Engine:
Detailed diagnosis, repair, and overhaul of EJ25 SOHC and DOHC naturally aspirated and turbocharged engines. Includes cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system (oil pump, pan), cooling system, fuel system (injectors, pump, filter), ignition system (coils, plugs), and emissions control.
Transmission:
Service and repair for 4-speed automatic (4EAT) and 5-speed manual transmissions. Includes disassembly, inspection, reassembly, hydraulic control systems, clutch system (manual), drivetrain components (axles, differentials, driveshafts).
Brakes:
Diagnosis and repair of hydraulic braking systems, including ABS. Covers brake pads, rotors, calipers, master cylinder, brake lines, parking brake.
Suspension Steering:
Front and rear suspension components (struts, shocks, control arms, sway bars), wheel alignment procedures, power steering system (pump, rack and pinion).
Electrical Electronics:
Complete wiring diagrams, component testing, diagnosis of starting and charging system, lighting, wipers, HVAC controls, power accessories, sensors, engine control unit (ECU) troubleshooting.
Body Interior:
Body panel repair, door mechanisms, interior trim, seats, dashboard, HVAC system service (blower motor, evaporator, heater core), body hardware (hinges, latches).
Fuel System:
Fuel pump, fuel filter, fuel injectors, fuel lines, fuel tank, evaporative emission control system (EVAP).
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, hangers, oxygen sensors.
Climate Control:
Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, blower motor, climate controls.
Lighting Systems:
Headlights, taillights, brake lights, turn signals, interior lighting, fog lights (if equipped), wiring and relays.
Maintenance:
Scheduled maintenance, oil changes, fluid checks and replacements (engine oil, transmission fluid, brake fluid, coolant), filter replacements (oil, air, fuel), spark plug replacement, tire rotation, brake pad replacement, battery maintenance.
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, wiring diagram interpretation, OBD-II diagnostic trouble codes (DTCs) and their meaning.
Repair Overhaul:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for virtually all vehicle systems. Includes engine rebuild procedures, transmission overhaul, brake system repairs, suspension component replacement, electrical component repair.
Engine Rebuild:
Detailed procedures for complete engine disassembly, inspection, machining, and reassembly.
Transmission Rebuild:
Step-by-step guides for overhauling both manual and automatic transmissions.
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment.
Body Panel Replacement:
Instructions for removing and installing body panels, doors, fenders, hood, tailgate.
Electrical Component Replacement:
Guidance on replacing starters, alternators, ignition coils, sensors, ECUs, etc.
Depth:
Factory-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed specifications, torque values, diagnostic procedures, and internal component repairs.
Component Identification:
Detailed diagrams and part identification for all major components.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Troubleshooting Charts:
Extensive charts for diagnosing issues based on symptoms.
Oil Change:
Typically every 3,000 to 5,000 miles or 3-6 months, depending on driving conditions. Consult the manual for specific recommendations.
Engine Oil Filter:
Subaru part numbers for oil filters commonly include 15208AA031, 15208AA080 (check manual for exact fitment).
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed. Subaru part numbers typically include 16546AA030, 16546AA050.
Spark Plug Replacement:
Approximately every 60,000-100,000 miles, depending on plug type (copper, platinum, iridium). Consult manual for specific plug type and gap. Common NGK part numbers include BKR6E-11.
Timing Belt Replacement:
Crucial for EJ series engines. Typically recommended every 60,000-105,000 miles or 5-7 years. Subaru part numbers for timing belt kits often include 13028AA202, 13028AA190. Failure to replace can lead to catastrophic engine damage.
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter for 2.5L engines. Verify with manual.
Engine Oil Viscosity:
Typically 5W-30 or 10W-30. Consult manual for exact recommendation based on climate. Synthetic oils are recommended.
Coolant Capacity:
Approx. 6.8 quarts (6.4 liters). Verify with manual.
Head Gaskets:
While not as prevalent as in later generations with the EJ253, some early EJ25 engines (especially DOHC versions) could experience head gasket failures. The manual provides diagnostic and repair procedures.
Crankshaft Thrust Bearing:
A known issue for some EJ25 engines, particularly those with automatic transmissions. The manual details inspection and potential repair strategies.
E Grinding Noise:
Some owners report a 'grinding' noise from the front differential or viscous coupling unit, especially during tight turns. The manual offers diagnostic steps for the AWD system.
Oil Leaks:
Valve cover gaskets and oil pan gaskets are common wear items that can develop leaks. The manual provides detailed procedures for their replacement.