2001 impreza service manual quick reference index engine 1 section
Contents
1. 127 2 Fill engine coolant lt Ref to CO 25 FILLING OF ENGINE COOLANT REPLACEMENT Engine Coolant gt CO 51 ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 13 Engine Cooling System Trouble in General A INSPECTION Trouble Possible cause Corrective action Replenish engine coolant inspect for leakage and repair 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 ignition control system lt Ref to EN SOHC 2 Basic Diagnostic Procedure gt or g Improper ignition timing lt Ref to EN SOHCw oOBD 2 Basic Diagnostic Proce dure gt or lt Ref to EN DOHC TURBO 2 PROCE DURE Basic Diagnostic Procedure gt h Clogged or leaking radiator Clean or repair or replace Over heating i Improper engine oil in engine coolant Replace engine coolant Inspect and repair fuel injection system lt Ref to EN SOHC 2 Basic Diagnostic Procedure gt or j Air fuel mixture ratio too lean lt Ref to EN SOHCw oOBD 2 Basic Diagnostic Proce dure gt or lt Ref to EN DOHC TURBO 2 PROCE DURE Basic Diagnostic Procedure gt k Excessive back pressure in exhaust system Clean or replace Insufficient clearance between piston and cylinder Adjust or replace m Slipping clutch Repair or replace Dragging brake Adjust I2. No 25 Is the fuse blown out Is the resistance more than 1 MQ Is the resistance less than 1 Q Replace fuse Go to step 11 Go to step 12 Repair open circuit in harness between main fan relay and ignition switch Replace main fan relay Replace main fan relay CHECK HARNESS BETWEEN MAIN FAN RELAY TERMINAL AND MAIN FAN MOTOR CONNECTOR Measure resistance of harness between main fan motor connector and main fan relay termi nal Connector amp terminal F17 2 F66 No 25 Is the resistance less than 1 Q Go to step 13 Repair open circuit in harness between main fan motor connector and main fan relay terminal CHECK HARNESS BETWEEN MAIN FAN RELAY AND ECM 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between main fan relay connector and ECM connector Connector amp terminal F66 No 27 B134 No 3 Is the resistance less than 1 Q Go to step 14 Repair open circuit in harness between main fan relay and ECM NOTE CHECK POOR CONTACT Check poor contact in connector between main fan and ECM Is there poor contact in con nector between main fan motor and ECM Inspection by your Subaru distributor is required because probable cause is deterioration of multiple parts CO 12 Repair poor con tact connector Contact with your Subaru distributor RADIATOR MAIN FAN SYSTE
3. 1 NON TURBO MODEL 1 Disconnect battery ground cable RADIATOR COOLING 5 Disconnect radiator outlet hose from thermostat cover vehi 2 Lift up the vehicle 3 Drain engine coolant completely lt Ref to CO 25 DRAINING OF ENGINE COOLANT RE PLACEMENT Engine Coolant gt 4 Disconnect connectors of radiator main fan A and sub fan B motor EN0077 6 Disconnect ATF cooler hoses from radiator cles only EN0078 EN0102 7 Lower the vehicle 8 Remove air intake duct 37 B2M2925 AT COOLING 10 Remove reservoir tank RADIATOR 15 Lift radiator up and away from vehicle B2M2926 2 Kr db NS SUN M Q EE B2M2933 EES AH B2M2930 Remove radiator upper brackets 13 B2M2932 14 While slightly lifting radiator slide it to left CO 38 RADIATOR 2 TURBO MODEL WARNING The radiator is pressurized Wait until engine cools down before working on the radiator 1 Set the vehicle on the lift 2 Disconnect battery ground cable 3 Lift up the vehicle 4 Remove under cover 5 Drain engine coolant completely lt Ref to CO 25 DRAINING OF ENGINE COOLANT RE PLACEMENT Engine Coolant gt 6 Disconnect connectors of rad
4. 4 Remove under cover 5 Drain engine coolant completely lt Ref to CO 25 DRAINING OF ENGINE COOLANT RE PLACEMENT Engine Coolant gt 6 Disconnect connectors from radiator main fan and sub fan motors 7 Remove bolt which installs water by pass pipe of oil cooler onto oil pump S2M0027 8 Disconnect radiator outlet hose A and heater hose B from water pump 9 Disconnect water by pass hose C and oil cool er hose D 10 Lower the vehicle 11 Disconnect over flow hose COOLING 12 Remove reservoir tank 13 Remove radiator main fan and sub fan assem blies Ref to CO 46 REMOVAL Radiator Main Fan and Fan Motor and Ref to CO 48 RE MOVAL Radiator Sub Fan and Fan Motor 14 Remove V belts Ref to ME DOHC TURBO 43 REMOVAL V belt gt 15 Remove timing belt Ref to ME DOHC TUR BO 47 REMOVAL Timing Belt Assembly 16 Remove automatic belt tension adjuster A 17 Remove belt idler B 18 Remove belt idler No 2 C ex is AD A Q B p 9 TOPR O S2M1160A 19 Remove camshaft position sensor lt Ref to FU DOHC 29 REMOVAL Camshaft Po sition Sensor gt 20 Remove left hand camshaft sprockets by using ST ST 499207400 CAMSHAFT SPROCKET WRENCH D IAG z S2M1161A 29 WATER COOLING 21
5. B137 No 17 CHECK POOR CONTACT Check poor contact in connector between sub fan and ECM Is the resistance more than 1 Go to step 13 MQ Go to step 14 Replace sub fan relay Go to step 15 Repair open circuit in harness between sub fan motor connector and sub fan relay terminal Go to step 16 Repair open circuit in harness between sub fan relay and ECM Contact with your Subaru distributor Is there poor contact in con nector between sub fan motor and ECM Repair poor con tact connector CO 22 RADIATOR SUB FAN SYSTEM CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 V TOR CAUTION Be careful not to overheat engine during re pair 1 Turn ignition switch to OFF 2 Disconnect connector from sub fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 96 C 205 F 4 Turn the A C switch ON 5 Measure voltage while A C compressor is rotating 6 Measure voltage between sub fan motor connector and chassis ground Connector amp terminal F16 No 2 Chassis ground Go to step 18 COOLING Go to step 20 CHECK POOR CONTACT Check poor contact in sub fan motor connec tor Is there poor contact in sub fan motor connector Repair poor con tact in sub fan motor connector Go to step 19 CHECK SUB FAN MOTOR Connect battery positive terminal to termi nal No 2 and negative termi
6. s 7 21122 5 10 15 26 27128 1 26 27 28 2 4 6 8129 34 35 23 1112 16 19 20 24 30 E EN0880 9 RADIATOR MAIN FAN SYSTEM COOLING 2 TURBO MODEL BATTERY SBF 1 CN w CD IGNITION 872 SWITCH LHD RHD LHD RHD EH SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 MOTOR MOTOR AIR CONDITIONING RELAY HOLDER Gi ive 27 lt ED r3 GD ma Ele ers 21 22 25 121 TS 14 TES Ee TL Te 9 112131415 rA e 7 8 9 26 to t9 14 15 t7 18 19 20 21 1213 14 15 16 1718 19 20 21 22 23 24 314 Eee E e 30 22 23 24125 26 27128 29 30 31 Ge 1121314 516 718 9 10 11 12 13 14 15 16 17 18 RHD EN0260 CO 10 RADIATOR MAIN FAN SYSTEM COOLING B INSPECTION 1 NON TURBO MODEL DETECTING CONDITION Vehicle speed is below 19 km h 12 MPH Condition TROUBLE SYMPTOM Engine coolant temperature is above 95 C Radiator main fan does not rotate under the 203 F above conditions Step Check Yes No CHECK POWER SUPPLY TO MAIN FAN MO the volt
7. 18 1 ft lb ee Ve JA o Ec S2M1163 CO 32 WATER 4 Install left hand camshaft sprockets by using ST ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque 98 10 0 kgf m 72 4 ft lb S2M1161A 5 Install camshaft position sensor lt Ref to FU DOHC TURBO 29 INSTALLATION Cam shaft Position Sensor gt 6 Install belt idler No 2 C 7 Install belt idler B 8 Install automatic belt tension adjuster A which has atension rod held by apin lt Ref to ME DOHC TURBO 48 AUTOMATIC BELT TENSION AD JUSTER ASSEMBLY AND BELT IDLER INSTAL LATION Timing Belt Assembly gt Tightening torque 39 4 4 0 kgf m 28 9 ft lb 6 Ee ELE QD SAY Eon EOS A B Di B3 d 9 exu AY Cy 4 z yall 2 A DAN 20 S2M1160A 9 Install timing belt Ref to ME DOHC TURBO 49 TIMING BELT INSTALLATION Timing Belt Assembly 10 Install V belts Ref to ME DOHC 43 INSTALLATION V belt gt 11 Install radiator main fan and sub fan motor as semblies Ref to CO 47 INSTALLATION Radi ator Main Fan and Fan Motor and Ref to CO 48 INSTALLATION Radiator Sub Fan and Fan Motor COOLING 12 Install reservoir tank 13 Connect over flow hose 14 Lift up the vehicle 15 Connect radiator outlet hose A and heater hose B to water pump 16 Connect water by pass hose C
8. 2 Measure resistance between main fan motor motor connector connector and chassis ground and chassis Connector amp terminal ground F17 No 1 Chassis ground CHECK POOR CONTACT Is there poor contact in main Repair poor con Go to step 6 Check poor contact in main fan motor connec fan motor connector tact in main fan tor motor connector CHECK MAIN FAN MOTOR Does the main fan rotate Repair poor con Replace main fan Connect battery positive terminal to termi tact in main fan motor with a new nal No 3 and negative terminal to terminal motor connector No 1 of main fan motor connector CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 V Go to step 8 Go to step 9 RELAY1 1 Turn ignition switch to OFF 2 Remove main fan relay1 from A C relay holder 3 Measure voltage between main fan relay1 terminal and chassis ground Connector amp terminal F66 No 26 Chassis ground CO 13 RADIATOR MAIN FAN SYSTEM COOLING CHECK POWER SUPPLY TO MAIN FAN RELAY1 1 Turn ignition switch to ON 2 Measure voltage between main fan relay1 terminal and chassis ground Connector amp terminal F66 27 Chassis ground Is the voltage more than 10 V Go to step 12 Go to step 11 CHECK 30 A FUSE 1 Remove 30 A fuse from A C relay holder 2 Check condition of fuse Is the fuse blown out Replace fuse Go to step 10 CHECK POWER SUPPLY
9. 1743 COOLING 9 Connect radiator outlet hose 107 10 Install under cover 11 Lower the vehicle 12 Install V belt covers 15 Fill coolant lt Ref to CO 25 FILLING OF EN GINE COOLANT REPLACEMENT Engine Cool ant gt CO 43 RADIATOR COOLING C INSPECTION 1 Remove radiator cap top off radiator and attach tester to radiator in place of cap Non Turbo model F5 A 116 2 Apply a pressure 157 kPa 1 6 kg cm 23 psi to radiator to check if 1 Engine coolant leaks at around radiator 2 Engine coolant leaks at around hoses or connections CAUTION Engine should be off Wipe engine coolant from check points in ad vance Be careful to prevent engine coolant from spurting out when removing tester Becareful also not to deform filler neck of ra diator when installing or removing tester CO 44 RADIATOR 8 Radiator Cap A INSPECTION 1 Attach radiator cap to tester G2M0223 2 Increase pressure until tester gauge pointer stops Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds Standard pressure 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit pressure 83 kPa 0 85 kg cm 12 psi CAUTION Be sure to remove foreign matter and rust from the cap in
10. 7 CO 3 GENERAL DESCRIPTION COOLING TURBO MODEL H2M1785B 1 Thermostat case 6 Header by pass hose Tightening torque kgf m ft lb 2 Gasket 7 Coolant filler tank by pass hose T1 First 12 1 2 8 7 3 Thermostat 8 Water by pass pipe Second 12 1 2 8 7 4 Water pump ASSY 2 6 4 0 65 4 7 5 Gasket CO 4 GENERAL DESCRIPTION 2 RADIATOR AND RADIATOR FAN NON TURBO MODEL COOLING EN0068 Radiator lower cushion Radiator Radiator upper cushion Radiator upper bracket Clamp Radiator inlet hose Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank Sub fan shroud Radiator sub fan Sub fan motor gt oI lI EI C ON gt gt OI I gt I m T LE N L Main fan shroud Radiator main fan Main fan motor ATF hose clamp AT vehicles only ATF inlet hose A AT vehicles only ATF outlet hose A AT vehicles only ATF pipe AT vehicles only ATF inlet hose B AT vehicles only ATF outlet hose B AT vehicles only Radiator outlet hose 5 23 24 Radiator lower bracket Radiator drain plug Tightening torque kgf m ft lb 1 T2
11. Go to step 19 CHECK MAIN FAN MOTOR Connect battery positive terminal to termi nal No 2 and negative terminal to terminal No 1 of main fan motor connector Does the main fan rotate Repair poor con tact in main fan motor connector Replace main fan motor with a new one CHECK POWER SUPPLY TO MAIN FAN RELAY2 1 Turn ignition switch to OFF 2 Remove main fan relay2 from A C relay holder 3 Measure voltage between main fan relay2 terminal and chassis ground Connector amp terminal F30 No 23 Chassis ground Is the voltage more than 10 V Go to step 21 Go to step 22 CHECK POWER SUPPLY TO MAIN FAN RELAY2 1 Turn ignition switch to ON 2 Measure voltage between main fan relay2 terminal and chassis ground Connector amp terminal F30 No 22 Chassis ground Is the voltage more than 10 V Go to step 25 Go to step 24 CHECK 30 A FUSE 1 Remove 30 A fuse from A C relay holder 2 Check condition of fuse Is the fuse blown out Replace fuse Go to step 23 CHECK POWER SUPPLY TO A C RELAY HOLDER 30 A FUSE TERMINAL Measure voltage of harness between A C relay holder 30 A fuse terminal and chassis ground Connector amp terminal F27 No 1 Chassis ground Is the voltage more than 10 V Repair open circuit in harness between 30 A fuse and main fan relay terminal Repair open circuit in harness between main fuse box co
12. LHD RHD LHD RHD EH SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 MOTOR MOTOR AIR CONDITIONING RELAY HOLDER Gi ive 27 lt ED r3 GD ma Ele ers 21 22 25 121 TS 14 TES Ee TL Te 9 112131415 rA e 7 8 9 26 to t9 14 15 t7 18 19 20 21 1213 14 15 16 1718 19 20 21 22 23 24 314 Eee E e 30 22 23 24125 26 27128 29 30 31 Ge 1121314 516 718 9 10 11 12 13 14 15 16 17 18 RHD EN0260 CO 18 RADIATOR SUB FAN SYSTEM COOLING B INSPECTION A C switch is turned ON Vehicle speed is below 19 km h 12 MPH 1 NON TURBO MODEL Condition 2 3 Engine coolant temperature is above 100 C E 212 F System for A C equipped vehicles only DETECTING CONDITION Condition 1 Engine coolant temperature is below 95 C 203 F A C switch is turned OFF Vehicle speed is below 19 km h 12 MPH TROUBLE SYMPTOM Radiator sub fan does not rotate under condi tions 1 and 2 above Yes No CHECK POWER SUPPLY TO SUB FAN MO Is the voltage more than 10 Go to step 2 Go to step 5 TOR CAUTION Be careful not to overheat engine during re pair 1 Turn ignition switch to OFF 2 Disconnect connector from sub f
13. Remove left hand belt cover No 2 Tightening torque First 12 1 2 kgf m 8 7 ft lb Second 23 Disconnect heater hose from water pump Remove water pump VL S2M1829 B INSTALLATION 1 NON TURBO MODEL 1 Install water pump onto left hand cylinder head CAUTION Replace gasket with a new one When installing water pump tighten bolts in two stages in alphabetical sequence as shown in figure CO 30 12 1 2 kgf m 8 7 ft Ib S2M0760A 2 Install left hand belt cover No 2 Tightening torque 5 N m 0 5 kgf m 3 6 ft lb A LI a N O GR 2 3 Install tensioner bracket Tightening torque 25 2 5 kgf m 18 1 ft lb H2M2380 WATER COOLING 4 Install left hand camshaft sprockets by using ST 11 Connect over flow hose ST 4992707100 CAMSHAFT SPROCKET WRENCH Tightening torque 78 8 0 kgf m 57 9 ft lb SCH Ho NV EI st SEL A x 2 2039 5 Install belt idler 2 Tightening torque 39 4 0 kgf m 28 9 ft lb ENO0063 SPP S 13 Lift up the vehicle CS DA 14 Connect radiator outlet hose and heater hose NO NEA to water pump S2M0024 6 Install automatic belt tension adjuster which ten sion rod is holded with pin Ref to ME SOHC 47 AUTOMATIC BEL
14. Run the engine at idle Vehicle stationary 2 Turn the A C switch to OFF 3 Warm the engine coolant temperature over 96 C 205 F TROUBLE SYMPTOM Radiator sub fan does not rotate under the above conditions COOLING Radiator sub fan does not rotate at high speed when the following conditions are both met 1 Engine coolant temperature is above 90 C 194 F 2 A C is ON Does the radiator sub fan rotate Go to step 2 Go to step 3 CHECK OPERATION OF RADIATOR 1 Turn the A C switch ON at condition of step 1 Does radiator sub fan rotate faster when A C com pressor is operated Radiator main fan system is okay Go to step 17 CHECK POWER SUPPLY TO SUB FAN MO TOR CAUTION Be careful not to overheat engine during re pair 1 Turn ignition switch to OFF 2 Disconnect connector from sub fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 96 C 205 F 4 Stop the engine and turn ignition switch to ON 5 Measure voltage between sub fan motor connector and chassis ground Connector amp terminal F16 No 3 Chassis ground Is the voltage more than 10 V Go to step 4 Go to step 7 CHECK GROUND CIRCUIT OF SUB FAN MOTOR 1 Turn ignition switch to OFF 2 Measure resistance between sub fan motor connector and chassis ground Connector amp terminal F16 No 1 Chassis ground Is the resistance less than 5 Q
15. SUB FAN AND FAN MOTOR COOLING 10 Radiator Sub Fan and Fan Motor A REMOVAL 1 Disconnect battery ground cable 2 Lift up the vehicle 3 Remove under cover 4 Disconnect connector of sub fan motor SY EN0078 5 Lower the vehicle 6 Remove air intake duct Non Turbo model o 108 7 Remove bolts which hold sub fan shroud to radi ator 8 Remove over flow pipe Turbo model 9 Remove radiator sub fan shroud through the un der side of vehicle B INSTALLATION Install in the reverse order of removal Tightening torque 4 9 0 50 kgf m 3 6 ft lb C DISASSEMBLY 1 Remove clip which holds motor harness onto shroud 52 0937 2 Remove nut which holds fan itself onto fan motor and shroud assembly 123 CO 48 RADIATOR SUB FAN AND FAN MOTOR 3 Remove bolts which install fan motor onto shroud Lei Xo j 121 D ASSEMBLY Assemble in the reverse order of disasssembly Tightening torque 4 4 0 45 kgf m 3 3 ft lb Ce 121 Tightening torque 3 4 0 35 kgf m 2 5 ft lb 123 CO 49 COOLING RESERVOIR TANK COOLING 11 Reservoir Tank A REMOVAL 1 Disconnect over flow hose from r
16. 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 liters 2 2 US qt 1 8 Imp qt Drain 2 1 liters 2 2 US qt 1 8 Imp qt of coolant from the cooling system and add 2 1 liters 2 2 US qt 1 8 Imp qt of the undiluted solution of SUBARU cool ant If a coolant concentration of 50 is needed drain all the coolant and refill with the undiluted solution Only 25 La a z 5 on 5 o Necessary concentration 0 SE of coolant 5 Co 3 3 2 2 6 2 2 1 1 8 1 1 1 0 9 0 10 20 30 40 50 Concentration of coolant the vehicle cooling system Concentration of coolant in vehicle and quantity to be drained B2M3129A CO 26 WATER 5 Water Pump A REMOVAL 1 NON TURBO MODEL 1 Disconnect ground cable from the battery 2 Lift up the vehicle 3 Remove under cover 4 Drain engine coolant completely lt Ref to CO 25 DRAINING OF ENGINE COOL ANT REPLACEMENT Engine Coolant gt 5 Disconnect connectors from radiator main fan A and sub fan B motor
17. T3 T5 4 4 0 45 3 3 12 1 2 8 7 18 1 8 13 0 3 4 0 35 2 5 4 9 0 50 3 6 GENERAL DESCRIPTION COOLING TURBO MODEL ENO0069 1 Radiator lower cushion 10 Over flow pipe 19 Engine coolant filler tank 2 Radiator 11 Sub fan shroud 20 Engine coolant filler tank cap 3 Radiator upper cushion 12 Radiator sub fan 21 Engine coolant hose 4 Radiator upper bracket 13 Radiator sub fan motor 5 Clamp 14 Main fan shroud Tightening torque N m kgf m ft Ib 6 Radiator inlet hose 15 Radiator main fan T1 4 4 0 45 3 3 7 Engine coolant reservoir tank cap 16 Radiator main fan motor T2 18 1 8 13 0 8 Over flow hose 17 Radiator outlet hose T3 3 4 0 35 2 5 9 Engine coolant reservoir tank 18 Radiator drain plug T4 4 9 0 50 3 6 CO 6 GENERAL DESCRIPTION C CAUTION Wear working clothing including cap protec tive goggles and protective shoes during opera tion Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement careful not to burn your hands because each part in the vehic
18. advance otherwise results of pres sure test will be incorrect CO 45 COOLING RADIATOR MAIN FAN AND FAN MOTOR COOLING 9 Radiator Main Fan and Fan 7 Disconnect over flow hose Motor CNW A REMOVAL 8 Remove over flow pipe Turbo model 9 Remove reservoir tank 2 Lift up the vehicle 3 Remove under cover 4 Disconnect connector of main fan motor A 5 Lower the vehicle 6 Remove air intake duct Non Turbo model 108 CO 46 RADIATOR MAIN FAN AND FAN MOTOR B INSTALLATION Install in the reverse order of removal NOTE When the main fan motor assembly cannot be in stalled as is loosen the sub fan motor assembly securing bolts to install it Tightening torque 4 9 0 50 kgf m 3 6 ft lb B2M2926 C DISASSEMBLY 1 Remove clip which holds motor connector onto shroud 52 0937 2 Remove nut which holds fan itself onto fan motor and shroud assembly 120 COOLING 3 Remove bolts which install fan motor onto Lei ENO0121 D ASSEMBLY Assemble in the reverse order of disassembly Tightening torque 4 4 N m 0 45 kgf m 3 3 ft Ib ENO0121 Tightening torque 3 4 N m 0 35 kgf m 2 5 ft Ib EN0120 CO 47 RADIATOR
19. amp terminal F30 No 21 B134 No 28 CHECK POOR CONTACT Is there poor contact in con Repair poor con Contact with your Check poor contact in connector between main nector between main fan motor tact connector Subaru distributor fan and ECM and ECM NOTE Inspection by your Subaru distributor is required because probable cause is deterioration of multiple parts CO 16 RADIATOR SUB FAN SYSTEM COOLING 3 Radiator Sub Fan System A SCHEMATIC 1 NON TURBO MODEL BATTERY SBF 1 No 3 GD swen ORO 5 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER 3 __ 18 20 19 MAIN SUB FAN MOTOR MOTOR LHD 2 RHD 7 LHD 12 RHD 17 9 Co LHD aD 1 2 3 4 5 6 7 8 9 10 11 1121314 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 ED 0 GH 112 3 516 7 8 poe 229 9 to t1 te t7 18 19 20 21 in 30 31 32 33 1112 12 1314 1 2212 stabs 5 516 s 7 21122 5 10 15 26 27128 1 26 27 28 2 4 6 8129 34 35 23 1112 16 19 20 24 30 E EN0880 17 RADIATOR SUB FAN SYSTEM COOLING 2 TURBO MODEL BATTERY SBF 1 CN w CD IGNITION 872 SWITCH
20. and oil cooler hose D S2M1159A 17 Install bolt which installs water by pass pipe onto oil pump S2M0027 18 Connect connectors to radiator main fan and sub fan motors 19 Install under cover 20 Lower the vehicle 21 Connect battery ground cable CO 33 WATER COOLING 22 Fill coolant lt Ref to CO 25 FILLING OF EN GINE COOLANT REPLACEMENT Engine Cool ant gt C INSPECTION 1 Check water pump bearing for smooth rotation 2 Check water pump pulley for abnormalities 3 Using a dial gauge measure impeller runout in thrust direction while rotating the pulley Thrust runout limit 0 5 mm 0 020 in G2M0211 4 Check clearance between impeller and pump case Clearance between impeller and pump case Standard 0 5 0 7 mm 0 020 0 028 in Limit 1 0 mm 0 039 in G2M0212 5 After water pump installation check pulley shaft for engine coolant leaks If leaks are noted replace water pump assembly CO 34 THERMOSTAT 6 Thermostat A REMOVAL 1 Lift up the vehicle 2 Remove under cover 3 Drain engine coolant completely lt Ref to CO 25 DRAINING OF ENGINE COOLANT RE PLACEMENT Engine Coolant gt Eu E oce TENE EN0073 4 Disconnect radiator outlet hose from thermostat cover Non Turbo model EN0112 5 Disconnect radiato
21. motor connector and main fan relay terminal CHECK HARNESS BETWEEN MAIN FAN RELAY AND ECM 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between main fan relay connector and ECM connector Connector amp terminal F66 No 28 B137 No 17 Is the resistance less than 1 Q Go to step 16 Repair open circuit in harness between main fan relay and ECM CHECK POOR CONTACT Check poor contact in connector between main fan and ECM Is there poor contact in con nector between main fan motor and ECM CO 14 Repair poor con tact connector Contact with your Subaru distributor RADIATOR MAIN FAN SYSTEM CHECK POWER SUPPLY TO MAIN FAN MO TOR CAUTION Be careful not to overheat engine during re pair 1 Turn ignition switch to OFF 2 Disconnect connector from main fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 96 C 205 F 4 Turn the A C switch ON 5 Measure voltage while A C compressor is rotating 6 Measure voltage between main fan motor connector and chassis ground Connector amp terminal F17 No 2 Chassis ground Is the voltage more than 10 V Go to step 18 COOLING Go to step 20 CHECK POOR CONTACT Check poor contact in main fan motor connec tor Is there poor contact in main fan motor connector Repair poor con tact in main fan motor connector
22. 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 1 SECTION FUEL INJECTION FUEL SYSTEMS FU SOHC EMISSION CONTROL EC SOHC AUX EMISSION CONTROL DEVICES INTAKE INDUCTION IN SOHC MECHANICAL ME SOHC This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles COOLING co This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of LUBRICATION LU components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition IGNITION 63 When replacement of parts during repair work is needed be sure to use SUBARU genuine parts STARTING CHARGING SYSTEMS sc EXHAUST EX SOHC ENGINE DIAGNOSTICS EN SOHC 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 G1830GE2 a ew Et COOLING 1 General 2 Radiator Main BIR DEE 3 Radiator Sub Fan 4 Engine COON EE Sa Mater PUD SE lt EE teri EE 8 R
23. B FAN RE Is the voltage more than 10 V to step 10 Go to step 9 LAY 1 Turn ignition switch to ON 2 Measure voltage between sub fan relay ter minal and chassis ground Connector amp terminal 228 20 Chassis ground 19 RADIATOR SUB FAN SYSTEM COOLING CHECK 20 A FUSE Is the fuse blown out 1 Remove 20 A fuse from A C relay holder 2 Check condition of fuse CHECK POWER SUPPLY TO A C RELAY HOLDER 20 A FUSE TERMINAL Measure voltage of harness between A C relay holder 20 A fuse terminal and chassis ground Connector amp terminal 227 3 Chassis ground CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 17 from joint box 3 Check condition of fuse Is the voltage more than 10 V Is the fuse blown out Replace fuse Repair open circuit in harness between 20 A fuse and sub fan relay terminal Replace fuse Go to step 8 Repair open circuit in harness between main fuse box connector and 20 A fuse terminal Repair open circuit in harness between sub fan relay and ignition switch CHECK SUB FAN RELAY 1 Turn ignition switch to OFF 2 Measure resistance of sub fan relay Terminal No 17 No 18 Is the resistance more than 1 MQ Go to step 11 Replace sub fan relay CHECK SUB FAN RELAY Is the resistance less than 1 1 Connect battery to terminals 20 and O 19 of sub fan relay 2 Measur
24. Go to step 5 Repair open circuit in harness between sub fan motor connector and chassis ground CHECK POOR CONTACT Check poor contact in sub fan motor connec tor Is there poor contact in sub fan motor connector Repair poor con tact in sub fan motor connector Go to step 6 CHECK MAIN FAN MOTOR Connect battery positive terminal to termi nal No 3 and negative terminal to terminal No 1 of sub fan motor connector CHECK POWER SUPPLY TO SUB FAN RELAY1 1 Turn ignition switch to OFF 2 Remove sub fan relay1 from A C relay holder 3 Measure voltage between sub fan relay1 ter minal and chassis ground Connector amp terminal F28 No 7 Chassis ground Does the main fan rotate Is the voltage more than 10 V CO 21 Repair poor con tact in sub fan motor connector Go to step 8 Replace sub fan motor with a new one Go to step 9 RADIATOR SUB FAN SYSTEM COOLING CHECK POWER SUPPLY TO SUB FAN RELAY1 1 Turn ignition switch to ON 2 Measure voltage between sub fan relay1 ter minal and chassis ground Connector amp terminal F28 No 5 Chassis ground CHECK 30 A FUSE 1 Remove 30 A fuse from A C relay holder 2 Check condition of fuse Is the voltage more than 10 Go to step 12 Go to step 11 Is the fuse blown out Replace fuse Go to step 10 CHECK POWER SUPPLY TO A C RELAY HOLDER 30 A FUSE TERMINAL Measure voltage of ha
25. M COOLING 2 TURBO MODEL TROUBLE SYMPTOM DETECTING CONDITION above condone does s Sg x Engine coolant temperature is above 990 Syaa e olana onone mean 1 Engine coolant temperature is above 90 C 194 F 2 A C is ON A C compressor is rotated Vehicle speed is below 19 km h 12 MPH CHECK OPERATION OF RADIATOR Does the main radiator fan Go to step 2 Go to step 3 1 Run the engine at idle Vehicle stationary rotate 2 Turn the A C switch to OFF 3 Warm the engine coolant temperature over 96 C 205 F CHECK OPERATION OF RADIATOR Does the main radiator fan Radiator main fan Go to step 17 1 Turn the A C switch ON at condition of step rotate faster when com system is okay 1 pressor is operated CHECK POWER SUPPLY TO MAIN FAN MO 15 the voltage more than 10 V to step 4 Go to step 7 TOR CAUTION Be careful not to overheat engine during re pair 1 Turn ignition switch to OFF 2 Disconnect connector from main fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 96 C 205 F 4 Stop the engine and turn ignition switch to ON 5 Measure voltage between main fan motor connector and chassis ground Connector amp terminal F17 No 3 Chassis ground CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 5 Go to step 5 Repair open circuit MOTOR Q in harness 1 Turn ignition switch to OFF between main fan
26. T TENSION ADJUSTER AS SEMBLY AND BELT IDLER INSTALLATION Timing Belt Assembly 7 Install timing belt Ref to ME SOHC 48 TIM ING BELT INSTALLATION Timing Belt Assem bly gt 8 Install V belts lt Ref to ME SOHC 42 INSTAL LATION V belt gt 9 Install radiator main fan and sub fan motor as semblies lt Ref to CO 47 INSTALLATION Radia tor Main Fan and Fan Motor gt and lt Ref to CO 48 INSTALLATION Radiator Sub Fan and Fan Mo tor gt 10 Install reservoir tank 112 B2M2926 CO 31 WATER COOLING 15 Connect connectors to radiator main fan A 2 TURBO MODEL SE 1 Install water pump onto left hand cylinder head CAUTION Replace gasket with a new one When installing water pump tighten bolts in two stages in alphabetical sequence as shown oS in figure Tightening torque ain First 12 1 2 kgf m 8 7 ft lb 77 12 1 2 kgf m 8 7 ft lb EN0078 H2M1846C 16 Install under cover 2 Install left hand belt cover No 2 17 Lower the vehicle Tightening torque 18 Connect battery ground cable T 0 5 ee 3 6 ft lb So B G6MO095 Ref to CO 25 FILLING OF EN 19 Fill coolant 52 1162 GINE COOLANT REPLACEMENT Engine Cool 9 Install tensioner bracket ant gt Tightening torque 25 2 5 kgf m
27. TO A C RELAY HOLDER 30 A FUSE TERMINAL Measure voltage of harness between A C relay holder 30 A fuse terminal and chassis ground Connector amp terminal F27 1 Chassis ground Is the voltage more than 10 V Repair open circuit in harness between 30 A fuse and main fan relay terminal Repair open circuit in harness between main fuse box connector and 30 A fuse terminal CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 18 from joint box 3 Check condition of fuse CHECK MAIN FAN RELAY 1 Turn ignition switch to OFF 2 Remove main fan relay1 3 Measure resistance of main fan relay1 Terminal No 26 No 25 Is the fuse blown out Is the resistance more than 1 MQ Replace fuse Go to step 13 Repair open circuit in harness between main fan relay and ignition switch Replace main fan relay CHECK MAIN FAN RELAY 1 Connect battery to terminals No 27 and No 28 of main fan relay1 2 Measure resistance of main fan relay1 Terminal No 26 No 25 Is the resistance less than 1 Q Go to step 14 Replace main fan relay CHECK HARNESS BETWEEN MAIN FAN RELAY TERMINAL AND MAIN FAN MOTOR CONNECTOR Measure resistance of harness between main fan motor connector and main fan relay termi nal Connector amp terminal F17 No 3 F66 No 25 Is the resistance less than 1 Q Go to step 15 Repair open circuit in harness between main fan
28. adiator Cap ee o Ue ped a ee pe ER AR RU A A ete ea Ru edd 9 Main Fan and Fan Motor 10 Radiator Sub Fan and Fan Motor rete ette etae Vile Reservoir Tank uite teet en e e eer Y n E EXER IR Le PRAE REI E tci e 12 Coolant Filler Tank ert e Ba s aisi teo Rude 13 Engine Cooling System Trouble in 52 GENERAL DESCRIPTION COOLING 1 General Description A SPECIFICATIONS Non turbo Tuto Electric fan Forced engine coolant circulation sys Cooling system te m Total engine coolant capacity Q US qt Imp qt 1 6AT Approx 7 3 7 71 6 42 1 6MT Approx 7 4 7 82 6 51 2 0AT Approx 6 9 7 29 6 07 2 0MT Approx 7 7 4 6 2 Approx 7 7 8 14 6 78 Type Centrifugal impeller type Discharge performance Discharge Pump speed total engine coolant head 20 2 5 3 US gal 4 4 Imp gal min 700 rpm 0 3 mAq 1 0 ftAq Engine coolant temperature 85 C 185 F Discharge performance Discharge 100 0 26 4 US gal 22 0 Imp gal min Pump speed total engine coolant head Engine coolant temperature 3 000 rpm 5 0 mAq 16 4 ftAq 85 C 185 F Water pump Discharge performance Impeller diameter Discharge 200 0 52 8 US gal 44 0 Imp gal min Pump speed total engine coolant head 6 000 rpm 23 0 mAq 75 5 Engine coolant temp
29. adiator filler neck position 2 Remove bolts which install reservoir tank onto radiator main fan shroud 3 Remove reservoir tank B2M2926 B INSTALLATION Install in the reverse order of removal Tightening torque 4 9 0 50 kgf m 3 6 ft lb B2M2926 C INSPECTION Make sure the engine coolant level is between full and low CO 50 COOLANT FILLER TANK 12 Coolant Filler Tank A REMOVAL WARNING The radiator is pressurized Wait until engine cools down before working on the radiator 1 Drain coolant about 3 0 3 2 US qt 2 6 Imp qt lt Ref to CO 25 DRAINING OF ENGINE COOL ANT REPLACEMENT Engine Coolant gt 2 Remove air cleaner upper cover and air intake boot Ref to TURBO 7 REMOVAL Air Cleaner gt 3 Remove air cleaner element 4 Disconnect engine coolant hoses from coolant filler tank 5 Remove bolts and nut which install coolant filler tank 6 Disconnect engine coolant hose which con nects the under side of coolant filler tank 7 Remove coolant filler tank OO 126 COOLING B INSTALLATION 1 Install in the reverse order of removal Tightening torque T1 19 1 9 kgf m 13 7 ft lb 2 21 2 1 kgf m 15 2 ft lb
30. age more than 10 V to step 2 Go to step 5 TOR CAUTION Be careful not to overheat engine during re pair 1 Turn ignition switch to OFF 2 Disconnect connector from main fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 95 C 203 F 4 Stop the engine and turn ignition switch to ON 5 Measure voltage between main fan motor connector and chassis ground Connector amp terminal F17 No 2 Chassis ground CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 5 Go to step 3 Repair open circuit MOTOR Q in harness 1 Turn ignition switch to OFF between main fan 2 Measure resistance between main fan motor motor connector connector and chassis ground and chassis Connector amp terminal ground F17 No 1 Chassis ground CHECK POOR CONTACT Is there poor contact in main Repair poor con Go to step 4 Check poor contact in main fan motor connec fan motor connector tact in main fan tor motor connector CHECK MAIN FAN MOTOR Does the main fan rotate Repair poor con Replace main fan Connect battery positive terminal to termi tact in main fan motor with a new nal No 2 and negative terminal to terminal motor connector one 1 of main fan motor connector CHECK POWER SUPPLY TO MAIN FAN RE Is the voltage more than 10 V to step 6 Go to step 7 LAY 1 Turn ignition switch to OFF 2 Remove main fan relay from A C rela
31. an motor and main fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 100 C 212 F 4 Stop the engine and turn ignition switch to ON 5 Measure voltage between sub fan motor connector and chassis ground Connector amp terminal F16 No 2 Chassis ground CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than 5 Go to step 3 Repair open circuit MOTOR 07 harness 1 Turn ignition switch to OFF between sub fan 2 Measure resistance between sub fan motor motor connector connector and chassis ground and chassis Connector amp terminal ground F16 No 1 Chassis ground CHECK POOR CONTACT Is there poor contact in sub fan Repair poor con Go to step 4 Check poor contact in sub fan motor connec motor connector tact in sub fan tor motor connector CHECK SUB FAN MOTOR Does the sub fan rotate Repair poor con Replace sub fan Connect battery positive terminal to termi tact in sub fan motor with a new nal No 2 and negative terminal to terminal motor connector No 1 of sub fan motor connector CHECK POWER SUPPLY SUB FAN RE Is the voltage more than 10 V to step 6 Go to step 7 LAY 1 Turn ignition switch to OFF 2 Remove sub fan relay from A C relay holder 3 Measure voltage between sub fan relay ter minal and chassis ground Connector amp terminal 228 18 Chassis ground CHECK POWER SUPPLY TO SU
32. condition of fuse Is the fuse blown out CO 23 Replace fuse Repair open circuit in harness between sub fan relay and ignition switch RADIATOR SUB FAN SYSTEM COOLING CHECK SUB FAN RELAY Is the resistance more than 1 Go to step 26 Replace sub fan 1 Turn ignition switch to OFF MQ relay 2 Remove sub fan relay2 3 Measure resistance of main fan relay2 Terminal No 18 No 17 CHECK MAIN FAN RELAY Is the resistance less than 1 Go to step 27 Replace sub fan 1 Connect battery to terminals No 19 and O relay 20 of sub fan relay2 2 Measure resistance of main fan relay2 Terminal No 18 No 17 CHECK HARNESS BETWEEN SUB FAN RE Is the resistance less than 1 Go to step 28 Repair open circuit LAY TERMINAL AND SUB FAN MOTOR 07 in harness CONNECTOR between sub fan Measure resistance of harness between sub motor connector fan motor connector and sub fan relay2 termi and sub fan relay nal terminal Connector amp terminal F16 2 F29 17 CHECK HARNESS BETWEEN SUB the resistance less than 1 Go to step 29 Repair open circuit LAY AND ECM 07 harness 1 Turn ignition switch to OFF between sub fan 2 Disconnect connector from ECM relay and ECM 3 Measure resistance of harness between sub fan relay connector and ECM connector Connector amp terminal F29 No 19 B137 No 28 CHECK POOR CONTACT Is there poor contact in con Repair poor con Contact with yo
33. ctors to radiator main fan motor A and sub f tor B coe J A and sub fan motor B TI ects Aun 5H 2 2930 6 Install reservoir tank Tightening torque 4 9 0 50 kgf m 3 6 ft lb 12 Install under cover 13 Lower the vehicle 8 Lift up the vehicle CO 41 RADIATOR COOLING 14 Connect battery ground cable 2 TURBO MODEL 1 Attach radiator mounting cushions to holes on the vehicle e up gt KR CN d Nd E SPA pum m e E B2M2934 cS vo fes G6MO095 15 Fill coolant Ref to CO 25 FILLING OF EN GINE COOLANT REPLACEMENT Engine Cool ant 16 Check ATF level Ref to AT 9 INSPECTION 2 Install radiator brackets and tighten bolts Automatic Transmission Fluid gt Tightening torque 1825 1 840 5 kgf m 13 0 3 6 ft lb gt 3 Connect radiator inlet hose A and water tank hose B CO 42 RADIATOR 4 Install reservoir tank Tightening torque 4 9 1 5 0 5020 15 kgf m 3 6 1 1 ft lb lt A SCH n lp A 4 29 5 Connect over flow hose 6 Lift up the vehicle 7 Connect connectors to radiator main fan mo tor A and sub fan motor B 52
34. e resistance of sub fan relay Terminal 17 18 Go to step 12 Replace sub fan relay NOTE CHECK HARNESS BETWEEN SUB FAN RE LAY TERMINAL AND SUB FAN MOTOR CONNECTOR Measure resistance of harness between sub fan motor connector and sub fan relay terminal Connector amp terminal F16 No 2 F28 No 17 CHECK HARNESS BETWEEN SUB FAN RE LAY AND ECM 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between sub fan relay connector and ECM connector Connector amp terminal 228 No 19 B134 12 CHECK POOR CONTACT 15 there poor contact in con Check poor contact in connnector between sub nector between sub fan motor fan and ECM and ECM Is the resistance less than 1 Q Is the resistance less than 1 Q Inspection by your Subaru distributor is required because probable cause is deterioration of multiple parts CO 20 Go to step 13 Go to step 14 Repair poor con tact connector Repair open circuit in harness between sub fan motor and sub fan relay connector Repair open circuit in harness between sub fan relay and ECM Contact with your Subaru distributor RADIATOR SUB FAN SYSTEM 2 TURBO MODEL DETECTING CONDITION Condition Engine coolant temperature is above 96 C 205 F A C compressor is rotated Vehicle speed is below 19 km h 12 MPH CHECK OPERATION OF RADIATOR 1
35. erature 85 C 185 F 76 mm 2 99 in Number of impeller vanes 8 Pump pulley diameter and case Clearance between impeller Standard 60 mm 2 36 in 0 5 0 7 mm 0 020 0 028 in Limit Thrust runout of impeller end 1 0 mm 0 039 in 0 5 mm 0 020 in Type Wax pellet type Starts to open Thermostat Fully opened 76 80 C 169 176 F 91 C 196 F Valve lift Valve bore 9 0 mm 0 354 in or more 35 mm 1 38 in Motor Radiator fan Fan diameter x Blade Type Main fan 70 W 120 W Sub fan 70 W 120 W 320 mm 11 81 in x 5 main fan 320 mm 11 81 in x 7 sub fan Down flow pressure type Core dimensions 691 5 x 340 x 16 mm 691 5 x 340 x 27 mm 27 22 x 13 39 x 0 63 in 27 22 x 13 39 x 1 06 in Radiator Pressure range in which cap valve is open Above 108415 kPa 1 1 0 15 kg cm 1622 psi Below 1 0 to 4 9 kPa 70 01 to 0 05 kg cm 0 1 to 0 7 psi Fins Reservoir tank Capacity CO 2 Corrugated fin type 0 5 2 0 5 US qt 0 4 Imp qt GENERAL DESCRIPTION COOLING B COMPONENT 1 WATER PUMP NON TURBO MODEL H2M2354A 1 Water pump ASSY 5 Gasket Tightening torque kgf m ft lb 2 Gasket 6 Thermostat cover Ti First 12 1 2 8 7 3 Heater by pass hose Second 12 1 2 8 7 4 Thermostat T2 6 4 0 65 4
36. iator main fan A and sub fan motor B EN0078 COOLING 7 Disconnect oil cooler hoses from oil cooler pipes if equipped 52 1743 8 Disconnect radiator outlet hose from thermostat cover 107 9 Lower the vehicle 10 11 Disconnect over flow hose Remove air intake duct 12 Remove reservoir tank CO 39 S2M0931 RADIATOR COOLING 13 Remove V belt covers 14 tank hose B from radiator EN0048 Disconnect radiator inlet hose A and water 035 INSTALLATION 1 NON TURBO MODEL 1 Attach radiator mounting cushions to holes on the vehicle ze 9 ER Rg p puo A p E f Eu e S 2 2934 2 Install radiator while fitting radiator pins to cush ions NOTE Fit pins on lower side of radiator into cushions on body side 3 Install radiator brackets and tighten bolts Tightening torque 18 1 8 kgf m 13 0 ft lb 16 While slightly lifting radiator slide it to left 17 Lift radiator up and away from vehicle CO 40 RADIATOR COOLING 4 Attach power steering hose to the radiator 9 Connect ATF cooler hoses AT vehicles only M 5 Connect radiator inlet hose 10 Connect conne
37. le is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect negative terminal from battery CO 7 COOLING COOLING GENERAL DESCRIPTION D PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977300 B2M4157 499207100 B2M3859 CRANK PULLEY WRENCH CAMSHAFT SPROCKET WRENCH Used for stopping crankshaft pulley when loosening and tightening crankshaft pulley bolts Used for removing and installing camshaft sprocket Non turbo LH side only 499207400 B2M4158 CAMSHAFT SPROCKET WRENCH CO 8 Used for removing and installing camshaft sprocket RADIATOR MAIN FAN SYSTEM COOLING 2 Radiator Main Fan System A SCHEMATIC 1 NON TURBO MODEL BATTERY SBF 1 No 3 GD swen ORO 5 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER 3 __ 18 20 19 MAIN SUB FAN MOTOR MOTOR LHD 2 RHD 7 LHD 12 RHD 17 9 Co LHD aD 1 2 3 4 5 6 7 8 9 10 11 1121314 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 ED 0 GH 112 3 516 7 8 poe 229 9 to t1 te t7 18 19 20 21 in 30 31 32 33 1112 12 1314 1 2212 stabs 5 516
38. mproper transmission oil Replace Defective thermostat Replace Inspect radiator fan relay engine coolant temperature sensor or radiator motor and replace there Atmospheric temperature extremely low Partly cover radiator front area Defective thermostat Replace Loosened or damaged connecting units on hoses Repair or replace Leakage from water pump Replace Leakage from water pipe Repair or replace Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket e Damaged or cracked cylinder head and crankcase Repair or replace f Damaged or cracked thermostat case Repair or replace g Leakage from radiator Repair or replace a Defective drive belt Replace b Defective radiator fan Replace c Defective water pump bearing Replace water pump d Defective water pump mechanical seal Replace water pump a Insufficient engine coolant Malfunction of electric fan Over cooling Engine coolant leaks CO 52
39. nal to terminal No 1 of sub fan motor connector Does the main fan rotate Repair poor con tact in sub fan motor connector Replace sub fan motor with a new one CHECK POWER SUPPLY TO SUB FAN RELAY2 Is the voltage more than 10 V 1 Turn ignition switch to OFF 2 Remove sub fan relay2 from A C relay holder 3 Measure voltage between sub fan relay ter minal and chassis ground Connector amp terminal 229 18 Chassis ground Go to step 21 Go to step 22 CHECK POWER SUPPLY TO SUB FAN RELAY2 1 Turn ignition switch to ON 2 Measure voltage between sub fan relay ter minal and chassis ground Connector amp terminal 229 20 Chassis ground Is the voltage more than 10 V Go to step 23 Go to step 24 CHECK 30 A FUSE 1 Remove 30 A fuse from A C relay holder 2 Check condition of fuse Is the fuse blown out Replace fuse Go to step 23 CHECK POWER SUPPLY TO A C RELAY HOLDER 30 A FUSE TERMINAL Measure voltage of harness between A C relay holder 30 A fuse terminal and chassis ground Connector amp terminal F27 No 3 Chassis ground Is the voltage more than 10 V Repair open circuit in harness between 30 A fuse and sub fan relay terminal Repair open circuit in harness between sub fuse box connector and 30 A fuse terminal CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 17 from joint box 3 Check
40. nnector and 30 A fuse terminal CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 18 from joint box 3 Check condition of fuse Is the fuse blown out CO 15 Replace fuse Repair open circuit in harness between main fan relay and ignition switch RADIATOR MAIN FAN SYSTEM COOLING CHECK MAIN FAN RELAY Is the resistance more than 1 Go to step 26 Replace main fan 1 Turn ignition switch to OFF MQ relay 2 Remove main fan relay2 3 Measure resistance of main fan relay2 Terminal No 23 No 24 CHECK MAIN FAN RELAY Is the resistance less than 1 Go to step 27 Replace main fan 1 Connect battery to terminals No 21 and O relay 22 of main fan relay1 2 Measure resistance of main fan relay2 Terminal No 23 No 24 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 28 Repair open circuit RELAY TERMINAL AND MAIN FAN MOTOR Q in harness CONNECTOR between main fan Measure resistance of harness between main motor connector fan motor connector and main fan relay termi and main fan relay nal terminal Connector amp terminal F17 No 2 F66 No 24 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 29 Repair open circuit RELAY AND ECM 07 harness 1 Turn ignition switch to OFF between main fan 2 Disconnect connector from ECM relay and ECM 3 Measure resistance of harness between main fan relay connector and ECM connector Connector
41. r more than five minutes at 2 000 to 3 000 rpm 4 If engine coolant level drops in radiator add en gine coolant to filler neck position 5 If engine coolant level drops from upper level of reservoir tank add engine coolant to upper level 6 Attach radiator cap and reservoir tank cap prop erly B INSPECTION 1 RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM PERATURE The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram Measuring the temperature and specific gravity of the coolant will provide this information CO 25 ENGINE COOLANT COOLING Example If the coolant temperature is 25 C 77 F and its specific gravity is 1 054 the concentration is 35 point A the safe operating temperature is 14 C 7 F point B and the freezing temperature is 20 C 4 F point C 5 Safe operating temperature oz 2s Concentration 98 of coolant A no 1 100 1 090 1 080 1 070 1 060 1 050 1 040 1 030 Freezing temperature 1 020 1 010 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 B2M3128A 2 PROCEDURE TO ADJUST THE CON CENTRATION OF THE COOLANT To adjust the concentration of the coolant accord ing to temperature find the proper fluid concentra tion in the above diagram and replace the necessary amount of coolant with an undiluted so lution of
42. r outlet hose Turbo model EN0107 COOLING 6 Remove thermostat cover and gasket and pull out the thermostat fil ye LOR v d SE Ze 7 d E eu uu we G2M0214 INSTALLATION 1 Install the thermostat the water pump stall the thermostat cover together with a gasket CAUTION When reinstalling the thermostat use a new gasket The thermostat must be installed with the jig gle pin A facing to front side At this time set the jiggle pin of thermostat for front side Tightening torque 6 4 0 65 kgf m 4 7 ft lb p gt 2 Fill coolant Ref to CO 25 FILLING OF EN GINE COOLANT REPLACEMENT Engine Cool ant gt D CO 35 THERMOSTAT COOLING C INSPECTION Replace the thermostat if the valve does not close completely at an ambient temperature or if the fol lowing test shows unsatisfactory results Immerse the thermostat and a thermometer in wa ter Raise water temperature gradually and mea sure the temperature and valve lift when the valve begins to open and when the valve is fully opened During the test agitate the water for even temper ature distribution The measurement should be to the specification Starts to open 76 80 C 169 176 F Fully opens 91 C 196 F H2M2357A A Thermometer B Thermostat CO 36 7 Radiator REMOVAL
43. rness between A C relay holder 30 A fuse terminal and chassis ground Is the voltage more than 10 V Repair open circuit in harness between 30 A fuse and sub fan relay Repair open circuit in harness between sub fuse box connector and Connector amp terminal terminal 30 A fuse terminal 227 3 Chassis ground CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 17 from joint box 3 Check condition of fuse Is the fuse blown out Replace fuse Repair open circuit in harness between sub fan relay and ignition switch Replace sub fan relay CHECK SUB FAN RELAY 1 Turn ignition switch to OFF 2 Remove main fan relay1 3 Measure resistance of sub fan relay1 Terminal No 7 No 8 CHECK SUB FAN RELAY Is the resistance less than 1 1 Connect battery to terminals No 6 and No 5 O of sub fan relay1 2 Measure resistance of sub fan relay Terminal No 7 No 8 CHECK HARNESS BETWEEN SUB FAN 5 the resistance less than 1 LAY TERMINAL AND SUB FAN MOTOR Q CONNECTOR Measure resistance of harness between sub fan motor connector and sub fan relay terminal Connector amp terminal F16 No 3 F28 No 8 CHECK HARNESS BETWEEN SUB FAN 15 the resistance less than 1 LAY AND ECM Q 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between sub fan relay connector and ECM connector Connector amp terminal F28 No 6
44. s EN0077 RE COOLING 6 Disconnect radiator outlet hose and heater hose from water pump 7 Lower the vehicle 8 Remove air intake duct ENO0063 B2M2926 11 Remove radiator main fan and sub fan assem blies lt Ref to CO 46 REMOVAL Radiator Main Fan and Fan Motor gt and lt Ref to CO 48 RE MOVAL Radiator Sub Fan and Fan Motor gt 12 Remove V belts lt Ref to ME SOHC 42 REMOVAL V belt gt CO 27 WATER COOLING 18 Remove tensioner bracket lt Ref to ME SOHC 46 TIMING BELT REMOV AL Timing Belt Assembly gt 14 Remove automatic belt tension adjuster 13 Remove timing belt A Ge KY S2M0024 16 Remove left hand camshaft sprocket by using ST ST 499207100 CAMSHAFT SPROCKET LC ff qum 0 2 2039 A MS 17 d nand belt cover No m SCH ESD 5e SE H2M2380 19 Disconnect heater hose from water pump 20 Remove water pump 3 x UT x B2M3894 xU a gt CO 28 WATER 2 TURBO MODEL WARNING The radiator is pressurized Wait until engine cools down before working on the radiator 1 Set the vehicle on the lift 2 Disconnect ground cable from the battery 3 Lift up the vehicle
45. ur Check poor contact in connector between sub nector between sub fan motor tact connector Subaru distributor fan and ECM and ECM NOTE Inspection by your Subaru distributor is required because probable cause is deterioration of multiple parts CO 24 ENGINE COOLANT 4 Engine Coolant A REPLACEMENT 1 DRAINING OF ENGINE COOLANT 1 Lift up the vehicle 2 Remove under cover 3 Remove drain cock to drain engine coolant into container NOTE Remove radiator cap so that engine coolant will drain faster D Ell 2 FILLING OF ENGINE COOLANT 1 Fill engine coolant into radiator up to filler neck position Coolant capacity fill up to FULL level 1 60 AT model Approx 7 3 0 7 71 US qt 6 42 Imp qt 1 60 MT model Approx 7 4 0 7 82 US qt 6 51 Imp qt Non turbo 2 00 AT model Approx 6 9 0 7 29 US qt 6 07 Imp qt Non turbo 2 00 MT model Approx 7 0 7 4US qt 6 2 Imp qt Turbo model Approx 7 7 0 8 14 US qt 6 78 Imp qt CAUTION The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially made for SUBARU engine which has an aluminum crankcase Always use SUBARU Genuine Cool ant since other coolant may cause corrosion COOLING 2 Fill engine coolant into reservoir tank up to upper level Full level Low level D S2M0552A 3 Warm up engine completely fo
46. y holder 3 Measure voltage between main fan relay ter minal and chassis ground Connector amp terminal F66 No 26 Chassis ground CHECK POWER SUPPLY TO MAIN FAN RE Is the voltage more than 10 V to step 10 Go to step 9 LAY 1 Turn ignition switch to ON 2 Measure voltage between main fan relay ter minal and chassis ground Connector amp terminal F66 No 28 Chassis ground CHECK 20 A FUSE Is the fuse blown out Replace fuse Go to step 8 1 Remove 20 A fuse from A C relay holder 2 Check condition of fuse CO 11 RADIATOR MAIN FAN SYSTEM COOLING CHECK POWER SUPPLY TO A C RELAY HOLDER 20 A FUSE TERMINAL Measure voltage of harness between A C relay holder 20 A fuse terminal and chassis ground Connector amp terminal F27 No 1 Chassis ground Is the voltage more than 10 V Repair open circuit in harness between 20 A fuse and main fan relay terminal Repair open circuit in harness between main fuse box connector and 20 A fuse terminal CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 18 from joint box 3 Check condition of fuse CHECK MAIN FAN RELAY 1 Turn ignition switch to OFF 2 Remove main fan relay 3 Measure resistance of main fan relay Terminal No 26 No 25 CHECK MAIN FAN RELAY 1 Connect battery to terminals No 27 and No 28 of main fan relay 2 Measure resistance of main fan relay Terminal No 26
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