ENGINE+1+SECTION Subaru

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE 1 SECTION
FUEL INJECTION (FUEL SYSTEMS) FU
EMISSION CONTROL EC
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION) IN
MECHANICAL ME
This service manual has been prepared
to provide SUBARU service personnel
EXHAUST EX
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. COOLING CO
This manual includes the procedures
for maintenance, disassembling, reas-
cardiagn.com
sembling, inspection and adjustment of LUBRICATION LU
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. IGNITION IG
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. STARTING/CHARGING SYSTEMS SC
ENGINE (DIAGNOSTICS) EN
All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G1840GE2

cardiagn.com
FUEL INJECTION (FUEL SYSTEMS)
FU
Page
1. General Description ....................................................................................2
2. Throttle Body.............................................................................................16
3. Intake Manifold..........................................................................................17
4. Engine Coolant Temperature Sensor........................................................31
5. Crankshaft Position Sensor.......................................................................32
6. Camshaft Position Sensor.........................................................................33
7. Knock Sensor............................................................................................34
8. Throttle Position Sensor............................................................................35
9. Intake Air Temperature and Pressure Sensor...........................................37
10. Atmospheric Pressure Sensor ..................................................................38
cardiagn.com
11. Idle Air Control Solenoid Valve .................................................................39
12. Air Assist Injector Solenoid Valve .............................................................40
13. Fuel Injector ..............................................................................................41
14. Front Oxygen (A/F) Sensor .......................................................................47
15. Rear Oxygen Sensor.................................................................................49
16. Engine Control Module..............................................................................51
17. Main Relay ................................................................................................52
18. Fuel Pump Relay.......................................................................................53
19. Fuel ...........................................................................................................54
20. Fuel Tank ..................................................................................................55
21. Fuel Filler Pipe ..........................................................................................58
22. Fuel Pump.................................................................................................62
23. Fuel Level Sensor .....................................................................................65
24. Fuel Sub Level Sensor..............................................................................66
25. Fuel Filter ..................................................................................................68
26. Fuel Cut Valve...........................................................................................69
27. Fuel Damper Valve ...................................................................................70
28. Fuel Delivery, Return and Evaporation Lines............................................71
29. Fuel System Trouble in General ...............................................................75
GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Model 1600 cc and 2000 cc 2500 cc
Capacity 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm2, 53.6 — 98 psi)
Fuel pump
More than 65 2 (17.2 US gal, 14.3 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type
cardiagn.com
FU-2
GENERAL DESCRIPTION
cardiagn.com
FU-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
(25)
T7 (2) (26)
T4
(21)
T3
(4) T7
(3) T5
T7
(5) (8) (9)
(6)
T8
(2)
T6
(7)
T3
(27) T2
(14)
(10)
cardiagn.com
T7 T7
T6 (21)
T8 (4)
(15) (3)
(5)
T8 (6)
(17)
(1) T8
(24)
(11)
(23)
T3 T8
T7
T7
T4
(22) T3
(28) (16)
(20) T1
T3
T1 T1 (19)
(19) (12) (24)
T1
(13)
(20) (18)
T1
T1
(20)
T7
T3
(19)
EN1383
FU-4
GENERAL DESCRIPTION
(1) Intake manifold gasket RH (15) O-ring (28) Accelerator cable bracket
(2) Fuel injector pipe (16) Plug cord holder LH
(3) Fuel injector (17) Fuel pipe protector RH Tightening torque: N·m (kgf-m, ft-lb)
(4) O-ring (18) Fuel pipe ASSY T1: 1.5 (0.15, 1.1)
(5) O-ring (19) Fuel hose T2: 3.4 (0.35, 2.5)
(6) O-ring (20) Clip T3: 5.0 (0.51, 3.7)
(7) Plug (21) Clip T4: 6.4 (0.65, 4.7)
(8) PCV valve (22) Air assist injector solenoid valve T5: 7.4 (0.75, 5.4)
(9) Purge control solenoid valve (23) Air assist injector solenoid valve T6: 17(1.7, 12.5)
(10) Nipple bracket T7: 19 (1.9, 14.0)
(11) Intake manifold (24) Guide pin T8: 25 (2.5, 18.4)
(12) Intake manifold gasket LH (25) Atmospheric pressure sensor
(13) Fuel pipe protector LH bracket
(14) Intake air temperature and pres- (26) Atmospheric pressure sensor
sure sensor (27) Plug cord holder RH
cardiagn.com
FU-5
GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
cardiagn.com
B2M3455C
(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, 16.2)
FU-6
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
cardiagn.com
B2M2282B
(1) Crankshaft 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-7
GENERAL DESCRIPTION
4. FUEL TANK
• 1600 CC and 2000 CC MODEL
T1
T1
(25)
(16)
(9) D
(8) (10) (11)

(6) D (11)
C
B (11)
A (14)
(13)
(7) (24)
T1 (12) (24)
(11)
C
(9) (11)
(8)
(5) (15)
B
(11)
cardiagn.com
(17)
(19) (18) (20)
A
(4) (11)
(21)
(11)
(22)
(2)
T3 (18)
T3
(19)
(11)
(23)
(3)
(2)
T2
T2
(1)
T2
EN0439
FU-8
GENERAL DESCRIPTION
(1) Heat shield cover (11) Clip (21) Fuel pipe ASSY
(2) Fuel tank band (12) Evaporation hose B (22) Evaporation hose F
(3) Protector RH (13) Joint pipe (23) Fuel return hose B
(4) Fuel tank (14) Evaporation hose C (24) Evaporation hose G
(5) Fuel pump gasket (15) Evaporation pipe ASSY (25) Evaporation hose H
(6) Fuel pump ASSY (16) Evaporation pipe
(7) Fuel meter unit (17) Evaporation hose D Tightening torque: N·m (kgf-m, ft-lb)
(8) Fuel cut valve gasket (18) Retainer T1: 4.4 (0.45, 3.3)
(9) Fuel cut valve (19) Quick connector T2: 7.4 (0.75, 5.4)
(10) Evaporation hose A (20) Evaporation hose E T3: 33 (3.4, 24.3)
cardiagn.com
FU-9
GENERAL DESCRIPTION
• 2500 CC MODEL
T1
T1
(30)
(17)
(10) E
(9) (11) (12)

(7) D (12)
C
B (12)
A (15)
T1 (14)
(8) (29)
(13) (29)
(12)
T1
D
(9) (12)
(8)
(28)
(6) (16)
E
B (12)
(12)
(18)
(21) (20) (22)
A
cardiagn.com
(19)
(5) (27)
(12)
(12)
(26)
(23) F
(12)
(24)
(2)
T3 (20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
(3) T2
T2
EN1503
FU-10
GENERAL DESCRIPTION
(1) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B
(2) Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket
(3) Protector LH (15) Evaporation hose C (27) Jet pump filter
(4) Protector RH (16) Evaporation pipe ASSY (28) Fuel sub meter unit
(5) Fuel tank (17) Evaporation pipe (29) Evaporation hose G
(6) Fuel pump gasket (18) Evaporation hose D (30) Evaporation hose H
(7) Fuel pump ASSY (19) Fuel return hose A
(8) Fuel meter unit (20) Retainer Tightening torque: N·m (kgf-m, ft-lb)
(9) Fuel cut valve gasket (21) Quick connector T1: 4.4 (0.45, 3.3)
(10) Fuel cut valve (22) Evaporation hose E T2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSY T3: 33 (3.4, 24.3)
(12) Clip (24) Evaporation hose F
cardiagn.com
FU-11
GENERAL DESCRIPTION
5. FUEL LINE
(19)
(18)
B
(24) (20) (17)
A (16)
(25) (15)
(24)
(22)
(21) (13)
T
(23) (14)
B
(1) (1)
C
A C
cardiagn.com
(12)
(8)
(1) (1) (10)

(9) (1)
(1)
(1)
(1)
(10) (11)
(7)
(1)
(6) (2)
(1)
(5)
(4)
(3)
EN0440
FU-12
GENERAL DESCRIPTION
(1) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A
(2) Fuel delivery hose A (12) Grommet (22) Connector
(3) Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B
(4) Fuel filter holder (14) Canister (24) Clamp
(5) Fuel filter cup (15) Canister bracket plate (25) Front canister bracket
(6) Fuel filter (16) Cushion
(7) Evaporation hose (17) Canister bracket spacer Tightening torque: N·m (kgf-m, ft-lb)
(8) Fuel damper (18) Rear canister bracket T: 23 (2.3, 17.0)
(9) Fuel delivery hose B (19) Two-way valve return hose
(10) Fuel return hose (20) Two-way valve
cardiagn.com
FU-13
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
(1)
(3)
T
cardiagn.com
(5) (2)
T
(3)
(6)
T
(4)
(3)
(7)
EN0441
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Filler pipe protector
(2) Evaporation hose holder (7) Air vent pipe holder
(3) Clip (8) Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb)
(4) Clamp (9) Filler ring T: 7.5 (0.76, 5.53)
(5) Air vent hose (10) Filler cap
FU-14
GENERAL DESCRIPTION
C: CAUTION • Be careful not to burn your hands, because each

• Wear working clothing, including a cap, protec- part on the vehicle is hot after running.
tive goggles, and protective shoes during opera- • Be sure to tighten fasteners including bolts and
tion. nuts to the specified torque.
• Remove contamination including dirt and corro- • Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
• Keep the disassembled parts in order and pro- • Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect the ground
• Before removal, installation or disassembly, be cable from battery.
sure to clarify the failure. Avoid unnecessary re- • Place “NO FIRE” signs near the working area.
moval, installation, disassembly, and replacement. • Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA190 CARTRIDGE Troubleshooting for electrical system.
(Newly adopted
tool)
cardiagn.com
B2M3876
22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
B2M3877
FU-15
THROTTLE BODY
2. Throttle Body 6) Disconnect the air by-pass hose from air assist
injector solenoid valve.
A: REMOVAL
1) Disconnect the ground cable from battery.
B2M3457A
G6M0095 (A) Throttle position sensor

(B) Idle air control solenoid valve
2) Remove the air cleaner case.
(C) Air by-pass hose from air assist injector sole-
noid valve
7) Disconnect the engine coolant hoses from throt-

tle body.
cardiagn.com
H2M2947
3) Disconnect the accelerator cable (A).

4) Disconnect the cruise control cable (B). (With
cruise control model)
B2M4255
8) Remove the bolts which install throttle body to

intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
Throttle body;
B2M4254A
22 N·m (2.2 kgf-m, 16.2 ft-lb)
5) Disconnect the connectors from idle air control Air cleaner case;
solenoid valve and throttle position sensor. 6.5 N·m (0.66 kgf-m, 4.8 ft-lb)
FU-16
INTAKE MANIFOLD
3. Intake Manifold (3) Remove the bolts which hold power steering
pipes onto intake manifold protector.
A: REMOVAL NOTE:
1) Release the fuel pressure. Do not disconnect the power steering hose.
<Ref. to FU-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Open the fuel flap lid and remove fuel filler cap.
B2M4126
(4) Remove the bolts which install power steer-

ing pump bracket.
G6M0095
4) Remove the air intake duct and air cleaner as-

sembly.
cardiagn.com
<Ref. to IN-7, REMOVAL, Air Intake Duct.> and
<Ref. to IN-6, REMOVAL, Air Cleaner Case.>
5) Disconnect the accelerator cable (A).
6) Disconnect the cruise control cable (B). (With
cruise control model)
B2M3151
(5) Disconnect the connector from power steer-

ing pump switch.
B2M4254A
7) Remove the power steering pump and tank from

brackets.
(1) Remove the resonator chamber.
<Ref. to IN-8, REMOVAL, Resonator Cham- EN0360
ber.>
(2) Remove the front side V-belt. (6) Remove the power steering tank from the
<Ref. to ME-44, REMOVAL, V-belt.> bracket by pulling it upwards.
EN0361
FU-17
INTAKE MANIFOLD
(7) Place the power steering pump and tank on 12) Remove the air cleaner case stay RH and en-
right side wheel apron. gine harness bracket, and disconnect the engine
harness connectors from bulkhead harness con-
nectors.
EN0208
8) Disconnect the spark plug cords from spark B2M4260

plugs.
9) Disconnect the PCV hose from intake manifold. 13) Disconnect the connectors from engine coolant
temperature sensor.
cardiagn.com
B2M4258
B2M4261
10) Disconnect the engine coolant hose from throt-
tle body. 14) Disconnect the knock sensor connector.
B2M4255 B2M4262
11) Disconnect the brake booster hose. 15) Disconnect the connector from crankshaft posi-
tion sensor.
B2M4259
B2M1252
FU-18
INTAKE MANIFOLD
16) Disconnect the connector from oil pressure 19) Remove the bolts which hold intake manifold
switch. onto cylinder heads.
B2M1253 B2M4128
17) Disconnect the connector from camshaft posi- 20) Remove the intake manifold.
tion sensor.
cardiagn.com
B2M0160
B2M4263
B: INSTALLATION
18) Disconnect the fuel hoses from fuel pipes. 1) Install the intake manifold onto cylinder heads.
WARNING: NOTE:
• Do not spill fuel. Always use new gaskets.
• Catch the fuel from hoses in a container or
cloth. Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
S2M0500F
B2M4128
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-19
INTAKE MANIFOLD
2) Connect the fuel hoses. 6) Connect the knock sensor connector.
S2M0500F B2M4262
7) Connect the connectors to engine coolant tem-

perature sensor.
(B) Return hose
3) Connect the connector to camshaft position sen-

sor.
cardiagn.com
B2M4261
8) Install the air cleaner case stay RH and engine

harness bracket, and connect the engine harness
connectors to bulkhead connectors.
B2M4263
4) Connect the connector to oil pressure switch.
B2M4260
9) Connect the brake booster hose.

B2M1253
5) Connect the connector to crankshaft position

sensor.
B2M4259
B2M1252
FU-20
INTAKE MANIFOLD
10) Connect the engine coolant hose to throttle (3) Tighten the bolts which install power steer-
body. ing pump on bracket.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
B2M4255
11) Connect the PCV hose to intake manifold.

B2M3151
(4) Install the power steering pipes onto right

side intake manifold protector.
cardiagn.com
B2M4258
12) Connect the spark plug cords to spark plugs.

13) Install the power steering pump and tank on
brackets. B2M4126
(1) Install the power steering tank on bracket.
(5) Install the front side V-belt.
<Ref. to ME-44, INSTALLATION, V-belt.>
(6) Install the resonator chamber.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
EN0361
(2) Connect the connector to power steering

pump switch.
B6M1237
14) Connect the accelerator cable (A).
EN0360
FU-21
INTAKE MANIFOLD
15) Connect the cruise control cable (B). (With C: DISASSEMBLY

cruise control models) 1) Disconnect the engine ground cable from intake
manifold.
B2M4254A
16) Install the air intake duct and air cleaner as- B2M4265
sembly. 2) Disconnect the connector from ignition coil and

<Ref. to IN-7, INSTALLATION, Air Intake Duct.> ignitor assembly.
and <Ref. to IN-6, INSTALLATION, Air Cleaner
Case.>
17) Connect the connector to fuel pump relay.
cardiagn.com
B2M3472
3) Remove the ignition coil and ignitor assembly.

EN0344
18) Connect the battery ground cable to battery.
B2M3473
4) Disconnect the connector from intake air tem-

G6M0095 perature and pressure sensor.
B2M3474
FU-22
INTAKE MANIFOLD
5) Remove the intake air temperature and pressure 10) Disconnect the air by-pass hoses from air as-
sensor from intake manifold. sist solenoid valve.
B2M3475 B2M4266
6) Disconnect the connectors from throttle position 11) Remove the air assist injector solenoid valve
sensor and idle air control solenoid valve. from intake manifold.
cardiagn.com
B2M3479 B2M3478
7) Disconnect the air by-pass hose from throttle 12) Disconnect the pressure regulator vacuum
body. hose from intake manifold.
B2M3480 H2M2961
8) Remove the throttle body. 13) Remove the fuel pipe protector LH.
H2M2951 B2M4129
9) Disconnect the connector from air assist injector

solenoid valve.
FU-23
INTAKE MANIFOLD
14) Remove the fuel pipe protector RH. 20) Remove the purge control solenoid valve.
B2M4130 B2M3487
15) Disconnect the connectors from fuel injectors. 21) Remove the bolt which installs injector pipe on
intake manifold as shown in the figure.
cardiagn.com
B2M4270
H2M2965
16) Disconnect the connector from purge control
solenoid valve. 22) Remove the bolt which installs injector pipe on
intake manifold.
B2M3485
H2M2966
17) Disconnect the air by-pass hose from purge
control solenoid valve. 23) Remove the two bolts which hold fuel pipes on
18) Remove the harness bands (A) and harness the left side of intake manifold.
bracket (B) which hold engine harness onto intake
manifold.
B2M4272
B2M4271A
19) Remove the engine harness from intake mani-

fold.
FU-24
INTAKE MANIFOLD
24) Remove the fuel injectors. 27) Loosen the clamp which holds front right side
(1) Remove the fuel injector securing clip. fuel hose to injector pipe, and remove the pipe from
fuel hose.
B2M3488
B2M4274
(2) Remove the fuel injector while lifting up the
fuel injector pipe. 28) Remove the fuel injector pipe.
cardiagn.com
H2M2970 H2M2975
25) Disconnect the air by-pass hoses from intake 29) Remove the bolt which installs fuel pipes on in-
manifold. take manifold.
B2M4149A B2M3491
26) Loosen the clamp which holds front left side 30) Remove the fuel pipe assembly and pressure
fuel hose to injector pipe, and remove the pipe from regulator from intake manifold.
fuel hose.
B2M4273
FU-25
INTAKE MANIFOLD
D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe,

1) Install the fuel pipe assembly and pressure reg- and tighten the clamp screw.
ulator, etc. to intake manifold.
2) Tighten the bolt which installs fuel pipes on in-
take manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M4273
6) Connect the air assist hoses.
B2M3491
3) Connect the right side fuel hose to injector pipe,

and tighten the clamp screw.
cardiagn.com
B2M4149A
B2M4274
4) Install the fuel injector pipe.
H2M2975
FU-26
INTAKE MANIFOLD
7) Install the fuel injectors. 9) Tighten the two bolts which install fuel pipes on
NOTE: the left side of intake manifold.
Always use new O-rings. Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3492G
B2M4272
(A) O-ring
(B) Fuel injector
10) Tighten the bolt which installs injector pipe on
intake manifold.
NOTE: Tightening torque:
Do not forget to install the fuel injector securing clip. 5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
cardiagn.com
B2M3488
H2M2966
8) Tighten the bolt which installs injector pipe on in- 11) Install the purge control solenoid valve.
take manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3487
H2M2965
FU-27
INTAKE MANIFOLD
12) Connect the hoses to purge control solenoid 16) Install the fuel pipe protector RH.
valve.
Tightening torque:
CAUTION: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
Carefully connect the evaporation hoses.
B2M4130
B2M1893E
17) Install the fuel pipe protector LH.
(A) To fuel pipe Tightening torque:
(B) To intake manifold 19 N·m (1.9 kgf-m, 14.0 ft-lb)
13) Install the engine harness onto intake manifold.
Tightening torque:
cardiagn.com
16 N·m (1.6 kgf-m, 11.8 ft-lb)
14) Connect the connectors to fuel injectors and
purge control solenoid valve.
15) Hold the engine harness by harness band (A)
and harness bracket (B).
B2M4129
18) Connect the pressure regulator vacuum hose

to intake manifold.
B2M4271A
NOTE:
Do not use the harness band on harnesses where
they are supposed to be protected by the fuel pipe
protector.
H2M2961
FU-28
INTAKE MANIFOLD
19) Install the air assist injector solenoid valve to 23) Connect the connector to throttle position sen-
bracket. sor and idle air control solenoid valve.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3479
24) Connect the air by-pass hose to throttle body.

B2M3478
20) Connect the air by-pass hoses to air assist so-

lenoid valve.
cardiagn.com
B2M3480
25) Install the intake air temperature and pressure

sensor.
B2M4266
Tightening torque:
21) Connect the connector to air assist solenoid 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
valve.
22) Install the throttle body to intake manifold.
NOTE:
Replace the gasket with a new one.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
B2M3475
NOTE:
Replace the O-ring with a new one.
H2M2951
H2M2999
FU-29
INTAKE MANIFOLD
26) Connect the connector to intake air tempera-

ture and pressure sensor.
27) Install the ignition coil and ignitor assembly.
B2M3473
28) Connect the connector to ignition coil and igni-

tor assembly.
29) Install the engine ground cable to intake mani-
fold.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
cardiagn.com
B2M2779
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.
FU-30
ENGINE COOLANT TEMPERATURE SENSOR
4. Engine Coolant Temperature B: INSTALLATION

Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 16 N·m (1.6 kgf-m, 11.8 ft-lb)
B2M4275
G6M0095
2) Remove the air intake duct and air cleaner as-

sembly.
3) Disconnect the connector from engine coolant
cardiagn.com
temperature sensor.
B2M4261
4) Remove the engine coolant temperature sensor.
FU-31
CRANKSHAFT POSITION SENSOR
5. Crankshaft Position Sensor B: INSTALLATION

A: REMOVAL
1) Disconnect the ground cable from battery. Tightening torque:
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G6M0095
B2M1252B
2) Remove the bolt which installs crankshaft posi-
tion sensor to cylinder block.
cardiagn.com
G2M0408
3) Remove the crankshaft position sensor, and dis-

connect the connector from it.
G2M0409
FU-32
CAMSHAFT POSITION SENSOR
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.
B2M2322
G6M0095
B: INSTALLATION
2) Disconnect the connector from camshaft posi- Install in the reverse order of removal.
tion sensor.
Tightening torque:
Camshaft position sensor support;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor;
cardiagn.com
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M4263
3) Remove the bolt which installs camshaft position

sensor to camshaft position sensor support.
B2M2375
4) Remove the bolt which installs camshaft position

sensor support to camshaft cap LH.
B2M2321
FU-33
KNOCK SENSOR
7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to cylinder block.
A: REMOVAL
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° angle relative to engine rear.
G6M0095
H2M3511C
2) Connect the knock sensor connector.
cardiagn.com
H2M2947
3) Disconnect the knock sensor connector.
B2M4262
3) Install the air cleaner case.
B2M4262
4) Remove the knock sensor from cylinder block.
H2M2947
S2M1673
G6M0095
FU-34
THROTTLE POSITION SENSOR
8. Throttle Position Sensor B: INSTALLATION

A: REMOVAL
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing the throttle position sensor, ad-
just to the specified data.
G6M0095
2) Disconnect the connector from throttle position

sensor.
H2M2979
C: ADJUSTMENT
1) Turn the ignition switch to OFF.
cardiagn.com
2) Loosen the throttle position sensor holding
screws.
B2M3493
3) Remove the throttle position sensor holding

screws, and remove it.
B2M3765
3) When using the voltage meter;

(1) Take out the ECM.
(2) Turn the ignition switch to ON.
(3) Adjust the throttle position sensor to proper
position to allow the voltage signal to ECM to be
H2M2979 in specification.
Connector & terminal/Specified voltage
(B136) No. 15 — (B136) No. 17/0.45 — 0.55 V
[Fully closed.]
B2M4131A
FU-35
THROTTLE POSITION SENSOR
(4) Tighten the throttle position sensor holding (4) Connect the Subaru Select Monitor to data
screws. link connector.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3148
5) Turn the ignition switch to ON, and Subaru Se-

B2M3765 lect Monitor switch to ON.
6) Select the {2. Each System Check} in Main
4) When using the Subaru Select Monitor; Menu.
(1) Turn the ignition switch to OFF. 7) Select the {Engine Control System} in Selection
(2) Loosen the throttle position sensor holding Menu.
screws. 8) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
cardiagn.com
9) Select the {1.12 Data Display} in Data Display
Menu.
10) Adjust the throttle position sensor to the proper
position to match with the following specifications.
Condition: Throttle fully closed
Throttle opening angle 0.00 %
Throttle sensor voltage 0.50 V
11) Tighten the throttle position sensor holding
B2M3765 screws.
For detailed operation procedures, refer to the Sub- 1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
aru Select Monitor Operation Manual.
(3) Insert the cartridge to Subaru Select Moni-
tor.
B2M3765
S2M0286A
FU-36
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR
9. Intake Air Temperature and B: INSTALLATION

Pressure Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
B2M3497
G6M0095
2) Disconnect the spark plug cord from ignition coil NOTE:

and ignitor assembly. Replace the O-ring with a new one.
cardiagn.com
B2M3495 H2M2999
3) Disconnect the connector from intake air tem-

perature and pressure sensor.
B2M4276
4) Remove the intake air temperature and pressure

sensor.
B2M3497
FU-37
ATMOSPHERIC PRESSURE SENSOR
10.Atmospheric Pressure Sen- B: INSTALLATION

sor Install in the reverse order of removal.
Tightening torque:
EN1001
G6M0095
2) Disconnect the connector from atmospheric

pressure sensor.
3) Remove the atmospheric pressure sensor from
bracket.
cardiagn.com
EN1001
FU-38
IDLE AIR CONTROL SOLENOID VALVE
11.Idle Air Control Solenoid B: INSTALLATION

Valve Install in the reverse order of removal.
NOTE:
A: REMOVAL Always use a new gasket.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
2) Disconnect the connector from idle air control B2M3501

solenoid valve.
cardiagn.com
B2M3500
3) Remove the idle air control solenoid valve from

throttle body.
B2M3501
FU-39
AIR ASSIST INJECTOR SOLENOID VALVE
12.Air Assist Injector Solenoid B: INSTALLATION

Valve Install in the reverse order of removal.
Tightening torque:
B2M3503
G6M0095
2) Disconnect the connector from air assist injector

solenoid valve and disconnect the air by-pass hos-
es.
cardiagn.com
B2M4266
3) Remove the air assist injector solenoid valve

from intake manifold.
B2M3503
FU-40
FUEL INJECTOR
13.Fuel Injector (3) Remove the bolts which install power steer-
ing pump to bracket.
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure.
2) Open the fuel filler flap lid and remove fuel filler
cap.
B2M3151
(4) Disconnect the connector from power steer-

ing pump switch.
G6M0095
cardiagn.com
4) Remove the resonator chamber.
<Ref. to IN-8, REMOVAL, Resonator Chamber.>
5) Remove the spark plug cords from spark plugs
EN0360
(#1 and #3 cylinders).
(5) Remove the power steering tank from the
bracket by pulling it upwards.
B2M4127
6) Remove the power steering pump and tank from

EN0361
brackets.
(1) Remove the front side V-belt. (6) Place the power steering pump and tank on
<Ref. to ME-44, REMOVAL, V-belt.> the right side wheel apron.
(2) Remove the bolts which hold power steering
pipes onto intake manifold protector.
EN0208
B2M4126
FU-41
FUEL INJECTOR
7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold.
(1) Remove the fuel injector securing clip.
B2M4130
B2M4283
8) Disconnect the connector from fuel injector.
(2) Remove the fuel injector while lifting up the
fuel injector pipe.
cardiagn.com
B2M4280
9) Remove the bolts which hold injector pipe to in-

B2M3509
take manifold.
B2M4281
B2M4282
FU-42
FUEL INJECTOR
2. LH SIDE 8) Move the washer tank, and secure it away from

working area.
cap.
B2M3140
9) Remove the spark plug cords from spark plugs

(#2 and #4 cylinders).
G6M0095
4) Remove the two bolts which install washer tank

on body.
cardiagn.com
B2M4287
10) Remove the fuel pipe protector LH.
B2M3139
5) Disconnect the connector from front window

washer motor.
6) Disconnect the connector from rear gate glass
washer motor.
B2M4129
11) Disconnect the connector from fuel injector.
B6M0562
7) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a
suitable cap. B2M4294
FU-43
FUEL INJECTOR
12) Remove the bolt which installs injector pipe to (2) Remove the fuel injector while lifting up the
intake manifold. fuel injector pipe.
B2M4133 H2M3241
B: INSTALLATION
1. RH SIDE
NOTE:
Replace the O-rings with a new one.
cardiagn.com
H2M2994
13) Remove the bolt which holds fuel pipe on the

left side intake manifold.
B2M3492G
(A) O-ring
(B) Fuel injector
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
H2M2995
14) Remove the fuel injector from intake manifold.

(1) Remove the fuel injector securing clip.
B2M4282
H2M2997
FU-44
FUEL INJECTOR
Tightening torque: 2. LH SIDE

19 N·m (1.9 kgf-m, 14.0 ft-lb)
NOTE:
Replace the O-rings with a new one.
B2M4132
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M3492G
(A) O-ring
(B) Fuel injector
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
cardiagn.com
B2M4130
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
H2M2994
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B6M1237
H2M2995
FU-45
FUEL INJECTOR
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
B2M4133
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
cardiagn.com
B2M4129
FU-46
FRONT OXYGEN (A/F) SENSOR
14.Front Oxygen (A/F) Sensor B: INSTALLATION

1) Before installing the front oxygen (A/F) sensor,
A: REMOVAL apply anti-seize compound only to the threaded
1) Disconnect the ground cable from battery. portion of front oxygen (A/F) sensor to make the
next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
G6M0095
2) Disconnect the connector from front oxygen (A/

F) sensor.
cardiagn.com
G2M0412
2) Install the front oxygen (A/F) sensor.

Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
B2M4243
3) Lift-up the vehicle.

4) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (A/F) sensor, and
leave it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
5) Remove the front oxygen (A/F) sensor.
CAUTION: G2M0411
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will 3) Lower the vehicle.
damage exhaust pipe. 4) Connect the connector of front oxygen (A/F)
sensor.
G2M0411
B2M4243
FU-47
FRONT OXYGEN (A/F) SENSOR
G6M0095
cardiagn.com
FU-48
REAR OXYGEN SENSOR
15.Rear Oxygen Sensor B: INSTALLATION

1) Before installing the rear oxygen sensor, apply
A: REMOVAL anti-seize compound only to the threaded portion of
1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas-
ier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to the protec-
tor of rear oxygen sensor.
G6M0095
2) Disconnect the connector from rear oxygen sen-

sor.
cardiagn.com
B2M0742A
2) Install the rear oxygen sensor.

Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
B2M4244

4) Apply SUBARU CRC or its equivalent to the
threaded portion of rear oxygen sensor, and leave
it for 1 minute or more.
5) Remove the rear oxygen sensor.
CAUTION: B2M0741
When removing the oxygen sensor, wait until
the exhaust pipe cools, otherwise it will dam- 3) Lower the vehicle.
age exhaust pipe. 4) Connect the connector to rear oxygen sensor.
B2M0741 B2M4244
FU-49
REAR OXYGEN SENSOR
G6M0095
cardiagn.com
FU-50
ENGINE CONTROL MODULE
16.Engine Control Module B: INSTALLATION

A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage to
fuel injection system.
G6M0095
2) Remove the lower inner trim of passenger side.

<Ref. to EI-45, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of front passenger seat.
4) Remove the protect cover.
cardiagn.com
EN0532
5) Remove the nuts (A) which hold ECM to bracket.

6) Remove the clip (B) from bracket.
(A)
(A)
(B)
EN0533
7) Disconnect the ECM connectors and take out

the ECM.
FU-51
MAIN RELAY
17.Main Relay B: INSTALLATION

A: REMOVAL
G6M0095
2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds main relay bracket
on body.
4) Disconnect the connectors from main relay.
cardiagn.com
EN0534
FU-52
FUEL PUMP RELAY
18.Fuel Pump Relay B: INSTALLATION

A: REMOVAL
G6M0095
2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds fuel pump relay
bracket on body.
4) Disconnect the connector from fuel pump relay.
cardiagn.com
EN0535
5) Remove the fuel pump relay from mounting

bracket.
FU-53
FUEL
19.Fuel 5) Drain fuel from the fuel tank.

Set a container under the vehicle and remove the
A: OPERATION drain plug from fuel tank.
• 1600 cc and 2000 cc MODEL
1. RELEASING OF FUEL PRESSURE
WARNING:
• 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.
EN0999
• 2500 cc MODEL
EN0344
2) Start the engine and run it until it stalls.
cardiagn.com
3) After the engine stalls, crank it for 5 more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
EN0839
WARNING:
• Place “NO FIRE” signs near the working area. 6) Tighten the fuel drain plug.
• Be careful not to spill fuel on the floor. Tightening torque:
1) Set the vehicle on a lift. 26 N·m (2.7 kgf-m, 19.2 ft-lb)
2) Disconnect the ground cable from battery. • 1600 cc and 2000 cc MODEL
G6M0095 EN0999
3) Open the fuel filler flap lid and remove fuel filler • 2500 cc MODEL
cap.
EN0839
FU-54
FUEL TANK
20.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
A: REMOVAL
WARNING:
1) Set the vehicle on a lift.
3) Drain fuel from the fuel tank.
<Ref. to FU-54, DRAINING FUEL, OPERATION, EN0539
Fuel.>
4) Remove the rear seat. 10) Move the clips, and disconnect quick connec-
5) Disconnect the connector (A) of fuel tank cord to tor.
rear harness. <Ref. to FU-71, REMOVAL, Fuel Delivery, Return
6) Push the grommet (B) which holds fuel tank cord and Evaporation Lines.>
on floor panel into under the body. 11) Disconnect the fuel hoses.
(B)
cardiagn.com
(A) EN0540
EN0537
7) Remove the rear crossmember. <Ref. to RS-21, 12) Support the fuel tank with transmission jack,
REMOVAL, Rear Crossmember.> and remove the bolts from bands and dismount fuel
8) Disconnect the two-way valve hose (A) from tank from the vehicle.
two-way valve and disconnect the canister hose (B) WARNING:
from canister. A helper is required to perform this work.
(A) (B)
EN0840
EN0541
FU-55
FUEL TANK
B: INSTALLATION 5) Connect the fuel hoses, and secure them with

1) Support the fuel tank with transmission jack and clips and quick connector.
push the fuel tank harness into access hole with <Ref. to FU-73, INSTALLATION, Fuel Delivery,
grommet. Return and Evaporation Lines.>
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
EN0540
6) Tighten the band mounting bolts.

Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
EN0541
3) Connect the two-way valve hose (A) to two-way
cardiagn.com
valve and connect the canister hose (B) to canister.
(A) (B)
EN0541
7) Install the rear crossmember. <Ref. to RS-21,

INSTALLATION, Rear Crossmember.>
EN0840
8) Connect the connector (A) to fuel tank cord and
4) Connect the fuel filler hose and air vent hose. plug the service hole with gromment (B).
(B)
(A)
EN0539 EN0537
9) Set the rear seat and floor mat.
FU-56
FUEL TANK
EN0344
C: INSPECTION
1) Make sure there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
cardiagn.com
FU-57
FUEL FILLER PIPE
21.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
A: REMOVAL tank.
WARNING: • 1600 cc and 2000 cc MODEL
cap.
EN0999
• 2500 cc MODEL
cardiagn.com
G6M0095
5) Remove the screws holding packing in place.

EN0839
10) Tighten the fuel drain plug and then install the
front right side tank cover.
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
EN0542
6) Remove the rear right side wheel nuts.

8) Remove the rear right side wheel.
EN0999
• 2500 cc MODEL
B2M1748
EN0839
FU-58
FUEL FILLER PIPE
11) Remove the fuel filler pipe protector. 16) Move the clip and separate air vent hose (B).
(A)
(B)
EN0544 EN0548
12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of the
fuel filler pipe. vehicle.
18) Remove the air vent pipe together with clip
from body.
cardiagn.com
EN0545
13) Disconnect the air vent hose from fuel filler EN0549
pipe.
B: INSTALLATION
1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set cup
(B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward in-
EN0546 side, straighten it with a screwdriver.
14) Remove the bolt which holds fuel filler pipe
bracket on body.
B2M1196A
EN0547
15) Loosen the clamp and separate fuel filler hose

(A) from fuel filler pipe.
FU-59
FUEL FILLER PIPE
4) Install the air vent pipe. 7) Insert the air vent hose approx. 25 to 30 mm
(0.98 to 1.18 in) into the lower end of air vent pipe
and hold clip.
L = 27.5±2.5 mm (1.083±0.098 in)
EN0549
5) Connect the air vent hose to fuel filler pipe.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
8) Tighten the bolt which holds fuel filler pipe brack-
cardiagn.com
et on body.
EN0546
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)
6) Insert the fuel filler hose (A) approx. 35 to 40 mm
(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
(A)
(B) EN0547
9) Tighten the bolts which hold evaporation hoses

onto clip of fuel filler pipe.
EN0548
EN0545
FU-60
FUEL FILLER PIPE
10) Install the fuel filler pipe protector.
EN0544
11) Install the rear right wheel.
cardiagn.com
B2M1748
12) Lower the vehicle.

13) Tighten the wheel nuts.
EN0344
G6M0095
FU-61
FUEL PUMP
22.Fuel Pump 6) Tighten the fuel drain plug.
A: REMOVAL Tightening torque:

26 N·m (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
SURE, OPERATION, Fuel.> EN0999
cap. 7) Raise the rear seat and turn floor mat up.
3) Disconnect the ground cable from battery. 8) Remove the access hole lid.
cardiagn.com
EN0553
G6M0095
4) Lift-up the vehicle. 9) Disconnect the connector from fuel pump.

5) Drain fuel from the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
tank.
EN0554
10) Disconnect the quick connector and then dis-

connect fuel delivery hose (A).
EN0999
<Ref. to FU-71, REMOVAL, Fuel Delivery, Return
and Evaporation Lines.>
FU-62
FUEL PUMP
11) Move the clip and then disconnect the fuel re- 5) Drain fuel from the fuel tank. Set a container un-
turn hose (B). der the vehicle and remove the drain plug from fuel
tank.
(A)
(B)
EN0555
EN0839
12) Remove the nuts which install fuel pump as-
sembly onto fuel tank. 6) Tighten the fuel drain plug.
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
cardiagn.com
EN0556
13) Take off the fuel pump assembly from fuel tank.
• 2500 cc MODEL EN0839
1) Release the fuel pressure. <Ref. to FU-54, RE- 7) Raise the rear seat and turn floor mat up.
LEASING OF FUEL PRESSURE, OPERATION, 8) Remove the access hole lid.
Fuel.>
cap.
EN0553
9) Disconnect the connector from fuel pump.
G6M0095
S2M0172
FU-63
FUEL PUMP
10) Disconnect the quick connector and then dis- • 2500 cc MODEL
connect fuel delivery hose (A). <Ref. to FU(TUR-
BO)-68, Fuel Delivery, Return and Evaporation
Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (B) and jet pump hose (C).
S2M0063A
C: INSPECTION
Connect the lead harness to connector terminal of
fuel pump and apply battery power supply to check
S2M0060A whether the pump operates.
12) Remove the nuts which install fuel pump as- WARNING:
sembly onto fuel tank. • Wipe off the fuel completely.
• Keep the battery as far apart from fuel pump
as possible.
• Be sure to turn the battery supply ON and
cardiagn.com
OFF on battery side.
• Do not run the fuel pump for a long time un-
der non-load condition.
S2M0061
3 2 1
6 5 4
13) Take off the fuel pump assembly from fuel tank.
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
EN1502
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten the nuts in alphabetical sequence
shown in the figure to specified torque.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
(C) (A) (E)
(H)
(G)
(F) (B) (D)

EN0557
FU-64
FUEL LEVEL SENSOR
23.Fuel Level Sensor 3) Remove the bolt which installs fuel level sensor
on mounting bracket.
A: REMOVAL • 1600 cc and 2000 cc MODEL
WARNING:
;;;;
;
;
NOTE:
Fuel level sensor is built in the fuel pump assembly.
1) Remove the fuel pump assembly.
<Ref. to FU-62, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
• 1600 cc and 2000 cc MODEL EN0560
• 2500 cc MODEL
cardiagn.com
EN0559
• 2500 cc MODEL EN0846

S2M0145
B: INSTALLATION
S2M0145
FU-65
FUEL SUB LEVEL SENSOR
24.Fuel Sub Level Sensor 6) Remove the service hole cover.
A: REMOVAL
NOTE:
Fuel sub level sensor is equipped to only 2500 cc
model.
WARNING:
G2M0863
7) Disconnect the connector from fuel sub meter.

8) Disconnect the fuel jet pump hose.
G6M0095
cardiagn.com
3) Drain fuel from the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel S2M0151
tank.
9) Remove the bolts which install fuel sub meter
unit on fuel tank.
EN0839
4) Tighten the fuel drain plug. S2M0152
Tightening torque: 10) Remove the fuel sub meter unit.

26 N·m (2.7 kgf-m, 19.2 ft-lb)
S2M0153
EN0839
5) Remove the rear seat.
FU-66
FUEL SUB LEVEL SENSOR
B: INSTALLATION
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3178
cardiagn.com
FU-67
FUEL FILTER
25.Fuel Filter
A: REMOVAL
WARNING:
2) Disconnect the fuel delivery hoses from fuel fil-
ter.
cardiagn.com
S2M0195
3) Remove the filter from holder.

B: INSTALLATION
CAUTION:
• If fuel hoses are damaged at the connecting
portion, replace it with a new one.
• If clamps are badly damaged, replace with
new ones.
1) Install in the reverse order of removal.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 N·m (0.13 kgf-m, 0.94 ft-lb)
S2M0195
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU-68
FUEL CUT VALVE
26.Fuel Cut Valve B: INSTALLATION

A: REMOVAL
Tightening torque:
WARNING: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
1) Remove the fuel tank.
<Ref. to FU-55, REMOVAL, Fuel Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
S2M0177
S2M0176
cardiagn.com
3) Remove the bolts which install fuel cut valve.
FU-69
FUEL DAMPER VALVE
27.Fuel Damper Valve B: INSTALLATION

A: REMOVAL
2) Remove the fuel damper valve from fuel return
line.
EN0852
cardiagn.com
FU-70
FUEL DELIVERY, RETURN AND EVAPORATION LINES
28.Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove fuel filler
cap.
Evaporation Lines 4) Remove the floor mat. <Ref. to EI-53, REMOV-
A: REMOVAL AL, Floor Mat.>
1) Set the vehicle on a lift. 5) Remove the fuel delivery pipes and hoses, fuel
2) Release the fuel pressure. return pipes and hoses, evaporation pipes and hos-
es.
cardiagn.com
EN0564
FU-71
6) In the engine compartment, detach the fuel de- 9) Separate the quick connector on fuel delivery
livery hoses, return hoses and evaporation hose. and return line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
NOTE:
Replace the retainer with new ones.
S2M0500F

(B) Return hose

8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B) S2M0228A
from canister.
cardiagn.com
(A) Connector
(A) (B) (B) Retainer
(C) Pipe
EN0840
FU-72
B: INSTALLATION CAUTION:
1) Connect the quick connector on fuel delivery • Pull the connector to ensure it is connected
line. securely.
NOTE: • Ensure the two retainer pawls are engaged in
their mating positions in the connector.
• Always use a new retainer.
• Make sure that the connected portion is not dam- • Be sure to inspect the hoses and their con-
aged or has dust. If necessary, clean the seal sur- nections for any leakage of fuel.
face of pipe.
S2M0231A
S2M0229A
(A) Connector
(1) Set the new retainer (B) to connector (A). (B) Retainer
cardiagn.com
(2) Push the pipe into connector completely. (C) Pipe
NOTE:
2) Connect the fuel delivery hose to pipe with an
At this time, two clicking sounds are heard. overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the fitting length is specified.
Type B: When the fitting length is not specified.
2 : 2.5±1.5 mm (0.098±0.059 in)
L: 22.5±2.5 mm (0.886±0.098 in)
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
FU-73
3) Connect the evaporation hose to pipe by approx.

15 mm (0.59 in) from the hose end.
L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
Be sure to inspect the hoses and their connec-
tions for any leakage of fuel.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
cardiagn.com
C: INSPECTION
1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tight.
FU-74
FUEL SYSTEM TROUBLE IN GENERAL
29.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
❍ Defective terminal contact.
securely.
❍ Trouble in electromagnetic or electronic circuit parts. Replace the fuel pump.
2) Lowering of fuel pump function. Replace the fuel pump.
3) Clogged dust or water in the fuel filter. Replace the fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace the fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace the air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
cardiagn.com
Clean, correct or replace the air breather tube or air vent
5) Clogged or bent air breather tube or air vent tube.
tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel
1) Retightening.
filler pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace the packing.
3) Cracked fuel separator. Replace the separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE: season, drain water which may have accumulat-
• When the vehicle is left unattended for an ex- ed in the fuel filter and fuel tank in the manner
tended period of time, water may accumulate in the same as that described under “Affected areas”
fuel tank. below.
To prevent water condensation. (4) Affected areas
(1) Top off the fuel tank or drain the fuel com- When water condensation is notched in the fuel
pletely. filter, drain water from both the fuel filter and fuel
(2) Drain water condensation from the fuel filter. tank or use a water removing agent (or anti-
• Refilling the fuel tank. freeze solution) in the fuel tank.
Refill the fuel tank while there is still some fuel left in • Observe the instructions, notes, etc., indicated
the tank. on the label affixed to the anti-freeze solution (wa-
• Protecting the fuel system against freezing and ter removing agent) container before use.
water condensation.
(3) Cold areas
In snow-covered areas, mountainous areas, ski-
ing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-
ing system. Refueling will also complement the
effect of anti-freeze solution each time the fuel
level drops to about one-half. After the winter
FU-75
FUEL SYSTEM TROUBLE IN GENERAL
cardiagn.com
FU-76
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
EC
Page
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter.............................................................................6
4. Canister.......................................................................................................7
5. Purge Control Solenoid Valve .....................................................................8
6. Two-way Valve............................................................................................9
cardiagn.com
GENERAL DESCRIPTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
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.
• Keep the disassembled parts in order and pro-
tect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
• Be careful not to burn your hands, because each
part on the vehicle is hot after running.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or safety stands at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
cardiagn.com
EC-2
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter 7) Separate the center exhaust pipe from rear ex-
haust pipe.
A: REMOVAL CAUTION:
1) Set the vehicle on a lift. Be careful, the exhaust pipe is hot.
B2M3109
G6M0095
8) Remove the nuts which hold front exhaust pipe
3) Disconnect the front oxygen (A/F) sensor con-
onto cylinder heads.
nector.
cardiagn.com
B2M3200
B2M4243
9) Remove the front and center exhaust pipe from
4) Disconnect the connector from rear oxygen sen-
hanger bracket.
sor connector.
CAUTION:
Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
B2M4244

6) Remove the under cover. B2M3111
EC-3
10) Separate the front catalytic converter from front 3) Tighten the nuts which hold front exhaust pipe
exhaust pipe. onto cylinder heads.
The rear catalytic converter is integrated with front 30 N·m (3.1 kgf-m, 22.4 ft-lb)
catalytic converter. Therefore, the procedure for re-
moving rear catalytic converter is the same as the
description above.
B2M3200
4) Tighten the bolts which install front and center

S2M0923 exhaust pipe to rear exhaust pipe.
Tightening torque:
B: INSTALLATION 18 N·m (1.8 kgf-m, 13.0 ft-lb)
NOTE:
cardiagn.com
Replace gaskets with new ones.
1) Install the front catalytic converter to front ex-
haust pipe.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3109
5) Tighten the bolt which holds front and center ex-

haust pipe assembly to hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
S2M0923
2) Install the front and center exhaust pipe assem-

bly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger brack-
et.
B2M3111
6) Install the under cover.
B2M3111
EC-4

8) Connect the front oxygen (A/F) sensor connec-
tor.
B2M4243
9) Connect the connector to rear oxygen sensor

connector.
cardiagn.com
B2M4244
G6M0095
NOTE:
The rear catalytic converter is integrated with front
catalytic converter. Therefore, the procedure for in-
stalling rear catalytic converter is the same as the
description above.
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-5
REAR CATALYTIC CONVERTER
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. <Ref. to EC-3, REMOVAL, Front Catalytic
Converter.>
B2M4164A
(A) Front catalytic converter
cardiagn.com
(B) Rear catalytic converter
B: INSTALLATION
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 ones described under front catalyt-
ic converter. <Ref. to EC-4, INSTALLATION, Front
Catalytic Converter.>
B2M4164A
(A) Front catalytic converter

(B) Rear catalytic converter
C: INSPECTION
nections and welds.
EC-6
CANISTER
4. Canister
A: REMOVAL
2) Loosen the two clamps which hold two canister
hoses, and disconnect the three evaporation hoses
from canister.
EN0898
3) Remove the canister from body.
cardiagn.com
B2M4166
B: INSTALLATION
Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-7
PURGE CONTROL SOLENOID VALVE
5. Purge Control Solenoid Valve B: INSTALLATION

A: REMOVAL
16 N·m (1.6 kgf-m, 11.6 ft-lb)
G6M0095
H2M2985
2) Remove the bolt which installs purge control so-
lenoid valve onto intake manifold. CAUTION:
Carefully connect the evaporation hoses.
cardiagn.com
H2M2985
3) Take out the purge control solenoid valve B2M1893E

through the bottom of intake manifold.
4) Disconnect the connector and hoses from purge A: To fuel pipe
control solenoid valve. B: To intake manifold
C: INSPECTION
Make sure hoses are not cracked or loose.
H2M2986
EC-8
TWO-WAY VALVE
6. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to EC-7,
REMOVAL, Canister.>
3) Remove the two-way valve with bracket as a sin-
gle unit from body.
EN0901
4) Remove the two-way valve from bracket.

B: INSTALLATION
cardiagn.com
C: INSPECTION
1) Make sure that the hoses are not cracked or
loose.
EC-9
TWO-WAY VALVE
cardiagn.com
EC-10
INTAKE (INDUCTION)
IN
Page
2. Air Cleaner Element ....................................................................................5
3. Air Cleaner Case.........................................................................................6
4. Air Intake Duct.............................................................................................7
5. Resonator Chamber....................................................................................8
cardiagn.com
GENERAL DESCRIPTION
INTAKE (INDUCTION)
A: COMPONENT
T3
T3
(5)
(7)
(6) (4)
(3)
T3
(9)
(8)
T1
(2)
(1) T4 T3
cardiagn.com
(11) T2
(11)
T2 (20)
(19)
(20)
(13)
(19)
(11)
(14)
(10)
(16) (12)
T5
T6
T5
(18) T5
(17)
(15)
EN1336
IN-2
GENERAL DESCRIPTION
INTAKE (INDUCTION)
(1) Spacer (11) Clip (20) Spacer

(2) Bush (12) Air cleaner element
(3) Resonator chamber (13) Air cleaner case B Tightening torque: N·m (kgf-m, ft-lb)
(4) Cushion rubber (14) Air cleaner case stay LH (MT vehi- T1: 33 (3.4, 24.6)
(5) Air intake duct A (1600 cc and cles) T2: 6.5 (0.66, 4.8)
2000 cc model) (15) Air cleaner case stay LH (AT vehi- T3: 7.5 (0.76, 5.5)
(6) Air intake duct A (2500 cc model) cles) T4: 14 (1.4, 10)
(7) Air intake duct B (16) Air cleaner case stay RH T5: 16 (1.6, 11.6)
(8) Holder (17) Engine harness bracket T6: 3 (0.3, 2.2)
(9) Cushion (18) Clamp
(10) Air cleaner case A (19) Bush
cardiagn.com
IN-3
GENERAL DESCRIPTION
INTAKE (INDUCTION)
B: CAUTION
tion.
points.
sensor or units, be sure to disconnect the ground
cable from battery.
cardiagn.com
IN-4
AIR CLEANER ELEMENT
INTAKE (INDUCTION)
2. Air Cleaner Element

A: REMOVAL
1) Remove the clip (A) above the air cleaner case.
H2M2947B
2) Remove the air cleaner element.

B: INSTALLATION
CAUTION:
Fasten with a clip after inserting the lower tab
cardiagn.com
of the case.
C: INSPECTION
Replace if excessively damaged or dirty.
IN-5
AIR CLEANER CASE
INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
1) Loosen the clamp which connects air cleaner
case to throttle body.
H2M2946
2) Disconnect the hoses and intake duct from air

cleaner case.
3) Remove the bolts which install air cleaner case
to stays.
cardiagn.com
H2M2947

B: INSTALLATION
C: INSPECTION
Inspect for cracks and loose connections.
IN-6
AIR INTAKE DUCT
INTAKE (INDUCTION)
4. Air Intake Duct • 2500 cc MODEL
A: REMOVAL
1) Remove the bolts which install air intake duct A
on the front side of body.
B6M1224
B: INSTALLATION
EN0061
C: INSPECTION
1) Inspect for cracks and loose connections.
• 2500 cc MODEL 2) Inspect that no foreign objects are mixed in the
air intake duct.
cardiagn.com
B6M1222
2) Remove the bolt which installs air intake duct B

on body.
EN1004
3) Remove the air intake ducts as a unit.

EN0063
IN-7
RESONATOR CHAMBER
INTAKE (INDUCTION)
5. Resonator Chamber B: INSTALLATION

A: REMOVAL
1) Remove the air intake duct. <Ref. to IN-7, RE- Tightening torque:
MOVAL, Air Intake Duct.> 33 N·m (3.4 kgf-m, 24.6 ft-lb)
2) Remove the resonator chamber.
B6M1237
B6M1237
C: INSPECTION
Inspect for cracks and loose connections.
cardiagn.com
IN-8
MECHANICAL
ME
Page
2. Compression .............................................................................................24
3. Idle Speed .................................................................................................25
4. Ignition Timing...........................................................................................26
5. Intake Manifold Vacuum............................................................................27
6. Engine Oil Pressure ..................................................................................28
7. Fuel Pressure............................................................................................29
8. Valve Clearance........................................................................................30
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................42
cardiagn.com
11. Preparation for Overhaul...........................................................................43
12. V-belt.........................................................................................................44
13. Crankshaft Pulley ......................................................................................46
14. Belt Cover .................................................................................................48
15. Timing Belt Assembly................................................................................49
16. Camshaft Sprocket....................................................................................54
17. Crankshaft Sprocket..................................................................................56
18. Valve Rocker Assembly ............................................................................57
19. Camshaft...................................................................................................59
20. Cylinder Head Assembly...........................................................................63
21. Cylinder Block ...........................................................................................71
22. Engine Trouble in General ........................................................................95
23. Engine Noise...........................................................................................101
GENERAL DESCRIPTION
MECHANICAL
A: SPECIFICATIONS
Model 1600 cc 2000 cc 2500 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline
Type
engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
87.9 x 65.8 99.5 x 79.0
Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)
(3.46 x 2.591) (3.917 x 3.110)
Displacement cm3 (cu in) 1,597 (97.45) 1,994 (121.67) 2,457 (150)
Compression ratio 10.0
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 1,020 — 1,275 (10.4 — 13.0, 148 — 185)
rpm)
Engine Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 10° BTDC 4° BTDC 1° BTDC
Intake valve timing
Closing 46° ABDC 48° ABDC 51° ABDC
Opening 42° BBDC 48° BBDC 50° BBDC
Exhaust valve timing
Closing 10° ATDC 4° ATDC 6° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
cardiagn.com
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed [At neutral position
700±100 (No load)
on MT, or “P” or “N” position on rpm
850±100 (A/C switch ON)
AT]
Firing order 1→3→2→4
Ignition timing BTDC/rpm 5°±10°/700 10°±10°/700
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
Belt
tensioner 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 bush I.D. 18.00 — 18.08 mm (0.7087 — 0.7118 in)
Belt STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
tensioner Limit 0.175 mm (0.0069 in)
STD 0.20 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Valve STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
Clearance between shaft and arm
rocker arm Limit 0.10 mm (0.0039 in)
ME-2
GENERAL DESCRIPTION
MECHANICAL
Bend limit 0.025 mm (0.0010 in)

STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.10 mm (0.0039 in)
STD 39.378 — 39.478 mm (1.5503 — 1.5542 in)
Intake
Limit 39.278 mm (1.5464 in)
1600 cc
STD 39.565 — 39.665 mm (1.5577 — 1.5616 in)
Exhaust
Limit 39.465 mm (1.5537 in)
STD 38.732 — 38.832 mm (1.5249 — 1.5288 in)
Intake
Limit 38.632 mm (1.5209 in)
Cam lobe height 2000 cc
Camshaft STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
STD 39.485 — 39.585 mm (1.5545 — 1.5585 in)
Intake
Limit 39.385 mm (1.5506 in)
2500 cc
STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Camshaft journal O.D. 31.928 — 31.945 mm (1.2570 — 1.2577 in)
Camshaft journal hole I.D. 32.000 — 32.018 mm (1.2598 — 1.2605 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
cardiagn.com
Cylinder
Surface grinding limit 0.1 mm (0.004 in)
head
Standard height 97.5 mm (3.84 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve seat Limit 1.7 mm (0.067 in)
Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 2.1 mm (0.083 in)
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve guide Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)
STD 1.0 mm (0.039 in)
Intake
Limit 0.6 mm (0.024 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.6 mm (0.024 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm(0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 120.6 mm (4.75 in)
Overall length
Exhaust 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Valve 214 — 246 N (21.8 — 25.1 kgf, 48.1 — 55.3 lb)/
spring 45.0 mm (1.772 in)
Tension/spring height
526 — 582 N (53.6 — 59.3 kgf, 118.3 — 130.8 lb)/
34.7 mm (1.366 in)
ME-3
GENERAL DESCRIPTION
MECHANICAL
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 87.905 — 87.915 mm (3.4608 — 3.4612 in)
1600 cc STD
B 87.895 — 87.905 mm (3.4604 — 3.4608 in)
A 92.005 — 92.015 mm (3.6222 — 3.6226 in)
Cylinder bore 2000 cc STD
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
A 99.505 — 99.515 mm (3.9175 — 3.9179 in)
Cylinder 2500 cc STD
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
block
STD 0.015 mm (0.0006 in)
Taper
Limit 0.050 mm (0.0020 in)
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 87.885 — 87.895 mm (3.4600 — 3.4604 in)
STD
B 87.875 — 87.885 mm (3.4596 — 3.4600 in)
1600 cc 0.25 mm (0.0098 in)
88.125 — 88.135 mm (3.4695 — 3.4699 in)
OS
0.50 mm (0.0197 in)
88.375 — 88.385 mm (3.4793 — 3.4797 in)
cardiagn.com
OS
A 91.985 — 91.995 mm (3.6214 — 3.6218 in)
STD
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
Outer diameter 2000 cc 0.25 mm (0.0098 in)
92.225 — 92.235 mm (3.6309 — 3.6313 in)
Piston OS
0.50 mm (0.0197 in)
92.475 — 92.485 mm (3.6407 — 3.6411 in)
OS
A 99.485 — 99.495 mm (3.9167 — 3.9171 in)
STD
B 99.475 — 99.485 mm (3.9163 — 3.9167 in)
2500 cc 0.25 mm (0.0098 in)
99.725 — 99.735 mm (3.9262 — 3.9266 in)
OS
0.50 mm (0.0197 in)
99.975 — 99.985 mm (3.9360 — 3.9364 in)
OS
Standard inner diameter of piston pin hole 23.000 — 23.006 mm (0.9055 — 0.9057 in)
Outer diameter 22.994 — 23.000 mm (0.9053 — 0.9055 in)
Standard clearance between piston pin and hole in pis-
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Piston pin ton
Piston pin must be fitted into position with thumb at 20°C
Degree of fit
(68°F).
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.50 mm (0.0079 — 0.0197 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
Clearance STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Top ring
between piston Limit 0.15 mm (0.0059 in)
ring and piston Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring groove ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94
Limit 0.10 mm (0.0039 in)
Connecting in) in length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
ME-4
GENERAL DESCRIPTION
MECHANICAL
1600 cc STD 0.010 — 0.038 mm (0.0004 — 0.0015 in)

2000 cc Limit 0.05 mm (0.0020 in)
Oil clearance
STD 0.012 — 0.037 mm (0.0005 — 0.0015 in)
2500 cc
Limit 0.05 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in)
1.510 — 1.513 mm (0.0594 — 0.0596 in)
US
1600 cc
0.05 mm (0.0020 in)
2000 cc 1.520 — 1.523 mm (0.0598 — 0.0600 in)
Connecting US
rod bearing 0.25 mm (0.0098 in)
1.620 — 1.623 mm (0.0638 — 0.0639 in)
Thickness at US
center portion STD 1.490 — 1.502 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in)
1.504 — 1.512 mm (0.0592 — 0.0595 in)
US
2500 cc 0.05 mm (0.0020 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
US
0.25 mm (0.0098 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
US
Connecting Clearance between piston pin STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing and bushing Limit 0.030 mm (0.0012 in)
Bend limit 0.035 mm (0.0014 in)
cardiagn.com
Crank pin and Out-of-roundness 0.020 mm (0.0008 in) or less
crank journal Grinding limit 0.250 mm (0.0098 in)
STD 47.984 — 48.000 mm (1.8880 — 1.8898 in)
0.03 mm (0.0012 in)
47.954 — 47.970 mm (1.8879 — 1.8886 in)
US
1600 cc 0.05 mm (0.0020 in)
47.934 — 47.950 mm (1.8872 — 1.8878 in)
US
0.25 mm (0.0098 in)
47.734 — 47.750 mm (1.8793 — 1.8799 in)
Crank pin outer US
diameter STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
US
2000 cc
0.05 mm (0.0020 in)
2500 cc 51.934 — 51.950 mm (2.0446 — 2.0453 in)
US
0.25 mm (0.0098 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
US
Crankshaft STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #3 0.05 mm (0.0020 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal US
outer diameter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#2, #4, #5 0.05 mm (0.0020 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
ME-5
GENERAL DESCRIPTION
MECHANICAL
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
#1, #3 0.05 mm (0.0020 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm (0.0098 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft Crankshaft bear- US
bearing ing thickness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #4, #5 0.05 mm (0.0020 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
US
0.25 mm (0.0098 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
US
cardiagn.com
ME-6
GENERAL DESCRIPTION
MECHANICAL
B: COMPONENT
1. TIMING BELT
cardiagn.com
B2M3122A
(1) Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb)
(2) Timing belt guide (MT vehicles ASSY T1: 5 (0.5, 3.6)
only) (10) Belt idler No. 2 T2: 10 (1.0, 7.2)
(3) Crankshaft sprocket (11) Camshaft sprocket No. 2 T3: 25 (2.5, 18.1)
(4) Belt cover No. 2 (LH) (12) Timing belt T4: 39 (4.0, 28.9)
(5) Camshaft sprocket No. 1 (13) Front belt cover T5: 78 (8.0, 57.9)
(6) Belt idler (No. 1) (14) Belt cover (LH) T6: <Ref. to ME-46, Installation,
(7) Tensioner bracket (15) Crankshaft pulley (1600 cc and Crankshaft Pulley.>
(8) Belt idler (No. 2) 2000 cc model) T7: <Ref. to ME-46, Installation,
(16) Crankshaft pulley (2500 cc model) Crankshaft Pulley.>
ME-7
GENERAL DESCRIPTION
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
cardiagn.com
B2M1954D
(1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref. to ME-63, Installation,
(3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) Cylinder Head Assembly.>
(4) Camshaft cap (RH) (14) Oil filler cap T2: 5 (0.5, 3.6)
(5) Oil seal (15) Gasket T3: 10 (1.0, 7.2)
(6) Camshaft (RH) (16) Oil filler pipe T4: 18 (1.8, 13.0)
(7) Plug (17) O-ring T5: 25 (2.5, 18.1)
(8) Spark plug pipe gasket (18) Rocker cover (LH) T6: 6.4 (0.65, 4.7)
(9) Cylinder head (RH) (19) Stud bolt
(10) Cylinder head gasket
ME-8
GENERAL DESCRIPTION
MECHANICAL
3. VALVE ROCKER ASSEMBLY
cardiagn.com
B2M1956A
(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb)
(2) Valve rocker nut (7) Exhaust rocker shaft T1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (8) Exhaust valve rocker arm T2: 10 (1.0, 7.2)
(4) Spring T3: 25 (2.5, 18.1)
(5) Rocker shaft support
ME-9
GENERAL DESCRIPTION
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
cardiagn.com
B2M1955D
(1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve oil seal
(2) Intake valve (6) Valve spring
(3) Valve guide (7) Retainer
(4) Valve spring seat (8) Retainer key
ME-10
GENERAL DESCRIPTION
MECHANICAL
5. CYLINDER BLOCK
cardiagn.com
EN1498
(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 (16) Oil strainer T2: 6.4 (0.65, 4.7)
(4) Gasket (17) Gasket T3: 10 (1.0, 7.2)
(5) Oil separator cover (18) Oil pan T4: 25 (2.5, 18.1)
(6) Water by-pass pipe (19) Drain plug T5: 47 (4.8, 34.7)
(7) Oil pump (20) Metal gasket T6: 69 (7.0, 50.6)
(8) Front oil seal (21) Oil level gauge guide T7: First 12 (1.2, 8.7)
(9) Rear oil seal (22) Water pump sealing Second 12 (1.2, 8.7)
(10) O-ring (23) Oil filter T8: 16 (1.6, 11.6)
(11) Service hole cover (24) Gasket T9: 44 (4.5, 33)
(12) Cylinder block (LH) (25) Water pump hose T10: 25 (2.5, 18.1)
(13) Water pump T11: 54 (5.5, 39.8)
ME-11
GENERAL DESCRIPTION
MECHANICAL
6. CRANKSHAFT AND PISTON
cardiagn.com
B2M3429A
ME-12
GENERAL DESCRIPTION
MECHANICAL
(1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4

(2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT) (11) Connecting rod
(4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)
(6) Oil ring (14) Crankshaft T2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3
cardiagn.com
ME-13
GENERAL DESCRIPTION
MECHANICAL
7. ENGINE MOUNTING
T2
T2
(2)
(2)
T1
(1)
T1
(1)
cardiagn.com
T3
T3
EN1005
(1) Front cushion rubber (2) Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
ME-14
GENERAL DESCRIPTION
MECHANICAL
C: CAUTION • Rotating parts and sliding parts such as piston,

• Wear working clothing, including a cap, protec- bearing and gear should be coated with oil prior to
tive goggles, and protective shoes during opera- assembly.
tion. • Be careful not to let oil, grease or coolant contact
• Remove contamination including dirt and corro- the timing belt, clutch disc and flywheel.
sion before removal, installation or disassembly. • All removed parts, if to be reused, should be re-
• Keep the disassembled parts in order and pro- installed in the original positions and directions.
tect them from dust or dirt. • Bolts, nuts and washers should be replaced with
• Before removal, installation or disassembly, be new ones as required.
sure to clarify the failure. Avoid unnecessary re- • Even if necessary inspections have been made
moval, installation, disassembly, and replacement. in advance, proceed with assembly work while
• Be careful not to burn your hands, because each making rechecks.
part in the vehicle is hot after running. • Remove or install engine in an area where chain
• Be sure to tighten fasteners including bolts and hoists, lifting devices, etc. are available for ready
nuts to the specified torque. use.
• Place shop jacks or safety stands at the specified • Be sure not to damage coated surfaces of body
points. panels with tools or stain seats and windows with
• Before disconnecting electrical connectors of coolant or oil. Place a cover over fenders, as re-
sensors or units, be sure to disconnect the ground quired, for protection.
cable from battery. • Prior to starting work, prepare the following:
• All parts should be thoroughly cleaned, paying Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
cardiagn.com
special attention to the engine oil passages, pis-
tons and bearings. jacks, etc.
• Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
18231AA010 CAMSHAFT • Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket. (LH side)
tool) WRENCH • Also the CAMSHAFT SPROCKET WRENCH
(499207100) can be used.
NOTE:
For common use with turbo model, this ST is
changed and registered as a newly adoped tool.
Though the previous ST also can be used.
B2M3859
24082AA190 CARTRIDGE Troubleshooting for electrical systems.
(Newly adopted
tool)
B2M3876
ME-15
GENERAL DESCRIPTION
MECHANICAL

22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
B2M3877
498267800 CYLINDER • Used for replacing valve guides.
HEAD TABLE • Used for removing and installing valve springs.
cardiagn.com
B2M3850
498277200 STOPPER SET Used for installing automatic transmission assem-
bly to engine.
B2M2043
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH
B2M3851
ME-16
GENERAL DESCRIPTION
MECHANICAL

498457100 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER LH
B2M3852
498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-
STOPPER ening and tightening crankshaft pulley bolt, etc.
cardiagn.com
B2M3853
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
498747000 PISTON GUIDE Used for installing piston in cylinder.
(1600 cc model)
398744300
(2000 cc model)
498747300
(2500 cc model)
B2M3854
ME-17
GENERAL DESCRIPTION
MECHANICAL

498857100 VALVE OIL Used for press-fitting of intake and exhaust valve
SEAL GUIDE guide oil seals.
B2M3855
499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.
cardiagn.com
B2M3856
499037100 CONNECTING Used for removing and installing connecting rod
ROD BUSHING bushing.
REMOVER &
INSTALLER
B2M3857
499057000 TORX PLUS Used for removing flywheel (Dual mass flywheel).
B2M4159
ME-18
GENERAL DESCRIPTION
MECHANICAL

499097700 PISTON PIN Used for removing piston pin.
REMOVER
ASSY
B2M3858
499207400 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket. (RH side)
WRENCH
cardiagn.com
B2M4158
499497000 TORX PLUS Used for removing and installing camshaft cap.
B2M3873
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
B2M3875
ME-19
GENERAL DESCRIPTION
MECHANICAL

499587200 CRANKSHAFT • Used for installing crankshaft oil seal.
OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).
B2M3861
499587500 OIL SEAL Used for installing camshaft oil seal.
INSTALLER
cardiagn.com
B2M3874
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL
INSTALLER
B2M3860
499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal.
• Used with OIL SEAL INSTALLER (499587500).
B2M3862
ME-20
GENERAL DESCRIPTION
MECHANICAL

499597100 CRANKSHAFT • Used for installing crankshaft oil seal.
OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).
B2M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
cardiagn.com
B2M3864
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
B2M3868
ME-21
GENERAL DESCRIPTION
MECHANICAL

499767700 VALVE GUIDE Used for installing valve guides.
(Intake side) ADJUSTER
499767800
(Exhaust side)
B2M3865
499817100 ENGINE STAND • Stand used for engine disassembly and assem-
bly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
cardiagn.com
B2M3869
499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolts. (2500 cc model)
B2M3870
bolts. (1600 cc and 2000 cc model)
B2M4157
ME-22
GENERAL DESCRIPTION
MECHANICAL

499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS
Compression Gauge Used for measuring compression.
Tachometer (Secondary pick-up type) Used for measuring idle speed.
Timing Light Used for measuring ignition timing.
E: PROCEDURE
It is possible to conduct the following service proce-
cardiagn.com
dures with engine on the vehicle, however, the pro-
cedures described in this section are based on the
condition that the engine is removed from the vehi-
cle.
• V-belt
• Timing Belt
• Valve Rocker Assembly
• Camshaft
• Cylinder Head
ME-23
COMPRESSION
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release the fuel pressure. <Ref. to FU-54, RE-
LEASING OF FUEL PRESSURE, OPERATION,
Fuel.> or <Ref. to FU(w/oOBD)-51, RELEASING
OF FUEL PRESSURE, OPERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG-5, RE-
MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)-5,
REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against spark
cardiagn.com
plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
B2M3133
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
1,275 kPa (13.0 kgf/cm2, 185 psi)
Limit;
1,020 kPa (10.4 kgf/cm2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm2, 7 psi), or less
ME-24
IDLE SPEED
MECHANICAL
3. Idle Speed 5) When using the tachometer (Secondary pick-up

type).
A: INSPECTION (1) Attach the pick-up clip to No. 1 cylinder
1) Before checking idle speed, check the following: spark plug cord.
(1) Ensure the air cleaner element is free from (2) Start the engine, and then read the engine
clogging, ignition timing is correct, spark plugs idle speed.
are in good condition, and the hoses are con-
nected properly.
(2) Ensure the malfunction indicator light
(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-15, SPECIAL TOOLS, PREPARA-
TION TOOL, General Description.>
(1) Insert the cartridge to SUBARU SELECT B2M3131
MONITOR.
NOTE:
(2) Connect the SUBARU SELECT MONITOR
• When using the OBD-II general scan tool, care-
to data link connector.
fully read its operation manual.
• This ignition system provides simultaneous igni-
cardiagn.com
tion for #1 and #2 plugs. It must be noted that some
tachometers may register twice that of actual en-
gine speed.
6) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral (MT), or
N or P (AT) position):
B2M3148
700±100 rpm
(3) Turn the igintion switch to ON, and SUBA- 7) Check the idle speed when loaded. (Turn the air
RU SELECT MONITOR switch to ON. conditioning switch to “ON” and operate the com-
(4) Select the {2. Each System Check} in Main pressor for at least 1 minute before measurement.)
Menu. Idle speed [A/C “ON”, no load and gears in neu-
(5) Select the {Engine Control System} in Se- tral (MT) or N or P (AT) position]:
lection Menu. 850±100 rpm
(6) Select the {1. Current Data Display & Save}
in Engine Control System Diagnosis. CAUTION:
(7) Select the {1.12 Data Display} in Data Dis- Never rotate the idle adjusting screw. If the idle
play Menu. speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Con-
(8) Start the engine, and then read the engine
trol System”. <Ref. to EN-2, Basic Diagnostic
idle speed.
Procedure.> or <Ref. to EN(w/oOBD)-2, Basic
Diagnostic Procedure.>
ME-25
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.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with timing light.
3) Start the engine at idle speed and check the ig-
nition timing.
Ignition timing [BTDC/rpm]:
5°±10°/700 (1600cc MODEL)
10°±10°/700 (2000cc and 2500 cc MODEL)
cardiagn.com
B2M3130
If the timing is not correct, check the ignition control

system.
Refer to Engine Control System. <Ref. to EN-2, Ba-
sic Diagnostic Procedure.> or <Ref. to EN(w/
oOBD)-2, Basic Diagnostic Procedure.>
ME-26
INTAKE MANIFOLD VACUUM
MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
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.
By observing the gauge needle movement, the in-
ternal condition of engine can be diagnosed as de-
scribed below. B2M3134
Vacuum pressure (at idling, A/C “OFF”):

Less than −60.0 kPa (−450 mmHg, −17.72 in-
Hg)
Diagnosis of engine condition by measurement of manifold vacuum

Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten- Leakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises. damaged vacuum hose
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes steady
cardiagn.com
above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME-27
ENGINE OIL PRESSURE
MECHANICAL
6. Engine Oil Pressure 7) Start the engine, and then measure the oil pres-
sure.
A: INSPECTION
S2M0242
G6M0095
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm
2) Remove the generator from bracket. <Ref. to 294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
SC-14, REMOVAL, Generator.> rpm
3) Disconnect the connector from oil pressure
switch. CAUTION:
• If the oil pressure is out of specification,
4) Remove the oil pressure switch from engine cyl-
check the oil pump, oil filter and lubrication
inder block. <Ref. to LU-21, REMOVAL, Oil Pres-
line. <Ref. to LU-25, INSPECTION, Engine Lubri-
cardiagn.com
sure Switch.>
cation System Trouble in General.>
5) Connect the oil pressure gauge hose to cylinder
• If the oil pressure warning light is turned ON
block.
and oil pressure is in specification, replace the
oil pressure switch. <Ref. to LU-25, INSPEC-
TION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU-21, INSTALLATION,
Oil Pressure Switch.>
Tightening torque:
G6M0095
25 N·m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion. <Ref. to ME-44, INSTALLATION, V-belt.>
ME-28
FUEL PRESSURE
MECHANICAL
7. Fuel Pressure 6) Measure the fuel pressure while disconnecting

the pressure regulator vacuum hose from intake
A: INSPECTION manifold.
WARNING: Fuel pressure:
Before removing the fuel pressure gauge, re- Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm2,
lease the fuel pressure. 41 — 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
2) Open the fuel flap lid, and then remove the fuel
filler cap.
S2M0554
7) After connecting the pressure regulator vacuum

hose, measure the fuel pressure.
Fuel pressure:
cardiagn.com
Standard; 206 — 235 kPa (2.1 — 2.4 kg/cm2,
30 — 34 psi)
H2M2535
3) Disconnect the fuel delivery hoses from fuel

damper, and then connect the fuel pressure gauge.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
S2M0195
4) Connect the connector of fuel pump relay.
EN0344
5) Start the engine.
ME-29
VALVE CLEARANCE
MECHANICAL
8. Valve Clearance 8) When inspecting the #2 and #4 cylinders;

(1) Disconnect the spark plug cords from spark
A: INSPECTION plugs (LH Side) <Ref. to IG-5, LH SIDE, RE-
CAUTION: MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)-
Inspection and adjustment of the valve clear- 5, LH SIDE, REMOVAL, Spark Plug.>.
ance should be performed while engine is cold. (2) Disconnect the PCV hose from rocker cover
(LH).
(3) Remove the bolts, and then remove the
rocker cover (LH).
3) Remove the under cover.
9) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
5) Disconnect the ground cable from battery. clockwise using ST.
ST 499977300 CRANK PULLEY WRENCH
(1600 cc and 2000 cc model)
(2500 cc model)
NOTE:
When arrow mark (A) on the camshaft sprocket
(LH) comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
cardiagn.com
G6M0095
6) Remove the belt cover (LH).
B2M2027B
B2M2031
7) When inspecting the #1 and #3 cylinders;

(1) Disconnect the spark plug cords from spark
plugs RH side. <Ref. to IG-5, RH SIDE, RE-
MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)-
5, RH SIDE, REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, and then remove the
rocker cover (RH).
ME-30
VALVE CLEARANCE
MECHANICAL
10) Measure the #1 cylinder valve clearance by us- 13) After inspection, install the related parts in the
ing thickness gauge. reverse order of removal.
CAUTION: Tightening torque:
• Insert the thickness gauge (A) in as horizon- Resonator chamber;
tal a direction as possible with respect to the 33 N·m (3.4 kgf-m, 24 ft-lb)
valve stem end face.
• Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
0.25±0.02 mm (0.0098±0.0008 in)
B6M1237
cardiagn.com
B2M2028B
11) If necessary, adjust the valve clearance. <Ref.

to ME-32, ADJUSTMENT, Valve Clearance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
• Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before measuring valve clearances.
• To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crankshaft pulley clockwise 90° at a time starting
with arrow mark on camshaft sprocket (LH) facing
up.
B2M2029B
ME-31
VALVE CLEARANCE
MECHANICAL
B: ADJUSTMENT 2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
CAUTION:
(2) Place suitable thickness gauge.
Adjustment of the valve clearance should be
(3) While noting the valve clearance, tighten the
performed while engine is cold.
valve rocker adjust screw.
1) Set the #1 cylinder piston to top dead center of (4) When specified valve clearance is obtained,
compression stroke by rotating crankshaft pulley tighten the valve rocker nut.
clockwise using ST.
ST 499977300 CRANK PULLEY WRENCH Tightening torque:
(1600 cc and 2000 cc model) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
ST 499977100 CRANK PULLEY WRENCH CAUTION:
(2500 cc model) • Insert the thickness gauge in as horizontal a
NOTE: direction as possible with respect to the valve
When arrow mark (A) on the camshaft sprocket stem end face.
(LH) comes exactly to the top, #1 cylinder piston is • Adjust the exhaust valve clearances while
brought to the top dead center of compression lifting up the vehicle.
stroke. Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
0.25±0.02 mm (0.0098±0.0008 in)
cardiagn.com
B2M2027B
B2M2030
3) Ensure the valve clearances are within specifi-

cations.
4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to the top dead cen-
ter on compression stroke.
5) Ensure the valve clearances are within specifi-
cations. If necessary, readjust the valve clearanc-
es.
ME-32
VALVE CLEARANCE
MECHANICAL
6) Similar to adjustment procedures used for #1

cylinder, adjust the #2, #3 and #4 cylinder valve
clearances.
NOTE:
• Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before adjusting valve clearances.
• To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crankshaft pulley clockwise 90° at a time starting
with arrow mark on camshaft sprocket (LH) facing
up.
cardiagn.com
B2M2029B
ME-33
ENGINE ASSEMBLY
MECHANICAL
9. Engine Assembly 10) Remove the air cleaner case stay.

• MT MODEL
A: REMOVAL
1) Set the vehicle on lift arms.
2) Open the front hood fully, and then support with
the hood stay.
4) Remove the filler cap.
S2M0900
• AT MODEL
cardiagn.com
G6M0095
6) Remove the air intake duct and air cleaner case.

<Ref. to IN-7, REMOVAL, Air Intake Duct.> and B2M4251
<Ref. to IN-6, REMOVAL, Air Cleaner Case.> 11) Disconnect the following connectors and ca-
7) Remove the under cover. bles.
8) Remove the radiator from vehicle. <Ref. to CO- (1) Front oxygen (A/F) sensor connector (With
39, REMOVAL, Radiator.> OBD)
9) Collect the refrigerant, and then remove the
pressure hoses. (With A/C)
(1) Place and connect the attachment hose to
refrigerant recycle system.
(2) Collect the refrigerant from A/C system.
(3) Disconnect the A/C pressure hoses from
A/C compressor.
B2M4243
(2) Front oxygen sensor connector (Without

OBD)
B2M3385
B2M3108
ME-34
ENGINE ASSEMBLY
MECHANICAL
(3) Engine ground cable (6) Accelerator cable and cruise control cable
S2M0731 B2M3415A
(4) Engine harness connectors

(A) Accelerator cable
(B) Cruise control cable
(7) Pressure switch
cardiagn.com
EN0360
12) Disconnect the following hoses.

(1) Brake booster vacuum hose
B2M4292
(5) Generator connector, terminal and A/C

compressor connector
B2M3419
(2) Heater inlet outlet hose
B2M3386B
(A) Generator connector and terminal

(B) A/C compressor connector
B2M3390
ME-35
ENGINE ASSEMBLY
MECHANICAL
13) Remove the power steering pump from brack- (6) Place the power steering pump on right side
et. wheel apron.
(1) Remove the resonator chamber.
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt.<Ref. to ME-
44, FRONT SIDE BELT, REMOVAL, V-belt.>
(3) Remove the pipe with bracket.
EN0208
14) Remove the front and center exhaust pipe.

<Ref. to EX-7, REMOVAL, Front Exhaust Pipe.> or
<Ref. to EX(w/oOBD)-9, REMOVAL, Front Exhaust
Pipe.>
B2M4126
15) Remove the nuts which hold lower side of
(4) Remove the bolts which install power steer- transmission to engine.
ing pump bracket.
cardiagn.com
B2M2047
B2M3151
16) Remove the nuts which install front cushion
(5) Remove the power steering tank from rubber onto front crossmember.
bracket by pulling it upward.
S2M1927
EN0361
ME-36
ENGINE ASSEMBLY
MECHANICAL
17) Separate the torque converter clutch from drive 20) Support the engine with a lifting device and
plate. (AT model) wire ropes.
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove other bolts while rotating the en-
gine using ST.
(2500 cc model)
B2M3391
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.
cardiagn.com
S2M0207
18) Remove the pitching stopper.
G2M0298A
(A) Transmission
(B) Garage jack
H3M1839
BO0002
22) Separation of the engine and transmission.
19) Disconnect the fuel delivery hose, return hose
(1) Remove the starter. <Ref. to SC-5, RE-
and evaporation hose.
MOVAL, Starter.>
CAUTION: (2) Remove the bolts which hold upper side of
• Disconnect the hose with its end wrapped transmission to engine.
with cloth to prevent fuel from splashing.
• Catch fuel from the hose into container.
B3M2044
S2M0500
ME-37
ENGINE ASSEMBLY
MECHANICAL
23) Install the ST to torque converter clutch case. B: INSTALLATION

(AT model) 1) Install the front cushion rubbers.
ST 498277200 STOPPER SET
Tightening torque:
34 N·m (3.5 kgf-m, 25.3 ft-lb)
2) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
CAUTION:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge,
etc.
H2M1961A
24) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
cardiagn.com
CAUTION: B2M3391
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, (2) Apply a small amount of grease to the spline
etc. of main shaft. (MT model)
3) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
B2M3391
25) Remove the front cushion rubbers.
B3M2044
4) Remove the lifting device and wire ropes.
B2M3391
5) Remove the garage jack.
ME-38
ENGINE ASSEMBLY
MECHANICAL
6) Install the pitching stopper. 10) Install the power steering pump on bracket.
(1) Install the power steering tank on bracket.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
EN0361
(2) Install the power steering pump on bracket,

H3M1839A and then tighten the bolts.
7) Remove the ST from torque converter clutch Tightening torque:
case. (AT model) 20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
cardiagn.com
ST 498277200 STOPPER SET
8) Install the starter. <Ref. to SC-6, INSTALLA-
TION, Starter.>
9) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate. B2M3151A
(2) Tighten other bolts while rotating the engine
by using ST. (3) Tighten the bolts which install power steer-
ing pump bracket, and then install the spark plug
CAUTION: cords.
Be careful not to drop the bolts into torque con-
verter clutch housing.
(2500 cc model)
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M4126
(4) Connect the power steering switch connec-

tor.
S2M0207
(3) Clog the plug onto service hole.
EN0360
ME-39
ENGINE ASSEMBLY
MECHANICAL
(5) Install the front side V-belt, and adjust it. 13) Install the front and center exhaust pipe.
<Ref. to ME-44, FRONT SIDE BELT, INSTAL- <Ref. to EX-8, INSTALLATION, Front Exhaust
LATION, V-belt.> Pipe.> and <Ref. to EX(w/oOBD)-10, INSTALLA-
(6) Install the resonator chamber. TION, Front Exhaust Pipe.>
14) Connect the following hoses.
Tightening torque:
(1) Fuel delivery hose, return hose and evapo-
33 N·m (3.4 kgf-m, 24.6 ft-lb)
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
15) Connect the following connectors.
(1) Engine ground cables
Tightening torque:
14 N·m (1.4 kgf-m, 10.1 ft-lb)
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
B6M1237
(5) Power steering pressure switch
11) Tighten the nuts which hold lower side of trans- 16) Connect the following cables.
mission to engine. (1) Accelerator cable
Tightening torque: (2) Cruise control cables (With cruise control)
cardiagn.com
50 N·m (5.1 kgf-m, 36.9 ft-lb) CAUTION:
After connecting each cable, adjust them.
17) Install the air cleaner case stay.
Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
18) Install the A/C pressure hoses.
<Ref. to AC-37, INSTALLATION, Hose and Tube.>
NOTE:
Use new O-rings.
B3M2047
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
12) Tighten the nuts which install front cushion rub-
ber onto crossmember.
Tightening torque:
85 N·m (8.7 kgf-m, 63 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
B2M3385
19) Install the radiator to vehicle. <Ref. to CO-42,

INSTALLATION, Radiator.>
20) Install the air intake duct and air cleaner case.
<Ref. to IN-7, INSTALLATION, Air Intake Duct.>
and <Ref. to IN-6, INSTALLATION, Air Cleaner
Case.>
B2M3880A 21) Install the under cover.
22) Install battery in the vehicle, and then connect
the cables.
ME-40
ENGINE ASSEMBLY
MECHANICAL
23) Fill engine coolant. C: INSPECTION

<Ref. to CO-26, FILLING OF ENGINE COOLANT, 1) Make sure the pipes and hoses are installed cor-
REPLACEMENT, Engine Coolant.> rectly.
24) Check the ATF level and correct if necessary. 2) Make sure the engine coolant and ATF are at
(AT model) specified levels.
<Ref. to AT-9, INSPECTION, Automatic Transmis-
sion Fluid.>
25) Charge the A/C system with refrigerant.
<Ref. to AC-22, OPERATION, Refrigerant Charg-
ing Procedure.>
26) Remove the front hood stay, and then close the
front hood.
27) Take off the vehicle from lift arms.
cardiagn.com
ME-41
ENGINE MOUNTING
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to ME-34,
REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
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.
cardiagn.com
ME-42
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
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817100 ENGINE STAND
B2M2582A
cardiagn.com
2) In this section the procedures described under
each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME-43
V-BELT
MECHANICAL
12.V-belt 3) Remove the A/C belt.

4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
1) Remove the V-belt cover.
B2M2585
B: INSTALLATION
1. FRONT SIDE BELT
CAUTION:
Wipe off any oil or water on the belt and pulley.
B2M3401 1) Install the belt (C), and tighten the slider bolt so
as to obtain the specified belt tension <Ref. to ME-
2) Loosen the lock bolt (A). 45, INSPECTION, V-belt.>
cardiagn.com
3) Loosen the slider bolt (B). 2) Tighten the lock bolt (A)
4) Remove the front side belt (C). 3) Tighten the slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
Slider bolt:
8 N·m (0.8 kgf-m, 5.5 ft-lb)
B2M4291A
2. REAR SIDE BELT

1) Loosen the lock nut (A).
2) Loosen the slider bolt (B).
B2M4291A
B2M2584A
ME-44
V-BELT
MECHANICAL
2. REAR SIDE BELT C: INSPECTION

1) Install the belt, and tighten the slider bolt (B) so 1) Replace the belts, if cracks, fraying or wear is
as to obtain the specified belt tension. <Ref. to ME- found.
45, INSPECTION, V-belt.> 2) Check the drive belt tension and adjust it if nec-
2) Tighten the lock nut (A). essary by changing the generator installing position
and/or idler pulley installing position.
Tightening torque:
Lock nut (A); Belt tension
22.6 N·m (2.3 kgf-m, 16.6 ft-lb) (A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
B2M2584A
cardiagn.com
B2M4123A
C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-45
CRANKSHAFT PULLEY
MECHANICAL
13.Crankshaft Pulley (4) Tighten the crankshaft pulley bolts.
A: REMOVAL Tightening torque:

127 N·m (13.0 kgf-m, 94.0 ft-lb)
1) Remove the V-belt. <Ref. to ME-44, REMOVAL,
V-belt.>
2) Remove the crankshaft pulley bolt. To lock the
crankshaft, use ST.
ST 499977300 (1600 cc and 2000 cc model)
ST 499977100 (2500 cc model)
CRANKSHAFT PULLEY WRENCH
B2M2586A
3) Confirm that the tightening angle of crankshaft

pulley bolt is 45 degrees or more. If not, conduct the
following procedures.
CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be dam-
cardiagn.com
B2M2586D
aged. In this case, the bolt must be replaced.
• 2500 cc MODEL (1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(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 keeping
them in an angle between 45 degrees and 60
H2M2393E degrees.
3) Remove the crankshaft pulley. CAUTION:
Conduct the tightening procedures by confirm-
B: INSTALLATION ing the turning angle of crankshaft pulley bolt
1) Install the crankshaft pulley. referring to the gauge indicated on belt cover.
2) Install the pulley bolt. (1600 cc and 2000 cc mod- 4) Install the pulley bolt. (2500 cc model)
el) To lock the crankshaft, use ST.
To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH
ST 499977300 CRANK PULLEY WRENCH (1) Clean the crankshaft pulley thread using an
(1) Clean the crankshaft pulley thread using an air gun.
air gun. (2) Apply engine oil to the crankshaft pulley bolt
(2) Apply engine oil to the crankshaft pulley bolt seat and thread.
seat and thread. (3) Tighten the bolts temporarily with tightening
(3) Tighten the bolts temporarily with tightening torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
ME-46
CRANKSHAFT PULLEY
MECHANICAL
(4) Tighten the crankshaft pulley bolts. 7) Install the A/C belt.
Tightening torque:
177 N·m (18.0 kgf-m, 130.2 ft-lb)
B2M2584
C: INSPECTION
H2M2393A 1) Make sure the V-belt is not worn or otherwise
5) Confirm that the tightening angle of crankshaft damaged.
pulley bolt is 65 degrees or more. If not, conduct the 2) Check the tension of the belt. <Ref. to ME-45,
following procedures (1) through (4). INSPECTION, V-belt.>
(1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
cardiagn.com
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 65 degrees and 75
degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of crankshaft pulley bolt
referring to the gauge indicated on belt cover.
6) Install the A/C belt tensioner.
B2M2585
ME-47
BELT COVER
MECHANICAL
14.Belt Cover
A: REMOVAL
V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME-46,
REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover (LH).
4) Remove the front belt cover.
B2M2587B
(A) Belt cover (LH)
cardiagn.com
(B) Front belt cover
B: INSTALLATION
1) Install the front belt cover.
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2587B
(A) Belt cover (LH)

(B) Front belt cover
3) Install the crankshaft pulley. <Ref. to ME-46, IN-

STALLATION, Crankshaft Pulley.>
4) Install the V-belt. <Ref. to ME-44, INSTALLA-
TION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.
ME-48
TIMING BELT ASSEMBLY
MECHANICAL
15.Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
V-belt.>
3) Remove the belt cover. <Ref. to ME-48, RE-
MOVAL, Belt Cover.>
4) Remove the timing belt guide. (MT vehicle only)
cardiagn.com
EN0621
S2M0294
(2) Using white paint, put alignment and/or ar-
5) If the alignment mark (a) and/or arrow mark row marks on the timing belts in relation to crank
(which indicates rotation direction) on timing belt sprocket and cam sprockets.
fade away, put new marks before removing the tim-
ing belt as shown in procedures below.
(1) Turn the crankshaft using ST. Align the
mark (a) of sprocket to cylinder block notch (b)
and ensure the right side cam sprocket mark (c),
cam cap and cylinder head matching surface (d)
and/or left side cam sprocket mark (e) and belt
cover notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET
B2M2591
Specified data:
Z1: 46.8 tooth length
Z2: 43.7 tooth length
Z1 Z2
B2M2590A
B2M4789A
6) Remove the belt idler (No. 2).
ME-49
MECHANICAL
7) Remove the belt idler No. 2. B: INSTALLATION

1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly;
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
S2M1008 • Push the adjuster rod vertically.
• Be sure to slowly move the adjuster rod down
8) Remove the timing belt. applying a pressure of 294 N (30 kgf, 66 lb).
• Press-in the push adjuster rod gradually tak-
ing more than 3 minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of cylinder. Do not press the adjuster rod
into the cylinder. Doing so may damage the cyl-
inder.
cardiagn.com
• Do not release the press pressure until stop-
per pin is completely inserted.
B2M2594
(1) Attach the automatic belt tension adjuster
2. BELT IDLER AND AUTOMATIC BELT assembly to the vertical pressing tool.
TENSION ADJUSTER ASSEMBLY (2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
1) Remove the belt idler (No. 1). er rod is aligned with the stopper pin hole in the
cylinder.
B2M2596
2) Remove the automatic belt tension adjuster as- H2M2382

sembly. (3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod.
H2M2375
H2M2383A
ME-50
MECHANICAL
2) Install the automatic belt tension adjuster as- 2. TIMING BELT

sembly.
1) Preparation for the installation of automatic belt
Tightening torque: tension adjuster assembly. <Ref. to ME-50, AUTO-
25 N·m (2.5 kgf-m, 18.1 ft-lb) MATIC BELT TENSION ADJUSTER ASSEMBLY
AND BELT IDLER, INSTALLATION, Timing Belt
Assembly.>
2) Installation of timing belt
(1) Turn the camshaft sprocket No. 2 using
ST1, and then turn the camshaft sprocket No. 1
using ST2 so that their alignment marks (A)
come to top positions.
ST1 18231AA010 CAMSHAFT SPROCKET
WRENCH
NOTE:
H2M2384 Also the CAMSHAFT SPROCKET WRENCH
3) Install the belt idler (No. 1). (499207100) can be used.
ST2 499207400 CAMSHAFT SPROCKET
Tightening torque: WRENCH
39 N·m (4.0 kgf-m, 28.9 ft-lb)
cardiagn.com
B2M2602B
B2M2596
(2) While aligning alignment mark on the timing
belt (B) with marks on sprockets (A), position the
timing belt properly.
CAUTION:
Ensure belt's rotating direction is correct.
S2M2312A
3) Install the belt idler No. 2.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
ME-51
MECHANICAL
4) Install the belt idler (No. 2). (2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
Tightening torque:
ness gauge.
39 N·m (4.0 kgf-m, 28.9 ft-lb)
Clearance:
1.0±0.5 mm (0.039±0.020 in)
S2M1008
5) After ensuring that the marks on timing belt and S2M0297

camshaft sprockets are aligned, remove the stop-
per pin from belt tension adjuster. (3) Tighten the remaining bolts.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
cardiagn.com
H2M2387
6) Install the timing belt guide. (MT vehicles only)

(1) Temporarily tighten the remaining bolts. H2M2415
7) Install the belt cover. <Ref. to ME-48, INSTAL-

LATION, Belt Cover.>
8) Install the crankshaft pulley. <Ref. to ME-46,
TION, V-belt.>
S2M0294
ME-52
MECHANICAL
C: INSPECTION CAUTION:
• Always use a vertical type pressing tool to
1. TIMING BELT move the adjuster rod down.
1) Check the timing belt teeth for breaks, cracks, • Do not use a lateral type vise.
and wear. If any fault is found, replace belt. • Push the adjuster rod vertically.
2) Check the condition of back side of belt; if any • Press-in the push adjuster rod gradually tak-
crack is found, replace the belt. ing more than 3 minutes.
CAUTION: • Do not allow press pressure to exceed 9,807
• Be careful not to let oil, grease or coolant N (1,000 kgf, 2,205 lb).
contact the belt. Remove quickly and thorough- • Press the adjuster rod as far as the end sur-
ly if this happens. face of the cylinder. Do not press the adjuster
• Do not bend the belt sharply. rod into the cylinder. Doing so may damage the
cylinder.
Bending radius: h 4) Measure the extension of rod beyond the body.
60 mm (2.36 in) or more If it is not within specifications, replace with a new
one.
Rod extension: H
5.7±0.5 mm (0.224±0.020 in)
cardiagn.com
G2M0115
2. AUTOMATIC BELT TENSION ADJUST-

ER
H2M2381A
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary, re- 3. BELT TENSION PULLEY
place faulty parts.
1) Check the mating surfaces of timing belt and
CAUTION: contact point of adjuster rod for abnormal wear or
Slight traces of oil at rod's oil seal does not in- scratches. Replace the automatic belt tension ad-
dicate a problem. juster assembly if faulty.
2) Check that the adjuster rod does not move when 2) Check the tension pulley for smooth rotation.
a pressure of 294 N (30 kgf, 66 lb) is applied to it. Replace if noise or excessive play is noted.
This is to check adjuster rod stiffness. 3) Check the tension pulley for grease leakage.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using 4. BELT IDLER
the following procedures: 1) Check the belt idler for smooth rotation. Replace
(1) Slowly press the adjuster rod down to the if noise or excessive play is noted.
end surface of the cylinder. Repeat this motion 2 2) Check the belt outer contacting surfaces of idler
or 3 times. pulley for abnormal wear and scratches.
(2) With the adjuster rod moved all the way up, 3) Check the belt idler for grease leakage.
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
ME-53
CAMSHAFT SPROCKET
MECHANICAL
16.Camshaft Sprocket B: INSTALLATION

1) Install the camshaft sprocket No. 1. To lock the
A: REMOVAL camshaft, use ST.
1. REMOVAL ST 499207400 CAMSHAFT SPROCKET
WRENCH
V-belt.> Tightening torque:
2) Remove the crankshaft pulley. <Ref. to ME-46, 78 N·m (8.0 kgf-m, 57.9 ft-lb)
REMOVAL, Crankshaft Pulley.> CAUTION:
3) Remove the belt cover. <Ref. to ME-48, RE- Do not confuse the right and left side camshaft
MOVAL, Belt Cover.> sprockets during installation. The camshaft
4) Remove the timing belt assembly. <Ref. to ME- sprocket No. 2 is identified by a projection used
49, REMOVAL, Timing Belt Assembly.> to monitor camshaft position sensor.
5) Remove the camshaft position sensor. <Ref. to
FU-33, REMOVAL, Camshaft Position Sensor.> or
<Ref. to FU(w/oOBD)-32, REMOVAL, Camshaft
Position Sensor.>
6) Remove the camshaft sprocket No. 2. To lock
the camshaft, use ST.
ST 18231AA010 CAMSHAFT SPROCKET
WRENCH
cardiagn.com
NOTE:
Also the CAMSHAFT SPROCKET WRENCH
(499207100) can be used. B2M2599A
2) Install the camshaft sprocket No. 2. To lock cam-

shaft, use ST.
WRENCH
NOTE:
(499207100) can be used.
Tightening torque:
78 N·m (8.0 kgf-m, 57.9 ft-lb)
H2M2377A
7) Remove the camshaft sprocket No. 1. To lock

the camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
H2M2377A
3) Install the camshaft position sensor. <Ref. to

FU-33, INSTALLATION, Camshaft Position Sen-
sor.> or <Ref. to FU(w/oOBD)-32, INSTALLATION,
Camshaft Position Sensor.>
B2M2599A 4) Install the timing belt assembly. <Ref. to ME-50,
INSTALLATION, Timing Belt Assembly.>
ME-54
CAMSHAFT SPROCKET
MECHANICAL

TION, V-belt.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the camshaft sprocket notch for sensor
for damage and contamination of foreign matter.
cardiagn.com
ME-55
CRANKSHAFT SPROCKET
MECHANICAL
17.Crankshaft Sprocket B: INSTALLATION

1) Install the crankshaft sprocket.
A: REMOVAL
V-belt.>
MOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to ME-
49, REMOVAL, Timing Belt Assembly.>
5) Remove the camshaft sprocket. <Ref. to ME-54,
REMOVAL, Camshaft Sprocket.> S2M0414
6) Remove the crankshaft sprocket.
2) Install the camshaft sprocket. <Ref. to ME-54,
INSTALLATION, Camshaft Sprocket.>
3) Install the timing belt assembly. <Ref. to ME-50,
cardiagn.com
TION, V-belt.>
S2M0414 C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch for sensor
for damage and contamination of foreign matter.
ME-56
VALVE ROCKER ASSEMBLY
MECHANICAL
18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified
torque.
A: REMOVAL
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
V-belt.>
MOVAL, Belt Cover.>
REMOVAL, Camshaft Sprocket.>
6) Disconnect the PCV hose and remove rocker
cover.
B2M2605A
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alpha- 2) Adjust the valve clearances. <Ref. to ME-32,
betical sequence. ADJUSTMENT, Valve Clearance.>
CAUTION: 3) Install the rocker cover and connect PCV hose.
Leave two or three threads of bolts (g and h) en- 4) Install the camshaft sprocket. <Ref. to ME-54,
gaged to retain the valve rocker assembly. INSTALLATION, Camshaft Sprocket.>
cardiagn.com
TION, V-belt.>
C: DISASSEMBLY
1) Remove the bolts which secure rocker shaft.
B2M2605F 2) Extract the rocker shaft. Remove the valve rock-
(2) Remove the valve rocker assembly. er arms, springs and shaft supports from rocker
shaft.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove the nut and adjuster screw from valve
rocker.
D: ASSEMBLY
1) Install the adjuster screw and nut to valve rocker.
2) Arrange the valve rocker arms, springs and shaft
B2M2606 supports in assembly order and insert valve rocker
shaft.
B: INSTALLATION
1) Installation of valve rocker assembly Tightening torque (Shaft supports installing
(1) Temporarily tighten the bolts (a) through (d) bolts):
equally as shown in the figure. 5 N·m (0.5 kgf-m, 3.6 ft-lb)
CAUTION: CAUTION:
Do not allow the valve rocker assembly to Valve rocker arms, rocker shaft and shaft sup-
gouge knock pins. ports have identification marks. Ensure the
parts with same markings are properly assem-
(2) Tighten the bolts (e) through (h) to specified bled.
torque.
3) Install the valve rocker shaft securing bolts.
ME-57
VALVE ROCKER ASSEMBLY
MECHANICAL
E: INSPECTION 4) If oil clearance exceeds the limit, replace the

rocker shaft support or shaft, whichever shows
1. VALVE ROCKER ARM greater amount of wear.
1) Measure the inside diameter of valve rocker arm Rocker shaft support inside diameter:
and outside diameter of valve rocker shaft, and de- 22.005 — 22.026 mm (0.8663 — 0.8672 in)
termine the difference between the two (= oil clear-
ance). Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
Clearance between arm and shaft:
5) If cam or valve contact surface of valve rocker
Standard
arm is worn or dented excessively, replace the
0.020 — 0.054 mm (0.0008 — 0.0021 in) valve rocker arm.
Limit 6) Check that the valve rocker arm roller rotates
0.10 mm (0.0039 in) smoothly. If not, replace the valve rocker arm.
2. INTAKE AND EXHAUST VALVE ROCK-
ER SHAFT
Visually check the oil relief valve of shaft end for
any of the following abnormalities.
• Breaks in check ball body
• Foreign particles caught in valve spring
• Oil leakage at check ball
cardiagn.com
CAUTION:
B2M0072 Repair or replace the valve rocker shaft as nec-
essary.
B2M0073
2) If oil clearance exceeds the limit, replace the

valve rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) Measure the inside diameter of rocker shaft sup-
port and outside diameter of valve rocker shaft, and
determine the difference between the two (= oil
clearance).
Clearance between support and shaft:
Standard
0.005 — 0.039 mm (0.0002 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
ME-58
CAMSHAFT
MECHANICAL
19.Camshaft (1) Remove the bolts (a) through (b) in alpha-

betical sequence.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME-44, INSTALLA-
TION, V-belt.>
MOVAL, Belt Cover.>
REMOVAL, Camshaft Sprocket.> B2M2612B
6) Remove the crankshaft sprocket. <Ref. to ME- (2) Equally loosen the bolts (c) through (j) all the
56, REMOVAL, Crankshaft Sprocket.> way in alphabetical sequence.
7) Remove the belt cover No. 2 (LH).
8) Remove the belt cover No. 2 (RH).
CAUTION:
Do not damage or lose the seal rubber when re-
moving belt covers.
cardiagn.com
B2M2612C
(3) Remove the bolts (k) through (p) in alpha-

betical sequence using ST.
ST 499497000 TORX PLUS
B2M2601
9) Remove the tensioner bracket.
B2M2612D
(4) Remove the camshaft cap.

H2M2380
10) Remove the camshaft position sensor support.

(LH side only)
11) Remove the oil level gauge guide. (LH side
only)
12) Remove the valve rocker assembly. <Ref. to
ME-57, REMOVAL, Valve Rocker Assembly.>
13) Remove the camshaft cap.
B2M2613
14) Remove the camshaft.

15) Remove the oil seal.
ME-59
CAMSHAFT
MECHANICAL
16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly.
CAUTION:
• Do not remove the oil seal unless necessary.
• Do not scratch the journal surface when re-
moving oil seal.
B: INSTALLATION
1) Apply a coat of engine oil to the camshaft jour-
nals, and then install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket on the around of cam-
shaft cap. B2M2615
Liquid gasket: (4) Tighten the bolts (a) through (h) in alphabet-
THREE BOND 1280B ical sequence.
P/N K0877YA018 Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
cardiagn.com
B2M2619
NOTE: B2M2621B
Apply a coat of 3 mm (0.12 in) dia (A). liquid gasket (5) Tighten the TORX bolts (i) through (n) in al-
along edge (B) of the camshaft cap (C) mating sur- phabetical sequence using ST.
face. ST 499497000 TORX PLUS
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M1199B
(2) Temporarily tighten the bolts (g) through (j)

in alphabetical sequence. B2M2621C
B2M2612E
ME-60
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)
Tightening torque: 8) Install the camshaft position sensor support. (LH
side only)
10 N·m (1.0 kgf-m, 7.2 ft-lb)
9) Install the tensioner bracket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2621D
(7) Tighten the bolts (w) through (x) in alphabet-

ical sequence.
H2M2380
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb) 10) Install the belt cover No. 2 (RH).
Tightening torque:
cardiagn.com
5 N·m (0.5 kgf-m, 3.6 ft-lb)
11) Install the belt cover No. 2 (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips, and then

install the oil seal (A) on camshaft using ST1 and
ST2.
NOTE:
Use a new oil seal. B2M2601
ST1 499597000 OIL SEAL GUIDE 12) Install the crankshaft sprocket. <Ref. to ME-56,
ST2 499587500 OIL SEAL INSTALLER INSTALLATION, Crankshaft Sprocket.>
14) Install the timing belt assembly. <Ref. to ME-
50, INSTALLATION, Timing Belt Assembly.>
INSTALLATION, Crankshaft Pulley.>
TION, V-belt.>
S2M1864A
4) Install the plug using ST.

ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Adjust the valve clearance. <Ref. to ME-32, AD-
JUSTMENT, Valve Clearance.>
ME-61
CAMSHAFT
MECHANICAL
C: INSPECTION Model Item Unit: mm (in)

39.485 — 39.585
1. CAMSHAFT Intake
STD
(1.5545 — 1.5585)
1) Measure the bend, and repair or replace if nec- Limit 39.385 (1.5506)
2500 cc
essary. 39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit:
Limit 39.157 (1.5416)
0.025 mm (0.0010 in)
Cam base circle diameter A:
IN: 34.00 mm (1.3386 in)
EX: 34.00 mm (1.3386 in)
B2M2617
2) Check the journal for damage and wear. Re-

place if faulty.
B2M1209A
cardiagn.com
3) Measure the outside diameter of camshaft jour-
nal and inside diameter of cylinder head journal, 2. CAMSHAFT SUPPORT
and determine the difference between two (= oil
clearance). If the oil clearance exceeds specifica- Measure the thrust clearance of camshaft with dial
tions, replace the camshaft or cylinder head as gauge. If the clearance exceeds the limit, replace
necessary. the camshaft support.
Unit: mm (in) Standard:

Clear- Standard 0.055 — 0.090 (0.0022 — 0.0035)
0.030 — 0.090 mm (0.0012 — 0.0035 in)
ance at Limit:
journal Limit 0.10 (0.0039)
0.10 mm (0.0039 in)
31.928 — 31.945 (1.2570 —
Camshaft journal O.D.
1.2577)
32.000 — 32.018 (1.2598 —
Journal hole I.D.
1.2605)
4) Check the cam face condition; remove the minor

faults by grinding with oil stone. Measure the cam
height H; replace if the limit has been exceeded.
Cam height: H
Model Item Unit: mm (in)
B2M2618
39.378 — 39.478
STD
Intake (1.5503 — 1.5542)
Limit 39.278 (1.5464)
1600 cc
39.565 — 39.665
STD
Exhaust (1.5577 — 1.5616)
Limit 39.465 (1.5537)
38.732 — 38.832
STD
Intake (1.5249 — 1.528885)
Limit 39.632 (1.5209)
2000 cc
39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit 39.157 (1.5416)
ME-62
CYLINDER HEAD ASSEMBLY
MECHANICAL
20.Cylinder Head Assembly 13) Remove the cylinder head gasket.

CAUTION:
A: REMOVAL Do not scratch the mating surface of cylinder
1) Remove the V-belt. <Ref. to ME-44, REMOVAL, head and cylinder block.
V-belt.>
14) Similarly, remove the right side cylinder head.
REMOVAL, Crankshaft Pulley.> B: INSTALLATION
3) Remove the belt cover. <Ref. to ME-48, RE- 1) Install the cylinder head and gaskets on cylinder
MOVAL, Belt Cover.> block.
4) Remove the timing belt assembly. <Ref. to ME- CAUTION:
49, REMOVAL, Timing Belt Assembly.> • Use new cylinder head gaskets.
5) Remove the camshaft sprocket. <Ref. to ME-54, • Be careful not to scratch the mating surface
REMOVAL, Camshaft Sprocket.> of cylinder block and cylinder head.
6) Remove the intake manifold. <Ref. to FU-17,
REMOVAL, Intake Manifold.> or <Ref. to FU(w/ 2) Tighten the cylinder head bolts.
oOBD)-17, REMOVAL, Intake Manifold.> (1) Apply a coat of engine oil to the washers and
7) Remove the bolt which installs A/C compressor bolt threads.
bracket on cylinder head. (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
8) Remove the valve rocker assembly. <Ref. to lb) in alphabetical sequence.
ME-57, REMOVAL, Valve Rocker Assembly.> Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
9) Remove the camshaft. <Ref. to ME-59, RE- lb) in alphabetical sequence.
MOVAL, Camshaft.> (3) Back off all bolts by 180° first; back them off
cardiagn.com
10) Remove the cylinder head bolts in alphabetical by 180° again.
sequence shown in the figure. (4) Tighten the bolts (a) and (b) to 34 N·m (3.5
kgf-m, 25 ft-lb).
CAUTION: (5) Tighten the bolts (c), (d), (e) and (f) to 15
Leave the bolts (a) and (c) engaged by three or N·m (1.5 kgf-m, 11 ft-lb).
four threads to prevent cylinder head from fall- (6) Tighten all bolts by 80 to 90° in alphabetical
ing. sequence.
CAUTION:
Do not tighten bolts more than 90°°.
(7) Further tighten all bolts by 80 to 90° in al-
phabetical sequence shown in figure below.
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°°.
S2M1589A
11) While tapping the cylinder head with a plastic

hammer, separate it from cylinder block.
12) Remove the bolts (a) and (b) to remove cylin-
der head.
S2M1589B
3) Install the camshaft. <Ref. to ME-60, INSTALLA-

TION, Camshaft.>
4) Install the valve rocker assembly. <Ref. to ME-
57, INSTALLATION, Valve Rocker Assembly.>
5) Install the A/C compressor bracket on cylinder
head.
S2M1589A
ME-63
MECHANICAL
6) Install the intake manifold. <Ref. to FU-19, IN-

STALLATION, Intake Manifold.> or <Ref. to FU(w/
oOBD)-20, INSTALLATION, Intake Manifold.>
TION, V-belt.>
C: DISASSEMBLY
1) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring, and then remove the valve spring retainer
key. Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
cardiagn.com
• Mark each valve to prevent confusion.
• Use extreme care not to damage the lips of in-
take valve oil seals and exhaust valve oil seals.
B2M2630A
ME-64
MECHANICAL
D: ASSEMBLY
cardiagn.com
B2M2629B
(1) Valve (6) Retainer (11) Plug

(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve spring (10) Oil seal
1) Installation of valve spring and valve (4) Set the ST on valve spring.
(1) Place the cylinder head on ST. ST 499718000 VALVE SPRING REMOVER
(2) Coat the stem of each valve with engine oil
and insert valve into valve guide.
CAUTION:
When inserting the valve into valve guide, use
special care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder B2M2630A
head.
ME-65
MECHANICAL
(5) Compress the valve spring, and then fit the 2. INTAKE AND EXHAUST VALVE OIL
valve spring retainer key. SEAL
Replace the oil seal with new one, if lip is damaged
or spring out of place, or when the surfaces of in-
take valve and valve seat are reconditioned or in-
take valve guide is replaced. Use pliers to pinch
and remove oil seal from valve.
1) Place the cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
CAUTION:
B2M2634B • Apply engine oil to oil seal before press-fit-
ting.
(A) Retainer • When press-fitting oil seal, do not use ham-
(B) Painted face mer or strike in.
• Differentiate between intake valve oil seal
(6) After installing, tap the valve spring retainers and exhaust valve oil seal by noting their differ-
lightly with wooden hammer for better seating. ence in color.
E: INSPECTION ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
1. VALVE SPRING
cardiagn.com
Color of rubber part:
1) Check the valve springs for damage, free length, Intake [Black]
and tension. Replace the valve spring if it is not to
Exhaust [Brown]
the specifications presented below.
2) To measure the squareness of valve spring, Color of spring part:
stand the spring on a surface plate and measure its Intake [Silver]
deflection at the top using a try square. Exhaust [Silver]
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
214 — 246 N
(21.8 — 25.1 kgf, 48.1 — 55.3 lb)/
Tension/spring 45.0 mm (1.772 in)
height 526 — 582 N
(53.6 — 59.3 kgf, 118.3 — 130.8 lb)/
34.7 mm (1.366 in)
B2M2633A
F: ADJUSTMENT
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect important
areas by means of red lead check.
Also make sure that gasket installing surface
G2M0154 shows no trace of gas and water leaks.
2) Place the cylinder head on ST.
ME-66
MECHANICAL
3) Measure the warping of the cylinder head sur- 2. VALVE SEAT

face that mates with crankcase using a straight
Inspect the intake and exhaust valve seats, and
edge and thickness gauge.
then correct the contact surfaces with valve seat
If the warping exceeds 0.05 mm (0.0020 in), re-
cutter if they are defective or when valve guides are
grind the surface with a surface grinder.
replaced.
Warping limit:
Valve seat width: W
0.05 mm (0.0020 in)
Intake
Grinding limit: Standard 1.0 mm (0.039 in)
0.1 mm (0.004 in) Limit 1.7 mm (0.067 in)
Exhaust
Standard height of cylinder head:
Standard 1.4 mm (0.055 in)
97.5 mm (3.839 in)
Limit 2.1 mm (0.083 in)
CAUTION:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.
cardiagn.com
G2M0149
S2M1817A
(A) Straight edge

(B) Thickness gauge
B2M0074
ME-67
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
stem. The clearance can be checked by measuring ST1 498267800 CYLINDER HEAD TABLE
the outside diameter of valve stem and the inside ST2 499767200 VALVE GUIDE REMOVER
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake 0.035 — 0.062 mm (0.0014 — 0.0024
in)
Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026
in)
Limit G2M0150
0.15 mm (0.0059 in)
(3) Turn the cylinder head upside down and
place ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
cardiagn.com
B2M0387A
B2M0077D
(A) Valve guide
(4) Before installing new oversize valve guide,

make sure that neither scratches nor damages
B2M0076B
exist on the inside surface of valve guide holes
in cylinder head.
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
ME-68
MECHANICAL
(5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST.
oil, in the cylinder, and then insert the ST1 into Gently rotate the reamer clockwise while press-
valve guide. Press in until the valve guide upper ing it lightly into valve guide, and return it also ro-
end is flush with the upper surface of ST2. tating clockwise. After reaming, clean the valve
ST1 499767200 VALVE GUIDE REMOVER guide to remove chips.
Intake side: CAUTION:
ST2 499767700 VALVE GUIDE ADJUSTER • Apply engine oil to the reamer when reaming.
Exhaust side: • If the inner surface of the valve guide is torn,
ST2 499767800 VALVE GUIDE ADJUSTER the edge of the reamer should be slightly
ground with an oil stone.
• If the inner surface of the valve guide be-
comes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
B2M2632A
(6) Check the valve guide protrusion.
cardiagn.com
Valve guide protrusion: L
Intake
20.0 — 20.5 mm (0.787 — 0.807 in) B2M0078
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in) (8) Recheck the contact condition between
valve and valve seat after replacing valve guide.
B2M0077C
(A) Valve guide
ME-69
MECHANICAL
4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and re-
place if damaged, worn, or deformed, or if “H” is
less than the specified limit.
H:
Intake
Limit 0.6 mm (0.024 in)
Exhaust
Limit 0.6 mm (0.024 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
cardiagn.com
G2M0153
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
<Ref. to ME-67, VALVE SEAT, ADJUSTMENT,
Cylinder Head Assembly.> Install a new intake
valve oil seal after lapping.
ME-70
CYLINDER BLOCK
MECHANICAL
21.Cylinder Block 12) Remove the bolts (a) and (b) to remove cylin-
der head.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. <Ref. to FU-17,
REMOVAL, Intake Manifold.> or <Ref. to FU(w/
oOBD)-17, REMOVAL, Intake Manifold.>
V-belt.>
3) Remove the crankshaft pulley. <Ref. to ME-46, B2M2628A
4) Remove the belt cover. <Ref. to ME-48, RE- 13) Remove the cylinder head gasket.
MOVAL, Belt Cover.> CAUTION:
5) Remove the timing belt assembly. <Ref. to ME- Do not scratch the mating surface of cylinder
49, REMOVAL, Timing Belt Assembly.> head and cylinder block.
6) Remove the camshaft sprocket. <Ref. to ME-54, 14) Similarly, remove the right side cylinder head.
REMOVAL, Camshaft Sprocket.> 15) Remove the clutch housing cover (MT vehicles
7) Remove the crankshaft sprocket. <Ref. to ME- only).
46, REMOVAL, Crankshaft Pulley.> 16) Remove the flywheel (MT vehicles only) or
cardiagn.com
8) Remove the generator and A/C compressor with drive plate (AT vehicles only).
their brackets. Using the ST, lock the crankshaft.
9) Remove the rocker cover. ST 498497100 CRANKSHAFT STOPPER
10) Remove the cylinder head bolts in alphabetical • MT MODEL
sequence shown in the figure.
CAUTION:
Leave bolts (a) and (b) engaged by three or four
threads to prevent cylinder head from falling.
S2M1818C
• AT MODEL
B2M2628A
11) While tapping the cylinder head with a plastic

hammer, separate it from cylinder block.
B2M3395C
NOTE:
Use the ST to remove flywheel (MT vehicles only)
for 2500 cc model.
ME-71
CYLINDER BLOCK
MECHANICAL
ST1 498497100 CRANKSHAFT STOPPER 21) Removal of oil pan

ST2 499057000 TORX PLUS (1) Turn the cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance, and then remove
the oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
B2M3347A
17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater.
19) Remove the water pump.
20) Remove the oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in the fig-
ure when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cardiagn.com
S2M1820
cylinder block and oil pump.
22) Remove the oil strainer stay.
23) Remove the oil strainer.
24) Remove the baffle plate.
25) Remove the oil filter using ST.
ST 498547000 OIL FILTER WRENCH
S2M1819
B2M2611A
26) Remove the water pipe.
B2M2638
ME-72
CYLINDER BLOCK
MECHANICAL
cardiagn.com
S2M1590B
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
27) Remove the service hole cover and service 28) Rotate the crankshaft to bring #1 and #2 pis-
hole plugs using hexagon wrench [14 mm (0.55 tons to bottom dead center position, and then re-
in)]. move the piston circlip through service hole of #1
and #2 cylinders.
B2M2620
G2M0165
ME-73
CYLINDER BLOCK
MECHANICAL
29) Draw out the piston pin from #1 and #2 pistons 30) Similarly remove the piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 31) Remove the bolts which connect cylinder block
CAUTION: on the side of #2 and #4 cylinders.
Be careful not to confuse the original combina- 32) Back off the bolts which connect cylinder block
tion of piston, piston pin and cylinder. on the side of #1 and #3 cylinders two or three
turns.
33) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, and then remove the
cylinder block connecting bolts.
34) Separate the cylinder blocks (RH) and (LH).
CAUTION:
When separating the cylinder block, do not al-
low the connecting rod to fall and damage the
cylinder block.
G2M0166
cardiagn.com
B2M2408A
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
35) Remove the rear oil seal. 38) Draw out each piston from cylinder block using
36) Remove the crankshaft together with connect- wooden bar or hammer handle.
ing rod. CAUTION:
37) Remove the crankshaft bearings from cylinder Do not confuse the combination of piston and
block using hammer handle. cylinder.
CAUTION:
Do not confuse the combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.
ME-74
CYLINDER BLOCK
MECHANICAL
B: INSTALLATION
cardiagn.com
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Crankshaft T1: 25 (2.5, 18.1)
(3) Cylinder block T2: 47 (4.8, 34.7)
CAUTION: CAUTION:
Remove oil in the mating surface of bearing and Do not allow fluid packing to jut into O-ring
cylinder block before installation. Also apply a grooves, oil passages, bearing grooves, etc.
coat of engine oil to crankshaft pins.
1) Position the crankshaft on #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
S2M1826A
ME-75
CYLINDER BLOCK
MECHANICAL
3) Temporarily tighten the 10 mm cylinder block 6) Install the rear oil seal using ST1 and ST2.
connecting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
the figure. ST2 499587200 OIL SEAL INSTALLER
B2M0088D S2M1827A
4) Tighten the 10 mm cylinder block connecting

(A) Rear oil seal
bolts in alphabetical sequence.
(B) Fly wheel attaching bolt
Tightening torque:
47 N·m (4.8 kgf-m, 34.7 ft-lb) 7) Position the top ring gap at (A) or (B) in the fig-
ure.
8) Position the second ring gap at 180° on the re-
verse side for top ring gap.
cardiagn.com
• 1600 cc MODEL
B2M0088D
5) Tighten the 8 mm and 6 mm cylinder block con-

necting bolts in alphabetical sequence shown in the
figure. H2M3248
Tightening torque: • 2000 cc MODEL

(A) — (G): 25 N·m (2.5 kgf-m, 18.1 ft-lb)
180˚
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B0SH
B2M4617A
B2M0089F
ME-76
CYLINDER BLOCK
MECHANICAL
• 2500 cc MODEL 10) Position the lower rail gap at (D) in the figure.
• 1600 cc MODEL
180˚
(D)
B5SH
B2M4618A
EN1379
9) Position the expander gap at (C) in the figure.
• 1600 cc MODEL • 2000 cc MODEL
25˚
B0SH
cardiagn.com
(C) EN1378 B2M4621A
• 2000 cc MODEL • 2500 cc MODEL
25˚
B0SH
B5SH
B2M4619A B2M4622A
• 2500 cc MODEL NOTE:

Align the lower rail stopper (F) to the lateral hole (E)
on the piston.
B5SH
B2M4620A
B2M4601A
ME-77
CYLINDER BLOCK
MECHANICAL
11) Position the upper rail gap at (G) in the figure. 12) Install circlip.
• 1600 cc MODEL Install circlips in the piston holes located opposite
service holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
(G) NOTE:
Use new circlips.
EN1380
• 2000 cc MODEL
B2M1403A
30˚ CAUTION:
Piston front mark faces towards the front of the
engine.
B0SH
cardiagn.com
• 1600 cc MODEL
B2M4623A
• 2500 cc MODEL
30˚
EN1497
B5SH • 2000 cc MODEL
B2M4624A
CAUTION:
• Ensure ring gaps do not face the same direc-
tion.
B0SH
• Ensure ring gaps are not within the piston
skirt area.
B2M4625A
ME-78
CYLINDER BLOCK
MECHANICAL
• 2500 cc MODEL
B5SH
B2M4626A
(A) Front mark
cardiagn.com
B2M1322J
(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug T: 69 (7.0, 50.6)
(3) Circlip
13) Installing piston ST2 498747300 PISTON GUIDE (2500 cc
(1) Turn the cylinder block so that #1 and #2 cyl- model)
inders face upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cyl-
inders, and then insert the pistons in their cylin-
ders using ST2.
ST2 498747000 PISTON GUIDE (1600 cc
model)
ST2 398744300 PISTON GUIDE (2000 cc S2M0306A
model)
ME-79
CYLINDER BLOCK
MECHANICAL
14) Installing piston pin (5) Install the service hole plug and gasket.
(1) Insert the ST3 into service hole to align pis- NOTE:
ton pin hole with connecting rod small end. Use a new gasket.
CAUTION:
Apply a coat of engine oil to the ST3 before in-
sertion.
ST3 499017100 PISTON PIN GUIDE
B2M2620
G2M0189
(2) Apply a coat of engine oil to the piston pin,

and then insert the piston pin into piston and
connecting rod through service hole.
cardiagn.com
(3) Install the circlip.
NOTE:
Use new circlips.
S2M1828
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
B2M2625
ME-80
CYLINDER BLOCK
MECHANICAL
cardiagn.com
B2M1323K
(1) Piston (5) Service hole plug Tightening torque: N·m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring T2: 69 (7.0, 50.6)
(4) Gasket
(6) Turn the cylinder block so that #3 and #4 cyl- 19) Apply fluid packing to the matching surfaces,
inders face upward. Using the same procedures then and install the oil pan.
as used for #1 and #2 cylinders, install the pis-
Fluid packing:
tons and piston pins.
15) Install the water pipe.
S2M1833A
B2M2638
16) Install the baffle plate.

Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install the oil strainer stay.
ME-81
CYLINDER BLOCK
MECHANICAL
20) Apply fluid packing to the matching surfaces, ST1 498497100 CRANKSHAFT STOPPER
and then install the oil separator cover. ST2 499057000 TORX PLUS
Fluid packing:
B2M3347A
22) Install the housing cover.

S2M1834A 23) Installation of oil pump
(1) Discard the front oil seal after removal. Re-
21) Install the flywheel or drive plate. place with a new one using the ST.
To lock the crankshaft, use ST. ST 499587100 OIL SEAL INSTALLER
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N·m (7.3 kgf-m, 52.8 ft-lb)
cardiagn.com
S2M0235
(2) Apply fluid packing to the matching surface

of oil pump.
B2M3361A
Fluid packing:
B2M3393A
NOTE: S2M0739A
Use the ST to remove flywheel (MT vehicles only)

for 2500 cc model. (A) O-ring
(3) Apply a coat of engine oil to the inside of oil

seal.
ME-82
CYLINDER BLOCK
MECHANICAL
26) Install the oil filter using ST.

S2M0118B
(4) Install the oil pump on cylinder block. Be

B2M2611A
careful not to damage the oil seal during instal-
lation. 27) Tighten the cylinder head bolts.
Tightening torque: (1) Apply a coat of engine oil to the washers and
6.4 N·m (0.65 kgf-m, 4.7 ft-lb) bolt threads.
(2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
CAUTION: lb) in alphabetical sequence.
• Do not forget to the install the O-ring and seal Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
when installing oil pump. lb) in alphabetical sequence.
• Align flat surface of oil pump's inner rotor (3) Back off all bolts by 180° first; back them off
cardiagn.com
with crankshaft before installation. by 180° again.
24) Install the water pump and gasket. (4) Tighten the bolts (a) and (b) to 34 N·m (3.5
Tightening torque: kgf-m, 25 ft-lb).
First; 12 N·m (1.2 kgf-m, 8.7 ft-lb) (5) Tighten the bolts (c), (d), (e) and (f) to 15
Second; 12 N·m (1.2 kgf-m, 8.7 ft-lb) N·m (1.5 kgf-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90° in alphabetical
CAUTION: sequence.
• Be sure to use a new gasket.
• When installing the water pump, tighten the CAUTION:
bolts in two stages in alphabetical sequence as Do not tighten bolts more than 90°°.
shown in the figure. (7) Further tighten all bolts by 80 to 90° in al-
phabetical sequence.
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°°.
H2M1568B
25) Install the water by-pass pipe for heater.
B2M2628B
28) Install the oil level gauge guide, and then tight-
en the attaching bolt (left side only).
29) Install the rocker cover.
30) Install the crankshaft sprocket. <Ref. to ME-56,
INSTALLATION, Crankshaft Sprocket.>
ME-83
CYLINDER BLOCK
MECHANICAL
32) Install the timing belt assembly. <Ref. to ME-

50, INSTALLATION, Timing Belt Assembly.>
35) Install the generator and A/C compressor
brackets on cylinder head.
TION, V-belt.>
37) Install the intake manifold. <Ref. to FU-19, IN-
STALLATION, Intake Manifold.> or <Ref. to FU(w/
oOBD)-20, INSTALLATION, Intake Manifold.>
cardiagn.com
ME-84
CYLINDER BLOCK
MECHANICAL
C: DISASSEMBLY
B2M1320I
cardiagn.com
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
CAUTION:
Arrange the removed connecting rod, connect-
ing rod cap and bearing in order to prevent con-
fusion.
3) Remove the piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good order
to prevent confusion.
5) Remove the circlip.
ME-85
CYLINDER BLOCK
MECHANICAL
D: ASSEMBLY
B2M1320J
cardiagn.com
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install the connecting rod bearings on connect- E: INSPECTION
ing rods and connecting rod caps.
1. CYLINDER BLOCK
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage. Especial-
bearings. ly, inspect the important parts by means of red lead
2) Install the connecting rod on crankshaft. check.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect the crankcase surface that mates with
Position each connecting rod with the side cylinder head for warping by using a straight edge,
marked facing forward. and correct by grinding if necessary.
3) Install the connecting rod cap with connecting
rod nut. Warping limit:
Ensure the arrow on connecting rod cap faces the 0.05 mm (0.0020 in)
front during installation. Grinding limit:
CAUTION: 0.1 mm (0.004 in)
• Each connecting rod has its own mating cap. Standard height of cylinder block:
Make sure that they are assembled correctly by 201.0 mm (7.91 in)
checking their matching number.
• When tightening the connecting rod nuts, ap- 2. CYLINDER AND PISTON
ply oil on the threads. 1) The cylinder bore size is stamped on cylinder
4) Install the expander, lower rail and upper rail in block's front upper surface.
this order by hand. Then install the second ring and
CAUTION:
top ring with a piston ring expander.
Measurement should be performed at a temper-
ature 20°°C (68°°F).
NOTE:
Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as a guide line in selecting a standard piston.
ME-86
CYLINDER BLOCK
MECHANICAL
Standard diameter: 2) How to measure the inner diameter of each cyl-

1600 cc MODEL inder
A: 87.905 — 87.915 mm (3.4608 — 3.4612 Measure the inner diameter of each cylinder in both
in) the thrust and piston pin directions at the heights
B: 87.895 — 87.905 mm (3.4604 — 3.4608 shown in the figure, using a cylinder bore gauge.
in) CAUTION:
2000 cc MODEL Measurement should be performed at a temper-
A: 92.005 — 92.015 mm (3.6222 — 3.6226 ature 20°°C (68°°F).
in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 Taper:
in) Standard
2500 cc MODEL 0.015 mm (0.0006 in)
A: 99.505 — 99.515 mm (3.9175 — 3.9179 Limit
in) 0.050 mm (0.0020 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175 Out-of-roundness:
in) Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
cardiagn.com
H2M1732C
(A) Main journal size mark

(B) Cylinder block RH-LH combination mark
S2M1821A
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark (A) Piston pin direction
(E) #3 cylinder bore size mark (B) Thrust direction
(F) #4 cylinder bore size mark
3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
ME-87
CYLINDER BLOCK
MECHANICAL
4) How to measure the outer diameter of each pis-

ton
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
CAUTION:
Measurement should be performed at a temper-
ature of 20°°C (68°°F).
Piston grade point H:
1600 cc and 2000 cc MODEL
40.0 mm (1.575 in) B2M1305A
2500 cc MODEL
5) Calculate the clearance between cylinder and
37.0 mm (1.457 in) piston.
Piston outer diameter: CAUTION:
1600 cc MODEL Measurement should be performed at a temper-
Standard ature of 20°°C (68°°F).
A: 87.885 — 87.895 mm
(3.4600 — 3.4604 in) Cylinder to piston clearance at 20°C (68°F):
B: 87.875 — 87.885 mm Standard
(3.4596 — 3.4699 in) 0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.25 mm (0.0098 in) oversize Limit
cardiagn.com
88.125 — 88.135 mm 0.050 mm (0.0020 in)
(3.4695 — 3.4699 in) 6) Boring and honing
0.50 mm (0.0197 in) oversize (1) If the value of taper, out-of-roundness, or
88.375 — 88.385 mm cylinder-to-piston clearance measured exceeds
(3.4793 — 3.4797 in) the specified limit or if there is any damage on
2000 cc MODEL the cylinder wall, rebore it to use an oversize pis-
Standard ton.
A: 91.985 — 91.995 mm CAUTION:
(3.6214 — 3.6218 in) When any of the cylinders needs reboring, all
B: 91.975 — 91.985 mm other cylinders must be bored at the same time,
(3.6211 — 3.6214 in) and use oversize pistons. Do not perform bor-
0.25 mm (0.0098 in) oversize ing on one cylinder only, nor use an oversize
92.225 — 92.235 mm piston for one cylinder only.
(3.6309 — 3.6313 in) (2) If the cylinder inner diameter exceeds the
0.50 mm (0.0197 in) oversize limit after boring and honing, replace the crank-
92.475 — 92.485 mm case.
(3.6407 — 3.6411 in) CAUTION:
2500 cc MODEL Immediately after reboring, the cylinder diame-
Standard ter may differ from its real diameter due to tem-
A: 99.485 — 99.495 mm perature rise. Thus, pay attention to this when
(3.9167 — 3.9171 in) measuring the cylinder diameter.
B: 99.475 — 99.485 mm
Limit of cylinder enlarging (boring):
(3.9163 — 3.9167 in)
0.5 mm (0.020 in)
0.25 mm (0.0098 in) oversize
99.725 — 99.735 mm
(3.9262 — 3.9266 in)
0.50 mm (0.0197 in) oversize
99.975 — 99.985 mm
(3.9360 — 3.9364 in)
ME-88
CYLINDER BLOCK
MECHANICAL
3. PISTON AND PISTON PIN 5) Check the piston pin circlip for distortion, cracks
and wear.
1) Check the pistons and piston pins for damage,
cracks, and wear and the piston ring grooves for 4. PISTON RING
wear and damage. Replace if defective.
1) If the piston ring is broken, damaged, or worn, or
2) Measure the piston-to-cylinder clearance at
if its tension is insufficient, or when the piston is re-
each cylinder. <Ref. to ME-86, CYLINDER AND
placed, replace the piston ring with a new one of
PISTON, INSPECTION, Cylinder Block.> If any of
the same size as the piston.
the clearances is not to specification, replace the
piston or bore the cylinder to use an oversize pis- CAUTION:
ton. • Marks are shown on the end of top and sec-
3) Make the sure that piston pin can be inserted ond rings. When installing the rings to piston,
into piston pin hole with a thumb at 20°C (68°F). face these marks upward.
Replace if defective. • Oil ring is composed of upper rail, expander
and lower rail. Be careful of the rail direction
Standard clearance between piston pin and when installing oil ring to the pisiton.
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)
cardiagn.com
B2M1401
B2M4595A
(A) Upper rail

(B) Expander
(C) Lower rail
B2M0084
4) Check the circlip installation groove on piston for

burr (A). If necessary, remove the burr from groove
so that piston pin can lightly move.
B2M0420C
ME-89
CYLINDER BLOCK
MECHANICAL
2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD
inder, and then measure the piston ring gap with a
1) Replace the connecting rod, if the large or small
thickness gauge.
end thrust surface is damaged.
Unit: mm (in) 2) Check for bend or twist using a connecting rod
Standard Limit aligner. Replace the connecting rod if the bend or
0.20 — 0.35 twist exceeds the limit.
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Limit of bend or twist per 100 mm (3.94 in) in
Piston Second 0.35 — 0.50 length:
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
0.10 mm (0.0039 in)
Oil ring 0.20 — 0.50
1.5 (0.059)
rail (0.0079 — 0.0197)
cardiagn.com
S2M1823
3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the pis-
ton ring groove and piston ring.
Unit: mm (in)
Standard Limit B2M1184B
0.055 — 0.090
Clearance Top ring (0.0022 — 0.15 (0.0059) (A) Thickness gauge
between pis-
0.0035) (B) Connecting rod
ton ring and
piston ring 0.030 — 0.070
Second 3) Install the connecting rod fitted with bearing to
groove (0.0012 — 0.15 (0.0059)
ring crankshaft, and then measure the side clearance
0.0028)
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
B2M1402
EN0335
ME-90
CYLINDER BLOCK
MECHANICAL
4) Inspect the connecting rod bearing for scar, Connecting rod oil clearance:
peeling, seizure, melting, wear, etc.
• 2500 cc MODEL
5) Measure the oil clearance on individual connect-
Standard
ing rod bearings by means of plastigauge. If any oil
0.012 — 0.037 mm (0.0005 — 0.0015 in)
clearance is not within specification, replace the
defective bearing with a new one of standard size Limit
or undersize as necessary. (See the table below.) 0.050 mm (0.0020 in)
Connecting rod oil clearance: Unit: mm (in)

Bearing size
• 1600 cc MODEL Outer diameter of
Bearing (Thickness at cen-
Standard crank pin
ter)
0.010 — 0.038 mm (0.0004 — 0.0015 in) 1.490 — 1.502 51.984 — 52.000
Limit Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.05 mm (0.0020 in) 0.03
1.504 — 1.512 51.954 — 51.970
(0.0012)
Unit: mm (in) (0.0592 — 0.0595) (2.0454 — 2.0461)
undersize
Bearing size 0.05
Outer diameter of 1.514 — 1.522 51.934 — 51.950
Bearing (Thickness at cen- (0.0020)
crank pin (0.0596 — 0.0599) (2.0446 — 2.0453)
ter) undersize
1.492 — 1.501 47.954 — 48.000 0.25
Standard 1.614 — 1.622 51.734 — 51.750
(0.0587 — 0.0591) (4.8879 — 1.8898) (0.0098)
0.03 (0.0635 — 0.0639) (2.0368 — 2.0374)
undersize
cardiagn.com
1.510 — 1.513 47.954 — 47.970
(0.0012)
(0.0594 — 0.0596) (1.8879 — 1.8886)
undersize 6) Inspect the bushing at connecting rod small end,
0.05 and replace if worn or damaged. Also measure the
1.520 — 1.523 47.934 — 47.950
(0.0020) piston pin clearance at connecting rod small end.
(0.0598 — 0.0600) (1.8872 — 1.8878)
undersize
Clearance between piston pin and bushing:
0.25
(0.0098)
1.620 — 1.623 47.734 — 47.750 Standard
(0.0638 — 0.0639) (1.8793 — 1.8799) 0 — 0.022 mm (0 — 0.0009 in)
undersize
Limit
Connecting rod oil clearance: 0.030 mm (0.0012 in)
• 2000 cc MODEL
Standard
0.010 — 0.038 mm (0.0004 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size
Outer diameter of
Bearing (Thickness at cen-
crank pin
ter)
1.492 — 1.501 51.984 — 52.000 B2M0085
Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.03
1.510 — 1.513 51.954 — 51.970
(0.0012)
(0.0594 — 0.0596) (2.0454 — 2.0461)
undersize
0.05
1.520 — 1.523 51.934 — 51.950
(0.0020)
(0.0598 — 0.0600) (2.0446 — 2.0453)
undersize
0.25
1.620 — 1.623 51.734 — 51.750
(0.0098)
(0.0638 — 0.0639) (2.0368 — 2.0374)
undersize
EN0337
ME-91
CYLINDER BLOCK
MECHANICAL
7) Replacement procedure is as follows.

(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
cardiagn.com
(4) After the completion of reaming, clean the
bushing to remove chips.
ME-92
CYLINDER BLOCK
MECHANICAL
6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear.
BEARING If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and then
1) Clean the crankshaft completely and check for replace or recondition the crankshaft as necessary.
cracks by means of red lead check etc., and re- When grinding the crank journal or crank pin, finish
place if defective. them to specified dimensions according to the un-
2) Measure the crankshaft bend, and correct or re- dersize bearing to be used.
place if it exceeds the limit.
Crank pin and crank journal:
CAUTION:
Out-of-roundness
If a suitable V-block is not available, install the
#1 and #5 crankshaft bearing on cylinder block, 0.020 mm (0.0008 in) or less
position the crankshaft on these bearings and Taper limit
measure the crankshaft bend using a dial 0.07 mm (0.0028 in)
gauge. Grinding limit
0.250 mm (0.0098 in)
Crankshaft bend limit:
0.035 mm (0.0014 in)
cardiagn.com
G2M0179
EN0339
Unit: mm (in)
Crank journal diameter Crank pin diameter
#1, #3 #2, #4, #5 1600 cc 2000 cc 2500 cc
Journal 59.992 — 60.008 59.992 — 60.008 47.984 — 48.000 51.984 — 52.000 51.984 — 52.000
O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (1.8891 — 1.8898) (2.0466 — 2.0472) (2.0466 — 2.0472)
Standard Bearing
size 1.998 — 2.011 2.000 — 2.013 1.492 — 1.510 1.492 — 1.501 1.490 — 1.502
(Thickness (0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0594) (0.0587 — 0.0591) (0.0587 — 0.0591)
at center)
Journal 59.962 — 59.978 59.962 — 59.978 47.954 — 47.970 51.954 — 51.970 51.954 — 51.970
O.D. (2.3607 — 2.3613) (2.3607 — 2.3613) (1.8879 — 1.8886) (2.0454 — 2.0461) (2.0454 — 2.0461)
0.03
(0.0012) Bearing
undersize size 2.017 — 2.020 2.019 — 2.022 1.510 — 1.513 1.510 — 1.513 1.504 — 1.512
(Thickness (0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596) (0.0594 — 0.0596) (0.0592 — 0.0595)
at center)
Journal 59.942 — 59.958 59.942 — 59.958 47.934 — 47.950 51.934 — 51.950 51.934 — 51.950
O.D. (2.3599 — 2.3605) (2.3599 — 2.3605) (1.8872 — 1.8878) (2.0446 — 2.0453) (2.0446 — 2.0453)
0.05
(0.0020) Bearing
undersize size 2.027 — 2.030 2.029 — 2.032 1.520 — 1.523 1.520 — 1.523 1.514 — 1.522
(Thickness (0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600) (0.0598 — 0.0600) (0.0596 — 0.0599)
at center)
Journal 59.742 — 59.758 59.742 — 59.758 47.734 — 47.750 51.734 — 51.750 51.734 — 51.750
O.D. (2.3520 — 2.3527) (2.3520 — 2.3527) (1.8793 — 1.8799) (2.0368 — 2.0374) (2.0368 — 2.0374)
0.25
(0.0098) Bearing
undersize size 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623 1.620 — 1.623 1.614 — 1.622
(Thickness (0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639) (0.0638 — 0.0639) (0.0635 — 0.0639)
at center)
O.D. : Outer Diameter
ME-93
CYLINDER BLOCK
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If the clearance exceeds the limit,
replace bearing.
Crankshaft thrust clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)
EN0341
5) Inspect the individual crankshaft bearings for

signs of flaking, seizure, melting, and wear.
cardiagn.com
6) Measure the oil clearance on each crankshaft
bearing by means of plastigauge. If the measure-
ment is not within the specification, replace the de-
fective bearing with an undersize one, and then
replace or recondition the crankshaft as necessary.
Unit: mm (in)
Crankshaft oil clearance
0.010 — 0.030 (0.0004 —
Standard
0.0012)
Limit 0.040 (0.0016)
ME-94
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. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. • Starter • Defective battery-to-starter harness B
• Defective starter switch C
• Defective inhibitor switch or neutral switch C
• Defective starter B
• Battery • Poor terminal connection A
• Run-down battery A
• Defective charging system B
• Friction • Seizure of crankshaft and connecting rod bearing C
• Seized camshaft C
• Seized or stuck piston and cylinder C
cardiagn.com
2) Initial combustion does • Starter • Defective starter C
not occur. • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Fuel line • Defective fuel pump and relay A
• Lack of or insufficient fuel B
• Belt • Defective B
• Defective timing B
• Compression • Incorrect valve clearance C
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket C
• Improper valve seating C
• Defective valve stem C
• Worn or broken valve spring B
• Worn or stuck piston rings, cylinder and piston C
• Incorrect valve timing B
• Improper engine oil (low viscosity) B
ME-95
MECHANICAL

3) Initial combustion occur. • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Intake system • Defective intake manifold gasket B
• Defective throttle body gasket B
• Fuel line • Defective fuel pump and relay C
• Clogged fuel line C
4) Engine stalls after initial • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
cardiagn.com
combustion. oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked intake duct B
• Loosened or cracked PCV hose C
• Loosened or cracked vacuum hose C
• Defective intake manifold gasket B
• Dirty air cleaner element C
• Fuel line • Clogged fuel line C
ME-96
MECHANICAL

2. Rough idle and engine • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
stall oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked intake duct A
• Loosened or cracked PCV hose A
• Loosened or cracked vacuum hose A
• Defective PCV valve C
• Loosened oil filler cap B
• Dirty air cleaner element C
• Fuel line • Defective fuel pump and relay C
• Clogged fuel line C
• Belt • Defective timing C
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket B
• Loosened cylinder head bolts or defective gasket B
• Improper valve seating B
cardiagn.com
• Worn or stuck piston rings, cylinder and piston B
• Incorrect valve timing A
• Lubrication system • Incorrect oil pressure B
• Defective rocker cover gasket C
• Cooling system • Overheating C
• Others • Malfunction of evaporative emission control system A
• Stuck or damaged throttle valve B
• Accelerator cable out of adjustment C
ME-97
MECHANICAL

3. Low output, hesitation and • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
poor acceleration oOBD)-2, Basic Diagnostic Procedure.>
• Loosened or cracked vacuum hose B
• Defective PCV valve B
• Dirty air cleaner element A
• Fuel line • Defective fuel pump and relay B
• Clogged fuel line B
• Lack of or insufficient fuel C
• Belt • Defective timing B
• Loosened spark plugs or defective gasket B
• Loosened cylinder head bolts or defective gasket B
cardiagn.com
• Lubrication system • Incorrect oil pressure B
• Cooling system • Overheating C
• Over cooling C
• Others • Malfunction of evaporative emission control system A
4. Surging • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Loosened or cracked vacuum hose A
• Dirty air cleaner element B
• Fuel line • Defective fuel pump and relay B
• Clogged fuel line B
• Lack of or insufficient fuel C
• Worn or broken valve spring C
• Cooling system • Overheating B
• Others • Malfunction of evaporative emission control system C
ME-98
MECHANICAL

5. Engine does not return to • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
idle. oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked vacuum hose A
• Others • Stuck or damaged throttle valve A
• Accelerator cable out of adjustment B
6. Dieseling (Run-on) • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Cooling system • Overheating B
• Others • Malfunction of evaporative emission control system B
7. After burning in exhaust • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
system oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked intake duct C
• Loosened or cracked PCV hose C
• Loosened or cracked vacuum hose B
• Loosened oil filler cap C
cardiagn.com
• Lubrication system • Incorrect oil pressure C
• Cooling system • Over cooling C
• Others • Malfunction of evaporative emission control system C
8. Knocking • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Intake system • Loosened oil filler cap B
• Cooling system • Overheating A
9. Excessive engine oil con- • Intake system • Loosened or cracked PCV hose A
sumption • Defective PCV valve B
• Loosened oil filler cap C
• Compression • Defective valve stem A
• Worn or stuck piston rings, cylinder and piston A
• Lubrication system • Loosened oil pump attaching bolts and defective B
gasket
• Defective oil filter seal B
• Defective crankshaft oil seal B
• Defective rocker cover gasket B
• Loosened oil drain plug or defective gasket B
• Loosened oil pan fitting bolts or defective oil pan B
ME-99
MECHANICAL

10. Excessive fuel consump- • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
tion oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Dirty air cleaner element A
• Worn or stuck piston rings, cylinder and piston B
• Lubrication system • Incorrect oil pressure C
• Cooling system • Over cooling C
• Others • Accelerator cable out of adjustment B
cardiagn.com
ME-100
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
• Worn crankshaft main bearing
Oil pressure is low.
• Worn connecting rod bearing (big end)
Heavy and dull clank
• Loose flywheel mounting bolts
Oil pressure is normal.
• Damaged engine mounting
• Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when • Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. • Wrong spark plug
• Improper gasoline
Sound is reduced when fuel • Worn crankshaft main bearing
Clank when engine speed is injector connector of noisy cyl- • Worn bearing at crankshaft end of connecting rod
medium (1,000 to 2,000 rpm). inder is disconnected.
(NOTE*)
Sound is reduced when fuel • Worn cylinder liner and piston ring
cardiagn.com
injector connector of noisy cyl- • Broken or stuck piston ring
Knocking sound when engine inder is disconnected. • Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm Sound is not reduced if each • Unusually worn valve lifter
fuel injector connector is dis- • Worn cam gear
connected in turn. (NOTE*) • Worn camshaft journal bore in crankcase
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Defective generator brush and rotor contact
Gear scream when starting • Defective ignition starter switch
—
engine • Worn gear and starter pinion
Sound like polishing glass with • Loose drive belt
—
a dry cloth • Defective water pump shaft
• Loss of compression
Hissing sound — • Air leakage in air intake system, hoses, connections or mani-
folds
• Loose timing belt
Timing belt noise —
• Belt contacting case/adjacent part
Valve tappet noise — • Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN-49, OPERATION, Clear Memory Mode.> or <Ref. to EN(w/
oOBD)-30, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN-42, OPERATION, Inspection Mode.> or
<Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> after connecting fuel injector connector.
ME-101
ENGINE NOISE
MECHANICAL
cardiagn.com
ME-102
EXHAUST
EX
Page
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe .................................................................................10
4. Rear Exhaust Pipe ....................................................................................11
5. Muffler .......................................................................................................12
cardiagn.com
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. 1600 CC
(16)
(15)
(13)
(14)
T7 (16)
(11)
(10)
(12)
cardiagn.com
(9)
(16)
T1 T4
(27)
T6 T2
(26) T2
(17) (28)
(22) (18)
T4
(25)
T2 (24)
(23)
(8) T2
(3)
T3
(31)
(1) (30)
(2) T6
(3)
(19)
T1
(21) (29)
(4)
(7) T5
T2 (20)
T5 (31)
(6)
(5)
T5
EN1372
EX-2
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (13) Gasket (27) Rear oxygen sensor
CTR (14) Self-locking nut (28) Upper rear catalytic converter
(2) Lower front exhaust pipe cover (15) Muffler cover
CTR (16) Cushion rubber (29) Lower rear catalytic converter
(3) Clamp (17) Lower clamp cover
(4) Upper front exhaust pipe cover LH (18) Upper center exhaust pipe cover (30) Rear catalytic converter
(5) Lower front exhaust pipe cover LH (19) Lower center exhaust pipe cover (31) Gasket
(6) Front exhaust pipe (20) Protector
(7) Lower front exhaust pipe cover (21) Gasket Tightening torque: N·m (kgf-m, ft-lb)
RH (22) Front oxygen (A/F) sensor T1: 8 (0.8, 5.8)
(8) Upper front exhaust pipe cover (23) Front catalytic converter T2: 13 (1.3, 9.4)
RH (24) Center exhaust pipe T3: 18 (1.8, 13.0)
(9) Gasket (25) Lower front catalytic converter T4: 21 (2.1, 15.2)
(10) Spring cover T5: 30 (3.1, 22.4)
(11) Chamber (26) Upper front catalytic converter T6: 35 (3.6, 26.0)
(12) Rear exhaust pipe cover T7: 48 (4.9, 35.4)
cardiagn.com
EX-3
GENERAL DESCRIPTION
EXHAUST
2. 2000 CC AND 2500 CC
(16)
(15)
(13)
(14)
T2
T7 (16)
(11)
(10)
(17)
(9)
(16)
cardiagn.com
(12)
T1 T4
(28)
T6
T2
(27) T2
(18) (29)
(23) (19)
T4
(26)
T2 (25)
(24)
(8) T2
(3) T3
(32)
(1) (31)
(2) T6
(3)
(20)
T1
(22) (30)
(4)
(7) T5
T2 (21)
T5 (32)
(6)
(5)
T5
EN1373
EX-4
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (14) Self-locking nut (29) Upper rear catalytic converter
CTR (15) Muffler cover
(2) Lower front exhaust pipe cover (16) Cushion rubber (30) Lower rear catalytic converter
CTR (17) Rear exhaust pipe cover
(3) Clamp (18) Lower clamp (31) Rear catalytic converter
(4) Upper front exhaust pipe cover LH (19) Upper center exhaust pipe cover (32) Gasket
(5) Lower front exhaust pipe cover LH (20) Lower center exhaust pipe cover
(6) Front exhaust pipe (21) Protector Tightening torque: N·m (kgf-m, ft-lb)
(7) Lower front exhaust pipe cover (22) Gasket T1: 8 (0.8, 5.8)
RH (23) Front oxygen (A/F) sensor T2: 13 (1.3, 9.4)
(8) Upper front exhaust pipe cover (24) Front catalytic converter T3: 18 (1.8, 13.0)
RH (25) Center exhaust pipe T4: 21 (2.1, 15.2)
(9) Gasket (26) Lower front catalytic converter T5: 30 (3.1, 22.4)
(10) Spring cover T6: 35 (3.6, 26.0)
(11) Chamber (27) Upper front catalytic converter T7: 48 (4.9, 35.4)
(12) Rear exhaust pipe cover cover
(13) Gasket (28) Rear oxygen sensor
cardiagn.com
EX-5
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
tion.
points.
cable from battery.
cardiagn.com
EX-6
FRONT EXHAUST PIPE
EXHAUST
2. Front Exhaust Pipe 5) Separate the front and center exhaust pipe as-
sembly from rear exhaust pipe.
A: REMOVAL WARNING:
1) Disconnect the ground cable from battery. Be careful, the exhaust pipe is hot.
G6M0095
B2M3109
2) Disconnect the front oxygen (A/F) sensor con-
nector. 6) Remove the under cover.
7) Remove the nuts which hold front exhaust pipe
CAUTION:
Be careful not to pull down the front and center
cardiagn.com
exhaust pipe assembly.
B2M4243
3) Disconnect the rear oxygen sensor connector.
B2M3200
8) Remove the bolt which installs front and center

exhaust pipe assembly to hanger bracket.
B2M4244
B2M3111
EX-7
FRONT EXHAUST PIPE
EXHAUST
9) Remove the front and center exhaust pipe as- 4) Temporarily tighten the bolt which installs front
sembly from vehicle. and center exhaust pipe assembly to hanger brack-
CAUTION: et.
• Be careful not to let the front and center ex-
haust pipe assembly fall off when removing as
it is quite heavy.
• After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center ex-
haust pipe.
B2M3111
5) Tighten the nuts which hold front exhaust pipe

Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
cardiagn.com
S2M0923
11) Remove the front oxygen (A/F) sensor and the

rear oxygen sensor. <Ref. to FU-47, REMOVAL,
Front Oxygen (A/F) Sensor.> and <Ref. to FU-49,
REMOVAL, Rear Oxygen Sensor.> .
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and the rear
B2M3200
oxygen sensor. <Ref. to FU-47, INSTALLATION,
Front Oxygen (A/F) Sensor.> and <Ref. to FU-49, 6) Install the under cover.
INSTALLATION, Rear Oxygen Sensor.> . 7) Tighten the bolts which install front and center
2) Install the front exhaust pipe to center exhaust exhaust pipe assembly to rear exhaust pipe.
pipe.
Tightening torque:
NOTE: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
Replace the gaskets with new ones.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3109
S2M0923
3) Install the front and center exhaust pipe assem-

bly to vehicle.
EX-8
FRONT EXHAUST PIPE
EXHAUST
8) Tighten the bolt which holds front and center ex- C: INSPECTION
haust pipe assembly to hanger bracket. 1) Make sure there are no exhaust leaks from con-
Tightening torque: nections and welds.
35 N·m (3.6 kgf-m, 26.0 ft-lb) 2) Make sure there are no holes or rusting.
B2M3111

10) Connect the rear oxygen sensor connector.
cardiagn.com
B2M4244
11) Connect the front oxygen (A/F) sensor connec-

tor.
B2M4243
G6M0095
EX-9
CENTER EXHAUST PIPE
EXHAUST
3. Center Exhaust Pipe

A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe. <Ref. to EX-7,
REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX-8, INSTAL-
LATION, Front Exhaust Pipe.>
C: INSPECTION
nections and welds.
cardiagn.com
EX-10
REAR EXHAUST PIPE
EXHAUST
4. Rear Exhaust Pipe 2) Install the rear exhaust pipe bracket to cushion
rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
S2M0560
NOTE:
Replace the gaskets with new ones.
3) Install the rear exhaust pipe to muffler.
B2M3109 Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
2) Separate the rear exhaust pipe from muffler.
CAUTION:
cardiagn.com
Be careful not to pull down the rear exhaust
pipe.
G2M0382
4) Install the rear exhaust pipe to center exhaust

pipe.
G2M0382 Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
3) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B2M3109
C: INSPECTION
nections and welds.
S2M0560 2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
B: INSTALLATION cracked.
the cushion rubbers in advance.
EX-11
MUFFLER
EXHAUST
5. Muffler B: INSTALLATION
A: REMOVAL
1) Separate the muffler from rear exhaust pipe. NOTE:
Replace the gasket with a new one.
CAUTION:
Be careful, the exhaust pipe is hot. Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
G2M0382
G2M0382
the cushion rubbers in advance. C: INSPECTION
SUBARU CRC (Part No. 004301003) 1) Make sure there are no exhaust leaks from con-
nections and welds.
cardiagn.com
3) Make sure the cushion rubber is not worn or
cracked.
G2M0385
3) Remove the front, right and left cushion rubber,

and detach the muffler assembly.
EX-12
COOLING
CO
Page
2. Radiator Main Fan System........................................................................10
3. Radiator Sub Fan System .........................................................................18
4. Engine Coolant..........................................................................................26
5. Water Pump ..............................................................................................28
6. Thermostat ................................................................................................37
7. Radiator.....................................................................................................39
8. Radiator Cap .............................................................................................47
9. Radiator Main Fan and Fan Motor ............................................................48
10. Radiator Sub Fan and Fan Motor..............................................................50
cardiagn.com
11. Reservoir Tank..........................................................................................52
12. Coolant Filler Tank ....................................................................................53
13. Engine Cooling System Trouble in General ..............................................54
GENERAL DESCRIPTION
COOLING
A: SPECIFICATIONS
Model Non-turbo Turbo
Cooling system Electric fan + Forced engine coolant circulation system
1.6 L AT: Approx. 7.3
(7.71, 6.42)
1.6 L MT: Approx. 7.4 AT: Approx. 7.6
(7.82, 6.51) (8.03, 6.69)
Total engine coolant capacity 2 (US qt, Imp qt)
2.0 and 2.5 L AT: Approx. 6.9 MT: Approx. 7.7
(7.29, 6.07) (8.14, 6.78)
2.0 and 2.5 L MT: Approx. 7
(7.4, 6.2)
Type Centrifugal impeller type
Discharge 20 2 (5.3 US gal, 4.4 Imp gal)/min.
Discharge perfor- Pump speed—total engine
760 rpm — 0.3 mAq (1.0 ftAq)
mance I coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100 2 (26.4 US gal, 22.0 Imp gal)/min.
3,000 rpm — 5.0 mAq (16.4 ftAq)
mance II coolant head
cardiagn.com
Water pump Discharge 200 2 (52.8 US gal, 44.0 Imp gal)/min.
6,000 rpm — 23.0 mAq (75.5 ftAq)
mance III coolant head
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Clearance between Standard 0.5 — 0.7 mm (0.020 — 0.028 in)
impeller and case Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Main fan 70 W 120 W
Motor
Sub fan 70 W 120 W
Radiator fan
320 mm (11.81 in) × 5 (main fan)
Fan diameter × Blade
320 mm (11.81 in) × 7 (sub fan)
Type Down flow, pressure type
AT: 691.5 × 340 × 16
mm
691.5 × 340 × 16 mm (27.22 × 13.39 × 0.63 in)
Core dimensions
(27.22 × 13.39 × 0.63 in) MT: 691.5 × 340 × 27
mm
Radiator (27.22 × 13.39 × 1.06 in)
Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Pressure range in which cap valve is open
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir
Capacity 0.5 2 (0.5 US qt, 0.4 Imp qt)
tank
CO-2
GENERAL DESCRIPTION
COOLING
B: COMPONENT
1. WATER PUMP
• NON-TURBO MODEL
cardiagn.com
H2M2354A
(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)
(3) Heater by-pass hose Second 12 (1.2, 8.7)
(4) Thermostat T2: 6.4 (0.65, 4.7)
CO-3
GENERAL DESCRIPTION
COOLING
• TURBO MODEL
cardiagn.com
H2M1785B
(1) Thermostat cover (6) Heater by-pass hose Tightening torque: N·m (kgf-m, ft-lb)
(2) Gasket (7) Coolant filler tank by-pass hose T1: First 12 (1.2, 8.7)
(3) Thermostat (8) Water by-pass pipe Second 12 (1.2, 8.7)
(4) Water pump ASSY T2: 6.4 (0.65, 4.7)
(5) Gasket
CO-4
GENERAL DESCRIPTION
COOLING
2. RADIATOR AND RADIATOR FAN

• NON-TURBO MODEL
(8)
(6) (5)
T5
(10) (12)
(7)
T5
T3 (5)
T5
(15)
(4)
T1
(3)
(9)
(11) (13)
(24)
T4
cardiagn.com
T1 (16)
(17) T2
(2)
T4 (16)
(14)
(18)
(21) (16)
T2
(16)
(1)
(16)
(23) (19)
(20)
(16)
(5)
(22)
EN0068
(1) Radiator lower cushion (14) Radiator main fan (22) Radiator outlet hose
(2) Radiator (15) Radiator main fan motor (23) Radiator lower bracket
(3) Radiator upper cushion (16) ATF hose clamp (AT vehicles (24) Radiator drain plug
(4) Radiator upper bracket only)
(5) Clamp (17) ATF inlet hose A (AT vehicles Tightening torque: N·m (kgf-m, ft-lb)
(6) Radiator inlet hose only) T1: 4.4 (0.45, 3.3)
(7) Engine coolant reservoir tank cap (18) ATF outlet hose A (AT vehicles T2: 12 (1.2, 8.7)
(8) Over flow hose only) T3: 18 (1.8, 13.0)
(9) Engine coolant reservoir tank (19) ATF pipe (AT vehicles only) T4: 3.4 (0.35, 2.5)
(10) Radiator sub fan shroud (20) ATF inlet hose B (AT vehicles T5: 4.9 (0.50, 3.6)
(11) Radiator sub fan only)
(12) Radiator sub fan motor (21) ATF outlet hose B (AT vehicles
(13) Radiator main fan shroud only)
CO-5
GENERAL DESCRIPTION
COOLING
• TURBO MODEL
(21)
(20)
(19)
(5)
(5)
(6) (5)
T4
T4
(11)
(10) (7)
(8) T4
T2 (5)
(13)
(16)
(4)
T1
(3)
(9)
cardiagn.com
(2)
(12) (14)
(18)
T3
(5) T1
T3
(15)
(17)
(1)
(5)
(22)
EN0069
(1) Radiator lower cushion (10) Over flow pipe (19) Engine coolant filler tank
(2) Radiator (11) Radiator sub fan shroud (20) Engine coolant filler tank cap
(3) Radiator upper cushion (12) Radiator sub fan (21) Engine coolant hose
(4) Radiator upper bracket (13) Radiator sub fan motor (22) Radiator lower bracket
(5) Clamp (14) Radiator main fan shroud Tightening torque: N·m (kgf-m, ft-lb)
(6) Radiator inlet hose (15) Radiator main fan T1: 4.4 (0.45, 3.3)
(7) Engine coolant reservoir tank cap (16) Radiator main fan motor T2: 18 (1.8, 13.0)
(8) Over flow hose (17) Radiator outlet hose T3: 3.4 (0.35, 2.5)
(9) Engine coolant reservoir tank (18) Radiator drain plug T4: 4.9 (0.50, 3.6)
CO-6
GENERAL DESCRIPTION
COOLING
C: CAUTION
tion.
part in the vehicle is hot after running.
points.
cable from battery.
cardiagn.com
CO-7
GENERAL DESCRIPTION
COOLING
D: PREPARATION TOOL
1. NON-TURBO MODEL
499977100 CRANK PULLEY Used for stopping crankshaft pulley when
WRENCH loosening and tightening crankshaft pulley
bolts. (2500 cc model)
B2M3870
bolts. (1600 cc and 2000 cc model)
cardiagn.com
B2M4157
18231AA010 CAMSHAFT • Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket.
tool) WRENCH • Also the CAMSHAFT SPROCKET
WRENCH (499207100) can be used.
NOTE:
For common use with turbo model, this ST is
changed and registered as a newly adopted
tool. Though the previous ST also can be
used.
B2M3859
CO-8
GENERAL DESCRIPTION
COOLING
2. TURBO MODEL
bolts.
B2M4157
18231AA010 CAMSHAFT Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket. (Intake)
tool) WRENCH
cardiagn.com
B2M3859
499207400 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket. (Exhaust)
WRENCH
B2M4158
CO-9
RADIATOR MAIN FAN SYSTEM
COOLING
2. Radiator Main Fan System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17
AIR CONDITIONING No.18 AIR CONDITIONING

RELAY HOLDER RELAY HOLDER
1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
cardiagn.com
MAIN FAN SUB FAN
MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
CO-10
COOLING
2. TURBO MODEL
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2 No.17
*1 RHD : 7
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
cardiagn.com
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17
SUB FAN SUB FAN MAIN FAN MAIN FAN

RELAY2 RELAY1 RELAY2 RELAY1
M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
MOTOR MOTOR AIR CONDITIONING RELAY HOLDER
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0260
CO-11
COOLING
B: INSPECTION
1. NON-TURBO MODEL
DETECTING CONDITION:
• Engine coolant temperature is above 95°C (203°F).
• Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
• Radiator main fan does not rotate under the above conditions.
Step Check Yes No

1 CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 2. Go to step 5.
TOR.
CAUTION:
Be careful not to overheat the engine during
repair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from main fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 95°C
(203°F).
4)Stop the engine and turn ignition switch to
cardiagn.com
ON.
5)Measure the voltage between main fan
motor connector and chassis ground.
Connector & terminal
(F17) No. 2 (+) — Chassis ground (−):
2 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 5 Go to step 3. Repair the open
MOTOR. Ω? circuit in harness
1)Turn the ignition switch to OFF. between main fan
2)Measure the resistance between main fan motor connector
motor connector and chassis ground. and chassis
Connector & terminal ground.
(F17) No. 1 — Chassis ground:
3 CHECK POOR CONTACT. Is there poor contact in main Repair the poor Go to step 4.
Check poor contact in main fan motor connec- fan motor connector? contact in main fan
tor. motor connector.
4 CHECK MAIN FAN MOTOR. Does the main fan rotate? Repair the poor Replace the main
Connect the battery positive (+) terminal to ter- contact in main fan fan motor with a
minal No. 2, and ground (−) terminal to termi- motor connector. new one.
nal No. 1 of main fan motor connector.
5 CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 6. Go to step 7.
LAY.
2)Remove the main fan relay from A/C relay
holder.
3)Measure the voltage between main fan relay
terminal and chassis ground.
6 CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 10. Go to step 9.
LAY.
1)Turn the ignition switch to ON.
2)Measure the voltage between main fan relay
CO-12
COOLING
Step Check Yes No

7 CHECK 20 A FUSE. Is the fuse blown-out? Replace the fuse. Go to step 8.
1)Remove the 20 A fuse from A/C relay holder.
2)Check the condition of fuse.
8 CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 V? Repair the open Repair the open
HOLDER 20 A FUSE TERMINAL. circuit in harness circuit in harness
Measure the voltage of harness between A/C between 20 A fuse between main fuse
relay holder 20 A fuse terminal and chassis and main fan relay box connector and
ground. terminal. 20 A fuse terminal.
9 CHECK FUSE. Is the fuse blown-out? Replace the fuse. Repair the open
1)Turn the ignition switch to OFF. circuit in harness
2)Remove the fuse No. 18 from joint box. between main fan
3)Check the condition of fuse. relay and ignition
switch.
10 CHECK MAIN FAN RELAY. Is the resistance more than 1 Go to step 11. Replace the main
1)Turn the ignition switch to OFF. MΩ? fan relay.
2)Remove the main fan relay.
3)Measure the resistance of main fan relay.
Terminal
No. 26 — No. 25:
11 CHECK MAIN FAN RELAY. Is the resistance less than 1 Go to step 12. Replace the main
cardiagn.com
1)Connect the battery to terminals No. 27 and Ω? fan relay.
No. 28 of main fan relay.
2)Measure the resistance of main fan relay.
Terminal
No. 26 — No. 25:
12 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 13. Repair the open
RELAY TERMINAL AND MAIN FAN MOTOR Ω? circuit in harness
CONNECTOR. between main fan
Measure the resistance of harness between motor connector
main fan motor connector and main fan relay and main fan relay
terminal. terminal.
(F17) No. 2 — (F66) No. 25:
RELAY AND ECM. Ω? circuit in harness
2)Disconnect the connector from ECM. relay and ECM.
3)Measure the resistance of harness between
main fan relay connector and ECM connector.
(F66) No. 27 — (B134) No. 3:
14 CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Contact with your
Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor
fan and ECM. and ECM? service.
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.
CO-13
COOLING
2. TURBO MODEL
• A/C compressor is rotated.
TROUBLE SYMPTOM:
• Radiator main fan does not rotate under the above conditions.
• Radiator main fan does not rotate at high speed when the following conditions are both met:
(1) Engine coolant temperature is above 90°C (194°F)
(2) A/C is ON
Step Check Yes No

1 CHECK OPERATION OF RADIATOR. Does the main radiator fan Go to step 2. Go to step 3.
1)Run the engine at idle. (Vehicle stationary) rotate?
2)Turn the A/C switch to OFF.
3)Warm the engine coolant temperature over
96°C (205°F).
2 CHECK OPERATION OF RADIATOR. Does the main radiator fan Radiator main fan Go to step 17.
1)Turn the A/C switch ON at condition of step rotate faster when A/C com- system is okay.
1. pressor is operated?
cardiagn.com
TOR.
CAUTION:
repair.
motor.
(205°F).
ON.
4 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 5 Go to step 5. Repair the open
2)Measure the resistance between main fan motor connector
CO-14
COOLING
Step Check Yes No

7 CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 V? Go to step 8. Go to step 9.
RELAY1.
2)Remove the main fan relay1 from A/C relay
holder.
relay1 terminal and chassis ground.
RELAY1.
cardiagn.com
switch.
2)Remove the main fan relay1.
3)Measure the resistance of main fan relay1.
Terminal
No. 26 — No. 25:
No. 28 of main fan relay1.
Terminal
No. 26 — No. 25:
terminal. terminal.
(F17) No. 3 — (F66) No. 25:
(F66) No. 28 — (B137) No. 17:
CO-15
COOLING
Step Check Yes No

TOR.
CAUTION:
repair.
motor.
(205°F).
4)Turn the A/C switch ON.
5)Measure the voltage while A/C compressor
is rotating.
cardiagn.com
RELAY2.
2)Remove the main fan relay2 from A/C relay
holder.
RELAY2.
switch.
CO-16
COOLING
Step Check Yes No

Terminal
No. 23 — No. 24:
No. 22 of main fan relay1.
Terminal
No. 23 — No. 24:
terminal. terminal.
(F17) No. 2 — (F66) No. 24:
cardiagn.com
(F30) No. 21 — (B134) No. 28:
NOTE:
parts.
CO-17
RADIATOR SUB FAN SYSTEM
COOLING
3. Radiator Sub Fan System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
cardiagn.com
MAIN FAN SUB FAN
MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
CO-18
COOLING
2. TURBO MODEL
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2 No.17
*1 RHD : 7
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
cardiagn.com
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17
SUB FAN SUB FAN MAIN FAN MAIN FAN

RELAY2 RELAY1 RELAY2 RELAY1
M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
MOTOR MOTOR AIR CONDITIONING RELAY HOLDER
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0260
CO-19
COOLING
B: INSPECTION
1. NON-TURBO MODEL
NOTE:
System for A/C equipped vehicles only.
Condition (1):
• Engine coolant temperature is below 95°C (203°F).
• A/C switch is turned ON.
Condition (2):
• A/C switch is turned OFF.
TROUBLE SYMPTOM:
• Radiator sub fan does not rotate under conditions (1) and (2) above.
Step Check Yes No

1 CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? Go to step 2. Go to step 5.
TOR.
CAUTION:
cardiagn.com
repair.
2)Disconnect the connector from sub fan motor
and main fan motor.
(212°F).
ON.
5)Measure the voltage between sub fan motor
connector and chassis ground.
2 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than 5 Go to step 3. Repair the open
1)Turn the ignition switch to OFF. between sub fan
2)Measure the resistance between sub fan motor connector
3 CHECK POOR CONTACT. Is there poor contact in sub fan Repair the poor Go to step 4.
Check poor contact in sub fan motor connec- motor connector? contact in sub fan
4 CHECK SUB FAN MOTOR. Does the sub fan rotate? Repair the poor Replace the sub
Connect the battery positive (+) terminal to ter- contact in sub fan fan motor with a
nal No. 1 of sub fan motor connector.
5 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 6. Go to step 7.
LAY.
2)Remove the sub fan relay from A/C relay
holder.
3)Measure the voltage between sub fan relay
CO-20
COOLING
Step Check Yes No

6 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 10. Go to step 9.
LAY.
2)Measure the voltage between sub fan relay
relay holder 20 A fuse terminal and chassis and sub fan relay box connector and
2)Remove the fuse No. 17 from joint box. between sub fan
switch.
cardiagn.com
10 CHECK SUB FAN RELAY. Is the resistance more than 1 Go to step 11. Replace the sub
2)Measure the resistance of sub fan relay.
Terminal
No. 17 — No. 18:
11 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 12. Replace the sub
No. 19 of sub fan relay.
Terminal
No. 17 — No. 18:
12 CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Go to step 13. Repair the open
LAY TERMINAL AND SUB FAN MOTOR Ω? circuit in harness
CONNECTOR. between sub fan
Measure the resistance of harness between motor and sub fan
sub fan motor connector and sub fan relay ter- relay connector.
minal.
(F16) No. 2 — (F29) No. 17:
LAY AND ECM. Ω? circuit in harness
sub fan relay connector and ECM connector.
(F29) No. 19 — (B134) No. 12:
Check poor contact in connector between sub nector between sub fan motor contact connector. Subaru distributor
NOTE:
parts.
CO-21
COOLING
2. TURBO MODEL
• A/C compressor is rotated.
TROUBLE SYMPTOM:
• Radiator sub fan does not rotate under the above conditions.
• Radiator sub fan does not rotate at high speed when the following conditions are both met:
(1) Engine coolant temperature is above 90°C (194°F)
(2) A/C is ON
Step Check Yes No

1 CHECK OPERATION OF RADIATOR. Does the radiator sub fan Go to step 2. Go to step 3.
1)Run the engine at idle. (Vehicle stationary) rotate?
2)Turn the A/C switch to OFF.
3)Warm the engine coolant temperature over
96°C (205°F).
2 CHECK OPERATION OF RADIATOR. Does the radiator sub fan Radiator main fan Go to step 17.
1)Turn the A/C switch ON at condition of step rotate faster when A/C com- system is okay.
1. pressor is operated?
cardiagn.com
TOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan
motor.
(205°F).
ON.
4 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than 5 Go to step 5. Repair the open
2)Measure the resistance between sub fan motor connector
6 CHECK MAIN FAN MOTOR. Does the main fan rotate? Repair the poor Replace the sub
CO-22
COOLING
Step Check Yes No

7 CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 V? Go to step 8. Go to step 9.
RELAY1.
2)Remove the sub fan relay1 from A/C relay
holder.
3)Measure the voltage between sub fan relay1
RELAY1.
Measure the voltage of harness between A/C between 30 A fuse between sub fuse
cardiagn.com
switch.
3)Measure the resistance of sub fan relay1.
Terminal
No. 7 — No. 8:
13 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 14. Replace the sub
No. 5 of sub fan relay1.
Terminal
No. 7 — No. 8:
sub fan motor connector and sub fan relay ter- and sub fan relay
minal. terminal.
(F16) No. 3 — (F28) No. 8:
(F28) No. 6 — (B137) No. 17:
CO-23
COOLING
Step Check Yes No

TOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan
motor.
(205°F).
4)Turn the A/C switch ON.
5)Measure the voltage while A/C compressor
is rotating.
cardiagn.com
19 CHECK SUB FAN MOTOR. Does the main fan rotate? Repair the poor Replace the sub
RELAY2.
2)Remove the sub fan relay2 from A/C relay
holder.
RELAY2.
Measure the voltage of harness between A/C between 30 A fuse between sub fuse
switch.
CO-24
COOLING
Step Check Yes No

2)Remove the sub fan relay2.
Terminal
No. 18 — No. 17:
26 CHECK MAIN FAN RELAY. Is the resistance less than 1 Go to step 27. Replace the sub
No. 20 of sub fan relay2.
Terminal
No. 18 — No. 17:
sub fan motor connector and sub fan relay2 and sub fan relay
terminal. terminal.
(F16) No. 2 — (F29) No. 17:
cardiagn.com
(F29) No. 19 — (B137) No. 28:
NOTE:
parts.
CO-25
ENGINE COOLANT
COOLING
4. Engine Coolant 2. FILLING OF ENGINE COOLANT

A: REPLACEMENT 1) Fill engine coolant into the radiator up to filler
neck position.
1. DRAINING OF ENGINE COOLANT Coolant capacity (fill up to “FULL” level):
1) Lift-up the vehicle. 1.6 L AT model
2) Remove the under cover. Approx. 7.3 2(7.71 US qt, 6.42 Imp qt)
3) Remove the drain cock to drain engine coolant 1.6 L MT model
into container. Approx. 7.4 2 (7.82 US qt, 6.51 Imp qt)
NOTE: Non-turbo 2.0 L and 2.5 L AT model
Remove the radiator cap so that engine coolant will Approx. 6.9 2 (7.29 US qt, 6.07 Imp qt)
drain faster. Non-turbo 2.0 L and 2.5 L MT model
Approx. 7 2 (7.4 US qt, 6.2 Imp qt)
Turbo AT model
Approx. 7.6 2 (8.03 US qt, 6.69 Imp qt)
Turbo MT model
Approx. 7.7 2 (8.14 US qt, 6.78 Imp qt)
CAUTION:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made
for SUBARU engine, which has an aluminum
cardiagn.com
crankcase. Always use SUBARU Genuine Cool-
EN0073
ant, since other coolant may cause corrosion.
2) Fill engine coolant into the reservoir tank up to
upper level.
S2M0552A
3) Warm-up the engine completely for more than 5

minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in radiator, add
engine coolant to filler neck position.
5) If the engine coolant level drops from upper level
of reservoir tank, add engine coolant to upper level.
6) Attach the radiator cap and reservoir tank cap
properly.
CO-26
ENGINE COOLANT
COOLING
B: INSPECTION 2. PROCEDURE TO ADJUST THE CON-

CENTRATION OF THE COOLANT
1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEM- To adjust the concentration of the coolant accord-
PERATURE ing to temperature, find the proper fluid concentra-
tion in the above diagram and replace the
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%).
the coolant will provide this information. The amount of coolant that should be replaced can
[Example] be determined using the diagram.
If the coolant temperature is 25°C (77°F) and its [Example]
specific gravity is 1.054, the concentration is 35% Assume that the coolant concentration must be in-
(point A), the safe operating temperature is −14°C creased from 25% to 40%. Find point A, where the
(7°F) (point B), and the freezing temperature is 25% line of coolant concentration intersects with
−20°C (−4°F) (point C). the 40% curve of the necessary coolant concentra-
tion, and read the scale on the vertical axis of the
graph at height A. The quantity of coolant to be
drained is 2.12 (2.2 US qt, 1.8 Imp qt). Drain 2.1 2
(2.2 US qt, 1.8 Imp qt) of coolant from the cooling
system and add 2.12 (2.2 US qt, 1.8 Imp qt) of the
undiluted solution of SUBARU coolant.
cardiagn.com
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
B2M3128A
B2M3129A
CO-27
WATER PUMP
COOLING
5. Water Pump 7) Disconnect the radiator outlet hose and heater

hose from water pump.
A: REMOVAL
1. NON-TURBO MODEL
EN0112

9) Remove the air intake duct.
G6M0095

5) Drain the engine coolant completely.
cardiagn.com
<Ref. to CO-26, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors from radiator main
fan motor (A) and sub fan motor (B).
EN0063
(A) • 2500 cc MODEL
EN0077
(B)
B6M1224
10) Disconnect the over flow hose.
EN0078
B2M2925
CO-28
WATER PUMP
COOLING
11) Remove the reservoir tank. 17) Remove the camshaft sprocket (LH) by using
ST.
WRENCH
NOTE:
(499207100) can be used.
B2M2926
12) Remove the radiator main fan and sub fan as-
semblies. <Ref. to CO-48, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-50,
REMOVAL, Radiator Sub Fan and Fan Motor.>
13) Remove the V-belts.
<Ref. to ME-44, REMOVAL, V-belt.> B2M2039A
14) Remove the timing belt.
18) Remove the belt cover No. 2 (LH).
<Ref. to ME-49, TIMING BELT, REMOVAL, Timing
Belt Assembly.>
cardiagn.com
15) Remove the automatic belt tension adjuster.
B2M2040
19) Remove the tensioner bracket.

H2M2375
16) Remove the belt idler No. 2.
H2M2380
20) Disconnect the heater hose from water pump.

S2M0024 21) Remove the water pump.
B2M3894
CO-29
WATER PUMP
COOLING
2. TURBO MODEL 7) Remove the bolt which installs water by-pass

pipe of oil cooler onto oil pump.
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
S2M0027
8) Disconnect the radiator outlet hose (A) and heat-

er hose (B) from water pump.
9) Disconnect the water by-pass hose (C) and oil
cooler hose (D).
G6M0095

cardiagn.com
5) Drain the engine coolant completely. <Ref. to
CO-26, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).
S2M1159A
(A) 10) Lower the vehicle.

12) Remove the reservoir tank.
EN0077
(B)
S2M0931
13) Remove the radiator main fan and sub fan as-
semblies. <Ref. to CO-48, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-50,
REMOVAL, Radiator Sub Fan and Fan Motor.>
14) Remove the V-belts. <Ref. to ME(TURBO)-44,
EN0078
REMOVAL, V-belt.>
15) Remove the timing belt. <Ref. to ME(TURBO)-
16) Remove the automatic belt tension adjuster
(A).
17) Remove the belt idler (B).
CO-30
WATER PUMP
COOLING
18) Remove the belt idler No. 2 (C). 22) Remove the tensioner bracket.
S2M1160A S2M1163
19) Remove the camshaft position sensor. <Ref. to 23) Disconnect the heater hose from water pump.
FU(TURBO)-31, REMOVAL, Camshaft Position 24) Remove the water pump.
Sensor.>
20) Remove the camshaft sprockets (LH) by using
ST.
WRENCH (Intake)
ST 499207400 CAMSHAFT SPROCKET
WRENCH (Exhaust)
cardiagn.com
S2M1829
B: INSTALLATION
ST
1. NON-TURBO MODEL
1) Install water pump onto cylinder head (LH).
NOTE:
EN1320 • Replace the gasket with a new one.
21) Remove the belt cover No. 2 (LH). • When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
S2M1162
S2M0760A
CO-31
WATER PUMP
COOLING
2) Install the belt cover No. 2 (LH). 5) Install the belt idler No. 2.
Tightening torque: Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb) 39 N·m (4.0 kgf-m, 28.9 ft-lb)
B2M2040 S2M0024
3) Install the tensioner bracket. 6) Install the automatic belt tension adjuster which
tension rod is holded with pin. <Ref. to ME-50, AU-
Tightening torque:
TOMATIC BELT TENSION ADJUSTER ASSEM-
25 N·m (2.5 kgf-m, 18.1 ft-lb)
BLY AND BELT IDLER, INSTALLATION, Timing
Belt Assembly.>
7) Install the timing belt. <Ref. to ME-51, TIMING
BELT, INSTALLATION, Timing Belt Assembly.>
cardiagn.com
8) Install the V-belts. <Ref. to ME-44, INSTALLA-
TION, V-belt.>
9) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-49, INSTALLATION, Ra-
diator Main Fan and Fan Motor.> and <Ref. to CO-
50, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
H2M2380
10) Install the reservoir tank.
4) Install the camshaft sprockets (LH) by using ST.
WRENCH
NOTE:
(499207100) can be used.
Tightening torque:
78 N·m (8.0 kgf-m, 57.9 ft-lb)
B2M2926
11) Connect the over flow hose.
B2M2039A
B2M2925
CO-32
WATER PUMP
COOLING
12) Install air intake duct. 15) Connect the connectors to radiator main fan
• 1600 cc and 2000 cc MODEL motor (A) and sub fan motor (B).
(A)
EN0063 EN0077
• 2500 cc MODEL
(B)
cardiagn.com
EN0078
B6M1224
13) Lift-up the vehicle. 17) Lower the vehicle.
14) Connect the radiator outlet hose and heater 18) Connect the battery ground cable to battery.
hose to water pump.
G6M0095
EN0112
19) Fill engine coolant. <Ref. to CO-26, FILLING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
CO-33
WATER PUMP
COOLING
2. TURBO MODEL 4) Install the camshaft sprockets (LH) by using ST.

1) Install the water pump onto cylinder head (LH).
WRENCH (Intake)
NOTE: ST 499207400 CAMSHAFT SPROCKET
• Replace the gasket with a new one. WRENCH (Exhaust)
• When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in Tightening torque:
the figure. 98 N·m (10.0 kgf-m, 72.4 ft-lb)
Tightening torque:
First:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
ST
EN1320
5) Install the camshaft position sensor. <Ref. to

FU(TURBO)-31, INSTALLATION, Camshaft Posi-
tion Sensor.>
cardiagn.com
6) Install the belt idler No. 2 (C).
H2M1846C 7) Install the belt idler (B).
8) Install the automatic belt tension adjuster (A)
2) Install the belt cover No. 2 (LH). which has a tension rod held by a pin. <Ref. to
Tightening torque: ME(TURBO)-50, AUTOMATIC BELT TENSION
5 N·m (0.5 kgf-m, 3.6 ft-lb) ADJUSTER ASSEMBLY AND BELT IDLER, IN-
STALLATION, Timing Belt Assembly.>
Tightening torque:
39.4 N·m (4.0 kgf-m, 28.9 ft-lb)
S2M1162
3) Install the tensioner bracket.

Tightening torque: S2M1160A
25 N·m (2.5 kgf-m, 18.1 ft-lb)
9) Install the timing belt. <Ref. to ME(TURBO)-51,
TIMING BELT, INSTALLATION, Timing Belt As-
sembly.>
10) Install the V-belts. <Ref. to ME(TURBO)-45,
INSTALLATION, V-belt.>
11) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-49, INSTALLATION, Ra-
diator Main Fan and Fan Motor.> and <Ref. to CO-
50, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
S2M1163
CO-34
WATER PUMP
COOLING
12) Install the reservoir tank. 18) Connect the connectors to radiator main fan
(A)
S2M0931
EN0077
13) Connect the over flow hose.
15) Connect the radiator outlet hose (A) and heater (B)
hose (B) to water pump.
16) Connect the water by-pass hose (C) and oil
cooler hose (D).
cardiagn.com
EN0078

S2M1159A
17) Install the bolt which installs water by-pass pipe

onto oil pump.
G6M0095

Coolant.>
S2M0027
CO-35
WATER PUMP
COOLING
C: INSPECTION
1) Check the water pump bearing for smooth rota-
tion.
2) Check the water pump pulley for abnormalities.
3) Using a dial gauge, measure the impeller runout
in thrust direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check the clearance between impeller and
cardiagn.com
pump case.
Clearance between impeller and pump case:
Standard
0.5 — 0.7 mm (0.020 — 0.028 in)
Limit
1.0 mm (0.039 in)
G2M0212
5) After water pump installation, check the pulley

shaft for engine coolant leaks. If leaks are noted,
replace the water pump assembly.
CO-36
THERMOSTAT
COOLING
6. Thermostat 6) Remove the thermostat cover and gasket, and

pull out the thermostat.
A: REMOVAL
G2M0214
B: INSTALLATION
1) Install the thermostat in the water pump, and
then install the thermostat cover together with a
gasket.
EN0073 NOTE:
4) Disconnect the radiator outlet hose from thermo- • When reinstalling the thermostat, use a new gas-
stat cover. ket.
• The thermostat must be installed with the jiggle
cardiagn.com
• Non-turbo MODEL
pin (A) facing to front side.
• At this time, set the jiggle pin of thermostat for
front side.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0112
5) Disconnect the radiator outlet hose.

• Turbo MODEL
EN0100
2) Fill engine coolant. <Ref. to CO-26, FILLING OF

ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
EN0107
CO-37
THERMOSTAT
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
Immerse the thermostat and a thermometer in wa-
ter. Raise water temperature gradually, and mea-
sure the temperature and valve lift when the valve
begins to open and when the valve is fully opened.
During the test, agitate the water for even temper-
ature distribution. The measurement should be to
the specification.
Starts to open:
76 — 80°C (169 — 176°F)
Fully opens:
91°C (196°F)
cardiagn.com
H2M2357A
(A) Thermometer
(B) Thermostat
CO-38
RADIATOR
COOLING
7. Radiator 5) Disconnect the radiator outlet hose from thermo-

stat cover.
A: REMOVAL
1. NON-TURBO MODEL
EN0112
6) Disconnect the ATF cooler hoses from radiator.

(AT vehicles only)
G6M0095

cardiagn.com
EN0102
(A)
EN0077
(B)
EN0063
• 2500 cc MODEL
EN0078
B6M1224
CO-39
RADIATOR
COOLING
9) Disconnect the over flow hose. 13) Detach the power steering hose from the clip
on the radiator.
B2M2925
B2M2932
14) While slightly lifting the radiator, slide it to left.
15) Lift the radiator up and away from vehicle.
cardiagn.com
B2M2926
11) Disconnect the radiator inlet hose from engine.

B2M2933
B2M2930
12) Remove the radiator upper brackets.
B2M2931
CO-40
RADIATOR
COOLING
2. TURBO MODEL 7) Disconnect the oil cooler hoses from oil cooler
pipes. (if equipped)
WARNING:
The radiator is pressurized. Wait until the en-
tor.
S2M1743
8) Disconnect the radiator outlet hose from thermo-

stat cover.
G6M0095

cardiagn.com
EN0107
(A)
EN0077
EN0108
(B)
EN0078
S2M0931
CO-41
RADIATOR
COOLING
13) Remove the V-belt covers. B: INSTALLATION

1. NON-TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.
EN0048
14) Disconnect the radiator inlet hose (A) and wa-

ter tank hose (B) from radiator.
B2M2934
(A) 2) Install the radiator while fitting radiator pins to

cushions.
NOTE:
Fit pins on the lower side of radiator into cushions
on body side.
cardiagn.com
EN0109
(B) B2M2933
3) Install the radiator brackets and tighten bolts.

Tightening torque:
EN0110
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M2931
EN0035
16) While slightly lifting the radiator, slide it to left.

17) Lift the radiator up and away from vehicle.
CO-42
RADIATOR
COOLING
4) Attach the power steering hose to radiator. • 2500 cc MODEL
B2M2932 B6M1224
5) Connect the radiator inlet hose. 8) Lift-up the vehicle.

9) Connect the ATF cooler hoses. (AT vehicles
only)
cardiagn.com
B2M2930
6) Install the reservoir tank. EN0102

Tightening torque:
10) Connect the connectors to radiator main fan
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
(A)
B2M2926 EN0077
7) Install the air intake duct.

• 1600 cc and 2000 cc MODEL (B)
EN0078
EN0063
CO-43
RADIATOR
COOLING
11) Connect the radiator outlet hose. 2) Install the radiator brackets, and then tighten the
bolts.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
EN0112

14) Connect the battery ground cable to battery. EN0035
3) Connect the radiator inlet hose (A) and water

tank hose (B).
(A)
cardiagn.com
G6M0095

OF ENGINE COOLANT, REPLACEMENT, Engine EN0109
Coolant.>
16) Check the ATF level. <Ref. to AT-9, INSPEC-
TION, Automatic Transmission Fluid.>
2. TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.
(B)
EN0110
4) Install the reservoir tank.

Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M2934
S2M0934
CO-44
RADIATOR
COOLING
5) Connect the over flow hose. 12) Install the V-belt covers.
7) Connect the connectors to radiator main fan mo-
tor (A) and sub fan motor (B).
(A)
EN0048
13) Install the air intake duct.

EN0077
(B)
cardiagn.com
EN0108
EN0078
8) Connect the oil cooler hoses. (if equipped)
G6M0095

S2M1743
9) Connect the radiator outlet hose. Coolant.>
EN0107

CO-45
RADIATOR
COOLING
C: INSPECTION
1) Remove the radiator cap, top off radiator, and
then attach the tester to radiator in place of cap.
• Non-turbo MODEL
B2M3127
• Turbo MODEL
cardiagn.com
EN0116
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi)

to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
• Engine should be off.
• Wipe engine coolant from check points in ad-
vance.
• Be careful to prevent engine coolant from
spurting out when removing the tester.
• Be careful also not to deform the filler neck of
radiator when installing or removing tester.
CO-46
RADIATOR CAP
COOLING
8. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
G2M0223
2) Increase the pressure until tester gauge pointer

stops. Radiator cap is functioning properly if it holds
the service limit pressure for 5 to 6 seconds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
cardiagn.com
Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance otherwise, results of pres-
sure test will be incorrect.
CO-47
RADIATOR MAIN FAN AND FAN MOTOR
COOLING
9. Radiator Main Fan and Fan • Turbo MODEL (includes Non-turbo 2500 cc
MODEL)
Motor
A: REMOVAL
EN0108
G6M0095

4) Disconnect the connector of main fan motor (A).
cardiagn.com
(A)
B2M2925
8) Remove the over flow pipe. (Turbo model)

EN0077

• Non-turbo MODEL (except 2500 cc MODEL)
B2M2926
10) Remove the radiator main fan motor assembly.
EN0063
B2M2927
CO-48
RADIATOR MAIN FAN AND FAN MOTOR
COOLING
B: INSTALLATION 2) Remove the nut which holds fan itself onto fan
Install in the reverse order of removal. motor and shroud assembly.
NOTE:
When the main fan motor assembly cannot be in-
stalled as is, loosen the sub fan motor assembly
securing bolts to install it.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
EN0120
3) Remove the bolts which install fan motor onto

shroud.
B2M2927
Tightening torque:
cardiagn.com
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
EN0121
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M2926
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto shroud.
EN0121
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
S2M0937
EN0120
CO-49
RADIATOR SUB FAN AND FAN MOTOR
COOLING
10.Radiator Sub Fan and Fan • Turbo MODEL (includes Non-turbo 2500 cc
MODEL)
Motor
A: REMOVAL
EN0108
7) Remove the bolts which hold sub fan shroud to

radiator.
G6M0095 8) Remove the over flow pipe. (Turbo model)
2) Lift-up the vehicle. 9) Remove the radiator sub fan shroud through the
3) Remove the under cover. under side of vehicle.
4) Disconnect the connector of sub fan motor (B).
(B)
cardiagn.com
B2M2937
EN0078 B: INSTALLATION
5) Lower the vehicle. Install in the reverse order of removal.
6) Remove the air intake duct. Tightening torque:
• Non-turbo MODEL (except 2500 cc MODEL) 4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
EN0063
B2M2937
CO-50
RADIATOR SUB FAN AND FAN MOTOR
COOLING
C: DISASSEMBLY D: ASSEMBLY
1) Remove the clip which holds motor harness onto Assemble in the reverse order of disassembly.
shroud.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0937
2) Remove the nut which holds fan itself onto fan EN0121
motor and shroud assembly.
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
cardiagn.com
EN0123
3) Remove the bolts which install fan motor onto EN0123

shroud.
EN0121
CO-51
RESERVOIR TANK
COOLING
11.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose from radiator filler
neck position.
2) Remove the bolts which install reservoir tank
onto radiator main fan shroud.
B2M2926
B: INSTALLATION
cardiagn.com
Tightening torque:
4.9N·m (0.50 kgf-m, 3.6 ft-lb)
B2M2926
C: INSPECTION
Make sure the engine coolant level is between full
and low.
CO-52
COOLANT FILLER TANK
COOLING
12.Coolant Filler Tank B: INSTALLATION

A: REMOVAL
Tightening torque:
WARNING: T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb)
The radiator is pressurized. Wait until the en- T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb)
tor.
1) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
lmp qt). <Ref. to CO-26, DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove the air cleaner upper cover and air in-
take boot. <Ref. to IN(TURBO)-7, REMOVAL, Air
T1
Cleaner.>
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from cool-
ant filler tank.
cardiagn.com
T2
EN0125
EN0127
5) Remove the bolts and nut which install coolant
filler tank. 2) Fill engine coolant. <Ref. to CO-26, FILLING OF
6) Disconnect the engine coolant hose which con- ENGINE COOLANT, REPLACEMENT, Engine
nects under side of coolant filler tank. Coolant.>
7) Remove the coolant filler tank.
EN0126
CO-53
ENGINE COOLING SYSTEM TROUBLE IN GENERAL
COOLING
13.Engine Cooling System Trouble in General

A: INSPECTION
Trouble Possible cause Corrective action
Replenish the engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair the ignition control system.
<Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to
g. Improper ignition timing EN(w/oOBD)-2, Basic Diagnostic Procedure.> or <Ref.
to EN(TURBO)-2, PROCEDURE, Basic Diagnostic Pro-
cedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in engine coolant Replace the engine coolant.
Inspect and repair the fuel injection system.
<Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to
j. Air/fuel mixture ratio too lean EN(w/oOBD)-2, Basic Diagnostic Procedure.> or <Ref.
cardiagn.com
to EN(TURBO)-2, PROCEDURE, Basic Diagnostic Pro-
cedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
Inspect the radiator fan relay, engine coolant tempera-
q. Malfunction of electric fan
ture sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low Partly cover the radiator front area.
Over-cooling
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
Engine coolant
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace gasket.
leaks.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
a. Defective drive belt Replace.
b. Defective radiator fan Replace.
Noise
c. Defective water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.
CO-54
LUBRICATION
LU
Page
2. Oil Pressure System ...................................................................................7
3. Engine Oil..................................................................................................10
4. Oil Pump ...................................................................................................12
5. Oil Pan and Strainer..................................................................................16
6. Oil Pressure Switch...................................................................................21
7. Engine Oil Cooler ......................................................................................22
8. Engine Oil Filter.........................................................................................24
9. Engine Lubrication System Trouble in General.........................................25
cardiagn.com
GENERAL DESCRIPTION
LUBRICATION
A: SPECIFICATIONS
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
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)
Side clearance between inner rotor and pump STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Oil pump case LIMIT 0.12 mm (0.0047 in)
Case clearance between outer rotor and pump STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi)
600 rpm Discharge
Capacity at - quantity 3.2 2 (3.4 US qt, 2.8 Imp qt)/min.
80°C (176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi)
5,000 rpm Discharge
- quantity 32.6 2 (8.6 US gal, 7.2 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm2, 71 psi)
cardiagn.com
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter × width 80 × 70 mm (3.15 × 2.76 in)
Oil filter to engine thread size M 20 × 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm2, 10 psi)
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Non-Turbo model 4.0 2 (4.2 US qt, 3.5 Imp qt)
Oil capacity (at replacement)
Turbo model 4.5 2 (4.8 US qt, 4.0 Imp qt)
LU-2
GENERAL DESCRIPTION
LUBRICATION
B: COMPONENT
1. NON-TURBO MODEL
cardiagn.com
EN1491
(1) Plug (14) Oil filler duct (27) Gasket

(2) Gasket (15) O-ring
(3) Relief valve spring (16) Oil filler cap Tightening torque: N·m (kgf-m, ft-lb)
(4) Relief valve (17) O-ring T1: 5 (0.5, 3.6)
(5) Oil seal (18) Baffle plate T2: 5 (0.5, 3.6)
(6) Oil pump case (19) O-ring T3: 6.4 (0.65, 4.7)
(7) Inner rotor (20) Oil strainer T4: 10 (1.0, 7.2)
(8) Outer rotor (21) Oil level gauge guide T5: 44 (4.5, 32.5)
(9) Oil pump cover (22) O-ring T6: 6.4 (0.65, 4.7)
(10) Oil filter (23) Oil pan T7: 25 (2.5, 18.1)
(11) O-ring (24) Oil level gauge T8: 44 (4.5, 32.5)
(12) Oil pump ASSY (25) Drain plug
(13) Oil pressure switch (26) Metal gasket
LU-3
GENERAL DESCRIPTION
LUBRICATION
2. TURBO MODEL
T8 (16)
(17)
T7
(15)
(18)
T3
(14)
(19)
T3
(29) (20)
cardiagn.com
(9) T6
T2 T3
(8) (21)
(13)
(7) (23)
(6) (12) (22)
(24)
(26)
T7
(5) (11) T4
(2) T10
(4)
T5 T1 T1
(3)
(1) (10)
T9 (28) (27) (25)
EN1492
(1) Plug (15) Oil pump ASSY (29) O-ring

(2) Gasket (16) Oil pressure switch
(3) Relief valve spring (17) Oil filler duct Tightening torque: N·m (kgf-m, ft-lb)
(4) Relief valve (18) O-ring T1: 5 (0.5, 3.6)
(5) Oil seal (19) Cylinder head cover T2: 5 (0.5, 3.6)
(6) Oil pump case (20) Baffle plate T3: 6.4 (0.65, 4.7)
(7) Inner rotor (21) O-ring T4: 10 (1.0, 7.0)
(8) Outer rotor (22) Oil strainer T5: 44 (4.5, 32.5)
(9) Oil pump cover (23) Gasket T6: 69 (7.0, 50.9)
(10) Oil filter (24) Oil level gauge guide T7: 6.4 (0.65, 4.7)
(11) Connector (25) Oil pan T8: 25 (2.5, 18.1)
(12) Water by-pass pipe (26) Oil level gauge T9: 44 (4.5, 32.5)
(13) Oil cooler (27) Metal gasket T10: 54 (5.5, 40)
(14) O-ring (28) Drain plug
LU-4
GENERAL DESCRIPTION
LUBRICATION
C: CAUTION
tion.
points.
cable from battery.
cardiagn.com
LU-5
GENERAL DESCRIPTION
LUBRICATION
D: PREPARATION TOOL
bolt. (2500 cc model)
B2M3870
bolt. (1600 cc and 2000 cc model)
cardiagn.com
B2M4157
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
B2M3875
LU-6
OIL PRESSURE SYSTEM
LUBRICATION
2. Oil Pressure System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
No.13 SBF-4 SBF-1
4 1
IGNITION
B72 SWITCH
LHD RHD
AT MT
B36 B38 B36
23
22
4
i1 i3 i1
AT MT
LHD RHD
A7
COMBINATION
METER
WARNING LIGHT
OIL PRESSURE
cardiagn.com
A: i10
B: i11
B2
i2
LHD : 23
RHD : 14
B37
B21
5
E2
E11
OIL PRESSURE
SWITCH
B72 A: i10 B: i11 B21 i2
1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
3 4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 (LHD)
13 14 15 16
LHD: B36 RHD: 17 18 19 20
RHD: i1 i3
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21
12 13 14 15 16 17 18 19 20 21 22 23 24 7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1381
LU-7
OIL PRESSURE SYSTEM
LUBRICATION
2. TURBO MODEL
BATTERY
No.13 SBF-4 SBF-1
4 1
IGNITION
B72 SWITCH
LHD RHD
AT MT
B36 B38 B36
23
22
4
i1 i3 i1
AT MT
LHD RHD
A7
COMBINATION
METER
WARNING LIGHT
OIL PRESSURE
A: i10
B: i11
cardiagn.com
B2
RHD
LHD
i2
23
B37
B209 i2
14
I1
SMJ
B76 B37
F61 B21
14
14
E2 E2
E11 E11
OIL PRESSURE OIL PRESSURE

SWITCH SWITCH
B72 A: i10 B: i11 i2 B209
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 A1 K2 A3 K4 A5
1 2 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 B1 L2 L4 B5
3 4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C1 M2 C3 M4 C5
(LHD) D1 N2 N4 D5
E1 E5
LHD: B36 RHD: F61
i3
1 2 3 4 5 6 7 8 9
F1 F5
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 B21 10 11 12 13 14 15 16 17 18 19 20 21
G1 Q2 Q4 G5
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32
H1 R2 H3 R4 H5
1 2 3 4 (RHD) I1 S2 S4 I5
RHD: i1 5 6 7 8 J1 T2 J3 T4 J5
9 10 11 12
1 2 3 4 5 6 13 14 15 16
7 8 9 10 11 12 13 14 17 18 19 20
EN1382
LU-8
OIL PRESSURE SYSTEM
LUBRICATION
B: INSPECTION
Step Check Yes No
1 CHECK COMBINATION METER. Does the warning lights go on? Go to step 2. Repair or replace
1)Turn the ignition switch to ON. (engine OFF) the combination
2)Check other warning lights. meter. <Ref. to
IDI-5, INSPEC-
TION, Combina-
tion Meter
System.>
2 CHECK HARNESS CONNECTOR BETWEEN Is the voltage more than 10 V? Replace the oil Go to step 3.
COMBINATION METER AND OIL PRES- pressure switch.
SURE SWITCH.
2)Disconnect the connector from oil pressure
switch.
3)Turn the ignition switch ON.
4)Measure the voltage of harness between the
combination meter connector and chassis
ground.
(E11) No. 1 (+) — Chassis ground (-):
3 CHECK COMBINATION METER. Is the resistance less than 10 Replace the har- Repair or replace
cardiagn.com
1)Turn the ignition switch to OFF. Ω? ness connector the combination
2)Remove the combination meter. between combina- meter and the oil
3)Measure the resistance of combination tion meter and oil pressure switch
meter. pressure switch. warning light bulb.
Terminal
No. A7 — No. B2:
LU-9
ENGINE OIL
LUBRICATION
3. Engine Oil B: REPLACEMENT

1) Drain the engine oil by loosening the engine oil
A: INSPECTION drain plug.
1) Park the vehicle on a level surface. • Non-Turbo MODEL
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the en-
gine oil level is below the “L” line, add oil to bring (A)
the level up to “F” line.
5) After turning off the engine, wait a few minutes (B)
for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engine is warm, en- EN0009
gine oil level may show in the range between the
“F” line and notch mark. This is caused by thermal • Turbo MODEL
expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the “F” line when the engine is cold.
(A)
cardiagn.com
(B)
EN0010
(A) Gasket
B2M3883A (B) Drain plug
2) Open the engine oil filler cap for quick draining of

the engine oil.
B2M3883A
3) Replace the drain plug gasket.
LU-10
ENGINE OIL
LUBRICATION
4) Tighten the engine oil drain plug after draining Engine oil capacity: (Turbo model)
engine oil. Upper level
Tightening torque: 4.5 2 (4.8 US qt, 4.0 Imp qt)
44 N·m (4.5 kgf-m, 32.5 ft-lb) Lower level
3.5 2 (3.7 US qt, 3.1 Imp qt)
• Non-Turbo MODEL
(A)
(B)
EN0009 B2M3885A
• Turbo MODEL The proper viscosity helps vehicle get good cold
and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
cardiagn.com
(A) oil to be added is a different brand from that in
the engine; however, use oil having the API
(B)
classification and SAE viscosity No. designat-
ed by SUBARU.
NOTE:
If the vehicle is used in desert areas with very high
EN0010
temperatures or for other heavy duty applications,
the following viscosity oils may be used: API classi-
(A) Gasket fication: SL or SJ or SH
(B) Drain plug SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50.
5) Fill engine oil through the filler pipe up to upper
point on level gauge. Make sure that the vehicle is 6) Close the engine oil filler cap.
placed level when checking oil level. Use the en- 7) Start the engine and warm it up for a time.
gine oil of proper quality and viscosity, selected in 8) After the engine stops, recheck the oil level. If
accordance with the table in figure. necessary, add engine oil up to the upper level on
level gauge.
Recommended oil
API classification
SL or SJ or SH with the words “Energy Con-
serving or Energy conserving II”, CCMC
specification G4 or G5, ACEA specification
A1, A2 or A3, or New API mark displayed on
the container (If it is impossible to get SL or
SJ or SH grade, you may use SG grade.)
Engine oil capacity: (Non-Turbo model)
Upper level
4.0 2 (4.2 US qt, 3.5 Imp qt) B2M3883A
Lower level
3.0 2 (3.2 US qt, 2.6 Imp qt)
LU-11
OIL PUMP
LUBRICATION
4. Oil Pump 7) Remove the crankshaft position sensor.
A: REMOVAL
B2M1252
8) Remove the V-belts. <Ref. to ME-44, REMOV-

AL, V-belt.> or <Ref. to ME(TURBO)-44, REMOV-
G6M0095
AL, V-belt.>
2) Lift-up the vehicle. 9) Remove the rear side V-belt tensioner.
4) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)
cardiagn.com
S2M0113
10) Remove the crankshaft pulley by using ST.

1600 cc and 2000 cc model:
S2M0027
ST 499977300 CRANKSHAFT PULLEY
5) Remove the water pipe and hoses between oil WRENCH
cooler and water pump. (Turbo model) 2500 cc model:
ST 499977100 CRANKSHAFT PULLEY
WRENCH
S2M0112
6) Remove the radiator. <Ref. to CO-39, REMOV-

S2M0114
AL, Radiator.>
11) Remove the water pump. <Ref. to CO-28, RE-
MOVAL, Water Pump.>
LU-12
OIL PUMP
LUBRICATION
12) Remove the timing belt guide. (MT vehicles B: INSTALLATION

only) Install in the reverse order of removal.
Do the following:
1) Apply fluid packing to the matching surfaces of
oil pump.
Fluid packing:
S2M0115
13) Remove the crankshaft sprocket.
S2M0739B
2) Replace the O-ring (A) with a new one.

3) Apply a coat of engine oil to the inside of oil seal.
cardiagn.com
S2M0116
14) Remove the bolts which install oil pump onto

cylinder block.
S2M0118B
4) Be careful not to scratch the oil seal when install-

ing oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with crankshaft, and push the oil pump straight.
CAUTION:
S2M0117
Make sure the oil seal lip is not folded.
15) Remove the oil pump by using flat bladed 6) Install the oil pump.
screwdriver.
Tightening torque:
CAUTION: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
Be careful not to scratch the mating surfaces of
cylinder block and oil pump.
S2M0740B
S2M1819
LU-13
OIL PUMP
LUBRICATION
C: DISASSEMBLY D: ASSEMBLY
Remove the screws which secure oil pump cover 1) Install the front oil seal by using ST.
and disassemble oil pump. Inscribe alignment ST 499587100 OIL SEAL INSTALLER
marks on the inner and outer rotors so that they can NOTE:
be replaced in their original positions during reas- Use a new oil seal.
sembly.
CAUTION:
Before removing the relief valve, loosen the
plug when removing oil pump from cylinder
block.
S2M0235A
2) Apply a coat of engine oil to the inner and outer

rotors.
3) Install the inner and outer rotors in their original
positions.
cardiagn.com
4) Install the oil relief valve and relief valve spring
and plug.
NOTE:
Use a new gasket.
5) Install the oil pump cover.
Tightening torque:
T1: 5 N·m (0.5 kgf-m, 3.6 ft-lb)
T2: 44 N·m (4.5 kgf-m, 32.5 ft-lb)
S2M0735A
(A) Oil seal

(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
S2M0735B
LU-14
OIL PUMP
LUBRICATION
E: INSPECTION 3. SIDE CLEARANCE

1. TIP CLEARANCE Measure the clearance between the oil pump inner
rotor and pump cover. If clearance exceeds the lim-
Measure the tip clearance of rotors. If clearance ex- it, replace the rotor or pump body.
ceeds the limit, replace the rotors as a matched set.
Side clearance:
Tip clearance: Standard
Standard 0.02 — 0.07 mm (0.0008 — 0.0028 in)
0.04 — 0.14 mm (0.0016 — 0.0055 in) Limit
Limit 0.12 mm (0.0047 in)
0.18 mm (0.0071 in)
S2M0738
S2M0736
cardiagn.com
4. OIL RELIEF VALVE
2. CASE CLEARANCE
Check the valve for fitting condition and damage,
Measure the clearance between the outer rotor and and the relief valve spring for damage and deterio-
cylinder block rotor housing. If clearance exceeds ration. Replace the parts if defective.
the limit, replace the rotor.
Relief valve spring:
Case clearance: Free length
0.10 — 0.175 mm (0.0039 — 0.0069 in) Installed length
Limit 54.7 mm (2.154 in)
0.20 mm (0.0079 in) Load when installed
77.08 N (7.86 kgf, 17.33 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.
S2M0737
LU-15
OIL PAN AND STRAINER
LUBRICATION
5. Oil Pan and Strainer 8) Remove the pitching stopper.
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove the front wheels.
H3M1839

• Non-Turbo MODEL
G6M0095
4) Remove the air intake duct and air cleaner case.

(Non-Turbo model)
cardiagn.com
5) Disconnect the connector from mass air flow
sensor. (Turbo model)
B2M2931
• Turbo MODEL
EN0031
6) Remove the air intake boot and air cleaner upper

cover. (Turbo model)
EN0035
10) Support the engine with a lifting device and

wire ropes.
EN0032
7) Remove the intercooler (Turbo model) <Ref. to

IN(TURBO)-10, REMOVAL, Intercooler.>
G2M0297

CAUTION:
At this time, raise up the wire ropes.
LU-16
LUBRICATION
13) Drain the engine oil. 17) Insert the oil pan cutter blade between the cyl-
Set a container under the vehicle, and remove the inder block-to-oil pan clearance.
drain plug from oil pan. CAUTION:
• Non-Turbo MODEL Do not use a screwdriver or similar tool in place
of oil pan cutter.
• Non-Turbo MODEL
(A)
(B)
EN0009
• Turbo MODEL
EN0040
• Turbo MODEL
(A)
cardiagn.com
(B)
EN0010
(A) Gasket EN0041

(B) Drain plug
18) Remove the oil strainer.
14) Remove the front and center exhaust pipes.
(Non-Turbo model) <Ref. to EX-7, REMOVAL,
Front Exhaust Pipe.> or <Ref. to EX(w/oOBD)-9,
REMOVAL, Front Exhaust Pipe.>
15) Remove the nuts which install front cushion
rubber onto front crossmember.
S2M0238
19) Remove the baffle plate.
S2M1831
16) Remove the bolts which install oil pan on cylin-

der block while raising up engine.
S2M0309
LU-17
LUBRICATION
B: INSTALLATION 4) Tighten the bolts which install the oil pan onto
engine block.
CAUTION:
Before installing the oil pan, clean sealant from Tightening torque:
oil pan and engine block. 5 N·m (0.5 kgf-m, 3.6 ft-lb)
1) Install the baffle plate. • Non-Turbo MODEL
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0040
• Turbo MODEL
S2M0309
2) Install the oil strainer onto baffle plate.
cardiagn.com
NOTE:
Replace the O-ring with a new one.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
EN0041
5) Lower the engine onto front crossmember.

6) Tighten the nuts which install front cushion rub-
ber onto front crossmember.
Tightening torque:
69 N·m (7.0 kgf-m, 50.9 ft-lb)
S2M0238
3) Apply fluid packing to the mating surfaces and

install oil pan.
Fluid packing:
S2M1831
S2M1833A
LU-18
LUBRICATION
7) Install the front and center exhaust pipes. (Non- 12) Install the radiator upper brackets.
Turbo model) • Non-Turbo MODEL
<Ref. to EX-8, INSTALLATION, Front Exhaust
Pipe.> or <Ref. to EX(w/oOBD)-10, INSTALLA-
TION, Front Exhaust Pipe.>
NOTE:
Always use new gaskets.
B2M2931
• Turbo MODEL
B2M3200

cardiagn.com
CAUTION:
At this time, lower the lifting device and release
steel cables.
EN0035
10) Remove the lifting device and steel cables.
13) Install the air intake duct and air cleaner case.
(Non-Turbo model)
<Ref. to IN-6, INSTALLATION, Air Cleaner Case.>
and <Ref. to IN-7, INSTALLATION, Air Intake
Duct.>
14) Install the intercooler. (Turbo model) <Ref. to
IN(TURBO)-11, INSTALLATION, Intercooler.>
15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
G2M0297
11) Install the pitching stopper.

Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
EN0032
H3M1839A
LU-19
LUBRICATION
16) Connect the connector to mass air flow sensor.

(Turbo model)
EN0031
17) Install the front wheels.

cardiagn.com
G6M0095
19) Fill engine oil. <Ref. to LU-10, INSPECTION,

Engine Oil.>
C: INSPECTION
By visual check make sure the oil pan, oil strainer,
oil strainer stay and baffle plate are not damaged.
LU-20
OIL PRESSURE SWITCH
LUBRICATION
6. Oil Pressure Switch B: INSTALLATION

1) Apply fluid packing to the oil pressure switch
A: REMOVAL threads.
1) Remove the generator from bracket. <Ref. to
SC-14, REMOVAL, Generator.> Fluid packing:
2) Disconnect the terminal from oil pressure switch. THREE BOND 1215 or equivalent
G2M0091 S2M0124B
3) Remove the oil pressure switch. 2) Install the oil pressure switch onto engine block.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
cardiagn.com
S2M0119
S2M0119
3) Connect the terminal of oil pressure switch.
G2M0091
4) Install the generator on bracket. <Ref. to SC-14,

INSTALLATION, Generator.>
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU-21
ENGINE OIL COOLER
LUBRICATION
7. Engine Oil Cooler 7) Remove the connector and remove oil cooler.
A: REMOVAL
3) Drain the engine oil.
Set a container under the vehicle, and remove the
drain plug from oil pan.
(A)
(B)
EN0010
(A) Gasket
(B) Drain plug
cardiagn.com
S2M1835A
4) Drain the engine coolant.
5) Remove the water by-pass pipe between oil
cooler and water pump. (A) O-ring
(B) Oil cooler
(C) Connector
S2M0112
6) Remove the engine oil filter. <Ref. to LU-24, RE-

MOVAL, Engine Oil Filter.>
LU-22
ENGINE OIL COOLER
LUBRICATION
B: INSTALLATION C: INSPECTION
1) Install in the reverse order of removal. 1) Check that the coolant passages are not
clogged using air blow method.
Tightening torque:
2) Check the mating surfaces of cylinder block, O-
T: 54 N·m (5.5 kgf-m, 40 ft-lb)
ring groove and oil filter for damage.
NOTE:
Always use a new O-ring.
cardiagn.com
G2M0784
LU-23
ENGINE OIL FILTER
LUBRICATION
8. Engine Oil Filter

A: REMOVAL
2) Remove the oil filter with ST.
• Non-Turbo MODEL
EN0055
• Turbo MODEL
cardiagn.com
EN0056
B: INSTALLATION
1) Get a new oil filter and apply a thin coat of engine
oil to the seal rubber.
2) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
3) Tighten more (approx. 2/3 to 3/4 turn) after the
seal rubber contacts the oil pump case. Do not
tighten excessively, or oil may leak.
C: INSPECTION
1) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not neces-
sary.
2) Check the engine oil level. <Ref. to LU-10, IN-
SPECTION, Engine Oil.>
LU-24
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
LUBRICATION
9. Engine Lubrication System Trouble in General

A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Trouble Possible cause Corrective action
1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
1. Warning light remains 2) Low oil pressure Clogged oil passage Clean.
on. Excessive tip clearance and side clearance of oil
Replace.
pump rotor and gear
Clogged oil strainer or broken pipe Clean or replace.
Insufficient engine oil Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
1) Burn-out bulb Replace.
2. Warning light does
2) Poor contact of switch contact points Replace.
not go on.
3) Disconnection of wiring Repair.
cardiagn.com
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3. Warning light flickers
momentarily. Check for the same
3) Low oil pressure possible causes as
listed in 1.—2).
LU-25
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
LUBRICATION
cardiagn.com
LU-26
SPEED CONTROL SYSTEMS
SP
Page
2. Accelerator Pedal........................................................................................4
3. Accelerator Control Cable ...........................................................................9
cardiagn.com
GENERAL DESCRIPTION
A: SPECIFICATION
Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in)
Accelerator pedal
Stroke At pedal pad 52 — 57 mm (2.05 — 2.24 in)
B: COMPONENT
1. LHD MODEL
cardiagn.com
B2M4176A
(1) Accelerator bracket (7) Accelerator pedal lever (13) Kick-down switch (AT model)
(2) Stopper (8) Spring pin
(3) Bushing (9) Accelerator pedal Tightening torque: N·m (kgf-m, ft-lb)
(4) Clip (10) Accelerator stopper T: 18 (1.8, 13.0)
(5) Accelerator spring (11) Accelerator plate
(6) Accelerator pedal spring (12) Clip
SP-2
GENERAL DESCRIPTION
2. RHD MODEL
cardiagn.com
EN1493
(1) Accelerator bracket (6) Spring pin (11) Kick-down switch (AT model).
(2) Stopper (7) Accelerator spring
(3) Accelerator pedal lever (8) Bushing Tightening torque: N·m (kgf-m, ft-lb)
(4) Accelerator pedal spring (9) Clip T: 18 (1.8, 13.0)
(5) Accelerator pedal (10) Accelerator stopper
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.
tect them from dust and dirt.
points.
cable from battery.
SP-3
ACCELERATOR PEDAL
2. Accelerator Pedal • RHD SOHC MODEL

(C)
A: REMOVAL (B)
2) Remove the lock nut from accelerator cable (E)
bracket. (E)
3) Separate the accelerator cable from bracket.
4) Remove the accelerator cable end from throttle (D)
(E)
cam. (A)
5) Disconnect the accelerator cable from throttle
body. (E)
EN0921
CAUTION:
Be careful not to kink the accelerator cable. • LHD DOHC turbo MODEL
• SOHC MODEL
(D)
(E)
(A)
(A) (E)
(B)
(C)
cardiagn.com
(E)
(E) EN0922
(B) (C) (D) EN0918
• RHD DOHC turbo MODEL
• DOHC turbo MODEL (E) (C)
(B)
(A) (C)
(D) (A)
(B) (E)
(D)
EN0923
EN0919
(A) Toe board
(A) Lock nut (B) Accelerator cable
(B) Accelerator cable bracket (C) To accelerator pedal
(C) Accelerator cable (D) Brake booster
(D) Throttle cam (E) Clip
6) Remove the clip inside engine compartment. 7) Remove the instrument panel lower cover from
• LHD SOHC MODEL instrument panel, and connector.
8) Disconnect the connector from kick-down
switch. (AT model)
(A) 9) Remove the brake and clutch pedal bracket.
(LHD MT model) <Ref. to BR-65, REMOVAL,
(D) Brake Pedal.>
(C)
(E) (E)
(B)
EN0920
SP-4
ACCELERATOR PEDAL
10) Remove the accelerator pedal connecting bolt 13) Disconnect the accelerator cable bushing from
from accelerator pedal bracket. accelerator pedal lever.
• LHD MODEL
B4M1741B
EN0924
(A) Slot type screwdriver
• RHD MODEL
14) Disconnect the accelerator cable stopper (A)
from bracket.
cardiagn.com
EN0925
11) Disconnect the grommet from toe board.

B4M1742B
NOTE:
From the inside compartment, push the grommet 15) Separate the accelerator cable and bracket.
(A) into hole. B: INSTALLATION
CAUTION:
• If the cable clamp is damaged, replace it with
a new one.
• Never fail to cover the outer cable end with
boot.
• Be careful not to kink the accelerator cable.
• Always use new clevis pins.
B4M1740C
12) Pull out the cable from toe board hole.
SP-5
ACCELERATOR PEDAL
C: DISASSEMBLY • RHD MODEL

1) Remove the clip, and then remove the accelera-
tor pedal from bracket.
2) Pull out the spring pin, and then remove the ac-
celerator pedal from accelerator pedal lever.
• LHD MODEL
cardiagn.com
EN1494
(A) Accelerator bracket

(B) Stopper
(C) Bushing
EN0926 (D) Clip
(E) Accelerator spring
(A) Accelerator bracket (F) Accelerator pedal spring
(B) Stopper (G) Accelerator pedal lever
(C) Bushing (H) Spring pin
(D) Clip (I) Accelerator pedal
(E) Accelerator spring (J) Kick-down switch (AT model)
(F) Accelerator pedal spring
(G) Accelerator pedal lever D: ASSEMBLY
(H) Spring pin Assemble in the reverse order of disassembly.
(I) Accelerator pedal CAUTION:
(J) Kick-down switch (AT model) Clean and apply grease to the portions indicat-
ed in the figure.
Grease:
Nigtight — LYW No.2 or equivalent
SP-6
ACCELERATOR PEDAL
E: INSPECTION F: ADJUSTMENT
1) Check the pedal stroke and free play by operat-
1. ACCELERATOR PEDAL ing accelerator pedal by hand.
Lightly move the pedal pad in lateral direction to en- If it is not within specified value, adjust it by turning
sure that pedal deflection is in specified range. the nut connecting the accelerator cable to throttle
CAUTION: body.
If excessive deflection is noted, replace the Free play at pedal pad: L
bushing and clip with new ones. 1 — 4 mm (0.04 — 0.16 in)
Deflection of accelerator pedal: Stroke at pedal pad: A
Service limit 52 — 57 mm (2.05 — 2.24 in)
5.0 mm (0.197 in) or less
cardiagn.com
G4M0333
2. KICK-DOWN SWITCH
If the kick-down switch does not operate properly
(or if it does not stop at the specified position), re-
place with a new one.
Specified position: A
2+1.5/0 mm (0.079 +0.059/0 in)
B4M1739A
(A) Accelerator pedal

(B) Accelerator pedal bracket
Accelerator cable lock nut tightening torque:

12 N·m (1.2 kgf-m, 9 ft-lb)
B4M0155A
SP-7
ACCELERATOR PEDAL
2) Check to ensure the kick-down switch operates

at the specified value in relation to the stroke of the
accelerator pedal.
If it is not within specified value, adjust it by adjust-
ing the position of kick-down switch.
CAUTION:
Be careful not to rotate the kick-down switch.
Kick-down switch stroke: A
48±1 mm (1.89±0.04 in)
Kick-down switch tightening torque:
12 N·m (1.2 kgf-m, 9 ft-lb)
cardiagn.com
B4M1758C
(A) Kick down switch
SP-8
ACCELERATOR CONTROL CABLE
3. Accelerator Control Cable

A: REMOVAL
1) Remove the accelerator pedal. <Ref. to SP-4,
REMOVAL, Accelerator Pedal.>
2) Separate the accelerator cable and accelerator
pedal.
B: INSTALLATION
CAUTION:
• If the cable clamp is damaged, replace it with
a new one.
• Never fail to cover the outer cable end with
boot.
• Be careful not to kink the accelerator cable.
• Do not apply grease to the throttle cable on
engine side.
2) Adjustment after pedal installation. <Ref. to SP-
5, INSTALLATION, Accelerator Pedal.>
C: INSPECTION
cardiagn.com
1) Make sure the inner cable is not twisted or
frayed.
2) Make sure the outer cable is not cracked.
SP-9
ACCELERATOR CONTROL CABLE
cardiagn.com
SP-10
IGNITION
IG
Page
2. Spark Plug...................................................................................................5
3. Ignition Coil and Ignitor Assembly...............................................................8
4. Spark Plug Cord........................................................................................10
cardiagn.com
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item Designation
1600 cc CM12—100C
Model 2000 cc and
FH0137
2500 cc
1600 cc HITACHI
Manufacturer 2000 cc and
DIAMOND
2500 cc
Ignition coil
1600 cc 0.7 Ω±10%
and ignitor
assembly Primary coil resistance 2000 cc and
0.73 Ω±10%
2500 cc
1600 cc 13.0 kΩ±20%
Secondary coil resis-
tance 2000 cc and
12.8 kΩ±15%
2500 cc
Insulation resistance between primary
More than 100 MΩ
terminal and case
CHAMPION: RC8YC4
1600 cc
NGK: BKR6E-11 (Alternate)
Type and manufacturer
2000 cc and CHAMPION: RC10YC4
cardiagn.com
Spark plug
2500 cc NGK: BKR5E-11 (Alternate)
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
IG-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
1. 1600 CC MODEL
T1
(3)
(2)
(2)
cardiagn.com
(1)
T2
(4)
(4)
T2
EN1039
S6M0329B
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7)
(3) Ignition coil and ignitor ASSY T2: 21 (2.1, 15.2)
IG-3
GENERAL DESCRIPTION
IGNITION
2. 2000 CC AND 2500 CC MODEL
cardiagn.com
S6M0329B
(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, 15.2)
(3) Ignition coil and ignitor ASSY T2: 6.4 (0.65, 4.7)
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- • Place shop jacks or safety stands at the specified
tion. points.
• Remove contamination including dirt and corro- • Before disconnecting electrical connectors of
sion before removal, installation or disassembly. sensors or units, be sure to disconnect the ground
• Keep the disassembled parts in order and pro- cable from battery.
IG-4
SPARK PLUG
IGNITION
2. Spark Plug 2. LH SIDE

A: REMOVAL 1) Disconnect the ground cable from battery.
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug
CHAMPION: RC8YC4
1600 cc
2000 cc
CHAMPION: RC10YC4
and
2500 cc
G6M0095
1. RH SIDE 2) Disconnect the washer motor connector.

cardiagn.com
B6M0562
G6M0095 3) Disconnect the rear window glass washer hose

2) Remove the resonator chamber. <Ref. to IN-8, from washer motor, then plug connection with a
REMOVAL, Resonator Chamber.> suitable cap.
3) Remove the spark plug cords by pulling boot, not 4) Remove the two bolts which hold washer tank,
the cord itself. then take the tank away from the working area.
B2M2023
B2M4127
4) Remove the spark plugs with spark plug sock- 5) Remove the spark plugs cord by pulling boot, not
ets. the cord itself.
B2M4286 B2M4287
IG-5
SPARK PLUG
IGNITION
6) Remove the spark plugs with spark plug sock- C: INSPECTION

ets. Check the electrodes and inner and outer porcelain
of plugs, noting the type of deposits and the degree
of electrode erosion.
B2M4288
B: INSTALLATION S6M0420A
1. RH SIDE
(A) Electrode gap
(B) Carbon accumulation or wear
Tightening torque (Spark plug): (C) Cracks
21 N·m (2.1 kgf-m, 15.2 ft-lb) (D) Damage
CAUTION: (E) Damaged gasket
cardiagn.com
The above torque should be only applied to
new spark plugs without oil on their threads. 1) Normal:
In case their threads are lubricated, the torque Brown to grayish-tan deposits and slight electrode
should be reduced by approx. 1/3 of the speci- wear indicates correct spark plug heat range.
fied torque in order to avoid over-stressing.
2. LH SIDE
Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
G6M0087
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the speci- 2) Carbon fouled:
fied torque in order to avoid over-stressing. Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
G6M0088
IG-6
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
guides and stems. If the same condition remains Spark plug gap: L
after repair, use a hotter plug. 1.0 — 1.1 mm (0.039 — 0.043 in)
G6M0089 S6M0412B
4) Overheating: NOTE:
White or light gray insulator with black or gray Replace with a new spark plug if this area (A) is
brown spots and bluish burnt electrodes indicates worn to “ball” shape.
engine overheating. Moreover, the appearance re-
cardiagn.com
sults from incorrect ignition timing, loose spark
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
D: CLEANING
Clean the spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove the
carbon or oxide deposits, but do not wear away
porcelain.
If deposits are too stubborn, replace the spark
plugs.
IG-7
IGNITION COIL AND IGNITOR ASSEMBLY
IGNITION
3. Ignition Coil and Ignitor As- 4) Remove the ignition coil and ignitor assembly.
• 1600 cc MODEL
sembly
A: REMOVAL
EN1044
G6M0095
2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.
• 1600 cc MODEL
cardiagn.com
B6M0930
B: INSTALLATION
Tightening torque:
EN1040 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
• 2000 cc and 2500 cc MODEL CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
• 1600 cc MODEL
S6M0373
3) Disconnect the connector from ignition coil and

ignitor assembly. EN1044
IG-8
IGNITION COIL AND IGNITOR ASSEMBLY
IGNITION
• 2000 cc and 2500 cc MODEL Specified resistance: (2000 cc and 2500 cc)
[Primary side]
Between terminal No. 1 and No. 2
0.73 Ω±10%
0.73 Ω±10%
B6M0930
4 3 2 1
C: INSPECTION
Using the accurate tester, inspect the following
items, and replace if defective.
1) Primary resistance
2) Secondary coil resistance EN1041
CAUTION: [Secondary side]

If the resistance is extremely low, this indicates Between (A) and (B)
the presence of a short-circuit. 12.8 kΩ±15%
cardiagn.com
Specified resistance:(1600 cc) Between (C) and (D)
12.8 kΩ±15%
[Primary side]
Between terminal No. 1 and No. 4 (C)
0.7 Ω±10% (A)
0.7 Ω±10%
(D)
(B)
4 3 2 1 EN1043
3) Insulation between primary terminal and case:

100 MΩ or more.
EN1041
[Secondary side]
Between (A) and (B)
13.0 kΩ±20%
Between (C) and (D)
13.0 kΩ±20%
(C) (D)
(A) (B)
EN1042
IG-9
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 kΩ
#2 cord: 7.3 — 13.7 kΩ
#3 cord: 5.9 — 11.1 kΩ
#4 cord: 7.3 — 13.7 kΩ
cardiagn.com
S6M0337
IG-10
STARTING/CHARGING SYSTEMS
SC
Page
2. Starter .........................................................................................................5
3. Generator ..................................................................................................14
4. Battery.......................................................................................................20
cardiagn.com
GENERAL DESCRIPTION
A: SPECIFICATIONS
Item Designation
Type Reduction type
Vehicle type MT vehicles AT vehicles
Model M000T83981 M001T86381
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load charac-
Starter Current 90 A or less
teristics
Rotating speed 2,800 rpm or more 2,400 rpm or more
Voltage 7.5 V 7.7 V
Load character- Current 300 A 400 A
istics Torque 8.6 N (0.88 kgf, 1.93 lb) or more 16.0 N (1.63 kgf, 3.60 lb) or more
Rotating speed 920 rpm or more 740 rpm or more
Voltage 4V 3.5 V
Lock character-
Current 650 A or less 940 A or less
cardiagn.com
istics
Torque 14.7 N (1.50 kgf, 3.30 lb) or more 28.9 N (2.95 kgf, 6.50 lb) or more
Rotating-field three-phase type, Voltage regulator built-in type, with load
Type
response control system
Model A2TB2891
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Generator
Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 36 A or more
Output current 2,500 rpm — 65 A or more
5,000 rpm — 86 A or more
Regulated voltage 14.1 — 14.8 V [20°C (68°F)]
SC-2
GENERAL DESCRIPTION
B: COMPONENT
1. STARTER
cardiagn.com
H6M0492C
(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder
(3) Lever set (9) Gear ASSY (15) Brush
(4) Magnet switch ASSY (10) Ball (16) Sleeve bearing
(5) Stopper set (11) Packing (17) Rear bracket
(6) Over running clutch (12) Yoke
SC-3
GENERAL DESCRIPTION
2. GENERATOR
cardiagn.com
H6M0493C
(1) Pulley (5) Rotor (9) Brush

(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (11) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal
C: CAUTION • Be careful not to burn your hands, because each

• Wear working clothing, including a cap, protec- part in the vehicle is hot after running.
tive goggles, and protective shoes during opera- • Be sure to tighten fasteners including bolts and
tion. nuts to the specified torque.
• Remove contamination including dirt and corro- • Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
• Keep the disassembled parts in order and pro- • Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect the ground
• Before removal, installation or disassembly, be cable from battery.
SC-4
STARTER
2. Starter • AT vehicles
A: REMOVAL
EN0370
5) Disconnect the connector and terminal from

starter.
G6M0095
2) Remove the air cleaner case. (Non-Turbo Mod-

el)
cardiagn.com
S6M0002A
(A) Terminal
B6M1221 (B) Connector
3) Remove the intercooler. (Turbo Model) <Ref. to 6) Remove the starter from transmission.
IN(TURBO)-10, REMOVAL, Intercooler.>
4) Remove the air cleaner case stay. (Non-Turbo
Model)
• MT vehicles
EN1007
EN0369
SC-5
STARTER
B: INSTALLATION 2) Remove the bolts which hold switch assembly,

Install in the reverse order of removal. and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
Tightening torque:
50 N·m (5.1 kgf-m, 37 ft-lb) CAUTION:
Be careful because the pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.
EN1007
C: DISASSEMBLY
B2M4455A
1. STARTER ASSEMBLY
1) Loosen the nut which holds terminal M of switch (A) Switch ASSY
assembly, and then disconnect the connector. (B) Plunger
cardiagn.com
3) Remove both through-bolts and brush holder
screws, and then detach the rear bracket and brush
holder.
CAUTION:
Before removal, confirm the attachment loca-
tions of brush holder and rear bracket.
B2M4454A
(A) Terminal M
(B) Terminal B
(C) Terminal S
H6M0494B
(A) Brush holder

(B) Rear bracket
SC-6
STARTER
4) Remove the armature and yoke. The ball used 6) Remove the shaft assembly and overrunning
as a bearing will then be removed from the end of clutch as a unit.
armature. CAUTION:
CAUTION: Before removal, confirm the following:
Be sure to mark an alignment mark on the yoke • Lever direction
and front bracket before removing yoke. • Internal gear assembly position
H6M0495D B2M4458B
(A) Armature (A) Lever

(B) Ball (B) Shaft ASSY
(C) Yoke (C) Overrunning clutch
cardiagn.com
(D) Front bracket (D) Internal gear ASSY
5) Remove the packing A, three planetary gears,

packing B and plate.
CAUTION:
Before removal, confirm the inserting location
of packing A.
B2M4793A
(A) Packing A
(B) Planetary gear
(C) Plate
(D) Packing B
SC-7
STARTER
7) Remove the overrunning clutch from shaft as- 2. BRUSH HOLDER

sembly as follows:
Slightly open the metal fitting holding the insulating
(1) Remove the stopper from ring by lightly tap-
plate to brush holder. Remove the insulating plate.
ping the stopper with an appropriate tool (such
as a 14 mm (0.55 in) socket wrench). NOTE:
(2) Remove the ring, stopper and clutch from The brush and spring can be easily removed from
shaft. the brush holder at this time.
H6M0497B
(A) Brush holder

(B) Insulating plate
(C) Metal fitting
cardiagn.com
B2M4769A
(A) Socket wrench

(B) Ring
(C) Shaft
(D) Stopper
SC-8
STARTER
D: ASSEMBLY 3) When installing the yoke to the front bracket,

Assemble in the reverse order of disassembly. Do match bolt hole.
the following:
1) Carefully assemble all parts in the order of as-
sembly and occasionally inspect nothing has been
overlooked.
2) When installing the shaft assembly to front
bracket, be careful of the following.
• Lever direction
B2M4773A
(A) Bolt hole
4) When installing the rear bracket, match brush

holder and yoke's groove.
B2M4770
• Internal gear position
cardiagn.com
B2M4774
5) When installing the switch assembly, catch

plunger protrusion to lever edge.
6) Apply grease to the following parts during as-
B2M4771
sembly.
• Packing position • Front and rear bracket sleeve bearing
• Armature shaft gear
• Outer periphery of plunger
• Mating surface of plunger and lever
• Gear shaft splines
• Mating surface of lever and clutch
• Ball at the armature shaft end
• Internal and planetary gears
7) After assembling parts correctly, make sure the
starter operates properly.
B2M4772
SC-9
STARTER
E: INSPECTION 4) Armature short-circuit test

Check the armature for short-circuit by placing it on
1. ARMATURE growler tester. Hold a hacksaw blade against the
1) Check the commutator for any sign of burns of armature core while slowly rotating armature. A
rough surfaces or stepped wear. If wear is of a mi- short-circuited armature will cause the blade to vi-
nor nature, correct it by using sand paper. brate and to be attracted to core. If the hacksaw
2) Run-out test blade is attracted or vibrates, the armature, which
Check the commutator run-out, and then replace if is short-circuited, must be replaced or repaired.
it exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)
S6M0402A
(A) Iron sheet

(B) Grower tester
cardiagn.com
5) Armature ground test
Using a circuit tester, touch one probe to the com-
B2M4460A mutator segment and the other to shaft. There
should be no continuity. If there is continuity, the ar-
(A) Dial gauge mature is grounded.
(B) V-block
Replace the armature if it is grounded.
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
G6M0041
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
S6M0401A
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
(A) Depth of mold
tion of rotation (counterclockwise). It should rotate
(B) Segment smoothly. But in opposite direction, it should be
(C) Mold locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
SC-10
STARTER
4. BRUSH AND BRUSH HOLDER 5. SWITCH ASSEMBLY

1) Brush length Be sure there is continuity between the terminals S
Measure the brush length, and then replace if it ex- and M, and between terminal S and ground. Use a
ceeds the service limit. circuit tester (set in “ohm”).
Replace if abnormal wear or cracks are noticed. Also check to be sure there is no continuity be-
tween terminal M and B.
Brush length:
Standard Terminal / Specified resistance:
12.3 mm (0.484 in) S — M / Less than 1 Ω
Service limit S — Ground / Less than 1 Ω
7.0 mm (0.276 in) M — B / More than 1 M Ω
cardiagn.com
H6M0496B S6M0403
(A) Service limit line 6. SWITCH ASSEMBLY OPERATION

(B) Brush 1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
2) Brush movement starter body to ground terminal of battery. The pin-
Be sure the brush moves smoothly inside brush ion should be forced endwise on shaft.
holder.
3) Brush spring force CAUTION:
Measure the brush spring force with a spring scale. With the pinion forced endwise on shaft, starter
If it is less than the service limit, replace the brush motor can sometimes rotate because current
holder. flows, through pull-in coil, to motor. This is not
a problem.
Brush spring force: 2) Disconnect the connector from terminal M, and
Standard then connect the positive terminal of battery and
21.6 N (2.2 kgf, 4.9 lb) (when new) terminal M using a lead wire and ground terminal to
Service limit starter body.
5.9 N (0.6 kgf, 1.3 lb) In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
S6M0393A
(A) Terminal S
(B) Terminal M
SC-11
STARTER
7. PINION GAP 8. PERFORMANCE TEST

1) Measure the pinion gap while the pinion is pulled The starter should be submitted to performance
out as shown in the figure. tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
Pinion gap:
engine.
0.5 — 2.0 mm (0.020 — 0.079 in)
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.
S6M0394A
(A) Pinion
(B) Gap
(C) Stopper
cardiagn.com
S6M0395A
If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
(A) Variable resistance
nal M of switch assembly, and then connect
(B) Magnetic switch
terminal M to ground terminal (−) of battery with a
lead wire. Next, gently push the pinion back with (C) Starter body
your fingertips, and then measure the pinion gap. 1) No-load test
2) If the pinion gap is outside specified range, re- With switch on, adjust the variable resistance to ob-
move or add number of adjustment washers used tain 11 V, take the ammeter reading, and then mea-
on the mounting surface of switch assembly until sure the starter speed. Compare these values with
correct pinion gap is obtained. the specifications.
No-load test (Standard):
Voltage / Current
11 V / 90 A max.
Rotating speed
MT vehicles
2,800 rpm or more
AT vehicles
2,400 rpm or more
SC-12
STARTER
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within the specifications.
Load test (Standard):
Voltage / Load
MT vehicles
7.5 V/8.6 N (0.88 kgf, 1.93 lb)
AT vehicles
7.7 V/16.0 N (1.63 kgf, 3.60 lb)
Current / Speed
MT vehicles
300 A/920 rpm or more
AT vehicles
400 A/740 rpm or more
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
cardiagn.com
Lock test (Standard):
Voltage / Current
MT vehicles
4 V/650 A or less
AT vehicles
3.5 V/940 A or less
Torque
MT vehicles
14.7 N (1.50 kgf, 3.30 lb) or more
AT vehicles
28.9 N (2.95 kgf, 6.50 lb) or more
SC-13
GENERATOR
3. Generator • Turbo Model
A: REMOVAL
EN0048
4) Remove the front side V-belt.

G6M0095
<Ref. to ME-44, FRONT SIDE BELT, REMOVAL,
V-belt.> or <Ref. to ME(TURBO)-44, FRONT SIDE
2) Disconnect the connector and terminal from BELT, REMOVAL, V-belt.>
generator. 5) Remove the bolts which install generator onto
• Non-Turbo Model bracket.
cardiagn.com
B2M3105 S6M0352
• Turbo Model B: INSTALLATION

CAUTION:
Check and adjust the V-belt tension. <Ref. to
ME-45, INSPECTION, V-belt.> or <Ref. to
ME(TURBO)-45, INSPECTION, V-belt.>
EN0046
3) Remove the V-belt cover.

• Non-Turbo Model
S6M0352
B2M3106
SC-14
GENERATOR
C: DISASSEMBLY
1) Heat the portion (A) of rear cover to 50°C
(122°F) with heater drier.
H6M0498B
(A) Front bracket

B6M0476B (B) Pulley
(C) Nut
2) Remove the four through bolts. Then insert the
(D) Rotor
tip of a flat-head screwdriver into the gap between
stator core and front bracket. Pry them apart to dis- 4) Unsolder connection between rectifier and stator
assemble. coil to remove the stator coil.
CAUTION:
Finish the work rapidly (less than 3 seconds)
because the rectifier cannot withstand heat
cardiagn.com
very well.
G6M0065A
(A) Screwdriver
3) Hold the rotor with a vise and remove pulley nut.

G6M0068
5) Remove the screws which secure IC regulator to

rear cover, and then unsolder connection between
IC regulator and rectifier to remove the IC regula-
tor.
G6M0066
CAUTION:
When holding the rotor with vise, insert alumi-
num plates or wood pieces on the contact sur-
faces of vise to prevent rotor from damage.
G6M0069
SC-15
GENERATOR
6) Remove the brushes by unsoldering at pigtails. 2) Heat the bearing box in rear bracket [50 to 60°C
(122 to 140°F)], and then press the rear bearing
into rear bracket.
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bear-
ing box.
3) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.
E: INSPECTION
G6M0070
1. DIODE
7) Remove the nut and insulating bushing at termi-
nal B, and then remove the rectifier. CAUTION:
Never use a mega tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
positive side heat sink. The positive diode is in
good condition if resistance is 1 Ω or less only in the
cardiagn.com
direction from the diode lead to heat sink.
S6M0405A
(A) Ractifier
(B) Rear cover
(C) Nut
D: ASSEMBLY
To assemble, reverse order of disassembly.
1) Pulling up brush
Before assembling, press the brush down into S6M0406A
brush holder with your finger, and then secure in
that position by passing a [2 mm (0.08 in) dia. (A) Diode lead
length 4 to 5 cm (1.6 to 2.0 in)] wire (A) through the (B) Heat sink (Positive side)
hole shown in the figure.
CAUTION:
Be sure to remove the wire after reassembly.
S6M0411A
SC-16
GENERATOR
2) Checking negative diode 4) Insulation test

Check for continuity between the negative side Check the continuity between slip ring and rotor
heat sink and diode lead. The negative diode is in core or shaft. If resistance is 1 Ω or less, the rotor
good condition if resistance is 1 Ω or less only in the coil is grounded, and so replace the rotor assem-
direction from the heat sink to diode lead. bly.
S6M0407A G6M0076
5) Ball bearing (rear side)

(A) Diode lead
(1) Check the rear ball bearing. Replace if it is
(B) Heat sink (Negative side)
noisy or if the rotor does not turn smoothly.
2. ROTOR (2) The rear bearing can be removed by using
common bearing puller.
cardiagn.com
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness of the sliding surface. Repair the slip
ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. If the slip ring
is worn replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
G6M0077
Limit
22.1 mm (0.870 in) 3. STATOR
3) Continuity test 1) Continuity test
Check the resistance between slip rings using cir- Inspect the stator coil for continuity between each
cuit tester. end of the lead wires. If resistance is 1 M Ω or
If the resistance is not within specification, replace more, the lead wire is broken, and so replace the
the rotor assembly. stator assembly.
Specified resistance:
Approx. 2.7 — 3.2 Ω
G6M0078A
G6M0075 (A) Stator
SC-17
GENERATOR
2) Insulation test 2) Checking brush spring for proper pressure

Inspect the stator coil for continuity between stator Using a spring pressure indicator, push the brush
core and each end of lead wire. If resistance is 1 Ω into the brush holder until its tip protrudes 2 mm
or less, the stator coil is grounded, and so replace (0.08 in). Then measure the pressure of brush
the stator assembly. spring. If the pressure is less than 2.648 N (270 g,
9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 oz).
G6M0079
4. BRUSH
1) Measure the length of each brush. If wear ex- G6M0143
ceeds the service limit, replace the brush. Each

brush has the service limit mark (A) on it. 5. BEARING (FRONT SIDE)
1) Check the front ball bearing. If the resistance is
cardiagn.com
Brush length:
felt while rotating, or if abnormal noise is heard, re-
Standard
place the ball bearing.
18.5 mm (0.728 in)
2) Replacing front bearing
Service limit
(1) Remove the front bearing retainer.
5.0 mm (0.197 in)
(2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front brack-
et with a hand press or vise. A socket wrench
can serve as the tool.
H6M0499B
S6M0409A
(A) Front bracket

(B) Socket wrench
(3) Set a new bearing and closely install a fit

tool on the bearing outer race. Press the bearing
down into place with a hand press or vise. A
socket wrench can serve as the tool.
SC-18
GENERATOR
(4) Install the front bearing retainer.
S6M0410A
(A) Bearing
(B) Socket wrench
(C) Front bracket
cardiagn.com
SC-19
BATTERY
4. Battery C: INSPECTION
A: REMOVAL WARNING:
1) Disconnect the positive (+) cable after discon- • Electrolyte has toxicity; be careful handling
necting the ground (−) cable of battery. the fluid.
2) Remove the flange nuts from battery rods, and • Avoid contact with skin, eyes or clothing. Es-
then take off the battery holder. pecially at contact with eyes, blush with water
for 15 minutes and get prompt medical atten-
tion.
• Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
• Ventilate when charging or using in enclosed
space.
• For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a bat-
tery.
B6M1506 • Do not let the battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
3) Remove the battery. corrosive acid.
B: INSTALLATION • To lessen the risk of sparks, remove rings,
Install in the reverse order of removal. metal watch-bands, and other metal jewelry.
cardiagn.com
Never allow metal tools to contact the positive
Tightening torque: battery terminal and anything connected to it
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) while you are at the same time in contact with
NOTE: any other metallic portion of the vehicle be-
• Clean the battery cable terminals, and then apply cause a short circuit will be caused.
grease to retard formation of corrosion. 1. EXTERNAL PARTS:
• Connect the positive (+) cable of battery and then
the ground (−) cable of battery. Check for the existence of dirt or cracks on battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean with water and wipe with a dry
cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2. ELECTROLYTE LEVEL:
Check the electrolyte level in each cell. If the level
is below MIN LEVEL, bring the level to MAX LEVEL
by pouring distilled water into the battery cell. Do
not fill beyond MAX LEVEL.
SC-20
BATTERY
3. SPECIFIC GRAVITY OF ELECTROLYTE: 1. JUDGMENT OF BATTERY IN CHARGED

1) Measure the specific gravity of electrolyte using CONDITION
a hydrometer and a thermometer. 1) Specific gravity of electrolyte is held at a specific
Specific gravity varies with temperature of electro- value in a range from 1.250 to 1.290 for more than
lyte so that it must be corrected at 20°C (68°F) us- one hour.
ing the following equation: 2) Voltage per battery cell is held at a specific value
S20 = St + 0.0007 × (t − 20) in a range from 2.5 to 2.8 volts for more than one
S20: Specific gravity corrected at electrolyte hour.
temperature of 20°C 2. CHECK HYDROMETER FOR STATE OF
St : Measured specific gravity CHARGE
t : Measured temperature (°C)
Determine whether or not battery must be Hydrometer
State of charge Required action
charged, according to corrected specific indicator
gravity. Green dot Above 65% Load test
Standard specific gravity: 1.220 — 1.290 [at Dark dot Below 65% Charge battery
20°C (68°F)] Replace battery*
Clear dot Low electrolyte
(If cranking complaint)
*: Check electrical system before replacement.
3. NORMAL CHARGING
cardiagn.com
Charge the battery at current value specified by
manufacturer or at approx. 1/10 of battery's am-
pere-hour rating.
4. QUICK CHARGING
Quick charging is a method in which the battery is
G6M0103
charged in a short period of time with a relatively
2) Measuring the specific gravity of the electrolyte large current by using a quick charger.
in battery will disclose the state of charge of bat- Since a large current flow raises electrolyte temper-
tery. The relation between specific gravity and state ature, the battery is subject to damage if large cur-
of charge is as shown in the figure. rent is used for prolonged time. For this reason, the
quick charging must be carried out within a current
D: MEASUREMENT range that will not increase the electrolyte temper-
WARNING: ature above 40°C (104°F).
• Do not bring an open flame close to the bat- It should be also remembered that the quick charg-
tery at this time. ing is a temporary means to bring battery voltage
CAUTION: up to a fair value and, as a rule, a battery should be
• Prior to charging, corroded terminals should charged slowly with a low current.
be cleaned with a brush and common baking CAUTION:
soda solution. • Observe the items in 1. NORMAL CHARGING.
• Be careful since the battery electrolyte over- • Never use more than 10 amperes when
flows while charging the battery. charging the battery because that will shorten
• Observe the instructions when handling bat- battery life.
tery charger.
• Before charging the battery on vehicle, dis-
connect battery ground terminal. Failure to fol-
low this rule may damage alternator's diodes or
other electrical units.
SC-21
BATTERY
cardiagn.com
SC-22
ENGINE (DIAGNOSTICS)
EN
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................4
4. Electrical Components Location................................................................10
5. Engine Control Module (ECM) I/O Signal .................................................24
6. Engine Condition Data ..............................................................................27
7. Transmission Control Module (TCM) I/O Signal .......................................28
8. Data Link Connector .................................................................................31
9. OBD-II General Scan Tool ........................................................................32
10. Subaru Select Monitor...............................................................................34
cardiagn.com
11. Read Diagnostic Trouble Code (DTC) ......................................................41
12. Inspection Mode........................................................................................42
13. Drive Cycle................................................................................................47
14. Clear Memory Mode..................................................................................49
15. Compulsory Valve Operation Check Mode ...............................................50
16. Engine Malfunction Indicator Lamp (MIL) .................................................52
17. Diagnostics for Engine Starting Failure.....................................................62
18. List of Diagnostic Trouble Code (DTC) .....................................................83
19. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................90
20. General Diagnostic Table........................................................................292
BASIC DIAGNOSTIC PROCEDURE
1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
Step Check Yes No

1 CHECK ENGINE START FAILURE. Does the engine start? Go to step 2. Inspection using
1)Ask the customer when and how the trouble “Diagnostics for
occurred using the interview check list. <Ref. Engine Start Fail-
to EN-4, CHECK, Check List for Interview.> ure”. <Ref. to EN-
2)Start the engine. 62, Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does the CHECK ENGINE Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp illu- “General Diagnos-
minate? tics Table”. <Ref.
to EN-292,
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DIAGNOSTIC Does the Subaru Select Moni- Record the DTC. Repair the related
TROUBLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool Repair the trouble parts.
cardiagn.com
1)Turn the ignition switch to OFF. indicate DTC? cause. <Ref. to NOTE:
2)Connect the Subaru Select Monitor or OBD- EN-83, List of If a DTC is not
II general scan tool to data link connector. Diagnostic Trou- shown on display
3)Turn the ignition switch to ON and Subaru ble Code (DTC).> although the MIL il-
Select Monitor or OBD-II general scan tool Go to step 4. luminates, per-
switch to ON. form diagnostics of
4)Read the DTC on the Subaru Select Monitor MIL (CHECK EN-
or OBD-II general scan tool. GINE malfunction
indicator lamp) cir-
cuit or combination
meter. <Ref. to
EN-52, Engine
Malfunction Indica-
tor Lamp (MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Moni- Inspect using Complete the
1)Perform the clear memory mode. <Ref. to tor or OBD-II general scan tool “Diagnostics Pro- diagnosis.
EN-49, Clear Memory Mode.> indicate DTC? cedure with Diag-
2)Perform the inspection mode. <Ref. to EN- nostic Trouble
42, Inspection Mode.> Code (DTC)”.
<Ref. to EN-90,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN-2
BASIC DIAGNOSTIC PROCEDURE
2. AUTOMATIC TRANSMISSION
When the diagnostic trouble code (DTC) about au-
tomatic transmission is shown on display, carry out
the following basic check. After that, carry out the
replacement or repair work.
1) ATF level check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
2) Differential gear oil level check <Ref. to AT-11,
Differential Gear Oil.>
3) ATF leak check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-11,
Differential Gear Oil.>
5) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-15, Time Lag Test.>
9) Road test <Ref. to AT-12, Road Test.>
10) Shift characteristics <Ref. to AT-18, Transfer
cardiagn.com
Clutch Pressure Test.>
EN-3
CHECK LIST FOR INTERVIEW
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 km
Vin No. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
Outdoor temperature °C (°F)
❏ Hot
❏ Warm
❏ Cool
cardiagn.com
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
Engine temperature ❏ Cold
❏ Warming-up
❏ After warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
Vehicle speed MPH
Driving conditions ❏ Not affected
❏ At starting
❏ While idling
❏ At racing
❏ While accelerating
❏ While cruising
❏ While decelerating
❏ While turning (RH/LH)
Headlight ❏ ON/❏ OFF Rear defogger ❏ ON/❏ OFF
Blower ❏ ON/❏ OFF Radio ❏ ON/❏ OFF
A/C compressor ❏ ON/❏ OFF CD/Cassette ❏ ON/❏ OFF
Cooling fan ❏ ON/❏ OFF Car phone ❏ ON/❏ OFF
Front wiper ❏ ON/❏ OFF CB ❏ ON/❏ OFF
Rear wiper ❏ ON/❏ OFF
EN-4
CHECK LIST FOR INTERVIEW
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
❏ AT diagnostics indicator light
❏ ABS warning light
❏ Engine oil pressure warning light
b) Fuel level
• Lack of gasoline: ❏ Yes/❏ No
• Indicator position of fuel gauge:
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: ❏ Yes/❏ No
• What:
d) Intentional connecting or disconnecting of hoses: ❏ Yes/❏ No
• What:
e) Installing of parts other than genuine parts: ❏ Yes/❏ No
• What:
• Where:
cardiagn.com
f) Occurrence of noise: ❏ Yes/❏ No
• From where:
• What kind:
g) Occurrence of smell: ❏ Yes/❏ No
• From where:
• What kind:
h) Intrusion of water into engine compartment or passenger compartment: ❏ Yes/❏ No
i) Troubles occurred
❏ Engine does not start.
❏ Engine stalls during idling.
❏ Engine stalls while driving.
❏ Engine speed decreases.
❏ Engine speed does not decrease.
❏ Rough idling
❏ Poor acceleration
❏ Back fire
❏ After fire
❏ No shift
❏ Excessive shift shock
EN-5
GENERAL DESCRIPTION
3. General Description 8) Use the ECM mounting stud bolt at the body
head grounding points when measuring voltage
A: CAUTION and resistance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
• All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
• Be careful not to damage the airbag system
wiring harness when servicing the engine con-
trol module (ECM), transmission control mod-
EN1393
ule (TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity. (A) Stud bolt
• The ECM will be destroyed instantly.
• The fuel injector and other part will be damaged 9) Use the engine grounding terminal or engine
in just a few minutes more. proper as the grounding point to the body, when
3) Do not disconnect the battery cables while the measuring voltage and resistance in the engine
engine is running. compartment.
• A large counter electromotive force will be gener-
cardiagn.com
ated in the alternator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn the ignition
switch to OFF.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage and/
or resistance of individual sensors or all electrical
control modules at the harness side connector, use
a tapered pin with a diameter of less than 0.64 mm B2M2779
(0.025 in). Do not insert the pin more than 5 mm 10) Use the TCM mounting stud bolts at the body
(0.20 in) into the part. head grounding point, when measuring voltage and
6) Before removing the ECM from located position, resistance inside the passenger compartment.
disconnect two cables on battery.
• Otherwise, the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) The connectors to each sensor in the engine
compartment and the harness connectors on the
engine side and body side are all designed to be
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors EN1394
when washing the vehicle, or when servicing the
vehicle on a rainy day. (A) Stud bolt
11) Every MFI-related part is a precision part. Do

not drop them.
EN-6
GENERAL DESCRIPTION
12) Observe the following cautions when installing B: INSPECTION

a radio in MFI equipped models. Before performing diagnostics, check the following
CAUTION: items which might affect engine problems:
• The antenna must be kept as far apart as pos-
sible from the control unit.
1. BATTERY
(The ECM is located under the steering column, 1) Measure the battery voltage and specific gravity
inside of the instrument panel lower trim panel.) of electrolyte.
• The antenna feeder must be placed as far Standard voltage: 12 V
apart as possible from the ECM and MFI har-
ness. Specific gravity: Above 1.260
• Carefully adjust the antenna for correct 2) Check the condition of the main and other fuses,
matching. and harnesses and connectors. Also check for
• When mounting a large power type radio, pay proper grounding.
special attention to the three items above men-
tioned. 2. ENGINE GROUNDING
• Incorrect installation of the radio may affect Make sure the engine grounding cable is properly
the operation of the ECM. connected to the engine.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than 5 seconds to release pressure in the fuel
system. If the engine starts during this operation,
cardiagn.com
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics. B2M2779
15) Diagnostics should be conducted by rotating

with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer's complaint, and distinguish between the
three causes.
16) In AT vehicles, do not continue the stall for
more than 5 seconds at a time (from closed throttle,
fully open throttle to stall engine speed).
17) On ABS vehicle, when performing driving test
in jacked-up or lifted-up position, sometimes the
warning light may be lit, but this is not a malfunction
of the system. The reason for this is the speed dif-
ference between the front and rear wheels. After di-
agnosis of engine control system, perform the ABS
memory clearance procedure of self-diagnosis sys-
tem.
EN-7
GENERAL DESCRIPTION
C: NOTE 2. ENGINE AND EMISSION CONTROL SYS-

TEM
1. DESCRIPTION
• The Multipoint Fuel Injection (MFI) system is a
• The on-board diagnostics (OBD) system detects system that supplies the optimum air-fuel mixture
and indicates a fault in various inputs and outputs to the engine for all the various operating condi-
of the complex electronic control. CHECK ENGINE tions through the use of the latest electronic tech-
malfunction indicator lamp (MIL) in the combination nology.
meter indicates occurrence of a fault or trouble. With this system fuel, which is pressurized at a con-
• Further, against such a failure or sensors as may stant pressure, is injected into the intake air pas-
disable the drive, the fail-safe function is provided sage of the cylinder head. The injection quantity of
to ensure the minimal driveability. fuel is controlled by an intermittent injection system
• The OBD system incorporated with the vehicles where the electro-magnetic injection valve (fuel in-
within this engine family complies with Section jector) opens only for a short period of time, de-
1968.1, California Code of Regulations (OBD-II pending on the quantity of air required for one cycle
regulation). The OBD system monitors the compo- of operation. In actual operation, the injection quan-
nents and the system malfunction listed in Engine tity is determined by the duration of an electric
Section which affects on emissions. pulse applied to the fuel injector and this permits
• When the system decides that a malfunction oc- simple, yet highly precise metering of the fuel.
curs, MIL illuminates. At the same time of the MIL il- • Further, all the operating conditions of the engine
lumination or blinking, a diagnostic trouble code are converted into electric signals, and this results
(DTC) and a freeze frame engine conditions are in additional features of the system, such as large
stored into on-board computer.
cardiagn.com
improved adaptability, easier addition of compen-
• The OBD system stores freeze frame engine sating element, etc.
condition data (engine load, engine coolant tem- The MFI system also has the following features:
perature, fuel trim, engine speed and vehicle • Reduced emission of harmful exhaust gases.
speed, etc.) into on-board computer when it detects • Reduced in fuel consumption.
a malfunction first. • Increased engine output.
• If the OBD system detects the various malfunc- • Superior acceleration and deceleration.
tions including the fault of fuel trim or misfire, the
• Superior startability and warm-up perfor-
OBD system first stores freeze frame engine condi-
mance in cold weather since compensation is
tions about the fuel trim or misfire.
made for coolant and intake air temperature.
• When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off, 3. AUTOMATIC TRANSMISSION AND
but DTC remains at on-board computer. ELECTRONIC-HYDRAULIC CONTROL SYS-
• The OBD-II system is capable of communication TEM
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB. The electronic-hydraulic control system consists of
• The OBD-II diagnostics procedure is different various sensors and switches, a transmission con-
from the usual diagnostics procedure. When trou- trol module (TCM) and the hydraulic controller in-
bleshooting OBD-II vehicles, connect Subaru Se- cluding solenoid valves. The system controls the
lect Monitor or the OBD-II general scan tool to the transmission proper including shift control, lock-up
vehicle. control, overrunning clutch control, line pressure
control and shift timing control. It also controls the
AWD transfer clutch. In other words, the system
detects various operating conditions from various
input signals and sends output signals to shift sole-
noids 1, 2 and low clutch timing solenoid and 2-4
brake timing solenoid, line pressure duty solenoid,
lock-up duty solenoid, transfer duty solenoid and 2-
4 brake duty solenoid (a total of eight solenoids).
EN-8
GENERAL DESCRIPTION
D: PREPARATION TOOL
24082AA190 CARTRIDGE Troubleshooting for electrical
(New adopted tool) systems.
B2M3876
22771AA030 SELECT MONITOR KIT Troubleshooting for electrical
systems.
• English: 22771AA030 (With-
out printer)
• German: 22771AA070
(Without printer)
• French: 22771AA080
(Without printer)
cardiagn.com
• Spanish: 22771AA090
(Without printer)
B2M3877
EN-9
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Location

A: LOCATION
1. ENGINE
• Module
LHD model (1)
cardiagn.com
(3) (2) (4)
EN1423
RHD model (3) (2) (4)
(1)
EN1424
(1) Engine control module (ECM) (3) Test mode connector

(2) CHECK ENGINE malfunction indi- (4) Data link connector
cator lamp (MIL)
EN-10
(2)
B3M1575A EN0718
(3)
cardiagn.com
EN0716 (4) EN1425
EN-11
• Sensor
(1) (3) (4) (2) (5)
cardiagn.com
(7) (6)
EN0719
(1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor
(2) Intake air temperature and pressor (6) Camshaft position sensor
sure sensor (4) Throttle position sensor (7) Crankshaft position sensor
EN-12
B2M3713A B2M3714A
cardiagn.com
S2M1248B B2M2240A
B2M2241A B2M2242A
B2M0213J
EN-13
B2M4231A
(1) Front oxygen (A/F) sensor (3) Front catalytic converter
cardiagn.com
(2) Rear oxygen sensor (4) Rear catalytic converter
S2M0264A S2M0265A
OBD0524G OBD0525G
EN-14
LHD model (1)
(2)
EN1019
cardiagn.com
RHD model (1)
(2)
EN1020
(1) Fuel level sensor (2) Fuel sub level sensor (2500 cc
model only)
EN1036 EN1037
EN-15
• Solenoid Valve, Emission Control System Parts and Ignition System Parts
(3) (1) (4) (2)
cardiagn.com
EN0736
(1) Air assist injector solenoid valve (3) Purge control solenoid valve
(2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY
EN-16
B2M3715A H2M3259A
cardiagn.com
H2M3258B B2M3720A
EN-17
(1) (3) (4) (2)
(6) (5) (7)

EN0741
cardiagn.com
(1) (2)
(6) (5) (7) (3) (4)

EN0742
(1) Inhibitor switch (4) Fuel pump relay (7) Starter

(2) Fuel pump (5) Radiator main fan relay
(3) Main relay (6) Radiator sub fan relay
EN-18
B2M2246A EN1505
LHD model RHD model (3)

(3) (4) (4)
cardiagn.com
EN1504 EN1506
(6)
(5)
EN0746
B2M2247E
EN-19
2. TRANSMISSION
• Module
(1) (2)
EN0751
cardiagn.com
(1) (2)
EN0752
(1) Transmission control module (2) AT diagnostic indicator light (for

(TCM) (for AT vehicles) AT vehicles)
EN-20
B3M1592D B3M1652B
(2)
cardiagn.com
EN0754
EN-21
• Sensor
B2M2258A B2M2259A
cardiagn.com
B2M2260A B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles)

(2) Front vehicle speed sensor (for MT vehicles)
(3) Front vehicle speed sensor (for AT vehicles)
(4) Torque converter turbine speed sensor
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN-22
• Solenoid Valve and Switch (AT vehicles)
B2M2246F B2M2263K
cardiagn.com
B2M2264F
(1) Inhibitor switch

(2) Shift solenoid valve 1
(3) Shift solenoid valve 2
(4) Line pressure duty solenoid
(5) Lock-up duty solenoid
(6) Transfer duty solenoid
(7) 2-4 brake duty solenoid
(8) Low clutch timing solenoid valve
(9) 2-4 brake timing solenoid valve
• Solenoid Valve and Switch (MT vehicles)
B2M2265A
(1) Neutral position switch
EN-23
ENGINE CONTROL MODULE (ECM) I/O SIGNAL
5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
B2M2267A
cardiagn.com
Con- Signal (V)
Terminal
Content nector Ignition SW ON Note
No. Engine ON (Idling)
No. (Engine OFF)
Crank- Signal (+) B135 2* 1 0 −7 — +7 Sensor output waveform
shaft posi- Signal (−) B135 9* 8 0 0 —
tion sensor Shield B135 10 0 0 —
Camshaft Signal (+) B135 1* 2 0 −7 — +7 Sensor output waveform
position Signal (−) B135 8* 9 0 0 —
sensor Shield B135 10 0 0 —
Fully closed: 0.2 — 1.0
Signal B136 17 —
Fully opened: 4.2 — 4.7
Throttle
Power
position B136 15 5 5 —
supply
sensor
GND (sen-
B136 16 0 0 —
sor)
Signal B136 18 0 0 — 0.9 —
Rear oxy-
Shield B136 24 0 0 —
gen sen-
sor GND (sen-
B136 16 0 0 —
sor)
Front oxy- Signal 1 B134 23 0 — 1.0 0 — 1.0 —
gen (A/F)
sensor Signal 2 B134 22 0 — 1.0 0 — 1.0 —
heater
Rear oxygen sensor
B134 21 0 — 1.0 0 — 1.0 —
heater signal
Engine Signal B136 14 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
ture sen- B136 16 0 0 After warm-up the engine.
sor)
sor
“5” and “0” are repeatedly dis-
Vehicle speed signal B135 24 0 or 5 0 or 5
played when vehicle is driven.
*: With immobilizer
EN-24
Con- Signal (V)

Terminal
No. (Engine OFF)
Starter switch B135 28 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
ON: 12±0.5 On MT vehicle; Switch is ON
MT B135 26
Neutral OFF: 0 when gear is in neutral position.
position ON AT vehicle; Switch is ON
switch ON: 0
AT B135 26 when shift is in “N” or “P” posi-
OFF: 12±0.5
tion.
Test mode connector B135 14 5 5 When connected: 0
Knock Signal B136 4 2.8 2.8 —
sensor Shield B136 25 0 0 —
Back-up power supply B136 9 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B136 1 10 — 13 13 — 14 —
ply B136 2 10 — 13 13 — 14 —
Sensor power supply B136 15 5 5 —
Line end check 1 B135 20 0 0 —
Ignition #1, #2 B134 25 0 1 — 3.4 Waveform
cardiagn.com
control #3, #4 B134 26 0 1 — 3.4 Waveform
#1 B134 4 10 — 13 1 — 14 Waveform
Fuel injec- #2 B134 13 10 — 13 1 — 14 Waveform
tor #3 B134 14 10 — 13 1 — 14 Waveform
#4 B134 15 10 — 13 1 — 14 Waveform
Signal 1 B134 5 — 1 — 13 Waveform
Idle air Signal 2 B134 6 — 1 — 13 Waveform
control Signal 3 B134 19 — 1 — 13 Waveform
solenoid Signal 4 B134 20 — 1 — 13 Waveform
valve Power
B136 2 10 — 13 13 — 14 —
supply
ON: 0.5, or less
Fuel pump relay control B134 29* 16 0.5, or less —
OFF: 10 — 13
ON: 0.5, or less ON: 0.5, or less
A/C relay control B134 17 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 ON: 0.5, or less ON: 0.5, or less
B134 3 —
control OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 2 ON: 0.5, or less ON: 0.5, or less
B134 12 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
Torque control 1 signal B135 16 5 More than 4 V —
Torque control 2 signal B135 17 5 More than 4 V —
Torque control cut sig-
B134 31 8 8 —
nal
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B136 29 3.9 — 4.1 2.0 — 2.3
Atmo-
Power
spheric B136 15 5 5
supply —
pressure
sensor GND (sen-
B136 16 0 0
sor)
*: With immobilizer
EN-25
Con- Signal (V)

Terminal
No. (Engine OFF)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 For europe model
AT diagnosis input sig- Less than 1 ←→ Less than 1 ←→
B135 4 Waveform
nal More than 4 More than 4
ON: 0 ON: 0
Small light switch B136 3 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B136 30 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Rear defogger switch B135 21 —
OFF: 10 — 13 OFF: 13 — 14
Front oxygen (A/F) sen-
B136 19 2.8 — 3.2 2.8 — 3.2 —
sor signal 1
B136 6 2.4 — 2.7 2.4 — 2.7 —
sor signal 2
B136 7 0.2 — 4.9 0.2 — 4.9 —
sor signal 3
B136 20 0.2 — 4.9 0.2 — 4.9 —
sor signal 4
Pressure sensor B136 5 2.4 — 4.8 0.4 — 1.8 —
cardiagn.com
Intake air temperature
B136 13 2.3 — 2.5 1.4 — 1.6 —
sensor
SSM/GST communica- Less than 1 ←→ Less than 1 ←→
B135 3 —
tion line More than 4 More than 4
GND (sensors) B136 16 0 0 —
GND (injectors) B134 7 0 0 —
GND (ignition system) B134 27 0 0 —
GND (power supply) B134 8 0 0 —
B136 21 0 0 —
GND (control systems)
B136 22 0 0 —
GND (oxygen sensor
B134 35 0 0 —
heater 1)
GND (oxygen sensor
B134 34 0 0 —
heater 2)
EN-26
ENGINE CONDITION DATA
6. Engine Condition Data

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.
• A/C is turned to OFF.
• All accessory switches are turned to OFF.
cardiagn.com
EN-27
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
7. Transmission Control Module (TCM) I/O Signal

to B54 to B55
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10
24 23 22 21 20 19 24 23 22 21 20 19
to B56
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
24 23 22 21 20 19
TR0532
cardiagn.com
Check with ignition switch ON.
Con-
Termi- Resistance to
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Back-up power supply B56 1 Ignition switch OFF 10 — 13 —
B54 23 Ignition switch ON (with
Ignition power supply 10 — 13 —
B54 24 engine OFF)
Select lever in “P” range Less than 1
“P” range
B55 1 Select lever in any other than —
switch More than 8
“P” range (except “N” range)
Select lever in “N” range Less than 1
“N” range
switch More than 8
“N” range (except “P” range)
Select lever in “R” range Less than 1
“R” range
switch More than 8
“R” range
Select lever in “D” range Less than 1
Inhibitor “D” range
switch switch More than 8
“D” range
Select lever in “3” range Less than 1
“3” range
switch More than 8
“3” range
“2” range
switch More than 8
“2” range
“1” range
switch More than 8
“1” range
Brake pedal depressed. More than 10.5
Brake switch B55 12 —
Brake pedal released. Less than 1
ABS switch ON Less than 1
ABS signal B55 21 —
ABS switch OFF 6.5 — 15
EN-28

Con-
nal No. body (ohms)
No.
Hold switch ON Less than 1
Hold switch B55 16 —
Hold switch OFF More than 8
Power switch ON Less than 1
Power switch B55 23 —
Power switch OFF More than 10
Throttle fully opened. Less than 1
Kick-down switch B55 11 —
Throttle fully closed. More than 6.5
Light ON Less than 1
POWER indicator light B56 11 —
Light OFF More than 9
Light ON Less than 1
AT OIL TEMP indicator light B56 10 —
Light OFF More than 9
Throttle fully closed. 0.3 — 0.7
Throttle position sensor B54 3 —
Throttle fully open. 4.0 — 4.6
Throttle position sensor power Ignition switch ON (With
B54 2 4.8 — 5.3 —
supply engine OFF)
ATF temperature 20°C
1.6 — 2.0 2.1 — 2.9 k
(68°F)
ATF temperature sensor B54 11
ATF temperature 80°C
cardiagn.com
0.4 — 0.9 275 — 375
(176°F)
Vehicle stopped. 0
Rear vehicle speed sensor B55 24 Vehicle speed at least 20 450 — 650
More than 1 (AC range)
km/h (12 MPH)
Vehicle speed at least 20
Front vehicle speed sensor B55 18 More than 1 (AC range) 450 — 650
km/h (12 MPH)
Engine idling after warm-up.
0
Torque converter turbine (D range)
B55 8 450 — 650
speed sensor Engine idling after warm-up.
More than 1 (AC range)
(N range)
Vehicle speed at most 10 Less than 1←
Vehicle speed output signal B56 17 —
km/h (6 MPH) →More than 4
Ignition switch ON (with
More than 10.5
engine OFF)
Engine speed signal B55 17 —
8 — 11
engine ON)
When cruise control is set.
Less than 1
(SET lamp ON)
Cruise set signal B55 22 —
When cruise control is not
More than 6.5
set. (SET lamp OFF)
Torque control signal 1 B56 5 4 —
engine ON)
Torque control signal 2 B56 14 4 —
engine ON)
Torque control cut signal B55 10 Ignition switch ON 8 —
Intake manifold pressure sig-
B54 1 Engine idling after warm-up. 0.4 — 1.8 —
nal
1st or 4th gear More than 9
Shift solenoid 1 B54 22 10 — 16
2nd or 3rd gear Less than 1
1st or 2nd gear More than 9
Shift solenoid 2 B54 5 10 — 16
3rd or 4th gear Less than 1
EN-29

Con-
nal No. body (ohms)
No.
engine OFF)
1.5 — 4.0
Throttle fully closed after
warm-up.
Line pressure duty solenoid B54 9 2.0 — 4.5
engine OFF)
Less than 0.5
Throttle fully open after
warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid B54 7 10 — 17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Fuse removed from FWD
Transfer duty solenoid B54 6 switch (with throttle fully 10 — 17
Less than 0.5
open and with select lever in
1st gear).
engine OFF)
1.5 — 4.0
Throttle fully closed after
cardiagn.com
warm-up.
2-4 brake duty solenoid B54 18 2.0 — 4.5
engine OFF)
Less than 0.5
Throttle fully open after
warm-up.
1st gear Less than 1
2-4 brake timing solenoid B54 16 10 — 16
3rd gear More than 9
2nd gear Less than 1
Low clutch timing solenoid B54 15 10 — 16
4th gear More than 9
Sensor ground line 1 B54 20 — 0 Less than 1
B56 19
System ground line — 0 Less than 1
B54 21
Fuse removed. 6 — 9.1
FWD switch B55 20 —
Fuse installed. Less than 1
Fuse on FWD switch Less than 1
FWD indicator light B56 2 Fuse removed from FWD —
More than 9
switch
Data link signal (Subaru
B56 15 — — —
Select Monitor)
EN-30
DATA LINK CONNECTOR
8. Data Link Connector

A: NOTE
1) This connector is used both for the OBD-II general scan tools and Subaru Select Monitor.
2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal.
CAUTION:
Do not connect any scan tools other than the OBD-II general scan tools and Subaru Select Monitor,
because the circuit for Subaru Select Monitor may be damaged.
H2M1280
Terminal No. Contents Terminal No. Contents
cardiagn.com
1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
Subaru Select Monitor signal (ECM to Subaru
4 12 Ground
Select Monitor)*
Subaru Select Monitor signal (Subaru Select
5 13 Ground
Monitor to ECM)*
6 Line end check signal 1 14 Blank
7 Blank 15 Blank
8 Blank 16 Blank
*: Circuit only for Subaru Select Monitor
EN-31
OBD-II GENERAL SCAN TOOL
9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up diag-
nostic trouble code(s) (DTC(s)) and freeze frame
A: OPERATION data.
OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic
TOOL data
1) Prepare a general scan tool (OBD-II general (2) MODE $02: Powertrain freeze frame data
scan tool) required by SAE J1978. (3) MODE $03: Emission-related powertrain di-
2) Connect the OBD-II general scan tool to data agnostic trouble codes (DTCs)
link connector located in the lower portion of instru- (4) MODE $04: Clear/Reset emission-related
ment panel (on the driver's side). diagnostic information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes
(DTCs), refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN-83, List of Diagnostic Trouble
Code (DTC).>
EN0768
cardiagn.com
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID Data Unit of measure
01 Number of emission-related powertrain trouble codes and MIL status ON/OFF
03 Fuel system control status —
04 Calculated engine load value %
05 Engine coolant temperature °C
06 Short term fuel trim %
07 Long term fuel trim %
0B Intake manifold absolute pressure kPa
0C Engine revolution rpm
0D Vehicle speed km/h
0E Ignition timing advance °
0F Intake air temperature °C
10 Air flow rate from pressure sensor g/sec
11 Throttle valve opening angle %
13 Check whether oxygen sensor is installed. —
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor—bank
15 V and %
1 sensor 2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and %
1C On-board diagnosis system —
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PIDs (MODE
$01).
EN-32
OBD-II GENERAL SCAN TOOL
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.
PID Data Unit of measure
02 Trouble code that caused CARB required freeze frame data storage —
03 Fuel system control status —
04 Calculated engine load value %
05 Engine coolant temperature °C
06 Short term fuel trim %
07 Long term fuel trim %
0B Intake manifold absolute pressure kPa
0C Engine revolution rpm
0D Vehicle speed km/h
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE)
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain di-
cardiagn.com
agnostic trouble codes. <Ref. to EN-41, Read Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).
EN-33
SUBARU SELECT MONITOR
10.Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. HOW TO USE SUBARU SELECT MONI- Do not connect the scan tools except for Suba-
TOR ru Select Monitor and OBD-II general scan tool.
5) Turn the ignition switch to ON (engine OFF) and
1) Prepare the Subaru Select Monitor kit. <Ref. to
Subaru Select Monitor switch to ON.
EN-9, PREPARATION TOOL, General Descrip-
tion.>
S2M0288E
S2M0285
(A) Power switch
2) Connect the diagnosis cable to Subaru Select
6) Using the Subaru Select Monitor, call up diag-
cardiagn.com
Monitor.
3) Insert the cartridge into Subaru Select Monitor. nostic trouble code(s) (DTC(s)) and various data,
<Ref. to EN-9, PREPARATION TOOL, General then record them.
Description.> 2. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (NORMAL MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to EN-41,
Read Diagnostic Trouble Code (DTC).>
3. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (OBD MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to EN-41,
S2M0286A Read Diagnostic Trouble Code (DTC).>
4) Connect the Subaru Select Monitor to data link
connector.
(1) Data link connector located in the lower por-
tion of instrument panel (on the driver's side).
EN0768
EN-34
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

1) On the «Main Menu» display screen, select the {Each System Check} and press [YES] key.
2) On the «System Selection Menu» display screen, select the {Engine Control System} and press [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the «Engine Diagnosis» display screen, select the {Current Data Display & Save} and press [YES] key.
5) On the «Data Display Menu» display screen, select the {Data Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until desired data is shown.
• A list of the support data is shown in the following table.
Contents Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rpm
Engine coolant temperature signal Coolant Temp. °C or °F
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #1 Pulse ms
Idle air control signal ISC Valve Step STEP
Engine load data Engine Load %
cardiagn.com
Front oxygen (A/F) sensor output signal A/F Sensor #1 —
Rear oxygen sensor output signal Rear O2 Sensor V
Short term fuel trim A/F Correction #1 %
Knock sensor signal Knocking Correction deg
mmHg or kPa or inHg or
Atmospheric absolute pressure signal Atmosphere Pressure
psi
Intake manifold relative pressure signal Mani. Relative Pressure
psi
Intake manifold absolute pressure signal Mani. Absolute Pressure
psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Front oxygen (A/F) sensor heater current Front O2 Heater #1 A
Rear oxygen sensor heater current Rear O2 Heater Current A
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Fuel level signal Fuel Level V
Intake air temperature signal Intake Air Temp. °C or °F
Learned ignition timing Learned Ignition Timing deg
Ignition switch signal Ignition Switch ON or OFF
Test mode connector signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning signal A/C Compressor Signal ON or OFF
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Fuel pump relay signal Fuel Pump Relay ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal P/S Switch ON or OFF
Engine torque control signal #1 Torque Control Signal #1 ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Rear oxygen sensor rich signal Rear O2 Rich Signal ON or OFF
EN-35

Starter switch signal Starter Switch Signal ON or OFF
Idle switch signal Idle Switch Signal ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger Switch ON or OFF
Blower fan switch signal Blower Fan Switch ON or OFF
Small light switch signal Light Switch ON or OFF
Air assist injector solenoid valve signal Assist Air Sol. Valve ON or OFF
AT vehicle ID signal AT Vehicle ID Signal ON or OFF
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
cardiagn.com
EN-36
5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

key.
4) On the «Engine Diagnosis» display screen, select the {OBD System} and press [YES] key.
5) On the «OBD Menu» display screen, select the {Current Data Display & Save} and press [YES] key.
Number of diagnosis code Number of Diagnosis Code —
Malfunction indicator lamp status MI (MIL) ON or OFF
Monitoring test of misfire Misfire monitoring Complete or incomplete
Monitoring test of fuel system Fuel system monitoring Complete or incomplete
Monitoring test of comprehensive component Component monitoring Complete or incomplete
Test of catalyst Catalyst Diagnosis Complete or incomplete
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system No support
Test of secondary air system Secondary air system No support
cardiagn.com
Test of air conditioning system refrigerant A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater O2 Heater Diagnosis Complete or incomplete
Test of EGR system EGR system No support
Air fuel ratio control system for bank 1 Fuel System for Bank 1 —
Engine load data Calculated load value %
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
psi
Ignition timing advance for #1 cylinder Ignition timing adv. #1 °
Intake air temperature signal Intake Air Temp. °C or °F
Intake air amount Mass Air Flow g/s
Throttle position signal Throttle Opening Angle %
A/F sensor equipment A/F sensor ON or OFF
Rear oxygen sensor output signal Oxygen Sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD System —
NOTE:
EN-37
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

key.
5) On the «OBD Menu» display screen, select the {Freeze Frame Data} and press [YES] key.
Diagnostic trouble code (DTC) for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF
Engine load data Engine Load %
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
psi
cardiagn.com
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE)
key.
5) On the «OBD Menu» display screen, select the {O2 Sensor Monitor} and press [YES] key.
6) On the «O2 Sensor Select» display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
[YES] key.
• Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen
sensor.
Oxygen sensor for monitoring test <O2 Sensor Monitor (-------)> —
Rich to lean oxygen sensor threshold voltage Rich to lean sensor volt V
Lean to rich oxygen sensor threshold voltage Lean to rich sensor volt V
Low oxygen sensor voltage for switch time calculation Low sensor voltage V
High oxygen sensor voltage for switch time calculation High sensor voltage V
Rich to lean oxygen sensor switch time Rich to lean switch time sec
Lean to rich oxygen sensor switch time Lean to rich switch time sec
Maximum oxygen sensor voltage for test cycle Maximum sensor Voltage V
Minimum oxygen sensor voltage for test cycle Minimum sensor Voltage V
NOTE:
EN-38
8. LED OPERATION MODE FOR ENGINE

key.
4) On the «Engine Diagnosis» display screen, select the {Current Data Display & Save} and press [YES] key.
5) On the «Data Display Menu» display screen, select the {Data & LED Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
Contents Display Message LED “ON” requirements
Ignition switch signal Ignition Switch ON or OFF When ignition switch is turned to ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral Position Switch ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C Switch ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal A/C Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Fuel pump relay signal Fuel Pump Relay ON or OFF When fuel pump relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
When engine torque control signal 1 is
cardiagn.com
entered.
When engine torque control signal 2 is
entered.
Engine torque control permission When engine torque control permission sig-
Torque Control Permit ON or OFF
signal nal is entered.
Front oxygen (A/F) sensor rich sig- When front oxygen (A/F) sensor mixture ratio
Front O2 Rich Signal #1 ON or OFF
nal is rich.
When rear oxygen sensor mixture ratio is
Rear oxygen sensor rich signal Rear O2 Rich Signal ON or OFF
rich.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
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:
EN-39
9. READ CURRENT DATA FOR AT.

2) On the «System Selection Menu» display screen, select the {Transmission Control System} and press
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the «Transmission Diagnosis» display screen, select the {Current Data Display & Save} and press
[YES] key.
Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Vehicle Speed #1 km/h or MPH
Front vehicle speed sensor signal Vehicle Speed #2 km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. °C or °F
Throttle position signal Throttle Sensor Voltage V
Gear position Gear Position —
Line pressure control duty ratio Line Pressure Duty Ratio %
Lock up clutch control duty ratio Lock Up Duty Ratio %
cardiagn.com
Transfer clutch control duty ratio Transfer Duty Ratio %
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal AT Turbine Speed rpm
2-4 brake timing pressure control duty ratio 2-4B Duty Ratio %
Intake manifold pressure sensor voltage Mani. Pressure Voltage V
2 wheel drive switch signal 2WD Switch ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Stop lamp switch signal Stop Lamp Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
Neutral/Parking range signal N/P Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #1 Torque Control Signal #1 ON or OFF
Torque control output signal #2 Torque Control Signal #2 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF
NOTE:
EN-40
READ DIAGNOSTIC TROUBLE CODE (DTC)
11.Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL

Code (DTC) Refers to data denoting emission-related power-
train diagnostic trouble codes (DTCs).
A: OPERATION For details concerning diagnostic trouble codes
1. SUBARU SELECT MONITOR (NORMAL
MODE) Code (DTC).>
1) On the «Main Menu» display screen, select the NOTE:
{Each System Check} and press [YES] key. Refer to OBD-II general scan tool manufacturer's
2) On the «System Selection Menu» display instruction manual to access emission-related
screen, select the {Engine Control System} and powertrain diagnostic trouble codes (DTCs)
press [YES] key. (MODE $03).
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the «Engine Diagnosis» display screen, se-
lect the {Diagnostic Code(s) Display} and press
[YES] key.
5) On the «Diagnostic Code(s) Display» display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press [YES] key.
NOTE:
cardiagn.com
• For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
• For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the «Main Menu» display screen, select the
{2. Each System Check} and press [YES] key.
2) On the «System Selection Menu» display
screen, select the {Engine Control System} and
press [YES] key.
lect the {OBD System} and press [YES] key.
5) On the «OBD Menu» display screen, select the
{Diagnosis Code(s) Display} and press [YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
UAL.
• For detailed concerning diagnostic trouble codes
Code (DTC).>
EN-41
INSPECTION MODE
12.Inspection Mode
A: OPERATION
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle.
<Ref. to EN-47, Drive Cycle.>
DTC
Item
No.
P0031 Front oxygen (A/F) sensor heater circuit low input
P0032 Front oxygen (A/F) sensor heater circuit high input
P0037 Rear oxygen sensor heater circuit malfunction
P0038 Rear oxygen sensor heater circuit high input
P0066 Air assist injector solenoid valve circuit low input
P0067 Air assist injector solenoid valve circuit high input
P0106 Pressure sensor circuit range/performance problem (low input)
P0107 Pressure sensor circuit low input
P0108 Pressure sensor circuit high input
P0112 Intake air temperature sensor circuit low input
P0113 Intake air temperature sensor circuit high input
P0117 Engine coolant temperature sensor circuit low input
cardiagn.com
P0118 Engine coolant temperature sensor circuit high input
P0122 Throttle position sensor circuit low input
P0123 Throttle position sensor circuit high input
P0131 Front oxygen (A/F) sensor circuit malfunction (open circuit)
P0132 Front oxygen (A/F) sensor circuit malfunction (short circuit)
P0136 Rear oxygen sensor circuit malfunction
P0327 Knock sensor circuit low input
P0328 Knock sensor circuit high input
P0335 Crankshaft position sensor circuit malfunction
P0336 Crankshaft position sensor circuit range/performance problem
P0340 Camshaft position sensor circuit malfunction
P0341 Camshaft position sensor circuit range/performance problem
P0444 Evaporative emission control system purge control valve circuit low input
P0462 Fuel level sensor circuit low input
P0463 Fuel level sensor circuit high input
P0480 Cooling fan relay 1 circuit low input
P0500 Vehicle speed sensor malfunction
P0512 Starter switch circuit high input
P0513 Incorrect immobilizer key
P0562 Charge system circuit low input
P0563 Charge system circuit high input
P0604 Internal control module memory check sum error
P0703 Brake switch input malfunction
P0705 Transmission range sensor circuit malfunction
P0710 Transmission fluid temperature sensor circuit malfunction
P0715 Torque converter turbine speed sensor circuit malfunction
P0720 Output speed sensor (vehicle speed sensor 2) circuit malfunction
P0725 Engine speed input circuit malfunction
P0731 Gear 1 incorrect ratio
P0741 Torque converter clutch system malfunction
EN-42
INSPECTION MODE
DTC
Item
No.
P0743 Torque converter clutch system (Lock-up duty solenoid) electrical
P0748 Pressure control solenoid (Line pressure duty solenoid) electrical
P0753 Shift solenoid A (Shift solenoid 1) electrical
P0758 Shift solenoid B (Shift solenoid 2) electrical
P0778 2-4 brake pressure control solenoid valve circuit malfunction
P0785 2-4 brake timing control solenoid valve circuit malfunction
P1110 Atmospheric pressure sensor low input
P1111 Atmospheric pressure sensor high input
P1112 Atmospheric pressure sensor range/performance problem
P1146 Pressure sensor circuit range/performance problem (high input)
P1480 Cooling fan relay 1 circuit high input
P1507 Idle control system malfunction (fail-safe)
P1510 Idle air control solenoid valve signal 1 circuit low input
P1511 Idle air control solenoid valve signal 1 circuit high input
cardiagn.com
P1518 Starter switch circuit low input
P1540 Vehicle speed sensor malfunction 2
P1560 Back-up voltage circuit malfunction
P1570 Antenna
P1571 Reference code incompatibility
P1572 IMM circuit failure except antenna circuit
P1574 Key communication failure
P1576 EGI control module EEPROM
P1577 IMM control module EEPROM
P1590 Neutral position switch circuit high input (AT model)
P1591 Neutral position switch circuit low input (AT model)
P1592 Neutral position switch circuit (MT model)
P1594 Automatic transmission diagnosis input signal circuit malfunction
P1595 Automatic transmission diagnosis input signal circuit low input
P1596 Automatic transmission diagnosis input signal circuit high input
P1698 Engine torque control cut signal circuit low input
P1699 Engine torque control cut signal circuit high input
P1700 Throttle position sensor circuit malfunction for automatic transmission
P1701 Cruise control set signal circuit malfunction for automatic transmission
P1703 Low clutch timing control solenoid valve circuit malfunction
P1711 Engine torque control signal 1 circuit malfunction
P1712 Engine torque control signal 2 circuit malfunction
EN-43
INSPECTION MODE
1. PREPARATION FOR THE INSPECTION 2. SUBARU SELECT MONITOR

MODE 1) After performing the diagnostics and clearing the
1) Make sure that the fuel remains approx. half memory, check for any remaining unresolved trou-
amount [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 ble data. <Ref. to EN-49, Clear Memory Mode.>
Imp gal)] and the battery voltage is 12 V or more. 2) Warm up the engine.
2) Raise the vehicle using a garage jack and place 3) Prepare the Subaru Select Monitor kit. <Ref. to
on safety stands or drive the vehicle onto free roll- EN-9, PREPARATION TOOL, General Descrip-
ers. tion.>
WARNING:
• Before raising the vehicle, ensure the parking
brake is applied.
• Do not use a pantograph jack in place of a
safety stand.
• Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
• Do not abruptly depress/release the clutch
pedal or accelerator pedal during works even S2M0285
when engine is operating at low speeds since
this may cause vehicle to jump off free rollers. 4) Connect the diagnosis cable to Subaru Select
• In order to prevent the vehicle from slipping Monitor.
cardiagn.com
due to vibration, do not place any wooden 5) Insert the cartridge into Subaru Select Monitor.
blocks or similar items between the safety <Ref. to EN-9, PREPARATION TOOL, General
stands and the vehicle. Description.>
• Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
S2M0286A
6) Connect the test mode connector (A) at the low-

er portion of instrument panel (on the driver's side).
(A)
EN0773
B2M2969C
(A) Safety stand

(B) Free rollers
EN-44
INSPECTION MODE
7) Connect the Subaru Select Monitor to data link 14) Perform subsequent procedures as instructed
connector. on the display screen.
(1) Connect the Subaru Select Monitor to data • If trouble still remains in the memory, the corre-
link connector located in the lower portion of the sponding diagnostic trouble code (DTC) appears
instrument panel (on the driver's side). on the display screen.
NOTE:
UAL.
• For detailed concerning the diagnostic trouble
codes (DTCs), refer to the List of Diagnostic Trou-
ble Code (DTC).
<Ref. to EN-83, List of Diagnostic Trouble Code
(DTC).>
EN0768
• Release the parking brake.
• The speed difference between front and rear
(2) Connect the diagnosis cable to data link wheels may light either the ABS warning light, but
connector. this indicates no malfunctions. When the engine
CAUTION: control diagnosis is finished, perform the ABS
Do not connect the scan tools except for Suba- memory clearance procedure of self-diagnosis sys-
ru Select Monitor and OBD-II general scan tool. tem.
cardiagn.com
8) Turn the ignition switch to ON (engine OFF) and 3. OBD-II GENERAL SCAN TOOL
Subaru Select Monitor switch to ON. 1) After performing the diagnostics and clearing
memory, check for any remaining unresolved trou-
ble data: <Ref. to EN-49, Clear Memory Mode.>
2) Warm up the engine.
er side of instrument panel (on the driver's side).
S2M0288C
(A) Power switch
9) On the «Main Menu» display screen, select the (A)

{2. Each System Check} and press the [YES] key.
10) On the «System Selection Menu» display EN0773

press the [YES] key.
11) Press the [YES] key after displayed the infor-
mation of engine type.
lect the {Dealer Check Mode Procedure} and press
the [YES] key.
13) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
EN-45
INSPECTION MODE
4) Connect the OBD-II general scan tool to its data

link connector in the lower portion of instrument
panel (on the driver's side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-II general scan tool.
EN0768
5) Start the engine.

NOTE:
• Ensure the selector lever is placed in “P” position
cardiagn.com
before starting. (AT vehicles)
• Depress the clutch pedal when starting engine.
(MT vehicles)
6) Using the selector lever or shift lever, turn the “P”
position switch and “N” position switch to ON.
7) Depress the brake pedal to turn brake switch
ON. (AT vehicles)
8) Keep the engine speed in 2,500 — 3,000 rpm
range for 40 seconds.
9) Place the selector lever or shift lever in “D” posi-
tion (AT vehicles) or “1st” gear (MT vehicles) and
drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
• On AWD vehicles, release the parking brake.
• The speed difference between front and rear
wheels may light ABS warning light, but this indi-
cates no malfunctions. When the engine control di-
agnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
10) Using the OBD-II general scan tool, check for
diagnostic trouble code(s) (DTC(s)) and record the
result(s).
NOTE:
• For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
• For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC).
<Ref. to EN-83, List of Diagnostic Trouble Code
(DTC).>
EN-46
DRIVE CYCLE
13.Drive Cycle
A: OPERATION
There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose
malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check
whether they correctly resume their functions by driving in the required drive pattern.
1. PREPARATION FOR THE DRIVE CYCLE
1) Make sure that the fuel remains approx. half amount [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)],
and battery voltage is 12V or more.
2) After performing the diagnostics and cleaning memory, check for any remaining unresolved trouble data.
<Ref. to EN-49, Clear Memory Mode.>
3) Separate the test mode connector.
NOTE:
• Except for the water temperature specified items at starting, the diagnosis is carried out after engine warm
up.
• Carry out the diagnosis which is marked * on DTC twice, then, after finishing first diagnosis, stop the engine
and do second time at the same condition.
2. AFTER RUNNING 20 MINUTES AT 80 KM/H (50 MPH), IDLE ENGINE FOR 1 MINUTE.
DTC
cardiagn.com
Item Condition
No.
Intake air temperature sensor circuit range/perfor-
*P0111 Coolant temperature at start is less than 30°C (86°F).
mance problem
Insufficient coolant temperature for closed loop
*P0125 Coolant temperature at start is less than 20°C (68°F).
fuel control
Front oxygen (A/F) sensor circuit range/perfor-
*P0130 —
mance problem (Lean)
*P0133 Front oxygen (A/F) sensor circuit slow response —
*P0170 Fuel trim malfunction —
*P0420 Catalyst system efficiency below threshold —
Evaporative emission control system purge con-
P0445 —
trol valve circuit high input
Fuel level sensor circuit range/performance prob-
P0461 —
lem
*P0464 Fuel level sensor intermittent input —
Front oxygen (A/F) sensor circuit range/perfor-
*P1137 —
mance problem
Fuel level sensor circuit range/performance prob-
*P1442 —
lem 2
EN-47
DRIVE CYCLE
3. IDLE FOR 10 MINUTES

NOTE:
Before the diagnosis, drive the vehicle at 4 km/h (6 MPH) or more.
DTC No. Item Condition
*P0483 Cooling fan function problem —
*P0506 Idle control system RPM lower than expected —
*P0507 Idle control system RPM higher than expected —
4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN
Vehicle speed km/h (MPH)
96 (60)
cardiagn.com
65 (40)
0
50 100 150 (Seconds)
B2M4775
(A) Idle engine for 1 minute. (D) Decelerate with fully closed throt- (G) Stop vehicle with throttle fully
(B) Accelerate to 97 km/h (60 MPH) tle to 64 km/h (40 MPH). closed.Stop vehicle with throttle
within 20 seconds. (E) Drive vehicle at 64 km/h (40 MPH) fully closed.Stop vehicle with
(C) Drive vehicle at 97 km/h (60 MPH) for 10 seconds. throttle fully closed.
for 20 seconds. (F) Accelerate to 97 km/h (60 MPH)
within 10 seconds.
DTC No. Item Condition

*P0121 Throttle position sensor circuit range/performance problem (high input) —
*P0139 Rear oxygen sensor circuit slow response —
*P0301 Cylinder 1 misfire detected —
*P1142 Throttle position sensor circuit range/performance problem (low input) —
EN-48
CLEAR MEMORY MODE
14.Clear Memory Mode 3. OBD-II GENERAL SCAN TOOL

A: OPERATION For clear memory procedures using the OBD-II
general scan tool, refer to the OBD-II General Scan
1. SUBARU SELECT MONITOR (NORMAL Tool Instruction Manual.
MODE) After the memory has been cleared, the idle air
control solenoid valve must be initialized. To do
1) On the «Main Menu» display screen, select the this, turn the ignition switch to ON. Wait 3 seconds
{2. Each System Check} and press [YES] key. before starting the engine.
press [YES] key.
lect the {Clear Memory} and press [YES] key.
5) When the ‘Done’ and ‘Turn Ignition Switch OFF’
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:
• After the memory has been cleared, the idle air
cardiagn.com
this, turn the ignition switch to ON. Wait 3 seconds
before starting the engine.
UAL.
2. SUBARU SELECT MONITOR (OBD
MODE)
press [YES] key.
lect the {OBD System} and press [YES] key.
5) On the «OBD Menu» display screen, select the
{4. Diagnosis Code(s) Cleared} and press [YES]
key.
6) When the `Clear Diagnostic Code?' is shown on
the display screen, press [YES] key.
7) Turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
• After the memory has been cleared, the idle air
this, turn the ignition switch to ON. Wait 3 seconds
before starting the engine.
UAL.
EN-49
COMPULSORY VALVE OPERATION CHECK MODE
15.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link
connector.
Check Mode (1) Connect the Subaru Select Monitor to data
A: OPERATION link connector located in the lower portion of in-
1) Prepare the Subaru Select Monitor kit. <Ref. to strument panel (on the driver's side).
EN-9, PREPARATION TOOL, General Descrip-
tion.>
EN0768
(2) Connect the diagnosis cable to data link

S2M0285 connector.
2) Connect the diagnosis cable to Subaru Select CAUTION:
Monitor. Do not connect the scan tools except for Suba-
3) Insert the cartridge into Subaru Select Monitor. ru Select Monitor and OBD-II general scan tool.
cardiagn.com
<Ref. to EN-9, PREPARATION TOOL, General 6) Turn the ignition switch to ON (engine OFF) and
Description.> Subaru Select Monitor switch to ON.
S2M0286A S2M0288E

er portion of instrument panel (on the driver's side). (A) Power switch

press [YES] key.
(A) lect the {System Operation Check Mode} and press
[YES] key.
EN0773
11) On the «System Operation Check Mode» dis-
play screen, select the {Actuator ON/OFF Opera-
tion} and press [YES] key.
12) Select the desired compulsory actuator on the
«Actuator ON/OFF Operation» display screen and
press [YES] key.
EN-50
COMPULSORY VALVE OPERATION CHECK MODE
13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to
the «Actuator ON/OFF Operation» screen.
Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
Compulsory radiator fan relay operation check Radiator Fan Relay
Compulsory air conditioning relay operation check A/C Compressor Relay
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
Compulsory air assist injector solenoid valve operation check AAI Solenoid Valve
NOTE:
• The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
Pressure Switching Sol. 1
Pressure Switching Sol. 2
cardiagn.com
Fuel Tank Sensor Control Valve
• For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN-51
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
16.Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN-53, ACTIVATION OF CHECK ENGINE MALFUNC-
TION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check that engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN-54, CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check that engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN-56, CHECK ENGINE MALFUNCTION INDI-
CATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check that engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN-58, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
↓
5. Check that engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN-60, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp
(MIL).>
cardiagn.com
EN-52
B: ACTIVATION OF CHECK ENGINE 4) When the ignition switch is turned to ON (engine

MALFUNCTION INDICATOR OFF) or to START with the test mode connector
connected, the MIL blinks at a cycle of 3 Hz.
LAMP (MIL)
1) When the ignition switch is turned to ON (engine
OFF), the CHECK ENGINE malfunction indicator
lamp (MIL) in the combination meter illuminates.
NOTE:
If the MIL does not illuminate, perform diagnostics
of the CHECK ENGINE light circuit or the combina-
tion meter circuit. <Ref. to EN-54, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) DOES
NOT COME ON., Engine Malfunction Indicator
Lamp (MIL).> OBD0055A
cardiagn.com
EN0774
2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
OBD0054A
EN-53
C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME

ON.
• DIAGNOSIS:
• The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
• TROUBLE SYMPTOM:
• When the ignition switch is turned to ON (engine OFF), MIL does not come on.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36

23
22
i1 i3 i1
AT MT
LHD RHD
cardiagn.com
A7
C6
i2
1 LHD :16
1
COMBINATION
RHD :13
METER B37
A: i10
11
C: i12
B134 ECM
B72 B36 B134 i1 A: i10
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 7 8 9 10 11 12 13 14
24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 RHD: i2 C: i12 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21
7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22
22 23 24 25 26 27 28 29 30 31 32
EN1395
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 4. Go to step 2.
2)Measure the voltage between ECM connec-
tor and chassis ground.
(B134) No. 11 (+) — Chassis ground (−):
2 CHECK POOR CONTACT. Does the MIL come on when Repair the poor Go to step 3.
shaking or pulling ECM con- contact in ECM
nector and harness? connector.
EN-54
Step Check Yes No

3 CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair the con-
connected? <Ref. to FU-51, nection of ECM
Engine Control connector.
Module.>
4 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5. Repair the har-
TION METER AND ECM CONNECTOR. Ω? ness and connec-
1)Turn the ignition switch to OFF. tor.
2)Remove the combination meter. <Ref. to IDI- NOTE:
15, Combination Meter Assembly.> In this case, repair
3)Disconnect the connector from ECM and the following:
combination meter. • Open circuit in
4)Measure the resistance of harness between harness between
ECM and combination meter connector. ECM and combi-
Connector & terminal nation meter con-
(B134) No. 11 — (i12) No. 6: nector
• Poor contact in
coupling connector
(i2)
5 CHECK POOR CONTACT. Is there poor contact in combi- Repair the poor Go to step 6.
Check poor contact in combination meter con- nation meter connector? contact in combi-
nector. nation meter con-
nector.
cardiagn.com
6 CHECK HARNESS BETWEEN COMBINA- Is the voltage more than 10 V? Go to step 7. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
1)Turn the ignition switch to ON. NOTE:
2)Measure the voltage between combination • Broken down
meter connector and chassis ground. ignition relay
Connector & terminal • Blown out fuse
(i10) No. 7 (+) — Chassis ground (−): (No. 5)
• If replaced fuse
(No. 5) blows eas-
ily, check the har-
ness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
• Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
• Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
• Poor contact in
ignition relay con-
nector
• Poor contact in
ignition switch
connector
7 CHECK LAMP BULB. Is the lamp bulb condition OK? Repair the combi- Replace the lamp
Remove the engine malfunction indicator lamp nation meter con- bulb.
bulb. nector.
EN-55
D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF.
• DIAGNOSIS:
• The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
• Although MIL comes on when engine runs, but trouble code is not shown on Subaru Select Monitor or
OBD-II general scan tool display.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36

23
22
i1 i3 i1
AT MT
cardiagn.com
LHD RHD
A7
C6
i2
1 LHD :16
1
COMBINATION
RHD :13
METER B37
A: i10
11
C: i12
B134 ECM
B72 B36 B134 i1 A: i10
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 7 8 9 10 11 12 13 14
24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 RHD: i2 C: i12 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21
7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22
22 23 24 25 26 27 28 29 30 31 32
EN1395
Step Check Yes No

1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair the short Replace the ECM.
TION METER AND ECM CONNECTOR. circuit in harness <Ref. to FU-51,
1)Turn the ignition switch to OFF. between combina- Engine Control
2)Disconnect the connector from ECM. tion meter and Module.>
3)Turn the ignition switch to ON. ECM connector.
EN-56
cardiagn.com
EN-57
E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK

AT A CYCLE OF 3 HZ.
• DIAGNOSIS:
• The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
• Test mode connector circuit is open.
• During inspection mode, MIL does not blink at a cycle of 3 Hz.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
cardiagn.com
AT MT
B36 B38 B36
23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6 0 1 1 16
i2 B125 B126 B75 B76 B22 E3

1
1 LHD :16
COMBINATION RHD :13 B37
METER
A: i10
A11
B14
C: i12
A: B134
ECM
B: B135
B75 B125 B72 A: i10 C: i12 B22 B36
1 1 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 3 4 7 8 9 10 11 12 13 14 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
B135 i1 RHD: i2 B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
7 8 9 10 11 12 13 14
20 21 22 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 32 24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
EN1396
EN-58
Step Check Yes No

1 CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL cir-
FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to EN-
1)Turn the ignition switch to OFF. 54, CHECK
2)Disconnect the test mode connector. ENGINE MAL-
3)Turn the ignition switch to ON. (engine OFF) FUNCTION INDI-
CATOR LAMP
(MIL) DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
2 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair the ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in har-
1)Turn the ignition switch to OFF. ness between
2)Disconnect the connector from ECM. combination meter
3)Turn the ignition switch to ON. and ECM connec-
tor.
3 CHECK HARNESS BETWEEN TEST MODE Is the resistance less than 1 Go to step 4. Repair the har-
CONNECTOR AND CHASSIS GROUND. Ω? ness and connec-
2)Disconnect the connector from ECM. NOTE:
3)Measure the resistance of harness between In this case, repair
cardiagn.com
test mode connector and chassis ground. the following:
Connector & terminal • Open circuit in
(B76) No. 1 — Chassis ground: harness between
test mode connec-
tor and chassis
ground
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Go to step 5.
Check poor contact in ECM connector. connector? contact in ECM
connector.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 6. Repair the open
TEST MODE CONNECTOR. Ω? circuit in harness
1)Connect the test mode connector. between ECM and
2)Measure the resistance of harness between test mode connec-
ECM and chassis ground. tor.
(B135) No. 14 — Chassis ground:
6 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the ECM.
Check poor contact in ECM connector. connector? contact in ECM <Ref. to FU-51,
connector. Engine Control
Module.>
EN-59
F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK-

ING AT A CYCLE OF 3 HZ.
• DIAGNOSIS:
• Test mode connector circuit is shorted.
• MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
cardiagn.com
AT MT
B36 B38 B36
23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6 0 1 1 16
i2 B125 B126 B75 B76 B22 E3

1
1 LHD :16
COMBINATION RHD :13 B37
METER
A: i10
A11
B14
C: i12
A: B134
ECM
B: B135
B75 B125 B72 A: i10 C: i12 B22 B36
1 1 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 3 4 7 8 9 10 11 12 13 14 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
B135 i1 RHD: i2 B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
7 8 9 10 11 12 13 14
20 21 22 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 32 24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
EN1396
EN-60
Step Check Yes No

1 CHECK TEST MODE CONNECTOR. Does the MIL flash on and off? Go to step 2. System is in good
1)Disconnect the test mode connector. order.
2)Turn the ignition switch to ON. NOTE:
MIL blinks at a cy-
cle of 3 Hz when
test mode connec-
tor is connected.
2 CHECK HARNESS BETWEEN ECM CON- Is the resistance less than 5 Repair the short Replace the ECM.
NECTOR AND ENGINE GROUNDING TER- Ω? circuit in harness <Ref. to FU-51,
MINAL. between ECM and Engine Control
1)Turn the ignition switch to OFF. test mode connec- Module.>
2)Disconnect the connector from ECM. tor.
ECM connector and chassis ground.
cardiagn.com
EN-61
DIAGNOSTICS FOR ENGINE STARTING FAILURE
17.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN-68, CONTROL MODULE POWER SUPPLY AND GROUND
LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Fail-
ure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN-80, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
cardiagn.com
EN-62
cardiagn.com
EN-63
B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear
Memory Mode.> and INSPECTION MODE <Ref. to EN-42, Inspection Mode.> .
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
INHIBITOR SWITCH
P R N D 3 2 1
AT 12 12
cardiagn.com
11 7
MT
B12 T3 T7
MT
B135 ECM 28 AT
B14
STARTER
MOTOR
B72 B12 T7 B135
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7
1 2
5 6 7 8 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 17 18 19
3 4
9 10 11 12 20 21 22 23 24 25 26 27 28
EN0862
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Go to step 2. Go to step 3.
ate when the switch starts?
2 CHECK DIAGNOSTIC TROUBLE CODE Is the DTC stored in memory? Record the DTC. Go to step 3.
(DTC). <Ref. to EN-83, LIST, List of Repair the trouble
<Ref. to EN-41, OPERATION, Read Diagnos- Diagnostic Trouble Code case. <Ref. to EN-
tic Trouble Code (DTC).> (DTC).> 90, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
EN-64
Step Check Yes No

3 CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4. Go to step 5.
TOR.
2)Disconnect the connector from starter motor.
3)Turn the ignition switch to START.
4)Measure the power supply voltage between
starter motor connector terminal and engine
ground.
(B14) No. 1 (+) — Engine ground (−):
NOTE:
On AT vehicles, place the selector lever in the
“P” or “N” position.
4 CHECK GROUND CIRCUIT OF STARTER Is the resistance less than 5 Check the starter Repair the open
MOTOR. Ω? motor. <Ref. to circuit of ground
1)Turn the ignition switch to OFF. SC-5, Starter.> cable.
2)Disconnect the terminal from starter motor.
3)Measure the resistance of ground cable
between ground cable terminal and engine
ground.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the ground Go to step 6.
STARTER MOTOR CIRCUIT. Ω? short circuit.
cardiagn.com
2)Measure the resistance between starter
motor and ECM.
(B14) No. 1 — Engine ground:
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 7. Repair the ground
STARTER MOTOR CIRCUIT. Ω? short circuit.
2)Measure the resistance of fuse.
7 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 8. Repair the open
AND IGNITION SWITCH CONNECTOR. circuit in harness
1)Turn the ignition switch to OFF. between ignition
2)Disconnect the connector from ignition switch and battery.
switch.
3)Measure the power supply voltage between
ignition switch connector and chassis ground.
8 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 9. Replace the igni-
AND IGNITION SWITCH CONNECTOR. tion switch.
1)Connect the connector to ignition switch.
3)Measure the voltage between ignition switch
and chassis ground.
9 CHECK TRANSMISSION TYPE. Is the vehicle AT? Go to step 10. Repair the open
circuit between
ignition switch and
starter motor cir-
cuit.
EN-65
Step Check Yes No

10 CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than 1 Repair the open Go to step 11.
1)Turn the ignition switch to OFF. Ω? circuit in harness
2)Place the selector lever in the “P” or “N” posi- between starter
tion. motor and ignition
3)Separate the transmission harness connec- switch connector.
tor.
4)Measure the resistance between transmis-
sion harness connector receptacle's terminals.
(T3) No. 11 — No. 12:
11 CHECK TRANSMISSION HARNESS. Is the resistance less than 1 Go to step 12. Repair the open
1)Disconnect the connector from inhibitor Ω? circuit in harness
switch. between transmis-
2)Measure the resistance of harness between sion harness and
transmission harness and inhibitor switch con- inhibitor switch
nector. connector.
(T3) No. 11 — (T7) No. 7:
12 CHECK POOR CONTACT. Is there poor contact in inhibi- Repair the poor Replace the inhibi-
Check poor contact in inhibitor switch connector switch connector? contact in inhibitor tor switch.
tor. switch connector.
cardiagn.com
EN-66
cardiagn.com
EN-67
C: CONTROL MODULE POWER SUPPLY AND GROUND LINE

CAUTION:
Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
4 TO FRONT OXYGEN (A/F) SENSOR
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1 IGNITION
B72 BATTERY
SWITCH
B47 No.11 SBF-4 SBF-1
4 1
B19
C1
C2
C9
B7
A: B134
B: B135 ECM
1 AT MODEL: B6
cardiagn.com
C: B136
MT MODEL: B25
A34
A35
A27
C22
C21
1
A7
A8
B22
13
15
14
16
8
E3
B72 F44 B47 B22 B: B135 C: B136
1 2 3 4 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2
5 6 7 8 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
3 4
5 6 9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1397
Step Check Yes No

1 CHECK MAIN RELAY. Is the resistance less than 10 Go to step 2. Replace the main
1)Turn the ignition switch to OFF. Ω? relay.
2)Remove the main relay.
3)Connect the battery to main relay terminals
No. 1 and No. 2.
4)Measure the resistance between main relay
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
EN-68
Step Check Yes No

2 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Repair the open
1)Disconnect the connector from ECM. Ω? circuit in harness
2)Measure the resistance of harness between between ECM
ECM and chassis ground. connector and
Connector & terminal engine grounding
(B136) No. 21 — Chassis ground: terminal.
(B135) No. 25 — Chassis ground: (MT
vehicle)
(B135) No. 6 — Chassis ground: (AT
vehicle)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Go to step 4. Repair the open or
Measure the voltage between ECM connector ground short cir-
and chassis ground. cuit of power sup-
Connector & terminal ply circuit.
(B136) No. 9 (+) — Chassis ground (–):
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Go to step 5. Repair the open or
cardiagn.com
1)Turn the ignition switch to ON. ground short cir-
2)Measure the voltage between ECM connec- cuit of power sup-
tor and chassis ground. ply circuit.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 6. Repair the ground
MAIN RELAY CONNECTOR. MΩ? short circuit in har-
2)Measure the resistance between ECM and ECM connector
chassis ground. and main relay
Connector & terminal connector, then
(B135) No. 19 — Chassis ground: replace the ECM.
6 CHECK OUTPUT VOLTAGE FROM ECM. Is the voltage more than 10 V? Go to step 7. Replace the ECM.
1)Connect the connector to ECM.
7 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 8. Repair the open
Check the voltage between main relay connec- circuit in harness
tor and chassis ground. between ECM
Connector & terminal connector and
(B47) No. 2 (+) — Chassis ground (–): main relay con-
nector.
8 CHECK GROUND CIRCUIT OF MAIN RE- Is the resistance less than 5 Go to step 9. Repair the open
LAY. Ω? circuit between
1)Turn the ignition switch to OFF. main relay and
2)Measure the resistance between main relay chassis ground.
9 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 10. Repair the open or
Measure the voltage between main relay con- ground short cir-
nector and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(B47) No. 5 (+) — Chassis ground (−): cuit.
EN-69
Step Check Yes No

10 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check the ignition Repair the open or
1)Connect the main relay connector. control system. ground short cir-
2)Turn the ignition switch to ON. <Ref. to EN-72, cuit in harness
3)Measure the voltage between ECM connec- IGNITION CON- between ECM
tor and chassis ground. TROL SYSTEM, connector and
Connector & terminal Diagnostics for main relay con-
(B136) No. 1 (+) — Chassis ground (–): Engine Starting nector.
(B136) No. 2 (+) — Chassis ground (–): Failure.>
cardiagn.com
EN-70
cardiagn.com
EN-71
D: IGNITION CONTROL SYSTEM

CAUTION:
• WIRING DIAGRAM:
B134 ECM
27
26
25
IGNITION
B72
SWITCH BATTERY
NO.11 SBF-4 SBF-1
4 1
B22
14
6
4
5
cardiagn.com
E3
1 2.0L AND 2.5L: 4
1.6L: 2
2 2.0L AND 2.5L: 1
1.6L: 4
3 2.0L AND 2.5L: 2

1.6L: 1
E12
1
2
3
3
3 4
1 2
IGNITOR
&
IGNITION COIL ASSY
E12 B72 B22 B134
1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 5 6 7 8
9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1398
Step Check Yes No

1 CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check the fuel Go to step 2.
1)Remove the plug cord cap from each spark inder? pump system.
plug. <Ref. to EN-76,
2)Install new spark plug on plug cord cap. FUEL PUMP CIR-
CAUTION: CUIT, Diagnostics
Do not remove spark plug from engine. for Engine Start-
3)Contact the spark plug's thread portion on ing Failure.>
engine.
4)While opening the throttle valve fully, crank
engine to check that spark occurs at each cyl-
inder.
EN-72
Step Check Yes No

2 CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3. Repair the har-
NITION COIL & IGNITOR ASSEMBLY. ness and connec-
2)Disconnect the connector from ignition coil & NOTE:
ignitor assembly. In this case, repair
3)Turn the ignition switch to ON. the following:
4)Measure the power supply voltage between • Open circuit in
ignition coil & ignitor assembly connector and harness between
engine ground. ignition coil & igni-
Connector & terminal tor assembly, and
• 2.0 L and 2.5 L ignition switch
(E12) No. 2 (+) — Engine ground (−): connector
• 1.6 L • Poor contact in
(E12) No. 1 (+) — Engine ground (−): coupling connec-
tors (B22)
3 CHECK HARNESS OF IGNITION COIL & IG- Is the resistance between less Go to step 4. Repair the har-
NITOR ASSEMBLY GROUND CIRCUIT. than 5 Ω? ness and connec-
2)Measure the resistance between ignition coil NOTE:
& ignitor assembly connector and engine In this case, repair
ground. the following:
cardiagn.com
(E12) No. 3 — Engine ground: harness between
ignition coil & igni-
tor assembly con-
nector and engine
grounding terminal
4 CHECK IGNITION COIL & IGNITOR ASSEM- Is the resistance between 10 Go to step 5. Replace the igni-
BLY. and 15 kΩ? tion coil & ignitor
1)Remove the spark plug cords. assembly. <Ref. to
2)Measure the resistance between spark plug IG-8, Ignition Coil
cord contact portions to check secondary coil. and Ignitor Assem-
Terminals bly.>
• 2.0 L and 2.5 L
No. 1 — No. 2:
• 1.6 L
No. 4 — No. 1:
5 CHECK IGNITION COIL & IGNITOR ASSEM- Is the resistance between 10 Go to step 6. Replace the igni-
BLY. and 15 kΩ? tion coil & ignitor
Measure the resistance between spark plug assembly. <Ref. to
cord contact portions to check secondary coil. IG-8, Ignition Coil
Terminals and Ignitor Assem-
• 2.0 L and 2.5 L bly.>
No. 3 — No. 4:
• 1.6 L
No. 3 — No. 2:
6 CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 7. Replace the igni-
& IGNITOR ASSEMBLY. tion coil & ignitor
1)Connect the connector to ignition coil & igni- assembly. <Ref. to
tor assembly. IG-8, Ignition Coil
2)Check if the voltage varies synchronously and Ignitor Assem-
with engine speed when cranking, while moni- bly.>
toring voltage between ignition coil & ignitor
assembly connector and engine ground.
• 2.0 L and 2.5 L
(E12) No. 1 (+) — Engine ground (–):
• 1.6 L
(E12) No. 4 (+) — Engine ground (−):
EN-73
Step Check Yes No

7 CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 8. Replace the igni-
& IGNITOR ASSEMBLY. tion coil & ignitor
Check if the voltage varies synchronously with assembly. <Ref. to
engine speed when cranking, while monitoring IG-8, Ignition Coil
voltage between ignition coil & ignitor assem- and Ignitor Assem-
bly connector and engine ground. bly.>
• 2.0 L and 2.5 L
(E12) No. 4 (+) — Engine ground (–):
• 1.6 L
8 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 9. Repair the har-
NITION COIL & IGNITOR ASSEMBLY CON- Ω? ness and connec-
NECTOR. tor.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repair
3)Disconnect the connector from ignition coil & the following:
ignitor assembly. • Open circuit in
4)Measure the resistance of harness between harness between
ECM and ignition coil & ignitor assembly con- ECM and ignition
nector. coil & ignitor
Connector & terminal assembly connec-
cardiagn.com
• 2.0 L and 2.5 L tor
(B134) No. 25 — (E12) No. 1: • Poor contact in
• 1.6 L coupling connector
(B134) No. 25 — (E12) No. 4: (B22)
9 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 10. Repair the har-
NITION COIL & IGNITOR ASSEMBLY CON- Ω? ness and connec-
NECTOR. tor.
Measure the resistance of harness between NOTE:
ECM and ignition coil & ignitor assembly con- In this case, repair
nector. the following:
• 2.0 L and 2.5 L harness between
(B134) No. 26 — (E12) No. 4: ECM and ignition
• 1.6 L coil & ignitor
(B134) No. 26 — (E12) No. 2: assembly connec-
tor
• Poor contact in
coupling connector
(B22)
10 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 Go to step 11. Repair the ground
NITION COIL & IGNITOR ASSEMBLY CON- MΩ? short circuit in har-
NECTOR. ness between
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil & ignitor
Connector & terminal: assembly connec-
(B134) No. 25 — Engine ground: tor.
11 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 Go to step 12. Repair the ground
NITION COIL & IGNITOR ASSEMBLY CON- MΩ? short circuit in har-
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil & ignitor
Connector & terminal assembly connec-
(B134) No. 26 — Engine ground: tor.
EN-74
Step Check Yes No

12 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check the fuel
Check poor contact in ECM connector. connector? contact in ECM pump circuit. <Ref.
connector. to EN-76, FUEL
PUMP CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
cardiagn.com
EN-75
E: FUEL PUMP CIRCUIT

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
LHD 2 LHD
IGNITION
B61 F44 B72 BATTERY
SWITCH
No.11 SBF-4 SBF-1
FUEL PUMP 4 1
RELAY
2
1
3 2 B134 ECM
4
B46
cardiagn.com
B97
1
1 LHD :7
R1 RHD :5
2 WITH
IMMOBILIZER :29
WITHOUT
IMMOBILIZER :16
FUEL PUMP
1 1
4 3
R58 R57 R15
B46 B72 R58 F44 B97 R15 B134
1 2 1 2 3 1 2 1 2 3 4 5 6 7 8
1 2 1 2 3 4 1 2 3 4
3 4 4 5 6 3 4 5 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 5 6 7 8 5 6 7 8
24 25 26 27 28 29 30 31 32 33 34 35
EN1399
Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Go to step 2.
PUMP. operating sound? injector circuit.
Make sure that the fuel pump is in operation for <Ref. to EN-80,
2 seconds when turning ignition switch to ON. FUEL INJECTOR
NOTE: CIRCUIT, Diag-
Fuel pump operation can also be executed us- nostics for Engine
ing the Subaru Select Monitor (Function mode: Starting Failure.>
FD01).
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN-50, Com-
pulsory Valve Operation Check Mode.>
EN-76
Step Check Yes No

2 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Go to step 3. Repair the har-
1)Turn the ignition switch to OFF. Ω? ness and connec-
2)Remove the fuel pump access hole lid tor.
located on the right rear of trunk compartment NOTE:
floor (Sedan) or luggage compartment floor In this case, repair
(Wagon). the following:
3)Disconnect the connector from fuel pump. • Open circuit in
4)Measure the resistance of harness connec- harness between
tor between fuel pump and chassis ground. fuel pump connec-
Connector & terminal tor and chassis
(R58) No. 4 — Chassis ground: grounding terminal
• Poor contact in
coupling connector
(R15)
3 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V? Replace the fuel Go to step 4.
1)Turn the ignition switch to ON. pump. <Ref. to
2)Measure the voltage of power supply circuit FU-62, Fuel
between fuel pump connector and chassis Pump.>
ground.
(R58) No. 1 (+) — Chassis ground (−):
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Go to step 5. Repair the har-
cardiagn.com
AND FUEL PUMP RELAY CONNECTOR. Ω? ness and connec-
2)Measure the resistance of harness connec- NOTE:
tor between fuel pump and fuel pump relay. In this case, repair
Connector & terminal the following:
(R58) No. 1 — (B46) No. 4: • Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
• Poor contact in
coupling connec-
tors
(R15 and B97)
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 6. Repair the short
AND FUEL PUMP RELAY CONNECTOR. MΩ? circuit in harness
Measure the resistance of harness between between fuel
fuel pump and fuel pump relay connector. pump and fuel
Connector & terminal pump relay con-
(R58) No. 1 — Chassis ground: nector.
6 CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 7. Replace the fuel
1)Disconnect the connectors from fuel pump Ω? pump relay. <Ref.
relay and main relay. to FU-53, Fuel
2)Remove the fuel pump relay and main relay Pump Relay.>
with bracket.
3)Connect the battery to fuel pump relay con-
nector terminals No. 1 and No. 3.
4)Measure the resistance between connector
terminals of fuel pump relay.
Terminals
No. 2 — No. 4:
EN-77
Step Check Yes No

FUEL PUMP RELAY CONNECTOR. Ω? circuit in harness
1)Disconnect the connectors from ECM. between ECM and
2)Measure the resistance of harness between fuel pump relay
ECM and fuel pump relay connector. connector.
• With immobilizer
(B134) No. 29 — (B46) No. 3:
• Without immobilizer
(B134) No. 16 — (B46) No. 3:
8 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check the fuel
Check poor contact in ECM connector. connector? contact in ECM injector circuit.
connector. <Ref. to EN-80,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
cardiagn.com
EN-78
cardiagn.com
EN-79
F: FUEL INJECTOR CIRCUIT

CAUTION:
• Check or repair only faulty parts.
• After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear
Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
C2
C1
cardiagn.com
A: B134 C: B136 ECM
A13
A14
A15
A4
B22
10
11
12
1
E3
E5 E16 E6 E17
2
FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR

No.1 No.2 No.3 No.4
E5 E16 B47 F44 B22
E6 E17 1 2 1 2 3 4 1 2 3 4
3 4 5 6 7 8 5 6 7 8
1 2 5 6 9 10 11 12
13 14 15 16
C: B136 A: B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35
EN0866
Step Check Yes No

1 CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector emit Check the fuel Go to step 2.
TOR. “operating” sound? pressure. <Ref. to
While cranking the engine, check that each ME-29, INSPEC-
fuel injector emits “operating” sound. Use a TION, Fuel Pres-
sound scope or attach a screwdriver to injector sure.>
for this check.
EN-80
Step Check Yes No

2 CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 V? Go to step 3. Repair the har-
INJECTOR. ness and connec-
2)Disconnect the connector from #1 cylinder NOTE:
fuel injector. In this case, repair
4)Measure the power supply voltage between • Open circuit in
the fuel injector terminal and engine ground. harness between
Connector & terminal main relay and fuel
#1 (E5) No. 2 (+) — Engine ground (–): injector connector
#2 (E16) No. 2 (+) — Engine ground (−): • Poor contact in
#3 (E6) No. 2 (+) — Engine ground (–): main relay con-
#4 (E17) No. 2 (+) — Engine ground (–): nector
• Poor contact in
coupling connector
(B22)
• Poor contact in
fuel injector con-
nector
3 CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 4. Repair the har-
FUEL INJECTOR CONNECTOR. and 20 Ω? ness and connec-
cardiagn.com
2)Measure the resistance of harness between NOTE:
ECM and fuel injector connector. In this case, repair
(B134) No. 4 — (B136) No. 2: • Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
FUEL INJECTOR CONNECTOR. Ω? short circuit in har-
Measure the resistance of harness between ness between
ECM and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
Measure the resistance of harness between tor.
ECM and fuel injector connector. NOTE:
Connector & terminal In this case, repair
(B134) No. 13 — (B136) No. 2: the following:
• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
EN-81
Step Check Yes No

• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
cardiagn.com
• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
11 CHECK EACH FUEL INJECTOR. Is the resistance between 5 Go to step 12. Replace the faulty
1)Turn the ignition switch to OFF. and 20 Ω? fuel injector.
2)Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 — No. 2:
12 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Inspection using
Check poor contact in ECM connector. connector? contact in ECM “General Diagnos-
connector. tic Table”. <Ref. to
EN-292, INSPEC-
TION, General
Diagnostic Table.>
EN-82
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
18.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item Index
No.
P0031 Front oxygen (A/F) sensor heater cir- <Ref. to EN-90, DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER
cuit low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0032 Front oxygen (A/F) sensor heater cir- <Ref. to EN-94, DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER
cuit high input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0037 Rear oxygen sensor heater circuit <Ref. to EN-96, DTC P0037 — REAR OXYGEN SENSOR HEATER CIR-
malfunction CUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0038 Rear oxygen sensor heater circuit <Ref. to EN-100, DTC P0038 — REAR OXYGEN SENSOR HEATER CIR-
high input CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0066 Air assist injector solenoid valve cir- <Ref. to EN-102, DTC P0066 — AIR ASSIST INJECTOR SOLENOID
cuit low input VALVE CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0067 Air assist injector solenoid valve cir- <Ref. to EN-104, DTC P0067 — AIR ASSIST INJECTOR SOLENOID
cuit high input VALVE CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
cardiagn.com
P0106 Pressure sensor circuit range/perfor- <Ref. to EN-106, DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/
mance problem (low input) PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0107 Pressure sensor circuit low input <Ref. to EN-110, DTC P0107 — PRESSURE SENSOR CIRCUIT LOW
INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0108 Pressure sensor circuit high input <Ref. to EN-114, DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH
P0111 Intake air temperature sensor circuit <Ref. to EN-118, DTC P0111 — INTAKE AIR TEMPERATURE SENSOR
range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
high input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0117 Engine coolant temperature sensor <Ref. to EN-126, DTC P0117 — ENGINE COOLANT TEMPERATURE SEN-
circuit low input SOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0118 Engine coolant temperature sensor <Ref. to EN-128, DTC P0118 — ENGINE COOLANT TEMPERATURE SEN-
circuit high input SOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0121 Throttle position sensor circuit range/ <Ref. to EN-132, DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT
performance problem (high input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P0122 Throttle position sensor circuit low <Ref. to EN-134, DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT
input LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0123 Throttle position sensor circuit high <Ref. to EN-138, DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT
input HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0125 Insufficient coolant temperature for <Ref. to EN-140, DTC P0125 — INSUFFICIENT COOLANT TEMPERA-
closed loop fuel control TURE FOR CLOSED LOOP FUEL CONTROL —, Diagnostic Procedure
EN-83
DTC
Item Index
No.
P0130 Front oxygen (A/F) sensor circuit <Ref. to EN-142, DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT
range/performance problem (Lean) RANGE/PERFORMANCE PROBLEM (LEAN) —, Diagnostic Procedure with
malfunction (open circuit) MALFUNCTION (OPEN CIRCUIT) —, Diagnostic Procedure with Diagnostic
malfunction (short circuit) MALFUNCTION (SHORT CIRCUIT) —, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
slow response SLOW RESPONSE —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0136 Rear oxygen sensor circuit malfunc- <Ref. to EN-150, DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MAL-
tion FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0139 Rear oxygen sensor circuit slow <Ref. to EN-154, DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW
response RESPONSE —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0170 Fuel trim malfunction <Ref. to EN-156, DTC P0170 — FUEL TRIM MALFUNCTION —, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P0301 Cylinder 1 misfire detected <Ref. to EN-158, DTC P0301 — CYLINDER 1 MISFIRE DETECTED —,
cardiagn.com
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0327 Knock sensor circuit low input <Ref. to EN-166, DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT —
, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0328 Knock sensor circuit high input <Ref. to EN-168, DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT
—, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0335 Crankshaft position sensor circuit <Ref. to EN-170, DTC P0335 — CRANKSHAFT POSITION SENSOR CIR-
malfunction CUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0336 Crankshaft position sensor circuit <Ref. to EN-172, DTC P0336 — CRANKSHAFT POSITION SENSOR CIR-
range/performance problem CUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with
P0340 Camshaft position sensor circuit mal- <Ref. to EN-174, DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT
function MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0341 Camshaft position sensor circuit <Ref. to EN-176, DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT
range/performance problem RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0420 Catalyst system efficiency below <Ref. to EN-179, DTC P0420 — CATALYST SYSTEM EFFICIENCY
threshold BELOW THRESHOLD —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0444 Evaporative emission control system <Ref. to EN-184, DTC P0444 — EVAPORATIVE EMISSION CONTROL
purge control valve circuit low input SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT —, Diagnostic
P0445 Evaporative emission control system <Ref. to EN-188, DTC P0445 — EVAPORATIVE EMISSION CONTROL
purge control valve circuit high input SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT —, Diagnostic
P0461 Fuel level sensor circuit range/perfor- <Ref. to EN-190, DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/
mance problem PERFORMANCE PROBLEM —, Diagnostic Procedure with Diagnostic
EN-84
DTC
Item Index
No.
P0462 Fuel level sensor circuit low input <Ref. to EN-192, DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW
P0463 Fuel level sensor circuit high input <Ref. to EN-196, DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH
P0464 Fuel level sensor intermittent input <Ref. to EN-200, DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT
INPUT—, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0480 Cooling fan relay 1 circuit low input <Ref. to EN-203, DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW
P0483 Cooling fan function problem <Ref. to EN-207, DTC P0483 — COOLING FAN FUNCTION PROBLEM —,
P0500 Vehicle speed sensor malfunction <Ref. to EN-210, DTC P0500 — VEHICLE SPEED SENSOR MALFUNC-
TION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0506 Idle control system RPM lower than <Ref. to EN-212, DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER
expected THAN EXPECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0507 Idle control system RPM higher than <Ref. to EN-214, DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER
expected THAN EXPECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0512 Starter switch circuit high input <Ref. to EN-216, DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT
cardiagn.com
P0513 Incorrect immobilizer key <Ref. to IM-22, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF
UNREGISTERED KEY), Diagnostics Chart with Diagnostic Trouble Code
(DTC).>
P0562 Charge system circuit low input <Ref. to EN-218, DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT
P0563 Charge system circuit high input <Ref. to EN-220, DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT
P0604 Internal control module memory <Ref. to EN-222, DTC P0604 — INTERNAL CONTROL MODULE MEMORY
check sum error CHECK SUM ERROR —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0703 Brake switch input malfunction <Ref. to EN-224, DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION
P0705 Transmission range sensor circuit <Ref. to AT-119, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-diagnostic Trouble Code (DTC).>
P0710 Transmission fluid temperature sen- <Ref. to AT-46, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Proce-
sor circuit malfunction dure with Diagnostic Trouble Code (DTC).>
P0715 Torque converter turbine speed sen- <Ref. to AT-62, DTC 36 TORQUE CONVERTER TURBINE SPEED SEN-
sor circuit malfunction SOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0720 Output speed sensor (vehicle speed <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic
sensor 2) circuit malfunction Procedure with Diagnostic Trouble Code (DTC).>
P0725 Engine speed input circuit malfunc- <Ref. to AT-42, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion with Diagnostic Trouble Code (DTC).>
P0731 Gear 1 incorrect ratio <Ref. to EN-226, DTC P0731 — GEAR 1 INCORRECT RATIO —, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P0741 Torque converter clutch system mal- <Ref. to EN-228, DTC P0741 — TORQUE CONVERTER CLUTCH SYS-
function TEM MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0743 Torque converter clutch system <Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure
(Lock-up duty solenoid) electrical with Diagnostic Trouble Code (DTC).>
EN-85
DTC
Item Index
No.
P0748 Pressure control solenoid (Line pres- <Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic
sure duty solenoid) electrical Procedure with Diagnostic Trouble Code (DTC).>
P0753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
P0758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-74, DTC 72 SHIFT SOLENOID 2, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
P0778 2-4 brake pressure control solenoid <Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Proce-
valve circuit malfunction dure with Diagnostic Trouble Code (DTC).>
P0785 2-4 brake timing control solenoid <Ref. to AT-82, DTC 74 2-4 BRAKE TIMING SOLENOID, Diagnostic Proce-
valve circuit malfunction dure with Diagnostic Trouble Code (DTC).>
P1110 Atmospheric pressure sensor circuit <Ref. to EN-230, DTC P1110 — ATMOSPHERIC PRESSURE SENSOR
low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
high input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure
cardiagn.com
range/performance problem RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P1142 Throttle position sensor circuit range/ <Ref. to EN-242, DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT
performance problem (low input) RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic Proce-
P1146 Pressure sensor circuit range/perfor- <Ref. to EN-244, DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/
mance problem (high input) PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Procedure with
P1442 Fuel level sensor circuit range/perfor- <Ref. to EN-247, DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/
mance problem 2 PERFORMANCE PROBLEM 2 —, Diagnostic Procedure with Diagnostic
P1480 Cooling fan relay 1 circuit high input <Ref. to EN-249, DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH
P1507 Idle control system malfunction (fail- <Ref. to EN-252, DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION
safe) (FAIL-SAFE) —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1510 Idle air control solenoid valve signal <Ref. to EN-254, DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE
1 circuit low input SIGNAL 1 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
1 circuit high input SIGNAL 1 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
EN-86
DTC
Item Index
No.
P1518 Starter switch circuit low input <Ref. to EN-262, DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT
P1540 Vehicle speed sensor malfunction 2 <Ref. to EN-264, DTC P1540 — VEHICLE SPEED SENSOR MALFUNC-
TION 2 —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1560 Back-up voltage circuit malfunction <Ref. to EN-266, DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNC-
TION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1570 Antennna <Ref. to IM-24, DTC P1570 ANTENNA, Diagnostics Chart with Diagnostic
P1571 Reference code incompatibility <Ref. to IM-17, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diag-
nostics Chart with Diagnostic Trouble Code (DTC).>
P1572 IMM circuit failure except antenna <Ref. to IM-18, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA
circuit CIRCUIT), Diagnostics Chart with Diagnostic Trouble Code (DTC).>
P1574 Key communication failure <Ref. to IM-21, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostics
Chart with Diagnostic Trouble Code (DTC).>
cardiagn.com
P1576 EGI control module EEPROM <Ref. to IM-22, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnos-
tics Chart with Diagnostic Trouble Code (DTC).>
P1577 IMM control module EEPROM <Ref. to IM-22, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnos-
tics Chart with Diagnostic Trouble Code (DTC).>
P1590 Neutral position switch circuit high <Ref. to EN-268, DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT
input (AT model) HIGH INPUT (AT MODEL) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1591 Neutral position switch circuit low <Ref. to EN-272, DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT
input (AT model) LOW INPUT (AT MODEL) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1592 Neutral position switch circuit low <Ref. to EN-274, DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT
input (MT model) LOW INPUT (MT MODEL) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1594 Automatic transmission diagnosis <Ref. to EN-276, DTC P1594 — AUTOMATIC TRANSMISSION DIAGNO-
input signal circuit malfunction SIS INPUT SIGNAL CIRCUIT MALFUNCTION —, Diagnostic Procedure
input signal circuit low input SIS INPUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Procedure with
input signal circuit high input SIS INPUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P1698 Engine torque control cut signal cir- <Ref. to EN-282, DTC P1698 — ENGINE TORQUE CONTROL CUT SIG-
cuit low input NAL CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P1699 Engine torque control cut signal cir- <Ref. to EN-284, DTC P1699 — ENGINE TORQUE CONTROL CUT SIG-
cuit high input NAL CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P1700 Throttle position sensor circuit mal- <Ref. to AT-50, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Pro-
function for automatic transmission cedure with Diagnostic Trouble Code (DTC).>
P1701 Cruise control set signal circuit mal- <Ref. to EN-286, DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT
function for automatic transmission MALFUNCTION FOR AUTOMATIC TRANSMISSION —, Diagnostic Proce-
P1703 Low clutch timing control solenoid <Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic
valve circuit malfunction Procedure with Diagnostic Trouble Code (DTC).>
EN-87
DTC
Item Index
No.
P1711 Engine torque control signal 1 circuit <Ref. to EN-288, DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1
malfunction CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1712 Engine torque control signal 2 circuit <Ref. to EN-290, DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2
malfunction CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
cardiagn.com
EN-88
cardiagn.com
EN-89
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
19.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW IN-
PUT —
• DTC DETECTING CONDITION:
• Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION,
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.> .
• WIRING DIAGRAM:
MAIN RELAY BATTERY B47
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
B47 FRONT OXYGEN 4 5 6
(A/F) SENSOR
B18
cardiagn.com
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Go to step 2. Go to step 5.
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool
indicate DTC P0031 and
P0037 at the same time?
EN-90
Step Check Yes No

2 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 V? Go to step 3. Repair the power
GEN (A/F) SENSOR. supply line.
2)Disconnect the connector from front oxygen In this case, repair
(A/F) sensor. the following:
3)Turn the ignition switch to ON. • Open circuit in
4)Measure the voltage between front oxygen harness between
(A/F) sensor connector and engine ground. main relay and
Connector & terminal front oxygen (A/F)
(B18) No. 2 (+) — Engine ground (−): sensor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
main relay con-
nector
3 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 4. Repair the har-
Measure the resistance of harness between Ω? ness and connec-
ECM connector and chassis ground. tor.
Connector & terminal NOTE:
(B134) No. 35 — Chassis ground: In this case, repair
(B134) No. 34 — Chassis ground: the following:
cardiagn.com
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)
4 CHECK CURRENT DATA. Is the value more than 0.2 A? Repair the poor Go to step 5.
1)Start the engine. contact in connec-
2)Read the data of front oxygen (A/F) sensor tor.
heater current using Subaru Select Monitor or NOTE:
OBD-II general scan tool. In this case, repair
NOTE: the following:
•Subaru Select Monitor • Poor contact in
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
<Ref. to EN-34, Subaru Select Monitor.> • Poor contact in
•OBD-II scan tool ECM connector
For detailed operation procedures, refer to the
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 V? Go to step 7. Go to step 6.
1)Start and idle the engine.
6 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change less Repair the poor Go to step 7.
Measure the voltage between ECM connector than 1.0 V by shaking harness contact in ECM
and chassis ground. and connector of ECM while connector.
Connector & terminal monitoring the value with volt-
(B134) No. 22 (+) — Chassis ground (−): age meter?
Measure the voltage between ECM connector
and chassis ground.
EN-91
Step Check Yes No

9 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 10 Repair the har- Replace the front
1)Turn the ignition switch to OFF. Ω? ness and connec- oxygen (A/F) sen-
2)Measure the resistance between front oxy- tor. sor. <Ref. to FU-
gen (A/F) sensor connector terminals. NOTE: 54, Fuel.>
Terminals In this case, repair
No. 2 — No. 5: the following:
• Open or ground
short circuit in har-
ness between
front oxygen (A/F)
sensor and ECM
connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
cardiagn.com
EN-92
cardiagn.com
EN-93
B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH IN-
PUT —
CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Inspection Mode.> .
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
cardiagn.com
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 8 V? Go to step 3. Go to step 2.
EN-94
Step Check Yes No

and chassis ground.
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 A? Replace the ECM. END
HEATER CURRENT. <Ref. to FU-51,
1)Turn the ignition switch to OFF. Engine Control
2)Repair the battery short circuit in harness Module.>
between ECM and front oxygen (A/F) sensor
connector.
4)Read the data of front oxygen (A/F) sensor
heater current using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
•Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”.
<Ref. to EN-34, Subaru Select Monitor.>
•OBD-II general scan tool
cardiagn.com
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more
Repair the battery Go to step 5.
Measure the voltage between ECM connector than 8 V by shaking harness
short circuit in har-
and chassis ground. and connector of ECM while
ness between
ECM and front
(B134) No. 23 (+) — Chassis ground (−): age meter? oxygen (A/F) sen-
sor connector.
5 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more Repair the battery END
Measure the voltage between ECM connector than 8 V by shaking harness short circuit in har-
and chassis ground. and connector of ECM while ness between
Connector & terminal monitoring the value with volt- ECM and front
(B134) No. 22 (+) — Chassis ground (−): age meter? oxygen (A/F) sen-
sor connector.
EN-95
C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

—
• Two consecutive driving cycles with fault
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY BATTERY B47 B19
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
cardiagn.com
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
Step Check Yes No

1 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Go to step 2.
1)Turn the ignition switch to OFF. Ω?
2)Disconnect the connector from ECM.
EN-96
Step Check Yes No

1)Repair the harness and connector. Ω? ness and connec-
2)Measure the resistance of harness between tor.
ECM connector and chassis ground. NOTE:
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
3 CHECK CURRENT DATA. Is the value more than 0.2 A? Repair the con- Go to step 4.
1)Start the engine. nector.
2)Read the data of rear oxygen sensor heater NOTE:
current using Subaru Select Monitor or OBD-II In this case, repair
general scan tool. the following:
NOTE: • Poor contact in
•Subaru Select Monitor rear oxygen sen-
cardiagn.com
For detailed operation procedure, refer to the sor connector
“READ CURRENT DATA FOR ENGINE”. • Poor contact in
<Ref. to EN-34, Subaru Select Monitor.> rear oxygen sen-
•OBD-II scan tool sor connecting
For detailed operation procedures, refer to the harness connector
OBD-II General Scan Tool Instruction Manual. • Poor contact in
ECM connector
1)Start and idle the engine.
6 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 V? Contact with your Repair the battery
1)Disconnect the connector from rear oxygen Subaru distributor short circuit in har-
sensor. service. ness between
2)Measure the voltage between ECM connec- ECM and rear oxy-
tor and chassis ground. gen sensor con-
Connector & terminal nector.
7 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 V? Go to step 8. Repair the power
GEN SENSOR. supply line.
2)Disconnect the connector from rear oxygen In this case, repair
sensor. the following:
4)Measure the voltage between rear oxygen harness between
sensor connector and engine ground or chas- main relay and
sis ground. rear oxygen sen-
Connector & terminal sor connector
(B19) No. 2 (+) — Chassis ground (−): • Poor contact in
rear oxygen sen-
sor connector
EN-97
Step Check Yes No

8 CHECK REAR OXYGEN SENSOR. Is the resistance less than 30 Repair the har- Replace the rear
1)Turn the ignition switch to OFF. Ω? ness and connec- oxygen sensor.
2)Measure the resistance between rear oxy- tor. <Ref. to FU-49,
gen sensor connector terminals. NOTE: Rear Oxygen Sen-
Terminals In this case, repair sor.>
No. 1 — No. 2: the following:
• Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
cardiagn.com
EN-98
cardiagn.com
EN-99
D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
cardiagn.com
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 8 V? Go to step 2. Go to step 3.
and chassis ground.
EN-100
Step Check Yes No

2 CHECK CURRENT DATA. Is the value more than 7 A? Replace the ECM. END
1)Turn the ignition switch to OFF. <Ref. to FU-51,
2)Repair the battery short circuit in harness Engine Control
between ECM and rear oxygen sensor con- Module.>
nector.
4)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
3 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END
Check poor contact in ECM connector. connector? contact in ECM
connector.
cardiagn.com
EN-101
E: DTC P0066 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW IN-
PUT —
• Erroneous idling
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
cardiagn.com
2
1 AIR ASSIST
INJECTOR
B47 SOLENOID
VALVE
2
1
E42
E3
1
7
B22
24
B134 ECM
E42 B47 F44 B22 B134
1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
3 4 5 6 7 8 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
5 6 9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1402
EN-102
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the poor Go to step 2.
1)Turn the ignition switch to ON. contact in ECM
2)Measure the voltage between ECM and connector.
chassis ground.
2 CHECK POWER SUPPLY TO AIR ASSIST IN- Is the voltage more than 10 V? Go to step 3. Repair the har-
JECTOR SOLENOID VALVE. ness and connec-
2)Disconnect the connector from air assist NOTE:
injector solenoid valve. In this case, repair
4)Measure the voltage between air assist • Open circuit in
injector solenoid valve and engine ground. harness between
Connector & terminal air assist injector
(E42) No. 2 (+) — Engine ground (−): solenoid valve and
main relay con-
nector
• Poor contact in
coupling connector
(B22)
3 CHECK HARNESS BETWEEN ECM AND AIR Is the resistance less than 1 Go to step 4. Repair the har-
cardiagn.com
ASSIST INJECTOR SOLENOID VALVE CON- Ω? ness and connec-
NECTOR. tor.
3)Measure the resistance of harness between the following:
ECM and air assist injector solenoid valve con- • Open circuit in
nector. harness between
Connector & terminal ECM and air assist
(B134) No. 24 — (E42) No. 1: injector solenoid
valve connector
• Poor contact in
coupling connector
(B22)
4 CHECK HARNESS BETWEEN ECM AND AIR Is the resistance less than 10 Repair the ground Go to step 5.
ASSIST INJECTOR SOLENOID VALVE CON- Ω? short circuit in har-
Measure the resistance of harness between ECM and air assist
ECM and chassis ground. injector solenoid
Connector & terminal valve connector.
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the air
Check poor contact in ECM and air assist and air assist injector solenoid contact in ECM assist injector
injector solenoid valve connectors. valve connectors? and air assist solenoid valve.
injector solenoid <Ref. to FU-40, Air
valve connectors. Assist Injector
Solenoid Valve.>
EN-103
F: DTC P0067 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH IN-
PUT —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
cardiagn.com
2
1 AIR ASSIST
INJECTOR
B47 SOLENOID
VALVE
2
1
E42
E3
1
7
B22
24
B134 ECM
E42 B47 F44 B22 B134
1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
3 4 5 6 7 8 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
5 6 9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1402
EN-104
Step Check Yes No

2)Measure the voltage between ECM and
chassis ground.
2 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the battery Replace the air
1)Turn the ignition switch to OFF. short circuit in har- assist injector
2)Disconnect the connector from air assist ness between solenoid valve
injector solenoid valve. ECM and air assist <Ref. to FU-40, Air
3)Turn the ignition switch to ON. injector solenoid Assist Injector
4)Measure the voltage between ECM and valve connector. Solenoid Valve.>
chassis ground. After repair, and ECM <Ref. to
Connector & terminal replace the ECM. FU-51, Engine
(B134) No. 24 (+) — Chassis ground (−): <Ref. to FU-51, Control Module.>
Engine Control
Module.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more Repair the battery Contact with your
Measure the voltage between ECM and chas- than 10 V by shaking harness short circuit in har- Subaru distributor
sis ground. and connector of ECM while ness between service.
Connector & terminal monitoring the value with volt- ECM and air assist NOTE:
(B134) No. 24 (+) — Chassis ground (−): age meter? injector solenoid Inspection by DTM
cardiagn.com
valve connector. is required, be-
After repair, cause probable
replace the ECM. cause is deteriora-
<Ref. to FU-51, tion of multiple
Engine Control parts.
Module.>
EN-105
G: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) —
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
cardiagn.com
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-106
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2.
BLE CODE (DTC) ON DISPLAY. vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
2 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or Repair the air Go to step 3.
disconnection of hose on air intake system.
intake system?
3 CHECK PRESSURE SENSOR. Is the value within the specifi- Go to step 4. Replace the intake
1)Start the engine and warm-up engine until cations? air temperature
coolant temperature is greater than 60°C sensor and pres-
(140°F). sure sensor. <Ref.
2)Place the shift lever in the selector lever in to FU-37, Intake
“N” or “P” position. Air Temperature
cardiagn.com
3)Turn the A/C switch to OFF. and Pressure Sen-
4)Turn all accessory switches to OFF. sor.>
5)Read the data of intake manifold pressure
sensor signal using Subaru Select Monitor or
NOTE:
Specification:
•Intake manifold absolute pressure
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg, 5.91
— 13.78 inHg)
4 CHECK THROTTLE POSITION. Is the throttle positioning ratio Go to step 5. Adjust or replace
Read the data of throttle position signal using equal to or less than 5 % when the throttle posi-
Subaru Select Monitor or OBD-II general scan throttle is fully closed? tion sensor. <Ref.
tool. to FU-35, Throttle
NOTE: Position Sensor.>
EN-107
Step Check Yes No

5 CHECK THROTTLE POSITION. Is the throttle positioning ratio Replace the intake Replace the throt-
equal to or more than 85 % air temperature tle position sensor.
when throttle is fully open? and pressure sen- <Ref. to FU-35,
sor. <Ref. to FU- Throttle Position
37, Intake Air Sensor.>
Temperature and
Pressure Sensor.>
cardiagn.com
EN-108
cardiagn.com
EN-109
H: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
cardiagn.com
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-110
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 13.3 kPa Go to step 3. Go to step 2.
1)Start the engine. (100 mmHg, 3.94 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
NOTE:
2 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Even if MIL lights
Check poor contact in ECM and pressure sen- pressure sensor connector? contact in ECM or up, the circuit has
sor connector. pressure sensor returned to a nor-
connector. mal condition at
this time.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 5. Go to step 4.
and chassis ground.
cardiagn.com
4 CHECK INPUT SIGNAL FOR ECM. Does the voltage change more Repair the poor Contact with your
Measure the voltage between ECM connector than 4.5 V by shaking harness contact in ECM Subaru distributor
and chassis ground. and connector of ECM while connector. service.
Connector & terminal monitoring the value with volt- NOTE:
(B136) No. 15 (+) — Chassis ground (−): age meter? Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.2 V? Go to step 7. Go to step 6.
Measure the voltage between ECM and chas-
sis ground.
6 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change more Repair the poor Go to step 7.
SUBARU SELECT MONITOR.) than 13.3 kPa (100 mmHg, contact in ECM
Read the data of atmospheric absolute pres- 3.94 inHg) by shaking harness connector.
sure signal using Subaru Select Monitor. and connector of ECM while
NOTE: monitoring the value with Sub-
•Subaru Select Monitor aru Select Monitor?
7 CHECK HARNESS BETWEEN ECM AND IN- Is the voltage more than 4.5 V? Go to step 8. Repair the open
TAKE AIR TEMPERATURE AND PRESSURE circuit in harness
SENSOR CONNECTOR. between ECM and
1)Turn the ignition switch to OFF. intake air tempera-
2)Disconnect the connector from intake air ture and pressure
temperature and pressure sensor. sensor connector.
4)Measure the voltage between intake air tem-
perature sensor and pressure sensor connec-
tor and engine ground.
EN-111
Step Check Yes No

8 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Go to step 9. Repair the open
TAKE AIR TEMPERATURE AND PRESSURE Ω? circuit in harness
2)Disconnect the connector from ECM. ture and pressure
3)Measure the resistance of harness between sensor connector.
ECM and intake air temperature and pressure
sensor connector.
(B136) No. 16 — (E20) No. 1:
9 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance more than Go to step 10. Repair the ground
TAKE AIR TEMPERATURE AND PRESSURE 500 kΩ? short circuit in har-
SENSOR CONNECTOR. ness between
Measure the resistance of harness between ECM and intake
intake air temperature and pressure sensor air temperature
connector and engine ground. and pressure sen-
Connector & terminal sor connector.
(E20) No. 4 — Engine ground:
10 CHECK POOR CONTACT. Is there poor contact in intake Repair the poor Replace the intake
Check poor contact in intake manifold pressure manifold pressure sensor con- contact in intake air temperature
sensor connector. nector? air temperature and pressure sen-
and pressure sensor. <Ref. to FU-
cardiagn.com
sor connector. 37, Intake Air
Temperature and
Pressure Sensor.>
EN-112
cardiagn.com
EN-113
I: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT —

CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Operation.> .
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
cardiagn.com
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-114
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 119.5 Go to step 10. Go to step 2.
1)Start the engine. kPa (896.5 mmHg, 35.29
2)Read the data of intake manifold absolute inHg)?
NOTE:
and chassis ground.
cardiagn.com
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
SUBARU SELECT MONITOR.) than 13.3 kPa (100 mmHg, contact in ECM
Read the data of atmospheric absolute pres- 3.94 inHg) by shaking harness connector.
sure signal using Subaru Select Monitor. and connector of ECM while
NOTE: monitoring the value with Sub-
•Subaru Select Monitor aru Select Monitor?
6 CHECK HARNESS BETWEEN ECM AND IN- Is the voltage more than 4.5 V? Go to step 7. Repair the open
TAKE AIR TEMPERATURE AND PRESSURE circuit in harness
temperature and pressure sensor. sensor connector.
4)Measure the voltage between intake air tem-
perature and pressure sensor connector and
engine ground.
EN-115
Step Check Yes No

2)Disconnect the connector from ECM. ture and pressure
3)Measure the resistance of harness between sensor connector.
ECM and intake air temperature and pressure
sensor connector.
(B136) No. 5 — (E20) No. 4:
Measure the resistance of harness between intake air tempera-
ECM and intake air temperature and pressure ture and pressure
sensor connector. sensor connector.
(B136) No. 16 — (E20) No. 1:
9 CHECK POOR CONTACT. Is there poor contact in intake Repair the poor Replace the intake
Check poor contact in intake air temperature manifold pressure sensor con- contact in intake air temperature
and pressure sensor connector. nector? air temperature and pressure sen-
and pressure sensor. <Ref. to FU-
cardiagn.com
sor connector. 37, Intake Air
Temperature and
Pressure Sensor.>
10 CHECK HARNESS BETWEEN ECM AND IN- Is the value more than 119.5 Repair the battery Replace the intake
TAKE AIR TEMPERATURE AND PRESSURE kPa (896.5 mmHg, 35.29 short circuit in har- air temperature
SENSOR CONNECTOR. inHg)? ness between and pressure sen-
1)Turn the ignition switch to OFF and Subaru ECM and intake sor. <Ref. to FU-
Select Monitor or OBD-II general scan tool air temperature 37, Intake Air
switch to OFF. and pressure sen- Temperature and
2)Disconnect the connector from intake air sor connector. Pressure Sensor.>
temperature and pressure sensor.
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-II general scan tool
switch to ON.
NOTE:
EN-116
cardiagn.com
EN-117
J: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM —
• Poor driving performance
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
E20
LHD: B83
1 2 3
4 5 6
cardiagn.com
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-118
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
2 CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tempera- Replace the intake Inspect the DTC
TURE. ture between 75°C (167°F) air temperature P0125 using “17.
1)Start the engine and warm it up completely. and 95°C (203°F)? and pressure sen- List of Diagnostic
2)Measure the engine coolant temperature sor. <Ref. to FU- Trouble Code
using Subaru Select Monitor or OBD-II general 37, Intake Air (DTC)”. <Ref. to
scan tool. Temperature and EN-83, List of
NOTE: Pressure Sensor.> Diagnostic Trou-
•Subaru Select Monitor ble Code (DTC).>
cardiagn.com
EN-119
K: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

—
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
E20
LHD: B83
1 2 3
4 5 6
cardiagn.com
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-120
Step Check Yes No

1 CHECK CURRENT DATA. Is the value greater than 120°C Go to step 2. Repair the poor
1)Start the engine. (248°F)? contact.
2)Read the data of intake air temperature sen- NOTE:
sor signal using Subaru Select Monitor or In this case, repair
OBD-II general scan tool. the following:
•Subaru Select Monitor intake air tempera-
For detailed operation procedure, refer to the ture and pressure
“READ CURRENT DATA FOR ENGINE”. sensor
•OBD-II general scan tool ECM
For detailed operation procedure, refer to the • Poor contact in
OBD-II General Scan Tool Instruction Manual. coupling connector
(B21)
• Poor contact in
joint connector
(B83), (B122)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the value less than −40°C Replace the intake Repair the ground
TEMPERATURE AND PRESSURE SENSOR (−40°F)? air temperature short circuit in har-
AND ECM CONNECTOR. and pressure sen- ness between
1)Turn the ignition switch to OFF. sor. <Ref. to FU- intake air tempera-
2)Disconnect the connector from intake air 37, Intake Air ture sensor and
cardiagn.com
temperature and pressure sensor. Temperature and ECM connector.
3)Turn the ignition switch to ON. Pressure Sensor.>
4)Read the data of intake air temperature sen-
sor signal using Subaru Select Monitor or the
NOTE:
EN-121
L: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

—
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
E20
LHD: B83
1 2 3
4 5 6
cardiagn.com
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-122
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than −40°C Go to step 2. Repair the poor
1)Start the engine. (−40°F)? contact.
2)Read the data of intake air temperature sen- NOTE:
sor signal using Subaru Select Monitor or In this case, repair
•Subaru Select Monitor intake air tempera-
For detailed operation procedure, refer to the ture and pressure
“READ CURRENT DATA FOR ENGINE”. sensor
For detailed operation procedure, refer to the • Poor contact in
(B21)
• Poor contact in
joint connector
(B83), (B122)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 3.
TEMPERATURE AND PRESSURE SENSOR short circuit in har-
AND ECM CONNECTOR. ness between
cardiagn.com
temperature and pressure sensor. sensor and ECM
3)Measure the voltage between intake air tem- connector.
perature and pressure sensor connector and
engine ground.
3 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 4.
TEMPERATURE AND PRESSURE SENSOR short circuit in har-
AND ECM CONNECTOR. ness between
1)Turn the ignition switch to ON. intake air tempera-
2)Measure the voltage between intake air tem- ture and pressure
perature and pressure sensor connector and sensor and ECM
engine ground. connector.
EN-123
Step Check Yes No

4 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 V? Go to step 5. Repair the har-
TEMPERATURE AND PRESSURE SENSOR ness and connec-
AND ECM CONNECTOR. tor.
Measure the voltage between intake air tem- NOTE:
perature and pressure sensor connector and In this case, repair
engine ground. the following:
(E20) No. 2 (+) — Engine ground (−): harness between
intake air tempera-
ture and pressure
sensor and ECM
connector
• Poor contact in
intake air tempera-
ture and pressure
sensor
• Poor contact in
ECM
• Poor contact in
coupling connector
(B21)
• Poor contact in
cardiagn.com
joint connector
(B83) and (B122)
5 CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5 Replace the intake Repair the har-
TEMPERATURE AND PRESSURE SENSOR Ω? air temperature ness and connec-
AND ECM CONNECTOR. and pressure sen- tor.
1)Turn the ignition switch to OFF. sor. <Ref. to FU- NOTE:
2)Measure the resistance of harness between 37, Intake Air In this case, repair
intake air temperature and pressure sensor Temperature and the following:
connector and engine ground. Pressure Sensor.> • Open circuit in
Connector & terminal harness between
(E20) No. 1 — Engine ground: intake air tempera-
ture and pressure
sensor and ECM
connector
• Poor contact in
intake air tempera-
ture and pressure
sensor
• Poor contact in
ECM
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) and (B122)
EN-124
cardiagn.com
EN-125
M: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT —
• Hard to start
CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Operation.> .
• WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
3
1
2
E8
cardiagn.com
B122
1 2 3
4 5 6
E2
13
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1 13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
14
16
B136 ECM
EN1404
EN-126
Step Check Yes No

1 CHECK CURRENT DATA. Is the value greater than 150°C Go to step 2. Repair the poor
1)Start the engine. (302°F)? contact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repair
•Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. sor
For detailed operation procedures, refer to the • Poor contact in
(B21)
• Poor contact in
joint connector
(B83) or (B122)
2 CHECK HARNESS BETWEEN ENGINE Is the value less than −40°C Replace the Repair the ground
COOLANT TEMPERATURE SENSOR AND (−40°F)? engine coolant short circuit in har-
ECM CONNECTOR. temperature sen- ness between
1)Turn the ignition switch to OFF. sor. <Ref. to FU- engine coolant
2)Disconnect the connector from engine cool- 31, Engine Cool- temperature sen-
cardiagn.com
ant temperature sensor. ant Temperature sor and ECM con-
3)Turn the ignition switch to ON. Sensor.> nector.
4)Read the data of engine coolant temperature
NOTE:
EN-127
N: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT —
• Hard to start
CAUTION:
• WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
3
1
2
E8
cardiagn.com
B122
1 2 3
4 5 6
E2
13
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1 13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
14
16
B136 ECM
EN1404
EN-128
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than −40°C Go to step 2. Repair the poor
1)Start the engine. (−40°F)? contact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repair
•Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. sor
(B21)
• Poor contact in
joint connector
(B83) or (B122)
2 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair the battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turn the ignition switch to OFF. ECM and engine
2)Disconnect the connector from engine cool- coolant tempera-
cardiagn.com
ant temperature sensor. ture sensor con-
3)Measure the voltage between engine coolant nector.
temperature sensor connector and engine
ground.
3 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair the battery Go to step 4.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turn the ignition switch to ON. ECM and engine
2)Measure the voltage between engine coolant coolant tempera-
temperature sensor connector and engine ture sensor con-
ground. nector.
EN-129
Step Check Yes No

4 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 5. Repair the har-
COOLANT TEMPERATURE SENSOR AND ness and connec-
ECM CONNECTOR. tor.
Measure the voltage between engine coolant NOTE:
temperature sensor connector and engine In this case, repair
ground. the following:
(E8) No. 1 (+) — Engine ground (−): harness between
ECM and engine
coolant tempera-
ture sensor con-
nector
• Poor contact in
engine coolant
temperature sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
• Poor contact in
cardiagn.com
joint connector
(B83) or (B122)
5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair the har-
COOLANT TEMPERATURE SENSOR AND Ω? engine coolant ness and connec-
ECM CONNECTOR. temperature sen- tor.
1)Turn the ignition switch to OFF. sor. <Ref. to FU- NOTE:
2)Measure the resistance of harness between 31, Engine Cool- In this case, repair
engine coolant temperature sensor connector ant Temperature the following:
and engine ground. Sensor.> • Open circuit in
(E8) No. 2 — Engine ground: ECM and engine
coolant tempera-
ture sensor con-
nector
• Poor contact in
engine coolant
temperature sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
EN-130
cardiagn.com
EN-131
O: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (HIGH INPUT) —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
cardiagn.com
B122
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-132
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the throt-
BLE CODE (DTC) ON DISPLAY. vant DTC using tle position sensor.
“List of Diagnostic <Ref. to FU-35,
Trouble Code Throttle Position
(DTC)”. <Ref. to Sensor.>
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
cardiagn.com
EN-133
P: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
B122
cardiagn.com
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-134
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 0.1 V? Go to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-II mal condition at
general scan tool. this time. A tempo-
NOTE: rary poor contact
•Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE”. NOTE:
<Ref. to EN-34, Subaru Select Monitor.> In this case, repair
•OBD-II general scan tool the following:
OBD-II General Scan Tool Instruction Manual. throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
and chassis ground while throttle valve is fully
cardiagn.com
closed.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
5 CHECK INPUT SIGNAL FOR ECM. (USING Does the voltage change more Repair the poor Go to step 6.
SUBARU SELECT MONITOR.) than 0.1 V by shaking harness contact in ECM
Measure the voltage between ECM connector and connector of ECM while connector.
and chassis ground. monitoring the value with Sub-
aru Select Monitor?
EN-135
Step Check Yes No

6 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the har-
THROTTLE POSITION SENSOR CONNEC- ness and connec-
TOR. tor.
2)Disconnect the connectors from throttle posi- In this case, repair
tion sensor. the following:
4)Measure the voltage between throttle posi- harness between
tion sensor connector and engine ground. throttle position
Connector & terminal sensor and ECM
(E13) No. 4 (+) — Engine ground (−): connector
• Poor contact in
throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
cardiagn.com
7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair the har-
THROTTLE POSITION SENSOR CONNEC- Ω? ness and connec-
TOR. tor.
ECM connector and throttle position sensor the following:
connector. • Open circuit in
(B136) No. 17 — (E13) No. 3: throttle position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
throttle position
sensor connector
• Poor contact in
coupling connector
(B21)
THROTTLE POSITION SENSOR CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance of harness between throttle position
throttle position sensor connector and engine sensor and ECM
ground. connector.
9 CHECK POOR CONTACT. Is there poor contact in throttle Repair the poor Replace the throt-
Check poor contact in throttle position sensor position sensor connector? contact in throttle tle position sensor.
connector. position sensor <Ref. to FU-35,
connector. Throttle Position
Sensor.>
EN-136
cardiagn.com
EN-137
Q: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
B122
cardiagn.com
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-138
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 4.9 V? Go to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-II mal condition at
general scan tool. this time. A tempo-
NOTE: rary poor contact
•Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE”. NOTE:
<Ref. to EN-34, Subaru Select Monitor.> In this case, repair
•OBD-II general scan tool the following:
OBD-II General Scan Tool Instruction Manual. throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than 5 Go to step 3. Repair the har-
POSITION SENSOR AND ECM CONNEC- Ω? ness and connec-
TOR. tor.
cardiagn.com
2)Disconnect the connector from throttle posi- In this case, repair
tion sensor. the following:
3)Measure the resistance of harness between • Open circuit in
throttle position sensor connector and engine harness between
ground. throttle position
(E13) No. 2 — Engine ground: connector
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than 4.9 V? Repair the battery Replace the throt-
POSITION SENSOR AND ECM CONNEC- short circuit in har- tle position sensor.
TOR. ness between <Ref. to FU-35,
1)Turn the ignition switch to ON. throttle position Throttle Position
2)Measure the voltage between throttle posi- sensor and ECM Sensor.>
tion sensor connector and engine ground. connector. After
Connector & terminal repair, replace the
(E13) No. 3 (+) — Engine ground (−): ECM. <Ref. to FU-
51, Engine Con-
trol Module.>
EN-139
R: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL —
• Engine would not return to idling.
CAUTION:
• WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
3
1
2
E8
B122
1 2 3
cardiagn.com
4 5 6
E2
13
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1 13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
14
16
B136 ECM
EN1404
EN-140
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P0125.
2 CHECK THERMOSTAT. Does thermostat remain Replace the ther- Replace the
opened? mostat. <Ref. to engine coolant
CO-37, Thermo- temperature sen-
stat.> sor. <Ref. to FU-
31, Engine Cool-
ant Temperature
Sensor.>
cardiagn.com
EN-141
S: DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (LEAN) —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
cardiagn.com
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
EN-142
Step Check Yes No

2 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value equal to or more Go to step 3. Go to step 4.
TA. than 0.85 and equal to less
1)Start the engine. than 1.15 in idling?
2)While observing the Subaru Select Monitor
or OBD-II general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (160°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
3 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value more than 1.1 for a Go to step 6. Go to step 4.
TA. moment?
cardiagn.com
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase the engine speed to 5,000 rpm,
slowly depress accelerator pedal, taking ap-
proximately 5 seconds, and quickly release ac-
celerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. Ω? circuit between
1)Turn the ignition switch to OFF. ECM and front
2)Disconnect the connector from ECM and oxygen (A/F) sen-
front oxygen (A/F) sensor connector. sor.
3)Measure the resistance between ECM and
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (E24) No. 3:
(B136) No. 7 — (E24) No. 4:
(B136) No. 19 — (E24) No. 1:
(B136) No. 20 — (E24) No. 6:
FRONT OXYGEN (A/F) SENSOR. MΩ? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (A/F)
Connector & terminals sensor.
6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the front
Check the exhaust system parts. tem? the faulty parts. oxygen (A/F) sen-
NOTE: sor. <Ref. to FU-
Check the following items. 47, Front Oxygen
•Loose installation of portions (A/F) Sensor.>
•Damage (crack, hole etc.) of parts
•Looseness of front oxygen (A/F) sensor
•Looseness and ill fitting of parts between front
oxygen (A/F) sensor and rear oxygen sensor
EN-143
T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
cardiagn.com
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
EN-144
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- Ω? ness and connec-
TOR. tor.
2)Disconnect the connectors from ECM and In this case, repair
front oxygen (A/F) sensor connector. the following:
ECM and front oxygen (A/F) sensor connector. harness between
Connector & terminal ECM and front
(B136) No. 6 — (E24) No. 3: oxygen (A/F) sen-
(B136) No. 7 — (E24) No. 4: sor connector
(B136) No. 19 — (E24) No. 1: • Poor contact in
(B136) No. 20 — (E24) No. 6: front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
2 CHECK POOR CONTACT. Is there poor contact in front Repair the poor Replace the front
Check poor contact in front oxygen (A/F) sen- oxygen (A/F) sensor connec- contact in front oxygen (A/F) sen-
sor connector. tor? oxygen (A/F) sensor. <Ref. to FU-
sor connector. 47, Front Oxygen
(A/F) Sensor.>
cardiagn.com
EN-145
U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
cardiagn.com
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
EN-146
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 10 Replace the front Repair the ground
FRONT OXYGEN (A/F) SENSOR CONNEC- Ω? oxygen (A/F) sen- short circuit in har-
TOR. sor. <Ref. to FU- ness between
1)Turn the ignition switch to OFF. 47, Front Oxygen ECM and front
2)Disconnect the connector from ECM. (A/F) Sensor.> oxygen (A/F) sen-
3)Measure the resistance of harness between sor connector.
cardiagn.com
EN-147
V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

—
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, Operation.>
and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.> .
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
cardiagn.com
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
EN-148
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair the exhaust Replace the front
NOTE: tem? system. oxygen (A/F) sen-
Check the following items. sor. <Ref. to FU-
•Loose installation of front portion of exhaust 47, Front Oxygen
pipe onto cylinder heads (A/F) Sensor.>
•Loose connection between front exhaust pipe
and front catalytic converter
•Damage of exhaust pipe resulting in a hole
cardiagn.com
EN-149
W: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
cardiagn.com
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
Step Check Yes No

indicate DTC P0131 or P0132?
EN-150
Step Check Yes No

2 CHECK FAILURE CAUSE OF P0131 or Is the failure cause of P0131 or Check the fuel Go to step 3.
P0132. P0132 in the fuel system? system.
Inspect the DTC P0131 or P0132 using “17. NOTE:
List of Diagnostic Trouble Code (DTC)”. <Ref. In this case, it is
to EN-83, List of Diagnostic Trouble Code not necessary to
(DTC).> inspect DTC
P0136.
3 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 7. Go to step 4.
1)Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm for
2 minutes.
2)Read the data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN-34, Subaru
Select Monitor.>
cardiagn.com
4 CHECK REAR OXYGEN SENSOR DATA. Is the value fixed between 0.2 Go to step 5. Replace the rear
Read the data of rear oxygen sensor signal and 0.4 V? oxygen sensor.
using Subaru Select Monitor or OBD-II general <Ref. to FU-47,
scan tool. Front Oxygen (A/
1)Keep the engine speed at 4,500 rpm for 5 F) Sensor.>
seconds.
2)Release the accelerator quickly and idle the
engine for 10 seconds.
3)Repeat this cycle for three times.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 6.
REAR OXYGEN SENSOR CONNECTOR. Ω? circuit in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connectors from ECM and rear oxygen sen-
rear oxygen sensor. sor connector.
ECM and rear oxygen sensor connector.
(B136) No. 16 — (B19) No. 3:
6 CHECK GROUND CIRCUIT ON ECM. Is the resistance less than 5 Go to step 8. Go to step 7.
1)Turn the ignition switch to OFF. Ω?
2)Disconnect the connector from ECM.
EN-151
Step Check Yes No

1)Repair the harness and connector. Ω? ness and connec-
2)Measure the resistance of harness between tor.
ECM connector and chassis ground. NOTE:
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
8 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V? Replace the rear Repair the har-
GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec-
1)Turn the ignition switch to OFF. <Ref. to FU-47, tor.
2)Disconnect the connector from rear oxygen Front Oxygen (A/ NOTE:
sensor. F) Sensor.> In this case, repair
4)Measure the voltage between rear oxygen • Open circuit in
cardiagn.com
sensor harness connector and engine ground harness between
or chassis ground. rear oxygen sen-
Connector & terminal sor and ECM con-
(B19) No. 4 (+) — Engine ground (−): nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
9 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear
Check the exhaust system parts. tem? the faulty parts. oxygen sensor.
NOTE: <Ref. to FU-47,
Check the following items. Front Oxygen (A/
•Loose installation of portions F) Sensor.>
EN-152
cardiagn.com
EN-153
X: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
cardiagn.com
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
EN-154
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the rear
BLE CODE (DTC) ON DISPLAY. vant DTC using oxygen sensor.
Trouble Code Front Oxygen (A/
(DTC)”. <Ref. to F) Sensor.>
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
cardiagn.com
EN-155
Y: DTC P0170 — FUEL TRIM MALFUNCTION —

• Engine stalls.
CAUTION:
Step Check Yes No

1 CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 2.
on exhaust system? system.
disconnection of hose on air intake system.
intake system?
3 CHECK FUEL PRESSURE. Is the fuel pressure between Go to step 4. Repair the follow-
Warning: 284 — 314 kPa (2.9 — 3.2 ing items.
•Place “NO FIRE” signs near the working kg/cm2, 41 — 46 psi)? Fuel pressure too
area. high:
cardiagn.com
•Be careful not to spill fuel on the floor. • Clogged fuel
1)Release the fuel pressure. return line or
(1) Disconnect the connector from fuel bent hose
pump relay. Fuel pressure too
(2) Start the engine and run it until it stalls. low:
(3) After the engine stalls, crank it for 5 • Clogged fuel
more seconds. supply line
(4) Turn the ignition switch to OFF. • Improper fuel
2)Connect the connector to fuel pump relay. pump discharge
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)Install the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnect-
ing pressure regulator vacuum hose from
intake manifold.
Warning:
Before removing the fuel pressure gauge,
release the fuel pressure.
NOTE:
If the fuel pressure does not increase, squeeze
the fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN-156
Step Check Yes No

4 CHECK FUEL PRESSURE. Is the fuel pressure between Go to step 5. Repair the follow-
After connecting the pressure regulator vac- 206 — 235 kPa (2.1 — 2.4 ing items.
uum hose, measure the fuel pressure. kg/cm2, 30 — 34 psi)? Fuel pressure too
Warning: high:
Before removing the fuel pressure gauge, • Faulty pres-
release fuel pressure. sure regulator
NOTE: • Clogged fuel
•If the fuel pressure does not increase, return line or
squeeze the fuel return hose 2 to 3 times, then bent hose
measure fuel pressure again. Fuel pressure too
•If out of specification as measured at this low:
step, check or replace the pressure regulator • Faulty pres-
and pressure regulator vacuum hose. sure regulator
• Improper fuel
pump discharge
• Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERATURE Is the temperature between Go to step 6. Replace the
SENSOR. 70°C (158°F) and 100°C engine coolant
1)Start the engine and warm-up completely. (212°F)? temperature sen-
2)Read the data of engine coolant temperature sor. <Ref. to FU-
sensor signal using Subaru Select Monitor or 31, Engine Cool-
cardiagn.com
OBD-II general scan tool. ant Temperature
NOTE: Sensor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the voltage within the speci- Contact with your Replace the intake
SENSOR SIGNAL. fications? Subaru distributor air temperature
1)Start the engine and warm-up engine until service. and pressure sen-
coolant temperature is greater than 60°C NOTE: sor. <Ref. to FU-
(140°F). Inspection by DTM 37, Intake Air
2)Place the selector lever in “N” or “P” position. is required, be- Temperature and
3)Turn the A/C switch to OFF. cause probable Pressure Sensor.>
4)Turn all accessory switches to OFF. cause is deteriora-
5)Read the data of intake manifold pressure tion of multiple
sensor signal using Subaru Select Monitor or parts.
NOTE:
Specification:
Idling
24.0 — 41.3 kPa (180 — 310 mmHg, 7.09
— 12.20 inHg)
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
EN-157
Z: DTC P0301 — CYLINDER 1 MISFIRE DETECTED —

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN-160, DTC P0304 — CYLINDER 4 MISFIRE
DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AA:DTC P0302 — CYLINDER 2 MISFIRE DETECTED —
NOTE:
AB:DTC P0303 — CYLINDER 3 MISFIRE DETECTED —
NOTE:
cardiagn.com
EN-158
cardiagn.com
EN-159
AC:DTC P0304 — CYLINDER 4 MISFIRE DETECTED —

• Immediately at fault recognition (A misfire which could damage catalyst occurs.)
• Engine stalls.
• Rough driving
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 RHD
BATTERY
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
cardiagn.com
B47
C2
C1
A: B134 C: B136 ECM

A13
A14
A15
A4
B22
10
11
12
1
E3
E5 E16 E6 E17
2
FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR

No.1 No.2 No.3 No.4
E5 E16 B47 F44 B22
E6 E17 1 2 1 2 3 4 1 2 3 4
3 4 5 6 7 8 5 6 7 8
1 2 5 6 9 10 11 12
13 14 15 16
C: B136 A: B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35
EN0866
EN-160
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P0301,
P0302, P0303,
P0304.
tor and chassis ground on faulty cylinders.
#1 (B134) No. 4 (+) — Chassis ground
(−):
cardiagn.com
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 10 Repair the ground Go to step 4.
TOR AND ECM CONNECTOR. Ω? short circuit in har-
1)Turn the ignition switch to OFF. ness between fuel
2)Disconnect the connector from fuel injector injector and ECM
on faulty cylinders. connector.
3)Measure the resistance between ECM con-
nector and engine ground on faulty cylinders.
#1 (E5) No. 1 — Engine ground:
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 1 Go to step 5. Repair the har-
TOR AND ECM CONNECTOR. Ω? ness and connec-
Measure the resistance of harness connector tor.
between ECM connector and fuel injector on NOTE:
faulty cylinders. In this case, repair
#1 (B134) No. 4 — (E5) No. 1: • Open circuit in
#2 (B134) No. 13 — (E16) No. 1: harness between
#3 (B134) No. 14 — (E6) No. 1: ECM and fuel
#4 (B134) No. 15 — (E17) No. 1: injector connector
• Poor contact in
coupling connector
(B22)
5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace the faulty
Measure the resistance between fuel injector and 20 Ω? fuel injector. <Ref.
terminals on faulty cylinder. to FU-41, Fuel
Terminals Injector.>
No. 1 — No. 2:
EN-161
Step Check Yes No

6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair the poor Repair the har-
1)Turn the ignition switch to ON. contact in all con- ness and connec-
2)Measure the voltage between fuel injector nectors in fuel tor.
and engine ground on faulty cylinders. injector circuit. NOTE:
#1 (E5) No. 2 (+) — Engine ground (−): the following:
#2 (E16) No. 2 (+) — Engine ground (−): • Open circuit in
#3 (E6) No. 2 (+) — Engine ground (−): harness between
#4 (E17) No. 2 (+) — Engine ground (−): main relay and fuel
injector connector
on faulty cylinders
• Poor contact in
coupling connector
• Poor contact in
main relay con-
nector
• Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? Repair the battery Go to step 8.
TOR AND ECM CONNECTOR. short circuit in har-
cardiagn.com
2)Disconnect the connector from fuel injector ECM and fuel
on faulty cylinder. injector. After
3)Turn the ignition switch to ON. repair, replace
4)Measure the voltage between ECM connec- ECM. <Ref. to FU-
tor and chassis ground on faulty cylinders. 51, Engine Con-
Connector & terminal trol Module.>
(−):
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than 1 Replace the faulty Go to step 9.
1)Turn the ignition switch to OFF. Ω? fuel injector <Ref.
2)Measure the resistance between fuel injector to FU-41, Fuel
terminals on faulty cylinder. Injector.> and
Terminals ECM <Ref. to FU-
No. 1 — No. 2: 51, Engine Con-
trol Module.>
9 CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the cam- Go to step 10.
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position sen-
SENSOR. loosely installed? sor or crankshaft
position sensor.
10 CHECK CRANKSHAFT SPROCKET. Is the crankshaft sprocket Replace the crank- Go to step 11.
Remove the timing belt cover. rusted or does it have broken shaft sprocket.
teeth? <Ref. to ME-56,
Crankshaft
Sprocket.>
11 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 12.
TIMING BELT. from its proper position? tion condition of
Turn the crankshaft using ST, and align the timing belt. <Ref.
alignment mark on crankshaft sprocket with to ME-49, Timing
alignment mark on cylinder block. Belt Assembly.>
ST 499987500 CRANKSHAFT SOCKET
EN-162
Step Check Yes No

12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish the fuel
higher than the “Lower” level? so fuel meter indi-
cation is higher
than the “Lower”
level. After replen-
ishing fuel; Go to
step 13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or blink- Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). ing?
1)Clear the memory using Subaru Select Mon-
itor.
<Ref. to EN-49, Clear Memory Mode.>
2)Start engine, and drive the vehicle more than
10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire diag- Finish the diag- Repair the poor
nosed when the engine is run- nostics operation, contact.
ning? if the engine has NOTE:
no abnormality. In this case, repair
NOTE: the following:
Ex. Remove spark • Poor contact in
plug cord, etc. ignitor connector
• Poor contact in
cardiagn.com
ignition coil con-
nector
• Poor contact in
fuel injector con-
nector on faulty
cylinders
• Poor contact in
ECM connector
• Poor contact in
coupling connector
15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air Go to step 16.
tem? intake system.
NOTE:
Check the follow-
ing items:
• Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
• Are there cracks
or any disconnec-
tion of hoses?
16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Moni- Go to step 21. Go to step 17.
1)Turn the ignition switch to ON. tor or OBD-II general scan tool
2)Read the DTC. indicate only one DTC?
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listed
below.
17 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 22. Go to step 18.
(DTC) ON DISPLAY. tor or OBD-II general scan tool
P0302?
EN-163
Step Check Yes No

P0304?
P0303?
P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylinder? Repair or replace Go to DTC P0170.
the faulty parts. <Ref. to EN-156,
NOTE: DTC P0170 —
Check the follow- FUEL TRIM MAL-
ing items. FUNCTION —,
• Spark plug Diagnostic Proce-
• Spark plug cord dure with Diagnos-
• Fuel injector tic Trouble Code
• Compression (DTC).>
ratio
cardiagn.com
22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and #2 Repair or replace Go to DTC P0170.
cylinders? the faulty parts. <Ref. to EN-156,
NOTE: DTC P0170 —
• Check the fol- FUEL TRIM MAL-
lowing items. FUNCTION —,
• Spark plugs Diagnostic Proce-
• Fuel injectors dure with Diagnos-
• Ignition coil tic Trouble Code
• Compres- (DTC).>
sion ratio
• If no abnormal is
discovered, check
for “IGNITION
CONTROL SYS-
TEM” of #1 and #2
cylinders side.
<Ref. to EN-72,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
EN-164
Step Check Yes No

NOTE: DTC P0170 —
• Check the fol- FUEL TRIM MAL-
lowing items. FUNCTION —,
• Ignition coil tic Trouble Code
• If no abnormal is (DTC).>
discovered, check
for “16. D: IGNI-
TION CONTROL
SYSTEM” of #3
and #4 cylinders
side. <Ref. to EN-
72, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Start-
ing Failure.>
cardiagn.com
NOTE: DTC P0170 —
• Skipping timing tic Trouble Code
belt teeth (DTC).>
NOTE: DTC P0170 —
• Compression tic Trouble Code
ratio (DTC).>
• Skipping timing
belt teeth
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC P0170. Repair or replace
<Ref. to EN-156, the faulty parts.
DTC P0170 — NOTE:
FUEL TRIM MAL- Check the follow-
FUNCTION —, ing items.
Diagnostic Proce- • Spark plugs
dure with Diagnos- • Fuel injectors
tic Trouble Code • Compression
(DTC).> ratio
EN-165
AD:DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT —

• Knocking occurs.
CAUTION:
• WIRING DIAGRAM:
E14
1 2
KNOCK
SENSOR
B83
2
E14
1 2 3
4 5 6
cardiagn.com
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
16
B21
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1
4
B83
LHD
LHD
RHD RHD
25
4
B136 ECM
EN1406
EN-166
Step Check Yes No

1 CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than Go to step 2. Repair the har-
SOR AND ECM CONNECTOR. 700 kΩ? ness and connec-
3)Measure the resistance between ECM har- In this case, repair
ness connector and chassis ground. the following:
(B136) No. 4 — Chassis ground: harness between
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
(B21)
2 CHECK KNOCK SENSOR. Is the resistance more than Go to step 3. Repair the har-
1)Disconnect the connector from knock sen- 700 kΩ? ness and connec-
sor. tor.
2)Measure the resistance between knock sen- NOTE:
sor connector terminal and engine ground. In this case, repair
Terminal the following:
cardiagn.com
No. 2 — Engine ground: • Open circuit in
harness between
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
(B21)
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installa- Replace the knock Tighten the knock
INSTALLATION. tion bolt tightened securely? sensor. <Ref. to sensor installation
FU-34, Knock bolt securely.
Sensor.>
EN-167
AE:DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT —

• Knocking occurs.
CAUTION:
• WIRING DIAGRAM:
E14
1 2
KNOCK
SENSOR
B83
2
E14
1 2 3
4 5 6
cardiagn.com
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
16
B21
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1
4
B83
LHD
LHD
RHD RHD
25
4
B136 ECM
EN1406
Step Check Yes No

1 CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2. Go to step 3.
SOR AND ECM CONNECTOR. kΩ?
Measure the resistance of harness between
EN-168
Step Check Yes No

2 CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair the ground
1)Disconnect the connector from knock sen- kΩ? sensor. <Ref. to short circuit in har-
sor. FU-34, Knock ness between
2)Measure the resistance between knock sen- Sensor.> knock sensor con-
sor connector terminal and engine ground. nector and ECM
Terminal connector.
No. 2 — Engine ground: NOTE:
The harness be-
tween both con-
nectors is
shielded. Repair
the short circuit of
harness together
with shield.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 2 V? Even if MIL lights Repair the poor
1)Connect the connectors to ECM and knock up, the circuit has contact in ECM
sensor. returned to a nor- connector.
2)Turn the ignition switch to ON. mal condition at
3)Measure the voltage between ECM and this time. (How-
chassis ground. ever, the possibil-
Connector & terminal ity of poor contact
(B136) No. 4 (+) — Chassis ground (−): still remains.)
cardiagn.com
NOTE:
In this case, repair
the following:
• Poor contact in
knock sensor con-
nector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
EN-169
AF:DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

—
• Engine stalls.
• Failure of engine to start
CAUTION:
• WIRING DIAGRAM:
1 WITH E10
CRANKSHAFT
IMMOBILIZER:2
POSITION
WITHOUT 1 2
SENSOR
IMMOBILIZER:1
2 LHD:19
RHD:20
2
1
E10
cardiagn.com
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E2 17 18 19 20
2
17
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
9
B135 ECM
EN1407
EN-170
Step Check Yes No

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair the har- Go to step 2.
SHAFT POSITION SENSOR AND ECM CON- 100 kΩ? ness and connec-
NECTOR. tor.
2)Disconnect the connector from crankshaft In this case, repair
position sensor. the following:
crankshaft position sensor connector and harness between
engine ground. crankshaft posi-
Connector & terminal tion sensor and
(E10) No. 1 — Engine ground: ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 10 Repair the ground Go to step 3.
SHAFT POSITION SENSOR AND ECM CON- Ω? short circuit in har-
Measure the resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
cardiagn.com
(E10) No. 1 — Engine ground: The harness be-
tween both con-
nectors are
shielded. Repair
ground short circuit
in harness togeth-
er with shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 5 Go to step 4. Repair the har-
SHAFT POSITION SENSOR AND ECM CON- Ω? ness and connec-
NECTOR. tor.
crankshaft position sensor connector and In this case, repair
crankshaft posi-
tion sensor and
ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
4 CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 5. Tighten the crank-
SITION SENSOR. sor installation bolt tightened shaft position sen-
securely? sor installation bolt
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair the poor Replace the crank-
1)Remove the crankshaft position sensor. and 4 kΩ? contact in crankshaft position sen-
2)Measure the resistance between connector shaft position sensor. <Ref. to FU-
terminals of crankshaft position sensor. sor connector. 32, Crankshaft
Terminals Position Sensor.>
No. 1 — No. 2:
EN-171
AG:DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER-

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
1 WITH E10
CRANKSHAFT
IMMOBILIZER:2
POSITION
WITHOUT 1 2
SENSOR
IMMOBILIZER:1
2 LHD:19
RHD:20
2
1
E10
cardiagn.com
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E2 17 18 19 20
2
17
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
9
B135 ECM
EN1407
EN-172
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Inspect DTC Go to step 2.
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool P0335 using “List
indicate DTC P0335? of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 3. Tighten the crank-
SITION SENSOR. sor installation bolt tightened shaft position sen-
Turn the ignition switch to OFF. securely? sor installation bolt
securely.
3 CHECK CRANKSHAFT SPROCKET. Are the crankshaft sprocket Replace the crank- Go to step 4.
Remove the front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to ME-56,
Crankshaft
Sprocket.>
4 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Replace the crank-
TIMING BELT. from its proper position? tion condition of shaft position sen-
Turn the crankshaft using ST, and align the timing belt. <Ref. sor. <Ref. to <Ref.
alignment mark on crankshaft sprocket with to ME-49, Timing to FU-32, Crank-
alignment mark on cylinder block. Belt Assembly.> shaft Position Sen-
cardiagn.com
ST 499987500 CRANKSHAFT SOKET sor.>
EN-173
AH:DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CAMSHAFT 1 WITH IMMOBILIZER:1

POSITION WITHOUT IMMOBILIZER:2
SENSOR
2 LHD:20 E15
RHD:19
1 2
1
2
E15
cardiagn.com
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
2
18
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
8
B135 ECM
EN1408
EN-174
Step Check Yes No

1 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair the har- Go to step 2.
POSITION SENSOR AND ECM CONNEC- 100 kΩ? ness and connec-
TOR. tor.
2)Disconnect the connector from camshaft In this case, repair
camshaft position sensor connector and harness between
engine ground. camshaft position
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
cardiagn.com
tween both con-
nectors are
shielded. Repair
in harness togeth-
er with shield.
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 Go to step 4. Repair the har-
TOR. tor.
camshaft position sensor connector and In this case, repair
camshaft position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
4 CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 5. Tighten the cam-
TION SENSOR. installation bolt tightened shaft position sen-
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair the poor Replace the cam-
1)Remove the camshaft position sensor. and 4 kΩ? contact in camshaft position sen-
2)Measure the resistance between connector shaft position sensor. <Ref. to FU-
terminals of camshaft position sensor. sor connector. 33, Camshaft
No. 1 — No. 2:
EN-175
AI: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CAMSHAFT 1 WITH IMMOBILIZER:1

POSITION WITHOUT IMMOBILIZER:2
SENSOR
2 LHD:20 E15
RHD:19
1 2
1
2
E15
cardiagn.com
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
2
18
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
8
B135 ECM
EN1408
EN-176
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Inspect DTC Go to step 2.
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool P0340 using “List
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair the har- Go to step 3.
POSITION SENSOR AND ECM CONNEC- 100 kΩ? ness and connec-
TOR. tor.
2)Disconnect the connector from camshaft In this case, repair
camshaft position sensor connector and harness between
engine ground. camshaft position
• Poor contact in
ECM connector
• Poor contact in
cardiagn.com
coupling connector
(B21)
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground Go to step 4.
POSITION SENSOR AND ECM CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
tween both con-
nectors are
shielded. Repair
in harness togeth-
er with shield.
4 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 Go to step 5. Repair the har-
TOR. tor.
camshaft position sensor connector and In this case, repair
camshaft position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
securely.
EN-177
Step Check Yes No

6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace the cam-
1)Remove the camshaft position sensor. and 4 kΩ? shaft position sen-
2)Measure the resistance between connector sor. <Ref. to FU-
terminals of camshaft position sensor. 33, Camshaft
No. 1 — No. 2:
Turn the ignition switch to OFF. securely? sor installation bolt
securely.
8 CHECK CAMSHAFT SPROCKET. Are the camshaft sprocket Replace the cam- Go to step 9.
Remove the front belt cover. <Ref. to ME-48, teeth cracked or damaged? shaft sprocket.
Belt Cover.> <Ref. to ME-54,
Camshaft
Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Replace the cam-
TIMING BELT. from its proper position? tion condition of shaft position sen-
Turn the camshaft using ST, and align the timing belt. <Ref. sor. <Ref. to FU-
alignment mark on camshaft sprocket with to ME-49, Timing 33, Camshaft
alignment mark on timing belt cover LH. Belt Assembly.> Position Sensor.>
WRENCH
cardiagn.com
NOTE:
(499207100) can be used.
EN-178
AJ:DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD —

• Engine stalls.
• Idle mixture is out of specifications.
CAUTION:
cardiagn.com
EN-179
• WIRING DIAGRAM:
MAIN RELAY BATTERY
RHD
RHD
SBF-5
6 LHD 2 LHD
4
B61 F44
5
3
2
1
B47
2
2
REAR FRONT OXYGEN

OXYGEN (A/F) SENSOR
SENSOR E18
B19
3
1
4
6
3
1
cardiagn.com
5 LHD RHD 4
1 LHD RHD 1
B122 B83
C16
A21
C18
C24
A22
A23
C20
C19
C23
C7
C6
A: B134 C: B136 ECM

C21
C22
B22
16
E3
B19 B18 B122 B47 F44 E1 B83
1 2 1 2 3 1 2 1 2 3 4 1 2 3 4
1 2 3 1 2 3 4
3 4 4 5 6 3 4 5 6 7 8
4 5 6 5 6 7
5 6
(LHD) 8 9 10
C: B136 A: B134 B22

2 1
4 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
(RHD) 8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 5 6 7 8
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35 9 10 11 12
13 14 15 16
EN1409
EN-180
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Go to step 3.
Check for gas leaks or air suction caused by tem? the exhaust sys-
loose or dislocated nuts and bolts, and open tem. <Ref. to EX-
hole at exhaust pipes. 2, General
NOTE: Description.>
Check the following positions.
•Between cylinder head and front exhaust pipe
•Between front exhaust pipe and front catalytic
converter
cardiagn.com
•Between front catalytic converter and rear cat-
alytic converter
3 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear face of Replace the front Go to step 4.
Separate the rear catalytic converter from rear rear catalyst? catalytic converter
exhaust pipe. <Ref. to EC-3,
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to EC-
6, Rear Catalytic
Converter.>.
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front Go to step 5.
Remove the front catalytic converter. front face of front catalyst? catalytic con-
verter. <Ref. to
EC-3, Front Cata-
lytic Converter.>
5 CHECK REAR OYXGEN SENSOR HARNESS Is there damage or open on Repair the har- Go to step 6.
SHIELD. the rear oxygen sensor harness and connec-
Visually check the rear oxygen sensor harness ness shield? tor
shield for damage or open.
6 CHECK GROUND CIRCUIT ON ECM. Is the resistance less than 5 Go to step 7. Repair the har-
3)Measure the resistance of harness between NOTE:
ECM connector and chassis ground. In this case, repair
(B136) No. 21 — Chassis ground: • Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
EN-181
Step Check Yes No

7 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Contact with your Repair the har-
1)Repair the harness and connector. Ω? Subaru distributor ness and connec-
2)Measure the resistance of harness between service. tor.
ECM connector and chassis ground. NOTE: NOTE:
Connector & terminal Inspection by DTM In this case, repair
(B136) No. 22 — Chassis ground: is required, be- the following:
cause probable • Open circuit in
cause is deteriora- harness between
tion of multiple ECM and engine
parts. ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
cardiagn.com
EN-182
cardiagn.com
EN-183
AK:DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
E4
5 LHD 2 LHD
3
B61 F44 1 2
2
1
B47
F44
1 2 3 4
cardiagn.com
5 6 7 8
B134 ECM B47
1 2
3 4
5 6
2
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B22
1
2
E3
B134
E4 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1
2
24 25 26 27 28 29 30 31 32 33 34 35
PURGE CONTROL
SOLENOID VALVE
EN1410
EN-184
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if MIL lights Go to step 2.
1)Turn the ignition switch to ON. up, the circuit has
2)Measure the voltage between ECM and returned to a nor-
chassis ground. mal condition at
Connector & terminal this time. Contact
(B134) No. 2 (+) — Chassis ground (−): with your Subaru
distributor service.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
2 CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 10 Repair the ground Go to step 3.
TROL SOLENOID VALVE AND ECM CON- Ω? short circuit in har-
1)Turn the ignition switch to OFF. ECM and purge
2)Disconnect the connectors from purge con- control solenoid
trol solenoid valve and ECM. valve connector.
purge control solenoid valve connector and
cardiagn.com
engine ground.
3 CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 1 Go to step 4. Repair the open
TROL SOLENOID VALVE AND ECM CON- Ω? circuit in harness
NECTOR. between ECM and
Measure the resistance of harness between purge control sole-
ECM and purge control solenoid valve of har- noid valve connec-
ness connector. tor.
(B134) No. 2 — (E4) No. 2: In this case, repair
the following:
• Open circuit in
harness between
ECM and purge
control solenoid
valve connector
• Poor contact in
coupling connector
(B22)
4 CHECK PURGE CONTROL SOLENOID Is the resistance between 10 Go to step 5. Replace the purge
VALVE. and 100 Ω? control solenoid
1)Remove the purge control solenoid valve. valve. <Ref. to EC-
2)Measure the resistance between purge con- 8, Purge Control
trol solenoid valve terminals. Solenoid Valve.>
Terminals
No. 1 — No. 2:
5 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 V? Go to step 6. Repair the open
TROL SOLENOID VALVE. circuit in harness
1)Turn the ignition switch to ON. between main
2)Measure the voltage between purge control relay and purge
solenoid valve and engine ground. control solenoid
Connector & terminal valve connector.
EN-185
Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Contact with your
Check poor contact in purge control solenoid control solenoid valve connec- contact in purge Subaru distributor
valve connector. tor? control solenoid service.
valve connector. NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
cardiagn.com
EN-186
cardiagn.com
EN-187
AL:DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
E4
5 LHD 2 LHD
3
B61 F44 1 2
2
1
B47
F44
1 2 3 4
cardiagn.com
5 6 7 8
B134 ECM B47
1 2
3 4
5 6
2
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B22
1
2
E3
B134
E4 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1
2
24 25 26 27 28 29 30 31 32 33 34 35
PURGE CONTROL
SOLENOID VALVE
EN1410
EN-188
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change between Go to step 2. Even if MIL light
1)Turn the ignition switch to OFF. 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver's side). this time. In this
3)Turn the ignition switch to ON. case, repair the
4)While operating the purge control solenoid poor contact in
valve, measure the voltage between ECM and ECM connector.
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using the Subaru Select Monitor. For
procedure, refer to “Compulsory Valve Opera-
tion Check Mode”. <Ref. to EN-50, Compulsory
Valve Operation Check Mode.>
chassis ground.
cardiagn.com
Module.>
4 CHECK HARNESS BETWEEN PURGE CON- Is the voltage more than 10 V? Repair the battery Go to step 5.
TROL SOLENOID VALVE AND ECM CON- short circuit in har-
1)Turn the ignition switch to OFF. ECM and purge
2)Disconnect the connector from purge control control solenoid
solenoid valve. valve connector.
3)Turn the ignition switch to ON. After repair,
4)Measure the voltage between ECM and replace the ECM.
chassis ground. <Ref. to FU-51,
Connector & terminal Engine Control
(B134) No. 2 (+) — Chassis ground (−): Module.>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Replace the purge Go to step 6.
VALVE. Ω? control solenoid
1)Turn the ignition switch to OFF. valve <Ref. to EC-
2)Measure the resistance between purge con- 8, Purge Control
trol solenoid valve terminals. Solenoid Valve.>
Terminals and ECM <Ref. to
No. 1 — No. 2: FU-51, Engine
Control Module.>
Module.>
EN-189
AM:DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM —
CAUTION:
• WIRING DIAGRAM:
LHD model BATTERY B72

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
1 : 1.6L AND 2.0L MODEL
A: i10
R15
C: i12 2 : 2.5L MODEL
cardiagn.com
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-190
RHD model BATTERY B72

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
METER 2 : 2.5L MODEL
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
cardiagn.com
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the fuel
BLE CODE (DTC) ON DISPLAY. vant DTC using level sensor <Ref.
“List of Diagnostic to FU-65, Fuel
Trouble Code Level Sensor.>
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P0461.
EN-191
AN:DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
cardiagn.com
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-192

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
cardiagn.com
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

1 CHECK SPEEDOMETER AND TACHOME- Does the speedometer and Go to step 2. Repair or replace
TER OPERATION IN COMBINATION tachometer operate normally? the combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.12 Go to step 6. Go to step 3.
1)Turn the ignition switch to ON. (engine OFF) V?
EN-193
Step Check Yes No

3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change less Repair the poor Even if MIL lights
SUBARU SELECT MONITOR.) than 0.12 V by shaking har- contact in ECM up, the circuit has
Read the data of fuel level sensor signal using ness and connector of ECM connector. returned to a nor-
Subaru Select Monitor. while monitoring the value with mal condition at
NOTE: Subaru Select Monitor? this time. A tempo-
•Subaru Select Monitor rary poor contact
For detailed operation procedure, refer to the of the connector
“READ CURRENT DATA FOR ENGINE”. may be the cause.
<Ref. to EN-34, Subaru Select Monitor.> NOTE:
the following:
• Poor contact in
combination meter
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connec-
tors (B99)
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 0.12 Go to step 4. Go to step 8.
1)Turn the ignition switch to OFF. V?
2)Separate the fuel tank cord connector (R57)
cardiagn.com
and rear wiring harness connector (R15).
4)Measure the voltage of harness between
COMBINATION METER. MΩ? short circuit in har-
2)Disconnect the connector from connector ECM and combi-
(i10) and ECM connector. nation meter con-
3)Measure the resistance between ECM and nector.
chassis ground.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair or replace Repair the open
COMBINATION METER. Ω? the combination circuit between
Measure the resistance between ECM and meter. <Ref. to ECM and combi-
combination meter connector. IDI-4, Combina- nation meter con-
Connector & terminal tion Meter Sys- nector.
(B136) No. 27 — (i12) No. 2: tem.> NOTE:
the following:
Poor contact in
coupling connector
(i2)
7 CHECK ENGINE DISPLACEMENT. Is the engine displacement 2.5 Go to step 10. Go to step 8.
L?
8 CHECK FUEL TANK CORD. Is the resistance more than 1 Go to step 9. Repair the ground
1)Disconnect the connector from fuel pump MΩ? short circuit in fuel
assembly. tank cord.
2)Measure the resistance between fuel pump
assembly and chassis ground.
(R58) No. 3 — Chassis ground:
EN-194
Step Check Yes No

9 CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Repair the poor Replace the fuel
1)Remove the fuel pump assembly. <Ref. to and 2.5 Ω? contact in harness level sensor.
FU-62, Fuel Pump.> between ECM and
2)Measure the resistance between fuel level combination meter
sensor and terminals with its float set to the full connector.
position.
Terminals
No. 5 — No. 3:
1)Turn the ignition switch to OFF. MΩ? short circuit in fuel
2)Disconnect the connector from fuel sub level tank cord.
sensor.
3)Measure the resistance between fuel sub
level sensor and chassis ground.
1)Disconnect the connector from fuel pump MΩ? short circuit in fuel
assembly. tank cord.
2)Measure the resistance between fuel pump
assembly and chassis ground.
cardiagn.com
12 CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Go to step 13. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to and 2.5 Ω? level sensor.
FU-62, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 5:
13 CHECK FUEL SUB LEVLE SENSOR. Is the resistance between 0.5 Repair the poor Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to and 2.5 Ω? contact in harness sub level sensor.
FU-66, Fuel Sub Level Sensor.> between ECM and
2)Measure the resistance between fuel sub combination meter
level sensor and terminals with its float set to connector.
the full position.
Terminals
No. 1 — No. 2:
EN-195
AO:DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
cardiagn.com
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-196

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
cardiagn.com
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

1 CHECK SPEEDOMETER AND TACHOME- Does the speedometer and Go to step 2. Repair or replace
TER OPERATION IN COMBINATION tachometer operate normally? the combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
EN-197
Step Check Yes No

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.75 Go to step 3. Even if MIL lights
1)Turn the ignition switch to ON. (engine OFF) V? up, the circuit has
2)Measure the voltage between ECM connec- returned to a nor-
tor and chassis ground. mal condition at
Connector & terminal this time. A tempo-
(B136) No. 27 (+) — Chassis ground (−): rary poor contact
of the connector
may be the cause.
NOTE:
the following:
• Poor contact in
fuel pump connec-
tor
• Poor contact in
coupling connector
(B22, B99 and
R15)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 4.75 Go to step 4. Repair the battery
1)Turn the ignition switch to OFF. V? short circuit
2)Disconnect the combination meter connector between ECM and
(i10) and ECM connector. combination meter
cardiagn.com
3)Turn the ignition switch to ON. connector.
4)Measure the voltage of harness between
ECM and chassis ground.
FUEL TANK CORD. Ω? circuit between
1)Turn the ignition switch to OFF. ECM and fuel tank
2)Separate the fuel tank cord connector (R57) cord.
and rear wiring harness connector (R15).
fuel tank cord.
(B136) No. 27 — (R15) No. 2:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than 5 Go to step 6. Repair the open
CORD AND CHASSIS GROUND. Ω? circuit between
Measure the resistance between fuel tank cord fuel tank cord and
and chassis ground. chassis ground.
(R15) No. 6 — Chassis ground: In this case, repair
the following:
Poor contact in
coupling connec-
tors (B22 and B99)
6 CHECK FUEL TANK CORD. Is the resistance less than 10 Go to step 7. Repair the open
1)Disconnect the connector from fuel level Ω? circuit between
sensor. coupling connector
2)Measure the resistance between fuel level and fuel level sen-
sensor and coupling connector. sor.
(R57) No. 6 — (R58) No. 5:
7 CHECK ENGINE DISPLACEMENT. Is the engine displacement 2.5 Go to step 10. Go to step 7.
L?
EN-198
Step Check Yes No

1)Disconnect the connector from fuel level Ω? circuit between
sensor. coupling connector
2)Measure the resistance between fuel level and fuel level sen-
sensor and coupling connector. sor.
(R57) No. 2 — (R58) No. 3:
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace the fuel Replace the com-
1)Remove the fuel pump assembly. <Ref. to 100 Ω? level sensor. <Ref. bination meter.
FU-62, Fuel Pump.> to FU-65, Fuel <Ref. to IDI-15,
2)While moving the fuel level sensor float up Level Sensor.> Combination
and down, measure the resistance between Meter Assembly.>
fuel level sensor terminals.
Terminals
No. 3 — No. 5:
1)Disconnect the connector from fuel sub level Ω? circuit between
sensor. fuel level sensor
2)Measure the resistance between fuel level and fuel sub level
sensor and fuel sub level sensor. sensor.
(R58) No. 3 — (R59) No. 2:
cardiagn.com
Measure the resistance between fuel sub level Ω? circuit between
sensor and coupling connector. coupling connector
Connector & terminal and fuel sub level
(R57) No. 2 — (R59) No. 1: sensor.
12 CHECK FUEL LEVEL SENSOR. Is the resistance more than 53 Replace the fuel Go to step 13.
1)Remove the fuel pump assembly. <Ref. to Ω? level sensor. <Ref.
FU-62, Fuel Pump.> to FU(TURBO)-62,
2)While moving the fuel level sensor float up Fuel Level Sen-
and down, measure resistance between fuel sor.>
level sensor terminals.
Terminals
No. 3 — No. 5:
13 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than 45 Replace the fuel Replace the com-
1)Remove the fuel sub level sensor. <Ref. to Ω? sub level sensor. bination meter.
FU-66, Fuel Sub Level Sensor.> <Ref. to <Ref. to IDI-15,
2)While moving the fuel sub level sensor float FU(TURBO)-63, Combination
up and down, measure resistance between Fuel Sub Level Meter Assembly.>
fuel sub level sensor terminals. Sensor.>
Terminals
No. 1 — No. 2:
EN-199
AP:DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT—

CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
cardiagn.com
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-200

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
cardiagn.com
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK FUEL LEVEL SENSOR. Does the resistance change 2.5 L: Go to step 3. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to smoothly between approx. 0.5 1.6 L and 2.0 L: level sensor. <Ref.
FU-62, Fuel Pump.> Ω and approx. 52 Ω? Repair the poor to FU-65, Fuel
2)While moving the fuel level sensor float up contact in ECM, Level Sensor.>
and down, make sure that the resistance combination meter
between fuel level sensor terminals changes and coupling con-
smoothly. nectors.
Terminals
No. 3 — No. 5:
EN-201
Step Check Yes No

3 CHECK FUEL SUB LEVEL SENSOR. Does the resistance change Repair the poor Replace the fuel
1)Remove the fuel sub level sensor. smoothly between approx. 0.5 contact in ECM, sub level sensor.
2)<Ref. to FU-66, Fuel Sub Level Sensor.> Ω and approx. 44 Ω? combination meter <Ref. to FU-66,
3)While moving the fuel sub level sensor float and coupling con- Fuel Sub Level
up and down, make sure that the resistance nectors. Sensor.>
between fuel level sensor terminals changes
smoothly.
Terminals
No. 1 — No. 2:
cardiagn.com
EN-202
AQ:DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT —

• Radiator fan does not operate properly.
• Overheating
CAUTION:
cardiagn.com
EN-203
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
cardiagn.com
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
EN-204
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change between Repair the poor Go to step 2.
1)Turn the ignition switch to OFF. 0 and 10 V? contact in ECM
2)Connect the test mode connector at the connector.
lower portion of instrument panel (on the
driver's side).
4)While operating the radiator fan relay, mea-
sure the voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation can be executed
using the Subaru Select Monitor. For proce-
dure, refer to “Compulsory Valve Operation
Check Mode”.<Ref. to EN-34, Subaru Select
Monitor.>
2 CHECK GROUND SHORT CIRCUIT IN RADI- Is the resistance less than 10 Repair the ground Go to step 3.
ATOR MAIN FAN RELAY CONTROL CIR- Ω? short circuit in radi-
CUIT. ator main fan relay
1)Turn the ignition switch to OFF. control circuit.
2)Disconnect the connectors from ECM.
cardiagn.com
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 V? Go to step 4. Repair the open
1)Remove the main fan relay from A/C relay circuit in harness
holder. between ignition
2)Turn the ignition switch to ON. switch and fuse
3)Measure the voltage between fuse and relay and relay box (F/B)
box (F/B) connector and chassis ground. connector.
4 CHECK MAIN FAN RELAY. Is the resistance between 87 Go to step 5. Replace the main
1)Turn the ignition switch to OFF. and 107 Ω? fan relay.
2)Measure the resistance between main fan
relay terminals.
Terminal
No. 28 — No. 27:
5 CHECK OPEN CIRCUIT IN MAIN FAN RE- Is the resistance less than 1 Go to step 6. Repair the har-
LAY CONTROL CIRCUIT. Ω? ness and connec-
ECM and main fan relay connector. NOTE:
(B134) No. 3 — (F66) No. 27: the following:
• Open circuit in
harness between
ECM and main fan
relay connector
• Poor contact in
coupling connector
(F45)
6 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Contact with your
Check poor contact in ECM or main fan relay main fan relay connector? contact in ECM or Subaru distributor
connector. main fan relay service.
connector.
EN-205
cardiagn.com
EN-206
AR:DTC P0483 — COOLING FAN FUNCTION PROBLEM —

• Occurrence of noise
• Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cool-
ing function, the OBD system may detect malfunction.
cardiagn.com
EN-207
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
cardiagn.com
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
EN-208
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK ENGINE COOLANT AMOUNT Is the amount of engine cool- Check the radiator Add engine cool-
ant at specified level? fan and fan motor. ant.
<Ref. to CO-10,
Radiator Main Fan
System.> and
<Ref. to CO-18,
Radiator Sub Fan
System.>
cardiagn.com
EN-209
AS:DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
IGNITION B17
SWITCH BATTERY
1 2 3
SBF-4 SBF-1
1
No.18
4 B72
B72 1 2
3 4
A: i10
1 2 3 4 5 6 7 8 9 10
3
cardiagn.com
B56 TCM VEHICLE B22
SPEED
SENSOR 1 2 3 4
5 6 7 8
B17 9 10 11 12
17
13 14 15 16
1
2
B56
AT MT
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
COMBINATION 19 20 21 22 23 24
METER
A: i10
B22 B135
16
A2 1
E3 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
i2 B37
20 21 22 23 24 25 26 27 28
LHD: l2
24
1 LHD :9
RHD :7 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B135 ECM
RHD: i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1414
Step Check Yes No

1 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 2. Go to step 3.
EN-210
Step Check Yes No

2 CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Moni- Check the front Go to step 3.
tor or OBD-II general scan tool vehicle speed sen-
indicate DTC P0720? sor signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
3 CHECK SPEEDOMETER OPERATION IN Does the speedometer operate Go to step 4. Check the speed-
COMBINATION METER. normally? ometer and vehi-
cle speed sensor.
<Ref. to IDI-17,
Speedometer.>
and <Ref. to AT-
32, Front Vehicle
Speed Sensor.>
and <Ref. to AT-
36, Rear Vehicle
Speed Sensor.>
cardiagn.com
and <Ref. to AT-
37, Torque Con-
verter Turbine
Speed Sensor.>
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the poor Repair the har-
COMBINATION METER CONNECTOR. Ω? contact in ECM ness and connec-
1)Turn the ignition switch to OFF. connector. tor.
2)Disconnect the connector from combination NOTE:
meter. In this case, repair
3)Measure the resistance between ECM and the following:
(B135) No. 24 — (i10) No. 2: ECM and combi-
nation meter con-
nector
• Poor contact in
ECM connector
• Poor contact in
combination meter
connector
• Poor contact in
coupling connector
(i2)
EN-211
AT:DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED —

• Engine is difficult to start.
• Engine does not start.
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
cardiagn.com
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-212
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK AIR BY-PASS LINE. Does air flow out? Replace the idle Replace the throt-
1)Turn the ignition switch to OFF. air control solenoid tle body. <Ref. to
2)Remove the idle air control solenoid valve valve. <Ref. to FU- FU-16, INSTALLA-
from throttle body. <Ref. to FU-39, REMOVAL, 39, INSTALLA- TION, Throttle
Idle Air Control Solenoid Valve.> TION, Idle Air Body.>
3)Remove the throttle body from intake mani- Control Solenoid
fold. <Ref. to FU-16, REMOVAL, Throttle Valve.>
Body.>
4)Using an air gun, force air into the idle air
cardiagn.com
control solenoid valve installation area. Con-
firm that forced air subsequently escapes from
the throttle body interior.
EN-213
AU:DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED —

• Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
cardiagn.com
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-214
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air suc- Go to step 3.
1)Turn the ignition switch to ON. tem? tion and leaks.
2)Start the engine, and idle it.
3)Check the following items.
•Loose installation of intake manifold, idle air
control solenoid valve and throttle body
•Cracks of intake manifold gasket, idle air con-
trol solenoid valve gasket and throttle body
gasket
cardiagn.com
•Disconnections of vacuum hoses
3 CHECK THROTTLE CABLE. Does the throttle cable have Go to step 4. Adjust the throttle
play for adjustment? cable. <Ref. to SP-
9, INSTALLA-
TION, Accelerator
Control Cable.>
4 CHECK AIR BY-PASS LINE. Are foreign particles in by-pass Remove the for- Replace the idle
1)Turn the ignition switch to OFF. air line? eign particles from air control solenoid
2)Remove the idle air control solenoid valve by-pass air line. valve. <Ref. to FU-
from throttle body. <Ref. to FU-39, REMOVAL, 39, INSTALLA-
Idle Air Control Solenoid Valve.> TION, Idle Air
3)Confirm that there are no foreign particles in Control Solenoid
by-pass air line. Valve.>
EN-215
AV:DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
cardiagn.com
3
INHIBITOR SWITCH
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
B135 ECM 28 AT
B14
STARTER
MOTOR
B72 B12 T7 B135
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7
1 2
5 6 7 8 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 17 18 19
3 4
9 10 11 12 20 21 22 23 24 25 26 27 28
EN0862
EN-216
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check the starter
NOTE: ate when ignition switch is short circuit in motor circuit. <Ref.
Place the inhibitor switch in each position. turned to ON? starter motor cir- to EN-64,
cuit. STARTER
MOTOR CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>
cardiagn.com
EN-217
AW:DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT —

• Power source voltage of the ECM is low.
• Charge warning light comes on.
CAUTION:
• WIRING DIAGRAM:
GENERATOR SBF-1
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
cardiagn.com
3
B61 F44
2
1
B47
1
2
B136 ECM
B47 F44 B136
1 2 1 2 3 4 5 6 7
1 2 3 4
3 4 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
5 6 21 22 23 24 25 26 27 28 29 30
EN1416
EN-218
Step Check Yes No

1 CHECK GENERATOR. Is the voltage less than 10.8 Go to step 2. Repair the genera-
1)Start the engine. V? tor. <Ref. to CS-
2)Idle after warm-up. 21, General Diag-
3)Measure the voltage between generator B nostic.>
Terminal
Generator B terminal (+) — Chassis
ground (–):
2 CHECK GENERATOR. Is the voltage less than 10.8 Go to step 3. Repair the genera-
1)Run the engine at 5,000 rpm. V? tor. <Ref. to CS-
2)Measure the voltage between generator B 21, General Diag-
terminal and chassis ground. nostic.>
Terminal
ground (−):
3 CHECK BATTERY TERMINAL. Are the positive and ground Go to step 4. Tighten the clamp
Turn the ignition switch to OFF. battery terminals tightly of terminal.
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage less than 10.8 Go to step 5. Repair the har-
1)Run the engine at idle. V? ness connector
2)Measure the voltage between ECM connec- between battery,
tor and chassis ground. main relay and
cardiagn.com
Connector & terminal ECM.
5 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 6.
nectors between generator, nector.
battery and ECM?
6 CHECK ECM. Is the same DTC as in the cur- Replace the gen- Go to step 7.
1)Connect all connectors. rent diagnosis still being out- erator.
2)Erase the memory. <Ref. to EN-49, Clear put?
Memory Mode.>
3)Perform inspection mode. <Ref. to EN-42,
Inspection Mode.>
4)Read out the DTC. <Ref. to EN-41, Read
7 CHECK ANY OTHER TROUBLE CODES AP- Are other DTC being output? Proceed with the A temporary poor
PEARANCE. diagnosis corre- contact.
sponding to the
DTC.
EN-219
AX:DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT —

• Power source voltage of the ECM is high.
• Charge warning light comes on.
CAUTION:
• WIRING DIAGRAM:
GENERATOR SBF-1
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
cardiagn.com
3
B61 F44
2
1
B47
1
2
B136 ECM
B47 F44 B136
1 2 1 2 3 4 5 6 7
1 2 3 4
3 4 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
5 6 21 22 23 24 25 26 27 28 29 30
EN1416
EN-220
Step Check Yes No

1 CHECK GENERATOR. Is the voltage more than 16.2 Go to step 2. Repair the genera-
1)Start the engine. V? tor. <Ref. to CS-
2)Idle after warm-up. 21, General Diag-
3)Measure the voltage between generator B nostic.>
Terminal
ground (–):
2 CHECK GENERATOR. Is the voltage more than 16.2 Go to step 3. Repair the genera-
1)Run the engine at 5,000 rpm. V? tor. <Ref. to CS-
2)Measure the voltage between generator B 21, General Diag-
terminal and chassis ground. nostic.>
Terminal
ground (−):
3 CHECK BATTERY TERMINAL. Are the positive and ground Go to step 4. Tighten the clamp
Turn the ignition switch to OFF. battery terminals tightly of terminal.
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 16.2 Go to step 5. Repair the har-
1)Run the engine at idle. V? ness connector
2)Measure the voltage between ECM connec- between battery,
tor and chassis ground. main relay and
cardiagn.com
Connector & terminal ECM.
5 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 6.
nectors between generator, nector.
battery and ECM?
6 CHECK ECM. Is the same DTC as in the cur- Replace the gen- Go to step 7.
1)Connect all connectors. rent diagnosis still being out- erator.
2)Erase the memory. <Ref. to EN-49, Clear put?
Memory Mode.>
3)Perform the inspection mode. <Ref. to EN-
42, Inspection Mode.>
4)Read out the DTC. <Ref. to EN-41, Read
7 CHECK ANY OTHER TROUBLE CODES AP- Are other DTC being output? Proceed with the A temporary poor
PEARANCE. diagnosis corre- contact.
sponding to the
DTC.
EN-221
AY:DTC P0604 — INTERNAL CONTROL MODULE MEMORY CHECK SUM ER-

ROR —
• Immediately at fault recognition.
• Engine does not start.
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 TO FRONT OXYGEN (A/F) SENSOR
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1 IGNITION
B72 BATTERY
SWITCH
B47 No.11 SBF-4 SBF-1
4 1
cardiagn.com
B19
C1
C2
C9
B7
A: B134
B: B135 ECM
1 AT MODEL: B6
C: B136
MT MODEL: B25
A34
A35
A27
C22
C21
1
A7
A8
B22
13
15
14
16
8
E3
B72 F44 B47 B22 B: B135 C: B136
1 2 3 4 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2
5 6 7 8 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
3 4
5 6 9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1397
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Replace the ECM. It is not necessary
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool <Ref. to FU-51, to inspect DTC
indicate DTC P0604? Engine Control P0604.
Module.>
EN-222
cardiagn.com
EN-223
AZ:DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
BATTERY
No.16 SBF-2 SBF-1
LHD
RHD
OC WC
2
1
2
WC : WITH CRUISE CONTROL MODEL
BRAKE STOP
LIGHT LIGHT OC : WITHOUT CRUISE CONTROL MODEL
cardiagn.com
SWITCH SWITCH
B64 B64 : OC
WC OC
1
B65 : WC
3
RHD
LHD TO STOP LIGHTS

12
B55 TCM
B64 B65 B55
1 2 1 2 1 2 3 4 5 6 7 8 9
3 4 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
EN1417
Step Check Yes No

1 CHECK OPERATION OF BRAKE LIGHT. Does the brake light come on Go to step 2. Repair or replace
when depressing the brake the brake light cir-
pedal? cuit.
EN-224
Step Check Yes No

2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. Ω? the harness and
1)Disconnect the connectors from TCM and connector.
brake light switch. NOTE:
TCM and brake light switch connector. the following:
• LHD harness between
(B55) No. 12 — (B64) No.1: TCM and brake
• RHD light switch con-
Without cruise control nector
(B55) No. 12 — (B64) No. 2 • Poor contact in
With cruise control TCM connector
(B55) No. 12 — (B65) No. 3 • Poor contact in
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND Is the resistance more than 1 Go to step 4. Repair the ground
BRAKE LIGHT SWITCH CONNECTOR. MΩ? short circuit in har-
TCM and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 — Chassis ground: nector.
cardiagn.com
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V Go to step 5. Adjust or replace
1)Connect the connectors to TCM and brake when releasing the brake the brake light
light switch. pedal? switch. <Ref. to LI-
2)Measure the voltage between TCM and 8, STOP LIGHT
chassis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) — Chassis ground (−): Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 V Go to step 6. Adjust or replace
Measure the voltage between TCM and chas- when depressing the brake the brake light
sis ground. pedal? switch. <Ref. to LI-
Connector & terminal 8, STOP LIGHT
(B55) No. 12 (+) — Chassis ground (−): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
6 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Replace the TCM.
Check poor contact in TCM connector. connector? contact in TCM <Ref. to AT-46,
connector. Transmission Con-
trol Module
(TCM).>
EN-225
BA:DTC P0731 — GEAR 1 INCORRECT RATIO —

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN-227, DTC P0734 — GEAR 4 INCORRECT
RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB:DTC P0732 — GEAR 2 INCORRECT RATIO —
NOTE:
BC:DTC P0733 — GEAR 3 INCORRECT RATIO —
NOTE:
cardiagn.com
EN-226
BD:DTC P0734 — GEAR 4 INCORRECT RATIO —

• Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; excessive
tight corner “braking”
CAUTION:
• WIRING DIAGRAM:
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 3.
cardiagn.com
CIRCUIT. position sensor circuit? the throttle posi-
Check the throttle position sensor circuit. <Ref. tion sensor circuit.
to AT-50, DTC 31 THROTTLE POSITION
SENSOR, Diagnostic Procedure with Diagnos-
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in front Repair or replace Go to step 4.
CIRCUIT. vehicle speed sensor circuit? the front vehicle
Check the front vehicle speed sensor circuit. speed sensor cir-
<Ref. to AT-57, DTC 33 FRONT VEHICLE cuit.
SPEED SENSOR, Diagnostic Procedure with
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check the torque converter turbine speed sen- circuit? verter turbine
sor circuit. <Ref. to AT-62, DTC 36 TORQUE speed sensor cir-
CONVERTER TURBINE SPEED SENSOR, cuit.
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
5 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Go to step 6.
Check poor contact in TCM connector. connector? contact in TCM
connector.
6 CHECK MECHANICAL TROUBLE. Is there any mechanical trou- Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- ble in automatic transmission? the automatic <Ref. to AT-46,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>
EN-227
BE:DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION —

• No lock-up (after engine warm-up)
• No shift or excessive tight corner “braking”
CAUTION:
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in lock-up Repair or replace Go to step 3.
CUIT. duty solenoid circuit? the lock-up duty
cardiagn.com
Check the lock-up duty solenoid circuit. <Ref. solenoid circuit.
to AT-94, DTC 77 LOCK-UP DUTY SOLE-
NOID, Diagnostic Procedure with Diagnostic
3 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 4.
CIRCUIT. position sensor circuit? the throttle posi-
Check the throttle position sensor circuit. <Ref. tion sensor circuit.
to AT-50, DTC 31 THROTTLE POSITION
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check the torque converter turbine speed sen- circuit? verter turbine
sor circuit. <Ref. to AT-62, DTC 36 TORQUE speed sensor cir-
CONVERTER TURBINE SPEED SENSOR, cuit.
Code (DTC).>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in engine Repair or replace Go to step 6.
Check the engine speed input circuit. <Ref. to speed input circuit? the engine speed
AT-42, DTC 11 ENGINE SPEED SIGNAL, input circuit.
Code (DTC).>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in inhibitor Repair or replace Go to step 7.
Check the inhibitor switch circuit. <Ref. to AT- switch circuit? the inhibitor switch
119, CHECK INHIBITOR SWITCH., Diagnostic circuit.
Procedure for No-diagnostic Trouble Code
(DTC).>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in brake Repair or replace Go to step 8.
Check the brake light switch circuit. <Ref. to light switch circuit? the brake light
AT-110, CHECK BRAKE SWITCH., Diagnostic switch circuit.
Procedure for No-diagnostic Trouble Code
(DTC).>
8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9.
CUIT. temperature sensor circuit? the ATF tempera-
Check the ATF temperature sensor circuit. ture sensor circuit.
<Ref. to AT-46, DTC 27 ATF TEMPERATURE
EN-228
Step Check Yes No

9 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Go to step 10.
Check poor contact in TCM connector. connector? contact in TCM
connector.
10 CHECK MECHANICAL TROUBLE. Is there any mechanical trou- Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- ble in automatic transmission? the automatic <Ref. to AT-46,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>
cardiagn.com
EN-229
BF:DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
ATMOSPHERIC
PRESSURE
SENSOR
2
3
1
B2
cardiagn.com
4 LHD RHD 3
1 LHD RHD 1
B122 B83
29
15
16
B136 ECM
B2 B122 B83 B136
1 2 3 1 2 3 4 1 2 3 4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
4 5 6
21 22 23 24 25 26 27 28 29 30
EN1418
EN-230
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 0 kPa Go to step 3. Go to step 2.
1)Start the engine. (0 mmHg, 0 inHg)?
NOTE:
2 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Even if MIL lights
Check poor contact in ECM and pressure sen- pressure sensor connector? contact in ECM or up, the circuit has
sor connector. atmospheric pres- returned to a nor-
sure sensor con- mal condition at
nector. this time.
and chassis ground.
cardiagn.com
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
Measure the voltage between ECM and chas-
sis ground.
SUBARU SELECT MONITOR.) than 0 kPa (0 mmHg, 0 inHg) contact in ECM
Read the data of atmospheric absolute pres- by shaking harness and con- connector.
sure signal using Subaru Select Monitor. nector of ECM while monitor-
NOTE: ing the value with Subaru
•Subaru Select Monitor select monitor?
EN-231
Step Check Yes No

7 CHECK HARNESS BETWEEN ECM AND AT- Is the voltage more than 4.5 V? Go to step 8. Repair the har-
MOSPHERIC PRESSURE SENSOR CON- ness and connec-
NECTOR. tor.
2)Disconnect the connector from atmospheric In this case, repair
pressure sensor. the following:
4)Measure the voltage between atmospheric harness between
pressure sensor connector and engine ground. ECM and atmo-
Connector & terminal spheric pressure
• Poor contact in
joint connector
(B83) or (B122)
8 CHECK HARNESS BETWEEN ECM AND AT- Is the resistance less than 1 Go to step 9. Repair the har-
MOSPHERIC PRESSURE SENSOR CON- Ω? ness and connec-
NECTOR. tor.
ECM and pressure sensor connector. • Open circuit in
cardiagn.com
(B136) No. 16 — (B2) No. 1: ECM and pressure
sensor connector
9 CHECK HARNESS BETWEEN ECM AND AT- Is the resistance more than Go to step 10. Repair the ground
MOSPHERIC PRESSURE SENSOR CON- 500 kΩ? short circuit in har-
Measure the resistance of harness between ECM and pressure
pressure sensor connector and engine ground. sensor connector.
10 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the atmo-
Check poor contact in pressure sensor con- sure sensor connector? contact in atmospheric pressure
nector. spheric pressure sensor. <Ref. to
sensor connector. FU-38, Atmo-
spheric Pressure
Sensor.>
EN-232
cardiagn.com
EN-233
BG:DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

—
CAUTION:
• WIRING DIAGRAM:
ATMOSPHERIC
PRESSURE
SENSOR
2
3
1
B2
cardiagn.com
4 LHD RHD 3
1 LHD RHD 1
B122 B83
29
15
16
B136 ECM
B2 B122 B83 B136
1 2 3 1 2 3 4 1 2 3 4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
4 5 6
21 22 23 24 25 26 27 28 29 30
EN1418
EN-234
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 140 kPa Go to step 10. Go to step 2.
1)Start the engine. (1,050 mmHg, 41.34 inHg)?
NOTE:
and chassis ground.
cardiagn.com
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
SUBARU SELECT MONITOR.) than 0 kPa (0 mmHg, 0 inHg) contact in ECM
Read the data of atmospheric absolute pres- by shaking harness and con- connector.
sure signal using Subaru Select Monitor. nector of ECM while monitor-
NOTE: ing the value with Subaru
•Subaru Select Monitor Select Monitor?
6 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the har-
PRESSURE SENSOR CONNECTOR. ness and connec-
2)Disconnect the connector from atmospheric NOTE:
pressure sensor. In this case, repair
4)Measure the voltage between atmospheric • Open circuit in
pressure sensor connector and engine ground. harness between
Connector & terminal ECM and pressure
• Poor contact in
joint connector
(B83) or (B122)
EN-235
Step Check Yes No

PRESSURE SENSOR CONNECTOR. Ω? ness and connec-
ECM and pressure sensor connector. the following:
(B136) No. 29 — (B2) No. 2: harness between
ECM and pressure
sensor connector
PRESSURE SENSOR CONNECTOR. Ω? ness and connec-
ECM and pressure sensor connector. NOTE:
• Open circuit in
harness between
ECM and pressure
sensor connector
• Poor contact in
joint connector
cardiagn.com
(B83), (B122)
9 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the atmo-
Check poor contact in pressure sensor con- sure sensor connector? contact in atmospheric pressure
nector. spheric pressure sensor. <Ref. to
sensor connector. FU-38, Atmo-
spheric Pressure
Sensor.>
10 CHECK CURRENT DATA. Is the value more than 140 kPa Repair the battery Replace the atmo-
1)Turn the ignition switch to OFF. (1,050 mmHg, 41.34 inHg)? short circuit in har- spheric pressure
2)Disconnect the connector from atmospheric ness between sensor. <Ref. to
pressure sensor. ECM and atmo- FU-38, Atmo-
3)Turn the ignition switch to ON. spheric pressure spheric Pressure
4)Read the data of intake manifold absolute sensor connector. Sensor.>
NOTE:
EN-236
cardiagn.com
EN-237
BH:DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PER-

CAUTION:
• WIRING DIAGRAM:
ATMOSPHERIC
PRESSURE
SENSOR
2
3
1
B2
cardiagn.com
4 LHD RHD 3
1 LHD RHD 1
B122 B83
29
15
16
B136 ECM
B2 B122 B83 B136
1 2 3 1 2 3 4 1 2 3 4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
4 5 6
21 22 23 24 25 26 27 28 29 30
EN1418
EN-238
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1112.
2 CHECK ATMOSPHERIC PRESSURE SEN- Is the atmospheric pressure Replace the atmo- Go to step 3.
SOR FILTER. sensor filter non-functional? spheric pressure
1)Turn the ignition switch to OFF. (Check for contamination, sensor filter.
2)Disconnect the connector from atmospheric damage, water leakage, etc.)
pressure sensor.
3)Remove the atmospheric pressure sensor.
4)Check the atmospheric pressure sensor fil-
ter.
3 CHECK CURRENT DATA. Is the value between 73.3 kPa Replace the atmo- Replace the intake
1)Turn the ignition switch to ON. (550 mmHg, 21.65 inHg) and spheric pressure air temperature
cardiagn.com
2)Read the data of intake manifold absolute 106.6 kPa (800 mmHg, 31.50 sensor. <Ref. to and pressure sen-
pressure signal using Subaru Select Monitor or inHg)? FU-38, Atmo- sor. <Ref. to FU-
OBD-II general scan tool. spheric Pressure 37, Intake Air
NOTE: Sensor.> Temperature and
•Subaru Select Monitor Pressure Sensor.>
EN-239
BI: DTC P1137 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
cardiagn.com
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
EN-240
Step Check Yes No

2 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value equal to or more Go to step 3. Go to step 4.
TA. than 0.85 and equal to less
1)Start the engine. than 1.15 in idling?
2)While observing the Subaru Select Monitor
or OBD-II general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (160°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
3 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value more than 1.1 for a Go to step 6. Go to step 4.
TA. moment?
cardiagn.com
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase the engine speed to 5,000 rpm,
slowly depress the accelerator pedal, taking
approx. 5 seconds, and quickly release the ac-
celerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. Ω? circuit between
1)Turn the ignition switch to OFF. ECM and front
2)Disconnect the connector from ECM and oxygen (A/F) sen-
front oxygen (A/F) sensor connector. sor.
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (E24) No. 3:
(B136) No. 7 — (E24) No. 4:
(B136) No. 19 — (E24) No. 1:
(B136) No. 20 — (E24) No. 6:
FRONT OXYGEN (A/F) SENSOR. MΩ? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (A/F)
Connector & terminals sensor.
6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the front
Check the exhaust system parts. tem? the faulty parts. oxygen (A/F) sen-
NOTE: sor. <Ref. to FU-
Check the following items. 47, Front Oxygen
•Loose installation of portions (A/F) Sensor.>
•Looseness of front oxygen (A/F) sensor
EN-241
BJ:DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (LOW INPUT) —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
cardiagn.com
B122
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-242
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the throt-
BLE CODE (DTC) ON DISPLAY. vant DTC using tle position sensor.
Trouble Code Throttle Position
(DTC)”. <Ref. to Sensor.>
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1142.
cardiagn.com
EN-243
BK:DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) —
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
cardiagn.com
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-244
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1146.
disconnection of hose on the intake system.
air intake system?
3 CHECK PRESSURE SENSOR. Is the value within the specifi- Go to step 4. Replace the intake
1)Start the engine and warm-up engine until cations? air temperature
coolant temperature is greater than 60°C sensor and pres-
(140°F). sure sensor. <Ref.
2)Place the shift lever in the selector lever in to FU-37, Intake
“N” or “P” position. Air Temperature
3)Turn the A/C switch to OFF. and Pressure Sen-
cardiagn.com
4)Turn all accessory switches to OFF. sor.>
5)Read the data of intake manifold pressure
NOTE:
Specification:
•Intake manifold absolute pressure
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg, 5.91
— 13.78 inHg)
4 CHECK THROTTLE POSITION. Is the throttle positioning ratio Go to step 5. Adjust or replace
Read the data of throttle position signal using equal to or less than 5 % when the throttle posi-
Subaru Select Monitor or OBD-II general scan throttle is fully closed? tion sensor. <Ref.
tool. to FU-35, Throttle
NOTE: Position Sensor.>
EN-245
Step Check Yes No

5 CHECK THROTTLE POSITION. Is the throttle positioning ratio Replace the intake Replace the throt-
equal to or more than 85 % air temperature tle position sensor.
when throttle is fully open? and pressure sen- <Ref. to FU-35,
sor. <Ref. to FU- Throttle Position
37, Intake Air Sensor.>
Temperature and
Pressure Sensor.>
cardiagn.com
EN-246
BL:DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM 2 —
CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
cardiagn.com
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-247

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
cardiagn.com
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the fuel
BLE CODE (DTC) ON DISPLAY. vant DTC using level sensor. <Ref.
“List of Diagnostic to FU-65, Fuel
Trouble Code Level Sensor.>
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1442.
EN-248
BM:DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT —

• Radiator fan does not operate properly.
• Overheating
CAUTION:
cardiagn.com
EN-249
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
cardiagn.com
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
EN-250
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change between Even if MIL lights Go to step 2.
1)Turn the ignition switch to OFF. 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver's side). this time. In this
3)Turn the ignition switch to ON. case, repair the
4)While operating the radiator fan relay, mea- poor contact in
sure the voltage between ECM and chassis ECM connector.
ground.
NOTE:
Radiator fan relay operation can be executed
using the Subaru Select Monitor. For proce-
dure, refer to “Compulsory Valve Operation
Check Mode”.<Ref. to EN-50, Compulsory
Valve Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR FAN Is the voltage more than 10 V? Repair the battery Go to step 3.
RELAY CONTROL CIRCUIT. short circuit in radi-
1)Turn the ignition switch to OFF. ator fan relay con-
2)Remove the main fan relay and sub fan trol circuit.
relay. (with A/C models)
cardiagn.com
3)Disconnect the test mode connector.
chassis ground.
3 CHECK MAIN FAN RELAY. Is the resistance less than 1 Replace the main Go to step 4.
1)Turn the ignition switch to OFF. Ω? fan relay.
2)Remove the main fan relay.
3)Measure the resistance between main fan
relay terminals.
Terminal
No. 26 — No. 25:
4 CHECK SUB FAN RELAY. Is the resistance less than 1 Replace the sub Go to step 5.
1)Remove the sub fan relay. Ω? fan relay.
2)Measure the resistance between sub fan
relay terminals.
Terminal
No. 18 — No. 17
Module.>
EN-251
BN:DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

• Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
cardiagn.com
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-252
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in the air intake Repair the air suc- Go to step 3.
1)Turn the ignition switch to ON. system? tion and leaks.
2)Start the engine, and idle it.
3)Check the following items.
•Loose installation of intake manifold, idle air
control solenoid valve and throttle body
•Cracks of intake manifold gasket, idle air con-
trol solenoid valve gasket and throttle body
gasket
•Disconnections of vacuum hoses
cardiagn.com
3 CHECK THROTTLE CABLE. Does the throttle cable have Go to step 4. Adjust the throttle
play for adjustment? cable. <Ref. to SP-
9, INSTALLA-
TION, Accelerator
Control Cable.>
4 CHECK AIR BY-PASS LINE. Are foreign particles in by-pass Remove the for- Replace the idle
1)Turn the ignition switch to OFF. air line? eign particles from air control solenoid
2)Remove the idle air control solenoid valve by-pass air line. valve. <Ref. to FU-
from throttle body. <Ref. to FU-39, Idle Air 39, Idle Air Con-
Control Solenoid Valve.> trol Solenoid
3)Confirm that there are no foreign particles in Valve.>
the by-pass air line.
EN-253
BO:DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT

LOW INPUT —
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN-256, DTC P1516 — IDLE AIR CONTROL
SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
BP:DTC P1511 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT
HIGH INPUT —
NOTE:
SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
BQ:DTC P1512 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT
LOW INPUT —
NOTE:
Code (DTC).>
cardiagn.com
BR:DTC P1513 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT
HIGH INPUT —
NOTE:
Code (DTC).>
BS:DTC P1514 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT
LOW INPUT —
NOTE:
Code (DTC).>
BT:DTC P1515 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT
HIGH INPUT —
NOTE:
Code (DTC).>
EN-254
cardiagn.com
EN-255
BU:DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

LOW INPUT —
• Engine stalls.
• Engine breathing
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47
cardiagn.com
1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-256
Step Check Yes No

1 CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2. Repair the har-
TROL SOLENOID VALVE. ness and connec-
2)Disconnect the connector from idle air con- NOTE:
trol solenoid valve. In this case, repair
4)Measure the voltage between idle air control • Open circuit in
solenoid valve connector and engine ground. harness between
Connector & terminal idle air control
(E7) No. 2 (+) — Engine ground (−): solenoid valve and
main relay con-
nector
• Poor contact in
coupling connector
(B22)
2 CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 3. Repair the har-
TROL SOLENOID VALVE. ness and connec-
Measure the voltage between idle air control tor.
solenoid valve connector and engine ground. NOTE:
(E7) No. 5 (+) — Engine ground (−): the following:
• Open circuit in
cardiagn.com
harness between
idle air control
solenoid valve and
main relay con-
nector
• Poor contact in
coupling connector
(B22)
IDLE AIR CONTROL SOLENOID VALVE Ω? ness and connec-
CONNECTOR. tor.
2)Measure the resistance between ECM and In this case, repair
idle air control solenoid valve connector. the following:
DTC P1510; (B134) No. 5 — (E7) No. 4: harness between
DTC P1512; (B134) No. 6 — (E7) No. 1: ECM and idle air
DTC P1514; (B134) No. 19 — (E7) No. 6: control solenoid
DTC P1516; (B134) No. 20 — (E7) No. 3: valve connector
• Poor contact in
coupling connector
(B21)
IDLE AIR CONTROL SOLENOID VALVE Ω? short circuit in har-
CONNECTOR. ness between
1)Disconnect the connector from ECM. ECM and idle air
2)Measure the resistance between ECM con- control solenoid
nector and chassis ground. valve connector.
DTC P1510; (B134) No. 5 — Chassis
ground:
ground:
ground:
ground:
EN-257
Step Check Yes No

5 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the idle
Check poor contact in ECM connector and idle connector or idle air control contact in ECM air control solenoid
air control solenoid valve connector. solenoid valve connector? connector or idle valve. <Ref. to FU-
air control solenoid 39, Idle Air Con-
valve connector. trol Solenoid
Valve.>
cardiagn.com
EN-258
cardiagn.com
EN-259
BV:DTC P1517 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

HIGH INPUT —
• Engine stalls.
• Engine breathing
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47
cardiagn.com
1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-260
Step Check Yes No

indicate DTC P1511, P1513,
P1515 and P1517 at same
time?
2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Go to step 3. Repair the har-
2)Measure the resistance between ECM con- tor.
nector and chassis ground. NOTE:
(B136) No. 22 — Chassis ground: • Open circuit in
harness between
ECM connector
and engine ground
terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair the battery Replace the ECM.
cardiagn.com
IDLE AIR CONTROL SOLENOID VALVE short circuit in har- <Ref. to FU-51,
CONNECTOR. ness between Engine Control
1)Turn the ignition switch to OFF. ECM and idle air Module.>
2)Disconnect the connector from idle air con- control solenoid
trol solenoid valve. valve connector.
3)Turn the ignition switch to ON. After repair,
4)Measure the voltage between ECM connec- replace the ECM.
tor and chassis ground. <Ref. to FU-51,
Connector & terminal Engine Control
DTC P1511; (B134) No. 5 (+) — Chassis Module.>
ground (–):
DTC P1513; (B134) No. 6 (+) — Chassis
ground (–):
DTC P1515; (B134) No. 19 (+) — Chassis
ground (–):
DTC P1517; (B134) No. 20 (+) — Chassis
ground (–):
EN-261
BW:DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
BATTERY
B72
SBF-4 SBF-1
1 2
3 4
1
IGNITION
SWITCH
B72
T7
3
1 2 3 4 5 6
7 8 9 10 11 12
cardiagn.com
INHIBITOR SWITCH
P R N D 3 2 1
B135 ECM 26 12 12
11 7 B12
B12 T3 T7 1 2 3 4
5 6 7 8
9 10 11 12
B135
STARTER SWITCH
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B14
EN1419
EN-262
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check the starter
NOTE: when ignition switch is turned ness and connec- motor circuit. <Ref.
Place the inhibitor switch in the “P” or “N” posi- to START? tor. to EN-64,
tion. NOTE: STARTER
In this case, repair MOTOR CIR-
the following: CUIT, Diagnostics
• Open or ground for Engine Start-
short circuit in har- ing Failure.>
ness between
ECM and starter
motor connector
• Poor contact in
ECM connector
cardiagn.com
EN-263
BX:DTC P1540 — VEHICLE SPEED SENSOR MALFUNCTION 2 —

CAUTION:
• WIRING DIAGRAM:
IGNITION B17
SWITCH BATTERY
1 2 3
SBF-4 SBF-1
1
No.18
4 B72
B72 1 2
3 4
A: i10
1 2 3 4 5 6 7 8 9 10
3
cardiagn.com
B56 TCM VEHICLE B22
SPEED
SENSOR 1 2 3 4
5 6 7 8
B17 9 10 11 12
17
13 14 15 16
1
2
B56
AT MT
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
COMBINATION 19 20 21 22 23 24
METER
A: i10
B22 B135
16
A2 1
E3 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
i2 B37
20 21 22 23 24 25 26 27 28
LHD: l2
24
1 LHD :9
RHD :7 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B135 ECM
RHD: i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1414
EN-264
Step Check Yes No

1 CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Moni- Check the front Go to step 2.
tor or OBD-II general scan tool vehicle speed sen-
indicate DTC P0720? sor signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
2 CHECK SPEEDOMETER OPERATION IN Does the speedometer operate Go to step 3. Check the speed-
COMBINATION METER. normally? ometer and vehi-
cle speed sensor.
<Ref. to IDI-17,
Speedometer.>
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the poor Repair the har-
COMBINATION METER CONNECTOR. Ω? contact in ECM ness and connec-
1)Turn the ignition switch to OFF. connector. tor.
2)Disconnect the connector from combination NOTE:
meter. In this case, repair
3)Measure the resistance between ECM and the following:
cardiagn.com
(B135) No. 24 — (i10) No. 2: ECM and combi-
nation meter con-
nector
• Poor contact in
ECM connector
• Poor contact in
combination meter
connector
• Poor contact in
coupling connector
(i2)
EN-265
BY:DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
BATTERY
SBF-5
LHD 2 LHD
B61 F44
C9
A: B134
1 AT MODEL : B6
B: B135 ECM
MT MODEL : B25
C: B136
A27
C22
C21
A34
A35
1
A7
A8
cardiagn.com
B22
13
15
14
16
E3
F44 B22 B: B135 C: B136
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4
5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1420
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the poor Go to step 2.
1)Turn the ignition switch to OFF. contact in ECM
2)Measure the voltage between ECM and connector.
chassis ground.
EN-266
Step Check Yes No

MAIN FUSE BOX CONNECTOR. Ω? short circuit in har-
1)Disconnect the connector from ECM. ness between
2)Measure the resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
3 CHECK FUSE SBF-5. Is the fuse blown? Replace the fuse. Repair the har-
ness and connec-
tor.
NOTE:
the following:
• Open circuit in
harness between
ECM and battery
• Poor contact in
ECM connector
• Poor contact in
battery terminal
cardiagn.com
EN-267
BZ:DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT

MODEL) —
CAUTION:
• WIRING DIAGRAM:
BATTERY
B72
SBF-4 SBF-1
1 2
3 4
1
IGNITION
SWITCH
B72
T7
3
cardiagn.com
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P R N D 3 2 1
B135 ECM 26 12 12
11 7 B12
B12 T3 T7 1 2 3 4
5 6 7 8
9 10 11 12
B135
STARTER SWITCH
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B14
EN1419
EN-268
Step Check Yes No

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-II general scan tool P0705 using “List
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V? Go to step 3. Go to step 5.
chassis ground in selector lever “N” and “P”
positions.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Go to step 4. Go to step 5.
Measure the voltage between ECM and chas- 5.5 V?
sis ground in selector lever except for “N” and
“P” positions.
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Contact with your
cardiagn.com
Check poor contact in ECM connector. connector? contact in ECM Subaru distributor
connector. service.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Go to step 6.
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and inhibitor
(B135) No. 26 (+) — Chassis ground (−): switch connector.
6 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Go to step 7. Repair the har-
HIBITOR SWITCH CONNECTOR. Ω? ness and connec-
2)Disconnect the connectors from ECM and NOTE:
inhibitor switch. In this case, repair
ECM and inhibitor switch connector. • Open circuit in
(B135) No. 26 — (T7) No. 12: ECM and inhibitor
switch connector
• Poor contact in
coupling connector
(B12)
• Poor contact in
inhibitor switch
connector
• Poor contact in
ECM connector
EN-269
Step Check Yes No

7 CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Go to step 8. Repair the open
Measure the resistance of harness between Ω? circuit in harness
inhibitor switch connector and engine ground. between inhibitor
Connector & terminal switch connector
(T7) No. 7 — Engine ground: and starter motor
ground line.
NOTE:
the following:
• Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
• Poor contact in
starter motor con-
nector
• Poor contact in
starter motor
ground
• Starter motor
cardiagn.com
8 CHECK INHIBITOR SWITCH. Is the resistance less than 1 Go to step 9. Replace the inhibi-
Measure the resistance between inhibitor Ω? tor switch. <Ref. to
switch connector receptacle's terminals in AT-28, Inhibitor
selector lever “N” and “P” positions. Switch.>
Terminals
No. 7 — No. 12:
9 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair the selector Contact with your
cable connection to inhibitor cable connection. Subaru distributor
switch? <Ref. to CS-10, service.
INSPECTION, NOTE:
Select Cable.> Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN-270
cardiagn.com
EN-271
CA:DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MOD-
EL) —
CAUTION:
• WIRING DIAGRAM:
BATTERY
B72
SBF-4 SBF-1
1 2
3 4
1
IGNITION
SWITCH
B72
T7
3
cardiagn.com
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P R N D 3 2 1
B135 ECM 26 12 12
11 7 B12
B12 T3 T7 1 2 3 4
5 6 7 8
9 10 11 12
B135
STARTER SWITCH
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B14
EN1419
EN-272
Step Check Yes No

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Moni- Inspect the DTC Go to step 2.
tor or OBD-II general scan tool P0705 using “List
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Even if MIL lights Go to step 3.
1)Turn the ignition switch to ON. 5.5 V at except “N” and “P” up, the circuit has
2)Measure the voltage between ECM and positions? returned to a nor-
chassis ground. mal condition at
Connector & terminal this time.
TRANSMISSION HARNESS CONNECTOR. Ω? short circuit in har-
2)Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
3)Measure the resistance of harness between connector.
cardiagn.com
4 CHECK TRANSMISSION HARNESS CON- Is the resistance less than 10 Repair the ground Go to step 5.
NECTOR. Ω? short circuit in har-
1)Disconnect the connector from inhibitor ness between
switch. transmission har-
2)Measure the resistance of harness between ness and inhibitor
transmission harness connector and engine switch connector.
ground.
(T3) No. 12 — Engine ground:
5 CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 6. Replace the inhibi-
Measure the resistance between inhibitor MΩ at except “N” and “P” posi- tor switch. <Ref. to
switch connector receptacle's terminals in tions? AT-28, Inhibitor
selector lever except for “N” position. Switch.>
Terminals
No. 7 — No. 12:
6 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair the selector Contact with your
cable connection to inhibitor cable connection. Subaru distributor
switch? <Ref. to CS-10, service.
INSPECTION, NOTE:
Select Cable.> Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN-273
CB:DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT

MODEL) —
CAUTION:
• WIRING DIAGRAM:
B135 ECM
B25
1 2
26
cardiagn.com
B25
1
T2 B22
1 2 3 4
NEUTRAL 5 6 7 8
POSITION 9 10 11 12
SWITCH 13 14 15 16
T2
1 LHD : 16
2
B25 RHD : 15
B22 B135
1
1 2 3 4 5 6 7
E3 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
EN1421
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10V in Go to step 2. Go to step 4.
1)Turn the ignition switch to ON. neutral position?
chassis ground.
EN-274
Step Check Yes No

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1V in Go to step 3. Go to step 4.
Measure the voltage between ECM and chas- other position?
sis ground.
3 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Contact with your
Check poor contact in ECM connector. connector? contact in ECM Subaru distributor
connector. service.
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance more than Go to step 5. Repair the short
1)Turn the ignition switch to OFF. 1MΩ in neutral position? circuit in transmis-
2)Disconnect the connector from transmission sion harness or
harness. replace neutral
3)Measure the resistance between transmis- position switch.
sion harness and connector terminals.
(T2) No. 1 — No. 2:
5 CHECK NEUTRAL POSITION SWITCH. Is the resistance less than 1Ω Go to step 6. Repair the short
Measure the resistance between transmission in other positions? circuit in transmis-
harness connector terminals. sion harness or
replace neutral
position switch.
cardiagn.com
NEUTRAL POSITION SWITCH CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance between ECM and ECM and trans-
chassis ground. mission harness
Connector & terminal connector.
NEUTRAL POSITION SWITCH CONNEC- Ω? circuit in harness
TOR. between ECM and
1)Disconnect the connector from ECM. transmission har-
2)Measure the resistance of harness between ness connector.
ECM and transmission harness connector.
(B135) No. 26 — (B25) No. 1:
NEUTRAL POSITION SWITCH CONNEC- Ω? circuit between
TOR. transmission har-
Measure the resistance of harness between ness connector
transmission harness connector and engine and engine ground
ground. terminal.
9 CHECK POOR CONTACT. Is there poor contact in trans- Repair the poor Contact with your
Check poor contact in transmission harness mission harness connector? contact in trans- Subaru distributor
connector. mission harness service.
connector.
EN-275
CC:DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
cardiagn.com
4
B135 ECM
EN0889
Step Check Yes No

1 CHECK DRIVING CONDITION. Is the AT shift control function- Go to step 2. Replace the TCM.
1)Start and warm-up the engine until the radia- ing properly? <Ref. to AT-46,
tor fan makes one complete rotation. Transmission Con-
2)Drive the vehicle. trol Module
(TCM).>
EN-276
Step Check Yes No

2 CHECK ACCESSORY. Are the car phone and/or CB Repair the ground- Replace the TCM.
installed on vehicle? ing line of car <Ref. to AT-46,
phone or CB sys- Transmission Con-
tem. trol Module
(TCM).>
cardiagn.com
EN-277
CD:DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
cardiagn.com
4
B135 ECM
EN0889
EN-278
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Go to step 2. Even if MIL lights
TCM CONNECTOR. up, the circuit has
1)Turn the ignition switch to ON. returned to a nor-
2)Measure the voltage between ECM and mal condition at
chassis ground. this time.
(B135) No. 4 (+) — Chassis ground (−): In this case, repair
the following:
• Poor contact in
ECM connector
• Poor contact in
TCM connector
TCM CONNECTOR. Ω? short circuit in har-
2)Disconnect the connector from ECM and ECM and TCM
TCM. connector.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 V? Go to step 4. Repair the poor
cardiagn.com
1)Connect the connector to ECM. contact in ECM
2)Turn the ignition switch to ON. connector.
chassis ground.
4 CHECK TROUBLE CODE FOR AUTOMATIC Does the DTC appear for auto- Inspect the DTC Replace the TCM.
TRANSMISSION. matic transmission? for automatic <Ref. to AT-46,
Read the DTC for automatic transmission. transmission. Transmission Con-
<Ref. to AT-22, Read Diagnostic Trouble Code <Ref. to AT-42, trol Module
(DTC).> Diagnostic Proce- (TCM).>
dure with Diagnos-
tic Trouble Code
(DTC).>
EN-279
CE:DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
cardiagn.com
4
B135 ECM
EN0889
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair battery Go to step 2.
TCM CONNECTOR. short circuit in har-
1)Turn the ignition switch to ON. ness between
2)Measure the voltage between ECM and ECM and TCM
chassis ground. connector.
EN-280
Step Check Yes No

2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 5. Go to step 3.
TCM CONNECTOR.
and chassis ground.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Repair the poor Go to step 4.
TCM CONNECTOR. contact in ECM
Measure the voltage between ECM connector connector.
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change from Even if MIL lights Contact with your
Measure the voltage between ECM and chas- 1 V to 4 V while monitoring the up, the circuit has Subaru distributor
sis ground. value with voltage meter? returned to a nor- service.
Connector & terminal mal condition at NOTE:
(B135) No. 4 (+) — Chassis ground (−): this time. Inspection by DTM
NOTE: is required, be-
In this case, repair cause probable
the following: cause is deteriora-
• Poor contact in tion of multiple
ECM connector parts.
cardiagn.com
• Poor contact in
TCM connector
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 6. Repair the open
TCM CONNECTOR. circuit in harness
Measure the voltage between TCM and chas- between ECM and
sis ground. TCM connector.
6 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Check the TCM
Check poor contact in TCM connector. connector? contact in TCM power supply line
connector. and grounding
line.
EN-281
CF:DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B55 TCM 19 20 21 22 23 24
10
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
cardiagn.com
31
B134 ECM
EN0890
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 V? Repair the poor Go to step 2.
1)Start the engine and warm-up engine. contact in ECM
2)Turn the ignition switch to OFF. connector.
chassis ground.
EN-282
Step Check Yes No

2)Disconnect the connectors from ECM and ECM and TCM
TCM. connector.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the poor Repair the open
TCM CONNECTOR. Ω? contact in ECM or circuit in harness
Measure the resistance of harness between TCM connector. between ECM and
ECM and TCM connector. TCM connector.
(B134) No. 31 — (B55) No. 10:
cardiagn.com
EN-283
CG:DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B55 TCM 19 20 21 22 23 24
10
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
cardiagn.com
31
B134 ECM
EN0890
EN-284
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 V? Go to step 2. Repair the battery
1)Start the engine and warm-up engine. short circuit in har-
3)Disconnect the connector from TCM. ECM and TCM
4)Turn the ignition switch to ON. connector. After
5)Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to FU-
Connector & terminal 51, Engine Con-
(B134) No. 31 (+) — Chassis ground (−): trol Module.>
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change more Repair the battery Contact with your
TCM CONNECTOR. than 10 V by shaking harness short circuit in har- Subaru distributor
1)Turn the ignition switch to OFF. and connector of ECM while ness between service.
2)Measure the voltage between ECM and monitoring the value with volt- ECM and TCM NOTE:
chassis ground. age meter? connector. After Inspection by DTM
Connector & terminal repair, replace the is required, be-
(B134) No. 31 (+) — Chassis ground (−): ECM. <Ref. to FU- cause probable
51, Engine Con- cause is deteriora-
trol Module.> tion of multiple
parts.
cardiagn.com
EN-285
CH:DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION —
CAUTION:
• WIRING DIAGRAM:
B94
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B94 CCM
3
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
cardiagn.com
22
B55 TCM
EN1422
EN-286
Step Check Yes No

1 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 2. Repair the open
CCM CONNECTOR. Ω? circuit in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(B55) No. 22 — (B94) No. 3:
2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 10 Repair the short Go to step 3.
CCM CONNECTOR. Ω? circuit in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. CCM connector.
3 CHECK INPUT SIGNAL FOR TCM. Is the resistance less than 1 V? Go to step 4. Check the cruise
1)Connect the connector to TCM and CCM. control command
2)Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-6,
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
cardiagn.com
3)Start the engine. Switch.>
4)Cruise control main switch to ON.
5)Move the selector lever to “D” range and
slowly increase vehicle speed to 50 km/h (31
MPH).
6)Cruise control command switch to ON.
7)Measure the voltage between TCM and
chassis ground.
trol Module
(TCM).>
EN-287
CI: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC-

TION —
• Excessive shift shock
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
5
B135
1 2 3 4 5 6 7
cardiagn.com
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
16
B135 ECM
EN0892
Step Check Yes No

chassis ground.
EN-288
Step Check Yes No

Connector & terminal ECM and TCM
(B135) No. 16 (+) — Chassis ground (−): connector.
Module.>
TCM CONNECTOR. Ω? circuit in harness
2)Disconnect the connectors from ECM and TCM connector.
TCM.
ECM and TCM connector.
(B135) No. 16 — (B56) No. 5:
ECM and chassis ground. ECM and TCM
cardiagn.com
trol Module
(TCM).>
EN-289
CJ:DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC-

TION —
• Excessive shift shock
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
14
B135
1 2 3 4 5 6 7
cardiagn.com
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
17
B135 ECM
EN0893
Step Check Yes No

chassis ground.
EN-290
Step Check Yes No

Connector & terminal ECM and TCM
(B135) No. 17 (+) — Chassis ground (−): connector.
Module.>
TCM CONNECTOR. Ω? circuit in harness
2)Disconnect the connectors from ECM and TCM connector.
TCM.
ECM and TCM connector.
(B135) No. 17 — (B56) No. 14:
ECM and chassis ground. ECM and TCM
cardiagn.com
trol Module
(TCM).>
EN-291
GENERAL DIAGNOSTIC TABLE
20.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME-95, Engine Trouble in General.>
Symptom Problem parts
1) Idle air control solenoid valve
2) Intake air temperature and pressure sensor
3) Ignition parts (*1)
1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
3) Engine coolant temperature sensor (*2)
5) Air intake system (*5)
2. Rough idling 6) Fuel injection parts (*4)
7) Throttle position sensor
cardiagn.com
10) Oxygen sensor
11) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3. Engine does not return to idle. 3) Accelerator cable (*6)
4. Poor acceleration
8) A/C switch and A/C cut relay
9) Engine torque control signal circuit
5. Engine stalls or engine sags or hesitates at 4) Camshaft position sensor (*3)
acceleration. 5) Purge control solenoid valve
1) Intake manifold pressure sensor
2) Intake air temperature sensor
6. Surge 5) Crankshaft position sensor (*3)
EN-292
Symptom Problem parts

7. Spark knock 4) Engine coolant temperature sensor
5) Knock sensor
8. After burning in exhaust system
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
2. AUTOMATIC TRANSMISSION
NOTE:
cardiagn.com
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to AT-2, Ba-
sic Diagnostic Procedure.>
EN-293
cardiagn.com
EN-294

ENGINE+1+SECTION Subaru

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ENGINE+1+SECTION Subaru

Uploaded by

Copyright:

Available Formats

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

FUEL INJECTION (FUEL SYSTEMS) FU

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G1840GE2

2. AIR INTAKE SYSTEM

3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS

(8) (10) (11)

(9) (11) (12)

(1) (1) (10)

6. FUEL FILLER PIPE

C: CAUTION • Be careful not to burn your hands, because each

G6M0095 (A) Throttle position sensor

7) Disconnect the engine coolant hoses from throt-

3) Disconnect the accelerator cable (A).

8) Remove the bolts which install throttle body to

(4) Remove the bolts which install power steer-

4) Remove the air intake duct and air cleaner as-

(5) Disconnect the connector from power steer-

7) Remove the power steering pump and tank from

8) Disconnect the spark plug cords from spark B2M4260

2) Connect the fuel hoses. 6) Connect the knock sensor connector.

7) Connect the connectors to engine coolant tem-

3) Connect the connector to camshaft position sen-

8) Install the air cleaner case stay RH and engine

4) Connect the connector to oil pressure switch.

9) Connect the brake booster hose.

5) Connect the connector to crankshaft position

11) Connect the PCV hose to intake manifold.

(4) Install the power steering pipes onto right

12) Connect the spark plug cords to spark plugs.

(2) Connect the connector to power steering

14) Connect the accelerator cable (A).

15) Connect the cruise control cable (B). (With C: DISASSEMBLY

sembly. 2) Disconnect the connector from ignition coil and

3) Remove the ignition coil and ignitor assembly.

18) Connect the battery ground cable to battery.

4) Disconnect the connector from intake air tem-

9) Disconnect the connector from air assist injector

19) Remove the engine harness from intake mani-

D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe,

6) Connect the air assist hoses.

3) Connect the right side fuel hose to injector pipe,

4) Install the fuel injector pipe.

18) Connect the pressure regulator vacuum hose

24) Connect the air by-pass hose to throttle body.

20) Connect the air by-pass hoses to air assist so-

25) Install the intake air temperature and pressure

26) Connect the connector to intake air tempera-

28) Connect the connector to ignition coil and igni-

4. Engine Coolant Temperature B: INSTALLATION

2) Remove the air intake duct and air cleaner as-

4) Remove the engine coolant temperature sensor.

5. Crankshaft Position Sensor B: INSTALLATION

3) Remove the crankshaft position sensor, and dis-

3) Remove the bolt which installs camshaft position

4) Remove the bolt which installs camshaft position

7. Knock Sensor B: INSTALLATION

2) Remove the air cleaner case.

2) Connect the knock sensor connector.

3) Disconnect the knock sensor connector.

3) Install the air cleaner case.

4) Remove the knock sensor from cylinder block.

4) Connect the battery ground cable to battery.