Subaru 2002 Impreza User manual

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE2SECTION
This service manual has beenprepared
to provide SUBARU service personnel
withthe necessaryinformationanddata
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 INDUSTRIES LTD.
G1830BE3

FUEL INJECTION (FUEL SYSTEMS)
FU(D0HC TURB0)m
Page
1 .
2.
3.
4 .
5 .
6 .
7.
8.
9.
10.
11.
12 .
13.
14.
15.
16 .
17.
18.
19 .
20.
21.
22 .
23 .
24.
25.
26.
27 .
28 .
29 .
30 .
31 .
General Description .................................................................................... 2
Throttle Body
............................................................................................. 14
Intake Manifold
.......................................................................................... 15
Engine Coolant Temperature Sensor
........................................................ 29
Crankshaft PositionSensor
....................................................................... 30
Camshaft PositionSensor
......................................................................... 31
Knock Sensor
............................................................................................ 32
Throttle PositionSensor
............................................................................ 33
MassAir Flow and IntakeAir Temperature Sensor
.................................. 34
PressureSensor
....................................................................................... 35
IdleAir Control Solenoid Valve
................................................................. 36
Tumble GeneratorValve Assembly
.......................................................... 40
Fuel Injector
.............................................................................................. 37
Wastegate Control Solenoid Valve
........................................................... 41
FrontOxygen (NF) Sensor
....................................................................... 42
ExhaustTemperature Sensor
................................................................... 46
RearOxygen Sensor
................................................................................. 44
EngineControl Module
.............................................................................. 47
Main Relay
................................................................................................ 48
Fuel Pump Relay
....................................................................................... 49
Fuel PumpController
................................................................................ 50
Fuel
........................................................................................................... 51
FuelTank
.................................................................................................. 52
Fuel Pump
................................................................................................. 60
Fuel Filler Pipe
.......................................................................................... 55
Fuel Level Sensor
..................................................................................... 62
Fuel Sub Level Sensor
.............................................................................. 63
Fuel Filter
.................................................................................................. 65
Fuel Cut Valve
........................................................................................... 66
Fuel Deliverv
. Return and EvaporationLines ............................................ 68
Fuel DamperValve
................................................................................... 67
a.
32. Fuel SystemTrouble in General
............................................................... 71

GENERAL DESCRIPTION
FUEL INJECTION(FUELSYSTEMS)
Capacity
1. General Description
A: SPECIFICATIONS
60 8 (15.9 USgal, 13.2 Imp gal)
Location Under rear seat
FU(D0HCTURBO)-2
Type
Shutoff discharge pressure
Dischargeflow
Fuelpump
Fuelfilter
Impeller
450
- 677 kPa (4.59 - 6.9 kg/cm2,65.27 - 98.2 psi)
Morethan 130
8 (34.3 US gal, 28.6 Impgal)/h
[12
V at 300 kPa (3.06kg/cm2,43.5 psi)]
Cartridgetype

GENERAL DESCRIPTION FUEL INJECTION(FUELSYSTEMS)
FU(D0HCTURBO)-3

GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)
B: COMPONENT
1. INTAKE MANIFOLD
EN1135
FU(D0HCTURBO)-4

GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)
Fuelpipe ASSY
Fuelhose
Clip
Purgecontrolsolenoidvalve
Vacuum hose
Vacuum controlhose
Purgevalve
Purgehose
Intake manifoldgasket
Guidepin
Tumble generatorvalve
ASSY
Tumble generatorvalvegasket
Acceleratorcable bracket
Fuelinjector
Insulator
Fuelinjectorpipe
Pressure regulator
Pressureregulatorhose
Fuelpipe protector
RH
Blow-byhose stay
Intake manifold
Solenoidvalve cover
Solenoidvalve cover stay
Wastegatecontrolsolenoidvalve
ASSY
(25) Fuelpipeprotector LH
(26) Nipple
Tighteningtorque: N.m (kgf-m, ft-lb)
,
T1: 4.9 (0.5, 3.6)
T2: 6.4(0.65, 4.7)
T3: 8.25
(0.84, 6.1)
T4: 16 (1.6, 11.8)
T5: 17(1.73, 12.5)
T6: 19 (1.94, 13.7)
T7: 25(2.5, 18.1)
FU(D0HC TURB0)-5

GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)
2. AIR INTAKESYSTEM
EN113
~
(1) Gasket (5) Pressuresensor
(2) Throttlepositionsensor (6) Gasket
(3) Idleair controlsolenoidvalve (7) O-ring
(4) Throttlebody
Tighteningtorque: N.m (kgf-m, ft-lb)
T1: 1.6 (0.16,1.2)
T2: 2.8(0.29,2.1)
T3: 22 (2.2, 15.9)
FU(D0HCTURBO)-6

GENERAL DESCRIPTION FUEL INJECTION(FUELSYSTEMS)
3. CRANKSHAFT POSITION,CAMSHAFTPOSITIONAND KNOCK SENSORS
(1) Crankshaftpositionsensor (3) Camshaftpositionsensor Tighteningtorque: N.m (kgf-m, ft-lb)
(2) Knocksensor T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(D0HC TURBO)-7

GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)
4. FUELTANK
EN1119
FU(D0HC TURBO)-8

GENERAL DESCRIPTION
I
FUEL INJECTION (FUEL SYSTEMS)
Heatshieldcover
Fueltank band
ProtectorLH
Protector
RH
Fueltank
Canister hoseA
Clamp
Fuelpumpgasket
FuelpumpASSY
Fuelcut valve gasket
Fuel cut valve
EvaporationhoseA
Clip
Joint pipe
EvaporationhoseC
Evaporationhose
B
Evaporationhose D
Evaporationhose E
Evaporationpipe ASSY
Retainer
Quickconnector
Jet pump hose A
Fuel returnhoseA
FuelpipeASSY
Jet pump hose
B
Fuelreturn hose B
Evaporationhose F
Evaporationhose
G
Fuelsub levelsensor gasket
Jet pumpfilter
Fuelsub levelsensor
Protectorcover
Vent valve hose
Vent valve
Fueltank pressuresensor
Fueltank pressuresensor hose
Vent valve gasket
Tighteningtorque: N-m (kgf-m, ft-lb)
T1: 4.4 (0.45, 3.3)
T2: 7.4(0.75, 5.4)
T3: 33 (3.4,25)
FU(D0HC TURBO)-9

GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)
5. FUELLINE
EN1120
FU(D0HCTURBO)-I 0

GENERAL DESCRIPTION FUELINJECTION(FUELSYSTEMS)
Clamp
Fueldelivery hose
A
Fuelfilter bracket
Fuelfilter holder
Fuelfilter cup
Fuelfilter
Evaporationhose
Clip
Fueldelivery hose
B
Fuel returnhose A
Fuel returnhose B
Fueldamper
Evaporationhose
J
Evaporationhose K
Joint pipe
Canister hose
A
Air filter hose A
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(D0HC TURBO)-I1

GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)
6. FUEL FILLER PIPE
EN1 121
(1) Fuelfilter pipe ASSY (8) Filler pipepacking
(2) Evaporationhose holder (9) Fillerring
(3) Clamp
(4) Clamp
(5) Evaporationhose A
(6) Evaporationpipe
-
(1 0) Filler cap
(1 5)
Fuelfiller pipeprotector
Tighteningtorque: N.m (kgf-m, ft-lb)
(11) Shutvalve T1: 4.4 (0.45, 3.3)
(12) Evaporationhose 6 T2: 7.5 (0.76, 5.5)
(1 3) EvaporationhoseC
(7) Evaporationpipe holder (1 4) Joint pipe
FU(D0HCTURBO)-I 2

GENERAL DESCRIPTION FUEL
INJECTION (FUELSYSTEMS)
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, installationor disassembly.
.Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installationor disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
D: PREPARATIONTOOL
Becarefulnotto burnyour hands, becauseeach
part
On the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nutsto the specifiedtorque.
PlaceshopjacksorSafetystandsatthespecified
points.
Before disconnecting electrical COntleCtOrS 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 fuelon the floor-
ILLUSTRATION
B2M3876
TOOL NUMBER
24082AA150
(Newlyadopted
tool)
22771AA030
DESCRIPTION
CARTRIDGE
SELECT MONI-
TOR KIT
REMARKS
Troubleshootingfor electrical system.
Troubleshootingfor electrical systems.
English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French:22771AA080 (Without printer)
Spanish: 22771 AA090 (Without printer)
FU(D0HC TURBO)-13

THROTTLE BODY
FUEL INJECTION(FUELSYSTEMS)
2. Throttle Body
A: REMOVAL
1) Disconnectthe battery ground cable.
2) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-1
0, REMOVAL,Intercooler.>
3) Disconnectthe connector from the throttle posi-
tion sensor (A)and idle air cotrol solenoid valve (B)
and pressuresensor (C).
4) Disconnectthe acceleratorcable.
5) Disconnect the engine coolant hoses from the
throttle body.
6) Removethe boltswhich secure the throttle body
to intake manifold.
6: INSTALLATION
Install in the reverseorder of removal.
NOTE:
Always use a new gasket.
Tighteningtorque:
22 N-m (2.2 kgf-m, 15.9 Mb)
// EN0785
FU(D0HC TURBO)-14

a
FUELINJECTION(FUELSYSTEMS)
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(D0HC
OPERATION, Fuel.>
2) Disconnectthe battery ground cable.
TURBO)-51, RELEASING OF FUEL PRESSURE,
3) Lift up the vehicle.
4) Removethe under cover.
5) Drain the coolant about 3.0 0 (3.2 US qt, 2.6
Impqt).
6) Remove the air cleaner upper cover and air in-
take boot. <Ref. to IN(D0HC TURBO)-7, REMOV-
AL, Air Cleaner.>
7) Removethe air cleaner element.
8) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-1
0, REMOVAL, Intercooler.>
9) Disconnectthe accelerator cable.
10) Removethe coolantfiller tank. <Ref. to CO-51,
REMOVAL,Coolant FillerTank.>
11) Removethe power steering pump.
(1) Removethe front side V-belt.
<Ref.to ME(D0HCTURBO)-44, REMOVAL,V-
belt.>
(2) Disconnect the power steering switch con-
nector.
(3) Remove the bolts which secure the power
steering pipe bracketsto the intake manifold.
NOTE:
Do not disconnect the power steering hose.
(4) Remove the bolts which secure the power
steering pump bracket.
FU(D0HCTURBO)-15

INTAKE MANIFOLD
FUELINJECTION (FUELSYSTEMS)
(5) Remove the power steering tank from the
bracket by pullingit upward.
(6) Place the power steering pump on the right
side wheel apron.
12) Disconnect the emission hose from the PCV
valve.
13) Disconnect the engine coolant hoses from the
throttle body.
14) Disconnect the brake booster hose.
- EN0204
15) Disconnect the pressure hose from the intake
duct.
16) Disconnect the engine harness connectors
from the bulkheadharnessconnectors.
FU(D0HC TURBO)-16

FUELINJECTION(FUELSYSTEMS)
INTAKE MANIFOLD
17) Disconnect the connectors from the engine
coolanttemperature sensor
(A), oil pressureswitch
(B) and crankshaft position sensor (C).
v .
18) Disconnectthe knock sensor connector.
S2M1613
19) Disconnect the connector from the camshaft
positionsensor.
21) Disconnectthe engine harnessfixed by clip
(A)
from the bracket.
\\ I II
(6)
S2M2256A
22) Disconnect the fuel delivery hose, return hose
and evaporation hose.
WARNING:
Catchthe fuel from hoses in a container.
23) Removethe boltswhich securethe intakeman-
ifoldto the cylinder heads.
20) Disconnectthe connector from the ignitioncoil.
24) Removethe intake manifold.
EN0854
FU(D0HC TURBO)-17

INTAKE MANIFOLD
FUEL INJECTION (FUELSYSTEMS)
B: INSTALLATION
1) Installthe intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tighteningtorque:
25N-m(2.5 kgf-m,
18.1 ft-16)
2) Connectthe fuel delivery hose, return hose, and
evaporation hose.
3) Connectthe connector to the oil pressureswitch
(B), crankshaft position sensor (C) and engine
coolanttemperature sensor (A).
4) Connectthe connector
to the knock sensor.
S2M1613
5) Connect the connector to the camshaft position
sensor.
6) Connect the connector to the ignition coil.
EN0854 I
7) Connect the engine harness with clip (A) to the
bracket.
FU(D0HCTURBO)-I8