Subaru LEGACY 2004 Service Manual
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Subaru LEGACY 2004 Service Manual

Engine section
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Table of Contents

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See also: Service Manual , Owner's Manual
2004 LEGACY SERVICE MANUAL

ENGINE SECTION 1

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
LUBRICATION
SPEED CONTROL SYSTEMS
IGNITION
STARTING/CHARGING SYSTEMS
ENGINE (DIAGNOSTICS)
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
FU(H4SO 2.0)
EC(H4SO 2.0)
IN(H4SO 2.0)
ME(H4SO 2.0)
EX(H4SO 2.0)
CO(H4SO 2.0)
LU(H4SO 2.0)
SP(H4SO 2.0)
IG(H4SO 2.0)
SC(H4SO 2.0)
EN(H4SO 2.0)
(diag)
FU(H4SO 2.5)
EC(H4SO 2.5)
IN(H4SO 2.5)
ME(H4SO 2.5)
EX(H4SO 2.5)
CO(H4SO 2.5)
G2320GE2

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Summary of Contents for Subaru LEGACY 2004

  • Page 1: Engine Section

    (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 2 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...

  • Page 3: Table Of Contents

    FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.0) Page General Description ..................2 Throttle Body.....................10 Intake Manifold..................11 Engine Coolant Temperature Sensor............20 Crankshaft Position Sensor...............21 Camshaft Position Sensor.................22 Knock Sensor....................23 Throttle Position Sensor................25 Manifold Absolute Pressure Sensor............26 Intake Air Temperature Sensor ..............27 EGR Valve ....................28 Fuel Injector ....................29 Front Oxygen (A/F) Sensor ...............32 Rear Oxygen Sensor.................33...

  • Page 4: General Description

    General Description FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATION 64 2(16.9 US gal, 14.1 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 441 — 686 kPa (4.50 — 7.00 kg/cm , 64.0 — 99.5 psi) Fuel pump 75 2 (19.8 US gal, 16.5 Imp gal)/h or more Discharge...
  • Page 5 General Description FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (17) (19) (11) (10) (17) (14) (12) (12) (10) (13) (12) (16) (18) (16) (18) (15) (16) (18) FU-02056 FU(H4SO 2.0)-3...

  • Page 6: Air Intake System

    General Description FUEL INJECTION (FUEL SYSTEMS) Intake manifold (10) O-ring (19) PCV valve Gasket (11) Purge control solenoid valve ⋅ Guide pin (12) Plug cord holder Tightening torque: N m (kgf-m, ft-lb) EGR valve (EC, EK, K4 model) (13) Nipple (LHD model) T1: 1.5 (0.15, 1.1) Fuel pipe protector RH (14)
  • Page 7 General Description FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 ⋅ Crankshaft position sensor Camshaft position sensor support Tightening torque: N m (kgf-m, ft-lb) Knock sensor T1: 6.4 (0.65, 4.7) Camshaft position sensor T2: 24 (2.4, 17.4) FU(H4SO 2.0)-5...
  • Page 8 General Description FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (19) (17) (18) (15) (16) (17) (14) (15) (10) (12) (11) (13) (22) (22) (20) (21) (23) (24) (25) FU-01080 FU(H4SO 2.0)-6...
  • Page 9 General Description FUEL INJECTION (FUEL SYSTEMS) Fuel tank (12) Fuel sub level sensor upper plate (22) Retainer Fuel tank band RH (13) Fuel sub level sensor gasket (23) Heat shield cover Fuel tank band LH (14) Fuel filler hose (24) Fuel tank protector RH (Front) Delivery tube (15)

  • Page 10: Fuel Line

    General Description FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (28) (18) (26) (23) (15) (17) (19) (25) (27) (20) (22) (14) (13) (24) (21) (16) (22) (34) (11) (29) (10) (12) (33) (32) (30) (31) FU-01081 FU(H4SO 2.0)-8...
  • Page 11 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...

  • Page 12: Throttle Body

    Throttle Body FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the air intake chamber. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> 3) Disconnect the connectors from the throttle posi- tion sensor and manifold absolute pressure sensor.

  • Page 13: Intake Manifold

    Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 9) Disconnect the engine harness connectors from bulkhead harness connectors. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
  • Page 14 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 14) Disconnect the connector from oil pressure • Catch the fuel from hoses using a container switch (B). or cloth. FU-01087 FU-02062 15) Disconnect the connector from camshaft posi- (A) Fuel delivery hose tion sensor. (B) Return hose (C) Evaporation hose 18) Remove the bolts which secure intake manifold...
  • Page 15 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 6) Connect the connector to oil pressure switch (B). NOTE: If fuel hoses or clamps are damaged, replace them with new ones. Tightening torque (Hose clamp screw): ⋅ 1.25 N m (0.13 kgf-m, 0.94 ft-lb) FU-01087 7) Connect the connector to crankshaft position sensor.
  • Page 16 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 11) Connect the brake booster hose. C: DISASSEMBLY 1) Disconnect the engine ground terminal from in- take manifold. FU-02089 12) Connect the engine harness connectors to bulkhead harness connectors. FU-02063 2) Remove the ignition coil & ignitor ASSY. <Ref. to IG(H4SO 2.0)-8, REMOVAL, Ignition Coil &...
  • Page 17 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. • RH side FU-02066 FU-02070 8) Disconnect the connectors from fuel injector. FU-02071 FU-02067 • LH side 9) Remove the purge control solenoid valve. <Ref. to EC(H4SO 2.0)-7, REMOVAL, Purge Control So- lenoid Valve.>...
  • Page 18 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) (1) Remove the clip which secures fuel injector 17) Remove the bolt which installs fuel pipes on in- from injector pipe. take manifold. FU-02077 FU-02074 (2) Remove the fuel injector with lifting up the 18) Remove the fuel pipe assembly and pressure fuel injector pipe.
  • Page 19 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 4) Connect the fuel injector pipe LH to fuel hose, • LH side and tighten the clamp screw. Tightening torque: ⋅ 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02075 5) Install the fuel injectors. FU-02078 6) Install the clip which secures fuel injector.
  • Page 20 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 9) Secure the engine harness with harness band 12) Install the fuel pipe protector RH. (A) and bolts (B), (C). Tightening torque: ⋅ Tightening torque: 19 N m (1.9 kgf-m, 13.7 ft-lb) ⋅ (B): 16 N m (1.6 kgf-m, 11.8 ft-lb) ⋅...
  • Page 21 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) Tightening torque: ⋅ 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02063 E: INSPECTION Make sure the fuel pipe and fuel hoses are not damaged and the connections are tightened firmly. FU(H4SO 2.0)-19...

  • Page 22: Engine Coolant Temperature Sensor

    Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the generator. <Ref. to SC(H4SO 2.0)- 14, REMOVAL, Generator.> 3) Disconnect the connectors from engine coolant temperature sensor.

  • Page 23: Crankshaft Position Sensor

    Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. ⋅ T: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) IN-00203 FU-00058 2) Remove the bolt which installs crankshaft posi-...

  • Page 24: Camshaft Position Sensor

    Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00179 B: INSTALLATION Install in the reverse order of removal. IN-00203 Tightening torque: 2) Disconnect the connector from camshaft posi- Camshaft position sensor support tion sensor.

  • Page 25: Knock Sensor

    Knock Sensor FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Extraction area of knock sensor cord must be posi- tioned at a 60° angle relative to the engine rear. Tightening torque: ⋅...
  • Page 26 Knock Sensor FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. IN-00203 FU(H4SO 2.0)-24...

  • Page 27: Throttle Position Sensor

    Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure. <Ref. to FU(H4SO 2.0)-10, REMOVAL, Throttle Body.>...

  • Page 28: Manifold Absolute Pressure Sensor

    Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS) 9. Manifold Absolute Pressure Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from manifold abso- lute pressure sensor. FU-02079 3) Remove the manifold absolute pressure sensor from throttle body.

  • Page 29: Intake Air Temperature Sensor

    Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 10.Intake Air Temperature Sen- A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from intake air tem- perature sensor. 3) Remove the intake air temperature sensor. FU-02080 B: INSTALLATION Install in the reverse order of removal.

  • Page 30: Egr Valve

    EGR Valve FUEL INJECTION (FUEL SYSTEMS) 11.EGR Valve A: REMOVAL NOTE: EGR valve is equipped to EC, EK and K4 model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from EGR valve. 3) Remove the EGR valve from intake manifold. FU-02082 B: INSTALLATION Install in the reverse order of removal.

  • Page 31: Fuel Injector

    Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 12.Fuel Injector 8) Remove the clip which secure fuel injector. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
  • Page 32 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 5) Remove the fuel pipe protector LH. 8) Remove the bolts which hold fuel injector pipe onto intake manifold. FU-02065 FU-02072 6) Disconnect the connector from fuel injector. FU-02073 FU-02067 9) Remove the fuel injector while lifting up the fuel 7) Remove the clips which secure fuel injector.
  • Page 33 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: ⋅ ⋅ 6.4 N m (0.65 kgf-m, 4.7 ft-lb) 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02071 FU-02072 Tightening torque: Tightening torque: ⋅ ⋅ 19 N m (1.9 kgf-m, 13.7 ft-lb) 19 N m (1.9 kgf-m, 13.7 ft-lb) FU-02066...

  • Page 34: Front Oxygen (A/F) Sensor

    Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS) 13.Front Oxygen (A/F) Sensor B: INSTALLATION 1) Before installing front oxygen (A/F) sensor, ap- A: REMOVAL ply anti-seize compound only to the threaded por- 1) Disconnect the ground cable from battery. tion of front oxygen (A/F) sensor to make the next removal easier.

  • Page 35: Rear Oxygen Sensor

    Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS) 14.Rear Oxygen Sensor B: INSTALLATION 1) Before installing rear oxygen sensor, apply anti- A: REMOVAL seize compound only to the threaded portion of 1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas- ier.

  • Page 36: Engine Control Module (Ecm)

    Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS) 15.Engine Control Module (ECM) B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. • When replacing the ECM, be careful not to use the wrong spec.

  • Page 37: Main Relay

    Main Relay FUEL INJECTION (FUEL SYSTEMS) 16.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from main relay. FU-02093 B: INSTALLATION Install in the reverse order of removal.

  • Page 38: Fuel Pump Relay

    Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS) 17.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from fuel pump relay. FU-02094 B: INSTALLATION Install in the reverse order of removal.

  • Page 39: Electronic Throttle Control Relay

    Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS) 18.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from electric control throttle relay.

  • Page 40: Fuel

    Fuel FUEL INJECTION (FUEL SYSTEMS) 19.Fuel 6) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from the A: PROCEDURE fuel tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...

  • Page 41: Fuel Tank

    Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Tank (2) Push the grommet (B) down under the body and remove the service hole cover. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
  • Page 42 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 12) Remove the rear brake caliper and tie it to the 19) Remove the bolts which install parking brake side of vehicle body. cable clamp. FU-00462 FU-01130 13) Remove the parking brake cable from parking brake assembly.
  • Page 43 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) (3) Remove the bolts which secure rear sus- 23) Support the fuel tank with transmission jack, re- pension assembly to body. move the bolts from fuel tank bands and dismount the fuel tank from vehicle. WARNING: A helper is required to perform this work.
  • Page 44 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 2) Correctly insert the fuel filler hose (A) and vent Tightening torque: ⋅ hose (B) to specified position, and then tighten the T1: 125 N m (12.7 kgf-m, 92.2 ft-lb) ⋅ clamp. T2: 65 N m (6.2 kgf-m, 48 ft-lb) ⋅...
  • Page 45 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: ⋅ ⋅ 18 N m (1.8 kgf-m, 13.0 ft-lb) 33 N m (3.4 kgf-m, 25 ft-lb) FU-01130 FU-01128 Tightening torque: 15) Install the rear wheels. ⋅ 32 N m (3.3 kgf-m, 23.9 ft-lb) 16) Lower the vehicle.
  • Page 46 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 20) Connect the connector to fuel pump. FU-01125 21) Install the service hole cover of fuel pump. FU-01124 (A) Bolt (B) Grommet 22) Install the rear seat. 23) Install the fuse of fuel pump to main fuse box. C: INSPECTION 1) Check that the fuel tank is not holed, cracked, or otherwise damaged.

  • Page 47: Fuel Filler Pipe

    Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Filler Pipe 7) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from the A: REMOVAL fuel tank. WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 48 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Tighten the bolts which hold fuel filler pipe brack- et on the body. 1) Open the fuel filler flap lid. 2) Set the fuel saucer (A) with rubber packing (C) Tightening torque: ⋅...

  • Page 49: Fuel Pump

    Fuel Pump FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump 7) Remove the nuts which install fuel pump assem- bly onto fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. •...
  • Page 50 Fuel Pump FUEL INJECTION (FUEL SYSTEMS) • Do not run fuel pump for a long time under non-load condition. FU-01330 FU(H4SO 2.0)-48...

  • Page 51: Fuel Level Sensor

    Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Level Sensor A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly.

  • Page 52: Fuel Sub Level Sensor

    Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Sub Level Sensor 6) Remove the bolts which install the fuel sub level sensor on fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. •...

  • Page 53: Fuel Filter

    Fuel Filter FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filter A: SPECIFICATION Fuel filter forms a unit with fuel pump. Refer to Fuel Pump for removal and installation. <Ref. to FU(H4SO 2.0)-47, REMOVAL, Fuel Pump.> <Ref. to FU(H4SO 2.0)-47, INSTALLATION, Fuel Pump.> FU(H4SO 2.0)-51...

  • Page 54: Fuel Damper Valve

    Fuel Damper Valve FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Damper Valve A: REMOVAL 1. DELIVERY SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper valve from fuel delivery line. FU-01147 2.

  • Page 55: Fuel Delivery, Return And Evaporation Lines

    Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCE- DURE, Fuel.> 3) Open the fuel filler flap lid, and remove the fuel filler cap.
  • Page 56 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) CAUTION: CAUTION: Always use a new retainer. • Pull the connector to ensure it is connected securely. • Ensure the two retainer pawls are engaged in their mating positions in the connector. •...
  • Page 57 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) CAUTION: Be sure to inspect the hoses and their connec- tions for fuel leakage. FU-00129 (1) Hose (2) Clip (3) Pipe C: INSPECTION 1) Make sure that there are no cracks on the fuel pipes and fuel hoses.

  • Page 58: Fuel System Trouble In General

    Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS) 28.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to injector Fuel pump does not operate. Inspect contact, especially ground, and tighten it ❍...
  • Page 59 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 60 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 61 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.0) Page General Description ..................2 Front Catalytic Converter .................3 Rear Catalytic Converter ................4 EGR Valve ....................5 Canister......................6 Purge Control Solenoid Valve..............7 Two-way Valve...................9 PCV Valve ....................10...

  • Page 62: General Description

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

  • Page 63: Front Catalytic Converter

    Front Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrat- ed into center exhaust pipe as a unit; therefore, re- fer to “Center Exhaust Pipe” for removal procedure. <Ref.

  • Page 64: Rear Catalytic Converter

    Rear Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrat- ed into center exhaust pipe as a unit; therefore, re- fer to “Center Exhaust Pipe” for removal procedure. <Ref.

  • Page 65: Egr Valve

    EGR Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. EGR Valve A: SPECIFICATION Refer to “EGR Valve” for removal and installation. <Ref. to FU(H4SO 2.0)-28, EGR Valve.> or <Ref. to FU(H4SO 2.5)-30, EGR Valve.> EC(H4SO 2.0)-5...

  • Page 66: Canister

    Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Canister Tightening torque: ⋅ 8.3 N m (0.85 kgf-m, 6.1 ft-lb) A: REMOVAL 1) Lift-up the vehicle. 2) Remove the rear wheel LH. 3) Remove the mud guard LH. 4) Remove the protector. (Sedan model) 5) Disconnect the quick connector (A).

  • Page 67: Purge Control Solenoid Valve

    Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Purge Control Solenoid Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. ⋅ 19 N m (1.9 kgf-m, 14.0 ft-lb) •...
  • Page 68 Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) • 2.5 L model EC-00224 (A) To fuel pipe (Evaporation line) (B) To intake manifold C: INSPECTION Make sure the hoses are not cracked or loose. EC(H4SO 2.0)-8...

  • Page 69: Two-Way Valve

    Two-way Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Disconnect the evaporation hoses from two-way valve. 3) Remove the two-way valve as a unit with bracket from body. EC-00221 4) Remove the two-way valve from bracket. B: INSTALLATION Install in the reverse order of removal.

  • Page 70: Pcv Valve

    PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 8. PCV Valve A: REMOVAL Disconnect the PCV hose and remove the PCV valve. • 2.0 L model EC-02029 • 2.5 L model EC-00225 B: INSTALLATION Install in the reverse order of removal. NOTE: Apply liquid gasket to the bolt threads of PCV valve.
  • Page 71 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 72 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 73 INTAKE (INDUCTION) IN(H4SO 2.0) Page General Description ..................2 Air Cleaner Element ..................5 Air Cleaner Case..................6 Air Intake Chamber ..................8 Air Intake Duct.....................9 Resonator Chamber..................10...

  • Page 74: General Description

    General Description INTAKE (INDUCTION) 1. General Description A: COMPONENT (15) (14) (14) (13) (13) (11) (12) (10) (22) (16) (23) (19) (18) (17) (21) (20) IN-02004 IN(H4SO 2.0)-2...
  • Page 75 General Description INTAKE (INDUCTION) Air intake duct (14) Spacer (23) Intake air temperature sensor (Except for 2.5 L EC, EK, K4 Clip (15) Air intake chamber model) Resonator chamber (16) Stay LH (MT model) Air cleaner case (front) (17) Stay LH (AT model) ⋅...
  • Page 76 General Description INTAKE (INDUCTION) B: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust and dirt.

  • Page 77: Air Cleaner Element

    Air Cleaner Element INTAKE (INDUCTION) 2. Air Cleaner Element B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Fasten the air cleaner case (rear) with a clip after inserting the lower tab of the case. IN-00203 2) Disconnect the connector from mass air flow and IN-00207...

  • Page 78: Air Cleaner Case

    Air Cleaner Case INTAKE (INDUCTION) 3. Air Cleaner Case 6) Remove the air cleaner case (rear) and air cleaner element. A: REMOVAL 1) Disconnect the ground cable from battery. IN-00206 7) Remove the bolt (A) and nut (B) which hold the IN-00203 air cleaner case on body.
  • Page 79 Air Cleaner Case INTAKE (INDUCTION) B: INSTALLATION Install in the reverse order of removal. Tightening torque: ⋅ Bolt (A): 6.0 N m (0.6 kgf-m, 4.4 ft-lb) ⋅ Nut (B): 7.5 N m (0.76 kgf-m, 5.5 ft-lb) IN-00208 NOTE: Fasten with a clip after inserting the lower tab of the case.

  • Page 80: Air Intake Chamber

    Air Intake Chamber INTAKE (INDUCTION) 4. Air Intake Chamber B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. Clamp (A), (B) (Except for EC, EK, K4 model) ⋅ 3.0 N m (0.3 kgf-m, 2.2 ft-lb) Bolt (C) ⋅...

  • Page 81: Air Intake Duct

    Air Intake Duct INTAKE (INDUCTION) 5. Air Intake Duct A: REMOVAL 1) Remove the clips which install the air intake duct on the front side of body. 2) Remove the air intake duct. IN-00210 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Check for cracks or loose connections.

  • Page 82: Resonator Chamber

    Resonator Chamber INTAKE (INDUCTION) 6. Resonator Chamber A: REMOVAL Refer to “Air Cleaner Case” for removal procedure because the resonator chamber forms a single unit with air cleaner case. <Ref. to IN(H4SO 2.0)-6, RE- MOVAL, Air Cleaner Case.> B: INSTALLATION Refer to “Air Cleaner Case”...
  • Page 83 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 84 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 85 MECHANICAL ME(H4SO 2.0) Page General Description ..................2 Compression .....................22 Idle Speed ....................23 Ignition Timing...................24 Intake Manifold Vacuum................25 Engine Oil Pressure ..................26 Fuel Pressure....................27 Valve Clearance..................28 Engine Assembly ..................30 Engine Mounting ..................36 Preparation for Overhaul................37 V-belt......................38 Crank Pulley....................40 Timing Belt Cover..................42 Timing Belt ....................43 Cam Sprocket ...................48 Crank Sprocket ..................50...

  • Page 86: General Description

    General Description MECHANICAL 1. General Description A: SPECIFICATION Model 2.0 L 2.5 L Horizontally opposed, liquid cooled, 4-cylinder, Cylinder arrangement 4-stroke gasoline engine Belt driven, single over-head camshaft, 4-valve/ Valve system mechanism cylinder 99.5 × 79.0 Bore × Stroke 92 × 75 (3.62 × 2.95) mm (in) (3.917 ×...
  • Page 87 General Description MECHANICAL Refacing angle 90° Valve seat Intake Standard 0.8 — 1.4 (0.03 — 0.055) Contacting width mm (in) Exhaust Standard 1.2 — 1.8 (0.047 — 0.071) Inside diameter mm (in) 6.000 — 6.012 (0.2362 — 0.2367) Valve guide Intake 20.0 —...
  • Page 88 General Description MECHANICAL Bend twist per 100 mm (3.94 in) in mm (in) Limit 0.10 (0.0039) Connecting length Side clearance of mm (in) Standard 0.070 — 0.330 (0.0028 — 0.0130) large end Oil clearance mm (in) Standard 0.016 — 0.044 (0.00063 — 0.0017) Standard 1.492 —...
  • Page 89 General Description MECHANICAL B: COMPONENT 1. TIMING BELT (12) (10) (13) (11) (15) (14) (16) ME-00376 ⋅ Timing belt cover No. 2 (RH) (10) Belt idler No. 2 Tightening torque: N m (kgf-m, ft-lb) Timing belt guide (MT model) (11) Camshaft sprocket No.
  • Page 90 General Description MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT (10) (19) (14) (15) (16) (13) (10) (18) (17) (11) (19) (12) ME-00186 ⋅ Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N m (kgf-m, ft-lb) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref.
  • Page 91 General Description MECHANICAL 3. VALVE ROCKER ASSEMBLY ME-00187 ⋅ Intake valve rocker arm Rocker shaft support Tightening torque: N m (kgf-m, ft-lb) Valve rocker nut Intake rocker shaft T1: 5 (0.5, 3.6) Valve rocker adjust screw Exhaust rocker shaft T2: 10 (1.0, 7.2) Spring Exhaust valve rocker arm T3: 25 (2.5, 18.1)
  • Page 92 General Description MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEMBLY ME-00760 Exhaust valve Valve spring seat Retainer Intake valve Intake valve oil seal Retainer key Valve guide Valve spring Exhaust valve oil seal ME(H4SO 2.0)-8...
  • Page 93 General Description MECHANICAL 5. CYLINDER BLOCK (10) (11) (10) (14) (15) (10) (10) (26) (17) (16) (23) (12) (22) (18) (24) (21) (20) (13) (25) (19) ME-00810 ⋅ Oil pressure switch (14) Baffle plate Tightening torque: N m (kgf-m, ft-lb) Cylinder block (RH) (15) Oil filter connector...
  • Page 94 General Description MECHANICAL 6. CRANKSHAFT AND PISTON (10) (11) (12) (14) (12) (13) (12) (11) (15) (18) (10) (9) (8) (17) (16) (17) (16) ME-00190 Flywheel (MT model) Piston pin (15) Woodruff key Reinforcement (AT model) Snap ring (16) Crankshaft bearing #1, #3 Drive plate (AT model) (10) Connecting rod bolt...
  • Page 95 General Description MECHANICAL 7. ENGINE MOUNTING • 2.0 L model ME-00413 ⋅ Front cushion rubber Front engine mounting bracket Tightening torque: N m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.3, 31.0) T3: 85 (8.7, 63) ME(H4SO 2.0)-11...
  • Page 96 General Description MECHANICAL • 2.5 L model ME-02090 ⋅ Front cushion rubber Tightening torque: N m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 85 (8.7, 62.7) ME(H4SO 2.0)-12...
  • Page 97 General Description MECHANICAL C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to • Wear work clothing, including a cap, protective assembly. goggles and protective shoes during operation. • Be careful not to let oil, grease or coolant contact •...
  • Page 98 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SUBARU Troubleshooting for electrical system. SELECT MONI- • English: 22771AA030 (Without printer) TOR KIT • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 498267800 CYLINDER •...
  • Page 99 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498457100 ENGINE STAND Used with ENGINE STAND (499817100). ADAPTER LH ST-498457100 498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos- STOPPER ening/tightening crank pulley bolt. ST-498497100 398744300 PISTON GUIDE Used for installing piston in cylinder. (2.0 L model) ST-398744300 498747300 PISTON GUIDE...
  • Page 100 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve GUIDE guide oil seals. ST-498857100 499017100 PISTON PIN Used for installing piston pin, piston and connect- GUIDE ing rod. ST-499017100 499037100 CONNECTING Used for removing and installing connecting rod...
  • Page 101 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587500 OIL SEAL • Used for installing camshaft oil seal. INSTALLER • Used with OIL SEAL GUIDE (499597000). ST-499587500 499587700 CAMSHAFT OIL Used for installing cylinder head plug. SEAL INSTALLER ST-499587700 499097700 PISTON PIN Used for removing piston pin.
  • Page 102 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499497000 ® Used for removing and installing camshaft cap. TORX PLUS ST-499497000 499587100 OIL SEAL Used for installing oil pump oil seal. INSTALLER ST-499587100 499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal. •...
  • Page 103 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499718000 VALVE SPRING Used for removing and installing valve spring. REMOVER ST-499718000 499767200 VALVE GUIDE Used for removing valve guides. REMOVER ST-499767200 499767400 VALVE GUIDE Used for reaming valve guides. REAMER ST-499767400 499767700 VALVE GUIDE Used for installing valve guides.
  • Page 104 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767800 VALVE GUIDE Used for installing valve guides. (Exhaust side) ADJUSTER ST-499767800 499817100 ENGINE STAND • Stand used for engine disassembly and assem- bly. • Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100). ST-499817100 499977400 CRANK PULLEY...
  • Page 105 General Description MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18332AA000 OIL FILTER Used for removing and installing oil filter. (Outer WRENCH diameter: 68 mm (2.68 in)) ST18332AA000 18332AA010 OIL FILTER Used for removing and installing oil filter. (Outer WRENCH diameter: 65 mm (2.56 in)) ST18332AA010 499987500 CRANKSHAFT...

  • Page 106: Compression

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

  • Page 107: Idle Speed

    3) Stop the engine, and turn the ignition switch to OFF. NOTE: 4) When using Subaru Select Monitor, refer to the This ignition system provides simultaneous ignition following. <Ref. to ME(H4SO 2.0)-13, SPECIAL for #1 and #2 plugs. It must be noted that some ta-...

  • Page 108: Ignition Timing

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

  • Page 109: Intake Manifold Vacuum

    Intake Manifold Vacuum MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Idle the engine. 2) Disconnect the brake vacuum hose from the in- take manifold, and then install the vacuum gauge. 3) Keep the engine at the idle speed and read the vacuum gauge indication.

  • Page 110: Engine Oil Pressure

    Engine Oil Pressure MECHANICAL 6. Engine Oil Pressure CAUTION: • If the oil pressure is out of specification, A: INSPECTION check oil pump, oil filter and lubrication line. 1) Disconnect the ground cable from battery. <Ref. to LU(H4SO 2.0)-19, INSPECTION, Gener- al Diagnostic Table.>...

  • Page 111: Fuel Pressure

    Fuel Pressure MECHANICAL 7. Fuel Pressure A: INSPECTION WARNING: Before removing the fuel pressure gauge, re- lease fuel pressure. NOTE: When the fuel pressure is out of specification, check or replace the pressure regulator and pres- sure regulator vacuum hose. 1) Release the fuel pressure.

  • Page 112: Valve Clearance

    Valve Clearance MECHANICAL 8. Valve Clearance NOTE: When the arrow mark (A) on cam sprocket (LH) A: INSPECTION comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression NOTE: stroke. Inspection and adjustment of valve clearance should be performed while engine is cold.
  • Page 113 Valve Clearance MECHANICAL Valve clearance NOTE: Intake: • Be sure to set the cylinder pistons to their re- ± ± 0.20 0.04 mm (0.0079 0.0016 in) spective top dead centers on compression stroke Exhaust: before measuring valve clearances. ± ± 0.25 0.04 mm (0.0098 0.0016 in)

  • Page 114: Engine Assembly

    Engine Assembly MECHANICAL 9. Engine Assembly (1) Front oxygen (A/F) sensor connector A: REMOVAL 1) Set the vehicle on a lift. 2) Open the front hood fully and support with the front food stay. 3) Collect the refrigerant from A/C system. <Ref. to AC-20, PROCEDURE, Refrigerant Recovery Pro- cedure.>...
  • Page 115 Engine Assembly MECHANICAL (5) Generator connector and terminal 14) Remove the power steering pump from brack- (1) Loosen the lock bolt and slider bolt, and re- move the front side belt. <Ref. to ME(H4SO 2.0)-38, FRONT SIDE BELT, REMOVAL, V- belt.>...
  • Page 116 Engine Assembly MECHANICAL (4) Remove other bolts while rotating the en- 22) Support the transmission with a garage jack. gine using a socket wrench. CAUTION: • Doing this is very important because the transmission lowers for its own weight. This work is also of great importance for facilitating reinstallation.
  • Page 117 Engine Assembly MECHANICAL (3) Move the engine horizontally until main Tightening torque: ⋅ shaft is withdrawn from clutch cover. T1: 50 N m (5.1 kgf-m, 36.9 ft-lb) ⋅ (4) Slowly move the engine away from engine T2: 58 N m (5.9 kgf-m, 42.8 ft-lb) compartment.
  • Page 118 Engine Assembly MECHANICAL Tightening torque: NOTE: ⋅ 22 N m (2.2 kgf-m, 16 ft-lb) Make sure the front cushion rubber mounting bolts are securely installed. FU-00139 (2) Connect the power steering switch connec- LU-00223 tor. 15) Install the front and center exhaust pipe. <Ref.
  • Page 119 Engine Assembly MECHANICAL <Ref. to 4AT-31, INSPECTION, Automatic Trans- mission Fluid.> 27) Charge the A/C system with refrigerant. <Ref. to AC-21, PROCEDURE, Refrigerant Charging Procedure.> 28) Remove the front hood stay, and close the front hood. 29) Take off the vehicle from a lift. C: INSPECTION 1) Check pipes and hoses are installed firmly.

  • Page 120: Engine Mounting

    Engine Mounting MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove engine assembly. <Ref. ME(H4SO 2.0)-30, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine as- sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; ⋅ 35 N m (3.6 kgf-m, 25.8 ft-lb) C: INSPECTION...

  • Page 121: Preparation For Overhaul

    Preparation for Overhaul MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from the body, secure it in the ST shown below. 498457000 ENGINE STAND ADAPTER 498457100 ENGINE STAND ADAPTER 499817100 ENGINE STAND ME-00221 2) In this section the procedures described under each index are all connected and stated in order.

  • Page 122: V-Belt

    V-belt MECHANICAL 12.V-belt 4) Remove the belt tensioner. A: REMOVAL NOTE: Perform the following procedures with the engine installed to the body. 1. FRONT SIDE BELT 1) Remove the V-belt covers. ME-00225 B: INSTALLATION NOTE: Wipe off any oil or water on the belt and pulley. 1.
  • Page 123 V-belt MECHANICAL Tightening torque: Belt tension (without belt tension gauge) Lock nut (A); ⋅ 23 N m (2.3 kgf-m, 17.0 ft-lb) When installing new parts: 7 — 9 mm (0.276 — 0.354 in) At inspection: 9 — 11 mm (0.354 — 0.433 in) When installing new parts: 7.5 —...

  • Page 124: Crank Pulley

    Crank Pulley MECHANICAL 13.Crank Pulley CAUTION: If the tightening angle of crank pulley bolt is A: REMOVAL less than 45°, the bolt should be damaged. In 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, this case, the bolt must be replaced. REMOVAL, V-belt.>...
  • Page 125 Crank Pulley MECHANICAL Tightening torque: ⋅ 180 N m (18.4 kgf-m, 132.8 ft-lb) ME-00227 3) Confirm that the tightening angle of crank pulley bolt is 65 degrees or more. If the tightening angle of crank pulley bolt is less than 65 degrees, conduct the following procedures.

  • Page 126: Timing Belt Cover

    Timing Belt Cover MECHANICAL 14.Timing Belt Cover A: REMOVAL 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO 2.0)-40, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover (LH). 4) Remove the front timing belt cover. ME-00821 (A) Timing belt cover (LH) (B) Front timing belt cover...
  • Page 127 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 128 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 129 MECHANICAL ME(H4SO 2.0) Page General Description ..................2 Compression .....................22 Idle Speed ....................23 Ignition Timing...................24 Intake Manifold Vacuum................25 Engine Oil Pressure ..................26 Fuel Pressure....................27 Valve Clearance..................28 Engine Assembly ..................30 Engine Mounting ..................36 Preparation for Overhaul................37 V-belt......................38 Crank Pulley....................40 Timing Belt Cover..................42 Timing Belt ....................43 Cam Sprocket ...................48 Crank Sprocket ..................50...

  • Page 130: Timing Belt

    Timing Belt MECHANICAL 15.Timing Belt A: REMOVAL 1. TIMING BELT 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO 2.0)-40, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov- er.>...
  • Page 131 Timing Belt MECHANICAL 7) Remove the belt idler No. 2. B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUST- ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly. CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down.
  • Page 132 Timing Belt MECHANICAL 2) Install the automatic belt tension adjuster as- 499207400 CAM SPROCKET WRENCH sembly. Tightening torque: ⋅ 39 N m (4.0 kgf-m, 28.9 ft-lb) ME-00243 (2) While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, posi- tion the timing belt properly.
  • Page 133 Timing Belt MECHANICAL 5) After ensuring the marks on timing belt and cam Tightening torque: ⋅ sprockets are aligned, remove the stopper pin from 10 N m (1.0 kgf-m, 7.2 ft-lb) belt tension adjuster. ME-00247 ME-00245 7) Install the timing belt cover. 6) Install the timing belt guide.
  • Page 134 Timing Belt MECHANICAL 2. AUTOMATIC BELT TENSION ADJUST- 3. BELT TENSION PULLEY 1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or 1) Visually check the oil seals for leaks, and rod scratches.

  • Page 135: Cam Sprocket

    Cam Sprocket MECHANICAL 16.Cam Sprocket NOTE: Do not confuse left and right side cam sprockets A: REMOVAL during installation. Cam sprocket No. 2 is identified 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, by a protrusion used to monitor the camshaft posi- REMOVAL, V-belt.>...
  • Page 136 Cam Sprocket MECHANICAL 3) Check the cam sprocket protrusion used for sen- sor for damage and contamination of foreign mat- ter. ME(H4SO 2.0)-49...

  • Page 137: Crank Sprocket

    Crank Sprocket MECHANICAL 17.Crank Sprocket 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign A: REMOVAL matter. 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO 2.0)-40, REMOVAL, Crank Pulley.>...

  • Page 138: Valve Rocker Assembly

    Valve Rocker Assembly MECHANICAL 18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified torque. A: REMOVAL Tightening torque: 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, ⋅ 25 N m (2.5 kgf-m, 18.1 ft-lb) REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO ( g ) ( c ) ( e )
  • Page 139 Valve Rocker Assembly MECHANICAL E: INSPECTION 1. VALVE ROCKER ARM AND ROCKER SHAFT 1) Measure the inner diameter of valve rocker arm and outer diameter of valve rocker shaft, and deter- mine the difference (oil clearance) between the two values. Clearance between arm and shaft: Standard: 0.020 —...

  • Page 140: Camshaft

    Camshaft MECHANICAL 19.Camshaft (1) Remove the bolts (a) and (b) in alphabetical sequence. A: REMOVAL 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO ( a ) 2.0)-40, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover.
  • Page 141 Camshaft MECHANICAL (3) Install the valve rocker assembly. CAUTION: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when re- moving the oil seal. B: INSTALLATION 1) Apply a coat of engine oil to camshaft journals and install the camshaft.
  • Page 142 Camshaft MECHANICAL Tightening torque: 9) Install the tensioner bracket. ⋅ 10 N m (1.0 kgf-m, 7.2 ft-lb) Tightening torque: ⋅ 25 N m (2.5 kgf-m, 18.1 ft-lb) ( q ) ( o ) ( u ) ( s ) ( t ) ( v ) ( p ) ( r )
  • Page 143 Camshaft MECHANICAL C: INSPECTION Cam base circle diameter A: Intake: 34.00 mm (1.3386 in) 1. CAMSHAFT Exhaust: 34.00 mm (1.3386 in) 1) Measure the bend, and repair or replace if nec- essary. Service limit: 0.020 mm (0.00079 in) ME-00276 2. CAMSHAFT SUPPORT Measure the side clearance of camshaft with set- ting the dial gauge at end of camshaft.

  • Page 144: Cylinder Head

    Cylinder Head MECHANICAL 20.Cylinder Head CAUTION: Be careful not to scratch the mating surface of A: REMOVAL cylinder head and cylinder block. 1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, 14) Similarly, remove the right side cylinder head. REMOVAL, V-belt.> B: INSTALLATION 2) Remove the crank pulley.
  • Page 145 Cylinder Head MECHANICAL 7) Install the cam sprocket. <Ref. to ME(H4SO NOTE: 2.0)-48, INSTALLATION, Cam Sprocket.> Keep all the removed parts in order for re-installing 8) Install the timing belt. <Ref. to ME(H4SO 2.0)- in their original positions. 44, INSTALLATION, Timing Belt.> CAUTION: 9) Install the timing belt cover.
  • Page 146 Cylinder Head MECHANICAL 1) Installation of valve spring and valve: E: INSPECTION (1) Place the cylinder head on the ST. 1. VALVE SPRING ST 498267800 CYLINDER HEAD TABLE (2) Coat the stem of each valve with engine oil 1) Check the valve springs for damage, free length, and insert the valve into valve guide.
  • Page 147 Cylinder Head MECHANICAL Color of spring part: 2. VALVE SEAT Intake [Silver] Inspect the intake and exhaust valve seats, and Exhaust [Silver] correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are re- placed.
  • Page 148 Cylinder Head MECHANICAL Clearance between the valve guide and valve 498267800 CYLINDER HEAD TABLE stem: 499767200 VALVE GUIDE REMOVER Standard Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in) ME-00290 (3) Turn the cylinder head upside down and place the ST as shown in the figure.
  • Page 149 Cylinder Head MECHANICAL (6) Check the valve guide protrusion. 4. INTAKE AND EXHAUST VALVE Valve guide protrusion L: 1) Inspect the flange and stem of valve, and re- place if damaged, worn or deformed, or if “H” ex- Intake ceed the standard value. 20.0 —...

  • Page 150: Cylinder Block

    Cylinder Block MECHANICAL 21.Cylinder Block 12) Remove the bolts (a) and (c) to remove the cyl- inder head. A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the intake manifold. <Ref. to FU(H4SO 2.0)-11, REMOVAL, Intake Manifold.> 2) Remove the V-belts.
  • Page 151 Cylinder Block MECHANICAL 19) Remove the water pump after loosening the 25) Remove the oil filter. bolts in alphabetical sequence as shown in the fig- ure. ME-00299 26) Remove the water pipe. ME-00847 20) Remove the oil pump from cylinder block. Use a flat tip screwdriver as shown in the figure when removing the oil pump.
  • Page 152 Cylinder Block MECHANICAL ME-00139 Service hole plug Snap ring Service hole cover Gasket Piston pin O-ring 27) Remove the service hole cover and service 28) Rotate the crankshaft to bring #1 and #2 pis- hole plugs using a hexagon wrench (14 mm). tons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
  • Page 153 Cylinder Block MECHANICAL 30) Similarly remove the piston pins from #3 and #4 NOTE: pistons. Be careful not to confuse the original combination 31) Remove the bolts which connect cylinder block of piston, piston pin and cylinder. on the side of #2 and #4 cylinders. 32) Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  • Page 154 Cylinder Block MECHANICAL B: INSTALLATION ME-00144 Crankshaft bearing Cylinder block Rear oil seal Crankshaft NOTE: NOTE: Remove oil on the mating surface of bearing and Do not allow liquid gasket to flow into O-ring cylinder block before installation. Apply a coat of grooves, oil passages, bearing grooves, etc.
  • Page 155 Cylinder Block MECHANICAL Tightening torque: Tightening torque: ⋅ ⋅ 10 N m (1.0 kgf-m, 7.4 ft-lb) (E), (F), (G), (I): 20 N m (2.0 kgf-m, 14.8 ft-lb) ⋅ (H), (J): 18 N m (1.8 kgf-m, 13.3 ft-lb) ME-00398 ME-00399 4) Tighten the 10 mm cylinder block connecting bolts on RH side (E —...
  • Page 156 Cylinder Block MECHANICAL Tightening torque: 13) Position the upper rail gap at (C) in the figure. ⋅ (A) — (G): 25 N m (2.5 kgf-m, 18.1 ft-lb) ⋅ (H): 6.4 N m (0.65 kgf-m, 4.7 ft-lb) ME-02087 14) Align the upper rail spin stopper (E) to the side hole (D) on the piston.
  • Page 157 Cylinder Block MECHANICAL 17) Install the snap ring. CAUTION: Install snap rings in the piston holes located oppo- Piston front mark faces towards the front of en- site to the service holes in cylinder block, when po- gine. sitioning all pistons in the corresponding cylinders. NOTE: Use new snap rings.
  • Page 158 Cylinder Block MECHANICAL 19) Install the piston pin. (6) Install the service hole plug and gasket. (1) Apply a coat of engine oil to ST3. NOTE: (2) Insert ST3 into the service hole to align pis- Use a new gasket. ton pin hole with connecting rod small end.
  • Page 159 Cylinder Block MECHANICAL ME-00161 ⋅ Piston Service hole plug Tightening torque: N m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7) Snap ring O-ring T2: 70 (7.1, 50.6) Gasket (7) Place the cylinder block to face the #3 and 24) Apply liquid gasket to mating surfaces and in- #4 cylinder side upward.
  • Page 160 Cylinder Block MECHANICAL 25) Apply liquid gasket to mating surfaces and in- ST 499587100 OIL SEAL INSTALLER stall the oil separator cover. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent ME-00164 (2) Apply liquid gasket to the matching surface of oil pump.
  • Page 161 Cylinder Block MECHANICAL Tightening torque: CAUTION: ⋅ First: 12 N m (1.2 kgf-m, 8.7 ft-lb) Ensure the total “re-tightening angle” of the ⋅ Second: 12 N m (1.2 kgf-m, 8.7 ft-lb) step (6) and (7) does not exceed 180°. CAUTION: •...
  • Page 162 Cylinder Block MECHANICAL C: DISASSEMBLY ME-00168 Connecting rod cap Top ring Oil ring Connecting rod bearing Second ring Snap ring 1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion. 3) Remove the piston rings using the piston ring ex- pander.
  • Page 163 Cylinder Block MECHANICAL D: ASSEMBLY ME-00392 ⋅ Connecting rod bearing Second ring Tightening torque: N m (kgf-m, ft-lb) Connecting rod Top ring T: 45 (4.6, 33.3) Connecting rod cap Snap ring Oil ring Side mark 1) Apply oil to the surfaces of the connecting rod E: INSPECTION bearings.
  • Page 164 Cylinder Block MECHANICAL Standard diameter: Out-of-roundness: 2.0 L model Standard A: 92.005 — 92.015 mm (3.6222 — 3.6226 0.010 mm (0.0004 in) B: 91.995 — 92.005 mm (3.6218 — 3.6222 2.5 L model A: 99.505 — 99.515 mm (3.9175 — 3.9179 B: 99.495 —...
  • Page 165 Cylinder Block MECHANICAL Standard (2) If the cylinder inner diameter exceeds limit* after boring and honing, replace the cylinder 2.0 L model block. A: 92.005 — 92.015 mm (3.6222 — 3.6226 *: 2.0 L model B: 91.995 — 92.005 mm (3.6219 — 3.6222 92.515 mm (3.6423 in) 2.5 L model 2.5 L model...
  • Page 166 Cylinder Block MECHANICAL 4) Check the snap ring installation groove (A) on 2) Clean the piston ring groove and piston ring. the piston for burr. If necessary, remove burr from 3) Squarely place the piston ring and oil ring in cyl- the groove so that the piston pin can lightly move.
  • Page 167 Cylinder Block MECHANICAL Limit of bend or twist per 100 mm (3.94 in) in Connecting rod oil clearance: length: Standard 0.10 mm (0.0039 in) 0.016 — 0.044 mm (0.00063 — 0.0017 in) Unit: mm (in) Bearing size ( A ) Outer diameter of Bearings (Thickness at cen-...
  • Page 168 Cylinder Block MECHANICAL ST 499037100 CONNECTING ROD BUSH- Crank pin: ING REMOVER AND IN- 2.0 L model STALLER Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit To 51.750 mm (2.0374 in) dia. 2.5 L model Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in)
  • Page 169 Cylinder Block MECHANICAL Unit: mm (in) Crank journal outer diameter Crank pin outer diameter #1, #3 #2, #4, #5 59.992 — 60.008 59.992 — 60.008 51.984 — 52.000 Journal O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472) Standard Bearing size 1.998 —...

  • Page 170: Engine Trouble In General

    Engine Trouble in General MECHANICAL 22.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely Symptom Problem parts, etc.
  • Page 171 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 4) Engine stalls after initial Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> combustion. Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket...
  • Page 172 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 3. Low output, hesitation and Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> poor acceleration Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket...
  • Page 173 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 5. Engine does not return to Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> idle. Intake system Loosened or cracked vacuum hose Other Stuck or damaged throttle valve 6.
  • Page 174 Engine Trouble in General MECHANICAL Symptom Problem parts, etc. Possible cause RANK 10. Excessive fuel consump- Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> tion Intake system Dirty air cleaner element Belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing...

  • Page 175: 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 176 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 177 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 178 EXHAUST EX(H4SO 2.0) Page General Description ..................2 Front Exhaust Pipe..................7 Center Exhaust Pipe .................10 Rear Exhaust Pipe ..................11 Muffler .......................13...

  • Page 179: General Description

    General Description EXHAUST 1. General Description A: COMPONENT • 2.0 L model (19) (22) (20) (21) (19) (16) (19) (15) (18) (17) (23) (24) (12) (11) (14) (10) (13) EX-02020 EX(H4SO 2.0)-2...
  • Page 180 General Description EXHAUST Front catalytic converter upper (11) Center exhaust pipe lower cover (23) Rear exhaust pipe upper cover cover (12) Gasket (24) Rear exhaust pipe lower cover Front catalytic converter (13) Front catalytic converter lower ⋅ cover Center exhaust pipe Tightening torque: N m (kgf-m, ft-lb) Center exhaust pipe upper cover...
  • Page 181 General Description EXHAUST • 2.5 L model (22) (19) (19) (23) (21) (19) (21) (20) (19) (16) (19) (20) (15) (18) (17) (24) (25) (12) (11) (14) (10) (13) EX-02012 EX(H4SO 2.0)-4...
  • Page 182 General Description EXHAUST Front catalytic converter upper (11) Center exhaust pipe lower cover (23) Muffler (LH) cover (12) Gasket (24) Rear exhaust pipe upper cover Front catalytic converter (13) Front catalytic converter lower (25) Rear exhaust pipe lower cover cover Center exhaust pipe ⋅...
  • Page 183 General Description EXHAUST B: CAUTION • Wear work clothing, including a cap, protective goggles and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust and dirt.

  • Page 184: Front Exhaust Pipe

    Front Exhaust Pipe EXHAUST 2. Front Exhaust Pipe 7) Remove the nuts which hold front exhaust pipe onto cylinder heads. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. Be careful not to pull down the front and center exhaust pipe assembly.
  • Page 185 Front Exhaust Pipe EXHAUST 11) Remove the front oxygen (A/F) sensor and rear 5) Install the nuts to cylinder head which hold front oxygen sensor. <Ref. to FU(H4SO 2.0)-32, RE- exhaust pipe. MOVAL, Front Oxygen (A/F) Sensor.> <Ref. to Tightening torque: FU(H4SO 2.0)-33, REMOVAL, Rear Oxygen Sen- ⋅...
  • Page 186 Front Exhaust Pipe EXHAUST 9) Connect the rear oxygen sensor connector. FU-01116 10) Lower the vehicle. 11) Connect the front oxygen (A/F) sensor connec- tor. ME-00859 12) Connect the battery ground cable to battery. IN-00203 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds.

  • Page 187: Center Exhaust Pipe

    Center Exhaust Pipe EXHAUST 3. Center Exhaust Pipe A: REMOVAL After removing the center and front exhaust pipes as one unit, separate them. Refer to “Front Exhaust Pipe” for removal procedure. <Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.

  • Page 188: Rear Exhaust Pipe

    Rear Exhaust Pipe EXHAUST 4. Rear Exhaust Pipe 4) Remove the rear exhaust pipe bracket from cushion rubber. A: REMOVAL 1) Separate the rear exhaust pipe from center ex- haust pipe. EX-00219 B: INSTALLATION 1) Apply a coat of spray type lubricant to mating EX-00214 area of cushion rubber.
  • Page 189 Rear Exhaust Pipe EXHAUST • RH side (2.5 L model) EX-00218 4) Install the rear exhaust pipe to center exhaust pipe. Tightening torque: ⋅ 18 N m (1.8 kgf-m, 13.0 ft-lb) EX-00214 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds.

  • Page 190: Muffler

    Muffler EXHAUST 5. Muffler B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Separate the muffler from rear exhaust pipe. Use a new gasket and self-locking nut. • LH side Tightening torque: ⋅ 48 N m (4.9 kgf-m, 35.4 ft-lb) •...
  • Page 191 Muffler EXHAUST EX(H4SO 2.0)-14...
  • Page 192 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 193 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 194 COOLING CO(H4SO 2.0) Page General Description ..................2 Radiator Fan System ..................7 Engine Coolant..................13 Water Pump ....................15 Thermostat ....................18 Radiator.....................20 Radiator Cap .....................24 Radiator Main Fan and Fan Motor ............25 Radiator Sub Fan and Fan Motor..............27 Reservoir Tank..................29 Engine Cooling System Trouble in General ..........30...

  • Page 195: General Description

    General Description COOLING 1. General Description A: SPECIFICATION Cooling system Electric fan + Forced engine coolant circulation system MT: approx. 6.5 (6.9, 5.7) 2 (US qt, Imp qt) Total engine coolant capacity AT: approx. 6.4 (6.8, 5.6) (Model without ATF warmer) AT: approx.
  • Page 196 General Description COOLING Engine coolant temperature 96 — 99°C 95°C (203°F) or less 100°C (212°F) or more Vehicle speed A/C compressor load (203 — 210°F) Operation of radiator Operation of radiator Operation of radiator Low-Speed High-Speed 19 km/h (12 MPH) or less Low-Speed Low-Speed High-Speed...
  • Page 197 General Description COOLING B: COMPONENT 1. WATER PUMP CO-02031 ⋅ Water pump ASSY Thermostat Tightening torque: N m (kgf-m, ft-lb) Gasket Gasket T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Heater by-pass hose Thermostat cover ATF warmer by-pass hose (Model T2: 12 (1.2, 8.7) with ATF warmer) CO(H4SO 2.0)-4...
  • Page 198 General Description COOLING 2. RADIATOR AND RADIATOR FAN (10) (14) (27) (11) (26) (24) (12) (14) (28) (13) (14) (15) (20) (14) (22) (14) (21) (16) (14) (25) (23) (14) (17) (18) (14) (19) CO-02010 Radiator lower cushion (14) ATF hose clamp (AT model) (24) Radiator cap Radiator...
  • Page 199 General Description COOLING C: CAUTION • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Wear work clothing, including a cap, protective • Be sure to tighten fasteners including bolts and goggles, and protective shoes during operation. nuts to the specified torque.

  • Page 200: Radiator Fan System

    Radiator Fan System COOLING 2. Radiator Fan System A: WIRING DIAGRAM SBF-1 SBF-7 No.3 IGNITION SWITCH No.2 No.26 No.22 MAIN FUSE BOX (M/B) MAIN B143 RELAY 1 THROUGH JOINT CONNECTOR F109 B360 A/C RELAY HOLDER MAIN RELAY 2 RELAY MAIN FAN MOTOR THROUGH JOINT CONNECTOR...
  • Page 201 Monitor. NOTE: • When performing the compulsory operation check for the radiator fan relay using Subaru Select Monitor, the radiator main fan and sub fan will repeat such a operation as low speed revolution → high speed revolution → OFF in this order.
  • Page 202 Radiator Fan System COOLING Step Check CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 7. Go to step 6. LAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between sub fan relay terminal and chassis ground.
  • Page 203 Radiator Fan System COOLING Step Check CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 15. Repair the open Ω? RELAY 2 TERMINAL AND MAIN FAN MO- circuit of harness TOR CONNECTOR. between main fan 1) Disconnect the connector from main fan relay 2 terminal motor.
  • Page 204 Radiator Fan System COOLING Step Check CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 23. Repair the open Ω? RELAY 1 TERMINAL AND MAIN FAN MO- circuit of harness TOR CONNECTOR. between main fan 1) Disconnect the connector from main fan relay 1 terminal motor.
  • Page 205 Radiator Fan System COOLING Step Check CHECK MAIN FAN RELAY 2. Is the resistance more than 1 Go to step 31. Replace the main 1) Turn the ignition switch to OFF. MΩ? fan relay 2. 2) Remove the main fan relay 2. 3) Measure the resistance of main fan relay 2.

  • Page 206: Engine Coolant

    6.8 2(7.2 US qt, 6.0 Imp qt) NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. CO(H4SO 2.0)-13...
  • Page 207 The concentration and safe operating temperature amount of coolant with an undiluted solution of of SUBARU coolant is shown in the diagram. Mea- SUBARU genuine coolant (concentration 50%). suring the temperature and specific gravity of the The amount of coolant that should be replaced can coolant will provide this information.

  • Page 208: Water Pump

    Water Pump COOLING 4. Water Pump 7) Remove the belt cover No. 2 (LH). A: REMOVAL 1) Remove the radiator. <Ref. to CO(H4SO 2.0)- 20, REMOVAL, Radiator.> 2) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, REMOVAL, V-belt.> 3) Remove the timing belt. <Ref. to ME(H4SO 2.0)- 43, TIMING BELT, REMOVAL, Timing Belt.>...
  • Page 209 Water Pump COOLING Tightening torque: Tightening torque: ⋅ First: 78 N m (8.0 kgf-m, 57.9 ft-lb) ⋅ 12 N m (1.2 kgf-m, 8.7 ft-lb) Second: ⋅ 12 N m (1.2 kgf-m, 8.7 ft-lb) CO-00018 6) Install the belt idler No. 2. Tightening torque: ME-00847 ⋅...
  • Page 210 Water Pump COOLING Clearance between impeller and pump case: Standard value 0.5 — 1.5 mm (0.020 — 0.060 in) CO-00293 5) After water pump installation, check the pulley shaft for engine coolant leaks and noise. If leaks or noise are noted, replace the water pump assembly. CO(H4SO 2.0)-17...

  • Page 211: Thermostat

    Thermostat COOLING 5. Thermostat 6) Remove the thermostat cover and gasket, and then remove the thermostat. A: REMOVAL 1) Set the vehicle on a lift. 2) Lift-up the vehicle. 3) Remove the under cover. 4) Drain engine coolant completely. <Ref. to CO(H4SO 2.0)-13, DRAINING OF EN- GINE COOLANT, REPLACEMENT, Engine Cool- ant.>...
  • Page 212 Thermostat COOLING Tightening torque: Valve lift: ⋅ 12 N m (1.2 kgf-m, 8.7 ft-lb) 9.0 mm (0.354 in) or more ( A ) ( B ) CO-00033 (A) Thermometer (B) Thermostat CO-00155 (A) Thermostat cover (B) Gasket (C) Thermostat (D) Jiggle pin 2) Connect the radiator outlet hose to thermostat cover.

  • Page 213: Radiator

    Radiator COOLING 6. Radiator 7) Disconnect the connector (A) of radiator main fan motor and connector (B) of sub fan motor. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00274 IN-00203 3) Lift-up the vehicle. 4) Remove the under cover.
  • Page 214 Radiator COOLING 13) Remove the hood stay holder. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side. 3) Install the radiator upper brackets and tighten the bolts. Tightening torque: ⋅ 18 N m (1.8 kgf-m, 13.0 ft-lb) CO-00276...
  • Page 215 Radiator COOLING 10) Connect the ATF cooler hoses. (Model without 13) Install the heat shield cover. (Model without ATF warmer) ATF warmer) CO-00253 CO-00273 11) Connect the radiator outlet hose. 14) Install the under cover. 15) Lower the vehicle. 16) Connect the battery ground cable to battery. CO-00270 12) Connect the connector (A) to radiator main fan IN-00203...
  • Page 216 Radiator COOLING • Be careful to prevent engine coolant from spurting out when removing tester. • Be careful not to deform the filler neck of ra- diator when installing or removing the tester. CO(H4SO 2.0)-23...

  • Page 217: Radiator Cap

    Radiator Cap COOLING 7. Radiator Cap A: INSPECTION 1) Attach the radiator cap to tester. CO-00044 2) Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Standard pressure: 93 —...

  • Page 218: Radiator Main Fan And Fan Motor

    Radiator Main Fan and Fan Motor COOLING 8. Radiator Main Fan and Fan 11) Remove the bolts which hold the radiator main fan shroud to radiator. Motor A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00096 12) Remove the radiator main fan motor assembly.
  • Page 219 Radiator Main Fan and Fan Motor COOLING 3) Remove the bolts which install fan motor onto the shroud. CO-00098 D: ASSEMBLY Assemble in the reverse order of disassembly. Tightening torque: ⋅ 4.4 N m (0.45 kgf-m, 3.3 ft-lb) CO-00098 Tightening torque: ⋅...

  • Page 220: Radiator Sub Fan And Fan Motor

    Radiator Sub Fan and Fan Motor COOLING 9. Radiator Sub Fan and Fan 10) Remove the bolts which hold the radiator sub fan shroud to radiator. Motor A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. CO-00101 11) Remove the radiator sub fan motor assembly from the lower side of vehicle.
  • Page 221 Radiator Sub Fan and Fan Motor COOLING 3) Remove the bolts which install fan motor onto the shroud. CO-00098 D: ASSEMBLY Assemble in the reverse order of disassembly. Tightening torque: ⋅ 4.4 N m (0.45 kgf-m, 3.3 ft-lb) CO-00098 Tightening torque: ⋅...

  • Page 222: Reservoir Tank

    Reservoir Tank COOLING 10.Reservoir Tank A: REMOVAL 1) Disconnect the over flow hose. 2) Pull out the reservoir tank to the direction of ar- row while pushing the pawl (A). CO-00279 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Make sure the engine coolant level is between “FULL”...

  • Page 223: Engine Cooling System Trouble In General

    Engine Cooling System Trouble in General COOLING 11.Engine Cooling System Trouble in General A: INSPECTION Trouble Possible cause Corrective action Replenish engine coolant, inspect for leakage, and a. Insufficient engine coolant repair it if necessary. b. Loose timing belt Repair or replace timing belt tensioner. c.
  • Page 224 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 225 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 226 LUBRICATION LU(H4SO 2.0) Page General Description ..................2 Oil Pressure System ...................6 Engine Oil....................8 Oil Pump ....................10 Oil Pan and Strainer..................14 Oil Pressure Switch...................17 Engine Oil Filter..................18 General Diagnostic Table................19...

  • Page 227: General Description

    CCMC specification, G4 or G5 5W-30,0W-20 (2) New API certification mark (Star burst mark) label is on the container. LU-00071 (1) SAE viscosity No. and applicable temperature (2) Recommend CAUTION: When replacing oil, use only SUBARU genuine engine oil. LU(H4SO 2.0)-2...
  • Page 228 General Description LUBRICATION B: COMPONENT (13) (16) (15) (14) (12) (17) (11) (18) (10) (19) (23) (20) (26) (21) (22) (25) (24) LU-00228 Plug (13) Oil pressure switch (24) Drain plug Gasket (14) Oil filler duct (25) Metal gasket Relief valve spring (15) O-ring (26)
  • Page 229 General Description LUBRICATION C: CAUTION • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Wear work clothing, including a cap, protective • Be sure to tighten fasteners including bolts and goggles and protective shoes during operation. nuts to the specified torque.
  • Page 230 General Description LUBRICATION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18332AA010 OIL FILTER Used for removing and installing oil filter. (Outer WRENCH diameter: 65 mm (2.56 in)) ST18332AA010 499587100 OIL SEAL Used for installing oil seal into oil pump. INSTALLER ST-499587100 LU(H4SO 2.0)-5...

  • Page 231: Oil Pressure System

    Oil Pressure System LUBRICATION 2. Oil Pressure System A: WIRING DIAGRAM BATTERY No.5 SBF-7 SBF-1 IGNITION SWITCH COMBINATION METER OIL PRESSURE SWITCH 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 4 5 6...
  • Page 232 Oil Pressure System LUBRICATION B: INSPECTION Step Check CHECK COMBINATION METER. Does the warning light illumi- Go to step 2. Repair or replace 1)Turn the ignition switch to ON (engine OFF). nate? the combination 2)Check the warning light of combination meter.

  • Page 233: Engine Oil

    Engine Oil LUBRICATION 3. Engine Oil B: REPLACEMENT 1) Open the engine oil filler cap for quick draining of A: INSPECTION the engine oil. 1) Park the vehicle on a level surface. 2) Lift-up the vehicle. 2) Remove the oil level gauge and wipe it clean. 3) Drain engine oil by loosening the engine oil drain 3) Reinsert the level gauge all the way.
  • Page 234 Engine Oil LUBRICATION 8) After the engine stops, recheck the oil level. If necessary, add engine oil up to the upper level on level gauge. LU-00213 (A) Oil level gauge (B) Engine oil filler cap (C) Upper level (D) Lower level (E) Approx.

  • Page 235: Oil Pump

    Oil Pump LUBRICATION 4. Oil Pump 9) Remove the crank pulley using ST. ST 499977400 CRANK PULLEY WRENCH A: REMOVAL (2.0 L model) 1) Disconnect the ground cable from battery. ST 499977100 CRANK PULLEY WRENCH (2.5 L model) IN-00203 LU-00012 2) Lift-up the vehicle.
  • Page 236 Oil Pump LUBRICATION 13) Remove the bolts which install oil pump onto 3) Apply a coat of engine oil to the inside of oil seal. cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
  • Page 237 Oil Pump LUBRICATION C: DISASSEMBLY D: ASSEMBLY Remove the screws which secure oil pump cover 1) Install the front oil seal using ST. and then disassemble oil pump. Inscribe alignment ST 499587100 OIL SEAL INSTALLER marks on the inner and outer rotors so that they can NOTE: be replaced in their original positions during reas- Use a new oil seal.
  • Page 238 Oil Pump LUBRICATION E: INSPECTION 3. SIDE CLEARANCE Measure the clearance between oil pump inner ro- 1. TIP CLEARANCE tor and pump cover. If the clearance is out of the Measure the tip clearance of rotors. If the clearance standard value, replace the rotor or oil pump case. is out of the standard value, replace the rotors as a Side clearance: matched set.

  • Page 239: Oil Pan And Strainer

    Oil Pan and Strainer LUBRICATION 5. Oil Pan and Strainer 8) Support the engine with a lifting device and wire ropes. A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the front wheels. 3) Disconnect the ground cable from battery. LU-00222 9) Lift-up the vehicle.
  • Page 240 Oil Pan and Strainer LUBRICATION 17) Remove the baffle plate. 3) Apply liquid gasket to the mating surfaces and install the oil pan. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent LU-00034 4) Tighten the bolts which install oil pan onto cylin- der block.
  • Page 241 Oil Pan and Strainer LUBRICATION 6) Tighten the nuts which install front cushion rub- 12) Install the hood stay holder (A) and radiator up- ber onto front crossmember. per brackets (B). Tightening torque: ⋅ 69 N m (7.0 kgf-m, 50.9 ft-lb) LU-00232 13) Install the air intake chamber.

  • Page 242: Oil Pressure Switch

    Oil Pressure Switch LUBRICATION 6. Oil Pressure Switch 2) Install the oil pressure switch onto engine block. Tightening torque: A: REMOVAL ⋅ 25 N m (2.5 kgf-m, 18.1 ft-lb) 1) Remove the generator from bracket. <Ref. to SC(H4SO 2.0)-14, REMOVAL, Genera- tor.>...

  • Page 243: Engine Oil Filter

    Engine Oil Filter LUBRICATION 7. Engine Oil Filter A: REMOVAL 1) Lift-up the vehicle. 2) Remove the oil filter using ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) LU-00234 B: INSTALLATION 1) Clean the oil filter installing surface on cylinder...

  • Page 244: General Diagnostic Table

    General Diagnostic Table LUBRICATION 8. General Diagnostic Table A: INSPECTION Before performing diagnosis, make sure that the engine oil level is correct and no oil leakage exists. Symptom Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace. 1) Oil pressure switch failure Broken spring or seized contacts...
  • Page 245 General Diagnostic Table LUBRICATION LU(H4SO 2.0)-20...
  • Page 246 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 247 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 248 SPEED CONTROL SYSTEMS SP(H4SO 2.0) Page General Description ..................2 Accelerator Pedal..................4...
  • Page 249 General Description SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION LHD model 50 — 63 mm (1.97 — 2.48 in) Accelerator pedal Stroke At pedal pad RHD model 53 — 65 mm (2.09 — 2.56 in) B: COMPONENT • LHD model SP-02002 ⋅...
  • Page 250 General Description SPEED CONTROL SYSTEMS • RHD model SP-02003 ⋅ Accelerator pedal ASSY Tightening torque: N m (kgf-m, ft-lb) Stopper T: 18 (1.8, 13.0) C: CAUTION • Wear work clothing, including a cap, protective goggles and protective shoes during operation. •...

  • Page 251: Accelerator Pedal

    Accelerator Pedal SPEED CONTROL SYSTEMS 2. Accelerator Pedal A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector. 3) Remove the nut securing accelerator pedal as- sembly. • LHD model SP-02001 • RHD model SP-00052 B: INSTALLATION Install in the reverse order of removal.
  • Page 252 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 253 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 254 IGNITION IG(H4SO 2.0) Page General Description ..................2 Spark Plug....................5 Ignition Coil & Ignitor ASSY ................8 Spark Plug Cord..................10...

  • Page 255: General Description

    General Description IGNITION 1. General Description A: SPECIFICATION 1. 2.0 L MODEL Item Designation Model CM12-100C Ignition coil & ignitor Manufacturer HITACHI ASSY Secondary coil resistance 18.0 kΩ± 20% Manufacturer and Type CHAMPION: RC10YC4 Thread size (diameter, pitch, length) 14, 1.25, 19 Spark plug Spark plug gap mm (in)
  • Page 256 General Description IGNITION B: COMPONENT • 2.0 L model IG-00016 ⋅ Spark plug Spark plug cord (#2, #4) Tightening torque: N m (kgf-m, ft-lb) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7) Ignition coil & ignitor ASSY T2: 21 (2.1, 15.2) IG(H4SO 2.0)-3...
  • Page 257 General Description IGNITION • 2.5 L model IG-00094 ⋅ Spark plug Spark plug cord (#2, #4) Tightening torque: N m (kgf-m, ft-lb) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7) Ignition coil & ignitor ASSY T2: 21 (2.1, 15.2) C: CAUTION •...

  • Page 258: Spark Plug

    Spark Plug IGNITION 2. Spark Plug 2. LH SIDE 1) Remove the battery. A: REMOVAL 2) Remove the spark plug cords by pulling the boot. CAUTION: (Do not pull the cord itself.) All spark plugs installed on an engine must be of the same heat range.
  • Page 259 Spark Plug IGNITION C: INSPECTION 3) Oil fouled: Wet black deposits show excessive oil entrance Check the electrodes and inner and outer ceramic into combustion chamber through worn rings and insulator of plugs, noting the type of deposits and pistons or excessive clearance between valve the degree of electrode erosion.
  • Page 260 Spark Plug IGNITION NOTE: Replace with a new spark plug if the area (A) is worn to spherical shape. IG(H4SO 2.0)-7...

  • Page 261: Ignition Coil & Ignitor Assy

    Ignition Coil & Ignitor ASSY IGNITION 3. Ignition Coil & Ignitor ASSY 4) Remove the bolt (B) which secures the ignition coil & ignitor ASSY to intake manifold. A: REMOVAL • 2.0 L model 1) Disconnect the ground cable from battery. IG-02002 IN-00203 •...
  • Page 262 Ignition Coil & Ignitor ASSY IGNITION Specified resistance (2.0 L model): [Secondary side] Between (A) and (B) Ω± 18.0 k Between (C) and (D) Ω± 18.0 k IG-02003 Specified resistance (2.5 L model): [Secondary side] Between (A) and (B) Ω± 11.2 k Between (C) and (D) Ω±...

  • Page 263: Spark Plug Cord

    Spark Plug Cord IGNITION 4. Spark Plug Cord A: INSPECTION Check the following items: • Damage to cords, deformation, burning or rust formation of terminals • Resistance values of cords Resistance value (2.0 L model): Ω #1 cord: 5.9 — 11.1 k Ω...
  • Page 264 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 265 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 266 STARTING/CHARGING SYSTEMS SC(H4SO 2.0) Page General Description ..................2 Starter ......................6 Generator ....................14 Battery.......................20...

  • Page 267: General Description

    General Description STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATION Item Specification Vehicle model Type Reduction type Model M000T30471 M000T20171 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Revolving direction Counterclockwise (when observed from pinion) Number of pinion teeth Voltage 11 V...
  • Page 268 General Description STARTING/CHARGING SYSTEMS B: COMPONENT 1. STARTER (10) (16) (12) (11) (14) (15) (13) SC-02005 Front bracket Internal gear ASSY (13) Brush holder ASSY Sleeve bearing Shaft ASSY (14) Sleeve bearing Lever set Gear ASSY (15) Rear cover Magnet switch ASSY (10) Packing (16)
  • Page 269 General Description STARTING/CHARGING SYSTEMS 2. GENERATOR (13) (12) (11) (10) SC-00163 Pulley nut Bearing (13) Terminal Pulley Stator coil ⋅ Front cover IC regulator with brush Tightening torque: N m (kgf-m, ft-lb) Ball bearing (10) Brush T1: 4.7 (0.48, 3.5) Bearing retainer (11) Rectifier...
  • Page 270 General Description STARTING/CHARGING SYSTEMS C: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust and dirt.

  • Page 271: Starter

    Starter STARTING/CHARGING SYSTEMS 2. Starter 5) Disconnect the connector and terminal from starter. A: REMOVAL 1) Disconnect the ground cable from battery. SC-00006 (A) Terminals IN-00203 (B) Connector 2) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air In- 6) Remove the starter from transmission.
  • Page 272 Starter STARTING/CHARGING SYSTEMS C: DISASSEMBLY 4) Remove the through-bolts and brush holder screws of both sides, and then detach the rear cov- 1. STARTER ASSEMBLY er and brush holder assembly. 1) Loosen the nut which holds terminal M of switch assembly, and then disconnect the connector.
  • Page 273 Starter STARTING/CHARGING SYSTEMS 7) Remove the plate. (2) Remove the ring, stopper and clutch from shaft. SC-00065 (A) Plate 8) Remove the shaft assembly and overrunning clutch from front bracket as a unit. NOTE: Check the following points before removal. •...
  • Page 274 Starter STARTING/CHARGING SYSTEMS (1) Insert the ring into the shaft groove by lightly (2) Internal gear position tapping it with an appropriate tool (such as a fit socket wrench). SC-00070 4) Install the plate. SC-00067 (A) Ring (B) Stopper (2) Install the stopper to ring using a press. SC-00065 (A) Plate 5) Install the planetary gear.
  • Page 275 Starter STARTING/CHARGING SYSTEMS 8) Install the yoke to front bracket matching front 10) Install the rear cover matching it’s groove to bracket to the groove of yoke assembly. brush holder assembly. SC-00072 SC-00062 9) Install the brush holder to yoke assembly as fol- (A) Brush holder ASSY lows.
  • Page 276 Starter STARTING/CHARGING SYSTEMS 13) Connect the connector to terminal M of switch Depth of segment mold: assembly. 0.5 mm (0.020 in) SC-00059 SC-00022 (A) Terminal M (A) Depth of mold (B) Segment E: INSPECTION (C) Mold 1. ARMATURE 4) Armature short-circuit test 1) Check the commutator for any sign of burns of Check the armature for short-circuit by placing it on rough surfaces or stepped wear.
  • Page 277 Starter STARTING/CHARGING SYSTEMS 2. YOKE 5. SWITCH ASSEMBLY Make sure the pole is set in position. Be sure there is continuity between the terminals S and M, and between terminal S and ground. Use a 3. OVERRUNNING CLUTCH circuit tester (set in “ohm”). Inspect the teeth of pinion for wear and damage.
  • Page 278 Starter STARTING/CHARGING SYSTEMS 7. PERFORMANCE TEST Current / Speed MT model The starter should be submitted to performance 300 A / 870 rpm or more tests whenever it has been overhauled, to assure AT model its satisfactory performance when installed on the 400 A / 710 rpm or more engine.

  • Page 279: Generator

    Generator STARTING/CHARGING SYSTEMS 3. Generator 5) Remove the bolts which install the generator onto bracket. A: REMOVAL 1) Disconnect the ground cable from battery. SC-00179 B: INSTALLATION IN-00203 Install in the reverse order of removal. 2) Disconnect the connector and terminal from Tightening torque: generator.
  • Page 280 Generator STARTING/CHARGING SYSTEMS 2) Heat portion (A) of rear cover to 50°C (122°F) CAUTION: with a heater drier. When holding the rotor with a vise, place alumi- num plates or wooden pieces on the vise jaws to prevent rotor from damage. SC-00079 3) Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover.
  • Page 281 Generator STARTING/CHARGING SYSTEMS 6) Remove the bearing from rotor using a bearing (2) Unsolder the connection between IC regula- puller. tor and rectifier to remove the IC regulator. SC-00046 SC-00085 7) Unsolder connection between rectifier and stator 9) Remove the brush as follows. coil to remove the stator coil.
  • Page 282 Generator STARTING/CHARGING SYSTEMS 10) Remove the rectifier as follows. CAUTION: (1) Remove the bolt which secures the rectifier. Be sure to remove the wire after reassembly. SC-00089 SC-00092 (2) Remove the cover of terminal B. (A) Wire 2) Install the ball bearing. (1) Set the ball bearing on the front cover, and then securely install an appropriate tool (such as a fit socket wrench) to the bearing outer race.
  • Page 283 Generator STARTING/CHARGING SYSTEMS E: INSPECTION Slip ring outer diameter: Standard 1. DIODE 22.7 mm (0.894 in) Limit CAUTION: 22.1 mm (0.870 in) Never use a mega tester (designed for reading 3) Continuity test high voltage) or any other similar instrument Check the resistance between slip rings using cir- for this test;...
  • Page 284 Generator STARTING/CHARGING SYSTEMS 3. STATOR Brush length: Service limit (1) 1) Continuity test 5.0 mm (0.197 in) Inspect the stator coil for continuity between each Standard (2) end of the lead wires. If resistance is 1 MΩ or more, 18.5 mm (0.728 in) the lead wire is broken, and so replace the stator assembly.

  • Page 285: Battery

    Battery STARTING/CHARGING SYSTEMS 4. Battery • To lessen the risk of sparks, remove rings, metal watch-bands, and other metal jewelry. A: REMOVAL Never allow metal tools to contact the positive 1) Disconnect the positive (+) terminal after discon- battery terminal and anything connected to it while you are at the same time in contact with necting the negative (−) terminal of battery.
  • Page 286 Battery STARTING/CHARGING SYSTEMS D: MEASUREMENT 4. QUICK CHARGING Quick charging is a method that the battery is WARNING: charged in a short period of time with a relatively Do not bring an open flame close to the battery large current by using a quick charger. at this time.
  • Page 287 Battery STARTING/CHARGING SYSTEMS SC(H4SO 2.0)-22...
  • Page 288 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 289 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 290 Electrical Component Location ..............8 Engine Control Module (ECM) I/O Signal ..........17 Engine Condition Data ................21 Data Link Connector .................22 OBD-II General Scan Tool ................23 Subaru Select Monitor................25 Read Diagnostic Trouble Code (DTC) ............31 Inspection Mode..................32 Drive Cycle....................36 Clear Memory Mode..................38 Compulsory Valve Operation Check Mode ..........39...

  • Page 291: Basic Diagnostic Procedure

    Repair the related 1) Turn the ignition switch to OFF. aru Select Monitor? Repair the trouble parts. 2) Connect the Subaru Select Monitor to data cause. <Ref. to NOTE: link connector. EN(H4SO 3) Turn the ignition switch to ON, and the Sub- 2.0)(diag)-66, List...

  • Page 292: Check List For Interview

    Check List for Interview ENGINE (DIAGNOSTICS) 2. Check List for Interview CHECK 1. CHECK LIST No. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Engine No. Date of sale Fuel brand Date of repair Odometer reading...
  • Page 293 Check List for Interview ENGINE (DIAGNOSTICS) 2. CHECK LIST No. 2 Check the following items about the vehicle’s state when malfunction indicator light turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. ❏ Yes / ❏ No ❏...

  • Page 294: General Description

    General Description ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts as the grounding point to body when measuring voltage and resis- A: CAUTION tance inside the passenger compartment. 1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay.
  • Page 295 Calling the self-diagnosis result is performed by the performing diagnostics. Subaru Select Monitor. 15) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most impor- tant thing in diagnostics is to understand the cus- tomer’s complaint, and distinguish between the...
  • Page 296 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...

  • Page 297: Electrical Component Location

    Electrical Component Location ENGINE (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION 1. ENGINE • Control module EN-02413 EN-02451 Engine control module (ECM) Test mode connector Data link connector Malfunction indicator light EN(H4SO 2.0)(diag)-8...
  • Page 298 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01966 EN-01147 EN-02414 AT-01877 EN(H4SO 2.0)(diag)-9...
  • Page 299 Electrical Component Location ENGINE (DIAGNOSTICS) • Sensor EN-02415 Intake air temperature sensor Electronic throttle control Camshaft position sensor Manifold absolute pressure sensor Knock sensor Crankshaft position sensor Engine coolant temperature sen- EN(H4SO 2.0)(diag)-10...
  • Page 300 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02416 EN-02417 EN-02179 EN-02418 EN-00010 EN-00011 EN-00012 EN(H4SO 2.0)(diag)-11...
  • Page 301 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01973 Front oxygen (A/F) sensor Front catalytic converter Rear catalytic converter Rear oxygen sensor EN-02091 EN-02092 EN(H4SO 2.0)(diag)-12...
  • Page 302 Electrical Component Location ENGINE (DIAGNOSTICS) • Solenoid valve, actuator, emission control system parts and ignition system parts EN-02419 Purge control solenoid valve EGR Valve (EC, EK, K4 model) Ignition coil & ignitor ASSY EN(H4SO 2.0)(diag)-13...
  • Page 303 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02420 EN-02421 EN-02422 EN(H4SO 2.0)(diag)-14...
  • Page 304 Electrical Component Location ENGINE (DIAGNOSTICS) (4) (3) (6) (9) EN-02423 (8) (7) EN-01979 Inhibitor switch Fuel pump relay Radiator sub fan relay Fuel pump Electronic throttle control relay Radiator main fan relay 2 Main relay Radiator main fan relay 1 Starter EN(H4SO 2.0)(diag)-15...
  • Page 305 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02093 EN-00178 EN-02094 EN-02095 EN-02096 EN(H4SO 2.0)(diag)-16...

  • Page 306: Engine Control Module (Ecm) I/O Signal

    Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 18 19 20 21 22 23 26 27 20 21...
  • Page 307 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Connector Terminal DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) Electronic throttle control B137 Duty waveform Duty waveform Drive frequency: 1 kHz motor 2 (−) Electronic throttle control B137 10 —...
  • Page 308 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Connector Terminal DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) ON: 0.5 or less ON: 0.5 or less A/C relay control B135 — OFF: 10 — 13 OFF: 13 — 14 ON: 0.5 or less ON: 0.5 or less Radiator fan relay 1 control...
  • Page 309 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Connector Terminal DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) GND (sensor 2) B137 — GND (injector) B134 — B134 — GND (power supply) B137 — B136 — GND (control system) B136 —...

  • Page 310: Engine Condition Data

    Engine Condition Data ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Remarks SPECIFICATION 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm Racing Measuring condition: • After engine is warmed-up. • Gear position is in “N” or “P” range. •...

  • Page 311: Data Link Connector

    This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools except for OBD-II general scan tool and Subaru Select Monitor, be- cause the circuit for Subaru Select Monitor may be damaged. 9 10 11 12 13 EN-00037 Terminal No.

  • Page 312: Obd-Ii General Scan Tool

    OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 8. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up DTC and freeze frame data. A: OPERATION OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic 1.
  • Page 313 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is detected by on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure DTC that caused CARB to require freeze frame data storage...

  • Page 314: Subaru Select Monitor

    5) Turn the ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON. A: OPERATION 1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION TOOL, General Description.> EN-00040...
  • Page 315 Subaru Select Monitor ENGINE (DIAGNOSTICS) 4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
  • Page 316 Main switch signal Main Switch — OFF (At OFF) Integrated unit data reception Body Int. Unit Data — Integrated unit data update Body Int. Unit Count — NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.0)(diag)-27...
  • Page 317 EGR system incomplete NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. 6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
  • Page 318 Subaru Select Monitor ENGINE (DIAGNOSTICS) 7. LED OPERATION MODE FOR ENGINE 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
  • Page 319 Data reception signal Body Int. Unit Data ON or OFF entered. When counter update signal is Counter update signal Body Int. Unit Count ON or OFF entered. NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.0)(diag)-30...

  • Page 320: Read Diagnostic Trouble Code (Dtc)

    Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.

  • Page 321: Inspection Mode

    Inspection Mode ENGINE (DIAGNOSTICS) 11.Inspection Mode A: OPERATION Carry out trouble diagnosis shown in the following DTC table. When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle. <Ref. to EN(H4SO 2.0)(diag)-36, Drive Cycle.> Item P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
  • Page 322 Inspection Mode ENGINE (DIAGNOSTICS) Item P1570 Antenna P1571 Reference Code Incompatibility P1572 IMM Circuit Failure (Except Antenna Circuit) P1574 Key Communication Failure P1576 EGI Control Module EEPROM P1577 IMM Control Module EEPROM P1578 Meter Failure P2101 Throttle Actuator Control Motor Circuit Range/Performance P2102 Throttle Actuator Control Motor Circuit Low P2103...
  • Page 323 Inspection Mode ENGINE (DIAGNOSTICS) 2. SUBARU SELECT MONITOR 7) Connect the Subaru Select Monitor to data link connector located in the lower portion of the instru- 1) After clearing the memory, check for any remain- ment panel (on the driver’s side).
  • Page 324 Inspection Mode ENGINE (DIAGNOSTICS) • The speed difference between front and rear 9) Place the select lever or shift lever in “D” position wheels may light the ABS warning light, but this in- (AT model) or “1st” gear (MT model) and drive the dicates no malfunctions.

  • Page 325: Drive Cycle

    Drive Cycle ENGINE (DIAGNOSTICS) 12.Drive Cycle A: PROCEDURE There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check whether they correctly resume their functions by driving in the required drive pattern. 1.
  • Page 326 Drive Cycle ENGINE (DIAGNOSTICS) 3. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN 96 (60) 65 (40) EN-00195 Idle engine for 1 minute. Decelerate with throttle fully Accelerate to 96 km/h (60 MPH) closed to 65 km/h (40 MPH). within 10 seconds. Accelerate to 96 km/h (60 MPH) within 20 seconds.

  • Page 327: Clear Memory Mode

    {Memory Clear} and press the [YES] key. 5) When the “Done” and “Turn Ignition Switch OFF” are shown on the display screen, turn the ignition switch to OFF and then Subaru Select Monitor switch to OFF. NOTE: • Initial diagnosis of electronic control throttle is performed after memory clearance.

  • Page 328: Compulsory Valve Operation Check Mode

    Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) 14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link connector located in the lower portion of instrument Check Mode panel (on the driver’s side). A: PROCEDURE 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION TOOL,...
  • Page 329 Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) • A list of the support data is shown in the following table. DESCRIPTION Display Compulsory fuel pump relay oper- Fuel Pump ation check Compulsory radiator fan relay Radiator Fan Relay operation check Compulsory air conditioning relay A/C Compressor Relay operation check...

  • Page 330: Malfunction Indicator Light

    Malfunction Indicator Light ENGINE (DIAGNOSTICS) 15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.0)(diag)-42, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> ↓ 2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.0)(diag)-43, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>...

  • Page 331: Indicator Light

    Malfunction Indicator Light ENGINE (DIAGNOSTICS) B: ACTIVATION OF MALFUNCTION (3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Mal- INDICATOR LIGHT function indicator light illuminates if faulty. 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the com- bination meter illuminates.
  • Page 332 Malfunction Indicator Light ENGINE (DIAGNOSTICS) C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON DIAGNOSIS: The malfunction indicator light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not come on. WIRING DIAGRAM: IGNITION SWITCH...
  • Page 333 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 4. Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM con- nector and chassis ground.
  • Page 334 D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF. DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor display. WIRING DIAGRAM: IGNITION...
  • Page 335 Malfunction Indicator Light ENGINE (DIAGNOSTICS) E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK. DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • Test mode connector circuit is in open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during inspection mode. WIRING DIAGRAM: •...
  • Page 336 Malfunction Indicator Light ENGINE (DIAGNOSTICS) • RHD model IGNITION SWITCH BATTERY SBF-7 SBF-1 No.5 COMBINATION METER B135 1 2 3 4 5 6 7 8 9 6 7 8 9 10 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 4 5 6 B135...
  • Page 337 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator Go to step 2. Repair the mal- CATOR LIGHT. light illuminate? function indictor 1) Turn the ignition switch to OFF. light circuit. <Ref. 2) Disconnect the test mode connectors. to EN(H4SO 3) Turn the ignition switch to ON.
  • Page 338 Malfunction Indicator Light ENGINE (DIAGNOSTICS) F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING. DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when test mode connector is not connected. WIRING DIAGRAM: • LHD model IGNITION SWITCH BATTERY SBF-7 SBF-1 No.5 COMBINATION...
  • Page 339 Malfunction Indicator Light ENGINE (DIAGNOSTICS) • RHD model IGNITION SWITCH BATTERY SBF-7 SBF-1 No.5 COMBINATION METER B135 1 2 3 4 5 6 7 8 9 6 7 8 9 10 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 4 5 6 B135...

  • Page 340: Diagnostics For Engine Starting Failure

    Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) 16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check for fuel amount. ↓ 2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.0)(diag)-52, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start- ing Failure.> ↓ 3.
  • Page 341 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
  • Page 342 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK BATTERY. Is the voltage more than 12 V? Go to step 2. Charge or replace Check the battery voltage. the battery. CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Go to step 3.
  • Page 343 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF STARTER RE- Is the voltage more than 10 V? Go to step 9. Repair the open LAY. circuit in harness 1) Turn the ignition switch to OFF. between starter 2) Disconnect the connector from starter relay.

  • Page 344: Wiring Diagram

    Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MOD- ULE (ECM) CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
  • Page 345 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK MAIN RELAY. Is the resistance less than 10 Go to step 2. Replace the main Ω? 1) Turn the ignition switch to OFF. relay. 2) Remove the main relay. 3) Connect the battery to main relay terminals No.
  • Page 346 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair the open or 1) Turn the ignition switch to ON. control system. ground short cir- 2) Measure the voltage between ECM con- <Ref.
  • Page 347 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
  • Page 348 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check fuel pump Go to step 2. 1) Remove the plug cord cap from each spark inder? system. <Ref. to plug.
  • Page 349 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 7. Repair the har- Ω? NITION COIL & IGNITOR ASSY CONNEC- ness and connec- TOR. tor. 1) Turn the ignition switch to OFF.
  • Page 350 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) E: FUEL PUMP CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
  • Page 351 CIRCUIT, Diag- NOTE: nostics for Engine Fuel pump operation can also be executed us- Starting Failure.> ing Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.0)(diag)-39, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP.
  • Page 352 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 connector from ECM. between ECM and 2) Measure the resistance of harness fuel pump relay...
  • Page 353 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(di- ag)-38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OP- ERATION, Inspection Mode.>.
  • Page 354 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit oper- Check the fuel Go to step 2. TOR. ating sound? pressure. <Ref. to While cranking the engine, check each fuel ME(H4SO 2.0)-27, injector emits operating sound.

  • Page 355: List Of Diagnostic Trouble Code (Dtc)

    List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 17.List of Diagnostic Trouble Code (DTC) A: LIST Item NOTE P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H4SO 2.0)(diag)-71, DTC P0030 HO2S HEATER CONTROL Sensor 1) CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...

  • Page 356: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0134 O2 Sensor Circuit No Activity <Ref. to EN(H4SO 2.0)(diag)-116, DTC P0134 O2 SENSOR CIRCUIT NO Detected (Bank 1 Sensor 1) ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 357 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0463 Fuel Level Sensor Circuit High Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0463 FUEL LEVEL SENSOR CIR- CUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0500 Vehicle Speed Sensor <Ref.
  • Page 358 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1494 EGR Solenoid Valve Signal #2 Cir- <Ref. to EN(H4SO 2.0)(diag)-181, DTC P1494 EGR SOLENOID VALVE cuit Malfunction (Low Input) SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1495 EGR Solenoid Valve Signal #2 Cir- <Ref.
  • Page 359 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P2111 Throttle Actuator Control System - <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2111 THROTTLE ACTUATOR Stuck Open CONTROL SYSTEM - STUCK OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P2122 Throttle/Pedal Position Sensor/ <Ref.
  • Page 360 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 18.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 361 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? FRONT OXYGEN (A/F) SENSOR CONNEC- circuit in harness TOR. between ECM and 1) Start and warm-up the engine.
  • Page 362 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 363 Go to step 5. 1) Start the engine. contact connector. 2) Read the data of front oxygen (A/F) sensor NOTE: heater current using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”.
  • Page 364 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 10 Repair the har- Replace the front Ω? 1) Turn the ignition switch to OFF. ness and connec- oxygen (A/F) sen- 2) Measure the resistance between front oxy- tor.
  • Page 365 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) C: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 366 (ECM).> connector. 3) Turn the ignition switch to ON. 4) Read the data of front oxygen (A/F) sensor heater current using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.>...
  • Page 367 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) D: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 368 NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”. <Ref. rear oxygen sen- to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- sor connector itor.> • Poor contact in rear oxygen sen- sor connecting harness connector •...
  • Page 369 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 V? Go to step 7. Repair the power GEN SENSOR. supply line. 1) Turn the ignition switch to OFF. NOTE: 2) Disconnect the connector from rear oxygen In this case, repair...
  • Page 370 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) E: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 371 4) Read the data of rear oxygen sensor heater current using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.> CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END.
  • Page 372 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) F: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 373 Go to step 2. 1) Start the engine. (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.>...
  • Page 374 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 9. Repair the open Ω? MANIFOLD ABSOLUTE PRESSURE SEN- circuit in harness SOR CONNECTOR. between ECM and 1) Turn the ignition switch to OFF.
  • Page 375 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) G: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 376 1) Start the engine. kPa (896.5 mmHg, 35.29 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.>...
  • Page 377 ECM and sure sensor. <Ref. 1) Turn the ignition switch to OFF, and the manifold absolute to FU(H4SO 2.0)- Subaru Select Monitor switch to OFF. pressure sensor 26, Manifold Abso- 2) Disconnect the connector from manifold connector. lute Pressure Sen- absolute pressure sensor.
  • Page 378 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) H: DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 379 1) Start the engine. more than 120°C (248°F)? contact. 2) Read the data of intake air temperature NOTE: sensor signal using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”.
  • Page 380 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) I: DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 381 −40°C (−40°F)? 1) Start the engine. contact. 2) Read the data of intake air temperature NOTE: sensor signal using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to • Poor contact in “READ CURRENT DATA FOR ENGINE”.
  • Page 382 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5 Replace the intake Repair the har- Ω? TEMPERATURE SENSOR AND ECM CON- air temperature ness and connec- NECTOR. sensor.
  • Page 383 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) J: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Hard to start • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 384 Repair the poor 1) Start the engine. ture more than 150°C (302°F)? contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
  • Page 385 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) K: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Hard to start • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 386 Repair the poor ture less than −40°C (−40°F)? 1) Start the engine. contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
  • Page 387 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair the har- Ω? COOLANT TEMPERATURE SENSOR AND engine coolant ness and connec- ECM CONNECTOR. temperature sen- tor.
  • Page 388 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) L: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 389 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 390 Is the voltage more than 0.4 V? Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
  • Page 391 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) M: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 392 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 393 Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
  • Page 394 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) N: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 395 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 396 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) O: DTC P0130 O2 SENSOR CIRCUIT (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 397 Is the voltage 0.85 — 1.15 V? Go to step 3. Go to step 4. 1) Start the engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70°C (160°F).
  • Page 398 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the front Check exhaust system parts. system? faulty parts. oxygen (A/F) sen- sor. <Ref. to NOTE: FU(H4SO 2.0)-32, Check the following items.
  • Page 399 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) P: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 400 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Replace the front Repair the ground FRONT OXYGEN (A/F) SENSOR CONNEC- MΩ? oxygen (A/F) sen- short circuit in har- TOR.
  • Page 401 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 402 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 8 V? Replace the front Repair the battery FRONT OXYGEN (A/F) SENSOR CONNEC- oxygen (A/F) sen- short circuit in har- TOR.
  • Page 403 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) R: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 404 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 405 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) S: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN- SOR 1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 406 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 407 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) T: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 408 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 4.
  • Page 409 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the rear Check exhaust system parts. system? the faulty part. oxygen sensor. <Ref. to FU(H4SO NOTE: 2.0)-33, Rear Oxy- Check the following items: gen Sensor.>...
  • Page 410 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) U: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 411 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 4.
  • Page 412 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the rear Check exhaust system parts. system? the faulty part. oxygen sensor. <Ref. to FU(H4SO NOTE: 2.0)-33, Rear Oxy- Check the following items: gen Sensor.>...
  • Page 413 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) V: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 414 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the rear “List of Diagnostic oxygen sensor. Trouble Code <Ref. to FU(H4SO (DTC)”. <Ref. to 2.0)-33, Rear Oxy- EN(H4SO gen Sensor.>...
  • Page 415 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) W: DTC P0171 SYSTEM TOO LEAN (BANK 1) Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO 2.0)(diag)-126, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> X: DTC P0172 SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault...
  • Page 416 70 — 100°C (158 — engine coolant 1) Start the engine and warm-up completely. 212°F)? temperature sen- 2) Read the data of engine coolant tempera- sor. <Ref. to ture sensor signal using Subaru Select Moni- FU(H4SO 2.0)-20, tor. Engine Coolant Temperature Sen- NOTE: sor.>...
  • Page 417 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Y: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 418 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 419 Is the voltage more than 0.8 V? Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor...
  • Page 420 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Z: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 421 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 422 Go to step 2. Go to step 3. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
  • Page 423 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AA:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO 2.0)(diag)-135, DTC P0304 CYLIN- DER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AB:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.
  • Page 424 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AD:DTC P0304 CYLINDER 4 MISFIRE DETECTED DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • Immediately at fault recognition (A misfire which could damage catalyst occurs.) TROUBLE SYMPTOM: • Engine stalls. •...
  • Page 425 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 426 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 427 Does the malfunction indicator Go to step 15. Go to step 14. CATOR LIGHT. light illuminate or blink? 1) Clear the memory using Subaru Select Monitor. <Ref. to EN(H4SO 2.0)(diag)-38, Clear Mem- ory Mode.> 2) Start the engine, and drive the vehicle more than 10 minutes.
  • Page 428 • Are there cracks or any disconnec- tion of hoses? CHECK MISFIRE SYMPTOM. Does the Subaru Select Moni- Go to step 21. Go to step 17. 1) Turn the ignition switch to ON. tor or OBD-II general scan tool 2) Read the DTC.
  • Page 429 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #1 AND #2 CYLINDERS Are there any faults in #1 and Repair or replace Go to DTC P0171. #2 cylinders? faulty parts. <Ref. to EN(H4SO 2.0)(diag)-126, NOTE: DTC P0171 SYS- •...
  • Page 430 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check GROUP OF #2 AND #4 CYLINDERS Are there any faults in #2 and Repair or replace Go to DTC P0171. #4 cylinders? faulty parts. <Ref. to EN(H4SO 2.0)(diag)-126, NOTE: DTC P0171 SYS- Check the follow- TEM TOO LEAN...
  • Page 431 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AE:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 432 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 433 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AF:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 434 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2. Go to step 3. SOR AND ECM CONNECTOR. kΩ? Measure the resistance of harness between ECM connector and chassis ground.
  • Page 435 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AG:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 436 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 437 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AH:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN- GLE SENSOR) DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 438 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 439 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0400 EXHAUST GAS RECIRCULATION FLOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Movement performance problem when engine is low speed. • Erroneous idling • Movement performance problem CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 440 1) Start the engine. kPa (400 mmHg, 15.75 inHg)? EGR valve, mani- 2) Read the data of intake manifold absolute fold absolute pres- pressure signal using Subaru Select Monitor. sure sensor and throttle body are NOTE: installed securely. For detailed operation procedure, refer to “READ CURRENT DATA FOR ENGINE”.
  • Page 441 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN EGR SOLE- Is the resistance less than 1 Go to step 7. Repair the open Ω? NOID VALVE AND ECM CONNECTOR. circuit in harness 1) Turn the ignition switch to OFF. between ECM and 2) Detach the connector from EGR solenoid EGR solenoid...
  • Page 442 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 443 2) Measure the resistance between rear oxy- sor. gen sensor connector and ECM connector. Connector & terminals (B19) No. 3 — (B136) No. 18: CHECK SHIELD HARNESS. Is the shield harness opened? Repair the shield Contact with your harness. Subaru distributor service. EN(H4SO 2.0)(diag)-154...
  • Page 444 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AK:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT LOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 445 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if the mal- Go to step 2. 1) Turn the ignition switch to ON. function indicator 2) Measure the voltage between ECM and light illuminates, chassis ground.
  • Page 446 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AL:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT HIGH DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 447 ECM connector. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.0)(diag)-39, Compulsory Valve Operation Check Mode.> Connector & terminal −...
  • Page 448 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0462 appear on Check the combi- Temporary poor the Subaru Select Monitor? nation meter. contact occurs. <Ref. to IDI-3, Combination Meter System.> AN:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT...
  • Page 449 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AP:DTC P0512 STARTER REQUEST CIRCUIT DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 450 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY B225 STARTER MOTOR B135 B225 B135 1 2 3 4 1 2 3 4 5 6 5 6 7 8 7 8 9 10 11 12 4 5 6 13 14 15 16 17 10 11 12...
  • Page 451 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check starter Turn the ignition switch to ON. ate? short circuit in motor circuit. <Ref. starter motor cir- to EN(H4SO NOTE: cuit.
  • Page 452 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AQ:DTC P0519 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 453 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AS:DTC P0559 GENERATOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
  • Page 454 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN GENERATOR Is the resistance more than 1 Go to step 2. Repair the ground AND ECM CONNECTOR. MΩ? short circuit in har- 1) Turn the ignition switch to OFF. ness between 2) Disconnect the connectors from generator ECM and purge...
  • Page 455 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AU:DTC P0604 INTERNAL CONTROL MODULE READ ACCESS MEMORY (RAM) ERROR DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 456 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele- Temporary poor vant DTC using contact occurs. “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou-...
  • Page 457 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AW:DTC P0607 CONTROL MODULE PERFORMANCE DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 458 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 — 13 V? Go to step 2. Repair the open or 1) Turn the ignition switch to ON. ground short cir- 2) Measure the voltage between ECM con- cuit of power sup- nector and chassis ground.
  • Page 459 Step Check CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0691 appear on Check the radiator Temporary poor the Subaru Select Monitor? fan system. <Ref. contact occurs. to CO(H4SO 2.0)- 7, Radiator Fan System.> AZ:DTC P0692 COOLING FAN 1 CONTROL CIRCUIT HIGH...
  • Page 460 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BB:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 461 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 462 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BC:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 463 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 464 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Go to step 8. Repair the open Ω? Measure the resistance of harness between circuit in harness inhibitor switch connector and engine ground. between inhibitor Connector &...
  • Page 465 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BD:DTC P1134 A/F SENSOR MICRO-COMPUTER PROBLEM DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, Inspec- tion Mode.>.
  • Page 466 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the ECM. the List of Diag- <Ref. to FU(H4SO nostic Trouble 2.0)-34, Engine Code (DTC). <Ref. Control Module to EN(H4SO (ECM).>...
  • Page 467 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BE: DTC P1137 O2 SENSOR CIRCUIT (BANK1 SENSOR1) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 468 Is the voltage 0.85 — 1.15 V? Go to step 3. Go to step 4. 1) Start the engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70°C (160°F).
  • Page 469 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the front Check exhaust system parts. system? faulty parts. oxygen (A/F) sen- sor. <Ref. to NOTE: FU(H4SO 2.0)-32, Check the following items.
  • Page 470 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BF:DTC P1160 RETURN SPRING FAILURE NOTE: For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos- tic Trouble Code (DTC).> BG:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) NOTE:...
  • Page 471 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BM:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 472 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EGR SOLE- Is the voltage more than 10 V? Go to step 2. Repair the har- NOID VALVE. ness and connec- 1) Turn the ignition switch to OFF. tor.
  • Page 473 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BN:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 474 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 475 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BO:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 476 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY B225 STARTER MOTOR B135 B225 B135 1 2 3 4 1 2 3 4 5 6 5 6 7 8 7 8 9 10 11 12 4 5 6 13 14 15 16 17 10 11 12...
  • Page 477 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check starter Place the inhibitor switch in the “P” or “N” when ignition switch to ness and connec- motor circuit.
  • Page 478 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BP:DTC P1521 BRAKE SWITCH CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 479 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 2. Go to step 3. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground.
  • Page 480 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BQ:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER- ATION, Inspection Mode.>.
  • Page 481 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the poor Go to step 2. 1) Turn the ignition switch to OFF. contact in ECM 2) Measure the voltage between ECM and connector.
  • Page 482 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BS:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 483 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 484 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Go to step 2. Replace the elec- Ω? TROL RELAY. tronic throttle con- 1) Turn the ignition switch to OFF. trol relay.
  • Page 485 Go to step 16. 1) Connect all the connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 15.
  • Page 486 3) Turn the ignition switch to ON. Replace the elec- 4) Read the data of main throttle sensor signal tronic throttle con- using Subaru Select Monitor. trol if defective. CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 23.
  • Page 487 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 24. Repair the open Ω? ELECTRONIC THROTTLE CONTROL MO- circuit of harness TOR. connector. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM.
  • Page 488 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Does the valve return to the Repair the poor Replace the elec- TROL. specified position? contact in ECM tronic throttle con- Move the throttle valve to the fully open and Standard value: 3 mm (0.12 in) connector.
  • Page 489 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BT:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 490 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 491 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Go to step 2. Replace the elec- Ω? TROL RELAY. tronic throttle con- 1) Turn the ignition switch to OFF. trol relay.
  • Page 492 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BU:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 493 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 494 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ELECTRONIC THROTTLE CON- Is the resistance more than 1 Go to step 2. Replace the elec- TROL RELAY. MΩ? tronic throttle con- 1) Turn the ignition switch to OFF. trol relay.
  • Page 495 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BX:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 496 Is the voltage more than 0.4 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 497 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCELERATOR POSITION SEN- Is the resistance 0.5 — 2.5 Repair the poor Replace the accel- SOR. kΩ? contact in ECM erator position Measure the resistance of accelerator position connector.
  • Page 498 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BY:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 499 Is the voltage less than 4.8 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 500 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BZ:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 501 Is the voltage more than 0.4 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 502 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCELERATOR POSITION SEN- Is the resistance 0.28 — 1.68 Repair the poor Replace the accel- SOR. kΩ? contact in ECM erator position 1) Measure the resistance of accelerator posi- connector.
  • Page 503 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CA:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 504 Is the voltage less than 4.8 V? Go to step 2. Go to step 3. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 505 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CB:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” / “B” VOLTAGE RATIONALITY DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 506 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B134 B136 B137 :LHD B138 :RHD :LHD B138 :RHD ELECTRONIC THROTTLE CONTROL B362 B138 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6 12 13 14 15 16 17 18 19 20 21 22...
  • Page 507 Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage more than 0.8 V? Go to step 3. Go to step 4.
  • Page 508 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact. contact occurred, ECM and electronic throttle control. but it is normal at present.
  • Page 509 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CC:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)- 38, OPERATION, Clear Memory Mode.>...
  • Page 510 SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal and sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 12.
  • Page 511 2) Connect all the connectors. 3) Turn the ignition switch to ON. 4) Read the data of main throttle sensor signal and sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 18.
  • Page 512 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1 Go to step 18. Repair the short CELERATOR POSITION SENSOR. MΩ? circuit to sensor 1) Turn the ignition switch to OFF. power supply.
  • Page 513 General Diagnostic Table ENGINE (DIAGNOSTICS) 19.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in General.> Symptom Problem parts 1) Manifold absolute pressure sensor 2) Intake air temperature sensor 3) Ignition parts (*1) 1.
  • Page 514 General Diagnostic Table ENGINE (DIAGNOSTICS) Symptom Problem parts 1) Intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 6. Surge 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay 9) EGR valve...
  • Page 515 General Diagnostic Table ENGINE (DIAGNOSTICS) EN(H4SO 2.0)(diag)-226...
  • Page 516 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 517 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 518 FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.5) Page General Description ..................2 Throttle Body...................11 Intake Manifold ..................12 Engine Coolant Temperature Sensor............20 Crankshaft Position Sensor ..............21 Camshaft Position Sensor ..............22 Knock Sensor ..................23 Throttle Position Sensor ................24 Manifold Absolute Pressure Sensor .............25 Mass Air Flow and Intake Air Temperature Sensor ......26 Intake Air Temperature Sensor..............27 Tumble Generator Valve Assembly............28 Tumble Generator Valve Actuator ............29...
  • Page 519 General Description FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATION 64 2(16.9 US gal, 14.1 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 441 — 686 kPa (4.50 — 7.00 kg/cm , 64.0 — 99.5 psi) Fuel pump 75 2 (19.8 US gal, 16.5 Imp gal)/h or more Discharge...
  • Page 520 General Description FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (18) (17) (10) (17) (24) (11) (23) (15) (25) (13) (12) (15) (14) (11) (13) (16) (12) (14) (15) (15) (13) (13) (12) (12) (14) (14) (22) (20) (21) (21) (19) (21)
  • Page 521 General Description FUEL INJECTION (FUEL SYSTEMS) Intake manifold (11) Fuel injector pipe (24) Nipple (RHD model) Gasket (EC, EK and K4 model) (12) Fuel injector (25) Nipple (LHD model) Tumble generator valve ASSY (13) O-ring ⋅ (EC, EK and K4 model) (14) O-ring Tightening torque: N...
  • Page 522 General Description FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-01079 ⋅ Gasket O-ring Tightening torque: N m (kgf-m, ft-lb) Throttle body T1: 2.0 (0.2, 1.5) Manifold absolute pressure sensor T2: 8 (0.8, 5.8) FU(H4SO 2.5)-5...
  • Page 523 General Description FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 ⋅ Crankshaft position sensor Camshaft position sensor support Tightening torque: N m (kgf-m, ft-lb) Knock sensor T1: 6.4 (0.65, 4.7) Camshaft position sensor T2: 24 (2.4, 17.4) FU(H4SO 2.5)-6...
  • Page 524 General Description FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (19) (17) (18) (15) (16) (17) (14) (15) (10) (12) (11) (13) (22) (22) (20) (21) (23) (24) (25) FU-01080 FU(H4SO 2.5)-7...
  • Page 525 General Description FUEL INJECTION (FUEL SYSTEMS) Fuel tank (12) Fuel sub level sensor upper plate (22) Retainer Fuel tank band RH (13) Fuel sub level sensor gasket (23) Heat shield cover Fuel tank band LH (14) Fuel filler hose (24) Fuel tank protector RH (Front) Delivery tube (15)
  • Page 526 General Description FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (28) (18) (26) (23) (15) (17) (19) (25) (27) (20) (22) (14) (13) (24) (21) (16) (22) (34) (11) (29) (10) (12) (33) (32) (30) (31) FU-01081 FU(H4SO 2.5)-9...
  • Page 527 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
  • Page 528 Throttle Body FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the air intake chamber. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> 3) Disconnect the connectors from the throttle posi- tion sensor and manifold absolute pressure sensor.
  • Page 529 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold 10) Disconnect the connectors from engine coolant temperature sensor. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
  • Page 530 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 15) Disconnect the connector from camshaft posi- 18) Remove the bolts which secure intake manifold tion sensor. to cylinder head. FU-01335 FU-01089 16) Remove the EGR pipe from intake manifold. 19) Remove the intake manifold. (EC, EK and K4 model) B: INSTALLATION 1) Install the intake manifold onto cylinder heads.
  • Page 531 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3) Install the EGR pipe to intake manifold. (EC, EK 8) Connect the knock sensor connector. and K4 model) Tightening torque: ⋅ 34 N m (3.4 kgf-m, 24.6 ft-lb) FU-01334 9) Connect the connectors to engine coolant tem- perature sensor.
  • Page 532 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 15) Install the air cleaner case and air intake cham- 6) Disconnect the pressure regulator vacuum hose ber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air (A) from intake manifold. Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTAL- LATION, Air Intake Chamber.>...
  • Page 533 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 12) Remove the purge control solenoid valve. • LH side <Ref. to EC(H4SO 2.0)-7, REMOVAL, Purge Con- trol Solenoid Valve.> 13) Remove the harness band clips which install the engine harness. FU-01099 FU-01096 14) Remove the bolts which hold the engine har- ness to intake manifold.
  • Page 534 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 22) Remove the bolt which installs the fuel pipes on 2) Tighten the bolt which installs the fuel pipes on intake manifold. intake manifold. Tightening torque: ⋅ 6.4 N m (0.65 kgf-m, 4.7 ft-lb) FU-01337 23) Remove the fuel pipe assembly and pressure regulator, from intake manifold.
  • Page 535 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 8) Tighten the bolts which install injector pipe on in- 11) Tighten the bolts which install engine harness take manifold. on intake manifold. • RH side Tightening torque: ⋅ Tightening torque: 16 N m (1.6 kgf-m, 11.8 ft-lb) ⋅...
  • Page 536 Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 17) Install the fuel pipe protector RH. 21) Install the EGR valve. (EC, EK and K4 model) <Ref. to FU(H4SO 2.5)-30, INSTALLATION, EGR Tightening torque: Valve.> ⋅ 19 N m (1.9 kgf-m, 13.7 ft-lb) 22) Install the throttle body to intake manifold.

  • Page 537: Engine Coolant Temperature

    Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the generator. <Ref. to SC(H4SO 2.0)- 14, REMOVAL, Generator.> 3) Disconnect the connectors from engine coolant temperature sensor.
  • Page 538 Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. ⋅ T: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) IN-00203 FU-00058 2) Remove the bolt which installs crankshaft posi-...
  • Page 539 Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00179 B: INSTALLATION Install in the reverse order of removal. IN-00203 Tightening torque: 2) Disconnect the connector from camshaft posi- Camshaft position sensor support tion sensor.
  • Page 540 Knock Sensor FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Extraction area of knock sensor cord must be posi- tioned at a 60° angle relative to the engine rear. Tightening torque: ⋅...
  • Page 541 Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure. <Ref. to FU(H4SO 2.5)-11, REMOVAL, Throttle Body.>...
  • Page 542 Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS) 9. Manifold Absolute Pressure Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from manifold abso- lute pressure sensor. FU-01105 3) Remove the manifold absolute pressure sensor from throttle body.

  • Page 543: Mass Air Flow And Intake Air Temperature Sensor

    Mass Air Flow and Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 10.Mass Air Flow and Intake Air Temperature Sensor A: REMOVAL NOTE: Mass air flow and intake air temperature sensor is installed to EC, EK and K4 model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from mass air flow and intake air temperature sensor.
  • Page 544 Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 11.Intake Air Temperature Sen- A: REMOVAL NOTE: Intake air temperature sensor is installed to models except for EC, EK and K4. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from intake air tem- perature sensor.

  • Page 545: Tumble Generator Valve Assembly

    Tumble Generator Valve Assembly FUEL INJECTION (FUEL SYSTEMS) 12.Tumble Generator Valve As- 7) Remove the tumble generator valve body from intake manifold. sembly A: REMOVAL NOTE: This component is installed to EC, EK and K4 mod- 1) Release the fuel pressure. <Ref.
  • Page 546 Tumble Generator Valve Actuator FUEL INJECTION (FUEL SYSTEMS) 13.Tumble Generator Valve Ac- 3) Disconnect the ground cable from battery. tuator A: REMOVAL 1. RH SIDE NOTE: This component is installed to EC, EK and K4 mod- 1) Release the fuel pressure. <Ref.
  • Page 547 EGR Valve FUEL INJECTION (FUEL SYSTEMS) 14.EGR Valve A: REMOVAL NOTE: EGR valve is installed to EC, EK and K4 model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from EGR valve. FU-01152 3) Remove the EGR valve from intake manifold. FU-01153 B: INSTALLATION Install in the reverse order of removal.
  • Page 548 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 15.Fuel Injector 9) Remove the bolts which hold fuel injector pipe onto intake manifold. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler flap lid, and remove the fuel filler cap.
  • Page 549 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 7) Remove the harness band (B) which holds en- B: INSTALLATION gine harness to injector pipe. 1. RH SIDE Install in the reverse order of removal. NOTE: • Use new O-rings. • O-ring (B) is used for EC, EK and K4 model. FU-01338 8) Remove the bolts which hold fuel injector pipe onto intake manifold.
  • Page 550 Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE Tightening torque: ⋅ 19 N m (1.9 kgf-m, 13.7 ft-lb) Install in the reverse order of removal. NOTE: • Use new O-rings. • O-ring (B) is used for EC, EK and K4 model. FU-01093 FU-02157 (A) O-ring...
  • Page 551 Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS) 16.Front Oxygen (A/F) Sensor B: INSTALLATION 1) Before installing front oxygen (A/F) sensor, ap- A: REMOVAL ply anti-seize compound only to the threaded por- 1) Disconnect the ground cable from battery. tion of front oxygen (A/F) sensor to make the next removal easier.
  • Page 552 Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS) 17.Rear Oxygen Sensor B: INSTALLATION 1) Before installing rear oxygen sensor, apply anti- A: REMOVAL seize compound only to the threaded portion of 1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas- ier.
  • Page 553 Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS) 18.Engine Control Module (ECM) B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. • When replacing the ECM, be careful not to use the wrong spec.
  • Page 554 Main Relay FUEL INJECTION (FUEL SYSTEMS) 19.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from main relay. FU-02093 B: INSTALLATION Install in the reverse order of removal.
  • Page 555 Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from fuel pump relay. FU-02094 B: INSTALLATION Install in the reverse order of removal.
  • Page 556 Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS) 21.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the harness cover (A). FU-02092 4) Disconnect the connector from electric throttle control relay.
  • Page 557 Fuel FUEL INJECTION (FUEL SYSTEMS) 22.Fuel 6) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from fuel A: PROCEDURE tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 558 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Tank (2) Push the grommet (B) down under the body and remove service hole cover. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
  • Page 559 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 12) Remove the rear brake caliper and tie it to the 19) Remove the bolts which install the parking vehicle body side. brake cable clamp. FU-00462 FU-01130 13) Remove the parking brake cable from parking brake assembly.
  • Page 560 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) (3) Remove the bolts which secure the rear 23) Support the fuel tank with transmission jack, re- suspension assembly to body. move the bolts from fuel tank bands, and dismount the fuel tank from vehicle. WARNING: A helper is required to perform this work.
  • Page 561 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 2) Correctly insert the fuel filler hose (A) and vent Tightening torque: ⋅ hose (B) to specified position, and then tighten the T1: 125 N m (12.7 kgf-m, 92.2 ft-lb) ⋅ clamp. T2: 65 N m (6.2 kgf-m, 48 ft-lb) ⋅...
  • Page 562 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 6) Tighten the bolts which install the parking brake 14) Tighten the bolt which secures rear brake hose cable clamp. installation bracket. Tightening torque: Tightening torque: ⋅ ⋅ 18 N m (1.8 kgf-m, 13.0 ft-lb) 33 N m (3.4 kgf-m, 25 ft-lb) FU-01130...
  • Page 563 Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 20) Connect the connector to fuel pump. FU-01125 21) Install the service hole cover of fuel pump. FU-01124 (A) Bolt (B) Grommet 22) Install the rear seat. 23) Install the fuse of fuel pump to main fuse box. C: INSPECTION 1) Check that the fuel tank is not holed, cracked or otherwise damaged.
  • Page 564 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Filler Pipe 7) Set a container under the vehicle, and remove the drain plug from the fuel tank to drain fuel from A: REMOVAL fuel tank. WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 565 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Tighten the bolts which hold the fuel filler pipe bracket on the body. 1) Open the fuel filler flap lid. 2) Set the fuel saucer (A) with rubber packing (C) Tightening torque: ⋅...
  • Page 566 Fuel Pump FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Pump 7) Remove the nuts which install the fuel pump as- sembly onto fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. •...
  • Page 567 Fuel Pump FUEL INJECTION (FUEL SYSTEMS) • Do not run fuel pump for a long time under non-load condition. FU-01330 FU(H4SO 2.5)-50...
  • Page 568 Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Level Sensor A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly.
  • Page 569 Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Sub Level Sensor 6) Remove the nuts and bolts which install the fuel sub level sensor on fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 570 Fuel Filter FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Filter A: SPECIFICATION Fuel filter forms a unit with fuel pump. Refer to Fuel Pump for removal and installation. <Ref. to FU(H4SO 2.5)-49, REMOVAL, Fuel Pump.> <Ref. to FU(H4SO 2.5)-49, INSTALLATION, Fuel Pump.> FU(H4SO 2.5)-53...
  • Page 571 Fuel Damper Valve FUEL INJECTION (FUEL SYSTEMS) 29.Fuel Damper Valve A: REMOVAL 1. DELIVERY SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper valve from fuel delivery line. FU-01147 2.
  • Page 572 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) 30.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCE- DURE, Fuel.> 3) Open the fuel filler flap lid, and remove the fuel filler cap.
  • Page 573 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) (3) Hold the connector (A) and push retainer (B) (2) Push the pipe into the connector completely. down. ( A ) (4) Pull out the connector (A) from retainer (B). CAUTION: ( B ) Always use a new retainer.
  • Page 574 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS) ± ± 2: 2.5 1.5 mm (0.098 0.059 in) ± ± L: 22.5 2.5 mm (0.886 0.098 in) ( 1 ) ( 2 ) ( 3 ) Type A Type B FU-00128 (1) Pipe (2) Clamp...
  • Page 575 Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS) 31.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to injector Fuel pump does not operate. Inspect contact, especially ground, and tighten it ❍...
  • Page 576 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 577 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 578 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.5) Page General Description ..................2...
  • Page 579 General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in EC(H4SO 2.0) section. <Ref. to EC(H4SO 2.0)-2, General Description.> EC(H4SO 2.5)-2...
  • Page 580 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 581 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 582 INTAKE (INDUCTION) IN(H4SO 2.5) Page General Description ..................2...
  • Page 583 General Description INTAKE (INDUCTION) 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in IN(H4SO 2.0) section. <Ref. to IN(H4SO 2.0)-2, General Description.> IN(H4SO 2.5)-2...
  • Page 584 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 585 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 586 MECHANICAL ME(H4SO 2.5) Page General Description ..................2...
  • Page 587 General Description MECHANICAL 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in ME(H4SO 2.0) section. <Ref. to ME(H4SO 2.0)-2, General Description.> ME(H4SO 2.5)-2...
  • Page 588 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 589 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 590 EXHAUST EX(H4SO 2.5) Page General Description ..................2...
  • Page 591 General Description EXHAUST 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in EX(H4SO 2.0) section. <Ref. to EX(H4SO 2.0)-2, General Description.> EX(H4SO 2.5)-2...
  • Page 592 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 593 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 594 COOLING CO(H4SO 2.5) Page General Description ..................2...
  • Page 595 General Description COOLING 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to CO(H4SO 2.0)-2, General De- scription.> CO(H4SO 2.5)-2...
  • Page 596 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 597 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 598 LUBRICATION LU(H4SO 2.5) Page General Description ..................2...
  • Page 599 General Description LUBRICATION 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to LU(H4SO 2.0)-2, General De- scription.> LU(H4SO 2.5)-2...
  • Page 600 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 601 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 602 SPEED CONTROL SYSTEMS SP(H4SO 2.5) Page General Description ..................2...
  • Page 603 General Description SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to SP(H4SO 2.0)-2, General De- scription.> SP(H4SO 2.5)-2...
  • Page 604 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 605 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 606 IGNITION IG(H4SO 2.5) Page General Description ..................2...
  • Page 607 General Description IGNITION 1. General Description A: SPECIFICATION Specifications for 2.5 L model are included in IG(H4SO 2.0) section. <Ref. to IG(H4SO 2.0)-2, General Description.> IG(H4SO 2.5)-2...
  • Page 608 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 609 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 610 STARTING/CHARGING SYSTEMS SC(H4SO 2.5) Page General Description ..................2...
  • Page 611 General Description STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATION Specifications for 2.5 L model are the same as 2.0 L model. <Ref. to SC(H4SO 2.0)-2, General De- scription.> SC(H4SO 2.5)-2...
  • Page 612 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 613 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 614 Electrical Component Location ..............8 Engine Control Module (ECM) I/O Signal ..........17 Engine Condition Data ................21 Data Link Connector .................22 OBD-II General Scan Tool ................23 Subaru Select Monitor................26 Read Diagnostic Trouble Code (DTC) ............33 Inspection Mode..................34 Drive Cycle....................39 Clear Memory Mode..................41 Compulsory Valve Operation Check Mode ..........42...
  • Page 615 Repair the related 1) Turn the ignition switch to OFF. aru Select Monitor? Repair the trouble parts. 2) Connect the Subaru Select Monitor to data cause. <Ref. to NOTE: link connector. EN(H4SO 3) Turn the ignition switch to ON, and the Sub- 2.5)(diag)-70, List...
  • Page 616 Check List for Interview ENGINE (DIAGNOSTICS) 2. Check List for Interview CHECK 1. CHECK LIST No. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Engine No. Date of sale Fuel brand Date of repair Odometer reading...
  • Page 617 Check List for Interview ENGINE (DIAGNOSTICS) 2. CHECK LIST No. 2 Check the following items about the vehicle’s state when malfunction indicator light turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. ❏ Yes / ❏ No ❏...
  • Page 618 General Description ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts as the grounding point to chassis when measuring voltage and resis- A: CAUTION tance inside the passenger compartment. 1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay.
  • Page 619 Calling the self-diagnosis result is performed by the performing diagnostics. Subaru Select Monitor. 15) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most impor- tant thing in diagnostics is to understand the cus- tomer’s complaint, and distinguish between the...
  • Page 620 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
  • Page 621 Electrical Component Location ENGINE (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION 1. ENGINE • Control module • LHD model EN-02413 • RHD model EN-02451 Engine control module (ECM) Test mode connector Data link connector Malfunction indicator light EN(H4SO 2.5)(diag)-8...
  • Page 622 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01966 EN-01147 EN-02414 AT-01877 EN(H4SO 2.5)(diag)-9...
  • Page 623 Electrical Component Location ENGINE (DIAGNOSTICS) • Sensor EN-02530 Mass air flow and intake air tem- Electronic throttle control Intake air temperature sensor (KA perature sensor (EC, EK and K4 and KS model) Knock sensor model) Camshaft position sensor Manifold absolute pressure sensor Crankshaft position sensor Engine coolant temperature sen- Tumble generator valve position...
  • Page 624 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01970 EN-01971 EN-01972 EN-02179 EN-00010 EN-00011 EN-00012 EN-02531 EN(H4SO 2.5)(diag)-11...
  • Page 625 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02547 EN-01973 Front oxygen (A/F) sensor Front catalytic converter Rear catalytic converter Rear oxygen sensor EN-02091 EN-02092 EN(H4SO 2.5)(diag)-12...
  • Page 626 Electrical Component Location ENGINE (DIAGNOSTICS) • Solenoid valve, actuator, emission control system parts and ignition system parts EN-02452 Purge control solenoid valve Tumble generator valve actuator Fuel injector EGR Valve (EC, EK and K4 Ignition coil & ignitor ASSY model) EN(H4SO 2.5)(diag)-13...
  • Page 627 Electrical Component Location ENGINE (DIAGNOSTICS) EN-01975 EN-01976 EN-01977 EN-01978 EN-02453 EN(H4SO 2.5)(diag)-14...
  • Page 628 Electrical Component Location ENGINE (DIAGNOSTICS) • LHD model (4) (3) (6) (9) EN-02423 • RHD model (8) (7) EN-01979 Inhibitor switch Fuel pump relay Radiator sub fan relay Fuel pump Electronic throttle control relay Radiator main fan relay 2 Main relay Radiator main fan relay 1 Starter EN(H4SO 2.5)(diag)-15...
  • Page 629 Electrical Component Location ENGINE (DIAGNOSTICS) EN-02093 EN-00178 EN-02094 EN-02095 EN-02096 EN(H4SO 2.5)(diag)-16...
  • Page 630 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 18 19 20 21 22 23 26 27 20 21...
  • Page 631 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Termi- Connector DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) Front oxygen Signal 1 B134 0 — 1.0 0 — 1.0 — (A/F) sensor Signal 2 B134 0 — 1.0 0 —...
  • Page 632 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Termi- Connector DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) Fuel pump relay control ON: 0.5 or less B135 0.5 or less — (Model without immobilizer) OFF: 10 — 13 ON: 0.5 or less ON: 0.5 or less A/C relay control...
  • Page 633 Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Termi- Connector DESCRIPTION NOTE Ignition SW ON Engine ON (engine OFF) (idling) GND (oxygen sensor heater B134 — GND (Electronic throttle B137 — control) ON: 0 ON: 0 Main switch B137 —...
  • Page 634 Engine Condition Data ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Remarks SPECIFICATION 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm Racing Measuring condition: • After engine is warmed-up. • Gear position is in “N” or “P” range. •...
  • Page 635 This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools except for Subaru Select Monitor or OBD-II general scan tool, because the circuit for Subaru Select Monitor may be damaged. 9 10 11 12 13 EN-00037 Terminal No.
  • Page 636 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 8. OBD-II General Scan Tool OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic A: OPERATION data (2) MODE $02: Powertrain freeze frame data 1. HOW TO USE OBD-II GENERAL SCAN (3) MODE $03: Emission-related powertrain TOOL 1) Prepare a general scan tool (OBD-II general...
  • Page 637 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is detected by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure DTC that caused CARB required freeze frame data storage...
  • Page 638 OBD-II General Scan Tool ENGINE (DIAGNOSTICS) Test value & Test limit Unit sensor heater circuit (Bank 1 Sensor 2) <$81 or $02> Coolant thermostat (Coolant temperature below thermostat regulating tempera- °C ture) Evaporative emission control system vent control circuit range/performance 7.
  • Page 639 5) Turn ignition switch to ON (engine OFF) and turn Subaru Select Monitor switch to ON. A: OPERATION 1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.5)(diag)-7, PREPARATION TOOL, General Description.> EN-00040...
  • Page 640 Subaru Select Monitor ENGINE (DIAGNOSTICS) 4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
  • Page 641 Cancel switch signal Cancel Switch — OFF (At OFF) Integrated unit data reception Body Int. Unit Data — Integrated unit data update Body Int. Unit Count — NOTE: For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.5)(diag)-28...
  • Page 642 A/C system refrigerant no support Test of oxygen sensor Oxygen sensor complete Test of oxygen sensor heater O2 Heater Diagnosis complete Test of EGR system EGR system incomplete NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.5)(diag)-29...
  • Page 643 Ignition timing signal Ignition Timing Intake air volume Mass Air Flow g/sec °C Intake air temperature signal Intake Air Temp Throttle position signal Throttle Opening Angle NOTE: For detailed operation procedure, refer to SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO 2.5)(diag)-30...
  • Page 644 Subaru Select Monitor ENGINE (DIAGNOSTICS) 7. LED OPERATION MODE FOR ENGINE 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
  • Page 645 Data reception signal Body Int. Unit Data ON or OFF entered. When counter update signal is Counter update signal Body Int. Unit Count ON or OFF entered. NOTE: For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. EN(H4SO 2.5)(diag)-32...
  • Page 646 Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR (NORMAL MODE) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
  • Page 647 Inspection Mode ENGINE (DIAGNOSTICS) 11.Inspection Mode A: PROCEDURE Carry out trouble diagnosis shown in the following DTC table. When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle. <Ref. to EN(H4SO 2.5)(diag)-39, Drive Cycle.> Item Condition P0031...
  • Page 648 Inspection Mode ENGINE (DIAGNOSTICS) Item Condition P0852 Neutral Switch Input Circuit High — P1086 Tumble Generated Valve Position Sensor 2 Circuit Low — P1087 Tumble Generated Valve Position Sensor 2 Circuit High — P1088 Tumble Generated Valve Position Sensor 1 Circuit Low —...
  • Page 649 2.5)(diag)-41, Clear Memory Mode.> 2) Idle the engine. gal, 4.4 — 8.8 Imp gal)]. 3) Prepare the Subaru Select Monitor kit. <Ref. to 2) Lift-up the vehicle using a garage jack and place EN(H4SO 2.5)(diag)-7, PREPARATION TOOL, it on rigid racks, or drive the vehicle onto free roll- General Description.>...
  • Page 650 Inspection Mode ENGINE (DIAGNOSTICS) 7) Connect the Subaru Select Monitor to data link • The speed difference between front and rear connector located in the lower portion of the instru- wheels may light the ABS warning light, but this in- ment panel (on the driver’s side).
  • Page 651 Inspection Mode ENGINE (DIAGNOSTICS) 9) Place the select lever or shift lever in “D” range (AT model) or “1st” gear (MT model) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: • On AWD model, release the parking brake. •...
  • Page 652 Drive Cycle ENGINE (DIAGNOSTICS) 12.Drive Cycle A: PROCEDURE There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check whether they correctly resume their functions by driving in the required drive pattern. 1.
  • Page 653 Drive Cycle ENGINE (DIAGNOSTICS) 4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN (60) 64 (40) EN-00842 Idle engine for 10 seconds or Decelerate with throttle fully Stop vehicle with throttle fully more. closed to 64 km/h (40 MPH). closed. Accelerate to 97 km/h (60 MPH) Drive vehicle at 64 km/h (40 MPH) Vehicle speed km/h (MPH) within 20 seconds.
  • Page 654 {Memory Clear} and press the [YES] key. 5) When the “Done” and “Turn Ignition Switch OFF” are shown on the display screen, turn the ignition switch to OFF and then Subaru Select Monitor switch to OFF. NOTE: • Initial diagnosis of electronic control throttle is performed after memory clearance.
  • Page 655 Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) 14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link connector located in the lower portion of instrument Check Mode panel (on the driver’s side). A: OPERATION 1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO 2.5)(diag)-7, PREPARATION TOOL,...
  • Page 656 Compulsory Valve Operation Check Mode ENGINE (DIAGNOSTICS) • A list of the support data is shown in the following table. DESCRIPTION Display Compulsory fuel pump relay oper- Fuel Pump ation check Compulsory radiator fan relay Radiator Fan Relay operation check Compulsory air conditioning relay A/C Compressor Relay operation check...
  • Page 657 Malfunction Indicator Light ENGINE (DIAGNOSTICS) 15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.5)(diag)-45, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> ↓ 2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.5)(diag)-46, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>...

  • Page 658: Indicator Light

    Malfunction Indicator Light ENGINE (DIAGNOSTICS) B: ACTIVATION OF MALFUNCTION (3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Mal- INDICATOR LIGHT function indicator light illuminates if faulty. 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the com- bination meter illuminates.
  • Page 659 Malfunction Indicator Light ENGINE (DIAGNOSTICS) C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON DIAGNOSIS: The malfunction indicator light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not come on. WIRING DIAGRAM: •...
  • Page 660 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
  • Page 661 D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF. DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor display. WIRING DIAGRAM: • EC, EK and K4 model...
  • Page 662 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
  • Page 663 Malfunction Indicator Light ENGINE (DIAGNOSTICS) E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK. DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • Test mode connector circuit is in open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during inspection mode. WIRING DIAGRAM: •...
  • Page 664 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
  • Page 665 Malfunction Indicator Light ENGINE (DIAGNOSTICS) F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING. DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when test mode connector is not connected. WIRING DIAGRAM: • EC, EK and K4 model IGNITION SWITCH BATTERY SBF-7...
  • Page 666 Malfunction Indicator Light ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same as 2.0 L model.
  • Page 667 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) 16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check for fuel amount. ↓ 2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.5)(diag)-55, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start- ing Failure.> ↓ 3.
  • Page 668 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
  • Page 669 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) • KA and KS model NOTE: Fuel injection system for KA and KS model is the same as 2.0 L model. Refer to EN(H4SO 2.0) section. Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2.
  • Page 670 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK IGNITION SWITCH. Is the resistance less than 5 Go to step 9. Replace the igni- Ω? 1) Disconnect the connector from ignition tion switch. switch. 2) Measure the resistance between ignition switch terminals after turning the ignition switch to START position.
  • Page 671 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MOD- ULE (ECM) CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
  • Page 672 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same...
  • Page 673 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Go to step 8. Repair the open or 1) Connect the connectors to ECM and main ground short cir- relay.
  • Page 674 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
  • Page 675 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same...
  • Page 676 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FOR IGNITION COIL Does the voltage vary more Go to step 7. Replace the igni- & IGNITOR ASSY. than 10 V? tion coil & ignitor 1) Connect the connector to ignition coil & ASSY.
  • Page 677 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) E: FUEL PUMP CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
  • Page 678 CIRCUIT, Diag- NOTE: nostics for Engine Fuel pump operation can also be executed us- Starting Failure.> ing Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.5)(diag)-42, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP.
  • Page 679 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 8. Replace the fuel Ω? 1) Disconnect the connectors from fuel pump pump relay. <Ref. relay and main relay. to FU(H4SO 2.5)- 2) Remove the fuel pump relay and main relay 49, Fuel Pump.>...
  • Page 680 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(di- ag)-41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>.
  • Page 681 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS model is the same...
  • Page 682 Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step Check Is the resistance 5 — 20 Ω? CHECK EACH FUEL INJECTOR. Go to step 7. Replace the faulty 1) Turn the ignition switch to OFF. fuel injector. 2) Measure the resistance between each fuel injector terminals.
  • Page 683 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 17.List of Diagnostic Trouble Code (DTC) A: LIST 1. EC, EK AND K4 MODEL Item NOTE P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H4SO 2.5)(diag)-80, DTC P0030 HO2S HEATER CONTROL Sensor 1) CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
  • Page 684 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0132 O2 Sensor Circuit High Voltage <Ref. to EN(H4SO 2.5)(diag)-123, DTC P0132 O2 SENSOR CIRCUIT HIGH (Bank 1 Sensor 1) VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0133 O2 Sensor Circuit Slow Response <Ref.
  • Page 685 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0459 Evaporative Emission Control Sys- <Ref. to EN(H4SO 2.5)(diag)-169, DTC P0459 EVAPORATIVE EMISSION tem Purge Control Valve Circuit High CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnos- tic Procedure with Diagnostic Trouble Code (DTC).> P0462 Fuel Level Sensor Circuit Low Input <Ref.
  • Page 686 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1089 Tumble Generated Valve Position <Ref. to EN(H4SO 2.5)(diag)-200, DTC P1089 TUMBLE GENERATED Sensor 1 Circuit High VALVE POSITION SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1090 Tumble Generated Valve System 1 <Ref.
  • Page 687 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1497 EGR Solenoid Valve Signal #3 Cir- <Ref. to EN(H4SO 2.5)(diag)-221, DTC P1497 EGR SOLENOID VALVE cuit Malfunction (High Input) SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1498 EGR Solenoid Valve Signal #4 Cir- <Ref.
  • Page 688 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P2138 Throttle/Pedal Position Sensor/ <Ref. to EN(H4SO 2.5)(diag)-257, DTC P2138 THROTTLE/PEDAL POSI- Switch “D”/“E” Voltage Rationality TION SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> 2.
  • Page 689 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0133 O2 Sensor Circuit Slow Response <Ref. to EN(H4SO 2.0)(diag)-114, DTC P0133 O2 SENSOR CIRCUIT (Bank 1 Sensor 1) SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diag- nostic Trouble Code (DTC).> P0134 O2 Sensor Circuit No Activity <Ref.
  • Page 690 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P0462 Fuel Level Sensor Circuit Low Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0462 FUEL LEVEL SENSOR CIR- CUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0463 Fuel Level Sensor Circuit High Input <Ref.
  • Page 691 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P1493 EGR Solenoid Valve Signal #1 Cir- <Ref. to EN(H4SO 2.0)(diag)-181, DTC P1493 EGR SOLENOID VALVE cuit Malfunction (High Input) SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P1494 EGR Solenoid Valve Signal #2 Cir- <Ref.
  • Page 692 List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Item NOTE P2109 Throttle/Pedal Position Sensor A <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2109 THROTTLE ANGLE Minimum Stop Performance CLOSED POSITION ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P2111 Throttle Actuator Control System - <Ref.
  • Page 693 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO 2.0) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 694 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) EN(H4SO 2.5) ENGINE (DIAGNOSTICS) (diag) G2320GE2...
  • Page 695 Electrical Component Location ..............8 Engine Control Module (ECM) I/O Signal ..........17 Engine Condition Data ................21 Data Link Connector .................22 OBD-II General Scan Tool ................23 Subaru Select Monitor................26 Read Diagnostic Trouble Code (DTC) ............33 Inspection Mode..................34 Drive Cycle....................39 Clear Memory Mode..................41 Compulsory Valve Operation Check Mode ..........42...
  • Page 696 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) 18.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 697 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 698 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 699 Go to step 6. 1) Start the engine. contact connector. 2) Read the data of front oxygen (A/F) sensor NOTE: heater current using Subaru Select Monitor. In this case, repair the following: NOTE: For detailed operation procedure, refer to the •...
  • Page 700 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 8. Go to step 7. 1) Start and idle the engine. 2) Measure the voltage between ECM con- nector and chassis ground.
  • Page 701 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) C: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 702 (ECM).> connector. 3) Turn the ignition switch to ON. 4) Read the data of front oxygen (A/F) sensor heater current using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.>...
  • Page 703 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) D: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 704 NOTE: For detailed operation procedure, refer to the • Poor contact in “READ CURRENT DATA FOR ENGINE”. <Ref. rear oxygen sen- to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- sor connector itor.> • Poor contact in rear oxygen sen- sor connecting harness connector •...
  • Page 705 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Replace the ECM. Repair the battery 1) Disconnect the connector from rear oxygen <Ref. to FU(H4SO short circuit in har- sensor.
  • Page 706 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) E: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 707 4) Read the data of rear oxygen sensor heater current using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END.
  • Page 708 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) F: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 709 SELECT MONITOR. function indicator 1) Turn the ignition switch to OFF. light illuminates, 2) Connect the Subaru Select Monitor to data the circuit has link connector. returned to a nor- 3) Turn the ignition switch to ON, and the Sub- mal condition at aru Select Monitor switch to ON.
  • Page 710 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 7. Repair the open Ω? MASS AIR FLOW SENSOR CONNECTOR. circuit between 1) Turn the ignition switch to OFF. ECM and mass air 2) Disconnect the connector from ECM.
  • Page 711 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) G: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 712 SELECT MONITOR. function indicator 1) Turn the ignition switch to OFF. light illuminates, 2) Connect the Subaru Select Monitor to data the circuit has link connector. returned to a nor- 3) Turn the ignition switch to ON, and the Sub- mal condition at aru Select Monitor switch to ON.
  • Page 713 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) H: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 714 Go to step 3. 1) Start the engine. (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref.
  • Page 715 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 9. Repair the open MANIFOLD ABSOLUTE PRESSURE SEN- circuit in harness SOR CONNECTOR. between ECM and 1) Turn the ignition switch to OFF.
  • Page 716 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) I: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 717 1) Start the engine. kPa (896.5 mmHg, 35.29 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.>...
  • Page 718 ECM and sure sensor. <Ref. 1) Turn the ignition switch to OFF, and the manifold absolute to FU(H4SO 2.5)- Subaru Select Monitor switch to OFF. pressure sensor 25, Manifold Abso- 2) Disconnect the connector from manifold connector. lute Pressure Sen- absolute pressure sensor.
  • Page 719 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) J: DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 720 Repair the poor 1) Start the engine. more than 120°C (248°F)? contact. 2) Read the data of mass air flow and intake NOTE: air temperature sensor signal using Subaru In this case, repair Select Monitor. the following: • Poor contact in NOTE:...
  • Page 721 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) K: DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 722 Repair the poor less than −40°C (−40°F)? 1) Start the engine. contact. 2) Read the data of air flow and intake air tem- NOTE: perature sensor signal using Subaru Select In this case, repair Monitor. the following: • Poor contact in NOTE:...
  • Page 723 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 3 V? Go to step 6. Repair the har- FLOW AND INTAKE AIR TEMPERATURE ness and connec- SENSOR AND ECM CONNECTOR. tor.
  • Page 724 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) L: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Hard to start • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 725 Repair the poor 1) Start the engine. ture more than 150°C (302°F)? contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
  • Page 726 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) M: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Hard to start • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 727 Repair the poor ture less than −40°C (−40°F)? 1) Start the engine. contact. 2) Read the data of engine coolant tempera- NOTE: ture sensor signal using Subaru Select Moni- In this case, repair tor. the following: • Poor contact in NOTE:...
  • Page 728 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 6. Repair the har- COOLANT TEMPERATURE SENSOR AND ness and connec- ECM CONNECTOR. tor. Measure the voltage between engine coolant NOTE: temperature sensor connector and engine In this case, repair...
  • Page 729 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) N: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 730 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 731 Is the voltage more than 0.4 V? Go to step 3. Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
  • Page 732 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) O: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 733 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 734 Go to step 3. Go to step 4. 1)Turn the ignition switch to ON. 2)Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Temporary poor...
  • Page 735 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) P: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine will not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 736 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 737 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 738 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 739 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) R: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 740 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 741 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) S: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 742 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 743 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) T: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN- SOR 1) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 744 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 745 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) U: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 746 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 5.
  • Page 747 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 — 0.5 V? Replace the rear Repair the har- GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec- 1) Turn the ignition switch to OFF. <Ref.
  • Page 748 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) V: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 749 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 5.
  • Page 750 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 — 0.5 V? Replace the rear Repair the har- GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec- 1) Turn the ignition switch to OFF. <Ref.
  • Page 751 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) W: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 752 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 753 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Y: DTC P0172 SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 754 1) Start the engine and warm-up completely. 100°C (212°F)? temperature sen- 2) Read the data of engine coolant tempera- sor. <Ref. to ture sensor signal using Subaru Select Moni- FU(H4SO 2.5)-20, tor. Engine Coolant Temperature Sen- NOTE: sor.>...
  • Page 755 ON? 5) Read the data of manifold pressure sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”. <Ref. to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- itor.> EN(H4SO 2.5)(diag)-139...
  • Page 756 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Z: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 757 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 758 Is the voltage more than 0.8 V? Go to step 3. Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor...
  • Page 759 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AA:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 760 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 761 Go to step 3. Go to step 4. 1) Turn the ignition switch to ON. 2) Read the data of sub throttle sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact in con- Repair the poor...
  • Page 762 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AB:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO 2.5)(diag)-147, DTC P0304 CYLIN- DER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AC:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.
  • Page 763 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AE:DTC P0304 CYLINDER 4 MISFIRE DETECTED DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • Immediately at fault recognition (A misfire which could damage catalyst occurs.) TROUBLE SYMPTOM: • Engine stalls. •...
  • Page 764 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 765 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 766 Go to step 16. Go to step 15. CATOR LIGHT. light come on or blink? 1) Clear the memory using Subaru Select Monitor. <Ref. to EN(H4SO 2.5)(diag)-41, Clear Memory Mode.> 2) Start the engine, and drive the vehicle more than 10 minutes.
  • Page 767 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AF:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 768 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 769 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AG:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 770 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 771 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AH:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 772 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 773 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 6. Tighten the crank- SITION SENSOR. sor installation bolt tightened shaft position sen- securely? sor installation bolt securely.
  • Page 774 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN- GLE SENSOR) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 775 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 776 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK CAMSHAFT POSITION SENSOR. Is the resistance 1 — 4 kΩ? Repair the poor Replace the cam- 1) Remove the camshaft position sensor. contact in cam- shaft position sen- 2) Measure the resistance between connector shaft position sen- sor.
  • Page 777 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0400 EXHAUST GAS RECIRCULATION FLOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Movement performance problem when engine is low speed. • Erroneous idling • Movement performance problem CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 778 1) Start the engine. kPa (400 mmHg, 15.75 inHg)? EGR valve, mani- 2) Read the data of intake manifold absolute fold absolute pres- pressure signal using Subaru Select Monitor. sure sensor and throttle body are NOTE: installed securely. For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
  • Page 779 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN EGR SOLE- Is the resistance less than 1 Go to step 7. Repair the open Ω? NOID VALVE AND ECM CONNECTOR. circuit in harness 1) Turn the ignition switch to OFF. between ECM and 2) Detach the connector from EGR solenoid EGR solenoid...
  • Page 780 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AK:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 781 <Ref. to EC(H4SO 2.0)-4, Rear Catalytic Converter.> CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front Contact Subaru Remove the front catalytic converter. front face of front catalyst? catalytic con- distributor service. verter. <Ref. to NOTE: EC(H4SO 2.0)-3,...
  • Page 782 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AL:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT LOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 783 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 784 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Replace the ECM. Check poor contact in purge control solenoid control solenoid valve connec- contact in purge <Ref.
  • Page 785 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AM:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT HIGH DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 786 NOTE: ECM connector. Purge control solenoid valve operation can be executed using Subaru Select Monitor. Refer to “Compulsory Valve Operation Check Mode” for procedures. <Ref. to EN(H4SO 2.5)(diag)-42, Compulsory Valve Operation Check Mode.> Connector & terminal −...
  • Page 787 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the ECM. Check poor contact in ECM connector. connector? contact in ECM <Ref. to FU(H4SO connector. 2.5)-36, Engine Control Module (ECM).>...
  • Page 788 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0462 displayed on the Check the combi- Temporary poor Subaru Select Monitor? nation meter sys- contact occurs. tem. <Ref. to IDI-3, Combination Meter System.>...
  • Page 789 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0463 displayed on the Check the combi- Temporary poor Subaru Select Monitor? nation meter sys- contact occurs. tem. <Ref. to IDI-3, Combination Meter System.>...
  • Page 790 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AP:DTC P0500 VEHICLE SPEED SENSOR DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. Step Check CHECK OPTION CODE.
  • Page 791 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AQ:DTC P0512 STARTER REQUEST CIRCUIT DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 792 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY STARTER MOTOR B225 B135 B137 B225 B135 B137 4 5 6 11 12 15 16 19 20 23 24 10 11 12 13 14 15 16 17...
  • Page 793 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 794 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AR:DTC P0519 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 795 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AT:DTC P0559 GENERATOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
  • Page 796 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 797 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AV:DTC P0604 INTERNAL CONTROL MODULE READ ACCESS MEMORY (RAM) ERROR DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 798 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 799 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) AX:DTC P0607 CONTROL MODULE PERFORMANCE DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 800 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 801 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0691 displayed on the Check the radiator Temporary poor Subaru Select Monitor? fan system. <Ref. contact occurs. to CO(H4SO 2.0)- 7, Radiator Fan System.>...
  • Page 802 2.0 L model. CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0692 displayed on the Check the radiator Temporary poor Subaru Select Monitor? fan system. <Ref. contact occurs. to CO(H4SO 2.0)- 7, Radiator Fan System.>...
  • Page 803 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BC:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 804 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 805 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BD:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 806 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 807 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Go to step 9. Repair the open Ω? Measure the resistance of harness between circuit in harness inhibitor switch connector and engine ground. between inhibitor Connector &...
  • Page 808 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BE:DTC P1086 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 809 1) Start the engine. indicator light 2) Read the data of throttle position sensor lights up, the cir- signal using Subaru Select Monitor or OBD-II cuit has returned general scan tool. to a normal condi- tion at this time. A...
  • Page 810 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the har- TUMBLE GENERATOR VALVE POSITION ness and connec- SENSOR CONNECTOR. tor. 1) Turn the ignition switch to OFF.
  • Page 811 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BF:DTC P1087 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 812 1) Start the engine. indicator light 2) Read the data of throttle position sensor lights up, the cir- signal using Subaru Select Monitor or OBD-II cuit has returned general scan tool. to a normal condi- tion at this time. A...
  • Page 813 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BG:DTC P1088 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 814 1) Start the engine. indicator light 2) Read the data of tumble generator valve lights up, the cir- position sensor signal using Subaru Select cuit has returned Monitor or OBD-II general scan tool. to a normal condi- tion at this time. A...
  • Page 815 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the har- TUMBLE GENERATOR VALVE POSITION ness and connec- SENSOR CONNECTOR. tor. 1) Turn the ignition switch to OFF.
  • Page 816 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BH:DTC P1089 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 817 1) Start the engine. indicator light 2) Read the data of tumble generator valve lights up, the cir- position sensor signal using Subaru Select cuit has returned Monitor or OBD-II general scan tool. to a normal condi- tion at this time. A...
  • Page 818 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BI: DTC P1090 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE OPEN) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 819 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BJ:DTC P1091 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE CLOSE) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 820 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BK:DTC P1092 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE OPEN) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 821 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BL:DTC P1093 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE CLOSE) DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 822 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BM:DTC P1094 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNC- TION (OPEN) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 823 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? TUMBLE GENERATOR VALVE ACTUATOR circuit between CONNECTOR. ECM and tumble 1) Turn the ignition switch to OFF.
  • Page 824 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BN:DTC P1095 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNC- TION (SHORT) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 825 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit CONNECTOR. assembly. <Ref. to between ECM and 1) Turn the ignition switch to OFF.
  • Page 826 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BO:DTC P1096 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNC- TION (OPEN) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 827 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? TUMBLE GENERATOR VALVE ACTUATOR circuit between CONNECTOR. ECM and tumble 1) Turn the ignition switch to OFF.
  • Page 828 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BP:DTC P1097 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNC- TION (SHORT) DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 829 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit CONNECTOR. assembly. <Ref. to between ECM and 1) Turn the ignition switch to OFF.
  • Page 830 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BQ:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION (LOW INPUT) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 831 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BR:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION (HIGH INPUT) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 832 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BS:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 833 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 834 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BT:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 835 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 836 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Repair the poor Measure the voltage between ECM connector short circuit in har- contact in ECM and chassis ground.
  • Page 837 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BU:DTC P1160 RETURN SPRING FAILURE NOTE: For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO 2.5)(diag)-231, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos- tic Trouble Code (DTC).> BV:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) NOTE:...
  • Page 838 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CB:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 839 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK POWER SUPPLY TO EGR SOLE- Is the voltage more than 10 V? Go to step 2. Repair the har- NOID VALVE. ness and connec- 1) Turn the ignition switch to OFF. tor.
  • Page 840 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CC:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
  • Page 841 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2. using “List of Diag- nostic Trouble Code (DTC)”. <Ref. to EN(H4SO 2.5)(diag)-70, List of Diagnostic Trou- ble Code (DTC).>...
  • Page 842 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CD:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 843 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model IGNITION SWITCH BATTERY SBF-7 SBF-1 STARTER RELAY STARTER MOTOR B225 B135 B137 B225 B135 B137 4 5 6 11 12 15 16 19 20 23 24 10 11 12 13 14 15 16 17...
  • Page 844 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 845 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CE:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>. WIRING DIAGRAM: •...
  • Page 846 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 847 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CF:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 848 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 849 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 850 1) Connect all the connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage more than 0.8 V? Go to step 9. Go to step 10.
  • Page 851 3) Turn the ignition switch to ON. Replace the elec- 4) Read the data of main throttle sensor signal tronic throttle con- using Subaru Select Monitor. trol if defective. CHECK SENSOR OUTPUT. Is the voltage 1.64 — 1.70 V? Go to step 24.
  • Page 852 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 25. Repair the open Ω? ELECTRONIC THROTTLE CONTROL MO- circuit of harness TOR. connector. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM.
  • Page 853 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CG:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 854 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 855 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO 2.0) section. <Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trou- ble Code (DTC).> NOTE: Fuel injection sys- tem for KA and KS...
  • Page 856 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CH:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: Immediately at fault recognition. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 857 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) • KA and KS model NOTE: Fuel injection system for KA and KS model is the same as 2.0 L model. Refer to EN(H4SO 2.0) section. Step Check CHECK OPTION CODE. Is the option code EC, EK or Go to step 2.
  • Page 858 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CJ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 859 Is the voltage more than 0.4 V? Go to step 3. Go to step 4. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 860 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCELERATOR POSITION SEN- Is the resistance 0.2 — 1.0 Go to step 9. Replace the accel- SOR. kΩ? erator position Measure the resistance of accelerator position sensor. sensor. Terminals No.
  • Page 861 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CK:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 862 Is the voltage less than 4.8 V? Go to step 3. Go to step 4. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 863 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CL:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 864 Is the voltage more than 0.4 V? Go to step 3. Go to step 4. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 865 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK ACCELERATOR POSITION SEN- Is the resistance 0.15 — 0.63 Go to step 9. Replace the accel- SOR. kΩ? erator position 1) Measure the resistance of accelerator posi- sensor. tion sensor.
  • Page 866 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CM:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 867 Is the voltage less than 4.8 V? Go to step 3. Go to step 4. SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor Check poor contact in connector between contact.
  • Page 868 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CN:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” / “B” VOLTAGE RATIONALITY DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 869 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) WIRING DIAGRAM: • EC, EK and K4 model BATTERY ELECTRONIC SBF-8 THROTTLE B362 CONTROL RELAY MAIN RELAY B135 B136 B137 : TERMINAL NO. RANDOM ARRANGEMENT B138 : LHD B138 B122 : RHD B122 ELECTRONIC THROTTLE CONTROL...
  • Page 870 Go to step 5. 1) Turn the ignition switch to ON. 2) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage more than 0.8 V? Go to step 4. Go to step 5.
  • Page 871 Go to step 12. 1) Connect all the connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. CHECK SENSOR OUTPUT. Is the voltage less than 4.73 Go to step 11.
  • Page 872 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 17. Repair the short ELECTRONIC THROTTLE CONTROL. MΩ? circuit to sensor 1) Turn the ignition switch to OFF. power supply.
  • Page 873 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) CO:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY DTC DETECTING CONDITION: Immediately at fault recognition. TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)- 41, Clear Memory Mode.>...
  • Page 874 SOR OUTPUT. 1) Turn the ignition switch to ON. 2) Read the data of main accelerator position sensor signal and sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 13.
  • Page 875 2) Connect all the connectors. 3) Turn the ignition switch to ON. 4) Read the data of main throttle sensor signal and sub accelerator position sensor signal using Subaru Select Monitor. CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 19.
  • Page 876 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Go to step 17. Repair the poor Ω? CELERATOR POSITION SENSOR. contact in ECM 1) Connect the ECM connector. connector.
  • Page 877 General Diagnostic Table ENGINE (DIAGNOSTICS) 19.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in General.> Symptom Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Ignition parts (*1) 1.
  • Page 878 General Diagnostic Table ENGINE (DIAGNOSTICS) Symptom Problem parts 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6. Surge 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay...

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