I have recently gone through the whole thing so here is what I know.

The pump is that black round plastic thing near the back of the passenger side of the engine bay. You will know if it is in trouble because it will make a horrible scraping noise for about 30 seconds after a cold start in the morning. I don't know how long this can keep going on for before it seizes but mine did it for more than a month. They tell me a new pump costs $2000 + fitting. The pump gets like this because one or both of the valves down at the exhaust either seize open or shut after some time. One of mine occured at 104,000km and was replaced under warranty and then it (or the other one I assume) did it again at around 200,000km. There is a new plastic coated valve that Subaru replaced them with and my first one was done with one of those. These replacement valves cost $750 each and the dealer here wanted at least $600 in labour to do it. And they wanted to do both of mine even though only one had failed because they said it was such a big job getting to them they might as well do both. I said "NO" because it was me paying for it and they were making the profit.

I originally knew the valve had stuck because the engine management light came on (with the flashing cruise control light) and they read the code, but the next day the lights went out by themselves and the following day I started to hear the noise of the pump. I went to another Subaru specialist here (Advanced Service Centre) and they said they couldn't do anything either other than the full $4000 + replacement.

So, the easy (and relatively cheap) cure.
I purchased the two blanking plates and gaskets on the internet for about $23- just Google it - Subaru air pump blanking plates - all 06/07 WRX, STI, Liberty and Foresters will need them one day - and they arrived within the week. I then went to Boxer Service in Brendale on the northern edge of Brisbane and they installed these blanking plates for $297 (it took them about 3 hours) so that they can't be seen and offered to remove the air-pump and plumbing. I chose to leave everything in place so an external inspection looks like it is stock. They also pulled the fuse (so the warning lights came on again). Then I took it to Chip-Torque at Nerang on the Gold Coast where I paid $1100 for an Ezy-Flash Pro and installation and $225 for a dyno run. The Ezy-Flash Pro has a number of tunes downloaded including a 98 octane high boost which saw the power jump from 126kW atw to 142kW atw and torque from 320Nm to 370Nm. This is the tune that I quickly became addicted to and can't get myself to go back to any other. It also has a 98 low boost, 95 high boost, stock tune, valet tune and security cut out. It will also read any codes and delete them and do high speed data logging and performance readouts. To me it was worth every cent I paid. Oh, and you will have to sign a disclaimer for legal purposes because I assume the tune will actually make the car illegal for the first 30 secs after a cold start.

Good luck.

 

So, the easy (and relatively cheap) cure.
I purchased the two blanking plates and gaskets on the internet for about $23- just Google it - Subaru air pump blanking plates - all 06/07 WRX, STI, Liberty and Foresters will need them one day - and they arrived within the week. I then went to Boxer Service in Brendale on the northern edge of Brisbane and they installed these blanking plates for $297 (it took them about 3 hours) so that they can't be seen and offered to remove the air-pump and plumbing. I chose to leave everything in place so an external inspection looks like it is stock. They also pulled the fuse (so the warning lights came on again). Then I took it to Chip-Torque at Nerang on the Gold Coast where I paid $1100 for an Ezy-Flash Pro and installation and $225 for a dyno run. The Ezy-Flash Pro has a number of tunes downloaded including a 98 octane high boost which saw the power jump from 126kW atw to 142kW atw and torque from 320Nm to 370Nm. This is the tune that I quickly became addicted to and can't get myself to go back to any other. It also has a 98 low boost, 95 high boost, stock tune, valet tune and security cut out. It will also read any codes and delete them and do high speed data logging and performance readouts. To me it was worth every cent I paid. Oh, and you will have to sign a disclaimer for legal purposes because I assume the tune will actually make the car illegal for the first 30 secs after a cold start.

ok, im gunna have to read over a few times to try and fully understand, but basically the "cheap" method requires to buy the blanking plates to cancel the secndary air pump, i got lost after that, why did you need to do the ezy flash? If you removed the air pump would you still need the ezy flash?

Thanks again Guzzla, you have helped me alot.

 

why did you need to do the ezy flash? If you removed the air pump would you still need the ezy flash?

Thanks again Guzzla, you have helped me alot.

When the air-pump is removed or deleted (remove fuse) the engine management light stays on and the cruise light flashes. Subaru can't do anything to stop that other than getting into the ECU and that is what the Ezy-Flash Pro does. You could drive around with the engine management light on all the time (and cruise flashing) but you would then never know when there was another problem and you could never use your cruise control.

 

i think i figured it out, so basically after the blocking plates, you need to delete the codes from the system, so the warning light come on? How much would that have cost you on its own just to delete the codes?, if you didn't add that extra kw and torque installation that you did.

Would the air pump issue be a problem on the 2005 (MY06) forester? you know, the July 2005 forester that they released updated with 169kw?

 

The 04/05 engine didn't use an air-pump as it wasn't needed to pass the emission standards of the time. It came in with the update in July 2005 that is known as the 06. You can go to Subaru to get the codes deleted but they will come back the next day as soon as you do a cold start. Wippels Subaru charged me $60 to read and delete the codes originally. You need to reflash the ECU so these codes do not return and Subaru won't (can't) do that. There are other choices - look on Ozfoz forum and there is a stack of information there. A tuner called Throttlehappy (based at Coffs Harbour but travels all over Australia doing tuning) seems to be very popular and apparently does a great tune. I went to Chip-Torque at the Gold Coast because Boxer Service who did the blocking plates and air-pump delete recommended them from their experience with other customers and they were convenient. (Just google them and they have all the info on a wesite with You Tube videos showing exactly how to use the Ezy-Flash Pro.) I also found them very professional to deal with and I was happy to pay for the service and product that I received. A few years ago I was quoted $2000 locally to get an ECUTEC tune and that's about what MRT in Sydney quote too I think. I have found the Ezy-Flash Pro easy to use, it plugs into the diagnostic port jsut below the steering column and only takes a few seconds to read and a few more to do any changes you want. It can only be used on your car but can be unlocked from your car if you sell it (however the car would then be back to its stock tune and the warning lights would be on again).

I'll be holding onto my car for a long time yet and just intend giving it up with the car. To me it was a cheap (approx $1650 with the blocking plates, installation, Ezy-Flash Pro & dyno run) solution to a problem that independent servicers couldn't fix and that Subaru wanted at least $4100 to do something that could then fail again. And the reflash gave me a faster, better driving car that uses no more petrol. If you thought a stock XT was responsive then this is just extra cream on the cake.

 

excellent, great info, thanks

 

Is the secondary air pump problem, an issue with the NON turbo 2006+ models?

 

Been overseas and just got back. No, as far as I know the non-turbos don't have a secondary air pump.

 

Hello my car is a 2007 model Subaru Forester atmospheric engine. I am stuck, the car is not getting gas at work in the morning. Later, when I slowly depress the accelerator pedal, I get squeezed by 2500 cycles, and after that I get more attacking. And the engine malfunction light is off. What could be the problem? Thank you

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