Technicians Reference Booklet Subaru Boxer Engine Series Module 104

This Technicians Reference Booklet introduces the Subaru 2.2 liter (SOHC) naturally aspirated (N/A), (Phase 1) and (Phase 2) engines, the 2.5 liter (DOHC) (Phase 1) and (SOHC) (Phase 2) engines, the 2.0 liter Turbo engine and the 3.0 and 3.3 liter six cylinder engines.

Technician Reference Booklet 6 Cylinder Boxer Engines Series Module 104-H6 (6cyl Boxer Engine Series-011822-MSA5P0631C)

It reviews the mechanical features of these engines and the differences between existing engines. It also covers the procedures used in diagnosing and overhauling these engines. The text and illustrations are derived from and follow the classroom lectures and slide presentations and they are intended to supplement and reinforce classroom  instruction and serve as a home-study reference source. A list of applicable Service Bulletins, Important Notes and Cautions, and Special Tools are given within this booklet.

Pages for Diagnostic Tips and Notes are also provided. Technicians worksheets are to be completed during the hands-on lab work segments of the Boxer Engine Series Module.

Always refer to the appropriate model year Subaru Service Manual and the applicable service bulletins for all specification and detailed servicing procedures.


  • Slide Sequence
  • Introduction
  • General Overview
    • 2.2L Engine Identification
  • 2.2L Engine (Phase 1) Features
  • 2.2L Engine Servicing & Diagnostics
    • In Vehicle Servicing
    • Engine Diagnostics
  • 2.2L Engine Disassembly
  • 2.2L Component Inspection and Servicing
    • Precautions
  • 2.2L Engine Reassembly
  • Notes and Cautions
    • 2.2L Engine Disassembly
    • 2.2L Engine Reassembly
  • Engine Enhancements 2.2 Liter (Phase 1)
  • Other Engine Modifications
  • 1999 2.2 Liter (SOHC) (Phase 2) Engine Enhancements
  • New Features of the Phase Two Engines
  • 2.5 Liter Engine Features
    • Spark Plug Replacement Procedure for 2.5 Liter Engine
    • Installation
  • 1997 2.5 Engine DOHC (Phase 1)
  • 2.5 Engines 1999 Enhancements DOHC (Phase 1) and SOHC (Phase 2)
  • New Features of the 2.5 Liter (Phase 2) SOHC Engines
  • 2.0 Liter Engine Features
  • 3.0 Liter Engine
    • General Information
    • 3.0 Liter Engine Features
    • 3.0 Specifications
  • 3.0 Liter Engine Disassembly
    • Unloading Cam Sprockets
    • Removal of Oil Pump
    • O-Ring Placement Inner Cover
    • Removal of Cylinder Head
    • Removal of Oil Pan
    • Piston Pin Access
    • Spliting Block Halves
    • Lubrication System
    • Coolant System
    • Valve Adjustment
    • Chain Tensioners
  • 3.0 Liter Engine Reassembly
  • Fuji Bond Application Guide for Block Halves
    • Oil Pan Extension Housing (Upper Oil Pan)
    • Fuji Bond Application Guide for Oil Pan (Lower)
    • Fuji Bond Application Guide for Inner Cover
    • Fuji Bond Application Guide for Outer Cover (Front Chain Cover)
  • 3.3 Liter Engine Service Procedures
  • Special Tools
    • General Hand Tools and Supplies
  • Reference Materials
  • Service Bulletins
  • 104 Module Service Help-Line Updates

Language: English
Format: PDF
Pages: 84

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