2011 IMPREZA WRX STI 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. Al 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. Te ae ae) Ermine (aa eke ae eae} De oa oa) CUS ore eco rreln tc} ety Bee ead Borel ESC y ee) ery CLF ME(wio STI) Ore) ) UC) ee) ocr) G11108E3Wwoo'ubelpiedFUEL INJECTION (FUEL SYSTEMS) FU(w/o STI) Page 1. General Description es ee) 2. Throttle Body 15 3. Intake Manifold eve 17 4. Engine Coolant Temperature Sensor 32 5. Crankshaft Position Sensor 33 6. Camshaft Position Sensor... sevens 35 7. Knock Sensor 37 8 Throttle Position Sensor 39 9. Mass Air Flow and Intake Air Temperature Sensor 40 10. Manifold Absolute Pressure Sensor At 11. Fuel Injector . . 43 12. Tumble Generator Valve Assembly 46 18. Tumble Generator Valve Actuator 47 14. Oil Flow Control Solenoid Valve... seven 48 15. Wastegate Control Solenoid Valve 49 16. Front Oxygen (A/F) Sensor 50 17. Rear Oxygen Sensor . 52 18 Ene Condo] Modul (ECM) 54 19. Main Relay nn rennen esnnnniennnee 55 20. Fuel Pump Relay ST 21. Electronic Throttle Control Relay 59 22. Fuel Pump Control Unit sev 61 23. Fuel 62 24. Fuel Tank - 65 25. Fuel Filler Pipe . - 72 26. Fuel Pump 75 27. Fuel Level Sensor 7 28. Fuel Sub Level Sensor 2 78 29. Fuel Filter 80 30. Fuel Damper enn tiie . 84 31. Purge Damper 85 32. Fuel Delivery, Return and Evaporation Lines 86 33. Fuel System Trouble in General . 21General Description FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATION Capacity 64 0 (169 US gal, 141 imp gal Fuel ink Location Under rear seat Type Impeller iting Shutoff discharge pressure {560 — B60 KPa (6 61 — 8.67 kolo, 788 — 123.3 psi) Bischange ro 155 2 (40.9 US gal, 34.1 Imp galjh or more [12 Vat 300 KPa (3.06 kgfiom?, 43.5 psi} Fuel fiter Inetank ype FU(wio STI)-2General Description FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 4. INTAKE MANIFOLD Fus702 FU(wio STI)-3FUEL INJECTION (FUEL SYSTEMS) a @) ®) @ ©) ©) a @) @ (10) (11) (12) (13) (14) (15) Prossure regulator, Fuel hose A Clamp Purge control solenoid valve 1 Vacuum hose D Vacuum hose G Intake manifold gasket Guido pin Tumble generator valve ASSY Ful injector Seal ring Purge control solenoid valve 2 Fuel injector pipe LH Fuel injector pipe RH Solenoid valve bracket General Description (18) (17) (18) (19) (20) 2) (22) (23) (24) (25) (28) (7) (28) (29) (30) Manifold absolute prossure sensor Filter Intake manifold Wastegate control solenoid valve ASsY Vacuum hose Fuel pipe protector LH Fuel pipe protector RH O-ring ‘Solenid valve bracket ‘Vacuum hose B ‘Vacuum hose A Air control hose Nipple Fucl hose B Ful hose C FU(wio STI)-4 (31) Vacuum hose (82) O+ing (33) Fuel pipe (84) Ong (35) Rubber Tightening torque:Nm (kgf-m, felb) Tt: 1.25 (0.4, 0.9) T2: 3.5 (04,26) Ta: 6.4(0.7, 47) TA: 8.30.8, 6.1) TS: 19(19, 140) To: 23(2.3,17.0) TH: 2525.1General Description FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM Fu.05844| (1) Oring (2) Throttle body Tightening torque: (kgf, eb) T:_ 8 (08,59) FU(wio STI)-5General Description FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS TH Fu.05851 (1) Crankshaft position sensor (3) Camshaft position sensor LH Tightening torque:N-m (kgf-m, ft-lb) (2) Knock sensor (4) Camshaft position sensor RH TI: 6.4 (0.7, 4.7) Ta_26 (24, 17.7) FU(wio STI)-6General Description FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK 2 4s 72 i 4 t WS mn kaa Se 7: Fussras FU(wio STI)-7General Description FUEL INJECTION (FUEL SYSTEMS) (1) Fu! tank (11) Fuel sub evel sensor (21) Fuol tank protector LH (2) Fuel tank band RH (12) Fuel sub level sensor upper plate (22) Clip. (3) Fuel tank band LH (13) Fuel sub level sensor gasket (23) SelFocking nut (4) Fusl delivery tube (14) Fuol sub evel sensor protector (24) Rubber cap (8) Fuel retum tube (15) Fuel sub level sensor fter (6) Jet pump tube (18) Retainer (7) Fust pump ASSY (17) Stopper RH (8) Fuel pump upper plate (18) Stopper LH T2: 9(0.9, 6.6) (®) Fuel pump gasket (19) Heat shield cover 73: 18 (1.8, 13.3) (10) Fuel level sensor (20) Fuel tank protector RH Ta: 33 FU(wio STI)-8General Description FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE as eae EN © Fu.srot FU(wio STI)-9FUEL INJECTION (FUEL SYSTEMS) a @) ®) @ 6) ©) a @) @) (19) (1) (12) (13) (14) (18) (16) 7) (18) (19) Clip Fuel return hose A. Fuel return hose 8 Evaporation hose A Evaporation hose B. Fuel delivery hose A Fuel delivery hose B Fuel damper holder Clamp Purge damper Purge damper bracket Damper bracket Fuel damper A Fuel damper B Clamp Fuel pipe ASSY Pressure hose Fuel tank pressure sensor bracket A Fuel tank pressure sensor bracket 8 General Description (20) 1 (22) (23) (24) (25) (28) (27) (28) (29) (30) (31) (32) (33) (34) (35) (38) (@7) (38) Ful tank pressure sensor Vacuum hose Evaporation hose C Clamp Fue! filer hose PCV drain tube Evaporation hose D Evaporation hose E Pressure control solancid valve Pressure control solenoid valve bracket A Pressure control solenoid valve bracket B Evaporation hose F Evaporation hose G Drain hose Drain separator Drain separator bracket Drain tube A Drain valve bracket Drain valve It.can be roused ifthe quick connector sido is disconnected. FU(wio STI)-10 (89) Purge tube (40) Vent tube (41) Drain tube 8 (42) Canistor (43) Canister cover LH (44) Center canister cover, (45) Canister cover RH (48) Clamp Tightening torque:Nvm (kat, folb) TH 1.25 (0.1, 0.8) 2 (02,15) 25 (03,18) Té: 7.5 (08, 55) TS: (0.8, 5.9) To: 19(4.3, 9.6) Tr: 16 (1.8, 13.)General Description FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE Fussri| (1) Fuel filler pipe (8) Evaporation hose A (14) Evaporation hose C (2) Evaporation pipe A (9) Grommet (18) Clip @) Fustfilarcap (19) Evaporation pipe 8 (4). Filing (11) Quick connector “Tightening torque:Nm (kgm, Told) (©) Filerpipe gasket (12) Evaporation hose B Tt: 44 (04, 3.2) (6) Shutvale (13) Evaporation pipe protector Ta:_7.5 (08, 55) @) Clip FU(w/o STI)-14General Description FUEL INJECTION (FUEL SYSTEMS) 7. FUEL PUMP a @ @) “ 6 ‘Sub tank bracket ASSY o-ring O-ing Fuel pump harness Spring ® ” @ @ (10) Fu95705 Fuel fiter (11) Cushion ip (12) Fuel level sensor Spacer (13) Fuel temperature sensor Pump ASSY Sub tank FU(wio STI)-12General Description FUEL INJECTION (FUEL SYSTEMS) Cc: CAUTION Wear appropriate work clothing, ining a cap, protective goggles and protective shoes when performing any wor =" Remove contamination including clit and corrosion before removal, installation or disassembly. + Keep the disassembled parts in order and protect them from dust and dirt + Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, in- stallation, disassembly and replacement. + Vehicle components are extremely hot after driving. Be wary of receiving bums from heated parts + Be sure to tighten fasteners including bolts and nuts to the specified torque. + Place shop jacks or rigid racks at the specified points. + Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. + Place "NO OPEN FLAMES’ signs near the working area + Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. Ifthe oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environ- mental protection. * Follow all government and local regulations concerning disposal of refuse when disposing fuel. D: PREPARATION TOOL 4. SPECIAL TOOL ILLUSTRATION TOOLNUMBER [DESCRIPTION REMARKS 76353AA000 [CLAMP PLIERS | + Used for removing and installing the PCV hose. + This tool is made by the French company CAILLAU. (code) 54.0.000.205 ‘Te make it easier to obtain, it has been provided ee ED witha tool number ST1H259AA000 48371AA000 | CONNECTOR Used for disconnecting the quick connector on REMOVER: the fuel return hose side of the engine compart- ‘ment (intake manifold). sT1@971AA000 1871AA000 | FUEL PIPE Used for draining fuel. ADAPTER a“) oT a or STIBA7AAGOO FU(wio STI)-13General Description FUEL INJECTION (FUEL SYSTEMS) ILLUSTRATION TOOL NUMBER [DESCRIPTION REMARKS -42098AE000 | QUICK CONNEC. | Used for removing the quick connector TOR RELEASE ‘ST42000AE000 1B022XU0 | SUBARU SELECT | Used for draining fuel and each inspection MONITOR I KIT STIBO22KU0 2. GENERAL TOOL TOOL NAME REMARKS: Circuit tester Used for measuring resistance and voltage. (Oscilloscope Used for inspecting the waveform of each sensor. FU(wio STI)-14Throttle Body 2. Throttle Body A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain approximately 3.0 0 (3.2 US qt, 2.6 Imp ql) of coolant. 5) Remove the intercooler. 6) Disconnect the connectors from the throttle posi- tion sensor. 7) Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loos- en the clamp which connects the throttle body and intake duct. 8) Remove the intake duct from the throttle body. Tightening torque: 71: 3 Nim (0.3 kaf-m, 2.2 ft-lb) 72: 6.4 N-m (0.7 kgt-m, 4.7 ft-lb) FUEL INJECTION (FUEL SYSTEMS) 9) Disconnect the engine coolant hose from throttle body. 10) Remove the throttle body from the intake man- INSTALLATION Install in the reverse order of removal NOTE: Use new O-rings. Tightening torque: 8 N-m (0.8 kgf-m, 5.9 ft-lb) FU(w/o STI)-15Throttle Body FUEL INJECTION (FUEL SYSTEMS) C: INSPECTION 1. THROTTLE SENSOR INSPECTION (METHOD WITH CIRCUIT TESTER) 1) Remove the lower inner trim of passenger's Trim> 6) Measure the voltage between ECM connector terminals. @ Tls[s[4[s[2[s] Tiel fis] 10 [9 6 27.2322 aol als FABIEN F-04040) (A) To ECM connector Throttle | Accelerator side, TThrattlo opening Throtle sensor_| THOUS open Standard Main 0.0% ‘Approx. 0.6 V 100.0% ‘Approx. 3.96 V Sub 0.0% ‘Approx. 1.48 700.0% ‘Approx. 4.17 V 3. OTHER INSPECTIONS 1) Check that the throttle body has no deformation, ‘cracks or other damages. 2) Check that the engine coolant hose has no cracks, damage or loose part. FU(wio STI)-16Intake Manifold . Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 3. 14) Disconnect the connector (A) from the PCV. A: REMOVAL 1) Remove the V-belt covers. ME-02308 2) Collect the refrigerant from A/C system. 3) Release the fuel pressure. 4) Disconnect the ground cable from battery. 5) Open the fuel filler lid and remove the fuel filer cap. 6) Lift up the vehicle. 7) Remove the under cover. 8) Drain approximately 3.0 0 (3.2 US qt, 2.6 Imp qt) of coolant. 9) Remove the air intake duct and air cleaner case. 10) Remove the intercooler. 11) Remove the generator. 12) Remove the coolant filer tank. 18) Disconnect the A/C pressure hoses from A/C compressor. hose assembly and the connector (B) from the knock sensor. Fu.0s706) 15) Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loos- ‘en the clamp which connects the throttle body and intake duct. 16) Remove the intake duct from the throttle body. 17) Disconnect the engine coolant hose from throt- tle body. 7_Fisa60 Disconnect the vacuum hose from nipple. _ — 18) FU(wio STI)-17Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 19) Disconnect the brake booster vacuum hose. er —] 21) Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp which holds the intake duct to the turbocharger. Pa we 22) Disconnect the bulkhead harness connectors from the engine harness connectors. VM 23) Remove the engine harness connector from the engine hamess bracket E-04172 24) Disconnect the connector (A) from the engine Coolant temperature sensor, connector (B) from the oil pressure switch, and connector (C) from the crankshaft position sensor aS) O Fu.0s714 25) Disconnect the connector from power steering pump switch. FU(wio STI)-18Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 26) Disconnect the connector from the secondary 28) Disconnect the connector from the oil flow con- air combination valve. trol solenoid vaive. Fv.osrs0 27) Disconnect the connector from camshaft posi 29) Disconnect the air duct from the secondary air tion sensor. pump, and remove the bolts securing the air duct ‘on the rocker cover LH. FU(wio STI)-19Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 30) Disconnect the connector from ignition coil. A russris 31) Disconnect the connector from the front oxygen (A/F) sensor, and remove the clip (A) and stay (B) whieh hold the engine hamess to the rocker cover RH. 32) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RE- LEASE CAUTION: * Be careful not to spill fuel. + Catch the fuel from hoses using a container or cloth. (A) Fuel datvery hose (8) Fuot return hose (©) Evaporation hose 33) Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: + Be careful not to spill fuel. + Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel return pipe as shown in the figure. (2) Insert the front side of ST into the quick con- nector. FU(wio STI)-20Intake Manifold (3) Insert the back side of ST into the quick con- nector and push ST in the direction of arrow mark to disconnect the fuel return hose. 34) Remove the clip and disconnect the evapora tion hose from the fuel pipe. \ — ol Ws VIS S 35) Remove the intake manifold from cylinder head == Salk 2 Foot FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 1) Install the intake manifold onto cylinder heads. NOTE: Use a new gasket. Tightening torque: Fu.os0es 2) Connect the fuel delivery hose, fuel return hose, and evaporation hose. (A) Fuel delivery hose (8) Fuel retun hose (©) Evaporation hose 3) Connect the front oxygen (A/F) sensor connec- tor, and secure the engine harness to the rocker cover RH with clip (A) and stay (B). Tightening torque: 6.4.N-m (0.7 kgf-m, 4.7 ft-lb) FU(wio STI)-24Intake Manifold FUEL INJECTION (FUEL SYSTEMS) ition coil 6) Connect the connector to oil flow control sole- noid valve. 5) Connect the air duct to the secondary air pump, Pott Ft __ruosrse| and install the air duct on the rocker cover LH, 7) Connect the connectors to camshaft position Tightening torque: ani 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) FU(wio STI)-22Intake Manifold 8) Connect the connector to the secondary air com- bination valve 9) Connect the connector to the power steering pump switch. 10) Connect the connector (A) to the engine cool- ant temperature sensor, connector (B) to the oil pressure switch, and the connector (C) to the ‘orankshaft position sensor. Sy) Fusrit FUEL INJECTION (FUEL SYSTEMS) 41) Install the engine harness connector to engine hamess bracket, then connect the bulkhead har- ness connector to the engine harness connector. Py. a Sd 12) Connect the air control hose (A) to the waste- gate actuator, and install the turbocharger to the in- take duct. Tightening torque: ‘3 Nm (0.3 kgf-m, 2.2 ft-lb) FU(wio STI)-23Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 14) Connect the brake booster vacuum hose. i) NX i a BN Ks a 15) Connect the vacuum hose to the nipple. / je \ L say Vz A § iN |\ 71 VRE 46) Connect the engine coolant hoses to throttle body. 17) Install the intake duct to the throttle body. Tightening torque: 3.Nem (0.3 kgf-m, 2.2 ft-lb) 18) Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold. Tightening torque: 6.4 Nm (0.7 kgt-m, 4.7 ft-lb) 19) Connect the connector (A) to the PCV hose as- sembly and the connector (B) to the knock sensor. Fu.05706 20) Install the A/C pressure hoses to A/C compres- sor. 21) Install the coolant filler tank. 22) Install the generator. 23) Install the intercooler. 25) Connect the battery ground terminal 26) Lift up the vehicle. 27) Install the under cover. 28) Lower the vehicle. 29) Fill engine coolant. 30) Charge the A/C system with refrigerant. FU(w/o STI)-24Intake Manifold 31) Install the V-belt cover. Tightening torque: 13 N-m (1.3 kgf-m, 9.6 ft-lb) Cc: DISASSEMBLY 1) Remove the fuel pipe protector RH from the in- take manifold, FR Fu.oe?, 2) Remove the engine ground terminal from the fuel pipe protector LH and remove the fuel pipe pro- tector LH from the intake manifold t Fuses 3) Disconnect the vacuum hose (A) from intake manifold, FUEL INJECTION (FUEL SYSTEMS) 4) Disconnect the vacuum hose (B) and the con- nector (C) from the fuel pipe, and remove the purge control solenoid valve 1 from the intake manifold. Fu.os342, 6) Disconnect the connector from the wastegate control solenoid valve and the manifold absolute pressure sensor, and remove the solenoid valve bracket assembly from the intake manifold, 7) Disconnect the connector from the purge control solenoid valve 2, and disconnect the vacuum hose from the intake duct and the fuel pipe 8) Disconnect the connectors from the throttle posi- tion sensor. f= Fu.05873) FU(wio STI)-25Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 9) Remove the throttle body from the intake mani- fold. 10) Disconnect the connector from the fuel injector and tumble generator valve assembly. 1) Remove the bolts which hold fuel injector pipe onto intake manifold. + RH side Fuca 11) Remove the PCV pipe (A), harness assembly (8) and intake dust (C) from the intake manifold Fu.os310) 14) Remove the fuel injector. + RH side 12) Remove the bolt which secures the fuel injector pipe LH onto the intake manifold, and disconnect the pressure regulator vacuum hose from the in- take manifola, FU(wio STI)-26Intake Manifold 15) Remove the bolts which hold fuel pipe onto in- take manifold, FU.05236) 16) Remove the bolt which holds fuel injector pipe RH onto intake manifold, — Fuss 17) Loosen the clamp which holds the fuel hose to the fuel injector pipe RH and the fuel pipe, and then disconnect the pipe from the fuel hose. Fu.08237 18) Remove the fuel injector pipe and the fuel pipe. 19) Remove the tumble generator valve assembly from the intake manifold Fu.cooss| FUEL INJECTION (FUEL SYSTEMS) 20) Remove the nipple from the intake manifold D: ASSEMBLY 1) Apply liquid gasket to the nipple threads, and in- stall the nipple to the intake manifold Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 23 N:m (2.3 kgf, 17.0 ft-lb) : a yy ~Aayl 2) Install the tumble generator valve assembly onto intake manifold, NOTE: Use new O-rings. Tightening torque: 8.3 Nim (0. . 3) Install the fuel injector pipe. FU(wlo STI)-27Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 4) Connect fuel hoses to the fuel injector pipe and the fuel pipe. F-05237 5) Secure the fuel injector pipe RH to intake mani- fold with bott. 7) Install the fuel injector. NOTE: Use new O-rings, rubbers and seal rings. + RH side Fucoxos1| Se tae a vans Tightening torque: 6) Secure the fuel pipe to intake manifold with 6.4 Nm (0.7 kgt-m, 4.7 ft-lb) bolts. FU.05236) 8) Secure the fuel injector pipe to intake manifold with bolts, Tightening torque: 19 N-m (1.9 kgf-m, 14.0 ft-lb) + RH side F-03080) Fuctst0) FU(wio STI)-28Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 9) Secure the fuel injector pipe LH to intake mani- 12) Install the throttle body to the intake manifold fold with bolt, and connect the pressure regulator ge. vacuum hose to the intake manifold. Use new O-nas Tightening torque: Tightening torque: 6.4 Nm (0.7 kgt-m, 4.7 ft-lb) Nm (08 kofem, 6.9 feb) \ Fu.oss19 10) Install PCV pipe (A), hamess assembly (B)and 43) intake duct (C) to the intake manifold ae Tightening torque: 6.4.N-m (0.7 kgf-m, 4.7 ft-lb) Fuose73) Fuosoed 11) Connect the connector to the fuel injector and the tumble generator valve assembly. FU(wio STI)-28Intake Manifold FUEL INJECTION (FUEL SYSTEMS) 14) Connect the vacuum hose to the intake duct and the fuel pipe, then connect the connector to the purge control solenoid valve 2. NOTE: Connect the vacuum hose as shown in the figure. 0.02517 (A). Purge control solenoid valve 1 (8) Purge control solenoid valve 2 (a) To intake manifold (0) To intake duct (€) To tue! pipe 15) Install the solenoid valve bracket assembly to the intake manifold, and connect the connector to the wastegate control solenoid valve and the man- ifold absolute pressure sensor. Tightening torque: T1: 17 Nm (1.7 kgf-m, 12.5 ft-lb) T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb) 16) Connect the filter assembly. Fu.05942_ 17) Connect the vacuum hose and the connector the fuel pipe, and install the purge control solenoid valve 1 to the intake manifold NOTE: Connect the vacuum hose as shown in the figure. a © Eco2st7 (A) Purge control solenoid valve 1 (8). Purge control solenoid valve 2 (@) To intake manifold (b) To intake duct (©) Totus! pipo FU(wio STI)-30Intake Manifold FUEL INJECTION (FUEL SYSTEMS) Tightening torque: —oom 6.4 N 4. fc. S| aes 18) Connect the vacuum hose to the intake mani- fold. NOTE: Connect the vacuum hose as shown in the figure. © 002517) (A). Purge control solencid valve 1 (8) Purge control solenoid valve 2 (@) To intako manifold (0) To intake duct (c) To fusl pipe 19) Install the fuel pipe protector LH to the intake manifold, and install the engine ground terminal to the fuel pipe protector LH. Tightening torque: 19 Nem (1.9 kgf-m, 14.0 ft-lb) 20) Install the fuel pipe protector RH to the intake manifold. Tightening torque: 19 Nem (1.9 kgf-m, 14.0 ft-lb) Fu-o3087 E: INSPECTION 41) Check that the intake manifold and fuel pipe have no deformation, cracks and other damages. 2) Check that the hose has no cracks, damage or loose part FU(wio STI)-34Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2)Remove the generator. 3) Drain engine coolant. 4) Disconnect the connector (A) from the engine coolant temperature sensor, and remove the en- gine coolant temperature sensor. B: INSTALLATION Install in the reverse order of removal. NOTE Use a new gasket. Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb) C: INSPECTION 1) Check that the engine coolant temperature sen- sor has no deformation, cracks or other damages. 2) Immerse the engine coolant temperature sensor and a thermometer in water. CAUTION Take care not to allow water to get into th: gine coolant temperature sensor connector. Completely remove any water inside, Coy — 4053 (A) Thermometer (8) Engine coolant temperature sensor (©) Hexagonal part height: To approx." 3) Raise water temperature gradually, measure the resistance between the engine coolant tempera- ture sensor terminals when the temperature is 20°C (68°F) and 80°C (176°F). NOTE: Agitate the water for even temperature distribution. 0.02426) Weiorenpo=: | Taina | Sondre aces ||, | 24s B00 (76F) Taie2001e ka FU(wio STI)-32Crankshaft Position Sensor 5. Crankshaft Po: A: REMOVAL 1) Remove the collector cover. 2) Disconnect the ground cable from battery. ion Sensor wN.00203| 3) Remove the bolt which secures crankshaft posi- tion sensor to oil pump. FUEL INJECTION (FUEL SYSTEMS) C: INSPECTION 4. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER) Measure the resistance between crankshaft posi- tion sensor terminals. 0.02426; "Terminal No. ‘Standard 4) Remove the sensor, and then disconnect the connector from the crankshaft position sensor. Fuoss4e| B: INSTALLATION Install in the reverse order of removal. Tightening torque: 6.4 Nm (0.7 kgt-m, 4.7 ft-lb) and 2 2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE) 1) Prepare an oscilloscope. 2)Remove the lower inner trim of passenger's side. 3) Turn over the floor mat of passenger's seat 4) Remove the eee cover. Ae ne es 2,040,204 KO ———= Fussite 5) Remove the nuts and bolts which hold the ECM. to the bracket Fusosss7| FU(wio STI)-33Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 6) Connect the probe to ECM connector. Fu.o4Ts8. (A) ToECM connector "Terminal No. Probe 7 + 5 = 7) Start the engine and let it idle. 8) Check the pattern is the same as the waveform and voltage shown below. a Me (A). One crankshaft rotation 9) After inspection, install the related parts in the reverse order of removal. Tightening torque: 7.5 N-m (0.8 kgf-m, 5.5 ft-lb) 3. OTHER INSPECTIONS Check that the crankshaft position sensor has no deformation, cracks or other damages. FU(w/o STI)-34Camshaft Position Sensor A: REMOVAL 41. CAMSHAFT POSITION SENSOR RH 1) Disconnect the ground cable from battery. = he AN —alé hae) COIN Pt inom 2) Disconnect the connector (A) from the camshaft position sensor RH, and remove the camshaft po- sition sensor RH from the rear side of the cylinder head 2. CAMSHAFT POSITION SENSOR LH 1) Remove the collector cover. 2) Disconnect the ground cable from battery 1N-00003 3) Remove the intake manifold. FUEL INJECTION (FUEL SYSTEMS) 4) Remove the camshaft position sensor LH. 7 “) Fu.05841 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 6.4 Nem (0.7 kgf-m, 4.7 ft-lb) Cc: INSPECTION 4. CAMSHAFT POSITION SENSOR (METH- OD WITH OSCILLOSCOPE) 1) Prepare an oscilloscope. 2)Remove the lower inner trim of passenger's side. 3) Turn over the floor mat of passenger's seat 4) Remove the protect cover. Pes Yew) oN eieee \ Aaa rm SSIS, 5) Remove the nuts and bolts which hold the ECM. to the bracket. Fuosei7, FU(w/o STI)-35Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS) 6) Connect the probe to ECM connector. w Tle[sl4[sl21i fa silo rate zfalish aslza) [la Fuows? (8) To ECM connector Comat post T Tern No, Probe RH a = LH 6 + RHland LH 20 7 7) Start the engine and let it idle. 8) Check the pattern is the same as the waveform and voltage shown below. (A) One camshatt rotation 9) After inspection, install the related parts in the reverse order of removal Tightening torque: 7.5 Nim (0.8 kgt-m, 5.5 ft-lb) 2. OTHER INSPECTIONS Check that the camshaft position sensor has no de- formation, cracks or other damages. FU(w/o STI)-36Knock Sensor 7. Knock Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the intercooler. 3) Disconnect the connector from the knock sen- sor. Ls, euiosis0 FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 1) Install the knock sensor to the cylinder block NOTE: The portion of the knock sensor cord that is pulled ‘out must be positioned at a 60° angle relative to the engine rear. Tightening torque: 24 Nim (2.4 kgf-m, 17.7 ft-lb) (A) Front side of vehicle 2) Connect the knock sensor connector. Fuoszi6 3) Install the intercooler. FU(wio STI)-39Mass Air Flow and Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS) 9. Mass Air Flow and Intake Air 2) Check the voltage changes when air is blown to Temperature Sensor the mass air flow sensor unit in arrow direction. A: REMOVAL 1) Disconnect the ground cable from battery Lr Fu.o406s 2. CHECK THE INTAKE AIR TEMPERA- TURE SENSOR UNIT (NAAT waar) Measure the resistance between intake air temper- 2) Disconnect the connector (A) from the mass air _ature sensor terminals. flow and intake air temperature sensor, and re- move the mass air flow and intake air temperature sensor. 7 f, fo fo Tot i x \ Fu-04064 | NY —— | ‘Temperature [Terminal No. ‘Standard \\ =20°C (-4F) 160224 ko 20°C (68) sand2 | 2aseo24 B: INSTALLATION 50°C (40°F) 0.58020.067 kx Install in the reverse order of removal. Tightening torque: 3. OTHER INSPECTIONS , A ‘ 1) Check that the mass air flow and intake air tem- iien @eiskgEte 27; felb) perature sensor has no deformation, cracks or oth- Cc: INSPECTION er damages. 1. CHECK THE MASS AIR FLOW SENSOR 2) “heck that the mass air flow and intake air tem- ine perature sensor has no dirt 1) Connect the battery positive terminal to terminal No. 3 and the battery ground terminal to terminal No. 4, the circuit tester positive terminal to terminal No. 5 and the circuit tester ground terminal to termi- nal No. 4. (sl4[s[211] A | al F-04082 FU(wio STI)-40Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS) 10.Manifold Absolute Pressure Sensor A: REMOVAL 1) Remove the collector cover. 2) Disconnect the ground cable from battery. WI / at 3) Disconnect the connector (A) from manifold ab- solute pressure sensor, and remove the filter as- sembly (B) from intake manifold 4) Remove the manifold absolute pressure sensor from the solenoid valve bracket. B: INSTALLATION Install in the reverse order of removal. Tightening torque: 6.4.N-m (0.7 kgf-m, 4.7 ft-lb) C: INSPECTION 1) Check that the manifold absolute pressure sen- ‘sor has no deformation, cracks or other damages, 2) Connect dry-cell battery positive terminal to ter- minal No. 3 and dry-cell battery ground terminal to terminal No. 1, circuit tester positive terminal to ter- minal No. 2 and the circuit tester negative terminal to terminal No. 1 NOTE: + Use new dry-cell batteries. * Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of thrée batteries in series is between 4.8 V and 5.2 V. ) tv f) tev 5) s9v y i} 54.8~5.29 Fu.ous 3) Check the voltage at a normal atmospheric pres- sure NOTE: The atmospheric pressure at higher altitude is low- er than normal. Therefore, the voltage is lower than the standard value. Terminal No. 2(+) and 1 (-) Standard Approx. 22 V (when 25°C (77°F) FU(wlo STI)-44Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS) 4) Connect the Mighty Vac to the pressure port (A) of manifold absolute pressure sensor. Fucus? 5) Check the voltage when generating vacuum and positive pressure using Mighty Vac. CAUTION: Do not apply vacuum of less than -88 — 200 kPa (-0.9 — 2.04 kgflcm2, 12.8 — 29.0 psi). Do- ing so may damage the manifold absolute pres- sure sensor. NOTE: When vacuum occurs at the pressure port of man- ifold absolute pressure sensor, the voltage will drop from the value as in step 3). When positive pres- sure occurs, on the other hand, the voltage will rise. Pressure | TarinalNe. | — Standard 20a 09 kg Feprox 10 crt 128 pa) (when 25°C aepantt ey | oe 12 KPa (1.88 kat nega ort 220 pa oe FU(wio STI)-42Fuel Injector 11.Fuel Injector A: REMOVAL 4. RH SIDE 1) Release the fuel pressure. 2) Disconnect the ground cable from battery. 3) Open the fuel filer id and remove the fuel filler cap. 4) Remove the intake manifold. 5) Remove the fuel pipe protector RH from the in- take manifold Fu.02087 6) Disconnect the connector from fuel injector. 7) Remove the bolt which holds fuel injector pipe RH onto intake manifold. Fu.03080 FUEL INJECTION (FUEL SYSTEMS) 8) Remove the fuel injector. 2. LH SIDE 1) Release the fuel pressure. 2) Disconnect the ground cable from battery. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Remove the intake manifold. 5) Remove the engine ground terminal from the {uel pipe protector LH and remove the fuel pipe pro- tector LH from the intake manifold cy 00096 6) Disconnect the connector from fuel injector. FU(wio STI)-43Fuel Injector FUEL INJECTION (FUEL SYSTEMS) 7) Remove the bolt which holds fuel injector pipe B: INSTALLATION LH onto intake manifold. 4. RH SIDE Install in the reverse order of removal, NOTE: Use new O-rings, rubbers and seal rings. Tightening torque: 19 Nem (1.9 kgf-m, 14.0 ft-lb) Fu-o30s7 FU(w/o STI)-442. LH SIDE Install in the reverse order of removal. NOTE Use new O-rings, rubbers and seal rings. Tightening torque: 6.4 N-m (0.7 kgf-m, 4.7 ft-lb) Fuel Injector FUEL INJECTION (FUEL SYSTEMS) C: INSPECTION 1) Check that the fuel injector has no deformation, cracks or other damages. 2) Measure the resistance between fuel injector terminals. ali / : \ w/aie | i i sled eR) La, I Ec.02428 | 6 4 U /2 BA a "Terminal No Standard ] Tightening torque: Tand2 ‘Approx. 12.0 2 (when 20°C (68°F) | 19 Nm (1.9 kgf-m, 14. Fu.03086, FU(w/o STI)-45Tumble Generator Valve Assembly FUEL INJECTION (FUEL SYSTEMS) 12.Tumble Generator Valve As- sembly A: REMOVAL 1) Release the fuel pressure. 2) Disconnect the ground cable from battery. 3) Open the fuel filer lid and remove the fuel filler cap. 4) Remove the intake manifold. 5) Disconnect the connector from the tumble gen- erator valve assembly. SW LL) ave 6) Remove the fuel injector. 7) Remove the tumble generator valve assembly from the intake manifold Fu.03000) B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 8.3 Nem (0.8 kgf-m, 6.1 ft-lb) C: INSPECTION 41) Check that the tumble generator valve assembly has no deformation, cracks or other damages. 2) Check tumble generator valve for contamination or clogging FU(w/o STI)-46Tumble Generator Valve Actuator FUEL INJECTION (FUEL SYSTEMS) 13.Tumble Generator Valve Ac- tuator A: SPECIFICATION The tumble generator valve assembly cannot be disassembled Refer to “Tumble Generator Valve Assembly” for removal and installation procedures. B: INSTALLATION Refer to “Camshaft” for installation_procedure. Cc: DISASSEMBLY 1) Remove the two mounting bolts securing oil re- turn cover, and remove the oil return cover and gasket, 2) Remove the bolt securing oil flow contro! sole- noid valve, and remove the oil flow control solenoid valve Fu.oso0e {A)_ Oil flow control solenoid valve (8) Oillreturn cover (C) Gasket (D) Front camshaft eap D: ASSEMBLY 1) Install the oil flow control solenoid valve Tightening torque: 6.4.N-m (0.7 kgf-m, 4.7 ft-lb) 2) Apply liquid gasket to the two bolts securing oi return cover. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent 3) Attach the oil return cover and gasket. NOTE: Use a new gasket Tightening torque: ‘9 N-m (0.9 kgf-m, 6.6 ft-Ib) Fu.os700 (A) Oil flow contro solencid valve (8) Oi|retun cover (C) Gasket (O) Front camshaft cap E: INSPECTION 1) Check that the oil flow control solenoid valve has no deformation, cracks or other damages. 2)Measure the resistance between the oil flow control solenoid valve terminals. Ec-02426) Terminal No: Tand2 Standard 7A205 2 (20°C (68°F) FU(wio STI)-48Wastegate Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS) 15.Wastegate Control Solenoid Valve A: REMOVAL 1) Remove the collector cover. 2) Disconnect the ground cable from battery. 3) Disconnect the connector (A) from the waste- gate control solenoid valve. 4) Disconnect the vacuum hose (B) and air control hose (C) from the wastegate control solenoid valve. 5) Remove the wastegate control solenoid valve from the bracket L__=" = _®\_wasr] B: INSTALLATION Install in the reverse order of removal. Tightening torque: 6.4 N-m (0.7 kgf-m, 4.7 ft-lb) C: INSPECTION 4. WASTEGATE CONTROL SOLENOID VALVE 1) Check that the wastegate control solenoid valve has no deformation, cracks or other damages. 2) Check the resistance between the wastegate control solenoid valve terminals. (Tr) (2/1 2 ce.02425 Terminal No Siandard “Vand2 DED 0 20°C (68°F) 3) Check that air does not come out from (B) when air is blown into (A). Lx Fuo4060 4) Connect the battery positive terminal to the ter- minal No. 1 and the battery ground terminal to the terminal No. 2. Check that air is discharged from (8), when supplying air to (A). 2 | { "0 t [ ee 2. OTHER INSPECTIONS Check that the vacuum hose and air contro! hose have no cracks, damage or loose part. Fuo407o FU(wio STI)-49Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS) 16.Front Oxygen (A/F) Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the air intake duct (rear) and air cleaner case. 3) Disconnect the connectors from front oxygen (AV F) sensor, 4) Lift up the vehicie. 5) Remove the under cover. 6) Apply spray-type lubricant to the threaded por- tion of front oxygen (A/F) sensor, and leave it for ‘one minute or more. 7) Remove the front oxygen (A/F) sensor. CAUTION: When removing the front oxygen (A/F} wait until exhaust pipe cools, otherwise it will damage the exhaust pipe. B: INSTALLATION CAUTION: Iflubricantis spilt onto the exhaust pipe, wipe it off completely with cloth to avoid emission of ‘smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, ap- ply anti-seize compound only to the threaded por- tion of front oxygen (A/F) sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protec- tor of front oxygen (A/F) sensor. Anti-selze compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor. Tightening torque: 30 N:m (3.1 kgf-m, 22.1 ft-lb) 3) Install the under cover. 4) Lower the vehicle. 5) Connect the connector of front oxygen (A/F) sensor. 6) Install the air intake duct (rear) and air cleaner case. FU(wio STI)-50Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS) 7) Connect the battery ground terminal. Cc: INSPECTION 1) Check that the front oxygen (A/F) sensor has no deformation, cracks or other damages. 2) Measure the resistance between front oxygen (AIF) sensor terminals. Fu.05147 "Terminal No. Standard 2and 4 2,420.24 0 20°C (68°F) FU(w/o STI)-54Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS) 17.Rear Oxygen Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Disconnect the connector from the rear oxygen sensor, and remove the clip (A) holding the rear ox- ygen sensor hamess. 4) Apply spray-type lubricant to the threaded por- tion of rear oxygen sensor, and leave it for one minute or more. 5) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will dam- age the exhaust pipe. B: INSTALLATION CAUTION: Iflubricantis spilt onto the exhaust pipe, wipe it off completely with cloth to avoid emission of ‘smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of fear oxygen sensor to make the next removal eas- ier. CAUTION: Never apply anti-seize compound to the protec- tor of rear oxygen sensor. Anti-selze compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 21 Nem (2.1 kgt-m, 15.5 ft-lb) SOs ate Ais 3) Connect the connector to the rear oxygen sen- sor, and hold the rear oxygen sensor hamess with the clip (A) 4) Lower the vehicle, FU(wio STI)-52Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground terminal. | SYNC, eae Cc: INSPECTION 1) Check that the rear oxygen sensor has no defor- mation, cracks or other damages. 2) Measure the resistance between rear oxygen sensor terminals By AER BuoW79 Terminal No Standard BET 5 when 2S tend? (oer) FU(wio STI)-53Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS) 18.Engine Control Module (ECM) A: REMOVAL 1) Disconnect the ground cable from battery. 2)Remove the lower inner trim of passenger's side. 3) Turn over the floor mat of passenger's seat. 4) Remove the protect cover. pL RE fe 8S 5) Remove the nuts and bolts which hold the ECM. to the bracket, abe! re < 6) Disconnect the ECM connectors, and take out the ECM Fu03417 B: INSTALLATION Install in the reverse order of removal CAUTION: + When the ECM of model with immobilizer has been replaced, be sure to perform the registra- tion of immobilizer system. (Refer to “PC appli- cation help for Subaru Select Monitor”) * If replacing ECM or the bracket, replace both parts with new parts at a time. * After installing the bracket to ECM, do not separate the bracket. * Ifthe bracket has been installed to ECM in the wrong direction, replace both parts to new parts. NOTE: ‘When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system, Tightening torque: 7.5 N-m (0.8 kgf-m, 5.5 ft-lb) Cc: INSPECTION Check that the ECM has no deformation, cracks or other damages. FU(w/o STI)-54Main Relay 19.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. iN-o209 2) Remove the main relay trom the relay block on the back side of the glove box. B: INSTALLATION Install in the reverse order of removal. FUEL INJECTION (FUEL SYSTEMS) INSPECTION 1) Check that the main relay has no deformation, cracks or other damages. 2) Measure the resistance between main relay ter- minals "Terminal Na. Standard Tand 2 TM or more Sand 4 130.4 — 230.8 2 (when 20°C (68°F) FU(w/o STI)-55Main Relay FUEL INJECTION (FUEL SYSTEMS) 3) Connect battery positive terminal to terminal No. 3nd battery ground terminal to terminal No. 4, and measure the resistance between the main relay ter- minals. o~>) “= ) 1. al Let orl P) WW ade 13] 4t ae isan =e =a aa Teter ia FU(w/o STI)-56Fuel Pump Relay 20.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. iN-209 2) Remove the fuel pump relay from the relay block on the back side of the glove box. B: INSTALLATION Install in the reverse order of removal. FUEL INJECTION (FUEL SYSTEMS) INSPECTION 41) Check that the fuel pump relay has no deforma- tion, cracks or other damages. 2) Measure the resistance between fuel pump relay terminals. "Terminal Na. Standard Tand 2 TM or more Sand 4 99.8 — 136.4 2 (when 20°C (68°F) FU(wio STI)-57Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS) 3) Connect battery positive terminal to terminal No. and battery ground terminal to terminal No. 4, and measure the resistance between the fuel pump re- lay terminals. —> "S) 1. TIS, NI & tw oft Nhe” Ld ~—- 1 tooo 2 3/44 — euowrr Temnnal No Tanda Tard Tess than 12 FU(wio STI)-58Electronic Throttle Control Relay 21.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the electronic throttle control relay from the relay block on the back side of the glove box. FUEL INJECTION (FUEL SYSTEMS) C: INSPECTION 41) Check that the electronic throttle control relay has no deformation, cracks or other damages. 2)Measure the resistance between electronic throttle control relay terminals. "Terminal Na. Standard | i tand 2 TM or more B: INSTALLATION Sand 4 99.8 — 136.4 2 (when 20°C (GBF) | Install in the reverse order of removal. FU(wio STI)-59Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS) 3) Connect battery positive terminal to terminal No. and battery ground terminal to terminal No. 4, and measure the resistance between the electronic throttle control relay terminals. n>) r—S f=} 4 Q)- . 4) ott ye nak Cte oleae 2 3/44 — FU-04077 | Teaminal Na Standard ‘and? Tees than 12 FU(wio STI)-60Fuel Pump Control Unit FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump Control Unit A: REMOVAL 1) Disconnect the ground cable from battery ' ff 2)Remove the right side trunk side tim. (4 door model) 3) Remove the right side rear quarter trim. (5 door model) 4) Disconnect the connector (A) from the fuel pump control unit, and remove the fuel pump control unit. + 4 door model B: INSTALLATION Install in the reverse order of removal. Tightening torque: 5. N-m (0.5 kgf-m, 3.7 ft-lb) C: INSPECTION ‘Check that the fuel pump control unit has no defor- mation, cracks or other damages. FU(wio STI)-64FUEL INJECTION (FUEL SYSTEMS) 23.Fuel A: PROCEDURE 4. RELEASING OF FUEL PRESSURE WARNING: Place “NO OPEN FLAMES" signs near the working area. ‘CAUTION: Be careful not to spill fuel. 1) Remove the fuse of fuel pump from main fuse box. Fu, 2) Start the engine and run It unti it stalls. 3) After the engine stalls, crank it for five more sec- onds. 4) Turn the ignition switch to OFF 5) Install the fuse of fuel pump to the main fuse box. 2. DRAINING FUEL (WITH SUBARU SE- LECT MONITOR) WARNING: Place "NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. NOTE; + If the fuel pump cannot be driven, refer to the procedures for draining from the fuel filer hose + Be careful not to let the battery run-out. 1) Release the fuel pressure. Fuel 2) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RE- LEASE CAUTION: + Be careful not to spill fuel. * Catch the fuel from hoses using a container or cloth. ERIN ice KG KS (©) TINS tne 04s (A). Fuel dalvary hose (8) Fusl retum hose (©) Evaporation hose 3) Connect ST to the fuel delivery hose, ST 184714A000 FUEL PIPE ADAPTER 4) Connect the gasoline proof hose to ST and put the end of the hose in the container. 5) Drive the fuel pump and drain the fuel using Sub- aru Select Monitor. CAUTION: Be careful not to spill fuel. 6) Install the related parts in the reverse order after draining the fuel. 3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE) + 4 door model WARNING: Place “NO OPEN FLAMES" signs near the working area. CAUTION: + Be careful not to spill fuel. + Fuel may remain in the fuel filler pipe. Drain- ing the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (010 or less) before the operation. 1) Lift up the vehiole 2)Remove the rear exhaust pipe and muffler. FU(wio STI)-62Fuel FUEL INJECTION (FUEL SYSTEMS) 3) Remove the rear sub frame. 4) Open the fuel filler lid and remove the fuel filer cap. 5) Drain the fuel from the fuel filler pipe through the filer opening using the gasoline proof pump and the gasoline proof hose (010 or less). 6) Disconnect the fuel filler hose from the fuel filler pipe assembly. CAUTION: * Be careful not to spill fuel. + Catch the fuel from hoses using a container or cloth. 7) Set the container under the vehicle and insert the gasoline proof hose (010 or less) into the fuel filler hose to drain the fuel CAUTION: Be careful not to spill fuel. 8) Install the related parts in the reverse order after draining the fuel NOTE: Correctly insert the fuel filer hose to spool, and then install the clamp as shown in the figure. Tightening torque: FU05815 (1) Fuel filer hose (2) Clamp (3) Spool (4) Fuel filer pipe + 5 door model WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: + Be careful not to spill fuel. + Fuel may remain in the fuel filler pipe. Drain- ing the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (010 or less) before the operation. 1) Lift up the vehicle. 2)Remove the rear exhaust pipe and muffler. 3) Open the fuel filler id and remove the fuel filler cap. 4) Drain the fuel from the fue! filer pipe through the filler opening using the gasoline proof pump and the gasoline proof hose (010 or less) 5) Disconnect the fuel filler hose from the fuel filler pipe assembly. CAUTION: * Be careful not to spill fuel. * Catch the fuel from hoses using a container OTF y S/N ruSunte 6) Set the container under the vehicle and insert the gasoline proof hose (010 or less) into the fuel filler hose to drain the fuel. CAUTION: Be careful not to spill fuel. FU(wio STI)-63Fuel FUEL INJECTION (FUEL SYSTEMS) 7) Install the related parts in the reverse order after draining the fuel. NOTE: Correctly insert the fuel filler hose to spool, and then install the clamp as shown in the figure. Tightening torque: 2.5 Nm (0.3 kgf-m, 1.8 ft-lb) FU.05815; (1) Fuel ler hose (2) Clamp () Spool (4) Fuel filr pipe FU(w/o STI)-64Fuel Tank 24.Fuel Tank A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. ‘CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Remove the rear seat cushion. 5) Remove the service hole cover of fuel pump. (1) Disconnect fuel pump connector (A), and re- move clip (B). (2) Remove the screw (C) (3) Push the grommet (D) down and remove the service hole cover. FUEL INJECTION (FUEL SYSTEMS) 6) Remove the service hole cover of fuel sub level sensor. 7) Disconnect the quick connector of fuel delivery tube (A) and fuel return tube (B). 8) Remove the rear wheels. 9) Lift up the vehicle. 10)Remove the rear ABS wheel speed sensor from the rear housing. housing, FU(wio STI)-65Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 412) Remove the rear disc brake assembly and tie it to the body side of the vehicle 18) Remove the parking brake cable clamp from the body. Fucasts 13) Remove the parking brake cable from parking brake assembly. 14) Remove the rear exhaust pipe and muffler. 15) Remove the propeller shaft. 16) Remove the heat shield cover and fuel tank protector. 17) Disconnect the connector from the rear ABS wheel speed sensor. Fucny? 19) Remove the rear suspension assembly WARNING: Ahelper is required to perform this work. (1) Support the rear differential with the trans- mission jack (2) Remove the bolt and nut which secures rear shock absorber to rear suspension arm || (3) Remove the bolts which seoure the rear Suspension assembly to the body. v.03 (4) Remove the rear suspension assembly. FU(w/o STI)-66Fuel Tank 20) Disconnect evaporation hose (B) from connec- tor (A). FUEL INJECTION (FUEL SYSTEMS) 22) Disconnect the fuel filler hose (A) and evapora- tion hose (B). ~_Fuosri 21) Disconnect the quick connector of the evapora- tion hose from the evaporation pipe. NOTE: Disconnect the quick connector as shown in the fig- ure. \\ Fu-vsiz0 23) Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and re- move the fuel tank from the vehicle. WARNING: + Ahelper is required to perform this work. + Fuel may remai cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank. B: INSTALLATION 1) Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band. WARNING: Abhelper is required to perform this work. FU(wio STI)-67Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 2) Securely insert the fue! filer hose (A) and evap- ration hose (B) until the hose end contacts the ‘spool, then attach the clamp or clip as shown in the figure. Tightening torque: 2.5 Nm (0.3 kgf-m, 1.8 ft-lb) Ty Fu.ose4e (1) Hose (2) Clamp oreip (3) Spool @) Pipe 3) Connect the quick connector of the evaporation hose to the evaporation pipe. CAUTION: * Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe. + When connecting the quick connector, se- curely insert the pipe all the way before locking the retainer. + When itis difficult to lock the retainer, make sure that the pipe is securely inserted. + Make sure that the quick connector is secure- ly connected. —te) ec.07205) _ = 5 oe 4) Connect evaporation hose (B) to connector (A). FU(wio STI)-68Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 5) Tighten the bolts of the fuel tank band in the or- der shown in the figure. Tightening torque: ‘33 Nm (3.4 kgf-m, 24.3 ft-lb) Fu.03500 6) Install the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the trans- mission jack. (2) Support the rear suspension assembly and install the rear suspension assembly to the body. Tightening torque: T1: 70 N-m (7.1 kgf-m, 51.6 ft-lb) T2: 145 Nim (14.8 kgf-m, 106.9 ft-lb) (3) Install the rear shock absorber to the rear suspension arm. NOTE; Use a new self-locking nut Tightening torque: 120 Nm (12.2 kof-m, 88.5 ft-lb) FU.0%358 7) Install the parking brake cable clamp to the body. Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb) \ \\, \ ’ TN ‘ & }) \\ KA B a. 8) Connect the connector to the rear ABS wheel speed sensor. Fuas277| 9) Install the heat shield cover. Tightening torque: 18 Nem (1.8 kgf-m, 13.3 ft-lb) 10) Install the fuel tank protector. Tightening torque: ‘Nut: 9 N-m (0.9 kgf-m, 6.6 ft-lb) Bolt: 18 N-m (1.8 kgt-m, 13.3 ft-lb) 11) Install the propeller shaft. 12) Install the rear exhaust pipe and muffler. 13) Lower the vehicle. 414) Connect the parking brake cable to the parking brake assembly. FU(wio STI)-69Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 16) install the rear disc brake assembly. Tightening torque: (66 N-m (6.7 kgf-m, 48.7 ft-lb) Funssa 16) install the rear brake hose bracket to the rear housing Tightening torque: 33 N-m (3.4 kgf-m, 24.3 ft-lb) 17) Attach the rear ABS wheel speed sensor to the rear housing. Tightening torque: 7 kgi Fuss? 18) Install the rear wheels. Tightening torque: 100 N-m (10.2 kgf-m, 73.8 ft-Ib) 19) Connect the quick connector of fuel delivery tube (A) and fuel return tube (B). NOTE: When connecting, be careful not to reverse the de- livery side and return side. 20) Install the service hole cover of fuel sub level sensor. Fu.03955) 21) Attach the service hole cover of the fuel pump, and attach the connector and clip. oho y OI yon ae 3)\y° Zs Fusr4s: (A) Connector ®) Clip (©) Screw (©) Grommet 22) Install the rear seat cushion. FU(wio STI)-70Fuel Tank FUEL INJECTION (FUEL SYSTEMS) 23) Connect the battery ground terminal. 24) Inspect the wheel alignment and adjust if nec- essary, C: INSPECTION 1) Check that the fuel tank and fuel pipe have no deformation, cracks and other damages. 2) Check that the fuel hose has no cracks, damage of loose part. FU(wio STI)-74Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filler Pipe A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. ‘CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Open the fuel filler lid, and remove the filler cap. 5) Remove the screws which secure the fuel filler ring, and then remove the fuel filler ring. £03835) 6) Remove the rear whee! RH. 7) Lift up the vehicle. 8) Remove the rear mud guard RH. 9) Remove the rear sub frame. 10) Remove the bolts and nuts which secure fuel filler pipe assembly onto the vehicle body. Fuses 11) Disconnect the evaporation hose (A) and the fuel filler hose (B) from the fuel filer pipe assembly. a / Fu.osr5s: 12) Remove the fuel filer pipe assembly from the underside of the vehicle, FU(wio STI)-72Fuel Filler Pipe B: INSTALLATION 1) Open the fuel filler ld. 2) Altach the fuel filler pipe gasket to the fuel filler pipe assembly, and insert the fuel filler pipe assem- bly from inside of the rear fender. 3) Install the fuel filler ring to the fuel filler pipe as- sembly. NOTE: If the edges of rubber gasket are folded toward in- side, straighten it with a flat tip screwdriver. Fut (A) Fuol filer pipe gasket (8) Fuol saucer (C) Fuel filer ring (0) Rubber gasket FUEL INJECTION (FUEL SYSTEMS) 4) Securely insert the evaporation hose (A) and the fuel filler hose (B) until the hose ends contact the spool, then attach the clamp or clip as shown in the figure. Tightening torque: f-m, 1.8 ft-lb) TH] __Fu.05646 (1) Hose (2) Clamp or dip (3) Spool (4) Pipe FU(wio STI)-73Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS) 5) Install the fuel filler pipe assembly to vehicle body. Tightening torque: 7.5 N-m (0.8 kgf-m, 5.5 ft-lb) 6) Install the rear sub frame. 7) Install the rear mud guard RH. 8) Lower the vehicle. 9) Install the rear wheel RH. Tightening torque: 100 Nom (10.2 kaf-m, 73.8 ft-lb) 10) Connect the battery ground terminal. 11) Inspect the wheel alignment and adjust if nec- essary, Cc: DISASSEMBLY 1) Remove the shut valve from the fuel filler pipe. 2) Remove the evaporation pipe from the fuel filer pipe. Fu.osi26 D: ASSEMBLY Assemble in the reverse order of disassembly Tightening torque: 7.5 Nem (0.8 kgf-m, 5.5 ft-lb) E: INSPECTION 1) Check that the fuel filler pipe and evaporation pipe have no deformation, cracks or other damag- es. 2) Check that the hose has no cracks, damage or loose part. FU(wio STI)-74Fuel Pump FUEL INJECTION (FUEL SYSTEMS) 6) Disconnect the connector from fuel pump. 26.Fuel Pump A: REMOVAL WARNING: Place "NO OPEN FLAMES” signs near the working area. CAUTION: + Be careful not to spill fuel. + If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE Fuel pump assembly consists of fuel pump, fuel fi- ter and fuel level sensor. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 1.00203 4) Remove the rear seat cushion. 5) Remove the service hole cover. (1) Remove the screws (A) (2) Push the grommet (B) down and remove service hole cover. Fu.ceos2 F-03063 7) Disconnect the quick connectors of fuel delivery tube (A), fuel return tube (B), and jet pump tube (C). Fuctzas| 8) Remove the nuts which hold the fuel pump up- per plate to the fuel tank Fu.ousa4 9) Remove the fuel pump assembly from the fuel tank. FU(wio STI)-75Fuel Pump FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal while being careful of the following + Make sure the sealing portion is free from fuel or foreign matter before installation. + Align protrusion (A) of the gasket to the position shown in the figure. + Insert the protrusion (B) of gasket to the fuel pump upper plate. (3 places) + Align the protrusion (C) of fuel pump assembly with the cutout on the fuel pump upper plate. * Tighten the nuts to the specified torque in the or- der as shown in the figure. NOTE: Use a new gasket, Tightening torque: 4.4.N-m (0.4 kgf-m, 3.2 ft-lb) (@) Front side of vehicle C: INSPECTION 1) Check that the fuel pump has no deformation, cracks or other damages. 2) Connect the battery positive terminal to terminal No. 5 and the battery ground terminal to terminal No. 6, and inspect the fuel pump operation WARNING: + Wipe off fuel completely. + Keep the battery as far apart from fuel pump as possible. * Do not run the fuel pump for a long time un- der non-load condition. CE FU.04110 FU(wio STI)-76Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Level Sensor A: REMOVAL WARNING: Place "NO OPEN FLAMES” signs near the working area. CAUTION: + Be careful not to spill fuel. + If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spi NOTE ‘The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Disconnect the connector (A) from the sub tank bracket assembly. 3) Remove the fuel temperature sensor (B) from sub tank FU.0AO 4) Slide the fuel level sensor in the direction of the arrow and remove the fuel level sensor by pressing the claw (A) of the fuel level sensor. wy B: INSTALLATION Install in the reverse order of removal C: INSPECTION 1) Check that the fue! level sensor has no damage. 2) Measure the fuel level sensor float position NOTE: ‘When inspecting the fuel level sensor, perform the ‘work with the sensor installed to the fuel pump. ay Fu-04302| () FULL (2) EMPTY (3) Fuel tank seating surface Float position ‘Standard FULL to Fuel tank seating einai 13544 mm (6:315:0.167 in) EMPTY to Fuel tank seating shes 23.724 mm (0.93320.157 in) 3) Measure the resistance between fuel level sen- sor terminals. Fu.04303 Float postion | TerminaiNo | Standard FULL (A) 2081.00 EMPTY (B) dane 31.9:1.00 FU(wio STI)-77Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS) 6) Disconnect the connector from the fuel sub level 28.Fuel Sub Level Sensor A: REMOVAL WARNING: Place "NO OPEN FLAMES” signs near the working area. CAUTION: + Be careful not to spill fuel. + If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Remove the rear seat cushion. 5) Remove the service hole cover. —_Fu.03355 sensor. Fused 7) Disconnect the quick connectors of fuel delivery tube (A), fuel return tube (8), and jet pump tube (C). 8) Remove the rubber cap (D) from the nut. / J 6 — iby Fu.ow 9) Remove the bolts and nuts which hold fuel sub level sensor protector and fuel sub level sensor up- per plate to the fuel tank Furs Fu.ciss0) 10) Remove the fuel sub level sensor from the fuel tank. FU(wio STI)-78