Subaru 2002 Impreza User manual

2002 IMPREZA SERVICE MANUAL QUICK REFERENCEINDEX
ENGINE1 SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessaryinformationand data
for the correct maintenance and repair
of SUBARUvehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experiencedmechanics.
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
SUBARUgenuineparts.
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 INDUSTRIESLTD. G1830BE2

FUEL INJECTION (FUEL SYSTEMS)
FU(S0HC)r
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 .
Page
GeneralDescription .................................................................................... 2
Throttle Body
............................................................................................. 14
Intake Manifold
.......................................................................................... 15
EngineCoolant TemperatureSensor
........................................................ 27
Crankshaft Position Sensor
....................................................................... 28
Camshaft PositionSensor
......................................................................... 29
Knock Sensor
............................................................................................ 30
Throttle PositionSensor
............................................................................ 31
IntakeAir Temperature and Pressure Sensor
........................................... 34
Atmospheric Pressure Sensor
.................................................................. 35
IdleAir Control Solenoid Valve
................................................................. 36
Air Assist InjectorSolenoid Valve
............................................................. 37
Fuel Injector
.............................................................................................. 38
Front Oxygen (NF) Sensor
....................................................................... 43
RearOxygenSensor
................................................................................. 45
EngineControl Module
.............................................................................. 47
Main Relay
................................................................................................ 48
Fuel Pump Relay
....................................................................................... 49
Fuel
........................................................................................................... 50
FuelTank .................................................................................................. 51
Fuel Filler Pipe
.......................................................................................... 54
Fuel Pump
................................................................................................. 59
Fuel Level Sensor ..................................................................................... 62
Fuel Sub Level Sensor
.............................................................................. 63
Fuel Filter
.................................................................................................. 65
Fuel Cut Valve
........................................................................................... 66
Fuel DamperValve
................................................................................... 67
Fuel Delivery, Return and Evaporation Lines
............................................ 68
Fuel SystemTrouble in General
............................................................... 71

GENERAL DESCRIPTION
FUEL INJECTION (FUELSYSTEMS)
Type
Shutoff discharge pressure
Discharge
flow
Impeller
370
- 677 kPa (3.77 - 6.9 kg/cm2,53.6 - 98 psi)
Morethan65
9 (17.2 US gal, 14.3 Imp gal)/h
I1 2 V at 300 kPa (3.06 kn/cm2,43.5 usi)l
Fueltank
I Capacity I 60 8 (15.9 USaal, 13.2 Impaal) I
I Location I Under rear seat I
Fuel pump
Fuelfilter
I Cartridgetype I
FU(S0HC)-2

GENERAL DESCRIPTION FUEL INJECTION(FUELSYSTEMS)
FU(SOHC)9

GENERAL DESCRIPTION
FUEL INJECTION(FUELSYSTEMS)
B: COMPONENT
1. INTAKEMANIFOLD
EN1172
FU(S0HC)-4

GENERAL DESCRIPTION FUELINJECTION(FUELSYSTEMS)
Intake manifoldgasket
Fuelinjectorpipe
RH
Fuelinjector
O-ring
O-ring
O-ring
Plug
PCV valve
Purgecontrolsolenoidvalve
Nipple
Intake manifold
Fuelinjectorpipe
LH
Fuelpipe protector LH
Intakeair temperature and pres-
sure sensor
O-ring
Plugcordholder
LH
Fuelpipeprotector RH
FuelpipeASSY
Fuelhose
Clip
Clip
Air assistinjectorsolenoidvalve
Air assist injectorsolenoidvalve
bracket
Guide pin
Atmospheric pressuresensor
bracket
Atmospheric pressuresensor
Plugcord holder
RH
(28) Acceleratorcable bracket
Tighteningtorque: N.m (kgf-m, ft-lb)
T1: 3.4 (0.35,2.5)
T2: 4.9 (0.5, 3.6)
T3: 6.4 (0.65, 4.7)
T4: lg(1.9, 13.7)
T5: 16 (1.6, 11.8)
T6: 25 (2.5, 18.1)
T7: 7.35(0.75, 5.42)
T8: 17f1.7, 12.5)
T9: l.S(O.15, 1.1)
FU(S0HC)-5

GENERAL DESCRIPTION
FUEL INJECTION(FUELSYSTEMS)
2. AIR INTAKESYSTEM
1;;1
B2M3455C
(1) Gasket (4) Throttlebody
(2) Throttlepositionsensor
(3)
Idleair controlsolenoidvalve
Tighteningtorque:N.m (kgf-m, ft-lb)
Tl: l.S(O.16, 1.2)
T2: 22 (2.2, 15.9)
FU(S0HC)-6

GENERAL DESCRIPTION FUEL
INJECTION (FUELSYSTEMS)
3. CRANKSHAFT POSITION,CAMSHAFT
POSITIONAND KNOCK SENSORS
I
(1) Crankshaftpositionsensor (4) Camshaft positionsensor support Tightening torque: N-m (kgf-m, ft-lb)
(2) Knocksensor T1: 6.4(0.65, 4.7)
(3) Camshaftpositionsensor T2: 24 (2.4, 17.4)
FU(S0HC)-7

GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)
4. FUELTANK
EN1119
FU(S0HC)-8

GENERAL DESCRIPTION FUELINJECTION[FUEL SYSTEMS)
Heatshieldcover
Fueltank band
Protector
LH
Protector RH
Fueltank
Canisterhose
A
Clamp
Fuelpump gasket
FuelpumpASSY
Fuelcut valve gasket
Fuelcut valve
Evaporationhose
A
Clip
Joint pipe
Evaporationhose
C
Evaporationhose €3
Evaporationhose D
Evaporationhose E
Evaporationpipe ASSY
Retainer
Quickconnector
Jet pump hoseA
FuelreturnhoseA
Fuelpipe ASSY
Jet pump hose
€3
Fuel returnhose B
Evaporationhose F
Evaporationhose
G
(29) Fuelsub level sensor gasket
(30) Jet pumpfilter
(31) Fuelsub level sensor
(32) Protectorcover
(33) Vent valve hose
(34) Vent valve
(35) Fueltank pressuresensor
(36)
(37) Vent valve gasket
Fueltank pressuresensor hose
Tighteningtorque: N-m (kgf-m, ft-lb)
TI: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4,25)
FU(S0HC)-9

GENERAL DESCRIPTION
FUEL INJECTION(FUELSYSTEMS)
5. FUELLINE
EN1120
FU(S0HC)-10

GENERAL DESCRIPTION
FUELINJECTION(FUELSYSTEMS)
Clip
Fuel delivery hose
A
Fuelfilter bracket
Fuelfilter holder
Fuelfilter cup
Fuelfilter
Evaporationhose
Clip
Fueldelivery hose
B
Fuel returnhose A
Fuel returnhose 6
Fuel damper
Evaporationhose
J
Evaporationhose K
Jointpipe
Canister hose A
Air filter hoseA
Drainvalve hose
Air filter hose
B
Drainfilter
Drainvalve
Canister upper bracket
Cushion rubber
Canister lower bracket
(25) Canister holder
(26) Evaporationhose
L
(27) Pressurecontrolsolenoidvalve
(28) Canister hose
B
(29) Canister
(30) Fuel pipe ASSY
Tighteningtorque: N-m (kgf-m, ft-lb)
T1: 25(2.5, 18.1)
T2:
23 (2.3, 16.6)
T3: 1.25(0.13, 0.94)
FU(S0HC)-11

GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)
6. FUEL FILLER PIPE
EN1 121
Fuelfilter pipe ASSY (9)
Evaporationhose holder (1 0)
Clamp (11)
Clamp (1 2)
Evaporationhose A (1 3)
Evaporationpipe (1 4)
Evaporationpipeholder (1 5)
Fillerpipepacking
Fillerring
Fillercap
T1: 4.4 (0.45, 3.3)
S hut valve T2: 7.5 (0.76, 5.53)
Evaporationhose B
EvaporationhoseC
Joint pipe
Fuelfiller pipe protector
Tighteningforque: N.m (kgf-m, ft-lb)
FU(S0HC)-12

GENERAL DESCRIPTION FUELINJECTION(FUELSYSTEMS)
Becareful notto burnyour hands, becauseeach
part
On the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nutsto the specified torque.
Placeshopjacks or safety standsat the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from
0 Place “NO FIRE signs near the working area.
o Becareful not to Spillfuel on the floor-
C: CAUTION
0 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
0 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
0 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.
D: PREPARATIONTOOL
SELECT MONI-
TOR KIT
ILLUSTRATION
Troubleshootingfor electricalsystem.
Troubleshootingfor electricalsystems.
English: 22771AA030 (Withoutprinter)
German: 22771AA070 (Without printer)
French:22771AA080 (Withoutprinter)
Spanish: 22771 AA090 (Without printer)
82M3076
TOOL NUMBER
24082AA150
Newlyadopted
001)
22771AA030
DESCRlPTlON
ZARTRIDGE REMARKS
I
FU(S0HC)-13

THROTTLE BODY
FUEL INJECTION (FUELSYSTEMS)
2. Throttle Body
A: REMOVAL
1) Disconnectthe battery ground cable.
2) Remove the air cleaner case.<Ref. to IN(S0-
HC)-6, REMOVAL,Air Cleaner Case.>
3) Disconnectthe accelerator cable (A).
4) Disconnect the cruise control cable
(B). (With
cruise control model)
5) Disconnectthe connectors from the idle air con-
trol solenoid valve and throttle position sensor.
6) Disconnectthe air by-pass hosefrom the throttle
body.
I
B2M3457A
(A) Throttle position sensor
(B) Idleair control solenoid valve
(C) Air by-passhosefrom air assist injector sole-
noid valve
7) Disconnect the engine coolant hoses from the
throttle body.
8) Remove the bolts which install throttle body to
the intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tighteningtorque:
Throttle
body;
22 N-m (2.2 kgf-m, 15.9 ft-lb)
FU(S0HC)-14

FUEL INJECTION (FUELSYSTEMS)
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
1) Releasethe fuel pressure. <Ref. to FU(S0HC)-
TION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnectthe battery ground cable.
50, RELEASING OF FUEL PRESSURE, OPERA-
4) Remove the air intake duct and air cleaner as-
sembly. <Ref. to IN(S0HC)-7, REMOVAL, Air In-
take Duct.>and <Ref.to IN(S0HC)-6,REMOVAL,
Air Cleaner Case.>
5) Disconnectthe accelerator cable (A).
6) Disconnect the cruise control cable
(B). (With
cruise control model)
7) Removethe power steering pump.
(1) Remove the resonator chamber. <Ref. to
IN(S0HC)-8, REMOVAL, Resonator Cham-
ber.>
(2) Remove the front side V-belt. <Ref. to
ME(S0HC)-43, REMOVAL,V-belt.>
(3) Removethe boltswhich hold powersteering
pipes onto the intake manifold protector.
NOTE:
Do not disconnect the power steering hose.
(4) Removethe bolts which install power steer-
ing pump bracket
(5) Disconnect the connector from the power
steering pump switch.
(6) Remove the power steering tank from the
bracket by pulling it upwards.
/t/
EN0361
FU(S0HC)-15

INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
(7) Placethe power steering pump on the right
side wheel apron.
8) Disconnectthe spark plug cords from the spark
9) Disconnectthe PCV hose from the intake mani-
fold.
plugs.
10) Disconnect the engine coolant hose from the
throttle body.
11) Disconnectthe brake booster hose.
12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
- 9 B2M4260
r. I I 7-
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnectthe knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU(S0HC)-16

INTAKE MANIFOLD FUEL
INJECTION (FUEL SYSTEMS)
16) Disconnect the connectorfrom the oil pressure
switch.
19) Remove the bolts which hold intake manifold
onto the cylinder heads.
17) Disconnect the connector from the camshaft
positionsensor.
~
18) Disconnect the fuel hosesfrom the fuel pipes.
WARNING:
Do not spill fuel.
Catchfuel from hoses ina container or cloth.
(A) Fuel delivery hose
(B) Return hose
(C) Evaporationhose
20) Removethe intake manifold.
B: INSTALLATION
1) Install the intake manifold onto the cylinder
heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 fi-lb)
FU(S0HC)-17

INTAKE MANIFOLD
FUELINJECTION (FUEL SYSTEMS)
2) Connectthe fuel hoses.
6) Connect the knock sensor connector
(A) Fueldelivery hose
(B) Returnhose
(C) Evaporationhose
3) Connect the connector to the camshaft position
sensor.
4) Connectthe connectorto the oil pressureswitch.
5) Connectthe connector to the crankshaft position
sensor.
7) Connect the connectors to the engine coolant
temperature sensor.
8) Install the air cleaner case stay RH and engine
harness bracket, and connect the engine harness
connectors to the bulkhead connectors.
9) Connect the brake booster hose.
-.-----
FU(S0HC)-18