Subaru 2001 IMPREZA Bedienungsanleitung

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)

COOLING CO

Page

1. General Description ....................................................................................2

2. Radiator Main Fan System..........................................................................9

3. Radiator Sub Fan System.........................................................................17

4. Engine Coolant..........................................................................................25

5. Water Pump..............................................................................................27

6. Thermostat................................................................................................35

7. Radiator.....................................................................................................37

8. Radiator Cap.............................................................................................45

9. Radiator Main Fan and Fan Motor ............................................................46

10. Radiator Sub Fan and Fan Motor..............................................................48

11. Reservoir Tank..........................................................................................50

12. Coolant Filler Tank....................................................................................51

13. Engine Cooling System Trouble in General..............................................52

CO-2

COOLING GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

Model Non-turbo Turbo

Cooling system Electric fan + Forced engine coolant circulation sys-

tem

Total engine coolant capacity 2(US qt, Imp qt)

1.6AT: Approx. 7.3

(7.71, 6.42)

1.6MT: Approx. 7.4

(7.82, 6.51)

2.0AT: Approx. 6.9

(7.29, 6.07)

2.0MT: Approx. 7

(7.4, 6.2)

Approx. 7.7

(8.14, 6.78)

Water pump

Type Centrifugal impeller type

Discharge performance I

Discharge 20 2(5.3 US gal, 4.4 Imp gal)/min.

Pump speed—total engine

coolant head 700 rpm —0.3 mAq (1.0 ftAq)

Engine coolant temperature 85°C (185°F)

Discharge performance II

Discharge 100 2(26.4 US gal, 22.0 Imp gal)/min.

Pump speed—total engine

coolant head 3,000 rpm —5.0 mAq (16.4 ftAq)

Engine coolant temperature 85°C (185°F)

Discharge performance III

Discharge 200 2(52.8 US gal, 44.0 Imp gal)/min.

Pump speed—total engine

coolant head 6,000 rpm —23.0 mAq (75.5 ftAq)

Engine coolant temperature 85°C (185°F)

Impeller diameter 76 mm (2.99 in)

Number of impeller vanes 8

Pump pulley diameter 60 mm (2.36 in)

Clearancebetweenimpeller

and case Standard 0.5 —0.7 mm (0.020 —0.028 in)

Limit 1.0 mm (0.039 in)

“Thrust”runout of impeller end 0.5 mm (0.020 in)

Thermostat

Type Wax pellet type

Starts to open 76 —80°C (169 —176°F)

Fully opened 91°C (196°F)

Valve lift 9.0 mm (0.354 in) or more

Valve bore 35 mm (1.38 in)

Radiator fan Motor Main fan 70 W 120 W

Sub fan 70 W 120 W

Fan diameter ×Blade 320 mm (11.81 in) ×5 (main fan)

320 mm (11.81 in) ×7 (sub fan)

Radiator

Type Down flow, pressure type

Core dimensions 691.5 ×340 ×16 mm

(27.22 ×13.39 ×0.63 in) 691.5 ×340 ×27 mm

(27.22 ×13.39 ×1.06 in)

Pressure range in which cap valve is open

Above: 108±15 kPa

(1.1±0.15 kg/cm2, 16±2 psi)

Below: −1.0 to −4.9 kPa

(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)

Fins Corrugated fin type

Reservoir

tank Capacity 0.5 2(0.5 US qt, 0.4 Imp qt)

CO-3

COOLING

GENERAL DESCRIPTION

B: COMPONENT

1. WATER PUMP

•NON-TURBO MODEL

H2M2354A

(1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.7)

Second 12 (1.2, 8.7)

(3) Heater by-pass hose

(4) Thermostat T2: 6.4 (0.65, 4.7)

CO-4

COOLING GENERAL DESCRIPTION

•TURBO MODEL

H2M1785B

(1) Thermostat case (6) Header by-pass hose Tightening torque: N·m (kgf-m, ft-lb)

(2) Gasket (7) Coolant filler tank by-pass hose T1: First 12 (1.2, 8.7)

Second 12 (1.2, 8.7)

(3) Thermostat (8) Water by-pass pipe

(4) Water pump ASSY T2: 6.4 (0.65, 4.7)

(5) Gasket

CO-5

COOLING

GENERAL DESCRIPTION

2. RADIATOR AND RADIATOR FAN

•NON-TURBO MODEL

EN0068

T3 T5 T5

(10)

(13)

(15)

(8)

(7)

(9)

(16)

(5)

(6)

(22)

(1)

(2)

(23)

(24)

(3)

(4)

(21)

(20) (19)

(17)

(18)

(12)

(11)

(14)

(1) Radiator lower cushion (13) Main fan shroud (23) Radiator lower bracket

(2) Radiator (14) Radiator main fan (24) Radiator drain plug

(3) Radiator upper cushion (15) Main fan motor

(4) Radiator upper bracket (16) ATF hose clamp (AT vehicles only) Tightening torque: N·m (kgf-m, ft-lb)

(5) Clamp (17) ATF inlet hose A (AT vehicles only) T1: 4.4 (0.45, 3.3)

(6) Radiator inlet hose (18) ATF outlet hose A (AT vehicles

only) T2: 12 (1.2, 8.7)

(7) Engine coolant reservoir tank cap T3: 18 (1.8, 13.0)

(8) Over flow hose (19) ATF pipe (AT vehicles only) T4: 3.4 (0.35, 2.5)

(9) Engine coolant reservoir tank (20) ATF inlet hose B (AT vehicles only) T5: 4.9 (0.50, 3.6)

(10) Sub fan shroud (21) ATF outlet hose B (AT vehicles

only)

(11) Radiator sub fan

(12) Sub fan motor (22) Radiator outlet hose

CO-6

COOLING GENERAL DESCRIPTION

•TURBO MODEL

EN0069

(13) (16)

(7)

(20)

(19)

(5)

(21)

(9)

(12)

(15)

(11)

(14)

(5)

(6)

(17)

(1)

(23)

(18)

(3)

(4)

(8)

(2)

(10)

(1) Radiator lower cushion (10) Over flow pipe (19) Engine coolant filler tank

(2) Radiator (11) Sub fan shroud (20) Engine coolant filler tank cap

(3) Radiator upper cushion (12) Radiator sub fan (21) Engine coolant hose

(4) Radiator upper bracket (13) Radiator sub fan motor

(5) Clamp (14) Main fan shroud Tightening torque: N·m (kgf-m, ft-lb)

(6) Radiator inlet hose (15) Radiator main fan T1: 4.4 (0.45, 3.3)

(7) Engine coolant reservoir tank cap (16) Radiator main fan motor T2: 18 (1.8, 13.0)

(8) Over flow hose (17) Radiator outlet hose T3: 3.4 (0.35, 2.5)

(9) Engine coolant reservoir tank (18) Radiator drain plug T4: 4.9 (0.50, 3.6)

CO-7

COOLING

GENERAL DESCRIPTION

C: CAUTION

•Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust or dirt.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly, and replacement.

•Be careful not to burn your hands, because each

part in 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.

CO-8

COOLING GENERAL DESCRIPTION

D: PREPARATION TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977300 CRANK PULLEY

WRENCH Used for stopping crankshaft pulley when

loosening and tightening crankshaft pulley

bolts.

499207100 CAMSHAFT

SPROCKET

WRENCH

Used for removing and installing camshaft

sprocket. (Non-turbo LH side only)

499207400 CAMSHAFT

SPROCKET

WRENCH

Used for removing and installing camshaft

sprocket.

B2M4157

B2M3859

B2M4158

CO-9

COOLING

RADIATOR MAIN FAN SYSTEM

2. Radiator Main Fan System

A: SCHEMATIC

1. NON-TURBO MODEL

BATTERY SBF-1 No.3

No.17

No.18

SBF-4

B72 IGNITION

SWITCH

F27 20A

AIR CONDITIONING

RELAY HOLDER

F29 SUB

FAN

RELAY

SUB FAN

MOTOR

F16

F27 20A

AIR CONDITIONING

RELAY HOLDER

F66 MAIN

FAN

RELAY

MAIN FAN

MOTOR

F17

B134 ECM

F45

B62

LHD :2

RHD :7

LHD :12

RHD :17

F17

2 1

F16

F67

F27 F28

1 2

3 4

5 6

11 12

13 14

19 20

21 22

27 28

F31

F29 F66

F30

B134

1 2 3 4 5 6 7 8

10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31 32 33 34 35

F45

3412 89

10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

567

F45

1234 56789

10 11 12 13 14 15 16 17 18 19 20

LHD: RHD:

EN0880

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