Subaru 2001 IMPREZA User manual

FUJI HEAVY INDUSTRIES LTD. G1830GE3
2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE 2 SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUEL INJECTION (FUEL SYSTEMS) FU(SOHCw/oOBD)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(SOHCw/oOBD)
EXHAUST EX(SOHCw/oOBD)
IGNITION IG(SOHCw/oOBD)
ENGINE(DIAGNOSTICS) EN(SOHCw/oOBD)
FUEL INJECTION (FUEL SYSTEMS) FU(DOHC TURBO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(DOHC TURBO)
INTAKE (INDUCTION) IN(DOHC TURBO)
MECHANICAL ME(DOHC TURBO)
EXHAUST EX(DOHC TURBO)
IGNITION IG(DOHC TURBO)
ENGINE (DIAGNOSTICS) EN(DOHC TURBO)

FUEL INJECTION (FUEL SYSTEMS)
FU(DOHC TURBO)
Page
1. General Description ....................................................................................2
2. Throttle Body.............................................................................................14
3. Intake Manifold..........................................................................................15
4. Engine Coolant Temperature Sensor........................................................27
5. Crankshaft Position Sensor.......................................................................28
6. Camshaft Position Sensor.........................................................................29
7. Knock Sensor............................................................................................30
8. Throttle Position Sensor............................................................................31
9. Mass Air Flow and Intake Air Temperature Sensor ..................................32
10. Pressure Sensor .......................................................................................33
11. Idle Air Control Solenoid Valve .................................................................34
12. Fuel Injector ..............................................................................................35
13. Tumble Generator Valve Assembly ..........................................................38
14. Wastegate Control Solenoid Valve ...........................................................40
15. Front Oxygen (A/F) Sensor.......................................................................41
16. Rear Oxygen Sensor.................................................................................43
17. Exhaust Temperature Sensor...................................................................44
18. Engine Control Module..............................................................................45
19. Main Relay................................................................................................46
20. Fuel Pump Relay.......................................................................................47
21. Fuel Pump Controller................................................................................48
22. Fuel...........................................................................................................49
23. Fuel Tank..................................................................................................50
24. Fuel Filler Pipe..........................................................................................52
25. Fuel Pump.................................................................................................56
26. Fuel Level Sensor.....................................................................................58
27. Fuel Sub Level Sensor..............................................................................59
28. Fuel Filter..................................................................................................61
29. Fuel Cut Valve...........................................................................................62
30. Fuel Damper Valve ...................................................................................63
31. Fuel Delivery, Return and Evaporation Lines............................................64
32. Fuel System Trouble in General ...............................................................67

FU(DOHC TURBO)-2
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Model
Fuel tank Capacity 60 2(15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Fuel pump
Type Impeller
Shutoff discharge pressure 450 —677 kPa (4.59 —6.9 kg/cm2, 65.27 —98.2 psi)
Discharge flow More than 130 2(34.3 US gal, 28.6 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type

FU(DOHC TURBO)-3
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION

FU(DOHC TURBO)-4
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
EN0778
(18)
(17)
(16)
(14)
(15)
(13)
T6
T1
T5
T6
T1
T1
(8)
(8)
(7)
(6)
(2)
(2)
(3)
(3)
(26)
T7
(1)
(5)
(2)
(3)
(4)
(16)
(14)
(15)
(25)
(26)
T6
T6
T5
T3
T6
T6
T3
T6
T7 T6
T6
T4
(10)
(11)
(9)
(24)
(22)
(23)
(20)
(19)
(21)
(9)
(12)
(12)
(10)
(11)
T3

FU(DOHC TURBO)-5
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(1) Fuel pipe ASSY (13) Accelerator cable bracket (25) Fuel pipe protector LH
(2) Fuel hose (14) Fuel injector (26) Nipple
(3) Clip (15) Insulator
(4) Purge control solenoid valve (16) Fuel injector pipe Tightening torque: N·m (kgf-m, ft-lb)
(5) Vacuum hose (17) Pressure regulator T1: 5 (0.50, 3.7)
(6) Vacuum control hose (18) Pressure regulator hose T2: 7.4 (0.75, 5.5)
(7) Purge valve (19) Fuel pipe protector RH T3: 8.25 (0.84, 6.1)
(8) Purge hose (20) Blow-by hose stay T4: 16 (1.63, 11.8)
(9) Tumble generator valve gasket (21) Intake manifold T5: 17 (1.73, 12.5)
(10) Guide pin (22) Solenoid valve cover T6: 19 (1.94, 14.0)
(11) Tumble generator valve ASSY (23) Solenoid valve cover stay T7: 25 (2.55, 18.4)
(12) Intake manifold gasket (24) Wastegate control solenoid valve
ASSY

FU(DOHC TURBO)-6
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
EN0779
(1)
(5)
(3)
(2)
(4)
T1
T1
T2
T3
(1) Gasket (5) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve T2: 2.8 (0.29, 2.1)
(4) Throttle body T3: 22 (2.2, 16)

FU(DOHC TURBO)-7
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT
POSITION AND KNOCK SENSORS
T1
T2
T1
(3)
(2)
(1)
EN0780
(1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)

FU(DOHC TURBO)-8
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
4. FUEL TANK
EN0998
T1 T1
T3
T2
T2 T2
T2
T3
(7)
(6)
(8)
(9)
(10)
(9)
(8)
(19)
(18)
(22)
(12) (12)
(12)
(23)
(12)
(12)
(24)
(25)
(12)
(21) (20)
(1)
(2)
(3)
(3)
(2)
(5)
AB
(28)
(29)
(16)
E
F
A
B
T1
T1
DC
E
D
(20)
(12)
(12)
(12)
(12)
(12)
(29)
(13)
(14)
(11)
(17) (30)
(27)
(26)
(15)

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

FU(DOHC TURBO)-10
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
5. FUEL LINE
EN0440
(12)
(11)
(1)
(1)
(1)
(7)
(1)
(1) (9) (10)
(10)
(1)
(6)
(5)
(4) (3)
(2)
(1) (1)
(8)
(24)
(24)
(18)
(23)
(13)
(14)
(1) (1)
(21)
(20)
(25)
(22)
(19)
(17)
(16)
(15)
C
B
B
A
C
A
T

FU(DOHC TURBO)-11
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(1) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A
(2) Fuel delivery hose A (12) Grommet (22) Connector
(3) Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B
(4) Fuel filter holder (14) Canister (24) Clamp
(5) Fuel filter cup (15) Canister bracket plate (25) Front canister bracket
(6) Fuel filter (16) Cushion
(7) Evaporation hose (17) Canister bracket spacer Tightening torque: N·m (kgf-m, ft-lb)
(8) Fuel damper (18) Rear canister bracket T: 23 (2.34, 17.0)
(9) Fuel delivery hose B (19) Two-way valve return hose
(10) Fuel return hose (20) Two-way valve

FU(DOHC TURBO)-12
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(11)
T
T
(4)
(2)
(8)
(1)
(6)
(3)
(3)
(7)
(9)
(10)
(5)
(3)
T
T
T
EN0441
(1) Fuel filter pipe ASSY (6) Air vent pipe Tightening torque: N·m (kgf-m, ft-lb)
(2) Evaporation hose holder (7) Air vent pipe holder T: 7.5 (0.76, 5.5)
(3) Clamp (8) Filler pipe packing
(4) Clamp (9) Filler ring
(5) Air vent hose (10) Filler cap

FU(DOHC TURBO)-13
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
C: CAUTION
•Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
•Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
•Keep the disassembled parts in order and pro-
tect them from dust or dirt.
•Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
•Be careful not to burn your hands, because each
part on the vehicle is hot after running.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Place shop jacks or safety stands at the specified
points.
•Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
•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
24082AA150
(Newly adopted
tool)
CARTRIDGE Troubleshooting for electrical system.
22771AA030 SELECT MONI-
TOR KIT Troubleshooting for electrical systems. •English: 22771AA030 (Without printer)
•German: 22771AA070 (Without printer)
•French: 22771AA080 (Without printer)
•Spanish: 22771AA090 (Without printer)
B2M3876
B2M3877

FU(DOHC TURBO)-14
FUEL INJECTION (FUEL SYSTEMS) THROTTLE BODY
2. Throttle Body
A: REMOVAL
1) Disconnect battery ground cable.
2) Remove intercooler. <Ref. to IN(DOHC TUR-
BO)-10, REMOVAL, Intercooler.>
3) Disconnect connector from throttle position sen-
sor (A) and idle air cotrol solenoid valve (B) and
pressure sensor (C).
4) Disconnect accelerator cable.
5) Disconnect engine coolant hoses from throttle
body.
6) Remove bolts which secure throttle body to in-
take manifold.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
G6M0095
(A)
(B)
(C)
EN0782
H2M1890
EN0784
EN0785

FU(DOHC TURBO)-15
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
1) Release fuel pressure. <Ref. to FU(DOHC TUR-
BO)-49, RELEASING OF FUEL PRESSURE, OP-
ERATION, Fuel.>
2) Remove under cover.
3) Drain coolant about 3.0 2(3.2 US qt, 2.6 Imp
qt).
4) Remove battery from engine compartment.
5) Remove air cleaner upper cover and air intake
boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL,
Air Cleaner.>
6) Remove air cleaner element.
7) Remove intercooler. <Ref. to IN(DOHC TUR-
BO)-10, REMOVAL, Intercooler.>
8) Disconnect accelerator cable.
9) Remove power steering pump from bracket.
(1) Remove front side V-belt. <Ref. to
ME(DOHC TURBO)-43, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
(3) Remove bolts which secure power steering
pipe brackets to intake manifold.
NOTE:
Do not disconnect power steering hose.
(4) Remove bolts which secure power steering
pump to bracket.
(5) Remove power steering tank from the
bracket by pulling it upward.
EN0073
H6M0426
H2M1890
EN0360
EN0206
H2M1954
EN0361

FU(DOHC TURBO)-16
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
(6) Place power steering pump on the right side
wheel apron.
10) Disconnect emission hose from PCV valve.
11) Disconnect engine coolant hoses from throttle
body.
12) Disconnect brake booster hose (A).
13) Remove coolant filler tank. <Ref. to CO-51, RE-
MOVAL, Coolant Filler Tank.>
14) Disconnect Pressure hose from intake duct.
15) Disconnect engine harness connectors from
bulkhead harness connectors, and remove engine
harness connectors from bracket.
16) Disconnect connectors from engine coolant
temperature sensor (A), oil pressure switch (B) and
crankshaft position sensor (C).
17) Disconnect knock sensor connector.
EN0208
EN0789
EN0784
EN0204
EN0787
EN0788
(A)
(B)
(C)
EN0790
S2M1613

FU(DOHC TURBO)-17
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
18) Disconnect connector from camshaft position
sensor.
19) Disconnect fuel delivery hose, return hose and
evaporation hose.
WARNING:
Catch fuel from hoses in a container.
20) Remove bolts which secure intake manifold to
cylinder heads.
21) Remove intake manifold.
B: INSTALLATION
1) Install intake manifold onto cylinder heads.
CAUTION:
Always use new gaskets.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Connect fuel delivery hose, return hose, and
evaporation hose.
3) Connect connector to oil pressure switch (B),
crankshaft position sensor (C) and engine coolant
temperature sensor (A).
4) Connect connector to knock sensor.
B2M1251
EN0214
EN0792
EN0792
EN0214
(A)
(B)
(C)
EN0790
S2M1613

FU(DOHC TURBO)-18
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
5) Connect connector to camshaft position sensor.
6) Connect engine harness connector to bulkhead
harness connectors, and install engine harness
connector to bracket.
7) Connect brake booster vacuum hose (A).
8) Connect engine coolant hoses to throttle body.
9) Connect emission hose to PCV valve.
10) Connect pressure hose to intake duct.
11) Install coolar filler tank. <Ref. to CO-51, IN-
STALLATION, Coolant Filler Tank.>
12) Install power steering pump on bracket.
(1) Install power steering tank on bracket.
(2) Connect connector to power steering pump
switch.
B2M1251
EN0788
EN0204
EN0784
EN0789
EN0787
EN0361
EN0360

FU(DOHC TURBO)-19
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
(3) Install power steering pump on bracket, and
tighten bolts.
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
(4) Install power steering pipe brackets on right
side intake manifold.
(5) Install front side V-belt. <Ref. to ME(DOHC
TURBO)-43, REMOVAL, V-belt.>
13) Connect accelerator cable.
14) Install intercooler. <Ref. to IN(DOHC TURBO)-
11, INSTALLATION, Intercooler.>
15) Install air cleaner element.
16) Install air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(DOHC TURBO)-7, IN-
STALLATION, Air Cleaner.>
17) Connect connector to fuel pump relay.
18) Install battery and connect battery cables.
19) Install under cover.
20) Fill coolant. <Ref. to CO-25, FILLING OF EN-
GINE COOLANT, Engine Coolant.>
H2M1954
EN0206
H2M1890
EN0344
H6M0426