1999-2003 of release
Repair and operation of the car
Subaru of Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ Operation manual
+ Routine maintenance
+ Cooling systems, heating
- Power supply system and release
- System of injection of fuel
Dropping pressure in a power supply system
Depletion of a fuel tank
Check of a state and replacement of fuel lines and their nipple connections
Service of components of an inlet air path
Removal and installation of the case of a throttle
Service of components of the drive of a butterfly valve
Removal, service and installation of the inlet pipeline
Service of the fuel pump
Removal and installation of the main MFI relay
Removal and installation of the relay of the fuel pump
Removal and installation of the sensor of a reserve of fuel
Removal and installation of the fuel level sensor in an additional chamber of a fuel tank
Removal, check and installation of the fuel filter
Removal and installation of the locking valve of a cut-off of fuel
Removal and installation of the damping fuel valves
Removal and installation of a fuel tank
Removal and installation of a jellied mouth of a fuel tank
Removal and installation of components of system of injection of fuel
+ Control systems of the engine and decrease in toxicity of the fulfilled gases
+ System of production of the fulfilled gases
+ Electric equipment of the engine
+ Manual box and differential
+ Automatic transmission
+ Brake system
+ Suspension bracket and steering
+ Onboard electric equipment
System of injection of fuel
General information and precautionary measuresDesign of an inlet air path of 4-cylinder models (2.0 and 2.5 l)
Design of an inlet air path of 6-cylinder models (3.0 l)
Design of assembly of MAP and IAT sensors (4-cylinder engines)
Design of the sensor of atmospheric pressure (only l models 2.0 and 2.5 with OBD II)
The executive TPS lever is mechanically connected to an axis of a butterfly valve
Design of the IAC valve used on 4-cylinder engines
Design of the electromagnetic valve of pumping of air to air injectors (only l models 2.0 and 2.5 with OBD II)
The principle of management of pressure pulsations in the inlet pipeline
Function chart of a fuel supply system of the 4-cylinder engine
Function chart of a fuel supply system of the 6-cylinder engine
Fuel pressure regulator design
Design of the fuel injector used on models 2.0 and 2.5 of the l equipped with system of onboard self-diagnostics of OBD II
Design of the fuel injector used on models 2.0 and 2.5 of the l equipped with firm system of onboard self-diagnostics of Subaru
Design of the fuel injector used on models of 3.0 l
Design of a fuel tank
Fastening of a fuel tank is carried out by means of two metal assembly tapes which are lined with pillows
Design of assembly of the fuel pump
Design and principle of functioning of the pump of pumping
Design of the fuel level sensor in an additional chamber of a gasoline tank
Design dokatalitichesky a lambda probe, applied on 4-cylinder models (with OBD II)
Design dokatalitichesky a lambda probe, applied on 6-cylinder models
Design post-catalytic lambda probe of 4-cylinder models
Design post-catalytic lambda probe of 6-cylinder models
Design and principle of functioning of the ECT sensor
Design of the CKP sensor of the 4-cylinder engine
Principle of functioning of the CKP sensor of 4-cylinder engines
Principle of functioning of the CKP sensor of 6-cylinder engines
Principle of functioning of the CMP sensor of 4-cylinder engines
Principle of functioning of the CMP sensor of 6-cylinder engines
Design of the KS sensor of 4-cylinder engines
Design of the KS sensor of 4-cylinder engines
The principle of functioning of the VSS sensor on models with RKPP
The principle of functioning of the VSS sensor on models with AT
All models considered in the present manual are equipped with electronic system of distributed fuel injection (MFI). Due to use in a control system of the latest technological solutions of MFI provides optimization of configuration of air and fuel mix in any service conditions of the engine.
Fuel is in a power supply system under constant pressure and through injectors is injected into inlet ports of each of engine cylinders. The dosage of supply of fuel is carried out by management of time of opening of electromagnetic valves of injectors according to the amount of the air forced in the engine determined by specific conditions of functioning. Duration of opening of injectors is defined by parameters of the electric impulses formed by the module of management (ECM) that allows to carry out very exact dosage of air and fuel mix.
ECM determines the necessary length of managing directors of impulses on the basis of the analysis of the data on the speed of the movement of the car which are continuously arriving from information sensors, the provision of a butterfly valve, temperature of cooling liquid and so forth.
Besides the listed functions the MFI system exercises also control of toxicity of the fulfilled gases, optimization of a ratio of fuel consumption and return of the engine, control of functioning of pedals of gas and a brake, and also provides adequate starting parameters and warming up of the engine in cold weather, proceeding from data on temperatures of cooling liquid and the soaked-up air.
System of air supply
The air banished via the air cleaner comes to the throttle case, from where, in the quantity determined by the provision of a butterfly valve on the inlet pipeline moves to inlet ports of cylinders of the engine where mixes up with the fuel injected through injectors, forming gas mixture. Stability of turns of idling is provided at the expense of a transmission of part of air mass bypassing the throttle case directly in the inlet pipeline. Control of amount of additional air is exercised by ECM by means of management of functioning of the special perepuskny valve.
Inlet air path
The inlet air path of the 4-cylinder engine consists of an airintaking sleeve, a rezonatorny chamber and assembly of the air cleaner. The resonator is located above the air cleaner on a stream and effectively promotes decrease in level of the noise background arising at absorption of air in the engine.
On 6-cylinder models the structure of an inlet air path switched on two resonators installed one above the air cleaner on a stream, another below.
Pressure sensors in the inlet pipeline (MAP) and temperatures of the soaked-up air (IAT)
On models 2.0 and 2.5 of the l equipped with 4-cylinder engines, MAP and IAT sensors are united in the uniform assembly established on assembly of the inlet pipeline. The MAP sensor serves for measurement of absolute value of pressure in the pipeline, the IAT sensor – for measurement of temperature of the air which is soaked up in the engine. The parameters traced by sensors will be transformed to electric signals and transferred to ECM exercising control of configuration of air and fuel mix, and also the moments of injection and ignition.
On models of 3.0 l with the 6-cylinder engine the MAP sensor is installed from above on the throttle case. And continuously gives out the alarm tension which size is proportional to the size of absolute value of pressure in the inlet pipeline on ECM. On the basis of the analysis of information arriving from the MAP sensor (in a compartment with the data delivered by other sensors) ECM defines the moments of injection of fuel and ignition of air and fuel mix. The IAT sensor is fixed on the case of the air cleaner and traces temperature of the air stream passing on an air duct. The thermistor, which resistance in inverse proportion to temperature of a sensitive element is the basis for a design of the sensor. ECM uses information arriving from the sensor at correction of composition of air and fuel mix.
The sensor of atmospheric pressure, - only l models 2.0 and 2.5 with OBD II
The sensor is used only on 4-cylinder models 2.0 and 2.5 of the l equipped with system of onboard self-diagnostics of OBD II and supplies ECM with information on pressure of atmospheric air. The design of the sensor is presented on an illustration.
The gate placed in the throttle case copes from a gas pedal according to which situation to a greater or lesser extent blocks a throttle opening through passage that allows to regulate an expense of the air engine coming to combustion chambers. On single turns when the pedal of gas is completely released, the gate almost completely blocks a throttle and the bulk of air (more than a half) comes to the inlet pipeline via the special electromagnetic valve of stabilization of turns of idling (IAC) bypassing the throttle case. Use of the IAC valve allows to exercise control of stability of turns of idling regardless of changes of the current load of the engine (for example, at turning on of the conditioner of air or other power-intensive consumers).
Sensor of provision of a butterfly valve (TPS)
TPS is established on the case of a throttle and is mechanically connected to an axis of a butterfly valve.
The sensor develops and sends ECM the alarm tension which size is directly proportional to extent of opening of the gate. To the closed and opened provisions of the gate there correspond accurately certain values of tension.
Electromagnetic valve of stabilization of turns of idling (IAC)
The IAC valve is built in the case of a throttle and exercises control of the size of a consumption of the air bypassed bypassing the last during the operation of the engine on single turns. The valve works on ECM signals, allowing the last to support turns of idling of the engine at the set level.
On 4-cylinder engines (2.0 and 2.5 l) the IAC valve represents the step motor consisting from the coupled windings placed in the general casing two, a rod, a permanent magnet and a spring. The casing of the valve is built in assembly of the case of a throttle. The rod is placed between pair windings and from the party turned towards a magnet is equipped with a carving. Change of polarity of the impulses of the operating current passed through windings involves change of polarity of a permanent magnet that forces to rotate navernuty on a rod and the nut connected to a magnet. Rotation of a nut leads to movement of the sprung rod making mechanical opening or closing of the valve.
On 6-cylinder engines (3.0 l) the IAC valve of rotary type consisting from placed in a casing of the coil, a rotary element, and a spring is used. The casing of the valve is also integrated into assembly of the case of a throttle.
The electromagnetic valve of pumping of air to injectors, - only l models 2.0 and 2.5 with OBD II
The valve is switched on in the line connecting the throttle case to an injector and fixed on the inlet pipeline. Opening and closing of the valve happens at the command of ECM exercising control of pumping. The design of the valve is presented on an illustration.
Control unit pressure pulsations in the inlet pipeline, - only models of 3.0 l
The device allows to support the size of the torque developed by the engine at a maximum level regardless of engine turns. In a partition between the right and left sections of the inlet pipeline the rotary induction gate set in motion by the actuation mechanism installed on assembly of the pipeline is built in. In the course of functioning of the engine in the inlet pipeline pressure pulsations increasing efficiency of functioning of an inlet air path are generated. The maximum return of such mechanism is reached at distribution of jumps of consolidations in the correct direction, - that becomes possible at the expense of a choice of position of the gate installed in a partition according to engine turns /
Fuel supply system
The submersible fuel pump placed in a gasoline tank provides supply of fuel under pressure to each of injectors. Gasoline moves from the pump to injectors on a fuel path with the filter of thin cleaning which is switched on in it. The special regulator supports fuel pressure in the highway at the set optimum level. Through injectors fuel in necessary quantity is injected directly into combustion chambers of each of engine cylinders where mixes up with air and forms gas mixture. The amount of fuel and the moment of injection are calculated by the module of management. Excess of fuel on the returnable line comes back to a fuel tank. The function chart of a fuel supply system is presented on illustrations.
Fuel pressure regulator
The regulator of pressure is installed since the end of the line of supply of fuel brought to injectors and consists of two chambers divided by a diaphragm: fuel and spring. The fuel chamber is connected to the line of supply of fuel, spring – to the inlet pipeline. Besides, the fuel chamber is equipped with the reducing valve connected to the line of return of fuel. At increase in depth of depression in the inlet pipeline procrastination of a diaphragm leads to opening of the reducing valve, - as a result pressure in the fuel highway decreases. Decrease in depth of depression in the pipeline leads to push-up of a diaphragm a spring and to increase in the giving pressure. The described mechanism allows to support a difference between pressure of injection and depression in the inlet pipeline at the constant level making 294.0 kPas (3.00 kgfs/cm 2) for the models equipped with RKPP and 299.1 kPas (3.05 kgfs/cm 2) for models with AT.
In MFI system injectors with the top supply of fuel and air pumping are used. The scheme of connection of injectors provides cooling them with a fuel stream. Injectors of such design differ in the compact sizes, high thermal stability, the lowered noise background and simplicity in service.
Duration of opening of the electromagnetic needle valve of an injector is defined by length of the developed ECM of the operating impulse. In view of the fact that the injector nozzle section, size of opening of the valve and pressure of supply of fuel are supported by constants, the amount of the fuel injected into the combustion chamber is defined only by duration of time of the opening corresponding to length of the operating ECM impulse.
On models of 3.0 l, and also 2.0 and 2.5 l equipped with system of onboard diagnostics of OBD II efficiency of dispersion of injectable fuel increase due to pumping of the air given to injectors from the IAC valve on the channel which is specially organized in a body of the inlet pipeline. The Melkodispersnost of dispersion not only increases efficiency of combustion of gas mixture, but also allows to reduce the level of the maintenance of toxic components in combustion products.
On all models it is used fuel a two-chamber design, providing free space under installation of back differential. For pumping of fuel from an additional chamber in the main the special pump of pumping is used, each chamber is equipped with the individual fuel level sensor.
The tank fastens under the bottom in back part of the car by means of two assembly tapes.
The fuel pump consists of a driving electric motor, a rotor, a casing, a cover, the control valve and the filter and is united in uniform assembly with the sensor of a reserve of fuel and the pump of pumping. Use of the pump of rotor type allows in an essential measure to lower the level of the noise background made by it during the work.
At inclusion of ignition there is an activation of the relay of the fuel pump then the electric motor starts rotating, setting in motion a pump rotor.
At rotation of a rotor fuel, fuel under the influence of centrifugal force starts flowing on special channels from one cavity formed by shovels in another, the friction arising thus leads to creation of the pressure difference defining the pressure developed by the pump.
The fuel pushed by the rotating rotor gets to a gap between an anchor and a magnet of an electric motor, then is pushed out via the control valve.
When pressure of a discharge (dumping) reaches some preset value, the special safety valve preventing the excessive growth of pressure opens.
At a stop of the engine and fuel pump the effort developed by a spring leads to an overshoot the control valve of digit port that allows to keep pressure in a path of a power supply system.
Two filtering elements are built in pump assembly. To the inlet port of the pump the mesh filter protecting the pump from hit in it rather large foreign inclusions is installed. The output port of the pump is equipped with the filter of cartridge type, steady against influence of a high pressure preventing hit in a power supply system of the smallest particles.
The pump of pumping, united in uniform assembly with the fuel pump / sensor of a reserve of fuel, uses energy of rotation of the excess stream of fuel returned from the engine for creation of the depression providing pumping of fuel from an additional chamber of a gasoline tank in the main.
At violation of passability of a nozzle of the returnable line fuel comes back to a tank via the safety valve.
The fuel level sensor in an additional compartment of a fuel tank
The separate sensor of control of level of fuel is installed in the additional camera of a gasoline tank. The sensor is switched on in the line of pumping of fuel in the main chamber and serves for alignment of levels of fuel in both chambers of a tank when functioning the pump of pumping.
Dokatalitichesky a lambda probe (only models with OBD II)
The sensitive element dokatalitichesky a lambda probe is created from solid electrolyte on the basis of oxide of zirconium (ZrO2) possessing ability to develop EMF at bilateral contact with the zones sated with ions of oxygen of various concentration, and the size of this EMF depends on a difference in concentration of ions. This property of oxide of zirconium is used in dokatalitichesky a lambda probe for determination of concentration of oxygen in the fulfilled engine gases.
From a small amount of ZrO 2 the tube closed since one end shipped by the external surface in the final highway of the engine ahead of the catalytic converter while the internal surface contacts to atmospheric air is created. The platinum covering having porous structure is applied on an external surface of a tube. The case of a probe is grounded on the mass of an exhaust pipe, the internal electrode by means of an electrical wiring is brought to ECM which is continuously tracing the current developed by the sensor and on the basis of the analysis of the arriving information carrying out correction of composition of air and fuel mix.
In addition the ceramic heating element providing serviceability of functioning of a probe before warming up of the engine is built in the sensor.
At combustion in cylinders of the engine of the enriched air and fuel mix all oxygen which is almost containing in combustion products is absorbed during the catalytic reaction happening in a layer of the platinum covering an external surface of a zirconium tube. As a result the difference of concentration of ions of oxygen from external and internal surfaces of a tube is very big that as appropriate affects the size developed by the EMF sensitive element.
Contains in products of combustion of the grown poor mix the bigger amount of oxygen is considerable, and the platinum catalyst is not capable completely it to absorb. Increase of concentration of ions of oxygen from the inside of a zirconium tube leads to decrease developed by the EMF sensor.
Insignificant deviations of composition of air and fuel mix from stekhiometrichesky number has very strong impact on the content of oxygen in combustion products, causing noticeable deviations in size EMF. On the basis of the analysis of information of ECM arriving from a lambda probe easily defines the current composition of gas mixture and in case of need develops command for its corresponding adjustment.
Post-catalytic lambda probe
Post-catalytic the lambda probe serves for determination of concentration of oxygen in the fulfilled gases of the engine and is established below the catalytic converter on a stream. The deviation of composition of air and fuel mix from stekhiometrichesky number towards impoverishment leads to increase of concentration of oxygen in the fulfilled gases, and vice versa. The lambda probe allows ECM to trace such deviations in time and in due time to make necessary adjustment.
The design post-catalytic a lambda probe very slightly differs from the design of the dokatalitichesky sensor described above.
The principle of functioning post-catalytic a lambda probe is explained on an illustration. It should be noted that working temperature post-catalytic a lambda probe is much lower than the working temperature of the dokatalitichesky sensor and lies within range from 300 to 400 °s.n the models equipped two lambda probes (dokatalitichesky and post-catalytic), distinctions in indications of sensors allow to estimate efficiency of functioning of the catalytic converter.
Sensor of temperature of cooling liquid of the engine (ECT)
The sensor of temperature of cooling liquid is installed on a branch pipe of a cooling path and is a thermistor which resistance changes in inverse proportion to temperature. Information issued by the sensor is used by ECM at management of parameters of ignition and injection of fuel, and also when determining the moments of a purge of a coal adsorber.
Sensor of provision of a cranked shaft (CKP)
On 4-cylinder engines the sensor of provision of a cranked shaft (CKP) is installed on assembly of the oil pump in the central part of a forward half of the block of cylinders. Is located on 6-cylinder CKP engines in back part of the block. The sensor has a non-demountable design and consists of a magnet, the core and the contact plug.
When passing before the sensitive CKP element of teeth of the rotor plate rotating together with shaft as a result of reduction of an air gap there is a change of a magnetic flux in a sensor winding which is followed by generation of an impulse of alarm tension.
On the basis of the analysis of information of ECM arriving from the sensor defines the angular provision of a cranked shaft.
Sensor of provision of a camshaft (CMP)
On 4-cylinder engines the CMP sensor is located on a support of a camshaft of the left head of cylinders, on 6-cylinder engines – on the right head.
The principle of functioning of CMP is similar described above for the sensor of provision of a cranked shaft. Instead of a gear rotor in a special way the placed ledges from the back party of a cogwheel of the left camshaft (4-cylinder engines), or grooves in the forming surface of the special plate established on a pin of the right inlet camshaft (6-cylinder engines) are used here.
On the basis of the analysis of information of ECM on the current angular provision of a camshaft arriving from the sensor traces the moments of phases of gas distribution in cylinders.
Sensor of a detonation (KS)
The KS sensor is installed on the block of cylinders and serves for tracking of the moments of emergence of a detonation in the engine.
The design of the sensor is presented on illustrations. When the level of vibrations of the engine as a result of a detonation increases, the small weight placed in the sensor case influences a piezoelement which immediately starts generating alarm tension, notifying ECM on need of the corresponding correction of a corner of an advancing of ignition.
Sensor of speed of the movement (VSS)
The VSS sensor is installed on a transmission case.
On models with RKPP the sensor generates and gives out on ECM and a combination of devices of 4 alarm impulses on each turn of forward differential.
On models with AT for one turn of forward differential the sensor develops a 16-pulse signal transmitted to the module of management of transmission (TCM) where it will be transformed to a standard 4-pulse signal and is given further for ECM and a combination of devices.
Management of supply of fuel and configuration of air and fuel mix
See the Section of the Control system of the engine and decrease in toxicity of the fulfilled.
Security measures and rules of observance of purity during the work with fuel system
Do not come nearer to a venue of works with naked flame or the lit cigarette. Always keep in readiness the fire extinguisher!
Fuel couples are poisonous, - watch ensuring normal ventilation of a workplace!
The fuel system is under pressure. When opening system fuel can escape from it with a high pressure, - before an otpuskaniye of nipple sockets wrap them in rags. Use goggles!
Collars of tape and tightening type can be applied to fastening of hose connections. After a detachment of hoses tightening collars should be replaced tape or worm. Fixing of locks of some collars demands use of special adaptations, - consult with experts firm HUNDRED Subarus.
Before undocking of nipple sockets carefully wipe them outside in order to avoid hit of dirt in a path.
Stack the removed components on a pure lining and turn in polyethylene or paper, - avoid application for rubbing and a reversing of components vorsyashcheysya rags.
If repair demands time, track that all open openings in knots and components of a power supply system were carefully muffled.
Establish into place only pure details. Take out spare parts from packing only just before installation. Do not apply details which were stored unpacked (for example, in a toolbox).
Avoid use of compressed air at an open fuel path. Whenever possible try not to move the car.
Do not apply the sealants containing silicone. The particles of silicone which got to the engine do not burn down and can be the reason of damage a lambda probe.
Security measures at removal of a fuel tank
Before removal empty a fuel tank (see the Section Depletion of a Fuel Tank).
Buck acts from the lower party of the car. Before an otpuskaniye of assembly tapes, prop up a tank from below a cart jack, - between a tank and a head of a jack lay wooden whetstone.
The empty tank is explosive and before utilization has to be cut on part, - try not to allow when cutting a tank of sparking! It will be most correct to hand over a tank in special place of acceptance.
After installation of a tank start the engine and check tightness of all connections.
Recommendations about economy of fuel consumption
Information on fuel consumption is output to the car dashboard.
Style of driving has essential impact on fuel consumption. Some councils for reasonable use of a pedal of an accelerator on the cars equipped with system of injection of fuel are given below:
a) In any weather (even in a frost) begin the movement right after implementation of start of the engine;
b) At a car stop for a while more on 40 with, suppress the engine;
c) Try to move always on the highest transfer;
d) On distant trips try to support the constant speed of the movement. Avoid the movement at excessively high speeds. Operate the car circumspectly, avoid causeless braking;
e) Transport the car excessive freight, in the absence of need remove the top luggage carrier from a roof;
f) Regularly check pressure of a rating of tires, - try not to allow its excessive decrease.