Subaru Legacy MY05-09 Service Manual Complete

2004 Model Year
PDF S e rvi c e M a n u a l
GENERAL INFORMATION SECTION (Pub.No.G2320GE1)
ENGINE SECTION 1 (Pub.No.G2320GE2)
TRANSMISSION SECTION (Pub.No.G2320GE5)
CHASSIS SECTION (Pub.No.G2320GE6)
BODY SECTION (Pub.No.G2320GE7)
WIRING SYSTEM SECTION (Pub.No.G2320GE8)

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
FOREWORD FW
HOW TO USE THIS MANUALS HU
SPECIFICATIONS SPC
PRECAUTION PC
This service manual has been prepared
to provide SUBARU service personnel
NOTE NT
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. IDENTIFICATION ID
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of RECOMMENDED MATERIALS RM
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual PRE-DELIVERY INSPECTION PI
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. PERIODIC MAINTENANCE SERVICES PM
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G2320GE1

FOREWORD
FW
Page
1. Foreword....................................................................................................2
Foreword
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair, or diagnosis of Subaru LEGACY.
Applied model:
BL*****, BP***** from 2004MY
The manuals contain the latest information at the

time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2
HOW TO USE THIS MANUALS
HU
Page
1. How to Use This Manuals ...........................................................................2
How to Use This Manuals
1. How to Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
the diagnostic information has also been added
where necessary.
2. CONTENTS
The first page has an index with tabs.
HU-2
3. COMPONENT
Illustrations are provided for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol.
To order parts, refer to parts catalogue.
Example:
T2
(3) (6)
T3
(7)
(5) T3
(4)
(2)
(8)
T8 T1 (1) (20)
T2 (21) T3
T6 (5)
T10 T2
T5 (1) T3
(2)
(12) (22) (23) T3
(6) (9) (14) (16)
T4 (18)
(10)
(3) (11) T1
(4) (4) (11)
(13)
(10) (15)
(9) T2
(17)
(19)
T6
(4) (10) T4
(3)
(4)
(7) (15)
T2
T11 T6 (22) T5
(3) (12) (35)
T4 (34)
T5
(8) (27) T3
(10) T2
(26)
(23) (24)
T2 (14) (25)
T7
(24)
(36)
(25)
(13) (31)
(30)
T2 T5
(10) (29) (37) (33)
(17) (28) (32)
(16)
(18)
T4
T3 T1
:Selective part
T1 :Replacement part
(21)
:Sealing point
:Should be lubricated with oil.
(20) :Should be lubricated with grease.

T9 (19)
T1 , T2 .... :Tightening torque
HU-00017
HU-3
4. SPECIFICATION
If necessary, specifications are also included.
5. INSPECTION
Inspections to be carried out before and after maintenance are included.
6. MAINTENANCE
• Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also
describes the use of special tool, tightening torque, caution for each procedure.
• If many serviceable parts are included in one service procedure, appropriate reference is provided for each
parts.
Example:
15.Main Shaft Assembly for Sin- (A)
gle-Range
A: REMOVAL (B)
1) Remove the manual transmission assembly
from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
(C)
11) Tighten the lock nuts to the specified torque us-

ing ST1 and ST2.
NOTE: (D)
Secure the lock nuts in two Places affer tightening.
ST2 499987003 SOCKET WRENCH
ST1 498937000 TRANSMISSION HOLDER
(E) (F)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb) (G)
(H)
ST2 ST1
HU-00020
(A) Component (D) Cautions (G) Tightening torque

(B) Process (E) Tool number of special tool (H) Illustration
(C) Reference (F) Name of special tool
HU-4
7. DIAGNOSIS
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to
the SI units. Metric and yard/pound measurements
are also included.
Example:
Tightening torque:
44 N!m (4.5 kgf-m, 33 ft-lb)
Item SI units Conventional unit Remarks
Force N (Newton) kgf 1 kgf = 9.80655 N
Mass (Weight) kg, g kg, g
Capacity 2, m2 or cm3 2 or cc 1 cc = 1 cm3 = 1 m2
Torque N!m kgf-m, kgf-cm 1 kgf-m = 9.80655 N!m
Rotating speed rpm rpm
Pressure kPa (kilopascal) kgf/cm2 1 kgf/cm2 = 98.0655 kPa
mmHg 1 mmHg = 0.133322 kPa
Power W PS 1 PS = 0.735499 kW
Calorie W!h cal 1 kcal = 1.16279 W!h
Fuel consumption rate g/kw!h g/PS!h 1 g/PS!h=1.3596 g/kW!h
The figure used in these manuals are described in the SI units and conventional units are described in ( ).
HU-5
9. EXPLANATION OF TERMINOLOGY
• List
AAI : Air Assist Injection M/B : Main Fuse & Relay Box
A/B : Airbag MD : Mini Disc
ABS : Antilock Brake System MPI : Multi Point Injection
A/C : Air Conditioner MP-T : Multi-Plate Transfer
A/F : Air Fuel Ratio MT : Manual Transmission
ALT : Generator Non-turbo : Natural Aspiration
ASSY : Assembly NC : Normal Close (Relay)
AT : Automatic Transmission NO : Normal Open (Relay)
ATF : Automatic Transmission Fluid OP : Option Parts
BATT : Battery P/S : Power Steering
CD-R/RW : CD Recordable/Rewritable P/W : Power Window
CPU : Central Processing Unit PCD : Pitch Circle Diameter
DOHC : Double Overhead Camshaft PCV : Positive Crankcase Ventilation
DVD : Digital Versatile Disc RH : RH (Right Hand)
ECM : Engine Control Module (ECM) Rr : Rear
EGR : Exhaust Gas Recirculation SOHC : Single Overhead Camshaft
ELR : Emergency Locking Retractor SRS : Supplemental Restraint System
EX : Exhaust SSM : Subaru Select Monitor
F/B : Fuse & Joint Box ST : Special Tool
FL : Fusible Link SW : Switch
Ft : Full-time AWD TCS : Traction Control System
FWD : Front Wheel Drive TGV : Tumble Generated Valve
GPS : Global Positioning System T/M : Transmission
H/U : Hydraulic Unit ViS-C : Viscous Coupling
IG : Ignition VSV : Vacuum Switching Valve
INT : Intermittent VTD : Variable Torque Distribution
ISC : Idle Speed Control W/H : Wiring Harness
LH : LH (Left Hand) Pr : Primary
LSD : Limited Slip Differential 2ndr : Secondary
HU-6
SPECIFICATIONS
SPC
Page
1. LEGACY......................................................................................................2
LEGACY
SPECIFICATIONS
1. LEGACY
A: DIMENSION
1. SEDAN MODEL
Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC
Overall length mm (in) 4,665 (183.7)
Overall width mm (in) 1,730 (68.1)
Overall height (at C.W.) mm (in) 1,425 (56.1)
Length mm (in) 1,900 (74.8)
Compartment Width mm (in) 1,445 (56.9)
Height mm (in) 1,165 (45.9), 1,100 (43.3)★1
Wheelbase mm (in) 2,670 (105.1)
Front mm (in) 1,495 (58.9)
Tread
Rear mm (in) 1,490 (58.7)
Minimum road clearance mm (in) 150 (5.9)
★1:
With sunroof
2. WAGON MODEL
Length mm (in) 1,840 (72.4)
Height mm (in) 1,190 (46.9), 1,145 (45.1)★1
Front mm (in) 1,495 (58.9)
Tread
Rear mm (in) 1,485 (58.5)
Minimum road clearance mm (in) 150 (5.9) 155 (6.1) 150 (5.9)
★1:
With sunroof
3. OUTBACK MODEL
Model 2.0 L SOHC 3.0 L DOHC
Length mm (in) 1,840 (72.4)
Height mm (in) 1,190 (46.9), 1,145 (45.1)★1
Front mm (in) 1,495 (58.9)
Tread
Rear mm (in) 1,485 (58.5)
Minimum road clearance mm (in) 200 (7.9)
★1:
With sunroof
SPC-2
LEGACY
SPECIFICATIONS
B: ENGINE
Horizontally
opposed, liquid
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gas-
Engine type cooled, 6-cylin-
oline engine
der, 4-stroke gas-
oline engine
Valve arrangement Overhead camshaft
99.5 " 79.0 89.2 " 80.0
Bore " Stroke mm (in) 92 " 75 (3.62 " 2.95)
(3.917 " 3.110) (3.512 " 3.150)
Displacement cm3 (cu in) 1,994 (121.67) 2,457 (149.9) 3,000 (183.06)
Compression ratio 10.0 9.5 10.0 10.7
1—6—3—2—
Ignition order 1—3—2—4
5—4
Idle speed at Park or Neutral
rpm 650 650 650 650
position
Maximum output kW (PS)/rpm 101 (137)/5,600 180 (245)/6,400 121 (165)/5,600 180 (245)/6,600
187 (19.1, 137.9)/ 310 (31.6, 228.6)/ 226 (23.0, 166.7)/ 297 (30.3, 219.1)/
Maximum torque N!m (kgf-m, ft-lb)/rpm
4,400 2,400 4,400 4,200
C: ELECTRICAL
Ignition timing (at idling) BTDC 13# 14# 13# 15#
CHAMPION:
CHAMPION: RC10YC4
Spark plug Type and manufacturer NGK:ILFR6B NGK: NGK:ILFR6B
RC10YC4
PFR5B-11★1
Generator 12V — 110A
12V — 48AH 12V — 48AH
EC, MT — —
(55D23L) (55D23L)
EK,
K4 12V — 52AH 12V — 52AH 12V — 52AH
Type and AT —
(65D23L) (75D23L) (75D23L)
Battery capacity
(5HR) 12V — 48AH
KA —
(55D23L) 12V — 27AH 12V — 48AH
12V — 27AH (34B19L) (55D23L)
KS —
(34B19L)
★1
: EC, EK model
SPC-3
LEGACY
SPECIFICATIONS
D: TRANSMISSION
SEDAN, WAGON
Model 2.0 L
3.0 L
2.0 L SOHC DOHC 2.5 L SOHC
DOHC
turbo
Transmission type 4AT 5MT 5AT 4AT 5MT 5AT
Clutch type TCC DSPD TCC TCC DSPD TCC
1st 2.785 3.454 3.540 2.785 3.454 3.540
2nd 1.545 1.947 2.264 1.545 2.062 2.264
3rd 1.000 1.366 1.471 1.000 1.448 1.471
Gear ratio 4th 0.694 0.972 1.000 0.694 1.088 1.000
0.825,
5th — 0.738 0.834 — 0.834
0.780★1
Rev. 2.272 3.333 2.370 2.272 3.333 2.370
Auxiliary transmission gear High — 1,000 — — 1,000 —
ratio★2 Low — 1,447 — — 1,196 —
1st reduc- Type of gear Helical — Helical Helical — Helical
tion Gear ratio 1.000 — 1.000 1.000 — 1.000
Reduction gear
Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
(Front) Final
3.700,
reduction Gear ratio 4.111 4.111 3.272 4.111 3.083
4.111★1
Transfer Type of gear — Helical — — Helical —
reduction Gear ratio — 1.000 — — 1.000 —
Reduction gear
Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
(Rear) Final
3.700,
reduction Gear ratio 4.111 4.111 3.272 4.111 3.083
4.111★1
OUTBACK
Model 3.0 L
2.5 L SOHC
DOHC
Transmission type 4AT 5MT 5AT
Clutch type TCC DSPD TCC
1st 2.785 3.454 3.540
2nd 1.545 2.062 2.264
3rd 1.000 1.448 1.471
Gear ratio
4th 0.694 1.088 1.000
5th — 0.825 0.834
Rev. 2.272 3.333 2.370
Auxiliary transmission gear High — 1,000 —
ratio★2 Low — 1,196 —
1st reduc- Type of gear Helical — Helical
tion Gear ratio 1.000 — 1.000
Reduction gear
Type of gear Hypoid Hypoid Hypoid
(Front) Final
3.900,
reduction Gear ratio 4.444 3.272
4.111★1
Transfer Type of gear — Helical —
reduction Gear ratio — 1.000 —
Reduction gear
Type of gear Hypoid Hypoid Hypoid
(Rear) Final
3.900,
reduction Gear ratio 4.444 3.272
4.111★1
5MT: 5-forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
SPC-4
LEGACY
SPECIFICATIONS
5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse

DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
★1
: KA, K4 model
★2
: Dual range model only
E: STEERING
SEDAN, WAGON
Model
2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC
Type Rack and Pinion
Turns, lock to lock 3.2 2.8 3.2 2.8
Center of tire
Minimum turning width to center of 10.8 (35.4)
m (ft) tire width
diameter
Wall to wall 11.6 (38.1)
OUTBACK
Model
2.5 L SOHC 3.0 L DOHC
Type Rack and Pinion
Turns, lock to lock 3.2
Center of tire
Minimum turning width to center of 10.8 (35.4)
m (ft) tire width
diameter
Wall to wall 11.6 (38.1)
F: SUSPENSION
Front Macpherson strut type suspension
Rear Multi-link type suspension
G: BRAKE
Model Except for 2.0 L DOHC turbo 2.0 L DOHC turbo
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Ventilated disc brake
Parking Brake Mechanical on rear brakes
H: TIRE
SEDAN, WAGON OUTBACK
Model 2.0 L DOHC
2.0 L SOHC 2.5 L SOHC 3.0 L DOHC 2.5 L SOHC 3.0 L DOHC
turbo
16 " 6 1/2JJ
Wheel size 16 " 6 1/2JJ 17 " 7JJ 17 " 7JJ 16 " 6 1/2JJ 17 " 7JJ
17 " 7JJ
215/60 R16 95V 215/55 R17 94V
205/55 R16 89V 215/60 R16 215/55 R17
Tire size 205/55 R16 89V 215/45 R17 87W 215/45 R17 87W
215/45 R17 87W
95H★1 93H★1
Type Steel belted radial, Tubeless
★1:
KA model
SPC-5
LEGACY
SPECIFICATIONS
I: CAPACITY
2.0 L SOHC 2.0 L DOHC turbo
Model 4AT 5MT
5AT
LHD RHD LHD RHD
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1)
Capacity (at
2 (US qt, Imp qt) 4.5 (4.8, 4.0) 5.0 (5.3, 4.4)
overhaul)
Engine oil Filling
amount of
2 (US qt, Imp qt) 4.0 (4.2, 3.5)
engine oil
(at replace)
3.5 (3.7, 3.1)
Transmission gear oil 2 (US qt, Imp qt) — —
4.0 (4.2, 3.5)★2
ATF 2 (US qt, Imp qt) 8.4 (8.9, 7.4) — 9.8 (10.4, 8.6)
Front differential gear oil 2 (US qt, Imp qt) 1.2 (1.3, 1.1) — 1.4 (1.5 1.2)
Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
Power steering fluid 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
6.3 6.4
(6.7, 5.5) (6.8, 5.6) 6.4 6.5
Engine coolant 2 (US qt, Imp qt) 6.7 6.8 7.3 (7.7, 6.4)
(6.8, 5.6) (6.9, 5.7)
(7.1, 5.9)★1 (7.2, 6.0)★1

Model 4AT 5MT 5AT
LHD RHD LHD RHD LHD RHD
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1)
Capacity (at
2 (US qt, Imp qt) 4.5 (4.8, 4.0) 7.2 (7.6, 6.3)
overhaul)
Engine oil Filling
amount of
2 (US qt, Imp qt) 4.0 (4.2, 3.5) Approx. 5.5 (5.8, 4.8)
engine oil
(at replace)
3.5 (3.7, 3.1)
Transmission gear oil 2 (US qt, Imp qt) — —
4.0 (4.2, 3.5)★2
ATF 2 (US qt, Imp qt) 9.3 (9.8, 8.2) — 9.8 (10.4, 8.6)
Front differential gear oil 2 (US qt, Imp qt) 1.2 (1.3, 1.1) — 1.4 (1.5, 1.2)
Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
Power steering fluid 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
6.3 6.4 7.2 (7.6, 6.3)
(6.7, 5.5) (6.8, 5.6) 6.4 6.5
Engine coolant 2 (US qt, Imp qt) 6.7 6.8 7.7 7.8
(6.8, 5.6) (6.9, 5.7) ★1
(7.1, 5.9)★1
(7.2, 6.0)★1 (8.1, 6.7) (8.2, 6.9)★1
★1
: With ATF cooler (with warmer function)
★2:
Dual range model only
SPC-6
LEGACY
SPECIFICATIONS
J: WEIGHT
1. SEDAN MODEL
• LHD model
Option code★1 EC
2.0 L SOHC
AWD
Model
2.0 i
5MT (Single range)
Front kgf (lb) 740 (1,631) 755 (1,664) 760 (1,676) 760 (1,676) 765 (1,686) 775 (1,709)
Curb weight
Rear kgf (lb) 590 (1,301) 590 (1,301) 590 (1,301) 590 (1,301) 605 (1,334) 615 (1,356)
(C.W.)
Total kgf (lb) 1,330 (2,932) 1,345 (2,965) 1,350 (2,976) 1,350 (2,976) 1,370 (3,020) 1,390 (3,064)
Maximum Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
permissible
axle weight Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible Total kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control — — — ❍ ❍ ❍
McIntosh audio — — — — — —
Leather interior — — — — — —
Winter pack — — — ❍ ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire — — — — — ❍
A/C — ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — — — — ❍ ❍
Sunroof — — — — ❍ ❍
Navigation system — — ❍ — — ❍
Self levelizer — — — — — —
★1:
For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-7
LEGACY
SPECIFICATIONS
Option code★1 EC
2.0 L SOHC
AWD
Model
2.0 i
4AT
Front kgf (lb) 760 (1,676) 775 (1,709) 780 (1,720) 780 (1,720) 785 (1,731) 795 (1,753)
Curb weight
Rear kgf (lb) 590 (1,301) 590 (1,301) 590 (1,301) 590 (1,301) 605 (1,334) 615 (1,356)
(C.W.)
Total kgf (lb) 1,350 (2,976) 1,365 (3,009) 1,370 (3,020) 1,370 (3,020) 1,390 (3,064) 1,410 (3,109)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
15 inch tire — — — — — —
Option
17 inch tire — — — — — ❍
A/C — ❍ ❍ ❍ ❍ ❍
Sunroof — — — — ❍ ❍
★1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-8
LEGACY
SPECIFICATIONS
Option code★1 EC
2.5 L SOHC
AWD
Model
2.5 i
5MT (Single range)
Front kgf (lb) 760 (1,676) 770 (1,698) 765 (1,686) 770 (1,698) 765 (1,686) 775 (1,709)
Curb weight
Rear kgf (lb) 600 (1,323) 605 (1,334) 600 (1,323) 605 (1,334) 605 (1,334) 610 (1,345)
(C.W.)
Total kgf (lb) 1,360 (2,998) 1,375 (3,031) 1,365 (3,009) 1,375 (3,031) 1,370 (3,020) 1,385 (3,053)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control ❍ ❍ ❍ ❍ ❍ ❍
Leather interior — — — — ❍ ❍
Winter pack — — — — ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire — ❍ — ❍ — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — — — — — —
Sunroof — — — — — —
Navigation system — — ❍ ❍ ❍ ❍
SPC-9
LEGACY
SPECIFICATIONS
Option code★1 EC
2.5 L SOHC
AWD
Model
2.5 i
5MT (Single range) 4AT
Front kgf (lb) 775 (1,709) 780 (1,720) 785 (1,731) 780 (1,720) 790 (1,742) 785 (1,731)
Curb weight
Rear kgf (lb) 615 (1,356) 625 (1,378) 625 (1,378) 600 (1,323) 605 (1,334) 600 (1,323)
(C.W.)
Total kgf (lb) 1,390 (3,064) 1,405 (3,097) 1,410 (3,109) 1,380 (3,042) 1,395 (3,075) 1,385 (3,053)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Leather interior ❍ ❍ ❍ — — —
Winter pack ❍ ❍ ❍ — — —
15 inch tire — — — — — —
Option
17 inch tire — ❍ ❍ — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag ❍ ❍ ❍ — — —
Sunroof ❍ ❍ ❍ — — —
SPC-10
LEGACY
SPECIFICATIONS
Option code★1 EC
2.5 L SOHC
AWD
Model
2.5 i
4AT
Front kgf (lb) 790 (1,742) 785 (1,731) 795 (1,753) 800 (1,764) 805 (1,774) 805 (1,774)
Curb weight
Rear kgf (lb) 605 (1,334) 605 (1,334) 610 (1,345) 615 (1,356) 625 (1,378) 625 (1,378)
(C.W.)
Total kgf (lb) 1,395 (3,075) 1,390 (3,064) 1,405 (3,097) 1,415 (3,120) 1,430 (3,153) 1,430 (3,153)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — ❍ ❍ ❍
Control
Leather interior — ❍ ❍ ❍ ❍ ❍
Winter pack — ❍ ❍ ❍ ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire ❍ — ❍ — ❍ ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — — — ❍ ❍ ❍
Sunroof — — — ❍ ❍ ❍
Navigation system ❍ ❍ ❍ — — ❍
SPC-11
LEGACY
SPECIFICATIONS
Option code★1 EC
3.0 L DOHC
AWD
Model
3.0 R, 3.0 R-A
5AT
Front kgf (lb) 875 (1,929) 880 (1,940) 890 (1,962) 890 (1,962)
Curb weight
Rear kgf (lb) 625 (1,378) 630 (1,389) 635 (1,400) 635 (1,400)
(C.W.)
Total kgf (lb) 1,495 (3,296) 1,510 (3,329) 1,525 (3,362) 1,525 (3,362)
Maximum Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
permissible
axle weight Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible Total kgf (lb) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475)
weight (M.P.W.)
Vehicle Dynamics
— ❍ ❍ ❍
Control
Cruise control ❍ ❍ ❍ ❍
McIntosh audio — — — —
Leather interior ❍ ❍ ❍ ❍
Winter pack ❍ ❍ ❍ ❍
15 inch tire — — — —
Option
17 inch tire — — — —
A/C ❍ ❍ ❍ ❍
Side airbag ❍ ❍ ❍ ❍
Curtain airbag — — ❍ ❍
Sunroof — — ❍ ❍
Navigation system — — — ❍
Self levelizer — — — —
SPC-12
LEGACY
SPECIFICATIONS
Option code★1 K4 KS K4
2.0 L SOHC
AWD
Model
2.0 i
Front kgf (lb) 750 (1,653) 740 (1,631) 755 (1,664) 750 (1,653) 760 (1,676) 770 (1,698)
Curb weight
Rear kgf (lb) 590 (1,301) 590 (1,301) 590 (1,301) 590 (1,301) 600 (1,323) 590 (1,301)
(C.W.)
Total kgf (lb) 1,340 (2,954) 1,330 (2,932) 1,345 (2,965) 1,340 (2,954) 1,360 (2,998) 1,360 (2,998)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control — — ❍ — — —
Winter pack — — — — — —
15 inch tire — — — — — —
Option
17 inch tire — — — — — —
A/C ❍ — ❍ ❍ ❍ ❍
Side airbag — — ❍ — — —
Sunroof — — — — ❍ —
Navigation system — — — — — —
SPC-13
LEGACY
SPECIFICATIONS
Option code★1 K4 KS K4 KS
2.0 L SOHC 2.5 L SOHC
AWD
Model
2.0 i 2.5 i
4AT 5MT (Single range)
Front kgf (lb) 775 (1,709) 770 (1,698) 780 (1,720) 770 (1,698) 775 (1,709) 760 (1,676)
Curb weight
Rear kgf (lb) 590 (1,301) 590 (1,301) 595 (1,312) 610 (1,345) 620 (1,367) 595 (1,312)
(C.W.)
Total kgf (lb) 1,365 (3,009) 1,360 (2,998) 1,375 (3,031) 1,380 (3,042) 1,395 (3,075) 1,355 (2,987)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control ❍ — — ❍ ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire — — — — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag ❍ — — ❍ ❍ —
Curtain airbag — — — ❍ ❍ —
Sunroof — — ❍ ❍ ❍ —
SPC-14
LEGACY
SPECIFICATIONS
Option code★1 KS K4
AWD
Model
2.5 i
Front kgf (lb) 770 (1,698) 770 (1,698) 790 (1,742) 795 (1,753) 795 (1,753) 800 (1,764)
Curb weight
Rear kgf (lb) 605 (1,334) 610 (1,345) 610 (1,345) 620 (1,367) 615 (1,356) 625 (1,378)
(C.W.)
Total kgf (lb) 1,375 (3,031) 1,380 (3,042) 1,400 (3,086) 1,415 (3,120) 1,410 (3,109) 1,425 (3,142)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — ❍ ❍ — —
Control
Cruise control ❍ ❍ — — ❍ ❍
Leather interior — ❍ — — ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire — — — ❍ — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — — ❍ ❍ ❍ ❍
Curtain airbag — — ❍ ❍ ❍ ❍
Sunroof ❍ ❍ ❍ ❍ ❍ ❍
SPC-15
LEGACY
SPECIFICATIONS
AWD
Model
2.5 i 3.0 R, 3.0 R-A
4AT 5AT
Front kgf (lb) 780 (1,720) 790 (1,742) 790 (1,742) 890 (1,962) 880 (1,940)
Curb weight
Rear kgf (lb) 595 (1,312) 605 (1,334) 610 (1,345) 635 (1,400) 635 (1,400)
(C.W.)
Total kgf (lb) 1,375 (3,031) 1,395 (3,075) 1,400 (3,086) 1,525 (3,362) 1,515 (3,340)
Maximum Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
permissible
axle weight Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible Total kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 2,030 (4,475) 2,030 (4,475)
weight (M.P.W.)
Vehicle Dynamics
— — — ❍ —
Control
Cruise control ❍ ❍ ❍ ❍ ❍
McIntosh audio — — — — —
Leather interior — — ❍ ❍ ❍
Winter pack — — — — —
15 inch tire — — — — —
Option
17 inch tire — — — — —
A/C ❍ ❍ ❍ ❍ ❍
Side airbag — — — ❍ ❍
Curtain airbag — — — ❍ ❍
Sunroof — ❍ ❍ ❍ ❍
Navigation system — — — — —
Self levelizer — — — — —
SPC-16
LEGACY
SPECIFICATIONS
• RHD model
Option code★1 EK
2.0 L SOHC
AWD
Model
2.0 i
Front kgf (lb) 755 (1,664) 760 (1,676) 770 (1,698) 775 (1,709) 775 (1,709) 780 (1,720)
Curb weight
Rear kgf (lb) 590 (1,301) 590 (1,301) 605 (1,334) 610 (1,345) 590 (1,301) 590 (1,301)
(C.W.)
Total kgf (lb) 1,345 (2,965) 1,350 (2,976) 1,375 (3,031) 1,385 (3,053) 1,365 (3,009) 1,370 (3,020)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control — — — — — —
15 inch tire — — — — — —
Option
17 inch tire — — — ❍ — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — ❍ ❍ ❍ — ❍
Curtain airbag — — ❍ ❍ — —
Sunroof — — ❍ ❍ — —
★1:
SPC-17
LEGACY
SPECIFICATIONS
Option code★1 EK
AWD
Model
2.0 i 2.5 i
4AT 5MT (Single range)
Front kgf (lb) 790 (1,742) 795 (1,753) 760 (1,676) 765 (1,686) 770 (1,698) 775 (1,709)
Curb weight
Rear kgf (lb) 605 (1,334) 610 (1,345) 600 (1,323) 600 (1,323) 605 (1,334) 620 (1,367)
(C.W.)
Total kgf (lb) 1,395 (3,075) 1,405 (3,097) 1,360 (2,998) 1,365 (3,009) 1,375 (3,031) 1,395 (3,075)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control — — — — — ❍
Leather interior — — — — — ❍
Winter pack — — — — — ❍
15 inch tire — — — — — —
Option
17 inch tire — ❍ — — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ — ❍ ❍ ❍
Curtain airbag ❍ ❍ — — — ❍
Sunroof ❍ ❍ — — — ❍
SPC-18
LEGACY
SPECIFICATIONS
Option code★1 EK
2.5 L SOHC
AWD
Model
2.5 i
Front kgf (lb) 785 (1,731) 785 (1,731) 780 (1,720) 785 (1,731) 790 (1,742) 805 (1,774)
Curb weight
Rear kgf (lb) 625 (1,378) 625 (1,378) 600 (1,323) 600 (1,323) 610 (1,345) 615 (1,356)
(C.W.)
Total kgf (lb) 1,410 (3,109) 1,410 (3,109) 1,380 (3,042) 1,385 (3,053) 1,400 (3,086) 1,420 (3,131)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — ❍
Control
Cruise control ❍ ❍ — — — ❍
Leather interior ❍ ❍ — — — ❍
Winter pack ❍ ❍ — — — ❍
15 inch tire — — — — — —
Option
17 inch tire ❍ ❍ — — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ — ❍ ❍ ❍
Curtain airbag ❍ ❍ — — — ❍
Sunroof ❍ ❍ — — — ❍
Navigation system — ❍ — — — —
SPC-19
LEGACY
SPECIFICATIONS
Option code★1 EK
AWD
Model
2.5 i 3.0 R, 3.0 R-A
4AT 5AT
Front kgf (lb) 810 (1,785) 805 (1,774) 810 (1,785) 890 (1,962) 890 (1,962)
Curb weight
Rear kgf (lb) 620 (1,367) 620 (1,367) 620 (1,367) 635 (1,400) 635 (1,400)
(C.W.)
Total kgf (lb) 1,430 (3,153) 1,425 (3,142) 1,430 (3,153) 1,525 (3,362) 1,525 (3,362)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
❍ ❍ ❍ ❍ ❍
Control
Leather interior ❍ ❍ ❍ ❍ ❍
Winter pack ❍ ❍ ❍ ❍ ❍
15 inch tire — — — — —
Option
17 inch tire ❍ — ❍ — —
A/C ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ ❍ ❍ ❍
Curtain airbag ❍ ❍ ❍ ❍ ❍
Sunroof ❍ ❍ ❍ ❍ ❍
Navigation system — ❍ ❍ — ❍
SPC-20
LEGACY
SPECIFICATIONS
Option code★1 KA
2.0 L SOHC
AWD
Model
2.0 i
Front kgf (lb) 755 (1,664) 760 (1,676) 765 (1,687) 780 (1,720) 775 (1,709) 780 (1,720)
Curb weight
Rear kgf (lb) 590 (1,301) 590 (1,301) 595 (1,312) 610 (1,345) 590 (1,301) 590 (1,301)
(C.W.)
Total kgf (lb) 1,340 (2,954) 1,350 (2,976) 1,360 (2,998) 1,390 (3,064) 1,365 (3,009) 1,370 (3,020)
Unladen mass Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
mass (G.V.M.)
Vehicle Dynamics
— — — — — —
Control
Cruise control — ❍ ❍ ❍ — ❍
15 inch tire — — ❍ — — —
Option 17 inch tire — — — ❍ — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — — — ❍ — —
Curtain airbag — — — ❍ — —
Sunroof — — — ❍ — —
Grade up — — — — — —
★1:
SPC-21
LEGACY
SPECIFICATIONS
Option code★1 KA
2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC
AWD
Model
2.0 i 2.0 GT 2.5 i
4AT 5AT 5MT (Single range)
Front kgf (lb) 785 (1,731) 800 (1,764) 845 (1,863) 860 (1,896) 765 (1,687) 770 (1,698)
Curb weight
Rear kgf (lb) 595 (1,312) 610 (1,345) 615 (1,356) 635 (1,400) 600 (1,323) 605 (1,334)
(C.W.)
Total kgf (lb) 1,380 (3,042) 1,410 (3,109) 1,460 (3,219) 1,495 (3,296) 1,365 (3,009) 1,375 (3,031)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,900 (4,189) 1,900 (4,189) 2,000 (4,409) 2,000 (4,409) 1,930 (4,255) 1,930 (4,255)
mass (G.V.M.)
Vehicle Dynamics
— — — — — —
Control
McIntosh audio — — — ❍ — —
Leather interior — — — ❍ — —
15 inch tire ❍ — — — — —
Option 17 inch tire — ❍ — — — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — ❍ ❍ ❍ — —
Curtain airbag — ❍ — ❍ — —
Sunroof — ❍ — ❍ — —
Grade up — — — — — —
★1:
SPC-22
LEGACY
SPECIFICATIONS
Option code★1 KA
2.5 L SOHC
AWD
Model
2.5 i
Front kgf (lb) 775 (1,709) 780 (1,720) 785 (1,731) 785 (1,731) 790 (1,742) 795 (1,753)
Curb weight
Rear kgf (lb) 615 (1,356) 620 (1,367) 625 (1,378) 595 (1,312) 605 (1,334) 615 (1,356)
(C.W.)
Total kgf (lb) 1,390 (3,064) 1,400 (3,086) 1,410 (3,109) 1,380 (3,042) 1,395 (3,053) 1,410 (3,109)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
mass (G.V.M.)
Vehicle Dynamics
— — — — — —
Control
Leather interior — — ❍ — — —
Winter pack — — ❍ — — —
15 inch tire — — — — — —
Option 17 inch tire — ❍ ❍ — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ ❍ — — ❍
Curtain airbag ❍ ❍ ❍ — — ❍
Sunroof ❍ ❍ ❍ — — ❍
Navigation system — — ❍ — — —
Grade up — — — — — —
★1:
SPC-23
LEGACY
SPECIFICATIONS
Option code★1 KA
2.5 L SOHC
AWD
Model
2.5 i
4AT
Front kgf (lb) 800 (1,764) 785 (1,731) 795 (1,753) 805 (1,774) 810 (1,786) 815 (1,797)
Curb weight
Rear kgf (lb) 625 (1,378) 605 (1,334) 610 (1,345) 615 (1,356) 625 (1,378) 625 (1,378)
(C.W.)
Total kgf (lb) 1,425 (3,142) 1,390 (3,064) 1,405 (3,097) 1,420 (3,131) 1,435 (3,164) 1,440 (3,175)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
mass (G.V.M.)
Vehicle Dynamics
— — — ❍ ❍ ❍
Control
Winter pack — — — — — ❍
15 inch tire — — — — — —
Option 17 inch tire ❍ — ❍ — ❍ ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag ❍ — — ❍ ❍ ❍
Curtain airbag ❍ — — ❍ ❍ ❍
Sunroof ❍ — — ❍ ❍ ❍
Navigation system — — — — — ❍
Grade up — ❍ ❍ ❍ ❍ ❍
★1:
SPC-24
LEGACY
SPECIFICATIONS
2. WAGON MODEL
• LHD model
Option code★1 EC
2.0 L SOHC
AWD
Model
2.0 i
5MT (Dual range)
Front kgf (lb) 750 (1,653) 765 (1,686) 770 (1,698) 770 (1,698) 775 (1,709) 785 (1,731)
Curb weight
Rear kgf (lb) 610 (1,345) 610 (1,345) 610 (1,345) 610 (1,345) 635 (1,400) 645 (1,422)
(C.W.)
Total kgf (lb) 1,360 (2,998) 1,375 (3,031) 1,380 (3,042) 1,380 (3,042) 1,410 (3,109) 1,430 (3,153)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
15 inch tire — — — — — —
Option
17 inch tire — — — — — ❍
A/C — ❍ ❍ ❍ ❍ ❍
Sunroof — — — — ❍ ❍
★1:
SPC-25
LEGACY
SPECIFICATIONS
Option code★1 EC
2.0 L SOHC
AWD
Model
2.0 i
4AT
Front kgf (lb) 760 (1,676) 775 (1,709) 780 (1,720) 780 (1,720) 785 (1,731) 790 (1,742)
Curb weight
Rear kgf (lb) 610 (1,345) 610 (1,345) 610 (1,345) 610 (1,345) 635 (1,400) 640 (1,410)
(C.W.)
Total kgf (lb) 1,370 (3,020) 1,385 (3,053) 1,390 (3,064) 1,390 (3,064) 1,420 (3,131) 1,430 (3,153)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
15 inch tire — — — — — —
Option
17 inch tire — — — — — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — ❍ ❍ ❍ ❍ ❍
Sunroof — — — — ❍ ❍
SPC-26
LEGACY
SPECIFICATIONS
Option code★1 EC
2.5 L SOHC
AWD
Model
2.5 i
5MT (Dual range)
Front kgf (lb) 770 (1,698) 780 (1,720) 775 (1,709) 780 (1,720) 780 (1,720) 785 (1,731)
Curb weight
Rear kgf (lb) 620 (1,367) 625 (1,378) 620 (1,367) 625 (1,378) 620 (1,367) 630 (1,389)
(C.W.)
Total kgf (lb) 1,390 (3,064) 1,405 (3,097) 1,395 (3,075) 1,405 (3,097) 1,400 (3,086) 1,415 (3,120)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Leather interior — — — — ❍ ❍
Winter pack — — — — ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire — ❍ — ❍ — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Sunroof — — — — — —
Navigation system — — ❍ ❍ ❍ ❍
SPC-27
LEGACY
SPECIFICATIONS
Option code★1 EC
2.5 L SOHC
AWD
Model
2.5 i
5MT (Dual range) 4AT
Front kgf (lb) 785 (1,731) 790 (1,742) 800 (1,764) 780 (1,720) 790 (1,742) 785 (1,731)
Curb weight
Rear kgf (lb) 645 (1,422) 655 (1,444) 660 (1,455) 620 (1,367) 625 (1,378) 620 (1,367)
(C.W.)
Total kgf (lb) 1,430 (3,153) 1,445 (3,186) 1,460 (3,219) 1,400 (3,086) 1,415 (3,120) 1,405 (3,097)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — ❍ — — —
Control
McIntosh audio — — ❍ — — —
15 inch tire — — — — — —
Option
17 inch tire — ❍ ❍ — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag ❍ ❍ ❍ — — —
Sunroof ❍ ❍ ❍ — — —
SPC-28
LEGACY
SPECIFICATIONS
Option code★1 EC
2.5 L SOHC
AWD
Model
2.5 i
4AT
Front kgf (lb) 790 (1,742) 785 (1,731) 795 (1,753) 800 (1,764) 805 (1,775) 815 (1,797)
Curb weight
Rear kgf (lb) 625 (1,378) 625 (1,378) 630 (1,389) 645 (1,422) 655 (1,444) 660 (1,455)
(C.W.)
Total kgf (lb) 1,415 (3,120) 1,410 (3,109) 1,425 (3,142) 1,445 (3,186) 1,460 (3,219) 1,475 (3,252)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — ❍ ❍ ❍
Control
McIntosh audio — — — — — ❍
Winter pack — ❍ ❍ ❍ ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire ❍ — ❍ — ❍ ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — — — ❍ ❍ ❍
Sunroof — — — ❍ ❍ ❍
Navigation system ❍ ❍ ❍ — — ❍
Self levelizer — — — — — ❍
SPC-29
LEGACY
SPECIFICATIONS
Option code★1 EC K4
3.0 L DOHC 2.0 L SOHC
AWD
Model
3.0 R 2.0 i
5AT 5MT (Dual range)
Front kgf (lb) 880 (1,940) 890 (1,962) 890 (1,962) 760 (1,676) 750 (1,653) 765 (1,686)
Curb weight
Rear kgf (lb) 640 (1,410) 665 (1,466) 665 (1,466) 610 (1,345) 610 (1,345) 610 (1,345)
(C.W.)
Total kgf (lb) 1,520 (3,351) 1,555 (3,428) 1,555 (3,428) 1,370 (3,020) 1,360 (2,998) 1,375 (3,031)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
❍ ❍ ❍ — — —
Control
Cruise control ❍ ❍ ❍ — — ❍
15 inch tire — — — — — —
Option
17 inch tire — — — — — —
A/C ❍ ❍ ❍ ❍ — ❍
Curtain airbag — ❍ ❍ — — —
Sunroof — ❍ ❍ — — —
Navigation system — — ❍ — — —
SPC-30
LEGACY
SPECIFICATIONS
Option code★1 KS K4 KS
2.0 L SOHC
AWD
Model 2.0 i
5MT
4AT
(Dual range)
Front kgf (lb) 760 (1,676) 770 (1,698) 775 (1,709) 785 (1,731) 770 (1,698)
Curb weight
Rear kgf (lb) 610 (1,345) 610 (1,345) 610 (1,345) 635 (1,400) 610 (1,345)
(C.W.)
Total kgf (lb) 1,370 (3,020) 1,380 (3,042) 1,385 (3,053) 1,420 (3,131) 1,380 (3,042)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — —
Control
Cruise control — — ❍ — —
Leather interior — — — — —
15 inch tire — — — — —
Option
17 inch tire — — — — —
A/C ❍ ❍ ❍ ❍ ❍
Side airbag — — ❍ ❍ —
Curtain airbag — — — ❍ —
Sunroof — — — ❍ —
★1:
SPC-31
LEGACY
SPECIFICATIONS
Option code★1 K4
2.5 L SOHC
AWD
Model
2.5 i
Front kgf (lb) 780 (1,720) 780 (1,720) 790 (1,742) 790 (1,742) 790 (1,742) 790 (1,742)
Curb weight
Rear kgf (lb) 635 (1,400) 645 (1,422) 650 (1,433) 655 (1,444) 635 (1,400) 645 (1,422)
(C.W.)
Total kgf (lb) 1,415 (3,120) 1,425 (3,142) 1,440 (3,175) 1,445 (3,186) 1,425 (3,142) 1,435 (3,164)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Leather interior — — — ❍ — —
15 inch tire — — — — — —
Option
17 inch tire — — ❍ ❍ — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — ❍ ❍ ❍ — ❍
Sunroof ❍ ❍ ❍ ❍ ❍ ❍
Navigation system — — — ❍ — —
SPC-32
LEGACY
SPECIFICATIONS
Option code★1 K4
AWD
Model 3.0 R,
2.5 i
3.0 R-A
4AT 5AT
Front kgf (lb) 800 (1,764) 795 (1,753) 800 (1,764) 810 (1,785) 890 (1,962)
Curb weight
Rear kgf (lb) 650 (1,433) 645 (1,422) 650 (1,433) 650 (1,433) 665 (1,466)
(C.W.)
Total kgf (lb) 1,450 (3,196) 1,440 (3,175) 1,450 (3,196) 1,460 (3,219) 1,555 (3,428)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — ❍ ❍
Control
Leather interior — ❍ ❍ ❍ ❍
Winter pack — — — ❍ —
15 inch tire — — — — —
Option
17 inch tire ❍ — ❍ ❍ —
A/C ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ ❍ ❍ ❍
Curtain airbag ❍ ❍ ❍ ❍ ❍
Sunroof ❍ ❍ ❍ ❍ ❍
Navigation system — — — ❍ —
★1:
SPC-33
LEGACY
SPECIFICATIONS
Option code★1 KA
2.0 L SOHC
AWD
Model
2.0 i
Front kgf (lb) 770 (1,698) 775 (1,709) 790 (1,742) 780 (1,720) 785 (1,731) 800 (1,764)
Curb weight
Rear kgf (lb) 610 (1,345) 615 (1,356) 640 (1,410) 610 (1,345) 615 (1,356) 640 (1,410)
(C.W.)
Total kgf (lb) 1,380 (3,042) 1,390 (3,064) 1,430 (3,153) 1,390 (3,064) 1,400 (3,086) 1,440 (3,175)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244)
mass (G.V.M.)
Vehicle Dynamics
— — — — — —
Control
15 inch tire — ❍ — — ❍ —
Option 17 inch tire — — ❍ — — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — — ❍ — — ❍
Curtain airbag — — ❍ — — ❍
Sunroof — — ❍ — — ❍
Grade up — — — — — —
★1:
SPC-34
LEGACY
SPECIFICATIONS
Option code★1 KA
2.0 L DOHC turbo 2.5 L SOHC
AWD
Model
2.0 GT 2.5 i
Front kgf (lb) 845 (1,863) 850 (1,874) 860 (1,896) 775 (1,709) 780 (1,720) 785 (1,731)
Curb weight
Rear kgf (lb) 635 (1,400) 645 (1,422) 665 (1,466) 620 (1,367) 625 (1,378) 645 (1,422)
(C.W.)
Total kgf (lb) 1,480 (3,263) 1,495 (3,296) 1,525 (3,362) 1,395 (3,075) 1,405 (3,097) 1,430 (3,153)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 2,010 (4,431) 2,010 (4,431) 2,010 (4,431) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266)
mass (G.V.M.)
Vehicle Dynamics
— — — — — —
Control
McIntosh audio — ❍ ❍ — — —
Leather interior — ❍ ❍ — — —
15 inch tire — — — — — —
Option 17 inch tire — — — — ❍ —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — — ❍ — — ❍
Sunroof — — ❍ — — ❍
Grade up — — — — — —
★1:
SPC-35
LEGACY
SPECIFICATIONS
Option code★1 KA
2.5 L SOHC
AWD
Model
2.5 i
Front kgf (lb) 795 (1,753) 805 (1,774) 780 (1,720) 790 (1,742) 795 (1,753) 800 (1,764)
Curb weight
Rear kgf (lb) 650 (1,433) 660 (1,455) 620 (1,667) 625 (1,378) 640 (1,410) 650 (1,433)
(C.W.)
Total kgf (lb) 1,445 (3,186) 1,465 (3,230) 1,400 (3,086) 1,415 (3,120) 1,435 (3,164) 1,450 (3,197)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,935 (4,266) 1,935 (4,266) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288)
mass (G.V.M.)
Vehicle Dynamics
— ❍ — — — —
Control
McIntosh audio — ❍ — — — —
Leather interior — ❍ — — — —
Winter pack — ❍ — — — —
15 inch tire — — — — — —
Option 17 inch tire ❍ ❍ — ❍ — ❍
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ — — ❍ ❍
Curtain airbag ❍ ❍ — — ❍ ❍
Sunroof ❍ ❍ — — ❍ ❍
Navigation system — ❍ — — — —
Grade up — — — — — —
★1:
SPC-36
LEGACY
SPECIFICATIONS
Option code★1 KA
2.5 L SOHC
AWD
Model
2.5 i
4AT
Front kgf (lb) 785 (1,731) 790 (1,742) 800 (1,764) 810 (1,786) 815 (1,797)
Curb weight
Rear kgf (lb) 620 (1,367) 630 (1,389) 645 (1,422) 650 (1,433) 660 (1,455)
(C.W.)
Total kgf (lb) 1,405 (3,097) 1,420 (3,131) 1,445 (3,186) 1,460 (3,219) 1,470 (3,241)
Unladen mass Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288)
mass (G.V.M.)
Vehicle Dynamics
— ❍ ❍ ❍ ❍
Control
McIntosh audio — — — — ❍
Leather interior ❍ ❍ ❍ ❍ ❍
Winter pack — — — — ❍
15 inch tire — — — — —
Option 17 inch tire — ❍ — ❍ ❍
A/C ❍ ❍ ❍ ❍ ❍
Side airbag — — ❍ ❍ ❍
Curtain airbag — — ❍ ❍ ❍
Sunroof — — ❍ ❍ ❍
Navigation system — — — — ❍
Grade up ❍ ❍ ❍ ❍ ❍
★1:
SPC-37
LEGACY
SPECIFICATIONS
3. OUTBACK
• LHD model
Option code★1 EC
2.5 L SOHC
AWD
Model
OBK 2.5 i
Front kgf (lb) 785 (1,731) 795 (1,753) 800 (1,764) 795 (1,753) 805 (1,774) 810 (1,785)
Curb weight
Rear kgf (lb) 645 (1,422) 670 (1,477) 675 (1,488) 645 (1,422) 670 (1,477) 675 (1,488)
(C.W.)
Total kgf (lb) 1,430 (3,153) 1,465 (3,230) 1,475 (3,252) 1,440 (3,175) 1,475 (3,252) 1,485 (3,274)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Cruise control — ❍ ❍ — ❍ ❍
Leather interior — — ❍ — — ❍
Winter pack — ❍ ❍ — ❍ ❍
15 inch tire — — — — — —
Option
17 inch tire — — — — — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — ❍ ❍ — ❍ ❍
Sunroof — ❍ ❍ — ❍ ❍
Self levelizer — ❍ ❍ ❍ ❍ ❍
★1:
SPC-38
LEGACY
SPECIFICATIONS
Option code★1 EC K4
3.0 L DOHC 2.5 L SOHC
AWD
Model
OBK 3.0 R, OBK 3.0 R-A OBK 2.5 i
Front kgf (lb) 885 (1,951) 890 (1,962) 900 (1,984) 900 (1,984) 785 (1,731) 795 (1,753)
Curb weight
Rear kgf (lb) 660 (1,455) 660 (1,455) 685 (1,510) 685 (1,510) 645 (1,422) 670 (1,477)
(C.W.)
Total kgf (lb) 1,545 (3,406) 1,550 (3,417) 1,585 (3,494) 1,585 (3,494) 1,430 (3,153) 1,465 (3,230)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— ❍ ❍ ❍ — —
Control
Leather interior ❍ ❍ ❍ ❍ — —
Winter pack ❍ ❍ ❍ ❍ — —
15 inch tire — — — — — —
Option
17 inch tire — — — — — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag — ❍ ❍ — ❍
Sunroof — — ❍ ❍ — ❍
Self levelizer ❍ ❍ ❍ ❍ — —
SPC-39
LEGACY
SPECIFICATIONS
2.5 L SOHC
AWD
Model
OBK 2.5 i
Front kgf (lb) 785 (1,731) 795 (1,753) 795 (1,753) 795 (1,753) 805 (1,774) 810 (1,785)
Curb weight
Rear kgf (lb) 640 (1,410) 655 (1,444) 660 (1,455) 645 (1,422) 670 (1,477) 670 (1,477)
(C.W.)
Total kgf (lb) 1,425 (3,142) 1,450 (3,196) 1,455 (3,208) 1,440 (3,175) 1,475 (3,252) 1,480 (3,263)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Leather interior — — ❍ — — ❍
15 inch tire — — — — — —
Option
17 inch tire — — — — — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — — — ❍ ❍ ❍
Sunroof — ❍ ❍ — ❍ ❍
SPC-40
LEGACY
SPECIFICATIONS
AWD
Model
OBK 2.5 i OBK 3.0 R, OBK 3.0 R-A
4AT 5AT
Front kgf (lb) 795 (1,753) 805 (1,774) 805 (1,774) 900 (1,984) 890 (1,962)
Curb weight
Rear kgf (lb) 640 (1,410) 655 (1,444) 660 (1,455) 685 (1,510) 685 (1,510)
(C.W.)
Total kgf (lb) 1,435 (3,164) 1,460 (3,219) 1,465 (3,230) 1,585 (3,494) 1,575 (3,472)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — ❍ —
Control
Leather interior — — ❍ ❍ ❍
15 inch tire — — — — —
Option
17 inch tire — — — — —
A/C ❍ ❍ ❍ ❍ ❍
Side airbag — — — ❍ ❍
Curtain airbag — — — ❍ ❍
Sunroof — ❍ ❍ ❍ ❍
Self levelizer — — — ❍ ❍
SPC-41
LEGACY
SPECIFICATIONS
• RHD model
Option code★1 EK
AWD
Model OBK 3.0 R,
OBK 2.5 i
OBK 3.0 R-A
5MT (Dual range) 4AT 5AT
Front kgf (lb) 800 (1,764) 790 (1,742) 810 (1,785) 800 (1,764) 815 (1,797) 895 (1,973)
Curb weight
Rear kgf (lb) 675 (1,488) 645 (1,422) 670 (1,477) 645 (1,422) 670 (1,477) 680 (1,499)
(C.W.)
Total kgf (lb) 1,475 (3,252) 1,435 (3,164) 1,480 (3,263) 1,445 (3,186) 1,485 (3,274) 1,575 (3,472)
permissible
(M.P.A.W.)
Maximum
weight (M.P.W.)
Vehicle Dynamics
— — — — — —
Control
Leather interior ❍ — ❍ — ❍ —
Winter pack ❍ — ❍ — ❍ —
15 inch tire — — — — — —
Option
17 inch tire — — — — — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Curtain airbag ❍ — ❍ — ❍ ❍
Sunroof ❍ — ❍ — ❍ ❍
Navigation system — — — — ❍ —
Self levelizer ❍ ❍ ❍ ❍ ❍ ❍
SPC-42
LEGACY
SPECIFICATIONS
Option code★1 EK
3.0 L DOHC
AWD
Model
OBK 3.0 R, OBK 3.0 R-A
5AT
Front kgf (lb) 905 (1,995) 905 (1,995)
Curb weight
Rear kgf (lb) 685 (1,510) 685 (1,510)
(C.W.)
Total kgf (lb) 1,590 (1,301) 1,590 (1,301)
Maximum Front kgf (lb) 1,040 (2,293) 1,040 (2,293)
permissible
axle weight Rear kgf (lb) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible Total kgf (lb) 2,060 (4,542) 2,060 (4,542)
weight (M.P.W.)
Vehicle Dynamics
❍ ❍
Control
Cruise control ❍ ❍
McIntosh audio — —
Leather interior ❍ ❍
Winter pack ❍ ❍
15 inch tire — —
Option
17 inch tire — —
A/C ❍ ❍
Side airbag ❍ ❍
Curtain airbag ❍ ❍
Sunroof ❍ ❍
Navigation system — ❍
Self levelizer ❍ ❍
SPC-43
LEGACY
SPECIFICATIONS
Option code★1 KA
2.5 L SOHC
AWD
Model
OBK 2.5 i
Front kgf (lb) 790 (1,742) 800 (1,764) 800 (1,764) 805 (1,774) 800 (1,764) 810 (1,785)
Curb weight
Rear kgf (lb) 640 (1,410) 665 (1,466) 670 (1,477) 670 (1,477) 640 (1,410) 665 (1,466)
(C.W.)
Total kgf (lb) 1,430 (3,153) 1,465 (3,230) 1,470(3,241) 1,475 (3,252) 1,440 (3,175) 1,475 (3,252)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343)
mass (G.V.M.)
Vehicle Dynamics
— — — — — —
Control
Leather interior — ❍ ❍ ❍ — ❍
Winter pack — — — ❍ — —
15 inch tire — — — — — —
Option 17 inch tire — — — — — —
A/C ❍ ❍ ❍ ❍ ❍ ❍
Side airbag — — ❍ ❍ — —
Curtain airbag — — ❍ ❍ — —
Sunroof — ❍ ❍ ❍ — ❍
Self levelizer — ❍ ❍ — — ❍
Grade up — — — ❍ — —
★1:
SPC-44
LEGACY
SPECIFICATIONS
Option code★1 KA
AWD
Model
OBK 2.5 i OBK 3.0 R, OBK 3.0 R-A
4AT 5AT
Front kgf (lb) 810 (1,785) 810 (1,785) 885 (1,951) 900 (1,984) 905 (1,995)
Curb weight
Rear kgf (lb) 670 (1,477) 675 (1,488) 655 (1,444) 685 (1,510) 685 (1,510)
(C.W.)
Total kgf (lb) 1,480 (3,263) 1,485 (3,274) 1,540 (3,395) 1,585 (3,494) 1,590 (1,301)
Unladen mass Front kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
(U.W.) Rear kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
Total kgf (lb) 1,970 (4,343) 1,970 (4,343) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542)
mass (G.V.M.)
Vehicle Dynamics
— — — ❍ ❍
Control
Leather interior ❍ ❍ — ❍ ❍
Winter pack — — — — ❍
15 inch tire — — — — —
Option 17 inch tire — — — — —
A/C ❍ ❍ ❍ ❍ ❍
Side airbag ❍ ❍ — ❍ ❍
Curtain airbag ❍ ❍ — ❍ ❍
Sunroof ❍ ❍ — ❍ ❍
Navigation system — ❍ — — ❍
Self levelizer ❍ ❍ ❍ ❍ ❍
Grade up — — — — —
★1:
SPC-45
LEGACY
SPECIFICATIONS
SPC-46
PRECAUTION
PC
Page
1. Precaution ...................................................................................................2
Precaution
PRECAUTION
1. Precaution 7. AIRBAG DISPOSAL

A: CAUTION To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules in the
Please clearly understand and adhere to the follow-
same way as other refuse. Follow the special in-
ing general precautions. They must be strictly fol-
structions for disposal in this manual. Follow all
lowed to avoid minor or serious injury to the person
government regulations concerning disposal of
doing the work or people in the area.
refuse.
1. ABS 8. AIRBAG MODULE
Handle the ABS as a total system. Do not disas-
Adhere to the following when handing and storing
semble or attempt to repair parts which are not in-
the airbag module to prevent bodily injury from un-
structed in this manual. Follow the instructions in
expected deployment:
this manual during performing the maintenance of
• Do not hold the harnesses or connectors to carry
ABSCM&H/U. To disassemble parts without in-
the module.
structions could prevent the ABS system from op-
erating when needed or cause it to operate • Do not face the bag in the direction that it opens
incorrectly and result in injury. towards yourself or other people.
• Do not face the bag in the direction that it opens
2. VEHICLE DYNAMICS CONTROL (VDC) towards the floor or walls.
Handle the VDC as a total system. Do not disas- 9. AIRBAG SPECIAL TOOL
semble or attempt to repair individual parts. Doing
so could prevent the VDC system from operating To prevent unexpected deployment, only use spe-
when needed or cause it to operate incorrectly and cial tools.
result in injury. 10.WINDOW
3. BRAKE FLUID Always wear safety glasses when working around
If brake fluid gets in your eyes or on your skin, do any glass to prevent glass fragments from damag-
the following: ing your eyes.
• Wash out your eyes and seek immediate medical 11.WINDOW ADHESIVE
attention.
Always use the recommended or equivalent adhe-
• Wash your skin with soap and then rinse thor-
sive when attaching glass to prevent it from coming
oughly with water.
loose and falling, resulting in accidents and injury.
4. RADIATOR FAN
The radiator fan may rotate without warning, even
when the engine is not ON. Do not place your hand,
cloth, tools or other items near the fan at any time.
5. ROAD TEST
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
6. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low the instructions in this manual when performing
maintenance on the airbag components or nearby,
and the airbag wiring harnesses or nearby.
To prevent unexpected deployment, turn the igni-
tion switch to OFF and disconnect the ground cable
from battery, then wait at least 20 seconds to dis-
charge electricity before beginning work.
PC-2
NOTE
NT
Page
1. Note.............................................................................................................2
Note
NOTE
1. Note NOTE:
• When using a lift, follow its operation manual be-
A: NOTE fore work.
This is the information that can improve the effi- • Do not work or leave unattended while the vehi-
ciency of maintenance and assure the sound work. cle is supported with jack, support it with rigid
1. FASTENERS NOTICE racks.
• Be sure to use the rigid racks with rubber at-
Fasteners are used to prevent the parts from dam- tached to cradle to support the vehicle.
age, dislocation and play due to looseness. Fasten- • When using a plate lift, use a rubber attachment.
ers must be tightened to the specified torque.
Do not apply paint, lubricant, rust retardant or other
substance to the surface around bolts, nuts, etc.
Doing so will make it difficult to obtain the correct
torque and result in looseness and other problem.
2. STATIC ELECTRICITY DAMAGE
(A)
Do not touch the control modules, connectors, logic
boards and other such parts when there is a possi- (C)
bility of static electricity. Always use a static elec- (B)

tricity prevention cord or touch grounded metal for NT-00070
the elimination of static electricity before conduct-
ing work. (A) 80 mm (3.1 in) or more
(B) 100 — 150 mm (3.94 — 5.91 in)
3. BATTERY
(C) 120 — 190 mm (4.72 — 7.48 in)
When removing the battery terminal, always be
sure to turn the ignition switch to OFF to prevent • Align the cushion rubber end of plate lift with the
electrical damage of the control module from over- end of rubber attachment (portion b). Also, align the
current. Be sure to remove the battery ground ca- protrusion portion of the supporting locations with
ble first. the end of attachment (portion a).
• Do not use the plate lift whose attachment does
4. SERVICE PARTS not reach the supporting locations.
Use genuine parts for maximum performance and
maintenance when conducting repairs. Subaru/FHI
will not be responsible for poor performance result-
ing from the use of parts except for genuine parts.
5. PROTECTING VEHICLE UNDER MAIN-
TENACE
Make sure to attach the fender cover, seat covers,
etc. before work.
6. ENSURING SECURITY DURING WORK
When working in a group of two or more, perform
the work with calling each other to ensure mutual
safety.
7. LIFTS AND JACKS
When using a lift or shop jack to raise a vehicle, or
using rigid rack to support a vehicle, always follow
instructions concerning jack-up points and weight
limits to prevent the vehicle from falling, which
could result in injury. Be especially careful that the
vehicle is balanced before raising it. Be sure to set
the wheel stoppers when jacking-up only the front
or rear side of the vehicle.
NT-2
Note
NOTE
(1)
(2)
(3)
(6)
(4)
(6)
(5)
a (6)
(6) a
b
NT-00086
(1) Supporting locations (3) Swing arm lift (5) Plate lift
(2) Pantograph jack (4) Rigid rack (6) Attachment
NT-3
Note
NOTE
(A) (1)
(B) (2)
NT-00072
(A) Front (B) Rear
(1) Front crossmember (2) Rear differential
NT-4
Note
NOTE
8. TIE DOWNS
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to
the specified locations on the vehicle.
• TIE-DOWN LOCATION
(1) (1)
(1)
NT-00073
(1) Hook for tie-down
NT-5
Note
NOTE
• CHAIN DIRECTION AT TIE-DOWN CONDI- • VEHICLE SINKING VOLUME AT TIE-DOWN

TION CONDITION
Measure the distance between the highest tire
point and highest arch point before and after tie-
down. Difference of measurement value (sinking
volume) shall be within 50 mm (1.97 in) and make
sure to fix the vehicle securely.
L
L
NT-00076
NT-00074
• CHAIN PULLING RANGE AT TIE-DOWN CON-

DITION
(2) (2)
(2) (2)
(2) (2)
(2) (2)
(3) (3) (3) (3)

: (1) NT-00075
(1) Chain pulling range at tie-down condition

(2) 20#
(3) 45#
NT-6
Note
NOTE
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a
loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle
damage resulting from excessive weight.
• Do not tow other vehicles with a front tie-down hook.
• Make sure the towing vehicle is heavier than the towed vehicle.
• FRONT
Remove the fog light cover (except for OUTBACK model) and hook cover, and then install the hook.
(A)
(B)
(A)
(B)
(C)
(C) (C)
NT-00087
(A) Fog light cover (except for OUT- (B) Hook cover (C) Hook
BACK model)
• REAR
NT-00078
NT-7
Note
NOTE
• NOTES
Towing Notes MT AT
Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a ❍ ❍
basic rule for AWD model.
NT-00023
Rope • Check if both front and rear wheels are rotated nor- ❍ ▲
mally.
• AT model driving conditions: Allow driving speed less
than 30 km/h (19 MPH).
Allow driving distance less than 30 km (19 miles).
NT-00024
Raising the front wheels Prohibited for full-time AWD model. ✕ ✕
NT-00025
Lifting up the front wheels • Prohibited, due to damage on bumper, front grille, etc. ✕ ✕
• Do not raise the vehicle with bumper.
NT-00026
Marked ❍: OK, Marked ✕: Prohibited, Marked ▲: Conditionally OK.
NT-8
Note
NOTE
CAUTION:
• Check ATF, gear oil and rear differential oil before driving.
• Place the shift lever in “N” position during towing.
• Do not lift up the rear wheels to avoid unsteady rotation.
• Turn the ignition key to “ACC”, then check the steering wheel moves freely.
• Release the parking brake to avoid tire dragging.
• Since the power steering does not work, be careful for the heavy steering effort (When engine is
stopped)
• Since the servo brake does not work, be careful that the brake is not applied effectively. (When en-
gine is stopped)
• In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trailer)
for towing.
10.FRONT HOOD STAY INSTALLATION
• AT THE CHECK AND GENERAL MAINTENANCE
NT-00079
• WHEN WIDER HOOD OPENING IS NECESSARY

Set the stay into the hole of lower hood as shown in the figure below.
NT-00080
NT-9
Note
NOTE
11.GENERAL SCAN TOOL (2) Let the vehicle ride on the tester and free
roller gently.
Using general scan tools will greatly improve the ef-
ficiency of repairing engine electronic controls. CAUTION:
Subaru Select Monitor can be used to diagnose the Fix the vehicle using a pulling metal (chain or
engine, ABS, air conditioner and other parts. wire) to the front and rear towing hooks or tie-
down hook to prevent the lateral runout of front
12.AWD CIRCUIT MEASURES wheels and springing out of vehicle.
1) Full-time AWD MT model
Since viscous coupling (limited slip differential) is
used in the center differential, cut-off of AWD circuit
cannot be carried out.
2) Full-time AWD 5AT model
Since VTD type is used in the center differential,
cut-off of AWD circuit cannot be carried out.
3) Full-time AWD 4AT model
Insert a spare fuse into FWD fuse holder in the fuse
box located in the left side of engine room to select (A)
the FWD. Since electronically controlled MT-P hy- NT-00033
draulic multi-plate clutch is adapted for center dif-
ferential, select FWD. When maintenance is (A) Free roller
performed with jack-up or on the free roller, check (3) Set the speedometer tester.
the illumination of AWD warning light in the combi- (4) Conduct the speedometer test work.
nation meter.
CAUTION:
Do not operate the clutch quickly and do not ac-
celerate or decelerate suddenly during work.
2) Rear wheel jack-up system
(1) Set the vehicle on speedometer tester.
CAUTION:
Fix the vehicle using a pulling metal (chain or
wire) to the front and rear towing hooks or tie-
down hook to prevent the lateral runout of front
(A)
wheels and springing out of vehicle.
(2) Jack up the rear wheels and set the rigid
racks to the specified locations of side sill.
(B)
NT-00081 (A)
NT-00034
(A) FWD fuse holder
(B) AWD warning light (A) Rigid rack
13.SPEEDOMETER TEST (3) Conduct the speedometer test work.

1) Rear wheel free roller system CAUTION:
(1) Set the free roller on the floor of rear wheel Do not operate the clutch quickly and do not ac-
side securely according to the wheel base and celerate or decelerate suddenly during work.
rear tread of the vehicle.
NT-10
Note
NOTE
14.BRAKE TEST Specifications:

1) Full-time AWD MT model Braking force
(1) Perform this test after driving the vehicle 2 to Rear wheel total More than 10% of load on front or rear
3 km (1.24 to 1.86 miles) on road in order to sta- wheels
bilize the viscous torque of viscous coupling. Difference between Less than 8% of load on front or rear
(2) Keep the front or rear wheels on the ground right and left wheels
for this test. wheels
NOTE: Grand total More than 50% of vehicle weight at
the time of test
Effect of the viscous torque on braking force will be
added approx. 25 kg compared with FWD model. • When measurement is difficult to carry out be-
cause both of front wheels are locked, check if
break force measurement in this condition con-
forms to grand total.
15.ON THE CAR WHEEL BALANCING
CAUTION:
• Carry out this procedures after measuring
the balance of each single tire.
(C) (A) • Set the vehicle so that the front and rear
(B)
wheels are same height.
NT-00029
• Release the parking brake during measure-
(A) Brake tester
ment.
(B) Position for measuring front wheel
• Rotate each wheel by hands, and make sure it
rotates without dragging.
(C) Position for measuring rear wheel
• Do not operate the clutch quickly and do not
(3) When the brake dragging force is large. accelerate or decelerate suddenly during work.
• Check the dragging of brake pad or brake • When an error is indicated during engine
shoe. drive, do not use the motor drive together.
• Since it may be affected by the viscosity of 1) Set the rigid rack to the specified locations of
viscous couping, jack up either of the front or side sill, jack up the front or rear two wheels of non-
rear two wheels to check the each wheel rota- measuring side and set the pickup stands to two
tion condition with the viscous coupling affection wheels of measuring side.
removed.
2) Full-time AWD AT model
(1) Keep the front or rear wheels on the ground (A)
during measurement.
(B)
NT-00031
(A) Balancer body

(C) (A)
(B) (B) Pickup stand
NT-00029
2) For drive wheel, drive the tires with engine for
(A) Brake tester
measurement.
(B) Position for measuring front wheel
3) For non-drive wheel, drive the tires from the on
the car wheel balancer for measurement.
(C) Position for measuring rear wheel
(2) When the brake dragging force is large.

• Check the dragging of brake pad or brake
shoe.
NT-11
Note
NOTE
NT-12
IDENTIFICATION
ID
Page
1. Identification ................................................................................................2
Identification
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle.
• POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION
(2)
(1)
(4)
(5)
(6)
(3)
ID-00072
(1) ID plate (EC and EK model) (4) Tire inflation pressure label (Driver (5) Saudi Arabia plate (Saudi Arabia
ADR compliance plate (KA model) side) (KA model) model)
(2) Vehicle identification number Tire inflation pressure label (Driver Built date plate (KA model)
(VIN) side) (Except for KA model) (6) Vehicle identification number
(3) Model number plate (VIN) (EK and KA model)
• ENGINE • AUTOMATIC TRANSMISSION
(1)
(1) (2)
(2)
ID-00059 ID-00067
(1) Engine serial number (Punch mark) (1) AT type label

(2) Engine type (Crankcase upper side) (2) Transmission serial number label
ID-2
Identification
IDENTIFICATION
• MANUAL TRANSMISSION VA1-TYPE

(1)
(1)
(2)
ID-00068 DI-00396
(1) Transmission serial No. (1) Type (label)

(2) MT type label
VA2-TYPE
• REAR DIFFERENTIAL
T-TYPE
(1)
(1)
DI-00397
ID-00056 (1) Type (label)
(1) Type (white paint)

• MODEL NUMBER PLATE
ID-00073
ID-3
Identification
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the V.I.N. is as follows:
• EC, EK, KA AND K4 MODEL
]JF1BL5LJ34G002001[
The starting and ending brackets ( ] [ ) are stop marks.
Digits Code Meaning Details
1—3 JF1 Manufacturer body area JF1: Passenger car, FHI made (Except for KA OUTBACK
model)
JF2: Passenger car, FHI made (KA OUTBACK model)
4 B Car line LEGACY
5 L Body type L: Sedan
P: Wagon
6 5 Displacement 5: 2.0 L AWD
9: 2.5 L AWD
E: 3.0 L AWD
7 L Steering position L: LHD (Left-hand drive model)
K: RHD (Right-hand drive model)
8 J Engine & transmission J: SOHC MPI 5MT Single range
K: SOHC MPI 5MT Dual range
L: SOHC MPI 4AT-SS
U: DOHC MPI 5AT-SS
V: DOHC MPI Turbo 5AT-SS
9 3 Drive type 3: Full-time AWD Single range
4: Full-time AWD Dual range
5: AWD AT
A: AWD AT OUTBACK
B: Full-time AWD Dual range OUTBACK
10 4 Model year 4: 2004MY
11 G Factory location G: FHI (Gunma)
12 — 17 002001 Serial number From 002001
• KS MODEL
]JF1BL54MX4G002001[
The starting and ending brackets ( ] [ ) are stop marks.
1—3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 B Car line LEGACY
P: Wagon
6 5 Displacement 5: 2.0 L AWD
9: 2.5 L AWD
7 4 Grade 4: 2.0i
6: 2.5i
8: OUTBACK 2.5 i
8 M Restraint M: Manual belts, dual airbag
9 X Check digit 0—9&X
10 4 Model year 4: 2004MY
11 G Transmission type G: Full-time AWD 5MT Single range
H: Full-time AWD 4AT
J: Full-time AWD 5MT Dual range
12 — 17 002001 Serial number From 002001
ID-4
Identification
IDENTIFICATION
3. MODEL NUMBER PLATE

The model number plate indicates the type, V.I.N. <Ref. to ID-4, MEANING OF V.I.N., IDENTIFICATION,
Identification.>, applied model, option code, trim code, engine type, transmission type and the exterior color
code. This information is helpful when placing orders for parts.
• BL5ALHJ

1 B Series LEGACY
P: Wagon
3 5 Engine displacement 5: 2.0 L AWD
Drive system 9: 2.5 L AWD
Suspension system E: 3.0 L AWD
4 A Model year A: 2004MY
5 L Destination K: Right-hand drive model market
L: Left-hand drive model market
6 H Grade B: 2.0 GT
H: 2.0 i
J: 2.5 i
L: 3.0 R
M: 3.0 R-A
N: 3.0 R
P: 3.0 R-A
R: OUTBACK 2.5 i
V: OUTBACK 3.0 R
W: OUTBACK 3.0 R-A
7 J Transmission, fuel feed J: SOHC MPI 5MT
system K: SOHC MPI Dual range 5MT
L: SOHC MPI 4AT TIP
V: DOHC MPI Turbo 5AT TIP
U: DOHC MPI 5AT TIP
The engine and transmission type are as follows:

• ENGINE
EJ202NTAHB
1 and 2 EJ Engine type EJ: 4 cylinders
EZ: 6 cylinders
3 and 4 20 Displacement 20: 2.0L
25: 2.5L
30: 3.0L
5 2 Fuel feed system 2: D-MPI-NA (SOHC)-B
3: MPI-NA (SOHC)
D: MPI-NA (DOHC, H6)
X: MPI Twin scroll single turbo
6 N Detailed specifications Used when ordering parts. See the parts catalog for details.
7 T Transmission L: 5AT without ATF cooler (with warmer function)
P: 4AT without ATF cooler (with warmer function)
S: 5MT (Flexible type flywheel)
T: 5MT (Dual mass type flywheel)
V: 4AT with ATF cooler (with warmer function) (H4), 5AT (H6)
8 — 10 AHB Detailed specifications Used when ordering parts. See the parts catalog for details.
ID-5
Identification
IDENTIFICATION
• TRANSMISSION
TY757VRAAB
1 T Transmission T: Transmission
2 Y Transmission type Y: Full-time AWD MT center differential
V, G: Full-time AWD AT center differential
Z: Full-time AWD AT MPT
3 and 4 75 Classification 75: 5MT
1B: 4AT
5C: 5AT
5 7 Series LEGACY
6 V Transmission specifica- C: Full-time AWD VTD type 5AT
tion L: Full-time AWD MPT type 4AT
M: Full-time AWD VTD type 4AT
V: Full-time AWD 5MT Single range with viscous coupling cen-
ter differential
X: Full-time AWD 5MT Dual range with viscous coupling center
differential
7 — 10 RAAB Detailed specifications Used when ordering parts. See the parts catalog for details.
• REAR DIFFERENTIAL
XJ
Code Reduction gear ratio LSD
XJ 4.111 None
T2 4.111 None
VB 3.700 None
EZ 3.900 Viscous
XU 3.272 Viscous
CF 4.444 Viscous
XT 3.083 Viscous
JE 4.111 Viscous
ID-6
Identification
IDENTIFICATION
• OPTION
ECXV
1—2 EC Destination EC: For Europe (LHD model)
EK: For Europe (RHD model)
KS: For GCC counties
K4: For Middle and South America
KA: For Australia
Nothing: For Hong Kong
3 X Option equipment A: Vehicle dynamics control, Cruise control, Power pack, 17
inch tire
B: Cruise control, Winter pack, 17 inch tire
E: Vehicle dynamics control, Cruise control, Power pack
F: Cruise control, Winter pack
G: Cruise control, 15 inch tire
I: Cruise control, Winter pack, Power pack, 17 inch tire
K: Cruise control, 17 inch tire
S: Cruise control, Winter pack, Power pack
U: Cruise control
V: 17 inch tire
X: Nothing
Y: Vehicle dynamics control, Cruise control, Power pack, Winter
pack, 17 inch tire
Z: Vehicle dynamics control, Cruise control, Power pack, Winter
pack
2: Cruise control, Power pack, 17 inch tire
3: Cruise control, Power pack
4: Cruise control, McIntosh audio, Power pack
5: Cruise control, McIntosh audio, Power pack, 17 inch tire
4 V Option equipment A: A/C
B: A/C, Side airbag, Self levelizer
F: A/C, Grade up pack
J: A/C, Sunroof
K: A/C, Side airbag, Curtain airbag, Navigation system
N: A/C, Side airbag, Curtain airbag, Navigation system, Self
levelizer, Sunroof
O: A/C, Side airbag, Navigation system
Q: A/C, Side airbag, Curtain airbag, Sunroof, Grade up pack
S: A/C, Self levelizer
U: A/C, Sunroof, Self levelizer
V: Side airbag
W: A/C, Side airbag, Curtain airbag, Sunroof
X: nothing
Y: A/C, Side airbag, Curtain airbag, Sunroof, Self levelizer
Z: A/C, Side airbag
ID-7
Identification
IDENTIFICATION
ID-8
RECOMMENDED MATERIALS
RM
Page
1. Recommended Materials ............................................................................2
Recommended Materials
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or a
substitute of equivalent quality.
2. FUEL
Always use gasoline of the same or higher octane
value than specified in the owner’s manual. Ignor-
ing the specifications below will result in damage or
poor operation of the engine and fuel injection sys-
tem. Use the specified gasoline to correct perfor-
mance.
• Unleaded gasoline
Use unleaded gasoline and not leaded gasoline for
the vehicle with catalytic converter installed to re-
duce air pollution. Using leaded gasoline will dam-
age the catalytic converter.
Model Use kind RON
Unleaded More than 95 RON
2.0 L, 2.5 L
gasoline More than 90 RON*
Unleaded
TURBO More than 98 RON
gasoline
Unleaded
3.0 L More than 95 RON
gasoline
*: KA and KS model
RM-2
3. LUBRICANTS
Use either the lubricants in the table below or equivalent. See the table below to choose the correct SAE vis-
cosity.
Lubricant Recommended Alternative
API Spec. CCMC Spec. ACEA Spec. API Spec.
Engine oil SL, SJ Grade “Energy conserving”, or SH G4 or G5 A1, A2 or A3 SG, SF
SERVICE S
PI
L
SAE
0W-20
EN
NG
R
E
VI
GY R
CONS E
RM-00006
SERVICE S
PI
A
SAE
5W-30
EN
NG
R
E
VI
GY R
CONS E
RM-00001
TR OLEUM
PE
FOR
N
IN
AM ER I CA
ST I
GASOLINE
TUTE
ENGINES
C
ER D
T I F IE
RM-00002
Manual transmission oil GL-5 — — —
AT front differential gear GL-5 — — —
oil
Rear differential gear oil GL-5 — — —
RM-3
SAE viscosity No. and applicable temperature

Engine oil
SOHC model
(˚C) –30 –20 –10 0 10 20 30 40
(˚F) –22 –4 14 32 50 68 86 104
10W-30 or 10W-40
5W-30
0W-20 Recommend
RM-00007
3.0 L and DOHC turbo model
(˚C) –30 –20 –10 0 10 20 30 40
(˚F) –22 –4 14 32 50 68 86 104
10W-30 or 10W-40
5W-30 Recommend
RM-00003
RM-4
SAE viscosity No. and applicable temperature

Manual transmission oil, rear differential gear oil and AT front differential gear oil
(˚F) –30 –20 –10 0 10 20 30 40
(˚C) –22 –4 14 32 50 68 86 104
90
85W
80W
75W-90
RM-00004
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
CAUTION:
Be sure to use the recommended or equivalent ATF for 5AT. Using the ATF other than recommended
or equivalent would be a trouble cause.
Fluid Recommended Item number Alternative Remarks
Automatic transmission If it is impossible to
fluid IDEMITSU: APOL- get recommended or
4AT SUBARU ATF K0410Y0700 LOIL ATF HP alternative ATF,
Castrol: Transmax J DEXRON III can be
used.
IDEMITSU: ATF HP
5AT SUBARU ATF K0410Y0700 —
Castrol: Transmax J
Power steering fluid DEXRON III — — —
Brake fluid FMVSS No. 116
— — —
DOT3
Clutch fluid FMVSS No. 116
— — —
DOT3
5. COOLANT
Use genuine coolant to protect the engine.
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water (Soft water)
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any compressor oil other than DENSO OIL 8.
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil DENSO OIL 8 — None
RM-5
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative
Supplementary • Oxygen sensor
Spray type lubricant — —
lubricants • Bolts, etc.
Grease MT main shaft CLUTCH GREASE K0879Y0501 —
Clutch master cylinder push rod SILICONE GREASE G-40M 004404003 —
• Gear shift lever
• Select lever
• Clutch operating cylinder
• Clutch pedal SUNLIGHT2 003602010 —
• Brake pedal
• Clutch bearing
• Clutch release lever
• Door latch
SILICONE GREASE G-30M 004404002 —
• Door striker
Steering gearbox VALIANT GREASE M2 003608001 —
Disc brake
NIGLUBE RX-2 K0779GA102 —
(Lock pin, guide pin, piston boot)
Between brake pad and shim Molykote AS-880N K0777YA010 —
Brake pad clip Molykote M7439 — —
Front axle PTJ NSG301 — —
• Front axle EBJ
• Rear axle BJ NTG2218-M — —
• Rear axle EBJ
Rear axle DOJ NKG205 — —
8. ADHESIVE
Use the adhesives shown in the table below, or equivalent.
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield, rear window Dow Automotive’s
glass, rear quarter Adhesive: Gurit-ESSEX
glass, rear gate and Betaseal 1502 or equivalent
body Glass primer: Betawipe VP — —
04604, Betawipe 5001
Paint surface primer: Betap-
rime 5402
Rearview mirror base REPAIR KIT IN MR 65029FC000 —
Soft vinyl 3M’s EC-776, EC-847 or EC-1022
CEMEDINE 540 —
(Spray type)
Momentary sealant CEMEDINE 3000 — ARMSTRONG’s Eastman 910
RM-6
9. SEAL MATERIAL
Use the seal material shown in the table below, or equivalent.
Seal material Application point Recommended Item number Alternative
Seal material • MT transmission case
• Cylinder block
• Converter case THREE BOND 1215 004403007 DOW CORNING’s No. 7038
• DOHC camshaft cap
(Turbo model)
Transmission oil pan (AT
THREE BOND 1217B K0877YA020 —
model)
Engine oil pan (Except
THREE BOND 1207C 004403012 —
for 3.0 L model)
• Rear differential
• Engine oil pressure
switch
• Cylinder head (Nip- THREE BOND 1324 004403042 —
ple)
• Camshaft bowl-shape
plug
• Rear differential
THREE BOND 1105 004403010 DOW CORNING’s No. 7038
• PCV valve
Steering adjusting screw THREE BOND 1141 004403006 —
• SOHC camshaft cap
• Cam cap (3.0 L
model)
• Semicircular plug (3.0
L model)
• Rocker cover (3.0 L
THREE BOND 1280B K0877YA018 THREE BOND 1217G
model)
• Oil pan (Pan upper)
• Block (Pan upper)
• Back cover (Front
cover, block head, pan
upper)
• Front sealing cover
3M Butyl Rubber 8626 — —
• Rear sealing cover
RM-7
RM-8
PRE-DELIVERY INSPECTION
PI
Page
1. Pre-delivery Inspection................................................................................2
Pre-delivery Inspection
1. Pre-delivery Inspection
A: GENERAL DESCRIPTION
The purposes of the pre-delivery inspection (PDI) are as follows.
• Remove the additional parts used for ensuring the vehicle quality during transportation and restore the ve-
hicle to its normal state.
• Check if the vehicle before delivery is in a normal state.
• Check for any damage to the vehicle or parts that may have taken place during transportation or storage.
• Check if the vehicle after repair is in a normal state.
• Make sure to provide a complete vehicle to the customer.
For the above reasons, all SUBARU dealers (dealerships) carry out the PDIs before delivering a vehicle.
Refer to this manual unless otherwise specified.
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE
STATIC CHECKS JUST AFTER VEHICLE RECEIPT
PROCEDURE Check point
1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually check the body paints for damage or stains in detail.
(2) Visually check the glass and light lenses for any damage, cracks or
excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
3. Fuse installation If the vehicle is about to be delivered to the customer, attach a back-up fuse.
4. Air conditioner harness connection If the vehicle is about to be delivered to the customer, connect air conditioner
harness.
5. Check the doors for lock/unlock and open/close (1) Using the key, check if the trunk lid can be locked or unlocked normally.
operations. (2) Open and close all doors to see that there are no abnormal conditions.
(3) Operate the power door lock switch to check that the door (rear gate) is
locked and unlocked normally.
6. Double lock operation check Check the double lock for normal operations.
7. Check the operation of child safety lock system Check that the child safety lock system operates normally.
8. Check the trunk lid for open/close operations. (1) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
(2) Operate the opener cancel lever of trunk lock to check that it operates
normally.
(3) Open and close the trunk lid to see that there are no abnormal conditions.
9. Check the rear gate for lock/unlock and open/ (1) Check if the rear gate can be unlocked normally through the emergency
close operations. hole.
(2) Open and close the rear gate to see that there are no abnormal condi-
tions.
10. Operation check of fuel lid opener lock release Operate the fuel lid opener to check that the fuel lid is unlocked normally.
lever
11. Accessory check Check that the following accessories are provided.
• Owner’s manual
• Warranty booklet
• Maintenance note
• Spare key
• Jack
• Tool set
• Spare tire
12. Operation check of front hood lock release Operate the front hood lock release lever to check that the front hood is
system unlocked normally.
13. Battery Check the battery terminals for any abnormal conditions such as rust and
trace of battery fluid leaks.
14. Brake fluid Check that the fluid level is normal.
PI-2

15. Engine oil Check that the oil level is normal.
16. Transmission gear oil Check that the transmission gear oil level is normal.
17. AT front differential oil Check that the AT front differential oil level is normal.
18. Engine coolant Check that the engine coolant level is normal.
19. Clutch fluid Check that the clutch fluid level is normal.
20. Window washer fluid Check that the window washer fluid level is normal.
21. Front hood latch check Check that the hood is closed and latched securely.
22. Keyless entry system Check that the keyless entry system operates normally.
23. Seat (1) Check the seat surfaces for stain or dirt.
(2) Check the seat installation conditions and functionality.
24. Seat belt Check the seat belt installation conditions and functionality.
25. Wheel alignment Check that the wheel alignments are properly adjusted.
CHECKS WITH ENGINE RUNNING

26. Test mode connector Test mode connectors
27. Immobilizer system (1) Check that the engine starts with all keys that are equipped on vehicle.
(2) 60 seconds after turning ignition switch from ON to ACC or OFF, or imme-
diately after removing key, check that the security indicator light blinking.
28. Starting condition Start the engine and check that the engine starts smoothly.
29. Exhaust system Check that the exhaust noise is normal and no leaks are found.
30. Indicator and warning lights Check that all the indicator and warning lights are gone out.
31. Clock Check that the clock operates normally.
32. Audio Check the radio, CD and MD player for normal operation.
33. Navigation system (1) Check all display functions for normal operation.
(2) Check the map disc (DVD) are provided on vehicle.
(3) Check that the navigation system operates normally.
34. Front accessory power supply socket Check that the front accessory power socket operates normally.
35. Lighting system Check that the lighting system operates normally.
36. Wiper deicer Check that the wiper deicer operates normally.
37. Rear fog light Check that the rear fog light operates normally.
38. Illumination control Check that the illumination control operates normally.
39. Window washer Check that the window washer system operates normally.
40. Wiper Check that the wiper system operates normally.
41. Power window operation check Check the power window for normal operations.
42. Cargo fan Check that the cargo fan operates normally.
43. Sunroof Check that the sunroof operates normally.
44. Door mirror Check that the remote control mirror operates normally.
DYNAMIC TEST WITH VEHICLE RUNNING

45. Brake test Check the foot brake for normal operations.
46. Parking brake Check the parking brake for normal operations.
47. AT shift control Check that the AT shift patterns are correct.
48. Heater & ventilation Check that the heater & ventilation system operates normally.
49. Air conditioner Check that the air conditioner operates normally.
50. Cruise control Check that the cruise control system operates normally.
CHECKS AFTER DYNAMIC TEST

51. ATF level Check that the ATF level is correct.
52. Power steering fluid level Check that the power steering fluid level is normal.
PI-3

53. Fluid leak check Check for fluid/oil leaks.
54. Water leak test Spray the vehicle with water and check for water leaks.
55. Appearance check 2 (1) Remove the protective coating (if any).
(2) Check the body paints for damage and stain.
(3) Check the plated parts for damage and rust.
1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER

• If the vehicle is covered with protective coating, HARNESS
visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har-
dents. ness disconnected to protect the air conditioner
• When the protective coating is removed, visually compressor. Connect the harness as shown in the
check the body paints for damage or stains in detail figure. (Except for 3.0 L model)
and repair as necessary.
• Visually check the windshield glass, door glass-
es and light lenses for any damage, cracks or ex-
cessive gaps to the body sheet metal and repair as
necessary.
• Visually check the plated parts, such as the
grilles and door knobs, for damage or loss of gloss
and replace the parts as necessary.
2. TIRE CHECK
• Check the tires for damage, abnormal condi- PI-00159
tions, and dents on the wheels.
5. CHECK DOORS FOR LOCK/UNLOCK
• Check the tire size, spare tire and tire air pres-
sure described on the tire air pressure label (driv- AND OPEN/CLOSE OPERATIONS
er’s side). 1) Using the key, lock and unlock the door several
times to check for normal operation. Open and
3. FUSE INSTALLATION close the door several times for smooth movement.
Fuses for the back-up circuit have been removed to
prevent battery discharge. If the vehicle is about to
be delivered to the customer, attach a 20 A fuse (A)
as shown in the figure. (A)
(B)
PI-00191
(A)
(A) Unlock
(B) Lock
PI-00158
2) Completely close the driver’s door, and then
check the smooth movement with operating door
lock knob from lock to unlock several times.
Set the door lock knob (A) to lock position. Then
pull the inner remote (B) to ensure that doors will
not open.
PI-4
For other doors, place the door lock knob (A) to lock 6. CHECK DOUBLE LOCK OPERATION
position and then pull the inner remote (B) to en-
1) Fully open all the windows.
sure that doors will not open.
2) Remove the key.
3) Lock all the doors using the door key cylinder or
keyless transmitter.
4) Verify that all the doors including rear gate are
(A) not unlocked when pressing power door lock switch
to unlock side.
5) Verify that the door is not opened when operat-
ing door lock knob to unlock position and pulling in-
(B)
ner remote. Perform the same check for other
doors.
PI-00192 6) Check that all the doors are unlocked when door
is unlocked using door key cylinder or keyless
(A) Door lock knob transmitter, or ignition switch is turned to ON.
(B) Inner remote
7. CHECK OPERATION OF CHILD SAFETY
3) Close all the doors, and then press the lock on LOCK SYSTEM
power door lock switch at driver’s side. Check that 1) Set the child safety lock on both rear doors to the
all doors including rear gate are locked. lock position.
2) Close the rear doors completely.
3) Check that the lock levers of the rear doors are in
the unlock position. Then, pull inner remote of rear
doors to ensure that doors will not open.
(A) (B)
PI-00193
4) Press the driver’s side power door lock switch to

unlock side. Check that all doors including rear
gate are unlocked.
PI-00164
(A) Lock
(B) Unlock
4) Pull the outer handles to ensure that doors will

open.
8. CHECK TRUNK LID FOR OPEN/CLOSE
OPERATIONS
PI-00194 1) Operate the trunk lock release lever to check
that the trunk opens normally.
5) Insert the key to ignition switch, and open the 2) Open and close the trunk lid several times for
driver’s side door. Press lock on power door lock. smooth movement.
Check that the door is not locked.
PI-5
3) Put the lever (A) in the cancel lever of trunk lid to 11.ACCESSORY CHECK
cancel position, and close the trunk lid. Check that
Check that the following accessories are provided.
the trunk lid will not open even when the trunk lock
• Owner’s manual
release lever is operated. Also, check that the trunk
lid will open with keyless transmitter, then put the • Warranty booklet
lever back. • Maintenance note
• Spare key
• Jack
• Tool set
• Spare tire
(A)
(B) (A)
PI-00200
9. CHECK REAR GATE FOR LOCK/UN-

LOCK AND OPEN/CLOSE OPERATIONS
PI-00168
1) Open and close the rear gate several times for
smooth movement.
2) Operate the rear gate lever to check that the rear
gate is locked and unlocked normally.
(B)
(1) Remove the cover inside the rear gate.
(A)
PI-00169
(A) Jack
(B) Jack handle
PI-00165
12.OPERATION CHECK OF FRONT HOOD
(2) Operate the lever to check that the rear gate
LOCK RELEASE SYSTEM
is locked and unlocked normally.
Operate the front hood lock release lever (A) to
check that the front hood is unlocked normally.
(A)
PI-00166
10.OPERATION CHECK OF FUEL LID PI-00195

OPENER LOCK RELEASE LEVER
Operate the fuel lid opener and verify that the fuel
lid is unlocked normally. Check that the filler cap is
securely closed.
PI-6
Operate the lever (B) and check that the front hood 14.BRAKE FLUID
is opened normally. Support the front hood with
Check that the brake fluid level is normal. If the
hood stay.
amount is insufficient, carry out a brake line test to
identify brake fluid leaks and check the brake oper-
ation. After that, refill the brake fluid tank with the
specified type of fluid.
(A)
(B)
PI-00172
(A) MAX. level

(B) MIN. level
15.ENGINE OIL
(B)
Check the engine oil amount. If the amount of oil is
insufficient, check that no leaks are found. Then,
PI-00202 add the necessary amount of the specified engine
13.BATTERY oil.
• Except for 3.0 L model
Check the battery terminals to make sure that there
are no rust or corrosions due to fluid leaks. Check (B)
(A)
that the battery caps are securely tightened.
(A) (C)
(E)
(D)
(B)
LU-00213
(C) (A) Oil level gauge

PI-00012 (B) Engine oil filler cap
(C) Upper level
(A) Cap
(D) Lower level
(B) Upper level
(E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
(C) Lower level
PI-7
• 3.0 L model 17.AT FRONT DIFFERENTIAL OIL

Check that the AT front differential oil level is nor-
(B)
mal. If the amount of oil is insufficient, check that no
(A) (C) leaks are found. Then, add the necessary amount
F
of the specified AT front differential oil.
• 4AT model
L
(D)
(A)
(B) (A)
LU-00111 (C)
(A) Oil level gauge

(B) Engine oil filler cap
(C) Upper level
(D) Lower level
PI-00183
16.TRANSMISSION GEAR OIL (A) Oil level gauge

Check that the transmission gear oil level is normal. (B) Upper level
If the amount of fluid is insufficient, check that no (C) Lower level
leaks are found. Then, add the necessary amount
of the specified transmission gear oil. • 5AT model
(A) (A) (A)
F
(B)
(C)
L
(B)
(C)
PM-00030 PI-00184
(A) Oil level gauge (A) Oil level gauge

(B) Upper level (B) Upper level
(C) Lower level (C) Lower level
18.ENGINE COOLANT
Check that the engine coolant level on the reservoir
tank is normal. If the amount of engine coolant is in-
sufficient, check that no leaks are found. Then, add
the necessary amount of coolant with the specified
concentration.
PI-8
19.CLUTCH FLUID 4) Press the trunk open button (except for EK mod-
el) or “UNLOCK” button (EK model) for more than
Check that the clutch fluid level is normal. If the
one second. Check if the trunk is unlocked and the
amount of fluid is insufficient, check that no leaks
hazard light flashes twice.
are found. Then, add the necessary amount of
specified fluid.
(A)
(C)
(B)
PI-00174
PI-00173
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
20.WINDOW WASHER FLUID

Check that the window washer fluid level is normal.
If the amount is insufficient, check that no leaks are
found. Then, add the necessary amount of washer PI-00196
fluid.
5) Press the “LOCK” button on the keyless trans-
21.FRONT HOOD LATCH CHECK mitter with the trunk lock opened. Check if the all
Retract the hood stay and close the front hood. doors are locked, hazard light blinks five times and
Check that the front hood is securely latched. warning shows trunk open.
6) Press the “LOCK” button momentarily on the
22.KEYLESS ENTRY SYSTEM keyless transmitter. Check that all the doors are
locked and room light goes off.
NOTE:
The following inspections show the initial settings.
When the settings are different from the initial set-
tings, use Subaru Select Monitor to check the de-
tails of each setting for inspections. <Ref. to
LAN(diag)-26, OPERATION, Read Current Data.>
1) Fully open all the door windows.
2) Remove the key from the ignition switch and
close all the doors including rear gate.
3) Press the “LOCK” or “UNLOCK” button on the
keyless transmitter 1 sec. or more and check if the PI-00175
door window of driver seat is opened/closed.
PI-00108
PI-9
7) Press the “UNLOCK” button momentarily on the 26.TEST MODE CONNECTOR

keyless transmitter. Check that the driver’s door is
Turn the ignition switch to ON and check that the
unlocked and hazard light blinks twice and room
malfunction indicator light starts blinking. If the light
light is lit for 15 seconds.
blinks, return the ignition key to LOCK. Pull out the
And press the “UNLOCK” button momentarily
test mode connector from the back of glove box
again in 5 seconds (except for EK model). Check
lower cover, and disconnect the test mode connec-
that all the doors including rear gate are unlocked.
tor. Then, turn the ignition key to ON again. If the
malfunction indicator light blinks at that time in spite
of the disconnected test mode connector, carry out
an engine diagnosis.
(A)
PI-00176
PI-00201
(A) Test mode connector (green)
NOTE:
If it is difficult to pull out the test mode connector,
remove the glove box lower cover, and disconnect
the test mode connector.
PI-00196
8) Close all the doors including rear gate and press

the “LOCK” button on the keyless transmitter.
Press the “OPEN” button on the keyless transmitter
and wait for 25 seconds. Check if all the doors in-
cluding rear gate are locked. (Except for EK model)
23.SEAT (B)
1) Check the seat surfaces for stains or dirt. (A)
2) Check that each seat provides full functionality in
PI-00197
sliding and reclining. Check all available functions
of the rear seat such as a trunk-through center arm- (A) Test mode connector (green)
rest.
(B) Glove box lower cover
24.SEAT BELT
27.IMMOBILIZER SYSTEM
1) Check installation condition of seat belt.
2) Pull out the seat belt and then release it. Check 1) Check that the engine starts with all keys that
that the belt retracts smoothly. are equipped on vehicle.
2) 60 seconds after turning the ignition switch from
25.WHEEL ALIGNMENT ON to ACC or OFF, or immediately after removing
Check the wheel alignment. <Ref. to FS-8, Wheel the key, check that the security indicator light blink-
Alignment.> <Ref. to RS-8, Wheel Alignment.> ing.
NOTE:
If malfunctions occur, refer to “IMMOBILIZER (DI-
AGNOSIS)”.
PI-10
28.STARTING CONDITION 39.WINDOW WASHER

Start the engine and check that the engine starts Check that the window washer system injects
smoothly. If the battery voltage is low, recharge or washer fluid to the specified area of the windshield
replace the battery. If any noises are observed, im- shown in the figure.
mediately stop the engine and check and repair the
Front injection position:
abnormal components.
A: 250 mm (9.84 in)
29.EXHAUST SYSTEM B: 435 mm (17.1 in)
Listen to the exhaust sound to see if no noises are A A
observed. Check the exhaust leaks.
30.INDICATOR AND WARNING LIGHTS
Check that all the indicator and warning lights are
off.
B
31.CLOCK
Check the clock for normal operations and enough
accuracy.
(1) PI-00185
32.AUDIO
(1) Nozzle
Check the radio for full functionality and normal
noise level. Also check the CD, MD unit operations. Rear injection position:
33.NAVIGATION SYSTEM Wagon model
A: 70 mm (2.8 in)
1) Check all display function for normal operation. B: 70#
(For operating procedure, refer to operating manu-
als.)
2) Check the map disc (DVD) are provided on vehi-
cle.
A
3) Check that the navigation systems operate nor-
mally.
34.FRONT ACCESSORY POWER SUPPLY
SOCKET B
1) Check operation for the front accessory power

socket. PI-00104
2) Check operation of the accessory power socket
in console box. 40.WIPER
35.LIGHTING SYSTEM Check the front and rear wipers for normal opera-
tions.
1) Check the headlight operations.
2) Check the stop light operation. 41.POWER WINDOW OPERATION CHECK
3) Check other lights for normal operations. Operate the power window switches one by one to
36.WIPER DEICER check that each of the power windows goes up and
down without noises.
Check that the wiper deicer operates normally.
42.CARGO FAN
37.REAR FOG LIGHT
Check the cargo fan for normal operations.
Check that the rear fog light operates normally.
43.SUNROOF
38.ILLUMINATION CONTROL
Check the sunroof for normal operations.
Check that the illumination control operates nor-
mally. 44.DOOR MIRROR
Check the remote control mirror for normal opera-
tions.
PI-11
45.BRAKE TEST 50.CRUISE CONTROL

Check the foot brake for normal operations. Operate the cruise control system. Check that the
system is activated and deactivated correctly.
46.PARKING BRAKE
Check the parking brake for normal operations. 51.ATF LEVEL
When applying the parking brake with force of 200 While engine is idling, check that the ATF level is
N (20.4 kgf, 45.0 lb), check that the lever stroke of normal. If the amount is insufficient, check that no
parking brake lever is 5 to 6 notches. leaks are found. Then add the necessary amount of
the specified ATF.
47.AT SHIFT CONTROL • 4AT
1) Turn the ignition switch to ON.
2) While brake pedal is not depressed, check if the (A)
select lever does not move from “P” range.
3) While brake pedal is depressed, check if the se-
lect lever moves from “P” range.
F
4) Set the select lever to other than “P” range. (C) (B)
HOT
L
5) When the ignition switch is turned OFF, check if (D)
the ignition key switch cannot be removed.

(C)
F
6) Set the AT select lever to each gear position and
COLD
(E)
L
(D)
check the shifting while driving the vehicle.
PI-00189
(A) Level gauge

(B) ATF level range [70 — 80#C (158 — 176#F)] at
P “HOT”
R (C) Upper level
N (D) Lower level
D (E) ATF level range [20 — 30#C (68 — 86#F)] at
“COLD”
• 5AT
PI-00199
• 4AT
(A) (A)
Selector Posi- Gear Position
F
(C)
HOT
tion (B)
1st 2nd 3rd 4th
L
(D)
D OK OK OK OK
SPORT shift OK OK OK OK F
(C)
COLD
• 5AT (E)
L
(D)
Selector Posi- Gear Position
tion 1st 2nd 3rd 4th 5th PI-00190
D OK OK OK OK OK
(A) Level gauge
SPORT shift OK OK OK OK OK
(B) ATF level range [70 — 80#C (158 — 176#F)] at
48.HEATER & VENTILATION “HOT”
(C) Upper level
Operate the heater and ventilation system to check (D) Lower level
for normal airflow outlet control, air inlet control, air-
(E) ATF level range [20 — 30#C (68 — 86#F)] at
flow capacity and heating performance. “COLD”
49.AIR CONDITIONER
Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
is provided.
PI-12
52.POWER STEERING FLUID LEVEL 55.APPEARANCE CHECK 2

Check that the power steering fluid level is normal. 1) When vehicle body is covered with protective
If the amount is insufficient, check that no leaks are film, peel it off.
found. Then add the necessary amount of the NOTE:
specified power steering fluid. • Use of steam facilitates peeling off the warp
guard.
• For the vehicle left for a long time or at low tem-
perature, sprinkle some water heated 50 — 60#C
(122 — 140#F) over the vehicle to raise its surface
temperature before peeling off the wrap guard. Do
not use the water heated to over 60#C (140#F).
HOT MAX • If the adhesive remains exists on the coated sur-
COLD MAX
HOT MIN
face, soak a flannel rag, etc. with a small amount of
COLD MIN coating wax or solvent such as oil benzene and
IPA, put the soaked cloth on the remains lightly,
PS-00463
and then wipe them off with a flannel rag, etc.
53.FLUID LEAK CHECK • Keep solvent from touching the resin or rubber
parts. Do not use coating wax or solvent while the
Check entire areas of the vehicle for any trace of
component surface temperature is high due to hot
coolant/oil/fluid leaks.
weather, etc.
54.WATER LEAK TEST • If the coated surface is swollen out due to seams
or moisture, expose the vehicle to the sunlight for a
Spray the vehicle with water using a hose and
few hours or heat the seam and swollen portions
check that no water enters the passenger compart-
using a dryer, etc.
ment.
• Dispose of the peeled wrap guard as burnable in-
• Before performing the water leakage test, re-
dustrial garbage.
move anything that may obstruct the operation or
which must be kept dry. 2) Check the whole vehicle body for flaking paint,
• Close all the windows and doors securely. Close damage by transportation, corrosion, dirt, cracks or
the hood and trunk lid before starting the test. blisters.
• Spray the vehicle with water using a hose. The NOTE:
rate of water spray must be approx. 20 to 25 2 (5.3 • It is better to determine an inspection pattern in
to 6.6 US gal, 4.4 to 5.5 Imp gal) per minute. order to avoid missing an area, since the total in-
When spraying water on areas adjacent to the floor spection area is wide.
and wheel house, increase the pressure. When • Do not repair the body paint unless absolutely
spraying water on areas other than the floor and necessary. Also, if the vehicle is in need of repair to
wheel house, decrease the pressure. But the force remove scratches or corroded paint, the repair area
of water must be made strong occasionally by must be limited to the minimum. Re-painting and
pressing the end of the hose. spray painting must be avoided as possible.
NOTE: 3) Check each window glass for scratches careful-
Be sure to keep the hose at least 10 cm (3.9 in) ly. Slight damage may be removed by polishing
from vehicle. with cerium oxide. (Fill a cup half with cerium oxide,
Check the following areas. and add warm water to it. Then agitate the content
• Front window and body framework mating por- until it turns to wax. Apply this wax to a soft cloth,
tion and polish the glass with it.)
• Door mating portions 4) Check each portion of the vehicle body and un-
derside components for the formation of rust. If rust
• Glass mating portions
is discovered, remove it with sandpaper of #80 to
• Rear quarter window mating portions
#180 and treat the surface with rust preventive. Af-
• Rear window and body framework mating portion ter this treatment is completed, flush the portion
• Around roof drips thoroughly, and prepare the surface for repair
If any dampness in the compartments is discovered painting.
after the water has been applied, carefully check all 5) Check each portion of body and all of the plated
the areas that may have possibly contributed to the parts for deformation or distortion. Also, check
leak. each lamp lens for cracks.
PI-13
6) Peel the protective tape, vinyl wrapping and

identification seal attached to the following places.
• Seat
• Door trim
• Floor carpet
• Side sill
• Front hood lock release lever
• Edge rear
• Rear wiper
• Sedan rear combination light (Trunk lid opening
portion)
• Roof rail
• Door mirror
PI-14
PERIODIC MAINTENANCE SERVICES
PM
Page
1. General Description ....................................................................................2
2. Schedule .....................................................................................................3
3. Engine Oil....................................................................................................7
4. Engine Oil Filter...........................................................................................9
5. Spark Plug.................................................................................................10
6. V-belt.........................................................................................................11
7. Timing Belt ................................................................................................14
8. Fuel Line ...................................................................................................17
9. Air Cleaner Element ..................................................................................18
10. Cooling System .........................................................................................20
11. Engine Coolant..........................................................................................22
12. Clutch System ...........................................................................................24
13. Transmission Gear Oil ..............................................................................25
14. Automatic Transmission Fluid ...................................................................26
15. Front and Rear Differential Gear Oil .........................................................28
16. Brake Line .................................................................................................30
17. Brake Fluid ................................................................................................32
18. Disc Brake Pad and Disc ..........................................................................33
19. Parking Brake............................................................................................34
20. Suspension ...............................................................................................35
21. Wheel Bearing...........................................................................................37
22. Axle Boots and Joints................................................................................38
23. Steering System (Power Steering)............................................................39
General Description
1. General Description
A: GENERAL DESCRIPTION
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they occur.
PM-2
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. EUROPE AREA
For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring
to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 120,000 km (75,000 miles) or 96 months.
Maintenance interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48 60 72 84 96
" 1,000 km 1.6 5 15 30 45 60 75 90 105 120 Remarks
" 1,000 miles 1 3 9 19 28 38 47 56 66 75
1 Engine oil 3.0 L R R R R R R R R R
Others R R R R R R R R
2 Engine oil filter 3.0 L R R R R R R R R R
Others R R R R R R R R
3 Spark plug Others R
3.0 L R R R R
4 Drive belt(s) For 3.0 L model,
replace every
I I I I I I I I
160,000 km
(100,000 miles).
5 Camshaft drive belt R
6 Fuel line I I I I
7 Air cleaner element I R I R I R I R
8 Cooling system I I I I
9 Coolant R R R R
10 Clutch system I I I I
11 Transmission oil I R I R
12 ATF I R I R
13 Front & rear differential I R I R
14 Brake line I I I I
15 Brake fluid R R R R
16 Disc brake pads & discs I I I I I I I I
17 Parking brake I I I I
18 Suspension I I I I
19 Wheel bearing (I)
20 Axle boots & joint I I I I I I I I
21 Steering system I I I I
Symbols used:
R: Replace
I: Inspection
(I): Recommended service for safe vehicle operation.
NOTE:
(1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(2) ATF filter is maintenance free part. ATF filter needs replacement when it is physically damaged or ATF leaked.
(3) Periodic inspection and replacement of the camshaft drive chains on the 3.0 L models is not required.
PM-3
Schedule
2. EXCEPT FOR EUROPE AREA

For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
Months 12 24 36 48
" 1,000 km 5 12.5 25 37.5 50 Remarks
" 1,000 miles 3 7.5 15 22.5 30
1 Engine oil 3.0 L R R R R R
Others R R R R
2 Engine oil filter 3.0 L R R R R R
Others R R R R
For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
Months 12 24 36 48
" 1,000 km 1.6 25 50 75 100 Remarks
" 1,000 miles 1 15 30 45 60
3 Spark plugs Turbo and 3.0 L R
2.5 L, 2.0 L non-
R R R R
turbo
4 Drive belt(s) For 3.0 L model, replace every 160,000 km (100,000
I I I I
miles).
5 Camshaft drive belt R
6 Fuel line I I
7 Air cleaner element I R I R
8 Cooling system I I
9 Coolant R R
10 Clutch system I I I I
11 Transmission oil R R
12 ATF R R
13 Front & rear differential oil R R
14 Brake line I I I I
15 Brake fluid R R
16 Disc brake pads & discs I I I I
17 Parking brake I I I I
18 Suspension I I
19 Wheel bearing (I)
20 Axle boots & joint I I I I
21 Steering system (Power steering) I I I I
Symbols used:
R: Replace
I: Inspection
(I): Recommended service for safe vehicle operation.
NOTE:
(1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(2) ATF filter is maintenance free part. ATF filter needs replacement when it is physically damaged or ATF leaked.
(3) Periodic inspection and replacement of the camshaft drive chains on the 3.0 L models is not required.
PM-4
Schedule
B: MAINTENANCE SCHEDULE 2
1. EUROPE AREA
Salt or other
Repeat Extremely High humid-
Repeat short corrosive Repeat tow-
Item Every rough/muddy cold weather ity or moun-
distance drive used or ing trailer
road drive area tain area
coastal area
Engine oil Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Engine oil filter Replace Replace Replace
Fuel line 12 months
15,000 km I
9,000 miles
Transmission oil Replace
more fre-
quently
ATF Replace
more fre-
quently
Front & rear dif- Replace
ferential oil more fre-
quently
Brake line 12 months
15,000 km I I I I
9,000 miles
Brake fluid 12 months
15,000 km R
9,000 miles
Brake pads 12 months
15,000 km I I I I
9,000 miles
Brake linings 12 months
and drums 15,000 km I I I I
9,000 miles
Parking brake 12 months
15,000 km I I I I
9,000 miles
Suspension 12 months
15,000 km I I I
9,000 miles
Axle boots & 12 months
joints 15,000 km I I I I
9,000 miles
Steering system 12 months
(Power steering) 15,000 km I I I
9,000 miles
PM-5
Schedule
2. EXCEPT FOR EUROPE AREA

Salt or other
Repeat Extremely High humid-
Repeat short corrosive Repeat tow-
Item Every rough/muddy cold weather ity or moun-
distance drive used or ing trailer
road drive area tain area
coastal area
Engine oil Replace Replace Replace
Engine oil filter Replace Replace Replace
Fuel line 6 months
12,500 km I
7,500 miles
Transmission oil Replace
more fre-
quently
ATF Replace
more fre-
quently
Front & rear dif- Replace
ferential oil more fre-
quently
Brake line 6 months
12,500 km I I I I
7,500 miles
Brake fluid 12 months
25,000 km R
15,000 miles
Brake pads 6 months
12,500 km I I I I
7,500 miles
Brake linings 6 months
and drums 12,500 km I I I I
7,500 miles
Parking brake 6 months
12,500 km I I I I
7,500 miles
Suspension 6 months
12,500 km I I I
7,500 miles
Axle boots & 6 months
joints 12,500 km I I I I
7,500 miles
Steering system 6 months
(Power steering) 12,500 km I I I
7,500 miles
PM-6
Engine Oil
3. Engine Oil • 2.0 L non-turbo and 2.5 L model
A: REPLACEMENT
1) Open the engine oil filter cap for quick draining of
engine oil.
(A) (B)
LU-00218
• 3.0 L model
PM-00161
(A) Oil level gauge

(B) Oil filler cap
• 3.0 L model
(B)
LU-02011
(A) (C)
3) Tighten the engine oil drain plug after draining
F
engine oil.
L
(D)
NOTE:
Use a new drain plug gasket.
Tightening torque:
44 N!m (4.5 kgf-m, 33 ft-lb)
LU-00111 • DOHC turbo model
(A) Oil level gauge
(B) Oil filler cap
(C) Upper level
(D) Lower level
2) Drain the engine oil by removing engine oil drain

plug.
• DOHC turbo model
LU-00219
• 2.0 L non-turbo and 2.5 L model
LU-00219
LU-00218
PM-7
Engine Oil
• 3.0 L model B: INSPECTION

1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the en-
gine oil level is below the “L” line, add oil to bring
the level up to the “F” line.
LU-02011
(B)
(A)
4) Fill engine oil through level gauge up to the cen-
ter between upper level and lower level. Place the
vehicle on a level surface when checking oil level. (C)
Use engine oil of proper quality and viscosity, se-
(E)
lected in accordance with following.
(D)
Recommended oil:
Refer to “RM” section. <Ref. to RM-3, LUBRI-
CANTS, RECOMMENDED MATERIALS, Rec-
LU-00213
ommended Materials.>
Engine oil capacity (A) Oil level gauge
(B) Oil filler cap
Except for 3.0 L model
(C) Upper level
Upper level:
(D) Lower level
Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level: (E) Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
Approx. 3.0 2 (3.2 US qt, 2.6 Imp qt) • 3.0 L model
3.0 L model
Upper level: (B)
Approx. 5.5 2 (5.8 US qt, 4.8 Imp qt) (A) (C)
F
Lower level:
L
(D)
The proper viscosity oil make the engine ideal tem-
perature, and cranking speed increased by reduc-
ing viscaus friction in hot condition.
CAUTION:
When replenishing oil, it does not matter if the LU-00111
oil to be added is a different brand from that in
the engine; however, use oil having the API (A) Oil level gauge
classification and SAE viscosity No. designat- (B) Oil filler cap
ed by SUBARU. (C) Upper level
NOTE: (D) Lower level
If the vehicle is used in areas with very high temper- 5) After turning off the engine, wait a few minutes
atures or for other heavy duty applications, the fol- for the oil to drain back into the oil pan before
lowing viscosity oils must be used: API checking the level.
classification: SL, SJ or SH
6) Just after driving or while the engine is warm, en-
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W- gine oil level may show in the range between the
50. “F” line and the notch mark. This is caused by ther-
5) Close the engine oil filler cap. mal expansion of engine oil.
6) Start the engine and warm it up for a time. 7) To prevent overfilling the engine oil, do not add
7) After the engine stops, recheck the oil level. oil above the “F” line when the engine is cold.
<Ref. to PM-8, INSPECTION, Engine Oil.>
PM-8
Engine Oil Filter
4. Engine Oil Filter 6) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
A: REPLACEMENT NOTE:
1) Remove the under cover. The filter element and filter case are permanently
2) Remove the oil filter using ST. jointed; therefore, interior cleaning is not neces-
ST 18332AA000 OIL FILTER WRENCH (Outer sary.
diameter: 68 mm (2.68 in))
7) Check the engine oil level. <Ref. to PM-8, IN-
ST 18332AA010 OIL FILTER WRENCH (Outer SPECTION, Engine Oil.>
PM-00163
• Turbo model
LU-00227
ST 498547000 OIL FILTER WRENCH

• 3.0 L model
LU-00131
3) Obtain a new oil filter and apply a thin coat of en-

gine oil to the seal rubber.
4) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
5) Tighten more (approx. 1 turn for oil filter 68 mm
(2.68 in) in outer diameter, approx. 3/4 turn for oil
filter 65 mm (2.56 in) in outer diameter) after the
seal rubber contacts the cylinder block. Do not
tighten excessively, or oil may leak.
PM-9
Spark Plug
5. Spark Plug • 3.0 L model
A: REPLACEMENT
1. SOHC MODEL (A)
1) Remove the intake duct and intake chamber.

2) Remove the battery.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a spark plug socket.
(B)
IG-02004
(A) Bracket
(B) Connector
PM-00001
5) Tighten the new spark plug lightly with hand, and

then secure with a spark plug socket to the speci-
fied torque.
Recommended spark plug:
2.5 L EC, EK model
NGK: PFR5B-11 PM-00112
Except for 2.5 L EC, EK model
CHAMPION: RC10YC4 6) Tighten the new spark plug lightly with hand, and
then secure with a spark plug socket to the speci-
Tightening torque: fied torque.
21 N!m (2.1 kgf-m, 15.2 ft-lb)
Recommended spark plug:
NOTE: NGK: ILFR6B
• Be sure to place the gasket between the cylinder
head and spark plug. Tightening torque:
• If the torque wrench is not available, tighten the 21 N!m (2.1 kgf-m, 15.2 ft-lb)
spark plug until gasket contacts cylinder head; then 7) Tighten the ignition coil.
tighten further 1/4 to 1/2 turns.
Tightening torque:
2. DOHC MODEL 16 N!m (1.6 kgf-m, 11.7 ft-lb)
1) Remove the battery and battery carrier. NOTE:
2) Remove the air cleaner case. • Be sure to place the gasket between the cylinder
3) Detach the connector from ignition coil. head and spark plug.
4) Remove the ignition coil. • If the torque wrench is not available, tighten the
• Except for 3.0 L model spark plug until gasket contacts cylinder head; then
tighten further 1/4 to 1/2 turns.
PM-00145
PM-10
V-belt
6. V-belt Belt tension (with belt tension gauge):

(A)
A: INSPECTION When installing new one: 640 — 785 N
(65.3 — 80.0 kgf, 144 — 176 lb)
1. EXCEPT FOR 3.0 L MODEL
At inspection: 490 — 640 N (50 — 65 kgf,
1) Replace the belts if crack, fraying or wear is 110 — 144 lb)
found. (B)
2) Check the V-belt tension and adjust it if neces- When installing new one: 620 — 760 N (63
sary by changing the generator installing position — 77 kgf, 140 — 170 lb)
or idler pulley installing position. <Ref. to PM-12, At inspection: 350 — 450 N (36 — 46 kgf, 79
REPLACEMENT, V-belt.> — 101 lb)
Belt tension (without belt tension gauge): (A)
(A)
When installing new one: 7 — 9 mm (0.276 P/S GEN A/C
— 0.354 in) (B)
At inspection: 9 — 11 mm (0.354 — 0.433
in)
(B)
When installing new one: 7.5 — 8.5 mm I/P
(0.295 — 0.335 in) C/P
At inspection: 9.0 — 10.0 mm (0.354 — PM-00154
0.394 in)
(A) Front side belt
98 N (10kg)
(B) Rear side belt
P/S GEN A/C C/P Crank pulley
(A) (B)
GEN Generator
P/S Power steering oil pump pulley
A/C A/C compressor pulley
I/P Idler pulley
I/P
C/P
PM-00002
(A) Front side belt

(B) Rear side belt
C/P Crank pulley
GEN Generator
I/P Idler pulley
PM-11
V-belt
2. 3.0 L MODEL • Turbo model

1) Replace the belts if crack, fraying or wear is
found.
2) Check that the V-belt automatic tensioner indica-
tor (A) is within the range (D).
(A)
(D)
ME-00807
3) Loosen the lock bolt (A).

4) Loosen the slider bolt (B).
(C) 5) Remove the front side belt (C).
(B)
6) Install a new V-belt, and tighten the slider bolt so
as to obtain the specified belt tension.
7) Tighten the lock bolt (A).
8) Tighten the slider bolt (B).
Tightening torque:
Lock bolt
25 N!m (2.5 kgf-m, 18 ft-lb)
Slider bolt
8 N!m (0.8 kgf-m, 5.8 ft-lb)
ME-00475
(A) Indicator (B)

(B) Generator (C)
(C) Power steering oil pump

(D) Service limit
B: REPLACEMENT
(A) PM-00004
1. FRONT SIDE BELT (FOR POWER
STEERING OIL PUMP AND GENERATOR) 2. REAR SIDE BELT (FOR A/C)
NOTE: NOTE:
Wipe off any oil and water on the belt and pulley. Wipe off any oil and water on the belt and pulley.
1) Remove the collector cover. (If equipped) 1) Remove the front side belt.
2) Remove the V-belt covers. 2) Loosen the lock nut (A).
• Non-turbo model 3) Loosen the slider bolt (B).
4) Remove the rear side belt.
5) Install a new V-belt, and tighten the slider bolt so
6) Tighten the lock nut (A).
PM-00003
PM-12
V-belt
Tightening torque:
23 N!m (2.3 kgf-m, 17.0 ft-lb)
(B)
(A)
PM-00005
7) Install the front side belt.

• Non-turbo model <Ref. to ME(H4SO 2.0)-38,
FRONT SIDE BELT, INSTALLATION, V-belt.>
• Turbo model <Ref. to ME(H4DOTC)-39, FRONT
SIDE BELT, INSTALLATION, V-belt.>
3. 3.0 L MODEL
1) Fit the tool to the belt tensioner mounting bolt.
2) Turn the tool clockwise, and loosen the V-belt to
remove.
ME-00473
3) Remove the V-belt cover.

4) Install in the reverse order of removal.
(6)
(1)
(4)
(2) (5)
(3) ME-00474
(1) Power steering oil pump

(2) Belt tension adjuster
(3) Crankshaft pulley
(4) A/C compressor
(5) Belt idler
(6) Generator
PM-13
Timing Belt
7. Timing Belt ST 499987500 CRANKSHAFT SOCKET
A: REPLACEMENT
(B)
1. SOHC MODEL
1) Protect the radiator with cardboard and blanket.
2) Remove the V-belt covers.
(B)
(A)
(B)
PM-00003
3) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,

V-belt.>
4) Remove the A/C compressor V-belt tensioner.
5) Use the ST to lock the crankshaft, and remove
the pulley bolt. PM-00009
ST 499977100 CRANK PULLEY WRENCH
(A) Notch
(B) Alignment mark
ST
11) Remove the belt idler.
12) Remove the belt idler (No. 2).
PM-00007
6) Remove the crank pulley.

7) Remove the belt cover (LH).
8) Remove the front timing belt cover.
9) Remove the timing belt guide. (MT model) PM-00010
10) Turn the crankshaft and align the alignment
13) Remove the timing belt.
marks on crankshaft, and left and right cam sprock-
ets with notches of belt cover and cylinder block. 14) Remove the automatic belt tension adjuster as-
sembly.
PM-00011
15) Install in the reverse order of removal. <Ref. to

ME(H4SO 2.0)-44, INSTALLATION, Timing Belt.>
PM-14
Timing Belt
2. DOHC MODEL 9) Remove the timing belt guide. (Except for non-
turbo AT model)
1) Protect the radiator with cardboard and blanket.
2) Remove the V-belts. <Ref. to ME(H4DOTC)-39,
V-belt.>
3) Remove the A/C compressor V-belt tensioner.
4) Remove the pulley bolt. Use the ST to lock
crankshaft.
• Except for turbo MT model:
• Turbo MT model:
PM-00008
ST
PM-00093
5) Remove the crank pulley. ME-00727

6) Remove the belt cover (LH).
7) Remove the belt cover (RH).
8) Remove the front belt cover.
ME-00728
ME-00729
10) Turn the crankshaft and align the alignment

marks on crankshaft, and left and right cam sprock-
ets with notches of belt cover and cylinder block.
Use the ST to turn crankshaft.
PM-15
Timing Belt
ST 499987500 CRANKSHAFT SOCKET CAUTION:

When installing the timing belt, be sure to align
all alignment marks on the belt with corre-
sponding marks on the sprockets. If incorrectly
installed, interference between pistons and
valves may occur.
B: INSPECTION
1. SOHC MODEL
1) Remove the front timing belt cover and timing
ME-00070 belt cover (LH).
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
27 mm (1.06 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
ME-00071
11) Remove the belt idler. W
PM-00016
4) Install the front timing belt cover and timing belt

cover (LH).
2. DOHC MODEL
PM-00095
1) Remove the timing belt cover (LH).
12) Remove the timing belt. 2) While cranking engine at least four rotations,
13) Remove the automatic belt tension adjuster as- check the timing belt back surface for cracks or
sembly. damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
4) Install the timing belt cover (LH).
W
PM-00096
14) Install in the reverse order of removal. <Ref. to

ME(H4DOTC)-43, Timing Belt.>
PM-00097
PM-16
Fuel Line
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose band, etc. If
faulty parts are found, repair or replace them.
<Ref. to FU(H4SO 2.0)-53, Fuel Delivery, Return
and Evaporation Lines.>
• Turbo model
<Ref. to FU(H4DOTC)-56, Fuel Delivery, Return
and Evaporation Lines.>
• 3.0 L model
<Ref. to FU(H6DO)-54, Fuel Delivery, Return and
Evaporation Lines.>
PM-17
Air Cleaner Element
9. Air Cleaner Element • Non-turbo model
A: REPLACEMENT
1) Disconnect the ground cable from battery.
(B)
PM-00182
• Turbo model
IN-00203
2) Disconnect the connector from mass air flow (B) (B)

sensor. (2.0 L turbo, 3.0 L and 2.5 L EC, EK, K4 (A)
model)
• 3.0 L and 2.5 L EC, EK, K4 model
(A)
PM-00183
5) Remove the air cleaner case (rear).

6) Remove the air cleaner element.
IN-00204
• Turbo model
IN-00206

NOTE:
• Fasten with a clip after inserting the lower tab of
PM-00181 the case.
3) Loosen the clamps (A) which connect the air
cleaner case to intake duct. (Turbo model)
4) Remove the clips (B) on air cleaner case.
IN-00207
PM-18
Air Cleaner Element
• Refer to “COMPONENT” for tightening torque.

2.0 L non-turbo and 2.5 L model
<Ref. to IN(H4SO 2.0)-2, COMPONENT, Gen-
eral Description.>
Turbo model
<Ref. to IN(H4DOTC)-2, COMPONENT, Gener-
al Description.>
3.0 L model
<Ref. to IN(H6DO)-2, COMPONENT, General
Description.>
PM-19
Cooling System
10.Cooling System NOTE:

Rust or dirt on the cap may prevent valve from func-
A: INSPECTION tioning normally: be sure to clean the cap before
1) To check the radiator for leakage, fill it with en- testing.
gine coolant, and attach the radiator cap tester (A) Raise the pressure until the needle of gauge stops
to the filler neck, and apply pressure. Check the fol- and see if the pressure can be retained for five to
lowing points: six seconds. The radiator cap is normal if a pres-
Non-turbo model: sure above the service limit value has been main-
157 kPa (1.6 kg/cm2, 23 psi) tained for this period.
Turbo model:
122 kPa (1.2 kg/cm2, 18 psi) Radiator cap valve open pressure
• Each portion of radiator for leakage Non-turbo model
• Hose joints and other connections for leakage Standard:
NOTE: 93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
• For turbo model, be sure to install the tester to fill- psi)
er tank side. Service limit:
• When attaching or detaching tester or when op- 83 kPa (0.85 kg/cm2, 12 psi)
erating tester, use special care not to deform radi- Turbo model
ator filler neck.
• Non-turbo model Filler tank side
Standard:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
Service limit:
83 kPa (0.85 kg/cm2, 12 psi)
Radiator side
Standard:
122 — 152 kPa (1.24 — 1.55 kg/cm2, 18 —
22 psi)
(A)
Service limit:
PM-00128
112 kPa (1.14 kg/cm2, 16 psi)
• Turbo model
(A)
PM-00023
PM-00184
• When performing this check, be sure to keep the

engine stationary and fill radiator with coolant.
• Wipe off check points before applying pressure.
• Use care not to spill coolant when detaching
tester from radiator.
(A)
• Do not remove the radiator side cap. (Turbo
model)
2) Check the radiator cap valve open pressure us-
ing radiator cap tester. (B)
(A)
PM-00089
(A) Check points for deformation

(B) Check points for deformation, damage, rust
PM-20
Cooling System
3) Start the engine, and then check it does not

overheat or it is cooled excessively. If it overheats
or it is cooled excessively, check the cooling sys-
tem.
<Ref. to CO(H4SO 2.0)-15, Water Pump.> <Ref. to
CO(H4SO 2.0)-18, Thermostat.> <Ref. to
CO(H4SO 2.0)-20, Radiator.> <Ref. to CO(H4SO
2.0)-24, Radiator Cap.>
• Turbo model
<Ref. to CO(H4DOTC)-15, Water Pump.> <Ref. to
CO(H4DOTC)-17, Thermostat.> <Ref. to
CO(H4DOTC)-19, Radiator.> <Ref. to
CO(H4DOTC)-23, Radiator Cap.>
• 3.0 L model
<Ref. to CO(H6DO)-11, Water Pump.> <Ref. to
CO(H6DO)-12, Thermostat.> <Ref. to CO(H6DO)-
13, Radiator.> <Ref. to CO(H6DO)-16, Radiator
Cap.>
4) Check the radiator fan operates using Subaru
Select Monitor, when the coolant temperature ex-
ceeds 95#C (203#F). If it does not operate, check
the radiator fan system.
<Ref. to CO(H4SO 2.0)-8, INSPECTION, Radiator
Fan System.>
• Turbo model
<Ref. to CO(H4DOTC)-9, INSPECTION, Radiator
Fan System.>
• 3.0 L model
<Ref. to CO(H6DO)-7, INSPECTION, Radiator Fan
System.>
PM-21
Engine Coolant
11.Engine Coolant Coolant capacity (fill up to “FULL” level):
A: REPLACEMENT LHD AT model

2.0 L non-turbo and 2.5 L model (without ATF
1. REPLACEMENT OF COOLANT cooler (with warmer))
WARNING: 2.0 L non-turbo and 2.5 L model (with ATF
The radiator is of the pressurized type. Do not cooler (with warmer))
attempt to open the radiator cap immediately Approx. 6.7 2 (7.1 US qt, 5.9 Imp qt)
after the engine has been stopped. 3.0 L model (without ATF cooler (with warm-
1) Lift-up the vehicle. er))
2) Remove the under cover. Approx. 7.2 2 (7.6 US qt, 6.3 Imp qt)
3) Place a container under drain pipe. 3.0 L model (with ATF cooler (with warmer))
4) Remove the drain cock to drain engine coolant Approx. 7.7 2 (8.1 US qt, 6.8 Imp qt)
into container.
LHD MT model
2.0 L non-turbo and 2.5 L model
RHD AT model
2.0 L non-turbo and 2.5 L model (without ATF
cooler (with warmer))
2.0 L non-turbo and 2.5 L model (with ATF
cooler (with warmer))
CO-00248
Turbo model
5) For quick draining, open the radiator cap. Approx. 7.3 2 (7.7 US qt, 6.4 Imp qt)
NOTE: 3.0 L model (without ATF cooler (with warm-
• For turbo model, be sure to open the radiator cap er))
on the filler tank side. Approx. 7.2 2 (7.6 US qt, 6.3 Imp qt)
• Be careful not to spill coolant on the floor. 3.0 L model (with ATF cooler (with warmer))
6) Drain the coolant from reservoir tank. Approx. 7.8 2 (8.2 US qt, 6.9 Imp qt)
7) Tighten the radiator drain cock securely after RHD MT model
draining coolant. 2.0 L non-turbo and 2.5 L model
8) Slowly pour the coolant into radiator. Pour the Approx. 6.5 2 (6.9 US qt, 5.7 Imp qt)
coolant up to air bleeder hole, and then install the NOTE:
cap. (Turbo model) The SUBARU Genuine Coolant containing anti-
9) Pour the coolant from radiator filler port to neck freeze and anti-rust agents is especially made for
of filler. Then, pour the coolant into reservoir tank SUBARU engine, which has an aluminum crank-
up to “FULL” level. case. Always use SUBARU Genuine Coolant,
Recommended engine coolant: since other coolant may cause corrosion.
Refer to “RM” section. <Ref. to RM-5, COOL- 10) Securely install the radiator cap.
ANT, RECOMMENDED MATERIALS, Recom- 11) Run the engine for more than five minutes at
mended Materials.> 2,000 to 3,000 rpm. (Run engine until radiator be-
comes hot in order to purge air trapped in cooling
system.)
12) Stop the engine and wait until coolant temper-
ature lowers. Then open the radiator cap to check
coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
“FULL” level.
13) After adding coolant, securely install the radia-
tor and reservoir tank caps.
PM-22
Engine Coolant
2. RERATIONSHIP OF SUBARU COOLANT If a coolant concentration of 50% is needed, drain

CONCENTRATION AND FREEZING TEM- all the coolant and refill with the undiluted solution
PERTAURE only.
Concentration and safe operating temperature of
Quantity of coolant to be
SUBARU coolant is shown in the diagram. Measur-
drained (US qt, Imp qt)

ing the temperature and specific gravity of the cool-
ant will provide this information.
[Example]
If the coolant temperature is 25#C (77#F), its specif-
ic gravity is 1.054 and the concentration is 45% Necessary Concentration
of coolant
(point A), the safe operating temperature is $14#C
(7#F) (point B), and the freezing temperature is
3
$20#C ($4#F) (point C). (3.2, 45%
2.6) A
Specific gravity
2 40%
Safe operating temperature 35%
(2.1,
30%
of coolant
Concentration 1.8)
of coolant 1 25%
(1.1, 20%
0.9)
1.100 10% 15%
0
10 20 30 40 50
1.090
Concentration of coolant in
1.080 the vehicie cooling system %
60%
1.070 B Concentration of coolant in vehicie
C and quantity to be drained
1.060 50% CO-00012
(1.054)
A
1.050
40%
1.040
Freezing
1.030 30%
temperature
1.020
20%
(77 F)
1.010
25 C
10%
1.000
-40 -30 -20 -10 0 10 20 30 40 50
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
Coolant temperature C ( F) CO-00237
3. PROCEDURE TO ADJUST THE CON-

CENTRATION OF THE COOLANT
To adjust the concentration of coolant according to
temperature, find the proper fluid concentration in
the above diagram and replace the necessary
amount of coolant with an undiluted solution of
SUBARU genuine coolant (concentration 50%).
The amount of coolant that should be replaced can
be determined using the diagram.
[Example]
Assume that the coolant concentration must be in-
creased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
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 2.1 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1
2 (2.2 US qt, 1.8 Imp qt) of coolant from the cool-
ing system and add 2.1 2 (2.2 US qt, 1.8 Imp qt) of
the undiluted solution of SUBARU coolant.
PM-23
Clutch System
12.Clutch System • Be careful not to allow dirt or dust to get into the
reservoir tank.
A: INSPECTION AND ADJUSTMENT
1) Push the release lever to retract the push rod of
the operating cylinder and check if the fluid level in
(A)
the clutch reservoir tank rises or not.
(C)
(B)
(C)
(B) (A)
PM-00165
(A) Reservoir tank

(B) MIN. level
PM-00164 (C) MAX. level
(A) Release lever

(B) Push rod
(C) Operating cylinder
2) If the fluid level rises, pedal free play is correct.

3) If the fluid level does not rise, or the push rod
cannot be retracted, adjust the clutch pedal. <Ref.
to CL-26, Clutch Pedal.>
4) Check the fluid level using the scale on the out-
side of the clutch reservoir tank (A). If the level is
below “MIN” (B), inspect the clutch master cylinder,
operating cylinder and hydraulic line for fluid leaks.
If fluid leaks are found, repair or replace. If fluid
leaks are not found, add clutch fluid to bring it up to
“MAX” (C) of clutch reservoir tank.
Recommended clutch fluid:
Refer to “RM” section. <Ref. to RM-5, FLUID,
RECOMMENDED MATERIALS, Recommend-
ed Materials.>
CAUTION:
Prevent the clutch fluid from being splashed
over vehicle body. If the clutch fluid is splashed
over vehicle body, flush it, and then wipe it up.
NOTE:
• Avoid mixing different brands of brake fluid to
prevent degradation of the fluid.
PM-24
Transmission Gear Oil
13.Transmission Gear Oil

A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug.
NOTE:
• Before starting work, cool off the transmission
gear oil well.
• If transmission gear oil adheres to the exhaust
pipe, wipe it off completely.
PM-00166
2) Replace the gasket with new one, and then tight-

en the drain plug to specified torque.
Tightening torque:
69 N!m (7.0 kgf-m, 50.6 ft-lb)
3) Fill the transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Recommended gear oil:
NOTE:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
Gear oil capacity:
3.5 2 (3.7 US qt, 3.1 Imp qt)
(A)
(B)
(C)
PM-00030
(A) Oil level gauge

(B) Upper level
(C) Lower level
PM-25
Automatic Transmission Fluid
14.Automatic Transmission Flu- • 5AT model

id
(A) (A)
A: INSPECTION
F
(C)
HOT
(B)
CAUTION:
L
(D)
The level of ATF varies with fluid temperature.
Pay attention to the fluid temperature when
F
checking ATF level. (C)
COLD
(E)
L
1) Raise the ATF temperature by driving a distance (D)
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en-
gine to raise ATF temperature to 70 — 80#C (158 PI-00190
— 176#F) on Subaru Select Monitor. <Ref. to
4AT(diag)-17, READ CURRENT DATA, OPERA- (A) Level gauge
TION, Subaru Select Monitor.> (B) ATF level range at “HOT” [70 — 80#C (158 —
2) Make sure the vehicle is level. 176#F)]
3) After selecting all positions (P, R, N, D), shift the (C) Upper level
select lever in “P” range. Measure the ATF level (D) Lower level
with engine idling for one or two minutes. (E) ATF level range at “COLD” [20 — 30#C (68 —
• 4AT model 86#F)]
(A) 4) Make sure that ATF level is above the center of

upper and lower marks at “HOT” side.
5) If the ATF level is below the center between up-
per and lower marks, add the recommended ATF
until the fluid level is found above the center be-
F
(C) (B)
HOT
tween upper and lower marks.

L
(D)
CAUTION:
(C)
F
• Use care not to exceed the upper limit level.

COLD
(E)
L
(D) • Addition of ATF to the upper limit mark on

PI-00189 “HOT” side when the ATF temperature is below
70#C (158#F) will overfilling of ATF, causing a
(A) Level gauge transmission failure.
(B) ATF level range at “HOT” [70 — 80#C (158 — 6) Check ATF level after raising ATF temperature
176#F)]
to 70 — 80#C (158 — 176#F) by running the vehicle
(C) Upper level or by idling the engine again.
(D) Lower level 7) Check the ATF for leaks.
(E) ATF level range at “COLD” [20 — 30#C (68 — Check for leaks in the transmission. If there are
86#F)] leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
PM-26
Automatic Transmission Fluid
B: REPLACEMENT • 4AT model
1. AUTOMATIC TRANSMISSION FLUID (A)
1) Drain the ATF by removing drain plug.

NOTE:
Before starting work, cool off the ATF well.
F
(C) (B)
HOT
• 4AT model
L
(D)
(C)
F
COLD
(E)
L
(D)
PI-00189
(A) Level gauge

(B) ATF level range at “HOT” [70 — 80#C (158 —
(B) 176#F)]
(C) Upper level
(A) (D) Lower level
PM-00167 (E) ATF level range at “COLD” [20 — 30#C (68 —
86#F)]
(A) Front differential gear oil drain plug
(B) ATF drain plug • 5AT model
• 5AT model
(A) (A)
F
(C)
HOT
(B)
L
(D)
(A)
F
(C)
COLD
(E)
L
(D)
PI-00190
PM-00168 (A) Level gauge

(B) ATF level range at “HOT” [70 — 80#C (158 —
(A) ATF drain plug 176#F)]
2) Replace the gasket with new one, and then tight- (C) Upper level
en the drain plug to specified torque. (D) Lower level
(E) ATF level range at “COLD” [20 — 30#C (68 —
Tightening torque: 86#F)]
4AT model
25 N!m (2.55 kgf-m, 18.4 ft-lb) 2. ATF FILTER
5AT model
20 N!m (2.0 kgf-m, 4.5 ft-lb) NOTE:
Basically ATF filter is maintenance free, but when it
3) Pour ATF from the ATF charge pipe. has physically damaged or ATF leaked, the ATF fil-
Recommended ATF: ter needs replacement.
Refer to “RM” section. <Ref. to RM-5, FLUID, For the replacement procedure of ATF filter, refer
RECOMMENDED MATERIALS, Recommend- to “ATF FILTER”.
ed Materials.> • 4AT model
Capacity: <Ref. to 4AT-64, ATF Filter.>
Fill the same amount of ATF drained. • 5AT model
<Ref. to 5AT-60, ATF Filter.>
4) Check the ATF level. <Ref. to PM-26, INSPEC-
TION, Automatic Transmission Fluid.>
PM-27
Front and Rear Differential Gear Oil
15.Front and Rear Differential NOTE:

Gear Oil tives. Thus, do not mix two or more brands.
A: REPLACEMENT Differential gear oil capacity:
1. FRONT DIFFERENTIAL (MT MODEL) 4AT model
1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp
Front differential gear oil for MT model lubricates qt)
the transmission and differential together. Refer to
“Transmission Oil” for replacement procedure.
(A)
<Ref. to PM-25, Transmission Gear Oil.>
2. FRONT DIFFERENTIAL (AT MODEL) (B) (A)
(C)
1) Drain the differential gear oil by removing drain
plug using TORX® BIT T70.
NOTE:
• Before starting work, cool off the differential gear
oil well.
• If front differential gear oil adheres to the exhaust PI-00183
pipe, wipe it off completely.
(A) Oil level gauge
• 4AT model
(B) Upper level
(C) Lower level
5AT model
1.3 — 1.5 2 (1.4 — 1.6 US qt, 1.1 — 1.3 Imp
qt)
(A) (A)
F
PM-00169 (B)
(C)
L
• 5AT model
PI-00184
(A) Oil level gauge

(B) Upper level
(C) Lower level
3. REAR DIFFERENTIAL
PM-00170
1) Drain the oil by removing drain plug.
2) Replace the gasket with new one, and then tight- 2) Remove the filler plug for quick draining oil.
en the drain plug to specified torque. 3) Install the drain plug after draining oil.
Tightening torque: NOTE:
70 N!m (7.1 kgf-m, 16 ft-lb) • Apply liquid gasket to the drain plug threads for
3) Fill differential gear oil through the oil level T-type.
gauge hole up to the upper point of level gauge. • Use a new gasket for VA-type.
Recommended gear oil: Liquid gasket:
Refer to “RM” section. <Ref. to RM-3, LUBRI- THREE BOND 1105 (Part No. 004403010)
PM-28
Front and Rear Differential Gear Oil
Tightening torque: Liquid gasket:

T-type THREE BOND 1105 (Part No. 004403010)
49.0 N!m (5.0 kgf-m, 36.2 ft-lb)
Tightening torque:
VA1-type T-type
34 N!m (3.5 kgf-m, 25.3 ft-lb)
49.0 N!m (5.0 kgf-m, 36.2 ft-lb)
VA2-type
VA1-type
29 N!m (3.0 kgf-m, 21.4 ft-lb)
34 N!m (3.5 kgf-m, 25.3 ft-lb)
4) Pour oil to the bottom end of filler plug hole. VA2-type
Recommended gear oil: 29 N!m (3.0 kgf-m, 21.4 ft-lb)
• Except for VA2-type
(A)
(B)
PM-00037
(A) Filler plug

(B) Drain plug
• VA2-type
(A)
(B) DI-00355
(A) Filler plug

(B) Drain plug
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
NOTE:
tives. Thus, do not mix two or more brands.
5) Install the filler plug.
NOTE:
• Apply liquid gasket to the filer plug threads for T-
type.
• Use a new aluminum gasket for VA-type.
PM-29
Brake Line
16.Brake Line Brake pedal free play (Pulling up direction of

pedal)
A: INSPECTION 0.5 — 2.0 mm (0.02 — 0.08 in)
1. BRAKE LINE
1) Check for scratches, swelling, corrosion, traces
of fluid leakage on the brake hoses or pipe joints.
2) Check the possibility of adjacent parts interfering
with brake pipes/hoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc. (A)
on master cylinder, wheel cylinder and pressure
control valve.
PM-00185
NOTE:
• When the brake fluid level in the reservoir tank is
(A) Pedal free play
lower than specified limit, the brake warning light
on the combination meter will come on. 2) If the free play is out of specifications above, ad-
• Visually check the brake hose for damage. (Use just the brake pedal as follows:
a mirror where it is difficult to see) (1) Make sure the engine is off. (No vacuum is
applied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion. [Pulling up the brake pedal pad with a force
of less than 10 N (1 kgf, 2 lb) to a stroke of 0.5 to
(2) 2.0 mm (0.02 to 0.08 in).]
(3) If there is no free play between clevis pin
(1) and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.3 mm (0.012 in).
PM-00171
(A)
(1) Front brake hose (H) (B)
(2) Front brake pipe (C)
(D)
(I) (E)
(F)
(2)
(J)
(G)
(1)
PM-00186
(A) Brake switch

(B) Adjusting nut
PM-00172
(C) 0.3 mm (0.012 in)
(D) Stopper
(1) Rear brake pipe (E) Clevis pin
(2) Rear brake hose (F) Clevis
(G) Pedal free play
2. SERVICE BRAKE (H) Lock nut
1) Check the free play of brake pedal with pulling (I) Brake booster operating rod
up the force of less than 10 N (1 kgf, 2 lb). (J) Play at pin
PM-30
Brake Line
3) Check the pedal stroke. Replace the both check valve and vacuum hose if
While the engine is idling, depress the brake pedal the check valve is faulty. Engine side of vacuum
with a 490 N (50 kgf, 110 lb) load and measure the hose is indicated by marking “ENG” as shown.
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between pedal and steering wheel again.
The difference between the two measurements
must be less than specified value. If the distance is (A) (B)
more than specified value, there is possibility of air (C)
inside the hydraulic unit.
Brake pedal reserve distance A:
95 mm (3.7 in)/ 490 N (50 kgf, 110 lb) or less
PM-00046
1 2 =A
(A) Engine side
(A) (B) Brake booster side
(C) ENG
1
2
5) Check the vacuum hose for cracks or other dam-
age.
NOTE:
(B) When installing the vacuum hose on the engine
PM-00045
and brake booster, do not use soapy water or lubri-
cating oil on their connections.
(A) Steering wheel
(B) Toe board 6) Check the vacuum hose to make sure it is tightly
secured.
4) Check to see if air is in the hydraulic brake line
by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short dis-
tance on a straight road.
3. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal
several times applying the same pedal force. Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine. Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds.
Make sure the pedal height should not change.
4) A check valve is built into the vacuum hose. Dis-
connect the vacuum hose to inspect function of
check valve.
Blow compressed air into vacuum hose from its
brake booster side end. Make sure air must flow
out of engine side end of hose. Next, blow com-
pressed air into hose from engine side. Make sure
air should not flow out of hose.
PM-31
Brake Fluid
17.Brake Fluid NOTE:

• Cover the bleeder with cloth, when loosening it,
A: REPLACEMENT to prevent brake fluid from being splashed over sur-
1) Either jack-up the vehicle and place a rigid rack rounding parts.
under it, or lift-up the vehicle. • During the bleeding operation, keep the brake
2) Remove all the wheels. reservoir tank filled with brake fluid to eliminate en-
3) Drain the brake fluid from master cylinder. try of air.
4) Refill the reservoir tank with recommended • The brake pedal operation must be very slow.
brake fluid. • For convenience and safety, two people should
Recommended brake fluid: do the work.
Refer to “RM” section. <Ref. to RM-5, FLUID, • The amount of brake fluid required is approx. 500
RECOMMENDED MATERIALS, Recommend- m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake
ed Materials.> system.
6) Instruct your co-worker to depress the brake
NOTE:
pedal slowly two or three times and then hold it de-
• Avoid mixing different brands of brake fluid to
pressed.
prevent degrading the quality of fluid.
7) Loosen the bleeder screw approximately 1/4
• Be careful not to allow dirt or dust to get into the
turn until a small amount of brake fluid drains into
reservoir tank.
the container, and then quickly tighten the screw.
Air bleeding sequence (1) % (2) % (3) % (4) 8) Repeat steps 6) and 7) until there are no air bub-
(1) (4)
bles in drained brake fluid and new fluid flows
through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
(5) (6)
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold the
brake pedal depressed and tighten the screw and
install bleeder cap.
(3) (2)
PM-00047
Tightening torque:
(1) Front RH
8 N!m (0.8 kgf-m, 5.8 ft-lb)
(2) Rear LH 10) Bleed air from each wheel cylinder by following
(3) Front LH steps from 5) to 9).
(4) Rear RH
11) Depress the brake pedal with a force of approx.
294 N (30 kgf, 66 lb) and hold it there for approx. 20
(5) Secondary
seconds. At this time check the pedal to see if it
(6) Primary
makes any unusual movement. Visually inspect the
5) Install one end of a vinyl tube onto the air bleeder bleeder screws and brake pipe joints to confirm
and insert the other end of the tube into a container there is no fluid leakage.
to collect the brake fluid. 12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
confirm brakes are operating properly.
PM-00048
PM-32
Disc Brake Pad and Disc
18.Disc Brake Pad and Disc

(A)
A: INSPECTION (C)
1) Jack-up the vehicle and support with rigid racks. (B)
Then remove the wheels.
2) Visually check the pad thickness through inspec-
tion hole of disc brake assembly. Replace the pad if
necessary.
NOTE:
When replacing a pad, always replace the pads for PM-00140
both the left and right wheels at the same time. Also
replace the pad clips if they are twisted or worn. (A) Pad thickness
(B) Back metal
(C) Lining
3) Check the disc rotor, and correct or replace if it is

damaged or worn.
• Front
Disc rotor thickness mm (in)
15, 16-inch 24 (0.94)
(A) Standard
17-inch 30 (1.18)
PM-00049 15, 16-inch 22 (0.87)
Wear limit
17-inch 28 (1.10)
(A) Inspection hole
• Rear
• Front
Disc rotor thickness mm (in)
Pad thickness mm (in) Solid disc type 10 (0.39)
15-inch 11 (0.43) Standard
Ventilated disc type 18 (0.71)
Standard 16-inch 11 (0.43) Solid disc type 8.5 (0.34)
17-inch 11 (0.43) Wear limit
15-inch 1.5 (0.059)
Wear limit 16-inch 1.5 (0.059) 4) Remove the caliper body. <Ref. to BR-20, Front
17-inch 1.5 (0.059) Disc Brake Assembly.> <Ref. to BR-28, Rear Disc
Brake Assembly.>
• Rear 5) Tighten the wheel nuts to secure disk rotor.
6) Set a dial gauge at a point less than 10 mm (0.39
Pad thickness mm (in)
in) from outer periphery of the rotor, and then mea-
Solid disc type 9 (0.35)
Standard sure the disk rotor runout.
Solid disc type 1.5 (0.059) Disc rotor runout limit:
Wear limit Front: 0.05 mm (0.002 in)
Ventilated disc type 1.5 (0.059)
Rear: 0.05 mm (0.002 in)
PM-00051
PM-33
Parking Brake
19.Parking Brake 4) When the shoe return spring tension is exces-

sively weakened, replace it.
A: INSPECTION
Inspect the brake linings and disc rotor of both
B: ADJUSTMENT
sides of the rear brake at the same time by remov- For rear disc brake, adjust the parking brake after
ing disc rotor. bleeding air.
1) Inspect the brake shoes for damage or deforma- 1) Remove the rear cover (rubber) installed at back
tion and check the brake linings for wear. plate.
2) Turn the adjuster toward arrow mark (upward)
NOTE: until it is locked slightly, by using flat-tip screwdriver
Always replace both primary and secondary brake as shown in the illustration.
shoes for the left and right wheels at the same time.
Thickness of brake lining (except for back met- (A)
al):
(B)
Standard value: 3.2 mm (0.126 in)
Wear limit: 1.5 mm (0.059 in)
(C)
PM-00056
(A)
(A) Adjuster
(B) Cover (rubber)
(B) (C) Back plate
(C)
PM-00054 3) Turn back (downward) the adjuster 3 to 4 notch-
es.
(A) Forward
4) Install the cover (rubber) in original position cor-
(B) Brake shoe (Primary side) rectly.
(C) Brake shoe (Secondary side)
2) Check the inside of disk rotor for wear, dents or

other damage. If the inside surface of dick rotor is
streaked, correct the surface with emery cloth
(#200 or more). If it is unevenly worn or tapered,
correct or replace it.
Brake drum inside diameter:
Standard value: 170 mm (6.69 in)
Wear limit: 171 mm (6.73 in)
(B)
(A)
PM-00055
(A) Inside diameter

(B) Disc
3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
PM-34
Suspension
20.Suspension NOTE:
When the front arm ball joint has been removed or
A: INSPECTION replaced, check the toe-in of front wheel. If the front
1. SUSPENSION BALL JOINT wheel toe-in is not at specified value, adjust the
toe-in. <Ref. to FS-8, Wheel Alignment.>
1) Jack-up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out.
If relative movement is observed between the (A)
brake disc cover (A) and end of front arm (D), ball
joint (C) may be excessively worn.
PM-00059
(A) Dust seal

(A)
(D) 2. FRONT, REAR SUSPENSION BUSHING
(C) (B) Apply pressure with tire lever etc, and inspect the
PM-00057
bushing for wear or crack. Replace the bushings if
3) Grasp the end of front arm and move it up and there is wear or crack.
down. Relative movement (A) between the housing
(D) and front arm (C) boss indicates ball joint (B)
may be excessively worn.
(D)
(A)
PM-00180
(C)
3. WHEEL ARCH HEIGHT
(B)
PM-00058 1) Unload the cargoes and set the vehicle in curb
4) If relative movement is observed in the step 2), weight (empty) condition.
3), remove and inspect the ball joint. If the free play 2) Check the wheel arch height of front and rear
exceeds standard value, replace the ball joint. suspensions to ensure that they are within speci-
<Ref. to FS-17, Front Ball Joint.> fied values. <Ref. to FS-8, Wheel Alignment.>
5) Damage of dust seal 3) When the wheel arch height is out of standard,
Visually inspect the ball joint dust seal. If it is dam- visually inspect following components and replace
aged, remove the front arm. <Ref. to FS-19, Front deformed parts.
Arm.> And measure free play of ball joint. <Ref. to • Suspension components [Front strut assembly
FS-17, Front Ball Joint.> and rear damper assembly]
(1) When looseness exceeds standard value, • Parts connecting suspension and body
replace the ball joint. 4) If no components are deformed, adjust the
(2) If the dust seal is damaged, replace with a wheel arch height by replacing the suspension
new ball joint. which wheel arch height is out of standard. <Ref. to
FS-8, Wheel Alignment.> <Ref. to RS-8, Wheel
Alignment.>
PM-35
Suspension
4. WHEEL ALIGNMENT OF FRONT SUS- • Rear suspension

PENSION <Ref. to RS-2, General Description.>
1) Check the alignment of front suspension to en- 8. DAMAGE TO SUSPENSION PARTS
sure that following items conform to standard val-
Check the following parts and the fastening portion
ues.
of the vehicle body for deformation or excessive
• Toe-in rusting which impairs the suspension. If necessary,
• Camber replace the damaged parts with new ones. If minor
• Caster rust formation, pitting, etc. are noted, remove the
• Steering angle rust and take rust prevention measure.
<Ref. to FS-8, Wheel Alignment.> • Front suspension
2) When the caster angle does not conform to ref- • Front arm
erence obviously, visually inspect the following • Crossmember
components and replace deformed parts. • Strut
• Suspension components [Strut assembly, cross-
• Rear suspension
member, front arm, etc.]
• Sub frame
• Parts connecting suspension and body
• Front link
3) When the toe-in and camber are out of standard
• Rear link
value, adjust them so that they conform to standard
value. • Upper link
4) When the right-and-left turning angles of tire are • Rear arm
out of standard, adjust to standard value. • Shock absorber
• In the area where salt is sprayed to melt snow on
5. WHEEL ALIGNMENT OF REAR SUS- a road in winter, check suspension parts for dam-
PENSION age caused by rust every 12 months after lapse of
1) Check the alignment of rear suspension to en- 60 months. Take rust prevention measure as re-
sure that following items are within standard val- quired.
ues.
• Toe-in
• Camber
• Thrust angle
<Ref. to RS-8, Wheel Alignment.>
2) When the camber angle does not conform to
standard value, visually inspect the following com-
ponents. If the deformation is observed, replace the
damaged parts.
• Suspension components [Shock absorber, front
link, rear link, upper link, rear arm, sub frame, etc]
• Parts connecting suspension and body
3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to
standard value.
6. OIL LEAKAGE OF STRUT AND SHOCK
ABSORBER
Visually inspect the front strut and rear shock ab-
sorber for oil leakage. Replace the front strut and
rear shock absorber if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS
Check the bolts and nuts for looseness. Retighten
the bolts and nuts to specified torque. If the self-
locking nuts and bolts are removed, replace them
with new ones.
• Front suspension
<Ref. to FS-2, General Description.>
PM-36
Wheel Bearing
21.Wheel Bearing If the hub is noisy or binds, replace the rear axle.
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Jack-up the front side of vehicle.
2) While holding the front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts, and remove the front
PM-00173
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub and measure axial
play in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract the front arm from front crossmember.
6) Remove the PTJ of front drive shaft from trans-
mission. <Ref. to DS-13, Front Axle.>
7) While supporting the front drive shaft horizontal-
ly with one hand, turn the hub with the other hand to
check for noise or binding.
If the hub is noisy or binds, replace the front axle.
PM-00173
2. REAR WHEEL BEARING

1) Jack-up the rear side of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts, and remove the rear
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub and measure axial
play in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential. <Ref. to DS-26, Rear Drive Shaft.>
6) While supporting rear drive shaft horizontally
with one hand, turn the hub with the other hand to
check for noise or binding.
PM-37
Axle Boots and Joints
22.Axle Boots and Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, re-
place them with new ones. <Ref. to DS-22, Front
Drive Shaft.> <Ref. to DS-26, Rear Drive Shaft.>
• Front
(A)
PM-00174
• Rear
(B)
PM-00175
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace them with new ones. <Ref. to DS-10,
Propeller Shaft.>
PM-38
Steering System (Power Steering)
23.Steering System (Power 2. STEERING SHAFT JOINT

Steering) When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
A: INSPECTION check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
1. STEERING WHEEL age to sealing or worn serrations. If the joint is
1) Set the steering wheel in a straight-ahead posi- loose, retighten the mounting bolts to the specified
tion, and check the wheel spokes to make sure torque.
they are correctly set in their specified positions.
Tightening torque:
2) Lightly turn the steering wheel to the left and
24 N!m (2.4 kgf-m, 17.4 ft-lb)
right to determine the point where front wheels start
to move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 — 17 mm (0 — 0.67 in)
(1)
PS-00450
(1) Steering wheel free play
Move the steering wheel vertically toward the shaft

to ascertain if there is play in the direction.
PM-00176
Maximum permissible play:
0.5 mm (0.020 in) 3. GEARBOX
3) Drive the vehicle and check the following items 1) With the vehicle placed on a level surface, turn
during operation. the steering wheel 90# in both the left and right di-
(1) Steering force: rections.
The effort required for steering should be While the wheel is being rotated, reach under the
smooth and even at all points, and should not vehicle and check for looseness in gearbox.
vary.
(2) Pulled to one side: Tightening torque:
Steering wheel should not be pulled to either 59 N!m (6.0 kgf-m, 43.4 ft-lb)
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not show any sign of
runout.
(4) Return factor:
Steering wheel should return to its original posi-
tion after it has been turned and then released.
PM-00177
2) Check the boot for damage, cracks or deteriora-

tion.
PM-39
3) With the vehicle placed on a level surface, quick- 4. TIE-ROD

ly turn the steering wheel to the left and right.
1) Check the tie-rod and tie-rod ends for bends,
While steering wheel is being rotated, check the
scratches or other damage.
gear backlash. If any noise is noticed, adjust the
gear backlash.
4) Adjustment for LHD model
(1) Apply liquid gasket to at least 1/3 of entire
perimeter of adjusting screw thread.
(2) Tighten adjusting screw to 25 N!m (2.5 kgf-
m, 18.0 ft-lb) and then loosen.
(3) Tighten adjusting screw to 3.9 N!m (0.40
kgf-m, 2.9 ft-lb) and then loosen 20#. (A)
5) Adjustment for RHD model
(B)
(1) Apply liquid gasket to at least 1/3 of entire PM-00069
perimeter of adjusting screw thread.
(2) Tighten adjusting screw to 9.8 N!m (1.0 kgf- (A) Tie-rod end
m, 7.2 ft-lb) and then loosen. (B) Knuckle arm
(3) Tighten adjusting screw to 4.9 N!m (0.50
kgf-m, 3.6 ft-lb) and then loosen. 2) Check the connections of knuckle ball joints for
(4) Tighten adjusting screw to 4.9 N!m (0.50 play, inspect for damage on dust seals, and check
kgf-m, 3.6 ft-lb) and then loosen 37#. free play of ball studs. If castle nut is loose, retight-
en it to the specified torque, then tighten further up
to 60# until cotter pin hole is aligned.
Tightening torque:
27 N!m (2.75 kgf-m, 19.9 ft-lb)
(A)
3) Check the lock nut on the tie-rod for tightness. If
it is loose, retighten it to the specified torque.
Tightening torque:
83 N!m (8.5 kgf-m, 61.5 ft-lb)
5. POWER STEERING FLUID LEVEL
PM-00068
NOTE:
(A) Apply liquid gasket to at least 1/3 of entire • At power steering fluid temperature 20#C (68#F);
perimeter read the fluid level on the “COLD” side.
6) Install the lock nut. While holding adjusting • At power steering fluid temperature 80#C
screw with a wrench, tighten the lock nut using ST. (176#F); read the fluid level on the “HOT” side.
ST 926230000 SPANNER 1) Place the vehicle with engine “OFF” on a level
surface.
Tightening torque (lock nut): 2) Remove the cover. (3.0 L and turbo model)
LHD model 3) Check the fluid level using the scale on the out-
25 N!m (2.5 kgf-m, 18.0 ft-lb) side of the reservoir tank (A). If the level is below
RHD model “MIN” (B), add fluid to bring it up to “MAX” (C).
39 N!m (4.0 kgf-m, 28.9 ft-lb)
Hold the adjusting screw with a wrench to prevent it
from turning while tightening the lock nut.
(C)
(A)
(B)
PM-00178
PM-40
NOTE: 2) Clips are fitted outside of positions (A) and (B) of

If fluid level is at MAX level or above, drain fluid to boot.
keep the level in the specified range of indicator by 3) Boot does not have crack and hole.
using a syringe or the like. NOTE:
Recommended fluid: Rotate the position (B) of gearbox boot against the
Refer to “RM” section. <Ref. to RM-5, FLUID, twist of it produced by adjustment of toe-in, etc. Ap-
RECOMMENDED MATERIALS, Recommend- ply grease to the groove (C).
ed Materials.>
Fluid capacity:
(C)
0.8 2 (0.8 US qt, 0.7 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox of
power steering system, hoses, pipes and their cou-
plings for fluid leaks. (B)
If the fluid leaks are found, retighten their fitting (A)
bolts (or nuts) and/or replace their parts. PM-00090
NOTE:
10.FITTING BOLTS AND NUTS
• Wipe the leaked fluid off after correcting fluid
leaks. Inspect the fitting bolts and nuts of oil pump and
• Also pay attention to clearances between hoses bracket for looseness, and retighten them if neces-
(or pipes) and other parts when inspecting fluid sary.
leaks. Inspect and/or retighten them when engine is cold.
7. HOSES OF OIL PUMP FOR DAMAGES
Check the pressure hose and return hose of oil
pump for crack, swell or damage. Replace the hose
with a new one if necessary.
NOTE:
Prevent hoses from turning and/or bending when
installing hoses.
PM-00179
8. POWER STEERING PIPES FOR DAMAG-

ES
Check the power steering pipes for corrosion and
damage.
Replace the pipes with new ones if necessary.
9. GEARBOX BOOTS
Inspect both sides of the gearbox boot as follows,
and correct the defects if necessary.
1) Positions (A) and (B) of the gearbox boot are fit-
ted correspondingly in grooves (A) and (B) of the
gearbox and rod (C).
PM-41
PM-42
ENGINE SECTION 1
FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.0)
EMISSION CONTROL EC(H4SO 2.0)

(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION) IN(H4SO 2.0)
MECHANICAL ME(H4SO 2.0)

EXHAUST EX(H4SO 2.0)
of SUBARU vehicles. COOLING CO(H4SO 2.0)
sembling, inspection and adjustment of LUBRICATION LU(H4SO 2.0)
Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP(H4SO 2.0)
their vehicle in optimum condition. IGNITION IG(H4SO 2.0)
SUBARU genuine parts. STARTING/CHARGING SYSTEMS SC(H4SO 2.0)
ENGINE (DIAGNOSTICS) EN(H4SO 2.0)

(diag)


cations contained in this manual are COOLING CO(H4SO 2.5)
approval.

ENGINE SECTION 1
LUBRICATION LU(H4SO 2.5)
SPEED CONTROL SYSTEMS SP(H4SO 2.5)
IGNITION IG(H4SO 2.5)
STARTING/CHARGING SYSTEMS SC(H4SO 2.5)

(diag)
G2320GE2
FUEL INJECTION
(FUEL SYSTEMS)
FU(H4SO 2.0)
Page
2. Throttle Body.............................................................................................10
3. Intake Manifold..........................................................................................11
4. Engine Coolant Temperature Sensor........................................................20
5. Crankshaft Position Sensor.......................................................................21
6. Camshaft Position Sensor.........................................................................22
7. Knock Sensor............................................................................................23
8. Throttle Position Sensor............................................................................25
9. Manifold Absolute Pressure Sensor..........................................................26
10. Intake Air Temperature Sensor .................................................................27
11. EGR Valve ................................................................................................28
12. Fuel Injector ..............................................................................................29
13. Front Oxygen (A/F) Sensor .......................................................................32
14. Rear Oxygen Sensor.................................................................................33
15. Engine Control Module (ECM) ..................................................................34
16. Main Relay ................................................................................................35
17. Fuel Pump Relay.......................................................................................36
18. Electronic Throttle Control Relay ..............................................................37
19. Fuel ...........................................................................................................38
20. Fuel Tank ..................................................................................................39
21. Fuel Filler Pipe ..........................................................................................45
22. Fuel Pump.................................................................................................47
23. Fuel Level Sensor .....................................................................................49
24. Fuel Sub Level Sensor..............................................................................50
25. Fuel Filter ..................................................................................................51
26. Fuel Damper Valve ...................................................................................52
27. Fuel Delivery, Return and Evaporation Lines............................................53
28. Fuel System Trouble in General ...............................................................56
General Description
FUEL INJECTION (FUEL SYSTEMS)
A: SPECIFICATION
Capacity 64 2(16.9 US gal, 14.1 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Shutoff discharge pressure 441 — 686 kPa (4.50 — 7.00 kg/cm2, 64.0 — 99.5 psi)
Fuel pump
75 2 (19.8 US gal, 16.5 Imp gal)/h or more
Discharge
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter In-tank type
FU(H4SO 2.0)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T4 (7) T2
(17)
T2
(9)
T4
(8) T6
T4
(19) (11)
(10) (7)
T5
T3 T4
(14) (17)
T2
(12) (4)
T4 T4 T2
(12)
T5 (9)
(8)
T5
(10)
T5
(5) (13)
(2)
(3) T3
(1)
T5
T4
T4
T1 (12)
T1 T1
(16) T2
(3)
(16) (18) (2) (6)
T1
(18)
(15)
T1
(16) T4
T1
T2
(18)
FU-02056
FU(H4SO 2.0)-3
General Description
(1) Intake manifold (10) O-ring (19) PCV valve

(2) Gasket (11) Purge control solenoid valve
(3) Guide pin (12) Plug cord holder Tightening torque: N!m (kgf-m, ft-lb)
(4) EGR valve (EC, EK, K4 model) (13) Nipple (LHD model) T1: 1.5 (0.15, 1.1)
(5) Fuel pipe protector RH (14) Nipple (RHD model) T2: 6.4 (0.65, 4.7)
(6) Fuel pipe protector LH (15) Fuel pipe ASSY T3: 17 (1.7, 12.5)
(7) Fuel injector pipe (16) Fuel hose T4: 19 (1.9, 13.7)
(8) Fuel injector (17) Clip T5: 25 (2.5, 18.1)
(9) O-ring (18) Clamp T6: 23 (2.3, 17.0)
2. AIR INTAKE SYSTEM
T1
(3)
T2
(4)
(2)
(1)
FU-02057
(1) Gasket (4) O-ring Tightening torque: N!m (kgf-m, ft-lb)

(2) Throttle body T1: 2.0 (0.20, 1.5)
(3) Manifold absolute pressure sensor T2: 8 (0.8, 5.8)
FU(H4SO 2.0)-4
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
T1
T2
(1)
(2)
T1
(3)
(4) T1
FU-00414
(1) Crankshaft position sensor (4) Camshaft position sensor support Tightening torque: N!m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor T2: 24 (2.4, 17.4)
FU(H4SO 2.0)-5
General Description
4. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8) (17) T1
(14)
(7)
(15)
(10)
(9) (12)
(11)
(1)
(13)
(22)
T4 (6)
(5) (22)
(20)
(3)
(2) T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2 T3
FU-01080
FU(H4SO 2.0)-6
General Description
(1) Fuel tank (12) Fuel sub level sensor upper plate (22) Retainer
(2) Fuel tank band RH (13) Fuel sub level sensor gasket (23) Heat shield cover
(3) Fuel tank band LH (14) Fuel filler hose (24) Fuel tank protector RH (Front)
(4) Delivery tube (15) Clamp (25) Fuel tank protector LH (Front)
(5) Return tube (16) Vent hose
(6) Jet pump tube (17) Clip Tightening torque: N!m (kgf-m, ft-lb)
(7) Fuel pump assembly (18) Fuel tank protector RH (Rear) T1: 4.4 (0.45, 3.3)
(8) Fuel pump upper plate (19) Fuel tank protector LH (Rear) T2: 9.0 (0.92, 6.6)
(9) Fuel pump gasket (20) Stopper RH T3: 17.5 (1.78, 12.9)
(10) Fuel level sensor (21) Stopper LH T4: 33 (3.4, 25)
(11) Fuel sub level sensor
FU(H4SO 2.0)-7
General Description
5. FUEL LINE
T1 (1)
(28)
(26) (18)
(23)
(25) (19) (17) (15)

(27) (1)
(20) (22) (14)
(13)
(24)
(21) (1) A (16)
T2 (1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
B T3
T2
(4) (1)
(5) A
(1) T2
B
(3) (1)
(2) (33)
(1) (9)
(32)
(6)
(1) (7) (30) (31)
(8)
FU-01081
FU(H4SO 2.0)-8
General Description
(1) Clip (14) Two-way valve hose A (27) Filler cap

(2) Fuel return hose (15) Purge hose A (28) Tether
(3) Evaporation hose A (16) Purge hose B (29) Clip
(4) Fuel delivery hose A (17) Two-way valve hose B (30) Fuel hose
(5) Fuel delivery hose B (18) Canister drain hose B (31) Purge hose C
(6) Fuel damper (19) Two-way valve drain hose (32) Connector
(7) Fuel damper holder (20) Two-way valve (33) Purge pipe
(8) Fuel damper bracket (21) Two-way valve hose C (34) Two-way valve bracket
(9) Fuel pipe ASSY (22) Connector
(10) Clamp (23) Evaporation hose holder Tightening torque: N!m (kgf-m, ft-lb)
(11) Canister (24) Fuel filler pipe ASSY T1: 4.4 (0.45, 3.2)
(12) Canister protector (Sedan model) (25) Filler pipe packing T2: 7.5 (0.76, 5.53)
(13) Canister drain hose A (26) Filler ring T3: 8.3 (0.85, 6.1)
C: CAUTION • Be careful not to burn yourself, because each

• Wear work clothing, including a cap, protective part on the vehicle is hot after running.
goggles and protective shoes during operation. • Be sure to tighten fasteners including bolts and
• Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation or disassembly. • Place shop jacks or rigid racks at the specified
• Keep the disassembled parts in order and pro- points.
tect them from dust and dirt. • Before disconnecting electrical connectors of
• Before removal, installation or disassembly, be sensors or units, be sure to disconnect the ground
sure to clarify the failure. Avoid unnecessary re- cable from battery.
moval, installation, disassembly and replacement. • Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230 CARTRIDGE Troubleshooting for electrical system.
ST24082AA230
22771AA030 SUBARU SELECT Troubleshooting for electrical system.
MONITOR KIT • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
ST22771AA030
FU(H4SO 2.0)-9
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203
2) Remove the air intake chamber. <Ref. to

IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.>
3) Disconnect the connectors from the throttle posi-
tion sensor and manifold absolute pressure sensor.
(B)
(A) FU-02058
(A) Throttle position sensor

(B) Manifold absolute pressure sensor
4) Disconnect the engine coolant hoses from throt-

tle body.
5) Remove the bolts which secure throttle body to
intake manifold.
FU-02059
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use a new gasket.
Tightening torque:
8 N!m (0.8 kgf-m, 5.8 ft-lb)
FU(H4SO 2.0)-10
Intake Manifold
3. Intake Manifold 9) Disconnect the engine harness connectors from

bulkhead harness connectors.
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL
PRESSURE, PROCEDURE, Fuel.>
2) Open the fuel filler flap lid, and remove the fuel
filler cap.
FU-02061
10) Disconnect the connectors from engine coolant

temperature sensor.
IN-00203
4) Remove the air cleaner case and air intake

chamber. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, REMOV-
AL, Air Intake Chamber.>
5) Disconnect the spark plug cords from spark
plugs. FU-00055
6) Disconnect the engine coolant hoses from throt- 11) Disconnect the knock sensor connector.
tle body.
FU-01334
FU-02060
12) Disconnect the connector from crankshaft posi-
7) Disconnect the PCV hose from intake manifold. tion sensor.
8) Disconnect the brake booster hose.
FU-00056
FU-02089
13) Disconnect the connector from power steering
pump switch (A).
FU(H4SO 2.0)-11
Intake Manifold
14) Disconnect the connector from oil pressure • Catch the fuel from hoses using a container
switch (B). or cloth.
(A)
(B)
(A)
(C)
FU-01087 (B) FU-02062

15) Disconnect the connector from camshaft posi-
tion sensor. (A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
18) Remove the bolts which secure intake manifold

to cylinder head.
FU-01335
16) Remove the EGR pipe from intake manifold.

(EC, EK, K4 model)
FU-00260
19) Remove the intake manifold.

B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Use a new gasket.
Tightening torque:
FU-00148 25 N!m (2.5 kgf-m, 18.1 ft-lb)
17) Disconnect the fuel hoses from fuel pipes.
WARNING:
• Be careful not to spill fuel.
FU-00260
2) Connect the fuel hoses.
FU(H4SO 2.0)-12
Intake Manifold
NOTE: 6) Connect the connector to oil pressure switch (B).

If fuel hoses or clamps are damaged, replace them
with new ones.
Tightening torque (Hose clamp screw):
1.25 N!m (0.13 kgf-m, 0.94 ft-lb) (A)
(B)
(A)
(C) FU-01087
7) Connect the connector to crankshaft position

sensor.
(B) FU-02062
(A) Fuel delivery hose

(B) Return hose
3) Install the EGR pipe to intake manifold. (EC, EK,

K4 model)
Tightening torque: FU-00056
34 N!m (3.4 kgf-m, 24.6 ft-lb)
8) Connect the knock sensor connector.
FU-00148
FU-01334
4) Connect the connector to camshaft position sen- 9) Connect the connectors to engine coolant tem-
sor. perature sensor.
FU-01335
FU-00055
5) Connect the connector to power steering pump 10) Connect the PCV hose to intake manifold.
switch (A).
FU(H4SO 2.0)-13
Intake Manifold
11) Connect the brake booster hose. C: DISASSEMBLY

1) Disconnect the engine ground terminal from in-
take manifold.
FU-02089
12) Connect the engine harness connectors to

bulkhead harness connectors. FU-02063
2) Remove the ignition coil & ignitor ASSY. <Ref. to

IG(H4SO 2.0)-8, REMOVAL, Ignition Coil & Ignitor
ASSY.>
3) Remove the throttle body. <Ref. to FU(H4SO
2.0)-10, REMOVAL, Throttle Body.>
4) Remove the EGR valve. (EC, EK, K4 model)
<Ref. to FU(H4SO 2.0)-28, REMOVAL, EGR
Valve.>
5) Disconnect the pressure regulator vacuum hose
from intake manifold.
FU-02061
13) Connect the engine coolant hoses to throttle

body.
FU-02064
6) Remove the fuel pipe protector LH.

FU-02060
14) Connect the spark plug cords to spark plugs.

15) Install the air cleaner case and air intake cham-
ber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTAL-
LATION, Air Intake Chamber.>
16) Install the fuse of fuel pump to main fuse box.
17) Connect the battery ground cable to battery.
FU-02065
IN-00203
FU(H4SO 2.0)-14
Intake Manifold
7) Remove the fuel pipe protector RH. • RH side
FU-02066 FU-02070
8) Disconnect the connectors from fuel injector.
FU-02071
FU-02067
• LH side
9) Remove the purge control solenoid valve. <Ref.
to EC(H4SO 2.0)-7, REMOVAL, Purge Control So-
lenoid Valve.>
10) Remove the harness band (A) and bolts (B),
(C) which secure engine harness to intake mani-
fold.
(B) (A)
FU-02072
(A) (A)
FU-02068
(C)
FU-02073
13) Remove the fuel injector.
FU-02069
11) Remove the engine harness from intake mani-

fold.
12) Remove the bolts which install injector pipe on
the intake manifold as shown in the figure.
FU(H4SO 2.0)-15
Intake Manifold
(1) Remove the clip which secures fuel injector 17) Remove the bolt which installs fuel pipes on in-
from injector pipe. take manifold.
FU-02074 FU-02077
(2) Remove the fuel injector with lifting up the 18) Remove the fuel pipe assembly and pressure
fuel injector pipe. regulator, from intake manifold.
14) Loosen the clamp which holds fuel injector pipe D: ASSEMBLY
LH to fuel hose, and then disconnect the pipe from
fuel hose. 1) Install the fuel pipe assembly and pressure reg-
ulator to intake manifold.
NOTE:
• Use a new gasket.
• When assembling the nipple, apply liquid gasket.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010)
2) Tighten the bolt which installs fuel pipes on in-
take manifold.
Tightening torque:
FU-02075 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
15) Loosen the clamp which holds fuel injector pipe
RH to fuel hose, and then disconnect the pipe from
fuel hose.
FU-02077
3) Connect the fuel injector pipe RH to fuel hose,

and tighten the clamp screw.
FU-02076
16) Remove the fuel injector pipe.
FU-02076
FU(H4SO 2.0)-16
Intake Manifold
4) Connect the fuel injector pipe LH to fuel hose, • LH side

Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02075
5) Install the fuel injectors. FU-02078

6) Install the clip which secures fuel injector.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-02074
7) Tighten the bolts which install injector pipe on in-

FU-02073
take manifold.
• RH side 8) Install the engine harness onto intake manifold.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02070
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-02071
FU(H4SO 2.0)-17
Intake Manifold
9) Secure the engine harness with harness band 12) Install the fuel pipe protector RH.
(A) and bolts (B), (C).
Tightening torque:
Tightening torque: 19 N!m (1.9 kgf-m, 13.7 ft-lb)
(B): 16 N!m (1.6 kgf-m, 11.8 ft-lb)
(C): 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
(B) (A)
(A) (A) FU-02066
13) Install the fuel pipe protector LH.

FU-02068
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
(C)
FU-02069
10) Install the purge control solenoid valve. <Ref. FU-02065

to EC(H4SO 2.0)-7, INSTALLATION, Purge Con-
trol Solenoid Valve.> 14) Connect the pressure regulator vacuum hose
11) Connect the connectors to fuel injector. to intake manifold.
FU-02064
FU-02067
15) Install the EGR valve. (EC, EK, K4 model)
<Ref. to FU(H4SO 2.0)-28, INSTALLATION, EGR
Valve.>
16) Install the throttle body to intake manifold.
<Ref. to FU(H4SO 2.0)-10, INSTALLATION, Throt-
tle Body.>
17) Install the ignition coil & ignitor ASSY. <Ref. to
IG(H4SO 2.0)-8, INSTALLATION, Ignition Coil &
Ignitor ASSY.>
18) Install the engine ground terminal to intake
manifold.
FU(H4SO 2.0)-18
Intake Manifold
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02063
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
damaged and the connections are tightened firmly.
FU(H4SO 2.0)-19
Engine Coolant Temperature Sensor
4. Engine Coolant Temperature

Sensor
A: REMOVAL
IN-00203
2) Remove the generator. <Ref. to SC(H4SO 2.0)-

14, REMOVAL, Generator.>
temperature sensor.
FU-00055
4) Remove the engine coolant temperature sensor.

B: INSTALLATION
Tightening torque:
18 N!m (1.8 kgf-m, 13.0 ft-lb)
FU(H4SO 2.0)-20
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)
IN-00203
FU-00058
2) Remove the bolt which installs crankshaft posi-
tion sensor to cylinder block.
FU-00056
3) Remove the crankshaft position sensor, and dis-

connect the connector from it.
FU-00057
FU(H4SO 2.0)-21
Camshaft Position Sensor
6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself.
A: REMOVAL
FU-00179
B: INSTALLATION
IN-00203
2) Disconnect the connector from camshaft posi- Tightening torque:
tion sensor. Camshaft position sensor support
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-01335
3) Remove the bolt which installs camshaft position

sensor to the support.
FU-00177

sensor support to camshaft cap LH.
FU-00178
5) Remove the camshaft position sensor and the

support as a unit.
FU(H4SO 2.0)-22
Knock Sensor
7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to cylinder block.
A: REMOVAL
1) Disconnect the ground cable from battery. NOTE:
Extraction area of knock sensor cord must be posi-
tioned at a 60" angle relative to the engine rear.
Tightening torque:
24 N!m (2.4 kgf-m, 17.4 ft-lb)
(A)
IN-00203
2) Remove the air cleaner case. <Ref. to IN(H4SO

2.0)-6, REMOVAL, Air Cleaner Case.> 60
3) Remove the harness bracket from intake mani-
fold. FU-00413
(A) Front side
FU-02078
4) Disconnect the knock sensor connector.
FU-01334
3) Install the harness bracket to intake manifold.

Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-01334
5) Remove the knock sensor from cylinder block.
FU-02078
4) Install the air cleaner case.

<Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air
Cleaner Case.>
FU-00519
FU(H4SO 2.0)-23
Knock Sensor
IN-00203
FU(H4SO 2.0)-24
Throttle Position Sensor
8. Throttle Position Sensor

A: SPECIFICATION
Throttle body is a non-disassembled part, so do not
remove the throttle position sensor from throttle
body.
Refer to “Throttle Body” for removal and installation
procedure. <Ref. to FU(H4SO 2.0)-10, REMOVAL,
Throttle Body.> <Ref. to FU(H4SO 2.0)-10, IN-
STALLATION, Throttle Body.>
FU(H4SO 2.0)-25
Manifold Absolute Pressure Sensor
9. Manifold Absolute Pressure

Sensor
A: REMOVAL
IN-00203
2) Disconnect the connector from manifold abso-

lute pressure sensor.
FU-02079
3) Remove the manifold absolute pressure sensor

from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
2.0 N!m (0.20 kgf-m, 1.5 ft-lb)
FU(H4SO 2.0)-26
Intake Air Temperature Sensor
10.Intake Air Temperature Sen-

sor
A: REMOVAL
IN-00203
2) Disconnect the connector from intake air tem-

perature sensor.
3) Remove the intake air temperature sensor.
FU-02080
B: INSTALLATION
FU(H4SO 2.0)-27
EGR Valve
11.EGR Valve
A: REMOVAL
NOTE:
EGR valve is equipped to EC, EK and K4 model.
IN-00203
2) Disconnect the connector from EGR valve.

3) Remove the EGR valve from intake manifold.
FU-02082
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU(H4SO 2.0)-28
Fuel Injector
12.Fuel Injector 8) Remove the clip which secure fuel injector.
A: REMOVAL
1. RH SIDE
filler cap.
FU-02074
9) Remove the bolts which hold fuel injector pipe

onto intake manifold.
IN-00203

2.0)-6, REMOVAL, Air Cleaner Case.>
5) Remove the spark plug cords from spark plugs FU-02070
(#1 and #3 cylinders).
6) Remove the fuel pipe protector RH.
FU-02071
10) Remove the fuel injector while lifting up the fuel

FU-02066
injector pipe.
7) Disconnect the connector from fuel injector.
2. LH SIDE
filler cap.
4) Remove the spark plug cords from spark plugs
FU-02067
FU(H4SO 2.0)-29
Fuel Injector
5) Remove the fuel pipe protector LH. 8) Remove the bolts which hold fuel injector pipe
FU-02065
FU-02072
FU-02067 FU-02073
7) Remove the clips which secure fuel injector. 9) Remove the fuel injector while lifting up the fuel
injector pipe.
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02074
FU-02070
FU(H4SO 2.0)-30
Fuel Injector
Tightening torque: Tightening torque:

6.4 N!m (0.65 kgf-m, 4.7 ft-lb) 19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02071 FU-02072

19 N!m (1.9 kgf-m, 13.7 ft-lb) 19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02066 FU-02065
2. LH SIDE
NOTE:
Use new O-rings.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-02073
FU(H4SO 2.0)-31
Front Oxygen (A/F) Sensor
13.Front Oxygen (A/F) Sensor B: INSTALLATION

1) Before installing front oxygen (A/F) sensor, ap-
A: REMOVAL ply anti-seize compound only to the threaded por-
1) Disconnect the ground cable from battery. tion of front oxygen (A/F) sensor to make the next
removal easier.
Anti-seize compound:
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor.
Tightening torque:
IN-00203 21 N!m (2.1 kgf-m, 15.2 ft-lb)
2) Remove the air intake duct. <Ref. to IN(H4SO
2.0)-9, REMOVAL, Air Intake Duct.>
3) Remove the connector of front oxygen (A/F)
sensor.
FU-01114
3) Install the under cover.

4) Lower the vehicle.
5) Hold the harness with clip.
ME-00859 6) Connect the connector of front oxygen (A/F)
4) Remove the clip holding harness. sensor.
5) Lift-up the vehicle.
6) Remove the under cover.
7) Apply spray-type lubricant to the threaded por-
tion of front oxygen (A/F) sensor, and leave it for
one minute or more.
8) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the front oxygen (A/F) sensor,
wait until exhaust pipe cools, otherwise it will
damage the exhaust pipe. ME-00859
7) Install the air intake duct. <Ref. to IN(H4SO 2.0)-

9, INSTALLATION, Air Intake Duct.>
FU-01114
IN-00203
FU(H4SO 2.0)-32
Rear Oxygen Sensor
14.Rear Oxygen Sensor B: INSTALLATION

1) Before installing rear oxygen sensor, apply anti-
A: REMOVAL seize compound only to the threaded portion of
1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas-
ier.
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to the pro-
tector of rear oxygen sensor.
2) Install the rear oxygen sensor.
Tightening torque:
IN-00203 21 N!m (2.1 kgf-m, 15.2 ft-lb)
3) Disconnect the connector from rear oxygen sen-
sor.
FU-01117

4) Connect the connector to rear oxygen sensor.
FU-01116
4) Remove the clip holding harness.

tion of rear oxygen sensor, and leave it for one
minute or more.
6) Remove the rear oxygen sensor.
CAUTION:
When removing the rear oxygen sensor, wait
until exhaust pipe cools, otherwise it will dam-
age the exhaust pipe. FU-01116

FU-01117
IN-00203
FU(H4SO 2.0)-33
Engine Control Module (ECM)
15.Engine Control Module (ECM) 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.
damage the harnesses and connectors.
Tightening torque:
5 N!m (0.5 kgf-m, 3.6 ft-lb)
IN-00203
2) Remove the lower inner trim of passenger’s

side. <Ref. to EI-60, REMOVAL, Lower Inner
Trim.>
3) Detach the floor mat of front passenger seat.
4) Remove the protect cover.
FU-02090
5) Remove the nuts (A) which hold ECM to bracket.

6) Remove the clip (B) from bracket.
(A)
(B)
(A)
FU-02091
7) Disconnect the ECM connectors and take out

the ECM.
FU(H4SO 2.0)-34
Main Relay
16.Main Relay
A: REMOVAL
IN-00203
2) Remove the glove box. <Ref. to EI-51, REMOV-

AL, Glove Box.>
3) Remove the harness cover (A).
(A)
FU-02092
4) Disconnect the connector from main relay.
FU-02093
B: INSTALLATION
FU(H4SO 2.0)-35
Fuel Pump Relay
17.Fuel Pump Relay

A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
4) Disconnect the connector from fuel pump relay.
FU-02094
B: INSTALLATION
FU(H4SO 2.0)-36
Electronic Throttle Control Relay
18.Electronic Throttle Control

Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
4) Disconnect the connector from electric control

throttle relay.
FU-02095
B: INSTALLATION
FU(H4SO 2.0)-37
Fuel
19.Fuel 6) Set a container under the vehicle and remove

the drain plug from fuel tank to drain fuel from the
A: PROCEDURE fuel tank.
1. RELEASING OF FUEL PRESSURE
WARNING:
• Place “NO FIRE” signs near the working area.
1) Remove the fuse of fuel pump from main fuse
box.
FU-01123
7) Tighten the fuel drain plug.

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
FU-01122 8) Install the fuel tank protector.
2) Start the engine and run until it stalls. NOTE:
3) After the engine stalls, crank it for five more sec- Use a new nut.
onds. Tightening torque:
4) Turn the ignition switch to OFF. Nut
2. DRAINING FUEL 9.0 N!m (0.92 kgf-m, 6.6 ft-lb)
Bolt
WARNING: 17.5 N!m (1.78 kgf-m, 12.9 ft-lb)
1) Set the vehicle on a lift.
IN-00203
filler cap.
5) Remove the fuel tank protector.
FU(H4SO 2.0)-38
Fuel Tank
20.Fuel Tank (2) Push the grommet (B) down under the body
and remove the service hole cover.
A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area. (A)
2) Release the fuel pressure. (A)
3) Drain fuel from the fuel tank.
(B)
<Ref. to FU(H4SO 2.0)-38, DRAINING FUEL, FU-01126
PROCEDURE, Fuel.>
4) Remove the rear seat. 8) Disconnect the connector (A) from fuel sub level
sensor.
5) Remove the service hole cover from fuel pump.
9) Disconnect the quick connector from the fuel de-
(1) Remove the bolts (A).
livery (B) and return hose (C). <Ref. to FU(H4SO
(2) Push the grommet (B) down under the body 2.0)-53, REMOVAL, Fuel Delivery, Return and
and remove the service hole cover. Evaporation Lines.>
(A)
(A) (A) (C)
(B) (B)
FU-01124
FU-01127
6) Disconnect the connector from fuel pump. 10) Remove the rear wheels.
11) Remove the bolts which secure rear brake
hose installation bracket.
FU-01125
7) Remove the service hole cover from fuel sub lev-

el sensor. FU-01128
FU(H4SO 2.0)-39
Fuel Tank
12) Remove the rear brake caliper and tie it to the 19) Remove the bolts which install parking brake
side of vehicle body. cable clamp.
FU-00462 FU-01130
13) Remove the parking brake cable from parking

brake assembly. <Ref. to PB-7, REMOVAL, Park-
ing Brake Assembly (Rear Disc Brake).>
15) Remove the rear exhaust pipe.
<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex-
haust Pipe.>
16) Remove the propeller shaft. <Ref. to DS-10,
REMOVAL, Propeller Shaft.>
17) Remove the heat shield cover.
18) Disconnect the connector from rear ABS wheel FU-01131
speed sensor. 20) Remove the rear suspension assembly.

CAUTION:
A helper is required to perform this work.
(1) Support the rear differential with transmis-
sion jack.
(2) Remove the bolt which installs rear shock
absorber to rear suspension arm.
FU-01129
FU-01132
FU(H4SO 2.0)-40
Fuel Tank
(3) Remove the bolts which secure rear sus- 23) Support the fuel tank with transmission jack, re-
pension assembly to body. move the bolts from fuel tank bands and dismount
the fuel tank from vehicle.
WARNING:
FU-01133
FU-01137
B: INSTALLATION
1) Support the fuel tank with transmission jack, set
the fuel tank, and then temporarily tighten the bolts
of fuel tank band.
WARNING:
FU-01134
(4) Remove the rear suspension assembly.

21) Disconnect the two-way valve hose (A) from
two-way valve, and then remove the two-way valve
from bracket.
FU-01137
(A)
FU-01135
22) Loosen the clamp and disconnect the fuel filler

hose (A) and vent hose (B) from fuel filler pipe.
(A)
(B)
FU-01136
FU(H4SO 2.0)-41
Fuel Tank
2) Correctly insert the fuel filler hose (A) and vent Tightening torque:
hose (B) to specified position, and then tighten the T1: 125 N!m (12.7 kgf-m, 92.2 ft-lb)
clamp. T2: 65 N!m (6.2 kgf-m, 48 ft-lb)
T3: 175 N!m (17.8 kgf-m, 129 ft-lb)
(A) T1 T1
(B)
T1
T1
FU-01136
FU-01150
(2) (3)
(1)
L/2
T2 T3
L T3 T2
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp (3) Tighten the bolts which install rear shock ab-
(3) Pipe sorber to rear suspension arm. <Ref. to RS-11,
INSTALLATION, Rear Arm.>
3) Install the two-way valve to bracket, and connect Tightening torque:
the two-way valve hose (A) to two-way valve.
62 N!m (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
4) Tighten the bolts of fuel tank band.
6) Tighten the bolts which install parking brake ca-
Tightening torque: ble clamp.
33 N!m (3.4 kgf-m, 25 ft-lb)
5) Install the rear suspension assembly.
CAUTION:
sion jack.
(2) Support the rear suspension assembly, and
then tighten the bolts which secure rear suspen-
sion assembly to body.
FU(H4SO 2.0)-42
Fuel Tank

18 N!m (1.8 kgf-m, 13.0 ft-lb) 33 N!m (3.4 kgf-m, 25 ft-lb)
FU-01130 FU-01128
Tightening torque: 15) Install the rear wheels.

32 N!m (3.3 kgf-m, 23.9 ft-lb) 16) Lower the vehicle.
17) Connect the connector (A) to fuel sub level sen-
sor.
18) Connect the quick connector to the fuel delivery
(B) and return hose (C).
<Ref. to FU(H4SO 2.0)-54, INSTALLATION, Fuel
Delivery, Return and Evaporation Lines.>
NOTE:
Be careful not to misconnect the delivery side and
return side.
FU-01131
7) Connect the connector to ABS wheel speed sen-

sor.
(A)
(C)
(B)
FU-01127
19) Install the service hole cover of fuel sub level

sensor.
FU-01129
8) Install the heat shield cover. (A)

9) Install the propeller shaft. <Ref. to DS-11, IN-
STALLATION, Propeller Shaft.>
10) Install the rear exhaust pipe.
<Ref. to EX(H4SO 2.0)-11, INSTALLATION, Rear (A)
Exhaust Pipe.>
12) Connect the parking brake cable to parking (B)
brake assembly. <Ref. to PB-8, INSTALLATION, FU-01126
Parking Brake Assembly (Rear Disc Brake).>
13) Install the rear brake caliper. (A) Bolt
14) Tighten the bolt which secures rear brake hose (B) Grommet
installation bracket.
FU(H4SO 2.0)-43
Fuel Tank
20) Connect the connector to fuel pump.
FU-01125
21) Install the service hole cover of fuel pump.
(A) (A)
(B)
FU-01124
(A) Bolt
(B) Grommet
22) Install the rear seat.

C: INSPECTION
1) Check that the fuel tank is not holed, cracked, or
otherwise damaged.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and those connections are tight.
FU(H4SO 2.0)-44
Fuel Filler Pipe
21.Fuel Filler Pipe 7) Set a container under the vehicle and remove
A: REMOVAL fuel tank.
WARNING:
2) Open the fuel filler flap lid, and remove the filler
cap.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
9) Remove the mud guard. <Ref. to EI-29, RE-
MOVAL, Mud Guard.>
IN-00203 10) Remove the rear sub frame. <Ref. to RS-23,
REMOVAL, Rear Sub Frame.>
4) Remove the screws which secure the packing.
11) Remove the bolts which hold fuel filler pipe
bracket on the body.
FU-00095
5) Lift-up the vehicle. FU-01139

6) Remove the rear wheel RH.
(A)
(B)
FU-00096
FU-01136
13) Remove the fuel filler pipe to under side of the

vehicle.
FU(H4SO 2.0)-45
Fuel Filler Pipe
B: INSTALLATION 5) Tighten the bolts which hold fuel filler pipe brack-
1) Open the fuel filler flap lid. et on the body.
2) Set the fuel saucer (A) with rubber packing (C) Tightening torque:
and insert the fuel filler pipe into hole from the inner 7.5 N!m (0.75 kgf-m, 5.4 ft-lb)
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward the
inside, straighten it with a flat tip screwdriver.
(A)
FU-01139
6) Install the rear sub frame. <Ref. to RS-23, IN-

(B) STALLATION, Rear Sub Frame.>
7) Install the mud guard. <Ref. to EI-29, INSTAL-
(C)
LATION, Mud Guard.>
8) Install the rear wheel RH.
FU-00103
4) Correctly insert the fuel filler hose (A) and vent

hose (B) to specified position, and then tighten the
clamp.
(A)
(B)
FU-00096

FU-01136
(2) (3)
(1)
L/2
L IN-00203
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipe
FU(H4SO 2.0)-46
Fuel Pump
22.Fuel Pump 7) Remove the nuts which install fuel pump assem-
bly onto fuel tank.
A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area. (B)
• Be careful not to spill fuel on the floor. (C)
• Reduce the fuel in the fuel tank to less than
3/4 beforehand. Be careful that fuel may spill
when the fuel is more than 3/4.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor. (A) FU-01140
<Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL (A) Delivery hose
PRESSURE, PROCEDURE, Fuel.> (B) Return hose
2) Drain fuel. <Ref. to FU(H4SO 2.0)-38, DRAIN- (C) Jet pump hose
ING FUEL, PROCEDURE, Fuel.>
8) Take off the fuel pump assembly from fuel tank.
3) Remove the rear seat.
4) Remove the service hole cover. B: INSTALLATION
(1) Remove the bolts (A). Install in the reverse order of removal.
(2) Push the grommet (B) down under the body NOTE:
and remove the service hole cover. Use a new gasket.
(1) Ensure the sealing portion is free from fuel or
foreign particles before installation.
(2) Tighten the nuts to specified torque in the order
as shown in the figure.
(A) (A) Tightening torque:
4.4 N!m (0.45 kgf-m, 3.3 ft-lb)
1
(B) 4 8
FU-01124
5) Disconnect the connector from fuel pump.

6 5
7 3
2
FU-01141
C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump and apply the battery power supply to
FU-01125
check whether the pump operates.
6) Disconnect the quick connector and then discon- WARNING:
nect the fuel delivery hose, return hose and jet • Wipe off the fuel completely.
pump hose. <Ref. to FU(H4SO 2.0)-53, REMOV- • Keep battery as far apart from fuel pump as
AL, Fuel Delivery, Return and Evaporation Lines.> possible.
• Be sure to turn the battery supply to ON and
OFF on the battery side.
FU(H4SO 2.0)-47
Fuel Pump
• Do not run fuel pump for a long time under

non-load condition.
2 1
4 3
6 5
FU-01330
FU(H4SO 2.0)-48
Fuel Level Sensor
23.Fuel Level Sensor

A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4SO 2.0)-47, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
FU-01142
3) Remove the fuel level sensor.

B: INSTALLATION
FU(H4SO 2.0)-49
Fuel Sub Level Sensor
24.Fuel Sub Level Sensor 6) Remove the bolts which install the fuel sub level
sensor on fuel tank.
A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area. (C)
• Reduce the fuel in the fuel tank to less than (A)
1) Drain fuel. <Ref. to FU(H4SO 2.0)-38, DRAIN-
2) Remove the rear seat. (B)
FU-01144
3) Remove the service hole cover.
(1) Remove the bolts (A). (A) Jet pump hose
(2) Push the grommet (B) down under the body (B) Delivery hose
and remove the service hole cover. (C) Return hose
7) Remove the fuel sub level sensor.

(A) B: INSTALLATION
NOTE:
(A) Use a new gasket.
(2) Tighten the nuts and bolts to specified torque in
(B)
FU-01126 the order as shown in the figure.
4) Disconnect the connector from fuel sub level Tightening torque:
sensor. 4.4 N!m (0.45 kgf-m, 3.3 ft-lb)
3
1
2
4
FU-01143 FU-01145
5) Disconnect the quick connector and then discon-
nect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H4SO 2.0)-53, REMOV-
AL, Fuel Delivery, Return and Evaporation Lines.>
FU-01146
FU(H4SO 2.0)-50
Fuel Filter
25.Fuel Filter
A: SPECIFICATION
Fuel filter forms a unit with fuel pump.
Refer to Fuel Pump for removal and installation.
<Ref. to FU(H4SO 2.0)-47, REMOVAL, Fuel
Pump.>
Pump.>
FU(H4SO 2.0)-51
Fuel Damper Valve
26.Fuel Damper Valve

A: REMOVAL
1. DELIVERY SIDE
2) Remove the fuel damper valve from fuel delivery
line.
FU-01147
2. RETURN SIDE
Fuel damper valve forms a unit with fuel injector
pipe RH.
Refer to “Intake Manifold” for removal. <Ref. to
FU(H4SO 2.0)-14, DISASSEMBLY, Intake Mani-
fold.>
B: INSTALLATION
1. DELIVERY SIDE
Tightening torque:
1.25 N!m (0.13 kgf-m, 0.94 ft-lb)
2. RETURN SIDE
pipe RH.
Refer to “Intake Manifold” for installation. <Ref. to
FU(H4SO 2.0)-16, ASSEMBLY, Intake Manifold.>
FU(H4SO 2.0)-52
Fuel Delivery, Return and Evaporation Lines
27.Fuel Delivery, Return and Evaporation Lines

A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler flap lid, and remove the fuel filler cap.
4) Remove the floor mat. <Ref. to EI-73, REMOVAL, Floor Mat.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the fuel return pipes and hoses, evap-
oration pipes and hoses.
FU-01148
6) In the engine compartment, disconnect the fuel 9) Separate the quick connector on fuel line.
delivery hoses, return hoses and evaporation hose. (1) Clean the pipe and connector, if they are
covered with dust.
(A) (2) To prevent from damaging or entering for-
eign matter, wrap the pipes and connectors with
plastic bag, etc.
(C)
(B) FU-02062

(B) Return hose
(C) Evaporation hose FU-01333
7) Lift-up the vehicle. (3) Hold the connector (A) and push retainer (B)
8) Remove the fuel tank. <Ref. to FU(H4SO 2.0)- down.
39, REMOVAL, Fuel Tank.> (4) Pull out the connector (A) from retainer (B).
FU(H4SO 2.0)-53
CAUTION: CAUTION:
Always use a new retainer. • Pull the connector to ensure it is connected
securely.
• Ensure the two retainer pawls are engaged in
their mating positions in the connector.
• Be sure to inspect the hoses and their con-
nections for fuel leakage.
(B)
(A) (C)
FU-00124
(A)
(A) Connector
(B) Retainer
(C) Pipe (B) (C)
FU-00127
B: INSTALLATION
1) Connect the quick connector on fuel line. (A) Connector
(B) Retainer
CAUTION:
(C) Pipe
• Always use a new retainer.
• Make sure that the connected portion is not 2) Connect the fuel delivery hose to the pipe with
damaged or has dust. If necessary, clean the an overlap of 20 to 25 mm (0.79 to 0.98 in).
seal surface of pipe. Type A: When the amount of inserting is specified.
Type B: When the amount of inserting is not speci-
fied.
(A)
2: 2.5#1.5 mm (0.098#0.059 in)
L: 22.5#2.5 mm (0.886#0.098 in)
(B)
(1) (2) (3)
Type A
FU-00125
L
(A) Seal surface
(B) Pipe
Type B
(1) Set the new retainer (B) to connector (A).

FU-00128
(2) Push the pipe into the connector completely.
(A) (1) Pipe
(2) Clamp
(B) (3) Hose
3) Connect the return hose and evaporation hose

(C)
to pipe by approx. 15 mm (0.59 in) from the hose
end.
Fuel return hose:
L = 22.5#2.5 mm (0.885#0.098 in)
FU-00126
Fuel evaporation hose:
L = 17.5#2.5 mm (0.689#0.098 in)
(A) Connector
(B) Retainer
(C) Pipe
FU(H4SO 2.0)-54
CAUTION:
Be sure to inspect the hoses and their connec-
tions for fuel leakage.
(2) (3)
(1)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipe
C: INSPECTION
1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tightened firmly.
FU(H4SO 2.0)-55
Fuel System Trouble in General
28.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient fuel supply to injector
1) Fuel pump does not operate.
Inspect contact, especially ground, and tighten it
❍ Defective terminal contact.
securely.
❍ Trouble in electromagnetic or electronic circuit parts. Replace the faulty parts.
2) Decline of fuel pump function. Replace the fuel pump.
3) Clogged dust or water in the fuel filter. Replace 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 air breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out of 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.
Clean, correct or replace 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 filler
1) Retightening.
pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace the packing.
3) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE:
• When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
Fill fuel fully to prevent those problem. And also drain the water condensation from fuel filter.
• In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0"C (32"F) throughout the winter season, use water removing agent in the fuel system to prevent freezing
fuel system and accumulating water. Fill the water removing agent at the time when the fuel reduced at half
to maintain the advantage.
• When water condensation is noticed in the fuel filter, drain the water from both the fuel filter and fuel tank
or use water removing agent in the fuel tank.
• Before using water removing agent, follow the cautions noted on the bottle.
FU(H4SO 2.0)-56
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
EMISSION CONTROL
EC(H4SO 2.0)
Page
1. General Description ..................................................................................2
2. Front Catalytic Converter .........................................................................3
3. Rear Catalytic Converter ..........................................................................4
4. EGR Valve ..................................................................................................5
5. Canister......................................................................................................6
6. Purge Control Solenoid Valve..................................................................7
7. Two-way Valve...........................................................................................9
8. PCV Valve ................................................................................................10
General Description
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
• Wear work clothing, including a cap, protective
goggles and protective shoes during operation.
• Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
• Keep the disassembled parts in order and pro-
tect them from dust and 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 yourself, 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 rigid racks at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
EC(H4SO 2.0)-2
Front Catalytic Converter
2. Front Catalytic Converter

A: REMOVAL
The front and rear catalytic converters are integrat-
ed into center exhaust pipe as a unit; therefore, re-
fer to “Center Exhaust Pipe” for removal procedure.
<Ref. to EX(H4SO 2.0)-10, REMOVAL, Center Ex-
haust Pipe.>
B: INSTALLATION
fer to “Center Exhaust Pipe” for installation
procedure. <Ref. to EX(H4SO 2.0)-10, INSTALLA-
TION, Center Exhaust Pipe.>
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(H4SO 2.0)-3
Rear Catalytic Converter
3. Rear Catalytic Converter

A: REMOVAL
fer to “Center Exhaust Pipe” for removal procedure.
<Ref. to EX(H4SO 2.0)-10, REMOVAL, Center Ex-
haust Pipe.>
B: INSTALLATION
fer to “Center Exhaust Pipe” for installation
procedure. <Ref. to EX(H4SO 2.0)-10, INSTALLA-
TION, Center Exhaust Pipe.>
C: INSPECTION
nections and welds.
EC(H4SO 2.0)-4
EGR Valve
4. EGR Valve
A: SPECIFICATION
Refer to “EGR Valve” for removal and installation.
<Ref. to FU(H4SO 2.0)-28, EGR Valve.> or <Ref.
to FU(H4SO 2.5)-30, EGR Valve.>
EC(H4SO 2.0)-5
Canister
5. Canister Tightening torque:

8.3 N!m (0.85 kgf-m, 6.1 ft-lb)
A: REMOVAL
2) Remove the rear wheel LH.
3) Remove the mud guard LH.
4) Remove the protector. (Sedan model)
5) Disconnect the quick connector (A). (B) (A)
6) Remove the canister (B) from body.
(B) (A)
(B)
(B)
EC-02027
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-02027
B: INSTALLATION
NOTE:
Make sure there are no damage or dust on the con-
nection of quick connector. If necessary, clean the
seal surface of pipe.
EC(H4SO 2.0)-6
Purge Control Solenoid Valve
6. Purge Control Solenoid Valve B: INSTALLATION

A: REMOVAL
19 N!m (1.9 kgf-m, 14.0 ft-lb)
• 2.0 L model
IN-00203
2) Disconnect the connector and hoses of purge

EC-02015
control solenoid valve, and then remove the purge
control solenoid valve. • 2.5 L model
• 2.0 L model
EC-00223
EC-02015
NOTE:
• 2.5 L model Connect the evaporation hose as shown in the fig-
ure.
• 2.0 L model
(B)
EC-00223 (A)
EC-02016
EC(H4SO 2.0)-7
• 2.5 L model
(B)
(A)
EC-00224
(A) To fuel pipe (Evaporation line)

(B) To intake manifold
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(H4SO 2.0)-8
Two-way Valve
7. Two-way Valve
A: REMOVAL
2) Disconnect the evaporation hoses from two-way
valve.
3) Remove the two-way valve as a unit with bracket
from body.
EC-00221
4) Remove the two-way valve from bracket.

B: INSTALLATION
Tightening torque:
7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
EC(H4SO 2.0)-9
PCV Valve
8. PCV Valve
A: REMOVAL
Disconnect the PCV hose and remove the PCV
valve.
• 2.0 L model
EC-02029
• 2.5 L model
EC-00225
B: INSTALLATION
NOTE:
Apply liquid gasket to the bolt threads of PCV
valve. (2.0 L model)
Liquid gasket:
Tightening torque:
23 N!m (2.3 kgf-m, 17 ft-lb)
EC(H4SO 2.0)-10
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
INTAKE (INDUCTION)
IN(H4SO 2.0)
Page
2. Air Cleaner Element ....................................................................................5
3. Air Cleaner Case.........................................................................................6
4. Air Intake Chamber .....................................................................................8
5. Air Intake Duct.............................................................................................9
6. Resonator Chamber..................................................................................10
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2
T2
(15)
(14)
(14)
(13)
(13)
(11) (12)
(10)
T4
(22)
T4
(16)
(23)
T3
(19) T3
(18) T4
T3
(17)
(9) T6
(9)
(21)
(8)
(7)
T5
(4)
(20)
(3)
T1
(2)
(6)
(6) (5)
(5)
(1)
IN-02004
IN(H4SO 2.0)-2
General Description
INTAKE (INDUCTION)
(1) Air intake duct (14) Spacer (23) Intake air temperature sensor
(2) Clip (15) Air intake chamber (Except for 2.5 L EC, EK, K4
(3) Resonator chamber (16) Stay LH (MT model) model)
(4) Air cleaner case (front) (17) Stay LH (AT model)
(5) Spacer (18) Clamp Tightening torque: N!m (kgf-m, ft-lb)
(6) Cushion (19) Stay RH T1: 6.0 (0.6, 4.4)
(7) Air cleaner element (20) Cushion T2: 6.5 (0.66, 4.8)
(8) Air cleaner case (rear) (21) Mass air flow and intake air tem- T3: 16 (1.6, 11.6)
(9) Clip perature sensor (2.5 L EC, EK, K4 T4: 3.0 (0.3, 2.2)
(10) Clamp model) T5: 7.5 (0.76, 5.5)
(11) Intake duct (22) Bushing (Except for 2.5 L EC, EK, T6: 1.0 (0.10, 0.7)
(12) Clamp K4 model)
(13) Cushion
IN(H4SO 2.0)-3
General Description
INTAKE (INDUCTION)
B: CAUTION
goggles, and protective shoes during operation.
points.
cable from battery.
IN(H4SO 2.0)-4
Air Cleaner Element
INTAKE (INDUCTION)
2. Air Cleaner Element B: INSTALLATION

A: REMOVAL
Fasten the air cleaner case (rear) with a clip after
inserting the lower tab of the case.
IN-00203
2) Disconnect the connector from mass air flow and IN-00207

intake air temperature sensor. (2.5 L EC, EK, K4
model) C: INSPECTION
Replace if excessively damaged or dirty.
IN-00204
3) Remove the clip (A) from upper side of air clean-

er case.
(A)
IN-00254
4) Pull the air cleaner case (rear) to rearward of the

vehicle, and then remove the air cleaner element.
NOTE:
Be careful that the power steering hose is secured
to the under side of air cleaner case (rear).
IN(H4SO 2.0)-5
Air Cleaner Case
INTAKE (INDUCTION)
3. Air Cleaner Case 6) Remove the air cleaner case (rear) and air
cleaner element.
A: REMOVAL
IN-00206
7) Remove the bolt (A) and nut (B) which hold the
IN-00203 air cleaner case on body.
3) Disconnect the connector from mass air flow and (B)
intake air temperature sensor. (2.5 L EC, EK, K4
model)
(A)
IN-00208
8) Remove the air cleaner case (front).
IN-00204
4) Loosen the clamp (A) which connects the air

cleaner case to intake duct.
5) Remove the clip (B) from upper side of air clean-
er case.
(B) (A)
IN-00205
IN(H4SO 2.0)-6
Air Cleaner Case
INTAKE (INDUCTION)
B: INSTALLATION
Tightening torque:
Bolt (A): 6.0 N!m (0.6 kgf-m, 4.4 ft-lb)
Nut (B): 7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
(B)
(A)
IN-00208
NOTE:
Fasten with a clip after inserting the lower tab of the
case.
IN-00207
C: INSPECTION
Check for cracks or loose connection.
IN(H4SO 2.0)-7
Air Intake Chamber
INTAKE (INDUCTION)
4. Air Intake Chamber B: INSTALLATION

A: REMOVAL
(Except for EC, EK, K4 model) Clamp (A), (B)
3.0 N!m (0.3 kgf-m, 2.2 ft-lb)
Bolt (C)
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
(B) (C)
(C) (A)
IN-00203

perature sensor. (Except for EC, EK, K4 model)
IN-02005
C: INSPECTION
1) Check for cracks or loose connections.
2) Inspect that no foreign objects in the air intake
chamber.
FU-02080
3) Loosen the clamp (A) which connects the air in-

take chamber to throttle body.
4) Loosen the clamp (B) which connects the intake
duct to air intake chamber.
5) Remove the bolt (C) which secures the air intake
chamber to the stay.
(B) (C)
(C) (A)
IN-02005
6) Disconnect the three parts of blow-by hose, and

remove the air intake chamber.
IN(H4SO 2.0)-8
Air Intake Duct
INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
1) Remove the clips which install the air intake duct
on the front side of body.
2) Remove the air intake duct.
IN-00210
B: INSTALLATION
C: INSPECTION
duct.
IN(H4SO 2.0)-9
Resonator Chamber
INTAKE (INDUCTION)
6. Resonator Chamber
A: REMOVAL
Refer to “Air Cleaner Case” for removal procedure
because the resonator chamber forms a single unit
with air cleaner case. <Ref. to IN(H4SO 2.0)-6, RE-
MOVAL, Air Cleaner Case.>
B: INSTALLATION
Refer to “Air Cleaner Case” for installation proce-
dure because the resonator chamber forms a sin-
gle unit with air cleaner case. <Ref. to IN(H4SO
2.0)-7, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
Check for cracks or loose connections.
IN(H4SO 2.0)-10
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
MECHANICAL
ME(H4SO 2.0)
Page
2. Compression .............................................................................................22
3. Idle Speed .................................................................................................23
4. Ignition Timing...........................................................................................24
5. Intake Manifold Vacuum............................................................................25
6. Engine Oil Pressure ..................................................................................26
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. Engine Assembly ......................................................................................30
10. Engine Mounting .......................................................................................36
11. Preparation for Overhaul...........................................................................37
12. V-belt.........................................................................................................38
13. Crank Pulley..............................................................................................40
14. Timing Belt Cover......................................................................................42
15. Timing Belt ................................................................................................43
16. Cam Sprocket ...........................................................................................48
17. Crank Sprocket .........................................................................................50
18. Valve Rocker Assembly ............................................................................51
19. Camshaft...................................................................................................53
20. Cylinder Head ...........................................................................................57
21. Cylinder Block ...........................................................................................63
22. Engine Trouble in General ........................................................................83
23. Engine Noise.............................................................................................88
General Description
MECHANICAL
A: SPECIFICATION
Model 2.0 L 2.5 L
Horizontally opposed, liquid cooled, 4-cylinder,
Cylinder arrangement
4-stroke gasoline engine
Belt driven, single over-head camshaft, 4-valve/
Valve system mechanism
cylinder
99.5 ! 79.0
Bore ! Stroke mm (in) 92 ! 75 (3.62 ! 2.95)
(3.917 ! 3.110)
Displacement cm3 (cu in) 1,994 (121.67) 2,457 (150)
Compression ratio 10.0
Compression pressure (at 350 rpm) kPa (kg/cm2, 1,020 — 1,275 (10.4 — 13.0, 148 — 185)
psi)
Engine Number of piston rings Pressure ring: 2, Oil ring: 1
Open BTDC 2" BTDC 2"
Intake valve timing
Close ABDC 54" ABDC 56"
Open BBDC 39" BBDC 50"
Exhaust valve timing
Close ATDC 5" ATDC 8"
Intake 0.20#0.04 (0.0079#0.0016)
Valve clearance mm (in)
Exhaust 0.25#0.04 (0.0098#0.0016)
Idle speed [at neutral position on MT, or “P” or 650#100 (No load)
rpm
“N” range on AT] 800#100 (A/C ON)
Ignition order 1$3$2$4
Ignition timing BTDC/rpm 13"#10"/650
NOTE:
US: undersize OS: oversize
Belt ten-
sion Protrusion of adjuster rod mm (in) 5.2 — 6.2 (0.205 — 0.244)
adjuster
Spacer O.D. mm (in) 17.955 — 17.975 (0.7069 — 0.7077)
Tensioner bushing I.D. mm (in) 18.00 — 18.08 (0.7087 — 0.7118)
Belt ten-
sioner Clearance between spacer
mm (in) Standard 0.025 — 0.125 (0.0010 — 0.0049)
and bushing
Side clearance of spacer mm (in) Standard 0.20 — 0.55 (0.0079 — 0.0217)
Valve rocker Clearance between shaft and
mm (in) Standard 0.020 — 0.054 (0.0008 — 0.0021)
arm arm
Bend limit mm (in) 0.020 (0.00079)
Side clearance mm (in) Standard 0.030 — 0.090 (0.0012 — 0.0035)
Intake Standard 39.646 — 39.746 (1.5609 — 1.5648)
2.0 L
Cam lobe height Exhaust Standard 39.351 — 39.451 (1.5493 — 1.5532)
Camshaft mm (in) Intake Standard 39.485 — 39.585 (1.5545 — 1.5585)
2.5 L
Exhaust Standard 39.904 — 40.004 (1.5710 — 1.5750)
Camshaft journal O.D. mm (in) 31.928 — 31.945 (1.2570 — 1.2577)
Camshaft journal hole I.D. mm (in) 32.000 — 32.018 (1.2598 — 1.2605)
Oil clearance mm (in) Standard 0.055 — 0.090 (0.0022 — 0.0035)
Surface warpage limit (mating with cylinder
mm (in) 0.03 (0.001)
Cylinder block)
Head Grinding limit mm (in) 0.1 (0.004)
Standard height mm (in) 97.5 (3.84)
ME(H4SO 2.0)-2
General Description
MECHANICAL
Refacing angle 90"

Valve seat Intake Standard 0.8 — 1.4 (0.03 — 0.055)
Contacting width mm (in)
Inside diameter mm (in) 6.000 — 6.012 (0.2362 — 0.2367)
Valve guide Intake 20.0 — 21.0 (0.787 — 0.827)
Protrusion above head mm (in)
Exhaust 16.5 — 17.5 (0.650 — 0.689)
Head edge thick- Intake Standard 0.8 — 1.2 (0.03 — 0.047)
mm (in)
ness Exhaust Standard 1.0 — 1.4 (0.039 — 0.055)
Intake 5.950 — 5.965 (0.2343 — 0.2348)
Stem outer diameters mm (in)
Exhaust 5.945 — 5.960 (0.2341 — 0.2346)
Valve
Intake 0.035 — 0.062 (0.0014 — 0.0024)
Valve stem gap mm (in) Standard
Exhaust 0.040 — 0.067 (0.0016 — 0.0026)
Intake 120.6 (4.75)
Overall length mm (in)
Exhaust 121.7 (4.79)
Free length mm (in) 54.30 (2.1378)
Valve Squareness 2.5", 2.4 mm (0.094 in)
springs Tension/spring Set 214 — 246 (22 — 25, 48 — 55)/ 45.0 (1.772)
N (kgf, lb)/mm (in)
height Lift 526 — 582 (54 — 59, 119 — 130)/ 34.7 (1.366)
Surface warpage limit (mating with cylinder
mm (in) 0.025 (0.00098)
head)
Grinding limit mm (in) 0.1 (0.004)
A 92.005 — 92.015 (3.6222 — 3.6226)
2.0 L Standard
Cylinder Cylinder inner B 91.995 — 92.005 (3.6218 — 3.6222)
block diameter mm (in) A 99.505 — 99.515 (3.9175 — 3.9179)
2.5 L Standard
B 99.495 — 99.505 (3.9171 — 3.9175)
Taper mm (in) Standard 0.015 (0.0006)
Out-of-roundness mm (in) Standard 0.010 (0.0004)
Piston clearance mm (in) Standard %0.010 — 0.010 (%0.00039 — 0.00039)
Boring limit mm (in) 0.5 (0.020)
A 92.005 — 92.015 (3.6222 — 3.6226)
Standard
B 91.995 — 92.005 (3.6219 — 3.6222)
2.0 L
0.25 (0.0098) OS 92.245 — 92.265 (3.6317 — 3.6325)
Outer diameter 0.50 (0.0197) OS 92.495 — 92.515 (3.6415 — 3.6423)
Piston mm (in) A 99.505 — 99.515 (3.9175 — 3.9179)
Standard
B 99.495 — 99.505 (3.9171 — 3.9175)
2.5 L
0.25 (0.0098) OS 99.745 — 99.765 (3.9270 — 3.9278)
0.50 (0.0197) OS 99.995 — 100.015 (3.9368 — 3.9376)
Piston pin standard diameter mm (in) 23.000 — 23.006 (0.9055 — 0.9057)
Outer diameter mm (in) 22.994 — 23.000 (0.9053 — 0.9055)
Standard clearance between piston and piston
mm (in) 0.004 — 0.008 (0.0002 — 0.0003)
Piston pin pin
Piston pin must be fitted into position with thumb
Degree of fit
at 20"C (68"F).
Top ring Standard 0.20 — 0.35 (0.0079 — 0.0138)
Second 2.0 L Standard 0.40 — 0.50 (0.0157 — 0.0197)
Ring closed gap mm (in)
ring 2.5 L Standard 0.35 — 0.50 (0.0138 — 0.0197)
Piston Ring
Oil ring Standard 0.20 — 0.50 (0.0079 — 0.0197)
Ring groove gap mm (in)
Second ring Standard 0.030 — 0.070 (0.0012 — 0.0028)
ME(H4SO 2.0)-3
General Description
MECHANICAL
Bend twist per 100

mm (3.94 in) in mm (in) Limit 0.10 (0.0039)
Connecting length
Rod
Side clearance of
mm (in) Standard 0.070 — 0.330 (0.0028 — 0.0130)
large end
Standard 1.492 — 1.501 (0.0587 — 0.0591)
Bearing of Bearing size 0.03 (0.0012) US 1.510 — 1.513 (0.0594 — 0.0596)
large end (Thickness at cen- mm (in)
ter) 0.05 (0.0020) US 1.520 — 1.523 (0.0598 — 0.0600)
0.25 (0.0098) US 1.620 — 1.623 (0.0638 — 0.0639)
Clearance between
Bush of
piston pin and mm (in) Standard 0 — 0.022 (0 — 0.0009)
small end
bushing
Bend limit mm (in) 0.035 (0.0014)
Out-of-roundness 2.0 L 0.005 (0.0002)
mm (in) 2.5 L 0.003 (0.0001)
Crank pin Cylindricality 2.0 L 0.006 (0.0002)
mm (in) 2.5 L 0.004 (0.0002)
Grinding limit (dia.) mm (in) To 51.750 (2.0374)
Out-of-roundness mm (in) 0.005 (0.0002)
Crank journal Cylindricality mm (in) 0.006 (0.0002)
Grinding limit (dia.) mm (in) To 59.750 (2.3524)
Crankshaft Standard 51.984 — 52.000 (2.0466 — 2.0472)
Crank pin outer 0.03 (0.0012) US 51.954 — 51.970 (2.0454 — 2.0461)
mm (in)
diameter 0.05 (0.0020) US 51.934 — 51.950 (2.0446 — 2.0453)
0.25 (0.0098) US 51.734 — 51.750 (2.0368 — 2.0374)
Standard 59.992 — 60.008 (2.3619 — 2.3625)
Crank journal outer 0.03 (0.0012) US 59.962 — 59.978 (2.3607 — 2.3613)
mm (in)
diameter 0.05 (0.0020) US 59.942 — 59.958 (2.3599 — 2.3605)
0.25 (0.0098) US 59.742 — 59.758 (2.3520 — 2.3527)
Standard 1.998 — 2.011 (0.0787 — 0.0792)
0.03 (0.0012) US 2.017 — 2.020 (0.0794 — 0.0795)
#1, #3
0.05 (0.0020) US 2.027 — 2.030 (0.0798 — 0.0799)
Main bear- Main bearing 0.25 (0.0098) US 2.127 — 2.130 (0.0837 — 0.0839)
ing mm (in) Standard 2.000 — 2.013 (0.0787 — 0.0793)
#2, #4, 0.03 (0.0012) US 2.019 — 2.022 (0.0795 — 0.0796)
#5 0.05 (0.0020) US 2.029 — 2.032 (0.0799 — 0.0800)
0.25 (0.0098) US 2.129 — 2.132 (0.0838 — 0.0839)
ME(H4SO 2.0)-4
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(5) T1 (1)
(2)
T2
T5 (3)
(6)
(4)
T4 (7)
(8)
(12) T3
T1
(9) T1
T4
T4
(10)
(13)
(11)
(15) T5
(14)
T6
(16) T1
T6
ME-00376
(1) Timing belt cover No. 2 (RH) (10) Belt idler No. 2 Tightening torque: N&m (kgf-m, ft-lb)
(2) Timing belt guide (MT model) (11) Camshaft sprocket No. 2 T1: 5 (0.5, 3.6)
(3) Crankshaft sprocket (12) Timing belt T2: 10 (1.0, 7.2)
(4) Timing belt cover No. 2 (LH) (13) Front timing belt cover T3: 25 (2.5, 18.1)
(5) Camshaft sprocket No. 1 (14) Timing belt cover (LH) T4: 39 (4.0, 28.9)
(6) Belt idler (No. 1) (15) Crank pulley (2.0 L model) T5: 78 (8.0, 57.9)
(7) Tensioner bracket (16) Crank pulley (2.5 L model) T6: <Ref. to ME(H4SO 2.0)-40,
(8) Belt idler (No. 2) INSTALLATION, Crank Pulley.>
(9) Automatic belt tension adjuster
ASSY
ME(H4SO 2.0)-5
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT

(1)
(2) T3
T2
(4)
T4
(6) (7)
T5
(8)
(3) (9)
T3
(10)
T1 (8)
(5)
(19)
(8)
(14)
(15)
T1 (7)
(16)
(13)
T4 T6
(10) (2)
(17) (18)
(11)
(19)
(12)
(5) T3 T5
T3
T4
(3) T2
T5
ME-00186
(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(H4SO 2.0)-57,
(3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) INSTALLATION, Cylinder
(4) Camshaft cap (RH) (14) Oil filler cap Head.>
(5) Oil seal (15) Gasket T2: 5 (0.5, 3.6)
(6) Camshaft (RH) (16) Oil filler duct T3: 10 (1.0, 7.2)
(7) Plug (17) O-ring T4: 18 (1.8, 13.0)
(8) Spark plug pipe gasket (18) Rocker cover (LH) T5: 25 (2.5, 18.1)
(9) Cylinder head (RH) (19) Stud bolt T6: 6.4 (0.65, 4.7)
(10) Cylinder head gasket
ME(H4SO 2.0)-6
General Description
MECHANICAL
3. VALVE ROCKER ASSEMBLY
(1) (2)
(4)
(3)
(5)
(4)
(2)
T2
(1)
T1
(6) (3)
(1) (2)
(4)
T3
(5)
(4)
(2) (3)
(8)
(1)
(2)
T1
(3) (2)
T2 (7)
T2 (3)
(3)
T2
T3
ME-00187
(1) Intake valve rocker arm (5) Rocker shaft support Tightening torque: N&m (kgf-m, ft-lb)
(2) Valve rocker nut (6) Intake rocker shaft T1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (7) Exhaust rocker shaft T2: 10 (1.0, 7.2)
(4) Spring (8) Exhaust valve rocker arm T3: 25 (2.5, 18.1)
ME(H4SO 2.0)-7
General Description
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1) (1)
(3) (4) (5) (6) (7)

(8)
(2)
(2)
(3)
(4)
(9)
(6)
(7)
(8)
ME-00760
(1) Exhaust valve (4) Valve spring seat (7) Retainer

(2) Intake valve (5) Intake valve oil seal (8) Retainer key
(3) Valve guide (6) Valve spring (9) Exhaust valve oil seal
ME(H4SO 2.0)-8
General Description
MECHANICAL
5. CYLINDER BLOCK
T2
T2
T8
T4
(1)
(5)
(7) T5
(2) (3) (6)
T2 (4)
T4
T6
(10)
(8) (11)
(9) T2
(10)
(4)
T2
(3)
(14) T4
(15)
T6
(10)
(4)
T10
(10)
(26)
T6
(17)
(16) (23)
(3)
(22) (12)
T2
(18)
T3 T5
T2 T4
(24)
(21) T7
(20) (13)
(25)
T1 (19)
T9
ME-00810
(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: <Ref. to ME(H4SO 2.0)-67,
(7) Oil pump (20) Metal gasket INSTALLATION, Cylinder
(8) Front oil seal (21) Oil level gauge guide Block.>
(9) Rear oil seal (22) Water pump sealing T6: 70 (7.1, 50.6)
(10) O-ring (23) Oil filter T7: First 12 (1.2, 8.7)
(11) Service hole cover (24) Gasket Second 12 (1.2, 8.7)
(12) Cylinder block (LH) (25) Water pump hose T8: 16 (1.6, 11.6)
(13) Water pump (26) Seal T9: 44 (4.5, 33)
T10: 45 (4.6, 33.3)
ME(H4SO 2.0)-9
General Description
MECHANICAL
6. CRANKSHAFT AND PISTON
(1)
T2
(4)
(5) (6)
(9)
(8)
(10)
(11)
(3) T2
(12)
(9)
(7)
(14)
T1
(12) (2)
(13)
T1
(12) (9)
(7)
(15) (11)
(18) (10)
(9) (8) (6) (4)

(5)
(17)
(16)
(17)
(16)
ME-00190
(1) Flywheel (MT model) (8) Piston pin (15) Woodruff key
(2) Reinforcement (AT model) (9) Snap ring (16) Crankshaft bearing #1, #3
(3) Drive plate (AT model) (10) Connecting rod bolt (17) Crankshaft bearing #2, #4
(4) Top ring (11) Connecting rod (18) Crankshaft bearing #5
(5) Second ring (12) Connecting rod bearing Tightening torque: N&m (kgf-m, ft-lb)
(6) Oil ring (13) Connecting rod cap T1: 45 (4.6, 33.3)
(7) Piston (14) Crankshaft T2: 72 (7.3, 52.8)
ME(H4SO 2.0)-10
General Description
MECHANICAL
7. ENGINE MOUNTING
• 2.0 L model
T2
T2
(2)
(2)
T1
(1)
(1) T1
T3
T3
ME-00413
(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(H4SO 2.0)-11
General Description
MECHANICAL
• 2.5 L model
(1)
T1
T2 T1
T2
ME-02090
(1) Front cushion rubber Tightening torque: N&m (kgf-m, ft-lb)

T1: 35 (3.6, 25.8)
T2: 85 (8.7, 62.7)
ME(H4SO 2.0)-12
General Description
MECHANICAL
C: CAUTION • Rotating parts and sliding parts such as piston,

• Wear work clothing, including a cap, protective bearing and gear should be coated with oil prior to
goggles and protective shoes during operation. assembly.
• Remove contamination including dirt and corro- • Be careful not to let oil, grease or coolant contact
sion before removal, installation or disassembly. the timing belt, clutch disc and flywheel.
• Keep the disassembled parts in order and pro- • All removed parts, if to be reused, should be re-
tect them from dust and dirt. installed in the original positions and directions.
• Before removal, installation or disassembly, be • Bolts, nuts and washers should be replaced with
sure to clarify the failure. Avoid unnecessary re- new ones as required.
moval, installation, disassembly and replacement. • Even if necessary inspections have been made
• Be careful not to burn yourself, because each in advance, proceed with assembly work while
part on the vehicle is hot after running. making rechecks.
• Be sure to tighten fasteners including bolts and • Remove or install the engine in an area where
nuts to the specified torque. chain hoists, lifting devices, etc. are available for
• Place shop jacks or rigid racks at the specified ready use.
points. • Be sure not to damage coated surfaces of body
• Before disconnecting electrical connectors of panels with tools, or not to stain seats and windows
sensors or units, be sure to disconnect the ground with coolant or oil. Place a cover over fenders, as
cable from battery. required, for protection.
• All parts should be thoroughly cleaned, paying • Prior to starting work, prepare the following:
special attention to the engine oil passages, pis- Service tools, clean cloth, containers to catch cool-
tons and bearings. ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
• Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOL
18231AA010 CAM • Used for removing and installing cam sprocket.
SPROCKET (LH side)
WRENCH • CAM SPROCKET WRENCH (499207100) can
also be used.
ST18231AA010
ST24082AA230
ME(H4SO 2.0)-13
General Description
MECHANICAL

22771AA030 SUBARU Troubleshooting for electrical system.
SELECT MONI- • English: 22771AA030 (Without printer)
TOR KIT • German: 22771AA070 (Without printer)
ST22771AA030
498267800 CYLINDER • Used for replacing valve guides.
HEAD TABLE • Used for removing and installing valve spring.
ST-498267800
498277200 STOPPER SET Used for installing automatic transmission assem-
bly to engine.
ST-498277200
498457000 ENGINE STAND Used with ENGINE STAND (499817100).
ADAPTER RH
ST-498457000
ME(H4SO 2.0)-14
General Description
MECHANICAL

ADAPTER LH
ST-498457100
498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-
STOPPER ening/tightening crank pulley bolt.
ST-498497100
398744300 PISTON GUIDE Used for installing piston in cylinder. (2.0 L model)
ST-398744300
498747300 PISTON GUIDE Used for installing piston in cylinder. (2.5 L model)
ST-498747300
ME(H4SO 2.0)-15
General Description
MECHANICAL

498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve
GUIDE guide oil seals.
ST-498857100
499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.
ST-499017100
499037100 CONNECTING Used for removing and installing connecting rod
ROD BUSHING bushing.
REMOVER AND
INSTALLER
ST-499037100
499587200 CRANKSHAFT • Used for installing crankshaft oil seal.
OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).
ST-499587200
ME(H4SO 2.0)-16
General Description
MECHANICAL

499587500 OIL SEAL • Used for installing camshaft oil seal.
INSTALLER • Used with OIL SEAL GUIDE (499597000).
ST-499587500
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL
INSTALLER
ST-499587700
499097700 PISTON PIN Used for removing piston pin.
REMOVER
ASSY
ST-499097700
499207400 CAM Used for removing and installing cam sprocket.
SPROCKET (RH side)
WRENCH
ST-499207400
ME(H4SO 2.0)-17
General Description
MECHANICAL

499497000 ®
TORX PLUS Used for removing and installing camshaft cap.
ST-499497000
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
ST-499587100
499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal.
• Used with CAMSHAFT OIL SEAL INSTALLER
(499587500).
ST-499597000
OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL
ST-499597100
ME(H4SO 2.0)-18
General Description
MECHANICAL

499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
ST-499718000
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
ST-499767200
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
ST-499767400
499767700 VALVE GUIDE Used for installing valve guides. (Intake side)
ADJUSTER
ST-499767700
ME(H4SO 2.0)-19
General Description
MECHANICAL

499767800 VALVE GUIDE Used for installing valve guides. (Exhaust side)
ADJUSTER
ST-499767800
499817100 ENGINE STAND • Stand used for engine disassembly and assem-
bly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
ST-499817100
499977400 CRANK PULLEY Used for stopping rotation of crank pulley when
WRENCH loosening/tightening crank pulley bolt. (2.0 L
model)
ST-499977400
WRENCH loosening/tightening crank pulley bolt. (2.5 L
model)
ST-499977100
ME(H4SO 2.0)-20
General Description
MECHANICAL

18332AA000 OIL FILTER Used for removing and installing oil filter. (Outer
WRENCH diameter: 68 mm (2.68 in))
ST18332AA000
ST18332AA010
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
ST-499987500
2. GENERAL TOOL
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-
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(H4SO 2.0)-21
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.
4) Remove all the spark plugs. <Ref. to IG(H4SO
2.0)-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 the
spark plug hole.
NOTE:
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 the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
ME-00192
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard:
1,020 — 1,275 kPa (10.4 — 13.0 kgf/cm2,
148 — 185 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm2, 7 psi) or less
ME(H4SO 2.0)-22
Idle Speed
MECHANICAL
3. Idle Speed (2) Start the engine, and read engine idle
speed.
A: INSPECTION
1) Before checking the idle speed, check the fol-
lowing:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and hoses are connected
properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Idle the engine.
3) Stop the engine, and turn the ignition switch to ME-00811
OFF. NOTE:
4) When using Subaru Select Monitor, refer to the This ignition system provides simultaneous ignition
following. <Ref. to ME(H4SO 2.0)-13, SPECIAL for #1 and #2 plugs. It must be noted that some ta-
TOOL, PREPARATION TOOL, General Descrip- chometers may register twice that of actual engine
tion.> speed.
(1) Insert the cartridge to the Subaru Select 6) Check the idle speed when unloaded. (With
Monitor. headlights, heater fan, rear defroster, radiator fan,
(2) Connect the Subaru Select Monitor to data A/C, etc. OFF)
link connector.
Idle speed [No load and gears in “N” or “P”
range]:
650#100 rpm
(1)
7) Check the idle speed when loaded. (Turn the A/
C switch to “ON” and operate the compressor for at
least one minute before measurement.)
Idle speed [A/C “ON” and gears in “N” or “P”
range]:
800#100 rpm
AT-01712 NOTE:
Idle speed cannot be adjusted manually, because
(1) Data link connector the idle speed is automatically adjusted. If the idle
speed is out of specifications, refer to General Di-
(3) Turn the ignition switch to ON, and Subaru
agnosis Table under “Engine Control System”.
select monitor switch to ON.
<Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic
(4) Select {Each System Check} in the Main Procedure.>
Menu.
(5) Select {Engine} in the Selection Menu.
(6) Select {Current Data Display & Save} in the
Engine Control System Diagnosis.
(7) Select {Data Display} in the Data Display
Menu.
(8) Start the engine, and read engine idle
speed.
5) When using the tachometer (Secondary pick-up
type):
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.
ME(H4SO 2.0)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
careful not to burn yourself at measurement.
1) Idle the engine.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with the timing light.
3) Start the engine and check the ignition timing at
the following idle speed.
Ignition timing [BTDC/rpm]:
13"#10"/650
20 10
ME-00812
If the timing is not correct, check the ignition control

system. <Ref. to EN(H4SO 2.0)(diag)-2, Basic Di-
agnostic Procedure.>
ME(H4SO 2.0)-24
Intake Manifold Vacuum
MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
1) Idle the engine.
2) Disconnect the brake vacuum hose from the in-
take manifold, and then install the vacuum gauge.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
By observing the gauge needle movement, the in-
ternal condition of the engine can be diagnosed as
described below.
ME-00813
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 intake manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten- Air leakage around intake manifold gasket, disconnection or
dency becomes more evident as engine temperature rises. damage of vacuum hose
2. When engine speed is reduced slowly from higher speed, Exhaust pressure is too high, or exhaust system is clogged.
needle stops temporarily when it is lowering or becomes steady
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- Valve anchoring
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
range.
ME(H4SO 2.0)-25
Engine Oil Pressure
MECHANICAL
6. Engine Oil Pressure CAUTION:

• If the oil pressure is out of specification,
A: INSPECTION check oil pump, oil filter and lubrication line.
1) Disconnect the ground cable from battery. <Ref. to LU(H4SO 2.0)-19, INSPECTION, Gener-
al Diagnostic Table.>
• If the oil pressure warning light is turned to
ON but oil pressure is within specification, re-
place the oil pressure switch. <Ref. to LU(H4SO
2.0)-19, INSPECTION, General Diagnostic Ta-
ble.>
NOTE:
The specified value is based on an engine oil tem-
perature of 80"C (176"F).
IN-00203 8) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H4SO 2.0)-17, IN-
2) Remove the generator from bracket. <Ref. to STALLATION, Oil Pressure Switch.>
SC(H4SO 2.0)-14, REMOVAL, Generator.>
3) Disconnect the connector from oil pressure Tightening torque:
switch. 25 N&m (2.5 kgf-m, 18.1 ft-lb)
4) Remove the pressure switch from cylinder block.
<Ref. to LU(H4SO 2.0)-17, REMOVAL, Oil Pres-
sure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
IN-00203
7) Start the engine, and measure oil pressure.
ME-00196
Oil pressure:
Standard
88 kPa (0.9 kg/cm2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
ME(H4SO 2.0)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, re-
lease fuel pressure.
NOTE:
When the fuel pressure is out of specification,
check or replace the pressure regulator and pres-
sure regulator vacuum hose.
filler cap.
3) Disconnect the fuel delivery hose from fuel
damper, and connect a fuel pressure gauge.
ME-00814

5) Start the engine.
6) Measure the fuel pressure while disconnecting
pressure regulator vacuum hose from intake mani-
fold.
Fuel pressure:
Standard: 284 — 314 kPa (2.9 — 3.2 kg/cm2,
41 — 46 psi)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard: 206 — 235 kPa (2.1 — 2.4 kg/cm2,
30 — 34 psi)
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.
ME(H4SO 2.0)-27
Valve Clearance
MECHANICAL
8. Valve Clearance NOTE:

When the arrow mark (A) on cam sprocket (LH)
A: INSPECTION comes exactly to the top, #1 cylinder piston is
NOTE: brought to the top dead center of compression
Inspection and adjustment of valve clearance stroke.
should be performed while engine is cold.
(A)
ME-00200
10) Measure #1 cylinder valve clearance using

thickness gauge.
CAUTION:
• Insert the thickness gauge (A) in as horizon-
tally as possible with respect to the valve stem
IN-00203
end face.
6) Remove the timing belt cover (LH). • Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance (Standard):
Intake:
0.20#0.04 mm (0.0079#0.0016 in)
Exhaust:
0.25#0.04 mm (0.0098#0.0016 in)
(A)
ME-00199
7) When inspecting #1 and #3 cylinders:

(1) Disconnect the spark plug cords from spark
plugs RH side. <Ref. to IG(H4SO 2.0)-5, RH
SIDE, REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH). ME-00201
(3) Remove the bolts, then remove the rocker
cover (RH). 11) If necessary, adjust the valve clearance. <Ref.
8) When inspecting #2 and #4 cylinders: to ME(H4SO 2.0)-29, ADJUSTMENT, Valve Clear-
(1) Disconnect the spark plug cords from spark ance.>
plugs (LH Side). <Ref. to IG(H4SO 2.0)-5, LH 12) Measure the valve clearance in #3, #2 and #4
SIDE, REMOVAL, Spark Plug.> cylinder in the same measurement procedure as #1
(2) Disconnect the PCV hose from rocker cover cylinder.
(LH).
cover (LH).
9) Set #1 cylinder piston to top dead center of com-
pression stroke by rotating the crank pulley clock-
wise using the socket wrench.
ME(H4SO 2.0)-28
Valve Clearance
MECHANICAL
NOTE: Valve clearance

• Be sure to set the cylinder pistons to their re- Intake:
spective top dead centers on compression stroke 0.20#0.04 mm (0.0079#0.0016 in)
before measuring valve clearances. Exhaust:
• By rotating the crank pulley clockwise every 180" 0.25#0.04 mm (0.0098#0.0016 in)
from the state that #1 cylinder piston is on the top
dead center of compression stroke, #3, #2 and #4
cylinder pistons come to the top dead center of
compression stroke in this order.
13) After inspection, install the related parts in the
reverse order of removal.
B: ADJUSTMENT
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold. ME-00203
1) Set #1 cylinder piston to top dead center of com- 3) Adjust the valve clearance in #3, #2 and #4 cyl-
pression stroke by rotating the crank pulley clock- inder in the same adjustment procedure as #1 cyl-
wise using the socket wrench. inder.
NOTE: NOTE:
When the arrow mark (A) on cam sprocket (LH) • Be sure to set the cylinder pistons to their re-
comes exactly to the top, #1 cylinder piston is spective top dead centers on compression stroke
brought to the top dead center of compression before adjusting valve clearances.
stroke. • By rotating the crank pulley clockwise every 180"
from the state that #1 cylinder piston is on the top
(A) dead center of compression stroke, #3, #2 and #4
cylinder pistons come to the top dead center of
compression stroke in this order.
4) Ensure the valve clearances of each cylinder are
within specifications. If necessary, readjust the
valve clearances.
ME-00200
2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
(2) Place a suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When the specified valve clearance is ob-
tained, tighten the valve rocker nut.
Tightening torque:
10 N&m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
• Insert the thickness gauge in as horizontally
as possible with respect to the valve stem end
face.
• Adjust the exhaust valve clearances while
lifting-up the vehicle.
ME(H4SO 2.0)-29
Engine Assembly
MECHANICAL
9. Engine Assembly (1) Front oxygen (A/F) sensor connector
A: REMOVAL
2) Open the front hood fully and support with the
front food stay.
3) Collect the refrigerant from A/C system. <Ref. to
AC-20, PROCEDURE, Refrigerant Recovery Pro-
cedure.>
PRESSURE, PROCEDURE, Fuel.> or <Ref. to ME-00859
FU(H4SO 2.5)-40, RELEASING OF FUEL PRES- (2) Rear oxygen sensor connector
SURE, PROCEDURE, Fuel.>
5) Remove the fuel filler cap.
FU-01116
(3) Engine ground cable

IN-00203
7) Remove the air intake duct, air cleaner case and

air intake chamber.
<Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake
Duct.> <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
9) Remove the radiator from vehicle. <Ref. to
CO(H4SO 2.0)-20, REMOVAL, Radiator.> ME-00206
10) Disconnect the A/C pressure hoses from A/C (4) Engine harness connectors
compressor.
11) Remove the air intake chamber stay.
ME-00817
ME-00816
12) Disconnect the following connectors and ca-

bles.
ME(H4SO 2.0)-30
Engine Assembly
MECHANICAL
(5) Generator connector and terminal 14) Remove the power steering pump from brack-
et.
(1) Loosen the lock bolt and slider bolt, and re-
(A)
move the front side belt. <Ref. to ME(H4SO
2.0)-38, FRONT SIDE BELT, REMOVAL, V-
belt.>
(2) Remove the power steering pump bracket.
(B)
ME-00818
(A) Terminal
(B) Generator connector
(6) A/C compressor connectors

FU-00139
(3) Place the power steering pump on the right

side wheel apron.
15) Remove the front and center exhaust pipe.
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Ex-
haust Pipe.>
16) Remove the nuts which hold lower side of
transmission to engine.
ME-00819
(7) Power steering switch connector
ME-00210
17) Remove the nuts which install front cushion

rubber onto front crossmember.
FU-00878
13) Disconnect the following hoses.

(1) Brake booster vacuum hose
LU-00223
18) Separate the torque converter clutch from drive

plate. (AT model)
ME-00820 (1) Lower the vehicle.
(2) Heater inlet and outlet hoses (2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
ME(H4SO 2.0)-31
Engine Assembly
MECHANICAL
(4) Remove other bolts while rotating the en- 22) Support the transmission with a garage jack.
gine using a socket wrench. CAUTION:
• Doing this is very important because the
transmission lowers for its own weight. This
work is also of great importance for facilitating
reinstallation.
(A)
ME-00212 (B)
19) Remove the pitching stopper.
ME-00215
(A) Transmission
(B) Garage jack
• Before removing the engine away from trans-

mission, check to be sure no work has been
overlooked.
ME-00213 23) Separation of engine and transmission.
20) Disconnect the fuel delivery hose (A), return (1) Remove the starter. <Ref. to SC(H4SO 2.0)-
hose (B) and evaporation hose (C). 6, REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
CAUTION: transmission to engine.
• Catch fuel from the hose into container.
• Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
(A)
(C)
(B) ME-00216
24) Set the ST to converter case. (AT model)

ST 498277200 STOPPER SET
FU-01088
21) Support the engine with a lifting device and

wire ropes.
ST
ME-00217
25) Remove the engine from vehicle.

(1) Slightly raise the engine.
LU-00222
(2) Raise the transmission with garage jack.
ME(H4SO 2.0)-32
Engine Assembly
MECHANICAL
(3) Move the engine horizontally until main Tightening torque:

shaft is withdrawn from clutch cover. T1: 50 N&m (5.1 kgf-m, 36.9 ft-lb)
(4) Slowly move the engine away from engine T2: 58 N&m (5.9 kgf-m, 42.8 ft-lb)
compartment.
NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil level gauge, etc.
26) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
35 N&m (3.6 kgf-m, 25.8 ft-lb) T2 T1
ME-00218
2) Position the engine in engine compartment and
align it with transmission. 8) Remove the ST from converter case. (AT model)
NOTE: NOTE:
Be careful not to damage adjacent parts or body Be careful not to drop the ST into the converter
panels with crank pulley, oil level gauge, etc. case when removing the ST.
9) Install the starter. <Ref. to SC(H4SO 2.0)-6, IN-
STALLATION, Starter.>
10) Install the torque converter clutch to drive plate.
(AT model)
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
using a socket wrench.
CAUTION:
LU-00222 Be careful not to drop bolts into the torque con-
3) Apply a small amount of grease to splines of verter clutch housing.
main shaft. (MT model) Tightening torque:
4) Tighten the bolts which hold upper side of trans- 25 N&m (2.5 kgf-m, 18.1 ft-lb)
mission to engine.
Tightening torque:
50 N&m (5.1 kgf-m, 36.9 ft-lb)
ME-00212
(3) Clog the service hole plug and prevent for-

eign matters from being mixed.
ME-00216 11) Install the power steering pump on bracket.
5) Remove the lifting device and wire ropes. (1) Install the power steering pump on bracket,
6) Remove the garage jack. and tighten the bolts.
7) Install the pitching stopper.
ME(H4SO 2.0)-33
Engine Assembly
MECHANICAL

22 N&m (2.2 kgf-m, 16 ft-lb) Make sure the front cushion rubber mounting bolts
are securely installed.
FU-00139
(2) Connect the power steering switch connec- LU-00223

tor. 15) Install the front and center exhaust pipe.
<Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front
Exhaust Pipe.>
17) Connect the following hoses:
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
18) Connect the following connectors:
FU-00878
(1) Front oxygen (A/F) sensor connector
(2) Rear oxygen sensor connector
(3) Install the front side belt and adjust it. <Ref. (3) Engine ground cable
to ME(H4SO 2.0)-38, FRONT SIDE BELT, IN-
STALLATION, V-belt.> Tightening torque:
12) Lift-up the vehicle. 14 N&m (1.4 kgf-m, 10.1 ft-lb)
13) Tighten the nuts which hold lower side of trans- (4) Engine harness connectors
mission to engine. (5) Generator connector and terminal
Tightening torque: (6) A/C compressor connector
50 N&m (5.1 kgf-m, 36.9 ft-lb) 19) Install the air intake chamber stay.
Tightening torque:
16 N&m (1.6 kgf-m, 11.6 ft-lb)
20) Install the A/C pressure hoses.
<Ref. to AC-38, INSTALLATION, Hose and Tube.>
21) Install the radiator to vehicle. <Ref. to
CO(H4SO 2.0)-21, INSTALLATION, Radiator.>
22) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H4SO 2.0)-9, IN-
STALLATION, Air Intake Duct.> <Ref. to IN(H4SO
2.0)-7, INSTALLATION, Air Cleaner Case.> <Ref.
ME-00219 to IN(H4SO 2.0)-8, INSTALLATION, Air Intake
14) Tighten the nuts which install the front cushion Chamber.>
rubber onto crossmember. 23) Install the under cover.
24) Install the battery in the vehicle, and connect
Tightening torque:
cables.
85 N&m (8.7 kgf-m, 63 ft-lb)
25) Fill engine coolant.
<Ref. to CO(H4SO 2.0)-13, FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
26) Check the ATF level and replenish it if neces-
sary.
ME(H4SO 2.0)-34
Engine Assembly
MECHANICAL
<Ref. to 4AT-31, INSPECTION, Automatic Trans-

mission Fluid.>
27) Charge the A/C system with refrigerant. <Ref.
to AC-21, PROCEDURE, Refrigerant Charging
Procedure.>
28) Remove the front hood stay, and close the front
hood.
29) Take off the vehicle from a lift.
C: INSPECTION
1) Check pipes and hoses are installed firmly.
2) Check that the engine coolant and ATF are at
specified levels.
ME(H4SO 2.0)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(H4SO 2.0)-30, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
35 N&m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that no crack or other damages do not
exist.
ME(H4SO 2.0)-36
Preparation for Overhaul
MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from the body, secure
it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
LH
ST3 499817100 ENGINE STAND
ST3 ST1
ST2
ME-00221
2) In this section the procedures described under

each index are all connected and stated in order.
The procedure for overhauling of the engine will be
completed 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(H4SO 2.0)-37
V-belt
MECHANICAL
12.V-belt 4) Remove the belt tensioner.
A: REMOVAL
NOTE:
Perform the following procedures with the engine
installed to the body.
1. FRONT SIDE BELT
ME-00225
B: INSTALLATION
NOTE:
Wipe off any oil or water on the belt and pulley.
1. FRONT SIDE BELT
1) Install a V belt (C), and tighten the slider bolt so
ME-00222
as to obtain the specified belt tension. <Ref. to
ME(H4SO 2.0)-39, INSPECTION, V-belt.>
2) Loosen the lock bolt (A). 2) Tighten the lock bolt (A).
3) Loosen the slider bolt (B). 3) Tighten the slider bolt (B).
4) Remove the front side belt (C).
Tightening torque:
Lock bolt (A):
25 N&m (2.5 kgf-m, 18.1 ft-lb)
(B)
(C)
(B)
(C)
(A) ME-00223
2. REAR SIDE BELT

1) Loosen the lock nut (A). (A) ME-00223
2. REAR SIDE BELT
(B) 1) Install the belt tensioner.
2) Install a V belt, and tighten the slider bolt (B) so
<Ref. to ME(H4SO 2.0)-39, INSPECTION, V-belt.>
3) Tighten the lock nut (A).
(A)
ME-00224
3) Remove the rear side belt.
ME(H4SO 2.0)-38
V-belt
MECHANICAL
Tightening torque: Belt tension (without belt tension gauge)

Lock nut (A);
(A)
23 N&m (2.3 kgf-m, 17.0 ft-lb)
When installing new parts:
7 — 9 mm (0.276 — 0.354 in)
(B)
At inspection:
9 — 11 mm (0.354 — 0.433 in)
(B)
(A) 7.5 — 8.5 mm (0.295 — 0.335 in)
At inspection:
9.0 — 10.0 mm (0.354 — 0.394 in)
ME-00224 98 N (10 kg, 22 Ib)
C: INSPECTION P/S GEN (A) (B)

A/C
1) Replace the belts, if cracks, fraying or wear is
found.
2) Remove the V-belt cover and reservoir tank.
(with belt tension gauge)
3) Check the V-belt tension and adjust it if neces- I/P
sary by changing the generator installing position C/P
or idler pulley installing position. ME-00226
Belt tension (with belt tension gauge)
(A) Front side belt
(A) (B) Rear side belt
When installing new parts: C/P Crank pulley
618 — 755 N (63 — 77 kgf, 139 — 170 lb)
GEN Generator
At inspection:
490 — 640 N (50.0 — 65.3 kgf, 110.2 — 143.9
A/C Air conditioning compressor pulley
lb)
I/P Idler pulley
(B)
740 — 880 N (75.5 — 89.7 kgf, 166 — 198 lb)
At inspection:
350 — 450 N (35.7 — 45.9 kgf, 78.7 — 101.2
lb)
(A)
P/S GEN A/C
(B)
I/P
C/P
PM-00154
(A) Front side belt

(B) Rear side belt
C/P Crank pulley
GEN Generator
A/C Air conditioning compressor pulley
I/P Idler pulley
ME(H4SO 2.0)-39
Crank Pulley
MECHANICAL
13.Crank Pulley CAUTION:

If the tightening angle of crank pulley bolt is
A: REMOVAL less than 45", the bolt should be damaged. In
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, this case, the bolt must be replaced.
REMOVAL, V-belt.> (1) Replace and clean the crank pulley bolts.
2) Remove the crank pulley bolt. To lock the crank-
shaft, use ST. Crank pulley bolt:
ST 499977400 CRANK PULLEY WRENCH Part No. 12369AA011
(2.0 L model) (2) Clean the crankshaft thread using com-
ST 499977100 CRANK PULLEY WRENCH pressed air.
(2.5 L model) (3) Apply engine oil to the crank pulley bolt seat
and thread.
(4) Tighten the bolts temporarily with tightening
torque of 44 N&m (4.5 kgf-m, 33 ft-lb).
ST
(5) Tighten the crank pulley bolts keeping them
in an angle 45" — 60".
NOTE:
Conduct the tightening procedures by confirming
the turning angle of the crank pulley bolt referring to
the gauge indicated on the timing belt cover.
ME-00227 4) Install the belt tensioner.
B: INSTALLATION
1. 2.0 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
(1) Clean the crankshaft thread using com-
ME-00225
pressed air.
(2) Apply engine oil to the crank pulley bolt seat 5) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
and thread. INSTALLATION, V-belt.>
(3) Tighten the bolts temporarily with tightening 2. 2.5 L MODEL
(4) Tighten the crank pulley bolts. 1) Install the crank pulley.
Tightening torque: To lock the crankshaft, use ST.
130 N&m (13.3 kgf-m, 95.9 ft-lb) ST 499977100 CRANK PULLEY WRENCH
pressed air.
(2) Apply engine oil to the crank pulley bolt seat
ST and thread.
(4) Tighten the crank pulley bolts.
ME-00227
3) Confirm that the tightening angle of the crank

pulley bolt is 45" or more. Perform the following
procedures when less than 45".
ME(H4SO 2.0)-40
Crank Pulley
MECHANICAL
Tightening torque:
180 N&m (18.4 kgf-m, 132.8 ft-lb)
ST
ME-00227
3) Confirm that the tightening angle of crank pulley

bolt is 65 degrees or more. If the tightening angle of
crank pulley bolt is less than 65 degrees, conduct
the following procedures.
(1) Replace the crank pulley bolts and clean
them.
crank pulley bolt:
12369AA011
pressed air.
(3) Apply engine oil to the crank pulley bolt seal
and thread.
(5) Tighten the crank pulley bolts keeping them
in an angle between 65 degrees and 75 de-
grees.
NOTE:
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
ME-00225
5) Install the V-belt. <Ref. to ME(H4SO 2.0)-38, IN-

STALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to ME(H4SO
2.0)-39, INSPECTION, V-belt.>
ME(H4SO 2.0)-41
Timing Belt Cover
MECHANICAL
14.Timing Belt Cover

A: REMOVAL
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover (LH).
4) Remove the front timing belt cover.
(B)
(A)
ME-00821
(A) Timing belt cover (LH)

(B) Front timing belt cover
B: INSTALLATION
1) Install the front timing belt cover.
Tightening torque:
5 N&m (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (LH).
Tightening torque:
5 N&m (0.5 kgf-m, 3.6 ft-lb)
(B)
(A)
ME-00821
(A) Timing belt cover (LH)

(B) Front timing belt cover
3) Install the crank pulley. <Ref. to ME(H4SO 2.0)-

40, INSTALLATION, Crank Pulley.>
4) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: INSPECTION
Check the cover for damage.
ME(H4SO 2.0)-42
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
MECHANICAL
ME(H4SO 2.0)
Page
2. Compression .............................................................................................22
3. Idle Speed .................................................................................................23
4. Ignition Timing...........................................................................................24
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. Engine Assembly ......................................................................................30
10. Engine Mounting .......................................................................................36
12. V-belt.........................................................................................................38
13. Crank Pulley..............................................................................................40
15. Timing Belt ................................................................................................43
16. Cam Sprocket ...........................................................................................48
17. Crank Sprocket .........................................................................................50
18. Valve Rocker Assembly ............................................................................51
19. Camshaft...................................................................................................53
20. Cylinder Head ...........................................................................................57
21. Cylinder Block ...........................................................................................63
23. Engine Noise.............................................................................................88
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL (d)
1. TIMING BELT
(c)
REMOVAL, V-belt.>
2.0)-40, REMOVAL, Crank Pulley.> (b) (a)
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt guide. (MT model)
(f)
(e)
ME-00232
ME-00065 (2) Using white paint, put alignment marks or

arrow marks on the timing belts in relation to the
5) If the alignment mark (a) or arrow mark (which crank sprocket and cam sprockets.
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) To turn crankshaft, use the ST: Align the
mark (a) of sprocket to the cylinder block notch
(b), and then ensure the right side cam sprocket
mark (c), cam cap and cylinder head matching
surface (d) or left side cam sprocket mark (e),
timing belt cover notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET
ME-00233
Specified data:
Z1: Length of 46.8 teeth
Z2: Length of 43.7 teeth
Z1 Z2
ST
ME-00231
ME-000234
6) Remove the belt idler (No. 2).
ME(H4SO 2.0)-43
Timing Belt
MECHANICAL
7) Remove the belt idler No. 2. B: INSTALLATION

1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
ME-00235 • Push the adjuster rod vertically.
8) Remove the timing belt. • Press-in the push adjuster rod gradually tak-
ing more than three 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 the cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cyl-
inder.
• Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
ME-00236 assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
2. BELT IDLER AND AUTOMATIC BELT pressure of 294 N (30 kgf, 66 lb) until the adjust-
TENSION ADJUSTER ASSEMBLY er rod is aligned with the stopper pin hole in the
1) Remove the belt idler (No. 1). cylinder.
ME-00237 ME-00239
2) Remove the automatic belt tension adjuster as- (3) With a 2 mm (0.08 in) dia. stopper pin or a 2
sembly. mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in cylinder, secure the
adjuster rod.
ME-00238
ME-00350
ME(H4SO 2.0)-44
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster as- ST2 499207400 CAM SPROCKET WRENCH
sembly.
(A)
Tightening torque:
39 N!m (4.0 kgf-m, 28.9 ft-lb)
ME-00243
(2) While aligning the alignment mark (B) on

timing belt with the mark (A) on sprockets, posi-
ME-00241
tion the timing belt properly.
3) Install the belt idler (No. 1).
Tightening torque:
39 N!m (4.0 kgf-m, 28.9 ft-lb)
ME-00244
3) Install the belt idler No. 2.

Tightening torque:
39 N!m (4.0 kgf-m, 28.9 ft-lb)
ME-00242
4) Install the belt idler (No. 2).
2. TIMING BELT
Tightening torque:
1) Prepare for installation of automatic belt tension 39 N!m (4.0 kgf-m, 28.9 ft-lb)
adjuster assembly. <Ref. to ME(H4SO 2.0)-44, AU-
TOMATIC BELT TENSION ADJUSTER ASSEM-
BLY AND BELT IDLER, INSTALLATION, Timing
Belt.>
2) Installation of timing belt:
(1) Turn the cam sprocket No. 2 using ST1, and
turn the cam sprocket No. 1 using ST2 so that
their alignment marks (A) come to top positions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can ME-00235
also be used.
ME(H4SO 2.0)-45
Timing Belt
MECHANICAL
5) After ensuring the marks on timing belt and cam Tightening torque:
sprockets are aligned, remove the stopper pin from 10 N!m (1.0 kgf-m, 7.2 ft-lb)
belt tension adjuster.
ME-00247
ME-00245
7) Install the timing belt cover.
6) Install the timing belt guide. (MT model) <Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
(1) Temporarily tighten the timing belt guide ing Belt Cover.>
mounting bolts. 8) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks
and wear. If any fault is found, replace the belt.
2) Check the condition of the backside of belt. If
ME-00230 cracks are found, replace the belt.
(2) Check and adjust the clearance between CAUTION:
timing belt and timing belt guide by using thick- • Be careful not to let oil, grease or coolant
ness gauge. contact the belt. Remove quickly and thorough-
ly if this happens.
Clearance:
• Do not bend the timing belt sharply.
1.0"0.5 mm (0.039"0.020 in)
In radial diameter h:
60 mm (2.36 in) or more
ME-00246
(3) Tighten the timing belt guide mounting bolts.

ME-00248
ME(H4SO 2.0)-46
Timing Belt
MECHANICAL
2. AUTOMATIC BELT TENSION ADJUST- 3. BELT TENSION PULLEY

ER 1) Check the mating surfaces of timing belt and
1) Visually check the oil seals for leaks, and rod contact point of adjuster rod for abnormal wear or
ends for abnormal wear or scratches. If necessary, scratches. Replace the automatic belt tension ad-
replace the faulty parts. juster assembly if faulty.
2) Check that the adjuster rod does not move when 2) Check the belt tension pulley for smooth rota-
a pressure of 294 N (30 kgf, 66 lb) is applied to it. tion. Replace if noise or excessive play occurs.
This is to check adjuster rod stiffness. 3) Check the belt 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 occurs.
end surface of the cylinder. Repeat this opera- 2) Check the outer contacting surfaces of idler pul-
tion two to three times. ley 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 the 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.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Push the adjuster rod vertically.
• Press the adjuster rod gradually taking more
than three minutes.
N (1,000 kgf, 2,205 lb).
face of cylinder. Do not press the adjuster rod
into cylinder. Doing so may damage the cylin-
der.
4) Measure the amount of rod protrusion beyond
the body. If it is not within specifications, replace
with a new one.
Amount of rod protrusion H:
5.7"0.5 mm (0.224"0.020 in)
ME-00249
ME(H4SO 2.0)-47
Cam Sprocket
MECHANICAL
16.Cam Sprocket NOTE:

Do not confuse left and right side cam sprockets
A: REMOVAL during installation. Cam sprocket No. 2 is identified
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, by a protrusion used to monitor the camshaft posi-
REMOVAL, V-belt.> tion sensor.
3) Remove the timing belt cover. <Ref. to ST
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. <Ref. to
FU(H4SO 2.0)-22, REMOVAL, Camshaft Position
Sensor.>
6) Remove the cam sprocket No. 2. To lock the ME-00251
camshaft, use ST. 2) Install the cam sprocket No. 2. To lock the cam-
ST 18231AA010 CAM SPROCKET WRENCH shaft, use ST.
NOTE: ST 18231AA010 CAM SPROCKET WRENCH
CAM SPROCKET WRENCH (499207100) can NOTE:
also be used. CAM SPROCKET WRENCH (499207100) can
also be used.
Tightening torque:
78 N!m (8.0 kgf-m, 57.9 ft-lb)
ST
ME-00250
7) Remove the cam sprocket No. 1. To lock the

camshaft, use ST.
ST
ST 499207400 CAM SPROCKET WRENCH
ME-00250
3) Install the camshaft position sensor. <Ref. to

ST
FU(H4SO 2.0)-22, INSTALLATION, Camshaft Po-
sition Sensor.>
4) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
ME-00251 40, INSTALLATION, Crank Pulley.>
B: INSTALLATION 7) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
1) Install the cam sprocket No. 1. To lock the cam-
shaft, use ST. C: INSPECTION
ST 499207400 CAM SPROCKET WRENCH 1) Check the cam sprocket teeth for abnormal wear
Tightening torque: and scratches.
78 N!m (8.0 kgf-m, 57.9 ft-lb) 2) Make sure there is no free play between cam
sprocket and key.
ME(H4SO 2.0)-48
Cam Sprocket
MECHANICAL
3) Check the cam sprocket protrusion used for sen-

sor for damage and contamination of foreign mat-
ter.
ME(H4SO 2.0)-49
Crank Sprocket
MECHANICAL
17.Crank Sprocket 3) Check the crank sprocket protrusion used for

sensor for damage and contamination of foreign
A: REMOVAL matter.
REMOVAL, V-belt.>
er.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
2.0)-48, REMOVAL, Cam Sprocket.>
6) Remove the crank sprocket.
ME-00252
B: INSTALLATION
1) Install the crank sprocket.
ME-00252
2) Install the cam sprocket. <Ref. to ME(H4SO

2.0)-48, INSTALLATION, Cam Sprocket.>
ing Belt Cover.>
C: INSPECTION
1) Check the crank sprocket teeth for abnormal
wear and scratches.
2) Make sure there is no free play between crank
sprocket and key.
ME(H4SO 2.0)-50
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)
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO (g) (a) (c) (e)
er.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
6) Disconnect the PCV hose and remove the rock- (f) (d) (b) (h) ME-00255
er cover.
7) Removal of valve rocker assembly 2) Adjust the valve clearance. <Ref. to ME(H4SO
(1) Remove the bolts (a) through (h) in alpha- 2.0)-29, ADJUSTMENT, Valve Clearance.>
betical sequence. 3) Install the rocker cover and connect PCV hose.
NOTE: 2.0)-48, INSTALLATION, Cam Sprocket.>
Leave two or three threads of bolts (g) and (h) en-
gaged in order to retain the valve rocker assembly.
(b) (h) (f) (d) 6) Install the timing belt cover.
ing Belt Cover.>
C: DISASSEMBLY
1) Remove the bolts which secure the rocker shaft.
(c) (e) (g) (a) ME-00253 2) Extract the rocker shaft. Remove the valve rock-
(2) Remove the valve rocker assembly. er arms, springs and shaft supports from rocker
shaft.
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
3) Remove the nut and adjusting screw from valve
rocker.
D: ASSEMBLY
1) Install the adjusting screw and nut to valve rock-
er.
ME-00254 2) Arrange the valve rocker arms, springs and shaft
supports in assembly order, and then insert the
B: INSTALLATION valve rocker shaft.
1) Install the valve rocker assembly.
(1) Temporarily tighten the bolts (a) through (d) Tightening torque (Shaft supports installing
equally in order as shown in the figure. bolts):
5 N!m (0.5 kgf-m, 3.6 ft-lb)
NOTE:
Do not allow the valve rocker assembly to damage NOTE:
knock pins. Valve rocker arms, rocker shaft and shaft supports
(2) Tighten the bolts (e) through (h) to specified have identification marks. Ensure the parts with
torque. same markings are properly assembled.
3) Install the valve rocker shaft securing bolts.
ME(H4SO 2.0)-51
Valve Rocker Assembly
MECHANICAL
E: INSPECTION
1. VALVE ROCKER ARM AND ROCKER
SHAFT
1) Measure the inner diameter of valve rocker arm
and outer diameter of valve rocker shaft, and deter-
mine the difference (oil clearance) between the two
values.
Clearance between arm and shaft:
Standard:
0.020 — 0.054 mm (0.0008 — 0.0021 in)
ME-00256
ME-00257
2) If the oil clearance exceeds the standard value,

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) If the cam or valve contact surface of valve rock-
er arm is worn or dented excessively, replace the
valve rocker arm.
4) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker arm.
ME(H4SO 2.0)-52
Camshaft
MECHANICAL
19.Camshaft (1) Remove the bolts (a) and (b) in alphabetical

sequence.
A: REMOVAL
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO (a)
er.>
(b)
5) Remove the cam sprocket. <Ref. to ME(H4SO ME-00260
2.0)-48, REMOVAL, Cam Sprocket.> (2) Equally loosen the bolts (c) through (j) all the
6) Remove the crank sprocket. <Ref. to ME(H4SO way in alphabetical sequence.
2.0)-50, REMOVAL, Crank Sprocket.>
7) Remove the timing belt cover No. 2 (LH). (i) (c) (e)
8) Remove the timing belt cover No. 2 (RH).

NOTE: (g)
Do not damage or lose the seal rubber when re-
moving the timing belt covers.
(h)
(j)
(f) (d) ME-00261
(3) Remove the bolts (k) through (p) in alpha-

betical sequence using ST.
ST 499497000 TORX® PLUS
(m) (k) (o)
ME-00258
9) Remove the tensioner bracket.
(p) (l) ( n ) ME-00262
(4) Remove the camshaft cap.
ME-00259
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(H4SO 2.0)-51, REMOVAL, Valve Rocker As-
sembly.> ME-00263
13) Remove the camshaft cap.
14) Remove the camshaft.
15) Remove the oil seal.
16) Remove the plug from the rear side of cam-
shaft.
ME(H4SO 2.0)-53
Camshaft
MECHANICAL
CAUTION: (3) Install the valve rocker assembly.

• Do not remove the oil seal unless necessary.
• Do not scratch the journal surface when re-
moving the oil seal.
B: INSTALLATION
1) Apply a coat of engine oil to camshaft journals
and install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket to the mating surfaces of
camshaft cap.
ME-00267
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018) (4) Tighten the bolts (a) through (h) in alphabet-
ical sequence.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(g) (a) (c)
(e)
(f)
(h)
ME-00264
NOTE:
• Apply a coat of liquid gasket of 3 mm (0.12 in) in
diameter (A) along the edge (B) of camshaft cap (d) (b) ME-00268
(C) mating surface. ®
(5) Tighten the TORX bolts (i) through (n) in al-
• Assemble them within 20 min. after applying liq- phabetical sequence using ST.
uid gasket. ST 499497000 TORX® PLUS
Tightening torque:
(A) 18 N!m (1.8 kgf-m, 13.0 ft-lb)
(k) (i) (m)
(B)
(C)
ME-00265
(2) Temporarily tighten the bolts (g) through (j) (l)

(n)
in alphabetical sequence. (j) ME-00269
(6) Tighten the bolts (o) through (v) in alphabet-

(i)
ical sequence.
(g)
(h)
(j)
ME-00266
ME(H4SO 2.0)-54
Camshaft
MECHANICAL
Tightening torque: 9) Install the tensioner bracket.

10 N!m (1.0 kgf-m, 7.2 ft-lb)
Tightening torque:
(o) (q) 25 N!m (2.5 kgf-m, 18.1 ft-lb)
(u)
(s)
(t)
(v)
(r) (p) ME-00270
(7) Tighten the bolts (w) and (x) in alphabetical ME-00273

sequence.
10) Install the timing belt cover No. 2 (RH).
Tightening torque:
Tightening torque:
10 N!m (1.0 kgf-m, 7.2 ft-lb)
5 N!m (0.5 kgf-m, 3.6 ft-lb)
11) Install the timing belt cover No. 2 (LH).
Tightening torque:
(w) 5 N!m (0.5 kgf-m, 3.6 ft-lb)
(x)
ME-00271
3) Apply a coat of grease to oil seal lips and install

the oil seal (A) on camshaft using ST1 and ST2.
NOTE:
ME-00274
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE 12) Install the crank sprocket.
ST2 499587500 OIL SEAL INSTALLER <Ref. to ME(H4SO 2.0)-50, INSTALLATION,
Crank Sprocket.>
2.0)-48, INSTALLATION, Cam Sprocket.>
ST1
ing Belt Cover.>
ST2
16) Install the crank pulley. <Ref. to ME(H4SO
(A)
2.0)-40, INSTALLATION, Crank Pulley.>
ME-00272 17) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
4) Install the plug using ST. INSTALLATION, V-belt.>
ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Adjust the valve clearance. <Ref. to ME(H4SO
2.0)-29, ADJUSTMENT, Valve Clearance.>
6) Install the rocker cover and connect PCV hose.
7) Install the oil level gauge guide. (LH side only)
8) Install the camshaft position sensor support. (LH
side only)
ME(H4SO 2.0)-55
Camshaft
MECHANICAL
C: INSPECTION Cam base circle diameter A:

Intake: 34.00 mm (1.3386 in)
1. CAMSHAFT Exhaust: 34.00 mm (1.3386 in)
1) Measure the bend, and repair or replace if nec-
essary.
Service limit:
0.020 mm (0.00079 in)
H
A
ME-00276
2. CAMSHAFT SUPPORT
Measure the side clearance of camshaft with set-
ting the dial gauge at end of camshaft. If side clear-
ME-00275
ance exceeds the limit, replace the camshaft
2) Check the journal for damage and wear. Re- support.
place if faulty.
Standard:
3) Measure the outer diameter of camshaft journal
0.030 — 0.090 mm (0.0012 — 0.0035 in)
and inner diameter of cylinder head journal, and
determine the difference (oil clearance) between
the two values. If the oil clearance exceeds stan-
dard value, replace the camshaft or cylinder head
as necessary.
Unit: mm (in)
Clear-
0.055 — 0.090
ance at Standard
(0.0022 — 0.0035)
journal
31.928 — 31.945
Camshaft journal O.D.
(1.2570 — 1.2577)
32.000 — 32.018
Journal hole I.D.
(1.2598 — 1.2605)
4) Check the cam face condition, and remove the

minor faults by grinding with oil stone. Measure the
cam height H. If it exceeds the limit, replace it.
Cam height: H:
Model Parts Unit: mm (in)
Stan- 39.646 — 39.746
Intake
dard (1.5609 — 1.5648)
2.0 L
Stan- 39.351 — 39.451
Exhaust
dard (1.5493 — 1.5532)
Stan- 39.485 — 39.585
Intake
dard (1.5545 — 1.5585)
2.5 L
Stan- 39.904 — 40.004
Exhaust
dard (1.5710 — 1.5750)
ME(H4SO 2.0)-56
Cylinder Head
MECHANICAL
20.Cylinder Head CAUTION:

Be careful not to scratch the mating surface of
A: REMOVAL cylinder head and cylinder block.
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, 14) Similarly, remove the right side cylinder head.
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO B: INSTALLATION
2.0)-40, REMOVAL, Crank Pulley.> 1) Install the cylinder head and gaskets on cylinder
3) Remove the timing belt cover. <Ref. to block.
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov- CAUTION:
er.> • Use new cylinder head gaskets.
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)- • Be careful not to scratch the mating surface
43, REMOVAL, Timing Belt.> of cylinder block and cylinder head.
5) Remove the cam sprocket. <Ref. to ME(H4SO 2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
6) Remove the intake manifold. <Ref. to FU(H4SO bolt threads.
2.0)-11, REMOVAL, Intake Manifold.>
(2) Tighten all bolts to 29 N!m (3.0 kgf-m, 22 ft-
7) Remove the bolt which installs the A/C compres-
lb) in alphabetical sequence.
sor bracket on cylinder head.
Then tighten all bolts to 69 N!m (7.0 kgf-m, 51 ft-
8) Remove the valve rocker assembly. <Ref. to lb) in alphabetical sequence.
ME(H4SO 2.0)-51, REMOVAL, Valve Rocker As-
(3) Back off all bolts by 180# in reverse order of
sembly.>
installation, and back them off again by 180#.
9) Remove the camshaft. <Ref. to ME(H4SO 2.0)-
(4) Tighten all bolts to 42 N!m (3.9 kgf-m, 31 ft-
53, REMOVAL, Camshaft.>
lb) in alphabetical sequence.
10) Remove the cylinder head bolts in alphabetical
(5) Tighten all bolts by 80# — 90# in alphabeti-
sequence as shown in the figure.
cal sequence.
NOTE: (6) Tighten all bolts by 40# — 45# in alphabeti-
Leave bolts (a) and (c) engaged by three or four cal sequence.
threads to prevent the cylinder head from falling.
NOTE:
Do not tighten the bolts more than 45#.
(e) (c) (7) Further tighten bolts (a) and (b) by 40#—
45#.
(a) NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90#.
(b)
(f) (a) (f)

(d) ME-00278
11) While tapping the cylinder head with a plastic (c)

hammer, separate it from cylinder block.
12) Remove the bolts (a) and (c) to remove the cyl-
(d)
inder head.
(b)
(e) (c) (e) ME-00279
3) Install the camshaft. <Ref. to ME(H4SO 2.0)-54,

(a) INSTALLATION, Camshaft.>
4) Install the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, INSTALLATION, Valve Rocker
(b)
Assembly.>
(f)
5) Install the A/C compressor bracket on cylinder
head.
(d) ME-00278 6) Install the intake manifold.
13) Remove the cylinder head gasket. <Ref. to FU(H4SO 2.0)-12, INSTALLATION, Intake
Manifold.>
ME(H4SO 2.0)-57
Cylinder Head
MECHANICAL
7) Install the cam sprocket. <Ref. to ME(H4SO NOTE:

2.0)-48, INSTALLATION, Cam Sprocket.> Keep all the removed parts in order for re-installing
8) Install the timing belt. <Ref. to ME(H4SO 2.0)- in their original positions.
CAUTION:
• Mark each valve to prevent confusion.
• Use extreme care not to damage the lips of
ing Belt Cover.>
the intake valve oil seals and exhaust valve oil
10) Install the crank pulley. <Ref. to ME(H4SO seals.
2.0)-40, INSTALLATION, Crank Pulley.>
ST
C: DISASSEMBLY
1) Place the cylinder head on the ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring and remove the valve spring retainer key.
Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
ME-00280
D: ASSEMBLY
(1) (8)
(3) (5) (7)

(11)
(12)
(2) (4) (6)
(9)
(10)
(13)
ME-00281
(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 springs (10) Oil seal
ME(H4SO 2.0)-58
Cylinder Head
MECHANICAL
1) Installation of valve spring and valve: E: INSPECTION

(1) Place the cylinder head on the ST.
ST 498267800 CYLINDER HEAD TABLE 1. VALVE SPRING
(2) Coat the stem of each valve with engine oil 1) Check the valve springs for damage, free length,
and insert the valve into valve guide. and tension. Replace the valve spring if it is not
CAUTION: within the standard value presented in the table.
Use extreme care not to damage the oil lips 2) To measure the squareness of the valve spring,
when inserting the valve into valve guide. stand the spring on a surface plate and measure its
(3) Install the valve spring and retainer. deflection at the top of spring using a try square.
NOTE: Free length
54.30 (2.1378)
Be sure to install the valve springs with their close- mm (in)
coiled end facing the seat on the cylinder head. 214 — 246
Tension/spring Set
(22 — 25, 48 — 55)/45.0 (1.772)
(4) Set the ST on valve spring. height
526 — 582
ST 499718000 VALVE SPRING REMOVER N (kgf, lb)/mm
Lift (54 — 59, 119 — 130)/34.7
(in)
(1.366)
Squareness 2.5#, 2.4 mm (0.094 in)
ST
ME-00280
(5) Compress the valve spring and fit the valve

spring retainer key.
ME-00283
2. INTAKE AND EXHAUST VALVE OIL

SEAL
(B)
In the following case, pinch and remove the oil seal
from valve using pliers, and then replace it with a
new one.
• When the lip is damaged.
(B)
(A) • When the spring is out of the specified position.
• When readjusting the surfaces of intake valve
ME-00282 and valve sheet.
• When replacing the intake valve guide.
(A) Retainer key 1) Place the cylinder head on ST1.
(B) Valve springs 2) Using ST2, press-fit the oil seal.
(6) After installing, tap the valve spring retainers CAUTION:
lightly with a plastic hammer for better seating. • Apply engine oil to oil seal before press-fit-
ting.
• When press-fitting the oil seal, do not use a
hammer or strike in.
• Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
ME(H4SO 2.0)-59
Cylinder Head
MECHANICAL
Color of spring part: 2. VALVE SEAT

Intake [Silver]
Inspect the intake and exhaust valve seats, and
Exhaust [Silver] correct the contact surfaces with a valve seat cutter
if they are defective or when valve guides are re-
placed.
ST2
Valve seat width W:
Standard
ST1
Intake (A)
0.8 — 1.4 mm (0.03 — 0.055 in)
Exhaust (B)
1.2 — 1.8 mm (0.047 — 0.071 in)
ME-00284
F: ADJUSTMENT (A) (B)
1. CYLINDER HEAD
1) Make sure that no crack or other damage do not
exist. In addition to visual inspection, inspect impor- W
W
tant areas by means of red lead check.
Also make sure the gasket installing surface shows
no trace of gas and water leaks. ME-00397
2) Place the cylinder head on the ST.
ST 498267800 CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds the limit, regrind the surface
with a surface grinder.
Warping limit:
0.03 mm (0.0012 in)
Grinding limit: ME-00287
0.1 mm (0.004 in)
3. VALVE GUIDE
Standard height of cylinder head:
97.5 mm (3.839 in) 1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
NOTE: respectively the outer diameter of valve stem and
Uneven torque for the cylinder head bolts can inner diameter of valve guide with a micrometer.
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.
(A)
(B)
ST
ME-00285
(A) Straight edge

(B) Thickness gauge
ME(H4SO 2.0)-60
Cylinder Head
MECHANICAL
Clearance between the valve guide and valve ST1 498267800 CYLINDER HEAD TABLE
stem: ST2 499767200 VALVE GUIDE REMOVER
Standard
Intake
0.035 — 0.062 mm (0.0014 — 0.0024 in)
Exhaust
ST2
0.040 — 0.067 mm (0.0016 — 0.0026 in)
ST1
ME-00290
(3) Turn the cylinder head upside down and

place the ST as shown in the figure.
Intake side:
(A)
ST 499767700 VALVE GUIDE ADJUSTER
ME-00763
Exhaust side:
(A) Valve guide
ST 499767800 VALVE GUIDE ADJUSTER
ST
(A)
ME-00291
ME-00289
(A) Valve guide
2) If the clearance between valve guide and stem
exceeds the standard value, replace the valve (4) Before installing a new valve guide, make
guide or valve itself whichever shows greater sure that neither scratches nor damages exist
amount of wear. See the following procedure for on the inside surface of the valve guide holes in
valve guide replacement. cylinder head.
Valve guide inner diameter: (5) Put a new valve guide, coated with sufficient
6.000 — 6.012 mm (0.2362 — 0.2367 in) oil, in cylinder, and insert the ST1 into valve
guide. Press in until the valve guide upper end is
Valve stem outer diameters: flush with the upper surface of ST2.
Intake ST1 499767200 VALVE GUIDE REMOVER
5.950 — 5.965 mm (0.2343 — 0.2348 in) Intake side:
Exhaust ST2 499767700 VALVE GUIDE ADJUSTER
5.945 — 5.960 mm (0.2341 — 0.2346 in) Exhaust side:
(1) Place the cylinder head on ST1 with the ST2 499767800 VALVE GUIDE ADJUSTER
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert ST2 into the valve guide and press it ST1
down to remove the valve guide. ST2
ME-00292
ME(H4SO 2.0)-61
Cylinder Head
MECHANICAL
(6) Check the valve guide protrusion. 4. INTAKE AND EXHAUST VALVE
Valve guide protrusion L: 1) Inspect the flange and stem of valve, and re-
Intake place if damaged, worn or deformed, or if “H” ex-
20.0 — 21.0 mm (0.787 — 0.827 in) ceed the standard value.
Exhaust H:
16.5 — 17.5 mm (0.650 — 0.689 in) Intake
Standard: 0.8 — 1.2 mm (0.03 — 0.047 in)
Exhaust
Standard: 1.0 — 1.4 mm (0.039 — 0.055 in)
Valve overall length:
L
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
(A)
ME-00293
(A) Valve guide
(7) Ream the inside of valve guide using ST.

Put the reamer in valve guide, and rotate the
reamer slowly clockwise while pushing it lightly. H
Bring the reamer back while rotating it clock-
wise. After reaming, clean the valve guide to re-
move chips.
CAUTION:
• Apply engine oil to the reamer when reaming.
• If the inner surface of the valve guide is torn,
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 chip,
use a new reamer or remedy the reamer. H
ST 499767400 VALVE GUIDE REAMER
ME-00295
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
<Ref. to ME(H4SO 2.0)-60, VALVE SEAT, AD-
JUSTMENT, Cylinder Head.> Install a new intake
valve oil seal after lapping.
ME-00294
(8) Recheck the contact condition between

valve and valve seat after replacing the valve
guide.
ME(H4SO 2.0)-62
Cylinder Block
MECHANICAL
21.Cylinder Block 12) Remove the bolts (a) and (c) to remove the cyl-
inder head.
A: REMOVAL
(a) (e) (c)
NOTE:
Before conducting this procedure, drain the engine
oil completely.
(A)
1) Remove the intake manifold. <Ref. to FU(H4SO
2.0)-11, REMOVAL, Intake Manifold.>
REMOVAL, V-belt.>
2.0)-40, REMOVAL, Crank Pulley.> (d) (f) (b)
ME-00296
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov- (A) Front side
er.>
5) Remove the timing belt. <Ref. to ME(H4SO 2.0)- 13) Remove the cylinder head gasket.
43, REMOVAL, Timing Belt.> NOTE:
6) Remove the cam sprocket. <Ref. to ME(H4SO Do not scratch the mating surface of cylinder head
2.0)-48, REMOVAL, Cam Sprocket.> and cylinder block.
7) Remove the crank sprocket. <Ref. to ME(H4SO 14) Similarly, remove the right side cylinder head.
2.0)-40, REMOVAL, Crank Pulley.> 15) Remove the clutch housing cover. (MT model)
8) Remove the generator and A/C compressor with 16) Remove the flywheel (MT model) or drive plate
their brackets. (AT model).
9) Remove the rocker cover. Lock the crankshaft using ST.
10) Remove the cylinder head bolts in alphabetical ST 498497100 CRANKSHAFT STOPPER
sequence as shown in the figure. • MT model
NOTE:
Leave bolts (a) and (c) engaged by three or four
threads to prevent the cylinder head from falling.
(a) (e) (c)
(A)
ST
ME-00297
• AT model
(d) (f) (b)
ME-00296
(A) Front side
11) While tapping the cylinder head with a plastic

ME-00298
17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater.
ME(H4SO 2.0)-63
Cylinder Block
MECHANICAL
19) Remove the water pump after loosening the 25) Remove the oil filter.
bolts in alphabetical sequence as shown in the fig-
ure.
(F)
(E)
(A)
(D)
(C) (B)
ME-00299
26) Remove the water pipe.

ME-00847
20) Remove the oil pump from cylinder block.

Use a flat tip screwdriver as shown in the figure
when removing the oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
ME-00300
ME-00138
21) Remove the oil pan.

(1) Place the cylinder block to face the #2 and
#4 piston side 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 remove the
oil pan.
NOTE:
Do not use a screwdriver or similar tools in place of
oil pan cutter.
22) Remove the oil strainer stay.
23) Remove the oil strainer.
24) Remove the baffle plate.
ME(H4SO 2.0)-64
Cylinder Block
MECHANICAL
(1)
(2)
(3)
(4)
(6)
(4)
(5)
(3)
(4)
(3)
(2)
(1)
(4)
(3)
(2)
(1)
ME-00139
(1) Service hole plug (3) Snap ring (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 a hexagon wrench (14 mm). tons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.
ME-00140
ME-00141
29) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097700 PISTON PIN REMOVER
ME(H4SO 2.0)-65
Cylinder Block
MECHANICAL
NOTE: 30) Similarly remove the piston pins from #3 and #4

Be careful not to confuse the original combination pistons.
of piston, piston pin and cylinder. 31) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
32) Back off the bolts which connect cylinder block
on the side of #1 and #3 cylinders two or three
ST
turns.
33) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, then remove the cyl-
inder block connecting bolts.
34) Separate the cylinder block (RH) and (LH).
NOTE:
When separating the cylinder block, do not allow
ME-00142 the connecting rod to fall or damage the cylinder
block.
(5)
(1)
(4)
(2)
(4)
(3)
(1)
(5)
ME-00143
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
35) Remove the rear oil seal. 38) Draw out each piston from cylinder block using
36) Remove the crankshaft together with connect- a wooden bar or hammer handle.
ing rod. NOTE:
37) Remove the crankshaft bearings from cylinder Be careful not to confuse the original combination
block using a hammer handle. of piston and cylinder.
NOTE:
Be careful not to confuse the crankshaft bearing
combination. Press the bearing at the end opposite
to locking lip.
ME(H4SO 2.0)-66
Cylinder Block
MECHANICAL
B: INSTALLATION
(4)
(1)
(3)
(2)
(3)
ME-00144
(1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal
(2) Crankshaft
NOTE: NOTE:
Remove oil on the mating surface of bearing and Do not allow liquid gasket to flow into O-ring
cylinder block before installation. Apply a coat of grooves, oil passages, bearing grooves, etc.
engine oil to crankshaft pins.
1) Position the crankshaft on the #2 and #4 cylinder
block.
2) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent
ME-00145
3) Tighten the 10 mm cylinder block connecting

bolts on LH side (A — D) in alphabetical sequence.
ME(H4SO 2.0)-67
Cylinder Block
MECHANICAL

10 N!m (1.0 kgf-m, 7.4 ft-lb) (E), (F), (G), (I): 20 N!m (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 N!m (1.8 kgf-m, 13.3 ft-lb)
(A)
(D) (G) (E)
(J)
(B)
(C) (H)
(I) (F)
ME-00398
ME-00399
4) Tighten the 10 mm cylinder block connecting
bolts on RH side (E — J) in alphabetical sequence. 7) Further tighten the LH side bolts (A — D) to 90#
in alphabetical sequence.
Tightening torque:
10 N!m (1.0 kgf-m, 7.4 ft-lb)
(A)
(D)
(G) (E)
(J)
(B)
(C)
(H)
(I) (F) ME-00398
ME-00399 8) Further tighten the RH side bolts (E — J) to 90#

5) Further tighten the LH side bolts (A — D) in al-
phabetical sequence.
Tightening torque:
(A), (C): 20 N!m (2.0 kgf-m, 14.8 ft-lb) (G) (E)
(B), (D): 15 N!m (1.5 kgf-m, 10.8 ft-lb) (J)
(H)
(I) (F)
(A)
(D) ME-00399
9) Tighten the 8 mm and 6 mm cylinder block con-

(B) necting bolts on LH side (A — H) in alphabetical se-
quence.
(C)
ME-00398
6) Further tighten the RH side bolts (E — J) in al-

ME(H4SO 2.0)-68
Cylinder Block
MECHANICAL
Tightening torque: 13) Position the upper rail gap at (C) in the figure.
(A) — (G): 25 N!m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
(G)
(C) (A) (B)

(E)
25
(C)
ME-02087
(D) (F) 14) Align the upper rail spin stopper (E) to the side
(H) ME-00147 hole (D) on the piston.
10) Install the rear oil seal using ST1 and ST2. (D) (E)
ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER
(B) (A)
ST2 (F) (G)
ME-00843
15) Position the expander gap at 180# on the re-

ST1 verse side of (C) that shown (F) in the figure.
ME-00148
(A) Rear oil seal (F)

(B) Flywheel attaching bolt
11) Position the top ring gap at (A) or (B) in the fig-
ure.
12) Position the second ring gap at 180# on the re-
verse side of the top ring gap.
ME-02088
16) Position the lower rail gap at 120# on counter-

clockwise of (C) that shown (G) in the figure.
(A) (B)
ME-00718
(G) (C)
120 ME-02089
CAUTION:
• Ensure ring gaps do not face the same direc-
tion.
• Ensure ring gaps are not within the piston
skirt area.
ME(H4SO 2.0)-69
Cylinder Block
MECHANICAL
17) Install the snap ring. CAUTION:

Install snap rings in the piston holes located oppo- Piston front mark faces towards the front of en-
site to the service holes in cylinder block, when po- gine.
sitioning all pistons in the corresponding cylinders.
NOTE:
Use new snap rings.
#3
#1 (A)
#4 ME-00742
(A) Front mark

(A) #2
ME-00306
(A) Front side
(5) T
(4)
(5)
(1)
(3) (4)
(3)
(2)
(2)
(1)
ME-00155
(1) Piston (4) Gasket Tightening torque: N!m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug T: 70 (7.1, 50.6)
(3) Snap ring
18) Install the piston. ST 2 398744300 PISTON GUIDE (2.0 L model)
(1) Place the cylinder block to face the #1 and ST 2 498747300 PISTON GUIDE (2.5 L model)
#2 cylinder side upward.
(2) Using ST1, turn the crankshaft so that #1 ST1
and #2 connecting rods are set at bottom dead
center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2
ME-00157
ME(H4SO 2.0)-70
Cylinder Block
MECHANICAL
19) Install the piston pin. (6) Install the service hole plug and gasket.
(1) Apply a coat of engine oil to ST3. NOTE:
(2) Insert ST3 into the service hole to align pis- Use a new gasket.
ton pin hole with connecting rod small end.
ST3 499017100 PISTON PIN GUIDE
ST1
ST3
ME-00140
ME-00158
(3) Apply a coat of engine oil to piston pin, and

insert the piston pin into piston and connecting
rod through service hole.
(4) Install the snap ring.
NOTE:
Use new snap rings.
ME-00159
(5) Apply liquid gasket around the service hole

plug.
Liquid gasket:
equivalent
ME-00160
ME(H4SO 2.0)-71
Cylinder Block
MECHANICAL
(5) T2 T1
(6)
(3) (4)
(2) (7)
(1)
(3)
(2)
(1)
ME-00161
(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) Snap ring (7) O-ring T2: 70 (7.1, 50.6)
(4) Gasket
(7) Place the cylinder block to face the #3 and 24) Apply liquid gasket to mating surfaces and in-
#4 cylinder side upward. Following the same stall the oil pan.
procedures as used for #1 and #2 cylinders, in-
Liquid gasket:
stall the pistons and piston pins.
THREE BOND 1207C (Part No. 004403012) or
20) Install the water pipe.
equivalent
ME-00300
ME-00162
21) Install the baffle plate.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
22) Install the oil strainer and O-ring.
Tightening torque:
10 N!m (1.0 kgf-m, 7.2 ft-lb)
23) Install the oil strainer stay.
ME(H4SO 2.0)-72
Cylinder Block
MECHANICAL
25) Apply liquid gasket to mating surfaces and in- ST 499587100 OIL SEAL INSTALLER
stall the oil separator cover.
Liquid gasket:
equivalent
ME-00164
(2) Apply liquid gasket to the matching surface

of oil pump.
Liquid gasket:
ME-00163 THREE BOND 1215 (Part No. 004403007) or
26) Install the flywheel. (MT model) equivalent
<Ref. to CL-16, INSTALLATION, Flywheel.>
To lock the crankshaft, use the ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N!m (7.3 kgf-m, 52.8 ft-lb)
(A)
ME-00165
(A) O-ring
(3) Apply a coat of engine oil to the inside of oil

seal.
ST
ME-00297
27) Install the drive plate.

To lock the crankshaft, use the ST.
Tightening torque:
72 N!m (7.3 kgf-m, 52.8 ft-lb)
ME-00312
(4) Install the oil pump on cylinder block. Be

careful not to damage the oil seal during instal-
lation.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
ME-00298 CAUTION:
• Do not forget to install the O-ring and seal
28) Install the housing cover.
when installing the oil pump.
29) Installation of oil pump:
• Align the flat surface of oil pump’s inner rotor
(1) Discard the front oil seal after removal. Re-
with crankshaft before installation.
place with a new one using ST.
30) Install the water pump and gasket.
ME(H4SO 2.0)-73
Cylinder Block
MECHANICAL
Tightening torque: CAUTION:

First: 12 N!m (1.2 kgf-m, 8.7 ft-lb) Ensure the total “re-tightening angle” of the
Second: 12 N!m (1.2 kgf-m, 8.7 ft-lb) step (6) and (7) does not exceed 180#.
CAUTION:
(c) (a) (f)
• Be sure to use a new gasket.
• When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
shown in the figure. (A)
(F)
(E)
(A)
(D)
(e) (b) (d)
ME-00309
(C) (B)
(A) Front side
34) Install the oil level gauge guide and tighten the
bolt (left side only).
ME-00847 35) Install the rocker cover.
31) Install the water by-pass pipe for heater. 36) Install the crank sprocket.
32) Install the oil filter. <Ref. to ME(H4SO 2.0)-50, INSTALLATION,
33) Tighten the cylinder head bolts. Crank Sprocket.>
(1) Apply a coat of engine oil to washers and 37) Install the cam sprocket. <Ref. to ME(H4SO
bolt threads. 2.0)-48, INSTALLATION, Cam Sprocket.>
(2) Tighten all bolts to 29 N!m (3.0 kgf-m, 22 ft- 38) Install the timing belt. <Ref. to ME(H4SO 2.0)-
lb) in alphabetical sequence. 44, INSTALLATION, Timing Belt.>
Then tighten all bolts to 69 N!m (7.0 kgf-m, 51 ft- 39) Install the timing belt cover.
lb) in alphabetical sequence. <Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
(3) Back off all bolts by 180# first; and back ing Belt Cover.>
them off again by 180#. 40) Install the crank pulley. <Ref. to ME(H4SO
(4) Tighten the bolts (a) and (b) to 34 N!m (3.5 2.0)-40, INSTALLATION, Crank Pulley.>
kgf-m, 25 ft-lb). 41) Install the generator and A/C compressor
(5) Tighten the bolts (c), (d), (e) and (f) to 15 brackets on cylinder head.
N!m (1.5 kgf-m, 11 ft-lb). 42) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
(6) Tighten all bolts by 80# — 90# in alphabeti- INSTALLATION, V-belt.>
cal sequence. 43) Install the intake manifold.
CAUTION: <Ref. to FU(H4SO 2.0)-12, INSTALLATION, Intake
Manifold.>
(7) Further tighten all bolts by 80# — 90# in al-
ME(H4SO 2.0)-74
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(1)
(2)
(2)
(5)
(4)
(3)
(6)
ME-00168
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Snap ring
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.
ME(H4SO 2.0)-75
Cylinder Block
MECHANICAL
D: ASSEMBLY
(3)
T (1)
(1)
(2)
(4)
(5)
(6)
(8)
(7)
ME-00392
(1) Connecting rod bearing (5) Second ring Tightening torque: N!m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 45 (4.6, 33.3)
(3) Connecting rod cap (7) Snap ring
(4) Oil ring (8) Side mark
1) Apply oil to the surfaces of the connecting rod E: INSPECTION
bearings.
2) Install the connecting rod bearings on connect- 1. CYLINDER BLOCK
ing rods and connecting rod caps. 1) Visually check for cracks and damage. Especial-
3) Position each connecting rod with the marked ly, inspect the important parts by means of red lead
side facing forward, and install it. check.
4) Install the connecting rod cap with connecting 2) Check the oil passages for clogging.
rod nut. 3) Inspect the cylinder block surface that mates
Ensure the arrow on connecting rod cap faces to- with cylinder head for warping by using a straight
ward front during installation. edge, and correct by grinding if necessary.
CAUTION: Warping limit:
• Each connecting rod has its own mating cap. 0.025 mm (0.00098 in)
Make sure that they are assembled correctly by
checking their matching number. Grinding limit:
• When tightening the connecting rod nuts, ap- 0.1 mm (0.004 in)
ply oil on the threads. Standard height of cylinder block:
5) Install the expander, lower rail and upper rail in 201.0 mm (7.91 in)
this order by hand. Install the second ring and top
ring with a piston ring expander. 2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
• Measurement should be performed at a temper-
ature of 20#C (68#F).
• Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as guide lines in selecting a standard piston.
ME(H4SO 2.0)-76
Cylinder Block
MECHANICAL
Standard diameter: Out-of-roundness:

2.0 L model Standard
A: 92.005 — 92.015 mm (3.6222 — 3.6226 0.010 mm (0.0004 in)
in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222
in) (A) (B)
2.5 L model
A: 99.505 — 99.515 mm (3.9175 — 3.9179
in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175
in)
H1
H2
H3
H4
(A) (B)
#5
4
ME-00171
#4
5
#3 (A) Piston pin direction

#2 (F) (B) Thrust direction
B
#1 (D) H1 10 mm (0.39 in)

A
H2 45 mm (1.77 in)
(E) (C) H3 80 mm (3.15 in)
H4 115 mm (4.53 in)
ME-00170
3) When the piston is to be replaced due to general
(A) Main journal size mark or cylinder wear, determine a suitable sized piston
(B) Cylinder block (RH)-(LH) combination mark by measuring the piston clearance.
(C) #1 cylinder bore size mark 4) How to measure the outer diameter of each pis-
(D) #2 cylinder bore size mark ton:
(E) #3 cylinder bore size mark Measure the outer diameter of each piston at the
(F) #4 cylinder bore size mark height as shown in the figure. (Thrust direction)
NOTE:
2) How to measure the inner diameter of each cyl-
Measurement should be performed at a tempera-
inder:
ture of 20#C (68#F).
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights as Piston grade point H:
shown in the figure, using a cylinder bore gauge. 2.0 L model
NOTE: 40.0 mm (1.575 in)
Measurement should be performed at a tempera- 2.5 L model
ture of 20#C (68#F). 37.0 mm (1.457 in)
Taper:
Standard
0.015 mm (0.0006 in)
ME(H4SO 2.0)-77
Cylinder Block
MECHANICAL
Standard (2) If the cylinder inner diameter exceeds limit*

2.0 L model after boring and honing, replace the cylinder
A: 92.005 — 92.015 mm (3.6222 — 3.6226 block.
in) *: 2.0 L model
B: 91.995 — 92.005 mm (3.6219 — 3.6222 92.515 mm (3.6423 in)
in)
2.5 L model 2.5 L model
A: 99.505 — 99.515 mm (3.9175 — 3.9179 100.015 mm (3.9376 in)
in) NOTE:
B: 99.495 — 99.505 mm (3.9171 — 3.9175 Immediately after reboring, the cylinder diameter
in) may differ from its real diameter due to temperature
0.25 mm (0.0098 in) oversize rise. Thus, pay attention when measuring the cylin-
2.0 L model der diameter.
92.245 — 92.265 mm (3.6317 — 3.6325 in) Limit of cylinder boring:
2.5 L model 0.5 mm (0.020 in)
99.745 — 99.765 mm (3.9270 — 3.9278 in)
3. PISTON AND PISTON PIN
0.50 mm (0.0197 in) oversize
2.0 L model 1) Check the pistons and piston pins for damage,
92.495 — 92.515 mm (3.6415 — 3.6423 in) cracks and wear, and the piston ring grooves for
wear and damage. Replace if defective.
2.5 L model
2) Measure the piston-to-cylinder clearance at
99.995 — 100.015 mm (3.9368 — 3.9376 in)
each cylinder. <Ref. to ME(H4SO 2.0)-76, CYLIN-
DER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within the
standard value, replace the piston. Or bore the cyl-
inder to use an oversize piston.
3) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20#C (68#F).
Replace if defective.
H Clearance between piston hole and piston pin:
Standard
ME-00172 0.004 — 0.008 mm (0.0002 — 0.0003 in)
5) Calculate the clearance between cylinder and
piston.
NOTE:
Cylinder to piston clearance at 20#C (68#F):
Standard
$0.010 — 0.010 mm ($0.00039 — 0.00039 in)
6) Boring and honing
ME-00173
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the standard value or if there is any damage on
the cylinder wall, rebore it to use an oversize pis-
ton.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform bor-
ing on one cylinder only. Nor use an oversize
piston for one cylinder only. ME-00174
ME(H4SO 2.0)-78
Cylinder Block
MECHANICAL
4) Check the snap ring installation groove (A) on 2) Clean the piston ring groove and piston ring.
the piston for burr. If necessary, remove burr from 3) Squarely place the piston ring and oil ring in cyl-
the groove so that the piston pin can lightly move. inder, and measure the piston ring gap with a thick-
ness gauge.
Standard mm (in)
0.20 — 0.35
Top ring
(0.0079 — 0.0138)
(A)
0.40 — 0.50
2.0 L
Piston ring Second (0.0157 — 0.0197)
gap ring 0.35 — 0.50
2.5 L
(0.0138 — 0.0197)
0.20 — 0.50
Oil ring rail
ME-00175
(0.0079 — 0.0197)
5) Check the piston pin snap ring for distortion,

cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or
if its tension is insufficient, or when the piston is re-
placed, replace the piston ring with a new one of
the same size as the piston.
CAUTION:
• Mark is displayed on the end of top and sec-
ME-00177
ond rings. When installing the rings to the pis-
ton, face these marks upward. 4) Measure the clearance between piston ring and
• Oil ring consists of the upper rail, expander piston ring groove with a thickness gauge.
and lower rail. Be careful about the direction of Standard mm (in)
rail when installing the oil ring to piston.
Clearance 0.040 — 0.080
Top ring
between pis- (0.0016 — 0.0031)
ton ring and
piston ring 0.030 — 0.070
Second ring
groove (0.0012 — 0.0028)
(A)
(B)
(C)
(A)
(B)
ME-00178
(C)
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small
end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if the bend or
ME-00789 twist exceeds the limit.
(A) Upper rail
(B) Expander
(C) Lower rail
ME(H4SO 2.0)-79
Cylinder Block
MECHANICAL
Limit of bend or twist per 100 mm (3.94 in) in Connecting rod oil clearance:
length: Standard
0.10 mm (0.0039 in) 0.016 — 0.044 mm (0.00063 — 0.0017 in)
Unit: mm (in)
(A) Bearing size
Outer diameter of
Bearings (Thickness at cen-
crank pin
ter)
1.492 — 1.501 51.984 — 52.000
(B) 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
(A)
6) Inspect the bushing at connecting rod small end,
and replace if worn or damaged. Also measure the
(B) piston pin clearance at the connecting rod small
end.
Clearance between piston pin and bushing:
ME-00179 Standard
0 — 0.022 mm (0 — 0.0009 in)
(A) Thickness gauge
(B) Connecting rod
3) Install the connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). If side clearance exceeds the limit, re-
place the connecting rod.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
ME-00181
ME-00180
4) Inspect the connecting rod bearing for scar, ME-00174
peeling, seizure, melting, wear, etc. 7) Replacement procedure is as follows.

5) Measure the oil clearance on individual connect- (1) Remove the bushing from connecting rod
ing rod bearings by means of plastigauge. If any oil with ST and press.
clearance is not within the specification, replace the (2) Press the bushing with ST after applying oil
defective bearing with a new one of standard size on the periphery of bushing.
or undersize as necessary. (See the table below.)
ME(H4SO 2.0)-80
Cylinder Block
MECHANICAL
ST 499037100 CONNECTING ROD BUSH- Crank pin:

ING REMOVER AND IN- 2.0 L model
STALLER Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
ST Grinding limit
To 51.750 mm (2.0374 in) dia.
2.5 L model
Out-of-roundness
0.003 mm (0.0001 in)
Cylindricality
0.004 mm (0.0002 in)
ME-00182
Grinding limit
(3) Make two 3 mm (0.12 in)-holes in bushing. To 51.750 mm (2.0374 in) dia.
Ream the inside of bushing.
(4) After completion of reaming, clean the bush- Crank journal:
ing to remove chips. Out-of-roundness
0.005 mm (0.0002 in)
6. CRANKSHAFT AND CRANKSHAFT Cylindricality
BEARING 0.006 mm (0.0002 in)
1) Clean the crankshaft completely, and check it for Grinding limit
cracks using red lead. Replace if faulty. To 59.750 mm (2.3524 in) dia.
2) Measure the bend of crankshaft. If it exceeds the
limit, repair or replace it.
NOTE:
If a suitable V-block is not available, install #1 and
#5 crankshaft bearing on cylinder block, position
the crankshaft on these bearings, and then mea-
sure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
ME-00184
ME-00183
3) Inspect the crank journal and crank pin for wear.

If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and re-
place or recondition crankshaft as necessary.
When grinding the crank journal or crank pin, finish
them to the specified dimensions according to the
undersize bearing to be used.
ME(H4SO 2.0)-81
Cylinder Block
MECHANICAL
Unit: mm (in)
Crank journal outer diameter
Crank pin outer diameter
#1, #3 #2, #4, #5
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard
Bearing size 1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at center) (0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
0.03 (0.0012) (2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
undersize Bearing size 2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
0.05 (0.0020) (2.3599 — 2.3605) (2.3599 — 2.3605) (2.0446 — 2.0453)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
0.25 (0.0098) (2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
4) Measure the side clearance of crankshaft at cen-
ter bearing. If clearance exceeds the limit, replace
the bearing.
Crankshaft side clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
ME-00322
5) Inspect individual crankshaft bearings for signs

of flaking, seizure, melting and wear.
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 replace
or recondition the crankshaft as necessary.
Crankshaft oil clearance:
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
ME(H4SO 2.0)-82
Engine Trouble in General
MECHANICAL
22.Engine Trouble in General

A: INSPECTION
NOTE:
“RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
Symptom Problem parts, etc. Possible cause RANK
1. Engine does not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor 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
2) Initial combustion does Starter Defective starter C
not occur. Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
Fuel line Defective fuel pump and relay A
Lack of or insufficient fuel B
Belt Trouble B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plug or defective gasket C
Loosened cylinder head bolt or defective gasket C
Improper valve sealing 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
3) Initial combustion occurs. Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> 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
Belt Trouble B
Defective timing B
ME(H4SO 2.0)-83
MECHANICAL

4) Engine stalls after initial Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
combustion. 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
Belt Trouble B
Defective timing B
2. Rough idle and engine Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
stall 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
Clogged fuel line C
Belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plug or defective gasket B
Loosened cylinder head bolt or defective gasket B
Improper valve sealing B
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 Over-heating C
Other Evaporative emission control system malfunction A
Stuck or damaged throttle valve B
ME(H4SO 2.0)-84
MECHANICAL

3. Low output, hesitation and Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
poor acceleration Intake system Loosened or cracked intake duct A
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
Over-cooling C
4. Surging Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
Intake system Loosened or cracked intake duct A
Dirty air cleaner element B
Clogged fuel line B
Worn or broken valve spring C
Cooling system Over-heating B
Other Evaporative emission control system malfunction C
ME(H4SO 2.0)-85
MECHANICAL

5. Engine does not return to Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
idle. Intake system Loosened or cracked vacuum hose A
Other Stuck or damaged throttle valve A
6. Dieseling (Run-on) Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
Other Evaporative emission control system malfunction B
7. After burning in exhaust Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
system Intake system Loosened or cracked intake duct C
Loosened oil filler cap C
Lubrication system Incorrect oil pressure C
Cooling system Over-cooling C
8. Knocking Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
Intake system Loosened oil filler cap B
Cooling system Over-heating A
9. Excessive engine oil con- Intake system Loosened or cracked PCV hose A
sumption Defective PCV valve B
Compression Defective valve stem A
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective gas- B
ket
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(H4SO 2.0)-86
MECHANICAL

10. Excessive fuel consump- Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.> A
tion Intake system Dirty air cleaner element A
ME(H4SO 2.0)-87
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 camshaft main bearing
Oil pressure is low.
Heavy and dull clank • Worn connecting rod bearing (big end)
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 camshaft main bearing
Clank when engine speed is injector connector of noisy cyl- • Worn bearing at crankshaft end of connecting rod
1,000 to 2,000 rpm inder is disconnected.
(NOTE*)
Sound is reduced when fuel • Worn cylinder liner and piston ring
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 with case/adjacent part
Valve tappet noise — Incorrect valve clearance
NOTE*)
When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, carry out the clear memory mode <Ref. to EN(H4SO 2.0)(diag)-38, OPERATION, Clear Memory Mode.> and inspec-
tion mode <Ref. to EN(H4SO 2.0)(diag)-32, OPERATION, Inspection Mode.> after connecting the fuel injector connector.
ME(H4SO 2.0)-88
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
EXHAUST
EX(H4SO 2.0)
Page
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe .................................................................................10
4. Rear Exhaust Pipe ....................................................................................11
5. Muffler .......................................................................................................13
General Description
EXHAUST
A: COMPONENT
• 2.0 L model
(19) (22)
T7 (20) (21)
(19)
(16) (19)
(15)
(18)
(17)
(5)
(1)
(23)
(4)
(6)
(3)
(2)
T6
T2
T5 (7)
T3
(24)
(12) (11) T1
(14)
T1 (8)
(10) (8)
(13)
T3
T4
T1
T1
T1
T4
(9)
EX-02020
EX(H4SO 2.0)-2
General Description
EXHAUST
(1) Front catalytic converter upper (11) Center exhaust pipe lower cover (23) Rear exhaust pipe upper cover
cover (12) Gasket (24) Rear exhaust pipe lower cover
(2) Front catalytic converter (13) Front catalytic converter lower
(3) Center exhaust pipe cover Tightening torque: N!m (kgf-m, ft-lb)
(4) Center exhaust pipe upper cover (14) Front oxygen (A/F) sensor T1: 13 (1.3, 9.4)
(5) Rear catalytic converter upper (15) Gasket T2: 18 (1.8, 13.0)
cover (16) Spring T3: 21 (2.1, 15.2)
(6) Rear catalytic converter (17) Chamber T4: 30 (3.1, 22.4)
(7) Rear oxygen sensor (18) Rear exhaust pipe T5: 35 (3.6, 26.0)
(8) Gasket (19) Cushion rubber T6: 40.8 (4.2, 30.1)
(9) Front exhaust pipe (20) Self-locking nut T7: 48 (4.9, 35.4)
(10) Rear catalytic converter lower (21) Gasket
cover (22) Muffler
EX(H4SO 2.0)-3
General Description
EXHAUST
• 2.5 L model
(19) (22)
(19) (23)
(21)
(19) (21)
T7
(20)
(16) (19) (19)
(20)
(15)
T7
(18)
(17)
(5)
(1) (24)
(4)
(6)
(3)
(2)
T6
T2
T5 (7)
T3
(25)
(12) (11) T1
(14)
T1 (8)
(10) (8)
(13)
T3
T4
T1
T1
T1
T4
(9)
EX-02012
EX(H4SO 2.0)-4
General Description
EXHAUST
(1) Front catalytic converter upper (11) Center exhaust pipe lower cover (23) Muffler (LH)
cover (12) Gasket (24) Rear exhaust pipe upper cover
(2) Front catalytic converter (13) Front catalytic converter lower (25) Rear exhaust pipe lower cover
(3) Center exhaust pipe cover
(4) Center exhaust pipe upper cover (14) Front oxygen (A/F) sensor Tightening torque: N!m (kgf-m, ft-lb)
(5) Rear catalytic converter upper (15) Gasket T1: 13 (1.3, 9.4)
cover (16) Spring T2: 18 (1.8, 13.0)
(6) Rear catalytic converter (17) Chamber T3: 21 (2.1, 15.2)
(7) Rear oxygen sensor (18) Rear exhaust pipe T4: 30 (3.1, 22.4)
(8) Gasket (19) Cushion rubber T5: 35 (3.6, 26.0)
(9) Front exhaust pipe (20) Self-locking nut T6: 40.8 (4.2, 30.1)
(10) Rear catalytic converter lower (21) Gasket T7: 48 (4.9, 35.4)
cover (22) Muffler (RH)
EX(H4SO 2.0)-5
General Description
EXHAUST
B: CAUTION
points.
cable from battery.
EX(H4SO 2.0)-6
Front Exhaust Pipe
EXHAUST
2. Front Exhaust Pipe 7) Remove the nuts which hold front exhaust pipe
onto cylinder heads.
A: REMOVAL CAUTION:
1) Disconnect the ground cable from battery. Be careful not to pull down the front and center
exhaust pipe assembly.
IN-00203
2) Disconnect the front oxygen (A/F) sensor con- EX-00215

nector.
8) Remove the bolt which holds center exhaust
pipe to hanger bracket.
ME-00859
3) Lift-up the vehicle. EX-00216

4) Disconnect the rear oxygen sensor connector.
9) Remove the front and center exhaust pipe as-
sembly from the vehicle.
CAUTION:
• 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-
FU-01116 haust pipe.
5) Separate the center exhaust pipe from rear ex-
haust pipe.
EX-00217
EX-00214
EX(H4SO 2.0)-7
Front Exhaust Pipe
EXHAUST
11) Remove the front oxygen (A/F) sensor and rear 5) Install the nuts to cylinder head which hold front
oxygen sensor. <Ref. to FU(H4SO 2.0)-32, RE- exhaust pipe.
MOVAL, Front Oxygen (A/F) Sensor.> <Ref. to
Tightening torque:
FU(H4SO 2.0)-33, REMOVAL, Rear Oxygen Sen-
30 N!m (3.1 kgf-m, 22.4 ft-lb)
sor.> or <Ref. to FU(H4SO 2.5)-34, REMOVAL,
Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO
2.5)-35, REMOVAL, Rear Oxygen Sensor.>
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear ox-
ygen sensor. <Ref. to FU(H4SO 2.0)-32, INSTAL-
LATION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.0)-33, INSTALLATION, Rear Oxygen
Sensor.> or <Ref. to FU(H4SO 2.5)-34, INSTALLA-
TION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.5)-35, INSTALLATION, Rear Oxygen EX-00215
Sensor.> 6) Install the under cover.
2) Install the front exhaust pipe to center exhaust 7) Tighten the bolts which install the center exhaust
pipe. pipe to rear exhaust pipe.
NOTE:
Tightening torque:
Use a new gasket.
18 N!m (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
40.8 N!m (4.2 kgf-m, 30.1 ft-lb)
EX-00214
8) Tighten the bolt which holds the center exhaust

EX-00217
3) Install the front and center exhaust pipe assem-
Tightening torque:
bly to the vehicle.
35 N!m (3.6 kgf-m, 26.0 ft-lb)
4) Temporarily tighten the bolt which holds the cen-
ter exhaust pipe to hanger bracket.
EX-00216
EX-00216
EX(H4SO 2.0)-8
Front Exhaust Pipe
EXHAUST
9) Connect the rear oxygen sensor connector.
FU-01116

11) Connect the front oxygen (A/F) sensor connec-
tor.
ME-00859
IN-00203
C: INSPECTION
nections and welds.
EX(H4SO 2.0)-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 “Front Exhaust
Pipe” for removal procedure. <Ref. to EX(H4SO
2.0)-7, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to “Front Exhaust Pipe” for
installation procedure. <Ref. to EX(H4SO 2.0)-8,
INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
nections and welds.
EX(H4SO 2.0)-10
Rear Exhaust Pipe
EXHAUST
4. Rear Exhaust Pipe 4) Remove the rear exhaust pipe bracket from
cushion rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from center ex-
haust pipe.
EX-00219
B: INSTALLATION
EX-00214
1) Apply a coat of spray type lubricant to mating
area of cushion rubber.
2) Separate the rear exhaust pipe from muffler. 2) Install the rear exhaust pipe bracket to cushion
CAUTION: rubber.
Be careful not to pull down the rear exhaust
pipe.
• LH side
EX-00219
3) Install the rear exhaust pipe to muffler.

NOTE:
EX-00222
Use a new gasket and self-locking nut.
• RH side (2.5 L model)
Tightening torque:
48 N!m (4.9 kgf-m, 35.4 ft-lb)
• LH side
EX-00218

EX-00222
EX(H4SO 2.0)-11
Rear Exhaust Pipe
EXHAUST
EX-00218
4) Install the rear exhaust pipe to center exhaust

pipe.
Tightening torque:
18 N!m (1.8 kgf-m, 13.0 ft-lb)
EX-00214
C: INSPECTION
nections and welds.
3) Make sure the cushion rubber is not worn or
cracked.
EX(H4SO 2.0)-12
Muffler
EXHAUST
5. Muffler B: INSTALLATION
A: REMOVAL
1) Separate the muffler from rear exhaust pipe. NOTE:
• LH side Use a new gasket and self-locking nut.
Tightening torque:
48 N!m (4.9 kgf-m, 35.4 ft-lb)
• LH side
EX-00222
EX-00222
EX-00218

• LH side EX-00218
C: INSPECTION
nections and welds.
cracked.
EX-00220
EX-00221
3) Remove the front and rear cushion rubber, and

then remove the muffler.
EX(H4SO 2.0)-13
Muffler
EXHAUST
EX(H4SO 2.0)-14
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
COOLING
CO(H4SO 2.0)
Page
2. Radiator Fan System ..................................................................................7
3. Engine Coolant..........................................................................................13
4. Water Pump ..............................................................................................15
5. Thermostat ................................................................................................18
6. Radiator.....................................................................................................20
7. Radiator Cap .............................................................................................24
8. Radiator Main Fan and Fan Motor ............................................................25
9. Radiator Sub Fan and Fan Motor..............................................................27
10. Reservoir Tank..........................................................................................29
11. Engine Cooling System Trouble in General ..............................................30
General Description
COOLING
A: SPECIFICATION
Cooling system Electric fan + Forced engine coolant circulation system
MT: approx. 6.5 (6.9, 5.7)
Total engine coolant capacity 2 (US qt, Imp qt) AT: approx. 6.4 (6.8, 5.6) (Model without ATF warmer)
AT: approx. 6.8 (7.1, 6.0) (Model with ATF warmer)
Type Centrifugal impeller type
Discharge 2 (US gal, Imp gal) /min 20 (5.3, 4.4)
Discharge perfor- Pump speed — Discharge pres-
760 rpm — 2.9 kPa (0.3 mAq)
mance I sure
Engine coolant temperature 85!C (185!F)
3,000 rpm — 49.0 kPa (5.0 mAq)
mance II sure
Water pump
6,000 rpm — 225.4 kPa (23.0 mAq)
mance III sure
Impeller diameter mm (in) 76 (2.99)
Number of impeller vanes 8
Pump pulley diameter mm (in) 60 (2.36)
Clearance between impeller
Standard mm (in) 0.5 — 1.5 (0.020 — 0.06)
and case
Type Wax pellet type
Starting temperature to open 80 — 84!C (176 — 183!F)
Thermostat Fully opens 95!C (203!F)
Valve lift mm (in) 9.0 (0.354) or more
Valve bore mm (in) 35 (1.38)
Main fan 90 W
Motor input
Sub fan 90 W
Radiator fan
Fan diameter / Main fan 300 mm (11.81 in) /4
Blades Sub fan 300 mm (11.81 in) /5
Type Down flow, pressure type
Width " Height " 687.4 " 340 " 16
Core dimensions mm (in)
Thickness (27.06 " 13.39 " 0.63)
Radiator Above: 108#15, or more
Pressure range in which cap 2 (1.1#0.15, 16#2)
valve is open kPa (kg/cm , psi) Below: $1.0 — $4.9, or less
($0.01 — $0.05, $0.1 — $0.7)
Fins Corrugated fin type
Reservoir
Capacity 2 (US qt, Imp qt) 0.45 (0.48, 0.40)
tank
CO(H4SO 2.0)-2
General Description
COOLING
Engine coolant temperature

96 — 99!C
95!C (203!F) or less 100!C (212!F) or more
Vehicle speed A/C compressor load (203 — 210!F)
Operation of radiator Operation of radiator Operation of radiator
fan fan fan
OFF OFF Low-Speed High-Speed
19 km/h (12 MPH) or less Low Low-Speed Low-Speed High-Speed
High High-Speed High-Speed High-Speed
20 — 69 km/h
Low High-Speed High-Speed High-Speed
(12 — 43 MPH)
70 — 105 km/h
Low OFF Low-Speed High-Speed
(43 — 65 MPH)
High Low-Speed High-Speed High-Speed
OFF OFF OFF High-Speed
106 km/h (66 MPH) or more Low OFF Low-Speed High-Speed
High OFF Low-Speed High-Speed
CO(H4SO 2.0)-3
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(2)
(1)
T1
T1
(5) (3)
(4)
T2 (6)
(7)
CO-02031
(1) Water pump ASSY (5) Thermostat Tightening torque: N%m (kgf-m, ft-lb)
(2) Gasket (6) Gasket T1: First 12 (1.2, 8.7)
(3) Heater by-pass hose (7) Thermostat cover Second 12 (1.2, 8.7)
(4) ATF warmer by-pass hose (Model T2: 12 (1.2, 8.7)
with ATF warmer)
CO(H4SO 2.0)-4
General Description
COOLING
2. RADIATOR AND RADIATOR FAN
T2
T1
(6) (5)
T3 (8)
(5)
(4)
T2
(7)
(10) T1
T4
(14)
(27)
(3)
(11)
(26)
(24)
T2
T4 (12) (9)
(14)
(2) T2
(13) (28)
B
(14)
(15)
(5) (20) (14) T2
A
(22)
(14)
(21)
(5) (16) (14)
(1)
(25) T2
T2
(23)
(14)
B (17)
(18)
A
(14)
(19)
CO-02010
(1) Radiator lower cushion (14) ATF hose clamp (AT model) (24) Radiator cap
(2) Radiator (15) ATF inlet hose A (Model without (25) Heat shield cover (Model without
(3) Radiator upper cushion ATF warmer) ATF warmer)
(4) Radiator upper bracket (16) ATF outlet hose A (Model without (26) ATF inlet hose A (Model with ATF
(5) Clamp ATF warmer) warmer)
(6) Radiator inlet hose (17) ATF pipe (Model without ATF (27) ATF outlet hose A (Model without
(7) Engine coolant reservoir tank cap warmer) ATF warmer)
(8) Over flow hose (18) ATF outlet hose B (Model without (28) ATF pipe (Model with ATF warmer)
(9) Engine coolant reservoir tank ATF warmer)
(10) Radiator sub fan shroud (19) ATF inlet hose B (Model without Tightening torque: N%m (kgf-m, ft-lb)
(11) Radiator sub fan, radiator sub fan ATF warmer) T1: 4.4 (0.45, 3.3)
motor assembly (20) Radiator outlet hose T2: 7.5 (0.76, 5.5)
(12) Radiator main fan shroud (21) Radiator drain plug T3: 12 (1.2, 8.9)
(13) Radiator main fan, radiator main (22) O-ring T4: 3.4 (0.35, 2.5)
fan motor assembly (23) Radiator lower bracket
CO(H4SO 2.0)-5
General Description
COOLING

goggles, and protective shoes during operation. • Be sure to tighten fasteners including bolts and
D: PREPARATION TOOL
1. SPECIAL TOOL
499977400 CRANK PULLEY Used for stopping rotation of crank pulley
WRENCH when loosening/tightening crank pulley bolt.
(2.0 L model)
ST-499977400
499977100 CRANK PULLEY Used for stopping rotation of crank pulley
WRENCH when loosening/tightening crank pulley bolt.
(2.5 L model)
ST-499977100
18231AA010 CAM SPROCKET • Used for removing and installing cam
WRENCH sprocket.
• CAM SPROCKET WRENCH (499207100)
can also be used.
ST18231AA010
CO(H4SO 2.0)-6
Radiator Fan System
COOLING
2. Radiator Fan System

A: WIRING DIAGRAM
SBF-1 SBF-7
No.3 IGNITION
SWITCH
No.2
No.26
MAIN FUSE BOX (M/B) No.22

MAIN
FAN B: B143
RELAY 1
C: F35
E: F36
C10
C11
B7
E6
E5
E3
THROUGH JOINT
CONNECTOR
10 1
20 F109 B360
23
1
A/C RELAY HOLDER

MAIN SUB
FAN FAN
2
F27
RELAY 2 RELAY
MAIN FAN
M MOTOR
THROUGH JOINT
21
22
F17 CONNECTOR
3
F108 B361
1
16 7
F16
1
*1
*1
*2
2.5 L EC, EK, K4 MODEL: A31
EXCEPT FOR 2.5 L EC, EK, K4 MODEL: A10
E E SUB FAN M A: B134
MOTOR
*2
2.5 L EC, EK, K4 MODEL: B34
ECM
B: B135
EXCEPT FOR 2.5 L EC, EK, K4 MODEL: A9
F16 B361 B360 F108 F109 F27
F17 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 1
7 8 9 10 11 12 13 14 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 20 21 22 23 24 2 4 5
2 1 3 6
C: F35 E: F36 B: B135 10 13 7
8 9 11 14 16 17
1 2 3 4 5 1 2 3 1 2 3 4 5 6 7 12 15
6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A: B134 18 19
20 21 22 23 24 25 26 27 24 25 30
28 29
1 2 3 4 5 6 7 28 29 30 31 32 33 34 35 22 26 31
B: B143 20 21
8 9 10 11 12 13 14 15 16 17 23 27
18 19 20 21 22 23 24 25 26 27 1 2 3 4 5 6 7 8 9
28 29 30 31 32 33 34 10 11 12 13 14 15 16 17 18 19 20
CO-02011
CO(H4SO 2.0)-7
Radiator Fan System
COOLING
B: INSPECTION
DETECTING CONDITION:
• Engine coolant temperature is more than 96!C (205!F).
• Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOMS:
Radiator main and sub fan do not rotate under the above conditions.
Step Check Yes No

1 CHECK OPERATION OF RADIATOR FAN. Do the radiator main fan and Go to step 2. Go to step 3.
1) Connect the test mode connector. sub fan rotate at low speed?
3) Perform the compulsory operation check for
the radiator fan relay using Subaru Select
Monitor.
NOTE:
• When performing the compulsory operation
check for the radiator fan relay using Subaru
Select Monitor, the radiator main fan and sub
fan will repeat such a operation as low speed
revolution &'high speed revolution &'OFF in
this order.
• Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for more operation procedure. <Ref. to
EN(H4SO 2.0)(diag)-39, Compulsory Valve
Operation Check Mode.> <Ref. to EN(H4SO
2.5)(diag)-42, Compulsory Valve Operation
Check Mode.>
2 CHECK OPERATION OF RADIATOR FAN. Do the radiator main fan and Radiator fan sys- Go to step 27.
1) Connect the test mode connector. sub fan rotate at high speed? tem is normal.
Monitor.
NOTE:
revolution & high speed revolution &'OFF in
this order.
Refer to Compulsory Valve Operation Check
EN(H4SO 2.0)(diag)-39, Compulsory Valve
Operation Check Mode.> <Ref. to EN(H4SO
Check Mode.>
3 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 4. Go to step 5.
LAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 20 (+) — Chassis ground ($):
CO(H4SO 2.0)-8
Radiator Fan System
COOLING
Step Check Yes No

LAY.
5 CHECK FUSE. Is the fuse blown out? Replace the fuse. Repair the power
1) Turn the ignition switch to OFF. supply line.
2) Remove the fuse No. 3.
3) Check the condition of fuse.
7 CHECK SUB FAN RELAY. Is the resistance more than 1 Go to step 8. Replace the sub
1) Turn the ignition switch to OFF. M(? fan relay.
2) Measure the resistance between sub fan
relay terminals.
Terminals
No. 20 — No. 21:
8 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 9. Replace the sub
1) Connect the battery to terminals No. 22 and (? fan relay.
No. 23 of sub fan relay.
relay terminals.
Terminals
No. 20 — No. 21:
9 CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Go to step 10. Measure the open
LAY TERMINAL AND SUB FAN MOTOR (? circuit of harness
CONNECTOR. between sub fan
1) Disconnect the connector from sub fan relay terminal and
motor. sub fan motor con-
2) Measure the resistance of harness nector.
between sub fan relay terminal and sub fan
motor connector.
(F16) No. 2 — (F27) No. 21:
10 CHECK HARNESS BETWEEN SUB FAN MO- Is the resistance less than 1 Go to step 11. Repair the open
TOR CONNECTOR AND MAIN FAN RELAY 2 (? harness between
CONNECTOR. sub fan motor con-
1) Remove the main fan relay 2 from A/C relay nector and main
holder. fan relay 2 connec-
2) Measure the resistance of harness tor.
between sub fan motor connector and main fan
relay 2 connector.
(F16) No. 1 — (F27) No. 5:
11 CHECK POOR CONTACT. Is there poor contact in sub fan Repair the poor Go to step 12.
Check the poor contact in sub fan motor con- motor connector? contact in sub fan
nector. motor connector.
12 CHECK SUB FAN MOTOR. Does the sub fan rotate? Go to step 13. Replace the sub
Connect the battery positive (+) terminal to ter- fan motor.
minal No. 2 of sub fan motor, and the ground ($
) terminal to terminal No. 1.
13 CHECK MAIN FAN RELAY 2. Is the resistance less than 1 Go to step 14. Replace the main
Measure the resistance of main fan relay 2. (? fan relay 2.
Terminals
No. 2 — No. 5:
CO(H4SO 2.0)-9
Radiator Fan System
COOLING
Step Check Yes No

14 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 15. Repair the open
RELAY 2 TERMINAL AND MAIN FAN MO- (? circuit of harness
TOR CONNECTOR. between main fan
1) Disconnect the connector from main fan relay 2 terminal
motor. and main fan
2) Measure the resistance of harness motor connector.
between main fan relay 2 terminal and main
fan motor connector.
(F17) No. 2 — (F27) No. 2:
15 CHECK MAIN FAN MOTOR AND GROUND Is the resistance less than 5 Go to step 16. Repair the open
CIRCUIT. (? circuit in harness
Measure the resistance between main fan between main fan
motor connector and chassis ground. motor connector
Connector & terminal and chassis
(F17) No. 1 — Chassis ground: ground.
16 CHECK POOR CONTACT. Is there poor contact in main Repair the poor Go to step 17.
Check poor contact in main fan motor connec- fan motor connector? contact in main fan
tor. motor connector.
17 CHECK MAIN FAN MOTOR. Does the main fan rotate? Go to step 18. Replace the main
minal No. 2 of main fan motor, and the ground
($) terminal to terminal No. 1.
18 CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Go to step 19. Repair the open
LAY AND ECM. (? circuit in harness
1) Disconnect the connector from ECM. between sub fan
2) Measure the resistance between sub fan relay terminal and
relay terminal and ECM connector. ECM.
2.5 L EC, EK, K4 model
(B134) No. 31 — (F27) No. 22:
Except for 2.5 L EC, EK, K4 model
(B134) No. 10 — (F27) No. 22:
19 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check the DTC.
Check poor contact in ECM connector. connector? contact in ECM Repair the trouble
connector. cause. <Ref. to
EN(H4SO
2.0)(diag)-31,
Read Diagnostic
Trouble Code
(DTC).> <Ref. to
EN(H4SO
2.5)(diag)-33,
Read Diagnostic
Trouble Code
(DTC).>
20 CHECK MAIN FAN RELAY 1. Is the resistance more than 1 Go to step 21. Replace the main
1) Turn the ignition switch to OFF. M(? fan relay 1.
2) Remove the main fan relay 1 from A/C relay
holder.
3) Measure the resistance of terminal in main
fan relay 1 switch.
1) Connect the battery to terminal of main fan (? fan relay 1.
relay 1 coil.
2) Measure the resistance between terminals
of main fan relay 1 switch.
CO(H4SO 2.0)-10
Radiator Fan System
COOLING
Step Check Yes No

motor. and main fan
(F17) No. 2 — (F36) No. 6:
RELAY 1 AND ECM. (? circuit of harness
1) Disconnect the connector from ECM. between main fan
2) Measure the resistance between main fan relay 1 terminal
relay 1 terminal and ECM connector. and ECM.
(B135) No. 34 — (B143) No. 7:
(B134) No. 9 — (B143) No. 7:
relay 2 terminal and ECM connector. relay 2 terminal
Connector & terminal and ECM.
(B135) No. 34 — (F27) No. 3:
(B134) No. 9 — (F27) No. 3:
25 CHECK FUSE. Is the fuse blown out? Replace the fuse. Go to step 26.
2) Remove the fuse No. 2 and No. 26.
26 CHECK POOR CONTACT. Is there a poor contact in ECM Repair the poor Repair the power
Check poor contact in ECM connector. connector? contact in ECM supply circuit for
connector. main fuse box.
27 CHECK OPERATION OF RADIATOR FAN. Does the sub fan rotate? Go to step 20. Go to step 28.
Check if the sub fan rotates when both fans do
not rotate at high speed under the step 2.
28 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 1 Go to step 29. Repair the open
RELAY 2. (? circuit in harness
1) Remove the main fan relay 2 from A/C relay between main fan
holder. relay 2 and chas-
2) Measure the resistance between main fan sis ground.
relay 2 terminal and chassis ground.
(F27) No. 4 — Chassis ground:
29 CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 30. Repair the power
LAY 2. supply line.
2) Measure the voltage between main fan
CO(H4SO 2.0)-11
Radiator Fan System
COOLING
Step Check Yes No

2) Remove the main fan relay 2.
3) Measure the resistance of main fan relay 2.
Terminals
(F27) No. 2 — (F27) No. 4:
1) Connect the battery to terminals No. 1 and (? fan relay 2.
No. 3 of main fan relay 2.
Terminals
(F27) No. 4 — (F27) No. 5:
CO(H4SO 2.0)-12
Engine Coolant
COOLING
3. Engine Coolant 2) Fill engine coolant into the reservoir tank up to

“FULL” level.
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
3) Remove the drain plug to drain engine coolant FULL
into container.
FULL
LOW
LOW
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
CO-00269
3) Warm-up the engine completely for more than

(B) five 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 “FULL” lev-
el of reservoir tank, add engine coolant to “FULL”
level.
6) Attach the radiator cap and reservoir tank cap
properly.
(A) CO-00268
(A) Drain plug

(B) Heat shield cover
4) Install the drain plug.

2. FILLING OF ENGINE COOLANT
1) Fill engine coolant into the radiator up to the filler
neck position.
Coolant capacity (fill up to “FULL” level):
MT model:
6.5 2(6.9 US qt, 5.7 Imp qt)
AT model (model without ATF warmer):
6.4 2(6.8 US qt, 5.6 Imp qt)
AT model (model with ATF warmer):
6.8 2(7.2 US qt, 6.0 Imp qt)
NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
CO(H4SO 2.0)-13
Engine Coolant
COOLING
B: INSPECTION 2. PROCEDURE TO ADJUST THE CON-

1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEM- To adjust the concentration of coolant according to
PERTAURE temperature, find the proper fluid concentration in
The concentration and safe operating temperature amount of coolant with an undiluted solution of
of SUBARU coolant is shown in the diagram. Mea- SUBARU genuine coolant (concentration 50%).
suring the temperature and specific gravity of the The amount of coolant that should be replaced can
coolant will provide this information. be determined using the diagram.
[Example] [Example]
If the coolant temperature is 25!C (77!F) and its Assume that the coolant concentration must be in-
specific gravity is 1.054, the concentration is 45% creased from 25% to 40%. Find point A, where the
(point A), the safe operating temperature is $14!C 25% line of coolant concentration intersects with
(7!F) (point B), and the freezing temperature is $ the 40% curve of the necessary coolant concentra-
20!C ($4!F) (point C). tion, and read the scale on the vertical axis of the
Specific gravity
Safe operating temperature drained is 2.1 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1
of coolant
Concentration
of coolant ing system and add 2.1 2 (2.2 US qt, 1.8 Imp qt) of
1.100 If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
1.090
only.
1.080
60%
1.070 B
C
1.060 50%
(1.054)
A
1.050
40%
1.040
Freezing Necessary Concentration
1.030 30% of coolant
temperature
1.020
20% 3
(77 F)
1.010 (3.2,
25 C
45%
10% 2.6) A
1.000 40%
-40 -30 -20 -10 0 10 20 30 40 50 2 35%
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (2.1,
1.8) 30%
1 25%
(1.1, 20%
0.9)
10% 15%
0
10 20 30 40 50
the vehicie cooling system %
Concentration of coolant in vehicie

and quantity to be drained
CO-00012
CO(H4SO 2.0)-14
Water Pump
COOLING
4. Water Pump 7) Remove the belt cover No. 2 (LH).
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H4SO 2.0)-
20, REMOVAL, Radiator.>
REMOVAL, V-belt.>
43, TIMING BELT, REMOVAL, Timing Belt.>
4) Remove the automatic belt tension adjuster.
CO-00019
CO-00016
5) Remove the belt idler No. 2.
CO-00020
9) Disconnect the hose from water pump.

10) Remove the water pump.
CO-00017
6) Remove the cam sprocket (LH) using ST.

ST 18231AA010 CAM SPROCKET WRENCH
NOTE: CO-00021
CAM SPROCKET WRENCH (499207100) can
also be used. B: INSTALLATION
1) Install the water pump onto cylinder block (LH).
NOTE:
ST • Use a new gasket.
• When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
figure.
CO-00018
CO(H4SO 2.0)-15
Water Pump
COOLING

First: 78 N%m (8.0 kgf-m, 57.9 ft-lb)
12 N%m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N%m (1.2 kgf-m, 8.7 ft-lb) ST
(F)
(E)
(A)
(D)
(C) (B)
CO-00018

ME-00847 Tightening torque:
39 N%m (4.0 kgf-m, 28.9 ft-lb)
2) Connect the hose to the water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N%m (2.5 kgf-m, 18.1 ft-lb)
CO-00017
7) Install the automatic belt tension adjuster to

which tension rod is held with pin. <Ref. to
ME(H4SO 2.0)-44, AUTOMATIC BELT TENSION
CO-00020 ADJUSTER ASSEMBLY AND BELT IDLER, IN-
4) Install the belt cover No. 2 (LH). STALLATION, Timing Belt.>
Tightening torque: 45, TIMING BELT, INSTALLATION, Timing Belt.>
5 N%m (0.5 kgf-m, 3.6 ft-lb) 9) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
10) Install the radiator. <Ref. to CO(H4SO 2.0)-21,
INSTALLATION, Radiator.>
C: INSPECTION
1) Check the water pump bearing for smooth rota-
tion.
2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or dam-
aged.
CO-00019 4) Inspect the clearance between impeller and
5) Install the cam sprocket (LH) using ST. pump case.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
CO(H4SO 2.0)-16
Water Pump
COOLING
Clearance between impeller and pump case:

Standard value
0.5 — 1.5 mm (0.020 — 0.060 in)
CO-00293
5) After water pump installation, check the pulley

shaft for engine coolant leaks and noise. If leaks or
noise are noted, replace the water pump assembly.
CO(H4SO 2.0)-17
Thermostat
COOLING
5. Thermostat 6) Remove the thermostat cover and gasket, and

then remove the thermostat.
A: REMOVAL
4) Drain engine coolant completely.
<Ref. to CO(H4SO 2.0)-13, DRAINING OF EN-
GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
(B)
(C)
(B)
(A) CO-00268
(A)
(A) Drain plug
(B) Heat shield cover
CO-00154
5) Disconnect the radiator outlet hose from thermo-
(A) Thermostat cover
stat cover.
(B) Gasket
(C) Thermostat
B: INSTALLATION
1) Install a gasket to thermostat, and install the
thermostat and gasket to water pump as a unit.
Then, install the thermostat cover.
NOTE:
• When reinstalling the thermostat, use a new gas-
ket.
CO-00270 • The thermostat must be installed with the jiggle
pin facing to the up side.
CO(H4SO 2.0)-18
Thermostat
COOLING
Tightening torque: Valve lift:

12 N%m (1.2 kgf-m, 8.7 ft-lb) 9.0 mm (0.354 in) or more
(A)
(B)
CO-00033
(D)
(A) Thermometer
(B) Thermostat
T
(C)
(B)
(A)
CO-00155

(B) Gasket
(C) Thermostat
(D) Jiggle pin
2) Connect the radiator outlet hose to thermostat

cover.
5) Fill with engine coolant. <Ref. to CO(H4SO 2.0)-
13, FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
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.
• Inspection method
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.
Starting temperature to open:
80 — 84!C (176 — 183!F)
Fully opens:
95!C (203!F)
CO(H4SO 2.0)-19
Radiator
COOLING
6. Radiator 7) Disconnect the connector (A) of radiator main

fan motor and connector (B) of sub fan motor.
A: REMOVAL
(A)
CO-00274
IN-00203

5) Remove the heat shield cover from radiator.
(Model without ATF warmer)
(B)
CO-00275

stat cover.
CO-00273

<Ref. to CO(H4SO 2.0)-13, DRAINING OF EN-
ant.>
CO-00270
9) Disconnect the ATF cooler hoses from ATF

pipes. (Model without ATF warmer)
Plug the ATF pipe to prevent ATF leaks.
CO-00253

11) Disconnect the over flow hose.
12) Remove the reservoir tank. <Ref. to CO(H4SO
2.0)-29, REMOVAL, Reservoir Tank.>
CO(H4SO 2.0)-20
Radiator
COOLING
13) Remove the hood stay holder. NOTE:

Make pins on the lower side of radiator be fitted into
the radiator lower cushions on body side.
3) Install the radiator upper brackets and tighten
the bolts.
Tightening torque:
18 N%m (1.8 kgf-m, 13.0 ft-lb)
CO-00276

15) Disconnect the radiator inlet hose from engine.
CO-00278
4) Connect the radiator inlet hose.
CO-00277
16) Remove the radiator upper brackets.
CO-00277

6) Install the hood stay holder.
CO-00278
17) Lift the radiator up and away from vehicle.

B: INSTALLATION
1) Attach the radiator lower cushions to holes on
the radiator lower bracket.
CO-00276
7) Install the reservoir tank. <Ref. to CO(H4SO

2.0)-29, INSTALLATION, Reservoir Tank.>
8) Connect the over flow hose.
CO-00041
2) Install the radiator to vehicle.
CO(H4SO 2.0)-21
Radiator
COOLING
10) Connect the ATF cooler hoses. (Model without 13) Install the heat shield cover. (Model without
ATF warmer) ATF warmer)
CO-00253 CO-00273
11) Connect the radiator outlet hose. 14) Install the under cover.
CO-00270
12) Connect the connector (A) to radiator main fan

motor and connector (B) to sub fan motor. IN-00203
17) Fill with engine coolant. <Ref. to CO(H4SO

2.0)-13, FILLING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
18) Check the ATF level. <Ref. to 4AT-31, IN-
SPECTION, Automatic Transmission Fluid.>
C: INSPECTION
(A)
1) Remove the radiator cap, top off the radiator with
coolant, and then attach the tester in place of cap.
CO-00274
(B) CO-00094
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi)

CO-00275 to the radiator to check if:
• Engine coolant leaks at/around radiator.
• Engine coolant leaks at/around hoses or connec-
tions.
CAUTION:
• Engine should be turned off.
• Wipe engine coolant from check points in ad-
vance.
CO(H4SO 2.0)-22
Radiator
COOLING
• Be careful to prevent engine coolant from

spurting out when removing tester.
• Be careful not to deform the filler neck of ra-
diator when installing or removing the tester.
CO(H4SO 2.0)-23
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
CO-00044
2) Increase pressure until the tester gauge pointer

stops. Radiator cap is functioning properly if it holds
the service limit pressure for five to six seconds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
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(H4SO 2.0)-24
Radiator Main Fan and Fan Motor
COOLING
8. Radiator Main Fan and Fan 11) Remove the bolts which hold the radiator main
fan shroud to radiator.
Motor
A: REMOVAL
CO-00096
12) Remove the radiator main fan motor assembly.

B: INSTALLATION
IN-00203
NOTE:
When the radiator main fan motor assembly cannot
be installed, loosen the bolts which secure radiator
5) Disconnect the connector (A) of main fan motor. sub fan motor assembly.
Tightening torque:
7.5 N%m (0.76 kgf-m, 5.5 ft-lb)
(A)
CO-00274
6) Remove the heat shield cover. (Model without

ATF warmer)
CO-00096
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto the shroud.
2) Remove the nut which holds the fan onto fan
motor and shroud.
CO-00273
7) Remove the ATF hose from the clip of radiator

main fan motor assembly. (Model without ATF
warmer)
10) Remove the reservoir tank. <Ref. to CO(H4SO CO-00102
2.0)-29, REMOVAL, Reservoir Tank.>
CO(H4SO 2.0)-25
COOLING
3) Remove the bolts which install fan motor onto

the shroud.
CO-00098
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
4.4 N%m (0.45 kgf-m, 3.3 ft-lb)
CO-00098
Tightening torque:
3.4 N%m (0.35 kgf-m, 2.5 ft-lb)
CO-00102
CO(H4SO 2.0)-26
Radiator Sub Fan and Fan Motor
COOLING
9. Radiator Sub Fan and Fan 10) Remove the bolts which hold the radiator sub
fan shroud to radiator.
Motor
A: REMOVAL
CO-00101
11) Remove the radiator sub fan motor assembly

from the lower side of vehicle.
B: INSTALLATION
IN-00203
4) Remove the under cover. Tightening torque:
5) Disconnect the connector (B) of sub fan motor. 7.5 N%m (0.76 kgf-m, 5.5 ft-lb)
(B)
CO-00101
CO-00275
6) Remove the heat shield cover. (Model without C: DISASSEMBLY

ATF warmer) 1) Remove the clip which holds the fan motor con-
nector onto shroud.
2) Remove the nut which holds fan onto the fan
motor and shroud assembly.
CO-00273

sub fan motor assembly. (Model without ATF
warmer) CO-00097

CO(H4SO 2.0)-27
COOLING
3) Remove the bolts which install fan motor onto

the shroud.
CO-00098
D: ASSEMBLY
Tightening torque:
4.4 N%m (0.45 kgf-m, 3.3 ft-lb)
CO-00098
Tightening torque:
3.4 N%m (0.35 kgf-m, 2.5 ft-lb)
CO-00097
CO(H4SO 2.0)-28
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Pull out the reservoir tank to the direction of ar-
row while pushing the pawl (A).
(A)
CO-00279
B: INSTALLATION
C: INSPECTION
Make sure the engine coolant level is between
“FULL” and “LOW”.
CO(H4SO 2.0)-29
Engine Cooling System Trouble in General
COOLING
11.Engine Cooling System Trouble in General

A: INSPECTION
Trouble Possible cause Corrective action
Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair it if necessary.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on timing belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair ignition control system.
g. Improper ignition timing <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Proce-
dure.>
Over-heating
h. Clogged or leaking radiator Clean, repair or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
Inspect and repair the fuel injection system. <Ref. to
j. Air/fuel mixture ratio too lean
EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Correct or replace.
n. Dragging brake Adjustment.
Inspect radiator fan relay, engine coolant temperature
o. Defective radiator fan
sensor or radiator motor and replace them.
a. Ambient temperature extremely low Partly cover radiator front area.
Over-cooling
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on hoses Correct or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Correct or replace.
Engine coolant
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
leaks
e. Damaged or cracked cylinder head and crankcase Correct or replace.
f. Damaged or cracked thermostat case Correct or replace.
g. Leakage from radiator Correct or replace.
a. Defective timing belt Replace.
b. Defective radiator fan Replace.
Strange noise
c. Defective water pump bearing Replace water pump.
d. Defective water pump mechanical seal Replace water pump.
CO(H4SO 2.0)-30
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
LUBRICATION
LU(H4SO 2.0)
Page
2. Oil Pressure System ...................................................................................6
3. Engine Oil....................................................................................................8
4. Oil Pump ...................................................................................................10
5. Oil Pan and Strainer..................................................................................14
6. Oil Pressure Switch...................................................................................17
7. Engine Oil Filter.........................................................................................18
8. General Diagnostic Table..........................................................................19
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter ! thickness mm (in) 78 ! 7 (3.07 ! 0.28)
Tip clearance between inner and
Standard value mm (in) 0.04 — 0.14 (0.0016 — 0.0055)
outer rotors
Side clearance between inner rotor
and pump case
OIL PUMP Case clearance between outer
rotor and pump case
Discharge
pressure kPa (kg/cm2, psi) 98 (1.0, 14)
600 rpm
Performance at Discharge rate 2 (US qt, Imp qt)/min. 3.2 (3.4, 2.8)
80"C (176"F) Discharge
kPa (kg/cm2, psi) 294 (3.0, 43)
5,000 rpm pressure
Discharge rate 2 (US qt, Imp qt)/min. 32.6 (34.4, 28.7)
Relief valve working pressure 2, 490 (5.0, 71)
kPa (kg/cm psi)
Filter type Full-flow filter type
Outer diameter 68 mm 800 (124)
Filtration area cm2 (sq in)
Outer diameter 65 mm 470 (73)
Oil filter By-pass valve opening pressure kPa (kg/cm2, psi) 157 (1.60, 22.8)
Outer diameter 68 mm 68 ! 65 (2.68 ! 2.56)
Outer diameter ! width mm (in)
Outer diameter 65 mm 65 ! 74.4 (2.56 ! 2.93)
Installation screw specifications M 20 ! 1.5
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure kPa (kg/cm2, psi) 14.7 (0.15, 2.1)
Proof pressure kPa (kg/cm2,
psi) 981 (10, 142) or more
Oil capacity (at replacement) 2 (US qt, Imp qt) 4.0 (4.2, 3.5)
Recommended oil:
API classification SL, SJ with the “Energy
Conserving” logo is printed, or SH (if you SAE (1)
cannot obtain the oil with SL, SJ or SH ( C) -30 -20 -15 0 15 30 40
grades, you may use SG, SF grades “ENER- ( F) -22 -4 5 32 59 86 104
GY CONSERVING” oil.)
10W-30,10W-40
ACEA specification, A1, A2 or A3
CCMC specification, G4 or G5 5W-30,0W-20 (2)
New API certification mark (Star burst mark)

label is on the container.
LU-00071
(1) SAE viscosity No. and applicable temperature

(2) Recommend
CAUTION:
When replacing oil, use only SUBARU genuine
engine oil.
LU(H4SO 2.0)-2
General Description
LUBRICATION
B: COMPONENT
(13) (16)
(15)
T5
(14)
T3
(12)
(17) T1
(11)
T3
T3
(18)
T1
(10)
(9) (19) T3
(8) T2 (23)
(20)
(26)
(7)
(6)
(21)
T4
(22)
(5)
T6
(4) T1
(3) T1
(2) (1)
(25)
T6 (24)
LU-00228
(1) Plug (13) Oil pressure switch (24) Drain plug

(2) Gasket (14) Oil filler duct (25) Metal gasket
(3) Relief valve spring (15) O-ring (26) Gasket
(4) Relief valve (16) Oil filler cap
(5) Oil seal (17) O-ring Tightening torque: N#m (kgf-m, ft-lb)
(6) Oil pump case (18) Baffle plate T1: 5 (0.5, 3.6)
(7) Inner rotor (19) O-ring T2: 5.4 (0.55, 4.0)
(8) Outer rotor (20) Oil strainer T3: 6.4 (0.65, 4.7)
(9) Oil pump cover (21) Oil level gauge guide T4: 10 (1.0, 7.2)
(10) Oil filter (22) Oil pan T5: 25 (2.5, 18.1)
(11) O-ring (23) Oil level gauge T6: 44 (4.5, 32.5)
(12) Oil pump ASSY
LU(H4SO 2.0)-3
General Description
LUBRICATION

D: PREPARATION TOOL
1. SPECIAL TOOL
WRENCH removing and tightening crank pulley bolt. (2.0 L
model)
ST-499977400
WRENCH removing and tightening crank pulley bolt. (2.5 L
model)
ST-499977100
ST18332AA000
LU(H4SO 2.0)-4
General Description
LUBRICATION

ST18332AA010
499587100 OIL SEAL Used for installing oil seal into oil pump.
INSTALLER
ST-499587100
LU(H4SO 2.0)-5
Oil Pressure System
LUBRICATION
2. Oil Pressure System

A: WIRING DIAGRAM
BATTERY
No.5 SBF-7 SBF-1
6 3
B72 IGNITION
SWITCH
3
4
WARNING LIGHT
COMBINATION
OIL PRESSURE
METER
i10
15
i3
17
B38
B21
31
E2
E11
OIL PRESSURE
SWITCH
B21 B72 B38 i10
1 2 3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11
4 5 6 10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 21 22
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
LU-00229
LU(H4SO 2.0)-6
Oil Pressure System
LUBRICATION
B: INSPECTION
Step Check Yes No
1 CHECK COMBINATION METER. Does the warning light illumi- Go to step 2. Repair or replace
1)Turn the ignition switch to ON (engine OFF). nate? the combination
2)Check the warning light of combination meter. <Ref. to IDI-
meter. 3, INSPECTION,
Combination
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.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from oil pressure
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage of harness between oil
pressure switch 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
1)Turn the ignition switch to OFF. %? ness connector the combination
2)Remove the combination meter. between combina- meter. <Ref. to IDI-
3)Measure the resistance of the combination tion meter and oil 3, INSPECTION,
meter. pressure switch. Combination
Connector & terminal Meter System.>
(i10) No. 3 — (i10) No. 15:
(i10) No. 4 — (i10) No. 15:
LU(H4SO 2.0)-7
Engine Oil
LUBRICATION
3. Engine Oil B: REPLACEMENT

1) Open the engine oil filler cap for quick draining of
A: INSPECTION the engine oil.
1) Park the vehicle on a level surface. 2) Lift-up the vehicle.
2) Remove the oil level gauge and wipe it clean. 3) Drain engine oil by loosening the engine oil drain
3) Reinsert the level gauge all the way. Be sure that plug.
the level gauge is correctly inserted and properly
orientated. NOTE:
4) Remove it again and check the engine oil level. If Prepare a container for draining of engine oil.
the engine oil level is below “L” line, add oil to bring
the level up to “F” line.
5) After turning off the engine, wait a few minutes
for the oil to return to the oil pan before checking
the level.
gine oil level show in the range between “F” line
and the notch mark. This is caused by thermal ex-
pansion of the engine oil.
NOTE: LU-00230
To prevent overfilling the engine oil, do not add oil
above “F” line when the engine is cold. 4) Tighten the engine oil drain plug after draining
the engine oil.
(B) NOTE:
(A)
Use a new drain plug gasket.
Tightening torque:
(C)
44 N#m (4.5 kgf-m, 32.5 ft-lb)
(E) 5) Use the engine oil of proper quality and viscosi-
(D)
ty, fill engine oil through the oil filler duct to upper
level on level gauge. Make sure that the vehicle is
parked on a level surface when checking oil level.
LU-00213 Recommended oil:
Refer to “SPECIFICATION” for the recom-
(A) Oil level gauge mended oil. <Ref. to LU(H4SO 2.0)-2, SPECI-
(B) Engine oil filler cap FICATION, General Description.>
(C) Upper level
(D) Lower level
Engine oil capacity:
Upper level
4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 2 (3.2 US qt, 2.6 Imp qt)
6) Close the engine oil filler cap.
7) Start the engine and warm it up for a time.
LU(H4SO 2.0)-8
Engine Oil
LUBRICATION
8) After the engine stops, recheck the oil level. If

necessary, add engine oil up to the upper level on
level gauge.
(B)
(A)
(C)
(E)
(D)
LU-00213
(A) Oil level gauge

(C) Upper level
(D) Lower level
LU(H4SO 2.0)-9
Oil Pump
LUBRICATION
4. Oil Pump 9) Remove the crank pulley using ST.

A: REMOVAL (2.0 L model)
1) Disconnect the ground cable from battery. ST 499977100 CRANK PULLEY WRENCH
(2.5 L model)
IN-00203
LU-00012
3) Remove the under cover. 10) Remove the water pump. <Ref. to CO(H4SO
4) Lower the vehicle. 2.0)-15, REMOVAL, Water Pump.>
5) Remove the radiator. <Ref. to CO(H4SO 2.0)- 11) Remove the timing belt guide. (MT model)
20, REMOVAL, Radiator.>
6) Remove the crankshaft position sensor.
LU-00013

LU-00046

REMOVAL, V-belt.>
8) Remove the belt tensioner.
LU-00014
LU-00011
LU(H4SO 2.0)-10
Oil Pump
LUBRICATION
13) Remove the bolts which install oil pump onto 3) Apply a coat of engine oil to the inside of oil seal.
cylinder block.
NOTE:
When disassembling and checking the oil pump,
loosen the relief valve plug before removing the oil
pump.
ME-00312
4) Position the oil pump, aligning the notched area

with the crankshaft, and push the oil pump straight.
CAUTION:
• Make sure the oil seal lip is not folded.
LU-00015 • Be careful not to scratch oil seal when install-
14) Remove the oil pump by using flat tip screw- ing oil pump on cylinder block.
driver. 5) Install the oil pump.
CAUTION: Tightening torque:
Be careful not to scratch mating surfaces of 6.4 N#m (0.65 kgf-m, 4.7 ft-lb)
T
LU-00019
LU-00016
B: INSTALLATION
Perform the following.
1) Apply liquid gasket to the matching surfaces of
oil pump.
Liquid gasket:
equivalent
2) Replace the O-ring (A) with a new one.
(A)
LU-00017
LU(H4SO 2.0)-11
Oil Pump
LUBRICATION
C: DISASSEMBLY D: ASSEMBLY
Remove the screws which secure oil pump cover 1) Install the front oil seal using ST.
and then disassemble oil pump. Inscribe alignment ST 499587100 OIL SEAL INSTALLER
marks on the inner and outer rotors so that they can NOTE:
be replaced in their original positions during reas- Use a new oil seal.
sembly.
CAUTION:
Before disassembling the oil pump, remove the
relief valve.
(E) ST
(D)
LU-00021
(C)
(B)
2) Apply a coat of engine oil to the inner and outer
rotors.
3) Install the inner and outer rotors in their original
positions.
(A)
4) Install the oil relief valve and relief valve spring
(F) (I) and plug.
NOTE:
Use a new gasket.
5) Install the oil pump cover.
(G)
(H)
Tightening torque:
T1: 5.4 N#m (0.55 kgf-m, 4.0 ft-lb)
T2: 44 N#m (4.5 kgf-m, 32.5 ft-lb)
LU-00020
T1
(A) Oil seal
(B) Oil pump case
(C) Inner rotor
(D) Outer rotor
(E) Oil pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
T2
LU-00022
LU(H4SO 2.0)-12
Oil Pump
LUBRICATION
E: INSPECTION 3. SIDE CLEARANCE

1. TIP CLEARANCE Measure the clearance between oil pump inner ro-
tor and pump cover. If the clearance is out of the
Measure the tip clearance of rotors. If the clearance standard value, replace the rotor or oil pump case.
is out of the standard value, replace the rotors as a
matched set. Side clearance:
Standard value
Tip clearance: 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Standard value
0.04 — 0.14 mm (0.0016 — 0.0055 in)
LU-00025
LU-00023 4. OIL RELIEF VALVE

2. CASE CLEARANCE Check the valve for fitting condition and damage,
and the relief valve spring for damage and deterio-
Measure the clearance between the outer rotor and ration. Replace the parts if defective.
oil pump rotor housing. If the clearance is out of the
standard value, replace the oil pump case. Relief valve spring:
Free length
Case clearance: 72.8 mm (2.866 in)
Standard value
Installed length
0.10 — 0.175 mm (0.0039 — 0.0069 in)
54.7 mm (2.154 in)
Load when installed
81.3 N (8.29 kgf, 18.24 lb)
5. OIL PUMP CASE
Check the 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.
LU-00024
LU(H4SO 2.0)-13
Oil Pan and Strainer
LUBRICATION
5. Oil Pan and Strainer 8) Support the engine with a lifting device and wire
ropes.
A: REMOVAL
2) Remove the front wheels.
LU-00222

CAUTION:
IN-00203
When lifting up the vehicle, raise up wire ropes
at the same time.
4) Remove the air intake duct and air cleaner case.
<Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake
11) Drain engine oil. <Ref. to LU(H4SO 2.0)-8, RE-
Duct.> <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
PLACEMENT, Engine Oil.>
Cleaner Case.>
12) Remove the front and center exhaust pipe.
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Ex-
haust Pipe.> <Ref. to EX(H4SO 2.0)-10, REMOV-
6) Remove the pitching stopper. AL, Center Exhaust Pipe.>
LU-00231
7) Remove the hood stay holder (A) and radiator

upper brackets (B). LU-00223
14) Remove the bolts which install oil pan on cylin-

der block with engine raised up.
15) Insert the oil pan cutter blade into the clearance
between cylinder block and oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
(B) (B) 16) Remove the oil strainer.
(A)
LU-00232
LU(H4SO 2.0)-14
LUBRICATION
17) Remove the baffle plate. 3) Apply liquid gasket to the mating surfaces and
install the oil pan.
(D)
Liquid gasket:
equivalent
(C)
(B)
LU-00034
(A) 4) Tighten the bolts which install oil pan onto cylin-
der block.
Tightening torque:
5 N#m (0.5 kgf-m, 3.6 ft-lb)
LU-00189
(D)
(A) Oil pan
(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
B: INSTALLATION
CAUTION: (C)
Before installing the oil pan, clean the mating
surface of oil pan and cylinder block.
(B)
Tightening torque:
6.4 N#m (0.65 kgf-m, 4.7 ft-lb)
2) Install the oil strainer onto baffle plate. (A)
NOTE:
Replace O-ring with new one.
Tightening torque:
10 N#m (1.0 kgf-m, 7.2 ft-lb)
LU-00189
(A) Oil pan

(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
5) Lower the engine onto front crossmember.
LU(H4SO 2.0)-15
LUBRICATION
6) Tighten the nuts which install front cushion rub- 12) Install the hood stay holder (A) and radiator up-
ber onto front crossmember. per brackets (B).
Tightening torque:
69 N#m (7.0 kgf-m, 50.9 ft-lb)
(B) (B)
(A)
LU-00232
13) Install the air intake chamber.

LU-00223
<Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air In-
take Chamber.>
7) Install the front and center exhaust pipe. 14) Install the air intake duct and air cleaner case.
<Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front <Ref. to IN(H4SO 2.0)-9, INSTALLATION, Air In-
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-10, IN- take Duct.> <Ref. to IN(H4SO 2.0)-7, INSTALLA-
STALLATION, Center Exhaust Pipe.> TION, Air Cleaner Case.>
8) Install the under cover. 15) Install the front wheels.
9) Lower the vehicle. 16) Connect the battery ground cable to battery.
CAUTION:
When lowing the vehicle, lower the lift-up de-
vice and wire ropes at the same time.
10) Remove the lifting device and wire ropes.
IN-00203
17) Fill engine oil. <Ref. to LU(H4SO 2.0)-8, IN-

SPECTION, Engine Oil.>
LU-00222
C: INSPECTION
Visually check that the oil pan, oil strainer, oil
11) Install the pitching stopper. strainer stay and baffle plate are not damaged.
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)
T2
T1
LU-00233
LU(H4SO 2.0)-16
Oil Pressure Switch
LUBRICATION
6. Oil Pressure Switch 2) Install the oil pressure switch onto engine block.

25 N#m (2.5 kgf-m, 18.1 ft-lb)
1) Remove the generator from bracket.
<Ref. to SC(H4SO 2.0)-14, REMOVAL, Genera-
tor.>
2) Disconnect the terminal from oil pressure switch.
LU-00037
3) Connect the terminal to oil pressure switch.
LU-00036
3) Remove the oil pressure switch.
LU-00036
4) Install the generator to bracket.

<Ref. to SC(H4SO 2.0)-14, INSTALLATION, Gen-
LU-00037 erator.>
B: INSTALLATION C: INSPECTION
1) Apply liquid gasket to the oil pressure switch Check the oil pressure switch installation portion for
threads. oil leakage and oil seepage.
Liquid gasket:
equivalent
LU-00038
LU(H4SO 2.0)-17
Engine Oil Filter
LUBRICATION
7. Engine Oil Filter

A: REMOVAL
2) Remove the oil filter using ST.
ST 18332AA000 OIL FILTER WRENCH (Outer
LU-00234
B: INSTALLATION
1) Clean the oil filter installing surface on cylinder
block.
3) Install the oil filter turning it by hand, being care-
ful not to damage the seal rubber.
4) Tighten more after the seal rubber contacts the
cylinder block.
NOTE:
• In case of oil filter in outer diameter 68 mm (2.68
in), tighten by approx. one turn.
• In case of oil filter in outer diameter 65 mm (2.56
in), tighten by approx. 2/3 to 3/4 turn.
• Over-tightening may cause oil leak.
C: INSPECTION
1) After installing the oil filter, run engine and make
sure that no oil is leaking around the 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(H4SO
2.0)-8, INSPECTION, Engine Oil.>
LU(H4SO 2.0)-18
General Diagnostic Table
LUBRICATION
8. General Diagnostic Table

A: INSPECTION
Before performing diagnosis, make sure that the engine oil level is correct and no oil leakage exists.
Symptom Possible cause Corrective action
1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogging of oil filter Replace.
Malfunction of oil by-pass valve in oil filter Clean or replace.
Malfunction of oil relief valve in 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) Malfunction of combination meter Replace.
2. Warning light does
2) Poor contact of switch contact points Replace.
not come on.
3) Disconnection of wiring Repair.
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(H4SO 2.0)-19
LUBRICATION
LU(H4SO 2.0)-20
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
SPEED CONTROL SYSTEMS
SP(H4SO 2.0)
Page
2. Accelerator Pedal........................................................................................4
General Description
A: SPECIFICATION
LHD model 50 — 63 mm (1.97 — 2.48 in)
Accelerator pedal Stroke At pedal pad
RHD model 53 — 65 mm (2.09 — 2.56 in)
B: COMPONENT
• LHD model
(1) T
(3)
(4)
(2)
SP-02002
(1) Accelerator pedal ASSY (3) Clip Tightening torque: N!m (kgf-m, ft-lb)
(2) Accelerator plate (4) Stopper T: 18 (1.8, 13.0)
SP(H4SO 2.0)-2
General Description
• RHD model
(1)
(2)
SP-02003
(1) Accelerator pedal ASSY Tightening torque: N!m (kgf-m, ft-lb)

(2) Stopper T: 18 (1.8, 13.0)
C: CAUTION
points.
cable from battery.
SP(H4SO 2.0)-3
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
2) Disconnect the connector.
3) Remove the nut securing accelerator pedal as-
sembly.
• LHD model
SP-02001
• RHD model
SP-00052
B: INSTALLATION
Tightening torque:
18 N!m (1.8 kgf-m, 13.0 ft-lb)
C: DISASSEMBLY
NOTE:
Accelerator pedal cannot be disassembled.
SP(H4SO 2.0)-4
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
IGNITION
IG(H4SO 2.0)
Page
2. Spark Plug...................................................................................................5
3. Ignition Coil & Ignitor ASSY ........................................................................8
4. Spark Plug Cord........................................................................................10
General Description
IGNITION
A: SPECIFICATION
1. 2.0 L MODEL
Item Designation
Model CM12-100C
Ignition coil & ignitor
Manufacturer HITACHI
ASSY
Secondary coil resistance 18.0 k!" 20%
Manufacturer and Type CHAMPION: RC10YC4
Thread size (diameter, pitch, length) mm 14, 1.25, 19
Spark plug
Spark plug gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
Electrode Nickel
2. 2.5 L MODEL
Item Designation
Model FH 0286
Manufacturer DIAMOND
ASSY
Secondary coil resistance 11.2 k!"15%
EC, EK, K4 model NGK: PFR5B-11
Manufacturer and Type Except for EC, EK,
CHAMPION: RC10YC4
K4 model
Spark plug
EC, EK, K4 model Platinum
Electrode Except for EC, EK,
Nickel
K4 model
IG(H4SO 2.0)-2
General Description
IGNITION
B: COMPONENT
• 2.0 L model
T1
(3)
(2)
(2)
(1)
T2
(4)
(4)
T2
IG-00016
(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 & ignitor ASSY T2: 21 (2.1, 15.2)
IG(H4SO 2.0)-3
General Description
IGNITION
• 2.5 L model
(4)
(4)
(1)
T2
(3)
T1
(2)
(2)
T2
(1)
IG-00094
(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)
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear work clothing, including a cap, protective nuts to the specified torque.
goggles, and protective shoes during operation. • Place shop jacks or rigid racks at the specified
• Remove contamination including dirt and corro- points.
sion before removal, installation or disassembly. • Before disconnecting electrical connectors of
• Keep the disassembled parts in order and pro- sensors or units, be sure to disconnect the ground
tect them from dust and dirt. cable from battery.
IG(H4SO 2.0)-4
Spark Plug
IGNITION
2. Spark Plug 2. LH SIDE

A: REMOVAL 1) Remove the battery.
2) Remove the spark plug cords by pulling the boot.
CAUTION: (Do not pull the cord itself.)
All spark plugs installed on an engine must be
of the same heat range.
Spark plug:
<Ref. to IG(H4SO 2.0)-2, SPECIFICATION,
General Description.>
1. RH SIDE
IG-00021
IN-00203

3) Remove the spark plug cords by pulling the boot.
IG-00022
(Do not pull the cord itself.)
B: INSTALLATION
1. RH SIDE
Tightening torque:
21 N#m (2.1 kgf-m, 15.2 ft-lb)
NOTE:
The above torque should be only applied to new
spark plugs without oil on their threads.
IG-00017 In case their threads are lubricated, the torque
4) Remove the spark plug with a spark plug socket. should be reduced by approx. 1/3 of the specified
torque in order to avoid over-stressing.
2. LH SIDE
Tightening torque:
21 N#m (2.1 kgf-m, 15.2 ft-lb)
NOTE:
should be reduced by approx. 1/3 of the specified
IG(H4SO 2.0)-5
Spark Plug
IGNITION
C: INSPECTION 3) Oil fouled:

Check the electrodes and inner and outer ceramic Wet black deposits show excessive oil entrance
insulator of plugs, noting the type of deposits and into combustion chamber through worn rings and
the degree of electrode erosion. pistons or excessive clearance between valve
guides and stems. If the same condition remains
after repair, use a hotter plug.
(A)
(B) (C)
(D)
(E)
IG-00010
(A) Spark plug gap IG-00013

(B) Carbon accumulation or wear 4) Overheating:
(C) Crack White or light gray insulator with black or brown
(D) Damage spots and bluish burnt electrodes indicate engine
(E) Damaged gasket overheating. Moreover, the appearance results
from incorrect ignition timing, loose spark plugs,
1) Normal: wrong selection of fuel, hotter range plug, etc. It is
Brown to grayish-tan deposits and slight electrode advisable to replace with plugs having colder heat
wear indicate correct spark plug heat range. range.
IG-00011 IG-00014
2) Carbon fouled: CAUTION:
Dry fluffy carbon deposits on insulator and elec- Avoid using a plug cleaner because of the
trode are mostly caused by slow speed driving in spark plug with a platinum tip. (2.5 L model)
the city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc. D: ADJUSTMENT
It is advisable to replace with plugs having hotter Adjust the spark plug gap, if necessary, by measur-
heat range. ing with a gap gauge. (2.0 L model)
Spark plug gap: L
1.0 — 1.1 mm (0.039 — 0.043 in)
L
(A)
IG-00012
IG-00015
IG(H4SO 2.0)-6
Spark Plug
IGNITION
NOTE:
Replace with a new spark plug if the area (A) is
worn to spherical shape.
IG(H4SO 2.0)-7
Ignition Coil & Ignitor ASSY
IGNITION
3. Ignition Coil & Ignitor ASSY 4) Remove the bolt (B) which secures the ignition
coil & ignitor ASSY to intake manifold.
A: REMOVAL • 2.0 L model
(B)
(A)
(B)
IG-02002
IN-00203
• 2.5 L model
2) Disconnect the spark plug cords from ignition
(B)
coil & ignitor ASSY.
• 2.0 L model
(A)
(B)
IG-00096
B: INSTALLATION
IG-02001
• 2.5 L model Tightening torque:
6.4 N#m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Connect the spark plug cords to correct posi-
tions. Failure to do so will damage the unit.
C: INSPECTION
Check the following using a tester. Replace if de-
fective.
• Secondary coil resistance
CAUTION:
IG-00095 • If the resistance is extremely low, it indicates
3) Disconnect the connector (A) from ignition coil & the presence of a short-circuit.
ignitor ASSY. • Ignitor is integrated with the coil. Therefore
the resistance of primary side coil cannot be
measured.
IG(H4SO 2.0)-8
IGNITION
Specified resistance (2.0 L model):

[Secondary side]
Between (A) and (B)
18.0 k!"20%
Between (C) and (D)
18.0 k!"20%
(C)
(D)
(A)
(B)
IG-02003
Specified resistance (2.5 L model):

[Secondary side]
Between (A) and (B)
11.2 k!"15%
Between (C) and (D)
11.2 k!"15%
(C) (D)
(A) (B)
IG-00097
IG(H4SO 2.0)-9
Spark Plug Cord
IGNITION
4. Spark Plug Cord

A: INSPECTION
Check the following items:
• Damage to cords, deformation, burning or rust
formation of terminals
• Resistance values of cords
Resistance value (2.0 L model):
#1 cord: 5.9 — 11.1 k!
#2 cord: 8.8 — 14.8 k!
#3 cord: 6.8 — 11.7 k!
#4 cord: 8.8 — 14.8 k!
Resistance value (2.5 L model):
#1 cord: 7.1 — 12.1 k!
#2 cord: 12.1 — 19.9 k!
#3 cord: 7.7 — 13.0 k!
#4 cord: 12.3 — 20.2 k!
IG-00102
IG(H4SO 2.0)-10
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
STARTING/CHARGING SYSTEMS
SC(H4SO 2.0)
Page
2. Starter .........................................................................................................6
3. Generator ..................................................................................................14
4. Battery.......................................................................................................20
General Description
A: SPECIFICATION
Item Specification
Vehicle model MT AT
Type Reduction type
Model M000T30471 M000T20171
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Revolving direction Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load charac-
Current 95 A or less 90 A or less
teristics
Starter Rotating speed 2,500 rpm or more 2,000 rpm or more
Voltage 7.5 V 7.7 V
Current 300 A 400 A
Load character-
istics 8.84 N!m (0.90 kgf-m, 6.5 ft-lb) or 16.7 N!m (1.70 kgf-m, 12.3 ft-lb) or
Torque
more more
Rotating speed 870 rpm or more 710 rpm or more
Voltage 4V 3.5 V
Lock character- Current 680 A or less 960 A or less
istics 17 N!m (1.73 kgf-m, 12.5 ft-lb) or 31 N!m (3.16 kgf-m, 22.9 ft-lb) or
Torque
more more
Rotating-field three-phase type, voltage regulator built-in type, with load
Model
response control system
Model A3TG0491
Voltage and output 12 V — 110 A
Polarity on ground side Negative
Generator
Revolving direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 50 A or more
Output current 2,500 rpm — 91 A or more
Regulated voltage 14.1 — 14.8 V [20"C (68"F)]
EC, EK, K4 12 V — 52 AH (65D23L)
12 V — 48 AH (55D23L)
Type and capac- model 12 V — 52 AH (75D23L)
Battery
ity 12 V — 27 AH (34B19L)
KS, KA model
12 V — 48 AH (55D23L)
SC(H4SO 2.0)-2
General Description
B: COMPONENT
1. STARTER
(1)
(4)
(10)
(9)
(3)
(2)
(8)
(7)
(6)
(5)
(16)
(12)
(11)
(14)
(15)
(13)
SC-02005
(1) Front bracket (7) Internal gear ASSY (13) Brush holder ASSY
(2) Sleeve bearing (8) Shaft ASSY (14) Sleeve bearing
(3) Lever set (9) Gear ASSY (15) Rear cover
(4) Magnet switch ASSY (10) Packing (16) Rear cover set
(5) Stopper set (11) Yoke ASSY
(6) Overrunning clutch (12) Armature
SC(H4SO 2.0)-3
General Description
2. GENERATOR
(7)
(6)
(5)
(4)
(3)
T1
(2)
(1)
T1
T2
(13)
(12)
(11)
(10)
(9)
(8)
SC-00163
(1) Pulley nut (7) Bearing (13) Terminal

(2) Pulley (8) Stator coil
(3) Front cover (9) IC regulator with brush Tightening torque: N!m (kgf-m, ft-lb)
(4) Ball bearing (10) Brush T1: 4.7 (0.48, 3.5)
(5) Bearing retainer (11) Rectifier T2: 108 (11.0, 80)
(6) Rotor (12) Rear cover
SC(H4SO 2.0)-4
General Description
C: CAUTION
points.
cable from battery.
SC(H4SO 2.0)-5
Starter
2. Starter 5) Disconnect the connector and terminal from

starter.
A: REMOVAL
SC-00006
IN-00203 (A) Terminals

(B) Connector
2) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air In- 6) Remove the starter from transmission.
take Chamber.>
3) Remove the intercooler. (Turbo model) NOTE:
In case of MT model, the bolt is used in place of nut
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool-
(A) shown in the figure.
er.>
4) Remove the air intake chamber stay LH. (Non- (A)
turbo model).
• MT model
SC-00184
B: INSTALLATION
SC-00176
NOTE:
• AT model In case of MT model, the bolt is used in place of nut
(A) shown in the figure.
Tightening torque:
50 N!m (5.1 kgf-m, 37 ft-lb)
(A)
SC-00177
SC-00184
SC(H4SO 2.0)-6
Starter
C: DISASSEMBLY 4) Remove the through-bolts and brush holder

screws of both sides, and then detach the rear cov-
1. STARTER ASSEMBLY er and brush holder assembly.
1) Loosen the nut which holds terminal M of switch
assembly, and then disconnect the connector.
(A)
(A) (B)
SC-00062
(A) Brush holder ASSY

SC-00059
(B) Rear cover
(A) Terminal M
5) Remove the armature and yoke assembly from
2) Remove the bolts which hold switch assembly, front bracket.
and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
(B)
(A)
(A)
(C)
SC-00063
SC-00060
(A) Armature
(B) Yoke ASSY
(A) Switch ASSY (C) Front bracket
3) Remove the nuts of both sides, and then remove 6) Remove the packing A, planetary gear and
rear cover set. packing B.
(C)
(A)
(A)
(B)
SC-00061 SC-00064
(A) Rear cover set (A) Packing A

(B) Planetary gear
(C) Packing B
SC(H4SO 2.0)-7
Starter
7) Remove the plate. (2) Remove the ring, stopper and clutch from
shaft.
(A) (A)
(B)
(D)
(C)
SC-00065
(A) Plate
8) Remove the shaft assembly and overrunning

clutch from front bracket as a unit.
NOTE:
Check the following points before removal.
• Lever direction
• Position of internal gear assembly
(A) SC-00014
(A) Socket wrench

(B) Ring
(C) Shaft
(D) Stopper
(B)
(C) (D)
SC-00066
D: ASSEMBLY
NOTE:
(A) Lever Apply grease to the following parts before assem-
(B) Shaft ASSY bly.
(C) Overrunning clutch • Sleeve bearing
(D) Internal gear ASSY • Pinion shaft rotating part
• Shaft spline portion
9) Remove the overrunning clutch from shaft as- • Inside of reduction system
sembly as follows: • Lever fulcrum/Clutch rotating part
(1) Remove the stopper from ring by lightly tap- 1) Install the overrunning clutch to shaft assembly.
ping the stopper with an appropriate tool (such
2) Install the stopper to shaft assembly as follows.
as a fit socket wrench).
SC(H4SO 2.0)-8
Starter
(1) Insert the ring into the shaft groove by lightly (2) Internal gear position
tapping it with an appropriate tool (such as a fit
socket wrench).
(A)
(B)
SC-00070
4) Install the plate.

SC-00067
(A) Ring
(B) Stopper (A)
(2) Install the stopper to ring using a press.
(A)
(B)
SC-00065
(A) Plate
5) Install the planetary gear.

6) Install the packing A and B while taking care of
SC-00068 installing positions.
(A) Ring
(B) Stopper
(B)
3) Install the shaft assembly to front bracket while
taking care of the following points.
(1) Lever direction (A)
SC-00071
(A) Packing A
(B) Packing B
7) Install the armature to yoke assembly.

SC-00069
SC(H4SO 2.0)-9
Starter
8) Install the yoke to front bracket matching front 10) Install the rear cover matching it’s groove to
bracket to the groove of yoke assembly. brush holder assembly.
(A)
(B)
SC-00072 SC-00062
9) Install the brush holder to yoke assembly as fol-

lows.
(B) Rear cover
(1) Press the brush down into brush holder, and
then fix the brush in that position using an appro- 11) Install rear cover set.
priate tool (such as a fit socket wrench).
(A)
SC-00061
SC-00073
(2) Match the brush holder to groove of yoke, (A) Rear cover set
and then slide the brush holder into yoke assem- 12) Install the switch assembly to front bracket as
bly to install. follows.
(1) Insert the plunger and plunger spring into
switch assembly.
(2) Hook the plunger protrusion on lever edge
to install plunger to front bracket.
(A)
SC-00074
SC-00060
(A) Switch ASSY
SC(H4SO 2.0)-10
Starter
13) Connect the connector to terminal M of switch Depth of segment mold:

assembly. 0.5 mm (0.020 in)
(A) (B)
(C)
(A)
SC-00059 SC-00022
(A) Terminal M (A) Depth of mold

(B) Segment
E: INSPECTION (C) Mold
1. ARMATURE
4) Armature short-circuit test
1) Check the commutator for any sign of burns of Check the armature for short-circuit by placing it on
rough surfaces or stepped wear. If wear is of a mi- growler tester. Hold an iron sheet against the arma-
nor nature, correct it by using sand paper. ture core while slowly rotating the armature. A
2) Run-out test short-circuited armature will cause the iron sheet to
Check the commutator for run-out, and then re- vibrate and to be attracted to core. If the iron sheet
place if it exceeds the limit. is attracted or vibrates, the armature, which is
Commutator run-out: short-circuited, must be replaced or repaired.
Standard
(A)
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in) (B)
(A)
SC-00023
(A) Iron sheet

(B) Growler tester
(B)
SC-00021 5) Armature ground test
Using a circuit tester, touch one probe to the com-
(A) Dial gauge mutator segment and the other to shaft. There
(B) V-block should be no continuity. If there is continuity, the ar-
mature is grounded.
3) Depth of segment mold Replace the armature if it is grounded.
Check the depth of segment mold.
SC-00024
SC(H4SO 2.0)-11
Starter
2. YOKE 5. SWITCH ASSEMBLY

Make sure the pole is set in position. Be sure there is continuity between the terminals S
and M, and between terminal S and ground. Use a
3. OVERRUNNING CLUTCH circuit tester (set in “ohm”).
Inspect the teeth of pinion for wear and damage. Also check to be sure there is no continuity be-
Replace if it is damaged. Rotate the pinion in the tween terminal M and B.
right direction of rotation (counterclockwise). It
Terminal / Specified resistance:
should rotate smoothly. But in the opposite direc-
S — M / Less than 1 #
tion, it should be locked.
S — Ground / Less than 1 #
CAUTION: M — B / More than 1 M#
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
B
1) Brush length S
Measure the brush length, and then replace if it ex- M
ceeds the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard
SC-00075
12.3 mm (0.484 in)
Service limit 6. SWITCH ASSEMBLY OPERATION
7.0 mm (0.276 in)
1) Using a lead wire, connect the terminal S of
switch assembly to positive terminal of battery, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.
CAUTION:
With the pinion forced endwise on shaft, starter
(A) motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
(B) 2) Disconnect the connector from terminal M. Then
SC-00102 using a lead wire, connect the positive terminal of
battery and terminal M and ground terminal to start-
(A) Service limit line er body.
(B) Brush In this test set up, the pinion should return to its
original position even when it is pulled out with a
2) Brush movement
screwdriver.
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
(A)
Measure the brush spring force with a spring scale. (B)
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38
lb) (when new)
Service limit SC-00076
2.5 N (0.25 kgf, 0.56 lb)

(A) Terminal S
(B) Terminal M
SC(H4SO 2.0)-12
Starter
7. PERFORMANCE TEST Current / Speed

MT model
The starter should be submitted to performance
tests whenever it has been overhauled, to assure 300 A / 870 rpm or more
its satisfactory performance when installed on the AT model
engine. 400 A / 710 rpm or more
Three performance tests, no-load test, load test, 3) Lock test
and lock test, are presented here; however, if the With the starter stalled, or not rotating, measure the
load test and lock test cannot be performed, carry torque developed and current draw when the volt-
out at least the no-load test. age is adjusted to the specified voltage.
For these performance tests, use the circuit shown Lock test (Standard):
in the figure.
Voltage / Current
MT model
4 V / 680 A or less
B
AT model
S (B) (A) 3.5 V / 960 A or less
M
Torque
(C) + MT model
12V
17 N!m (1.73 kgf-m, 12.5 ft-lb)
V A AT model
SC-00077
31 N!m (3.16 kgf-m, 22.9 ft-lb)
(A) Variable resistance

(B) Starter body
(C) Magnetic switch
1) No-load test
With switch on, adjust the variable resistance for
the voltage to obtain 11 V, read the ammeter and
measure the starter speed. Compare these values
with the specifications.
No-load test (Standard):
Voltage / Current
MT model
11 V / 95 A or less
AT model
11 V / 90 A or less
Rotating speed
MT model
2,500 rpm or more
AT model
2,000 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.
Load test (Standard):
Voltage / Load
MT model
7.5 V / 8.84 N!m (0.90 kgf-m, 6.5 ft-lb)
AT model
7.7 V / 16.7 N!m (1.70 kgf-m, 12.3 ft-lb)
SC(H4SO 2.0)-13
Generator
3. Generator 5) Remove the bolts which install the generator

onto bracket.
A: REMOVAL
SC-00179
IN-00203
B: INSTALLATION
2) Disconnect the connector and terminal from
generator. Tightening torque:
• Non-turbo model 25 N!m (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Check and adjust the V-belt tension.
<Ref. to ME(H4SO 2.0)-39, INSPECTION, V-
belt.> or <Ref. to ME(H4DOTC)-40, INSPEC-
TION, V-belt.>
SC-00178
• Turbo model
SC-00179
C: DISASSEMBLY
1) Remove the four through-bolts.
ME-00830

4) Remove the front side belts.
<Ref. to ME(H4SO 2.0)-38, FRONT SIDE BELT,
REMOVAL, V-belt.> or <Ref. to ME(H4DOTC)-39,
FRONT SIDE BELT, REMOVAL, V-belt.>
SC-00078
SC(H4SO 2.0)-14
Generator
2) Heat portion (A) of rear cover to 50"C (122"F) CAUTION:

with a heater drier. When holding the rotor with a vise, place alumi-
num plates or wooden pieces on the vise jaws
(A) to prevent rotor from damage.
(A)
(B)
SC-00079
(C)
3) Then insert the tip of a flat tip screwdriver into the
(D)
gap between stator core and front cover. Pry them SC-00036
apart to disassemble.
(A) Front cover
(B) Pulley
(C) Nut
(D) Rotor
(A) 5) Remove the ball bearing as follows.

(1) Remove the bolt, and then remove the bear-
ing retainer.
(A)
SC-00080
(A) Screwdriver
4) Hold the rotor with a vise and remove pulley nut.
SC-00081
(2) Firmly install an appropriate tool (such as a

fit socket wrench) to bearing inner race.
SC-00035
SC-00082
(3) Push the ball bearing off the front cover us-
ing a press.
SC(H4SO 2.0)-15
Generator
6) Remove the bearing from rotor using a bearing (2) Unsolder the connection between IC regula-
puller. tor and rectifier to remove the IC regulator.
SC-00046 SC-00085
7) Unsolder connection between rectifier and stator 9) Remove the brush as follows.
coil to remove the stator coil. (1) Remove cover A.
CAUTION:
Do not allow a 180 — 270 W soldering iron to
contact the terminals for more than 5 seconds (A)
at once because the rectifier cannot withstand
so much heat.
SC-00086
(A) Cover A
(2) Remove cover B.
SC-00083 (A)
8) Remove the IC regulator as follows.

(1) Remove the screws which secure IC regula-
tor to rear cover.
SC-00087
(A) Cover B
(3) Separate the brush from connection to re-

move.
SC-00084
SC-00088
SC(H4SO 2.0)-16
Generator
10) Remove the rectifier as follows. CAUTION:

(1) Remove the bolt which secures the rectifier. Be sure to remove the wire after reassembly.
(A)
SC-00089 SC-00092
(2) Remove the cover of terminal B.
(A) Wire
2) Install the ball bearing.

(1) Set the ball bearing on the front cover, and
then securely install an appropriate tool (such as
a fit socket wrench) to the bearing outer race.
(2) Press the ball bearing into the specified po-
sition using a press.
(3) Install the bearing retainer.
3) Press the bearing (rear side) into the rotor shaft
SC-00090 using a press to install.
4) Heat the bearing box in rear cover [50 to 60"C
(3) Remove the nut of terminal B, and then re- (122 to 140"F)], and then press the rear bearing
move the rectifier. into rear cover.
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bear-
ing box.
5) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.
SC-00091
D: ASSEMBLY
1) Pulling up brush
Before assembling, press the brush down into
brush holder, and then fix them in that position by
passing a [1 mm (0.08 in) dia. 40 to 50 mm (1.6 to
2.0 in) long] wire through the hole as shown in the
figure.
SC(H4SO 2.0)-17
Generator
E: INSPECTION Slip ring outer diameter:

Standard
1. DIODE 22.7 mm (0.894 in)
CAUTION: Limit
Never use a mega tester (designed for reading 22.1 mm (0.870 in)
high voltage) or any other similar instrument 3) Continuity test
for this test; otherwise, the diodes may be dam- Check the resistance between slip rings using cir-
aged. cuit tester.
1) Checking positive diode If the resistance is not within the specified range,
Check for continuity between the diode lead and replace the rotor assembly.
positive side heat sink. The positive diode is in Specified resistance:
good condition if resistance is 1 # or less only in the Approx. 1.8 — 2.2 #
direction from the diode lead to heat sink.
(A) (B)
SC-00044
SC-00042
4) Insulation test
(A) Diode lead Check the continuity between slip ring and rotor
(B) Heat sink (positive side) core or shaft. If resistance is 1 # or less, the rotor
coil is grounded, and so replace the rotor assem-
2) Checking negative diode bly.
Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if resistance is 1 # or less only in the
direction from the heat sink to diode lead.
(A)
(B) SC-00045
5) Ball bearing (rear side)

Check the rear ball bearing. Replace if it is noisy or
SC-00043
if the rotor does not turn smoothly.
(A) Diode lead

(B) Heat sink (negative side)
2. ROTOR
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness on 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 the rotor assembly.
SC(H4SO 2.0)-18
Generator
3. STATOR Brush length:

Service limit (1)
1) Continuity test
5.0 mm (0.197 in)
Inspect the stator coil for continuity between each
end of the lead wires. If resistance is 1 M# or more, Standard (2)
the lead wire is broken, and so replace the stator 18.5 mm (0.728 in)
assembly.
(A)
(1)
(A)
(2)
SC-00162
SC-00047 2) Checking brush spring for proper pressure
Using a spring pressure indicator, push the brush
(A) Stator into the brush holder until its tip protrudes 2 mm
2) Insulation test (0.08 in). Then measure the pressure of brush
Inspect the stator coil for continuity between stator spring. If the pressure is less than 2.648 N (270 g,
core and each end of lead wire. If resistance is 1 # 9.52 oz), replace the brush spring with a new one.
or less, the stator coil is grounded, and so replace The new spring must have a pressure of 4.609 to
the stator assembly. 5.786 N (470 to 590 g, 16.58 to 20.810 oz).
SC-00093
SC-00048
4. BRUSH 5. BEARING (FRONT SIDE)

1) Measure the length of each brush. If wear ex- Check the front ball bearing. If the resistance is felt
ceeds the service limit, replace the brush. Each while rotating, or if abnormal noise is heard, re-
brush has the service limit mark (A) on it. place the ball bearing.
SC(H4SO 2.0)-19
Battery
4. Battery • To lessen the risk of sparks, remove rings,

metal watch-bands, and other metal jewelry.
A: REMOVAL Never allow metal tools to contact the positive
1) Disconnect the positive (+) terminal after discon- battery terminal and anything connected to it
necting the negative ($) terminal of battery. while you are at the same time in contact with
2) Remove the flange nuts from battery rods and any other metallic portion of the vehicle. This
take off battery holder. may cause short circuit.
1. EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and
terminal posts for dirt or cracks. 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
SC-00180 is below MIN level, bring the level to MAX level by
3) Remove the battery. pouring distilled water into the battery cell. Do not
fill beyond MAX level.
B: INSTALLATION
Install in the reverse order of removal. 3. SPECIFIC GRAVITY OF ELECTROLYTE
Tightening torque: 1) Measure specific gravity of electrolyte using a
3.4 N!m (0.35 kgf-m, 2.5 ft-lb) hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
NOTE: lyte so that it must be corrected at 20"C (68"F) us-
• Clean the battery cable terminals and apply ing the following equation:
grease to retard the formation of corrosion.
• Connect the positive (+) terminal, and then con- S20 = St + 0.0007 % (t $ 20)
nect the negative ($) terminal of battery. S20: Specific gravity corrected at electrolyte
• Initial diagnosis of electronic control throttle is temperature of 20"C (68"F)
performed after battery installation. For this reason, St: Measured specific gravity
start the engine after 10 seconds or more have t: Measured temperature ("C)
elapsed since the ignition switch was turned to ON. Determine whether or not battery must be
charged, according to corrected specific
C: INSPECTION gravity.
WARNING: Standard specific gravity: 1.220 — 1.290
• Electrolyte has toxicity; be careful handling [20"C (68"F)]
the fluid. 2) Measuring the specific gravity of the electrolyte
• Avoid contact with skin, eyes or clothing. Es- in the battery will disclose the state of charge of the
pecially at contact with eyes, flush with water battery. The relation between specific gravity and
for 15 minutes and get prompt medical atten- state of charge is as shown in the figure.
tion.
• Batteries produce explosive gases. Keep Battery with standard specific gravity 1,280 (20 C)
1.28
sparks, flame, cigarettes away.
Good
1.24
• Ventilate when charging or using in enclosed 1.22
Specific gravity ( C)
space. 1.20
Need to charge
• For safety, in case an explosion does occur, 1.16
wear eye protection or shield your eyes when 1.12

working near any battery. Never lean over a bat- 1.08
tery.
1.04
• Do not let battery fluid contact eyes, skin, 0 10 20 30 40 50 60 70 80 90 100
Amount of discharge (%) SC-00054
fabrics, or paint-work because battery fluid is
corrosive acid.
SC(H4SO 2.0)-20
Battery
D: MEASUREMENT 4. QUICK CHARGING

WARNING: Quick charging is a method that the battery is
Do not bring an open flame close to the battery charged in a short period of time with a relatively
at this time. large current by using a quick charger.
Since a large current flow raises electrolyte temper-
CAUTION: ature, the battery is subject to damage if the large
• Prior to charging, corroded terminals should current is used for prolonged time. For this reason,
be cleaned with a brush and common caustic the quick charging must be carried out within a cur-
soda solution. rent range that will not increase the electrolyte tem-
• Be careful since battery electrolyte overflows perature above 40"C (104"F).
while charging the battery. Also the quick charging is a temporary means to
• Observe instructions when handling the bat- bring battery voltage up to a fair value and, as a
tery charger. rule, a battery should be charged slowly with a low
• Before charging the battery on vehicle, dis- current.
connect the battery ground terminal to prevent
damage of generator diodes or other electrical CAUTION:
modules. • Observe the items in 3. NORMAL CHARGING.
• Never use more than 10 A when charging the
1. JUDGMENT OF BATTERY IN CHARGED battery because it will shorten the battery life.
CONDITION
1) Specific gravity of electrolyte should be held
within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a spe-
cific value in a range from 2.5 to 2.8 V for more than
one hour.
2. CHECK HYDROMETER FOR STATE OF
CHARGE
Hydrometer Charge bat-
Corrective action
indicator tery
Green Above 65% Load test
Dark Below 65% Charge battery
Low electro- Replace battery*
Clear
lyte (If cranking is difficult)
* Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approx. 1/10 of battery’s am-
pere-hour rating.
SC(H4SO 2.0)-21
Battery
SC(H4SO 2.0)-22
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
ENGINE (DIAGNOSTICS)
EN(H4SO 2.0)(diag)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................3
4. Electrical Component Location ...................................................................8
5. Engine Control Module (ECM) I/O Signal .................................................17
6. Engine Condition Data ..............................................................................21
7. Data Link Connector .................................................................................22
8. OBD-II General Scan Tool ........................................................................23
9. Subaru Select Monitor...............................................................................25
10. Read Diagnostic Trouble Code (DTC) ......................................................31
11. Inspection Mode........................................................................................32
12. Drive Cycle................................................................................................36
13. Clear Memory Mode..................................................................................38
14. Compulsory Valve Operation Check Mode ...............................................39
15. Malfunction Indicator Light ........................................................................41
16. Diagnostics for Engine Starting Failure.....................................................51
17. List of Diagnostic Trouble Code (DTC) .....................................................66
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................71
19. General Diagnostic Table........................................................................224
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 trou- “Diagnostics for
ble occurred using the interview check list. Engine Starting
<Ref. to EN(H4SO 2.0)(diag)-3, CHECK, Failure”. <Ref. to
Check List for Interview.> EN(H4SO
2) Start the engine. 2.0)(diag)-51,
Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator Go to step 3. Inspection using
INDICATOR LIGHT. light illuminate? “General Diagnos-
tic Table”. <Ref. to
EN(H4SO
2.0)(diag)-224,
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY. Is DTC displayed on the Sub- Record the DTC. Repair the related
1) Turn the ignition switch to OFF. aru Select Monitor? Repair the trouble parts.
2) Connect the Subaru Select Monitor to data cause. <Ref. to NOTE:
link connector. EN(H4SO If DTC is not
3) Turn the ignition switch to ON, and the Sub- 2.0)(diag)-66, List shown on display
aru Select Monitor switch to ON. of Diagnostic Trou- although the en-
4) Read DTC on Subaru Select Monitor. ble Code (DTC).> gine warning light
Go to step 4. illuminates, per-
form the diagnos-
tics of malfunction
indicator light cir-
cuit or combination
meter. <Ref. to
EN(H4SO 2.0)(di-
ag)-41, Malfunc-
tion Indicator
Light.>
4 PERFORM DIAGNOSIS. Is DTC displayed on the Sub- Check on “Diag- Finish the diagno-
1) Perform the clear memory mode. <Ref. to aru Select Monitor? nostic Chart with sis.
EN(H4SO 2.0)(diag)-38, Clear Memory Diagnostic Trou-
Mode.> ble Code (DTC)”
2) Perform the inspection mode. <Ref. to <Ref. to EN(H4SO
EN(H4SO 2.0)(diag)-32, Inspection Mode.> 2.0)(diag)-71,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(H4SO 2.0)(diag)-2
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 km
Odometer reading
V.I.N. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
Ambient air temperature !C (!F)
❏ Hot
❏ Warm
❏ Cool
❏ 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 km/h (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 Audio ❏ ON / ❏ OFF
A/C compressor ❏ ON / ❏ OFF Car phone ❏ ON / ❏ OFF
Radiator fan ❏ ON / ❏ OFF
Front wiper ❏ ON / ❏ OFF
Rear wiper ❏ ON / ❏ OFF
2. CHECK LIST No. 2

Check the following items about the vehicle’s state when malfunction indicator light turns on.
NOTE:
a) Other warning lights or indicators turn on. ❏ Yes / ❏ No
❏ Low fuel warning light
❏ Charge indicator light
❏ AT diagnostic indicator light
❏ ABS warning light
❏ Oil pressure indicator light
b) Fuel level
• Lack of gasoline: ❏ Yes / ❏ No
• Indicator position of fuel gauge:
• Experienced running out of fuel: ❏ Yes / ❏ No
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 other parts except genuine parts: ❏ Yes / ❏ No
• What:
• Where:
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
❏ Does not shift.
❏ Excessive shift shock
General Description
3. General Description 8) Use ECM mounting stud bolts as the grounding

point to body when measuring voltage and resis-
A: CAUTION tance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION: (A)
• All airbag system wiring harnesses and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
• Be careful not to damage the airbag system
wiring harness when servicing the ECM, TCM,
main relay and fuel pump relay.
2) Never connect the battery in reverse polarity. EN-00001
• The ECM will be destroyed instantly.
• The fuel injector and other parts will be dam- (A) Stud bolt
aged.
3) Do not disconnect the battery terminals while the 9) Use engine grounding terminal or engine as the
engine is running. grounding point to body when measuring voltage
A large counter electromotive force will be generat- and resistance in the engine compartment.
ed in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and ECM, be sure to turn the ignition switch
to OFF. Perform the inspection mode after con-
necting the connectors.
5) Poor contact has been identified as a primary
cause of this problem. Measure the voltage or re-
sistance of individual sensor or all electrical control
modules using a tapered pin with a diameter of less
FU-02063
than 0.64 mm (0.025 in). Do not insert the pin more
than 5 mm (0.20 in) into the part. 10) Use TCM mounting stud bolts as the grounding
6) Remove the ECM from the located position after point to body when measuring voltage and resis-
disconnecting two cables on battery. tance inside the passenger compartment.
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) Connectors of each sensor in the engine com-
partment and the harness connectors on the en-
gine side and body side are all designed to be
waterproof. However, it is still necessary to take
(A)
care not to allow water to get into the connectors EN-00154
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.
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
• The antenna must be kept as far apart as pos-
sible from the control unit. (The ECM is located
under the steering column, inside of instrument
panel lower trim panel.)
General Description
• The antenna feeder must be placed as far 2. ENGINE GROUND

apart as possible from the ECM and MFI har-
Make sure the engine grounding terminal is proper-
ness.
ly connected to engine.
• Carefully adjust the antenna for correct
matching.
• When mounting a large power type radio, pay
special attention to the three items mentioned
above.
• Incorrect installation of the radio may affect
the operation of ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system. If engine starts during this operation, FU-02063
run it until it stops.
14) Problems in the electronic-controlled automatic 3. SELF-DIAGNOSIS FUNCTION
transmission may be caused by failure of the en- When detecting a malfunction by self-diagnosis
gine, the electronic control system, the transmis- function on ECM, malfunction indicator light illumi-
sion proper, or by a combination of these. These nates and malfunction occurrence is displayed.
three causes must be distinguished clearly when Calling the self-diagnosis result is performed by the
performing diagnostics. Subaru Select Monitor.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
16) For AT models, do not hold the stall for more
than five seconds. (from closed throttle, fully open
throttle to stall engine speed.)
17) On the model with ABS, when performing driv-
ing test in jacked-up or lifted-up position, some-
times the warning light may be lit, but this is not a
malfunction of the system. The reason for this is the
speed difference between the front and rear
wheels. After diagnosis of engine control system,
perform the ABS memory clear procedure of self-
diagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems.
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
General Description
C: PREPARATION TOOL
ST24082AA230
ST22771AA030
Electrical Component Location
4. Electrical Component Location

A: LOCATION
1. ENGINE
• Control module
(3) (1)
(4) (2)
EN-02413
(4)
(2) (3) (1)

EN-02451
(1) Engine control module (ECM) (3) Test mode connector (4) Data link connector
(2) Malfunction indicator light
(1)
(2)
EN-01147 EN-01966
(4)
(3)
EN-02414 AT-01877
• Sensor
(3) (4) (1) (2) (5)
(7)
(6)
EN-02415
(1) Intake air temperature sensor (4) Electronic throttle control (6) Camshaft position sensor
(2) Manifold absolute pressure sensor (5) Knock sensor (7) Crankshaft position sensor
(3) Engine coolant temperature sen-
sor
(1)
(2)
EN-02416 EN-02417
(3)
EN-02179 (4) EN-02418
(5)
(6)
EN-00010 EN-00011
(7)
EN-00012
(1)
(3)
(4)
(2)
EN-01973
(1) Front oxygen (A/F) sensor (3) Front catalytic converter (4) Rear catalytic converter
(2) Rear oxygen sensor
(1) (2)
(4)
(3)
EN-02091 EN-02092
• Solenoid valve, actuator, emission control system parts and ignition system parts
(1) (3) (2)
EN-02419
(1) Purge control solenoid valve (2) EGR Valve (EC, EK, K4 model) (3) Ignition coil & ignitor ASSY
(1)
(2)
EN-02420 EN-02421
(3)
EN-02422
(1) (5) (4) (3) (2)
(8) (7) (6) (9) (3)

EN-02423
(1) (2)
(8) (7) (6) (9) (5) (4) (3)

EN-01979
(1) Inhibitor switch (4) Fuel pump relay (7) Radiator sub fan relay
(2) Fuel pump (5) Electronic throttle control relay (8) Radiator main fan relay 2
(3) Main relay (6) Radiator main fan relay 1 (9) Starter
(2)
EN-00178 EN-02093
(3)
(6)
(8)
(4) (7)
(5)
EN-02094 EN-02095
(9)
EN-02096
Engine Control Module (ECM) I/O Signal
5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
B134 B135
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
B136 B137
1 2 3 4 5 6 1 2 3 4 5 6 7
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01982
Signal (V)
Connector Terminal
DESCRIPTION Ignition SW ON Engine ON NOTE
No. No.
(engine OFF) (idling)
Crankshaft Sensor output wave-
Signal (+) B136 27 0 "7 — +7
position sen- form
sor (Model Signal (") B136 24 0 0 —
with immobi-
lizer) Shield B136 32 0 0 —
Crankshaft Sensor output wave-
Signal (+) B136 26 0 "7 — +7
position sen- form
without immo-
bilizer) Shield B136 32 0 0 —
Camshaft Sensor output wave-
Signal (+) B136 26 0 "7 — +7
position sen- form
with immobi-
lizer) Shield B136 32 0 0 —
Camshaft Sensor output wave-
Signal (+) B136 27 0 "7 — +7
position sen- form
without immo-
bilizer) Shield B136 32 0 0 —
0.3 — 0.9
0.4 — 1.1
Main B137 23 (After engine is —
Fully opens: 3.7 — 4.3
Electronic warmed-up.)
throttle control 3.9 — 4.8 4.05 — 4.95
Sub B137 24 Fully opens: (After engine is —
0.65 — 1.5 warmed-up.)
Electronic throttle control
B137 2 Duty waveform Duty waveform Drive frequency: 1 kHz
motor 1 (+)
motor 2 (+)
motor 1 (")
Signal (V)
Connector Terminal
No. No.
motor 2 (")
B137 6 10 — 13 13 — 14 —
motor 1 power supply
B137 7 10 — 13 13 — 14 —
motor 2 power supply
Electronic throttle control ON: 0 ON: 0 When ignition switch is
B137 9
motor relay OFF: 10 — 13 OFF: 13 — 14 turned to ON: ON
Fully closed: 0.5 — 1.5 Fully closed: 0.5 — 1.5
Main B137 29 —
Fully opens: 3 — 5 Fully opens: 3 — 5
Accelerator Power
B137 25 5 5 —
position sen- supply
sor Ground B137 31 0 0 —
Fully closed: 0.5 — 1.5 Fully closed: 0.5 — 1.5
Sub B137 30 —
Fully opens: 3 — 5 Fully opens: 3 — 5
Rear oxygen Signal B136 19 0 0 — 0.9 —
sensor Shield B136 30 0 0 —
Front oxygen Signal 1 B135 2 0 — 1.0 13 — 14 —
(A/F) sensor
Signal 2 B135 3 0 — 1.0 13 — 14 —
heater
Rear oxygen sensor heater
B134 1 0 — 1.0 13 — 14 —
signal
Engine coolant temperature After engine is
B136 22 1.0 — 1.6 1.0 — 1.6
sensor warmed-up.
OFF: 0 OFF: 0
Starter switch B135 23 —
ON: 10 — 13 ON: 13 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 20 —
OFF: 0 OFF: 0
Ignition switch B135 13 10 — 13 13 — 14 —
Neutral position switch ON: 0
B135 12 —
(AT model) OFF: 10 — 14
Neutral position switch ON: 10 — 14
B135 12 —
(MT model) OFF: 0
Test mode connector B135 24 5 5 When connected: 0
Signal B136 23 2.8 2.8 —
Knock sensor
Shield B136 12 0 0 —
Ignition switch “OFF”:
Back-up power supply B136 7 10 — 13 13 — 14
10 — 13
Control module power sup- B136 3 10 — 13 13 — 14 —
ply B136 4 10 — 13 13 — 14 —
Sensor power supply 1 B136 17 5 5 —
Sensor power supply 2 B137 25 5 5 —
1 B134 23 0 1 — 3.4 Waveform
Ignition control
2 B134 24 0 1 — 3.4 Waveform
#1 B134 17 10 — 13 1 — 14 Waveform
#2 B134 27 10 — 13 1 — 14 Waveform
Fuel injector
#3 B134 34 10 — 13 1 — 14 Waveform
#4 B134 33 10 — 13 1 — 14 Waveform
Fuel pump relay control
B135 44 0.5 or less 0.5 or less —
(Model with immobilizer)
Fuel pump relay control
B134 27 0.5 or less 0.5 or less —
(Model without immobilizer)
Signal (V)
Connector Terminal
No. No.
ON: 0.5 or less ON: 0.5 or less
A/C relay control B135 35 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 control B134 10 —
OFF: 10 — 13 OFF: 13 — 14
OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B135 14 10 — 13 13 — 14 —
Light “ON”: 1 or less
Malfunction indicator light B135 15 1 or less —
Light “OFF”: 10 — 14
Engine speed output B135 27 — 0 — 13 or more Waveform
ON: 1 or less ON: 1 or less
Purge control solenoid valve B134 8 —
OFF: 10 — 13 OFF: 13 — 14
Signal A+ B134 13 0 or 10 — 13 0 or 13 — 14 —
EGR solenoid Signal A" B134 12 0 or 10 — 13 0 or 13 — 14 —
valve Signal B+ B134 3 0 or 10 — 13 0 or 13 — 14 —
Signal B" B134 4 0 or 10 — 13 0 or 13 — 14 —
Power steering switch B135 8 —
OFF: 10 — 13 OFF: 13 — 14
Front oxygen (A/F) sensor
B136 35 — 2.05 — 2.25 —
signal 1
B136 33 — 2.05 — 2.25 —
signal 2
B136 34 0 0 —
shield
Manifold absolute pressure
B136 20 4.0 — 4.8 1.1 — 1.9 —
sensor
Intake air temperature sen- intake air temperature:
B136 28 3.3 — 3.5 3.3 — 3.5
sor 25!C (75!F)
Generator control B135 16 0 — 6.5 0 — 6.5 —
Less than 1#$ More Less than 1#$ More
SSM communication line B135 32 —
than 4 than 4
ON: 0 ON: 0
Main switch B137 14 —
OFF: 10 — 13 OFF: 13 — 14
When clutch pedal is When clutch pedal is
depressed: 0 depressed: 0
Clutch switch B137 22 —
released: 10 — 13 released: 13 — 14
When brake pedal is When brake pedal is
Brake switch 1 B137 12 —
depressed: 10 — 13 depressed: 13 — 14
released: 0 released: 0
When operating noth- When operating noth-
ing: 3.5 — 4.5 ing: 3.5 — 4.5
When operating RES/ When operating RES/
Cruise control command ACC: 2.5 — 3.5 ACC: 2.5 — 3.5
B136 21 —
switch When operating SET/ When operating SET/
COAST: 0.5 — 1.5 COAST: 0.5 — 1.5
When operating CAN- When operating CAN-
CEL: 0 — 0.5 CEL: 0 — 0.5
GND (sensor 1) B136 18 0 0 —
Signal (V)
Connector Terminal
No. No.
GND (sensor 2) B137 31 0 0 —
GND (injector) B134 7 0 0 —
B134 2 0 0 —
GND (power supply)
B137 1 0 0 —
B136 5 0 0 —
GND (control system)
B136 6 0 0 —
GND (oxygen sensor heater
B135 5 0 0 —
1)
B135 6 0 0 —
2)
GND (Electronic throttle B136 1 0 0 —
control) B136 2 0 0 —
Engine Condition Data
6. Engine Condition Data

Remarks SPECIFICATION
1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm Racing
Measuring condition:
• After engine is warmed-up.
• Gear position is in “N” or “P” range.
• A/C is turned OFF.
• All accessory switches are turned OFF.
Data Link Connector
7. Data Link Connector

A: NOTE
This connector is used for Subaru Select Monitor.
CAUTION:
Do not connect any scan tools except for OBD-II general scan tool and Subaru Select Monitor, be-
cause the circuit for Subaru Select Monitor may be damaged.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
EN-00037
Terminal No. Remarks Terminal No. Remarks

1 Power supply 9 Empty
2 Empty 10 Subaru Select Monitor signal
3 Empty 11 Empty
4 Empty 12 Ground
5 Empty 13 Ground
6 Empty 14 Empty
7 Empty 15 Empty
8 Empty 16 Empty
OBD-II General Scan Tool
8. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up DTC
and freeze frame data.
A: OPERATION OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
1. HOW TO USE OBD-II GENERAL SCAN data
TOOL (2) MODE $02: Powertrain freeze frame data
1) Prepare a general scan tool (OBD-II general (3) MODE $03: Emission-related powertrain
scan tool) required by SAE J1978. DTC
2) Connect the OBD-II general scan tool to data (4) MODE $04: Clear/Reset emission-related
link connector located in the lower portion of instru- diagnostic information
ment panel (on driver’s side). Read out the data according to repair procedures.
(For detailed operation procedures, refer to the op-
eration manual of OBD-II general scan tool.)
NOTE:
For details concerning DTC, refer to “List of Diag-
nostic Trouble Code (DTC)”. <Ref. to EN(H4SO
2.0)(diag)-66, List of Diagnostic Trouble Code
(DTC).>
EN-02533
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refer to data denoting the current operating condition of analog input/output, digital input/output or the pow-
ertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID Data Unit of measure
Number of emission-related powertrain DTC, malfunction indicator light status and diagnosis
01 —
support information
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 manifold absolute pressure sensor g/sec
11 Throttle valve absolute 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
1C Supporting OBD system —
21 Driving distance after MIL illuminates km
24 A/F value and A/F sensor output voltage — and V
NOTE:
Refer to OBD-II general scan tool manufacturer’s operation manual to access generic OBD-II PIDs (MODE
$01).
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refer to data denoting the operating condition when trouble is detected by on-board diagnosis system.
02 DTC that caused CARB to require freeze frame data storage —
NOTE:
Refer to OBD-II general scan tool manufacturer’s operation manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE (DTC))
Refer to “Read Diagnostic Trouble Code (DTC)” for information about data denoting emission-related pow-
ertrain DTC. <Ref. to EN(H4SO 2.0)(diag)-31, Read Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refer 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 operation manual to clear or reset emission-related diag-
nostic information (MODE $04).
Subaru Select Monitor
9. Subaru Select Monitor 5) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
A: OPERATION
(A)
1. HOW TO USE SUBARU SELECT MONI-
TOR
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(H4SO 2.0)(diag)-7, PREPARATION TOOL,
EN-00040
(A) Power switch
6) Using the Subaru Select Monitor, call up DTCs

and data, then record them.
2. READ DIAGNOSTIC TROUBLE CODE
EN-00038 (DTC) FOR ENGINE (NORMAL MODE)
2) Connect the diagnosis cable to Subaru Select Refer to “Read Diagnostic Trouble Code (DTC)” for
Monitor. information about how to indicate DTCs. <Ref. to
3) Insert the cartridge to Subaru Select Monitor. EN(H4SO 2.0)(diag)-31, Read Diagnostic Trouble
<Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION Code (DTC).>
TOOL, General Description.>
(DTC) FOR ENGINE (OBD MODE)
Refer to “Read Diagnostic Trouble Code (DTC)” for
information about how to indicate DTCs. <Ref. to
EN(H4SO 2.0)(diag)-31, Read Diagnostic Trouble
Code (DTC).>
EN-00039
4) Connect the Subaru Select Monitor to data link

connector.
(1) Data link connectors is located in the lower
portion of instrument panel (on the driver’s side).
EN-02533
(2) Connect the diagnosis cable to data link

connector.
CAUTION:
Do not connect the scan tools except for OBD-
II general scan tool and Subaru Select Monitor.
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
3) Press the [YES] key after the information of engine type has been displayed.
4) On the «Engine Diagnosis» display screen, select the {Current Data Display/Save}, and then press the
[YES] key.
5) On the «Data Display Menu» display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
• A list of the support data is shown in the following table.
Unit
Remarks Display Note (at idling)
of measure
Engine load Engine Load % 1 — 3%
Engine coolant temperature signal Coolant Temp. !C % 75 !C
A/F correction 1 A/F Correction #1 % "10 — +10%
A/F learning 1 A/F Learning #1 % "15 — +15%
Intake manifold absolute pressure Mani. Absolute Pressure kpa 200 — 300 kpa
600 — 800 rpm (Agree
Engine speed signal Engine Speed rpm with the tachometer indi-
cation)
Vehicle speed signal Vehicle Speed km/h 0 km/h (at parking)
Ignition timing signal Ignition Timing deg 10 — 15 deg
Intake air temperature signal Intake Air Temp. !C (Ambient air temperature)
Throttle opening angle signal Throttle Opening Angle % 1 — 2%
Rear oxygen sensor voltage Rear O2 Sensor V 0.01 — 0.85 V
Battery voltage Battery Voltage V 12 — 14 V
Injection 1 pulse width Fuel Injection #1 Pulse ms 2 — 4 ms
Knock sensor correction Knocking Correction deg 0.0 deg
Atmospheric pressure signal Atmosphere Pressure kpa (Atmosphere pressure)
(Mani. Absolute Pressure
Intake manifold relative pressure Mani. Relative Pressure kpa
" Atmosphere pressure)
Learned ignition timing Learned Ignition Timing ! "2 — 2!
Acceleration opening angle signal Accel. Opening Angle % 0.0%
Rear O2 heater current Rear O2 Heater Current A 0.9 — 1.1 A
Purge control solenoid duty ratio CPC Valve Duty Ratio % 0 — 3%
EGR steps No. of EGR Steps STEP 0
Generator duty ratio ALT Duty % 0 — 100%
A/F Sensor #1 Resis-
A/F sensor resistance value 1 ohm 25 — 27 mA
tance
A/F sensor output lambda 1 A/F Sensor #1 — 0.85 — 1.15
A/F correction 3 A/F Correction #3 % 3.5 — 6.5%
Front oxygen (A/F) sensor current A/F Heater Current A 5 — 10 A
Main-Throttle Sensor
Main-throttle position sensor fully closed voltage V 0.3 — 0.7 V
Closed Position Voltage
AT/MT identification terminal AT Vehicle ID Signal — ON/OFF
Test mode terminal Test Mode Signal — OFF
Neutral position switch signal Neutral Position Switch — ON
Soft idle switch signal Idle Switch Signal — ON
Ignition switch signal Ignition Switch — ON
Power steering switch input signal P/S Switch — OFF (At OFF)
Air conditioning switch signal A/C Switch — OFF (At OFF)
Handle switch signal Handle Switch — RHD/LHD
Starter switch signal Starter Switch — OFF
Rear O2 monitor Rear O2 Rich Signal — OFF
Unit
of measure
Knocking signal Knocking Signal — OFF
Crankshaft position sensor signal Crankshaft Position Sig. — OFF
Camshaft position sensor signal Camshaft Position Sig. — OFF
Rear defogger switch signal Rear Defogger SW — OFF (At OFF)
Blower fan switch signal Blower Fan SW — OFF (At OFF)
Light switch signal Light Switch — OFF (At OFF)
Wiper switch signal Wiper Switch — OFF (At OFF)
A/C middle pressure switch signal A/C Mid Pressure Switch — OFF (At OFF)
Air conditioner compressor relay output signal A/C Compressor Signal — OFF (At OFF)
Radiator fan relay 1 signal Radiator Fan Relay #1 — OFF (At OFF)
Fuel pump relay signal Fuel Pump Relay — ON
AT coordinate retard angle demand signal Retard Signal from AT — OFF
AT coordinate fuel cut demand signal Fuel Cut Signal from AT — OFF
Torque Permission Sig-
AT coordinate permission demand — ON
nal
Throttle motor duty Throttle Motor Duty % 5 — 10%
Throttle power supply voltage Throttle Motor Voltage V (Battery voltage)
Sub throttle sensor voltage Sub-throttle Sensor V 1.48 — 1.50 V
Main throttle sensor voltage Main-throttle Sensor V 0.62 V
Sub acceleration sensor voltage Sub-accelerator Sensor V 0.5 — 1.5 V
Main acceleration sensor voltage Main-accelerator Sensor V 0.5 — 1.5 V
Memorized Cruise
Memory vehicle speed km/h 0 km/h
Speed
Fuel level sensor resistance Fuel Level Resistance & 0 — 100 &
ETC motor relay signal ETC Motor Relay — ON
Clutch switch signal Clutch Switch — OFF (At OFF)
Stop light switch signal Stop Light Switch — OFF (At OFF)
SET/COAST switch signal SET/COAST Switch — OFF (At OFF)
RES/ACC switch signal RESUME/ACCEL Switch — OFF (At OFF)
Brake switch signal Brake Switch — OFF (At OFF)
Main switch signal Main Switch — OFF (At OFF)
Integrated unit data reception Body Int. Unit Data — ON
Integrated unit data update Body Int. Unit Count — ON
NOTE:
For detailed operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”.
5. READ CURRENT DATA FOR ENGINE (OBD MODE)

4) On the «Engine Diagnosis» display screen, select the {OBD system} and press the [YES] key.
5) On the «OBD Menu» display screen, select the {Current Data Display & Save}, and press the [YES] key.
7) Using the scroll key, move the display screen up or down until the desired data is shown.
DESCRIPTION Display Unit of measure
Number of diagnosis code Number of Diag. Code: 0
Condition of malfunction indicator light MI (MIL) OFF
Monitoring test of misfire Misfire monitoring —
Monitoring test of fuel system Fuel system monitoring complete
Monitoring test of comprehensive component Component monitoring complete
Test of catalyst Catalyst Diagnosis —
Test of heating-type 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
Test of air conditioning system refrigerant A/C system refrigerant no support
Test of oxygen sensor Oxygen sensor complete
Test of oxygen sensor heater O2 Heater Diagnosis complete
Test of EGR system EGR system incomplete
NOTE:
6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)
2) On the «System Selection Menu» display screen, select the {Engine Control System} and press the [YES]
key.
4) On the «Engine Diagnosis» display screen, select the {OBD System} and press the [YES] key.
5) On the «OBD Menu» display screen, select the {Freeze Frame Data} and press the [YES] key.
• A list of support data is shown in the following table.
Contents Display Unit of measure
DTC for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 —
Engine load data Engine Load %
Engine coolant temperature signal Coolant Temp. !C or !F
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 %
Intake manifold absolute pressure signal Mani. Absolute Pressure mmHg, kPa, inHg or psi
Engine speed signal Engine Speed rpm
Vehicle speed signal Vehicle Speed km/h or MPH
NOTE:
7. LED OPERATION MODE FOR ENGINE

[YES] key.
5) On the «Data Display Menu» display screen, select the {Data & LED Display} and press the [YES] key.
Remarks Display Message LED “ON” requirements
AT/MT identification signal AT Vehicle ID Signal ON or OFF Illuminate (AT model)
Test mode signal Test Mode Signal ON or OFF D check
When neutral position signal is
Neutral position switch signal Neutral Position Switch ON or OFF
entered.
When idle switch signal is
Idle switch signal Idle Switch Signal ON or OFF
entered.
When ignition switch is turned
Ignition switch signal Ignition Switch ON or OFF
ON.
When power steering switch is
Power steering switch signal P/S Switch ON or OFF
entered.
When air conditioning switch is
Air conditioning switch signal A/C Switch ON or OFF
input.
When handle switch signal is
Handle switch signal Handle SW RHD or LHD
input.
Starter switch signal Starter Switch ON or OFF When starter switch is input.
Rear oxygen sensor rich sig- When rear oxygen sensor mix-
Rear O2 Rich Signal ON or OFF
nal ture ratio is rich.
Knocking signal Knocking Signal ON or OFF When knocking signal is input.
Crankshaft position sensor When crankshaft position sen-
Crankshaft Position Signal ON or OFF
signal sor signal is input.
Camshaft position sensor sig- When camshaft position sen-
Camshaft Position Signal ON or OFF
nal sor signal is entered.
When rear defogger switch is
Rear defogger switch signal Rear Defogger Switch ON or OFF
turned ON.
When blower fan switch is
Blower fan switch signal Blower Fan Switch ON or OFF
turned ON.
When light switch is turned
Light switch signal Light Switch ON or OFF
ON.
When small light switch is
Small light switch signal Light Switch ON or OFF
turned ON.
When windshield wiper switch
Windshield wiper switch signal Wiper Switch ON or OFF
is turned ON.
A/C middle pressure switch When A/C middle pressure
A/C Mid Pressure Switch ON or OFF
signal switch is turned ON.
When air conditioning relay is
Air conditioning relay signal A/C Compressor Signal ON or OFF
in function.
When radiator fan relay 1 is in
Radiator fan relay 1 signal Radiator Fan Relay #1 ON or OFF
function.
function.
Fuel pump relay signal Fuel Pump Relay ON or OFF ON output
When AT retard angle demand
AT retard angle demand signal Retard Signal ON or OFF
signal is input.
When AT fuel cut signal is
AT fuel cut signal Fuel Cut ON or OFF
input.

AT coordinate permission sig- When AT coordinate permis-
Torque Control Permission ON or OFF
nal sion signal is input.
When clutch switch is turned
Clutch switch signal Clutch Switch ON or OFF
to ON.
When stop switch is turned to
Stop light switch signal Stop Light Switch ON or OFF
ON.
When SET/COAST switch is
SET/COAST switch signal SET/COAST Switch ON or OFF
turned to ON.
When RES/ACC switch is
RES/ACC switch signal RESUME/ACCEL Switch ON or OFF
turned to ON.
When brake switch is turned to
Brake switch signal Brake Switch ON or OFF
ON.
When main switch is turned to
Main switch signal Main Switch ON or OFF
ON.
When cancel switch is turned
Cancel switch signal Cancel Switch ON or OFF
to ON.
Electronic throttle control When electronic throttle con-
ETC Motor Relay ON or OFF
motor relay signal trol motor relay is in function.
When data reception signal is
Data reception signal Body Int. Unit Data ON or OFF
entered.
When counter update signal is
Counter update signal Body Int. Unit Count ON or OFF
entered.
NOTE:
Read Diagnostic Trouble Code (DTC)
10.Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL
MODE)
1) On the «Main Menu» display screen, select the
{Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display
screen, select the {Engine} and press the [YES]
key.
3) Press the [YES] key after the information of en-
gine type has been displayed.
4) On the «Engine Diagnosis» screen, select the
{DTC Display}, and then press the [YES] key.
5) On the «Diagnostic Code(s) Display» screen,
select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)}, and then press the [YES] key.
NOTE:
• For detailed operation procedure, refer to “SUB-
ARU SELECT MONITOR OPERATION MANUAL”.
• For details concerning DTC, refer to “List of Diag-
(DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
key.
4) On the «Engine Diagnosis» display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the «OBD Menu» display screen, select the
{DTC Display} and press the [YES] key.
6) Make sure DTC is shown on the screen.
NOTE:
(DTC).>
Inspection Mode
11.Inspection Mode
A: OPERATION
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle.
<Ref. to EN(H4SO 2.0)(diag)-36, Drive Cycle.>
DTC Item
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1)
P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
P0038 HO2S Heater Control Circuit High (Bank 1 Sensor 2)
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input
P0112 Intake Air Temperature Circuit Low Input
P0113 Intake Air Temperature Circuit High Input
P0117 Engine Coolant Temperature Circuit Low Input
P0118 Engine Coolant Temperature Circuit High Input
P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Input
P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Input
P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
P0137 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)
P0138 O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)
P0222 Throttle/Pedal Position Sensor/Switch “B” Circuit Low Input
P0223 Throttle/Pedal Position Sensor/Switch “B” Circuit High Input
P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)
P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)
P0335 Crankshaft Position Sensor “A” Circuit
P0340 Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor)
P0458 Evaporative Emission Control System Purge Control Valve Circuit Low
P0459 Canister Purge Solenoid Circuit (High)
P0462 Fuel Level Sensor Circuit Low Input
P0463 Fuel Level Sensor Circuit High Input
P0500 Vehicle Speed Sensor
P0512 Starter Request Circuit
P0513 Incorrect Immobilizer Key
P0519 Idle Control System Malfunction (Fail-Safe)
P0558 Generator Circuit Low Input
P0600 Serial Communication Link
P0604 Internal Control Module Random Access Memory (RAM) Error
P0605 Internal Control Module Read Only Memory (ROM) Error
P0607 Control Module Performance
P0638 Throttle Actuator Control Range/Performance (Bank 1)
P0691 Cooling Fan 1 Control Circuit Low
P0692 Cooling Fan 1 Control Circuit High
P0851 Neutral Switch Input Circuit Low
P0852 Neutral Switch Input Circuit High
P1160 Return Spring Failure
P1134 A/F Sensor Micro-Computer Problem
P1518 Starter Switch Circuit Low Input
P1560 Back-up Voltage Circuit Malfunction
Inspection Mode
DTC Item
P1570 Antenna
P1571 Reference Code Incompatibility
P1572 IMM Circuit Failure (Except Antenna Circuit)
P1574 Key Communication Failure
P1576 EGI Control Module EEPROM
P1577 IMM Control Module EEPROM
P1578 Meter Failure
P2101 Throttle Actuator Control Motor Circuit Range/Performance
P2102 Throttle Actuator Control Motor Circuit Low
P2103 Throttle Actuator Control Motor Circuit High
P2109 Throttle/Pedal Position Sensor A Minimum Stop Performance
P2100 Throttle Control Motor Circuit Open
P2111 Throttle Actuator Control System - Stuck Open
P2122 Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input
P2123 Throttle/Pedal Position Sensor/Switch “D” Circuit High Input
P2127 Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input
P2128 Throttle/Pedal Position Sensor/Switch “E” Circuit High Input
P2135 Throttle/Pedal Position Sensor/Switch “A”/“B” Voltage Rationality
P2138 Throttle/Pedal Position Sensor/Switch “D”/“E” Voltage Rationality
1. PREPARATION FOR THE INSPECTION • Since the rear wheels will also rotate, do not
MODE place anything near them. Also, make sure that
nobody goes in front of the vehicle.
1) Check that the battery voltage is more than 12 V
and fuel remains half [20 — 40 2 (5.3 — 10.6 US
gal, 4.4 — 8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks, or drive the vehicle onto free roll-
ers.
WARNING:
• Before lifting-up the vehicle, ensure parking
brakes are applied.
• Do not use a pantograph jack in place of a rig-
id rack.
(A)
• Secure a rope or wire to the front or rear tow-
ing hooks to prevent the lateral runout of front
wheels.
• Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
• In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the rigid racks
and vehicle. (B)
EN-00041
(A) Rigid rack

(B) Free rollers
Inspection Mode
2. SUBARU SELECT MONITOR 7) Connect the Subaru Select Monitor to data link
connector located in the lower portion of the instru-
1) After clearing the memory, check for any remain-
ment panel (on the driver’s side).
ing unresolved trouble data. <Ref. to EN(H4SO
2.0)(diag)-38, Clear Memory Mode.>
2) Idle the engine.
EN-02533
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor.
8) Turn the ignition switch to ON (engine OFF) and
EN-00038 turn Subaru Select Monitor switch to ON.
4) Connect the diagnosis cable to Subaru Select
Monitor. (A)
5) Insert the cartridge to Subaru Select Monitor.
<Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION
EN-00040
(A) Power switch

EN-00039
6) Connect the test mode connector (A) located at screen, select the {Engine} and press the [YES]
the lower portion of glove box. key.
{D Check} and press the [YES] key.
13) When the “Perform D Check?” is shown on the
screen, press the [YES] key.
14) Perform subsequent procedures as instructed
on the display screen.
(A) • If trouble still remains in the memory, the corre-
sponding DTC appears on the display screen.
EN-02424
NOTE:
• For the details concerning DTCs, refer to “List of
Diagnostic Trouble Code (DTC)”.
<Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic
Trouble Code (DTC).>
• Release the parking brake.
Inspection Mode
• The speed difference between front and rear 9) Place the select lever or shift lever in “D” position
wheels may light the ABS warning light, but this in- (AT model) or “1st” gear (MT model) and drive the
dicates no malfunctions. When engine control diag- vehicle at 5 to 10 km/h (3 to 6 MPH).
nosis is finished, perform the ABS memory NOTE:
clearance procedure of self-diagnosis function. • On AWD vehicles, release the parking brake.
3. OBD-II GENERAL SCAN TOOL • The speed difference between front and rear
wheels may light ABS warning light, but this indi-
1) After clearing memory, check for any remaining cates no malfunctions. When the engine control di-
unresolved trouble data: <Ref. to EN(H4SO agnosis is finished, perform the ABS memory
2.0)(diag)-38, Clear Memory Mode.> clearance procedure of self-diagnosis system.
2) Warm up the engine.
10) Using the OBD-II general scan tool, check for
3) Connect the test mode connector (A) at the low-
DTC and record the result(s).
er side of instrument panel (on the driver’s side).
NOTE:
• For detailed operation procedures, refer to the
operation manual of OBD-II general scan tool.
nostic Trouble Code (DTC)”.
<Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnos-
tic Trouble Code (DTC).>
(A)
EN-02424
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:
ru Select Monitor and OBD-II general scan tool.
EN-02533

NOTE:
• Ensure the select lever is placed in “P” position
before starting. (AT model)
• Depress the clutch pedal when starting engine.
(MT model)
6) Using the select 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 model)
8) Keep the engine speed in 2,500 — 3,000 rpm
range for 40 seconds.
Drive Cycle
12.Drive Cycle
A: PROCEDURE
There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose
malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check
whether they correctly resume their functions by driving in the required drive pattern.
1. PREPARATION FOR 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(H4SO 2.0)(diag)-38, 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 Item Condition
Insufficient Coolant Temperature for Closed Loop Fuel Control Coolant temperature at start is
*P0125
less than 20!C (68!F).
*P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) —
*P0171 System too Lean (Bank 1) —
*P0172 System too Rich (Bank 1) —
*P0420 Catalyst System Efficiency Below Threshold (Bank 1) —
*P0483 Cooling Fan Rationality Check —
P1137 O2 Sensor Circuit (Bank1 Sensor1) —
Drive Cycle
3. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN
(H)
(C)
96 (60)
(D) (F) (G)
65 (40)
(B) (E)
(A)
0
50 100 150 (I)
EN-00195
(A) Idle engine for 1 minute. (D) Decelerate with throttle fully (F) Accelerate to 96 km/h (60 MPH)
(B) Accelerate to 96 km/h (60 MPH) closed to 65 km/h (40 MPH). within 10 seconds.
within 20 seconds. (E) Drive vehicle at 65 km/h (40 MPH) (G) Stop vehicle with throttle fully
(C) Drive vehicle at 96 km/h (60 MPH) for 10 seconds. closed.
for 20 seconds. (H) Vehicle speed km/h (MPH)
(I) Seconds
DTC Item Condition

*P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) —
P0130 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) —
Diagnosis frequency is different
P0301 Cylinder 1 Misfire Detected
from misfire ratio.
from misfire ratio.
from misfire ratio.
from misfire ratio.
P0400 Exhaust gas recirculation flow —
P0559 Generator Circuit High Input —
P0700 Transmission Control System (MIL Request) —
P1134 A/F Sensor Micro-Computer Problem —
P1492 EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) —
P1493 EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) —
P1521 Brake Switch Circuit Range/Performance Problem (High Input) —
Clear Memory Mode
13.Clear Memory Mode

A: OPERATION
MODE)
key.
lect the {Memory Clear} and press the [YES] key.
5) When the “Done” and “Turn Ignition Switch OFF”
are shown on the display screen, turn the ignition
switch to OFF and then Subaru Select Monitor
switch to OFF.
NOTE:
• Initial diagnosis of electronic control throttle is
performed after memory clearance. For this rea-
son, start the engine after 10 seconds or more have
elapsed since the ignition switch was turned to ON.
MODE)
key.
{DTC Clear} and press the [YES] key.
6) When the “Perform Diagnostic Code(s) Clear?”
is shown on the screen, press the [YES] key.
7) Turn the ignition switch to OFF and then turn the
Subaru Select Monitor switch to OFF.
NOTE:
Compulsory Valve Operation Check Mode
14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link
connector located in the lower portion of instrument
Check Mode panel (on the driver’s side).
A: PROCEDURE
EN-02533
CAUTION:
ru Select Monitor.
EN-00038 6) Turn the ignition switch to ON (engine OFF) and
2) Connect the diagnosis cable to Subaru Select turn Subaru Select Monitor switch to ON.
Monitor.
3) Insert the cartridge to Subaru Select Monitor. (A)
EN-00040
(A) Power switch

EN-00039
4) Connect the test mode connector (A) located at 8) On the «System Selection Menu» display
the lower portion of glove box. screen, select the {Engine} and press the [YES]
key.
lect the {System Operation Check Mode} and press
the [YES] key.
11) On the «System Operation Check Mode» dis-
play screen, select the {Actuator ON/OFF Opera-
(A) tion} and press the [YES] key.
12) Select the desired compulsory actuator on the
EN-02424 «Actuator ON/OFF Operation» display screen and
press the [YES] key.
13) Pressing the [NO] key completes the compul-
sory valve operation check mode. The display will
then return to the «Actuator ON/OFF Operation»
screen.
• A list of the support data is shown in the following

table.
DESCRIPTION Display
Compulsory fuel pump relay oper-
Fuel Pump
ation check
Compulsory radiator fan relay
Radiator Fan Relay
operation check
Compulsory air conditioning relay
A/C Compressor Relay
operation check
Compulsory purge control sole-
CPC Solenoid
noid valve operation check
NOTE:
• The following parts will be displayed but not func-
tional.
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure switching solenoid 1
Wastegate control solenoid
PCV Solenoid
Vent Control Solenoid
AAI Solenoid
Fuel Tank Sensor Control Valve

Malfunction Indicator Light
15.Malfunction Indicator Light

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.0)(diag)-42, ACTIVATION OF MALFUNCTION INDICATOR
LIGHT, Malfunction Indicator Light.>
'
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.0)(diag)-43, MALFUNCTION INDICATOR
LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
'
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4SO 2.0)(diag)-45, MALFUNCTION INDICATOR
LIGHT DOES NOT GO OFF., Malfunction Indicator Light.>
'
4. Check that the malfunction indicator light does not blink. <Ref. to EN(H4SO 2.0)(diag)-46, MALFUNCTION INDICATOR LIGHT
DOES NOT BLINK., Malfunction Indicator Light.>
'
5. Check that the malfunction indicator light remains blinking. <Ref. to EN(H4SO 2.0)(diag)-49, MALFUNCTION INDICATOR
LIGHT REMAINS BLINKING., Malfunction Indicator Light.>
B: ACTIVATION OF MALFUNCTION (3) Malfunction indicator light blinks at a cycle of

INDICATOR LIGHT 3 Hz after diagnosis if there is no trouble. Mal-
function indicator light illuminates if faulty.
1) When the ignition switch is turned to ON (engine
OFF), the malfunction indicator light (A) in the com-
bination meter illuminates. (1)
NOTE: (2)
If the malfunction indicator light does not illuminate,
perform the diagnosis of malfunction indicator light (4)
circuit or the combination meter circuit. <Ref. to
EN(H4SO 2.0)(diag)-43, MALFUNCTION INDICA-
(3)
TOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
EN-01681
(1) ON
(2) OFF
(3) Ignition switch ON
(4) 1 second
(A)
EN-01984
2) After starting the engine, the malfunction indica-

tor light goes out. If it does not, either the engine or
emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start
3) Turn the ignition switch to OFF and connect the

test mode connector.
(1) When the ignition switch is turned to ON
(engine OFF), the malfunction indicator light illu-
minates.
(2) Malfunction indicator light blinks at a cycle of
0.5 Hz after starting the engine. (During diagno-
sis)
C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON

DIAGNOSIS:
The malfunction indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not come on.
WIRING DIAGRAM:
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
i3
8
B38
15
B135 ECM E
B72 B135 i10 B38
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-02425
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 con-
nector and chassis ground.
(B135) No. 15 (+) — Chassis ground ("):
2 CHECK POOR CONTACT. Does the malfunction indicator Repair the poor Go to step 3.
Check for poor connection by shaking or pull- light illuminate? contact in ECM
ing ECM connector and harness. connector.
3 CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair the con-
Check the connection of ECM connector. connected? <Ref. to FU(H4SO nection of ECM
2.0)-34, Engine connector.
Control Module
(ECM).>
4 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5. Repair the har-
TION METER AND ECM CONNECTOR. &? ness and connec-
1) Turn the ignition switch to OFF. tor.
2) Remove the combination meter. <Ref. to NOTE:
IDI-16, 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 harness between
between ECM and combination meter connec- ECM and combi-
tor. nation meter con-
Connector & terminal nector
(B135) No. 15 — (i10) No. 16: • Poor contact in
coupling connector
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.
6 CHECK HARNESS BETWEEN COMBINA- Is the voltage more than 10 V? Replace the board Check the follow-
TION METER AND IGNITION SWITCH CON- of combination ing and repair if
NECTOR. meter. <Ref. to IDI- necessary.
1) Turn the ignition switch to ON. 16, Combination NOTE:
2) Measure the voltage between combination Meter Assembly.> • Blown out fuse
meter connector and chassis ground. (No. 5)
Connector & terminal • Open or short
(i10) No. 3 (+) — Chassis ground ("): circuit in harness
(i10) No. 4 (+) — Chassis ground ("): between fuse (No.
5) and battery ter-
minal
• Poor contact in
ignition switch con-
nector
D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF.

DIAGNOSIS:
The malfunction indicator light circuit is shorted.
TROUBLE SYMPTOM:
Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select
Monitor display.
WIRING DIAGRAM:
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
i3
8
B38
15
B135 ECM E
B72 B135 i10 B38
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-02425
Step Check Yes No

1 CHECK HARNESS BETWEEN COMBINA- Does the malfunction indicator Repair the short Replace the ECM.
TION METER AND ECM CONNECTOR. light illuminate? circuit in harness <Ref. to FU(H4SO
1) Turn the ignition switch to OFF. between combina- 2.0)-34, Engine
2) Disconnect the connector from ECM. tion meter and Control Module
3) Turn the ignition switch to ON. ECM connector. (ECM).>
E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK.

DIAGNOSIS:
• The malfunction indicator light circuit is open or shorted.
• Test mode connector circuit is in open.
TROUBLE SYMPTOM:
Malfunction indicator light does not blink during inspection mode.
WIRING DIAGRAM:
• LHD model
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
2
16
1
B122
B21
36
1 1
E2
i3
B75 B76
8
B38
E
B24
B15
B: B135 ECM E
B21 B75 B72 i10 B38
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 1 1 2 3
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
12 13 14 15 16 17 18 19 20 21 22 2 4 5 6
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 B: B135
42 43 44 45 46 47 B122
48 49 50 51 52 53 54
1 2 3 4 1 2 3 4 5 6 7
5 6 7 8 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
EN-02426
• RHD model
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
B83
1 1 2
i3
B75 B76 1
8
B38
B24
B29
B15
B: B135 ECM E
B75 B72 i10 B38 B83
1 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4
2 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8
B: 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 29 30 31 32 33 34 35
EN-02427
Step Check Yes No

1 CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator Go to step 2. Repair the mal-
CATOR LIGHT. light illuminate? function indictor
1) Turn the ignition switch to OFF. light circuit. <Ref.
2) Disconnect the test mode connectors. to EN(H4SO
3) Turn the ignition switch to ON. (engine 2.0)(diag)-43,
OFF) MALFUNCTION
INDICATOR
LIGHT DOES
NOT COME ON,
Malfunction Indica-
tor Light.>
2 CHECK HARNESS BETWEEN COMBINA- Does the malfunction indicator Repair the short Go to step 3.
TION METER AND ECM CONNECTOR. light illuminate? circuit in harness
1) Turn the ignition switch to OFF. between combina-
2) Disconnect the connector from ECM. tion meter and
3) Turn the ignition switch to ON. ECM connector.
3 CHECK HARNESS BETWEEN TEST MODE Is the resistance less than 1 Go to step 4. Repair the har-
CONNECTOR AND CHASSIS GROUND. &? ness and connec-
2) Disconnect the connector from ECM. NOTE:
3) Measure the resistance of harness In this case, repair
between test mode connector and chassis the following:
ground. • Open circuit in
Connector & terminal harness between
(B76) No. 1 — Chassis ground: 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. &? circuit in harness
1) Connect the test mode connector. between ECM and
2) Measure the resistance of harness test mode connec-
between ECM and chassis ground. tor.
(B135) No. 24 — 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(H4SO
connector. 2.0)-34, Engine
Control Module
(ECM).>
F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING.

DIAGNOSIS:
Test mode connector circuit is shorted.
TROUBLE SYMPTOM:
Malfunction indicator light blinks when test mode connector is not connected.
WIRING DIAGRAM:
• LHD model
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
2
16
1
B122
B21
36
1 1
E2
i3
B75 B76
8
B38
E
B24
B15
B: B135 ECM E
B21 B75 B72 i10 B38
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 1 1 2 3
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
12 13 14 15 16 17 18 19 20 21 22 2 4 5 6
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 B: B135
42 43 44 45 46 47 B122
48 49 50 51 52 53 54
1 2 3 4 1 2 3 4 5 6 7
5 6 7 8 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
EN-02426
• RHD model
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
B83
1 1 2
i3
B75 B76 1
8
B38
B24
B29
B15
B: B135 ECM E
B75 B72 i10 B38 B83
1 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4
2 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8
B: 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 29 30 31 32 33 34 35
EN-02427
Step Check Yes No

1 CHECK TEST MODE CONNECTOR. Does the malfunction indicator Go to step 2. System is in good
1) Disconnect the test mode connectors. light blink? order.
2) Turn the ignition switch to ON. NOTE:
Malfunction indica-
tor light blinks at a
cycle 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 CHASSIS GROUNDING TER- &? circuit in harness <Ref. to FU(H4SO
MINAL. between ECM and 2.0)-34, Engine
1) Turn the ignition switch to OFF. test mode connec- Control Module
2) Disconnect the connector from ECM. tor. (ECM).>
3) Measure the resistance of harness
between ECM connector and chassis ground.
Diagnostics for Engine Starting Failure
16.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Check for fuel amount.
'
2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.0)(diag)-52, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>
'
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO 2.0)(diag)-55, CHECK POWER SUPPLY AND GROUND
LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>
'
4. Inspection of ignition control system. <Ref. to EN(H4SO 2.0)(diag)-58, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
'
5. Inspection of fuel pump circuit. <Ref. to EN(H4SO 2.0)(diag)-61, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
'
6. Inspection of fuel injector circuit. <Ref. to EN(H4SO 2.0)(diag)-64, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)-
38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPER-
ATION, Inspection Mode.>.
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
LHD E
15
13
RHD
16
14
STARTER
RELAY
B225
LHD
16
14
RHD
15
13
P N
AT 11 7
12 12
MT
B12 T3 T7
STARTER MOTOR
MT
AT
E
M
B14
23
B135
ECM
B72 B225
B135 B12 T7
1 2 9 13 17 21 1 2 3 4 1 2 3 4 5 6
1 2 3 1 2 3
10 14 18 22 4 5 6 7
4 5 6 3 4 5 6 7 8 7 8 9 10 11 12
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19
9 10 11 12
5 6 20 21 22 23 24 25 26 27
7 8 28 29 30 31 32 33 34 35
25 29 33 37
26 30 34 38
27 28 31 32 35 36 39 40
EN-02428
Step Check Yes No

1 CHECK BATTERY. Is the voltage more than 12 V? Go to step 2. Charge or replace
Check the battery voltage. the battery.
2 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Go to step 3. Go to step 4.
ate?
3 CHECK DTC. Is DTC displayed? <Ref. to Inspect the rele- Repair the poor
EN(H4SO 2.0)(diag)-31, vant DTC using contact in ECM
OPERATION, Read Diagnostic List of Diagnostic connector.
Trouble Code (DTC).> Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
4 CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 5. Go to step 6.
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:
Place the select lever in the “P” or “N” range.
5 CHECK GROUND CIRCUIT OF STARTER Is the resistance less than 5 Check the starter Repair the open
MOTOR. &? motor. <Ref. to circuit of ground
1) Turn the ignition switch to OFF. SC(H4SO 2.0)-6, cable.
2) Disconnect the ground cable terminal from Starter.>
starter motor.
3) Measure the resistance of ground cable
between ground cable terminal and engine
ground.
6 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 7. Repair the open
AND IGNITION SWITCH CONNECTOR. circuit in harness
1) Disconnect the connector from ignition between ignition
switch. switch and bat-
2) Measure the power supply voltage between tery, and check
ignition switch connector and chassis ground. fuse SBF No. 7
Connector & terminal and SBF No. 1.
7 CHECK IGNITION SWITCH. Is the resistance less than 5 Go to step 8. Replace the igni-
1) Disconnect the connector from ignition &? tion switch.
switch.
2) Measure the resistance between ignition
switch terminals after turning the ignition
switch to START position.
Terminals
No. 2 — No. 3:
Step Check Yes No

8 CHECK INPUT VOLTAGE OF STARTER RE- Is the voltage more than 10 V? Go to step 9. Repair the open
LAY. circuit in harness
1) Turn the ignition switch to OFF. between starter
2) Disconnect the connector from starter relay. fan relay and igni-
3) Connect the connector to ignition switch. tion switch.
4) Measure the input voltage between starter
relay connector and chassis ground after turn-
ing the ignition switch to START position.
LHD MODEL
RHD MODEL
9 CHECK STARTER RELAY. Is the resistance less than 1 Go to step 10. Replace the
1) Connect the battery to starter relay termi- &? starter relay.
nals No. 15 and No. 16.
2) Measure the resistance between starter
relay terminals.
Terminals
No. 13 — No. 14:
10 CHECK INPUT VOLTAGE FROM ECM. Is the voltage more than 10 V? Replace the ECM. Repair the open or
1) Turn the ignition switch to OFF. <Ref. to FU(H4SO ground short cir-
2) Connect the connector to starter relay. 2.0)-34, Engine cuit in harness
3) Disconnect the connectors from ECM. Control Module between ECM and
4) Measure the voltage between ECM and (ECM).> starter relay.
chassis ground.
C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MOD-

ULE (ECM)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
1
2 IGNITION
B72 BATTERY
SWITCH
B47 No.12 SBF-7 SBF-1
6 3
B14
B13
C7
C3
C4
A: B134
B: B135
ECM
C: B136
D: B137
C1
A2
B5
B6
C2
A7
C5
C6
D1
B21
52
34
36
35
37
E2
E E
A: B134 B: B135 C: B136

B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33 28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
D: B137
34 35 36 37 38 39 40 41
42 43 44 45 46 47 B72 B47
48 49 50 51 52 53 54 1 2 3 4 5 6 7
1 2 3 1 2 8 9 10 11 12 13 14 15 16 17
4 5 6 3 4 18 19 20 21 22 23 24 25
5 6 26 27 28 29 30 31
EN-02429
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. &? 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:
2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Go to step 3. Repair the open
1) Disconnect the connector from ECM. &? circuit in harness
2) Measure the resistance of harness between ECM
between ECM and chassis ground. connector and
Connector & terminal engine grounding
(B134) No. 2 — Chassis ground: terminal.
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.
1) Turn the ignition switch to ON. ground short cir-
2) Measure the voltage between ECM con- cuit of power sup-
nector and chassis ground. ply circuit.
5 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 6. Repair the open
Measure the voltage between main relay con- circuit in harness
nector and chassis ground. between ECM
Connector & terminal connector and
(B47) No. 1 (+) — Chassis ground ("): main relay connec-
tor.
1) Connect the connectors to ECM and main ground short cir-
relay. cuit in harness
2) Turn the ignition switch to ON. between ECM
3) Measure the voltage between ECM con- connector and
nector and chassis ground. main relay connec-
Connector & terminal tor.
7 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 8. 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.
Step Check Yes No

8 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair the open or
1) Turn the ignition switch to ON. control system. ground short cir-
2) Measure the voltage between ECM con- <Ref. to EN(H4SO cuit in harness
nector and chassis ground. 2.0)(diag)-58, between ECM
Connector & terminal IGNITION CON- connector and
(B136) No. 3 (+) — Chassis ground ("): TROL SYSTEM, main relay connec-
(B136) No. 4 (+) — Chassis ground ("): Diagnostics for tor.
Engine Starting
Failure.>
D: IGNITION CONTROL SYSTEM

CAUTION:
WIRING DIAGRAM:
B134 ECM
24
23
IGNITION
B72
SWITCH BATTERY
No.12 SBF-7 SBF-1
6 3
B21
15
13
49
E2
E12
3
4
1
2
3 4
1 2
IGNITION COIL
&
IGNITOR ASSY
E E
E12 B72 B225 B21 B134
1 2 3 4 1 2 3 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
4 5 6 8 9 10 11 12 13 14 15 16 17
10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
3 4 18 19 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
5 6 28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
7 8 25 29 33 37
42 43 44 45 46 47
26 30 34 38
48 49 50 51 52 53 54
27 28 31 32 35 36 39 40
EN-02430
Step Check Yes No

1 CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check fuel pump Go to step 2.
1) Remove the plug cord cap from each spark inder? system. <Ref. to
plug. EN(H4SO
2) Install a new spark plug on plug cord cap. 2.0)(diag)-61,
CAUTION: FUEL PUMP CIR-
Do not remove the spark plug from engine. CUIT, Diagnostics
3) Contact the spark plug’s thread portion on for Engine Start-
engine. ing Failure.>
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
2 CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3. Repair the har-
NITION COIL & IGNITOR ASSY. ness and connec-
2) Disconnect the connector from ignition coil NOTE:
& ignitor ASSY. 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 ASSY connector and harness between
engine ground. ignition coil & igni-
Connector & terminal tor ASSY, and
(E12) No. 1 (+) — Engine ground ("): main relay connec-
tor
• Poor contact in
coupling connector
• Blown out fuse
3 CHECK HARNESS OF IGNITION COIL & IG- Is the resistance less than 5 Go to step 4. Repair the har-
NITOR ASSY GROUND CIRCUIT. &? ness and connec-
2) Measure the resistance between ignition NOTE:
coil & ignitor ASSY connector and engine In this case, repair
ground. the following:
Connector & terminal • Open circuit in
(E12) No. 3 — Engine ground: harness between
ignition coil & igni-
tor ASSY connec-
tor and engine
grounding terminal
4 CHECK IGNITION COIL & IGNITOR ASSY. Is the resistance 10 — 15 k&? Go to step 5. Replace the igni-
1) Remove the spark plug cords. tion coil & ignitor
2) Measure the resistance between spark ASSY. <Ref. to
plug cord contact portions to check secondary IG(H4SO 2.0)-8,
coil. Ignition Coil & Igni-
Terminals tor ASSY.>
No. 1 — No. 2:
No. 3 — No. 4:
5 CHECK INPUT SIGNAL FOR IGNITION COIL Does the voltage vary more Go to step 6. Replace the igni-
& IGNITOR ASSY. than 10 V? tion coil & ignitor
1) Connect the connector to ignition coil & ASSY. <Ref. to
ignitor ASSY. IG(H4SO 2.0)-8,
2) Check if voltage varies synchronously with Ignition Coil & Igni-
engine speed when cranking, while monitoring tor ASSY.>
voltage between ignition coil & ignitor ASSY
connector and engine ground.
(E12) No. 2 (+) — Engine ground ("):
Step Check Yes No

6 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 7. Repair the har-
NITION COIL & IGNITOR ASSY CONNEC- &? ness and connec-
TOR. 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 ASSY. • Open circuit in
between ECM and ignition coil & ignitor ASSY ECM and ignition
connector. coil & ignitor ASSY
Connector & terminal connector
(B134) No. 23 — (E12) No. 4: • Poor contact in
(B134) No. 24 — (E12) No. 2: coupling connector
7 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 Go to step 8. Repair the ground
NITION COIL & IGNITOR ASSY CONNEC- M&? short circuit in har-
TOR. ness between
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil & ignitor ASSY
Connector & terminal: connector.
(B134) No. 23 — Engine ground:
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 pump circuit. <Ref.
connector. to EN(H4SO
2.0)(diag)-61,
FUEL PUMP CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>
E: FUEL PUMP CIRCUIT

CAUTION:
WIRING DIAGRAM:
No.11
B72 IGNITION
SWITCH BATTERY
No.12 SBF-7 SBF-1
FUEL PUMP 6 3
RELAY
2
3
4 17 B135 ECM
1
RHD
B362
LHD
B98 B97
16
4
R2 R1
LHD
FUEL PUMP
FUEL PUMP RHD CONDENSER
5 1
M 6 2
R58 R142
E E
B362 B72 R142 B97 B98 R58 B135
3 1 2 3 1 1 2 3 4 5 6 7 1 2 3 1 2 1 2 3 4 5 6 7
1 2 4 5 6 2 8 9 10 11 12 13 14 15 16 4 5 6 7 8 3 4
4 8 9 10 11 12 13 14 15 16 17 18 19
5 6 20 21 22 23 24 25 26 27
5
7 8 28 29 30 31 32 33 34 35
6
EN-02431
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.
Check if the fuel pump is in operation for two <Ref. to EN(H4SO
seconds when turning the ignition switch to 2.0)(diag)-64,
ON. FUEL INJECTOR
NOTE: CIRCUIT, Diag-
Fuel pump operation can also be executed us- nostics for Engine
ing Subaru Select Monitor. Starting Failure.>
Refer to “Compulsory Valve Operation Check
Mode” for procedures. <Ref. to EN(H4SO
Check Mode.>
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. &? ness and connec-
2) Remove the fuel pump access hole lid. tor.
3) Disconnect the connector from fuel pump. NOTE:
4) Measure the resistance of harness connec- In this case, repair
tor between fuel pump and chassis ground. the following:
(R58) No. 6 — Chassis ground: harness between
fuel pump connec-
tor and chassis
grounding terminal
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(H4SO 2.0)-47,
between fuel pump connector and chassis Fuel Pump.>
ground.
(R58) No. 5 (+) — Chassis ground ("):
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Go to step 5. Repair the har-
AND FUEL PUMP RELAY CONNECTOR. &? 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. 5 — (B362) No. 1: • Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
• Poor contact in
coupling connector
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 6. Repair the short
AND FUEL PUMP RELAY CONNECTOR. M&? circuit in harness
Measure the resistance of harness between between fuel pump
fuel pump and fuel pump relay connector. and fuel pump
Connector & terminal relay connector.
(R58) No. 5 — Chassis ground:
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 &? pump relay. <Ref.
relay and main relay. to FU(H4SO 2.0)-
2) Remove the fuel pump relay and main relay 47, Fuel Pump.>
with bracket.
3) Connect the battery to fuel pump relay con-
nector terminals No. 3 and No. 4.
4) Measure the resistance between connector
terminals of fuel pump relay.
Terminals
No. 2 — No. 1:
Step Check Yes No

FUEL PUMP RELAY CONNECTOR. &? circuit in harness
1) Disconnect the connector from ECM. between ECM and
2) Measure the resistance of harness fuel pump relay
between ECM and fuel pump relay connector. connector.
(B135) No. 17 — (B362) No. 4:
Check poor contact in ECM connector. connector? contact in ECM injector circuit.
connector. <Ref. to EN(H4SO
2.0)(diag)-64,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
F: FUEL INJECTOR CIRCUIT

CAUTION:
• Check or repair only faulty parts.
• After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(di-
ag)-38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OP-
ERATION, Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
BATTERY
3
SBF-8
6
4
2
1
B47
B134 ECM
17
27
34
33
B21
48
42
43
44
45
E2
E5 E16 E6 E17
2
FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR

No. 1 No. 2 No. 3 No. 4
B21 B134
E5 E16 B47
E6 E17 1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
3 4 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 16 17
1 2 5 6 23 24 25 26 27 28 29 30 31 32 33 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02432
Step Check Yes No

1 CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit oper- Check the fuel Go to step 2.
TOR. ating sound? pressure. <Ref. to
While cranking the engine, check each fuel ME(H4SO 2.0)-27,
injector emits operating sound. Use a sound INSPECTION,
scope or apply a screwdriver to the injector for Fuel Pressure.>
this check.
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 fuel injector. NOTE:
3) Turn the ignition switch to ON. In this case, repair
4) Measure the power supply voltage between the following:
fuel injector terminal and engine ground. • Open circuit in
#1 (E5) No. 2 (+) — Engine ground ("): main relay and fuel
#2 (E16) No. 2 (+) — Engine ground ("): injector connector
#3 (E6) No. 2 (+) — Engine ground ("): • Poor contact in
#4 (E17) No. 2 (+) — Engine ground ("): main relay connec-
tor
• Poor contact in
coupling connector
• Poor contact in
fuel injector con-
nector
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 4. Repair the har-
FUEL INJECTOR CONNECTOR. &? ness and connec-
1) Disconnect the connector from ECM. tor.
2) Measure the resistance of harness NOTE:
between ECM and fuel injector connector. In this case, repair
#1 (B134) No. 17 — (E5) No. 1: • Open circuit in
#2 (B134) No. 27 — (E16) No. 1: harness between
#3 (B134) No. 34 — (E6) No. 1: ECM and fuel
#4 (B134) No. 33 — (E17) No. 1: injector connector
• Poor contact in
coupling connector
4 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 5. Repair the ground
FUEL INJECTOR CONNECTOR. M&? short circuit in har-
Measure the resistance of harness between ness between
ECM and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
#1 (B134) No. 17 — Chassis ground:
5 CHECK EACH FUEL INJECTOR. Is the resistance 5 — 20 &? Go to step 6. Replace the faulty
1) Turn the ignition switch to OFF. fuel injector.
2) Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 — No. 2:
6 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(H4SO
2.0)(diag)-224,
INSPECTION,
General Diagnos-
tic Table.>
List of Diagnostic Trouble Code (DTC)
17.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC Item NOTE
P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H4SO 2.0)(diag)-71, DTC P0030 HO2S HEATER CONTROL
Sensor 1) CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0031 HO2S Heater Control Circuit Low <Ref. to EN(H4SO 2.0)(diag)-73, DTC P0031 HO2S HEATER CONTROL
(Bank 1 Sensor 1) CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0032 HO2S Heater Control Circuit High <Ref. to EN(H4SO 2.0)(diag)-76, DTC P0032 HO2S HEATER CONTROL
(Bank 1 Sensor 1) CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0107 Manifold Absolute Pressure/Baro- <Ref. to EN(H4SO 2.0)(diag)-83, DTC P0107 MANIFOLD ABSOLUTE
metric Pressure Circuit Low Input PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
metric Pressure Circuit High Input PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic
P0112 Intake Air Temperature Circuit Low <Ref. to EN(H4SO 2.0)(diag)-89, DTC P0112 INTAKE AIR TEMPERATURE
Input CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0113 Intake Air Temperature Circuit High <Ref. to EN(H4SO 2.0)(diag)-91, DTC P0113 INTAKE AIR TEMPERATURE
Input CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0117 Engine Coolant Temperature Circuit <Ref. to EN(H4SO 2.0)(diag)-94, DTC P0117 ENGINE COOLANT TEM-
Low Input PERATURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic
High Input PERATURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic
P0122 Throttle/Pedal Position Sensor/ <Ref. to EN(H4SO 2.0)(diag)-99, DTC P0122 THROTTLE/PEDAL POSI-
Switch “A” Circuit Low Input TION SENSOR/SWITCH “A” CIRCUIT LOW INPUT, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
Switch “A” Circuit High Input TION SENSOR/SWITCH “A” CIRCUIT HIGH INPUT, Diagnostic Procedure
P0125 Insufficient Coolant Temperature for <Ref. to EN(H4SO 2.0)(diag)-105, DTC P0125 INSUFFICIENT COOLANT
Closed Loop Fuel Control TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P0130 O2 Sensor Circuit (Bank 1 Sensor 1) <Ref. to EN(H4SO 2.0)(diag)-107, DTC P0130 O2 SENSOR CIRCUIT
(BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0131 O2 Sensor Circuit Low Voltage (Bank <Ref. to EN(H4SO 2.0)(diag)-110, DTC P0131 O2 SENSOR CIRCUIT LOW
1 Sensor 1) VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0132 O2 Sensor Circuit High Voltage <Ref. to EN(H4SO 2.0)(diag)-112, DTC P0132 O2 SENSOR CIRCUIT HIGH
(Bank 1 Sensor 1) VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0133 O2 Sensor Circuit Slow Response <Ref. to EN(H4SO 2.0)(diag)-114, DTC P0133 O2 SENSOR CIRCUIT
(Bank 1 Sensor 1) SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
DTC Item NOTE

P0134 O2 Sensor Circuit No Activity <Ref. to EN(H4SO 2.0)(diag)-116, DTC P0134 O2 SENSOR CIRCUIT NO
Detected (Bank 1 Sensor 1) ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0171 System Too Lean (Bank 1) <Ref. to EN(H4SO 2.0)(diag)-126, DTC P0171 SYSTEM TOO LEAN (BANK
1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0172 System Too Rich (Bank 1) <Ref. to EN(H4SO 2.0)(diag)-126, DTC P0172 SYSTEM TOO RICH (BANK
Switch “B” Circuit Low Input TION SENSOR/SWITCH “B” CIRCUIT LOW INPUT, Diagnostic Procedure
Switch “B” Circuit High Input TION SENSOR/SWITCH “B” CIRCUIT HIGH INPUT, Diagnostic Procedure
P0301 Cylinder 1 Misfire Detected <Ref. to EN(H4SO 2.0)(diag)-134, DTC P0301 CYLINDER 1 MISFIRE
DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0327 Knock Sensor 1 Circuit Low Input <Ref. to EN(H4SO 2.0)(diag)-142, DTC P0327 KNOCK SENSOR 1 CIR-
(Bank 1 or Single Sensor) CUIT LOW INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
P0328 Knock Sensor 1 Circuit High Input <Ref. to EN(H4SO 2.0)(diag)-144, DTC P0328 KNOCK SENSOR 1 CIR-
(Bank 1 or Single Sensor) CUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
P0335 Crankshaft Position Sensor “A” Cir- <Ref. to EN(H4SO 2.0)(diag)-146, DTC P0335 CRANKSHAFT POSITION
cuit SENSOR “A” CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0340 Camshaft Position Sensor “A” Circuit <Ref. to EN(H4SO 2.0)(diag)-148, DTC P0340 CAMSHAFT POSITION
(Bank 1 or Single Sensor) SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Proce-
P0400 Exhaust Gas Recirculation Flow <Ref. to EN(H4SO 2.0)(diag)-150, DTC P0400 EXHAUST GAS RECIRCU-
LATION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0420 Catalyst System Efficiency Below <Ref. to EN(H4SO 2.0)(diag)-153, DTC P0420 CATALYST SYSTEM EFFI-
Threshold (Bank 1) CIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diag-
P0458 Evaporative Emission Control Sys- <Ref. to EN(H4SO 2.0)(diag)-155, DTC P0458 EVAPORATIVE EMISSION
tem Purge Control Valve Circuit Low CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic
tem Purge Control Valve Circuit High CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P0462 Fuel Level Sensor Circuit Low Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0462 FUEL LEVEL SENSOR CIR-
CUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
DTC Item NOTE

P0463 Fuel Level Sensor Circuit High Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0463 FUEL LEVEL SENSOR CIR-
CUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0500 Vehicle Speed Sensor <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0500 VEHICLE SPEED SENSOR,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0512 Starter Request Circuit <Ref. to EN(H4SO 2.0)(diag)-160, DTC P0512 STARTER REQUEST CIR-
CUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0513 Incorrect Immobilizer Key <Ref. to IM(diag)-17, DTC P0513 INCORRECT IMMOBILIZER KEY, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
P0519 Idle Control System Malfunction <Ref. to EN(H4SO 2.0)(diag)-163, DTC P0519 IDLE CONTROL SYSTEM
(Fail-Safe) MALFUNCTION (FAIL-SAFE), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0558 Generator Circuit Low Input <Ref. to EN(H4SO 2.0)(diag)-163, DTC P0558 GENERATOR CIRCUIT
LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0559 Generator Circuit High Input <Ref. to EN(H4SO 2.0)(diag)-164, DTC P0559 GENERATOR CIRCUIT
HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0600 Serial Communication Link <Ref. to EN(H4SO 2.0)(diag)-165, DTC P0600 SERIAL COMMUNICATION
LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0604 Internal Control Module Read <Ref. to EN(H4SO 2.0)(diag)-166, DTC P0604 INTERNAL CONTROL MOD-
Access Memory (RAM) Error ULE READ ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
P0605 Internal Control Module Read Only <Ref. to EN(H4SO 2.0)(diag)-167, DTC P0605 INTERNAL CONTROL MOD-
Memory (ROM) Error ULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with
P0607 Control Module Performance <Ref. to EN(H4SO 2.0)(diag)-168, DTC P0607 CONTROL MODULE PER-
FORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638 Throttle Actuator Control Range/Per- <Ref. to EN(H4SO 2.0)(diag)-169, DTC P0638 THROTTLE ACTUATOR
formance (Bank 1) CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with
P0691 Cooling Fan 1 Control Circuit Low <Ref. to EN(H4SO 2.0)(diag)-170, DTC P0691 COOLING FAN 1 CONTROL
CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0692 Cooling Fan 1 Control Circuit High <Ref. to EN(H4SO 2.0)(diag)-170, DTC P0692 COOLING FAN 1 CONTROL
CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0700 Transmission Control System (MIL <Ref. to EN(H4SO 2.0)(diag)-170, DTC P0700 TRANSMISSION CONTROL
Request) SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0851 Neutral Switch Input Circuit Low <Ref. to EN(H4SO 2.0)(diag)-171, DTC P0851 NEUTRAL SWITCH INPUT
P0852 Neutral Switch Input Circuit High <Ref. to EN(H4SO 2.0)(diag)-173, DTC P0852 NEUTRAL SWITCH INPUT
(DTC).>
P1134 A/F Sensor Micro-Computer Problem <Ref. to EN(H4SO 2.0)(diag)-176, DTC P1134 A/F SENSOR MICRO-COM-
PUTER PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1137 O2 Sensor Circuit (Bank1 Sensor1) <Ref. to EN(H4SO 2.0)(diag)-178, DTC P1137 O2 SENSOR CIRCUIT
(BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1160 Return Spring Failure <Ref. to EN(H4SO 2.0)(diag)-181, DTC P1160 RETURN SPRING FAILURE,
P1492 EGR Solenoid Valve Signal #1 Cir- <Ref. to EN(H4SO 2.0)(diag)-181, DTC P1492 EGR SOLENOID VALVE
cuit Malfunction (Low Input) SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure
cuit Malfunction (High Input) SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
DTC Item NOTE

P1518 Starter Switch Circuit Low Input <Ref. to EN(H4SO 2.0)(diag)-186, DTC P1518 STARTER SWITCH CIR-
(DTC).>
P1521 Brake Switch Circuit Range/Perfor- <Ref. to EN(H4SO 2.0)(diag)-189, DTC P1521 BRAKE SWITCH CIRCUIT
mance Problem (High Input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT), Diagnostic Procedure
P1560 Back-Up Voltage Circuit Malfunction <Ref. to EN(H4SO 2.0)(diag)-191, DTC P1560 BACK-UP VOLTAGE CIR-
CUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1570 Antenna <Ref. to IM(diag)-18, DTC P1570 ANTENNA, Diagnostic Procedure with
P1571 Reference Code Incompatibility <Ref. to IM(diag)-21, DTC P1571 REFERENCE CODE INCOMPATIBILITY,
P1572 IMM Circuit Failure (Except antenna <Ref. to IM(diag)-22, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
circuit) ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1574 Key Communication Failure <Ref. to IM(diag)-25, DTC P1574 KEY COMMUNICATION FAILURE, Diag-
P1576 EGI Control Module EEPROM <Ref. to IM(diag)-25, DTC P1576 EGI CONTROL MODULE EEPROM, Diag-
P1577 IMM Control Module EEPROM <Ref. to IM(diag)-25, DTC P1577 IMM CONTROL MODULE EEPROM,
P1578 Meter Failure <Ref. to IM(diag)-26, DTC P1578 METER FAILURE, Diagnostic Procedure
P2100 Throttle Control Motor Circuit Open <Ref. to EN(H4SO 2.0)(diag)-192, DTC P2100 THROTTLE CONTROL
MOTOR CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P2101 Throttle Actuator Control Motor Cir- <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE ACTUATOR
cuit Range/Performance CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Proce-
cuit Low CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic
cuit High CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
P2109 Throttle/Pedal Position Sensor A <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2109 THROTTLE ANGLE
Minimum Stop Performance CLOSED POSITION ERROR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
DTC Item NOTE

P2111 Throttle Actuator Control System - <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2111 THROTTLE ACTUATOR
Stuck Open CONTROL SYSTEM - STUCK OPEN, Diagnostic Procedure with Diagnostic
Switch “D” Circuit Low Input TION SENSOR/SWITCH “D” CIRCUIT LOW INPUT, Diagnostic Procedure
Switch “D” Circuit High Input TION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT, Diagnostic Procedure
Switch “E” Circuit Low Input TION SENSOR/SWITCH “E” CIRCUIT LOW INPUT, Diagnostic Procedure
Switch “E” Circuit High Input TION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT, Diagnostic Procedure
Switch “A”/“B” Voltage Rationality TION SENSOR/SWITCH “A” / “B” VOLTAGE RATIONALITY, Diagnostic
Switch “D”/“E” Voltage Rationality TION SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY, Diagnostic
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
18.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- &? circuit in harness
TOR. between ECM and
1) Start and warm-up the engine. front oxygen (A/F)
2) Turn the ignition switch to OFF. sensor connector.
3) Disconnect the connectors from ECM and
front oxygen (A/F) sensor.
between ECM and front oxygen (A/F) sensor
connector.
(B135) No. 2 — (E24) No. 3:
(B135) No. 3 — (E24) No. 3:
FRONT OXYGEN (A/F) SENSOR CONNEC- &? circuit in harness
Measure the resistance of harness between front oxygen (A/F)
ECM and front oxygen (A/F) sensor connector. sensor connector.
(B136) No. 33 — (E24) No. 1:
(B136) No. 35 — (E24) No. 2:
3 CHECK HARNESS BETWEEN MAIN RELAY Is the resistance less than 1 Go to step 4. Repair the open
AND FRONT OXYGEN (A/F) SENSOR CON- &? circuit in harness
NECTOR. between ECM and
main relay and front oxygen (A/F) sensor con- sensor connector.
nector.
(B47) No. 3 — (E24) No. 4:
4 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 5 Go to step 5. Replace the front
Measure the resistance between front oxygen &? oxygen (A/F) sen-
(A/F) sensor connector terminals. sor. <Ref. to
Terminals FU(H4SO 2.0)-32,
No. 3 — No. 4: Front Oxygen (A/
F) Sensor.>
5 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front
Check the poor contact in ECM and front oxy- front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen-
gen (A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to
sensor connector. FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>
B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

Immediately at fault recognition
CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Do DTC P0031 and P0037 Go to step 2. Go to step 5.
appear at the same time on the
Subaru Select Monitor?
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)
(E24) No. 4 (+) — Engine ground ("): sensor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
main relay connec-
tor
3 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Go to step 4. Repair the har-
Measure the resistance of harness between &? ness and connec-
ECM connector and chassis ground. tor.
Connector & terminal NOTE:
(B135) No. 5 — Chassis ground: In this case, repair
(B135) No. 6 — Chassis ground: the following:
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
4 CHECK CURRENT DATA. Is the current more than 0.2 A? Repair the poor Go to step 5.
1) Start the engine. contact connector.
2) Read the data of front oxygen (A/F) sensor NOTE:
heater current using Subaru Select Monitor. In this case, repair
NOTE: the following:
For detailed operation procedure, refer to • Poor contact in
“READ CURRENT DATA FOR ENGINE”. <Ref. front oxygen (A/F)
to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- sensor connector
itor.> • Poor contact in
ECM connector
5 CHECK INPUT SIGNAL FROM ECM. Is the voltage less than 1 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 by Repair the poor Go to step 7.
Measure the voltage between ECM connector shaking the ECM harness and contact in ECM
and chassis ground. connector while monitoring the connector.
Connector & terminal value of voltage meter?
Step Check Yes No

7 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. &? ness and connec- oxygen (A/F) sen-
2) Measure the resistance between front oxy- tor. sor. <Ref. to
gen (A/F) sensor connector terminals. NOTE: FU(H4SO 2.0)-32,
Terminals In this case, repair Front Oxygen (A/
No. 3 — No. 4: the following: F) Sensor.>
• Open or ground
short circuit in har-
ness between front
oxygen (A/F) sen-
sor and ECM con-
nector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
C: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 8 V? Go to step 2. Go to step 3.
2 CHECK FRONT OXYGEN (A/F) SENSOR Is the current more than 2.3 A? Replace the ECM. END.
HEATER CURRENT. <Ref. to FU(H4SO
1) Turn the ignition switch to OFF. 2.0)-34, Engine
2) Repair the battery short circuit in harness Control Module
between ECM and front oxygen (A/F) sensor (ECM).>
connector.
4) Read the data of front oxygen (A/F) sensor
heater current using Subaru Select Monitor.
NOTE:
For detailed operation procedure, refer to
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(H4SO 2.0)(diag)-25, Subaru Select Mon-
itor.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change by Repair the battery END.
Measure the voltage between ECM connector shaking the ECM harness and short circuit in har-
and chassis ground. connector? ness between
Connector & terminal ECM and front
(B135) No. 2 (+) — Chassis ground ("): oxygen (A/F) sen-
(B135) No. 3 (+) — Chassis ground ("): sor connector.
D: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY BATTERY T5 B47 B138
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
B19
4
2
T5
2 B21
1
REAR
OXYGEN SENSOR 1 2 3 4 5 6 7 8 9 10 11
B47
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
B19 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
6 B83 :LHD
4
1 A: B134
7 B138 :RHD
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
C19
C18
C30
A1
A: B134 B: B135
B: B135 ECM
1 2 3 4 5 6 7
C: B136 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
B5
B6
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
52
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
E E
EN-02435
Step Check Yes No

1 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 2. Repair the har-
between ECM connector and chassis ground. In this case, repair
(B135) No. 5 — Chassis ground: • Open circuit in
(B135) No. 6 — Chassis ground: harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK CURRENT DATA. Is the current more than 0.2 A? Repair the con- Go to step 3.
1) Start the engine. nector.
2) Read the data of rear oxygen sensor heater NOTE:
current using Subaru Select Monitor. In this case, repair
“READ CURRENT DATA FOR ENGINE”. <Ref. rear oxygen sen-
to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- sor connector
rear oxygen sen-
sor connecting
harness connector
• Poor contact in
ECM connector
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Replace the ECM. Repair the battery
1) Disconnect the connector from rear oxygen <Ref. to FU(H4SO short circuit in har-
sensor. 2.0)-34, Engine ness between
2) Measure the voltage between ECM con- Control Module ECM and rear oxy-
nector and chassis ground. (ECM).> gen sensor con-
Connector & terminal nector. After
(B134) No. 1 (+) — Chassis ground ("): repair, replace the
ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
Step Check Yes No

6 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 V? Go to step 7. 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 chassis ground. main relay and
Connector & terminal rear oxygen sen-
(B19) No. 2 (+) — Chassis ground ("): sor connector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
coupling connector
7 CHECK REAR OXYGEN SENSOR. Is the resistance less than 30 Repair the har- Replace the rear
1) Turn the ignition switch to OFF. &? ness and connec- oxygen sensor.
2) Measure the resistance between rear oxy- tor. <Ref. to FU(H4SO
gen (A/F) sensor connector terminals. NOTE: 2.0)-33, Rear Oxy-
Terminals In this case, repair gen Sensor.>
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
• Poor contact in
coupling connector
E: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
B19
4
2
T5
2 B21
1
REAR
OXYGEN SENSOR 1 2 3 4 5 6 7 8 9 10 11
B47
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
B19 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
6 B83 :LHD
4
1 A: B134
7 B138 :RHD
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
C19
C18
C30
A1
A: B134 B: B135
B: B135 ECM
1 2 3 4 5 6 7
C: B136 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
B5
B6
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
52
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
E E
EN-02435
Step Check Yes No

1 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 8 V? Go to step 2. Go to step 3.
Measure the voltage between ECM connector
and chassis ground.
2 CHECK CURRENT DATA. Is the current more than 7 A? Replace the ECM. END.
1) Turn the ignition switch to OFF. <Ref. to FU(H4SO
2) Repair the battery short circuit in harness 2.0)-34, Engine
between ECM and rear oxygen sensor con- Control Module
nector. (ECM).>
4) Read the data of rear oxygen sensor heater
current using Subaru Select Monitor.
NOTE:
itor.>
3 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END.
connector.
F: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
MANIFOLD E21
ABSOLUTE
PRESSURE 1 2 3
SENSOR
1
2
3
E21 B83
B183
1 2 3 4
5 6 7 8
B21
E2
19
20
7
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B83 :LHD 5
B183 :RHD 1
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 31 32 33 34 35
18
20
17
B136 ECM
EN-02437
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.
NOTE:
itor.>
2 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Even if the mal-
Check the poor contact in ECM and manifold manifold pressure sensor con- contact in ECM or function indicator
pressure sensor connector. nector? manifold pressure light illuminates,
sensor connector. the circuit has
returned to a nor-
mal condition at
this time.
3 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 4.5 V? Go to step 5. Go to step 4.
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change by Repair the poor Replace the ECM.
Measure the voltage between ECM connector shaking the ECM harness and contact in ECM <Ref. to FU(H4SO
and chassis ground. connector? connector. 2.0)-34, Engine
Connector & terminal Control Module
(B136) No. 17 (+) — Chassis ground ("): (ECM).>
5 CHECK INPUT SIGNAL FROM 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 Is the value more than 13.3 Repair the poor Go to step 7.
SUBARU SELECT MONITOR). kPa (100 mmHg, 3.94 inHg) contact in ECM
Read the data of atmospheric absolute pres- when shaking the ECM har- connector.
sure signal using Subaru Select Monitor. ness and connector?
NOTE:
itor.>
7 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 8. Repair the open
MANIFOLD ABSOLUTE PRESSURE SEN- circuit in harness
SOR CONNECTOR. between ECM and
1) Turn the ignition switch to OFF. manifold absolute
2) Disconnect the connector from manifold pressure sensor
absolute pressure sensor. connector.
4) Measure the voltage between manifold
absolute pressure sensor connector and
engine ground.
Step Check Yes No

MANIFOLD ABSOLUTE PRESSURE SEN- &? circuit in harness
2) Disconnect the connector from ECM. pressure sensor
3) Measure the resistance of harness connector.
between ECM and manifold absolute pressure
sensor connector.
(B136) No. 18 — (E21) No. 1:
9 CHECK POOR CONTACT. Is there poor contact in mani- Repair the poor Replace the mani-
Check poor contact in manifold absolute pres- fold absolute pressure sensor contact in manifold absolute pres-
sure sensor connector. connector? fold absolute pressure sensor. <Ref.
sure sensor to FU(H4SO 2.0)-
connector. 26, Manifold Abso-
lute Pressure Sen-
sor.>
G: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
MANIFOLD E21
ABSOLUTE
PRESSURE 1 2 3
SENSOR
1
2
3
E21 B83
B183
1 2 3 4
5 6 7 8
B21
E2
19
20
7
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B83 :LHD 5
B183 :RHD 1
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 31 32 33 34 35
18
20
17
B136 ECM
EN-02437
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:
itor.>
and chassis ground.
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change by Repair the poor Replace the ECM.
4 CHECK INPUT SIGNAL FROM ECM. Is the voltage less than 0.2 V? Go to step 6. Go to step 5.
and chassis ground.
5 CHECK INPUT SIGNAL FOR ECM (USING Is the value more than 13.3 Repair the poor Go to step 6.
NOTE:
itor.>
engine ground.
sensor connector.
(B136) No. 20 — (E21) No. 2:
Step Check Yes No

Measure the resistance of harness between manifold absolute
ECM and manifold absolute pressure sensor pressure sensor
connector. connector.
(B136) No. 18 — (E21) No. 1:
sure sensor connector. connector? fold absolute pres-sure sensor. <Ref.
lute Pressure Sen-
sor.>
10 CHECK HARNESS BETWEEN ECM AND Is the value more than 119.5 Repair the battery Replace the mani-
MANIFOLD ABSOLUTE PRESSURE SEN- kPa (896.5 mmHg, 35.29 short in harness fold absolute pres-
SOR CONNECTOR. inHg)? between ECM and sure sensor. <Ref.
1) Turn the ignition switch to OFF, and the manifold absolute to FU(H4SO 2.0)-
Subaru Select Monitor switch to OFF. pressure sensor 26, Manifold Abso-
2) Disconnect the connector from manifold connector. lute Pressure Sen-
absolute pressure sensor. sor.>
3) Turn the ignition switch to ON, and the Sub-
aru Select Monitor switch to ON.
NOTE:
itor.>
H: DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
• Erroneous idling
• Poor driving performance
CAUTION:
WIRING DIAGRAM:
E20
INTAKE AIR
TEMPERATURE 1 2
SENSOR
B83
1
2
E20
B183
1 2 3 4
5 6 7 8
E2
B21
19
6
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B136
5 B83 :LHD
1 2 3 4 5 6
1 B183 :RHD 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
28
18
B136 ECM
EN-02438
Step Check Yes No

1 CHECK CURRENT DATA. Is the intake air temperature Go to step 2. Repair the poor
1) Start the engine. more than 120!C (248!F)? contact.
2) Read the data of intake air temperature NOTE:
sensor signal using Subaru Select Monitor. In this case, repair
“READ CURRENT DATA FOR ENGINE”. <Ref. intake air tempera-
to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- ture sensor
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
2 CHECK HARNESS BETWEEN INTAKE AIR Is the intake air temperature Replace the intake Repair the ground
TEMPERATURE SENSOR AND ECM CON- less than "40!C ("40!F)? air temperature short circuit in har-
NECTOR. sensor. <Ref. to ness between
1) Turn the ignition switch to OFF. FU(H4SO 2.0)-27, intake air tempera-
2) Disconnect the connector from intake air Intake Air Temper- ture sensor and
temperature sensor. ature Sensor.> ECM connector.
4) Read the data of intake air temperature
sensor signal using Subaru Select Monitor.
NOTE:
itor.>
I: DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
E20
INTAKE AIR
TEMPERATURE 1 2
SENSOR
B83
1
2
E20
B183
1 2 3 4
5 6 7 8
E2
B21
19
6
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B136
5 B83 :LHD
1 2 3 4 5 6
1 B183 :RHD 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
28
18
B136 ECM
EN-02438
Step Check Yes No

1) Start the engine. less than "40!C ("40!F)? contact.
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
2 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 3.
TEMPERATURE SENSOR AND ECM CON- short circuit in har-
NECTOR. ness between
1) Turn the ignition switch to OFF. intake air tempera-
2) Disconnect the connector from intake air ture sensor and
temperature sensor. ECM connector.
3) Measure the voltage between intake air
temperature 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 SENSOR AND ECM CON- short circuit in har-
1) Turn the ignition switch to ON. intake air tempera-
2) Measure the voltage between intake air ture sensor and
temperature sensor connector and engine ECM connector.
ground.
4 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 V? Go to step 5. Repair the har-
TEMPERATURE SENSOR AND ECM CON- ness and connec-
NECTOR. tor.
Measure the voltage between intake air tem- NOTE:
perature sensor connector and engine ground. In this case, repair
(B136) No. 28 (+) — Engine ground ("): • Open circuit in
harness between
intake air tempera-
ture sensor and
ECM connector
• Poor contact in
intake air tempera-
ture sensor
• Poor contact in
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
Step Check Yes No

5 CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5 Replace the intake Repair the har-
TEMPERATURE SENSOR AND ECM CON- &? air temperature ness and connec-
NECTOR. sensor. <Ref. to tor.
1) Turn the ignition switch to OFF. FU(H4SO 2.0)-27, NOTE:
2) Measure the resistance of harness Intake Air Temper- In this case, repair
between intake air temperature sensor con- ature Sensor.> the following:
nector and engine ground. • Open circuit in
(B136) No. 18 — Engine ground: intake air tempera-
ture sensor and
ECM connector
• Poor contact in
intake air tempera-
ture sensor
• Poor contact in
ECM
• Poor contact in
joint connector
J: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
• Hard to start
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
2
1
E8 B83
B183
1 2 3 4
5 6 7 8
E2
19
8
B21
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
5 B83 :LHD
1 B183 :RHD 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 31 32 33 34 35
22
18
B136 ECM
EN-02439
Step Check Yes No

1 CHECK CURRENT DATA. Is the engine coolant tempera- Go to step 2. Repair the poor
1) Start the engine. ture more than 150!C (302!F)? contact.
2) Read the data of engine coolant tempera- NOTE:
ture sensor signal using Subaru Select Moni- In this case, repair
tor. the following:
NOTE: • Poor contact in
For detailed operation procedure, refer to engine coolant
“READ CURRENT DATA FOR ENGINE”. <Ref. temperature sen-
to EN(H4SO 2.0)(diag)-25, Subaru Select Mon- sor
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
2 CHECK HARNESS BETWEEN ENGINE Is the engine coolant tempera- Replace the Repair the ground
COOLANT TEMPERATURE SENSOR AND ture less than "40!C ("40!F)? engine coolant short circuit in har-
ECM CONNECTOR. temperature sen- ness between
1) Turn the ignition switch to OFF. sor. <Ref. to engine coolant
2) Disconnect the connectors from the engine FU(H4SO 2.0)-20, temperature sen-
coolant temperature sensor. Engine Coolant sor and ECM con-
3) Turn the ignition switch to ON. Temperature Sen- nector.
4) Read the data of engine coolant tempera- sor.>
ture sensor signal using Subaru Select Moni-
tor.
NOTE:
itor.>
K: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
• Hard to start
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
2
1
E8 B83
B183
1 2 3 4
5 6 7 8
E2
19
8
B21
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
5 B83 :LHD
1 B183 :RHD 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 31 32 33 34 35
22
18
B136 ECM
EN-02439
Step Check Yes No

1) Start the engine. ture less than "40!C ("40!F)? contact.
tor. the following:
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
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 connectors from engine coolant tempera-
coolant temperature sensor. ture sensor con-
3) Measure the voltage between engine cool- nector.
ant temperature sensor connector and engine
ground.
1) Turn the ignition switch to ON. ECM and engine
2) Measure the voltage between engine cool- coolant tempera-
ant temperature sensor connector and engine ture sensor con-
ground. nector.
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
(E8) No. 2 (+) — 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
• Poor contact in
joint connector
Step Check Yes No

5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair the har-
COOLANT TEMPERATURE SENSOR AND &? engine coolant ness and connec-
ECM CONNECTOR. temperature sen- tor.
1) Turn the ignition switch to OFF. sor. <Ref. to NOTE:
2) Measure the resistance of harness FU(H4SO 2.0)-20, In this case, repair
between engine coolant temperature sensor Engine Coolant the following:
connector and engine ground. Temperature Sen- • Open circuit in
Connector & terminal sor.> harness between
(E8) No. 1 — 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
• Poor contact in
joint connector
L: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

1 CHECK SENSOR OUTPUT. Is the voltage more than 0.4 V? Go to step 2. Go to step 3.
2) Read the data of main throttle sensor signal
using Subaru Select Monitor.
2 CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Temporary poor
Check poor contact in connector between nector between ECM and elec- contact. contact occurred,
ECM and electronic throttle control. tronic throttle control? but it is normal at
present.
ELECTRONIC THROTTLE CONTROL. &? circuit of harness
1) Turn the ignition switch to OFF. connector.
2) Disconnect the connector from ECM.
3) Disconnect the connectors from electronic
throttle control.
4) Measure the resistance between ECM con-
nector and electronic throttle control connector.
(B137) No. 23 — (E78) No. 5:
(B136) No. 17 — (E78) No. 4:
4 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 5. Repair the chas-
ELECTRONIC THROTTLE CONTROL. M&? sis short circuit of
Measure the resistance between ECM connec- harness.
tor and chassis ground.
5 CHECK POWER SUPPLY OF ELECTRONIC Is the voltage 4.5 — 5.5 V? Go to step 6.
Repair the poor
THROTTLE CONTROL. contact in ECM
1) Connect the ECM connector. connector.
2) Turn the ignition switch to ON. Replace the ECM
3) Measure the voltage between electronic if defective. <Ref.
throttle control connector and engine ground. to FU(H4SO 2.0)-
Connector & terminal 34, Engine Con-
(E78) No. 4 (+) — Engine ground ("): trol Module
(ECM).>
6 CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance more than 10 Repair the poor Repair the poor
1) Turn the ignition switch to OFF. &? contact of elec- contact in ECM
2) Measure the resistance between electronic tronic throttle con- connector.
throttle control connector and engine ground. trol connector. Replace the ECM
Connector & terminal Replace the accel- if defective. <Ref.
(E78) No. 5 — Engine ground: erator position to FU(H4SO 2.0)-
sensor if defective. 34, Engine Con-
trol Module
(ECM).>
M: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

1 CHECK SENSOR OUTPUT. Is the voltage less than 4.63 Go to step 2. Go to step 3.
1) Turn the ignition switch to ON. V?
present.
throttle control.
(B137) No. 23 — (E78) No. 5:
(B136) No. 18 — (E78) No. 1:
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 5. Repair the poor
ELECTRONIC THROTTLE CONTROL. &? contact in ECM
2) Measure the resistance between electronic Replace the ECM
throttle control connector and engine ground. if defective. <Ref.
Connector & terminal to FU(H4SO 2.0)-
(E78) No. 1 — Engine ground: 34, Engine Con-
trol Module
(ECM).>
5 CHECK SENSOR OUTPUT POWER SUP- Is the voltage less than 10 V? Go to step 6. Repair the battery
PLY. short circuit in har-
Measure the voltage between electronic throt- ness between
tle control connector and engine ground. ECM connector
Connector & terminal and electronic
(E78) No. 5 (+) — Engine ground ("): throttle control
connector.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Repair the poor Repair the short
ELECTRONIC THROTTLE CONTROL. M&? contact in harness. circuit to sensor
1) Turn the ignition switch to OFF. Repair the elec- power supply.
2) Disconnect the connector from ECM. tronic throttle con-
3) Measure the resistance between ECM control.
nectors.
(B137) No. 23 — (B136) No. 17:
N: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
TROUBLE SYMPTOM:
Engine would not return to idling.
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
2
1
E8 B83
B183
1 2 3 4
5 6 7 8
E2
19
8
B21
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
5 B83 :LHD
1 B183 :RHD 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 31 32 33 34 35
22
18
B136 ECM
EN-02439
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2.
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
2 CHECK THERMOSTAT. Does the thermostat remain Replace the ther- Replace the
opened? mostat. <Ref. to engine coolant
CO(H4SO 2.0)-18, temperature sen-
Thermostat.> sor. <Ref. to
FU(H4SO 2.0)-20,
Engine Coolant
Temperature Sen-
sor.>
O: DTC P0130 O2 SENSOR CIRCUIT (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
Step Check Yes No

2 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage 0.85 — 1.15 V? Go to step 3. Go to step 4.
TA.
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:
to EN(H4SO 2.0)(diag)-25, Subaru Select
Monitor.>
• OBD-II general scan tool
For detailed operation procedures, refer to
OBD-II General Scan Tool Instruction Manual.
3 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage more than 1.1 V? Go to step 6. Go to step 4.
TA.
1) Race the engine at speeds from idling to
5,000 rpm for a total of 5 cycles.
signal during racing using Subaru Select Moni-
tor or OBD-II general scan tool.
NOTE:
• Air fuel ratio is rich at normal condition or
during racing.
• To increase engine speed to 5,000 rpm,
slowly depress accelerator pedal, taking
approximately 5 seconds, and quickly release
accelerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. &? 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
Connector & terminals
(B136) No. 33 — (E24) No. 1:
(B136) No. 35 — (E24) No. 2:
FRONT OXYGEN (A/F) SENSOR. M&? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (A/F)
Connector & terminals sensor.
Step Check Yes No

6 CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the front
Check exhaust system parts. system? faulty parts. oxygen (A/F) sen-
NOTE: sor. <Ref. to
Check the following items. FU(H4SO 2.0)-32,
• Loose part of exhaust system and incom- Front Oxygen (A/
plete installation 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
P: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Replace the front Repair the ground
FRONT OXYGEN (A/F) SENSOR CONNEC- M&? oxygen (A/F) sen- short circuit in har-
TOR. sor. <Ref. to ness between
1) Turn the ignition switch to OFF. FU(H4SO 2.0)-32, ECM and front
2) Disconnect the connector from ECM and Front Oxygen (A/ oxygen (A/F) sen-
front oxygen (A/F) sensor connector. F) Sensor.> sor connector.
between ECM and chassis ground.
Q: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 8 V? Replace the front Repair the battery
FRONT OXYGEN (A/F) SENSOR CONNEC- oxygen (A/F) sen- short circuit in har-
1) Turn the ignition switch to ON. FU(H4SO 2.0)-32, ECM and front
2) Disconnect the connector from front oxygen Front Oxygen (A/ oxygen (A/F) sen-
(A/F) sensor. F) Sensor.> sor connector.
3) Measure the voltage of harness between
ECM connector and chassis ground.
R: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, 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 any fault in exhaust Repair the exhaust Replace the front
NOTE: system? system. oxygen (A/F) sen-
Check the following items. sor. <Ref. to
• Loose installation of front portion of exhaust FU(H4SO 2.0)-32,
pipe onto cylinder heads Front Oxygen (A/
• Loose connection between front exhaust F) Sensor.>
pipe and front catalytic converter
• Damage of exhaust pipe resulting in a hole
S: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN-

SOR 1)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- &? ness and connec-
TOR. tor.
2) Disconnect the connector from ECM and In this case, repair
front oxygen (A/F) sensor connector. the following:
3) Measure the resistance of harness • Open circuit in
between ECM and front oxygen (A/F) sensor harness between
connector. ECM and front
Connector & terminals oxygen (A/F) sen-
(B136) No. 33 — (E24) No. 1: sor connector
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
sor connector. FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>
T: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
B19
4
2
T5
2 B21
1
REAR
OXYGEN SENSOR 1 2 3 4 5 6 7 8 9 10 11
B47
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
B19 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
6 B83 :LHD
4
1 A: B134
7 B138 :RHD
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
C19
C18
C30
A1
A: B134 B: B135
B: B135 ECM
1 2 3 4 5 6 7
C: B136 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
B5
B6
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
52
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
E E
EN-02435
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Go to step 2.
using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0137.
2 CHECK REAR OXYGEN SENSOR DATA. Is the voltage more than 490 Go to step 5. Go to step 3.
1) Warm-up the engine until engine coolant mV?
temperature is above 70!C (158!F), and keep
the engine speed at 5,000 rpm.
2) Read the data of rear oxygen sensor signal
NOTE:
itor.>
3 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 4.
REAR OXYGEN SENSOR CONNECTOR. &? circuit in harness
1) Turn the ignition switch to OFF. between ECM and
2) Disconnect the connector from ECM and rear oxygen sen-
rear oxygen sensor. sor connector.
3) Measure the resistance in harness
between ECM and rear oxygen sensor con-
nector.
(B136) No. 19 — (B19) No. 4:
(B136) No. 18 — (B19) No. 3:
4 CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 — 0.5 V? Replace the rear Repair the har-
GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec-
1) Turn the ignition switch to OFF. <Ref. to FU(H4SO tor.
2) Disconnect the connector from rear oxygen 2.0)-33, Rear Oxy- NOTE:
sensor. gen Sensor.> In this case, repair
4) Measure the voltage between rear oxygen • Open circuit in
sensor harness connector and chassis ground. harness between
(B19) No. 4 (+) — Chassis ground ("): sor and ECM con-
nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
Step Check Yes No

5 CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the rear
Check exhaust system parts. system? the faulty part. oxygen sensor.
NOTE: <Ref. to FU(H4SO
Check the following items: 2.0)-33, Rear Oxy-
• Loose part of exhaust system and incom- gen Sensor.>
plete installation
sensor
U: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
B19
4
2
T5
2 B21
1
REAR
OXYGEN SENSOR 1 2 3 4 5 6 7 8 9 10 11
B47
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
B19 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
6 B83 :LHD
4
1 A: B134
7 B138 :RHD
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
C19
C18
C30
A1
A: B134 B: B135
B: B135 ECM
1 2 3 4 5 6 7
C: B136 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
B5
B6
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
52
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
E E
EN-02435
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0138.
temperature is above 70!C (158!F), and lower
the engine speed rapidly from 5,000 rpm.
NOTE:
itor.>
REAR OXYGEN SENSOR CONNECTOR. &? circuit in harness
nector.
(B136) No. 19 — (B19) No. 4:
(B136) No. 18 — (B19) No. 3:
nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
Step Check Yes No

plete installation
sensor
V: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
B19
4
2
T5
2 B21
1
REAR
OXYGEN SENSOR 1 2 3 4 5 6 7 8 9 10 11
B47
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
B19 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
6 B83 :LHD
4
1 A: B134
7 B138 :RHD
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
C19
C18
C30
A1
A: B134 B: B135
B: B135 ECM
1 2 3 4 5 6 7
C: B136 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
B5
B6
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
52
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
E E
EN-02435
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the rear
“List of Diagnostic oxygen sensor.
Trouble Code <Ref. to FU(H4SO
(DTC)”. <Ref. to 2.0)-33, Rear Oxy-
EN(H4SO gen Sensor.>
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
W: DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO 2.0)(diag)-126, DTC P0172 SYSTEM TOO
RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
X: DTC P0172 SYSTEM TOO RICH (BANK 1)
TROUBLE SYMPTOM:
• 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.
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 EGR VALVE. Is the EGR valve stuck? Replace the EGR Go to step 4.
valve.
4 CHECK PURGE CONTROL SOLENOID Is the purge control solenoid Replace the purge Go to step 5.
VALVE. valve stuck? control solenoid
valve.
5 CHECK PCV VALVE. Is the PCV valve stuck? Replace the PCV Go to step 6.
valve.
6 CHECK FUEL PRESSURE. Is fuel pressure 284 — 314 Go to step 7. Repair the follow-
Warning: kPa (2.9 — 3.2 kg/cm2, 41 — ing items.
• Place “NO FIRE” signs near the working 46 psi)? Fuel pressure is
area. too high:
• Be careful not to spill fuel. • Clogged fuel
1) Release the fuel pressure. return line or
(1) Disconnect the connector from fuel bent hose
pump relay. Fuel pressure is
(2) Start the engine and run it until it stalls. too low:
(3) After the engine stalls, crank it for five • Improper fuel
more seconds. pump discharge
(4) Turn the ignition switch to OFF. • Clogged fuel
2) Connect the connector to fuel pump relay. supply line
3) Disconnect the fuel delivery hose, and con-
nect the fuel pressure gauge.
4) Install the fuel filler cap.
5) Start the engine and idle while gear posi-
tion is neutral.
6) Measure the fuel pressure while discon-
necting pressure regulator vacuum hose from
intake manifold.
Warning:
Release fuel pressure before removing the
fuel pressure gauge,.
NOTE:
If fuel pressure does not increase, squeeze fuel
return hose 2 to 3 times, then measure fuel
pressure again.
Step Check Yes No

7 CHECK FUEL PRESSURE. Is measured value 206 — 235 Go to step 8. Repair the follow-
After connecting the pressure regulator vac- kPa (2.1 — 2.4 kg/cm2, 30 — ing items.
uum hose, measure fuel pressure. 34 psi)? Fuel pressure is
Warning: too high:
Release fuel pressure before removing the • Faulty pres-
fuel pressure gauge,. sure regulator
NOTE: • Clogged fuel
• If fuel pressure does not increase, squeeze return line or
fuel return hose 2 to 3 times, then measure bent hose
fuel pressure again. Fuel pressure is
• If the measured value at this step is out of too low:
specification, check or replace pressure regu- • Faulty pres-
lator and pressure regulator vacuum hose. sure regulator
• Improper fuel
pump discharge
• Clogged fuel
supply line
8 CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 9. Replace the
SENSOR. ture 70 — 100!C (158 — engine coolant
1) Start the engine and warm-up completely. 212!F)? temperature sen-
2) Read the data of engine coolant tempera- sor. <Ref. to
ture sensor signal using Subaru Select Moni- FU(H4SO 2.0)-20,
tor. Engine Coolant
NOTE: Temperature Sen-
For detailed operation procedure, refer to sor.>
itor.>
9 CHECK MANIFOLD PRESSURE SENSOR Is the measurement value 24.0 Replace the ECM. Replace the mani-
SIGNAL. — 41.3 kPa (180 — 310 <Ref. to FU(H4SO fold pressure sen-
1) Start and warm-up the engine until engine mmHg, 7.09 — 12.20 inHg) 2.0)-34, Engine sor. <Ref. to
coolant temperature is above 60!C (140!F). when idling and 73.3 — 106.6 Control Module FU(H4SO 2.0)-26,
2) Place the select lever in “N” or “P” position. kPa (550 — 800 mmHg, 21.65 (ECM).> Manifold Absolute
3) Turn the A/C switch to OFF. — 31.50 inHg) when the igni- Pressure Sensor.>
4) Turn all accessory switches to OFF. tion turns to ON?
5) Read the data of manifold pressure sensor
signal using Subaru Select Monitor.
NOTE:
itor.>
Y: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

2) Read the data of sub throttle sensor signal
2 CHECK POOR CONTACT. Is there poor contact? Repair the poor Temporary poor
Check poor contact in connector between contact. contact occurred,
ECM and electronic throttle control. but it is normal at
present.
throttle control.
(B137) No. 24 — (E78) No. 2:
(B136) No. 17 — (E78) No. 4:
ELECTRONIC THROTTLE CONTROL. M&? sis short circuit of
5 CHECK SENSOR POWER SUPPLY. Is the voltage 4.5 — 5.5 V? Go to step 6.
Repair the poor
1) Connect the ECM connector. contact in ECM
2) Turn the ignition switch to ON. connector.
3) Measure the voltage between electronic Replace the ECM
(E78) No. 4 (+) — Engine ground ("): 34, Engine Con-
trol Module
(ECM).>
1) Turn the ignition switch to OFF. &? contact of elec- contact in ECM
Connector & terminal Replace the elec- if defective. <Ref.
(E78) No. 2 — Engine ground: tronic throttle con- to FU(H4SO 2.0)-
trol if defective. 34, Engine Con-
trol Module
(ECM).>
Z: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

present.
throttle control.
(B136) No. 18 — (E78) No. 1:
(B137) No. 24 — (E78) No. 2:
trol Module
(ECM).>
5 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 10 V? Go to step 6. Repair the battery
ELECTRONIC THROTTLE CONTROL. short circuit in har-
connector.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Repair the poor Sensor power sup-
ELECTRONIC THROTTLE CONTROL. M&? contact. Replace ply circuit may be
1) Turn the ignition switch to OFF. the electronic shorted.
2) Disconnect the connector from ECM. throttle control.
terminals.
(B137) No. 24 — (B136) No. 17:
AA:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO 2.0)(diag)-135, DTC P0304 CYLIN-
DER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB:DTC P0302 CYLINDER 2 MISFIRE DETECTED
NOTE:
AC:DTC P0303 CYLINDER 3 MISFIRE DETECTED
NOTE:
AD:DTC P0304 CYLINDER 4 MISFIRE DETECTED

• Two consecutive driving cycles with fault
• Immediately at fault recognition (A misfire which could damage catalyst occurs.)
TROUBLE SYMPTOM:
• Engine stalls.
• Rough driving
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
BATTERY
3
SBF-8
6
4
2
1
B47
B134 ECM
17
27
34
33
B21
48
42
43
44
45
E2
E5 E16 E6 E17
2

No. 1 No. 2 No. 3 No. 4
B21 B134
E5 E16 B47
E6 E17 1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
3 4 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 16 17
1 2 5 6 23 24 25 26 27 28 29 30 31 32 33 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02432
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0301, P0302,
P0303 and P0304.
nector and chassis ground on faulty cylinders.
#1 (B134) No. 17 (+) — Chassis ground ("):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance more than 1 Go to step 4. Repair the ground
TOR AND ECM CONNECTOR. M&? 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.
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. &? ness and connec-
Measure the resistance of harness connector tor.
between ECM connector and fuel injector on NOTE:
faulty cylinders. In this case, repair
• Poor contact in
coupling connector
5 CHECK FUEL INJECTOR. Is the resistance 5 — 20 &? Go to step 6. Replace the faulty
Measure the resistance between fuel injector fuel injector. <Ref.
terminals on faulty cylinder. to FU(H4SO 2.0)-
Terminals 29, Fuel Injector.>
No. 1 — No. 2:
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:
Connector & terminal In this case, repair
#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
injector connector
on faulty cylinders
• Poor contact in
coupling connector
• Poor contact in
main relay connec-
tor
• 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-
1) Turn the ignition switch to OFF. ness between
2) Disconnect the connector from fuel injector ECM and fuel
on faulty cylinder. injector. After
3) Turn the ignition switch to ON. repair, replace the
4) Measure the voltage between ECM con- ECM. <Ref. to
nector and chassis ground on faulty cylinders. FU(H4SO 2.0)-34,
Connector & terminal Engine Control
#1 (B134) No. 17 (+) — Chassis ground ("): Module (ECM).>
8 CHECK FUEL INJECTOR. Is the resistance less than 1 Replace the faulty Go to step 9.
1) Turn the ignition switch to OFF. &? fuel injector <Ref.
2) Measure the resistance between fuel injec- to FU(H4SO 2.0)-
tor terminals on faulty cylinder. 29, Fuel Injector.>
Terminals and ECM <Ref. to
No. 1 — No. 2: FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
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(H4SO
2.0)-50, Crank
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 align- timing belt. <Ref.
ment mark on crankshaft sprocket with align- to ME(H4SO 2.0)-
ment mark on cylinder block. 43, Timing Belt.>
Step Check Yes No

12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish fuel so
higher than the “Lower” level? fuel meter indica-
tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step 13.
13 CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator Go to step 15. Go to step 14.
CATOR LIGHT. light illuminate or blink?
1) Clear the memory using Subaru Select
Monitor.
<Ref. to EN(H4SO 2.0)(diag)-38, Clear Mem-
ory Mode.>
2) Start the engine, and drive the vehicle more
than 10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire iden- Finish diagnostics 1. Repair the poor
tified when the engine is run- operation, if the contact.
ning. Ex. Disconnection of engine has no NOTE:
spark plug cord. abnormality. In this case, repair
the following:
• Poor contact in
ignitor connector
• Poor contact in
ignition coil con-
nector
• Poor contact in
fuel injector con-
nector on faulty
cylinders
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2. If there is no
poor contact,
check the follow-
ings and contact
with your Subaru
distributor service.
• Fuel condi-
tion
• Whether
addition agent
is used or not
• Plug condi-
tion
• Plug cord
condition
• Engine oil
condition
Step Check Yes No

15 CHECK AIR INTAKE SYSTEM. Is there any fault in air intake Repair the air Go to step 16.
system? 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. display only one DTC?
<Ref. to EN(H4SO 2.0)(diag)-25, Subaru
Select Monitor.>
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
Is any other DTC displayed? indicate DTC P0301 and
P0302?
P0304?
P0303?
P0304?
21 ONLY ONE CYLINDER Is there any fault in that cylin- Repair or replace Go to DTC P0171.
der? faulty parts. <Ref. to EN(H4SO
NOTE: 2.0)(diag)-126,
Check the follow- DTC P0171 SYS-
ing items. TEM TOO LEAN
• Spark plug (BANK 1), Diag-
• Spark plug cord nostic Procedure
• Fuel injector with Diagnostic
• Compression Trouble Code
ratio (DTC).>
Step Check Yes No

22 GROUP OF #1 AND #2 CYLINDERS Are there any faults in #1 and Repair or replace Go to DTC P0171.
#2 cylinders? faulty parts. <Ref. to EN(H4SO
NOTE: 2.0)(diag)-126,
• Check the fol- DTC P0171 SYS-
lowing items. TEM TOO LEAN
• Spark plugs (BANK 1), Diag-
• Fuel injectors nostic Procedure
• Ignition coil with Diagnostic
• Compres- Trouble Code
sion ratio (DTC).>
• If no abnormal is
discovered, check
for “IGNITION
CONTROL SYS-
TEM” of #1 and #2
cylinders side.
<Ref. to EN(H4SO
2.0)(diag)-58,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
NOTE: 2.0)(diag)-126,
• Check the fol- DTC P0171 SYS-
lowing items. TEM TOO LEAN
• Ignition coil with Diagnostic
• If no abnormal is Trouble Code
discovered, check (DTC).>
for “16. D: IGNI-
TION CONTROL
SYSTEM” of #3
and #4 cylinders
side. <Ref. to
EN(H4SO
2.0)(diag)-58,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
NOTE: 2.0)(diag)-126,
• Skipping timing with Diagnostic
belt teeth Trouble Code
(DTC).>
Step Check Yes No

NOTE: 2.0)(diag)-126,
• Compression with Diagnostic
ratio Trouble Code
• Skipping timing (DTC).>
belt teeth
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC P0170. Repair or replace
<Ref. to EN(H4SO faulty parts.
2.0)(diag)-126, NOTE:
DTC P0171 SYS- Check the follow-
TEM TOO LEAN ing items.
(BANK 1), Diag- • Spark plugs
nostic Procedure • Fuel injectors
with Diagnostic • Compression
Trouble Code ratio
(DTC).>
AE:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE

SENSOR)
TROUBLE SYMPTOM:
• Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
2
E14
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
1 2 3 4 5 6
E1
7 8 9 10 11 12 13 14 15 16
13
17 18 19 20 21 22 23 24 25 26 27
B20
28 29 30 31 32 33 34 35
12
23
B136 ECM
EN-02442
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 k&? ness and connec-
3) Measure the resistance between ECM har- In this case, repair
ness connector and chassis ground. the following:
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
2 CHECK KNOCK SENSOR. Is the resistance more than Go to step 3. Repair the har-
1) Disconnect the connector from knock sen- 700 k&? ness and connec-
sor. tor.
2) Measure the resistance between knock NOTE:
sensor connector terminal and engine ground. In this case, repair
Terminals the following:
No. 2 — Engine ground: • Poor contact in
knock sensor con-
nector
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installation Replace the knock Tighten the knock
INSTALLATION. bolt tightened securely? sensor. <Ref. to sensor installation
FU(H4SO 2.0)-23, bolt securely.
Knock Sensor.>
AF:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE

SENSOR)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
2
E14
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
1 2 3 4 5 6
E1
7 8 9 10 11 12 13 14 15 16
13
17 18 19 20 21 22 23 24 25 26 27
B20
28 29 30 31 32 33 34 35
12
23
B136 ECM
EN-02442
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. k&?
Measure the resistance of harness between
2 CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair the ground
1) Disconnect the connector from knock sen- k&? sensor. <Ref. to short circuit in har-
sor. FU(H4SO 2.0)-23, ness between
2) Measure the resistance between knock Knock Sensor.> knock sensor con-
sensor connector terminal and engine ground. nector and ECM
Terminals connector.
No. 2 — Engine ground: NOTE:
The harness be-
tween both con-
nectors are
shielded. Repair
the short circuit in
harness covered
with shield.
3 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 2 V? Even if the mal- Repair the poor
1) Connect the connectors to ECM and knock function indicator contact in ECM
sensor. light illuminates, connector.
2) Turn the ignition switch to ON. the circuit has
3) Measure the voltage between ECM and returned to a nor-
chassis ground. mal condition at
Connector & terminal this time. (How-
(B136) No. 23 (+) — Chassis ground ("): ever, the possibility
of poor contact still
remains.)
NOTE:
In this case, repair
the following:
• Poor contact in
knock sensor con-
nector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
AG:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT

TROUBLE SYMPTOM:
• Engine stalls.
• Failure of engine to start
CAUTION:
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR E10
1 2
2
1
E10
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1
B122
8
7
B20
B138
1 2 3 4
5 6 7 8
: WITH IMMOBILIZER: 27
* WITHOUT IMMOBILIZER: 26
B136
3 B138 :LHD 1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
4 B122 :RHD 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
24
32
*
B136 ECM E
EN-02443
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 k&? ness and connec-
NECTOR. tor.
2) Disconnect the connector from crankshaft In this case, repair
position sensor. the following:
between crankshaft position sensor connector harness between
and 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
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 10 Repair the ground Go to step 3.
SHAFT POSITION SENSOR AND ECM CON- &? short circuit in har-
Measure the resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
(E10) No. 1 — Engine ground: The harness be-
tween both con-
nectors are
shielded. Repair
the ground short
circuit in harness
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- &? ness and connec-
NECTOR. tor.
Measure the resistance of harness between NOTE:
crankshaft position sensor connector and In this case, repair
engine ground. the following:
crankshaft posi-
tion sensor and
ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
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 1 — 4 k&? Repair the poor Replace the crank-
1) Remove the crankshaft position sensor. contact in crankshaft position sen-
2) Measure the resistance between connector shaft position sensor. <Ref. to
terminals of crankshaft position sensor. sor connector. FU(H4SO 2.0)-21,
Terminals Crankshaft Posi-
No. 1 — No. 2: tion Sensor.>
AH:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN-

GLE SENSOR)
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
E15
1 2
2
1
E15
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1 B122
6
5
B20 B138
1 2 3 4
5 6 7 8
: WITH IMMOBILIZER: 26
* WITHOUT IMMOBILIZER: 27
B136
1 2 3 4 5 6
7 B138 :LHD 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
4 B122 :RHD 28 29 30 31 32 33 34 35
25
32
*
B136 ECM E
EN-02444
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 k&? ness and connec-
TOR. tor.
2) Disconnect the connector from camshaft In this case, repair
between camshaft position sensor connector harness between
and engine ground. camshaft position
Connector & terminal sensor and ECM
(E15) No. 1 — Engine ground: connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- &? short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
engine ground. connector.
tween both con-
nectors are
shielded. Repair
the ground short
circuit in harness
with shield.
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 Go to step 4. Repair the har-
POSITION SENSOR AND ECM CONNEC- &? ness and connec-
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
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 1 — 4 k&? Repair the poor Replace the cam-
1) Remove the camshaft position sensor. contact in camshaft position sen-
terminals of camshaft position sensor. sor connector. FU(H4SO 2.0)-22,
Terminals Camshaft Position
No. 1 — No. 2: Sensor.>
AI: DTC P0400 EXHAUST GAS RECIRCULATION FLOW

TROUBLE SYMPTOM:
• Movement performance problem when engine is low speed.
• Movement performance problem
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5 BATTERY
3 1 2 3
SBF-5 4 5 6
6
4
B21 B47
2
1
48
1 2
E2
B47 3 4
5 6
5
2
B21
EGR 1 2 3 4 5 6 7 8 9 10 11
VALVE 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E18
34 35 36 37 38 39 40 41
42 43 44 45 46 47
6
3
4
1
48 49 50 51 52 53 54
E2
30
25
29
26
B21
A: B134
A13
A12
A4
A3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
A: B134 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
C: B136 ECM
D: B137
C: B136
A2
D1
C5
C6
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
B21
D: B137
35
36
E2
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
E E
EN-02445
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK CURRENT DATA. Is the value more than 53.3 Make sure that the Go to step 3.
1) Start the engine. kPa (400 mmHg, 15.75 inHg)? EGR valve, mani-
2) Read the data of intake manifold absolute fold absolute pres-
pressure signal using Subaru Select Monitor. sure sensor and
NOTE: throttle body are
For detailed operation procedure, refer to installed securely.
itor.>
3 CHECK THE POWER SUPPLY OF EGR SO- Is the voltage more than 10 V? Go to step 4. Repair the open
LENOID VALVE. circuit in harness
1) Detach the connector from EGR solenoid between main
valve. relay and EGR
2) Turn the ignition switch to ON. solenoid valve
3) Measure the voltage between EGR sole- connector.
noid valve and engine ground.
4 CHECK EGR SOLENOID VALVE. Is the resistance 20 — 30 &? Go to step 5. Replace the EGR
Measure the resistance between EGR sole- solenoid valve.
noid valve terminals. <Ref. to FU(H4SO
NOTE: 2.0)-28, EGR
Make sure there is no foreign material between Valve.>
EGR solenoid valve and valve seat.
Terminals
No. 1 — No. 2:
No. 3 — No. 2:
No. 4 — No. 5:
No. 6 — No. 5:
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage 0 — 10 V? Repair the poor Go to step 6.
1) Turn the ignition switch to OFF. contact portion in
2) Connect the connector to ECM and EGR ECM connector.
solenoid valve.
4) Measure the voltage between ECM and
chassis ground.
Step Check Yes No

6 CHECK HARNESS BETWEEN EGR SOLE- Is the resistance less than 1 Go to step 7. Repair the open
NOID VALVE AND ECM CONNECTOR. &? circuit in harness
2) Detach the connector from EGR solenoid EGR solenoid
valve and ECM. valve connector.
between EGR solenoid valve and ECM con-
nector.
(B134) No. 4 — (E18) No. 6:
(B134) No. 12 — (E18) No. 1:
(B134) No. 3 — (E18) No. 4:
(B134) No. 13 — (E18) No. 3:
7 CHECK HARNESS BETWEEN EGR SOLE- Is the resistance more than 1 Go to step 8. Repair the short
NOID VALVE AND ECM CONNECTOR. M&? circuit in harness
Measure the resistance of harness between between main
EGR solenoid valve and chassis ground. relay and EGR
Connector & terminal solenoid valve
(B134) No. 4 — Chassis ground: connector.
8 CHECK POOR CONTACT. Is there poor contact for ECM Repair the poor Even if the mal-
Check poor contact for ECM and EGR sole- and EGR solenoid valve con- contact of ECM function indicator
noid valve connector. nector? and EGR solenoid light illuminates,
valve connector. the circuit has
returned to the
specified condi-
tion at this time.
AJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK

1)
TROUBLE SYMPTOM:
• Engine stalls.
• Idle mixture is out of specifications.
CAUTION:
WIRING DIAGRAM:
B83
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
B19
4
2
T5
2 B21
1
REAR
OXYGEN SENSOR 1 2 3 4 5 6 7 8 9 10 11
B47
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
B19 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
6 B83 :LHD
4
1 A: B134
7 B138 :RHD
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
C19
C18
C30
A1
A: B134 B: B135
B: B135 ECM
1 2 3 4 5 6 7
C: B136 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
B5
B6
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
52
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
E E
EN-02435
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele- Go to step 2.
vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, 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 any fault in exhaust Repair or replace Go to step 3.
Check for gas leaks or air suction caused by system? the exhaust sys-
loose or dislocated nuts and bolts, and open tem. <Ref. to
hole at exhaust pipes. EX(H4SO 2.0)-2,
NOTE: General Descrip-
Check the following positions. tion.>
• Between cylinder head and front exhaust
pipe
• Between front exhaust pipe and front cata-
lytic converter
• Between front catalytic converter and rear
catalytic converter
3 CHECK CATALYTIC CONVERTER. Is there damage at rear face or Replace the cata- Go to step 5.
front face of front catalyst? lytic converter.
<Ref. to EC(H4SO
2.0)-3, Front Cata-
lytic Converter.>
4 CHECK REAR OXYGEN SENSOR GROUND Is the resistance less than 1 Go to step 5. Repair the open
HARNESS. &? circuit in harness
1) Disconnect the rear oxygen sensor and between ECM and
ECM connectors. rear oxygen sen-
2) Measure the resistance between rear oxy- sor.
gen sensor connector and ECM connector.
(B19) No. 3 — (B136) No. 18:
5 CHECK SHIELD HARNESS. Is the shield harness opened? Repair the shield Contact with your
harness. Subaru distributor
service.
AK:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E4
5
BATTERY
3
SBF-8 1 2
6
4
2
1 B47
B47 1 2
3 4
5 6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B134 ECM 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
8
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
B21
48
41
E2
E4
1
2
E
PURGE CONTROL
SOLENOID VALVE
EN-02446
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if the mal- Go to step 2.
1) Turn the ignition switch to ON. function indicator
2) Measure the voltage between ECM and light illuminates,
chassis ground. the circuit has
Connector & terminal returned to a nor-
(B134) No. 8 (+) — Chassis ground ("): mal condition at
this time.
2 CHECK HARNESS BETWEEN PURGE CON- Is the resistance more than 1 Go to step 3. Repair the ground
TROL SOLENOID VALVE AND ECM CON- M&? 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.
between purge control solenoid valve connec-
tor and engine ground.
(E4) No. 2 — 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- &? circuit in harness
Measure the resistance of harness between purge control sole-
ECM and purge control solenoid valve. noid valve connec-
(B134) No. 8 — (E4) No. 2: NOTE:
the following:
• Open circuit in
harness between
ECM and purge
control solenoid
valve connector
• Poor contact in
coupling connector
4 CHECK PURGE CONTROL SOLENOID Is the resistance 10 — 100 &? Go to step 5. Replace the purge
VALVE. control solenoid
1) Remove the purge control solenoid valve. valve. <Ref. to
2) Measure the resistance between purge EC(H4SO 2.0)-7,
control solenoid valve terminals. Purge Control
Terminals Solenoid Valve.>
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.
6 CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Replace the ECM.
Check poor contact in purge control solenoid control solenoid valve connec- contact in purge <Ref. to FU(H4SO
valve connector. tor? control solenoid 2.0)-34, Engine
valve connector. Control Module
(ECM).>
AL:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E4
5
BATTERY
3
SBF-8 1 2
6
4
2
1 B47
B47 1 2
3 4
5 6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B134 ECM 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
8
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
B21
48
41
E2
E4
1
2
E
PURGE CONTROL
SOLENOID VALVE
EN-02446
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage 0 — 10 V? Go to step 2. Even if the mal-
1) Turn the ignition switch to OFF. function indicator
2) Connect the test mode connector at the light illuminates,
lower portion of instrument panel (on the the circuit has
driver’s side). returned to a nor-
3) Turn the ignition switch to ON. mal condition at
4) While operating the purge control solenoid this time. In this
valve, measure voltage between ECM and case, repair the
chassis ground. poor contact in
NOTE: ECM connector.
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. Refer to
“Compulsory Valve Operation Check Mode” for
procedures. <Ref. to EN(H4SO 2.0)(diag)-39,
Compulsory Valve Operation Check Mode.>
chassis ground.
Control Module
(ECM).>
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-
2) Disconnect the connector from purge con- control solenoid
trol 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(H4SO
Connector & terminal 2.0)-34, Engine
(B134) No. 8 (+) — Chassis ground ("): Control Module
(ECM).>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Replace the purge Go to step 6.
VALVE. &? control solenoid
1) Turn the ignition switch to OFF. valve <Ref. to
No. 1 — No. 2: and ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
Control Module
(ECM).>
AM:DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0462 appear on Check the combi- Temporary poor
the Subaru Select Monitor? nation meter. contact occurs.
<Ref. to IDI-3,
Combination
Meter System.>
AN:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0463 appear on Check the combi- Temporary poor
the Subaru Select Monitor? nation meter. contact occurs.
<Ref. to IDI-3,
Combination
Meter System.>
AO:DTC P0500 VEHICLE SPEED SENSOR

CAUTION:
Step Check Yes No

1 CHECK DTC OF ABS. Is DTC of ABS displayed? Perform the diag- Repair the poor
Check DTC of ABS. nosis according to contact in ECM.
DTC. <Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
AP:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
LHD E
15
13
RHD
16
14
STARTER
RELAY
B225
LHD
16
14
RHD
15
13
P N
AT 11 7
12 12
MT
B12 T3 T7
STARTER MOTOR
MT
AT
E
M
B14
23
B135
ECM
B72 B225
B135 B12 T7
1 2 9 13 17 21 1 2 3 4 1 2 3 4 5 6
1 2 3 1 2 3
10 14 18 22 4 5 6 7
4 5 6 3 4 5 6 7 8 7 8 9 10 11 12
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19
9 10 11 12
5 6 20 21 22 23 24 25 26 27
7 8 28 29 30 31 32 33 34 35
25 29 33 37
26 30 34 38
27 28 31 32 35 36 39 40
EN-02428
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check starter
Turn the ignition switch to ON. ate? short circuit in motor circuit. <Ref.
NOTE: starter motor cir- to EN(H4SO
Place the inhibitor switch in each position. cuit. 2.0)(diag)-52,
STARTER
MOTOR CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>
AQ:DTC P0519 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0519.
2 CHECK AIR INTAKE SYSTEM. Is there any fault in air intake Repair air suction Go to step 3.
1) Turn the ignition switch to ON. system? and leaks.
3) Check the following items:
• Loose installation of intake manifold and
throttle body
• Cracks of intake manifold gasket and throttle
body gasket
• Disconnections of vacuum hoses
3 CHECK ELECTRONIC THROTTLE CON- Are foreign matters found Remove foreign Perform the diag-
TROL. inside the electronic throttle matters from the nosis of DTC
1) Turn the ignition switch to OFF. control? electronic throttle P2101.
2) Replace the electronic throttle control. control.
3) Check the electronic throttle control.
AR:DTC P0558 GENERATOR CIRCUIT LOW INPUT

CAUTION:
For diagnostic procedure, refer to DTC P0559. <Ref. to EN(H4SO 2.0)(diag)-164, DTC P0559 GENER-
ATOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>.
AS:DTC P0559 GENERATOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
B135
ECM
1 2 3 4 5 6 7
B135 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
16 28 29 30 31 32 33 34 35
F26
1 2 3
F26
3
GENERATOR
EN-02447
Step Check Yes No

1 CHECK HARNESS BETWEEN GENERATOR Is the resistance more than 1 Go to step 2. Repair the ground
AND ECM CONNECTOR. M&? short circuit in har-
2) Disconnect the connectors from generator ECM and purge
and ECM. control solenoid
3) Measure the resistance of harness valve connector.
between generator connector and engine
ground.
(F26) No. 3 — Engine ground:
2 CHECK HARNESS BETWEEN GENERATOR Is the resistance less than 1 Repair the poor Repair the open
AND ECM CONNECTOR. &? contact in connec- circuit in harness
Measure the resistance of harness between tor. between ECM and
ECM and generator of harness connector. generator connec-
(B136) No. 16 — (F26) No. 3: NOTE:
the following:
• Open circuit in
harness between
ECM and genera-
tor connector
• Poor contact in
coupling connector
AT:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:
For the diagnostic procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
AU:DTC P0604 INTERNAL CONTROL MODULE READ ACCESS MEMORY

(RAM) ERROR
TROUBLE SYMPTOM:
• Engine does not start.
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
1
2 IGNITION
B72 BATTERY
SWITCH
6 3
B14
B13
C7
C3
C4
A: B134
B: B135
ECM
C: B136
D: B137
C1
A2
B5
B6
C2
A7
C5
C6
D1
B21
52
34
36
35
37
E2
E E
A: B134 B: B135 C: B136

B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33 28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
D: B137
34 35 36 37 38 39 40 41
42 43 44 45 46 47 B72 B47
48 49 50 51 52 53 54 1 2 3 4 5 6 7
1 2 3 1 2 8 9 10 11 12 13 14 15 16 17
4 5 6 3 4 18 19 20 21 22 23 24 25
5 6 26 27 28 29 30 31
EN-02429
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele- Temporary poor
vant DTC using contact occurs.
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
AV:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO 2.0)(diag)-168, DTC P0607 CON-
TROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AW:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
1
2 IGNITION
B72 BATTERY
SWITCH
6 3
B14
B13
C7
C3
C4
A: B134
B: B135
ECM
C: B136
D: B137
C1
A2
B5
B6
C2
A7
C5
C6
D1
B21
52
34
36
35
37
E2
E E
A: B134 B: B135 C: B136

B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33 28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
D: B137
34 35 36 37 38 39 40 41
42 43 44 45 46 47 B72 B47
48 49 50 51 52 53 54 1 2 3 4 5 6 7
1 2 3 1 2 8 9 10 11 12 13 14 15 16 17
4 5 6 3 4 18 19 20 21 22 23 24 25
5 6 26 27 28 29 30 31
EN-02429
Step Check Yes No

1 CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 — 13 V? Go to step 2. Repair the open or
1) Start the engine. ground short cir-
3 CHECK ECM GROUND HARNESS. Is the voltage less than 1 V? Repair the poor Further tighten the
Measure the voltage between ECM connector contact in ECM engine ground ter-
and chassis ground. connector. minal.
Connector & terminal Replace the ECM
(B136) No. 2 (+) — Chassis ground ("): if defective. <Ref.
(B136) No. 5 (+) — Chassis ground ("): to FU(H4SO 2.0)-
(B136) No. 6 (+) — Chassis ground ("): 34, Engine Con-
trol Module
(ECM).>
AX:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE
ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos-
AY:DTC P0691 COOLING FAN 1 CONTROL CIRCUIT LOW

TROUBLE SYMPTOM:
• Radiator fan does not operate properly.
• Overheating
CAUTION:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0691 appear on Check the radiator Temporary poor
the Subaru Select Monitor? fan system. <Ref. contact occurs.
to CO(H4SO 2.0)-
7, Radiator Fan
System.>
AZ:DTC P0692 COOLING FAN 1 CONTROL CIRCUIT HIGH

TROUBLE SYMPTOM:
• Overheating
CAUTION:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does DTC P0692 appear on Check the radiator Temporary poor
the Subaru Select Monitor? fan system. <Ref. contact occurs.
to CO(H4SO 2.0)-
7, Radiator Fan
System.>
BA:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 4AT(diag)-2, Basic Diagnostic Procedure.>
BB:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B135
1 2 3 4 5 6 7
B135 ECM 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
12
B25
MT 1 2
AT
B25
B12
2
T2
1 2 3 4
NEUTRAL 5 6 7 8
POSITION INHIBITOR SWITCH 9 10 11 12
SWITCH
P R N D 3 2 1
T2 11 7
1
12 12 T7
B25
B12 T3 T7 1 2 3 4 5 6
7 8 9 10 11 12
LHD 6
RHD
B122
LHD 1 1 2 3 4
5 6 7 8
B122
STARTER MOTOR
LHD B21
B21
RHD
36
1 2 3 4 5 6 7 8 9 10 11
E3 12 13 14 15 16 17 18 19 20 21 22
LHD 23 24 25 26 27 28 29 30 31 32 33
M 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B14 48 49 50 51 52 53 54
EN-02448
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if the mal- Go to step 3.
2) Place the select lever other than “N” and light illuminates,
“P” range. the circuit has
Connector & terminal this time.
TRANSMISSION HARNESS CONNECTOR. M&? short circuit in har-
2) Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
4 CHECK TRANSMISSION HARNESS CON- Is the resistance more than 1 Go to step 5. Repair the ground
NECTOR. M&? short circuit in har-
1) Disconnect the connector from inhibitor ness between
switch. transmission har-
2) Measure the resistance of harness ness connector
between transmission harness connector and and inhibitor
engine ground. switch connector.
(T3) No. 11 — Engine ground:
5 CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 6. Replace the inhibi-
Measure the resistance between inhibitor M&? tor switch. <Ref. to
switch connector receptacle’s terminals with 4AT-52, Inhibitor
select lever at other than “N” and “P” range. Switch.>
Terminals
No. 7 — No. 12:
6 CHECK SELECT CABLE CONNECTION. Is there any fault in select Repair the select Replace the ECM.
cable connection to inhibitor cable connection. <Ref. to FU(H4SO
switch? <Ref. to CS-14, 2.0)-34, Engine
INSPECTION, Control Module
Select Cable.> (ECM).>
BC:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B135
1 2 3 4 5 6 7
B135 ECM 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
12
B25
MT 1 2
AT
B25
B12
2
T2
1 2 3 4
NEUTRAL 5 6 7 8
POSITION INHIBITOR SWITCH 9 10 11 12
SWITCH
P R N D 3 2 1
T2 11 7
1
12 12 T7
B25
B12 T3 T7 1 2 3 4 5 6
7 8 9 10 11 12
LHD 6
RHD
B122
LHD 1 1 2 3 4
5 6 7 8
B122
STARTER MOTOR
LHD B21
B21
RHD
36
1 2 3 4 5 6 7 8 9 10 11
E3 12 13 14 15 16 17 18 19 20 21 22
LHD 23 24 25 26 27 28 29 30 31 32 33
M 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B14 48 49 50 51 52 53 54
EN-02448
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
chassis ground with select lever at “N” and “P”
range.
sis ground with select lever at other than “N”
and “P” range.
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poorReplace the ECM.
Control Module
(ECM).>
5 CHECK INPUT SIGNAL FROM 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. 12 (+) — 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. &? ness and connec-
2) Disconnect the connectors from ECM and NOTE:
inhibitor switch. In this case, repair
3) Measure the resistance of harness the following:
between ECM and inhibitor switch connector. • Open circuit in
(B135) No. 12 — (T7) No. 11: ECM and inhibitor
switch connector
• Poor contact in
coupling connector
• Poor contact in
inhibitor switch
connector
• Poor contact in
ECM connector
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 &? circuit in harness
inhibitor switch connector and engine ground. between inhibitor
Connector & terminal switch connector
(T7) No. 11 — Engine ground: and ground line.
NOTE:
the following:
• Open circuit in
harness between
inhibitor switch
connector and
ground line
8 CHECK INHIBITOR SWITCH. Is the resistance less than 1 Go to step 9. Replace the inhibi-
Measure the resistance between inhibitor &? tor switch. <Ref. to
select lever at “N” and “P” range. Switch.>
Terminals
No. 7 — No. 12:
BD:DTC P1134 A/F SENSOR MICRO-COMPUTER PROBLEM

CAUTION:
38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, Inspec-
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the ECM.
the List of Diag- <Ref. to FU(H4SO
nostic Trouble 2.0)-34, Engine
Code (DTC). <Ref. Control Module
to EN(H4SO (ECM).>
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
It is not necessary
to inspect DTC
P1134.
BE: DTC P1137 O2 SENSOR CIRCUIT (BANK1 SENSOR1)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-6
5 B47
3 50
1 2
4 B21 E2 3 4
6 5 6
4
2 FRONT OXYGEN
1 (A/F) SENSOR
B47 E24 E24

3
1
2
2 1
4 3
E2
B21
51
4
3
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
C33
C35
C34
B2
B3
B: B135
B: B1
B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B5
B6
E
C: B136
B21
52
1 2 3 4 5 6
E2 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
EN-02433
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect DTC using Go to step 2.
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage 0.85 — 1.15 V? Go to step 3. Go to step 4.
TA.
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 during idling using Subaru Select Moni-
tor or OBD-II general scan tool.
NOTE:
to EN(H4SO 2.0)(diag)-25, Subaru Select
Monitor.>
OBD-II General Scan Tool Instruction Manual.
3 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage more than 1.1 V? Go to step 6. Go to step 4.
TA.
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
• Air fuel ratio is rich at normal condition or
during racing.
• To increase engine speed to 5,000 rpm,
slowly depress accelerator pedal, taking
approximately 5 seconds, and quickly release
accelerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. &? circuit between
front oxygen (A/F) sensor connector. sor.
3) Measure the resistance between ECM and
(B136) No. 33 — (E24) No. 1:
(B136) No. 35 — (E24) No. 2:
FRONT OXYGEN (A/F) SENSOR. M&? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (A/F)
Connector & terminals sensor.
Step Check Yes No

6 CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Replace the front
Check exhaust system parts. system? faulty parts. oxygen (A/F) sen-
NOTE: sor. <Ref. to
Check the following items. FU(H4SO 2.0)-32,
• Loose part of exhaust system and incom- Front Oxygen (A/
plete installation F) Sensor, .>
• Looseness of front oxygen (A/F) sensor
sensor
BF:DTC P1160 RETURN SPRING FAILURE

NOTE:
BG:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H4SO 2.0)(diag)-182, DTC P1498 EGR SO-
LENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnos-
BH:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
LENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnos-
BI: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
BJ:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
BK:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
BL:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
BM:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
• Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5 BATTERY
3 1 2 3
SBF-5 4 5 6
6
4
B21 B47
2
1
48
1 2
E2
B47 3 4
5 6
5
2
B21
EGR 1 2 3 4 5 6 7 8 9 10 11
VALVE 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E18
34 35 36 37 38 39 40 41
42 43 44 45 46 47
6
3
4
1
48 49 50 51 52 53 54
E2
30
25
29
26
B21
A: B134
A13
A12
A4
A3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
A: B134 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
C: B136 ECM
D: B137
C: B136
A2
D1
C5
C6
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
B21
D: B137
35
36
E2
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
E E
EN-02445
Step Check Yes No

1 CHECK POWER SUPPLY TO EGR SOLE- Is the voltage more than 10 V? Go to step 2. Repair the har-
NOID VALVE. ness and connec-
2) Disconnect the connector from EGR sole- NOTE:
noid valve. In this case, repair
4) Measure the voltage between EGR sole- • Open circuit in
noid valve connector and engine ground. harness between
Connector & terminal EGR solenoid
(E18) No. 2 (+) — Engine ground ("): valve and main
(E18) No. 5 (+) — Engine ground ("): relay connector
• Poor contact in
coupling connector
EGR SOLENOID VALVE CONNECTOR. &? ness and connec-
2) Measure the resistance between ECM and NOTE:
EGR solenoid valve connector. In this case, repair
DTC P1492; (B134) No. 13 — (E18) No. 3: • Open circuit in
DTC P1494; (B134) No. 12 — (E18) No. 1: harness between
DTC P1496; (B134) No. 3 — (E18) No. 4: ECM and EGR
DTC P1498; (B134) No. 4 — (E18) No. 6: solenoid valve
connector
• Poor contact in
coupling connector
EGR SOLENOID VALVE CONNECTOR. M&? short in harness
2) Measure the resistance between ECM con- EGR solenoid
nector and chassis ground. valve connector.
DTC P1492; (B134) No. 13 — Chassis
ground:
ground:
ground:
ground:
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the EGR
Check poor contact in ECM connector and connector or EGR solenoid contact in ECM solenoid valve.
EGR solenoid valve connector. valve connector? connector or EGR <Ref. to FU(H4SO
solenoid valve 2.0)-28, EGR
connector. Valve.>
BN:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5 BATTERY
3 1 2 3
SBF-5 4 5 6
6
4
B21 B47
2
1
48
1 2
E2
B47 3 4
5 6
5
2
B21
EGR 1 2 3 4 5 6 7 8 9 10 11
VALVE 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E18
34 35 36 37 38 39 40 41
42 43 44 45 46 47
6
3
4
1
48 49 50 51 52 53 54
E2
30
25
29
26
B21
A: B134
A13
A12
A4
A3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
A: B134 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
C: B136 ECM
D: B137
C: B136
A2
D1
C5
C6
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
B21
D: B137
35
36
E2
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
E E
EN-02445
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
2) Measure the resistance between ECM con- tor.
nector and chassis ground. NOTE:
(B137) No. 1 — Chassis ground: ECM connector
and engine ground
terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair the battery Replace the ECM.
EGR SOLENOID VALVE CONNECTOR. short in harness <Ref. to FU(H4SO
1) Turn the ignition switch to OFF. between ECM and 2.0)-34, Engine
2) Disconnect the connector from EGR sole- EGR solenoid Control Module
noid valve. valve connector. (ECM).>
3) Turn the ignition switch to ON. After repairing,
4) Measure the voltage between ECM con- replace the ECM.
nector and chassis ground. <Ref. to FU(H4SO
DTC P1493; (B134) No. 13 (+) — Chassis Control Module
ground ("): (ECM).>
DTC P1495; (B134) No. 12 (+) — Chassis
ground ("):
DTC P1497; (B134) No. 3 (+) — Chassis
ground ("):
DTC P1499; (B134) No. 4 (+) — Chassis
ground ("):
BO:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
LHD E
15
13
RHD
16
14
STARTER
RELAY
B225
LHD
16
14
RHD
15
13
P N
AT 11 7
12 12
MT
B12 T3 T7
STARTER MOTOR
MT
AT
E
M
B14
23
B135
ECM
B72 B225
B135 B12 T7
1 2 9 13 17 21 1 2 3 4 1 2 3 4 5 6
1 2 3 1 2 3
10 14 18 22 4 5 6 7
4 5 6 3 4 5 6 7 8 7 8 9 10 11 12
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19
9 10 11 12
5 6 20 21 22 23 24 25 26 27
7 8 28 29 30 31 32 33 34 35
25 29 33 37
26 30 34 38
27 28 31 32 35 36 39 40
EN-02428
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check starter
Place the inhibitor switch in the “P” or “N” when ignition switch to ness and connec- motor circuit. <Ref.
range. START? tor. to EN(H4SO
NOTE: 2.0)(diag)-52,
In this case, repair STARTER
the following: MOTOR CIR-
• Open or ground CUIT, Diagnostics
short circuit in har- for Engine Start-
ness between ing Failure.>
ECM and starter
motor connector
• Poor contact in
ECM connector
BP:DTC P1521 BRAKE SWITCH CIRCUIT RANGE/PERFORMANCE PROBLEM

(HIGH INPUT)
CAUTION:
WIRING DIAGRAM:
BATTERY
No.4 SBF-9 SBF-1
E
4
BREKE SWITCH
B65
1
12
B137
ECM
B65 B137
1 2 1 2 3 4 5 6 7
3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-02545
Step Check Yes No

chassis ground.
1) Turn the ignition switch to ON. short circuit
2) Measure the voltage between brake switch between ECM and
connectors. brake switch.
3 CHECK BRAKE SWITCH. Is the resistance less than 1 Go to step 4. Replace the brake
1) Turn the ignition switch to OFF. &? switch. <Ref. to
2) Measure the resistance between ECM and CC-6, Stop Light
chassis ground with brake pedal depressed. and Brake
Terminal Switch.>
(B65) No. 1 — (B65) No. 4:
4 CHECK BRAKE SWITCH. Is the resistance more than 1 Check the poor Replace the brake
Measure the resistance between brake switch M&? contact in ECM switch. <Ref. to
connectors with brake pedal depressed. connector. CC-6, Stop Light
Terminal and Brake
(B65) No. 1 — (B65) No. 4: Switch.>
BQ:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
1
2 IGNITION
B72 BATTERY
SWITCH
6 3
B14
B13
C7
C3
C4
A: B134
B: B135
ECM
C: B136
D: B137
C1
A2
B5
B6
C2
A7
C5
C6
D1
B21
52
34
36
35
37
E2
E E
A: B134 B: B135 C: B136

B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33 28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
D: B137
34 35 36 37 38 39 40 41
42 43 44 45 46 47 B72 B47
48 49 50 51 52 53 54 1 2 3 4 5 6 7
1 2 3 1 2 8 9 10 11 12 13 14 15 16 17
4 5 6 3 4 18 19 20 21 22 23 24 25
5 6 26 27 28 29 30 31
EN-02429
Step Check Yes No

1 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the poor Go to step 2.
1) Turn the ignition switch to OFF. contact in ECM
2) Measure the voltage between ECM and connector.
chassis ground.
2 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the ground Go to step 3.
MAIN FUSE BOX CONNECTOR. &? short circuit in har-
1) Disconnect the connector from ECM. ness between
2) Measure the resistance of harness ECM connector
between ECM and chassis ground. and battery termi-
Connector & terminal nal.
3 CHECK FUSE No. 13. Is the fuse blown out? 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
BR:DTC P2100 THROTTLE CONTROL MOTOR CIRCUIT OPEN

NOTE:
Refer to DTC P2101 for diagnostic procedure. <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE
BS:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

1 CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Go to step 2. Replace the elec-
TROL RELAY. &? tronic throttle con-
1) Turn the ignition switch to OFF. trol relay.
2) Remove the electronic throttle control relay.
3) Connect the battery to electronic throttle
control relay terminals No. 5 and No. 6.
4) Measure the resistance between electronic
throttle control relay terminals.
Terminals
No. 7 — No. 8:
2 CHECK POWER SUPPLY OF ELECTRONIC Is the voltage more than 10 V? Go to step 3. Repair the open or
THROTTLE CONTROL RELAY. ground short cir-
Measure the voltage between electronic throt- cuit of power sup-
tle control relay connector and chassis ground. ply circuit.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 10 V? Go to step 4. Repair the power
ELECTRONIC THROTTLE CONTROL RE- supply short cir-
LAY. cuit in harness
2) Turn the ignition switch to ON. electronic throttle
3) Measure the voltage between electronic control.
throttle control relay connector and chassis
ground.
ELECTRONIC THROTTLE CONTROL RE- M&? short circuit in har-
LAY. ness between
1) Turn the ignition switch to OFF. ECM and elec-
2) Measure the resistance between electronic tronic throttle con-
throttle control relay connector and chassis trol relay.
ground.
ELECTRONIC THROTTLE CONTROL RE- &? circuit in harness
LAY. between ECM and
Measure the resistance between ECM connec- electronic throttle
tor and electronic throttle control relay connec- control relay.
tor.
(B137) No. 9 — (B362) No. 6:
(B137) No. 6 — (B362) No. 8:
(B137) No. 7 — (B362) No. 8:
1) Connect all the connectors.
nector terminals.
(B137) No. 24 (+) — (B136) No. 8 ("):
7 CHECK SENSOR OUTPUT. Is the voltage less than 4.8 V? Go to step 8. Go to step 9.
terminals.
(B137) No. 23 (+) — (B136) No. 18 ("):
Step Check Yes No

8 CHECK POOR CONTACT. Is there poor contact? Repair the poor Go to step 13.
Check poor contact in connector between contact.
ECM and electronic throttle control.
throttle control.
(B136) No. 17 — (E78) No. 4:
(B137) No. 23 — (E78) No. 5:
(B137) No. 24 — (E78) No. 2:
ELECTRONIC THROTTLE CONTROL. M&? short circuit of har-
Measure the resistance between ECM connec- ness.
11 CHECK SENSOR POWER SUPPLY. Is the voltage 4.5 — 5.5 V? Go to step 12. Repair the poor
trol Module
(ECM).>
12 CHECK SHORT CIRCUIT IN ECM. Is the resistance more than 10 Go to step 13. Repair the poor
1) Turn the ignition switch to OFF. &? contact in ECM
2) Measure the resistance between electronic connector.
throttle control connector and engine ground. Replace the ECM
Connector & terminal if defective. <Ref.
(E78) No. 2 — Engine ground: to FU(H4SO 2.0)-
trol Module
(ECM).>
13 CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 14. Go to step 16.
14 CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 15. Go to step 16.
Read the data of sub throttle sensor signal
Step Check Yes No

throttle control.
(B136) No. 18 — (E78) No. 1:
(B137) No. 23 — (E78) No. 5:
(B137) No. 24 — (E78) No. 2:
trol Module
(ECM).>
1) Turn the ignition switch to ON. ness between
2) Measure the voltage between electronic ECM connector
throttle control connector and engine ground. and electronic
Connector & terminal throttle control
(E78) No. 4 (+) — Engine ground ("): connector.
19 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 10 V? Go to step 20. Repair the short
ELECTRONIC THROTTLE CONTROL. circuit in harness
Measure the voltage between electronic throt- between ECM
tle control connector and engine ground. connector and
Connector & terminal electronic throttle
(E78) No. 5 (+) — Engine ground ("): control connector.
20 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 21. Repair the short
ELECTRONIC THROTTLE CONTROL. M&? circuit to sensor
1) Turn the ignition switch to OFF. power supply.
2) Remove the ECM.
nectors.
(B137) No. 23 — (B136) No. 17:
(B137) No. 24 — (B136) No. 17:
21 CHECK SENSOR OUTPUT. Is the voltage 0.5 — 1.0 V? Go to step 22. Repair the poor
1) Turn the ignition switch to OFF. contact of elec-
2) Connect the connectors except for the electronic throttle con-
tric control throttle relay. trol connector.
3) Turn the ignition switch to ON. Replace the elec-
4) Read the data of main throttle sensor signal tronic throttle con-
using Subaru Select Monitor. trol if defective.
Read the data of sub throttle sensor signal contact in ECM
using Subaru Select Monitor. connector.
Replace the elec-
tronic throttle con-
trol if defective.
Step Check Yes No

ELECTRONIC THROTTLE CONTROL MO- &? circuit of harness
TOR. connector.
throttle control.
(B137) No. 2 — (E78) No. 3:
(B137) No. 3 — (E78) No. 3:
(B137) No. 4 — (E78) No. 6:
(B137) No. 5 — (E78) No. 6:
ELECTRONIC THROTTLE CONTROL MO- supply short cir-
TOR. cuit in harness
1) Connect the connector to ECM. between ECM and
3) Measure the voltage between electronic control.
throttle control connector and engine ground.
ELECTRONIC THROTTLE CONTROL MO- M&? circuit of harness.
TOR.
26 CHECK ELECTRONIC THROTTLE CON- Is the resistance more than 1 Go to step 27. Repair the short
TROL MOTOR HARNESS. M&? circuit of harness.
Measure the resistance between electronic
throttle control connector terminals.
(E78) No. 3 — (E78) No. 6:
27 CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 10 Go to step 28. Repair the open
TROL GROUND CIRCUIT. &? circuit of harness.
Measure the resistance between ECM connec-
TROL. &? tronic throttle con-
Measure the resistance between electronic trol.
throttle control terminals.
Terminals
No. 1 — No. 2:
Step Check Yes No

29 CHECK ELECTRONIC THROTTLE CON- Does the valve return to the Repair the poor Replace the elec-
TROL. specified position? contact in ECM tronic throttle con-
Move the throttle valve to the fully open and Standard value: 3 mm (0.12 in) connector. trol.
fully closed positions with fingers. from fully closed position Replace the ECM
Check that the valve returns to the specified if defective. <Ref.
position when releasing fingers. to FU(H4SO 2.0)-
34, Engine Con-
trol Module
(ECM).>
BT:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

TROL RELAY. &? tronic throttle con-
Terminals
No. 7 — No. 8:
ELECTRONIC THROTTLE CONTROL RE- supply short cir-
LAY. cuit in harness
3) Measure the voltage between electronic control relay.
ground.
ELECTRONIC THROTTLE CONTROL RE- M&? short circuit in har-
LAY. ness between
ground.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the poor Repair the open
ELECTRONIC THROTTLE CONTROL RE- &? contact in ECM circuit in harness
LAY. connector. between ECM and
Measure the resistance between ECM connec- Replace the ECM electronic throttle
tor and electronic throttle control relay connec- if defective. <Ref. control relay.
tor. to FU(H4SO 2.0)-
(B137) No. 9 — (B362) No. 6: trol Module
(B137) No. 6 — (B362) No. 8: (ECM).>
(B137) No. 7 — (B362) No. 8:
BU:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

1 CHECK ELECTRONIC THROTTLE CON- Is the resistance more than 1 Go to step 2. Replace the elec-
TROL RELAY. M&? tronic throttle con-
Terminals
No. 7 — No. 8:
2 CHECK POWER SUPPLY SHORT CIRCUIT Is the voltage more than 5 V? Go to step 3. Repair the power
OF ELECTRONIC THROTTLE CONTROL supply short cir-
RELAY. cuit in harness
1) Turn the ignition switch to ON. between ECM and
2) Measure the voltage between electronic electronic throttle
throttle control relay connector and chassis control relay.
ground.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Repair the poor Repair the ground
ELECTRONIC THROTTLE CONTROL RE- M&? contact in ECM short circuit in har-
LAY. connector. ness between
1) Turn the ignition switch to OFF. Replace the ECM ECM and elec-
2) Disconnect the connector from ECM. if defective. <Ref. tronic throttle con-
3) Measure the resistance between ECM con- to FU(H4SO 2.0)- trol relay.
nector and chassis ground. 34, Engine Con-
Connector & terminal trol Module
(B137) No. 9 — Chassis ground: (ECM).>
BV:DTC P2109 THROTTLE ANGLE CLOSED POSITION ERROR

NOTE:
BW:DTC P2111 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK OPEN
NOTE:
BX:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB
B315
ACCELERATOR
PEDAL POSITION 1 2 3 4 5 6
SENSOR
B138
3
B315 B122
B83
AT B138 :LHD
1 1 2 3 4
5 5 6 7 8
B122 :RHD
MT
AT B21
B83 :LHD
2
1 1 2 3 4 5 6 7 8 9 10 11
B138 :RHD
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
D19
D25
D29
D31
C17
D30
C18
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134
C: B136 ECM
D: B137 A: B134
1 2 3 4 5 6 7
D1
A2
C1
C2
C6
C5
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
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
37
36
35
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
D: B137
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
E
EN-02449
Step Check Yes No

1 CHECK ACCELERATOR POSITION SEN- Is the voltage more than 0.4 V? Go to step 2. Go to step 3.
SOR OUTPUT.
2) Read the data of main accelerator position
ECM and accelerator position sensor. but it is normal at
present.
3 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Go to step 4. Repair the open
CELERATOR POSITION SENSOR. &? circuit of harness
3) Disconnect the connector from accelerator
position sensor.
nector and accelerator position sensor connec-
tor.
(B137) No. 29 — (B315) No. 5:
(B137) No. 25 — (B315) No. 3:
4 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1 Go to step 5. Repair the chas-
CELERATOR POSITION SENSOR. M&? sis short circuit of
5 CHECK POWER SUPPLY OF ACCELERA- Is the voltage 4.5 — 5.5 V? Go to step 6. Repair the poor
TOR POSITION SENSOR. contact in ECM
3) Measure the voltage between accelerator if defective. <Ref.
position sensor connector and engine ground. to FU(H4SO 2.0)-
(B315) No. 3 (+) — Engine ground ("): trol Module
(ECM).>
6 CHECK ACCELERATOR POSITION SEN- Is the resistance 1.2 — 4.8 Go to step 7. Replace the accel-
SOR. k&? erator position
Measure the resistance of accelerator position sensor.
sensor.
Terminals
No. 3 — No. 4:
sensor.
Terminals
No. 5 — No. 4:
Check the measured value is within the specifi-
cation without depressing the accelerator
pedal.
Step Check Yes No

8 CHECK ACCELERATOR POSITION SEN- Is the resistance 0.5 — 2.5 Repair the poor Replace the accel-
SOR. k&? contact in ECM erator position
Measure the resistance of accelerator position connector. sensor.
sensor. Replace the ECM
Terminals if defective. <Ref.
No. 5 — No. 4: to FU(H4SO 2.0)-
Check the measured value is within the specifi- 34, Engine Con-
cation with the accelerator pedal depressed. trol Module
(ECM).>
BY:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB
B315
ACCELERATOR
SENSOR
B138
3
B315 B122
B83
AT B138 :LHD
1 1 2 3 4
5 5 6 7 8
B122 :RHD
MT
AT B21
B83 :LHD
2
1 1 2 3 4 5 6 7 8 9 10 11
B138 :RHD
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
D19
D25
D29
D31
C17
D30
C18
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134
C: B136 ECM
D: B137 A: B134
1 2 3 4 5 6 7
D1
A2
C1
C2
C6
C5
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
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
37
36
35
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
D: B137
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
E
EN-02449
Step Check Yes No

1 CHECK ACCELERATOR POSITION SEN- Is the voltage less than 4.8 V? Go to step 2. Go to step 3.
SOR OUTPUT.
present.
position sensor.
tor.
(B137) No. 31 — (B315) No. 4:
4 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Go to step 5. Repair the poor
CELERATOR POSITION SENSOR. &? contact in ECM
2) Measure the resistance between accelera- Replace the ECM
tor position sensor connector and engine if defective. <Ref.
ground. to FU(H4SO 2.0)-
(B315) No. 4 — Engine ground: trol Module
(ECM).>
5 CHECK HARNESS BETWEEN ECM AND AC- Is the voltage less than 6 V? Go to step 6. Repair the battery
CELERATOR POSITION SENSOR. short circuit in har-
1) Connect the ECM connector. ness between
2) Turn the ignition switch to ON. ECM connector
3) Measure the voltage between accelerator and accelerator
position sensor connector and engine ground. position sensor
Connector & terminal connector.
6 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1 Repair the poor Repair the short
CELERATOR POSITION SENSOR. M&? contact in acceler- circuit to sensor
1) Turn the ignition switch to OFF. ator position sen- power supply.
2) Disconnect the connector from ECM. sor connector.
3) Measure the resistance between ECM con- Replace the accel-
nectors. erator position
Connector & terminal sensor if defective.
(B137) No. 29 — (B137) No. 25:
(B137) No. 29 — (B136) No. 17:
BZ:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB
B315
ACCELERATOR
SENSOR
B138
3
B315 B122
B83
AT B138 :LHD
1 1 2 3 4
5 5 6 7 8
B122 :RHD
MT
AT B21
B83 :LHD
2
1 1 2 3 4 5 6 7 8 9 10 11
B138 :RHD
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
D19
D25
D29
D31
C17
D30
C18
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134
C: B136 ECM
D: B137 A: B134
1 2 3 4 5 6 7
D1
A2
C1
C2
C6
C5
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
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
37
36
35
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
D: B137
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
E
EN-02449
Step Check Yes No

SOR OUTPUT.
2) Read the data of sub accelerator position
present.
position sensor.
tor.
(B137) No. 30 — (B315) No. 2:
(B136) No. 17 — (B315) No. 1:
CELERATOR POSITION SENSOR. M&? sis short circuit of
(ECM).>
sensor.
Terminals
No. 1 — No. 6:
1) Measure the resistance of accelerator posi- sensor.
tion sensor.
Terminals
No. 2 — No. 6:
2) Check the measured value is within the
specification without depressing the accelera-
tor pedal.
Step Check Yes No

SOR. k&? contact in ECM erator position
1) Measure the resistance of accelerator posi- connector. sensor.
tion sensor. Replace the ECM
No. 2 — No. 6: to FU(H4SO 2.0)-
2) Check the measured value is within the 34, Engine Con-
specification with the accelerator pedal trol Module
depressed. (ECM).>
CA:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB
B315
ACCELERATOR
SENSOR
B138
3
B315 B122
B83
AT B138 :LHD
1 1 2 3 4
5 5 6 7 8
B122 :RHD
MT
AT B21
B83 :LHD
2
1 1 2 3 4 5 6 7 8 9 10 11
B138 :RHD
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
D19
D25
D29
D31
C17
D30
C18
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134
C: B136 ECM
D: B137 A: B134
1 2 3 4 5 6 7
D1
A2
C1
C2
C6
C5
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
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
37
36
35
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
D: B137
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
E
EN-02449
Step Check Yes No

SOR OUTPUT.
present.
position sensor.
tor.
(B136) No. 18 — (B315) No. 6:
(ECM).>
CELERATOR POSITION SENSOR. M&? contact in acceler- circuit to sensor
(B137) No. 30 — (B137) No. 25:
(B137) No. 30 — (B136) No. 17:
CB:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” / “B”

VOLTAGE RATIONALITY
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
8 MAIN RELAY
D9
D6
D7
ECM
A: B134 C: B136 D: B137 E
C30
D23
D24
C17
C18
C1
C2
C5
C6
A2
D1
D4
D5
D2
D3
B83 :LHD
B138 :RHD
1 7 B83 :LHD
5 3 B138 :RHD
B21 B20
37
36
35
20
39
38
19
15
16
E2 E1
4
5
6
2
3
1
E ELECTRONIC
THROTTLE CONTROL
E
E78
B362 B83 B21 B20 E78
B138 1 2 3 4 1 2 3
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 4 5 6
1 2
4 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5 5 6 7 8
7 8
6
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02440
Step Check Yes No

3) Disconnect the connectors from the elec-
tronic throttle control.
(B137) No. 23 — (E78) No. 5:
(B137) No. 24 — (E78) No. 2:
(B136) No. 17 — (E78) No. 4:
ELECTRONIC THROTTLE CONTROL. M&? short circuit of har-
trol Module
(ECM).>
1) Turn the ignition switch to OFF. &? contact in ECM
trol Module
(ECM).>
1) Connect all the connectors. V?
Read the data of sub throttle sensor signal V?
Step Check Yes No

present.
throttle control.
(B137) No. 23 — (E78) No. 5:
(B137) No. 24 — (E78) No. 2:
(B136) No. 17 — (E78) No. 4:
trol Module
(ECM).>
3) Measure the voltage between electronic and electronic
throttle control connector and engine ground. throttle control
ELECTRONIC THROTTLE CONTROL. M&? circuit to sensor
nectors.
(B137) No. 23 — (B136) No. 17:
(B137) No. 24 — (B136) No. 17:
16 CHECK ELECTRONIC THROTTLE CON- Is the resistance more than 1 Repair the poor Repair the short
TROL HARNESS. M&? contact in ECM circuit of harness.
1) Disconnect the connector from ECM. connector.
2) Disconnect the connectors from electronic Replace the ECM
throttle control. if defective. <Ref.
3) Measure the resistance between electronic to FU(H4SO 2.0)-
throttle control connector terminals. 34, Engine Con-
(E78) No. 5 — (E78) No. 2: (ECM).>
CC:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” / “E”

VOLTAGE RATIONALITY
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB
B315
ACCELERATOR
SENSOR
B138
3
B315 B122
B83
AT B138 :LHD
1 1 2 3 4
5 5 6 7 8
B122 :RHD
MT
AT B21
B83 :LHD
2
1 1 2 3 4 5 6 7 8 9 10 11
B138 :RHD
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
D19
D25
D29
D31
C17
D30
C18
42 43 44 45 46 47
48 49 50 51 52 53 54
A: B134
C: B136 ECM
D: B137 A: B134
1 2 3 4 5 6 7
D1
A2
C1
C2
C6
C5
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
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
37
36
35
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
D: B137
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
E
EN-02449
Step Check Yes No

SOR OUTPUT.
sensor signal and sub accelerator position
ECM and accelerator position sensor.
position sensor.
tor.
(B137) No. 29 — (B315) No. 5:
(B137) No. 25 — (B315) No. 3:
(B137) No. 30 — (B315) No. 2:
(B136) No. 17 — (B315) No. 1:
4 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1 Go to step 5. Repair the ground
CELERATOR POSITION SENSOR. M&? short circuit of har-
(B315) No. 1 (+) — Engine ground ("): (ECM).>
sensor.
Terminals
No. 3 — No. 4:
sensor.
Terminals
No. 1 — No. 6:
sensor without depressing the accelerator
pedal.
Terminals
No. 5 — No. 4:
Step Check Yes No

pedal.
Terminals
No. 2 — No. 6:
sensor with the accelerator pedal depressed.
Terminals
No. 5 — No. 4:
Terminals
No. 2 — No. 6:
SOR OUTPUT.
and sub accelerator position sensor signal
position sensor.
tor.
(B137) No. 31 — (B315) No. 4:
(B136) No. 18 — (B315) No. 6:
(B315) No. 6 — Engine ground: (ECM).>
Step Check Yes No

17 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1 Go to step 18. Repair the short
CELERATOR POSITION SENSOR. M&? circuit to sensor
nectors.
(B137) No. 29 — (B137) No. 25:
(B137) No. 29 — (B136) No. 17:
(B137) No. 30 — (B137) No. 25:
(B137) No. 30 — (B136) No. 17:
CELERATOR POSITION SENSOR. M&? contact in ECM circuit in harness
1) Turn the ignition switch to OFF. connector. between ECM
2) Disconnect the connector from ECM. Replace the ECM connector and
3) Disconnect the connector from the acceler- if defective. <Ref. accelerator posi-
ator position sensor. to FU(H4SO 2.0)- tion sensor con-
4) Measure the resistance between connector 34, Engine Con- nector.
terminals of accelerator position sensor. trol Module
Connector & terminal (ECM).>
(B315) No. 5 — (B315) No. 2:
19.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in
General.>
Symptom Problem parts
1) Manifold absolute pressure sensor
2) Intake air temperature sensor
3) Ignition parts (*1)
1. 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
7) Electronic throttle control
10) Oxygen sensor
11) Fuel pump and fuel pump relay
12) EGR valve
1) Engine coolant temperature sensor
3. Engine does not return to idle. 3) Manifold absolute pressure sensor
5) EGR valve
4. Poor acceleration
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
12) EGR valve
5. Engine stalls, engine sags or hesitates at accel- 5) Camshaft position sensor (*3)
eration. 6) Purge control solenoid valve
10) EGR valve

6. Surge 5) Camshaft position sensor (*3)
9) EGR valve
7. Spark knock 4) Knock sensor
7) EGR valve
8. After burning in exhaust system 3) Engine coolant temperature sensor (*2)
*1: Check ignition coil & ignitor ASSY and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check the fuel injector and fuel pressure regulator.
*5: Inspect air leak in air intake system.
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
FUEL INJECTION
(FUEL SYSTEMS)
FU(H4SO 2.5)
Page
2. Throttle Body...........................................................................................11
3. Intake Manifold ........................................................................................12
4. Engine Coolant Temperature Sensor....................................................20
5. Crankshaft Position Sensor ...................................................................21
6. Camshaft Position Sensor .....................................................................22
7. Knock Sensor ..........................................................................................23
8. Throttle Position Sensor ........................................................................24
9. Manifold Absolute Pressure Sensor .....................................................25
10. Mass Air Flow and Intake Air Temperature Sensor .............................26
11. Intake Air Temperature Sensor..............................................................27
12. Tumble Generator Valve Assembly.......................................................28
13. Tumble Generator Valve Actuator .........................................................29
14. EGR Valve ................................................................................................30
15. Fuel Injector.............................................................................................31
16. Front Oxygen (A/F) Sensor ....................................................................34
17. Rear Oxygen Sensor...............................................................................35
18. Engine Control Module (ECM) ...............................................................36
19. Main Relay ...............................................................................................37
20. Fuel Pump Relay .....................................................................................38
21. Electronic Throttle Control Relay ..........................................................39
22. Fuel...........................................................................................................40
23. Fuel Tank .................................................................................................41
24. Fuel Filler Pipe.........................................................................................47
25. Fuel Pump................................................................................................49
26. Fuel Level Sensor ...................................................................................51
27. Fuel Sub Level Sensor............................................................................52
28. Fuel Filter .................................................................................................53
29. Fuel Damper Valve ..................................................................................54
30. Fuel Delivery, Return and Evaporation Lines.......................................55
31. Fuel System Trouble in General ............................................................58
General Description
A: SPECIFICATION
Fuel tank
Type Impeller
Fuel pump
75 2 (19.8 US gal, 16.5 Imp gal)/h or more
Discharge
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(H4SO 2.5)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T2
(7) (18)
T2
T2
T4 T6
T4
T4
T2 T2 T4
T4 (8)
(17) (10)
(17) T6
(9) T3
T4
(24)
(11) T4 T4
T3
T3
T6
(15) (23) (25)
(1) T4
(13)
(2) T2
(12)
(15)
(14)
(11)
(13)
(16) T4
(12)
T4 T5
(14) (5)
T5
(5) (2) T7
(3) (15) (15)
T7 (13) (13)
(12)
(6) (12)
(14)
T4 (14)
(3)
(4)
(22) T1
(20)
(21) (4)
(6)
(21)
(19)
(21)
T1
T1
(20)
T2
T1
(21)
FU-02096
FU(H4SO 2.5)-3
General Description
(1) Intake manifold (11) Fuel injector pipe (24) Nipple (RHD model)
(2) Gasket (EC, EK and K4 model) (12) Fuel injector (25) Nipple (LHD model)
(3) Tumble generator valve ASSY (13) O-ring
(EC, EK and K4 model) (14) O-ring Tightening torque: N!m (kgf-m, ft-lb)
(4) Gasket (15) O-ring T1: 1.5 (0.15, 1.1)
(5) Tumble generator valve actuator (16) Purge control solenoid valve T2: 6.4 (0.65, 4.7)
(EC, EK and K4 model) (17) Plug cord holder T3: 8.75 (0.89, 6.5)
(6) Guide pin (18) Nipple T4: 19 (1.9, 13.7)
(7) PCV pipe (EC, EK and K4 model) (19) Fuel pipe ASSY T5: 25 (2.5, 18.1)
(8) EGR valve (EC, EK and K4 (20) Fuel hose T6: 17 (1.7, 12.5)
model) (21) Clip T7: 6 (0.61, 4.4)
(9) Fuel pipe protector RH (22) Pressure regulator
(10) Fuel pipe protector LH (23) Gasket (EC, EK and K4 model)
FU(H4SO 2.5)-4
General Description
T2
T1
(3)
(4)
(1)
(2)
FU-01079
(1) Gasket (4) O-ring Tightening torque: N!m (kgf-m, ft-lb)

(2) Throttle body T1: 2.0 (0.2, 1.5)
(3) Manifold absolute pressure sensor T2: 8 (0.8, 5.8)
FU(H4SO 2.5)-5
General Description
T1
T2
(1)
(2)
T1
(3)
(4) T1
FU-00414
(1) Crankshaft position sensor (4) Camshaft position sensor support Tightening torque: N!m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor T2: 24 (2.4, 17.4)
FU(H4SO 2.5)-6
General Description
4. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8) (17) T1
(14)
(7)
(15)
(10)
(9) (12)
(11)
(1)
(13)
(22)
T4 (6)
(5) (22)
(20)
(3)
(2) T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2 T3
FU-01080
FU(H4SO 2.5)-7
General Description
(7) Fuel pump assembly (18) Fuel tank protector RH (Rear) T1: 4.4 (0.45, 3.3)
FU(H4SO 2.5)-8
General Description
5. FUEL LINE
T1 (1)
(28)
(26) (18)
(23)
(25) (19) (17) (15)

(27) (1)
(20) (22) (14)
(13)
(24)
(21) (1) A (16)
T2 (1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
B T3
T2
(4) (1)
(5) A
(1) T2
B
(3) (1)
(2) (33)
(1) (9)
(32)
(6)
(1) (7) (30) (31)
(8)
FU-01081
FU(H4SO 2.5)-9
General Description

(3) Evaporation hose A (16) Purge hose B (29) Clip
(6) Fuel damper (19) Two-way valve drain hose (32) Connector
(7) Fuel damper holder (20) Two-way valve (33) Purge pipe
(8) Fuel damper bracket (21) Two-way valve hose C (34) Two-way valve bracket

D: PREPARATION TOOL
ST24082AA230
ST22771AA030
FU(H4SO 2.5)-10
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203

3) Disconnect the connectors from the throttle posi-
tion sensor and manifold absolute pressure sensor.
(B) (A)
FU-01083
(A) Throttle position sensor

(B) Manifold absolute pressure sensor
4) Disconnect the engine coolant hoses (A) from

throttle body.
5) Remove the bolts (B) which secure throttle body
to intake manifold.
(B)
(A)
(B)
(A) FU-01084
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
8 N!m (0.8 kgf-m, 5.8 ft-lb)
FU(H4SO 2.5)-11
Intake Manifold
3. Intake Manifold 10) Disconnect the connectors from engine coolant

temperature sensor.
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(H4SO
2.5)-40, RELEASING OF FUEL PRESSURE,
PROCEDURE, Fuel.>
filler cap.
FU-00055
IN-00203

chamber. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
5) Disconnect the spark plug cords from spark FU-01334
plugs. 12) Disconnect the connector from crankshaft posi-

6) Disconnect the engine coolant hoses (A) from tion sensor.
throttle body.
(A)
FU-00056
(A) FU-01085
13) Disconnect the connector from power steering
7) Disconnect the PCV hose (A) from intake mani- pump switch (A).
fold. 14) Disconnect the connector from oil pressure
8) Disconnect the brake booster hose (B). switch (B).
9) Disconnect the engine harness connectors (C)
from bulkhead harness connectors.
(B)
(B)
(A)
(A)
(C)
FU-01087
FU-01086
FU(H4SO 2.5)-12
Intake Manifold
15) Disconnect the connector from camshaft posi- 18) Remove the bolts which secure intake manifold
tion sensor. to cylinder head.
FU-01335 FU-01089
16) Remove the EGR pipe from intake manifold. 19) Remove the intake manifold.
(EC, EK and K4 model)
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
FU-00148
17) Disconnect the fuel hoses from fuel pipes.

WARNING:
• Be careful not to spill fuel.
• Catch the fuel from hoses using a container
or cloth.
FU-01089
(A)
2) Connect the fuel hoses.
NOTE:
If fuel hoses or clamps are damaged, replace them
with new ones.
(C) (A)
(B)
FU-01088
(A) Fuel delivery hose (C)

(B)
(B) Return hose
FU-01088

(B) Return hose
Tightening torque (Hose clamp screw):

1.25 N!m (0.13 kgf-m, 0.94 ft-lb)
FU(H4SO 2.5)-13
Intake Manifold
3) Install the EGR pipe to intake manifold. (EC, EK 8) Connect the knock sensor connector.
and K4 model)
Tightening torque:
34 N!m (3.4 kgf-m, 24.6 ft-lb)
FU-01334
9) Connect the connectors to engine coolant tem-

perature sensor.
FU-00148
4) Connect the connector to camshaft position sen-

sor.
FU-00055
10) Connect the PCV hose (A) to intake manifold.

11) Connect the brake booster hose (B).
FU-01335 12) Connect the engine harness connectors (C) to
bulkhead harness connectors.
5) Connect the connector to power steering pump
switch (A). (B)
6) Connect the connector to oil pressure switch (B).
(A)
(C)
(B)
(A)
FU-01086
13) Connect the engine coolant hoses (A) to throt-

FU-01087
tle body.
7) Connect the connector to crankshaft position (A)
sensor.
(A) FU-01085
14) Connect the spark plug cords to spark plugs.

FU-00056
FU(H4SO 2.5)-14
Intake Manifold
15) Install the air cleaner case and air intake cham- 6) Disconnect the pressure regulator vacuum hose
ber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air (A) from intake manifold.
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTAL-
LATION, Air Intake Chamber.>
(A)
FU-01092
IN-00203
C: DISASSEMBLY
1) Disconnect the engine ground terminal from in-
take manifold.
FU-01093
FU-01090
2) Remove the ignition coil & ignitor ASSY. <Ref. to

IG(H4SO 2.0)-8, REMOVAL, Ignition Coil & Ignitor
ASSY.>
3) Remove the throttle body. <Ref. to FU(H4SO
2.5)-11, REMOVAL, Throttle Body.>
FU-01094
4) Remove the EGR valve. (EC, EK and K4 model)
<Ref. to FU(H4SO 2.5)-30, REMOVAL, EGR 9) Disconnect the connectors (A) from fuel injector.
Valve.> 10) Remove the harness band (B) which holds en-
5) Remove the PCV pipe. (EC, EK and K4 model) gine harness to injector pipe.
(B)
FU-01091 (A) FU-01336
11) Remove the tumble generator valve actuator.

(EC, EK and K4 model) <Ref. to FU(H4SO 2.5)-29,
REMOVAL, Tumble Generator Valve Actuator.>
FU(H4SO 2.5)-15
Intake Manifold
12) Remove the purge control solenoid valve. • LH side

<Ref. to EC(H4SO 2.0)-7, REMOVAL, Purge Con-
trol Solenoid Valve.>
13) Remove the harness band clips which install
the engine harness.
FU-01099
FU-01096
14) Remove the bolts which hold the engine har-

ness to intake manifold.
FU-01100
17) Remove the fuel injectors from injector pipe.

RH to fuel hose, and then disconnect the pipe from
fuel hose.
FU-01097
15) Remove the engine harness from intake mani-

fold.
16) Remove the bolts which install injector pipe on
the intake manifold as shown in the figure.
• RH side
FU-01101

LH to fuel hose, and then disconnect the pipe from
fuel hose.
FU-01098
FU-01102

21) Remove the bolt which installs pressure regu-
lator on intake manifold.
FU(H4SO 2.5)-16
Intake Manifold
22) Remove the bolt which installs the fuel pipes on 2) Tighten the bolt which installs the fuel pipes on
intake manifold. intake manifold.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-01337
23) Remove the fuel pipe assembly and pressure

regulator, from intake manifold. FU-01337
24) Remove the intake manifold. (EC, EK and K4
model) 3) Tighten the bolt which installs pressure regulator
on intake manifold.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
4) Connect the fuel injector pipe.
5) Connect the fuel injector pipe LH to fuel hose,
FU-01104
D: ASSEMBLY
1) Install the intake manifold. (EC, EK and K4 mod-
el)
NOTE:
• Use a new gasket. FU-01102
• When assembling the nipple, apply liquid gasket.
6) Connect the fuel injector pipe RH to fuel hose,
Liquid gasket: and tighten the clamp screw.
Tightening torque:
8.75 N!m (0.89 kgf-m, 6.5 ft-lb)
FU-01101
7) Install the fuel injectors.
FU-01104
FU(H4SO 2.5)-17
Intake Manifold
8) Tighten the bolts which install injector pipe on in- 11) Tighten the bolts which install engine harness
take manifold. on intake manifold.
• RH side
Tightening torque:
Tightening torque: 16 N!m (1.6 kgf-m, 11.8 ft-lb)
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01097
FU-01098
12) Hold the engine harness by harness band clips.
• LH side
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01096
13) Install the purge control solenoid valve. <Ref.

to EC(H4SO 2.0)-7, INSTALLATION, Purge Con-
FU-01099
trol Solenoid Valve.>
14) Install the tumble generator valve actuator.
9) Tighten the two bolts which install fuel pipes on (EC, EK and K4 model) <Ref. to FU(H4SO 2.5)-29,
intake manifold. INSTALLATION, Tumble Generator Valve Actua-
Tightening torque: tor.>
6.4 N!m (0.65 kgf-m, 4.7 ft-lb) 15) Connect the connectors (A) to fuel injector.
16) Hold the engine harness to injector pipe by har-
ness band (B).
(B)
FU-01100
10) Install the engine harness onto intake manifold. (A) FU-01336
FU(H4SO 2.5)-18
Intake Manifold
17) Install the fuel pipe protector RH. 21) Install the EGR valve. (EC, EK and K4 model)
<Ref. to FU(H4SO 2.5)-30, INSTALLATION, EGR
Tightening torque:
Valve.>
19 N!m (1.9 kgf-m, 13.7 ft-lb)
<Ref. to FU(H4SO 2.5)-11, INSTALLATION,
Throttle Body.>
23) Install the ignition coil & ignitor ASSY. <Ref. to
IG(H4SO 2.0)-8, INSTALLATION, Ignition Coil &
Ignitor ASSY.>
24) Install the engine ground terminal to intake
manifold.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01094
18) Install the fuel pipe protector LH.

Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01090
E: INSPECTION
FU-01093
19) Connect the pressure regulator vacuum hose

(A) to intake manifold.
(A)
FU-01092
20) Install the PCV pipe. (EC, EK and K4 model)
FU-01091
FU(H4SO 2.5)-19

Sensor
A: REMOVAL
IN-00203

temperature sensor.
FU-00055

B: INSTALLATION
Tightening torque:
18 N!m (1.8 kgf-m, 13.0 ft-lb)
FU(H4SO 2.5)-20

A: REMOVAL
T: 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-00058
FU-00056

FU-00057
FU(H4SO 2.5)-21
6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself.
A: REMOVAL
FU-00179
B: INSTALLATION
IN-00203
2) Disconnect the connector from camshaft posi- Tightening torque:
tion sensor. Camshaft position sensor support
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-01335

sensor to the support.
FU-00177
4) Remove the bolt which installs the camshaft po-

sition sensor support to camshaft cap LH.
FU-00178
5) Remove the camshaft position sensor and the

support as a unit.
FU(H4SO 2.5)-22
Knock Sensor

A: REMOVAL
Extraction area of knock sensor cord must be posi-
Tightening torque:
24 N!m (2.4 kgf-m, 17.4 ft-lb)
(A)
IN-00203

2.0)-6, REMOVAL, Air Cleaner Case.> 60
FU-00413
(A) Front side
FU-01334
FU-01334
3) Install the air cleaner case. <Ref. to IN(H4SO

2.0)-7, INSTALLATION, Air Cleaner Case.>
FU-00519
IN-00203
FU(H4SO 2.5)-23

A: SPECIFICATION
body.
procedure. <Ref. to FU(H4SO 2.5)-11, REMOVAL,
Throttle Body.> <Ref. to FU(H4SO 2.5)-11, IN-
STALLATION, Throttle Body.>
FU(H4SO 2.5)-24

Sensor
A: REMOVAL
IN-00203

lute pressure sensor.
FU-01105

from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
2.0 N!m (0.2 kgf-m, 1.5 ft-lb)
FU(H4SO 2.5)-25
Mass Air Flow and Intake Air Temperature Sensor
10.Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
NOTE:
Mass air flow and intake air temperature sensor is
installed to EC, EK and K4 model.
IN-00203
2) Disconnect the connector from mass air flow and

intake air temperature sensor.
3) Remove the mass air flow and intake air temper-
ature sensor.
FU-01106
B: INSTALLATION
Tightening torque:
1.0 N!m (0.10 kgf-m, 0.74 ft-lb)
FU(H4SO 2.5)-26
Intake Air Temperature Sensor
11.Intake Air Temperature Sen-

sor
A: REMOVAL
NOTE:
Intake air temperature sensor is installed to models
except for EC, EK and K4.
IN-00203

perature sensor.
3) Remove the intake air temperature sensor.
FU-02080
B: INSTALLATION
FU(H4SO 2.5)-27
Tumble Generator Valve Assembly
12.Tumble Generator Valve As- 7) Remove the tumble generator valve body from
intake manifold.
sembly
A: REMOVAL
NOTE:
This component is installed to EC, EK and K4 mod-
el.
filler cap. FU-01104
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
8.75 N!m (0.89 kgf-m, 6.5 ft-lb)
IN-00203

<Ref. to FU(H4SO 2.5)-12, REMOVAL, Intake
Manifold.>
5) Disconnect the connector from tumble generator
valve actuator.
FU-01107
6) Remove the fuel injectors.

<Ref. to FU(H4SO 2.5)-31, REMOVAL, Fuel In-
jector.>
FU(H4SO 2.5)-28
Tumble Generator Valve Actuator
13.Tumble Generator Valve Ac- 3) Disconnect the ground cable from battery.
tuator
A: REMOVAL
1. RH SIDE
NOTE:
This component is installed to EC, EK and K4 mod-
el.
<Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL IN-00203
PRESSURE, PROCEDURE, Fuel.> 4) Disconnect the connector from tumble generator
2) Open the fuel filler flap lid and remove the fuel valve LH.
filler cap. 5) Remove the tumble generator valve LH.
FU-01109
IN-00203
4) Remove the intake manifold. B: INSTALLATION

<Ref. to FU(H4SO 2.5)-12, REMOVAL, Intake 1. RH SIDE
Manifold.>
5) Disconnect the connector from tumble generator Install in the reverse order of removal.
valve RH. Tightening torque:
6) Remove the tumble generator valve RH. 6 N!m (0.61 kgf-m, 4.4 ft-lb)
2. LH SIDE
Tightening torque:
6 N!m (0.61 kgf-m, 4.4 ft-lb)
FU-01108
2. LH SIDE
filler cap.
FU(H4SO 2.5)-29
EGR Valve
14.EGR Valve
A: REMOVAL
NOTE:
EGR valve is installed to EC, EK and K4 model.
IN-00203
FU-01152
FU-01153
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU(H4SO 2.5)-30
Fuel Injector
15.Fuel Injector 9) Remove the bolts which hold fuel injector pipe
A: REMOVAL
1. RH SIDE
filler cap.
FU-01098

injector pipe.
IN-00203

(#1 and #3 cylinders). FU-01110
6) Remove the fuel pipe protector RH. 2. LH SIDE

filler cap.
FU-01094
7) Disconnect the connector (A) from fuel injector.

8) Remove the harness band (B) which holds en-
gine harness to injector pipe.
(B)
FU-01093
6) Disconnect the connector (A) from fuel injector.
(A) FU-01336
FU(H4SO 2.5)-31
Fuel Injector
7) Remove the harness band (B) which holds en- B: INSTALLATION

gine harness to injector pipe.
1. RH SIDE
NOTE:
(B) • Use new O-rings.
• O-ring (B) is used for EC, EK and K4 model.
(A) (A)
FU-01338
(A)
8) Remove the bolts which hold fuel injector pipe (B)
(C)
(D)
FU-02157
(A) O-ring
(B) O-ring
(C) Fuel injector
(D) O-ring
Tightening torque:
FU-01099
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01100 FU-01098
9) Remove the fuel injector while lifting up the fuel Tightening torque:
injector pipe. 19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01110
FU-01094
FU(H4SO 2.5)-32
Fuel Injector
2. LH SIDE Tightening torque:

19 N!m (1.9 kgf-m, 13.7 ft-lb)
NOTE:
• Use new O-rings.
• O-ring (B) is used for EC, EK and K4 model.
(A)
(B) FU-01093
(C)
(D)
FU-02157
(A) O-ring
(B) O-ring
(C) Fuel injector
(D) O-ring
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-01100
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-01099
FU(H4SO 2.5)-33
16.Front Oxygen (A/F) Sensor B: INSTALLATION

A: REMOVAL ply anti-seize compound only to the threaded por-
1) Disconnect the ground cable from battery. tion of front oxygen (A/F) sensor to make the next
removal easier.
SS-30 JET LUBE
CAUTION:
Tightening torque:
IN-00203 21 N!m (2.1 kgf-m, 15.2 ft-lb)
3) Remove the connector of front oxygen (A/F)
sensor.
FU-01114

ME-00859 6) Connect the connector of front oxygen (A/F)
4) Remove the clip holding harness. sensor.
one minute or more.
CAUTION:
wait until exhaust pipe cools, otherwise it will
damage the exhaust pipe. ME-00859

FU-01114
IN-00203
FU(H4SO 2.5)-34
Rear Oxygen Sensor
17.Rear Oxygen Sensor B: INSTALLATION

A: REMOVAL seize compound only to the threaded portion of
1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas-
ier.
SS-30 JET LUBE
CAUTION:
tor of rear oxygen sensor.
Tightening torque:
IN-00203 21 N!m (2.1 kgf-m, 15.2 ft-lb)
sor.
FU-01117

FU-01116

minute or more.
CAUTION:
age the exhaust pipe. FU-01116

FU-01117
IN-00203
FU(H4SO 2.5)-35
18.Engine Control Module (ECM) B: INSTALLATION

A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
Tightening torque:
5 N!m (0.5 kgf-m, 3.6 ft-lb)
IN-00203

Trim.>
FU-02090
5) Remove the nuts (A) which hold the ECM to

bracket.
(A)
(B)
(A)
FU-02091

the ECM.
FU(H4SO 2.5)-36
Main Relay
19.Main Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
FU-02093
B: INSTALLATION
FU(H4SO 2.5)-37
Fuel Pump Relay
20.Fuel Pump Relay

A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
FU-02094
B: INSTALLATION
FU(H4SO 2.5)-38

Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
4) Disconnect the connector from electric throttle

control relay.
FU-02095
B: INSTALLATION
FU(H4SO 2.5)-39
Fuel

the drain plug from fuel tank to drain fuel from fuel
A: PROCEDURE tank.
WARNING:
box.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
2) Start the engine and run it until it stalls. NOTE:
Bolt
IN-00203
filler cap.
FU(H4SO 2.5)-40
Fuel Tank
and remove service hole cover.
A: REMOVAL
WARNING:
(B)
<Ref. to FU(H4SO 2.5)-40, DRAINING FUEL, FU-01126
PROCEDURE, Fuel.>
8) Disconnect the connector (A) from fuel sub level
sensor.
livery (B) and return hose (C). <Ref. to FU(H4SO
(2) Push the grommet (B) down under the body 2.5)-55, REMOVAL, Fuel Delivery, Return and
and remove service hole cover. Evaporation Lines.>
(A)
(A) (A) (C)
(B) (B)
FU-01124
FU-01127
11) Remove the bolts which secure the rear brake
FU-01125

el sensor. FU-01128
FU(H4SO 2.5)-41
Fuel Tank
12) Remove the rear brake caliper and tie it to the 19) Remove the bolts which install the parking
vehicle body side. brake cable clamp.
FU-00462 FU-01130

<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex-
haust Pipe.>
FU-01131
18) Disconnect the connector from rear ABS wheel
CAUTION:
sion jack.
(2) Remove the bolt which installs the rear
shock absorber to rear suspension arm.
FU-01129
FU-01132
FU(H4SO 2.5)-42
Fuel Tank
(3) Remove the bolts which secure the rear 23) Support the fuel tank with transmission jack, re-
suspension assembly to body. move the bolts from fuel tank bands, and dismount
WARNING:
FU-01133
FU-01137
B: INSTALLATION
of fuel tank band.
WARNING:
FU-01134

from bracket.
FU-01137
(A)
FU-01135

(A)
(B)
FU-01136
FU(H4SO 2.5)-43
Fuel Tank
T3: 175 N!m (17.8 kgf-m, 129 ft-lb)
(A) T1 T1
(B)
T1
T1
FU-01136
FU-01150
(2) (3)
(1)
L/2
T2 T3
L T3 T2
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp (3) Tighten the bolts which install the rear shock
(3) Pipe absorber to rear suspension arm. <Ref. to RS-
11, INSTALLATION, Rear Arm.>
62 N!m (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
Tightening torque:
33 N!m (3.4 kgf-m, 25 ft-lb)
CAUTION:
sion jack.
then tighten the bolts which secure the rear sus-
pension assembly to body.
FU(H4SO 2.5)-44
Fuel Tank
6) Tighten the bolts which install the parking brake 14) Tighten the bolt which secures rear brake hose
cable clamp. installation bracket.
FU-01130 FU-01128

sor.
(B) and return hose (C). <Ref. to FU(H4SO 2.5)-
56, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
NOTE:
return side.
FU-01131
7) Connect the connector to rear ABS wheel speed

sensor.
(A)
(C)
(B)
FU-01127

sensor.
FU-01129

10) Install the rear exhaust pipe. <Ref. to EX(H4SO
2.0)-11, INSTALLATION, Rear Exhaust Pipe.> (A)

12) Connect the parking brake cable to parking
brake assembly. <Ref. to PB-8, INSTALLATION, (B)
Parking Brake Assembly (Rear Disc Brake).> FU-01126
13) Install the rear brake caliper.
(A) Bolt
(B) Grommet
FU(H4SO 2.5)-45
Fuel Tank
FU-01125
(A) (A)
(B)
FU-01124
(A) Bolt
(B) Grommet

C: INSPECTION
1) Check that the fuel tank is not holed, cracked or
otherwise damaged.
FU(H4SO 2.5)-46
Fuel Filler Pipe
24.Fuel Filler Pipe 7) Set a container under the vehicle, and remove
the drain plug from the fuel tank to drain fuel from
WARNING:
cap.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
MOVAL, Mud Guard.>
4) Remove the screws which secure the packing. 11) Remove the bolts which hold the fuel filler pipe
FU-00095

6) Remove the rear wheel RH. 12) Loosen the clamp and disconnect the fuel filler
(A)
(B)
FU-00096
FU-01136

vehicle.
FU(H4SO 2.5)-47
Fuel Filler Pipe
B: INSTALLATION 5) Tighten the bolts which hold the fuel filler pipe
1) Open the fuel filler flap lid. bracket on the body.
2) Set the fuel saucer (A) with rubber packing (C) Tightening torque:
side of apron.
NOTE:
(A)
FU-01139

(C)
LATION, Mud Guard.>
FU-00103

clamp.
(A)
(B)
FU-00096

FU-01136
(2) (3)
(1)
L/2
L IN-00203
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipe
FU(H4SO 2.5)-48
Fuel Pump
25.Fuel Pump 7) Remove the nuts which install the fuel pump as-
sembly onto fuel tank.
A: REMOVAL
WARNING:
NOTE:
<Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL (A) Delivery hose
2) Drain the fuel. <Ref. to FU(H4SO 2.5)-40, (C) Jet pump hose
DRAINING FUEL, PROCEDURE, Fuel.>
and remove the service hole cover. Use a new gasket.
4.4 N!m (0.45 kgf-m, 3.3 ft-lb)
1
(B) 4 8
FU-01124

6 5
7 3
2
FU-01141
C: INSPECTION
of fuel pump and apply the battery power supply to
FU-01125
6) Disconnect the quick connector and then discon- WARNING:
nect the fuel delivery hose, return hose and jet • Wipe off the fuel completely.
pump hose. <Ref. to FU(H4SO 2.5)-55, REMOV- • Keep battery as far apart from fuel pump as
AL, Fuel Delivery, Return and Evaporation possible.
Lines.> • Be sure to turn the battery supply to ON and
FU(H4SO 2.5)-49
Fuel Pump

non-load condition.
2 1
4 3
6 5
FU-01330
FU(H4SO 2.5)-50
Fuel Level Sensor

A: REMOVAL
WARNING:
NOTE:
FU(H4SO 2.5)-49, REMOVAL, Fuel Pump.>
et.
FU-01142

B: INSTALLATION
FU(H4SO 2.5)-51
27.Fuel Sub Level Sensor 6) Remove the nuts and bolts which install the fuel
sub level sensor on fuel tank.
A: REMOVAL
WARNING:
1) Drain fuel. <Ref. to FU(H4SO 2.5)-40, DRAIN-
(B)
2) Remove the rear seat. FU-01144

(A) B: INSTALLATION
NOTE:
(B)
3
1
2
4
FU-01143 FU-01145
pump hose. <Ref. to FU(H4SO 2.5)-55, REMOV-
AL, Fuel Delivery, Return and Evaporation
Lines.>
FU-01146
FU(H4SO 2.5)-52
Fuel Filter
28.Fuel Filter
A: SPECIFICATION
Refer to Fuel Pump for removal and installation.
<Ref. to FU(H4SO 2.5)-49, REMOVAL, Fuel
Pump.>
Pump.>
FU(H4SO 2.5)-53
Fuel Damper Valve
29.Fuel Damper Valve

A: REMOVAL
1. DELIVERY SIDE
2) Remove the fuel damper valve from fuel delivery
line.
FU-01147
2. RETURN SIDE
pipe RH.
Refer to “Intake Manifold” for removal. <Ref. to
FU(H4SO 2.5)-15, DISASSEMBLY, Intake Mani-
fold.>
B: INSTALLATION
1. DELIVERY SIDE
Tightening torque:
1.25 N!m (0.13 kgf-m, 0.94 ft-lb)
2. RETURN SIDE
pipe RH.
Refer to “Intake Manifold” for installation. <Ref. to
FU(H4SO 2.5)-17, ASSEMBLY, Intake Manifold.>
FU(H4SO 2.5)-54

A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
FU-01148
6) In the engine compartment, disconnect the fuel 8) Remove the fuel tank. <Ref. to FU(H4SO 2.5)-
delivery hoses, return hoses, and evaporation 41, REMOVAL, Fuel Tank.>
hose. 9) Separate the quick connector on fuel line.
(1) Clean the pipe and connector, if they are
(A)
covered with dust.
(2) To prevent from damaging or entering for-
plastic bag, etc.
(C)
(B)
FU-01088

(B) Return hose
FU-01333
FU(H4SO 2.5)-55
(3) Hold the connector (A) and push retainer (B) (2) Push the pipe into the connector completely.
down.
(A)
(4) Pull out the connector (A) from retainer (B).
CAUTION: (B)
Always use a new retainer.
(C)
(B)
FU-00126
(A) (C)
(A) Connector
(B) Retainer
(C) Pipe
FU-00124
CAUTION:
(A) Connector
• Pull the connector to ensure it is connected
(B) Retainer securely.
(C) Pipe • Ensure the two retainer pawls are engaged in
B: INSTALLATION • Be sure to inspect the hoses and their con-
1) Connect the quick connector on fuel line. nections for fuel leakage.
CAUTION:
• Make sure that the connected portion is not
damaged or dust-covered. If necessary, clean
the seal surface of pipe.
(A)
(A)
(B) (C)
FU-00127
(B)
(A) Connector
(B) Retainer
(C) Pipe
FU-00125
2) Connect the fuel delivery hose to the pipe with
(A) Seal surface an overlap of 20 to 25 mm (0.79 to 0.98 in).
(B) Pipe Type A: When the amount to be inserted is speci-
fied.
(1) Set the new retainer (B) to connector (A). Type B: When the amount to be inserted is not
specified.
FU(H4SO 2.5)-56
2: 2.5#1.5 mm (0.098#0.059 in)

L: 22.5#2.5 mm (0.886#0.098 in)
(1) (2) (3)
Type A
Type B
FU-00128
(1) Pipe
(2) Clamp
(3) Hose

to the pipe by approx. 15 mm (0.59 in) from hose
end.
Fuel return hose:
L = 22.5#2.5 mm (0.885#0.098 in)
L = 17.5#2.5 mm (0.689#0.098 in)
CAUTION:
(2) (3)
(1)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipe
C: INSPECTION
2) Make sure the fuel pipe and fuel hose connec-
tions are tightened firmly.
FU(H4SO 2.5)-57

A: INSPECTION
❍ Defective terminal contact
securely.
❍ Trouble in electromagnetic or electronic circuit parts Replace the faulty parts.
2) Decline of fuel pump function Replace the fuel pump.
3) Clogged dust or water in the fuel filter Replace 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 mixed in the fuel system Inspect or retighten each connection part.
6) Clogged or bent air breather tube or pipe Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator Replace.
1) Loosened joints of the fuel pipe Retighten.
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.
5) Clogged or bent air breather tube or air vent tube
tube.
Loose joints at air breather tube, air vent tube, and fuel filler
1) Retighten.
pipe
2) Defective packing air tightness on the fuel saucer Correct or replace the packing.
3) Inoperative fuel pump modulator or circuit Replace.
1) Defective operation of fuel level sensor Replace.
2) Defective operation of fuel meter Replace.
5. Noise
1) Large operation noise or vibration of fuel pump Replace.
NOTE:
• When the vehicle is left unused for an extended period of time, water may accumulate in the fuel tank. Fill
fuel fully to prevent those problem. And also drain the water condensation from fuel filter.
fuel system and accumulating water. Fill the water removing agent each time the fuel is reduced to half to
maintain the advantage.
FU(H4SO 2.5)-58
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
EMISSION CONTROL
EC(H4SO 2.5)
Page
General Description
A: SPECIFICATION
Specifications for 2.5 L model are included in
EC(H4SO 2.0) section. <Ref. to EC(H4SO 2.0)-2,
EC(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
INTAKE (INDUCTION)
IN(H4SO 2.5)
Page
General Description
INTAKE (INDUCTION)
A: SPECIFICATION
IN(H4SO 2.0) section. <Ref. to IN(H4SO 2.0)-2,
IN(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
MECHANICAL
ME(H4SO 2.5)
Page
General Description
MECHANICAL
A: SPECIFICATION
ME(H4SO 2.0) section. <Ref. to ME(H4SO 2.0)-2,
ME(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
EXHAUST
EX(H4SO 2.5)
Page
General Description
EXHAUST
A: SPECIFICATION
EX(H4SO 2.0) section. <Ref. to EX(H4SO 2.0)-2,
EX(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
COOLING
CO(H4SO 2.5)
Page
General Description
COOLING
A: SPECIFICATION
Specifications for 2.5 L model are the same as 2.0
L model. <Ref. to CO(H4SO 2.0)-2, General De-
scription.>
CO(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
LUBRICATION
LU(H4SO 2.5)
Page
General Description
LUBRICATION
A: SPECIFICATION
L model. <Ref. to LU(H4SO 2.0)-2, General De-
scription.>
LU(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
SP(H4SO 2.5)
Page
General Description
A: SPECIFICATION
L model. <Ref. to SP(H4SO 2.0)-2, General De-
scription.>
SP(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
IGNITION
IG(H4SO 2.5)
Page
General Description
IGNITION
A: SPECIFICATION
IG(H4SO 2.0) section. <Ref. to IG(H4SO 2.0)-2,
IG(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
SC(H4SO 2.5)
Page
General Description
A: SPECIFICATION
L model. <Ref. to SC(H4SO 2.0)-2, General De-
scription.>
SC(H4SO 2.5)-2
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
EN(H4SO 2.5)(diag)
Page
11. Inspection Mode........................................................................................34
12. Drive Cycle................................................................................................39

A: PROCEDURE
1. ENGINE
Step Check Yes No

<Ref. to EN(H4SO 2.5)(diag)-3, CHECK, Failure”. <Ref. to
Check List for Interview.> EN(H4SO
2) Start the engine. 2.5)(diag)-54,
Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator Go to step 3. Inspection using
EN(H4SO
2.5)(diag)-261,
INSPECTION,
General Diagnos-
tic Table.>
link connector. EN(H4SO If DTC is not
3) Turn the ignition switch to ON, and the Sub- 2.5)(diag)-70, List shown on display
aru Select Monitor switch to ON. of Diagnostic Trou- although the en-
4) Read DTC on Subaru Select Monitor. ble Code (DTC).> gine warning light
Go to step 4. illuminates, per-
form the diagnos-
tics of malfunction
indicator light cir-
cuit or combination
meter. <Ref. to
EN(H4SO 2.5)(di-
ag)-44, Malfunc-
tion Indicator
Light.>
4 PERFORM DIAGNOSIS. Is DTC displayed on the Sub- Check on “Diag- Finish the diagno-
1) Perform the clear memory mode. <Ref. to aru Select Monitor? nostic Chart with sis.
EN(H4SO 2.5)(diag)-41, Clear Memory Diagnostic Trou-
Mode.> ble Code (DTC)”
2) Perform the inspection mode. <Ref. to <Ref. to EN(H4SO
EN(H4SO 2.5)(diag)-34, Inspection Mode.> 2.5)(diag)-80,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>

A: CHECK
1. CHECK LIST No. 1
NOTE:
Date of repair km
Odometer reading
V.I.N. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
❏ Hot
❏ Warm
❏ Cool
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
❏ Warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
❏ At starting
❏ While idling
❏ At racing
❏ While cruising
2. CHECK LIST No. 2

NOTE:
b) Fuel level
• What:
• What:
e) Installing of other parts except for genuine parts: ❏ Yes / ❏ No
• What:
• Where:
• From where:
• What kind:
• From where:
• What kind:
❏ Rough idling
❏ Back fire
❏ After fire
❏ Does not shift.
General Description

point to chassis when measuring voltage and resis-
CAUTION: (A)
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
• The fuel injector and other parts will be dam- (A) Stud bolt
aged.
3) Do not disconnect the battery terminals while the 9) Use engine grounding terminal or engine as the
engine is running. grounding point to the chassis when measuring
A large counter electromotive force will be generat- voltage and resistance in the engine compartment.
ed in the generator, and this voltage may damage
sensor and ECM, be sure to turn the ignition switch
to OFF. Perform the inspection mode after con-
necting the connectors.
FU-01090
than 5 mm (0.20 in) into the part. 10) Use TCM mounting stud bolts as the grounding
6) Remove the ECM from the located position after point to chassis when measuring voltage and resis-
disconnecting two cables on battery. tance inside the passenger compartment.
Otherwise, the ECM may be damaged.
CAUTION:
NOTE:
Immobilizer system must be registered when in-
stalling the ECM of the model with immobilizer. For
doing so, all ignition keys and ID cards should be (A)
prepared. Refer to “REGISTRATION MANUAL EN-00154
FOR IMMOBILIZER”.
7) Connectors of each sensor in the engine com- (A) Stud bolt
partment and the harness connectors on the en- 11) Every MFI-related part is a precision part. Do
gine side and body side are all designed to be not drop them.
waterproof. However, it is still necessary to take 12) Observe the following cautions when installing
care not to allow water to get into the connectors a radio in MFI equipped models.
vehicle on a rainy day. CAUTION:
under the steering column, inside of instrument
panel lower trim panel.)
General Description

ness.
ly connected to engine.
matching.
special attention to the three items mentioned
above.
the operation of ECM.
fuel system. If engine starts during this operation, FU-01090
14) Problems in the electronic-controlled automatic 3. SELF-DIAGNOSIS FUNCTION
transmission may be caused by failure of the en- When detecting a malfunction by self-diagnosis
gine, the electronic control system, the transmis- function on ECM, malfunction indicator light illumi-
sion proper, or by a combination of these. These nates and malfunction occurrence is displayed.
three causes must be distinguished clearly when Calling the self-diagnosis result is performed by the
performing diagnostics. Subaru Select Monitor.
three causes.
16) For AT models, do not hold the stall for more
than five seconds. (from closed throttle, fully open
throttle to stall engine speed.)
perform the ABS memory clear procedure of self-
diagnosis function.
B: INSPECTION
items which might affect engine problems.
1. BATTERY
electrolyte.
proper grounding.
General Description
C: PREPARATION TOOL
ST24082AA230
ST22771AA030

A: LOCATION
1. ENGINE
• Control module
• LHD model
(3) (1)
(4) (2)
EN-02413
• RHD model
(4)
(2) (3) (1)

EN-02451
(1)
(2)
EN-01147 EN-01966
(4)
(3)
EN-02414 AT-01877
• Sensor
(8) (3) (9) (4) (2) (5)
(1) (7) (6) (8)
EN-02530
(1) Mass air flow and intake air tem- (4) Electronic throttle control (9) Intake air temperature sensor (KA
perature sensor (EC, EK and K4 (5) Knock sensor and KS model)
model) (6) Camshaft position sensor
(2) Manifold absolute pressure sensor (7) Crankshaft position sensor
(3) Engine coolant temperature sen- (8) Tumble generator valve position
sor sensor
(1)
(2)
EN-01970 EN-01971
(3)
(4)
EN-02179 EN-01972
(5)
(6)
EN-00010 EN-00011
(7)
(8)
EN-00012 EN-02531
(9)
EN-02547
(1)
(3)
(4)
(2)
EN-01973
(1) Front oxygen (A/F) sensor (3) Front catalytic converter (4) Rear catalytic converter
(2) Rear oxygen sensor
(1) (2)
(4)
(3)
EN-02091 EN-02092
(5) (4) (2) (3) (5)
(3) (1)
EN-02452
(1) Purge control solenoid valve (3) Tumble generator valve actuator (5) Fuel injector
(2) EGR Valve (EC, EK and K4 (4) Ignition coil & ignitor ASSY
model)
(1) (2)
EN-01975 EN-01976
(4)
(3)
EN-01977 EN-01978
(5) EN-02453
• LHD model
(1) (5) (4) (3) (2)
(8) (7) (6) (9) (3)

EN-02423
• RHD model
(1) (2)
(8) (7) (6) (9) (5) (4) (3)

EN-01979
(2)
EN-00178 EN-02093
(3)
(6)
(8)
(4) (7)
(5)
EN-02094 EN-02095
(9)
EN-02096

B134 B135
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
B136 B137
1 2 3 4 5 6 1 2 3 4 5 6 7
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01982
Termi- Signal (V)

Connector
DESCRIPTION nal Ignition SW ON Engine ON NOTE
No.
No. (engine OFF) (idling)
Crankshaft Signal (+) B135 10 0 "7 — +7 Sensor output waveform
position sen- Signal (") B135 22 0 0 —
sor Shield B135 31 0 0 —
Camshaft Signal (+) B135 11 0 "7 — +7 Sensor output waveform
0.64 — 0.72
0.64 — 0.72 Fully closed: 0.6
Main B136 18 (After engine is
Fully opens: 3.96 Fully open: 3.96
throttle control 1.51 — 1.58
1.51 — 1.58 Fully closed: 1.48
Sub B136 29 (After engine is
Fully opens: 4.17 Fully open: 4.17
warmed-up.)
B137 5 Duty waveform Duty waveform Drive frequency: 500 Hz
motor (+)
motor (")
B137 6 10 — 13 13 — 14 —
motor power supply
B135 35
Fully closed: 1 Fully closed: 1
Main B136 17 —
Fully opens: 3.3 Fully opens: 3.3
Accelerator Power
B136 15 5 5 —
Sub B136 28 —
Termi- Signal (V)

Connector
No.
Front oxygen Signal 1 B134 3 0 — 1.0 0 — 1.0 —
(A/F) sensor
heater Signal 2 B134 2 0 — 1.0 0 — 1.0 —
Rear oxygen sensor heater
B135 2 0 — 1.0 0 — 1.0 —
signal
B136 14 1.0 — 1.4 1.0 — 1.4 After engine is warmed-up.
sensor
Tumble generator valve RH
B134 19 0 or 10 — 13 0 or 13 — 14 Sensor output waveform
(open)
Tumble generator valve RH
(close)
Tumble generator valve LH
(open)
Tumble generator valve LH
(close)
Tumble generator valve Fully open: 0.2 — 1.0
B136 27 —
position sensor RH Fully closed: 4.2 — 4.7
Tumble generator valve Fully open: 0.2 — 1.0
B136 26 —
position sensor LH Fully closed: 4.2 — 4.7
Starter switch B137 8 0 0 Cranking: 8 — 14
ON: 0 ON: 0
Starter relay B135 32 —
OFF: 10 — 13 OFF: 13 — 14
A/C switch (Model with ON: 10 — 13 ON: 13 — 14
B137 17 —
immobilizer) OFF: 0 OFF: 0
A/C switch (Model without ON: 10 — 13 ON: 13 — 14
B137 16 —
immobilizer) OFF: 0 OFF: 0
Ignition switch (Model with
B137 14 10 — 13 13 — 14 —
immobilizer)
Ignition switch (Model with-
B137 15 10 — 13 13 — 14 —
out immobilizer)
Switch is ON when select
ON: 0
Neutral position switch B137 9 or shift lever is shifted into
OFF: 12#0.5
“P” or “N” range.
Test mode connector
B137 15 5 5 When connected: 0
(Model with immobilizer)
Test mode connector
B137 14 5 5 When connected: 0
(Model without immobilizer)
Signal B136 25 2.8 2.8 —
Knock sensor
Shield B136 33 0 0 —
Ignition switch “OFF”: 10
— 13
Control module power sup- B135 6 10 — 13 13 — 14 —
ply B135 5 10 — 13 13 — 14 —
Sensor power 1 B136 16 5 5 —
supply 2 B136 15 5 5 —
1 B135 18 0 1 — 3.4 Waveform
Ignition control
2 B135 17 0 1 — 3.4 Waveform
#1 B136 6 10 — 13 1 — 14 Waveform
#2 B136 5 10 — 13 1 — 14 Waveform
Fuel injector
#3 B136 4 10 — 13 1 — 14 Waveform
#4 B136 3 10 — 13 1 — 14 Waveform
Fuel pump relay control ON: 0.5 or less
B135 27 0.5 or less —
(Model with immobilizer) OFF: 10 — 13
Termi- Signal (V)

Connector
No.
Fuel pump relay control ON: 0.5 or less
B135 26 0.5 or less —
(Model without immobilizer) OFF: 10 — 13
OFF: 10 — 13 OFF: 13 — 14
OFF: 10 — 13 OFF: 13 — 14
OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control (Model
B137 16 10 — 13 13 — 14 —
with immobilizer)
Self-shutoff control (Model
B137 17 10 — 13 13 — 14 —
without immobilizer)
Light “ON”: 1 or less
Malfunction indicator light B134 17 — —
Purge control solenoid valve B134 14 —
OFF: 10 — 13 OFF: 13 — 14
Signal A+ B134 11 0 or 10 — 13 0 or 10 — 13 —
EGR solenoid Signal A" B134 10 0 or 10 — 13 0 or 10 — 13 —
valve Signal B+ B134 9 0 or 10 — 13 0 or 10 — 13 —
Signal B" B134 8 0 or 10 — 13 0 or 10 — 13 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B137 13 —
OFF: 10 — 13 OFF: 13 — 14
B134 33 — 2.05 — 2.25 —
signal 1
B134 26 — 1.75 — 1.95 —
signal 2
B134 25 0 0 —
shield
Manifold absolute pressure
B136 22 4.0 — 4.8 1.1 — 1.9 —
sensor
Signal B136 23 — 0.3 — 4.5 —
Air flow sensor Shield B136 32 0 0 —
Ground B136 31 0 0 —
Intake air temperature sen- intake air temperature:
B136 13 3.15 — 3.33 3.15 — 3.33
sor 25!C (75!F)
Less than 1$% More Less than 1$%
than 4 More than 4
1 B136 35 0 0 —
GND (sensor)
2 B136 34 0 0 —
GND (ignition system) B135 12 0 0 —
B135 4 0 0 —
GND (power supply)
B135 1 0 0 —
B137 2 0 0 —
B137 1 0 0 —
B134 7 0 0 —
1)
Termi- Signal (V)

Connector
No.
B134 6 0 0 —
2)
GND (Electronic throttle
B137 3 0 0 —
control)
ON: 0 ON: 0
Main switch B137 14 —
OFF: 10 — 13 OFF: 13 — 14
When operating
When operating noth- nothing: 3.5 — 4.5
ing: 3.5 — 4.5 When operating
When operating RES/ RES/ACC:
Cruise control command ACC: 2.5 — 3.5 2.5 — 3.5
B136 21 —
switch When operating SET/ When operating
COAST: 0.5 — 1.5 SET/COAST:
When operating CAN- 0.5 — 1.5
CEL: 0 — 0.5 When operating
CANCEL: 0 — 0.5

Remarks SPECIFICATION
1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm Racing
• A/C is turned OFF.
• All accessory switches are turned OFF.
Data Link Connector

A: NOTE
CAUTION:
Do not connect any scan tools except for Subaru Select Monitor or OBD-II general scan tool, because
the circuit for Subaru Select Monitor may be damaged.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
EN-00037

3 Empty 11 Empty
4 Empty 12 Ground
5 Empty 13 Ground
6 Empty 14 Empty
7 Empty 15 Empty
8 Empty 16 Empty
8. OBD-II General Scan Tool OBD-II general scan tool functions consist of:
A: OPERATION data
(2) MODE $02: Powertrain freeze frame data
1. HOW TO USE OBD-II GENERAL SCAN
(3) MODE $03: Emission-related powertrain
TOOL DTC
1) Prepare a general scan tool (OBD-II general (4) MODE $04: Clear/Reset emission-related
scan tool) required by SAE J1978. diagnostic information
2) Open the cover and connect the OBD-II general (5) MODE $06: Request on-board monitoring
scan tool to data link connector located in the lower test results for non-continuously monitored sys-
portion of instrument panel (on the driver’s side). tems
(6) MODE $07: Request on-board monitoring
test results for continuously monitored systems
(7) MODE $09: Request vehicle information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the op-
eration manual of OBD-II general scan tool.)
NOTE:
For details concerning DTC, refer to “List of Diag-
EN-02533 2.5)(diag)-70, List of Diagnostic Trouble Code
(DTC).>
3) Using the OBD-II general scan tool, call up DTC
Refer to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
Number of emission-related powertrain DTC and malfunction indicator light status and diag-
01 —
nosis support information
10 Air flow rate from mass air flow sensor g/sec
11 Throttle valve absolute opening angle %
15 Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor V and %
1C Supporting OBD system —
21 Driving distance after MIL illuminates km
24 A/F value and A/F sensor output voltage — and V
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE
$01).

Refer to data denoting the operating condition when trouble is detected by the on-board diagnosis system.
02 DTC that caused CARB required freeze frame data storage —
0C Engine speed rpm
10 Air flow rate from mass air flow sensor g/sec
11 Throttle valve opening angle %
NOTE:
Refer to OBD-II general scan tool manufacturer’s operation manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE (DTC))
Refer to “Read Diagnostic Trouble Code (DTC)” for information about data denoting emission-related pow-
ertrain DTC. <Ref. to EN(H4SO 2.5)(diag)-33, Read Diagnostic Trouble Code (DTC).>
Refer 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 operation manual to clear or reset emission-related diag-
6. MODE $06
Refer to test value of troubleshooting and data of test limit on support data bit sequence table. List of support
data is shown in the following table.
TID CID Test value & Test limit Unit
$01 $01 Catalyst system efficiency below threshold —
$81
$02 Exhaust gas recirculation control circuit range/performance mmHg
$02
$81 Evaporative emission control system (CPC open malfunction) —
$02 Evaporative emission control system small leak pa
$03 Evaporative emission control system small leak (Immediate normality judgment) pa
$03 $04 Evaporative emission control system large leak pa
Evaporative emission control system very small leak (Immediate normality judg-
$05 pa
ment)
$06 Evaporative emission control system very small leak pa
$01 O2 sensor circuit slow response (Bank 1 Sensor 1) Lean % Rich
$05 millisecond
$02 O2 sensor circuit slow response (Bank 1 Sensor 1) Rich % Lean
$81
$06 O2 sensor circuit (Bank 1 Sensor 2) <$81 or $02> V
$02
$07 $01 O2 sensor circuit slow response (Bank 1 Sensor 2) second
TID CID Test value & Test limit Unit

$81
$0B O2 sensor heater circuit (Bank 1 Sensor 2) <$81 or $02> W
$02
Coolant thermostat (Coolant temperature below thermostat regulating tempera-
$0C $01 !C
ture)
$01
$0D Evaporative emission control system vent control circuit range/performance Pa
$82
7. MODE $07
Refer to the data of DTC (pending code) for troubleshooting result about emission in first time.
8. MODE $09
Refer to the data of vehicle specification (VIN, calibration ID, etc.).
9. Subaru Select Monitor 5) Turn ignition switch to ON (engine OFF) and turn
A: OPERATION
(A)
1. HOW TO USE SUBARU SELECT MONI-
TOR
EN-00040
(A) Power switch
6) Using the Subaru Select Monitor, call up DTC

EN-00038 (DTC) FOR ENGINE (NORMAL MODE)
2) Connect the diagnosis cable to Subaru Select Refer to “Read Diagnostic Trouble Code (DTC)” for
Monitor. information about how to indicate DTCs. <Ref. to
3) Insert the cartridge to Subaru Select Monitor. EN(H4SO 2.5)(diag)-33, Read Diagnostic Trouble
<Ref. to EN(H4SO 2.5)(diag)-7, PREPARATION Code (DTC).>
information about how to indicate DTCs. <Ref. to
EN(H4SO 2.5)(diag)-33, Read Diagnostic Trouble
Code (DTC).>
EN-00039

connector.
(1) Data link connector is located in the lower
portion of instrument panel (on the driver’s side).
EN-02533

connector.
CAUTION:
ru Select Monitor or OBD-II general scan tool.

[YES] key.
Unit
of measure
Engine load Engine Load % 3.5%
Engine coolant temperature signal Coolant Temp. !C & 75 !C
Intake manifold absolute pressure Mani. Absolute Pressure mmHg 200 — 300 mmHg
cation)
Ignition timing signal Ignition Timing deg 12.5 — 13.5 deg
Intake air temperature signal Intake Air Temp. !C (Ambient air temperature)
Amount of intake air Mass Air Flow g/s 2.8 — 3.2 g/s
Throttle opening angle signal Throttle Opening Angle % 1.2 — 1.6%
Rear oxygen sensor voltage Rear O2 Sensor V 0.6 — 0.85 V
Mass air flow voltage Air Flow Sensor Voltage V 1.1 — 1.2 V
Injection 1 pulse width Fuel Injection #1 Pulse ms 2.56 — 3.3 ms
Knock sensor correction Knocking Correction deg 0.0 deg
Atmospheric pressure signal Atmosphere Pressure mmHg (Atmosphere pressure)
(Mani. Absolute Pressure
Intake manifold relative pressure Mani. Relative Pressure mmHg
" Atmosphere pressure)
EGR steps No. of EGR Steps STEP 0
Generator duty ratio ALT Duty % 0%
A/F sensor current value 1 A/F Sensor #1 Current mA "0.2 — 0.2 mA
tance
A/F sensor output lambda 1 A/F Sensor #1 — 0.85 — 1.05
A/F correction 3 A/F Correction #3 % 5.08%
A/F learning 3 A/F Learning #3 % 0%
Throttle motor duty Throttle Motor Duty % "12 — "20%
Throttle power supply voltage Throttle Motor Voltage V (Battery voltage)
Sub throttle sensor voltage Sub-throttle Sensor V 1.48 — 1.50 V
Sub acceleration sensor voltage Sub-accelerator Sensor V 1.12 V
Main acceleration sensor voltage Main-accelerator Sensor V 0.98 — 1.0 V
Memorized Cruise
Memory vehicle speed km/h 0 km/h
Speed
AT/MT identification terminal AT Vehicle ID Signal — ON/OFF
TGV position sensor voltage RH TGV Position Sensor R V 0 — 12
TGV position sensor voltage LH TGV Position Sensor L V 0 — 12
Unit
of measure
Fuel level sensor resistance Fuel Level Resistance ' 4 — 100 '
Test mode terminal Test Mode Signal — OFF
Neutral position switch signal Neutral Position Switch — ON
Soft idle switch signal Idle Switch Signal — ON
Ignition switch signal Ignition Switch — ON
Power steering switch input signal P/S Switch — OFF (At OFF)
Air conditioning switch signal A/C Switch — OFF (At OFF)
Handle switch signal Handle Switch — RHD/LHD
Starter switch signal Starter Switch — OFF
Rear O2 monitor Rear O2 Rich Signal — OFF
Knocking signal Knocking Signal — OFF
Crankshaft position sensor signal Crankshaft Position Sig. — OFF
Camshaft position sensor signal Camshaft Position Sig. — OFF
Rear defogger switch signal Rear Defogger SW — OFF (At OFF)
Blower fan switch signal Blower Fan SW — OFF (At OFF)
Light switch signal Light Switch — OFF (At OFF)
Wiper switch signal Wiper Switch — OFF (At OFF)
A/C middle pressure switch signal A/C Mid Pressure Switch — OFF (At OFF)
Air conditioner compressor relay output signal A/C Compressor Signal — OFF (At OFF)
Fuel pump relay signal Fuel Pump Relay — ON
Tumble generator valve output signal TGV Output — OFF
Tumble generated valve drive signal TGV Drive — Open
AT coordinate retard angle demand signal Retard Signal from AT — OFF
AT coordinate fuel cut demand signal Fuel Cut Signal from AT — OFF
Torque Permission Sig-
AT coordinate permission demand — ON
nal
ETC motor relay signal ETC Motor Relay — ON
Ban of torque down signal Ban of Torque Down — ON/OFF
Request torque down signal Request Torque Down — ON/OFF
Clutch switch signal Clutch Switch — OFF (At OFF)
Stop light switch signal Stop Light Switch — OFF (At OFF)
SET/COAST switch signal SET/COAST Switch — OFF (At OFF)
RES/ACC switch signal RESUME/ACCEL Switch — OFF (At OFF)
Brake switch signal Brake Switch — OFF (At OFF)
Main switch signal Main Switch — OFF (At OFF)
Cancel switch signal Cancel Switch — OFF (At OFF)
Integrated unit data reception Body Int. Unit Data — ON
Integrated unit data update Body Int. Unit Count — ON
NOTE:
For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”.

5) On the «OBD Menu» display screen, select the {Current Data Display/Save}, and press the [YES] key.
Monitoring test of misfire Misfire monitoring no support
Monitoring test of fuel system Fuel system monitoring complete
Monitoring test of comprehensive component Component monitoring complete
Test of catalyst Catalyst Diagnosis no support
Test of oxygen sensor Oxygen sensor complete
Test of oxygen sensor heater O2 Heater Diagnosis complete
Test of EGR system EGR system incomplete
NOTE:

2) On the «System Selection Menu» display screen, select the {Engine Control System} and press the [YES]
key.
• A list of support data is shown in the following table.
Contents Display Unit of measure
DTC for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF
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 %
Ignition timing signal Ignition Timing !
Intake air volume Mass Air Flow g/sec
Intake air temperature signal Intake Air Temp !C
Throttle position signal Throttle Opening Angle %
NOTE:
For detailed operation procedure, refer to SUBARU SELECT MONITOR OPERATION MANUAL.

[YES] key.
Test mode signal Test Mode Signal ON or OFF D check
When clear memory connec-
Clear memory signal Clear Memory Terminal ON or OFF
tor is connected.
entered.
entered.
to ON.
entered.
input.
Handle switch signal Handle SW RHD or LHD
input.
nal sor signal is entered.
turned to ON.
turned to ON.
When light switch is turned to
Light switch signal Light Switch ON or OFF
ON.
turned to ON.
Windshield wiper switch signal Wiper SW ON or OFF
is turned to ON.
signal switch is turned to ON.
in function.
function.
function.
Fuel pump relay signal Fuel Pump Relay ON or OFF ON output
Tumble generator valve output
TGV Output ON or OFF Yes
signal

Tumble generated valve drive
TGV Drive Open or Close Opening direction
signal
signal is input.
input.
to ON.
ON.
turned to ON.
turned to ON.
ON.
ON.
to ON.
entered.
entered.
NOTE:
10.Read Diagnostic Trouble

Code (DTC)
A: OPERATION
MODE)
key.
NOTE:
(DTC).>
MODE)
key.
NOTE:
(DTC).>
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle.
<Ref. to EN(H4SO 2.5)(diag)-39, Drive Cycle.>
DTC Item Condition
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1) —
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1) —
P0102 Mass or Volume Air Flow Circuit Low Input —
P0103 Mass or Volume Air Flow Circuit High Input —
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input —
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input —
P0112 Intake Air Temperature Circuit Low Input —
P0113 Intake Air Temperature Circuit High Input —
P0117 Engine Coolant Temperature Circuit Low Input —
P0118 Engine Coolant Temperature Circuit High Input —
P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Input —
P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Input —
P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) —
P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) —
P0171 System too Lean (Bank 1) —
P0172 System too Rich (Bank 1) —
P0222 Throttle/Pedal Position Sensor/Switch “B” Circuit Low Input —
P0223 Throttle/Pedal Position Sensor/Switch “B” Circuit High Input —
P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) —
P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) —
P0335 Crankshaft Position Sensor “A” Circuit —
P0340 Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor) —
P0400 Exhaust Gas Recirculation Flow —
P0458 Evaporative Emission Control System Purge Control Valve Circuit
—
Low
P0462 Fuel Level Sensor Circuit Low Input —
P0463 Fuel Level Sensor Circuit High Input —
P0500 Vehicle Speed Sensor —
P0512 Starter Request Circuit —
P0513 Incorrect Immobilizer Key —
P0519 Idle Control System Malfunction (Fail-Safe) —
P0558 Generator Circuit Low Input —
P0600 Serial Communication Link —
P0604 Internal Control Module Random Access Memory (RAM) Error —
P0605 Internal Control Module Read Only Memory (ROM) Error —
P0607 Control Module Performance —
P0638 Throttle Actuator Control Range/Performance (Bank 1) —
P0691 Cooling Fan 1 Control Circuit Low —
P0692 Cooling Fan 1 Control Circuit High —
P0851 Neutral Switch Input Circuit Low —
Inspection Mode
DTC Item Condition

P0852 Neutral Switch Input Circuit High —
P1086 Tumble Generated Valve Position Sensor 2 Circuit Low —
P1087 Tumble Generated Valve Position Sensor 2 Circuit High —
P1088 Tumble Generated Valve Position Sensor 1 Circuit Low —
P1089 Tumble Generated Valve Position Sensor 1 Circuit High —
P1090 Tumble Generated Valve System 1 (Valve Open) Engine coolant temperature is "5 — 5!C ("41
— 41!F) at engine start.
P1091 Tumble Generated Valve System 1 (Valve Close) —
P1092 Tumble Generated Valve System 2 (Valve Open) Engine coolant temperature is "5 — 5!C ("41
— 41!F) at engine start.
P1093 Tumble Generated Valve System 2 (Valve Close) —
P1094 Tumble Generated Valve Signal 1 Circuit Malfunction (Open) —
P1095 Tumble Generated Valve Signal 1 Circuit Malfunction (Short) —
P1096 Tumble Generated Valve Signal 2 Circuit Malfunction (Open) —
P1097 Tumble Generated Valve Signal 2 Circuit Malfunction (Short) —
P1110 Atmospheric Pressure sensor circuit malfunction (Low input) —
P1111 Atmospheric Pressure sensor circuit malfunction (High input) —
P1152 O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) —
P1153 O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) —
P1160 Return Spring Failure —
P1518 Starter Switch Circuit Low Input —
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 —
P1578 Meter Failure —
P2101 Throttle Actuator Control Motor Circuit Range/Performance —
P2102 Throttle Actuator Control Motor Circuit Low —
P2103 Throttle Actuator Control Motor Circuit High —
P2109 Throttle/Pedal Position Sensor A Minimum Stop Performance —
P2122 Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input —
P2123 Throttle/Pedal Position Sensor/Switch “D” Circuit High Input —
P2127 Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input —
P2128 Throttle/Pedal Position Sensor/Switch “E” Circuit High Input —
P2135 Throttle/Pedal Position Sensor/Switch “A”/“B” Voltage Rationality —
P2138 Throttle/Pedal Position Sensor/Switch “D”/“E” Voltage Rationality —
Inspection Mode
1. PREPARATION FOR THE INSPECTION 2. SUBARU SELECT MONITOR

MODE 1) After clearing the memory, check for any remain-
1) Check if the battery voltage is more than 12 V ing unresolved trouble data. <Ref. to EN(H4SO
and fuel remains half [20 — 40 2 (5.3 — 10.6 US 2.5)(diag)-41, Clear Memory Mode.>
gal, 4.4 — 8.8 Imp gal)]. 2) Idle the engine.
2) Lift-up the vehicle using a garage jack and place 3) Prepare the Subaru Select Monitor kit. <Ref. to
it on rigid racks, or drive the vehicle onto free roll- EN(H4SO 2.5)(diag)-7, PREPARATION TOOL,
ers. General Description.>
WARNING:
brakes are applied.
id rack.
wheels.
• Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when EN-00038
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.
due to vibration, do not place any wooden 5) Insert the cartridge to Subaru Select Monitor.
blocks or similar items between the rigid racks <Ref. to EN(H4SO 2.5)(diag)-7, PREPARATION
and vehicle. TOOL, General Description.>
• Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
EN-00039
6) Connect the test mode connector (A) located at

the lower portion of glove box.
(A)
(A)
EN-02424
(B)
EN-00041
(A) Rigid rack

(B) Free rollers
Inspection Mode
7) Connect the Subaru Select Monitor to data link • The speed difference between front and rear
connector located in the lower portion of the instru- wheels may light the ABS warning light, but this in-
ment panel (on the driver’s side). dicates no malfunctions. When engine control diag-
nosis is finished, perform the ABS memory clear
procedure of self-diagnosis function.
3. OBD-II GENERAL SCAN TOOL
1) After performing the diagnostics and clearing
memory, check for any remaining unresolved trou-
ble data: <Ref. to EN(H4SO 2.5)(diag)-41, Clear
Memory Mode.>
2) Warm up the engine.
3) Connect the test mode connector (A) at the low-
EN-02533 er side of globe box.
CAUTION:
turn Subaru Select Monitor switch to ON.
(A)
(A)
EN-02424

link connector in the lower portion of instrument
panel (on the driver’s side).
CAUTION:
EN-00040 Do not connect the scan tools except for Suba-
(A) Power switch

key.
EN-02533
screen, press the [YES] key. 5) Start the engine.
14) Perform subsequent procedures as instructed NOTE:
on the display screen. • Ensure the select lever is placed in “P” range be-
• If trouble still remains in the memory, the corre- fore starting. (AT model)
sponding DTC appears on the display screen. • Depress the clutch pedal when starting engine.
NOTE: (MT model)
• For detailed operation procedure, refer to “SUB- 6) Using the select lever or shift lever, turn the “P”
ARU SELECT MONITOR OPERATION MANUAL”. position switch and “N” position switch to ON.
• For the details concerning DTCs, refer to “List of 7) Depress the brake pedal to turn brake switch
Diagnostic Trouble Code (DTC)”. ON. (AT model)
<Ref. to EN(H4SO 2.5)(diag)-70, List of Diagnostic 8) Keep the engine speed in 2,500 — 3,000 rpm
Trouble Code (DTC).> range for 40 seconds.
• Release the parking brake.
Inspection Mode
9) Place the select lever or shift lever in “D” range

(AT model) or “1st” gear (MT model) and drive the
vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
• On AWD model, release the parking brake.
• 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.
NOTE:
operation manual of OBD-II general scan tool.
• For detailed concerning DTC, refer to “List of Di-
agnostic Trouble Code (DTC)”.
<Ref. to EN(H4SO 2.5)(diag)-70, List of Diagnos-
Drive Cycle
12.Drive Cycle
A: PROCEDURE
There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose
malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check
whether they correctly resume their functions by driving in the required drive pattern.
1. 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 12 V or more.
2) After performing the diagnostics and cleaning memory, check for any remaining unresolved trouble data.
<Ref. to EN(H4SO 2.5)(diag)-41, Clear Memory Mode.>
NOTE:
• Except for the engine coolant temperature specified items at starting, the diagnosis is carried out after en-
gine 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 Item Condition
Insufficient Coolant Temperature for Closed Loop
*P0125 Engine coolant temperature is less than 20!C (68!F) at engine start.
Fuel Control
O2 Sensor Circuit Slow Response (Bank 1 Sen-
*P0133 —
sor 1)
Catalyst System Efficiency Below Threshold
*P0420 —
(Bank 1)
Evaporative Emission Control System Purge
P0459 —
Control Valve Circuit High
3. IDLE FOR 10 MINUTES

NOTE:
Before the diagnosis, drive the vehicle at 10 km/h (6 MPH) or more.
DTC Item Condition
O2 Sensor Heater Circuit Range/Performance
P0030 —
(Bank 1 Sensor 1)
Drive Cycle
4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN
(H)
(C)
97 (60)
(D) (F) (G)
64 (40)
(B) (E)
(A)
0
50 100 150 (I)
EN-00842
(A) Idle engine for 10 seconds or (D) Decelerate with throttle fully (G) Stop vehicle with throttle fully
more. closed to 64 km/h (40 MPH). closed.
(B) Accelerate to 97 km/h (60 MPH) (E) Drive vehicle at 64 km/h (40 MPH) (H) Vehicle speed km/h (MPH)
within 20 seconds. for 20 seconds. (I) Seconds
(C) Drive vehicle at 97 km/h (60 MPH) (F) Accelerate to 97 km/h (60 MPH)
for 20 seconds. within 10 seconds.
DTC Item Condition

In some cases, diagnosis may
*P0301 Cylinder 1 Misfire Detected
complete at once.
complete at once.
complete at once.
complete at once.
P0559 Generator circuit high input —
P0700 Transmission Control System (MIL request) —
Clear Memory Mode

A: OPERATION
MODE)
key.
switch to OFF.
NOTE:
MODE)
key.
NOTE:
connector located in the lower portion of instrument
Check Mode panel (on the driver’s side).
A: OPERATION
EN-02533
CAUTION:
EN-00038 6) Turn the ignition switch to ON (engine OFF) and
2) Connect the diagnosis cable to Subaru Select turn Subaru Select Monitor switch to ON.
Monitor.
EN-00040
(A) Power switch

EN-00039
key.
the [YES] key.
12) Select the desired compulsory actuator on the
EN-02424 «Actuator ON/OFF Operation» display screen and
press the [YES] key.
screen.

table.
DESCRIPTION Display
Fuel Pump
ation check
Radiator Fan Relay
operation check
operation check
CPC Solenoid
NOTE:
tional.
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Wastegate control solenoid
PCV Solenoid
AAI Solenoid


A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.5)(diag)-45, ACTIVATION OF MALFUNCTION INDICATOR
(
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.5)(diag)-46, MALFUNCTION INDICATOR
(
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4SO 2.5)(diag)-48, MALFUNCTION INDICATOR
LIGHT DOES NOT GO OFF., Malfunction Indicator Light.>
(
4. Check that the malfunction indicator light does not blink. <Ref. to EN(H4SO 2.5)(diag)-50, MALFUNCTION INDICATOR LIGHT
(
5. Check that the malfunction indicator light remains blinking. <Ref. to EN(H4SO 2.5)(diag)-52, MALFUNCTION INDICATOR

NOTE: (2)
EN(H4SO 2.5)(diag)-46, MALFUNCTION INDICA-
(3)
Indicator Light.>
EN-01681
(1) ON
(2) OFF
(4) 1 second
(A)
EN-01984

emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start

minates.
sis)

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
• EC, EK and K4 model
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
i3
8
B38
17
B134 ECM E
B72 B134 i10 B38
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
EN-01985
• KA and KS model
NOTE:
Fuel injection system for KA and KS model is the same as 2.0 L model. Refer to EN(H4SO 2.0) section.
Step Check Yes No

1 CHECK OPTION CODE. Is the option code EC, EK or Go to step 2. Refer to EN(H4SO
K4? 2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
Check for poor connection by shaking or pull- light illuminate? contact in ECM
ing ECM connector and harness. connector.
Check the connection of ECM connector. connected? <Ref. to FU(H4SO nection of ECM
2.5)-36, Engine connector.
Control Module
(ECM).>
TION METER AND ECM CONNECTOR. '? ness and connec-
coupling connector
nector.
5) and battery ter-
minal
• Poor contact in
nector

DIAGNOSIS:
TROUBLE SYMPTOM:
Monitor display.
WIRING DIAGRAM:
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
i3
8
B38
17
B134 ECM E
B72 B134 i10 B38
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
EN-01985
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
TION METER AND ECM CONNECTOR. light illuminate? circuit in harness <Ref. to FU(H4SO
1) Turn the ignition switch to OFF. between combina- 2.5)-36, Engine
2) Disconnect the connector from ECM. tion meter and Control Module
3) Turn the ignition switch to ON. ECM connector. (ECM).>

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
*1 : WITH IMMOBILIZER: D15
WITHOUT IMMOBILIZER: D14
* 2 : TERMINAL No. RANDOM ARRANGEMENT

16
LHD
B138 B122
1 1 RHD
*2 2
i3
B75 B76
*2 1
8
B38
B21
36
C19
A17
*1
E2
A: B134 C: B136 D: B137 ECM E E
B75 B72 i10 B38 B21
1 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11
2 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B138 A: B134 C: B136 34 35 36 37 38 39 40 41

D: B137
42 43 44 45 46 47
48 49 50 51 52 53 54
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
5 6 7 8 8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02454
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2) Disconnect the test mode connectors. to EN(H4SO
3) Turn the ignition switch to ON. (engine 2.5)(diag)-46,
OFF) MALFUNCTION
INDICATOR
LIGHT DOES
NOT COME ON,
Malfunction Indica-
tor Light.>
3 CHECK HARNESS BETWEEN COMBINA- Does malfunction indicator Repair the short Go to step 4.
CONNECTOR AND CHASSIS GROUND. '? ness and connec-
tor and chassis
ground
connector.
TEST MODE CONNECTOR. '? circuit in harness
Model with immobilizer
Model without immobilizer
Control Module
(ECM).>

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
* 2 : TERMINAL No. RANDOM ARRANGEMENT

16
LHD
B138 B122
1 1 RHD
*2 2
i3
B75 B76
*2 1
8
B38
B21
36
C19
A17
*1
E2
A: B134 C: B136 D: B137 ECM E E
B75 B72 i10 B38 B21
1 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11
2 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B138 A: B134 C: B136 34 35 36 37 38 39 40 41

D: B137
42 43 44 45 46 47
48 49 50 51 52 53 54
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
5 6 7 8 8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02454
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
Malfunction indica-
tor light blinks
when test mode
connector is con-
nected.
NECTOR AND CHASSIS GROUNDING TER- '? circuit in harness <Ref. to FU(H4SO
MINAL. between ECM and 2.5)-36, Engine
1) Turn the ignition switch to OFF. test mode connec- Control Module
2) Disconnect the connector from ECM. tor. (ECM).>

A: PROCEDURE
(
2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.5)(diag)-55, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>
(
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO 2.5)(diag)-58, CHECK POWER SUPPLY AND GROUND
(
4. Inspection of ignition control system. <Ref. to EN(H4SO 2.5)(diag)-61, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
(
5. Inspection of fuel pump circuit. <Ref. to EN(H4SO 2.5)(diag)-64, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
(
6. Inspection of fuel injector circuit. <Ref. to EN(H4SO 2.5)(diag)-67, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>

CAUTION:
41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>.
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
E
15
13
LHD
16
14
RHD
STARTER
RELAY
B225 STARTER MOTOR
15
13
RHD
16
14
LHD
M
B14
B32
D8
ECM
B: B135
D: B137
B72 B225
B: B135 D: B137
1 2 3 1 2 9 13 17 21
4 5 6 10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02455
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
ate?
EN(H4SO 2.5)(diag)-33, vant DTC using contact in ECM
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
TOR.
motor.
ground.
NOTE:
Place the select lever in the “P” or “N” range.
MOTOR. '? motor. <Ref. to circuit of ground
starter motor.
ground.
ignition switch connector and chassis ground. fuse SBF No. 7
Connector & terminal and SBF No. 1.
Step Check Yes No

1) Disconnect the connector from ignition '? tion switch.
switch.
switch terminals after turning the ignition
Terminals
No. 2 — No. 3:
2) Disconnect the connector from starter relay. fan relay and igni-
3) Connect the connector to ignition switch. tion switch.
relay connector and chassis ground after turn-
LHD model
RHD model
1) Connect the battery to starter relay termi- '? starter relay.
relay terminals.
Terminals
No. 13 — No. 14:
11 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Replace the ECM. Repair the open or
1) Turn the ignition switch to OFF. <Ref. to FU(H4SO ground short cir-
2) Connect the connector to starter relay. 2.5)-36, Engine cuit in harness
3) Disconnect the connectors from ECM. Control Module between ECM and
4) Measure the voltage between ECM and (ECM).> starter relay.
chassis ground.

ULE (ECM)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
* 3
* 4
B72
IGNITION
SWITCH BATTERY
6 3
B19
B6
*B51
2
*
A: B134
B: B135 ECM
D: B137
* 2 : WITH IMMOBILIZER: D14
* 3 : LHD MODEL: 1
B12
RHD MODEL: 2
B1
A6
A7
D3
D7
D1
D2
B4
*4 : LHD MODEL: 2
RHD MODEL: 1
B21
52
47
34
36
35
37
E2
E E
B72 B47 B21 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
12 13 14 15 16 17 18 19 20 21 22
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02456
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Turn the ignition switch to OFF. '? relay.
No. 1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
1) Disconnect the connector from ECM. '? circuit in harness
LHD model main relay connec-
(B47) No. 1 (+) — Chassis ground ("): tor.
RHD model
Step Check Yes No

2) Measure the voltage between ECM con- <Ref. to EN(H4SO cuit in harness
nector and chassis ground. 2.5)(diag)-61, between ECM
Connector & terminal IGNITION CON- connector and
(B135) No. 5 (+) — Chassis ground ("): TROL SYSTEM, main relay connec-
(B135) No. 6 (+) — Chassis ground ("): Diagnostics for tor.
Engine Starting
Failure.>

CAUTION:
WIRING DIAGRAM:
B135 ECM
17
18
B225 RELAY HOLDER B47 MAIN RELAY

BATTERY
15A SBF-8
2 1 3 5
B21
15
13
49
E2
E12
3
1
2
4
3 4
1 2
IGNITION COIL
&
IGNITOR ASSY
E E
E12 B47 B225 B21 B135
1 2 3 4 1 2 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
3 4 8 9 10 11 12 13 14 15 16 17 18 19
10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
5 6 3 4
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33 20 21 22 23 24 25 26 27
5 6 28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
7 8 25 29 33 37
42 43 44 45 46 47
26 30 34 38
48 49 50 51 52 53 54
27 28 31 32 35 36 39 40
EN-01989
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Remove the plug cord cap from each spark inder? system. <Ref. to
plug. EN(H4SO
2) Install a new spark plug on plug cord cap. 2.5)(diag)-64,
CAUTION: FUEL PUMP CIR-
Do not remove the spark plug from engine. CUIT, Diagnostics
3) Contact the spark plug’s thread portion on for Engine Start-
engine. ing Failure.>
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
Connector & terminal tor ASSY and
(E12) No. 2 (+) — Engine ground ("): main relay connec-
tor
• Poor contact in
coupling connector
• Blown out fuse
NITOR ASSY GROUND CIRCUIT. '? ness and connec-
ignition coil & igni-
tor ASSY connec-
tor and engine
grounding terminal
5 CHECK IGNITION COIL & IGNITOR ASSY. Is the resistance 10 — 15 k'? Go to step 6. Replace the igni-
1) Remove the spark plug cords. tion coil & ignitor
2) Measure the resistance between spark ASSY. <Ref. to
plug cord contact portions to check secondary IG(H4SO 2.0)-8,
coil. Ignition Coil & Igni-
Terminals tor ASSY.>
No. 1 — No. 2:
No. 3 — No. 4:
Step Check Yes No

6 CHECK INPUT SIGNAL FOR IGNITION COIL Does the voltage vary more Go to step 7. Replace the igni-
& IGNITOR ASSY. than 10 V? tion coil & ignitor
1) Connect the connector to ignition coil & ASSY. <Ref. to
ignitor ASSY. IG(H4SO 2.0)-8,
2) Check if voltage varies synchronously with Ignition Coil & Igni-
engine speed when cranking, while monitoring tor ASSY.>
voltage between ignition coil & ignitor ASSY
connector and engine ground.
NITION COIL & IGNITOR ASSY CONNEC- '? ness and connec-
TOR. tor.
NITION COIL & IGNITOR ASSY CONNEC- M'? short circuit in har-
TOR. ness between
9 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check fuel pump
Check poor contact in ECM connector. connector? contact in ECM circuit. <Ref. to
connector. EN(H4SO
2.5)(diag)-64,
FUEL PUMP CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>

CAUTION:
WIRING DIAGRAM:
No.11
B72 IGNITION
SWITCH BATTERY
No.12 SBF-7 SBF-1
FUEL PUMP 6 3
RELAY
2
3
4
1
* B135 ECM
B362
RHD
LHD
* : WITH IMMOBILIZER: 27
B98 B97 WITHOUT IMMOBILIZER: 26
16
4
R2 R1
RHD
LHD
FUEL PUMP
FUEL PUMP CONDENSER
5 1
M 6 2
R58 R142
E E
B362 B72 R142 B97 B98 R58 B135
1 2 3 1 1 2 3 4 5 6 7 1 2 3 1 2 1 2 3 4 5 6 7
3
1 2 4 5 6 2 8 9 10 11 12 13 14 15 16 4 5 6 7 8 3 4
4 8 9 10 11 12 13 14 15 16 17 18 19
5 6 20 21 22 23 24 25 26 27
5
7 8 28 29 30 31 32 33 34 35
6
EN-02457
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Go to step 3.
PUMP. operating sound? injector circuit.
Check the fuel pump is in operation for two <Ref. to EN(H4SO
seconds when turning the ignition switch to 2.5)(diag)-67,
ON. FUEL INJECTOR
NOTE: CIRCUIT, Diag-
Fuel pump operation can also be executed us- nostics for Engine
ing Subaru Select Monitor. Starting Failure.>
Refer to “Compulsory Valve Operation Check
Mode” for procedures. <Ref. to EN(H4SO
Check Mode.>
3 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Go to step 4. Repair the har-
1) Turn the ignition switch to OFF. '? ness and connec-
2) Remove the fuel pump access hole lid. tor.
3) Disconnect the connector from fuel pump. NOTE:
4) Measure the resistance of harness connec- In this case, repair
tor between fuel pump and chassis ground. the following:
(R58) No. 6 — Chassis ground: harness between
fuel pump connec-
tor and chassis
grounding terminal
4 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V? Replace the fuel Go to step 5.
1) Turn the ignition switch to ON. pump. <Ref. to
2) Measure the voltage of power supply circuit FU(H4SO 2.5)-49,
between fuel pump connector and chassis Fuel Pump.>
ground.
(R58) No. 5 (+) — Chassis ground ("):
AND FUEL PUMP RELAY CONNECTOR. '? ness and connec-
2) Measure the resistance of harness connec- NOTE:
tor between fuel pump and fuel pump relay. In this case, repair
(R58) No. 5 — (B362) No. 1: • Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
• Poor contact in
coupling connector
6 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 7. Repair the short
AND FUEL PUMP RELAY CONNECTOR. M'? circuit in harness
fuel pump and fuel pump relay connector. and fuel pump
Connector & terminal relay connector.
Step Check Yes No

7 CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 8. Replace the fuel
1) Disconnect the connectors from fuel pump '? pump relay. <Ref.
relay and main relay. to FU(H4SO 2.5)-
2) Remove the fuel pump relay and main relay 49, Fuel Pump.>
with bracket.
3) Connect the battery to fuel pump relay con-
nector terminals No. 3 and No. 4.
terminals of fuel pump relay.
Terminals
No. 2 — No. 1:
FUEL PUMP RELAY CONNECTOR. '? circuit in harness
2) Measure the resistance of harness fuel pump relay
between ECM and fuel pump relay connector. connector.
(B135) No. 27 — (B362) No. 4:
(B135) No. 26 — (B362) No. 4:
Check poor contact in ECM connector. connector? contact in ECM injector circuit.
connector. <Ref. to EN(H4SO
2.5)(diag)-67,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>

CAUTION:
• After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(di-
ag)-41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection
Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
BATTERY
3
SBF-8
6
4
2
1
B47
B136 ECM
6
3
B21
48
42
43
44
45
E2
E5 E16 E6 E17
2

No. 1 No. 2 No. 3 No. 4
E5 E16 B47 B21 B136
E6 E17 1 2
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6
3 4 7 8 9 10 11 12 13
12 13 14 15 16 17 18 19 20 21 22 14 15 16
1 2 5 6
23 24 25 26 27 28 29 30 31 32 33 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-01991
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit oper- Check the fuel Go to step 3.
TOR. ating sound? pressure. <Ref. to
While cranking the engine, check each fuel ME(H4SO 2.0)-27,
injector emits operating sound. Use a sound INSPECTION,
scope or apply a screwdriver to the injector for Fuel Pressure.>
this check.
tor
• Poor contact in
coupling connector
• Poor contact in
fuel injector con-
nector
FUEL INJECTOR CONNECTOR. '? ness and connec-
• Poor contact in
coupling connector
FUEL INJECTOR CONNECTOR. M'? short circuit in har-
Step Check Yes No

6 CHECK EACH FUEL INJECTOR. Is the resistance 5 — 20 '? Go to step 7. Replace the faulty
injector terminals.
Terminals
No. 1 — No. 2:
7 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Inspection using
EN(H4SO
2.5)(diag)-261,
INSPECTION,
General Diagnos-
tic Table.>

A: LIST
1. EC, EK AND K4 MODEL
DTC Item NOTE
ble Code (DTC).>
P0102 Mass or Volume Air Flow Circuit Low <Ref. to EN(H4SO 2.5)(diag)-92, DTC P0102 MASS OR VOLUME AIR
Input FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0103 Mass or Volume Air Flow Circuit High <Ref. to EN(H4SO 2.5)(diag)-95, DTC P0103 MASS OR VOLUME AIR
Input FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0112 Intake Air Temperature Circuit Low <Ref. to EN(H4SO 2.5)(diag)-103, DTC P0112 INTAKE AIR TEMPERA-
Input TURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0113 Intake Air Temperature Circuit High <Ref. to EN(H4SO 2.5)(diag)-105, DTC P0113 INTAKE AIR TEMPERA-
Input TURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
DTC Item NOTE

P0301 Cylinder 1 misfire detected <Ref. to EN(H4SO 2.5)(diag)-146, DTC P0301 CYLINDER 1 MISFIRE
(DTC).>
DTC Item NOTE

(DTC).>
(DTC).>
Code (DTC).>
(DTC).>
Code (DTC).>
(DTC).>
P1086 Tumble Generated Valve Position <Ref. to EN(H4SO 2.5)(diag)-192, DTC P1086 TUMBLE GENERATED
Sensor 2 Circuit Low VALVE POSITION SENSOR 2 CIRCUIT LOW, Diagnostic Procedure with
Sensor 2 Circuit High VALVE POSITION SENSOR 2 CIRCUIT HIGH, Diagnostic Procedure with
Sensor 1 Circuit Low VALVE POSITION SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with
DTC Item NOTE

Sensor 1 Circuit High VALVE POSITION SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with
P1090 Tumble Generated Valve System 1 <Ref. to EN(H4SO 2.5)(diag)-202, DTC P1090 TUMBLE GENERATED
(Valve Open) VALVE SYSTEM 1 (VALVE OPEN), Diagnostic Procedure with Diagnostic
(Valve Close) VALVE SYSTEM 1 (VALVE CLOSE), Diagnostic Procedure with Diagnostic
(Valve Open) VALVE SYSTEM 2 (VALVE OPEN), Diagnostic Procedure with Diagnostic
(Valve Close) VALVE SYSTEM 2 (VALVE CLOSE), Diagnostic Procedure with Diagnostic
P1094 Tumble Generated Valve Signal 1 <Ref. to EN(H4SO 2.5)(diag)-206, DTC P1094 TUMBLE GENERATED
Circuit Malfunction (Open) VALVE SIGNAL 1 CIRCUIT MALFUNCTION (OPEN), Diagnostic Procedure
Circuit Malfunction (Short) VALVE SIGNAL 1 CIRCUIT MALFUNCTION (SHORT), Diagnostic Proce-
Circuit Malfunction (Open) VALVE SIGNAL 2 CIRCUIT MALFUNCTION (OPEN), Diagnostic Procedure
Circuit Malfunction (Short) VALVE SIGNAL 2 CIRCUIT MALFUNCTION (SHORT), Diagnostic Proce-
P1110 Atmospheric Pressure Sensor Circuit <Ref. to EN(H4SO 2.5)(diag)-214, DTC P1110 ATMOSPHERIC PRES-
Malfunction (Low Input) SURE SENSOR CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
P1111 Atmospheric Pressure Sensor Circuit <Ref. to EN(H4SO 2.5)(diag)-215, DTC P1111 ATMOSPHERIC PRES-
Malfunction (High Input) SURE SENSOR CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Pro-
P1152 O2 Sensor Circuit Range/Perfor- <Ref. to EN(H4SO 2.5)(diag)-216, DTC P1152 O2 SENSOR CIRCUIT
mance (Low) (Bank1 Sensor1) RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Proce-
P1153 O2 Sensor Circuit Range/Perfor- <Ref. to EN(H4SO 2.5)(diag)-218, DTC P1153 O2 SENSOR CIRCUIT
mance (High) (Bank1 Sensor1) RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Proce-
DTC Item NOTE

(DTC).>
(DTC).>
P1572 IMM Circuit Failure (Except Antenna <Ref. to IM(diag)-22, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
Circuit) ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Code (DTC).>
DTC Item NOTE

2. KA AND KS MODEL
DTC Item NOTE
ble Code (DTC).>
P0112 Intake Air Temperature Circuit Low <Ref. to EN(H4SO 2.0)(diag)-89, DTC P0112 INTAKE AIR TEMPERATURE
(DTC).>
P0113 Intake Air Temperature Circuit High <Ref. to EN(H4SO 2.0)(diag)-91, DTC P0113 INTAKE AIR TEMPERATURE
(DTC).>
P0130 O2 Sensor Circuit (Bank 1 Sensor 1) <Ref. to EN(H4SO 2.0)(diag)-107, DTC P0130 O2 SENSOR CIRCUIT
(BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
DTC Item NOTE

(DTC).>
DTC Item NOTE

(DTC).>
(DTC).>
Code (DTC).>
(DTC).>
Code (DTC).>
(DTC).>
P1134 A/F Sensor Micro-Computer Problem <Ref. to EN(H4SO 2.0)(diag)-176, DTC P1134 A/F SENSOR MICRO-COM-
PUTER PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1137 O2 Sensor Circuit (Lamda=1) (Bank1 <Ref. to EN(H4SO 2.0)(diag)-178, DTC P1137 O2 SENSOR CIRCUIT
Sensor1) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
DTC Item NOTE

(DTC).>
P1521 Brake Switch Circuit Range/Perfor- <Ref. to EN(H4SO 2.0)(diag)-189, DTC P1521 BRAKE SWITCH CIRCUIT
mance Problem (High Input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT), Diagnostic Procedure
(DTC).>
P1572 IMM Circuit Failure (Except antenna <Ref. to IM(diag)-22, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
circuit) ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P2100 Throttle Control Motor Circuit Open <Ref. to EN(H4SO 2.0)(diag)-192, DTC P2100 THROTTLE CONTROL
MOTOR CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
DTC Item NOTE

Code (DTC).>
P2111 Throttle Actuator Control System - <Ref. to EN(H4SO 2.0)(diag)-205, DTC P2111 THROTTLE ACTUATOR
Stuck Open CONTROL SYSTEM - STUCK OPEN, Diagnostic Procedure with Diagnostic
ENGINE SECTION 1



(diag)


approval.

ENGINE SECTION 1

(diag)
G2320GE2
EN(H4SO 2.5)(diag)
Page
11. Inspection Mode........................................................................................34
12. Drive Cycle................................................................................................39

A: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
SENSOR RELAY BATTERY
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
FRONT OXYGEN (A/F) SENSOR CONNEC- !? circuit in harness
1) Start and warm-up the engine. front oxygen (A/F)
2) Turn the ignition switch to OFF. sensor connector.
3) Disconnect the connectors from ECM and
connector.
(B134) No. 2 — (E24) No. 6:
(B134) No. 3 — (E24) No. 6:
ECM and front oxygen (A/F) sensor connector. sensor connector.
(B134) No. 26 — (E24) No. 1:
(B134) No. 33 — (E24) No. 3:
main relay and front oxygen (A/F) sensor con- sensor connector.
nector.
(B327) No. 4 — (E24) No. 4:
5 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 5 Go to step 6. Replace the front
Measure the resistance between front oxygen !? oxygen (A/F) sen-
(A/F) sensor connector terminals. sor. <Ref. to
Terminals FU(H4SO 2.5)-34,
No. 4 — No. 6: Front Oxygen (A/
F) Sensor.>
6 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front
Check the poor contact in ECM and front oxy- front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen-
gen (A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to
sensor connector. FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>
B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

Immediately at fault recognition.
CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Do DTC P0031 and P0037 Go to step 3. Go to step 6.
appear at the same time on the
Subaru Select Monitor?
(E24) No. 4 (+) — Engine ground ("): sensor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
main relay connec-
tor
Measure the resistance of harness between !? ness and connec-
ECM connector and chassis ground. tor.
(B134) No. 6 — Chassis ground: In this case, repair
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector.
• Poor contact in
coupling connector
5 CHECK CURRENT DATA. Is the current more than 0.2 A? Repair the poor Go to step 6.
1) Start the engine. contact connector.
2) Read the data of front oxygen (A/F) sensor NOTE:
heater current using Subaru Select Monitor. In this case, repair
For detailed operation procedure, refer to the • Poor contact in
“READ CURRENT DATA FOR ENGINE”. <Ref. front oxygen (A/F)
to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- sensor connector
ECM connector.
Step Check Yes No

8 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. !? ness and connec- oxygen (A/F) sen-
2) Measure the resistance between front oxy- tor. sor. <Ref. to
gen (A/F) sensor connector terminals. NOTE: FU(H4SO 2.5)-34,
Terminals In this case, repair Front Oxygen (A/
No. 4 — No. 6: the following: F) Sensor.>
• Open or ground
ness between front
oxygen (A/F) sen-
sor and ECM con-
nector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
C: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the current more than 2.3 A? Replace the ECM. END.
HEATER CURRENT. <Ref. to FU(H4SO
1) Turn the ignition switch to OFF. 2.5)-36, Engine
2) Repair the battery short circuit in harness Control Module
between ECM and front oxygen (A/F) sensor (ECM).>
connector.
heater current using Subaru Select Monitor.
NOTE:
For detailed operation procedure, refer to the
itor.>
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change by Repair the battery END.
Measure the voltage between ECM connector shaking the ECM harness and short circuit in har-
and chassis ground. connector? ness between
D: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
OXYGEN SENSOR
RELAY BATTERY B19 B327 B83
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
4
2
B21
2
REAR
1
OXYGEN SENSOR
1 2 3 4 5 6 7 8 9 10 11
B327 B19 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
B83 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
RHD
*
RHD
*
LHD 4 A: B134
LHD 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B83 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D24
C35
D31
B2
B: B135
A: B134
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
ECM 20 21 22 23 24 25 26 27
C: B136 28 29 30 31 32 33 34 35
D: B137
C: B136
A6
A7
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
B21
52
D: B137
E2
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
* : TERMINAL No. RANDOM ARRANGEMENT
E E 26 27 28 29 30 31
EN-02458
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Repair the har-
1) Turn the ignition switch to OFF. !? ness and connec-
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
3 CHECK CURRENT DATA. Is the current 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. In this case, repair
For detailed operation procedure, refer to the • Poor contact in
“READ CURRENT DATA FOR ENGINE”. <Ref. rear oxygen sen-
to EN(H4SO 2.5)(diag)-26, Subaru Select Mon- sor connector
rear oxygen sen-
sor connecting
harness connector
• Poor contact in
ECM connector
Step Check Yes No

6 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Replace the ECM. Repair the battery
1) Disconnect the connector from rear oxygen <Ref. to FU(H4SO short circuit in har-
sensor. 2.5)-36, Engine ness between
2) Measure the voltage between ECM con- Control Module ECM and rear oxy-
nector and chassis ground. (ECM).> gen sensor con-
Connector & terminal nector. After
(B135) No. 2 (+) — Chassis ground ("): repair, replace the
ECM. <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
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 chassis ground. main relay and
(B19) No. 2 (+) — Chassis ground ("): sor connector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
coupling connector
1) Turn the ignition switch to OFF. !? ness and connec- oxygen sensor.
2) Measure the resistance between rear oxy- tor. <Ref. to FU(H4SO
gen (A/F) sensor connector terminals. NOTE: 2.5)-35, Rear Oxy-
Terminals In this case, repair gen Sensor.>
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
• Poor contact in
coupling connector
E: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
OXYGEN SENSOR
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
4
2
B21
2
REAR
1
OXYGEN SENSOR
1 2 3 4 5 6 7 8 9 10 11
B327 B19 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
B83 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
RHD
*
RHD
*
LHD 4 A: B134
LHD 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B83 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D24
C35
D31
B2
B: B135
A: B134
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
ECM 20 21 22 23 24 25 26 27
C: B136 28 29 30 31 32 33 34 35
D: B137
C: B136
A6
A7
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
B21
52
D: B137
E2
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
E E 26 27 28 29 30 31
EN-02458
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
and chassis ground.
3 CHECK CURRENT DATA. Is the current more than 7 A? Replace the ECM. END.
1) Turn the ignition switch to OFF. <Ref. to FU(H4SO
2) Repair the battery short circuit in harness 2.5)-36, Engine
between ECM and rear oxygen sensor con- Control Module
nector. (ECM).>
4) Read the data of rear oxygen sensor heater
current using Subaru Select Monitor.
NOTE:
itor.>
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END.
connector.
F: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

INTAKE AIR TEMPERATURE
SENSOR
B3
5
B83
* RHD
RHD
*
2 LHD
8 LHD
B83
31
32
23
35
13
E
B136 ECM * : TERMINAL No. RANDOM ARRANGEMENT
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4 5
1 2 3 4
3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-02459
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 READ THE DATA CONNECTING SUBARU Is the voltage 0.2 — 4.7 V? Even if the mal- Go to step 3.
SELECT MONITOR. function indicator
1) Turn the ignition switch to OFF. light illuminates,
2) Connect the Subaru Select Monitor to data the circuit has
link connector. returned to a nor-
3) Turn the ignition switch to ON, and the Sub- mal condition at
aru Select Monitor switch to ON. this time. A tempo-
4) Start the engine. rary poor contact
5) Read the voltage of mass air flow sensor of the connector or
using Subaru Select Monitor. harness may be
NOTE: the cause. Repair
For detailed operation procedure, refer to the harness or con-
“READ CURRENT DATA SHOWN ON DIS- nector in the mass
PLAY FOR ENGINE”. <Ref. to EN(H4SO air flow sensor.
2.5)(diag)-26, Subaru Select Monitor.> NOTE:
the following:
• Open or ground
ness between
mass air flow sen-
sor and ECM con-
nector
• Poor contact in
mass air flow sen-
sor or ECM con-
nector
3 CHECK INPUT SIGNAL OF ECM. Is the voltage more than 0.2 V? Go to step 5. Go to step 4.
and chassis ground while engine is idling.
4 CHECK INPUT SIGNAL FOR ECM (USING Does the voltage change by Repair the poor Replace the ECM.
SUBARU SELECT MONITOR). shaking the harness and con- contact in ECM <Ref. to FU(H4SO
Measure the voltage between ECM connector nector of ECM while monitor- connector. 2.5)-36, Engine
and chassis ground while engine is idling. ing the value with Subaru Control Module
Select Monitor? (ECM).>
5 CHECK POWER SUPPLY TO MASS AIR Is the voltage more than 5 V? Go to step 6. Repair the open
FLOW SENSOR. circuit between
1) Turn the ignition switch to OFF. mass air flow sen-
2) Disconnect the connector from mass air sor and main relay
flow sensor.
4) Measure voltage between mass air flow
sensor connector and chassis ground.
Step Check Yes No

MASS AIR FLOW SENSOR CONNECTOR. !? circuit between
1) Turn the ignition switch to OFF. ECM and mass air
2) Disconnect the connector from ECM. flow sensor con-
between ECM and mass air flow sensor con-
nector.
(B136) No. 23 — (B3) No. 3:
(B136) No. 31 — (B3) No. 2:
(B136) No. 35 — (B3) No. 5:
MASS AIR FLOW SENSOR CONNECTOR. M!? short circuit
Measure the resistance of harness between between ECM and
ECM and chassis ground. mass air flow sen-
Connector & terminal sor connector.
8 CHECK POOR CONTACT. Is there poor contact in mass Repair the poor Replace the mass
Check poor contact in mass air flow sensor air flow sensor connector? contact in mass air air flow and intake
connector. flow sensor con- air temperature
nector. sensor. <Ref. to
FU(H4SO 2.5)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
G: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
B83
* RHD
RHD
*
2 LHD
8 LHD
B83
31
32
23
35
13
E
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4 5
1 2 3 4
3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-02459
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
aru Select Monitor switch to ON. this time.
5) Read the voltage of mass air flow sensor
NOTE:
itor.>
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 5 V? Repair the battery Go to step 4.
MASS AIR FLOW SENSOR CONNECTOR. short circuit in har-
2) Disconnect the connector from mass air- mass air flow sen-
flow sensor. sor connector and
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Replace the mass Repair the open
MASS AIR FLOW SENSOR CONNECTOR. !? air flow sensor. circuit in harness
1) Turn the ignition switch to OFF. <Ref. to FU(H4SO between mass air
2) Disconnect the connector from ECM. 2.5)-26, Mass Air flow sensor con-
3) Measure the resistance of harness Flow and Intake nector and ECM
between ECM connector and mass air flow Air Temperature connector.
sensor connector. Sensor.>
(B3) No. 2 — (B136) No. 31:
H: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
MANIFOLD E21
ABSOLUTE
PRESSURE 1 2 3
SENSOR
2
1
3
E21 B83
B122
B138
1 2 3 4
5 6 7 8
E2
19
20
B21
7
B21
1 2 3 4 5 6 7 8 9 10 11
B83
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
* RHD
B138 : LHD 34 35 36 37 38 39 40 41
* RHD
B122 : RHD
42 43 44 45 46 47
48 49 50 51 52 53 54
3 LHD 2
8 LHD 1
B83 B136
1 2 3 4 5 6
* : TERMINAL No. RANDOM ARRANGEMENT 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
35
22
16
B136 ECM
EN-02460
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK CURRENT DATA. Is the value less than 13.3 kPa Go to step 4. Go to step 3.
1) Start the engine. (100 mmHg, 3.94 inHg)?
NOTE:
itor.>
3 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Even if the mal-
Check the poor contact in ECM and manifold manifold pressure sensor con- contact in ECM or function indicator
pressure sensor connector. nector? manifold pressure light illuminates,
sensor connector. the circuit has
returned to a nor-
mal condition at
this time.
and chassis ground.
5 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change when Repair the poor Replace the ECM.
6 CHECK INPUT SIGNAL TO ECM. Is the voltage less than 0.2 V? Go to step 8. Go to step 7.
sis ground.
7 CHECK INPUT SIGNAL TO ECM (USING Is the value more than 13.3 Repair the poor Go to step 8.
NOTE:
itor.>
Step Check Yes No

engine ground.
MANIFOLD ABSOLUTE PRESSURE SEN- !? circuit in harness
sensor connector.
(B136) No. 35 — (E21) No. 2:
lute Pressure Sen-
sor.>
I: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
MANIFOLD E21
ABSOLUTE
PRESSURE 1 2 3
SENSOR
2
1
3
E21 B83
B122
B138
1 2 3 4
5 6 7 8
E2
19
20
B21
7
B21
1 2 3 4 5 6 7 8 9 10 11
B83
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
* RHD
B138 : LHD 34 35 36 37 38 39 40 41
* RHD
B122 : RHD
42 43 44 45 46 47
48 49 50 51 52 53 54
3 LHD 2
8 LHD 1
B83 B136
1 2 3 4 5 6
* : TERMINAL No. RANDOM ARRANGEMENT 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
35
22
16
B136 ECM
EN-02460
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK CURRENT DATA. Is the value more than 119.5 Go to step 11. Go to step 3.
1) Start the engine. kPa (896.5 mmHg, 35.29
2) Read the data of intake manifold absolute inHg)?
NOTE:
itor.>
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change when Repair the poor Replace the ECM.
5 CHECK INPUT SIGNAL TO ECM. Is the voltage less than 0.2 V? Go to step 7. Go to step 6.
and chassis ground.
6 CHECK INPUT SIGNAL TO ECM (USING Is the value more than 13.3 Repair the poor Go to step 7.
NOTE:
itor.>
engine ground.
Step Check Yes No

sensor connector.
(B136) No. 22 — (E21) No. 1:
(B136) No. 35 — (E21) No. 2:
sure sensor connector. connector? fold absolute pres-
sure sensor. <Ref.
lute Pressure Sen-
sor.>
11 CHECK HARNESS BETWEEN ECM AND Is the value more than 119.5 Repair battery Replace the mani-
MANIFOLD ABSOLUTE PRESSURE SEN- kPa (896.5 mmHg, 35.29 short in harness fold absolute pres-
SOR CONNECTOR. inHg)? between ECM and sure sensor. <Ref.
1) Turn the ignition switch to OFF, and the manifold absolute to FU(H4SO 2.5)-
Subaru Select Monitor switch to OFF. pressure sensor 25, Manifold Abso-
2) Disconnect the connector from manifold connector. lute Pressure Sen-
absolute pressure sensor. sor.>
3) Turn the ignition switch to ON, and the Sub-
aru Select Monitor switch to ON.
NOTE:
itor.>
J: DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
B83
* RHD
RHD
*
2 LHD
8 LHD
B83
31
32
23
35
13
E
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4 5
1 2 3 4
3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-02459
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Start the engine. more than 120#C (248#F)? contact.
2) Read the data of mass air flow and intake NOTE:
air temperature sensor signal using Subaru In this case, repair
Select Monitor. the following:
For detailed operation procedure, refer to the mass air flow and
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN MASS AIR Is the intake air temperature Replace the mass Repair the ground
FLOW AND INTAKE AIR TEMPERATURE less than "40#C ("40#F)? air flow and intake short circuit in har-
SENSOR AND ECM CONNECTOR. air temperature ness between
1) Turn the ignition switch to OFF. sensor. <Ref. to mass air flow and
2) Disconnect the connector from mass air FU(H4SO 2.5)-26, intake air tempera-
flow and intake air temperature sensor. Mass Air Flow and ture sensor and
3) Turn the ignition switch to ON. Intake Air Temper- ECM connector.
4) Read the data of mass air flow and intake ature Sensor.>
air temperature sensor signal using Subaru
Select Monitor.
NOTE:
itor.>
K: DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
B83
* RHD
RHD
*
2 LHD
8 LHD
B83
31
32
23
35
13
E
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4 5
1 2 3 4
3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-02459
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Start the engine. less than "40#C ("40#F)? contact.
2) Read the data of air flow and intake air tem- NOTE:
perature sensor signal using Subaru Select In this case, repair
Monitor. the following:
For detailed operation procedure, refer to the mass air flow and
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 10 V? Repair the battery Go to step 4.
FLOW AND INTAKE AIR TEMPERATURE short circuit in har-
SENSOR AND ECM CONNECTOR. ness between
1) Turn the ignition switch to OFF. mass air flow and
2) Disconnect the connector from mass air intake air tempera-
flow and intake air temperature sensor. ture sensor and
3) Measure the voltage between mass air flow ECM connector.
and intake air temperature sensor connector
and engine ground.
1) Turn the ignition switch to ON. mass air flow and
2) Measure the voltage between mass air flow intake air tempera-
and intake air temperature sensor connector ture sensor and
and engine ground. ECM connector.
Step Check Yes No

5 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 3 V? Go to step 6. Repair the har-
FLOW AND INTAKE AIR TEMPERATURE ness and connec-
SENSOR AND ECM CONNECTOR. tor.
Measure the voltage between mass air flow NOTE:
and intake air temperature sensor connector In this case, repair
and engine ground. the following:
(B3) No. 4 (+) — Engine ground ("): harness between
mass air flow and
intake air tempera-
ture sensor and
ECM connector
• Poor contact in
mass air flow and
intake air tempera-
ture sensor
• Poor contact in
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
6 CHECK HARNESS BETWEEN MASS AIR Is the resistance less than 5 Replace the mass Repair the har-
FLOW AND INTAKE AIR TEMPERATURE !? air flow and intake ness and connec-
SENSOR AND ECM CONNECTOR. air temperature tor.
1) Turn the ignition switch to OFF. sensor. <Ref. to NOTE:
between mass air flow and intake air tempera- Mass Air Flow and the following:
ture sensor connector and engine ground. Intake Air Temper- • Open circuit in
Connector & terminal ature Sensor.> harness between
(B3) No. 5 — Engine ground: mass air flow and
intake air tempera-
ture sensor and
ECM connector
• Poor contact in
mass air flow and
intake air tempera-
ture sensor
• Poor contact in
ECM
• Poor contact in
joint connector
L: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
• Hard to start
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR
1 2
2
1
E8
B83
1 2 3 4
5 6 7 8
E2
19
8
B21
B83
B21
RHD
* 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
RHD
* 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
LHD 3
48 49 50 51 52 53 54
LHD 8
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 31 32 33 34 35
14
35
B136 ECM
EN-02461
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Start the engine. ture more than 150#C (302#F)? contact.
tor. the following:
For detailed operation procedure, refer to the engine coolant
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN ENGINE Is the engine coolant tempera- Replace the Repair the ground
COOLANT TEMPERATURE SENSOR AND ture less than "40#C ("40#F)? engine coolant short circuit in har-
2) Disconnect the connectors from the engine FU(H4SO 2.5)-20, temperature sen-
tor.
NOTE:
itor.>
M: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
• Hard to start
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR
1 2
2
1
E8
B83
1 2 3 4
5 6 7 8
E2
19
8
B21
B83
B21
RHD
* 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
RHD
* 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
LHD 3
48 49 50 51 52 53 54
LHD 8
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 31 32 33 34 35
14
35
B136 ECM
EN-02461
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Start the engine. ture less than "40#C ("40#F)? contact.
tor. the following:
For detailed operation procedure, refer to the engine coolant
ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
2) Disconnect the connectors from engine coolant tempera-
ground.
ground. nector.
Step Check Yes No

ECM CONNECTOR. tor.
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
• Poor contact in
joint connector
COOLANT TEMPERATURE SENSOR AND !? engine coolant ness and connec-
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
• Poor contact in
joint connector
N: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
* : TERMINAL NO. RANDOM ARRANGEMENT
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
present.
ELECTRONIC THROTTLE CONTROL. !? circuit of harness
throttle control.
(B136) No. 18 — (E57) No. 6:
(B136) No. 16 — (E57) No. 5:
ELECTRONIC THROTTLE CONTROL. M!? sis short circuit of
Repair the poor
3) Measure the voltage between electronic if defective. <Ref.
throttle control connector and engine ground. to FU(H4SO 2.5)-
(E57) No. 5 (+) — Engine ground ("): trol Module
(ECM).>
1) Turn the ignition switch to OFF. !? contact of elec- contact in ECM
Connector & terminal Replace the accel- if defective. <Ref.
(E57) No. 6 — Engine ground: erator position to FU(H4SO 2.5)-
sensor if defective. 36, Engine Con-
trol Module
(ECM).>
O: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1)Turn the ignition switch to ON. V?
2)Read the data of main throttle sensor signal
present.
throttle control.
(B136) No. 18 — (E57) No. 6:
(B136) No. 35 — (E57) No. 3:
ELECTRONIC THROTTLE CONTROL. !? contact in ECM
trol Module
(ECM).>
6 CHECK SENSOR OUTPUT POWER SUP- Is the voltage less than 10 V? Go to step 7. Repair the battery
PLY. short circuit in har-
connector.
ELECTRONIC THROTTLE CONTROL. M!? contact in harness. circuit to sensor
1) Turn the ignition switch to OFF. Replace the elec- power supply.
nectors.
(B136) No. 18 — (B136) No. 16:
P: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
TROUBLE SYMPTOM:
Engine will not return to idling.
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR
1 2
2
1
E8
B83
1 2 3 4
5 6 7 8
E2
19
8
B21
B83
B21
RHD
* 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
RHD
* 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
LHD 3
48 49 50 51 52 53 54
LHD 8
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 31 32 33 34 35
14
35
B136 ECM
EN-02461
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
3 CHECK ENGINE COOLING SYSTEM. Is there any fault in engine Replace the ther- Replace the
NOTE: cooling system? mostat. <Ref. to engine coolant
Check the following items. CO(H4SO 2.0)-18, temperature sen-
• Thermostat open stuck Thermostat.> sor. <Ref. to
• Coolant level FU(H4SO 2.5)-20,
• Coolant freeze Engine Coolant
• Tire diameter Temperature Sen-
sor.>
Q: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Replace the front Repair the ground
FRONT OXYGEN (A/F) SENSOR CONNEC- M!? oxygen (A/F) sen- short circuit in har-
1) Turn the ignition switch to OFF. FU(H4SO 2.5)-34, ECM and front
2) Disconnect the connector from ECM and Front Oxygen (A/ oxygen (A/F) sen-
front oxygen (A/F) sensor connector. F) Sensor.> sor connector.
R: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
1) Turn the ignition switch to ON. FU(H4SO 2.5)-34, ECM and front
S: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
3 CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair the exhaust Replace the front
NOTE: system? system. oxygen (A/F) sen-
Check the following items. sor. <Ref. to
• Loose installation of front portion of exhaust FU(H4SO 2.5)-34,
pipe onto cylinder heads Front Oxygen (A/
• Loose connection between front exhaust F) Sensor.>
pipe and front catalytic converter
• Damage of exhaust pipe resulting in a hole
T: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN-

SOR 1)
CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
FRONT OXYGEN (A/F) SENSOR CONNEC- !? ness and connec-
TOR. tor.
2) Disconnect the connector from ECM and In this case, repair
Connector & terminal oxygen (A/F) sen-
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
Front Oxygen (A/
F) Sensor.>
U: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
OXYGEN SENSOR
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
4
2
B21
2
REAR
1
OXYGEN SENSOR
1 2 3 4 5 6 7 8 9 10 11
B327 B19 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
B83 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
RHD
*
RHD
*
LHD 4 A: B134
LHD 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B83 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D24
C35
D31
B2
B: B135
A: B134
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
ECM 20 21 22 23 24 25 26 27
C: B136 28 29 30 31 32 33 34 35
D: B137
C: B136
A6
A7
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
B21
52
D: B137
E2
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
E E 26 27 28 29 30 31
EN-02458
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0137.
temperature is above 70#C (158#F), and keep
the engine speed at 5,000 rpm.
NOTE:
itor.>
REAR OXYGEN SENSOR CONNECTOR. !? circuit in harness
nector.
(B137) No. 24 — (B19) No. 3:
(B136) No. 35 — (B19) No. 4:
Step Check Yes No

nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
plete installation
sensor
V: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
OXYGEN SENSOR
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
4
2
B21
2
REAR
1
OXYGEN SENSOR
1 2 3 4 5 6 7 8 9 10 11
B327 B19 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
B83 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
RHD
*
RHD
*
LHD 4 A: B134
LHD 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B83 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D24
C35
D31
B2
B: B135
A: B134
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
ECM 20 21 22 23 24 25 26 27
C: B136 28 29 30 31 32 33 34 35
D: B137
C: B136
A6
A7
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
B21
52
D: B137
E2
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
E E 26 27 28 29 30 31
EN-02458
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0138.
temperature is above 70#C (158#F), and lower
the engine speed rapidly from 5,000 rpm.
NOTE:
itor.>
REAR OXYGEN SENSOR CONNECTOR. !? circuit in harness
nector.
(B137) No. 24 — (B19) No. 3:
(B136) No. 35 — (B19) No. 4:
Step Check Yes No

nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
plete installation
sensor
W: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
OXYGEN SENSOR
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
4
2
B21
2
REAR
1
OXYGEN SENSOR
1 2 3 4 5 6 7 8 9 10 11
B327 B19 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
B83 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
RHD
*
RHD
*
LHD 4 A: B134
LHD 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B83 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D24
C35
D31
B2
B: B135
A: B134
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
ECM 20 21 22 23 24 25 26 27
C: B136 28 29 30 31 32 33 34 35
D: B137
C: B136
A6
A7
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
B21
52
D: B137
E2
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
E E 26 27 28 29 30 31
EN-02458
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele- Replace the rear
vant DTC using oxygen sensor.
“List of Diagnostic <Ref. to FU(H4SO
Trouble Code 2.5)-35, Rear Oxy-
(DTC)”. <Ref. to gen Sensor.>
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
X: DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO 2.5)(diag)-137, DTC P0172 SYSTEM TOO
Y: DTC P0172 SYSTEM TOO RICH (BANK 1)

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair exhaust Go to step 3.
3 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or Repair air intake Go to step 4.
disconnection of hose on air system.
intake system?
4 CHECK EGR VALVE. Is the EGR valve stuck? Replace the EGR Go to step 5.
valve.
5 CHECK PURGE CONTROL SOLENOID Is the purge control solenoid Replace the purge Go to step 6.
VALVE. valve stuck? control solenoid
valve.
6 CHECK PCV VALVE. Is the PCV valve stuck? Replace the PCV Go to step 7.
valve.
Step Check Yes No

area. too high:
(3) After the engine stalls, crank it for five • Improper fuel
more seconds. pump discharge
3) Disconnect the fuel delivery hose, and con-
nect the fuel pressure gauge.
tion is neutral.
intake manifold.
Warning:
fuel pressure gauge.
NOTE:
If fuel pressure does not increase, squeeze fuel
return hose 2 to 3 times, then measure fuel
pressure again.
Warning: too high:
fuel pressure gauge. sure regulator
• If the measured value at this step is out of too low:
specification, check or replace pressure regu- • Faulty pres-
lator and pressure regulator vacuum hose. sure regulator
• Improper fuel
pump discharge
• Clogged fuel
supply line
9 CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 10. Replace the
SENSOR. ture between 70#C (158#F) and engine coolant
1) Start the engine and warm-up completely. 100#C (212#F)? temperature sen-
ture sensor signal using Subaru Select Moni- FU(H4SO 2.5)-20,
tor. Engine Coolant
For detailed operation procedure, refer to the sor.>
itor.>
Step Check Yes No

10 CHECK MANIFOLD PRESSURE SENSOR Is the measurement value 24.0 Replace the ECM. Replace the mani-
SIGNAL. — 41.3 kPa (180 — 310 <Ref. to FU(H4SO fold pressure sen-
1) Start and warm-up the engine until engine mmHg, 7.09 — 12.20 inHg) 2.5)-36, Engine sor. <Ref. to
coolant temperature is above 60#C (140#F). when idling and 73.3 — 106.6 Control Module FU(H4SO 2.5)-25,
2) Place the select lever in “N” or “P” position. kPa (550 — 800 mmHg, 21.65 (ECM).> Manifold Absolute
3) Turn the A/C switch to OFF. — 31.50 inHg) when the igni- Pressure Sensor.>
4) Turn all accessory switches to OFF. tion turns to ON?
5) Read the data of manifold pressure sensor
signal using Subaru Select Monitor.
NOTE:
itor.>
Z: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
present.
throttle control.
(B136) No. 29 — (E57) No. 4:
(B136) No. 16 — (E57) No. 5:
ELECTRONIC THROTTLE CONTROL. M!? sis short circuit of
Repair the poor
trol Module
(ECM).>
1) Turn the ignition switch to OFF. !? contact of elec- contact in ECM
Connector & terminal Replace the elec- if defective. <Ref.
(E57) No. 4 — Engine ground: tronic throttle con- to FU(H4SO 2.5)-
trol if defective. 36, Engine Con-
trol Module
(ECM).>
AA:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
present.
throttle control.
(B136) No. 35 — (E57) No. 3:
(B136) No. 29 — (E57) No. 4:
trol Module
(ECM).>
connector.
ELECTRONIC THROTTLE CONTROL. M!? contact. Replace ply circuit may be
1) Turn the ignition switch to OFF. the electronic shorted.
2) Disconnect the connector from ECM. throttle control.
terminals.
(B136) No. 29 — (B136) No. 16:
AB:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
AC:DTC P0302 CYLINDER 2 MISFIRE DETECTED
NOTE:
AD:DTC P0303 CYLINDER 3 MISFIRE DETECTED
NOTE:
AE:DTC P0304 CYLINDER 4 MISFIRE DETECTED

• Two consecutive driving cycles with fault
• Immediately at fault recognition (A misfire which could damage catalyst occurs.)
TROUBLE SYMPTOM:
• Engine stalls.
• Rough driving
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
BATTERY
3
SBF-8
6
4
2
1
B47
B136 ECM
6
B21
48
42
43
44
45
E2
E5 E16 E6 E17
2

No. 1 No. 2 No. 3 No. 4
E5 E16 B47 B21 B136
E6 E17 1 2
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6
3 4 7 8 9 10 11 12 13
12 13 14 15 16 17 18 19 20 21 22 14 15 16
1 2 5 6
23 24 25 26 27 28 29 30 31 32 33 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-01991
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
nector and chassis ground on faulty cylinders.
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance more than 1 Go to step 5. Repair the ground
TOR AND ECM CONNECTOR. M!? 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.
nector and engine ground on faulty cylinders.
5 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 1 Go to step 6. Repair the har-
TOR AND ECM CONNECTOR. !? ness and connec-
Measure the resistance of harness connector tor.
between ECM connector and fuel injector on NOTE:
faulty cylinders. In this case, repair
• Poor contact in
coupling connector
6 CHECK FUEL INJECTOR. Is the resistance 5 — 20 !? Go to step 7. Replace the faulty
Measure the resistance between fuel injector fuel injector. <Ref.
terminals on faulty cylinder. to FU(H4SO 2.5)-
Terminals 31, Fuel Injector.>
No. 1 — No. 2:
Step Check Yes No

7 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
injector connector
on faulty cylinders
• Poor contact in
coupling connector
• Poor contact in
main relay connec-
tor
• Poor contact in
fuel injector con-
nector on faulty
cylinders
8 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? Repair the battery Go to step 9.
TOR AND ECM CONNECTOR. short circuit in har-
2) Disconnect the connector from fuel injector ECM and fuel
on faulty cylinder. injector. After
3) Turn the ignition switch to ON. repair, replace the
4) Measure the voltage between ECM con- ECM. <Ref. to
nector and chassis ground on faulty cylinders. FU(H4SO 2.5)-36,
#1 (B136) No. 6 (+) — Chassis ground ("): Module (ECM).>
9 CHECK FUEL INJECTOR. Is the resistance less than 1 Replace the faulty Go to step 10.
1) Turn the ignition switch to OFF. !? fuel injector <Ref.
2) Measure the resistance between fuel injec- to FU(H4SO 2.5)-
tor terminals on faulty cylinder. 31, Fuel Injector.>
Terminals and ECM <Ref. to
No. 1 — No. 2: FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
10 CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the cam- Go to step 11.
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position sen-
SENSOR. loosely installed? sor or crankshaft
position sensor.
11 CHECK CRANK SPROCKET. Is the crank sprocket rusted or Replace the crank Go to step 12.
Remove the timing belt cover. does it have broken teeth? sprocket. <Ref. to
ME(H4SO 2.0)-50,
Crank Sprocket.>
12 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 13.
TIMING BELT. from its proper position? tion condition of
Turn the crankshaft, and align alignment mark timing belt. <Ref.
on crank sprocket with alignment mark on cyl- to ME(H4SO 2.0)-
inder block. 43, Timing Belt.>
Step Check Yes No

13 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 14. 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 14.
14 CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator Go to step 16. Go to step 15.
CATOR LIGHT. light come on or blink?
1) Clear the memory using Subaru Select
Monitor. <Ref. to EN(H4SO 2.5)(diag)-41,
Clear Memory Mode.>
2) Start the engine, and drive the vehicle more
than 10 minutes.
15 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
the following:
• Poor contact in
ignition coil con-
nector
• Poor contact in
fuel injector con-
nector on faulty
cylinders
• Poor contact in
ECM connector
• Poor contact in
coupling connector
16 CHECK AIR INTAKE SYSTEM. Is there any fault in air intake Repair the air Go to step 17.
system? 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?
17 CHECK CYLINDER. Is there any fault in that cylin- Repair or replace Go to DTC P0171
der? the faulty parts. and P0172. <Ref.
NOTE: to EN(H4SO
Check the follow- 2.5)(diag)-136,
ing items. DTC P0171 SYS-
• Spark plug TEM TOO LEAN
• Fuel injector (BANK 1), Diag-
• Compression nostic Procedure
pressure with Diagnostic
Trouble Code
(DTC).>
AF:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE

SENSOR)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
2
E14
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
1 2 3 4 5 6
E1
7 8 9 10 11 12 13 14 15 16
13
17 18 19 20 21 22 23 24 25 26 27
B20
28 29 30 31 32 33 34 35
33
25
B136 ECM
EN-01998
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR AND ECM CONNECTOR. 700 k!? ness and connec-
ness connector and chassis ground. the following:
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
1) Disconnect the connector from knock sen- 700 k!? ness and connec-
sor. tor.
Terminals the following:
No. 2 — Engine ground: • Poor contact in
knock sensor con-
nector
4 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installation Replace the knock Tighten knock sen-
INSTALLATION. bolt tightened securely? sensor. <Ref. to sor installation bolt
FU(H4SO 2.5)-23, securely.
Knock Sensor.>
AG:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE

SENSOR)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
2
E14
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
1 2 3 4 5 6
E1
7 8 9 10 11 12 13 14 15 16
13
17 18 19 20 21 22 23 24 25 26 27
B20
28 29 30 31 32 33 34 35
33
25
B136 ECM
EN-01998
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR AND ECM CONNECTOR. k!?
1) Disconnect the connector from knock sen- k!? sensor. <Ref. to short circuit in har-
sor. FU(H4SO 2.5)-23, ness between
The harness be-
tween both con-
nectors are
shielded. Repair
harness covered
with shield.
remains.)
NOTE:
the following:
• Poor contact in
knock sensor con-
nector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
AH:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
E10
1 2
2
1
E10
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1
B122
8
7
B20 B138
1 2 3 4
5 6 7 8
B135
1 2 3 4 5 6 7
3 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
4 28 29 30 31 32 33 34 35
B138 : LHD
B122 : RHD
22
10
31
B135 ECM
E
EN-02463
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SHAFT POSITION SENSOR AND ECM CON- 100 k!? ness and connec-
NECTOR. tor.
2) Disconnect the connector from crankshaft In this case, repair
(E10) No. 1 — Engine ground: ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 10 Repair the ground Go to step 4.
SHAFT POSITION SENSOR AND ECM CON- !? short circuitrepair
NECTOR. the ground short
Measure the resistance of harness between circuit in harness
crankshaft position sensor connector and between crank-
engine ground. shaft position sen-
Connector & terminal sor and ECM
(E10) No. 1 — Engine ground: connector.
NOTE:
The harness be-
tween both con-
nectors are
shielded. Repair
the ground short
circuit in harness
with shield.
4 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 5 Go to step 5. Repair the har-
SHAFT POSITION SENSOR AND ECM CON- !? 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
Step Check Yes No

securely.
6 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance 1 — 4 k!? Repair the poor Replace the crank-
terminals of crankshaft position sensor. sor connector. FU(H4SO 2.5)-21,
AI: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN-
GLE SENSOR)
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
E15
1 2
2
1
E15
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B122
E1
B138
6
5
B20
1 2 3 4
5 6 7 8
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 29 30 31 32 33 34 35
7
B138 : LHD
B122 : RHD
23
11
31
B135 ECM
E
EN-02464
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair the har- Go to step 3.
POSITION SENSOR AND ECM CONNEC- 100 k!? ness and connec-
TOR. tor.
and engine ground. camshaft position
(E15) No. 1 — Engine ground: connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground Go to step 4.
POSITION SENSOR AND ECM CONNEC- !? short circuit in har-
TOR. ness between
tween both con-
nectors are
shielded. Repair
the ground short
circuit in harness
with shield.
POSITION SENSOR AND ECM CONNEC- !? ness and connec-
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
securely.
Step Check Yes No

6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance 1 — 4 k!? Repair the poor Replace the cam-
terminals of camshaft position sensor. sor connector. FU(H4SO 2.5)-22,
AJ:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

TROUBLE SYMPTOM:
• Movement performance problem when engine is low speed.
• Movement performance problem
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5 BATTERY
3 1 2 3
SBF-5 4 5 6
6
4
B21 B47
2
1
48
1 2
E2
B47 3 4
5 6
5
2
B21
EGR 1 2 3 4 5 6 7 8 9 10 11
VALVE 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E18
34 35 36 37 38 39 40 41
42 43 44 45 46 47
6
3
4
1
48 49 50 51 52 53 54
E2
30
25
29
26
B21
A: B134
A10
A11
A8
A9
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
A: B134 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
B: B135 ECM
D: B137
B: B135
B1
B4
D1
D2
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
B21
D: B137
35
36
E2
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
E E
EN-02001
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK CURRENT DATA. Is the value more than 53.3 Make sure that the Go to step 3.
1) Start the engine. kPa (400 mmHg, 15.75 inHg)? EGR valve, mani-
2) Read the data of intake manifold absolute fold absolute pres-
pressure signal using Subaru Select Monitor. sure sensor and
NOTE: throttle body are
For detailed operation procedure, refer to the installed securely.
itor.>
3 CHECK THE POWER SUPPLY OF EGR SO- Is the voltage more than 10 V? Go to step 4. Repair the open
LENOID VALVE. circuit in harness
1) Detach the connector from EGR solenoid between main
valve. relay and EGR
2) Turn the ignition switch to ON. solenoid valve
3) Measure the voltage between EGR sole- connector.
noid valve and engine ground.
4 CHECK EGR SOLENOID VALVE. Is the resistance 20 — 30 !? Go to step 5. Replace the EGR
Measure the resistance between EGR sole- solenoid valve.
noid valve terminals. <Ref. to FU(H4SO
NOTE: 2.5)-30, EGR
Make sure there is no foreign material between Valve.>
EGR solenoid valve and valve seat.
Terminals
No. 1 — No. 2:
No. 3 — No. 2:
No. 4 — No. 5:
No. 6 — No. 5:
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage 0 — 10 V? Repair the poor Go to step 6.
1) Turn the ignition switch to OFF. contact portion in
2) Connect the connector to ECM and EGR ECM connector.
solenoid valve.
chassis ground.
Step Check Yes No

6 CHECK HARNESS BETWEEN EGR SOLE- Is the resistance less than 1 Go to step 7. Repair the open
NOID VALVE AND ECM CONNECTOR. !? circuit in harness
2) Detach the connector from EGR solenoid EGR solenoid
valve and ECM. valve connector.
between EGR solenoid valve and ECM con-
nector.
(B134) No. 8 — (E18) No. 6:
(B134) No. 10 — (E18) No. 1:
(B134) No. 9 — (E18) No. 4:
(B134) No. 11 — (E18) No. 3:
7 CHECK HARNESS BETWEEN EGR SOLE- Is the resistance more than 1 Go to step 8. Repair the short
NOID VALVE AND ECM CONNECTOR. M!? circuit in harness
Measure the resistance of harness between between main
EGR solenoid valve and chassis ground. relay and EGR
Connector & terminal solenoid valve
(B134) No. 8 — Chassis ground: connector.
8 CHECK POOR CONTACT. Is there poor contact for ECM Repair the poor Even if the mal-
Check poor contact for ECM and EGR sole- and EGR solenoid valve con- contact of ECM function indicator
noid valve connector. nector? and EGR solenoid light illuminates,
valve connector. the circuit has
returned to the
specified condi-
tion at this time.
AK:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK

1)
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
OXYGEN SENSOR
SBF-6
5 1 2
1 2 1 2 3 4
3 3 4
3 4 5 6 7 8
5 6
6
4
2
B21
2
REAR
1
OXYGEN SENSOR
1 2 3 4 5 6 7 8 9 10 11
B327 B19 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
B83 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
RHD
*
RHD
*
LHD 4 A: B134
LHD 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B83 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D24
C35
D31
B2
B: B135
A: B134
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
ECM 20 21 22 23 24 25 26 27
C: B136 28 29 30 31 32 33 34 35
D: B137
C: B136
A6
A7
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
B21
52
D: B137
E2
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
E E 26 27 28 29 30 31
EN-02458
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is not
necessary to in-
spect DTC P0420.
3 CHECK EXHAUST SYSTEM. Is there any fault in exhaust Repair or replace Go to step 4.
Check for gas leaks or air suction caused by system? the exhaust sys-
loose or dislocated nuts and bolts, and open tem. <Ref. to
hole at exhaust pipes. EX(H4SO 2.0)-2,
NOTE: General Descrip-
Check the following positions. tion.>
• Between cylinder head and front exhaust
pipe
• Between front exhaust pipe and front cata-
lytic converter
• Between front catalytic converter and rear
catalytic converter
4 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear face of Replace the front Go to step 5.
Separate the rear catalytic converter from rear rear catalyst? catalytic con-
exhaust pipe. verter. <Ref. to
EC(H4SO 2.0)-3,
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to
EC(H4SO 2.0)-4,
Rear Catalytic
Converter.>
5 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front Contact Subaru
Remove the front catalytic converter. front face of front catalyst? catalytic con- distributor service.
verter. <Ref. to NOTE:
EC(H4SO 2.0)-3, Inspection by DTM
Front Catalytic is required, be-
Converter.> cause probable
cause is deteriora-
tion of multiple
parts.
AL:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E4
5
BATTERY
3 1 2
SBF-8
6
4
2
1 B47
B47 1 2
3 4
5 6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B134 ECM 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
14
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
B21
48
41
E2
E4
1
2
E
PURGE CONTROL
SOLENOID VALVE
EN-02002
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
this time.
TROL SOLENOID VALVE AND ECM CON- M!? short circuit in har-
TROL SOLENOID VALVE AND ECM CON- !? circuit in harness
ECM and purge control solenoid valve. noid valve connec-
(B134) No. 14 — (E4) No. 2: NOTE:
the following:
• Open circuit in
harness between
ECM and purge
control solenoid
valve connector
• Poor contact in
coupling connector
5 CHECK PURGE CONTROL SOLENOID Is the resistance 10 — 100 !? Go to step 6. Replace the purge
No. 1 — No. 2:
Step Check Yes No

Check poor contact in purge control solenoid control solenoid valve connec- contact in purge <Ref. to FU(H4SO
valve connector. tor? control solenoid 2.5)-36, Engine
valve connector. Control Module
(ECM).>
AM:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E4
5
BATTERY
3 1 2
SBF-8
6
4
2
1 B47
B47 1 2
3 4
5 6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B134 ECM 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
14
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
B21
48
41
E2
E4
1
2
E
PURGE CONTROL
SOLENOID VALVE
EN-02002
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage 0 — 10 V? Go to step 3. Even if the mal-
1) Turn the ignition switch to OFF. function indicator
lower portion of glove box. the circuit has
3) Turn the ignition switch to ON. returned to a nor-
4) While operating the purge control solenoid mal condition at
valve, measure voltage between ECM and this time. In this
chassis ground. case, repair the
NOTE: poor contact in
Purge control solenoid valve operation can be ECM connector.
executed using Subaru Select Monitor. Refer to
“Compulsory Valve Operation Check Mode” for
procedures. <Ref. to EN(H4SO 2.5)(diag)-42,
Compulsory Valve Operation Check Mode.>
chassis ground.
Control Module
(ECM).>
5 CHECK HARNESS BETWEEN PURGE CON- Is the voltage more than 10 V? Repair the battery Go to step 6.
chassis ground. <Ref. to FU(H4SO
(B134) No. 14 (+) — Chassis ground ("): Control Module
(ECM).>
6 CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Replace the purge Go to step 7.
VALVE. !? control solenoid
1) Turn the ignition switch to OFF. valve <Ref. to
No. 1 — No. 2: and ECM. <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
Step Check Yes No

Control Module
(ECM).>
AN:DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0462 displayed on the Check the combi- Temporary poor
Subaru Select Monitor? nation meter sys- contact occurs.
tem. <Ref. to IDI-3,
Combination
Meter System.>
AO:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0463 displayed on the Check the combi- Temporary poor
Subaru Select Monitor? nation meter sys- contact occurs.
tem. <Ref. to IDI-3,
Combination
Meter System.>
AP:DTC P0500 VEHICLE SPEED SENSOR

CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
DTC. <Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
AQ:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
E
15
13
LHD
16
14
RHD
STARTER
RELAY
B225 STARTER MOTOR
15
13
RHD
16
14
LHD
M
B14
B32
D8
ECM
B: B135
D: B137
B72 B225
B: B135 D: B137
1 2 3 1 2 9 13 17 21
4 5 6 10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02455
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check starter
Turn the ignition switch to ON. ate? short circuit in motor circuit. <Ref.
NOTE: starter motor cir- to EN(H4SO
Place the inhibitor switch in each position. cuit. 2.5)(diag)-55,
STARTER
MOTOR CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>
AR:DTC P0519 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0519.
throttle body
body gasket
2) Remove the electronic throttle control. control.
AS:DTC P0558 GENERATOR CIRCUIT LOW INPUT

CAUTION:
For diagnostic procedure, refer to DTC P0559. <Ref. to EN(H4SO 2.5)(diag)-179, DTC P0559 GENER-
ATOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>.
AT:DTC P0559 GENERATOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
B134
ECM
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
22
F26
1 2 3
F26
3
GENERATOR
EN-02465
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK HARNESS BETWEEN GENERATOR Is the resistance more than 1 Go to step 3. Repair the ground
AND ECM CONNECTOR. M!? short circuit in har-
2) Disconnect the connectors from generator ECM and purge
and ECM. control solenoid
3) Measure the resistance of harness valve connector.
between generator connector and engine
ground.
(F26) No. 3 — Engine ground:
3 CHECK HARNESS BETWEEN GENERATOR Is the resistance less than 1 Repair the poor Repair the open
AND ECM CONNECTOR. !? contact in connec- circuit in harness
Measure the resistance of harness between tor. between ECM and
ECM and generator of harness connector. generator connec-
(B134) No. 22 — (F26) No. 3: NOTE:
the following:
• Open circuit in
harness between
ECM and genera-
tor connector
• Poor contact in
coupling connector
AU:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:
For the diagnostic procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
AV:DTC P0604 INTERNAL CONTROL MODULE READ ACCESS MEMORY

(RAM) ERROR
TROUBLE SYMPTOM:
• Engine does not start.
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
* 34
* B72
IGNITION
SWITCH BATTERY
6 3
B19
B6
*B51
2
*
A: B134
B: B135 ECM
D: B137
* 3 : LHD MODEL: 1
B12
RHD MODEL: 2
B1
A6
A7
D3
D7
D1
D2
B4
* 4 : LHD MODEL: 2
RHD MODEL: 1
B21
52
47
34
36
35
37
E2
E E
B72 B47 B21 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
12 13 14 15 16 17 18 19 20 21 22
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02456
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele- Temporary poor
vant DTC using contact occurs.
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
AW:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO 2.5)(diag)-183, DTC P0607 CON-
TROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AX:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
* 34
* B72
IGNITION
SWITCH BATTERY
6 3
B19
B6
*B51
2
*
A: B134
B: B135 ECM
D: B137
* 2 : WITH IMMOBILIZER: D14
* 3 : LHD MODEL: 1
B12
RHD MODEL: 2
B1
A6
A7
D3
D7
D1
D2
B4
*4 : LHD MODEL: 2
RHD MODEL: 1
B21
52
47
34
36
35
37
E2
E E
B72 B47 B21 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
12 13 14 15 16 17 18 19 20 21 22
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02456
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
(B137) No. 1 (+) — Chassis ground ("): if defective. <Ref.
(B137) No. 2 (+) — Chassis ground ("): to FU(H4SO 2.5)-
(B137) No. 3 (+) — Chassis ground ("): 36, Engine Con-
trol Module
(ECM).>
AY:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
AZ:DTC P0691 COOLING FAN 1 CONTROL CIRCUIT LOW

TROUBLE SYMPTOM:
• Overheating
CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0691 displayed on the Check the radiator Temporary poor
Subaru Select Monitor? fan system. <Ref. contact occurs.
to CO(H4SO 2.0)-
7, Radiator Fan
System.>
BA:DTC P0692 COOLING FAN 1 CONTROL CIRCUIT HIGH

TROUBLE SYMPTOM:
• Overheating
CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is DTC P0692 displayed on the Check the radiator Temporary poor
Subaru Select Monitor? fan system. <Ref. contact occurs.
to CO(H4SO 2.0)-
7, Radiator Fan
System.>
BB:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 4AT(diag)-2, Basic Diagnostic Procedure.>
BC:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B12
B137 ECM
1 2 3 4
5 6 7 8
9 10 11 12
9
T7
1 2 3 4 5 6
7 8 9 10 11 12
B137
INHIBITOR SWITCH 1 2 3 4 5 6 7
P R N D 3 2 1 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
12 12
26 27 28 29 30 31
11 7
B12 T3 T7
EN-02004
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
3 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if the mal- Go to step 4.
2) Shift the select lever except for “N” and “P” light illuminates,
range. the circuit has
Connector & terminal this time.
TRANSMISSION HARNESS CONNECTOR. M!? short circuit in har-
2) Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
5 CHECK TRANSMISSION HARNESS CON- Is the resistance more than 1 Go to step 6. Repair the ground
NECTOR. M!? short circuit in har-
1) Disconnect the connector from inhibitor ness between
switch. transmission har-
2) Measure the resistance of harness ness connector
between transmission harness connector and and inhibitor
engine ground. switch connector.
(T3) No. 12 — Engine ground:
6 CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 7. Replace the inhibi-
Measure the resistance between inhibitor M!? tor switch. <Ref. to
select lever at other than “N” and “P” range. Switch.>
Terminals
No. 7 — No. 12:
BD:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B12
B137 ECM
1 2 3 4
5 6 7 8
9 10 11 12
9
T7
1 2 3 4 5 6
7 8 9 10 11 12
B137
INHIBITOR SWITCH 1 2 3 4 5 6 7
P R N D 3 2 1 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
12 12
26 27 28 29 30 31
11 7
B12 T3 T7
EN-02004
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
chassis ground with select lever at “N” and “P”
range.
sis ground with select lever at other than “N”
and “P” range.
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poorReplace the ECM.
Control Module
(ECM).>
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and inhibitor
(B137) No. 9 (+) — Chassis ground ("): switch connector.
7 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Go to step 8. Repair the har-
HIBITOR SWITCH CONNECTOR. !? ness and connec-
2) Disconnect the connectors from ECM and NOTE:
inhibitor switch. In this case, repair
3) Measure the resistance of harness the following:
between ECM and inhibitor switch connector. • Open circuit in
(B137) No. 9 — (T7) No. 12: ECM and inhibitor
switch connector
• Poor contact in
coupling connector
• Poor contact in
inhibitor switch
connector
• Poor contact in
ECM connector
Step Check Yes No

8 CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Go to step 9. Repair the open
Measure the resistance of harness between !? circuit in harness
inhibitor switch connector and engine ground. between inhibitor
Connector & terminal switch connector
(T7) No. 12 — Engine ground: and ground line.
NOTE:
the following:
• Open circuit in
harness between
inhibitor switch
connector and
ground line
9 CHECK INHIBITOR SWITCH. Is the resistance less than 1 Go to step 10. Replace the inhibi-
Measure the resistance between inhibitor !? tor switch. <Ref. to
select lever at “N” and “P” range. Switch.>
Terminals
No. 7 — No. 12:
BE:DTC P1086 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

LOW
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR VALVE

POSITION SENSOR LH
E50
1 2 3
1
3
2
E50
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
E2 48 49 50 51 52 53 54
20
19
11
B21
B83 B83
RHD
* B122
RHD
*
B138
2 LHD 3
1 LHD 8 1 2 3 4
5 6 7 8
B138 : LHD B83
B122 : RHD
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
35
26
16
28 29 30 31 32 33 34 35
B136 ECM
EN-02466
Step Check Yes No

1 CHECK CURRENT DATA. Is the voltage less than 0.1 V? Go to step 2. Even if malfunction
1) Start the engine. indicator light
2) Read the data of throttle position sensor lights up, the cir-
signal using Subaru Select Monitor or OBD-II cuit has returned
general scan tool. to a normal condi-
NOTE: tion at this time. A
• Subaru Select Monitor temporary poor
For detailed operation procedure, refer to the contact of the con-
“READ CURRENT DATA FOR ENGINE”. <Ref. nector may be the
to EN(H4SO 2.5)(diag)-26, Subaru Select cause.
Monitor.> NOTE:
• OBD-II general scan tool In this case, repair
For detailed operation procedures, refer to the the following:
operation manual of OBD-II general scan tool. • Poor contact in
throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 4. Go to step 3.
and chassis ground while tumble generator
valve is fully closed.
3 CHECK INPUT SIGNAL FOR ECM. Shake the ECM harness and Repair the poor Contact your Sub-
Measure the voltage between ECM connector connector, while monitoring contact in ECM aru distributor ser-
and chassis ground. value of voltage meter. Does connector. vice.
Connector & terminal the voltage change? NOTE:
(B136) No. 16 (+) — Chassis ground ("): Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.1 V? Go to step 6. Go to step 5.
and chassis ground.
5 CHECK INPUT SIGNAL FOR ECM. (USING Shake the ECM harness and Repair the poor Go to step 6.
SUBARU SELECT MONITOR) connector, while monitoring contact in ECM
Measure the voltage between ECM connector value of Subaru Select Moni- connector.
and chassis ground. tor. Does the voltage change?
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-
TUMBLE GENERATOR VALVE POSITION ness and connec-
SENSOR CONNECTOR. tor.
2) Disconnect the connectors from tumble In this case, repair
generator valve position sensor. the following:
4) Measure the voltage between tumble gen- harness between
erator valve position sensor connector and tumble generator
engine ground. valve position sen-
Connector & terminal sor and ECM con-
(E50) No. 1 (+) — Engine ground ("): nector
• Poor contact in
tumble generator
valve position sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
• Poor contact in
joint connector
TUMBLE GENERATOR VALVE POSITION !? ness and connec-
between ECM connector and tumble generator the following:
valve position sensor connector. • Open circuit in
(B136) No. 26 — (E50) No. 3: tumble generator
valve position sen-
sor and ECM con-
nector
• Poor contact in
ECM connector
• Poor contact in
tumble generator
valve position sen-
sor connector
• Poor contact in
coupling connector
TUMBLE GENERATOR VALVE POSITION M!? short circuit in har-
SENSOR CONNECTOR. ness between tum-
Measure the resistance of harness between ble generator valve
tumble generator valve position sensor con- position sensor
nector and engine ground. and ECM connec-
9 CHECK POOR CONTACT. Is there poor contact in tumble Repair the poor Replace the tum-
Check poor contact in tumble generator valve generator valve position sen- contact in tumble ble generator valve
position sensor connector. sor connector? generator valve assembly. <Ref. to
position sensor FU(H4SO 2.5)-28,
connector. Tumble Generator
Valve Assembly.>
BF:DTC P1087 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

HIGH
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR VALVE

POSITION SENSOR LH
E50
1 2 3
1
3
2
E50
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
E2 48 49 50 51 52 53 54
20
19
11
B21
B83 B83
RHD
* B122
RHD
*
B138
2 LHD 3
1 LHD 8 1 2 3 4
5 6 7 8
B138 : LHD B83
B122 : RHD
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
35
26
16
28 29 30 31 32 33 34 35
B136 ECM
EN-02466
Step Check Yes No

1 CHECK CURRENT DATA. Is the voltage more than 4.9 V? Go to step 2. Even if malfunction
2) Read the data of throttle position sensor lights up, the cir-
signal using Subaru Select Monitor or OBD-II cuit has returned
general scan tool. to a normal condi-
Monitor.> NOTE:
tumble generator
valve position sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN TUMBLE Is the resistance less than 5 Go to step 3. Repair the har-
GENERATOR VALVE POSITION SENSOR !? ness and connec-
AND ECM CONNECTOR. tor.
2) Disconnect the connector from throttle In this case, repair
between throttle position sensor connector and harness between
engine ground. tumble generator
Connector & terminal valve position sen-
(E50) No. 2 — Engine ground: sor and ECM con-
nector
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than 4.9 V? Repair the battery Replace the tum-
POSITION SENSOR AND ECM CONNEC- short circuit in har- ble generator valve
TOR. ness between tum- assembly. <Ref. to
1) Turn the ignition switch to ON. ble generator valve FU(H4SO 2.5)-28,
2) Measure the voltage between throttle posi- position sensor Tumble Generator
tion sensor connector and engine ground. and ECM connec- Valve Assembly.>
Connector & terminal tor. After repair,
(E50) No. 3 (+) — Engine ground ("): replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
BG:DTC P1088 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT

LOW
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR VALVE E54

POSITION SENSOR RH
1 2 3
B21
1
3
2
E54
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E2
20
19
10
B21
B83
B83
B122
RHD
*
RHD
* B138
1 2 3 4
2 LHD 3 5 6 7 8
1 LHD 8
B138 : LHD B83
B122 : RHD
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 31 32 33 34 35
27
35
16
B136 ECM
EN-02467
Step Check Yes No

1 CHECK CURRENT DATA. Is the voltage less than 0.1 V? Go to step 2. Even if malfunction
2) Read the data of tumble generator valve lights up, the cir-
position sensor signal using Subaru Select cuit has returned
Monitor or OBD-II general scan tool. to a normal condi-
Monitor.> NOTE:
tumble generator
valve position sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 4. Go to step 3.
and chassis ground while throttle valve is fully
closed.
3 CHECK INPUT SIGNAL FOR ECM. Shake the ECM harness and Repair the poor Contact your Sub-
Measure the voltage between ECM connector connector, while monitoring contact in ECM aru distributor ser-
and chassis ground. value of voltage meter. Does connector. vice.
Connector & terminal the voltage change? NOTE:
(B136) No. 16 (+) — Chassis ground ("): Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.1 V? Go to step 6. Go to step 5.
and chassis ground.
5 CHECK INPUT SIGNAL FOR ECM. (USING Shake the ECM harness and Repair the poor Go to step 6.
SUBARU SELECT MONITOR) connector, while monitoring contact in ECM
Measure the voltage between ECM connector value of Subaru Select Moni- connector.
and chassis ground. tor. Does the voltage change?
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-
TUMBLE GENERATOR VALVE POSITION ness and connec-
2) Disconnect the connectors from throttle In this case, repair
4) Measure the voltage between throttle posi- harness between
tion sensor connector and engine ground. tumble generator
(E54) No. 1 (+) — Engine ground ("): sor and ECM con-
nector
• Poor contact in
throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
• Poor contact in
joint connector
TUMBLE GENERATOR VALVE POSITION !? ness and connec-
between ECM connector and throttle position the following:
sensor connector. • Open circuit in
(B136) No. 27 — (E54) No. 3: tumble generator
valve position sen-
sor and ECM con-
nector
• Poor contact in
ECM connector
• Poor contact in
tumble generator
valve position sen-
sor connector
• Poor contact in
coupling connector
THROTTLE POSITION SENSOR CONNEC- M!? short circuit in har-
TOR. ness between tum-
Measure the resistance of harness between ble generator valve
tumble generator valve position sensor con- position sensor
nector and engine ground. and ECM connec-
Check poor contact in tumble generator valve generator valve position sen- contact in tumble ble generator valve
position sensor connector. sor connector? generator valve assembly. <Ref. to
position sensor FU(H4SO 2.5)-28,
connector. Tumble Generator
Valve Assembly.>
BH:DTC P1089 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT

HIGH
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR VALVE E54

POSITION SENSOR RH
1 2 3
B21
1
3
2
E54
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E2
20
19
10
B21
B83
B83
B122
RHD
*
RHD
* B138
1 2 3 4
2 LHD 3 5 6 7 8
1 LHD 8
B138 : LHD B83
B122 : RHD
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 31 32 33 34 35
27
35
16
B136 ECM
EN-02467
Step Check Yes No

1 CHECK CURRENT DATA. Is the voltage more than 4.9 V? Go to step 2. Even if malfunction
2) Read the data of tumble generator valve lights up, the cir-
position sensor signal using Subaru Select cuit has returned
Monitor or OBD-II general scan tool. to a normal condi-
Monitor.> NOTE:
tumble generator
valve position sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN TUMBLE Is the resistance less than 5 Go to step 3. Repair the har-
GENERATOR VALVE POSITION SENSOR !? ness and connec-
AND ECM CONNECTOR. tor.
2) Disconnect the connector from throttle In this case, repair
between tumble generator valve position sen- harness between
sor connector and engine ground. tumble generator
(E54) No. 2 — Engine ground: sor and ECM con-
nector
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN TUMBLE Is the voltage more than 4.9 V? Repair the battery Replace the tum-
GENERATOR VALVE POSITION SENSOR short circuit in har- ble generator valve
AND ECM CONNECTOR. ness between tum- assembly. <Ref. to
1) Turn the ignition switch to ON. ble generator valve FU(H4SO 2.5)-28,
2) Measure the voltage between throttle posi- position sensor Tumble Generator
tion sensor connector and engine ground. and ECM connec- Valve Assembly.>
Connector & terminal tor. After repair,
(E54) No. 3 (+) — Engine ground ("): replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
BI: DTC P1090 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE OPEN)

CAUTION:
Step Check Yes No

vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH. Does the tumble generator Replace the tum- Clean the tumble
1) Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve generator valve.
bly. or foreign materials clogged) assembly. <Ref. to
2) Check the tumble generator valve body. FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>
BJ:DTC P1091 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE CLOSE)

CAUTION:
Step Check Yes No

vant DTC using
Trouble Code
(DTC)” <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
Tumble Generator
Valve Assembly.>
BK:DTC P1092 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE OPEN)

CAUTION:
Step Check Yes No

vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
Tumble Generator
Valve Assembly.>
BL:DTC P1093 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE CLOSE)

CAUTION:
Step Check Yes No

vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
Tumble Generator
Valve Assembly.>
BM:DTC P1094 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNC-

TION (OPEN)
CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
E55
2
E2
32
21
B21
19
18
B134 ECM
E55 B21 B134
1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 16 17
23 24 25 26 27 28 29 30 31 32 33 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02468
Step Check Yes No

TUMBLE GENERATOR VALVE ACTUATOR !? circuit between
CONNECTOR. ECM and tumble
1) Turn the ignition switch to OFF. generator valve
2) Disconnect the connector from tumble gen- connector.
erator valve and ECM connector. NOTE:
3) Measure the resistance between tumble In this case, repair
generator valve actuator and ECM connector. the following:
(E55) No. 1 — (B134) No. 19: harness between
(E55) No. 2 — (B134) No. 18: ECM and tumble
generator valve
actuator connector
• Poor contact in
coupling connector
Check poor contact in tumble generator valve generator valve actuator con- contact in tumble ble generator valve
actuator connector. nector? generator valve assembly. <Ref. to
actuator connec- FU(H4SO 2.5)-28,
tor. Tumble Generator
Valve Assembly.>
BN:DTC P1095 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNC-

TION (SHORT)
CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
E55
2
E2
32
21
B21
19
18
B134 ECM
E55 B21 B134
1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 16 17
23 24 25 26 27 28 29 30 31 32 33 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02468
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit
CONNECTOR. assembly. <Ref. to between ECM and
1) Turn the ignition switch to OFF. FU(H4SO 2.5)-28, tumble generator
2) Disconnect the connector from tumble gen- Tumble Generator valve actuator.
erator valve connector. Valve Assembly.>
3) Measure the voltage between tumble gen-
erator valve actuator and chassis ground.
(E55) No. 1 (+) — Chassis ground ("):
BO:DTC P1096 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNC-

TION (OPEN)
CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
E51
2
E2
33
22
B21
29
28
B134 ECM
E51 B21 B134
1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 16 17
23 24 25 26 27 28 29 30 31 32 33 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02469
Step Check Yes No

TUMBLE GENERATOR VALVE ACTUATOR !? circuit between
CONNECTOR. ECM and tumble
1) Turn the ignition switch to OFF. generator valve
2) Disconnect the connector from tumble gen- connector.
erator valve and ECM connector. NOTE:
3) Measure the resistance between tumble In this case, repair
generator valve actuator and ECM connector. the following:
(E51) No. 1 — (B134) No. 29: harness between
(E51) No. 2 — (B134) No. 28: ECM and tumble
generator valve
actuator connector
• Poor contact in
coupling connector
Check poor contact in tumble generator valve generator valve actuator con- contact in tumble ble generator valve
actuator connector. nector? generator valve assembly. <Ref. to
actuator connec- FU(H4SO 2.5)-28,
tor. Tumble Generator
Valve Assembly.>
BP:DTC P1097 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNC-

TION (SHORT)
CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
E51
2
E2
33
22
B21
29
28
B134 ECM
E51 B21 B134
1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 16 17
23 24 25 26 27 28 29 30 31 32 33 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02469
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit
CONNECTOR. assembly. <Ref. to between ECM and
1) Turn the ignition switch to OFF. FU(H4SO 2.5)-28, tumble generator
2) Disconnect the connector from tumble gen- Tumble Generator valve actuator.
erator valve connector. Valve Assembly.>
3) Measure the voltage between tumble gen-
erator valve actuator and chassis ground.
BQ:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Replace the ECM.
using “List of Diag- <Ref. to FU(H4SO
Code (DTC)”. Control Module
<Ref. to EN(H4SO (ECM).>
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
It is not necessary
to inspect DTC
P1110.
BR:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
CAUTION:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Replace the ECM.
using “List of Diag- <Ref. to FU(H4SO
Code (DTC)”. Control Module
<Ref. to EN(H4SO (ECM).>
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
It is not necessary
to inspect DTC
P1111.
BS:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1

SENSOR1)
CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
FRONT OXYGEN (A/F) SENSOR CONNEC- !? ness and connec-
TOR. tor.
2) Disconnect the connectors from ECM and In this case, repair
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
Front Oxygen (A/
F) Sensor.>
BT:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1

SENSOR1)
CAUTION:
WIRING DIAGRAM:
OXYGEN (A/F)
B327
SBF-6
6
1 2
4 50
3 4
5 B21 E2 5 6
3
4
2 FRONT OXYGEN
1 (A/F) SENSOR
E24
B327 E24
1 2 3
4 5 6
6
1
3
B21
E2
51
4
3
B21 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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E
B134
26
33
25
2
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
6
7
E
B21
52
E2
EN-01992
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
FRONT OXYGEN (A/F) SENSOR CONNEC- M!? short circuit in har-
TOR. ness between
front oxygen (A/F) sensor. sor connector.
FRONT OXYGEN (A/F) SENSOR CONNEC- M!? short circuit in har-
TOR. ness between
Measure the resistance of harness between ECM and front
ECM connector and chassis ground. oxygen (A/F) sen-
4 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 5. Go to step 6.
1) Connect the connector to ECM and front
oxygen (A/F) sensor.
5 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Repair the poor
Measure the voltage between ECM connector short circuit in har- contact in ECM
and chassis ground. ness between connector.
sor connector.
After repair,
replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
6 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 4.95 Go to step 7. Replace the front
Measure the voltage between ECM connector V? oxygen (A/F) sen-
and chassis ground. sor. <Ref. to
Connector & terminal FU(H4SO 2.5)-34,
(B134) No. 33 (+) — Chassis ground ("): Front Oxygen (A/
F) Sensor.>
Step Check Yes No

7 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Repair the poor
Measure the voltage between ECM connector short circuit in har- contact in ECM
and chassis ground. ness between connector.
sor connector.
After repair,
replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
BU:DTC P1160 RETURN SPRING FAILURE

NOTE:
BV:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
BW:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
BX:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
BY:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
BZ:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
CA:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
CB:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5 BATTERY
3 1 2 3
SBF-5 4 5 6
6
4
B21 B47
2
1
48
1 2
E2
B47 3 4
5 6
5
2
B21
EGR 1 2 3 4 5 6 7 8 9 10 11
VALVE 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E18
34 35 36 37 38 39 40 41
42 43 44 45 46 47
6
3
4
1
48 49 50 51 52 53 54
E2
30
25
29
26
B21
A: B134
A10
A11
A8
A9
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
A: B134 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
B: B135 ECM
D: B137
B: B135
B1
B4
D1
D2
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
B21
D: B137
35
36
E2
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
E E
EN-02001
Step Check Yes No

1 CHECK POWER SUPPLY TO EGR SOLE- Is the voltage more than 10 V? Go to step 2. Repair the har-
NOID VALVE. ness and connec-
2) Disconnect the connector from EGR sole- NOTE:
noid valve. In this case, repair
4) Measure the voltage between EGR sole- • Open circuit in
noid valve connector and engine ground. harness between
Connector & terminal EGR solenoid
(E18) No. 2 (+) — Engine ground ("): valve and main
(E18) No. 5 (+) — Engine ground ("): relay connector
• Poor contact in
coupling connector
EGR SOLENOID VALVE CONNECTOR. !? ness and connec-
2) Measure the voltage between ECM and NOTE:
EGR solenoid valve connector. In this case, repair
DTC P1492; (B134) No. 11 — (E18) No. 3: • Open circuit in
DTC P1494; (B134) No. 10 — (E18) No. 1: harness between
DTC P1496; (B134) No. 9 — (E18) No. 4: ECM and EGR
DTC P1498; (B134) No. 8 — (E18) No. 6: solenoid valve
connector
• Poor contact in
coupling connector
EGR SOLENOID VALVE CONNECTOR. M!? short in harness
2) Measure the resistance between ECM con- EGR solenoid
nector and chassis ground. valve connector.
ground:
ground:
ground:
ground:
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the EGR
Check poor contact in ECM connector and connector or EGR solenoid contact in ECM solenoid valve.
EGR solenoid valve connector. valve connector? connector or EGR <Ref. to FU(H4SO
solenoid valve 2.5)-30, EGR
connector. Valve.>
CC:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5 BATTERY
3 1 2 3
SBF-5 4 5 6
6
4
B21 B47
2
1
48
1 2
E2
B47 3 4
5 6
5
2
B21
EGR 1 2 3 4 5 6 7 8 9 10 11
VALVE 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E18
34 35 36 37 38 39 40 41
42 43 44 45 46 47
6
3
4
1
48 49 50 51 52 53 54
E2
30
25
29
26
B21
A: B134
A10
A11
A8
A9
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
A: B134 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
B: B135 ECM
D: B137
B: B135
B1
B4
D1
D2
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
B21
D: B137
35
36
E2
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
E E
EN-02001
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to EN(H4SO
2.5)(diag)-70, List
of Diagnostic Trou-
ble Code (DTC).>
1) Turn the ignition switch to OFF. !? ness and connec-
2) Measure the resistance between ECM con- tor.
nector and chassis ground. NOTE:
(B137) No. 2 — Chassis ground: ECM connector
and engine ground
terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair battery Replace the ECM.
EGR SOLENOID VALVE CONNECTOR. short in harness <Ref. to FU(H4SO
1) Turn the ignition switch to OFF. between ECM and 2.5)-36, Engine
2) Disconnect the connector from EGR sole- EGR solenoid Control Module
noid valve. valve connector. (ECM).>
3) Turn the ignition switch to ON. After repairing,
4) Measure the voltage between ECM con- replace the ECM.
nector and chassis ground. <Ref. to FU(H4SO
DTC P1493; (B134) No. 11 (+) — Chassis Control Module
ground ("): (ECM).>
DTC P1495; (B134) No. 10 (+) — Chassis
ground ("):
DTC P1497; (B134) No. 9 (+) — Chassis
ground ("):
DTC P1499; (B134) No. 8 (+) — Chassis
ground ("):
CD:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
E
15
13
LHD
16
14
RHD
STARTER
RELAY
B225 STARTER MOTOR
15
13
RHD
16
14
LHD
M
B14
B32
D8
ECM
B: B135
D: B137
B72 B225
B: B135 D: B137
1 2 3 1 2 9 13 17 21
4 5 6 10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02455
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
2 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check starter
Place the inhibitor switch in the “P” or “N” when ignition switch to ness and connec- motor circuit. <Ref.
range. START? tor. to EN(H4SO
NOTE: 2.5)(diag)-55,
In this case, repair STARTER
the following: MOTOR CIR-
• Open or ground CUIT, Diagnostics
short circuit in har- for Engine Start-
ness between ing Failure.>
ECM and starter
motor connector
• Poor contact in
ECM connector
CE:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO IGNITION COIL
5
SBF-8
6
4
No.13
* 3
* 4
B72
IGNITION
SWITCH BATTERY
6 3
B19
B6
*B51
2
*
A: B134
B: B135 ECM
D: B137
* 3 : LHD MODEL: 1
B12
RHD MODEL: 2
B1
A6
A7
D3
D7
D1
D2
B4
* 4 : LHD MODEL: 2
RHD MODEL: 1
B21
52
47
34
36
35
37
E2
E E
B72 B47 B21 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
12 13 14 15 16 17 18 19 20 21 22
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02456
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
chassis ground.
MAIN FUSE BOX CONNECTOR. !? short circuit in har-
4 CHECK FUSE No. 13. Is the fuse blown out? 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
CF:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
TROL RELAY. !? tronic throttle con-
Terminals
No. 7 — No. 8:
4 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Go to step 5. Repair power sup-
ELECTRONIC THROTTLE CONTROL RE- ply short circuit in
LAY. harness between
1) Disconnect the connector from ECM. ECM and elec-
2) Turn the ignition switch to ON. tronic throttle con-
3) Measure the voltage between electronic trol.
ground.
ELECTRONIC THROTTLE CONTROL RE- M!? short circuit in har-
LAY. ness between
ground.
ELECTRONIC THROTTLE CONTROL RE- !? circuit in harness
tor.
(B135) No. 35 — (B362) No. 6:
(B137) No. 6 — (B362) No. 8:
Step Check Yes No

throttle control.
(B136) No. 18 — (E57) No. 6:
(B136) No. 29 — (E57) No. 4:
(B136) No. 16 — (E57) No. 5:
ELECTRONIC THROTTLE CONTROL. M!? short circuit of har-
trol Module
(ECM).>
1) Turn the ignition switch to OFF. !? contact in ECM
trol Module
(ECM).>
14 CHECK SENSOR OUTPUT. Is the voltage 4.63 V? Go to step 15. Go to step 17.
Step Check Yes No

throttle control.
(B136) No. 35 — (E57) No. 3:
(B136) No. 18 — (E57) No. 6:
(B136) No. 29 — (E57) No. 4:
trol Module
(ECM).>
ELECTRONIC THROTTLE CONTROL. M!? circuit to sensor
2) Remove the ECM.
nectors.
(B136) No. 18 — (B136) No. 16:
(B136) No. 29 — (B136) No. 16:
2) Connect the connectors except for the electronic throttle con-
Replace the elec-
trol if defective.
Step Check Yes No

ELECTRONIC THROTTLE CONTROL MO- !? circuit of harness
TOR. connector.
throttle control.
(B137) No. 5 — (E57) No. 2:
(B137) No. 4 — (E57) No. 1:
ELECTRONIC THROTTLE CONTROL MO- ply short circuit in
TOR. harness between
1) Connect the connector to ECM. ECM and elec-
ELECTRONIC THROTTLE CONTROL MO- M!? circuit of harness.
TOR.
TROL MOTOR HARNESS. M!? circuit of harness.
(E57) No. 2 — (E57) No. 1:
TROL GROUND CIRCUIT. !? circuit of harness.
TROL. !? tronic throttle con-
Terminals
No. 1 — No. 2:
TROL. specified position? contact in ECM tronic throttle con-
Move the throttle valve to the fully open and Standard value: 3 mm (0.12 in) connector. trol.
fully closed positions with fingers. from fully closed position Replace the ECM
Check that the valve returns to the specified if defective. <Ref.
position when releasing fingers. to FU(H4SO 2.5)-
36, Engine Con-
trol Module
(ECM).>
CG:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
TROL RELAY. !? tronic throttle con-
Terminals
No. 7 — No. 8:
3) Measure the voltage between electronic trol relay.
ground.
ELECTRONIC THROTTLE CONTROL RE- M!? short circuit in har-
LAY. ness between
ground.
ELECTRONIC THROTTLE CONTROL RE- !? contact in ECM circuit in harness
tor and electronic throttle control relay connec- if defective. <Ref. control relay.
tor. to FU(H4SO 2.5)-
(B135) No. 35 — (B362) No. 6: trol Module
(B137) No. 6 — (B362) No. 8: (ECM).>
CH:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
TROL RELAY. M!? tronic throttle con-
Terminals
No. 7 — No. 8:
3 CHECK POWER SUPPLY SHORT CIRCUIT Is the voltage more than 5 V? Go to step 4. Repair power sup-
OF ELECTRONIC THROTTLE CONTROL ply short circuit in
RELAY. harness between
1) Turn the ignition switch to ON. ECM and elec-
2) Measure the voltage between electronic tronic throttle con-
ground.
ELECTRONIC THROTTLE CONTROL RE- M!? contact in ECM short circuit in har-
2) Disconnect the connector from ECM. if defective. <Ref. tronic throttle con-
3) Measure the resistance between ECM con- to FU(H4SO 2.5)- trol relay.
nector and chassis ground. 36, Engine Con-
(B135) No. 35 — Chassis ground: (ECM).>
CI: DTC P2109 THROTTLE ANGLE CLOSED POSITION ERROR

NOTE:
CJ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB B315
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
3
B315 B122
B138
LHD 6
LHD 1 1 2 3 4
5 6 7 8
RHD 5
RHD 1 B21
B138
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B83
* RHD 23 24 25 26 27 28 29 30 31 32 33
* RHD LHD 1 34 35 36 37 38 39 40 41
LHD 8 42 43 44 45 46 47
6 LHD 48 49 50 51 52 53 54
1 RHD
*
B138
RHD
*
B83
C19
C15
C17
C34
C16
C28
C35
B: B135
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
C: B136 ECM
28 29 30 31 32 33 34 35
D: B137
C: B136
D3
D1
B1
B4
D2
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
LHD 28 29 30 31 32 33 34 35
B21
37
36
35
D: B137
E2
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
E * : TERMINAL No. RANDOM ARRANGEMENT
EN-02470
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR OUTPUT.
present.
CELERATOR POSITION SENSOR. !? circuit of harness
position sensor.
tor.
(B136) No. 17 — (B315) No. 5:
(B136) No. 15 — (B315) No. 3:
CELERATOR POSITION SENSOR. M!? sis short circuit of
(ECM).>
SOR. k!? erator position
sensor.
Terminals
No. 3 — No. 4:
Step Check Yes No

sensor.
Terminals
No. 5 — No. 4:
pedal.
SOR. k!? contact in ECM erator position
No. 5 — No. 4: to FU(H4SO 2.5)-
(ECM).>
CK:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB B315
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
3
B315 B122
B138
LHD 6
LHD 1 1 2 3 4
5 6 7 8
RHD 5
RHD 1 B21
B138
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B83
* RHD 23 24 25 26 27 28 29 30 31 32 33
* RHD LHD 1 34 35 36 37 38 39 40 41
LHD 8 42 43 44 45 46 47
6 LHD 48 49 50 51 52 53 54
1 RHD
*
B138
RHD
*
B83
C19
C15
C17
C34
C16
C28
C35
B: B135
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
C: B136 ECM
28 29 30 31 32 33 34 35
D: B137
C: B136
D3
D1
B1
B4
D2
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
LHD 28 29 30 31 32 33 34 35
B21
37
36
35
D: B137
E2
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
EN-02470
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR OUTPUT.
present.
position sensor.
tor.
(B136) No. 34 — (B315) No. 4:
CELERATOR POSITION SENSOR. !? contact in ECM
(ECM).>
CELERATOR POSITION SENSOR. M!? contact in acceler- circuit to sensor
(B136) No. 17 — (B136) No. 15:
(B136) No. 17 — (B136) No. 16:
CL:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB B315
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
3
B315 B122
B138
LHD 6
LHD 1 1 2 3 4
5 6 7 8
RHD 5
RHD 1 B21
B138
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B83
* RHD 23 24 25 26 27 28 29 30 31 32 33
* RHD LHD 1 34 35 36 37 38 39 40 41
LHD 8 42 43 44 45 46 47
6 LHD 48 49 50 51 52 53 54
1 RHD
*
B138
RHD
*
B83
C19
C15
C17
C34
C16
C28
C35
B: B135
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
C: B136 ECM
28 29 30 31 32 33 34 35
D: B137
C: B136
D3
D1
B1
B4
D2
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
LHD 28 29 30 31 32 33 34 35
B21
37
36
35
D: B137
E2
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
EN-02470
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR OUTPUT.
present.
position sensor.
tor.
(B136) No. 28 — (B315) No. 2:
(B136) No. 16 — (B315) No. 1:
CELERATOR POSITION SENSOR. M!? sis short circuit of
(ECM).>
sensor.
Terminals
No. 1 — No. 6:
Step Check Yes No

tion sensor.
Terminals
No. 2 — No. 6:
tor pedal.
SOR. k!? contact in ECM erator position
No. 2 — No. 6: to FU(H4SO 2.5)-
2) Check the measured value is within the 36, Engine Con-
specification with the accelerator pedal trol Module
depressed. (ECM).>
CM:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB B315
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
3
B315 B122
B138
LHD 6
LHD 1 1 2 3 4
5 6 7 8
RHD 5
RHD 1 B21
B138
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B83
* RHD 23 24 25 26 27 28 29 30 31 32 33
* RHD LHD 1 34 35 36 37 38 39 40 41
LHD 8 42 43 44 45 46 47
6 LHD 48 49 50 51 52 53 54
1 RHD
*
B138
RHD
*
B83
C19
C15
C17
C34
C16
C28
C35
B: B135
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
C: B136 ECM
28 29 30 31 32 33 34 35
D: B137
C: B136
D3
D1
B1
B4
D2
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
LHD 28 29 30 31 32 33 34 35
B21
37
36
35
D: B137
E2
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
EN-02470
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR OUTPUT.
present.
position sensor.
tor.
(B136) No. 35 — (B315) No. 6:
(ECM).>
CELERATOR POSITION SENSOR. M!? contact in acceler- circuit to sensor
(B136) No. 28 — (B136) No. 15:
(B136) No. 28 — (B136) No. 16:
CN:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” / “B”

VOLTAGE RATIONALITY
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
ELECTRONIC SBF-8
THROTTLE B362
CONTROL RELAY
7
5
6
MAIN RELAY
8
B35
D6
ECM
B: B135 C: B136 D: B137 E

C35
C16
C19
C29
C18
D3
D1
B1
D4
D5
D2
B4
B83
LHD 8
B138 : LHD
B138
LHD 3
B122 : RHD 8
1 RHD
* RHD 5
2 RHD
* LHD 5
B21 B83 B20
37
36
35
20
39
38
19
15
16
1
E2 E1
B122
B21
36
E2
5
6
1
E ELECTRONIC E E
THROTTLE CONTROL
E57
B362 B122 B21 B20 E57
B83 1 2 3 4 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8
1 2
4 B138 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33 13 14 15 16
5
7 8
6 1 2 3 4 34 35 36 37 38 39 40 41
5 6 7 8 42 43 44 45 46 47
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-02462
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
(B136) No. 18 — (E57) No. 6:
(B136) No. 29 — (E57) No. 4:
(B136) No. 16 — (E57) No. 5:
ELECTRONIC THROTTLE CONTROL. M!? short circuit of har-
trol Module
(ECM).>
Step Check Yes No

1) Turn the ignition switch to OFF. !? contact in ECM
trol Module
(ECM).>
present.
throttle control.
(B136) No. 35 — (E57) No. 3:
(B136) No. 18 — (E57) No. 6:
(B136) No. 29 — (E57) No. 4:
trol Module
(ECM).>
Step Check Yes No

ELECTRONIC THROTTLE CONTROL. M!? circuit to sensor
nectors.
(B136) No. 18 — (B136) No. 16:
(B136) No. 29 — (B136) No. 16:
TROL HARNESS. M!? contact in ECM circuit of harness.
2) Disconnect the connectors from the elec- Replace the ECM
tronic throttle control. if defective. <Ref.
3) Measure the resistance between electronic to FU(H4SO 2.5)-
throttle control connector terminals. 36, Engine Con-
(E57) No. 6 — (E57) No. 4: (ECM).>
CO:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” / “E”

VOLTAGE RATIONALITY
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN SUB B315
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
3
B315 B122
B138
LHD 6
LHD 1 1 2 3 4
5 6 7 8
RHD 5
RHD 1 B21
B138
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B83
* RHD 23 24 25 26 27 28 29 30 31 32 33
* RHD LHD 1 34 35 36 37 38 39 40 41
LHD 8 42 43 44 45 46 47
6 LHD 48 49 50 51 52 53 54
1 RHD
*
B138
RHD
*
B83
C19
C15
C17
C34
C16
C28
C35
B: B135
1 2 3 4 5 6 7
B: B135 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
C: B136 ECM
28 29 30 31 32 33 34 35
D: B137
C: B136
D3
D1
B1
B4
D2
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
LHD 28 29 30 31 32 33 34 35
B21
37
36
35
D: B137
E2
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
EN-02470
• KA and KS model
NOTE:
Step Check Yes No

to EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
Fuel injection sys-
tem for KA and KS
model is the same
as 2.0 L model.
SOR OUTPUT.
position sensor.
tor.
(B136) No. 17 — (B315) No. 5:
(B136) No. 15 — (B315) No. 3:
(B136) No. 28 — (B315) No. 2:
(B136) No. 16 — (B315) No. 1:
CELERATOR POSITION SENSOR. M!? short circuit of har-
(B315) No. 1 (+) — Engine ground ("): (ECM).>
sensor.
Terminals
No. 3 — No. 4:
Step Check Yes No

sensor.
Terminals
No. 1 — No. 6:
pedal.
Terminals
No. 5 — No. 4:
pedal.
Terminals
No. 2 — No. 6:
Terminals
No. 5 — No. 4:
Terminals
No. 2 — No. 6:
SOR OUTPUT.
position sensor.
tor.
(B136) No. 34 — (B315) No. 4:
(B136) No. 35 — (B315) No. 6:
Step Check Yes No

(B315) No. 6 — Engine ground: (ECM).>
CELERATOR POSITION SENSOR. M!? circuit to sensor
nectors.
(B136) No. 17 — (B136) No. 15:
(B136) No. 17 — (B136) No. 16:
(B136) No. 28 — (B136) No. 15:
(B136) No. 28 — (B136) No. 16:
CELERATOR POSITION SENSOR. M!? contact in ECM circuit in harness
ator position sensor. to FU(H4SO 2.5)- tion sensor con-
(B315) No. 5 — (B315) No. 2:

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in
General.>
2) Mass air flow and intake air temperature sensor
1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2)
5) Air intake system (*5)
2. Rough idling
10) Oxygen sensor
12) EGR valve
3. Engine does not return to idle. 3) Manifold absolute pressure sensor
5) EGR valve
4. Poor acceleration 7) Crankshaft position sensor (*3)
12) EGR valve
13) Tumble generator valve
5. Engine stalls, engine sags or hesitates at accel-
6) Purge control solenoid valve
eration.
10) EGR valve

6. Surge
9) EGR valve
4) Knock sensor
7. Spark knock
7) EGR valve
*4: Check the fuel injector and fuel pressure regulator.
ENGINE SECTION 2
FUEL INJECTION (FUEL SYSTEMS) FU(H4DOTC)
EMISSION CONTROL EC(H4DOTC)

INTAKE (INDUCTION) IN(H4DOTC)
MECHANICAL ME(H4DOTC)
EXHAUST EX(H4DOTC)
of SUBARU vehicles. COOLING CO(H4DOTC)
sembling, inspection and adjustment of LUBRICATION LU(H4DOTC)
Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP(H4DOTC)
their vehicle in optimum condition. IGNITION IG(H4DOTC)
SUBARU genuine parts. STARTING/CHARGING SYSTEMS SC(H4DOTC)
ENGINE (DIAGNOSTICS) EN(H4DOTC)(diag)

approval.

FUEL INJECTION
(FUEL SYSTEMS)
FU(H4DOTC)
Page
2. Throttle Body.............................................................................................12
3. Intake Manifold..........................................................................................13
7. Knock Sensor............................................................................................26
9. Mass Air Flow and Intake Air Temperature Sensor ..................................28
11. Fuel Injector ..............................................................................................30
12. Oil Flow Control Solenoid Valve................................................................31
13. Wastegate Control Solenoid Valve ...........................................................32
17. Main Relay ................................................................................................36
18. Fuel Pump Relay.......................................................................................37
20. Fuel Pump Control Unit.............................................................................39
21. Fuel ...........................................................................................................40
22. Fuel Tank ..................................................................................................41
23. Fuel Filler Pipe ..........................................................................................47
24. Fuel Pump.................................................................................................49
27. Fuel Filter ..................................................................................................54
28. Fuel Bypass Valve ....................................................................................55
General Description
A: SPECIFICATION
Capacity 64 2 (16.9 US gal, 14.1 Imp gal)
Fuel tank
Type Impeller
Fuel pump
155 2 (40.9 US gal, 34.1 Imp gal)/h or more.
Discharge
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(H4DOTC)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T3
T3
(18)
T3
T3
(15)
T2
(23)
(19) (16)
T2 (17)
(23)
(4)
(6)
(20)
(5) T4 T2
(10)
(12)
T4 (1)
T2
T2
(14) (3)
(2) T1
(3)
T4
T4 (10)
(11)
(22) T2 (12)
T4
T5
T4 (13)
(21)
T4
T5
(9) (11)
(9)
(8)
(7)
(7) (8)
FU-01154
FU(H4DOTC)-3
General Description
(1) Fuel pipe ASSY (12) O-ring (22) Coolant filler tank stay
(2) Fuel hose (13) Fuel injector pipe LH (23) O-ring
(3) Clip (14) Fuel injector pipe RH
(4) Purge control solenoid valve (15) Solenoid valve bracket !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456
(5) Vacuum hose (16) Manifold absolute pressure sensor !7- 789(.:8793(7876
(6) Vacuum control hose (17) Filter !;- <89(.:8<<3(=8>6
(7) Intake manifold gasket (18) Intake manifold !?- >8?(.:8>93(<876
(8) Guide pin (19) Wastegate control solenoid valve !=- 7@(.78@=3(7?8A6
(9) Intake manifold (lower) ASSY !9- ;9(.;893(7>876
(10) Fuel injector (20) Vacuum hose
(11) Seal ring (21) Ground stay
FU(H4DOTC)-4
General Description
(2)
(1)
FU-01155
(1) O-ring !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456

(2) Throttle body !- >(.:8>3(98@6
FU(H4DOTC)-5
General Description
T1
(4)
T2
T1
T1
(1)
(6)
(3)
(2)
T1
(5)
T1
FU-01156
(1) Crankshaft position sensor (5) Exhaust camshaft position sensor !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456
(2) Knock sensor LH !7- <8=(.:8<93(=8A6
(3) Intake camshaft position sensor (6) Exhaust camshaft position sensor !;- ;=(.;8=3(7A8=6
LH RH
(4) Intake camshaft position sensor
RH
FU(H4DOTC)-6
General Description
4. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8) (17) T1
(14)
(7)
(15)
(10)
(9) (12)
(11)
(1)
(13)
(22)
T4
(6)
(2)
(5) (22)
(20)
(3)
T4
(21)
T4
T3 (4)
T3
T3
T3
(23)
(24)
(25)
T3
T2 T3
T2
FU-01328
FU(H4DOTC)-7
General Description
(1) Fuel tank (12) Fuel sub level sensor upper plate (23) Heat shield cover
(2) Fuel tank band RH (13) Fuel sub level sensor gasket (24) Fuel tank protector RH (Front)
(3) Fuel tank band LH (14) Fuel filler hose (25) Fuel tank protector LH (Front)
(4) Delivery tube (15) Clamp
(5) Return tube (16) Vent hose !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456
(6) Jet pump tube (17) Clip !7- =8=(.:8=93(?8?6
(7) Fuel pump ASSY (18) Protector RH (Rear) !;- @8:(.:8@;3(<8<6
(8) Fuel pump upper plate (19) Protector LH (Rear) !?- 7A89(.78A>3(7;8@6
(9) Fuel pump gasket (20) Stopper RH !=- ??(.?8=3(;96
(10) Fuel level sensor (21) Stopper LH
(11) Fuel sub level sensor (22) Retainer
FU(H4DOTC)-8
General Description
5. FUEL LINE
T1 (1)
(28)
(26) (18)
(23)
(25) (19) (17) (15)

(27) (1)
(20) (22) (14)
(13)
(24)
(21) (1) A (16)
T2 (1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
B T3
T2
(6)
(4) (5) (1)

A
(1) T2
(1)
(8) B
(3)
T2 (2) (1) (9)
(1) T2 (32)
(33)
(6) (30) (31)
(7)
FU-01329
FU(H4DOTC)-9
General Description

(2) Fuel return hose A (15) Purge hose A (28) Tether
(3) Evaporation hose (16) Purge hose B (29) Clip
(6) Fuel bypass valve (19) Two-way valve drain hose (32) Fuel hose connector
(7) Fuel bypass valve bracket (20) Two-way valve (33) Purge pipe
(8) Fuel return hose B (21) Two-way valve hose C (34) Two-way valve bracket
(10) Clamp (23) Evaporation hose holder !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456
(11) Canister (24) Fuel filler pipe ASSY !7- =8=(.:8=93(?8;6
(12) Canister protector (Sedan model) (25) Filler pipe packing !;- A89(.:8A<3(989?6
(13) Canister drain hose A (26) Filler ring !?- >8?(.:8>93(<876
FU(H4DOTC)-10
General Description

D: PREPARATION TOOL
ST24082AA230
ST22771AA030
FU(H4DOTC)-11
Throttle Body
2. Throttle Body Tightening torque:

8 N!m (0.8 kgf-m, 5.9 ft-lb)
A: REMOVAL
1) Remove the collector cover.
FU-01159
IN-00203
3) Remove the intercooler. <Ref. to IN(H4DOTC)-

12, REMOVAL, Intercooler.>
4) Disconnect the connectors from throttle position
sensor.
FU-01157
5) Disconnect the engine coolant hose from throttle

body.
FU-01158
6) Remove the bolts which secure throttle body to

intake manifold.
B: INSTALLATION
NOTE:
Always use new O-rings.
FU(H4DOTC)-12
Intake Manifold
3. Intake Manifold 13) Disconnect the engine coolant hose from throt-
tle body.
A: REMOVAL
<Ref. to FU(H4DOTC)-40, RELEASING OF FUEL
filler cap.
FU-01158
IN-00203

7) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Imp qt). FU-01161
8) Remove the intake duct from air cleaner case. 15) Disconnect the engine harness connectors
9) Remove the intercooler. <Ref. to IN(H4DOTC)- from bulkhead harness connectors.
10) Remove the generator. <Ref. to SC(H4SO
2.0)-14, REMOVAL, Generator.>
11) Remove the coolant filler tank.
<Ref. to CO(H4DOTC)-31, REMOVAL, Coolant
Filler Tank.>
12) Disconnect the PCV hose assembly from cylin-
der block.
FU-01162
FU-01160
FU-01163
FU(H4DOTC)-13
Intake Manifold
16) Disconnect the connectors from the engine 20) Disconnect the connector from the exhaust
coolant temperature sensor (A), oil pressure switch camshaft position sensor (A) and exhaust oil flow
(B) and crankshaft position sensor (C). control solenoid valve (B).
(A)
(B)
(C)
(B) (A)
FU-00027 FU-01167
17) Disconnect the knock sensor connector. 21) Disconnect the connector from ignition coil.
FU-01164 IG-00092
18) Disconnect the connector from intake camshaft 22) Remove the engine harness bracket from rock-
position sensor. er cover.
FU-01165 FU-02155
19) Disconnect the connector from the intake oil 23) Disconnect the fuel delivery hose, return hose
flow control solenoid valve. and evaporation hose.
FU-01166
FU(H4DOTC)-14
Intake Manifold
CAUTION: NOTE:
• Be careful not to spill fuel. If fuel hoses or clamps are damaged, replace them
• Catch the fuel from hoses using a container with new ones.
or cloth.
FU-01168
FU-01168
3) Tighten the hose clamp screws.
24) Remove the bolts which hold intake manifold
Tightening torque:
onto the cylinder heads.
1.25 N!m (0.13 kgf-m, 0.94 ft-lb)
4) Connect the connector to the exhaust camshaft
position sensor (A) and exhaust oil flow control so-
lenoid valve (B).
FU-01169

(B) (A)
B: INSTALLATION
FU-01167
NOTE: 5) Connect the connector to intake oil flow control
Use a new gasket. solenoid valve.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
FU-01166
FU-01169
2) Connect the fuel delivery hose, return hose and

evaporation hose.
FU(H4DOTC)-15
Intake Manifold
6) Connect the connector to the engine coolant 10) Install the engine harness bracket to rocker
temperature sensor (A), oil pressure switch (B) and cover.
crankshaft position sensor (C).
(A)
(B)
(C)
FU-02155
FU-00027
11) Connect the engine harness connector to bulk-
7) Connect the connector to knock sensor. head harness connector.
FU-01164 FU-01162
8) Connect the connector to intake camshaft posi-

tion sensor.
FU-01163
12) Connect the brake booster hose.

FU-01165
9) Connect the connector to ignition coil.
FU-01161
IG-00092
FU(H4DOTC)-16
Intake Manifold
13) Connect the engine coolant hose to throttle 2) Remove the solenoid valve bracket assembly
body. from intake manifold, and disconnect the connector
from the wastegate control solenoid valve, manifold
absolute pressure sensor and purge control sole-
noid valve.
FU-01158
14) Connect the PCV hose assembly to cylinder

block.
EC-00219
3) Disconnect the evaporation hoses (A) and filter

assembly (B).
(A)
FU-01160
(B)
15) Install the coolant filler tank.
<Ref. to CO(H4DOTC)-31, INSTALLATION, Cool-
FU-01172
ant Filler Tank.>
16) Install the intercooler. <Ref. to IN(H4DOTC)- 4) Disconnect the connectors from throttle position
12, INSTALLATION, Intercooler.> sensor.
17) Install the intake duct to air cleaner case.
22) Fill with engine coolant.
<Ref. to CO(H4DOTC)-13, FILLING OF ENGINE
23) Install the collector cover.
C: DISASSEMBLY FU-01157
1) Disconnect the engine ground terminal from 5) Remove the throttle body from intake manifold.
ground stay.
FU-01159
FU-01170
FU(H4DOTC)-17
Intake Manifold
6) Disconnect the connectors from fuel injector. 10) Remove the coolant filler tank stay from intake
manifold.
FU-01173
FU-01177
7) Remove the bolt which secures the air bypass
pipe to intake manifold. 11) Remove the bolts which hold fuel injector pipe
• RH side
FU-01174
8) Disconnect the PCV pipe (A), harness assembly

FU-01178
(B) and intake duct (C) from intake manifold.
• LH side
(B)
(A)
(C)
FU-01175
FU-01179
9) Remove the bolt which holds fuel injector pipe
LH onto the front side of intake manifold. 12) Remove the bolt which holds the fuel pipe to in-
take manifold.
FU-01176
FU-01180
FU(H4DOTC)-18
Intake Manifold
13) Remove the fuel injectors. D: ASSEMBLY

1) Install the intake manifold (lower) to intake man-
ifold (upper).
NOTE:
Use new O-rings.
Tightening torque:
8.3 N!m (0.85 kgf-m, 6.1 ft-lb)
FU-01181
14) Remove the bolts which hold the fuel injector

pipe RH onto the lower side of intake manifold.
FU-01184
2) Install the fuel injector pipe.

3) Connect the both fuel injector pipes with a fuel
hose and secure them with clamps.
FU-01182
15) Loosen the clamp which holds fuel hose to in-

jector pipe, and then disconnect the pipe from fuel
hose.
FU-01183
4) Tighten the bolt which secures the fuel injector

pipe RH onto the lower side of intake manifold.
Tightening torque:
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
FU-01183

17) Remove the intake manifold (upper) from in-
take manifold (lower).
FU-01182
FU-01184
FU(H4DOTC)-19
Intake Manifold
5) Install the fuel injectors. • RH side
FU-01181 FU-01178
6) Tighten the bolt which secures fuel pipe onto in- 8) Install the coolant filler tank stay to intake mani-
take manifold. fold.
FU-01180 FU-01177
7) Tighten the bolts which secure fuel injector pipe 9) Tighten the bolt which installs fuel injector pipe
onto intake manifold. LH on the front side of intake manifold.
19 N!m (1.94 kgf-m, 13.7 ft-lb) 6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
• LH side
FU-01176
FU-01179
10) Install the PCV pipe (A), harness assembly (B)
and intake duct (C) to intake manifold.
FU(H4DOTC)-20
Intake Manifold

(B)
(A)
(C)
FU-01175 FU-01159
11) Tighten the bolt which secures air bypass pipe 14) Connect the connector to throttle position sen-
onto intake manifold. sor.
Tightening torque:
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
FU-01157
15) Connect the evaporation hoses (A) and filter

FU-01174 assembly (B).
12) Connect the connectors to fuel injector.
(A)
(B)
FU-01172
FU-01173

NOTE:
Use new O-rings.
FU(H4DOTC)-21
Intake Manifold
NOTE:
Connect the evaporation hose as shown in the fig-
ure.
(A)
(B)
EC-00273
(A) To intake manifold

(B) To evaporation pipe
16) Connect the connector to the wastegate control

solenoid valve, manifold absolute pressure sensor
and purge control solenoid valve, and install the so-
lenoid bracket assembly to intake manifold.
Tightening torque:
19 N!m (1.94 kgf-m, 13.7 ft-lb)
EC-00219
17) Install the engine ground terminal to ground

stay.
Tightening torque:
19 N!m (1.94 kgf-m, 13.7 ft-lb)
FU-01170
E: INSPECTION
Make sure that the fuel hoses and fuel pipes are not
cracked and that connections are tight.
FU(H4DOTC)-22

Sensor
A: REMOVAL
IN-00203

4) Drain coolant. <Ref. to CO(H4DOTC)-13,
DRAINING OF ENGINE COOLANT, REPLACE-
temperature sensor.
FU-00055

B: INSTALLATION
Tightening torque:
18 N!m (1.8 kgf-m, 13.3 ft-lb)
FU(H4DOTC)-23
5. Crankshaft Position Sensor Tightening torque:

T: 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
A: REMOVAL
T
FU-00058
IN-00203

FU-00056

FU-00057
B: INSTALLATION
FU(H4DOTC)-24
6. Camshaft Position Sensor 4) Remove the sensor cover.
A: REMOVAL
1. INTAKE SIDE
FU-02156

tion sensor RH.
6) Remove the camshaft position sensor RH from
the lower side of cylinder head.
IN-00203

tion sensor RH.
4) Remove the camshaft position sensor RH from
the rear side of cylinder head.
FU-01186
7) Remove the camshaft position sensor LH in the

same procedure as RH.
B: INSTALLATION
FU-01185
Tightening torque:
5) Remove the camshaft position sensor LH in the 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
same procedure as RH.
2. EXHAUST SIDE
IN-00203

FU(H4DOTC)-25
Knock Sensor

A: REMOVAL
1) Remove the collector cover. NOTE:
2) Disconnect the ground cable from battery. Extraction area of knock sensor cord must be posi-
Tightening torque:
24 N!m (2.4 kgf-m, 17.4 ft-lb)
(A)
IN-00203
3) Remove the intercooler. <Ref. to IN(H4DOTC)- 60

4) Disconnect the knock sensor connector. FU-00413
(A) Front side
FU-01164
FU-01164
3) Install the intercooler.

<Ref. to IN(H4DOTC)-12, INSTALLATION, Inter-
cooler.>
FU-00519
IN-00203
FU(H4DOTC)-26

A: SPECIFICATION
body.
Refer to “Throttle Body” for removal and installa-
tion. <Ref. to FU(H4DOTC)-12, REMOVAL, Throt-
tle Body.> <Ref. to FU(H4DOTC)-12,
INSTALLATION, Throttle Body.>
FU(H4DOTC)-27
9. Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
IN-00203

ature sensor.
FU-01187
B: INSTALLATION
Tightening torque:
1.0 N!m (0.10 kgf-m, 0.74 ft-lb)
FU(H4DOTC)-28
10.Manifold Absolute Pressure

Sensor
A: REMOVAL
IN-00203

lute pressure sensor (A), and remove the filter as-
sembly (B) from intake manifold.
from solenoid valve bracket.
(A)
(B)
FU-01188
B: INSTALLATION
Tightening torque:
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
FU(H4DOTC)-29
Fuel Injector
11.Fuel Injector 4) Disconnect the ground cable from battery.
A: REMOVAL
1. RH SIDE
filler cap.
4) Disconnect the ground cable from battery. IN-00203

6) Remove the screw and remove the fuel injector.
IN-00203

<Ref. to CO(H4DOTC)-31, REMOVAL, Coolant FU-01190
Filler Tank.> B: INSTALLATION
7) Remove the screw and remove the fuel injector. 1. RH SIDE
NOTE:
Use new O-rings.
Tightening torque:
3.5 N!m (0.36 kgf-m, 2.6 ft-lb)
2. LH SIDE
FU-01189 NOTE:
Use new O-rings.
2. LH SIDE
Tightening torque:
1) Release the fuel pressure. 3.5 N!m (0.36 kgf-m, 2.6 ft-lb)
filler cap.
FU(H4DOTC)-30
Oil Flow Control Solenoid Valve
12.Oil Flow Control Solenoid

Valve
A: REMOVAL
1. INTAKE SIDE
Oil flow control solenoid valve forms a unit with
camshaft cap.
Refer to “Camshaft” for removal. <Ref. to
ME(H4DOTC)-53, REMOVAL, Camshaft.>
2. EXHAUST SIDE
IN-00203

4) Remove the oil flow control solenoid valve from
cylinder head.
FU-01191
B: INSTALLATION
1. INTAKE SIDE
2. EXHAUST SIDE
FU(H4DOTC)-31
Wastegate Control Solenoid Valve
13.Wastegate Control Solenoid

Valve
A: REMOVAL
IN-00203
3) Disconnect the connector from wastegate con-

trol solenoid valve (A).
4) Disconnect the pressure hose (B) from waste-
gate control solenoid valve.
5) Remove the wastegate control solenoid valve
from bracket.
(B)
(A)
FU-01192
B: INSTALLATION
Tightening torque:
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
FU(H4DOTC)-32
14.Front Oxygen (A/F) Sensor 3) Connect the connector of front oxygen (A/F)
sensor.
A: REMOVAL
FU-01193

IN-00203
3) Disconnect the connector from front oxygen (A/

F) sensor.
one minute or more.
CAUTION:
When removing the oxygen (A/F) sensor, wait
IN-00203
age exhaust pipe. 5) Install the collector cover.
FU-01193
B: INSTALLATION
ply anti-seize compound only to the threaded por-
tion of front oxygen (A/F) sensor to make the next
removal easier.
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (A/F) sensor.
Tightening torque:
21 N!m (2.1 kgf-m, 15.2 ft-lb)
FU(H4DOTC)-33
Rear Oxygen Sensor
15.Rear Oxygen Sensor Tightening torque:

21 N!m (2.1 kgf-m, 15.2 ft-lb)
A: REMOVAL
FU-01194
IN-00203
2) Lift-up the vehicle. 5) Connect the battery ground cable to battery.
sor.
minute or more.
CAUTION:
age exhaust pipe.
IN-00203
FU-01194
B: INSTALLATION
1) Before installing rear oxygen (A/F) sensor, apply
anti-seize compound only to the threaded portion of
rear oxygen (A/F) sensor to make the next removal
easier.
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
FU(H4DOTC)-34
16.Engine Control Module (ECM) Tightening torque:

5 N!m (0.5 kgf-m, 3.6 ft-lb)
A: REMOVAL
IN-00203
2) Remove the lower inner trim of passenger side.

<Ref. to EI-60, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of front passenger’s seat.
FU-00896
5) Remove the nuts (A) which hold the ECM to

bracket.
(A)
(A)
(B)
FU-00897

the ECM.
B: INSTALLATION
CAUTION:
to the fuel injection system.
FU(H4DOTC)-35
Main Relay
17.Main Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-01118
FU-01119
B: INSTALLATION
FU(H4DOTC)-36
Fuel Pump Relay
18.Fuel Pump Relay

A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-01118
FU-01120
B: INSTALLATION
FU(H4DOTC)-37

Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-01118
4) Disconnect the connector from electronic throttle

control relay.
FU-01121
B: INSTALLATION
FU(H4DOTC)-38
Fuel Pump Control Unit
20.Fuel Pump Control Unit

A: REMOVAL
IN-00203
2) Remove the rear quarter trim. <Ref. to EI-63,

REMOVAL, Rear Quarter Trim.>
3) Remove the fuel pump control unit.
FU-01195
4) Disconnect the connector from fuel pump control

unit.
B: INSTALLATION
FU(H4DOTC)-39
Fuel

drain plug from fuel tank to drain fuel from the fuel
A: PROCEDURE tank.
WARNING:
box.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
FU-01122
2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for five more sec-
onds.
2. DRAINING FUEL
WARNING:
IN-00203
3) Open the fuel filler flap lid and remove the fuel
filler cap.
FU(H4DOTC)-40
Fuel Tank
A: REMOVAL
WARNING:
(B)
<Ref. to FU(H4DOTC)-40, DRAINING FUEL, FU-01126
PROCEDURE, Fuel.>
8) Disconnect the connector (A) from fuel sub level
sensor.
(1) Remove the bolt (A).
livery (B) and return hose (C).
(2) Push the grommet (B) down under the body <Ref. to FU(H4DOTC)-56, REMOVAL, Fuel Deliv-
and remove the service hole cover. ery, Return and Evaporation Lines.>
(A)
(A) (A) (C)
(B) (B)
FU-01124
FU-01127
6) Disconnect the connector from fuel pump. 10) Remove the rear wheel.
11) Remove the bolts which secure rear brake
FU-01125

el sensor. FU-01128
FU(H4DOTC)-41
Fuel Tank
FU-00462 FU-01130

<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Ex-
haust Pipe.>
18) Disconnect the connector from rear ABS wheel FU-01131

CAUTION:
sion jack.
(2) Remove the bolt which installs the rear
shock absorber to rear suspension arm.
FU-01129
FU-01132
FU(H4DOTC)-42
Fuel Tank
(3) Remove the bolts which secure the rear WARNING:

suspension assembly to body. A helper is required to perform this work.
FU-01133
FU-01137
B: INSTALLATION
of fuel tank band.
WARNING:
FU-01134

from bracket.
FU-01137
(A)
FU-01135

(A)
(B)
FU-01136
23) Support the fuel tank with transmission jack, re-

move the bolts from fuel tank bands and dismount
FU(H4DOTC)-43
Fuel Tank
T3: 175 N!m (17.8 kgf-m, 129 ft-lb)
(A) T1 T1
(B)
T1
T1
FU-01136
FU-01150
(2) (3)
(1)
L/2
T2 T3
L T3 T2
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp (3) Tighten the bolt which installs the rear shock
(3) Pipes absorber to rear suspension arm. <Ref. to RS-
11, INSTALLATION, Rear Arm.>
62 N!m (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
4) Tighten the bolt of fuel tank band.
33 N!m (3.4 kgf-m, 25 ft-lb)
CAUTION:
sion jack.
then tighten the bolts which secure the rear sus-
pension assembly to body.
FU(H4DOTC)-44
Fuel Tank

FU-01130 FU-01128
Tightening torque: 15) Install the rear wheel.

sor.
(B) and return hose (C).
<Ref. to FU(H4DOTC)-57, INSTALLATION, Fuel
Delivery, Return and Evaporation Lines.>
NOTE:
return side.
FU-01131

sor.
(A)
(C)
(B)
FU-01127

sensor.
FU-01129

Tightening torque:
17.5 N!m (1.78 kgf-m, 12.9 ft-lb)
9) Install the propeller shaft. <Ref. to DS-11, IN- (A)
10) Install the rear exhaust pipe.
<Ref. to EX(H4DOTC)-11, INSTALLATION, Rear
(B)
Exhaust Pipe.> FU-01126
12) Connect the parking brake cable to parking (A) Bolt
brake assembly. <Ref. to PB-8, INSTALLATION, (B) Grommet
13) Install the rear brake caliper.
14) Tighten the bolts which secure the rear brake
FU(H4DOTC)-45
Fuel Tank
FU-01125
(A) (A)
(B)
FU-01124
(A) Bolt
(B) Grommet

C: INSPECTION
1) Check that the fuel tank is not holed, cracked or
otherwise damaged.
not cracked and that connections are tight.
FU(H4DOTC)-46
Fuel Filler Pipe
23.Fuel Filler Pipe 7) Set a container under the vehicle and remove
drain plug from fuel tank to drain fuel from the fuel
A: REMOVAL tank.
WARNING:
2) Open the fuel filler flap lid and remove the filler
cap.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
MOVAL, Mud Guard.>
4) Remove the screws which secure packing. 11) Remove the bolts which hold the fuel filler pipe
FU-00095

6) Remove the rear wheel RH. 12) Loosen the clamp, and disconnect the fuel filler
(A)
(B)
FU-00096
FU-01136

vehicle.
FU(H4DOTC)-47
Fuel Filler Pipe
B: INSTALLATION Tightening torque:

1) Open the fuel filler flap lid. 7.5 N!m (0.75 kgf-m, 5.4 ft-lb)
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
NOTE:
(A)
FU-01139

STALLATION, Rear Sub Frame.>
(B)
LATION, Mud Guard.>
(C)
FU-00103

pipe (B) to specified position, and then tighten the
clamp.
(A)
FU-00096
(B)
FU-01136
(2) (3)
(1)
IN-00203
L/2
L
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipes
5) Tighten the bolts which hold the fuel filler pipe

FU(H4DOTC)-48
Fuel Pump
24.Fuel Pump (2) Push the grommet (B) down under the body
A: REMOVAL
WARNING:
• Reduce the fuel in the fuel tank to less than (A) (A)
NOTE:
level sensor. (B)
FU-01124
1) Release the fuel pressure. 10) Disconnect the connector from fuel pump.
2) Open the fuel filler flap lid and remove the fuel
filler cap.
FU-01125
11) Disconnect the quick connector and then dis-

connect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H4DOTC)-56, REMOVAL,
Fuel Delivery, Return and Evaporation Lines.>
IN-00203
12) Remove the nuts which install the fuel pump
4) Lift-up the vehicle. assembly onto fuel tank.
6) Set a container under the vehicle and remove
fuel tank. (B)
(C)
(A) FU-01140
(A) Delivery hose

(B) Return hose
FU-01123 (C) Jet pump hose
NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
FU(H4DOTC)-49
Fuel Pump
B: INSTALLATION
NOTE:
• Ensure the sealing portion is free from fuel or for-
eign particles before installation.
• Tighten the nuts to specified torque in the order
Tightening torque:
4.4 N!m (0.45 kgf-m, 3.3 ft-lb)
1
4 8
6 5
7 3
2
FU-01141
C: INSPECTION
of fuel pump, and apply the battery power supply to
check whether the pump operate.
WARNING:
• Wipe off the fuel completely.
• Keep battery as far apart from fuel pump as
possible.
non-load condition.
2 1
4 3
6 5
FU-01330
FU(H4DOTC)-50
Fuel Level Sensor

A: REMOVAL
WARNING:
NOTE:
1) Remove the fuel pump assembly.
<Ref. to FU(H4DOTC)-49, REMOVAL, Fuel
Pump.>
et.
FU-01142

B: INSTALLATION
FU(H4DOTC)-51
26.Fuel Sub Level Sensor 7) Disconnect the connector from fuel sub level
sensor.
A: REMOVAL
WARNING:
FU-01143

pump hose. <Ref. to FU(H4DOTC)-56, REMOVAL,
9) Remove the bolts which install the fuel sub level
sensor on fuel tank.
IN-00203
2) Lift-up the vehicle. (C)

3) Set a container under the vehicle and remove
the drain plug from fuel tank to drain the fuel from (A)
fuel tank.
(B)
FU-01144
(A) Jet pump hose

(B) Delivery hose
(C) Return hose

FU-01123

Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
(2) Push the grommet (B) down under the body
(A)
(A)
(B)
FU-01126
FU(H4DOTC)-52
B: INSTALLATION
NOTE:
• Ensure the sealing portion is free from fuel and
• Tighten the nuts and bolts to specified torque in
the order as shown in the figure.
Tightening torque:
4.4 N!m (0.45 kgf-m, 3.3 ft-lb)
3
1
2
4
FU-01145
FU-01146
FU(H4DOTC)-53
Fuel Filter
27.Fuel Filter
A: SPECIFICATION
Refer to “Fuel Pump” for removal and installation.
<Ref. to FU(H4DOTC)-49, REMOVAL, Fuel
Pump.> <Ref. to FU(H4DOTC)-50, INSTALLA-
TION, Fuel Pump.>
FU(H4DOTC)-54
Fuel Bypass Valve
28.Fuel Bypass Valve

A: REMOVAL
2) Disconnect the fuel return line and delivery line
from fuel bypass valve.
3) Remove the fuel bypass valve from vehicle.
(A)
(B)
T (B)
(C)
(D) FU-01331
(A) Fuel return line

(B) Fuel delivery line
(C) Fuel bypass valve
(D) Fuel bypass valve bracket
B: INSTALLATION
Tightening torque:
7.5 N!m (0.76 kgf-m, 5.53 ft-lb)
(A)
(B)
T (B)
(C)
(D) FU-01331
(A) Fuel return line

(C) Fuel bypass valve
(D) Fuel bypass valve bracket
FU(H4DOTC)-55

A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H4DOTC)-40, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler flap lid and remove the fuel filler cap.
FU-01332
6) In the engine compartment, disconnect the fuel 9) Separate the quick connector of fuel line.
covered with dust.
(A)
plastic bag etc.
(C)
(B)
FU-01088

(B) Return hose
(C) Evaporation hose FU-01333
7) Lift-up the vehicle. (3) Hold the connector (A) and push retainer (B)
8) Remove the fuel tank. <Ref. to FU(H4DOTC)- down.
41, REMOVAL, Fuel Tank.> (4) Pull out the connector (A) from retainer (B).
FU(H4DOTC)-56
CAUTION: CAUTION:
securely.
• Be sure to inspect hoses and their connec-
(B)
(A) (C)
FU-00124
(A)
(A) Connector
(B) Retainer
(C) Pipes (B) (C)
FU-00127
B: INSTALLATION
(B) Retainer
CAUTION:
• Always use a new retainer. (C) Pipes
fied.
(A)
2: 2.5#1.5 mm (0.098#0.059 in)
L: 22.5#2.5 mm (0.886#0.098 in)
(B)
(1) (2) (3)
Type A
FU-00125
L
(A) Seal surface
(B) Pipes
Type B
(1) Set the new retainer (B) to connector (A).
(2) Push the pipe into the connector completely. FU-00128
(A) (1) Pipes

(2) Clamp
(B) (3) Hose

(C) to pipe by approx. 15 mm (0.59 in) from the hose
end.
Fuel return hose:
L = 22.5#2.5 mm (0.885#0.098 in)
FU-00126
L = 17.5#2.5 mm (0.689#0.098 in)
(A) Connector
(B) Retainer
(C) Pipes
FU(H4DOTC)-57
CAUTION:
Be sure to inspect hoses and their connections
for fuel leakage.
(2) (3)
(1)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipes
C: INSPECTION
FU(H4DOTC)-58

A: INSPECTION
❍ Defective terminal contact.
securely.
❍ Trouble in electromagnetic or electronic circuit parts. Replace the faulty parts.
2) Lowering of fuel pump function. Replace the fuel pump.
3) Clogged dust or water in the fuel filter. Replace 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 air breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
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.
5) Clogged air breather tube or air vent tube.
tube.
1) Retightening.
pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace the packing.
3) Inoperative fuel pump modulator or circuit. Replace.
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE:
• Before using a water removing agent, follow the cautions that noted on the bottle.
FU(H4DOTC)-59
FU(H4DOTC)-60
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

EMISSION CONTROL
EC(H4DOTC)
Page
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter.............................................................................4
4. Canister.......................................................................................................5
5. Purge Control Solenoid Valve .....................................................................6
6. Two-way Valve............................................................................................7
7. PCV Valve...................................................................................................8
General Description
A: CAUTION
points.
cable from battery.
EC(H4DOTC)-2

A: REMOVAL
1) Remove the center exhaust pipe.
<Ref. to EX(H4DOTC)-6, REMOVAL, Center Ex-
haust Pipe.>
2) Separate the front catalytic converter (A) from
rear catalytic converter (B).
(A)
(B)
EC-00217
B: INSTALLATION
NOTE:
Always use new gasket.
C: INSPECTION
nections and welds.
EC(H4DOTC)-3

A: REMOVAL
haust Pipe.>
2) Separate the rear catalytic converter (B) from
front catalytic converter (A).
(A)
(B)
EC-00217
B: INSTALLATION
NOTE:
C: INSPECTION
nections and welds.
EC(H4DOTC)-4
Canister
4. Canister B: INSTALLATION
A: REMOVAL
1) Lift-up the vehicle. NOTE:
2) Remove the rear wheel LH. Make sure there are no damage or dust on the con-
3) Remove the rear mud guard LH. nection of quick connector. If necessary, clean the
4) Remove the canister protector.
5) Disconnect the quick connector (A). Tightening torque:
6) Remove the canister (B) from body. 8.3 N!m (0.85 kgf-m, 6.1 ft-lb)
(B) (A) (B) (A)
(B) (B)
EC-02027 EC-02027
C: INSPECTION
cracked or loose.
EC(H4DOTC)-5
5. Purge Control Solenoid Valve B: INSTALLATION

A: REMOVAL
1) Remove the collector cover. Tightening torque:
2) Disconnect the ground cable from battery. 19 N!m (1.94 kgf-m, 13.7 ft-lb)
IN-00203 EC-00220
3) Remove the solenoid valve bracket assembly NOTE:

from intake manifold. Connect the evaporation hose as shown in the fig-
ure.
(A)
EC-00219
(B)
4) Disconnect the connector from purge control so- EC-00273
lenoid valve.
5) Disconnect the evaporation hose from the intake (A) To intake manifold
manifold and fuel pipe assembly. (B) To fuel pipe ASSY
6) Remove the purge control solenoid valve from
solenoid valve bracket assembly. Tightening torque:
19 N!m (1.94 kgf-m, 13.7 ft-lb)
EC-00220
EC-00219
C: INSPECTION
EC(H4DOTC)-6
Two-way Valve
6. Two-way Valve
A: REMOVAL
valve.
from body.
EC-00221

B: INSTALLATION
Tightening torque:
7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
EC(H4DOTC)-7
PCV Valve
7. PCV Valve
A: REMOVAL
<Ref. to FU(H4DOTC)-13, REMOVAL, Intake Man-
ifold.>
2) Remove the PCV valve from intake manifold.
EC-00222
B: INSTALLATION
NOTE:
valve.
Liquid gasket:
equivalent
Tightening torque:
23 N!m (2.35 kgf-m, 17.0 ft-lb)
EC(H4DOTC)-8
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

INTAKE (INDUCTION)
IN(H4DOTC)
Page
2. Air Cleaner Element ....................................................................................7
3. Air Cleaner Case.........................................................................................8
4. Air Intake Duct.............................................................................................9
6. Intake Duct ................................................................................................11
7. Intercooler .................................................................................................12
8. Turbocharger.............................................................................................14
9. Air By-pass Valve......................................................................................16
General Description
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
T1
(3)
(1)
(3)
(2)
(5) T2
(6)
(4)
T4
(5)
(7)
(13)
T2
(10)
T3
(9)
(11)
(11) (12)
(12)
(8)
IN-02016
(1) Mass air flow and intake air tem- (7) Air cleaner case (front) Tightening torque: N!m (kgf-m, ft-lb)
perature sensor (8) Air intake duct T1: 1.0 (0.10, 0.74)
(2) Air cleaner case (rear) (9) Clip T2: 2.5 (0.25, 1.8)
(3) Clip (10) Resonator chamber T3: 6.0 (0.61, 4.4)
(4) Air intake boot (11) Cushion T4: 7.5 (0.76, 5.5)
(5) Clamp (12) Spacer
(6) Air cleaner element (13) Cushion
IN(H4DOTC)-2
General Description
INTAKE (INDUCTION)
2. INTAKE DUCT
(1)
(2)
T2
(4)
(3)
T2
T2 (2)
(5)
(9)
(8)
T1 (6)
T1
(11) (7)
(12)
(10)
(13)
IN-00214
(1) PCV hose ASSY (7) Vacuum hose (13) Brake booster hose
(2) Intake manifold (8) PCV pipe
(3) Solenoid valve bracket ASSY (9) Vacuum hose Tightening torque: N!m (kgf-m, ft-lb)
(4) Intake duct (10) Air by-pass pipe T1: 6.5 (0.66, 4.8)
(5) Engine harness ASSY (11) Clamp T2: 19 (1.9, 13.7)
(6) Vacuum hose (12) Vacuum hose
IN(H4DOTC)-3
General Description
INTAKE (INDUCTION)
3. INTERCOOLER
T1
T3
(3)
(2) T2
(4) (5)
(1)
IN-00215
(1) Intercooler (4) Intake duct Tightening torque: N!m (kgf-m, ft-lb)
(2) Gasket (5) Clamp T1: 3.0 (0.3, 2.2)
(3) Air by-pass valve T2: 6.5 (0.66, 4.8)
T3: 16 (1.6, 11.6)
IN(H4DOTC)-4
General Description
INTAKE (INDUCTION)
4. TURBOCHARGER
T2
T4
(1)
(2)
(3)
(4)
(2)
(2)
T3
(5)
(6)
(2)
T1 (2)
T1
IN-00216
(1) Oil inlet pipe (4) Water pipe Tightening torque: N!m (kgf-m, ft-lb)
(2) Metal gasket (5) Gasket T1: 4.7 (0.48, 3.5)
(3) Turbocharger (6) Oil outlet pipe T2: 5.0 (0.51, 3.7)
T3: 23 (2.3, 17.0)
T4: 16 (1.6, 11.8)
IN(H4DOTC)-5
General Description
INTAKE (INDUCTION)
B: CAUTION
points.
cable from battery.
IN(H4DOTC)-6
Air Cleaner Element
INTAKE (INDUCTION)

A: REMOVAL
When installing the air cleaner case (rear), align the
protrusion part of air cleaner case (rear) to the hole
of air cleaner case (front).
IN-00203
2) Disconnect the connector (A) from mass air flow

sensor. IN-00220
3) Loosen the clamps (B) which connect air intake
boot to intake duct. C: INSPECTION
4) Remove the clips (C) from air cleaner case. Replace if excessively damaged or dirty.
(C) (A) (C)
(B)
(B)
IN-00218
5) Remove the air cleaner case (rear) and air in-

take boot.
IN(H4DOTC)-7
Air Cleaner Case
INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
1) Remove the air intake duct. <Ref. to
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
<Ref. to IN(H4DOTC)-7, REMOVAL, Air Cleaner
Element.>
3) Remove the bolts (A) and nut (B) which install air
cleaner case (front) on the body.
(B)
(A)
IN-02017

B: INSTALLATION
Tightening torque:
Bolt: 6.0 N!m (0.61 kgf-m, 4.4 ft-lb)
Nut: 7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
IN(H4DOTC)-8
Air Intake Duct
INTAKE (INDUCTION)
4. Air Intake Duct

A: REMOVAL
Remove the clips which install the air intake duct on
the front side of body.
IN-00217
B: INSTALLATION
C: INSPECTION
1) Check for cracks or loose connection.
duct.
IN(H4DOTC)-9
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
with air cleaner case. <Ref. to IN(H4DOTC)-8, RE-
B: INSTALLATION
gle unit with air cleaner case. <Ref. to
IN(H4DOTC)-8, INSTALLATION, Air Cleaner
Case.>
C: INSPECTION
IN(H4DOTC)-10
Intake Duct
INTAKE (INDUCTION)
6. Intake Duct
A: REMOVAL
IN-00203

ifold.>
4) Remove the sensor, engine harness and fuel
pipe attached to the intake manifold. <Ref. to
FU(H4DOTC)-17, DISASSEMBLY, Intake Mani-
fold.>
5) Remove the intake duct from intake manifold.
IN-00221
B: INSTALLATION
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
IN-00221
IN(H4DOTC)-11
Intercooler
INTAKE (INDUCTION)
7. Intercooler B: INSTALLATION
A: REMOVAL
2) Loosen the clamp, and then remove the air by- 16 N!m (1.6 kgf-m, 11.6 ft-lb)
pass pipe (A) from air by-pass valve.
3) Loosen the clamp, and then remove the intake
duct (B) from intercooler.
(A)
(B)
IN-00224
IN-00222
4) Remove the bolts which secure intake duct to

turbocharger.
IN-00223
C: DISASSEMBLY
1) Remove the intake ducts from intercooler.
2) Remove the air by-pass valve from intercooler.
IN-00223
5) Remove the bolts which secure intercooler to

bracket, and then remove the intercooler.
IN-00225
IN-00224
IN(H4DOTC)-12
Intercooler
INTAKE (INDUCTION)
D: ASSEMBLY
Tightening torque:
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
IN-00225
IN(H4DOTC)-13
Turbocharger
INTAKE (INDUCTION)
8. Turbocharger 11) Separate the turbocharger joint pipe from tur-

bocharger.
A: REMOVAL
IN-00227
12) Remove the bolts which secure oil pipe bracket

to turbocharger.
13) Remove the oil inlet pipe from turbocharger.
IN-00203

5) Remove the intercooler bracket RH.
6) Remove the linear motion mounting.
<Ref. to ME(H4DOTC)-37, REMOVAL, Linear Mo-
tion Mounting.>
7) Remove the linear motion mounting bracket.
(A)
IN-00228
14) Remove the bolts which secure turbocharger to

bracket.
(B)
IN-00251
(A) Linear motion mounting bracket

(B) Turbocharger bracket

IN-00229
haust Pipe.> 15) Disconnect the hoses from the oil outlet pipe
9) Lower the vehicle. (A) and coolant pipe (B) located under the turbo-
10) Disconnect the engine coolant hose which is charger.
connected to coolant filler tank.
(B) (A)
IN-00230
IN-00226 16) Take out the turbocharger from engine com-

partment.
IN(H4DOTC)-14
Turbocharger
INTAKE (INDUCTION)

1) Connect the hoses to the oil outlet pipe (A) and 35 N!m (3.6 kgf-m, 25.8 ft-lb)
coolant pipe (B) located under the turbocharger.
(B) (A) IN-00227

IN-00230 5) Connect the engine coolant hose which is con-
2) Install the turbocharger to bracket. nected to the coolant filler tank.
Tightening torque:
33 N!m (3.4 kgf-m, 24.6 ft-lb)
IN-00226

IN-00229
7) Install the center exhaust pipe.
<Ref. to EX(H4DOTC)-7, INSTALLATION, Center
3) Install the oil inlet pipe to turbocharger. Exhaust Pipe.>
Tightening torque: 8) Install the linear motion mounting bracket.
T1: 5.0 N!m (0.51 kgf-m, 3.7 ft-lb)
T2: 16 N!m (1.6 kgf-m, 11.6 ft-lb)
(A)
T2
T1 (B)
IN-00252

IN-02018
(B) Turbocharger bracket
4) Install the joint pipe to turbocharger.
NOTE: Tightening torque:
Use a new gasket. 40 N!m (4.1 kgf-m, 29.5 ft-lb)
9) Install the linear motion mounting.
<Ref. to ME(H4DOTC)-37, INSTALLATION, Linear
Motion Mounting.>
10) Install the intercooler bracket RH.
11) Install the intercooler. <Ref. to IN(H4DOTC)-
12, INSTALLATION, Intercooler.>
IN(H4DOTC)-15
Air By-pass Valve
INTAKE (INDUCTION)
9. Air By-pass Valve

A: REMOVAL
2) Disconnect the air by-pass hose (A) from air by-
pass valve.
3) Remove the air by-pass valve (B) from intercool-
er.
(B)
(A)
IN-00231
B: INSTALLATION
Tightening torque:
6.5 N!m (0.66 kgf-m, 4.8 ft-lb)
(B)
(A)
IN-00231
(A) Air by-pass hose

(B) Air by-pass valve
IN(H4DOTC)-16
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

MECHANICAL
ME(H4DOTC)
Page
2. Compression .............................................................................................21
3. Idle Speed .................................................................................................22
4. Ignition Timing...........................................................................................23
7. Fuel Pressure............................................................................................26
8. Valve Clearance........................................................................................27
9. Engine Assembly ......................................................................................30
10. Engine Mounting .......................................................................................36
11. Linear Motion Mounting.............................................................................37
13. V-belt.........................................................................................................39
14. Crank Pulley..............................................................................................41
16. Timing Belt ................................................................................................43
17. Cam Sprocket ...........................................................................................51
18. Crank Sprocket .........................................................................................52
19. Camshaft...................................................................................................53
20. Cylinder Head ...........................................................................................59
21. Cylinder Block ...........................................................................................66
22. Intake and Exhaust Valve .........................................................................86
23. Piston ........................................................................................................87
24. Connecting Rod ........................................................................................88
25. Crankshaft.................................................................................................89
27. Engine Noise.............................................................................................96
General Description
MECHANICAL
A: SPECIFICATION
Belt driven, double overhead camshaft,
4 valves/cylinder
Bore ! Stroke mm (in) 92 ! 75 (3.62 ! 2.95)
Displacement 3 1,994 (121.67)
cm (cu in)
Compression pressure
(at 400 rpm) kPa (kg/cm2, psi) 1,100 — 1,300 (11.2 — 13.3, 160 — 189)
Number of piston rings Pressure ring: 2, Oil ring: 1

Max.retard ATDC 6"
Open
Min.advance BTDC 37"
Engine Intake valve timing
Max.retard ABDC 62"
Close
Min.advance ABDC 19"
Max.retard BBDC 60"
Open
Min.advance BBDC 30"
Max.retard BTDC 2"
Close
Min.advance ATDC 28"
Intake 0.20 +0.04#0.06 (0.0079 +0.0016#0.0024)
Exhaust 0.35$0.05 (0.0138$0.0020)
No-load 650$50
Idle speed [“P”/“N” range] rpm
A/C ON 825$50
Ignition order 1%3%2%4
Ignition timing BTDC/rpm 14"$3"/650
NOTE:
OS: Oversize US: Undersize
Belt ten-
sion Protrusion of adjuster rod mm (in) 5.2 — 6.2 (0.205 — 0.244)
adjuster
Spacer O.D. mm (in) 17.955 — 17.975 (0.7069 — 0.7077)
Belt ten- Tensioner bush I.D. mm (in) 18.0 — 18.08 (0.7087 — 0.7118)
sioner Clearance between spacer and bush mm (in) Standard 0.025 — 0.125 (0.0010 — 0.0049)
Side clearance of spacer mm (in) Standard 0.2 — 0.55 (0.0079 — 0.0217)
Bend limit mm (in) 0.020 (0.0079) or less
Intake Standard 45.85 — 45.95 (1.805 — 1.809)
Cam lobe height mm (in)
Camshaft Exhaust Standard 45.75 — 45.85 (1.801 — 1.805)
Front 37.946 — 37.963 (1.4939 — 1.4946)
Journal O.D. mm (in) Standard
Center rear 29.946 — 29.963 (1.1790 — 1.1796)
Clearance at journal mm (in) Standard 0.037 — 0.072 (0.0015 — 0.0028)
Surface warpage limit mm (in) 0.035 (0.0014)
Cylinder
Head
Refacing angle 90"
Valve seat Intake Standard 0.6 — 1.4 (0.024 — 0.055)
Valve guide
Protrusion above head mm (in) 15.8 — 16.2 (0.622 — 0.638)
ME(H4DOTC)-2
General Description
MECHANICAL
Intake Standard 1.0 — 1.4 (0.039 — 0.055)

Head edge thickness mm (in)
Intake 5.955 — 5.970 (0.2344 — 0.2350)
Stem outer diameters mm (in)
Exhaust 5.945 — 5.960 (0.2341 — 0.2346)
Valve
Intake 0.030 — 0.057 (0.0012 — 0.0022)
Valve stem gap mm (in) Standard
Exhaust 0.040 — 0.067 (0.0016 — 0.0026)
Intake 104.4 (4.110)
Exhaust 104.65 (4.1201)
Free length mm (in) 44.67 (1.759)
Squareness 2.5", 2.0 mm (0.079 in)
Valve 206 — 236
springs Set
Tension/spring height (21.0 — 24.1, 46.3 — 53.1)/36.0 (1.417)
N (kgf, lb)/mm (in) 485 — 537
Lift
(49.5 — 54.8, 109 — 121)/26.00 (1.024)
Surface warpage limit
mm (in) 0.025 (0.00098)
(mating with cylinder head)
Cylinder inner diameter A 92.005 — 92.015 (3.6222 — 3.6226)
Cylinder Standard
mm (in) B 91.995 — 92.005 (3.6218 — 3.6222)
block
Taper mm (in) Standard 0.015 (0.0006)
Piston clearance mm (in) Standard #0.010 — 0.010 (#0.00039 — 0.00039)
Boring limit mm (in) 0.5 (0.020)
A 92.005 — 92.015 (3.6222 — 3.6226)
Standard
B 91.995 — 92.005 (3.6219 — 3.6222)
Piston Outer diameter mm (in)
0.25 (0.0098) OS 92.245 — 92.265 (3.6317 — 3.6467)
0.50 (0.0197) OS 92.495 — 92.515 (3.6415 — 3.6423)
Standard clearance between piston and piston pin
Standard 0.004 — 0.008 (0.0002 — 0.0003)
mm (in)
Piston pin
Piston pin must be fitted into position with
Degree of fit
thumb at 20"C (68"F).
Outer circle side:
0.20 — 0.25 (0.0079 — 0.0098)
Top ring Standard
Inner circle side:
Ring closed gap mm (in) 0.20 — 0.35 (0.0079 — 0.014)
Piston ring Second ring Standard 0.40 — 0.50 (0.016 — 0.020)
Ring groove gap mm (in)
Second ring Standard 0.030 — 0.070 (0.0012 — 0.0028)
Bend or twist per 100 mm (3.94 in) in length
Connecting Limit 0.10 (0.0039)
mm (in)
rod
Side clearance of large end mm (in) Standard 0.070 — 0.330 (0.0028 — 0.0130)
Standard 1.486 — 1.498 (0.0585 — 0.0590)
Bearing of Bearing size 0.03 (0.0012) US 1.504 — 1.512 (0.0592 — 0.0595)
large end (Thickness at center)
0.05 (0.0020) US 1.514 — 1.522 (0.0596 — 0.0599)
mm (in)
0.25 (0.0098) US 1.614 — 1.622 (0.0635 — 0.0639)
Bushing of Clearance between piston pin and bushing
Standard 0 — 0.022 (0 — 0.0009)
small end mm (in)
ME(H4DOTC)-3
General Description
MECHANICAL
Bend limit mm (in) 0.035 (0.0014)

Crank pin and Out-of-roundness mm (in) 0.005 (0.0002) or less
crank journal Grinding limit (dia.) mm (in) 51.750 (2.0374)
Standard 51.984 — 52.000 (2.0466 — 2.0472)
Crank pin outer diameter 0.03 (0.0012) US 51.954 — 51.970 (2.0454 — 2.0461)
mm (in) 0.05 (0.0020) US 51.934 — 51.950 (2.0447 — 2.0453)
Crankshaft 0.25 (0.0098) US 51.734 — 51.750 (2.0368 — 2.0374)
Standard 59.992 — 60.008 (2.3619 — 2.3625)
Crank journal outer diameter 0.03 (0.0012) US 59.962 — 59.978 (2.3607 — 2.3613)
mm (in) 0.05 (0.0020) US 59.942 — 59.958 (2.3599 — 2.3605)
0.25 (0.0098) US 59.742 — 59.758 (2.3520 — 2.3527)
Standard 1.998 — 2.011 (0.0787 — 0.0792)
0.03 (0.0012) US 2.017 — 2.020 (0.0794 — 0.0795)
#1, #3
Bearing size 0.05 (0.0020) US 2.027 — 2.030 (0.0798 — 0.0799)
Main bear- (Thickness at 0.25 (0.0098) US 2.127 — 2.130 (0.0837 — 0.0839)
ing center) Standard 2.000 — 2.013 (0.0787 — 0.0793)
mm (in) 0.03 (0.0012) US 2.019 — 2.022 (0.0795 — 0.0796)
#2, #4, #5
0.05 (0.0020) US 2.029 — 2.032 (0.0799 — 0.0800)
0.25 (0.0098) US 2.129 — 2.132 (0.0838 — 0.0839)
ME(H4DOTC)-4
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(1)
(2)
T2
(3)
T1
(4)
T1 (5)
(9)
T5 T3
(6)
(12)
(8)
(7)
T5 T4 T3 (14)
T1 T1
T5
T4
(10)
(14)
(11)
T4
(17)
(13)
T1
(15)
(16)
(18)
T6
T1
ME-02010
(1) Timing belt cover No. 2 (RH) (10) Intake cam sprocket (LH) !"#$%&'"'#(%)*+,&-(N&m(./#0123(0%1456
(2) Timing belt guide (11) Exhaust cam sprocket (LH) !7- 8(.9:83(;:<6
(3) Crank sprocket (12) Timing Belt !=- 79(.7:93(>:=6
(4) Timing belt cover No. 2 (LH) (13) Belt idler No. 2 !;- =8(.=:83(7?:76
(5) Tensioner bracket (14) Belt idler !@- ;A(.@:93(=?:A6
(6) Automatic belt tension adjuster (15) Timing belt cover (LH) !8- <Ref. to ME(H4DOTC)-51,
ASSY (16) Front belt cover INSTALLATION, Cam
(7) Belt idler (17) Timing belt cover (RH) Sprocket.>
(8) Exhaust cam sprocket (RH) (18) Crank pulley !<- <Ref. to ME(H4DOTC)-41,
(9) Intake cam sprocket (RH) INSTALLATION, Crank Pulley.>
ME(H4DOTC)-5
General Description
MECHANICAL
T4 (1)
T2
(2)
(6)
T2
T5 T6
(28) T6
(8)
(9)
T2
T5
(29)
(13)
T3 (4)
(7)
(5) (14)
(10)
(12)
(3)
T1
(32)
(30)
(11) (31)
T3 T2
(9) (23)
(8)
(24)
T2
(25)
(15)
(16)
(6) T4
(14) (19)
T6 T5
(27) (26)
(21)
T6
(12) (17)
(28) (32) (20)
(30)
(18)
(31)
T5
T3
(22) T4
(11)
T1 T4
T3
ME-00799
ME(H4DOTC)-6
General Description
MECHANICAL
(1) Rocker cover (RH) (15) Cylinder head (LH) (30) Stud bolt
(2) Rocker cover gasket (RH) (16) Intake camshaft (LH) (31) Oil flow control solenoid valve
(3) Camshaft cap (Front RH) (17) Exhaust camshaft (LH) (Exhaust)
(4) Intake camshaft cap (Rear RH) (18) Camshaft cap (Front LH) (32) Gasket
(5) Intake camshaft (RH) (19) Intake camshaft cap (Rear LH)
(6) Oil flow control solenoid valve (20) Exhaust camshaft cap (Rear LH) !"#$%&'"'#(%)*+,&-(N&m(./#0123(0%1456
(Intake) (21) Rocker cover gasket (LH) !7- <Ref. to ME(H4DOTC)-59,
(7) Exhaust camshaft cap (Rear RH) (22) Rocker cover (LH) INSTALLATION, Cylinder
(8) Gasket (23) Oil filler cap Head.>
(9) Oil return cover (24) Gasket !=- ?(.9:?3(8:A6
(10) Exhaust camshaft (RH) (25) Oil filler duct !;- 79(.7:93(>:=6
(11) Cylinder head bolt (26) O-ring !@- <:@(.9:<83(@:>6
(12) Oil seal (27) Oil pipe (LH) !8- =9(.=:93(7@:86
(13) Cylinder head (RH) (28) Gasket !<- =A(.;:93(=7:@6
(14) Cylinder head gasket (29) Oil pipe (RH)
ME(H4DOTC)-7
General Description
MECHANICAL
(1) (11) (4) (5) (6) (7) (8) (9)
(3)
(2)
(11) (4) (5) (6) (7) (8) (9)
(12)
(4)
(10)
(6)
(12) (7)
(4) (8)
(10) (9)
(6)
(7)
(8)
(9)
ME-00795
(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter
(2) Intake valve (6) Valve springs (10) Exhaust valve oil seal
(3) Cylinder head (7) Retainer (11) Intake valve guide
(4) Valve spring seat (8) Retainer key (12) Exhaust valve guide
ME(H4DOTC)-8
General Description
MECHANICAL
4. CYLINDER BLOCK
T6 T2
T2
T4
(1)
T5
(6)
T2 (7)
T4
(8) (2)
(3) T2
(4) (5)
(10)
(9)
T2 T6 (10)
(4) (11)
(14) (3) (10)
T4
T2 (25) (4)
(24) (3)
T8 T6 (12)
(10) (21)
T4
(16)
(15)
T2 T5
(22)
T7
(17) T2
T3
(13)
(23)
(20)
(19)
T1 (18)
T8
ME-02011
(1) Oil pressure switch (14) Baffle plate !"#$%&'"'#(%)*+,&-(N&m(./#0123(0%1456

(2) Cylinder block (RH) (15) Oil strainer !7- 8(.9:83(;:<6
(3) Service hole plug (16) Gasket !=- <:@(.9:<83(@:>6
(4) Gasket (17) Oil pan !;- 79(.7:93(>:=6
(5) Oil separator cover (18) Drain plug !@- =8(.=:83(7?:76
(6) Water by-pass pipe (19) Metal gasket !8- <Ref. to ME(H4DOTC)-69,
(7) Oil pump (20) Oil level gauge guide INSTALLATION, Cylinder
(8) Front oil seal (21) Oil filter Block.>
(9) Rear oil seal (22) Gasket !<- >9(.>:73(87:<6
(10) O-ring (23) Water pump hose !>- B"*C%(7=(.7:=3(?:>6(
(11) Service hole cover (24) Plug D&E)'F(7=(.7:=3(?:>6
(12) Cylinder block (LH) (25) Connector !?- @@(.@:83(;;6
(13) Water pump
ME(H4DOTC)-9
General Description
MECHANICAL
(2)
T2
(8)
(7) (1)
(3)
(4)
(5) (10)
(11)
(8) (6)
(9)
T1 (13)
(11)
(12) (12)
(9)
(11) T1
(6)
(8)
(14) (11)
(5)
(10) (4)
(3)
(8)
(7)
(17)
(16)
(15)
(16)
(15)
ME-02012
(1) Reinforcement (8) Snap ring (15) Crankshaft bearing #1, #3

(2) Drive plate (9) Connecting rod nut (16) Crankshaft bearing #2, #4
(3) Top ring (10) Connecting rod (17) Crankshaft bearing #5
(4) Second ring (11) Connecting rod bearing
(5) Oil ring (12) Connecting rod cap !"#$%&'"'#(%)*+,&-(N&m(./#0123(0%1456
(6) Piston (13) Crankshaft !7- 8=(.8:;3(;?:@6
(7) Piston pin (14) Woodruff key !=- >=(.>:;3(8;:76
ME(H4DOTC)-10
General Description
MECHANICAL
6. ENGINE MOUNTING
(1)
T1
T2 T1
T2
ME-02090
(1) Front cushion rubber !"#$%&'"'#(%)*+,&-(N&m(./#0123(0%1456

!7- ;8(.;:<3(=8:?6
!=- ?8(.?:>3(<=:>6
ME(H4DOTC)-11
General Description
MECHANICAL
7. LINEAR MOTION MOUNTING
T2
T2
(4)
(2)
T1
(3)
T1
(1)
T1
T1
ME-02091
(1) Linear motion mounting (4) Bracket !"#$%&'"'#(%)*+,&-(N&m(./#0123(0%1456

(2) Linear motion mounting bracket !7- ;;(.;:@3(=@:;6
(3) Dynamic damper !=- ;9(.;:73(==:76
ME(H4DOTC)-12
General Description
MECHANICAL
C: CAUTION
points.
cable from battery.
• All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
• Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
• Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
• All removed parts, if to be reused, should be re-
installed in the original positions and directions.
• Bolts, nuts and washers should be replaced with
new ones as required.
• Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
• Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
• Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fender, as re-
quired, for protection.
• Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
ME(H4DOTC)-13
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
498267600 CYLINDER • Used for replacing valve guides.
ST-498267600

ADAPTER RH
ST-498457000

ADAPTER LH
ST-498457100
498497100 CRANKSHAFT Used for stopping rotation of drive plate when

STOPPER loosening/tightening crank pulley bolt.
ST-498497100
ME(H4DOTC)-14
General Description
MECHANICAL

398744300 PISTON GUIDE Used for installing piston in cylinder.
ST-398744300
ST-498857100
499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.
ST-499017100
499037100 CONNECTING Used for removing and installing connecting rod

REMOVER AND
INSTALLER
ST-499037100
ME(H4DOTC)-15
General Description
MECHANICAL

REMOVER
ASSY
ST-499097700
499977500 CAM Used for removing and installing the intake cam
SPROCKET sprocket and exhaust cam sprocket.
WRENCH
ST-499977500

ST-499587200

ST-499597100
ME(H4DOTC)-16
General Description
MECHANICAL

REMOVER
ST-499718000
18251AA020 VALVE GUIDE Used for installing intake and exhaust valve
ADJUSTER guides.
ST18251AA020

REMOVER
ST-499767200

REAMER
ST-499767400
ME(H4DOTC)-17
General Description
MECHANICAL

499817000 ENGINE STAND • Stand used for engine disassembly and assem-
bly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
ST-499817000
WRENCH loosening/tightening crank pulley bolt.
ST-499977400
499987500 CRANKSHAFT Used for rotating crankshaft.

SOCKET
ST-499987500
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
ST-499587100
ME(H4DOTC)-18
General Description
MECHANICAL

499587600 OIL SEAL Used for installing camshaft oil seal for DOHC
INSTALLER engine.
ST-499587600
ST18332AA000
ST18332AA010
499597200 OIL SEAL GUIDE • Used for installing camshaft oil seal for DOHC
engine.
• Used with OIL SEAL INSTALLER (499587600)
ST-499597200
ME(H4DOTC)-19
General Description
MECHANICAL

bly to engine.
ST-498277200
ST24082AA230

ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
E: PROCEDURE
It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures
described in this section are based on the condition that the engine is removed from vehicle.
• V-belt
• Timing belt
• Camshaft
• Cylinder head
ME(H4DOTC)-20
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
ment.
switch to OFF.
4) Release the fuel pressure. <Ref. to
FU(H4DOTC)-40, RELEASING OF FUEL PRES-
5) Remove all the spark plugs.
<Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
spark plug hole.
NOTE:
ME-00007
10) Perform at least two measurements per cylin-

der, and make sure that the values are correct.
Compression pressure (Throttle fully open):
Standard:
1,100 — 1,300 kPa (11.2 — 13.3 kg/cm2, 160
— 189 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm2, 7 psi) or less
ME(H4DOTC)-21
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
lowing:
properly.
not illuminate.
2) Idle the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
connector.
6) Turn the ignition switch to ON and Subaru Select
Monitor switch to ON.
7) Select {Each System Check} in Main Menu.
8) Select {Engine} in Selection Menu.
9) Select {Current Data Display & Save} in Engine
Control System Diagnosis.
10) Select {Data Display} in Data Display Menu.
11) Start the engine, and read the engine idle
speed.
12) 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]:
650$50 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least one minute before mea-
surement.)
Idle speed [A/C “ON”, and gears in neutral]:
825$50 rpm
NOTE:
the idle speed is automatically adjusted. If the idle
<Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic
Procedure.>
ME(H4DOTC)-22
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
1) Before checking the ignition timing, check the
following:
clogging, spark plugs are in good condition, and
hoses are connected properly.
not illuminate.
2) Idle the engine.
OFF.
connector.
idle speed.
14"$3"/650
system. Refer to “Engine Control System”. <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Proce-
dure.>
ME(H4DOTC)-23
MECHANICAL

A: INSPECTION
2) Idle the engine.
3) Disconnect the brake vacuum hose from intake
manifold, and then install the vacuum gauge.
4) Keep the engine at idle speed and read the vac-
uum gauge indication.
By observing the gauge needle movement, internal
condition of the engine can be diagnosed as de-
scribed below.
ME-00801

#66.7 kPa (#500 mmHg, #19.70 inHg) or less
1. Needle motion is steady but lower than normal position. This Leakage around intake manifold gasket, or disconnected or
tendency 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
3. Needle intermittently drops to the lower position than normal. Leakage around cylinder
4. Needle drops suddenly and intermittently from normal posi- Sticky valve
tion.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME(H4DOTC)-24
Engine Oil Pressure
MECHANICAL
6. Engine Oil Pressure 6) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H4DOTC)-16, IN-
A: INSPECTION STALLATION, Oil Pressure Switch.>
Tightening torque:
2) Remove the oil pressure switch from engine cyl-
25 N&m (2.5 kgf-m, 18.1 ft-lb)
inder block. <Ref. to LU(H4DOTC)-16, REMOVAL,
Oil Pressure Switch.>
block.
IN-00203
5) Start the engine, and measure the oil pressure.
ME-00009
Oil pressure:
Standard:
98 kPa (1.0 kgf/cm2, 14 psi) or more (At 600
rpm)
588 kPa (6.0 kgf/cm2, 85 psi) or more (At
6,000 rpm)
CAUTION:
check oil pump, oil filter and lubrication line.
!"#$%&'(&)*+,-./0123456&789:;107/86&;<=><#
)?@A>BC'>(<&9DE'#F&0A(?@G#&><&H#<#ACG%I
• If the oil pressure warning light is turned to
ON and oil pressure is within specification, re-
place the oil pressure switch. !"#$%& '(
)*+,-./0123456&789:;107/86&;<=><#&)?@A>BC3
'>(<&9DE'#F&0A(?@G#&><&H#<#ACG%I
NOTE:
The specified value is based on an engine oil tem-
perature of 80"C (176"F).
ME(H4DOTC)-25
Fuel Pressure
MECHANICAL
7. Fuel Pressure Fuel pressure:

Standard: 230 — 260 kPa (2.35 — 2.65 kgf/
A: INSPECTION cm2, 33 — 38 psi)
WARNING:
lease the fuel pressure.
NOTE:
2) Release the fuel pressure. <Ref. to
FU(H4DOTC)-40, RELEASING OF FUEL PRES- ME-00802
NOTE:
filler cap.
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard val-
4) Disconnect the fuel delivery hose and connect ues during high-altitude operations.
box.
FU-01122

fold.
Fuel pressure:
Standard: 284 — 314 kPa (2.9 — 3.2 kgf/cm2,
41 — 46 psi)
ME-00802

ME(H4DOTC)-26
Valve Clearance
MECHANICAL
8. Valve Clearance NOTE:

Turn the crankshaft using a socket wrench.
A: INSPECTION
Inspection and adjustment of valve clearance
ME-00733
12) Measure the #1 cylinder intake valve and #3

cylinder exhaust valve clearance by using thick-
ness gauge (A).
NOTE:
• Insert the thickness gauge in as horizontal a di-
rection as possible with respect to the valve lifter.
IN-00203 • Measure the exhaust valve clearances while lift-
ing-up the vehicle.
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> Valve clearance
7) Remove a bolt which secures timing belt cover Intake:
(RH). 0.20+0.04#0.06mm (0.0079+0.0016#0.0024 in)
8) Loosen the remaining bolts which secure timing Exhaust:
belt cover (RH), then remove the timing belt cover. 0.35$0.05 mm (0.0138$0.0020 in)
9) When inspecting #1 and #3 cylinders: • If the measured value is not within specification,
(1) Remove the air cleaner case. take notes of the value in order to adjust the valve
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Clean- clearance later on.
er Case.>
(2) Disconnect the connector from ignition coil.
(3) Remove the ignition coil.
(4) Place a suitable container under the vehicle. (A)
(5) Disconnect the PCV hose from rocker cover
(RH).
cover (RH).
10) When inspecting #2 and #4 cylinders:
(1) Disconnect the battery cable, and then re-
ME-00019
move the battery and battery carrier.
(2) Disconnect the connector from ignition coil. 13) If necessary, adjust the valve clearance. <Ref.
(3) Remove the ignition coil. to ME(H4DOTC)-28, ADJUSTMENT, Valve Clear-
(4) Place a suitable container under the vehicle. ance.>
(5) Disconnect the PCV hose from rocker cover 14) Further turn the crank pulley clockwise and
(LH). then measure the valve clearances again.
cover (LH).
11) Turn the crank pulley clockwise until arrow
mark on the cam sprocket is set to position shown
in the figure.
ME(H4DOTC)-27
Valve Clearance
MECHANICAL
(1) Set the arrow mark on cam sprocket to the B: ADJUSTMENT

position shown in the figure, and measure the #2
cylinder exhaust valve and #3 cylinder intake CAUTION:
valve clearances. Adjustment of valve clearance should be per-
formed while engine is cold.
1) Measure all valve clearances. <Ref. to
ME(H4DOTC)-27, INSPECTION, Valve Clear-
ance.>
NOTE:
Record each valve clearance after it has been
measured.
ME-00734
(2) Set the arrow mark on cam sprocket to the

cylinder intake valve and #4 cylinder exhaust
valve clearances.
ME-00024
2) Remove the camshaft. <Ref. to ME(H4DOTC)-

3) Remove the valve lifter.
4) Measure the thickness of valve lifter with a mi-
crometer.
ME-00735
(3) Set the arrow mark on cam sprocket to the

cylinder exhaust valve and #4 cylinder intake
valve clearances.
ME-00025
5) Select a valve lifter of suitable thickness based

on the measured valve clearance and valve lifter
thickness, by referring to the following table.
Unit: (mm)
Intake valve: S = (V + T) # 0.20
ME-00736 Exhaust valve: S = (V + T) # 0.35
15) After inspection, install the related parts in the S: Valve lifter thickness required
reverse order of removal. V: Measured valve clearance
T: Valve lifter thickness to be used
ME(H4DOTC)-28
Valve Clearance
MECHANICAL
Part number Thickness mm (in) Part number Thickness mm (in)

13228 AB101 4.68 (0.1843) 13228 AB611 5.19 (0.2043)
13228 AB111 4.69 (0.1846) 13228 AB621 5.20 (0.2047)
13228 AB121 4.70 (0.1850) 13228 AB631 5.21 (0.2051)
13228 AB131 4.71 (0.1854) 13228 AB641 5.22 (0.2055)
13228 AB141 4.72 (0.1858) 13228 AB651 5.23 (0.2059)
13228 AB151 4.73 (0.1862) 13228 AB661 5.24 (0.2063)
13228 AB161 4.74 (0.1866) 13228 AB671 5.25 (0.2067)
13228 AB171 4.75 (0.1870) 13228 AB681 5.26 (0.2071)
13228 AB181 4.76 (0.1874) 13228 AB691 5.27 (0.2075)
13228 AB191 4.77 (0.1878) 13228 AB701 4.38 (0.1724)
13228 AB201 4.78 (0.1882) 13228 AB711 4.40 (0.1732)
13228 AB211 4.79 (0.1886) 13228 AB721 4.42 (0.1740)
13228 AB221 4.80 (0.1890) 13228 AB731 4.44 (0.1748)
13228 AB231 4.81 (0.1894) 13228 AB741 4.46 (0.1756)
13228 AB241 4.82 (0.1898) 13228 AB751 4.48 (0.1764)
13228 AB251 4.83 (0.1902) 13228 AB761 4.50 (0.1771)
13228 AB261 4.84 (0.1906) 13228 AB771 4.52 (0.1780)
13228 AB271 4.85 (0.1909) 13228 AB781 4.54 (0.1787)
13228 AB281 4.86 (0.1913) 13228 AB791 4.56 (0.1795)
13228 AB291 4.87 (0.1917) 13228 AB801 4.58 (0.1803)
13228 AB301 4.88 (0.1921) 13228 AB811 4.60 (0.1811)
13228 AB311 4.89 (0.1925) 13228 AB821 4.62 (0.1819)
13228 AB321 4.90 (0.1929) 13228 AB831 4.64 (0.1827)
13228 AB331 4.91 (0.1933) 13228 AB841 4.66 (0.1835)
13228 AB341 4.92 (0.1937) 13228 AB851 5.29 (0.2083)
13228 AB351 4.93 (0.1941) 13228 AB861 5.31 (0.2091)
13228 AB361 4.94 (0.1945) 13228 AB871 5.33 (0.2098)
13228 AB371 4.95 (0.1949) 13228 AB881 5.35 (0.2106)
13228 AB381 4.96 (0.1953) 13228 AB891 5.37 (0.2114)
13228 AB391 4.97 (0.1957) 13228 AB901 5.39 (0.2122)
13228 AB401 4.98 (0.1961) 13228 AB911 5.41 (0.2123)
13228 AB411 4.99 (0.1965) 13228 AB921 5.43 (0.2138)
13228 AB421 5.00 (0.1969) 13228 AB931 5.45 (0.2146)
13228 AB431 5.01 (0.1972) 13228 AB941 5.47 (0.2154)
13228 AB441 5.02 (0.1976) 13228 AB951 5.49 (0.2161)
13228 AB451 5.03 (0.1980) 13228 AB961 5.51 (0.2169)
13228 AB461 5.04 (0.1984) 13228 AB971 5.53 (0.2177)
13228 AB471 5.05 (0.1988) 13228 AB981 5.55 (0.2185)
13228 AB481 5.06 (0.1992) 13228 AB991 5.57 (0.2193)
13228 AB491 5.07 (0.1996) 13228 AC001 5.59 (0.2201)
13228 AB501 5.08 (0.2000) 13228 AC011 5.61 (0.2209)
13228 AB511 5.09 (0.2004) 13228 AC021 5.63 (0.2217)
13228 AB521 5.10 (0.2008) 13228 AC031 5.65 (0.2224)
13228 AB531 5.11 (0.2012) 6) Inspect all valves for clearance again at this
13228 AB541 5.12 (0.2016) stage. If the valve clearance is not correct, repeat
13228 AB551 5.13 (0.2020) the procedure over again from the first step.
13228 AB561 5.14 (0.2024) 7) After inspection, install the related parts in the
13228 AB571 5.15 (0.2028) reverse order of removal.
13228 AB581 5.16 (0.2031)
13228 AB591 5.17 (0.2035)
13228 AB601 5.18 (0.2039)
ME(H4DOTC)-29
Engine Assembly
MECHANICAL
9. Engine Assembly 10) Disconnect the A/C pressure hoses from A/C
compressor.
A: REMOVAL
2) Open the front hood fully and support with a front
food stay.
AC-20, Refrigerant Recovery Procedure.>
(1) Remove the fuse of fuel pump from main
fuse box.
ME-00803
11) Repair the air intake system.

(1) Remove the intercooler. (DOHC turbo mod-
el) <Ref. to IN(H4DOTC)-12, REMOVAL, Inter-
cooler.>
(2) Remove the air cleaner element and air
cleaner case. <Ref. to IN(H4DOTC)-8, REMOV-
AL, Air Cleaner Case.>
12) Disconnect the following connectors and ca-
FU-01122 bles.
(2) Start the engine, and run until stalls. (1) Engine harness connectors
(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the fuel filler cap.
FU-01162
IN-00203

CO(H4DOTC)-19, REMOVAL, Radiator.>
<Ref. to CO(H4DOTC)-31, REMOVAL, Coolant
FU-01163
Filler Tank.>
ME(H4DOTC)-30
Engine Assembly
MECHANICAL
(2) Engine ground terminals 14) Remove the power steering pump from brack-
et.
(1) Loosen the lock bolt and slider bolt, and re-
move the front side belt. <Ref. to ME(H4DOTC)-
39, FRONT SIDE BELT, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
ME-00028
(3) Generator connector, terminal and A/C

compressor connector
(B) (A)
ME-00035
(3) Remove the power steering pump from en-

gine.
ME-00804
(A) A/C compressor connector

(B) Generator connector and terminal

(1) Brake booster vacuum hose ME-00809
(4) Place the power steering pump on the right

side wheel apron.
15) Remove the linear motion mounting. <Ref. to
ME(H4DOTC)-37, REMOVAL, Linear Motion
Mounting.>
haust Pipe.>
FU-01161

(3) Remove the hose between intake manifold
(A) and pressure regulator (B).
(A) (B)
ME-00846
ME(H4DOTC)-31
Engine Assembly
MECHANICAL
18) Disconnect the oil flow control solenoid valve (4) Remove other bolts while rotating the en-
connector and ground cable. gine using a socket wrench.
ME-00805 ME-00044
ME-02092
19) Remove the nuts which hold lower side of the LU-00221
transmission to engine. 23) Disconnect the fuel delivery hose, return hose
and evaporation hose.
CAUTION:
• Collect fuel from the hose into container.
• Disconnect the hose with its end wrapped
ME-00040

ME-00045

wire ropes.
LU-00223

plate.
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con- LU-00222
verter clutch to drive plate.
ME(H4DOTC)-32
Engine Assembly
MECHANICAL
25) Support the transmission with a garage jack. (4) Slowly move the engine away from engine
CAUTION: compartment.
Doing this is very important because the trans- NOTE:
mission lowers for its own weight. This work is Be careful not to damage adjacent parts or body
also of great importance for facilitating reinstal- panels with crank pulley, oil level gauge, etc.
lation. 28) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers to engine.
Tightening torque:
35 N&m (3.6 kgf-m, 25.8 ft-lb)
2) Install the engine onto transmission.
Position the engine in engine compartment and
align it with transmission.
NOTE:
ME-00048 Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
CAUTION:
3) Tighten the bolts which hold upper side of trans-
Before moving the engine away from transmis-
mission to engine.
sion, check to be sure no work has been over-
looked. Tightening torque:
26) Separation of engine and transmission. 50 N&m (5.1 kgf-m, 36.9 ft-lb)
(1) Remove the starter. <Ref. to SC(H4SO 2.0)-
6, REMOVAL, Starter.>
(2) Install the ST to converter case.
ME-00050

ST
ME-00049
(3) Remove the bolts which hold upper side of

the transmission to engine.
LU-00222
5) Remove the garage jack.
ME-00050
27) Remove the engine from vehicle.

(1) Slightly raise the engine.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
ME(H4DOTC)-33
Engine Assembly
MECHANICAL
6) Install the pitching stopper. (1) Install the power steering pump.
T1: 50 N&m (5.1 kgf-m, 36.9 ft-lb) 20.1 N&m (2.05 kgf-m, 14.8 ft-lb)
T2: 58 N&m (5.9 kgf-m, 43 ft-lb)
T2
T1
ME-00037
LU-00224 (2) Connect the power steering switch connec-
7) Remove the ST from converter case. tor.
NOTE:
Be careful not to drop the ST into the converter
case when removing the ST.
8) Install the starter. <Ref. to SC(H4SO 2.0)-6, IN-
STALLATION, Starter.>
9) Install the torque converter clutch to drive plate.
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine ME-00035
by using ST.
(3) Install the front side belt and adjust it. <Ref.
CAUTION: to ME(H4DOTC)-39, FRONT SIDE BELT, IN-
Be careful not to drop bolts into the torque con- STALLATION, V-belt.>
verter clutch housing. 12) Lift-up the vehicle.
ST 499977400 CRANK PULLEY WRENCH 13) Tighten the nuts which hold lower side of the
Tightening torque:
25 N&m (2.5 kgf-m, 18.1 ft-lb) Tightening torque:
50 N&m (5.1 kgf-m, 36.9 ft-lb)
ME-00044
ME-00040
10) Install the linear motion mounting. <Ref. to
ME(H4DOTC)-37, INSTALLATION, Linear Motion 14) Tighten the nuts which install the front cushion
Mounting.> rubber onto crossmember.
11) Install the power steering pump on bracket.
Tightening torque:
85 N&m (8.7 kgf-m, 62.7 ft-lb)
ME(H4DOTC)-34
Engine Assembly
MECHANICAL
NOTE: (1) Install the intercooler. (DOHC turbo model)

Make sure the front cushion rubber mounting bolts <Ref. to IN(H4DOTC)-12, INSTALLATION, In-
and locator are securely installed. tercooler.>
(2) Install the air cleaner element and air clean-
er case. <Ref. to IN(H4DOTC)-8, INSTALLA-
TION, Air Cleaner Case.>
NOTE:
Use new O-rings.
Tightening torque:
25 N&m (2.5 kgf-m, 18.1 ft-lb)
LU-00223
15) Install the center exhaust pipe.

<Ref. to EX(H4DOTC)-7, INSTALLATION, Center
Exhaust Pipe.>
16) Connect the oil flow control solenoid valve con-
nector and ground cable of exhaust side.
ME-00803
22) Install the radiator. <Ref. to CO(H4DOTC)-20,

23) Install the coolant filler tank. (DOHC turbo mod-
el) <Ref. to CO(H4DOTC)-31, INSTALLATION,
Coolant Filler Tank.>
24) Install the window washer tank.
ME-00805 25) Install the battery to vehicle, and connect the
battery ground terminal.
27) Charge the A/C system with refrigerant.
<Ref. to AC-21, PROCEDURE, Refrigerant Charg-
ing Procedure.>
hood.
ME-02092 30) Take off the vehicle from a lift.
17) Lower the vehicle. C: INSPECTION
18) Connect the following hoses. 1) Check pipes and hoses are connected firmly.
(1) Fuel delivery hose, return hose and evapo- 2) Check the engine coolant and ATF are at speci-
ration hose fied levels.
(4) Pressure regulator hose
19) Connect the following connectors and termi-
nals.
(1) Engine ground terminals
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connector
20) Install the air intake system.
ME(H4DOTC)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
ME(H4DOTC)-30, REMOVAL, Engine Assembly.>
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
35 N&m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that cracks or other damages do not ex-
ist.
ME(H4DOTC)-36
Linear Motion Mounting
MECHANICAL
11.Linear Motion Mounting Tightening torque:

33 N&m (3.4 kgf-m, 24.3 ft-lb)
A: REMOVAL
2) Remove the air cleaner case.
3) Remove the linear motion mounting bracket.
ME-00853
Tightening torque:
30 N&m (3.1 kgf-m, 22.1 ft-lb)
ME-00852
4) Remove the speed nut (A), and remove the dy-

namic damper (B).
(A)
(B) ME-00852
ME-02093
ME-00853
B: INSTALLATION
ME(H4DOTC)-37
MECHANICAL

A: PROCEDURE
1) After removing the engine from body, secure it in
the STs shown below.
RH
LH
ST3 499817000 ENGINE STAND
ST2
ST1
ST3 ME-00057
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(H4DOTC)-38
V-belt
MECHANICAL
13.V-belt 4) Remove the A/C belt tensioner.
A: REMOVAL
NOTE:
Perform the following procedures with the engine
installed to the body.
1. FRONT SIDE BELT
ME-00061
B: INSTALLATION
NOTE:
Wipe off any oil or water on the belt and pulley.
1. FRONT SIDE BELT
1) Install a V-belt (C), and tighten the slider bolt so
as to obtain the specified belt tension. <Ref. to
ME-00807
ME(H4DOTC)-40, INSPECTION, V-belt.>
2) Tighten the lock bolt (A).
3) Loosen the lock bolt (A). 3) Tighten the slider bolt (B).
5) Remove the front side belt (C). Tightening torque:
Lock bolt (A):
25 N&m (2.5 kgf-m, 18.1 ft-lb)
(B) Slider bolt (B):
(C) 8 N&m (0.8 kgf-m, 5.9 ft-lb)
(B)
(C)
(A)
ME-00059
2. REAR SIDE BELT (A)

1) Loosen the lock nut (A).
2) Loosen the slider bolt (B). ME-00059
2. REAR SIDE BELT

1) Remove the A/C belt tensioner.
2) Install a V-belt, and tighten the slider bolt (B) so
(B)
<Ref. to ME(H4DOTC)-40, INSPECTION, V-belt.>
(A)
ME-00060
3) Remove the A/C belt.
ME(H4DOTC)-39
V-belt
MECHANICAL
3) Tighten the lock nut (A). Belt tension (without belt tension gauge)
Tightening torque: (A)
Lock nut (A): When installing new parts:
22.6 N&m (2.3 kgf-m, 16.6 ft-lb) 7 — 9 mm (0.276 — 0.354 in)
At inspection:
9 — 11 mm (0.354 — 0.433 in)
(B)
(B) When installing new parts:
7.5 — 8.5 mm (0.295 — 0.335 in)
At inspection:
9.0 — 10.0 mm (0.354 — 0.394 in)
(A)
98 N (10 kgf, 22 lb)
ME-00060 GEN A/C

P/S (A) (B)
C: INSPECTION
1) Replace the belts, if crack, fraying or wear is
found.
2) Check the V-belt tension and adjust it if neces- I/P
sary by changing the generator installing position C/P
and idler pulley installing position.
ME-00062
Belt tension (with belt tension gauge)
(A) C/P Crank pulley
When installing new parts: GEN Generator
618 — 755 N (63 — 77 kgf, 139 — 170 lb) P/S Power steering oil pump pulley
At inspection: A/C A/C compressor pulley
490 — 640 N (50 — 65 kgf, 110 — 144 lb) I/P Idler pulley
(B)
740 — 880 N (75 — 90 kgf, 166 — 198 lb)
At inspection:
350 — 450 N (36 — 46 kgf, 78 — 101 lb)
(A)
P/S GEN A/C
(B)
I/P
C/P
PM-00154
(A) Front side belt

(B) Rear side belt
C/P Crank pulley
GEN Generator
I/P Idler pulley
ME(H4DOTC)-40
Crank Pulley
MECHANICAL
14.Crank Pulley Crank pulley bolt:

Part No. 12369AA011
A: REMOVAL (2) Clean the crankshaft thread using com-
1) Remove the V-belts. <Ref. to ME(H4DOTC)-39, pressed air.
REMOVAL, V-belt.> (3) Tighten the bolts temporarily with tightening
2) Remove the crank pulley bolt. To lock the crank- torque of 44 N&m (4.5 kgf-m, 33 ft-lb).
shaft, use ST. (4) Tighten the crank pulley bolts keeping them
ST 499977400 CRANK PULLEY WRENCH in an angle 45" — 60".
NOTE:
the turning angle of the crank pulley bolt referring to
the gauge indicated on the timing belt cover.
4) Install the A/C belt tensioner.
ST
ME-00063

B: INSTALLATION
To lock the crankshaft, use ST. ME-00061
ST 499977400 CRANK PULLEY WRENCH 5) Install the V-belts. <Ref. to ME(H4DOTC)-39,

(1) Clean the crank shaft thread using com- INSTALLATION, V-belt.>
pressed air.
C: INSPECTION
and thread. 1) Check the V-belt is not worn or otherwise dam-
(3) Tighten the bolts temporarily with tightening aged.
torque of 44 N&m (4.5 kgf-m, 33 ft-lb). 2) Check the tension of the belt. <Ref. to
ME(H4DOTC)-40, INSPECTION, V-belt.>
Tightening torque:
130 N&m (13.3 kgf-m, 95.9 ft-lb)
ST
ME-00063
3) Confirm that the tightening angle of the crank

pulley bolt is 45" or more. Perform the following
procedures when less than 45".
CAUTION:
If the tightening angle of crank pulley bolt is
less than 45", the bolt should be damaged. In
this case, the bolt must be replaced.
(1) Replace and clean the crank pulley bolts.
ME(H4DOTC)-41
Timing Belt Cover
MECHANICAL
15.Timing Belt Cover

A: REMOVAL
REMOVAL, V-belt.>
<Ref. to ME(H4DOTC)-41, REMOVAL, Crank Pul-
ley.>
3) Remove the timing belt cover (LH) (A).
4) Remove the timing belt cover (RH) (B).
5) Remove the front timing belt cover (C).
(A)
(B) (C)
ME-00064
B: INSTALLATION
1) Install the front timing belt cover (C).
Tightening torque:
5 N&m (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (RH) (B).
Tightening torque:
5 N&m (0.5 kgf-m, 3.6 ft-lb)
3) Install the timing belt cover (LH) (A).
Tightening torque:
5 N&m (0.5 kgf-m, 3.6 ft-lb)
(A)
(B) (C)
ME-00064
4) Install the crank pulley. <Ref. to ME(H4DOTC)-

5) Install the V-belts. <Ref. to ME(H4DOTC)-39,
C: INSPECTION
Check the cover for damage.
ME(H4DOTC)-42
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

MECHANICAL
ME(H4DOTC)
Page
2. Compression .............................................................................................21
3. Idle Speed .................................................................................................22
4. Ignition Timing...........................................................................................23
7. Fuel Pressure............................................................................................26
8. Valve Clearance........................................................................................27
9. Engine Assembly ......................................................................................30
10. Engine Mounting .......................................................................................36
11. Linear Motion Mounting.............................................................................37
13. V-belt.........................................................................................................39
14. Crank Pulley..............................................................................................41
16. Timing Belt ................................................................................................43
17. Cam Sprocket ...........................................................................................51
18. Crank Sprocket .........................................................................................52
19. Camshaft...................................................................................................53
20. Cylinder Head ...........................................................................................59
21. Cylinder Block ...........................................................................................66
22. Intake and Exhaust Valve .........................................................................86
23. Piston ........................................................................................................87
24. Connecting Rod ........................................................................................88
25. Crankshaft.................................................................................................89
27. Engine Noise.............................................................................................96
Timing Belt
MECHANICAL
16.Timing Belt (2) Using white paint, put alignment and/or ar-
row marks on the timing belts in relation to the
A: REMOVAL cam sprockets.
1. TIMING BELT
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to
ME(H4DOTC)-41, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover.
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing Belt
Cover.>
4) Remove the timing belt guide.
ME-00070
ME-00065
5) If the alignment mark or arrow mark (which indi- ME-00071
cates rotation direction) on timing belt fade away, Z1: 54.5 tooth length
put new marks before removing the timing belt as Z2: 51 tooth length
shown in procedures below. Z3: 28 tooth length
(1) Turn the crankshaft using ST, and align the
alignment marks on crank sprocket, intake cam
sprocket (LH), exhaust cam sprocket (LH), in-
take cam sprocket (RH) and exhaust cam Z3
Z1 Z2
Z3
sprocket (RH) with notches of timing belt cover
and cylinder block.
ME-00072
6) Remove the belt idler (A).
(C)
(B)
ST
ME-00069
(A)
ME-00073
ME(H4DOTC)-43
Timing Belt
MECHANICAL
7) Remove the timing belt. B: INSTALLATION

CAUTION:
1. AUTOMATIC BELT TENSION ADJUST-
After the timing belt has been removed, never
rotate the intake and exhaust cam sprocket. If
ER ASSEMBLY AND BELT IDLER
the cam sprocket is rotated, the intake and ex- 1) Preparation for installation of automatic belt ten-
haust valve heads strike together and valve sion adjuster assembly.
stems are bent. CAUTION:
2. BELT IDLER AND AUTOMATIC BELT • Always use a vertical type pressing tool to
TENSION ADJUSTER ASSEMBLY move the adjuster rod down.
1) Remove the belt idler (B) and (C). • Push the adjuster rod vertically.
• Be sure to move the adjuster rod down slowly
applying a pressure of 294 N (30 kgf, 66 lb).
(C)
• Press-in the push adjuster rod gradually tak-
(B) ing more than three minutes.
N (1,000 kgf, 2,205 lb).
face of the cylinder. Do not press the adjuster
(A) rod into cylinder. Doing so may damage the cyl-
inder.
ME-00074
• Do not release the press pressure until stop-
2) Remove the belt idler No. 2. per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
ME-00075
3) Remove the automatic belt tension adjuster as-

sembly.
ME-00077
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in cylinder, secure the
adjuster rod.
ME-00076
ME-00078
ME(H4DOTC)-44
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster as- (1) Align the mark (A) on crank sprocket with
sembly. the mark on oil pump cover at cylinder block.
Tightening torque:
39 N!m (4.0 kgf-m, 28.9 ft-lb)
(A)
ME-00081
(2) Align single line mark (A) on the exhaust

ME-00079
cam sprocket (RH) with notch (B) on timing belt
cover.
Tightening torque:
(A)
39 N!m (4.0 kgf-m, 28.9 ft-lb)
(B)
ME-00082
(3) Align single line mark (A) on the intake cam

sprocket (RH) with notch (B) on timing belt cov-
ME-00075 er. (Ensure double lines (C) on intake and ex-
4) Install the belt idlers. haust cam sprockets are aligned.)
(B)
Tightening torque:
39 N!m (4.0 kgf-m, 28.9 ft-lb)
(A)
(C)
ME-00083
ME-00080
2. TIMING BELT
1) Preparation for installation of automatic belt ten-
sion adjuster assembly. <Ref. to ME(H4DOTC)-44,
AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
2) Crankshaft and cam sprocket alignment
ME(H4DOTC)-45
Timing Belt
MECHANICAL
(4) Align single line mark (A) on exhaust cam (6) Ensure that the cam and crank sprockets
sprocket (LH) with notch (B) on timing belt cover are positioned properly.
by turning the sprocket counterclockwise (as CAUTION:
viewed from front of engine). • Intake and exhaust camshafts for this DOHC
engine can be independently rotated with the
timing belts removed. As can be seen from the
figure, if the intake and exhaust valves are lifted
(B)
simultaneously, their heads will interfere with
each other, resulting in bent valves.
(A)
(A)
ME-00084
(5) Align single line mark (A) on intake cam

sprocket (LH) with notch (B) on timing belt cover
by turning the sprocket clockwise (as viewed
from front of engine).
Ensure double lines (C) on intake and exhaust
cam sprockets are aligned.
(B)
(A)
(C)
(B)
ME-00086
ME-00085
(A) Intake camshaft

(B) Exhaust camshaft
• When the timing belts are not installed, four

camshafts are held at the “zero-lift” position,
where all cams on camshafts do not push the
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
• When the camshafts are rotated to install the
timing belts, #2 intake and #4 exhaust cam of
camshafts (LH) are held to push their corre-
sponding valves down. (Under this condition,
these valves are held lifted.) Camshafts (RH)
are held so that their cams do not push valves
down.
• Camshafts (LH) must be rotated from the “ze-
ro-lift” position to the position where the timing
belt is to be installed with the smallest possible
angle, in order to prevent mutual interference of
intake and exhaust valve heads.
ME(H4DOTC)-46
Timing Belt
MECHANICAL
• Do not allow the camshafts to rotate in the di-

rection shown in the figure as this causes both
intake and exhaust valves to lift simultaneous-
ly, resulting in interference with their heads.
(A)
(A)
(B)
(A)
(A)
(B)
ME-00314
(A) Revolving direction

(B) Timing belt installation position
ME(H4DOTC)-47
Timing Belt
MECHANICAL
3) Installation of timing belt:

Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in
the figure. While aligning marks, position the timing belt properly.
CAUTION:
• Disengagement of more than one timing belt tooth may result in interference between valve and
piston.
• Ensure the belt’s rotating direction is correct.
(1) (2)
(4) (5)
(3) (6)
(D) (B)
(A)
RH-IN LH-IN
RH-EX LH-EX
(E) (7) (C)

ME-00089
(1) Arrow mark (4) 54.5 tooth length (7) Install it in the end
(2) Timing belt (5) 51 tooth length
(3) 28 tooth length (6) 28 tooth length
4) Install the belt idlers. 6) Install the timing belt guide.
Tightening torque: (1) Temporarily tighten the bolts.
39 N!m (4.0 kgf-m, 28.9 ft-lb) (2) Check and adjust the clearance between
timing belt and timing belt guide.
NOTE:
Make sure that the marks on the timing belt and Clearance:
sprockets are aligned. 1.0"0.5 mm (0.039"0.020 in)
ME-00090 ME-00091
5) After ensuring that the marks on the timing belt (3) Tighten the bolt.
and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
ME(H4DOTC)-48
Timing Belt
MECHANICAL

10 N!m (1.0 kgf-m, 7.2 ft-lb) Slight trace of oil at rod’s oil seal does not indicate
a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this opera-
tion two to three times.
ME-00095
(2) With the adjuster rod moved all the way up,
7) Install the timing belt cover. apply a pressure of 294 N (30 kgf, 66 lb) to it.
<Ref. to ME(H4DOTC)-42, INSTALLATION, Tim- Check the adjuster rod stiffness.
ing Belt Cover.> (3) If the adjuster rod is not stiff and moves
8) Install the crank pulley. down, replace the automatic belt tension adjust-
<Ref. to ME(H4DOTC)-41, INSTALLATION, Crank er assembly with a new one.
Pulley.> CAUTION:
9) Install the V-belts. <Ref. to ME(H4DOTC)-39, • Always use a vertical type pressing tool to
INSTALLATION, V-belt.> move the adjuster rod down.
C: INSPECTION • Do not use a lateral type vise.
• Push the adjuster rod vertically.
1. TIMING BELT • Press-in the push adjuster rod gradually tak-
1) Check the timing belt teeth for breaks, cracks ing more than three minutes.
and wear. If any fault is found, replace the timing • Do not allow press pressure to exceed 9,807
belt. N (1,000 kgf, 2,205 lb).
2) Check the condition of the backside of timing • Press the adjuster rod as far as the end sur-
belt. If cracks are found, replace the timing belt. face of the cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cyl-
CAUTION: inder.
• Be careful not to let oil, grease or engine
coolant contact the belt. Remove quickly and 4) Measure the amount of rod protrusion beyond
thoroughly if this happens. the body. If it is not within specifications, replace
• Do not bend the timing belt sharply. with a new one.
In radial diameter h: Amount of rod protrusion H:

60 mm (2.36 in) or more 5.7"0.5 mm (0.224"0.020 in)
ME-00100
ME-00099
2. AUTOMATIC BELT TENSION ADJUST- 3. BELT TENSION PULLEY

ER 1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
1) Visually check the oil seals for leaks, and rod
scratches. Replace the belt tension pulley if faulty.
ends for abnormal wear and scratches. If neces-
2) Check the belt tension pulley for smooth rota-
sary, replace the automatic belt tension adjuster
tion. Replace if noise or excessive play occurs.
assembly.
3) Check the belt tension pulley for grease leakage.
ME(H4DOTC)-49
Timing Belt
MECHANICAL
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pul-
ley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME(H4DOTC)-50
Cam Sprocket
MECHANICAL
17.Cam Sprocket C: INSPECTION

1) Check the cam sprocket teeth for abnormal wear
A: REMOVAL and scratches.
1) Remove the V-belts. <Ref. to ME(H4DOTC)-39, 2) Make sure there is no free play between cam
REMOVAL, V-belt.> sprocket and key.
2) Remove the crank pulley. 3) Check the cam sprocket protrusion used for sen-
<Ref. to ME(H4DOTC)-41, REMOVAL, Crank Pul- sor for damage and contamination of foreign mat-
ley.> ter.
Cover.>
<Ref. to ME(H4DOTC)-43, REMOVAL, Timing
Belt.>
5) Remove the cam sprocket. To lock the cam-
shaft, use ST.
ME-00838
B: INSTALLATION
1) Install the cam sprocket. To lock the camshaft,
use ST.
Tightening torque:
Tighten to 29.5 N!m (3.0 kgf-m, 21.8 ft-lb) of
torque, and then tighten further by 45#
ME-00838
2) Install the timing belt. <Ref. to ME(H4DOTC)-44,

INSTALLATION, Timing Belt.>
<Ref. to ME(H4DOTC)-42, INSTALLATION, Tim-
ing Belt Cover.>
<Ref. to ME(H4DOTC)-41, INSTALLATION, Crank
Pulley.>
ME(H4DOTC)-51
Crank Sprocket
MECHANICAL
18.Crank Sprocket C: INSPECTION

A: REMOVAL wear and scratches.
1) Remove the V-belts. <Ref. to ME(H4DOTC)-39, 2) Make sure there is no free play between crank
REMOVAL, V-belt.> sprocket and key.
2) Remove the crank pulley. 3) Check the crank sprocket protrusion used for
<Ref. to ME(H4DOTC)-41, REMOVAL, Crank Pul- sensor for damage and contamination of foreign
ley.> matter.
Cover.>
<Ref. to ME(H4DOTC)-43, REMOVAL, Timing
Belt.>
5) Remove the cam sprocket.
<Ref. to ME(H4DOTC)-51, REMOVAL, Cam
Sprocket.>
ME-00103
B: INSTALLATION
ME-00103
2) Install the cam sprocket.

<Ref. to ME(H4DOTC)-51, INSTALLATION, Cam
Sprocket.>
3) Install the timing belt.
ing Belt.>
ing Belt Cover.>
5) Install the crank pulley. <Ref. to ME(H4DOTC)-
ME(H4DOTC)-52
Camshaft
MECHANICAL
19.Camshaft 10) Remove the timing belt cover No. 2 (RH).
A: REMOVAL
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to
Cover.>
4) Remove the timing belt. <Ref. to ME(H4DOTC)-
43, REMOVAL, Timing Belt.> ME-00107
5) Remove the cam sprocket. <Ref. to 11) Remove the spark plug cords.
ME(H4DOTC)-51, REMOVAL, Cam Sprocket.> 12) Remove the oil level gauge guide. (LH side)
6) Remove the crank sprocket. <Ref. to 13) Remove the rocker cover and gasket.
ME(H4DOTC)-52, REMOVAL, Crank Sprocket.> 14) Remove the oil pipe.
7) Disconnect the oil flow control solenoid valve as-
sembly connector.
ME-00712
15) Remove the camshaft position sensor on ex-

ME-00808
haust side.
FU-01186
ME-00105
16) Loosen the oil flow control solenoid valve as-
9) Remove the timing belt cover No. 2 (LH). sembly and intake camshaft cap bolts equally, a lit-
tle at a time in alphabetical sequence shown in the
figure.
(A)
(E) (C)
(F) (D)
(B)
ME-00106
ME-00771
ME(H4DOTC)-53
Camshaft
MECHANICAL
17) Loosen the exhaust camshaft cap bolts equal- Exhaust camshaft (LH):
ly, a little at a time in alphabetical sequence shown Rotate 45# counterclockwise.
in the figure.
A
77.5 (b)
(a)
11
(A)
(E) (C)
(F) (D)
(B)
ME-00772
18) Remove the oil flow control solenoid valve as- B

sembly, intake camshaft cap and camshaft. 77.5
(b)
19) Remove the exhaust camshaft caps and cam- 11 (a)
shaft.
NOTE:
Arrange camshaft caps in order so that they can be
installed in their original positions.
20) Similarly, remove the camshafts (RH) and re-
lated parts.
ME-00111
B: INSTALLATION
1) Camshaft installation: A Cylinder head (LH)
Apply engine oil to the cylinder head at camshaft B Cylinder head (RH)
bearing location before installing the camshaft. In- (a) Intake camshaft
stall the camshaft so that each valve is close to or in (b) Exhaust camshaft
contact with “base circle” of cam lobe.
2) Camshaft cap and oil flow control solenoid valve
NOTE:
assembly installation:
• When the camshafts are positioned as shown in
the figure, camshafts need to be rotated at a mini- (1) Apply small amount of liquid gasket to the
mum to align with the timing belt during installation. cap mating surface.
• Camshaft (RH) need not be rotated when set at NOTE:
the position shown in the figure. Do not apply liquid gasket excessively. Otherwise,
Intake camshaft (LH): the excessive liquid gasket may come out and flow
Rotate 80# clockwise. toward oil seal, resulting in oil leaks.
Liquid gasket:
equivalent
ME-00773
(2) Apply engine oil to the cap bearing surface,

and install the cap on camshaft as shown by
identification mark.
ME(H4DOTC)-54
Camshaft
MECHANICAL
(3) Gradually tighten the camshaft cap and oil 5) Rocker cover installation:
control valve assembly in at least two stages in (1) Install the gasket on rocker cover. Install the
alphabetical sequence shown in the figure, and peripheral gasket and ignition coil gasket.
then tighten to the specified torque. (2) Apply liquid gasket to the designated point
Tightening torque: of cylinder head.
T1: 10 N!m (1.0 kgf-m, 7.2 ft-lb) Liquid gasket:
T2: 20 N!m (2.0 kgf-m, 14.5 ft-lb) THREE BOND 1215 (Part No. 004403007) or
equivalent
(G)
(C) (L)
T2
T1
(E) (A) (K)
(F)
(B) (J)
T1
T2
(H) (D) (I)

ME-00839
(4) After tightening the camshaft cap, ensure

the camshaft rotates only slightly while holding it
at “base circle”.
3) Install the camshaft position sensor on exhaust
side.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
ME-00776
(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
(4) Tighten the rocker cover tightening bolt in al-
phabetical sequence shown in the figure, and
FU-01186 then tighten to the specified torque.
4) Camshaft oil seal installation: Tightening torque:
Apply grease to the new oil seal lips and press onto 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
the front end of camshaft by using ST1 and ST2.
(C),(K) (H)
NOTE:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER (E)
ST2 499597200 OIL SEAL GUIDE (B),(J)
(A),(I)
(G)
(D),(L) (F) ME-00777
ST1
ST2
ME-00116
ME(H4DOTC)-55
Camshaft
MECHANICAL
6) Install the oil pipe. 11) Install the timing belt cover No. 2 (LH).
29 N!m (3.0 kgf-m, 21.4 ft-lb) 5 N!m (0.5 kgf-m, 3.6 ft-lb)
ME-00712 ME-00106
7) Connect the oil flow control solenoid valve con- 12) Install the tensioner bracket.
nector.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
ME-00808
8) Install the spark plug cord. ME-00105

9) Similarly, install the parts on right-hand side.
10) Install the timing belt cover No. 2 (RH). 13) Install the crank sprocket.
Tightening torque: Sprocket.>
5 N!m (0.5 kgf-m, 3.6 ft-lb) 14) Install the cam sprocket.
Sprocket.>
15) Install the timing belt. <Ref. to ME(H4DOTC)-
ing Belt Cover.>
Pulley.>
ME-00107
ME(H4DOTC)-56
Camshaft
MECHANICAL
C: INSPECTION (6) Measure the widest point of the plastigauge

1) Measure the bend, and repair or replace if nec- on each journal. If oil clearance exceeds the lim-
essary. it, replace the camshaft. If necessary, replace
the camshaft caps and cylinder head as a set.
Standard value:
0.020 mm (0.0008 in) or less Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
ME-00118
ME-00119
2) Check the journal for damage and wear. Re-
place if faulty. (7) Completely remove the plastigauge.
3) Measure the outside diameter of camshaft jour- 5) Check the cam face condition, and remove the
nal. If the journal diameter is not within specifica- minor faults by grinding with oil stone. Measure the
tion, check the oil clearance. cam height H. If it exceeds the limit or has partial
wear, replace it.
Camshaft journal
Front Center, rear
Cam height H:
Standard value 37.946 — 37.963 29.946 — 29.963 Standard
mm (in) (1.4939 — 1.4946) (1.1790 — 1.1796) Intake
45.85 — 45.95 mm (1.805 — 1.809 in)
4) Measurement of the camshaft journal oil clear-
Exhaust
ance:
45.75 — 45.85 mm (1.801 — 1.805 in)
(1) Clean the bearing caps and camshaft jour-
nals. Cam base circle diameter A:
(2) Place the camshafts on cylinder head. 37.0 mm (1.457 in)
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the cam-
shaft journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the H
figure, and then tighten to the specified torque.
Do not turn the camshaft.
Tightening torque:
T1: 10 N!m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N!m (2.0 kgf-m, 14.5 ft-lb) A
ME-00120
T2
(A)
(E) (C)
T1
(F) (D)
(B)
ME-00774
(5) Remove the bearing caps.
ME(H4DOTC)-57
Camshaft
MECHANICAL
6) Measure the side clearance of camshaft with dial

gauge. If the clearance exceeds the limit or has
partial wear, replace the caps and cylinder head as
a set. If necessary, replace the camshaft.
Standard:
0.068 — 0.116 mm (0.0027 — 0.0047 in)
ME-00121
ME(H4DOTC)-58
Cylinder Head
MECHANICAL
20.Cylinder Head 11) Remove the cylinder head gasket.

CAUTION:
A: REMOVAL Be careful not to scratch the mating surface of
1) Remove the V-belts. <Ref. to ME(H4DOTC)-39, cylinder head and cylinder block.
REMOVAL, V-belt.>
12) Similarly, remove the cylinder head (RH).
<Ref. to ME(H4DOTC)-41, REMOVAL, Crank Pul- B: INSTALLATION
ley.> 1) Install the cylinder head and gaskets on cylinder
3) Remove the timing belt cover. block.
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing Belt CAUTION:
Cover.> • Use new cylinder head gaskets.
4) Remove the timing belt. • Be careful not to scratch the mating surface
<Ref. to ME(H4DOTC)-43, REMOVAL, Timing of cylinder head and cylinder block.
Belt.>
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
Sprocket.>
(2) Tighten all bolts to 29 N!m (3.0 kgf-m, 21.4
ft-lb) in alphabetical sequence.
ifold.> (3) Retighten all bolts to 69 N!m (7.0 kgf-m, 51
ft-lb) in alphabetical sequence.
7) Remove the bolt which installs the A/C compres-
sor bracket on cylinder head. (4) Back off all bolts by 180# in the reverse or-
der of installation, and back them off again by
8) Remove the camshaft. <Ref. to ME(H4DOTC)-
180#.
9) Remove the cylinder head bolts in alphabetical (5) Tighten all bolts to 49 N!m (5.0 kgf-m, 36 ft-
sequence shown in the figure. lb) in alphabetical sequence.
Leave the bolts (A) and (D) engaged by three or (6) Tighten all bolts by 80 — 90# in alphabetical
four threads to prevent the cylinder head from fall- sequence.
ing. (7) Tighten all bolts by 40 — 45# in alphabetical
sequence.
CAUTION:
(D) (F) (A)
(8) Further tighten the bolts (A) and (B) by 40 —
45#.
CAUTION:
Ensure the total “re-tightening angle” [in the
(B) (E) (C)
former two steps], do not exceed 90#.
ME-00122
(C) (A) (F)
Remove the bolts (A) and (D) to remove cylinder
head.
(F) (A) (E) (B) (D)

(D)
ME-00123
3) Install the camshaft. <Ref. to ME(H4DOTC)-54,

INSTALLATION, Camshaft.>
4) Install the A/C compressor bracket on cylinder
(B) (E) (C) head.
5) Install the intake manifold.
ME-00122 <Ref. to FU(H4DOTC)-15, INSTALLATION, Intake
Manifold.>
ME(H4DOTC)-59
Cylinder Head
MECHANICAL

Sprocket.>
ing Belt.>
ing Belt Cover.>
Pulley.>
C: DISASSEMBLY
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
CAUTION:
seals.
ST2
ST1
ME-00124
ME(H4DOTC)-60
Cylinder Head
MECHANICAL
D: ASSEMBLY
(1) (11) (4) (5) (6) (7) (8) (9)
(3)
(2)
(11) (4) (5) (6) (7) (8) (9)
(12)
(4)
(10)
(6)
(12) (7)
(4) (8)
(10) (9)
(6)
(7)
(8)
(9)
ME-00795
(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter
(2) Intake valve (6) Valve spring (10) Exhaust valve oil seal
(3) Cylinder head (7) Retainer (11) Intake valve guide
(4) Valve spring seat (8) Retainer key (12) Exhaust valve guide
ME(H4DOTC)-61
Cylinder Head
MECHANICAL
1) Installation of valve spring and valve: NOTE:

(1) Coat the stem of each valve with engine oil Uneven torque for the cylinder head nuts can
and insert the valve into valve guide. cause warping. When reinstalling, pay special at-
NOTE: tention to the torque so as to tighten evenly.
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip. (A)
(2) Set the cylinder head on ST1.

(3) Install the valve spring and retainer using
ST2.
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Be sure to install the valve spring with their close- (B)
coiled end facing the seat on the cylinder head. ME-00126
2. VALVE SEAT
ST2 Inspect the intake and exhaust valve seats, and
correct the contact surfaces with a valve seat cutter
if they are defective or when valve guides are re-
placed.
Valve seat width W:
ST1 Intake
Standard
ME-00124 0.6 — 1.4 mm (0.024 — 0.055 in)
Exhaust
(4) Compress the valve spring and fit the valve Standard
spring retainer key. 1.2 — 1.8 mm (0.047 — 0.071 in)
(5) After installing, tap the valve spring retainers
lightly with a wooden hammer for better seating.
2) Apply oil to the surfaces of the valve lifter.
3) Install the valve lifter.
E: INSPECTION
1. CYLINDER HEAD
W
1) Make sure that cracks or other damages do not
exist. In addition to visual inspection, inspect impor-
tant areas by means of red lead check.
2) Measure the warping of the cylinder head sur- ME-00127
face that mates with crankcase using a straight 3. VALVE GUIDE
edge (A) and thickness gauge (B).
If the warping exceeds the limit, regrind the surface 1) Check the clearance between valve guide and
with a surface grinder. stem. The clearance can be checked by measuring
the outer diameter of valve stem and inner diame-
Warping limit: ter of valve guide respectively with a micrometer.
0.035 mm (0.0014 in)
Clearance between the valve guide and valve
Grinding limit: stem:
0.3 mm (0.012 in) Standard
Standard height of cylinder head: Intake
127.5 mm (5.02 in) 0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
ME(H4DOTC)-62
Cylinder Head
MECHANICAL
2) If the clearance between valve guide and stem ST1 499767200 VALVE GUIDE REMOVER
exceeds the standard value, replace the valve ST2 18251AA020 VALVE GUIDE ADJUSTER
guide or valve itself whichever shows greater
amount of wear or has abnormality such as
scratch. See the following procedure for valve ST1
guide replacement.
ST2
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust ME-00130
5.945 — 5.960 mm (0.2341 — 0.2346 in) (6) Check the valve guide protrusion.
(1) Place the cylinder head on ST1 with the
Valve guide protrusion L:
combustion chamber upward so that valve
15.8 — 16.2 mm (0.622 — 0.638 in)
guides fit the holes in ST1.
(2) Insert the ST2 into valve guide and press it (7) Ream the inside of valve guide using ST.
down to remove the valve guide. Put the reamer in valve guide, and rotate the
ST1 498267600 CYLINDER HEAD TABLE reamer slowly clockwise pushing it lightly. Bring
ST2 499767200 VALVE GUIDE REMOVER the reamer back while rotating it clockwise. After
reaming, clean the valve guide to remove chips.
ST2
NOTE:
• Apply engine oil to the reamer when reaming.
• If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
• If the inner surface of the valve guide becomes
ST1 lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.
ME-00128
(3) Turn the cylinder head upside down and valve and valve seat after replacing the valve
place the ST as shown in the figure. guide.
ST 18251AA020 VALVE GUIDE ADJUSTER
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and re-
place them if damaged, worn, deformed, or if “H” is
ST exceed the standard value or if they have partial
wear.
L H:
Intake (A)
Standard
1.0 — 1.4 mm (0.039 — 0.055 in)
ME-00757
Exhaust (B)
Standard
(4) Before installing a new valve guide, make 1.3 — 1.7 mm (0.051 — 0.067 in)
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder, and insert the ST1 into valve
guide. Press-in until the valve guide upper end is
flush with the upper surface of ST2.
ME(H4DOTC)-63
Cylinder Head
MECHANICAL
Valve overall length: 6. INTAKE AND EXHAUST VALVE OIL

Intake (A) SEAL
104.4 mm (4.110 in)
Replace the oil seal with a new one, if the lip is
Exhaust (B) damaged or spring is out of place, or when the sur-
104.65 mm (4.1201 in) faces of intake valve and valve seat are recondi-
tioned or intake valve guide is replaced.
1) Place the cylinder head on ST1.
2) Press-fit the oil seal to the specified dimension
(A)
indicated in the figure using ST2.
H
NOTE:
• Apply engine oil to oil seal before force-fitting.
• Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their difference
in color.
Color of rubber part:
Intake [Black]
(B)
Exhaust [Brown]
Color of spring part:
Intake [Silver]
H
Exhaust [Silver]
ST2
ME-00758
2) Put a small amount of grinding compound on the

seat surface, and lap the valve and seat surface.
Install a new intake valve oil seal after lapping.
5. VALVE SPRINGS
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not ME-00133
within the standard value presented in the table.
2) To measure the squareness of the valve spring, 7. VALVE LIFTER
stand the spring on a surface plate and measure its 1) Check the valve lifter visually.
deflection at the top of spring using a try square. 2) Measure the outer diameter of valve lifter.
Free length mm (in) 44.67 (1.759) Outer diameter:
206 — 236 (21.0 — 24.1, 34.959 — 34.975 mm (1.3763 — 1.3770 in)
Tension/spring Set
46.3 — 53.1)/36.0 (1.417)
height
N (kgf, lb)/mm (in) Lift 485 — 537 (21.0 — 24.1, 109
— 121) /26.0 (1.024)
Squareness 2.5#, 2.0 mm (0.079 in)
ME-00134
ME-00132
ME(H4DOTC)-64
Cylinder Head
MECHANICAL
3) Measure the inner diameter of valve lifter mating

part on cylinder head.
Inner diameter:
34.994 — 35.016 mm (1.3777 — 1.3786 in)
ME-00135
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the standard or has partial wear in inner surface,
replace the cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
ME(H4DOTC)-65
Cylinder Block
MECHANICAL
21.Cylinder Block 10) Remove the drive plate.

To lock crankshaft, use ST.
A: REMOVAL ST 498497100 CRANKSHAFT STOPPER
NOTE:
Before conducting this procedure, drain engine oil
completely.
ifold.>
REMOVAL, V-belt.>
3) Remove the crank pulley. ST
<Ref. to ME(H4DOTC)-41, REMOVAL, Crank Pul- ME-00136
ley.>
4) Remove the timing belt cover. 11) Remove the oil separator cover.
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing Belt 12) Remove the oil pump by using flat tip screw-
Cover.> driver.
5) Remove the timing belt. CAUTION:
<Ref. to ME(H4DOTC)-43, REMOVAL, Timing Be careful not to scratch the mating surface of
Belt.> cylinder block and oil pump.
Sprocket.>
<Ref. to ME(H4DOTC)-52, REMOVAL, Crank
Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head.
<Ref. to ME(H4DOTC)-59, REMOVAL, Cylinder
Head.> ME-00138
ST 498497100 CRANKSHAFT STOPPER 13) Remove the water by-pass pipe for heater.
14) Remove the oil filter.
15) Removal of oil pan:
(1) Place the cylinder block to face the #2 and
#4 cylinder side 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 remove the
oil pan. Do not use a screwdriver or similar tools
ST in place of oil pan cutter.
ME-00778
16) Remove the oil strainer stay.
18) Remove the baffle plate.
19) Remove the water pipe.
ME(H4DOTC)-66
Cylinder Block
MECHANICAL
(1)
(2)
(3)
(4)
(6)
(4)
(5)
(3)
(4)
(3)
(2)
(1)
(4)
(3)
(2)
(1)
ME-00139
(1) Service hole plug (3) Snap ring (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
21) Remove the service hole cover and service 22) Rotate the crankshaft to bring #1 and #2 pis-
hole plugs using a hexagon wrench [14 mm]. tons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.
ME-00140
ME-00141
23) Draw out the piston pins from #1 and #2 pistons

using ST.
ST 499097700 PISTON PIN REMOVER
ME(H4DOTC)-67
Cylinder Block
MECHANICAL
NOTE: 24) Similarly remove the piston pins from #3 and #4

Be careful not to confuse the original combination pistons.
of piston, piston pin and cylinder. 25) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
26) Back off the bolts which connect cylinder block
on the side of #1 and #3 cylinders two or three
ST
turns.
27) Place the cylinder block to face the #1 and #3
cylinder side upward, and remove cylinder block
connecting bolts.
28) Separate the cylinder block (LH) and (RH).
NOTE:
ME-00142 the connecting rod to fall and damage the cylinder
block.
(5)
(1)
(4)
(2)
(4)
(3)
(1)
(5)
ME-00143
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
29) Remove the rear oil seal. NOTE:
30) Remove the crankshaft together with connect- Be careful not to confuse the original combination
ing rod. of piston and cylinder.
31) Remove the crankshaft bearings from cylinder
block using a hammer handle.
NOTE:
Do not confuse the combination of crankshaft bear-
ings.
Press the bearing at the end opposite to locking lip.
32) Draw out each piston from cylinder block using
a wooden bar or hammer handle.
ME(H4DOTC)-68
Cylinder Block
MECHANICAL
B: INSTALLATION
(4)
(1)
(3)
(2)
(3)
ME-00144
(1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal
(2) Crankshaft
1) Remove oil on the mating surface of bearing and 4) Apply a coat of engine oil to washers and bolt
cylinder block before installation. Apply a coat of threads.
engine oil to crankshaft pins. 5) Tighten the 10 mm cylinder block connecting
2) Position the crankshaft on the #2 and #4 cylinder bolts on LH side (A — D) in alphabetical sequence.
block.
Tightening torque:
3) Apply liquid gasket to the mating surface of #1
10 N!m (1.0 kgf-m, 7.4 ft-lb)
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or (A)
equivalent
(D)
NOTE:
Do not allow liquid gasket to run over to O-ring
grooves, oil passages, bearing grooves, etc. (B)
(C)
ME-00840
ME-00145
ME(H4DOTC)-69
Cylinder Block
MECHANICAL
6) Tighten the 10 mm cylinder block connecting 9) Further tighten the LH side bolts (A — D) to 90#
bolts on RH side (E — J) in alphabetical sequence. in alphabetical sequence.
Tightening torque:
10 N!m (1.0 kgf-m, 7.4 ft-lb)
(A)
(D)
(G) (E)
(J)
(B)
(C)
ME-00840
(H) 10) Further tighten the RH side bolts (E — J) to 90#
(I) (F)
ME-00841
7) Further tighten the LH side bolts (A — D) in al-
Tightening torque: (G) (E)
(J)
(A), (C): 20 N!m (2.0 kgf-m, 14.8 ft-lb)
(B), (D): 15 N!m (1.5 kgf-m, 10.8 ft-lb)
(H)
(I) (F)
(A)
ME-00841
(D) 11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts on LH side (A — H) in alphabetical se-
quence.
(B)
Tightening torque:
(C)
(A) — (G): 25 N!m (2.5 kgf-m, 18.1 ft-lb)
ME-00840
(H): 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
8) Further tighten the RH side bolts (E — J) in al-
phabetical sequence. (G)
Tightening torque: (E)

(C) (A) (B)
(E), (F), (G), (I): 20 N!m (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 N!m (1.8 kgf-m, 13.3 ft-lb)
(G) (E)
(J) (F)
(D)
(H) ME-00147
(H)
(I) (F)
ME-00841
ME(H4DOTC)-70
Cylinder Block
MECHANICAL
12) Install the rear oil seal using ST1 and ST2. 16) Align the upper rail spin stopper (E) to the side
ST1 499597100 CRANKSHAFT OIL SEAL hole (D) on the piston.
GUIDE (D) (E)
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
(B) (A)
ST2 (F) (G)
ME-00843
17) Position the expander gap at 180# on the re-

ST1 verse side of (C) that shown (F) in the figure.
ME-00148
(A) Rear oil seal (F)

(B) Flywheel attaching bolt
13) Position the top ring gap at (A) or (B) in the fig-
ure.
14) Position the second ring gap at 180# on the re-
verse side of the top ring gap.
ME-02088
18) Position the lower rail gap at 120# on counter-

clockwise of (C) that shown (G) in the figure.
(A) (B)
ME-00718
15) Position the upper rail gap at (C) in the figure.

(G) (C)
120 ME-02089
CAUTION:
tion.
25
skirt area.
(C)
19) Install the snap ring.
ME-02087
Install snap rings in the piston holes located oppo-
site to the service holes in cylinder block, when po-
ME(H4DOTC)-71
Cylinder Block
MECHANICAL
NOTE:
Use new snap rings.
#3
#1
#4
(A) #2
ME-00154
(A) Front side
(5) T
(4)
(5)
(1)
(3) (4)
(3)
(2)
(2)
(1)
ME-00155
(1) Piston (4) Gasket !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456

(2) Piston pin (5) Service hole plug !- 78(.79:3(;:9<6
(3) Snap ring
20) Installation of piston: (3) Apply a coat of engine oil to the pistons and
(1) Place the cylinder block to face the #1 and cylinders and insert pistons in their cylinders us-
#2 cylinder side upward. ing ST2.
(2) Using the ST1, turn the crankshaft so that ST2 398744300 PISTON GUIDE
#1 and #2 connecting rods are set at bottom
dead center. ST1
ST1 499987500 CRANKSHAFT SOCKET
ST2
ME-00157
ME(H4DOTC)-72
Cylinder Block
MECHANICAL
NOTE: (4) Apply liquid gasket around the service hole

Piston front mark faces towards the front of engine. plug.
Liquid gasket:
equivalent
(A)
ME-00722
(A) Front mark
21) Installation of piston pin: ME-00160

(1) Apply a coat of engine oil to ST3 before in- (5) Install the service hole plug and gasket.
sertion, and then insert it into the service hole to
NOTE:
align piston pin hole with connecting rod small
Use a new gasket.
end.
ST3 499017100 PISTON PIN GUIDE
ST1
ST3
ME-00140
ME-00158

rod through service hole.
(3) Install the snap ring.
NOTE:
Use new snap rings.
ME-00159
ME(H4DOTC)-73
Cylinder Block
MECHANICAL
(5) T2 T1
(6)
(3) (4)
(2) (7)
(1)
(3)
(2)
(1)
ME-00161
(1) Piston (5) Service hole plug !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456

(2) Piston pin (6) Service hole cover !:- <9=(.89<;3(=976
(3) Snap ring (7) O-ring !>- 78(.79:3(;:9<6
(4) Gasket
(6) Place the cylinder block to face the #3 and Tightening torque:
#4 cylinder side upward. Following the same 5 N!m (0.5 kgf-m, 3.6 ft-lb)
procedures as used for #1 and #2 cylinders, in-
stall the pistons and piston pins.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
24) Install the oil strainer and O-ring.
Tightening torque:
10 N!m (1.0 kgf-m, 7.2 ft-lb)
ME-00162
25) Install the oil strainer stay.
26) Apply liquid gasket to mating surfaces and in- 27) Apply liquid gasket to mating surfaces and in-
stall the oil pan. stall the oil separator cover.
Liquid gasket: NOTE:
THREE BOND 1207C (Part No. 004403012) or Install them within 20 min. from applying liquid gas-
equivalent ket.
Liquid gasket:
equivalent
ME(H4DOTC)-74
Cylinder Block
MECHANICAL
Tightening torque: (2) Apply liquid gasket to the matching surface

6.4 N!m (0.65 kgf-m, 4.7 ft-lb) of oil pump.
Liquid gasket:
equivalent
ME-00163
(A)
ST 498497100 CRANKSHAFT STOPPER ME-00165
Tightening torque: (A) O-ring

72 N!m (7.3 kgf-m, 53.1 ft-lb)
(3) Apply a coat of engine oil to the inside of oil
seal.
ST
ME-00136
29) Installation of oil pump:

ME-00312
(1) Install the front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER (4) Install the oil pump on cylinder block. Be
careful not to damage the oil seal during instal-
NOTE: lation.
Use a new front oil seal.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
• Do not forget to install the O-ring and seal
when installing the oil pump.
• Align the flat surface of oil pump’s inner rotor
with crankshaft before installation.
30) Install the water pump and gasket.
Tightening torque:
ME-00164 First: 12 N!m (1.2 kgf-m, 8.7 ft-lb)
Second: 12 N!m (1.2 kgf-m, 8.7 ft-lb)
ME(H4DOTC)-75
Cylinder Block
MECHANICAL
CAUTION:
• Be sure to use a new gasket.
• When installing the water pump, tighten the
bolts in two stages in alphabetical sequence as
shown in the figure.
(F)
(E)
(A)
(D)
(C) (B)
ME-02094
31) Install the water by-pass pipe for heater.

32) Install the oil filter.
33) Install the water by-pass pipe between oil cool-
er and water pump.
NOTE:
Always use new O-rings.
35) Install the cylinder head.
<Ref. to ME(H4DOTC)-59, INSTALLATION, Cylin-
der Head.>
36) Install the oil level gauge guide. (LH side)
37) Install the rocker cover.
Sprocket.>
Sprocket.>
ing Belt.>
ing Belt Cover.>
Pulley.>
43) Install the generator and A/C compressor
brackets on cylinder head.
45) Install the intake manifold.
<Ref. to FU(H4DOTC)-15, INSTALLATION, Intake
Manifold.>
ME(H4DOTC)-76
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(1)
(2)
(2)
(5)
(4)
(3)
(6)
ME-00168
NOTE:
rod cap and bearing in order to prevent confusion.
3) Remove the piston rings using a piston ring ex-
pander.
NOTE:
Arrange the removed piston rings in proper order to
prevent confusion.
ME(H4DOTC)-77
Cylinder Block
MECHANICAL
D: ASSEMBLY
(3)
T (1)
(1)
(2)
(4)
(5)
(6)
(8)
(7)
ME-00169
(1) Connecting rod bearing (5) Second ring !"#$%&'"'#(%)*+,&-(N!m(./#0123(0%1456

(2) Connecting rod (6) Top ring !- =;(.=9<3(??6
(3) Connecting rod cap (7) Snap ring
(4) Oil ring (8) Side mark
1) Apply oil to the surfaces of the connecting rod
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
NOTE:
Position each connecting rod with the side marked
facing forward.
3) Install the connecting rod cap.
Ensure the arrow mark on connecting rod cap fac-
ing front during installation.
CAUTION:
• Each connecting rod has its own mating cap.
checking their matching number.
• When tightening the connecting rod nuts, ap-
ply oil on the threads.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a piston ring expander.
ME(H4DOTC)-78
Cylinder Block
MECHANICAL
E: INSPECTION Standard diameter:

A: 92.005 — 92.015 mm (3.6222 — 3.6226 in)
1. CYLINDER BLOCK B: 91.995 — 92.005 mm (3.6219 — 3.6222 in)
1) Visually check for cracks and damage. Especial-
ly, inspect the important parts by means of red lead
check.
2) Check the oil passages for clogging.
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge,
and correct by grinding if necessary.
Warping limit:
0.025 mm (0.00098 in)
Grinding limit:
(A) (B)
0.1 mm (0.004 in)
Standard height of cylinder block:
#5
5
201.0 mm (7.91 in)
#4
4
2. CYLINDER AND PISTON #3
#2 (F)
A
1) The cylinder bore size is stamped on the cylinder
#1 (D)
B
block’s front upper surface.
NOTE:
• Measurement should be performed at a temper- (E) (C)
ature of 20#C (68#F). ME-00170
• Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used (A) Main journal size mark
as guide lines in selecting a standard piston. (B) Cylinder block (RH) $ (LH) combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark
2) How to measure the inner diameter of each cyl-

inder:
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights as
shown in the figure, using a cylinder bore gauge.
NOTE:
Taper:
Standard
0.015 mm (0.0006 in)
ME(H4DOTC)-79
Cylinder Block
MECHANICAL
Out-of-roundness: Piston outer diameter:

Standard Standard
0.010 mm (0.0004 in) A: 92.005 — 92.015 mm (3.6222 — 3.6226
in)
B: 91.995 — 92.005 mm (3.6219 — 3.6222
(A) (B) in)
92.245 — 92.265 mm (3.6317 — 3.6467 in)
92.495 — 92.515 mm (3.6415 — 3.6423 in)
H1
H2
H3 H
H4
ME-00172

piston.
NOTE:
ME-00171
(A) Piston pin direction
(B) Thrust direction Cylinder to piston clearance at 20#C (68#F):
H1: 10 mm (0.39 in) Standard
H2: 45 mm (1.77 in) $0.010 — 0.010 mm ($0.00039 — 0.00039 in)
H3: 80 mm (3.15 in) 6) Boring and honing:
H4: 115 mm (4.53 in) (1) If one of the values of taper, out-of-round-
ness, or cylinder-to-piston clearance exceeds
3) When the piston is to be replaced due to general the specified limit or is out of standard, or if there
or cylinder wear, determine a suitable sized piston is any damage on the cylinder wall, rebore it to
by measuring the piston clearance. use an oversize piston.
4) How to measure the outer diameter of each pis-
ton: CAUTION:
When any of the cylinders needs reboring, all
Measure the outer diameter of each piston at the
other cylinders must be bored at the same time,
height as shown in the figure. (Thrust direction)
and use oversize pistons. Do not perform bor-
NOTE: ing on one cylinder only. Nor use an oversize
Measurement should be performed at a tempera- piston for one cylinder only.
ture of 20#C (68#F). (2) If the cylinder inner diameter exceeds
Piston grade point H: 92.515 mm (3.6423 in) after boring and honing,
40.0 mm (1.57 in) replace the crankcase.
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter.
3. PISTON AND PISTON PIN
1) Check the pistons and piston pins for damage,
cracks, and wear and the piston ring grooves for
wear and damage. Replace if defective.
ME(H4DOTC)-80
Cylinder Block
MECHANICAL
2) Measure the piston-to-cylinder clearance at 4. PISTON RING

each cylinder. <Ref. to ME(H4DOTC)-79, CYLIN-
1) If the piston ring is broken, damaged or worn, or
DER AND PISTON, INSPECTION, Cylinder
if its tension is insufficient, or when the piston is re-
Block.> If any of the clearances is out of specifica-
placed, replace the piston ring with a new one of
tion, replace the piston or bore the cylinder to use
the same size as the piston.
an oversize piston.
3) Make sure that the piston pin can be inserted CAUTION:
into the piston pin hole with your thumb at 20#C • Marks are displayed on the end of top and
(68#F). Replace if defective. second rings. When installing the rings to the
piston, face those marks upward.
Standard clearance between piston pin and • Oil ring consists of the upper rail, expander
hole in piston: and lower rail. When installing on piston, be
Standard careful of each rail’s direction.
0.004 — 0.008 mm (0.0002 — 0.0003 in)
(A)
(B)
(C)
ME-00173 (A)
(B)
(C)
ME-00789
ME-00174
4) Check the snap ring installation groove on the (A) Upper rail
piston for burr (A). If necessary, remove burr from (B) Expander
the groove so that the piston pin can lightly move. (C) Lower rail
2) Squarely place the piston ring and oil ring in cyl-

inder, and measure the piston ring gap with a thick-
ness gauge.
(A) Standard
mm (in)
Outer circle side: 0.20 — 0.25
(0.0079 — 0.0098)
Top ring
Inner circle side: 0.20 — 0.30
Piston ring (0.0079 — 0.014)
ME-00175
gap 0.40 — 0.50
Second ring
5) Check the piston pin snap ring for distortion, (0.016 — 0.020)
cracks and wear. 0.20 — 0.50
Oil ring rail
(0.0079 — 0.0197)
ME(H4DOTC)-81
Cylinder Block
MECHANICAL
NOTE: Limit of bend or twist per 100 mm (3.94 in) in

Difference between outer and inner perimeters of length:
top ring should be within 0.05 mm (0.0020 in). 0.10 mm (0.0039 in)
(A)
(B)
ME-00177
3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
NOTE:
Before measuring the clearance, clean the piston (A)
ring groove and piston ring.
Standard
(B)
mm (in)
Clearance 0.030 — 0.070
Top ring
between (0.0012 — 0.0028)
piston ring ME-00179
and piston 0.030 — 0.070
Second ring
ring groove (0.0012 — 0.0028)
(A) Thickness gauge
(B) Connecting rod

clearance). If side clearance exceeds the limit or
has partial wear, replace the connecting rod.
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
ME-00178
5. CONNECTING ROD
aligner. Replace the connecting rod if the bend or
twist exceeds the limit.
ME-00180
4) Inspect the connecting rod bearing for scar,

peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on individual connect-
ing rod bearings by means of plastigauge. If any oil
clearance is not within the specification, replace the
defective bearing with a new one of standard size
ME(H4DOTC)-82
Cylinder Block
MECHANICAL
Connecting rod oil clearance: ST 499037100 CONNECTING ROD BUSH-

Standard ING REMOVER AND IN-
0.026 — 0.052 mm (0.0010 — 0.0020 in) STALLER
Unit: mm (in)
Bearing size
Outer diameter of
Bearings (Thickness at cen- ST
crank pin
ter)
1.486 — 1.498 51.984 — 52.000
Standard
(0.0585 — 0.0590) (2.0466 — 2.0472)
0.03
1.504 — 1.512 51.954 — 51.970
(0.0012)
(0.0592 — 0.0595) (2.0454 — 2.0461)
undersize
0.05 ME-00182
1.514 — 1.522 51.934 — 51.950
(0.0020)
(0.0596 — 0.0599) (2.0447 — 2.0453) (3) Make two 3 mm (0.12 in) holes in bushing.
undersize
0.25 Ream the inside of bushing.
1.614 — 1.622 51.734 — 51.750 (4) After completion of reaming, clean the bush-
(0.0098)
(0.0635 — 0.0639) (2.0368 — 2.0374)
undersize ing to remove chips.
6) Inspect the bushing at connecting rod small end, 6. CRANKSHAFT AND CRANKSHAFT
and replace if worn or damaged. Also measure the BEARING
piston pin clearance at the connecting rod small 1) Clean the crankshaft completely, and check it for
end. cracks using red lead. Replace if defective.
Clearance between piston pin and bushing: 2) Measure the bend of crankshaft. If it exceeds the
Standard limit, repair or replace it.
0 — 0.022 mm (0 — 0.0009 in) NOTE:
the crankshaft on these bearings, and then mea-
sure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
ME-00181
ME-00183

ME-00174 place or recondition crankshaft as necessary.
7) Replacement procedure is as follows. them to the specified dimensions according to the
(1) Remove the bushing from connecting rod undersize bearing to be used.
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ME(H4DOTC)-83
Cylinder Block
MECHANICAL
Crank pin and crank journal:

Out-of-roundness
0.005 mm (0.0002 in) or less
Cylindricality
0.006 mm (0.0002 in)
Grinding limit (dia.)
51.750 mm (2.0374 in)
ME-00184
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3 #2, #4, #5
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard
Bearing size 1.998 — 2.011 2.000 — 2.013 1.486 — 1.498
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
0.03 (0.0012) (2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
0.05 (0.0020) (2.3599 — 2.3605) (2.3599 — 2.3605) (2.0447 — 2.0453)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
0.25 (0.0098) (2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
O.D. : Outer Diameter
ME(H4DOTC)-84
Cylinder Block
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If clearance exceeds the limit, re-
place the bearing.
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
ME-00313

of flaking, seizure, melting, and wear.
Standard
0.010 — 0.030 mm (0.00039 — 0.0012 in)
ME(H4DOTC)-85
Intake and Exhaust Valve
MECHANICAL
22.Intake and Exhaust Valve

A: SPECIFICATION
Refer to “Cylinder Head” for removal and installa-
tion procedures of intake and exhaust valves. <Ref.
to ME(H4DOTC)-59, REMOVAL, Cylinder Head.>
der Head.>
ME(H4DOTC)-86
Piston
MECHANICAL
23.Piston
A: SPECIFICATION
Refer to “Cylinder Block” for removal and installa-
tion procedures of pistons. <Ref. to ME(H4DOTC)-
66, REMOVAL, Cylinder Block.> <Ref. to
ME(H4DOTC)-69, INSTALLATION, Cylinder
Block.>
ME(H4DOTC)-87
Connecting Rod
MECHANICAL
24.Connecting Rod
A: SPECIFICATION
tion procedures of connecting rod. <Ref. to
ME(H4DOTC)-66, REMOVAL, Cylinder Block.>
der Block.>
ME(H4DOTC)-88
Crankshaft
MECHANICAL
25.Crankshaft
A: SPECIFICATION
tion procedures of crankshaft. <Ref. to
ME(H4DOTC)-66, REMOVAL, Cylinder Block.>
der Block.>
ME(H4DOTC)-89
MECHANICAL

A: INSPECTION
NOTE:
“RANK” shown in the chart refers to the possibility of the cause of trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
Defective ignition starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Run-down battery A
Seized camshaft C
Immobilizer system <Ref. to IM(diag)-2, Basic Diagnostic Procedure.> A
not occur. Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Belt Trouble B
Defective timing B
ME(H4DOTC)-90
MECHANICAL

3) Initial combustion occurs. Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Belt Trouble B
Defective timing B
4) Engine stalls after initial Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Belt Trouble B
Defective timing B
ME(H4DOTC)-91
MECHANICAL

2. Rough idle and engine Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Belt Defective timing C
Cooling System Over-heating C
ME(H4DOTC)-92
MECHANICAL

3. Low output, hesitation and Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line B
Cooling System Over-heating C
Over-cooling C
4. Surging Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line B
Cooling System Over-heating B
ME(H4DOTC)-93
MECHANICAL

5. Engine does not return to Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
6. Dieseling (Run-on) Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Cooling System Over-heating B
7. After burning in exhaust Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Cooling System Over-cooling C
8. Knocking Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Cooling System Over-heating A
Lubrication system Loosened oil pump attaching bolts and defective gas-
B
ket
Defective oil filter O-ring B
ME(H4DOTC)-94
MECHANICAL

10. Excessive fuel consump- Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Cooling System Over-cooling C
ME(H4DOTC)-95
Engine Noise
MECHANICAL
27.Engine Noise
A: INSPECTION
speed increases.
• Worn camshaft
• Worn crankshaft main bearing
• Worn connecting rod bearing (large end)
Heavy and dull clank
• Loose flywheel mounting bolts
Oil pressure is normal.
• Damaged engine mounting
Sound is noticeable when • Accumulation of carbon inside combustion chamber
High-pitched clank
accelerating with an overload. • Wrong spark plug
Sound is reduced when fuel • Worn crankshaft main bearing
(NOTE*)
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Defective generator brush and rotor contact
—
—
folds
• Belt contacting case/adjacent part
Valve tappet noise — • Incorrect valve clearance
NOTE*:
Therefore, carry out the clear memory mode <Ref. to EN(H4DOTC)(diag)-30, OPERATION, Clear Memory Mode.> and inspec-
tion mode <Ref. to EN(H4DOTC)(diag)-28, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H4DOTC)-96
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

EXHAUST
EX(H4DOTC)
Page
2. Front Exhaust Pipe......................................................................................5
3. Center Exhaust Pipe ...................................................................................6
4. Joint Pipe ..................................................................................................10
5. Rear Exhaust Pipe ....................................................................................11
6. Muffler .......................................................................................................12
General Description
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
T1
(2) (3)
T1
(4) T2
(1)
T3
EX-00248
(1) Front exhaust pipe ASSY (3) Turbocharger joint pipe Tightening torque: N!m (kgf-m, ft-lb)
(2) Gasket (4) Front exhaust pipe cover T1: 35 (3.6, 26.0)
T2: 30 (3.1, 22.1)
T3: 7.5 (0.76, 5.5)
EX(H4DOTC)-2
General Description
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
(15)
(15)
(19)
(18)
(15) (21)
(18)
(15) (15)
(17)
(13)
(16)
T6 (20)
(12)
(14)
(10)
T5 T8
(1) A T7
(7)
A
(4)
(22)
(2) (3)
T2
(11)
T4 (6)
(8)
T5 T1 (9)
T5
T1
T3
(5)
EX-02005
(1) Gasket (12) Gasket Tightening torque: N!m (kgf-m, ft-lb)

(2) Front catalytic converter (13) Rear exhaust pipe T1: 13 (1.3, 9.6)
(3) Center exhaust pipe (Front) (14) Chamber T2: 18 (1.8, 13.3)
(4) Front oxygen (A/F) sensor (15) Cushion rubber T3: 23 (2.3, 17.0)
(5) Bracket (16) Spring T4: 30 (3.1, 22.1)
(6) Gasket (17) Bolt T5: 35 (3.6, 26.0)
(7) Center pipe upper cover (Rear) (18) Gasket T6: 48 (4.9, 35.4)
(8) Clamp (19) Muffler (RH) T7: <Ref. to FU(H4DOTC)-33,
(9) Rear catalytic converter lower (20) Self-locking nut INSTALLATION, Front Oxygen
cover (21) Muffler (LH) (A/F) Sensor.>
(10) Rear oxygen sensor (22) Center exhaust pipe (Rear) T8: <Ref. to FU(H4DOTC)-34,
(11) Rear catalytic converter INSTALLATION, Rear Oxygen
Sensor.>
EX(H4DOTC)-3
General Description
EXHAUST
B: CAUTION
points.
cable from battery.
EX(H4DOTC)-4
Front Exhaust Pipe
EXHAUST
2. Front Exhaust Pipe 2) Install the front exhaust pipe assembly to turbo-
charger joint pipe.
35 N!m (3.6 kgf-m, 26.0 ft-lb)
3) Remove the front exhaust pipe cover.
4) Remove the nuts which hold front exhaust pipe
assembly onto turbocharger joint pipe.
EX-00201
3) Install the front exhaust pipe cover.

EX-00201 5) Lower the vehicle.
5) While holding the front exhaust pipe assembly, C: INSPECTION
remove the nuts which hold front exhaust pipe as- 1) Check the connections and welds for exhaust
sembly to cylinder head exhaust port. leaks.
2) Check the rear exhaust pipe for holes or rust.
EX-00202
6) Remove the front exhaust pipe assembly.

B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the front exhaust pipe assembly.
Tightening torque:
30 N!m (3.1 kgf-m, 22.1 ft-lb)
EX-00202
EX(H4DOTC)-5
Center Exhaust Pipe
EXHAUST
3. Center Exhaust Pipe 12) Remove the turbocharger cover.
A: REMOVAL
1) Set the vehicle on a lift. (B)
2) Remove the collector cover. (A)
5) Remove the intercooler bracket.
EX-00249

(B) Turbocharger cover
13) Separate the center exhaust pipe from turbo-

charger.
EX-00203

8) Remove the universal joint bolts and then re-
move the universal joint.
CAUTION:
Scribe alignment marks on the universal joint
so that it can be reassembled at the original
EX-00204
serration.
14) Disconnect the connector from front oxygen (A/
F) sensor.
EX-00008
9) Lower the vehicle. EX-00205

10) Remove the linear motion mounting. <Ref. to
ME(H4DOTC)-37, REMOVAL, Linear Motion 15) Lift-up the vehicle.
Mounting.> 16) Disconnect the connector from rear oxygen
11) Remove the linear motion mounting bracket. sensor.
EX-00206
EX(H4DOTC)-6
Center Exhaust Pipe
EXHAUST
17) Separate the center exhaust pipe from rear ex- 3) Connect the center exhaust pipe to turbocharg-
haust pipe. er.
Tightening torque:
35 N!m (3.6 kgf-m, 26.0 ft-lb)
EX-00207

pipe bracket to transmission. EX-00204
4) Install the center exhaust pipe to rear exhaust

pipe.
Tightening torque:
35 N!m (3.6 kgf-m, 26.0 ft-lb)
EX-00208
19) Remove the intercooler bracket.

CAUTION:
EX-00207
Be careful not to pull down the center exhaust
pipe. 5) Connect the connector to rear oxygen sensor.
EX-00209 EX-00206

B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds center
exhaust pipe to transmission.
EX(H4DOTC)-7
Center Exhaust Pipe
EXHAUST
6) Tighten the bolt which holds center exhaust pipe 12) Connect the connector of front oxygen (A/F)
bracket to transmission. sensor.
Tightening torque:
30 N!m (3.1 kgf-m, 22.1 ft-lb)
EX-00205

EX-00208
14) Install the universal joint.
(1) Align the bolt hole on the long yoke side of
7) Tighten the bolt which holds center exhaust pipe universal joint with the cutout at the serrated
to hanger bracket. section of shaft end, and then insert the univer-
Tightening torque: sal joint.
35 N!m (3.6 kgf-m, 26.0 ft-lb) (2) Align the bolt hole on the short yoke side of
universal joint with the cutout at the serrated
section of gearbox assembly. Lower the univer-
sal joint completely.
(3) Temporarily tighten the bolt of short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at the
serrated section.
(4) Tighten the long yoke side bolt, and also
tighten the short yoke side bolt.
Tightening torque:
EX-00209
24 N!m (2.4 kgf-m, 17.4 ft-lb)
8) Lower the vehicle. CAUTION:
9) Install the turbocharger cover. • Make sure the universal joint bolts are tight-
10) Install the linear motion mounting bracket. ened through the shaft serration notches.
Tightening torque: • Excessively large tightening torque of uni-
T1: 7.4 N!m (0.75 kgf-m, 5.4 ft-lb) versal joint bolts may lead to heavy steering
T2: 40 N!m (4.1 kgf-m, 29.5 ft-lb) wheel operation.
Standard clearance between gearbox and DOJ:
T1 15 mm (0.59 in) or more
(B)
T1
(A)
T1
T1
T2
EX-00250
(A) Linear motion mounting bracket EX-00008

(B) Turbocharger cover
11) Install the linear motion mounting. <Ref. to 16) Lower the vehicle.
ME(H4DOTC)-37, INSTALLATION, Linear Motion
Mounting.>
EX(H4DOTC)-8
Center Exhaust Pipe
EXHAUST
17) Install the intercooler bracket.
EX-00203
18) Install the intercooler. <Ref. to IN(H4DOTC)-

12, INSTALLATION, Intercooler.>
C: INSPECTION
1) Check the connections and welds for exhaust
leaks.
2) Check the rear exhaust pipe for holes or rust.
EX(H4DOTC)-9
Joint Pipe
EXHAUST
4. Joint Pipe C: INSPECTION

A: REMOVAL leaks.
1) Remove the collector cover. 2) Check the rear exhaust pipe for holes or rust.
IN-00203

5) Remove the front exhaust pipe cover.
6) Remove the nuts which hold front exhaust man-
ifold to turbocharger joint pipe.
EX-00201

haust Pipe.>
8) Remove the turbocharger. <Ref. to
IN(H4DOTC)-14, REMOVAL, Turbocharger.>
9) Remove the joint pipe from the lower side of ve-
hicle.
B: INSTALLATION
Tightening torque:
T: 35 N!m (3.6 kgf-m, 26.0 ft-lb)
EX-02019
EX(H4DOTC)-10
Rear Exhaust Pipe
EXHAUST
5. Rear Exhaust Pipe Tightening torque:

35 N!m (3.6 kgf-m, 26.0 ft-lb)
A: REMOVAL
2) Separate the rear exhaust pipe from center ex-
haust pipe.
EX-00207

C: INSPECTION
EX-00207 1) Check the connections and welds for exhaust
3) Separate the rear exhaust pipe from both muf- leaks.
flers. 2) Check the rear exhaust pipe for holes or rust.
3) Check the cushion rubber for wear or crack.
CAUTION:
pipe.
EX-00210

B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the rear exhaust pipe to both mufflers.
Tightening torque:
48 N!m (4.9 kgf-m, 35.4 ft-lb)
EX-00210

pipe.
EX(H4DOTC)-11
Muffler
EXHAUST
6. Muffler C: INSPECTION
A: REMOVAL leaks.
1) Separate the muffler (RH) from rear exhaust 2) Check the mufflers for holes or rust.
pipe. 3) Check the cushion rubber for wear or crack.
EX-00210
2) Remove the cushion rubbers, and detach the

muffler.
CAUTION:
Be careful not to drop the muffler during remov-
al.
NOTE:
To facilitate removal, apply a coat of spray type lu-
bricant to the mating area of cushion rubbers in ad-
vance.
EX-00211
3) Perform the same procedure for muffler (LH).

B: INSTALLATION
NOTE:
Always use a new gasket and self-locking nuts.
Tightening torque:
48 N!m (4.9 kgf-m, 35.4 ft-lb)
EX-00210
EX(H4DOTC)-12
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

FUEL INJECTION
(FUEL SYSTEMS)
FU(H4DOTC)
Page
2. Throttle Body.............................................................................................12
3. Intake Manifold..........................................................................................13
7. Knock Sensor............................................................................................26
9. Mass Air Flow and Intake Air Temperature Sensor ..................................28
11. Fuel Injector ..............................................................................................30
13. Wastegate Control Solenoid Valve ...........................................................32
17. Main Relay ................................................................................................36
18. Fuel Pump Relay.......................................................................................37
20. Fuel Pump Control Unit.............................................................................39
21. Fuel ...........................................................................................................40
22. Fuel Tank ..................................................................................................41
23. Fuel Filler Pipe ..........................................................................................47
24. Fuel Pump.................................................................................................49
27. Fuel Filter ..................................................................................................54
28. Fuel Bypass Valve ....................................................................................55
COOLING
CO(H4DOTC)
Page
3. Engine Coolant..........................................................................................13
4. Water Pump ..............................................................................................15
5. Thermostat ................................................................................................17
6. Radiator.....................................................................................................19
7. Radiator Cap .............................................................................................23
10. Reservoir Tank..........................................................................................30
11. Coolant Filler Tank ....................................................................................31
General Description
COOLING
A: SPECIFICATION
Total engine coolant capacity 2 (US qt, Imp qt) Approx. 7.3 (7.7, 6.4)
Discharge amount
20 (5.3, 4.4)
2 (US gal, Imp gal)/min
Discharge perfor-
Pump speed — Discharge
mance I 760 rpm — 2.9 kPa (0.3 mAq)
pressure
Discharge amount
100 (26.4, 22.0)
Discharge perfor-
mance II 3,000 rpm — 49.0 kPa (5.0 mAq)
pressure
Water pump Engine coolant temperature 85!C (185!F)
Discharge amount
200 (52.8, 44.0)
Discharge perfor-
mance III 6,000 rpm — 225.4 kPa (23.0 mAq)
pressure
Impeller diameter mm (in) 76 (2.99)
Pump pulley diameter mm (in) 60 (2.36)
Clearance between
Standard mm (in) 0.5 — 1.5 (0.020 — 0.059)
impeller and case
Main fan W 90
Motor input
Sub fan W 90
Radiator fan
Type Down flow
Width " Height " Thickness
Core dimensions 687.4 " 340 " 16 (27.06 " 13.39 " 0.63)
mm (in)
Above: 108#15
Coolant filler tank side (1.1#0.15, 16#2)
Radiator Pressure range in Below: $1.0 — $4.9
kPa (kg/cm2, psi)
which cap valve is ($0.01 — $0.05, $0.1 — $0.7)
open
Radiator side Above only: 137#14.7
kPa (kg/cm2, psi) (1.40#0.15, 20#2.1)
Reservoir
tank
CO(H4DOTC)-2
General Description
COOLING

96 — 99!C
95!C (203!F) or less 100!C (212!F) or more
Vehicle speed A/C compressor load (205 — 210!F)
Operation of radiator Operation of radiator Operation of radiator
fan fan fan
19 km/h (12 MPH) or less Low Low-Speed Low-Speed High-Speed
20 — 69 km/h
Low High-Speed High-Speed High-Speed
(12 — 43 MPH)
70 — 105 km/h
Low OFF Low-Speed High-Speed
(43 — 65 MPH)
High Low-Speed High-Speed High-Speed
OFF OFF OFF High-Speed
106 km/h (66 MPH) or more Low OFF Low-Speed High-Speed
High OFF Low-Speed High-Speed
CO(H4DOTC)-3
General Description
COOLING
B: COMPONENT
1. WATER PUMP
T2
(5)
(8)
(4)
T2
T1
T1
(3) (7)
(6)
(2)
T2
(1)
CO-00002
(1) Thermostat cover (5) Gasket Tightening torque: N%m (kgf-m, ft-lb)
(2) Gasket (6) Heater by-pass hose T1: First 12 (1.2, 8.7)
(3) Thermostat (7) Coolant filler by-pass hose Second 12 (1.2, 8.7)
(4) Water pump ASSY (8) Water by-pass pipe T2: 12 (1.2, 8.7)
CO(H4DOTC)-4
General Description
COOLING
(27)
(26)
(25)
(24)
(5)
(5)
T3
T3
(5)
(6) (10)
(8)
(7)
T2
(5)
(29)
(11) T2
T4
(9)
T1
(13) (12)
(4)
(3)
(15) (17)
(2) T3
T1
(14)
(18) (15)
(5) T3 (16)
B (30)
(15)
T3
B
C
(21) (19)
(23)
(22) (1)
(5) C
(28) (15)
(20)
CO-02004
CO(H4DOTC)-5
General Description
COOLING
(1) Radiator lower cushion (14) Radiator main fan ASSY (26) Engine overflow hose
(2) Radiator (15) ATF hose clamp (27) Engine air breather hose
(3) Radiator upper cushion (16) ATF inlet hose A (28) Radiator lower bracket
(4) Radiator upper bracket (17) ATF outlet hose A (29) Overflow hose B
(5) Clamp (18) ATF pipe (30) Heat shield cover
(6) Radiator inlet hose (19) ATF inlet hose B
(7) Engine coolant reservoir tank cap (20) ATF outlet hose B Tightening torque: N%m (kgf-m, ft-lb)
(8) Overflow hose A (21) Radiator outlet hose T1: 3.4 (0.35, 2.5)
(9) Engine coolant reservoir tank (22) Radiator drain plug T2: 4.4 (0.45, 3.3)
(10) Overflow pipe (23) O-ring T3: 7.5 (0.76, 5.5)
(11) Radiator sub fan shroud (24) Engine coolant filler tank T4: 18 (1.8, 13.0)
(12) Radiator main fan shroud (25) Radiator cap (Engine coolant filler
(13) Radiator sub fan ASSY tank cap)
C: CAUTION
points.
cable from battery.
CO(H4DOTC)-6
General Description
COOLING
D: PREPARATION TOOL
499977400 CRANK PULLEY Used for stopping crank pulley when loosen-
WRENCH ing and tightening crank pulley bolts.
ST-499977400
499977500 CAM SPROCKET Used for removing and installing the intake
WRENCH and exhaust camshaft sprocket.
ST-499977500
CO(H4DOTC)-7
Radiator Fan System
COOLING

A: WIRING DIAGRAM
SBF-1 SBF-7
No.3 IGNITION
SWITCH
No.2
No.26
No.22
MAIN FUSE BOX (M/B)
MAIN
FAN
RELAY 1 B: B143
C: F35
E: F36
C10
C11
B7
E6
E7
E3
THROUGH JOINT
CONNECTOR
10 1
20 RW
GB
GL
LR
F109 B360
23
1
MAIN SUB
FAN FAN A/C RELAY HOLDER
2
RELAY 2 RELAY F27

MAIN FAN
M MOTOR
21
22
F17
3
5
BW
YG
RL
RL
B
1
THROUGH JOINT
CONNECTOR
16 7
F16 F108 B361

1
B25
B24
E E
M B135
ECM
SUB FAN MOTOR
F16 B361 B360 F108 F109 F27
F17 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 1
7 8 9 10 11 12 13 14 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 20 21 22 23 24 2 4 5
2 1 3 6
B135 10 13 7
8 9 11 14 16 17
B: B143 C: F35 E: F36 1 2 3 4 5 6 7 12 15
8 9 10 11 12 13 14 15 16 17 18 19 18 19
24 25 30
1 2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 3 20 21 22 23 24 25 26 27 28 29
22 26 31
10 11 12 13 14 15 16 17 18 19 20 6 7 8 9 10 11 12 4 5 6 7 28 29 30 31 32 33 34 35 20 21
23 27
CO-00298
CO(H4DOTC)-8
Radiator Fan System
COOLING
B: INSPECTION
TROUBLE SYMPTOMS:
Radiator main and sub fan do not rotate under the above conditions.
Step Check Yes No

1 CHECK OPERATION OF RADIATOR FAN. Do the radiator main fan and Go to step 2. Go to step 3.
1) Connect the test mode connector. sub fan rotate at low speed?
Monitor.
NOTE:
revolution &'high speed revolution &'OFF in
this order.
• Refer to Compulsory Valve Operation Check
EN(H4DOTC)(diag)-31, Compulsory Valve
Operation Check Mode.>
2 CHECK OPERATION OF RADIATOR FAN. Do the radiator main fan and Radiator fan sys- Go to step 27.
1) Connect the test mode connector. sub fan rotate at high speed? tem is normal.
Monitor.
NOTE:
revolution & high speed revolution &'OFF in
this order.
• Refer to Compulsory Valve Operation Check
LAY.
2) Remove the sub fan relay from A/C relay
holder.
LAY.
CO(H4DOTC)-9
Radiator Fan System
COOLING
Step Check Yes No

7 CHECK SUB FAN RELAY. Is the resistance more than 1 Go to step 8. Replace the sub
1) Turn the ignition switch to OFF. M(? fan relay.
relay terminals.
Terminals
No. 20 — No. 21:
8 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 9. Replace the sub
1) Connect the terminals No. 22 and No. 23 of (? fan relay.
sub fan relay to battery.
relay terminals.
Terminals
No. 20 — No. 21:
LAY TERMINAL AND SUB FAN MOTOR (? circuit of harness
CONNECTOR. between sub fan
1) Disconnect the connector from sub fan relay terminal and
motor. sub fan motor con-
between sub fan relay terminal and sub fan
motor connector.
(F16) No. 2 — (F27) No. 21:
10 CHECK HARNESS BETWEEN SUB FAN MO- Is the resistance less than 1 Go to step 11. Repair the open
TOR CONNECTOR AND MAIN FAN RELAY 2 (? harness between
CONNECTOR. sub fan motor con-
1) Remove the main fan relay 2 from A/C relay nector and main
holder. fan relay 2 connec-
2) Measure the resistance of harness tor.
between sub fan motor connector and main fan
relay 2 connector.
(F16) No. 1 — (F27) No. 5:
11 CHECK POOR CONTACT. Is there poor contact in sub fan Repair the poor Go to step 12.
Check the poor contact in sub fan motor con- motor connector? contact in sub fan
nector. motor connector.
12 CHECK SUB FAN MOTOR. Does the sub fan rotate? Go to step 13. Replace the sub
minal No. 2 of sub fan motor, and the ground ($
) terminal to terminal No. 1.
Measure the resistance of main fan relay 2. (? fan relay 2.
Terminals
No. 2 — No. 5:
CO(H4DOTC)-10
Radiator Fan System
COOLING
Step Check Yes No

motor. and main fan
(F17) No. 2 — (F27) No. 2:
15 CHECK MAIN FAN MOTOR AND GROUND Is the resistance less than5 (? Go to step 16. Repair the open
CIRCUIT. circuit in harness
motor connector and chassis ground. motor connector
Connector & terminal and chassis
(F17) No. 1 — Chassis ground: ground.
16 CHECK POOR CONTACT. Is there poor contact in main Repair the poor Go to step 17.
Check poor contact in main fan motor connec- fan motor connector? contact in main fan
tor. motor connector.
17 CHECK MAIN FAN MOTOR. Does the main fan rotate? Go to step 18. Replace the main
minal No. 2 of main fan motor, and the ground
($) terminal to terminal No. 1.
LAY AND ECM. (? circuit in harness
1) Disconnect the connector from ECM. between sub fan
2) Measure the resistance between sub fan relay terminal and
relay terminal and ECM connector. ECM.
(B135) No. 25 — (F27) No. 22:
19 CHECK POOR CONTACT. Is there a poor contact in ECM Repair the poor Check the DTC.
Check poor contact in ECM connector. connector? contact in ECM Repair the trouble
connector. cause. <Ref. to
EN(H4DOTC)(diag
)-27, Read Diag-
nostic Trouble
Code (DTC).>
holder.
fan relay 1 switch.
1) Connect the terminal of main fan relay 1 (? fan relay 1.
coil side terminal to battery.
motor. and main fan
(F17) No. 2 — (F36) No. 6:
CO(H4DOTC)-11
Radiator Fan System
COOLING
Step Check Yes No

1) Disconnect the connector from ECM. between main fan
2) Measure the resistance between main fan relay 1 terminal
relay 1 terminal and ECM connector. and ECM.
(B135) No. 24 — (B143) No. 7:
relay 2 terminal and ECM connector. relay 2 terminal
Connector & terminal and ECM.
(B135) No. 24 — (F27) No. 3:
25 CHECK FUSE. Is the fuse blown out? Replace the fuse. Go to step 26.
2) Remove the fuse No. 2 and No. 26.
26 CHECK POOR CONTACT. Is there a poor contact in ECM Repair the poor Repair the power
Check poor contact in ECM connector. connector? contact in ECM supply circuit for
connector. main fuse box.
27 CHECK OPERATION OF RADIATOR FAN. Does the sub fan rotate? Go to step 20. Go to step 28.
Check the sub fan rotates when both fans do
not rotate at high speed under the step 2.
28 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 1 Go to step 29. Repair the open
RELAY 2. (? circuit in harness
1) Remove the main fan relay 2 from A/C relay between main fan
holder. relay 2 and chas-
2) Measure the resistance between main fan sis ground.
29 CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 30. Repair the power
LAY 2. supply line.
2) Measure the voltage between main fan
2) Remove the main fan relay 2.
Terminals
(F27) No. 4 — (F27) No. 5:
1) Connect the battery to terminals No. 1 and (? fan relay 2.
No. 3 of main fan relay 2.
Terminals
(F27) No. 4 — (F27) No. 5:
CO(H4DOTC)-12
Engine Coolant
COOLING
3. Engine Coolant 4) Warm up the engine completely for more than

five minutes at 2,000 to 3,000 rpm.
A: REPLACEMENT 5) If the engine coolant level drops in coolant filler
tank, add engine coolant to filler neck position.
1. DRAINING OF ENGINE COOLANT 6) If the engine coolant level drops from “FULL” lev-
1) Lift-up the vehicle. el of reservoir tank, add engine coolant to “FULL”
2) Remove the under cover. level.
3) Remove the drain plug to drain engine coolant 7) Attach the coolant filler tank cap and reservoir
into container. tank cap properly.
NOTE: 8) Install the collector cover.
Remove the coolant filler tank cap so that engine
coolant will drain faster.
CO-00248
4) Install the drain plug.

2) Fill engine coolant into coolant filler tank up to
the filler neck position.
CAUTION:
Do not confuse the cap of coolant filler tank and
cap of radiator.
NOTE:
• When pouring the engine coolant, the radiator
side cap must not be removed.
• The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
3) Fill engine coolant into the reservoir tank up to
“FULL” level.
FULL
FULL
LOW
LOW
CO-00010
CO(H4DOTC)-13
Engine Coolant
COOLING
B: INSPECTION 2. PROCEDURE TO ADJUST THE CON-

1. RERATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEM- To adjust the concentration of coolant according to
PERTAURE temperature, find the proper fluid concentration in
Concentration and safe operating temperature of amount of coolant with an undiluted solution of
SUBARU coolant is shown in the diagram. Measur- SUBARU genuine coolant (concentration 50%).
ing the temperature and specific gravity of the cool- The amount of coolant that should be replaced can
ant will provide this information. be determined using the diagram.
[Example] [Example]
If the coolant temperature is 25!C (77!F) and its Assume that the coolant concentration must be in-
specific gravity is 1.054, the concentration is 45% creased from 25% to 40%. Find point A, where the
(point A), the safe operating temperature is $14!C 25% line of coolant concentration intersects with
(7!F) (point B), and the freezing temperature is $ the 40% curve of the necessary coolant concentra-
20!C ($4!F) (point C). tion, and read the scale on the vertical axis of the
Specific gravity
Safe operating temperature drained is 2.1 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1
of coolant
Concentration
of coolant ing system and add 2.1 2 (2.2 US qt, 1.8 Imp qt) of
1.100 If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
1.090
only.
1.080
60%
1.070 B
C
1.060 50%
(1.054)
A
1.050
40%
1.040
Freezing Necessary Concentration
1.030 30% of coolant
temperature
1.020
20% 3
(77 F)
1.010 (3.2,
25 C
45%
10% 2.6) A
1.000 40%
-40 -30 -20 -10 0 10 20 30 40 50 2 35%
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (2.1,
1.8) 30%
1 25%
(1.1, 20%
0.9)
10% 15%
0
10 20 30 40 50
the vehicie cooling system %
Concentration of coolant in vehicie

and quantity to be drained
CO-00012
CO(H4DOTC)-14
Water Pump
COOLING
4. Water Pump 13) Remove the water pump.
A: REMOVAL
2) Remove the radiator. <Ref. to CO(H4DOTC)-19,
REMOVAL, Radiator.>
REMOVAL, V-belt.>
4) Remove the timing belt. <Ref. to ME(H4DOTC)-
5) Remove the automatic belt tension adjuster (A).
6) Remove the belt idler (B). CO-00021
7) Remove the belt idler No. 2 (C). B: INSTALLATION

1) Install the water pump onto cylinder block (LH).
NOTE:
(A) • Always use new gasket.
(B) • When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
(C) First:
12 N%m (1.2 kgf-m, 8.7 ft-lb)
CO-00023
Second:
8) Remove the camshaft position sensor. <Ref. to 12 N%m (1.2 kgf-m, 8.7 ft-lb)
FU(H4DOTC)-25, REMOVAL, Camshaft Position
Sensor.> (F)
(E)
9) Remove the cam sprocket (LH) using ST. <Ref. (A)
to ME(H4DOTC)-51, REMOVAL, Cam Sprocket.> (D)
(C) (B)
ME-02094
2) Install the hose to water pump.

3) Install the belt cover No. 2 (LH).
Tightening torque:
CO-00025 5 N%m (0.5 kgf-m, 3.6 ft-lb)
11) Remove the belt cover No. 2 (LH).
CO-00024
CO-00024
12) Disconnect the hose from water pump.
CO(H4DOTC)-15
Water Pump
COOLING
4) Install the tensioner bracket. C: INSPECTION

Tightening torque: 1) Check the water pump bearing for smooth rota-
25 N%m (2.5 kgf-m, 18.1 ft-lb) tion.
2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or dam-
aged.
4) Inspect the clearance between impeller and
pump case.
Clearance between impeller and pump case:
Standard value
0.5 — 1.5 mm (0.020 — 0.059 in)
CO-00025
5) Install the cam sprocket (LH) using ST. <Ref. to

ME(H4DOTC)-51, INSTALLATION, Cam Sprock-
et.>
6) Install the camshaft position sensor. <Ref. to
FU(H4DOTC)-25, INSTALLATION, Camshaft Po-
sition Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B). CO-00293
9) Install the automatic belt tension adjuster (A) 5) After water pump installation, check the pulley
which has a tension rod held by a pin. <Ref. to shaft for engine coolant leaks and noise. If leaks or
ME(H4DOTC)-44, AUTOMATIC BELT TENSION noise are noted, replace the water pump assembly.
ADJUSTER ASSEMBLY AND BELT IDLER, IN-
STALLATION, Timing Belt.>
Tightening torque:
39 N%m (4.0 kgf-m, 28.9 ft-lb)
(A)
(B)
(C)
CO-00023
10) Install the timing belt. <Ref. to ME(H4DOTC)-

45, TIMING BELT, INSTALLATION, Timing Belt.>
12) Install the radiator. <Ref. to CO(H4DOTC)-20,
CO(H4DOTC)-16
Thermostat
COOLING
5. Thermostat 6) Remove the thermostat cover, and then remove

the gasket and thermostat.
A: REMOVAL
<Ref. to CO(H4DOTC)-13, DRAINING OF EN-
ant.>
(C)
(B)
CO-00248
5) Disconnect the radiator outlet hose from the (A)

thermostat cover.
CO-00154

(B) Gasket
(C) Thermostat
B: INSTALLATION
1) Install the gasket to thermostat, and install the
thermostat and gasket to water pump as a unit.
Then, install the thermostat cover.
CO-00249
NOTE:
• When reinstalling the thermostat, use a new gas-
ket.
• The thermostat must be installed with the jiggle
pin facing upward.
CO(H4DOTC)-17
Thermostat
COOLING
Tightening torque: Valve lift:

12 N%m (1.2 kgf-m, 8.7 ft-lb) 9.0 mm (0.354 in) or more
(A)
(B)
CO-00033
(D)
(A) Thermometer
(B) Thermostat
T
(C)
(B)
(A)
CO-00155

(B) Gasket
(C) Thermostat
(D) Jiggle pin
2) Connect the radiator outlet hose to thermostat

cover.
5) Fill with engine coolant. <Ref. to CO(H4DOTC)-
C: INSPECTION
ature distribution. The measurement should be to
the specification.
Starting temperature to open:
76 — 80!C (169 — 176!F)
Fully opens:
91!C (196!F)
CO(H4DOTC)-18
Radiator
COOLING
6. Radiator 8) Disconnect the connectors of radiator main fan

motor (A) and sub fan motor (B).
A: REMOVAL
WARNING:
(A)
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
CO-00251
(B)
IN-00203

6) Remove the heat shield cover from radiator. CO-00252
9) Disconnect the ATF cooler hoses from ATF

pipes.
Plug the ATF pipe to prevent ATF leaks.
CO-00250

<Ref. to CO(H4DOTC)-13, DRAINING OF EN-
GINE COOLANT, REPLACEMENT, Engine Cool- CO-00253
ant.> 10) Disconnect the radiator outlet hose from ther-
mostat cover.
CO-00249

IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
CO(H4DOTC)-19
Radiator
COOLING
14) Remove the reservoir tank. <Ref. to B: INSTALLATION

CO(H4DOTC)-30, REMOVAL, Reservoir Tank.> 1) Attach the radiator lower cushions to holes on
15) Disconnect the radiator inlet hose (A) from ra- the radiator lower bracket.
diator.
16) Remove the hood stay holder (B).
(A)
(B)
CO-00041
CO-00255
17) Disconnect the two coolant filler tank hoses NOTE:
from radiator. Make pins on the lower side of radiator be fitted into
the bolts.
Tightening torque:
18 N%m (1.8 kgf-m, 13.0 ft-lb)
CO-00256
CO-00040
4) Connect the two coolant filler tank hoses to radi-

ator.
CO-00040
19) While lifting the radiator up, slide it to the left.

CO-00256
5) Connect the radiator inlet hose (A).
CO(H4DOTC)-20
Radiator
COOLING
6) Install the hood stay holder (B). 13) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
(A)
(A)
(B)
CO-00255
CO-00251
7) Install the reservoir tank. <Ref. to
CO(H4DOTC)-30, INSTALLATION, Reservoir
Tank.>
(B)
9) Install the air intake duct.
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
take Duct.>
11) Connect the ATF cooler hoses.
CO-00252
14) Install the heat shield cover.
CO-00253
12) Connect the radiator outlet hose.
CO-00250

CO-00249
IN-00203

19) Check the ATF level. <Ref. to 5AT-27, IN-
SPECTION, Automatic Transmission Fluid.>
CO(H4DOTC)-21
Radiator
COOLING
C: INSPECTION
1) Remove the coolant filler tank cap and fill engine
coolant to coolant filler tank, then attach the tester
to radiator in place of cap.
CO-00257

to the radiator to check if:
• Engine coolant leaks at or around radiator.
tions.
CAUTION:
• Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
vance.
• Be careful not to deform the filler neck of
coolant filler tank when installing or removing
the tester.
CO(H4DOTC)-22
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
CO-00044

Coolant filler tank side
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
83 kPa (0.85 kg/cm2, 12 psi)
Radiator side
Standard pressure:
122 — 152 kPa (1.24 — 1.55 kg/cm2, 18 —
22 psi)
112 kPa (1.14 kg/cm2, 16 psi)
CAUTION:
• Be sure to remove foreign matter and rust
from the cap in advance. Otherwise, results of
pressure test will be incorrect.
• Not to confuse the cap of coolant filler tank
and cap of radiator.
CO(H4DOTC)-23
COOLING
8. Radiator Main Fan and Fan 8) Remove the ATF hose from the clip of radiator
main fan motor assembly.
Motor
A: REMOVAL
CO-00258

IN-00203 12) Remove the over flow pipe.
3) Lift-up the vehicle. 13) Remove the reservoir tank. <Ref. to
4) Remove the under cover. CO(H4DOTC)-30, REMOVAL, Reservoir Tank.>
5) Disconnect the main fan motor connector (A). 14) Remove the mounting bolts from radiator main
fan motor assembly.
(A)
CO-00251
CO-00259
6) Remove the heat shield cover from radiator.
15) Disconnect the radiator inlet hose (A) from ra-
diator.
(A)
CO-00250
(B)
7) Drain the coolant about 1 2 (1.06 US qt, 0.88
Imp qt). <Ref. to CO(H4DOTC)-13, DRAINING OF CO-00255
ENGINE COOLANT, REPLACEMENT, Engine
Coolant.> 17) Remove the radiator main fan motor assembly
from vehicle.
CO(H4DOTC)-24
COOLING
B: INSTALLATION 12) Connect the main fan motor connector (A).

1) Install the radiator main fan motor assembly to
vehicle.
2) Connect the radiator inlet hose (A) to radiator. (A)
3) Install the hood stay holder (B).
(A)
CO-00251

(B) 14) Lower the vehicle.
CO-00255
4) Install the mounting bolts of radiator main fan

motor assembly.
IN-00203

CO-00259 COOLANT, REPLACEMENT, Engine Coolant.>
5) Install the reservoir tank. <Ref. to 17) Install the collector cover.
CO(H4DOTC)-30, INSTALLATION, Reservoir
Tank.>
6) Install the over flow pipe.
10) Attach the ATF hose to the clip of radiator main
fan motor assembly.
11) Install the heat shield cover to radiator.
CO-00250
CO(H4DOTC)-25
COOLING
C: DISASSEMBLY D: ASSEMBLY
1) Remove the clip which holds fan motor connec- Assemble in the reverse order of disassembly.
tor onto shroud.
Tightening torque:
2) Remove the nut which holds fan itself onto fan
4.4 N%m (0.45 kgf-m, 3.3 ft-lb)
CO-00102 CO-00050
3) Remove the bolts which hold fan motor onto Tightening torque:
shroud. 3.4 N%m (0.35 kgf-m, 2.5 ft-lb)
CO-00050 CO-00102
CO(H4DOTC)-26
COOLING
9. Radiator Sub Fan and Fan 14) Remove the mounting bolts of radiator sub fan
motor assembly.
Motor
A: REMOVAL
CO-00292
15) Disconnect the radiator inlet hose (A) from ra-

diator.
IN-00203
3) Lift-up the vehicle. (A)

5) Disconnect the sub fan motor connector (B).
(B)
(B)
CO-00255
17) Remove the radiator sub fan motor assembly

from vehicle.
B: INSTALLATION
CO-00252
1) Install the radiator sub fan motor assembly to ve-
6) Remove the heat shield cover from radiator. hicle.
2) Connect the radiator inlet hose (A) to radiator.
3) Install the hood stay holder (B).
(A)
CO-00250 (B)
7) Drain the coolant about 1 2 (1.06 US qt, 0.88

Imp qt). <Ref. to CO(H4DOTC)-13, DRAINING OF CO-00255
Coolant.>
sub fan motor assembly.
12) Remove the over flow pipe.
13) Remove the reservoir tank. <Ref. to
CO(H4DOTC)-30, REMOVAL, Reservoir Tank.>
CO(H4DOTC)-27
COOLING
4) Install the mounting bolts of radiator sub fan mo- 15) Connect the battery ground cable to battery.
tor assembly.
IN-00203
CO-00292
5) Install the reservoir tank. <Ref. to <Ref. to CO(H4DOTC)-13, FILLING OF ENGINE
CO(H4DOTC)-30, INSTALLATION, Reservoir COOLANT, REPLACEMENT, Engine Coolant.>
Tank.> 17) Install the collector cover.
6) Install the over flow pipe.
C: DISASSEMBLY
1) Remove the clip which holds fan motor connec-
tor onto shroud.
10) Attach the ATF hose to the clip of radiator sub
fan motor assembly.
11) Install the heat shield cover to radiator.
CO-00097
CO-00250 3) Remove the bolts which hold fan motor onto

shroud.
12) Connect the sub fan motor connector (B).
(B)
CO-00050
CO-00252

CO(H4DOTC)-28
COOLING
D: ASSEMBLY
Tightening torque:
4.4 N%m (0.45 kgf-m, 3.3 ft-lb)
CO-00050
Tightening torque:
3.4 N%m (0.35 kgf-m, 2.5 ft-lb)
CO-00097
CO(H4DOTC)-29
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Disconnect the over flow hose (A).
3) Pull out the reservoir tank to the arrow direction
while pushing the claw (B).
(B) (A)
CO-00263
B: INSTALLATION
C: INSPECTION
CO(H4DOTC)-30
Coolant Filler Tank
COOLING
11.Coolant Filler Tank

A: REMOVAL
WARNING:
2) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Imp qt). <Ref. to CO(H4DOTC)-13, DRAINING OF
Coolant.>
3) Disconnect the engine coolant hoses from cool-
ant filler tank.
4) Remove the bolts which install the coolant filler
tank.
5) Disconnect the engine coolant hose which con-
nects the under side of coolant filler tank.
CO-00264
B: INSTALLATION
Tightening torque:
16 N%m (1.6 kgf-m, 11.8 ft-lb)
CO-00264
2) Fill with engine coolant. <Ref. to CO(H4DOTC)-

CO(H4DOTC)-31
COOLING

A: INSPECTION
b. Loose timing belt Repair or replace 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
g. Improper ignition timing EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
Over-heating h. Clogged or leaking radiator Clean, repair or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
Inspect and repair the fuel injection system. <Ref. to
j. Air/fuel mixture ratio too lean EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
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 Adjustment.
o. Defective radiator fan
sensor or radiator motor and replace there.
Over-cooling
a. Loosened or damaged connecting units on hoses Repair or replace.
c. Leakage from water pipe Repair or replace.
Engine coolant
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.
Noise
CO(H4DOTC)-32
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

LUBRICATION
LU(H4DOTC)
Page
3. Engine Oil....................................................................................................8
4. Oil Pump .....................................................................................................9
8. Engine Lubrication System Trouble in General.........................................18
General Description
LUBRICATION
A: SPECIFICATION
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter ! thickness mm (in) 78 ! 12 (3.07 ! 0.47)
Tip clearance between inner and outer rotors mm (in) 0.04 — 0.14 (0.0016 — 0.0055)
Side clearance between inner rotor and pump case mm (in) 0.02 — 0.07 (0.0008 — 0.0028)
Case clearance between outer
Oil pump rotor and pump case
Discharge
pressure kPa (kg/cm2, psi) 98 (1.0, 14)
600 rpm
Performance at! Discharge 2 (US qt, Imp qt)/min. 6.5 (6.9, 5.7) or more
80"C (176"F) Discharge
kPa (kg/cm2, psi) 588 (6.0, 85)
6,000 rpm pressure
Discharge 2 (US qt, Imp qt)/min. 59.0 (62.3, 51.9) or more
Relief valve working pressure 2, 588 (6.0, 85)
kPa (kg/cm psi)
Outer diameter
800 (124)
68 mm (2.68 in)
Filtration area cm2 (sq in)
Outer diameter
470 (72.9)
65 mm (2.56 in)
Oil filter By-pass valve opening pressure kPa (kg/cm2, psi) 160 (1.63, 23.2)
Outer diameter
68 ! 65 (2.68 ! 2.56)
68 mm (2.68 in)
Outer diameter ! width mm (in)
Outer diameter
65 ! 74.4 (2.56 ! 2.93)
65 mm (2.56 in)
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure kPa (kg/cm2, psi) 14.7 (0.15, 2.1)
Proof pressure kPa (kg/cm2,psi) 981 (10, 142) or more
Recommended oil
API classification
SL or SJ or SH with the words “Energy Con- SAE (1)
serving or Energy conserving II”, CCMC ( C) -30 -20 -15 0 15 30 40
specification G4 or G5, ACEA specification ( F) -22 -4 5 32 59 86 104
A1, A2 or A3, or New API mark displayed on
10W-30
the container (If it is impossible to get SL or
SJ or SH grade, you may use SG grade.) 5W-30
LU-00206
LU(H4DOTC)-2
General Description
LUBRICATION
B: COMPONENT
(13)
T6
(26)
T3
(14)
(15)
(12)
T3
(11)
(28) (27) (16)
T5 T7
(17)
T3
(10)
(9) (18)
T4
(8) T2 (23)
(19)
(20)
(7) (21)
(6)
(22)
T4
(5)
(4) (2)
T1
T1
(24)
(3) T5
(1) T5 (25)
LU-02022
(1) Plug (14) Oil filler duct (27) Plug

(2) Gasket (15) O-ring (28) Connector
(3) Relief valve spring (16) Rocker cover
(4) Relief valve (17) Baffle plate Tightening torque: N#m (kgf-m, ft-lb)
(5) Oil seal (18) O-ring T1: 5 (0.5, 3.6)
(6) Oil pump case (19) Oil strainer T2: 5.4 (0.55, 4.0)
(7) Inner rotor (20) Gasket T3: 6.4 (0.65, 4.7)
(8) Outer rotor (21) Oil level gauge guide T4: 10 (1.0, 7.0)
(9) Oil pump cover (22) Oil pan T5: 44 (4.5, 32.5)
(10) Oil filter (23) Oil level gauge T6: 25 (2.5, 18.1)
(11) O-ring (24) Metal gasket T7: 70 (7.1, 51.6)
(12) Oil pump ASSY (25) Drain plug
(13) Oil pressure switch (26) Oil filler cap
LU(H4DOTC)-3
General Description
LUBRICATION

D: PREPARATION TOOL
1. SPECIAL TOOL
WRENCH removing and tightening crank pulley bolt.
ST-499977400
499587100 OIL SEAL Used for installing oil seal into oil pump.
INSTALLER
ST-499587100
ST18332AA000
LU(H4DOTC)-4
General Description
LUBRICATION

ST18332AA010
LU(H4DOTC)-5
Oil Pressure System
LUBRICATION

A: WIRING DIAGRAM
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
A4
A3
COMBINATION
METER
WARNING LIGHT
OIL PRESSURE
A: i10
A15
i3
17
B38
B21
31
E2
E11
E
OIL PRESSURE
SWITCH
B21
B72 A: i10 B38
1 2 3 4 5 6 7 8 9 10 11
1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21 22
4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
LU-00241
LU(H4DOTC)-6
Oil Pressure System
LUBRICATION
B: INSPECTION
Step Check Yes No
1)Turn the ignition switch to ON (engine OFF). nate? the combination
2)Check the warning light of combination meter. <Ref. to IDI-
meter. 3, INSPECTION,
Combination
Meter System.>
SURE SWITCH.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from oil pressure
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage of harness between
combination meter connector and chassis
ground.
(E11) No. 1 (+) — Chassis ground ($):
1)Turn the ignition switch to OFF. %? ness connector the combination
2)Remove the combination meter. between combina- meter. <Ref. to IDI-
3)Measure the resistance of combination tion meter and oil 3, INSPECTION,
Terminals Meter System.>
No. 4 — No. 15:
No. 3 — No. 15:
LU(H4DOTC)-7
Engine Oil
LUBRICATION
3. Engine Oil 4) Tighten the engine oil drain plug after draining
engine oil.
A: INSPECTION NOTE:
1) Park the vehicle on a level surface. Use a new metal gasket.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that Tightening torque:
the level gauge is correctly inserted and properly 44 N#m (4.5 kgf-m, 32.5 ft-lb)
orientated.
4) Remove it again and check the engine oil level. If
the engine oil level is below “L” line, add oil to bring
the level up to “F” line.
for the oil to return to the oil pan before checking
the level.
and notch mark. This is caused by thermal expan-
sion of the engine oil. LU-00219
NOTE: 5) Use the engine oil of proper quality and viscosi-

To prevent overfilling the engine oil, do not add oil ty, fill engine oil through the oil filler duct to upper
above “F” line when the engine is cold. point on level gauge. Make sure that the vehicle is
(A)
(B) Recommended oil:
<Ref. to LU(H4DOTC)-2, SPECIFICATION,
(C)
Engine oil capacity:
(E)
Upper level
(D) 4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 2 (3.2 US qt, 2.6 Imp qt)
LU-00213 6) Close the engine oil filler cap.
(A) Oil level gauge 8) After the engine stops, recheck the oil level. If
(B) Engine oil filler cap necessary, add engine oil up to the upper level on
(C) Upper level level gauge.
(D) Lower level
(E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) (B)
(A)
B: REPLACEMENT
1) Open the engine oil filler cap for quick draining of (C)
engine oil. (E)
3) Drain engine oil by loosening the engine oil drain (D)
plug.
LU-00213
(A) Oil level gauge

(C) Upper level
(D) Lower level
LU-00219
LU(H4DOTC)-8
Oil Pump
LUBRICATION
4. Oil Pump 9) Remove the crank pulley by using ST. <Ref. to

A: REMOVAL
LU-00012
10) Remove the water pump. <Ref. to

CO(H4DOTC)-15, REMOVAL, Water Pump.>
IN-00203 11) Remove the timing belt guide.
5) Remove the radiator. <Ref. to CO(H4DOTC)-19,
REMOVAL, Radiator.>
LU-00013
LU-00046

REMOVAL, V-belt.>
8) Remove the rear side V-belt tensioner.
LU-00014
13) Remove the bolts which hold oil pump onto cyl-
inder block.
LU-00011
LU-00015
14) Remove the oil pump by using flat bladed

screwdriver.
LU(H4DOTC)-9
Oil Pump
LUBRICATION
CAUTION: Tightening torque:

Be careful not to scratch mating surfaces of 6.4 N#m (0.65 kgf-m, 4.7 ft-lb)
T
LU-00019
LU-00016
C: DISASSEMBLY
B: INSTALLATION Remove the screws which secure oil pump cover
Install in the reverse order of removal. and then disassemble oil pump. Inscribe alignment
Perform the following. marks on the inner and outer rotors so that they can
1) Apply liquid gasket to the matching surfaces of be replaced in their original positions during reas-
oil pump. sembly.
Liquid gasket: CAUTION:
THREE BOND 1215 (Part No. 004403007) or Before disassembling the oil pump, remove the
equivalent relief valve.
(E)
(D)
(C)
(B)
(A)
LU-00017
(A)
2) Replace the O-ring (A) with a new one.
3) Apply a coat of engine oil to the inside of oil seal. (F) (I)
(G)
(H)
LU-00020
ME-00312
(A) Oil seal
(B) Pump case
4) Position the oil pump, aligning the notched area
(C) Inner rotor
with crankshaft, and push the oil pump straight.
(D) Outer rotor
CAUTION: (E) Pump cover
• Make sure the oil seal lip is not folded. (F) Relief valve
• Be careful not to scratch oil seal when install- (G) Relief valve spring
ing oil pump on cylinder block.
(H) Plug
5) Install the oil pump. (I) Gasket
LU(H4DOTC)-10
Oil Pump
LUBRICATION
D: ASSEMBLY E: INSPECTION
1) Install the front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER
1. TIP CLEARANCE
NOTE: Measure the tip clearance of rotors. If the clearance
Use a new oil seal. exceeds the standard value, replace the rotors as a
matched set.
Tip clearance:
Standard value
0.04 — 0.14 mm (0.0016 — 0.0055 in)
ST
LU-00021
2) Apply a coat of engine oil to the inner and outer

rotors.
3) Install the inner and outer rotors in their original
positions. LU-00023
4) Install the oil relief valve and relief valve spring 2. CASE CLEARANCE
and plug.
Measure the clearance between outer rotor and oil
NOTE: pump rotor housing. If the clearance exceeds the
Use a new gasket. standard value, replace the oil pump case.
5) Install the oil pump cover.
Case clearance:
Tightening torque: Standard value
T1: 5.4 N#m (0.55 kgf-m, 4.0 ft-lb) 0.10 — 0.175 mm (0.0039 — 0.0069 in)
T2: 44 N#m (4.5 kgf-m, 32.5 ft-lb)
T1
LU-00024
T2
LU-00022
LU(H4DOTC)-11
Oil Pump
LUBRICATION
3. SIDE CLEARANCE
Measure the clearance between oil pump inner ro-
tor and pump cover. If the clearance exceeds the
standard value, replace the rotor or pump body.
Side clearance:
Standard value
0.02 — 0.07 mm (0.0008 — 0.0028 in)
LU-00025
4. OIL RELIEF VALVE

Check the valve for fitting condition and damage,
and the relief valve spring for damage and deterio-
ration. Replace the parts if defective.
Relief valve spring:
Free length
73.7 mm (2.902 in)
Installed length
54.7 mm (2.154 in)
Load when installed
93.1 N (9.49 kgf, 20.88 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.
LU(H4DOTC)-12
LUBRICATION
5. Oil Pan and Strainer 10) Remove the radiator upper brackets.
A: REMOVAL
2) Remove the front wheels.
CO-00040

wire ropes.
IN-00203
5) Disconnect the connector from mass airflow

sensor.
6) Remove the air intake boot and air cleaner upper
cover.
LU-00222

CAUTION:
When lifting up the vehicle, raise up wire ropes
at the same time.
14) Drain engine oil.
LU-00220 15) Remove the front exhaust pipe.
<Ref. to EX(H4DOTC)-5, REMOVAL, Front Ex-
7) Remove the intercooler.
haust Pipe.>
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool-
er.>
LU-02023
LU-00221
17) Remove the bolts which install oil pan on cylin-
der block with the engine raised up.
<Ref. to ME(H4DOTC)-37, REMOVAL, Linear Mo-
18) Insert the oil pan cutter blade into the clearance
tion Mounting.>
between cylinder block and oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
LU(H4DOTC)-13
LUBRICATION
20) Remove the baffle plate. 3) Apply liquid gasket to the mating surfaces and
install the oil pan.
(D)
Liquid gasket:
equivalent
(C)
(B)
LU-00034
(A) 4) Tighten the bolts which install oil pan onto en-
gine block.
Tightening torque:
5 N#m (0.5 kgf-m, 3.6 ft-lb)
LU-00189
(D)
(A) Oil pan
(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
B: INSTALLATION
CAUTION: (C)
Before installing the oil pan, wipe clean the oil
pan and the mating face of engine block.
1) Install the baffle plate. (B)
Tightening torque:
6.4 N#m (0.65 kgf-m, 4.7 ft-lb)
2) Install the oil strainer onto baffle plate. (A)
NOTE:
Tightening torque:
10 N#m (1.0 kgf-m, 7.2 ft-lb) LU-00189
(A) Oil pan

(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
5) Lower the engine onto front crossmember.

6) Tighten the nuts which hold front cushion rubber
onto front crossmember.
LU(H4DOTC)-14
LUBRICATION
Tightening torque: 13) Install the radiator upper brackets.

83 N#m (8.5 kgf-m, 61 ft-lb)
CO-00040
LU-02023 14) Install the intercooler. <Ref. to IN(H4DOTC)-
7) Install the front exhaust pipe. 12, INSTALLATION, Intercooler.>
<Ref. to EX(H4DOTC)-5, INSTALLATION, Front 15) Install the air intake boot and air cleaner upper
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-8, INSTAL- cover.
LATION, Front Exhaust Pipe.> 16) Connect the connector to mass air flow sensor.
CAUTION:
When lowing the vehicle, lower the lift-up de-
vice and wire ropes at the same time.
LU-00220
17) Install the front wheels.

LU-00222

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)
IN-00203
20) Fill engine oil. <Ref. to LU(H4DOTC)-8, IN-

SPECTION, Engine Oil.>
C: INSPECTION
T2
Visually check that the oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
T1
LU-00224
12) Install the linear motion mounting.

<Ref. to ME(H4DOTC)-37, INSTALLATION, Linear
Motion Mounting.>
LU(H4DOTC)-15
Oil Pressure Switch
LUBRICATION
6. Oil Pressure Switch 2) Install the oil pressure switch onto engine block.

25 N#m (2.5 kgf-m, 18.1 ft-lb)
2) Remove the generator from bracket.
<Ref. to SC(H4SO 2.0)-14, REMOVAL, Genera-
tor.>
LU-00037
3) Connect the terminal to oil pressure switch.
LU-00036
LU-00036
4) Install the generator to bracket.

<Ref. to SC(H4SO 2.0)-14, INSTALLATION, Gen-
erator.>
LU-00037 5) Install the collector cover.
1) Apply liquid gasket to the oil pressure switch Make sure oil does not leak or seep from where the
threads. oil pressure switch is installed.
Liquid gasket:
equivalent
LU-00038
LU(H4DOTC)-16
Engine Oil Filter
LUBRICATION

A: REMOVAL
3) Remove the oil filter using STs.
LU-00227
B: INSTALLATION
1) Clean the oil filter installation surface on cylinder
block or oil cooler.
gine oil to seal rubber.
3) Install the oil filter, turning it by hand, being care-
ful not to damage seal rubber.
4) Tighten more after the seal rubber contacts oil
cooler.
NOTE:
• In case of oil filter in diameter 68 mm (2.68 in),
tighten by approx. one turn.
• In case of oil filter in diameter 65 mm (2.56 in),
tighten by approx. 2/3 to 3/4 turn.
• Over-tightening may cause oil leak.
C: INSPECTION
1) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
sary.
2) Check the engine oil level.
<Ref. to LU(H4DOTC)-8, INSPECTION, Engine
Oil.>
LU(H4DOTC)-17
Engine Lubrication System Trouble in General
LUBRICATION
8. Engine Lubrication System Trouble in General

A: INSPECTION
Replace.
pump rotor and gear
not come on.
listed in 1).— 2).
LU(H4DOTC)-18
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

SP(H4DOTC)
Page
General Description
A: SPECIFICATION
Specifications for Turbo model is included in
SP(H4SO 2.0) section. <Ref. to SP(H4SO 2.0)-2,
SP(H4DOTC)-2
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

IGNITION
IG(H4DOTC)
Page
2. Spark Plug...................................................................................................4
3. Ignition Coil & Ignitor ASSY ........................................................................7
General Description
IGNITION
A: SPECIFICATION
Item Specification
Model FK0186
Ignition system Independent ignition coil
ASSY
Manufacturer Diamond Electric
Manufacturer and type NGK: ILFR6B
Spark plug
Electrode Iridium
B: COMPONENT
T2
T1
(2)
(1)
T1
(1)
(2)
T2
IG-00098
(1) Spark plug Tightening torque: N!m (kgf-m, ft-lb)

T2: 16 (1.6, 11.7)
IG(H4DOTC)-2
General Description
IGNITION
C: CAUTION
goggle and protective shoes during operation.
points.
cable from battery.
IG(H4DOTC)-3
Spark Plug
IGNITION
2. Spark Plug 2. LH SIDE

A: REMOVAL 1) Remove the collector cover.
2) Remove the battery and battery carrier.
CAUTION: 3) Disconnect the connector from ignition coil.
All spark plugs installed on an engine must be 4) Remove the ignition coil.
NOTE:
Spark plug: Turn the #4 ignition coil by 180" to remove it.
<Ref. to IG(H4DOTC)-2, SPECIFICATION,
1. RH SIDE
IG-00093

B: INSTALLATION
1. RH SIDE
IN-00203 Install in the reverse order of removal.
3) Remove the air cleaner case. Tightening torque (Spark plug):
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner 21 N!m (2.1 kgf-m, 15.2 ft-lb)
Case.>
4) Disconnect the connector from ignition coil. Tightening torque (Ignition coil):
5) Remove the ignition coil. 16 N!m (1.6 kgf-m, 11.7 ft-lb)
NOTE: NOTE:
Turn the #3 ignition coil by 180" to remove it. The above torque should only be applied to new
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified 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)
IG-00092 Tightening torque (Ignition coil):
16 N!m (1.6 kgf-m, 11.7 ft-lb)
NOTE:
The above torque should only be applied to new
IG(H4DOTC)-4
Spark Plug
IGNITION
C: INSPECTION 3) Oil fouled:

Check the electrodes and inner and outer ceramic Wet black deposits show excessive oil entrance
insulator of plugs, noting the type of deposits and into combustion chamber through worn rings and
the degree of electrode erosion. pistons or excessive clearance between valve
(E)
(C)
(B) (D)
(A)
IG-02010
(A) Spark plug gap IG-00013

(B) Carbon accumulation or wear 4) Overheating:
(C) Crack White or light gray insulator with black or brown
(D) Damage spots and bluish burnt electrodes indicate engine
(E) Damaged gasket overheating. Moreover, the appearance results
from incorrect ignition timing, loose spark plugs,
1) Normal: wrong selection of fuel, hotter range plug, etc. It is
Brown to grayish-tan deposits and slight electrode advisable to replace with plugs having colder heat
wear indicate correct spark plug heat range. range.
IG-00011 IG-00014
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
the city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
IG-00012
IG(H4DOTC)-5
Spark Plug
IGNITION
D: ADJUSTMENT
Clean the spark plugs using a wire brush.
Clean and remove the carbon or oxide deposits.
But do not wear away ceramic insulator.
If deposits are too stubborn, replace the plugs.
After cleaning the spark plugs, correct the spark
plug gap using a gap gauge.
NOTE:
Do not use a plug cleaner because the spark plugs
are applied with iridium tip.
Spark plug gap: L
0.7 — 0.8 mm (0.028 — 0.031 in)
L
(A)
IG-00015
NOTE:
Replace with a new spark plug if this area (A) is
worn to “ball” shape.
IG(H4DOTC)-6
IGNITION
3. Ignition Coil & Ignitor ASSY

A: REMOVAL
Direct ignition type has been adopted. Refer to
“Spark Plug” for removal procedure. <Ref. to
IG(H4DOTC)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
Tightening torque:
16 N!m (1.6 kgf-m, 11.7 ft-lb)
C: INSPECTION
For inspection procedure, refer to “Diagnostics for
Engine Starting Failure”. <Ref. to EN(H4DOTC)(di-
ag)-48, IGNITION CONTROL SYSTEM, Diagnos-
tics for Engine Starting Failure.>
IG(H4DOTC)-7
IGNITION
IG(H4DOTC)-8
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

SC(H4DOTC)
Page
General Description
A: SPECIFICATION
Specifications for Turbo model is included in
SC(H4SO 2.0) section. <Ref. to SC(H4SO 2.0)-2,
SC(H4DOTC)-2
ENGINE SECTION 2

EXHAUST EX(H4DOTC)

approval.

EN(H4DOTC)(diag)
Page
10. Inspection Mode........................................................................................28

A: PROCEDURE
1. ENGINE
Step Check Yes No

<Ref. to EN(H4DOTC)(diag)-3, CHECK, Check Failure”. <Ref. to
List for Interview.> EN(H4DOTC)(diag
2) Start the engine. )-42, Diagnostics
for Engine Start-
ing Failure.>
2 CHECK ILLUMINATION OF MALFUNCTION Does malfunction indicator Go to step 3. Inspection using
EN(H4DOTC)(diag
)-202, General
Diagnostic Table.>
3 CHECK INDICATION OF DTC ON SCREEN. Is DTC displayed on the Sub- Record the DTC. Repair the related
link connector. EN(H4DOTC)(diag If DTC is not
3) Turn the ignition switch to ON, and the Sub- )-55, List of Diag- shown on display
aru Select Monitor switch to ON. nostic Trouble although the mal-
4) Read DTC on Subaru Select Monitor. Code (DTC).> Go function indicator
to step 4. light illuminates,
perform the diag-
nostics for mal-
function indicator
light circuit or com-
bination meter.
<Ref. to
EN(H4DOTC)(di-
ag)-33, Malfunc-
tion Indicator
Light.>
4 PERFORM THE DIAGNOSIS. Is DTC displayed on the Sub- Check on “Diag- Finish the diagno-
1) Perform clear memory mode. <Ref. to aru Select Monitor? nostic Chart with sis.
EN(H4DOTC)(diag)-30, Clear Memory Mode.> Diagnostic Trou-
2) Perform the inspection mode. <Ref. to ble Code (DTC)”
EN(H4DOTC)(diag)-28, Inspection Mode.> <Ref. to
EN(H4DOTC)(diag
)-60, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
EN(H4DOTC)(diag)-2

A: CHECK
1. CHECK LIST No. 1
NOTE:
Date of repair km
Odometer reading
V.I.N. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
❏ Hot
❏ Warm
❏ Cool
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
❏ Warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
❏ At starting
❏ While idling
❏ At racing
❏ While cruising
EN(H4DOTC)(diag)-3
2. CHECK LIST No. 2

NOTE:
b) Fuel level
• What:
• What:
• What:
• Where:
• From where:
• What kind:
• From where:
• What kind:
❏ Rough idling
❏ Back fire
❏ After fire
❏ Does not shift.
EN(H4DOTC)(diag)-4
General Description

point to the body when measuring voltage and re-
A: CAUTION sistance inside the passenger compartment.
CAUTION: (A)
nectors are colored yellow. Do not use the elec-
trical test equipment on these circuits.
The ECM will be destroyed instantly.
The fuel injector and other part will be damaged. (A) Stud bolt
3) Do not disconnect the battery terminals while the
engine is running. 9) Use engine grounding terminal or engine proper
A large counter electromotive force will be generat- as the grounding point to the body when measuring
ed in the generator, and this voltage may damage voltage and resistance in the engine compartment.
sensor and the ECM, be sure to turn the ignition
switch to OFF.
than 5 mm (0.20 in) into the part.
FU-01170
6) Remove the ECM from the located position after
disconnecting two cables on battery. 10) Every MFI-related part is a precision part. Do
Otherwise, the ECM may be damaged. not drop them.
CAUTION:
the wrong spec. ECM to avoid any damage on CAUTION:
the fuel injection system. • The antenna must be kept as far apart as pos-
NOTE:
under the steering column, inside of the instru-
Immobilizer system must be registered when in-
ment panel lower trim panel.)
stalling the ECM of the model with immobilizer. For
• The antenna feeder must be placed as far
doing so, all ignition keys and ID cards should be
prepared. Refer to “REGISTRATION MANUAL
ness.
FOR IMMOBILIZER”.
7) Connectors to each sensor in the engine com- matching.
partment and the harness connectors on the en- • When mounting a large power type radio, pay
gine side and body side are all designed to be special attention to the three items above men-
waterproof. However, it is still necessary to take tioned.
care not to allow water to get into the connectors
the operation of the ECM.
vehicle on a rainy day.
fuel system. If engine starts during this operation,
EN(H4DOTC)(diag)-5
General Description

three causes.
perform the ABS memory clearance procedure of
self-diagnosis function.
B: INSPECTION
items which might affect engine problems:
1. BATTERY
electrolyte.
proper grounding.
2. ENGINE GROUND
ly connected to the engine.
FU-01170
3. SELF-DIAGNOSIS FUNCTION
When detecting a malfunction by self-diagnosis
function on ECM, malfunction indicator light illumi-
nates and malfunction occurrence is displayed.
Calling the self-diagnosis result is performed by
Subaru Select Monitor.
EN(H4DOTC)(diag)-6
General Description
C: PREPARATION TOOL
ST24082AA230
ST22771AA030
EN(H4DOTC)(diag)-7

A: LOCATION
1. ENGINE
• Control module
(4)
(2) (3) (1)

EN-02451
(1)
(2)
EN-01147 EN-01966
(4)
(3)
EN-02476 EN-02477
EN(H4DOTC)(diag)-8
• Sensor
(8) (5) (1) (2) (3) (5)
(6) (7) (4) (6)
EN-01926
(1) Manifold absolute pressure sen- (3) Electronic throttle control (7) Crankshaft position sensor
sor (4) Knock sensor (8) Mass air flow and intake air tem-
(2) Engine coolant temperature sen- (5) Intake camshaft position sensor perature sensor
sor (6) Exhaust camshaft position sensor
EN(H4DOTC)(diag)-9
(1)
(2)
EN-01927 EN-00295
(4)
(3)
EN-01928 EN-02169
(5)
(6)
EN-01798 EN-01929
(7)
(8)
EN-01930 EN-02089
EN(H4DOTC)(diag)-10
(2)
(3)
(1)
(4)
EN-01931
(1) Front oxygen (A/F) sensor (3) Rear oxygen sensor (4) Rear catalytic converter
(2) Front catalytic converter
(3)
(1)
(2)
(4)
EN-01932 EN-01933
EN(H4DOTC)(diag)-11
(3) (4) (1) (2) (4) (3)
(5) (5)
EN-01934
(1) Wastegate control solenoid valve (4) Intake oil flow control solenoid (5) Exhaust oil flow control solenoid
(2) Purge control solenoid valve valve valve
(3) Ignition coil
EN(H4DOTC)(diag)-12
(3)
(1) (2)
EN-01935 EN-01936
(5)
(4)
EN-01937 EN-01938
(1) (2)
(8) (7) (6) (9) (5) (4) (3)

EN-01898
EN(H4DOTC)(diag)-13
(2)
EN-00178 EN-02093
(3)
(6)
(8)
(4) (7)
(5)
EN-02094 EN-02095
(9)
EN-02096
EN(H4DOTC)(diag)-14

To B134 To B135 To B136 To B137
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
EN-01812
Con- Signal (V)

Termi-
Description nector Ignition SW ON Engine ON Note
nal No.
Crank- Signal (+) B135 10 0 "7 — +7 Waveform
shaft posi- Signal (") B135 22 0 0 —
tion sensor Shield B135 31 0 0 —
Signal B137 25 0 0 — 0.9 —
Rear oxy-
Shield B137 31 0 0 —
gen sen-
sor GND
B136 35 0 0 —
(sensor)
Front oxy- Signal 1 B134 3 — — Waveform
gen (A/F)
sensor Signal 2 B134 2 — — Waveform
heater
Rear oxygen sensor
B135 2 0 — 13 — Waveform
heater signal
Engine Signal B136 14 1.0 — 1.4 1.0 — 1.4 After engine is warmed-up.
coolant
tempera- GND
ture sen- B136 35 0 0 After engine is warmed-up.
(sensor)
sor
Signal B136 23 — 0.3 — 4.5 —
Air flow
Shield B136 32 0 0 —
sensor
GND B136 31 0 0 —
Intake air temperature
B136 13 0.3 — 4.6 0.3 — 4.6 —
sensor signal
Wastegate control sole-
B134 32 0 or 10 — 13 0 or 13 — 14 Waveform
noid valve
ON: 10 — 13 ON: 13 — 14
OFF: 0 OFF: 0
ON: 0 ON: 0
Neutral position switch B137 9 —
OFF: 10 — 13 OFF: 13 — 14
EN(H4DOTC)(diag)-15
Con- Signal (V)

Termi-
nal No.
Test mode connector B137 15 10 — 13 13 — 14 When connected: 0
Knock Signal B136 25 2.8 2.8 —
Back-up power supply B135 19 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control module power B135 5 10 — 13 13 — 14 —
supply B135 6 10 — 13 13 — 14 —
Sensor power supply B136 16 5 5 —
#1 B135 18 0 13 — 14 Waveform
Ignition #2 B135 17 0 13 — 14 Waveform
control #3 B135 16 0 13 — 14 Waveform
#4 B135 16 0 13 — 14 Waveform
#1 B136 6 10 — 13 1 — 14 Waveform
Fuel injec- #2 B136 5 10 — 13 1 — 14 Waveform
tor #3 B136 4 10 — 13 1 — 14 Waveform
#4 B136 3 10 — 13 1 — 14 Waveform
Fuel pump Signal 1 B137 28 10 — 13 13 — 14 —
control unit Signal 2 B135 27 0 or 5 0 or 5 Waveform
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 ON: 0.5 or less ON: 0.5 or less
B135 25 —
control OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 2 ON: 0.5 or less ON: 0.5 or less
B135 24 Model with A/C
control OFF: 10 — 13 OFF: 13 — 14
Malfunction indicator Light “ON”: 1 or less
B134 17 — —
light Light “OFF”: 10 — 14
Purge control solenoid ON: 1 or less ON: 1 or less
B134 14 Waveform
valve OFF: 10 — 13 OFF: 13 — 14
Signal B136 22 1.7 — 2.4 1.1 — 1.6
Manifold
Power
absolute B136 16 5 5
supply —
pressure
sensor GND
B136 35 0 0
(sensor)
ON: 0 ON: 0
Blower fan switch B137 13 With manual A/C model only
OFF: 10 — 13 OFF: 13 — 14
Power steering oil pres- ON: 0
B137 10 10 — 13 —
sure switch OFF: 13 — 14
Front oxygen (A/F) sen-
B134 33 2.8 — 3.2 2.8 — 3.2 —
sor signal (+)
B134 26 2.4 — 2.7 2.4 — 2.7 —
sor signal (")
B134 25 0 0 —
sor shield
SSM communication Less than 1#$ More Less than 1#$ More
B137 20 —
line than 4 than 4
GND (sensor) B136 35 0 0 —
B135 4 0 0 —
GND (power supply)
B135 1 0 0 —
B137 1 0 0 —
B137 2 0 0 —
EN(H4DOTC)(diag)-16
Con- Signal (V)

Termi-
nal No.
GND (Front oxygen (A/
B134 7 0 0 —
F) sensor heater 1)
GND (Front oxygen (A/
B134 6 0 0 —
F) sensor heater 2)
Intake camshaft posi-
B135 8 0 or 5 0 or 5 Waveform
tion sensor (LH)
Intake camshaft posi-
B135 9 0 or 5 0 or 5 Waveform
tion sensor (RH)
0.64 — 0.72
0.64 — 0.72 Fully closed: 0.6 Fully open:
Fully open: 3.96 3.96
warmed-up.)
1.51 — 1.58
Electronic 1.51 — 1.58 Fully closed: 1.48 Fully open:
throttle Fully open: 4.17 4.17
warmed-up.)
control
Power
B136 16 5 5 —
supply
GND
B136 35 0 0 —
(sensor)
Electronic throttle con-
trol motor (+)
trol motor (")
B137 6 10 — 13 13 — 14 —
trol motor power supply
Electronic throttle con- ON: 0 ON: 0 When ignition switch is turned
B135 35
trol motor relay OFF: 10 — 13 OFF: 13 — 14 to ON: ON
Intake ON: 10 — 13 ON: 13 — 14
Signal (+) B134 19 —
AVCS OFF: 0 OFF: 0
solenoid
(LH) Signal (") B134 29 0 0 —
Intake ON: 10 — 13 ON: 13 — 14
Signal (+) B134 18 —
AVCS OFF: 0 OFF: 0
solenoid
(RH) Signal (") B134 28 0 0 —
Exhaust ON: 10 — 13 ON: 13 — 14
Signal (+) B134 21 —
AVCS OFF: 0 OFF: 0
solenoid
(LH) Signal (") B134 31 0 0 —
Exhaust ON: 10 — 13 ON: 13 — 14
Signal (+) B134 20 —
AVCS OFF: 0 OFF: 0
solenoid
(RH) Signal (") B134 30 0 0 —
Exhaust Signal (+) B135 20 0 "7 — +7 Waveform
camshaft Signal (") B135 28 0 0 —
position
(LH)
Exhaust Signal (+) B135 21 0 "7 — +7 Waveform
camshaft Signal (") B135 29 0 0 —
position
(RH)
EN(H4DOTC)(diag)-17
Con- Signal (V)

Termi-
nal No.
Main B136 17 —
Fully open: 3.3 Fully open: 3.3
Power
B136 15 5 5 —
supply
GND
B136 34 0 0 —
Accelera- (sensor)
tor position Fully closed: 1 Fully closed: 1
Sub B136 28 —
sensor Fully open: 3.3 Fully open: 3.3
Shield B137 2 0 0 —
Power
B136 16 5 5 —
supply
GND
B136 35 0 0 —
(sensor)
ON: 0 ON: 0
Starter relay B135 32 ON: Cranking
OFF: 10 — 13 OFF: 13 — 14
A/C middle pressure ON: 0 ON: 0
B136 30 —
switch OFF: 10 — 13 OFF: 13 — 14
Clear memory switch B137 24 5 5 When connected: 0
When operating noth- When operating noth-
ing: 3.5 — 4.5 ing: 3.5 — 4.5
When operating RES/ When operating RES/
Cruise control com- ACC: 2.5 — 3.5 ACC: 2.5 — 3.5
B136 11 —
mand switch When operating SET/ When operating SET/
COAST: 0.5 — 1.5 COAST: 0.5 — 1.5
When operating CAN- When operating CAN-
CEL: 0 — 0.5 CEL: 0 — 0.5
Cruise control main ON: 0 ON: 0
B136 7 —
switch OFF: 5 OFF: 5
EN(H4DOTC)(diag)-18

Remarks Specification
1.2 — 2.9 (%): Idling
Engine load
4.7 — 12.8 (%): 2,500 rpm racing
• Gear position is in neutral.
• A/C is turned off.
• Turn all accessory switches to OFF.
EN(H4DOTC)(diag)-19
Data Link Connector

A: NOTE
CAUTION:
Do not connect any scan tools other than Subaru Select Monitor, because the circuit for the Subaru
Select Monitor may be damaged.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
EN-00037

3 Empty 11 Empty
4 Empty 12 Ground
5 Empty 13 Ground
6 Line end check signal 1 14 Empty
7 Empty 15 Empty
8 Empty 16 Empty
EN(H4DOTC)(diag)-20
8. Subaru Select Monitor CAUTION:

A: OPERATION ru Select Monitor.
1. HOW TO USE SUBARU SELECT MONI- 5) Turn ignition switch to ON (engine OFF) and turn
TOR Subaru Select Monitor switch to ON.
(A)
EN(H4DOTC)(diag)-7, PREPARATION TOOL,
EN-00040
(A) Power switch
EN-00038 6) Using the Subaru Select Monitor, call up DTC

Monitor. 2. READ DIAGNOSTIC TROUBLE CODE
3) Insert the cartridge to Subaru Select Monitor. (DTC) FOR ENGINE (NORMAL MODE)
<Ref. to EN(H4DOTC)(diag)-7, PREPARATION
information about how to indicate DTC. <Ref. to
EN(H4DOTC)(diag)-27, Read Diagnostic Trouble
Code (DTC).>
EN(H4DOTC)(diag)-27, Read Diagnostic Trouble
Code (DTC).>
EN-00039

connector.
(1) Data link connector is located in the lower
portion of the instrument panel (on the driver’s
side).
EN-02097

connector.
EN(H4DOTC)(diag)-21

3) Press the [YES] key after the information of engine type was displayed.
4) On the «Engine Diagnosis» screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the «Data Display Menu» screen, select the {Data Display} and press the [YES] key.
Unit
of measure
Engine coolant temperature signal Coolant Temp. !C 80 — 100!C
Intake manifold absolute pressure Mani. Absolute Pressure mmHg 220 — 275 mmHg
cation)
Ignition timing signal Ignition Timing deg 10 — 15 deg
Intake air temperature signal Intake Air Temp. !C 20 — 50!C
Amount of intake air Mass Air Flow g/s 2.1 — 3.1 g/s
Throttle opening angle signal Throttle Opening Angle % 2.0 — 2.4%
Rear oxygen sensor voltage Rear O2 Sensor V 0 — 1.0 V
Mass air flow voltage Air Flow Sensor Voltage V 1.0 — 1.7 V
Injection 1 pulse width Fuel Injection #1 Pulse ms 1.2 — 2.2 ms
Knock sensor correction Knock Correction deg 0.0 deg
Primary supercharged pressure control signal Primary Control % 0.0%
Generator duty ratio ALT Duty % 0 — 100%
Fuel pump duty ratio Fuel Pump Duty % 30 — 40%
AVCS advance angle amount RH VVT Adv. Ang. Amount R deg %5 deg
AVCS advance angle amount LH VVT Adv. Ang. Amount L deg %5 deg
Oil flow control solenoid valve duty RH (AVCS) OCV Duty R % 0 — 20%
Oil flow control solenoid valve duty LH (AVCS) OCV Duty L % 0 — 20%
Oil flow control solenoid valve current RH OCV Current R mA 40 — 100 mA
Oil flow control solenoid valve current LH OCV Current L mA 40 — 100 mA
A/F sensor current value 1 A/F Sensor #1 Current mA "20 — 20 mA
tance
A/F sensor output lambda 1 A/F Sensor #1 — 1.0
A/F correction 3 A/F Correction #3 % 0.00%
Throttle motor duty Throttle Motor Duty % "5%
Throttle power supply voltage Throttle Motor Voltage V 12 — 15 V
Sub throttle sensor voltage Sub-throttle Sensor V 1.5 V
Sub accelerator sensor voltage Sub-accelerator Sensor V 1.1 V
Main accelerator sensor voltage Main-accelerator Sensor V 1.0 V
Atmospheric pressure signal Atmospheric Pressure mmHg —
Intake manifold absolute
Intake manifold relative pressure Mani. Relative Pressure mmHg pressure " Atmospheric
pressure
EN(H4DOTC)(diag)-22
Unit
of measure
Memorized Cruise
Memory vehicle speed km/h —
Speed
Estimated Cumulative
Estimated cumulative driving distance km —
Driving Distance
Exhaust AVCS retard angle amount RH Exh. VVT Retard Ang. R deg %5 deg
Exhaust AVCS retard angle amount LH Exh. VVT Retard Ang. L deg %5 deg
Exhaust oil flow control solenoid valve duty ratio RH Exh. OCV Duty R % 0 — 20%
Exhaust oil flow control solenoid valve duty ratio LH Exh. OCV Duty L % 0 — 20%
Exhaust oil flow control solenoid valve current value RH Exh. OCV Current R mA 40 — 100 mA
Exhaust oil flow control solenoid valve current value LH Exh. OCV Current L mA 40 — 100 mA
NOTE:
EN(H4DOTC)(diag)-23

5) On the «OBD Menu» screen, select the {Current Data Display/Save}, and then press the [YES] key.
6) On the «Data Display Menu» screen, select the {Data Display} and press the [YES] key.
Description Display Unit of measure
Number of diagnosis code Number of Diag. Code: —
Condition of malfunction indicator light MI (MIL) ON or OFF
Monitoring test of misfire Misfire monitoring no support
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 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
NOTE:
EN(H4DOTC)(diag)-24

4) On the «Engine Diagnosis» screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the «Data Display» screen, select the {Data & LED Display} and press the [YES] key.
When test mode connector is
Test mode signal Test Mode Signal ON or OFF
connected.
When clear memory connec-
Clear memory signal Clear Memory Terminal ON or OFF
tor is connected.
entered.
entered.
to ON.
entered.
Handle switch signal Handle SW LHD or RHD
input.
input.
nal sor signal is input.
turned to ON.
turned to ON.
turned to ON.
Windshield wiper switch signal Wiper SW ON or OFF
is turned to ON.
signal switch is turned to ON.
in function.
function.
function.
signal is input.
input.
EN(H4DOTC)(diag)-25

When torque down output sig-
Torque down output signal Torque Down Output ON or OFF
nal is input.
When torque down demand
Torque down demand signal Request Torque Down ON or OFF
signal is input.
to ON.
ON.
turned to ON.
turned to ON.
ON.
ON.
to ON.
entered.
entered.
NOTE:
EN(H4DOTC)(diag)-26
9. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
MODE)
key.
gine type was displayed.
NOTE:
• For detailed operation procedure, refer to the
“SUBARU SELECT MONITOR OPERATION
MANUAL”.
• For details concerning DTCs, refer to the List of
Diagnostic Trouble Code (DTC). <Ref. to
EN(H4DOTC)(diag)-55, List of Diagnostic Trouble
Code (DTC).>
MODE)
key.
NOTE:
MANUAL”.
EN(H4DOTC)(diag)-55, List of Diagnostic Trouble
Code (DTC).>
EN(H4DOTC)(diag)-27
Inspection Mode
10.Inspection Mode 2. SUBARU SELECT MONITOR

A: PROCEDURE 1) After clearing the memory, check for any remain-
ing unresolved trouble data. <Ref. to
1. PREPARATION FOR THE INSPECTION EN(H4DOTC)(diag)-30, Clear Memory Mode.>
MODE 2) Idle the engine.
1) Check battery voltage is more than 12 V and fuel EN(H4DOTC)(diag)-7, PREPARATION TOOL,
remains half [20 to 40 2 (5.3 to 10.6 US gal, 4.4 to General Description.>
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks, or drive the vehicle onto free roll-
ers.
WARNING:
brakes are applied.
id rack.
ing hooks to prevent the lateral runout of front EN-00038
wheels. 4) Connect the diagnosis cable to Subaru Select
• Do not abruptly depress/release clutch pedal Monitor.
or accelerator pedal during works even when 5) Insert the cartridge to Subaru Select Monitor.
the engine is operating at low speeds since this <Ref. to EN(H4DOTC)(diag)-7, PREPARATION
may cause vehicle to jump off free rollers. TOOL, General Description.>
blocks or similar items between the rigid racks
and the vehicle.
• Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
EN-00039

(A)
(A)
EN-01983
(B)
EN-00041
(A) Rigid rack

(B) Free rollers
EN(H4DOTC)(diag)-28
Inspection Mode
7) Connect the Subaru Select Monitor to data link • Release the parking brake.
connector located in the lower portion of the instru- • The speed difference between front and rear
ment panel (on the driver’s side). wheels may light either the ABS warning light, but
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis function.
EN-02097
CAUTION:
ru Select Monitor.
(A)
EN-00040
(A) Power switch

key.
• If trouble still remains in the memory, the corre-
sponding DTC appears on the display screen.
NOTE:
MANUAL”.
Diagnostic Trouble Code (DTC).
<Ref. to EN(H4DOTC)(diag)-55, List of Diagnostic
EN(H4DOTC)(diag)-29
Clear Memory Mode

A: OPERATION
MODE)
key.
switch to OFF and then Subaru Select Monitor to
OFF.
NOTE:
MANUAL”.
MODE)
key.
NOTE:
MANUAL”.
EN(H4DOTC)(diag)-30
Check Mode ment panel (on the driver’s side).
A: OPERATION
EN(H4DOTC)(diag)-7, PREPARATION TOOL,
EN-02097
CAUTION:
ru Select Monitor.
EN-00038 6) Turn ignition switch to ON (engine OFF) and turn
2) Connect the diagnosis cable to Subaru Select Subaru Select Monitor switch to ON.
Monitor.
<Ref. to EN(H4DOTC)(diag)-7, PREPARATION
EN-00040
(A) Power switch

EN-00039
key.
the [YES] key.
11) On the «System Operation Check Mode»
screen, select the {Actuator ON/OFF Operation}
and press the [YES] key.
(A)
12) On the «Actuator ON/OFF Operation» screen,
EN-01983 select the desired compulsory actuator and press
the [YES] key.
screen.
EN(H4DOTC)(diag)-31

table.
Description Display
Compulsory fuel pump relay operation
Fuel Pump
check
Compulsory radiator fan relay operation Radiator Fan
check Relay
Compulsory air conditioning relay oper- A/C Compressor
ation check Relay
Compulsory purge control solenoid
CPC Solenoid
valve operation check
Compulsory wastegate control sole- Wastegate con-
noid valve operation check trol solenoid
NOTE:
tional.
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure Switching Solenoid
PCV Solenoid
AAI Solenoid
Vcut Solenoid

MANUAL”.
EN(H4DOTC)(diag)-32

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4DOTC)(diag)-34, ACTIVATION OF MALFUNCTION INDICATOR
&
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4DOTC)(diag)-35, MALFUNCTION INDICATOR
&
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4DOTC)(diag)-37, MALFUNCTION INDICATOR LIGHT
DOES NOT GO OFF., Malfunction Indicator Light.>
&
4. Check that the malfunction indicator light does not blink. <Ref. to EN(H4DOTC)(diag)-38, MALFUNCTION INDICATOR LIGHT
&
5. Check that the malfunction indicator light remains blinking. <Ref. to EN(H4DOTC)(diag)-40, MALFUNCTION INDICATOR
EN(H4DOTC)(diag)-33

NOTE: (2)
EN(H4DOTC)(diag)-35, MALFUNCTION INDICA-
(3)
Indicator Light.>
EN-01681
(1) ON
(2) OFF
(4) 1 second
(A)
EN-01984

the emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1) No trouble
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start

minates.
sis)
EN(H4DOTC)(diag)-34

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72 SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
16
COMBINATION
METER
i3
i10
8
B38
17
ECM
B134 E
i10 B72 B38 B134
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 1 2 3 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
EN-01939
EN(H4DOTC)(diag)-35
Step Check Yes No

2 CHECK POOR CONTACT. Does malfunction indicator Repair the poor Go to step 3.
Check for poor connection when shaking or light illuminate? contact in ECM
pulling ECM connector and harness. connector.
Check the connection of ECM connector. connected? <Ref. to nection of ECM
FU(H4DOTC)-35, connector.
Engine Control
Module (ECM).>
coupling connector
nector.
meter connector and chassis ground. • Open or short
Connector & terminal circuit in harness
(i10) No. 3 (+) — Chassis ground ("): between fuse and
(i10) No. 4 (+) — Chassis ground ("): battery terminal
• Poor contact in
nector
EN(H4DOTC)(diag)-36

DIAGNOSIS:
TROUBLE SYMPTOM:
Monitor display.
WIRING DIAGRAM:
IGNITION
B72 SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
16
COMBINATION
METER
i3
i10
8
B38
17
ECM
B134 E
i10 B72 B38 B134
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 1 2 3 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
EN-01939
Step Check Yes No

1 CHECK HARNESS BETWEEN COMBINA- Does malfunction indicator Repair the short Replace the ECM.
TION METER AND ECM CONNECTOR. light illuminate? circuit in harness <Ref. to
1) Turn the ignition switch to OFF. between combina- FU(H4DOTC)-35,
2) Disconnect the connector from ECM. tion meter and Engine Control
3) Turn the ignition switch to ON. ECM connector. Module (ECM).>
EN(H4DOTC)(diag)-37

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72 SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
16
COMBINATION
METER
i3
1 1
*
i10 B75 B76
*
8
B38
B138
D15
C19
A17
A: B134 C: B136 D: B137 ECM

E
B75 B76 B72 A: B134 C: B136 D: B137
1 1 1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
2 2 4 5 6 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17
7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
i10 B38 B138
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8
EN-02401
EN(H4DOTC)(diag)-38
Step Check Yes No

1 CHECK STATUS OF MALFUNCTION INDI- Does malfunction indicator Go to step 2. Repair the mal-
1) Turn the ignition switch to OFF. light circuit.
2) Disconnect the test mode connectors. <Ref. to
3) Turn the ignition switch to ON. (engine EN(H4DOTC)(diag
OFF) )-35, MALFUNC-
TION INDICA-
TOR LIGHT
DOES NOT
COME ON, Mal-
function Indicator
Light.>
2 CHECK HARNESS BETWEEN COMBINA- Does malfunction indicator Repair the ground Go to step 3.
TION METER AND ECM CONNECTOR. light illuminate? short circuit in har-
2) Disconnect the connector from ECM. combination meter
3) Turn the ignition switch to ON. and ECM connec-
tor.
CONNECTOR AND ECU. '? ness and connec-
between test mode connector and ECM. the following:
(B76) No. 1 — (B136) No. 19: harness between
test mode connec-
tor and ECM
• Poor contact in
joint connector
4 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Go to step 5.
connector.
ECM and test mode connector. test mode connec-
(B137) No. 15 — (B75) No. 1:
6 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Replace the ECM.
Check poor contact in ECM connector. connector? contact in ECM <Ref. to
connector. FU(H4DOTC)-35,
Engine Control
Module (ECM).>
EN(H4DOTC)(diag)-39

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72 SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
16
COMBINATION
METER
i3
1 1
*
i10 B75 B76
*
8
B38
B138
D15
C19
A17
A: B134 C: B136 D: B137 ECM

E
B75 B76 B72 A: B134 C: B136 D: B137
1 1 1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
2 2 4 5 6 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17
7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
i10 B38 B138
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8
EN-02401
EN(H4DOTC)(diag)-40
Step Check Yes No

1) Disconnect the test mode connectors light blink? order.
Malfunction indica-
tor light blinks at a
cycle of 3 Hz when
test mode connec-
tor is connected.
NECTOR AND CHASSIS GROUNDING TER- '? circuit in harness <Ref. to
MINAL. between ECM and FU(H4DOTC)-35,
1) Turn the ignition switch to OFF. test mode connec- Engine Control
2) Disconnect the connector from ECM. tor. Module (ECM).>
EN(H4DOTC)(diag)-41

A: PROCEDURE
&
2. Inspection of starter motor circuit. <Ref. to EN(H4DOTC)(diag)-43, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>
&
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag)-46, CHECK POWER SUPPLY AND GROUND
&
4. Inspection of ignition control system. <Ref. to EN(H4DOTC)(diag)-48, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
&
5. Inspection of fuel pump circuit. <Ref. to EN(H4DOTC)(diag)-51, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
&
6. Inspection of fuel injector circuit. <Ref. to EN(H4DOTC)(diag)-53, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H4DOTC)(diag)-42

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)(diag)-
30, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)(diag)-28, PROCE-
DURE, Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
No.21 SBF-7 SBF-1
2 3
B72 IGNITION
SWITCH
16
14
STARTER RELAY
B225
STARTER MOTOR
15
13
M
B14
B32
D8
B: B135 D: B137 ECM E
B225
B: B135 D: B137 B72
1 2 9 13 17 21
10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 4 5 6
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02402
EN(H4DOTC)(diag)-43
Step Check Yes No

ate?
EN(H4DOTC)(diag)-27, vant DTC using contact in ECM
(DTC). <Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
TOR.
motor.
ground.
NOTE:
Set the selector lever in the “P” or “N” range.
starter motor.
ground.
5 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 6. Check the follow-
AND IGNITION SWITCH CONNECTOR. ing and repair if
1) Disconnect the connector from ignition necessary.
switch. • Blown out
2) Measure the power supply voltage between fuse
ignition switch connector and chassis ground. • Open circuit
Connector & terminal in harness
(B72) No. 3 (+) — Chassis ground ("): between igni-
tion switch and
battery
switch.
switch terminals while turning the ignition
Terminals
No. 2 — No. 3:
EN(H4DOTC)(diag)-44
Step Check Yes No

7 CHECK INPUT VOLTAGE OF STARTER RE- Is the voltage more than 10 V? Go to step 8. Repair the open or
LAY. ground short cir-
1) Turn the ignition switch to OFF. cuit in harness
2) Disconnect the connector from starter relay. between starter
3) Connect the connector to ignition switch. relay and ignition
4) Measure the input voltage between starter switch.
relay connector and chassis ground while turn-
relay terminals.
Terminals
No. 13 — No. 14:
9 CHECK INPUT VOLTAGE FROM ECM. Is the resistance less than 1 Go to step 10. Repair the open
1) Turn the ignition switch to OFF. '? circuit in harness
2) Connect the starter relay connector. between ECM and
3) Disconnect the connectors from ECM. starter relay.
between ECM and starter relay connector.
(B135) No. 32 — (B225) No. 15:
10 CHECK INPUT VOLTAGE FOR STARTER Is the voltage more than 10 V? Go to step 11. Repair the open or
MOTOR. ground short cir-
1) Turn the ignition switch to OFF. cuit in harness
2) Connect the connector to ECM. between starter
3) Turn the ignition switch to START. relay and starter.
4) Measure the voltage between starter motor
and engine ground.
11 CHECK HARNESS BETWEEN IGNITION Is the resistance less than 1 Check engine con- Repair the open
SWITCH AND ECM. '? trol module (ECM) circuit between
1) Turn the ignition switch to OFF. power supply and ignition switch and
2) Disconnect the connector from ignition ground line. <Ref. ECM.
switch and ECM. to
3) Measure the resistance of harness EN(H4DOTC)(diag
between ignition switch and ECM connector. )-46, CHECK
Connector & terminal POWER SUPPLY
(B137) No. 8 — (B72) No. 2: AND GROUND
LINE OF ENGINE
CONTROL MOD-
ULE (ECM), Diag-
nostics for Engine
Starting Failure.>
EN(H4DOTC)(diag)-45

ULE (ECM)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3 TO FRONT OXYGEN(A/F) SENSOR SBF-6

5
SBF-8
6
4
No.13
1
2 IGNITION
B72
SWITCH BATTERY
B47
No.12 SBF-7 SBF-1
6 3
D16
B19
D14
B5
B6
A: B134
B: B135 ECM
D: B137
B12
A6
A7
B1
B4
D7
D1
D2
D3
B21
54
35
34
12
36
37
E2
E E
B72 B47 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02403
EN(H4DOTC)(diag)-46
Step Check Yes No

No. 1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
1) Connect the main relay connector. control system. ground short cir-
2) Turn the ignition switch to ON. <Ref. to cuit in harness
3) Measure the voltage between ECM con- EN(H4DOTC)(diag between ECM
nector and chassis ground. )-48, IGNITION connector and
Connector & terminal CONTROL SYS- main relay connec-
(B135) No. 5 (+) — Chassis ground ("): TEM, Diagnostics tor.
(B135) No. 6 (+) — Chassis ground ("): for Engine Start-
ing Failure.>
EN(H4DOTC)(diag)-47

CAUTION:
WIRING DIAGRAM:
B135 ECM
18
17
16
15
IGNITION
SWITCH
SBF-1 SBF-7 No.12
3 6
B72
B21
49
13
14
15
16
E2
E31 E32 E33 E34

3
2
E
E
IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL

No.1 No.2 No.3 No.4
E31 B21 B72 B135

E32
1 2 3 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 16 17 18 19
E33 4 5 6
12 13 14 15 16 17 18 19 20 21 22 20 21 22 23 24 25 26 27
E34 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
1 42 43 44 45 46 47
2 48 49 50 51 52 53 54
3
EN-02404
EN(H4DOTC)(diag)-48
Step Check Yes No

1 CHECK SPARK PLUG CONDITION. Is the spark plug’s status OK? Go to step 2. Replace the spark
1) Remove the spark plug. <Ref. to plug.
IG(H4DOTC)-4, REMOVAL, Spark Plug.>
2) Check the spark plug condition. <Ref. to
IG(H4DOTC)-5, INSPECTION, Spark Plug.>
2 INSPECTION FOR SPARK OF IGNITION Does spark occur at each cyl- Check fuel pump Go to step 3.
SYSTEM. inder? system. <Ref. to
1) Connect the spark plug to ignition coil. EN(H4DOTC)(diag
2) Release the fuel pressure. <Ref. to )-51, FUEL PUMP
FU(H4DOTC)-40, RELEASING OF FUEL CIRCUIT, Diag-
PRESSURE, PROCEDURE, Fuel.> nostics for Engine
3) Contact the spark plug’s thread portion on Starting Failure.>
engine.
4) While the throttle valve is opening fully,
crank the engine to check that spark occurs at
each cylinder.
Connector & terminal tor ASSY, and igni-
(E31) No. 3 (+) — Engine ground ("): tion switch
(E32) No. 3 (+) — Engine ground ("): connector
(E33) No. 3 (+) — Engine ground ("): • Poor contact in
(E34) No. 3 (+) — Engine ground ("): coupling connector
(E32) No. 2 — Engine ground: ignition coil & igni-
(E33) No. 2 — Engine ground: tor ASSY connec-
(E34) No. 2 — Engine ground: tor and engine
grounding terminal
TOR. tor.
(B135) No. 17 — (E32) No. 1:
(B135) No. 18 — (E31) No. 1:
EN(H4DOTC)(diag)-49
Step Check Yes No

TOR. ness between
7 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Replace the igni-
Check poor contact in ECM connector. connector? contact in ECM tion coil & ignitor
connector. ASSY.
EN(H4DOTC)(diag)-50

CAUTION:
WIRING DIAGRAM:
BATTERY
No.31
1 2
FUEL PUMP
RELAY B362
B98
7
4
R2
10
FUEL PUMP
CONTROL UNIT
R122
5
9
8
7
6
R2
5
6
B98
D28
B27
5
6
FUEL
PUMP
ECM E E
R58 M B: B135
D: B137
B362 B98 R58 R122 B: B135 D: B137
3 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 1 2 3
4 3 4 5 6 7 8 9 10 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
4 5 6 7 8
5 6 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
5 28 29 30 31 32 33 34 35 26 27 28 29 30 31
7 8
6
EN-01944
EN(H4DOTC)(diag)-51
Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Display DTC.
PUMP. operating sound? injector circuit. <Ref. to
Make sure that fuel pump is in operation for 2 <Ref. to EN(H4DOTC)(diag
seconds when turning the ignition switch to EN(H4DOTC)(diag )-27, OPERA-
ON. )-53, FUEL INJEC- TION, Read Diag-
NOTE: TOR CIRCUIT, nostic Trouble
Fuel pump operation can also be executed us- Diagnostics for Code (DTC).>
ing Subaru Select Monitor. Engine Starting
Refer to “Compulsory Valve Operation Check Failure.>
Mode” for procedures. <Ref. to
EN(H4DOTC)(diag)-52

CAUTION:
• After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)(di-
ag)-30, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)(diag)-28,
PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
B47 C: B136 D: B137 ECM

C6
D7
C5
C4
C3
B21
34
45
44
48
42
43
E2
E5 E16 E6 E17
2
1
2
1
2
1
2
1
#1 #2 #3 #4
E E
FUEL INJECTORS
E5 E6 C: B136 B21
E16 E17
1 2 3 4 5 6
1 2 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11
14 15 16
12 13 14 15 16 17 18 19 20 21 22
17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B47 D: B137
1 2 1 2 3 4 5 6 7
3 4 8 9 10 11 12 13 14 15 16 17
5 6 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-01945
EN(H4DOTC)(diag)-53
Step Check Yes No

1 CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump produce Check the fuel Go to step 2.
TOR. operating sound? pressure. <Ref. to
While cranking the engine, check that each ME(H4DOTC)-26,
fuel injector emits operating sound. Use a INSPECTION,
sound scope or attach a screwdriver to the Fuel Pressure.>
injector for this check.
tor
• Poor contact in
coupling connector
• Poor contact in
fuel injector con-
nector
(B136) No. 6 — (E5) No. 1: • Open circuit in
(B136) No. 5 — (E16) No. 1: harness between
(B136) No. 4 — (E6) No. 1: ECM and fuel
(B136) No. 3 — (E17) No. 1: injector connector
• Poor contact in
coupling connector
ECM and chassis ground. ECM and fuel
injector terminals.
Terminals
No. 1 — No. 2:
6 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Inspection using
EN(H4DOTC)(diag
)-202, INSPEC-
TION, General
Diagnostic Table.>
EN(H4DOTC)(diag)-54

A: LIST
DTC Item Note
P0031 HO2S Heater Control Circuit Low <Ref. to EN(H4DOTC)(diag)-60, DTC P0031 HO2S HEATER CONTROL
P0032 HO2S Heater Control Circuit High <Ref. to EN(H4DOTC)(diag)-62, DTC P0032 HO2S HEATER CONTROL
P0037 HO2S Heater Control Circuit Low <Ref. to EN(H4DOTC)(diag)-64, DTC P0037 HO2S HEATER CONTROL
P0038 HO2S Heater Control Circuit High <Ref. to EN(H4DOTC)(diag)-67, DTC P0038 HO2S HEATER CONTROL
P0102 Mass or Volume Air Flow Circuit <Ref. to EN(H4DOTC)(diag)-69, DTC P0102 MASS OR VOLUME AIR
Low Input FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0103 Mass or Volume Air Flow Circuit <Ref. to EN(H4DOTC)(diag)-72, DTC P0103 MASS OR VOLUME AIR
High Input FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0107 Manifold Absolute Pressure/Baro- <Ref. to EN(H4DOTC)(diag)-74, DTC P0107 MANIFOLD ABSOLUTE
P0108 Intake Air Pressure Sensor Circuit <Ref. to EN(H4DOTC)(diag)-76, DTC P0108 MANIFOLD ABSOLUTE
High Input PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic
P0112 Intake Air Temperature Circuit Low <Ref. to EN(H4DOTC)(diag)-78, DTC P0112 INTAKE AIR TEMPERATURE
(DTC).>
P0113 Intake Air Temperature Circuit High <Ref. to EN(H4DOTC)(diag)-80, DTC P0113 INTAKE AIR TEMPERATURE
(DTC).>
P0117 Engine Coolant Temperature Cir- <Ref. to EN(H4DOTC)(diag)-83, DTC P0117 ENGINE COOLANT TEMPER-
cuit Low Input ATURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0118 Engine Coolant Temperature Cir- <Ref. to EN(H4DOTC)(diag)-85, DTC P0118 ENGINE COOLANT TEMPER-
cuit High Input ATURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0122 Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-88, DTC P0122 THROTTLE/PEDAL POSITION
Switch “A” Circuit Low Input SENSOR/SWITCH “A” CIRCUIT LOW INPUT, Diagnostic Procedure with
P0123 Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-90, DTC P0123 THROTTLE/PEDAL POSITION
Switch “A” Circuit High Input SENSOR/SWITCH “A” CIRCUIT HIGH INPUT, Diagnostic Procedure with
P0131 O2 Sensor Circuit Low Voltage <Ref. to EN(H4DOTC)(diag)-92, DTC P0131 O2 SENSOR CIRCUIT LOW
P0132 O2 Sensor Circuit High Voltage <Ref. to EN(H4DOTC)(diag)-94, DTC P0132 O2 SENSOR CIRCUIT HIGH
P0134 O2 Sensor Circuit No Activity <Ref. to EN(H4DOTC)(diag)-96, DTC P0134 O2 SENSOR CIRCUIT NO
P0137 O2 Sensor Circuit Low Voltage <Ref. to EN(H4DOTC)(diag)-98, DTC P0137 O2 SENSOR CIRCUIT LOW
EN(H4DOTC)(diag)-55
DTC Item Note

P0138 O2 Sensor Circuit High Voltage <Ref. to EN(H4DOTC)(diag)-101, DTC P0138 O2 SENSOR CIRCUIT HIGH
P0171 System Too Lean (Bank 1) <Ref. to EN(H4DOTC)(diag)-103, DTC P0171 SYSTEM TOO LEAN (BANK
P0172 System Too Rich (Bank 1) <Ref. to EN(H4DOTC)(diag)-104, DTC P0172 SYSTEM TOO RICH (BANK
P0222 Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-107, DTC P0222 THROTTLE/PEDAL POSI-
P0230 Fuel Pump Primary Circuit <Ref. to EN(H4DOTC)(diag)-111, DTC P0230 FUEL PUMP PRIMARY CIR-
P0245 Turbo/Super Charger Wastegate <Ref. to EN(H4DOTC)(diag)-114, DTC P0245 TURBO/SUPER CHARGER
Solenoid “A” Low WASTEGATE SOLENOID “A” LOW, Diagnostic Procedure with Diagnostic
P0246 Turbo/Super Charger Wastegate <Ref. to EN(H4DOTC)(diag)-116, DTC P0246 TURBO/SUPER CHARGER
Solenoid “A” High WASTEGATE SOLENOID “A” HIGH, Diagnostic Procedure with Diagnostic
P0261 Cylinder 1 Injector Circuit Low <Ref. to EN(H4DOTC)(diag)-118, DTC P0261 CYLINDER 1 INJECTOR
P0327 Knock Sensor 1 Circuit Low Input <Ref. to EN(H4DOTC)(diag)-122, DTC P0327 KNOCK SENSOR 1 CIRCUIT
(Bank 1 or Single Sensor) LOW INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
P0328 Knock Sensor 1 Circuit High Input <Ref. to EN(H4DOTC)(diag)-124, DTC P0328 KNOCK SENSOR 1 CIRCUIT
(Bank 1 or Single Sensor) HIGH INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
P0335 Crankshaft Position Sensor “A” Cir- <Ref. to EN(H4DOTC)(diag)-126, DTC P0335 CRANKSHAFT POSITION
(DTC).>
P0340 Camshaft Position Sensor “A” Cir- <Ref. to EN(H4DOTC)(diag)-128, DTC P0340 CAMSHAFT POSITION SEN-
cuit (Bank 1or Single Sensor) SOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
P0345 Camshaft Position Sensor “A” Cir- <Ref. to EN(H4DOTC)(diag)-130, DTC P0345 CAMSHAFT POSITION SEN-
cuit (Bank 2) SOR “A” CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0350 Ignition Coil Primary/Secondary <Ref. to EN(H4DOTC)(diag)-132, DTC P0350 IGNITION COIL PRIMARY/
Circuit SECONDARY CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0365 Camshaft Position Sensor “B” Cir- <Ref. to EN(H4DOTC)(diag)-135, DTC P0365 CAMSHAFT POSITION SEN-
cuit (Bank 1) SOR “B” CIRCUIT (BANK 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0390 Camshaft Position Sensor “B” Cir- <Ref. to EN(H4DOTC)(diag)-137, DTC P0390 CAMSHAFT POSITION SEN-
cuit (Bank 2) SOR “B” CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0458 Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-139, DTC P0458 EVAPORATIVE EMISSION
tem Purge Control Valve Circuit CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic
Low Procedure with Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-56
DTC Item Note

P0459 Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-141, DTC P0459 EVAPORATIVE EMISSION
tem Purge Control Valve Circuit CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnos-
High tic Procedure with Diagnostic Trouble Code (DTC).>
P0500 Vehicle Speed Sensor <Ref. to EN(H4DOTC)(diag)-143, DTC P0500 VEHICLE SPEED SENSOR,
P0512 Starter Request Circuit <Ref. to EN(H4DOTC)(diag)-144, DTC P0512 STARTER REQUEST CIR-
P0519 Idle Control System Malfunction <Ref. to EN(H4DOTC)(diag)-146, DTC P0519 IDLE CONTROL SYSTEM
Code (DTC).>
P0562 System Voltage Low <Ref. to EN(H4DOTC)(diag)-147, DTC P0562 SYSTEM VOLTAGE LOW,
P0563 System Voltage High <Ref. to EN(H4DOTC)(diag)-149, DTC P0563 SYSTEM VOLTAGE HIGH,
P0600 Serial Communication Link <Ref. to EN(H4DOTC)(diag)-151, DTC P0600 SERIAL COMMUNICATION
P0604 Internal Control Module Read <Ref. to EN(H4DOTC)(diag)-151, DTC P0604 INTERNAL CONTROL MOD-
P0605 Internal Control Module Read Only <Ref. to EN(H4DOTC)(diag)-151, DTC P0605 INTERNAL CONTROL MOD-
P0607 Control Module Performance <Ref. to EN(H4DOTC)(diag)-152, DTC P0607 CONTROL MODULE PER-
P0638 Throttle Actuator Control Range/ <Ref. to EN(H4DOTC)(diag)-154, DTC P0638 THROTTLE ACTUATOR
Performance (Bank 1) CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with
P0700 Transmission Control System (MIL <Ref. to EN(H4DOTC)(diag)-154, DTC P0700 TRANSMISSION CONTROL
Code (DTC).>
P0851 Neutral Switch Input Circuit Low <Ref. to EN(H4DOTC)(diag)-154, DTC P0851 NEUTRAL SWITCH INPUT
P0852 Neutral Switch Input Circuit High <Ref. to EN(H4DOTC)(diag)-154, DTC P0852 NEUTRAL SWITCH INPUT
(DTC).>
P1110 Atmospheric Pressure Sensor Cir- <Ref. to EN(H4DOTC)(diag)-155, DTC P1110 ATMOSPHERIC PRESSURE
cuit Malfunction (Low Input) SENSOR CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure
P1111 Atmospheric Pressure Sensor Cir- <Ref. to EN(H4DOTC)(diag)-155, DTC P1111 ATMOSPHERIC PRESSURE
cuit Malfunction (High Input) SENSOR CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
P1160 Return Spring Failure <Ref. to EN(H4DOTC)(diag)-155, DTC P1160 RETURN SPRING FAILURE,
P1518 Starter Switch Circuit Low Input <Ref. to EN(H4DOTC)(diag)-156, DTC P1518 STARTER SWITCH CIRCUIT
P1560 Back-Up Voltage Circuit Malfunc- <Ref. to EN(H4DOTC)(diag)-158, DTC P1560 BACK-UP VOLTAGE CIR-
tion CUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1572 IMM Circuit Failure (Except <Ref. to IM(diag)-22, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
Antenna Circuit) ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H4DOTC)(diag)-57
DTC Item Note

P2088 OCV Solenoid Valve Signal A Cir- <Ref. to EN(H4DOTC)(diag)-160, DTC P2088 OCV SOLENOID VALVE
cuit Open (Bank 1) SIGNAL A CIRCUIT OPEN (BANK 1), Diagnostic Procedure with Diagnostic
cuit Short (Bank 1) SIGNAL A CIRCUIT SHORT (BANK 1), Diagnostic Procedure with Diagnos-
P2090 OCV Solenoid Valve Signal B Cir- <Ref. to EN(H4DOTC)(diag)-164, DTC P2090 OCV SOLENOID VALVE
cuit Open (Bank 1) SIGNAL B CIRCUIT OPEN (BANK 1), Diagnostic Procedure with Diagnostic
cuit Short (Bank 1) SIGNAL B CIRCUIT SHORT (BANK 1), Diagnostic Procedure with Diagnos-
cuit Open (Bank 2) SIGNAL A CIRCUIT OPEN (BANK 2), Diagnostic Procedure with Diagnostic
cuit Short (Bank 2) SIGNAL A CIRCUIT SHORT (BANK 2), Diagnostic Procedure with Diagnos-
cuit Open (Bank 2) SIGNAL B CIRCUIT OPEN (BANK 2), Diagnostic Procedure with Diagnostic
cuit Short (Bank 2) SIGNAL B CIRCUIT SHORT (BANK 2), Diagnostic Procedure with Diagnos-
P2101 Throttle Actuator Control Motor Cir- <Ref. to EN(H4DOTC)(diag)-176, DTC P2101 THROTTLE ACTUATOR
P2109 Throttle/Pedal Position Sensor A <Ref. to EN(H4DOTC)(diag)-184, DTC P2109 THROTTLE ANGLE CLOSED
Minimum Stop Performance POSITION ERROR, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H4DOTC)(diag)-58
DTC Item Note

EN(H4DOTC)(diag)-59

A: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
Detect as soon as the malfunction occurs.
CAUTION:
WIRING DIAGRAM:
B18
MAIN RELAY BATTERY
1 2
SBF-6 3 4
5
3
6 B47
4
1 2
3
2 3 4
1 5 6
FRONT OXYGEN
B47 (A/F) SENSOR
B18
B21
4
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A26
A33
A25
A2
A3
A: B134
1 2 3 4 5 6 7
A: B134 ECM 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
A6
A7
B21
54
F2
EN-01946
EN(H4DOTC)(diag)-60
Step Check Yes No

(B18) No. 3 (+) — Engine ground ("): sensor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
main relay connec-
tor
2 CHECK HARNESS BETWEEN FRONT OXY- Is the resistance less than 1 Go to step 3. Repair the open
GEN (A/F) SENSOR AND ECM. '? circuit in harness
2) Disconnect the connectors from ECM. front oxygen (A/F)
3) Measure the voltage between front oxygen sensor.
(A/F) sensor connector and ECM.
(B18) No. 4 — (B134) No. 2:
(B18) No. 4 — (B134) No. 3:
3 CHECK HARNESS BETWEEN FRONT OXY- Is the resistance more than 1 Go to step 4. Repair the ground
GEN (A/F) SENSOR AND ECM. M'? short circuit in har-
Measure the resistance between ECM connec- ness between
tor and chassis ground. ECM and front
(B134) No. 2 — Chassis ground: sor.
4 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance 2.4 '? Repair the poor Replace the front
1) Turn the ignition switch to OFF. contact in ECM oxygen (A/F) sen-
2) Measure the resistance between front oxy- connector. sor. <Ref. to
gen (A/F) sensor connector terminals. FU(H4DOTC)-33,
Terminals Front Oxygen (A/
No. 3 — No. 4: F) Sensor.>
EN(H4DOTC)(diag)-61
B: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
MAIN RELAY BATTERY
1 2
SBF-6 3 4
5
3
6 B47
4
1 2
3
2 3 4
1 5 6
FRONT OXYGEN
B47 (A/F) SENSOR
B18
B21
4
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A26
A33
A25
A2
A3
A: B134
1 2 3 4 5 6 7
A: B134 ECM 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
A6
A7
B21
54
F2
EN-01946
EN(H4DOTC)(diag)-62
Step Check Yes No

1) Turn the ignition switch to OFF. '? circuit in harness
2) Disconnect the connector from ECM. between ECM
3) Measure the resistance between ECM con- connector and
nector and chassis ground. chassis ground.
2 CHECK VOLTAGE BETWEEN ECM AND Is the voltage more than 10 V? Repair the battery Repair the poor
FRONT OXYGEN (A/F) SENSOR. short circuit in har- contact in ECM
Measure the voltage between ECM connector ness between connector.
and chassis ground. ECM and front
EN(H4DOTC)(diag)-63
C: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

B19 B47
5 1 2
1 2
3
3 4 3 4
6 5 6
4 B19
2
B83 T6
2 T5
1
1 2 3 4 2 1
B47 5 6 7 8 4 3
1
REAR
OXYGEN SENSOR B21
T6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2
4
23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41
42 43 44 45 46 47
1
3
B19 48 49 50 51 52 53 54
B: 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
B83
28 29 30 31 32 33 34 35
D25
D31
C35
B2
C: B136
1 2 3 4 5 6
B: B135 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
C: B136 ECM 28 29 30 31 32 33 34 35
B21
35
D: B137 D: B137
E2
E 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B4
B1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
* : TERMINAL NO. RANDOM ARRANGEMENT E
EN-01947
EN(H4DOTC)(diag)-64
Step Check Yes No

ECM and engine
ground cable
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 1 Go to step 3. Repair the ground
REAR OXYGEN SENSOR. M'? short circuit in har-
1) Disconnect the connector from rear oxygen ness between
sensor. ECM and rear oxy-
2) Measure the resistance between ECM con- gen sensor con-
nector and chassis ground. nector.
3 CHECK HARNESS BETWEEN ECM AND Does the resistance change by Repair the poor Go to step 4.
REAR OXYGEN SENSOR. shaking the ECM harness and contact in ECM
Measure the resistance between ECM connec- connector? connector.
1) Connect the connector to ECM. NOTE:
3) Measure the voltage between rear oxygen the following:
sensor connector and chassis ground. • Open circuit in
(T6) No. 1 (+) — Chassis ground ("): main relay and
rear oxygen sen-
sor connector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
coupling connector
EN(H4DOTC)(diag)-65
Step Check Yes No

1) Turn the ignition switch to OFF. '? ness and connec- oxygen sensor.
2) Measure the resistance between rear oxy- tor. <Ref. to
gen sensor connector terminals. NOTE: FU(H4DOTC)-34,
Terminals In this case, repair Rear Oxygen Sen-
No. 1 — No. 2: the following: sor.>
• 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
• Poor contact in
coupling connector
EN(H4DOTC)(diag)-66
D: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

B19 B47
5 1 2
1 2
3
3 4 3 4
6 5 6
4 B19
2
B83 T6
2 T5
1
1 2 3 4 2 1
B47 5 6 7 8 4 3
1
REAR
OXYGEN SENSOR B21
T6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2
4
23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41
42 43 44 45 46 47
1
3
B19 48 49 50 51 52 53 54
B: 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
B83
28 29 30 31 32 33 34 35
D25
D31
C35
B2
C: B136
1 2 3 4 5 6
B: B135 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
C: B136 ECM 28 29 30 31 32 33 34 35
B21
35
D: B137 D: B137
E2
E 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B4
B1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-01947
EN(H4DOTC)(diag)-67
Step Check Yes No

ECM and engine
ground cable
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair the battery Repair the poor
REAR OXYGEN SENSOR. short circuit in har- connection in ECM
Measure the voltage between ECM and chas- ness between connector.
sis ground. ECM and rear oxy-
Connector & terminal gen sensor.
EN(H4DOTC)(diag)-68
E: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
*
*
B83
32
23
31
35
13
E
B136 ECM
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4
1 2 3 4 5 3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-01948
EN(H4DOTC)(diag)-69
Step Check Yes No

aru Select Monitor switch to ON. this time. A tempo-
4) Start and idle the engine. rary poor contact
5) Read the voltage of mass air flow sensor of the connector or
using Subaru Select Monitor. harness may be
NOTE: the cause. Repair
For detailed operation procedure, refer to the harness or con-
“READ CURRENT DATA SHOWN ON DIS- nector in the mass
PLAY FOR ENGINE”. <Ref. to air flow sensor.
EN(H4DOTC)(diag)-21, Subaru Select Moni- NOTE:
tor.> In this case, repair
the following:
• Open or ground
ness between
mass air flow sen-
sor and ECM con-
nector
• Poor contact in
mass air flow sen-
sor or ECM con-
nector
2 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 0.2 V? Go to step 4. Go to step 3.
and chassis ground while engine is idling.
3 CHECK INPUT SIGNAL FOR ECM (USING Does the voltage change by Repair the poor Replace and
SUBARU SELECT MONITOR). shaking the harness and con- contact in ECM check it again
Measure the voltage between ECM connector nector of ECM while monitor- connector. because of ECM
and chassis ground while engine is idling. ing the value with Subaru malfunction possi-
Select Monitor? bility.
4 CHECK POWER SUPPLY TO MASS AIR Is the voltage more than 10 V? Go to step 5. Repair the open
FLOW SENSOR. circuit between
1) Turn the ignition switch to OFF. mass air flow sen-
2) Disconnect the connector from mass air sor and main relay.
flow sensor.
MASS AIR FLOW SENSOR CONNECTOR. '? circuit between
1) Turn the ignition switch to OFF. ECM and mass air
2) Disconnect the connector from ECM. flow sensor con-
between ECM and mass air flow sensor con-
nector.
(B136) No. 23 — (B3) No. 3:
(B136) No. 31 — (B3) No. 2:
(B136) No. 35 — (B3) No. 5:
EN(H4DOTC)(diag)-70
Step Check Yes No

MASS AIR FLOW SENSOR CONNECTOR. M'? short circuit
ECM and chassis ground. mass air flow sen-
7 CHECK POOR CONTACT. Is there poor contact in mass Repair the poor Replace the mass
Check poor contact in mass air flow sensor air flow sensor connector? contact in mass air air flow and intake
connector. flow sensor con- air temperature
nector. sensor. <Ref. to
FU(H4DOTC)-28,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H4DOTC)(diag)-71
F: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
*
*
B83
32
23
31
35
13
E
B136 ECM
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4
1 2 3 4 5 3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-01948
EN(H4DOTC)(diag)-72
Step Check Yes No

aru Select Monitor switch to ON. this time.
5) Read the voltage of mass air flow sensor
NOTE:
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to
EN(H4DOTC)(diag)-21, Subaru Select Moni-
tor.>
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 5 V? Repair the battery Go to step 3.
MASS AIR FLOW SENSOR CONNECTOR. short circuit in har-
2) Disconnect the connector from mass air- mass air flow sen-
flow sensor. sor connector and
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Replace the mass Repair the open
MASS AIR FLOW SENSOR CONNECTOR. '? air flow sensor. circuit in harness
1) Turn the ignition switch to OFF. <Ref. to between mass air
2) Disconnect the connector from ECM. FU(H4DOTC)-28, flow sensor con-
3) Measure the resistance of harness Mass Air Flow and nector and ECM
between ECM connector and mass air flow Intake Air Temper- connector.
sensor connector. ature Sensor.>
(B3) No. 2 — (B136) No. 31:
EN(H4DOTC)(diag)-73
G: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
MANIFOLD ABSOLUTE
PRESSURE SENSOR
2
1
3
E21
E2
19
20
7
B21
*
*
B83
22
35
16
B136 ECM
E21 B83 B21 B136
1 2 3 1 2 3 4 1 2 3 4 5 6
5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 7 8 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22
17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-01949
Step Check Yes No

and chassis ground.
EN(H4DOTC)(diag)-74
Step Check Yes No

2 CHECK INPUT SIGNAL FROM ECM. Does the voltage change by Repair the poor Replace the ECM.
Measure the voltage between ECM connector shaking the harness and con- contact in ECM <Ref. to
and chassis ground. nector of ECM while monitor- connector. FU(H4DOTC)-35,
Connector & terminal ing the value with voltage Engine Control
(B136) No. 16 (+) — Chassis ground ("): meter? Module (ECM).>
3 CHECK INPUT SIGNAL FROM ECM. Is the voltage less than 0.7 V? Go to step 4. Replace the ECM.
Measure the voltage between ECM and chas- <Ref. to
sis ground. FU(H4DOTC)-35,
(B136) No. 22 (+) — Chassis ground ("): Module (ECM).>
2) Disconnect the connector from the manifold pressure sensor
engine ground.
MANIFOLD ABSOLUTE PRESSURE SEN- '? circuit in harness
sensor connector.
(B136) No. 35 — (E21) No. 1:
MANIFOLD ABSOLUTE PRESSURE SEN- M'? short circuit in har-
SOR CONNECTOR. ness between
Measure the resistance of harness between ECM and mani-
manifold absolute pressure sensor connector fold absolute pres-
and engine ground. sure sensor
sure sensor to FU(H4DOTC)-
connector. 28, Mass Air Flow
and Intake Air
Temperature Sen-
sor.>
EN(H4DOTC)(diag)-75
H: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
MANIFOLD ABSOLUTE
PRESSURE SENSOR
2
1
3
E21
E2
19
20
7
B21
*
*
B83
22
35
16
B136 ECM
E21 B83 B21 B136
1 2 3 1 2 3 4 1 2 3 4 5 6
5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 7 8 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22
17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-01949
Step Check Yes No

and chassis ground.
EN(H4DOTC)(diag)-76
Step Check Yes No

2 CHECK INPUT SIGNAL FROM ECM. Does the voltage change by Repair the poor Replace the ECM.
Measure the voltage between ECM connector shaking the harness and con- contact in ECM <Ref. to
and chassis ground. nector of ECM while monitor- connector. FU(H4DOTC)-35,
Connector & terminal ing the value with voltage Engine Control
(B136) No. 16 (+) — Chassis ground ("): meter? Module (ECM).>
3 CHECK INPUT SIGNAL FROM ECM. Is the voltage more than 4.5 V? Go to step 4. Replace the ECM.
Measure the voltage between ECM connector <Ref. to
and chassis ground. FU(H4DOTC)-35,
2) Disconnect the connector from the manifold pressure sensor
engine ground.
sensor connector.
(B136) No. 22 — (E21) No. 2:
(B136) No. 35 — (E21) No. 1:
sure sensor to FU(H4DOTC)-
lute Pressure Sen-
sor.>
EN(H4DOTC)(diag)-77
I: DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
*
*
B83
32
23
31
35
13
E
B136 ECM
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4
1 2 3 4 5 3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-01948
EN(H4DOTC)(diag)-78
Step Check Yes No

1 CHECK CURRENT DATA. Is engine coolant temperature Go to step 2. Repair the poor
“READ CURRENT DATA SHOWN ON DIS- mass air flow and
PLAY FOR ENGINE”. <Ref. to intake air tempera-
EN(H4DOTC)(diag)-21, Subaru Select Moni- ture sensor
tor.> • Poor contact in
ECM
• Poor contact in
joint connector
2 CHECK HARNESS BETWEEN MASS AIR Is the value less than "36!C Replace the mass Repair the ground
FLOW AND INTAKE AIR TEMPERATURE ("33!F)? air flow and intake short circuit in har-
SENSOR AND ECM CONNECTOR. air temperature ness between
1) Turn the ignition switch to OFF. sensor. <Ref. to mass air flow and
2) Disconnect the connector mass air flow and FU(H4DOTC)-28, intake air tempera-
intake air temperature sensor. Mass Air Flow and ture sensor and
3) Turn the ignition switch to ON. Intake Air Temper- ECM connector.
4) Read the data of intake air temperature ature Sensor.>
NOTE:
tor.>
EN(H4DOTC)(diag)-79
J: DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
1
B47
MASS AIR FLOW AND

SENSOR
B3
5
*
*
B83
32
23
31
35
13
E
B136 ECM
B3 B47 B136 B83
1 2 1 2 3 4 5 6
1 2 3 4
1 2 3 4 5 3 4 7 8 9 10 11 12 13 14 15 16
5 6 7 8
5 6 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
EN-01948
EN(H4DOTC)(diag)-80
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than "36!C (" Go to step 2. Repair the poor
1) Start the engine. 33!F)? contact.
“READ CURRENT DATA SHOWN ON DIS- mass air flow and
PLAY FOR ENGINE”. <Ref. to intake air tempera-
EN(H4DOTC)(diag)-21, Subaru Select Moni- ture sensor
tor.> • Poor contact in
ECM
• Poor contact in
joint connector
1) Turn the ignition switch to OFF. mass air flow and
2) Disconnect the connector mass air flow and intake air tempera-
intake air temperature sensor. ture sensor and
3) Measure the voltage between mass air flow ECM connector.
and intake air temperature sensor connector
and engine ground.
1) Turn the ignition switch to ON. mass air flow and
2) Measure the voltage between mass air flow intake air tempera-
and intake air temperature sensor connector ture sensor and
and engine ground. ECM connector.
4 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 4 V? Go to step 5. Repair the har-
FLOW AND INTAKE AIR TEMPERATURE ness and connec-
SENSOR AND ECM CONNECTOR. tor.
Measure the voltage between mass air flow NOTE:
and intake air temperature sensor connector In this case, repair
and engine ground. the following:
(B3) No. 4 (+) — Engine ground ("): ness between
mass air flow and
intake air tempera-
ture sensor and
ECM connector
• Poor contact in
mass air flow and
intake air tempera-
ture sensor
• Poor contact in
ECM
• Poor contact in
joint connector
EN(H4DOTC)(diag)-81
Step Check Yes No

5 CHECK HARNESS BETWEEN MASS AIR Is the resistance less than 5 Replace the mass Repair the har-
FLOW AND INTAKE AIR TEMPERATURE '? air flow and intake ness and connec-
SENSOR AND ECM CONNECTOR. air temperature tor.
1) Turn the ignition switch to OFF. sensor. <Ref. to NOTE:
2) Measure the resistance of harness FU(H4DOTC)-28, In this case, repair
between mass air flow and intake air tempera- Mass Air Flow and the following:
ture sensor and engine ground. Intake Air Temper- • Open circuit in
Connector & terminal ature Sensor.> ness between
(B3) No. 5 — Engine ground: mass air flow and
intake air tempera-
ture sensor and
ECM connector
• Poor contact in
mass air flow and
intake air tempera-
ture sensor
• Poor contact in
ECM
• Poor contact in
joint connector
EN(H4DOTC)(diag)-82
K: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
• Hard to start
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT 1 2
TEMPERATURE
SENSOR
B83
2
1
E8
1 2 3 4
5 6 7 8
E2
19
8
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 31 32 33 34 35
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
14
35
B136 ECM
EN-01950
EN(H4DOTC)(diag)-83
Step Check Yes No

tor. the following:
“READ CURRENT DATA SHOWN ON DIS- temperature sen-
PLAY FOR ENGINE”. <Ref. to sor
EN(H4DOTC)(diag)-21, Subaru Select Moni- • Poor contact in
tor.> ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
2 CHECK HARNESS BETWEEN ENGINE Is engine coolant temperature Replace the Repair the ground
COOLANT TEMPERATURE SENSOR AND more than "40!C ("40!F)? engine coolant short circuit in har-
2) Disconnect the connectors from the engine FU(H4DOTC)-23, temperature sen-
tor.
NOTE:
tor.>
EN(H4DOTC)(diag)-84
L: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
• Hard to start
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT 1 2
TEMPERATURE
SENSOR
B83
2
1
E8
1 2 3 4
5 6 7 8
E2
19
8
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 31 32 33 34 35
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
14
35
B136 ECM
EN-01950
EN(H4DOTC)(diag)-85
Step Check Yes No

1) Start the engine. less than "40!C ("40!F)? contact.
tor. the following:
“READ CURRENT DATA SHOWN ON DIS- temperature sen-
PLAY FOR ENGINE”. <Ref. to sor
EN(H4DOTC)(diag)-21, Subaru Select Moni- • Poor contact in
tor.> ECM
• Poor contact in
coupling connector
• Poor contact in
joint connector
2) Disconnect the connectors from the engine coolant tempera-
ground.
ground. nector.
ECM CONNECTOR. tor.
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
• Poor contact in
joint connector
EN(H4DOTC)(diag)-86
Step Check Yes No

COOLANT TEMPERATURE SENSOR AND '? engine coolant ness and connec-
2) Measure the resistance of harness FU(H4DOTC)-23, In this case, repair
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
• Poor contact in
joint connector
EN(H4DOTC)(diag)-87
M: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
• Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
EN(H4DOTC)(diag)-88
Step Check Yes No

Check the poor contact in connector between nector between ECM and elec- contact. contact occurred,
present.
ELECTRONIC THROTTLE CONTROL. '? circuit of harness
(B136) No. 16 — (E57) No. 5:
(B136) No. 18 — (E57) No. 6:
ELECTRONIC THROTTLE CONTROL. M'? sis short circuit of
Repair the poor
3) Measure the voltage between electronic if defective.
throttle control connector and engine ground. <Ref. to
Connector & terminal FU(H4DOTC)-35,
(E57) No. 5 (+) — Engine ground ("): Engine Control
Module (ECM).>
1) Turn the ignition switch to OFF. '? contact of elec- contact in ECM
Connector & terminal Replace the elec- if defective.
(E57) No. 6 — Engine ground: tronic throttle con- <Ref. to
trol if defective. FU(H4DOTC)-35,
Engine Control
Module (ECM).>
EN(H4DOTC)(diag)-89
N: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
• Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
EN(H4DOTC)(diag)-90
Step Check Yes No

present.
(B136) No. 18 — (E57) No. 6:
(B136) No. 35 — (E57) No. 3:
3) Check the voltage change by shaking the
harness and connector of ECM and engine
harness connector while monitoring the value
with voltage meter.
ELECTRONIC THROTTLE CONTROL. M'? contact in harness. circuit to sensor
1) Turn the ignition switch to OFF. Repair the elec- power supply.
nectors.
(B136) No. 18 — (B136) No. 16:
EN(H4DOTC)(diag)-91
O: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
MAIN RELAY BATTERY
1 2
SBF-6 3 4
5
3
6 B47
4
1 2
3
2 3 4
1 5 6
FRONT OXYGEN
B47 (A/F) SENSOR
B18
B21
4
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A26
A33
A25
A2
A3
A: B134
1 2 3 4 5 6 7
A: B134 ECM 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
A6
A7
B21
54
F2
EN-01946
EN(H4DOTC)(diag)-92
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- M'? short circuit in har-
TOR. ness between
front oxygen (A/F) sensor connector. sor connector.
2 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Replace the front Repair harness
FRONT OXYGEN (A/F) SENSOR CONNEC- M'? oxygen (A/F) sen- short in harness
TOR. sor. <Ref. to between ECM and
Measure the resistance of harness between FU(H4DOTC)-33, front oxygen (A/F)
ECM connectors. Front Oxygen (A/ sensor connector.
Connector & terminal F) Sensor.>
(B134) No. 26 — (B134) No. 33:
EN(H4DOTC)(diag)-93
P: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
MAIN RELAY BATTERY
1 2
SBF-6 3 4
5
3
6 B47
4
1 2
3
2 3 4
1 5 6
FRONT OXYGEN
B47 (A/F) SENSOR
B18
B21
4
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A26
A33
A25
A2
A3
A: B134
1 2 3 4 5 6 7
A: B134 ECM 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
A6
A7
B21
54
F2
EN-01946
EN(H4DOTC)(diag)-94
Step Check Yes No

1) Turn the ignition switch to ON. FU(H4DOTC)-33, ECM and front
EN(H4DOTC)(diag)-95
Q: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN-

SOR 1)
CAUTION:
WIRING DIAGRAM:
B18
MAIN RELAY BATTERY
1 2
SBF-6 3 4
5
3
6 B47
4
1 2
3
2 3 4
1 5 6
FRONT OXYGEN
B47 (A/F) SENSOR
B18
B21
4
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
A26
A33
A25
A2
A3
A: B134
1 2 3 4 5 6 7
A: B134 ECM 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
A6
A7
B21
54
F2
EN-01946
EN(H4DOTC)(diag)-96
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Replace the front Repair the open
FRONT OXYGEN (A/F) SENSOR CONNEC- '? oxygen (A/F) sen- circuit in harness
TOR. sor. <Ref. to between ECM and
1) Turn the ignition switch to OFF. FU(H4DOTC)-33, front oxygen (A/F)
2) Disconnect the connector from ECM and Front Oxygen (A/ sensor connector.
front oxygen (A/F) sensor. F) Sensor.>
connector.
(B134) No. 26 — (B18) No. 1:
(B134) No. 33 — (B18) No. 2:
EN(H4DOTC)(diag)-97
R: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

B19 B47
5 1 2
1 2
3
3 4 3 4
6 5 6
4 B19
2
B83 T6
2 T5
1
1 2 3 4 2 1
B47 5 6 7 8 4 3
1
REAR
OXYGEN SENSOR B21
T6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2
4
23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41
42 43 44 45 46 47
1
3
B19 48 49 50 51 52 53 54
B: 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
B83
28 29 30 31 32 33 34 35
D25
D31
C35
B2
C: B136
1 2 3 4 5 6
B: B135 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
C: B136 ECM 28 29 30 31 32 33 34 35
B21
35
D: B137 D: B137
E2
E 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B4
B1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-01947
EN(H4DOTC)(diag)-98
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
2 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 6. Go to step 3.
1) Warm-up the engine until engine coolant
the engine speed at 2,000 rpm to 3,000 rpm for
2 minutes.
NOTE:
tor.>
3 CHECK REAR OXYGEN SENSOR DATA. Is the voltage 0.2 — 0.4 V? Go to step 4. Replace the rear
Read the data of rear oxygen sensor signal oxygen sensor.
using Subaru Select Monitor. <Ref. to
FU(H4DOTC)-34,
Rear Oxygen Sen-
sor.>
REAR OXYGEN SENSOR CONNECTOR. '? circuit in harness
nector.
(B137) No. 25 — (T6) No. 4:
5 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V? Replace the rear Repair the har-
1) Turn the ignition switch to OFF. <Ref. to tor.
2) Disconnect the connector from rear oxygen FU(H4DOTC)-34, NOTE:
sensor. Rear Oxygen Sen- In this case, repair
3) Turn the ignition switch to ON. sor.> the following:
(T6) No. 4 (+) — Chassis ground ("): sor and ECM con-
nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
EN(H4DOTC)(diag)-99
Step Check Yes No

6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear
Check exhaust system parts. tem? the faulty part. oxygen sensor.
NOTE: <Ref. to
Check the following items: FU(H4DOTC)-34,
• Loose part of exhaust system and incom- Rear Oxygen Sen-
plete installation sor.>
sensor
EN(H4DOTC)(diag)-100
S: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
MAIN RELAY BATTERY

B19 B47
5 1 2
1 2
3
3 4 3 4
6 5 6
4 B19
2
B83 T6
2 T5
1
1 2 3 4 2 1
B47 5 6 7 8 4 3
1
REAR
OXYGEN SENSOR B21
T6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2
4
23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41
42 43 44 45 46 47
1
3
B19 48 49 50 51 52 53 54
B: 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
B83
28 29 30 31 32 33 34 35
D25
D31
C35
B2
C: B136
1 2 3 4 5 6
B: B135 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
C: B136 ECM 28 29 30 31 32 33 34 35
B21
35
D: B137 D: B137
E2
E 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B4
B1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-01947
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
2 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 6. Go to step 3.
1) Warm-up the engine until engine coolant
the engine speed at 2,000 rpm to 3,000 rpm for
two minutes.
NOTE:
tor.>
3 CHECK REAR OXYGEN SENSOR DATA. Is the voltage 0.2 — 0.4 V? Go to step 4. Replace the rear
Read the data of rear oxygen sensor signal oxygen sensor.
using Subaru Select Monitor. <Ref. to
FU(H4DOTC)-34,
Rear Oxygen Sen-
sor.>
REAR OXYGEN SENSOR CONNECTOR. '? circuit in harness
nector.
(B137) No. 25 — (T6) No. 4:
5 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V? Replace the rear Repair the har-
1) Turn the ignition switch to OFF. <Ref. to tor.
2) Disconnect the connector from rear oxygen FU(H4DOTC)-34, NOTE:
sensor. Rear Oxygen Sen- In this case, repair
3) Turn the ignition switch to ON. sor.> the following:
(T6) No. 4 (+) — Chassis ground ("): sor and ECM con-
nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
Step Check Yes No

6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear
Check exhaust system parts. tem? the faulty part. oxygen sensor.
NOTE: <Ref. to
Check the following items: FU(H4DOTC)-34,
• Loose part of exhaust system and incom- Rear Oxygen Sen-
plete installation sor.>
sensor
T: DTC P0171 SYSTEM TOO LEAN (BANK 1)

NOTE:
For diagnostic procedure, refer to DTC P0172. <Ref. to EN(H4DOTC)(diag)-104, DTC P0172 SYSTEM TOO
U: DTC P0172 SYSTEM TOO RICH (BANK 1)

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
Step Check Yes No

1 CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair exhaust Go to step 2.
2 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or Repair air intake Go to step 3.
disconnection of hoses on air system.
intake system?
area. too high:
(3) After the engine stalls, crank it for 5 more • Improper fuel
seconds. pump discharge
3) Disconnect the fuel delivery hose from fuel
filter, and connect the fuel pressure gauge.
tion is neutral.
intake manifold.
Warning:
NOTE:
If fuel pressure does not increase, squeeze the
fuel return hose 2 to 3 times, then measure fuel
pressure again.
Step Check Yes No

Warning: too high:
fuel pressure gauge. sure regulator
• If out of specification as measured at this too low:
step, check or replace pressure regulator and • Faulty pres-
pressure regulator vacuum hose. sure regulator
• Improper fuel
pump discharge
• Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERATURE Is engine coolant temperature Go to step 6. Replace the
SENSOR. more than 60!C (140!F)? engine coolant
1) Start the engine and warm-up completely. temperature sen-
ture sensor signal using Subaru Select Moni- FU(H4DOTC)-23,
tor. Engine Coolant
For detailed operation procedure, refer to sor.>
tor.>
6 CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value within Go to step 7. Replace the mass
TEMPERATURE SENSOR. the following? air flow and intake
1) Start and warm-up the engine until engine Ignition ON: 73.3 — 106.6 kPa air temperature
coolant temperature is greater than 60!C (550 — 800 mmHg, 21.65 — sensor. <Ref. to
(140!F). 31.50 inHg) Idling: 24.0 — 41.3 FU(H4DOTC)-28,
2) Place the shift lever in neutral position. kPa (180 — 310 mmHg, 7.09 Mass Air Flow and
3) Turn the A/C switch to OFF. — 12.20 inHg) Intake Air Temper-
4) Turn all accessory switches to OFF. ature Sensor.>
5) Read the data of mass air flow and intake
Select Monitor.
NOTE:
tor.>
Step Check Yes No

7 CHECK MASS AIR FLOW AND INTAKE AIR Subtract the ambient tempera- Replace the ECM. Check mass air
TEMPERATURE SENSOR. ture from intake air tempera- <Ref. to flow and intake air
1) Start and warm-up the engine until engine ture, and is the value from " FU(H4DOTC)-35, temperature sen-
coolant temperature is greater than 60!C 10!C (14!F) to 50!C (122!F)? Engine Control sor. <Ref. to
(140!F). Module (ECM).> FU(H4DOTC)-28,
2) Place the shift lever in neutral position. Mass Air Flow and
3) Turn the A/C switch to OFF. Intake Air Temper-
4) Turn all accessory switches to OFF. ature Sensor.>
5) Open the hood.
6) Measure the ambient temperature.
7) Read the data of mass air flow and intake
Select Monitor.
NOTE:
tor.>
V: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
• Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
Step Check Yes No

Check the poor contact in connector between contact. contact occurred,
present.
(B136) No. 16 — (E57) No. 5:
(B136) No. 29 — (E57) No. 4:
ELECTRONIC THROTTLE CONTROL. M'? sis short circuit of
Repair the poor
throttle control connector and engine ground. if defective.
Connector & terminal <Ref. to
(E57) No. 5 (+) — Engine ground ("): FU(H4DOTC)-35,
Engine Control
Module (ECM).>
1) Turn the ignition switch to OFF. '? contact of elec- contact in ECM
Connector & terminal Replace the elec- if defective.
(E57) No. 4 — Engine ground: tronic throttle con- <Ref. to
trol if defective. FU(H4DOTC)-35,
Engine Control
Module (ECM).>
W: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
• Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
Step Check Yes No

present.
(B136) No. 35 — (E57) No. 3:
(B136) No. 29 — (E57) No. 4:
ELECTRONIC THROTTLE CONTROL. M'? contact. Repair the ply circuit may be
1) Turn the ignition switch to OFF. electronic throttle shorted.
2) Disconnect the connector from ECM. control.
terminals.
(B136) No. 29 — (B136) No. 16:
X: DTC P0230 FUEL PUMP PRIMARY CIRCUIT

CAUTION:
WIRING DIAGRAM:
BATTERY
No.31
1 2
FUEL PUMP
RELAY B362
B98
7
4
R2
10
FUEL PUMP
CONTROL UNIT
R122
5
9
8
7
6
R2
5
6
B98
D28
B27
5
6
FUEL
PUMP
ECM E E
R58 M B: B135
D: B137
B362 B98 R58 R122 B: B135 D: B137
3 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 1 2 3
4 3 4 5 6 7 8 9 10 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
4 5 6 7 8
5 6 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
5 28 29 30 31 32 33 34 35 26 27 28 29 30 31
7 8
6
EN-01944
Step Check Yes No

1 CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage more than 10 V? Go to step 2. Repair the power
PUMP CONTROL UNIT. supply circuit.
2) Disconnect the connector from fuel pump In this case, repair
control unit. the following:
3) Turn the ignition switch to ON. • Open or ground
4) Measure the voltage between fuel pump short circuit in har-
control unit and chassis ground. ness between fuel
Connector & terminal pump relay and
(R122) No. 10 (+) — Chassis ground ("): fuel pump control
unit
• Poor contact in
fuel pump control
unit connector
• Poor contact in
fuel pump relay
connector
2 CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 Go to step 3. Repair the har-
CONTROL UNIT. '? ness and connec-
between fuel pump control unit and chassis In this case, repair
Connector & terminal • Open circuit
(R122) No. 5 — Chassis ground: between fuel pump
control unit and
chassis ground
• Poor contact in
fuel pump control
unit connector
3 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Go to step 4. Repair the open
CONTROL UNIT AND FUEL PUMP CONNEC- '? circuit between
TOR. fuel pump control
1) Disconnect the connector from fuel pump. unit and fuel
2) Measure the resistance of harness pump.
between fuel pump control unit and fuel pump
connector.
(R122) No. 7 — (R58) No. 5:
(R122) No. 6 — (R58) No. 6:
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 5. Repair the ground
CONTROL UNIT AND FUEL PUMP CONNEC- M'? short circuit
TOR. between fuel pump
Measure the resistance of harness between control unit and
fuel pump control unit and chassis ground. fuel pump.
Step Check Yes No

CONTROL UNIT AND ECM CONNECTOR. '? ness and connec-
3) Measure the resistance in harness In this case, repair
between fuel pump control unit and ECM con- the following:
nector. • Open circuit
Connector & terminal between fuel pump
(R122) No. 9 — (B137) No. 28: control unit and
(R122) No. 8 — (B135) No. 27: ECM
• Poor contact in
fuel pump control
unit and ECM con-
nector
6 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 7. Repair the ground
CONTROL UNIT AND ECM CONNECTOR. M'? short circuit
fuel pump control unit and chassis ground. control unit and
Connector & terminal ECM.
Check poor contact in ECM and fuel pump
and fuel pump control unit con- contact in ECM
control unit connector. nector? and fuel pump
control unit.
8 CHECK EXPERIENCE OF RUNNING OUT OF Did the vehicle experience run- Finish the diagno- Replace the fuel
FUEL. ning out of fuel? sis. pump control unit.
NOTE: <Ref. to
DTC record may FU(H4DOTC)-39,
be conducted as a Fuel Pump Control
result of fuel pump Unit.>
idling while running
out of fuel.
Y: DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-5
B47
6
4
1 2
3 4
2
5 6
1
B47
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
B134 ECM
E64
1 2
32
B21
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 36 37 38 39 40 41
B21
42 43 44 45 46 47
48
40
48 49 50 51 52 53 54
E2
E64
2
1
E
WASTEGATE
CONTROL SOLENOID
VALVE
EN-01952
Step Check Yes No

this time.
2 CHECK HARNESS BETWEEN WASTEGATE Is the resistance more than 1 Go to step 3. Repair the ground
CONTROL SOLENOID VALVE AND ECM M'? short circuit in har-
CONNECTOR. ness between
1) Turn the ignition switch to OFF. ECM and waste-
2) Disconnect the connectors from wastegate gate control sole-
control solenoid valve and ECM. noid valve
3) Measure the resistance in harness connector.
between wastegate control solenoid valve con-
nector and engine ground.
3 CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than 1 Go to step 4. Repair the open
CONTROL SOLENOID VALVE AND ECM '? circuit in harness
CONNECTOR. between ECM and
Measure the resistance of harness between wastegate control
wastegate control solenoid valve of harness solenoid valve
connector and ECM. connector.
(B134) No. 32 — (E64) No. 1: In this case, repair
the following:
• Open circuit in
harness between
ECM and waste-
gate control sole-
noid valve
connector
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance 30 — 34 '? Go to step 5. Replace the
NOID VALVE. wastegate control
1) Remove the wastegate control solenoid solenoid valve.
valve. <Ref. to
2) Measure the resistance between wastegate FU(H4DOTC)-32,
control solenoid valve terminals. Wastegate Con-
Terminals trol Solenoid
No. 1 — No. 2: Valve.>
5 CHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 V? Go to step 6. Repair the open
CONTROL SOLENOID VALVE. circuit in harness
2) Measure the voltage between wastegate relay and waste-
control solenoid valve and engine ground. gate control sole-
Connector & terminal noid valve
6 CHECK POOR CONTACT. Is there poor contact in waste- Repair the poor Replace the ECM.
Check poor contact in wastegate control sole- gate control solenoid valve contact in waste- <Ref. to
noid valve connector. connector? gate control sole- FU(H4DOTC)-35,
noid valve Engine Control
connector. Module (ECM).>
Z: DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-5
B47
6
4
1 2
3 4
2
5 6
1
B47
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
B134 ECM
E64
1 2
32
B21
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 36 37 38 39 40 41
B21
42 43 44 45 46 47
48
40
48 49 50 51 52 53 54
E2
E64
2
1
E
WASTEGATE
CONTROL SOLENOID
VALVE
EN-01952
Step Check Yes No

chassis ground.
Engine Control
Module (ECM).>
3 CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 V? Repair the battery Go to step 4.
CONTROL SOLENOID VALVE AND ECM short circuit in har-
CONNECTOR. ness between
1) Turn the ignition switch to OFF. ECM and waste-
2) Disconnect the connector from wastegate gate control sole-
control solenoid valve. noid valve
3) Turn the ignition switch to ON. connector. After
4) Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to
(B134) No. 32 (+) — Chassis ground ("): Engine Control
Module (ECM).>
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance less than 1 Replace the Go to step 5.
NOID VALVE. '? wastegate control
1) Turn the ignition switch to OFF. solenoid valve and
2) Measure the resistance between wastegate ECM. <Ref. to
control solenoid valve terminals. FU(H4DOTC)-32,
Terminals Wastegate Con-
No. 1 — No. 2: trol Solenoid
Valve.> <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Engine Control
Module (ECM).>
AA:DTC P0261 CYLINDER 1 INJECTOR CIRCUIT LOW

NOTE:
For the diagnostic procedure, refer to DTC P0270. <Ref. to EN(H4DOTC)(diag)-119, DTC P0270 CYLIN-
DER 4 INJECTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB:DTC P0264 CYLINDER 2 INJECTOR CIRCUIT LOW
NOTE:
AC:DTC P0267 CYLINDER 3 INJECTOR CIRCUIT LOW
NOTE:
AD:DTC P0270 CYLINDER 4 INJECTOR CIRCUIT LOW

TROUBLE SYMPTOM:
• Engine stalls.
• Rough driving
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
B47 C: B136 D: B137 ECM

C6
D7
C5
C4
C3
B21
34
45
44
48
42
43
E2
E5 E16 E6 E17
2
1
2
1
2
1
2
1
#1 #2 #3 #4
E E
FUEL INJECTORS
E5 E6 C: B136 B21
E16 E17
1 2 3 4 5 6
1 2 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11
14 15 16
12 13 14 15 16 17 18 19 20 21 22
17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B47 D: B137
1 2 1 2 3 4 5 6 7
3 4 8 9 10 11 12 13 14 15 16 17
5 6 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-01945
Step Check Yes No

1 CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Go to step 2. Repair the har-
1) Turn the ignition switch to OFF. ness and connec-
2) Disconnect the connector from fuel injector. tor.
4) Measure the voltage between fuel injector In this case, repair
and engine ground on faulty cylinders. the following:
#4 (E17) No. 2 (+) — Engine ground ("): on faulty cylinders
• Poor contact in
coupling connector
• Poor contact in
main relay connec-
tor
• Poor contact in
fuel injector con-
nector on faulty
cylinders
2 CHECK FUEL INJECTOR. Is the resistance less than 11 Go to step 3. Replace the faulty
1) Turn the ignition switch to OFF. — 12 '? fuel injector and
2) Measure the resistance between fuel injec- ECM. <Ref. to
tor terminals on faulty cylinder. FU(H4DOTC)-30,
Terminals Fuel Injector.>
No. 1 — No. 2:
3 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 4. Repair the har-
1) Connect the connector to the fuel injector. ness and connec-
2) Turn the ignition switch to ON. tor.
3) Measure the voltage between ECM con- NOTE:
nector and chassis ground on faulty cylinders. In this case, repair
#1 (B136) No. 6 (+) — Chassis ground ("): • Open circuit in
#2 (B136) No. 5 (+) — Chassis ground ("): harness between
#3 (B136) No. 4 (+) — Chassis ground ("): ECM and fuel
#4 (B136) No. 3 (+) — Chassis ground ("): injector connector
• Poor contact in
coupling connector
4 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Repair the poor Repair ground
1) Turn the ignition switch to OFF. '? contact in fuel open circuit in
2) Disconnect the connector from ECM. injector and ECM ECM.
3) Measure the resistance between ECM con- connector.
AE:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE

SENSOR)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
2
E14
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1
B136
13
B20
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
25
33
B136 ECM
E
EN-01953
Step Check Yes No

SOR AND ECM CONNECTOR. 700 k'? ness and connec-
ness connector and chassis ground. the followingin this
Connector & terminal case, repair the fol-
(B136) No. 25 — Chassis ground: lowing:
• Open circuit in
harness between
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
1) Disconnect the connector from knock sen- 700 k'? ness and connec-
sor. tor.
Terminals the followingin this
No. 2 — Engine ground: case, repair the fol-
lowing:
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installation Replace the knock Tighten knock sen-
INSTALLATION. bolt tightened securely? sensor. <Ref. to sor installation bolt
FU(H4DOTC)-26, securely.
Knock Sensor.>
AF:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE

SENSOR)
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
2
E14
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1
B136
13
B20
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
25
33
B136 ECM
E
EN-01953
Step Check Yes No

SOR AND ECM CONNECTOR. k'?
1) Disconnect the connector from knock sen- k'? sensor. <Ref. to short circuit in har-
sor. FU(H4DOTC)-26, ness between
The harness be-
tween both con-
nectors are
shielded. Repair
harness covered
with shield.
remains.)
NOTE:
the following:
• Poor contact in
knock sensor con-
nector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
AG:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
2
1
E10
E10
1 2
E1
B20
8
7
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
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 29 30 31 32 33 34 35
22
10
31
B135 ECM
E
EN-01954
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
SHAFT POSITION SENSOR AND ECM CON- 100 k'? ness and connec-
NECTOR. tor.
2) Disconnect the connector from the crank- In this case, repair
shaft position sensor. the following:
(E10) No. 1 — (B135) No. 10: ECM connector
(E10) No. 2 — (B135) No. 22: • Poor contact in
ECM connector
• Poor contact in
coupling connector
3 CHECK HARNESS BETWEEN CRANK- Is the resistance more than 1 Go to step 4. Repair the ground
SHAFT POSITION SENSOR AND ECM CON- M'? short circuit in har-
Measure the resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
(E10) No. 2 — Engine ground: tween both con-
nectors are
shielded. Repair
the ground short
circuit in harness
together with
shield.
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance 1 — 4 k'? Repair the poor Replace the crank-
terminals of crankshaft position sensor. sor connector. FU(H4DOTC)-24,
AH:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN-

GLE SENSOR)
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
INTAKE INTAKE
CAMSHAFT CAMSHAFT
B47 POSITION POSITION
SENSOR LH SENSOR RH
1
2
3
2
3
E35 E36
48
B21 E2
E1
19
B20 E1
2
1
B20
*
*
B83
C35
B8
B9
B : B135
ECM
C : B136
E
B47 B21
E35 B20 B: B135 C: B136
1 2 1 2 3 4 5 6 7 8 9 10 11
E36 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 12 13 14 15 16 17 18 19 20 21 22
5 6 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 23 24 25 26 27 28 29 30 31 32 33
1 2 3 9 10 11 12 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
13 14 15 16 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 34 35 36 37 38 39 40 41
B83 42 43 44 45 46 47
48 49 50 51 52 53 54
1 2 3 4
5 6 7 8
EN-02405
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
2 CHECK POWER SUPPLY OF CAMSHAFT Is the voltage more than 10 V? Repair the battery Go to step 3.
POSITION SENSOR. short circuit
1) Turn the ignition switch to OFF. between main
2) Disconnect the connector from camshaft relay connector
position sensor. and camshaft
3) Measure the voltage between camshaft position sensor
position sensor connector and engine ground. connector.
3 CHECK POWER SUPPLY OF CAMSHAFT Is the voltage more than 10 V? Go to step 4. Repair the open or
POSITION SENSOR. ground short cir-
1) Turn the ignition switch to ON. cuit between main
2) Measure the voltage between camshaft relay connector
position sensor connector and engine ground. and camshaft
Connector & terminal position sensor
4 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 1 Go to step 5. Repair the open
POSITION SENSOR CONNECTOR AND '? circuit between
ECM. camshaft position
1) Turn the ignition switch to OFF. sensor and ECM.
3) Measure the resistance between camshaft
position sensor connector and ECM.
(E36) No. 2 — (B135) No. 9:
(E36) No. 3 — (B136) No. 35:
5 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than 1 Go to step 6. Repair the ground
POSITION SENSOR CONNECTOR AND M'? short circuit
ECM. between camshaft
Measure the resistance between camshaft position sensor
position sensor connector and engine ground. and ECM.
securely.
7 CHECK CAMSHAFT POSITION SENSOR. Is there any abnormality in Replace the cam- Go to step 8.
Check waveform of camshaft position sensor. waveform? shaft position sen-
<Ref. to EN(H4DOTC)(diag)-15, Engine Con- sor. <Ref. to
trol Module (ECM) I/O Signal.> FU(H4DOTC)-24,
Crankshaft Posi-
tion Sensor.>
Engine Control
Module (ECM).>
AI: DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2)

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY
3
SBF-8
6
4
2
1
INTAKE INTAKE
CAMSHAFT CAMSHAFT
B47 POSITION POSITION
SENSOR LH SENSOR RH
1
2
3
2
3
E35 E36
48
B21 E2
E1
19
B20 E1
2
1
B20
*
*
B83
C35
B8
B9
B : B135
ECM
C : B136
E
B47 B21
E35 B20 B: B135 C: B136
1 2 1 2 3 4 5 6 7 8 9 10 11
E36 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 12 13 14 15 16 17 18 19 20 21 22
5 6 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 23 24 25 26 27 28 29 30 31 32 33
1 2 3 9 10 11 12 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
13 14 15 16 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 34 35 36 37 38 39 40 41
B83 42 43 44 45 46 47
48 49 50 51 52 53 54
1 2 3 4
5 6 7 8
EN-02405
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
2 CHECK POWER SUPPLY OF CAMSHAFT Is the voltage more than 10 V? Repair the battery Go to step 3.
POSITION SENSOR. short circuit
1) Turn the ignition switch to OFF. between main
2) Disconnect the connector from camshaft relay connector
position sensor. and camshaft
3) Measure the voltage between camshaft position sensor
position sensor connector and engine ground. connector.
3 CHECK POWER SUPPLY OF CAMSHAFT Is the voltage more than 10 V? Go to step 4. Repair the open or
POSITION SENSOR. ground short cir-
1) Turn the ignition switch to ON. cuit between main
2) Measure the voltage between camshaft relay connector
position sensor connector and engine ground. and camshaft
Connector & terminal position sensor
4 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 1 Go to step 5. Repair the open
POSITION SENSOR CONNECTOR AND '? circuit between
ECM. camshaft position
1) Turn the ignition switch to OFF. sensor and ECM.
3) Measure the resistance between camshaft
position sensor connector and ECM.
(E35) No. 2 — (B135) No. 8:
(E35) No. 3 — (B136) No. 35:
POSITION SENSOR CONNECTOR AND M'? short circuit
ECM. between camshaft
Measure the resistance between camshaft position sensor
position sensor connector and engine ground. and ECM.
securely.
7 CHECK CAMSHAFT POSITION SENSOR. Is there any abnormality in Replace the cam- Go to step 8.
Check waveform of camshaft position sensor. waveform? shaft position sen-
<Ref. to EN(H4DOTC)(diag)-15, Engine Con- sor. <Ref. to
trol Module (ECM) I/O Signal.> FU(H4DOTC)-25,
Camshaft Position
Sensor.>
Engine Control
Module (ECM).>
AJ:DTC P0350 IGNITION COIL PRIMARY/SECONDARY CIRCUIT

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
B135 ECM
18
17
16
15
IGNITION
SWITCH
SBF-1 SBF-7 No.12
3 6
B72
B21
49
13
14
15
16
E2
E31 E32 E33 E34

3
2
E
E
IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL

No.1 No.2 No.3 No.4
E31 B21 B72 B135

E32
1 2 3 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 16 17 18 19
E33 4 5 6
12 13 14 15 16 17 18 19 20 21 22 20 21 22 23 24 25 26 27
E34 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
1 42 43 44 45 46 47
2 48 49 50 51 52 53 54
3
EN-02404
Step Check Yes No

Connector & terminal tor ASSY and igni-
2 CHECK HARNESS OF ECM AND IGNITION Is the resistance less than 5 Go to step 3. Repair the har-
COIL & IGNITOR ASSY GROUND CIRCUIT. '? ness and connec-
3) Measure the resistance between ignition In this case, repair
coil & ignitor ASSY connector and engine the following:
(E34) No. 2 — Engine ground: grounding terminal
• Poor contact in
coupling connector
TOR. torrepair the
1) Disconnect the connector from ignition coil harness and con-
& ignitor ASSY. nector.
between ECM and ignition coil & ignitor ASSY In this case, repair
connector. the following:
(B135) No. 18 — (E31) No. 1: harness between
(B135) No. 17 — (E32) No. 1: ECM and ignition
(B135) No. 16 — (E33) No. 1: coil & ignitor ASSY
(B135) No. 15 — (E34) No. 1: connector
• Poor contact in
coupling connector
4 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 Repair the poor Repair the har-
NITION COIL & IGNITOR ASSY CONNEC- M'? contact in terminal. ness and connec-
TOR. torrepair the
Measure the resistance of harness between harness and con-
ignition coil & ignitor ASSY connector and nector.
engine ground.
Connector & terminal:
AK:DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1)

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
EXHAUST EXHAUST
CAMSHAFT CAMSHAFT E62
POSITION POSITION
SENSOR LH SENSOR RH E65
1 2
2
2
1
E65 E62
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1
11
12
10
9
B20
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 29 30 31 32 33 34 35
20
28
21
29
30
B135 ECM
E
EN-01956
Step Check Yes No

POSITION SENSOR AND ECM CONNEC- '? ness and connec-
TOR. tor.
and ECM. camshaft position
(E62) No. 1 — (B135) No. 29: connector
ECM connector
• Poor contact in
coupling connector
POSITION SENSOR AND ECM CONNEC- M'? short circuit in har-
TOR. ness between
nectors are
shielded. Repair
the ground short
circuit in harness
together with
shield.
3 CHECK CONDITION OF CAMSHAFT POSI- Is the crankshaft position sen- Go to step 4. Tighten the crank-
TION SENSOR. sor installation bolt tightened shaft position sen-
securely.
4 CHECK CAMSHAFT POSITION SENSOR. Is the resistance 1 — 4 k'? Repair the poor Replace the cam-
terminals of camshaft position sensor. sor connector. FU(H4DOTC)-25,
AL:DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2)

TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
WIRING DIAGRAM:
EXHAUST EXHAUST
CAMSHAFT CAMSHAFT E62
POSITION POSITION
SENSOR LH SENSOR RH E65
1 2
2
2
1
E65 E62
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E1
11
12
10
9
B20
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 29 30 31 32 33 34 35
20
28
21
29
30
B135 ECM
E
EN-01956
Step Check Yes No

POSITION SENSOR AND ECM CONNEC- '? ness and connec-
TOR. tor.
and ECM. camshaft position
(E65) No. 1 — (B135) No. 28: connector
ECM connector
• Poor contact in
coupling connector
POSITION SENSOR AND ECM CONNEC- M'? short circuit in har-
TOR. ness between
nectors are
shielded. Repair
the ground short
circuit in harness
together with
shield.
3 CHECK CONDITION OF CAMSHAFT POSI- Is the crankshaft position sen- Go to step 4. Tighten the crank-
TION SENSOR. sor installation bolt tightened shaft position sen-
securely.
4 CHECK CAMSHAFT POSITION SENSOR. Is the resistance 1 — 4 k'? Repair the poor Replace the cam-
terminals of camshaft position sensor. sor connector. FU(H4DOTC)-25,
AM:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY B47
3
SBF-8 1 2
6 3 4
4 5 6
2
1
B47 B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
14
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E4
B21 1 2
48
41
E2
E4
1
2
PURGE CONTROL
SOLENOID VALVE
EN-01957
Step Check Yes No

this time.
TROL SOLENOID VALVE AND ECM CON- M'? short circuit in har-
TROL SOLENOID VALVE AND ECM CON- '? circuit in harness
ECM and purge control solenoid valve of har- noid valve connec-
ness connector. tor.
(B134) No. 14 — (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
4 CHECK PURGE CONTROL SOLENOID Is the resistance 29 — 35 '? Go to step 5. Replace the purge
2) Measure the resistance between purge EC(H4DOTC)-6,
No. 1 — No. 2:
Check poor contact in purge control solenoid control solenoid valve connec- contact in purge <Ref. to
valve connector. tor? control solenoid FU(H4DOTC)-35,
valve connector. Engine Control
Module (ECM).>
AN:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5 BATTERY B47
3
SBF-8 1 2
6 3 4
4 5 6
2
1
B47 B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B134 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
14
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E4
B21 1 2
48
41
E2
E4
1
2
PURGE CONTROL
SOLENOID VALVE
EN-01957
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does the purge control sole- Go to step 2. Even if the mal-
1) Turn the ignition switch to OFF. noid valve operate? function indicator
lower portion of instrument panel (on the the circuit has
driver’s side). returned to a nor-
3) Turn the ignition switch to ON. mal condition at
this time. In this
case, repair the
poor contact in
ECM connector.
2 CHECK PURGE CONTROL SOLENOID Is the resistance less than 29 Go to step 3. Replace the purge
VALVE. — 35 '? control solenoid
1) Turn the ignition switch to OFF. valve. <Ref. to
2) Disconnect the connector from purge con- EC(H4DOTC)-6,
trol solenoid valve. Purge Control
3) Measure the resistance between purge Solenoid Valve.>
control solenoid valve terminals.
Terminals
No. 1 — No. 2:
3 CHECK HARNESS BETWEEN PURGE CON- Is the voltage less than 1 V? Go to step 4. Repair the battery
chassis ground. <Ref. to
Module (ECM).>
Engine Control
Module (ECM).>
AO:DTC P0500 VEHICLE SPEED SENSOR

CAUTION:
Step Check Yes No

the DTC. <Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
AP:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
No.21 SBF-7 SBF-1
2 3
B72 IGNITION
SWITCH
16
14
STARTER RELAY
B225
STARTER MOTOR
15
13
M
B14
B32
D8
B: B135 D: B137 ECM E
B225
B: B135 D: B137 B72
1 2 9 13 17 21
10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 4 5 6
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02402
Step Check Yes No

1 CHECK HARNESS BETWEEN IGNITION Is the voltage more than 10 V? Repair the battery Repair the poor
SWITCH AND ECM. short circuit in har- contact in ECM.
1) Disconnect the connectors from ECM. ness between igni-
2) Measure the voltage between ECM and tion switch and
chassis ground. ECM.
AQ:DTC P0519 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

TROUBLE SYMPTOM:
• Engine keeps running at higher revolution than specified idling revolution.
• Fuel is cut according to fail-safe function.
CAUTION:
Step Check Yes No

vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0519.
throttle body
body gasket
2) Remove the electronic throttle control. control.
AR:DTC P0562 SYSTEM VOLTAGE LOW

Detect in case of low power supply voltage of ECM.
TROUBLE SYMPTOM:
Charge indicator light illuminates.
CAUTION:
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
5
BATTERY
3
SBF-8
6
4
2
1
B47
5
6
B135 ECM
B135 B47
1 2 3 4 5 6 7 1 2
8 9 10 11 12 13 14 15 16 17 18 19 3 4
20 21 22 23 24 25 26 27 5 6
28 29 30 31 32 33 34 35
EN-01958
Step Check Yes No

1 CHECK BATTERY. Is the voltage more than 12 V Go to step 2. Charge or replace
1) Turn the ignition switch to OFF. and the gravity more than the battery.
2) Measure battery voltage and specific grav- 1.26?
ity of electrolyte.
2 CHECK GENERATOR. Is the voltage less than 10.8 Go to step 3. Repair the genera-
1) Start the engine. V? tor. <Ref. to
2) Run the engine at idle after warming up. SC(H4SO 2.0)-14,
3) Measure the voltage between generator B Generator.>
Terminals
Generator B terminal (+) — Chassis
ground ("):
3 CHECK GENERATOR. Is the voltage less than 10.8 Go to step 4. Repair the genera-
1) Run the engine at 5,000 rpm. V? tor. <Ref. to
2) Measure the voltage between generator B SC(H4SO 2.0)-14,
terminal and chassis ground. Generator.>
Terminals
ground ("):
4 CHECK BATTERY TERMINAL. Are the positive and negative Go to step 5. Tighten the clamp
1) Turn the ignition switch to OFF. battery terminals clamped of terminal.
2) Check the installation of positive and nega- tightly?
tive terminals of battery.
5 CHECK INPUT VOLTAGE OF ECM. Is the voltage less than 10.8 Go to step 6. Repair the har-
1) Run the engine at idle. V? ness connectors
2) Measure the voltage between ECM con- between battery,
nector and chassis ground. main relay and
6 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the poor Go to step 7.
Check the poor contact in connectors between nectors between generator, contact.
generator, battery and ECM. battery and ECM?
7 CHECK ECM. Is the same DTC displayed? Replace the gen- Go to step 8.
1) Connect all the connectors. erator.
2) Erase the memory. <Ref. to
EN(H4DOTC)(diag)-30, Clear Memory Mode.>
3) Perform the inspection mode. <Ref. to
EN(H4DOTC)(diag)-28, Inspection Mode.>
4) Read the DTC. <Ref. to
EN(H4DOTC)(diag)-27, Read Diagnostic Trou-
ble Code (DTC).>
Check if the same DTC is displayed.
8 CHECK ANY OTHER DTC IS DISPLAYED. Is any other DTC displayed? Perform the diag- Temporary poor
Check if any other DTC is displayed. nosis of DTC dis- contact occurs.
played.
AS:DTC P0563 SYSTEM VOLTAGE HIGH

Detect in case of high power supply voltage of ECM.
TROUBLE SYMPTOM:
Charge indicator light illuminates.
CAUTION:
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
5
BATTERY
3
SBF-8
6
4
2
1
B47
5
6
B135 ECM
B135 B47
1 2 3 4 5 6 7 1 2
8 9 10 11 12 13 14 15 16 17 18 19 3 4
20 21 22 23 24 25 26 27 5 6
28 29 30 31 32 33 34 35
EN-01958
Step Check Yes No

1 CHECK BATTERY. Is the voltage more than 12 V Go to step 2. Replace the bat-
1) Turn the ignition switch to OFF. and the gravity more than tery.
2) Measure battery voltage and specific grav- 1.26?
ity of electrolyte.
2 CHECK GENERATOR. Is the voltage more than 16.2 Go to step 3. Repair the genera-
1) Start the engine. V? tor. <Ref. to
2) Run the engine at idle after warming up. SC(H4SO 2.0)-14,
3) Measure the voltage between generator B Generator.>
Terminals
ground ("):
3 CHECK GENERATOR. Is the voltage more than 16.2 Go to step 4. Repair the genera-
1) Run the engine at 5,000 rpm. V? tor. <Ref. to
2) Measure the voltage between generator B SC(H4SO 2.0)-14,
terminal and chassis ground. Generator.>
Terminals
ground ("):
4 CHECK BATTERY TERMINAL. Are the positive and negative Go to step 5. Tighten the clamp
1) Turn the ignition switch to OFF. battery terminals clamped of terminal.
2) Check the installation of positive and nega- tightly?
tive terminals of battery.
5 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 16.2 Go to step 6. Repair the har-
1) Run the engine at idle. V? ness connectors
2) Measure the voltage between ECM con- between battery,
nector and chassis ground. main relay and
6 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the poor Go to step 7.
Check the poor contact in connectors between nectors between generator, contact.
generator, battery and ECM. battery and ECM?
7 CHECK ECM. Is the same DTC displayed? Replace the gen- Go to step 8.
1) Connect all the connectors. erator.
2) Erase the memory. <Ref. to
EN(H4DOTC)(diag)-30, Clear Memory Mode.>
3) Perform the inspection mode. <Ref. to
EN(H4DOTC)(diag)-28, Inspection Mode.>
4) Read the DTC. <Ref. to
EN(H4DOTC)(diag)-27, Read Diagnostic Trou-
ble Code (DTC).>
Check if the same DTC is displayed.
8 CHECK ANY OTHER DTC IS DISPLAYED. Is any other DTC displayed? Perform the diag- Temporary poor
Check if any other DTC is displayed. nosis of DTC dis- contact occurs.
played.
AT:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:
For the diagnostic procedure, refer to LAN system.
AU:DTC P0604 INTERNAL CONTROL MODULE READ ACCESS MEMORY
(RAM) ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-152, DTC P0607 CONTROL
MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AV:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-152, DTC P0607 CONTROL
MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AW:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY

5
SBF-8
6
4
No.13
1
2 IGNITION
B72
SWITCH BATTERY
B47
No.12 SBF-7 SBF-1
6 3
D16
B19
D14
B5
B6
A: B134
B: B135 ECM
D: B137
B12
A6
A7
B1
B4
D7
D1
D2
D3
B21
54
35
34
12
36
37
E2
E E
B72 B47 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02403
Step Check Yes No

(B137) No. 1 (+) — Chassis ground ("): if defective.
(B137) No. 2 (+) — Chassis ground ("): <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
AX:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-176, DTC P2101 THROTTLE
AY:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 5AT(diag)-2, Basic Diagnostics Procedure.>
AZ:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW
NOTE:
BA:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH
NOTE:
BB:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(LOW INPUT)
CAUTION:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is DTC P1110 displayed on the Replace the ECM. Temporary poor
Subaru Select Monitor? <Ref. to contact occurs.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
NOTE:
Atmospheric pres-
sure sensor is built
in ECM.
BC:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(HIGH INPUT)
CAUTION:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is DTC P1111 displayed on the Replace the ECM. Temporary poor
Subaru Select Monitor? <Ref. to contact occurs.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
NOTE:
Atmospheric pres-
sure sensor is built
in ECM.
BD:DTC P1160 RETURN SPRING FAILURE

NOTE:
BE:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
No.21 SBF-7 SBF-1
2 3
B72 IGNITION
SWITCH
16
14
STARTER RELAY
B225
STARTER MOTOR
15
13
M
B14
B32
D8
B: B135 D: B137 ECM E
B225
B: B135 D: B137 B72
1 2 9 13 17 21
10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 4 5 6
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02402
Step Check Yes No

nostic Trouble
Code (DTC)”.
<Ref. to
EN(H4DOTC)(diag
)-55, List of Diag-
nostic Trouble
Code (DTC).>
2 CHECK HARNESS BETWEEN STARTER Is the resistance more than 1 Repair the ground Repair the poor
RELAY AND ECM. M'? short circuit contact in ECM
1) Disconnect the connectors from starter between starter connector.
relay and ECM. motor and ECM.
BF:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
MAIN RELAY

5
SBF-8
6
4
No.13
1
2 IGNITION
B72
SWITCH BATTERY
B47
No.12 SBF-7 SBF-1
6 3
D16
B19
D14
B5
B6
A: B134
B: B135 ECM
D: B137
B12
A6
A7
B1
B4
D7
D1
D2
D3
B21
54
35
34
12
36
37
E2
E E
B72 B47 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02403
Step Check Yes No

chassis ground.
MAIN FUSE BOX CONNECTOR. '? short circuit in har-
3 CHECK FUSE No. 13 Is the fuse blown out? 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
BG:DTC P2088 OCV SOLENOID VALVE SIGNAL A CIRCUIT OPEN (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
B134
1 2 3 4 5 6 7
18
28
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
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B21
23
24
E38
E2
1 2
E38
1
2
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01960
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Go to step 2. Repair the open
FLOW CONTROL SOLENOID VALVE. '? circuit in harness
2) Disconnect the connector from ECM and oil oil flow control
flow control solenoid valve. solenoid valve
3) Measure the resistance between ECM and connector.
oil flow control solenoid valve. NOTE:
(B134) No. 18 — (E38) No. 1: the following:
harness between
ECM and oil flow
control solenoid
valve connector
• Poor contact in
coupling connector
2 CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 '? Repair the poor Replace the oil
VALVE. contact in ECM flow control sole-
1) Disconnect the oil flow control solenoid and oil flow con- noid valve. <Ref.
valve connector. trol solenoid valve. to ME(H4DOTC)-
2) Measure the resistance between oil flow 53, Camshaft.>
Terminals
No. 1 — No. 2:
BH:DTC P2089 OCV SOLENOID VALVE SIGNAL A CIRCUIT SHORT (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
B134
1 2 3 4 5 6 7
18
28
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
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B21
23
24
E38
E2
1 2
E38
1
2
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01960
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND OIL Is the resistance more than 1 Go to step 2. Repair the short
FLOW CONTROL SOLENOID VALVE. M'? circuit between
1) Turn the ignition switch to OFF. ECM and oil flow
2) Disconnect the connector from ECM and oil control solenoid
flow control solenoid valve. valve connector.
3) Measure the resistance between oil flow
control solenoid valve and engine ground.
Terminals
No. 1 — No. 2:
BI: DTC P2090 OCV SOLENOID VALVE SIGNAL B CIRCUIT OPEN (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
B134
1 2 3 4 5 6 7
20
30
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
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B21
E63
25
26
E2
1 2
E63
1
2
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01961
Step Check Yes No

harness between
ECM and oil flow
control solenoid
valve connector
• Poor contact in
coupling connector
Terminals
No. 1 — No. 2:
BJ:DTC P2091 OCV SOLENOID VALVE SIGNAL B CIRCUIT SHORT (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
B134
1 2 3 4 5 6 7
20
30
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
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B21
E63
25
26
E2
1 2
E63
1
2
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01961
Step Check Yes No

Terminals
No. 1 — No. 2:
BK:DTC P2092 OCV SOLENOID VALVE SIGNAL A CIRCUIT OPEN (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
B134 ECM
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
19
29
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E37
B21 1 2
27
28
E2
E37
1
2
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01962
Step Check Yes No

harness between
ECM and oil flow
control solenoid
valve connector
• Poor contact in
coupling connector
Terminals
No. 1 — No. 2:
BL:DTC P2093 OCV SOLENOID VALVE SIGNAL A CIRCUIT SHORT (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
B134 ECM
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
19
29
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E37
B21 1 2
27
28
E2
E37
1
2
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01962
Step Check Yes No

Terminals
No. 1 — No. 2:
BM:DTC P2094 OCV SOLENOID VALVE SIGNAL B CIRCUIT OPEN (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
B134 ECM
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
21
31
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E66
B21 1 2
29
30
E2
E66
1
2
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01963
Step Check Yes No

harness between
ECM and oil flow
control solenoid
valve connector
• Poor contact in
coupling connector
Terminals
No. 1 — No. 2:
BN:DTC P2095 OCV SOLENOID VALVE SIGNAL B CIRCUIT SHORT (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
B134 ECM
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
21
31
B21
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 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E66
B21 1 2
29
30
E2
E66
1
2
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01963
Step Check Yes No

Terminals
No. 1 — No. 2:
BO:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
• Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
Step Check Yes No

TROL RELAY. '? tronic throttle con-
3) Connect the battery to terminals No. 5 and
No. 6 of electronic throttle control relay.
Terminals
No. 7 — No. 8:
ground.
ELECTRONIC THROTTLE CONTROL RE- M'? short circuit in har-
LAY. ness between
ground.
ELECTRONIC THROTTLE CONTROL RE- '? circuit in harness
tor.
(B135) No. 35 — (B362) No. 6:
(B137) No. 6 — (B362) No. 8:
nector terminals.
(B136) No. 18 (+) — (B136) No. 35 ("):
nector terminals.
(B136) No. 29 (+) — (B136) No. 35 ("):
Step Check Yes No

Check the poor contact in connector between contact.
(B136) No. 16 — (E57) No. 5:
ELECTRONIC THROTTLE CONTROL. M'? short circuit of har-
Engine Control
Module (ECM).>
1) Turn the ignition switch to OFF. '? contact in ECM
Connector & terminal if defective.
(E57) No. 6 — Engine ground: <Ref. to
(E57) No. 4 — Engine ground: FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Step Check Yes No

(B136) No. 35 — (E57) No. 3:
(B136) No. 18 — (E57) No. 6:
(B136) No. 29 — (E57) No. 4:
ELECTRONIC THROTTLE CONTROL. '? contact in ECM
Engine Control
Module (ECM).>
ELECTRONIC THROTTLE CONTROL. M'? circuit to sensor
2) Remove the ECM.
nectors.
(B136) No. 18 — (B136) No. 35:
(B136) No. 29 — (B136) No. 35:
2) Connect the connectors except of the electronic throttle con-
Replace the elec-
trol if defective.
Step Check Yes No

ELECTRONIC THROTTLE CONTROL MO- '? circuit of harness
TOR. connector.
(B137) No. 5 — (E57) No. 2:
(B137) No. 4 — (E57) No. 1:
ELECTRONIC THROTTLE CONTROL MO- ply short circuit in
TOR. harness between
1) Connect the connector to ECM. ECM and elec-
ELECTRONIC THROTTLE CONTROL MO- M'? circuit of harness.
TOR.
TROL MOTOR HARNESS. M'? circuit of harness.
(E57) No. 2 — (E57) No. 1:
TROL GROUND CIRCUIT. '? circuit of harness.
TROL. '? tronic throttle con-
Terminals
No. 1 — No. 2:
TROL. specified position? Standard contact in ECM tronic throttle con-
Move the throttle valve to the fully open and value: 3 mm (0.12 in) from fully connector. trol.
fully closed positions with fingers. closed position Replace the ECM
Check the valve returns to the specified posi- if defective.
tion when releasing fingers. <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
BP:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
• Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
Step Check Yes No

TROL RELAY. '? tronic throttle con-
3) Connect the battery to terminals No. 5 and
No. 6 of electronic throttle control relay.
Terminals
(B362) No. 7 — (B362) No. 8:
3) Measure the voltage between electronic trol relay.
ground.
ELECTRONIC THROTTLE CONTROL RE- M'? short circuit in har-
LAY. ness between
ground.
ELECTRONIC THROTTLE CONTROL RE- '? contact in ECM circuit in harness
tor and electronic throttle control relay connec- if defective. control relay.
tor. <Ref. to
(B135) No. 35 — (B362) No. 6: Engine Control
(B137) No. 6 — (B362) No. 8: Module (ECM).>
BQ:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362
B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
Step Check Yes No

TROL RELAY. M'? tronic throttle con-
Terminals
No. 7 — No. 8:
2 CHECK POWER SUPPLY SHORT CIRCUIT Is the voltage more than 5 V? Go to step 3. Repair power sup-
OF ELECTRONIC THROTTLE CONTROL ply short circuit in
RELAY. harness between
1) Turn the ignition switch to ON. ECM and elec-
2) Measure the voltage between electronic tronic throttle con-
ground.
ELECTRONIC THROTTLE CONTROL RE- M'? contact in ECM short circuit in har-
2) Disconnect the connector from ECM. if defective. tronic throttle con-
3) Measure the resistance between ECM con- <Ref. to trol relay.
nector and chassis ground. FU(H4DOTC)-35,
(B135) No. 35 — Chassis ground: Module (ECM).>
BR:DTC P2109 THROTTLE ANGLE CLOSED POSITION ERROR

NOTE:
BS:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
MAIN SUB
B315
ACCELERATOR 1 2 3 4 5 6
POSITION
SENSOR
B21
3
B315
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
4 23 24 25 26 27 28 29 30 31 32 33
7 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
B83 B122
C15
C17
C34
C16
C28
C35
1 2 3 4
5 6 7 8
ECM
C: B136
C: B136
D: B137
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
D1
D2
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B21
18 19 20 21 22 23 24 25
36
26 27 28 29 30 31
E2
E * : TERMINAL NO. RANDOM ARRANGEMENT
EN-01964
Step Check Yes No

SOR OUTPUT.
present.
CELERATOR POSITION SENSOR. '? circuit of harness
3) Disconnect the connector from the acceler-
ator position sensor.
tor.
(B136) No. 17 — (B315) No. 5:
(B136) No. 15 — (B315) No. 3:
CELERATOR POSITION SENSOR. M'? sis short circuit of
3) Measure the voltage between accelerator if defective.
position sensor connector and chassis ground. <Ref. to
Module (ECM).>
SOR. k'? erator position
sensor.
Terminals
No. 3 — No. 4:
sensor.
Terminals
No. 5 — No. 4:
pedal.
Step Check Yes No

SOR. k'? contact in ECM erator position
No. 5 — No. 4: to FU(H4DOTC)-
(ECM).>
BT:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
MAIN SUB
B315
POSITION
SENSOR
B21
3
B315
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
4 23 24 25 26 27 28 29 30 31 32 33
7 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
B83 B122
C15
C17
C34
C16
C28
C35
1 2 3 4
5 6 7 8
ECM
C: B136
C: B136
D: B137
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
D1
D2
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B21
18 19 20 21 22 23 24 25
36
26 27 28 29 30 31
E2
EN-01964
Step Check Yes No

SOR OUTPUT.
Turn the ignition switch to ON.
present.
tor.
(B136) No. 34 — (B315) No. 4:
CELERATOR POSITION SENSOR. '? contact in ECM
tor position sensor connector and chassis if defective. <Ref.
ground. to FU(H4DOTC)-
(B315) No. 4 — Chassis ground: trol Module
(ECM).>
position sensor connector and chassis ground. position sensor
CELERATOR POSITION SENSOR. M'? contact in acceler- circuit to sensor
nector terminals. erator position
(B136) No. 17 — (B136) No. 15:
(B136) No. 17 — (B136) No. 16:
BU:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
MAIN SUB
B315
POSITION
SENSOR
B21
3
B315
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
4 23 24 25 26 27 28 29 30 31 32 33
7 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
B83 B122
C15
C17
C34
C16
C28
C35
1 2 3 4
5 6 7 8
ECM
C: B136
C: B136
D: B137
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
D1
D2
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B21
18 19 20 21 22 23 24 25
36
26 27 28 29 30 31
E2
EN-01964
Step Check Yes No

SOR OUTPUT.
present.
tor.
(B136) No. 28 — (B315) No. 2:
(B136) No. 16 — (B315) No. 1:
CELERATOR POSITION SENSOR. M'? sis short circuit of
Module (ECM).>
sensor.
Terminals
No. 1 — No. 6:
tion sensor.
Terminals
No. 2 — No. 6:
tor pedal.
Step Check Yes No

SOR. k'? contact in ECM erator position
Terminals if defective.
No. 2 — No. 6: <Ref. to
2) Check the measured value is within the FU(H4DOTC)-35,
specification with the accelerator pedal Engine Control
depressed. Module (ECM).>
BV:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
MAIN SUB
B315
POSITION
SENSOR
B21
3
B315
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
4 23 24 25 26 27 28 29 30 31 32 33
7 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
B83 B122
C15
C17
C34
C16
C28
C35
1 2 3 4
5 6 7 8
ECM
C: B136
C: B136
D: B137
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
D1
D2
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B21
18 19 20 21 22 23 24 25
36
26 27 28 29 30 31
E2
EN-01964
Step Check Yes No

SOR OUTPUT.
present.
tor.
(B136) No. 35 — (B315) No. 6:
tor position sensor connector and chassis if defective.
ground. <Ref. to
(B315) No. 6 — Chassis ground: Engine Control
Module (ECM).>
CELERATOR POSITION SENSOR. M'? contact in acceler- circuit to sensor
2) Measure the resistance between ECM con- sor connector.
nector terminals. Replace the accel-
Connector & terminal erator position
(B137) No. 28 — (B137) No. 15: sensor if defective.
(B137) No. 28 — (B137) No. 16:
BW:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” / “B”

VOLTAGE RATIONALITY
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-8
7
ELECTRONIC
5
THROTTLE
CONTROL RELAY 6
MAIN RELAY
8
B362 B35
D6
B: B135 D: B137
ECM
C: B136
C35
C16
C29
C18
D4
B1
D1
D3
D5
B4
D2
* B84
*
* B138
*
7
B122
3
B20 B21
15
38
20
36
16
39
19
35
37
E1 E2
6
5
4
E57
ELECTRONIC E E
THROTTLE
CONTROL
B362 B20 B21 B84 E57
1 2 3 4 B122 1 2 3 4 5 6
3 1 2 3 4 5 6 7 8 9 10 11
1 2 5 6 7 8
4 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 B138
23 24 25 26 27 28 29 30 31 32 33
5 13 14 15 16
7 8
6 34 35 36 37 38 39 40 41 1 2 3 4
42 43 44 45 46 47 5 6 7 8
48 49 50 51 52 53 54
B: B135 C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-01951
Step Check Yes No

nector terminals.
(B136) No. 18 (+) — (B136) No. 35 ("):
terminals.
(B136) No. 29 (+) — (B136) No. 35 ("):
(B136) No. 16 — (E57) No. 5:
ELECTRONIC THROTTLE CONTROL. M'? short circuit of har-
Engine Control
Module (ECM).>
1) Turn the ignition switch to OFF. '? contact in ECM
Connector & terminal if defective.
(E57) No. 6 — Engine ground: <Ref. to
Engine Control
Module (ECM).>
Step Check Yes No

Check the poor contact in connector between contact. contact occurred,
present.
(B136) No. 35 — (E57) No. 3:
(B136) No. 18 — (E57) No. 6:
(B136) No. 29 — (E57) No. 4:
ELECTRONIC THROTTLE CONTROL. '? contact in ECM
Engine Control
Module (ECM).>
13 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Go to step 14. Repair the battery
ELECTRONIC THROTTLE CONTROL. M'? circuit to sensor
nectors.
(B136) No. 18 — (B136) No. 35:
(B136) No. 29 — (B136) No. 35:
TROL HARNESS. M'? contact in ECM circuit of harness.
2) Disconnect the connectors from the elec- Replace the ECM
tronic throttle control. if defective.
3) Measure the resistance between electronic <Ref. to
throttle control connector terminals. FU(H4DOTC)-35,
(E57) No. 6 — (E57) No. 4: Module (ECM).>
BX:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” / “E”

VOLTAGE RATIONALITY
TROUBLE SYMPTOM:
WIRING DIAGRAM:
MAIN SUB
B315
POSITION
SENSOR
B21
3
B315
B122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
4 23 24 25 26 27 28 29 30 31 32 33
7 34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
B83
B83 B122
C15
C17
C34
C16
C28
C35
1 2 3 4
5 6 7 8
ECM
C: B136
C: B136
D: B137
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
D1
D2
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B21
18 19 20 21 22 23 24 25
36
26 27 28 29 30 31
E2
EN-01964
Step Check Yes No

SOR OUTPUT.
tor.
(B136) No. 17 — (B315) No. 5:
(B136) No. 15 — (B315) No. 3:
(B136) No. 28 — (B315) No. 2:
(B136) No. 16 — (B315) No. 1:
CELERATOR POSITION SENSOR. M'? short circuit of har-
sensor.
Terminals
No. 3 — No. 4:
sensor.
Terminals
No. 1 — No. 6:
pedal.
Terminals
No. 5 — No. 4:
Step Check Yes No

pedal.
Terminals
No. 2 — No. 6:
Terminals
No. 5 — No. 4:
Terminals
No. 2 — No. 6:
SOR OUTPUT.
tor.
(B136) No. 34 — (B315) No. 4:
(B136) No. 35 — (B315) No. 6:
tor position sensor connector and chassis if defective.
ground. <Ref. to
(B315) No. 4 — Chassis ground: Engine Control
(B315) No. 6 — Chassis ground: Module (ECM).>
Step Check Yes No

CELERATOR POSITION SENSOR. M'? circuit to sensor
nector terminals.
(B136) No. 17 — (B136) No. 15:
(B136) No. 17 — (B136) No. 16:
(B136) No. 28 — (B136) No. 15:
(B136) No. 28 — (B136) No. 16:
CELERATOR POSITION SENSOR. M'? contact in ECM circuit in harness
ator position sensor. to FU(H4DOTC)- tion sensor con-
(B315) No. 5 — (B315) No. 2:

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4DOTC)-90, Engine Trouble in
General.>
1. Engine stalls during idling.
2. Rough idling 6) Air intake system (*5)
10) Oxygen sensor
3. Engine does not return to idle.
4) Mass air flow sensor
4. Poor acceleration 6) Engine coolant temperature sensor (*2)
5. Engine stalls or engine sags or hesitates at 4) Crankshaft position sensor (*3)
acceleration. 5) Camshaft position sensor (*3)
6) Purge control solenoid valve
6.Surge
7) Throttle position sensor

7. Spark knock
4) Knock sensor
*4: Check fuel injector, fuel pressure regulator and fuel filter.
ENGINE SECTION 3
FUEL INJECTION (FUEL SYSTEMS) FU(H6DO)
EMISSION CONTROL EC(H6DO)

INTAKE (INDUCTION) IN(H6DO)
MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)
of SUBARU vehicles. COOLING CO(H6DO)
sembling, inspection and adjustment of LUBRICATION LU(H6DO)
Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP(H6DO)
their vehicle in optimum condition. IGNITION IG(H6DO)
SUBARU genuine parts. STARTING/CHARGING SYSTEMS SC(H6DO)
ENGINE (DIAGNOSTICS) EN(H6DO)(diag)

approval.

FU(H6DO)
Page
2. Throttle Body...........................................................................................11
3. Intake Manifold ........................................................................................12
4. Engine Coolant Temperature Sensor....................................................18
5. Crankshaft Position Sensor ...................................................................19
6. Camshaft Position Sensor .....................................................................20
7. Knock Sensor ..........................................................................................21
8. Throttle Position Sensor ........................................................................22
9. Manifold Absolute Pressure Sensor .....................................................23
10. Mass Air Flow and Intake Air Temperature Sensor .............................24
11. EGR Valve ................................................................................................25
12. Fuel Injector.............................................................................................26
13. Variable Valve Lift Diagnosis Oil Pressure Switch ..............................28
14. Oil Temperature Sensor .........................................................................29
15. Front Oxygen (A/F) Sensor ....................................................................30
16. Rear Oxygen Sensor...............................................................................32
17. Engine Control Module (ECM) ...............................................................34
18. Main Relay ...............................................................................................35
19. Fuel Pump Relay .....................................................................................36
20. Electronic Throttle Control Relay ..........................................................37
21. Fuel Pump Control Unit ..........................................................................38
22. Fuel...........................................................................................................39
23. Fuel Tank .................................................................................................40
24. Fuel Filler Pipe.........................................................................................46
25. Fuel Pump................................................................................................48
26. Fuel Level Sensor ...................................................................................50
27. Fuel Sub Level Sensor............................................................................51
28. Fuel Filter .................................................................................................52
29. Fuel Bypass Valve...................................................................................53
30. Fuel Delivery, Return and Evaporation Lines.......................................54
31. Fuel System Trouble in General ............................................................57
General Description
A: SPECIFICATION
Fuel tank
Type Impeller
Fuel pump
125 2 (33 US gal, 27.5 Imp gal)/h or more
Discharge
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(H6DO)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T5
T3
(16)
T4 (9) T4 (10)
T5 (18)
(17)
T6
T6 T5 (15)
T3
(7)
(5) (6)
T4 T5
(17)
(9)
(8)
T4
(3) (10)
T5
(1)
(2)
T3
(11)
(4)
(14) (2)
(13)
(14) T5
T1 T2
T2
T2
T2 (14)
(13)
(14)
T2
(12) T1
FU-02107
FU(H6DO)-3
General Description
(1) Intake manifold (10) Plug Tightening torque: N!m (kgf-m, ft-lb)
(2) O-ring (11) Fuel pipe protector LH T1: 1.5 (0.15, 1.1)
(3) Manifold pressure sensor (12) Fuel pipe ASSY T2: 5 (0.5, 3.6)
(4) Filter (13) Hose T3: 6.4 (0.65, 4.7)
(5) Fuel pipe protector RH (14) Clamp T4: 17 (1.7, 12.5)
(6) Purge control solenoid valve (15) EGR valve (Except for KA model) T5: 19 (1.9, 13.7)
(7) Hose (16) Gasket (Except for KA model) T6: 25 (2.5, 18.1)
(8) Hose (17) Gasket (Except for KA model)
(9) Nipple (18) EGR pipe (Except for KA model)
2. FUEL INJECTOR
(6)
(5)
(4)
(3) T
(2) (1)
(5)
(4)
(3)
(2)
FU-02108
(1) Fuel injector pipe LH (4) Injection rubber Tightening torque: N!m (kgf-m, ft-lb)
(2) Insulator (5) O-ring T: 19 (1.9, 14)
(3) Fuel injector (6) Fuel injector pipe RH
FU(H6DO)-4
General Description
(2)
(1)
FU-02109
(1) O-ring Tightening torque: N!m (kgf-m, ft-lb)

(2) Throttle body T: 8 (0.8, 5.8)
FU(H6DO)-5
General Description
T4
T4
(2)
T1
T2 (3)
(4) T1
(6)
(1)
T1
(5)
T3 (8)
(7)
T2
FU-02110
(1) Crankshaft position sensor (6) Variable valve lift diagnosis oil Tightening torque: N!m (kgf-m, ft-lb)
(2) Knock sensor RH pressure switch RH T1: 6.4 (0.65, 4.7)
(3) Knock sensor LH (7) Variable valve lift diagnosis oil T2: 17 (1.7, 12.5)
(4) Camshaft position sensor RH pressure switch LH T3: 18 (1.8, 13.3)
(5) Camshaft position sensor LH (8) Oil temperature sensor T4: 25 (2.5, 18)
FU(H6DO)-6
General Description
5. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8) (17) T1
(14)
(7)
(15)
(10)
(9) (12)
(11)
(1)
(13)
(22)
T4 (6)
(5) (22)
(20)
(3)
(2) T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2 T3
FU-01080
FU(H6DO)-7
General Description
(7) Fuel pump ASSY (18) Fuel tank protector RH (Rear) T1: 4.4 (0.45, 3.3)
FU(H6DO)-8
General Description
6. FUEL LINE
T1 (1)
(28)
(26) (18)
(23)
(25) (19) (17) (15)

(27) (1)
(20) (22) (14)
(13)
(24)
(21) (1) A (16)
T2 (1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
B T3
T2
(1)
(1) (1) A
(4)
(3) T2
B
(2) (1)
(5) (33)
(1) (9)
(32)
(1)
(6) (30) (31)
T2
T2 (8) (7)
FU-02182
FU(H6DO)-9
General Description

(3) Evaporation hose (16) Purge hose B (29) Clip
(6) Fuel bypass valve (19) Two-way valve drain hose (32) Connector
(7) Bracket (20) Two-way valve (33) Purge pipe
(8) Bracket (21) Two-way valve hose C (34) Two-way valve bracket

D: PREPARATION TOOL
ST24082AA230
ST22771AA030
FU(H6DO)-10
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Disconnect the connectors from throttle position
sensor.
FU-02111
5) Disconnect the engine coolant hoses (A) from

throttle body.
6) Remove the bolts (B) which secure throttle body
to intake manifold.
(A)
(B)
(B)
(A) FU-02112
B: INSTALLATION
NOTE:
Use a new O-ring.
Tightening torque:
8 N!m (0.8 kgf-m, 5.8 ft-lb)
FU(H6DO)-11
Intake Manifold
3. Intake Manifold 8) Disconnect the PCV hose.
A: REMOVAL
<Ref. to FU(H6DO)-39, RELEASING OF FUEL
filler cap.
EC-02021
IN-00203

chamber. <Ref. to IN(H6DO)-5, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H6DO)-7, REMOVAL, FU-02115
Air Intake Chamber.> 10) Disconnect the fuel hoses from fuel pipe.
6) Disconnect the connector (A) and (B).
(A)
FU-02116
(B) FU-02113
11) Remove the EGR pipe from EGR valve. (Ex-
7) Disconnect the engine coolant hoses from throt- cept for KA model)
tle body.
CAUTION:
Be careful not to drop gaskets.
FU-02114
FU-00547
12) Disconnect the connector from EGR valve. (Ex-

cept for KA model)
FU(H6DO)-12
Intake Manifold
13) Remove the fuel pipe protector LH. • LH side
FU-02117 FU-02121
14) Remove the bolts, which hold fuel injector pipe • RH side
LH onto cylinder head.
FU-02122
FU-02118
B: INSTALLATION
NOTE:
Use a new O-ring.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
• RH side
FU-02119
16) Remove the bolts, which hold fuel injector pipe

RH onto cylinder head.
FU-02122
FU-02120
17) Remove bolts which hold intake manifold onto

cylinder heads.
FU(H6DO)-13
Intake Manifold
• LH side Tightening torque:

19 N!m (1.9 kgf-m, 14 ft-lb)
FU-02121
2) Install the bolts, which hold fuel injector pipe RH FU-02118

onto cylinder head. 5) Install the fuel pipe protector LH.
19 N!m (1.9 kgf-m, 14 ft-lb) 19 N!m (1.9 kgf-m, 14 ft-lb)
FU-02120 FU-02117
3) Install the fuel pipe protector RH. 6) Connect the connector to EGR valve. (Except for
Tightening torque: KA model)
19 N!m (1.9 kgf-m, 14 ft-lb) 7) Install the EGR pipe to EGR valve. (Except for
KA model)
NOTE:
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-02119
4) Install the bolts which hold fuel injector pipe LH

onto cylinder head.
FU-00547
FU(H6DO)-14
Intake Manifold
8) Connect the fuel hoses to fuel pipe. 12) Connect the connector (A) and (B).
(A)
FU-02116 (B) FU-02113
9) Connect the brake booster hose. 13) Install the air cleaner case and air intake cham-
ber. <Ref. to IN(H6DO)-6, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H6DO)-7, INSTALLA-
TION, Air Intake Chamber.>
FU-02115
10) Connect the PCV hose.
IN-00203

C: DISASSEMBLY
1) Remove the throttle body. <Ref. to FU(H6DO)-
11, REMOVAL, Throttle Body.>
2) Remove the EGR valve. <Ref. to FU(H6DO)-25,
EC-02021 REMOVAL, EGR Valve.>
3) Disconnect the pressure regulator vacuum hose
11) Connect the engine coolant hoses to throttle from intake manifold.
body.
FU-02123
FU-02114
4) Remove the manifold absolute pressure sensor.
<Ref. to FU(H6DO)-23, REMOVAL, Manifold Ab-
solute Pressure Sensor.>
5) Remove the purge control solenoid valve. <Ref.
to EC(H6DO)-7, REMOVAL, Purge Control Sole-
noid Valve.>
FU(H6DO)-15
Intake Manifold
6) Loosen the clamp which holds fuel injector pipe Tightening torque:
to fuel hose, and then disconnect the pipe from fuel 5 N!m (0.5 kgf-m, 3.6 ft-lb)
hose.
FU-02125
FU-02124
7) Remove the bolts which install fuel pipes on in-

take manifold.
FU-02126
2) Connect the fuel injector pipe to fuel hose, and

tighten the clamp screw.
FU-02125
Tightening torque:
1.5 N!m (0.15 kgf-m, 1.1 ft-lb)
FU-02126
D: ASSEMBLY FU-02124
NOTE: 3) Install the purge control solenoid valve. <Ref. to
When assembling the nipple, apply liquid gasket. EC(H6DO)-7, INSTALLATION, Purge Control So-
Liquid gasket: lenoid Valve.>
THREE BOND 1105 (Part No. 004403010) 4) Install the manifold absolute pressure sensor.
1) Tighten the bolts which install fuel pipes on in- <Ref. to FU(H6DO)-23, INSTALLATION, Manifold
take manifold. Absolute Pressure Sensor.>
FU(H6DO)-16
Intake Manifold
5) Connect the pressure regulator vacuum hose to

intake manifold.
FU-02123
6) Install the EGR valve. <Ref. to FU(H6DO)-25,

INSTALLATION, EGR Valve.>
7) Install the throttle body to intake manifold. <Ref.
to FU(H6DO)-11, INSTALLATION, Throttle
Body.>
E: INSPECTION
FU(H6DO)-17

Sensor
A: REMOVAL
IN-00203
3) Disconnect the connector from engine coolant

temperature sensor.
FU-00572
B: INSTALLATION
Tightening torque:
16 N!m (1.6 kgf-m, 12 ft-lb)
FU-00572
FU(H6DO)-18

A: REMOVAL
2) Disconnect the ground cable from battery. 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
IN-00203 FU-02128

FU-02127
FU-02128
6) Disconnect the connector from crankshaft posi-

tion sensor.
FU(H6DO)-19
6. Camshaft Position Sensor 7) Remove the camshaft position sensor RH in the

same procedure as LH.
A: REMOVAL
B: INSTALLATION
2) Disconnect the ground cable from battery. Install in the reverse order of removal.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
Fuel pipe protector
19 N!m (1.9 kgf-m, 14 ft-lb)
IN-00203
3) Remove the generator harness from fuel pipe

protector LH.
FU-02117

tion sensor LH.
FU-02129
6) Remove the camshaft position sensor LH.
FU-02130
FU(H6DO)-20
Knock Sensor
7. Knock Sensor 3) Install the intake manifold. <Ref. to FU(H6DO)-

13, INSTALLATION, Intake Manifold.>
A: REMOVAL 4) Connect the battery ground cable to battery.
IN-00203

IN-00203

<Ref. to FU(H6DO)-12, REMOVAL, Intake Mani-
fold.>
FU-00577
B: INSTALLATION
Tightening torque:
25 N!m (2.5 kgf-m, 18 ft-lb)
NOTE:
For the knock sensor’s installation angle, refer to
the figure below.
30˚ 10˚ 45˚
(A) FU-00578
(A) Front side
FU(H6DO)-21

A: SPECIFICATION
body.
procedure. <Ref. to FU(H6DO)-11, REMOVAL,
Throttle Body.> <Ref. to FU(H6DO)-11, INSTAL-
LATION, Throttle Body.>
FU(H6DO)-22

Sensor
A: REMOVAL
IN-00203

lute pressure sensor (A), and remove the filter as-
sembly (B) from intake manifold.
(A) (B)
FU-02131

from intake manifold.
B: INSTALLATION
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU(H6DO)-23
10.Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
IN-00203

IN-02009

ature sensor.
FU-02132
B: INSTALLATION
Tightening torque:
1.0 N!m (0.10 kgf-m, 0.74 ft-lb)
FU(H6DO)-24
EGR Valve
11.EGR Valve Tightening torque:

EGR valve
A: REMOVAL 19 N!m (1.9 kgf-m, 14 ft-lb)
NOTE: EGR pipe
Model except for KA is equipped with EGR valve. 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
FU-02133
IN-00203

4) Remove the starter. <Ref. to SC(H6DO)-6, RE-
MOVAL, Starter.>
5) Remove the EGR pipe from the EGR valve and
cylinder head.
FU-02133

B: INSTALLATION
Install in the reverse of removal.
NOTE:
Replace the old gaskets with new ones.
FU(H6DO)-25
Fuel Injector
12.Fuel Injector 9) Remove the bolts which hold fuel injector pipe
A: REMOVAL
1. RH SIDE
filler cap.
FU-02120

injector pipe.
2. LH SIDE
IN-00203
filler cap.
5) Remove the air cleaner case. <Ref. to 4) Remove the battery.
IN(H6DO)-5, REMOVAL, Air Cleaner Case.> 5) Remove the generator harness from fuel pipe
6) Remove the fuel pipe protector RH. protector LH.
FU-02119
FU-02117
FU-02134
FU-02135
8) Remove the engine harness from fuel injector
pipe RH. 8) Remove the engine harness from fuel injector
pipe LH.
FU(H6DO)-26
Fuel Injector
9) Remove the bolts which hold fuel injector pipe 2. LH SIDE

NOTE:
Use new O-rings.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02118

injector pipe.
B: INSTALLATION
1. RH SIDE FU-02118
Install in the reverse order of removal. Tightening torque:

NOTE: 19 N!m (1.9 kgf-m, 13.7 ft-lb)
Use new O-rings.
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02117
FU-02120
Tightening torque:
19 N!m (1.9 kgf-m, 13.7 ft-lb)
FU-02119
FU(H6DO)-27
Variable Valve Lift Diagnosis Oil Pressure Switch
13.Variable Valve Lift Diagnosis B: INSTALLATION

Oil Pressure Switch Install in the reverse order of removal.
NOTE:
A: REMOVAL Apply liquid gasket to the thread of variable valve
1) Remove the collector cover. lift diagnosis oil pressure switch.
Liquid gasket:
equivalent
Tightening torque:
17 N!m (1.7 kgf-m, 12.5 ft-lb)
IN-00203

4) Disconnect the connector from variable valve lift
diagnosis oil pressure switch.
5) Remove the variable valve lift diagnosis oil pres-
sure switch.
• LH side
FU-02136
• RH side
FU-02137
FU(H6DO)-28
Oil Temperature Sensor
14.Oil Temperature Sensor

A: REMOVAL
IN-00203

4) Disconnect the connector from oil temperature
sensor.
5) Remove the oil temperature sensor.
FU-02138
B: INSTALLATION
Tightening torque:
18 N!m (1.8 kgf-m, 13.3 ft-lb)
FU(H6DO)-29
15.Front Oxygen (A/F) Sensor • LH side
A: REMOVAL
FU-02141
• RH side
IN-00203

4) Disconnect the connector of front oxygen (A/F)
sensor.
• LH side
FU-02142
B: INSTALLATION
ply anti-seize compound only to the threaded por-
tion of front oxygen (A/F) sensor to make the next
removal easier.
FU-02139 Anti-seize compound:
• RH side SS-30 JET LUBE
CAUTION:
Tightening torque:
21 N!m (2.1 kgf-m, 15.2 ft-lb)
• LH side
FU-02140

one minute or more.
CAUTION:
wait until exhaust pipe cools, otherwise it will FU-02141
damage the exhaust pipe.
FU(H6DO)-30
• RH side
FU-02142
3) Connect the connector of front oxygen (A/F)

sensor.
• LH side
FU-02139
• RH side
FU-02140

IN-00203
FU(H6DO)-31
Rear Oxygen Sensor
16.Rear Oxygen Sensor • LH side
A: REMOVAL
FU-02145
• RH side
IN-00203

sor.
• LH side
FU-02146
B: INSTALLATION
seize compound only to the threaded portion of
rear oxygen sensor to make the next removal eas-
ier.
FU-02143 Anti-seize compound:
• RH side SS-30 JET LUBE
CAUTION:
tor of rear oxygen sensor.
Tightening torque:
21 N!m (2.1 kgf-m, 15.2 ft-lb)
• LH side
FU-02144

minute or more.
CAUTION:
When removing the rear oxygen sensor, wait FU-02145
age the exhaust pipe.
FU(H6DO)-32
Rear Oxygen Sensor
• RH side
FU-02146

• LH side
FU-02143
• RH side
FU-02144

IN-00203
FU(H6DO)-33
17.Engine Control Module (ECM) • When replacing the ECM, immobilizer system
must be registered. For doing so, all ignition
A: REMOVAL keys and ID cards should be prepared. Refer to
1) Disconnect the ground cable from battery. “REGISTRATION MANUAL FOR IMMOBILIZ-
ER”.
Tightening torque:
5 N!m (0.5 kgf-m, 3.6 ft-lb)
IN-00203

Trim.>
FU-02090
5) Remove the nuts (A) which hold ECM to bracket.

(A)
(B)
(A)
FU-02091
7) Disconnect the ECM connectors, and take out

the ECM.
B: INSTALLATION
CAUTION:
FU(H6DO)-34
Main Relay
18.Main Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
FU-02093
B: INSTALLATION
FU(H6DO)-35
Fuel Pump Relay
19.Fuel Pump Relay

A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
FU-02094
B: INSTALLATION
FU(H6DO)-36

Relay
A: REMOVAL
IN-00203

AL, Glove Box.>
(A)
FU-02092
4) Disconnect the connector from electronic throttle

control relay.
FU-02095
B: INSTALLATION
FU(H6DO)-37
Fuel Pump Control Unit
21.Fuel Pump Control Unit

A: REMOVAL
IN-00203
2) Remove the rear quarter trim. <Ref. to EI-63,

REMOVAL, Rear Quarter Trim.>
3) Remove the fuel pump control unit.
• Wagon model
FU-02159
• Sedan model
FU-02160
4) Disconnect the connector from fuel pump control

unit.
B: INSTALLATION
FU(H6DO)-38
Fuel
22.Fuel 6) Set a container under the vehicle, and remove

the drain plugs from fuel tank to drain the fuel from
A: PROCEDURE fuel tank.
WARNING:
box.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
2) Start the engine and run until it stalls. NOTE:
Bolt
IN-00203
filler cap.
FU(H6DO)-39
Fuel Tank
A: REMOVAL
WARNING:
3) Drain fuel from fuel tank.
(B)
<Ref. to FU(H6DO)-39, DRAINING FUEL, PRO- FU-01126
CEDURE, Fuel.>
4) Remove the rear seat. 8) Disconnect the connector (A) from fuel sub level
sensor.
livery (B) and return hose (C). <Ref. to FU(H6DO)-
(2) Push the grommet (B) down under the body 54, REMOVAL, Fuel Delivery, Return and Evap-
and remove the service hole cover. oration Lines.>
(A)
(A) (A) (C)
(B) (B)
FU-01124
FU-01127
11) Remove the bolts which secure the rear brake
FU-01125

el sensor. FU-01128
FU(H6DO)-40
Fuel Tank
FU-00462 FU-01130

<Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust
Pipe.>
FU-01131
18) Disconnect the connector from rear ABS wheel
CAUTION:
sion jack.
(2) Remove the bolt which installs rear shock
absorber to rear suspension arm.
FU-01129
FU-01132
FU(H6DO)-41
Fuel Tank
(3) Remove the bolts which secure rear sus- 23) Support the fuel tank with transmission jack, re-
pension assembly to body. move the bolts from fuel tank bands, and dismount
WARNING:
FU-01133
FU-01137
B: INSTALLATION
of fuel tank band.
WARNING:
FU-01134

from bracket.
FU-01137
(A)
FU-01135
22) Loosen the clamp, and disconnect the fuel filler

(A)
(B)
FU-01136
FU(H6DO)-42
Fuel Tank
T3: 175 N!m (17.8 kgf-m, 129 ft-lb)
(A) T1 T1
(B)
T1
T1
FU-01136
FU-01150
(2) (3)
(1)
L/2
T2 T3
L T3 T2
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp (3) Tighten the bolts which install rear shock ab-
(3) Pipe sorber to rear suspension arm. <Ref. to RS-11,
INSTALLATION, Rear Arm.>
62 N!m (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
33 N!m (3.4 kgf-m, 25 ft-lb)
CAUTION:
sion jack.
then tighten the bolts which secure rear suspen-
sion assembly to body.
FU(H6DO)-43
Fuel Tank

FU-01130 FU-01128

sor.
18) Connect the quick connector of the fuel delivery
(B) and return hose (C). <Ref. to FU(H6DO)-55,
INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
NOTE:
return side.
FU-01131

sor.
(A)
(C)
(B)
FU-01127

sensor.
FU-01129

10) Install the rear exhaust pipe. <Ref. to
EX(H6DO)-8, INSTALLATION, Rear Exhaust (A)
Pipe.>
12) Connect the parking brake cable to parking (B)
brake assembly. <Ref. to PB-8, INSTALLATION, FU-01126
13) Install the rear brake caliper. (A) Bolt
14) Tighten the bolt which secures rear brake hose (B) Grommet
installation bracket.
FU(H6DO)-44
Fuel Tank
FU-01125
(A) (A)
(B)
FU-01124
(A) Bolt
(B) Grommet

C: INSPECTION
1) Check that the fuel tank is not holed, cracked, or
otherwise damaged.
FU(H6DO)-45
Fuel Filler Pipe
24.Fuel Filler Pipe 7) Set a container under the vehicle, and remove
the drain plug from fuel tank to drain the fuel from
WARNING:
cap.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 N!m (2.65 kgf-m, 19.2 ft-lb)
MOVAL, Mud Guard.>
4) Remove the screws which secure packing.
11) Remove the bolts which hold fuel filler pipe
FU-00095

6) Remove the rear wheel RH.
(A)
(B)
FU-00096
FU-01136

vehicle.
FU(H6DO)-46
Fuel Filler Pipe
B: INSTALLATION 5) Tighten the bolts which hold fuel filler pipe brack-
1) Open the fuel filler flap lid. et on the body.
2) Set the fuel saucer (A) with rubber packing (C), Tightening torque:
side of apron.
NOTE:
(A)
FU-01139

(C)
LATION, Mud Guard.>
FU-00103

clamp.
(A)
(B)
FU-00096

FU-01136
(2) (3)
(1)
L/2
L IN-00203
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipe
FU(H6DO)-47
Fuel Pump
25.Fuel Pump 7) Remove the nuts which install fuel pump assem-
bly onto fuel tank.
A: REMOVAL
WARNING:
NOTE:
<Ref. to FU(H6DO)-39, RELEASING OF FUEL (A) Delivery hose
2) Drain the fuel. <Ref. to FU(H6DO)-39, DRAIN- (C) Jet pump hose
and remove service hole cover. Use a new gasket.
4.4 N!m (0.45 kgf-m, 3.3 ft-lb)
1
(B) 4 8
FU-01124

6 5
7 3
2
FU-01141
C: INSPECTION
of fuel pump, and apply the battery power supply to
FU-01125
6) Disconnect the quick connector, and then dis- WARNING:
connect the fuel delivery hose, return hose and jet • Wipe off the fuel completely.
pump hose. <Ref. to FU(H6DO)-54, REMOVAL, • Keep battery as far apart from fuel pump as
Fuel Delivery, Return and Evaporation Lines.> possible.
FU(H6DO)-48
Fuel Pump

non-load condition.
2 1
4 3
6 5
FU-01330
FU(H6DO)-49
Fuel Level Sensor

A: REMOVAL
WARNING:
NOTE:
FU(H6DO)-48, REMOVAL, Fuel Pump.>
et.
FU-01142

B: INSTALLATION
FU(H6DO)-50
27.Fuel Sub Level Sensor 6) Remove the nuts and bolts which install fuel sub
level sensor on fuel tank.
A: REMOVAL
WARNING:
1) Drain the fuel. <Ref. to FU(H6DO)-39, DRAIN-
(B)
2) Remove the rear seat. FU-01144

(A) B: INSTALLATION
NOTE:
(B)
3
1
2
4
FU-01143 FU-01145
5) Disconnect the quick connector, and then dis-
connect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H6DO)-54, REMOVAL,
FU-01146
FU(H6DO)-51
Fuel Filter
28.Fuel Filter
A: SPECIFICATION
Refer to “Fuel Pump” for removal and installation.
<Ref. to FU(H6DO)-48, REMOVAL, Fuel Pump.>
<Ref. to FU(H6DO)-48, INSTALLATION, Fuel
Pump.>
FU(H6DO)-52
Fuel Bypass Valve
29.Fuel Bypass Valve

A: REMOVAL
2) Disconnect the pressure regulator vacuum
hose.
3) Disconnect the fuel delivery line and return line
from fuel bypass valve.
4) Remove the fuel bypass valve from vehicle
body.
(A) (B)
(C)
(B)
T
T
FU-02180
(A) Pressure regulator vacuum hose

(C) Fuel return line
B: INSTALLATION
Tightening torque:
7.5 N!m (0.76 kgf-m, 5.53 ft-lb)
FU(H6DO)-53

A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H6DO)-39, RELEASING OF FUEL PRESSURE, PROCEDURE,
Fuel.>
FU-02181
6) In the engine compartment, disconnect the fuel 9) Separate the quick connector on fuel line.
covered with dust.
(A) (B)
plastic bag, etc.
FU-02148

(B) Evaporation hose
FU-01333
8) Remove the fuel tank. <Ref. to FU(H6DO)-40, (3) Hold the connector and push retainer down.
REMOVAL, Fuel Tank.> (4) Pull out the connector from retainer.
FU(H6DO)-54
CAUTION: CAUTION:
securely.
• Be sure to inspect the hoses and their con-
nections for fuel leakage.
(B)
(A) (C)
FU-00124
(A)
(A) Connector
(B) Retainer
(C) Pipe (B) (C)
FU-00127
B: INSTALLATION
(B) Retainer
CAUTION:
(C) Pipe
fied.
(A)
2: 2.5"1.5 mm (0.098"0.059 in)
L: 22.5"2.5 mm (0.886"0.098 in)
(B)
(1) (2) (3)
Type A
FU-00125
L
(A) Seal surface
(B) Pipe
Type B
(1) Set the new retainer to connector.

FU-00128
(2) Push the pipe into the connector completely.
(A) (1) Pipe
(2) Clamp
(B) (3) Hose

(C)
to the pipe by approx. 15 mm (0.59 in) from the
hose end.
Fuel return hose:
L = 22.5"2.5 mm (0.885"0.098 in)
FU-00126
L = 17.5"2.5 mm (0.689"0.098 in)
(A) Connector
(B) Retainer
(C) Pipe
FU(H6DO)-55
CAUTION:
(2) (3)
(1)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipe
C: INSPECTION
1) Make sure that there are no crack on the fuel
FU(H6DO)-56

A: INSPECTION
❍ Defective terminal contact
securely.
❍ Trouble in electromagnetic or electronic circuit parts Replace the fuel pump.
2) Decline of fuel pump function Replace the fuel pump.
3) Clogged dust or water in the fuel filter Replace 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 mixed in the fuel system Inspect or retighten each connection part.
6) Clogged or bent air breather tube or pipe Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator Replace.
1) Loosened joints of the fuel pipe Retighten.
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.
5) Clogged or bent air breather tube or air vent tube
tube.
1) Retighten.
pipe
2) Defective packing air tightness on the fuel saucer Correct or replace the packing.
3) Cracked fuel separator Replace separator.
4) Inoperative fuel pump modulator or circuit Replace.
1) Defective operation of fuel level sensor Replace.
2) Defective operation of fuel meter Replace.
3) Defective body integrated unit Replace.
5. Noise
1) Large operation noise or vibration of fuel pump Replace.
NOTE:
0#C (32#F) throughout the winter season, use water removing agent in the fuel system to prevent freezing
• When water condensation is noticed in the fuel filter, drain water from both the fuel filter and fuel tank or
use a water removing agent in the fuel tank.
FU(H6DO)-57
FU(H6DO)-58
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

EMISSION CONTROL
EC(H6DO)
Page
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter.............................................................................4
4. EGR Valve ..................................................................................................5
5. Canister.......................................................................................................6
6. Purge Control Solenoid Valve .....................................................................7
7. Two-way Valve............................................................................................8
8. PCV Valve...................................................................................................9
General Description
A: CAUTION
points.
cable from battery.
EC(H6DO)-2

A: REMOVAL
ed into front exhaust pipe as one unit; therefore, re-
fer to “Front Exhaust Pipe” for removal procedure.
<Ref. to EX(H6DO)-5, REMOVAL, Front Exhaust
Pipe.>
(A)
(B)
EC-02018
(A) Front catalytic converter

(B) Rear catalytic converter
B: INSTALLATION
fer to “Front Exhaust Pipe” for installation
procedure. <Ref. to EX(H6DO)-6, INSTALLATION,
Front Exhaust Pipe.>
(A)
(B)
EC-02018

C: INSPECTION
nections and welds.
EC(H6DO)-3

A: REMOVAL
fer to “Front Exhaust Pipe” for removal procedure.
Pipe.>
(A)
(B)
EC-02018

B: INSTALLATION
fer to “Front Exhaust Pipe” for installation
procedure. <Ref. to EX(H6DO)-6, INSTALLATION,
Front Exhaust Pipe.>
(A)
(B)
EC-02018

C: INSPECTION
nections and welds.
EC(H6DO)-4
EGR Valve
4. EGR Valve
A: SPECIFICATION
Refer to “EGR valve” for removal and installation.
<Ref. to FU(H6DO)-25, EGR Valve.>
EC(H6DO)-5
Canister
5. Canister Tightening torque:

8.3 N!m (0.85 kgf-m, 6.1 ft-lb)
A: REMOVAL
2) Remove the rear wheel LH.
3) Remove the mud guard LH.
4) Remove the protector. (Sedan model)
5) Disconnect the quick connector (A). (B) (A)
6) Remove the canister (B) from body.
(B) (A)
(B)
(B)
EC-02027
C: INSPECTION
cracked or loose.
EC-02027
B: INSTALLATION
NOTE:
Make sure there are no damage or dust on the con-
nection of quick connector. If necessary, clean the
EC(H6DO)-6
6. Purge Control Solenoid Valve NOTE:

Connect the evaporation hose as shown in the fig-
A: REMOVAL ure.
(B)
(A)
EC-02020
IN-00203 (A) To fuel pipe (Evaporation line)

3) Remove the air intake chamber. <Ref. to (B) To intake manifold
4) Disconnect the connector and hoses of purge C: INSPECTION
control solenoid valve, and then remove the purge Make sure the hoses are not cracked or loose.
control solenoid valve.
EC-02019
B: INSTALLATION
Tightening torque:
19 N!m (1.9 kgf-m, 14.0 ft-lb)
EC-02019
EC(H6DO)-7
Two-way Valve
7. Two-way Valve
A: REMOVAL
valve.
from body.
EC-00221

B: INSTALLATION
Tightening torque:
7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
EC(H6DO)-8
PCV Valve
8. PCV Valve
A: REMOVAL
1) Disconnect the PCV hose.
EC-02021
2) Remove the PCV valve from rocker cover.
EC-02022
B: INSTALLATION
NOTE:
valve.
Liquid gasket:
Tightening torque:
25 N!m (2.5 kgf-m, 18 ft-lb)
EC(H6DO)-9
PCV Valve
EC(H6DO)-10
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

INTAKE (INDUCTION)
IN(H6DO)
Page
2. Air Cleaner Element ..................................................................................4
3. Air Cleaner Case .......................................................................................5
4. Air Intake Chamber ...................................................................................7
5. Air Intake Duct...........................................................................................8
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2
T2
(14)
(14)
(13)
T3 (13)
(11)
(15)
(10)
T3
(12)
T3
(16)
(9)
(9) T5
(18)
(8)
(7)
T4
(4)
(17)
(3)
T1
(2)
(6)
(6) (5)
(5)
(1)
IN-02008
IN(H6DO)-2
General Description
INTAKE (INDUCTION)
(1) Air intake duct (10) Clamp (18) Mass air flow and intake air tem-
(2) Clip (11) Intake duct perature sensor
(3) Resonator chamber (12) Clamp
(4) Air cleaner case (front) (13) Cushion Tightening torque: N!m (kgf-m, ft-lb)
(5) Spacer (14) Spacer T1: 6.0 (0.6, 4.4)
(6) Cushion (15) Air intake chamber T2: 6.4 (0.65, 4.7)
(7) Air cleaner element (16) Clamp T3: 3.0 (0.3, 2.2)
(8) Air cleaner case (rear) (17) Cushion T4: 7.5 (0.76, 5.5)
(9) Clip T5: 1.0 (0.10, 0.7)
B: CAUTION
points.
cable from battery.
IN(H6DO)-3
Air Cleaner Element
INTAKE (INDUCTION)

A: REMOVAL
case.
IN-00203
2) Disconnect the connector from mass air flow and IN-00207

C: INSPECTION
Replace if excessively damaged or dirty.
IN-02009
3) Remove the clip (A) from the upper side of air

cleaner case.
(A)
IN-02010
4) Pull the air cleaner case (rear) to the rearward of

vehicle, and then remove the air cleaner element.
NOTE:
Be careful that the power steering hose is secured
to the under side of air cleaner case (rear).
IN(H6DO)-4
Air Cleaner Case
INTAKE (INDUCTION)
3. Air Cleaner Case 6) Remove the air cleaner case (rear) and air
cleaner element.
A: REMOVAL
IN-00206
7) Remove the bolt (A) and nut (B) which hold air
IN-00203 cleaner case on the body.
2) Remove the air intake duct. <Ref. to IN(H6DO)-
8, REMOVAL, Air Intake Duct.>
3) Disconnect the connector from mass air flow and (B)
(A)
IN-00208
IN-02009
4) Loosen the clamp (A) which connects air cleaner

case to intake duct.
5) Remove the clip (B) from the upper side of air
cleaner case.
(B)
(A)
IN-02011
IN(H6DO)-5
Air Cleaner Case
INTAKE (INDUCTION)
B: INSTALLATION
Tightening torque:
Bolt (A): 6.0 N!m (0.6 kgf-m, 4.4 ft-lb)
Nut (B): 7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
(B)
(A)
IN-00208
NOTE:
case.
IN-00207
C: INSPECTION
Check for cracks or loose connection.
IN(H6DO)-6
Air Intake Chamber
INTAKE (INDUCTION)
4. Air Intake Chamber

A: REMOVAL
2) Loosen the clamp (A) which connects air intake
chamber to throttle body.
3) Loosen the clamp (B) which connects intake
duct to air intake chamber.
4) Remove the bolt (C) which secures air intake
chamber to the stay.
(A)
(B)
(C) (C)
IN-02012
5) Disconnect one part of blow-by hose, and re-

move the air intake chamber.
B: INSTALLATION
Tightening torque:
Clamp (A), (B)
3.0 N!m (0.3 kgf-m, 2.2 ft-lb)
Bolt (C)
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
(A)
(B)
(C) (C)
IN-02012
C: INSPECTION
chamber.
IN(H6DO)-7
Air Intake Duct
INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
1) Remove the clips which install air intake duct on
the front side of body.
IN-02013
B: INSTALLATION
C: INSPECTION
duct.
IN(H6DO)-8
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
with air cleaner case. <Ref. to IN(H6DO)-5, RE-
B: INSTALLATION
gle unit with air cleaner case. <Ref. to IN(H6DO)-6,
INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H6DO)-9
Resonator Chamber
INTAKE (INDUCTION)
IN(H6DO)-10
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

MECHANICAL
ME(H6DO)
Page
2. Compression .............................................................................................22
3. Idle Speed .................................................................................................23
4. Ignition Timing...........................................................................................24
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. V-belt.........................................................................................................33
10. Engine Assembly ......................................................................................34
11. Engine Mounting .......................................................................................40
13. Crank Pulley..............................................................................................42
14. Front Chain Cover.....................................................................................43
15. Timing Chain Assembly ............................................................................45
16. Cam Sprocket ...........................................................................................50
17. Crank Sprocket .........................................................................................51
18. Rear Chain Cover .....................................................................................52
19. Camshaft...................................................................................................54
20. Cylinder Head ...........................................................................................58
21. Cylinder Block ...........................................................................................63
23. Oil Switching Solenoid Valve ....................................................................79
24. ATF Warmer Cock ....................................................................................80
26. Engine Noise.............................................................................................88
General Description
MECHANICAL
A: SPECIFICATION
Chain driven, double overhead camshaft,
4-valve/cylinder
Bore ! Stroke mm (in) 89.2 ! 80 (3.512 ! 3.150)
Displacement 3 2,999 (183)
cm (cu in)
Compression pressure
(350 rpm and fully open throttle): kPa (kg/cm2, psi) 1,275 — 1,471 (13.0 — 15.0, 185 — 213)
Number of piston rings Pressure ring: 2, Oil ring: 1

Min. Open BTDC 47"
advance Close ABDC 23"
Engine Intake valve timing
Max. Open ATDC 3"
retard Close ABDC 73"
Open BBDC 60"
Close ATDC 6"
Intake 0.20+0.04 -0.06 (0.0079+0.0016-0.0024)
Exhaust 0.35#0.05 (0.0138#0.020)
No
650#50
load
Idling speed [“P” or “N” range] rpm
A/C
770#50
ON
Ignition order 1 $ 6 $3 $ 2 $ 5 $ 4
Ignition timing BTDC/rpm 15"#8"/650
NOTE:
OS: Oversize US: undersize
Intake Standard 0.075 — 0.135 (0.0030 — 0.0053)
Side clearance mm (in)
HIGH Standard 42.09 — 42.19 (1.6571 — 1.6610)
Intake LOW1 Standard 38.14 — 38.24 (1.5016 — 1.5055)
Cam lobe height mm (in)
LOW2 Standard 34.94 — 35.04 (1.3756 — 1.3795)
Camshaft HIGH Standard 32.00 (1.2598)
Cam base circle diam- Intake LOW1 Standard 31.84 (1.2535)
mm (in)
eter LOW2 Standard 31.84 (1.2535)
Exhaust Standard 32.00 (1.2598)
Front: Standard 37.946 — 37.963 (1.4939 — 1.4946)
Journal O.D. mm (in)
Except for front Standard 25.946 — 25.963 (1.0215 — 1.0222)
Flatness mm (in) Standard 0.02 (0.0008)
Cylinder
Inner diameter of valve lifter hole mm (in) 32.994 — 33.016 (1.2990 — 1.2998)
head
Standard height mm (in) 124#0.05 (4.88#0.0020)
Refacing angle 90"
Valve seat Intake Standard 1.0 (0.039)
Valve guide
Protrusion above head mm (in) 11.4 — 11.8 (0.449 — 0.465)
ME(H6DO)-2
General Description
MECHANICAL
Intake Standard 1.0 (0.039)

Head edge thickness mm (in)
Intake 5.455 — 5.470 (0.2148 — 0.2145)
Stem outer diameter mm (in)
Exhaust 5.455 — 5.460 (0.2148 — 0.2150)
Valve Intake Standard 0.030 — 0.057 (0.0012 — 0.0022)
Stem oil clearance
Intake 99.7 (3.925)
Exhaust 105.2 (4.142)
Outer diameter of valve lifter mm (in) 32.959 — 32.975 (1.2976 — 1.2982)
Inner 39.55 (1.5571)
Intake
Free length mm (in) Outer 41.18 (1.6213)
Exhaust 46.32 (1.8236)
Valve spring
Inner 2.5", 1.7 mm (0.067 in)
Intake
Squareness Outer 2.5", 1.8 mm (0.071 in)
Exhaust 2.5", 2.0 mm (0.079 in)
Standard height mm (in) 202 (7.95)
Stan- A 89.205 — 89.215 (3.5120 — 3.5124)
Cylinder inner diameter mm (in)
Cylinder dard B 89.195 — 89.205 (3.5116 — 3.5120)
block Cylindricality mm (in) Standard 0.030 (0.0012)
Piston clearance mm (in) Standard %0.010 — 0.010 (%0.0004 — 0.0004)
A 89.205 — 89.215 (3.5120 — 3.5124)
Standard
B 89.195 — 89.205 (3.5116 — 3.5120)
Outer diameter mm (in)
Piston 0.25 (0.0098) OS 89.445 — 89.465 (3.5215 — 3.5222)
0.50 (0.0197) OS 89.695 — 89.715 (3.5313 — 3.5321)
Inner diameter of piston pin hole Standard 22.000 — 22.006 (0.8661 — 0.8664)
Outer diameter mm (in) Standard 21.994 — 22.000 (0.8659 — 0.8661)
Piston pin Standard clearance between piston and piston pin
Standard 0.004 — 0.008 (0.0002 — 0.0003)
mm (in)
Ring closed gap mm (in) Second ring Standard 0.35 — 0.50 (0.0138 — 0.0197)
Piston ring
Ring groove gap mm (in) Second ring Standard 0.030 — 0.070 (0.0012 — 0.0028)
Connecting
Side clearance of large end mm (in) Standard 0.070 — 0.330 (0.0028 — 0.0130)
rod
Standard 1.490 — 1.506 (0.0587 — 0.0593)
Bearing of
Bearing size 0.03 (0.0012) US 1.509 — 1.513 (0.0594 — 0.0596)
large end mm (in)
(Thickness at center) 0.05 (0.0020) US 1.519 — 1.523 (0.0598 — 0.0600)
0.25 (0.0098) US 1.619 — 1.623 (0.0637 — 0.0639)
Bushing of
Clearance between piston pin and bushing mm (in) Standard 0 — 0.022 (0 — 0.0009)
small end
ME(H6DO)-3
General Description
MECHANICAL
Out-of-roundness mm (in) 0.005 (0.0002)

Crank pin and crank journal
Cylindricality mm (in) 0.006 (0.0002)
Standard 51.984 — 52.000 (2.0466 — 2.0472)
0.03 (0.0012) US 51.954 — 51.970 (2.0454 — 2.0461)
Crank pin outer diameter mm (in)
0.05 (0.0020) US 51.934 — 51.950 (2.0446 — 2.0453)
0.25 (0.0098) US 51.734 — 51.750 (2.0368 — 2.0374)
Standard 63.992 — 64.008 (2.5194 — 2.5200)
#1, #3, 0.03 (0.0012) US 63.962 — 63.978 (2.5182 — 2.5188)
Crankshaft
#5, #7 0.05 (0.0020) US 63.942 — 63.958 (2.5174 — 2.5180)
Crank journal outer diameter 0.25 (0.0098) US 63.742 — 63.758 (2.5095 — 2.5102)
mm (in) Standard 63.992 — 64.008 (2.5194 — 2.5200)
#2, #4, 0.03 (0.0012) US 63.962 — 63.978 (2.5182 — 2.5188)
#6 0.05 (0.0020) US 63.942 — 63.958 (2.5174 — 2.5180)
0.25 (0.0098) US 63.742 — 63.758 (2.5095 — 2.5102)
Thrust clearance mm (in) Standard 0.030 — 0.115 (0.0012 — 0.0045)
Standard 1.992 — 2.005 (0.0784 — 0.0789)
#1, #3, 0.03 (0.0012) US 2.011 — 2.014 (0.0792 — 0.0793)
#5, #7 0.05 (0.0020) US 2.021 — 2.024 (0.0796 — 0.0797)
Main bear- Bearing size 0.25 (0.0098) US 2.121 — 2.124 (0.0835 — 0.0836)
mm (in)
ing (Thickness at center) Standard 1.996 — 2.009 (0.0786 — 0.0791)
#2, #4, 0.03 (0.0012) US 2.015 — 2.018 (0.0793 — 0.0794)
#6 0.05 (0.0020) US 2.025 — 2.028 (0.0797 — 0.0798)
0.25 (0.0098) US 2.125 — 2.128 (0.0837 — 0.0838)
ME(H6DO)-4
General Description
MECHANICAL
B: COMPONENT
1. V-BELT
(5)
(6)
(4)
(3)
T2
(2)
T3
T3
(7)
T1 (8)
(9)
T4
(1)
ME-02020
(1) V-belt (6) Generator plate Tightening torque: N&m (kgf-m, ft-lb)
(2) Collector cover bracket (7) A/C compressor stay T1: 6.4 (0.65, 4.7)
(3) Belt tension adjuster ASSY (8) Idler pulley T2: 20 (2.0, 14)
(4) Power steering pump bracket (9) Idler pulley cover T3: 25 (2.5, 18)
(5) Generator T4: 33 (3.4, 25)
ME(H6DO)-5
General Description
MECHANICAL
2. TIMING CHAIN COVER
T3
(8)
T3
T2
T3
(7)
(4)
T3
T2 T3
T1
(2) (5) (6)

(1)
(3)
T2
T2
T4
ME-02021
(1) Crank pulley cover (5) Oil seal Tightening torque: N&m (kgf-m, ft-lb)
(2) O-ring (6) Front chain cover T1: <Ref. to ME(H6DO)-42, Crank
(3) Crank pulley (7) Rear chain cover Pulley.>
(4) Sealing washer (8) Water pump gasket T2: <Ref. to ME(H6DO)-43, Front
Chain Cover.>
T3: <Ref. to ME(H6DO)-52, Rear
Chain Cover.>
T4: 6.4 (0.65, 4.7)
ME(H6DO)-6
General Description
MECHANICAL
3. TIMING CHAIN
(4)
(3)
(9)
(1)
(8)
(2) T1
T6
(5)
(6)
T4
(11)
T2
(12)
T4 (17)
(10)
(13)
(24) (18) (19)
(25) T4
(7) (14)
T3
(22) (23)
T1
(22) T4
(24) T4 (16)
(15)
(20) T1
T5
T3
(21)
ME-02022
(1) Crank sprocket (13) Chain tensioner lever (LH) (25) Idler sprocket (upper)
(2) Oil relief case (14) Chain tensioner (LH)
(3) Inner rotor (15) Water pump Tightening torque: N&m (kgf-m, ft-lb)
(4) Outer rotor (16) O-ring T1: 6.4 (0.64, 4.7)
(5) Chain guide (CTR) (17) Chain guide (LH) T2: 7.8 (0.80, 5.8)
(6) Intake cam sprocket (RH) (18) Chain guide (LH: between cams) T3: <Ref. to ME(H6DO)-50, Cam
(7) Exhaust cam sprocket (RH) (19) Timing chain (LH) Sprocket.>
(8) Chain guide (RH: between cams) (20) Intake cam sprocket (LH) T4: 16 (1.6, 11.6)
(9) Timing chain (RH) (21) Exhaust cam sprocket (LH) T5: 69 (7.0, 50.6)
(10) Chain guide (RH) (22) Idler sprocket plate T6: <Ref. to LU(H6DO)-8, Oil Pump.>
(11) Chain tensioner lever (RH) (23) Idler sprocket (lower)
(12) Chain tensioner (RH) (24) Idler sprocket collar
ME(H6DO)-7
General Description
MECHANICAL
T2
(1)
(7) T2
T4
(2)
(8) (9)
T3
(14)
(10) (4)
(16)
(11) (15) (3)
(6) (17)
(5)
(12)
(13)
(18)
T1 (19)
(20)
(21)
T1
(26)
T4
(35)
(22)
(28)
(23) (27)
(24)
(25)
(32)
(29)
T2
(33)
(30)
(31)
(34) T5
T2
T3
ME-02095
ME(H6DO)-8
General Description
MECHANICAL
(1) Rocker cover (RH) (14) Intake camshaft (RH) (29) Exhaust camshaft cap (Rear LH)
(2) Oil switching solenoid valve (RH) (15) Exhaust camshaft (RH) (30) Exhaust camshaft cap (Center
(3) Oil switching solenoid valve holder (16) Cylinder head (RH) LH)
(RH) (17) Water hose (31) Exhaust camshaft cap (Front LH)
(4) Oil switching solenoid valve gas- (18) Cylinder head gasket (RH) (32) Front camshaft cap (LH)
ket (19) Oil switching solenoid valve (LH) (33) Plug
(5) Rear chain cover (20) Oil switching solenoid valve holder (34) Oil pipe (LH)
(6) Oil pipe (RH) (LH) (35) Rocker cover (LH)
(7) Oil flow control solenoid valve (21) Oil switching solenoid valve gas-
(RH) ket Tightening torque:N&m (kgf-m, ft-lb)
(8) Intake camshaft cap (Center RH) (22) Cylinder head gasket (LH) T1: <Ref. to ME(H6DO)-58, Cylinder
(9) Intake camshaft cap (Rear RH) (23) Cylinder head (LH) Head.>
(10) Exhaust camshaft cap (Rear RH) (24) Intake camshaft (LH) T2: <Ref. to ME(H6DO)-54,
(11) Exhaust camshaft cap (Center (25) Exhaust camshaft (LH) Camshaft.>
RH) (26) Oil flow control solenoid valve (LH) T3: 9.75 (1.0, 7.2)
(12) Exhaust camshaft cap (Front RH) (27) Intake camshaft cap (Rear LH) T4: 16 (1.6, 12)
(13) Front camshaft cap (RH) (28) Intake camshaft cap (Center LH) T5: 60 (6.1, 44)
ME(H6DO)-9
General Description
MECHANICAL
(1)
(16)
(3) (4) (5) (6) (7) (8) (9) (10) (11)
(2)
(16)
(12)
(4)
(17)
(13)
(14)
(8)
(9)
(15)
ME-02024
(1) Exhaust valve (7) Valve spring (Outer) (13) Exhaust valve stem seal
(2) Intake valve (8) Retainer (14) Valve spring
(3) Intake valve guide (9) Retainer key (15) Valve lifter (Exhaust)
(4) Valve spring seat (10) Shim (16) Cylinder head plug
(5) Intake valve stem seal (11) Valve lifter (Intake) (17) Cylinder head
(6) Valve spring (Inner) (12) Exhaust valve guide
ME(H6DO)-10
General Description
MECHANICAL
6. CYLINDER BLOCK
T3
T8
(1)
(19) T1
(3)
(20)
(4) T1
(19)
(5)
T5
T8
T8
(19) (2)
(19)
T5 (5) (6)
T2
(19)
(5)
(7)
(17) (14)
(13)
(13)
T10
(18) (19)
T7 (19)
(16) T4 T2
(5)
T2
(5)
T2
(19)
(13)
(21) T1
(14) T9 T2
(13)
(22) (8)
T2
(15) (23) (9)
(13)
(13) T6
(14) (10)
T1
T6
(11)
(12)
T1
ME-02108
ME(H6DO)-11
General Description
MECHANICAL
(1) Cylinder block (RH) (13) Clamp Tightening torque:N&m (kgf-m, ft-lb)
(2) Cylinder block (LH) (14) Hose T1: 6.4 (0.65, 4.7)
(3) Rear oil seal (15) Oil cooler pipe T2: 18 (1.8, 13.0)
(4) Service hole cover (16) Oil cooler T3: 25 (2.5, 18)
(5) O-ring (17) Connector T4: 16 (1.6, 12)
(6) Oil pan upper (18) Oil filter T5: 37 (3.8, 27)
(7) Oil pressure switch (19) Plug T6: 44 (4.5, 33)
(8) Oil strainer (20) Crankshaft position sensor holder T7: 54 (5.5, 40)
(9) Magnet (21) Relief valve T8: 70 (7.1, 52)
(10) Oil pan lower (22) Relief valve spring T9: 23 (2.3, 17)
(11) Metal gasket (23) Plug T10: 90 (9.2, 67)
(12) Drain plug
ME(H6DO)-12
General Description
MECHANICAL
T1
(7)
(12) (13) T2
(1)
(4) (14)
(9)
(5)
(6)
(7)
(11) (2)
(8)
(3)
(10)
(11)
(15)
(10) (8)
(7)
(11) (13)
(6)
(5)
(12)
(4)
(18)
(17) T1
(16)
(17) (7)
(16) (9)
(17)
(16)
ME-02101
(1) Reinforcement (9) Piston pin (17) Crankshaft bearing #2, #4, #6
(2) Drive plate (10) Connecting Rod (18) Crankshaft bearing #7
(3) Crankshaft sensor plate (11) Connecting rod bearing
(4) Top ring (12) Connecting rod bolt Tightening torque: N&m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 53 (5.4, 39)
(6) Oil ring (14) Crankshaft T2: 81 (8.3, 60)
(7) Snap ring (15) Woodruff key
(8) Piston (16) Crankshaft bearing #1, #3, #5
ME(H6DO)-13
General Description
MECHANICAL
8. ENGINE MOUNTING
(1)
T1
T2 T1
T2
ME-00445
(1) Front cushion rubber Tightening torque: N&m (kgf-m, ft-lb)

T1: 35 (3.6, 25.8)
T2: 85 (8.7, 63)
ME(H6DO)-14
General Description
MECHANICAL
C: CAUTION
points.
cable from battery.
• All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
• Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
• Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
• All removed parts, if to be reused, should be re-
installed in the original positions and directions.
• Bolts, nuts and washers should be replaced with
new ones as required.
• Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
• Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
• Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
• Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
ME(H6DO)-15
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
18250AA010 CYLINDER • Used for replacing valve guides.
ST18250AA010
18232AA000 ENGINE STAND Used for disassembling and assembling engine.
ST18232AA000
498497100 CRANKSHAFT Used for stopping rotation of flywheel or drive

STOPPER plate when loosening/tightening crank pulley bolt.
ST-498497100
18254AA000 PISTON PIN Used for installing piston in cylinder.

GUIDE
ST18254AA000
ME(H6DO)-16
General Description
MECHANICAL

ST-499585500
18253AA000 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.
ST18253AA000
18350AA000 CONNECTING Used for removing and installing connecting rod

REMOVER AND
INSTALLER
ST18350AA000

REMOVER
ASSY
ST-499097500
ME(H6DO)-17
General Description
MECHANICAL

499977500 CAM Used for removing and installing intake cam
SPROCKET sprocket.
WRENCH
ST-499977500
18231AA020 CAM Used for removing and installing exhaust cam

SPROCKET sprocket.
WRENCH
ST18231AA020

ST-499587200

ST-499597100
ME(H6DO)-18
General Description
MECHANICAL

REMOVER
ST-499718000
18251AA040 VALVE GUIDE Used for installing valve guides.

ADJUSTER
ST18251AA040

REMOVER
ST-499765700

REAMER
ST-499765900
ME(H6DO)-19
General Description
MECHANICAL

WRENCH loosening/tightening crank pulley bolt.
ST-499977100
18252AA000 CRANKSHAFT Used for rotating crankshaft.

SOCKET
ST18252AA000
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
ST-498547000
ST24082AA230
ME(H6DO)-20
General Description
MECHANICAL

ST22771AA030
18233AA000 PISTON PIN Used for removing and installing snap ring of pis-
SNAP RING PLI- ton pin.
ERS
ST18233AA000

bly to engine.
ST-498277200
2. GENERAL TOOL
TOOL NAME REMARKS
E: PROCEDURE
It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures
described in this section are based on the condition that the engine is removed from the vehicle.
• Camshaft
• Cylinder head
ME(H6DO)-21
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
ment.
switch to OFF.
4) Remove all the spark plugs. <Ref. to IG(H6DO)-
4, REMOVAL, Spark Plug.>
spark plug hole.
NOTE:
ME-00446
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 — 1,471 kPa (13.0 — 15.0 kg/cm2, 185
— 213 psi)
Service limit:
1, 128 kPa (11.5 kgf/cm2, 164 psi)
ME(H6DO)-22
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
lowing:
properly.
not illuminate.
2) Idle the engine.
OFF.
4) Insert the cartridge to the Subaru Select Monitor.
connector.
11) Start the engine, and read engine idle speed.
12) Check the idle speed when no-loaded. (Head-
light, heater fan, rear defroster, radiator fan, A/C,
etc. are OFF.)
Idle speed [No load and gears in neutral]:
650#50 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least one minute before mea-
surement.)
Idle speed [A/C “ON”, and gears in neutral]:
770#50 rpm
NOTE:
the idle speed is automatically adjusted. If the idle
<Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Pro-
cedure.>
ME(H6DO)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
careful not to burn yourself at measurement.
1. WITH SUBARU SELECT MONITOR
1) Before checking the ignition timing speed, check
the following:
clogging, spark plugs are in good condition, and
hoses are connected properly.
not illuminate.
2) Idle the engine.
OFF.
4) Insert the cartridge to the Subaru Select Monitor.
connector.
the idle speed.
15"#8"/650
system. Refer to “Engine Control System”. <Ref. to
EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
ME(H6DO)-24
MECHANICAL

A: INSPECTION
1) Idle the engine.
2) Disconnect the brake vacuum hose from the in-
take manifold, and then install the vacuum gauge.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
By observing the gauge needle movement, the in-
ternal condition of the engine can be diagnosed as
described below.
FU-02115

%60.0 kPa (%450 mmHg, %17.72 inHg) or less
1. Needle is steady but lower than normal position. This ten- Leakage around intake manifold gasket, disconnection or dam-
dency becomes more evident as engine temperature rises. aged vacuum hose
2. When engine speed is reduced slowly from higher speed, Exhaust pressure is too high, or exhaust system is clogged.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Valve anchoring
tion.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME(H6DO)-25
Engine Oil Pressure
MECHANICAL
6. Engine Oil Pressure

A: INSPECTION
1) Remove the oil pressure switch from cylinder
block. <Ref. to LU(H6DO)-12, REMOVAL, Oil
Pressure Switch.>
block.
4) Start the engine, and measure oil pressure.
OIL PRESSURE (at oil temperature of 80"C
(176"F)):
Standard:
135 kPa (1.4 kg/cm2, 20 psi) or more (at 600
rpm)
500 kPa (5.1 kg/cm2, 73 psi) or more (at
5,000 rpm)
CAUTION:
check oil pump, oil filter and lubrication line.
<Ref. to LU(H6DO)-16, INSPECTION, General
Diagnostic Table.>
• If the oil pressure warning light come on and
oil pressure is in specification, replace the oil
pressure switch. <Ref. to LU(H6DO)-16, IN-
SPECTION, General Diagnostic Table.>
5) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H6DO)-12, INSTAL-
LATION, Oil Pressure Switch.>
Tightening torque:
25 N&m (2.5 kgf-m, 18.1 ft-lb)
ME(H6DO)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
WARNING:
lease fuel pressure.
NOTE:
filler cap.
3) Disconnect the fuel delivery hose and connect
box.
FU-01122

fold.
Fuel pressure:
Standard: 333 — 363 kPa (3.4 — 3.7 kgf/cm2,
48 — 53 psi)
Fuel pressure:
Standard: 279 — 309 kPa (2.85 — 3.15 kgf/
cm2, 40 — 45 psi)
NOTE:
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
ME(H6DO)-27
Valve Clearance
MECHANICAL
8. Valve Clearance (2) Disconnect the PCV hose and blow-by hose
from rocker cover (LH).
A: INSPECTION
Inspection and adjustment of valve clearance
ME-00460
(3) Remove the fuel pipe protector (LH).
IN-00203

7) When inspecting RH side cylinders:
(1) Remove the air intake duct and air cleaner
FU-02117
case. <Ref. to IN(H6DO)-8, REMOVAL, Air In-
take Duct.> <Ref. to IN(H6DO)-5, REMOVAL, (4) Remove the fuel injectors. <Ref. to
Air Cleaner Case.> FU(H6DO)-26, REMOVAL, Fuel Injector.>
(2) Remove the fuel tank protector (RH). (5) Remove the ignition coil. <Ref. to
IG(H6DO)-7, REMOVAL, Ignition Coil & Ignitor
ASSY.>
(6) Remove the rocker cover (LH).
FU-02119
(3) Remove the fuel injectors. <Ref. to

FU(H6DO)-26, REMOVAL, Fuel Injector.>
(4) Disconnect the connector of oil pressure
switch.
(5) Remove the ignition coil. <Ref. to
IG(H6DO)-7, REMOVAL, Ignition Coil & Ignitor
ASSY.>
(6) Remove the rocker cover (RH).
8) When inspecting LH side cylinders:
(1) Disconnect the battery cable, and then re-
move the battery and battery carrier.
ME(H6DO)-28
Valve Clearance
MECHANICAL
9) Turn the crankshaft clockwise until the cam is • If the measured value is not within specification,
set to position shown in the figure. take notes of the value in order to adjust the valve
clearance later on.
(A)
(3) (4) (3) (4)
(10 ) (10 )
(23 ) (23 )
(1) (1)
ME-00464
11) If necessary, adjust the valve clearance. <Ref.

to ME(H6DO)-29, ADJUSTMENT, VALVE CLEAR-
ANCE.>
(2) (2) 12) Further turn the crank pulley clockwise and
then measure the valve clearances again.
13) After inspection, install the related parts in the
reverse order of removal.
B: ADJUSTMENT
ME-02025 1. INTAKE SIDE
(1) Valve clearance (Intake side) CAUTION:
(2) Valve clearance (Exhaust side) • Adjustment of valve clearance should be per-
(3) High lift cam formed while engine is cold.
(4) Low lift cam • Do not wear gloves during removal and in-
stallation of valve lifter.
10) Measure the clearance of intake valve and ex- • Do not use a valve lifter which got high im-
haust valve using thickness gauge (A). pact due to drop, etc.
NOTE: • When installing the valve lifter, align the anti-
• Measure it within the range of #30" that shown in rotation of valve lifter with groove on cylinder
the figure. head, and then insert the valve lifter.
• Measure it in low lift cam for intake side. 1) Measure all valve clearances.
• Insert the thickness gauge in as horizontal a di- <Ref. to ME(H6DO)-28, INSPECTION, Valve
rection as possible with respect to the valve lifter. Clearance.>
Valve clearance NOTE:
Intake: Record each valve clearance after it has been
0.20+0.04%0.06 mm (0.0079+0.0016%0.0024 in) measured.
Exhaust: 2) Remove the camshaft. <Ref. to ME(H6DO)-54,
0.35#0.05 mm (0.0138#0.0020 in) REMOVAL, Camshaft.>
4) Measure the thickness of shim with a microme-
ter.
5) Select a shim of suitable thickness using mea-
sured valve clearance and shim thickness, by refer-
ring to the following table.
Unit: (mm)
S = (V + T) % 0.20
S: Required shim thickness
V: Measured valve clearance
T: Shim thickness to be used
ME(H6DO)-29
Valve Clearance
MECHANICAL
Part No. Thickness mm (in) Part No. Thickness mm (in)

13218AK890 1.92 (0.0756) 13218AL400 2.50 (0.0984)
13218AK900 1.94 (0.0764) 13218AL410 2.51 (0.0988)
13218AK910 1.96 (0.0772) 13218AL420 2.52 (0.0992)
13218AK920 1.98 (0.0780) 13218AL430 2.53 (0.0996)
13218AK930 2.00 (0.0787) 13218AL440 2.54 (0.1000)
13218AK940 2.02 (0.0795) 13218AL450 2.55 (0.1004)
13218AK950 2.04 (0.0803) 13218AL460 2.56 (0.1008)
13218AK960 2.06 (0.0811) 13218AL470 2.57 (0.1012)
13218AK970 2.07 (0.0815) 13218AL480 2.58 (0.1016)
13218AK980 2.08 (0.0819) 13218AL490 2.59 (0.1020)
13218AK990 2.09 (0.0823) 13218AL500 2.60 (0.1024)
13218AL000 2.10 (0.0827) 13218AL510 2.61 (0.1028)
13218AL010 2.11 (0.0831) 13218AL520 2.62 (0.1032)
13218AL020 2.12 (0.0835) 13218AL530 2.64 (0.1039)
13218AL030 2.13 (0.0839) 13218AL540 2.66 (0.1047)
13218AL040 2.14 (0.0843) 13218AL550 2.68 (0.1055)
13218AL050 2.15 (0.0846) 13218AL560 2.70 (0.1063)
13218AL060 2.16 (0.0850) 13218AL570 2.72 (0.1071)
13218AL070 2.17 (0.0854) 13218AL580 2.74 (0.1079)
13218AL080 2.18 (0.0858) 13218AL590 2.76 (0.1087)
13218AL090 2.19 (0.0862)
2. EXHAUST SIDE
13218AL100 2.20 (0.0866)
13218AL110 2.21 (0.0870) CAUTION:
13218AL120 2.22 (0.0874) Adjustment of valve clearance should be per-
13218AL130 2.23 (0.0878) formed while engine is cold.
13218AL140 2.24 (0.0882) 1) Measure all valve clearances.
13218AL150 2.25 (0.0886) <Ref. to ME(H6DO)-28, INSPECTION, Valve
13218AL160 2.26 (0.0890) Clearance.>
13218AL170 2.27 (0.0894) NOTE:
13218AL180 2.28 (0.0898) Record each valve clearance after it has been
13218AL190 2.29 (0.0902) measured.
13218AL200 2.30 (0.0906) 2) Remove the camshaft. <Ref. to ME(H6DO)-54,
13218AL210 2.31 (0.0909) REMOVAL, Camshaft.>
13218AL220 2.32 (0.0913) 3) Remove the valve lifter.
13218AL230 2.33 (0.0917) 4) Measure the thickness of valve lifter with a mi-
13218AL240 2.34 (0.0921)
crometer.
13218AL250 2.35 (0.0925)
13218AL260 2.36 (0.0929)
13218AL270 2.37 (0.0933)
13218AL280 2.38 (0.0937)
13218AL290 2.39 (0.0941)
13218AL300 2.40 (0.0945)
13218AL310 2.41 (0.0949)
13218AL320 2.42 (0.0953)
13218AL330 2.43 (0.0957)
ME-00025
13218AL340 2.44 (0.0961)
13218AL350 2.45 (0.0965)
13218AL360 2.46 (0.0969)
13218AL370 2.47 (0.0972)
13218AL380 2.48 (0.0976)
13218AL390 2.49 (0.0980)
ME(H6DO)-30
Valve Clearance
MECHANICAL
5) Select a valve lifter of suitable thickness using Part No. Thickness mm (in)
measured valve clearance and valve lifter thick- 13228AC850 4.89 (0.1925)
ness, by referring to the following table. 13228AC860 4.90 (0.1929)
Unit: (mm) 13228AC870 4.91 (0.1933)
S = (V + T) % 0.35 13228AC880 4.92 (0.1937)
S: Valve lifter thickness required 13228AC890 4.93 (0.1941)
V: Measured valve clearance 13228AC900 4.94 (0.1945)
T: Valve lifter thickness to be used 13228AC910 4.95 (0.1949)
13228AC920 4.96 (0.1953)
Part No. Thickness mm (in) 13228AC930 4.97 (0.1957)
13228AD180 4.32 (0.1701) 13228AC940 4.98 (0.1961)
13228AD190 4.34 (0.1709) 13228AC950 4.99 (0.1965)
13228AD200 4.36 (0.1717) 13228AC960 5.00 (0.1969)
13228AD210 4.38 (0.1724) 13228AC970 5.01 (0.1972)
13228AD220 4.40 (0.1732) 13228AC980 5.02 (0.1976)
13228AD230 4.42 (0.1740) 13228AC990 5.03 (0.1980)
13228AD240 4.44 (0.1748) 13228AC000 5.04 (0.1984)
13228AD250 4.46 (0.1756) 13228AC010 5.05 (0.1988)
13228AD260 4.48 (0.1764) 13228AC020 5.06 (0.1992)
13228AD270 4.50 (0.1772) 13228AC030 5.07 (0.1996)
13228AD280 4.52 (0.1780) 13228AC040 5.08 (0.2000)
13228AD290 4.54 (0.1787) 13228AC050 5.09 (0.2004)
13228AD300 4.56 (0.1795) 13228AC060 5.10 (0.2008)
13228AD310 4.58 (0.1803) 13228AC070 5.11 (0.2012)
13228AD320 4.60 (0.1811) 13228AC080 5.12 (0.2016)
13228AC580 4.62 (0.1819) 13228AC090 5.13 (0.2020)
13228AC590 4.63 (0.1823) 13228AC100 5.14 (0.2024)
13228AC600 4.64 (0.1827) 13228AC110 5.15 (0.2028)
13228AC610 4.65 (0.1831) 13228AC120 5.16 (0.2032)
13228AC620 4.66 (0.1835) 13228AC130 5.17 (0.2035)
13228AC630 4.67 (0.1839) 13228AC140 5.18 (0.2039)
13228AC640 4.68 (0.1843) 13228AC150 5.19 (0.2043)
13228AC650 4.69 (0.1846) 13228AC160 5.20 (0.2047)
13228AC660 4.70 (0.1850) 13228AC170 5.21 (0.2051)
13228AC670 4.71 (0.1854) 13228AD330 5.23 (0.2059)
13228AC680 4.72 (0.1858) 13228AD340 5.25 (0.2067)
13228AC690 4.73 (0.1862) 13228AD350 5.27 (0.2075)
13228AC700 4.74 (0.1866) 13228AD360 5.29 (0.2083)
13228AC710 4.75 (0.1870) 13228AD370 5.31 (0.2091)
13228AC720 4.76 (0.1874) 13228AD380 5.33 (0.2098)
13228AC730 4.77 (0.1878) 13228AD390 5.35 (0.2106)
13228AC740 4.78 (0.1882) 13228AD400 5.37 (0.2114)
13228AC750 4.79 (0.1886) 13228AD410 5.39 (0.2122)
13228AC760 4.80 (0.1890) 13228AD420 5.41 (0.2130)
13228AC770 4.81 (0.1894) 13228AD430 5.43 (0.2138)
13228AC780 4.82 (0.1898) 13228AD440 5.45 (0.2146)
13228AC790 4.83 (0.1902) 13228AD450 5.47 (0.2154)
13228AC800 4.84 (0.1906) 13228AD460 5.49 (0.2161)
13228AC810 4.85 (0.1909) 13228AD470 5.51 (0.2169)
13228AC820 4.86 (0.1913) 13228AD480 5.53 (0.2177)
13228AC830 4.87 (0.1917) 13228AD490 5.55 (0.2185)
13228AC840 4.88 (0.1921) 13228AD500 5.57 (0.2193)
ME(H6DO)-31
Valve Clearance
MECHANICAL
Part No. Thickness mm (in)

13228AD510 5.59 (0.2201)
ME(H6DO)-32
V-belt
MECHANICAL
9. V-belt C: INSPECTION
1) Replace the V-belt, if cracks, fraying or wear is
A: REMOVAL found.
1) Install the tool to belt tension adjuster assembly 2) Check that the V-belt automatic belt tension indi-
installation bolt. cator (A) is within the range (D).
2) Rotate the tool clockwise and loosen the V-belt
to remove. (A)
(D)
(C)
(B)
ME-00473

B: INSTALLATION
(6)
(1)
(4) ME-00475
(A) Indicator
(2) (5) (B) Generator
(C) Power steering oil pump pulley
(3) ME-00474 (D) Service limit
(1) Power steering oil pump pulley

(2) Belt tension adjuster ASSY
(3) Crank pulley
(4) A/C compressor
(5) Belt idler
(6) Generator
ME(H6DO)-33
Engine Assembly
MECHANICAL
10.Engine Assembly (2) Engine harness connectors
A: REMOVAL
2) Open the front hood fully and support with the
front food stay.
AC-20, PROCEDURE, Refrigerant Recovery Pro-
cedure.>
<Ref. to FU(H6DO)-39, RELEASING OF FUEL ME-02026
PRESSURE, PROCEDURE, Fuel.> (3) Generator connector, terminal and A/C
6) Remove the fuel filler cap. compressor connector
7) Disconnect the ground cable from battery. (4) Power steering switch connector
IN-00203
8) Remove the air intake duct, air cleaner case and

air intake chamber. FU-02115
<Ref. to IN(H6DO)-8, REMOVAL, Air Intake Duct.> (2) Heater inlet and outlet hoses
<Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner (3) Pressure regulator vacuum hose
Case.> <Ref. to IN(H6DO)-7, REMOVAL, Air In- 14) Remove the power steering pump from brack-
take Chamber.> et.
CO(H6DO)-13, REMOVAL, Radiator.> NOTE:
10) Remove the V-belts. <Ref. to ME(H6DO)-33, Do not disconnect the hose and pipe from pump
REMOVAL, V-BELT.> body.
11) Disconnect the A/C pressure hoses from A/C
compressor. <Ref. to AC-38, REMOVAL, Hose and (B) (C)
Tube.> (A)
12) Disconnect the following connectors:
ME-00482
(A) Power steering pump

(B) Generator
(C) A/C compressor
ME-00476
ME(H6DO)-34
Engine Assembly
MECHANICAL
(1) Place the power steering pump on the right 20) Remove the nuts which install front cushion
side wheel apron. rubber onto front crossmember.
(A)
ME-00483 ME-00485

(A) Cloth
plate.
15) Lift-up the vehicle. (1) Lower the vehicle.
16) Remove the under cover. (2) Remove the service hole plug (A).
17) Remove the front exhaust pipe. (3) Remove the bolts which hold torque con-
<Ref. to EX(H6DO)-5, REMOVAL, Front Exhaust verter clutch to drive plate.
Pipe.> (4) Remove other bolts while rotating the en-
gine using a socket wrench.
NOTE:
Be careful not to let the front exhaust pipe interfere
with water pipes on engine side.
18) Remove the ground cable.
ME-02027
19) Remove the nuts which hold lower side of

(A)
ME-00486
ME-00484
ME-00487
ME(H6DO)-35
Engine Assembly
MECHANICAL
23) Disconnect the fuel delivery hose and evapora- 26) Separation of engine and transmission:
tion hose. (1) Remove the starter. <Ref. to SC(H6DO)-6,
CAUTION: REMOVAL, Starter.>
• Catch fuel from the hose into container. (2) Remove the bolts which hold upper side of
• Disconnect the hose with its end wrapped transmission to engine.
ME-00491
FU-02116 27) Set the ST to torque converter clutch case.

24) Support the engine with a lifting device and ST 498277200 STOPPER SET
wire ropes.
ST
ME-00492
ME-00489 28) Remove the engine from vehicle.

25) Support the transmission with a garage jack. (1) Slightly raise the engine.
CAUTION: (3) Move the engine horizontally until main
Doing this is very important because the trans- shaft is withdrawn from clutch cover.
mission lowers for its own weight. This work is (4) Slowly move the engine away from engine
also of great importance for facilitating reinstal- compartment.
lation.
NOTE:
(A)
(B)
ME-00490
(A) Transmission
(B) Garage jack ME-00489
29) Remove the front cushion rubbers.

CAUTION:
Before removing the engine away from trans-
mission, check to be sure no work has been
overlooked.
ME(H6DO)-36
Engine Assembly
MECHANICAL

1) Install the front cushion rubbers. T1: 50 N&m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N&m (5.9 kgf-m, 42.8 ft-lb)
Tightening torque:
35 N&m (3.6 kgf-m, 25.8 ft-lb)
2) Position the engine in engine compartment and
align it with transmission.
NOTE:
T2
T1
ME-00493
7) Remove the ST from torque converter clutch

case.
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing the ST.
ME-00489
8) Install the starter. <Ref. to SC(H6DO)-6, IN-
3) Tighten the bolts which hold upper side of trans- STALLATION, Starter.>
mission to engine. 9) Install the torque converter clutch to drive plate.
Tightening torque: (1) Tighten the bolts which hold torque convert-
50 N&m (5.1 kgf-m, 36.9 ft-lb) er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
using a socket wrench.
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing the ST.
Tightening torque:
25 N&m (2.5 kgf-m, 18.1 ft-lb)
ME-00491
ME-00489
5) Remove the garage jack.

ME-02107
ME(H6DO)-37
Engine Assembly
MECHANICAL
(3) Install the service hole plug to prevent for- NOTE:

eign matters from being mixed. • Be care not to let the front exhaust pipe interfere
10) Install the power steering pump on bracket. with water pipes and crossmember on engine side.
Tightening torque: • Be care not to scratch the flange surface of front
20.1 N&m (2.05 kgf-m, 14.8 ft-lb) exhaust pipe with stud bolt on engine.
15) Connect the ground cable.
ME-00450
ME-02027
12) Tighten the nuts which hold lower side of trans- 16) Install the under cover.
mission to the engine. 17) Lower the vehicle.
18) Connect the following hoses.
Tightening torque: (1) Fuel delivery hose and evaporation hose
50 N&m (5.1 kgf-m, 36.9 ft-lb) (2) Heater inlet and outlet hoses
(4) Pressure regulator vacuum hose
19) Connect the following connectors:
Tightening torque:
14 N&m (1.4 kgf-m, 10.1 ft-lb)
ME-00484
13) Tighten the nuts which install the front cushion

rubber onto crossmember.
Tightening torque:
85 N&m (8.7 kgf-m, 63 ft-lb)
NOTE:
ME-00476
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed. (2) Engine harness connectors
(B) (A) (A) (B)

ME-00494 ME-02026
14) Install the front exhaust pipe. (3) Generator connector and terminal
<Ref. to EX(H6DO)-6, INSTALLATION, Front Ex- (4) A/C compressor connector
haust Pipe.> (5) Power steering switch connector
ME(H6DO)-38
Engine Assembly
MECHANICAL

<Ref. to AC-38, INSTALLATION, Hose and Tube.>
21) Install the V-belts. <Ref. to ME(H6DO)-33, IN-
STALLATION, V-BELT.>
22) Install the radiator to vehicle. <Ref. to
CO(H6DO)-14, INSTALLATION, Radiator.>
23) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H6DO)-8, INSTAL-
LATION, Air Intake Duct.> <Ref. to IN(H6DO)-6,
INSTALLATION, Air Cleaner Case.> <Ref. to
IN(H6DO)-7, INSTALLATION, Air Intake Cham-
ber.>
24) Install the battery in the vehicle, and connect
cables.
<Ref. to CO(H6DO)-9, FILLING OF ENGINE
26) Check the ATF level and replenish it if neces-
sary.
mission Fluid.>
27) Charge the A/C system with refrigerant. <Ref.
to AC-21, PROCEDURE, Refrigerant Charging
Procedure.>
hood.
30) Take off the vehicle from a lift.
C: INSPECTION
1) Check pipes and hoses are installed firmly.
2) Check the engine coolant and ATF are at speci-
fied levels.
ME(H6DO)-39
Engine Mounting
MECHANICAL
11.Engine Mounting
A: REMOVAL
ME(H6DO)-34, REMOVAL, Engine Assembly.>
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting:
35 N&m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that there are no cracks or other damag-
es.
ME(H6DO)-40
MECHANICAL

A: REMOVAL
ME(H6DO)-34, REMOVAL, ENGINE ASSEM-
BLY.>
2) Set the engine on ST1.
ST 18232AA000 ENGINE STAND
ST
ME-00495
3) Before servicing overhaul, remove the sensor,

pipe and hose that installed to engine.
(1) Remove the intake manifold.
<Ref. to FU(H6DO)-12, REMOVAL, Intake Man-
ifold.>
(2) Remove the generator. <Ref. to SC(H6DO)-
(3) Remove the A/C compressor. <Ref. to AC-
33, REMOVAL, Compressor.>
(4) Remove the EGR pipe. <Ref. to FU(H6DO)-
25, REMOVAL, EGR Valve.>
(5) Disconnect the water pipe and hose.
(6) Disconnect the engine harness.
(7) Remove the spark plug. <Ref. to IG(H6DO)-
4, REMOVAL, Spark Plug.>
(8) Remove the camshaft position sensor.
<Ref. to FU(H6DO)-20, REMOVAL, Camshaft
Position Sensor.>
(9) Remove the crankshaft position sensor.
<Ref. to FU(H6DO)-19, REMOVAL, Crankshaft
Position Sensor.>
(10)Remove the knock sensor. <Ref. to
FU(H6DO)-21, REMOVAL, Knock Sensor.>
(11)Remove the engine coolant temperature
sensor. <Ref. to FU(H6DO)-18, REMOVAL, En-
gine Coolant Temperature Sensor.>
(12)Remove the oil pressure switch. <Ref. to
LU(H6DO)-12, REMOVAL, Oil Pressure
Switch.>
(13)Remove the oil filter. <Ref. to LU(H6DO)-13,
REMOVAL, Engine Oil Filter.>
(14)Remove the oil cooler. <Ref. to LU(H6DO)-
14, REMOVAL, Oil Cooler.>
ME(H6DO)-41
Crank Pulley
MECHANICAL
13.Crank Pulley 3) Install the crank pulley cover.

NOTE:
A: REMOVAL Attach the O-ring to crank pulley cover.
1) Remove the crank pulley cover.
Tightening torque:
6.4 N&m (0.65 kgf-m, 4.7 ft-lb)
ME-02028
2) Remove the crank pulley bolt. To lock the crank-

shaft, use ST. ME-02028
ST 499977100 CRANK PULLEY WRENCH C: INSPECTION

1) Check the crank pulley cover for oil and air leak-
age.
2) Check crank pulley for looseness.
ME-00497

B: INSTALLATION
2) Install the crank pulley bolt. To lock the crank-
shaft, use ST.
(1) Clean the crank pulley thread using com-
pressed air.
and thread.
Tightening torque:
178 N&m (18.1 kgf-m, 131 ft-lb)
ME-00497
ME(H6DO)-42
Front Chain Cover
MECHANICAL
14.Front Chain Cover 3) Install the front chain cover. Temporarily tighten
the bolts.
A: REMOVAL CAUTION:
1) Remove the crank pulley. <Ref. to ME(H6DO)- Do not install the bolts in wrong place.
42, REMOVAL, CRANK PULLEY.>
2) Remove the front chain cover.
(A)
NOTE:
Chain cover installation bolt has three different siz- (C) (B)
es. To prevent the confusion in installation, keep
these bolts on container individually.
(A) (C) (A)

(B)
(C) (B)
ME-02029
(A) M6 ! 16
(C) (A) (B) M6 ! 30
(B)
(C) M6 ! 45
*: Sealing washer
ME-02029
4) Tighten the bolts in the numerical order as
(A) M6 ! 16 shown in the figure.
(B) M6 ! 30
(C) M6 ! 45
*: Sealing washer
B: INSTALLATION
1) Remove the used liquid gasket from mating sur-
face, and degrease it.
2) Apply liquid gasket to the matching surface of
front chain cover.
Liquid gasket
THREE BOND 1280B (Part No. K0877YA018)
Applying liquid gasket diameter
2.5#0.5 mm (0.098#0.020 in)
ME-02030
ME(H6DO)-43
Front Chain Cover
MECHANICAL
Tightening torque:
6.6 N&m (0.67 kgf-m, 4.8 ft-lb)
(25) (34)
(24) (33)
(23) (35)
(11) (32)
(12)
(9) (13)
(10)
(8)
(26) (36)
(6) (3) (1)
(27) (37)
(7)
(4)
(5)
(28) (2)
(38)
(19)
(29) (30) (31) (22) (39)
(40)
(18)
(21)
(17) (20)
(16) (15) (14)
ME-02031
5) Install the crank pulley. <Ref. to ME(H6DO)-42,
INSTALLATION, CRANK PULLEY.>
C: INSPECTION
Check the cover surface for scratch and damage.
Check for oil leakage on cover mating surface and
installation part of crank pulley.
ME(H6DO)-44
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

MECHANICAL
ME(H6DO)
Page
2. Compression .............................................................................................22
3. Idle Speed .................................................................................................23
4. Ignition Timing...........................................................................................24
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. V-belt.........................................................................................................33
10. Engine Assembly ......................................................................................34
11. Engine Mounting .......................................................................................40
13. Crank Pulley..............................................................................................42
14. Front Chain Cover.....................................................................................43
15. Timing Chain Assembly ............................................................................45
16. Cam Sprocket ...........................................................................................50
17. Crank Sprocket .........................................................................................51
18. Rear Chain Cover .....................................................................................52
19. Camshaft...................................................................................................54
20. Cylinder Head ...........................................................................................58
21. Cylinder Block ...........................................................................................63
23. Oil Switching Solenoid Valve ....................................................................79
24. ATF Warmer Cock ....................................................................................80
26. Engine Noise.............................................................................................88
Timing Chain Assembly
MECHANICAL
15.Timing Chain Assembly 8) Remove the chain tensioner (LH).

NOTE:
A: REMOVAL Be careful not to come out the plunger.
1) Remove the crank pulley. <Ref. to ME(H6DO)-
2) Remove the front chain cover. <Ref. to
ME(H6DO)-43, REMOVAL, FRONT CHAIN COV-
ER.>
3) Remove the chain tensioner (RH).
NOTE:
Be careful not to come out the plunger (A).
ME-02034
(A)
9) Remove the chain tensioner lever (LH).
ME-00501
4) Remove the chain guide (RH: between cams).
ME-02035
10) Remove the chain guide (LH: between cams).
ME-02032
5) Remove the chain guide (RH).

6) Remove the chain tensioner lever (RH).
ME-02036
(A)
11) Remove the chain guide (LH).
(B)
ME-02033
(A) Chain guide (RH)

(B) Chain tensioner lever (RH) ME-02037
7) Remove the timing chain (RH).
ME(H6DO)-45
MECHANICAL
12) Remove the chain guide (CTR). NOTE:

Work on the rubber mat or other anti-skid materials.
ME-02038
13) Remove the idler sprocket (upper). ME-00511
2) Using ST, align the “Top mark” on crank sprock-

et to 9 o’clock position as shown in the figure
ST 18252AA000 CRANKSHAFT SOCKET
ME-02039
14) Remove the timing chain (LH).

15) Remove the idler sprocket (lower).
ME-02040
3) Using ST, align the key groove on exhaust cam

sprocket to 12 o’clock position as shown in the fig-
ure
ME-00510
B: INSTALLATION
NOTE:
• Be careful that the foreign matter is not into or ME-02041
onto assembled component during installation.
• Apply engine oil to the chain guide, chain ten-
sioner lever and idler sprocket when installing.
1) Preparation for chain tensioner installation
(1) Insert the screw, spring pin and tension rod
into tensioner body.
(2) While depressing the tensioner onto rubber
mat, twist it to shorten tension rod. Then insert
the thin pin into the hole between tension rod
and tension body to keep shortened.
ME(H6DO)-46
MECHANICAL
4) Align the intake cam sprocket as shown in the (2) Set the routing of timing chain (LH) on idler
figure. sprocket (lower), water pump, exhaust cam
sprocket (LH) and intake cam sprocket (LH).
RH LH
NOTE:
(A) Check that the mark on timing chain (A) and cam
sprocket (B) is aligned as same as aligned on crank
(B) sprocket.
(C)
(A)
ME-02042
(B)
(A) Top mark

(B) 40"
(C) 15"
5) Turn the crank sprocket clockwise, align the

“Top mark” to 12 o’clock position (Piston #1 is in
TDC position)
NOTE:
Do not rotate the crank shaft and cam sprocket until
the timing chain routing was completed.
(B)
6) Install the idler sprocket (lower).
Tightening torque:
69 N!m (7.0 kgf-m, 50.6 ft-lb)
(A)
ME-02043
(A) Dark blue

(B) Mark
(3) Install the chain idler (upper).

Tightening torque:
69 N!m (7.0 kgf-m, 50.6 ft-lb)
ME-00510
7) Install the timing chain (LH).

(1) Align the timing mark (B) on the crank
sprocket with mark (A) on the timing chain (LH).
(A)
ME-02039
(4) Install the chain guide (LH: between cams).
(B)
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
ME-00515
(A) Gold
(B) Mark
ME(H6DO)-47
MECHANICAL
NOTE: (7) Install the chain tensioner (LH).

Use a new installing bolt. Tightening torque:
16 N!m (1.6 kgf-m, 11.6 ft-lb)
ME-02036
(5) Install the chain guide (LH). ME-02034
Tightening torque: 8) Install the timing chain (RH).

16 N!m (1.6 kgf-m, 11.6 ft-lb) (1) Align the marks of timing chain LH and RH
on the idler sprocket (lower).
(B)
(A)
(C)
(D)
ME-02037
ME-00518
(6) Install the chain tensioner lever (LH).
Tightening torque: (A) Idler sprocket (lower)
16 N!m (1.6 kgf-m, 11.6 ft-lb) (B) Timing chain (RH)
(C) Timing chain (LH)
(D) Dark blue
(2) Set the routing of timing chain (RH) on in-

take cam sprocket, and then set the routing on
exhaust cam sprocket.
ME-02035
ME(H6DO)-48
MECHANICAL
NOTE: NOTE:
Check that the mark on timing chain (A) and cam Use a new installing bolt.
sprocket (B) is aligned as same as aligned on crank
sprocket.
(A)
(B)
ME-02032
(6) Install the chain tensioner (RH).

Tightening torque:
16 N!m (1.6 kgf-m, 11.6 ft-lb)
(B)
(A)
ME-02044
ME-00520
(A) Gold
(B) Mark (7) Adjust the clearance between chain guide
(RH) and chain guide (CTR) within 8.4 — 8.6
(3) Install the chain guide (RH). mm (0.331 — 0.339 in). Install the chain guide
(4) Install the chain tensioner lever (RH). (CTR).
NOTE:
(A) Use a new installing bolt.
(B)
ME-02033
(A) Chain guide (RH)

ME-00521
(B) Chain tensioner lever (RH)
(8) Check that each mark on the sprocket and
(5) Install the chain guide (RH: between cams). timing chain is matched, and then draw out the
Tightening torque: stopper pin from chain tensioner.
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
ME(H6DO)-49
Cam Sprocket
MECHANICAL
16.Cam Sprocket ST 499977500 CAM SPROCKET WRENCH
A: REMOVAL
ER.>
3) Remove the timing chain assembly.
<Ref. to ME(H6DO)-45, REMOVAL, TIMING
CHAIN ASSEMBLY.>
4) Remove the cam sprocket. To lock the crank- ME-02045
shaft, use the ST. ST 18231AA020 CAM SPROCKET WRENCH
ME-02046
ME-02045
3) Install the timing chain assembly.
ST 18231AA020 CAM SPROCKET WRENCH <Ref. to ME(H6DO)-46, INSTALLATION, TIMING
CHAIN ASSEMBLY.>
4) Install the front chain cover.
<Ref. to ME(H6DO)-43, INSTALLATION, FRONT
CHAIN COVER.>
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear
and scratches.
ME-02046 2) Make sure there is no free play between cam
sprocket and key.
B: INSTALLATION
1) Install the cam sprocket. To lock the crankshaft,
use the ST.
Tightening torque:
29.5 N!m (3.0 kgf-m, 21.8 ft-lb)
2) Further tighten the bolt.
Tightening angle:
Intake
45"#5"
Exhaust
25"#5"
ME(H6DO)-50
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
ER.>
CHAIN ASSEMBLY.>
4) Remove the cam sprocket. <Ref. to ME(H6DO)-
50, REMOVAL, CAM SPROCKET.>
5) Remove the crank sprocket (A).
(A)
ME-02047
B: INSTALLATION
1) Install the crank sprocket (A).
(A)
ME-02047
2) Install the cam sprocket. <Ref. to ME(H6DO)-50,

INSTALLATION, CAM SPROCKET.>
<Ref. to ME(H6DO)-46, INSTALLATION, TIMING
CHAIN ASSEMBLY.>
CHAIN COVER.>
C: INSPECTION
wear and scratches.
2) Make sure there is no free play between crank
sprocket and key.
ME(H6DO)-51
Rear Chain Cover
MECHANICAL
18.Rear Chain Cover Applying liquid gasket diameter

(A) 1.0#0.5 mm (0.039#0.020 in)
A: REMOVAL (B) 3.0#1.0 mm (0.118#0.039 in)
42, REMOVAL, CRANK PULLEY.> (A)
ER.>
3) Remove the timing chain. <Ref. to ME(H6DO)-
45, REMOVAL, TIMING CHAIN ASSEMBLY.>
4) Remove the cam sprocket. <Ref. to ME(H6DO)-
50, REMOVAL, CAM SPROCKET.>
6) Remove the oil pump. <Ref. to LU(H6DO)-8, (B) ME-02049
REMOVAL, Oil Pump.> 3) Install the O-ring.
7) Remove the water pump. <Ref. to CO(H6DO)-
11, REMOVAL, Water Pump.> NOTE:
8) Remove the rear chain cover. • Do not reuse the O-ring.
• Do not install the O-ring in wrong place.
NOTE:
Installation bolt has seven different sizes. To pre- (A) (A)
vent the confusion in installation, keep these bolts
on container individually.
(A) (B) (C) (D) (D)

(C)
(E)
(B)
ME-02050
(G) (F) (A) 14.2 $ 1.9

(B) 19.2 $ 2.4
ME-02048 (C) 25 $ 2
(D) 31.2 $ 1.9
(A) M6 $ 14
(B) M6 $ 18 (Silver) 4) Temporarily tighten the rear chain cover.
(C) M6 $ 30
(D) M6 $ 18
(E) M8 $ 40
(F) M8 $ 30
(G) M6 $ 22
B: INSTALLATION
1) Remove the used liquid gasket from mating sur-
face, and degrease it.
rear chain cover.
Liquid gasket
THREE BOND 1280B (Part No. K0877A018)
ME(H6DO)-52
Rear Chain Cover
MECHANICAL
NOTE: 12) Install the crank pulley. <Ref. to ME(H6DO)-42,

Do not install the bolts in wrong place. INSTALLATION, CRANK PULLEY.>
(A) (B) (C) (D)

(E)
(G) (F)
ME-02048
(A) M6 $ 14
(B) M6 $ 18 (Silver)
(C) M6 $ 30
(D) M6 $ 18
(E) M8 $ 40
(F) M8 $ 30
(G) M6 $ 22
5) Tighten the bolts in the numerical order as

Tightening torque:
(1) — (11) 9 N!m (0.9 kgf-m, 6.5 ft-lb)
(12) — (19) 20 N!m (2.0 kgf-m, 14 ft-lb)
(20) — (30) 9 N!m (0.9 kgf-m, 6.5 ft-lb)
(31) — (38) 12 N!m (1.2 kgf-m, 8.7 ft-lb)
(39) — (45) 9 N!m (0.9 kgf-m, 6.5 ft-lb)
(29)
(45) (31)(32) (2) (3) (20)
(44) (1) (4) (30) (21)
(33) (19)
(43)
(18) (22)
(42) (23)
(34)
(41) (24)
(35) (12)
(40) (6) (25)
(39) (26)
(5) (7)
(13) (27)
(38)
(11) (8) (14) (28)
(37)
(36) (10) (9) (17) (16) (15)
ME-02051
6) Install the water pump. <Ref. to CO(H6DO)-11,

INSTALLATION, Water Pump.>
7) Install the oil pump. <Ref. to LU(H6DO)-8, IN-
STALLATION, Oil Pump.>
9) Install the cam sprocket. <Ref. to ME(H6DO)-50,
INSTALLATION, CAM SPROCKET.>
10) Install the timing chain. <Ref. to ME(H6DO)-46,
INSTALLATION, TIMING CHAIN ASSEMBLY.>
CHAIN COVER.>
ME(H6DO)-53
Camshaft
MECHANICAL
19.Camshaft 10) Loosen the camshaft cap bolts equally, a little

at a time in alphabetical sequence shown in the fig-
A: REMOVAL ure.
42, REMOVAL, Crank Pulley.>
ME(H6DO)-43, REMOVAL, FRONT CHAIN COV- (2) (7) (9) (5)
ER.>
3) Remove the timing chain assembly. (4)
(8) (10) (6)
CHAIN ASSEMBLY.> (3)
(14) (16) (12)
<Ref. to ME(H6DO)-50, REMOVAL, Cam Sprock- (1)
(13) (15) (11) ME-02054
et.>
5) Remove the crank sprocket. 11) Remove the camshaft caps and camshaft (LH).
<Ref. to ME(H6DO)-51, REMOVAL, Crank Sprock- NOTE:
et.> Arrange camshaft caps in order so that they can be
6) Remove the rear chain cover. installed in their original positions.
<Ref. to ME(H6DO)-52, REMOVAL, Rear Chain
12) Similarly, remove the camshafts (RH) and re-
Cover.>
lated parts.
7) Disconnect the oil valve.
B: INSTALLATION
1) Apply engine oil to camshaft journals, and install
the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket sparingly to back side of
front camshaft cap as shown in the figure.
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess gasket to come out
ME-02052
and flow toward cam journal, resulting in en-
gine burnt.
8) Remove the rocker cover (LH).
Liquid gasket
Applying liquid gasket diameter:
2.0#0.5 mm (0.079#0.020 in)
ME-00529
9) Remove the plugs (LH).
ME-02057
(2) Apply engine oil to cap bearing surface, and

install the cap to camshaft.
(3) Tighten the rocker cover bolts in the numer-
ical order as shown in the figure.
ME-02055
ME(H6DO)-54
Camshaft
MECHANICAL
Tightening torque: • RH side

(1) — (12): 16 N!m (1.6 kgf-m, 11.6 ft-lb)
(13) — (16): 9.75 N!m (1.0 kgf-m, 7.2 ft-lb)
(15) (10) (8) (12)
(13)
(9) (7) (11)
(3) (1) (5)

(14) ME-02060
(16)
(2) Tighten the rocker cover bolts in the numer-
(4) (2) (6) ME-02058 ical order as shown in the figure.
3) Install the plugs. Tightening torque:
Tightening torque: 6.4 N!m (0.64 kgf-m, 4.6 ft-lb)
6.0 N!m (6.1 kgf-m, 44.3 ft-lb) • LH side
(10) (1) (3) (7)
(6) (5)
(9)
(8) (4) (2) ME-02061
ME-02055
4) Install the rocker cover. • RH side

(1) Apply liquid gasket sparingly to the mating (8) (1) (3)
surface of cylinder head and rocker cover as
(5)
CAUTION:
Do not apply fluid packing excessively. Failure (6)
to do so may cause excess gasket to come out
and flow toward cam journal, resulting in en- (7)
gine burnt.
Liquid gasket (10)
(9)
(4) (2)
THREE BOND 1280B (Part No. K0877YA018) ME-02062
• LH side 5) Connect the oil pipe.
ME-02059 ME-02052
6) Install the rear chain cover. <Ref. to ME(H6DO)-

52, INSTALLATION, Rear Chain Cover.>
ME(H6DO)-55
Camshaft
MECHANICAL
7) Install the crank sprocket. (6) Measure the widest point of the plastigauge
<Ref. to ME(H6DO)-51, INSTALLATION, Crank on each journal. If oil clearance exceeds the lim-
Sprocket.> it, replace the camshaft. If necessary, replace
8) Install the cam sprocket. the camshaft caps and cylinder head as a set.
<Ref. to ME(H6DO)-50, INSTALLATION, Cam Standard:
Sprocket.> 0.037 — 0.072 mm (0.0015 — 0.0028 in)
CHAIN ASSEMBLY.>
CHAIN COVER.>
<Ref. to ME(H6DO)-42, INSTALLATION, Crank
Pulley.>
C: INSPECTION
ME-00119
1) Check the camshaft for bend, and repair or re-
place if necessary. (7) Completely remove the plastigauge.
5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H. If it exceeds the limit, replace it.
Cam height: H:
Standard:
Intake
HIGH: 42.09 — 42.19 mm (1.6571 — 1.6610
in)
LOW1: 38.14 — 38.24 mm (1.5016 — 1.5055
ME-00539 in)
2) Check the journal for damage and wear. Re- LOW2: 34.94 — 35.04 mm (1.3756 — 1.3795
place if faulty. in)
3) Measure the outside diameter of camshaft jour- Exhaust
nal. If the journal diameter is not within specifica- 41.65 — 41.75 mm (1.6398 — 1.6437 in)
tions, check the oil clearance. Cam base circle diameter A:
Camshaft journal Intake
Front Except for front HIGH: 32.0 mm (1.2598 in)
Standard LOW1: 31.84 mm (1.2535 in)
37.946 — 37.963 25.946 — 25.963 LOW2: 31.84 mm (1.2535 in)
value
(1.4939 — 1.4946) (1.0215 — 1.0222)
mm (in) Exhaust
32.0 mm (1.2598 in)
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on the cylinder head.
(Without installing the valve rocker.) H
(3) Place a plastigauge across each of the cam-

shaft journals.
(4) Install the bearing cap.
NOTE:
A
Do not turn the camshaft. ME-00120
(5) Remove the bearing caps.
ME(H6DO)-56
Camshaft
MECHANICAL
6) Measure the side clearance of camshaft with dial

gauge. If the side clearance exceeds the limit or off-
set wearing is emitted, replace the caps and cylin-
der head as a set. If necessary, replace the
camshaft.
Standard:
Intake
0.075 — 0.135 mm (0.0030 — 0.0053 in)
Exhaust
0.030 — 0.090 mm (0.0012 — 0.0035 in)
ME(H6DO)-57
Cylinder Head
MECHANICAL
20.Cylinder Head 12) Similarly, remove the cylinder head (RH).
A: REMOVAL B: INSTALLATION
1) Remove the crank pulley. <Ref. to ME(H6DO)- 1) Install the cylinder head and gaskets on cylinder
42, REMOVAL, Crank Pulley.> block.
2) Remove the front chain cover. <Ref. to CAUTION:
ME(H6DO)-43, REMOVAL, FRONT CHAIN COV- • Use new cylinder head gaskets.
ER.> • Be careful not to scratch the mating surface
3) Remove the timing chain assembly. of cylinder head and cylinder block.
<Ref. to ME(H6DO)-45, REMOVAL, TIMING 2) Tighten the cylinder head bolts.
CHAIN ASSEMBLY.> (1) Apply a coat of engine oil to washers and
4) Remove the cam sprocket. cylinder head bolt threads.
<Ref. to ME(H6DO)-50, REMOVAL, Cam Sprock- (2) Install the cylinder head to cylinder block,
et.> and then tighten the bolts with torque of 20 N!m
5) Remove the crank sprocket. (2.0 kgf-m, 14 ft-lb) in numerical sequence as
<Ref. to ME(H6DO)-51, REMOVAL, Crank Sprock- shown in the figure.
et.> (3) Tighten the bolts with torque of 50 N!m (3.0
6) Remove the rear chain cover. kgf-m, 37 ft-lb) in numerical sequence as shown
<Ref. to ME(H6DO)-52, REMOVAL, Rear Chain in the figure.
Cover.> (4) Back off all bolts by 180" in reverse order of
7) Remove the camshaft. <Ref. to ME(H6DO)-54, installation, and back them off again by 180".
REMOVAL, Camshaft.> (5) Tighten the bolts with torque of 20 N!m (2.0
8) Tighten the cylinder head bolts in the numerical kgf-m, 14 ft-lb) in numerical sequence as shown
order as shown in the figure. in the figure.
Leave bolts (2) and (4) engaged by three or four (6) Tighten the bolts (1) and (4) with torque of
threads to prevent the cylinder head from falling. 48 N!m (3.5 kgf-m, 35.4 ft-lb) in numerical se-
quence.
(8) (6)
(7) Tighten the bolts (5) and (8) with torque of
(2) (4) 44 N!m (4.5 kgf-m, 32.5 ft-lb) in numerical se-
quence.
(8) Tighten the bolts 90" in the numerical order
(9) Tighten the bolt (1) — (4) 45" in the numeri-
cal order.
(3) (1)
(1) (3)
(5) (7) ME-02063
(7) (5)
10) Remove the bolts (2) and (4) to remove the cyl-
inder head.
(8) (6) (6) (8)
(2) (4)
(4) (2) ME-02064
3) Install the camshaft. <Ref. to ME(H6DO)-54, IN-

STALLATION, CAMSHAFT.>
4) Install the rear chain cover. <Ref. to ME(H6DO)-
52, INSTALLATION, Rear Chain Cover.>
(3) (1)
(5) (7) ME-02063
Sprocket.>
11) Remove the cylinder head gasket. 6) Install the cam sprocket.
CAUTION: <Ref. to ME(H6DO)-50, INSTALLATION, Cam
Be careful not to scratch the mating surface of Sprocket.>
cylinder head and cylinder block.
ME(H6DO)-58
Cylinder Head
MECHANICAL
7) Install the timing chain assembly. • Install the valve spring with the painted side fac-
<Ref. to ME(H6DO)-46, INSTALLATION, TIMING ing to retainer.
CHAIN ASSEMBLY.>
8) Install the front chain cover. (1) (4)
CHAIN COVER.>
Pulley.>
C: DISASSEMBLY
(2) (3)
1) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE ME-00546
3) Set the ST on valve spring retainer. Compress (1) Seat
the valve spring and remove the valve spring re- (2) Valve spring
tainer key. Remove each valve and valve spring. (3) Retainer
ST 499718000 VALVE SPRING REMOVER (4) Painted face
NOTE:
Keep all the removed parts in order for re-installing (4) Set the ST on valve spring.
in their original positions. ST 499718000 VALVE SPRING REMOVER
CAUTION:
ST
seals.
ST
ME-00545
(5) Compress the valve spring and fit the valve

spring retainer key.
(6) After installing, tap the valve spring retainers
lightly with a wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter and
ME-00545
valve shim.
D: ASSEMBLY 3) Install the valve lifter and valve shim.
1) Installation of valve spring and valve: E: INSPECTION
(1) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE 1. VALVE SPRING
(2) Coat the stem of each valve with engine oil 1) Check the valve springs for damage, free length,
and insert the valve into valve guide. and tension. Replace the valve spring if it is not
NOTE: within the standard value presented in the table.
When inserting the valve into valve guide, use spe-
Inner 39.55 (1.5571)
cial care not to damage the oil seal lip. Intake
Free length mm (in) Outer 41.18 (1.6213)
(3) Install the valve spring and retainer.
Exhaust 46.32 (1.8236)
NOTE: 2.5", 1.7 mm
• Be sure to install the valve springs with their Inner
(0.067 in)
close-coiled end facing the seat on the cylinder Intake
2.5", 1.8 mm
head. Squareness Outer
(0.071 in)
2.5", 2.0 mm
Exhaust
(0.079 in)
ME(H6DO)-59
Cylinder Head
MECHANICAL
2) To measure the squareness of the valve spring, Outer diameter:

stand the spring on a surface plate and measure its 32.959 — 32.975 mm (1.2976 — 1.2982 in)
deflection at the top of spring using a try square.
ME-00134
ME-00132
3) Measure the inner diameter of valve lifter hole of
2. INTAKE AND EXHAUST VALVE OIL cylinder head.
SEAL Inner diameter:
Replace the oil seal with a new one, if the lip is 32.994 — 33.016 mm (1.2990 — 1.2998 in)
damaged or spring is out of place, or when the sur-
faces of intake valve and valve seat are recondi-
tioned or intake valve guide is replaced.
1) Set the cylinder head on ST1.
2) Press-fit the oil seal to the specified dimension
indicated in the figure using ST2.
ST1 18250AA010 CYLINDER HEAD TABLE
NOTE:
• Apply engine oil to oil seal before force-fitting.
ME-00550
• When press-fitting the oil seal, do not use a ham-
mer or strike in. NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter hole is out of the
standard or offset wearing is emitted, replace the
cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
F: ADJUSTMENT
1. CYLINDER HEAD
ME-00548 1) Make sure that no crack or other damages do
not exist. In addition to visual inspection, inspect
3. VALVE LIFTER important areas by means of red lead check. Check
1) Check the valve lifter visually. that there are no marks of gas leaking or water
2) Measure the outer diameter of valve lifter. leaking on gasket installing surface.
2) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE
3) Measure the flatness of the cylinder head sur-
face that mates with crankcase using a straight
edge (A) and thickness gauge (B).
Flatness:
Standard
0.02 mm (0.0008 in)
Standard height of cylinder head:
124#0.05 mm (4.88#0.0020 in)
ME(H6DO)-60
Cylinder Head
MECHANICAL
NOTE: 2) If the clearance between valve guide and stem is

Uneven torque for the cylinder head nuts can out of standard, replace the valve guide or valve it-
cause warping. When reinstalling, pay special at- self whichever shows greater amount of wear or
tention to the torque so as to tighten evenly. damaged and etc. See the following procedure for
valve guide replacement.
Valve guide inner diameter:
5.500 — 5.512 mm (0.2165 — 0.2170 in)
(A) Valve stem outer diameters:
Intake
5.445 — 5.470 mm (0.2144 — 0.2154 in)
Exhaust
(B)
5.455 — 5.460 mm (0.2148 — 0.2150 in)
(1) Place the cylinder head on ST1 with the
ME-00551 combustion chamber upward so that valve
guides enter the holes in ST1.
2. VALVE SEAT
(2) Insert ST2 into the valve guide and press it
Inspect the intake and exhaust valve seats, and down to remove the valve guide.
correct the contact surfaces with a valve seat cutter ST1 18250AA010 CYLINDER HEAD TABLE
if they are defective or when valve guides are re- ST2 499765700 VALVE GUIDE REMOVER
placed.
Valve seat width W:
Intake
Standard
1.0 mm (0.039 in)
Exhaust
Standard
1.5 mm (0.059 in)
ME-00553
(3) Turn the cylinder head upside down and

place the ST as shown in the figure.
ST 18251AA040 VALVE GUIDE ADJUSTER
ST
ME-00127 L
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
respectively the outer diameter of valve stem and ME-00757
inner diameter of valve guide with a micrometer. (4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
Clearance between the valve guide and valve
on the inside surface of the valve guide holes in
stem:
cylinder head.
Standard (5) Put a new valve guide, coated with sufficient
Intake oil, in cylinder, and insert the ST1 into valve
0.030 — 0.057 mm (0.0012 — 0.0022 in) guide. Press in until the valve guide upper end is
Exhaust flush with the upper surface of ST2.
0.040 — 0.067 mm (0.0016 — 0.0026 in) ST1 499765700 VALVE GUIDE REMOVER
ME(H6DO)-61
Cylinder Head
MECHANICAL
ST2 18251AA040 VALVE GUIDE ADJUSTER Valve overall length:

Intake (A)
99.7 mm (3.925 in)
ST1 Exhaust (B)
105.2 mm (4.142 in)
ST2
(A)
ME-00130
H
(6) Check the valve guide protrusion.
+1
Valve guide protrusion L: 90 0
11.4 — 11.8 mm (0.449 — 0.465 in)
(7) Ream the inside of valve guide using ST.
Put the reamer in valve guide, and rotate the
reamer slowly clockwise while pushing it lightly.
Bring the reamer back while rotating it clock- (B)
wise. After reaming, clean the valve guide to re-
move chips.
H
NOTE:
• Apply engine oil to the reamer when reaming. +1
• If the inner surface of the valve guide is torn, the 90 0
edge of the reamer should be slightly ground with ME-02096

an oil stone.
• If the inner surface of the valve guide becomes 2) Put a small amount of grinding compound on the
lustrous and the reamer does not chip, use a new seat surface and lap the valve and seat surface. In-
reamer or remedy the reamer. stall a new intake valve oil seal after lapping.
valve and valve seat after replacing the valve
guide.
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 ex-
ceed the standard value or offset wearing is
emitted.
H:
Intake (A)
Standard
1.0 mm (0.039 in)
Exhaust (B)
Standard
1.2 mm (0.047 in)
ME(H6DO)-62
Cylinder Block
MECHANICAL
21.Cylinder Block 11) Remove the crankshaft position sensor brack-

et.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
42, REMOVAL, Crank Pulley.>
ER.>
3) Remove the timing chain assembly. ME-00559
CHAIN ASSEMBLY.> 12) Rotate the engine to set oil pan upper.
4) Remove the cam sprocket. 13) Remove the bolts which secure oil pan lower to
<Ref. to ME(H6DO)-50, REMOVAL, Cam Sprock- oil pan upper.
et.>
<Ref. to ME(H6DO)-51, REMOVAL, Crank Sprock-
et.>
6) Remove the rear chain cover.
<Ref. to ME(H6DO)-52, REMOVAL, Rear Chain
Cover.>
7) Remove the camshaft. <Ref. to ME(H6DO)-54,
REMOVAL, Camshaft.>
8) Remove the cylinder head. <Ref. to ME(H6DO)- ME-00560
58, REMOVAL, CYLINDER HEAD.>
9) Remove the drive plate. 14) Insert a oil pan cutter blade between cylinder
Lock the crankshaft using ST. block-to-oil pan clearance and remove the oil pan.
ST 498497100 CRANKSHAFT STOPPER CAUTION:
Do not use a screwdriver or similar tools in
place of oil pan cutter.
ST
ME-00557
10) Remove the crankshaft position sensor plate.

ME-00561
ME-00558
ME(H6DO)-63
Cylinder Block
MECHANICAL
16) Remove the bolts which install oil pan upper 19) Draw out the piston pin from #1 and #2 pistons
onto cylinder block. using ST.
NOTE: ST 499097500 PISTON PIN REMOVER
Installation bolts have five different sizes. To pre- NOTE:
vent the confusion in installation, keep these bolts Be careful not to confuse the original combination
on container individually. of piston, piston pin and cylinder.
(B) (C) (D) (E) (E)

(A) (D)
(A) (A)
(A) (A)
(B)
(A) (A)
(A) (A)
(A) (A)
(A) (A) (A) (A) (A)
ME-02065 ME-00565
(A) M8 $ 40
20) Similarly remove the piston pins from #3, #4, #5
and #6 pistons.
(B) M8 $ 65
21) Remove the bolts which secure the cylinder
(C) M8 $ 85
block.
(D) M8 $ 130
(E) M8 $ 24
17) Remove the service hole cover and service

hole plugs using a hexagon wrench.
ME-00566
22) Separate the cylinder block (LH) and (RH).

NOTE:
ME-00563 the connecting rod to fall and damage the cylinder
18) Rotate the crankshaft to bring #1 and #2 pis- block.
tons to bottom dead center position, then remove 23) Remove the rear oil seal.
the piston snap ring through service hole of #1 and 24) Remove the crankshaft together with connect-
#2 cylinders using ST. ing rod.
ST 18233AA000 PISTON PIN SNAP RING 25) Remove the crankshaft bearings from cylinder
PRIERS block using a hammer handle.
NOTE:
ST4 • Do not confuse the combination of crankshaft
bearings.
• Press the bearing at the end opposite to locking
lip.
26) Draw out each piston from cylinder block using
a wooden bar or hammer handle.
NOTE:
Be careful not to confuse the original combination
ME-00564 of piston and cylinder.
ME(H6DO)-64
Cylinder Block
MECHANICAL
B: INSTALLATION 6) Retighten all bolts in the numerical order as

1) After setting the cylinder block to ST, install the shown in the figure.
crankshaft bearing. Tightening torque:
ST 18232AA000 ENGINE STAND (1) — (11), (13): 25 N!m (2.5 kgf-m, 18 ft-lb)
NOTE: (12), (14): 20 N!m (2.0 kgf-m, 14 ft-lb)
Remove oil on the mating surface of bearing and
(14)
cylinder block before installation. Apply a coat of (8) (6) (1) (3) (9) (11)
engine oil to crankshaft pins.
2) Position the crankshaft and connecting rod on
the #2, #4 and #6 cylinder block.
3) Apply liquid gasket to the mating surface of #1,
#3 and #5 cylinder block, and position it on #2, #4
and #6 cylinder block.
Liquid gasket (13)
THREE BOND 1215B (Part No. 004403007) (12) (10) (4) (2) (5) (7) ME-00568
NOTE: 7) Tighten all bolts 90" in the numerical order as
Do not allow liquid gasket to jut into O-ring grooves, shown in the figure.
oil passages, bearing grooves, etc.
(14)
(8) (6) (1) (3) (9) (11)
1.0#0.2 mm (0.039#0.008 in)
(13)
(12) (10) (4) (2) (5) (7) ME-00568
8) Install the upper bolt to cylinder block.

Tightening torque:
ME-00567
25 N!m (2.5 kgf-m, 18 ft-lb)
4) Apply a coat of engine oil to washers and bolt NOTE:
threads. Remove the liquid gasket which is running over to
5) Tighten all bolts in the numerical order as shown sealing surface between cylinder block and rear
in the figure. chain cover, cylinder block and oil pan upper, after
Tightening torque: tightening the bolts which combine the cylinder
(1) — (11), (13): 25 N!m (2.5 kgf-m, 18 ft-lb) block.
(12), (14): 20 N!m (2.0 kgf-m, 14 ft-lb)
(14)
(8) (6) (1) (3) (9) (11)
(13) ME-00569
(12) (10) (4) (2) (5) (7) ME-00568 9) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
ME(H6DO)-65
Cylinder Block
MECHANICAL
NOTE: 15) Install the snap ring.

Apply engine oil to the pressing-in portion. Install snap rings in the piston holes located oppo-
site to the service holes in cylinder block, when po-
NOTE:
(A)
Use new snap rings.
#5
(B)
#3
#6
ST2 ST1
ME-00570 #1
#4
(A) Rear oil seal
(B) Drive plate installation bolt
(A) #2 ME-00573
10) Position the top ring gap at (A) in the figure.
11) Position the second ring gap at (B). (A) Front side of vehicle
180˚ 16) Installing the piston:

(1) Using ST1, turn the crankshaft so that #3
and #4 connecting rods small end are set on the
service hole (A).
(A) (B) ST1 18252AA000 CRANKSHAFT SOCKET
(A)
ME-02066
12) Position the upper rail gap at (C) in the figure.

13) Position the expander gap at (D) in the figure.
14) Position the lower rail gap at (E) in the figure.
(E) (A) ST1

ME-00574
(C)
35˚ (2) Apply a thin coat of engine oil to piston and
25˚
cylinder.
(3) Using ST2, press-fit the piston into cylinder.
ST2 18254AA000 PISTON GUIDE
(D)
ME-02067
CAUTION:
tion.
skirt area. ST2
• Ensure R mark faces to top side of piston.

ME-00576
ME(H6DO)-66
Cylinder Block
MECHANICAL
NOTE: 19) Apply liquid gasket to the matching surface of

Piston front mark (A) faces towards the front of en- oil pan upper.
gine. Liquid gasket
Full line part
3.0#1.0 mm (0.12#0.04 in)
Broken line part
(A) 1.0 mm (0.04 in)
(A) (A)
(A)
ME-02076
17) Installing piston pin: (A)
(1) Apply a coat of engine oil to ST3 before in-

sertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 18253AA000 PISTON GUIDE
ME-02068
ST3 (A) O-ring
NOTE:
Use new O-rings.
20) Temporarily tighten the oil pan upper.
NOTE:
Do not install the bolts in wrong place.
ME-00577 (B) (C) (D) (E) (E)

(A) (D)
(A)
rod through service hole. (A)
(A) (A)
(3) Using the ST4, install the snap ring. (B)
(A) (A)
ST4 18233AA000 PISTON PIN SNAP RING
PRIERS (A) (A)
(A) (A)
NOTE:
Use new snap rings. (A) (A) (A) (A) (A) ME-02069
(A) M8 $ 40
ST4
(B) M8 $ 65
(C) M8 $ 85
(D) M8 $ 130
(E) M8 $ 24
*: Coating
ME-00564
(4) Similarly install the #1, #2, #5 and #6 pis-

tons.
18) Install the service hole plug and O-ring.
NOTE:
Use a new O-ring.
ME(H6DO)-67
Cylinder Block
MECHANICAL
21) Tighten the oil pan upper installing bolts in the 24) Tighten the oil pan lower installing bolts in the
numerical order as shown in the figure. numerical order as shown in the figure.
(19) (8) (10) (20) (22) (2) (1) (15)

(21) (24)
(14)
(5) (3) (13)
(17) (3) (1)
(18)
(4) (12)
(13) (16)
(11) (12) (5) (11)
(2) (4)
(15) (14)
(6) (10)
(23) (25)
(26) (9) (6) (7) (27) (7) (8) (9)
ME-02070 ME-00582
22) Install the oil strainer. 25) Install the crankshaft sensor bracket.
6.4 N!m (0.65 kgf-m, 4.7 ft-lb) 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
ME-00559
26) Install the crankshaft sensor plate.

ME-00561

oil pan lower.
Liquid gasket
5.0#1.0 mm (0.20#0.04 in)
ME-00558

ME-00581
ME(H6DO)-68
Cylinder Block
MECHANICAL
Tightening torque:
81 N!m (8.3 kgf-m, 60 ft-lb)
ST
ME-00557
28) Install the cylinder head. <Ref. to ME(H6DO)-

58, INSTALLATION, CYLINDER HEAD.>
29) Install the camshaft. <Ref. to ME(H6DO)-54,
INSTALLATION, CAMSHAFT.>
30) Install the rear chain cover. <Ref. to
ME(H6DO)-52, INSTALLATION, Rear Chain Cov-
er.>
Sprocket.>
32) Install the cam sprocket. <Ref. to ME(H6DO)-
50, INSTALLATION, Cam Sprocket.>
CHAIN ASSEMBLY.>
CHAIN COVER.>
Pulley.>
ME(H6DO)-69
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(6) (1)
(3)
(4)
(5)
(2)
(2)
(1)
(5)
(2) (4)
(3)
(6)
ME-02097
NOTE:
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using the piston ring ex-
pander.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
ME(H6DO)-70
Cylinder Block
MECHANICAL
D: ASSEMBLY
(6) (1)
(3)
(4)
(5)
(7)
(2)
(2)
(7)
(2) (1)
(5)
(4)
(3)
T (6)
ME-02098
(1) Connecting rod cap (5) Oil ring Tightening torque: N!m (kgf-m, ft-lb)
(2) Connecting rod bearing (6) Snap ring T: 53 (5.4, 39)
(3) Top ring (7) Connecting rod
(4) Second ring
1) Apply oil to the surfaces of the connecting rod E: INSPECTION
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps. 1. CYLINDER BLOCK
2) Install the connecting rod on crankshaft. 1) Visually check for cracks and damage. Especial-
NOTE: ly, inspect the important parts by means of red lead
Position each connecting rod with the side marked check.
facing forward. 2) Check the oil passages for clogging.
3) Install the connecting rod cap. 3) Inspect the crankcase surface that mates with
Ensure the arrow on connecting rod cap faces the cylinder head for warping by using a straight edge.
front during installation. Standard height of cylinder block:
CAUTION: 202 mm (7.95 in)
• Each connecting rod has its own mating cap. 2. CYLINDER AND PISTON
checking their matching number. 1) The cylinder bore size is stamped on the cylinder
• When tightening the connecting rod nuts, ap- block’s front upper surface.
ply oil on the threads. NOTE:
4) Install the oil ring spacer, upper rail and lower rail • Measurement should be performed at a temper-
in this order by hand. Then install the second ring ature of 20"C (68"F).
and top ring with a piston ring expander. • Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as guide lines in selecting a standard piston.
ME(H6DO)-71
Cylinder Block
MECHANICAL
Standard diameter: Cylindricality:

A: 89.205 — 89.215 mm (3.5120 — 3.5124 in) Standard
B: 89.195 — 89.205 mm (3.5116 — 3.5120 in) 0.030 mm (0.0012 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
(A)
(B)
(A)
#7 #6
B B B
B A B
#6 #4 #5
#5 #2 #3 H1
#1
#4
#3 (B)
#2 H2
2 4
2 4
#1
H3
(C)
ME-00585
(A) Main journal size mark

(B) Cylinder bore size mark
Unit: mm (in) ME-00586
(C) Cylinder block (RH) % (LH) combination mark
2) How to measure the inner diameter of each cyl- (A) Piston pin direction
inder: (B) Thrust direction
Measure the inner diameter of each cylinder in both H1: 10 mm (0.39 in)
the thrust and piston pin directions at the heights as H2: 45 mm (1.77 in)
shown in the figure, using a cylinder bore gauge. H3: 80 mm (3.15 in)
NOTE: 3) When the piston is to be replaced due to general
Measurement should be performed at a tempera- or cylinder wear, determine a suitable sized piston
ture of 20"C (68"F). by measuring the piston clearance.
4) How to measure the outer diameter of each pis-
ton:
Measure the outer diameter of each piston at the
height as shown in the figure. (Thrust direction)
NOTE:
ture of 20"C (68"F).
ME(H6DO)-72
Cylinder Block
MECHANICAL
Piston grade point H: 3. PISTON AND PISTON PIN

37.3 mm (1.4685 in)
1) Check the pistons and piston pins for damage,
Piston outer diameter: cracks and wear, and the piston ring grooves for
Standard wear and damage. Replace if defective.
A: 89.205 — 89.215 mm (3.5120 — 3.5124 2) Measure the piston-to-cylinder clearance at
in) each cylinder. <Ref. to ME(H6DO)-71, CYLINDER
B: 89.195 — 89.205 mm (3.5116 — 3.5220 AND PISTON, INSPECTION, CYLINDER
in) BLOCK.> If any of the clearances is not within
0.25 mm (0.0098 in) oversize specification, replace the piston or bore the cylinder
89.445 — 89.465 mm (3.5215 — 3.5222 in) to use an oversize piston.
0.50 mm (0.0197 in) oversize 3) Make sure that the piston pin can be inserted
89.695 — 89.715 mm (3.5313 — 3.5321 in) into the piston pin hole with a thumb at 20"C (68"F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
ME-00172

piston.
NOTE:
ME-00173
ture of 20"C (68"F).
Cylinder to piston clearance at 20"C (68"F):
Standard
%0.010 — 0.010 mm (%0.00039 — 0.00039 in)
6) Boring and honing:
(1) If the value of cylindricality, out-of-round-
ness, or cylinder-to-piston clearance measured
is out of standard or if there is any damage on
the cylinder wall, rebore it to use an oversize pis-
ton.
ME-00174
CAUTION:
When any of the cylinders needs reboring, all 4) Check the snap ring installation groove (A) on
other cylinders must be bored at the same time, the piston for burr. If necessary, remove burr from
and use oversize pistons. Do not perform bor- the groove so that the piston pin can lightly move.
ing on one cylinder only. Nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds
89.715 mm (3.5321 in) after boring and honing,
replace the crankcase. (A)
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter. ME-00175
5) Check the piston pin snap ring for distortion,

cracks and wear.
ME(H6DO)-73
Cylinder Block
MECHANICAL
4. PISTON RING 3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
1) If the piston ring is broken, damaged, or worn, or
if its tension is insufficient, or when the piston is re- NOTE:
placed, replace the piston ring with a new one of Before measuring the clearance, clean the piston
the same size as the piston. ring groove and piston ring.
CAUTION: Standard
• Mark is displayed on the end of top and sec- mm (in)
ond rings. When installing the rings to the pis- 0.040 — 0.080
Clearance Top ring
ton, face this mark upward. between piston (0.0016 — 0.0031)
• Oil ring consists of the upper rail, expander ring and piston 0.030 — 0.070
and lower rail. When installing on piston, be ring groove Second ring
(0.0012 — 0.0028)
careful of each rail’s direction. Clearance between oil ring 0.045 — 0.125
and oil ring groove (0.0018 — 0.0049)
(A)
(B)
(a)
(b)
(C)
(c)
ME-00591
(A) Top ring ME-00178

(B) Second ring
(C) Oil ring
(a) Upper rail
(b) Expander
(c) Lower rail
2) Squarely place the piston ring and oil ring in cyl-

inder, and measure the piston ring gap with a thick-
ness gauge.
Standard
mm (in)
0.20 — 0.35
Top ring
(0.0079 — 0.0138)
0.35 — 0.50
Piston ring gap Second ring
(0.0138 — 0.0197)
0.20 — 0.60
Oil ring
(0.0079 — 0.0236)
ME-00592
ME(H6DO)-74
Cylinder Block
MECHANICAL
5. CONNECTING ROD 5) Measure the oil clearance on individual connect-

ing rod bearings by means of plastigauge. If any oil
clearance is not within the specification, replace the
defective bearing with a new one of standard size
aligner. Replace the connecting rod if it has the
bend or twist. Connecting rod oil clearance:
Standard
0.016 — 0.043 mm (0.0006 — 0.0017 in)
(A)
Unit: mm (in)
Bearing size
Outer diameter of
(B)
Bearings (Thickness at cen-
crank pin
ter)
1.490 — 1.506 51.984 — 52.000
Standard
(0.0587 — 0.0593) (2.0466 — 2.0472)
0.03
1.509 — 1.513 51.954 — 51.970
(0.0012)
(0.0594 — 0.0596) (2.0454 — 2.0461)
undersize
0.05
1.519 — 1.523 51.934 — 51.950
(0.0020)
(0.0598 — 0.0600) (2.0446 — 2.0453)
undersize
0.25
(A) 1.619 — 1.623 51.734 — 51.750
(0.0098)
(0.0637 — 0.0639) (2.0368 — 2.0374)
undersize
(B) 6) Inspect the bushing at connecting rod small end,

and replace if worn or damaged. Also measure the
piston pin clearance at the connecting rod small
end.
ME-00179
Clearance between piston pin and bushing:
(A) Thickness gauge Standard
(B) Connecting rod 0 — 0.022 mm (0 — 0.0009 in)
clearance). If side clearance exceeds the limit or
offset wearing is emitted, replace the connecting
rod.
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
ME-00181
ME-00180
4) Inspect the connecting rod bearing for scar,

peeling, seizure, melting, wear, etc. ME-00174
ME(H6DO)-75
Cylinder Block
MECHANICAL
7) Replacement procedure is as follows. Crank pin and crank journal:

(1) Remove the bushing from connecting rod Out-of-roundness
with ST and press. 0.005 mm (0.0002 in)
(2) Press the bushing with ST after applying oil Cylindricality
on the periphery of bushing. 0.006 mm (0.0002 in)
ST 18350AA000 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
ST
ME-00184
ME-00597
(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
(4) After completion of reaming, clean the bush-
ing to remove chips.
6. CRANKSHAFT AND CRANKSHAFT
BEARING
1) Clean the crankshaft completely, and check it for
cracks using red lead. Replace if defective.
2) Check the crankshaft for bend, and repair or re-
place if needed.
NOTE:
the crankshaft on these bearings, and then check
the crankshaft for bend using a dial gauge.
ME-00598

place or recondition crankshaft as necessary.
them to the specified dimensions according to the
undersize bearing to be used.
ME(H6DO)-76
Cylinder Block
MECHANICAL
Unit: mm (in)
Crank journal diameter
Crank pin outer diameter
#1, #3, #5, #7 #2, #4, #6
63.992 — 64.008 51.984 — 52.000
Journal O.D.
(2.5194 — 2.5200) (2.0466 — 2.0472)
Standard: Bearing size
1.992 — 2.005 1.996 — 2.009 1.490 — 1.506
(Thickness at
(0.0784 — 0.0789) (0.0786 — 0.0791) (0.0587 — 0.0593)
center)
63.962 — 63.978 51.954 — 51.970
Journal O.D.
(2.5182 — 2.5188) (2.0454 — 2.0461)
0.03 (0.0012)
undersize Bearing size
2.011 — 2.014 2.015 — 2.018 1.509 — 1.513
(Thickness at
(0.0792 — 0.0793) (0.0793 — 0.0794) (0.0594 — 0.0596)
center)
63.942 — 63.958 51.934 — 51.950
Journal O.D.
(2.5174 — 2.5180) (2.0446 — 2.0453)
0.05 (0.0020)
2.021 — 2.024 2.025 — 2.028 1.519 — 1.523
(Thickness at
(0.0796 — 0.0797) (0.0797 — 0.0798) (0.0598 — 0.0600)
center)
63.742 — 63.758 51.734 — 51.750
Journal O.D.
(2.5095 — 2.5102) (2.0368 — 2.0374)
0.25 (0.0098)
2.121 — 2.124 2.125 — 2.128 1.619 — 1.623
(Thickness at
(0.0835 — 0.0836) (0.0837 — 0.0838) (0.0637 — 0.0639)
center)
4) Measure the thrust clearance of crankshaft at
center bearing. If clearance exceeds the limit, re-
place the bearing.
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
ME-00600

of flaking, seizure, melting, and wear.
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
ME(H6DO)-77
Oil Flow Control Solenoid Valve
MECHANICAL
22.Oil Flow Control Solenoid

Valve
A: REMOVAL
Oil flow control solenoid valve is a unit with cam-
shaft cap.
Refer to “Camshaft” for removal. <Ref. to
ME(H6DO)-54, REMOVAL, Camshaft.>
B: INSTALLATION
ME(H6DO)-78
Oil Switching Solenoid Valve
MECHANICAL
23.Oil Switching Solenoid Valve B: INSTALLATION

1) Install the oil switching solenoid valve holder.
A: REMOVAL
(1) Temporarily tighten the bolts by tightening
torque of 5 — 10 N!m (0.5 — 1.0 kgf-m, 3.7 —
7.4 ft-lb) in order indicated in the figure.
(2) Tighten the bolts by tightening torque of
10#0.5 N!m (1.0#0.05 kgf-m, 7.4#0.37 ft-lb).
(5)
(2)
IN-00203 (1)
2) Remove the air intake chamber.

<Ref. to IN(H6DO)-7, REMOVAL, Air Intake Cham- (3)
ber.> (4)
3) Disconnect the connector from oil switching so-
lenoid valve.
ME-02073
2) Install the oil temperature sensor.

<Ref. to FU(H6DO)-29, INSTALLATION, Oil Tem-
perature Sensor.>
3) Install the variable valve lift diagnosis oil pres-
sure switch.
<Ref. to FU(H6DO)-28, INSTALLATION, Variable
Valve Lift Diagnosis Oil Pressure Switch.>
4) Install the oil switching solenoid valve.
5) Connect the connector to oil switching solenoid
ME-02071 valve.
4) Remove the oil switching solenoid valve.
5) Remove the variable valve lift diagnosis oil pres-
sure switch.
<Ref. to FU(H6DO)-28, REMOVAL, Variable Valve
Lift Diagnosis Oil Pressure Switch.>
6) Remove the oil temperature sensor.
<Ref. to FU(H6DO)-29, REMOVAL, Oil Tempera-
ture Sensor.>
7) Remove the oil flow control solenoid valve hold-
er from cylinder head.
ME-02071
6) Install the air intake chamber.

<Ref. to IN(H6DO)-7, INSTALLATION, Air Intake
Chamber.>
ME-02072
ME(H6DO)-79
ATF Warmer Cock
MECHANICAL
24.ATF Warmer Cock B: INSTALLATION

A: REMOVAL
1) Set the vehicle on a lift. Tightening torque:
2) Remove the collector cover. 16 N!m (1.6 kgf-m, 11.8 ft-lb)
(A)
T (B)
(A)
ME-02075
IN-00203
(A) Water pipe
4) Lift-up the vehicle. (B) ATF warmer
6) Remove the front exhaust pipe.
Pipe.>
7) Disconnect the water hose from ATF warmer
cock.
8) Remove the ATF warmer cock from cylinder
head.
(A)
(B)
(A)
ME-02074
(A) Water pipe

(B) ATF warmer
ME(H6DO)-80
MECHANICAL

A: INSPECTION
NOTE:
“RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
Defective ignition starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Run-down battery A
Seized camshaft C
not occur. Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Chain Trouble B
Defective timing B
Trouble of tappet C
Trouble of tappet (In case noise occurs with valve B
moving or harness trouble involved to variable valve lift
occurred in past time.)
ME(H6DO)-81
MECHANICAL

3) Initial combustion occurs. Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Chain Trouble B
Defective timing B
Trouble of tappet C
4) Engine stalls after initial Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Chain Trouble B
Defective timing B
Trouble of tappet C
ME(H6DO)-82
MECHANICAL

2. Rough idle and engine Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Chain Defective timing C
Trouble of tappet C
ME(H6DO)-83
MECHANICAL

3. Low output, hesitation and Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line B
Chain Defective timing B
Trouble of tappet C
Over-cooling C
ME(H6DO)-84
MECHANICAL

4. Surging Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line B
Trouble of tappet C
5. Engine does not return to Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
6. Dieseling (Run-on) Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
ME(H6DO)-85
MECHANICAL

7. After burning in exhaust Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Trouble of tappet C
8. Knocking Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Trouble of tappet C
Cooling system Over-heating A
Lubrication system Loosened oil pump attaching bolts and defective gas- B
ket
Defective oil filter o-ring B
ME(H6DO)-86
MECHANICAL

10. Excessive fuel consump- Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Trouble of tappet C
ME(H6DO)-87
Engine Noise
MECHANICAL
26.Engine Noise
A: INSPECTION
speed increases.
• Worn camshaft
• Worn camshaft main bearing
Heavy and dull clank • Worn connecting rod bearing (big end)
Oil pressure is normal. Damaged engine mounting
Sound is noticeable when • Accumulation of carbon inside combustion chamber
High-pitched clank
accelerating with an overload. • Wrong spark plug
Sound is reduced when fuel • Worn crankshaft main bearing
(NOTE*)
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Defective generator brush and rotor contact
—
—
folds
• Belt contacting with case/adjacent part
Valve tappet noise —
• Trouble of tappet
NOTE*:
Therefore, carry out the clear memory mode <Ref. to EN(H6DO)(diag)-40, OPERATION, Clear Memory Mode.> and inspection
mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H6DO)-88
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

EXHAUST
EX(H6DO)
Page
2. Front Exhaust Pipe ...................................................................................5
3. Rear Exhaust Pipe.....................................................................................8
4. Muffler ......................................................................................................10
General Description
EXHAUST
A: COMPONENT
(24) (16)
(24) (17)
(26)
(24)
(26)
T6
(25)
(24)
(21) (24)
(25)
(20)
(23) T6
(22)
(19)
T4 (18)
(1)
T1 T5
T2
(2) (8)
T3 (15)
(14)
T3
(3) T3
(7)
(5)
(9)
(13)
(4)
(12) (10)
T1
(6)
T3 (11)
T4
T4
EX-02013
EX(H6DO)-2
General Description
EXHAUST
(1) Front catalytic converter upper (11) Front catalytic converter lower (23) Rear exhaust pipe
cover (RH) cover (LH) (24) Cushion rubber
(2) Front catalytic converter lower (12) Front exhaust pipe (LH) (25) Self-locking nut
cover (RH) (13) Front catalytic converter (LH) (26) Gasket
(3) Gasket (14) Front oxygen (A/F) sensor (LH)
(4) Front exhaust pipe (RH) (15) Rear oxygen sensor (LH) Tightening torque: N!m (kgf-m, ft-lb)
(5) Front catalytic converter (RH) (16) Muffler (RH) T1: 13 (1.3, 9.4)
(6) Front oxygen (A/F) sensor (RH) (17) Muffler (LH) T2: 18 (1.8, 13.0)
(7) Rear oxygen sensor (RH) (18) Rear catalytic converter T3: 21 (2.1, 15.2)
(8) Gasket (19) Bracket T4: 30 (3.1, 22.4)
(9) Gasket (20) Gasket T5: 35 (3.6, 26.0)
(10) Front catalytic converter upper (21) Spring T6: 48 (4.9, 35.4)
cover (LH) (22) Chamber
EX(H6DO)-3
General Description
EXHAUST
B: CAUTION
points.
cable from battery.
EX(H6DO)-4
Front Exhaust Pipe
EXHAUST
2. Front Exhaust Pipe CAUTION:

Be careful not to pull down the front exhaust
A: REMOVAL pipe assembly.
EX-02016
IN-00203
7) Remove the bolts which hold front exhaust pipe
2) Lift-up the vehicle. assembly to hanger bracket.
4) Disconnect the front oxygen (A/F) sensor con-
nector (A) and rear oxygen sensor connector (B).
(A)
(B)
EX-00061
8) Remove the front exhaust pipe assembly from

EX-02014
vehicle.
5) Separate the front exhaust pipe from rear ex- CAUTION:
haust pipe. • Be careful not to let the front exhaust pipe as-
sembly fall off when removing, as it is quite
CAUTION: heavy.
Be careful, exhaust pipe is hot. • After removing the front exhaust pipe assem-
bly, do not apply excessive pulling force on the
rear exhaust pipe.
9) Disconnect the front exhaust pipe (RH) from
front exhaust pipe assembly.
EX-02015
6) Remove the nuts which hold front exhaust pipe

onto cylinder heads.
EX-02017
10) Remove the front oxygen (A/F) sensor and rear

oxygen sensor. <Ref. to FU(H6DO)-30, REMOV-
AL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H6DO)-32, REMOVAL, Rear Oxygen Sensor.>
EX(H6DO)-5
Front Exhaust Pipe
EXHAUST
B: INSTALLATION 7) Tighten the bolts which install the front exhaust

1) Install the front oxygen (A/F) sensor and rear ox- pipe to rear exhaust pipe.
ygen sensor. <Ref. to FU(H6DO)-30, INSTALLA- Tightening torque:
TION, Front Oxygen (A/F) Sensor.> <Ref. to 18 N!m (1.8 kgf-m, 13.0 ft-lb)
FU(H6DO)-32, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe (RH) to front ex-
haust pipe assembly.
NOTE:
Use a new gasket.
Tightening torque:
30 N!m (3.1 kgf-m, 22.4 ft-lb)
EX-02015
8) Tighten the bolts which hold the front exhaust

pipe assembly to hanger bracket.
Tightening torque:
35 N!m (3.6 kgf-m, 26.0 ft-lb)
EX-02017
3) Install the front exhaust pipe assembly to vehi-

cle.
4) Temporarily tighten the bolts which hold front ex-
haust pipe assembly to hanger bracket.
EX-00061
9) Connect the front oxygen (A/F) sensor connec-

tor (A) and rear oxygen sensor connector (B).
(A)
EX-00061
5) Install the nuts to cylinder head which hold front

(B)
exhaust pipe.
Tightening torque:
30 N!m (3.1 kgf-m, 22.4 ft-lb) EX-02014
EX-02016
EX(H6DO)-6
Front Exhaust Pipe
EXHAUST
IN-00203
C: INSPECTION
nections and welds.
EX(H6DO)-7
Rear Exhaust Pipe
EXHAUST
3. Rear Exhaust Pipe 4) Remove the rear exhaust pipe bracket from
cushion rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from front ex-
haust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
EX-00219
B: INSTALLATION
1) Apply a coat of spray type lubricant to the mating
2) Install the rear exhaust pipe bracket to cushion
EX-02015 rubber.
2) Separate the rear exhaust pipe from muffler.
CAUTION:
pipe.
• LH side
EX-00219
3) Install the rear exhaust pipe to muffler.

NOTE:
Tightening torque:
EX-00222
48 N!m (4.9 kgf-m, 35.4 ft-lb)
• RH side • LH side
EX-00218 EX-00222
EX(H6DO)-8
Rear Exhaust Pipe
EXHAUST
• RH side
EX-00218

pipe.
Tightening torque:
18 N!m (1.8 kgf-m, 13.0 ft-lb)
EX-02015
C: INSPECTION
nections and welds.
cracked.
EX(H6DO)-9
Muffler
EXHAUST
4. Muffler 3) Remove the front and rear cushion rubber, and

then remove the muffler.
A: REMOVAL
1) Separate the muffler from rear exhaust pipe.
B: INSTALLATION
CAUTION:
Be careful, exhaust pipe is hot. NOTE:
• LH side
Tightening torque:
48 N!m (4.9 kgf-m, 35.4 ft-lb)
• LH side
EX-00222
• RH side
EX-00222
• RH side
EX-00218

• LH side EX-00218
C: INSPECTION
nections and welds.
cracked.
EX-00220
• RH side
EX-00221
EX(H6DO)-10
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

COOLING
CO(H6DO)
Page
3. Engine Coolant............................................................................................9
4. Water Pump ..............................................................................................11
5. Thermostat ................................................................................................12
6. Radiator.....................................................................................................13
7. Radiator Cap .............................................................................................16
10. Reservoir Tank..........................................................................................22
11. Radiator Fan Control Unit .........................................................................23
General Description
COOLING
A: SPECIFICATION
Model with ATF warmer (LHD) Approx. 7.7 (8.1, 6.8)
Total engine coolant capacity
Model with ATF warmer (RHD) Approx. 7.8 (8.2, 6.9)
2 (US qt, Imp qt)
Model without ATF warmer Approx. 7.2 (7.6, 6.3)
Discharge amount
320 (84.5, 70.4)
Discharge perfor-
mance I 5,500 rpm — 176.5 kPa (18 mAq)
Water pump pressure
Impeller diameter mm (in) 73.2 (2.88)
Number of pump sprocket teeth 22
Main fan W 160
Motor input
Sub fan W 160
Radiator fan
Type Down flow, pressure type
Width " Height " Thickness
Core dimensions 690 " 349 " 16 (27.17 " 13.74 " 0.63)
mm (in)
Radiator Above: 108#15
Pressure range in
(1.1#0.15, 16#2)
which cap valve is kPa (kg/cm2, psi) Below: $1.0 — $4.9
open
($0.01 — $0.05, $0.1 — $0.7)
Reservoir
tank
CO(H6DO)-2
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(4)
(3)
(5)
T
(2)
(1)
CO-02036
(1) Water pump ASSY (4) Gasket Tightening torque: N%m (kgf-m, ft-lb)
(2) O-ring (5) Thermostat cover T: 6.4 (0.65, 4.7)
(3) Thermostat
CO(H6DO)-3
General Description
COOLING
(27)
T4
(14) T2
(13)
(19)
(12)
T4
(16)
(18)
T5 (5)
(9)
(8)
(6) T1 T4
(4)
T3
(7) (20)
(22)
(17) (21)
(3) (9)
(10) T1
(7) (23)
T3 (15)
T4
(7)
T4
(11)
(21)
(21)
(24)
(7)
(2) (25)
(21)
(21)
(1) (21)
(21)
(26)
CO-02027
(1) Radiator lower bracket (13) Radiator sub fan motor (25) ATF inlet hose B
(2) Radiator lower cushion (14) Radiator sub fan shroud (26) ATF outlet hose B
(3) Engine coolant drain cock (15) Radiator main fan (27) Radiator fan control unit
(4) Radiator (16) Radiator main fan motor
(5) Radiator upper bracket (17) Radiator main fan shroud Tightening torque: N%m (kgf-m, ft-lb)
(6) Radiator upper cushion (18) Engine coolant reservoir tank cap T1: 3.8 (0.39, 2.8)
(7) Clamp (19) Over flow hose T2: 5.4 (0.55, 4.0)
(8) Radiator inlet hose A (20) Engine coolant reservoir tank T3: 6.2 (0.63, 4.6)
(9) Clamp (21) ATF hose clamp T4: 7.5 (0.76, 5.5)
(10) Radiator inlet hose B (22) ATF inlet hose A T5: 12 (1.2, 8.7)
(11) Radiator outlet hose (23) ATF outlet hose A
(12) Radiator sub fan (24) ATF pipe
CO(H6DO)-4
General Description
COOLING

D: PREPARATION TOOL
1. SPECIAL TOOL
499977100 CRANK PULLEY Used for stopping crank pulley when loosen-
WRENCH ing and tightening crank pulley bolts.
ST-499977100
499977500 CAM SPROCKET Used for removing and installing intake cam
WRENCH sprocket.
ST-499977500
18231AA020 CAM SPROCKET Used for removing and installing exhaust
WRENCH cam sprocket.
ST18231AA020
2. GENERAL TOOL
TOOL NAME REMARKS
Radiator cap tester Used for measuring pressure.
CO(H6DO)-5
Radiator Fan System
COOLING

A: WIRING DIAGRAM
SBF-1 SBF-7
No.2 IGNITION
SWITCH
No.26
MAIN FUSE BOX (M/B)

MAIN
FAN B: B143
RELAY 1
E: F36
B7
E6
THROUGH
JOINT CONNECTOR
16 7
F108 B361
3
1
2
PWM
CONTROLLER
F106
2
F17
A: B134
A31
B30
B: B135
E E
M M
MAIN FAN MOTOR SUB FAN MOTOR ECM
F106 B361 F108

A: B134 B: B135
1 2 3 4 5 6 1 2 3 4 5 6 7 8
1 2 3
7 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
E: F36 B: B143 F17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
1 2 3 1 2 3 4 5 6 7 8 9 1 2
4 5 6 7 10 11 12 13 14 15 16 17 18 19 20
CO-02028
CO(H6DO)-6
Radiator Fan System
COOLING
B: RADIATOR FAN CONTROL OUTPUT WAVEFORM
(V)
(A)
(B)
CO-02026
(A) 5V (B) 2 ms
C: INSPECTION
• A/C switch is OFF.
TROUBLE SYMPTOMS:
Radiator main fan and sub fan do not rotate under the above conditions.
Step Check Yes No

1) Turn the ignition switch to OFF. M&? fan relay 1.
holder.
fan relay 1 switch.
1) Connect the terminal of main fan relay 1 &? fan relay 1.
coil to battery.
3 CHECK POWER SUPPLY TO ECM. Is the voltage more than 10 V? Go to step 4. Repair the power
4) Measure the voltage between ECM termi-
nal and chassis ground.
(B135) No. 30 (+) — Chassis ground ($):
CO(H6DO)-7
Radiator Fan System
COOLING
Step Check Yes No

4 CHECK POWER SUPPLY TO RADIATOR Is the voltage more than 10 V? Go to step 5. Repair the power
FAN CONTROL UNIT. supply line.
2) Connect the connector to ECM.
3) Disconnect the connector from radiator fan
control unit.
5) Measure the voltage between radiator fan
control unit terminal and chassis ground.
5 CHECK HARNESS BETWEEN ECM AND RA- Is the resistance less than 1 Go to step 6. Repair the open
DIATOR FAN CONTROL UNIT. &? circuit in harness
2) Disconnect the connector from ECM. radiator fan con-
3) Measure the resistance between radiator trol unit.
fan control unit and ECM connector.
(B134) No. 31 — (F106) No. 2:
6 CHECK RADIATOR FAN CONTROL UNIT Is the resistance less than 5 Go to step 7. Repair the open
AND GROUND CIRCUIT. &? circuit in harness
1) Connect the connector to ECM and radiator between radiator
fan control unit. fan control unit
2) Measure the resistance between radiator connector and
fan control unit connector and chassis ground. chassis ground.
7 CHECK FAN MOTOR. Does the fan motor rotate? Go to step 8. Replace the fan
1) Disconnect the connector from radiator fan motor which does
control unit. not rotate.
2) Connect the battery positive (+) terminal to
terminal No. 1, and the ground ($) terminal to
terminal No. 3 of radiator fan control unit.
8 CHECK ECM OUTPUT SIGNAL. Is the waveform output? Replace the radia- Replace the ECM.
1) Turn the ignition switch to OFF. tor fan control unit. <Ref. to
2) Connect the test mode connector. <Ref. to FU(H6DO)-34,
3) Turn the ignition switch to ON. CO(H6DO)-23, Engine Control
4) Using the oscilloscope, check the output Radiator Fan Con- Module (ECM).>
signal. <Ref. to CO(H6DO)-7, RADIATOR FAN trol Unit.>
CONTROL OUTPUT WAVEFORM, Radiator
Fan System.>
(B134) No. 31 (+) — Chassis ground ($):
CO(H6DO)-8
Engine Coolant
COOLING
3. Engine Coolant 2) Fill engine coolant into the reservoir tank up to

“FULL” level.
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
2) Remove the under cover. (1)
3) Remove the drain plug to drain engine coolant (2)
into container.
NOTE:
Remove the coolant filler tank cap so that engine
coolant will drain faster.
CO-00110
(1) FULL
(2) LOW
3) Warm-up the engine completely for more than

five minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in coolant filler
tank, add engine coolant to filler neck position.
5) If the engine coolant level drops from “FULL” lev-
el of reservoir tank, add engine coolant to “FULL”
CO-02012 level.
4) Install the drain plug. 6) Attach the coolant filler tank cap and reservoir
tank cap properly.
B: INSPECTION
1) Fill engine coolant into coolant filler tank up to
the filler neck position. 1. RERATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEM-
PERATURE
Model with ATF warmer (LHD)
Approx. 7.7 2 (8.1 US qt, 6.8 Imp qt) Concentration and safe operating temperature of
Model with ATF warmer (RHD) SUBARU coolant is shown in the diagram. Measur-
Approx. 7.8 2 (8.2 US qt, 6.9 Imp qt) ing the temperature and specific gravity of the cool-
Model without ATF warmer ant will provide this information.
NOTE:
SUBARU Genuine Coolant containing anti-freeze
and anti-rust agents is especially made for SUBA-
RU engine, which has an aluminum crankcase. Al-
ways use SUBARU Genuine Coolant, since other
coolant may cause corrosion.
CO(H6DO)-9
Engine Coolant
COOLING
[Example] If a coolant concentration of 50% is needed, drain

If the coolant temperature is 25!C (77!F), its specif- all the coolant and refill with the undiluted solution
ic gravity is 1.054, the concentration is 45% (point only.
A), the safe operating temperature is $14!C (7!F)
(point B), and the freezing temperature is $20!C
($4!F) (point C).
Specific gravity
Safe operating temperature

of coolant
Concentration
of coolant Necessary Concentration
of coolant
1.100
3
1.090 (3.2, 45%
2.6) A
1.080 40%
60% 2 35%
1.070 (2.1,
B 30%
C 1.8)
1.060 50% 1 25%
(1.054) 20%
A (1.1,
1.050 0.9)
40% 10% 15%
1.040 0
10 20 30 40 50
Freezing Concentration of coolant in
1.030 30%
temperature the vehicie cooling system %
1.020
20% Concentration of coolant in vehicie
(77 F)
1.010 and quantity to be drained

25 C
CO-00012
10%
1.000
-40 -30 -20 -10 0 10 20 30 40 50
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
2. PROCEDURE TO ADJUST THE CON-

To adjust the concentration of coolant according to
temperature, find the proper fluid concentration in
amount of coolant with an undiluted solution of
SUBARU genuine coolant (concentration 50%).
The amount of coolant that should be replaced can
be determined using the diagram.
[Example]
Assume that the coolant concentration must be in-
creased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
the 40% curve of the necessary coolant concentra-
tion, and read the scale on the vertical axis of the
drained is 2.1 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1
ing system and add 2.1 2 (2.2 US qt, 1.8 Imp qt) of
CO(H6DO)-10
Water Pump
COOLING
4. Water Pump 3) Install the front chain cover.

<Ref. to ME(H6DO)-43, INSTALLATION, Front
A: REMOVAL Chain Cover.>
1) Remove the radiator. <Ref. to CO(H6DO)-13, 4) Install the V-belts.
REMOVAL, Radiator.> <Ref. to ME(H6DO)-33, INSTALLATION, V-belt.>
2) Remove the V-belts. 5) Install the radiator. <Ref. to CO(H6DO)-14, IN-
<Ref. to ME(H6DO)-33, REMOVAL, V-belt.> STALLATION, RADIATOR.>
3) Remove the front chain cover. 6) Fill with engine coolant. <Ref. to CO(H6DO)-9,
<Ref. to ME(H6DO)-43, REMOVAL, Front Chain FILLING OF ENGINE COOLANT, REPLACE-
Cover.> MENT, Engine Coolant.>
C: INSPECTION
<Ref. to ME(H6DO)-45, REMOVAL, Timing Chain
1) Check the water pump bearing for smooth rota-
Assembly.>
tion.
2) Check the water pump sprocket for abnormali-
NOTE: ties.
When the water pump cannot be removed easier,
screw-in the bolts (A) to screw part to remove water
pump.
(A)
(A)
CO-02013
B: INSTALLATION
1) Install the water pump to rear chain cover.
NOTE:
Apply engine coolant to O-ring.
Tightening torque
6.4 N%m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
• Use new O-rings.
• Apply engine coolant to O-ring to install water
pump easier.
CO-02014

<Ref. to ME(H6DO)-46, INSTALLATION, Timing
Chain Assembly.>
CO(H6DO)-11
Thermostat
COOLING
5. Thermostat Tightening torque:

6.4 N%m (0.65 kgf-m, 4.7 ft-lb)
A: REMOVAL 3) Connect the radiator outlet hose to thermostat
1) Set the vehicle on a lift. cover.
2) Lift-up the vehicle. 4) Install the under cover.
3) Remove the under cover. 5) Lower the vehicle.
4) Drain engine coolant completely. 6) Fill with engine coolant. <Ref. to CO(H6DO)-9,
<Ref. to CO(H6DO)-9, DRAINING OF ENGINE FILLING OF ENGINE COOLANT, REPLACE-
COOLANT, REPLACEMENT, Engine Coolant.> MENT, Engine Coolant.>
stat cover. C: INSPECTION
ature distribution. The measurement should con-
CO-02015 form to the specification.
6) Remove the thermostat cover and then remove Starting temperature to open:
the thermostat. 80 — 84!C (176 — 183!F)
Fully opens:
95!C (203!F)
Valve lift:
9.0 mm (0.354 in) or more
(A)
CO-02016
B: INSTALLATION (B)
1) Install the gasket to thermostat.
NOTE:
Use a new gasket. CO-00033
2) Install the thermostat and thermostat cover.
(A) Thermometer
NOTE:
(B) Thermostat
The thermostat must be installed with the jiggle pin
facing upward.
CO-02016
CO(H6DO)-12
Radiator
COOLING
6. Radiator 10) Remove the hood stay holder.
A: REMOVAL
WARNING:
CO-02017

IN(H6DO)-8, REMOVAL, Air Intake Duct.>
12) Disconnect the connector from radiator fan
control unit.
IN-00203

<Ref. to CO(H6DO)-9, DRAINING OF ENGINE
7) Disconnect the outlet hose from radiator. CO-02018
13) Remove the reservoir tank. <Ref. to

CO(H6DO)-22, REMOVAL, Reservoir Tank.>
14) Disconnect the inlet hose from radiator.
(A)
CO-02015
8) Disconnect the ATF cooler hose from radiator.

(model without ATF warmer)
(B) CO-02019
(A) Radiator inlet hose

(B) Radiator upper bracket
CO-00253
CO(H6DO)-13
Radiator
COOLING
B: INSTALLATION 7) Install the air intake duct.

1) Attach the radiator lower cushions to holes on <Ref. to IN(H6DO)-8, INSTALLATION, Air Intake
the vehicle. Duct.>
8) Install the hood stay holder.
CO-00126
CO-02017
NOTE: 10) Connect the ATF cooler hoses. (model without
Make pins on the lower side of radiator be fitted into ATF warmer)
the bolts.
Tightening torque:
12 N%m (1.2 kgf-m, 8.7 ft-lb)
4) Connect the radiator inlet hose.
(A)
CO-00253
11) Connect the radiator outlet hose.
(B) CO-02019
(A) Radiator inlet hose

(B) Radiator upper bracket
5) Install the reservoir tank. <Ref. to CO(H6DO)-

22, INSTALLATION, Reservoir Tank.> CO-02015
6) Connect the connector to radiator fan control
unit.
CO-02018
IN-00203
CO(H6DO)-14
Radiator
COOLING
15) Fill with engine coolant.

16) Check the ATF level.
mission Fluid.>
C: INSPECTION
1) Remove the radiator cap, top off the radiator with
coolant, and then attach the tester in place of cap.
CO-00127

to the radiator to check if:
• Engine coolant leaks at/around radiator.
tions.
CAUTION:
vance.
• Be careful not to deform the filler neck of ra-
diator when installing or removing the tester.
CO(H6DO)-15
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
CO-00044

Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
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
pressure test will be incorrect.
• Do not confuse the cap of coolant filler tank
with cap of radiator.
CO(H6DO)-16
COOLING
8. Radiator Main Fan and Fan 13) Remove the reservoir tank. <Ref. to
CO(H6DO)-22, REMOVAL, Reservoir Tank.>
Motor 14) Disconnect the inlet hose from radiator.
A: REMOVAL
CO-02020
15) Remove the radiator sub fan motor assembly.
IN-00203
4) Remove the hood stay holder.
CO-00129
16) Remove the radiator main fan motor assembly.

NOTE:
When removing the main fan assembly with lifting it
CO-02017 up, the main fan shroud contacts to inlet part of en-
5) Remove the air intake duct. <Ref. to IN(H6DO)- gine coolant. To avoid contacting it, move the main
8, REMOVAL, Air Intake Duct.> fan assembly to sub fan assembly side before re-
6) Disconnect the connector from radiator fan con- moval.
trol unit.
CO-00130
CO-02029

10) Disconnect the ATF hose from the clip of radi-
ator main fan shroud. (model without ATF warmer)
11) Remove the radiator main fan motor harness
from clip.
CO(H6DO)-17
COOLING
B: INSTALLATION D: ASSEMBLY
Install in the reverse order of removal. Assemble in the reverse order of disassembly.
7.5 N%m (0.76 kgf-m, 5.5 ft-lb) 3.8 N%m (0.39 kgf-m, 2.8 ft-lb)
CO-00130 CO-00133
C: DISASSEMBLY Tightening torque:

1) Remove the nut which holds fan itself onto fan 6.2 N%m (0.63 kgf-m, 4.6 ft-lb)
CO-00132
CO-00132
E: INSPECTION
2) Remove the screws which hold the fan motor 1) Disconnect the connector from radiator fan con-
onto shroud. trol unit.
NOTE:
Do not remove the main fan motor harness connec-
tor.
CO-00133
CO-02018
CO(H6DO)-18
COOLING
2) Connect the battery to radiator fan control unit as

CO-02037
3) Check the fan motor for operations. If it does not

operate, replace the fan motor.
CO(H6DO)-19
COOLING
9. Radiator Sub Fan and Fan 7) Remove the bolts which hold sub fan shroud to
radiator.
Motor
A: REMOVAL
CO-00129

10) Remove the radiator sub fan shroud through
the under side of vehicle.
IN-00203
B: INSTALLATION
4) Remove the hood stay holder. Install in the reverse order of removal.
Tightening torque:
7.5 N%m (0.76 kgf-m, 5.5 ft-lb)
CO-02017
5) Remove the air intake duct. <Ref. to IN(H6DO)-

8, REMOVAL, Air Intake Duct.>
CO-00129
6) Disconnect the connector from radiator fan con-
trol unit. C: DISASSEMBLY
CO-02029
CO-00136
CO(H6DO)-20
COOLING
2) Remove the screws which hold the fan motor NOTE:

onto shroud. Do not remove the main fan motor harness connec-
tor.
CO-00133
3) Remove the bolts which hold the radiator fan CO-02018

control unit onto shroud. 2) Connect the battery to radiator fan control unit as
D: ASSEMBLY shown in the figure.
Radiator fan control unit bolt tightening torque:
5.4 N%m (0.55 kgf-m, 4.0 ft-lb)
Tightening torque:
3.8 N%m (0.39 kgf-m, 2.8 ft-lb)
CO-02037
3) Check the fan motor for operations. If it does not

operate, replace the fan motor.
CO-00133
Tightening torque:
6.2 N%m (0.63 kgf-m, 4.6 ft-lb)
CO-00136
E: INSPECTION
1) Disconnect the connector from radiator fan con-
trol unit.
CO(H6DO)-21
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Pull out the reservoir tank to the direction of ar-
row while pushing the pawl (A).
(A)
CO-02021
B: INSTALLATION
C: INSPECTION
CO(H6DO)-22
Radiator Fan Control Unit
COOLING
11.Radiator Fan Control Unit

A: SPECIFICATION
Radiator fan control unit forms a unit with radiator
sub fan motor. Refer to “Radiator Sub Fan and Fan
Motor” for removal and installation.
<Ref. to CO(H6DO)-20, REMOVAL, Radiator Sub
Fan and Fan Motor.> <Ref. to CO(H6DO)-20, IN-
STALLATION, Radiator Sub Fan and Fan Motor.>
<Ref. to CO(H6DO)-20, DISASSEMBLY, Radiator
Sub Fan and Fan Motor.> <Ref. to CO(H6DO)-21,
ASSEMBLY, Radiator Sub Fan and Fan Motor.>
CO(H6DO)-23
COOLING

A: INSPECTION
c. Malfunction of water pump Replace.
d. Clogged engine coolant passage Clean.
Inspect and repair ignition control system. <Ref. to
e. Improper ignition timing EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
f. Clogged or leaking radiator Clean, repair or replace.
g. Improper engine oil in engine coolant Replace engine coolant.
Over-heating
Inspect and repair fuel injection system. <Ref. to
h. Air/fuel mixture ratio too lean EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
i. Excessive back pressure in exhaust system Clean or replace.
j. Insufficient clearance between piston and cylinder Adjust or replace.
k. Slipping clutch Correct or replace.
l. Dragging brake Adjust.
m. Faulty transmission gear oil Replace.
n. Malfunction of radiator fan
sensor or fan motor, and replace them.
Over-cooling
a. Loosened or damaged connecting units on hoses Correct or replace.
c. Leakage from water pipe Correct or replace.
Engine coolant
leaks
e. Damaged or cracked cylinder head and crankcase Correct or replace.
f. Damaged or cracked thermostat case Correct or replace.
g. Leakage from radiator Correct or replace.
a. Defective drive belt Replace.
Noise
CO(H6DO)-24
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

LUBRICATION
LU(H6DO)
Page
3. Engine Oil....................................................................................................7
4. Oil Pump .....................................................................................................8
5. Oil Pump Relief Valve ...............................................................................10
9. Oil Cooler ..................................................................................................14
10. General Diagnostic Table..........................................................................16
General Description
LUBRICATION
A: SPECIFICATION
Inner rotor 7
Number of teeth
Outer rotor 8
Oil pump Outer rotor diameter ! thickness mm (in) 86 ! 13 (3.39 ! 0.51)
Tip clearance between inner and outer rotors mm (in) 0.04 — 0.14 (0.0016 — 0.0055)
Side clearance between inner rotor and pump case mm (in) 0.020 — 0.046 (0.0008 — 0.0018)
Case clearance between outer rotor and pump case mm (in) 0.110 — 0.175 (0.0043 — 0.0069)
Filtration area cm2 (sq in) 1,300 (201.5)
Oil filter By-pass valve opening pressure 2
kPa (kg/cm , psi) 160 (1.63, 23.2)
Outer diameter ! width mm (in) 80 ! 75 (3.15 ! 2.95)
Relief valve operation pressure kPa (kg/cm2, psi) 708 (7.2, 102.7)
Oil pressure Operating voltage — Power consumption 12 V — 3.4 W or less
switch Warning light activation pressure kPa (kg/cm2, psi) 15 (0.15, 2.2)
Proof pressure kPa (kg/cm2, psi) 980 (10.0, 142) or more
Recommended oil CAUTION:

For the API specification SL and SJ, use the When replenishing oil, it does not matter if the
logo mark with “Energy Conserving” (If the oil to be added is a different brand from that in
SL, SJ grade is not available, use SH grade). the engine; however, use oil having the API
ACEA specification A1, A2 or A3 classification and SAE viscosity No. designat-
CCMC specification G4 or G5 ed by SUBARU.
New API specification mark (Star burst mark)
label is on the container.
SAE (1)
( C) -30 -20 -15 0 15 30 40
( F) -22 -4 5 32 59 86 104
10W-30
5W-30 (2)
LU-02031

(2) Recommended
The proper viscosity helps the vehicle to get good

cold and hot starting by reducing viscous friction
and thus increasing cranking speed.
LU(H6DO)-2
General Description
LUBRICATION
B: COMPONENT
(14)
(13)
(15)
(12)
T2 T7 (8) (16)
T6 (17)
(10) (7) (6) (7) (8)
(20)
(11) (9)
T9 (18)
T8
(19)
(8)
T3 T4
(7) T4
(6) (8)
T4
(7) (21)
(25)
(5) T5
(22)
(7) (24)
(7) T1
(23)
T4 (2)
(6)
T8
(1)
T1
T7
(3) (4)
T1
LU-02010
LU(H6DO)-3
General Description
LUBRICATION
(1) Oil pan lower (14) Outer rotor Tightening torque: N"m (kgf-m, ft-lb)
(2) Magnet (15) Crank sprocket T1: 6.4 (0.65, 4.7)
(3) Drain plug (16) Oil pan upper T2: <Ref. to LU(H6DO)-8,
(4) Gasket (17) Plug INSTALLATION, Oil Pump.>
(5) Oil cooler pipe (18) Plug T3: 16 (1.6, 12)
(6) Hose (19) Plug T4: 18 (1.8, 13)
(7) Clamp (20) Oil pressure switch T5: 23 (2.3, 17)
(8) O-ring (21) Plug T6: 25 (2.5, 18)
(9) Oil cooler (22) Oil strainer T7: 37 (3.8, 27)
(10) Connector (23) Plug T8: 44 (4.5, 33)
(11) Oil filter (24) Relief valve spring T9: 90 (9.2, 66)
(12) Oil pump cover (25) Relief valve
(13) Inner rotor

D: PREPARATION TOOL
1. SPECIAL TOOL
WRENCH removing and tightening crank pulley bolt.
ST-499977100
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
ST-498547000
LU(H6DO)-4
Oil Pressure System
LUBRICATION

A: WIRING DIAGRAM
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
A4
A3
COMBINATION
METER
WARNING LIGHT
OIL PRESSURE
A: i10
A15
i3
17
B38
B21
31
E2
E11
E
OIL PRESSURE
SWITCH
B21
B72 A: i10 B38
1 2 3 4 5 6 7 8 9 10 11
1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21 22
4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
LU-00241
LU(H6DO)-5
Oil Pressure System
LUBRICATION
B: INSPECTION
Step Check Yes No
1) Turn the ignition switch to ON. (engine nate? the combination
OFF) meter. <Ref. to IDI-
2) Check the warning light of combination 3, INSPECTION,
meter. Combination
Meter System.>
SURE SWITCH.
2) Disconnect the connector from oil pressure
switch.
combination meter connector and chassis
ground.
(E11) No. 1 (+) — Chassis ground (#):
1) Turn the ignition switch to OFF. $? ness connector the combination
2) Remove the combination meter. between combina- meter. <Ref. to IDI-
3) Measure the resistance of combination tion meter and oil 3, INSPECTION,
Terminals Meter System.>
No. 4 — No. 15:
No. 3 — No. 15:
LU(H6DO)-6
Engine Oil
LUBRICATION
3. Engine Oil NOTE:

Prepare a container for draining of engine oil.
A: INSPECTION
1) Park the vehicle on a level surface.
2) Extract 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 properly
orientated.
4) Remove it again and check the reading. If the
engine oil level is below “L” line, add oil to bring the
level up to “F” line.
for the oil to return to the oil pan before checking LU-02011
the level.
4) Tighten the engine oil drain plug after draining
6) Just after driving or while the engine is warm, en- engine oil.
and the notch mark. This is caused by thermal ex- NOTE:
pansion of the engine oil. Use a new drain plug gasket.
NOTE: Tightening torque:
To prevent overfilling the engine oil, do not add oil 44 N"m (4.5 kgf-m, 32.5 ft-lb)
above “F” line when the engine is cold. 5) Use the engine oil of proper quality and viscosi-
ty, fill engine oil through the oil filler duct to upper
(B) point on level gauge. Make sure that the vehicle is
(A) (C)
F
Recommended oil:
Refer to “SPECIFICATION” for the recom-
L
(D)
mended oil. <Ref. to LU(H6DO)-2, SPECIFI-
CATION, General Description.>
Engine oil capacity (when replacing engine oil):
5.5 2 (5.8 US qt, 4.8 Imp qt)
LU-00111 6) Close the engine oil filler cap.
(A) Oil level gauge
8) After the engine stops, recheck the oil level. If
necessary, add engine oil up to the upper level on
(C) Upper level
level gauge.
(D) Lower level
(B)
B: REPLACEMENT (A) (C)
1) Open the engine oil filler cap for quick draining of
F
the engine oil.

L
2) Lift-up the vehicle. (D)

3) Drain engine oil by loosening the engine oil drain
plug.
LU-00111
(A) Oil level gauge

(C) Upper level
(D) Lower level
LU(H6DO)-7
Oil Pump
LUBRICATION
4. Oil Pump B: INSTALLATION

1) Apply a coat of engine oil to the whole area of in-
A: REMOVAL ner rotor and outer rotor.
LU-02032
IN-00203
2) Set the inner rotor onto opening edge of crank
shaft, and install the inner rotor, and then assemble
3) Lift-up the vehicle. the outer rotor.
4) Remove the under cover. 3) Install the oil pump cover.
5) Drain engine coolant. <Ref. to CO(H6DO)-9, 4) Tighten the bolts in the numerical order as
DRAINING OF ENGINE COOLANT, REPLACE- shown in the figure.
6) Lower the vehicle. CAUTION:
Ensure that the bolt is installed in correct posi-
7) Remove the radiator. <Ref. to CO(H6DO)-13,
tion.
REMOVAL, Radiator.>
8) Remove the V-belts. <Ref. to ME(H6DO)-33, Tightening torque:
REMOVAL, V-belt.> 6.4 N"m (0.65 kgf-m, 4.7 ft-lb)
ME(H6DO)-43, REMOVAL, Front Chain Cover.> (3)
10) Remove the timing chain. <Ref. to ME(H6DO)- (9) (7)
45, REMOVAL, Timing Chain Assembly.> (2)

(5)
(8)
12) Remove the oil pump cover. (1) (6) (4)
(12)
(11)
(16) (10)
(17)
(14)
(15) (13)
LU-02013
Bolt installing position Bolt dimension

(1) and (3) 6 ! 14 ! 14
(2) and (4) 6 ! 35 ! 18
(5), (6), (7), (8), (9), (10) and (11) 6 ! 35 ! 15
LU-02012 (12), (15), (16) and (17) 6 ! 16 ! 16
13) Remove the inner rotor and outer rotor. (13) and (14) 6 ! 26 ! 15

6) Install the timing chain. <Ref. to ME(H6DO)-46,
INSTALLATION, Timing Chain Assembly.>
7) Install the front chain cover. <Ref. to ME(H6DO)-
43, INSTALLATION, Front Chain Cover.>
8) Install the V-belts. <Ref. to ME(H6DO)-33, IN-
STALLATION, V-belt.>
9) Install the radiator. <Ref. to CO(H6DO)-14, IN-
STALLATION, Radiator.>
LU(H6DO)-8
Oil Pump
LUBRICATION
11) Fill engine coolant. 3. SIDE CLEARANCE

Measure the clearance between oil pump inner ro-
tor and rear chain cover. If the clearance exceeds
C: INSPECTION the limit, replace rotors as a matched set.
1. TIP CLEARANCE Side clearance:
Standard value
Measure the tip clearance of rotors. If the clearance 0.020 — 0.046 mm (0.0008 — 0.0018 in)
exceeds the limit, replace the rotors as a matched
set.
Tip clearance:
Standard value
0.04 — 0.14 mm (0.0016 — 0.0055 in)
LU-02016
4. OIL PUMP CASE

Check the worn shaft hole, clogged oil passage,
crank and other parts for faults.
LU-02014
2. CASE CLEARANCE
Measure the clearance between the outer rotor and
rear chain cover rotor housing. If the clearance ex-
ceeds the limit, replace the outer rotor.
Case clearance:
Standard value
0.110 — 0.175 mm (0.0043 — 0.0069 in)
LU-02015
LU(H6DO)-9
Oil Pump Relief Valve
LUBRICATION
5. Oil Pump Relief Valve Tightening torque:

T: 44 N"m (4.5 kgf-m, 33 ft-lb)
A: REMOVAL
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cov-
er as one unit; therefore, refer to “Oil Pump” for re-
moval procedure. <Ref. to LU(H6DO)-8,
REMOVAL, Oil Pump.>
2. OIL PAN UPPER SIDE
1) Remove the oil pan. <Ref. to LU(H6DO)-11, RE-
MOVAL, Oil Pan and Strainer.>
2) Remove the plug, relief valve spring and relief
valve.
LU-02034
2) Install the oil pan. <Ref. to LU(H6DO)-11, IN-

STALLATION, Oil Pan and Strainer.>
(1)
C: INSPECTION
Check the worn shaft hole of oil pump relief valve
(2) case, clogged oil passage, crank and other parts
for faults.
(3)
LU-02033
(1) Relief valve

(2) Relief valve spring
(3) Plug
B: INSTALLATION
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cov-
er as one unit; therefore, refer to “Oil Pump” for in-
stallation procedure. <Ref. to LU(H6DO)-8,
INSTALLATION, Oil Pump.>
2. OIL PAN UPPER SIDE
1) Install the relief valve, relief valve spring and
plug.
NOTE:
Apply the engine oil to relief valve.
LU(H6DO)-10
LUBRICATION
6. Oil Pan and Strainer Tightening torque:

6.4 N"m (0.65 kgf-m, 4.7 ft-lb)
A: REMOVAL
NOTE:
Before removing the oil pan upper, remove the en-
gine from vehicle. <Ref. to ME(H6DO)-34, RE-
MOVAL, Engine Assembly.> <Ref. to ME(H6DO)-
63, REMOVAL, Cylinder Block.>
4) Drain the engine oil. <Ref. to LU(H6DO)-7, RE-
LU-00124
PLACEMENT, Engine Oil.>
5) Insert the oil pan cutter blade between oil pan 2) Apply liquid gasket to the mating surfaces and
upper and oil pan lower. install the oil pan.
CAUTION: Liquid gasket
Do not use a screwdriver or similar tool in place THREE BOND 1280B (Part No. K0877YA018)
of oil pan cutter. Liquid gasket applying diameter
6) Remove the oil pan lower. 5.0%1.0 mm (0.197%0.039 in)
LU-00123
LU-00125
7) Remove the oil strainer. 3) Tighten the oil pan lower installing bolts in the
numerical order as shown in the figure.
Tightening torque:
6.4 N"m (0.65 kgf-m, 4.7 ft-lb)
(2) (1) (15)

(14)
(3) (13)
(4) (12)
LU-00124
(5) (11)
B: INSTALLATION (6) (10)
CAUTION: (7) (8) (9)
Before installing the oil pan, wipe clean the LU-00126
mating surface of oil pan lower and oil pan up-
per.
5) Fill engine oil. <Ref. to LU(H6DO)-7, INSPEC-
1) Install the oil strainer to oil pan upper. TION, ENGINE OIL.>
NOTE: C: INSPECTION
Visually check that the oil pan, oil strainer and oil
strainer stay are not damaged.
LU(H6DO)-11
Oil Pressure Switch
LUBRICATION
7. Oil Pressure Switch Liquid gasket

A: REMOVAL equivalent
LU-00129
2) Install the oil pressure switch.

IN-00203
3) Lift-up the vehicle. Tightening torque:

4) Remove the under cover. 25 N"m (2.5 kgf-m, 18.1 ft-lb)
LU-00128
LU-00127 3) Connect the terminal of oil pressure switch.

LU-00127
LU-00128 4) Install the under cover.
1) Apply liquid gasket to the oil pressure switch Make sure oil does not leak or seep from where the
threads. oil pressure switch is installed.
LU(H6DO)-12
Engine Oil Filter
LUBRICATION

A: REMOVAL
1) Drain the engine oil by removing engine oil drain
plug.
LU-02011

3) Remove the oil filter using ST.
LU-02035
B: INSTALLATION
1) Clean the oil filter installing surface of oil cooler.
3) Install the oil filter turning it by hand, being care-
ful not to damage seal rubber.
4) Tighten more (approx. 3/4 turn) after the seal
rubber contacts the oil cooler. Do not tighten exces-
sively, or oil may leak.
7) Fill engine oil. <Ref. to LU(H6DO)-7, INSPEC-
TION, ENGINE OIL.>
C: INSPECTION
1) After installing the oil filter, run engine and make
sure that no oil is leaking around seal rubber.
NOTE:
sary.
2) Check the engine oil level. <Ref. to LU(H6DO)-
7, INSPECTION, ENGINE OIL.>
LU(H6DO)-13
Oil Cooler
LUBRICATION
9. Oil Cooler 8) Remove the connector and remove oil cooler.
A: REMOVAL
3) Drain the engine coolant.
(A)
4) Drain the engine oil. <Ref. to LU(H6DO)-7, RE- (B)
PLACEMENT, Engine Oil.> (C)
5) Remove the bolts which hold the water pipe to
engine. LU-00135
(A) Connector
(B) Oil cooler
(C) O-ring
B: INSPECTION
1) Check that engine coolant passages are not
clogged using an compressed air.
2) Check that the oil pan upper and O-ring installing
surface of oil filter are not damaged.
LU-02036 C: INSTALLATION
6) Disconnect the water hose from oil cooler. 1) Install the oil cooler to oil pan upper with connec-
tor pipe.
Tightening torque:
T: 54 N"m (5.5 kgf-m, 39.8 ft-lb)
NOTE:
Use new O-rings.
(A)
LU-02037
7) Remove the oil filter using ST. <Ref. to

LU(H6DO)-13, REMOVAL, Engine Oil Filter.> T
ST 498547000 OIL FILTER WRENCH (B)
NOTE: (C)
Set a container under the vehicle. LU-00136
(A) Connector
(B) Oil cooler
(C) O-ring
2) Install the oil filter using ST. <Ref. to LU(H6DO)-

13, INSTALLATION, ENGINE OIL FILTER.>
LU-00134
LU(H6DO)-14
Oil Cooler
LUBRICATION
LU-00134
3) Connect the water hose.
LU-02037
4) Install the water pipe to engine.

Tightening torque:
6.4 N"m (0.65 kgf-m, 4.7 ft-lb)
LU-02036
5) Fill engine oil. <Ref. to LU(H6DO)-7, REPLACE-

MENT, Engine Oil.>
6) Fill engine coolant. <Ref. to CO(H6DO)-9, FILL-
ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
7) Check the engine oil level. <Ref. to LU(H6DO)-
7, INSPECTION, ENGINE OIL.>
LU(H6DO)-15
LUBRICATION

A: INSPECTION
Replace.
pump rotor and gear
not come on.
listed in 1) — 2).
LU(H6DO)-16
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

SP(H6DO)
Page
General Description
A: SPECIFICATION
Specifications for 3.0 L DOHC Non-turbo model is
the same as SOHC model. <Ref. to SP(H4SO 2.0)-
2, General Description.>
SP(H6DO)-2
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

IGNITION
IG(H6DO)
Page
2. Spark Plug .................................................................................................4
3. Ignition Coil & Ignitor ASSY .....................................................................7
General Description
IGNITION
A: SPECIFICATION
Item Specification
Model FK0140
Ignition system Independent ignition coil
ASSY
Manufacturer Diamond Electric
Manufacturer and type NGK: ILFR6B
Spark plug
Electrode Iridium
B: COMPONENT
T1
(1)
(2)
T2
(1)
(2)
T2
T1
IG-00052
(1) Spark plug Tightening torque: N!m (kgf-m, ft-lb)

T2: 21 (2.1, 15.2)
IG(H6DO)-2
General Description
IGNITION
C: CAUTION
points.
cable from battery.
IG(H6DO)-3
Spark Plug
IGNITION
2. Spark Plug 7) Remove the spark plug with a spark plug socket.
A: REMOVAL
CAUTION:
All spark plugs installed on an engine must be
Spark plug:
NGK: ILFR6B
1. RH SIDE
1) Remove the collector cover. IG-02005
(B) (B) (C) (D)
(A)
IG-02011
IN-00203
3) Remove the air cleaner case. (A) Ratchet handle

<Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner (B) Extension bar
Case.> (C) Universal joint
4) Remove the bracket. (D) Spark plug socket
5) Disconnect the connector from ignition coil.
6) Remove the ignition coil. 2. LH SIDE
NOTE: 1) Remove the collector cover.
Turn the #5 ignition coil to remove it. 2) Remove the battery and battery carrier.
3) Remove the bracket.
4) Disconnect the connector from ignition coil.
5) Remove the ignition coil.
(A)
NOTE:
Turn the #6 ignition coil to remove it.
(A)
(B)
IG-02004
(A) Bracket
(B) Connector
(B) IG-02006
(A) Bracket
(B) Connector
IG(H6DO)-4
Spark Plug
IGNITION
6) Remove the spark plug with a spark plug socket. 2. LH SIDE

Tightening torque (Spark plug):
21 N!m (2.1 kgf-m, 15.2 ft-lb)
Tightening torque (Ignition coil):
16 N!m (1.6 kgf-m, 11.7 ft-lb)
NOTE:
C: INSPECTION
Check the electrodes and inner and outer ceramic
insulator of plugs, noting the type of deposits and
(B) (B) (C) (D) the degree of electrode erosion.
(A) (A)
IG-02011 (B) (C)
(A) Ratchet handle

(B) Extension bar
(C) Universal joint
(D)
(D) Spark plug socket
(E)
IG-00010
B: INSTALLATION
(A) Spark plug gap
1. RH SIDE
(B) Carbon accumulation or wear
Install in the reverse order of removal. (C) Crack
Tightening torque (Spark plug): (D) Damage
21 N!m (2.1 kgf-m, 15.2 ft-lb) (E) Damaged gasket
Tightening torque (Ignition coil): 1) Normal:

16 N!m (1.6 kgf-m, 11.7 ft-lb) Brown to grayish-tan deposits and slight electrode
NOTE: wear indicate correct spark plug heat range.
IG-00011
IG(H6DO)-5
Spark Plug
IGNITION
2) Carbon fouled: D: ADJUSTMENT

Dry fluffy carbon deposits on insulator and elec- Clean the spark plugs using a wire brush.
trode are mostly caused by slow speed driving in Clean and remove the carbon or oxide deposits.
the city, weak ignition, too rich fuel mixture, dirty air But do not wear away ceramic insulator at this time.
cleaner, etc. If deposits are too stubborn, replace the spark
It is advisable to replace with plugs having hotter plugs.
heat range. After cleaning the spark plugs, correct the spark
plug gap using a gap gauge.
NOTE:
Do not use a plug cleaner because the spark plugs
are applied with iridium tip.
Spark plug gap: L
0.7 — 0.8 mm (0.028 — 0.031 in)
IG-00012 L
(A)
3) Oil fouled:
Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and
pistons or excessive clearance between valve
IG-00015
NOTE:
Replace with a new spark plug if the area (A) is
worn to “ball” shape.
IG-00013
4) Overheating:
White or light gray insulator with black or brown
spots and bluish burnt electrodes indicate engine
overheating. Moreover, those appearance also re-
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.
IG-00014
IG(H6DO)-6
IGNITION
3. Ignition Coil & Ignitor ASSY

A: REMOVAL
Direct ignition type has been adopted. Refer to
“Spark Plug” for removal procedure. <Ref. to
IG(H6DO)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
Tightening torque:
16 N!m (1.6 kgf-m, 11.7 ft-lb)
C: INSPECTION
For inspection procedure, refer to “Diagnostics for
Engine Starting Failure”. <Ref. to EN(H6DO)(diag)-
59, IGNITION CONTROL SYSTEM, Diagnostics
for Engine Starting Failure.>
IG(H6DO)-7
IGNITION
IG(H6DO)-8
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

SC(H6DO)
Page
2. Starter.........................................................................................................6
3. Generator .................................................................................................14
4. Battery......................................................................................................20
General Description
A: SPECIFICATION
Item Specification
Type Reduction type
Model M000T20171
Voltage and output 12 V — 1.4 kW
Revolving direction Counterclockwise (when observed from pinion)
Number of pinion teeth 9
Voltage 11 V
No-load charac-
Current 90 A or less
Starter teristics
Rotating speed 2,000 rpm or more
Voltage 7.7 V
Load character- Current 400 A
istics Torque 16.7 N!m (1.70 kgf-m, 12.3 ft-lb) or more
Rotating speed 710 rpm or more
Voltage 3.5 V
Lock character-
Current 960 A or less
istics
Torque 31 N!m (3.16 kgf-m, 22.9 ft-lb) or more
Rotating-field three-phase type, voltage regulator built-in type, with load
Model
response control system
Model A3TG0591
Voltage and output 12 V — 110 A
Polarity on ground side Negative
Generator
Revolving direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
Output current 2,500 rpm — 91 A or more
Regulated voltage 14.1 — 14.8 V [20"C (68"F)]
For Europe 12 V — 52 AH (75D23L)
Type and capac-
Battery For other desti-
ity 12V — 48 AH (55D23L)
nations
SC(H6DO)-2
General Description
B: COMPONENT
1. STARTER
(1)
(4)
(10)
(9)
(3)
(2)
(8)
(7)
(6)
(5)
(16)
(12)
(11)
(14)
(15)
(13)
SC-02005
(1) Front bracket (7) Internal gear ASSY (13) Brush holder ASSY
(2) Sleeve bearing (8) Shaft ASSY (14) Sleeve bearing
(3) Lever set (9) Gear ASSY (15) Rear cover
(4) Magnet switch ASSY (10) Packing (16) Rear cover set
(5) Stopper set (11) Yoke ASSY
(6) Overrunning clutch (12) Armature
SC(H6DO)-3
General Description
2. GENERATOR
(7)
(6)
(5)
(4)
(3)
T1
(2)
(1)
T1
T2
(13)
(12)
(11)
(10)
(9)
(8)
SC-00163
(1) Pulley nut (7) Bearing (13) Terminal

(2) Pulley (8) Stator coil
(3) Front cover (9) IC regulator with brush Tightening torque: N!m (kgf-m, ft-lb)
(4) Ball bearing (10) Brush T1: 4.7 (0.48, 3.5)
(5) Bearing retainer (11) Rectifier T2: 108 (11.0, 80)
(6) Rotor (12) Rear cover
SC(H6DO)-4
General Description
C: CAUTION
points.
cable from battery.
SC(H6DO)-5
Starter
2. Starter B: INSTALLATION
A: REMOVAL
2) Disconnect the ground cable from battery. 50 N!m (5.1 kgf-m, 37 ft-lb)
IN-00203 SC-00165
3) Remove the air intake chamber. C: DISASSEMBLY

<Ref. to IN(H6DO)-7, REMOVAL, Air Intake Cham-
ber.> 1. STARTER ASSEMBLY
4) Disconnect the connector and terminal from 1) Loosen the nut which holds terminal M of switch
starter. assembly, and then disconnect the connector.
(A)
SC-00164 SC-00059
5) Remove the starter from transmission.
(A) Terminal M
2) Remove the bolts which hold switch assembly,

and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
(A)
SC-00165
SC-00060
(A) Switch ASSY
SC(H6DO)-6
Starter
3) Remove the nuts of both sides, and then remove 6) Remove the packing A, planetary gear and
rear cover set. packing B.
(C)
(A)
(A)
(B)
SC-00061 SC-00064
(A) Rear cover set (A) Packing A

(B) Planetary gear
4) Remove the through-bolts and brush holder
(C) Packing B
screws of both sides, and then detach the rear cov-
er and brush holder assembly. 7) Remove the plate.
(A) (A)
(B)
SC-00062 SC-00065
(A) Brush holder ASSY (A) Plate

(B) Rear cover
8) Remove the shaft assembly and overrunning
5) Remove the armature and yoke assembly from clutch from front bracket as a unit.
front bracket.
NOTE:
Check the following points before removal.
• Lever direction
(B)
• Position of internal gear assembly
(A)
(A)
(C)
SC-00063
(A) Armature (B)

(B) Yoke ASSY (C) (D)
(C) Front bracket SC-00066
(A) Lever
(B) Shaft ASSY
(C) Overrunning clutch
(D) Internal gear ASSY
SC(H6DO)-7
Starter
9) Remove the overrunning clutch from shaft as- (1) Insert the ring into the shaft groove by lightly
sembly as follows: tapping it with an appropriate tool (such as a fit
(1) Remove the stopper from ring by lightly tap- socket wrench).
ping the stopper with an appropriate tool (such
as a fit socket wrench).
(2) Remove the ring, stopper and clutch from
shaft.
(A)
(A) (B)
(B)
(D) SC-00067
(C)
(2) Install the stopper to ring using a press.
(A)
(B)
SC-00068
(A) Ring
(B) Stopper
SC-00014
3) Install the shaft assembly to front bracket while

(A) Socket wrench
taking care of the following points.
(B) Ring
(1) Lever direction
(C) Shaft
(D) Stopper
D: ASSEMBLY
NOTE:
Apply grease to the following parts before assem-
bly.
• Sleeve bearing
• Pinion shaft rotating part
• Shaft spline portion
• Inside of reduction system SC-00069
• Lever fulcrum/Clutch rotating part (2) Internal gear position

1) Install the overrunning clutch to shaft assembly.
2) Install the stopper to shaft assembly as follows.
SC-00070
SC(H6DO)-8
Starter
4) Install the plate. (1) Press the brush down into brush holder, and
then fix the brush in that position using an appro-
priate tool (such as a fit socket wrench).
(A)
SC-00065
(A) Plate SC-00073
5) Install the planetary gear. (2) Match the brush holder to groove of yoke,
6) Install the packing A and B while taking care of and then slide the brush holder into yoke assem-
installing positions. bly to install.
(B)
(A)
SC-00071 SC-00074
10) Install the rear cover matching it’s groove to

(A) Packing A brush holder assembly.
(B) Packing B
7) Install the armature to yoke assembly.

8) Install the yoke to front bracket matching front (A)
bracket to the groove of yoke assembly. (B)
SC-00062

(B) Rear cover
SC-00072
9) Install the brush holder to yoke assembly as fol-

lows.
SC(H6DO)-9
Starter
11) Install rear cover set. E: INSPECTION

1. ARMATURE
(A) 1) Check the commutator for any sign of burns of
rough surfaces or stepped wear. If wear is of a mi-
nor nature, correct it by using sand paper.
2) Run-out test
Check the commutator for run-out, and then re-
place if it exceeds the limit.
Commutator run-out:
SC-00061 Standard
0.05 mm (0.0020 in)
(A) Rear cover set Service limit
Less than 0.10 mm (0.0039 in)
12) Install the switch assembly to front bracket as
follows.
(A)
(1) Insert the plunger and plunger spring into
switch assembly.
(2) Hook the plunger protrusion on lever edge
to install plunger to front bracket.
(A)
(B)
SC-00021
(A) Dial gauge

(B) V-block
3) Depth of segment mold

SC-00060 Check the depth of segment mold.
(A) Switch ASSY Depth of segment mold:
0.5 mm (0.020 in)
13) Connect the connector to terminal M of switch
assembly.
(B)
(C)
(A)
(A)
SC-00022
SC-00059 (A) Depth of mold

(B) Segment
(A) Terminal M
(C) Mold
SC(H6DO)-10
Starter
4) Armature short-circuit test 4. BRUSH AND BRUSH HOLDER

Check the armature for short-circuit by placing it on
1) Brush length
growler tester. Hold an iron sheet against the arma-
Measure the brush length, and then replace if it ex-
ture core while slowly rotating the armature. A
ceeds the service limit.
short-circuited armature will cause the iron sheet to
Replace if abnormal wear or cracks are noticed.
vibrate and to be attracted to core. If the iron sheet
is attracted or vibrates, the armature, which is Brush length:
short-circuited, must be replaced or repaired. Standard
12.3 mm (0.484 in)
(A) Service limit
7.0 mm (0.276 in)
(B)
(A)
SC-00023
(A) Iron sheet

(B)
(B) Growler tester SC-00102
5) Armature ground test

(A) Service limit line
Using a circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There (B) Brush
should be no continuity. If there is continuity, the ar- 2) Brush movement
mature is grounded. Be sure the brush moves smoothly inside brush
Replace the armature if it is grounded. holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38
lb) (when new)
Service limit
SC-00024 2.5 N (0.25 kgf, 0.56 lb)
2. YOKE 5. SWITCH ASSEMBLY
Make sure the pole is set in position. Be sure there is continuity between the terminals S
and M, and between terminal S and ground. Use a
3. OVERRUNNING CLUTCH circuit tester (set in “ohm”).
Inspect the teeth of pinion for wear and damage. Also check to be sure there is no continuity be-
Replace if it is damaged. Rotate the pinion in the tween terminal M and B.
right direction of rotation (counterclockwise). It
should rotate smoothly. But in the opposite direc-
tion, it should be locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
SC(H6DO)-11
Starter
Terminal / Specified resistance: 7. PERFORMANCE TEST

S — M / Less than 1 #
The starter should be submitted to performance
S — Ground / Less than 1 # tests whenever it has been overhauled, to assure
M — B / More than 1 M# its satisfactory performance when installed on the
engine.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
B load test and lock test cannot be performed, carry
S
out at least the no-load test.
M For these performance tests, use the circuit shown
in figure.
SC-00075
B
S (B) (A)
6. SWITCH ASSEMBLY OPERATION M
1) Using a lead wire, connect the terminal S of
(C) +
switch assembly to positive terminal of battery, and 12V
starter body to ground terminal of battery. The pin-
V A
ion should be forced endwise on shaft.
CAUTION: SC-00077
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current (A) Variable resistor
flows, through pull-in coil, to motor. This is not (B) Magnetic switch
a problem. (C) Starter body
2) Disconnect the connector from terminal M. Then 1) No-load test
using a lead wire, connect the positive terminal of With switch on, adjust the variable resistor to obtain
battery and terminal M and ground terminal to start- 11 V, take the ammeter reading, and then measure
er body. the starter speed. Compare these values with the
In this test set up, the pinion should return to its specifications.
original position even when it is pulled out with a
screwdriver. No-load test (standards):
Voltage/Current
MAX. 11 V/90 A
(A)
(B) Rotating speed
More than 2,000 rpm
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.
SC-00076 Load test (standards):
Voltage/Load
(A) Terminal S
7.7 V/16.7 N!m (1.70 kgf-m, 12.3 ft-lb)
(B) Terminal M
Current/Speed
More than 400 A/710 rpm
SC(H6DO)-12
Starter
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to specified voltage.
Lock test (standards):
Voltage/Current
Less than 3.5 V/960 A
Torque
31 N!m (3.16 kgf-m, 22.9 ft-lb)
SC(H6DO)-13
Generator
3. Generator B: INSTALLATION
A: REMOVAL
2) Disconnect the ground cable from battery. 25 N!m (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Check and adjust the V-belt tension.
<Ref. to ME(H6DO)-33, INSPECTION, V-belt.>
(B)
IN-00203
3) Disconnect the connector and terminal from

generator. (A)
SC-00141
C: DISASSEMBLY
1) Remove the four through-bolts.
SC-02003
4) Remove the V-belt.

<Ref. to ME(H6DO)-33, REMOVAL, V-belt.>
5) Remove the bolt (A) and loosen the bolt (B), and SC-00078
then remove the generator from bracket.
2) Heat the portion (A) of rear cover to 50"C
(122"F) with a heater drier.
(B) (A)
(A)
SC-00141
SC-00079
SC(H6DO)-14
Generator
3) Then insert the tip of a flat-tip screwdriver into 5) Remove the ball bearing as follows.
the gap between stator core and front cover. Pry (1) Remove the bolt, and then remove the bear-
them apart to disassemble. ing retainer.
(A)
(A)
SC-00080 SC-00081
(A) Screwdriver
(2) Firmly install an appropriate tool (such as a
fit socket wrench) to bearing inner race.
4) Hold the rotor with a vise and remove pulley nut.
SC-00082
SC-00035
(3) Push the ball bearing off the front cover us-
CAUTION: ing a press.
When holding the rotor with a vise, place alumi- 6) Remove the bearing from rotor using a bearing
num plates or wooden pieces on the vise jaws puller.
to prevent rotor from damage.
(A)
(B)
(C) SC-00046
(D)
SC-00036
(A) Front cover

(B) Pulley
(C) Nut
(D) Rotor
SC(H6DO)-15
Generator
7) Unsolder the connection between rectifier and 9) Remove the brush as follows.
stator coil to remove stator coil. (1) Remove the cover A.
CAUTION:
Do not allow a 180 — 270 W soldering iron to
contact the terminals for more than 5 seconds (A)
at once because the rectifier cannot withstand
so much heat.
SC-00086
(A) Cover A
(2) Remove the cover B.
SC-00083 (A)
8) Remove the IC regulator as follows.

(1) Remove the screws which secure IC regula-
tor to rear cover.
SC-00087
(A) Cover B
(3) Separate the brush from connection to re-

move.
SC-00084
(2) Unsolder the connection between IC regula-

tor and rectifier to remove IC regulator.
SC-00088
10) Remove the rectifier as follows.

(1) Remove the bolts which secure rectifier.
SC-00085
SC-00089
SC(H6DO)-16
Generator
(2) Remove the cover of terminal B. 3) Press the bearing (rear side) into the rotor shaft
using a press to install.
4) Heat the bearing box in rear cover [50 to 60"C
(122 to 140"F)], and then press the rear bearing
into rear cover.
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bear-
ing box.
5) After reassembly, turn the pulley by hand to
SC-00090
check that rotor turns smoothly.
(3) Remove the nut of terminal B, and then re- E: INSPECTION
move the rectifier.
1. DIODE
CAUTION:
Never use a mega tester (designed for reading
high voltage) or any other similar instrument
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 # or less only in the
SC-00091
direction from the diode lead to heat sink.
D: ASSEMBLY
(A)
Assemble in the reverse order of disassembly. (B)
1) Pulling up brush
Before assembling, press the brush down into
brush holder, and then fix them in that position by
passing a [1 mm (0.08 in) dia. 40 to 50 mm (1.6 to
2.0 in) long] wire through the hole as shown in the
figure.
CAUTION:
Be sure to remove the wire after reassembly. SC-00042
(A)
(A) Diode lead
(B) Heat sink (positive side)
SC-00092
(A) Wire
2) Install the ball bearing.

(1) Set the ball bearing on the front cover, and
then securely install an appropriate tool (such as
a fit socket wrench) to the bearing outer race.
(2) Press the ball bearing into the specified po-
sition using a press.
(3) Install the bearing retainer.
SC(H6DO)-17
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 # or less, the rotor
good condition if resistance is 1 # or less only in the coil is grounded, and so replace the rotor assem-
direction from the heat sink to diode lead. bly.
(A)
(B)
SC-00043 SC-00045
5) Ball bearing (rear side)

(A) Diode lead
Check the rear ball bearing. Replace if it is noisy or
(B) Heat sink (negative side)
if the rotor does not turn smoothly.
2. ROTOR 3. STATOR
1) Slip ring surface 1) Continuity test
Inspect the slip rings for contamination or any Inspect the stator coil for continuity between each
roughness on the sliding surface. Repair the slip end of the lead wires. If resistance is 1 M# or more,
ring surface using a lathe or sand paper. the lead wire is broken, and so replace the stator
2) Slip ring outer diameter assembly.
Measure the slip ring outer diameter. If the slip ring
(A)
is worn, replace the rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test
Check the resistance between slip rings using cir-
cuit tester. SC-00047
If the resistance is not within the specified range,
replace the rotor assembly. (A) Stator
Specified resistance: 2) Insulation test

Approx. 2.0 — 2.4 # Inspect the stator coil for continuity between stator
core and each end of lead wire. If resistance is 1 #
or less, the stator coil is grounded, and so replace
the stator assembly.
SC-00044
SC-00048
SC(H6DO)-18
Generator
4. BRUSH
1) Measure the length of each brush. If wear ex-
ceeds the service limit, replace the brush. Each
brush has the service limit mark (A) on it.
Brush length:
Service limit (1)
5.0 mm (0.197 in)
Standard (2)
18.5 mm (0.728 in)
(1)
(A)
(2)
SC-00162
2) Checking brush spring for proper pressure

Using a spring pressure indicator, push the brush
into the brush holder until its tip protrudes 2 mm
(0.08 in). Then measure the pressure of brush
spring. If the pressure is less than 2.2 N (224 g,
7.91 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.8 to 6.0
N (489 to 612 g, 17.26 to 21.60 oz).
SC-00093
5. BEARING (FRONT SIDE)

Check the front ball bearing. If the resistance is felt
while rotating, or if noise is heard, replace the ball
bearing.
SC(H6DO)-19
Battery
4. Battery • Do not let battery fluid contact eyes, skin,

fabrics, or paint-work because battery fluid is
A: REMOVAL corrosive acid.
1) Remove the battery cable holder from battery • To lessen the risk of sparks, remove rings,
rod. metal watch-bands, and other metal jewelry.
2) Disconnect the positive (+) terminal after discon- Never allow metal tools to contact the positive
necting the negative ($) terminal of battery. battery terminal and anything connected to it
3) Remove the flange nuts from battery rods and while you are at the same time in contact with
take off battery holder. any other metallic portion of the vehicle. This
may cause short circuit.
(A)
1. EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and
(B)
terminal posts for dirt or cracks. 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
SC-02004 Check the electrolyte level in each cell. If the level
is below MIN level, bring the level to MAX level by
(A) Battery cable holder pouring distilled water into the battery cell. Do not
(B) Battery rod fill beyond MAX level.
4) Remove the battery. 3. SPECIFIC GRAVITY OF ELECTROLYTE
B: INSTALLATION 1) Measure specific gravity of electrolyte using a
Install in the reverse order of removal. hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
Tightening torque: lyte so that it must be corrected at 20"C (68"F) us-
3.4 N!m (0.35 kgf-m, 2.5 ft-lb) ing the following equation:
NOTE:
S20 = St + 0.0007 % (t $ 20)
• Clean the battery cable terminals and apply
S20: Specific gravity corrected at electrolyte
grease to retard the formation of corrosion.
temperature of 20"C (68"F)
• Connect the positive (+) terminal, and then con-
St: Measured specific gravity
nect the negative ($) terminal of battery.
t: Measured temperature ("C)
performed after battery installation. For this reason, Determine whether or not battery must be
start the engine after 10 seconds or more have charged, according to corrected specific
elapsed since the ignition switch was turned to ON. gravity.
Standard specific gravity: 1.220 — 1.290
C: INSPECTION [20"C (68"F)]
WARNING: 2) Measuring the specific gravity of the electrolyte
• Electrolyte has toxicity; be careful of han- in the battery will disclose the state of charge of the
dling the fluid. battery. The relation between specific gravity and
• Avoid contact with skin, eyes or clothing. Es- state of charge is as shown in the figure.
pecially at contact with eyes, flush with water
Battery with standard specific gravity 1,280 (20 C)
for 15 minutes and get prompt medical atten- 1.28
tion.
Good
1.24
• Batteries produce explosive gases. Keep 1.22
Specific gravity ( C)
1.20
sparks, flame, cigarettes away.
Need to charge
1.16
• Ventilate when charging or using in enclosed
space. 1.12
• For safety, in case an explosion does occur, 1.08

wear eye protection or shield your eyes when 1.04
0 10 20 30 40 50 60 70 80 90 100
working near any battery. Never lean over a bat-
Amount of discharge (%) SC-00054
tery.
SC(H6DO)-20
Battery
D: MEASUREMENT 4. QUICK CHARGING

WARNING: Quick charging is a method that the battery is
Do not bring an open flame close to the battery charged in a short period of time with a relatively
at this time. large current by using a quick charger.
Since a large current flow raises electrolyte temper-
CAUTION: ature, the battery is subject to damage if the large
• Prior to charging, corroded terminals should current is used for prolonged time. For this reason,
be cleaned with a brush and common caustic the quick charging must be carried out within a cur-
soda solution. rent range that will not increase the electrolyte tem-
• Be careful since battery electrolyte overflows perature above 40"C (104"F).
while charging the battery. Also the quick charging is a temporary means to
• Observe instructions when handling the bat- bring battery voltage up to a fair value and, as a
tery charger. rule, a battery should be charged slowly with a low
• Before charging the battery on the vehicle, current.
disconnect the battery ground terminal to pre-
vent damage of generator diodes or other elec- CAUTION:
trical units. • Observe the items in 3. NORMAL CHARGING.
• Never use more than 10 A when charging the
1. JUDGMENT OF BATTERY IN CHARGED battery because it will shorten the battery life.
CONDITION
1) Specific gravity of electrolyte should be held
within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a spe-
cific value in a range from 2.5 to 2.8 volts for more
than one hour.
2. CHECK HYDROMETER FOR STATE OF
CHARGE
Hydrometer Charge bat-
Corrective action
indicator tery
Green Above 65% Load test
Dark Below 65% Charge battery
Low electro- Replace battery*
Clear
lyte (If cranking is difficult)
* Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at the current value specified by
manufacturer or at approximately 1/10 of battery’s
ampere-hour rating.
SC(H6DO)-21
Battery
SC(H6DO)-22
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

EN(H6DO)(diag)
Page
11. Inspection Mode........................................................................................33
12. Drive Cycle................................................................................................38

A: PROCEDURE
1. ENGINE
Step Check Yes No

ble occurred using the interview check list. Engine Start Fail-
<Ref. to EN(H6DO)(diag)-3, CHECK, Check ure”. <Ref. to
List for Interview.> EN(H6DO)(diag)-
2) Start the engine. 52, Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF MALFUNCTION Does check malfunction indica- Go to step 3. Inspection using
INDICATOR LIGHT. tor light illuminate? “General Diagnos-
EN(H6DO)(diag)-
265, INSPEC-
TION, General
Diagnostic Table.>
link connector. EN(H6DO)(diag)- If DTC is not
3) Turn the ignition switch to ON, and the Sub- 66, List of Diag- shown on display
aru Select Monitor switch to ON. nostic Trouble although the mal-
4) Read DTC on Subaru Select Monitor. Code (DTC).> Go function indicator
to step 4. light illuminates,
perform the diag-
nostics of malfunc-
tion indicator light
circuit or combina-
tion meter. <Ref. to
EN(H6DO)(diag)-
43, Malfunction In-
dicator Light.>
4 PERFORM THE DIAGNOSIS. Is DTC displayed on the Sub- Check on “Diag- Finish the diagno-
1) Perform clear memory mode. <Ref. to aru Select Monitor? nostic Procedure sis.
EN(H6DO)(diag)-40, Clear Memory Mode.> with Diagnostic
2) Perform the inspection mode. <Ref. to Trouble Code
EN(H6DO)(diag)-33, Inspection Mode.> (DTC)”
<Ref. to
EN(H6DO)(diag)-
72, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
EN(H6DO)(diag)-2

A: CHECK
1. CHECK LIST No. 1
NOTE:
Date of repair km
Odometer reading
V.I.N. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
❏ Hot
❏ Warm
❏ Cool
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
❏ Warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
❏ At starting
❏ While idling
❏ At racing
❏ While cruising
EN(H6DO)(diag)-3
2. CHECK LIST No. 2

NOTE:
b) Fuel level
• What:
• What:
• What:
• Where:
• From where:
• What kind:
• From where:
• What kind:
❏ Rough idling
❏ Back fire
❏ After fire
❏ Does not shift.
EN(H6DO)(diag)-4
General Description

point to chassis when measuring voltage and resis-
CAUTION: (A)
• All air bag system wiring harnesses and con-
nectors are yellow. Do not use the electrical
test equipment on these circuits.
• Be careful not to damage the Airbag system
• The fuel injector and other part will be damaged. (A) Stud bolt
3) Do not disconnect the battery terminals while the
engine is running. 9) Use engine grounding terminal or engine proper
A large counter electromotive force will be generat- as the grounding point to chassis when measuring
ed in the generator, and this voltage may damage voltage and resistance in the engine compartment.
sensor and the ECM, be sure to turn the ignition
switch to OFF. Perform the clear memory mode af-
ter connecting the connectors.
EN-02473
than 5 mm (0.20 in) into the part.
6) Remove the ECM from the located position after 10) Use TCU mounting stud bolts as the body side
disconnecting two cables on battery. grounding point to chassis when measuring voltage
Otherwise, the ECM may be damaged. and resistance inside the passenger compartment.
CAUTION:
7) Connectors to each sensor in the engine com-
partment and the harness connectors on the en-
gine 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
(A)
when washing the vehicle, or when servicing the EN-00154
vehicle on a rainy day.
(A) Stud bolt
11) Every MFI-related part is a precision part. Do

not drop them.
CAUTION:
under the steering column, inside of the instru-
ment panel lower trim panel.)
EN(H6DO)(diag)-5
General Description

ness.
ly connected to the engine.
matching.
special attention to the three items above men-
tioned.
the operation of the ECM.
fuel system. If engine starts during this operation, EN-02473
14) Problems in the electronic-controlled automatic C: NOTE
transmission may be caused by failure of the en- 1. GENERAL DESCRIPTION
gine, the electronic control system, the transmis-
sion proper, or by a combination of these. These • The on-board diagnostics (OBD) system detects
three causes (engine, electrical control system, and indicates a fault in various inputs and outputs
transmission) must be distinguished clearly when of the complex electronic control. Malfunction indi-
performing diagnostics. cator light in the combination meter indicates oc-
15) Diagnostics should be conducted by rotating currence of a fault or trouble.
with simple, easy operations and proceeding to • Further, against such a failure or sensors as may
complicated, difficult operations. The most impor- disable the drive, the fail-safe function is provided
tant thing in diagnostics is to understand the cus- to ensure the minimal driveability.
tomer’s complaint, and distinguish between the • The OBD system incorporated with the vehicles
three causes (engine, electrical control system, within this engine family complies with Section
transmission). 1968.1, California Code of Regulations (OBD-II
16) In AT models, do not continue the stall for more regulation). The OBD system monitors the compo-
than five seconds at a time. (from closed throttle, nents and the system malfunction listed in Engine
fully open throttle to stall speed reading, and then Section which affects on emissions.
decrease engine speed.). • When the system decides that a malfunction oc-
17) On the model with ABS, when performing driv- curs, malfunction indicator light illuminates. At the
ing test in jacked-up or lifted-up position, some- same time of the malfunction indicator light illumi-
times the warning light may be lit, but this is not a nation or blinking, a diagnostic DTC and a freeze
malfunction of the system. The reason for this is the frame engine conditions are stored into on-board
speed difference between the front and rear computer.
wheels. After diagnosis of engine control system, • The OBD system stores freeze frame engine
perform the ABS memory clearance procedure of condition data (engine load, engine coolant tem-
self-diagnosis system. perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
B: INSPECTION a malfunction first.
Before performing diagnostics, check the following • If the OBD system detects the various malfunc-
items which might affect engine problems: tions including the fault of fuel trim or misfire, the
1. BATTERY OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
1) Measure battery voltage and specific gravity of • When the malfunction does not occur again for
electrolyte. three consecutive driving cycles, malfunction indi-
Standard voltage: 12 V cator light is turned off, but DTC remains at on-
board computer.
Specific gravity: Above 1.260 • The OBD-II system is capable of communication
2) Check the condition of the main and other fuses, with a general scan tool (OBD-II general scan tool)
and harnesses and connectors. Also check for formed by ISO 9141 CARB.
proper grounding.
EN(H6DO)(diag)-6
General Description
• The OBD-II diagnostics procedure is different pending on the quantity of air required for one cycle
from the usual diagnostics procedure. When trou- of operation. In actual operation, the injection quan-
bleshooting OBD-II vehicles, connect Subaru Se- tity is determined by the duration of an electric
lect Monitor or the OBD-II general scan tool to the pulse applied to the fuel injector and this permits
vehicle. simple, yet highly precise metering of the fuel.
• Further, all the operating conditions of the engine
2. ENGINE AND EMISSION CONTROL SYS- are converted into electric signals, and this results
TEM in additional features of the system, such as large
• The Multipoint Fuel Injection (MFI) system is a improved adaptability, easier addition of compen-
system that supplies the optimum air-fuel mixture sating element, etc.
to the engine for all the various operating condi- The MFI system also has the following features:
tions through the use of the latest electronic tech- • Reduced emission of harmful exhaust gases.
nology. • Reduced in fuel consumption.
With this system fuel, which is pressurized at a con- • Increased engine output.
stant pressure, is injected into the intake air pas- • Superior acceleration and deceleration.
sage of the cylinder head. The injection quantity of • Superior startability and warm-up perfor-
fuel is controlled by an intermittent injection system mance in cold weather since compensation is
where the electro-magnetic injection valve (fuel in- made for coolant and intake air temperature.
jector) opens only for a short period of time, de-
D: PREPARATION TOOL
ST24082AA230
ST22771AA030
EN(H6DO)(diag)-7

A: LOCATION
1. ENGINE
• Control module
• LHD model
(3) (1)
(2) (4)
EN-02474
• RHD model
(4)
(2) (1) (3)

EN-02475
EN(H6DO)(diag)-8
(1)
(2)
EN-01147 EN-01966
(4)
(3)
EN-02414 AT-01877
EN(H6DO)(diag)-9
• Sensor
(6) (5) (4) (7) (5) (6) (8)
(1) (2) (3)
EN-02478
(1) Mass air flow and intake air tem- (3) Engine coolant temperature sen- (6) Camshaft position sensor
perature sensor sor (7) Crankshaft position sensor
(2) Manifold absolute pressure sensor (4) Electronic throttle control (8) Oil temperature sensor
(5) Knock sensor
EN(H6DO)(diag)-10
(1)
(2)
EN-02479 EN-02535
(4)
(3)
EN-00895 EN-02536
(5)
(6)
(5)
EN-00897 EN-02537
(8)
(7)
EN-00899 EN-02538
EN(H6DO)(diag)-11
(7)
(2) (4) (6)
(1) (3) (5)
EN-02480
(1) Front oxygen (A/F) sensor LH (4) Rear oxygen sensor RH (7) Rear catalytic converter
(2) Front oxygen (A/F) sensor RH (5) Front catalytic converter LH
(3) Rear oxygen sensor LH (6) Front catalytic converter RH
(2)
(5)
(1) (6)
EN-02539 EN-02540
(4)
(3)
EN-02541 EN-02542
EN(H6DO)(diag)-12
(7)
EN-02543
(3) (6) (5) (2) (5) (6) (3)

(1)
(4)
(4)
EN-02481
(1) Purge control solenoid valve (4) Oil flow control solenoid valve (6) Variable valve lift diagnosis oil
(2) EGR valve (5) Oil switching solenoid valve pressure switch
(3) Ignition coil & ignitor ASSY
EN(H6DO)(diag)-13
(1) (2)
EN-02482 EN-02483
(4)
(3)
EN-02484 EN-02485
(5)
(6)
EN-02486
EN(H6DO)(diag)-14
• LHD model
(1) (3) (4) (5) (2)
(6) (7) (2)

EN-02487
• RHD model
(1) (2)
(6) (7) (5) (4) (3) (2)

EN-02488
(1) Inhibitor switch (4) Fuel pump relay (7) Starter

(2) Fuel pump (5) Electronic throttle control relay
(3) Main relay (6) Radiator fan relay
EN(H6DO)(diag)-15
(2)
EN-00178 EN-02093
(5)
(4)
(6)
(3)
EN-02544 EN-02489
(7)
EN-02490
EN(H6DO)(diag)-16

To B134 To B135 To B136 To B137
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
EN-01812
Signal (V)
Connector Terminal
Description Ignition SW ON Engine ON Reference
No. No.
Crankshaft Signal (+) B135 10 0 "7 — +7 Waveform
B135 8 0.275 0 or 5 Waveform
(LH)
B135 9 0.275 0 or 5 Waveform
(RH)
0.64 — 0.72
0.64 — 0.94 Fully closed: 0.6
Fully opens: 4.01 Fully opened: 4.01
throttle control 1.51 — 1.58
1.51 — 1.76 Fully closed: 1.48
warmed-up.)
motor (+)
motor (")
B137 6 10 — 13 12 — 14 —
motor power supply
B135 35
Main B136 17 —
Accelerator Power
B136 15 5 5 —
Sub B136 28 —
Engine coolant tempera-
ture sensor
EN(H6DO)(diag)-17
Signal (V)
Connector Terminal
No. No.
ON: 0 ON: 0
Starter relay B135 32 —
OFF: 10 — 13 OFF: 13 — 14
ON: 10 — 13 ON: 13 — 14
OFF: 0 OFF: 0
Switch is ON when select
ON: 0
Neutral position switch B137 9 lever is shifted into “P” or
OFF: 12#0.5
“N” range.
Test mode connector B137 15 12 — 14 12 — 14 When connected: 0
Knock sensor Signal B136 25 2.4 2.4 —
1 Shield B136 33 0 0 —
Knock sensor Signal B136 24 2.4 2.4 —
2 Shield B136 33 0 0 —
Ignition switch “OFF”: 10
— 13
Control module power B135 6 10 — 13 13 — 14 —
supply B135 5 10 — 13 13 — 14 —
Sensor power supply B136 16 5 5 —
#1 B135 18 0 13 — 14 Waveform
#2 B135 17 0 13 — 14 Waveform
#3 B135 16 0 13 — 14 Waveform
Ignition control
#4 B135 15 0 13 — 14 Waveform
#5 B135 14 0 13 — 14 Waveform
#6 B135 13 0 13 — 14 Waveform
#1 B136 6 10 — 13 1 — 14 Waveform
#2 B136 5 10 — 13 1 — 14 Waveform
#3 B136 4 10 — 13 1 — 14 Waveform
Fuel injector
#4 B136 3 10 — 13 1 — 14 Waveform
#5 B136 2 10 — 13 1 — 14 Waveform
#6 B136 1 10 — 13 1 — 14 Waveform
ON: 0.5, or less ON: 0.5, or less
OFF: 10 — 13 OFF: 13 — 14
ON: 0.5, or less ON: 0.5, or less
Radiator fan control B134 31 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan control power ON: 0.5, or less ON: 0.5, or less
B135 30 —
supply OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B137 16 0 0 —
Light “ON”: 1, or less
Malfunction indicator light B134 17 — —
Engine speed output B134 23 — 0 — 13, or more Waveform
Purge control solenoid ON: 1, or less ON: 1, or less
B134 14 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal A+ B134 11 10 — 13 10 — 13 —
EGR solenoid Signal A" B134 10 10 — 13 10 — 13 —
valve Signal B+ B134 9 10 — 13 10 — 13 —
Signal B" B134 8 10 — 13 10 — 13 —
ON: 1, or less ON: 1, or less
OFF: 10 — 13 OFF: 13 — 14
Manifold absolute pres-
B136 22 3.5 — 4.8 1.1 — 1.9 —
sure sensor
EN(H6DO)(diag)-18
Signal (V)
Connector Terminal
No. No.
Signal B136 23 0.74 0.3 — 4.5 —
Air flow sensor Shield B136 32 0 0 —
Ground B136 31 0 0 —
Intake air temperature intake air tempera-
B136 13 3.15 — 3.33 3.15 — 3.33
sensor ture:25!C (75!F)
Front oxygen Signal (+) B134 33 2.8 — 3.2 2.8 — 3.2 —
(A/F) sensor Signal (") B134 26 2.4 — 2.7 2.4 — 2.7 —
RH Shield B134 25 0 0 —
Front oxygen Signal 1 B134 3 12 — 14 — Waveform
(A/F) sensor
heater RH Signal 2 B134 2 12 — 14 — Waveform
Front oxygen Signal (+) B134 34 2.8 — 3.2 2.8 — 3.2 —

(A/F) sensor Signal (") B134 27 2.4 — 2.7 2.4 — 2.7 —
LH Shield B134 25 0 0 —
Front oxygen Signal 1 B134 1 12 — 14 — Waveform
(A/F) sensor
heater LH Signal 2 B135 7 12 — 14 — Waveform

sensor RH Shield B137 31 0 0 —
Rear oxygen sensor
B135 2 12 — 14 — Waveform
heater RH signal
sensor LH Shield B137 31 0 0 —
Rear oxygen sensor
B135 3 12 — 14 — Waveform
heater LH signal
Immobilizer communica-
B137 19 10 10 —
tion 1
Immobilizer communica-
B137 27 10 10 —
tion 2
Fuel pump Signal 1 B137 28 0 13 — 14 —
control unit Signal 2 B135 27 0 0 or 5 —
When operating When operating
nothing: 3.5 — 4.5 nothing: 3.5 — 4.5
RES/ACC: RES/ACC:
2.5 — 3.5 2.5 — 3.5
Cruise control command
B136 11 When operating SET/ When operating SET/ —
switch
COAST: COAST:
0.5 — 1.5 0.5 — 1.5
CANCEL: CANCEL:
0 — 0.5 0 — 0.5
ON: 0 ON: 0
Cruise control main switch B136 7 —
OFF: 5 OFF: 5
EN(H6DO)(diag)-19
Signal (V)
Connector Terminal
No. No.
Oil flow con- Signal (+) B134 18 0 0.6 —
trol solenoid
valve RH Signal (") B134 28 0 0 —
Oil flow con- Signal (+) B134 19 0 0.6 —
trol solenoid
valve LH Signal (") B134 29 0 0 —
Oil switching Signal (+) B134 21 0 1.9 —
solenoid valve
RH Signal (") B134 20 0 0 —
Oil switching Signal (+) B135 25 0 1.9 —
solenoid valve
LH Signal (") B135 24 0 0 —
Oil temperature sensor
signal
Variable valve lift diagnosis
B135 21 0 0 —
oil pressure switch RH
Variable valve lift diagnosis
B135 29 0 0 —
oil pressure switch LH
Less than 1 $% Less than 1 $%
More than 4 More than 4
GND (sensor) B136 35 0 0 —
B135 4 0 0 —
GND (power supply)
B135 1 0 0 —
B137 2 0 0 —
B137 1 0 0 —
GND (Front oxygen (A/F)
B134 7 0 0 —
sensor heater RH)
GND (Front oxygen (A/F)
B134 5 0 0 —
sensor heater LH)
GND (Electronic throttle
B137 3 0 0 —
control)
EN(H6DO)(diag)-20

Remarks Specification
1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm racing
• Turn the A/C to OFF.
• Turn all accessory switches to OFF.
EN(H6DO)(diag)-21
Data Link Connector

A: NOTE
CAUTION:
Do not connect any scan tools other than the Subaru Select Monitor and the OBD-II general scan
tools, because the circuit for the Subaru Select Monitor may be damaged.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
EN-00037

3 Empty 11 Empty
4 Empty 12 Ground
5 Empty 13 Ground
6 Empty 14 Empty
7 Empty 15 Empty
8 Empty 16 Empty
EN(H6DO)(diag)-22
8. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up DTC
A: OPERATION OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN data
TOOL (2) MODE $02: Powertrain freeze frame data
1) Prepare a general scan tool (OBD-II general (3) MODE $03: Emission-related powertrain
scan tool) required by SAE J1978. DTC
2) Open the cover and connect the OBD-II general (4) MODE $04: Clear/Reset emission-related
scan tool to the data link connector located in the diagnostic information
lower portion of the instrument panel (on the driv- Read out data according to repair procedures. (For
er’s side). detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning DTCs, refer to the List of Di-
agnostic Trouble Code (DTC). <Ref. to
EN(H6DO)(diag)-66, List of Diagnostic Trouble
Code (DTC).>
EN-02533

Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
01 Number of emission-related powertrain DTC and malfunction indicator light status ON/OFF
06 Short term fuel trim (bank 1) %
07 Long term fuel trim (bank 1) %
10 Air flow rate of manifold absolute pressure sensor g/sec
11 Throttle valve opening angle %
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank
24 V and %
1)
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank
28 V and %
2)
1C On-board diagnostic system —
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE
$01).
EN(H6DO)(diag)-23

Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
02 DTC that caused CARB required freeze frame data storage —
0C Engine speed rpm
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 DTC)
Refer to “Read Diagnostic Trouble Code” for information about data denoting emission-related powertrain
DTC. <Ref. to EN(H6DO)(diag)-32, Read Diagnostic Trouble Code (DTC).>
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-
EN(H6DO)(diag)-24
9. Subaru Select Monitor CAUTION:

A: OPERATION ru Select Monitor and OBD-II general scan tool.
1. HOW TO USE SUBARU SELECT MONI- 5) Turn ignition switch to ON (engine OFF) and turn
TOR Subaru Select Monitor switch to ON.
(A)
EN(H6DO)(diag)-7, PREPARATION TOOL, Gen-
eral Description.>
EN-00040
(A) Power switch
EN-00038 6) Using the Subaru Select Monitor, call up DTC

Monitor. 2. READ DIAGNOSTIC TROUBLE CODE
3) Insert the cartridge to Subaru Select Monitor. (DTC) FOR ENGINE (NORMAL MODE)
<Ref. to EN(H6DO)(diag)-7, PREPARATION
EN(H6DO)(diag)-32, Read Diagnostic Trouble
Code (DTC).>
EN(H6DO)(diag)-32, Read Diagnostic Trouble
Code (DTC).>
EN-00039

connector.
(1) Data link connector located in the lower por-
tion of the instrument panel (on the driver’s
side).
EN-02533

connector.
EN(H6DO)(diag)-25

[YES] key.
Unit of
measure
Engine load Engine load % 3.5%
Engine coolant tempera- & 75!C (After engine is
Engine coolant temperature signal !C
ture warmed-up.)
A/F compensation 1 A/F Compensation 1 % 3.1%
A/F learning 1 A/F learning 1 % 0.0%
A/F compensation 2 A/F Compensation 2 % 4.7%
Intake manifold absolute
Intake manifold absolute pressure mmHg 200 — 300 mmHg
pressure
Engine speed signal Engine speed rpm 600 — 800 rpm
Meter vehicle speed signal Meter vehicle speed km/h 0 km/h
Ignition timing signal Ignition timing deg 13 — 15 deg
Intake air temperature signal Intake air temperature !C (Ambient air temperature)
Amount of intake air Amount of intake air g/s 3.8 g/s
Throttle opening angle signal Throttle valve angle % 1.2 — 1.6%
Front oxygen sensor
Front oxygen sensor voltage value 1 V 0.035 V
voltage value 1
Front oxygen sensor
Front oxygen sensor voltage value 2 V 0.020 V
voltage value 2
Mass air flow voltage Mass air flow voltage V 1.1 — 1.2 V
Injection 1 pulse width Injection 1 pulse width ms 2.82 ms
Injection 2 pulse width Injection 2 pulse width ms 2.82 ms
Knock sensor compensation Knock correction deg 0 deg
Atmospheric pressure signal Atmospheric pressure mmHg (Atmospheric pressure)
(Intake manifold absolute
Intake manifold relative
Intake manifold relative pressure mmHg pressure — Atmospheric
pressure
pressure)
Acceleration opening
Acceleration opening angle signal % 0%
angle
Radiator fan output Radiator fan output % 0%
Purge control solenoid valve duty ratio CPC duty % 0 — 3%
EGR step number EGR step number STEP 0
Generator duty ALT duty % 0%
Fuel pump duty Fuel pump duty % 33%
VVT advance angle
Variable valve timing advance angle amount R deg 0 deg
amount R
VVT advance angle
Variable valve timing advance angle amount L deg 0 deg
amount L
Oil flow control solenoid valve duty R OCV duty R % 9.4%
Oil flow control solenoid valve duty L OCV duty L % 9.4%
Oil flow control solenoid valve current R OCV current R mA 64 mA
Oil flow control solenoid valve current L OCV current L mA 64 mA
EN(H6DO)(diag)-26
Unit of
measure
A/F sensor current value
Front oxygen (A/F) sensor current value 1 mA 0.0 mA
1
A/F sensor current value
Front oxygen (A/F) sensor current value 2 mA 0.0 mA
2
A/F sensor resistance
Front oxygen (A/F) sensor resistance value 1 ' 31 '
value 1
A/F sensor resistance
Front oxygen (A/F) sensor resistance value 2 ' 31 '
value 2
A/F sensor output
Front oxygen (A/F) sensor output lambda 1 — 1.01
lambda 1
A/F sensor output
Front oxygen (A/F) sensor output lambda 2 — 1.00
lambda 2
A/F compensation 3 A/F Compensation 3 % "0.16%
Throttle motor duty Throttle motor duty % "27%
Throttle power supply
Throttle power supply voltage V (Battery voltage)
voltage
Sub throttle sensor volt-
Sub throttle sensor voltage V 1.50 V
age
Main throttle sensor volt-
Main throttle sensor voltage V 0.64 V
age
Sub acceleration sensor
Sub acceleration sensor voltage V 1.10 V
voltage
Main acceleration sensor
Main acceleration sensor voltage V 0.98 V
voltage
Memory vehicle speed Memory vehicle speed km/h 0 km/h
A/F compensation 4 A/F compensation 4 % 0.31%
Fuel level sensor resistance Fuel level resistance ' 4 — 96 '
& 85!C (After engine is
Engine oil temperature Oil Temperature !C
warmed-up.)
Oil switching solenoid valve duty R OSV duty R % 17.3%
Oil switching solenoid valve duty L OSV duty L % 17.3%
Oil switching solenoid valve current R OSV current R mA 192 mA
Oil switching solenoid valve current L OSV current L mA 192 mA
Variable valve lift lift mode VVL Lift Mode — 1
#1 cylinder roughness
#1 cylinder roughness monitor — 0
monitor
monitor
monitor
monitor
monitor
monitor
Test mode terminal Test mode terminal — U check
Neutral position switch signal Neutral SW — Neutral
Idle switch signal Soft idle SW — In idle
Ignition switch signal Ignition SW — ON input
Power steering SW input
Power steering switch signal — OFF input (when OFF)
signal
EN(H6DO)(diag)-27
Unit of
measure
Air conditioning switch signal A/C SW — OFF input (when OFF)
Steering wheel switch signal Steering wheel SW — Hi input
Starter switch signal Starter SW — OFF input
Front oxygen monitor 1 Front oxygen monitor 1 — Rich
Front oxygen monitor 2 Front oxygen monitor 2 — Rich
Knocking signal Knock signal — No
Crankshaft position sensor signal Crankshaft angle signal — Yes
Camshaft position sensor signal Camshaft angle signal — Yes
Rear defogger switch signal Rear defogger SW — OFF input (when OFF)
Blower fan switch signal Blower fan SW — OFF input (when OFF)
Light switch signal Light SW — OFF input (when OFF)
Wiper switch signal Wiper SW — OFF input (when OFF)
A/C lock signal A/C lock signal — OFF input
A/C middle pressure switch signal A/C middle pressure SW — OFF input
A/C compressor relay
A/C compressor relay signal — OFF output
output
AT coordinate retard
AT coordinate retard angle demand signal — Yes
angle demand
AT coordinate fuel cut
AT coordinate fuel cut demand signal — No
demand
Vehicle dynamics control (VDC) torque down prohibition VDC torque down prohi-
— ON
output bition output
VDC torque down
Vehicle dynamics control (VDC) torque down demand — OFF
demand
AT coordinate permis-
AT coordinate permission signal — ON
sion signal
Electronic throttle control motor relay signal ETC motor relay — ON
Stop light switch signal Stop light SW — OFF
SET/COAST switch signal SET/COAST SW — OFF
RESUME/ACCEL switch signal RESUME/ACCEL SW — OFF
Brake switch signal Brake SW — OFF
Main switch signal Main SW — OFF
Body integrated unit data reception Body Int. Unit Data — ON
Body integrated unit counter update Body Int. Unit Count — ON
Cruise control cancel switch signal CC Cancel SW — OFF
EN(H6DO)(diag)-28

5) On the «OBD Menu» display screen, select the {Current Data Display/Save}, and press the [YES] key.
Monitoring test of misfire Misfire monitoring No
Monitoring test of fuel system Fuel system monitoring Finish
Monitoring test of comprehensive component Component monitoring Finish
Test of catalyst Catalyst Diagnosis No
Test of heating-type catalyst Heated catalyst No
Test of evaporative emission purge control system Evaporative purge system No
Test of secondary air system Secondary air system No
Test of air conditioning system refrigerant A/C system refrigerant No
Test of oxygen sensor Oxygen sensor Finish
Test of oxygen sensor heater Oxygen sensor heater Finish
Test of EGR system EGR system Finish
A/F control #1 Fuel system for Bank 1 OPEN early period
A/F control #2 Fuel system for Bank 2 OPEN early period
Load Calculated load valve %
Engine coolant temperature Coolant Temp. !C
A/F compensation #1 Short term fuel trim B1 %
A/F learning #1 Long term fuel trim B1 %
A/F compensation #2 Short term fuel trim B2 %
A/F learning #2 Long term fuel trim B2 %
Intake manifold absolute pressure Mani. Absolute Pressure kPa
Engine speed Engine Speed rpm
Vehicle speed Vehicle Speed km/h
Ignition timing #1 Ignition timing adv. #1 !
Intake air temperature Intake Air Temp. !C
Amount of intake air Mass Air Flow g/s
Throttle valve angle Throttle Opening Angle %
Oxygen sensor #12 Oxygen sensor #12 V
A/F compensation #12 Short term fuel trim #12 %
OBD system OBD System —
Oxygen sensor #11 Oxygen sensor #11 Support
Oxygen sensor #12 Oxygen sensor #12 Support
A/F sensor #11 A/F sensor #11 —
A/F sensor #11 A/F sensor #11 V
NOTE:
For detailed operation procedures, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(H6DO)(diag)-29

DTC of freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 —
Air fuel ratio control system for bank 2 Fuel system for bank 2 —
Short term fuel trim by front oxygen (A/F) sensor (bank 1) Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor (bank 1) Long term fuel trim B1 %
Short term fuel trim by front oxygen (A/F) sensor (bank 2) Short term fuel trim B2 %
Long term fuel trim by front oxygen (A/F) sensor (bank 2) Long term fuel trim B2 %
NOTE:
EN(H6DO)(diag)-30

[YES] key.
Remarks Display Message When LED “ON” required
Test mode signal Test mode terminal D check/U check D check
Neutral position switch signal Neutral SW Neutral/Other than neutral Neutral
Idle switch signal Soft idle SW Idle/Other than idle In idle
Ignition switch signal Ignition SW ON Input/OFF Input ON input
Power steering switch signal Power steering SW ON Input/OFF Input ON input
Air conditioning switch signal A/C SW ON Input/OFF Input ON input
Steering wheel switch signal Steering wheel SW Hi input/Low input Low input
Starter switch signal Starter SW ON Input/OFF Input ON input
Front oxygen monitor 1 FtO2 monitor 1 Lean/Rich Rich
Front oxygen monitor 2 FtO2 monitor 2 Lean/Rich Rich
Knocking signal Knock signal Yes/No Yes
Crankshaft position sensor signal Crankshaft angle signal Yes/No Yes
Camshaft position sensor signal Camshaft angle signal Yes/No Yes
Rear defogger switch signal Rear defogger SW ON Input/OFF Input ON input
Blower fan switch signal Blower fan SW ON Input/OFF Input ON input
Light switch signal Light SW ON Input/OFF Input ON input
Windshield wiper switch signal Wiper SW ON Input/OFF Input ON input
Air conditioning lock signal A/C lock signal ON Input/OFF Input ON input
A/C middle pressure switch signal A/C middle pressure SW ON Input/OFF Input ON input
Air conditioner compressor relay sig-
Compressor relay ON output/OFF output ON output
nal
AT retard angle demand signal AT retard angle demand Yes/No Yes
AT fuel cut signal AT fuel cut Yes/No Yes
VDC torque down prohibition output Torque down output ON/OFF Prohibition
VDC torque down demand Torque down demand Yes/No Yes
AT coordinate permission
AT coordinate permission signal ON/OFF Permission
signal
Electronic throttle control motor relay
ETC motor relay ON/OFF ON
signal
Stop light switch signal Stop SW ON Input/OFF Input ON input
SET/COAST switch signal SET/CST SW ON Input/OFF Input ON input
RESUME/ACCEL switch signal RES/ACC SW ON Input/OFF Input ON input
Brake switch signal Brake SW ON Input/OFF Input ON input
Main switch signal Main SW ON Input/OFF Input ON input
Body integrated unit data reception Body Int. Unit Data Yes/No Yes
Body integrated unit counter update Body Int. Unit Count Yes/No Yes
Cruise control cancel switch signal CC Cancel SW ON Input/OFF Input ON input
NOTE:
EN(H6DO)(diag)-31
10.Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL

Code (DTC) Refers to data denoting emission-related power-
train DTC.
A: OPERATION For details concerning DTCs, refer to the List of Di-
agnostic Trouble Code (DTC). <Ref. to
MODE) Code (DTC).>
1) On the «Main Menu» display screen, select the NOTE:
{Each System Check} and press the [YES] key. Refer to OBD-II general scan tool manufacturer’s
2) On the «System Selection Menu» display instruction manual to access power train DTC
screen, select the {Engine} and press the [YES] (MODE $03).
key.
NOTE:
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
• For details concerning DTC, refer to the List of
Code (DTC).>
MODE)
key.
NOTE:
UAL.
• For details concerning DTC, refer to the List of
Code (DTC).>
EN(H6DO)(diag)-32
Inspection Mode
11.Inspection Mode
A: PROCEDURE
When performing the diagnose without the “List of Diagnostic Trouble Code (DTC)”, refer the item of drive cy-
cle. <Ref. to EN(H6DO)(diag)-38, Drive Cycle.>
DTC Item On condition
P0011 “A” Camshaft Position-Timing Over-Advanced or System Performance (Bank 1) —
P0021 “A” Camshaft Position-Timing Over-Advanced or System Performance (Bank 2) —
P0077 Intake Valve Control Solenoid Circuit High (Bank 1) —
P0083 Intake Valve Control Solenoid Circuit High (Bank 2) —
P0102 Mass or Volume Air Flow Circuit Low Input —
P0103 Mass or Volume Air Flow Circuit High Input —
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input —
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input —
P0112 Intake Air Temperature Circuit Low Input —
P0113 Intake Air Temperature Circuit High Input —
P0117 Engine Coolant Temperature Circuit Low Input —
P0118 Engine Coolant Temperature Circuit High Input —
P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Input —
P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Input —
P0171 System Too Lean (Bank 1) —
P0172 System Too Rich (Bank 1) —
P0174 System Too Lean (Bank 2) —
P0175 System Too Rich (Bank 2) —
P0197 Engine Oil Temperature Sensor Circuit Low —
P0198 Engine Oil Temperature Sensor Circuit High —
P0222 Throttle/Pedal Position Sensor/Switch “B” Circuit Low Input —
P0223 Throttle/Pedal Position Sensor/Switch “B” Circuit High Input —
P0230 Fuel Pump Primary Circuit —
P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) —
P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) —
P0332 Knock Sensor 2 Circuit Low Input (Bank 2) —
P0333 Knock Sensor 2 Circuit High Input (Bank 2) —
P0335 Crankshaft Position Sensor “A” Circuit —
P0340 Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor) —
EN(H6DO)(diag)-33
Inspection Mode

P0345 Camshaft Position Sensor “A” Circuit (Bank 2) —
P0458 Evaporative Emission Control System Purge Control Valve Circuit Low —
P0462 Fuel Level Sensor Circuit Low Input —
P0463 Fuel Level Sensor Circuit High Input —
P0500 Vehicle Speed Sensor —
P0512 Starter Request Circuit —
P0519 Idle Control System Malfunction (Fail-Safe) —
P0558 Generator Circuit Low Input —
P0600 Serial Communication Link —
P0604 Internal Control Module Random Access Memory (RAM) Error —
P0605 Internal Control Module Read Only Memory (ROM) Error —
P0607 Control Module Performance —
P0638 Throttle Actuator Control Range/Performance (Bank 1) —
P0691 Cooling Fan 1 Control Circuit Low —
P0692 Cooling Fan 1 Control Circuit High —
P0700 Transmission Control System (MIL Request) —
P1160 Return Spring Failure —
P1518 Starter Switch Circuit Low input —
P1560 Back-up Voltage Circuit Malfunction —
P2088 OCV Solenoid Valve Signal A Circuit Open (Bank 1) —
P2089 OCV Solenoid Valve Signal A Circuit Short (Bank 1) —
P2092 OCV Solenoid Valve Signal A Circuit Open (Bank 2) —
P2093 OCV Solenoid Valve Signal A Circuit Short (Bank 2) —
P2101 Throttle Actuator Control Motor Circuit Range/Performance —
P2102 Throttle Actuator Control Motor Circuit Low —
P2103 Throttle Actuator Control Motor Circuit High —
P2109 Throttle/Pedal Position Sensor A Minimum Stop Performance —
P2122 Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input —
P2123 Throttle/Pedal Position Sensor/Switch “D” Circuit High Input —
P2127 Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input —
P2128 Throttle/Pedal Position Sensor/Switch “E” Circuit High Input —
P2135 Throttle/Pedal Position Sensor/Switch “A”/“B” Voltage Rationality —
P2138 Throttle/Pedal Position Sensor/Switch “D”/“E” Voltage Rationality —
1. PREPARATION FOR THE INSPECTION • Do not abruptly depress/release clutch pedal

MODE or accelerator pedal during works even when
1) Check battery voltage is more than 12 V and fuel may cause vehicle to jump off free rollers.
remains half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 —
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place blocks or similar items between the rigid racks
it on rigid racks or drive the vehicle onto free rollers. and the vehicle.
WARNING:
brakes are applied.
id rack.
wheels.
EN(H6DO)(diag)-34
Inspection Mode
• Since the rear wheels will also rotate, do not 5) Insert the cartridge to Subaru Select Monitor.
place anything near them. Also, make sure that <Ref. to EN(H6DO)(diag)-7, PREPARATION
nobody goes in front of the vehicle. TOOL, General Description.>
EN-00039
(A)
(B) (A)
EN-00041
(A) Rigid racks EN-02424
(B) Free rollers 7) Connect the Subaru Select Monitor to data link
2. SUBARU SELECT MONITOR ment panel (on the driver’s side).
1) After clearing the memory, check for any remain-
ing unresolved trouble data. <Ref. to EN(H6DO)(di-
ag)-40, Clear Memory Mode.>
2) Idle the engine.
eral Description.>
EN-02533
CAUTION:
EN-00038

Monitor.
EN(H6DO)(diag)-35
Inspection Mode
8) Turn ignition switch to ON (engine OFF) and turn 3) Connect the test mode connector (A) located at
Subaru Select Monitor switch to ON. the lower portion of glove box.
(A)
(A)
EN-00040 EN-02424

(A) Power switch
link connector in the lower portion of the instrument
9) On the «Main Menu» display screen, select the panel (on the driver’s side).
{Each System Check} and press the [YES] key. CAUTION:
10) On the «System Selection Menu» display Do not connect the scan tools except for Suba-
screen, select the {Engine} and press the [YES] ru Select Monitor or OBD-II general scan tool.
key.
• If trouble still remains in the memory, the corre-
sponding DTC appears on the display screen. EN-02533
NOTE: 5) Start the engine.

NOTE:
• Ensure the select lever is placed in the “P” posi-
UAL.
tion before starting. (AT model)
• Depress the clutch pedal when starting the en-
gine. (MT model)
<Ref. to EN(H6DO)(diag)-66, List of Diagnostic
Trouble Code (DTC).> 6) Using the select lever or shift lever, turn the “P”
• Release the parking brake. position switch and the “N” position switch to ON.
• The speed difference between front and rear 7) Depress the brake pedal to turn the brake switch
wheels may light either the ABS warning light, but ON. (AT model)
this indicates no malfunctions. When engine con- 8) Keep the engine speed in the 2,500 — 3,000
trol diagnosis is finished, perform the ABS memory rpm range for 40 seconds.
clearance procedure of self-diagnosis system. 9) Shift the select lever or shift lever in the “D”
range (AT model) or “1st” gear (MT model) and
3. OBD-II GENERAL SCAN TOOL drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
1) After performing the diagnostics and clearing the NOTE:
memory, check for any remaining unresolved trou- • On AWD vehicles, release the parking brake.
ble data: <Ref. to EN(H6DO)(diag)-40, Clear Mem- • The speed difference between front and rear
ory Mode.> wheels may light either the ABS warning light, but
2) Idle the engine. this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
EN(H6DO)(diag)-36
Inspection Mode
NOTE:
OBD-II General Scan Tool Operation Manual.
<Ref. to EN(H6DO)(diag)-66, List of Diagnostic
EN(H6DO)(diag)-37
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are three driving patterns. By driving the vehicle with specified pattern, follow-
ing trouble items could be diagnosed. After the repair of following trouble items, be sure to drive the vehicle
with specified patterns to check the trouble was repaired correctly.
1. PREPARATION FOR DRIVE CYCLE
1) Check battery voltage is more than 12 V and fuel remains half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8
Imp gal)].
2) After performing the diagnostics and clearing the memory, check for any remaining unresolved trouble da-
ta: <Ref. to EN(H6DO)(diag)-40, Clear Memory Mode.>
NOTE:
• Perform the diagnosis after warming up the engine except the engine coolant temperature was specified
at engine start.
• Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine
and perform second diagnosis in same condition.
2. DRIVE THE VEHICLE WITH 80 KM/H (50 MPH) FOR 20 MINUTES, AND THEN IDLE THE EN-
GINE FOR A MINUTE.
Engine coolant temperature at
*P0125 Insufficient Coolant Temperature For Closed Loop Fuel Control engine start is 20!C (68!F) or
less.
*P0420 Catalyst System Efficiency Below Threshold (Bank 1) —
3. 10 MINUTES IDLING
NOTE:
Drive the vehicle in more than 10 km/h (6 MPH) before diagnosis.
*P0459 Evaporative Emission Control System Purge Control Valve Circuit High —
EN(H6DO)(diag)-38
Drive Cycle
4. DRIVE THE VEHICLE WITH FOLLOWING DRIVE PATTERNS
(H)
(C)
97 (60)
(D) (F) (G)
64 (40)
(B) (E)
(A)
0
50 100 150 (I)
EN-00842
(A) Idle the engine for more than 10 (D) Decelerate the vehicle to 64 km/h (G) Stop the vehicle with throttle fully
seconds. (40 MPH) with throttle fully closed. closed.
(B) Accelerate the vehicle to 97 km/h (E) Drive the vehicle at 64 km/h (40 (H) Vehicle speed km/h (MPH)
(60 MPH) within 20 seconds. MPH) for 20 seconds. (I) Sec.
(C) Drive the vehicle at 97 km/h (60 (F) Accelerate the vehicle to 97 km/h
MPH) for 20 seconds. (60 MPH) within 10 seconds.

P0076 Intake Valve Control Solenoid Circuit Low (Bank 1) —
P0082 Intake Valve Control Solenoid Circuit Low (Bank 2) —
*P0101 Mass or Volume Air Flow Circuit Range/Performance —
*P0301 Cylinder 1 Misfire Detected Diagnosis may complete at once
P0400 Exhaust Gas Recirculation Flow —
P0559 Generator Circuit High Input —
P1026 VVL System 1 Malfunction —
P1028 VVL System 2 Malfunction —
EN(H6DO)(diag)-39
Clear Memory Mode
13.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)
key.
switch to OFF.
NOTE:
UAL.
MODE)
key.
7) Turn the ignition switch to OFF and then turn off
the Subaru Select Monitor.
NOTE:
UAL.
EN(H6DO)(diag)-40
Check Mode ment panel (on the driver’s side).
A: OPERATION
eral Description.>
EN-02533
CAUTION:
EN-00038 6) Turn ignition switch to ON (engine OFF) and turn
2) Connect the diagnosis cable to Subaru Select on the Subaru Select Monitor switch.
Monitor.
<Ref. to EN(H6DO)(diag)-7, PREPARATION
EN-00040
(A) Power switch

EN-00039
key.
the [YES] key.
12) Select the desired actuator on the «Actuator
EN-02424 ON/OFF Operation» display screen and press the
[YES] key.
screen.
EN(H6DO)(diag)-41

table.
DESCRIPTION Display
Fuel Pump
ation check
Radiator Fan Relay
operation check
operation check
CPC Solenoid
NOTE:
tional.
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure Switching Solenoid 1
Pressure Switching Solenoid 2
Supercharger Control Solenoid
PCV Solenoid
AAI Solenoid
Atmospheric pressure switching solenoid
Exhaust Bypass Valve Control Permit Flag

UAL.
EN(H6DO)(diag)-42

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H6DO)(diag)-43, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
Malfunction Indicator Light.>
(
2. Malfunction indicator light does not come on. <Ref. to EN(H6DO)(diag)-45, MALFUNCTION INDICATOR LIGHT DOES NOT
COME ON, Malfunction Indicator Light.>
(
3. Malfunction indicator light does not go off. <Ref. to EN(H6DO)(diag)-47, MALFUNCTION INDICATOR LIGHT DOES NOT GO
OFF., Malfunction Indicator Light.>
(
4. Malfunction indicator light does not blink. <Ref. to EN(H6DO)(diag)-48, MALFUNCTION INDICATOR LIGHT DOES NOT
BLINK., Malfunction Indicator Light.>
(
5. Malfunction indicator light keep blinking. <Ref. to EN(H6DO)(diag)-50, MALFUNCTION INDICATOR LIGHT REMAINS BLINK-
ING., Malfunction Indicator Light.>
B: ACTIVATION OF MALFUNCTION 2) After starting the engine, the malfunction indica-

INDICATOR LIGHT tor light goes out. If it does not, either the engine or
the emission control system is malfunctioning.
off), the malfunction indicator light (A) in the combi- (1)
nation meter illuminates. (3)
NOTE: (4)
If the malfunction indicator light does not illuminate, (2)
(4)
EN(H6DO)(diag)-45, MALFUNCTION INDICATOR
LIGHT DOES NOT COME ON, Malfunction Indica- (5)
tor Light.> (6)
EN-01679
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start

(A) test mode connector.
EN-01984
minates.
(2) After the engine starts, malfunction indicator
light blinks in a cycle of 0.5 Hz. (During diagno-
sis)
EN(H6DO)(diag)-43
(3) After the diagnosis is completed, malfunc-

tion indicator light does not blink at a cycle of 3
Hz if there is no fault. Malfunction indicator light
illuminates when the trouble occurs.
(1)
(2)
(4)
(3)
EN-01681
(1) ON
(2) OFF
(4) 1 second
EN(H6DO)(diag)-44

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
i3
8
B38
17
B134 ECM E
B72 B134 i10 B38
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
EN-01985
Step Check Yes No

Check for poor connection when shaking or light illuminate? contact in ECM
pulling ECM connector and harness. connector.
EN(H6DO)(diag)-45
Step Check Yes No

Check the connection of ECM connector. connected? <Ref. to nection of ECM
FU(H6DO)-34, connector.
Engine Control
Module (ECM).>
IDI-16, Combination Meter Assembly.> In this case repair
coupling connector
nector.
2) Measure the voltage between combination Meter Assembly.> • Brown out fuse
5) and battery ter-
minal
• Poor contact in
nector
EN(H6DO)(diag)-46

DIAGNOSIS:
TROUBLE SYMPTOM:
Monitor display.
WIRING DIAGRAM:
IGNITION
B72
SWITCH BATTERY
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER
i10
16
i3
8
B38
17
B134 ECM E
B72 B134 i10 B38
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
4 5 6 8 9 10 11 12 13 14 15 16 17 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
EN-01985
Step Check Yes No

TION METER AND ECM CONNECTOR. light illuminate? circuit in harness <Ref. to
1) Turn the ignition switch to OFF. between combina- FU(H6DO)-34,
2) Disconnect the connector from ECM. tion meter and Engine Control
3) Turn the ignition switch to ON. ECM connector. Module (ECM).>
EN(H6DO)(diag)-47

DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER *1 LHD: 3
RHD: TERMINAL No. RANDOM ARRANGEMENT
i10
*2 LHD: 2
16
*3 LHD: B122
RHD: B138
*3
1 1
* 1
i3
B75 B76
*2
8
B38
A17
D15
A: B134 D: B137 ECM E E
B75 B72 i10 B38
1 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
2 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
A: B134 D: B137 B122 B138
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 5 6 7 8
18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 26 27 28 29 30 31
EN-02491
EN(H6DO)(diag)-48
Step Check Yes No

2) Disconnect the test mode connectors. to
3) Turn the ignition switch to ON. (engine EN(H6DO)(diag)-
OFF) 45, MALFUNC-
TION INDICA-
TOR LIGHT
DOES NOT
COME ON, Mal-
function Indicator
Light.>
2 CHECK HARNESS BETWEEN COMBINA- Does the malfunction indicator Repair the short Go to step 3.
CONNECTOR AND CHASSIS GROUND. '? ness and connec-
3) Measure the resistance of harness In this case repair
tor and chassis
ground
4 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Go to step 5.
connector.
connector. FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-49

DIAGNOSIS:
TROUBLE SYMPTOM:
Malfunction indicator light blinks without test mode connector connected.
WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.5 SBF-7 SBF-1
6 3
3
4
COMBINATION
METER *1 LHD: 3
i10
*2 LHD: 2
16
*3 LHD: B122
RHD: B138
*3
1 1
* 1
i3
B75 B76
*2
8
B38
A17
D15
A: B134 D: B137 ECM E E
B75 B72 i10 B38
1 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
2 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20
A: B134 D: B137 B122 B138
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 5 6 7 8
18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 26 27 28 29 30 31
EN-02491
Step Check Yes No

Malfunction indica-
tor light blinks
when test mode
connector is con-
nected.
EN(H6DO)(diag)-50
Step Check Yes No

NECTOR AND CHASSIS GROUNDING TER- '? circuit in harness <Ref. to
MINAL. between ECM and FU(H6DO)-34,
1) Turn the ignition switch to OFF. test mode connec- Engine Control
2) Disconnect the connector from ECM. tor. Module (ECM).>
EN(H6DO)(diag)-51

A: PROCEDURE
(
2. Inspection of starter motor circuit <Ref. to EN(H6DO)(diag)-53, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
(
3. Inspection of ECM power supply and ground line. <Ref. to EN(H6DO)(diag)-56, CHECK POWER SUPPLY AND GROUND
(
4. Inspection of ignition control system. <Ref. to EN(H6DO)(diag)-59, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
(
5. Inspection of fuel pump circuit. <Ref. to EN(H6DO)(diag)-62, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
(
6. Inspection of fuel injector circuit. <Ref. to EN(H6DO)(diag)-64, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H6DO)(diag)-52

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-40,
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE,
Inspection Mode.>.
WIRING DIAGRAM:
IGNITION
B72
SWITCH
BATTERY
SBF-7 SBF-1
3
2
No.21
E
*3
*1
STARTER
RELAY
B225 STARTER MOTOR
*2
*4
M
B14 *1 LHD: 15
RHD: 16
*2 LHD: 16
RHD: 15
*3 LHD: 13
RHD: 14
*4 LHD: 14
RHD: 13
B32
D8
ECM
B: B135
D: B137
B72 B225
B: B135 D: B137
1 2 3 1 2 9 13 17 21
4 5 6 10 14 18 22 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4
11 12 15 16 19 20 23 24 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
5 6
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
7 8 25 29 33 37 28 29 30 31 32 33 34 35 26 27 28 29 30 31
26 30 34 38
27 28 31 32 35 36 39 40
EN-02492
EN(H6DO)(diag)-53
Step Check Yes No

ate?
EN(H6DO)(diag)-32, OPERA- vant DTC using contact in ECM
TION, Read Diagnostic Trouble List of Diagnostic connector.
Code (DTC).> Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
66, List of Diag-
nostic Trouble
Code (DTC).>
TOR.
motor.
ground.
NOTE:
Shift the select lever to “P” or “N” range.
1) Turn the ignition switch to OFF. SC(H6DO)-6, cable.
starter motor.
ground.
ignition switch connector and chassis ground. fuse SBF No.7 and
Connector & terminal SBF No.1.
switch.
switch terminals while turning the ignition
Terminals
No. 2 — No. 3:
EN(H6DO)(diag)-54
Step Check Yes No

2) Disconnect the connector from starter relay. relay and ignition
3) Connect the connector to ignition switch. switch.
relay connector and chassis ground while turn-
LHD model
RHD model
relay terminals.
Terminals
No. 13 — No. 14:
10 CHECK INPUT VOLTAGE FROM ECM. Is the voltage more than 10 V? Replace the ECM. Repair the open or
1) Turn the ignition switch to OFF. <Ref. to ground short cir-
2) Connect the connector to starter relay. FU(H6DO)-34, cuit in harness
3) Disconnect the connectors from ECM. Engine Control between ECM and
4) Measure the voltage between ECM and Module (ECM).> starter relay.
chassis ground.
EN(H6DO)(diag)-55

ULE (ECM)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
3 TO OXYGEN SENSOR SBF-6

5
SBF-8
6
4
No.13
2
1 IGNITION
B72 BATTERY
SWITCH
6 3
D16
B19
D14
B5
B6
A: B134
B: B135 ECM
D: B137
B12
A4
A5
A6
A7
D3
D7
D1
D2
B1
B4
B21
54
52
12
37
34
36
35
E2
E E
B72 B47 B21 A: B134 B: B135 D: B137
1 2 3 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11
4 5 6 3 4 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
12 13 14 15 16 17 18 19 20 21 22
5 6 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02493
EN(H6DO)(diag)-56
Step Check Yes No

No. 1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
(B47) No. 2 (+) — Chassis ground ("): main relay connec-
tor.
EN(H6DO)(diag)-57
Step Check Yes No

2) Measure the voltage between ECM con- <Ref. to cuit in harness
nector and chassis ground. EN(H6DO)(diag)- between ECM
Connector & terminal 59, IGNITION connector and
(B135) No. 5 (+) — Chassis ground ("): CONTROL SYS- main relay connec-
(B135) No. 6 (+) — Chassis ground ("): TEM, Diagnostics tor.
for Engine Start-
ing Failure.>
EN(H6DO)(diag)-58

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN
RELAY B327
B225 RELAY 2
HOLDER
SBF-8
2 1 4 6
B135 ECM
18
15
14
17
16
13
B21
14
15
49
13
16
17
18
E2
E31 E32 E33 E34 E45 E46

2
1
2
3
1
2
3
1
3
1
3
1
3
3
1
2
E E
IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
B225 B21 B135

E31 E34 B327
E32 E45 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
1 2 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
E33 E46 3 4 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
5 6 5 6 28 29 30 31 32 33 34 35
34 35 36 37 38 39 40 41
1 7 8 25 29 33 37
42 43 44 45 46 47
2 26 30 34 38
48 49 50 51 52 53 54
3 27 28 31 32 35 36 39 40
EN-02494
Step Check Yes No

1 CHECK SPARK PLUG CONDITION. Is the spark plug’s status OK? Go to step 2. Replace the spark
1) Remove the spark plug. <Ref. to plug.
IG(H6DO)-4, REMOVAL, Spark Plug.>
2) Check the spark plug condition. <Ref. to
IG(H6DO)-5, INSPECTION, Spark Plug.>
EN(H6DO)(diag)-59
Step Check Yes No

1) Connect the spark plug to ignition coil. inder? system. <Ref. to
2) Release the fuel pressure. EN(H6DO)(diag)-
3) Contact the spark plug’s thread portion on 62, FUEL PUMP
engine. CIRCUIT, Diag-
4) While opening the throttle valve fully, start nostics for Engine
the engine to check that spark occurs at each Starting Failure.>
cylinder.
& ignitor ASSY. In this case repair
Connector & terminal tor ASSY, and igni-
coil & ignitor ASSY connector and engine In this case repair
(E45) No. 2 — Engine ground: grounding terminal
TOR. tor.
2) Disconnect the connector from ECM. In this case repair
(B135) No. 16 — (E33) No. 1:
(B135) No. 15 — (E34) No. 1:
(B135) No. 14 — (E45) No. 1:
(B135) No. 13 — (E46) No. 1:
EN(H6DO)(diag)-60
Step Check Yes No

TOR. ness between
7 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Check fuel pump
Check poor contact in ECM connector. connector? contact in ECM circuit. <Ref. to
connector. EN(H6DO)(diag)-
62, FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
EN(H6DO)(diag)-61

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
No.11
1 2
FUEL PUMP
RELAY B362
*2
*71
*3
10
FUEL PUMP
CONTROL UNIT
*1 LHD: 16
RHD: 4
R122
*2 LHD: B97
RHD: B98
*3 LHD: R1
7
6
9
8
RHD: R2
*4 LHD: 6
RHD: 5
*3 *5 LHD: 15
* 54
RHD: 6
*
*2
D28
B27
5
6
FUEL ECM
PUMP E E
R58 M B: B135
D: B137
B362 B98 R122 R58 B: B135 D: B137
1 2 3 1 2 3 4 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3
1 2 4 5 6 7 8 5 6 7 8 9 10 3 4 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
4
5 6 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
5 B97 28 29 30 31 32 33 34 35 26 27 28 29 30 31
7 8
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
EN-02504
EN(H6DO)(diag)-62
Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Display DTC.
PUMP. operating sound? injector circuit. <Ref. to
Make sure that fuel pump is in operation for <Ref. to EN(H6DO)(diag)-
two seconds when turning the ignition switch to EN(H6DO)(diag)- 32, OPERATION,
ON. 64, FUEL INJEC- Read Diagnostic
NOTE: TOR CIRCUIT, Trouble Code
Fuel pump operation can also be executed us- Diagnostics for (DTC).>
ing Subaru Select Monitor. Engine Starting
Refer to “Compulsory Valve Operation Check Failure.>
Mode” for procedures. <Ref. to
EN(H6DO)(diag)-41, Compulsory Valve Oper-
ation Check Mode.>
EN(H6DO)(diag)-63

CAUTION:
• After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-
40, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCE-
WIRING DIAGRAM:
MAIN RELAY BATTERY
SBF-8
6
4
5
3
2
1
B47
B136 ECM
2
6
1
3
B21
44
46
48
42
43
47
45 E2
E5 E16 E6 E17 E43 E44

2
1
2
1
E
FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
E43 E44 B47 B136 B21
E5 E16 1 2 1 2 3 4 5 6
3 4 1 2 3 4 5 6 7 8 9 10 11
7 8 9 10 11 12 13 14 15 16
E6 E17 12 13 14 15 16 17 18 19 20 21 22
5 6 17 18 19 20 21 22 23 24 25 26 27
23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 35
1 2
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
EN-02505
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(H6DO)-27,
fuel injector emits operating sound. Use a INSPECTION,
sound scope or apply a screwdriver to the Fuel Pressure.>
injector for this check.
EN(H6DO)(diag)-64
Step Check Yes No

3) Turn the ignition switch to ON. In this case repair
#5 (E43) No. 2 (+) — Engine ground ("): tor
coupling connector
• Poor contact in
fuel injector con-
nector
between ECM and fuel injector connector. In this case repair
#5 (B136) No. 2 — (E43) No. 1: • Poor contact in
#6 (B136) No. 1 — (E44) No. 1: coupling connector
injector terminals.
Terminals
No. 1 — No. 2:
6 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Inspection using
connector. tics Table”. <Ref.
to
EN(H6DO)(diag)-
265, INSPEC-
TION, General
Diagnostic Table.>
EN(H6DO)(diag)-65

A: LIST
DTC Item Reference
P0011 “A” Camshaft Position-Timing Over- <Ref. to EN(H6DO)(diag)-72, DTC P0011 “A” CAMSHAFT POSITION - TIM-
Advanced or System Performance ING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diag-
(Bank 1) nostic Procedure with Diagnostic Trouble Code (DTC).>
P0021 “A” Camshaft Position-Timing Over- <Ref. to EN(H6DO)(diag)-73, DTC P0021 “A” CAMSHAFT POSITION - TIM-
Advanced or System Performance ING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diag-
(Bank 2) nostic Procedure with Diagnostic Trouble Code (DTC).>
P0030 HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H6DO)(diag)-74, DTC P0030 HO2S HEATER CONTROL CIR-
Sensor 1) CUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0031 HO2S Heater Control Circuit Low <Ref. to EN(H6DO)(diag)-76, DTC P0031 HO2S HEATER CONTROL CIR-
(Bank 1 Sensor 1) CUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0032 HO2S Heater Control Circuit High <Ref. to EN(H6DO)(diag)-79, DTC P0032 HO2S HEATER CONTROL CIR-
(Bank 1 Sensor 1) CUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0050 HO2S Heater Control Circuit (Bank 2 <Ref. to EN(H6DO)(diag)-86, DTC P0050 HO2S HEATER CONTROL CIR-
Sensor 1) CUIT (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0076 Intake Valve Control Solenoid Circuit <Ref. to EN(H6DO)(diag)-98, DTC P0076 INTAKE VALVE CONTROL
Low (Bank 1) SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic
High (Bank 1) SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic
Low (Bank 2) SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic
High (Bank 2) SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic
P0101 Mass or Volume Air Flow Circuit <Ref. to EN(H6DO)(diag)-106, DTC P0101 MASS OR VOLUME AIR FLOW
Range/Performance CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic
P0102 Mass or Volume Air Flow Circuit Low <Ref. to EN(H6DO)(diag)-108, DTC P0102 MASS OR VOLUME AIR FLOW
(DTC).>
EN(H6DO)(diag)-66
DTC Item Reference

P0103 Mass or Volume Air Flow Circuit High <Ref. to EN(H6DO)(diag)-111, DTC P0103 MASS OR VOLUME AIR FLOW
(DTC).>
P0107 Manifold Absolute Pressure/Baro- <Ref. to EN(H6DO)(diag)-113, DTC P0107 MANIFOLD ABSOLUTE PRES-
metric Pressure Circuit Low Input SURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Pro-
P0108 Manifold Absolute Pressure/Baro- <Ref. to EN(H6DO)(diag)-116, DTC P0108 MANIFOLD ABSOLUTE PRES-
metric Pressure Circuit High Input SURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Pro-
P0112 Intake Air Temperature Circuit Low <Ref. to EN(H6DO)(diag)-119, DTC P0112 INTAKE AIR TEMPERATURE
(DTC).>
P0113 Intake Air Temperature Circuit High <Ref. to EN(H6DO)(diag)-121, DTC P0113 INTAKE AIR TEMPERATURE
(DTC).>
P0117 Engine Coolant Temperature Circuit <Ref. to EN(H6DO)(diag)-124, DTC P0117 ENGINE COOLANT TEMPERA-
Low Input TURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0118 Engine Coolant Temperature Circuit <Ref. to EN(H6DO)(diag)-126, DTC P0118 ENGINE COOLANT TEMPERA-
High Input TURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0122 Throttle/Pedal Position Sensor/ <Ref. to EN(H6DO)(diag)-129, DTC P0122 THROTTLE/PEDAL POSITION
Switch “A” Circuit Low Input SENSOR/SWITCH “A” CIRCUIT LOW INPUT, Diagnostic Procedure with
Switch “A” Circuit High Input SENSOR/SWITCH “A” CIRCUIT HIGH INPUT, Diagnostic Procedure with
P0125 Insufficient Coolant Temperature For <Ref. to EN(H6DO)(diag)-133, DTC P0125 INSUFFICIENT COOLANT
P0131 O2 Sensor Circuit Low Voltage (Bank <Ref. to EN(H6DO)(diag)-134, DTC P0131 O2 SENSOR CIRCUIT LOW
P0132 O2 Sensor Circuit High Voltage <Ref. to EN(H6DO)(diag)-136, DTC P0132 O2 SENSOR CIRCUIT HIGH
P0133 O2 Sensor Circuit Slow Response <Ref. to EN(H6DO)(diag)-138, DTC P0133 O2 SENSOR CIRCUIT SLOW
(Bank 1 Sensor 1) RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0134 O2 Sensor Circuit No Activity <Ref. to EN(H6DO)(diag)-140, DTC P0134 O2 SENSOR CIRCUIT NO
P0153 O2 Sensor Circuit Slow Response <Ref. to EN(H6DO)(diag)-153, DTC P0153 O2 SENSOR CIRCUIT SLOW
(Bank 2 Sensor 1) RESPONSE (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic
EN(H6DO)(diag)-67
DTC Item Reference

P0154 O2 Sensor Circuit No Activity <Ref. to EN(H6DO)(diag)-155, DTC P0154 O2 SENSOR CIRCUIT NO
P0171 System Too Lean (Bank 1) <Ref. to EN(H6DO)(diag)-163, DTC P0171 SYSTEM TOO LEAN (BANK 1),
P0172 System Too Rich (Bank 1) <Ref. to EN(H6DO)(diag)-163, DTC P0172 SYSTEM TOO RICH (BANK 1),
P0174 System Too Lean (Bank 2) <Ref. to EN(H6DO)(diag)-163, DTC P0174 SYSTEM TOO LEAN (BANK 2),
P0175 System Too Rich (Bank 2) <Ref. to EN(H6DO)(diag)-164, DTC P0175 SYSTEM TOO RICH (BANK 2),
P0197 Engine Oil Temperature Sensor Cir- <Ref. to EN(H6DO)(diag)-166, DTC P0197 ENGINE OIL TEMPERATURE
cuit Low SENSOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0198 Engine Oil Temperature Sensor Cir- <Ref. to EN(H6DO)(diag)-168, DTC P0198 ENGINE OIL TEMPERATURE
cuit High SENSOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Switch “B” Circuit Low Input SENSOR/SWITCH “B” CIRCUIT LOW INPUT, Diagnostic Procedure with
Switch “B” Circuit High Input SENSOR/SWITCH “B” CIRCUIT HIGH INPUT, Diagnostic Procedure with
P0230 Fuel Pump Primary Circuit <Ref. to EN(H6DO)(diag)-174, DTC P0230 FUEL PUMP PRIMARY CIR-
P0301 Cylinder 1 Misfire Detected <Ref. to EN(H6DO)(diag)-177, DTC P0301 CYLINDER 1 MISFIRE
P0327 Knock Sensor 1 Circuit Low Input <Ref. to EN(H6DO)(diag)-185, DTC P0327 KNOCK SENSOR 1 CIRCUIT
(Bank 1 or Single Sensor) LOW INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
P0328 Knock Sensor 1 Circuit High Input <Ref. to EN(H6DO)(diag)-187, DTC P0328 KNOCK SENSOR 1 CIRCUIT
(Bank 1 or Single Sensor) HIGH INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
P0332 Knock Sensor 2 Circuit Low Input <Ref. to EN(H6DO)(diag)-189, DTC P0332 KNOCK SENSOR 2 CIRCUIT
(Bank 2) LOW INPUT (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0333 Knock Sensor 2 Circuit High Input <Ref. to EN(H6DO)(diag)-191, DTC P0333 KNOCK SENSOR 2 CIRCUIT
(Bank 2) HIGH INPUT (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H6DO)(diag)-68
DTC Item Reference

P0335 Crankshaft Position Sensor “A” Cir- <Ref. to EN(H6DO)(diag)-193, DTC P0335 CRANKSHAFT POSITION SEN-
cuit SOR “A” CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0340 Camshaft Position Sensor “A” Circuit <Ref. to EN(H6DO)(diag)-195, DTC P0340 CAMSHAFT POSITION SEN-
(Bank 1 or Single Sensor) SOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
P0345 Camshaft Position Sensor “A” Circuit <Ref. to EN(H6DO)(diag)-197, DTC P0345 CAMSHAFT POSITION SEN-
(Bank 2) SOR “A” CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0400 Exhaust Gas Recirculation Flow <Ref. to EN(H6DO)(diag)-199, DTC P0400 EXHAUST GAS RECIRCULA-
TION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0420 Catalyst System Efficiency Below <Ref. to EN(H6DO)(diag)-202, DTC P0420 CATALYST SYSTEM EFFI-
P0458 Evaporative Emission Control Sys- <Ref. to EN(H6DO)(diag)-203, DTC P0458 EVAPORATIVE EMISSION
P0459 Evaporative Emission Control Sys- <Ref. to EN(H6DO)(diag)-205, DTC P0459 EVAPORATIVE EMISSION
P0462 Fuel Level Sensor Circuit Low Input <Ref. to EN(H6DO)(diag)-207, DTC P0462 FUEL LEVEL SENSOR CIR-
(DTC).>
P0463 Fuel Level Sensor Circuit High Input <Ref. to EN(H6DO)(diag)-207, DTC P0463 FUEL LEVEL SENSOR CIR-
(DTC).>
P0500 Vehicle Speed Sensor <Ref. to EN(H6DO)(diag)-207, DTC P0500 VEHICLE SPEED SENSOR,
P0512 Starter Request Circuit <Ref. to EN(H6DO)(diag)-208, DTC P0512 STARTER REQUEST CIRCUIT,
P0519 Idle Control System Malfunction <Ref. to EN(H6DO)(diag)-211, DTC P0519 IDLE CONTROL SYSTEM MAL-
(Fail-Safe) FUNCTION (FAIL-SAFE), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0558 Alternator Circuit Low <Ref. to EN(H6DO)(diag)-211, DTC P0558 ALTERNATOR CIRCUIT LOW,
P0559 Alternator Circuit High <Ref. to EN(H6DO)(diag)-212, DTC P0559 ALTERNATOR CIRCUIT HIGH,
P0600 Serial Communication Link <Ref. to EN(H6DO)(diag)-213, DTC P0600 SERIAL COMMUNICATION
P0604 Internal Control Module Random <Ref. to EN(H6DO)(diag)-214, DTC P0604 INTERNAL CONTROL MODULE
Access Memory (RAM) Error RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
P0605 Internal Control Module Read Only <Ref. to EN(H6DO)(diag)-215, DTC P0605 INTERNAL CONTROL MODULE
Memory (ROM) Error READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diag-
P0607 Control Module Performance <Ref. to EN(H6DO)(diag)-216, DTC P0607 CONTROL MODULE PERFOR-
MANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638 Throttle Actuator Control Range/Per- <Ref. to EN(H6DO)(diag)-217, DTC P0638 THROTTLE ACTUATOR CON-
formance (Bank 1) TROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diag-
P0691 Cooling Fan 1 Control Circuit Low <Ref. to EN(H6DO)(diag)-218, DTC P0691 COOLING FAN 1 CONTROL
P0692 Cooling Fan 1 Control Circuit High <Ref. to EN(H6DO)(diag)-218, DTC P0692 COOLING FAN 1 CONTROL
(DTC).>
EN(H6DO)(diag)-69
DTC Item Reference

P0700 Transmission Control System (MIL <Ref. to EN(H6DO)(diag)-218, DTC P0700 TRANSMISSION CONTROL
Code (DTC).>
P1026 VVL System 1 Performance <Ref. to EN(H6DO)(diag)-219, DTC P1026 VVL SYSTEM 1 PERFOR-
P1028 VVL System 2 Performance <Ref. to EN(H6DO)(diag)-221, DTC P1028 VVL SYSTEM 2 PERFOR-
P1160 Return Spring Failure <Ref. to EN(H6DO)(diag)-223, DTC P1160 RETURN SPRING FAILURE,
P1492 EGR Solenoid Valve Signal #1 Cir- <Ref. to EN(H6DO)(diag)-223, DTC P1492 EGR SOLENOID VALVE SIG-
cuit Malfunction (Low Input) NAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with
cuit Malfunction (High Input) NAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
P1518 Starter Switch Circuit Low Input <Ref. to EN(H6DO)(diag)-228, DTC P1518 STARTER SWITCH CIRCUIT
P1560 Back-Up Voltage Circuit Malfunction <Ref. to EN(H6DO)(diag)-231, DTC P1560 BACK-UP VOLTAGE CIRCUIT
MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P2088 OCV Solenoid Valve Signal A Circuit <Ref. to EN(H6DO)(diag)-233, DTC P2088 OCV SOLENOID VALVE SIG-
Open (Bank 1) NAL A CIRCUIT OPEN (BANK 1), Diagnostic Procedure with Diagnostic
Short (Bank 1) NAL A CIRCUIT SHORT (BANK 1), Diagnostic Procedure with Diagnostic
Open (Bank 2) NAL A CIRCUIT OPEN (BANK 2), Diagnostic Procedure with Diagnostic
Short (Bank 2) NAL A CIRCUIT SHORT (BANK 2), Diagnostic Procedure with Diagnostic
P2101 Throttle Actuator Control Motor Cir- <Ref. to EN(H6DO)(diag)-241, DTC P2101 THROTTLE ACTUATOR CON-
cuit Range/Performance TROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
cuit Low TROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
EN(H6DO)(diag)-70
DTC Item Reference

cuit High TROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P2109 Throttle Angle Sensor Closed Posi- <Ref. to EN(H6DO)(diag)-249, DTC P2109 THROTTLE ANGLE SENSOR
tion Error CLOSED POSITION ERROR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Switch “D” Circuit Low Input SENSOR/SWITCH “D” CIRCUIT LOW INPUT, Diagnostic Procedure with
Switch “D” Circuit High Input SENSOR/SWITCH “D” CIRCUIT HIGH INPUT, Diagnostic Procedure with
Switch “E” Circuit Low Input SENSOR/SWITCH “E” CIRCUIT LOW INPUT, Diagnostic Procedure with
Switch “E” Circuit High Input SENSOR/SWITCH “E” CIRCUIT HIGH INPUT, Diagnostic Procedure with
Switch “A”/“B” Voltage Rationality SENSOR/SWITCH “A” / “B” VOLTAGE RATIONALITY, Diagnostic Proce-
Switch “D”/“E” Voltage Rationality SENSOR/SWITCH “D” / “E” VOLTAGE RATIONALITY, Diagnostic Proce-
EN(H6DO)(diag)-71
ENGINE SECTION 3

MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)

approval.

EN(H6DO)(diag)
Page
11. Inspection Mode........................................................................................33
12. Drive Cycle................................................................................................38

A: DTC P0011 “A” CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYS-
TEM PERFORMANCE (BANK 1)
TROUBLE SYMPTOM:
• Engine stalls.
CAUTION:
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, Inspection
Mode.>.
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY

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2004 Model Year

ENGINE SECTION 1 (Pub.No.G2320GE2)

ENGINE SECTION 2 (Pub.No.G2320GE3)

ENGINE SECTION 3 (Pub.No.G2320GE4)

TRANSMISSION SECTION (Pub.No.G2320GE5)

CHASSIS SECTION (Pub.No.G2320GE6)

BODY SECTION (Pub.No.G2320GE7)

WIRING SYSTEM SECTION (Pub.No.G2320GE8)

HOW TO USE THIS MANUALS HU

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G2320GE1

The manuals contain the latest information at the

1. How to Use This Manuals

:Should be lubricated with oil.

(20) :Should be lubricated with grease.

15.Main Shaft Assembly for Sin- (A)

11) Tighten the lock nuts to the specified torque us-

(A) Component (D) Cautions (G) Tightening torque

5MT: 5-forward speeds with synchromesh and 1-reverse

5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse

2.5 L SOHC 3.0 L DOHC

1. Precaution 7. AIRBAG DISPOSAL

bility of static electricity. Always use a static elec- (B)

(A) Front (B) Rear

(1) Front crossmember (2) Rear differential

(1) Hook for tie-down

• CHAIN DIRECTION AT TIE-DOWN CONDI- • VEHICLE SINKING VOLUME AT TIE-DOWN

• CHAIN PULLING RANGE AT TIE-DOWN CON-

(3) (3) (3) (3)

(1) Chain pulling range at tie-down condition

Marked ❍: OK, Marked ✕: Prohibited, Marked ▲: Conditionally OK.

• WHEN WIDER HOOD OPENING IS NECESSARY

13.SPEEDOMETER TEST (3) Conduct the speedometer test work.

14.BRAKE TEST Specifications:

(A) Balancer body

(2) When the brake dragging force is large.

(1) Engine serial number (Punch mark) (1) AT type label

• MANUAL TRANSMISSION VA1-TYPE

(1) Transmission serial No. (1) Type (label)

ID-00056 (1) Type (label)

(1) Type (white paint)

3. MODEL NUMBER PLATE

Digits Code Meaning Details

The engine and transmission type are as follows:

SAE viscosity No. and applicable temperature

(˚C) –30 –20 –10 0 10 20 30 40

(˚F) –22 –4 14 32 50 68 86 104

(˚C) –30 –20 –10 0 10 20 30 40

(˚F) –22 –4 14 32 50 68 86 104

SAE viscosity No. and applicable temperature

(˚F) –30 –20 –10 0 10 20 30 40

(˚C) –22 –4 14 32 50 68 86 104

PROCEDURE Check point

CHECKS WITH ENGINE RUNNING

DYNAMIC TEST WITH VEHICLE RUNNING

CHECKS AFTER DYNAMIC TEST

PROCEDURE Check point

1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER

4) Press the driver’s side power door lock switch to

4) Pull the outer handles to ensure that doors will

9. CHECK REAR GATE FOR LOCK/UN-

10.OPERATION CHECK OF FUEL LID PI-00195

(A) MAX. level