Subaru 2001 IMPREZA User manual

FUJI HEAVY INDUSTRIES LTD. G1830GE2
2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE 1 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(SOHC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(SOHC)
INTAKE (INDUCTION) IN(SOHC)
MECHANICAL ME(SOHC)
EXHAUST EX(SOHC)
COOLING CO
LUBRICATION LU
SPEED CONTROL SYSTEMS SP
IGNITION IG(SOHC)
STARTING/CHARGING SYSTEMS SC
ENGINE (DIAGNOSTICS) EN(SOHC)

IGNITION IG(SOHC)
Page
1. General Description ....................................................................................2
2. Spark Plug...................................................................................................5
3. Ignition Coil and Ignitor Assembly...............................................................8
4. Spark Plug Cord........................................................................................10

IG(SOHC)-2
IGNITION GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Item Designation
Ignition coil
and ignitor
assembly
Model 1600cc CM12—100C
2000cc FH0137
Manufacturer 1600cc HITACHI
2000cc DIAMOND
Primary coil resistance 1600cc 0.7 Ω±10%
2000cc 0.73 Ω±10%
Secondary coil resis-
tance 1600cc 13.0 kΩ±20%
2000cc 12.8 kΩ±15%
Insulation resistance between primary
terminal and case More than 10 MΩ
Spark plug Type and manufacturer 1600cc RC8YC4 .......... CHAMPION
Alternate BKR6E-11 .......... NGK
2000cc RC10YC4 .......... CHAMPION
Alternate BKR5E-11 .......... NGK
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 —1.1 (0.039 —0.043)

IG(SOHC)-3
IGNITION
GENERAL DESCRIPTION
B: COMPONENT
1. 1600CC MODEL
S6M0329B
EN1039
T1
T2
T2
(1)
(2)
(2)
(3)
(4)
(4)
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7)
(3) Ignition coil and ignitor ASSY T2: 21 (2.1, 15.2)

IG(SOHC)-4
IGNITION GENERAL DESCRIPTION
2. 2000CC MODEL
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.
S6M0329B
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3) T1: 21 (2.1, 15)
(3) Ignition coil and ignitor ASSY T2: 6.4 (0.65, 4.7)

IG(SOHC)-5
IGNITION
SPARK PLUG
2. Spark Plug
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
1. RH SIDE
1) Disconnect battery ground cable.
2) Remove air intake duct. <Ref. to IN(SOHC)-8,
REMOVAL, Resonator Chamber.>
(1) Remove resonator chamber. <Ref. to IN
(SOHC)>
3) Remove spark plug cords by pulling boot, not
cord itself.
4) Remove spark plugs with the spark plug socket.
2. LH SIDE
1) Disconnect battery ground cable.
2) Disconnect washer motor connector.
3) Disconnect rear window glass washer hose from
washer motor, then plug connection with a suitable
cap.
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working ar-
ea.
5) Remove spark plugs cord by pulling boot, not
cord itself.
Spark plug
1600cc CHAMPION: RC8YC4
NGK: BKR6E-11 (Alternate)
2000cc CHAMPION: RC10YC4
NGK: BKR5E-11 (Alternate)
G6M0095
B2M4127
B2M4286
G6M0095
B6M0562B
B2M2023
B2M4287

IG(SOHC)-6
IGNITION SPARK PLUG
6) Remove spark plug with the spark plugs socket.
B: INSTALLATION
1. RH SIDE
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
20.6 N·m (2.10 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
2. LH SIDE
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
20.6 N·m (2.10 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
C: INSPECTION
Check electrodes and inner and outer porcelain of
plugs, noting the type of deposits and the degree of
electrode erosion.
1) Normal
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
B2M4288
(A) Electrode gap
(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket
S6M0420A
G6M0087
G6M0088

IG(SOHC)-7
IGNITION
SPARK PLUG
3) Oil fouled
Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and
pistons or excessive clearance between valve
guides and stems. If same condition remains after
repair, use a hotter plug.
4) Overheating
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance 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.
D: CLEANING
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away porce-
lain.
If deposits are too stubborn, replace plugs.
E: ADJUSTMENT
Correct it if the spark plug gap is measured with a
gap gauge, and it is necessary.
Spark plug gap: L
1.0 —1.1 mm (0.039 —0.043 in)
NOTE:
Replae with new spark plug if this area is worn to
“ball”shape.
G6M0089
G6M0090
S6M0412A

IG(SOHC)-8
IGNITION IGNITION COIL AND IGNITOR ASSEMBLY
3. Ignition Coil and Ignitor As-
sembly
A: REMOVAL
1) Disconnect battery ground cable.
2) Disconnect spark plug cords from ignition coil
and ignitor assembly.
•1600cc MODEL
•2000cc MODEL
3) Disconnect connector from ignition coil and igni-
tor assembly.
4) Remove ignition coil and ignitor assembly.
•1600cc MODEL
•2000cc MODEL
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
•1600cc MODEL
•2000cc MODEL
G6M0095
EN1040
S6M0373
EN1044
B6M0930
EN1044
B6M0930

IG(SOHC)-9
IGNITION
IGNITION COIL AND IGNITOR ASSEMBLY
C: INSPECTION
Using accurate tester, inspect the following items,
and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:(1600cc)
[Primary side]
Between terminal No. 1 and No. 4
0.7
Ω
ΩΩ
Ω±
±±
±
10%
Between terminal No. 1 and No. 2
0.7
Ω
ΩΩ
Ω±
±±
±
10%
[Secondary side]
Between (A) and (B)
13.0 k
Ω
ΩΩ
Ω±
±±
±
20%
Between (C) and (D)
13.0 k
Ω
ΩΩ
Ω±
±±
±
20%
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73
Ω
ΩΩ
Ω±
±±
±
10%
Between terminal No. 2 and No. 4
0.73
Ω
ΩΩ
Ω±
±±
±
10%
[Secondary side]
Between (A) and (B)
12.8 k
Ω
ΩΩ
Ω±
±±
±
15%
Between (C) and (D)
12.8 k
Ω
ΩΩ
Ω±
±±
±
15%
3) Insulation between primary terminal and case:
10 MΩor more.
EN1041
1234
EN1042
(A) (B)
(C) (D)
EN1041
1234
EN1043
(C)
(A)
(D)
(B)