2001 IMPREZA SERVICE MANUAL

ENGINE 1 SECTION

QUICK REFERENCE INDEX

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, reassembling, inspection and adjustment of components and diagnostics for guidance 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.

FUEL INJECTION (FUEL SYSTEMS) FU(SOHC)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES)

EC(SOHC)

INTAKE (INDUCTION) IN(SOHC)

MECHANICAL

EXHAUST

ME(SOHC)

EX(SOHC)

COOLING

LUBRICATION

SPEED CONTROL SYSTEMS

IGNITION

STARTING/CHARGING SYSTEMS

ENGINE (DIAGNOSTICS)

CO

LU

SP

IG(SOHC)

SC

EN(SOHC)

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

G1830GE2

IGNITION

IG(SOHC)

Page

1.

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

2.

Spark Plug...................................................................................................5

3.

Ignition Coil and Ignitor Assembly...............................................................8

4.

Spark Plug Cord........................................................................................10

IGNITION

1. General Description

A: SPECIFICATIONS

GENERAL DESCRIPTION

Ignition coil and ignitor assembly

Item

Model

Manufacturer

1600cc

2000cc

1600cc

2000cc

1600cc

Primary coil resistance

Secondary coil resistance

2000cc

1600cc

2000cc

Insulation resistance between primary terminal and case

1600cc

Type and manufacturer

Spark plug 2000cc

Thread size

Spark gap mm mm (in)

Alternate

Alternate

Designation

CM12—100C

FH0137

HITACHI

DIAMOND

0.7

Ω±

10%

0.73

Ω±

10%

13.0 k

Ω±

20%

12.8 k

Ω±

15%

More than 10 M

Ω

RC8YC4 .......... CHAMPION

BKR6E-11 .......... NGK

RC10YC4 .......... CHAMPION

BKR5E-11 .......... NGK

14, P = 1.25

1.0 — 1.1 (0.039 — 0.043)

IG(SOHC)-2

B: COMPONENT

1. 1600CC MODEL

GENERAL DESCRIPTION

T1

(3)

(2)

(2)

(1)

T2

(4)

T2

(4)

IGNITION

(1) Spark plug

(2) Spark plug cord (#1, #3)

(3) Ignition coil and ignitor ASSY

(4) Spark plug cord (#2, #4)

Tightening torque: N·m (kgf-m, ft-lb)

T1: 6.4 (0.65, 4.7)

T2: 21 (2.1, 15.2)

IG(SOHC)-3

IGNITION

2. 2000CC MODEL

GENERAL DESCRIPTION

S6M0329B

(1)

(2)

(3)

Spark plug

Spark plug cord (#1, #3)

Ignition coil and ignitor ASSY

(4)

C: CAUTION

• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.

• Remove contamination including dirt and corrosion before removal, installation or disassembly.

• Keep the disassembled parts in order and protect them from dust or dirt.

• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.

Spark plug cord (#2, #4)

Tightening torque: N·m (kgf-m, ft-lb)

T1: 21 (2.1, 15)

T2: 6.4 (0.65, 4.7)

• Be careful not to burn your hands, because each part on the vehicle is hot after running.

• Be sure to tighten fasteners including bolts and nuts to the specified torque.

• Place shop jacks or safety stands at the specified points.

• Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.

IG(SOHC)-4

2. Spark Plug

A: REMOVAL

CAUTION:

All spark plugs installed on an engine, must be of the same heat range.

1600cc

2000cc

Spark plug

CHAMPION: RC8YC4

NGK: BKR6E-11 (Alternate)

CHAMPION: RC10YC4

NGK: BKR5E-11 (Alternate)

1. RH SIDE

1) Disconnect battery ground cable.

SPARK PLUG

2. LH SIDE

1) Disconnect battery ground cable.

IGNITION

2) Disconnect washer motor connector.

G6M0095

G6M0095

2) Remove air intake duct. <Ref. to IN(SOHC)-8,

REMOVAL, Resonator Chamber.>

(1) Remove resonator chamber. <Ref. to IN

(SOHC)>

3) Remove spark plug cords by pulling boot, not cord itself.

B6M0562B

3) Disconnect rear window glass washer hose from washer motor, then plug connection with a suitable cap.

4) Remove the two bolts which hold the washer tank, then take the tank away from the working area.

B2M4127

4) Remove spark plugs with the spark plug socket.

B2M2023

5) Remove spark plugs cord by pulling boot, not cord itself.

B2M4287

B2M4286

IG(SOHC)-5

SPARK PLUG

IGNITION

6) Remove spark plug with the spark plugs socket.

C: INSPECTION

Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion.

B2M4288

B: INSTALLATION

1. RH SIDE

1) Install in the reverse order of removal.

Tightening torque (Spark plug):

20.6 N·m (2.10 kgf-m, 15.2 ft-lb)

CAUTION:

The above torque should be only applied to new spark plugs without oil on their threads.

In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing.

2. LH SIDE

1) Install in the reverse order of removal.

Tightening torque (Spark plug):

20.6 N·m (2.10 kgf-m, 15.2 ft-lb)

CAUTION:

The above torque should be only applied to new spark plugs without oil on their threads.

In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing.

S6M0420A

(A) Electrode gap

(B) Carbon accumulation or wear

(C) Cracks

(D) Damage

(E) Damaged gasket

1) Normal

Brown to grayish-tan deposits and slight electrode wear indicate correct spark plug heat range.

G6M0087

2) Carbon fouled

Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture, dirty air cleaner, etc.

It is advisable to replace with plugs having hotter heat range.

G6M0088

IG(SOHC)-6

SPARK PLUG

3) Oil fouled

Wet black deposits show excessive oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems. If same condition remains after repair, use a hotter plug.

IGNITION

E: ADJUSTMENT

Correct it if the spark plug gap is measured with a gap gauge, and it is necessary.

Spark plug gap: L

1.0 — 1.1 mm (0.039 — 0.043 in)

G6M0089

4) Overheating

White or light gray insulator with black or gray brown spots and bluish burnt electrodes indicate engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark plugs, wrong selection of fuel, hotter range plug, etc. It is advisable to replace with plugs having colder heat range.

S6M0412A

NOTE:

Replae with new spark plug if this area is worn to

“ball” shape.

G6M0090

D: CLEANING

Clean spark plugs in a sand blast type cleaner.

Avoid excessive blasting. Clean and remove carbon or oxide deposits, but do not wear away porcelain.

If deposits are too stubborn, replace plugs.

IG(SOHC)-7

IGNITION COIL AND IGNITOR ASSEMBLY

IGNITION

3. Ignition Coil and Ignitor Assembly

A: REMOVAL

1) Disconnect battery ground cable.

4) Remove ignition coil and ignitor assembly.

• 1600cc MODEL

EN1044

G6M0095

2) Disconnect spark plug cords from ignition coil and ignitor assembly.

• 1600cc MODEL

• 2000cc MODEL

• 2000cc MODEL

EN1040

B6M0930

B: INSTALLATION

1) Install in the reverse order of removal.

Tightening torque:

6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

CAUTION:

Be sure to connect wires to their proper positions. Failure to do so will damage unit.

• 1600cc MODEL

S6M0373

3) Disconnect connector from ignition coil and ignitor assembly.

• 2000cc MODEL

EN1044

B6M0930

IG(SOHC)-8

C: INSPECTION

IGNITION COIL AND IGNITOR ASSEMBLY

Using accurate tester, inspect the following items, and replace if defective.

1) Primary resistance

2) Secondary coil resistance

CAUTION:

If the resistance is extremely low, this indicates the presence of a short-circuit.

Specified resistance:(1600cc)

[Primary side]

Between terminal No. 1 and No. 4

0.7

Ω

10%

Between terminal No. 1 and No. 2

0.7

Ω

10%

Specified resistance:

[Primary side]

Between terminal No. 1 and No. 2

0.73

Ω

10%

Between terminal No. 2 and No. 4

0.73

Ω

10%

4 3 2 1

IGNITION

EN1041

4 3 2 1

[Secondary side]

Between (A) and (B)

12.8 k

Ω

15%

Between (C) and (D)

12.8 k

Ω

15%

(A)

(C)

EN1041

[Secondary side]

Between (A) and (B)

13.0 k

Ω

20%

Between (C) and (D)

13.0 k

Ω

20%

(B)

(D)

EN1043

3) Insulation between primary terminal and case:

10 M

Ω

or more.

(C)

(D)

(A)

(B)

EN1042

IG(SOHC)-9

SPARK PLUG CORD

IGNITION

4. Spark Plug Cord

A: INSPECTION

Check for:

1) Damage to cords, deformation, burning or rust formation of terminals

2) Resistance values of cords

Resistance value:

#1 cord: 5.6 — 10.6

#2 cord: 7.3 — 13.7

#3 cord: 5.9 — 11.1

#4 cord: 7.3 — 13.7

S6M0337

IG(SOHC)-10