Engine Mechanical:
Complete teardown and reassembly of all engine variants (EJ251, EJ253, EJ205, EJ257, EJ259), including cylinder heads, pistons, crankshaft, timing belt/chain, lubrication system, cooling system.
Engine Management:
Fuel injection (MPI), ignition system (coil-on-plug, distributorless), emissions control systems (EVAP, EGR), ECU diagnostics, sensor operations, wiring diagrams.
Transmission Manual:
Clutch system, gearbox disassembly/reassembly, gear ratios, shift linkage, lubrication, torque specifications.
Transmission Automatic:
Transmission fluid changes, torque converter operation, valve body diagnostics, planetary gearsets, electronic control unit (ECU) interface, troubleshooting.
Drivetrain:
Front and rear differentials, viscous coupling unit (VCU), center differential (AWD systems), driveshafts, CV joints, wheel bearings.
Suspension:
Front McPherson struts, rear multi-link independent suspension, stabilizer bars, bushings, alignment specifications, shock absorber/strut replacement.
Steering:
Power steering system (pump, rack, hoses), steering column, universal joints, tie rod ends, alignment specifications.
Brakes:
Front and rear disc brakes (vented/solid depending on model), ABS system (components, diagnostics, bleeding procedures), parking brake, brake fluid specifications, hydraulic lines.
Electrical System:
12V battery, alternator, starter motor, lighting (headlights, taillights, interior), fuses, relays, circuit diagrams, body control module (BCM).
HVAC:
Air conditioning system (refrigerant types, servicing, component replacement), heater core, blower motor, climate control panels, ducting.
Body And Interior:
Exterior panel removal/installation (bumpers, fenders, doors, hood, trunk), interior trim panels, seats, airbags (SRS system diagnostics and safety precautions), glass replacement.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant flush and fill, brake fluid flush, power steering fluid change.
Troubleshooting:
Diagnostic trouble codes (DTCs) explanation, symptom-based troubleshooting guides, electrical diagnostic flowcharts, common issue diagnosis.
Component Replacement:
Detailed step-by-step guides for replacing major components like engines, transmissions, alternators, starters, radiators, fuel pumps, brake calipers, CV axles, wheel bearings.
Engine Rebuilds:
Instructions for complete engine teardown, inspection of internal components, piston ring replacement, bearing replacement, cylinder head resurfacing, and reassembly with torque specifications.
Timing Belt Replacement:
Crucial procedures for timing belt replacement, including proper camshaft and crankshaft alignment to prevent engine damage.
Bodywork And Paint:
Repair of minor body damage, panel alignment, procedures for body panel removal and installation, possibly some paint touch-up guidance.
Electrical Diagnostics:
Detailed wiring diagrams for all major systems, fuse box layouts, relay functions, diagnostic procedures for common electrical faults.
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Includes detailed specifications, torque values, and diagnostic procedures.
Diagnostic Tools:
Information on using OBD-II scanners, Subaru Select Monitor (SSM), and specific diagnostic tools for various systems.
Engine Code Examples:
EJ251, EJ253 (2.5L SOHC NA), EJ205 (2.0L DOHC Turbo), EJ257 (2.5L DOHC Turbo - WRX STI), EJ259 (2.5L SOHC NA - later years).
Engine Type:
Horizontally-opposed (Boxer) 4-cylinder, naturally aspirated and turbocharged.
Displacement Examples:
2.0L (1994cc), 2.5L (2457cc).
Horsepower Range:
Approx. 165-175 hp (NA), 227-270 hp (Turbo WRX/STI models).
Torque Range:
Approx. 184-190 lb-ft (NA), 236-300 lb-ft (Turbo WRX/STI models).
Fuel Delivery:
Multi-Point Fuel Injection (MPI), Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded gasoline, Octane rating 91 or higher recommended for turbocharged models.
Timing Belt Replacement Interval:
Typically 60,000 miles or 5 years, whichever comes first (for EJ251/253/259). Turbo models might have different intervals or chain-driven camshafts depending on specific year/STI variant.
NHTSA Frontal Crash Rating:
Generally good for the era, specific year ratings apply. Check NHTSA website for individual year performance.
IIHS Small Overlap Frontal Rating:
N/A for this generation as tests were not standard at launch.
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Available Traction Control System (TCS) on some models.
Stability Control:
Available Vehicle Dynamics Control (VDC) on select higher trims and later years.
Airbags:
Front driver and passenger airbags standard. Side airbags and curtain airbags available on some models/trims.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
Crumple Zones:
Designed with front and rear crumple zones for energy absorption.
Oil Change Interval:
Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (consult manual for specific recommendation).
Engine Air Filter Replacement Interval:
Every 15,000-30,000 miles or as needed based on inspection.
Cabin Air Filter Replacement Interval:
Every 15,000-30,000 miles or annually.
Spark Plug Replacement Interval:
Iridium spark plugs (standard on many models) typically last 60,000-100,000 miles. Check manual for exact type and interval.
Engine Oil Spec:
Viscosity: 5W-30 or 10W-30 (depending on climate and engine variant). API SN or higher, ILSAC GF-5 or higher. Check manual for exact specification and capacity.
Coolant Spec:
Subaru Super Coolant (Blue) or equivalent. Mixture: 50/50 with distilled water. Capacity: Approx. 6.4-7.5 US quarts.
Brake Fluid Spec:
DOT 3 or DOT 4 (check manual for exact spec). Always use fresh, sealed fluid.
Power Steering Fluid Spec:
Subaru Genuine Power Steering Fluid or equivalent DEXRON III compatible fluid. Check manual for exact type and capacity.
Head Gaskets:
Although less prevalent than in earlier generations, Subaru's EJ series engines can still be prone to head gasket leaks, particularly if overheated or subjected to high stress.
Turbocharger Issues:
For WRX/STI models, turbocharger longevity can be affected by oil maintenance, driving style (avoiding heat soak), and use of quality oil. Turbo seals and wastegate issues can occur.
Clutch Wear:
Manual transmission clutches can wear prematurely with aggressive driving or heavy towing.
Suspension Bushings:
Worn suspension bushings can lead to noise, poor handling, and alignment issues over time.
Automatic Transmission Failures:
Certain automatic transmissions in this era, particularly if not properly maintained, can experience issues with solenoids or torque converters.
Maintenance Schedule Emphasis
Emphasis:
The manual will detail specific mileage and time-based maintenance schedules critical for maintaining Subaru's Boxer engine and AWD system health.