2...
  • Page 32 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification Emisson control label Vacuum hose piping label ID plate (Europe model) ADR compliance plate (Australia model) Tire inflation pressure label...
  • Page 33 IDENTIFICATION IDENTIFICATION GI0010A GI0011A ID-3...
  • Page 34 IDENTIFICATION IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1GD5LJ31G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line IMPREZA...
  • Page 35 IDENTIFICATION IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. GD9AL7R Digits Code...
  • Page 36 IDENTIFICATION IDENTIFICATION • Transmission TV1B4VYAAA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V: Full-time AWD AT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1B: AT Series 4: 5MT 4: AT Transmission specifica-...
  • Page 37 IDENTIFICATION IDENTIFICATION • Option code ECPS Digits Code Meaning Details 1 to 2 Destination EC: EC KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1 3 to 4 Main option of vehicle — ID-7...
  • Page 38 IDENTIFICATION IDENTIFICATION ID-8...
  • Page 39 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 40 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality. 2. FUEL Always use a gasoline of the same or higher octane value than specified in the owner's manual.
  • Page 41 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SL or SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 API: SH or SG...
  • Page 42 — 5. COOLANT Use genuine coolant to protect the engine. The table below shows the ratio of coolant to distilled water. Coolant Recommended Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution Distilled water — Tap water RM-4...
  • Page 43 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for DH-PR. Air conditioner Recommended Item number Alternative Refrigerant HFC134a —...
  • Page 44 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • Engine case Three Bond 1215 004403007 Dow Corning’s No. 7038 • Torque converter clutch case Transmission Three Bond 1217B...
  • Page 45 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 46 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. •...
  • Page 47 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION B: PDI PROCEDURE Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
  • Page 48 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 24. Read memory and test mode connectors (1) Read memory and test mode connectors 25. Starting condition (2) Start the engine and check that the engine starts smoothly. 26.
  • Page 49 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER HARNESS • If the vehicle is covered with protective coating, visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har- dents. ness disconnected to protect the air conditioner •...
  • Page 50 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 5. CHECK THE DOORS FOR LOCK/UN- 6. CHECK THE TRUNK LID FOR OPEN/ LOCK AND OPEN/CLOSE OPERATIONS. CLOSE OPERATIONS. Using the key, lock and unlock the door several • Operate the trunk lock release lever and verify times to check for normal operation.
  • Page 51 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 9. ACCESSORY CHECK 10.OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM Check that the following accessories are provided in the luggage compartment or cargo area. Operate the hood release knob (A) and check that • Owner's manual the hood is unlocked normally.
  • Page 52 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 11.BATTERY 15.AT FRONT DIFFERENTIAL OIL Check the battery terminals to make sure that no Check the AT front differential oil amount. If the rust or corrosions due to fluid leaks are found. amount is insufficient, check that no leaks are Check that the battery caps are securely tightened.
  • Page 53 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 20.KEYLESS ENTRY SYSTEM 24.READ MEMORY AND TEST MODE CON- NECTORS Check the keyless entry system operations as fol- lows. Turn the ignition switch to ON and check that the • Remove the key from the ignition switch and check-engine light starts blinking.
  • Page 54 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 30.CIGARETTE LIGHTER 36.PARKING BRAKE Check the cigarette lighter operations. Check the parking brake for normal operations. 31.LIGHTING SYSTEM 37.AT SHIFT CONTROL • Check the headlight operations. Set the AT select lever to each gear position while checking that the demanded gear position is cor- •...
  • Page 55 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 42.POWER STEERING FLUID LEVEL 44.WATER LEAK TEST Check that the power steering fluid level is normal. Spray the vehicle with water and check that no wa- If insufficient, check that no leaks are found. Then ter enters the passenger compartment. add the necessary amount of the specified power •...
  • Page 56 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PI-12...

  • Page 57: Table Of Contents

    PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................6 Engine Oil Filter...................8 Spark Plugs....................9 Drive Belt(s) ....................10 Camshaft Drive Belt ..................12 Fuel Line ....................15 Fuel Filter ....................16 Air Cleaner Element ..................17 Cooling System ..................18 Coolant......................19 Idle Mixture....................21 Clutch System ...................22 Hill-holder System ..................24 Transmission Oil ..................25 ATF ......................26...

  • Page 58: General Description

    GENERAL DESCRIPTION PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
  • Page 59 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. MAINTENANCE SCHEDULE 1 – (1) For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.

  • Page 60: Schedule

    SCHEDULE PERIODIC MAINTENANCE SERVICES Maintenance Interval [Number of months or km (miles), whichever occurs first] Months Remarks × 1,000 km × 1,000 miles Axle boots & joints Steering system (Power steering) Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) Periodic inspection and replacement of the camshaft drive chains on the 3.0 liter models are not required.
  • Page 61 SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace Replace...

  • Page 62: Engine Oil

    API classification 3) Replace the drain plug gasket. and SAE viscosity No. designated by SUBARU. 4) Tighten the engine oil drain plug after draining • If vehicle is used in desert areas with very high engine oil.
  • Page 63 ENGINE OIL PERIODIC MAINTENANCE SERVICES B: INSPECTION 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation.

  • Page 64: Engine Oil Filter

    ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT 1) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH GI0012A 2) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install the oil filter by turning it by hand, being careful not to damage the seal rubber.

  • Page 65: Spark Plugs

    SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs A: REPLACEMENT 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench. GI0018A 5) Set the new spark plug.

  • Page 66: Drive Belt(S)

    DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6. Drive Belt(s) B: REPLACEMENT A: INSPECTION 1. V-BELT COVER 1) Replace the belts, if cracks, fraying or wear is 1) Remove the V-belt cover. found. 2) Check the drive belt tension and adjust it if nec- essary by changing the generator installing position and/or idler pulley installing position.
  • Page 67 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 3. REAR SIDE BELT (DRIVING AIR CONDI- TIONER) NOTE: • Wipe off any oil or water on the belt and pulley. • Before removing the rear side belt, remove the front side belt. 1) Loosen the lock nut (A). 2) Loosen the slider bolt (B).

  • Page 68: Camshaft Drive Belt

    CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7. Camshaft Drive Belt 10) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprock- A: REPLACEMENT ets with notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET 1.
  • Page 69 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 10) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprock- 1) Remove the radiator fan and air conditioner fan. ets with notches of belt cover and cylinder block. To turn the crankshaft, use ST.
  • Page 70 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES B: INSTALLATION C: INSPECTION 1. SOHC MODEL 1. SOHC MODEL Install in the reverse order of removal. <Ref. to ME- 1) Remove the belt covers (RH) and (LH). 49, Timing Belt Assembly.> 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or 2.

  • Page 71: Fuel Line

    FUEL LINE PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU-71, Fuel Delivery, Return and Evaporation Lines.>...

  • Page 72: Fuel Filter

    FUEL FILTER PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU-68, Fuel Filter.> or <Ref. to FU(w/ oOBD)-65, Fuel Filter.> or <Ref. to FU(TURBO)- 65, Fuel Filter.> PM-16...

  • Page 73: Air Cleaner Element

    AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2. TURBO MODEL A: REPLACEMENT NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a spe- cial non-inflammable slow-evaporating viscous liq- uid.

  • Page 74: Cooling System

    COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 11.Cooling System 2) Check the radiator cap valve open pressure us- ing radiator cap tester. A: INSPECTION NOTE: 1) Check the radiator for leakage, filling it with cool- Rust or dirt on the cap may prevent the valve from ant and attach the radiator cap tester to filler neck.

  • Page 75: Coolant

    Approx. 7.0 2 (7.4 US qt, 6.2 Imp qt) NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- EN0073 case. Always use SUBARU Genuine Coolant, 5) For quick draining, open the radiator cap.
  • Page 76 The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.

  • Page 77: Idle Mixture

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

  • Page 78: Clutch System

    CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 14.Clutch System 2) Pedal-to-floor plate gap in disengaged position. (1) With the engine idling, pull the parking brake A: INSPECTION AND ADJUSTMENT lever completely. (2) Slowly depress the clutch pedal while mov- 1. MECHANICAL CLUTCH TYPE ing shift lever into reverse.
  • Page 79 CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 5) Check the fluid level using the scale on the out- side of the clutch master cylinder tank (A). If the lev- el is below “MIN” (B), add clutch fluid to bring it up to “MAX” (C). Recommended clutch fluid: FMVSS No.

  • Page 80: Hill-Holder System

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

  • Page 81: Transmission Oil

    TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 16.Transmission Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug after al- lowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0041 2) Reinstall the drain plug after draining gear oil and tighten it to the specified torque.

  • Page 82: Atf

    PERIODIC MAINTENANCE SERVICES 17.ATF 4) Fluid temperature rising speed • By idling the engine A: INSPECTION Time for temperature rise to 70°C (158°F) with at- 1) Raise the ATF temperature to 70 to 80°C (158 to mospheric temperature of 0°C (32°F): More than 176°F) from 20 to 30°C (68 to 86°F) (when cold) by 25 minutes driving a distance of 5 to 10 km (3 to 6 miles).
  • Page 83 PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 2. ATF FILTER NOTE: 1. AUTOMATIC TRANSMISSION FLUID ATF filter is a maintenance free part. ATF filter 1) Drain the ATF (Automatic Transmission Fluid) needs replacement, when it has physically dam- by removing drain plug after allowing the engine to aged or ATF leaked.

  • Page 84: Front & Rear Differential Oil

    FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Oil 3. REAR DIFFERENTIAL 1) Drain the oil by removing drain plug. A: REPLACEMENT 2) Remove the filler plug for quick draining oil. 1. FRONT DIFFERENTIAL (MANUAL 3) Reinstall the drain plug after draining oil. TRANSMISSION) NOTE: •...
  • Page 85 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 5) Install the filler plug onto rear differential gear case firmly. NOTE: • Apply fluid packing to the filler plug before instal- lation in Except Non-turbo AT model. • Non-turbo AT model uses a new aluminum gas- ket.

  • Page 86: Brake Line

    BRAKE LINE PERIODIC MAINTENANCE SERVICES 19.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on the brake hoses or pipe 1 —...
  • Page 87 BRAKE LINE PERIODIC MAINTENANCE SERVICES 3) Check the pedal stroke. 4) Check valve is built into the vacuum hose. Dis- connect the vacuum hose to inspect function of While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the check valve.

  • Page 88: Brake Fluid

    BRAKE FLUID PERIODIC MAINTENANCE SERVICES 20.Brake Fluid NOTE: • Cover the bleeder with waste cloth, when loosen- A: REPLACEMENT ing it, to prevent brake fluid from being splashed 1) Either jack-up the vehicle and place a safety over surrounding parts. stand under it, or lift-up the vehicle.

  • Page 89: Disc Brake Pads And Discs

    DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs 3) Check the disc rotor, and correct or replace if it is damaged or worn. A: INSPECTION • Non-turbo MODEL 1. DISC BRAKE PAD AND DISC Brake disc thickness mm (in) Front Rear...

  • Page 90: Brake Linings And Drums

    BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 22.Brake Linings and Drums 3) Check the brake drum for wear, dents or other damage. A: INSPECTION If the inside surface of brake drum is streaked, cor- rect the surface with emery cloth (#200 or more). If 1.
  • Page 91 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2) Check the brake drum for wear, dents or other B: ADJUSTMENT damage. If the inside surface of brake drum is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, tapered, or The main brake is adjusted automatically, and so the outside surface of brake drum is damaged, cor- there is no need to adjust it.

  • Page 92: Suspension

    SUSPENSION PERIODIC MAINTENANCE SERVICES 23.Suspension 5) Damage of dust seal Visually inspect the ball joint dust seal. If it is dam- A: INSPECTION aged, remove the transverse link. <Ref. to FS-16, Front Transverse Link.> And measure free play of 1. SUSPENSION BALL JOINT ball joint.
  • Page 93 SUSPENSION PERIODIC MAINTENANCE SERVICES 3. WHEEL ARCH HEIGHT 5. WHEEL ALIGNMENT OF REAR SUS- PENSION 1) Unload cargoes and set the vehicle in curb weight (empty) condition. 1) Check the alignment of rear suspension to en- 2) Then, check the wheel arch height of front and sure that following items are within standard val- rear suspensions to ensure that they are within ues.
  • Page 94 SUSPENSION PERIODIC MAINTENANCE SERVICES 8. DAMAGE TO SUSPENSION PARTS 1) Check the following parts and the fastening por- tion of the vehicle body for deformation or exces- sive rusting which impairs the suspension. If necessary, replace the damaged parts with new ones.

  • Page 95: Wheel Bearing

    WHEEL BEARING PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 6) While supporting the rear drive shaft horizontally with one hand, turn the hub COMPL with the other A: INSPECTION to check for noise or binding. If the hub COMPL is noisy or binds, disassemble 1.

  • Page 96: Axle Boots & Joints

    AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 25.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, re- place them with new ones. <Ref. to DS-33, Front Drive Shaft.>...

  • Page 97: Steering System (Power Steering)

    STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the point of the crossing direction).
  • Page 98 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL perimeter of adjusting screw thread. NOTE: The fluid level must be checked when the temper- ature of reservoir tank surface is approx. 20°C (68°F).
  • Page 99 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary. NOTE: Prevent the hoses from revolving and/or turning when installing hoses.

  • Page 100: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES 27.Supplemental Restraint System A: INSPECTION Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
  • Page 101 2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 1 SECTION FUEL INJECTION (FUEL SYSTEMS) EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) MECHANICAL This service manual has been prepared to provide SUBARU service personnel EXHAUST with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 103 FUEL INJECTION (FUEL SYSTEMS) Page General Description ..................2 Throttle Body.....................16 Intake Manifold..................17 Engine Coolant Temperature Sensor............31 Crankshaft Position Sensor...............32 Camshaft Position Sensor.................33 Knock Sensor....................34 Throttle Position Sensor................35 Intake Air Temperature and Pressure Sensor...........37 Atmospheric Pressure Sensor ..............38 Idle Air Control Solenoid Valve ..............39 Air Assist Injector Solenoid Valve .............40 Fuel Injector ....................41 Front Oxygen (A/F) Sensor ...............47...

  • Page 104: General Description

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 1600 cc and 2000 cc 2500 cc 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure...
  • Page 105 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) FU-3...
  • Page 106 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (25) (26) (21) (27) (14) (10) (21) (15) (17) (24) (11) (23) (22) (28) (16) (20) (19) (24) (12) (19) (13) (18) (20) (20) (19) EN1383 FU-4...
  • Page 107 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Intake manifold gasket RH (15) O-ring (28) Accelerator cable bracket Fuel injector pipe (16) Plug cord holder LH Fuel injector (17) Fuel pipe protector RH Tightening torque: N·m (kgf-m, ft-lb) O-ring (18) Fuel pipe ASSY T1: 1.5 (0.15, 1.1) O-ring (19)

  • Page 108: Air Intake System

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM B2M3455C Gasket Throttle body Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor T1: 1.6 (0.16, 1.2) Idle air control solenoid valve T2: 22 (2.2, 16.2) FU-6...
  • Page 109 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS B2M2282B Crankshaft position sensor Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) Knock sensor Camshaft position sensor support T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU-7...
  • Page 110 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK • 1600 CC and 2000 CC MODEL (25) (16) (10) (11) (11) (11) (14) (13) (24) (12) (24) (11) (11) (15) (11) (17) (19) (18) (20) (11) (21) (11) (22) (18) (19) (11) (23)
  • Page 111 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (11) Clip (21) Fuel pipe ASSY Fuel tank band (12) Evaporation hose B (22) Evaporation hose F Protector RH (13) Joint pipe (23) Fuel return hose B Fuel tank (14) Evaporation hose C (24) Evaporation hose G Fuel pump gasket...
  • Page 112 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) • 2500 CC MODEL (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (29) (13) (12) (12) (28) (16) (12) (12) (18) (21) (20) (22) (19) (27) (12) (12) (26) (23) (12) (24) (20) (12) (25)
  • Page 113 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
  • Page 114 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) EN0440 FU-12...
  • Page 115 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
  • Page 116 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (10) (11) EN0441 Fuel filler pipe ASSY Air vent pipe (11) Filler pipe protector Evaporation hose holder Air vent pipe holder Clip Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb) Clamp Filler ring T: 7.5 (0.76, 5.53)
  • Page 117 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.

  • Page 118: Throttle Body

    THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 6) Disconnect the air by-pass hose from air assist injector solenoid valve. A: REMOVAL 1) Disconnect the ground cable from battery. B2M3457A (A) Throttle position sensor G6M0095 (B) Idle air control solenoid valve 2) Remove the air cleaner case.

  • Page 119: Intake Manifold

    INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold (3) Remove the bolts which hold power steering pipes onto intake manifold protector. A: REMOVAL NOTE: 1) Release the fuel pressure. Do not disconnect the power steering hose. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.>...
  • Page 120 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place the power steering pump and tank on 12) Remove the air cleaner case stay RH and en- right side wheel apron. gine harness bracket, and disconnect the engine harness connectors from bulkhead harness con- nectors.
  • Page 121 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect the connector from oil pressure 19) Remove the bolts which hold intake manifold switch. onto cylinder heads. B2M1253 B2M4128 17) Disconnect the connector from camshaft posi- 20) Remove the intake manifold. tion sensor. B2M0160 B2M4263 B: INSTALLATION...
  • Page 122 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel hoses. 6) Connect the knock sensor connector. S2M0500F B2M4262 7) Connect the connectors to engine coolant tem- (A) Fuel delivery hose perature sensor. (B) Return hose (C) Evaporation hose 3) Connect the connector to camshaft position sen- sor.
  • Page 123 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 10) Connect the engine coolant hose to throttle (3) Tighten the bolts which install power steer- body. ing pump on bracket. Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) B2M4255 11) Connect the PCV hose to intake manifold. B2M3151 (4) Install the power steering pipes onto right side intake manifold protector.
  • Page 124 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Connect the cruise control cable (B). (With C: DISASSEMBLY cruise control models) 1) Disconnect the engine ground cable from intake manifold. B2M4254A B2M4265 16) Install the air intake duct and air cleaner as- sembly.
  • Page 125 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 5) Remove the intake air temperature and pressure 10) Disconnect the air by-pass hoses from air as- sensor from intake manifold. sist solenoid valve. B2M3475 B2M4266 6) Disconnect the connectors from throttle position 11) Remove the air assist injector solenoid valve sensor and idle air control solenoid valve.
  • Page 126 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 14) Remove the fuel pipe protector RH. 20) Remove the purge control solenoid valve. B2M4130 B2M3487 15) Disconnect the connectors from fuel injectors. 21) Remove the bolt which installs injector pipe on intake manifold as shown in the figure. B2M4270 H2M2965 16) Disconnect the connector from purge control...
  • Page 127 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 24) Remove the fuel injectors. 27) Loosen the clamp which holds front right side fuel hose to injector pipe, and remove the pipe from (1) Remove the fuel injector securing clip. fuel hose. B2M3488 B2M4274 (2) Remove the fuel injector while lifting up the 28) Remove the fuel injector pipe.
  • Page 128 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe, and tighten the clamp screw. 1) Install the fuel pipe assembly and pressure reg- ulator, etc. to intake manifold. 2) Tighten the bolt which installs fuel pipes on in- take manifold.
  • Page 129 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 7) Install the fuel injectors. 9) Tighten the two bolts which install fuel pipes on the left side of intake manifold. NOTE: Always use new O-rings. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3492G B2M4272 (A) O-ring...
  • Page 130 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 12) Connect the hoses to purge control solenoid 16) Install the fuel pipe protector RH. valve. Tightening torque: CAUTION: 19 N·m (1.9 kgf-m, 14.0 ft-lb) Carefully connect the evaporation hoses. B2M4130 B2M1893E 17) Install the fuel pipe protector LH. (A) To fuel pipe Tightening torque: (B) To intake manifold...
  • Page 131 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 19) Install the air assist injector solenoid valve to 23) Connect the connector to throttle position sen- bracket. sor and idle air control solenoid valve. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3479 24) Connect the air by-pass hose to throttle body.
  • Page 132 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 26) Connect the connector to intake air tempera- ture and pressure sensor. 27) Install the ignition coil and ignitor assembly. B2M3473 28) Connect the connector to ignition coil and igni- tor assembly. 29) Install the engine ground cable to intake mani- fold.

  • Page 133: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 16 N·m (1.6 kgf-m, 11.8 ft-lb) 1) Disconnect the ground cable from battery. B2M4275 G6M0095 2) Remove the air intake duct and air cleaner as- sembly.

  • Page 134: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) G6M0095 B2M1252B 2) Remove the bolt which installs crankshaft posi- tion sensor to cylinder block.

  • Page 135: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam- shaft position sensor support as a unit. A: REMOVAL 6) Remove the camshaft position sensor itself. 1) Disconnect the ground cable from battery. B2M2322 G6M0095 B: INSTALLATION...

  • Page 136: Knock Sensor

    KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...

  • Page 137: Throttle Position Sensor

    THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing the throttle position sensor, ad- just to the specified data.
  • Page 138 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3148 5) Turn the ignition switch to ON, and Subaru Se- lect Monitor switch to ON. B2M3765 6) Select the {2. Each System Check} in Main 4) When using the Subaru Select Monitor;...

  • Page 139: Intake Air Temperature And Pressure Sensor

    INTAKE AIR TEMPERATURE AND PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Air Temperature and B: INSTALLATION Install in the reverse order of removal. Pressure Sensor Tightening torque: A: REMOVAL 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) 1) Disconnect the ground cable from battery. B2M3497 G6M0095 NOTE:...

  • Page 140: Atmospheric Pressure Sensor

    ATMOSPHERIC PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Atmospheric Pressure Sen- B: INSTALLATION Install in the reverse order of removal. Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect the ground cable from battery. EN1001 G6M0095 2) Disconnect the connector from atmospheric pressure sensor.

  • Page 141: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use a new gasket. 1) Disconnect the ground cable from battery. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 2) Disconnect the connector from idle air control...

  • Page 142: Air Assist Injector Solenoid Valve

    AIR ASSIST INJECTOR SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 12.Air Assist Injector Solenoid B: INSTALLATION Install in the reverse order of removal. Valve Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect the ground cable from battery. B2M3503 G6M0095 2) Disconnect the connector from air assist injector...

  • Page 143: Fuel Injector

    FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13.Fuel Injector (3) Remove the bolts which install power steer- ing pump to bracket. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 144 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold. (1) Remove the fuel injector securing clip. B2M4130 B2M4283 8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the fuel injector pipe.
  • Page 145 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 8) Move the washer tank, and secure it away from working area. 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 146 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12) Remove the bolt which installs injector pipe to (2) Remove the fuel injector while lifting up the intake manifold. fuel injector pipe. B2M4133 H2M3241 B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Replace the O-rings with a new one.
  • Page 147 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 2. LH SIDE 19 N·m (1.9 kgf-m, 14.0 ft-lb) Install in the reverse order of removal. NOTE: Replace the O-rings with a new one. B2M4132 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M3492G (A) O-ring (B) Fuel injector...
  • Page 148 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M4133 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M4129 FU-46...

  • Page 149: Front Oxygen (A/F) Sensor

    21 N·m (2.1 kgf-m, 15.2 ft-lb) B2M4243 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen (A/F) sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the front oxygen (A/F) sensor.
  • Page 150 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. G6M0095 FU-48...

  • Page 151: Rear Oxygen Sensor

    Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) B2M4244 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of rear oxygen sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the rear oxygen sensor.
  • Page 152 REAR OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. G6M0095 FU-50...

  • Page 153: Engine Control Module

    ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 16.Engine Control Module B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage to fuel injection system.

  • Page 154: Main Relay

    MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 17.Main Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds main relay bracket on body.

  • Page 155: Fuel Pump Relay

    FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 18.Fuel Pump Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds fuel pump relay bracket on body.

  • Page 156: Fuel

    FUEL FUEL INJECTION (FUEL SYSTEMS) 19.Fuel 5) Drain fuel from the fuel tank. Set a container under the vehicle and remove the A: OPERATION drain plug from fuel tank. • 1600 cc and 2000 cc MODEL 1. RELEASING OF FUEL PRESSURE WARNING: •...

  • Page 157: Fuel Tank

    FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler hose and air vent hose from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
  • Page 158 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Connect the fuel hoses, and secure them with clips and quick connector. 1) Support the fuel tank with transmission jack and <Ref. to FU-73, INSTALLATION, Fuel Delivery, push the fuel tank harness into access hole with Return and Evaporation Lines.>...
  • Page 159 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 10) Connect the connector to fuel pump relay. EN0344 C: INSPECTION 1) Make sure there are no cracks, holes, or other damage on the fuel tank. 2) Make sure that the fuel hoses and fuel pipes are not cracked and that connections are tight.

  • Page 160: Fuel Filler Pipe

    FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un- der the vehicle and remove the drain plug from fuel A: REMOVAL tank. • 1600 cc and 2000 cc MODEL WARNING: •...
  • Page 161 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 11) Remove the fuel filler pipe protector. 16) Move the clip and separate air vent hose (B). EN0544 EN0548 12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of the fuel filler pipe.
  • Page 162 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 4) Install the air vent pipe. 7) Insert the air vent hose approx. 25 to 30 mm (0.98 to 1.18 in) into the lower end of air vent pipe and hold clip. L = 27.5 ± ± ± ± 2.5 mm (1.083 ± ± ± ± 0.098 in) EN0549 5) Connect the air vent hose to fuel filler pipe.
  • Page 163 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 10) Install the fuel filler pipe protector. EN0544 11) Install the rear right wheel. B2M1748 12) Lower the vehicle. 13) Tighten the wheel nuts. 14) Connect the connector to fuel pump relay. EN0344 15) Connect the battery ground cable to battery.

  • Page 164: Fuel Pump

    FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump 6) Tighten the fuel drain plug. Tightening torque: A: REMOVAL 26 N·m (2.7 kgf-m, 19.2 ft-lb) WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
  • Page 165 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 11) Move the clip and then disconnect the fuel re- 5) Drain fuel from the fuel tank. Set a container un- turn hose (B). der the vehicle and remove the drain plug from fuel tank.
  • Page 166 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 10) Disconnect the quick connector and then dis- • 2500 cc MODEL connect fuel delivery hose (A). <Ref. to FU(TUR- BO)-68, Fuel Delivery, Return and Evaporation Lines.> 11) Move the clips, and then disconnect the fuel re- turn hose (B) and jet pump hose (C).
  • Page 167 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Level Sensor 3) Remove the bolt which installs fuel level sensor on mounting bracket. A: REMOVAL • 1600 cc and 2000 cc MODEL WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 168 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Sub Level Sensor 6) Remove the service hole cover. A: REMOVAL NOTE: Fuel sub level sensor is equipped to only 2500 cc model. WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 169 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3178 FU-67...
  • Page 170 FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filter A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.>...
  • Page 171 FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Cut Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Remove the fuel tank.
  • Page 172 FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Damper Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Remove the fuel damper valve from fuel return line.
  • Page 173 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove fuel filler cap. Evaporation Lines 4) Remove the floor mat. <Ref. to EI-53, REMOV- AL, Floor Mat.> A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel 1) Set the vehicle on a lift.
  • Page 174 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 6) In the engine compartment, detach the fuel de- 9) Separate the quick connector on fuel delivery livery hoses, return hoses and evaporation hose. and return line. (1) Clean the pipe and connector, if they are covered with dust.
  • Page 175 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION CAUTION: • Pull the connector to ensure it is connected 1) Connect the quick connector on fuel delivery securely. line. • Ensure the two retainer pawls are engaged in NOTE: their mating positions in the connector.
  • Page 176 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 3) Connect the evaporation hose to pipe by approx. 15 mm (0.59 in) from the hose end. L = 17.5 ± ± ± ± 2.5 mm (0.689 ± ± ± ± 0.098 in) CAUTION: Be sure to inspect the hoses and their connec- tions for any leakage of fuel.
  • Page 177 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 29.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten ❍...
  • Page 178 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) FU-76...
  • Page 179 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister.......................7 Purge Control Solenoid Valve ..............8 Two-way Valve....................9...
  • Page 180 GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
  • Page 181 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter 7) Separate the center exhaust pipe from rear ex- haust pipe. A: REMOVAL CAUTION: 1) Set the vehicle on a lift. Be careful, the exhaust pipe is hot. 2) Disconnect the ground cable from battery.
  • Page 182 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 10) Separate the front catalytic converter from front 3) Tighten the nuts which hold front exhaust pipe exhaust pipe. onto cylinder heads. NOTE: Tightening torque: The rear catalytic converter is integrated with front 30 N·m (3.1 kgf-m, 22.4 ft-lb) catalytic converter.
  • Page 183 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7) Lower the vehicle. 8) Connect the front oxygen (A/F) sensor connec- tor. B2M4243 9) Connect the connector to rear oxygen sensor connector. B2M4244 10) Connect the battery ground cable to battery. G6M0095 NOTE: The rear catalytic converter is integrated with front...
  • Page 184 REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal and installation procedures are the same as the those for the front catalytic con- verter.
  • Page 185 CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Canister A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the two clamps which hold two canister hoses, and disconnect the three evaporation hoses from canister. EN0898 3) Remove the canister from body. B2M4166 B: INSTALLATION 1) Install in the reverse order of removal.
  • Page 186 PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Purge Control Solenoid Valve B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 16 N·m (1.6 kgf-m, 11.6 ft-lb) G6M0095 H2M2985 2) Remove the bolt which installs purge control so-...
  • Page 187 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Remove the canister from body. <Ref. to EC-7, REMOVAL, Canister.> 3) Remove the two-way valve with bracket as a sin- gle unit from body. EN0901 4) Remove the two-way valve from bracket.
  • Page 188 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC-10...
  • Page 189 INTAKE (INDUCTION) Page General Description ..................2 Air Cleaner Element ..................5 Air Cleaner Case..................6 Air Intake Duct.....................7 Resonator Chamber..................8...
  • Page 190 GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: COMPONENT (11) (11) (20) (19) (20) (13) (19) (11) (14) (10) (12) (16) (18) (17) (15) EN1336 IN-2...
  • Page 191 GENERAL DESCRIPTION INTAKE (INDUCTION) Spacer (11) Clip (20) Spacer Bush (12) Air cleaner element Resonator chamber (13) Air cleaner case B Tightening torque: N·m (kgf-m, ft-lb) Cushion rubber (14) Air cleaner case stay LH (MT vehi- T1: 33 (3.4, 24.6) cles) Air intake duct A (1600 cc and T2: 6.5 (0.66, 4.8)
  • Page 192 GENERAL DESCRIPTION INTAKE (INDUCTION) B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 193 AIR CLEANER ELEMENT INTAKE (INDUCTION) 2. Air Cleaner Element A: REMOVAL 1) Remove the clip (A) above the air cleaner case. H2M2947B 2) Remove the air cleaner element. B: INSTALLATION Install in the reverse order of removal. CAUTION: Fasten with a clip after inserting the lower tab of the case.
  • Page 194 AIR CLEANER CASE INTAKE (INDUCTION) 3. Air Cleaner Case A: REMOVAL 1) Loosen the clamp which connects air cleaner case to throttle body. H2M2946 2) Disconnect the hoses and intake duct from air cleaner case. 3) Remove the bolts which install air cleaner case to stays.
  • Page 195 AIR INTAKE DUCT INTAKE (INDUCTION) 4. Air Intake Duct • 2500 cc MODEL A: REMOVAL 1) Remove the bolts which install air intake duct A on the front side of body. • 1600 cc and 2000 cc MODEL B6M1224 B: INSTALLATION Install in the reverse order of removal.
  • Page 196 RESONATOR CHAMBER INTAKE (INDUCTION) 5. Resonator Chamber B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Remove the air intake duct. <Ref. to IN-7, RE- 33 N·m (3.4 kgf-m, 24.6 ft-lb) MOVAL, Air Intake Duct.> 2) Remove the resonator chamber.
  • Page 197 MECHANICAL Page General Description ..................2 Compression .....................24 Idle Speed ....................25 Ignition Timing...................26 Intake Manifold Vacuum................27 Engine Oil Pressure ..................28 Fuel Pressure....................29 Valve Clearance..................30 Engine Assembly ..................34 Engine Mounting ..................42 Preparation for Overhaul................43 V-belt......................44 Crankshaft Pulley ..................46 Belt Cover ....................48 Timing Belt Assembly................49 Camshaft Sprocket..................54 Crankshaft Sprocket..................56 Valve Rocker Assembly ................57...
  • Page 198 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Model 1600 cc 2000 cc 2500 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline Type engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder 87.9 x 65.8 99.5 x 79.0 Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95) (3.46 x 2.591)
  • Page 199 GENERAL DESCRIPTION MECHANICAL Bend limit 0.025 mm (0.0010 in) 0.030 — 0.090 mm (0.0012 — 0.0035 in) Thrust clearance Limit 0.10 mm (0.0039 in) 39.378 — 39.478 mm (1.5503 — 1.5542 in) Intake Limit 39.278 mm (1.5464 in) 1600 cc 39.565 —...
  • Page 200 GENERAL DESCRIPTION MECHANICAL Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in) Surface grinding limit 0.1 mm (0.004 in) 87.905 — 87.915 mm (3.4608 — 3.4612 in) 1600 cc 87.895 — 87.905 mm (3.4604 — 3.4608 in) 92.005 — 92.015 mm (3.6222 — 3.6226 in) Cylinder bore 2000 cc 91.995 —...
  • Page 201 GENERAL DESCRIPTION MECHANICAL 0.010 — 0.038 mm (0.0004 — 0.0015 in) 1600 cc 2000 cc Limit 0.05 mm (0.0020 in) Oil clearance 0.012 — 0.037 mm (0.0005 — 0.0015 in) 2500 cc Limit 0.05 mm (0.0020 in) 1.492 — 1.501 mm (0.0587 — 0.0591 in) 0.03 mm (0.0012 in) 1.510 —...
  • Page 202 GENERAL DESCRIPTION MECHANICAL 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 in) 2.017 — 2.020 mm (0.0794 — 0.0795 in) #1, #3 0.05 mm (0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in) 0.25 mm (0.0098 in) 2.127 —...

  • Page 203: Timing Belt

    GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT B2M3122A Belt cover No. 2 (RH) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb) ASSY Timing belt guide (MT vehicles T1: 5 (0.5, 3.6) only) (10) Belt idler No. 2 T2: 10 (1.0, 7.2) Crankshaft sprocket (11) Camshaft sprocket No.
  • Page 204 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT B2M1954D Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref. to ME-63, Installation, Cylinder Head Assembly.> Exhaust valve rocker ASSY (13) Camshaft cap (LH) Camshaft cap (RH)

  • Page 205: Valve Rocker Assembly

    GENERAL DESCRIPTION MECHANICAL 3. VALVE ROCKER ASSEMBLY B2M1956A Intake valve rocker arm Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb) Valve rocker nut Exhaust rocker shaft T1: 5 (0.5, 3.6) Valve rocker adjust screw Exhaust valve rocker arm T2: 10 (1.0, 7.2) Spring T3: 25 (2.5, 18.1) Rocker shaft support...
  • Page 206 GENERAL DESCRIPTION MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEMBLY B2M1955D Exhaust valve Intake valve oil seal Exhaust valve oil seal Intake valve Valve spring Valve guide Retainer Valve spring seat Retainer key ME-10...

  • Page 207: Cylinder Block

    GENERAL DESCRIPTION MECHANICAL 5. CYLINDER BLOCK EN1498 Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb) Cylinder block (RH) (15) Oil filter connector T1: 5 (0.5, 3.6) Service hole plug (16) Oil strainer T2: 6.4 (0.65, 4.7) Gasket (17) Gasket T3: 10 (1.0, 7.2)
  • Page 208 GENERAL DESCRIPTION MECHANICAL 6. CRANKSHAFT AND PISTON B2M3429A ME-12...
  • Page 209 GENERAL DESCRIPTION MECHANICAL Flywheel (MT) Circlip (17) Crankshaft bearing #2, #4 Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5 Drive plate (AT) (11) Connecting rod Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)

  • Page 210: Engine Mounting

    GENERAL DESCRIPTION MECHANICAL 7. ENGINE MOUNTING EN1005 Front cushion rubber Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.3, 31.0) T3: 85 (8.7, 63) ME-14...
  • Page 211 GENERAL DESCRIPTION MECHANICAL C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to • Wear working clothing, including a cap, protec- assembly. tive goggles, and protective shoes during opera- •...
  • Page 212 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SELECT MONI- Troubleshooting for electrical systems. TOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) B2M3877 498267800 CYLINDER •...
  • Page 213 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498457100 ENGINE STAND Used with ENGINE STAND (499817000). ADAPTER LH B2M3852 498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos- STOPPER ening and tightening crankshaft pulley bolt, etc. B2M3853 498547000 OIL FILTER Used for removing and installing oil filter.
  • Page 214 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498857100 VALVE OIL Used for press-fitting of intake and exhaust valve SEAL GUIDE guide oil seals. B2M3855 499017100 PISTON PIN Used for installing piston pin, piston and connect- GUIDE ing rod. B2M3856 499037100 CONNECTING Used for removing and installing connecting rod...
  • Page 215 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499097700 PISTON PIN Used for removing piston pin. REMOVER ASSY B2M3858 499207400 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket. (RH side) WRENCH B2M4158 499497000 TORX PLUS Used for removing and installing camshaft cap. B2M3873 499587100 OIL SEAL...
  • Page 216 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE INSTALLER (499597100). B2M3861 499587500 OIL SEAL Used for installing camshaft oil seal. INSTALLER B2M3874 499587700 CAMSHAFT OIL Used for installing cylinder head plug.
  • Page 217 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499597100 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL INSTALLER (499587200). B2M3863 499718000 VALVE SPRING Used for removing and installing valve spring. REMOVER B2M3864 499767200 VALVE GUIDE...
  • Page 218 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767700 VALVE GUIDE Used for installing valve guides. (Intake side) ADJUSTER 499767800 (Exhaust side) B2M3865 499817100 ENGINE STAND • Stand used for engine disassembly and assem- bly. • Used with ENGINE STAND ADAPTER RH (498457000) &...
  • Page 219 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499987500 CRANKSHAFT Used for rotating crankshaft. SOCKET B2M3871 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Compression Gauge Used for measuring compression. Tachometer (Secondary pick-up type) Used for measuring idle speed. Timing Light Used for measuring ignition timing.
  • Page 220 COMPRESSION MECHANICAL 2. Compression A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 1) After warming-up the engine, turn the ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release the fuel pressure.

  • Page 221: Idle Speed

    2) Warm-up the engine. 3) Stop the engine, and then turn the igintion switch to OFF. 4) When using the SUBARU SELECT MONITOR <Ref. to ME-15, SPECIAL TOOLS, PREPARA- TION TOOL, General Description.> (1) Insert the cartridge to SUBARU SELECT B2M3131 MONITOR.

  • Page 222: Ignition Timing

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

  • Page 223: Intake Manifold Vacuum

    INTAKE MANIFOLD VACUUM MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Warm-up the engine. 2) Disconnect the brake vacuum hose, and then in- stall the vacuum gauge to hose fitting on manifold. 3) Keep the engine at idle speed, and then read the vacuum gauge indication.

  • Page 224: Engine Oil Pressure

    ENGINE OIL PRESSURE MECHANICAL 6. Engine Oil Pressure 7) Start the engine, and then measure the oil pres- sure. A: INSPECTION 1) Disconnect the ground cable from battery. S2M0242 Oil pressure: G6M0095 98 kPa (1.0 kg/cm , 14 psi) or more at 800 rpm 2) Remove the generator from bracket.

  • Page 225: Fuel Pressure

    FUEL PRESSURE MECHANICAL 7. Fuel Pressure 6) Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake A: INSPECTION manifold. WARNING: Fuel pressure: Before removing the fuel pressure gauge, re- Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm lease the fuel pressure.

  • Page 226: Valve Clearance

    VALVE CLEARANCE MECHANICAL 8. Valve Clearance 8) When inspecting the #2 and #4 cylinders; (1) Disconnect the spark plug cords from spark A: INSPECTION plugs (LH Side) <Ref. to IG-5, LH SIDE, RE- MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)- CAUTION: 5, LH SIDE, REMOVAL, Spark Plug.>.
  • Page 227 VALVE CLEARANCE MECHANICAL 10) Measure the #1 cylinder valve clearance by us- 13) After inspection, install the related parts in the ing thickness gauge. reverse order of removal. CAUTION: Tightening torque: • Insert the thickness gauge (A) in as horizon- Resonator chamber;...
  • Page 228 VALVE CLEARANCE MECHANICAL B: ADJUSTMENT 2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. CAUTION: (2) Place suitable thickness gauge. Adjustment of the valve clearance should be (3) While noting the valve clearance, tighten the performed while engine is cold.
  • Page 229 VALVE CLEARANCE MECHANICAL 6) Similar to adjustment procedures used for #1 cylinder, adjust the #2, #3 and #4 cylinder valve clearances. NOTE: • Be sure to set the cylinder pistons to their re- spective top dead centers on compression stroke before adjusting valve clearances.

  • Page 230: Engine Assembly

    ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly 10) Remove the air cleaner case stay. • MT MODEL A: REMOVAL 1) Set the vehicle on lift arms. 2) Open the front hood fully, and then support with the hood stay. 3) Release the fuel pressure. <Ref. to FU-54, RE- LEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
  • Page 231 ENGINE ASSEMBLY MECHANICAL (3) Engine ground cable (6) Accelerator cable and cruise control cable S2M0731 B2M3415A (4) Engine harness connectors (A) Accelerator cable (B) Cruise control cable (7) Pressure switch EN0360 12) Disconnect the following hoses. (1) Brake booster vacuum hose B2M4292 (5) Generator connector, terminal and A/C compressor connector...
  • Page 232 ENGINE ASSEMBLY MECHANICAL 13) Remove the power steering pump from brack- (6) Place the power steering pump on right side wheel apron. (1) Remove the resonator chamber. (2) Loosen the lock bolt and slider bolt, and then remove the front side V-belt.<Ref. to ME- 44, FRONT SIDE BELT, REMOVAL, V-belt.>...
  • Page 233 ENGINE ASSEMBLY MECHANICAL 17) Separate the torque converter clutch from drive 20) Support the engine with a lifting device and plate. (AT model) wire ropes. (1) Lower the vehicle. (2) Remove the service hole plug. (3) Remove the bolts which hold torque con- verter clutch to drive plate.
  • Page 234 ENGINE ASSEMBLY MECHANICAL 23) Install the ST to torque converter clutch case. B: INSTALLATION (AT model) 1) Install the front cushion rubbers. ST 498277200 STOPPER SET Tightening torque: 34 N·m (3.5 kgf-m, 25.3 ft-lb) 2) Install the engine onto transmission. (1) Position the engine in engine compartment and align it with transmission.
  • Page 235 ENGINE ASSEMBLY MECHANICAL 6) Install the pitching stopper. 10) Install the power steering pump on bracket. (1) Install the power steering tank on bracket. Tightening torque: T1: 50 N·m (5.1 kgf-m, 37 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb) EN0361 (2) Install the power steering pump on bracket, and then tighten the bolts.
  • Page 236 ENGINE ASSEMBLY MECHANICAL (5) Install the front side V-belt, and adjust it. 13) Install the front and center exhaust pipe. <Ref. to ME-44, FRONT SIDE BELT, INSTAL- <Ref. to EX-8, INSTALLATION, Front Exhaust LATION, V-belt.> Pipe.> and <Ref. to EX(w/oOBD)-10, INSTALLA- TION, Front Exhaust Pipe.>...
  • Page 237 ENGINE ASSEMBLY MECHANICAL 23) Fill engine coolant. C: INSPECTION <Ref. to CO-26, FILLING OF ENGINE COOLANT, 1) Make sure the pipes and hoses are installed cor- REPLACEMENT, Engine Coolant.> rectly. 24) Check the ATF level and correct if necessary. 2) Make sure the engine coolant and ATF are at (AT model) specified levels.
  • Page 238 ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove the engine assembly. <Ref. to ME-34, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine as- sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; 34 N·m (3.5 kgf-m, 25.3 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.

  • Page 239: Preparation For Overhaul

    PREPARATION FOR OVERHAUL MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND B2M2582A 2) In this section the procedures described under each index are all connected and stated in order.
  • Page 240 V-BELT MECHANICAL 12.V-belt 3) Remove the A/C belt. 4) Remove the A/C belt tensioner. A: REMOVAL 1. FRONT SIDE BELT NOTE: Perform the following procedures 1) to 4) with the engine installed to body. 1) Remove the V-belt cover. B2M2585 B: INSTALLATION 1.
  • Page 241 V-BELT MECHANICAL 2. REAR SIDE BELT C: INSPECTION 1) Replace the belts, if cracks, fraying or wear is 1) Install the belt, and tighten the slider bolt (B) so found. as to obtain the specified belt tension. <Ref. to ME- 2) Check the drive belt tension and adjust it if nec- 45, INSPECTION, V-belt.>...

  • Page 242: Crankshaft Pulley

    CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley (4) Tighten the crankshaft pulley bolts. Tightening torque: A: REMOVAL 127 N·m (13.0 kgf-m, 94.0 ft-lb) 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley bolt. To lock the crankshaft, use ST. ST 499977300 (1600 cc and 2000 cc model) ST 499977100...
  • Page 243 CRANKSHAFT PULLEY MECHANICAL (4) Tighten the crankshaft pulley bolts. 7) Install the A/C belt. Tightening torque: 177 N·m (18.0 kgf-m, 130.2 ft-lb) B2M2584 C: INSPECTION 1) Make sure the V-belt is not worn or otherwise H2M2393A damaged. 5) Confirm that the tightening angle of crankshaft 2) Check the tension of the belt.

  • Page 244: Belt Cover

    BELT COVER MECHANICAL 14.Belt Cover A: REMOVAL 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover (LH). 4) Remove the front belt cover. B2M2587B (A) Belt cover (LH) (B) Front belt cover B: INSTALLATION...

  • Page 245: Timing Belt Assembly

    TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly A: REMOVAL 1. TIMING BELT 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME-48, RE- MOVAL, Belt Cover.>...
  • Page 246 TIMING BELT ASSEMBLY MECHANICAL 7) Remove the belt idler No. 2. B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUST- ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly; CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down.
  • Page 247 TIMING BELT ASSEMBLY MECHANICAL 2) Install the automatic belt tension adjuster as- 2. TIMING BELT sembly. 1) Preparation for the installation of automatic belt Tightening torque: tension adjuster assembly. <Ref. to ME-50, AUTO- MATIC BELT TENSION ADJUSTER ASSEMBLY 25 N·m (2.5 kgf-m, 18.1 ft-lb) AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>...
  • Page 248 TIMING BELT ASSEMBLY MECHANICAL 4) Install the belt idler (No. 2). (2) Check and adjust the clearance between timing belt and timing belt guide by using thick- Tightening torque: ness gauge. 39 N·m (4.0 kgf-m, 28.9 ft-lb) Clearance: 1.0 ± ± ± ± 0.5 mm (0.039 ± ± ± ± 0.020 in) S2M1008 5) After ensuring that the marks on timing belt and S2M0297...
  • Page 249 TIMING BELT ASSEMBLY MECHANICAL C: INSPECTION CAUTION: • Always use a vertical type pressing tool to 1. TIMING BELT move the adjuster rod down. • Do not use a lateral type vise. 1) Check the timing belt teeth for breaks, cracks, and wear.

  • Page 250: Camshaft Sprocket

    CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install the camshaft sprocket No. 1. To lock the A: REMOVAL camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET 1. REMOVAL WRENCH 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, Tightening torque: V-belt.> 78 N·m (8.0 kgf-m, 57.9 ft-lb) 2) Remove the crankshaft pulley.
  • Page 251 CAMSHAFT SPROCKET MECHANICAL 7) Install the V-belt. <Ref. to ME-44, INSTALLA- TION, V-belt.> C: INSPECTION 1) Check the sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprock- et and key. 3) Check the camshaft sprocket notch for sensor for damage and contamination of foreign matter.

  • Page 252: Crankshaft Sprocket

    CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket B: INSTALLATION 1) Install the crankshaft sprocket. A: REMOVAL 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME-48, RE- MOVAL, Belt Cover.>...
  • Page 253 VALVE ROCKER ASSEMBLY MECHANICAL 18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified torque. A: REMOVAL Tightening torque: 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, 25 N·m (2.5 kgf-m, 18.1 ft-lb) V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.>...
  • Page 254 VALVE ROCKER ASSEMBLY MECHANICAL E: INSPECTION 4) If oil clearance exceeds the limit, replace the rocker shaft support or shaft, whichever shows 1. VALVE ROCKER ARM greater amount of wear. 1) Measure the inside diameter of valve rocker arm Rocker shaft support inside diameter: and outside diameter of valve rocker shaft, and de- 22.005 —...
  • Page 255 CAMSHAFT MECHANICAL 19.Camshaft (1) Remove the bolts (a) through (b) in alpha- betical sequence. A: REMOVAL 1) Remove the V-belt. <Ref. to ME-44, INSTALLA- TION, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME-48, RE- MOVAL, Belt Cover.>...
  • Page 256 CAMSHAFT MECHANICAL 16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly. CAUTION: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when re- moving oil seal. B: INSTALLATION 1) Apply a coat of engine oil to the camshaft jour- nals, and then install the camshaft.
  • Page 257 CAMSHAFT MECHANICAL (6) Tighten the bolts (o) through (v) in alphabet- 6) Install the rocker cover and connect PCV hose. ical sequence. 7) Install the oil level gauge guide. (LH side only) 8) Install the camshaft position sensor support. (LH Tightening torque: side only) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
  • Page 258 CAMSHAFT MECHANICAL C: INSPECTION Model Item Unit: mm (in) 39.485 — 39.585 1. CAMSHAFT (1.5545 — 1.5585) Intake 1) Measure the bend, and repair or replace if nec- Limit 39.385 (1.5506) 2500 cc essary. 39.257 — 39.357 (1.5455 — 1.5495) Exhaust Limit: Limit...

  • Page 259: Cylinder Head Assembly

    CYLINDER HEAD ASSEMBLY MECHANICAL 20.Cylinder Head Assembly 13) Remove the cylinder head gasket. CAUTION: A: REMOVAL Do not scratch the mating surface of cylinder 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, head and cylinder block. V-belt.> 14) Similarly, remove the right side cylinder head. 2) Remove the crankshaft pulley.
  • Page 260 CYLINDER HEAD ASSEMBLY MECHANICAL 6) Install the intake manifold. <Ref. to FU-19, IN- STALLATION, Intake Manifold.> or <Ref. to FU(w/ oOBD)-20, INSTALLATION, Intake Manifold.> 7) Install the camshaft sprocket. <Ref. to ME-54, INSTALLATION, Camshaft Sprocket.> 8) Install the timing belt assembly. <Ref. to ME-50, INSTALLATION, Timing Belt Assembly.>...
  • Page 261 CYLINDER HEAD ASSEMBLY MECHANICAL D: ASSEMBLY B2M2629B Valve Retainer (11) Plug Valve guide Retainer key (12) Camshaft cap Valve spring seat Spark plug gasket (13) Valve rocker ASSY Oil seal Camshaft Valve spring (10) Oil seal 1) Installation of valve spring and valve (4) Set the ST on valve spring.
  • Page 262 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Compress the valve spring, and then fit the 2. INTAKE AND EXHAUST VALVE OIL valve spring retainer key. SEAL Replace the oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of in- take valve and valve seat are reconditioned or in- take valve guide is replaced.
  • Page 263 CYLINDER HEAD ASSEMBLY MECHANICAL 3) Measure the warping of the cylinder head sur- 2. VALVE SEAT face that mates with crankcase using a straight Inspect the intake and exhaust valve seats, and edge and thickness gauge. then correct the contact surfaces with valve seat If the warping exceeds 0.05 mm (0.0020 in), re- cutter if they are defective or when valve guides are grind the surface with a surface grinder.
  • Page 264 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (2) Insert the ST2 into valve guide and press it down to remove valve guide. 1) Check the clearance between valve guide and ST1 498267800 CYLINDER HEAD TABLE stem. The clearance can be checked by measuring ST2 499767200 VALVE GUIDE REMOVER the outside diameter of valve stem and the inside...
  • Page 265 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST. oil, in the cylinder, and then insert the ST1 into Gently rotate the reamer clockwise while press- valve guide. Press in until the valve guide upper ing it lightly into valve guide, and return it also ro- end is flush with the upper surface of ST2.
  • Page 266 CYLINDER HEAD ASSEMBLY MECHANICAL 4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and re- place if damaged, worn, or deformed, or if “H” is less than the specified limit. Intake Standard 1.0 mm (0.039 in) Limit 0.6 mm (0.024 in) Exhaust Standard 1.2 mm (0.047 in)
  • Page 267 CYLINDER BLOCK MECHANICAL 21.Cylinder Block 12) Remove the bolts (a) and (b) to remove cylin- der head. A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely if applicable. 1) Remove the intake manifold. <Ref. to FU-17, REMOVAL, Intake Manifold.> or <Ref. to FU(w/ oOBD)-17, REMOVAL, Intake Manifold.>...
  • Page 268 CYLINDER BLOCK MECHANICAL ST1 498497100 CRANKSHAFT STOPPER 21) Removal of oil pan ST2 499057000 TORX PLUS (1) Turn the cylinder block with #2 and #4 piston sides facing upward. (2) Remove the bolts which secure oil pan to cylinder block. (3) Insert a oil pan cutter blade between cylin- der block-to-oil pan clearance, and then remove the oil pan.
  • Page 269 CYLINDER BLOCK MECHANICAL S2M1590B Service hole plug Circlip Service hole cover Gasket Piston pin O-ring 27) Remove the service hole cover and service 28) Rotate the crankshaft to bring #1 and #2 pis- hole plugs using hexagon wrench [14 mm (0.55 tons to bottom dead center position, and then re- in)].
  • Page 270 CYLINDER BLOCK MECHANICAL 29) Draw out the piston pin from #1 and #2 pistons 30) Similarly remove the piston pins from #3 and #4 using ST. pistons. ST 499097700 PISTON PIN REMOVER 31) Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
  • Page 271 CYLINDER BLOCK MECHANICAL B: INSTALLATION B2M2407A Crankshaft bearing Rear oil seal Tightening torque: N·m (kgf-m, ft-lb) Crankshaft T1: 25 (2.5, 18.1) Cylinder block T2: 47 (4.8, 34.7) CAUTION: CAUTION: Remove oil in the mating surface of bearing and Do not allow fluid packing to jut into O-ring cylinder block before installation.
  • Page 272 CYLINDER BLOCK MECHANICAL 3) Temporarily tighten the 10 mm cylinder block 6) Install the rear oil seal using ST1 and ST2. connecting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE the figure. ST2 499587200 OIL SEAL INSTALLER B2M0088D S2M1827A 4) Tighten the 10 mm cylinder block connecting...
  • Page 273 CYLINDER BLOCK MECHANICAL • 2500 cc MODEL 10) Position the lower rail gap at (D) in the figure. • 1600 cc MODEL 180˚ B5SH B2M4618A EN1379 9) Position the expander gap at (C) in the figure. • 1600 cc MODEL •...
  • Page 274 CYLINDER BLOCK MECHANICAL 11) Position the upper rail gap at (G) in the figure. 12) Install circlip. • 1600 cc MODEL Install circlips in the piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new circlips.
  • Page 275 CYLINDER BLOCK MECHANICAL • 2500 cc MODEL B5SH B2M4626A (A) Front mark B2M1322J Piston Gasket Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole plug T: 69 (7.0, 50.6) Circlip 13) Installing piston ST2 498747300 PISTON GUIDE (2500 cc model) (1) Turn the cylinder block so that #1 and #2 cyl- inders face upward.
  • Page 276 CYLINDER BLOCK MECHANICAL 14) Installing piston pin (5) Install the service hole plug and gasket. (1) Insert the ST3 into service hole to align pis- NOTE: ton pin hole with connecting rod small end. Use a new gasket. CAUTION: Apply a coat of engine oil to the ST3 before in- sertion.
  • Page 277 CYLINDER BLOCK MECHANICAL B2M1323K Piston Service hole plug Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7) Circlip O-ring T2: 69 (7.0, 50.6) Gasket (6) Turn the cylinder block so that #3 and #4 cyl- 19) Apply fluid packing to the matching surfaces, inders face upward.
  • Page 278 CYLINDER BLOCK MECHANICAL 20) Apply fluid packing to the matching surfaces, ST1 498497100 CRANKSHAFT STOPPER and then install the oil separator cover. ST2 499057000 TORX PLUS Fluid packing: THREE BOND 1215 or equivalent B2M3347A 22) Install the housing cover. 23) Installation of oil pump S2M1834A (1) Discard the front oil seal after removal.
  • Page 279 CYLINDER BLOCK MECHANICAL 26) Install the oil filter using ST. ST 498547000 OIL FILTER WRENCH S2M0118B (4) Install the oil pump on cylinder block. Be B2M2611A careful not to damage the oil seal during instal- lation. 27) Tighten the cylinder head bolts. (1) Apply a coat of engine oil to the washers and Tightening torque: bolt threads.
  • Page 280 CYLINDER BLOCK MECHANICAL 32) Install the timing belt assembly. <Ref. to ME- 50, INSTALLATION, Timing Belt Assembly.> 33) Install the belt cover. <Ref. to ME-48, INSTAL- LATION, Belt Cover.> 34) Install the crankshaft pulley. <Ref. to ME-46, INSTALLATION, Crankshaft Pulley.> 35) Install the generator and A/C compressor brackets on cylinder head.
  • Page 281 CYLINDER BLOCK MECHANICAL C: DISASSEMBLY B2M1320I Connecting rod cap Top ring Oil ring Connecting rod bearing Second ring Circlip 1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. CAUTION: Arrange the removed connecting rod, connect- ing rod cap and bearing in order to prevent con- fusion.
  • Page 282 CYLINDER BLOCK MECHANICAL D: ASSEMBLY B2M1320J Connecting rod bearing Second ring Tightening torque: N·m (kgf-m, ft-lb) Connecting rod Top ring T: 44.6 (4.55, 32.9) Connecting rod cap Circlip Oil ring 1) Install the connecting rod bearings on connect- E: INSPECTION ing rods and connecting rod caps.
  • Page 283 CYLINDER BLOCK MECHANICAL Standard diameter: 2) How to measure the inner diameter of each cyl- inder 1600 cc MODEL Measure the inner diameter of each cylinder in both A: 87.905 — 87.915 mm (3.4608 — 3.4612 the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge.
  • Page 284 CYLINDER BLOCK MECHANICAL 4) How to measure the outer diameter of each pis- Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) CAUTION: Measurement should be performed at a temper- ature of 20° ° ° ° C (68° ° ° ° F). Piston grade point H: 1600 cc and 2000 cc MODEL 40.0 mm (1.575 in)
  • Page 285 CYLINDER BLOCK MECHANICAL 3. PISTON AND PISTON PIN 5) Check the piston pin circlip for distortion, cracks and wear. 1) Check the pistons and piston pins for damage, cracks, and wear and the piston ring grooves for 4. PISTON RING wear and damage.
  • Page 286 CYLINDER BLOCK MECHANICAL 2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD inder, and then measure the piston ring gap with a 1) Replace the connecting rod, if the large or small thickness gauge. end thrust surface is damaged. 2) Check for bend or twist using a connecting rod Unit: mm (in) aligner.
  • Page 287 CYLINDER BLOCK MECHANICAL 4) Inspect the connecting rod bearing for scar, Connecting rod oil clearance: peeling, seizure, melting, wear, etc. • 2500 cc MODEL 5) Measure the oil clearance on individual connect- Standard ing rod bearings by means of plastigauge. If any oil 0.012 —...
  • Page 288 CYLINDER BLOCK MECHANICAL 7) Replacement procedure is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSH- ING REMOVER AND IN- STALLER G2M0177 (3) Make two 3 mm (0.12 in) holes in bushing.
  • Page 289 CYLINDER BLOCK MECHANICAL 6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the BEARING bearing with a suitable (undersize) one, and then 1) Clean the crankshaft completely and check for replace or recondition the crankshaft as necessary.
  • Page 290 CYLINDER BLOCK MECHANICAL 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) EN0341 5) Inspect the individual crankshaft bearings for signs of flaking, seizure, melting, and wear.

  • Page 291: Engine Trouble In General

    ENGINE TROUBLE IN GENERAL MECHANICAL 22.Engine Trouble in General A: INSPECTION 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 — Rarely TROUBLE PROBLEM PARTS, ETC.
  • Page 292 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3) Initial combustion occur. • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Defective intake manifold gasket •...
  • Page 293 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 2. Rough idle and engine • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ stall oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked intake duct •...
  • Page 294 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ poor acceleration oOBD)-2, Basic Diagnostic Procedure.> • Intake system •...
  • Page 295 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ idle. oOBD)-2, Basic Diagnostic Procedure.> • Intake system •...
  • Page 296 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ tion oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Dirty air cleaner element •...

  • Page 297: Engine Noise

    ENGINE NOISE MECHANICAL 23.Engine Noise A: INSPECTION Type of sound Condition Possible cause • Valve mechanism is defective. • Incorrect valve clearance Sound increases as engine Regular clicking sound • Worn valve rocker speed increases. • Worn camshaft • Broken valve spring •...
  • Page 298 ENGINE NOISE MECHANICAL ME-102...
  • Page 299 EXHAUST Page General Description ..................2 Front Exhaust Pipe..................7 Center Exhaust Pipe .................10 Rear Exhaust Pipe ..................11 Muffler .......................12...
  • Page 300 GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT 1. 1600 CC (16) (15) (13) (14) (16) (11) (10) (12) (16) (27) (26) (17) (28) (22) (18) (25) (24) (23) (31) (30) (19) (29) (21) (20) (31) EN1372 EX-2...
  • Page 301 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (13) Gasket (27) Rear oxygen sensor (14) Self-locking nut (28) Upper rear catalytic converter Lower front exhaust pipe cover (15) Muffler cover (16) Cushion rubber (29) Lower rear catalytic converter Clamp (17) Lower clamp cover Upper front exhaust pipe cover LH...
  • Page 302 GENERAL DESCRIPTION EXHAUST 2. 2000 CC AND 2500 CC (16) (15) (13) (14) (16) (11) (10) (17) (16) (12) (28) (27) (18) (29) (23) (19) (26) (25) (24) (32) (31) (20) (30) (22) (21) (32) EN1373 EX-4...
  • Page 303 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (14) Self-locking nut (29) Upper rear catalytic converter (15) Muffler cover Lower front exhaust pipe cover (16) Cushion rubber (30) Lower rear catalytic converter cover (17) Rear exhaust pipe Clamp (18) Lower clamp (31) Rear catalytic converter Upper front exhaust pipe cover LH...
  • Page 304 GENERAL DESCRIPTION EXHAUST B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 305 FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 5) Separate the front and center exhaust pipe as- sembly from rear exhaust pipe. A: REMOVAL WARNING: 1) Disconnect the ground cable from battery. Be careful, the exhaust pipe is hot. G6M0095 B2M3109 2) Disconnect the front oxygen (A/F) sensor con- 6) Remove the under cover.
  • Page 306 FRONT EXHAUST PIPE EXHAUST 9) Remove the front and center exhaust pipe as- 4) Temporarily tighten the bolt which installs front sembly from vehicle. and center exhaust pipe assembly to hanger brack- CAUTION: • Be careful not to let the front and center ex- haust pipe assembly fall off when removing as it is quite heavy.
  • Page 307 FRONT EXHAUST PIPE EXHAUST 8) Tighten the bolt which holds front and center ex- C: INSPECTION haust pipe assembly to hanger bracket. 1) Make sure there are no exhaust leaks from con- nections and welds. Tightening torque: 2) Make sure there are no holes or rusting. 35 N·m (3.6 kgf-m, 26.0 ft-lb) B2M3111 9) Lower the vehicle.
  • Page 308 CENTER EXHAUST PIPE EXHAUST 3. Center Exhaust Pipe A: REMOVAL After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX-7, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
  • Page 309 Tightening torque: G2M0382 18 N·m (1.8 kgf-m, 13.0 ft-lb) 3) Apply a coat of SUBARU CRC to mating area of the cushion rubbers in advance. SUBARU CRC (Part No. 004301003) 4) Remove the rear exhaust pipe bracket from the cushion rubber.
  • Page 310 Be careful, the exhaust pipe is hot. 48 N·m (4.9 kgf-m, 35.4 ft-lb) G2M0382 G2M0382 2) Apply a coat of SUBARU CRC to mating area of C: INSPECTION the cushion rubbers in advance. 1) Make sure there are no exhaust leaks from con- SUBARU CRC (Part No.
  • Page 311 COOLING Page General Description ..................2 Radiator Main Fan System................10 Radiator Sub Fan System .................18 Engine Coolant..................26 Water Pump ....................28 Thermostat ....................37 Radiator.....................39 Radiator Cap .....................47 Radiator Main Fan and Fan Motor ............48 Radiator Sub Fan and Fan Motor..............50 Reservoir Tank..................52 Coolant Filler Tank ..................53 Engine Cooling System Trouble in General ..........54...
  • Page 312 GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Model Non-turbo Turbo Cooling system Electric fan + Forced engine coolant circulation system 1.6 L AT: Approx. 7.3 (7.71, 6.42) 1.6 L MT: Approx. 7.4 AT: Approx. 7.6 (7.82, 6.51) (8.03, 6.69) 2 (US qt, Imp qt) Total engine coolant capacity 2.0 and 2.5 L AT: Approx.
  • Page 313 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP • NON-TURBO MODEL H2M2354A Water pump ASSY Gasket Tightening torque: N·m (kgf-m, ft-lb) Gasket Thermostat cover T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Heater by-pass hose Thermostat T2: 6.4 (0.65, 4.7) CO-3...
  • Page 314 GENERAL DESCRIPTION COOLING • TURBO MODEL H2M1785B Thermostat cover Heater by-pass hose Tightening torque: N·m (kgf-m, ft-lb) Gasket Coolant filler tank by-pass hose T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Thermostat Water by-pass pipe Water pump ASSY T2: 6.4 (0.65, 4.7) Gasket CO-4...
  • Page 315 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN • NON-TURBO MODEL (12) (10) (15) (11) (13) (24) (16) (17) (16) (14) (18) (21) (16) (16) (16) (23) (19) (20) (16) (22) EN0068 Radiator lower cushion (14) Radiator main fan (22) Radiator outlet hose Radiator (15)
  • Page 316 GENERAL DESCRIPTION COOLING • TURBO MODEL (21) (20) (19) (11) (10) (13) (16) (12) (14) (18) (15) (17) (22) EN0069 Radiator lower cushion (10) Over flow pipe (19) Engine coolant filler tank Radiator (11) Radiator sub fan shroud (20) Engine coolant filler tank cap Radiator upper cushion (12) Radiator sub fan...
  • Page 317 GENERAL DESCRIPTION COOLING C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 318 GENERAL DESCRIPTION COOLING D: PREPARATION TOOL 1. NON-TURBO MODEL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. (2500 cc model) B2M3870 499977300 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts.
  • Page 319 GENERAL DESCRIPTION COOLING 2. TURBO MODEL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977300 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. B2M4157 18231AA010 CAMSHAFT Used for removing and installing camshaft (Newly adopted SPROCKET sprocket. (Intake) tool) WRENCH B2M3859...
  • Page 320 RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2...
  • Page 321 RADIATOR MAIN FAN SYSTEM COOLING 2. TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.18 LHD : 2 No.17 RHD : 7 LHD : 12 RHD : 17 B137 ECM SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 SUB FAN MAIN FAN...
  • Page 322 RADIATOR MAIN FAN SYSTEM COOLING B: INSPECTION 1. NON-TURBO MODEL DETECTING CONDITION: • Engine coolant temperature is above 95°C (203°F). • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. Step Check CHECK POWER SUPPLY TO MAIN FAN MO-...
  • Page 323 Contact with your Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-13...
  • Page 324 RADIATOR MAIN FAN SYSTEM COOLING 2. TURBO MODEL DETECTING CONDITION: • Engine coolant temperature is above 96°C (205°F). • A/C compressor is rotated. • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. •...
  • Page 325 RADIATOR MAIN FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 V? Go to step 8. Go to step 9. RELAY1. 1)Turn the ignition switch to OFF. 2)Remove the main fan relay1 from A/C relay holder.
  • Page 326 Repair the poor Contact with your Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 18.
  • Page 327 Contact with your Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-17...
  • Page 328 RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2...
  • Page 329 RADIATOR SUB FAN SYSTEM COOLING 2. TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.18 LHD : 2 No.17 RHD : 7 LHD : 12 RHD : 17 B137 ECM SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 SUB FAN MAIN FAN...
  • Page 330 RADIATOR SUB FAN SYSTEM COOLING B: INSPECTION 1. NON-TURBO MODEL NOTE: System for A/C equipped vehicles only. DETECTING CONDITION: Condition (1): • Engine coolant temperature is below 95°C (203°F). • A/C switch is turned ON. • Vehicle speed is below 19 km/h (12 MPH). Condition (2): •...
  • Page 331 Contact with your Check poor contact in connector between sub nector between sub fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-21...
  • Page 332 RADIATOR SUB FAN SYSTEM COOLING 2. TURBO MODEL DETECTING CONDITION: • Engine coolant temperature is above 96°C (205°F). • A/C compressor is rotated. • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator sub fan does not rotate under the above conditions. •...
  • Page 333 RADIATOR SUB FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 V? Go to step 8. Go to step 9. RELAY1. 1)Turn the ignition switch to OFF. 2)Remove the sub fan relay1 from A/C relay holder.
  • Page 334 Repair the poor Contact with your Check poor contact in connector between sub nector between sub fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? Go to step 18.
  • Page 335 Contact with your Check poor contact in connector between sub nector between sub fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-25...

  • Page 336: Engine Coolant

    Approx. 7.7 2 (8.14 US qt, 6.78 Imp qt) CAUTION: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Cool- EN0073 ant, since other coolant may cause corrosion.
  • Page 337 The concentration and safe operating temperature necessary amount of coolant with an undiluted so- of the SUBARU coolant is shown in the diagram. lution of SUBARU genuine coolant (concentration Measuring the temperature and specific gravity of 50%).

  • Page 338: Water Pump

    WATER PUMP COOLING 5. Water Pump 7) Disconnect the radiator outlet hose and heater hose from water pump. A: REMOVAL 1. NON-TURBO MODEL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. EN0112 8) Lower the vehicle. 9) Remove the air intake duct.
  • Page 339 WATER PUMP COOLING 11) Remove the reservoir tank. 17) Remove the camshaft sprocket (LH) by using ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE: Also the CAMSHAFT SPROCKET WRENCH (499207100) can be used. B2M2926 12) Remove the radiator main fan and sub fan as- semblies.
  • Page 340 WATER PUMP COOLING 2. TURBO MODEL 7) Remove the bolt which installs water by-pass pipe of oil cooler onto oil pump. WARNING: The radiator is pressurized. Wait until the en- gine cools down before working on the radia- tor. 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery.
  • Page 341 WATER PUMP COOLING 18) Remove the belt idler No. 2 (C). 22) Remove the tensioner bracket. S2M1160A S2M1163 19) Remove the camshaft position sensor. <Ref. to 23) Disconnect the heater hose from water pump. FU(TURBO)-31, REMOVAL, Camshaft Position 24) Remove the water pump. Sensor.>...
  • Page 342 WATER PUMP COOLING 2) Install the belt cover No. 2 (LH). 5) Install the belt idler No. 2. Tightening torque: Tightening torque: 5 N·m (0.5 kgf-m, 3.6 ft-lb) 39 N·m (4.0 kgf-m, 28.9 ft-lb) B2M2040 S2M0024 3) Install the tensioner bracket. 6) Install the automatic belt tension adjuster which tension rod is holded with pin.
  • Page 343 WATER PUMP COOLING 12) Install air intake duct. 15) Connect the connectors to radiator main fan motor (A) and sub fan motor (B). • 1600 cc and 2000 cc MODEL EN0077 EN0063 • 2500 cc MODEL EN0078 B6M1224 16) Install the under cover. 17) Lower the vehicle.
  • Page 344 WATER PUMP COOLING 2. TURBO MODEL 4) Install the camshaft sprockets (LH) by using ST. ST 18231AA010 CAMSHAFT SPROCKET 1) Install the water pump onto cylinder head (LH). WRENCH (Intake) NOTE: ST 499207400 CAMSHAFT SPROCKET • Replace the gasket with a new one. WRENCH (Exhaust) •...
  • Page 345 WATER PUMP COOLING 12) Install the reservoir tank. 18) Connect the connectors to radiator main fan motor (A) and sub fan motor (B). S2M0931 EN0077 13) Connect the over flow hose. 14) Lift-up the vehicle. 15) Connect the radiator outlet hose (A) and heater hose (B) to water pump.
  • Page 346 WATER PUMP COOLING C: INSPECTION 1) Check the water pump bearing for smooth rota- tion. 2) Check the water pump pulley for abnormalities. 3) Using a dial gauge, measure the impeller runout in thrust direction while rotating the pulley. “Thrust” runout limit: 0.5 mm (0.020 in) G2M0211 4) Check the clearance between impeller and...
  • Page 347 THERMOSTAT COOLING 6. Thermostat 6) Remove the thermostat cover and gasket, and pull out the thermostat. A: REMOVAL 1) Lift-up the vehicle. 2) Remove the under cover. 3) Drain the engine coolant completely. <Ref. to CO-26, DRAINING OF ENGINE COOLANT, RE- PLACEMENT, Engine Coolant.>...
  • Page 348 THERMOSTAT COOLING C: INSPECTION Replace the thermostat if the valve does not close completely at an ambient temperature or if the fol- lowing test shows unsatisfactory results. Immerse the thermostat and a thermometer in wa- ter. Raise water temperature gradually, and mea- sure the temperature and valve lift when the valve begins to open and when the valve is fully opened.
  • Page 349 RADIATOR COOLING 7. Radiator 5) Disconnect the radiator outlet hose from thermo- stat cover. A: REMOVAL 1. NON-TURBO MODEL 1) Disconnect the ground cable from battery. EN0112 6) Disconnect the ATF cooler hoses from radiator. (AT vehicles only) G6M0095 2) Lift-up the vehicle. 3) Drain the engine coolant completely.
  • Page 350 RADIATOR COOLING 9) Disconnect the over flow hose. 13) Detach the power steering hose from the clip on the radiator. B2M2925 B2M2932 10) Remove the reservoir tank. 14) While slightly lifting the radiator, slide it to left. 15) Lift the radiator up and away from vehicle. B2M2926 11) Disconnect the radiator inlet hose from engine.
  • Page 351 RADIATOR COOLING 2. TURBO MODEL 7) Disconnect the oil cooler hoses from oil cooler pipes. (if equipped) WARNING: The radiator is pressurized. Wait until the en- gine cools down before working on the radia- tor. 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery.
  • Page 352 RADIATOR COOLING 13) Remove the V-belt covers. B: INSTALLATION 1. NON-TURBO MODEL 1) Attach the radiator mounting cushions to holes on the vehicle. EN0048 14) Disconnect the radiator inlet hose (A) and wa- ter tank hose (B) from radiator. B2M2934 2) Install the radiator while fitting radiator pins to cushions.
  • Page 353 RADIATOR COOLING 4) Attach the power steering hose to radiator. • 2500 cc MODEL B2M2932 B6M1224 5) Connect the radiator inlet hose. 8) Lift-up the vehicle. 9) Connect the ATF cooler hoses. (AT vehicles only) B2M2930 6) Install the reservoir tank. EN0102 Tightening torque: 10) Connect the connectors to radiator main fan...
  • Page 354 RADIATOR COOLING 11) Connect the radiator outlet hose. 2) Install the radiator brackets, and then tighten the bolts. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) EN0112 12) Install the under cover. 13) Lower the vehicle. 14) Connect the battery ground cable to battery. EN0035 3) Connect the radiator inlet hose (A) and water tank hose (B).
  • Page 355 RADIATOR COOLING 5) Connect the over flow hose. 12) Install the V-belt covers. 6) Lift-up the vehicle. 7) Connect the connectors to radiator main fan mo- tor (A) and sub fan motor (B). EN0048 13) Install the air intake duct. EN0077 EN0108 14) Connect the battery ground cable to battery.
  • Page 356 RADIATOR COOLING C: INSPECTION 1) Remove the radiator cap, top off radiator, and then attach the tester to radiator in place of cap. • Non-turbo MODEL B2M3127 • Turbo MODEL EN0116 2) Apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) to the radiator to check if: (1) Engine coolant leaks at/around radiator.

  • Page 357: Radiator Cap

    RADIATOR CAP COOLING 8. Radiator Cap A: INSPECTION 1) Attach the radiator cap to tester. G2M0223 2) Increase the pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 to 6 seconds. Standard pressure: 93 —...
  • Page 358 RADIATOR MAIN FAN AND FAN MOTOR COOLING 9. Radiator Main Fan and Fan • Turbo MODEL (includes Non-turbo 2500 cc MODEL) Motor A: REMOVAL 1) Disconnect the ground cable from battery. EN0108 7) Disconnect the over flow hose. G6M0095 2) Lift-up the vehicle. 3) Remove the under cover.
  • Page 359 RADIATOR MAIN FAN AND FAN MOTOR COOLING B: INSTALLATION 2) Remove the nut which holds fan itself onto fan motor and shroud assembly. Install in the reverse order of removal. NOTE: When the main fan motor assembly cannot be in- stalled as is, loosen the sub fan motor assembly securing bolts to install it.
  • Page 360 RADIATOR SUB FAN AND FAN MOTOR COOLING 10.Radiator Sub Fan and Fan • Turbo MODEL (includes Non-turbo 2500 cc MODEL) Motor A: REMOVAL 1) Disconnect the ground cable from battery. EN0108 7) Remove the bolts which hold sub fan shroud to radiator.
  • Page 361 RADIATOR SUB FAN AND FAN MOTOR COOLING C: DISASSEMBLY D: ASSEMBLY 1) Remove the clip which holds motor harness onto Assemble in the reverse order of disassembly. shroud. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) S2M0937 2) Remove the nut which holds fan itself onto fan EN0121 motor and shroud assembly.

  • Page 362: Reservoir Tank

    RESERVOIR TANK COOLING 11.Reservoir Tank A: REMOVAL 1) Disconnect the over flow hose from radiator filler neck position. 2) Remove the bolts which install reservoir tank onto radiator main fan shroud. 3) Remove the reservoir tank. B2M2926 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.9N·m (0.50 kgf-m, 3.6 ft-lb) B2M2926...

  • Page 363: Coolant Filler Tank

    COOLANT FILLER TANK COOLING 12.Coolant Filler Tank B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) The radiator is pressurized. Wait until the en- T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) gine cools down before working on the radia- tor.

  • Page 364: Engine Cooling System Trouble In General

    ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 13.Engine Cooling System Trouble in General A: INSPECTION Trouble Possible cause Corrective action Replenish the engine coolant, inspect for leakage, and a. Insufficient engine coolant repair. b. Loose timing belt Repair or replace the timing belt tensioner. c.
  • Page 365 LUBRICATION Page General Description ..................2 Oil Pressure System ...................7 Engine Oil....................10 Oil Pump ....................12 Oil Pan and Strainer..................16 Oil Pressure Switch...................21 Engine Oil Cooler ..................22 Engine Oil Filter..................24 Engine Lubrication System Trouble in General.........25...
  • Page 366 GENERAL DESCRIPTION LUBRICATION 1. General Description A: SPECIFICATIONS Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 7 mm (3.07 × 0.28 in) STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in) Tip clearance between inner and outer rotor LIMIT 0.18 mm (0.0071 in)
  • Page 367 GENERAL DESCRIPTION LUBRICATION B: COMPONENT 1. NON-TURBO MODEL EN1491 Plug (14) Oil filler duct (27) Gasket Gasket (15) O-ring Relief valve spring (16) Oil filler cap Tightening torque: N·m (kgf-m, ft-lb) Relief valve (17) O-ring T1: 5 (0.5, 3.6) Oil seal (18) Baffle plate T2: 5 (0.5, 3.6)
  • Page 368 GENERAL DESCRIPTION LUBRICATION 2. TURBO MODEL (16) (17) (15) (18) (14) (19) (20) (29) (21) (13) (23) (12) (22) (24) (26) (11) (10) (25) (27) (28) EN1492 Plug (15) Oil pump ASSY (29) O-ring Gasket (16) Oil pressure switch Relief valve spring (17) Oil filler duct Tightening torque: N·m (kgf-m, ft-lb)
  • Page 369 GENERAL DESCRIPTION LUBRICATION C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 370 GENERAL DESCRIPTION LUBRICATION D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolt. (2500 cc model) B2M3870 499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolt.
  • Page 371 OIL PRESSURE SYSTEM LUBRICATION 2. Oil Pressure System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH COMBINATION METER LHD : 23 RHD : 14 OIL PRESSURE SWITCH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8 9 10 11 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24...
  • Page 372 OIL PRESSURE SYSTEM LUBRICATION 2. TURBO MODEL BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH COMBINATION METER B209 OIL PRESSURE OIL PRESSURE SWITCH SWITCH B209 A1 K2 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 B1 L2 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...
  • Page 373 OIL PRESSURE SYSTEM LUBRICATION B: INSPECTION Step Check CHECK COMBINATION METER. Does the warning lights go on? Go to step 2. Repair or replace 1)Turn the ignition switch to ON. (engine OFF) the combination 2)Check other warning lights. meter. <Ref. to IDI-5, INSPEC- TION, Combina- tion Meter...
  • Page 374 ENGINE OIL LUBRICATION 3. Engine Oil B: REPLACEMENT 1) Drain the engine oil by loosening the engine oil A: INSPECTION drain plug. 1) Park the vehicle on a level surface. • Non-Turbo MODEL 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way.
  • Page 375 API classification and SAE viscosity No. designat- ed by SUBARU. NOTE: If the vehicle is used in desert areas with very high...

  • Page 376: Oil Pump

    OIL PUMP LUBRICATION 4. Oil Pump 7) Remove the crankshaft position sensor. A: REMOVAL 1) Disconnect the ground cable from battery. B2M1252 8) Remove the V-belts. <Ref. to ME-44, REMOV- AL, V-belt.> or <Ref. to ME(TURBO)-44, REMOV- G6M0095 AL, V-belt.> 2) Lift-up the vehicle.
  • Page 377 OIL PUMP LUBRICATION 12) Remove the timing belt guide. (MT vehicles B: INSTALLATION only) Install in the reverse order of removal. Do the following: 1) Apply fluid packing to the matching surfaces of oil pump. Fluid packing: THREE BOND 1215 or equivalent S2M0115 13) Remove the crankshaft sprocket.
  • Page 378 OIL PUMP LUBRICATION C: DISASSEMBLY D: ASSEMBLY Remove the screws which secure oil pump cover 1) Install the front oil seal by using ST. and disassemble oil pump. Inscribe alignment ST 499587100 OIL SEAL INSTALLER marks on the inner and outer rotors so that they can NOTE: be replaced in their original positions during reas- Use a new oil seal.
  • Page 379 OIL PUMP LUBRICATION E: INSPECTION 3. SIDE CLEARANCE Measure the clearance between the oil pump inner 1. TIP CLEARANCE rotor and pump cover. If clearance exceeds the lim- Measure the tip clearance of rotors. If clearance ex- it, replace the rotor or pump body. ceeds the limit, replace the rotors as a matched set.
  • Page 380 OIL PAN AND STRAINER LUBRICATION 5. Oil Pan and Strainer 8) Remove the pitching stopper. A: REMOVAL 1) Set the vehicle on lift arms. 2) Remove the front wheels. 3) Disconnect the ground cable from battery. H3M1839 9) Remove the radiator upper brackets. •...
  • Page 381 OIL PAN AND STRAINER LUBRICATION 13) Drain the engine oil. 17) Insert the oil pan cutter blade between the cyl- inder block-to-oil pan clearance. Set a container under the vehicle, and remove the drain plug from oil pan. CAUTION: • Non-Turbo MODEL Do not use a screwdriver or similar tool in place of oil pan cutter.
  • Page 382 OIL PAN AND STRAINER LUBRICATION B: INSTALLATION 4) Tighten the bolts which install the oil pan onto engine block. CAUTION: Tightening torque: Before installing the oil pan, clean sealant from 5 N·m (0.5 kgf-m, 3.6 ft-lb) oil pan and engine block. •...
  • Page 383 OIL PAN AND STRAINER LUBRICATION 7) Install the front and center exhaust pipes. (Non- 12) Install the radiator upper brackets. Turbo model) • Non-Turbo MODEL <Ref. to EX-8, INSTALLATION, Front Exhaust Pipe.> or <Ref. to EX(w/oOBD)-10, INSTALLA- TION, Front Exhaust Pipe.> NOTE: Always use new gaskets.
  • Page 384 OIL PAN AND STRAINER LUBRICATION 16) Connect the connector to mass air flow sensor. (Turbo model) EN0031 17) Install the front wheels. 18) Connect the battery ground cable to battery. G6M0095 19) Fill engine oil. <Ref. to LU-10, INSPECTION, Engine Oil.> C: INSPECTION By visual check make sure the oil pan, oil strainer, oil strainer stay and baffle plate are not damaged.
  • Page 385 OIL PRESSURE SWITCH LUBRICATION 6. Oil Pressure Switch B: INSTALLATION 1) Apply fluid packing to the oil pressure switch A: REMOVAL threads. 1) Remove the generator from bracket. <Ref. to Fluid packing: SC-14, REMOVAL, Generator.> THREE BOND 1215 or equivalent 2) Disconnect the terminal from oil pressure switch.
  • Page 386 ENGINE OIL COOLER LUBRICATION 7. Engine Oil Cooler 7) Remove the connector and remove oil cooler. A: REMOVAL 1) Lift-up the vehicle. 2) Remove the under cover. 3) Drain the engine oil. Set a container under the vehicle, and remove the drain plug from oil pan.
  • Page 387 ENGINE OIL COOLER LUBRICATION B: INSTALLATION C: INSPECTION 1) Install in the reverse order of removal. 1) Check that the coolant passages are not clogged using air blow method. Tightening torque: 2) Check the mating surfaces of cylinder block, O- T: 54 N·m (5.5 kgf-m, 40 ft-lb) ring groove and oil filter for damage.
  • Page 388 ENGINE OIL FILTER LUBRICATION 8. Engine Oil Filter A: REMOVAL 1) Remove the under cover. 2) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH • Non-Turbo MODEL EN0055 • Turbo MODEL EN0056 B: INSTALLATION 1) Get a new oil filter and apply a thin coat of engine oil to the seal rubber.
  • Page 389 ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION 9. Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists. Trouble Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace.
  • Page 390 ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION LU-26...
  • Page 391 SPEED CONTROL SYSTEMS Page General Description ..................2 Accelerator Pedal..................4 Accelerator Control Cable ................9...
  • Page 392 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in) Accelerator pedal Stroke At pedal pad 52 — 57 mm (2.05 — 2.24 in) B: COMPONENT 1. LHD MODEL B2M4176A Accelerator bracket Accelerator pedal lever...
  • Page 393 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 2. RHD MODEL EN1493 Accelerator bracket Spring pin (11) Kick-down switch (AT model). Stopper Accelerator spring Accelerator pedal lever Bushing Tightening torque: N·m (kgf-m, ft-lb) Accelerator pedal spring Clip T: 18 (1.8, 13.0) Accelerator pedal (10) Accelerator stopper C: CAUTION...

  • Page 394: Accelerator Pedal

    ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 2. Accelerator Pedal • RHD SOHC MODEL A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lock nut from accelerator cable bracket. 3) Separate the accelerator cable from bracket. 4) Remove the accelerator cable end from throttle cam.
  • Page 395 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 10) Remove the accelerator pedal connecting bolt 13) Disconnect the accelerator cable bushing from from accelerator pedal bracket. accelerator pedal lever. • LHD MODEL B4M1741B EN0924 (A) Slot type screwdriver • RHD MODEL 14) Disconnect the accelerator cable stopper (A) from bracket.
  • Page 396 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS C: DISASSEMBLY • RHD MODEL 1) Remove the clip, and then remove the accelera- tor pedal from bracket. 2) Pull out the spring pin, and then remove the ac- celerator pedal from accelerator pedal lever. •...
  • Page 397 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS E: INSPECTION F: ADJUSTMENT 1) Check the pedal stroke and free play by operat- 1. ACCELERATOR PEDAL ing accelerator pedal by hand. Lightly move the pedal pad in lateral direction to en- If it is not within specified value, adjust it by turning sure that pedal deflection is in specified range.
  • Page 398 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 2) Check to ensure the kick-down switch operates at the specified value in relation to the stroke of the accelerator pedal. If it is not within specified value, adjust it by adjust- ing the position of kick-down switch. CAUTION: Be careful not to rotate the kick-down switch.
  • Page 399 ACCELERATOR CONTROL CABLE SPEED CONTROL SYSTEMS 3. Accelerator Control Cable A: REMOVAL 1) Remove the accelerator pedal. <Ref. to SP-4, REMOVAL, Accelerator Pedal.> 2) Separate the accelerator cable and accelerator pedal. B: INSTALLATION 1) Install in the reverse order of removal. CAUTION: •...
  • Page 400 ACCELERATOR CONTROL CABLE SPEED CONTROL SYSTEMS SP-10...
  • Page 401 IGNITION Page General Description ..................2 Spark Plug....................5 Ignition Coil and Ignitor Assembly...............8 Spark Plug Cord..................10...
  • Page 402 GENERAL DESCRIPTION IGNITION 1. General Description A: SPECIFICATIONS Item Designation 1600 cc CM12—100C Model 2000 cc and FH0137 2500 cc 1600 cc HITACHI Manufacturer 2000 cc and DIAMOND 2500 cc Ignition coil 0.7 Ω±10% 1600 cc and ignitor Primary coil resistance 2000 cc and assembly 0.73 Ω±10%...
  • Page 403 GENERAL DESCRIPTION IGNITION B: COMPONENT 1. 1600 CC MODEL EN1039 S6M0329B Spark plug Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7) Ignition coil and ignitor ASSY T2: 21 (2.1, 15.2) IG-3...
  • Page 404 GENERAL DESCRIPTION IGNITION 2. 2000 CC AND 2500 CC MODEL S6M0329B Spark plug Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) Spark plug cord (#1, #3) 21 (2.1, 15.2) Ignition coil and ignitor ASSY 6.4 (0.65, 4.7) C: CAUTION •...
  • Page 405 SPARK PLUG IGNITION 2. Spark Plug 2. LH SIDE 1) Disconnect the ground cable from battery. A: REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug CHAMPION: RC8YC4 1600 cc NGK: BKR6E-11 (Alternate) 2000 cc CHAMPION: RC10YC4 NGK: BKR5E-11 (Alternate)
  • Page 406 SPARK PLUG IGNITION 6) Remove the spark plugs with spark plug sock- C: INSPECTION ets. Check the electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion. B2M4288 B: INSTALLATION S6M0420A 1.
  • Page 407 SPARK PLUG IGNITION 3) Oil fouled: E: ADJUSTMENT Wet black deposits show excessive oil entrance Correct it if the spark plug gap is measured with a into combustion chamber through worn rings and gap gauge, and it is necessary. pistons or excessive clearance between valve Spark plug gap: L guides and stems.
  • Page 408 IGNITION COIL AND IGNITOR ASSEMBLY IGNITION 3. Ignition Coil and Ignitor As- 4) Remove the ignition coil and ignitor assembly. • 1600 cc MODEL sembly A: REMOVAL 1) Disconnect the ground cable from battery. EN1044 • 2000 cc and 2500 cc MODEL G6M0095 2) Disconnect the spark plug cords from ignition coil and ignitor assembly.
  • Page 409 IGNITION COIL AND IGNITOR ASSEMBLY IGNITION • 2000 cc and 2500 cc MODEL Specified resistance: (2000 cc and 2500 cc) [Primary side] Between terminal No. 1 and No. 2 0.73 Ω± Ω± 10% Ω± Ω± Between terminal No. 2 and No. 4 0.73 Ω±...
  • Page 410 SPARK PLUG CORD IGNITION 4. Spark Plug Cord A: INSPECTION Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 — 10.6 k Ω Ω Ω Ω #2 cord: 7.3 —...
  • Page 411 STARTING/CHARGING SYSTEMS Page General Description ..................2 Starter ......................5 Generator ....................14 Battery.......................20...
  • Page 412 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATIONS Item Designation Type Reduction type Vehicle type MT vehicles AT vehicles Model M000T83981 M001T86381 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Direction of rotation Counterclockwise (when observed from pinion) Number of pinion teeth Voltage...
  • Page 413 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS B: COMPONENT 1. STARTER H6M0492C Sleeve bearing Internal gear ASSY (13) Armature Front bracket Shaft ASSY (14) Brush holder Lever set Gear ASSY (15) Brush Magnet switch ASSY (10) Ball (16) Sleeve bearing Stopper set (11) Packing (17) Rear bracket...
  • Page 414 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 2. GENERATOR H6M0493C Pulley Rotor Brush Front cover Bearing (10) Rectifier Ball bearing Stator coil (11) Rear cover Bearing retainer IC regulator with brush (12) Terminal C: CAUTION • Be careful not to burn your hands, because each part in the vehicle is hot after running.
  • Page 415 STARTER STARTING/CHARGING SYSTEMS 2. Starter • AT vehicles A: REMOVAL 1) Disconnect the ground cable from battery. EN0370 5) Disconnect the connector and terminal from starter. G6M0095 2) Remove the air cleaner case. (Non-Turbo Mod- S6M0002A (A) Terminal B6M1221 (B) Connector 3) Remove the intercooler.
  • Page 416 STARTER STARTING/CHARGING SYSTEMS B: INSTALLATION 2) Remove the bolts which hold switch assembly, and then remove the switch assembly, plunger and Install in the reverse order of removal. plunger spring from starter as a unit. Tightening torque: CAUTION: 50 N·m (5.1 kgf-m, 37 ft-lb) Be careful because the pinion gap adjustment washer may sometimes be used on the mount- ing surface of switch assembly.
  • Page 417 STARTER STARTING/CHARGING SYSTEMS 4) Remove the armature and yoke. The ball used 6) Remove the shaft assembly and overrunning as a bearing will then be removed from the end of clutch as a unit. armature. CAUTION: CAUTION: Before removal, confirm the following: Be sure to mark an alignment mark on the yoke •...
  • Page 418 STARTER STARTING/CHARGING SYSTEMS 7) Remove the overrunning clutch from shaft as- 2. BRUSH HOLDER sembly as follows: Slightly open the metal fitting holding the insulating (1) Remove the stopper from ring by lightly tap- plate to brush holder. Remove the insulating plate. ping the stopper with an appropriate tool (such NOTE: as a 14 mm (0.55 in) socket wrench).
  • Page 419 STARTER STARTING/CHARGING SYSTEMS D: ASSEMBLY 3) When installing the yoke to the front bracket, match bolt hole. Assemble in the reverse order of disassembly. Do the following: 1) Carefully assemble all parts in the order of as- sembly and occasionally inspect nothing has been overlooked.
  • Page 420 STARTER STARTING/CHARGING SYSTEMS E: INSPECTION 4) Armature short-circuit test Check the armature for short-circuit by placing it on 1. ARMATURE growler tester. Hold a hacksaw blade against the armature core while slowly rotating armature. A 1) Check the commutator for any sign of burns of short-circuited armature will cause the blade to vi- rough surfaces or stepped wear.
  • Page 421 STARTER STARTING/CHARGING SYSTEMS 4. BRUSH AND BRUSH HOLDER 5. SWITCH ASSEMBLY 1) Brush length Be sure there is continuity between the terminals S and M, and between terminal S and ground. Use a Measure the brush length, and then replace if it ex- circuit tester (set in “ohm”).
  • Page 422 STARTER STARTING/CHARGING SYSTEMS 7. PINION GAP 8. PERFORMANCE TEST 1) Measure the pinion gap while the pinion is pulled The starter should be submitted to performance out as shown in the figure. tests whenever it has been overhauled, to assure its satisfactory performance when installed on the Pinion gap: engine.
  • Page 423 STARTER STARTING/CHARGING SYSTEMS 2) Load test Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within the specifications. Load test (Standard): Voltage / Load MT vehicles 7.5 V/8.6 N (0.88 kgf, 1.93 lb) AT vehicles 7.7 V/16.0 N (1.63 kgf, 3.60 lb) Current / Speed...
  • Page 424 GENERATOR STARTING/CHARGING SYSTEMS 3. Generator • Turbo Model A: REMOVAL 1) Disconnect the ground cable from battery. EN0048 4) Remove the front side V-belt. <Ref. to ME-44, FRONT SIDE BELT, REMOVAL, G6M0095 V-belt.> or <Ref. to ME(TURBO)-44, FRONT SIDE 2) Disconnect the connector and terminal from BELT, REMOVAL, V-belt.>...
  • Page 425 GENERATOR STARTING/CHARGING SYSTEMS C: DISASSEMBLY 1) Heat the portion (A) of rear cover to 50°C (122°F) with heater drier. H6M0498B (A) Front bracket (B) Pulley B6M0476B (C) Nut 2) Remove the four through bolts. Then insert the (D) Rotor tip of a flat-head screwdriver into the gap between stator core and front bracket.
  • Page 426 GENERATOR STARTING/CHARGING SYSTEMS 6) Remove the brushes by unsoldering at pigtails. 2) Heat the bearing box in rear bracket [50 to 60°C (122 to 140°F)], and then press the rear bearing into rear bracket. CAUTION: Grease should not be applied to rear bearing. Remove the oil completely if it is found on bear- ing box.
  • Page 427 GENERATOR STARTING/CHARGING SYSTEMS 2) Checking negative diode 4) Insulation test Check for continuity between the negative side Check the continuity between slip ring and rotor core or shaft. If resistance is 1 Ω or less, the rotor heat sink and diode lead. The negative diode is in good condition if resistance is 1 Ω...
  • Page 428 GENERATOR STARTING/CHARGING SYSTEMS 2) Insulation test 2) Checking brush spring for proper pressure Inspect the stator coil for continuity between stator Using a spring pressure indicator, push the brush core and each end of lead wire. If resistance is 1 Ω into the brush holder until its tip protrudes 2 mm or less, the stator coil is grounded, and so replace (0.08 in).
  • Page 429 GENERATOR STARTING/CHARGING SYSTEMS (4) Install the front bearing retainer. S6M0410A (A) Bearing (B) Socket wrench (C) Front bracket SC-19...
  • Page 430 BATTERY STARTING/CHARGING SYSTEMS 4. Battery C: INSPECTION WARNING: A: REMOVAL • Electrolyte has toxicity; be careful handling 1) Disconnect the positive (+) cable after discon- the fluid. necting the ground (−) cable of battery. • Avoid contact with skin, eyes or clothing. Es- 2) Remove the flange nuts from battery rods, and pecially at contact with eyes, blush with water then take off the battery holder.
  • Page 431 BATTERY STARTING/CHARGING SYSTEMS 3. SPECIFIC GRAVITY OF ELECTROLYTE: 1. JUDGMENT OF BATTERY IN CHARGED CONDITION 1) Measure the specific gravity of electrolyte using a hydrometer and a thermometer. 1) Specific gravity of electrolyte is held at a specific Specific gravity varies with temperature of electro- value in a range from 1.250 to 1.290 for more than lyte so that it must be corrected at 20°C (68°F) us- one hour.
  • Page 432 BATTERY STARTING/CHARGING SYSTEMS SC-22...
  • Page 433 Engine Control Module (ECM) I/O Signal ..........24 Engine Condition Data ................27 Transmission Control Module (TCM) I/O Signal ........28 Data Link Connector .................31 OBD-II General Scan Tool ................32 Subaru Select Monitor................34 Read Diagnostic Trouble Code (DTC) ............41 Inspection Mode..................42 Drive Cycle....................47 Clear Memory Mode..................49 Compulsory Valve Operation Check Mode ..........50...

  • Page 434: Basic Diagnostic Procedure

    If a DTC is not II general scan tool to data link connector. Diagnostic Trou- shown on display 3)Turn the ignition switch to ON and Subaru ble Code (DTC).> although the MIL il- Select Monitor or OBD-II general scan tool Go to step 4.
  • Page 435 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. AUTOMATIC TRANSMISSION When the diagnostic trouble code (DTC) about au- tomatic transmission is shown on display, carry out the following basic check. After that, carry out the replacement or repair work. 1) ATF level check <Ref. to AT-9, Automatic Trans- mission Fluid.>...

  • Page 436: Check List For Interview

    CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer's name Engine No. Date of sale Fuel brand Date of repair Odometer reading...
  • Page 437 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST NO. 2 Check the following items about the vehicle's state when MIL turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. ❏ Yes/❏ No ❏...
  • Page 438 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use the ECM mounting stud bolt at the body head grounding points when measuring voltage A: CAUTION and resistance inside the passenger compartment. 1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay.
  • Page 439 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 12) Observe the following cautions when installing B: INSPECTION a radio in MFI equipped models. Before performing diagnostics, check the following items which might affect engine problems: CAUTION: • The antenna must be kept as far apart as pos- 1.
  • Page 440 (TCM) and the hydraulic controller in- from the usual diagnostics procedure. When trou- cluding solenoid valves. The system controls the bleshooting OBD-II vehicles, connect Subaru Se- transmission proper including shift control, lock-up lect Monitor or the OBD-II general scan tool to the control, overrunning clutch control, line pressure vehicle.
  • Page 441 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA190 CARTRIDGE Troubleshooting for electrical (New adopted tool) systems. B2M3876 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems. • English: 22771AA030 (With- out printer) • German: 22771AA070 (Without printer) •...

  • Page 442: Electrical Components Location

    ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. ENGINE • Module LHD model EN1423 RHD model EN1424 Engine control module (ECM) Test mode connector CHECK ENGINE malfunction indi- Data link connector cator lamp (MIL) EN-10...
  • Page 443 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0718 B3M1575A EN0716 EN1425 EN-11...
  • Page 444 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • Sensor EN0719 Atmospheric pressure sensor Engine coolant temperature sen- Knock sensor Intake air temperature and pres- Camshaft position sensor sure sensor Throttle position sensor Crankshaft position sensor EN-12...
  • Page 445 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) B2M3713A B2M3714A S2M1248B B2M2240A B2M2241A B2M2242A B2M0213J EN-13...
  • Page 446 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) B2M4231A Front oxygen (A/F) sensor Front catalytic converter Rear oxygen sensor Rear catalytic converter S2M0264A S2M0265A OBD0524G OBD0525G EN-14...
  • Page 447 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN1019 RHD model EN1020 Fuel level sensor Fuel sub level sensor (2500 cc model only) EN1036 EN1037 EN-15...
  • Page 448 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • Solenoid Valve, Emission Control System Parts and Ignition System Parts EN0736 Air assist injector solenoid valve Purge control solenoid valve Idle air control solenoid valve Ignition coil & ignitor ASSY EN-16...
  • Page 449 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) B2M3715A H2M3259A H2M3258B B2M3720A EN-17...
  • Page 450 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0741 EN0742 Inhibitor switch Fuel pump relay Starter Fuel pump Radiator main fan relay Main relay Radiator sub fan relay EN-18...
  • Page 451 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) B2M2246A EN1505 LHD model RHD model EN1504 EN1506 EN0746 B2M2247E EN-19...
  • Page 452 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. TRANSMISSION • Module EN0751 EN0752 Transmission control module AT diagnostic indicator light (for (TCM) (for AT vehicles) AT vehicles) EN-20...
  • Page 453 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) B3M1592D B3M1652B EN0754 EN-21...
  • Page 454 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • Sensor B2M2258A B2M2259A B2M2260A B2M2261A OBD0653B (1) Rear vehicle speed sensor (for AT vehicles) (2) Front vehicle speed sensor (for MT vehicles) (3) Front vehicle speed sensor (for AT vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles) (6) Brake light switch EN-22...
  • Page 455 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • Solenoid Valve and Switch (AT vehicles) B2M2246F B2M2263K B2M2264F (1) Inhibitor switch (2) Shift solenoid valve 1 (3) Shift solenoid valve 2 (4) Line pressure duty solenoid (5) Lock-up duty solenoid (6) Transfer duty solenoid (7) 2-4 brake duty solenoid (8) Low clutch timing solenoid valve (9) 2-4 brake timing solenoid valve...
  • Page 456 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B2M2267A Signal (V) Con- Terminal Content nector Note Ignition SW ON Engine ON (Idling) (Engine OFF) −7 — +7 Signal (+) B135 Sensor output waveform Crank- shaft posi-...
  • Page 457 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Terminal Content nector Note Ignition SW ON Engine ON (Idling) (Engine OFF) Starter switch B135 Cranking: 8 — 14 ON: 10 — 13 ON: 13 — 14 A/C switch B135 —...
  • Page 458 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Terminal Content nector Note Ignition SW ON Engine ON (Idling) (Engine OFF) Fuel level sensor B136 0.12 — 4.75 0.12 — 4.75 For europe model Less than 1 ←→ Less than 1 ←→...

  • Page 459: Engine Condition Data

    ENGINE CONDITION DATA ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Content Specified data 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm racing Measuring condition: • After warm-up the engine. • Gear position is in “N” or “P” position. •...
  • Page 460 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL ENGINE (DIAGNOSTICS) 7. Transmission Control Module (TCM) I/O Signal A: ELECTRICAL SPECIFICATION to B54 to B55 to B56 TR0532 Check with ignition switch ON. Con- Termi- Resistance to Content nector Measuring conditions Voltage (V) nal No.
  • Page 461 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL ENGINE (DIAGNOSTICS) Check with ignition switch ON. Con- Termi- Resistance to Content nector Measuring conditions Voltage (V) nal No. body (ohms) Hold switch ON Less than 1 Hold switch — Hold switch OFF More than 8 Power switch ON Less than 1 Power switch...
  • Page 462 6 — 9.1 FWD switch — Fuse installed. Less than 1 Fuse on FWD switch Less than 1 FWD indicator light — Fuse removed from FWD More than 9 switch Data link signal (Subaru — — — Select Monitor) EN-30...
  • Page 463 A: NOTE 1) This connector is used both for the OBD-II general scan tools and 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 Subaru Select Monitor, because the circuit for Subaru Select Monitor may be damaged.
  • Page 464 OBD-II GENERAL SCAN TOOL ENGINE (DIAGNOSTICS) 9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up diag- nostic trouble code(s) (DTC(s)) and freeze frame A: OPERATION data. OBD-II general scan tool functions consist of: 1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic TOOL data...
  • Page 465 OBD-II GENERAL SCAN TOOL ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure Trouble code that caused CARB required freeze frame data storage...

  • Page 466: Subaru Select Monitor

    1. HOW TO USE SUBARU SELECT MONI- ru Select Monitor and OBD-II general scan tool. 5) Turn the ignition switch to ON (engine OFF) and 1) Prepare the Subaru Select Monitor kit. <Ref. to Subaru Select Monitor switch to ON. EN-9, PREPARATION TOOL, General Descrip- tion.>...
  • Page 467 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) 4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine Control System} and press [YES] key.
  • Page 468 ON or OFF Air assist injector solenoid valve signal Assist Air Sol. Valve ON or OFF AT vehicle ID signal AT Vehicle ID Signal ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-36...
  • Page 469 Rear oxygen sensor output signal Oxygen Sensor #12 Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 On-board diagnostic system OBD System — NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-37...
  • Page 470 Vehicle Speed km/h or MPH NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press [YES] key.
  • Page 471 Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF entered. When camshaft position sensor signal is Camshaft position sensor signal Camshaft Position Sig. ON or OFF entered. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-39...
  • Page 472 ON or OFF Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-40...
  • Page 473 (DTCs). A: OPERATION For details concerning diagnostic trouble codes (DTCs), refer to the List of Diagnostic Trouble Code 1. SUBARU SELECT MONITOR (NORMAL (DTC). <Ref. to EN-83, List of Diagnostic Trouble MODE) Code (DTC).> 1) On the «Main Menu» display screen, select the NOTE: {Each System Check} and press [YES] key.

  • Page 474: Inspection Mode

    INSPECTION MODE ENGINE (DIAGNOSTICS) 12.Inspection Mode A: OPERATION Carry out trouble diagnosis shown in the following DTC table. When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle. <Ref. to EN-47, Drive Cycle.> Item P0031 Front oxygen (A/F) sensor heater circuit low input...
  • Page 475 INSPECTION MODE ENGINE (DIAGNOSTICS) Item P0743 Torque converter clutch system (Lock-up duty solenoid) electrical P0748 Pressure control solenoid (Line pressure duty solenoid) electrical P0753 Shift solenoid A (Shift solenoid 1) electrical P0758 Shift solenoid B (Shift solenoid 2) electrical P0778 2-4 brake pressure control solenoid valve circuit malfunction P0785 2-4 brake timing control solenoid valve circuit malfunction...
  • Page 476 Imp gal)] and the battery voltage is 12 V or more. 2) Raise the vehicle using a garage jack and place 3) Prepare the Subaru Select Monitor kit. <Ref. to EN-9, PREPARATION TOOL, General Descrip- on safety stands or drive the vehicle onto free roll- tion.>...
  • Page 477 INSPECTION MODE ENGINE (DIAGNOSTICS) 7) Connect the Subaru Select Monitor to data link 14) Perform subsequent procedures as instructed connector. on the display screen. (1) Connect the Subaru Select Monitor to data • If trouble still remains in the memory, the corre-...
  • Page 478 INSPECTION MODE ENGINE (DIAGNOSTICS) 4) Connect the OBD-II general scan tool to its data link connector in the lower portion of instrument panel (on the driver's side). CAUTION: Do not connect the scan tools except for Suba- ru Select Monitor and OBD-II general scan tool. EN0768 5) Start the engine.

  • Page 479: Drive Cycle

    DRIVE CYCLE ENGINE (DIAGNOSTICS) 13.Drive Cycle A: OPERATION There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check whether they correctly resume their functions by driving in the required drive pattern. 1.
  • Page 480 DRIVE CYCLE ENGINE (DIAGNOSTICS) 3. IDLE FOR 10 MINUTES NOTE: Before the diagnosis, drive the vehicle at 4 km/h (6 MPH) or more. DTC No. Item Condition *P0483 Cooling fan function problem — *P0506 Idle control system RPM lower than expected —...

  • Page 481: Clear Memory Mode

    4) On the «Engine Diagnosis» display screen, se- lect the {Clear Memory} and press [YES] key. 5) When the ‘Done’ and ‘Turn Ignition Switch OFF’ are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: •...
  • Page 482 COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 15.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link connector. Check Mode (1) Connect the Subaru Select Monitor to data link connector located in the lower portion of in- A: OPERATION strument panel (on the driver's side).
  • Page 483 EGR Solenoid Valve ASV Solenoid Valve PCV Solenoid Valve Vent Control Solenoid Valve FICD Solenoid Pressure Switching Sol. 1 Pressure Switching Sol. 2 Fuel Tank Sensor Control Valve • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN-51...
  • Page 484 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) 16.Engine Malfunction Indicator Lamp (MIL) A: PROCEDURE 1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN-53, ACTIVATION OF CHECK ENGINE MALFUNC- TION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> ↓...
  • Page 485 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) B: ACTIVATION OF CHECK ENGINE 4) When the ignition switch is turned to ON (engine OFF) or to START with the test mode connector MALFUNCTION INDICATOR connected, the MIL blinks at a cycle of 3 Hz. LAMP (MIL) 1) When the ignition switch is turned to ON (engine OFF), the CHECK ENGINE malfunction indicator...

  • Page 486: Wiring Diagram

    ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • TROUBLE SYMPTOM: • When the ignition switch is turned to ON (engine OFF), MIL does not come on. •...
  • Page 487 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Check CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair the con- connected? <Ref. to FU-51, nection of ECM Engine Control connector. Module.> CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5.
  • Page 488 • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. • TROUBLE SYMPTOM: • Although MIL comes on when engine runs, but trouble code is not shown on Subaru Select Monitor or OBD-II general scan tool display. • WIRING DIAGRAM:...
  • Page 489 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) EN-57...
  • Page 490 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ. • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • Test mode connector circuit is open. •...
  • Page 491 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Check CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL cir- FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to EN- 1)Turn the ignition switch to OFF. 54, CHECK 2)Disconnect the test mode connector.
  • Page 492 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK- ING AT A CYCLE OF 3 HZ. • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON. •...
  • Page 493 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Check CHECK TEST MODE CONNECTOR. Does the MIL flash on and off? Go to step 2. System is in good 1)Disconnect the test mode connector. order. 2)Turn the ignition switch to ON. NOTE: MIL blinks at a cy- cle of 3 Hz when...
  • Page 494 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 17.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN-68, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
  • Page 495 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN-63...
  • Page 496 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN-42, Inspection Mode.> . • WIRING DIAGRAM: BATTERY SBF-4 SBF-1...
  • Page 497 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4. Go to step 5. TOR. 1)Turn the ignition switch to OFF. 2)Disconnect the connector from starter motor. 3)Turn the ignition switch to START.
  • Page 498 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than 1 Repair the open Go to step 11. Ω? 1)Turn the ignition switch to OFF. circuit in harness 2)Place the selector lever in the “P” or “N” posi- between starter tion.
  • Page 499 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN-67...
  • Page 500 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.> •...
  • Page 501 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Repair the open Ω? 1)Disconnect the connector from ECM. circuit in harness 2)Measure the resistance of harness between between ECM ECM and chassis ground.
  • Page 502 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check the ignition Repair the open or 1)Connect the main relay connector. control system. ground short cir- 2)Turn the ignition switch to ON. <Ref.
  • Page 503 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN-71...
  • Page 504 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN-42, Inspection Mode.> . • WIRING DIAGRAM: B134 IGNITION SWITCH...
  • Page 505 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3. Repair the har- NITION COIL & IGNITOR ASSEMBLY. ness and connec- 1)Turn the ignition switch to OFF. tor.
  • Page 506 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 8. Replace the igni- & IGNITOR ASSEMBLY. tion coil & ignitor Check if the voltage varies synchronously with assembly.
  • Page 507 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check the fuel Check poor contact in ECM connector. connector? contact in ECM pump circuit. <Ref. connector. to EN-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting...
  • Page 508 NOTE: nostics for Engine Fuel pump operation can also be executed us- Starting Failure.> ing the Subaru Select Monitor (Function mode: FD01). For the procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN-50, Com- pulsory Valve Operation Check Mode.>...
  • Page 509 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Go to step 3. Repair the har- Ω? 1)Turn the ignition switch to OFF. ness and connec- 2)Remove the fuel pump access hole lid tor.
  • Page 510 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair the open Ω? FUEL PUMP RELAY CONNECTOR. circuit in harness 1)Disconnect the connectors from ECM. between ECM and 2)Measure the resistance of harness between fuel pump relay...
  • Page 511 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN-79...
  • Page 512 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.> •...
  • Page 513 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 V? Go to step 3. Repair the har- INJECTOR. ness and connec- 1)Turn the ignition switch to OFF. tor. 2)Disconnect the connector from #1 cylinder NOTE: fuel injector.
  • Page 514 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 8. Repair the har- and 20 Ω? FUEL INJECTOR CONNECTOR. ness and connec- Measure the resistance of harness between tor.
  • Page 515 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 18.List of Diagnostic Trouble Code (DTC) A: LIST Item Index P0031 Front oxygen (A/F) sensor heater cir- <Ref. to EN-90, DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER cuit low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 516 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0130 Front oxygen (A/F) sensor circuit <Ref. to EN-142, DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT range/performance problem (Lean) RANGE/PERFORMANCE PROBLEM (LEAN) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0131 Front oxygen (A/F) sensor circuit <Ref.
  • Page 517 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0462 Fuel level sensor circuit low input <Ref. to EN-192, DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0463 Fuel level sensor circuit high input <Ref.
  • Page 518 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0748 Pressure control solenoid (Line pres- <Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic sure duty solenoid) electrical Procedure with Diagnostic Trouble Code (DTC).> P0753 Shift solenoid A (Shift solenoid 1) <Ref.
  • Page 519 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P1516 Idle air control solenoid valve signal <Ref. to EN-256, DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE 4 circuit low input SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 520 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P1711 Engine torque control signal 1 circuit <Ref. to EN-288, DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 malfunction CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1712 Engine torque control signal 2 circuit <Ref.
  • Page 521 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-89...
  • Page 522 26 27 28 29 EN1400 Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Go to step 2. Go to step 5. BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool indicate DTC P0031 and...
  • Page 523 Repair the poor Go to step 5. 1)Start the engine. contact in connec- 2)Read the data of front oxygen (A/F) sensor tor. heater current using Subaru Select Monitor or NOTE: OBD-II general scan tool. In this case, repair the following: NOTE: •Subaru Select Monitor...
  • Page 524 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change less Repair the poor Go to step 9. Measure the voltage between ECM connector than 1.0 V by shaking harness contact in ECM and chassis ground.
  • Page 525 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-93...
  • Page 526 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH IN- PUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 527 ECM and front oxygen (A/F) sensor connector. 3)Turn the ignition switch to ON. 4)Read the data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 528 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 529 Repair the con- Go to step 4. 1)Start the engine. nector. 2)Read the data of rear oxygen sensor heater NOTE: current using Subaru Select Monitor or OBD-II In this case, repair general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
  • Page 530 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK REAR OXYGEN SENSOR. Is the resistance less than 30 Repair the har- Replace the rear Ω? 1)Turn the ignition switch to OFF. ness and connec- oxygen sensor. 2)Measure the resistance between rear oxy- tor.
  • Page 531 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-99...
  • Page 532 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 533 ECM and rear oxygen sensor con- Module.> nector. 3)Turn the ignition switch to ON. 4)Read the data of rear oxygen sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 534 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) E: DTC P0066 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW IN- PUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling •...
  • Page 535 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the poor Go to step 2. 1)Turn the ignition switch to ON. contact in ECM 2)Measure the voltage between ECM and connector.
  • Page 536 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC P0067 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH IN- PUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling •...
  • Page 537 Does the voltage change more Repair the battery Contact with your Measure the voltage between ECM and chas- than 10 V by shaking harness short circuit in har- Subaru distributor sis ground. and connector of ECM while ness between service. Connector & terminal...
  • Page 538 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 539 3)Turn the A/C switch to OFF. and Pressure Sen- 4)Turn all accessory switches to OFF. sor.> 5)Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 540 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK THROTTLE POSITION. Is the throttle positioning ratio Replace the intake Replace the throt- equal to or more than 85 % air temperature tle position sensor. when throttle is fully open? and pressure sen- <Ref.
  • Page 541 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-109...
  • Page 542 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 543 Go to step 2. 1)Start the engine. (100 mmHg, 3.94 inHg)? 2)Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 544 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Go to step 9. Repair the open Ω? TAKE AIR TEMPERATURE AND PRESSURE circuit in harness SENSOR CONNECTOR. between ECM and 1)Turn the ignition switch to OFF.
  • Page 545 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-113...
  • Page 546 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 547 Go to step 2. 1)Start the engine. kPa (896.5 mmHg, 35.29 2)Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 548 SENSOR CONNECTOR. inHg)? ness between and pressure sen- 1)Turn the ignition switch to OFF and Subaru ECM and intake sor. <Ref. to FU- Select Monitor or OBD-II general scan tool air temperature 37, Intake Air switch to OFF.
  • Page 549 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-117...
  • Page 550 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) J: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER- FORMANCE PROBLEM — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 551 95°C (203°F)? and pressure sen- List of Diagnostic 2)Measure the engine coolant temperature sor. <Ref. to FU- Trouble Code using Subaru Select Monitor or OBD-II general 37, Intake Air (DTC)”. <Ref. to scan tool. Temperature and EN-83, List of Pressure Sensor.>...
  • Page 552 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) K: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 553 ECM connector. 3)Turn the ignition switch to ON. Pressure Sensor.> 4)Read the data of intake air temperature sen- sor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 554 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) L: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 555 Repair the poor 1)Start the engine. (−40°F)? contact. 2)Read the data of intake air temperature sen- NOTE: sor signal using Subaru Select Monitor or In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
  • Page 556 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 V? Go to step 5. Repair the har- TEMPERATURE AND PRESSURE SENSOR ness and connec- AND ECM CONNECTOR. tor.
  • Page 557 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-125...
  • Page 558 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) M: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Hard to start • Erroneous idling •...
  • Page 559 Repair the poor 1)Start the engine. (302°F)? contact. 2)Read the data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor or In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
  • Page 560 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Hard to start • Erroneous idling •...
  • Page 561 Repair the poor 1)Start the engine. (−40°F)? contact. 2)Read the data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor or In this case, repair OBD-II general scan tool. the following: • Poor contact in NOTE: •Subaru Select Monitor...
  • Page 562 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 5. Repair the har- COOLANT TEMPERATURE SENSOR AND ness and connec- ECM CONNECTOR. tor. Measure the voltage between engine coolant NOTE: temperature sensor connector and engine In this case, repair...
  • Page 563 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-131...
  • Page 564 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR- MANCE PROBLEM (HIGH INPUT) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling •...
  • Page 565 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the throt- BLE CODE (DTC) ON DISPLAY. vant DTC using tle position sensor. “List of Diagnostic <Ref.
  • Page 566 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 567 Even if MIL lights 1)Start the engine. up, the circuit has 2)Read the data of throttle position sensor sig- returned to a nor- nal using Subaru Select Monitor or OBD-II mal condition at general scan tool. this time. A tempo- rary poor contact...
  • Page 568 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the har- THROTTLE POSITION SENSOR CONNEC- ness and connec- TOR. tor. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connectors from throttle posi- In this case, repair...
  • Page 569 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-137...
  • Page 570 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 571 Even if MIL lights 1)Start the engine. up, the circuit has 2)Read the data of throttle position sensor sig- returned to a nor- nal using Subaru Select Monitor or OBD-II mal condition at general scan tool. this time. A tempo- rary poor contact...
  • Page 572 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) R: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 573 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 574 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) S: DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR- MANCE PROBLEM (LEAN) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 575 70°C (160°F). If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3)Read the data of front oxygen (A/F) sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 576 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 577 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the har- Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- ness and connec- TOR. tor. 1)Turn the ignition switch to OFF.
  • Page 578 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 579 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than 10 Replace the front Repair the ground Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- oxygen (A/F) sen- short circuit in har- TOR.
  • Page 580 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, Operation.> and Inspection Mode <Ref.
  • Page 581 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 582 30 31 32 33 34 35 EN1401 Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Go to step 2. Go to step 3. BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool indicate DTC P0131 or P0132?
  • Page 583 70°C (158°F), and keep the engine speed at 2,000 rpm to 3,000 rpm for 2 minutes. 2)Read the data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA SHOWN ON DIS-...
  • Page 584 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 8. Repair the har- Ω? 1)Repair the harness and connector. ness and connec- 2)Measure the resistance of harness between tor.
  • Page 585 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-153...
  • Page 586 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) X: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 587 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the rear BLE CODE (DTC) ON DISPLAY. vant DTC using oxygen sensor. “List of Diagnostic <Ref.
  • Page 588 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Y: DTC P0170 — FUEL TRIM MALFUNCTION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 589 1)Start the engine and warm-up completely. (212°F)? temperature sen- 2)Read the data of engine coolant temperature sor. <Ref. to FU- sensor signal using Subaru Select Monitor or 31, Engine Cool- OBD-II general scan tool. ant Temperature Sensor.> NOTE: •Subaru Select Monitor...
  • Page 590 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Z: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN-160, DTC P0304 — CYLINDER 4 MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AA:DTC P0302 —...
  • Page 591 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-159...
  • Page 592 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AC:DTC P0304 — CYLINDER 4 MISFIRE DETECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • Immediately at fault recognition (A misfire which could damage catalyst occurs.) •...
  • Page 593 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 594 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair the poor Repair the har- 1)Turn the ignition switch to ON. contact in all con- ness and connec- 2)Measure the voltage between fuel injector nectors in fuel tor.
  • Page 595 Is the MIL coming on or blink- Go to step 15. Go to step 14. FUNCTION INDICATOR LAMP (MIL). ing? 1)Clear the memory using Subaru Select Mon- itor. <Ref. to EN-49, Clear Memory Mode.> 2)Start engine, and drive the vehicle more than 10 minutes.
  • Page 596 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 23. Go to step 19. (DTC) ON DISPLAY. tor or OBD-II general scan tool indicate DTC P0303 and...
  • Page 597 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #3 AND #4 CYLINDERS Are there faults in #3 and #4 Repair or replace Go to DTC P0170. cylinders? the faulty parts. <Ref. to EN-156, DTC P0170 — NOTE: FUEL TRIM MAL- •...
  • Page 598 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AD:DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 599 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than Go to step 2. Repair the har- SOR AND ECM CONNECTOR. 700 kΩ? ness and connec- 1)Turn the ignition switch to OFF. tor.
  • Page 600 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AE:DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 601 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair the ground 1)Disconnect the connector from knock sen- kΩ? sensor. <Ref. to short circuit in har- sor.
  • Page 602 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AF:DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 603 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair the har- Go to step 2. SHAFT POSITION SENSOR AND ECM CON- 100 kΩ? ness and connec- NECTOR. tor. 1)Turn the ignition switch to OFF.
  • Page 604 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AG:DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER- FORMANCE PROBLEM — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 605 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Inspect DTC Go to step 2. BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool P0335 using “List...
  • Page 606 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AH:DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 607 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair the har- Go to step 2. POSITION SENSOR AND ECM CONNEC- 100 kΩ? ness and connec- TOR. tor. 1)Turn the ignition switch to OFF. NOTE: 2)Disconnect the connector from camshaft In this case, repair...
  • Page 608 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR- MANCE PROBLEM — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 609 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Inspect DTC Go to step 2. BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool P0340 using “List...
  • Page 610 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace the cam- 1)Remove the camshaft position sensor. and 4 kΩ? shaft position sen- 2)Measure the resistance between connector sor.
  • Page 611 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 612 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY MAIN RELAY SBF-5 FRONT OXYGEN REAR OXYGEN (A/F) SENSOR SENSOR B122 B134 B136 B122 1 2 3 4 1 2 3 4 4 5 6 5 6 7 8 4 5 6 (LHD) B136...
  • Page 613 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 614 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Contact with your Repair the har- Ω? 1)Repair the harness and connector. Subaru distributor ness and connec- 2)Measure the resistance of harness between service. tor. ECM connector and chassis ground.
  • Page 615 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-183...
  • Page 616 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AK:DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 617 Connector & terminal this time. Contact (B134) No. 2 (+) — Chassis ground ( − − − − ): with your Subaru distributor service. NOTE: Inspection by DTM required, cause probable...
  • Page 618 CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Contact with your Check poor contact in purge control solenoid control solenoid valve connec- contact in purge Subaru distributor valve connector. tor? control solenoid service. valve connector. NOTE:...
  • Page 619 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-187...
  • Page 620 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AL:DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 621 ECM and ECM connector. chassis ground. NOTE: Purge control solenoid valve operation can be executed using the Subaru Select Monitor. For procedure, refer to “Compulsory Valve Opera- tion Check Mode”. <Ref. to EN-50, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No.
  • Page 622 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AM:DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 623 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) RHD model BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 3 4 5 6 1 2 3 : 1.6L AND 2.0L MODEL COMBINATION METER : 2.5L MODEL 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12...
  • Page 624 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AN:DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 625 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) RHD model BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 3 4 5 6 1 2 3 : 1.6L AND 2.0L MODEL COMBINATION METER : 2.5L MODEL 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12...
  • Page 626 •Subaru Select Monitor of the connector For detailed operation procedure, refer to the may be the cause. “READ CURRENT DATA FOR ENGINE”. <Ref. to EN-34, Subaru Select Monitor.> NOTE: In this case, repair the following: • Poor contact in combination meter connector •...
  • Page 627 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Repair the poor Replace the fuel and 2.5 Ω? 1)Remove the fuel pump assembly. <Ref. to contact in harness level sensor. FU-62, Fuel Pump.>...
  • Page 628 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AO:DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 629 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) RHD model BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 3 4 5 6 1 2 3 : 1.6L AND 2.0L MODEL COMBINATION METER : 2.5L MODEL 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12...
  • Page 630 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.75 Go to step 3. Even if MIL lights 1)Turn the ignition switch to ON. (engine OFF) up, the circuit has 2)Measure the voltage between ECM connec- returned to a nor- tor and chassis ground.

  • Page 631: Fuel Level Sensor

    DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FUEL TANK CORD. Is the resistance less than 10 Go to step 9. Repair the open Ω? 1)Disconnect the connector from fuel level circuit between sensor. coupling connector 2)Measure the resistance between fuel level and fuel level sen- sensor and coupling connector.
  • Page 632 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AP:DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT— • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 633 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) RHD model BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 3 4 5 6 1 2 3 : 1.6L AND 2.0L MODEL COMBINATION METER : 2.5L MODEL 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12...

  • Page 634: Fuel Sub Level Sensor

    DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FUEL SUB LEVEL SENSOR. Does the resistance change Repair the poor Replace the fuel 1)Remove the fuel sub level sensor. smoothly between approx. 0.5 contact in ECM, sub level sensor. Ω...
  • Page 635 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AQ:DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Radiator fan does not operate properly. •...
  • Page 636 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 AIR CONDITIONING No.18 AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2 RHD :7 LHD :12...
  • Page 637 4)While operating the radiator fan relay, mea- sure the voltage between ECM terminal and ground. NOTE: Radiator fan relay operation can be executed using the Subaru Select Monitor. For proce- dure, refer to “Compulsory Valve Operation Check Mode”.<Ref. to EN-34, Subaru Select Monitor.> Connector & terminal (B134) No.
  • Page 638 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-206...
  • Page 639 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AR:DTC P0483 — COOLING FAN FUNCTION PROBLEM — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Occurrence of noise • Overheating CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 640 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 AIR CONDITIONING No.18 AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2 RHD :7 LHD :12...
  • Page 641 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 642 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AS:DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 643 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Moni- Check the front Go to step 3. tor or OBD-II general scan tool vehicle speed sen- indicate DTC P0720? sor signal circuit.
  • Page 644 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AT:DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine is difficult to start. •...
  • Page 645 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 646 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AU:DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 647 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 648 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AV:DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 649 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check the starter ate when ignition switch is short circuit in motor circuit. <Ref. NOTE: turned to ON? starter motor cir- to EN-64, Place the inhibitor switch in each position.
  • Page 650 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AW:DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Power source voltage of the ECM is low. • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 651 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage less than 10.8 Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to CS- 2)Idle after warm-up. 21, General Diag- 3)Measure the voltage between generator B nostic.>...
  • Page 652 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AX:DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Power source voltage of the ECM is high. • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 653 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage more than 16.2 Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to CS- 2)Idle after warm-up. 21, General Diag- 3)Measure the voltage between generator B nostic.>...
  • Page 654 30 31 32 33 34 35 EN1397 Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Replace the ECM. It is not necessary BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool <Ref. to FU-51,...
  • Page 655 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-223...
  • Page 656 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AZ:DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 657 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 3. Repair or replace Ω? BRAKE LIGHT SWITCH CONNECTOR. the harness and 1)Disconnect the connectors from TCM and connector.
  • Page 658 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BA:DTC P0731 — GEAR 1 INCORRECT RATIO — NOTE: For the diagnostic procedure, refer to DTC P0734. <Ref. to EN-227, DTC P0734 — GEAR 4 INCORRECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> BB:DTC P0732 —...
  • Page 659 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BD:DTC P0734 — GEAR 4 INCORRECT RATIO — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; excessive tight corner “braking”...
  • Page 660 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BE:DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • No lock-up (after engine warm-up) • No shift or excessive tight corner “braking” CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 661 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Go to step 10. Check poor contact in TCM connector. connector? contact in TCM connector. CHECK MECHANICAL TROUBLE. Is there any mechanical trou- Repair or replace Replace the TCM.
  • Page 662 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BF:DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 663 Go to step 2. 1)Start the engine. (0 mmHg, 0 inHg)? 2)Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 664 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND AT- Is the voltage more than 4.5 V? Go to step 8. Repair the har- MOSPHERIC PRESSURE SENSOR CON- ness and connec- NECTOR. tor. 1)Turn the ignition switch to OFF.
  • Page 665 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-233...
  • Page 666 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BG:DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 667 Go to step 2. 1)Start the engine. (1,050 mmHg, 41.34 inHg)? 2)Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 668 Pressure 4)Read the data of intake manifold absolute sensor connector. Sensor.> pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 669 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-237...
  • Page 670 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BH:DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PER- FORMANCE PROBLEM — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 671 2)Read the data of intake manifold absolute 106.6 kPa (800 mmHg, 31.50 sensor. <Ref. to and pressure sen- pressure signal using Subaru Select Monitor or inHg)? FU-38, Atmo- sor. <Ref. to FU- OBD-II general scan tool. spheric Pressure 37, Intake Air Sensor.>...
  • Page 672 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BI: DTC P1137 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR- MANCE PROBLEM — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 673 70°C (160°F). If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3)Read the data of front oxygen (A/F) sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 674 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BJ:DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR- MANCE PROBLEM (LOW INPUT) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
  • Page 675 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the throt- BLE CODE (DTC) ON DISPLAY. vant DTC using tle position sensor. “List of Diagnostic <Ref.
  • Page 676 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BK:DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 677 3)Turn the A/C switch to OFF. and Pressure Sen- 4)Turn all accessory switches to OFF. sor.> 5)Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 678 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK THROTTLE POSITION. Is the throttle positioning ratio Replace the intake Replace the throt- equal to or more than 85 % air temperature tle position sensor. when throttle is fully open? and pressure sen- <Ref.
  • Page 679 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BL:DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM 2 — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 680 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) RHD model BATTERY No.13 SBF-4 SBF-1 IGNITION SWITCH 3 4 5 6 1 2 3 : 1.6L AND 2.0L MODEL COMBINATION METER : 2.5L MODEL 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12...
  • Page 681 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BM:DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Radiator fan does not operate properly. •...
  • Page 682 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 AIR CONDITIONING No.18 AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2 RHD :7 LHD :12...
  • Page 683 ECM and chassis ECM connector. ground. NOTE: Radiator fan relay operation can be executed using the Subaru Select Monitor. For proce- dure, refer to “Compulsory Valve Operation Check Mode”.<Ref. to EN-50, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No.
  • Page 684 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BN:DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 685 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2. BLE CODE (DTC) ON DISPLAY. vant DTC using “List of Diagnostic Trouble Code (DTC)”.
  • Page 686 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BO:DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT LOW INPUT — NOTE: For the diagnostic procedure, refer to DTC P1516. <Ref. to EN-256, DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 687 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-255...
  • Page 688 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BU:DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
  • Page 689 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2. Repair the har- TROL SOLENOID VALVE. ness and connec- 1)Turn the ignition switch to OFF. tor.
  • Page 690 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the idle Check poor contact in ECM connector and idle connector or idle air control contact in ECM air control solenoid air control solenoid valve connector.
  • Page 691 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-259...
  • Page 692 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BV:DTC P1517 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
  • Page 693 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Go to step 2. Go to step 3. BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool...
  • Page 694 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BW:DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 695 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check the starter when ignition switch is turned ness and connec- motor circuit. <Ref. NOTE: to START? tor.
  • Page 696 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BX:DTC P1540 — VEHICLE SPEED SENSOR MALFUNCTION 2 — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 697 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Moni- Check the front Go to step 2. tor or OBD-II general scan tool vehicle speed sen- indicate DTC P0720? sor signal circuit.
  • Page 698 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BY:DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 699 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the ground Go to step 3. Ω? MAIN FUSE BOX CONNECTOR. short circuit in har- 1)Disconnect the connector from ECM. ness between 2)Measure the resistance of harness between ECM connector...
  • Page 700 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BZ:DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT MODEL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 701 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2. tor or OBD-II general scan tool P0705 using “List indicate DTC P0705? of Diagnostic Trouble Code (DTC)”.
  • Page 702 Terminals No. 7 — No. 12: CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair the selector Contact with your cable connection to inhibitor cable connection. Subaru distributor switch? <Ref. to CS-10, service. INSPECTION, NOTE: Select Cable.> Inspection by DTM...
  • Page 703 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN-271...
  • Page 704 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CA:DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MOD- EL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 705 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Moni- Inspect the DTC Go to step 2. tor or OBD-II general scan tool P0705 using “List indicate DTC P0705?
  • Page 706 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CB:DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT MODEL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 707 Is the poor contact in ECM Repair the poor Contact with your Check poor contact in ECM connector. connector? contact in ECM Subaru distributor connector. service. CHECK NEUTRAL POSITION SWITCH. Is the resistance more than Go to step 5. Repair the short 1)Turn the ignition switch to OFF.
  • Page 708 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CC:DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 709 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCESSORY. Are the car phone and/or CB Repair the ground- Replace the TCM. installed on vehicle? ing line of car <Ref. to AT-46, phone or CB sys- Transmission Con- tem.
  • Page 710 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CD:DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 711 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Go to step 2. Even if MIL lights TCM CONNECTOR. up, the circuit has 1)Turn the ignition switch to ON. returned to a nor- 2)Measure the voltage between ECM and mal condition at...
  • Page 712 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CE:DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 713 Even if MIL lights Contact with your Measure the voltage between ECM and chas- 1 V to 4 V while monitoring the up, the circuit has Subaru distributor sis ground. value with voltage meter? returned to a nor- service. Connector & terminal...
  • Page 714 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CF:DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN- PUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 715 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the ground Go to step 3. Ω? TCM CONNECTOR. short circuit in har- 1)Turn the ignition switch to OFF. ness between 2)Disconnect the connectors from ECM and ECM and TCM...
  • Page 716 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CG:DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN- PUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 717 Repair the battery Contact with your TCM CONNECTOR. than 10 V by shaking harness short circuit in har- Subaru distributor 1)Turn the ignition switch to OFF. and connector of ECM while ness between service. 2)Measure the voltage between ECM and...
  • Page 718 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CH:DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION, Clear Memory Mode.>...
  • Page 719 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? CCM CONNECTOR. circuit in harness 1)Turn the ignition switch to OFF. between TCM and 2)Disconnect the connectors from TCM and CCM connector.
  • Page 720 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CI: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC- TION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 721 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Go to step 3. Measure the voltage between ECM and chas- short circuit in har- sis ground.
  • Page 722 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CJ:DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC- TION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 723 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Go to step 3. Measure the voltage between ECM and chas- short circuit in har- sis ground.

  • Page 724: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 20.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME-95, Engine Trouble in General.> Symptom Problem parts 1) Idle air control solenoid valve 2) Intake air temperature and pressure sensor 3) Ignition parts (*1) 1.

  • Page 725: Automatic Transmission

    GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 7. Spark knock 4) Engine coolant temperature sensor 5) Knock sensor 6) Fuel injection parts (*4) 7) Fuel pump and fuel pump relay 1) Intake manifold pressure sensor 2) Intake air temperature sensor...
  • Page 726 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) EN-294...
  • Page 727 2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 2 SECTION FUEL INJECTION (FUEL SYSTEMS) FU(w/oOBD) EMISSION CONTROL EC(w/oOBD) (AUX. EMISSION CONTROL DEVICES) EXHAUST EX(w/oOBD) IGNITION IG(w/oOBD) This service manual has been prepared to provide SUBARU service personnel ENGINE(DIAGNOSTICS) EN(w/oOBD) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 729 FUEL INJECTION (FUEL SYSTEMS) FU(w/oOBD) Page General Description ..................2 Throttle Body.....................16 Intake Manifold..................17 Engine Coolant Temperature Sensor............30 Crankshaft Position Sensor...............31 Camshaft Position Sensor.................32 Knock Sensor....................33 Throttle Position Sensor................35 Intake Air Temperature and Pressure Sensor...........38 Idle Air Control Solenoid Valve ..............39 Fuel Injector ....................40 Oxygen Sensor ..................46 Engine Control Module................48...
  • Page 730 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 1600 cc and 2000 cc 2500 cc 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure...
  • Page 731 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) FU(w/oOBD)-3...
  • Page 732 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (20) (23) (22) (13) (20) (14) (16) (10) (21) (15) (19) (18) (21) (11) (18) (12) (19) (17) (19) (18) EN1385 FU(w/oOBD)-4...
  • Page 733 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH Fuel injector pipe (13) Intake air temperature and pres- (23) Accelerator cable bracket sure sensor Fuel injector O-ring (14) O-ring Tightening torque: N·m (kgf-m, ft-lb) O-ring (15)
  • Page 734 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM B2M3455C Gasket Throttle body Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor T1: 1.6 (0.16, 1.2) Idle air control solenoid valve T2: 22 (2.2, 16.2) FU(w/oOBD)-6...
  • Page 735 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS B2M2282B Crankshaft position sensor Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) Knock sensor Camshaft position sensor support T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU(w/oOBD)-7...
  • Page 736 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK • 1600 CC and 2000 CC MODEL (25) (16) (10) (11) (11) (11) (14) (13) (24) (12) (24) (11) (11) (15) (11) (17) (19) (18) (20) (11) (21) (11) (22) (18) (19) (11) (23)
  • Page 737 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (11) Clip (21) Fuel pipe ASSY Fuel tank band (12) Evaporation hose B (22) Evaporation hose F Protector RH (13) Joint pipe (23) Fuel return hose B Fuel tank (14) Evaporation hose C (24) Evaporation hose G Fuel pump gasket...
  • Page 738 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) • 2500 CC MODEL (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (29) (13) (12) (12) (28) (16) (12) (12) (18) (21) (20) (22) (19) (27) (12) (12) (26) (23) (12) (24) (20) (12) (25)
  • Page 739 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
  • Page 740 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) EN0440 FU(w/oOBD)-12...
  • Page 741 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
  • Page 742 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (10) (11) EN0441 Fuel filler pipe ASSY Air vent pipe holder Tightening torque: N·m (kgf-m, ft-lb) Evaporation hose holder Filler pipe packing T: 7.5 (0.76, 5.5) Clip Filler ring Clamp (10) Filler cap Air vent hose...
  • Page 743 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
  • Page 744 THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 6) Disconnect the air by-pass hose from purge con- trol solenoid valve. A: REMOVAL 1) Disconnect the ground cable from battery. H2M2949 (A) Throttle position sensor G6M0095 (B) Idle air control solenoid valve 2) Remove the air cleaner case.
  • Page 745 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 7) Remove the power steering pump and tank from brackets. A: REMOVAL (1) Remove the resonator chamber. <Ref. to 1) Release the fuel pressure. <Ref. to FU(w/ IN-8, REMOVAL, Resonator Chamber.> oOBD)-51, RELEASING OF FUEL PRESSURE, (2) Remove the front side V-belt.
  • Page 746 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (6) Remove the power steering tank from the 11) Disconnect the brake booster hose. bracket by pulling it upward. B2M4259 EN0361 12) Remove the air cleaner case stay RH and en- gine harness bracket, and then disconnect the en- (7) Place the power steering pump and tank on right side wheel apron.
  • Page 747 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Disconnect the connector from crankshaft posi- 18) Disconnect the fuel hoses from fuel pipes. tion sensor. WARNING: • Do not spill fuel. • Catch the fuel from hoses in a container or cloth. B2M1252 16) Disconnect the connector from oil pressure switch.
  • Page 748 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 4) Connect the connector to oil pressure switch. 1) Install the intake manifold onto cylinder heads. NOTE: Always use new gaskets. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) B2M1253 5) Connect the connector to crankshaft position sensor.
  • Page 749 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Install the air cleaner case stay RH and engine 13) Install the power steering pump and tank on harness bracket, and then connect the engine har- brackets. ness connectors to bulkhead connectors. (1) Install the power steering tank on bracket. EN0361 B2M4260 9) Connect the brake booster hose.
  • Page 750 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (5) Install the front side V-belt. <Ref. to ME-44, 18) Connect the battery ground cable to battery. INSTALLATION, V-belt.> (6) Install the resonator chamber. Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb) G6M0095 C: DISASSEMBLY 1) Disconnect the engine ground cable from intake manifold.
  • Page 751 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 4) Disconnect the connector from intake air tem- 9) Remove the fuel pipe protector LH. perature and pressure sensor. B2M4129 H2M2959 10) Remove the fuel pipe protector RH. 5) Remove the intake air temperature and pressure sensor from intake manifold.
  • Page 752 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 13) Disconnect the air by-pass hose (A) from purge 18) Remove the bolt which installs injector pipe on control solenoid valve. intake manifold. EN1003 H2M2966 14) Remove the harness bands (A) and harness 19) Remove the two bolts which hold fuel pipes on bracket (B) which hold engine harness onto intake the left side of intake manifold.
  • Page 753 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 21) Loosen the clamp which holds front left side 25) Remove the fuel pipe assembly (B) and pres- fuel hose to injector pipe, and then remove the pipe sure regulator (A) from intake manifold. from fuel hose.
  • Page 754 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe, and then tighten the clamp screw. 1) Install the fuel pipe assembly (B) and pressure regulator (A), etc. to intake manifold. B2M4289 H2M2976A 6) Install the fuel injectors.
  • Page 755 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 7) Tighten the bolt which installs injector pipe on in- 10) Install the purge control solenoid valve. take manifold. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3487 11) Connect the hoses to purge control solenoid valve.
  • Page 756 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Install the fuel pipe protector RH. 18) Install the throttle body to intake manifold. NOTE: Tightening torque: Replace the gasket with a new one. 19 N·m (1.9 kgf-m, 14.0 ft-lb) Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) B2M4130 16) Install the fuel pipe protector LH.
  • Page 757 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 20) Install the intake air temperature and pressure 25) Install the engine ground cable to intake mani- sensor. fold. Tightening torque: Tightening torque: 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) 19 N·m (1.9 kgf-m, 14.0 ft-lb) H2M2960 B2M4265 E: INSPECTION...
  • Page 758 ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 16 N·m (1.6 kgf-m, 11.8 ft-lb) 1) Disconnect the ground cable from battery. B2M4275 G6M0095 2) Remove the air intake duct and air cleaner as- sembly.
  • Page 759 CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) G6M0095 B2M1252B 2) Remove the bolt which installs crankshaft posi- tion sensor to cylinder block.
  • Page 760 CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam- shaft position sensor support as a unit. A: REMOVAL 6) Remove the camshaft position sensor itself. 1) Disconnect the ground cable from battery. B2M2322 G6M0095 B: INSTALLATION...
  • Page 761 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...
  • Page 762 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 4) Connect the battery ground cable to battery. G6M0095 FU(w/oOBD)-34...
  • Page 763 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing the throttle position sensor, ad- just to the specified data.
  • Page 764 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3148 5) Turn the ignition switch to ON, and Subaru Se- lect Monitor switch to ON. 6) Select the {2. Each System Check} in Main Menu. 7) Select the {Engine Control System} in Selection Menu.
  • Page 765 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 10) Adjust the throttle position sensor to the proper position to match with the following specifications. Condition: Throttle fully closed Throttle opening angle 0.00 % Throttle sensor voltage 0.50 V 11) Tighten the throttle position sensor holding screws.
  • Page 766 INTAKE AIR TEMPERATURE AND PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Air Temperature and B: INSTALLATION Install in the reverse order of removal. Pressure Sensor Tightening torque: A: REMOVAL 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) 1) Disconnect the ground cable from battery. H2M2982 G6M0095 NOTE:...
  • Page 767 IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 10.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use a new gasket. 1) Disconnect the ground cable from battery. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 2) Disconnect the connector from idle air control...
  • Page 768 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 11.Fuel Injector (3) Remove the bolts which install power steer- ing pump to bracket. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(w/oOBD)-51, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 769 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold. (1) Remove the fuel injector securing clip. B2M4130 H2M2991 8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the fuel injector pipe.
  • Page 770 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 8) Move the washer tank, and secure it away from working area. 1) Release the fuel pressure. <Ref. to FU(w/ oOBD)-51, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 771 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12) Remove the bolt which installs injector pipe to (2) Remove the fuel injector while lifting up the intake manifold. fuel injector pipe. B2M4133 H2M3241 B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Replace the O-rings with a new one.
  • Page 772 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 2. LH SIDE 19 N·m (1.9 kgf-m, 14.0 ft-lb) Install in the reverse order of removal. NOTE: Replace the O-rings with a new one. B2M4132 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M3372A (A) O-ring (B) Fuel injector...
  • Page 773 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M4133 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M4129 FU(w/oOBD)-45...
  • Page 774 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) B2M3108 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of oxygen sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the oxygen sensor.
  • Page 775 OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. G6M0095 FU(w/oOBD)-47...
  • Page 776 ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 13.Engine Control Module B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage to fuel injection system.
  • Page 777 MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 14.Main Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds main relay bracket on body.
  • Page 778 FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 15.Fuel Pump Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds fuel pump relay bracket on body.
  • Page 779 FUEL FUEL INJECTION (FUEL SYSTEMS) 16.Fuel 5) Drain fuel from the fuel tank. Set a container under the vehicle and remove the A: OPERATION drain plug from fuel tank. • 1600 cc and 2000 cc MODEL 1. RELEASING OF FUEL PRESSURE WARNING: •...
  • Page 780 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 17.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler hose and air vent hose from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
  • Page 781 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Connect the fuel hoses, and then secure them with clips and quick connector. <Ref. to FU(w/ 1) Support the fuel tank with transmission jack and oOBD)-69, INSTALLATION, Fuel Delivery, Return push the fuel tank harness into access hole with and Evaporation Lines.>...
  • Page 782 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 10) Connect the connector to fuel pump relay. EN0344 C: INSPECTION 1) Make sure there are no cracks, holes, or other damage on the fuel tank. 2) Make sure that the fuel hoses and fuel pipes are not cracked and that connections are tight.
  • Page 783 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 18.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un- der the vehicle and remove the drain plug from fuel A: REMOVAL tank. • 1600 cc and 2000 cc MODEL WARNING: •...
  • Page 784 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 11) Remove the fuel filler pipe protector. 16) Move the clip and separate air vent hose (B). EN0544 EN0548 12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of the fuel filler pipe.
  • Page 785 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 6) Insert the fuel filler hose (A) approx. 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe 1) Hold the fuel filler flap open. and tighten the clamp.
  • Page 786 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 9) Tighten the bolts which hold evaporation hoses 15) Connect the battery ground cable to battery. onto clip of fuel filler pipe. G6M0095 EN0545 10) Install the fuel filler pipe protector. EN0544 11) Install the rear right wheel. B2M1748 12) Lower the vehicle.
  • Page 787 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 19.Fuel Pump 6) Tighten the fuel drain plug. Tightening torque: A: REMOVAL 26 N·m (2.7 kgf-m, 19.2 ft-lb) WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
  • Page 788 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 11) Move the clip and then disconnect the fuel re- 5) Drain fuel from the fuel tank. Set a container un- turn hose (B). der the vehicle and remove the drain plug from fuel tank.
  • Page 789 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 10) Disconnect the quick connector, and then dis- • 2500 cc MODEL connect fuel delivery hose (A). <Ref. to FU(w/ oOBD)-68, REMOVAL, Fuel Delivery, Return and Evaporation Lines.> 11) Move the clips, and then disconnect the fuel re- turn hose (B) and jet pump hose (C).
  • Page 790 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Level Sensor • 2500 cc MODEL A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in the fuel pump assembly. 1) Remove the fuel pump assembly.
  • Page 791 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Sub Level Sensor 6) Remove the service hole cover. A: REMOVAL NOTE: Fuel sub level sensor is equipped to only 2500 cc model. WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 792 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3178 FU(w/oOBD)-64...

  • Page 793: Fuel Filter

    FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Filter C: INSPECTION 1) Check the inside of fuel filter for dirt and water A: REMOVAL sediment. 2) If it is clogged, or if replacement interval has WARNING: been reached, replace it. • Place “NO FIRE” signs near the working area. 3) If water is found in it, shake and expel the water •...

  • Page 794: Fuel Cut Valve

    FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Cut Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Remove the fuel tank.

  • Page 795: Fuel Damper Valve

    FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Damper Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(w/ oOBD)-51, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Remove the fuel damper valve from fuel return line.

  • Page 796: Fuel Delivery, Return And Evaporation Lines

    FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove fuel filler cap. Evaporation Lines 4) Remove the floor mat. <Ref. to EI-53, REMOV- AL, Floor Mat.> A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel 1) Set the vehicle on a lift.
  • Page 797 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate the quick connector on fuel delivery (1) Set the new retainer (B) to connector (A). and return line. (2) Push the pipe into connector completely. (1) Clean the pipe and connector, if they are NOTE: covered with dust.
  • Page 798 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel delivery hose to pipe with an C: INSPECTION overlap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure that there are no cracks on the fuel Type A: When the fitting length is specified.

  • Page 799: Fuel System Trouble In General

    FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 26.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten ❍...
  • Page 800 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) FU(w/oOBD)-72...
  • Page 801 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(w/oOBD) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister.......................7 Purge Control Solenoid Valve ..............8 Two-way Valve....................9...

  • Page 802: General Description

    GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...

  • Page 803: Front Catalytic Converter

    FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter 7) Remove the nuts which hold front exhaust pipe onto cylinder heads. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. B2M3200 8) Remove the front and center exhaust pipe from hanger bracket.
  • Page 804 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) B: INSTALLATION 4) Tighten the bolts which install front and center exhaust pipe assembly to rear exhaust pipe. NOTE: Tightening torque: Replace gaskets with new ones. 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Install the front catalytic converter to front ex- haust pipe.
  • Page 805 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 9) Connect the battery ground cable to battery. G6M0095 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EC(w/oOBD)-5...

  • Page 806: Rear Catalytic Converter

    REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal and installation procedures are the same as the those for the front catalytic con- verter.

  • Page 807: Canister

    CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Canister A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the two clamps which hold two canister hoses, and disconnect the three evaporation hoses from canister. EN0898 3) Remove the canister from body. B2M4166 B: INSTALLATION 1) Install in the reverse order of removal.

  • Page 808: Purge Control Solenoid Valve

    PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Purge Control Solenoid Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 16 N·m (1.6 kgf-m, 11.6 ft-lb) G6M0095 H2M2985 2) Remove the bolt which installs purge control so-...

  • Page 809: Two-Way Valve

    TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Remove the canister from body. <Ref. to EC(w/ oOBD)-7, REMOVAL, Canister.> 3) Remove the two-way valve with bracket as a sin- gle unit from body. EN0901 4) Remove the two-way valve from bracket.
  • Page 810 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(w/oOBD)-10...
  • Page 811 EXHAUST EX(w/oOBD) Page General Description ..................2 Front Exhaust Pipe..................9 Center Exhaust Pipe .................12 Rear Exhaust Pipe ..................13 Muffler .......................14...
  • Page 812 GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT 1. WITH CATALYTIC CONVERTER (1600 CC MODEL) (16) (15) (13) (14) (16) (11) (10) (12) (16) (26) (17) (27) (22) (18) (25) (24) (23) (30) (29) (19) (28) (21) (20) (30) EN1374 EX(w/oOBD)-2...
  • Page 813 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (14) Self-locking nut (27) Upper rear catalytic converter cover (15) Muffler Lower front exhaust pipe cover (16) Cushion rubber (28) Lower rear catalytic converter cover (17) Lower clamp Clamp (18) Upper center exhaust pipe cover (29) Rear catalytic converter Upper front exhaust pipe cover LH...
  • Page 814 GENERAL DESCRIPTION EXHAUST 2. WITH CATALYTIC CONVERTER (2000 CC AND 2500 CC MODEL) (16) (15) (13) (14) (16) (11) (10) (17) (16) (12) (27) (18) (28) (23) (19) (26) (25) (24) (31) (30) (20) (29) (22) (21) (31) EN1375 EX(w/oOBD)-4...
  • Page 815 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (15) Muffler (28) Upper rear catalytic converter cover (16) Cushion rubber Lower front exhaust pipe cover (17) Rear exhaust pipe (29) Lower rear catalytic converter cover (18) Lower clamp Clamp (19) Upper center exhaust pipe cover (30) Rear catalytic converter Upper front exhaust pipe cover LH...

  • Page 816: General Description

    GENERAL DESCRIPTION EXHAUST 3. WITHOUT CATALYTIC CONVERTER (16) (15) (13) (14) (16) (11) (10) (24) (16) (12) (23) (17) (18) (22) (21) (25) (20) (19) (25) Muffler cutter (Except 1600cc Model) EN1376 EX(w/oOBD)-6...
  • Page 817 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (11) Chamber (23) Upper center exhaust pipe cover (12) Rear exhaust pipe cover (24) Rear exhaust pipe Lower front exhaust pipe cover (13) Gasket (25) Gasket (14) Self-locking nut Clamp (15) Muffler Tightening torque: N·m (kgf-m, ft-lb) Upper front exhaust pipe cover LH (16)
  • Page 818 GENERAL DESCRIPTION EXHAUST B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.

  • Page 819: Front Exhaust Pipe

    FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 6) Remove the nuts which hold front exhaust pipe onto cylinder heads. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. Be careful not to pull down the front and center exhaust pipe assembly.
  • Page 820 FRONT EXHAUST PIPE EXHAUST B: INSTALLATION 7) Tighten the bolts which install front and center exhaust pipe assembly to rear exhaust pipe. 1) Install the oxygen sensor. (With catalytic con- verter) <Ref. to FU(w/oOBD)-46, INSTALLATION, Tightening torque: Oxygen Sensor.> 18 N·m (1.8 kgf-m, 13.0 ft-lb) 2) Install the front exhaust pipe to center exhaust pipe.
  • Page 821 FRONT EXHAUST PIPE EXHAUST 11) Connect the battery ground cable to battery. G6M0095 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EX(w/oOBD)-11...

  • Page 822: Center Exhaust Pipe

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

  • Page 823: Rear Exhaust Pipe

    Tightening torque: G2M0382 18 N·m (1.8 kgf-m, 13.0 ft-lb) 3) Apply a coat of SUBARU CRC to mating area of the cushion rubbers in advance. SUBARU CRC (Part No. 004301003) 4) Remove the rear exhaust pipe bracket from the cushion rubber.

  • Page 824: Muffler

    Be careful, the exhaust pipe is hot. 48 N·m (4.9 kgf-m, 35.4 ft-lb) G2M0382 G2M0382 2) Apply a coat of SUBARU CRC to mating area of C: INSPECTION the cushion rubbers in advance. 1) Make sure there are no exhaust leaks from con- SUBARU CRC (Part No.
  • Page 825 IGNITION IG(w/oOBD) Page General Description ..................2 Spark Plug....................5 Ignition Coil and Ignitor Assembly...............8 Spark Plug Cord..................10...

  • Page 826: General Description

    GENERAL DESCRIPTION IGNITION 1. General Description A: SPECIFICATIONS Item Designation 1600 cc CM12—100C 2000 cc Model FH0137 2500 cc 1600 cc HITACHI 2000 cc Manufacturer DIAMOND 2500 cc 0.7 Ω±10% Ignition coil and ignitor 1600 cc assembly 2000 cc Primary coil resistance 0.73 Ω±10% 2500 cc 1600 cc...
  • Page 827 GENERAL DESCRIPTION IGNITION B: COMPONENT 1. 1600 CC MODEL EN1039 Spark plug Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7) Ignition coil and ignitor ASSY T2: 21 (2.1, 15.2) IG(w/oOBD)-3...
  • Page 828 GENERAL DESCRIPTION IGNITION 2. 2000 CC AND 2500 CC MODEL S6M0329B Spark plug Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) Spark plug cord (#1, #3) 21 (2.1, 15.2) Ignition coil and ignitor ASSY 6.4 (0.65, 4.7) C: CAUTION •...

  • Page 829: Spark Plug

    SPARK PLUG IGNITION 2. Spark Plug 4) Remove the spark plugs with the spark plug sockets. A: REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug NGK: BKR6E* 1600 cc CHAMPION: RC8YC4** NGK: BKR6E-11** (Alternate) 2000 cc NGK: BKR6E*...
  • Page 830 SPARK PLUG IGNITION 5) Remove the spark plug cords by pulling boot, not 2. LH SIDE the cord itself. 1) Install in the reverse order of removal. Tightening torque (Spark plug): 21 N·m (2.1 kgf-m, 15.2 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads.
  • Page 831 SPARK PLUG IGNITION 2) Carbon fouled: D: CLEANING Dry fluffy carbon deposits on insulator and elec- Clean the spark plugs in a sand blast type cleaner. trode are mostly caused by slow speed driving in Avoid excessive blasting. Clean and remove the city, weak ignition, too rich fuel mixture, dirty air carbon or oxide deposits, but do not wear away cleaner, etc.

  • Page 832: Ignition Coil And Ignitor Assembly

    IGNITION COIL AND IGNITOR ASSEMBLY IGNITION 3. Ignition Coil and Ignitor As- 4) Remove the ignition coil and ignitor assembly. • 1600 cc MODEL sembly A: REMOVAL 1) Disconnect the ground cable from battery. EN1044 • 2000 cc and 2500 cc MODEL G6M0095 2) Disconnect the spark plug cords from ignition coil and ignitor assembly.
  • Page 833 IGNITION COIL AND IGNITOR ASSEMBLY IGNITION • 2000 cc and 2500 cc MODEL Specified resistance:(2000 cc and 2500 cc) [Primary side] Between terminal No. 1 and No. 2 0.73 Ω± Ω± 10% Ω± Ω± Between terminal No. 2 and No. 4 0.73 Ω±...

  • Page 834: Spark Plug Cord

    SPARK PLUG CORD IGNITION 4. Spark Plug Cord A: INSPECTION Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 — 10.6 #2 cord: 7.3 — 13.7 #3 cord: 5.9 —...
  • Page 835 Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description ..................6 Electrical Components Location..............10 Engine Control Module (ECM) I/O Signal ..........20 Subaru Select Monitor................23 Read Diagnostic Trouble Code (DTC) ............26 Inspection Mode..................28 Clear Memory Mode..................30 Compulsory Valve Operation Check Mode ..........31 Engine Malfunction Indicator Lamp (MIL) ..........32...

  • Page 836: Basic Diagnostic Procedure

    DTC? <Ref. to Repair the trouble parts. 1)Turn the ignition switch to OFF. EN(w/oOBD)-63, LIST, List of cause. <Ref. to NOTE: 2)Connect the Subaru Select Monitor to data Diagnostic Trouble Code EN(w/oOBD)-66, If a DTC is not link connector. (DTC).> Diagnostic Proce-...
  • Page 837 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. WITHOUT SUBARU SELECT MONITOR CAUTION: • Check the connector while it is connected unless specified otherwise. • Be sure to check again from the beginning in order to prevent secondary trouble caused by repair work.

  • Page 838: Check List For Interview

    CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer's name Engine No. Date of sale Fuel brand Date of repair Odometer reading...
  • Page 839 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST NO. 2 Check the following items about the vehicle's state when MIL turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. ❏ Yes/❏ No ❏...
  • Page 840 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use the ECM mounting stud bolt at the body head grounding points when measuring voltage A: CAUTION and resistance inside the passenger compartment. 1) Airbag system wiring harness is routed near en- gine control module (ECM), main relay and fuel pump relay.

  • Page 841: General Description

    GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 12) Observe the following cautions when installing 2) Check the condition of the main and other fuses, a radio in MFI equipped models. and harnesses and connectors. Also check for proper grounding. CAUTION: • The antenna must be kept as far apart as pos- 2.
  • Page 842 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA190 CARTRIDGE Troubleshooting for electrical (Newly adopted tool) systems. B2M3876 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems. • English: 22771AA030 (With- out printer) • German: 22771AA070 (Without printer) •...
  • Page 843 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) EN(w/oOBD)-9...

  • Page 844: Electrical Components Location

    ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. MODULE LHD model EN0713 RHD model EN0714 Engine control module (ECM) Read memory connector CHECK ENGINE malfunction indi- Test mode connector cator lamp (MIL) Data link connector EN(w/oOBD)-10...
  • Page 845 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0718 S2M0256A EN0717 EN1034 EN(w/oOBD)-11...
  • Page 846 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. SENSOR EN0928 Engine coolant temperature sen- Throttle position sensor Vehicle speed sensor Knock sensor Intake air temperature and pres- Crankshaft position sensor sure sensor Camshaft position sensor EN(w/oOBD)-12...
  • Page 847 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) S2M1248A H2M3255A H2M3256A S2M1406B B2M0213M B2M0212F S2M0907C EN(w/oOBD)-13...
  • Page 848 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0929 Oxygen sensor (With catalyst model) S2M0264B EN(w/oOBD)-14...
  • Page 849 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN(w/oOBD)-15...
  • Page 850 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS EN0930 Purge control solenoid valve Ignition coil and ignitor ASSY CO resistor (Without catalyst model) Idle air control solenoid valve EN(w/oOBD)-16...
  • Page 851 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) H2M3258A H2M3259A H2M3261A S2M1764B EN(w/oOBD)-17...
  • Page 852 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN1031 RHD model EN1032 Fuel pump Main relay Fuel pump relay EN(w/oOBD)-18...
  • Page 853 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN0744 EN0744 EN1501 RHD model EN0748 EN(w/oOBD)-19...
  • Page 854 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION H2M3262A Signal (V) Connec- Terminal Content Ignition SW Note Engine ON tor No. (Idling) ON (Engine OFF) ±6 Signal (+) B135 Sensor output waveform Crankshaft position Signal (−)
  • Page 855 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note Engine ON tor No. (Idling) ON (Engine OFF) Test mode connector B135 When connected: 0 Read memory connector B135 When connected: 0 Back-up power supply B136 10 —...
  • Page 856 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note tor No. Engine ON (Idling) ON (Engine OFF) Signal 1 B134 — 1 — 13 Waveform Idle air con- Signal 2 B134 — 1 — 13 Waveform trol sole- Signal 3...

  • Page 857: Data Link Connector

    1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. S2M0288E (A) Power switch 6) Using the Subaru Select Monitor, call up any DTCs and various data, then record them. S2M0285 2. READ DIAGNOSTIC TROUBLE CODE 2) Connect the diagnosis cable to Subaru Select (DTC) FOR ENGINE.
  • Page 858 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) 3. READ CURRENT DATA SHOWN ON DISPLAY. 1) On the «Main Menu» display screen, select the {2. Each System Check} and press [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine Control System} and press [YES] key.
  • Page 859 SUBARU SELECT MONITOR ENGINE (DIAGNOSTICS) NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 4. LED OPERATION MODE FOR ENGINE Contents Message LED “ON” requirements Ignition switch signal ON or OFF When ignition switch is turned ON.
  • Page 860 Diagnostic Code(s)} and press [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. • For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(w/oOBD)-63, LIST, List of Diagnostic Trouble Code (DTC).>...
  • Page 861 READ DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) The CHECK ENGINE malfunction indicator lamp (MIL) flashes code corresponding to faulty parts. The long segment (1.3 seconds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies “one”. And middle segment (0.5 seconds ON) means OK code. NOTE: •...

  • Page 862: Inspection Mode

    (A) Test mode connector this may cause vehicle to jump off free rollers. 2) Connect the Subaru Select Monitor to data link • In order to prevent the vehicle from slipping connector. <Ref. to EN(w/oOBD)-10, LOCATION, due to vibration, do not place any wooden Electrical Components Location.>...
  • Page 863 ABS warning light, but this • For detailed operation procedure, refer to the indicates no malfunctions. When the engine control SUBARU SELECT MONITOR OPERATION MAN- diagnosis is finished, perform the ABS memory. UAL. 3. WITHOUT SUBARU SELECT MONITOR...

  • Page 864: Clear Memory Mode

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

  • Page 865: Compulsory Valve Operation Check Mode

    COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 10.Compulsory Valve Operation Check Mode A: OPERATION 1) Connect the test mode connector at the lower portion of instrument panel (on the driver's side). EN1450 (A) Test mode connector 2) Each valve functions when the ignition switch is turned to ON (engine OFF).

  • Page 866: Engine Malfunction Indicator Lamp (Mil)

    ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) 11.Engine Malfunction Indicator Lamp (MIL) A: PROCEDURE 1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(w/oOBD)-32, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> ↓ 2.
  • Page 867 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) EN(w/oOBD)-33...
  • Page 868 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • TROUBLE SYMPTOM: • When the ignition switch is turned ON (engine OFF), MIL does not come on. •...
  • Page 869 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Check CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair the con- connected? nection of ECM connector. CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5. Repair the har- Ω? TION METER AND ECM CONNECTOR.
  • Page 870 • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. • TROUBLE SYMPTOM: • Although MIL comes on when engine runs, but trouble code is not shown on Subaru Select Monitor or OBD-II general scan tool display. • WIRING DIAGRAM:...
  • Page 871 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) EN(w/oOBD)-37...
  • Page 872 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ. • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • Test mode connector circuit is in open. •...
  • Page 873 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Check CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL cir- FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to 1)Turn the ignition switch to OFF. EN(w/oOBD)-34, 2)Disconnect the test mode connector at lower CHECK ENGINE...
  • Page 874 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK- ING AT A CYCLE OF 3 HZ. • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
  • Page 875 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM CON- Is the resistance less than 5 Repair the short Replace the ECM. Ω? NECTOR AND ENGINE GROUNDING TER- circuit in harness <Ref. to FU(w/ MINAL. between ECM and oOBD)-48, Engine 1)Turn the ignition switch to OFF.

  • Page 876: Diagnostics For Engine Starting Failure

    DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 12.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN(w/oOBD)-44, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(w/oOBD)-48, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
  • Page 877 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN(w/oOBD)-43...
  • Page 878 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> • WIRING DIAGRAM: BATTERY SBF-4 SBF-1...
  • Page 879 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4. Go to step 5. TOR. 1)Turn the ignition switch to OFF. 2)Disconnect the connector from starter motor. 3)Turn the ignition switch to START.
  • Page 880 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than 1 Repair the open Go to step 11. Ω? 1)Turn the ignition switch to OFF. circuit in harness 2)Place the selector lever in the “P” or “N” posi- between starter tion.
  • Page 881 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN(w/oOBD)-47...
  • Page 882 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.>...
  • Page 883 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Repair the open Ω? 1)Disconnect the connector from ECM. circuit in harness 2)Measure the resistance of harness between between ECM ECM and chassis ground.
  • Page 884 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check the ignition Repair the open or 1)Connect the main relay connector. control system. ground short cir- 2)Turn the ignition switch to ON. <Ref.
  • Page 885 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN(w/oOBD)-51...
  • Page 886 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of the faulty parts, conduct the CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> •...
  • Page 887 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check the fuel Go to step 2. 1)Remove the plug cord cap from each spark inder? pump system. plug. <Ref. to EN(w/ 2)Install new spark plug on the plug cord cap.
  • Page 888 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 7. Replace the igni- & IGNITOR ASSEMBLY. tion coil & ignitor Check if the voltage varies synchronously with assembly.
  • Page 889 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 11. Repair the har- Ω? NITION COIL & IGNITOR ASSEMBLY CON- ness and connec- NECTOR. tor. Measure the resistance of harness between NOTE: ECM and ignition coil &...
  • Page 890 INJECTOR CIR- NOTE: CUIT, Diagnostics Fuel pump operation check can also be execut- for Engine Start- ed using the Subaru Select Monitor. For the ing Failure.> procedure, refer to “COMPULSORY VALVE OPERATION CHECK MODE”.<Ref. to EN(w/ oOBD)-31, OPERATION, Compulsory Valve Operation Check Mode.>...
  • Page 891 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Go to step 3. Repair the har- Ω? 1)Turn the ignition switch to OFF. ness and connec- 2)Raise the rear seat, and turn floor mat up. tor.
  • Page 892 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair the open Ω? FUEL PUMP RELAY CONNECTOR. circuit in harness 1)Disconnect the connectors from ECM. between ECM and 2)Measure the resistance of harness between fuel pump relay...
  • Page 893 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) EN(w/oOBD)-59...
  • Page 894 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only the faulty parts. • After repair or replacement of the faulty parts, conduct the CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.>...
  • Page 895 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 V? Go to step 3. Repair the har- INJECTOR. ness and connec- 1)Turn the ignition switch to OFF. tor. 2)Disconnect the connector from #1 cylinder NOTE: fuel injector.
  • Page 896 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 8. Repair the har- and 20 Ω? FUEL INJECTOR CONNECTOR. ness and connec- Measure the resistance of harness between tor.

  • Page 897: List Of Diagnostic Trouble Code (Dtc)

    LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 13.List of Diagnostic Trouble Code (DTC) A: LIST Trouble Item Contents of diagnosis Index code Crankshaft position sen- • No signal entered from crankshaft <Ref. to EN(w/oOBD)-66, DTC 11 CRANKSHAFT position sensor when starter switch is POSITION SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 898 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Trouble Item Contents of diagnosis Index code Torque control signal (AT) • Abnormal signal is entered from <Ref. to EN(w/oOBD)-98, DTC 38 TORQUE TCM. CONTROL SIGNAL, Diagnostic Procedure with • Harness connector between ECM Diagnostic Trouble Code (DTC).>...
  • Page 899 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(w/oOBD)-65...

  • Page 900: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 14.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11 CRANKSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from crankshaft position sensor when ignition switch is ON. • The harness connector between ECM and crankshaft position sensor is open or shorted. •...
  • Page 901 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CONDITION OF CRANKSHAFT PO- Are the crankshaft position Go to step 2. Tighten the crank- SITION SENSOR INSTALLATION. sensor installing bolts tight- shaft position sen- ened securely? sor installing bolts securely.
  • Page 902 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) B: DTC 12 STARTER SWITCH • DIAGNOSIS: • The starter switch signal is abnormal. • The harness connector between ECM and starter switch is open or shorted. • TROUBLE SYMPTOM: • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES.
  • Page 903 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the voltage more than 10 V? Repair the poor Repair the open or NITION SWITCH CONNECTOR. contact in ECM ground short cir- 1)Turn the ignition switch to OFF.
  • Page 904 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC 13 CAMSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor. • The harness connector between ECM and camshaft position sensor is open or shorted. •...
  • Page 905 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 3. Replace the cam- 1)Remove the camshaft position sensor. and 4 kΩ? shaft position sen- 2)Measure the resistance between connector sor.
  • Page 906 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR • DIAGNOSIS: • The engine coolant temperature sensor signal is abnormal. • The harness connector between ECM and engine coolant temperature sensor is open or shorted. •...
  • Page 907 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair the battery Go to step 2. COOLANT TEMPERATURE SENSOR AND short circuit in har- ECM CONNECTOR. ness between 1)Turn the ignition switch to OFF.
  • Page 908 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Go to step 5. Repair the har- Ω? COOLANT TEMPERATURE SENSOR AND ness and connec- ECM CONNECTOR. tor. 1)Turn the ignition switch to OFF. NOTE: 2)Measure the resistance of harness between In this case, repair...
  • Page 909 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(w/oOBD)-75...
  • Page 910 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) E: DTC 22 KNOCK SENSOR • DIAGNOSIS: • The knock sensor signal is abnormal. • The harness connector between ECM and knock sensor is open or shorted. • TROUBLE SYMPTOM: • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES.
  • Page 911 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 3 V? Go to step 2. Go to step 3. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM connec- tor and chassis ground.
  • Page 912 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE • DIAGNOSIS: • The idle air control solenoid valve is not in function. • The harness connector between ECM and idle air control solenoid valve is open or shorted. •...
  • Page 913 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2. Repair the har- TROL SOLENOID VALVE. ness and connec- 1)Turn the ignition switch to OFF. tor.
  • Page 914 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK AIR BY-PASS LINE. Are foreign particles in the by- Remove the for- Replace the idle 1)Turn the ignition switch to OFF. pass air line? eign particles from air control solenoid 2)Remove the idle air control solenoid valve by-pass air line.
  • Page 915 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(w/oOBD)-81...
  • Page 916 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC 26 INTAKE AIR TEMPERATURE SENSOR • DIAGNOSIS: • The intake air temperature sensor signal is abnormal. • The harness connector between ECM and intake air temperature sensor is open or shorted. •...
  • Page 917 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance between 2 Go to step 2. Replace the intake SOR. and 3 kΩ at 20°C (68°F)? air temperature 1)Turn the ignition switch to OFF. sensor.
  • Page 918 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Contact with your Check poor contact in ECM connector. connector? contact in ECM Subaru distributor connector. service. NOTE: Inspection by your Subaru distributor service is required, because probable...
  • Page 919 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(w/oOBD)-85...
  • Page 920 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC 31 THROTTLE POSITION SENSOR • DIAGNOSIS: • The throttle position sensor signal is abnormal. • The throttle position sensor is installed abnormally. • The harness connector between ECM and throttle position sensor is open or shorted. •...
  • Page 921 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? THROTTLE POSITION SENSOR. circuit between 1)Disconnect the connector from ECM and ECM and throttle throttle position sensor.
  • Page 922 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC 32 OXYGEN SENSOR • DIAGNOSIS: • The oxygen sensor is not in function. • The harness connector between ECM and oxygen sensor is open or shorted. • TROUBLE SYMPTOM: •...
  • Page 923 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FOR OTHER CAUSES AFFECTING Is CO % more than 2 % after Check the fuel Go to step 2. EXHAUST GAS. the engine warm up? system. NOTE: •Check for use of improper fuel. •Check if engine oil or coolant level is extremely low.
  • Page 924 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR ECM. Do 0.1 and 1 V waveform pat- Go to step 9. Replace the oxy- 1)Connect the connector to ECM and oxygen terns alternately appear on the gen sensor.
  • Page 925 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(w/oOBD)-91...
  • Page 926 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) J: DTC 33 VEHICLE SPEED SIGNAL • DIAGNOSIS: • The vehicle speed signal is abnormal. • The harness connector between ECM and vehicle speed sensor is open or shorted. • TROUBLE SYMPTOM: •...
  • Page 927 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 3 V? Go to step 3. Go to step 4. 1)Lift-up the vehicle. 2)Set the positive (+) terminal and ground lead of oscilloscope at ECM connector terminals.
  • Page 928 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) K: DTC 35 PURGE CONTROL SOLENOID VALVE • DIAGNOSIS: • The purge control solenoid valve is not in function. • The harness connector between ECM and purge control solenoid valve is open or shorted. •...
  • Page 929 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION SOUND OF PURGE Does the purge control sole- Go to step 2. Go to step 3. CONTROL SOLENOID VALVE. noid valve produce operating 1)Turn the ignition switch to OFF. sound? 2)Connect the test mode connector at lower portion of instrument panel (on driver’s side).
  • Page 930 CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Contact with your Check poor contact in purge control solenoid control solenoid valve connec- contact in purge Subaru distributor valve connector. tor? control solenoid service. valve connector. NOTE:...
  • Page 931 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(w/oOBD)-97...
  • Page 932 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) L: DTC 38 TORQUE CONTROL SIGNAL • DIAGNOSIS: • Abnormal signal entered from TCM • The harness connector between ECM and TCM is shorted. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.>...
  • Page 933 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the ground Go to step 2. Ω? TCM CONNECTOR. short circuit in har- 1)Disconnect the connectors from ECM and ness between TCM.
  • Page 934 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) M: DTC 45 PRESSURE SENSOR • DIAGNOSIS: • The pressure sensor signal is abnormal. • The harness connector between ECM and pressure sensor is open or shorted. • TROUBLE SYMPTOM: • Erroneous idling •...
  • Page 935 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage between 4.5 and Go to step 2. Repair the open or PRESSURE SENSOR CONNECTOR. 5.5 V? ground short cir- 1)Disconnect the connector from pressure cuit in harness sensor.
  • Page 936 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES) • DIAGNOSIS: • The CO resistor signal is abnormal. • The harness connector between ECM and CO resistor is open or shorted. • The CO value is not adjusted to specifications. •...
  • Page 937 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage between 0.5 and Go to step 3. Go to step 2. 1)Turn the ignition switch to ON. 4.5 V? 2)Measure the voltage between ECM and chassis ground.
  • Page 938 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC 51 NEUTRAL POSITION SWITCH (MT VEHICLE) • DIAGNOSIS: • The neutral position switch signal is abnormal. • The harness connector between ECM and neutral position switch is open or shorted. •...
  • Page 939 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Go to step 3. Go to step 2. 1)Turn the ignition switch to ON. 5.5 V in neutral position? 2)Measure the voltage between ECM and chassis ground.
  • Page 940 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE) • DIAGNOSIS: • The park/neutral position switch signal is abnormal. • The shift cable is connected abnormally. • The harness connector between ECM/TCM and inhibitor switch is open or shorted. •...
  • Page 941 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V? Go to step 2. Go to step 3. 1)Turn the ignition switch to ON. 2)Measure the voltage between ECM and chassis ground in selector lever “N”...
  • Page 942 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC 85 CHARGE SYSTEM • DIAGNOSIS: • Power source voltage of the ECM is low or high. • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.>...
  • Page 943 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage between 10.8 V Go to step 2. Repair the genera- 1)Start the engine. and 16.2 V? tor. <Ref. to SC- 2)Idle after warm-up. 14, Generator.> 3)Measure the voltage between generator B terminal and chassis ground.

  • Page 944: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 15.General Diagnostic Table A: INSPECTION NOTE: • Malfunction of parts other than those listed is also possible. • The right-hand priority column indicates inspection priority of probable causes of the symptom. Carry out the check starting from A. Symptom Problem parts Priority...
  • Page 945 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 5. Rough idling 1) Spark plug 2) Pressure sensor 3) Engine coolant temperature sensor 4) Pressure regulator 5) Idle air control solenoid valve 6) Air leak in air intake system 7) ECM power supply 8) Throttle position sensor 9) Camshaft position sensor 10) Crankshaft position sensor...
  • Page 946 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 13. Poor engine revving 1) Pressure regulator 2) Pressure sensor 3) Engine coolant temperature sensor 4) Throttle sensor 5) Fuel pump 14. Remarks 1) ECM power supply 2) Pressure sensor 3) Pressure regulator 4) Idle air control solenoid valve 5) Air leak in air intake system A*: Including ECM ground circuit...
  • Page 947 FUEL INJECTION (FUEL SYSTEMS) FU(TURBO) Page General Description ..................2 Throttle Body.....................14 Intake Manifold..................15 Engine Coolant Temperature Sensor............29 Crankshaft Position Sensor...............30 Camshaft Position Sensor.................31 Knock Sensor....................32 Throttle Position Sensor................33 Mass Air Flow and Intake Air Temperature Sensor ........34 Pressure Sensor ..................35 Idle Air Control Solenoid Valve ..............36 Fuel Injector ....................37 Tumble Generator Valve Assembly ............41...

  • Page 948: General Description

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS 60 2 (15.9 US gal, 13.2 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 450 — 677 kPa (4.59 — 6.9 kg/cm , 65.27 — 98.2 psi) Fuel pump More than 130 2 (34.3 US gal, 28.6 Imp gal)/h Discharge flow...
  • Page 949 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) FU(TURBO)-3...
  • Page 950 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (19) (18) (22) (17) (20) (24) (16) (23) (21) (14) (26) (15) (26) (12) (13) (25) (12) (11) (27) (27) (10) (11) (16) (10) (14) (15) EN1389 FU(TURBO)-4...
  • Page 951 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Fuel pipe ASSY (13) Accelerator cable bracket (25) Fuel pipe protector LH Fuel hose (14) Fuel injector (26) Nipple Clip (15) Insulator (27) Tumble generator valve actuator Purge control solenoid valve (16) Fuel injector pipe Vacuum hose (17) Pressure regulator...
  • Page 952 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM EN1134 Gasket Pressure sensor Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor Gasket T1: 1.6 (0.16, 1.2) Idle air control solenoid valve O-ring T2: 2.8 (0.29, 2.1) Throttle body T3: 22 (2.2, 16.2) FU(TURBO)-6...
  • Page 953 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS EN0780 Crankshaft position sensor Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) Knock sensor T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU(TURBO)-7...
  • Page 954 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (13) (29) (12) (12) (28) (16) (12) (12) (18) (21) (20) (27) (22) (19) (12) (12) (23) (12) (24) (20) (12) (25) EN0998 FU(TURBO)-8...
  • Page 955 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
  • Page 956 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) EN0440 FU(TURBO)-10...
  • Page 957 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
  • Page 958 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (10) (11) EN0441 Fuel filler pipe ASSY Air vent pipe (11) Filler pipe protector Evaporation hose holder Air vent pipe holder Clip Filler pipe packing Clamp Filler ring Tightening torque: N·m (kgf-m, ft-lb) Air vent hose (10) Filler cap...
  • Page 959 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.

  • Page 960: Throttle Body

    THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 5) Disconnect the engine coolant hoses from throt- tle body. A: REMOVAL 1) Disconnect the ground cable from battery. EN0784 6) Remove the bolts which secure throttle body to G6M0095 intake manifold. 2) Remove the intercooler.

  • Page 961: Intake Manifold

    INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 12) Remove the power steering pump. (1) Remove the front side V-belt. A: REMOVAL <Ref. to ME(TURBO)-44, REMOVAL, V-belt.> 1) Release the fuel pressure. <Ref. to FU(TUR- (2) Disconnect the power steering switch con- BO)-53, RELEASING OF FUEL PRESSURE, OP- nector.
  • Page 962 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (5) Remove the power steering tank from the 15) Disconnect the brake booster hose. bracket by pulling it upward. EN0204 EN0361 16) Disconnect the pressure hose from intake duct. (6) Place the power steering pump on right side wheel apron.
  • Page 963 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 18) Disconnect the connectors from the engine 22) Disconnect the engine harness fixed by clip (A) coolant temperature sensor (A), oil pressure switch from the bracket. (B) and crankshaft position sensor (C). S2M2256A EN0790 23) Disconnect the fuel delivery hose, return hose 19) Disconnect the knock sensor connector.
  • Page 964 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 4) Connect the connector to knock sensor. 1) Install the intake manifold onto cylinder heads. NOTE: Always use new gaskets. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) S2M1613 5) Connect the connector to camshaft position sen- sor.
  • Page 965 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Connect the engine harness connector to bulk- 11) Connect the emission hose to PCV valve. head harness connectors. EN0789 EN0788 12) Connect the pressure hose to intake duct. EN0787 S2M2260 9) Connect the brake booster vacuum hose. 13) Install the power steering pump.
  • Page 966 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (3) Install the power steering pump, and then 19) Connect the connector to fuel pump relay. tighten the bolts. Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) EN0344 20) Connect the battery ground cable to battery. H2M1954 (4) Install the power steering pipe brackets on right side intake manifold.
  • Page 967 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) C: DISASSEMBLY 4) Disconnect the connector from the throttle posi- tion sensor (A), idle air control solenoid valve (B) 1) Remove the fuel pipe protector LH. and pressure sensor (C). 5) Disconnect the engine harness fixed by clip (D) from the intake manifold.
  • Page 968 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Disconnect the connector from tumble generator 13) Disconnect the evaporation hoses from purge valve sensor. valve. EN0800 EN0804 10) Disconnect the connector from purge control 14) Remove the two bolts which hold fuel pipes on solenoid valve.
  • Page 969 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Remove the bolts which hold fuel injector pipe 16) Remove the fuel injector. onto intake manifold. • LH SIDE EN0810 17) Remove the harness bracket which holds en- EN0806 gine harness onto intake manifold. EN0807 EN0811 •...
  • Page 970 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 22) Remove the fuel pipe assembly and pressure 2) Install the air intake duct to intake manifold. regulator from intake manifold. Tightening torque: 23) Remove the intake duct from intake manifold. 19 N·m (1.9 kgf-m, 14.0 ft-lb) EN1115 EN1115 24) Remove the tumble generator valve assembly...
  • Page 971 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 7) Install the harness bracket which holds engine 9) Tighten the bolts which install fuel injector pipe harness onto intake manifold. onto intake manifold. Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 19 N·m (1.9 kgf-m, 14.0 ft-lb) •...
  • Page 972 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 10) Tighten the two bolts which install fuel pipes on 12) Connect the evaporation hose to intake mani- the left side of intake manifold. fold. Tightening torque: 4.9 N·m (0.5 kgf-m, 3.6 ft-lb) EN0803 13) Install the purge control solenoid valve.
  • Page 973 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Connect the connector to purge control sole- 19) Install the throttle body to intake manifold. noid valve. NOTE: Replace the gasket with a new one. Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) EN0801 16) Connect the connector to tumble generator valve sensor.
  • Page 974 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 22) Install the engine ground cable to intake mani- 24) Install the fuel pipe protector LH. fold. Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 19 N·m (1.9 kgf-m, 14.0 ft-lb) EN0793 EN0795 E: INSPECTION Make sure the fuel pipe and fuel hoses are not...

  • Page 975: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 18 N·m (1.8 kgf-m, 13.3 ft-lb) 1) Disconnect the ground cable from battery. G6M0095 2) Remove the generator <Ref.

  • Page 976: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) G6M0095 B2M1252B 2) Remove the bolt which installs crankshaft posi- tion sensor to cylinder block.

  • Page 977: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) G6M0095 G2M0417 2) Disconnect the connector from camshaft posi- tion sensor.

  • Page 978: Knock Sensor

    KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...

  • Page 979: Throttle Position Sensor

    THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 EN0820 2) Remove the intercooler. <Ref. to IN(TURBO)- 10, REMOVAL, Intercooler.>...

  • Page 980: Mass Air Flow And Intake Air Temperature Sensor

    MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Mass Air Flow and Intake Air B: INSTALLATION Install in the reverse order of removal. Temperature Sensor Tightening torque: A: REMOVAL 7.5 N·m (0.76 kgf-m, 5.5 ft-lb) 1) Disconnect the ground cable from battery.
  • Page 981 PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Pressure Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Replace the O-ring for the pressure sensor with new ones. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 2) Remove the idle air control solenoid valve.

  • Page 982: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use a new gasket. 1) Disconnect the ground cable from battery. Tightening torque: 2.8 N·m (0.29 kgf-m, 2.1 ft-lb) G6M0095 2) Disconnect the connector from idle air control...

  • Page 983: Fuel Injector

    FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12.Fuel Injector 7) Remove the bolts which hold injector pipe to in- take manifold. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(TUR- BO)-53, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 984 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 7) Remove the bolts which hold injector pipe to in- take manifold. 1) Release the fuel pressure. <Ref. to FU(TUR- BO)-53, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 985 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) 1. RH SIDE Install in the reverse order of removal. NOTE: Replace the O-ring and insulators with new ones. EN0794 2. LH SIDE Install in the reverse order of removal. NOTE: S2M2250A Replace the O-ring and insulators with new ones.
  • Page 986 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) EN0806 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) EN0807 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) EN0793 FU(TURBO)-40...

  • Page 987: Tumble Generator Valve Assembly

    TUMBLE GENERATOR VALVE ASSEMBLY FUEL INJECTION (FUEL SYSTEMS) 13.Tumble Generator Valve As- 8) Remove the tumble generator valve body from intake manifold. sembly A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(TUR- BO)-53, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
  • Page 988 TUMBLE GENERATOR VALVE ACTUATOR FUEL INJECTION (FUEL SYSTEMS) 14.Tumble Generator Valve Ac- 3) Remove the tumble generator valve actuator LH. tuator A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(TUR- BO)-53, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.>...

  • Page 989: Wastegate Control Solenoid Valve

    WASTEGATE CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 15.Wastegate Control Solenoid 5) Remove the wastegate control solenoid valve from bracket Valve A: REMOVAL 1) Disconnect the ground cable from battery. EN0830 B: INSTALLATION Install in the reverse order of removal. G6M0095 Tightening torque: 2) Remove the solenoid valve cover.
  • Page 990 7) Remove the service hole cover. A: REMOVAL 1) Disconnect the ground cable from battery. EN0832 8) Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen (A/F) sensor, and G6M0095 leave it for 1 minute or more.
  • Page 991 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 7) Connect the connector of front oxygen (A/F) sensor. 1) Before installing the front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier.

  • Page 992: Oxygen Sensor

    21 N·m (2.1 kgf-m, 15.2 ft-lb) side of crossmember. EN0835 S2M2254 5) Apply SUBARU CRC or its equivalent to the 3) Connect the connector to rear oxygen sensor. threaded portion of rear oxygen sensor, and leave it for 1 minute or more.
  • Page 993 REAR OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 4) Connect the clip to crossmember. S2M2254 5) Lower the vehicle. 6) Connect the battery ground cable to battery. G6M0095 FU(TURBO)-47...

  • Page 994: Exhaust Temperature Sensor

    2) Remove the joint pipe. <Ref. to EX(TURBO)-12, screws. REMOVAL, Joint Pipe.> Tightening torque: 3) Apply SUBARU CRC or its equivalent to the 21 N·m (2.1 kgf-m, 15.2 ft-lb) threaded portion of exhaust temperature sensor, and leave it for 1 minute or more.

  • Page 995: Engine Control Module

    ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 19.Engine Control Module B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage to fuel injection system.

  • Page 996: Main Relay

    MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 20.Main Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds main relay bracket on body.

  • Page 997: Fuel Pump Relay

    FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Pump Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds fuel pump relay bracket on body.

  • Page 998: Fuel Pump Controller

    FUEL PUMP CONTROLLER FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump Controller B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the rear quarter trim. <Ref. to EI-46, REMOVAL, Rear Quarter Trim.> 3) Disconnect the connector from fuel pump control unit.

  • Page 999: Fuel

    FUEL FUEL INJECTION (FUEL SYSTEMS) 23.Fuel 5) Drain fuel from the fuel tank. Set a container under the vehicle and remove the A: OPERATION drain plug from fuel tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...

  • Page 1000: Fuel Tank

    FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler hose and air vent hose from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
  • Page 1001 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 2) Set the fuel tank and temporarily tighten the 6) Tighten the band mounting bolts. bolts of fuel tank bands. Tightening torque: WARNING: 33 N·m (3.4 kgf-m, 24.3 ft-lb) A helper is required to perform this work. EN0541 EN0541 7) Install the rear crossmember.

  • Page 1002: Fuel Filler Pipe

    FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un- der the vehicle and remove the drain plug from fuel A: REMOVAL tank. WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 1003 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 13) Disconnect the air vent hose from fuel filler B: INSTALLATION pipe. 1) Hold the fuel filler flap open. 2) Set the fuel saucer (A) with rubber packing (C) and insert the fuel filler pipe into hole from the inner side of apron.
  • Page 1004 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 6) Insert the fuel filler hose (A) approx. 35 to 40 mm 9) Tighten the bolts which hold evaporation hoses (1.38 to 1.57 in) over the lower end of fuel filler pipe onto clip of fuel filler pipe. and tighten the clamp.

This manual is also suitable for:

2001 impreza

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