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Subaru Legacy 2003 Service Manual

Subaru Legacy 2003 Service Manual

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2003 Model Year

PDF Service Manual

GENERAL INFORMATION SECTION (Pub.No.G2300GE1)

ENGINE SECTION 1 (Pub.No.G2300GE2)

ENGINE SECTION 2 (Pub.No.G2300GE3)

ENGINE SECTION 3 (Pub.No.G2300GE4)

TRANSMISSION SECTION (Pub.No.G2300GE5)

CHASSIS SECTION (Pub.No.G2300GE6)

BODY SECTION (Pub.No.G2300GE7)

WIRING SYSTEM SECTION (Pub.No.G2300GE8)

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Page 1 2003 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G2300GE1) ENGINE SECTION 1 (Pub.No.G2300GE2) ENGINE SECTION 2 (Pub.No.G2300GE3) ENGINE SECTION 3 (Pub.No.G2300GE4) TRANSMISSION SECTION (Pub.No.G2300GE5) CHASSIS SECTION (Pub.No.G2300GE6) BODY SECTION (Pub.No.G2300GE7) WIRING SYSTEM SECTION (Pub.No.G2300GE8)
Page 2 SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. IDENTIFICATION This manual includes the procedures...
Page 4 FOREWORD Page Foreword .....................2...
Page 5 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru Legacy. Applied model: BE***** and BH***** from 2003MY. The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc.
Page 6: How To Use This Manuals
HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
Page 7 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
Page 8 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 3. COMPONENTS Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue.
Page 9 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 4. SPECIFICATIONS If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure.
Page 10 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
Page 11 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS MEMO: HU-6...
Page 12 SPECIFICATIONS Page Legacy......................2 OUTBACK....................10...
Page 13 LEGACY SPECIFICATIONS 1. Legacy A: DIMENSIONS Model Sedan Wagon Overall length mm (in) 4,605 (181.3) 4,680 (184.3) Overall width mm (in) 1,695 (66.7) 1,695 (66.7) Overall height (at CW) mm (in) 1,415 (55.7) 1,515 (59.6) Compartment Length mm (in) 1,965 (77.4) 1,925 (75.8) Width mm (in)
Page 14 LEGACY SPECIFICATIONS C: ELECTRICAL Model Sedan/Wagon 2.0 L Non-TURBO 2.5 L Non-TURBO Ignition timing at idling speed BTDC/rpm 10°±10° Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst) CHAMPION: RC10YC4 (with catalyst) Alternate NGK: BKR5E-11 (with catalyst) With OBD CHAMPION: RC10YC4 Alternate NGK: BKR6E-11...
Page 15 LEGACY SPECIFICATIONS Model Sedan 2.0 L TURBO Transmission type 4AT-SS Clutch type DSPD Gear ratio 3.166 2.785 1.882 1.545 1.296 1.000 0.972 0.694 0.738 — Reverse 3.333 2.272 Reduction gear 1st reduction Type of gear — Helical (Front drive) Gear ratio —...
Page 16 LEGACY SPECIFICATIONS I: CAPACITY Model Sedan/Wagon 2.0 L 2.5 L 2 (US gal, Imp gal) Fuel tank 64 (16.9, 14.1) 2 (US qt, Imp qt) Engine oil (When replacing) Approx. 4.0 (4.2, 3.5), 4.5 (4.8, 4.0)* 2 (US qt, Imp qt) Transmission gear oil 3.5 (3.7, 3.1) —...
Page 17 LEGACY SPECIFICATIONS Option code *1 Model 2.5 L Curb weight (C.W.) Front kg (lb) (1,775) (1,830) (1,750) (1,810) (1,730) (1,785) Rear kg (lb) (1,335) (1,345) (1,345) (1,355) (1,345) (1,355) Total kg (lb) 1,410 1,440 1,405 1,435 1,395 1,425 (3,110) (3,175) (3,095) (3,165) (3,075)
Page 18 LEGACY SPECIFICATIONS Option code *1 Model 2.0 L 2.5 L GL (GX) GX (RX) Unladen mass (U.M.) Front kg (lb) 780 (1,720) 775 (1,710) 775 (1,710) 785 (1,730) Rear kg (lb) 585 (1,290) 585 (1,290) 595 (1,310) 595 (1,310) Total kg (lb) 1,365 (3,010) 1,360 (3,000)
Page 19 LEGACY SPECIFICATIONS 2. WAGON • LHD Vehicle Option code *1 KO, KS Model 2.0 L Curb weight (C.W.) Front kg (lb) (1,720) (1,765) (1,710) (1,740) (1,740) (1,775) Rear kg (lb) (1,435) (1,435) (1,445) (1,445) (1,445) (1,445) Total kg (lb) 1,430 1,450 1,430 1,445...
Page 20 LEGACY SPECIFICATIONS • RHD Vehicle Option code *1 Model 2.0 L 2.5 L Curb weight (C.W.) Front kg (lb) (1,710) (1,740) (1,750) (1,785) (1,740) (1,775) Rear kg (lb) (1,445) (1,445) (1,435) (1,435) (1,445) (1,445) Total kg (lb) 1,430 1,445 1,445 1,460 1,445 1,460...
Page 21 OUTBACK SPECIFICATIONS 2. OUTBACK A: DIMENSIONS Model OUTBACK Overall length mm (in) 4,720 (185.8) Overall width mm (in) 1,745 (68.7) Overall height (at CW) mm (in) 1,580 (62.2), 1,590 (62.6)*3 Compartment Length mm (in) 1,925 (75.8) Width mm (in) 1,440 (56.7), 1,420 (55.9)*1 Height mm (in) 1,190 (46.9), 1,175 (46.3)*2...
Page 22 OUTBACK SPECIFICATIONS C: ELECTRICAL Model OUTBACK 2.5 L 3.0 L Ignition timing at idling BTDC/rpm 10°±10° 10°±8° speed Spark plug Type and manufacturer CHAMPION: RC10YC4 NGK: PLFR6A-11 Alternate NGK: BKR6E-11 NGK: BKR5E-11 Generator 12V — 90A 12V — 100A Battery Type and capacity (5HR) For Europe and MT: 12V —...
Page 23 OUTBACK SPECIFICATIONS E: STEERING Model OUTBACK Type Rack and Pinion Turns, lock to lock Minimum turning circle Curb to curb 11.2±1.0 (36.7±3.3) m (ft) Wall to wall 12.0±1.0 (39.4±3.3) F: SUSPENSION Model OUTBACK Front Macpherson strut type, Independent, Coil spring Rear Multi-link type, Independent, Coil spring G: BRAKE...
Page 24 OUTBACK SPECIFICATIONS J: WEIGHT 1. OUTBACK • LHD vehicle Option code *1 Model 2.5 L Curb weight (C.W.) Front kg (lb) 810 (1,785) 825 (1,820) 815 (1,795) 830 (1,830) Rear kg (lb) 670 (1,475) 670 (1,475) 670 (1,475) 670 (1,475) Total kg (lb) 1,480 (3,265)
Page 25 OUTBACK SPECIFICATIONS • RHD vehicle Option code *1 Model 2.5 L 3.0 L Curb weight (C.W.) Front kg (lb) 800 (1,765) 815 (1,795) 915 (2,020) Rear kg (lb) 670 (1,475) 670 (1,475) 695 (1,530) Total kg (lb) 1,470 (3,240) 1,485 (3,275) 1,610 (3,550) Maximum permissible Front...
Page 26 PRECAUTION Page Precaution ....................2...
Page 27 PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handing and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...
Page 28 NOTE Page Note......................2...
Page 29 ECM from rush current. 4. SERVICE PARTS Use authentic service parts for maximum performance and maintenance, when conducting repairs. Subaru/ FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer.
Page 30 NOTE NOTE • Pantograph jack With side sill cover NT-00049 Without side sill cover NT-00050 • Lift NT-00046 NT-3...
Page 31 NOTE NOTE • Safety stand NT-00047 Front Front crossmember Rear differential gear Rear NT-00036 NT-4...
Page 32 NOTE NOTE 6. TIE DOWNS Tie-downs are used when transporting vehicles and when using the chassis dynamo. • Tie-down points Attach tie-downs only to the specified points on the vehicle. Hook for towing (Except OUTBACK) Hook for towing (OUTBACK) Hook for tie-down Hook for towing Hook for tie-down and tie-down...
Page 33 NOTE NOTE • Chain direction at tie-down condition 7. TOWING Avoid towing vehicles except when the vehicle can- not be driven. For vehicles with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damag- ing the hook or vehicle: •...
Page 34 For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-7...
Page 35 NOTE NOTE MEMO: NT-8...
Page 36 IDENTIFICATION Page Identification ....................2...
Page 37 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification Emission control label Vehicle identification number • ID plate (Europe model) •...
Page 38 IDENTIFICATION IDENTIFICATION Model number plate J F 1 B E 5 L J 3 3 G 0 E 9 E L 7 J E J 2 5 1 N J E A A T Y 7 5 4 V F B A A ID-00049 2.
Page 39 IDENTIFICATION IDENTIFICATION • GCC countries (Saudi Arabia, etc.) ]JF1BE54MX3G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line Legacy/OUTBACK series Body type E: Sedan H: Station Wagon/OUTBACK Displacement...
Page 40 IDENTIFICATION IDENTIFICATION The engine and transmission type are as follows: • Engine EJ251NJEAA Digits Code Meaning Details 1 and 2 Engine type EJ: 4 cylinders EZ: 6 cylinders 3 and 4 Displacement 20: 2.0 L 25: 2.5 L 30: 3.0 L Fuel feed system 1: D-MPI SOHC-A 6: MPI TWIN TURBO...
Page 41 IDENTIFICATION IDENTIFICATION • Rear differential 2 • Option code ECPS Code Reduction Digits Code Meaning Details gear ratio 1 to 2 Destination EC: EC 3.900 KO: KO K4: K4 4.111 KS: KS 4.444 EK: EK 4.444 No (Strengthened type) KA: KA 3.700 K1: K1 4.444...
Page 42 RECOMMENDED MATERIALS Page Recommended Materials ................2...
Page 43: Gasoline Engines
RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials • Unleaded gasoline Use unleaded gasoline and not leaded gasoline on A: RECOMMENDED MATERIALS vehicles with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the 1. GENERAL catalytic converter. To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc.
Page 44 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil (˚C) –30 –20 –10 –4 (˚F) –22 10W-30 or 10W-40 5W-30 Recommend RM-00003 Manual transmission oil and rear differential gear oil –30 –20 –10 (˚C) –22 –4 (˚F) 75W-90 RM-00004 RM-3...
Page 45 Water for dilution Distilled water — Tap water 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for ZXL200PG. Air conditioner Recommended Item number...
Page 46 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary lubricants • O2 sensor SUBARU CRC 004301003 — • Bolts, etc. Grease MT main shaft FX clutch grease 000040901 —...
Page 47 RECOMMENDED MATERIALS RECOMMENDED MATERIALS MEMO: RM-6...
Page 48 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
Page 49 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. •...
Page 50 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION B: PDI PROCEDURE Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective film, visually check the vehicle body for damage and dents.
Page 51 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 1. Test mode connector (1) Disconnect the test mode connector. 2. Starting condition (1) Start the engine and check that the engine starts smoothly. 3. Exhaust system (1) Check that the exhaust noise is normal and no leaks are found. 4.
Page 52 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 3.0 L model 1) When vehicle is covered with protective film, in- spect visually for damage or dents to vehicle body surface. 2) When protective film is removed, check the body paints for small areas of damage or stains and re- pair as necessary.
Page 53 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION • Vehicles with power door locks: • Using the key, open the trunk lid several times to check for normal operation. Sit in the driver seat, close the driver's door com- • Open and close the trunk lid several times for pletely, and place the lock lever to the lock position.
Page 54 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 9. OPERATION CHECK OF FUEL LID 11. OPERATION CHECK OF HOOD LOCK OPENER LOCK RELEASE LEVER RELEASE SYSTEM Operate the fuel lid opener and verify that the fuel By operating front hood release knob, confirm front lid opens normally.
Page 55 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 13. BRAKE FLUID 16. AT FRONT DIFFERENTIAL OIL Check the brake fluid amount. If the amount is in- Check the AT front differential oil amount. If the sufficient, carry out a brake line test to identify amount is insufficient, check that no leaks are brake fluid leaks and check the brake operation.
Page 56 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 20. FRONT HOOD LATCH CHECK 24. WHEEL ALIGNMENT Retract the front hood stay and close the hood. Check the wheel alignments. <Ref. to FS-6, Wheel Check that the front hood is securely latched. Alignment.> and <Ref. to RS-8, Wheel Align- ment.>...
Page 57 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 26. STARTING CONDITION Front Injection position: Start the engine and check that the engine starts A: 350 mm (13.78 in) smoothly. If any battery voltage problems are B: 150 mm (5.91 in) found, recharge or replace the battery. If any ab- C: 300 mm (11.81 in) normal noises are observed, immediately stop the D: 600 mm (23.62 in)
Page 58 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 38. AT SHIFT CONTROL 42. ATF LEVEL Set the AT select lever to each gear position while Check that the ATF level is normal. If insufficient, checking that the demanded gear position is cor- check that no leaks are found. Then add the neces- rectly attained.
Page 59 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 45. WATER LEAK TEST • It is desirable not to make corrections to the body paint unless absolutely needed. However, if any Spray the vehicle with water and check that no wa- corrections are required to remove scratches or ter enters the passenger compartment.
Page 60: Table Of Contents
PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................7 Engine Oil Filter...................9 Spark Plugs....................10 Drive Belt(s) ....................12 Camshaft Drive Belt ..................15 Fuel Line ....................18 Fuel Filter ....................19 Air Cleaner Element ..................20 Cooling System ..................21 Coolant......................22 Clutch System ...................24 Hill-holder System ..................25 Idle Mixture....................26 Transmission Oil ..................27...
Page 61: General Description
GENERAL DESCRIPTION PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
Page 62: Schedule
SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. EUROPE For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.
Page 63 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT EUROPE For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
Page 64 SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 1. EUROPE Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace...
Page 65 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT EUROPE Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace Replace...
Page 66: Engine Oil
ENGINE OIL PERIODIC MAINTENANCE SERVICES 3. Engine Oil 3.0 L model A: REPLACEMENT ( B ) ( A ) NOTE: ( C ) Replace engine oil and engine oil filter at the same ( E ) time. ( D ) 1) Drain engine oil by loosening engine oil drain plug.
Page 67 ( D ) gine; however, use oil having the API classification, and SAE viscosity No. designated by SUBARU. • If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,...
Page 68: Engine Oil Filter
ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter 2) Remove under cover. 3) Remove oil filter with ST. A: REPLACEMENT ST 498547000 OIL FILTER WRENCH 1. EXCEPT 3.0 L MODEL 1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH ( B ) PM-00109...
Page 69: Spark Plugs
SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs 2. 2.0 L TURBO AND 3.0 L MODEL 1) Disconnect battery cables and then remove bat- A: REPLACEMENT tery and battery carrier. 1. 2.0 L NON-TURBO AND 2.5 L MODEL 2) Remove washer tank and put it aside. 3) Remove air cleaner lower case.
Page 70 SPARK PLUGS PERIODIC MAINTENANCE SERVICES 9) Tighten ignition coil. Tightening torque: 16 N·m (1.6 kgf-m, 11.7 ft-lb) NOTE: • Be sure to place the gasket between the cylinder head and spark plug. • If torque wrench is not available, tighten spark plug until gasket contacts cylinder head: then tight- en further 1/4 to 1/2 turn.
Page 71: Drive Belt(S)
DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6. Drive Belt(s) 2. 3.0 L MODEL 1) Replace belts, if cracks, fraying or wear is found. A: INSPECTION 2) Check that the V-belt automatic tensioner indica- 1. EXCEPT 3.0 L MODEL tor is within the range (D). 1) Replace belts, if cracks, fraying or wear is found.
Page 72 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 11) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension. 1. EXCEPT 3.0 L MODEL 12) Tighten the lock bolt (A). 13) Tighten the slider bolt (B). 1) Remove V-belt cover.
Page 73 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 3) Install in the reverse order of removal. ( F ) ( A ) ( D ) ( E ) ( B ) ( C ) PM-00119 (A) Power steering oil pump (B) Belt tension adjuster (C) Crankshaft pulley (D) A/C compressor (E) Belt idler...
Page 74: Camshaft Drive Belt
CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7. Camshaft Drive Belt 9) Remove timing belt guide. (MT vehicle only) A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove radiator fan. <Ref. to CO(H4SO)-28, Radiator Main Fan and Fan Motor.> and <Ref. to CO(H4SO)-30, Radiator Sub Fan and Fan Motor.>...
Page 75 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 13) Remove timing belt. 10) Remove timing belt guide. (MT vehicle only) 14) Remove automatic belt tension adjuster as- sembly. PM-00008 11) Turn the crankshaft and align the alignment PM-00123 marks on crankshaft, and left and right camshaft sprockets with notches of belt cover and cylinder 15) Install in the reverse order of removal.
Page 76 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 13) Remove the timing belt. 2. TURBO MODEL 14) Remove the automatic belt tension adjuster as- 1) Remove the left and right timing belt covers. sembly. 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or damage.
Page 77: Fuel Line
FUEL LINE PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. •...
Page 78: Fuel Filter
FUEL FILTER PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT Refer to Fuel section for replacing fuel filter. • 2.0 L non-TURBO and 2.5 L with OBD models <Ref. to FU(H4SO)-67, Fuel Filter.> • 2.0 L non-TURBO and 2.5 L without OBD models <Ref.
Page 79: Air Cleaner Element
AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2. 2.0 L TURBO AND 3.0 L MODEL 1) Loosen clamp (A), and separate air cleaner up- A: REPLACEMENT per cover and air intake boot. (3.0 L model) 1. 2.0 L NON-TURBO AND 2.5 L MODEL 2) Remove the clip (B) above the air cleaner upper cover.
Page 80: Cooling System
COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 11.Cooling System 2) Check the radiator cap valve open pressure us- ing radiator cap tester. A: INSPECTION NOTE: 1) Check radiator for leakage, filling it with coolant Rust or dirt on cap may prevent valve from func- and attach radiator cap tester (A) to the filler neck.
Page 81: Coolant
Approx. 7.9 2 (8.4 US qt, 7.0 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. 9) Securely install radiator cap.
Page 82 The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.
Page 83: Clutch System
CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 13.Clutch System 5) Check the fluid level using the scale on the out- side of the clutch master cylinder tank (A). If the lev- A: INSPECTION AND ADJUSTMENT el is below “MIN” (B), add clutch fluid to bring it up to “MAX”...
Page 84: Hill-Holder System
HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 14.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or high- er inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly;...
Page 85: Idle Mixture
IDLE MIXTURE PERIODIC MAINTENANCE SERVICES 15.Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIXTURE Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”...
Page 86: Transmission Oil
TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 16.Transmission Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain gear oil by removing drain plug after allow- ing the engine to cool for 3 to 4 hours. NOTE: • Before starting work, cool off the engine well. •...
Page 87: Atf
PERIODIC MAINTENANCE SERVICES 17.ATF 4) Fluid temperature rising speed • By idling the engine A: INSPECTION Time for temperature rise to 70°C (158°F) with at- 1) Raise ATF temperature to 70 to 80°C (158 to mospheric temperature of 0°C (32°F): More than 176°F) by driving for approx.
Page 88 PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 1. AUTOMATIC TRANSMISSION FLUID 1) Drain ATF (Automatic Transmission Fluid) by re- moving drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. PM-00032 (A) Front differential drain plug (B) ATF drain plug...
Page 89: Front & Rear Differential Oil
FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Oil 2) Reinstall drain plug after draining differential gear oil and tighten it to the specified torque. A: REPLACEMENT Tightening torque: 1. FRONT DIFFERENTIAL (MANUAL 44 N·m (4.5 kgf-m, 32.5 ft-lb) TRANSMISSION) NOTE: •...
Page 90 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 3. REAR DIFFERENTIAL 4) After installing drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler • VA type plug. 1) Drain oil by removing drain plug. 2) Remove filler plug for quicker draining.
Page 91: Brake Line
BRAKE LINE PERIODIC MAINTENANCE SERVICES 19.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on brake hoses or pipe 1 —...
Page 92 BRAKE LINE PERIODIC MAINTENANCE SERVICES (4) If there is no free play between clevis pin 4) Check to see if air is in the hydraulic brake line and clevis, turn brake switch adjusting nut until by the feel of pedal operation. If air appears to exist the clearance between stopper and screw of in the line, bleed it from the system.
Page 93: Brake Fluid
BRAKE FLUID PERIODIC MAINTENANCE SERVICES 20.Brake Fluid NOTE: • Cover bleeder with waste cloth, when loosening A: REPLACEMENT it, to prevent brake fluid from being splashed over 1) Either jack up vehicle and place a safety stand surrounding parts. under it, or lift up vehicle. •...
Page 94: Disc Brake Pads And Discs
DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs • Turbo model Brake disc thickness mm (in) A: INSPECTION Front Rear 1. DISC BRAKE PAD AND DISC Standard 24 (0.94) 18 (0.71) Wear limit 22 (0.87) 16 (0.63) 1) Jack up vehicle and support with rigid racks.
Page 95: Parking Brake
PARKING BRAKE PERIODIC MAINTENANCE SERVICES 22. Parking Brake 3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them. A: INSPECTION 4) When the shoe return spring tension is exces- Inspect brake linings and drums of both sides of the sively weakened, replace it, taking care to identify rear brake at the same time by removing brake upper and lower springs.
Page 96 PARKING BRAKE PERIODIC MAINTENANCE SERVICES B: ADJUSTMENT 1. SHOE CLEARANCE 1) Remove adjusting hole cover from back plate. 2) Turn adjusting screw using a slot-type screw- driver until brake shoe is in close contact with disc rotor. PM-00056 (A) Adjusting screw (B) Cover (rubber) (C) Back plate 3) Turn back (downward) adjusting screw 3 or 4...
Page 97: Suspension
SUSPENSION PERIODIC MAINTENANCE SERVICES 23.Suspension 5) Damage of dust seal Visually inspect ball joint dust seal. If it is damaged, A: INSPECTION remove transverse link. <Ref. to FS-14, Front Transverse Link.> And measure free play of ball 1. SUSPENSION BALL JOINT joint.
Page 98 SUSPENSION PERIODIC MAINTENANCE SERVICES 3. WHEEL ARCH HEIGHT 6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER 1) Unload cargoes and set vehicle in curb weight (empty) condition. Visually inspect front strut and rear shock absorber 2) Then, check wheel arch height of front and rear for oil leakage as instructed.
Page 99: Wheel Bearing
WHEEL BEARING PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 2. REAR WHEEL BEARING 1) Jack up the rear of vehicle. A: INSPECTION 2) While holding rear wheel by hand, swing it in and 1. FRONT WHEEL BEARING out to check bearing free play. 3) Loosen wheel nuts and remove rear wheel.
Page 100: Axle Boots & Joints
AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 25.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones. <Ref. to DS-28, Front Drive Shaft.>...
Page 101: Tire Rotation
TIRE ROTATION PERIODIC MAINTENANCE SERVICES 26.Tire Rotation A: INSPECTION 1) Replace the tire if the tread depth is less than 1.6 mm (0.063 in) or if wear indicators appear across the tire tread. (It is recommended that both right and left tires are replaced as a set.) 2) Adjust the wheel alignment if abnormally uneven tire wear is found.
Page 102: Steering System (Power Steering)
STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 27.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When steering wheel free play is excessive, dis- connect universal joint of steering shaft and check A: INSPECTION it for any play and yawing torque (at the point of the crossing direction).
Page 103 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL perimeter of adjusting screw thread. 1) Place vehicle with engine “off” on the flat and level surface. 2) Inspect fluid level by indicator of reservoir tank. If the level is at lower point or below, add fluid to keep the level in the specified range of the indica- tor.
Page 104 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check pressure hose and return hose of oil pump for crack, swell or damage. Replace hose with a new one if necessary. NOTE: Prevent hoses from revolving and/or turning when installing hoses.
Page 105 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES MEMO: PM-46...
Page 106 EC(H4SO) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO) MECHANICAL ME(H4SO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4SO)
Page 107 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SOw/oOBD) SPEED CONTROL SYSTEMS SP(H4SOw/oOBD) IGNITION IG(H4SOw/oOBD) STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD) ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD) G2300GE2...
Page 108 FUEL INJECTION (FUEL SYSTEMS) FU(H4SO) Page General Description ..................2 Throttle Body.....................14 Intake Manifold..................15 Engine Coolant Temperature Sensor............26 Crankshaft Position Sensor...............27 Camshaft Position Sensor.................28 Knock Sensor....................29 Throttle Position Sensor................30 Pressure Sensor ..................32 Intake Air Temperature Sensor ..............33 Idle Air Control Solenoid Valve ..............34 EGR Valve ....................35 Fuel Injector ....................36 Front Oxygen (A/F) Sensor ...............41...
Page 109: General Description
GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model Specification 64 2 (16.9 US gal, 14.1 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
Page 110 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) MEMO: FU(H4SO)-3...
Page 111 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (19) (21) (23) (19) (15) (10) (20) (11) (22) (14) (18) (17) (20) (12) (17) (13) (16) (18) (16) (17) FU-00377 FU(H4SO)-4...
Page 112 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Intake manifold gasket RH (11) Intake manifold (21) Plug cord holder RH (2) Fuel injector pipe (12) Intake manifold gasket LH (22) Accelerator cable bracket (3) Fuel injector (13) Fuel pipe protector LH (23) EGR valve (4) O-ring (14) Plug cord holder LH...
Page 113 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-00247 (1) Gasket (5) Throttle body Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor (6) Intake air temperature sensor T1: 1.6 (0.16, 1.2) (3) Idle air control solenoid valve (7) Grommet T2: 22 (2.2, 15.9) (4) Pressure sensor...
Page 114 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITIOM, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 (1) Crankshaft position sensor (4) Camshaft position sensor support Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor T1: 6.4 (0.65, 4.7) (3) Camshaft position sensor T2: 24 (2.4, 17.4) FU(H4SO)-7...
Page 115 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK ( 6 ) (13) (28) (29) (36) (17) (34) (10) (12) (30) (14) (33) (11) (38) (16) ( 7 ) (37) ( 5 ) (31) (15) ( 9 ) ( 8 ) (22) (21) (27)
Page 116 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Heat shield cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...
Page 117 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (29) (28) (30) (31) (32) (26) (25) (27) ( 1 ) (24) ( 1 ) (17) ( 1 ) (19) (23) (18) ( 1 ) (20) (22) ( 1 ) (16) (21) ( 7 ) ( 3 )
Page 118 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Clamp (12) Damper valve (Delivery) (23) Evaporation pipe ASSY (2) Fuel return hose A (13) Bracket (24) Purge hose (3) Damper valve (Return) (14) Fuel delivery hose C (25) Evaporation hose C (4) Fuel return hose B (15) Fuel pipe ASSY (26) Canister drain hose (5) Clip...
Page 119 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE ( 5 ) ( 4 ) ( 6 ) ( 1 ) ( 7 ) ( 2 ) ( 3 ) FU-00628 (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap...
Page 120 24082AA210 CARTRIDGE Troubleshooting for electrical system. (Newly adopted tool) ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...
Page 121: Throttle Body
THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 7) Remove the bolts (B) which install throttle body to the intake manifold. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00253 B: INSTALLATION FU-00009 1) Install in the reverse order of removal. 2) Remove the air cleaner case.
Page 122: Intake Manifold
INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold NOTE: Do not disconnect the power steering hose. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO)- 48, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Open the fuel flap lid, and remove the fuel filler cap.
Page 123 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place the power steering pump on the right 12) Remove the air cleaner case stay RH and en- side wheel apron. gine harness bracket, and disconnect the engine harness connectors from the bulkhead harness connectors.
Page 124 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect the connector from the oil pressure 19) Disconnect the fuel hoses from the fuel pipes. switch. WARNING: • Do not spill fuel. • Catch fuel from hoses in a container or cloth. ( A ) ( B ) FU-00146...
Page 125 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel hoses. 5) Connect the connector to the oil pressure switch. ( A ) ( B ) ( C ) FU-00259 FU-00146 6) Connect the connector to the crankshaft position (A) Fuel delivery hose sensor.
Page 126 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Install the air cleaner case stay RH and engine 14) Install the power steering pump and reservoir harness bracket, and connect the engine harness tank to bracket. connectors to the bulkhead connectors. (1) Install the reservoir tank to bracket. FU-00258 FU-00020 10) Connect the brake booster hose.
Page 127 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (5) Install the front side V-belt. <Ref. to 19) Connect the battery ground cable to battery. ME(H4SO)-42, INSTALLATION, V-belt.> (6) Install the resonator chamber. Tightening torque: 33 N·m (3.4 kgf-m, 24.6 ft-lb) FU-00009 C: DISASSEMBLY 1) Disconnect the engine ground terminal from the intake manifold.
Page 128 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 6) Disconnect the pressure regulator vacuum hose 10) Disconnect the connector from the purge con- from the intake manifold. trol solenoid valve. FU-00265 FU-00269 7) Remove the fuel pipe protector LH. 11) Disconnect the air by-pass hose from the purge control solenoid valve.
Page 129 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Remove the bolt which installs injector pipe on 18) Loosen the clamp which holds the front left side the intake manifold as shown in figure. fuel hose to the injector pipe and remove the pipe. FU-00272 FU-00171 16) Remove the two bolts which hold fuel pipes on...
Page 130 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 6) Install the fuel injectors. 1) Install the fuel pipe assembly and pressure reg- NOTE: ulator, etc. to the intake manifold. Replace the O-rings with new ones. 2) Tighten the bolt which installs the fuel pipes on the intake manifold.
Page 131 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) Tightening torque: NOTE: 19 N·m (1.94 kgf-m, 13.7 ft-lb) Connect the evaporation hose as shown in the fig- ure. FU-00284 FU-00285 8) Tighten the two bolts which install the fuel pipes on the left side of intake manifold. (A) To fuel pipe Tightening torque: (B) To intake manifold...
Page 132 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Install the fuel pipe protector LH. 21) Install the engine ground terminal to the intake manifold. Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) Tightening torque: 19 N·m (1.94 kgf-m, 13.7 ft-lb) FU-00266 FU-00287 16) Connect the pressure regulator vacuum hose to the intake manifold.
Page 133: 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. FU-00009 2) Remove the air intake duct and air cleaner as- sembly. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> and <Ref.
Page 134: Crankshaft Position Sensor
CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) FU-00009 FU-00058 2) Remove the bolt which install crankshaft position sensor to the cylinder block.
Page 135: Camshaft Position Sensor
CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam- shaft position sensor support as a unit. A: REMOVAL 6) Remove the camshaft position sensor itself. 1) Disconnect the ground cable from battery. FU-00179 FU-00009 B: INSTALLATION...
Page 136: Knock Sensor
KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to the cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60×...
Page 137: Throttle Position Sensor
THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor CAUTION: When installing throttle position sensor, adjust A: REMOVAL to the specified data. 1) Disconnect the ground cable from battery. FU-00290 FU-00009 C: ADJUSTMENT 2) Disconnect the connector from the throttle posi- 1) Turn the ignition switch to OFF.
Page 138 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) ( A ) EN-00710 5) Turn the ignition switch to ON, and the Subaru Select Monitor switch to ON. FU-00291 6) Select the {2. Each System Check} in Main 4) When using Subaru Select Monitor;...
Page 139: Pressure Sensor
PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Pressure Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 FU-00295 2) Disconnect the connector from the pressure sensor.
Page 140: Intake Air Temperature Sensor
INTAKE AIR TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Intake Air Temperature Sen- A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector from the intake air temperature sensor. 3) Remove the intake air temperature sensor from air cleaner case.
Page 141: Idle Air Control Solenoid Valve
IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use new gasket. 1) Disconnect the ground cable from battery. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 2) Disconnect the connector from the idle air con- FU-00299...
Page 142: Egr Valve
EGR VALVE FUEL INJECTION (FUEL SYSTEMS) 12.EGR Valve A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector from EGR valve. FU-00210 3) Remove the EGR valve from intake manifold. FU-00211 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00211...
Page 143: Fuel Injector
FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13.Fuel Injector (3) Remove the bolts which install the power steering pump to the bracket. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO)- 48, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.>...
Page 144 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. (1) Remove the fuel injector securing clip. FU-00267 FU-00305 8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the fuel injector pipe. FU-00303 FU-00306 9) Remove the bolt which holds the injector pipe to...
Page 145 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 4) Remove the two bolts which install the washer 9) Remove the spark plug cords from the spark tank on the body. plugs (#2 and #4 cylinders). FU-00190 FU-00307 5) Disconnect the connector from the front window 10) Remove the fuel pipe protector LH.
Page 146 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13) Remove the bolt which holds the fuel pipe on B: INSTALLATION the left side intake manifold. 1. RH SIDE Install in the reverse order of removal. NOTE: Replace O-rings with new ones. ( A ) FU-00170 ( B ) 14) Remove the fuel injector from the intake mani-...
Page 147 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) FU-00267 FU-00170 Tightening torque: Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb) 19 N·m (1.94 kgf-m, 13.7 ft-lb) FU-00261 FU-00309 2.
Page 148: Front Oxygen (A/F) Sensor
21 N·m (2.1 kgf-m, 15.2 ft-lb) EX-00029 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the front oxygen (A/F) sensor.
Page 149 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. FU-00009 FU(H4SO)-42...
Page 150: Rear Oxygen Sensor
2) Install the rear oxygen sensor. Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) EX-00030 4) Apply SUBARU CRC or its equivalent to the threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the rear oxygen sensor.
Page 151 REAR OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. FU-00009 FU(H4SO)-44...
Page 152: Engine Control Module
ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 16.Engine Control Module A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the lower inner trim of passenger side. <Ref. to EI-39, REMOVAL, Lower Inner Trim.> 3) Detach the floor mat of front passenger seat. 4) Remove the protect cover.
Page 153: Main Relay
MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 17.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the passenger's side front side sill cov- 3) Remove the bolt which holds main bracket on the body. 4) Disconnect the connectors from the main relay. FU-00441 B: INSTALLATION Install in the reverse order of removal.
Page 154: Fuel Pump Relay
FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 18.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the passenger's side front side sill cov- 3) Remove the bolt which holds fuel pump relay bracket on the body. 4) Disconnect the connector from the fuel pump.
Page 155: Fuel
FUEL FUEL INJECTION (FUEL SYSTEMS) 19.Fuel 4) Remove the protector RH (Front). A: OPERATION 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Disconnect the connector from fuel pump relay (A).
Page 156 FUEL FUEL INJECTION (FUEL SYSTEMS) 7) Lower the vehicle. 12) Drain the fuel from fuel tank by using a hand pump. 8) Remove the sub service hole cover. WARNING: Do not use a motor pump when draining the fu- 13) After draining the fuel, reinstall the fuel sub lev- el sensor.
Page 157 FUEL FUEL INJECTION (FUEL SYSTEMS) (3) Install the sub service hole cover. FU-00445 (4) Set the rear seat and floor mat. FU(H4SO)-50...
Page 158: Fuel Tank
FU-00443 service hole cover into body side. 13) Remove the rear exhaust pipe and muffler. NOTE: To facilitate the removal, apply a coat of SUBARU CRC to matching area of rubber cushions in ad- vance. SUBARU CRC (Part No. 004301003)
Page 159 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) (1) Separate the rear exhaust pipe from center 16) Remove the bolts which hold parking brake ca- exhaust pipe. ble holding bracket. 17) Remove the parking brake cable from cabin by forcibly pulling it backward. FU-00455 (2) Remove the right and left rubber cushions.
Page 160 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 21) Remove the rear suspension assembly. 23) Disconnect the two-way vlave hose (A) from two-way valve, and then disconnect the evapora- CAUTION: tion hose (B) from evaporation pipe. A helper is required to perform this work. (1) Support the rear differential with transmis- sion jack.
Page 161 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 6) Install the rear side protector. CAUTION: A helper is required to perform this work. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) LH side RH side FU-00468 FU-00465 3) Connect the two-way valve hose (A) to two-way valve, and then connect the evaporation hose (B) 7) Install the rear suspension assembly.
Page 162 To facilitate the procedure, apply a coat of SUBA- RU CRC to matching area of the rubber cushions in advance. FU-00461 SUBARU CRC (Part No. 004301003) (1) Install the right and left rubber cushions. 10) Install the parking brake cable to cabin by forc- ibly pushing it forward.
Page 163 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) (2) Install the front rubber cushion and attach 21) Connect the fuel hoses, and then hold them muffler assembly. with the quick connector. <Ref. to FU(H4SO)-71, INSTALLATION, Fuel Delivery, Return and Evapo- ration Lines.> ( A ) ( B ) FU-00457...
Page 164 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 25) Connect the connectors to fuel tank cord, and then plug the service hole with grommet. FU-00450 26) Install the holder clip which secures fuel tank cord on bracket. FU-00449 27) Set the rear seat and floor mat. 28) Connect the connector to fuel pump relay (A).
Page 165: Fuel Filler Pipe
FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Filler Pipe 8) Remove the protector RH (Front). A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO)- 48, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Open the fuel filler flap lid, and then remove the filler cap.
Page 166 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 11) Remove the fuel filler pipe protector. 15) Move the clip, and then separate the air vent hose (B). ( B ) ( A ) FU-00476 FU-00675 12) Remove the bolts which hold evaporation pipe bracket on fuel filler pipe.
Page 167 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 7) Tighten the bolts which hold evaporation pipe NOTE: bracket on fuel pipe. Do not allow clips to touch air vent hose (B) and rear suspension crossmember. ( B ) ( A ) FU-00675 5) Insert the air vent hose approx.
Page 168 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 12) Connect the connector to fuel pump relay (A). ( A ) FU-00648 13) Connect the battery ground cable to battery. FU-00009 FU(H4SO)-61...
Page 169: Fuel Pump
FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump 7) Tighten the fuel drain plug, and then install the protector RH (Front). A: REMOVAL Tightening torque: WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb) • Place “NO FIRE” signs near the working area. •...
Page 170 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 11) Move the clips, and then disconnect the jet C: DISASSEMBLY pump hose (C). 1) Remove the fuel pump and pump holder. 12) Disconnect the quick connector, and then dis- NOTE: connect the fuel delivery hose (A) and return hose When disassembling the pump holder, be careful (B).
Page 171: Fuel Level Sensor
FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Level Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL WARNING: WARNING: • Ground cable must be connnected. • Place “NO FIRE” signs near the working area. • Spark may occur and ignite if fuel is nearby. •...
Page 172: Fuel Sub Level Sensor
FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Sub Level Sensor 5) Tighten the fuel drain plug and install the protec- tor RH (Front). A: REMOVAL Tightening torque: WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb) • Place “NO FIRE” signs near the working area. •...
Page 173 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 9) Disconnect the fuel jet pump hose. FU-00447 10) Remove the bolts which install fuel sub level sensor on fuel tank. FU-00448 11) Remove the fuel sub level sensor. B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) FU-00448...
Page 174: Fuel Filter
FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filter B: INSTALLATION NOTE: A: REMOVAL • If the fuel hoses are damaged at the connecting WARNING: portion, replace it with a new one. • Place “NO FIRE” signs near the working area. •...
Page 175: Fuel Cut Valve
FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Cut Valve A: REMOVAL 1) Remove the fuel tank. <Ref. to FU(H4SO)-51, REMOVAL, Fuel Tank.> 2) Move the clip, and then disconnect the evapora- tion hose from fuel cut valve. FU-00684 3) Remove the bolts which install fuel cut valve. B: INSTALLATION Install in the reverse order of removal.
Page 176: Fuel Damper Valve
FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Damper Valve A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO)- 48, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Remove the fuel damper valve from fuel delivery line (A) and return line (B). ( B ) ( A ) FU-00686...
Page 177: Fuel Delivery, Return And Evaporation Lines
FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Delivery, Return and 3) Open the fuel filler flap lid, and then remove the fuel filler cap. Evaporation Lines 4) Remove the floor mat. <Ref. to EI-48, REMOV- AL, Floor Mat.> A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel 1) Set the vehicle on the lift.
Page 178 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) NOTE: NOTE: Replace the retainer with new ones. At this time, two clicking sounds are heard. ( A ) ( B ) ( B ) ( C ) ( C ) ( A ) FU-00124 FU-00126...
Page 179 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) L: 22.5 ± ± ± ± 2.5 mm (0.886 ± ± ± ± 0.098 in) ( 3 ) ( 1 ) ( 2 ) ( A ) ( B ) FU-00688 (1) Fitting (2) Clamp...
Page 180: Fuel System Trouble In General
FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 29.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten Defective terminal contact.
Page 181 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) MEMO: FU(H4SO)-74...
Page 182 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................4 EGR Valve ....................5 Canister.......................6 Purge Control Solenoid Valve ..............7 Two-way Valve....................8...
Page 183: General Description
GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 184: Front Catalytic Converter
FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal procedure is the same as that for the center exhaust pipe.
Page 185: Rear Catalytic Converter
REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal procedure is the same as that for the center exhaust pipe.
Page 186: Egr Valve
EGR VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. EGR Valve A: REMOVAL For work procedures, refer to “FU(H4SO)” section. <Ref. to FU(H4SO)-35, REMOVAL, EGR Valve.> B: INSTALLATION For work procedures, refer to “FU(H4SOH4SO)” section. <Ref. to FU(H4SO)-35, INSTALLATION, EGR Valve.> EC(H4SO)-5...
Page 187: Canister
CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Canister A: REMOVAL 1) Lift-up the vehicle. 2) Loosen two clamps which hold two canister hos- es, and disconnect evaporation three hoses from canister. EC-00150 3) Remove canister from body. EC-00151 B: INSTALLATION 1) Install in the reverse order of removal.
Page 188: Purge Control Solenoid Valve
PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Purge Control Solenoid Valve B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00009 EC-00014 2) Disconnect the connector and hoses from purge...
Page 189: 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 hoses from two-way valve. EC-00153 3) Remove two-way valve with bracket as a single unit from body. EC-00154 4) Remove two-way valve from bracket. B: INSTALLATION 1) Install in the reverse order of removal.
Page 190 INTAKE (INDUCTION) IN(H4SO) Page General Description ..................2 Air Cleaner ....................5 Air Cleaner Case..................6 Air Intake Duct.....................7 Resonator Chamber..................8...
Page 191: General Description
GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: COMPONENT ( 6 ) ( 4 ) ( 3 ) ( 7 ) ( 5 ) ( 8 ) ( 6 ) ( 2 ) ( 1 ) (10) (10) (19) (18) (19) ( 9 ) (12)
Page 192 GENERAL DESCRIPTION INTAKE (INDUCTION) (1) Spacer (11) Air cleaner element (19) Spacer (2) Bushing (12) Air cleaner case B (20) Grommet (3) Resonator chamber (13) Air cleaner case stay LH (MT vehi- (21) Intake air temperature sensor cles) (4) Cushion rubber (5) Air intake duct A (14) Air cleaner case stay LH (AT vehi- Tightening torque: N·m (kgf-m, ft-lb)
Page 193 GENERAL DESCRIPTION INTAKE (INDUCTION) B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 194: Air Cleaner
AIR CLEANER INTAKE (INDUCTION) 2. Air Cleaner A: REMOVAL 1) Remove bolt (A) which install air cleaner case to stays. 2) Remove the clip (B) above the air cleaner case. ( A ) ( B ) ( B ) ( B ) ( A ) IN-00058 3) Remove air cleaner element.
Page 195: Air Cleaner Case
AIR CLEANER CASE INTAKE (INDUCTION) 3. Air Cleaner Case A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector (A) of intake air tem- perature sensor. 3) Remove the bolts (B) which install air cleaner case to stay. IN-00040 4) Disconnect the hoses and intake duct from air cleaner case.
Page 196: Air Intake Duct
AIR INTAKE DUCT INTAKE (INDUCTION) 4. Air Intake Duct A: REMOVAL 1) Remove bolts which install air intake duct on the front side of body. IN-00059 2) Remove bolt which installs air intake duct on body. IN-00060 3) Remove air intake ducts as a unit. IN-00061 B: INSTALLATION Install in the reverse order of removal.
Page 197: Resonator Chamber
RESONATOR CHAMBER INTAKE (INDUCTION) 5. Resonator Chamber A: REMOVAL 1) Remove air intake duct. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> 2) Remove resonator chamber. IN-00062 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 33 N·m (3.4 kgf-m, 24.6 ft-lb) IN-00062 C: INSPECTION Inspect for cracks and loose connections.
Page 198 MECHANICAL ME(H4SO) Page General Description ..................2 Compression .....................23 Idle Speed ....................24 Ignition Timing...................25 Intake Manifold Vacuum................26 Engine Oil Pressure ..................27 Fuel Pressure....................28 Valve Clearance..................29 Engine Assembly ..................32 Engine Mounting ..................39 Preparation for Overhaul................40 V-belt......................41 Crankshaft Pulley ..................43 Belt Cover ....................45 Timing Belt Assembly................46 Camshaft Sprocket..................51 Crankshaft Sprocket..................53...
Page 199: General Description
GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Model 2000 cc 2500 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso- Type line engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95) 99.5 x 79.0 (3.917 x 3.110) Displacement 1,994 (121.67)
Page 200 GENERAL DESCRIPTION MECHANICAL Belt ten- sioner Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in) adjuster Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in) Tensioner bushing I.D. 18.00 — 18.08 mm (0.7087 — 0.7118 in) 0.025 —...
Page 201 GENERAL DESCRIPTION MECHANICAL Free length 54.30 mm (2.1378 in) Squareness 2.5°, 2.4 mm (0.094 in) Valve 214 — 246 N (22 — 25 kgf, 48 — 55 lb)/ spring 45.0 mm (1.772 in) Tension/spring height 526 — 582 N (54 — 59 kgf, 119 — 130 lb)/ Lift 34.7 mm (1.366 in) Surface warpage limit (mating with cylinder head)
Page 202 GENERAL DESCRIPTION MECHANICAL 0.010 — 0.038 mm (0.0004 — 0.0015 in) 2000 cc Limit 0.05 mm (0.0020 in) Oil clearance 0.012 — 0.038 mm (0.0005 — 0.0015 in) 2500 cc Limit 0.05 mm (0.0020 in) 1.492 — 1.501 mm (0.0587 — 0.0591 in) 0.03 mm (0.0012 in) US 1.510 —...
Page 203 GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT (12) (10) (13) (11) (15) (14) (16) ME-00376 (1) Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb) ASSY (2) Timing belt guide (MT vehicles T1: 5 (0.5, 3.6) only) (10) Belt idler No.
Page 204 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT ( 1 ) ( 2 ) ( 4 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) ( 3 ) (10) ( 8 ) ( 5 ) (19) ( 8 ) (14) (15)
Page 205 GENERAL DESCRIPTION MECHANICAL 3. VALVE ROCKER ASSEMBLY ( 1 ) ( 2 ) ( 4 ) ( 3 ) ( 5 ) ( 4 ) ( 2 ) ( 1 ) ( 6 ) ( 3 ) ( 2 ) ( 1 ) ( 4 ) ( 5 )
Page 206 GENERAL DESCRIPTION MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEMBLY ( 1 ) ( 1 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 2 ) ( 2 ) ( 3 ) ( 4 ) ( 9 ) ( 6 )
Page 207 GENERAL DESCRIPTION MECHANICAL 5. CYLINDER BLOCK (11) (10) (14) (10) (10) (10) (26) (15) (12) (17) (16) (22) (18) (24) (21) (23) (25) (13) (20) (19) ME-00377 (1) Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb) (2) Cylinder block (RH) (15) Oil filter connector T1: 5 (0.5, 3.6) (3) Service hole plug...
Page 208 GENERAL DESCRIPTION MECHANICAL MEMO: ME(H4SO)-11...
Page 209 GENERAL DESCRIPTION MECHANICAL 6. CRANKSHAFT AND PISTON ( 1 ) ( 6 ) ( 5 ) ( 4 ) ( 9 ) ( 8 ) (10) (11) ( 3 ) ( 9 ) (12) ( 7 ) (14) ( 2 ) (12) (13) (12)
Page 210 GENERAL DESCRIPTION MECHANICAL (1) Flywheel (MT vehicles only) (9) Circlip (17) Crankshaft bearing #2, #4 (2) Reinforcement (AT vehicles only) (10) Connecting rod bolt (18) Crankshaft bearing #5 (3) Drive plate (AT vehicles only) (11) Connecting rod (4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb) (5) Second ring...
Page 211 GENERAL DESCRIPTION MECHANICAL 7. ENGINE MOUNTING ME-00413 (1) Front cushion rubber (3) 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)-14...
Page 212 GENERAL DESCRIPTION MECHANICAL C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to • Wear working clothing, including a cap, protec- assembly. tive goggles, and protective shoes during opera- •...
Page 213 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SELECT MONI- Troubleshooting for electrical systems. TOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 498267800 CYLINDER HEAD •...
Page 214 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498457100 ENGINE STAND Used with ENGINE STAND (499817000). ADAPTER LH ST-498457100 498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos- STOPPER ening and tightening crankshaft pulley bolt, etc. ST-498497100 498547000 OIL FILTER Used for removing and installing oil filter.
Page 215 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498747300 PISTON GUIDE Used for installing piston in cylinder. (2500 cc model) ST-498747300 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.
Page 216 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE INSTALLER (499597100). ST-499587200 499587500 OIL SEAL Used for installing camshaft oil seal. INSTALLER ST-499587500 499587700 CAMSHAFT OIL Used for installing cylinder head plug.
Page 217 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499497000 TORX PLUS Used for removing and installing camshaft cap. 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 218 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767200 VALVE GUIDE Used for removing valve guides. REMOVER ST-499767200 499767400 VALVE GUIDE Used for reaming valve guides. REAMER ST-499767400 499767700 VALVE GUIDE Used for installing valve guides. (Intake side) ADJUSTER 499767800 (Exhaust side) ST-499767700 499817100...
Page 219 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977400 CRANK PULLEY Used for stopping rotation of crankshaft pulley (2000 cc model) WRENCH when loosening and tightening crankshaft pulley bolts. ST-499977400 499987500 CRANKSHAFT Used for rotating crankshaft. SOCKET ST-499987500 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Compression gauge...
Page 220: 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) Lower the fuel pressure.
Page 221: Idle Speed
(CHECK ENGINE light) does not illuminate. 2) Warm-up the engine. 3) Stop the engine, and then turn the igintion switch to OFF. 4) When using the SUBARU SELECT MONITOR <Ref. to ME(H4SO)-15, SPECIAL TOOLS, PREP- ARATION TOOL, General Description.> ME-00193 (1) Insert the cartridge to SUBARU SELECT MONITOR.
Page 222: Ignition Timing
IGNITION TIMING MECHANICAL 4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 1) Warm-up the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with timing light.
Page 223: Intake Manifold Vacuum
INTAKE MANIFOLD VACUUM MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Warm-up the engine. 2) Disconnect the brake vacuum hose, and then in- stall the vacuum gauge to hose fitting on manifold. 3) Keep the engine at idle speed, and then read the vacuum gauge indication.
Page 224: Engine Oil Pressure
ENGINE OIL PRESSURE MECHANICAL 6. Engine Oil Pressure CAUTION: • If the oil pressure is out of specification, A: INSPECTION check the oil pump, oil filter and lubrication 1) Disconnect the ground cable from battery. line. <Ref. to LU(H4SO)-19, INSPECTION, En- gine Lubrication System Trouble in General.>...
Page 225: Fuel Pressure
FUEL PRESSURE MECHANICAL 7. Fuel Pressure 5) Start the engine. 6) Measure the fuel pressure while disconnecting A: INSPECTION the pressure regulator vacuum hose from intake manifold. WARNING: Before removing the fuel pressure gauge, lower Fuel pressure: the fuel pressure. Standard;...
Page 226: Valve Clearance
VALVE CLEARANCE MECHANICAL 8. Valve Clearance 9) Set the #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley A: INSPECTION clockwise using a socket wrench. NOTE: NOTE: Inspection and adjustment of the valve clearance When arrow mark (A) on the camshaft sprocket should be performed while engine is cold.
Page 227 VALVE CLEARANCE MECHANICAL 12) Similar to measurement procedures used for B: ADJUSTMENT #1 cylinder, measure the #2, #3 and #4 cylinder NOTE: valve clearances. Adjustment of the valve clearance should be per- NOTE: formed while engine is cold. • Be sure to set the cylinder pistons to their re- 1) Set the #1 cylinder piston to top dead center of spective top dead centers on compression stroke compression stroke by rotating crankshaft pulley...
Page 228 VALVE CLEARANCE MECHANICAL Valve clearance: Intake; 0.20 ± ± ± ± 0.02 mm (0.0079 ± ± ± ± 0.0008 in) Exhaust; 0.25 ± ± ± ± 0.02 mm (0.0098 ± ± ± ± 0.0008 in) ME-00203 3) Ensure the valve clearances are within specifi- cations.
Page 229: Engine Assembly
ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly 11) Disconnect the following connectors and ca- bles. A: REMOVAL (1) Front oxygen (A/F) sensor connector 1) Set the vehicle on lift arms. 2) Open the front hood fully, and then support with the hood stay. 3) Lower the fuel pressure.
Page 230 ENGINE ASSEMBLY MECHANICAL (4) Engine harness connectors (7) Pressure switch FU-00017 12) Disconnect the following hoses. (1) Brake booster vacuum hose ME-00207 (5) Generator connector, terminal and A/C ME-00329 compressor connector (2) Heater inlet outlet hose ( B ) ( A ) ME-00208 ME-00330 (A) Generator connector and terminal...
Page 231 ENGINE ASSEMBLY MECHANICAL (3) Remove the pipe with bracket. 15) Remove the nuts which hold lower side of transmission to engine. ME-00331 ME-00210 (4) Remove the bolts which install power steer- ing pump bracket. 16) Remove the nuts which install front cushion rubber onto front crossmember.
Page 232 ENGINE ASSEMBLY MECHANICAL 18) Remove the pitching stopper. 21) Support the transmission with a garage jack. CAUTION: Before moving the engine away from transmis- sion, check to be sure no work has been over- looked. Doing this is very important in order to facilitate re-installation and because the trans- mission lowers under its own weight.
Page 233 ENGINE ASSEMBLY MECHANICAL 24) Remove the engine from vehicle. 3) Tighten the bolts which hold upper side of trans- mission to engine. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. Tightening torque: (3) Move the engine horizontally until main 50 N·m (5.1 kgf-m, 36.9 ft-lb) shaft is withdrawn from clutch cover.
Page 234 ENGINE ASSEMBLY MECHANICAL 9) Install the torque converter clutch onto drive (3) Tighten the bolts which install power steer- plate. (AT vehicles) ing pump bracket, and then install the spark plug cords. (1) Tighten the bolts which hold torque convert- er clutch to drive plate.
Page 235 ENGINE ASSEMBLY MECHANICAL 11) Tighten the nuts which hold lower side of trans- 18) Install the air cleaner case stay. mission to engine. Tightening torque: Tightening torque: 16 N·m (1.6 kgf-m, 11.6 ft-lb) 50 N·m (5.1 kgf-m, 36.9 ft-lb) 19) Install the A/C pressure hoses. <Ref. to AC-42, INSTALLATION, Flexible Hose.>...
Page 236: Engine Mounting
ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove engine assembly. <Ref. ME(H4SO)-32, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine as- sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; 34 N·m (3.5 kgf-m, 25.3 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.
Page 237: Preparation For Overhaul
PREPARATION FOR OVERHAUL MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND ME-00221 2) In this section the procedures described under each index are all connected and stated in order.
Page 238: V-Belt
V-BELT MECHANICAL 12.V-belt 4) Remove the A/C belt tensioner. A: REMOVAL 1. FRONT SIDE BELT NOTE: Perform the following procedures 1) to 4) with the engine installed to body. 1) Remove the V-belt cover. ME-00225 ME-00606 2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B).
Page 239 V-BELT MECHANICAL B: INSTALLATION C: INSPECTION 1) Replace the belts, if cracks, fraying or wear is 1. FRONT SIDE BELT found. 1) Wipe off any oil or water on the belt and pulley. 2) Check the drive belt tension and adjust it if nec- 2) Install the belt (C), and tighten the slider bolt so essary by changing the generator installing position as to obtain the specified belt tension.
Page 240: Crankshaft Pulley
CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley 3) Confirm that the tightening angle of crankshaft pulley bolt is 45 degrees or more. If the tightening A: REMOVAL angle of crankshaft pulley bolt is less than 45 de- grees, conduct the following procedures. 1) Remove the V-belt.
Page 241 CRANKSHAFT PULLEY MECHANICAL (2) Apply engine oil to the crankshaft pulley bolt 5) Install the A/C belt. seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 N·m (4.5 kgf-m, 33 ft-lb). (4) Tighten the crankshaft pulley bolts. Tightening torque: 177 N·m (18.0 kgf-m, 130.2 ft-lb) ME-00228...
Page 242: Belt Cover
BELT COVER MECHANICAL 14.Belt Cover A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-43, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover (LH). 4) Remove the front belt cover. ( B ) ( A ) ME-00229 (A) Belt cover (LH)
Page 243: Timing Belt Assembly
TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly ST 499987500 CRANKSHAFT SOCKET A: REMOVAL 1. TIMING BELT 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-43, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(H4SO)-45, REMOVAL, Belt Cover.>...
Page 244 TIMING BELT ASSEMBLY MECHANICAL Specified data: 2) Remove the automatic belt tension adjuster as- sembly. : 46.8 tooth length : 43.7 tooth length ME-00238 ME-00234 B: INSTALLATION 6) Remove the belt idler (No. 2). 1. AUTOMATIC BELT TENSION ADJUST- 7) Remove the belt idler No. 2. ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly;...
Page 245 TIMING BELT ASSEMBLY MECHANICAL (3) With a 2 mm (0.08 in) dia. stopper pin or a 2 2. TIMING BELT mm (0.08 in) (nominal) dia. hex bar wrench in- 1) Preparation for the installation of automatic belt serted into the stopper pin hole in the cylinder, tension adjuster assembly.
Page 246 TIMING BELT ASSEMBLY MECHANICAL 4) Install the belt idler (No. 2). (2) Check and adjust the clearance between timing belt and timing belt guide by using thick- Tightening torque: ness gauge. 39 N·m (4.0 kgf-m, 28.9 ft-lb) Clearance: 1.0 ± ± ± ± 0.5 mm (0.039 ± ± ± ± 0.020 in) ME-00235 5) After ensuring that the marks on timing belt and ME-00246...
Page 247 TIMING BELT ASSEMBLY MECHANICAL C: INSPECTION • Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into 1. TIMING BELT the cylinder. Doing so may damage the cylinder. 4) Measure the extension of rod beyond the body. 1) Check the timing belt teeth for breaks, cracks, and wear.
Page 248: Camshaft Sprocket
CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install the camshaft sprocket No. 1. To lock the A: REMOVAL camshaft, use ST. 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- ST 499207400 CAMSHAFT SPROCKET MOVAL, V-belt.> WRENCH 2) Remove crankshaft pulley.
Page 249 CAMSHAFT SPROCKET MECHANICAL 6) Install crankshaft pulley. <Ref. ME(H4SO)-43, INSTALLATION, CRANKSHAFT PULLEY.> 7) Install the V-belt. <Ref. to ME(H4SO)-42, IN- STALLATION, V-belt.> C: INSPECTION 1) Check the sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprock- et and key.
Page 250: Crankshaft Sprocket
CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket C: INSPECTION 1) Check the sprocket teeth for abnormal wear and A: REMOVAL scratches. 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- 2) Make sure there is no free play between sprock- MOVAL, V-belt.> et and key. 2) Remove crankshaft pulley.
Page 251: Valve Rocker Assembly
VALVE ROCKER ASSEMBLY MECHANICAL 18.Valve Rocker Assembly B: INSTALLATION 1) Installation of valve rocker assembly A: REMOVAL (1) Temporarily tighten the bolts (a) through (d) 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- equally as shown in the figure. MOVAL, V-belt.> NOTE: 2) Remove crankshaft...
Page 252 VALVE ROCKER ASSEMBLY MECHANICAL D: ASSEMBLY 2) If oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows greater 1) Install the adjuster screw and nut to valve rocker. amount of wear. 2) Arrange the valve rocker arms, springs and shaft supports in assembly order and insert valve rocker Rocker arm inside diameter: shaft.
Page 253: Camshaft
CAMSHAFT MECHANICAL 19.Camshaft (1) Remove the bolts (a) through (b) in alpha- betical sequence. A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4SO)-42, IN- STALLATION, V-belt.> 2) Remove crankshaft pulley. <Ref. ( a ) ME(H4SO)-43, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(H4SO)-45, REMOVAL, Belt Cover.>...
Page 254 CAMSHAFT MECHANICAL 16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly. NOTE: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when remov- ing oil seal. B: INSTALLATION 1) Apply a coat of engine oil to the camshaft jour- nals, and then install the camshaft.
Page 255 CAMSHAFT MECHANICAL (6) Tighten the bolts (o) through (v) in alphabet- 6) Install the rocker cover and connect PCV hose. ical sequence. 7) Install the oil level gauge guide. (LH side only) 8) Install the camshaft position sensor support. (LH Tightening torque: side only) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
Page 256 CAMSHAFT MECHANICAL C: INSPECTION Cam base circle diameter A: IN: 34.00 mm (1.3386 in) 1. CAMSHAFT EX: 34.00 mm (1.3386 in) 1) Measure the bend, and repair or replace if nec- essary. Limit: 0.025 mm (0.0010 in) ME-00276 2. CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial gauge.
Page 257: Cylinder Head Assembly
CYLINDER HEAD ASSEMBLY MECHANICAL 20.Cylinder Head Assembly 13) Remove the cylinder head gasket. NOTE: A: REMOVAL Do not scratch the mating surface of cylinder head 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- and cylinder block. MOVAL, V-belt.> 14) Similarly, remove the right side cylinder head. 2) Remove crankshaft pulley.
Page 258 CYLINDER HEAD ASSEMBLY MECHANICAL 5) Install the A/C compressor bracket on cylinder ST 498267800 CYLINDER HEAD TABLE head. 2) Set the ST on valve spring. Compress the valve 6) Install the intake manifold. <Ref. to FU(H4SO)- spring, and then remove the valve spring retainer 17, INSTALLATION, Intake Manifold.>...
Page 259 CYLINDER HEAD ASSEMBLY MECHANICAL 1) Installation of valve spring and valve E: INSPECTION (1) Place cylinder head on 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 valve into valve guide.
Page 260 CYLINDER HEAD ASSEMBLY MECHANICAL Color of spring part: 2. VALVE SEAT Intake [Silver] Inspect the intake and exhaust valve seats, and Exhaust [Silver] then correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.
Page 261 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (2) Insert the ST2 into valve guide and press it down to remove valve guide. 1) Check the clearance between valve guide and ST1 498267800 CYLINDER HEAD TABLE stem. The clearance can be checked by measuring ST2 499767200 VALVE GUIDE REMOVER the outside diameter of valve stem and the inside...
Page 262 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Put new valve guide, coated with sufficient ST 499767400 VALVE GUIDE REAMER oil, in the cylinder, and then insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER Intake side:...
Page 263 CYLINDER HEAD ASSEMBLY MECHANICAL 2) Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. <Ref. to ME(H4SO)-63, VALVE SEAT, ADJUST- MENT, Cylinder Head Assembly.> Install a new in- take valve oil seal after lapping. ME(H4SO)-66...
Page 264: Cylinder Block
CYLINDER BLOCK MECHANICAL 21.Cylinder Block 12) Remove the bolts (a) and (c) to remove cylinder head. A: REMOVAL ( a ) ( e ) ( c ) NOTE: Before conducting this procedure, drain the engine oil completely if applicable. ( A ) 1) Remove the intake manifold.
Page 265 CYLINDER BLOCK MECHANICAL ST1 498497100 CRANKSHAFT STOPPER (3) Insert a oil pan cutter blade between cylin- der block-to-oil pan clearance, and then remove ST2 499057000 TORX PLUS the oil pan. ( A ) NOTE: Do not use a screwdriver or similar tool in place of oil pan cutter.
Page 266 CYLINDER BLOCK MECHANICAL 26) Remove the water pipe. ME-00300 ( 1 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 2 ) ( 3 ) ( 4 ) ( 3 ) ( 3 ) ( 4 ) ( 2 ) ( 1 ) ( 4 )
Page 267 CYLINDER BLOCK MECHANICAL 27) Remove the service hole cover and service 33) Set up the cylinder block so that #1 and #3 cyl- hole plugs using hexagon wrench [14 mm (0.55 inders are on the upper side, and then remove the in)].
Page 268 CYLINDER BLOCK MECHANICAL ( 5 ) ( 1 ) ( 4 ) ( 2 ) ( 4 ) ( 3 ) ( 1 ) ( 5 ) ME-00143 (1) Cylinder block (3) Crankshaft (5) Piston (2) Rear oil seal (4) Crankshaft bearing 35) Remove the rear oil seal.
Page 269 CYLINDER BLOCK MECHANICAL B: INSTALLATION ( 1 ) ( 4 ) ( 1 ) ( 3 ) ( 2 ) ( 3 ) ME-00144 (1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal (2) Crankshaft NOTE: NOTE: Remove oil in the mating surface of bearing and Do not allow fluid packing to jut into O-ring grooves, cylinder block before installation.
Page 270 CYLINDER BLOCK MECHANICAL 3) Tighten the 10 mm cylinder block connecting 6) Further tighten the RH side bolts (E — J) to 90° bolts in alphabetical sequence shown in the figure. in alphabetical sequence. (LH side) Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) ( G ) ( E ) ( J )
Page 271 CYLINDER BLOCK MECHANICAL 10) Position the second ring gap at 180° on the re- 12) Position the lower rail gap at (D) in the figure. verse side for top ring gap. • 2000 cc MODEL • 2000 cc MODEL 180˚ ( D ) 25˚...
Page 272 CYLINDER BLOCK MECHANICAL • 2500 cc MODEL • 2500 cc MODEL ( A ) ME-00404 ME-00415 NOTE: (A) Front mark • Ensure ring gaps do not face the same direction. • Ensure ring gaps are not within the piston skirt area.
Page 273 CYLINDER BLOCK MECHANICAL ( 5 ) ( 5 ) ( 4 ) ( 4 ) ( 3 ) ( 3 ) ( 1 ) ( 2 ) ( 2 ) ( 1 ) ME-00155 (1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb) (2) Piston pin (5) Service hole plug T: 70 (7.0, 50.6)
Page 274 CYLINDER BLOCK MECHANICAL (5) Apply fluid packing around the service hole (6) Install the service hole plug and gasket. plug. NOTE: Use a new gasket. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent ME-00140 ME-00160 ( 5 ) ( 6 ) ( 3 ) ( 4 )
Page 275 CYLINDER BLOCK MECHANICAL 17) Install the water pipe. 23) Install the flywheel or drive plate. To lock the crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N·m (7.3 kgf-m, 52.8 ft-lb) • MT VEHICLES ME-00300 18) Install the baffle plate. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 19) Install the oil strainer and O-ring.
Page 276 CYLINDER BLOCK MECHANICAL 25) Installation of oil pump NOTE: (1) Discard the front oil seal after removal. Re- • Do not forget to install the O-ring and seal when place with a new one using the ST. installing oil pump. ST 499587100 OIL SEAL INSTALLER •...
Page 277 CYLINDER BLOCK MECHANICAL 32) Install the crankshaft sprocket. <Ref. to NOTE: ME(H4SO)-53, INSTALLATION, Crankshaft Ensure that the total “re-tightening angle” [in the Sprocket.> former two steps], do not exceed 180º. 33) Install camshaft sprocket. <Ref. ME(H4SO)-51, INSTALLATION, Camshaft ( c ) ( a ) ( f ) Sprocket.>...
Page 278 CYLINDER BLOCK MECHANICAL D: ASSEMBLY ( 3 ) ( 1 ) ( 1 ) ( 2 ) ( 4 ) ( 5 ) ( 6 ) ( 8 ) ( 7 ) ME-00392 (1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb) (2) Connecting rod (6) Top ring...
Page 279 CYLINDER BLOCK MECHANICAL Standard diameter: Out-of-roundness: 2000 cc model Standard A: 92.005 — 92.015 mm (3.6222 — 3.6226 0.010 mm (0.0004 in) Limit B: 91.995 — 92.005 mm (3.6218 — 3.6222 0.050 mm (0.0020 in) 2500 cc model ( A ) ( B ) A: 99.505 —...
Page 280 CYLINDER BLOCK MECHANICAL Piston outer diameter: 6) Boring and honing (1) If the value of taper, out-of-roundness, or Standard: cylinder-to-piston clearance measured exceeds • 2000 cc model the specified limit or if there is any damage on A: 91.985 — 91.995 mm the cylinder wall, rebore it to use an oversize pis- (3.6214 —...
Page 281 CYLINDER BLOCK MECHANICAL 3) Make sure that piston pin can be inserted into 4. PISTON RING piston pin hole with a thumb at 20°C (68°F). Re- 1) If the piston ring is broken, damaged, or worn, or place if defective. if its tension is insufficient, or when the piston is re- Standard clearance between piston pin and placed, replace the piston ring with a new one of...
Page 282 CYLINDER BLOCK MECHANICAL 3) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD inder, and then measure the piston ring gap with a 1) Replace the connecting rod, if the large or small thickness gauge. end thrust surface is damaged. 2) Check for bend or twist using a connecting rod Unit: mm (in) aligner.
Page 283 CYLINDER BLOCK MECHANICAL 4) Inspect the connecting rod bearing for scar, 6) Inspect the bushing at connecting rod small end, peeling, seizure, melting, wear, etc. and replace if worn or damaged. Also measure the piston pin clearance at connecting rod small end. 5) Measure the oil clearance on individual connect- ing rod bearings by means of plastigauge.
Page 284 CYLINDER BLOCK MECHANICAL 6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the BEARING bearing with a suitable (undersize) one, and then 1) Clean the crankshaft completely and check for replace or recondition the crankshaft as necessary.
Page 285 CYLINDER BLOCK MECHANICAL 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) ME-00322 5) Inspect the individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
Page 286: Engine Trouble In General
ENGINE TROUBLE IN GENERAL MECHANICAL 22.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely TROUBLE PROBLEM PARTS, ETC.
Page 287 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 4) Engine stalls after initial • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> combustion. • Intake system • Loosened or cracked intake duct • Loosened or cracked PCV hose •...
Page 288 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> poor acceleration • Intake system • Loosened or cracked intake duct • Loosened or cracked PCV hose •...
Page 289 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> idle. • Intake system • Loosened or cracked vacuum hose • Others •...
Page 290 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- • Engine control system <Ref. to EN(H4SO)-2, Basic Diagnostic Procedure.> tion • Intake system • Dirty air cleaner element • Belt • Defective timing •...
Page 291: 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 292 EXHAUST EX(H4SO) Page General Description ..................2 Front Exhaust Pipe..................5 Center Exhaust Pipe ...................8 Rear Exhaust Pipe ..................9 Muffler .......................10...
Page 293: General Description
GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT (19) (21) (19) (19) (20) (18) (17) (16) (23) ( 6 ) ( 8 ) (12) ( 9 ) ( 1 ) ( 4 ) ( 2 ) (24) ( 7 ) (15) ( 5 ) ( 3 )
Page 294 GENERAL DESCRIPTION EXHAUST (1) Upper front exhaust pipe cover (12) Upper rear catalytic converter (23) Rear oxygen sensor cover (2) Lower front exhaust pipe cover (24) Gasket (3) Front exhaust pipe (13) Lower rear catalytic converter cover (4) Front oxygen (A/F) sensor Tightening torque: N·m (kgf-m, ft-lb) (5) Front catalytic converter (14) Rear catalytic converter...
Page 295 GENERAL DESCRIPTION EXHAUST B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 296: Front Exhaust Pipe
FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 6) Remove under cover.<Ref. to EI-13, REMOVAL, Front Under Cover.> A: REMOVAL 7) Remove nuts which hold front exhaust pipe onto 1) Disconnect battery ground cable. cylinder heads. CAUTION: Be careful not to pull down front and center ex- haust pipe assembly.
Page 297 FRONT EXHAUST PIPE EXHAUST B: INSTALLATION Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Install front exhaust pipe to center exhaust pipe. NOTE: Replace gaskets with new ones. Tightening torque: 30 N·m (3.1 kgf-m, 22.4 ft-lb) FU-00455 7) Tighten bolt which holds front and center ex- haust pipe assembly to hanger bracket.
Page 298 FRONT EXHAUST PIPE EXHAUST 11) Connect battery ground cable. FU-00009 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EX(H4SO)-7...
Page 299: Center Exhaust Pipe
CENTER EXHAUST PIPE EXHAUST 3. Center Exhaust Pipe A: REMOVAL After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX(H4SO)-5, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
Page 300: Rear Exhaust Pipe
REAR EXHAUST PIPE EXHAUST 4. Rear Exhaust Pipe B: INSTALLATION NOTE: A: REMOVAL Replace gaskets and self-locking nuts with new 1) Separate rear exhaust pipe from center exhaust ones. pipe. 1) Install rear exhaust pipe to muffler. CAUTION: Tightening torque: Be careful, exhaust pipe is hot.
Page 301: Muffler
NOTE: 2) Make sure there are no holes or rusting. To facilitate removal, apply a coat of SUBARU 3) Make sure the cushion rubber is not worn or CRC to mating area of rubber cushions in advance.
Page 302 COOLING CO(H4SO) Page General Description ..................2 Radiator Main Fan System................6 Radiator Sub Fan System .................10 Engine Coolant..................14 Water Pump ....................16 Thermostat ....................21 Radiator.....................23 Radiator Cap .....................27 Radiator Main Fan and Fan Motor ............28 Radiator Sub Fan and Fan Motor..............30 Reservoir Tank..................32 Engine Cooling System Trouble in General ..........33...
Page 303: General Description
GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Electric fan + Forced engine coolant circula- Cooling system tion system 2.0 L MT: Approx. 7.0 (7.4, 6.2) 2.0 L AT: Approx. 6.9 (7.3, 6.1) 2 (US qt, Imp qt) Total engine coolant capacity 2.5 L MT: Approx.
Page 304 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) CO-00001 (1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb) (2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7)
Page 305 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN ( 5 ) ( 6 ) ( 5 ) ( 8 ) ( 4 ) (10) ( 7 ) ( 3 ) (11) (14) (12) (15) (14) ( 9 ) ( 2 ) (13) (16) (19)
Page 306 GENERAL DESCRIPTION COOLING C: CAUTION • Be careful not to burn your hands, because each part in the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
Page 307: Radiator Main Fan System
RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC BATTERY SBF-1 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 : 14 WITH OBD WITHOUT OBD : 13 WITH OBD : 12 WITHOUT OBD SUB FAN MAIN FAN B134 RELAY RELAY...
Page 308 RADIATOR MAIN FAN SYSTEM COOLING B: INSPECTION DETECTING CONDITION: Condition: • Engine coolant temperature is above 95°C (203°F). • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. Step Value CHECK POWER SUPPLY TO MAIN FAN MO-...
Page 309 RADIATOR MAIN FAN SYSTEM COOLING Step Value CHECK POWER SUPPLY TO MAIN FAN RE- 10 V Go to step 10. Go to step 9. LAY. 1) Turn ignition switch to ON. 2) Measure voltage between main fan relay terminal and chassis ground. Connector &...
Page 310 Check poor contact in connector between main tact connector. ARU distributor fan and ECM. service. Is there poor contact in connector between main fan motor and ECM? NOTE: Inspection by SUBARU distributor service is required, because probable cause is deterioration of multiple parts. CO(H4SO)-9...
Page 311: Radiator Sub Fan System
RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC BATTERY SBF-1 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 : 14 WITH OBD WITHOUT OBD : 13 WITH OBD : 12 WITHOUT OBD SUB FAN MAIN FAN B134 RELAY RELAY...
Page 312 RADIATOR SUB FAN SYSTEM COOLING B: INSPECTION NOTE: Radiator sub fan system is for model with A/C. DETECTING CONDITION: Condition (1): • Engine coolant temperature is below 95°C (203°F). • A/C switch is turned ON. • Vehicle speed is below 19 km/h (12 MPH). Condition (2): •...
Page 313 RADIATOR SUB FAN SYSTEM COOLING Step Value CHECK POWER SUPPLY TO SUB FAN RE- 10 V Go to step 6. Go to step 7. LAY. 1) Turn ignition switch to OFF. 2) Remove sub fan relay from A/C relay holder. 3) Measure voltage between sub fan relay ter- minal and chassis ground.
Page 314 Check poor contact in connector between sub tact connector. ARU distributor fan and ECM. service. Is there poor contact in connector between sub fan motor and ECM? NOTE: Inspection by SUBARU distributor service is required, because probable cause is deterioration of multiple parts. CO(H4SO)-13...
Page 315: Engine Coolant
Approx. 6.7 2 (7.1 US qt, 5.9 Imp qt) CAUTION: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Cool- ant, since other coolant may cause corrosion. CO(H4SO)-14...
Page 316 The concentration and safe operating temperature necessary amount of coolant with an undiluted so- of the SUBARU coolant is shown in the diagram. lution of SUBARU genuine coolant (concentration Measuring the temperature and specific gravity of 50).
Page 317: Water Pump
WATER PUMP COOLING 5. Water Pump 6) Disconnect radiator outlet hose and heater by- pass hose from water pump. A: REMOVAL 1) Disconnect ground cable from battery. CO-00085 7) Lower the vehicle. FU-00009 8) Remove air intake duct. 2) Lift-up the vehicle. 3) Remove under cover.
Page 318 WATER PUMP COOLING 12) Remove V-belts. 17) Remove left-hand belt cover No. 2. <Ref. to ME(H4SO)-41, REMOVAL, V-belt.> 13) Remove timing belt. <Ref. to ME(H4SO)-46, REMOVAL, Timing Belt Assembly.> 14) Remove automatic belt tension adjuster. CO-00019 18) Remove tensioner bracket. CO-00016 15) Remove belt idler No.
Page 319 WATER PUMP COOLING B: INSTALLATION 4) Install left-hand camshaft sprockets by using ST. ST 18231AA010 CAMSHAFT SPROCKET 1) Install water pump onto left-hand cylinder block. WRENCH NOTE: NOTE: • Replace gasket with a new one. Camshaft sprocket wrench (499207100) is also •...
Page 320 WATER PUMP COOLING 10) Install reservoir tank. 15) Connect connectors to radiator main fan (A) and sub fan (B) motors. ( B ) ( A ) CO-00087 CO-00084 11) Connect overflow hose. 16) Install under cover. CO-00086 LU-00095 12) Install air intake duct. 17) Lower the vehicle.
Page 321 WATER PUMP COOLING C: INSPECTION 1) Check water pump bearing for smooth rotation. 2) Check water pump pulley for abnormalities. 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley. “Thrust” runout limit: 0.5 mm (0.020 in) CO-00028 4) Check clearance between impeller and pump case.
Page 322: Thermostat
THERMOSTAT COOLING 6. Thermostat B: INSTALLATION 1) Install the thermostat in the water pump, and in- A: REMOVAL stall the thermostat cover together with a gasket. 1) Lift-up the vehicle. NOTE: 2) Remove under cover. • Replace gasket with a new one. •...
Page 323 THERMOSTAT COOLING Specified value: Starts to open: With OBD: 80 — 84 ° ° ° ° C (176 — 183 ° ° ° ° F) Without OBD: 76.0 — 80.0 ° ° ° ° C (169 — 176 ° ° ° ° F) Fully opens: With OBD: 95 °...
Page 324: Radiator
RADIATOR COOLING 7. Radiator 6) Disconnect radiator outlet hose from thermostat cover. A: REMOVAL 1) Disconnect battery ground cable. CO-00105 7) Disconnect ATF cooler hoses from radiator. (AT FU-00009 vehicles only) 2) Lift-up the vehicle. 3) Remove under cover. ( A ) CO-00088 LU-00095 (A) Clip...
Page 325 RADIATOR COOLING 11) Remove reservoir tank. 16) Lift radiator up and away from vehicle. CO-00092 CO-00087 12) Disconnect radiator inlet hose from engine. B: INSTALLATION 1) Attach radiator mounting cushions to holes on the vehicle. CO-00089 13) Remove radiator upper brackets. CO-00093 2) Install radiator while fitting radiator pins to cush- ions.
Page 326 RADIATOR COOLING 3) Install radiator brackets and tighten bolts. 7) Install air intake duct. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) IN-00059 8) Lift-up the vehicle. 9) Connect ATF cooler hoses. (AT vehicles only) CO-00090 4) Attach power steering hose to the radiator. ( A ) CO-00088 CO-00091...
Page 327 RADIATOR COOLING 12) Install under cover. C: INSPECTION 1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. LU-00095 13) Lower the vehicle. CO-00094 14) Connect battery ground cable. 2) Apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) to radiator to check if: (1) Engine coolant leaks at/around radiator.
Page 328: Radiator Cap
RADIATOR CAP COOLING 8. Radiator Cap A: INSPECTION 1) Attach radiator cap to tester. CO-00044 2) Increase pressure until 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 329: Radiator Main Fan And Fan Motor
RADIATOR MAIN FAN AND FAN MOTOR COOLING 9. Radiator Main Fan and Fan 7) Disconnect overflow hose. Motor A: REMOVAL 1) Disconnect battery ground cable. CO-00086 8) Remove reservoir tank. FU-00009 2) Lift-up the vehicle. 3) Remove under cover. CO-00087 9) Remove radiator main fan motor assembly.
Page 330 RADIATOR MAIN FAN AND FAN MOTOR COOLING B: INSTALLATION 3) Remove bolts which install fan motor onto shroud. Install in the reverse order of removal. NOTE: When the main fan motor assembly cannot be in- stalled as is, loosen the sub fan motor assembly securing bolts to install it.
Page 331: Radiator Sub Fan And Fan Motor
RADIATOR SUB FAN AND FAN MOTOR COOLING 10.Radiator Sub Fan and Fan 7) Remove bolts which hold sub fan shroud to radi- ator. Motor 8) Remove radiator sub fan shroud through the un- der side of vehicle. A: REMOVAL 1) Disconnect battery ground cable. CO-00101 FU-00009 B: INSTALLATION...
Page 332 RADIATOR SUB FAN AND FAN MOTOR COOLING 3) Remove bolts which install fan motor onto shroud. CO-00098 D: ASSEMBLY Assemble in the reverse order of disassembly. NOTE: ・Refer to “COMPONENT” for tightening torque. <Ref. to CO(H4SO)-3, COMPONENT, General De- scription.> E: INSPECTION 1) Connect battery positive (+) terminal to terminal No.
Page 333: Reservoir Tank
RESERVOIR TANK COOLING 11.Reservoir Tank A: REMOVAL 1) Disconnect overflow hose from radiator filler neck position. 2) Remove bolts which install reservoir tank onto radiator main fan shroud. 3) Remove reservoir tank. CO-00087 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.9N·m (0.50 kgf-m, 3.6 ft-lb) CO-00087...
Page 334: Engine Cooling System Trouble In General
ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 12.Engine Cooling System Trouble in General A: INSPECTION Trouble Corrective action Replenish engine coolant, inspect for leakage, and a. Insufficient engine coolant repair. b. Loose timing belt Repair or replace timing belt tensioner. c.
Page 335 ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING MEMO: CO(H4SO)-34...
Page 336 LUBRICATION LU(H4SO) Page General Description ..................2 Oil Pressure System ...................6 Engine Oil....................8 Oil Pump ....................10 Oil Pan and Strainer..................14 Oil Pressure Switch...................17 Engine Oil Filter..................18 Engine Lubrication System Trouble in General.........19...
Page 337: General Description
GENERAL DESCRIPTION LUBRICATION 1. General Description A: SPECIFICATIONS Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 7 mm (3.07 × 0.28 in) STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in) Tip clearance between inner and outer rotor LIMIT 0.18 mm (0.0071 in)
Page 338 GENERAL DESCRIPTION LUBRICATION B: COMPONENT (13) (16) (15) (14) (12) (17) (11) (18) (24) (10) ( 9 ) ( 8 ) ( 7 ) (19) ( 6 ) (20) (27) ( 5 ) (21) ( 4 ) ( 3 ) ( 2 ) ( 1 ) (22)
Page 339 GENERAL DESCRIPTION LUBRICATION C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove dirt and corrosion before removal, in- stallation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 340 GENERAL DESCRIPTION LUBRICATION D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANKSHAFT Used for stopping rotation of crankshaft pulley PULLEY when loosening and tightening crankshaft pulley WRENCH bolt. (2500 cc model) ST-499977100 499977400 CRANKSHAFT Used for stopping rotation of crankshaft pulley PULLEY when loosening and tightening crankshaft pulley WRENCH...
Page 341: Oil Pressure System
OIL PRESSURE SYSTEM LUBRICATION 2. Oil Pressure System A: SCHEMATIC BATTERY NO.5 IGNITION RELAY OIL PRESSURE SWITCH (GREEN) B21 (GRAY) A1 A2 A4 A5 A6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B1 B2 B4 B5 B6 C5 C6 9 10...
Page 342 OIL PRESSURE SYSTEM LUBRICATION B: INSPECTION Step Value CHECK COMBINATION METER. Warning light goes on. Go to step 2. Repair or replace 1) Turn ignition switch to ON. (engine OFF) the combination 2) Check other warning lights. meter. <Ref. to Does the warning lights go on? IDI-4, INSPEC- TION, Combina-...
Page 343: Engine Oil
When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the ILSAC LU-00094 or API classification and SAE viscosity No. des- 3) Replace drain plug gasket. ignated by SUBARU. LU(H4SO)-8...
Page 344 ENGINE OIL LUBRICATION NOTE: If vehicle is used in desert areas with very high tem- peratures or for other heavy duty applications, the following viscosity oils may be used: API classifica- tion: SL, SJ or SH SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W- 6) Close engine oil filler cap.
Page 345: Oil Pump
OIL PUMP LUBRICATION 4. Oil Pump 9) Remove crankshaft pulley by using ST. ST 499977100 CRANKSHAFT PULLEY A: REMOVAL WRENCH (2500 cc model) 1) Disconnect battery ground cable. ST 499977400 CRANKSHAFT PULLEY WRENCH (2000 cc model) FU-00009 LU-00012 2) Lift-up the vehicle. 3) Remove under cover.
Page 346 OIL PUMP LUBRICATION 14) Remove oil pump by using flat bladed screw- CAUTION: driver. Make sure the oil seal lip is not folded. CAUTION: 6) Install oil pump. Be careful not to scratch mating surfaces of Tightening torque: cylinder block and oil pump. 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) LU-00016 LU-00019...
Page 347 OIL PUMP LUBRICATION D: ASSEMBLY E: INSPECTION 1) Install front oil seal by using ST. 1. TIP CLEARANCE ST 499587100 OIL SEAL INSTALLER Measure the tip clearance of rotors. If the clearance NOTE: exceeds the limit, replace rotors as a set. Use a new oil seal.
Page 348 OIL PUMP LUBRICATION 3. SIDE CLEARANCE Measure clearance between oil pump inner rotor and pump cover. If the clearance exceeds the limit, replace rotor or pump body. Side clearance: Standard 0.02 — 0.07 mm (0.0008 — 0.0028 in) Limit 0.12 mm (0.0047 in) LU-00025 4.
Page 349: Oil Pan And Strainer
OIL PAN AND STRAINER LUBRICATION 5. Oil Pan and Strainer 7) Support engine with a lifting device and wire ropes. A: REMOVAL 1) Set the vehicle on lift arms. 2) Remove front wheels. 3) Disconnect battery ground cable. LU-00028 8) Lift-up the vehicle. CAUTION: When lifting up the vehicle, wire rope must be FU-00009...
Page 350 OIL PAN AND STRAINER LUBRICATION 14) Insert oil pan cutter blade between cylinder B: INSTALLATION block-to-oil pan clearance. CAUTION: CAUTION: Before installing oil pan, clean sealant from oil Do not use a screwdriver or similar tool in place pan and engine block. of oil pan cutter.
Page 351 OIL PAN AND STRAINER LUBRICATION Tightening torque: 10) Install pitching stopper. 5 N·m (0.5 kgf-m, 3.6 ft-lb) Tightening torque: T1: 50 N·m (5.1 kgf-m, 37 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb) LU-00051 4) Lower engine onto front crossmember. 5) Tighten nuts which secure front cushion rubber ME-00218 onto front crossmember.
Page 352: Oil Pressure Switch
OIL PRESSURE SWITCH LUBRICATION 6. Oil Pressure Switch 2) Install oil pressure switch onto engine block. Tightening torque: A: REMOVAL 25 N·m (2.5 kgf-m, 18.1 ft-lb) 1) Remove generator from bracket. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 2) Disconnect terminal from oil pressure switch. LU-00037 3) Connect terminal of oil pressure switch.
Page 353: Engine Oil Filter
ENGINE OIL FILTER LUBRICATION 7. Engine Oil Filter A: REMOVAL 1) Remove under cover. <Ref. to EI-13, REMOV- AL, Front Under Cover.> 2) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH LU-00100 B: INSTALLATION 1) Get a new oil filter and thinly apply engine oil to the seal rubber.
Page 354: Engine Lubrication System Trouble In General
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION 8. Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists. Trouble Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace. 1) Oil pressure switch failure Broken spring or seized contacts...
Page 355 ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION MEMO: LU(H4SO)-20...
Page 356 SPEED CONTROL SYSTEMS SP(H4SO) Page General Description ..................2 Accelerator Pedal..................5 Accelerator Control Cable .................10...
Page 357 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Free play At pedal pad 0 — 4 mm (0 — 0.16 in) Accelerator pedal Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in) B: COMPONENT 1. LHD MODEL ( 1 ) ( 2 ) ( 3 )
Page 358 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 2. RHD MODEL (11) ( 3 ) ( 2 ) ( 1 ) ( 8 ) ( 9 ) ( 7 ) ( 4 ) ( 6 ) ( 5 ) (10) SP-00022 (1) Accelerator bracket (6) Spring pin (11) Kick-down switch (AT vehicles only)
Page 359 GENERAL DESCRIPTION SPEED CONTROL 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 360 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 2. Accelerator Pedal • RHD SOHC MODEL A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lock nut from accelerator cable bracket. 3) Separate the accelerator cable from bracket. 4) Remove the accelerator cable end from throttle cam.
Page 361 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS • RHD MODEL 12) Disconnect the accelerator cable stopper from bracket. SP-00007 SP-00010 9) Remove the grommet from toe board. NOTE: (A) Accelerator cable stopper From the inside compartment, push the grommet 13) Separate the accelerator cable and bracket. (A) into hole.
Page 362 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS C: DISASSEMBLY • RHD MODEL 1) Remove the clip, and then remove the accelera- tor pedal from bracket. 2) Pull out the spring pin, and then remove the ac- ( J ) celerator pedal from accelerator pedal lever. ( G ) ( B ) •...
Page 363 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS E: INSPECTION F: ADJUSTMENT 1) Check the pedal stroke and free play by operat- 1. ACCELERATOR PEDAL ing accelerator pedal by hand. 1) Lightly move the pedal pad in lateral direction to 2) If it is not within specified value, adjust it by turn- ensure that pedal deflection is in specified range.
Page 364 ACCELERATOR PEDAL SPEED CONTROL SYSTEMS 3) Check to ensure the kick-down switch operates at the specified value in relation to the stroke of the accelerator pedal. If it is not within specified value, adjust it by adjust- ing the position of kick-down switch. NOTE: Be careful not to rotate kick-down switch.
Page 365 ACCELERATOR CONTROL CABLE SPEED CONTROL SYSTEMS 3. Accelerator Control Cable A: REMOVAL 1) Remove the accelerator pedal. <Ref. to SP(H4SO)-5, REMOVAL, Accelerator Pedal.> 2) Separate the accelerator cable and accelerator pedal. B: INSTALLATION 1) Install in the reverse order of removal. 2) Apply grease to engine side accelerator cable end.
Page 366 IGNITION IG(H4SO) Page General Description ..................2 Spark Plug....................5 Ignition Coil and Ignitor Assembly...............8 Spark Plug Cord..................10...
Page 367: General Description
GENERAL DESCRIPTION IGNITION 1. General Description A: SPECIFICATIONS Item Designation Model FH0137 Manufacturer DIAMOND Ignition coil 0.73 Ω±10% Primary coil resistance and ignitor Secondary coil resistance 12.8 kΩ±15% assembly Insulation resistance between primary More than 100 MΩ terminal and case RC10YC4 ..
Page 368 GENERAL DESCRIPTION IGNITION B: COMPONENT ( 2 ) ( 2 ) ( 3 ) ( 1 ) ( 4 ) ( 4 ) ( 1 ) IG-00036 (1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) (2) Spark plug cord (#1, #3) T1: 21 (2.1, 15) (3) Ignition coil and ignitor ASSY...
Page 369 GENERAL DESCRIPTION IGNITION C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 370 SPARK PLUG IGNITION 2. Spark Plug 2. LH SIDE 1) Disconnect battery ground cable. A: REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: CHAMPION: RC10YC4 (Alternate) NGK: BKR5E-11 NGK: BKR6E-11 1.
Page 371 SPARK PLUG IGNITION 6) Remove spark plug with the spark plugs socket. C: INSPECTION Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion. ( A ) ( B ) ( C ) IG-00049 B: INSTALLATION...
Page 372 SPARK PLUG IGNITION 3) Oil fouled E: ADJUSTMENT Wet black deposits show excessive oil entrance Correct it if the spark plug gap is measured with a into combustion chamber through worn rings and gap gauge, and it is necessary. pistons or excessive clearance between valve Spark plug gap: L guides and stems.
Page 373: Ignition Coil And Ignitor Assembly
IGNITION COIL AND IGNITOR ASSEMBLY IGNITION 3. Ignition Coil and Ignitor As- B: INSTALLATION 1) Install in the reverse order of removal. sembly Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. CAUTION: Be sure to connect spark plug cords to their proper positions.
Page 374 IGNITION COIL AND IGNITOR ASSEMBLY IGNITION [Secondary side] Between (A) and (B) 12.8 k Ω± Ω± 15% Ω± Ω± Between (C) and (D) 12.8 k Ω± Ω± Ω± 15% Ω± IG-00039 3) Insulation between primary terminal and case: 100 MΩ or more. IG(H4SO)-9...
Page 375: Spark Plug Cord
SPARK PLUG CORD IGNITION 4. Spark Plug Cord A: INSPECTION Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 — 10.6 #2 cord: 7.3 — 13.7 #3 cord: 5.9 —...
Page 376 STARTING/CHARGING SYSTEMS SC(H4SO) Page General Description ..................2 Starter ......................6 Generator ....................14 Battery.......................20...
Page 377: General Description
GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATIONS Item Designation Type Reduction type Vehicle model Model M000T83981 M001T86481 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Direction of rotation Counterclockwise (when observed from pinion) Number of pinion teeth Voltage 11 V...
Page 378 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS B: COMPONENT 1. STARTER ( 2 ) ( 4 ) (11) (10) ( 9 ) ( 3 ) ( 8 ) ( 1 ) ( 7 ) ( 6 ) (17) ( 5 ) (16) (15) (14) (13) (12)
Page 379 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 2. GENERATOR ( 7 ) ( 6 ) ( 5 ) ( 4 ) ( 3 ) ( 2 ) ( 1 ) (13) (12) (11) (10) ( 9 ) ( 8 ) SC-00163 (1) Pulley nut (7) Bearing (13) Terminal...
Page 380 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 381: Starter
STARTER STARTING/CHARGING SYSTEMS 2. Starter 4) Disconnect the connector and terminal from starter. A: REMOVAL 1) Disconnect the ground cable from battery. ( A ) ( B ) SC-00006 FU-00009 (A) Terminal (B) Connector 2) Remove the air cleaner case. <Ref.
Page 382 STARTER STARTING/CHARGING SYSTEMS C: DISASSEMBLY NOTE: Before removal, confirm the attachment locations 1. STARTER ASSEMBLY of brush holder and rear bracket. 1) Loosen nut which holds terminal M of switch as- sembly, and disconnect connector. ( A ) ( B ) ( B ) ( A ) ( C )
Page 383 STARTER STARTING/CHARGING SYSTEMS 5) Remove packing A, three planetary gears, pack- (2) Remove ring, stopper and clutch from shaft. ing B and plate. NOTE: ( A ) Before removal, confirm the inserting location of packing A. ( B ) ( D ) ( C ) ( A ) ( B )
Page 384 STARTER STARTING/CHARGING SYSTEMS D: ASSEMBLY • Lever direction Assemble in the reverse order of disassembly. Do the following: NOTE: When assembling, apply grease to the following parts. • Front and rear bracket sleeve bearing • Armature shaft gear • Outer periphery of plunger •...
Page 385 STARTER STARTING/CHARGING SYSTEMS 5) Install brush holder in alignment with Yoke’s 3) Depth of segment mold groove. Check the depth of segment mold. Depth of segment mold: 0.5 mm (0.020 in) ( B ) ( C ) SC-00159 ( A ) 6) Install rear bracket.
Page 386 STARTER STARTING/CHARGING SYSTEMS 5) Armature ground test 2) Brush movement Using a circuit tester, touch one probe to the com- Be sure brush moves smoothly inside brush holder. mutator segment and the other to shaft. There 3) Brush spring force should be no continuity.
Page 387 STARTER STARTING/CHARGING SYSTEMS 2) Disconnect the connector from terminal M, and Three performance tests, no-load test, load test, then connect the positive terminal of battery and and lock test, are presented here; however, if the terminal M using a lead wire and ground terminal to load test and lock test cannot be performed, carry starter body.
Page 388 STARTER STARTING/CHARGING SYSTEMS 3) Lock test With starter stalled, or not rotating, measure the torque developed and current draw when the volt- age is adjusted to the specified voltage. Lock test (Standard): Voltage / Current AT: 3.5 V / 940 A or less MT: 4 V / 650 A or less Torque AT: 28.9 N·m (2.95 kgf-m, 21.3 ft-lb) or more...
Page 389: Generator
GENERATOR STARTING/CHARGING SYSTEMS 3. Generator B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. Check and adjust the V-belt tension. <Ref. to ME(H4SO)-42, INSPECTION, V-belt.> FU-00009 2) Disconnect the connector and terminal from SC-00032 generator.
Page 390 GENERATOR STARTING/CHARGING SYSTEMS 3) Then insert the tip of a flat tip screwdriver into the (1) Remove the bolt, and then remove the bear- gap between stator core and front cover. Pry them ing retainer. apart to disassemble. SC-00081 SC-00080 (2) Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
Page 391 GENERATOR STARTING/CHARGING SYSTEMS time because the rectifier cannot withstand (2) Remove the cover B. heat very well. SC-00087 SC-00083 (A) Cover B 8) Remove the IC regulator as follows. (1) Remove the screws which secure IC regula- (3) Separate the brush from connection to re- move.
Page 392 GENERATOR STARTING/CHARGING SYSTEMS (3) Remove the nut of terminal B, and then re- D: ASSEMBLY move the rectifier. To assemble, reverse order of disassembly. 1) Pulling up brush Before assembling, press the brush down into brush holder, and then fix them in that position by passing a [1 mm (0.04 in) dia.
Page 393 GENERATOR STARTING/CHARGING SYSTEMS E: INSPECTION 2. ROTOR 1) Slip ring surface 1. DIODE Inspect the slip rings for contamination or any CAUTION: roughness of the sliding surface. Repair the slip Never use a mega tester (measuring use for ring surface using a lathe or sand paper. high voltage) or any other similar measure for 2) Slip ring outer diameter this test;...
Page 394 GENERATOR STARTING/CHARGING SYSTEMS 3. STATOR 4. BRUSH 1) Continuity test 1) Measure the length of each brush. If wear ex- Inspect the stator coil for continuity between each ceeds the service limit, replace the brush. Each end of the lead wires. If resistance is 1 M Ω or brush has the service limit mark (A) on it.
Page 395: Battery
BATTERY STARTING/CHARGING SYSTEMS 4. Battery • For safety, in case an explosion does occur, wear eye protection or shield your eyes when A: REMOVAL working near any battery. Never lean over a bat- tery. 1) Remove battery cable holder (A) from battery rod.
Page 396 BATTERY STARTING/CHARGING SYSTEMS 2) Measuring the specific gravity of the electrolyte 4. QUICK CHARGING in the battery will disclose the state of charge of the Quick charging is a method in which the battery is battery. The relation between the specific gravity charged in a short period of time with a relatively and the state of charge is as shown in figure.
Page 397 BATTERY STARTING/CHARGING SYSTEMS MEMO: SC(H4SO)-22...
Page 398 Engine Control Module (ECM) I/O Signal ..........24 Engine Condition Data ................27 Transmission Control Module (TCM) I/O Signal ........28 Data Link Connector .................29 OBD-II General Scan Tool ................30 Subaru Select Monitor................32 Read Diagnostic Trouble Code ..............39 Inspection Mode..................40 Drive Cycle....................45 Clear Memory Mode..................47 Compulsory Valve Operation Check Mode ..........48...
Page 399: Basic Diagnostic Procedure
2) Connect the Subaru Select Monitor or the NOTE: OBD-II general scan tool to data link con- nector. shown on display 3) Turn ignition switch to ON and the Subaru although the MI il- Select Monitor or OBD-II general scan tool luminates, per- switch to ON.
Page 400 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. AUTOMATIC TRANSMISSION When trouble code about automatic transmission is shown on display, carry out the following basic check. After that, carry out the replacement or re- pair work. 1) ATF level check <Ref. to AT-30, Automatic Transmission Fluid.>...
Page 401: Check List For Interview
CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer's name Engine no. Date of sale Fuel brand Date of repair Odometer reading...
Page 402 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST NO. 2 Check the following items about the vehicle's state when MI turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. Yes/ No Low fuel warning light Charge indicator light...
Page 403: General Description
GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and resis- A: CAUTION tance inside the passenger compartment. 1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay.
Page 404 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 12) Observe the following cautions when installing 2) Check the condition of the main and other fuses, a radio in MFI equipped models. and harnesses and connectors. Also check for proper grounding. CAUTION: • The antenna must be kept as far apart as pos- 2.
Page 405 When trou- sating element, etc. bleshooting OBD-II vehicles, connect Subaru Se- The MFI system also has the following features: lect Monitor or the OBD-II general scan tool to the •...
Page 406 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-9...
Page 407: Electrical Components Location
( 2 ) ( 3 ) ( 1 ) EN-01104 (1) Engine control module (ECM) (3) Test mode connector (2) Data link connector (for Subaru (4) CHECK ENGINE malfunction indi- Select Monitor and OBD-II general cator lamp (MI) scan tool) EN(H4SO)-10...
Page 408 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-00845 EN-00846 ( 4 ) CHECK ENGINE 100 120 140 x1000r/min AT OIL AIRBAG TEMP km/h 1 / 2 TRIP ( 3 ) EN-00847 EN-00848 EN(H4SO)-11...
Page 409 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SENSOR ( 1 ) ( 3 ) ( 4 ) ( 2 ) ( 5 ) ( 6 ) ( 7 ) EN-01105 (1) Intake air temperature sensor (5) Knock sensor (2) Pressure sensor (6) Camshaft position sensor (3) Engine coolant temperature sen- (7) Crankshaft position sensor...
Page 410 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 2 ) EN-00849 EN-00850 ( 3 ) ( 4 ) EN-00851 EN-00852 ( 5 ) ( 6 ) EN-00853 EN-00854 ( 7 ) EN-00855 EN(H4SO)-13...
Page 411 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 3 ) ( 2 ) ( 1 ) ( 4 ) EN-00685 (1) Front oxygen (A/F) sensor (3) Front catalytic converter (2) Rear oxygen sensor (4) Rear catalytic converter ( 2 ) ( 1 ) EN-00856 EN-00857 ( 4 )
Page 412 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01106 ( 1 ) ( 2 ) EN-01107 (1) Fuel level sensor (2) Fuel sub level sensor ( 1 ) ( 2 ) EN-01108 EN-01109 EN(H4SO)-15...
Page 413 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS ( 3 ) ( 4 ) ( 2 ) ( 1 ) ( 7 ) EN-01110 (1) EGR valve (3) Purge control solenoid valve (2) Idle air control solenoid valve (4) Ignition coil &...
Page 414 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 2 ) EN-00865 EN-00018 ( 3 ) ( 4 ) EN-00866 EN-00867 EN(H4SO)-17...
Page 415 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) ( 4 ) ( 7 ) ( 3 ) ( 5 ) ( 6 ) EN-01111 ( 2 ) ( 3 ) ( 1 ) ( 7 ) ( 4 ) ( 5 ) ( 6 ) EN-01112 (1) Inhibitor switch...
Page 416 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 2 ) ( 1 ) EN-00873 EN-01113 ( 3 ) ( 4 ) EN-00875 EN-00876 ( 6 ) ( 5 ) ( 7 ) EN-00877 EN-00878 EN(H4SO)-19...
Page 417 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. TRANSMISSION • MODULE ( 2 ) ( 1 ) EN-01114 ( 1 ) ( 2 ) EN-01115 Transmission Control Module AT diagnostic indicator light (for (TCM) (for AT vehicles) AT vehicles) ( 2 ) CHECK ENGINE 100 120 140...
Page 418 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SENSOR ( 3 ) ( 2 ) ( 1 ) EN-00881 EN-00882 ( 4 ) ( 5 ) EN-00883 EN-00884 ( 6 ) EN-00885 (1) Rear vehicle speed sensor (for AT vehicles) (2) Front vehicle speed sensor (for MT vehicles) (3) Front vehicle speed sensor (for AT vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles)
Page 419 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • SOLENOID VALVE AND SWITCH (AT VEHICLES) ( 2 ) ( 1 ) EN-00886 EN-00887 ( 9 ) ( 5 ) ( 4 ) ( 3 ) ( 6 ) ( 7 ) ( 8 ) (10) EN-00888 EN-00889...
Page 420 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-23...
Page 421: 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 B136 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 19 18 17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 35 34 33 32 31 30...
Page 422 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) ON: 10 — 13 ON: 13 — 14 A/C switch B136 — OFF: 0 OFF: 0 Ignition switch B136 10 —...
Page 423 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) ON: 0 ON: 0 Blower fan switch B137 — OFF: 10 — 13 OFF: 13 — 14 ON: 0 ON: 0 Rear defogger switch...
Page 424: Engine Condition Data
ENGINE CONDITION DATA ENGINE (DIAGNOSTICS) 6. Engine Condition Data A: ELECTRICAL SPECIFICATION Content Specified data 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm racing Measuring condition: • After warm-up the engine. • Gear position is in “N” or “P” position. •...
Page 425: Transmission Control Module (Tcm) I/O Signal
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL ENGINE (DIAGNOSTICS) 7. Transmission Control Module (TCM) I/O Signal A: ELECTRICAL SPECIFICATION <Ref. to AT-14, Transmission Control Module (TCM) I/O Signal.> EN(H4SO)-28...
Page 426: Data Link Connector
This connector is used both for OBD-II general scan tools and the Subaru Select Monitor. CAUTION: Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select Mon- itor, because the circuit for the Subaru Select Monitor may be damaged.
Page 427: Obd-Ii General Scan Tool
OBD-II GENERAL SCAN TOOL ENGINE (DIAGNOSTICS) 9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up diag- nostic trouble code(s) and freeze frame data. A: OPERATION OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic 1.
Page 428 OBD-II GENERAL SCAN TOOL ENGINE (DIAGNOSTICS) 3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure Trouble code that caused CARB required freeze frame data storage...
Page 429: Subaru Select Monitor
DTC. <Ref. to EN(H4SO)-39, Read Diagnostic Trouble Code.> EN-00039 4) Connect Subaru Select Monitor to data link con- nector. (1) Data link connector (A) located in the lower portion of the instrument panel (on the driver's side).
Page 430 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 Control System} and press the [YES] key.
Page 431 Power steering switch signal P/S Switch ON or OFF Wiper switch signal Wiper Switch ON or OFF NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. • For select monitor display details, refer to the following. EN(H4SO)-34...
Page 432 — Front oxygen (A/F) sensor equipment Oxygen sensor #11 Supported Oxygen sensor equipment Oxygen sensor #12 Supported Front oxygen (A/F) sensor output signal A/F Sensor #11 NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-35...
Page 433 Intake manifold absolute pressure signal Mani. Absolute Pressure psig Engine speed signal Engine Speed Vehicle speed signal Vehicle Speed km/h or MPH NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-36...
Page 434 Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF entered. When camshaft position sensor signal is Camshaft position sensor signal Camshaft Position Sig. ON or OFF entered. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SO)-37...
Page 435 Low Clutch Timing Sol. ON or OFF Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For select monitor display details, refer to the following. EN(H4SO)-38...
Page 436: Read Diagnostic Trouble Code
Code 3. OBD-II GENERAL SCAN TOOL A: OPERATION Refers to data denoting emission-related power- 1. SUBARU SELECT MONITOR (NORMAL train diagnostic trouble codes. MODE) For details concerning diagnostic trouble codes, re- fer to the List of Diagnostic Trouble Code (DTC).
Page 437: Inspection Mode
INSPECTION MODE ENGINE (DIAGNOSTICS) 12.Inspection Mode A: OPERATION Carry out trouble diagnosis shown in the following DTC table. When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle. <Ref. to EN(H4SO)-45, Drive Cycle.> Item DTC No.
Page 438 INSPECTION MODE ENGINE (DIAGNOSTICS) Item DTC No. P0733 Gear 3 incorrect ratio P0734 Gear 4 incorrect ratio P0741 Torque converter clutch circuit performance or stuck off P0743 Torque converter clutch circuit electrical P0748 Pressure control solenoid “A” electrical P0753 Shift solenoid “A” electrical P0758 Shift solenoid “B”...
Page 439 12V or more. 2) Warm up engine. 2) Raise the vehicle using a garage jack and place 3) Prepare Subaru Select Monitor kit. <Ref. to on safety stands or drive the vehicle onto free roll- EN(H4SO)-8, PREPARATION TOOL, General De- ers.
Page 440 INSPECTION MODE ENGINE (DIAGNOSTICS) 7) Connect Subaru Select Monitor to data link con- NOTE: nector. • For detailed operation procedure, refer to the (1) Connect Subaru Select Monitor to data link SUBARU SELECT MONITOR OPERATION MAN- connector (A) located in the lower portion of the UAL.
Page 441 INSPECTION MODE ENGINE (DIAGNOSTICS) 5) Start the engine. NOTE: • Ensure the selector lever is placed in the “P” po- sition before starting. (AT vehicles) • Depress clutch pedal when starting the engine. (MT vehicles) 6) Using the selector lever or shift lever, turn the “P” position switch and the “N”...
Page 442: Drive Cycle
DRIVE CYCLE ENGINE (DIAGNOSTICS) 13.Drive Cycle 2) After performing diagnostics and cleaning the memory, check for any remaining unresolved trou- A: OPERATION ble data. <Ref. to EN(H4SO)-47, Clear Memory Mode.> There are 3 drive patterns for trouble diagnosis. Driving in the specified pattern allows to diagnose 3) Separate test mode connector.
Page 443 DRIVE CYCLE ENGINE (DIAGNOSTICS) 4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN Vehicle speed km/h (MPH) ( C ) 96 (60) ( G ) ( D ) ( F ) 65 (40) ( E ) ( B ) ( A ) (Seconds) EN-00195 (A) Idle engine for 1 minute.
Page 444: Clear Memory Mode
4) On the «Engine Diagnosis» display screen, se- lect the {Clear Memory} and press the [YES] key. 5) When the `Done' and `Turn Ignition Switch OFF' are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: •...
Page 445: Compulsory Valve Operation Check Mode
{Actuator ON/OFF Opera- ( A ) tion} and press the [YES] key. EN-00711 12) Select the desired compulsory actuator on the «Actuator ON/OFF Operation» display screen and 5) Connect Subaru Select Monitor to data link con- press the [YES] key. nector. EN(H4SO)-48...
Page 446 FICD Solenoid Pressure Switching Sol. 1 Pressure Switching Sol. 2 AAI Solenoid Valve PCV Solenoid Valve Vent Control Solenoid Valve Fuel Tank Sensor Control Valve • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MAN- UAL. EN(H4SO)-49...
Page 447: Engine Malfunction Indicator Lamp (Mi)
ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) 16.Engine Malfunction Indicator Lamp (MI) A: PROCEDURE 1. Activation of check engine malfunction indicator lamp (MI). <Ref. to EN(H4SO)-50, ACTIVATION OF CHECK ENGINE MAL- FUNCTION INDICATOR LAMP (MI), Engine Malfunction Indicator Lamp (MI).> ↓...
Page 448 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) 4) When ignition switch is turned to ON (engine off) or to “START” with the test mode connector con- nected, the MI blinks at a cycle of 3 Hz. 1 sec. Ignition switch EN-00198 EN(H4SO)-51...
Page 449 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MI) DOES NOT COME • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MI) circuit is open or shorted. • TROUBLE SYMPTOM: • When ignition switch is turned ON (engine OFF), MI does not come on. •...
Page 450 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT SIGNAL FROM ECM. Go to step 4. Go to step 2. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No.
Page 451 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN COMBINA- 10 V Go to step 7. Check the follow- TION METER AND IGNITION SWITCH CON- ing and repair if NECTOR. necessary. 1) Turn ignition switch to ON. NOTE: 2) Measure voltage between combination •...
Page 452 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-55...
Page 453 • The CHECK ENGINE malfunction indicator lamp (MI) circuit is shorted. • TROUBLE SYMPTOM: • Although MI comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD- II general scan tool display. • WIRING DIAGRAM: BATTERY No.
Page 454 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN COMBINA- MI illuminates. Repair short circuit Replace ECM. TION METER AND ECM CONNECTOR. in harness <Ref. to 1) Turn ignition switch to OFF. between combina- FU(H4SO)-45, 2) Disconnect connector from ECM. tion meter and Engine Control 3) Turn ignition switch to ON.
Page 455 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MI) DOES NOT BLINK AT A CYCLE OF 3 HZ. • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MI) circuit is open or shorted. • Test mode connector circuit is in open. •...
Page 456 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) Step Value CHECK STATUS OF CHECK ENGINE MAL- MI illuminates. Go to step 2. Repair the MI cir- FUNCTION INDICATOR LAMP (MI). cuit. <Ref. to 1) Turn ignition switch to OFF. EN(H4SO)-52, 2) Disconnect test mode connector. CHECK ENGINE 3) Turn ignition switch to ON.
Page 457 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MI) REMAINS BLINK- ING AT A CYCLE OF 3 HZ. • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • MI blinks at a cycle of 3 Hz when ignition switch is turned to ON. •...
Page 458 ENGINE MALFUNCTION INDICATOR LAMP (MI) ENGINE (DIAGNOSTICS) Step Value CHECK TEST MODE CONNECTOR. MI illuminates. Go to step 2. System is in good 1) Disconnect test mode connector. order. 2) Turn ignition switch to ON. NOTE: Does MI flash on and off? MI blinks at a cycle of 3 Hz when test mode connector is...
Page 459: Diagnostics For Engine Starting Failure
DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 17.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN(H4SO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Fail- ure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO)-68, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
Page 460 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-63...
Page 461 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)-47, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(H4SO)-40, Inspection Mode.> . • WIRING DIAGRAM: IGNITION SWITCH BATTERY...
Page 462 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK OPERATION OF STARTER MOTOR. Operates. Go to step 2. Go to step 3. Does the starter motor operates, when the switch is ON? CHECK DTC. DTC indicated. Check DTC using Repair poor con- Is DTC displayed? “List of Diagnostic...
Page 463 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK TRANSMISSION TYPE. Target is AT vehicle. Go to step 8. Repair open or Is the target AT vehicle? short to ground between ignition switch and starter motor. CHECK INPUT VOLTAGE OF INHIBITOR 10 V Go to step 9.
Page 464 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-67...
Page 465 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.> and Inspection Mode. <Ref. to EN(H4SO)-40, OPERATION, Inspection Mode.>...
Page 466 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK MAIN RELAY. Go to step 2. Replace main 1) Turn the ignition switch to OFF. relay. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No.
Page 467 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT VOLTAGE FROM ECM. 10 V Go to step 7. Replace ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector &...
Page 468 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-71...
Page 469 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)-47, OPER- ATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-40, OPERATION, Inspection Mode.> . •...
Page 470 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK SPARK PLUG CONDITION. Go to step 2. Replace the spark 1) Remove the spark plug. <Ref. to plug. IG(H4SO)-5, REMOVAL, Spark Plug.> 2) Check the spark plug condition. <Ref. to IG(H4SO)-6, INSPECTION, Spark Plug.>...
Page 471 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR IGNITION COIL 10 V Go to step 7. Replace ignition & IGNITOR ASSEMBLY. coil & ignitor 1) Connect connector to ignition coil & ignitor assembly. <Ref. to assembly.
Page 472 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-75...
Page 473 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)-47, OPER- ATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)-40, OPERATION, Inspection Mode.> . •...
Page 474 Does fuel pump produce operating sound? nostics for Engine Starting Failure.> NOTE: Fuel pump operation can also be executed us- ing Subaru Select Monitor (Function mode: FD01). For the procedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN(H4SO)- 48, Compulsory Valve Operation Check Mode.>...
Page 475 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK FUEL PUMP RELAY. Go to step 7. Replace fuel pump 1) Disconnect connectors from fuel pump relay. <Ref. to relay and main relay. FU(H4SO)-47, 2) Remove fuel pump relay and main relay Fuel Pump with bracket.
Page 476 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-79...
Page 477 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)-47, OP- ERATION, Clear Memory Mode.> and Inspection Mode. <Ref. to EN(H4SO)-40, OPERATION, Inspec- tion Mode.>...
Page 478 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK OPERATION OF EACH FUEL INJEC- Operating sound produced. Check fuel pres- Go to step 2. TOR. sure. <Ref. to While cranking the engine, check that each ME(H4SO)-28, fuel injector emits “operating” sound. Use a INSPECTION, sound scope or attach a screwdriver to injector Fuel Pressure.>...
Page 479 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. There is poor contact. Repair poor con- Inspection using Check poor contact in ECM connector. tact in ECM con- “General Diagnos- Is there poor contact in ECM connector? nector.
Page 480: List Of Diagnostic Trouble Code (Dtc)
LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 18.List of Diagnostic Trouble Code (DTC) A: LIST Item Index P0030 HO2S Heater control circuit (Bank 1 Sensor 1) <Ref. to EN(H4SO)-90, DTC P0030 — HO2S HEATER CON- TROL CIRCUIT (BANK 1 SENSOR 1) —, Diagnostic Proce- dure with Diagnostic Trouble Code (DTC).>...
Page 481: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0125 Insufficient coolant temperature for closed loop <Ref. to EN(H4SO)-136, DTC P0125 — INSUFFICIENT fuel control COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0129 Barometric pressure too low <Ref.
Page 482 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0335 Crankshaft position sensor “A” circuit <Ref. to EN(H4SO)-180, DTC P0335 — CRANKSHAFT POSI- TION SENSOR “A” CIRCUIT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0336 Crankshaft position sensor “A” circuit range/per- <Ref.
Page 483 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0512 Starter request circuit <Ref. to EN(H4SO)-230, DTC P0512 — STARTER REQUEST CIRCUIT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> P0513 Incorrect immobilizer key <Ref. to IM-24, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF UNREGISTERED KEY), Diagnostic Procedure with Trouble Code (DTC).>...
Page 484 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P0753 Shift solenoid “A” electrical <Ref. to AT-72, DTC 71 SHIFT SOLENOID 1, Diagnostic Pro- cedure with Diagnostic Trouble Code (DTC).> P0758 Shift solenoid “B” electrical <Ref. to AT-76, DTC 72 SHIFT SOLENOID 2, Diagnostic Pro- cedure with Diagnostic Trouble Code (DTC).>...
Page 485 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P1495 EGR solenoid valve signal #2 circuit malfunction <Ref. to EN(H4SO)-279, DTC P1495 — EGR SOLENOID (high input) VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
Page 486 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Item Index P1570 Antenna <Ref. to IM-26, DTC P1570 ANTENNA, Diagnostic Procedure with Trouble Code (DTC).> P1571 Reference code imcompatibility <Ref. to IM-17, DTC P1571 REFERENCE CODE INCOMPATI- BILITY, Diagnostic Procedure with Trouble Code (DTC).> P1572 IMM circuit failure <Ref.
Page 487 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 19.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0030 — HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 488 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 1 Ω CHECK HARNESS BETWEEN ECM AND Go to step 2. Repair open circuit FRONT OXYGEN (A/F) SENSOR CONNEC- between ECM and TOR. front oxygen (A/F) 1) Start and warm-up engine. sensor connector.
Page 489 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) B: DTC P0031 — HO2S HEATER CONTROL CIRCUIT LOW (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)-47, OPER- ATION, Clear Memory Mode.>...
Page 490 CHECK ANY OTHER DTC ON DISPLAY. Indicated. Go to step 2. Go to step 5. Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0031 and P0037 at the same time? CHECK POWER SUPPLY TO FRONT OXY- 10 V Go to step 3.
Page 491 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT SIGNAL FROM ECM. 1.0 V Repair poor con- Go to step 7. Measure voltage between ECM connector and tact in ECM con- chassis ground. nector. Connector & terminal (B136) No.
Page 492 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-95...
Page 493 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC P0032 — HO2S HEATER CONTROL CIRCUIT HIGH (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)-47, OPER- ATION, Clear Memory Mode.>...
Page 494 ECM and front oxygen (A/F) sen- Module.> sor connector. 3) Turn ignition switch to ON. 4) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. Does the measured value exceed the spec- ified value? NOTE: •Subaru Select Monitor...
Page 495 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 496 Go to step 3. 1) Start engine. NOTE: 2) Read data of rear oxygen sensor heater In this case, repair current using Subaru Select Monitor or the following: OBD-II general scan tool. • Poor contact in Does the measured value exceed the spec-...
Page 497 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO REAR OXY- 10 V Go to step 7. Repair power sup- GEN SENSOR. ply line. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from rear oxygen In this case, repair sensor.
Page 498 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-101...
Page 499 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 500 Engine Control nector. Module.> 3) Turn ignition switch to ON. 4) Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. Does the measured value exceed the spec- ified value? NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 501 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC P0068 — MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRES- SURE CIRCUIT RANGE/PERFORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 502 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sen- sor signal using Subaru Select Monitor or OBD-II general scan tool. Is the measured value within the specified range? NOTE: •Subaru Select Monitor...
Page 503 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC P0107 — MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRES- SURE CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 504 Subaru Select Monitor. Does the measured value exceed the specified value by shaking harness and connector of ECM while monitoring the value with Subaru Select Monitor? NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 505 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 4.5 V Go to step 8. Repair open circuit PRESSURE SENSOR CONNECTOR. in harness 1) Turn ignition switch to OFF. between ECM and 2) Disconnect connector from pressure sen- pressure sensor sor.
Page 506 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-109...
Page 507 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC P0108 — MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRES- SURE CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 508 Subaru Select Monitor. Does the measured value exceed the specified value by shaking harness and connector of ECM while monitoring the value with Subaru Select Monitor? NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 509 Repair battery Replace pressure PRESSURE SENSOR CONNECTOR. 35.29 inHg) short circuit in har- sensor. <Ref. to 1) Turn ignition switch to OFF and Subaru ness between FU(H4SO)-32, Select Monitor or the OBD-II general scan ECM and pressure Pressure Sensor.> tool switch to OFF.
Page 510 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-113...
Page 511 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC P0111 — INTAKE AIR TEMPERATURE CIRCUIT RANGE/PERFOR- MANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 512 1) Start the engine and warm it up completely. sor. <Ref. to of Diagnostic 2) Measure engine coolant temperature using FU(H4SO)-33, Trouble Code Subaru Select Monitor or OBD-II general REMOVAL, Intake (DTC)”. <Ref. to scan tool. Air Temperature EN(H4SO)-83, List Is the measured value within the specified Sensor.>...
Page 513 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.
Page 514 Repair poor con- 1) Start engine. tact. 2) Read data of intake air temperature sensor NOTE: signal using Subaru Select Monitor or the In this case, repair OBD-II general scan tool. the following: Does the measured value exceed the spec- •...
Page 515 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.
Page 516 Repair poor con- 1) Start engine. tact. 2) Read data of intake air temperature sensor NOTE: signal using Subaru Select Monitor or the In this case, repair OBD-II general scan tool. the following: Is the measured value less than the speci- •...
Page 517 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 5 Ω CHECK HARNESS BETWEEN INTAKE AIR Replace intake air Repair harness TEMPERATURE SENSOR AND ECM CON- temperature sen- and connector. NECTOR. sor. <Ref. to NOTE: 1) Turn ignition switch to OFF. FU(H4SO)-33, In this case, repair 2) Measure resistance of harness between...
Page 518 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-121...
Page 519 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.
Page 520 Repair poor con- 1) Start engine. tact. 2) Read data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor In this case, repair or OBD-II general scan tool. the following: Does the measured value exceed the spec- • Poor contact in...
Page 521 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.
Page 522 Repair poor con- 1) Start engine. tact. 2) Read data of engine coolant temperature NOTE: sensor signal using Subaru Select Monitor In this case, repair or OBD-II general scan tool. the following: Is the measured value less than the speci- •...
Page 523 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ENGINE Go to step 5. Repair harness COOLANT TEMPERATURE SENSOR AND and connector. ECM CONNECTOR. NOTE: Measure voltage between engine coolant tem- In this case, repair perature sensor connector and engine ground.
Page 524 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-127...
Page 525 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC P0121 — THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT RANGE/PERFORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 526 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Replace throttle Is any other DTC displayed? vant DTC using position sensor. “List of Diagnostic <Ref. to Trouble Code FU(H4SO)-30, (DTC)”.
Page 527 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC P0122 — THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIR- CUIT LOW INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 528 1) Start engine. up, the circuit has 2) Read data of throttle position sensor signal returned to a nor- using Subaru Select Monitor or OBD-II gen- mal condition at eral scan tool. this time. A tempo- Is the measured value less than the speci-...
Page 529 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 4.5 V Go to step 7. Repair harness THROTTLE POSITION SENSOR CONNEC- and connector. TOR. NOTE: 1) Turn ignition switch to OFF. In this case, repair 2) Disconnect connectors from throttle posi- the following: tion sensor.
Page 530 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-133...
Page 531 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC P0123 — THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 532 1) Start engine. up, the circuit has 2) Read data of throttle position sensor signal returned to a nor- using Subaru Select Monitor or OBD-II gen- mal condition at eral scan tool. this time. A tempo- Does the measured value exceed the spec-...
Page 533 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 534 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 535 Mode.> . Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P0129 indicated. Replace ECM. It is not necessary Does the Subaru Select Monitor or OBD-II <Ref. to to inspect DTC general scan tool indicate DTC P0129? FU(H4SO)-45, P0129. Engine Control Module.>...
Page 536 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-139...
Page 537 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) S: DTC P0130 — O2 SENSOR 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 538 0.85 - 1.15 in idling. Go to step 3. Go to step 4. 1) Start 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 (158°F).
Page 539 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 1 MΩ Go to step 6. Repair ground FRONT OXYGEN (A/F) SENSOR. short circuit Measure resistance between ECM and chas- between ECM and sis ground. front oxygen (A/F) Connector &...
Page 540 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-143...
Page 541 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) T: 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 542 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 1 MΩ Replace front oxy- Repair short circuit FRONT OXYGEN (A/F) SENSOR CONNEC- gen (A/F) sensor. between ECM and TOR. <Ref. to front oxygen (A/F) 1) Turn ignition switch to OFF.
Page 543 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) U: DTC P0132 — O2 SENSOR CIRCUIT HIGH VOLTAGE (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)-47, OPER- ATION, Clear Memory Mode.>...
Page 544 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND Replace front oxy- Repair battery FRONT OXYGEN (A/F) SENSOR CONNEC- gen (A/F) sensor. short circuit in har- TOR. <Ref. to ness between 1) Turn ignition switch to OFF. FU(H4SO)-43, ECM and front 2) Disconnect connector from ECM.
Page 545 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) V: 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 546 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 547 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) W: DTC P0134 — O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (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)-47, OPER- ATION, Clear Memory Mode.>...
Page 548 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 1 Ω CHECK HARNESS BETWEEN ECM AND Go to step 2. Repair harness FRONT OXYGEN (A/F) SENSOR CONNEC- and connector. TOR. NOTE: 1) Turn ignition switch to OFF. In this case, repair 2) Disconnect connectors from ECM and front the following: oxygen (A/F) sensor connector.
Page 549 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) X: 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 550 ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. Indicated. Repair referring Go to step 2. Does the Subaru Select Monitor or OBD-II procedure for general scan tool indicate DTC P0131, P0132 P0131, P0132 and or P0134? P0134. NOTE:...
Page 551 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK EXHAUST SYSTEM. There is a fault. Repair or replace Replace rear oxy- Check exhaust system parts. faulty parts. gen sensor. <Ref. Is there a fault in exhaust system? to FU(H4SO)-43, Rear Oxygen Sen- NOTE:...
Page 552 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-155...
Page 553 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Y: 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 554 Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Check DTC refer- Go to step 3. Does the Subaru Select Monitor or OBD-II ring "List of Diag- general scan tool indicate DTC P0130, P0131, nostic Trouble P0132 or P0134? Code (DTC)".
Page 555 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK EXHAUST SYSTEM. There is a fault. Repair or replace Replace rear oxy- Check exhaust system parts. faulty parts. gen sensor. <Ref. Is there a fault in exhaust system? to FU(H4SO)-43, Rear Oxygen Sen- NOTE:...
Page 556 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-159...
Page 557 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Z: 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 558 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Replace rear oxy- Is any other DTC displayed? vant DTC using gen sensor. <Ref. “List of Diagnostic to FU(H4SO)-43, Trouble Code Rear Oxygen Sen- (DTC)”.
Page 559 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AA:DTC P0171 — SYSTEM TOO LEAN (BANK 1) — NOTE: For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(H4SO)-164, DTC P0172 — SYSTEM TOO RICH (BANK 1) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> EN(H4SO)-162...
Page 560 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-163...
Page 561 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AB:DTC P0172 — SYSTEM TOO RICH (BANK 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. • Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 562 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK FUEL PRESSURE. 284 — 314 kPa (2.9 — 3.2 kg/ Go to step 8. Repair the follow- ing items. , 41 — 46 psi) Warning: Fuel pressure too •Place “NO FIRE”...
Page 563 4) Turn all accessory switches to OFF. parts. 5) Read data of intake manifold pressure sen- sor signal using Subaru Select Monitor or OBD-II general scan tool. Is the measured value within the specified range? NOTE: •Subaru Select Monitor For detailed operation procedure, refer to the “READ CURRENT DATA FOR ENGINE”.
Page 564 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AC:DTC P0301 — CYLINDER 1 MISFIRE DETECTED — NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO)-168, DTC P0304 — CYLINDER 4 MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> AD:DTC P0302 —...
Page 565 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AF:DTC P0304 — CYLINDER 4 MISFIRE DETECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • Immediately at fault recognition (A misfire which could damage catalyst occurs.) •...
Page 566 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 567 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 5 - 20 Ω CHECK FUEL INJECTOR. Go to step 6. Replace faulty fuel Measure resistance between fuel injector ter- injector. <Ref. to minals on faulty cylinder. FU(H4SO)-36, Terminals Fuel Injector.>...
Page 568 The MI is coming on or blink- Go to step 15. Go to step 14. FUNCTION INDICATOR LAMP (MI). ing. 1) Clear memory using Subaru Select Moni- tor. <Ref. to EN(H4SO)-47, Clear Memory Mode.> 2) Start engine, and drive the vehicle more than 10 minutes.
Page 569 • Poor contact in ECM connec- • Poor contact in coupling con- nector (2) If there is no poor contact, con- tact SUBARU dis- tributor. Before contacting, the fol- lowing items must be checked: • Fuel for con- dition • Fuel addi- tives •...
Page 570 Go to step 21. Go to step 17. 1) Turn ignition switch to ON. 2) Read diagnostic trouble code (DTC). Does the Subaru Select Monitor or OBD-II general scan tool indicate only one DTC? •Subaru Select Monitor <Ref. to EN(H4SO)-32, Subaru Select Moni- tor.>...
Page 571 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value GROUP OF #1 AND #2 CYLINDERS There are faults. Repair or replace Go to DTC P0171. Are there faults in #1 and #2 cylinders? faulty parts. <Ref. to EN(H4SO)-162, NOTE: DTC P0171 —...
Page 572 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value GROUP OF #2 AND #4 CYLINDERS There are faults. Repair or replace Go to DTC P0171. Are there faults in #2 and #4 cylinders? faulty parts. <Ref. to EN(H4SO)-162, NOTE: DTC P0171 —...
Page 573 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AG:DTC P0327 — KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SIN- GLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Poor driving performance •...
Page 574 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN KNOCK SEN- 700 kΩ Go to step 2. Repair harness SOR AND ECM CONNECTOR. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from ECM. In this case, repair 3) Measure resistance between ECM harness the following:...
Page 575 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AH:DTC P0328 — KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SIN- GLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Poor driving performance •...
Page 576 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN KNOCK SEN- 400 kΩ Go to step 2. Go to step 3. SOR AND ECM CONNECTOR. Measure resistance of harness between ECM connector and chassis ground. Connector &...
Page 577 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AI: DTC P0335 — CRANKSHAFT POSITION SENSOR “A” CIRCUIT — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 578 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN CRANK- 100 kΩ Repair harness Go to step 2. SHAFT POSITION SENSOR AND ECM CON- and connector. NECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, repair 2) Disconnect connector from crankshaft posi- the following: tion sensor.
Page 579 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AJ:DTC P0336 — CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/ PERFORMANCE — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 580 Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P0335 indicated. Inspect DTC Go to step 2. Does the Subaru Select Monitor or OBD-II P0335 using “List general scan tool indicate DTC P0335? of Diagnostic Trouble Code (DTC)”. <Ref. to...
Page 581 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AK:DTC P0340 — CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 582 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN CAMSHAFT 100 kΩ Repair harness Go to step 2. POSITION SENSOR AND ECM CONNEC- and connector. TOR. NOTE: 1) Turn ignition switch to OFF. In this case, repair 2) Disconnect connector from camshaft posi- the following: tion sensor.
Page 583 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AL:DTC P0341 — CAMSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PER- FORMANCE (BANK 1 OR SINGLE SENSOR) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. •...
Page 584 Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P0340 indicated. Inspect DTC Go to step 2. Does the Subaru Select Monitor or OBD-II P0340 using “List general scan tool indicate DTC P0340? of Diagnostic Trouble Code (DTC)”. <Ref. to...
Page 585 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CAMSHAFT POSITION SENSOR. 1 - 4 kΩ Go to step 7. Replace camshaft 1) Remove camshaft position sensor. position sensor. 2) Measure resistance between connector ter- <Ref. to minals of camshaft position sensor.
Page 586 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-189...
Page 587 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AM:DTC P0400 — EXHAUST GAS RECIRCULATION FLOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Poor driving performance on low engine speed • Erroneous idling •...
Page 588 2) Rear the data of intake manifold absolute fold pressure sen- pressure signal using Subaru Select Moni- sor and throttle tor or OBD-II general scan tool. body are securely Does the measured value exceed the spec- installed.
Page 589 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT SIGNAL FROM ECM. 0 — 10 V Repair poor con- Go to step 6. 1) Turn ignition switch to OFF. tact in ECM con- 2) Connect connectors to ECM and EGR sole- nector.
Page 590 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-193...
Page 591 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AN:DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 592 Connector & terminal (B135) No. 19 - (T6) No. 3 Is the measured value less than the speci- fied value? CHECK SEALED WIRE. Connected. Contact SUBARU Repair sealed Is the sealed wire connected? distributor service. wire. NOTE: Inspection by DTM...
Page 593 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AO:DTC P0458 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 594 Connector & terminal this time. Contact (B134) No. 29 (+) — Chassis ground ( − − − − ): SUBARU distribu- tor service. Does the measured value exceed the spec- ified value? NOTE: Inspection by DTM...
Page 595 (E4) No. 1 (+) — Engine ground ( − − − − ): Does the measured value exceed the spec- ified value? CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in purge control solenoid tact in purge con- distributor service. valve connector. trol solenoid valve...
Page 596 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-199...
Page 597 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AP:DTC P0459 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON- TROL VALVE CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 598 ECM and connector. chassis ground. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For pro- cedure, refer to “Compulsory Valve Operation Check Mode”. <Ref. to EN(H4SO)-48, Compul- sory Valve Operation Check Mode.> Connector & terminal (B134) No.
Page 599 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. There is poor contact. Repair poor con- Replace ECM. Check poor contact in ECM connector. tact in ECM con- <Ref. to Is there poor contact in ECM connector? nector.
Page 600 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-203...
Page 601 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AQ:DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 602 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Replace fuel level Is any other DTC displayed? vant DTC using sensor <Ref. to “List of Diagnostic FU(H4SO)-64, Trouble Code Fuel Level Sen- (DTC)”.
Page 603 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AR:DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 604 Is the measured value less than the specified this time. A tempo- value by shaking harness and connector of rary poor contact ECM while monitoring the value with Subaru of the connector Select Monitor? may be the cause. NOTE: NOTE: •Subaru Select Monitor...
Page 605 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK HARNESS BETWEEN ECM AND Repair or replace Repair open circuit COMBINATION METER. combination between ECM and Measure resistance between ECM and combi- meter. <Ref. to combination meter nation meter connector.
Page 606 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-209...
Page 607 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AS:DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 608 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK SPEEDOMETER AND TACHOME- Operates normally. Go to step 2. Repair or replace TER OPERATION IN COMBINATION combination METER. meter. <Ref. to Does speedometer and tachometer operate IDI-4, Combina- normally? tion Meter Sys- tem.>...
Page 609 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 1 Ω CHECK FUEL TANK CORD. Go to step 7. Repair open circuit 1) Disconnect connector from fuel level sen- between coupling sor. connector and fuel 2) Measure resistance between fuel level sen- level sensor.
Page 610 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-213...
Page 611 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AT:DTC P0464 — FUEL LEVEL SENSOR CIRCUIT INTERMITTENT— • 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 612 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 613 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AU:DTC P0483 — COOLING FAN RATIONALITY CHECK — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Occurrence of noise • Overheating CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 614 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 NO. 3 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 SUB FAN MAIN FAN B134 RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR AIR CONDITIONING RELAY HOLDER B72 (BLUE) B134 2 3 4...
Page 615 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Check radiator fan Is any other DTC displayed? vant DTC using and fan motor. “List of Diagnostic <Ref. to Trouble Code CO(H4SO)-28, (DTC)”.
Page 616 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-219...
Page 617 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AV:DTC P0502 — VEHICLE SPEED SENSOR CIRCUIT LOW INPUT — NOTE: For the diagnostic procedure, refer to DTC P0503. <Ref. to EN(H4SO)-222, DTC P0503 — VEHICLE SPEED SENSOR INTERMITTENT/ERRATIC/HIGH —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
Page 618 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-221...
Page 619 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AW:DTC P0503 — VEHICLE SPEED SENSOR INTERMITTENT/ERRATIC/HIGH — • DTC DETECTING CONDITION: • Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 620 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: IGNITION RELAY BATTERY No. 5 B157 LHD MODEL : 10 RHD MODEL : 37 LHD MODEL : 9 VEHICLE RHD MODEL : 38 SPEED SENSOR COMBINATION METER B137 B137 A1 A2 A4 A5 A6...
Page 621 Is the transmission type AT? CHECK DTC P0720 ON DISPLAY. DTC P0720 indicated. Check front vehi- Go to step 3. Does the Subaru Select Monitor or OBD-II cle speed sensor general scan tool indicate DTC P0720? signal circuit. <Ref. to AT-58,...
Page 622 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-225...
Page 623 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AX:DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine is difficult to start. •...
Page 624 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 625 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AY:DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 626 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 627 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) AZ: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)-47, OPER- ATION, Clear Memory Mode.>...
Page 628 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-4 SBF-1 INHIBITOR SWITCH STARTER MOTOR B136 B136 1 2 3 4 5 6 1 2 3 4 10 11 12 13 14 15 16 17 7 8 9 10 11 12 5 6 7 8 18 19 20...
Page 629 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BA:DTC P0519 — IDLE AIR CONTROL CIRCUIT SYSTEM PERFORMANCE — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 630 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC indicated. Inspect the rele- Go to step 2. Is any other DTC displayed? vant DTC using “List of Diagnostic Trouble Code (DTC)”. <Ref. to EN(H4SO)-83, List of Diagnostic Trouble Code...
Page 631 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BB:DTC P0565 — CRUISE CONTROL ON SIGNAL — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 632 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 1 Ω CHECK HARNESS BETWEEN TCM AND Go to step 2. Repair open circuit CCM CONNECTOR. in harness 1) Turn ignition switch to OFF. between TCM and 2) Disconnect connectors from TCM and CCM connector.
Page 633 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BC:DTC P0604 — INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 634 ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P0604 indicated. Replace ECM. It is not necessary Does the Subaru Select Monitor or OBD-II <Ref. to to inspect DTC general scan tool indicate DTC P0604? FU(H4SO)-45, P0604. Engine Control Module.>...
Page 635 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BD:DTC P0691 — COOLING FAN 1 CONTROL CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Radiator fan does not operate properly. •...
Page 636 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 NO. 3 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 SUB FAN MAIN FAN B134 RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR AIR CONDITIONING RELAY HOLDER B72 (BLUE) B134 2 3 4...
Page 637 ECM terminal and ground. Does the measured value change within specified range? NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to “Compulsory Valve Operation Check Mode”.<Ref. to EN(H4SO)-32, Subaru Select Monitor.> Connector & terminal (B134) No.
Page 638 ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in ECM or main fan relay tact in ECM or distributor service. connector. main fan relay Is there poor contact in ECM or main fan relay connector.
Page 639 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BE:DTC P0692 — COOLING FAN 1 CONTROL CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Radiator fan does not operate properly. •...
Page 640 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: BATTERY SBF-1 NO. 3 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 SUB FAN MAIN FAN B134 RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR AIR CONDITIONING RELAY HOLDER B72 (BLUE) B134 2 3 4...
Page 641 ECM voltage between ECM and chassis ground. connector. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to “Compulsory Valve Operation Check Mode”.<Ref. to EN(H4SO)-48, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No.
Page 642 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-245...
Page 643 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BF:DTC P0703 — TORQUE CONVERTER/BRAKE SWITCH “B” CIRCUIT — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 644 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OPERATION OF BRAKE LIGHT. Brake light comes on. Go to step 2. Repair or replace Does brake light come on when depressing the brake light circuit. brake pedal? 1 Ω...
Page 645 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BG:DTC P0731 — GEAR 1 INCORRECT RATIO — NOTE: For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(H4SO)-250, DTC P0734 — GEAR 4 INCOR- RECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> BH:DTC P0732 —...
Page 646 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-249...
Page 647 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BJ:DTC P0734 — GEAR 4 INCORRECT RATIO — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; excessive tight corner “braking”...
Page 648 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-251...
Page 649 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BK:DTC P0741 — TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • No lock-up (after engine warm-up) •...
Page 650 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INHIBITOR SWITCH CIRCUIT. There is a fault. Repair or replace Go to step 7. Check inhibitor switch circuit. inhibitor switch cir- Is there any trouble in inhibitor switch circuit? cuit.
Page 651 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BL:DTC P0851 — NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 652 Does the measured value exceed the specified value at except "N" and "P" positions? CHECK SELECTOR CABLE CONNECTION. There is a fault. Repair selector Contact SUBARU Is there any fault in selector cable connection cable connection. distributor service. to inhibitor switch? <Ref.
Page 653 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BM:DTC P0851 — NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 654 Is the measured value less than the specified value at except neutral position? CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in ECM connector. tact in ECM con- distributor service. Is there poor contact in ECM connector? nector.
Page 655 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BN:DTC P0852 — NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 656 Is the measured value within the specified range? CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in ECM connector. tact in ECM con- distributor service. Is there poor contact in ECM connector. nector.
Page 657 No. 7 — No. 12: Is the measured value less than the specified value? CHECK SELECTOR CABLE CONNECTION. There is a fault. Repair selector Contact SUBARU Is there any fault in selector cable connection cable connection. distributor service. to inhibitor switch? <Ref. to CS-12, NOTE: Select Cable.>...
Page 658 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-261...
Page 659 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BO:DTC P0852 — NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 660 Is the measured value less than the specified value at except neutral position? CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in ECM connector. tact in ECM con- distributor service. Is there poor contact in ECM connector? nector.
Page 661 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in transmission harness tact in transmis- distributor service. connector. sion harness NOTE: Is there poor contact in transmission harness connector.
Page 662 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-265...
Page 663 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BP:DTC P0864 — TCM COMMUNICATION CIRCUIT RANGE/PERFORMANCE — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 664 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK DRIVING CONDITION. Operates properly. Go to step 2. Replace TCM. 1) Start and warm-up the engine until the radi- <Ref. to AT-76, ator fan makes one complete rotation. Transmission Con- 2) Drive the vehicle.
Page 665 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BQ:DTC P0865 — TCM COMMUNICATION CIRCUIT LOW — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 666 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND Go to step 2. Even if MI lights TCM CONNECTOR. up, the circuit has 1) Turn ignition switch to ON. returned to a nor- 2) Measure voltage between ECM and chas- mal condition at sis ground.
Page 667 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BR:DTC P0866 — TCM COMMUNICATION CIRCUIT HIGH — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 668 Is the measured value less than the specified value? CHECK OUTPUT SIGNAL FROM ECM. 1 V - 4 V Even if MI lights Contact SUBARU Measure voltage between ECM and chassis up, the circuit has distributor service. ground. returned to a nor- NOTE: Connector &...
Page 669 Mode.> . Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P1110 indicated. Replace ECM. It is not necessary Does the Subaru Select Monitor or OBD-II <Ref. to to inspect DTC general scan tool indicate DTC P1110? FU(H4SO)-45, P1110. Engine Control Module.>...
Page 670 Mode.> . Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P1111 indicated. Replace ECM. It is not necessary Does the Subaru Select Monitor or OBD-II <Ref. to to inspect DTC general scan tool indicate DTC P1111? FU(H4SO)-45, P1111. Engine Control Module.>...
Page 671 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BU: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)-47, OPER- ATION, Clear Memory Mode.>...
Page 672 ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. DTC P1134 indicated. Replace ECM. It is not necessary Does the Subaru Select Monitor or OBD-II <Ref. to to inspect DTC general scan tool indicate DTC P1134? FU(H4SO)-45, P1134. Engine Control Module.>...
Page 673 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BV: DTC P1137 — O2 SENSOR 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)-47, OPER- ATION, Clear Memory Mode.>...
Page 674 0.85 - 1.15 Go to step 3. Go to step 4. 1) Start 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 (158°F). If the engine is already warmed-up, operate at idle speed for at least 1 minute.
Page 675 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 1 MΩ Go to step 6. Repair ground FRONT OXYGEN (A/F) SENSOR. short circuit Measure resistance between ECM and chas- between ECM and sis ground. front oxygen (A/F) Connector &...
Page 676 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) BW:DTC P1492 — EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) — NOTE: For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H4SO)-280, DTC P1498 — EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) —, Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
Page 677 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CC:DTC P1498 — EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 678 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO EGR SOLE- 10 V Go to step 2. Repair harness NOID VALVE. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from EGR solenoid In this case, repair valve.
Page 679 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CD:DTC P1499 — EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 680 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ANY OTHER DTC ON DISPLAY. Other DTC indicated on dis- Go to step 2. Go to step 3. Is there any DTC on display? play. 5 Ω CHECK ECM GROUND CIRCUIT. Go to step 3.
Page 681 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CE:DTC P1510 — ISC SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) — NOTE: For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(H4SO)-286, DTC P1516 — ISC SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) —, Diagnostic Procedure with Diagnostic Trou- ble Code (DTC).>...
Page 682 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-285...
Page 683 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CK:DTC P1516 — ISC SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 684 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO IDLE AIR CON- 10 V Go to step 2. Repair harness TROL SOLENOID VALVE. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from idle air control In this case, repair solenoid valve.
Page 685 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CL:DTC P1517 — ISC SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Erroneous idling • Engine stalls. •...
Page 686 CHECK ANY OTHER DTC ON DISPLAY. Indicated at same time. Go to step 2. Go to step 3. Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1511, P1513, P1515 and P1517 at same time? 5 Ω...
Page 687 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CM: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)-47, OPER- ATION, Clear Memory Mode.>...
Page 688 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) • WIRING DIAGRAM: IGNITION SWITCH BATTERY SBF-4 SBF-1 INHIBITOR SWITCH STARTER MOTOR B136 B136 1 2 3 4 5 6 1 2 3 4 10 11 12 13 14 15 16 17 7 8 9 10 11 12 5 6 7 8 18 19 20...
Page 689 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OPERATION OF STARTER MOTOR. Operates. Repair harness Check starter Does starter motor operate when turning igni- and connector. motor circuit. <Ref. tion switch to “ST”? to EN(H4SO)-64, NOTE: STARTER In this case, repair NOTE:...
Page 690 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-293...
Page 691 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CN: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)-47, OPER- ATION, Clear Memory Mode.>...
Page 692 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. 10 V Repair poor con- Go to step 2. 1) Turn ignition switch to OFF. tact in ECM con- 2) Measure voltage between ECM and chas- nector.
Page 693 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CO:DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT MAL- FUNCTION (LOW INPUT) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 694 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT SIGNAL FROM ECM. Repair poor con- Go to step 2. 1) Start engine, and warm-up the engine. tact in ECM con- 2) Turn ignition switch to OFF. nector.
Page 695 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CP:DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT MAL- FUNCTION (HIGH INPUT) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(H4SO)-47, OPER- ATION, Clear Memory Mode.>...
Page 696 Engine Control Module.> Is the measured value less than the speci- fied value? CHECK HARNESS BETWEEN ECM AND 10 V Repair battery Contact SUBARU TCM CONNECTOR. short circuit in har- distributor service. 1) Turn ignition switch to OFF. ness between NOTE:...
Page 697 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CQ:DTC P1711 — ENGINE TORQUE CONTROL SIGNAL #1 CIRCUIT MALFUNC- TION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 698 Does the measured value exceed the specified value? CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in ECM connector. tact in ECM con- distributor service. Is there poor contact in ECM connector? nector.
Page 699 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) CR:DTC P1712 — ENGINE TORQUE CONTROL SIGNAL #2 CIRCUIT MALFUNC- TION — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref.
Page 700 Does the measured value exceed the specified value? CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact SUBARU Check poor contact in ECM connector. tact in ECM con- distributor service. Is there poor contact in ECM connector? nector.
Page 701: General Diagnostic Table
GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 20.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO)-89, Engine Trouble in Gen- eral.> Symptom Problem parts 1) Idle air control solenoid valve 2) Intake manifold pressure sensor 3) Intake air temperature sensor 4) Intake air temperature and pressure sensor...
Page 702 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 4) Engine coolant temperature sensor (*2) 6. Surge 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 8) Throttle position sensor 9) Fuel pump and fuel pump relay...
Page 703 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) MEMO: EN(H4SO)-306...
Page 704 FUEL INJECTION (FUEL SYSTEMS) FU(H4SOw/oOBD) Page General Description ..................2 Throttle Body.....................13 Intake Manifold..................14 Engine Coolant Temperature Sensor............26 Crankshaft Position Sensor...............27 Camshaft Position Sensor.................28 Knock Sensor....................29 Throttle Position Sensor................30 Intake Air Temperature and Pressure Sensor...........32 Idle Air Control Solenoid Valve ..............33 Fuel Injector ....................34 Oxygen Sensor ..................40 Engine Control Module................42...
Page 705 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 64 2 (16.9 US gal, 14.1 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
Page 706 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) MEMO: FU(H4SOw/oOBD)-3...
Page 707 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD ( 2 ) (20) ( 4 ) ( 3 ) ( 7 ) ( 8 ) ( 5 ) ( 2 ) ( 6 ) (22) (13) (20) ( 9 ) ( 4 ) ( 3 ) (14)
Page 708 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH (2) Fuel injector pipe (13) Intake air temperature and pres- sure sensor (3) Fuel injector Tightening torque: N.m (kgf-m, ft-lb) (4) O-ring (14) O-ring T1: 1.5 (0.15, 1.1)
Page 709 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM ( 3 ) ( 1 ) ( 2 ) ( 4 ) FU-00712 (1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor T1: 1.6 (0.16, 1.2) (3) Idle air control solenoid valve T2: 22 (2.2, 15.9) FU(H4SOw/oOBD)-6...
Page 710 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 (1) Crank angle position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor (4) Camshaft position sensor support T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU(H4SOw/oOBD)-7...
Page 711 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK ( 6 ) (13) (28) (29) (36) (17) (34) (10) (12) (30) (14) (33) (11) (38) (16) ( 7 ) (37) ( 5 ) (31) (15) ( 9 ) ( 8 ) (22) (21) (27)
Page 712 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Heat sealed cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...
Page 713 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE ( 7 ) ( 8 ) (13) ( 1 ) (11) (12) (10) ( 1 ) ( 1 ) ( 9 ) (18) ( 1 ) ( 4 ) ( 1 ) ( 6 ) ( 1 ) (14)
Page 714 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE ( 5 ) ( 4 ) ( 6 ) ( 1 ) ( 7 ) ( 2 ) ( 3 ) FU-00628 (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap...
Page 715 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
Page 716 THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 6) Disconnect air by-pass hose from purge control solenoid valve. A: REMOVAL ( B ) ( A ) 1) Disconnect battery ground cable. ( C ) FU-00716 FU-00009 (A) Throttle position sensor (B) Idle air control solenoid valve 2) Remove air cleaner case.
Page 717 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold NOTE: Do not disconnect power steering hose. A: REMOVAL 1) Release fuel pressure. <Ref. to FU(H4SOw/ oOBD)-45, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
Page 718 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place power steering pump and tank on the 12) Remove air cleaner case stay RH and engine right side wheel apron. harness bracket, and disconnect engine harness connectors from bulkhead harness connectors. FU-00430 FU-00258 8) Disconnect spark plug cords from spark plugs.
Page 719 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect connector from oil pressure switch. 19) Remove bolts which hold intake manifold onto cylinder heads and then remove intake manifold. FU-00146 FU-00260 17) Disconnect connector from camshaft position sensor. B: INSTALLATION 1) Install intake manifold onto cylinder heads. NOTE: Always use new gaskets.
Page 720 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3) Connect connector to camshaft position sensor. 7) Connect connectors to engine coolant tempera- ture sensor. FU-00147 FU-00145 4) Connect connector to oil pressure switch. 8) Install air cleaner case stay RH and engine har- ness bracket, and connect engine harness connec- tors to bulkhead connectors.
Page 721 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 11) Connect PCV hose to intake manifold. (4) Install power steering pipes onto right side intake manifold protector. FU-00719 FU-00718 12) Connect spark plug cords to spark plugs. (5) Install front V-belt. 13) Install power steering pump and tank on brack- ets.
Page 722 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 17) Connect connector to fuel pump relay. 3) Remove ignition coil and ignitor assembly. FU-00431 FU-00722 18) Connect battery ground cable. 4) Disconnect connector from intake air tempera- ture and pressure sensor. FU-00009 FU-00723 C: DISASSEMBLY 5) Remove intake air temperature and pressure 1) Disconnect engine ground terminal from intake...
Page 723 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Disconnect pressure regulator vacuum hose 12) Disconnect connector from purge control sole- from intake manifold. noid valve. FU-00265 FU-00728 9) Remove fuel pipe protector LH. 13) Disconnect air by-pass hose from purge control solenoid valve.
Page 724 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Remove purge control solenoid valve. (1) Remove fuel injector securing clip. FU-00730 FU-00733 17) Remove bolt which installs injector pipe on in- (2) Remove fuel injector while lifting up fuel in- take manifold as shown in figure. jector pipe.
Page 725 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 23) Remove fuel injector pipe. D: ASSEMBLY 1) Install fuel pipe assembly and pressure regula- tor, etc. to intake manifold. ( A ) FU-00735 24) Remove bolt which installs fuel pipes on intake ( B ) FU-00737 manifold.
Page 726 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 4) Install fuel injector pipe. NOTE: Do not forget to install the fuel injector securing clip. FU-00735 FU-00733 5) Connect left side fuel hose to injector pipe, and tighten clamp screw. 7) Tighten bolt which installs injector pipe on intake manifold.
Page 727 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Tighten bolt which install injector pipe on intake 14) Hold engine harness by harness band (A) and manifold. harness bracket (B). Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) ( A ) ( A ) ( B ) FU-00795 NOTE:...
Page 728 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 17) Connect pressure regulator vacuum hose to in- 20) Install intake air temperature and pressure sen- take manifold. sor. Tightening torque: 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) FU-00265 18) Install throttle body to intake manifold. FU-00724 NOTE: Replace gasket with a new one.
Page 729 ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove air intake duct and air cleaner assem- bly. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> and <Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner Case.>...
Page 730 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 battery ground cable. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) FU-00009 FU-00058 2) Remove bolt which install crankshaft position sensor to cylinder block.
Page 731 CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove camshaft position sensor and camshaft position sensor support as a unit. A: REMOVAL 6) Remove camshaft position sensor itself. 1) Disconnect battery ground cable. FU-00179 FU-00009 B: INSTALLATION 2) Disconnect connector from camshaft position Install in the reverse order of removal.
Page 732 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable from battery 24 N·m (2.4 kgf-m, 17.4 ft-lb) ground terminal. NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...
Page 733 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.
Page 734 TION TOOL, General Description.> (4) Connect Subaru Select Monitor to the data link connector (A). ( A ) FU-00435 5) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. 6) Select {2. Each System Check} in Main Menu. FU(H4SOw/oOBD)-31...
Page 735 INTAKE AIR TEMPERATURE AND PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Air Temperature and 4) Remove intake air temperature and pressure sensor. Pressure Sensor A: REMOVAL NOTE: This sensor is installed on AT vehicles only. 1) Disconnect battery ground cable. FU-00745 B: INSTALLATION Install in the reverse order of removal.
Page 736 IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 10.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use new gasket. 1) Disconnect battery ground cable. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 2) Disconnect connector from idle air control sole- FU-00747...
Page 737 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 11.Fuel Injector (2) Remove bolts which hold power steering pipes onto intake manifold protector. A: REMOVAL 1. RH SIDE 1) Release fuel pressure. <Ref. to FU(H4SOw/oOBD)-45, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
Page 738 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) (6) Place power steering pump and tank on the 11) Remove bolt which install injector pipe to intake right side wheel apron. manifold. FU-00430 FU-00304 8) Remove fuel pipe protector RH. (RHD model 12) Remove fuel injector from intake manifold. only) (1) Remove fuel injector securing clip.
Page 739 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 3) Disconnect battery ground cable. 8) Move washer tank, and secure it away from working area. FU-00009 FU-00192 4) Remove two bolts which install washer tank on body. 9) Remove spark plug cords from spark plugs (#2 and #4 cylinders).
Page 740 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12) Remove bolt which holds injector pipe to intake (2) Remove fuel injector while lifting up fuel in- manifold. jector pipe. FU-00309 FU-00313 13) Remove bolt which installs injector pipe to in- B: INSTALLATION take manifold.
Page 741 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 2. LH SIDE 19 N·m (1.9 kgf-m, 13.7 ft-lb) Install in the reverse order of removal. NOTE: Replace O-rings with new ones. ( C ) ( A ) ( B ) FU-00513 ( A ) Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb)
Page 742 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00309 Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00266 FU(H4SOw/oOBD)-39...
Page 743 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) FU-00752 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to thread- ed portion of oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove oxygen sensor.
Page 744 OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect battery ground cable. FU-00009 FU(H4SOw/oOBD)-41...
Page 745 ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 13.Engine Control Module B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect battery ground cable. When replacing ECM, be careful not to use the wrong spec. ECM to avoid any damage to the fuel injection system.
Page 746 MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 14.Main Relay A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove lower inner trim of passenger side. <Ref. to EI-39, REMOVAL, Lower Inner Trim.> 3) Disconnect connectors from main relay. 4) Remove bolt which holds main relay bracket on body.
Page 747 FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 15.Fuel Pump Relay A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove lower cover. <Ref. to EI-35, REMOV- AL, Instrument Panel Assembly.> 3) Disconnect connector from fuel pump relay. FU-00431 4) Remove fuel pump relay from mounting bracket. B: INSTALLATION Install in the reverse order of removal.
Page 748 FUEL FUEL INJECTION (FUEL SYSTEMS) 16.Fuel 4) Remove the protector RH (Front). A: OPERATION 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Disconnect the connector from fuel pump relay (A).
Page 749 FUEL FUEL INJECTION (FUEL SYSTEMS) 7) Lower the vehicle. 12) Drain the fuel from fuel tank by using a hand pump. 8) Remove the sub service hole cover. WARNING: Do not use a motor pump when draining the fu- 13) After draining the fuel, reinstall the fuel sub lev- el sensor.
Page 750 FUEL FUEL INJECTION (FUEL SYSTEMS) (3) Install the sub service hole cover. FU-00445 (4) Set the rear seat and floor mat. FU(H4SOw/oOBD)-47...
Page 751 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 17.Fuel Tank 7) Separate the quick connector of fuel delivery (A) and return hose (B).<Ref. to FU(H4SOw/oOBD)- A: REMOVAL 67, REMOVAL, Fuel Delivery, Return and Evapo- ration Lines.> 1) Set the vehicle on the lift. 2) Release the fuel pressure.
Page 752 13) Remove the rear exhaust pipe and muffler. 15) Disconnect the connector from ABS sensor. NOTE: To facilitate the removal, apply a coat of SUBARU CRC to matching area of rubber cushions in ad- vance. SUBARU CRC (Part No. 004301003) (1) Separate the rear exhaust pipe from center exhaust pipe.
Page 753 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 20) Remove the rear brake caliper, and then tie it (3) Remove the bolts which secure rear sus- up to the body side of vehicle as shown in the fig- pension assembly to body. ure.
Page 754 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 24) Loosen the clamp and disconnect the fuel filler 3) Connect the two-way valve hose (A) to two-way hose (A) and air vent hose (B) from fuel filler pipe. valve, and then connect the evaporation hose (B) to evaporation pipe.
Page 755 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 6) Install the rear side protector. (2) Tighten the bolt which holds rear shock ab- sorber to rear suspension arm. <Ref. to RS-11, Tightening torque: INSTALLATION, Rear Arm.> 18 N·m (1.8 kgf-m, 13.0 ft-lb) Tightening torque: LH side RH side...
Page 756 Tightening torque: RU CRC to matching area of the rubber cushions in 18 N·m (1.8 kgf-m, 13.0 ft-lb) advance. SUBARU CRC (Part No. 004301003) (1) Install the right and left rubber cushions. FU-00443 16) Install the rear wheel. 17) Lower the vehicle.
Page 757 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 21) Connect the fuel hoses, and then hold them 25) Connect the connectors to fuel tank cord, and with the quick connector. <Ref. to FU(H4SOw/ then plug the service hole with grommet. oOBD)-68, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.>...
Page 758 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 18.Fuel Filler Pipe 8) Remove the protector RH (Front). A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SOw/ oOBD)-45, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid, and then remove the filler cap.
Page 759 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 11) Remove the fuel filler pipe protector. 15) Move the clip, and then separate the air vent hose (B). ( B ) ( A ) FU-00476 FU-00675 12) Remove the bolts which hold evaporation pipe bracket on fuel filler pipe.
Page 760 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 4) Insert the fuel filler hose (A) approx. 35 to 40 mm 7) Tighten the bolts which hold evaporation pipe (1.38 to 1.57 in) over the lower end of fuel filler pipe, bracket on fuel pipe. and then tighten clamp.
Page 761 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 12) Connect the connector to fuel pump relay (A). ( A ) FU-00648 13) Connect the battery ground cable to battery. FU-00009 FU(H4SOw/oOBD)-58...
Page 762 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 19.Fuel Pump 7) Tighten the fuel drain plug, and then install the protector RH (Front). A: REMOVAL Tightening torque: WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb) • Place “NO FIRE” signs near the working area. •...
Page 763 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 11) Move the clips, and then disconnect the jet C: DISASSEMBLY pump hose (C). 1) Remove the fuel pump and pump holder. 12) Disconnect the quick connector, and then dis- NOTE: connect the fuel delivery hose (A) and return hose When disassembling the pump holder, be careful (B).
Page 764 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Level Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL WARNING: WARNING: • Ground cable must be connnected. • Place “NO FIRE” signs near the working area. • Spark may occur and ignite if fuel is nearby. •...
Page 765 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Sub Level Sensor 5) Tighten the fuel drain plug and install the protec- tor RH (Front). A: REMOVAL Tightening torque: WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb) • Place “NO FIRE” signs near the working area. •...
Page 766 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 9) Disconnect the fuel jet pump hose. FU-00447 10) Remove the bolts which install fuel sub level sensor on fuel tank. FU-00448 11) Remove the fuel sub level sensor. B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) FU-00448...
Page 767 FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Filter 1) Set the O-ring on the filter holder, and then in- stall by turning to the right. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: The fuel filter is built in fuel pump assembly.
Page 768 FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Cut Valve A: REMOVAL 1) Remove the fuel tank. <Ref. to FU(H4SOw/ oOBD)-48, REMOVAL, Fuel Tank.> 2) Move the clip, and then disconnect the evapora- tion hose from fuel cut valve. FU-00684 3) Remove the bolts which install fuel cut valve.
Page 769 FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Damper Valve A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SOw/ oOBD)-45, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Remove the fuel damper valve from fuel delivery line (A) and return line (B). ( B ) ( A ) FU-00686...
Page 770 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Set the vehicle on the lift. 2) Release the fuel pressure. <Ref. to FU(H4SOw/oOBD)-45, RELEASING OF FUEL PRESSURE, OPER- ATION, Fuel.> 3) Open the fuel filler flap lid, and then remove the fuel filler cap.
Page 771 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate the quick connector on fuel delivery NOTE: and return line. At this time, two clicking sounds are heard. (1) Clean the pipe and connector, if they are covered with dust. ( A ) (2) Hold the connector (A) and push retainer (B) down.
Page 772 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel delivery hose to pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. 2 : 2.5 ±...
Page 773 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 26.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten Defective terminal contact.
Page 774 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SOw/oOBD) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister.......................7 Purge Control Solenoid Valve ..............8 Two-way Valve....................9...
Page 775 GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 776 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter 7) Remove nuts which hold front exhaust pipe onto cylinder heads. A: REMOVAL 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. EX-00102 8) Remove front and center exhaust pipe assembly from hanger bracket.
Page 777 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) B: INSTALLATION 4) Tighten bolts which secure front and center ex- haust pipe assembly to rear exhaust pipe. NOTE: Tightening torque: Replace gaskets with new ones. 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Install front catalytic converter to front exhaust pipe.
Page 778 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 9) Connect battery ground cable. FU-00009 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EC(H4SOw/oOBD)-5...
Page 779 REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal and installation procedures are the same as the those for the front catalytic con- verter.
Page 780 CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Canister B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Lift-up the vehicle. 7.4 ± ± ± ± 2.0 N·m (0.75 ± ± ± ± 0.2 kgf-m, 5.4 ± ± ± ± 1.4 ft-lb) 2) Disconnect canister hoses from canister.
Page 781 PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Purge Control Solenoid Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable. 16 N·m (1.6 kgf-m, 11.6 ft-lb) FU-00009 EC-00039 2) Remove bolt which installs purge control sole- noid valve onto intake manifold.
Page 782 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Two-way Valve C: INSPECTION 1) Using a hand air pump, check if air goes through A: REMOVAL the valve from both A and B directions. 1) Lift-up the vehicle. 2) Disconnect hoses from two-way valve, and re- ( 2 ) ( 3 ) move it.
Page 783 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) MEMO: EC(H4SOw/oOBD)-10...
Page 784 INTAKE (INDUCTION) IN(H4SOw/oOBD) Page General Description ..................2...
Page 785 GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to IN(H4SO)-2, Gen- eral Description.> IN(H4SOw/oOBD)-2...
Page 786 MECHANICAL ME(H4SOw/oOBD) Page General Description ..................2...
Page 787 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to ME(H4SO)-2, General Description.> ME(H4SOw/oOBD)-2...
Page 788 EXHAUST EX(H4SOw/oOBD) Page General Description ..................2 Front Exhaust Pipe..................9 Center Exhaust Pipe .................12 Rear Exhaust Pipe ..................13 Muffler .......................14...
Page 789 GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT 1. WITH CATALYTIC CONVERTER (EXCEPT AUSTRALIA OUTBACK MODEL) (19) (21) (19) (19) (20) (18) (17) (16) ( 6 ) ( 8 ) (12) ( 9 ) ( 1 ) ( 7 ) ( 2 ) (23) (15)
Page 790 GENERAL DESCRIPTION EXHAUST (1) Upper front exhaust pipe cover (11) Gasket (21) Self-locking nut (2) Lower front exhaust pipe cover (12) Upper rear catalytic converter (22) Protector cover (3) Front exhaust pipe (23) Gasket (4) Oxygen sensor (13) Lower rear catalytic converter cover (5) Front catalytic converter Tightening torque: N·m (kgf-m, ft-lb)
Page 791 GENERAL DESCRIPTION EXHAUST 2. AUSTRALIA OUTBACK MODEL (16) (18) (16) (16) (17) (15) (14) (13) ( 6 ) ( 8 ) ( 1 ) ( 9 ) ( 7 ) (12) ( 2 ) (20) ( 5 ) ( 3 ) ( 4 ) (10) (11)
Page 792 GENERAL DESCRIPTION EXHAUST (1) Upper front exhaust pipe cover (9) Upper center exhaust pipe cover (19) Protector (2) Lower front exhaust pipe cover (10) Lower center exhaust pipe cover (20) Gasket (3) Front exhaust pipe (11) Gasket (4) Oxygen sensor (12) Center exhaust pipe Tightening torque: N·m (kgf-m, ft-lb) (5) Front catalytic converter...
Page 793 GENERAL DESCRIPTION EXHAUST 3. WITHOUT CATALYTIC CONVERTER (11) ( 9 ) (11) (11) (12) (10) ( 8 ) ( 7 ) ( 4 ) (13) ( 1 ) ( 5 ) ( 2 ) (16) ( 6 ) ( 3 ) (16) (14) (15)
Page 794 GENERAL DESCRIPTION EXHAUST (1) Upper front exhaust pipe cover (9) Self-locking nut Tightening torque: N·m (kgf-m, ft-lb) (2) Lower front exhaust pipe cover (10) Gasket T1: 8 (0.8, 5.8) (3) Front exhaust pipe (11) Cushion rubber T2: 13 (1.3, 9.4) (4) Upper center exhaust pipe cover (12) Muffler T3: 18 (1.8, 13.0)
Page 795 GENERAL DESCRIPTION EXHAUST B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 796 FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 6) Remove nuts which hold front exhaust pipe onto cylinder heads. A: REMOVAL CAUTION: 1) Disconnect battery ground cable. Be careful not to pull down front and center ex- haust pipe assembly. FU-00009 2) Disconnect front oxygen sensor connector.
Page 797 FRONT EXHAUST PIPE EXHAUST B: INSTALLATION 5) Tighten bolts which install front and center ex- haust pipe assembly to rear exhaust pipe. 1) Install front exhaust pipe to center exhaust pipe. Tightening torque: NOTE: 18 N·m (1.8 kgf-m, 13.0 ft-lb) Replace gaskets with new ones.
Page 798 FRONT EXHAUST PIPE EXHAUST 10) Connect battery ground cable. FU-00009 C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. EX(H4SOw/oOBD)-11...
Page 799 CENTER EXHAUST PIPE EXHAUST 3. Center Exhaust Pipe A: REMOVAL After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX(H4SOw/oOBD)-9, Removal.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
Page 800 REAR EXHAUST PIPE EXHAUST 4. Rear Exhaust Pipe 2) Install rear exhaust pipe to center exhaust pipe. Tightening torque: A: REMOVAL 18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Separate rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, exhaust pipe is hot. FU-00455 C: INSPECTION 1) Make sure there are no exhaust leaks from con-...
Page 801 2) Make sure there are no holes or rusting. NOTE: 3) Make sure the cushion rubber is not worn or To facilitate removal, apply a coat of SUBARU cracked. CRC to mating area of rubber cushions in advance. SUBARU CRC (Part No. 004301003)
Page 802 COOLING CO(H4SOw/oOBD) Page General Description ..................2...
Page 803 GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to CO(H4SO)-2, General Description.> CO(H4SOw/oOBD)-2...
Page 804 LUBRICATION LU(H4SOw/oOBD) Page General Description ..................2...
Page 805 GENERAL DESCRIPTION LUBRICATION 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to LU(H4SO)-2, General Description.> LU(H4SOw/oOBD)-2...
Page 806 SPEED CONTROL SYSTEMS SP(H4SOw/oOBD) Page General Description ..................2...
Page 807 GENERAL DESCRIPTION SPEED CONTROL SYSTEMS 1. General Description A: SPECIFICATION Specification of model without OBD is the same as that of model with OBD. <Ref. to SP(H4SO)-2, General Description.> SP(H4SOw/oOBD)-2...
Page 808 IGNITION IG(H4SOw/oOBD) Page General Description ..................2 Spark Plug....................5 Ignition Coil and Ignitor Assembly...............8 Spark Plug Cord..................10...
Page 809 GENERAL DESCRIPTION IGNITION 1. General Description A: SPECIFICATIONS Item Designation Model FH0137 Manufacturer DIAMOND 0.73 Ω±10% Ignition coil and ignitor Primary coil resistance assembly Secondary coil resistance 12.8 kΩ±15% Insulation resistance between primary terminal and More than 100 MΩ case Without catalytic con- BKR6E ..
Page 810 GENERAL DESCRIPTION IGNITION B: COMPONENT ( 2 ) ( 2 ) ( 3 ) ( 1 ) ( 4 ) ( 4 ) ( 1 ) IG-00036 (1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb) (2) Spark plug cord (#1, #3) T1: 21 (2.1, 15) (3) Ignition coil and ignitor ASSY...
Page 811 GENERAL DESCRIPTION IGNITION C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 812 SPARK PLUG IGNITION 2. Spark Plug 2. LH SIDE 1) Disconnect battery ground cable. A: REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: With catalytic converter CHAMPION: RC10YC4 NGK: BKR5E-11 (Alternate) Without catalytic converter NGK: BKR6E FU-00009...
Page 813 SPARK PLUG IGNITION 6) Remove spark plug with the spark plugs socket. C: INSPECTION Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion. ( A ) ( B ) ( C ) IG-00073 B: INSTALLATION...
Page 814 SPARK PLUG IGNITION 3) Oil fouled E: ADJUSTMENT Wet black deposits show excessive oil entrance Correct it if the spark plug gap is measured with a into combustion chamber through worn rings and gap gauge, and it is necessary. pistons or excessive clearance between valve Spark plug gap: L guides and stems.
Page 815 IGNITION COIL AND IGNITOR ASSEMBLY IGNITION 3. Ignition Coil and Ignitor As- B: INSTALLATION Install in the reverse order of removal. sembly Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. CAUTION: Be sure to connect wires to their proper posi- tions.
Page 816 IGNITION COIL AND IGNITOR ASSEMBLY IGNITION [Secondary side] Between (A) and (B) 12.8 k Ω± Ω± 15% Ω± Ω± Between (C) and (D) 12.8 k Ω± Ω± Ω± 15% Ω± IG-00039 3) Insulation between primary terminal and case: 100 MΩ or more. IG(H4SOw/oOBD)-9...
Page 817 SPARK PLUG CORD IGNITION 4. Spark Plug Cord A: INSPECTION Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 — 10.6 #2 cord: 7.3 — 13.7 #3 cord: 5.9 —...
Page 818 STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD) Page General Description ..................2...
Page 819 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD. <Ref. to SC(H4SO)-2, General Description.> SC(H4SOw/oOBD)-2...
Page 820 Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description ..................6 Electrical Components Location..............9 Engine Control Module (ECM) I/O Signal ..........18 Subaru Select Monitor................21 Read Diagnostic Trouble Code (DTC) ............24 Inspection Mode..................26 Clear Memory Mode..................28 Compulsory Valve Operation Check Mode ..........29 Engine Malfunction Indicator Lamp (MIL) ..........30...
Page 821 2) Connect the Subaru Select Monitor to data Repair the trouble NOTE: link connector. cause. <Ref. to 3) Turn ignition switch to ON and the Subaru EN(H4SOw/ shown on display Select Monitor switch to ON. oOBD)-59, Diag- although the MIL il- 4) Read DTC on the Subaru Select Monitor.
Page 822 BASIC DIAGNOSTIC PROCEDURE ENGINE (DIAGNOSTICS) 2. WITHOUT SUBARU SELECT MONITOR • Be sure to check again from the beginning in order to prevent secondary trouble caused by CAUTION: repair work. • Check the connector while it is connected un- less specified otherwise.
Page 823 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer's name Engine no. Date of sale Fuel brand Date of repair Odometer reading...
Page 824 CHECK LIST FOR INTERVIEW ENGINE (DIAGNOSTICS) 2. CHECK LIST NO. 2 Check the following items about the vehicle's state when MIL turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. Yes/ No Low fuel warning light Charge indicator light...
Page 825 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) 3. General Description 8) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and resis- A: CAUTION tance inside the passenger compartment. 1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay.
Page 826 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) • The antenna feeder must be placed as far 2. ENGINE GROUNDING apart as possible from the ECM and MFI har- Make sure the engine grounding terminal is proper- ness. ly connected to the engine. • Carefully adjust the antenna for correct matching.
Page 827 GENERAL DESCRIPTION ENGINE (DIAGNOSTICS) D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) ST24082AA210 22771AA030 SELECT MONI- Troubleshooting for electrical systems. TOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) •...
Page 828 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. MODULE • LHD model ( 1 ) ( 4 ) ( 3 ) ( 5 ) ( 2 ) EN-01013 • RHD model ( 4 ) ( 3 ) ( 5 ) ( 2 ) ( 1 )
Page 829 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 2 ) ( 1 ) EN-00845 EN-01016 ( 3 ) ( 5 ) ( 4 ) EN-01015 EN-01017 EN(H4SOw/oOBD)-10...
Page 830 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 2. SENSOR ( 7 ) ( 3 ) ( 2 ) ( 4 ) ( 1 ) ( 6 ) ( 5 ) EN-01018 (1) Engine coolant temperature sen- (3) Throttle position sensor (7) Vehicle speed sensor (4) Knock sensor (2) Intake air temperature and pres- (5) Crankshaft position sensor...
Page 831 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01019 EN-01023 ( 3 ) ( 4 ) EN-01020 EN-01024 ( 6 ) ( 5 ) EN-01021 EN-01025 ( 7 ) EN-01022 EN(H4SOw/oOBD)-12...
Page 832 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 8 ) EN-01026 (8) Oxygen sensor (With catalyst model) ( 8 ) EN-01027 EN(H4SOw/oOBD)-13...
Page 833 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS ( 2 ) ( 1 ) ( 4 ) ( 3 ) EN-01028 (1) Purge control solenoid valve (3) Ignition coil and ignitor ASSY (4) CO resistor (Without catalyst (2) Idle air control solenoid valve model)
Page 834 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01031 EN-01029 ( 4 ) ( 3 ) EN-01030 EN-01032 EN(H4SOw/oOBD)-15...
Page 835 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • LHD model ( 1 ) ( 4 ) ( 3 ) ( 5 ) ( 2 ) EN-01033 • RHD model ( 4 ) ( 3 ) ( 5 ) ( 2 ) ( 1 ) EN-01034 (1) Fuel pump (2) Main relay...
Page 836 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) ( 1 ) ( 2 ) EN-01035 EN-01037 ( 3 ) EN-01036 EN(H4SOw/oOBD)-17...
Page 837 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 B136 25 24 26 25 24 EN-01038 EN(H4SOw/oOBD)-18...
Page 838 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note Engine ON tor No. (Idling) ON (Engine OFF) ±6 Signal (+) B135 Sensor output waveform Crankshaft position Signal (−) B135 — sensor Shield B135 —...
Page 839 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Connec- Terminal Content Ignition SW Note tor No. Engine ON (Idling) ON (Engine OFF) Signal 1 B134 — 1 — 13 Waveform Idle air con- Signal 2 B134 — 1 — 13 Waveform trol sole- Signal 3...
Page 840 {Engine Control System} and EN-00039 press the [YES] key. 3) Press the [YES] key after displayed the informa- 4) Connect Subaru Select Monitor to data link con- tion of engine type. nector. 4) On the «Engine Diagnosis» display screen, se- (1) Data link connector (A) located in the lower lect the {1.
Page 841 Blower fan switch ON or OFF Light switch ON or OFF Idle switch signal ON or OFF *1: With catalyst model only *2: Without catalyst model only NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SOw/oOBD)-22...
Page 842 *1: On MT model, switch is turned ON when gear position is in neutral position. On AT model, switch is turned ON when shift position is in “P” or “N” position. *2: With catalyst model only NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. EN(H4SOw/oOBD)-23...
Page 843 Diagnostic Code(s)} and press the [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. • For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SOw/oOBD)-57, LIST, List of Diagnostic Trouble Code (DTC).>...
Page 844 READ DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) The CHECK ENGINE malfunction indicator lamp (MIL) flashes the code corresponding to the faulty parts. The long segment (1.3 seconds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies “one”. And middle segment (0.5 seconds ON) means OK code. NOTE: •...
Page 845 (A) Test mode connector engine is operating at low speeds since this 2) Connect Subaru select monitor to data link con- may cause vehicle to jump off free rollers. nector. <Ref. to EN(H4SOw/oOBD)-9, LOCATION, •...
Page 846 ABS warning light, but • For detailed operation procedure, refer to the this indicates no malfunctions. When engine con- SUBARU SELECT MONITOR OPERATION MAN- trol diagnosis is finished, perform the ABS memory UAL. clearance procedure of self-diagnosis system.
Page 847 4) On the «Engine Diagnosis» display screen, select the {Clear Memory} and press the [YES] key. 5) When the `Done' and `Turn Ignition Switch OFF' are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF.
Page 848 COMPULSORY VALVE OPERATION CHECK MODE ENGINE (DIAGNOSTICS) 10.Compulsory Valve Operation Check Mode A: OPERATION 1) Connect test mode connector at the lower por- tion of instrument panel (on the driver's side), to the side of the center console box. ( A ) EN-01040 (A) Test mode connector 2) Each valve functions when ignition switch is...
Page 849 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) 11.Engine Malfunction Indicator Lamp (MIL) A: PROCEDURE 1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(H4SOw/oOBD)-30, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> ↓ 2.
Page 850 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • TROUBLE SYMPTOM: • When ignition switch is turned ON (engine OFF), MIL does not come on. •...
Page 851 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. MIL illuminates. Repair poor con- Go to step 3. Does the MIL come on when shaking or pulling tact in ECM con- ECM connector and harness? nector. CHECK ECM CONNECTOR. ECM connector is connected Replace ECM.
Page 852 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value CHECK POOR CONTACT. There is poor contact. Repair poor con- Replace bulb or Check poor contact in combination meter con- tact in combination combination nector. <Ref. to IDI-14, Combination Meter meter connector. meter.
Page 853 • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. • TROUBLE SYMPTOM: • Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD- II general scan tool display. • WIRING DIAGRAM: BATTERY No.
Page 854 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz. • DIAGNOSIS: • The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. • Test mode connector circuit is in open. •...
Page 855 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value CHECK STATUS OF CHECK ENGINE MAL- MIL illuminates. Go to step 2. Repair the MIL cir- FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to 1) Turn ignition switch to OFF. EN(H4SOw/ 2) Disconnect test mode connector. oOBD)-31, 3) Turn ignition switch to ON.
Page 856 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK- ING AT A CYCLE OF 3 Hz. • DIAGNOSIS: • Test mode connector circuit is shorted. • TROUBLE SYMPTOM: • Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
Page 857 ENGINE MALFUNCTION INDICATOR LAMP (MIL) ENGINE (DIAGNOSTICS) Step Value 5 Ω CHECK HARNESS BETWEEN ECM CON- Repair short circuit Replace ECM. NECTOR AND ENGINE GROUNDING TER- in harness <Ref. to MINAL. between ECM and FU(H4SOw/ 1) Turn ignition switch to OFF. test mode connec- oOBD)-42, Engine 2) Disconnect connector from ECM.
Page 858 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) 12.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Inspection of starter motor circuit. <Ref. to EN(H4SOw/oOBD)-40, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> ↓ 2. Inspection of ECM power supply and ground line. <Ref. to EN(H4SOw/oOBD)-43, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>...
Page 859 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.> •...
Page 860 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK DTC. Trouble code is stored in mem- Record DTC. Go to step 3. <Ref. to EN(H4SOw/oOBD)-24, OPERATION, ory. Repair the trouble Read Diagnostic Trouble Code (DTC).> cause. <Ref. to Is the trouble code stored in memory? <Ref. to EN(H4SOw/ EN(H4SOw/oOBD)-57, LIST, List of Diagnostic oOBD)-59, Diag-...
Page 861 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN BATTERY 10 V Go to step 8. Repair open circuit AND IGNITION SWITCH CONNECTOR. in harness 1) Ignition switch to OFF. between ignition 2) Disconnect connector from ignition switch. switch and battery.
Page 862 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.>...
Page 863 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK MAIN RELAY. Go to step 2. Replace main 1) Turn the ignition switch to OFF. relay. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No.
Page 864 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK OUTPUT VOLTAGE FROM ECM. 10 V Go to step 7. Replace ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector &...
Page 865 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.> •...
Page 866 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK IGNITION SYSTEM FOR SPARKS. Spark occurs. Check fuel pump Go to step 2. 1) Remove plug cord cap from each spark system. <Ref. to plug. EN(H4SOw/ 2) Install new spark plug on plug cord cap. oOBD)-50, FUEL PUMP CIRCUIT, CAUTION:...
Page 867 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR IGNITION COIL 10 V Go to step 7. Replace ignition & IGNITOR ASSEMBLY. coil & ignitor Check if voltage varies synchronously with assembly. engine speed when cranking, while monitoring voltage between ignition coil &...
Page 868 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND IG- 1 MΩ Go to step 12. Repair ground NITION COIL & IGNITOR ASSEMBLY CON- short circuit in har- NECTOR. ness between Measure resistance of harness between ECM ECM and ignition and chassis ground.
Page 869 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) E: FUEL PUMP CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)-26, OP- ERATION, Inspection Mode.> •...
Page 870 INJECTOR CIR- CUIT, Diagnostics NOTE: for Engine Start- Fuel pump operation check can also be execut- ing Failure.> ed using Subaru Select Monitor. For the proce- dure, refer to the “COMPULSORY VALVE OPERATION CHECK MODE”.<Ref. EN(H4SOw/oOBD)-29, OPERATION, Compul- sory Valve Operation Check Mode.>...
Page 871 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK FUEL PUMP RELAY. Go to step 7. Replace fuel pump 1) Disconnect connector from fuel pump relay. relay. 2) Remove fuel pump relay from bracket. 3) Connect battery to fuel pump relay connec- tor terminals No.
Page 872 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 and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.> and <Ref. to EN(H4SOw/oOBD)- 26, OPERATION, Inspection Mode.>...
Page 873 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO EACH FUEL 10 V Go to step 3. Repair harness INJECTOR. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from #1 cylinder fuel In this case, repair injector.
Page 874 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO EACH FUEL 10 V Go to step 6. Repair harness INJECTOR. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from #4 cylinder fuel In this case, repair injector.
Page 875 DIAGNOSTICS FOR ENGINE STARTING FAILURE ENGINE (DIAGNOSTICS) Step Value 1 Ω CHECK HARNESS BETWEEN ECM AND Repair ground Go to step 11. FUEL INJECTOR CONNECTOR. short circuit in har- Measure resistance of harness between ECM ness between and fuel injector connector. ECM and fuel Connector &...
Page 876 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 13.List of Diagnostic Trouble Code (DTC) A: LIST Trouble Item Contents of diagnosis Index code Crankshaft position sen- • No signal entered from crankshaft <Ref. to EN(H4SOw/oOBD)-59, DTC 11 CRANK- position sensor when starter switch is SHAFT POSITION SENSOR, Diagnostic Proce- dure with Diagnostic Trouble Code (DTC).>...
Page 877 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Trouble Item Contents of diagnosis Index code Purge control solenoid • The purge control solenoid valve is <Ref. to EN(H4SOw/oOBD)-86, DTC 35 PURGE valve not in function. CONTROL SOLENOID VALVE, Diagnostic Pro- •...
Page 878 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 14.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11 CRANKSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from crankshaft position sensor when ignition switch is ON. • The harness connector between ECM and crankshaft position sensor is in short or open. •...
Page 879 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CONDITION OF CRANKSHAFT PO- Installing bolts are securely Go to step 2. Tighten crank- SITION SENSOR INSTALLATION. tightened. shaft position sen- Are the crankshaft position sensor installing sor installing bolts bolts tightened securely? securely.
Page 880 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ECM. DTC is displayed. Replace genera- Go to step 8. 1) Connect all connectors. tor. 2) Erase the memory. <Ref. to EN(H4SOw/ oOBD)-28, OPERATION, Clear Memory Mode.> 3) Perform inspection mode. <Ref. to EN(H4SOw/oOBD)-26, OPERATION, Inspection Mode.>...
Page 881 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) B: DTC 12 STARTER SWITCH • DIAGNOSIS: • The starter switch signal is abnormal. • The harness connector between ECM and starter switch is in short or open. • TROUBLE SYMPTOM: •...
Page 882 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND IG- 10 V Repair poor con- Repair open or NITION SWITCH CONNECTOR. tact in ECM con- ground short cir- 1) Turn ignition switch to OFF. nector.
Page 883 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) C: DTC 13 CAMSHAFT POSITION SENSOR • DIAGNOSIS: • No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor. • The harness connector between ECM and camshaft position sensor is in short or open. •...
Page 884 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CONDITION OF CAMSHAFT POSI- Bolts are securely tightened. Go to step 2. Tighten camshaft TION SENSOR INSTALLATION. position sensor Are the camshaft position sensor installing installing bolts bolts tightened securely? securely.
Page 885 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ECM. DTC is indicated. Replace ECM. Go to step 8. 1) Connect all connectors. 2) Erase the memory. <Ref. to EN(H4SOw/ oOBD)-28, OPERATION, Clear Memory Mode.> 3) Perform inspection mode. <Ref. to EN(H4SOw/oOBD)-26, OPERATION, Inspection Mode.>...
Page 886 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR • DIAGNOSIS: • The engine coolant temperature sensor signal is abnormal. • The harness connector between ECM and engine coolant temperature sensor is in short or open. •...
Page 887 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ENGINE 10 V Repair battery Go to step 2. COOLANT TEMPERATURE SENSOR AND short circuit in har- ECM CONNECTOR. ness between 1) Turn ignition switch to OFF. ECM and engine 2) Remove generator.
Page 888 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 5 Ω CHECK HARNESS BETWEEN ENGINE Go to step 5. Repair harness COOLANT TEMPERATURE SENSOR AND and connector. ECM CONNECTOR. NOTE: 1) Turn ignition switch to OFF. In this case, repair 2) Measure resistance of harness between the following: engine coolant temperature sensor connec-...
Page 889 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK ENGINE COOLANT TEMPERATURE 0.2 — 0.3 kΩ Replace ECM. Replace engine SENSOR. coolant tempera- 1) Raise temperature up to approx. 90°C ture sensor. (194°F). CAUTION: Be careful not to burn yourself. 2) Measure resistance between engine cool- ant temperature sensor terminals.
Page 890 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) E: DTC 22 KNOCK SENSOR • DIAGNOSIS: • The knock sensor signal is abnormal. • The harness connector between ECM and knock sensor is in short or open. • TROUBLE SYMPTOM: •...
Page 891 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. Go to step 2. Go to step 3. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No.
Page 892 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE • DIAGNOSIS: • The idle air control solenoid valve is not in function. • The harness connector between ECM and idle air control solenoid valve is in short or open. •...
Page 893 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK POWER SUPPLY TO IDLE AIR CON- 10 V Go to step 2. Repair harness TROL SOLENOID VALVE. and connector. 1) Turn ignition switch to OFF. NOTE: 2) Disconnect connector from idle air control In this case, repair solenoid valve.
Page 894 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK AIR INTAKE SYSTEM. The system is faulty. Repair air suction Go to step 9. 1) Turn ignition switch to ON. and leaks. 2) Start engine, and idle it. 3) Check the following items.
Page 895 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) G: DTC 26 INTAKE AIR TEMPERATURE SENSOR • DIAGNOSIS: • The intake air temperature sensor signal is abnormal. • The harness connector between ECM and intake air temperature sensor is in short or open. •...
Page 896 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INTAKE AIR TEMPERATURE SEN- 2 — 3 kΩ Go to step 2. Replace intake air SOR. temperature sen- 1) Turn ignition switch to OFF. sor. <Ref. to 2) Disconnect connector from intake air tem- FU(H4SOw/ perature sensor.
Page 897 CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact with your Check poor contact in ECM connector. tact in ECM con- Subaru distributor. Is there poor contact in ECM connector? nector. NOTE: Inspection by your Subaru distributor required,...
Page 898 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) H: DTC 31 THROTTLE POSITION SENSOR • DIAGNOSIS: • The throttle position sensor signal is abnormal. • The throttle position sensor is installed abnormally. • The harness connector between ECM and throttle position sensor is in short or open. •...
Page 899 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK CONDITION OF THROTTLE POSI- Installing screw is securely Go to step 2. Adjust throttle TION SENSOR INSTALLATION. tightened. position sensor Are the throttle position sensor installing screw and tighten throt- tightened securely? tle position sensor installing screws...
Page 900 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) I: DTC 32 OXYGEN SENSOR • DIAGNOSIS: • The oxygen sensor is not in function. • The harness connector between ECM and oxygen sensor is in short or open. • TROUBLE SYMPTOM: •...
Page 901 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK FOR OTHER CAUSES AFFECTING Check fuel sys- Go to step 2. EXHAUST GAS. tem. 1) Check for use of improper fuel. 2) Check if engine oil or coolant level is extremely low.
Page 902 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND OX- 0.2 V Go to step 8. Repair battery YGEN SENSOR. short circuit 1) Ignition switch to ON. between ECM and 2) Measure voltage between ECM and chas- oxygen sensor.
Page 903 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) J: DTC 33 VEHICLE SPEED SIGNAL • DIAGNOSIS: • The vehicle speed signal is abnormal. • The harness connector between ECM and vehicle speed sensor is in short or open. • TROUBLE SYMPTOM: •...
Page 904 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK SPEEDOMETER OPERATION IN Speedometer operates nor- Go to step 2. Check speedome- COMBINATION METER. mally. ter and vehicle Does speedometer operate normally? speed sensor. CHECK INPUT SIGNAL FOR ECM. Go to step 3.
Page 905 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) K: DTC 35 PURGE CONTROL SOLENOID VALVE • DIAGNOSIS: • The purge control solenoid valve is not in function. • The harness connector between ECM and purge control solenoid valve is in short or open. •...
Page 906 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK OPERATION SOUND OF PURGE The valve produces operating Go to step 2. Go to step 3. CONTROL SOLENOID VALVE. sound. 1) Turn ignition switch to OFF. 2) Connect test mode connector. 3) Turn ignition switch to ON.
Page 907 CHECK POOR CONTACT. There is poor contact. Repair poor con- Contact with your Check poor contact in purge control solenoid tact in purge con- Subaru distributor. valve connector. trol solenoid valve NOTE: Is there poor contact in purge control solenoid connector.
Page 908 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) L: DTC 38 TORQUE CONTROL SIGNAL • DIAGNOSIS: • Abnormal signal entered from TCM • The harness connector between ECM and TCM is in short. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.>...
Page 909 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK HARNESS BETWEEN ECM AND Repair ground Go to step 2. TCM CONNECTOR. short circuit in har- 1) Disconnect connectors from ECM and ness between TCM. ECM and TCM 2) Measure resistance of harness between connector.
Page 910 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) M: DTC 45 PRESSURE SENSOR • DIAGNOSIS: • The pressure sensor signal is abnormal. • The harness connector between ECM and pressure sensor is in short or open. • TROUBLE SYMPTOM: •...
Page 911 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK HARNESS BETWEEN ECM AND 4.5 — 5.5 V Go to step 2. Repair open or PRESSURE SENSOR CONNECTOR. ground short cir- 1) Disconnect connector from pressure sen- cuit in harness sor.
Page 912 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES) • DIAGNOSIS: • The CO resistor signal is abnormal. • The harness connector between ECM and CO resistor is in short or open. •...
Page 913 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. 0.5 — 4.5 V Go to step 3. Go to step 2. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chas- sis ground.
Page 914 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) O: DTC 51 NEUTRAL POSITION SWITCH (MT VEHICLE) • DIAGNOSIS: • The neutral position switch signal is abnormal. • The harness connector between ECM and neutral position switch is in short or open. •...
Page 915 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. 4.5 — 5.5 V Go to step 3. Go to step 2. 1) Select MT shift lever to neutral position. 2) Turn ignition switch to ON. 3) Measure voltage between ECM and chas- sis ground.
Page 916 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value 10 Ω CHECK HARNESS BETWEEN ECM AND Repair ground Go to step 8. NEUTRAL POSITION SWITCH CONNEC- short circuit in har- TOR. ness between Measure resistance between ECM and chas- ECM and trans- sis ground.
Page 917 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE) • DIAGNOSIS: • The park/neutral position switch signal is abnormal. • The shift cable is connected abnormally. • The harness connector between ECM and inhibitor switch is in short or open. •...
Page 918 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK INPUT SIGNAL FOR ECM. Go to step 2. Go to step 3. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chas- sis ground in selector lever “N” and “P” positions.
Page 919 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Q: DTC 85 CHARGE SYSTEM • DIAGNOSIS: • Power source voltage of the ECM is low or high. • TROUBLE SYMPTOM: • Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(H4SOw/oOBD)-28, OPERATION, Clear Memory Mode.>...
Page 920 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Value CHECK GENERATOR. 10.8 V — 16.2 V Go to step 2. Repair generator. 1) Start engine. <Ref. to 2) Idling after warm-up. SC(H4SO)-14, 3) Measure voltage between generator B ter- Generator.>...
Page 921 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) 15.General Diagnostic Table A: INSPECTION NOTE: • Malfunction of parts other than those listed is also possible. • The right-hand priority column indicates the inspection priority of probable causes of the symptom. Carry out the check starting from A. Symptom Problem parts Priority...
Page 922 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 5. Rough idling 1) Spark plug 2) Pressure sensor 3) Engine coolant temperature sensor 4) Pressure regulator 5) Idle air control solenoid valve 6) Air leak in air intake system 7) ECM power supply 8) Throttle position sensor 9) Camshaft position sensor 10) Crankshaft position sensor...
Page 923 GENERAL DIAGNOSTIC TABLE ENGINE (DIAGNOSTICS) Symptom Problem parts Priority 14. Remarks 1) ECM power supply 2) Pressure sensor 3) Pressure regulator 4) Idle air control solenoid valve 5) Air leak in air intake system A*: Including ECM ground circuit B*: Check hoses. EN(H4SOw/oOBD)-104...
Page 924 EC(H6DO) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H6DO) MECHANICAL ME(H6DO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H6DO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H6DO)
Page 926 FUEL INJECTION (FUEL SYSTEMS) FU(H6DO) Page General Description ..................2 Throttle Body.....................16 Intake Manifold..................17 Engine Coolant Temperature Sensor............29 Crankshaft Position Sensor...............30 Camshaft Position Sensor.................31 Knock Sensor....................32 Throttle Position Sensor................33 Intake Manifold Pressure Sensor ..............34 Intake Air Temperature Sensor ..............35 Idle Air Control Solenoid Valve ..............36 Induction Valve..................37 Induction Valve Control Solenoid ..............38 Fuel Injector ....................39...
Page 927 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 64 2 (16.9 US gal, 14.1 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
Page 928 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) MEMO: FU(H6DO)-3...
Page 929 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (15) (14) (15) (10) (16) (11) ( 9 ) ( 8 ) (15) (13) (10) (11) (12) (17) ( 7 ) (19) ( 6 ) (18) ( 4 ) ( 6 ) ( 2 ) ( 2 ) ( 4 )
Page 930 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Fuel damper valve (10) Nipple (19) Gasket (2) Clamp (11) Plug (3) Fuel pipe ASSY (12) Intake manifold Tightening torque: N·m (kgf-m, ft-lb) (4) Air assist hose (13) Induction valve control solenoid T1: 6.4 (0.65, 4.7) (5) Air assist and purge pipe ASSY (14) EGR valve T2: 5.0 (0.51, 3.7)
Page 931 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. FUEL INJECTOR ( 4 ) ( 3 ) ( 6 ) ( 5 ) ( 3 ) ( 1 ) ( 2 ) ( 3 ) ( 3 ) ( 4 ) ( 6 ) ( 5 ) ( 3 ) FU-00532...
Page 932 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. AIR INTAKE SYSTEM ( 3 ) ( 2 ) ( 1 ) ( 1 ) ( 5 ) ( 4 ) ( 6 ) FU-00533 (1) Gasket (5) O-ring Tightening torque: N·m (kgf-m, ft-lb) (2) Intake manifold pressure sensor (6) Throttle body T1: 1.6 (0.16, 1.2)
Page 933 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS ( 3 ) ( 2 ) ( 4 ) ( 1 ) FU-00534 (1) Crankshaft position sensor (3) Knock sensor RH Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor LH (4) Camshaft position sensor T1: 6.4 (0.65, 4.7)
Page 934 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) MEMO: FU(H6DO)-9...
Page 935 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL TANK ( 6 ) (13) (28) (29) (36) (17) (34) (10) (12) (30) (14) (33) (11) (38) (16) ( 7 ) (37) ( 5 ) (31) (15) ( 9 ) ( 8 ) (22) (21) (27)
Page 936 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Heat sealed cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...
Page 937 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL LINE (24) (23) (25) (26) (27) (21) (20) (22) ( 1 ) (19) ( 1 ) (12) ( 1 ) (14) (13) (18) ( 1 ) (15) (17) ( 1 ) (28) (16) ( 1 ) ( 1 )
Page 938 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Clamp (12) Two-way valve hose (23) Front canister bracket (2) Fuel return hose A (13) Two-way valve (24) Rear canister bracket (3) Fuel return hose B (14) Two-way valve bracket (25) Canister bracket spacer (4) Clip (15) Two-way valve drain hose (26) Cushion...
Page 939 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 7. FUEL FILLER PIPE ( 5 ) ( 4 ) ( 6 ) ( 1 ) ( 7 ) ( 2 ) ( 3 ) FU-00628 (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap...
Page 940 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
Page 941 THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 7) Disconnect throttle position sensor connector. A: REMOVAL 1) Disconnect battery ground cable. FU-00538 8) Disconnect engine coolant hoses from throttle body. FU-00535 9) Remove bolts which secure throttle body to in- 2) Remove air intake chamber.
Page 942 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold (3) Remove bolts which install power steering pump bracket. A: REMOVAL NOTE: 1) Release fuel pressure. <Ref. to FU(H6DO)-50, Do not separate hose and pipe from the main RELEASING OF FUEL PRESSURE, OPERA- pump.
Page 943 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (6) Place power steering pump on the right side 12) Move washer tank upward. wheel apron. ME-00459 FU-00542 13) Disconnect PCV hoses from cylinder head cov- 8) Remove two bolts which install washer tank on body.
Page 944 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Remove EGR pipe from EGR valve. 19) Disconnect fuel hoses from fuel pipes. NOTE: WARNING: Be careful not to drop gaskets. • Do not spill fuel. • Catch fuel from hoses in a container or cloth. FU-00547 FU-00550 17) Disconnect engine harness connectors from...
Page 945 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 24) Remove ground cable from fuel pipe protector 27) Remove bolts which holds intake manifold onto cylinder heads. FU-00554 FU-00557 25) Remove fuel pipe protector RH. FU-00558 FU-00555 28) Remove intake manifold. 26) Disconnect air assist hose (A). B: INSTALLATION Remove the bolt (B), which holds fuel injector pipe 1) Install intake manifold onto cylinder heads.
Page 946 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 2) Install the bolt (B), which holds fuel injector pipe 7) Connect air assist hose (A). RH onto cylinder head. Tightening torque: 19 N·m (1.9 kgf-m, 14 ft-lb) ( A ) ( B ) 3) Connect air assist hose (A).
Page 947 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 11) Connect fuel hoses. 15) Connect engine coolant hose to throttle body. FU-00545 FU-00550 12) Connect engine ground terminal to intake man- 16) Connect PCV hose to cylinder head cover. ifold. FU-00544 FU-00549 17) Install power steering pump and tank on brack- 13) Connect engine harness connectors to bulk- ets.
Page 948 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (3) Tighten bolts which install power steering 21) Install washer tank on body. pump on bracket. Tightening torque: 20.1 N·m (2.05 kgf-m, 14.8 ft-lb) ( B ) ( C ) ( A ) FU-00190 22) Connect accelerator cable (A).
Page 949 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 26) Connect battery ground cable. 5) Remove induction valve. FU-00560 FU-00009 C: DISASSEMBLY 6) Disconnect connector from induction valve con- trol solenoid. 1) Disconnect connectors from throttle position 7) Remove induction valve control solenoid. sensor.
Page 950 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 12) Remove engine harness assembly from intake 16) Remove fuel pipe and injector pipe assembly. manifold. ( A ) FU-00567 FU-00564 13) Remove PCV pipe from intake manifold. FU-00568 17) Remove induction valve vacuum hose from in- FU-00565 take manifold.
Page 951 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3) Connect pressure regulator vacuum hose (A) to 6) Install engine harness assembly to intake mani- intake manifold. fold. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) FU-00568 FU-00564 7) Install EGR valve. Tightening torque: ( A ) 19 N·m (1.9 kgf-m, 14 ft-lb) 8) Connect connector to EGR valve.
Page 952 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 11) Connect hoses to purge control solenoid valve. 15) Connect hoses to induction valve control sole- noid. CAUTION: Carefully connect the evaporation hoses. CAUTION: Carefully connect the vacuum hoses. ( B ) ( B ) ( A ) ( A ) FU-00570...
Page 953 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 19) Connect air by-pass hose (C) to idle air control solenoid valve. ( A ) ( B ) ( C ) FU-00537 FU(H6DO)-28...
Page 954 ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Disconnect connector from engine coolant tem- perature sensor. 3) Remove engine coolant temperature sensor. FU-00572 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 16 N·m (1.6 kgf-m, 12 ft-lb) FU-00572...
Page 955 CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor 6) Remove crankshaft position sensor, and discon- nect connector from it. A: REMOVAL 1) Disconnect battery ground cable. FU-00575 B: INSTALLATION FU-00009 Install in the reverse order of removal. 2) Remove air intake chamber.
Page 956 CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 6) Remove camshaft position sensor. A: REMOVAL 1) Disconnect battery ground cable. FU-00576 B: INSTALLATION Install in the reverse order of removal. FU-00009 Tightening torque: 2) Remove air cleaner. •...
Page 957 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor 4) Connect battery ground cable. A: REMOVAL 1) Disconnect battery ground cable from battery ground terminal. FU-00009 FU-00009 2) Remove intake manifold. <Ref. to FU(H6DO)-17, REMOVAL, Intake Mani- fold.> 3) Disconnect knock sensor connector. 4) Remove knock sensor from cylinder block.
Page 958 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor A: REMOVAL 1) Disconnect battery ground cable. FU-00535 2) Remove air intake chamber. <Ref. to IN(H6DO)- 6, REMOVAL, Air Intake Chamber.> 3) Disconnect connector from throttle position sen- sor. 4) Remove throttle position sensor holding screws, and remove throttle position sensor itself.
Page 959 INTAKE MANIFOLD PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Manifold Pressure Sensor A: REMOVAL 1) Disconnect battery ground cable. FU-00535 2) Disconnect connector from intake manifold pres- sure sensor. 3) Remove intake manifold pressure sensor from throttle body. FU-00580 B: INSTALLATION Install in the reverse order of removal.
Page 960 INTAKE AIR TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Intake Air Temperature Sen- A: REMOVAL 1) Disconnect battery ground cable. FU-00535 2) Disconnect connector from intake air tempera- ture sensor. 3) Remove intake air temperature sensor from air intake chamber. IN-00069 B: INSTALLATION Install in the reverse order of removal.
Page 961 IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid Valve A: REMOVAL 1) Disconnect battery ground cable. FU-00535 2) Disconnect connector (A) from idle air control solenoid valve. 3) Disconnect air by-pass hose (B) from idle air control solenoid valve.
Page 962 INDUCTION VALVE FUEL INJECTION (FUEL SYSTEMS) 12.Induction Valve A: REMOVAL 1) Disconnect battery ground cable. 2) Remove intake manifold. <Ref. to FU(H6DO)-17, REMOVAL, Intake Mani- fold.> 3) Remove induction valve from intake manifold. FU-00560 B: INSTALLATION Install in the reverse order of removal. NOTE: Always use a new gasket.
Page 963 INDUCTION VALVE CONTROL SOLENOID FUEL INJECTION (FUEL SYSTEMS) 13.Induction Valve Control Sole- noid A: REMOVAL 1) Disconnect battery ground cable. 2) Remove intake manifold. <Ref. to FU(H6DO)-17, REMOVAL, Intake Mani- fold.> 3) Disconnect connector from induction valve con- trol solenoid. 4) Remove induction valve control solenoid from in- take manifold.
Page 964 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 14.Fuel Injector (3) Remove bolts which install power steering pump bracket. A: REMOVAL CAUTION: Do not separate hose and pipe from the main 1. RH SIDE pump. 1) Release fuel pressure. <Ref. to FU(H6DO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
Page 965 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) (6) Place power steering pump on the right side 2. LH SIDE wheel apron. 1) Release fuel pressure. <Ref. to FU(H6DO)-50, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
Page 966 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 8) Move washer tank upward. B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Replace O-rings and insulators with new ones. ME-00459 9) Remove ground cable from fuel pipe protector ( A ) ( B ) ( C )
Page 967 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE Install in the reverse order of removal. NOTE: Replace O-rings and insulators with new ones. ( A ) ( B ) ( C ) ( D ) ( A ) FU-00584 (A) O-ring (B) Injection rubber (C) Fuel injector...
Page 968 A: REMOVAL 1) Disconnect battery ground cable. ( A ) FU-00588 6) Apply SUBARU CRC or its equivalent to thread- ed portion of front oxygen (A/F) sensor, and leave it FU-00009 for one minute or more. 2) Disconnect connector from front oxygen (A/F) SUBARU CRC (Part No.
Page 969 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION • RH side 1) Before installing front oxygen (A/F) sensor, ap- ply anti-seize compound only to threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: ( A ) SS-30 by JET LUBE CAUTION:...
Page 970 3) Disconnect connector from rear oxygen sensor. FU-00591 3) Connect connector to rear oxygen sensor. EX-00058 4) Apply SUBARU CRC or its equivalent to thread- ed portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor.
Page 971 ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 17.Engine Control Module 6) Remove clip from bracket. A: REMOVAL 1) Disconnect battery ground cable. FU-00595 7) Disconnect ECM connectors and take out ECM. B: INSTALLATION FU-00009 Install in the reverse order of removal. 2) Remove lower inner trim of passenger side.
Page 972 MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 18.Main Relay A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove lower inner trim of passenger side. <Ref. to EI-39, REMOVAL, Lower Inner Trim.> 3) Disconnect connectors from main relay. 4) Remove bolt which holds main relay bracket on body.
Page 973 FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 19.Fuel Pump Relay A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove lower cover. <Ref. to EI-35, REMOV- AL, Instrument Panel Assembly.> 3) Disconnect connector from fuel pump relay. FU-00431 4) Remove fuel pump relay from mounting bracket. B: INSTALLATION Install in the reverse order of removal.
Page 974 FUEL PUMP CONTROLLER FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Pump Controller A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove rear quarter Trim. <Ref. to EI-40, RE- MOVAL, Rear Quarter Trim.> 3) Disconnect connector from fuel pump control unit. FU-00672 4) Remove fuel pump control unit.
Page 975 FUEL FUEL INJECTION (FUEL SYSTEMS) 21.Fuel 5) Drain fuel from fuel tank. Set a container under the vehicle and remove drain A: OPERATION plug from fuel tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...
Page 976 FUEL FUEL INJECTION (FUEL SYSTEMS) 8) Remove sub service hole cover. 13) After draining fuel, reinstall fuel sub level sen- sor. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) FU-00445 9) Disconnect connector from fuel sub level sensor. FU-00448 NOTE: If you have not removed fuel tank yet, proceed with the procedure below for installation.
Page 977 FUEL FUEL INJECTION (FUEL SYSTEMS) (3) Install sub service hole cover. FU-00445 (4) Set rear seat and floor mat. FU(H6DO)-52...
Page 978 6) Push grommet which holds fuel tank cord on ser- 13) Remove rear exhaust pipe and muffler. vice hole cover into body side. NOTE: To facilitate removal, apply a coat of SUBARU CRC to matching area of rubber cushions in ad- vance. SUBARU CRC (Part No. 004301003) (1) Separate rear exhaust pipe from center ex- haust pipe.
Page 979 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) (2) Remove left and right rubber cushions. 17) Remove parking brake cable from cabin by forcibly pulling it backward. CAUTION: Be careful not to pull down muffler. FU-00459 18) Remove bolts which hold parking brake cable FU-00598 holding bracket.
Page 980 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 21) Remove rear suspension assembly. 23) Disconnect two-way valve hose (A) from two- way valve and disconnect evaporation hose (B) WARNING: from evaporation pipe. A helper is required to perform this work. (1) Support rear differential with transmission jack.
Page 981 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Tighten band mounting bolts. 1) Support fuel tank with transmission jack and Tightening torque: push fuel tank harness into access hole with grom- 33 N·m (3.4 kgf-m, 25 ft-lb) met. 2) Set fuel tank and temporarily tighten bolts of fuel tank bands.
Page 982 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 7) Install rear suspension assembly. (2) Tighten bolt which holds rear shock absorb- er to rear suspension arm. <Ref. to RS-14, IN- WARNING: STALLATION, Link Upper.> A helper is required to perform this work. Tightening torque: (1) Support rear suspension assembly and then 157 N·m (16 kgf-m, 116 ft-lb)
Page 983 14) Install rear exhaust pipe and muffler. 18 N·m (1.8 kgf-m, 13.0 ft-lb) NOTE: To facilitate the procedure, apply a coat of SUBA- RU CRC to matching area of rubber cushions in ad- vance. SUBARU CRC (Part No. 004301003) FU-00443 FU(H6DO)-58...
Page 984 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 16) Install rear wheel. 24) Install sub service hole cover. 17) Lower the vehicle. 18) Tighten wheel nuts to rear wheel. 19) Install parking brake cable. <Ref. to PB-7, IN- STALLATION, Parking Brake Cable.> 20) Install console box.
Page 985 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 30) Check wheel alignment and adjust if neces- sary. <Ref. to FS-6, INSPECTION, Wheel Align- ment.> C: INSPECTION 1) Make sure there are no cracks, holes, or other damage on the fuel tank. 2) Make sure that the fuel hoses and fuel pipes are not cracked and that connections are tight.
Page 986 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Filler Pipe 8) Remove the protector RH (Front). A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H6DO)- 50, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Open the fuel filler flap lid, and then remove the filler cap.
Page 987 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 11) Remove the fuel filler pipe protector. 15) Move the clip, and then separate the air vent hose (B). ( B ) ( A ) FU-00476 FU-00675 12) Remove the bolts which hold evaporation pipe bracket on fuel filler pipe.
Page 988 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 4) Insert the fuel filler hose (A) approx. 35 to 40 mm 7) Tighten the bolts which hold evaporation pipe (1.38 to 1.57 in) over the lower end of fuel filler pipe, bracket on fuel pipe. and then tighten clamp.
Page 989 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 12) Connect the connector to fuel pump relay (A). FU-00431 13) Connect the battery ground cable to battery. FU-00009 FU(H6DO)-64...
Page 990 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Pump 7) Tighten the fuel drain plug, and then install the protector RH (Front). A: REMOVAL Tightening torque: WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb) • Place “NO FIRE” signs near the working area. •...
Page 991 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 11) Move the clips, and then disconnect the jet C: DISASSEMBLY pump hose (C). 1) Remove the fuel pump and pump holder. 12) Disconnect the quick connector, and then dis- NOTE: connect the fuel delivery hose (A) and return hose When disassembling the pump holder, be careful (B).
Page 992 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Level Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL WARNING: WARNING: • Ground cable must be connnected. • Place “NO FIRE” signs near the working area. • Spark may occur and ignite if fuel is nearby. •...
Page 993 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Sub Level Sensor 5) Tighten the fuel drain plug and install the protec- tor RH (Front). A: REMOVAL Tightening torque: WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb) • Place “NO FIRE” signs near the working area. •...
Page 994 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 9) Disconnect the connector from fuel sub level B: INSTALLATION sensor. Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) FU-00446 10) Disconnect the fuel jet pump hose. FU-00448 FU-00447 11) Remove the bolts which install fuel sub level...
Page 995 FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Filter B: INSTALLATION NOTE: A: REMOVAL • If the fuel hoses are damaged at the connecting WARNING: portion, replace it with a new one. • Place “NO FIRE” signs near the working area. •...
Page 996 FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Cut Valve A: REMOVAL 1) Remove the fuel tank. <Ref. to FU(H6DO)-53, REMOVAL, Fuel Tank.> 2) Move the clip, and then disconnect the evapora- tion hose from fuel cut valve. FU-00684 3) Remove the bolts which install fuel cut valve. B: INSTALLATION Install in the reverse order of removal.
Page 997 FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 29.Fuel Damper Valve A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H6DO)- 50, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Remove the fuel damper valve from fuel delivery line (A) and return line (B). FU-00703 B: INSTALLATION Install in the reverse order of removal.
Page 998 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 30.Fuel Delivery, Return and 3) Open the fuel filler flap lid, and then remove the fuel filler cap. Evaporation Lines 4) Remove the floor mat. <Ref. to EI-51 REMOV- AL, Floor Mat.> A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel 1) Set the vehicle on the lift.
Page 999 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate the quick connector on fuel delivery (1) Set a new retainer (B) to connector (A). and return line. (2) Push the pipe into connector completely. (1) Clean the pipe and connector, if they are NOTE: covered with dust.
Page 1000 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel delivery hose to pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. 2 : 2.5 ±...
Page 1001 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 the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten Defective terminal contact.
Page 1002 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H6DO) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister.......................7 Purge Control Solenoid Valve ..............8 EGR Valve ....................10 Two-way valve ..................12...