Subaru 2003 Legacy Service Manual Download

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WI-39

WIRING SYSTEM

GROUND DISTRIBUTION

GND(L)-10

WI-00757

ENGINE CONTROL MODULE
(6-CYLINDER ENGINE MODEL)

C18

D21

D31

A15

B136

B134

B137

C17

A22

1 2 3

B252 (DARK GRAY)

(GRAY)

1 2 3 4
5 6 7 8

B134

1 2 3 4

10 11 12

19 20 21

14 15

8 9

16 17

B83

C: B136

1 2

8 9

10 11 12
19 20 21

13 14 15 16

17 18

22 23 24

(DARK GRAY)

(GRAY)

B79

B20

1 2 3 4
5 6 7 8
9 10 11 12

13 14 15 16

2 3

4 5

6 7

9 10

11 12

13 14

30 31

D: B137

10 11 12

19 20
29

13 14 15 16 17

27 28

22 23 24 25 26

B252

E49

B83

B79

CHECK CONNECTOR

IDLE SPEED CONTROL
SOLENOID VALVE

SHIELD AND
SENSOR GROUND
JOINT CONNECTOR

B20

1 2 3 4

5 6 7 8 9 10

13 14 15 16 17 18

REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(LH6)-09]

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Summary of Contents for 2003 Legacy

Page 1: ...ar PDF Service Manual ENGINE SECTION 1 Pub No G2300GE2 ENGINE SECTION 2 Pub No G2300GE3 TRANSMISSION SECTION Pub No G2300GE5 CHASSIS SECTION Pub No G2300GE6 BODY SECTION Pub No G2300GE7 WIRING SYSTEM...

Page 2: ...guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replaceme...

Page 3: ......

Page 4: ...FOREWORD FW Page 1 Foreword 2...

Page 5: ...uals are used when performing mainte nance repair or diagnosis of the Subaru Legacy Applied model BE and BH from 2003MY The manuals contain the latest information at the time of publication Changes in...

Page 6: ...HOW TO USE THIS MANUALS HU Page 1 How to Use This Manuals 2...

Page 7: ...RUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com ponent The specification maintenance and other information for the components are included...

Page 8: ...e parts refer to parts catalogue Example HU 00001 14 9 8 7 6 10 4 10 22 11 19 17 15 13 12 18 16 1 2 3 4 5 6 7 8 11 10 9 12 13 19 18 20 17 16 24 10 25 5 4 4 4 3 3 3 2 1 21 15 23 T7 T2 T2 T2 T2 T2 T2 T4...

Page 9: ...ded in one service procedure appropriate reference are provided for each part Example A Component D Caution G Tightening torque B Process E Tool number of special tool H Illustration C Reference F Nam...

Page 10: ...IAGNOSIS Tables showing a step by step process make it easy to conduct diagnosis 8 SI UNITS Measurements in these manuals are according to the SI units Metric and yard pound measurements are also incl...

Page 11: ...HU 6 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS MEMO...

Page 12: ...SPECIFICATIONS SPC Page 1 Legacy 2 2 OUTBACK 10...

Page 13: ...gasoline engine Valve arrangement Overhead camshaft type Bore Stroke mm in 92 75 3 62 2 95 99 5 79 0 3 917 3 110 Displacement cm3 cu in 1 994 121 67 2 457 149 9 Compression ratio 10 0 Firing order 1...

Page 14: ...R6G Generator 12V 90A Battery Type and capacity 5HR 12V 48AH 55D23L Model Sedan Wagon AWD 2 0 L Non TURBO 2 5 L Non TURBO Transmission type 5MT 4AT 5MT 4AT Clutch type DSPD TCC DSPD TCC Gear ratio 1st...

Page 15: ...111 4 111 Reductiongear Rear drive Transfer reduc tion Type of gear Helical Gear ratio 1 000 Final reduction Type of gear Hypoid Hypoid Gear ratio 4 111 4 111 Model 2 0 L 2 5 L Non TURBO 2 0 L TURBO...

Page 16: ...6 Engine coolant 2 US qt Imp qt 7 0 7 4 6 2 7 7 8 1 6 8 6 9 7 3 6 1 7 6 8 0 6 7 6 8 7 2 6 0 6 7 7 1 5 9 Option code 1 EC K4 KO KS Model 2 0 L AWD GL 5MT 4AT 5MT 4AT 5MT 4AT Curb weight C W Front kg lb...

Page 17: ...5 1 000 2 205 Maximum permissible weight M P W Total kg lb 1 910 4 210 1 910 4 210 1 910 4 210 1 910 4 210 1 910 4 210 1 910 4 210 Option Side airbag Air conditioner Audio Cruise control Cold weather...

Page 18: ...0 2 050 930 2 050 940 2 075 940 2 075 Rear kg lb 970 2 140 970 2 140 980 2 160 980 2 160 Total kg lb 1 900 4 190 1 900 4 190 1 920 4 235 1 920 4 235 Option Side airbag Air conditioner Audio Cruise con...

Page 19: ...ble weight M P W Total kg lb 1 920 4 235 1 920 4 235 1 920 4 235 1 920 4 235 1 920 4 235 1 920 4 235 Option Side airbag Air conditioner Audio Cruise control Cold weather pack Option code 1 EC K4 KS Mo...

Page 20: ...030 2 270 1 030 2 270 1 030 2 270 1 030 2 270 1 050 2 315 1 050 2 315 Maximum permissible weight M P W Total kg lb 1 920 4 235 1 920 4 235 1 920 4 235 1 920 4 235 1 980 4 365 1 980 4 365 Option Side...

Page 21: ...2 5 L mm in 190 7 5 3 0 L mm in 200 7 9 Model OUTBACK AWD 2 5 L 3 0 L Engine type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Horizontally opposed liquid cooled 6 cylinder...

Page 22: ...ttery Type and capacity 5HR For Europe and South America MT 12V 48AH 55D23L AT 12V 52AH 75D23L 12V 52AH 75D23L Others 12V 27AH 34B19L 12V 48H 55D23L Model OUTBACK AWD 2 5 L 3 0 L Transmission type 5MT...

Page 23: ...e Rear Disc brake Parking brake Mechanical on rear brakes Model OUTBACK Rim size 16 61 2JJ Tire size 215 60R16 Type Steel belted radial Tubeless Model OUTBACK AWD 2 5 L 3 0 L 5MT 4AT Fuel tank 2 US ga...

Page 24: ...315 1 050 2 315 Maximum permissible weight M P W Total kg lb 2 000 4 410 2 000 4 410 2 000 4 410 2 000 4 410 Option Side airbag Air conditioner Audio Cruise control Cold weather pack Leather trim Sun...

Page 25: ...335 Maximum permissible weight M P W Total kg lb 2 015 4 445 2 015 4 445 2 085 4 595 Option Side airbag Air conditioner Audio Cruise control Cold weather pack Leather trim Sunroof Self levelizer Opti...

Page 26: ...PRECAUTION PC Page 1 Precaution 2...

Page 27: ...the instructions in this manual when performing maintenance on airbag components or nearby and airbag wiring harnesses or nearby To prevent unexpected deployment perform one of the steps below and th...

Page 28: ...NOTE NT Page 1 Note 2...

Page 29: ...static electricity prevention cord or touch grounded metal before conducting work 3 IGNITION OFF BATTERY When removing the battery cables always be sure to turn the ignition off to prevent electrical...

Page 30: ...NT 3 NOTE NOTE Pantograph jack Lift NT 00049 With side sill cover NT 00050 Without side sill cover NT 00046...

Page 31: ...NT 4 NOTE NOTE Safety stand NT 00047 Front Rear Rear differential gear NT 00036 Front crossmember...

Page 32: ...porting vehicles and when using the chassis dynamo Tie down points Attach tie downs only to the specified points on the vehicle NT 00059 Hook for tie down Hook for tie down Hook for towing and tie dow...

Page 33: ...l be within 50 8 mm 1 97 in Make sure to fix a vehicle securely 7 TOWING Avoid towing vehicles except when the vehicle can not be driven For vehicles with AWD AT or VTD use a loader instead of towing...

Page 34: ...he hood in this position remove the windshield washer hose attaching clip from the hood 9 TRAINING For information about training contact a dealer or agent 10 GENERAL SCAN TOOL Using general scan tool...

Page 35: ...NT 8 NOTE NOTE MEMO...

Page 36: ...IDENTIFICATION ID Page 1 Identification 2...

Page 37: ...on control label Tire inflation pressure label Driver side Australia model Tire pressure label Driver side Except Australia model Saudi Arabia plate Saudi Arabia model Built date plate Australia model...

Page 38: ...AWD E 3 0 L AWD 7 L Steering position K RHD Right hand drive L LHD Left hand drive 8 J Engine transmission E DOHC MPI 4AT J SOHC MPI 5F R SOHC MPI 4AT D DOHC MPI TURBO 5F T DOHC MPI TURBO 4AT SS 9 3...

Page 39: ...6 GX 8 OUTBACK 8 M Restraint M Manual belts dual airbag 9 X Check digit 0 9 X 10 3 Model year 3 2003MY 4 2004MY 5 2005MY 11 G Transmission type G Full time AWD 5 speed MT single range H Full time AWD...

Page 40: ...Y Transmission type Y Full time AWD MT center differential V Full time AWD AT VTD Z Full time AWD AT MPT 3 and 4 75 Classification 75 MT 1A 1B AT 5 4 Series 4 5th Generation Legacy 6 V Transmission s...

Page 41: ...CPS Code Reduction gear ratio LSD T1 3 900 No T2 4 111 No TP 4 444 No BL 4 444 No Strengthened type VB 3 700 No CF 4 444 Viscous JP 4 111 Viscous Digits Code Meaning Details 1 to 2 EC Destination EC E...

Page 42: ...RECOMMENDED MATERIALS RM Page 1 Recommended Materials 2...

Page 43: ...line will damage the catalytic converter Australia specification Leaded gasoline On vehicles without catalytic converter use leaded gasoline with an octane value of 90 RON or higher 3 LUBRICANTS Use e...

Page 44: ...and applicable temperature Engine oil Manual transmission oil and rear differential gear oil RM 00003 F 22 4 14 50 68 86 104 C 30 20 10 0 10 20 30 40 5W 30 Recommend 32 10W 30 or 10W 40 RM 00004 C 22...

Page 45: ...ont differential gear oil Fluid Recommended Alternative Remarks Automatic transmission fluid DEXRON III Power steering fluid DEXRON III Brake fluid FMVSS No 116 DOT3 FMVSS No 116 DOT4 Clutch fluid FMV...

Page 46: ...e No 7439 003602001 Brake pad Molykote AS 880N K0777YA010 Front axle SFJ SSG 6003 28093TA000 Front axle BJ NTG2218 28093AA000 Rear axle BJ Molylex No 2 003601001 Rear axle DOJ VU 3A702 23223GA050 Thro...

Page 47: ...RM 6 RECOMMENDED MATERIALS RECOMMENDED MATERIALS MEMO...

Page 48: ...PRE DELIVERY INSPECTION PI Page 1 Pre delivery Inspection 2...

Page 49: ...l state Check if the vehicle before delivery is in a normal state Check for any damage or missing parts that may have taken place during transportation or storage Make sure to provide a complete vehic...

Page 50: ...e trunk lid to see that there are no abnormal conditions 8 Check the rear gate for lock unlock and open close operations 1 Using the key check if the rear gate can be lock and unlocked normally 2 Open...

Page 51: ...m operates normally 11 Power window operation check 1 Check the power window for correct operations Step Check point 1 Brake test 1 Check that the foot brake operates normally 2 Parking brake 1 Check...

Page 52: ...ent battery discharge Attach a 15 A fuse as shown in the figure 4 CONNECTION OF AIR CONDITIONER CUT CONNECTOR A vehicle just delivered has its air conditioner cut connector or air conditioner haness d...

Page 53: ...ull the outside door handles of the rear doors to ensure that the doors will open 7 CHECK THE TRUNK LID OPERATIONS OPEN CLOSE AS FOLLOWS Operate the trunk lock release lever and verify that the trunk...

Page 54: ...booklet Spare key Jack Tool set Spare tire Sedan Wagon 11 OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM By operating front hood release knob confirm front hood will unlock properly By operating lever co...

Page 55: ...o leaks are found Then add the necessary amount of the specified AT front differential oil 17 COOLANT Check the coolant amount on the reservoir If the amount is insufficient check that no leaks are fo...

Page 56: ...Check that all doors and the rear gate are automatically locked again 22 SEAT Check that each seat provides full functionality in sliding and reclining Check all available functions of the rear seat s...

Page 57: ...e headlight operations Check the brake light operations Check the other lights for normal operations 33 WINDOW WASHER Before inspection of the window washer system connect the washer connector to the...

Page 58: ...ly 42 ATF LEVEL Check that the ATF level is normal If insufficient check that no leaks are found Then add the neces sary amount of the specified ATF 43 POWER STEERING FLUID LEVEL Check that the power...

Page 59: ...the paint after removing the paint protec tive coating and washing the vehicle NOTE Before removing the protective coating be sure to wash the vehicle because the painted surface may be scratched if t...

Page 60: ...19 10 Air Cleaner Element 20 11 Cooling System 21 12 Coolant 22 13 Clutch System 24 14 Hill holder System 25 15 Idle Mixture 26 16 Transmission Oil 27 17 ATF 28 18 Front Rear Differential Oil 30 19 B...

Page 61: ...ERIODIC MAINTENANCE SERVICES GENERAL DESCRIPTION 1 General Description A GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become s...

Page 62: ...ired Maintenance interval Number of months or km miles whichever occurs first Months 12 24 36 48 60 72 84 96 Remarks 1 000 km 1 6 5 15 30 45 60 75 90 105 120 1 000 miles 1 3 9 19 28 38 47 56 66 75 1 E...

Page 63: ...amshaft drive chains on the 3 0 L models is not required Maintenance interval Number of months or km miles whichever occurs first Months 12 24 36 48 Remarks 1 000 km 5 12 5 25 37 5 50 1 000 miles 3 7...

Page 64: ...ntly Replace more fre quently Replace more fre quently Fuel line 12 months I 15 000 km 9 000 miles Transmission oil Replace more fre quently ATF Replace more fre quently Front rear dif ferential oil R...

Page 65: ...eplace more fre quently Replace more fre quently Fuel line 6 months I 12 500 km 7 500 miles Transmission oil Replace more fre quently ATF Replace more fre quently Front rear dif ferential oil Replace...

Page 66: ...gauge Make sure that vehicle is placed level when checking oil level Use engine oil of proper quality and viscosity selected in accor dance with the table in figure Engine oil amount for preparation 2...

Page 67: ...ECTION 1 Park vehicle on a level surface 2 Remove oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper orientat...

Page 68: ...cleaning is not necessary 6 Check the engine oil level Ref to PM 7 En gine Oil 2 3 0 L MODEL 1 Drain engine oil by loosening engine oil drain plug 2 Remove under cover 3 Remove oil filter with ST ST 4...

Page 69: ...spark plug lightly with hand and then secure with a plug wrench to the specified torque Tightening torque 21 N m 2 1 kgf m 15 ft lb NOTE Be sure to place the gasket between the cylinder head and spar...

Page 70: ...gnition coil Tightening torque 16 N m 1 6 kgf m 11 7 ft lb NOTE Be sure to place the gasket between the cylinder head and spark plug If torque wrench is not available tighten spark plug until gasket c...

Page 71: ...0 mm 0 354 0 433 in B replaced 7 5 8 5 mm 0 295 0 335 in reused 9 0 10 0 mm 0 354 0 394 in There is no belt B on models without an air con ditioner 2 3 0 L MODEL 1 Replace belts if cracks fraying or w...

Page 72: ...ension 9 Tighten the lock nut A Tightening torque 22 6 N m 2 3 kgf m 16 6 ft lb 10 Tighten the through bolt B Tightening torque 8 N m 0 8 kgf m 5 8 ft lb 11 Install a new belt and tighten the slider b...

Page 73: ...IC MAINTENANCE SERVICES DRIVE BELT S 3 Install in the reverse order of removal A Power steering oil pump B Belt tension adjuster C Crankshaft pulley D A C compressor E Belt idler F Generator PM 00119...

Page 74: ...ulley bolt To lock crankshaft use ST 2 0 L model ST 499977400 CRANKSHAFT PULLEY WRENCH 2 5 L model ST 499977100 CRANKSHAFT PULLEY WRENCH 6 Remove crankshaft pulley 7 Remove left side belt cover 8 Remo...

Page 75: ...pulley bolt To lock the crankshaft use ST MT model ST 499977100 CRANKSHAFT PULLEY WRENCH AT model ST 499977400 CRANKSHAFT PULLEY WRENCH 5 Remove the crankshaft pulley 6 Remove the air conditioning co...

Page 76: ...ss than 27 mm 1 06 in check idlers tensioner water pump pulley and cam sprocket to determine idler align ment squareness Replace worn timing belt 4 Install front timing belt cover and timing belt cov...

Page 77: ...If faulty parts are found repair or replace them 2 0 L non turbo and 2 5 L with OBD models Ref to FU H4SO 70 Fuel Delivery Return and Evaporation Lines 2 0 L non turbo and 2 5 L without OBD models Ref...

Page 78: ...models Ref to FU H4SO 67 Fuel Filter 2 0 L non TURBO and 2 5 L without OBD models Ref to FU H4SOw oOBD 64 Fuel Filter 2 0 L TURBO model Ref to FU H4DOSTC 64 Fuel Filter 3 0 L model Ref to FU H6DO 70...

Page 79: ...emoval NOTE Fasten with a clip after inserting the lower tab of the case 2 2 0 L TURBO AND 3 0 L MODEL 1 Loosen clamp A and separate air cleaner up per cover and air intake boot 3 0 L model 2 Remove t...

Page 80: ...lve open pressure us ing radiator cap tester NOTE Rust or dirt on cap may prevent valve from func tioning normally be sure to clean cap before test ing Raise the pressure until the needle of gauge sto...

Page 81: ...L non turbo and 2 5 L models MT model Approx 6 8 2 7 2 US qt 6 0 Imp qt AT model Approx 6 7 2 7 1 US qt 5 9 Imp qt 2 0 L turbo model MT model Approx 7 7 2 8 1 US qt 6 8 Imp qt AT model Approx 7 6 2 8...

Page 82: ...be in creased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read the scale on the vertical axis of the...

Page 83: ...utch system hoses piping and their couplings for fluid leaks If fluid leaks are found correct them by retightening their fitting bolt and or replacing their parts 5 Check the fluid level using the sca...

Page 84: ...ngine tends to stall Loos en adjusting nut gradually until smooth starting is enabled B When hill holder is released earlier than en gagement to clutch vehicle slips down slightly Tighten adjusting nu...

Page 85: ...ure with the CO meter 4 If out of specification adjust the idle mixture us ing CO adjusting screw of mass air flow sensor 5 After adjusting the CO value check and adjust increment coefficient of CO re...

Page 86: ...plug after draining gear oil and tighten it to the specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft lb NOTE Replace the gasket with a new one Each oil manufacturer has its base oil and add...

Page 87: ...uld be found below the center of these two marks CAUTION Use care not to exceed the upper limit level ATF level varies with temperature Remem ber that the addition of fluid to the upper limit mark whe...

Page 88: ...orque Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 3 Pour ATF into the oil charge pipe Recommended fluid Dexron III type automatic transmission flu id ATF amount Refill with the same amount of ATF th...

Page 89: ...e starting work cool off the engine well If transmission gear oil splashes on exhaust pipe wipe it clean 2 Reinstall drain plug after draining differential gear oil and tighten it to the specified tor...

Page 90: ...plug 2 Remove filler plug for quicker draining 3 Tighten drain plug after draining oil NOTE Apply fluid packing to drain plug threads before in stallation Fluid packing Three Bond 1105 Part No 004403...

Page 91: ...on meter will come on Visually check brake hose using a mirror where it is difficult to see for any damage B CHECKING 1 SERVICE BRAKE 1 Check the free play of brake pedal with a force of less than 10...

Page 92: ...l several times applying the same pedal force Make sure the travel distance should not change 2 With the brake pedal depressed start the en gine Make sure the pedal should move slightly to ward the fl...

Page 93: ...oz 17 6 Imp fl oz for to tal brake system 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it de pressed 7 Loosen bleeder screw approximately 1 4 turn until...

Page 94: ...han 10 mm 0 39 in from the outer periphery of the ro tor Disc rotor runout limit Front 0 075 mm 0 0030 in Rear 0 070 mm 0 0028 in NOTE When replacing a pad always replace the pads for both the left an...

Page 95: ...mm 0 059 in 2 Check brake drum for wear dents or other dam age If the inside surface of brake drum is streaked correct the surface with emery cloth 200 or more If it is unevenly worn tapered or the o...

Page 96: ...STROKE 1 Remove console box lid 2 Forcibly pull parking brake lever 3 to 5 times 3 Adjust parking brake lever by turning adjuster until parking brake lever stroke is set at 6 notches with operating f...

Page 97: ...Joint 5 Damage of dust seal Visually inspect ball joint dust seal If it is damaged remove transverse link Ref to FS 14 Front Transverse Link And measure free play of ball joint Ref to FS 16 Front Bal...

Page 98: ...ms are within standard values Toe in Camber angle Thrust angle Ref to RS 8 Wheel Alignment 2 When camber angle does not conform to stan dard value visually inspect parts listed below If de formation i...

Page 99: ...th one hand turn hub with the other to check for noise or binding If hub is noisy or binds disassemble front axle and check condition of oil seals bearing etc 2 REAR WHEEL BEARING 1 Jack up the rear o...

Page 100: ...front axle boots A and rear axle boots B for deformation damage or failure If faulty replace them with new ones Ref to DS 28 Front Drive Shaft Ref to DS 34 Rear Drive Shaft 2 PROPELLER SHAFT Inspect...

Page 101: ...ndicators appear across the tire tread It is recommended that both right and left tires are replaced as a set 2 Adjust the wheel alignment if abnormally uneven tire wear is found 3 Also rotate the tir...

Page 102: ...original posi tion after it has been turned and then released 2 STEERING SHAFT JOINT 1 When steering wheel free play is excessive dis connect universal joint of steering shaft and check it for any pl...

Page 103: ...y indicator of reservoir tank If the level is at lower point or below add fluid to keep the level in the specified range of the indica tor If at upper point or above drain fluid by using a syringe or...

Page 104: ...BOOTS Inspect both sides of gearbox boots as follows and correct the defects if necessary 1 A and B positions of gearbox boot are fitted correspondingly in A and B grooves of gearbox and the rod 2 Cl...

Page 105: ...PM 46 PERIODIC MAINTENANCE SERVICES STEERING SYSTEM POWER STEERING MEMO...

Page 106: ...le in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations contained in this manual are based o...

Page 107: ...ICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 G2300GE2 LUBRICATION LU H4SOw oOBD SPEED CONTROL SYSTEMS SP H4SOw oOBD IGNITION IG H4SOw oOBD STARTING CHARGING SYSTEMS SC H4SOw oOBD ENGINE DIAGNOSTI...

Page 108: ...r Temperature Sensor 33 11 Idle Air Control Solenoid Valve 34 12 EGR Valve 35 13 Fuel Injector 36 14 Front Oxygen A F Sensor 41 15 Rear Oxygen Sensor 43 16 Engine Control Module 45 17 Main Relay 46 18...

Page 109: ...l Specification Fuel tank Capacity 64 2 16 9 US gal 14 1 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 370 677 kPa 3 77 6 9 kg cm2 53 6 98 psi Discharge flow More...

Page 110: ...FU H4SO 3 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION MEMO...

Page 111: ...YSTEMS GENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD FU 00377 20 21 5 6 7 8 9 10 3 2 4 17 17 17 20 22 18 18 14 16 16 13 12 1 19 15 11 4 3 5 6 T2 T2 T1 T1 T1 T1 T1 T1 T5 T4 T4 T4 T2 T5 T4 T4 T3 T3...

Page 112: ...elerator cable bracket 3 Fuel injector 13 Fuel pipe protector LH 23 EGR valve 4 O ring 14 Plug cord holder LH 5 O ring 15 Fuel pipe protector RH Tightening torque N m kgf m ft lb 6 O ring 16 Fuel pipe...

Page 113: ...YSTEM 1 Gasket 5 Throttle body Tightening torque N m kgf m ft lb 2 Throttle position sensor 6 Intake air temperature sensor T1 1 6 0 16 1 2 3 Idle air control solenoid valve 7 Grommet T2 22 2 2 15 9 4...

Page 114: ...3 CRANKSHAFT POSITIOM CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 4 Camshaft position sensor support Tightening torque N m kgf m ft lb 2 Knock sensor T1 6 4 0 65 4 7 3 Camshaft po...

Page 115: ...ECTION FUEL SYSTEMS GENERAL DESCRIPTION 4 FUEL TANK FU 00626 1 2 2 3 4 5 6 7 8 9 31 33 37 38 36 30 34 11 10 12 13 14 14 14 15 16 17 18 19 20 26 24 25 23 32 21 22 21 27 30 30 30 35 29 28 T3 T3 T3 T3 T1...

Page 116: ...6 Fuel pump plate 21 Quick connector 36 Seal 7 Fuel pump ASSY 22 Jet pump hose B 37 Fuel pump holder 8 Fuel level sensor 23 Fuel sub level sensor gasket 38 Grommet 9 Fuel filter 24 Jet pump filter 10...

Page 117: ...SO 10 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 5 FUEL LINE B2M4171A FU 00627 9 8 7 6 5 4 4 3 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 23 22 21 14 13 11 12 15 10 20 19 18 17 16 32 31 30 29 28 27 26 2...

Page 118: ...se B 15 Fuel pipe ASSY 26 Canister drain hose 5 Clip 16 Evaporation hose B 27 Canister 6 Fuel pipe ASSY 17 Two way valve hose 28 Front canister bracket 7 Grommet 18 Two way valve 29 Rear canister brac...

Page 119: ...EMS GENERAL DESCRIPTION 6 FUEL FILLER PIPE 1 Fuel filler pipe ASSY 5 Filler ring Tightening torque N m kgf m ft lb 2 Clip 6 Filler cap T 7 4 0 75 5 4 3 Clamp 7 Fuel filler pipe protector 4 Filler pipe...

Page 120: ...e is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connector...

Page 121: ...e throttle position sensor and pres sure sensor 6 Disconnect the engine coolant hoses A from the throttle body 7 Remove the bolts B which install throttle body to the intake manifold B INSTALLATION 1...

Page 122: ...onnect the cruise control cable B With cruise control model 7 Remove the power steering pump and reservoir tank from bracket 1 Remove the resonator chamber Ref to IN H4SO 8 REMOVAL Resonator Chamber 2...

Page 123: ...from the throttle body 11 Disconnect the brake booster hose 12 Remove the air cleaner case stay RH and en gine harness bracket and disconnect the engine harness connectors from the bulkhead harness c...

Page 124: ...e fuel pipes WARNING Do not spill fuel Catch fuel from hoses in a container or cloth 20 Remove the bolts which hold intake manifold onto the cylinder heads 21 Remove the intake manifold B INSTALLATION...

Page 125: ...he connector to the camshaft position sensor 5 Connect the connector to the oil pressure switch 6 Connect the connector to the crankshaft position sensor 7 Connect the knock sensor connector 8 Connect...

Page 126: ...e to the intake manifold 13 Connect the spark plug cords to the spark plugs 14 Install the power steering pump and reservoir tank to bracket 1 Install the reservoir tank to bracket 2 Connect the conne...

Page 127: ...r cleaner case Ref to IN H4SO 7 INSTALLATION Air Intake Duct and Ref to IN H4SO 6 INSTALLATION Air Cleaner Case 18 Connect the connector to the fuel pump relay 19 Connect the battery ground cable to b...

Page 128: ...the fuel injec tors 10 Disconnect the connector from the purge con trol solenoid valve 11 Disconnect the air by pass hose from the purge control solenoid valve 12 Remove the harness bands A and harne...

Page 129: ...fuel injector while lifting up the fuel injector pipe 18 Loosen the clamp which holds the front left side fuel hose to the injector pipe and remove the pipe 19 Loosen the clamp which holds the front r...

Page 130: ...to the injector pipe and tighten the clamp screw 4 Install the fuel injector pipe 5 Connect the left side fuel hose to the injector pipe and tighten the clamp screw 6 Install the fuel injectors NOTE R...

Page 131: ...ect the evaporation hose as shown in the fig ure 11 Install the engine harness onto the intake man ifold Tightening torque 16 N m 1 6 kgf m 11 8 ft lb 12 Connect the connectors to the fuel injectors a...

Page 132: ...GR Valve 18 Install the throttle body to the intake manifold Ref to FU H4SO 14 INSTALLATION Throttle Body 19 Install the ignition coil and ignitor assembly 20 Connect the connector to the ignition coi...

Page 133: ...air intake duct and air cleaner as sembly Ref to IN H4SO 7 REMOVAL Air Intake Duct and Ref to IN H4SO 6 REMOVAL Air Cleaner Case 3 Disconnect the connector from the engine cool ant temperature sensor...

Page 134: ...ound cable from battery 2 Remove the bolt which install crankshaft position sensor to the cylinder block 3 Remove the crankshaft position sensor and dis connect the connector from it B INSTALLATION In...

Page 135: ...position sensor support 4 Remove the bolt which installs camshaft position sensor support to the camshaft cap LH 5 Remove the camshaft position sensor and cam shaft position sensor support as a unit...

Page 136: ...e cylinder block B INSTALLATION 1 Install the knock sensor to the cylinder block Tightening torque 24 N m 2 4 kgf m 17 4 ft lb NOTE The extraction area of the knock sensor cord must be positioned at a...

Page 137: ...n installing throttle position sensor adjust to the specified data C ADJUSTMENT 1 Turn the ignition switch to OFF 2 Loosen the throttle position sensor holding screws 3 When using voltage meter 1 Take...

Page 138: ...data link connector A 5 Turn the ignition switch to ON and the Subaru Select Monitor switch to ON 6 Select the 2 Each System Check in Main Menu 7 Select the Engine Control System in Selection Menu 8 S...

Page 139: ...ect the ground cable from battery 2 Disconnect the connector from the pressure sensor 3 Remove the pressure sensor B INSTALLATION Install in the reverse order of removal Tightening torque 1 6 N m 0 16...

Page 140: ...ir Temperature Sen sor A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the connector from the intake air temperature sensor 3 Remove the intake air temperature sensor from air cleane...

Page 141: ...he ground cable from battery 2 Disconnect the connector from the idle air con trol solenoid valve 3 Remove the idle air control solenoid valve from the throttle body B INSTALLATION Install in the reve...

Page 142: ...AL 1 Disconnect the ground cable from battery 2 Disconnect the connector from EGR valve 3 Remove the EGR valve from intake manifold B INSTALLATION Install in the reverse order of removal Tightening to...

Page 143: ...he spark plugs 1 and 3 cylinders 6 Remove the power steering pump and tank from the brackets 1 Remove the front side V belt Ref to ME H4SO 41 REMOVAL V belt 2 Remove the bolts which hold the power ste...

Page 144: ...e the fuel injector from the intake mani fold 1 Remove the fuel injector securing clip 2 Remove the fuel injector while lifting up the fuel injector pipe 2 LH SIDE 1 Release the fuel pressure Ref to F...

Page 145: ...the rear window glass washer hose from the washer motor then plug the connection with a suitable cap 8 Move the washer tank and secure it away from the working area 9 Remove the spark plug cords from...

Page 146: ...Remove the fuel injector securing clip 2 Remove the fuel injector while lifting up the fuel injector pipe B INSTALLATION 1 RH SIDE Install in the reverse order of removal NOTE Replace O rings with ne...

Page 147: ...f m 24 3 ft lb 2 LH SIDE Install in the reverse order of removal CAUTION Replace O rings with new ones Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb Tightening torque 19 N m 1 94 kgf m 13 7 ft lb Tig...

Page 148: ...CAUTION When removing the oxygen A F sensor wait until exhaust pipe cools otherwise it will dam age exhaust pipe B INSTALLATION 1 Before installing front oxygen A F sensor ap ply the anti seize compou...

Page 149: ...FU H4SO 42 FUEL INJECTION FUEL SYSTEMS FRONT OXYGEN A F SENSOR 5 Connect the battery ground cable to battery FU 00009...

Page 150: ...UTION When removing the oxygen sensor wait until exhaust pipe cools otherwise it will damage ex haust pipe B INSTALLATION 1 Before installing rear oxygen sensor apply the anti seize compound only to t...

Page 151: ...FU H4SO 44 FUEL INJECTION FUEL SYSTEMS REAR OXYGEN SENSOR 5 Connect the battery ground cable to battery FU 00009...

Page 152: ...mat of front passenger seat 4 Remove the protect cover 5 Remove the nuts A which hold ECM to the bracket 6 Remove the clip B from the bracket 7 Disconnect the ECM connectors and take out the ECM B INS...

Page 153: ...1 Disconnect the ground cable from battery 2 Remove the passenger s side front side sill cov er 3 Remove the bolt which holds main bracket on the body 4 Disconnect the connectors from the main relay...

Page 154: ...ble from battery 2 Remove the passenger s side front side sill cov er 3 Remove the bolt which holds fuel pump relay bracket on the body 4 Disconnect the connector from the fuel pump 5 Remove the fuel...

Page 155: ...F 2 DRAINING FUEL WARNING Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Set the vehicle on the lift 2 Disconnect the ground cable from battery 3 Lift up the veh...

Page 156: ...om fuel tank by using a hand pump WARNING Do not use a motor pump when draining the fu el 13 After draining the fuel reinstall the fuel sub lev el sensor Tightening torque T 4 4 N m 0 45 kgf m 3 3 ft...

Page 157: ...FU H4SO 50 FUEL INJECTION FUEL SYSTEMS FUEL 3 Install the sub service hole cover 4 Set the rear seat and floor mat FU 00445...

Page 158: ...ck connector of fuel delivery A and return hose B Ref to FU H4SO 70 RE MOVAL Fuel Delivery Return and Evaporation Lines 8 Remove the parking brake cable 1 Remove the console box Ref to EI 34 REMOVAL C...

Page 159: ...AL Propeller Shaft 15 Disconnect the connector from ABS sensor 16 Remove the bolts which hold parking brake ca ble holding bracket 17 Remove the parking brake cable from cabin by forcibly pulling it b...

Page 160: ...A from two way valve and then disconnect the evapora tion hose B from evaporation pipe 24 Loosen the clamp and disconnect the fuel filler hose A and air vent hose B from fuel filler pipe 25 Support t...

Page 161: ...e 33 N m 3 4 kgf m 25 ft lb 6 Install the rear side protector Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 7 Install the rear suspension assembly CAUTION A helper is required to perform this work 1 S...

Page 162: ...ing brake cable to cabin by forc ibly pushing it forward 11 Tighten the bolts which hold parking brake ca ble holding bracket Tightening torque 18 N m 1 8 kgf m 13 0 ft lb Tightening torque 32 N m 3 3...

Page 163: ...Tighten the wheel nuts to rear wheel 19 Install the parking brake cable Ref to PB 7 INSTALLATION Parking Brake Cable 20 Install the console box Ref to EI 34 IN STALLATION Console Box 21 Connect the fu...

Page 164: ...mat 28 Connect the connector to fuel pump relay A 29 Adjust the parking brake lever stroke Ref to PB 6 ADJUSTMENT Parking Brake Lever 30 Check the wheel alignment and adjust if neces sary Ref to FS 6...

Page 165: ...the screws holding packing in place 5 Lift up the vehicle 6 Remove the rear right side wheel nuts 7 Remove the wheel RH Rear 8 Remove the protector RH Front 9 Drain fuel from fuel tank Set a container...

Page 166: ...l filler pipe to under side of the vehicle B INSTALLATION 1 Hold the fuel filler flap open 2 Set the fuel saucer A with rubber packing C and then insert the fuel filler pipe into hole from the inner s...

Page 167: ...and hold clip L 27 5 2 5 mm 1 083 0 098 in 6 Tighten the bolt which holds fuel filler pipe brack et on body Tightening torque 7 4 N m 0 75 kg m 5 4 ft lb 7 Tighten the bolts which hold evaporation pi...

Page 168: ...FU H4SO 61 FUEL INJECTION FUEL SYSTEMS FUEL FILLER PIPE 12 Connect the connector to fuel pump relay A 13 Connect the battery ground cable to battery FU 00648 A FU 00009...

Page 169: ...fuel filler cap 3 Disconnect the ground cable from battery 4 Lift up the vehicle 5 Remove the protector RH Front 6 Drain the fuel from fuel tank Set a container un der the vehicle and then remove the...

Page 170: ...phabetical sequence shown in the figure to specified torque Tightening torque 5 9 N m 0 6 kgf m 4 3 ft lb C DISASSEMBLY 1 Remove the fuel pump and pump holder NOTE When disassembling the pump holder b...

Page 171: ...he fuel pump assembly Ref to FU H4SO 62 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et 3 Pushing the pawls with a screwdriver remove the fuel meter unit by pulling it downwards N...

Page 172: ...front side fuel tank cover 4 Drain fuel from fuel tank Set a container under the vehicle and then remove the drain plug from fuel tank 5 Tighten the fuel drain plug and install the protec tor RH Front...

Page 173: ...sconnect the fuel jet pump hose 10 Remove the bolts which install fuel sub level sensor on fuel tank 11 Remove the fuel sub level sensor B INSTALLATION Install in the reverse order of removal Tighteni...

Page 174: ...er 4 Remove the filter holder by turning it to the left from the body pawls and then take out the filter B INSTALLATION NOTE If the fuel hoses are damaged at the connecting portion replace it with a n...

Page 175: ...e fuel tank Ref to FU H4SO 51 REMOVAL Fuel Tank 2 Move the clip and then disconnect the evapora tion hose from fuel cut valve 3 Remove the bolts which install fuel cut valve B INSTALLATION Install in...

Page 176: ...Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H4SO 48 RELEASING OF FUEL PRESSURE OPERA TION Fuel 2 Remove the fuel damper valve from fuel delivery line A and return line B B INSTAL...

Page 177: ...at 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation pipes and hos es 6 In engine compartment detach the fuel delivery hoses return hoses and evaporation hose 7 Lift u...

Page 178: ...y NOTE At this time two clicking sounds are heard NOTE Pull the connector to ensure it is connected se curely Ensure the two retainer pawls are engaged in their mating positions in the connrcotr Be su...

Page 179: ...m hose end L 17 5 2 5 mm 0 689 0 098 in NOTE Be sure to inspect the hoses and their connections for any leakage of huel C INSPECTION 1 Make sure that there are no cracks on the fuel pipes and fuel hos...

Page 180: ...Corrective action 1 Insufficient fuel supply to the injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Trouble in electromagne...

Page 181: ...FU H4SO 74 FUEL INJECTION FUEL SYSTEMS FUEL SYSTEM TROUBLE IN GENERAL MEMO...

Page 182: ...ONTROL AUX EMISSION CONTROL DEVICES EC H4SO Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 4 4 EGR Valve 5 5 Canister 6 6 Purge Control Solenoid Valve 7 7 Two wa...

Page 183: ...s in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful...

Page 184: ...O 8 RE MOVAL Center Exhaust Pipe B INSTALLATION The front and rear catalytic converter and center exhaust pipe are integrated into one unit There fore the installation procedure is the same as that fo...

Page 185: ...ame as that for the center exhaust pipe Ref to EX H4SO 8 RE MOVAL Center Exhaust Pipe B INSTALLATION The front and rear catalytic converter and center exhaust pipe are integrated into one unit There f...

Page 186: ...ON CONTROL DEVICES EGR VALVE 4 EGR Valve A REMOVAL For work procedures refer to FU H4SO section Ref to FU H4SO 35 REMOVAL EGR Valve B INSTALLATION For work procedures refer to FU H4SOH4SO section Ref...

Page 187: ...mps which hold two canister hos es and disconnect evaporation three hoses from canister 3 Remove canister from body B INSTALLATION 1 Install in the reverse order of removal Tightening torque 23 N m 2...

Page 188: ...ector and hoses from purge control solenoid valve and then remove the purge control solenoid valve B INSTALLATION 1 Install in the reverse order of removal Tightening torque 19 N m 1 9 kgf m 13 7 ft l...

Page 189: ...1 LIft up the vehicle 2 Disconnect hoses from two way valve 3 Remove two way valve with bracket as a single unit from body 4 Remove two way valve from bracket B INSTALLATION 1 Install in the reverse...

Page 190: ...INTAKE INDUCTION IN H4SO Page 1 General Description 2 2 Air Cleaner 5 3 Air Cleaner Case 6 4 Air Intake Duct 7 5 Resonator Chamber 8...

Page 191: ...IN H4SO 2 INTAKE INDUCTION GENERAL DESCRIPTION 1 General Description A COMPONENT IN 00124 9 10 10 10 11 12 13 14 16 18 19 18 19 20 21 T4 T4 T2 T2 T4 15 1 2 3 4 6 6 8 7 T3 T6 T3 T3 T1 5 T3 T5 17...

Page 192: ...i cles 21 Intake air temperature sensor 4 Cushion rubber 5 Air intake duct A 14 Air cleaner case stay LH AT vehi cles Tightening torque N m kgf m ft lb 6 Air intake duct B T1 33 3 4 24 6 7 Cushion 15...

Page 193: ...them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands b...

Page 194: ...r cleaner case to stays 2 Remove the clip B above the air cleaner case 3 Remove air cleaner element B INSTALLATION Install in the reverse order of removal CAUTION Fasten with a clip after inserting th...

Page 195: ...e sensor 3 Remove the bolts B which install air cleaner case to stay 4 Disconnect the hoses and intake duct from air cleaner case 5 Loosen the clamp which connects air cleaner case to throttle body 6...

Page 196: ...on the front side of body 2 Remove bolt which installs air intake duct on body 3 Remove air intake ducts as a unit B INSTALLATION Install in the reverse order of removal C INSPECTION Inspect for crac...

Page 197: ...OVAL 1 Remove air intake duct Ref to IN H4SO 7 REMOVAL Air Intake Duct 2 Remove resonator chamber B INSTALLATION Install in the reverse order of removal Tightening torque 33 N m 3 4 kgf m 24 6 ft lb C...

Page 198: ...8 8 Valve Clearance 29 9 Engine Assembly 32 10 Engine Mounting 39 11 Preparation for Overhaul 40 12 V belt 41 13 Crankshaft Pulley 43 14 Belt Cover 45 15 Timing Belt Assembly 46 16 Camshaft Sprocket 5...

Page 199: ...placement cm3 cu in 1 994 121 67 2 457 150 Compression ratio 10 0 Compression pres sure at 200 300 rpm kPa kg cm2 psi 1 079 1 275 11 0 13 0 156 185 Number of piston rings Pressure ring 2 Oil ring 1 In...

Page 200: ...7 mm 1 5455 1 5495 in Limit 39 157 mm 1 5416 in Camshaft journal O D 31 928 31 945 mm 1 2570 1 2577 in Camshaft journal hole I D Cylinder head 32 000 32 018 mm 1 2598 1 2605 in Journal clearance STD 0...

Page 201: ...475 92 485 mm 3 6407 3 6411 in 2500 cc STD A 99 485 99 495 mm 3 9167 3 9171 in B 99 475 99 485 mm 3 9163 3 9167 in 0 25 mm 0 0098 in OS 99 725 99 735 mm 3 9262 3 9266 in 0 50 mm 0 0197 in OS 99 975 99...

Page 202: ...0 mm 2 0368 2 0374 in Crank journal outer diameter 1 3 STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 3607 2 3613 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605...

Page 203: ...kshaft sprocket 11 Camshaft sprocket No 2 T3 25 2 5 18 1 4 Belt cover No 2 LH 12 Timing belt T4 39 4 0 28 9 5 Camshaft sprocket No 1 13 Front belt cover T5 78 8 0 57 9 6 Belt idler No 1 14 Belt cover...

Page 204: ...Y 3 Exhaust valve rocker ASSY 13 Camshaft cap LH 4 Camshaft cap RH 14 Oil filler cap 5 Oil seal 15 Gasket T2 5 0 5 3 6 6 Camshaft RH 16 Oil filler duct T3 10 1 0 7 2 7 Plug 17 O ring T4 18 1 8 13 0 8...

Page 205: ...haft support Tightening torque N m kgf m ft lb 2 Valve rocker nut 6 Intake rocker shaft T1 5 0 5 3 6 3 Valve rocker adjuster screw 7 Exhaust rocker shaft T2 10 1 0 7 2 4 Spring 8 Exhaust valve rocker...

Page 206: ...TION 4 CYLINDER HEAD AND VALVE ASSEMBLY 1 Exhaust valve 4 Valve spring seat 7 Retainer 2 Intake valve 5 Intake valve oil seal 8 Retainer key 3 Valve guide 6 Valve spring 9 Exhaust valve oil seal ME 00...

Page 207: ...ain plug T5 Ref to ME H4SO 72 INSTAL LATION CYLINDER BLOCK 7 Oil pump 20 Metal gasket 8 Front oil seal 21 Oil level gauge guide T6 70 7 1 51 9 Rear oil seal 22 Water pump sealing T7 First 12 1 2 8 7 S...

Page 208: ...ME H4SO 11 MECHANICAL GENERAL DESCRIPTION MEMO...

Page 209: ...ME H4SO 12 MECHANICAL GENERAL DESCRIPTION 6 CRANKSHAFT AND PISTON 1 2 3 4 5 6 4 5 6 7 7 8 9 9 9 9 10 10 11 11 12 12 12 13 14 15 16 16 17 17 8 18 T1 T2 ME 00190...

Page 210: ...cles only 10 Connecting rod bolt 18 Crankshaft bearing 5 3 Drive plate AT vehicles only 11 Connecting rod 4 Top ring 12 Connecting rod bearing Tightening torque N m kgf m ft lb 5 Second ring 13 Connec...

Page 211: ...CHANICAL GENERAL DESCRIPTION 7 ENGINE MOUNTING 1 Front cushion rubber 3 Front engine mounting bracket Tightening torque N m kgf m ft lb T1 35 3 6 25 8 T2 42 4 3 31 0 T3 85 8 7 63 ME 00413 T2 T1 T1 T3...

Page 212: ...careful not to let oil grease or coolant contact the timing belt clutch disc and flywheel All removed parts if to be reused should be re installed in the original positions and directions Bolts nuts...

Page 213: ...ut printer Spanish 22771AA090 Without printer 498267800 CYLINDER HEAD TABLE Used for replacing valve guides Used for removing and installing valve springs 498277200 STOPPER SET Used for installing aut...

Page 214: ...ed for stopping rotation of flywheel when loos ening and tightening crankshaft pulley bolt etc 498547000 OIL FILTER WRENCH Used for removing and installing oil filter 398744300 2000 cc model PISTON GU...

Page 215: ...t valve guide oil seals 499017100 PISTON PIN GUIDE Used for installing piston pin piston and connect ing rod 499037100 CONNECTING ROD BUSHING REMOVER INSTALLER Used for removing and installing connect...

Page 216: ...STALLER Used for installing camshaft oil seal 499587700 CAMSHAFT OIL SEAL INSTALLER Used for installing cylinder head plug 499097700 PISTON PIN REMOVER ASSY Used for removing piston pin 499207400 CAMS...

Page 217: ...Used for installing camshaft oil seal Used with CAMSHAFT OIL SEAL INSTALLER 499587500 499597100 CRANKSHAFT OIL SEAL GUIDE Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL INSTALL...

Page 218: ...USTER Used for installing valve guides 499817100 ENGINE STAND Stand used for engine disassembly and assem bly Used with ENGINE STAND ADAPTER RH 498457000 LH 498457100 499977100 2500 cc model CRANK PUL...

Page 219: ...elt Valve Rocker Assembly Camshaft Cylinder Head 499977400 2000 cc model CRANK PULLEY WRENCH Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts 49998...

Page 220: ...Check the starter motor for suitable performance and operation 7 Hold the compression gauge tight against spark plug hole NOTE When using a screw in type compression gauge the screw put into cylinder...

Page 221: ...n read the engine idle speed 5 When using the tachometer Secondary pick up type 1 Attach the pick up clip to No 1 cylinder spark plug cord 2 Start the engine and then read the engine idle speed NOTE W...

Page 222: ...ition timing connect a timing light to 1 cylinder spark plug cord and illuminate the timing mark with timing light 3 Start the engine at idle speed and check the ig nition timing Ignition timing BTDC...

Page 223: ...ut lower than normal position This ten dency becomes more evident as engine temperature rises Leakage around intake manifold gasket or disconnection or damaged vacuum hose 2 When engine speed is reduc...

Page 224: ...at 5 000 rpm CAUTION If the oil pressure is out of specification check the oil pump oil filter and lubrication line Ref to LU H4SO 19 INSPECTION En gine Lubrication System Trouble in General If the o...

Page 225: ...ivery hoses from fuel damper and then connect the fuel pressure gauge 4 Connect the connector of fuel pump relay 5 Start the engine 6 Measure the fuel pressure while disconnecting the pressure regulat...

Page 226: ...the PCV hose from rocker cover LH 3 Remove the bolts and then remove the rocker cover LH 9 Set the 1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise us...

Page 227: ...learance should be per formed while engine is cold 1 Set the 1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise using socket wrench NOTE When arrow mark...

Page 228: ...arances are within specifi cations If necessary readjust the valve clearanc es 6 Similar to adjustment procedures used for 1 cylinder adjust the 2 3 and 4 cylinder valve clearances NOTE Be sure to set...

Page 229: ...p 6 Disconnect the ground cable from battery 7 Remove the air intake duct and air cleaner case Ref to IN H4SO 7 REMOVAL Air Intake Duct and Ref to IN H4SO 6 Removal Air Cleaner Case 8 Remove the under...

Page 230: ...t the following hoses 1 Brake booster vacuum hose 2 Heater inlet outlet hose 13 Remove the power steering pump from brack et 1 Remove the resonator chamber 2 Loosen the lock bolt and slider bolt and t...

Page 231: ...f to EX H4SO 5 REMOVAL Front Exhaust Pipe 15 Remove the nuts which hold lower side of transmission to engine 16 Remove the nuts which install front cushion rubber onto front crossmember 17 Separate th...

Page 232: ...ck CAUTION Before moving the engine away from transmis sion check to be sure no work has been over looked Doing this is very important in order to facilitate re installation and because the trans miss...

Page 233: ...tment and align it with transmission NOTE Be careful not to damage the adjacent parts or body panels with crankshaft pulley oil level gauge etc 2 Apply a small amount of grease to the spline of main s...

Page 234: ...hole 10 Install the power steering pump on bracket 1 Install the power steering tank on bracket 2 Install the power steering pump on bracket and then tighten the bolts Tightening torque 20 1 N m 2 05...

Page 235: ...control cables With cruise control 17 Adjust each connected cable 18 Install the air cleaner case stay Tightening torque 16 N m 1 6 kgf m 11 6 ft lb 19 Install the A C pressure hoses Ref to AC 42 INST...

Page 236: ...gine assembly Ref to ME H4SO 32 REMOVAL Engine Assembly 2 Remove the engine mounting from engine as sembly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 34 N...

Page 237: ...ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order It will be the complete procedure for overhauling of the engine itself when you go throug...

Page 238: ...with the engine installed to body 1 Remove the V belt cover 2 Loosen the lock bolt A 3 Loosen the slider bolt B 4 Remove the front side belt C 2 REAR SIDE BELT 1 Loosen the lock nut A 2 Loosen the sl...

Page 239: ...belt tension Ref to ME H4SO 42 INSPECTION V belt 2 Tighten the lock nut A Tightening torque Lock nut A 22 6 N m 2 3 kgf m 16 6 ft lb C INSPECTION 1 Replace the belts if cracks fraying or wear is found...

Page 240: ...tightening angle of crankshaft pulley bolt is 45 degrees or more If the tightening angle of crankshaft pulley bolt is less than 45 de grees conduct the following procedures 1 Replace the crankshaft pu...

Page 241: ...nd clean them Crankshaft pulley bolt 12369AA011 2 Clean the crankshaft thread using an air gun 3 Apply engine oil to the crankshaft pulley bolt seat and thread 4 Tighten the bolts temporarily with tig...

Page 242: ...INSTALLATION 1 Install the front belt cover Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 2 Install the belt cover LH Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 3 Install the crankshaft pulley Ref to M...

Page 243: ...tation direction on timing belt fade away put new marks before removing the tim ing belt as shown in procedures below 1 Turn the crankshaft using ST Align the mark a of sprocket to cylinder block notc...

Page 244: ...adjuster rod down Do not use a lateral type vise Push the adjuster rod vertically Press in the push adjuster rod gradually taking more than 3 minutes Do not allow press pressure to exceed 9 807 N 1 0...

Page 245: ...Ref to ME H4SO 47 AUTOMATIC BELT TENSION ADJUSTER AS SEMBLY AND BELT IDLER INSTALLATION Timing Belt Assembly 2 Installation of timing belt 1 Turn the camshaft sprocket No 2 using ST1 and then turn th...

Page 246: ...porarily tighten the remaining bolts 2 Check and adjust the clearance between timing belt and timing belt guide by using thick ness gauge Clearance 1 0 0 5 mm 0 039 0 020 in 3 Tighten the remaining bo...

Page 247: ...3 If the adjuster rod is not stiff and moves down replace the automatic belt tension adjust er assembly with a new one NOTE Always use a vertical type pressing tool to move the adjuster rod down Do n...

Page 248: ...MSHAFT SPROCKET WRENCH B INSTALLATION 1 Install the camshaft sprocket No 1 To lock the camshaft use ST ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque 78 N m 8 0 kgf m 57 9 ft lb NOTE Do not c...

Page 249: ...RANKSHAFT PULLEY 7 Install the V belt Ref to ME H4SO 42 IN STALLATION V belt C INSPECTION 1 Check the sprocket teeth for abnormal wear and scratches 2 Make sure there is no free play between sprock et...

Page 250: ...ATION 1 Install the crankshaft sprocket 2 Install the camshaft sprocket Ref to ME H4SO 51 INSTALLATION Camshaft Sprocket 3 Install the timing belt assembly Ref to ME H4SO 47 INSTALLATION Timing Belt A...

Page 251: ...r assembly to gouge knock pins 2 Tighten the bolts e through h to specified torque 3 Tighten the bolts a through d to specified torque Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 2 Adjust the valve...

Page 252: ...CKER SHAFT 1 Measure the inside diameter of valve rocker arm and outside diameter of valve rocker shaft and de termine the difference between the two oil clear ance Clearance between arm and shaft Sta...

Page 253: ...the belt cover No 2 RH NOTE Do not damage or lose the seal rubber when re moving belt covers 9 Remove the tensioner bracket 10 Remove the camshaft position sensor support LH side only 11 Remove the oi...

Page 254: ...REE BOND 1280B P N K0877YA018 NOTE Apply a coat of 3 mm 0 12 in dia A liquid gasket along edge B of the camshaft cap C mating sur face 2 Temporarily tighten the bolts g through j in alphabetical seque...

Page 255: ...de LH side only 8 Install the camshaft position sensor support LH side only 9 Install the tensioner bracket Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 10 Install the belt cover No 2 RH Tightening t...

Page 256: ...eded Cam height H Cam base circle diameter A IN 34 00 mm 1 3386 in EX 34 00 mm 1 3386 in 2 CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial gauge If the clearance exceeds the limit...

Page 257: ...tch the mating surface of cylinder head and cylinder block 14 Similarly remove the right side cylinder head B INSTALLATION 1 CYLINDER HEAD 1 Install the cylinder head and gaskets on cylinder block NOT...

Page 258: ...11 Install the V belt Ref to ME H4SO 42 IN STALLATION V belt C DISASSEMBLY 1 Place the cylinder head on ST ST 498267800 CYLINDER HEAD TABLE 2 Set the ST on valve spring Compress the valve spring and...

Page 259: ...To measure the squareness of valve spring stand the spring on a surface plate and measure its deflection at the top using a try square 2 INTAKE AND EXHAUST VALVE OIL SEAL Replace the oil seal with new...

Page 260: ...g exceeds 0 05 mm 0 0020 in re grind the surface with a surface grinder Warping limit 0 05 mm 0 0020 in Grinding limit 0 1 mm 0 004 in Standard height of cylinder head 97 5 mm 3 839 in NOTE Uneven tor...

Page 261: ...placement Valve guide inner diameter 6 000 6 012 mm 0 2362 0 2367 in Valve stem outer diameters Intake 5 950 5 965 mm 0 2343 0 2348 in Exhaust 5 945 5 960 mm 0 2341 0 2346 in 1 Place the cylinder head...

Page 262: ...clean the valve guide to remove chips NOTE Apply engine oil to the reamer when reaming If the inner surface of the valve guide is torn the edge of the reamer should be slightly ground with an oil sto...

Page 263: ...ER HEAD ASSEMBLY 2 Put a small amount of grinding compound on the seat surface and lap the valve and seat surface Ref to ME H4SO 63 VALVE SEAT ADJUST MENT Cylinder Head Assembly Install a new in take...

Page 264: ...C compressor with their brackets 9 Remove the rocker cover 10 Remove the cylinder head bolts in alphabetical sequence shown in the figure NOTE Leave bolts a and c engaged by three or four threads to...

Page 265: ...ratch the mating surface of cyl inder block and oil pump 21 Removal of oil pan 1 Turn the cylinder block to face the 2 and 4 piston sides upward 2 Remove the bolts which secure oil pan to cylinder blo...

Page 266: ...ME H4SO 69 MECHANICAL CYLINDER BLOCK 26 Remove the water pipe ME 00300 1 Service hole plug 3 Circlip 5 Service hole cover 2 Gasket 4 Piston pin 6 O ring ME 00139 1 2 3 3 4 4 5 6 1 2 3 4 1 2 3 4...

Page 267: ...not to confuse the original combination of piston piston pin and cylinder 30 Similarly remove the piston pins from 3 and 4 pistons 31 Remove the bolts which connect cylinder block on the side of 2 an...

Page 268: ...ck using hammer handle NOTE Do not confuse the combination of crankshaft bear ings Press bearing at the end opposite to locking lip 38 Draw out each piston from cylinder block using wooden bar or hamm...

Page 269: ...he crankshaft on 2 and 4 cylinder block 2 Apply fluid packing to the mating surface of 1 and 3 cylinder block and position it on 2 and 4 cylinder block Fluid packing Part No 004403007 THREE BOND 1215...

Page 270: ...ical sequence 6 Further tighten the RH side bolts E J to 90 in alphabetical sequence 7 Tighten the 8 mm and 6 mm cylinder block con necting bolts in alphabetical sequence shown in the figure Tightenin...

Page 271: ...ure 2000 cc MODEL 2500 cc MODEL 12 Position the lower rail gap at D in the figure 2000 cc MODEL 2500 cc MODEL NOTE Align the lower rail stopper F to the lateral hole E on the piston 13 Position the up...

Page 272: ...tall circlip Install circlips in the piston holes located opposite service holes in cylinder block when positioning all pistons in the corresponding cylinders NOTE Use new circlips CAUTION Piston fron...

Page 273: ...ISTON GUIDE 2500 cc model 16 Installing piston pin 1 Apply a coat of engine oil to the ST3 before insertion 2 Insert the ST3 into service hole to align pis ton pin hole with connecting rod small end S...

Page 274: ...t NOTE Use a new gasket 7 Turn the cylinder block to face the 3 and 4 piston side upward Using the same procedures as used for 1 and 2 cylinders install the pis tons and piston pins ME 00160 ME 00140...

Page 275: ...BOND 1215 or equivalent 22 Apply fluid packing to the matching surfaces and then install the oil separator cover Fluid packing Part No 004403007 THREE BOND 1215 or equivalent 23 Install the flywheel...

Page 276: ...lb Second 12 N m 1 2 kgf m 8 7 ft lb NOTE Be sure to use a new gasket When installing the water pump tighten the bolts in two stages in alphabetical sequence as shown in the figure 27 Install the wat...

Page 277: ...ankshaft pulley Ref to ME H4SO 43 INSTALLATION CRANKSHAFT PULLEY 37 Install the generator and A C compressor brackets on cylinder head 38 Install the V belt Ref to ME H4SO 42 IN STALLATION V belt 39 I...

Page 278: ...expander E INSPECTION 1 CYLINDER BLOCK 1 Visually check for cracks and damage Especial ly inspect the important parts by means of red lead check 2 Check the oil passages for clogging 3 Inspect the cr...

Page 279: ...0 050 mm 0 0020 in 3 When the piston is to be replaced due to general or cylinder wear determine a suitable sized piston by measuring the piston clearance 4 How to measure the outer diameter of each p...

Page 280: ...ed limit or if there is any damage on the cylinder wall rebore it to use an oversize pis ton NOTE When any of the cylinders needs reboring all other cylinders must be bored at the same time and use ov...

Page 281: ...circlip for distortion cracks and wear 4 PISTON RING 1 If the piston ring is broken damaged or worn or if its tension is insufficient or when the piston is re placed replace the piston ring with a new...

Page 282: ...e connecting rod fitted with bearing to crankshaft and then measure the side clearance thrust clearance Replace the connecting rod if the side clearance exceeds the specified limit Connecting rod side...

Page 283: ...onnecting rod with ST and press 2 Press the bushing with ST after applying oil on the periphery of bushing ST 499037100 CONNECTING ROD BUSH ING REMOVER AND IN STALLER 3 Make two 3 mm 0 12 in holes in...

Page 284: ...84 Unit mm in Crank journal diameter Crank pin diameter 1 3 2 4 5 2000 cc 2500 cc Standard Journal O D 59 992 60 008 2 3619 2 3625 59 992 60 008 2 3619 2 3625 51 984 52 000 2 0466 2 0472 51 984 52 000...

Page 285: ...clearance on each crankshaft bearing by means of plastigauge If the measure ment is not within the specification replace the de fective bearing with an undersize one and then replace or recondition t...

Page 286: ...and relay A Lack of or insufficient fuel B Belt Defective B Defective timing B Compression Incorrect valve clearance C Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defect...

Page 287: ...ystem Ref to EN H4SO 2 Basic Diagnostic Procedure A Intake system Loosened or cracked intake duct A Loosened or cracked PCV hose A Loosened or cracked vacuum hose A Defective intake manifold gasket B...

Page 288: ...Lubrication system Incorrect oil pressure B Cooling system Overheating C Over cooling C Others Malfunction of evaporative emission control system A 4 Surging Engine control system Ref to EN H4SO 2 Ba...

Page 289: ...ve gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn or stuck piston rings cylinder and piston C Incorrect valve timing A Lubrication system Incorrect oil pre...

Page 290: ...ct valve clearance B Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defective gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn or...

Page 291: ...Clank when engine speed is medium 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft main bearing Worn bearing at crankshaft end...

Page 292: ...EXHAUST EX H4SO Page 1 General Description 2 2 Front Exhaust Pipe 5 3 Center Exhaust Pipe 8 4 Rear Exhaust Pipe 9 5 Muffler 10...

Page 293: ...EX H4SO 2 EXHAUST GENERAL DESCRIPTION 1 General Description A COMPONENT EX 00104 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 19 20 21 22 23 24 24 T2 T1 T5 T2 T2 T3 T5 T4 T4 T4 T6...

Page 294: ...htening torque N m kgf m ft lb 5 Front catalytic converter 14 Rear catalytic converter T1 8 0 8 5 8 6 Upper front catalytic converter cover 15 Center exhaust pipe T2 13 1 3 9 4 16 Spring T3 18 1 8 13...

Page 295: ...rom dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because...

Page 296: ...d front exhaust pipe onto cylinder heads CAUTION Be careful not to pull down front and center ex haust pipe assembly 8 Remove bolt which installs front and center ex haust pipe assembly to hanger brac...

Page 297: ...exhaust pipe onto cylinder heads Tightening torque 30 N m 3 1 kgf m 22 4 ft lb 5 Install under cover Ref to EI 13 INSTALLA TION Front Under Cover 6 Tighten bolts which install front and center ex haus...

Page 298: ...EX H4SO 7 EXHAUST FRONT EXHAUST PIPE 11 Connect battery ground cable C INSPECTION 1 Make sure there are no exhaust leaks from con nections and welds 2 Make sure there are no holes or rusting FU 00009...

Page 299: ...the front exhaust pipe Ref to EX H4SO 5 REMOVAL Front Exhaust Pipe B INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit Refer to the procedure for install ing the front ex...

Page 300: ...st pipe 3 Remove rear exhaust pipe B INSTALLATION NOTE Replace gaskets and self locking nuts with new ones 1 Install rear exhaust pipe to muffler Tightening torque 48 N m 4 9 kgf m 35 4 ft lb 2 Instal...

Page 301: ...Remove front rubber cushion and detach muf fler assembly NOTE To facilitate removal apply a coat of SUBARU CRC to mating area of rubber cushion in advance SUBARU CRC Part No 004301003 B INSTALLATION...

Page 302: ...System 6 3 Radiator Sub Fan System 10 4 Engine Coolant 14 5 Water Pump 16 6 Thermostat 21 7 Radiator 23 8 Radiator Cap 27 9 Radiator Main Fan and Fan Motor 28 10 Radiator Sub Fan and Fan Motor 30 11...

Page 303: ...6 000 rpm 23 0 mAq 75 5 ftAq Engine coolant temperature 85 C 185 F Impeller diameter 76 mm 2 99 in Number of impeller vanes 8 Pump pulley diameter 60 mm 2 36 in Clearance between impel ler and case S...

Page 304: ...ON B COMPONENT 1 WATER PUMP 1 Water pump ASSY 5 Gasket Tightening torque N m kgf m ft lb 2 Gasket 6 Thermostat cover T1 First 12 1 2 8 7 Second 12 1 2 8 7 3 Heater by pass hose 4 Thermostat T2 6 5 0 6...

Page 305: ...ator inlet hose 15 ATF inlet hose A AT vehicles only 23 Radiator lower bracket 7 Engine coolant reservoir tank cap 8 Overflow hose 16 ATF outlet hose A AT vehicles only Tightening torque N m kgf m ft...

Page 306: ...ghten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of sensors or units be sure to dis...

Page 307: ...B100 F2 B72 1 2 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 3 4 1 2 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 BATTERY B134 ECM F16 F17 2 1 F2...

Page 308: ...ure resistance between main fan motor connector and chassis ground Connector terminal F17 No 1 Chassis ground Is the measured value less than the speci fied valve 5 Go to step 3 Repair open circuit in...

Page 309: ...use terminal 9 CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 18 from joint box 3 Check fuse Is the fuse blown out Fuse is blown out Replace fuse Repair open circuit in harness between main...

Page 310: ...ain fan relay connector and ECM connec tor Connector terminal With OBD F66 No 7 B134 No 14 Without OBD F66 No 7 B134 No 3 Is the measured value less than the speci fied valve 1 Go to step 14 Repair op...

Page 311: ...100 F2 B72 1 2 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 3 4 1 2 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 BATTERY B134 ECM F16 F17 2 1 F27...

Page 312: ...switch to ON 5 Measure voltage between sub fan motor connector and chassis ground Connector terminal F16 No 2 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 2 Go to...

Page 313: ...re voltage of harness between A C relay holder 20 A fuse terminal and chassis ground Connector terminal F27 No 3 Chassis ground Does the measured value exceed the specified value 10 V Repair open circ...

Page 314: ...nd sub fan relay connector 13 CHECK HARNESS BETWEEN SUB FAN RE LAY AND ECM 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between sub fan relay connector...

Page 315: ...7 1 US qt 5 9 Imp qt CAUTION The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially made for SUBARU engine which has an aluminum crankcase Always use SUBARU Genuine Cool...

Page 316: ...must be in creased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read the scale on the vertical axis o...

Page 317: ...tors from radiator main fan A and sub fan B motors 6 Disconnect radiator outlet hose and heater by pass hose from water pump 7 Lower the vehicle 8 Remove air intake duct 9 Disconnect overflow hose 10...

Page 318: ...Remove automatic belt tension adjuster 15 Remove belt idler No 2 16 Remove left hand camshaft sprocket by using ST ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE Camshaft sprocket wrench 499207100 is als...

Page 319: ...CH NOTE Camshaft sprocket wrench 499207100 is also available Tightening torque 78 N m 8 0 kgf m 57 9 ft lb 5 Install belt idler No 2 Tightening torque 39 N m 4 0 kgf m 28 9 ft lb 6 Install automatic b...

Page 320: ...or outlet hose and heater by pass hose to water pump 15 Connect connectors to radiator main fan A and sub fan B motors 16 Install under cover 17 Lower the vehicle 18 Connect battery ground cable 19 Fi...

Page 321: ...nout in thrust direction while rotating the pulley Thrust runout limit 0 5 mm 0 020 in 4 Check clearance between impeller and pump case Clearance between impeller and pump case Standard 0 5 0 7 mm 0 0...

Page 322: ...pin A facing the front side Tightening torque 6 5 N m 0 66 kgf m 4 8 ft lb 2 Fill coolant Ref to CO H4SO 14 FILLING OF ENGINE COOLANT REPLACEMENT Engine Coolant C INSPECTION Replace the thermostat if...

Page 323: ...22 COOLING THERMOSTAT Specified value Starts to open With OBD 80 84 C 176 183 F Without OBD 76 0 80 0 C 169 176 F Fully opens With OBD 95 C 203 F Without OBD 91 C 196 F A Thermometer B Thermostat CO 0...

Page 324: ...ING OF ENGINE COOL ANT REPLACEMENT Engine Coolant 5 Disconnect connectors of radiator main fan A and sub fan B motor 6 Disconnect radiator outlet hose from thermostat cover 7 Disconnect ATF cooler hos...

Page 325: ...on the radiator 15 While slightly lifting radiator slide it to left 16 Lift radiator up and away from vehicle B INSTALLATION 1 Attach radiator mounting cushions to holes on the vehicle 2 Install radi...

Page 326: ...t radiator inlet hose 6 Install reservoir tank Tightening torque 4 9 N m 0 50 kgf m 3 6 ft lb 7 Install air intake duct 8 Lift up the vehicle 9 Connect ATF cooler hoses AT vehicles only 10 Connect con...

Page 327: ...op off radiator and attach tester to radiator in place of cap 2 Apply a pressure of 157 kPa 1 6 kg cm2 23 psi to radiator to check if 1 Engine coolant leaks at around radiator 2 Engine coolant leaks a...

Page 328: ...s Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds Standard pressure 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Service limit pressure 83 kPa 0 85 kg cm2...

Page 329: ...battery ground cable 2 Lift up the vehicle 3 Remove under cover 4 Disconnect connector of main fan motor 5 Lower the vehicle 6 Remove air intake duct 7 Disconnect overflow hose 8 Remove reservoir tan...

Page 330: ...DISASSEMBLY 1 Remove clip which holds motor connector onto shroud 2 Remove nut which holds fan itself onto fan motor and shroud assembly 3 Remove bolts which install fan motor onto shroud D ASSEMBLY A...

Page 331: ...e bolts which hold sub fan shroud to radi ator 8 Remove radiator sub fan shroud through the un der side of vehicle B INSTALLATION Install in the reverse order of removal NOTE Refer to COMPONENT for ti...

Page 332: ...everse order of disassembly NOTE Refer to COMPONENT for tightening torque Ref to CO H4SO 3 COMPONENT General De scription E INSPECTION 1 Connect battery positive terminal to terminal No 2 and negative...

Page 333: ...ler neck position 2 Remove bolts which install reservoir tank onto radiator main fan shroud 3 Remove reservoir tank B INSTALLATION Install in the reverse order of removal Tightening torque 4 9N m 0 50...

Page 334: ...D 2 PROCEDURE Basic Diagnostic Procedure k Excessive back pressure in exhaust system Clean or replace l Insufficient clearance between piston and cylinder Adjust or replace m Slipping clutch Repair or...

Page 335: ...CO H4SO 34 COOLING ENGINE COOLING SYSTEM TROUBLE IN GENERAL MEMO...

Page 336: ...U H4SO Page 1 General Description 2 2 Oil Pressure System 6 3 Engine Oil 8 4 Oil Pump 10 5 Oil Pan and Strainer 14 6 Oil Pressure Switch 17 7 Engine Oil Filter 18 8 Engine Lubrication System Trouble i...

Page 337: ...in Capacity at 80 C 176 F 600 rpm Discharge pressure 98 kPa 1 0 kg cm2 14 psi Discharge quantity 3 2 2 3 4 US qt 2 8 Imp qt min 5 000 rpm Discharge pressure 294 kPa 3 0 kg cm2 43 psi Discharge quantit...

Page 338: ...ing Tightening torque N m kgf m ft lb 6 Oil pump case 18 Baffle plate T1 5 0 5 3 6 7 Inner rotor 19 O ring T2 6 4 0 65 4 7 8 Outer rotor 20 Oil strainer T3 10 1 0 7 2 9 Oil pump cover 21 Oil level gau...

Page 339: ...r dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part...

Page 340: ...ening and tightening crankshaft pulley bolt 2500 cc model 499977400 CRANKSHAFT PULLEY WRENCH Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolt 2000 c...

Page 341: ...11 12 13 14 15 16 17 18 19 20 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P...

Page 342: ...pressure switch 3 Turn ignition switch ON 4 Measure the voltage of harness between the combination meter connector and chas sis ground Connector terminal E11 No 1 Chassis ground Does the measured valu...

Page 343: ...5 Fill engine oil through filler pipe up to upper point on level gauge Make sure that vehicle is placed level when checking oil level Use engine oil of proper quality and viscosity selected in accor d...

Page 344: ...d API classifica tion SL SJ or SH SAE Viscosity No 30 40 10W 50 20W 40 20W 50 6 Close engine oil filler cap 7 Start engine and warm it up for a time 8 After engine stops recheck the oil level If nec e...

Page 345: ...VAL V belt 8 Remove rear side V belt tensioner 9 Remove crankshaft pulley by using ST ST 499977100 CRANKSHAFT PULLEY WRENCH 2500 cc model ST 499977400 CRANKSHAFT PULLEY WRENCH 2000 cc model 10 Remove...

Page 346: ...h oil seal when installing oil pump on cylinder block 5 Position the oil pump aligning the notched area with the crankshaft and push the oil pump straight CAUTION Make sure the oil seal lip is not fol...

Page 347: ...T1 5 N m 0 5 kgf m 3 6 ft lb T2 44 N m 4 5 kgf m 33 ft lb E INSPECTION 1 TIP CLEARANCE Measure the tip clearance of rotors If the clearance exceeds the limit replace rotors as a set Tip clearance Sta...

Page 348: ...alve for fitting condition and damage and the relief valve spring for damage and deterio ration Replace the parts if defective Relief valve spring Free length 72 8 mm 2 866 in Installed length 54 7 mm...

Page 349: ...re ropes 8 Lift up the vehicle CAUTION When lifting up the vehicle wire rope must be raised at the same time 9 Remove under cover Ref to EI 13 REMOV AL Front Under Cover 10 Drain engine oil Set contai...

Page 350: ...ATION CAUTION Before installing oil pan clean sealant from oil pan and engine block 1 Install baffle plate Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 2 Install oil strainer onto baffle plate CAUTI...

Page 351: ...TION When lowering vehicle wire rope must be re leased at the same time 9 Remove lifting device and steel cables 10 Install pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft lb T2 58 N m 5...

Page 352: ...gasket to oil pressure switch threads Fluid gasket Part No 004403042 THREE BOND 1324 or equivalent 2 Install oil pressure switch onto engine block Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 3 Conne...

Page 353: ...lter by turning it by hand being careful not to damage seal rubber 3 Tighten more approximately 2 3 to 3 4 turn af ter the seal rubber contacts the cylinder block Do not tighten excessively or oil may...

Page 354: ...y pass valve of oil filter Clean or replace Malfunction of oil relief valve of oil pump Clean or replace Clogged oil passage Clean Excessive tip clearance and side clearance of oil pump rotor and gear...

Page 355: ...LU H4SO 20 LUBRICATION ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL MEMO...

Page 356: ...SPEED CONTROL SYSTEMS SP H4SO Page 1 General Description 2 2 Accelerator Pedal 5 3 Accelerator Control Cable 10...

Page 357: ...edal pad 50 55 mm 1 97 2 17 in 1 Accelerator bracket 7 Accelerator pedal lever 13 Kick down switch AT vehicles only 2 Stopper 8 Spring pin 3 Bushing 9 Accelerator pedal 4 Clip 10 Accelerator stopper T...

Page 358: ...ing pin 11 Kick down switch AT vehicles only 2 Stopper 7 Accelerator spring 3 Accelerator pedal lever 8 Bushing Tightening torque N m kgf m ft lb 4 Accelerator pedal spring 9 Clip T1 12 1 2 9 0 5 Acce...

Page 359: ...m from dust and dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands bec...

Page 360: ...lip inside engine compartment LHD SOHC MODEL RHD SOHC MODEL DOHC turbo MODEL 6 Remove the instrument panel lower cover from instrument panel and connector 7 Disconnect the connector from kick down swi...

Page 361: ...ccelerator cable and bracket B INSTALLATION 1 Install in the reverse order of removal NOTE If the cable clamp is damaged replace it with a new one Never fail to cover the outer cable end with boot Be...

Page 362: ...apply grease to the portions indicated in the figure Grease Part No 003602010 SUNLIGHT No 2 A Accelerator bracket B Stopper C Bushing D Clip E Accelerator spring F Accelerator pedal spring G Accelera...

Page 363: ...operate properly or if it does not stop at the specified position re place with a new one Specified position A 2 0 3 5 mm 0 079 0 098 in F ADJUSTMENT 1 Check the pedal stroke and free play by operat i...

Page 364: ...ion to the stroke of the accelerator pedal If it is not within specified value adjust it by adjust ing the position of kick down switch NOTE Be careful not to rotate kick down switch Kick down switch...

Page 365: ...accelerator cable end Grease Part No 004404002 Slicolube G 30M NOTE If the cable clamp is damaged replace it with a new one Never fail to cover the outer cable end with boot Be careful not to kink the...

Page 366: ...IGNITION IG H4SO Page 1 General Description 2 2 Spark Plug 5 3 Ignition Coil and Ignitor Assembly 8 4 Spark Plug Cord 10...

Page 367: ...mbly Model FH0137 Manufacturer DIAMOND Primary coil resistance 0 73 10 Secondary coil resistance 12 8 k 15 Insulation resistance between primary terminal and case More than 100 M Spark plug Type and m...

Page 368: ...GENERAL DESCRIPTION B COMPONENT IG 00036 T2 T1 T1 2 2 1 4 4 3 1 1 Spark plug 4 Spark plug cord 2 4 Tightening torque N m kgf m ft lb 2 Spark plug cord 1 3 T1 21 2 1 15 3 Ignition coil and ignitor ASS...

Page 369: ...from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands becaus...

Page 370: ...r 3 Remove spark plug cords by pulling boot not cord itself 4 Remove spark plugs with the spark plug socket 2 LH SIDE 1 Disconnect battery ground cable 2 Disconnect washer motor connector 3 Disconnect...

Page 371: ...e torque should be only applied to new spark plugs without oil on their threads In case their threads are lubricated the torque should be reduced by approximately 1 3 of the specified torque in order...

Page 372: ...e re sults from incorrect ignition timing loose spark plugs wrong selection of fuel hotter range plug etc It is advisable to replace with plugs having colder heat range D CLEANING Clean spark plugs in...

Page 373: ...N m 0 65 kgf m 4 7 ft lb CAUTION Be sure to connect spark plug cords to their proper positions Failure to do so will damage unit C INSPECTION Using accurate tester inspect the following items and rep...

Page 374: ...IG H4SO 9 IGNITION IGNITION COIL AND IGNITOR ASSEMBLY Secondary side Between A and B 12 8 k 15 Between C and D 12 8 k 15 3 Insulation between primary terminal and case 100 M or more IG 00039 C A D B...

Page 375: ...ORD 4 Spark Plug Cord A INSPECTION Check for 1 Damage to cords deformation burning or rust formation of terminals 2 Resistance values of cords Resistance value 1 cord 5 6 10 6 2 cord 7 3 13 7 3 cord 5...

Page 376: ...STARTING CHARGING SYSTEMS SC H4SO Page 1 General Description 2 2 Starter 6 3 Generator 14 4 Battery 20...

Page 377: ...6 4 ft lb 16 0 N m 1 63 kgf m 11 8 ft lb Rotating speed 920 rpm or more 740 rpm or more Lock characteristics Voltage 4 V 3 5 V Current 650 A or less 940 A or less Torque 14 7 N m 1 50 kgf m 10 8 ft l...

Page 378: ...bearing 7 Internal gear ASSY 13 Armature 2 Front bracket 8 Shaft ASSY 14 Brush holder 3 Lever set 9 Gear ASSY 15 Brush 4 Magnet switch ASSY 10 Ball 16 Sleeve bearing 5 Stopper set 11 Packing 17 Rear b...

Page 379: ...ut 7 Bearing 13 Terminal 2 Pulley 8 Stator coil 3 Front cover 9 IC regulator with brush Tightening torque N m kgf m ft lb 4 Ball bearing 10 Brush T1 4 7 0 48 3 5 5 Bearing retainer 11 Rectifier T2 108...

Page 380: ...tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your ha...

Page 381: ...EMOVAL Air Cleaner Case 3 Remove the air cleaner case stay MT vehicles AT vehicles 4 Disconnect the connector and terminal from starter 5 Remove the starter from transmission B INSTALLATION Install in...

Page 382: ...gap adjustment washer may sometimes be used on the mounting surface of switch assembly 3 Remove both through bolts and brush holder screws and detach rear bracket and brush holder NOTE Before removal...

Page 383: ...ring by lightly tapping the stopper with an appropriate tool such as a socket 2 Remove ring stopper and clutch from shaft 2 BRUSH HOLDER Slightly open the metal fitting holding the insulating plate to...

Page 384: ...nternal and planetary gears 1 Install overrunning clutch to shaft assembly 2 Install stopper to shaft assembly in the following order 1 Insert the ring into the shaft groove by lightly tapping it with...

Page 385: ...eplace if it ex ceeds the limit Commutator run out Standard 0 05 mm 0 0020 in Service limit Less than 0 10 mm 0 0039 in 3 Depth of segment mold Check the depth of segment mold Depth of segment mold 0...

Page 386: ...t 7 0 mm 0 276 in 2 Brush movement Be sure brush moves smoothly inside brush holder 3 Brush spring force Measure brush spring force with a spring scale If it is less than the service limit replace bru...

Page 387: ...overhauled to assure its satisfactory performance when installed on the engine Three performance tests no load test load test and lock test are presented here however if the load test and lock test ca...

Page 388: ...ot rotating measure the torque developed and current draw when the volt age is adjusted to the specified voltage Lock test Standard Voltage Current AT 3 5 V 940 A or less MT 4 V 650 A or less Torque A...

Page 389: ...ide V belt Ref to ME H4SO 41 REMOVAL V belt 5 Remove the bolts which install generator onto bracket B INSTALLATION Install in the reverse order of removal CAUTION Check and adjust the V belt tension R...

Page 390: ...all bearing as follows 1 Remove the bolt and then remove the bear ing retainer 2 Firmly install an appropriate tool such as a fit socket wrench to bearing inner race 3 Push the ball bearing off the fr...

Page 391: ...older the connection between IC regula tor and rectifier to remove the IC regulator 9 Remove the brush as follows 1 Remove cover A 2 Remove the cover B 3 Separate the brush from connection to re move...

Page 392: ...earing 1 Set the ball bearing on the front cover and then securely install an appropriate tool such as a fit socket wrench to the bearing outer race 2 Press the ball bearing into the specified po siti...

Page 393: ...gs for contamination or any roughness of the sliding surface Repair the slip ring surface using a lathe or sand paper 2 Slip ring outer diameter Measure the slip ring outer diameter If the slip ring i...

Page 394: ...ace the brush Each brush has the service limit mark A on it Brush length Standard 18 5 mm 0 728 in Service limit 5 0 mm 0 197 in 2 Checking brush spring for proper pressure Using a spring pressure ind...

Page 395: ...al jewelry Never allow metal tools to contact the positive battery terminal and anything connected to it while you are at the same time in contact with any other metallic portion of the vehicle be cau...

Page 396: ...n one hour 2 CHECK HYDROMETER FOR STATE OF CHARGE 3 NORMAL CHARGING Charge the battery at current value specified by manufacturer or at approximately 1 10 of battery s ampere hour rating 4 QUICK CHARG...

Page 397: ...SC H4SO 22 STARTING CHARGING SYSTEMS BATTERY MEMO...

Page 398: ...Signal 28 8 Data Link Connector 29 9 OBD II General Scan Tool 30 10 Subaru Select Monitor 32 11 Read Diagnostic Trouble Code 39 12 Inspection Mode 40 13 Drive Cycle 45 14 Clear Memory Mode 47 15 Compu...

Page 399: ...ool switch to ON 4 Read DTC on the Subaru Select Monitor or OBD II general scan tool Does the Subaru Select Monitor or OBD II general scan tool indicate DTC DTC indicated Go to step 4 Repair the relat...

Page 400: ...rential gear oil level check Ref to AT 31 Differential Gear Oil 3 ATF leak check Ref to AT 30 Automatic Transmission Fluid 4 Differential gear oil leak check Ref to AT 31 Differential Gear Oil 5 Stall...

Page 401: ...thers Outdoor temperature F C Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine sp...

Page 402: ...of fuel gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of parts othe...

Page 403: ...ndividual sensors or all electrical control modules at the harness side connector use a tapered pin with a diameter of less than 0 64 mm 0 025 in Do not insert the pin more than 5 mm 0 20 in into the...

Page 404: ...ce procedure of self diagnosis sys tem B INSPECTION Before performing diagnostics check the following items which might affect engine problems 1 BATTERY 1 Measure battery voltage and specific gravity...

Page 405: ...element etc The MFI system also has the following features Reduced emission of harmful exhaust gases Reduced in fuel consumption Increased engine output Superior acceleration and deceleration Superio...

Page 406: ...EN H4SO 9 ENGINE DIAGNOSTICS GENERAL DESCRIPTION MEMO...

Page 407: ...lectrical Components Location A LOCATION 1 ENGINE MODULE 1 Engine control module ECM 3 Test mode connector 2 Data link connector for Subaru Select Monitor and OBD II general scan tool 4 CHECK ENGINE m...

Page 408: ...COMPONENTS LOCATION EN 00845 1 EN 00846 2 EN 00847 3 4 EN 00848 1 1 2 3 4 5 6 H C 7 0 2 3 D N R P CHECK ENGINE ATOIL TEMP FWD x1000r min ABS E F 1 2 AIRBAG 0 20 40 60 80 100 120 140 km h MPH 20 40 60...

Page 409: ...AL COMPONENTS LOCATION SENSOR 1 Intake air temperature sensor 5 Knock sensor 2 Pressure sensor 6 Camshaft position sensor 3 Engine coolant temperature sen sor 7 Crankshaft position sensor 4 Throttle p...

Page 410: ...EN H4SO 13 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00849 EN 00850 2 EN 00851 3 EN 00852 4 EN 00853 5 EN 00854 6 7 EN 00855...

Page 411: ...NGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Front oxygen A F sensor 3 Front catalytic converter 2 Rear oxygen sensor 4 Rear catalytic converter EN 00685 1 2 3 4 EN 00856 1 EN 00857 2 EN 00858 3...

Page 412: ...EN H4SO 15 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Fuel level sensor 2 Fuel sub level sensor EN 01106 1 2 EN 01107 1 2 EN 01108 1 EN 01109 2...

Page 413: ...S ELECTRICAL COMPONENTS LOCATION SOLENOID VALVE EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 EGR valve 3 Purge control solenoid valve 2 Idle air control solenoid valve 4 Ignition coil ign...

Page 414: ...EN H4SO 17 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00018 EN 00865 2 3 EN 00866 EN 00867 4...

Page 415: ...NE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Inhibitor switch 4 Fuel pump relay 7 Starter 2 Fuel pump 5 Radiator main fan relay 3 Main relay 6 Radiator sub fan relay EN 01111 1 2 3 4 5 6 7 EN 01112...

Page 416: ...EN H4SO 19 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00873 1 EN 01113 2 EN 00875 3 EN 00876 4 5 6 EN 00877 EN 00878 7...

Page 417: ...rol Module TCM for AT vehicles 2 AT diagnostic indicator light for AT vehicles EN 01114 1 2 EN 01115 1 2 EN 00879 1 2 1 1 2 3 4 5 6 H C 7 0 2 3 D N R P CHECK ENGINE ATOIL TEMP FWD x1000r min ABS E F 1...

Page 418: ...le speed sensor for AT vehicles 2 Front vehicle speed sensor for MT vehicles 3 Front vehicle speed sensor for AT vehicles 4 Torque converter turbine speed sensor 5 ATF temperature sensor for AT vehicl...

Page 419: ...olenoid valve 1 4 Shift solenoid valve 2 5 Line pressure duty solenoid 6 Lock up duty solenoid 7 Transfer duty solenoid 8 2 4 brake duty solenoid 9 Low clutch timing solenoid valve 10 2 4 brake timing...

Page 420: ...EN H4SO 23 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION MEMO...

Page 421: ...0 0 0 9 Shield B137 15 0 0 GND sen sor B135 19 0 0 Front oxy gen A F sensor heater Signal 1 B136 6 0 1 0 0 1 0 Signal 2 B136 17 0 1 0 0 1 0 Rear oxygen sensor heater signal B136 4 0 1 0 0 1 0 Engine...

Page 422: ...orm Fuel pump relay control B134 2 ON 0 5 or less OFF 10 13 0 5 or less A C relay control B134 9 ON 0 5 or less OFF 10 13 ON 0 5 or less OFF 13 14 Radiator fan relay 1 control B134 14 ON 0 5 or less O...

Page 423: ...mperature 25 C 75 F Immobilizer input out put 1 B137 17 Less than 1 More than 4 Less than 1 More than 4 Immobilizer input out put 2 B137 18 Less than 1 More than 4 Less than 1 More than 4 SSM GST comm...

Page 424: ...ne Condition Data A ELECTRICAL SPECIFICATION Measuring condition After warm up the engine Gear position is in N or P position A C is turned OFF All accessory switches are turned OFF Content Specified...

Page 425: ...EN H4SO 28 ENGINE DIAGNOSTICS TRANSMISSION CONTROL MODULE TCM I O SIGNAL 7 Transmission Control Module TCM I O Signal A ELECTRICAL SPECIFICATION Ref to AT 14 Transmission Control Module TCM I O Signal...

Page 426: ...n tools other than the OBD II general scan tools and the Subaru Select Mon itor because the circuit for the Subaru Select Monitor may be damaged EN 00037 12 11 10 9 13 15 14 16 3 2 1 7 8 4 5 6 Termina...

Page 427: ...83 List of Diagnostic Trouble Code DTC 2 MODE 01 CURRENT POWERTRAIN DIAGNOSTIC DATA Refers to data denoting the current operating condition of analog input output digital input output and or the powe...

Page 428: ...mission related pow ertrain diagnostic trouble codes Ref to EN H4SO 39 Read Diagnostic Trouble Code 5 MODE 04 CLEAR RESET EMISSION RELATED DIAGNOSTIC INFORMATION Refers to the mode used to clear or re...

Page 429: ...nosis cable to data link con nector CAUTION Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 5 Turn ignition switch to ON engine OFF and Subaru Select Monitor sw...

Page 430: ...ar O2 Sensor V Short term fuel trim A F Correction 1 Knock sensor signal Knocking Correction deg Atmospheric absolute pressure signal Atmosphere Pressure mmHg or kPa or inHg or psig Intake manifold re...

Page 431: ...r rich signal Rear O2 Rich Signal Rich lean Starter switch signal Starter Switch ON or OFF Idle switch signal Idle Switch Signal ON or OFF Crankshaft position sensor signal Crankshaft Position Sig ON...

Page 432: ...st of heated catalyst Heated catalyst No support Test of evaporative emission purge control system Evaporative purge system Complete or incomplete Test of secondary air system Secondary air system No...

Page 433: ...t of the support data is shown in the following table NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MANUAL Contents Display Unit of measure Diagnostic trouble code...

Page 434: ...ction Radiator main fan relay signal Radiator Fan Relay 1 ON or OFF When radiator main fan relay is in function Fuel pump relay signal Fuel Pump Relay ON or OFF When fuel pump relay is in function Kno...

Page 435: ...essure control duty ratio Line Pressure Duty Ratio Lock up clutch control duty ratio Lock Up Duty Ratio Transfer clutch control duty ratio Transfer Duty Ratio Power supply for throttle position sensor...

Page 436: ...lay screen select the 2 Each System Check and press the YES key 2 On the System Selection Menu display screen select the Engine Control System and press the YES key 3 Press the YES key after displayed...

Page 437: ...no activity detected Bank 1 Sensor 1 P0137 O2 sensor circuit low voltage Bank 1 Sensor 2 P0138 O2 sensor circuit high voltage Bank 1 Sensor 2 P0327 Knock sensor 1 circuit low input Bank 1 or Single se...

Page 438: ...n low input P1497 EGR solenoid valve signal 3 circuit malfunction high input P1498 EGR solenoid valve signal 4 circuit malfunction low input P1499 EGR solenoid valve signal 4 circuit malfunction high...

Page 439: ...ree rollers In order to prevent the vehicle from slipping due to vibration do not place any wooden blocks or similar items between the safety stands and the vehicle Since the rear wheels will also rot...

Page 440: ...s in the memory the corre sponding diagnostic trouble code DTC appears on the display screen NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL For detailed con...

Page 441: ...vehicles or 1st gear MT vehicles and drive the vehicle at 5 to 10 km h 3 to 6 MPH NOTE On AWD vehicles release the parking brake The speed difference between front and rear wheels may light the ABS wa...

Page 442: ...osis stop en gine and do the second time at the same condition 2 AFTER RUNNING 20 MINUTES AT 80 KM H 50 MPH IDLE ENGINE FOR 1 MINUTE 3 IDLE FOR 10 MINUTES NOTE Before diagnosis drive vehicle at 4 km h...

Page 443: ...le with throttle fully closed C Drive vehicle at 97 km h 60 MPH for 20 seconds DTC No Item Condition P0121 Throttle pedal position sensor switch A circuit range performance P0139 O2 Sensor circuit slo...

Page 444: ...ystem Check and press the YES key 2 On the System Selection Menu display screen select the Engine Control System and press the YES key 3 Press the YES key after displayed the informa tion of engine ty...

Page 445: ...e 2 Connect diagnosis cable to data link con nector CAUTION Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 6 Turn ignition switch to ON engine OFF and Subaru S...

Page 446: ...ehicle For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL Contents Display Compulsory fuel pump relay operation check Fuel Pump Relay Compulsory radiator fan relay o...

Page 447: ...2 Check engine malfunction indicator lamp MI does not come on Ref to EN H4SO 52 CHECK ENGINE MALFUNCTION INDICATOR LAMP MI DOES NOT COME ON Engine Malfunction Indicator Lamp MI 3 Check engine malfunct...

Page 448: ...OSTICS ENGINE MALFUNCTION INDICATOR LAMP MI 4 When ignition switch is turned to ON engine off or to START with the test mode connector con nected the MI blinks at a cycle of 3 Hz EN 00198 ON MIL OFF O...

Page 449: ...D MODEL 38 LHD MODEL 12 RHD MODEL 15 5 IGNITION RELAY SBF 4 No 5 SBF 1 4 1 B157 B72 B134 B36 i1 IGNITION SWITCH B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31...

Page 450: ...connector 4 CHECK HARNESS BETWEEN COMBINA TION METER AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Remove combination meter Ref to IDI 14 Combination Meter Assembly 3 Disconnect connector from EC...

Page 451: ...f necessary NOTE Broken down ignition relay Blown out fuse No 5 If replaced fuse No 5 blows eas ily check the har ness for short circuit of harness between fuse No 5 and ignition relay connector Open...

Page 452: ...EN H4SO 55 ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LAMP MI MEMO...

Page 453: ...D MODEL 36 LHD MODEL 9 RHD MODEL 38 LHD MODEL 12 RHD MODEL 15 5 IGNITION RELAY SBF 4 No 5 SBF 1 4 1 B157 B72 B134 B36 i1 IGNITION SWITCH B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 454: ...BETWEEN COMBINA TION METER AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Turn ignition switch to ON Does the MI come on MI illuminates Repair short circuit in harn...

Page 455: ...1 B72 IGNITION SWITCH BATTERY B72 3 4 1 2 B75 B76 1 2 1 2 1 1 B75 B76 B22 E3 A28 C3 B136 B134 ECM 16 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 IGNITION RELAY B157 B36 i1 COMBINATION METER A C 3 i12 A...

Page 456: ...om ECM 3 Measure resistance of harness between test mode connector and chassis ground Connector terminal B76 No 1 Chassis ground Is the measured value less than the speci fied value 1 Go to step 4 Rep...

Page 457: ...2 3 4 1 2 B75 B76 1 2 1 2 1 1 B75 B76 B22 E3 A28 C3 B136 B134 ECM 16 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 IGNITION RELAY B157 B36 i1 COMBINATION METER A C 3 i12 A4 i12 1 2 3 4 5 6 7 8 9 10 11 12...

Page 458: ...le of 3 Hz when test mode connector is connected 2 CHECK HARNESS BETWEEN ECM CON NECTOR AND ENGINE GROUNDING TER MINAL 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistanc...

Page 459: ...ply and ground line Ref to EN H4SO 68 CONTROL MODULE POWER SUPPLY AND GROUND LINE Diagnostics for Engine Starting Failure 3 Inspection of ignition control system Ref to EN H4SO 72 IGNITION CONTROL SYS...

Page 460: ...EN H4SO 63 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 461: ...O 47 Clear Memory Mode and INSPECTION MODE Ref to EN H4SO 40 Inspection Mode WIRING DIAGRAM EN 01118 12 INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 B72 12 11 T7 T3 B12 1 3 IGNITION...

Page 462: ...GROUND CIRCUIT OF STARTER MOTOR 1 Turn the ignition switch to OFF 2 Disconnect the terminal from starter motor 3 Measure the resistance of ground cable between ground cable terminal and engine ground...

Page 463: ...terminal and engine ground while turning ignition switch to ST Connector terminal B12 No 12 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 9 Repair open or ground s...

Page 464: ...EN H4SO 67 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 465: ...A35 C26 B21 D14 C19 13 15 14 16 B47 BATTERY MAIN RELAY 1 2 3 5 6 4 SBF 5 SBF 4 SBF 1 3 1 B72 IGNITION SWITCH ECM B134 A B135 B B136 C B137 D C5 8 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27...

Page 466: ...Go to step 3 Repair open circuit in harness between ECM connector and engine grounding terminal 3 CHECK INPUT VOLTAGE OF ECM Measure voltage between ECM connector and chassis ground Connector terminal...

Page 467: ...tor terminal B47 No 1 Chassis ground Is the measured value less than the speci fied value 5 Go to step 9 Repair open circuit between main relay and chassis ground 9 CHECK INPUT VOLTAGE OF MAIN RELAY M...

Page 468: ...EN H4SO 71 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 469: ...N Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 00717 32 33 B134 B72 3 4 1 2 3 4 1 2 E12 B22 1 2 3 4 5 6 7 8 13 14 15 16 9 10 11 12 6 5 4 3 4 1 2...

Page 470: ...ltage between ignition coil ignitor assembly connector and engine ground Connector terminal E12 No 2 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 4 Repair harness...

Page 471: ...ECM and ignition coil ignitor assembly connector Connector terminal B134 No 33 E12 No 1 B134 No 32 E12 No 4 Is the measured value less than the speci fied value 1 Go to step 8 Repair harness and conn...

Page 472: ...EN H4SO 75 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 473: ...40 OPERATION Inspection Mode WIRING DIAGRAM EN 01120 1 R3 B99 RHD FUEL PUMP RELAY SBF 4 SBF 1 SBF 5 No 13 4 1 B46 B72 IGNITION SWITCH BATTERY 4 3 1 2 No 11 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 474: ...NOTE In this case repair the following Open circuit in harness between fuel pump connec tor and chassis grounding terminal Poor contact in coupling connector 3 CHECK POWER SUPPLY TO FUEL PUMP 1 Turn i...

Page 475: ...ef to FU H4SO 47 Fuel Pump Relay 7 CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNECTOR 1 Disconnect connectors from ECM 2 Measure resistance of harness between ECM and fuel pump relay connector Co...

Page 476: ...EN H4SO 79 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 477: ...to EN H4SO 40 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01121 F44 B61 6 RHD RHD B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E6 E17 E5 E16 1 2 1 2 1 2 1 2 1 2 22 23 34 8 9 1 10 11 12 ECM B134 E5 E16...

Page 478: ...or Poor contact in coupling connector Poor contact in fuel injector con nector 3 CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR 1 Disconnect connector from ECM and fuel injector 2 Measure resis...

Page 479: ...CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector There is poor contact Repair poor con tact in ECM con nector Inspection using General Diagnos tic Table Re...

Page 480: ...ute pressure barometric pressure circuit high input Ref to EN H4SO 110 DTC P0108 MANIFOLD ABSO LUTE PRESSURE BAROMETRIC PRESSURE CIRCUIT HIGH INPUT Diagnostic Procedure with Diagnostic Trouble Code DT...

Page 481: ...e with Diagnostic Trouble Code DTC P0138 O2 sensor circuit high voltage Bank 1 Sensor 2 Ref to EN H4SO 156 DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE BANK 1 SENSOR 2 Diagnostic Proce dure with Diagnosti...

Page 482: ...ircuit high Ref to EN H4SO 200 DTC P0459 EVAPORATIVE EMIS SION CONTROL SYSTEM PURGE CONTROL VALVE CIR CUIT HIGH Diagnostic Procedure with Diagnostic Trouble Code DTC P0461 Fuel level sensor circuit ra...

Page 483: ...tic Trouble Code DTC P0710 Transmission fluid temperature sensor circuit Ref to AT 48 DTC 27 ATF TEMPERATURE SENSOR Diag nostic Procedure with Diagnostic Trouble Code DTC P0716 Input turbine speed sen...

Page 484: ...ure with Diagnostic Trouble Code DTC P0865 TCM communication circuit low Ref to EN H4SO 268 DTC P0865 TCM COMMUNICA TION CIRCUIT LOW Diagnostic Procedure with Diagnostic Trouble Code DTC P0866 TCM com...

Page 485: ...NPUT Diagnostic Procedure with Diagnostic Trouble Code DTC P1512 ISC solenoid valve signal 2 circuit malfunction low input Ref to EN H4SO 284 DTC P1512 ISC SOLENOID VALVE SIGNAL 2 CIRCUIT MALFUNCTION...

Page 486: ...1698 Engine torque control cut signal circuit malfunction low input Ref to EN H4SO 296 DTC P1698 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Tro...

Page 487: ...de Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44...

Page 488: ...ied value 1 Go to step 3 Repair open circuit between ECM and front oxygen A F sensor connector 3 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR CONNEC TOR Measure harness resistance between mai...

Page 489: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8...

Page 490: ...sis ground B136 No 16 Chassis ground Is the measured value less than the specified value 5 Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit in harness betw...

Page 491: ...poor con tact in ECM con nector Go to step 7 7 CHECK FRONT OXYGEN A F SENSOR 1 Turn ignition switch to OFF 2 Measure resistance between front oxygen A F sensor connector terminals Terminals No 3 No 4...

Page 492: ...EN H4SO 95 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 493: ...ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4...

Page 494: ...current using Subaru Select Monitor or the OBD II general scan tool Does the measured value exceed the spec ified value NOTE Subaru Select Monitor For detailed operation procedure refer to the READ C...

Page 495: ...n Mode WIRING DIAGRAM EN 01122 BATTERY F44 B61 6 T5 B19 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 4 1 3 1 4 3 2 8 B22 B83 B19 T5 T6 E3 B47 B19 B22 1...

Page 496: ...tact in rear oxygen sen sor connecting harness connector Poor contact in ECM connector Go to step 3 3 CHECK OUTPUT SIGNAL FROM ECM 1 Start and idle the engine 2 Measure voltage between ECM connector a...

Page 497: ...owing Open circuit in harness between main relay and rear oxygen sen sor connector Poor contact in rear oxygen sen sor connector Poor contact in coupling connector 7 CHECK REAR OXYGEN SENSOR 1 Turn ig...

Page 498: ...EN H4SO 101 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 499: ...on Mode WIRING DIAGRAM EN 01122 BATTERY F44 B61 6 T5 B19 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 4 1 3 1 4 3 2 8 B22 B83 B19 T5 T6 E3 B47 B19 B22...

Page 500: ...gnition switch to ON 4 Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD II general scan tool Does the measured value exceed the spec ified value NOTE Subaru Select...

Page 501: ...faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01123 19 3 15 PRESSURE SENSOR B1...

Page 502: ...EAD CURRENT DATA FOR ENGINE Ref to EN H4SO 32 Subaru Select Moni tor OBD II general scan tool For detailed operation procedure refer to the OBD II General Scan Tool Instruction Manual Ignition ON 73 3...

Page 503: ...arts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01123 19 3 15 PRESSURE SENSOR B135 B135...

Page 504: ...s ground Does the measured value exceed the specified value 4 5 V Go to step 5 Go to step 4 4 CHECK INPUT SIGNAL FOR ECM Measure voltage between ECM connector and chassis ground Connector terminal B13...

Page 505: ...s between ECM and pressure sensor connector Connector terminal B135 No 19 E21 No 1 Is the measured value less than the speci fied value 1 Go to step 9 Repair open circuit in harness between ECM and pr...

Page 506: ...EN H4SO 109 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 507: ...arts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01123 19 3 15 PRESSURE SENSOR B135 B135...

Page 508: ...ector and chassis ground Connector terminal B135 No 3 Chassis ground Does the measured value exceed the specified value by shaking harness and connector of ECM while monitoring the value with voltage...

Page 509: ...t in pressure sensor con nector Is there poor contact in pressure sensor con nector There is poor contact Repair poor con tact in pressure sensor connector Replace pressure sensor Ref to FU H4SO 32 Pr...

Page 510: ...EN H4SO 113 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 511: ...ct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01124 D6 B19 INTAKE AIR TEMPERATURE SENSOR B135 14...

Page 512: ...completely 2 Measure engine coolant temperature using Subaru Select Monitor or OBD II general scan tool Is the measured value within the specified range NOTE Subaru Select Monitor For detailed operat...

Page 513: ...Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01124 D6 B19 INTAKE AIR TEMPERATURE SENSOR B135 14 9 B21 E2...

Page 514: ...t in ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE SENSOR AND ECM CON NECTOR 1 Turn ignition switch to OFF 2 Disconnect connecto...

Page 515: ...Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01124 D6 B19 INTAKE AIR TEMPERATURE SENSOR B135 14 9 B21 E2...

Page 516: ...connector and engine ground Connector terminal E20 No 1 Engine ground Does the measured value exceed the spec ified value 10 V Repair battery short circuit in har ness between intake air tempera ture...

Page 517: ...nd Connector terminal E20 No 2 Engine ground Is the measured value less than the speci fied value 5 Replace intake air temperature sen sor Ref to FU H4SO 33 REMOVAL Intake Air Temperature Sensor Repai...

Page 518: ...EN H4SO 121 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 519: ...placement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01125 19 12 9 13 B1...

Page 520: ...in ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connect...

Page 521: ...placement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01125 19 12 9 13 B1...

Page 522: ...in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from engine coola...

Page 523: ...r Poor contact in coupling connector Poor contact in joint connector 5 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Measure resistance of h...

Page 524: ...EN H4SO 127 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 525: ...r repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01126...

Page 526: ...HER DTC ON DISPLAY Is any other DTC displayed DTC indicated Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 83 List of Diagnostic Trouble Code DTC NOTE In this case...

Page 527: ...or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01126 19 13 3...

Page 528: ...is ground while throttle valve is fully closed Connector terminal B135 No 3 Chassis ground Does the measured value exceed the specified value 4 5 V Go to step 4 Go to step 3 3 CHECK INPUT SIGNAL FOR E...

Page 529: ...connector and throttle position sensor connector Connector terminal B135 No 13 E13 No 3 Is the measured value less than the speci fied value 1 Go to step 8 Repair harness and connector NOTE In this c...

Page 530: ...EN H4SO 133 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 531: ...or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01126 19 13 3...

Page 532: ...CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNEC TOR 1 Turn ignition switch to OFF 2 Disconnect connector from throttle position sensor 3 Measure resistance of harness between throttle p...

Page 533: ...replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01125 19 12 9 13...

Page 534: ...ant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 83 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0125 Go to step 2 2 CHECK THERMOSTAT Does...

Page 535: ...parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does t...

Page 536: ...EN H4SO 139 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 537: ...lear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8 B22 E...

Page 538: ...Select Moni tor OBD II general scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual 0 85 1 15 in idling Go to step 3 Go to step 4 3 CHECK FRONT OXYGEN A...

Page 539: ...o step 6 Repair ground short circuit between ECM and front oxygen A F sensor 6 CHECK EXHAUST SYSTEM Check exhaust system parts Is there a fault in exhaust system NOTE Check the following items Loose i...

Page 540: ...EN H4SO 143 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 541: ...Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8 B22...

Page 542: ...connectors from ECM and front oxygen A F sensor connector 3 Measure resistance of harness between ECM and front oxygen A F sensor con nector Connector terminal B136 No 13 Chassis ground B136 No 22 Cha...

Page 543: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8...

Page 544: ...OFF 2 Disconnect connector from ECM 3 Measure voltage of harness between ECM connector and chassis ground Connector terminal B136 No 13 Chassis ground B136 No 22 Chassis ground Does the measured value...

Page 545: ...ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4...

Page 546: ...rouble Code DTC NOTE In this case it is not necessary to inspect DTC P0133 Go to step 2 2 CHECK EXHAUST SYSTEM Is there a problem in exhaust system NOTE Check the following items Loose installation of...

Page 547: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8...

Page 548: ...o 22 B18 No 2 Is the measured value less than the speci fied value 1 Go to step 2 Repair harness and connector NOTE In this case repair the following Open circuit in harness between ECM and fornt oxyg...

Page 549: ...Mode WIRING DIAGRAM EN 01122 BATTERY F44 B61 6 T5 B19 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 4 1 3 1 4 3 2 8 B22 B83 B19 T5 T6 E3 B47 B19 B22 1...

Page 550: ...ion Manual 490 mV Go to step 5 Go to step 3 3 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connectors from ECM and rear oxygen sensor 3 Measure...

Page 551: ...e a fault in exhaust system NOTE Check the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxy...

Page 552: ...EN H4SO 155 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 553: ...n Mode WIRING DIAGRAM EN 01122 BATTERY F44 B61 6 T5 B19 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 4 1 3 1 4 3 2 8 B22 B83 B19 T5 T6 E3 B47 B19 B22 1...

Page 554: ...rocedures refer to the OBD II General Scan Tool Instruction Manual 250 mV Go to step 5 Go to step 3 3 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn ignition switch to OFF 2 Disconn...

Page 555: ...e a fault in exhaust system NOTE Check the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxy...

Page 556: ...EN H4SO 159 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 557: ...n Mode WIRING DIAGRAM EN 01122 BATTERY F44 B61 6 T5 B19 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 4 1 3 1 4 3 2 8 B22 B83 B19 T5 T6 E3 B47 B19 B22 1...

Page 558: ...NY OTHER DTC ON DISPLAY Is any other DTC displayed DTC indicated Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 83 List of Diagnostic Trouble Code DTC NOTE In this...

Page 559: ...C PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AA DTC P0171 SYSTEM TOO LEAN BANK 1 NOTE For the diagnostic procedure refer to DTC P0172 Ref to EN H4SO 164 DTC P0172 SYSTEM TOO RICH BANK 1 Diagnostic Pro...

Page 560: ...EN H4SO 163 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 561: ...le Code DTC Ref to EN H4SO 83 List of Diagnostic Trouble Code DTC Go to step 2 2 CHECK EXHAUST SYSTEM Are there holes or loose bolts on exhaust sys tem There are holes or loose bolts on exhaust system...

Page 562: ...sure does not increase squeeze fuel return hose 2 to 3 times then measure fuel pressure again 284 314 kPa 2 9 3 2 kg cm2 41 46 psi Go to step 8 Repair the follow ing items Fuel pressure too high Clogg...

Page 563: ...NAL 1 Start the engine and warm up engine until coolant temperature is greater than 60 C 140 F 2 Place the selector lever in N or P posi tion 3 Turn A C switch to OFF 4 Turn all accessory switches to...

Page 564: ...cedure with Diagnostic Trouble Code DTC AD DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE For the diagnostic procedure refer to DTC P0304 Ref to EN H4SO 168 DTC P0304 CYLINDER 4 MISFIRE DETECTED Diagnosti...

Page 565: ...parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01121 F44 B61 6 RHD RHD B22 1 2 3 4 5 6...

Page 566: ...N FUEL INJEC TOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from fuel injector on faulty cylinders 3 Measure voltage between ECM connector and engine ground on faulty cylin...

Page 567: ...7 CHECK HARNESS BETWEEN FUEL INJEC TOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from fuel injector on faulty cylinder 3 Turn ignition switch to ON 4 Measure voltage betw...

Page 568: ...proper posi tion Dislocated from its proper posi tion Repair installation condition of timing belt Ref to ME H4SO 46 Timing Belt Assembly Go to step 12 12 CHECK FUEL LEVEL Is the fuel meter indicatio...

Page 569: ...r contact in fuel injector connector on faulty cylinders Poor contact in ECM connec tor Poor contact in coupling con nector 2 If there is no poor contact con tact SUBARU dis tributor Before contacting...

Page 570: ...tep 18 18 CHECK DIAGNOSTIC TROUBLE CODE DTC ON DISPLAY Does the Subaru Select Monitor or OBD II general scan tool indicate DTC P0303 and P0304 DTC P0303 and P0304 indi cated Go to step 23 Go to step 1...

Page 571: ...LINDERS Are there faults in 3 and 4 cylinders There are faults Repair or replace faulty parts NOTE Check the fol lowing items Spark plugs Fuel injectors Ignition coil If no abnormal is discovered chec...

Page 572: ...o Skipping timing belt teeth Go to DTC P0171 Ref to EN H4SO 162 DTC P0171 SYSTEM TOO LEAN BANK 1 Diagnostic Pro cedure with Diag nostic Trouble Code DTC 26 CYLINDER AT RANDOM Is the engine idle unstab...

Page 573: ...riving performance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OP...

Page 574: ...r contact in knock sensor con nector Poor contact in coupling connector 2 CHECK KNOCK SENSOR 1 Disconnect connector from knock sensor 2 Measure resistance between knock sensor connector terminal and e...

Page 575: ...driving performance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 O...

Page 576: ...r Ref to FU H4SO 29 Knock Sensor Repair ground short circuit in har ness between knock sensor con nector and ECM connector NOTE The harness be tween both con nectors is shielded Repair short circuit o...

Page 577: ...gine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mo...

Page 578: ...and ECM connector NOTE The harness be tween both con nectors are shielded Repair ground short circuit in harness togeth er with shield Go to step 3 3 CHECK HARNESS BETWEEN CRANK SHAFT POSITION SENSOR...

Page 579: ...ure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Insp...

Page 580: ...y Tightened securely Go to step 3 Tighten crank shaft position sen sor installation bolt securely 3 CHECK CRANKSHAFT SPROCKET Remove front belt cover Are crankshaft sprocket teeth cracked or dam aged...

Page 581: ...ailure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION I...

Page 582: ...ensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair ground short circuit in harness togeth er with shield Go to step 3 3 CHECK HARNESS BETWEEN CAMSHAFT POSITION SENS...

Page 583: ...e stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 O...

Page 584: ...TWEEN CAMSHAFT POSITION SENSOR AND ECM CONNEC TOR Measure resistance of harness between cam shaft position sensor connector and engine ground Connector terminal E15 No 1 Engine ground Is the measured...

Page 585: ...htened securely Tightened securely Go to step 8 Tighten camshaft position sensor installation bolt securely 8 CHECK CAMSHAFT SPROCKET Remove front belt cover Are camshaft sprocket teeth cracked or dam...

Page 586: ...EN H4SO 189 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 587: ...ent of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01129 F44 B61 6 RHD RHD B...

Page 588: ...fer to the OBD II General Scan Tool Instruction Manual 53 3 kPa 400 mmHg 15 75 inHg Check if EGR valve intake mani fold pressure sen sor and throttle body are securely installed Go to step 3 3 CHECK P...

Page 589: ...4 No 18 E18 No 6 B134 No 17 E18 No 1 B134 No 16 E18 No 4 B134 No 15 E18 No 3 Is the measured value less than the speci fied value 1 Go to step 7 Repair open circuit in harness between ECM and EGR sole...

Page 590: ...EN H4SO 193 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 591: ...O 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01130 F44 B61 6 RHD RHD BATTERY B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 4 C6 C17 C22 C13 B23 2 3 2 1 FRONT OXYGEN A F SENSOR B19 B14 C4 D15 REAR...

Page 592: ...tic converter Between front catalytic converter and rear cat alytic converter There is a fault Repair or replace exhaust system Ref to EX H4SO 2 Gen eral Description Go to step 3 3 CHECK CATALYTIC CON...

Page 593: ...ement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01131 F44 B61 6 RHD RHD...

Page 594: ...inal E4 No 2 Engine ground Does the measured value exceed the spec ified value 1 M Go to step 3 Repair ground short circuit in har ness between ECM and purge control solenoid valve connector 3 CHECK H...

Page 595: ...the spec ified value 10 V Go to step 6 Repair open circuit in harness between main relay and purge control solenoid valve connector 6 CHECK POOR CONTACT Check poor contact in purge control solenoid v...

Page 596: ...EN H4SO 199 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 597: ...cement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01131 F44 B61 6 RHD RH...

Page 598: ...minal B134 No 29 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 4 Go to step 3 3 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM...

Page 599: ...DIAGNOSTIC TROUBLE CODE DTC 6 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector There is poor contact Repair poor con tact in ECM con nector Replace ECM Re...

Page 600: ...EN H4SO 203 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 601: ...20 i10 A i28 i11 B i12 C B16 A3 3 6 2 1 16 6 2 B72 4 1 2 3 6 5 1 3 4 5 6 2 R57 i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 602: ...other DTC displayed DTC indicated Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 83 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to ins...

Page 603: ...10 A i28 i11 B i12 C B16 A3 3 6 2 1 16 6 2 B72 4 1 2 3 6 5 1 3 4 5 6 2 R57 i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 604: ...OR ENGINE Ref to EN H4SO 32 Subaru Select Moni tor 0 12 V Repair poor con tact in ECM con nector Even if MI lights up the circuit has returned to a nor mal condition at this time A tempo rary poor con...

Page 605: ...istance between fuel pump assembly and chassis ground Connector terminal R59 No 2 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 9 Repair ground short circuit in fue...

Page 606: ...EN H4SO 209 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 607: ...10 A i28 i11 B i12 C B16 A3 3 6 2 1 16 6 2 B72 4 1 2 3 6 5 1 3 4 5 6 2 R57 i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 608: ...OFF 2 Disconnect combination meter connector i10 and ECM connector 3 Turn ignition switch to ON 4 Measure voltage of harness between ECM and chassis ground Connector terminal B136 No 27 Chassis groun...

Page 609: ...ecified value 1 Go to step 9 Repair open circuit between coupling connector and fuel sub level sensor 9 CHECK FUEL LEVEL SENSOR Warning During work procedures if fuel tank is more than 3 4 full be car...

Page 610: ...EN H4SO 213 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 611: ...i10 A i28 i11 B i12 C B16 A3 3 6 2 1 16 6 2 B72 4 1 2 3 6 5 1 3 4 5 6 2 R57 i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 612: ...resistance between fuel level sensor terminals changes smoothly Terminals No 3 No 6 Does the resistance change smoothly Change smoothly Go to step 3 Replace fuel level sensor Ref to FU H4SO 64 Fuel Le...

Page 613: ...LE SYMPTOM Occurrence of noise Overheating CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4...

Page 614: ...OR MAIN FAN MOTOR MAIN FAN RELAY F28 F16 F66 F27 1 2 F17 B100 F2 B72 1 2 K9 J10 NO 3 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 BLUE 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 615: ...HER DTC ON DISPLAY Is any other DTC displayed DTC indicated Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 83 List of Diagnostic Trouble Code DTC Check radiator fan...

Page 616: ...EN H4SO 219 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 617: ...GNOSTIC TROUBLE CODE DTC AV DTC P0502 VEHICLE SPEED SENSOR CIRCUIT LOW INPUT NOTE For the diagnostic procedure refer to DTC P0503 Ref to EN H4SO 222 DTC P0503 VEHICLE SPEED SENSOR INTERMITTENT ERRATIC...

Page 618: ...EN H4SO 221 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 619: ...03 VEHICLE SPEED SENSOR INTERMITTENT ERRATIC HIGH DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO...

Page 620: ...5 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1...

Page 621: ...Go to step 4 Check speedome ter and vehicle speed sensor Ref to IDI 18 Speedometer and Ref to AT 54 Front Vehicle Speed Sensor and Ref to AT 58 Rear Vehicle Speed Sensor and Ref to AT 59 Torque Con v...

Page 622: ...EN H4SO 225 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 623: ...ct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01134 F44 B61 6 RHD RHD 20 6 5 19 B21 E2 ECM 2 5 6...

Page 624: ...INE 1 Turn ignition switch to OFF 2 Remove idle air control solenoid valve from throttle body Ref to FU H4SO 34 REMOVAL Idle Air Control Solenoid Valve 3 Remove throttle body from intake manifold Ref...

Page 625: ...Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01134 F44 B61 6 RHD RHD 20 6 5 19 B21 E2 ECM 2 5 6 3...

Page 626: ...dle air con trol solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses Is there any fault in air intake system There is a fault Repair air suction and leaks Go to step 3 3 CHEC...

Page 627: ...EST CIRCUIT DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode R...

Page 628: ...to ON Operates Repair battery short circuit in starter motor cir cuit Check starter motor circuit Ref to EN H4SO 62 Diagnostics for Engine Starting Failure EN 01118 12 INHIBITOR SWITCH STARTER MOTOR 7...

Page 629: ...Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01134 F44 B61 6 RHD RHD 20 6 5 19 B21 E2 ECM 2 5 6 3 4 1 3...

Page 630: ...olenoid valve gasket and throttle body gasket Disconnections of vacuum hoses Is there a fault in air intake system There is a fault Repair air suction and leaks Go to step 3 3 CHECK THROTTLE CABLE Doe...

Page 631: ...ycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection...

Page 632: ...short circuit in harness between TCM and CCM connector 3 CHECK INPUT SIGNAL FOR TCM 1 Connect connector to TCM and CCM 2 Lift up the vehicle or set the vehicle on free rollers CAUTION On AWD models r...

Page 633: ...WIRING DIAGRAM EN 01119 F44 B61 6 RHD RHD B9 C21 C23 B1 C12 B2 E3 B22 A7 A35 C26 B21 D14 C19 13 15 14 16 B47 BATTERY MAIN RELAY 1 2 3 5 6 4 SBF 5 SBF 4 SBF 1 3 1 B72 IGNITION SWITCH ECM B134 A B135 B...

Page 634: ...STIC TROUBLE CODE DTC Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Subaru Select Monitor or OBD II general scan tool indicate DTC P0604 DTC P0604 indicated Replace ECM Ref to FU H4SO 45...

Page 635: ...LOW DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct Cl...

Page 636: ...OR MAIN FAN MOTOR MAIN FAN RELAY F28 F16 F66 F27 1 2 F17 B100 F2 B72 1 2 K9 J10 NO 3 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 BLUE 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 637: ...ground Connector terminal B134 No 14 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 3 Repair ground short circuit in radi ator fan relay 1 control circuit 3 CHECK P...

Page 638: ...E CODE DTC 6 CHECK POOR CONTACT Check poor contact in ECM or main fan relay connector Is there poor contact in ECM or main fan relay connector There is poor contact Repair poor con tact in ECM or main...

Page 639: ...HIGH DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct C...

Page 640: ...OR MAIN FAN MOTOR MAIN FAN RELAY F28 F16 F66 F27 1 2 F17 B100 F2 B72 1 2 K9 J10 NO 3 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 BLUE 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 641: ...RADIATOR FAN RELAY CONTROL CIRCUIT 1 Turn ignition switch to OFF 2 Remove main fan relay and sub fan relay with A C models 3 Disconnect test mode connector 4 Turn ignition switch to ON 5 Measure volta...

Page 642: ...EN H4SO 245 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 643: ...AUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGR...

Page 644: ...resistance of harness between TCM and chassis ground Connector terminal B55 No 12 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair ground short circuit in har...

Page 645: ...c Procedure with Diagnostic Trouble Code DTC BH DTC P0732 GEAR 2 INCORRECT RATIO NOTE For the diagnostic procedure refer to DTC P0734 Ref to EN H4SO 250 DTC P0734 GEAR 4 INCOR RECT RATIO Diagnostic Pr...

Page 646: ...EN H4SO 249 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 647: ...e throttle position sensor circuit Go to step 3 3 CHECK FRONT VEHICLE SPEED SENSOR CIRCUIT Check front vehicle speed sensor circuit Is there any trouble in vehicle speed sensor 2 circuit Ref to AT 58...

Page 648: ...EN H4SO 251 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 649: ...ocedure with Diag nostic Trouble Code DTC There is a fault Repair or replace lock up duty sole noid circuit Go to step 3 3 CHECK THROTTLE POSITION SENSOR CIRCUIT Check throttle position sensor circuit...

Page 650: ...itch circuit Go to step 8 8 CHECK ATF TEMPERATURE SENSOR CIR CUIT Check ATF temperature sensor circuit Is there any trouble in ATF temperature sensor circuit Ref to AT 48 DTC 27 ATF TEMPERATURE SENSOR...

Page 651: ...ling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING...

Page 652: ...ed value exceed the spec ified value 1 M Go to step 4 Repair ground short circuit in har ness between ECM and trans mission harness connector 4 CHECK TRANSMISSION HARNESS CON NECTOR 1 Disconnect conne...

Page 653: ...M Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspecti...

Page 654: ...CHECK NEUTRAL POSITION SWITCH 1 Turn ignition switch to OFF 2 Disconnect connector from transmission harness 3 Measure resistance between transmission harness and connector terminals Connector termin...

Page 655: ...ling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING...

Page 656: ...Is the measured value within the specified range 4 5 5 5 V Go to step 4 Go to step 5 4 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector There is poor conta...

Page 657: ...ter motor grond line Poor contact in satrter motor con nector Poor contact in starter motor ground Starter motor 7 CHECK INHIBITOR SWITCH Measure resistance between inhibitor switch connector receptac...

Page 658: ...EN H4SO 261 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 659: ...M Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspecti...

Page 660: ...TCH Measure resistance between transmission har ness connector terminals Connector terminal T2 No 1 No 2 Is the measured value less than the specified value at except neutral position 1 Go to step 5 R...

Page 661: ...tact in transmission harness connector Is there poor contact in transmission harness connector There is poor contact Repair poor con tact in transmis sion harness connector Contact SUBARU distributor...

Page 662: ...EN H4SO 265 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 663: ...riving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION In...

Page 664: ...radi ator fan makes one complete rotation 2 Drive the vehicle Is AT shift control functioning properly Operates properly Go to step 2 Replace TCM Ref to AT 76 Transmission Con trol Module TCM 2 CHECK...

Page 665: ...cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspectio...

Page 666: ...and chassis ground Connector terminal B137 No 19 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 3 Repair ground short circuit in har ness between ECM and TCM connec...

Page 667: ...cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspectio...

Page 668: ...ured value less than the specified value 1 V Repair poor con tact in ECM con nector Go to step 4 4 CHECK OUTPUT SIGNAL FROM ECM Measure voltage between ECM and chassis ground Connector terminal B137 N...

Page 669: ...ement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode Step Value Yes No 1 CHECK ANY OTHER DTC O...

Page 670: ...cement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode Step Value Yes No 1 CHECK ANY OTHER DTC...

Page 671: ...Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8 B22 E3 EC...

Page 672: ...STIC TROUBLE CODE DTC Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Subaru Select Monitor or OBD II general scan tool indicate DTC P1134 DTC P1134 indicated Replace ECM Ref to FU H4SO 45...

Page 673: ...lear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01144 F44 B61 6 RHD RHD BATTERY SBF 5 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C16 C5 4 8 B22 E...

Page 674: ...ATA FOR ENGINE Ref to EN H4SO 32 Subaru Select Moni tor OBD II general scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual 0 85 1 15 Go to step 3 Go to...

Page 675: ...step 6 Repair ground short circuit between ECM and front oxygen A F sensor 6 CHECK EXHAUST SYSTEM Check exhaust system parts Is there any fault in exhaust system NOTE Check the following items Loose...

Page 676: ...Ref to EN H4SO 280 DTC P1498 EGR SOLENOID VALVE SIGNAL 4 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trou ble Code DTC BZ DTC P1495 EGR SOLENOID VALVE SIGNAL 2 CIRCUIT MALFUNCTI...

Page 677: ...ty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01129 F44 B61 6 RHD RHD BATTERY SBF...

Page 678: ...DTC P1496 B134 No 16 E18 No 4 DTC P1498 B134 No 15 E18 No 3 Is the measured value less than the speci fied value 1 Go to step 3 Repair harness and connector NOTE In this case repair the following Ope...

Page 679: ...lty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01129 F44 B61 6 RHD RHD BATTERY SBF...

Page 680: ...en circuit in harness between ECM connector and engine ground Poor contact in ECM connector Poor contact in coupling connector 3 CHECK HARNESS BETWEEN ECM AND EGR SOLENOID VALVE CONNECTOR 1 Turn ignit...

Page 681: ...Ref to EN H4SO 286 DTC P1516 ISC SOLENOID VALVE SIGNAL 4 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trou ble Code DTC CH DTC P1513 ISC SOLENOID VALVE SIGNAL 2 CIRCUIT MALFUNCTI...

Page 682: ...EN H4SO 285 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 683: ...y Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01134 F44 B61 6 RHD RHD 20 6 5 19 B21 E2 ECM 2 5 6 3 4 1 3 4 1 2...

Page 684: ...E7 No 6 DTC P1516 B134 No 19 E7 No 3 Is the measured value less than the speci fied value 1 Go to step 3 Repair harness and connector NOTE In this case repair the following Open circuit in harness bet...

Page 685: ...y Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION Inspection Mode WIRING DIAGRAM EN 01134 F44 B61 6 RHD RHD 20 6 5 19 B21 E2 ECM 2 5 6 3 4 1 3 4 1 2...

Page 686: ...in harness between ECM connector and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector 3 CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR...

Page 687: ...IRCUIT LOW INPUT DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory M...

Page 688: ...AM EN 01118 12 INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 B72 12 11 T7 T3 B12 1 3 IGNITION SWITCH AT MT AT MT T7 1 2 3 4 5 6 7 8 9 10 11 12 B72 3 4 1 2 20 B136 ECM BATTERY B12 1 2...

Page 689: ...igni tion switch to ST NOTE Place the inhibitor switch in the P or N posi tion Operates Repair harness and connector NOTE In this case repair the following Open or ground short circuit in har ness be...

Page 690: ...EN H4SO 293 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 691: ...D RHD B9 C21 C23 B1 C12 B2 E3 B22 A7 A35 C26 B21 D14 C19 13 15 14 16 B47 BATTERY MAIN RELAY 1 2 3 5 6 4 SBF 5 SBF 4 SBF 1 3 1 B72 IGNITION SWITCH ECM B134 A B135 B B136 C B137 D C5 8 5 6 7 8 2 1 9 4 3...

Page 692: ...NESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR 1 Disconnect connector from ECM 2 Measure resistance of harness between ECM and chassis ground Connector terminal B135 No 9 Chassis ground Does the measure...

Page 693: ...driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION I...

Page 694: ...TWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connectors from ECM and TCM 3 Measure resistance of harness between ECM and chassis ground Connector terminal B136 No 15 Chassis...

Page 695: ...driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 40 OPERATION I...

Page 696: ...ween ECM and TCM connector After repair replace ECM Ref to FU H4SO 45 Engine Control Module 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Measure voltage between ECM an...

Page 697: ...t TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO...

Page 698: ...RU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Disc...

Page 699: ...TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 47 OPER ATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 4...

Page 700: ...CM con nector Contact SUBARU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ign...

Page 701: ...r 3 12 Oxygen sensor 13 Fuel pump and fuel pump relay 3 Engine does not return to idle 1 Idle air control solenoid valve 2 Engine coolant temperature sensor 3 Accelerator cable 6 4 Throttle position s...

Page 702: ...temperature sensor 3 Intake air temperature and pressure sensor 4 Engine coolant temperature sensor 2 5 Crankshaft position sensor 3 6 Camshaft position sensor 3 7 Fuel injection parts 4 8 Throttle p...

Page 703: ...EN H4SO 306 ENGINE DIAGNOSTICS GENERAL DIAGNOSTIC TABLE MEMO...

Page 704: ...9 Intake Air Temperature and Pressure Sensor 32 10 Idle Air Control Solenoid Valve 33 11 Fuel Injector 34 12 Oxygen Sensor 40 13 Engine Control Module 42 14 Main Relay 43 15 Fuel Pump Relay 44 16 Fuel...

Page 705: ...TIONS Model Fuel tank Capacity 64 2 16 9 US gal 14 1 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 370 677 kPa 3 77 6 9 kg cm2 53 6 98 psi Discharge flow More tha...

Page 706: ...FU H4SOw oOBD 3 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION MEMO...

Page 707: ...JECTION FUEL SYSTEMS GENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD FU 00711 1 2 2 3 3 4 4 5 5 6 7 8 9 10 20 22 11 12 13 14 15 16 17 18 18 18 19 19 19 21 21 20 T5 T6 T6 T6 T5 T5 T5 T5 T5 T5 T5 T1 T...

Page 708: ...sure sensor 3 Fuel injector Tightening torque N m kgf m ft lb 4 O ring 14 O ring T1 1 5 0 15 1 1 5 O ring 15 Plug cord holder LH T2 3 4 0 35 2 5 6 Plug 16 Fuel pipe protector RH T3 5 0 0 51 3 7 7 PCV...

Page 709: ...FUEL SYSTEMS GENERAL DESCRIPTION 2 AIR INTAKE SYSTEM 1 Gasket 4 Throttle body Tightening torque N m kgf m ft lb 2 Throttle position sensor T1 1 6 0 16 1 2 3 Idle air control solenoid valve T2 22 2 2...

Page 710: ...ON 3 CRANKSHAFT POSITION CAMSHAFT POSITION AND KNOCK SENSORS 1 Crank angle position sensor 3 Camshaft position sensor Tightening torque N m kgf m ft lb 2 Knock sensor 4 Camshaft position sensor suppor...

Page 711: ...INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 4 FUEL TANK FU 00626 1 2 2 3 4 5 6 7 8 9 31 33 37 38 36 30 34 11 10 12 13 14 14 14 15 16 17 18 19 20 26 24 25 23 32 21 22 21 27 30 30 30 35 29 28 T3 T3 T3 T3...

Page 712: ...el pump plate 21 Quick connector 36 Seal 7 Fuel pump ASSY 22 Jet pump hose B 37 Fuel pump holder 8 Fuel level sensor 23 Fuel sub level sensor gasket 38 Grommet 9 Fuel filter 24 Jet pump filter 10 Fuel...

Page 713: ...C 21 Dumber valve Return 4 Clip 13 Canister bracket 22 Fuel return hose B 5 Fuel delivery hose B 14 Fuel pipe ASSY 6 Fuel return hose A 15 Evaporation hose B Tightening torque N m kgf m ft lb 7 Drain...

Page 714: ...SYSTEMS GENERAL DESCRIPTION 6 FUEL FILLER PIPE 1 Fuel filler pipe ASSY 5 Filler ring Tightening torque N m kgf m ft lb 2 Clip 6 Filler cap T 7 4 0 75 5 4 3 Clamp 7 Filler pipe protector 4 Filler pipe...

Page 715: ...art on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting ele...

Page 716: ...tion sensor 6 Disconnect air by pass hose from purge control solenoid valve 7 Disconnect engine coolant hoses from throttle body 8 Remove bolts which install throttle body to intake manifold B INSTALL...

Page 717: ...elerator cable A 6 Disconnect cruise control cable B With cruise control model 7 Remove power steering pump and tank from brackets 1 Remove resonator chamber Ref to IN H4SO 8 REMOVAL Resonator Chamber...

Page 718: ...gine coolant hose from throttle body 11 Disconnect brake booster hose 12 Remove air cleaner case stay RH and engine harness bracket and disconnect engine harness connectors from bulkhead harness conne...

Page 719: ...s in a container or cloth 19 Remove bolts which hold intake manifold onto cylinder heads and then remove intake manifold B INSTALLATION 1 Install intake manifold onto cylinder heads NOTE Always use ne...

Page 720: ...t position sen sor 6 Connect knock sensor connector 7 Connect connectors to engine coolant tempera ture sensor 8 Install air cleaner case stay RH and engine har ness bracket and connect engine harness...

Page 721: ...16 ft lb 4 Install power steering pipes onto right side intake manifold protector 5 Install front V belt Ref to ME H4SO 42 INSTALLATION V belt 6 Install resonator chamber Tightening torque 33 N m 3 4...

Page 722: ...ector from ignition coil and igni tor assembly 3 Remove ignition coil and ignitor assembly 4 Disconnect connector from intake air tempera ture and pressure sensor 5 Remove intake air temperature and p...

Page 723: ...ectors 12 Disconnect connector from purge control sole noid valve 13 Disconnect air by pass hose from purge control solenoid valve 14 Remove harness bands A and harness brack et B which hold engine ha...

Page 724: ...olts which hold fuel pipes on the left side of intake manifold 20 Remove fuel injectors 1 Remove fuel injector securing clip 2 Remove fuel injector while lifting up fuel in jector pipe 21 Loosen clamp...

Page 725: ...manifold D ASSEMBLY 1 Install fuel pipe assembly and pressure regula tor etc to intake manifold 2 Tighten bolt which installs fuel pipes on intake manifold Tightening torque 5 0 N m 0 51 kgf m 3 7 ft...

Page 726: ...lators NOTE Do not forget to install the fuel injector securing clip 7 Tighten bolt which installs injector pipe on intake manifold Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb 8 Tighten two bolts w...

Page 727: ...ightening torque 16 N m 1 6 kgf m 12 ft lb 13 Connect connectors to fuel injectors and purge control solenoid valve 14 Hold engine harness by harness band A and harness bracket B NOTE Do not use harne...

Page 728: ...NOTE Replace O ring with new one 21 Connect connector to intake air temperature and pressure sensor 22 Connect connectors to throttle position sensor and idle air control solenoid valve 23 Install ig...

Page 729: ...ve air intake duct and air cleaner assem bly Ref to IN H4SO 7 REMOVAL Air Intake Duct and Ref to IN H4SO 6 REMOVAL Air Cleaner Case 3 Disconnect connector from engine coolant tem perature sensor 4 Rem...

Page 730: ...sconnect battery ground cable 2 Remove bolt which install crankshaft position sensor to cylinder block 3 Remove crankshaft position sensor and discon nect connector from it B INSTALLATION Install in t...

Page 731: ...position sensor support 4 Remove bolt which installs camshaft position sensor support to camshaft cap LH 5 Remove camshaft position sensor and camshaft position sensor support as a unit 6 Remove camsh...

Page 732: ...Remove knock sensor from cylinder block B INSTALLATION 1 Install knock sensor to cylinder block Tightening torque 24 N m 2 4 kgf m 17 4 ft lb NOTE The extraction area of the knock sensor cord must be...

Page 733: ...en installing throttle position sensor adjust to the specified data C ADJUSTMENT 1 Turn ignition switch to OFF 2 Loosen throttle position sensor holding screws 3 When using voltage meter 1 Take out EC...

Page 734: ...iption 4 Connect Subaru Select Monitor to the data link connector A 5 Turn ignition switch to ON and Subaru Select Monitor switch to ON 6 Select 2 Each System Check in Main Menu 7 Select Engine Contro...

Page 735: ...nnect battery ground cable 2 Disconnect spark plug cord from ignition coil and ignitor assembly 3 Disconnect connector from intake air tempera ture and pressure sensor 4 Remove intake air temperature...

Page 736: ...1 Disconnect battery ground cable 2 Disconnect connector from idle air control sole noid valve 3 Remove idle air control solenoid valve from throttle body B INSTALLATION Install in the reverse order...

Page 737: ...MOVAL Air Cleaner Case 5 Remove resonator chamber Ref to IN H4SO 8 REMOVAL Resonator Chamber 6 Remove spark plug cords from spark plugs 1 and 3 cylinders 7 Remove power steering pump and tank from bra...

Page 738: ...ector pipe to intake manifold 11 Remove bolt which install injector pipe to intake manifold 12 Remove fuel injector from intake manifold 1 Remove fuel injector securing clip 2 Remove fuel injector whi...

Page 739: ...nnect connector from rear gate glass washer motor 7 Disconnect rear window glass washer hose from washer motor then plug connection with a suitable cap 8 Move washer tank and secure it away from worki...

Page 740: ...ide intake manifold 15 Remove fuel injector from intake manifold 1 Remove fuel injector securing clip 2 Remove fuel injector while lifting up fuel in jector pipe B INSTALLATION 1 RH SIDE Install in th...

Page 741: ...ft lb Tightening torque 32 N m 3 3 kgf m 23 9 ft lb 2 LH SIDE Install in the reverse order of removal NOTE Replace O rings with new ones Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb Tightening torqu...

Page 742: ...FU H4SOw oOBD 39 FUEL INJECTION FUEL SYSTEMS FUEL INJECTOR Tightening torque 19 N m 1 9 kgf m 13 7 ft lb Tightening torque 19 N m 1 9 kgf m 13 7 ft lb FU 00309 FU 00266...

Page 743: ...CAUTION When removing the oxygen sensor wait until exhaust pipe cools otherwise it will damage ex haust pipe B INSTALLATION 1 Before installing oxygen sensor apply anti seize compound only to threaded...

Page 744: ...FU H4SOw oOBD 41 FUEL INJECTION FUEL SYSTEMS OXYGEN SENSOR 5 Connect battery ground cable FU 00009...

Page 745: ...floor mat of passenger seat 4 Remove protect cover 5 Remove nuts A which hold ECM to bracket 6 Remove clip B from bracket 7 Disconnect ECM connectors and take out ECM B INSTALLATION Install in the re...

Page 746: ...Disconnect battery ground cable 2 Remove lower inner trim of passenger side Ref to EI 39 REMOVAL Lower Inner Trim 3 Disconnect connectors from main relay 4 Remove bolt which holds main relay bracket...

Page 747: ...y A REMOVAL 1 Disconnect battery ground cable 2 Remove lower cover Ref to EI 35 REMOV AL Instrument Panel Assembly 3 Disconnect connector from fuel pump relay 4 Remove fuel pump relay from mounting br...

Page 748: ...to OFF 2 DRAINING FUEL WARNING Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Set the vehicle on the lift 2 Disconnect the ground cable from battery 3 Lift up th...

Page 749: ...from fuel tank by using a hand pump WARNING Do not use a motor pump when draining the fu el 13 After draining the fuel reinstall the fuel sub lev el sensor Tightening torque T 4 4 N m 0 45 kgf m 3 3...

Page 750: ...FU H4SOw oOBD 47 FUEL INJECTION FUEL SYSTEMS FUEL 3 Install the sub service hole cover 4 Set the rear seat and floor mat FU 00445...

Page 751: ...h the grommet which holds fuel tank cord on service hole cover into body side 7 Separate the quick connector of fuel delivery A and return hose B Ref to FU H4SOw oOBD 67 REMOVAL Fuel Delivery Return a...

Page 752: ...not to pull down the muffler 3 Remove the front rubber cushion and then detach the muffler assembly 14 Remove the propeller shaft Ref to DS 14 REMOVAL Propeller Shaft 15 Disconnect the connector from...

Page 753: ...pport the rear differential with transmis sion jack 2 Remove the bolt which holds rear shock ab sorber to rear suspension arm 3 Remove the bolts which secure rear sus pension assembly to body 4 Remove...

Page 754: ...pport the fuel tank with transmission jack and then push the fuel tank harness into access hole with grommet 2 Set the fuel tank and then temporarily tighten the bolts of fuel tank bands CAUTION A hel...

Page 755: ...8 ft lb 2 Tighten the bolt which holds rear shock ab sorber to rear suspension arm Ref to RS 11 INSTALLATION Rear Arm Tightening torque 157 N m 16 kgf m 116 ft lb 8 Install the rear brake caliper Ref...

Page 756: ...004301003 1 Install the right and left rubber cushions 2 Install the front rubber cushion and attach muffler assembly 3 Install the rear exhaust pipe to center ex haust pipe Tightening torque 18 N m...

Page 757: ...ommet 26 Install the holder clip which secures fuel tank cord on bracket 27 Set the rear seat and floor mat 28 Connect the connector to fuel pump relay A 29 Adjust the parking brake lever stroke Ref t...

Page 758: ...emove the screws holding packing in place 5 Lift up the vehicle 6 Remove the rear right side wheel nuts 7 Remove the wheel RH Rear 8 Remove the protector RH Front 9 Drain fuel from fuel tank Set a con...

Page 759: ...ove the clip and then separate the air vent hose B 16 Remove the fuel filler pipe to under side of the vehicle B INSTALLATION 1 Hold the fuel filler flap open 2 Set the fuel saucer A with rubber packi...

Page 760: ...prox 25 to 30 mm 0 98 to 1 18 in into the lower end of air vent pipe and hold clip L 27 5 2 5 mm 1 083 0 098 in 6 Tighten the bolt which holds fuel filler pipe brack et on body Tightening torque 7 4 N...

Page 761: ...FU H4SOw oOBD 58 FUEL INJECTION FUEL SYSTEMS FUEL FILLER PIPE 12 Connect the connector to fuel pump relay A 13 Connect the battery ground cable to battery FU 00648 A FU 00009...

Page 762: ...e the fuel filler cap 3 Disconnect the ground cable from battery 4 Lift up the vehicle 5 Remove the protector RH Front 6 Drain the fuel from fuel tank Set a container un der the vehicle and then remov...

Page 763: ...in alphabetical sequence shown in the figure to specified torque Tightening torque 5 9 N m 0 6 kgf m 4 3 ft lb C DISASSEMBLY 1 Remove the fuel pump and pump holder NOTE When disassembling the pump hol...

Page 764: ...he fuel pump assembly Ref to FU H4SOw oOBD 59 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et 3 Pushing the pawls with a screwdriver remove the fuel meter unit by pulling it downw...

Page 765: ...he front side fuel tank cover 4 Drain fuel from fuel tank Set a container under the vehicle and then remove the drain plug from fuel tank 5 Tighten the fuel drain plug and install the protec tor RH Fr...

Page 766: ...Disconnect the fuel jet pump hose 10 Remove the bolts which install fuel sub level sensor on fuel tank 11 Remove the fuel sub level sensor B INSTALLATION Install in the reverse order of removal Tight...

Page 767: ...holder 4 Remove the filter holder by turning it to the left from the body pawls and then take out the filter B INSTALLATION NOTE If the fuel hoses are damaged at the connecting portion replace it wit...

Page 768: ...e fuel tank Ref to FU H4SOw oOBD 48 REMOVAL Fuel Tank 2 Move the clip and then disconnect the evapora tion hose from fuel cut valve 3 Remove the bolts which install fuel cut valve B INSTALLATION Insta...

Page 769: ...Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H4SOw oOBD 45 RELEASING OF FUEL PRESSURE OPERATION Fuel 2 Remove the fuel damper valve from fuel delivery line A and return line B B...

Page 770: ...n the fuel filler flap lid and then remove the fuel filler cap 4 Remove the floor mat Ref to EI 48 REMOVAL Floor Mat 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation...

Page 771: ...se a new retainer Make sure that the connected portion is not dam aged or has dust If necessary clean the seal sur face of pipe 1 Set a new retainer B to connector A 2 Push the pipe into connector com...

Page 772: ...059 in L 22 5 2 5 mm 0 886 0 098 in 3 Connect the evaporation hose to pipe by approx 15 mm 0 59 in from hose end L 17 5 2 5 mm 0 689 0 098 in NOTE Be sure to inspect the hoses and their connections f...

Page 773: ...cause Corrective action 1 Insufficient fuel supply to the injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Trouble in electr...

Page 774: ...ON CONTROL AUX EMISSION CONTROL DEVICES EC H4SOw oOBD Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 6 4 Canister 7 5 Purge Control Solenoid Valve 8 6 Two way Va...

Page 775: ...arts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be caref...

Page 776: ...ove under cover Ref to EI 13 REMOVAL Front Under Cover 6 Separate front and center exhaust pipe assem bly from rear exhaust pipe CAUTION Be careful exhaust pipe is hot 7 Remove nuts which hold front e...

Page 777: ...et 3 Tighten nuts which hold front exhaust pipe onto cylinder heads Tightening torque 30 N m 3 1 kgf m 22 4 ft lb 4 Tighten bolts which secure front and center ex haust pipe assembly to rear exhaust p...

Page 778: ...CONTROL AUX EMISSION CONTROL DEVICES FRONT CATALYTIC CONVERTER 9 Connect battery ground cable C INSPECTION 1 Make sure there are no exhaust leaks from con nections and welds 2 Make sure there are no h...

Page 779: ...atalytic Converter B INSTALLATION The front and rear catalytic converter and center exhaust pipe are integrated into one unit There fore the removal and installation procedures are the same as the one...

Page 780: ...from canister 3 Remove canister from body B INSTALLATION Install in the reverse order of removal Tightening torque 7 4 2 0 N m 0 75 0 2 kgf m 5 4 1 4 ft lb CAUTION Insert drain hose of canister into...

Page 781: ...ifold 3 Take out purge control solenoid valve through the bottom of the intake manifold 4 Disconnect connector and hoses from purge control solenoid valve B INSTALLATION Install in the reverse order o...

Page 782: ...n the reverse order of removal CAUTION Be careful not to install two way valve in the wrong direction C INSPECTION 1 Using a hand air pump check if air goes through the valve from both A and B directi...

Page 783: ...EC H4SOw oOBD 10 EMISSION CONTROL AUX EMISSION CONTROL DEVICES TWO WAY VALVE MEMO...

Page 784: ...INTAKE INDUCTION IN H4SOw oOBD Page 1 General Description 2...

Page 785: ...N H4SOw oOBD 2 INTAKE INDUCTION GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to IN H4SO 2 Gen eral Descriptio...

Page 786: ...MECHANICAL ME H4SOw oOBD Page 1 General Description 2...

Page 787: ...ME H4SOw oOBD 2 MECHANICAL GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to ME H4SO 2 General Description...

Page 788: ...EXHAUST EX H4SOw oOBD Page 1 General Description 2 2 Front Exhaust Pipe 9 3 Center Exhaust Pipe 12 4 Rear Exhaust Pipe 13 5 Muffler 14...

Page 789: ...GENERAL DESCRIPTION 1 General Description A COMPONENT 1 WITH CATALYTIC CONVERTER EXCEPT AUSTRALIA OUTBACK MODEL EX 00098 1 2 3 4 5 6 7 8 9 10 11 22 12 13 14 15 16 17 18 19 19 19 20 23 23 21 T2 T6 T1...

Page 790: ...catalytic converter cover 5 Front catalytic converter Tightening torque N m kgf m ft lb 6 Upper front catalytic converter cover 14 Rear catalytic converter T1 8 0 8 5 8 15 Center exhaust pipe T2 13 1...

Page 791: ...EX H4SOw oOBD 4 EXHAUST GENERAL DESCRIPTION 2 AUSTRALIA OUTBACK MODEL EX 00099 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 17 18 19 20 20 T2 T4 T4 T4 T5 T5 T1 T6 T5 T3...

Page 792: ...et 3 Front exhaust pipe 11 Gasket 4 Oxygen sensor 12 Center exhaust pipe Tightening torque N m kgf m ft lb 5 Front catalytic converter 13 Spring T1 8 0 8 5 8 6 Upper front catalytic converter cover 14...

Page 793: ...EX H4SOw oOBD 6 EXHAUST GENERAL DESCRIPTION 3 WITHOUT CATALYTIC CONVERTER EX 00100 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 16 16 T2 T4 T4 T4 T5 T5 T1 T6 T3...

Page 794: ...er front exhaust pipe cover 10 Gasket T1 8 0 8 5 8 3 Front exhaust pipe 11 Cushion rubber T2 13 1 3 9 4 4 Upper center exhaust pipe cover 12 Muffler T3 18 1 8 13 0 5 Lower center exhaust pipe cover 13...

Page 795: ...m from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands beca...

Page 796: ...front exhaust pipe onto cylinder heads CAUTION Be careful not to pull down front and center ex haust pipe assembly 7 Remove bolt which installs front and center ex haust pipe assembly to hanger bracke...

Page 797: ...which hold front exhaust pipe onto cylinder heads Tightening torque 30 N m 3 1 kgf m 22 4 ft lb 5 Tighten bolts which install front and center ex haust pipe assembly to rear exhaust pipe Tightening to...

Page 798: ...H4SOw oOBD 11 EXHAUST FRONT EXHAUST PIPE 10 Connect battery ground cable C INSPECTION 1 Make sure there are no exhaust leaks from con nections and welds 2 Make sure there are no holes or rusting FU 00...

Page 799: ...re for removing the front exhaust pipe Ref to EX H4SOw oOBD 9 Removal B INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit Refer to the procedure for install ing the front...

Page 800: ...down rear exhaust pipe 3 Remove rear exhaust pipe B INSTALLATION NOTE Replace gaskets with new ones 1 Install rear exhaust pipe to muffler Tightening torque 48 N m 4 9 kgf m 35 4 ft lb 2 Install rear...

Page 801: ...o 004301003 3 Remove front rubber cushion and detach muf fler assembly NOTE To facilitate removal apply a coat of SUBARU CRC to mating area of rubber cushion in advance SUBARU CRC Part No 004301003 B...

Page 802: ...COOLING CO H4SOw oOBD Page 1 General Description 2...

Page 803: ...CO H4SOw oOBD 2 COOLING GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to CO H4SO 2 General Description...

Page 804: ...LUBRICATION LU H4SOw oOBD Page 1 General Description 2...

Page 805: ...LU H4SOw oOBD 2 LUBRICATION GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to LU H4SO 2 General Description...

Page 806: ...SPEED CONTROL SYSTEMS SP H4SOw oOBD Page 1 General Description 2...

Page 807: ...H4SOw oOBD 2 SPEED CONTROL SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATION Specification of model without OBD is the same as that of model with OBD Ref to SP H4SO 2 General Descripti...

Page 808: ...IGNITION IG H4SOw oOBD Page 1 General Description 2 2 Spark Plug 5 3 Ignition Coil and Ignitor Assembly 8 4 Spark Plug Cord 10...

Page 809: ...0 73 10 Secondary coil resistance 12 8 k 15 Insulation resistance between primary terminal and case More than 100 M Spark plug Type and manufacturer Without catalytic con verter BKR6E NGK With cataly...

Page 810: ...ION GENERAL DESCRIPTION B COMPONENT 1 Spark plug 4 Spark plug cord 2 4 Tightening torque N m kgf m ft lb 2 Spark plug cord 1 3 T1 21 2 1 15 3 Ignition coil and ignitor ASSY T2 6 4 0 65 4 7 IG 00036 T2...

Page 811: ...em from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands bec...

Page 812: ...O 8 REMOVAL Resonator Chamber 3 Remove spark plug cords by pulling boot not cord itself 4 Remove spark plugs with the spark plug socket 2 LH SIDE 1 Disconnect battery ground cable 2 Disconnect washer...

Page 813: ...bove torque should be only applied to new spark plugs without oil on their threads In case their threads are lubricated the torque should be reduced by approximately 1 3 of the specified torque in ord...

Page 814: ...iming loose spark plugs wrong selection of fuel hotter range plug etc It is advisable to replace with plugs having colder heat range D CLEANING Clean spark plugs in a sand blast type cleaner Avoid exc...

Page 815: ...order of removal Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb CAUTION Be sure to connect wires to their proper posi tions Failure to do so will damage unit C INSPECTION Using accurate tester inspect...

Page 816: ...H4SOw oOBD 9 IGNITION IGNITION COIL AND IGNITOR ASSEMBLY Secondary side Between A and B 12 8 k 15 Between C and D 12 8 k 15 3 Insulation between primary terminal and case 100 M or more IG 00039 C A D...

Page 817: ...G CORD 4 Spark Plug Cord A INSPECTION Check for 1 Damage to cords deformation burning or rust formation of terminals 2 Resistance values of cords Resistance value 1 cord 5 6 10 6 2 cord 7 3 13 7 3 cor...

Page 818: ...STARTING CHARGING SYSTEMS SC H4SOw oOBD Page 1 General Description 2...

Page 819: ...SOw oOBD 2 STARTING CHARGING SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to SC H4SO 2 General Descri...

Page 820: ...Signal 18 6 Subaru Select Monitor 21 7 Read Diagnostic Trouble Code DTC 24 8 Inspection Mode 26 9 Clear Memory Mode 28 10 Compulsory Valve Operation Check Mode 29 11 Engine Malfunction Indicator Lamp...

Page 821: ...elect Monitor switch to ON 4 Read DTC on the Subaru Select Monitor Ref to EN H4SOw oOBD 24 WITH SUBARU SELECT MONITOR OPERA TION Read Diagnostic Trouble Code DTC Does the Subaru Select Monitor indicat...

Page 822: ...al Diag nostic Table Ref to EN H4SOw oOBD 102 INSPECTION General Diagnos tic Table 3 CHECK INDICATION OF DTC ON MIL 1 Perform the read diagnostic trouble code read memory mode Ref to EN H4SOw oOBD 24...

Page 823: ...s Others Outdoor temperature F C Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine...

Page 824: ...tion of fuel gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of parts...

Page 825: ...less than 0 64 mm 0 025 in Do not insert the pin more than 5 mm 0 20 in into the part 6 Before removing ECM from the located position disconnect two cables on battery Otherwise the ECM may be damaged...

Page 826: ...s tem B INSPECTION Before performing diagnostics check the following items which might affect engine problems 1 BATTERY 1 Measure battery voltage and specific gravity of electrolyte Standard voltage 1...

Page 827: ...KS 24082AA210 Newly adopted tool CARTRIDGE Troubleshooting for electrical systems 22771AA030 SELECT MONI TOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771A...

Page 828: ...ATION 4 Electrical Components Location A LOCATION 1 MODULE LHD model RHD model 1 Engine control module ECM 3 Read memory connector 5 Data link connector 2 CHECK ENGINE malfunction indi cator lamp MIL...

Page 829: ...EN H4SOw oOBD 10 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00845 1 EN 01016 2 3 4 EN 01015 EN 01017 5...

Page 830: ...ONENTS LOCATION 2 SENSOR 1 Engine coolant temperature sen sor 3 Throttle position sensor 7 Vehicle speed sensor 4 Knock sensor 2 Intake air temperature and pres sure sensor 5 Crankshaft position senso...

Page 831: ...EN H4SOw oOBD 12 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 01019 1 EN 01023 2 EN 01020 3 4 EN 01024 5 EN 01021 6 EN 01025 EN 01022 7...

Page 832: ...EN H4SOw oOBD 13 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 8 Oxygen sensor With catalyst model EN 01026 8 EN 01027 8...

Page 833: ...COMPONENTS LOCATION 3 SOLENOID VALVE EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 Purge control solenoid valve 3 Ignition coil and ignitor ASSY 4 CO resistor Without catalyst model 2 Idl...

Page 834: ...EN H4SOw oOBD 15 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 01029 EN 01031 2 EN 01030 3 EN 01032 4...

Page 835: ...EN H4SOw oOBD 16 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION LHD model RHD model 1 Fuel pump 2 Main relay 3 Fuel pump relay EN 01033 1 2 3 4 5 EN 01034 1 2 3 5 4...

Page 836: ...EN H4SOw oOBD 17 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 01035 1 EN 01037 2 EN 01036 3...

Page 837: ...l A ELECTRICAL SPECIFICATION To 17 30 14 28 16 18 31 15 29 8 23 35 22 34 7 8 23 20 22 11 21 12 10 2 3 1 9 17 14 28 19 16 13 27 18 15 262524 6 4 7 5 8 23 22 11 21 12 10 24 2 3 1 9 B134 To B135 20 33 19...

Page 838: ...ol ant temper ature sensor Signal B136 14 0 6 1 0 0 6 1 0 After warm up GND B136 16 0 0 Vehicle speed sensor B135 24 0 or 5 0 or 5 5 and 0 are repeatedly displayed when vehicle is driven Starter switc...

Page 839: ...diator fan relay 2 con trol B134 12 ON 0 OFF 10 13 ON 0 OFF 13 14 Self shutoff control B135 19 10 13 13 14 Malfunction indicator lamp B134 11 Light ON 1 max Light OFF 10 14 Engine speed output B134 30...

Page 840: ...ble code s and various data then record them 2 READ DIAGNOSTIC TROUBLE CODE DTC FOR ENGINE Refer to Read Diagnostic Trouble Code for infor mation about how to indicate DTC Ref to EN H4SOw oOBD 24 Read...

Page 841: ...1 Ignition switch signal ON or OFF Automatic transmission vehicle identification signal ON or OFF Test mode connector signal ON or OFF Neutral position switch signal ON or OFF Air conditioning switch...

Page 842: ...FF When knocking signal is entered Radiator fan relay signal 2 ON or OFF When radiator fan relay 2 is in function Engine torque control signal 1 ON or OFF When torque control signal 1 is entered Torqu...

Page 843: ...nostic trouble codes refer to the List of Diagnostic Trouble Code DTC Ref to EN H4SOw oOBD 57 LIST List of Diagnostic Trouble Code DTC 2 WITHOUT SUBARU SELECT MONITOR Step Value Yes No 1 CHECK STATUS...

Page 844: ...seconds ON signifies one And middle segment 0 5 seconds ON means OK code NOTE For detailed concerning diagnostic trouble codes refer to the List of Diagnostic Trouble Code DTC Ref to EN H4SOw oOBD 57...

Page 845: ...ear them Also make sure that nobody goes in front of the vehicle 2 WITH SUBARU SELECT MONITOR After performing diagnostics and clearing the mem ory check for any remaining unresolved trouble da ta 1 C...

Page 846: ...tor green 5 Turn ignition switch to ON Does the MIL come on MIL illuminates Go to step 2 Check the follow ing and repair if necessary NOTE Open or short circuit in engine control module power supply o...

Page 847: ...UNCTION INDICATOR LAMP MIL 1 Turn ignition switch to OFF 2 Set shift lever to neutral position MT vehi cles or set selector lever to P position AT vehicles 3 Connect test mode connector and read memor...

Page 848: ...side to the side of the center console box 2 Each valve functions when ignition switch is turned to ON engine OFF A list of the support portion is shown in the follow ing table A Test mode connector...

Page 849: ...Ow oOBD 30 ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP MIL Engine Malfunction Indicator Lamp MIL 2 Check engine malfunction indicator lamp MIL does not come on Ref to EN H4SOw oOBD 31 CHECK...

Page 850: ...1 V Go to step 4 Go to step 2 EN 01043 IGNITION RELAY SBF 4 No 5 SBF 1 A4 4 1 B157 B72 B134 B36 i1 IGNITION SWITCH B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B...

Page 851: ...combi nation meter con nector Poor contact in coupling connector 5 CHECK POOR CONTACT Check poor contact in combination meter con nector Ref to IDI 14 Combination Meter Assembly Is there poor contact...

Page 852: ...OOR CONTACT Check poor contact in combination meter con nector Ref to IDI 14 Combination Meter Assembly Is there poor contact in combination meter connector There is poor contact Repair poor con tact...

Page 853: ...ombina tion meter and ECM connector Replace ECM Ref to FU H4SOw oOBD 42 Engine Control Module EN 01043 IGNITION RELAY SBF 4 No 5 SBF 1 A4 4 1 B157 B72 B134 B36 i1 IGNITION SWITCH B36 B4 B5 B6 A4 A5 A6...

Page 854: ...1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 855: ...1 Is the measured value less than the speci fied value 1 Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit in harness between ECM and test mode connector 4...

Page 856: ...1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25...

Page 857: ...1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between ECM connector and engine ground Connector terminal B135 No 14 Engine ground Is the measured value...

Page 858: ...d ground line Ref to EN H4SOw oOBD 43 CONTROL MODULE POWER SUPPLY AND GROUND LINE Diagnostics for Engine Starting Failure 3 Inspection of ignition control system Ref to EN H4SOw oOBD 46 IGNITION CONTR...

Page 859: ...Inspection Mode WIRING DIAGRAM Step Value Yes No 1 CHECK OPERATION OF STARTER MOTOR Does starter motor operate when the switch starts Starter motor operates Go to step 2 Go to step 3 EN 01045 12 INHI...

Page 860: ...Does the measured value exceed the spec ified value 10 V Go to step 4 Go to step 5 4 CHECK GROUND CIRCUIT OF STARTER MOTOR 1 Turn ignition switch to OFF 2 Disconnect terminal from starter motor 3 Mea...

Page 861: ...tween ignition switch and starter motor circuit 10 CHECK INHIBITOR SWITCH CIRCUIT 1 Turn ignition switch to OFF 2 Place the selector lever in the P or N position 3 Separate transmission harness connec...

Page 862: ...1 B19 C2 E3 B22 A8 A7 A27 C22 C21 B6 B25 13 15 14 16 B47 BATTERY MAIN RELAY 1 2 3 5 4 6 F44 B61 SBF 5 6 LHD RHD RHD SBF 4 SBF 1 4 1 B72 IGNITION SWITCH ECM B134 A B135 B B136 C 5 6 7 8 2 1 9 4 3 10 24...

Page 863: ...to step 3 Repair open circuit in harness between ECM connector and engine grounding terminal 3 CHECK INPUT VOLTAGE OF ECM Measure voltage between ECM connector and chassis ground Connector terminal B...

Page 864: ...tor terminal B47 No 1 Chassis ground Is the measured value less than the speci fied value 5 Go to step 9 Repair open circuit between main relay and chassis ground 9 CHECK INPUT VOLTAGE OF MAIN RELAY M...

Page 865: ...w oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspection Mode WIRING DIAGRAM EN 01047 26 25 B134 B72 3 4 1 2 3 4 1 2 E12 B22 1 2 3 4 5 6 7 8 13 14 15 16 9 10 11 12 6 5 4...

Page 866: ...se repair the following Open circuit or ground short in harness between ignition coil igni tor assembly and ignition switch connector Poor contact in couplingconnector B22 3 CHECK HARNESS OF IGNITION...

Page 867: ...ignition coil ignitor assembly connector Connector terminal B134 No 26 E12 No 4 Is the measured value less than the speci fied value 1 Go to step 9 Repair harness and connector NOTE In this case repa...

Page 868: ...d Does the measured value exceed the specified value 1 M Go to step 12 Repair ground short circuit in har ness between ECM and ignition coil ignitor assembly connec tor 12 CHECK POOR CONTACT Check poo...

Page 869: ...N Inspection Mode WIRING DIAGRAM EN 01048 FUEL PUMP RELAY SBF 4 SBF 1 SBF 5 No 13 4 1 B46 B72 IGNITION SWITCH BATTERY 4 3 1 2 No 11 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 870: ...his case repair the following Open circuit in harness between fuel pump connec tor and chassis grounding terminal Poor contact in couplingconnector R57 and R1 3 CHECK POWER SUPPLY TO FUEL PUMP 1 Turn...

Page 871: ...FUEL PUMP RELAY CONNECTOR 1 Disconnect connectors from ECM 2 Measure resistance of harness between ECM and fuel pump relay connector Connector terminal With cruise control B134 No 29 B46 No 3 Without...

Page 872: ...wdriver to injector for this check Is the fuel injector emits operating sound Fuel injector emits operating sound Check fuel pres sure Ref to ME H4SO 28 INSPECTION Fuel Pressure Go to step 2 EN 01049...

Page 873: ...voltage between the fuel injector terminal and engine ground Connector terminal 2 E16 No 2 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 4 Repair harness and conne...

Page 874: ...AND FUEL INJECTOR CONNECTOR 1 Disconnect connector from ECM 2 Measure resistance of harness between ECM and fuel injector connector Connector terminal B134 No 4 B136 No 2 Is the measured value within...

Page 875: ...is ground Is the measured value less than the specified value 1 Repair ground short circuit in har ness between ECM and fuel injector connector Go to step 13 13 CHECK HARNESS BETWEEN ECM AND FUEL INJE...

Page 876: ...is abnor mal The harness connector between ECM and knock sensor is in short or open Ref to EN H4SOw oOBD 71 DTC 22 KNOCK SENSOR Diagnostic Procedure with Diagnostic Trouble Code DTC 24 Idle air contr...

Page 877: ...s abnormal The harness connector between ECM and CO resistor is in short or open The CO valve is not adjusted to specification Ref to EN H4SOw oOBD 93 DTC 46 CO RESISTOR GENERAL SPEC VEHICLES Diagnost...

Page 878: ...ine stalls Restarting impossible CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw o...

Page 879: ...ured value within the specified value 1 5 k Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit in harness between crankshaft posi tion sensor and ECM connect...

Page 880: ...ERATION Inspection Mode 4 Read out the trouble code Ref to EN H4SOw oOBD 24 OPERATION Read Diagnostic Trouble Code DTC Is the same trouble code DTC as in the current diagnosis still being output DTC i...

Page 881: ...4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspection Mode WIRING DIAGRAM Step Value Yes No 1 CHECK OPERATION OF STARTER MOTOR Does starter motor operate when igni...

Page 882: ...Disconnect connector from ECM 3 Turn ignition switch to ST 4 Measure power supply voltage between ECM connector and chassis ground Connector terminal B135 No 28 Chassis ground Does the measured value...

Page 883: ...engine to start CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATIO...

Page 884: ...fied value 1 5 k Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit in harness between camshaft position sensor and ECM connector Poor contact in couplingcon...

Page 885: ...OPERATION Inspection Mode 4 Read out the trouble code Ref to EN H4SOw oOBD 24 OPERATION Read Diagnostic Trouble Code DTC Is the same trouble code DTC as in the current diagnosis still being output DT...

Page 886: ...rroneous idling Poor driving performance CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN...

Page 887: ...ignition switch to ON 2 Measure voltage between engine coolant temperature sensor connector and engine ground Connector terminal E8 No 1 Engine ground Does the measured value exceed the spec ified va...

Page 888: ...ector Poor contact in couplingconnector B21 Poor contact in sensor ground joint connector B83 5 CHECK ENGINE COOLANT TEMPERATURE SENSOR 1 Remove engine coolant temperature sen sor 2 Immerse sensor in...

Page 889: ...URE SENSOR 1 Raise temperature up to approx 90 C 194 F CAUTION Be careful not to burn yourself 2 Measure resistance between engine cool ant temperature sensor terminals Terminals No 1 No 2 Is the meas...

Page 890: ...rmance CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspecti...

Page 891: ...or Ref to FU w oOBD Knock Sensor 4 CHECK HARNESS CONNECTOR BETWEEN ECM AND KNOCK SENSOR 1 Remove ECM connector 2 Measure resistance of harness connector between ECM and knock sensor Connector terminal...

Page 892: ...f faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspection Mode WIRING DIAGRAM EN 01054 5 6 19 20 B2...

Page 893: ...or NOTE In this case repair the following Open circuit in harness between ECM and idle air control solenoid valve connector Poor contact in couplingconnector B21 3 CHECK HARNESS BETWEEN ECM AND IDLE A...

Page 894: ...es in by pass air line Are foreign particles in by pass air line Foreign particles in by pass air line Remove foreign particles from by pass air line Replace idle air control solenoid valve Ref to FU...

Page 895: ...driving performance CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ER...

Page 896: ...sconnect connector from ECM 2 Measure resistance of harness connector between ECM and intake air temperature sensor connector Connector terminal B136 No 15 E20 No 3 Is the measured value less than the...

Page 897: ...he measured value exceed the specified value 1 M Go to step 7 Repair ground short circuit in har ness between ECM and idle air control solenoid valve connector 7 CHECK POOR CONTACT Check poor contact...

Page 898: ...oneous idling Engine stalls Poor driving performance CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode a...

Page 899: ...M AT vehi cle 2 Measure resistance between ECM and chassis ground Connector terminal B136 No 16 Chassis ground B136 No 17 Chassis ground B136 No 15 Chassis ground Does the measured value exceed the sp...

Page 900: ...is out of specifications CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26...

Page 901: ...sensor Connector terminal B18 No 2 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 4 Repair open circuit between main relay and oxygen sensor 4 CHECK HARNESS CONNECT...

Page 902: ...PUT VOLTAGE FOR ECM 1 Turn ignition switch OFF 2 Warm up engine until coolant temperature exceed 70 C 158 F and idle 3 Set plus probe to ECM connector termi nal and set minus probe to chassis ground C...

Page 903: ...157 B17 B56 B36 i10 B22 B135 BATTERY E4 13 24 ECM COMBINATION METER VEHICLE SPEED SENSOR 3 1 2 B17 B135 17 TCM B56 IGNITION RELAY No 5 B157 B22 E3 16 MT AT 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 904: ...Repair poor con tact in ECM Replace ECM Ref to FU H4SOw oOBD 42 Engine Control Module 4 CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR Measure voltage between ECM and chassis ground Connec...

Page 905: ...repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspection Mode WIRING DIAGR...

Page 906: ...lve 4 Turn ignition switch to ON 5 Measure voltage between ECM and chas sis ground Connector terminal B134 No 2 Chassis ground Does the measured value exceed the spec ified value 10 V Repair battery s...

Page 907: ...his case repair the following Open circuit in harness between main relay and purge control sole noid valve connec tor Poor contact in main relay con nector Poor contact in couplingconnector B22 7 CHEC...

Page 908: ...in short CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspec...

Page 909: ...Chassis ground Is the measured value less than the speci fied value 10 Repair ground short circuit in har ness between ECM and TCM connector Go to step 2 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR...

Page 910: ...CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspection Mode...

Page 911: ...r terminal B136 No 5 Chassis ground B136 No 16 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair ground short circuit in har ness between ECM and pressure senso...

Page 912: ...ifications TROUBLE SYMPTOM Erroneous idling Mixture ratio is too rich or too lean CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28...

Page 913: ...2 B136 No 16 B155 No 3 Is the measured value less than the speci fied value 1 Go to step 4 Repair open circuit in harness between ECM and CO resistor con nector 4 CHECK HARNESS BETWEEN CO RESIS TOR AN...

Page 914: ...short or open TROUBLE SYMPTOM Erroneous idling CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref...

Page 915: ...ION SWITCH 1 Turn ignition switch to OFF 2 Select MT shift lever to neutral position 3 Disconnect connector from transmission harness 4 Measure resistance between transmission harness and connector te...

Page 916: ...minal B135 No 26 Chassis ground Is the measured value less than the specified value 10 Repair ground short circuit in har ness between ECM and trans mission harness connector Go to step 8 8 CHECK POOR...

Page 917: ...in short or open TROUBLE SYMPTOM Erroneous idling CAUTION After repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and...

Page 918: ...ss between ECM and inhibitor switch connector Poor contact in couplingconnector B12 Poor contact in inhibitor switch connector Poor contact in ECM connector 4 CHECK HARNESS BETWEEN ECM AND TRANSMISSIO...

Page 919: ...repair or replacement of faulty parts conduct CLEAR MEMORY and INSPECTION MODES Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OP ERATION Inspection Mode WIRING DIAGR...

Page 920: ...4 CHECK INPUT VOLTAGE OF ECM 1 Run the engine at idle 2 Measure voltage between ECM connector and chassis ground Connector terminal B136 No 1 Chassis ground B136 No 2 Chassis ground Is the measured va...

Page 921: ...start internal combustion occurs 1 ECM power supply 2 Spark plug 3 Engine coolant temperature sensor 4 Pressure regulator 5 Pressure sensor 6 Fuel pump 7 Fuel injector 8 Camshaft position sensor 9 Cr...

Page 922: ...gnition coil 4 Fuel pump 5 Pressure regulator 6 Fuel injector 7 Pressure sensor 8 Engine coolant temperature sensor 9 Idle air control solenoid valve 10 Knock sensor A B B B B B C C C C 8 Poor return...

Page 923: ...RAL DIAGNOSTIC TABLE A Including ECM ground circuit B Check hoses 14 Remarks 1 ECM power supply 2 Pressure sensor 3 Pressure regulator 4 Idle air control solenoid valve 5 Air leak in air intake system...

Page 924: ...this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBAR...

Page 925: ......

Page 926: ...dle Air Control Solenoid Valve 36 12 Induction Valve 37 13 Induction Valve Control Solenoid 38 14 Fuel Injector 39 15 Front Oxygen A F Sensor 43 16 Rear Oxygen Sensor 45 17 Engine Control Module 46 18...

Page 927: ...NS Model Fuel tank Capacity 64 2 16 9 US gal 14 1 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 370 677 kPa 3 77 6 9 kg cm2 53 6 98 psi Discharge flow More than 8...

Page 928: ...FU H6DO 3 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION MEMO...

Page 929: ...FUEL SYSTEMS GENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD FU 00531 1 1 2 2 2 2 2 2 3 4 4 5 6 6 7 8 9 10 10 11 11 12 13 14 15 15 15 16 17 18 19 T2 T2 T2 T4 T4 T5 T5 T5 T5 T4 T4 T4 T4 T4 T1 T1 T4 T...

Page 930: ...ing torque N m kgf m ft lb 4 Air assist hose 13 Induction valve control solenoid T1 6 4 0 65 4 7 5 Air assist and purge pipe ASSY 14 EGR valve T2 5 0 0 51 3 7 6 Gasket 15 Gasket T3 17 1 7 12 7 Purge c...

Page 931: ...TION 2 FUEL INJECTOR 1 Fuel injector pipe LH 5 Insulator Tightening torque N m kgf m ft lb 2 Pressure regulator 6 Fuel injector T1 6 4 0 65 4 7 3 O ring 7 Fuel injector pipe RH T2 19 1 9 14 4 Injectio...

Page 932: ...IR INTAKE SYSTEM 1 Gasket 5 O ring Tightening torque N m kgf m ft lb 2 Intake manifold pressure sensor 6 Throttle body T1 1 6 0 16 1 2 3 Idle air control solenoid valve T2 2 8 0 29 2 1 4 Throttle posi...

Page 933: ...RIPTION 4 CRANKSHAFT POSITION CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 3 Knock sensor RH Tightening torque N m kgf m ft lb 2 Knock sensor LH 4 Camshaft position sensor T1 6 4 0...

Page 934: ...FU H6DO 9 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION MEMO...

Page 935: ...ECTION FUEL SYSTEMS GENERAL DESCRIPTION 5 FUEL TANK FU 00626 1 2 2 3 4 5 6 7 8 9 31 33 37 38 36 30 34 11 10 12 13 14 14 14 15 16 17 18 19 20 26 24 25 23 32 21 22 21 27 30 30 30 35 29 28 T3 T3 T3 T3 T1...

Page 936: ...pump plate 21 Quick connector 36 Seal 7 Fuel pump ASSY 22 Jet pump hose B 37 Fuel pump holder 8 Fuel level sensor 23 Fuel sub level sensor gasket 38 Grommet 9 Fuel filter 24 Jet pump filter 10 Fuel p...

Page 937: ...FU H6DO 12 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 6 FUEL LINE FU 00696 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 28 27 26 25 24 23 T1 T2 T2...

Page 938: ...er bracket spacer 4 Clip 15 Two way valve drain hose 26 Cushion 5 Fuel pipe ASSY 16 Drain hose 27 Canister bracket plate 6 Grommet 17 Fuel pipe connector 28 Evaporation hose D 7 Evaporation hose A 18...

Page 939: ...STEMS GENERAL DESCRIPTION 7 FUEL FILLER PIPE 1 Fuel filler pipe ASSY 5 Filler ring Tightening torque N m kgf m ft lb 2 Clip 6 Filler cap T 7 4 0 75 5 4 3 Clamp 7 Filler pipe protector 4 Filler pipe pa...

Page 940: ...hicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical conne...

Page 941: ...rom intake manifold pressure sensor A and idle air control solenoid valve B 6 Disconnect air by pass hose C from idle air control solenoid valve 7 Disconnect throttle position sensor connector 8 Disco...

Page 942: ...DO 6 REMOVAL Air Intake Chamber 5 Disconnect accelerator cable A 6 Disconnect cruise control cable B With cruise control model 7 Remove power steering pump and tank from brackets 1 Remove V belt Ref t...

Page 943: ...dow washer motor 10 Disconnect connector from rear gate glass washer motor 11 Disconnect rear window glass washer hose from washer motor then plug connection with a suitable cap 12 Move washer tank up...

Page 944: ...ngine ground terminal from intake manifold 19 Disconnect fuel hoses from fuel pipes WARNING Do not spill fuel Catch fuel from hoses in a container or cloth 20 Remove ground cable from fuel pipe protec...

Page 945: ...A Remove the bolt B which holds fuel injector pipe RH onto cylinder head 27 Remove bolts which holds intake manifold onto cylinder heads 28 Remove intake manifold B INSTALLATION 1 Install intake mani...

Page 946: ...round cable to fuel pipe protector RH 6 Install the bolt B which holds fuel injector pipe LH onto cylinder head Tightening torque 19 N m 1 9 kgf m 14 ft lb 7 Connect air assist hose A 8 Install fuel p...

Page 947: ...ors to bulk head connectors 14 Connect brake booster hose 15 Connect engine coolant hose to throttle body 16 Connect PCV hose to cylinder head cover 17 Install power steering pump and tank on brack et...

Page 948: ...otor connector 20 Connect rear window washer motor connector 21 Install washer tank on body 22 Connect accelerator cable A 23 Connect cruise control cable B With cruise control models 24 Install air i...

Page 949: ...3 Disconnect air by pass hose C from idle air control solenoid valve 4 Remove throttle body 5 Remove induction valve 6 Disconnect connector from induction valve con trol solenoid 7 Remove induction v...

Page 950: ...Disconnect pressure regulator vacuum hose A from intake manifold 16 Remove fuel pipe and injector pipe assembly 17 Remove induction valve vacuum hose from in take manifold D ASSEMBLY 1 Intake inductio...

Page 951: ...Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 6 Install engine harness assembly to intake mani fold Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb 7 Install EGR valve Tightening torque 19 N m 1 9 kg...

Page 952: ...19 N m 1 9 kgf m 14 ft lb 15 Connect hoses to induction valve control sole noid CAUTION Carefully connect the vacuum hoses 16 Install throttle body to intake manifold NOTE Replace gasket with a new on...

Page 953: ...FU H6DO 28 FUEL INJECTION FUEL SYSTEMS INTAKE MANIFOLD 19 Connect air by pass hose C to idle air control solenoid valve FU 00537 A B C...

Page 954: ...mperature Sensor A REMOVAL 1 Disconnect battery ground cable 2 Disconnect connector from engine coolant tem perature sensor 3 Remove engine coolant temperature sensor B INSTALLATION Install in the rev...

Page 955: ...e engine harness bracket from intake manifold 4 Remove service hole cover 5 Remove bolt which install crankshaft position sensor to cylinder block 6 Remove crankshaft position sensor and discon nect c...

Page 956: ...eaner 3 Remove ground cable from fuel pipe protector RH 4 Remove fuel pipe protector RH 5 Disconnect connector from camshaft position sensor 6 Remove camshaft position sensor B INSTALLATION Install in...

Page 957: ...sensor connector 4 Remove knock sensor from cylinder block B INSTALLATION 1 Install knock sensor to cylinder block Tightening torque 25 N m 2 5 kgf m 18 ft lb NOTE For the knock sensor s installation...

Page 958: ...ve air intake chamber Ref to IN H6DO 6 REMOVAL Air Intake Chamber 3 Disconnect connector from throttle position sen sor 4 Remove throttle position sensor holding screws and remove throttle position se...

Page 959: ...Disconnect battery ground cable 2 Disconnect connector from intake manifold pres sure sensor 3 Remove intake manifold pressure sensor from throttle body B INSTALLATION Install in the reverse order of...

Page 960: ...Intake Air Temperature Sen sor A REMOVAL 1 Disconnect battery ground cable 2 Disconnect connector from intake air tempera ture sensor 3 Remove intake air temperature sensor from air intake chamber B...

Page 961: ...2 Disconnect connector A from idle air control solenoid valve 3 Disconnect air by pass hose B from idle air control solenoid valve 4 Remove idle air control solenoid valve from throttle body B INSTALL...

Page 962: ...1 Disconnect battery ground cable 2 Remove intake manifold Ref to FU H6DO 17 REMOVAL Intake Mani fold 3 Remove induction valve from intake manifold B INSTALLATION Install in the reverse order of remov...

Page 963: ...ound cable 2 Remove intake manifold Ref to FU H6DO 17 REMOVAL Intake Mani fold 3 Disconnect connector from induction valve con trol solenoid 4 Remove induction valve control solenoid from in take mani...

Page 964: ...5 REMOVAL Air Cleaner 5 Remove power steering pump and tank from brackets 1 Remove V belt Ref to ME H6DO 28 REMOVAL V belt 2 Remove power steering oil pipe with brack et 3 Remove bolts which install p...

Page 965: ...g up fuel injector pipe 2 LH SIDE 1 Release fuel pressure Ref to FU H6DO 50 RELEASING OF FUEL PRESSURE OPERA TION Fuel 2 Open fuel flap lid and remove fuel filler cap 3 Disconnect battery ground cable...

Page 966: ...lds injector pipe onto cylinder head 13 Remove fuel injector while lifting up fuel injector pipe B INSTALLATION 1 RH SIDE Install in the reverse order of removal NOTE Replace O rings and insulators wi...

Page 967: ...all in the reverse order of removal NOTE Replace O rings and insulators with new ones Tightening torque 19 N m 1 9 kgf m 14 ft lb Tightening torque 19 N m 1 9 kgf m 14 ft lb A O ring B Injection rubbe...

Page 968: ...ss from clip A LH side RH side 6 Apply SUBARU CRC or its equivalent to thread ed portion of front oxygen A F sensor and leave it for one minute or more SUBARU CRC Part No 004301003 7 Remove front oxyg...

Page 969: ...nti seize compound SS 30 by JET LUBE CAUTION Never apply anti seize compound to protector of front oxygen A F sensor 2 Install front oxygen A F sensor Tightening torque 21 N m 2 1 kgf m 15 2 ft lb 3 S...

Page 970: ...oxygen sen sor in an unnatural way especially when ex haust pipe is cold otherwise it will damage exhaust pipe B INSTALLATION 1 Before installing rear oxygen sensor apply anti seize compound only to...

Page 971: ...ner Trim 3 Detach floor mat of front passenger seat 4 Remove protect cover 5 Remove nuts which hold ECM to bracket 6 Remove clip from bracket 7 Disconnect ECM connectors and take out ECM B INSTALLATIO...

Page 972: ...sconnect battery ground cable 2 Remove lower inner trim of passenger side Ref to EI 39 REMOVAL Lower Inner Trim 3 Disconnect connectors from main relay 4 Remove bolt which holds main relay bracket on...

Page 973: ...REMOVAL 1 Disconnect battery ground cable 2 Remove lower cover Ref to EI 35 REMOV AL Instrument Panel Assembly 3 Disconnect connector from fuel pump relay 4 Remove fuel pump relay from mounting brack...

Page 974: ...ntroller A REMOVAL 1 Disconnect battery ground cable 2 Remove rear quarter Trim Ref to EI 40 RE MOVAL Rear Quarter Trim 3 Disconnect connector from fuel pump control unit 4 Remove fuel pump control un...

Page 975: ...2 DRAINING FUEL WARNING Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Set vehicle on the lift 2 Disconnect battery ground cable 3 Lift up the vehicle 4 Remove f...

Page 976: ...l tank by using hand pump WARNING Do not use a motor pump when draining fuel 13 After draining fuel reinstall fuel sub level sen sor Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb NOTE If you have not...

Page 977: ...FU H6DO 52 FUEL INJECTION FUEL SYSTEMS FUEL 3 Install sub service hole cover 4 Set rear seat and floor mat FU 00445...

Page 978: ...A and return hose B Ref to FU H6DO 73 REMOV AL Fuel Delivery Return and Evaporation Lines 8 Remove parking brake cable 1 Remove console box Ref to EI 34 RE MOVAL Console Box 2 Remove parking brake br...

Page 979: ...5 Disconnect connector from ABS sensor 16 Remove bolts which hold parking brake cable holding bracket 17 Remove parking brake cable from cabin by forcibly pulling it backward 18 Remove bolts which hol...

Page 980: ...ody 4 Remove rear suspension assembly 22 Remove rear side fuel tank cover 23 Disconnect two way valve hose A from two way valve and disconnect evaporation hose B from evaporation pipe 24 Loosen clamp...

Page 981: ...ds WARNING A helper is required to perform this work 3 Connect two way valve hose A to two way valve and connect evaporation hose B to evapo ration pipe 4 Connect fuel filler hose A and air vent hose...

Page 982: ...ft lb T3 66 N m 6 7 kgf m 48 ft lb 2 Tighten bolt which holds rear shock absorb er to rear suspension arm Ref to RS 14 IN STALLATION Link Upper Tightening torque 157 N m 16 kgf m 116 ft lb 8 Install r...

Page 983: ...all rear exhaust pipe and muffler NOTE To facilitate the procedure apply a coat of SUBA RU CRC to matching area of rubber cushions in ad vance SUBARU CRC Part No 004301003 1 Install left and right rub...

Page 984: ...A TION Fuel Delivery Return and Evaporation Lines 22 Connect fuel jet pump hose 23 Connect connector to fuel sub level sensor 24 Install sub service hole cover 25 Connect connectors to fuel tank cord...

Page 985: ...wheel alignment and adjust if neces sary Ref to FS 6 INSPECTION Wheel Align ment C INSPECTION 1 Make sure there are no cracks holes or other damage on the fuel tank 2 Make sure that the fuel hoses and...

Page 986: ...he screws holding packing in place 5 Lift up the vehicle 6 Remove the rear right side wheel nuts 7 Remove the wheel RH Rear 8 Remove the protector RH Front 9 Drain fuel from fuel tank Set a container...

Page 987: ...the clip and then separate the air vent hose B 16 Remove the fuel filler pipe to under side of the vehicle B INSTALLATION 1 Hold the fuel filler flap open 2 Set the fuel saucer A with rubber packing...

Page 988: ...ox 25 to 30 mm 0 98 to 1 18 in into the lower end of air vent pipe and hold clip L 27 5 2 5 mm 1 083 0 098 in 6 Tighten the bolt which holds fuel filler pipe brack et on body Tightening torque 7 4 N m...

Page 989: ...FU H6DO 64 FUEL INJECTION FUEL SYSTEMS FUEL FILLER PIPE 12 Connect the connector to fuel pump relay A 13 Connect the battery ground cable to battery FU 00431 FU 00009...

Page 990: ...fuel filler cap 3 Disconnect the ground cable from battery 4 Lift up the vehicle 5 Remove the protector RH Front 6 Drain the fuel from fuel tank Set a container un der the vehicle and then remove the...

Page 991: ...phabetical sequence shown in the figure to specified torque Tightening torque 5 9 N m 0 6 kgf m 4 3 ft lb C DISASSEMBLY 1 Remove the fuel pump and pump holder NOTE When disassembling the pump holder b...

Page 992: ...he fuel pump assembly Ref to FU H6DO 65 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et 3 Pushing the pawls with a screwdriver remove the fuel meter unit by pulling it downwards N...

Page 993: ...ehicle 3 Remove the front side fuel tank cover 4 Drain fuel from fuel tank Set a container under the vehicle and then remove the drain plug from fuel tank 5 Tighten the fuel drain plug and install the...

Page 994: ...sub level sensor 10 Disconnect the fuel jet pump hose 11 Remove the bolts which install fuel sub level sensor on fuel tank 12 Remove the fuel sub level sensor B INSTALLATION Install in the reverse or...

Page 995: ...er 4 Remove the filter holder by turning it to the left from the body pawls and then take out the filter B INSTALLATION NOTE If the fuel hoses are damaged at the connecting portion replace it with a n...

Page 996: ...e fuel tank Ref to FU H6DO 53 REMOVAL Fuel Tank 2 Move the clip and then disconnect the evapora tion hose from fuel cut valve 3 Remove the bolts which install fuel cut valve B INSTALLATION Install in...

Page 997: ...9 Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H6DO 50 RELEASING OF FUEL PRESSURE OPERA TION Fuel 2 Remove the fuel damper valve from fuel delivery line A and return line B B INST...

Page 998: ...the fuel filler flap lid and then remove the fuel filler cap 4 Remove the floor mat Ref to EI 51 REMOV AL Floor Mat 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation...

Page 999: ...a new retainer Make sure that the connected portion is not dam aged or has dust If necessary clean the seal sur face of pipe 1 Set a new retainer B to connector A 2 Push the pipe into connector compl...

Page 1000: ...9 in L 22 5 2 5 mm 0 886 0 098 in 3 Connect the evaporation hose to pipe by approx 15 mm 0 59 in from hose end L 17 5 2 5 mm 0 689 0 098 in NOTE Be sure to inspect the hoses and their connections for...

Page 1001: ...use Corrective action 1 Insufficient fuel supply to the injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Trouble in electroma...

Page 1002: ...NTROL AUX EMISSION CONTROL DEVICES EC H6DO Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 6 4 Canister 7 5 Purge Control Solenoid Valve 8 6 EGR Valve 10 7 Two wa...

Page 1003: ...s in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful...

Page 1004: ...Lift up the vehicle 6 Remove under cover 7 Remove front oxygen A F sensor harness from the clips attached to both right and left cylinder head covers 8 Disconnect connector from rear oxygen sensor con...

Page 1005: ...pipe assembly to the vehi cle And temporarily tighten bolt which installs front exhaust pipe to hanger bracket 3 Tighten nuts which hold front exhaust pipe onto cylinder heads Tightening torque 30 N...

Page 1006: ...head covers 8 Install under cover 9 Lower the vehicle 10 Connect front oxygen A F sensor connector 11 Install air cleaner case and air intake duct Ref to IN H6DO 5 INSTALLATION Air Clean er and Ref to...

Page 1007: ...front and rear catalytic converter are integrated into one unit Therefore the removal and installa tion procedures are the same as the ones de scribed under front catalytic converter Ref to EC H6DO 4...

Page 1008: ...clamps which hold two canister hos es and disconnect evaporation hoses from canis ter 3 Remove canister from body B INSTALLATION Install in the reverse order of removal Tightening torque 23 N m 2 3 k...

Page 1009: ...belt 3 Remove power steering oil pipe with brack et 4 Remove bolts which install power steering pump bracket CAUTION Do not separate hose and pipe from the pump main unit 5 Remove power steering tank...

Page 1010: ...enoid valve through the bottom of the intake manifold B INSTALLATION Install in the reverse order of removal Tightening torque 19 N m 1 9 kgf m 14 ft lb CAUTION Carefully connect the evaporation hoses...

Page 1011: ...Remove starter Ref to SC H6DO 6 REMOV AL Starter 4 Remove EGR pipe from EGR valve and cylinder head 5 Remove EGR valve from intake manifold 6 Disconnect connector from EGR valve B INSTALLATION NOTE Re...

Page 1012: ...ng torque 6 4 N m 0 65 kgf m 4 7 ft lb 4 Install starter Ref to SC H6DO 6 INSTALLA TION Starter 5 Install air intake chamber Ref to IN H6DO 6 INSTALLATION Air Intake Chamber 6 Connect battery ground c...

Page 1013: ...AL 1 Lift up the vehicle 2 Disconnect hoses from two way valve 3 Remove two way valve with bracket as a single unit from body 4 Remove two way valve from bracket B INSTALLATION Install in the reverse...

Page 1014: ...INTAKE INDUCTION IN H6DO Page 1 General Description 2 2 Air Cleaner 5 3 Air Intake Chamber 6 4 Air Intake Duct 7 5 Resonator Chamber 8...

Page 1015: ...IN H6DO 2 INTAKE INDUCTION GENERAL DESCRIPTION 1 General Description A COMPONENT IN 00064 1 2 3 4 4 4 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 T1 T3 T3 T4 T4 T4 T2 T3...

Page 1016: ...e 11 Grommet 20 Clamp 3 Resonator chamber 12 Air intake chamber 4 Cushion 13 Grommet Tightening torque N m kgf m ft lb 5 Clip 14 Clamp T1 32 3 3 3 23 9 6 Air cleaner lower case 15 Clamp T2 6 4 0 65 4...

Page 1017: ...them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands b...

Page 1018: ...e Tightening torque 32 3 N m 3 3 kgf m 23 9 ft lb 2 Set the air cleaner element 3 Install the air cleaner upper cover NOTE Before installing air cleaner upper cover align holes with protruding portion...

Page 1019: ...nects air intake chamber to throttle body 4 Remove bolts B which install air intake cham ber to intake manifold 5 Loosen clamp C which connects air intake chamber to air intake boot 6 Disconnect hoses...

Page 1020: ...A REMOVAL Remove bolts which install air intake duct on the front side of body B INSTALLATION Install in the reverse order of removal C INSPECTION Inspect for cracks and loose connections Check that...

Page 1021: ...r Cleaner 4 Remove the resonator chamber mounting bolt on the right of engine compartment 5 Remove the front right tire and lift the vehicle 6 Remove front mudguard RH 7 Remove the resonator chamber A...

Page 1022: ...Engine Assembly 29 8 Engine Mounting 36 9 Preparation for Overhaul 37 10 Crankshaft Pulley 38 11 Front Chain Cover 39 12 Timing Chain Assembly 41 13 Camshaft Sprocket 46 14 Crankshaft Sprocket 47 15...

Page 1023: ...2 5 4 Ignition timing BTDC rpm 10 8 600 Camshaft Bend limit 0 020 mm 0 0008 in Thrust clearance Intake STD 0 075 0 135 mm 0 0030 0 0053 in Limit 0 155 mm 0 0061 in Exhaust STD 0 048 0 108 mm 0 0019 0...

Page 1024: ...07 3 5211 in 0 50 mm 0 0197 in OS 89 675 89 685 mm 3 5305 3 5309 in Standard inner diameter of piston pin hole 22 000 22 006 mm 0 8661 0 8664 in Piston pin Outer diameter 21 994 22 000 mm 0 8659 0 866...

Page 1025: ...958 mm 2 5174 2 5180 in 0 25 mm 0 0098 in US 63 742 63 758 mm 2 5095 2 5102 in 2 4 6 STD 63 992 64 008 mm 2 5194 2 5200 in 0 03 mm 0 0012 in US 63 962 63 978 mm 2 5182 2 5188 in 0 05 mm 0 0020 in US 6...

Page 1026: ...tay Tightening torque N m kgf m ft lb 2 Belt cover 8 Idler pulley T1 6 4 0 65 4 7 3 Belt tensioner 9 Idler pulley cover T2 20 2 0 14 4 Power steering pump bracket 10 Nut LHD T3 25 2 5 18 5 Generator 1...

Page 1027: ...htening torque N m kgf m ft lb 2 O ring 8 Rear chain cover T1 Ref to ME H6DO 38 Crankshaft Pulley 3 Crank pulley 9 Water pump gasket 4 Sealing washer T2 Ref to ME H6DO 39 Front Chain Cover 5 Oil seal...

Page 1028: ...lve case 18 Chain guide Left hand between cams T1 6 4 0 64 4 7 7 Relief valve case gasket T2 7 8 0 80 5 8 8 Chain guide Right hand between cams 19 Timing chain LH T3 13 1 3 9 4 20 Exhaust cam sprocket...

Page 1029: ...ap LH 6 Intake camshaft cap Center RH 18 Intake camshaft cap Front LH T2 Ref to ME H6DO 50 Camshaft 7 Intake camshaft cap Rear RH 19 Intake camshaft cap Center LH 8 Exhaust camshaft cap Front RH 20 In...

Page 1030: ...6 Valve spring 11 Exhaust valve guide 2 Intake valve 7 Retainer 12 Exhaust valve stem seal 3 Intake valve guide 8 Retainer key 13 Cylinder head plug 4 Valve spring seat 9 Valve lifter 14 Cylinder head...

Page 1031: ...ECHANICAL GENERAL DESCRIPTION 6 CYLINDER BLOCK ME 00693 1 3 4 5 2 19 6 5 5 7 9 5 8 5 19 19 19 19 18 17 13 14 13 19 10 16 13 14 13 15 19 13 13 11 12 14 T1 T6 T1 T1 T8 T3 T9 T2 T2 T2 T2 T3 T8 T8 T5 T3 T...

Page 1032: ...65 4 7 3 Rear oil seal 13 Clamp T2 18 1 8 13 0 4 Service hole cover 14 Hose T3 25 2 5 18 5 O ring 15 Oil cooler pipe T4 34 3 5 25 6 Oil pan upper 16 Oil cooler T5 37 3 8 27 7 Oil pressure switch 17 C...

Page 1033: ...7 3 Crankshaft sensor plate 11 Connecting rod bearing 4 Top ring 12 Connecting rod bolt Tightening torque N m kgf m ft lb 5 Second ring 13 Connecting rod cap T1 53 5 4 39 6 Oil ring 14 Crankshaft T2 8...

Page 1034: ...pis tons and bearings Rotating parts and sliding parts such as piston bearing and gear should be coated with oil prior to assembly Be careful not to let oil grease or coolant contact the clutch disc...

Page 1035: ...ng valve guides Used for removing and installing valve springs 18232AA000 ENGINE STAND Used for engine disassembly and assembly 498497100 CRANKSHAFT STOPPER Used for stopping rotation of flywheel when...

Page 1036: ...pin piston and con necting rod 18350AA000 CONNECTINGROD BUSHING REMOVER INSTALLER Used for removing and installing connecting rod bushing 499097500 PISTON PIN REMOVER ASSY Used for removing piston pin...

Page 1037: ...Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL INSTALLER 499587200 499718000 VALVE SPRING REMOVER Used for removing and installing valve spring 18251AA000 VALVE GUIDE ADJUSTER...

Page 1038: ...ey when loosening and tightening crankshaft pulley bolts 18252AA000 CRANKSHAFT SOCKET Used for rotating crankshaft 498547000 OIL FILTER WRENCH Used for removing and installing oil filter 24082AA210 Ne...

Page 1039: ...printer 18329AA000 SHIM REPLACER ASSY Used for correct valve clearance A 18330AA010 LIFTER If 498187200 SHIM REPLACER ASSY H4 tool is available it is commonly used for H6 by par tially replacing the...

Page 1040: ...r motor for satisfactory perfor mance and operation 6 Hold the compression gauge tight against the spark plug hole CAUTION When using a screw in type compression gauge the screw put into cylinder head...

Page 1041: ...Data Display Save in Engine Control System Diagnosis 7 Select 1 12 Data Display in Data Display Menu 8 Start the engine and read engine idle speed NOTE When using the OBD II general scan tool care ful...

Page 1042: ...REP ARATION TOOL General Description 1 Insert the cartridge to SUBARU SELECT MONITOR 2 Connect SUBARU SELECT MONITOR to the data link connector 3 Turn ignition switch to ON and SUBARU SELECT MONITOR s...

Page 1043: ...7 When inspecting RH side cylinder 1 Remove air intake duct and air cleaner case Ref to IN H6DO 7 REMOVAL Air In take Duct and Ref to IN H6DO 5 REMOV AL Air Cleaner 2 Remove V belt Ref to ME H6DO 28 R...

Page 1044: ...Coil and Ignitor Assembly 12 Remove rocker cover RH Ref to ME H6DO 50 REMOVAL Camshaft 8 When inspecting LH side cylinder 1 Set the vehicle on the lift 2 Remove battery 3 Remove washer tank mounting...

Page 1045: ...o the shim as shown in the figure ST 18252AA000 CRANKSHAFT SOCKET 10 Measure intake valve and exhaust valve clear ances by using thickness gauge A NOTE Insert the thickness gauge in as horizontal a di...

Page 1046: ...NOTE Record each valve clearance after it has been measured 2 Remove shim from valve lifter 1 Prepare the ST ST 18329AA000 SHIM REPLACER Ref to ME H6DO 14 PREPARATION TOOL General Description 2 Rotat...

Page 1047: ...2 29 0 0902 13218 AE790 2 30 0 0906 13218 AE800 2 31 0 0909 13218 AE810 2 32 0 0913 13218 AE820 2 33 0 0917 13218 AE830 2 34 0 0921 13218 AE840 2 35 0 0925 13218 AE850 2 36 0 0929 13218 AE860 2 37 0...

Page 1048: ...ge If the valve clearance is not correct repeat the procedure over again from the first step 7 After inspection install the related parts in the reverse order of removal 13218 AF270 2 78 0 1094 13218...

Page 1049: ...all in the reverse order of removal C INSPECTION 1 Replace belts if cracks fraying or wear is found 2 Check that the V belt automatic tensioner indica tor A is within the range D 1 Power steering oil...

Page 1050: ...Chamber and Ref to IN H6DO 5 RE MOVAL Air Cleaner 8 Lift up the vehicle 9 Remove under cover 10 Remove radiator from vehicle Ref to CO H6DO 27 REMOVAL Radiator 11 Remove V belt Ref to ME H6DO 28 RE MO...

Page 1051: ...ose and the pipe from the pump body 3 Remove power steering tank from the bracket by pulling it upward 4 Place power steering pump on the right side wheel apron 16 Remove front exhaust pipe Ref to EX...

Page 1052: ...ue converter clutch to drive plate 4 Remove other bolts while rotating the en gine using ST ST 499977100 CRANK PULLEY WRENCH 20 Remove pitching stopper 21 Disconnect fuel delivery hose return hose and...

Page 1053: ...77200 STOPPER SET 26 Remove engine from vehicle 1 Slightly raise engine 2 Raise transmission with garage jack 3 Move engine horizontally until main shaft is withdrawn from clutch cover 4 Slowly move e...

Page 1054: ...verter clutch case when removing ST ST 498277200 STOPPER SET 8 Install starter Ref to SC H6DO 6 INSTALLA TION Starter 9 Install torque converter clutch onto drive plate 1 Tighten bolts which hold tor...

Page 1055: ...N m 5 1 kgf m 36 9 ft lb 12 Tighten nuts which install front cushion rubber onto crossmember Tightening torque 74 N m 7 5 kgf m 54 ft lb NOTE Make sure the front cushion rubber mounting bolts A and lo...

Page 1056: ...CO H6DO 28 INSTALLATION Radiator 20 Install air intake duct cleaner case and air in take chamber Ref to IN H6DO 2 General Description 21 Install under cover 22 Install battery in the vehicle and conn...

Page 1057: ...ine assembly Ref to ME H6DO 29 REMOVAL Engine Assembly 2 Remove engine mounting from engine assem bly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 34 N m 3...

Page 1058: ...pipe Ref to EC H6DO 10 REMOVAL EGR Valve 5 Remove water pipe and hoses 6 Remove engine harness 7 Remove spark plugs Ref to IG H6DO 4 REMOVAL Spark Plug 8 Remove camshaft position sensor Ref to FU H6DO...

Page 1059: ...t To lock crankshaft use ST ST 499977100 CRANKSHAFT PULLEY WRENCH 1 Clean the crankshaft pulley thread using an air gun 2 Apply engine oil to the crankshaft pulley bolt seat and thread 3 Tighten the c...

Page 1060: ...r B INSTALLATION 1 Remove old fluid gasket on the matching sur face and degrease it 2 Apply fluid gasket to the mating surface of front chain cover Fluid gasket THREE BOND 1280B Part No K0877YA018 Flu...

Page 1061: ...lley Ref to ME H6DO 38 INSTALLATION Crankshaft Pulley C INSPECTION Check the cover surface for flaws and dents Check the cover mating surface and the mounting point of crankshaft pulley for oil leaks...

Page 1062: ...Make sure plunger A does not come out 4 Remove chain guide Right hand between cams 5 Remove chain guide RH 6 Remove chain tensioner lever RH 7 Remove timing chain RH 8 Remove chain tensioner LH NOTE...

Page 1063: ...ner 1 Put the screw spring pin and tension rod into the tensioner body 2 While pressing tensioner onto rubber mat twist it left and right to shorten tension rod Then set a thin pin into the holes betw...

Page 1064: ...lb 6 Install timing chain LH 1 Align the timing mark B on crankshaft sprocket with the matching mark A on timing chain LH 2 Route timing chain LH on idler sprocket Lower water pump exhaust cam sprocke...

Page 1065: ...ft lb 7 Install chain tensioner LH Tightening torque 16 N m 1 6 kgf m 11 6 ft lb 7 Install timing chain RH 1 On idler sprocket Lower align matching marks on timing chains LH and RH 2 Route timing cha...

Page 1066: ...e 16 N m 1 6 kgf m 11 6 ft lb 7 Adjust the clearance between chain guide RH and chain guide Center to the range be tween 8 4 mm 0 331 in to 8 6 mm 0 339 in And install chain guide Center Tightening to...

Page 1067: ...MSHAFT SPROCKET WRENCH B INSTALLATION 1 Install camshaft sprocket To lock camshaft use ST ST 18231AA000 CAMSHAFT SPROCKET WRENCH Tightening torque 13 N m 1 0 kgf m 7 2 ft lb 2 Install timing chain ass...

Page 1068: ...ft Sprocket 5 Remove crankshaft sprocket A B INSTALLATION 1 Install crankshaft sprocket A 2 Install camshaft sprocket Ref to ME H6DO 46 INSTALLATION Camshaft Sprocket 3 Install timing chain assembly R...

Page 1069: ...ve water pump Ref to CO H6DO 24 REMOVAL Water Pump 9 Remove rear chain cover NOTE There are seven different types of mounting bolts Sort them into separate containers to avoid confu sion at installati...

Page 1070: ...Ref to ME H6DO 46 INSTALLATION Camshaft Sprocket 11 Install timing chain Ref to ME H6DO 42 IN STALLATION Timing Chain Assembly 12 Install front chain cover Ref to ME H6DO 39 INSTALLATION Front Chain C...

Page 1071: ...lly a little at a time in numerical sequence shown in the figure RH 9 Remove camshaft cap and intake camshaft RH 10 Loosen camshaft cap bolts equally a little at a time in the numerical sequence shown...

Page 1072: ...p on camshaft 3 Tighten the camshaft cap bolts in the nu merical sequence shown in the figure Tightening torque 16 N m 1 6 kgf m 11 6 ft lb 4 Tighten the front camshaft cap bolts in the numerical sequ...

Page 1073: ...H6DO 38 INSTALLATION Crankshaft Pulley C INSPECTION 1 CAMSHAFT 1 Measure the bend and repair or replace if nec essary Limit 0 020 mm 0 0008 in 2 Check journal for damage and wear Replace if faulty 3 M...

Page 1074: ...asure the cam height H replace if the limit has been exceeded Cam height H Standard Intake 45 75 45 85 mm 1 8012 1 8051 in Exhaust 45 25 45 35 mm 1 7815 1 7854 in Limit Intake 45 65 mm 1 7972 in Exhau...

Page 1075: ...the washers and threaded parts of the cylinder head bolts with engine oil 2 Install the cylinder head on the cylinder block and tighten the bolts in the numerical order shown in the figure to a tighte...

Page 1076: ...e spring and valve 1 Place cylinder head on ST ST 18250AA000 CYLINDER HEAD TABLE 2 Coat stem of each valve with engine oil and insert valve into valve guide NOTE When inserting valve into valve guide...

Page 1077: ...1 2 Press fit oil seal to the specified dimension indi cated in the figure using ST2 NOTE Apply engine oil to stem seal before press fitting When press fitting stem seal do not use hammer or strike in...

Page 1078: ...torque for the cylinder head bolts can cause warping When reassembling pay special attention to the torque so as to tighten evenly 2 VALVE SEAT Inspect intake and exhaust valve seats and correct the...

Page 1079: ...ges exist on the inside surface of the valve guide holes in cylinder head 5 Put new valve guide in cylinder and insert ST1 into valve guide Press in until the valve guide upper end is flush with the u...

Page 1080: ...pecified limit H Intake Standard 1 0 mm 0 039 in Limit 0 8 mm 0 031 in Exhaust Standard 1 2 mm 0 047 in Limit 0 8 mm 0 031 in Valve overall length Intake 103 5 mm 4 075 in Exhaust 103 2 mm 4 063 in 2...

Page 1081: ...EMOVAL Rear Chain Cover 7 Remove camshafts Ref to ME H6DO 50 REMOVAL Camshaft 8 Remove cylinder head assembly Ref to ME H6DO 54 REMOVAL Cylinder Head Assem bly 9 Remove drive plate Using ST lock crank...

Page 1082: ...piston pins from 3 4 5 and 6 pistons 21 Remove bolts which connect cylinder block 22 Separate left hand and right hand cylinder blocks NOTE When separating cylinder block do not allow the connecting...

Page 1083: ...08 in 4 Apply engine oil to washers and threads of cylin der block connecting bolts Tighten the bolts follow ing the steps below 1 Tighten all the bolts in the numerical order shown in the figure Tigh...

Page 1084: ...rclip Install circlips in piston holes located opposite service holes in cylinder block when positioning all pistons in the corresponding cylinders NOTE Use new circlips 9 Installing piston NOTE Insta...

Page 1085: ...or pistons 1 and 2 5 and 6 12 Install service hole plug and cover 13 Apply fluid gasket to mating surface of upper oil pan 14 Install O ring Fluid gasket THREE BOND 1280B Part No K0877YA018 15 Tempora...

Page 1086: ...kgf m 4 7 ft lb 21 Install crankshaft position sensor plate 22 Install drive plate Using ST lock crankshaft ST 498497100 CRANKSHAFT STOPPER Tightening torque 81 N m 8 3 kgf m 60 ft lb 23 Install cylin...

Page 1087: ...ley C DISASSEMBLY 1 Remove connecting rod cap 2 Remove connecting rod bearing NOTE Arrange removed connecting rod connecting rod cap and bearing in order to prevent confusion 3 Remove piston rings usi...

Page 1088: ...r matching number When tightening the connecting rod nuts ap ply oil on the threads 4 Installation of piston rings and oil ring E INSPECTION 1 CYLINDER BLOCK 1 Visually check for cracks and damage Esp...

Page 1089: ...h cyl inder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure using a cylinder bore gauge CAUTION Measurement should be perfor...

Page 1090: ...cylinders needs reboring all other cylinders must be bored at the same time and use oversize pistons Do not perform boring on one cyl inder only nor use an oversize piston for one cylin der only 2 If...

Page 1091: ...assemble correctly 2 Squarely place piston ring and oil ring in cylin der and measure the piston ring gap with a thick ness gauge 3 Measure the clearance between piston ring and piston ring groove wi...

Page 1092: ...ing for scar peeling seizure melting wear etc 5 Measure the oil clearance on individual connect ing rod bearings by means of plastigauge If any oil clearance is not within specification replace the de...

Page 1093: ...an crankshaft completely and check for cracks by means of red lead check etc and re place if defective 2 Measure the crankshaft bend and correct or re place if it exceeds the limit NOTE If a suitable...

Page 1094: ...992 64 008 2 5194 2 5200 51 984 52 000 2 0466 2 0472 Bearing size Thickness at cen ter 1 992 2 005 0 0784 0 0789 1 996 2 000 0 0786 0 0787 1 490 1 502 0 0587 0 0591 0 03 0 0012 undersize Journal O D...

Page 1095: ...nd relay A Lack of or insufficient fuel B Chain Defective B Defective timing B Compression Incorrect valve clearance C Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defect...

Page 1096: ...ystem Ref to EN H6DO 2 Basic Diagnostic Procedure A Intake system Loosened or cracked intake duct A Loosened or cracked PCV hose A Loosened or cracked vacuum hose A Defective intake manifold gasket B...

Page 1097: ...Lubrication system Incorrect oil pressure B Cooling system Overheating C Over cooling C Others Malfunction of evaporative emission control system A 4 Surging Engine control system Ref to EN H6DO 2 Ba...

Page 1098: ...ve gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn or stuck piston rings cylinder and piston C Incorrect valve timing A Lubrication system Incorrect oil pre...

Page 1099: ...ect valve clearance B Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defective gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn o...

Page 1100: ...engine speed is medium 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft main bearing Worn bearing at crankshaft end of connecti...

Page 1101: ...ME H6DO 80 MECHANICAL ENGINE NOISE MEMO...

Page 1102: ...EXHAUST EX H6DO Page 1 General Description 2 2 Front Exhaust Pipe 5 3 Rear Exhaust Pipe 8 4 Muffler 9...

Page 1103: ...EX H6DO 2 EXHAUST GENERAL DESCRIPTION 1 General Description A COMPONENT EX 00110 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 24 22 21 20 25 24 23 T6 T4 T4 T4 T3 T3 T3 T5 T2 T1 T1 T1...

Page 1104: ...ing nut 4 Lower front catalytic converter cover RH 14 Lower rear catalytic converter cover Tightening torque N m kgf m ft lb 5 Front catalytic converter RH 15 Clamp T1 13 1 3 9 4 6 Front exhaust pipe...

Page 1105: ...rom dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because...

Page 1106: ...front oxygen A F sensor connector 4 Lift up the vehicle 5 Remove under cover 6 Disconnect rear oxygen sensor connector 7 Separate front exhaust pipe assembly from rear exhaust pipe WARNING Be careful...

Page 1107: ...st pipe 11 Separate front exhaust pipe RH from front ex haust pipe assembly B INSTALLATION 1 Install front exhaust pipe RH to front exhaust pipe assembly NOTE Replace gaskets with new ones Tightening...

Page 1108: ...kgf m 26 0 ft lb 8 Connect rear oxygen sensor connector 9 Install under cover 10 Lower the vehicle 11 Connect front oxygen A F sensor connectors 12 Install air cleaner case and air intake duct Ref to...

Page 1109: ...aust pipe 3 Remove rear exhaust pipe B INSTALLATION NOTE Replace gaskets and self lock nut with new ones 1 Install rear exhaust pipe to muffler Tightening torque 48 N m 4 9 kgf m 35 4 ft lb 2 Install...

Page 1110: ...3 Remove front rubber cushion and detach muf fler assembly NOTE To facilitate removal apply a coat of SUBARU CRC to mating area of rubber cushion in advance SUBARU CRC Part No 004301003 B INSTALLATIO...

Page 1111: ...EX H6DO 10 EXHAUST MUFFLER MEMO...

Page 1112: ...System 6 3 Radiator Sub Fan System 14 4 Engine Coolant 22 5 Water Pump 24 6 Thermostat 25 7 Radiator 27 8 Radiator Cap 31 9 Radiator Main Fan and Fan Motor 32 10 Radiator Sub Fan and Fan Motor 34 11...

Page 1113: ...mm 2 882 in Number of impeller vanes 6 Tooth number of pump sprocket 22 t Thermostat Type Wax pellet type Start to open 80 84 C 176 183 F Fully open 95 C 203 F Valve lift 9 0 mm 0 354 in or more Valve...

Page 1114: ...O H6DO 3 COOLING GENERAL DESCRIPTION B COMPONENT 1 WATER PUMP 1 Water pump ASSY 4 Gasket Tightening torque N m kgf m ft lb 2 O ring 5 Thermostat cover T 6 4 0 65 4 7 3 Thermostat CO 00106 1 2 3 4 5 T...

Page 1115: ...et 16 Radiator main fan motor 6 Radiator upper cushion 17 Main fan shroud Tightening torque N m kgf m ft lb 7 Clamp 18 Engine coolant reservoir tank cap T1 4 4 0 45 3 3 8 Radiator inlet hose A 19 Over...

Page 1116: ...ach part in the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnectin...

Page 1117: ...SBF 1 IGNITION SWITCH RELAY HOLDER BLACK B72 F16 B253 F17 F46 3 4 1 2 B137 BATTERY 17 24 28 B137 ENGINE CONTROL MODULE B253 FAN RELAY 5 1 3 4 3 3 4 4 1 1 2 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30...

Page 1118: ...ep 4 2 CHECK OPERATION OF RADIATOR FAN 1 Turn the A C switch to OFF 2 Perform checking procedure during coolant temperature is 98 101 C 208 214 F Does the radiator main fan rotate in low speed Rotates...

Page 1119: ...d Connector terminal F66 No 8 Chassis ground F30 No 21 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 9 Go to step 10 9 CHECK POWER SUPPLY TO MAIN FAN RE LAYS 1 AND...

Page 1120: ...ness between main fan motor connector and main fan relays 1 and 2 terminal Connector terminal F17 No 1 F66 No 9 F17 No 2 F30 No 20 Is the measured value less than the specified value 1 Go to step 16 R...

Page 1121: ...21 CHECK POWER SUPPLY TO MAIN FAN RE LAY 1 1 Turn ignition switch to OFF 2 Remove main fan relay 1 from A C relay holder 3 Measure voltage between main fan relay 1 terminal and chassis ground Connect...

Page 1122: ...ETWEEN MAIN FAN RELAY TERMINAL AND MAIN FAN MOTOR CONNECTOR Measure resistance of harness between main fan motor connector and main fan relay 1 ter minal Connector terminal F17 No 1 F66 No 9 Is the me...

Page 1123: ...1 Disconnect fan relay connector 2 Measure resistance of between main fan motor connector and fan relay connector Connector terminal F17 No 3 B253 No 5 Is the measured value less than the speci fied v...

Page 1124: ...is ground Is the measured value less than the specified value 1 Go to step 39 Repair open circuit in harness between fan relay connector and chassis ground 39 CHECK HARNESS BETWEEN FAN RELAY AND ECM 1...

Page 1125: ...SBF 1 IGNITION SWITCH RELAY HOLDER BLACK B72 F16 B253 F17 F46 3 4 1 2 B137 BATTERY 17 24 28 B137 ENGINE CONTROL MODULE B253 FAN RELAY 5 1 3 4 3 3 4 4 1 1 2 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30...

Page 1126: ...RATION OF RADIATOR FAN 1 Turn the A C switch to OFF 2 Perform checking procedure during coolant temperature is 98 101 C 208 214 F When A C compressor is operating does the radiator sub fan rotate in l...

Page 1127: ...nector terminal F28 No 28 Chassis ground F29 No 31 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 9 Go to step 10 9 CHECK POWER SUPPLY TO SUB FAN RE LAYS 1 AND 2 Me...

Page 1128: ...rness between sub fan motor connector and sub fan relays 1 and 2 terminal Connector terminal F16 No 1 F28 No 29 F16 No 2 F29 No 30 Is the measured value less than the specified value 1 Go to step 16 R...

Page 1129: ...HECK POWER SUPPLY TO SUB FAN RE LAY 1 1 Turn ignition switch to OFF 2 Remove sub fan relay 1 from A C relay holder 3 Measure voltage between sub fan relay 1 terminal and chassis ground Connector termi...

Page 1130: ...NESS BETWEEN SUB FAN RE LAY 1 AND SUB FAN MOTOR CONNECTOR Measure resistance of harness between sub fan motor connector and sub fan relay 1 termi nal Connector terminal F16 No 1 F28 No 29 Is the measu...

Page 1131: ...or Connector terminal F16 No 3 B253 No 5 Is the measured value less than the speci fied value 1 Go to step 34 Repair open circuit between sub fan motor connector and fan relay con nector 34 CHECK POWE...

Page 1132: ...en fan relay connector and chassis ground 39 CHECK HARNESS BETWEEN FAN RELAY AND ECM 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between fan relay con...

Page 1133: ...freeze and anti rust agents is especially made for SUBARU engine which has an aluminum crankcase Always use SUBARU Genuine Cool ant since other coolant may cause corrosion 2 Fill engine coolant into r...

Page 1134: ...must be in creased form 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read the scale on the vertical axis o...

Page 1135: ...ON 1 Install water pump onto rear chain cover NOTE Apply engine coolant to O ring Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb NOTE Replace O rings with a new one Applying engine coolant to O ring m...

Page 1136: ...r 5 Remove thermostat cover and gasket and pull out the thermostat B INSTALLATION 1 Install the thermostat to oil pan upper and install the thermostat cover together with a gasket NOTE When reinstalli...

Page 1137: ...e thermostat and a thermometer in wa ter Raise water temperature gradually and mea sure the temperature and valve lift when the valve begins to open and when the valve is fully opened During the test...

Page 1138: ...22 DRAINING OF ENGINE COOL ANT REPLACEMENT Engine Coolant 5 Disconnect connectors of radiator main fan mo tor A and sub fan motor B 6 Disconnect radiator outlet hose from radiator 7 Disconnect ATF co...

Page 1139: ...ip on the radiator 15 While slightly lifting radiator slide it to left 16 Lift radiator up and away from vehicle B INSTALLATION 1 Attach radiator mounting cushions to holes on the vehicle 2 Install ra...

Page 1140: ...Connect radiator inlet hoses 6 Install reservoir tank Tightening torque 4 9 N m 0 50 kgf m 3 6 ft lb 7 Install air intake duct 8 Lift up the vehicle 9 Connect ATF cooler hoses 10 Connect connectors t...

Page 1141: ...p off radiator and attach tester to radiator in place of cap 2 Apply a pressure of 157 kPa 1 6 kg cm2 23 psi to radiator to check if 1 Engine coolant leaks at around radiator 2 Engine coolant leaks at...

Page 1142: ...s Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds Standard pressure 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Service limit pressure 83 kPa 0 85 kg cm2...

Page 1143: ...n engine coolant completely Ref to CO H6DO 22 Engine Coolant 5 Disconnect connectors of main and sub fan mo tor 6 Lower the vehicle 7 Remove air intake duct 8 Disconnect over flow hose 9 Remove reserv...

Page 1144: ...o CO H6DO 3 COMPONENT General Description C DISASSEMBLY 1 Remove clip which holds motor connector onto shroud 2 Remove nut which holds fan itself onto fan motor and shroud assembly 3 Remove screws whi...

Page 1145: ...e bolts which hold sub fan shroud to radi ator 8 Remove radiator sub fan shroud through the un der side of vehicle B INSTALLATION Install in the reverse order of removal NOTE Refer to COMPONENT for ti...

Page 1146: ...disassembly NOTE Refer to COMPONENT for tightening torque Ref to CO H6DO 3 COMPONENT General Description E INSPECTION 1 Connect battery as shown in the figure Terminal No 1 No 4 Low speed No 1 No 2 No...

Page 1147: ...ler neck position 2 Remove bolts which install reservoir tank onto radiator main fan shroud 3 Remove reservoir tank B INSTALLATION Install in the reverse order of removal Tightening torque 4 9N m 0 50...

Page 1148: ...ston and cylinder Adjust or replace k Slipping clutch Repair or replace l Dragging brake Adjust m Improper transmission oil Replace n Defective thermostat Replace o Malfunction of electric fan Inspect...

Page 1149: ...CO H6DO 38 COOLING ENGINE COOLING SYSTEM TROUBLE IN GENERAL MEMO...

Page 1150: ...Description 2 2 Oil Pressure System 7 3 Engine Oil 9 4 Oil Pump 11 5 Oil Pump Relief Valve 13 6 Oil Pan and Strainer 14 7 Oil Pressure Switch 16 8 Engine Oil Filter 17 9 Oil Cooler 18 10 Engine Lubric...

Page 1151: ...59 in Case clearance between outer rotor and pump case Standard 0 11 0 18 mm 0 0043 0 0071 in Limit 0 25 mm 0 0098 in Oil filter Type Full flow filter type Filtration area 1 300 cm2 201 5 sq in By pas...

Page 1152: ...LU H6DO 3 LUBRICATION GENERAL DESCRIPTION MEMO...

Page 1153: ...LU H6DO 4 LUBRICATION GENERAL DESCRIPTION B COMPONENT LU 00109 1 2 3 4 5 6 6 7 7 7 7 7 7 8 8 8 8 9 10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 T1 T1 T1 T3 T3 T3 T3 T6 T4 T1 T2 T1 T1 T8 T8 T3 T5 T7...

Page 1154: ...4 7 3 Drain plug 15 Crank sprocket T2 7 8 0 80 5 8 4 Gasket 16 Oil pump cover T3 18 1 8 13 5 Oil cooler pipe 17 Inner rotor T4 25 2 5 18 6 Hose 18 Outer rotor T5 34 3 5 25 7 Clamp 19 Oil pan upper T6...

Page 1155: ...nd replacement Be careful not to burn your hands because each part in the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or...

Page 1156: ...B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 OIL P...

Page 1157: ...h ON 4 Measure the voltage of harness between the combination meter connector and chas sis ground Connector terminal E11 No 1 Chassis ground Is the measured value exceed the specified value 10 V Repla...

Page 1158: ...n before checking the level 6 To prevent overfilling the engine oil do not add oil above the F line when the engine is cold NOTE Just after driving or during warm up engine oil lev el may rise above t...

Page 1159: ...cold and hot starting by reducing viscous friction and thus increasing cranking speed CAUTION When replenishing oil it does not matter if the oil to be added is a different brand from that in the engi...

Page 1160: ...ner and outer rotor 2 Install the inner rotor by fitting it into the groove on the crankshaft and then assemble the outer ro tor 3 Install oil pump cover 4 Tighten the bolts in the numerical sequence...

Page 1161: ...chain cover rotor housing If the clearance exceeds the limit replace the rotor Case clearance Standard 0 11 0 18 mm 0 0043 0 0071 in Limit 0 25 mm 0 0098 in 3 SIDE CLEARANCE Measure clearance between...

Page 1162: ...en the bolts in the numerical sequence shown in the figure Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 3 Install timing chain assembly Ref to ME H6DO 42 INSTALLATION Timing Chain As sembly 4 Instal...

Page 1163: ...o not use a screwdriver or similar tool in place of oil pan cutter 6 Remove lower oil pan 7 Remove oil strainer B INSTALLATION CAUTION Before installing oil pan clean liquid gasket from lower oil pan...

Page 1164: ...D STRAINER 4 Install under cover Ref to EI 13 INSTALLA TION Front Under Cover 5 Fill engine oil Ref to LU H6DO 9 INSPEC TION Engine Oil C INSPECTION By visual check make sure oil pan oil strainer and...

Page 1165: ...ve oil pressure switch B INSTALLATION 1 Apply liquid gasket to oil pressure switch threads Liquid gasket THREE BOND 1324 or equivalent 2 Install oil pressure switch Tightening torque 25 N m 2 5 kgf m...

Page 1166: ...ter by turning it by hand being careful not to damage rubber seal 3 Tighten more approximately 3 4 turn after the rubber seal contacts the oil cooler Do not tighten excessively or oil may leak 4 Refil...

Page 1167: ...move bolts which installs water pipe to en gine 6 Disconnect water hoses from oil cooler 7 Remove oil filter using ST Ref to LU H6DO 17 REMOVAL Engine Oil Filter ST 498547000 OIL FILTER WRENCH NOTE Se...

Page 1168: ...ngine Oil Filter ST 498547000 OIL FILTER WRENCH 3 Install water hose 4 Install water pipe to engine Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 5 Fill engine oil Ref to LU H6DO 9 REPLACE MENT Engin...

Page 1169: ...s valve of oil filter Clean or replace Malfunction of oil relief valve of oil pump Clean or replace Clogged oil passage Clean Tip clearance and side clearance of oil pump rotor and gear Replace Clogge...

Page 1170: ...SPEED CONTROL SYSTEMS SP H6DO Page 1 General Description 2 2 Accelerator Pedal 4 3 Accelerator Control Cable 8...

Page 1171: ...oke At pedal pad 50 55 mm 1 97 2 17 in 1 Accelerator bracket 7 Accelerator pedal lever 13 Kick down switch 2 Stopper 8 Spring pin 3 Bushing 9 Accelerator pedal Tightening torque N m kgf m ft lb 4 Clip...

Page 1172: ...bly and replacement Be careful not to burn your hands because each part in the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jac...

Page 1173: ...MODEL RHD MODEL 6 Remove instrument panel lower cover from in strument panel and connector 7 Disconnect connector from kick down switch 8 Remove accelerator pedal connecting bolt from accelerator ped...

Page 1174: ...careful not to kink accelerator cable Refer to COMPONENT for the tightening torque Ref to SP H6DO 2 COMPONENT General De scription 2 Adjust the pedal after installation Ref to SP H6DO 7 ADJUSTMENT Ac...

Page 1175: ...2 If excessive deflection is noted replace bushing and clip with new ones Deflection of accelerator pedal Service limit 2 0 mm 0 079 in or less 2 KICK DOWN SWITCH If kick down switch does not operate...

Page 1176: ...htening torque of accelerator cable lock nut 12 N m 1 2 kgf m 9 ft lb 3 Check to ensure the kick down switch operates at the specified value in relation to the stroke of the accelerator pedal If it is...

Page 1177: ...erator cable end Grease Part No 004404002 Slicolube G 30M NOTE If cable clamp is damaged replace it with a new one Never fail to cover outer cable end with boot Be careful not to kink accelerator cabl...

Page 1178: ...IGNITION IG H6DO Page 1 General Description 2 2 Spark Plug 4 3 Ignition Coil and Ignitor Assembly 7...

Page 1179: ...nition coil and ignitor assembly Model FK0140 Manufacturer DIAMOND Spark plug Type and manufacturer NGK PLFR6A 11 Thread size mm 14 P 1 25 Spark gap mm in 1 0 1 1 0 039 0 043 1 Spark plug Tightening t...

Page 1180: ...from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands becaus...

Page 1181: ...eaner 3 Disconnect connector from ignition coil 4 Remove ignition coil 5 Remove spark plugs with the spark plug socket 2 LH SIDE 1 Disconnect battery cables and then remove bat tery and battery carrie...

Page 1182: ...w spark plugs without oil on their threads In case their threads are lubricated the torque should be reduced by approximately 1 3 of the specified torque in order to avoid over stress ing Tightening t...

Page 1183: ...ance re sults from incorrect ignition timing loose spark plugs wrong selection of fuel hotter range plug etc It is advisable to replace with plugs having colder heat range D CLEANING Clean spark plugs...

Page 1184: ...l of spark plugs B INSTALLATION Install in the reverse order of removal Tightening torque 16 N m 1 6 kgf m 12 ft lb C INSPECTION Because ignition coil is a direct ignition type the re sistance cannot...

Page 1185: ...IG H6DO 8 IGNITION IGNITION COIL AND IGNITOR ASSEMBLY MEMO...

Page 1186: ...STARTING CHARGING SYSTEMS SC H6DO Page 1 General Description 2 2 Starter 6 3 Generator 14 4 Battery 20...

Page 1187: ...or less Torque 16 0 N m 1 63 kgf m 11 8 ft lb Rotating speed 740 rpm or more Lock characteristics Voltage 3 5 V Current 940 A or less Torque 28 9 N m 2 95 kgf m 21 3 ft lb or more Generator Type Rotat...

Page 1188: ...bearing 7 Internal gear ASSY 13 Armature 2 Front bracket 8 Shaft ASSY 14 Brush holder 3 Lever set 9 Gear ASSY 15 Brush 4 Magnet switch ASSY 10 Ball 16 Sleeve bearing 5 Stopper set 11 Packing 17 Rear b...

Page 1189: ...ut 7 Bearing 13 Terminal 2 Pulley 8 Stator coil 3 Front cover 9 IC regulator with brush Tightening torque N m kgf m ft lb 4 Ball bearing 10 Brush T1 4 7 0 48 3 5 5 Bearing retainer 11 Rectifier T2 108...

Page 1190: ...tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your ha...

Page 1191: ...nect connector and terminal from starter 4 Remove starter from transmission B INSTALLATION Install in the reverse order of removal Tightening torque 50 N m 5 1 kgf m 37 ft lb C DISASSEMBLY 1 STARTER A...

Page 1192: ...older screws and detach rear bracket and brush holder NOTE Before removal confirm the attachment locations of brush holder and rear bracket 4 Remove armature and yoke from the front brack et 5 Remove...

Page 1193: ...opper with an appropriate tool such as a socket 2 Remove ring stopper and clutch from shaft 2 BRUSH HOLDER Slightly open the metal fitting holding the insulating plate to the brush holder Remove the i...

Page 1194: ...nternal and planetary gears 1 Install overrunning clutch to shaft assembly 2 Install stopper to shaft assembly in the following order 1 Insert the ring into the shaft groove by lightly tapping it with...

Page 1195: ...eplace if it ex ceeds the limit Commutator run out Standard 0 05 mm 0 0020 in Service limit Less than 0 10 mm 0 0039 in 3 Depth of segment mold Check the depth of segment mold Depth of segment mold 0...

Page 1196: ...ER 1 Brush length Measure the brush length and replace if it exceeds the service limit Replace if abnormal wear or cracks are noticed Brush length Standard 12 3 mm 0 484 in Service limit 7 0 mm 0 276...

Page 1197: ...this test set up the pinion should return to its original position even when it is pulled out with a screwdriver 7 PINION GAP 1 Measure pinion gap while the pinion is pulled out as shown in the figur...

Page 1198: ...and measure the starter speed Compare these values with the specifications No load test Standard Voltage Current 11 V 90 A max Rotating speed 2 400 rpm or more 2 Load test Apply the specified braking...

Page 1199: ...sen bolt B Then re move generator from bracket B INSTALLATION Install in the reverse order of removal C DISASSEMBLY 1 Remove the four through bolts 2 Heat the portion A of rear cover to 50 C 122 F wit...

Page 1200: ...mly install an appropriate tool such as a fit socket wrench to bearing inner race 3 Push the ball bearing off the front cover us ing a press 6 Remove the bearing from rotor using a bearing puller 7 Un...

Page 1201: ...een IC regula tor and rectifier to remove the IC regulator 9 Remove the brush as follows 1 Remove cover A 2 Remove the cover B 3 Separate the brush from connection to re move 10 Remove the rectifier a...

Page 1202: ...cover 50 to 60 C 122 to 140 F and then press the rear bearing into rear cover CAUTION Grease should not be applied to rear bearing Remove the oil completely if it is found on bear ing box 5 After rea...

Page 1203: ...Specified resistance Approx 2 0 2 4 4 Insulation test Check the continuity between slip ring and rotor core or shaft If resistance is 1 or less the rotor coil is grounded and so replace the rotor ass...

Page 1204: ...g a spring pressure indicator push the brush into the brush holder until its tip protrudes 2 mm 0 08 in Then measure the pressure of brush spring If the pressure is less than 2 2 N 224 g 7 91 oz repla...

Page 1205: ...or using in enclosed space For safety in case an explosion does occur wear eye protection or shield your eyes when working near any battery Never lean over a bat tery Do not let battery fluid contact...

Page 1206: ...ld at a specific value in a range from 1 250 to 1 290 for more than one hour 2 Voltage per battery cell is held at a specific value in a range from 2 5 to 2 8 volts for more than one hour 2 CHECK HYDR...

Page 1207: ...SC H6DO 22 STARTING CHARGING SYSTEMS BATTERY MEMO...

Page 1208: ...Signal 30 8 Data Link Connector 31 9 OBD II General Scan Tool 32 10 Subaru Select Monitor 34 11 Read Diagnostic Trouble Code 46 12 Inspection Mode 47 13 Drive Cycle 52 14 Clear Memory Mode 54 15 Compu...

Page 1209: ...scan tool switch to ON 4 Read DTC on the Subaru Select Monitor or OBD II general scan tool Does the Subaru Select Monitor or OBD II general scan tool indicate DTC DTC indicated Go to step 4 Repair the...

Page 1210: ...rential gear oil level check Ref to AT 31 Differential Gear Oil 3 ATF leak check Ref to AT 30 Automatic Transmission Fluid 4 Differential gear oil leak check Ref to AT 31 Differential Gear Oil 5 Stall...

Page 1211: ...thers Outdoor temperature F C Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine sp...

Page 1212: ...of fuel gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of parts othe...

Page 1213: ...ual sensors or all electrical control modules at the harness side connector use a tapered pin with a diameter of less than 0 64 mm 0 025 in Do not insert the pin more than 5 mm 0 20 in into the part 6...

Page 1214: ...e distinguished clearly when performing diagnostics 15 Diagnostics should be conducted by rotating with simple easy operations and proceeding to complicated difficult operations The most impor tant th...

Page 1215: ...oint Fuel Injection MFI system is a system that supplies the optimum air fuel mixture to the engine for all the various operating condi tions through the use of the latest electronic tech nology With...

Page 1216: ...24082AA210 Newly adopted tool CARTRIDGE Troubleshooting for electrical systems 22771AA030 SELECT MONI TOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA07...

Page 1217: ...Components Location A LOCATION 1 ENGINE MODULE LHD model RHD model EN 01065 1 2 3 4 1 Engine control module ECM 3 Test mode connector 2 Data link connector for Subaru Select Monitor and OBD II general...

Page 1218: ...EN H6DO 11 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00845 1 EN 00846 2 EN 00847 3 EN 01067 4...

Page 1219: ...ENTS LOCATION SENSOR 1 Intake air temperature sensor 4 Throttle position sensor 2 Intake manifold pressure sensor 5 Knock sensor 3 Engine coolant temperature sen sor 6 Camshaft position sensor 7 Crank...

Page 1220: ...EN H6DO 13 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00893 1 EN 00894 2 EN 00895 3 EN 00896 4 EN 00897 5 5 EN 00898 6 EN 00899 7...

Page 1221: ...OCATION 1 Front oxygen A F sensor LH 3 Rear oxygen sensor 5 Front catalytic converter RH 2 Front oxygen A F sensor RH 4 Front catalytic converter LH 6 Rear catalytic converter EN 00762 3 2 5 6 4 1 EN...

Page 1222: ...EN H6DO 15 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION LHD model RHD model EN 01068 1 2 1 Fuel level sensor 2 Fuel sub level sensor EN 01069 1 2 EN 01070 1 EN 01071 2...

Page 1223: ...ENOID VALVE EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 Induction control solenoid valve 3 Purge control solenoid valve 5 Induction control valve 2 Idle air control solenoid valve 4 EGR...

Page 1224: ...EN H6DO 17 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00909 1 EN 00910 2 EN 00911 3 EN 00912 4 EN 00913 5 EN 00914 6...

Page 1225: ...D model EN 01142 1 2 3 4 5 6 7 8 9 10 1 Inhibitor switch 5 Radiator main fan relay 1 9 Starter 2 Fuel pump 6 Radiator sub fan relay 1 10 Fuel pump controller 3 Main relay 7 Radiator main fan relay 2 4...

Page 1226: ...EN H6DO 19 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00873 1 EN 01072 2 EN 00875 3 EN 00876 4 EN 00919 5 6 7 8 EN 00920 9 EN 01073 10...

Page 1227: ...EN H6DO 20 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 2 TRANSMISSION MODULE LHD model RHD model EN 01074 1 2 1 Transmission Control Module TCM 2 AT diagnostic indicator light EN 01075 1 2...

Page 1228: ...EN H6DO 21 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00922 1 EN 01262 2...

Page 1229: ...S ELECTRICAL COMPONENTS LOCATION SENSOR 1 Rear vehicle speed sensor 2 Front vehicle speed sensor 3 Torque converter turbine speed sensor 4 ATF temperature sensor 5 Brake light switch 1 2 EN 00924 3 EN...

Page 1230: ...1 Inhibitor switch 2 Shift solenoid valve 1 3 Shift solenoid valve 2 4 Line pressure duty solenoid 5 Lock up duty solenoid 6 Transfer duty solenoid 7 2 4 brake duty solenoid 8 Low clutch timing soleno...

Page 1231: ...nal B135 10 0 0 Throttle posi tion sensor Signal B135 7 Fully closed 0 3 0 8 Fully open 4 2 4 7 0 3 0 8 Power supply B135 9 5 5 GND sensor B135 19 0 0 Rear oxy gen sensor Signal B135 17 0 0 5 0 0 9 Sh...

Page 1232: ...ntrol unit power supply B137 2 10 13 13 14 3 10 13 13 14 Sensor power supply B135 9 5 5 Line end check 1 B134 10 0 0 Ignition con trol 1 B136 24 0 Waveform 2 B136 23 0 Waveform 3 B136 22 0 Waveform 4...

Page 1233: ...han 1 More than 4 Waveform AT load signal B135 28 4 3 4 4 0 9 1 4 Small light switch B134 17 ON 0 OFF 10 13 ON 0 OFF 13 14 Blower fan switch B134 9 ON 0 OFF 10 13 ON 0 OFF 13 14 Rear defogger switch B...

Page 1234: ...ENGINE CONTROL MODULE ECM I O SIGNAL GND oxygen sensor heater LH 1 B137 21 0 0 2 B137 31 GND oxygen sensor heater RH 1 B137 9 0 0 2 B137 8 Content Con nector No Termi nal No Signal V Note Ignition SW...

Page 1235: ...AGNOSTICS ENGINE CONTROL MODULE ECM I O SIGNAL B MEASUREMENT Measure input output signal voltage 1 WAVEFORM EN 00799 0V 2V 0V 10 ms Crankshaft position sensor Terminal No 1 2 Crankshaft position senso...

Page 1236: ...ne Condition Data A ELECTRICAL SPECIFICATION Measuring condition After warm up the engine Gear position is in N or P position A C is turned OFF All accessory switches are turned OFF Content Specified...

Page 1237: ...SIGNAL 7 Transmission Control Module TCM I O Signal A ELECTRICAL SPECIFICATION For electrical specification of transmission control module TCM input output signal refer to AT section Ref to AT 14 ELE...

Page 1238: ...the Subaru Se lect Monitor because the circuit for the Subaru Select Monitor may be damaged Terminal No 4 to No 6 of the data link connector is used for the Subaru Select Monitor signal A Data link c...

Page 1239: ...C Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC 2 MODE 01 CURRENT POWERTRAIN DIAGNOSTIC DATA Refers to data denoting the current operating condition of analog input output digital input output...

Page 1240: ...ut data denoting emission related powertrain di agnostic trouble codes Ref to EN H6DO 46 Read Diagnostic Trouble Code 5 MODE 04 CLEAR RESET EMISSION RELATED DIAGNOSTIC INFORMATION Refers to the mode u...

Page 1241: ...to data link con nector CAUTION Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 5 Turn ignition switch to ON engine OFF and Subaru Select Monitor switch to ON...

Page 1242: ...nal 2 A F Sensor 2 Front oxygen A F sensor resistance 1 A F Sensor 1 Resistance Front oxygen A F sensor resistance 2 A F Sensor 2 Resistance Rear oxygen sensor output signal Rear O2 Sensor V Short ter...

Page 1243: ...nifold is displayed The ECM detects the pressure in the intake tube via the signal from the pressure sensor The ECM calculates the air mass required for the engine Engine Speed Display 0 16 383 rpm Th...

Page 1244: ...the atmospheric pressure via the signal from the atmosphere sensor Mani Relative Pressure Display 128 128 kPa 952 952 mm Hg 37 5 37 5 inHg A value calculated by subtracting the absolute pressure in th...

Page 1245: ...or idle control or other controls A C Switch Display ON or OFF When the A C switch is turned ON ON is dis played When turned OFF OFF is displayed This signal is used for idle control or other controls...

Page 1246: ...t torque down is possible is displayed This signal is trans mitted from the ECU in response to a torque down signal from the TCU When torque down is prohib ited ON is displayed When permitted OFF is d...

Page 1247: ...No support Test of air conditioning system refrigerant A C system refrigerant No support Test of oxygen sensor Bank 1 Bank 2 Rear Oxygen sensor Complete or incomplete Test of oxygen sensor heater Ban...

Page 1248: ...NITOR OPERATION MANUAL Contents Display Unit of measure Diagnostic trouble code DTC for freeze frame data Freeze frame data DTC Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF...

Page 1249: ...1 ON or OFF When radiator main fan relay is functioning Fuel pump relay signal Fuel Pump Relay ON or OFF When fuel pump relay is functioning Knocking signal Knocking Signal 1 or 2 ON or OFF When knock...

Page 1250: ...essure control duty ratio Line Pressure Duty Ratio Lock up clutch control duty ratio Lock Up Duty Ratio Transfer clutch control duty ratio Transfer Duty Ratio Power supply for throttle position sensor...

Page 1251: ...for the throttle sensor output correction Brake Clutch Duty Ratio Display 0 123 The duty value of the 2 4 brake duty solenoid The 2 4 brake duty solenoid is regulated by the TCM adjusting the 2 4 brak...

Page 1252: ...played When it does not exist OFF is displayed Torque Permission Signal Display ON or OFF The signal which notifies whether or not torque down is possible is displayed This signal is trans mitted fro...

Page 1253: ...lay screen select the 2 Each System Check and press the YES key 2 On the System Selection Menu display screen select the Engine Control System and press the YES key 3 Press the YES key after displayed...

Page 1254: ...pedal position sensor switch A circuit high input P0129 Barometric pressure too low P0130 O2 sensor circuit Bank 1 Sensor 1 P0134 O2 sensor circuit no activity detected Bank 1 Sensor 1 P0137 O2 senso...

Page 1255: ...P0771 Shift solenoid E performance or stuck off P0778 Pressure control solenoid B electrical P0785 Shift timing solenoid P0851 Neutral switch input circuit low P0852 Neutral switch input circuit high...

Page 1256: ...r to prevent the vehicle from slipping due to vibration do not place any wooden blocks or similar items between the safety stands and the vehicle Since the rear wheels will also rotate do not place an...

Page 1257: ...splay screen If trouble still remains in the memory the corre sponding diagnostic trouble code DTC appears on the display screen NOTE For detailed operation procedure refer to the SUBARU SELECT MONITO...

Page 1258: ...he vehicle at 5 to 10 km h 3 to 6 MPH NOTE On AWD vehicles release the parking brake The speed difference between front and rear wheels may light the ABS warning light but this in dicates no malfuncti...

Page 1259: ...warm up Carry out diagnosis which is marked on DTC twice Then after finishing 1st diagnosis stop engine and do the second time at the same condition 2 AFTER RUNNING 20 MINUTES AT 80 KM H 50 MPH IDLE E...

Page 1260: ...Condition P0121 Throttle pedal position sensor switch A circuit range performance Coolant temperature at start is more than 80 C 176 F P0139 O2 sensor circuit slow response Bank 1 Sensor 2 P0171 Syst...

Page 1261: ...ITOR OPERATION MANUAL 2 SUBARU SELECT MONITOR OBD MODE 1 On the Main Menu display screen select the 2 Each System Check and press the YES key 2 On the System Selection Menu display screen select the E...

Page 1262: ...N Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 6 Turn ignition switch to ON engine OFF and Subaru Select Monitor switch to ON 7 On the Main Menu display scre...

Page 1263: ...d operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL Contents Display Compulsory fuel pump relay operation check Fuel Pump Relay Compulsory radiator fan relay operation check Rad...

Page 1264: ...EN H6DO 57 ENGINE DIAGNOSTICS COMPULSORY VALVE OPERATION CHECK MODE MEMO...

Page 1265: ...ine Malfunction Indicator Lamp MI 3 Check engine malfunction indicator lamp MI does not go off Ref to EN H6DO 64 CHECK ENGINE MALFUNCTION INDICATOR LAMP MI DOES NOT GO OFF Engine Malfunction Indicator...

Page 1266: ...Engine Malfunction Indi cator Lamp MI 2 After starting the engine the MI goes out If it does not either the engine or the emission control system is malfunctioning 3 If the diagnosis system senses a m...

Page 1267: ...1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B137 i10 B72 3 4 1 2 BATTERY 15 ECM B157 10 11 12 13 14 15 16 17 18 19 20...

Page 1268: ...ion of ECM connector 4 CHECK HARNESS BETWEEN COMBINA TION METER AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Remove combination meter Ref to IDI 14 Combination Meter Assembly 3 Disconnect connect...

Page 1269: ...ary NOTE Broken down ignition relay Blown out fuse No 5 If replaced fuse No 5 blows eas ily check the har ness for short circuit of harness between fuse No 5 and ignition relay connector Open or short...

Page 1270: ...EN H6DO 63 ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LAMP MI MEMO...

Page 1271: ...G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B137 i10 B72 3 4 1 2 BATTERY 15 ECM B157 10 11 12...

Page 1272: ...S BETWEEN COMBINA TION METER AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Turn ignition switch to ON Does the MI come on MI comes on Repair short circuit in harnes...

Page 1273: ...6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B134 B157 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 1274: ...ECM 3 Measure resistance of harness between test mode connector and chassis ground Connector terminal B76 No 1 Chassis ground Is the measured value less than the speci fied value 1 Go to step 4 Repair...

Page 1275: ...A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B134 B157 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33...

Page 1276: ...e of 3 Hz when test mode connector is connected 2 CHECK HARNESS BETWEEN ECM CON NECTOR AND ENGINE GROUNDING TER MINAL 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance...

Page 1277: ...EN H6DO 70 ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LAMP MI MEMO...

Page 1278: ...ilure 3 Inspection of ignition control system Ref to EN H6DO 80 IGNITION CONTROL SYSTEM Diagnostics for Engine Starting Failure 4 Inspection of fuel pump circuit Ref to EN H6DO 84 FUEL PUMP CIRCUIT Di...

Page 1279: ...DO 54 OPERATION Clear Memory Mode and INSPECTION MODE Ref to EN H6DO 47 OPERATION In spection Mode WIRING DIAGRAM EN 01082 12 INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 12 11 T7 T3...

Page 1280: ...posi tion 10 V Go to step 4 Go to step 5 4 CHECK GROUND CIRCUIT OF STARTER MOTOR 1 Turn ignition switch to OFF 2 Measure resistance between ground cable terminal and engine ground Is the measured valu...

Page 1281: ...easure resistance between transmission harness connector terminals Connector terminal T3 No 11 No 12 Is the measured value less than the speci fied value 1 Repair open or short circuit in har ness bet...

Page 1282: ...EN H6DO 75 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 1283: ...2 D3 E49 B252 D9 C8 D8 D31 D21 5 1 3 B47 BATTERY MAIN RELAY 1 2 3 5 6 4 F44 B61 SBF 5 6 F46 B108 2 SBF 4 SBF 1 4 1 B72 IGNITION SWITCH ECM B134 A B136 C B137 D A22 7 B137 B136 C D A B134 B47 3 4 1 2 5...

Page 1284: ...ircuit in harness between ECM connector and engine grounding terminal 3 CHECK INPUT VOLTAGE OF ECM 1 Turn ignition switch to ON 2 Measure voltage between ECM connector and chassis ground Connector ter...

Page 1285: ...n relay and chassis ground 8 CHECK INPUT VOLTAGE OF MAIN RELAY Measure voltage between main relay connec tor and chassis ground Connector terminal B47 No 5 Chassis ground B47 No 6 Chassis ground Does...

Page 1286: ...EN H6DO 79 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 1287: ...ection Mode WIRING DIAGRAM EN 00806 E34 E45 E31 E32 E46 E33 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B72 3 4 1 2 ENGINE CONT...

Page 1288: ...N 4 Measure power supply voltage between ignition coil ignitor assembly connector and engine ground Connector terminal E31 No 3 Engine ground E32 No 3 Engine ground E33 No 3 Engine ground E34 No 3 Eng...

Page 1289: ...ground B136 No 22 Engine ground B136 No 21 Engine ground B136 No 20 Engine ground B136 No 19 Engine ground Does the measured value exceed the specified value 1 M Go to step 7 Repair ground short circu...

Page 1290: ...EN H6DO 83 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 1291: ...4 10 R57 R58 R15 9 BATTERY FUEL PUMP CONTROLLER FUEL PUMP FUEL PUMP RELAY SBF 5 F44 B61 B97 B46 R1 6 3 R3 B99 2 4 R122 7 B136 C 3 5 4 24 25 8 6 5 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18...

Page 1292: ...ound produced Check fuel injec tor circuit Ref to EN H6DO 86 FUEL INJECTOR CIRCUIT Diag nostics for Engine Starting Failure Read the diagnos tic Trouble Code DTC and check related DTC Ref to EN H6DO 8...

Page 1293: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E6 E17 E5 E16 E43 E44 1 2 1 2 1 2 1 2 C5 C6 D1 C4 16 10 15 14 13 ECM B137 D B136 C E5 E16 E6 E17 B22 E3 FUEL INJECTOR No 1 FUEL INJECTOR No 2 FUEL INJECTOR No 3...

Page 1294: ...rness between main relay and fuel injector connector Poor contact in main relay con nector Poor contact in coupling connector Poor contact in fuel injector con nector 3 CHECK HARNESS BETWEEN ECM AND F...

Page 1295: ...rminals No 1 No 2 Is the measured value within the specified range 5 20 Go to step 6 Replace faulty fuel injector 6 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM...

Page 1296: ...DTC P0068 Manifold absolute pressure barometric pressure circuit range performance Ref to EN H6DO 124 DTC P0068 MANIFOLD ABSOLUTE PRES SURE BAROMETRIC PRESSURE CIRCUIT RANGE PERFORMANCE Diagnostic Pro...

Page 1297: ...LOW RESPONSE BANK 1 SENSOR 2 Diagnostic Procedure with Diagnostic Trouble Code DTC P0150 O2 sensor circuit Bank 2 Sensor 1 Ref to EN H6DO 176 DTC P0150 O2 SENSOR CIRCUIT BANK 2 SENSOR 1 Diagnostic Pro...

Page 1298: ...aust gas recirculation flow Ref to EN H6DO 226 DTC P0400 EXHAUST GAS RECIRCULATION FLOW Diagnostic Procedure with Diagnostic Trouble Code DTC P0420 Catalyst System Efficiency Below Threshold Bank 1 Re...

Page 1299: ...Diagnostic Procedure with Diagnostic Trouble Code DTC P0691 Cooling fan 1 control circuit low Ref to EN H6DO 280 DTC P0691 COOLING FAN 1 CONTROL CIR CUIT LOW Diagnostic Procedure with Diagnostic Trou...

Page 1300: ...ut Ref to EN H6DO 306 DTC P1110 ATMOSPHERIC PRESSURE SEN SOR CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC P1111 Atmospheric pressure sensor circuit malfunction h...

Page 1301: ...le Code DTC P1711 Engine torque control signal 1 circuit malfunction Ref to EN H6DO 328 DTC P1711 ENGINE TORQUE CONTROL SIG NAL 1 CIRCUIT MALFUNCTION Diagnostic Procedure with Diagnostic Trouble Code...

Page 1302: ...EN H6DO 95 ENGINE DIAGNOSTICS LIST OF DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1303: ...ouble Code DTC A DTC P0030 HO2S HEATER CONTROL CIRCUIT BANK 1 SENSOR 1 DTC DETECTING CONDITION Two consecutive driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Cle...

Page 1304: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1305: ...ed value 1 Go to step 3 Repair open circuit in harness between ECM and front oxygen A F sensor connector 3 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR CONNEC TOR Measure resistance of harnes...

Page 1306: ...EN H6DO 99 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1307: ...HO2S HEATER CONTROL CIRCUIT LOW BANK 1 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 5...

Page 1308: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1309: ...O 34 Subaru Select Moni tor OBD II scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual 0 2 A Repair poor con tact in connector NOTE In this case repair...

Page 1310: ...l E47 No 2 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 8 Repair power sup ply line NOTE In this case repair the following Open circuit in harness between main rel...

Page 1311: ...HO2S HEATER CONTROL CIRCUIT HIGH BANK 1 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO...

Page 1312: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1313: ...ceed the spec ified value NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H6DO 34 Subaru Select Moni tor OBD II general scan tool For de...

Page 1314: ...EN H6DO 107 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1315: ...e WIRING DIAGRAM EN 01088 BATTERY F44 B61 6 T5 B19 B47 MAIN RELAY 2 1 3 5 4 6 F44 1 2 3 4 5 6 7 8 C13 B17 B19 B26 D21 D31 D9 D8 REAR OXYGEN SENSOR 5 3 6 4 1 3 4 2 1 5 B252 B83 B19 T5 T6 E49 B47 T6 B13...

Page 1316: ...In this case repair the following Poor contact in rear oxygen sen sor connector Poor contact in rear oxygen sen sor connecting harness connector Poor contact in ECM connector Go to step 3 3 CHECK OUTP...

Page 1317: ...owing Open circuit in harness between main relay and rear oxygen sen sor connector Poor contact in rear oxygen sen sor connector Poor contact in coupling connector 7 CHECK REAR OXYGEN SENSOR 1 Turn ig...

Page 1318: ...EN H6DO 111 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1319: ...de WIRING DIAGRAM EN 01088 BATTERY F44 B61 6 T5 B19 B47 MAIN RELAY 2 1 3 5 4 6 F44 1 2 3 4 5 6 7 8 C13 B17 B19 B26 D21 D31 D9 D8 REAR OXYGEN SENSOR 5 3 6 4 1 3 4 2 1 5 B252 B83 B19 T5 T6 E49 B47 T6 B1...

Page 1320: ...h to ON 3 Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD II general scan tool Does the measured value exceed the spec ified value NOTE Subaru Select Monitor For...

Page 1321: ...ION Inspec tion Mode WIRING DIAGRAM EN 01087 BATTERY F44 B61 SBF 5 6 B47 MAIN RELAY 1 2 3 5 4 6 9 8 21 31 2 1 5 B252 E49 ECM 18 29 19 5 4 7 6 20 30 4 1 3 FRONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT O...

Page 1322: ...ed value 1 Go to step 3 Repair open circuit in harness between ECM and front oxygen A F sensor connector 3 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR CONNEC TOR Measure resistance of harnes...

Page 1323: ...HO2S HEATER CONTROL CIRCUIT LOW BANK 2 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 5...

Page 1324: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1325: ...O 34 Subaru Select Moni tor OBD II scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual 0 2 A Repair poor con tact in connector NOTE In this case repair...

Page 1326: ...l E24 No 2 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 8 Repair power sup ply line NOTE In this case repair the following Open circuit in harness between main rel...

Page 1327: ...HO2S HEATER CONTROL CIRCUIT HIGH BANK 2 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO...

Page 1328: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1329: ...xceed the spec ified value NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H6DO 34 Subaru Select Moni tor OBD II general scan tool For d...

Page 1330: ...EN H6DO 123 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1331: ...repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 00811...

Page 1332: ...yed Another DTC is displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect...

Page 1333: ...faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 00811 9 19 8 5 8 B135 B20 E1 16...

Page 1334: ...ssis ground Does the measured value exceed the specified value 4 5 V Go to step 5 Go to step 4 4 CHECK INPUT SIGNAL FOR ECM Measure voltage between ECM connector and chassis ground Connector terminal...

Page 1335: ...nifold pressure sensor connector Connector terminal B135 No 19 E21 No 2 Is the measured value less than the speci fied value 1 Go to step 9 Repair open circuit in harness between ECM and intake manifo...

Page 1336: ...EN H6DO 129 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1337: ...faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 00811 9 19 8 5 8 B135 B20 E1 1...

Page 1338: ...onnector and chassis ground Connector terminal B135 No 9 Chassis ground Does the voltage change more than the speci fied value by shaking harness and connector of ECM while monitoring the value with v...

Page 1339: ...nd intake manifold pressure sensor connector Connector terminal B135 No 8 E21 No 1 Is the measured value less than the speci fied value 1 Go to step 8 Repair open circuit in harness between ECM and in...

Page 1340: ...olute pres sure signal using Subaru Select Monitor or OBD II general scan tool Does the measured value exceed the spec ified value NOTE Subaru Select Monitor For detailed operation procedure refer to...

Page 1341: ...AUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAG...

Page 1342: ...DISPLAY Is any other DTC displayed Another DTC is displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC NOTE In this case...

Page 1343: ...ter repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 00...

Page 1344: ...oor contact in ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE SENSOR AND ECM CON NECTOR 1 Turn ignition switch to OFF 2 Disconnec...

Page 1345: ...ter repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 00...

Page 1346: ...r tem perature sensor connector and engine ground Connector terminal E20 No 1 Engine ground Does the measured value exceed the spec ified value 10 V Repair battery short circuit in har ness between in...

Page 1347: ...Connector terminal E20 No 2 Engine ground Is the measured value less than the speci fied value 5 Replace intake air temperature sen sor Ref to FU H6DO 35 Intake Air Temper ature Sensor Repair harness...

Page 1348: ...EN H6DO 141 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1349: ...fter repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 0...

Page 1350: ...act in ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect con...

Page 1351: ...After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN...

Page 1352: ...in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from engine coola...

Page 1353: ...r Poor contact in coupling connector Poor contact in joint connector 5 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn ignition switch to OFF 2 Measure resistance of h...

Page 1354: ...EN H6DO 147 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1355: ...performance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mod...

Page 1356: ...TC ON DISPLAY Is any other DTC displayed Another DTC is displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC NOTE In this...

Page 1357: ...nce CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING...

Page 1358: ...round while throttle valve is fully closed Connector terminal B135 No 7 Chassis ground Does the measured value exceed the specified value 4 5 V Go to step 4 Go to step 3 3 CHECK INPUT SIGNAL FOR ECM M...

Page 1359: ...M connector and throttle position sensor connector Connector terminal B135 No 9 E13 No 3 Is the measured value less than the speci fied value 1 Go to step 8 Repair harness and connector NOTE In this c...

Page 1360: ...EN H6DO 153 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1361: ...nce CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING...

Page 1362: ...CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNEC TOR 1 Turn ignition switch to OFF 2 Disconnect connector from throttle position sensor 3 Measure resistance of harness between throttle p...

Page 1363: ...After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN...

Page 1364: ...o step 2 2 CHECK TIRE SIZE Is the tire size the same as designated tire and four wheel tire Same Go to step 3 Replace tire 3 CHECK ENGINE COOLANT Check the following items Engine coolant volume Engine...

Page 1365: ...r Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displa...

Page 1366: ...EN H6DO 159 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1367: ...c tion Mode WIRING DIAGRAM EN 01087 BATTERY F44 B61 SBF 5 6 B47 MAIN RELAY 1 2 3 5 4 6 9 8 21 31 2 1 5 B252 E49 ECM 18 29 19 5 4 7 6 20 30 4 1 3 FRONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F...

Page 1368: ...F sensor connector 3 CHECK INPUT SIGNAL FOR ECM 1 Connect ECM and front O2 A F sensor connector 2 Turn ignition switch to ON 3 After warming up engine idle engine 4 Measure voltage between ECM connect...

Page 1369: ...SENSOR CIRCUIT SLOW RESPONSE BANK 1 SENSOR 1 DTC DETECTING CONDITION Two consecutive driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H...

Page 1370: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1371: ...rouble Code DTC NOTE In this case it is not necessary to inspect DTC P0133 Go to step 2 2 CHECK EXHAUST SYSTEM NOTE Check the following items Loose installation of front portion of exhaust pipe onto c...

Page 1372: ...EN H6DO 165 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1373: ...SENSOR CIRCUIT NO ACTIVITY DETECTED BANK 1 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6...

Page 1374: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1375: ...xygen A F sensor connector Poor contact in ECM connector 2 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR CONNEC TOR Measure resistance of harness between ECM and front oxygen A F sensor connec...

Page 1376: ...NOSTIC TROUBLE CODE DTC Y DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE BANK 1 SENSOR 2 NOTE For diagnostic procedure refer to DTC P0138 Ref to EN H6DO 170 DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE BANK 1 SE...

Page 1377: ...e WIRING DIAGRAM EN 01088 BATTERY F44 B61 6 T5 B19 B47 MAIN RELAY 2 1 3 5 4 6 F44 1 2 3 4 5 6 7 8 C13 B17 B19 B26 D21 D31 D9 D8 REAR OXYGEN SENSOR 5 3 6 4 1 3 4 2 1 5 B252 B83 B19 T5 T6 E49 B47 T6 B13...

Page 1378: ...Tool Is the measured value within the specified range Output maximum value 0 49 V or more and output minimum value 0 25 V or less Go to step 4 Replace rear oxy gen sensor Ref to FU H6DO 45 Rear Oxygen...

Page 1379: ...ck the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fault in exhau...

Page 1380: ...EN H6DO 173 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1381: ...de WIRING DIAGRAM EN 01088 BATTERY F44 B61 6 T5 B19 B47 MAIN RELAY 2 1 3 5 4 6 F44 1 2 3 4 5 6 7 8 C13 B17 B19 B26 D21 D31 D9 D8 REAR OXYGEN SENSOR 5 3 6 4 1 3 4 2 1 5 B252 B83 B19 T5 T6 E49 B47 T6 B1...

Page 1382: ...HER DTC ON DISPLAY Is any other DTC displayed Another DTC is displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC NOTE In...

Page 1383: ...TC P0150 O2 SENSOR CIRCUIT BANK 2 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP E...

Page 1384: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1385: ...O2 A F sensor connector 3 CHECK INPUT SIGNAL FOR ECM 1 Connect ECM and front O2 A F sensor connector 2 Turn ignition switch to ON 3 After warming up engine idle engine 4 Measure voltage between ECM co...

Page 1386: ...EN H6DO 179 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1387: ...SENSOR CIRCUIT SLOW RESPONSE BANK 2 SENSOR 1 DTC DETECTING CONDITION Two consecutive driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H...

Page 1388: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1389: ...Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0153 Go to step 2 2 CHECK EXHAUST SYSTEM NOTE Check the following items Loose installation of front portion of exhaust pipe onto...

Page 1390: ...EN H6DO 183 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1391: ...SENSOR CIRCUIT NO ACTIVITY DETECTED BANK 2 SENSOR 1 DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6...

Page 1392: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1393: ...xygen A F sensor connector Poor contact in ECM connector 2 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR CONNEC TOR Measure resistance of harness between ECM and front oxygen A F sensor connec...

Page 1394: ...C PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AE DTC P0171 SYSTEM TOO LEAN BANK 1 NOTE For the diagnostic procedure refer to DTC P0172 Ref to EN H6DO 188 DTC P0172 SYSTEM TOO RICH BANK 1 Diagnostic Pro...

Page 1395: ...e bolts or discon nection of hose is found Repair air intake system Go to step 4 4 CHECK FUEL PRESSURE Warning Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Low...

Page 1396: ...k fuel injector Ref to FU H6DO 39 REMOVAL Fuel Injector 3 Check fuel injector Is fuel injector clogged Fuel injector is clogged Replace fuel injec tor Ref to FU H6DO 39 Fuel Injector Go to step 7 7 CH...

Page 1397: ...f to FU H6DO 34 Intake Manifold Pressure Sensor 10 CHECK INTAKE AIR TEMPERATURE SEN SOR 1 Start the engine and warm up engine until coolant temperature is greater than 75 C 167 F 2 Place the shift lev...

Page 1398: ...C PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AG DTC P0174 SYSTEM TOO LEAN BANK 2 NOTE For the diagnostic procedure refer to DTC P0175 Ref to EN H6DO 192 DTC P0175 SYSTEM TOO RICH BANK 2 Diagnostic Pro...

Page 1399: ...e bolts or discon nection of hose is found Repair air intake system Go to step 4 4 CHECK FUEL PRESSURE Warning Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Low...

Page 1400: ...k fuel injector Ref to FU H6DO 39 REMOVAL Fuel Injector 3 Check fuel injector Is fuel injector clogged Fuel injector is clogged Replace fuel injec tor Ref to FU H6DO 39 Fuel Injector Go to step 7 7 CH...

Page 1401: ...manifold pressure sensor Ref to FU H6DO 34 Intake Manifold Pressure Sensor 10 CHECK INTAKE AIR TEMPERATURE SEN SOR 1 Start the engine and warm up engine until coolant temperature is greater than 75 C...

Page 1402: ...EN H6DO 195 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1403: ...pection Mode WIRING DIAGRAM LHD model EN 01084 10 R57 R58 R15 9 BATTERY FUEL PUMP CONTROLLER FUEL PUMP FUEL PUMP RELAY SBF 5 F44 B61 B97 B46 R1 6 3 R3 B99 2 4 R122 7 B136 C 3 5 4 24 25 8 6 5 1 2 7 8 9...

Page 1404: ...ELAY SBF 5 B99 B46 R3 1 R2 B98 2 4 R122 7 B136 C 3 5 4 14 16 8 6 5 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 C16 ECM B136 B12 C B135 B B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 1...

Page 1405: ...chassis ground Connector terminal R122 No 5 Chassis ground Is the measured value less than the speci fied value 5 Go to step 3 Repair harness and connector NOTE In this case repair the following Open...

Page 1406: ...oller and ECM Poor contact in fuel pump control ler and ECM con nector 6 CHECK HARNESS BETWEEN FUEL PUMP CONTROLLER AND ECM CONNECTOR Measure resistance of harness between fuel pump controller and cha...

Page 1407: ...cedure with Diagnostic Trouble Code DTC AL DTC P0303 CYLINDER 3 MISFIRE DETECTED NOTE For the diagnostic procedure refer to DTC P0306 Ref to EN H6DO 202 DTC P0306 CYLINDER 6 MISFIRE DETECTED Diagnosti...

Page 1408: ...EN H6DO 201 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1409: ...Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01086 B22 F46 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E6 E17 E5 E16 E43 E44 1 2 1 2 1 2 1 2 C5 C6 D1 C4 16 10 15...

Page 1410: ...1 Chassis ground 2 B136 No 6 Chassis ground 3 B136 No 5 Chassis ground 4 B136 No 4 Chassis ground 5 B136 No 3 Chassis ground 6 B136 No 1 Chassis ground Does the measured value exceed the spec ified v...

Page 1411: ...faulty cylinder Terminals No 1 No 2 Is the measured value within the specified range 5 20 Go to step 6 Replace faulty fuel injector Ref to FU H6DO 39 Fuel Injector 6 CHECK POWER SUPPLY LINE 1 Turn ign...

Page 1412: ...1 Replace faulty fuel injector Ref to FU H6DO 39 Fuel Injector and ECM Ref to FU H6DO 46 Engine Control Module Go to step 9 9 CHECK INSTALLATION OF CAMSHAFT PO SITION SENSOR CRANKSHAFT POSITION SENSO...

Page 1413: ...g connector 15 CHECK AIR INTAKE SYSTEM Is there a fault in air intake system There is a malfunction Repair air intake system NOTE Check the follow ing items Are there air leaks or air suction caused b...

Page 1414: ...DTC P0302 P0304 and P0306 Indicated Go to step 27 Go to step 28 22 ONLY ONE CYLINDER Is there a fault in that cylinder There is a malfunction Repair or replace faulty parts NOTE Check the follow ing...

Page 1415: ...n 5 and 6 cylinders There is a malfunction Repair or replace faulty parts NOTE Check the fol lowing items Spark plugs fuel injector ignition coil and compres sion ratio If no abnormality is discovered...

Page 1416: ...pping timing chain Inspect DTC P0171 P0172 P0174 or P0175 using List of Diag nostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC 28 CYLINDER AT RANDOM Is the engine idle unst...

Page 1417: ...Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion...

Page 1418: ...sensor 1 RH connector Poor contact in coupling connector 2 CHECK KNOCK SENSOR 1 RH 1 Disconnect connector from knock sensor 1 RH 2 Measure resistance between knock sensor connector terminal and engin...

Page 1419: ...Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tio...

Page 1420: ...1 RH Ref to FU H6DO 32 Knock Sensor Repair ground short circuit in har ness between knock sensor 1 RH connector and ECM connec tor NOTE The harness be tween both con nectors is shielded Repair short c...

Page 1421: ...occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WI...

Page 1422: ...sensor 2 LH connector Poor contact in coupling connector 2 CHECK KNOCK SENSOR 2 LH 1 Disconnect connector from knock sensor 2 LH 2 Measure resistance between knock sensor 2 LH connector terminal and e...

Page 1423: ...occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WI...

Page 1424: ...r 2 LH Ref to FU H6DO 32 Knock Sensor Repair ground short circuit in har ness between knock sensor 2 LH connector and ECM connec tor NOTE The harness be tween both con nectors is shielded Repair short...

Page 1425: ...ngine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion...

Page 1426: ...ceed the specified value 1 M Go to step 3 Repair ground short circuit between crank shaft position sen sor and ECM 3 CHECK CONDITION OF CRANKSHAFT PO SITION SENSOR Is the crankshaft position sensor in...

Page 1427: ...Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION...

Page 1428: ...tened securely Go to step 3 Tighten crank shaft position sen sor installation bolt securely 3 CHECK CRANKSHAFT PLATE Are crankshaft plate teeth cracked or dam aged Cracked or damaged Replace crank sha...

Page 1429: ...parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01089 E15 3 2 1 10 2 8 10 1 10 B21 E2...

Page 1430: ...sensor and ECM Connector terminal E15 No 2 B135 No 1 E15 No 3 B135 No 10 Is the measured value less than the speci fied value 1 Go to step 4 Repair open circuit between camshaft position sensor and E...

Page 1431: ...ment of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01089 E15 3 2 1 10 2 8...

Page 1432: ...ion sensor installation bolt securely 3 CHECK CAMSHAFT SPROCKET Remove front chain cover Ref to ME H6DO 39 Front Chain Cover Are camshaft sprocket teeth cracked or dam aged Cracked or damaged Replace...

Page 1433: ...or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01090 F46 B4...

Page 1434: ...ction Manual 53 3 kPa 400 mmHg 15 75 inHg Check if EGR valve intake mani fold pressure sen sor and throttle body are securely installed Go to step 3 3 CHECK POWER SUPPLY TO EGR SOLE NOID VALVE 1 Disco...

Page 1435: ...B137 No 25 E18 No 6 B137 No 26 E18 No 1 B137 No 13 E18 No 4 B137 No 14 E18 No 3 Is the measured value less than the speci fied value 1 Go to step 7 Repair open circuit in harness between ECM and EGR...

Page 1436: ...EN H6DO 229 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1437: ...4 D5 D18 D29 D19 D20 D30 D7 D6 2 4 1 3 2 1 3 4 FRONT OXYGEN A F SENSOR RH E47 FRONT OXYGEN A F SENSOR LH E24 B19 B17 C13 B26 REAR OXYGEN SENSOR 5 4 6 2 4 3 1 3 2 B83 B19 T5 B21 E2 B83 T6 5 7 ECM B136...

Page 1438: ...converter Between front catalytic converter and rear catalytic converter Is there a fault in exhaust system There is a malfunction Repair or replace exhaust system Go to step 3 3 CHECK REAR CATALYTIC...

Page 1439: ...or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01092 16 B20...

Page 1440: ...inal E4 No 2 Engine ground Is the measured value less than the speci fied value 10 Repair ground short circuit in har ness between ECM and purge control solenoid valve connector Go to step 3 3 CHECK H...

Page 1441: ...the spec ified value 10 V Go to step 6 Repair open circuit in harness between main relay and purge control solenoid valve connector 6 CHECK POOR CONTACT Check poor contact in purge control solenoid v...

Page 1442: ...EN H6DO 235 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1443: ...or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01092 16 B20...

Page 1444: ...act in ECM connector Is there poor contact in ECM connector There is poor contact Repair poor con tact in ECM con nector Replace ECM Ref to FU H6DO 46 Engine Control Module 4 CHECK HARNESS BETWEEN PUR...

Page 1445: ...157 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 9 3 5 7 2 4 6 8 BATTERY 1 2 FUEL SUB LEVEL SENSOR FUEL SUB METER UNIT 6 3 FUEL LEVEL SENSOR i53 B157 R98 R1...

Page 1446: ...C displayed Another DTC is displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to...

Page 1447: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 9 3 5 7 2 4 6 8 BATTERY 1 2 FUEL SUB LEVEL SENSOR FUEL SUB METER UNIT 6 3 FUEL LEVEL SENSOR i53 B157 R98 R15 R5...

Page 1448: ...FOR ENGINE Ref to EN H6DO 34 Subaru Select Moni tor 0 12 V Repair poor con tact in ECM con nector Even if MI lights up the circuit has returned to a nor mal condition at this time A tempo rary poor co...

Page 1449: ...K CORD 1 Disconnect connector from fuel pump assembly 2 Measure resistance between fuel pump assembly and chassis ground Connector terminal R59 No 2 Chassis ground Does the measured value exceed the s...

Page 1450: ...EN H6DO 243 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1451: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 9 3 5 7 2 4 6 8 BATTERY 1 2 FUEL SUB LEVEL SENSOR FUEL SUB METER UNIT 6 3 FUEL LEVEL SENSOR i53 B157 R98 R15 R...

Page 1452: ...o OFF 2 Disconnect combination meter connector i10 and ECM connector 3 Turn ignition switch to ON 4 Measure voltage of harness between ECM and chassis ground Connector terminal B135 No 25 Chassis grou...

Page 1453: ...pecified value 10 Go to step 9 Repair open circuit between coupling connector and fuel sub level sensor 9 CHECK FUEL LEVEL SENSOR Warning During work procedures if fuel tank is more than 3 4 full be c...

Page 1454: ...EN H6DO 247 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1455: ...LE SYMPTOM Occurrence of noise Overheating CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6...

Page 1456: ...17 SBF 4 SBF 1 IGNITION SWITCH RELAY HOLDER BLACK B72 F16 B253 F17 F46 3 4 1 2 B137 BATTERY 17 24 28 B137 ENGINE CONTROL MODULE B253 FAN RELAY 5 1 3 4 3 3 4 4 1 1 2 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20...

Page 1457: ...N DISPLAY Is any other DTC displayed Another DTC is displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H6DO 89 List of Diagnostic Trouble Code DTC Check radiator f...

Page 1458: ...GNOSTIC TROUBLE CODE DTC BF DTC P0502 VEHICLE SPEED SENSOR CIRCUIT LOW INPUT NOTE For the diagnostic procedure refer to DTC P0503 Ref to EN H6DO 252 DTC P0503 VEHICLE SPEED SENSOR INTERMITTENT ERRATIC...

Page 1459: ...ONT VEHICLE SPEED SENSOR 17 18 5 6 4 B53 B11 T4 E4 B36 i1 B11 i10 B56 C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 B55 B 1 B134 ECM 1 2 5 6 7 8 13 14 15 16 9 10 1...

Page 1460: ...peed sensor Ref to IDI 18 Speedometer Ref to AT 54 Front Vehicle Speed Sensor Ref to AT 58 Rear Vehicle Speed Sensor and Ref to AT 59 Torque Con verter Turbine Speed Sensor 3 CHECK HARNESS BETWEEN ECM...

Page 1461: ...faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01094 C17 C10 A22 B20 E1 ECM 2...

Page 1462: ...2 2 CHECK AIR BY PASS LINE 1 Turn ignition switch to OFF 2 Remove idle air control solenoid valve from throttle body Ref to FU H6DO 36 Idle Air Control Solenoid Valve 3 Remove throttle body from inta...

Page 1463: ...ct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01094 C17 C10 A22 B20 E1 ECM 2 3 1 9 3 IDLE AIR C...

Page 1464: ...e air con trol solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses Is there a fault in air intake system There is a fault Repair air suction and leaks Go to step 3 3 CHECK TH...

Page 1465: ...Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01094 C17 C10 A22 B20 E1 ECM 2 3 1 9 3 IDLE AIR CONTROL SO...

Page 1466: ...terminal B136 No 10 E7 No 1 Is the measured value less than the speci fied value 1 Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit in harness between ECM...

Page 1467: ...Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01094 C17 C10 A22 B20 E1 ECM 2 3 1 9 3 IDLE AIR CONTROL S...

Page 1468: ...B136 No 10 Chassis ground Does the measured value exceed the spec ified value 10 V Repair battery short circuit in har ness between ECM and idle air control solenoid valve connector After repair repl...

Page 1469: ...EST CIRCUIT DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode R...

Page 1470: ...WIRING DIAGRAM EN 01082 12 INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 12 11 T7 T3 B12 B134 T7 1 2 3 4 5 6 7 8 9 10 11 12 16 B134 ECM BATTERY 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15...

Page 1471: ...1 CHECK OPERATION OF STARTER MOTOR NOTE Place the inhibitor switch in each position Does starter motor operate when ignition switch to ON Starter motor operates Repair battery short circuit in starte...

Page 1472: ...EN H6DO 265 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1473: ...ear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01094 C17 C10 A22 B20 E1 ECM 2 3 1 9 3 IDLE AIR CONTRO...

Page 1474: ...e play for adjustment Throttle cable has a play Go to step 3 Adjust throttle cable Ref to SP H6DO 8 Accelerator Con trol Cable 3 CHECK AIR INTAKE SYSTEM 1 Turn ignition switch to ON 2 Start engine and...

Page 1475: ...NATOR CIRCUIT HIGH INPUT DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memor...

Page 1476: ...exceed the spec ified value 1 M Go to step 2 Repair the short circuit in harness between ECM and generator connec tor 2 CHECK HARNESS BETWEEN GENERATOR AND ECM CONNECTOR Measure the resistance of harn...

Page 1477: ...cles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion...

Page 1478: ...ircuit in harness between TCM and CCM connector Go to step 3 3 CHECK INPUT SIGNAL FOR TCM 1 Connect connector to TCM and CCM 2 Lift up the vehicle or set the vehicle on free rollers CAUTION On AWD mod...

Page 1479: ...EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01083 D10 A14 D2 A2 D3 E49 B252 D9 C8 D8 D31 D21 5 1 3 B47 BATTERY MAIN RELAY 1 2 3 5 6 4 F44 B61 SBF 5 6 F46 B108 2 SBF 4 SBF 1 4 1 B72 IGNITIO...

Page 1480: ...IC TROUBLE CODE DTC Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Subaru Select Monitor or OBD II general scan tool indicate DTC P0604 DTC P0604 is indicated Replace ECM Ref to FU H6DO 4...

Page 1481: ...ement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01097 23 B20 E1 1 2 7...

Page 1482: ...ine ground Is the measured value less than the speci fied value 10 Repair ground short circuit in har ness between ECM and induc tion control sole noid valve connector Go to step 3 3 CHECK HARNESS BET...

Page 1483: ...specified range 10 V Go to step 6 Repair open circuit in harness between main relay and induction control solenoid valve connector 6 CHECK POOR CONTACT Check poor contact in induction control sole noi...

Page 1484: ...EN H6DO 277 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1485: ...ement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01097 23 B20 E1 1 2 7...

Page 1486: ...n switch to ON 4 Measure voltage between ECM and chas sis ground Connector terminal B137 No 23 Chassis ground Does the measured value exceed the spec ified value 10 V Repair battery short circuit in h...

Page 1487: ...LOW DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct Cl...

Page 1488: ...17 SBF 4 SBF 1 IGNITION SWITCH RELAY HOLDER BLACK B72 F16 B253 F17 F46 3 4 1 2 B137 BATTERY 17 24 28 B137 ENGINE CONTROL MODULE B253 FAN RELAY 5 1 3 4 3 3 4 4 1 1 2 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20...

Page 1489: ...7 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 3 Repair ground short circuit in radi ator fan relay 1 control circuit 3 CHECK POWER SUPPLY FOR RELAY 1 Turn ignitio...

Page 1490: ...E CODE DTC 6 CHECK POOR CONTACT Check poor contact in ECM or main fan relay connector Is there poor contact in ECM or main fan relay connector There is poor contact Repair poor con tact in ECM or main...

Page 1491: ...HIGH DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct Cl...

Page 1492: ...17 SBF 4 SBF 1 IGNITION SWITCH RELAY HOLDER BLACK B72 F16 B253 F17 F46 3 4 1 2 B137 BATTERY 17 24 28 B137 ENGINE CONTROL MODULE B253 FAN RELAY 5 1 3 4 3 3 4 4 1 1 2 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20...

Page 1493: ...emove main fan relay and sub fan relay with A C models 3 Disconnect test mode connector 4 Turn ignition switch to ON 5 Measure voltage between ECM and chas sis ground Connector terminal B137 No 28 Cha...

Page 1494: ...EN H6DO 287 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1495: ...cles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion...

Page 1496: ...d chassis ground Connector terminal B55 No 12 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair ground short circuit in har ness between TCM and brake light swi...

Page 1497: ...c Procedure with Diagnostic Trouble Code DTC BX DTC P0732 GEAR 2 INCORRECT RATIO NOTE For the diagnostic procedure refer to DTC P0734 Ref to EN H6DO 291 DTC P0734 GEAR 4 INCOR RECT RATIO Diagnostic Pr...

Page 1498: ...r or replace throttle position sensor circuit Go to step 3 3 CHECK FRONT VEHICLE SPEED SENSOR CIRCUIT Check front vehicle speed sensor circuit Ref to AT 58 DTC 33 FRONT VEHICLE SPEED SENSOR Diagnostic...

Page 1499: ...le in lock up duty solenoid circuit There is a malfunction Repair or replace lock up duty sole noid circuit Go to step 3 3 CHECK THROTTLE POSITION SENSOR CIRCUIT Check throttle position sensor circuit...

Page 1500: ...replace brake light switch circuit Go to step 8 8 CHECK ATF TEMPERATURE SENSOR CIR CUIT Check ATF temperature sensor circuit Ref to AT 48 DTC 27 ATF TEMPERATURE SEN SOR Diagnostic Procedure with Diag...

Page 1501: ...dling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRI...

Page 1502: ...ground Is the measured value less than the speci fied value 10 Repair ground short circuit in har ness between ECM and trans mission harness connector Go to step 4 4 CHECK TRANSMISSION HARNESS CON NEC...

Page 1503: ...idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIR...

Page 1504: ...n ECM connector Is there poor contact in ECM connector There is poor contact Repair poor con tact in ECM con nector Contact SUBARU distributor service NOTE Inspection by DTM is required be cause proba...

Page 1505: ...otor ground line Poor contact in starter motor con nector Poor contact in starter motor ground Starter motor 8 CHECK INHIBITOR SWITCH By moving select lever to N and P positions measure resistance bet...

Page 1506: ...EN H6DO 299 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1507: ...with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mod...

Page 1508: ...radi ator fan makes one complete rotation 2 Drive the vehicle Is AT shift control functioning properly Operates properly Go to step 2 Replace TCM Ref to AT 76 Transmission Con trol Module TCM 2 CHECK...

Page 1509: ...ault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRIN...

Page 1510: ...harness between ECM and chassis ground Connector terminal B135 No 20 Chassis ground Is the measured value less than the speci fied value 10 Repair ground short circuit in har ness between ECM and TCM...

Page 1511: ...fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode WIRI...

Page 1512: ...ed value 1 V Repair poor con tact in ECM con nector Go to step 4 4 CHECK OUTPUT SIGNAL FROM ECM Measure voltage between ECM and chassis ground Connector terminal B135 No 20 Chassis ground Does the mea...

Page 1513: ...of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode Step Value Yes No 1 CHECK ANY OTHER DTC ON DIS...

Page 1514: ...of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION Inspec tion Mode Step Value Yes No 1 CHECK ANY OTHER DTC ON DIS...

Page 1515: ...TC P1134 A F SENSOR MICRO COMPUTER PROBLEM DTC DETECTING CONDITION Immediately at fault recognition CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP E...

Page 1516: ...34 EN 01087 BATTERY F44 B61 SBF 5 6 B47 MAIN RELAY 1 2 3 5 4 6 9 8 21 31 2 1 5 B252 E49 ECM 18 29 19 5 4 7 6 20 30 4 1 3 FRONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B...

Page 1517: ...O2 SENSOR CIRCUIT RANGE PERFORMANCE HIGH BANK 1 SENSOR 1 Diagnostic Procedure with Diagnostic Trouble Code DTC CK DTC P1153 O2 SENSOR CIRCUIT RANGE PERFORMANCE HIGH BANK 1 SENSOR 1 DTC DETECTING CONDI...

Page 1518: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1519: ...Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H6DO 34 Subaru Select Moni tor OBD II general scan tool For detailed operation procedures re...

Page 1520: ...ose installation of portions Damage crack hole etc of parts Looseness of front oxygen A F sensor Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fa...

Page 1521: ...O2 SENSOR CIRCUIT RANGE PERFORMANCE HIGH BANK 2 SENSOR 1 Diagnostic Procedure with Diagnostic Trouble Code DTC CM DTC P1155 O2 SENSOR CIRCUIT RANGE PERFORMANCE HIGH BANK 2 SENSOR 1 DTC DETECTING CONDI...

Page 1522: ...ONT OXYGEN A F SENSOR RH E47 2 4 3 1 FRONT OXYGEN A F SENSOR LH E24 B137 E3 B22 B83 11 8 1 2 3 E2 B21 2 3 E2 B21 20 19 E49 B252 4 8 LHD RHD LHD RHD B252 B47 3 4 5 6 1 2 E24 E47 B137 1 2 7 8 9 5 6 3 4...

Page 1523: ...Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H6DO 34 Subaru Select Moni tor OBD II general scan tool For detailed operation procedures re...

Page 1524: ...ose installation of portions Damage crack hole etc of parts Looseness of front oxygen A F sensor Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fa...

Page 1525: ...RCUIT LOW INPUT DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mo...

Page 1526: ...WIRING DIAGRAM EN 01082 12 INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 12 11 T7 T3 B12 B134 T7 1 2 3 4 5 6 7 8 9 10 11 12 16 B134 ECM BATTERY 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15...

Page 1527: ...ge Does starter motor operate when turning igni tion switch to ST Starter motor operates Repair harness and connector NOTE In this case repair the following Open or ground short circuit in har ness be...

Page 1528: ...EN H6DO 321 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1529: ...e WIRING DIAGRAM EN 01083 D10 A14 D2 A2 D3 E49 B252 D9 C8 D8 D31 D21 5 1 3 B47 BATTERY MAIN RELAY 1 2 3 5 6 4 F44 B61 SBF 5 6 F46 B108 2 SBF 4 SBF 1 4 1 B72 IGNITION SWITCH ECM B134 A B136 C B137 D A2...

Page 1530: ...NESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR 1 Disconnect connector from ECM 2 Measure resistance of harness between ECM and chassis ground Connector terminal B137 No 10 Chassis ground Is the measured...

Page 1531: ...e driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATION...

Page 1532: ...TWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connectors from ECM and TCM 3 Measure resistance of harness between ECM and chassis ground Connector terminal B136 No 14 Chassis...

Page 1533: ...ve driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H6DO 47 OPERATIO...

Page 1534: ...ween ECM and TCM connector After repair replace ECM Ref to FU H6DO 46 Engine Control Module 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Measure voltage between ECM an...

Page 1535: ...fault TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN...

Page 1536: ...RU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Disc...

Page 1537: ...fault TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H6DO 54 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H...

Page 1538: ...RU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Disc...

Page 1539: ...nsor 3 11 Oxygen sensor 12 Fuel pump and fuel pump relay 13 EGR valve 3 Engine does not return to idle 1 Idle air control solenoid valve 2 Engine coolant temperature sensor 3 Accelerator cable 6 4 Thr...

Page 1540: ...ocedure 6 Surge 1 Intake manifold pressure sensor 2 Intake air temperature sensor 3 Engine coolant temperature sensor 2 4 Crankshaft position sensor 3 5 Camshaft position sensor 3 6 Fuel injection par...

Page 1541: ...EN H6DO 334 ENGINE DIAGNOSTICS GENERAL DIAGNOSTIC TABLE MEMO...

Page 1542: ...y to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts A...

Page 1543: ......

Page 1544: ...sor 33 10 Pressure Sensor 34 11 Idle Air Control Solenoid Valve 35 12 Fuel Injector 36 13 Front Oxygen A F Sensor 38 14 Rear Oxygen Sensor 39 15 Engine Control Module 40 16 Main Relay 41 17 Fuel Pump...

Page 1545: ...IONS Fuel tank Capacity 64 2 16 9 US gal 14 1 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 450 677 kPa 4 59 6 9 kg cm2 65 27 98 2 psi Discharge flow More than 13...

Page 1546: ...FU H4DOSTC 3 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION MEMO...

Page 1547: ...STC 4 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD FU 00625 16 10 18 6 9 14 T1 T1 T2 T4 T4 T2 T4 T3 3 3 12 13 17 3 3 3 3 4 2 2 2 10 11 9 T1 T1 T1 T3 T3 T3 5 15 1 8 2 3...

Page 1548: ...3 Clamp 12 Pressure regulator Tightening torque N m kgf m ft lb 4 Evaporation and fuel pipe ASSY 13 Hose T1 5 0 0 51 3 7 5 Gasket 14 Evaporation and coolant pipe ASSY T2 19 1 94 13 7 6 Purge hose T3...

Page 1549: ...N 2 AIR INTAKE SYSTEM 1 Gasket 5 Pressure sensor Tightening torque N m kgf m ft lb 2 Throttle position sensor 6 Gasket T1 1 6 0 16 1 2 3 Idle air control solenoid valve 7 O ring T2 2 8 0 29 2 1 4 Thro...

Page 1550: ...S GENERAL DESCRIPTION 3 CRANKSHAFT POSITIOM CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 3 Camshaft position sensor Tightening torque N m kgf m ft lb 2 Knock sensor T1 6 4 0 65 4 7...

Page 1551: ...JECTION FUEL SYSTEMS GENERAL DESCRIPTION 4 FUEL TANK FU 00626 1 2 2 3 4 5 6 7 8 9 31 33 37 38 36 30 34 11 10 12 13 14 14 14 15 16 17 18 19 20 26 24 25 23 32 21 22 21 27 30 30 30 35 29 28 T3 T3 T3 T3 T...

Page 1552: ...be 6 Fuel pump plate 21 Quick connector 36 Seal 7 Fuel pump ASSY 22 Jet pump hose B 37 Fuel pump holder 8 Fuel level sensor 23 Fuel sub level sensor gasket 38 Grommet 9 Fuel filter 24 Jet pump filter...

Page 1553: ...OSTC 10 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 5 FUEL LINE B2M4171A FU 00627 9 8 7 6 5 4 4 3 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 23 22 21 14 13 11 12 15 10 20 19 18 17 16 32 31 30 29 28 27 26...

Page 1554: ...ose B 15 Fuel pipe ASSY 26 Canister drain hose 5 Clip 16 Evaporation hose B 27 Canister 6 Fuel pipe ASSY 17 Two way valve hose 28 Front canister bracket 7 Grommet 18 Two way valve 29 Rear canister bra...

Page 1555: ...TEMS GENERAL DESCRIPTION 6 FUEL FILLER PIPE 1 Fuel filler pipe ASSY 5 Filler ring Tightening torque N m kgf m ft lb 2 Clip 6 Filler cap T 7 4 0 75 5 4 3 Clamp 7 Fuel filler pipe protector 4 Filler pip...

Page 1556: ...on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electr...

Page 1557: ...ol solenoid valve B and pressure sensor C 4 Disconnect the accelerator cable 5 Disconnect the engine coolant hoses from throt tle body 6 Remove the bolts which secure throttle body to intake manifold...

Page 1558: ...AL Air Cleaner 7 Remove the air cleaner element 8 Remove the intercooler Ref to IN H4DOSTC 13 REMOVAL Intercooler 9 Disconnect the accelerator cable 10 Remove the coolant filler tank Ref to CO H4DOSTC...

Page 1559: ...ce the power steering pump on the right side wheel apron 12 Remove the fuel pipe protector LH 13 Remove the fuel pipe protector RH 14 Disconnect the engine coolant hoses from throttle body 15 Disconne...

Page 1560: ...the pressure hose from intake duct 20 Disconnect the engine harness connectors from bulkhead harness connectors 21 Disconnect the connectors from the engine coolant temperature sensor A oil pressure s...

Page 1561: ...ver 26 Disconnect the fuel delivery hose return hose and evaporation hose WARNING Catch the fuel from hoses in a container 27 Remove the bolts which secure intake manifold to cylinder heads 28 Remove...

Page 1562: ...or C and engine coolant temperature sensor A 4 Connect the connector to knock sensor 5 Connect the connector to camshaft position sen sor 6 Connect the connector to ignition coil 7 Connect the engine...

Page 1563: ...nnect the engine coolant hoses to throttle body 12 Connect the engine coolant hoses to engine coolant pipe 13 Connect the emission hose to PCV valve 14 Connect the pressure hose to intake duct 15 Inst...

Page 1564: ...Install the power steering pump and tighten the bolts Tightening torque 22 N m 2 2 kgf m 15 9 ft lb 4 Install the purge control solenoid valve Tightening torque 19 N m 1 94 kgf m 13 7 ft lb 5 Install...

Page 1565: ...battery 25 Lift up the vehicle 26 Install the under cover 27 Fill the coolant Ref to CO H4DOSTC 15 FILLING OF ENGINE COOLANT REPLACE MENT Engine Coolant C DISASSEMBLY 1 Remove the engine ground cable...

Page 1566: ...o intake manifold 9 Remove the intake duct and engine harness from intake manifold as a unit 10 Remove the bolts which hold fuel injector pipe onto intake manifold LH SIDE RH SIDE 11 Remove the fuel i...

Page 1567: ...ch install fuel pipe on in take manifold D ASSEMBLY NOTE Replace the gasket with a new one 1 Install the fuel pipe assembly to intake manifold Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb 2 Install...

Page 1568: ...ighten the bolts which install fuel injector pipe onto intake manifold Tightening torque 19 N m 1 94 kgf m 13 7 ft lb LH SIDE RH SIDE 7 Install the intake duct and engine harness to in take manifold a...

Page 1569: ...nt pipe assembly Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb 13 Install the throttle body to intake manifold NOTE Replace the gasket with a new one Tightening torque 22 N m 2 2 kgf m 15 9 ft lb 14...

Page 1570: ...FUEL INJECTION FUEL SYSTEMS INTAKE MANIFOLD 16 Connect the engine harness with clip to engine coolant pipe E INSPECTION Make sure the fuel pipe and fuel hoses are not cracked and that connections are...

Page 1571: ...ant 2 Disconnect the ground cable from battery 3 Remove the generator Ref to SC H4DOSTC 14 REMOVAL Generator 4 Disconnect the connector from engine coolant temperature sensor 5 Remove the engine coola...

Page 1572: ...ound cable from battery 2 Remove the bolt which installs crankshaft posi tion sensor to cylinder block 3 Remove the crankshaft position sensor and then disconnect the connector from it B INSTALLATION...

Page 1573: ...1 Disconnect the ground cable from battery 2 Disconnect the connector from camshaft posi tion sensor 3 Remove the camshaft position sensor from camshaft support LH B INSTALLATION Install in the revers...

Page 1574: ...om cylinder block B INSTALLATION 1 Install the knock sensor to cylinder block Tightening torque 24 N m 2 4 kgf m 17 4 ft lb NOTE The extraction area of knock sensor cord must be positioned at a 60 ang...

Page 1575: ...attery 2 Remove the intercooler Ref to IN H4DOSTC 13 REMOVAL Intercooler 3 Disconnect the connector from throttle position sensor 4 Remove the throttle position sensor holding screws and then remove i...

Page 1576: ...erature Sensor A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the connector mass air flow and in take air temperature sensor 3 Remove the mass air flow and intake air temper ature s...

Page 1577: ...l solenoid valve Ref to FU H4DOSTC 35 REMOVAL Idle Air Control Solenoid Valve 3 Disconnect the connectors from pressure sen sor 4 Remove the pressure sensor from throttle body B INSTALLATION Install i...

Page 1578: ...m battery 2 Disconnect the connector from idle air control solenoid valve 3 Remove the idle air control solenoid valve from throttle body 4 Remove the gasket from throttle body B INSTALLATION Install...

Page 1579: ...hold injector pipe to in take manifold 4 Remove the fuel injector while lifting up the fuel injector pipe 2 LH SIDE 1 Remove the fuel pipe protector LH 2 Disconnect the connector from fuel injector 3...

Page 1580: ...kgf m 13 7 ft lb Tightening torque 19 N m 1 94 kgf m 13 7 ft lb 2 LH SIDE Install in the reverse order of removal NOTE Replace the O ring and insulators with new ones Tightening torque 19 N m 1 94 kgf...

Page 1581: ...ing the oxygen A F sensor wait until the exhaust pipe cools otherwise it will damage the exhaust pipe B INSTALLATION 1 Before installing the front oxygen A F sensor apply anti seize compound only to t...

Page 1582: ...oxygen sensor wait until the exhaust pipe cools otherwise it will damage the ex haust pipe B INSTALLATION 1 Before installing the rear oxygen sensor apply anti seize compound only to the threaded port...

Page 1583: ...er Trim 3 Detach the floor mat of front passenger seat 4 Remove the protect cover 5 Remove the nuts A which hold ECM to bracket 6 Remove the clip B from bracket 7 Disconnect the ECM connectors and tak...

Page 1584: ...the ground cable from battery 2 Remove the lower inner trim of passenger side Ref to EI 39 REMOVAL Lower Inner Trim 3 Disconnect the connectors from main relay 4 Remove the bolt which holds main relay...

Page 1585: ...Pump Relay A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the lower cover 3 Disconnect the connector from fuel pump relay A 4 Remove the fuel pump relay from mounting bracket B INSTALL...

Page 1586: ...MOVAL 1 Disconnect the ground cable from battery 2 Remove the rear quarter trim Ref to EI 40 REMOVAL Rear Quarter Trim 3 Remove the fuel pump controller 4 Disconnect the connector from the fuel pump c...

Page 1587: ...OFF 2 DRAINING FUEL WARNING Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Set the vehicle on the lift 2 Disconnect the ground cable from battery 3 Lift up the...

Page 1588: ...from fuel tank by using a hand pump WARNING Do not use a motor pump when draining the fu el 13 After draining the fuel reinstall the fuel sub lev el sensor Tightening torque T 4 4 N m 0 45 kgf m 3 3 f...

Page 1589: ...FU H4DOSTC 46 FUEL INJECTION FUEL SYSTEMS FUEL 3 Install the sub service hole cover 4 Set the rear seat and floor mat FU 00445...

Page 1590: ...the grommet which holds fuel tank cord on service hole cover into body side 7 Separate the quick connector of fuel delivery A and return hose B Ref to FU H4DOSTC 67 REMOVAL Fuel Delivery Return and Ev...

Page 1591: ...ot to pull down the muffler 3 Remove the front rubber cushion and then detach the muffler assembly 14 Remove the propeller shaft Ref to DS 14 REMOVAL Propeller Shaft 15 Disconnect the connector from A...

Page 1592: ...ort the rear differential with transmis sion jack 2 Remove the bolt which holds rear shock ab sorber to rear suspension arm 3 Remove the bolts which secure rear sus pension assembly to body 4 Remove t...

Page 1593: ...ort the fuel tank with transmission jack and then push the fuel tank harness into access hole with grommet 2 Set the fuel tank and then temporarily tighten the bolts of fuel tank bands CAUTION A helpe...

Page 1594: ...7 ft lb T2 108 N m 11 0 kgf m 80 ft lb T3 66 N m 6 7 kgf m 48 ft lb 2 Tighten the bolt which holds rear shock ab sorber to rear suspension arm Ref to RS 11 INSTALLATION Rear Arm Tightening torque 157...

Page 1595: ...all the rear exhaust pipe and muffler NOTE To facilitate the procedure apply a coat of SUBA RU CRC to matching area of the rubber cushions in advance SUBARU CRC Part No 004301003 1 Install the right a...

Page 1596: ...ON Fuel Delivery Return and Evaporation Lines 22 Connect the fuel jet pump hose 23 Connect the connector to fuel sub level sensor 24 Install the sub service hole cover 25 Connect the connectors to fue...

Page 1597: ...he wheel alignment and adjust if neces sary Ref to FS 6 INSPECTION Wheel Align ment C INSPECTION 1 Make sure there are no cracks holes or other damage on the fuel tank 2 Make sure that the fuel hoses...

Page 1598: ...ve the screws holding packing in place 5 Lift up the vehicle 6 Remove the rear right side wheel nuts 7 Remove the wheel RH Rear 8 Remove the protector RH Front 9 Drain fuel from fuel tank Set a contai...

Page 1599: ...e the clip and then separate the air vent hose B 16 Remove the fuel filler pipe to under side of the vehicle B INSTALLATION 1 Hold the fuel filler flap open 2 Set the fuel saucer A with rubber packing...

Page 1600: ...ox 25 to 30 mm 0 98 to 1 18 in into the lower end of air vent pipe and hold clip L 27 5 2 5 mm 1 083 0 098 in 6 Tighten the bolt which holds fuel filler pipe brack et on body Tightening torque 7 4 N m...

Page 1601: ...FU H4DOSTC 58 FUEL INJECTION FUEL SYSTEMS FUEL FILLER PIPE 12 Connect the connector to fuel pump relay A 13 Connect the battery ground cable to battery FU 00648 A FU 00009...

Page 1602: ...he fuel filler cap 3 Disconnect the ground cable from battery 4 Lift up the vehicle 5 Remove the protector RH Front 6 Drain the fuel from fuel tank Set a container un der the vehicle and then remove t...

Page 1603: ...alphabetical sequence shown in the figure to specified torque Tightening torque 5 9 N m 0 6 kgf m 4 3 ft lb C DISASSEMBLY 1 Remove the fuel pump and pump holder NOTE When disassembling the pump holder...

Page 1604: ...he fuel pump assembly Ref to FU H4DOSTC 59 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et 3 Pushing the pawls with a screwdriver remove the fuel meter unit by pulling it downward...

Page 1605: ...e front side fuel tank cover 4 Drain fuel from fuel tank Set a container under the vehicle and then remove the drain plug from fuel tank 5 Tighten the fuel drain plug and install the protec tor RH Fro...

Page 1606: ...isconnect the fuel jet pump hose 10 Remove the bolts which install fuel sub level sensor on fuel tank 11 Remove the fuel sub level sensor B INSTALLATION Install in the reverse order of removal Tighten...

Page 1607: ...older 4 Remove the filter holder by turning it to the left from the body pawls and then take out the filter B INSTALLATION NOTE If the fuel hoses are damaged at the connecting portion replace it with...

Page 1608: ...e fuel tank Ref to FU H4DOSTC 47 REMOVAL Fuel Tank 2 Move the clip and then disconnect the evapora tion hose from fuel cut valve 3 Remove the bolts which install fuel cut valve B INSTALLATION Install...

Page 1609: ...Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H4DOSTC 44 RELEASING OF FUEL PRES SURE OPERATION Fuel 2 Remove the fuel damper valve from fuel delivery line A and return line B B INS...

Page 1610: ...he fuel filler flap lid and then remove the fuel filler cap 4 Remove the floor mat Ref to EI 48 REMOVAL Floor Mat 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation pip...

Page 1611: ...s use a new retainer Make sure that the connected portion is not dam aged or has dust If necessary clean the seal sur face of pipe 1 Set a new retainer B to connector A 2 Push the pipe into connector...

Page 1612: ...059 in L 22 5 2 5 mm 0 886 0 098 in 3 Connect the evaporation hose to pipe by approx 15 mm 0 59 in from hose end L 17 5 2 5 mm 0 689 0 098 in NOTE Be sure to inspect the hoses and their connections fo...

Page 1613: ...se Corrective action 1 Insufficient fuel supply to the injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Trouble in electromag...

Page 1614: ...SION CONTROL AUX EMISSION CONTROL DEVICES EC H4DOSTC Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 4 4 Canister 5 5 Purge Control Solenoid Valve 6 6 Two way Val...

Page 1615: ...s in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful...

Page 1616: ...ipe Ref to EX H4DOSTC 7 REMOVAL Center Exhaust Pipe 2 Separate the center exhaust pipe LH and cen ter exhaust pipe RH B INSTALLATION NOTE Replace the gaskets with new ones Install in the reverse order...

Page 1617: ...onverter is installed at the rear ex haust pipe 1 Remove the rear exhaust pipe Ref to EX H4DOSTC 12 REMOVAL Rear Exhaust Pipe B INSTALLATION NOTE Replace the gaskets with new ones Install in the rever...

Page 1618: ...s which hold two canister hoses and then disconnect the evaporation three hoses from canister 3 Remove the canister from body B INSTALLATION 1 Install in the reverse order of removal Tightening torque...

Page 1619: ...e onto intake manifold 3 Disconnect the connector and hoses from purge control solenoid valve B INSTALLATION Install in the reverse order of removal Tightening torque 19 N m 1 94 kgf m 13 74 ft lb CAU...

Page 1620: ...ft up the vehicle 2 Disconnect the hoses from two way valve 3 Remove the two way valve with bracket as a sin gle unit from body 4 Remove the two way valve from bracket B INSTALLTION Install in the rev...

Page 1621: ...EC H4DOSTC 8 EMISSION CONTROL AUX EMISSION CONTROL DEVICES TWO WAY VALVE MEMO...

Page 1622: ...leaner 10 3 Air Intake Duct 11 4 Intake Duct 12 5 Intercooler 13 6 Turbocharger 15 7 Air By pass Valve 17 8 Turbocharging Pressure Relief Valve 18 9 Solenoid Box Assembly 19 10 Wastegate Control Solen...

Page 1623: ...rque N m kgf m ft lb 2 Air cleaner upper cover 9 Air intake duct T1 7 5 0 76 5 5 3 Air cleaner element 10 Resonator chamber ASSY T2 33 3 4 24 3 4 Spacer 11 Cushion rubber T3 2 5 0 25 1 8 5 Bush 12 Cla...

Page 1624: ...OSTC 3 INTAKE INDUCTION GENERAL DESCRIPTION 2 INTAKE DUCT 1 Clamp 3 Air by pass hose Tightening torque N m kgf m ft lb 2 Intake duct 4 Turbocharging pressure relief valve T 19 1 9 14 0 IN 00078 1 2 3...

Page 1625: ...pass valve 11 Gasket 2 Intercooler bracket RH 7 Gasket 12 Hose connector 3 Intercooler bracket LH 8 Intercooler duct Primary 4 Clamp 9 Gasket Tightening torque N m kgf m ft lb 5 Air intake duct 10 In...

Page 1626: ...IN H4DOSTC 5 INTAKE INDUCTION GENERAL DESCRIPTION MEMO...

Page 1627: ...H4DOSTC 6 INTAKE INDUCTION GENERAL DESCRIPTION 4 TURBOCHARGER IN 00080 1 2 2 2 2 2 2 3 4 5 6 7 8 9 10 10 11 12 13 13 14 15 16 17 18 19 20 21 22 T4 T4 T5 T1 T1 T3 T5 T1 T2 T2 T1 T1 T1 T1 T1 T1 T1 T5 T...

Page 1628: ...racket LH 5 Secondary turbocharger ASSY 17 Turbocharger upper cover Pri mary 6 Turbocharger cover Tightening torque N m kgf m ft lb 7 Turbocharger cover 18 Turbocharger lower cover Pri mary T1 6 5 0 6...

Page 1629: ...box ASSY 7 Purge control solenoid valve 13 Primary turbocharger 3 Exhaust gas control valve 8 Air by pass valve 14 Differential pressure sensor 4 Intake duct 9 Surge tank 15 Filter 5 Tubocharging pre...

Page 1630: ...hem from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands be...

Page 1631: ...5 Remove the air cleaner upper cover 6 Remove the air cleaner element 7 Remove the air cleaner lower case B INSTALLATION Install in the reverse order of removal Tightening torque 33 N m 3 4 kgf m 24...

Page 1632: ...ts which installs air intake duct on front side of body B INSTALLATION Install in the reverse order of removal Tightening torque 7 5 N m 0 76 kgf m 24 3 ft lb C INSPECTION 1 Inspect for cracks and loo...

Page 1633: ...to FU H4DOSTC 15 REMOVAL Intake Manifold 3 Remove the sensor engine harness and fuel pipe attached to intake manifold Ref to FU H4DOSTC 22 DISASSEMBLY Intake Mani fold 4 Remove the intake duct from i...

Page 1634: ...from pipes 2 Disconnect the hose from hose connector of so lenoid box assembly 3 Disconnect the air by pass hose from air by pass valve 4 Remove the bolts which secures intercooler to bracket 5 Separ...

Page 1635: ...ft lb C DISASSEMBLY 1 Loosen the clamps then remove the intercooler duct D ASSEMBLY Assemble in the reverse order of disassembly Tightening torque 16 N m 1 6 kgf m 11 7 ft lb IN 00093 IN 00089 IN 0009...

Page 1636: ...engine coolant hose 9 Remove the bolt which secures bracket of oil pipe to turbocharger 10 Remove the oil pipe from turbocharger 11 Remove the turbocharger bracket 12 Disconnect the oil and coolant ou...

Page 1637: ...6 Connect the engine coolant hose which is con nected to the coolant filler tank 7 Lift up the vehicle 8 Install the center exhaust pipe Ref to EX H4DOSTC 8 INSTALLATION Center Ex haust Pipe 9 Install...

Page 1638: ...ir By pass Valve A REMOVAL 1 Remove the air by pass valve from intercooler 2 Disconnect the air by pass hoses from air by pass valve B INSTALLATION Install in the reverse order of removal Tightening t...

Page 1639: ...ING PRESSURE RELIEF VALVE 8 Turbocharging Pressure Re lief Valve A REMOVAL Remove the turbocharging pressure relief valve from secondary turbocharger and joint part of air duct B INSTALLATION Install...

Page 1640: ...rom sole noid box 3 Disconnect the hose C for surge tank 4 Remove the lock plate on solenoid box side 5 Disconnect the hose connector 6 Remove the installation bolts and then remove the solenoid box a...

Page 1641: ...e is not damaged 1 Turbocharging pressure relief valve control solenoid valve 2 4 Turbocharging pressure relief valve control solenoid valve 1 6 Intake air valve control solenoid valve 2 Filter 5 Exha...

Page 1642: ...from engine compartment 3 Remove the front tire LH and then lift up the ve hicle 4 Remove the front mudguard LH 5 Pull out the wastegate control solenoid valve and bracket from the vehicle as a unit...

Page 1643: ...the surge tank installation nut from en gine compartment 3 Remove the front tire LH and lift the vehicle 4 Remove the front mudguard LH 5 Remove the surge tank B INSTALLATION Install in the reverse or...

Page 1644: ...nd cable from battery 2 Disconnect the connector A of differential pres sure sensor 3 Disconnect the hose B of differential pressure sensor 4 Remove the differential pressure sensor B INSTALLATION Ins...

Page 1645: ...IN H4DOSTC 24 INTAKE INDUCTION DIFFERENTIAL PRESSURE SENSOR MEMO...

Page 1646: ...Fuel Pressure 26 8 Valve Clearance 27 9 Engine Assembly 31 10 Engine Mounting 40 11 Preparation for Overhaul 41 12 V belt 42 13 Crankshaft Pulley 44 14 Belt Cover 46 15 Timing Belt Assembly 47 16 Cam...

Page 1647: ...No load 850 150 A C switch ON Firing order 1 3 2 4 Ignition timing BTDC rpm MT 14 10 700 rpm AT 14 10 650 rpm Belt ten sion adjuster Protrusion of adjuster rod 5 2 6 2 mm 0 205 0 244 in Belt ten sione...

Page 1648: ...rface grinding limit 0 1 mm 0 004 in Cylinder bore STD A 92 005 92 015 mm 3 6222 3 6226 in B 91 995 92 005 mm 3 6218 3 6222 in Taper STD 0 015 mm 0 0006 in Limit 0 050 mm 0 0020 in Out of roundness ST...

Page 1649: ...0 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 3607 2 3613 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 742 59 758 mm 2 3520 2 3527 in 2 4 STD 5...

Page 1650: ...2 5 18 1 4 Belt cover No 2 LH 14 Belt cover T4 39 4 0 28 9 5 Tensioner bracket 15 Belt cover LH T5 98 10 72 4 6 Automatic belt tension adjuster ASSY 16 Front belt cover T6 Ref to ME H4DOSTC 44 INSTAL...

Page 1651: ...CHANICAL GENERAL DESCRIPTION 2 CYLINDER HEAD AND CAMSHAFT ME 00602 T2 T4 T3 T5 T4 T2 T2 T1 7 6 14 9 8 10 15 16 13 12 32 29 30 31 3 4 27 23 24 21 32 18 19 14 26 28 25 20 22 17 16 11 5 4 1 3 2 T1 T3 T3...

Page 1652: ...2 Stud bolt 7 Intake camshaft cap Rear RH 20 Intake camshaft cap Front LH 8 Intake camshaft cap RH 21 Intake camshaft cap Center LH Tightening torque N m kgf m ft lb 9 Exhaust camshaft cap Front RH 22...

Page 1653: ...t valve 5 Intake valve oil seal 9 Valve lifter 2 Intake valve 6 Valve spring 10 Exhaust valve oil seal 3 Cylinder head 7 Retainer 11 Intake valve guide 4 Valve spring seat 8 Retainer key 12 Exhaust va...

Page 1654: ...ME H4DOSTC 9 MECHANICAL GENERAL DESCRIPTION MEMO...

Page 1655: ...HANICAL GENERAL DESCRIPTION 4 CYLINDER BLOCK ME 00623 7 T2 T2 T2 T3 T1 T9 8 14 10 18 19 21 22 20 23 T5 T10 T6 T8 T6 T2 T4 T6 T2 T5 T2 T4 T2 3 4 1 2 10 27 15 16 T2 17 T11 24 25 26 3 4 4 5 9 6 10 10 11...

Page 1656: ...7 2 5 Oil separator cover 19 Gasket T4 25 2 5 18 1 6 Water by pass pipe 20 Oil pan T5 Ref to ME H4DOSTC 74 INSTALLATION CYLINDER BLOCK 7 Oil pump 21 Drain plug 8 Front oil seal 22 Metal gasket 9 Rear...

Page 1657: ...ement AT vehicles only 11 Connecting rod bolt 19 Crankshaft bearing 5 4 Drive plate AT vehicles only 12 Connecting rod 5 Top ring 13 Connecting rod bearing Tightening torque N m kgf m ft lb 6 Second r...

Page 1658: ...ME H4DOSTC 13 MECHANICAL GENERAL DESCRIPTION 6 ENGINE MOUNTING 1 Front cushion rubber Tightening torque N m kgf m ft lb T1 35 3 5 25 3 T2 85 8 7 62 7 ME 00407 T1 T1 T2 T2 1...

Page 1659: ...ted with oil prior to assembly Be careful not to let oil grease or coolant contact the timing belt clutch disc and flywheel All removed parts if to be reused should be re installed in the original pos...

Page 1660: ...ning crankshaft pulley bolt etc 398744300 PISTON GUIDE Used for installing piston in cylinder for 2000 cc engine 498857100 VALVE OIL SEAL GUIDE Used for press fitting of intake and exhaust valve guide...

Page 1661: ...hing 499097600 MT vehicles PISTON PIN REMOVER ASSY Used for removing piston pin 499097700 AT vehicles PISTON PIN REMOVER ASSY Used for removing piston pin 499207400 CAMSHAFT SPROCKET WRENCH Used for r...

Page 1662: ...ft oil seal Used with CRANKSHAFT OIL SEAL GUIDE 499597100 499597100 CRANKSHAFT OIL SEAL GUIDE Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL INSTALLER 499587200 499718000 VALVE...

Page 1663: ...ENGINE STAND ADAPTER RH 498457000 LH 498457100 499977400 CRANK PULLEY WRENCH AT vehicles Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts 49997710...

Page 1664: ...r 499587100 OIL SEAL INSTALLER Used for installing oil pump oil seal 499587600 OIL SEAL INSTALLER Used for installing camshaft oil seal for DOHC engine 499597200 OIL SEAL GUIDE Used for installing cam...

Page 1665: ...ad 498277200 STOPPER SET Used for installing automatic transmission assem bly to engine 24082AA210 Newly adopted tool CARTRIDGE Troubleshooting for electrical systems 22771AA030 SELECT MONI TOR KIT Tr...

Page 1666: ...6 Check the starter motor for satisfactory perfor mance and operation 7 Hold the compression gauge tight against spark plug hole NOTE When using a screw in type compression gauge the screw put into cy...

Page 1667: ...System in Selection Menu 9 Select the 1 Current Data Display Save in Engine Control System Diagnosis 10 Select the 1 12 Data Display in Data Display Menu 11 Start the engine and then read the engine...

Page 1668: ...F 4 Insert the cartridge to SUBARU SELECT MONI TOR 5 Connect the SUBARU SELECT MONITOR to data link connector 6 Turn the ignition switch to ON and SUBARU SELECT MONITOR switch to ON 7 Select the 2 Eac...

Page 1669: ...normal position This ten dency becomes more evident as engine temperature rises Leakage around intake manifold gasket or disconnection or damaged vacuum hose 2 When engine speed is reduced slowly fro...

Page 1670: ...more at 5 000 rpm If the oil pressure is out of specification check oil pump oil filter and lubrication line Ref to LU H4DOSTC 22 INSPECTION Engine Lubrica tion System Trouble in General If the oil p...

Page 1671: ...elivery hoses from fuel fil ter and then connect the fuel pressure gauge 4 Connect the connector of fuel pump relay A 5 Start the engine 6 Measure the fuel pressure while disconnecting the pressure re...

Page 1672: ...cting the 1 and 3 cylinders 1 Pull out the engine harness connector with bracket from air cleaner upper cover 2 Remove the air cleaner case Ref to IN H4DOSTC 10 REMOVAL Air Cleaner 3 Disconnect the ig...

Page 1673: ...exhaust valve clearances while lift ing up the vehicle Valve clearance Intake 0 20 0 02 mm 0 0079 0 0008 in Exhaust 0 25 0 02 mm 0 0098 0 0008 in NOTE If the measured value is not within specificatio...

Page 1674: ...clearance and valve lifter thickness by referring to the following table 6 Set the suitable shim selected in step 4 to valve lifter ME 00411 ME 00023 ME 00024 Unit mm Intake valve S V T 0 20 Exhaust...

Page 1675: ...611 5 19 0 2043 13228 AB621 5 20 0 2047 13228 AB631 5 21 0 2051 13228 AB641 5 22 0 2055 13228 AB651 5 23 0 2059 13228 AB661 5 24 0 2063 13228 AB671 5 25 0 2067 13228 AB681 5 26 0 2071 13228 AB691 5 27...

Page 1676: ...rank it for 5 seconds more 4 Turn the ignition switch to OFF 5 Remove the filler cap 6 Disconnect the ground cable from battery 7 Remove the radiator from vehicle Ref to CO H4DOSTC 23 REMOVAL Radia to...

Page 1677: ...uum hose 2 Heater inlet outlet hose 13 Remove the power steering pump from brack et 1 Loosen the lock bolt and slider bolt and then remove the front side V belt Ref to ME H4DOSTC 42 REMOVAL V belt 2 D...

Page 1678: ...hicles 16 Remove the center exhaust pipe Ref to EX H4DOSTC 7 REMOVAL Center Exhaust Pipe 17 Remove the nuts which hold lower side of transmission to engine 18 Remove the nuts which install front cushi...

Page 1679: ...AT vehicles 1 Lower the vehicle 2 Remove the service hole plug 3 Remove the bolts which hold torque con verter clutch to drive plate 4 Remove the other bolts while rotating the engine using socket wre...

Page 1680: ...ansmission to engine 27 Remove the engine from vehicle 1 Slightly raise the engine 2 Raise the transmission with garage jack 3 Move the engine horizontally until the main shaft is withdrawn from clutc...

Page 1681: ...lb 3 Install the engine onto transmission 1 Position the engine in engine compartment and then align it with the transmission NOTE Be careful not to damage the adjacent parts or body panels with crank...

Page 1682: ...verter clutch onto drive plate AT vehicles 1 Tighten the bolts which hold torque convert er clutch to drive plate 2 Tighten other bolts while rotating the engine by using ST NOTE Be careful not to dro...

Page 1683: ...17 Install the center exhaust pipe Ref to EX H4DOSTC 8 INSTALLATION Center Exhaust Pipe 18 Lower the vehicle 19 Connect the following hoses 1 Fuel delivery hose return hose and evapo ration hose 2 He...

Page 1684: ...ank Ref to CO H4DOSTC 33 INSTALLATION Coolant Filler Tank 27 Install the window washer tank 28 Install the battery in the vehicle and connect cables 29 Fill coolant Ref to CO H4DOSTC 15 FILL ING OF EN...

Page 1685: ...ine assembly Ref to ME H4DOSTC 31 REMOVAL Engine Assem bly 2 Remove the engine mounting from engine as sembly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 3...

Page 1686: ...ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order It will be the complete procedure for overhauling of the engine itself when you go throu...

Page 1687: ...ff any oil or water on the belt and pulley 1 Install the belt C and tighten the slider bolt so as to obtain the specified belt tension Ref to ME H4DOSTC 43 INSPECTION V belt 2 Tighten the lock bolt A...

Page 1688: ...osition and or idler pulley installing position Belt tension A replaced 7 9 mm 0 276 0 354 in reused 9 11 mm 0 354 0 433 in B replaced 7 5 8 5 mm 0 295 0 335 in reused 9 0 10 0 mm 0 354 0 394 in with...

Page 1689: ...s 65 degrees or more If not conduct the following procedures 1 through 4 1 Replace the crankshaft pulley bolts Crankshaft pulley bolt 12369AA011 2 Clean the crankshaft thread using an air gun 3 Tighte...

Page 1690: ...ighten the bolts temporarily with tightening torque of 44 N m 4 5 kgf m 33 ft lb 4 Tighten the crankshaft pulley bolts keeping them in an angle between 45 degrees and 60 degrees NOTE Conduct the tight...

Page 1691: ...lt cover C B INSTALLATION 1 Install the front belt cover C Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 2 Install the belt cover RH B Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 3 Install the belt cove...

Page 1692: ...arrow mark which indicates rotation direction on timing belt fade away put new marks before removing the timing belt as follows 1 Turn the crankshaft using ST and align the alignment marks on cranksha...

Page 1693: ...tate the intake and exhaust camshaft sprock et If the camshaft sprocket is rotated the in take and exhaust valve heads strike together and valve stems are bent 2 BELT IDLER AND AUTOMATIC BELT TENSION...

Page 1694: ...sure until stopper pin is completely inserted 1 Attach the automatic belt tension adjuster assembly to the vertical pressing tool 2 Slowly move the adjuster rod down with a pressure of 294 N 30 kgf 66...

Page 1695: ...with notch B on belt cover by turning the sprocket counterclockwise as viewed from front of engine 5 Align the single line mark A on intake cam shaft sprocket LH with notch B on belt cover by turning...

Page 1696: ...he zero lift position to the position where the timing belt is to be installed at as small an angle as possible in order to prevent mutual interfer ence of intake and exhaust valve heads Do not allow...

Page 1697: ...timing belt and sprockets are aligned 5 After ensuring that the marks on the timing belt and sprockets are aligned remove the stopper pin from tensioner adjuster 1 Arrow mark 4 54 5 tooth length 7 In...

Page 1698: ...between timing belt and timing belt guide Clearance 1 0 0 5 mm 0 039 0 020 in 3 Tighten the bolts Tightening torque 10 N m 1 0 kgf m 7 2 ft lb Tightening torque 6 4 N m 0 7 kgf m 5 1 ft lb Tightening...

Page 1699: ...ce of the cylinder Repeat this motion 2 or 3 times 2 With the adjuster rod moved all the way up apply a pressure of 294 N 30 kgf 66 lb to it Check the adjuster rod stiffness 3 If the the adjuster rod...

Page 1700: ...07400 CAMSHAFT SPROCKET WRENCH Except INTAKE LH Tightening torque 98 N m 10 kgf m 72 4 ft lb NOTE Do not confuse the right and left side camshaft sprockets intake side during installation The cam shaf...

Page 1701: ...ATION 1 Install the crankshaft sprocket 2 Install the camshaft sprocket Ref to ME H4DOSTC 55 INSTALLATION Camshaft Sprocket 3 Install the timing belt assembly Ref to ME H4DOSTC 49 INSTALLATION Tim ing...

Page 1702: ...racket 8 Remove the belt cover No 2 LH 9 Remove the belt cover No 2 RH 10 Disconnect the ignition coil connector 11 Remove the ignition coil 12 Remove the rocker cover and gasket 13 Loosen the intake...

Page 1703: ...lure to do so may cause excess packing to come out and flow toward oil seal resulting in oil leaks Fluid packing Part No 004403007 THREE BOND 1215 or equivalent 2 Apply engine oil to cap bearing surfa...

Page 1704: ...e gasket is properly positioned during installation 5 Install the ignition coil 6 Connect the ignition coil connector 7 Similarly install the parts on right hand side 8 Install the belt cover No 2 RH...

Page 1705: ...east two stages in alphabetical sequence shown in the figure and then tighten to specified torque Do not turn the camshaft Tightening torque T1 10 N m 1 0 kgf m 7 2 ft lb T2 20 N m 2 0 kgf m 14 5 ft l...

Page 1706: ...1 457 in 6 Measure the thrust clearance of camshaft with dial gauge If the clearance exceeds the limit re place the caps and cylinder head as a set If neces sary replace the camshaft Standard 0 015 0...

Page 1707: ...er head and cylinder block 12 Similarly remove the right side cylinder head B INSTALLATION 1 Install the cylinder head and gaskets on cylinder block NOTE Use new cylinder head gaskets Be careful not t...

Page 1708: ...LATION Crankshaft Pulley 10 Install the V belt Ref to ME H4DOSTC 42 INSTALLATION V belt C DISASSEMBLY 1 Remove the valve shims and valve lifters 2 Compress the valve spring and remove the valve spring...

Page 1709: ...Intake valve oil seal 9 Valve lifter 2 Intake valve 6 Valve spring 10 Exhaust valve oil seal 3 Cylinder head 7 Retainer 11 Intake valve guide 4 Valve spring seat 8 Retainer key 12 Exhaust valve guide...

Page 1710: ...PECTION 1 CYLINDER HEAD 1 Make sure that no crack or other damage exists In addition to visual inspection inspect the impor tant areas by means of red check 2 Measure the warping of the cylinder head...

Page 1711: ...2350 in Exhaust 5 945 5 960 mm 0 2341 0 2346 in 1 Place the cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1 2 Insert the ST2 into valve guide and p...

Page 1712: ...ide becomes lustrous and the reamer does not chips use a new reamer or remedy the reamer 8 Recheck the contact condition between valve and valve seat after replacing the valve guide 4 INTAKE AND EXHAU...

Page 1713: ...E NOTE Apply engine oil to oil seal before force fitting Differentiate between the intake valve oil seal and exhaust valve oil seal by noting their difference in color Color of rubber part Intake Blac...

Page 1714: ...wing 1 Wearing rubber gloves remove the dam aged valve from the cylinder head 2 Prepare a large receptacle bucket or other container in a well ventilated location and fill the receptacle with water at...

Page 1715: ...E H4DOSTC 62 REMOVAL Cylinder Head Assembly 10 Remove the clutch disc and cover MT vehi cles Ref to CL 15 REMOVAL Clutch Disc and Cover 11 Remove the flywheel MT vehicles Ref to CL 20 REMOVAL Flywheel...

Page 1716: ...flat bladed screwdriver as shown in the fig ure when removing the oil pump NOTE Be careful not to scratch the mating surface of cyl inder block and oil pump ME 00138 1 Service hole plug 3 Circlip 5 Se...

Page 1717: ...ER AT vehicles NOTE Be careful not to confuse the original combination of piston piston pin and cylinder 27 Similarly remove the piston pins from 3 and 4 pistons 28 Remove the bolts which connect cyli...

Page 1718: ...using a hammer handle NOTE Do not confuse the combination of crankshaft bear ings Press the bearing at the end opposite to lock ing lip 35 Draw out each piston from cylinder block using a wooden bar o...

Page 1719: ...he crankshaft on 2 and 4 cylinder block 3 Apply fluid packing to the mating surface of 1 and 3 cylinder block and position it on 2 and 4 cylinder block Fluid packing Part No 004403007 THREE BOND 1215...

Page 1720: ...tical sequence 7 Further tighten the RH side bolts E J to 90 in alphabetical sequence 8 Tighten the 8 mm and 6 mm cylinder block con necting bolts in alphabetical sequence shown in the figure Tighteni...

Page 1721: ...osition the upper rail gap at G in the figure NOTE Ensure ring gaps do not face the same direction Ensure ring gaps are not within the piston skirt area 14 Installing the circlip Install the circlips...

Page 1722: ...ad center ST1 499987500 CRANKSHAFT SOCKET 3 Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders us ing ST2 ST2 398744300 PISTON GUIDE NOTE Piston front mark f...

Page 1723: ...pply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole 3 Using the ST install the circlip ST 499897200 PISTON CIRCLIP PLIERS NOTE Use new...

Page 1724: ...m 0 65 kgf m 4 7 ft lb 19 Install the oil strainer and O ring Tightening torque 10 N m 1 0 kgf m 7 ft lb 20 Install the oil strainer stay 21 Apply fluid packing to the matching surfaces and then insta...

Page 1725: ...nd Cover 26 Installation of oil pump 1 Discard the front oil seal after removal Re place with a new one using the ST ST 499587100 OIL SEAL INSTALLER 2 Apply fluid packing to the matching surface of oi...

Page 1726: ...assembly Ref to ME H4DOSTC 62 INSTALLATION CYLINDER HEAD ASSEMBLY 34 Install the oil level gauge guide and tighten the attaching bolt left side only 35 Install the rocker cover 36 Install the cranksha...

Page 1727: ...connecting rod cap and bearing in order to prevent confusion 3 Remove the piston rings using the piston ring ex pander 4 Remove the oil ring by hand NOTE Arrange the removed piston rings in proper or...

Page 1728: ...a piston ring expander E INSPECTION 1 CYLINDER BLOCK 1 Visually check for cracks and damage Especial ly inspect the important parts by means of red lead check 2 Check the oil passages for clogging 3 I...

Page 1729: ...m 0 0020 in 3 When the piston is to be replaced due to general or cylinder wear determine a suitable sized piston by measuring the piston clearance 4 How to measure the outer diameter of each pis ton...

Page 1730: ...on one cyl inder only nor use an oversize piston for one cylin der only 2 If the cylinder inner diameter exceeds the limit after boring and honing replace the crank case NOTE Immediately after rebori...

Page 1731: ...on piston be careful of each rail s direction 2 Clean up the piston ring groove and piston ring 3 Squarely place the piston ring and oil ring in cyl inder and then measure the piston ring gap with a t...

Page 1732: ...ecting rod bearing for scar peeling seizure melting wear etc 5 Measure the oil clearance on individual connect ing rod bearings by means of plastigauge If any oil clearance is not within specification...

Page 1733: ...and check for cracks by means of red lead check etc and re place if defective 2 Measure the crankshaft bend and correct or re place if it exceeds the limit NOTE If a suitable V block is not available...

Page 1734: ...13 0 0787 0 0793 1 486 1 498 0 0585 0 0590 0 03 0 0012 undersize Journal O D 59 962 59 978 2 3607 2 3613 59 962 59 978 2 3607 2 3613 51 954 51 970 2 0454 2 0461 Bearing size Thickness at cen ter 2 017...

Page 1735: ...p and relay A Lack of or insufficient fuel B Belt Defective B Defective timing B Compression Incorrect valve clearance C Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defe...

Page 1736: ...system Ref to EN H4DOSTC 2 Basic Diagnostic Procedure A Intake system Loosened or cracked intake duct A Loosened or cracked PCV hose A Loosened or cracked vacuum hose A Defective intake manifold gask...

Page 1737: ...B Lubrication system Incorrect oil pressure B Cooling system Overheating C Over cooling C Others Malfunction of evaporative emission control system A 4 Surging Engine control system Ref to EN H4DOSTC...

Page 1738: ...ctive gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn or stuck piston rings cylinder and piston C Incorrect valve timing A Lubrication system Incorrect oil...

Page 1739: ...rrect valve clearance B Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defective gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn...

Page 1740: ...g Improper gasoline Clank when engine speed is medium 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft main bearing Worn bearing...

Page 1741: ...ME H4DOSTC 96 MECHANICAL ENGINE NOISE MEMO...

Page 1742: ...EXHAUST EX H4DOSTC Page 1 General Description 2 2 Front Exhaust Pipe 5 3 Center Exhaust Pipe 7 4 Joint Pipe 11 5 Rear Exhaust Pipe 12 6 Muffler 13 7 Variable Muffler Control Unit 14...

Page 1743: ...lb 2 Upper exhaust manifold cover RH 7 Lower exhaust manifold cover LH T1 19 1 9 13 7 T2 35 3 6 26 0 3 Exhaust manifold RH 8 Exhaust manifold LH T3 39 4 0 28 9 4 Lower exhaust manifold cover RH 9 Upp...

Page 1744: ...ft lb 6 Gasket 18 Muffler T1 4 5 0 46 3 3 7 Joint pipe LH 19 Control cable MT vehicles T2 18 1 8 13 0 8 Hanger bracket RH 20 Plug AT vehicles T3 23 2 3 16 6 9 Hanger bracket LH 21 Grommet T4 30 3 0 2...

Page 1745: ...rom dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because...

Page 1746: ...pipe assembly with one hand remove the nuts which hold front ex haust pipe assembly to cylinder head exhaust port 7 Remove the front exhaust pipe assembly 8 Remove the covers from the exhaust manifold...

Page 1747: ...lb 4 Install the exhaust manifold covers LH Tightening torque 19 N m 1 9 kgf m 13 7 ft lb 5 Install the lower exhaust manifold cover RH Tightening torque 19 N m 1 9 kgf m 13 7 ft lb 6 Connect the conn...

Page 1748: ...Be careful the turbocharger cover and exhaust pipe are hot 7 Remove the bolts which install lower side of tur bocharger cover LH 8 Lower the vehicle 9 Remove the turbocharger cover RH 10 Remove the t...

Page 1749: ...CAUTION Be careful not to pull down the center exhaust pipe 19 Remove the center exhaust pipe B INSTALLATION NOTE Replace the gaskets with new ones 1 Install the center exhaust pipe and temporarily t...

Page 1750: ...ossmember 8 Tighten the bolt which holds center exhaust pipe bracket to transmission Tightening torque 30 N m 3 1 kgf m 22 4 ft lb 9 Tighten the bolts which hold center exhaust pipe to hanger bracket...

Page 1751: ...e vehicle 14 Tighten the bolts which install under side of tur bocharger cover RH Tightening torque 7 4 N m 0 75 kgf m 5 4 ft lb 15 Tighten the bolts which install under side of tur bocharger cover LH...

Page 1752: ...4DOSTC 7 REMOVAL Center Exhaust Pipe 6 Remove the turbocharger Ref to IN H4DOSTC 15 REMOVAL Turbocharger 7 Take off the joint pipe in the upward direction 2 SECONDARY SIDE 1 Remove the under cover 2 R...

Page 1753: ...move the rear exhaust pipe B INSTALLATION NOTE Replace the gaskets with new ones 1 Install the rear exhaust pipe to muffler Tightening torque 48 N m 4 9 kgf m 35 4 ft lb 2 Install the rear exhaust pip...

Page 1754: ...ler during remov al NOTE To facilitate removal apply a coat of SUBARU CRC to the mating area of rubber cushions in ad vance SUBARU CRC Part No 004301003 B INSTALLATION 1 Install in the reverse order o...

Page 1755: ...ve the cable B 4 Disconnect the variable muffler control unit and connector C of actuator 5 Remove the variable muffler control unit actua tor and bracket as a unit B INSTALLATION Install in the rever...

Page 1756: ...Radiator Sub Fan System 11 4 Engine Coolant 15 5 Water Pump 17 6 Thermostat 21 7 Radiator 23 8 Radiator Cap 27 9 Radiator Main Fan and Fan Motor 28 10 Radiator Sub Fan and Fan Motor 30 11 Reservoir Ta...

Page 1757: ...eed Discharge pres sure pressure leak 6 000 rpm 225 4 kPa 23 0 mAq 75 5 ftAq Engine coolant temperature 85 C 185 F Impeller diameter 76 mm 2 99 in Number of impeller vanes 8 Pump pulley diameter 60 mm...

Page 1758: ...hermostat case 5 Gasket Tightening torque N m kgf m ft lb 2 Gasket 6 Heater by pass hose T1 First 12 1 2 8 7 Second 12 1 2 8 7 3 Thermostat 7 Coolant filler tank by pass hose 4 Water pump ASSY 8 Water...

Page 1759: ...coolant filler tank cap 7 Engine coolant reservoir tank cap 19 Engine coolant hose Tightening torque N m kgf m ft lb 8 Overflow hose 20 Radiator lower bracket T1 3 4 0 35 2 5 9 Engine coolant reservo...

Page 1760: ...from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands becau...

Page 1761: ...499977400 AT model CRANK PULLEY WRENCH Used for fixing crankshaft pulley when loos ening and tightening crankshaft pulley bolts 18231AA010 CAMSHAFT SPROCKET WRENCH Used for removing and installing ca...

Page 1762: ...OTOR MAIN FAN RELAY F28 F16 F66 F27 1 2 F17 B100 F2 B72 1 2 8 9 NO 3 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 3 4 1 2 B137 BATTERY 17 28 B137 ECM F16 F17 2 1 F27 1 2 3 4 5 6 7 8 9 11 10 13 12 14 21...

Page 1763: ...asure resistance between main fan motor connector and chassis ground Connector terminal F17 No 1 Chassis ground Is the measured value less than the speci fied valve 5 Go to step 3 Repair open circuit...

Page 1764: ...fuse terminal 9 CHECK FUSE 1 Turn ignition switch to OFF 2 Remove fuse No 18 from joint box 3 Check fuse Is the fuse blown out Fuse is blown out Replace fuse Repair open circuit in harness between ma...

Page 1765: ...e of harness between main fan relay connector and ECM connec tor Connector terminal F66 No 7 B134 No 14 Is the measured value less than the speci fied valve 1 Go to step 14 Repair open circuit in harn...

Page 1766: ...OTOR MAIN FAN RELAY F28 F16 F66 F27 1 2 F17 B100 F2 B72 1 2 8 9 NO 3 NO 18 NO 17 SBF 4 SBF 1 IGNITION SWITCH B72 3 4 1 2 B137 BATTERY 17 28 B137 ECM F16 F17 2 1 F27 1 2 3 4 5 6 7 8 9 11 10 13 12 14 21...

Page 1767: ...switch to ON 5 Measure voltage between sub fan motor connector and chassis ground Connector terminal F16 No 2 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 2 Go t...

Page 1768: ...ure voltage of harness between A C relay holder 20 A fuse terminal and chassis ground Connector terminal F27 No 3 Chassis ground Does the measured value exceed the specified value 10 V Repair open cir...

Page 1769: ...etween sub fan motor and sub fan relay connector 13 CHECK HARNESS BETWEEN SUB FAN RE LAY AND ECM 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between s...

Page 1770: ...0 rpm 5 If engine coolant level drops in radiator add en gine coolant to filler neck position 6 If engine coolant level drops from upper level of reservoir tank add engine coolant to upper level 7 Att...

Page 1771: ...ntersects with the 40 curve of the necessary coolant concentra tion and read the scale on the vertical axis of the graph at height A The quantity of coolant to be drained is 2 1 liters 2 2 US qt 1 8 I...

Page 1772: ...7 Remove bolt and clamps and then remove wa ter by pass pipe MT model 8 Disconnect radiator outlet hose A and heater hose B from water pump 9 Disconnect water by pass hose C and oil cool er hose D 10...

Page 1773: ...sprocket by using ST ST 18231AA010 CAMSHAFT SPROCKET WRENCH Intake side ST 499207400 CAMSHAFT SPROCKET WRENCH Exhaust side 22 Remove tensioner bracket 23 Remove left hand belt cover No 2 24 Remove wa...

Page 1774: ...9 ft lb 8 Install automatic belt tension adjuster which ten sion rod is held with pin Ref to ME H4DOSTC 49 BELT IDLER AND AUTOMATIC BELT TEN SION ADJUSTER ASSEMBLY INSTALLATION Timing Belt Assembly 9...

Page 1775: ...T REPLACEMENT Engine Coolant C INSPECTION 1 Check water pump bearing for smooth rotation 2 Check water pump pulley for abnormalities 3 Using a dial gauge measure impeller runout in thrust direction wh...

Page 1776: ...out the thermostat B INSTALLATION 1 Install the thermostat in the water pump and in stall the thermostat cover together with a gasket NOTE Replace gasket with a new one Thermostat must be installed wi...

Page 1777: ...wa ter Raise water temperature gradually and mea sure the temperature and valve lift when the valve begins to open and when the valve is fully opened During the test agitate the water for even temper...

Page 1778: ...T REPLACEMENT Engine Coolant 5 Disconnect connectors of radiator main fan A and sub fan B motor 6 Disconnect radiator outlet hose from thermostat cover 7 Disconnect ATF cooler hoses from radiator AT v...

Page 1779: ...r 16 While slightly lifting radiator slide it to left 17 Lift radiator up and away from vehicle B INSTALLATION 1 Attach radiator mounting cushions to holes on the vehicle 2 Install radiator while fitt...

Page 1780: ...iator inlet hose A and engine cool ant filler tank hose B to radiator 6 Install reservoir tank Tightening torque 4 9 N m 0 50 kgf m 3 6 ft lb 7 Connect overflow hose 8 Install air intake duct 9 Lift u...

Page 1781: ...ission Fluid C INSPECTION 1 Remove radiator cap top off radiator and attach tester to radiator in place of cap 2 Apply a pressure of 157 kPa 1 6 kg cm2 23 psi to radiator to check if 1 Engine coolant...

Page 1782: ...ps Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds Standard pressure 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Service limit pressure 83 kPa 0 85 kg cm2...

Page 1783: ...vehicle 6 Remove air intake duct 7 Disconnect overflow hose 8 Remove reservoir tank 9 Remove radiator main fan motor assembly B INSTALLATION Install in the reverse order of removal NOTE When the main...

Page 1784: ...nto shroud D ASSEMBLY Assemble in the reverse order of disassembly Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb Tightening torque 3 4 N m 0 35 kgf m 2 5 ft lb E INSPECTION 1 Connect battery positive...

Page 1785: ...ub fan motor 5 Lower the vehicle 6 Remove air intake duct 7 Remove bolts which hold sub fan shroud to radi ator 8 Remove radiator sub fan shroud through the un der side of vehicle B INSTALLATION Insta...

Page 1786: ...e in the reverse order of disassembly Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb Tightening torque 3 4 N m 0 35 kgf m 2 5 ft lb E INSPECTION 1 Connect battery positive terminal to terminal No 2 an...

Page 1787: ...ller neck position 2 Remove bolts which install reservoir tank onto radiator main fan shroud 3 Remove reservoir tank B INSTALLATION Install in the reverse order of removal Tightening torque 4 9N m 0 5...

Page 1788: ...C 10 REMOVAL Air Cleaner 3 Remove the air cleaner element 4 Disconnect the engine coolant hoses from cool ant filler tank 5 Remove the bolts and nut which installs coolant filler tank 6 Disconnect the...

Page 1789: ...ressure in exhaust system Clean or replace l Insufficient clearance between piston and cylinder Adjust or replace m Slipping clutch Repair or replace n Dragging brake Adjust o Improper transmission oi...

Page 1790: ...e 1 General Description 2 2 Oil Pressure System 6 3 Engine Oil 8 4 Oil Pump 10 5 Oil Pan and Strainer 14 6 Oil Pressure Switch 18 7 Engine Oil Cooler 19 8 Engine Oil Filter 21 9 Engine Lubrication Sys...

Page 1791: ...in Capacity at 80 C 176 F 600 rpm Discharge pressure 98 kPa 1 0 kg cm2 14 psi Discharge quantity 4 6 2 4 9 US qt 4 0 Imp qt min 5 000 rpm Discharge pressure 294 kPa 3 0 kg cm2 43 psi Discharge quanti...

Page 1792: ...l pump case 21 O ring T5 69 7 0 51 7 Inner rotor 22 Oil strainer T6 6 4 0 65 4 7 8 Outer rotor 23 Gasket T7 25 2 5 18 1 9 Oil pump cover 24 Oil level gauge guide T8 44 4 5 33 10 Oil filter 25 Oil pan...

Page 1793: ...or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each pa...

Page 1794: ...ulley when loosening and tightening crankshaft pulley bolt 499977400 AT model CRANKSHAFT PULLEY WRENCH Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley b...

Page 1795: ...M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 OIL PRESSURE WARNING LIGHT B5 B8 B5 14 i1 B36 E2 E11 B21 OIL PRE...

Page 1796: ...ressure switch 3 Turn ignition switch ON 4 Measure the voltage of harness between the combination meter connector and chas sis ground Connector terminal E11 No 1 Chassis ground Does the measured value...

Page 1797: ...driving or while the engine is warm en gine oil level may show in the range between the F line and the notch mark This is caused by ther mal expansion of the engine oil 7 To prevent overfilling the en...

Page 1798: ...ction and thus increasing cranking speed CAUTION When replenishing oil it does not matter if the oil to be added is a different brand from that in the engine however use oil having the ILSAC or API cl...

Page 1799: ...aft position sensor 9 Remove V belts Ref to ME H4DOSTC 42 REMOVAL V belt 10 Remove rear side V belt tensioner 11 Remove crankshaft pulley by using ST ST 499977100 CRANKSHAFT PULLEY WRENCH MT model ST...

Page 1800: ...l pump Fluid gasket Part No 004403007 THREE BOND 1215 or equivalent 2 Replace O ring A with a new one 3 Apply engine oil to the inside of the oil seal 4 Be careful not to scratch oil seal when install...

Page 1801: ...Install inner and outer rotors in their original po sitions 4 Install oil relief valve and relief valve spring 5 Install oil pump cover Tightening torque T1 5 N m 0 5 kgf m 3 6 ft lb T2 44 N m 4 5 kgf...

Page 1802: ...y Side clearance Standard 0 02 0 07 mm 0 0008 0 0028 in Limit 0 12 mm 0 0047 in 4 OIL RELIEF VALVE Check the valve for fitting condition and damage and the relief valve spring for damage and deterio r...

Page 1803: ...e duct 6 Remove the two clips B from air cleaner upper cover 7 Remove the air intake boot and air cleaner upper cover 8 Remove the intercooler Ref to IN H4DOSTC 13 REMOVAL Intercooler 9 Remove pitchin...

Page 1804: ...while raising up engine 17 Insert oil pan cutter blade between cylinder block to oil pan clearance CAUTION Do not use a screwdriver or similar tool in place of oil pan cutter 18 Remove oil strainer 1...

Page 1805: ...Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 5 Lower engine onto front crossmember 6 Tighten nuts which secure front cushion rubber onto front crossmember Tightening torque 69 N m 7 0 kgf m 51 ft lb 7...

Page 1806: ...he clamp A which connects air intake boot to intake duct 15 Lock the two clips B to air cleaner upper cov er 16 Connect the connector to mass air flow sensor 17 Install front wheels 18 Connect battery...

Page 1807: ...gasket to oil pressure switch threads Fluid gasket Part No 004403042 THREE BOND 1324 or equivalent 2 Install oil pressure switch onto engine block Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 3 Conn...

Page 1808: ...ontainer under the vehicle and remove the drain plug from oil pan 4 Drain the coolant 5 Remove the water by pass pipe between oil cooler and water pump 6 Remove the engine oil filter Ref to LU H4DOSTC...

Page 1809: ...e order of removal Tightening torque T 54 N m 5 5 kgf m 40 ft lb CAUTION Always use a new O ring C INSPECTION 1 Check that the coolant passages are not clogged using an air blow method 2 Check the mat...

Page 1810: ...hand being careful not to damage seal rubber 3 Tighten more approximately 2 3 to 3 4 turn af ter the seal rubber contacts the oil pump case Do not tighten excessively or oil may leak C INSPECTION 1 A...

Page 1811: ...by pass valve of oil filter Clean or replace Malfunction of oil relief valve of oil pump Clean or replace Clogged oil passage Clean Excessive tip clearance and side clearance of oil pump rotor and gea...

Page 1812: ...SPEED CONTROL SYSTEMS SP H4DOSTC Page 1 General Description 2...

Page 1813: ...SP H4DOSTC 2 SPEED CONTROL SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATION Specification of TURBO model is also described on SP H4SO Ref to SP H4SO 2 General De scription...

Page 1814: ...IGNITION IG H4DOSTC Page 1 General Description 2 2 Spark Plug 5 3 Ignition Coil and Ignitor Assembly 8...

Page 1815: ...ion A SPECIFICATIONS Item Designation Ignition coil and ignitor assembly Model FK0186 Ignition type Direct ignition Manufacturer DIAMOND Spark plug Type and manufacturer NGK PFR6G Thread size mm 14 P...

Page 1816: ...IG H4DOSTC 3 IGNITION GENERAL DESCRIPTION B COMPONENT 1 Spark plug Tightening torque N m kgf m ft lb 2 Ignition coil and ignitor ASSY T1 21 2 1 15 2 T2 16 1 6 11 7 IG 00001 1 T1 T2 T1 1 2 2 T2...

Page 1817: ...from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands becaus...

Page 1818: ...he connector from ignition coil 4 Remove the ignition coil 5 Remove the spark plugs with the spark plug sockets 2 LH SIDE 1 Disconnect the battery cables and then remove the battery and battery carrie...

Page 1819: ...LH SIDE 1 Install in the reverse order of removal Tightening torque Spark plug 21 N m 2 1 kgf m 15 2 ft lb Tightening torque Ignition coil 16 N m 1 6 kgf m 11 7 ft lb NOTE The above torque should be o...

Page 1820: ...ray brown spots and bluish burnt electrodes indicates engine overheating Moreover the appearance re sults from incorrect ignition timing loose spark plugs wrong selection of fuel hotter range plug etc...

Page 1821: ...OSTC 5 REMOVAL Spark Plug B INSTALLATION Install in the reverse order of removal Tightening torque 16 N m 1 6 kgf m 11 7 ft lb C INSPECTION Ignitor is integrated with the coil Therefore resis tance ca...

Page 1822: ...STARTING CHARGING SYSTEMS SC H4DOSTC Page 1 General Description 2 2 Starter 6 3 Generator 14 4 Battery 17...

Page 1823: ...5 V 7 7 V Current 300 A 400 A Torque 8 6 N 0 88 kgf 6 4 lb or more 16 0 N 1 63 kgf 11 8 lb or more Rotating speed 920 rpm or more 740 rpm or more Lock characteristics Voltage 4 V 3 5 V Current 650 A o...

Page 1824: ...bearing 7 Internal gear ASSY 13 Armature 2 Front bracket 8 Shaft ASSY 14 Brush holder 3 Lever set 9 Shaft ASSY 15 Brush 4 Magnet switch ASSY 10 Ball 16 Sleeve bearing 5 Stopper set 11 Packing 17 Rear...

Page 1825: ...H4DOSTC 4 STARTING CHARGING SYSTEMS GENERAL DESCRIPTION 2 GENERATOR 1 Pulley 4 Bearing retainer 7 Rear cover ASSY 2 Front cover 5 Ball bearing 8 Terminal 3 Ball bearing 6 Rotor SC 00147 1 2 3 4 5 6 7...

Page 1826: ...ct them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hand...

Page 1827: ...nd terminal from starter 4 Remove the starter from transmission B INSTALLATION Install in the reverse order of removal Tightening torque 50 N m 5 1 kgf m 37 ft lb C DISASSEMBLY 1 STARTER ASSEMBLY 1 Lo...

Page 1828: ...on the mounting surface of switch assembly 3 Remove both through bolts and brush holder screws and then detach the rear cover and brush holder 4 Remove the armature and yoke from front brack et 5 Rem...

Page 1829: ...as follows 1 Remove the stopper from ring by lightly tap ping the stopper with an appropriate tool such as a fit socket wrench 2 Remove the ring stopper and clutch from shaft 2 BRUSH HOLDER Unlock me...

Page 1830: ...r and clutch Ball at the armature shaft end Internal and planetary gears 1 When installing shaft assembly to front bracket be careful of the following Lever direction Internal gear position Packing po...

Page 1831: ...use the iron sheet to vi brate and to be attracted to core If the iron sheet is attracted or vibrates the armature which is short circuited must be replaced or repaired 5 Armature ground test Using a...

Page 1832: ...t in ohm Also check to be sure there is no continuity be tween terminal M and B Terminal Specified resistance S M Less than 1 S Ground Less than 1 M B More than 1 M 6 SWITCH ASSEMBLY OPERATION 1 Conne...

Page 1833: ...8 PERFORMANCE TEST The starter should be submitted to performance tests whenever it has been overhauled to assure its satisfactory performance when installed on the engine Three performance tests no l...

Page 1834: ...vehicles 7 7 V 16 0 N 1 63 kgf 3 59 lb Current Speed MT vehicles 300 A 920 rpm or more AT vehicles 400 A 740 rpm or more 3 Lock test With the starter stalled or not rotating measure the torque develop...

Page 1835: ...bracket B INSTALLATION Install in the reverse order of removal CAUTION Check and adjust the V belt tension Ref to ME H4DOSTC 43 INSPECTION V belt C DISASSEMBLY 1 Remove the four through bolts 2 Heat t...

Page 1836: ...in dia length 4 to 5 cm 1 6 to 2 0 in wire through the hole shown in the figure CAUTION Be sure to remove the wire after reassembly 2 Install the ball bearing 1 Set the ball bearing on the front cover...

Page 1837: ...test Check the resistance between slip rings using cir cuit tester If the resistance is not within specification replace the rotor assembly Specified resistance Approx 1 8 2 2 4 Insulation test Check...

Page 1838: ...d to it while you are at the same time in contact with any other metallic portion of the vehicle be cause a short circuit will be caused 1 EXTERNAL PARTS Check for the existence of dirt or cracks on b...

Page 1839: ...rent value specified by manufacturer or at approx 1 10 of battery s am pere hour rating 4 QUICK CHARGING Quick charging is a method in which the battery is charged in a short period of time with a rel...

Page 1840: ...on Control Module TCM I O Signal 24 8 Data Link Connector 25 9 Subaru Select Monitor 26 10 Read Diagnostic Trouble Code 32 11 Inspection Mode 33 12 Clear Memory Mode 35 13 Compulsory Valve Operation C...

Page 1841: ...baru Select Monitor or the OBD II general scan tool to data link con nector 3 Turn the ignition switch to ON and the Subaru Select Monitor or OBD II general scan tool switch to ON 4 Read the DTC on th...

Page 1842: ...ferential gear oil level check Ref to AT 31 Differential Gear Oil 3 ATF leak check Ref to AT 30 Automatic Transmission Fluid 4 Differential gear oil leak check Ref to AT 31 Differential Gear Oil 5 Sta...

Page 1843: ...Others Outdoor temperature C F Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine...

Page 1844: ...l gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of parts other than...

Page 1845: ...f this problem To measure the voltage and or resistance of individual sensors or all electrical control modules at the harness side connector use a tapered pin with a diameter of less than 0 64 mm 0 0...

Page 1846: ...h might affect engine problems 1 BATTERY 1 Measure the battery voltage and specific gravity of electrolyte Standard voltage 12 V Specific gravity Above 1 260 2 Check the condition of the main and othe...

Page 1847: ...timing control It also controls the AWD transfer clutch In other words the system detects various operating conditions from various input signals and sends output signals to shift sole noids 1 2 and...

Page 1848: ...Electrical Components Location A LOCATION 1 ENGINE MODULE 1 Engine control module ECM 3 Read memory connector 2 CHECK ENGINE malfunction indi cator lamp MI 4 Test mode connector 5 Data link connector...

Page 1849: ...ENSOR 1 Pressure sensor 4 Knock sensor 7 Mass air flow and intake air tem perature sensor 2 Engine coolant temperature sen sor 5 Camshaft position sensor 6 Crankshaft position sensor 8 Differential pr...

Page 1850: ...EN H4DOSTC 11 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00959 1 EN 00963 2 3 EN 00960 EN 00964 5 EN 00961 5 6 EN 00965 7 EN 00962 8 EN 00966...

Page 1851: ...ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Front oxygen A F sensor 3 Rear oxygen sensor 2 Front catalytic converter 4 Rear catalytic converter EN 00967 1 2 3 4 EN 00968 1 2 EN 00970 EN 00969...

Page 1852: ...CAL COMPONENTS LOCATION SOLENOID VALVE ACTUATOR EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 Solenoid box ASSY 3 Purge control solenoid valve 5 Fuel injector 2 Idle air control solenoid v...

Page 1853: ...ef valve control solenoid valve 1 G Exhaust valve control solenoid valve For positive pressure B Filter E Exhaust valve control solenoid valve For negative pressure C Exhaust valve control duty sole n...

Page 1854: ...EN H4DOSTC 15 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00974 2 EN 00976 3 EN 00975 4 EN 00977 5...

Page 1855: ...S ELECTRICAL COMPONENTS LOCATION 1 Fuel pump 3 Fuel pump relay 5 Starter 2 Main relay 4 Fuel pump controller 6 Wastegate control solenoid valve EN 00978 2 6 5 4 3 1 EN 00979 1 EN 00982 2 EN 00980 3 EN...

Page 1856: ...C 17 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 2 TRANSMISSION MODULE 1 Transmission Control Module TCM for AT vehicles 2 AT diagnostic indicator light for AT vehicles EN 00985 1 2 EN 00879 1 A...

Page 1857: ...cle speed sensor for AT vehicles 2 Front vehicle speed sensor for MT vehicles 3 Front vehicle speed sensor for AT vehicles 4 Torque converter turbine speed sensor 5 ATF temperature sensor for AT vehic...

Page 1858: ...solenoid valve 1 4 Shift solenoid valve 2 5 Line pressure duty solenoid 6 Lock up duty solenoid 7 Transfer duty solenoid 8 2 4 brake duty solenoid 9 Low clutch timing solenoid valve 10 2 4 brake timin...

Page 1859: ...7 0 0 0 9 Shield B135 26 0 0 GND sen sor B135 19 0 0 Front oxy gen A F sensor heater Signal 1 B137 4 0 1 0 0 1 0 Signal 2 B137 5 0 1 0 0 1 0 Rear oxygen sensor heater signal B136 13 0 1 0 0 1 0 Engine...

Page 1860: ...n control 1 B136 24 0 13 14 Waveform 2 B136 23 0 13 14 Waveform 3 B136 22 0 13 14 Waveform 4 B136 21 0 13 14 Waveform Fuel injec tor 1 B137 1 10 13 1 14 Waveform 2 B136 6 10 13 1 14 Waveform 3 B136 5...

Page 1861: ...han 1 More than 4 GND sensors B135 19 0 0 GND injectors B136 8 0 0 GND ignition system B136 18 0 0 GND power supply B136 17 0 0 B134 22 0 0 GND control systems B134 7 0 0 B134 15 0 0 GND oxygen sensor...

Page 1862: ...ine Condition Data A ELECTRICAL SPECIFICATION Measuring condition After engine is warmed up Gear position is in neutral position A C is turned OFF All accessory switches are turned OFF Content Specifi...

Page 1863: ...H4DOSTC 24 ENGINE DIAGNOSTICS TRANSMISSION CONTROL MODULE TCM I O SIGNAL 7 Transmission Control Module TCM I O Signal A ELECTRICAL SPECIFICATION Ref to AT 14 Transmission Control Module TCM I O Signa...

Page 1864: ...lect Monitor signal CAUTION Do not connect any scan tools other than the OBD II general scan tools and Subaru Select Monitor because the circuit for the Subaru Se lect Monitor may be damaged EN 00037...

Page 1865: ...iagnosis cable to data link connector CAUTION Do not connect scan tools except for the Subaru Select Monitor and OBD II general scan tool 5 Turn the ignition switch to ON engine OFF and Subaru Select...

Page 1866: ...l Rear O2 Sensor V Short term fuel trim A F Correction 1 Knock sensor signal Knocking Signal deg Atmospheric absolute pressure signal Atmosphere Pressure mmHg or kPa or inHg or psig Intake manifold re...

Page 1867: ...ON or OFF Supercharged pressure relief valve solenoid 1 signal Relief Valve Solenoid 1 ON or OFF Supercharged pressure relief valve solenoid 2 signal Relief Valve Solenoid 2 ON or OFF Exhaust gas posi...

Page 1868: ...l trim B1 Long term fuel trim by front oxygen A F sensor Long term fuel trim B1 Intake manifold absolute pressure signal Mani Absolute Pressure mmHg or kPa or inHg or psig Engine speed signal Engine S...

Page 1869: ...ehicle Speed 2 km h or MPH Engine speed signal Engine Speed rpm Automatic transmission fluid temperature signal ATF Temp C or F Throttle position signal Throttle Sensor Voltage V Gear position Gear Po...

Page 1870: ...OTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MANUAL For select monitor display details refer to the following Automatic transmission diagnosis indicator lamp AT Di...

Page 1871: ...ed concerning diagnostic trouble codes refer to the List of Diagnostic Trouble Code DTC Ref to EN H4DOSTC 62 List of Diag nostic Trouble Code DTC 2 SUBARU SELECT MONITOR OBD MODE 1 On the Main Menu di...

Page 1872: ...vent the vehicle from slipping due to vibration do not place any wooden blocks or similar items between the safety stands and the vehicle Since the rear wheels will also rotate do not place anything n...

Page 1873: ...10 On the Engine Diagnosis display screen se lect the Dealer Check Mode Procedure and press YES key 11 When the Perform Inspection Dealer Check Mode is shown on the display screen press YES key 12 Per...

Page 1874: ...to OFF NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL 2 SUBARU SELECT MONITOR OBD MODE 1 On the Main Menu display screen select the 2 Each System Check and...

Page 1875: ...n the driver s side 2 Connect the diagnosis cable to data link connector CAUTION Do not connect scan tools except for the Subaru Select Monitor and OBD II general scan tool 6 Turn the ignition switch...

Page 1876: ...he SUBARU SELECT MONITOR OPERATION MANUAL Contents Display Compulsory fuel pump relay operation check Fuel Pump Relay Compulsory radiator fan relay operation check Radiator Fan Relay Compulsory air co...

Page 1877: ...lfunction Indicator Lamp MI 3 Check that engine malfunction indicator lamp MI does not go off Ref to EN H4DOSTC 44 CHECK ENGINE MALFUNC TION INDICATOR LAMP MI DOES NOT GO OFF Engine Malfunction Indica...

Page 1878: ...MI DOES NOT COME ON Engine Malfunction Indi cator Lamp MI 2 After starting the engine the MI goes out If it does not either the engine or emission control sys tem is malfunctioning 3 If the diagnosis...

Page 1879: ...ECM i1 E E 1 4 37 34 36 38 15 i10 A i11 B i11 i10 B137 B157 B5 B10 COMBINATION METER 3 4 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 10 11 12 13 14 15 16 17...

Page 1880: ...the con nection of ECM connector 4 CHECK HARNESS BETWEEN COMBINA TION METER AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Remove the combination meter Ref to IDI 15 Combination Meter Assembly...

Page 1881: ...repair if necessary NOTE Broken down ignition relay Blown out fuse No 5 If replaced fuse No 5 blows eas ily check the har ness for short circuit of harness between fuse No 5 and ignition relay connec...

Page 1882: ...EN H4DOSTC 43 ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LAMP MI MEMO...

Page 1883: ...t in harness between combina tion meter and ECM connector Replace the ECM Ref to FU H4DOSTC 40 Engine Con trol Module EN 00928 BATTERY IGNITION SWITCH IGNITION RELAY SBF 4 SBF 1 No 5 B72 B72 B36 B137...

Page 1884: ...EN H4DOSTC 45 ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LAMP MI MEMO...

Page 1885: ...i10 A i11 B A B B5 B10 COMBINATION METER B72 B22 B75 B134 B76 i10 B137 B157 B36 3 4 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 10 11 12 13 14 15 16 17 18 1...

Page 1886: ...or from ECM 3 Measure the resistance of harness between test mode connector and chassis ground Connector terminal B76 No 1 Chassis ground Is the measured value less than the speci fied value 1 Go to s...

Page 1887: ...N METER B72 B22 B75 B134 B76 i10 B137 B157 B36 3 4 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 3...

Page 1888: ...3 Hz when test mode connector is connected 2 CHECK HARNESS BETWEEN ECM CON NECTOR AND ENGINE GROUNDING TER MINAL 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM 3 Measure the res...

Page 1889: ...EN H4DOSTC 50 ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LAMP MI MEMO...

Page 1890: ...circuit Ref to EN H4DOSTC 52 STARTER MOTOR CIRCUIT Diagnostics for Engine Starting Failure 2 Inspection of ECM power supply and ground line Ref to EN H4DOSTC 56 CONTROL MODULE POWER SUPPLY AND GROUND...

Page 1891: ...4DOSTC 35 Clear Memory Mode and INSPECTION MODE Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00930 BATTERY IGNITION SWITCH STARTER MOTOR SBF 4 SBF 1 B72 B72 B14 B134 ECM E E 1 3 16 3 4 1 2 B...

Page 1892: ...STARTER MOTOR 1 Turn the ignition switch to OFF 2 Disconnect the terminal from starter motor 3 Measure the resistance of ground cable between ground cable terminal and engine ground Is the measured v...

Page 1893: ...nector terminal and engine ground while turning ignition switch to ST Connector terminal B12 No 12 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 9 Repair open or gr...

Page 1894: ...EN H4DOSTC 55 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 1895: ...2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 TO FRONT OXYGEN A F SENSOR A2 D8 D9 A22 C17 C8 C18 A7 A15 E1...

Page 1896: ...ss than the speci fied value 5 Go to step 3 Repair the open circuit in harness between ECM connector and engine grounding terminal 3 CHECK INPUT VOLTAGE OF ECM Measure the voltage between ECM connecto...

Page 1897: ...or and chassis ground Connector terminal B47 No 1 Chassis ground Is the measured value less than the speci fied value 5 Go to step 9 Repair the open circuit between main relay and chassis ground 9 CHE...

Page 1898: ...EN H4DOSTC 59 ENGINE DIAGNOSTICS DIAGNOSTICS FOR ENGINE STARTING FAILURE MEMO...

Page 1899: ...134 B136 B46 R122 E E M 10 7 6 FUEL PUMP RELAY FUEL PUMP CONTROLLER FUEL PUMP SBF 5 B46 R122 B134 A B136 C R15 R57 R58 R2 ECM B98 B99 R58 B99 R3 BATTERY 1 3 5 4 A13 C16 3 4 1 2 8 9 10 11 12 13 14 15 1...

Page 1900: ...n mode FD01 For the procedure refer to Compulsory Valve Operation Check Mode Ref to EN H4DOSTC 36 Compulsory Valve Opera tion Check Mode Operating sound produced Go to step 2 Record the DTC Repair the...

Page 1901: ...UIT HIGH INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC P0112 Intake Air Temperature Circuit Low Input Ref to EN H4DOSTC 92 DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT Diagnostic P...

Page 1902: ...POSITION SENSOR A CIRCUIT Diagnostic Procedure with Diagnostic Trouble Code DTC P0340 Camshaft Position Sensor A Circuit Bank 1 or Single Sensor Ref to EN H4DOSTC 142 DTC P0340 CAMSHAFT POSITION SEN S...

Page 1903: ...Diagnostic Trouble Code DTC P1230 Fuel Pump Controller Ref to EN H4DOSTC 194 DTC P1230 FUEL PUMP CONTROLLER Diagnostic Procedure with Diagnostic Trouble Code DTC P1235 Intake Control Solenoid Valve C...

Page 1904: ...to IM 17 DTC P1571 REFERENCE CODE INCOMPATIBILITY Diag nostic Procedure with Trouble Code DTC P1572 IMM Circuit Failure Except Antenna Circuit Ref to IM 18 DTC P1572 IMM CIRCUIT FAILURE EXCEPT ANTENNA...

Page 1905: ...aulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00933 BATTERY MAIN RELAY SBF 5 B47 1 2...

Page 1906: ...harness between ECM connector and chassis ground Connector terminal B137 No 8 Chassis ground B137 No 9 Chassis ground Is the measured value less than the specified value 5 Go to step 4 Repair the har...

Page 1907: ...contact in ECM connector Go to step 7 7 CHECK FRONT OXYGEN A F SENSOR 1 Turn the ignition switch to OFF 2 Measure the resistance between front oxy gen A F sensor connector terminals Terminals No 2 No...

Page 1908: ...EN H4DOSTC 69 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1909: ...mory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00933 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E E3 3 8 9 4 5 19...

Page 1910: ...urn the ignition switch to ON 4 Read the data of front oxygen A F sensor heater current using Subaru Select Monitor Does the measured value exceed the spec ified value NOTE For detailed operation proc...

Page 1911: ...on Mode WIRING DIAGRAM EN 00934 BATTERY MAIN RELAY B47 1 2 3 5 4 6 E E E3 3 3 6 B22 B122 3 4 1 2 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B136 B122 B47 T5 B137 1 2 7 8 9 5 6 3 4 10 11 12 19...

Page 1912: ...Poor contact in ECM connector Go to step 3 3 CHECK OUTPUT SIGNAL FROM ECM 1 Start and idle the engine 2 Measure the voltage between ECM con nector and chassis ground Connector terminal B136 No 13 Chas...

Page 1913: ...owing Open circuit in harness between main relay and rear oxygen sen sor connector Poor contact in rear oxygen sen sor connector Poor contact in coupling connector 7 CHECK REAR OXYGEN SENSOR 1 Turn th...

Page 1914: ...EN H4DOSTC 75 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1915: ...ion Mode WIRING DIAGRAM EN 00934 BATTERY MAIN RELAY B47 1 2 3 5 4 6 E E E3 3 3 6 B22 B122 3 4 1 2 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B136 B122 B47 T5 B137 1 2 7 8 9 5 6 3 4 10 11 12 1...

Page 1916: ...ry short circuit in harness between ECM and rear oxygen sensor con nector 3 Turn the ignition switch to ON 4 Read the data of rear oxygen sensor heater current using Subaru Select Monitor Does the mea...

Page 1917: ...ngine stalls Poor driving performance WIRING DIAGRAM EN 00951 B122 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 BATTERY E B122 1 B3 MASS AIR FLOW AND INTAKE AIR T...

Page 1918: ...ss between mass air flow sen sor and ECM con nector Poor contact in mass air flow sen sor or ECM con nector Go to step 2 2 CHECK INPUT SIGNAL FOR ECM Measure the voltage between ECM connector and chas...

Page 1919: ...K HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR Measure the resistance of harness between ECM and chassis ground Connector terminal B84 No 13 Chassis ground B135 No 27 Chassis ground B135 No...

Page 1920: ...EN H4DOSTC 81 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1921: ...onduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00951 B122 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25...

Page 1922: ...2 lb min or 0 3 4 58 V Even if MI lights up the circuit has returned to a nor mal condition at this time Go to step 2 2 CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR 1 Turn the ignition...

Page 1923: ...ty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00935 B122 PRESSURE SENSOR THROTTLE BODY...

Page 1924: ...L FOR ECM Measure the voltage between ECM connector and chassis ground Connector terminal B135 No 9 Chassis ground Does the measured value change by shaking harness and connector of ECM while monitor...

Page 1925: ...pressure sensor connector 8 CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR Measure the resistance of harness between intake manifold pressure sensor connector and engine ground Connector ter...

Page 1926: ...EN H4DOSTC 87 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1927: ...lty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00935 B122 PRESSURE SENSOR THROTTLE BODY...

Page 1928: ...y shaking harness and connector of ECM while monitor ing the value with voltage meter The value changes Repair the poor contact in ECM connector Contact SUBARU distributor service NOTE Inspection by D...

Page 1929: ...tor Connector terminal B135 No 8 E21 No 1 B135 No 19 E21 No 2 Is the measured value less than the speci fied value 1 Go to step 7 Repair the open circuit in harness between ECM and pressure sensor con...

Page 1930: ...EN H4DOSTC 91 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1931: ...lear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00951 B122 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 1...

Page 1932: ...ntact in joint connector 2 CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from mass air flow and i...

Page 1933: ...lear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00951 B122 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 1...

Page 1934: ...10 V Repair the battery short circuit in har ness between mass air flow and intake air tempera ture sensor and ECM connector Go to step 3 3 CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATU...

Page 1935: ...tor terminal B3 No 5 Engine ground Is the measured value less than the speci fied value 5 Replace the mass air flow and intake air temperature sensor Ref to FU H4DOSTC 33 Mass Air Flow and Intake Air...

Page 1936: ...EN H4DOSTC 97 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1937: ...epair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00936 B122 B1...

Page 1938: ...ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the co...

Page 1939: ...repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00936 B122 B...

Page 1940: ...NT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from engine cool ant temperature sensor 3 Measure the voltage between engine cool ant temperature s...

Page 1941: ...or contact in coupling connector Poor contact in joint connector 5 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Measure the resistance...

Page 1942: ...EN H4DOSTC 103 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1943: ...After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00937...

Page 1944: ...hassis ground Does the measured value exceed the specified value 4 5 V Go to step 4 Go to step 3 3 CHECK INPUT SIGNAL FOR ECM Measure the voltage between ECM connector and chassis ground Connector ter...

Page 1945: ...CM connector and throttle posi tion sensor connector Connector terminal B135 No 7 E13 No 3 Is the measured value less than the speci fied value 1 Go to step 8 Repair the har ness and connec tor NOTE I...

Page 1946: ...EN H4DOSTC 107 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1947: ...After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00937...

Page 1948: ...Disconnect the connector from throttle posi tion sensor 3 Measure the resistance of harness between throttle position sensor connector and engine ground Connector terminal E13 No 2 Engine ground Is t...

Page 1949: ...e WIRING DIAGRAM EN 00934 BATTERY MAIN RELAY B47 1 2 3 5 4 6 E E E3 3 3 6 B22 B122 3 4 1 2 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B136 B122 B47 T5 B137 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21...

Page 1950: ...con nector Connector terminal B135 No 26 T6 No 4 Does the measured value exceed the spec ified value 3 Repair the open circuit in harness between ECM and rear oxygen sen sor connector Go to step 4 4...

Page 1951: ...IC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC P DTC P0171 SYSTEM TOO LEAN BANK 1 NOTE For the diagnostic procedure refer to DTC P0172 Ref to EN H4DOSTC 114 DTC P0172 SYSTEM TOO RICH BANK 1 Diagnostic...

Page 1952: ...EN H4DOSTC 113 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1953: ...ar the working area Be careful not to spill fuel on the floor 1 Release the fuel pressure 1 Disconnect the connector from fuel pump relay 2 Start the engine and run it until it stalls 3 After the engi...

Page 1954: ...empera ture sensor signal using Subaru Select Monitor Does the measured value exceed the spec ified value NOTE For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4DO...

Page 1955: ...ntake manifold pressure sensor signal using Subaru Select Monitor Is the value obtained when ambient tem perature is subtracted from intake air tem perature within the specified range NOTE For detaile...

Page 1956: ...EN H4DOSTC 117 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1957: ...N H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00938 MAIN RELAY B47 1 2 3 5 4 6 BATTERY E B47 B137 F81 F44 B137 F81 WASTEGATE CONTR...

Page 1958: ...nal F81 No 1 Engine ground Does the measured value exceed the spec ified value 1 M Go to step 3 Repair the ground short circuit in har ness between ECM and waste gate control sole noid valve connector...

Page 1959: ...pec ified value 10 V Go to step 6 Repair the open circuit in harness between main relay and waste gate control sole noid valve connector 6 CHECK POOR CONTACT Check poor contact in wastegate control so...

Page 1960: ...EN H4DOSTC 121 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1961: ...EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00938 MAIN RELAY B47 1 2 3 5 4 6 BATTERY E B47 B137 F81 F44 B137 F81 WASTEGATE CONT...

Page 1962: ...tch to ON 4 Measure the voltage between ECM and chassis ground Connector terminal B137 No 24 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in...

Page 1963: ...20 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST VALVE...

Page 1964: ...in har ness between ECM and exhaust valve control duty solenoid valve connector 3 CHECK HARNESS BETWEEN EXHAUST VALVE CONTROL DUTY SOLENOID VALVE AND ECM CONNECTOR Measure the resistance of harness be...

Page 1965: ...alve and ECM connectors Is there poor contact in exhaust valve control duty solenoid valve and ECM connectors There is poor contact Repair the poor contact in exhaust valve control duty solenoid valve...

Page 1966: ...EN H4DOSTC 127 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1967: ...220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST VALV...

Page 1968: ...assis ground Connector terminal B137 No 11 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and exhaust valve control du...

Page 1969: ...ure with Diagnostic Trouble Code DTC W DTC P0264 CYLINDER 2 INJECTOR CIRCUIT LOW NOTE For the diagnostic procedure refer to DTC P0270 Ref to EN H4DOSTC 132 DTC P0270 CYLINDER 4 INJECTOR CIRCUIT LOW Di...

Page 1970: ...EN H4DOSTC 131 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1971: ...5 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00940 BATTERY FUEL INJECTORS MAIN RELAY E 4 1 2 SBF 5 3 1 2 2 1 2 1 1 2 1 9 10 11 12 1 2 1 2 7...

Page 1972: ...Poor contact in coupling connector Poor contact in fuel injector con nector 3 CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR 1 Disconnect the connector from ECM 2 Measure the resistance of har...

Page 1973: ...DTC 6 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector There is poor contact Repair the poor contact in ECM connector Inspection using General Diagnos tic...

Page 1974: ...EN H4DOSTC 135 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1975: ...formance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspect...

Page 1976: ...ontact in knock sensor con nector Poor contact in coupling connector 2 CHECK KNOCK SENSOR 1 Disconnect the connector from knock sen sor 2 Measure the resistance between knock sensor connector terminal...

Page 1977: ...rformance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspec...

Page 1978: ...Ref to FU H4DOSTC 31 Knock Sen sor Repair the ground short circuit in har ness between knock sensor con nector and ECM connector NOTE The harness be tween both con nectors is shielded Repair the short...

Page 1979: ...tart CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAG...

Page 1980: ...ECM connector NOTE The harness be tween both con nectors are shielded Repair the ground short circuit in harness together with shield Go to step 3 3 CHECK HARNESS BETWEEN CRANK SHAFT POSITION SENSOR A...

Page 1981: ...f engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mod...

Page 1982: ...r and ECM connector NOTE The harness be tween both con nectors are shielded Repair ground short circuit in harness togeth er with shield Go to step 3 3 CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR A...

Page 1983: ...LEAR MEMORY MODE Ref to EN H4DOSTC 35 Clear Memory Mode and INSPECTION MODE Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00944 SBF 4 SBF 1 B136 24 23 22 21 ECM No 11 E E 4 1 E31 E31 E32 E33...

Page 1984: ...sconnect the connector from ignition coil ignitor assembly 3 Turn the ignition switch to ON 4 Measure the power supply voltage between ignition coil ignitor assembly connector and engine ground Connec...

Page 1985: ...his case repair the following Open circuit in harness between ECM and ignition coil ignitor assembly connec tor Poor contact in coupling connector 6 CHECK HARNESS BETWEEN ECM AND IG NITION COIL IGNITO...

Page 1986: ...EN H4DOSTC 147 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1987: ...ement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00945 MAIN RELAY B47 1 2 3 5...

Page 1988: ...al E4 No 2 Engine ground Is the measured value less than the speci fied value 10 Repair the ground short circuit in har ness between ECM and purge control solenoid valve connector Go to step 3 3 CHECK...

Page 1989: ...ed the spec ified value 10 V Go to step 6 Repair the open circuit in harness between main relay and purge control solenoid valve connector 6 CHECK POOR CONTACT Check poor contact in purge control sole...

Page 1990: ...EN H4DOSTC 151 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1991: ...cement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00945 MAIN RELAY B47 1 2 3...

Page 1992: ...No 16 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 4 Go to step 3 3 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector...

Page 1993: ...AGNOSTIC TROUBLE CODE DTC 6 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector There is poor contact Repair the poor contact in ECM connector Replace the ECM...

Page 1994: ...EN H4DOSTC 155 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 1995: ...E SPEED SENSOR B134 B134 B56 B157 B157 ECM 38 37 1 No 15 B22 11 17 2 3 16 1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 2 9 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1...

Page 1996: ...ETER CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from combination meter 3 Measure the resistance between ECM and combination meter Connector terminal B134 No 1 i10 No 11 Is...

Page 1997: ...Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00947 BATTERY MAIN RELAY E E 6 4 5 3 2 1 10 IDLE AIR CONT...

Page 1998: ...OID VALVE CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM 3 Measure the resistance of harness between ECM and idle air control solenoid valve connector Connector termin...

Page 1999: ...d idle air control solenoid valve connectors Is there poor contact in ECM and idle air con trol solenoid valve connectors There is poor contact Repair the poor contact in ECM and idle air control sole...

Page 2000: ...EN H4DOSTC 161 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2001: ...Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00947 BATTERY MAIN RELAY E E 6 4 5 3 2 1 10 IDLE AIR CONT...

Page 2002: ...0 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and idle air control solenoid valve connector After repair replace th...

Page 2003: ...t Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00930 BATTERY IGNITION SWITCH STARTER MOTOR SBF 4 SBF 1...

Page 2004: ...he inhibitor switch in each position Does the starter motor operate when ignition switch to ON Operates Repair the battery short circuit in starter motor cir cuit After repair replace the ECM Ref to F...

Page 2005: ...ar Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERATION In spection Mode WIRING DIAGRAM EN 00948 B137 B47 E SBF 1 F26 F2 BATTERY GENERATOR MA...

Page 2006: ...Go to step 4 Tighten the clamp of terminal 4 CHECK INPUT VOLTAGE OF ECM 1 Run the engine at idle 2 Measure the voltage between ECM con nector and chassis ground Connector terminal B136 No 1 Chassis g...

Page 2007: ...ear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERATION In spection Mode WIRING DIAGRAM EN 00948 B137 B47 E SBF 1 F26 F2 BATTERY GENERATOR M...

Page 2008: ...Go to step 4 Tighten the clamp of terminal 4 CHECK INPUT VOLTAGE OF ECM 1 Run the engine at idle 2 Measure the voltage between ECM con nector and chassis ground Connector terminal B136 No 1 Chassis g...

Page 2009: ...us idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERATION Inspection M...

Page 2010: ...ured value exceed the spec ified value 1 M Go to step 4 Repair ground short circuit in har ness between ECM and trans mission harness connector 4 CHECK TRANSMISSION HARNESS CON NECTOR 1 Disconnect con...

Page 2011: ...OM Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERATION In...

Page 2012: ...4 CHECK NEUTRAL POSITION SWITCH 1 Turn ignition switch to OFF 2 Disconnect connector from transmission harness 3 Measure resistance between transmission harness and connector terminals Connector termi...

Page 2013: ...us idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERATION In spection...

Page 2014: ...nd Is the measured value within the specified range 4 5 5 5 V Go to step 4 Go to step 5 4 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector There is poor co...

Page 2015: ...rter motor grond line Poor contact in satrter motor con nector Poor contact in starter motor ground Starter motor 7 CHECK INHIBITOR SWITCH Measure resistance between inhibitor switch connector recepta...

Page 2016: ...EN H4DOSTC 177 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2017: ...TOM Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERATION I...

Page 2018: ...TCH Measure resistance between transmission har ness connector terminals Connector terminal T9 No 1 No 2 Is the measured value less than the specified value at except neutral position 1 Go to step 5 R...

Page 2019: ...ntact in transmission harness connector Is there poor contact in transmission harness connector There is poor contact Repair poor con tact in transmis sion harness connector Contact SUBARU distributor...

Page 2020: ...ts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Subar...

Page 2021: ...rts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Suba...

Page 2022: ...EN H4DOSTC 183 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2023: ...Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00933 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E E3 3 8 9 4 5 19 29 1...

Page 2024: ...o 19 B18 No 4 Is the measured value less than the speci fied value 1 Go to step 2 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between ECM and fron...

Page 2025: ...Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00933 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E E3 3 8 9 4 5 19 29...

Page 2026: ...between ECM and front oxygen A F sen sor connector 3 CHECK OUTPUT SIGNAL FOR ECM 1 Connect the connector to ECM 2 Turn the ignition switch to ON 3 Measure the voltage between ECM con nector and chassi...

Page 2027: ...ector and chassis ground Connector terminal B137 No 29 Chassis ground Does the measured value exceed the specified value 10 V Repair the battery short circuit in har ness between ECM and front oxygen...

Page 2028: ...EN H4DOSTC 189 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2029: ...ode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00933 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E E3 3 8 9 4 5 19 29 18...

Page 2030: ...WITH DIAGNOSTIC TROUBLE CODE DTC Step Value Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Subaru Select Monitor indicate DTC P1134 DTC P1134 indicated Replace the ECM Ref to FU H4DOSTC 40 Engine Co...

Page 2031: ...e CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode EN 01006 B122...

Page 2032: ...r 3 CHECK HARNESS BETWEEN ECM AND DIFFERENTIAL PRESSURE SENSOR Measure the resistance between differential pressure sensor and engine ground Connector terminal B221 No 3 engine ground Does the measure...

Page 2033: ...G DIAGRAM EN 00932 B134 B136 B46 R122 E E M 10 7 6 FUEL PUMP RELAY FUEL PUMP CONTROLLER FUEL PUMP SBF 5 B46 R122 B134 A B136 C R15 R57 R58 R2 ECM B98 B99 R58 B99 R3 BATTERY 1 3 5 4 A13 C16 3 4 1 2 8 9...

Page 2034: ...hassis ground Connector terminal R122 No 5 Chassis ground Is the measured value less than the speci fied value 5 Go to step 3 Repair the har ness and connec tor NOTE In this case repair the following...

Page 2035: ...troller and ECM Poor contact in fuel pump control ler and ECM con nector 6 CHECK HARNESS BETWEEN FUEL PUMP CONTROLLER AND ECM CONNECTOR Measure the resistance of harness between fuel pump controller a...

Page 2036: ...EN H4DOSTC 197 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2037: ...20 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST VALVE...

Page 2038: ...in har ness between ECM and intake air valve control solenoid valve connector 3 CHECK HARNESS BETWEEN INTAKE AIR VALVE CONTROL SOLENOID VALVE AND ECM CONNECTOR Measure the resistance of harness betwee...

Page 2039: ...valve and ECM connectors Is there poor contact in intake air valve control solenoid valve and ECM connectors There is poor contact Repair the poor contact in intake air valve control solenoid valve an...

Page 2040: ...EN H4DOSTC 201 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2041: ...220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST VALV...

Page 2042: ...r terminal B137 No 12 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and intake air valve control solenoid valve conne...

Page 2043: ...N 00939 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXH...

Page 2044: ...posi tive pressure connector Go to step 3 3 CHECK HARNESS BETWEEN EXHAUST VALVE CONTROL SOLENOID VALVE POS ITIVE PRESSURE AND ECM CONNECTOR Measure the resistance of harness between ECM and exhaust v...

Page 2045: ...d ECM connectors Is there poor contact in exhaust valve control solenoid valve positive pressure and ECM connectors There is poor contact Repair the poor contact in exhaust valve control sole noid val...

Page 2046: ...EN H4DOSTC 207 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2047: ...N 00939 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXH...

Page 2048: ...1 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and exhaust valve control sole noid valve posi tive pressure connecto...

Page 2049: ...N 00939 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXH...

Page 2050: ...connector and engine ground Connector terminal B136 No 3 Engine ground Does the measured value exceed the spec ified value 1 M Repair the ground short circuit in har ness between ECM and exhaust valve...

Page 2051: ...Repair the open circuit in harness between main relay and exhaust valve control sole noid valve nega tive pressure connector 6 CHECK POOR CONTACT Check poor contact in exhaust valve control solenoid...

Page 2052: ...EN H4DOSTC 213 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2053: ...N 00939 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXH...

Page 2054: ...l B136 No 3 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and exhaust valve control sole noid valve nega tive pressur...

Page 2055: ...EN H4DOSTC 36 Compul sory Valve Operation Check Mode 2 Check the operation of exhaust control valve actuator Does the actuator rod operate correctly NOTE Actuator rod operates in approx 7 second cy c...

Page 2056: ...acuum hoses 9 CHECK VACUUM HOSES BETWEEN SOLE NOID BOX AND SURGE TANK Are there cracks stuck or improper routing on vacuum hose There is no problem Go to step 10 Repair or replace the vacuum hoses 10...

Page 2057: ...EN H4DOSTC 36 Compul sory Valve Operation Check Mode 2 Check the operation of exhaust control valve actuator Does the actuator rod operate correctly NOTE Actuator rod operates in approx 7 second cy cl...

Page 2058: ...acuum hoses 9 CHECK VACUUM HOSES BETWEEN SOLE NOID BOX AND SURGE TANK Are there cracks stuck or improper routing on vacuum hose There is no problem Go to step 10 Repair or replace the vacuum hoses 10...

Page 2059: ...9 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST V...

Page 2060: ...ircuit in har ness between ECM and relief valve control sole noid valve 1 con nector 3 CHECK HARNESS BETWEEN RELIEF VALVE CONTROL SOLENOID VALVE 1 AND ECM CONNECTOR Measure the resistance of harness b...

Page 2061: ...lve 1 and ECM connectors Are there poor contact in relief valve control solenoid valve 1 and ECM connectors There are poor contacts Repair the poor contact in relief valve control sole noid valve 1 an...

Page 2062: ...EN H4DOSTC 223 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2063: ...39 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST...

Page 2064: ...hassis ground Connector terminal B136 No 12 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and relief valve control so...

Page 2065: ...9 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST V...

Page 2066: ...circuit in har ness between ECM and relief valve control sole noid valve 2 con nector 3 CHECK HARNESS BETWEEN RELIEF VALVE CONTROL SOLENOID VALVE 2 AND ECM CONNECTOR Measure the resistance of harness...

Page 2067: ...2 and ECM connectors Are there poor contact in ECM and relief valve control solenoid valve 2 and ECM connectors There are poor contacts Repair the poor contact in ECM and relief valve control solenoid...

Page 2068: ...EN H4DOSTC 229 ENGINE DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2069: ...39 B220 B47 E BATTERY MAIN RELAY 3 B136 ECM SBF 5 5 2 1 4 6 B47 3 4 1 2 5 6 B220 SOLENOID BOX ASSY 1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F A RELIEF VALVE SOLENOID 2 B RELIEF VALVE SOLENOID 1 C EXHAUST...

Page 2070: ...terminal B136 No 11 Chassis ground Does the measured value exceed the spec ified value 10 V Repair the battery short circuit in har ness between ECM and relief valve control sole noid valve 2 con nec...

Page 2071: ...r or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00947 BATTERY MAI...

Page 2072: ...lve gasket and throttle body gasket Disconnections of vacuum hoses Is there a fault in the air intake system There is no problem Go to step 3 Repair the air suc tion and leaks 3 CHECK THROTTLE CABLE D...

Page 2073: ...nduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 Inspection Mode WIRING DIAGRAM EN 00930 BATTERY IGNITION SWITCH STARTER MOTOR SBF 4 SB...

Page 2074: ...er motor operate when ignition switch to ST Operates Repair the har ness and connec tor NOTE In this case repair the following Open or ground short circuit in har ness between ECM and starter motor co...

Page 2075: ...137 3 4 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 TO FRONT OXYGEN A F SENSOR A2 D8 D9 A22 C17 C8...

Page 2076: ...EEN ECM AND MAIN FUSE BOX CONNECTOR 1 Disconnect the connector from ECM 2 Measure the resistance of harness between ECM and chassis ground Connector terminal B137 No 10 Chassis ground Does the measure...

Page 2077: ...driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPERA...

Page 2078: ...BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Disconnect connectors from ECM and TCM 3 Measure resistance of harness between ECM and chassis ground Connector terminal B136 No 14 Chassi...

Page 2079: ...e driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOSTC 33 OPER...

Page 2080: ...n ECM and TCM connector After repair replace ECM Ref to FU H4DOSTC 40 Engine Con trol Module 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Measure voltage between ECM a...

Page 2081: ...fault TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN...

Page 2082: ...BARU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn ignition switch to OFF 2 Di...

Page 2083: ...ault TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOSTC 35 OPERATION Clear Memory Mode and Inspection Mode Ref to EN...

Page 2084: ...ECM con nector Contact SUBARU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn i...

Page 2085: ...ion sensor 10 Idle air control solenoid valve 3 Engine does not start engine stalls after inter nal combustion 1 ECM power supply 2 Pressure sensor 3 Engine coolant temperature sensor 4 Spark plug 5 I...

Page 2086: ...ne torque control signal circuit 11 Ignition parts 1 8 Engine stalls or engine sags or hesitates at acceleration 1 Pressure sensor 2 Mass air flow and intake temperature sensor 3 Engine coolant temper...

Page 2087: ...EN H4DOSTC 248 ENGINE DIAGNOSTICS GENERAL DIAGNOSTIC TABLE MEMO...

Page 2088: ...nd diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condit...

Page 2089: ......

Page 2090: ...CONTROL SYSTEMS CS Page 1 General Description 2 2 Select Lever 8 3 Select Cable 12 4 MT Gear Shift Lever 15 5 MT Drive Select Lever 21 6 Drive Select Cable 23 7 General Diagnostic Table 25...

Page 2091: ...CS 2 CONTROL SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Item Specification Swing torque of rod against lever N kgf lb 3 7 0 38 0 84 or less...

Page 2092: ...etent spring 13 Indicator 23 Cover 4 Select lever ASSY 14 Blind 5 Spring pin 15 Cushion Tightening torque N m kgf m ft lb 6 Arm ASSY 16 Guide plate T1 7 5 0 76 5 5 7 Bushing 17 Snap pin T2 13 1 3 9 4...

Page 2093: ...cable 5 Bulb 17 Spring 29 Nut A 6 Guide plate 18 Rod 7 Lever 19 Clip Tightening torque N m kgf m ft lb 8 Spacer 20 Base plate T1 2 0 0 2 1 4 9 Bracket guide 21 Arm T2 7 5 0 76 5 5 10 Spring pin 22 Bu...

Page 2094: ...over 3 Plate ASSY 13 Cushion rubber 23 Clamp 4 Lever 14 Bushing B 5 Bushing 15 Joint Tightening torque N m kgf m ft lb 6 Bushing 16 Rod T1 7 5 0 76 5 5 7 Lock wire 17 Bracket T2 12 1 2 8 7 8 Boot 18 W...

Page 2095: ...IPTION 4 DRIVE SELECT LEVER 1 Knob 6 Spring Tightening torque N m kgf m ft lb 2 Cushion 7 Lever ASSY T1 1 6 0 16 1 2 3 Plate ASSY 8 Clip T2 18 1 8 13 0 4 Bushing 9 Clevis pin 5 Cable 10 Snap pin CS 00...

Page 2096: ...BARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Pl...

Page 2097: ...ef to EI 34 REMOV AL Console Box 10 Disconnect the connectors then remove the four bolts to take out the select lever assembly from the body B INSTALLATION 1 Mount the select lever onto the vehicle bo...

Page 2098: ...s If the following in spection reveals problems adjust the select cable and inhibitor switch Ref to CS 14 ADJUST MENT Select Cable and Ref to AT 50 AD JUSTMENT Inhibitor Switch 1 The engine starts ope...

Page 2099: ...3 Remove the bulb and then remove the indicator NOTE Be careful not to break the bulb during removal 4 Remove the blind 5 Remove the clips and then remove the guide plate 6 Remove the screw 7 Remove t...

Page 2100: ...on and Ref to CS 4 AT SELECT LEVER SPORT SHIFT MODEL COMPONENT General Description 3 Assembly is in the reverse order of disassembly 4 After completion of fitting transfer the select le ver to range P...

Page 2101: ...L Muffler 3 0 L model Ref to EX H6DO 5 REMOVAL Front Exhaust Pipe Ref to EX H6DO 8 REMOVAL Rear Exhaust Pipe and Ref to EX H6DO 9 RE MOVAL Muffler 6 Remove center and rear exhaust pipes and muf fler T...

Page 2102: ...ef to EX H4SOw oOBD 10 INSTALLATION Front Exhaust Pipe Ref to EX H4SOw oOBD 13 INSTALLATION Rear Exhaust Pipe and Ref to EX H4SOw oOBD 14 INSTALLATION Muffler 3 0 L model Ref to EX H6DO 6 INSTALLATION...

Page 2103: ...REMOVAL Rear Ex haust Pipe and Ref to EX H4DOSTC 13 RE MOVAL Muffler 3 Remove heat shield cover If equipped 4 Loosen the adjusting nut on each side 5 Turn adjusting nut B until it lightly touches the...

Page 2104: ...r 2 0 L non turbo and 2 5 L with OBD models Ref to EX H4SO 9 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 10 REMOVAL Muffler 2 0 L non turbo and 2 5 L without OBD models Ref to EX H4SOw oOBD 13 REMOVA...

Page 2105: ...pin 2 Insert gear shift lever from room side NOTE After inserting rod and stay temporarily put them onto transmission mount 3 Lift up the vehicle 4 Mount cushion rubber on the body Tightening torque 1...

Page 2106: ...4SOw oOBD 14 INSTALLATION Muffler 3 0 L model Ref to EX H6DO 8 INSTALLATION Rear Ex haust Pipe and Ref to EX H6DO 9 INSTAL LATION Muffler Turbo model Ref to EX H4DOSTC 12 INSTALLATION Rear Exhaust Pip...

Page 2107: ...Remove bushing and cushion rubber from stay 6 Remove O ring then disconnect bushing B 7 Draw out spring pin then remove bushing A from gear shift lever A Lock wire B Stay A Rod B Lever C Stay A Snap r...

Page 2108: ...n installing the spacer 4 Insert the gear shift lever into the boot hole 5 Install snap ring and stay to the bushing B 6 Tighten with lock wire to the extent that the boot will not come off NOTE Alway...

Page 2109: ...and rod etc for deformation dam age and wear Repair or replace any defective part Determine defective parts by comparing with new parts 2 Check the swing torque of the rod in relation of the gear shi...

Page 2110: ...able from lever assembly B INSTALLATION 1 Attach the drive select cable to the lever assem bly and secure with the clamp 2 Install drive select lever Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 3 Se...

Page 2111: ...ng D ASSEMBLY 1 Assemble in the reverse order of disassembly Tightening torque 1 6 N m 0 16 kgf m 1 2 ft lb 2 Make sure the select lever moves smoothly E INSPECTION 1 Make sure the select lever moves...

Page 2112: ...sole box Ref to EI 34 RE MOVAL Console Box 7 Remove the clamp 8 Remove the boot and insulator assembly 9 Remove cable from the under side of vehicle B INSTALLATION 1 Install in the reverse order of re...

Page 2113: ...n the nut 5 Make sure transmission is in HI position If isn t pull on cable to put transmission in HI position 6 Tighten the nut in the location where the cable end bolt stops naturally Tightening tor...

Page 2114: ...TIC TABLE 7 General Diagnostic Table A INSPECTION Symptom Remedy Starter does not run Adjust select cable and inhibitor switch or inspect circuit Back up light does not light up Adjust select cable an...

Page 2115: ...CS 26 CONTROL SYSTEMS GENERAL DIAGNOSTIC TABLE MEMO...

Page 2116: ...F Temperature Sensor 67 18 Transfer Duty Solenoid and Valve Body 70 19 ATF Filter 73 20 Transmission Control Module TCM 76 21 ATF Cooler Pipe and Hose 78 22 Air Breather Hose 83 23 Oil Charger Pipe 84...

Page 2117: ...ent pump Driving method Driven by engine Number of teeth Inner rotor 9 Outer rotor 10 Type 4 forward 1 reverse double row plan etary gears Multi plate clutch 3 sets Multi plate brake 2 sets One way cl...

Page 2118: ...2 US qt 7 4 7 7 Imp qt Except for 2 0 L non TURBO model 9 3 9 6 2 9 8 10 1 US qt 8 2 8 4 Imp qt Lubrication system Forced feed lubrication with oil pump Oil Automatic transmission fluid above mention...

Page 2119: ...16 12 13 15 1 Pitching stopper bracket 8 Oil drain pipe 15 Clip 2 O ring 9 Input shaft 16 Torque converter clutch case 3 Differential oil level gauge 10 O ring 4 Stay 11 Torque converter clutch ASSY T...

Page 2120: ...ue N m kgf m ft lb 2 Oil pump cover 13 Test plug T1 7 0 7 5 1 3 Seal ring 14 Stud bolt T2 13 1 3 9 4 4 Thrust needle bearing 15 O ring T3 18 1 8 13 0 5 Drive pinion shaft 16 O ring T4 25 2 5 18 1 6 Ro...

Page 2121: ...IPTION 3 TRANSMISSION CASE AND CONTROL DEVICE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 47 46 45 44 20 21 22 24 23 25 26 27 28 29 30 32 34 33 31 36 37 35 39 40 42 41 38 43 T4 T9 T5 T1 T10 T4 T9...

Page 2122: ...od 8 Straight pin 28 Manual plate 47 Gasket 3 0 L and TURBO mod els 9 Return spring 29 Spring pin 10 Shaft 30 Detention spring 11 Parking pawl 31 Ball Tightening torque N m kgf m ft lb 12 Parking supp...

Page 2123: ...ring 13 Side plate 24 ATF temperature sensor 4 O ring 14 Separate plate 25 Line pressure duty solenoid 5 Torque converter turbine speed sensor 15 Middle valve body 26 Low clutch timing solenoid 16 Se...

Page 2124: ...17 18 19 20 21 1 High clutch drum 8 Spring retainer 15 Dish plate 2 Lip seal 9 Cover 16 Driven plate 3 D ring 10 Snap ring 17 Drive plate 4 Reverse clutch piston 11 Driven plate 18 Retaining plate 5...

Page 2125: ...un gear 11 Thrust needle bearing 20 Spring retainer 3 Thrust needle bearing 12 Rear internal gear 21 2 4 brake piston 4 Snap ring 13 Washer 22 D ring 5 Front planetary carrier 14 Snap ring 23 D ring 6...

Page 2126: ...ring 24 Retaining plate 3 Driven plate 14 One way clutch 25 Leaf spring 4 Dish plate 15 Outer snap ring 26 Drive plate 5 Snap ring 16 Thrust needle bearing 27 Driven plate 6 Cover 17 Seal ring 28 Dish...

Page 2127: ...N GEAR MPT AT 00909 4 3 2 1 5 6 7 8 9 10 T 1 Seal ring 6 Snap ring Tightening torque N m kgf m ft lb 2 Ball bearing 7 Ball bearing T 100 10 2 73 8 3 Reduction drive gear 8 Reduction driven gear 4 Redu...

Page 2128: ...lutch LSD hub 27 Reduction driven gear 4 Needle bearing 16 Ball bearing 28 Snap ring 3 0 L model 5 Pinion gear 17 Revolution gear 29 Lock washer 6 Carrier 18 Driven plate Thick 30 Lock nut 7 Planetary...

Page 2129: ...T1 T2 T1 1 Crown gear 8 O ring 15 Differential bevel gear 2 Pinion shaft 9 Differential side retainer 3 Differential case RH 10 Circlip Tightening torque N m kgf m ft lb 4 Straight pin 11 Lock plate...

Page 2130: ...ring 19 Oil seal 2 Needle bearing 11 Transfer clutch piston 20 Dust cover 3 Snap ring 12 Rear drive shaft 21 Test plug 4 Pressure plate 13 Ball bearing 22 O ring 5 Drive plate 14 Seal ring 23 Clip 6 D...

Page 2131: ...ck 10 Multi plate clutch LSD piston 19 O ring 2 Driven plate 11 D ring 20 Rear wheel sensor 3 Driven plate Thin 12 Gasket 4 Driven plate Thick 13 Multi plate clutch LSD pipe Tightening torque N m kgf...

Page 2132: ...N 13 TRANSMISSION MOUNTING AT 00014 T2 T2 T4 T3 T5 T5 T1 1 2 3 4 1 Pitching stopper Tightening torque N m kgf m ft lb 2 Rear cushion rubber T1 35 3 6 26 3 Transmission rear crossmember T2 39 4 0 29 4...

Page 2133: ...careful not to burn your hands because each part on the vehicle is hot after running Use Subaru genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade...

Page 2134: ...OIL PRESSURE GAUGE ASSY Used for measuring oil pressure 498897200 ADAPTER Used oil pump housing when measuring reverse clutch pressure and line pressure 498897700 ADAPTER SET Used for measuring transf...

Page 2135: ...SSY Used for supporting engine 1 ENGINE SUPPORT BRACKET 41099AA010 2 ENGINE SUPPORT 41099AA020 499977400 CRANKSHAFT PULLEY WRENCH Used for rotating crankshaft Used for 2 0 L model 49977100 CRANKSHAFT...

Page 2136: ...earing outer race Used for removing front differential side retainer bearing outer ball race 498057300 INSTALLER Used for installing extension oil seal 498077000 REMOVER Used for removing differential...

Page 2137: ...TALLER 499247400 499787000 WRENCH ASSY Used for removing and installing differential side retainer 398437700 DRIFT Used for installing converter case oil seal 398487700 INSTALLER Used for installing t...

Page 2138: ...pring 498255400 PLATE Used for measuring backlash of hypoid gear 399893600 PLIERS Used for removing and installing clutch spring 498247001 MAGNET BASE Used for measuring gear backlash Used with DIAL G...

Page 2139: ...with MAGNET BASE 498247001 498517000 REPLACER Used for removing front roller bearing 398623600 SEAT Used for removing spring of transfer clutch piston 499267300 STOPPER PIN Used for installing inhibi...

Page 2140: ...Used for removing and installing drive pinion lock nut 398643600 GAUGE Used for measuring total end play extension end play and drive pinion height 498627100 SEAT Used for holding low clutch piston r...

Page 2141: ...surface 398744300 GAUGE Use for measuring contact face between multi plate clutch end and transmission VTD model 499737000 PULLER Used for removing reduction driven gear assem bly 499737100 PULLER SE...

Page 2142: ...937110 HOLDER Used for removing and installing drive pinion lock nut 498677100 COMPRESSOR Used for installing 2 4 brake snap ring 498437000 HIGH CLUTCH PISTON GUIDE Used for installing high clutch pis...

Page 2143: ...9580100 INSTALLER Used for press fitting the ball bearing for transfer clutch 499797000 DIFFERENTIAL OIL SEAL INSTALLER Used for installing differential side retainer oil seal 398497701 SEAT Used for...

Page 2144: ...AA010 SELECT MONI TOR KIT Troubleshooting for electrical systems ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 899524100 1 2 ST24082AA210 ST22771AA010 TOOL NAME REMARKS Depth gauge Used for measurin...

Page 2145: ...vel Remember that the addition of ATF to the up per limit mark when the transmission is cold will result in overfilling of ATF causing a trans mission failure 6 Check ATF level after raising ATF tempe...

Page 2146: ...ON Directly after the engine has been running the differential gear oil is hot Be careful not to burn yourself Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emit...

Page 2147: ...ar 40 to 50 km h 25 to 31 MPH Check the 1st gear engine brake when shifting between 2 1 range while driving in the 2 range 2nd gear 20 to 30 km h 12 to 19 MPH 6 LOCK UP FUNCTION Check that engine spee...

Page 2148: ...celerator pedal until the engine operates at full throttle 5 When the engine speed is stabilized record that speed quickly and release the accelerator pedal 6 Shift the select lever to N range and coo...

Page 2149: ...lve not fully open Erroneous engine operation Torque converter clutch s one way clutch slipping Greater than specifications D Line pressure too low Low clutch slipping One way clutch malfunction R Lin...

Page 2150: ...val between tests Make three measurements and take the average value 2 TEST METHODS 1 Fully apply the parking brake 2 Start the engine Check the idling speed A C OFF 3 Shift the select lever from N to...

Page 2151: ...h foot and parking brakes with all wheels chocked Same as for stall test conditions Measure the line pressure when select lever is in R 2 with engine under stall conditions Measure the line pressure w...

Page 2152: ...ARATION TOOL General Description 2 Connect the Subaru Select Monitor to data link connector 5 Check the line pressure in accordance with the following chart 3 EVALUATION Standard line pressure Range p...

Page 2153: ...ssure Test ST 498897700 OIL PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY 2 EVALUATION MPT model NOTE If oil pressure is not produced or if it does not change in the AWD mode the transfer...

Page 2154: ...e Cham ber 6 Remove intercooler TURBO model Ref to IN H4DOSTC 13 REMOVAL Intercool er 7 Remove air cleaner case stay Non TURBO model 8 Disconnect the following connectors 1 Transmission harness connec...

Page 2155: ...olt which holds right upper side of transmission to engine Except 3 0 L model 3 0 L model 16 Lift up the vehicle 17 Remove under cover 18 Remove front center rear exhaust pipe and muffler Non TURBO mo...

Page 2156: ...F to remove ATF drain plug 22 Disconnect ATF cooler hoses from pipes of transmission side and remove ATF level gauge guide 23 Remove propeller shaft Ref to DS 14 REMOVAL Propeller Shaft 24 Remove shif...

Page 2157: ...te transmission assembly and rear cushion rubber B INSTALLATION 1 Install rear cushion rubber to transmission as sembly Tightening torque 39 N m 4 0 kgf m 29 ft lb 2 Install ST to torque converter clu...

Page 2158: ...odel Ref to SC H6DO 6 INSTALLATION Start er 2 0 L TURBO model Ref to SC H4DOSTC 6 INSTALLATION Starter 3 Tighten bolt which holds right upper side of transmission to engine Tightening torque 50 N m 5...

Page 2159: ...nt into housing 15 Connect stabilizer link to transverse link and tighten bolts Non TURBO model NOTE Discard loosened self locking nut and replace with a new one Tightening torque T1 30 N m 3 1 kgf m...

Page 2160: ...nstall center exhaust pipe TURBO model Ref to EX H4DOSTC 8 INSTALLATION Cen ter Exhaust Pipe 25 Install under cover 26 Lower the vehicle 27 Install ATF level gauge 28 Connect the following connectors...

Page 2161: ...Ref to EX H4SO 5 REMOVAL Front Exhaust Pipe Ref to EX H4SO 9 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 10 RE MOVAL Muffler 2 0 L and 2 5 L without OBD models Ref to EX H4SOw oOBD 9 REMOVAL Front E...

Page 2162: ...ust Pipe Ref to EX H4SO 9 INSTALLA TION Rear Exhaust Pipe and Ref to EX H4SO 10 INSTALLATION Muffler Without OBD Ref to EX H4SOw oOBD 10 INSTALLATION Front Exhaust Pipe Ref to EX H4SOw oOBD 13 INSTALL...

Page 2163: ...ear Ex haust Pipe and Ref to EX H4DOSTC 13 RE MOVAL Muffler 5 Remove the heat shield cover If equipped 6 Remove the propeller shaft Ref to DS 14 RE MOVAL Propeller Shaft 7 Using the ST remove the oil...

Page 2164: ...continuity at equal points when the select lever is turned 1 5 in both directions from N range If there is continuity in one direction and the conti nuity in the other or if there is continuity at un...

Page 2165: ...URBO and 2 5 L models Ref to IN H4SO 6 REMOVAL Air Cleaner Case 4 Remove air intake chamber 3 0 L model Ref to IN H6DO 6 REMOVAL Air Intake Cham ber 5 Remove intercooler 2 0 L non TURBO model Ref to I...

Page 2166: ...the range select lever to parking position left side 15 Remove the inhibitor switch from transmission 16 Disconnect the inhibitor switch harness con nector from inhibitor switch A Range select lever B...

Page 2167: ...gf m 18 1 ft lb 7 Install the washer and snap pin to range select lever 8 Install the front and center exhaust pipes Non TURBO model 2 0 L and 2 5 L with OBD models Ref to EX H4SO 6 INSTALLATION Front...

Page 2168: ...d 2 5 L models Ref to IN H4SO 6 INSTALLATION Air Cleaner Case 14 Install air intake chamber 3 0 L model Ref to IN H6DO 6 INSTALLATION Air Intake Chamber 15 Install intercooler TURBO model Ref to IN H4...

Page 2169: ...nter rear exhaust pipes and muffler Non TURBO model With OBD Ref to EX H4SO 5 REMOVAL Front Exhaust Pipe Ref to EX H4SO 9 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 10 RE MOVAL Muffler Without OBD R...

Page 2170: ...23 Disconnect each solenoid connector and re move ATF temperature sensor from control valve 24 Remove the harness assembly A Front vehicle speed sensor B Torque converter turbine speed sensor A Rear...

Page 2171: ...les other than screw holes on transmission case Fluid packing THREE BOND 1217B Part No K0877YA020 5 Install the oil pan Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 6 Install the front and rear vehicle...

Page 2172: ...f to EX H4SOw oOBD 14 INSTALLATION Muffler 3 0 L model Ref to EX H6DO 6 INSTALLATION Front Ex haust Pipe Ref to EX H6DO 8 INSTALLA TION Rear Exhaust Pipe and Ref to EX H6DO 9 INSTALLATION Muffler 12 I...

Page 2173: ...REMOVAL When removing the rear vehicle speed sensor re fer to Front Vehicle Speed Sensor Ref to AT 54 REMOVAL Front Vehicle Speed Sensor B INSTALLATION When installing the rear vehicle speed sensor re...

Page 2174: ...REMOVAL When removing the torque converter turbine speed sensor refer to Front Vehicle Speed Sensor Ref to AT 54 REMOVAL Front Vehicle Speed Sensor B INSTALLATION When installing the torque converter...

Page 2175: ...ect each solenoid connector and re move ATF temperature sensor from control valve 9 Remove the control valve NOTE When removing the control valve body be careful not to interfere with transfer duty so...

Page 2176: ...Apply proper amount of liquid gasket to the en tire oil pan mating surface Liquid gasket THREE BOND 1217B Part No K0877YA020 Bolt length mm in A 30 1 18 B 55 2 17 A Lock up duty solenoid Blue B Low c...

Page 2177: ...om lower control valve body NOTE Arrange the removed bolts in good order to assem ble in the same place as disassembly because the bolts length are different 2 Remove the duty solenoids solenoids and...

Page 2178: ...m middle valve body 7 Remove the middle valve body 8 Remove upper separator plate from middle valve body 9 Remove valve springs and four steel balls from upper valve body 10 Place a shop cloth to the...

Page 2179: ...le in sepa rator plate and then install support plate and upper separator plate to middle valve body Tightening torque 8 N m 0 8 kgf m 5 8 ft lb 6 Insert six steel balls in their proper positions to m...

Page 2180: ...positions 12 Tighten the bolts and nuts Tightening torque 8 N m 0 8 kgf m 5 8 ft lb A Lower separator plate B Lower valve body Bolt length mm in A 40 1 57 B 62 2 44 C 73 2 87 D 79 3 11 AT 00076 A B A...

Page 2181: ...stall oil strainer to lower valve body Tightening torque 8 N m 0 8 kgf m 5 8 ft lb E INSPECTION Make sure that each component is free of harmful gouges cuts or dust Bolt length mm in A 12 0 47 B 62 2...

Page 2182: ...SENSOR For removal of ATF temperature sensor refer to Front Vehicle Speed Sensor Ref to AT 54 RE MOVAL Front Vehicle Speed Sensor A Oil pan B Drain plug A Lock up duty solenoid Blue B Low clutch timin...

Page 2183: ...1217B Part No K0877YA020 A Lock up duty solenoid Blue B Low clutch timing solenoid Gray C Line pressure duty solenoid Red D Shift solenoid 2 Yellow E Shift solenoid 1 Green F 2 4 brake timing solenoid...

Page 2184: ...6 Install the oil pan Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 7 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Ref to AT 30 Automatic Transmission Fluid 8 Check...

Page 2185: ...TURBO model Ref to EX H4DOSTC 7 REMOVAL Center Ex haust Pipe 9 Remove the rear exhaust pipe and muffler 2 0 L non TURBO and 2 5 L with OBD models Ref to EX H4SO 9 REMOVAL Rear Exhaust Pipe and Ref to...

Page 2186: ...nstall the transfer duty solenoid and trans fer valve body Tightening torque T 8 N m 0 8 kgf m 5 8 ft lb 2 Connect the transfer duty solenoid connec tor 2 Install a new gasket and the extension case t...

Page 2187: ...nt Ex haust Pipe Ref to EX H6DO 8 INSTALLA TION Rear Exhaust Pipe and Ref to EX H6DO 9 INSTALLATION Muffler 7 Install center and rear exhaust pipes and muf fler TURBO model Ref to EX H4DOSTC 8 INSTALL...

Page 2188: ...ttery 2 Lift up the vehicle 3 Remove front left mud guard Ref to EI 22 REMOVAL Mud Guard 4 Lower the vehicle 5 Release clamp of IN OUT of oil filter hose and remove hose from pipe NOTE Plug the pipe P...

Page 2189: ...4 kgf m 10 1 ft lb Required torque setting T2 Tightening torque L1 ST length 0 078 m 3 07 in L2 Torque wrench length Example NOTE Align ST with torque wrench while tightening ATF filter ST 498545400 O...

Page 2190: ...EL 1 Get new ATF filter and apply a thin coat of ATF to the oil seal 2 Install ATF filter Turn it by hand being careful not to damage oil seal 3 Using ST tighten ATF filter Calculate ATF filter torque...

Page 2191: ...nd then disconnect the connector 3 Disconnect the connectors from transmission control module LHD model RHD model except for Europe RHD model for Europe 4 Remove the transmission control module A Tran...

Page 2192: ...or Europe Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb RHD model for Europe Tightening torque 18 N m 1 8 kgf m 13 ft lb 2 Connect the connectors to transmission control module 3 Install in the rever...

Page 2193: ...nd the hose to protect it Turn it with pli ers and then pull directly out with your hand 6 Disconnect ATF cooler hoses from pipes NOTE Do not remove with a screwdriver or other point ed tools When the...

Page 2194: ...ect ATF cooler hoses from transmis sion NOTE Do not remove with a screwdriver or other point ed tools When the hose is difficult to remove wrap a shop cloth around the hose to protect it Turn it with...

Page 2195: ...areful not to lose ball and spring used with retaining screw B INSTALLATION 1 EXCEPT 3 0 L MODEL 1 Install the oil cooler outlet and inlet pipes NOTE Be sure to use a new aluminum washer Tightening to...

Page 2196: ...er cover 6 Install battery and washer tank 7 Fill ATF Ref to AT 30 Automatic Transmis sion Fluid NOTE Make sure there are no ATF leaks in joints between the transmission radiator pipes and hoses 2 3 0...

Page 2197: ...tery and washer tank 9 Fill ATF Ref to AT 30 Automatic Transmis sion Fluid NOTE Make sure there are no ATF leaks in joints between the transmission radiator pipes and hoses C INSPECTION Repair or repl...

Page 2198: ...all the air cleaner case 2 0 L non TURBO and 2 5 L models Ref to IN H4SO 6 INSTALLATION Air Cleaner Case 3 Install air intake chamber 3 0 L model Ref to IN H6DO 6 INSTALLATION Air Intake Chamber 4 Ins...

Page 2199: ...from the flange face B INSTALLATION 1 Install the oil charger pipe with new O ring Tightening torque 41 N m 4 2 kgf m 30 4 ft lb 2 Install the air cleaner case 2 0 L non TURBO and 2 5 L models Ref to...

Page 2200: ...clutch and then check the clip fits securely in its groove 3 Insert the input shaft while turning lightly by hand Normal protrusion A 50 55 mm 1 97 2 17 in 4 Holding the torque converter clutch assemb...

Page 2201: ...ce of reduction drive gear with vaseline NOTE Install thrust needle bearing in the correct direction 2 Install new gasket 3 Install the extension case to the transmission case 4 Tighten bolts to secur...

Page 2202: ...ghtly tapping the end of the rear drive shaft NOTE Be careful not to damage the oil seal in the exten sion 2 Remove the transmission clutch pipe without bending pipe 2 VTD MODEL 1 Remove snap ring usi...

Page 2203: ...300 INSTALLER 2 Press in the dust cover 3 Install the transfer clutch pipe to extension case without bending pipe 4 Install the transfer clutch assembly to the case NOTE Be careful not to damage the s...

Page 2204: ...1 2 and 3 ST1 398673600 COMPRESSOR ST2 498627100 SEAT ST3 398663600 PLIERS E INSPECTION Use forced air to make sure the transfer pipe and extension case routes are not clogged and do not leak Measure...

Page 2205: ...tapping the end of the rear drive shaft B INSTALLATION 1 Select the thrust needle bearing 2 Install the transfer clutch assembly to the case 3 Tighten bolts to secure the case Tightening torque 25 N m...

Page 2206: ...driven plates 4 Remove the snap ring with ST1 ST2 and ST3 and take out the return spring and transfer clutch piston seal ST1 399893600 PLIERS ST2 398673600 COMPRESSOR ST3 398623600 SEAT 5 Apply compr...

Page 2207: ...ring to ST ST 499257300 SNAP RING OUTER GUIDE 6 Using ST1 and ST2 install snap ring to rear drive shaft ST1 499257300 SNAP RING OUTER GUIDE ST2 499247400 INSTALLER A Transfer clutch piston B Rear driv...

Page 2208: ...CTION Transfer Clutch 10 Press fit a new ball bearing with ST ST 899580100 INSTALLER 11 Coat a new seal ring with vaseline and install it in the seal ring groove of the shaft NOTE Do not expand the se...

Page 2209: ...H in both clockwise and counterclockwise directions for approx ten times each while repeating acceler ation and braking intermittently 2 If the tight corner braking still persists drive the vehicle ag...

Page 2210: ...value B Thickness of special tool 15 mm 0 59 in L Distance between extension case edge and rear driveshaft edge 3 Using the special tool measure the distance 2 between the mating surface of transmissi...

Page 2211: ...0 0217 Calculation when clearance is 0 25 mm 0 0098 in H 90 50 0 45 90 35 0 25 0 35 H 3 5630 0 0177 3 5571 0 0098 0 0138 After calculation the value of H becomes be tween 0 35 mm 0 0138 in and 0 55 mm...

Page 2212: ...ool measure distance L from extension case joining surface to multi plate clutch LSD piston ST 398643600 Gauge L Measured value 15 mm L Measured value 0 59 in A Measured value B Special tool thickness...

Page 2213: ...value 0 2 0 6 mm 0 008 0 024 in Limit value 1 6 mm 0 063 in If outside the standard value replace the plate set drive and driven plate Select a multi plate clutch LSD piston side adjustment plate that...

Page 2214: ...AT 95 VTD MODEL ADJUSTMENT Transfer Clutch 2 Install drive plate and driven plate 3 Insert rear driveshaft into the center differential assembly 4 Join transmission case and extension case In stall re...

Page 2215: ...s Make sure the clutch hub is oriented in the cor rect direction E INSPECTION Inspect parts to make sure there are no holes cuts and that they are not dusty Inspect extension end play and adjust it to...

Page 2216: ...mission assembly from the ve hicle Ref to AT 39 REMOVAL Automatic Transmission Assembly 2 Remove rear vehicle speed sensor and sepa rate the transmission case and extension case Ref to AT 86 REMOVAL E...

Page 2217: ...embly 2 VTD MODEL 1 Set the select lever to P range 2 Using a plastic hammer install reduction driven gear assembly 3 Using a plastic hammer install the center differ ential assembly 4 Install a new s...

Page 2218: ...emove snap ring reduction driven gear 3 0 L model D ASSEMBLY 1 Install snap ring to reduction driven gear 3 0 L model 2 Using a press install a new ball bearing to re duction driven gear 3 Install sna...

Page 2219: ...act the reduction drive gear ST1 499737100 PULLER ST2 899524100 PULLER SET B INSTALLATION 1 Install the reduction drive gear assembly NOTE Insert it fully into position until the bearing shoulder bott...

Page 2220: ...Apply vaseline to outer surface of seal ring and shaft groove 4 Attach new seal rings E INSPECTION Rotate bearing by hand make sure it rotates smoothly Make sure that each component is free of harm fu...

Page 2221: ...ALLATION 1 Install the center differential assembly with the shim s NOTE Insert the center differential assembly and shim s completely into the bearing shoulder bottom 2 Insert the rear driveshaft Ref...

Page 2222: ...n gears and washers 4 Insert the shaft into the center differential as sembly 5 Install the snap ring 6 Using a press install a new ball bearing into the center differential assembly ST 498077000 REMO...

Page 2223: ...parking pawl return spring and shaft B INSTALLATION 1 Install the parking pawl shaft and return spring 2 Install the reduction drive gear Ref to AT 104 INSTALLATION Reduction Drive Gear 3 Install the...

Page 2224: ...the oil charger pipe Ref to AT 84 REMOVAL Oil Charger Pipe 9 Remove the oil cooler inlet and outlet pipes Ref to AT 78 REMOVAL ATF Cooler Pipe and Hose 10 Lightly tapping the torque converter clutch...

Page 2225: ...d gasket to the en tire torque converter clutch case mating surface Liquid gasket THREE BOND 1215 Part No 004403007 8 Install the torque converter clutch case assem bly without damaging bush and oil s...

Page 2226: ...e not to damage the bushing Normal protrusion A 50 55 mm 1 97 2 17 in 15 Install the torque converter clutch assembly Ref to AT 85 INSTALLATION Torque Converter Clutch Assembly 16 Install the transmis...

Page 2227: ...case and transmission case sections Ref to AT 109 RE MOVAL Torque Converter Clutch Case 10 Separate transmission case and extension case sections Ref to AT 86 REMOVAL Exten sion Case 11 Remove the red...

Page 2228: ...il pump housing NOTE Be careful not to bend the shims Be careful not to force the pinion against the housing bore 2 Tighten four bolts to secure the roller bearing Tightening torque 40 N m 4 1 kgf m 3...

Page 2229: ...tall the center differential carrier VTD mod el Ref to AT 106 INSTALLATION Center Differ ential Carrier 12 Combine the extension case with the transmis sion case and install vehicle speed sensor 1 rea...

Page 2230: ...p rotor assembly to oil pump hous ing 2 Align both pivots with the pivot holes of the cov er and install the oil pump cover being careful not to apply undue force to the pivots Tightening torque 25 N...

Page 2231: ...p clearance 0 02 0 15 mm 0 0008 0 0059 in 2 Side clearance Set a depth gauge to oil pump housing then measure oil pump housing to rotor clearances Side clearance 0 02 0 04 mm 0 0008 0 0016 in 3 If dep...

Page 2232: ...h Attach the thrust needle bearing to the oil pump cover with vaseline 5 After correctly installing the new gasket to the case mating surface carefully install the oil pump housing assembly Be careful...

Page 2233: ...rger pipe Ref to AT 84 REMOVAL Oil Charger Pipe 8 Remove the oil cooler inlet and outlet pipes Ref to AT 78 REMOVAL ATF Cooler Pipe and Hose 9 Separation of torque converter clutch case and transmissi...

Page 2234: ...Ref to AT 83 IN STALLATION Air Breather Hose 10 Install the oil cooler inlet and outlet pipes Ref to AT 80 INSTALLATION ATF Cooler Pipe and Hose 11 Install the oil charger pipe with O ring 12 Insert t...

Page 2235: ...rque wrench length Example ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE Install ST2 to torque wrench as straight as possi ble 6 Measure the starting torque of the bearing Make...

Page 2236: ...t lb 3 Rotate the drive pinion several times with ST1 and ST2 ST1 498937110 HOLDER ST2 499787700 WRENCH 4 Adjust the backlash between drive pinion and crown gear Ref to AT 128 ADJUSTMENT Front Differe...

Page 2237: ...ctive action Increase thickness of drive pin ion height adjusting shim in order to bring drive pin ion close to crown gear Flank contact Checking item Backlash is too small Contact pattern Corrective...

Page 2238: ...ontact pattern Corrective action Increase thickness of drive pin ion height adjusting shim in order to move drive pin ion close to crown gear 6 If tooth contact is correct mark the retainer posi tion...

Page 2239: ...to AT 109 REMOVAL Torque Converter Clutch Case 10 Remove the seal pipe if it is attached 11 Remove the differential side retainer with ST NOTE Hold the differential case assembly by hand to avoid dama...

Page 2240: ...12 Install the torque converter clutch assembly Ref to AT 85 INSTALLATION Torque Converter Clutch Assembly 13 Install the transmission assembly to the vehi cle Ref to AT 42 INSTALLATION Automatic Tran...

Page 2241: ...rely attach two claws to outer race set ST to side retainer ST 398527700 PULLER ASSY 5 Return removed claw to the original position and install pin and split pin 6 Hold the shaft of ST to avoid removi...

Page 2242: ...through the access window of the case ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE NOTE Measure the backlash by applying a pinion tooth between two bevel gear teeth Fix bevel pinion gear in pla...

Page 2243: ...ht contact is felt NOTE Screw in the RH side slightly deeper than the LH side ST 499787000 WRENCH ASSY 2 Remove the oil pump housing 3 Thoroughly remove the liquid gasket from the case mating surface...

Page 2244: ...drive pinion a few times Tight en the RH retainer 1 3 4 notches further This sets the preload Finally secure the retainer with its lock plate NOTE Turning the retainer by one tooth changes the backla...

Page 2245: ...or from stay 6 Disconnect the air breather hose 7 Remove the oil charger pipe Ref to AT 84 REMOVAL Oil Charger Pipe 8 Remove the oil cooler inlet and outlet pipes Ref to AT 78 REMOVAL ATF Cooler Pipe...

Page 2246: ...er clutch case assem bly to the transmission case assembly Ref to AT 110 INSTALLATION Torque Converter Clutch Case 8 Insert inhibitor switch and transmission connec tor into stay 9 Install air breathe...

Page 2247: ...verter Clutch Assembly 14 Install the transmission assembly to the vehi cle Ref to AT 42 INSTALLATION Automatic Transmission Assembly C DISASSEMBLY 1 Remove the snap ring and take out the retaining pl...

Page 2248: ...ll high clutch piston to reverse clutch piston 3 Install reverse clutch to high clutch drum Align the groove on the reverse clutch piston with the groove on the high clutch drum during installa tion 4...

Page 2249: ...the driven plate drive plate retain ing plate to high clutch drum 9 Install snap ring to high clutch drum 10 Apply compressed air intermittently to check for operation 11 Measure the clearance betwee...

Page 2250: ...table high clutch retaining plate 4 Inspect clearance between retaining plate and snap ring Reverse clutch At this time do not press down retaining plate Standard value 0 5 0 8 mm 0 020 0 031 in Allow...

Page 2251: ...t and outlet pipes Ref to AT 78 REMOVAL ATF Cooler Pipe and Hose 9 Remove rear vehicle speed sensor and sepa rate the transmission case and extension case Ref to AT 86 REMOVAL Extension Case 10 Remove...

Page 2252: ...tall carefully while rotating the low clutch and planetary gear assembly slowly paying special at tention not to damage the seal ring 2 Install the pressure plate driven plate drive plate retaining pl...

Page 2253: ...nd transmission con nector into stay 13 Install air breather hose Ref to AT 83 IN STALLATION Air Breather Hose 14 Install oil cooler pipes Ref to AT 80 INSTAL LATION ATF Cooler Pipe and Hose 15 Instal...

Page 2254: ...sher and thrust needle bearing 5 Take out rear internal gear 6 Remove the snap ring from the low clutch drum A Snap ring B Low clutch drum A Front planetary carrier B Low clutch drum A Rear sun gear B...

Page 2255: ...the one way clutch inner race to the low clutch drum and apply compressed air to remove the low clutch piston 10 Remove the one way clutch inner race 11 Remove the one way clutch after taking out the...

Page 2256: ...ST3 498437100 LOW CLUTCH PISTON GUIDE 6 Install the dish plate driven plates drive plates and retaining plate and secure with the snap ring 7 Check the low clutch for operation 1 Remove one way clutc...

Page 2257: ...rusion of washer and hole of rear planetary carrier 13 Install rear planetary carrier to low clutch drum 14 Install thrust needle bearing in the correct di rection A Rear internal gear B Washer A Rear...

Page 2258: ...race and plate and secure with the snap ring 21 Set the inner race Make sure that the forward clutch is free in the clockwise direction and locked in the counterclockwise direction as viewed from the...

Page 2259: ...NT Oil Pump 2 Place the same thickness of shim on both sides to prevent retaining plate from tilting 3 Inspect clearance between retaining plate and operation of the low clutch Standard value 0 7 1 1...

Page 2260: ...f to AT 86 REMOVAL Extension Case 10 Remove the reduction drive gear MPT model Ref to AT 104 REMOVAL Reduction Drive Gear 11 Remove the center differential carrier VTD model Ref to AT 106 REMOVAL Cent...

Page 2261: ...nstall the 2 4 brake piston and 2 4 brake retain er by aligning hole of 2 4 brake retainer and hole of transmission case 3 Install 2 4 brake piston return spring to transmis sion case A 2 4 brake pist...

Page 2262: ...iven plate retaining plate and snap ring 7 Install a new 2 4 brake oil seal to transmission case 8 After all 2 4 brake component parts have been installed blow in air intermittently and confirm the op...

Page 2263: ...ATION Reduction Drive Gear 20 Install the center differential carrier VTD mod el Ref to AT 106 INSTALLATION Center Differ ential Carrier 21 Insert inhibitor switch and transmission con nector into sta...

Page 2264: ...T Oil Pump 1 Inspect the clearance between the retaining plate and the snap ring NOTE Select a retaining plate with a suitable value from the following table so that the clearance becomes the standard...

Page 2265: ...ransmission case and extension case sections Ref to AT 86 REMOVAL Exten sion Case 11 Remove the reduction driven gear Ref to AT 101 REMOVAL Reduction Driven Gear 12 Remove the reduction drive gear MPT...

Page 2266: ...ion case Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 3 Place transmission case with the front facing up 4 Install thrust needle bearing 5 Installation of the low reverse brake Install dish plate dri...

Page 2267: ...e gear MPT model 16 Install the center differential carrier VTD mod el Ref to AT 106 INSTALLATION Center Differ ential Carrier 17 Install the extension case to the transmission case Ref to AT 86 INSTA...

Page 2268: ...to the inner race ST 398497701 ADAPTER 2 Apply vaseline to the groove of the inner race and to the seal ring 3 Install two seal rings to one way clutch inner race 2 ONE WAY CLUTCH OUTER RACE 1 Install...

Page 2269: ...clockwise direction and locked in the counterclockwise direction as viewed from the front of the vehicle E INSPECTION Make sure the snap ring is not worn and the seal rings are not damaged Measure the...

Page 2270: ...ate transmission case and extension case sections Ref to AT 86 REMOVAL Exten sion Case 11 Remove the reduction drive gear Ref to AT 104 REMOVAL Reduction Drive Gear 12 Remove the center differential c...

Page 2271: ...ke 9 Install 2 4 brake piston retainer and return spring to transmission case Ref to AT 146 IN STALLATION 2 4 Brake 10 Install planetary gear and low clutch assembly to transmission case Install caref...

Page 2272: ...y hand At this time not to damage the bushing Normal protrusion A 50 55 mm 1 97 2 17 in 24 Install the torque converter clutch assembly Ref to AT 85 INSTALLATION Torque Converter Clutch Assembly 25 In...

Page 2273: ...Ref to AT 83 REMOVAL Air Breather Hose 6 Disconnect inhibitor switch connector from stay 7 Wrap vinyl tape around the nipple attached to the air breather hose 8 Remove pitching stopper bracket 9 Remo...

Page 2274: ...ase to its original position 7 Install pitching stopper bracket Tightening torque 41 N m 4 2 kgf m 30 4 ft lb 8 Install inhibitor switch and adjust the inhibitor switch Ref to AT 49 Inhibitor Switch 9...

Page 2275: ...rter clutch assembly Ref to AT 85 INSTALLATION Torque Converter Clutch Assembly 13 Install the transmission assembly to the vehi cle Ref to AT 42 INSTALLATION Automatic Transmission Assembly C INSPECT...

Page 2276: ...21 7 Read Diagnostic Trouble Code DTC 24 8 Inspection Mode 26 9 Clear Memory Mode 27 10 POWER Indicator Light Display 28 11 List of Diagnostic Trouble Code DTC 29 12 Diagnostic Procedure for POWER In...

Page 2277: ...m 2 CHECK POWER INDICATOR LIGHT Turn ignition switch to ON Does not the POWER indicator light light up Indicator light flashes Go to step 4 Go to step 3 3 CHECK POWER INDICATOR LIGHT 1 Turn ignition s...

Page 2278: ...ef to AT 27 WITH SUBARU SELECT MONITOR OPERATION Clear Memory Mode Without Subaru Select Monitor Ref to AT 27 WITHOUT SUBARU SELECT MONITOR OPERATION Clear Memory Mode 4 Perform the inspection mode Re...

Page 2279: ...OPERATION Clear Memory Mode Without Subaru Select Monitor Ref to AT 27 WITHOUT SUBARU SELECT MONITOR OPERATION Clear Memory Mode 4 Perform the inspection mode Ref to AT 26 Inspection Mode 5 Calling u...

Page 2280: ...Various Others Place Highway Suburbs Inner city Uphill Rough road Others Outdoor temperature Hot Warm Cool Cold Vehicle speed km h MPH Malfunction indicator lamp MIL Continuously lit Not lit Select le...

Page 2281: ...4 mm 0 025 in in order to avoid poor contact Do not insert the pin more than 0 65 mm 0 0256 in B INSPECTION 1 BATTERY Measure battery voltage and specific gravity of electrolyte Standard voltage 12 V...

Page 2282: ...G Stop the engine while checking operation of se lect lever Without SPORT shift With SPORT shift 6 POWER SWITCH Make sure that POWER indicator light in combina tion meter comes ON when turning power s...

Page 2283: ...RIDGE Troubleshooting for electrical systems 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080...

Page 2284: ...1 Engine control module ECM 4 Transmission control module TCM 7 Data link connector 2 POWER indicator light AT diag nostic indicator light Except 3 0 L and TURBO model 8 Vehicle dynamic control modul...

Page 2285: ...AT 10 AUTOMATIC TRANSMISSION DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION AT 00323 1 AT 00764 2 AT 00765 3 AT 00766 4 AT 00767 5 AT 00768 6 AT 00769 7 AT 00770 8...

Page 2286: ...sensor Except 3 0 L model 4 Inhibitor switch 7 Torque converter turbine speed signal 5 Rear vehicle speed sensor with out VDC system or SPORT shift 2 Throttle sensor 3 0 L model 8 ATF temperature sens...

Page 2287: ...AT 12 AUTOMATIC TRANSMISSION DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION AT 00631 1 AT 00635 2 AT 00632 3 5 AT 00636 3 6 AT 00633 4 AT 00637 7 AT 00634 8...

Page 2288: ...lenoid 1 4 Low clutch timing solenoid 7 2 4 brake timing solenoid 2 Solenoid 2 5 Lock up duty solenoid 8 Transfer duty solenoid 3 Line pressure duty solenoid 6 2 4 brake duty solenoid 9 Sport shift so...

Page 2289: ...nge Less than 1 Select lever in any other than R range More than 8 D range switch B55 4 Select lever in D range Less than 1 Select lever in any other than D range More than 8 3 range switch B55 5 Sele...

Page 2290: ...ON 8 11 Cruise set signal B55 22 When cruise control is set SET lamp ON Less than 1 When cruise control is not set SET lamp OFF More than 6 5 Torque control signal 1 B56 5 Ignition switch ON with eng...

Page 2291: ...ift B55 21 ABS switch ON Less than 1 ABS switch OFF 6 5 15 Sensor ground line 1 B54 20 0 Less than 1 Sensor ground line 2 B55 9 0 Less than 1 System ground line B56 19 0 Less than 1 B54 21 Sensor grou...

Page 2292: ...SPORT shift mode OFF More than 4 SPORT shift mode with 2nd and 3rd gear Less than 1 SPORT shift indicator with SPORT shift B56 4 SPORT shift mode OFF More than 4 SPORT shift mode with 1st and 3rd gear...

Page 2293: ...S TRANSMISSION CONTROL MODULE TCM I O SIGNAL B SCHEMATIC AT 00772 1 2 3 4 5 7 6 8 9 12 37 36 35 34 33 32 31 30 29 28 27 26 25 24 17 14 13 16 15 18 21 20 19 10 11 38 39 46 40 41 42 43 44 45 47 48 49 52...

Page 2294: ...e 26 N range indicator light 10 ABS control module without VDC system 27 D range indicator light 50 POWER switch 28 3 range indicator light 51 HOLD switch 11 VDC control module with VDC system 29 2 ra...

Page 2295: ...L MODULE TCM I O SIGNAL C MEASUREMENT Only for models with VDC system measure input output signal voltage 1 WAVEFORM A Can communication line B Terminal No B56 No 9 B55 No 9 C Terminal No B56 No 18 B5...

Page 2296: ...S key after displayed the informa tion of transmission type 9 On the Transmission Diagnosis display screen select the Diagnostic Code s Display and press the YES key 10 On the Diagnostic Code s Displa...

Page 2297: ...or OFF Stop lamp switch signal Stop Light Switch ON or OFF Shift up signal with SPORT shift Up Switch ON or OFF Shift down signal with SPORT shift Down Switch ON or OFF SPORT shift mode with SPORT shi...

Page 2298: ...sion Control System and press the YES key 3 Press the YES key after displayed the informa tion of transmission type 4 On the Transmission Diagnosis display screen select the Clear Memory and press the...

Page 2299: ...OTE Blinks every 0 125 1 8 seconds until ignition switch is turned OFF Indicator light blinks at every 4 Hz interval Go to step 2 Repair power sup ply and ground cir cuit Ref to AT 34 CHECK POWER SUPP...

Page 2300: ...icates a ten and the short segment 0 2 sec on signifies a one 2 WITH SUBARU SELECT MONITOR Refer to Subaru Select Monitor for information about how to obtain and understand trouble codes Ref to AT 21...

Page 2301: ...g or tie down hooks to prevent the lateral runout of front wheels Do not abruptly depress release clutch pedal or accelerator pedal during works even when engine is operating at low speeds since this...

Page 2302: ...These trouble codes can be cleared by removing the specified Remove TCM connector at least 2 min utes CLEAR MEMORY Remove TCM connector B56 TCM connector is located in the line to the mem ory back up...

Page 2303: ...be determined by a DTC during on board diagnostics operation Problems which occurred previously can also be identified through the memory function If the POWER indicator does not show a problem althou...

Page 2304: ...s open or shorted output signal circuit Ref to AT 72 DTC 71 SHIFT SOLENOID 1 Diagnostic Procedure with Diagnostic Trouble Code DTC 72 Shift solenoid 2 Detects open or shorted output signal circuit Ref...

Page 2305: ...i12 C i1 B36 NO 5 BATTERY IGNITION RELAY T7 B12 1 2 3 4 5 6 7 8 9 10 11 12 i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TCM B55 B B56 C 1 2 3 4 5 6 7 8 9 10 11 12 B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7...

Page 2306: ...9 4 CHECK FUSE No 5 Remove fuse No 5 Is the fuse No 5 blown out Fuse is blown Replace fuse No 5 If replaced fuse No 5 is blown out easily repair short circuit in har ness between fuse No 5 and combi n...

Page 2307: ...onnector or harness may be the cause Repair harness or con nector in TCM Replace TCM Ref to AT 76 Transmission Con trol Module TCM 9 CHECK SUBARU SELECT MONITOR Do you have Subaru Select Monitor Subar...

Page 2308: ...AT 33 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR POWER INDICATOR LIGHT MEMO...

Page 2309: ...CTOR F2 B100 B11 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TCM B54 A B56 C B54 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B56 1...

Page 2310: ...OWER SUPPLY CIR CUIT 1 Turn ignition switch to ON engine OFF 2 Measure ignition power supply voltage between TCM connector and chassis ground Connector terminal B54 No 23 Chassis ground B54 No 24 Chas...

Page 2311: ...sion ground Connector terminal T4 No 16 Transmission ground Is the measured value less than the specified value 1 Go to step 8 Repair open circuit in harness between transmis sion and transmis sion gr...

Page 2312: ...AT 37 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR POWER INDICATOR LIGHT MEMO...

Page 2313: ...ATA LINK CONNECTOR LINE END CHECK CONNECTOR SHIELD AND SENSOR GROUND JOINT CONNECTOR F2 B100 B11 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TCM B54 A...

Page 2314: ...ed normally Are the name and year of the system dis played on the select monitor Name and year are displayed Go to step 6 Go to step 4 4 CHECK COMMUNICATION OF SELECT MONITOR 1 Turn ignition switch to...

Page 2315: ...ctor terminal B56 No 15 B40 No 10 Is the measured value less than the specified value 0 5 Go to step 9 Repair harness and connector between TCM and data link connec tor 9 CHECK HARNESS CONNECTOR BETWE...

Page 2316: ...AT 41 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION MEMO...

Page 2317: ...MPTOM No lock up after engine warm up POWER indicator light remains on when vehicle speed is 0 WIRING DIAGRAM AT 00775 9 30 H6T H4N 17 ECM B55 TCM H4N H6T EXCEPT 3 0L MODEL AND TURBO MODEL 3 0L MODEL...

Page 2318: ...tage between TCM connector and chassis ground Connector terminal B55 No 17 Chassis ground Does the measured value exceed the spec ified value 10 5 V Even if POWER indicator lights up the circuit has r...

Page 2319: ...H DIAGNOSTIC TROUBLE CODE DTC 7 CONFIRM DTC 11 Replace ECM with a new one Does the diag nostic trouble code DTC appear again after the memory has been cleared DTC11 is displayed Replace TCM Ref to AT...

Page 2320: ...AT 45 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2321: ...e any trouble There is a trouble Repair the ground terminal and or ground circuit of ECM Go to step 2 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM 1 Turn the ignition switch to OFF 2 Disconnect the c...

Page 2322: ...r indicator light lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM...

Page 2323: ...IAGNOSIS Input signal circuit of TCM to ATF temperature sensor is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 00776 11 20 11 12 ATF TEMPERATURE SENSOR B54 B11 T4 TCM B11 TR...

Page 2324: ...between TCM connector and chassis ground Connector terminal B54 No 20 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair short circuit in harness between TCM and...

Page 2325: ...ctor terminal B54 No 11 No 20 Is the measured value within the specified range 0 4 0 9 V Even if POWER indicator lights up the circuit has returned to a nor mal condition at this time Tempo rary poor...

Page 2326: ...AT 51 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2327: ...18 19 20 21 B135 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5 4 6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 24 25 26 27 16 17 18 28 29 19 20 21 30...

Page 2328: ...3 14 15 16 B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B137 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 E13 1 2 3 B252 B83 1 2 7 8 9 5 6...

Page 2329: ...BD model B134 No 7 Engine ground B134 No 35 Engine ground B135 No 21 Engine ground B136 No 5 Engine ground B136 No 16 Engine ground B136 No 26 Engine ground B137 No 14 Engine ground TURBO model B134 N...

Page 2330: ...ition sensor connec tor Connector terminal Except 3 0 L model B55 No 3 E13 No 3 3 0 L model B55 No 3 E13 No 2 Is the measured value less than the speci fied value 1 Go to step 6 Repair open circuit in...

Page 2331: ...ce of harness between TCM and ECM connector Connector terminal Non TURBO without OBD model B54 No 2 B136 No 15 Non TURBO with OBD model B54 No 2 B135 No 3 TURBO model B54 No 2 B135 No 9 3 0 L model B5...

Page 2332: ...voltage between TCM connector and chassis ground Connector terminal B54 No 2 Chassis ground Is the measured value within the specified range 4 8 5 3 V Even if POWER indicator lights up the circuit ha...

Page 2333: ...CODE DTC E DTC 33 FRONT VEHICLE SPEED SENSOR DIAGNOSIS The vehicle speed signal is abnormal The circuit in combination meter is faulty The harness connector between TCM and vehicle speed sensor is in...

Page 2334: ...6 14 15 7 8 9 16 17 18 22 23 24 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1...

Page 2335: ...tance of harness between TCM and transmission connector Connector terminal B54 No 10 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair short circuit in harness...

Page 2336: ...rness may be the case Repair harness or connector in the front vehicle speed sensor circuit Go to step 11 9 CHECK FRONT VEHICLE SPEED SENSOR USING OSCILLOSCOPE 1 Connect all connectors 2 Lift up the v...

Page 2337: ...nce between front and rear wheels may light the ABS warning light but this indicates no malfunction When AT control di agnosis is finished perform the ABS memory clearance procedure of on board diagno...

Page 2338: ...AT 63 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2339: ...r shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 00780 14 15 8 9 B11 B53 T4 TCM B55 NT TB 1 2 3 SENSOR TORQUE SHIELD JOINT CONNECTOR CONVERTER TURBINE SPEED B55 B11 1 2 5 6 7 8 13 14...

Page 2340: ...TCM and transmission connector Connector terminal B55 No 9 B11 No 15 Is the measured value less than the specified value 1 Go to step 4 Repair open circuit in harness between TCM and transmission con...

Page 2341: ...ometer with Subaru Select Monitor indications Is the revolution value same as the tachom eter reading shown on the combination meter Same as tachometer value Even if POWER indicator lights up the circ...

Page 2342: ...AT 67 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2343: ...BO with OBD model B56 No 14 B136 No 18 B56 No 15 B136 No 1 3 0 L model and TURBO model B56 No 14 B134 No 18 B56 No 5 B134 No 19 Is the measured value less than the speci fied value 1 Go to step 2 Repa...

Page 2344: ...ETWEEN TRANS MISSION AND BODY Check installing condition of ground line in transmission and body Is there any dirt or rust at ground line installing point Remove dirt and rust Go to step 6 6 CHECK GRO...

Page 2345: ...switch to OFF 2 Disconnect connectors from TCM and ECM 3 Measure resistance of harness between TCM and ECM connector Connector terminal 2 0 L and 2 5 L without OBD model B54 No 1 B136 No 11 2 0 L and...

Page 2346: ...if POWER indicator lights up the circuit has returned to a nor mal condition at this time A tempo rary poor contact of the connector or harness may be the cause Repair harness or con nector in the TCM...

Page 2347: ...OLENOID 1 DIAGNOSIS Output signal circuit of shift solenoid 1 is open or shorted TROUBLE SYMPTOM Does not shift WIRING DIAGRAM AT 00583 22 TRANSMISSION B54 TCM AT5 1 T4 B11 SHIFT SOLENOID 1 B54 1 2 7...

Page 2348: ...nector terminals Connector terminal T4 No 1 No 16 Is the measured value within the specified range 10 16 Go to step 4 Go to step 7 4 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect connectors to TCM an...

Page 2349: ...S CONNECTOR BETWEEN SHIFT SOLENOID 1 AND TRANSMISSION Measure resistance of harness between shift solenoid 1 and transmission connector Connector terminal AT5 No 1 T4 No 1 Is the measured value less t...

Page 2350: ...AT 75 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2351: ...OLENOID 2 DIAGNOSIS Output signal circuit of shift solenoid 2 is open or shorted TROUBLE SYMPTOM Does not shift WIRING DIAGRAM AT 00584 5 TRANSMISSION B54 TCM AT6 SHIFT SOLENOID 2 B54 1 2 7 8 9 5 6 3...

Page 2352: ...16 Go to step 4 Go to step 6 4 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect connectors to TCM and transmis sion 2 Lift up or raise the vehicle and support with safety stand NOTE Raise all wheels off...

Page 2353: ...enoids Duty Solenoids and ATF Temper ature Sensor 7 CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 2 AND TRANSMISSION Measure resistance of harness between shift solenoid 2 and transmission connector...

Page 2354: ...AT 79 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2355: ...DIAGNOSIS Output signal circuit of low clutch timing solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 00585 15 TRANSMISSION B54 TCM AT 9 LOW CLUTCH TIMING SOLENOID...

Page 2356: ...erminals Connector terminal T4 No 3 No 16 Is the measured value within the specified range 10 16 Go to step 4 Go to step 7 4 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect connectors to TCM and transm...

Page 2357: ...LOW CLUTCH TIMING SOLENOID AND TRANSMISSION Measure resistance of harness between low clutch timing solenoid and transmission con nector Connector terminal AT9 No 1 T4 No 3 Is the measured value less...

Page 2358: ...AT 83 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2359: ...D DIAGNOSIS Output signal circuit of 2 4 brake timing solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 00586 16 TRANSMISSION B54 TCM AT8 4 T4 B11 2 4 BRAKE TIMING SO...

Page 2360: ...or terminals Connector terminal T4 No 4 No 16 Is the measured value within the specified range 10 16 Go to step 4 Go to step 7 4 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect connectors to TCM and tr...

Page 2361: ...noid circuit There is poor contact Repair poor con tact Replace TCM Ref to AT 76 Transmission Con trol Module TCM 7 CHECK 2 4 BRAKE TIMING SOLENOID IN TRANSMISSION 1 Remove transmission connector fro...

Page 2362: ...on ground Connector terminal T4 No 4 Transmission ground Does the measured value exceed the specified value 1 M Even if POWER indicator lights up the circuit has returned to a nor mal condition at thi...

Page 2363: ...onnector Connector terminal B54 No 9 B11 No 5 Is the measured value less than the speci fied value 1 Go to step 2 Repair open circuit in harness between TCM and transmission con nector 2 CHECK HARNESS...

Page 2364: ...below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 3 Turn ignition switch to ON engine OFF 4 Move select lever to N 5 Throttle is fully closed 6 Measure voltage between...

Page 2365: ...en 3 Read line pressure duty solenoid data using Subaru Select Monitor Is line pressure duty solenoid data less than the specified value 25 Even if POWER indicator lights up the circuit has returned t...

Page 2366: ...ansmission connector 12 CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LINE PRESSURE DUTY SOLENOID Measure resistance of harness between trans mission connector and transmission ground Connector ter...

Page 2367: ...ector Connector terminal B54 No 18 B11 No 9 Is the measured value less than the speci fied value 1 Go to step 2 Repair open circuit in harness between TCM and transmission con nector 2 CHECK HARNESS C...

Page 2368: ...0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 3 Turn ignition switch to ON engine OFF 4 Move select lever to N 5 Throttle is fully closed 6 Measure voltage between TCM co...

Page 2369: ...d line pressure duty solenoid data using Subaru Select Monitor Is line pressure duty solenoid data less than the specified value 25 Even if POWER indicator lights up the circuit has returned to a nor...

Page 2370: ...mission con nector 12 CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND 2 4 BRAKE DUTY SO LENOID Measure resistance of harness between trans mission connector and transmission ground Connector terminal...

Page 2371: ...IAGNOSIS Output signal circuit of lock up duty solenoid is open or shorted TROUBLE SYMPTOM No lock up after engine warm up WIRING DIAGRAM AT 00589 7 TRANSMISSION B54 TCM AT3 13 T4 B11 LOCK UP DUTY SOL...

Page 2372: ...fied value 1 Go to step 3 Repair open circuit in harness between TCM and transmission con nector 3 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure resistance of harness connector between...

Page 2373: ...When AT control di agnosis is finished perform the ABS memory clearance procedure of on board diagnostics system Ref to ABS 22 Clear Memory Mode or Ref to VDC 25 Clear Memory Mode 5 Measure voltage b...

Page 2374: ...ABS memory clearance procedure of on board diagnostics system Ref to ABS 22 Clear Memory Mode or Ref to VDC 25 Clear Memory Mode Is lock up duty solenoid data the specified value 95 Go to step 9 Go t...

Page 2375: ...UTY SOLENOID AND TRANS MISSION Measure resistance of harness between lock up duty solenoid and transmission connector Connector terminal T4 No 13 AT3 No 1 Is the measured value less than the specified...

Page 2376: ...AT 101 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2377: ...SIS Output signal circuit of SPORT shift solenoid is open or shorted TROUBLE SYMPTOM Engine brake is effective at D 3 2 ranges WIRING DIAGRAM AT 00663 14 TRANSMISSION B54 TCM AT10 SPORT SHIFT SOLENOID...

Page 2378: ...sure resistance of harness between TCM connector and chassis ground Connector terminal B54 No 14 Chassis ground Does the measured value exceed the specified value 1 M Go to step 3 Repair short circuit...

Page 2379: ...sis ground Is the measured value less than the speci fied value 1V Even if POWER indicator lights up the circuit has returned to a nor mal condition at this time A tempo rary poor contact of the conne...

Page 2380: ...ssion con nector 9 CHECK HARNESS CONNECTOR BETWEEN SPORT SHIFT SOLENOID AND TRANSMIS SION Measure resistance of harness between SPORT shift solenoid connector and transmis sion ground Connector termin...

Page 2381: ...AGNOSIS Output signal circuit of transfer duty solenoid is open or shorted TROUBLE SYMPTOM Excessive braking in tight corners WIRING DIAGRAM AT 00590 6 TRANSMISSION B54 TCM AT4 6 T4 B11 TRANSFER DUTY...

Page 2382: ...ied range 10 17 Go to step 4 Go to step 13 4 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select Monitor Subaru Select Monitor is avail able Go to step 7 Go to step 5 5 CHECK OUTPUT SIGNAL EMITT...

Page 2383: ...d data of transfer duty solenoid using Subaru Select Monitor Transfer duty solenoid is indicated in Is transfer duty solenoid data within the specified range Approx 60 70 Even if POWER indicator light...

Page 2384: ...epair poor con tact Replace TCM Ref to AT 76 Transmission Con trol Module TCM 13 CHECK TRANSFER DUTY SOLENOID IN TRANSMISSION 1 Lift up the vehicle and place safety stand 2 Drain automatic transmissio...

Page 2385: ...nnector terminal T4 No 6 Transmission ground Does the measured value exceed the specified value 1 M Even if POWER indicator lights up the circuit has returned to a nor mal condition at this time A tem...

Page 2386: ...AT 111 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2387: ...3 4 5 6 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 9 18 1 4 6 3 B234 TCM B56 83 81 VDC CM F87 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14...

Page 2388: ...t in harness between TCM and VDCCM and poor contact in cou pling connector 4 CHECK HARNESS CONNECTOR BETWEEN TCM AND VDCCM Measure resistance of harness between TCM and VDCCM connector Connector termi...

Page 2389: ...as shown in figure Go to step 9 Repair poor con tact in VDCCM 9 CHECK INPUT SIGNAL FOR TCM USING OSCILLOSCOPE 1 Set oscilloscope to TCM connector termi nals Connector terminal Positive probe B56 No 18...

Page 2390: ...AT 115 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2391: ...aking WIRING DIAGRAM AT 00785 19 20 B24 A19 B11 T4 TCM B54 A B55 B NT TB 7 8 9 SHIELD AND SENSOR GROUND JOINT CONNECTOR REAR VEHICLE B55 B11 SPEED SENSOR B54 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17...

Page 2392: ...ANSMISSION Measure resistance of harness between TCM and chassis ground Connector terminal B55 No 24 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair short cir...

Page 2393: ...USING SUBARU SELECT MONITOR 1 Connect connectors to TCM and transmis sion 2 Connect Subaru Select Monitor to data link connector 3 Lift up or raise the vehicle and place safety stands NOTE Raise all w...

Page 2394: ...cates no malfunction When AT control di agnosis is finished perform the ABS memory clearance procedure of on board diagnostics system Ref to ABS 22 Clear Memory Mode or Ref to VDC 25 Clear Memory Mode...

Page 2395: ...AT 120 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2396: ...orm the ABS memory clearance procedure of on board diagnostics system Ref to ABS 22 Clear Memory Mode or Ref to VDC 25 Clear Memory Mode Does the transmission gear correspond to the gear which is show...

Page 2397: ...24 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 E C3 A16 O5 F45 B62 6 8 C2 B20 i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 i12 1 2 3 4 5 6 7...

Page 2398: ...ed value 1 Go to step 4 Repair open circuit in harness between TCM and FWD switch con nector 4 CHECK HARNESS CONNECTOR BETWEEN TCM AND FWD SWITCH Measure resistance of harness connector between TCM an...

Page 2399: ...ween TCM and chassis ground to make sure that circuit does not short Connector terminal B56 No 2 Chassis ground Does the measured value exceed the specified value 1 M Go to step 10 Repair short circui...

Page 2400: ...f ABS switch light up LED lights up Check ABS switch circuit Ref to ABS 118 DTC 44 ABS AT CON TROL NON CON TROLLED Diagnostics Chart with Subaru Select Monitor and Ref to ABS 120 DTC 44 ABS AT CONTROL...

Page 2401: ...s depressed does ON displayed ON is displayed Go to step CHECK POWER MODE SWITCH Ref to AT 128 CHECK POWER MODE SWITCH Diag nostic Procedure for No diagnostic Trouble Code DTC Go to step 2 2 CHECK KIC...

Page 2402: ...S CONNECTOR BETWEEN TCM AND KICK DOWN SWITCH Measure resistance of harness connector between TCM and chassis ground Connector terminal B55 No 11 Chassis ground Does the measured value exceed the speci...

Page 2403: ...4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 COMBINATION METER i10 A i11 B i12 C i1 B36 B12 H6L A8 B6 H4N C3 B5 P5 POWER H6R...

Page 2404: ...sconnect connector from power switch 3 Measure resistance of harness connector between power switch and chassis ground Connector terminal B133 No 4 Chassis ground Is the measured value less than the s...

Page 2405: ...ON with engine OFF 3 Measure signal voltage for TCM while turn ing power switch OFF Connector terminal B55 No 23 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 10...

Page 2406: ...AT 131 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2407: ...B1 B2 B3 B4 B11 B12 B5 A14 A22 A21 A20 A19 A16 A15 H4 H6 H4 H6 C3 A8 B5 P4 M5 L4 L5 O4 N4 M4 i10 i11 i12 A i1 B36 B C NO 5 15A BATTERY IGNITION RELAY T7 1 2 3 4 5 6 7 8 9 10 11 12 B12 1 2 3 4 5 6 7 8...

Page 2408: ...he D range is selected does N range LED light up LED lights up Go to step 40 Go to step 10 10 CHECK D RANGE SWITCH When the D range is selected does LED light up LED lights up Go to step 11 Go to step...

Page 2409: ...ector 23 CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn ignition switch to OFF 2 Disconnect connectors from TCM and inhibitor switch 3 Measure resistance of harness between TCM and in...

Page 2410: ...IBITOR SWITCH 1 Turn ignition switch to OFF 2 Disconnect connectors from TCM inhibitor switch and combination meter 3 Measure resistance of harness between TCM and chassis ground Connector terminal B5...

Page 2411: ...L model and TURBO model B55 No 3 i11 No 2 3 0 L model and TURBO model B55 No 3 i10 No 22 Is the measured value less than the speci fied value 1 Go to step 65 Repair open circuit in harness between TCM...

Page 2412: ...ange indicator light bulb from combination meter Is N range indicator light bulb OK Bulb is normal Go to step 39 Replace N range indicator light bulb Ref to IDI 14 Combination Meter Assembly 39 CHECK...

Page 2413: ...65 43 CHECK INPUT SIGNAL FOR TCM 1 Position select lever to any other than D range 2 Measure voltage between TCM and chas sis ground Connector terminal B55 No 4 Chassis ground Does the measured value...

Page 2414: ...ween TCM and inhibitor switch connector and poor contact in coupling connec tor 48 CHECK INPUT SIGNAL FOR TCM 1 Turn ignition switch to OFF 2 Connect connector to TCM and inhibitor switch 3 Turn ignit...

Page 2415: ...rt circuit in 3 range circuit 53 CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn ignition switch to OFF 2 Disconnect connector from TCM and inhibi tor switch 3 Measure resistance of ha...

Page 2416: ...1 Turn ignition switch to OFF 2 Disconnect connectors from TCM inhibitor switch and combination meter 3 Measure resistance of harness between TCM and chassis ground Connector terminal B55 No 6 Chassis...

Page 2417: ...bination meter 2 Measure resistance of harness between TCM and combination meter Connector terminal Except 3 0 L model and TURBO model B55 No 7 i11 No 5 3 0 L model and TURBO model B55 No 7 i10 No 15...

Page 2418: ...AT 143 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2419: ...ON E E i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 COMBINATION METER i10 A i11 B i12 C i1 B36 A1...

Page 2420: ...Measure resistance of harness connector between hold switch and chassis ground Connector terminal B133 No 4 Chassis ground Is the measured value less than the speci fied value 1 Go to step 5 Repair o...

Page 2421: ...alue exceed the specified value 1 M Go to step 10 Repair short circuit in harness between TCM hold switch and combination meter connector 10 CHECK INPUT SIGNAL FOR TCM 1 Connect connectors to TCM and...

Page 2422: ...AT 147 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2423: ...TROUBLE SYMPTOM No SPORT shift mode occurs Does not shift gears in SPORT shift mode WIRING DIAGRAM STEERING SHIFT SWITCH AT 00790 15 4 B55 TCM B237 SPORT SHIFT SWITCH B237 1 2 3 4 5 6 B55 1 2 7 8 9 5...

Page 2424: ...ift switch side is pressed Lights up Go to Inspection of SPORT shift indicator proce dures Ref to AT 156 CHECK SPORT SHIFT INDICATOR Diagnostic Proce dure for No diag nostic Trouble Code DTC Go to ste...

Page 2425: ...gnition switch to ON Engine is stopped 3 Move select lever to normal mode 4 Measure signal voltage for TCM Connector terminal B55 No 15 Chassis ground Does the measured value exceed the spec ified val...

Page 2426: ...terminal B237 No 2 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 19 Repair short circuit in harness between SPORT shift switch con nector and TCM connector 19 CHECK...

Page 2427: ...rness between SPORT shift switch con nector and TCM connector and poor contact in coupling connec tor 25 CHECK HARNESS CONNECTOR BETWEEN TCM AND SPORT SHIFT SWITCH 1 Disconnect steering roll connector...

Page 2428: ...or contact 31 CHECK harness connector between TCM and Steering roll connector 1 Disconnect connector from TCM 2 Measure harness resistance between TCM connector and steering roll connector Connector t...

Page 2429: ...the speci fied value 1 The circuit is returned to a nor mal condition Temporary poor contact of the har ness may be the case Repair poor contact of steering roll connector and steering shift switch ha...

Page 2430: ...AT 155 AUTOMATIC TRANSMISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 2431: ...M AT 00791 BATTERY No 5 IGNITION RELAY i11 i10 i1 B36 B56 COMBINATION METER TCM E B5 A4 A8 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M...

Page 2432: ...less than the speci fied value 1 Go to step 4 Repair open circuit in harness between TCM and combination meter connector and poor contact in coupling connec tor 4 CHECK HARNESS CONNECTOR BETWEEN TCM A...

Page 2433: ...DIAGRAM AT 00792 BATTERY No 5 IGNITION RELAY i12 i1 B36 B56 COMBINATION METER TCM E 13 12 21 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6...

Page 2434: ...sis ground Connector terminal B56 No 21 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 2 Repair short circuit in harness between TCM and combination meter connector...

Page 2435: ...oil level too high or too low Noise occurs while driving in D4 Final gear Low reverse brake Planetary gear Reduction gear Differential gear oil level too high or too low Engine stalls while shifting...

Page 2436: ...does not start in D 3 or 2 range only engine stalls Reverse clutch Vehicle starts in R range only engine revving up Control valve Acceleration during standing starts is poor high stall rpm Control val...

Page 2437: ...ve Lock up facing Engine speed signal Parking brake is not effected Select cable Select lever Parking mechanism Shift lever cannot be moved or is hard to move from P range ATF spurts out ATF level too...

Page 2438: ...e duty solenoid Control valve 2 4 brake timing solenoid 2 4 brake ATF deterioration Engine performance Low clutch timing solenoid Low clutch Slippage occurs from 3rd to 4th gear TCM Throttle position...

Page 2439: ...ward operation TCM Lock up duty solenoid Lock up facing Lock up damper Vibration occurs during turns tight corner braking phenome non TCM Front vehicle speed sensor Rear vehicle speed sensor Throttle...

Page 2440: ...g acceleration or while driving on rough terrain Select cable Select lever Detent spring Manual plate System does not shift to SPORT shift mode SPORT shift mode switch Engine brake is not effected in...

Page 2441: ...AT 166 AUTOMATIC TRANSMISSION DIAGNOSTICS SYMPTOM RELATED DIAGNOSTIC MEMO...

Page 2442: ...r Case and Extension Case Assembly 47 10 Transfer Drive Gear 51 11 Transfer Driven Gear 53 12 Center Differential 55 13 Reverse Check Sleeve 56 14 Transmission Case 59 15 Main Shaft Assembly for Singl...

Page 2443: ...780 0 825 0 738 Reverse 3 333 Auxiliary transmis sion gear ratio High 1 000 Low 1 447 1 196 Front reduction gear Final Type of gear Hypoid Gear ratio 3 900 3 700 3 900 4 111 Rear reduction gear Trans...

Page 2444: ...275 0 0108 32295AA051 0 200 0 0079 32295AA091 0 300 0 0118 32295AA061 0 225 0 0089 32295AA101 0 500 0 0197 Main shaft rear plate Dimension A mm in Part No Mark 4 00 4 13 0 1575 0 1626 32294AA041 1 3 8...

Page 2445: ...t No Thickness mm in Part No Thickness mm in 803020151 0 4 0 016 803020154 1 9 0 075 803020152 1 1 0 043 803020155 2 3 0 091 803020153 1 5 0 059 1st 2nd shifter fork Part No Mark Remarks 32804AA060 1...

Page 2446: ...5 0 75 0 0295 803050066 0 80 0 0315 803050067 0 85 0 0335 803050068 0 90 0 0354 803050069 0 95 0 0374 803050070 1 00 0 0394 803050071 1 05 0 0413 803050072 1 10 0 0433 803050073 1 15 0 0453 803050074...

Page 2447: ...MT 6 MANUAL TRANSMISSION AND DIFFERENTIAL GENERAL DESCRIPTION B COMPONENT 1 TRANSMISSION CASE MT 00002 T 3 1 2 4 5 12 10 11 18 13 9 8 7 6 16 14 15 17...

Page 2448: ...BO model 18 Oil level gauge TURBO model 4 Snap ring Outer 5 Speedometer driven gear 14 Oil seal Dual range Tightening torque N m kgf m ft lb 6 Washer 15 Transmission case ASSY Dual range T 44 4 5 32 5...

Page 2449: ...haft 19 Outer baulk ring 33 Washer 7 Key 20 Synchro cone 34 Lock washer 8 Woodruff key 21 Inner baulk ring 35 Lock nut 9 Drive pinion collar 22 2nd driven gear 10 Needle bearing 23 2nd driven gear bus...

Page 2450: ...MT 9 MANUAL TRANSMISSION AND DIFFERENTIAL GENERAL DESCRIPTION MEMO...

Page 2451: ...L TRANSMISSION AND DIFFERENTIAL GENERAL DESCRIPTION 3 MAIN SHAFT ASSEMBLY SINGLE RANGE T MT 00380 1 2 3 4 4 9 5 5 6 7 8 9 10 11 12 13 14 15 16 17 19 18 21 22 23 24 25 27 26 28 29 30 31 32 33 34 35 37...

Page 2452: ...SOHC 19 Baulk ring 2 0 L SOHC 35 Lock nut 20 5th gear thrust washer 36 Reverse idler gear shaft 7 3rd synchro cone Except 2 0 L SOHC 21 5th needle bearing race 37 Straight pin 22 Needle bearing 38 Rev...

Page 2453: ...LY DUAL RANGE MT 00381 3 4 4 T2 T3 T1 5 2 1 6 6 7 8 9 10 11 17 18 19 20 21 22 23 30 31 32 33 36 35 34 37 39 35 34 40 38 69 70 71 72 73 74 75 76 77 78 79 80 40 41 42 43 44 45 46 47 48 29 12 13 14 15 16...

Page 2454: ...13 Snap ring Outer 28 43 4th baulk ring 73 Gasket 14 Oil squeeze 44 4th drive gear 74 Straight pin 15 Straight pin 45 4th needle bearing race 75 High low shifter fork 16 Snap ring Outer 28 46 Needle...

Page 2455: ...nterlock plunger 18 Reverse shifter lever 3 Straight pin 11 1st 2nd fork rod 4 Reverse fork rod 12 3rd 4th shifter fork Tightening torque N m kgf m ft lb 5 Checking ball plug 13 1st 2nd shifter fork T...

Page 2456: ...Snap ring 8 Oil seal 23 Back up light switch 9 Snap ring Inner 24 Roller bearing Tightening torque N m kgf m ft lb 10 Reverse check plate 25 Transfer driven gear T1 6 4 0 65 4 7 11 Reverse check sprin...

Page 2457: ...driven gear 9 Roller bearing 3 Pinion shaft 10 Differential case Tightening torque N m kgf m ft lb 4 Straight pin 11 Oil seal T1 25 2 5 18 1 5 Washer 12 Differential side retainer T2 62 6 3 45 6 6 Di...

Page 2458: ...f m ft lb 2 Spacer 8 Cushion D T1 7 5 0 76 5 5 3 Cushion C 9 Center crossmember T2 35 3 6 26 4 Front plate 10 Rear plate T3 50 5 1 37 5 Dynamic damper Except Austra lia TURBO MT model 11 Front crossme...

Page 2459: ...of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply gear oil ont...

Page 2460: ...399780104 WEIGHT Used for measuring preload on roller bearing 498077000 5TH DRIVEN GEAR REMOVER Used for removing roller bearing of drive pinion shaft 498077300 CENTER DIFFER ENTIAL BEARING REMOVER Us...

Page 2461: ...ypoid gear Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring backlash between side gear and pinion and hypoid gear Used with MAGNET BASE 498247001 498427100 STOPPER Used for secur...

Page 2462: ...mission main shaft lock nut 499277100 BUSHING 1 2 INSTALLER Used for installing 1st driven gear thrust plate and 1st 2nd driven gear bushing Used for installing roller bearing outer races to different...

Page 2463: ...ling bearing cone of transfer driven gear extension core side 499787000 WRENCH ASSY Used for removing and installing differential side retainer 499827000 PRESS Used for installing speedometer oil seal...

Page 2464: ...nsmission main shaft Used with REMOVER 899714110 499917500 DRIVE PINION GAUGE ASSY Used for adjusting drive pinion shim 499927100 HANDLE Used for fitting transmission main shaft 499937100 TRANSMISSION...

Page 2465: ...nut 499987300 SOCKET WRENCH 50 Used for removing and installing driven gear assembly lock nut 899714110 REMOVER Used for fixing transmission main shaft drive pinion rear drive shaft 899864100 REMOVER...

Page 2466: ...ER Used for removing and installing straight pin 899988608 SOCKET WRENCH 27 Used for removing and installing drive pinion lock nut 398497701 ADAPTER Used for installing roller bearing onto differen ti...

Page 2467: ...aft 899824100 PRESS Used for installing speedometer shaft oil seal 499987100 SOCKET WRENCH 35 Used for removing and installing drive pinion lock nut 899984103 SOCKET WRENCH 35 Used for removing and in...

Page 2468: ...acklash 498077400 REMOVER Used for removing synchronizer cone of main shaft Used for removing 5th driven gear of drive pin ion shaft 41099AA000 ENGINE SUPPORT BRACKET Used for supporting engine 1 ENGI...

Page 2469: ...ner Bearing outer race 398643600 GAUGE Used for measuring total end play extension end play and drive pinion height 398177700 INSTALLER Used for installing bearing cone of transfer driven gear transfe...

Page 2470: ...del 398663600 PLIERS Used for removing and installing input shaft snap ring For dual range model 499757001 SNAP RING GUIDE Used for installing snap ring OUT 25 For dual range model 899858600 RETAINER...

Page 2471: ...ange model 899580100 INSTALLER Used when pressing ball bearings into input shaft For dual range model 399513600 INSTALLER Used when pressing ball bearings into input shaft For dual range model TOOL NA...

Page 2472: ...ransmission gear oil is hot Be careful not to burn yourself Be careful not to splash transmission gear oil on exhaust pipe it may cause smoke or fire If transmission gear oil splashes to exhaust pipes...

Page 2473: ...tercooler TURBO model Ref to IN H4DOSTC 13 REMOVAL Intercooler 7 Remove air cleaner case stay 8 Disconnect the following connectors 1 Neutral position switch connector 2 Back up light switch connector...

Page 2474: ...ase bearing TURBO model 1 Remove the clutch operating cylinder from transmission 2 Remove the plug using 10 mm hexagon wrench 3 Screw the 6 mm dia bolt into the release fork shaft and remove it 4 Rais...

Page 2475: ...Rear Exhaust Pipe and Ref to EX H4SOw oOBD 14 REMOVAL Muffler Non TURBO with OBD Ref to EX H4SO 9 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 10 REMOVAL Muffler TURBO model Ref to EX H4DOSTC 12 REMOV...

Page 2476: ...main shaft is withdrawn from clutch cover 32 Separate transmission assembly and rear cushion rubber B INSTALLATION 1 Install clutch release bearing and lever to trans mission TURBO model Ref to CL 22...

Page 2477: ...TC 6 INSTALLATION Starter 2 Tighten bolt which holds right upper side of transmission to engine Tightening torque 50 N m 5 1 kgf m 37 ft lb 8 Remove ST 9 Push the clutch release lever to fit bearing i...

Page 2478: ...N m 3 1 kgf m 22 1 ft lb TURBO model Tightening torque 45 N m 4 6 kgf m 33 2 ft lb 16 Connect rod to the joint Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 17 Connect stay to transmission bracket Tig...

Page 2479: ...NSTALLATION Muffler 23 Install under cover 24 Install operating cylinder Tightening torque 37 N m 3 8 kgf m 27 5 ft lb Non TURBO model TURBO model 25 Connect the following connectors 1 Transmission gr...

Page 2480: ...OBD Ref to EX H4SO 5 REMOVAL Front Exhaust Pipe Ref to EX H4SO 9 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 10 RE MOVAL Muffler 4 Remove center rear exhaust pipe and muffler TURBO model Ref to EX H...

Page 2481: ...oOBD 14 INSTALLATION Muffler With OBD Ref to EX H4SO 6 INSTALLATION Front Ex haust Pipe Ref to EX H4SO 9 INSTALLA TION Rear Exhaust Pipe and Ref to EX H4SO 10 INSTALLATION Muffler 6 Install center rea...

Page 2482: ...L Muffler 4 Remove heat shield cover If equipped 5 Remove propeller shaft Ref to DS 14 REMOVAL Propeller Shaft 6 Using ST remove the oil seal ST 398527700 PULLER ASSY 7 Using ST and hammer install the...

Page 2483: ...O model TURBO model 5 Lift up the vehicle 6 Remove back up light switch and neutral posi tion switch with harness 2 HIGH LOW SWITCH 1 Disconnect connector battery ground cable 2 Remove air intake duct...

Page 2484: ...ble to the clamp 3 Connect connector high low switch 4 Install air intake duct and cleaner case Ref to IN H4SO 6 INSTALLATION Air Cleaner Case and Ref to IN H4SO 7 INSTALLATION Air Intake Duct 5 Conne...

Page 2485: ...tion switch to OFF 2 Disconnect connector high low switch 3 Measure resistance between HIGH LOW switch terminals 4 Replace defective parts if outside the standard value Gear shift position Terminal No...

Page 2486: ...oval replace with a new one Ensure sensor mounting hole is clean and free of foreign matter Align tip end of key with key groove on end of speedometer shaft during installation 1 Hand tighten vehicle...

Page 2487: ...et with a new one Tightening torque 44 N m 4 5 kgf m 32 5 ft lb 3 Attach transmission to ST ST 499937100 TRANSMISSION STAND SET 4 Rotating parts should be coated with oil prior to assembly 5 All disas...

Page 2488: ...Install center differential and transfer driven gear into transfer case 2 Remove bearing cone from the extension case assembly and install to taper roller bearing of the transfer driven gear 3 While p...

Page 2489: ...on center differential 15 Apply proper amount of liquid gasket to the transfer case mating surface Liquid gasket THREE BOND 1215 Part No 004403007 Thrust washer 50 61 t Part No Thickness mm in 8030500...

Page 2490: ...with extension case as sembly to transmission case Tightening torque 24 5 N m 2 5 kgf m 18 1 ft lb C DISASSEMBLY 1 TRANSFER CASE 1 Remove reverse check assembly Ref to MT 56 REMOVAL Reverse Check Sle...

Page 2491: ...Install shift bracket to extension case Tightening torque 24 5 N m 2 5 kgf m 18 1 ft lb 3 Install transfer drive gear to extension case Ref to MT 51 INSTALLATION Transfer Drive Gear 2 TRANSFER CASE 1...

Page 2492: ...driven gear 3 Install the extension case assembly 4 Install transfer case and extension case assem bly Ref to MT 47 INSTALLATION Transfer Case and Extension Case Assembly 5 Install back up light swit...

Page 2493: ...l lubrication 2 Drive gear Replace drive gear in the following cases If their tooth surfaces and shaft are excessively broken or damaged 3 Measure clearance between snap ring and inner race of ball be...

Page 2494: ...ring outer race from extension case and transfer case B INSTALLATION 1 Install bearing outer race to extension case and transfer case 2 Install transfer driven gear 3 Install transfer case and extensi...

Page 2495: ...on 1 0 Imp ton 2 Using ST install roller bearing transfer case side ST 499757002 INSTALLER NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton E INSPECTION 1 Bearings Replace be...

Page 2496: ...xtension case as sembly Ref to MT 47 REMOVAL Transfer Case and Extension Case Assembly 5 Install the back up light switch and neutral posi tion switch Ref to MT 42 REMOVAL Switches and Harness 6 Insta...

Page 2497: ...heck sleeve Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 2 Install ball spring washer and plug to transfer case Tightening torque 10 N m 1 0 kgf m 7 2 ft lb 3 Install the shifter arm to transfer cas...

Page 2498: ...eve NOTE Be sure the bent section of reverse check spring is positioned in the groove in check cam 2 Hook the bent section of reverse check spring over reverse check plate 3 Rotate cam so that the pro...

Page 2499: ...to 1 ea between sleeve assembly and case to adjust the clearance NOTE Be careful not to break O ring when placing shim s When shim is removed the neutral position will move closer to reverse when shim...

Page 2500: ...ft rear plate 6 Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seal 7 Separate transmission case into right and left cases by loosening coupling bolts and n...

Page 2501: ...EMOVAL Switches and Harness 6 Using ST drive out straight pin and remove high low shifter lever ST 398791700 STRAIGHT PIN REMOVER 2 NOTE When driving out straight pin remove it in the direc tion that...

Page 2502: ...right and left roller bearing outer races Be careful not to damage retainer oil seal B INSTALLATION 1 SINGLE RANGE 1 Wipe off grease oil and dust on the mating sur faces of transmission cases with whi...

Page 2503: ...ear and preload adjustment of roller bearing NOTE Support drive pinion assembly with ST ST 498427100 STOPPER 9 Place the transmission with case left side facing downward and put ST1 on bearing outer r...

Page 2504: ...tened in Tighten lock plate NOTE Carry out this job on both upper and lower retain ers Tightening torque T 25 N m 2 5 kgf m 18 1 ft lb 18 Selecting of main shaft rear plate Ref to MT 73 ADJUSTMENT Mai...

Page 2505: ...ace the transmission with case left side fac ing downward and put ST1 on bearing outer race 11 Screw retainer assembly into left case from the bottom with ST2 Fit ST3 on the transmission main shaft Sh...

Page 2506: ...pping around retainer lightly with plastic hammer 17 Inspect and adjust backlash and tooth contact of hypoid gear Ref to MT 99 INSPECTION Front Differential Assembly 18 After checking the tooth contac...

Page 2507: ...nock pin NOTE Align the end face of seal with surface A when in stalling oil seal 3 Install the drive pinion assembly Ref to MT 87 INSTALLATION Drive Pinion Shaft Assem bly 4 Install transmission case...

Page 2508: ...mark engagement point on splines before hand Do not reuse ball bearing ST1 499757002 INSTALLER ST2 498077400 SYNCHRO CONE REMOV ER 6 Using ST1 and ST2 remove the rest of parts NOTE Replace sleeve and...

Page 2509: ...ng insert 3 Install 4th needle bearing race onto transmission main shaft using ST1 ST2 and a press NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST2...

Page 2510: ...on 1 1 US ton 1 0 Imp ton Face thrust washer in the correct direction ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER 7 Install bearing onto synchro cone 8 Install baulk ring and synchro cone o...

Page 2511: ...Secure lock nuts in two places after tightening ST1 499987003 SOCKET WRENCH ST2 498937000 TRANSMISSION HOLDER Tightening torque 118 N m 12 0 kgf m 86 8 ft lb 2 EXCEPT 2 0 L SOHC 1 Assemble each sleev...

Page 2512: ...ER ST2 499877000 RACE 4 5 INSTALLER 4 Install baulk ring needle bearing 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Align baulk ring and gear hub assembly with key groove...

Page 2513: ...bearing After press fitting make sure synchro cone ro tates freely ST 499757002 INSTALLER 9 Install synchro cone stopper and snap ring to 5th Rev sleeve and hub assembly 10 Install the rest parts to...

Page 2514: ...end face are dam aged When the ring inner surface is abnormally or par tially worn down When the contact surface of the synchronizer ring insert is scored or abnormally worn down 5 Shifting insert key...

Page 2515: ...in 4 Install the drive pinion assembly Ref to MT 87 INSTALLATION Drive Pinion Shaft Assem bly 5 Install transmission case Ref to MT 61 IN STALLATION Transmission Case 6 Install transfer case with exte...

Page 2516: ...d Do not reuse ball bearing ST1 499757002 INSTALLER ST2 498077400 SYNCHRO CONE REMOV ER 6 Using ST1 and ST2 remove the rest of parts NOTE Replace sleeve and hub with new ones Do not at tempt to disass...

Page 2517: ...ASSY B High low baulk ring C Friction damper D Low input gear E Needle bearing F Input low gear spacer G Ball MT 00216 A B B F C D G E A High low coupling sleeve B Shifting insert C High low synchron...

Page 2518: ...st washer to transmission main shaft NOTE Face thrust washer in the correct direction 5 Drive ball bearing onto the rear section of trans mission main shaft using ST1 ST2 and a press ST1 899714110 REM...

Page 2519: ...tion of trans mission main shaft NOTE Align groove in baulk ring with shifting insert 11 Tighten lock nuts to the specified torque using ST1 and ST2 NOTE Secure lock nuts in two places after tightenin...

Page 2520: ...ion open ends of spring 120 apart 2 Install 3rd drive gear inner baulk ring outer baulk ring synchro cone sleeve and hub assembly for 3rd needle bearing on transmission main shaft NOTE Align groove in...

Page 2521: ...2 499877000 RACE 4 5 INSTALLER 6 Using ST1 and ST2 install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft NOTE Face thrust washer in the correc...

Page 2522: ...aring Face the grooved side toward input gear Align high low baulk ring s groove with shifting in sert 14 Install new snap ring to the rod section of trans mission main shaft using ST1 and ST2 NOTE Se...

Page 2523: ...ce if the cone that contacts the baulk ring is rough or damaged Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases When the inner surfa...

Page 2524: ...ve pinion assembly Ref to MT 87 INSTALLATION Drive Pinion Shaft Assem bly 5 Install the transmission case Ref to MT 61 INSTALLATION Transmission Case 6 Install the transfer case with extension case as...

Page 2525: ...in selecting a suitable snap ring ST1 899580100 INSTALLER ST2 399513600 INSTALLER 2 Install snap ring on input shaft 3 Inspect clearance between ball bearing and snap ring Ref to MT 85 INSPECTION Inpu...

Page 2526: ...Gears Replace gears with new ones if their tooth sur faces are broken damaged or excessively worn Correct or replace if the cone that contacts the baulk ring is rough or damaged Correct or replace if...

Page 2527: ...clearance between snap ring and ball bearing Clearance 0 0 12 mm 0 0 0047 in If the measurement is not within specifications se lect suitable snap ring A Snap ring Snap ring Part No Thickness mm in 80...

Page 2528: ...right hand transmission main case without shim and tighten bearing mounting bolts 4 Inspection and adjustment of ST NOTE Loosen the two bolts and adjust so that the scale indicates 0 5 correctly when...

Page 2529: ...N Manual Transmission Assembly C DISASSEMBLY NOTE Attach a cloth to the end of driven shaft on the fric tional side of thrust needle bearing during disas sembly or reassembly to prevent damage 1 Strai...

Page 2530: ...Remove the key 9 Remove 2nd driven gear inner baulk ring syn chro cone and outer baulk ring 10 Remove 1st driven gear 2nd gear bushing gear and hub using ST1 and ST2 NOTE Replace gear and hub if nece...

Page 2531: ...th to the end of driven shaft to pre vent damage When press fitting align oil holes of shaft and bush ST1 499277200 INSTALLER ST2 499587000 INSTALLER 5 Install 2nd driven gear inner baulk ring synchro...

Page 2532: ...nut at two points 11 Using spring balancer check that starting torque of roller bearing is 0 1 to 1 5 N 0 01 to 0 15 kgf 0 02 to 0 33ft 12 Install roller bearing onto drive pinion NOTE When installing...

Page 2533: ...ecked for smooth rotation be fore the drive pinion assembly is disassembled In this case because a preload is working on the bearing its rotation feels like it is slightly dragging unlike the other be...

Page 2534: ...deformed excessively worn or defective in any way 6 Oil seal Replace the oil seal if the lip is deformed hard ened damaged worn or defective in any way 7 O ring Replace the O ring if the sealing face...

Page 2535: ...following table Repeat steps 1 through 4 to adjust starting torque 6 Recheck that starting torque is within specified range then clinch lock nut at four positions A Adjusting washer No 1 B Adjusting...

Page 2536: ...ot to damage retainer oil seal 7 Remove differential side retainers using ST ST 499787000 WRENCH ASSY 8 Remove side bearing outer race from transmis sion case B INSTALLATION 1 Install differential sid...

Page 2537: ...which it was removed 2 Loosen twelve bolts and remove hypoid driven gear 3 Drive out straight pin from differential assembly toward hypoid driven gear ST 899904100 REMOVER 4 Pull out pinion shaft and...

Page 2538: ...it Ref to MT 100 ADJUST MENT Front Differential Assembly NOTE Be sure the pinion gear tooth contacts adjacent gear teeth during measurement ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard...

Page 2539: ...axle shaft in differential case and hold it with outer snap ring 28 Using a thickness gauge measure clearance between the shaft and case is within specifications NOTE It it is not within specificatio...

Page 2540: ...maged excessively worn or seized The roller bearing on the drive pinion shaft has a worn or damaged roller path There is damage wear or seizure of the differ ential bevel pinion differential bevel gea...

Page 2541: ...t side case 3 TOOTH CONTACT OF HYPOID GEAR Check tooth contact of hypoid gear as follows Ap ply a uniform thin coat of red lead on both tooth sur faces of 3 or 4 teeth of the hypoid gear Move the hypo...

Page 2542: ...eeth contact with following table Tooth contact Checking item Tooth contact pattern is slightly shifted toward to toe side under no load rotation When loaded contact pattern moves toward heel Face con...

Page 2543: ...Checking item Contact areas is small Contact pattern Corrective action Increase thickness of drive pin ion adjusting shim in order to bring drive pinion close to driven gear Heel contact Outside end...

Page 2544: ...shaft and press fit oil seal with ST NOTE Use new oil seal if it has been removed ST 899824100 or 499827000 PRESS 2 Install vehicle speed sensor Ref to MT 45 IN STALLATION Vehicle Speed Sensor 3 Insta...

Page 2545: ...ft and secure with straight pin NOTE Be sure to install reverse idler shaft from the rear side 2 Inspect and adjust clearance between reverse idler gear and transmission case wall Ref to MT 104 INSTAL...

Page 2546: ...rse idler gear and shaft for dam age Replace if damaged D ADJUSTMENT 1 Select the appropriate reverse shifter lever from the table below and adjust until the gap between the reverse idler gear and tra...

Page 2547: ...hen pulling out straight pin remove it toward the inside of the case so that it does not hit against the case 11 Drive out straight pin and pull out 1 2 fork rod and shifter fork 12 Remove outer snap...

Page 2548: ...n Shaft As sembly 13 Install transmission case Ref to MT 61 IN STALLATION Transmission Case 14 Install transfer case with extension case as sembly Ref to MT 47 INSTALLATION Transfer Case and Extension...

Page 2549: ...0 0 051 in Clearance B 1st 2nd to 3rd 4th 0 4 1 4 mm 0 016 0 055 in A 3rd drive gear B Coupling sleeve C 4th drive gear 3rd 4th shifter fork Part No Mark Remarks 32810AA061 1 Approach to 4th gear by 0...

Page 2550: ...Install the following parts in main case Right side and push the shaft perfectly into case Counter gear shaft Two counter gear washers Two needle bearings Counter gear collar Counter gear Straight pin...

Page 2551: ...ON AND DIFFERENTIAL COUNTER GEAR D ADJUSTMENT Selection of snap ring If the measurement is not with in the specification select suitable snap ring Snap ring Part No Thickness mm in 031319000 1 50 0 05...

Page 2552: ...stopper or loose ness of installation bolt Tighten or replace b Loose engine mounting bolts Tighten or replace c Worn fork shifter broken shifter fork rail spring Replace d Worn or damaged ball bearin...

Page 2553: ...the differential and hypoid gear always appear as noise problems Therefore noise is the first indication of the trouble However noises from the engine muffler tire exhaust gas bear ing body etc are ea...

Page 2554: ...Disc and Cover 15 3 Flywheel 20 4 Release Bearing and Lever 22 5 Operating Cylinder 25 6 Master Cylinder 27 7 Clutch Pipe and Hose 29 8 Clutch Fluid 30 9 Clutch Fluid Air Bleeding 31 10 Clutch Pedal...

Page 2555: ...rivet head mm in Wear limit 0 3 0 012 Limit for deflection mm in 1 0 0 039 at R 107 4 21 Clutch release lever ratio 1 6 Clutch pedal Full stroke mm in 130 135 5 12 5 31 Model Australia 2 0 L Turbo Clu...

Page 2556: ...AND AUSTRALIA NON TURBO MODELS 1 Clutch release lever seal 6 Release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 15 7 1 6 11 6 3 Pivot 8 Clutch disc T2 72 7 3 52 8 4...

Page 2557: ...STRALIA NON TURBO MODELS 1 Clutch release lever sealing 6 Clutch release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 15 7 1 6 11 6 3 Pivot 8 Clutch disc T2 72 7 3 52...

Page 2558: ...1 Clutch release lever sealing 6 Clutch cover Tightening torque N m kgf m ft lb 2 Clutch release lever 7 Clutch disc T1 15 7 1 6 11 6 3 Clutch release lever shaft 8 Flywheel T2 44 4 5 32 5 4 Plug T3 7...

Page 2559: ...E NON TURBO MODEL LHD Model 1 Master cylinder ASSY 6 Washer Tightening torque N m kgf m ft lb 2 Clutch pipe 7 Operating cylinder T1 8 0 8 5 8 3 Clamp T2 15 1 5 10 8 4 Bracket T3 18 1 8 13 0 5 Clutch h...

Page 2560: ...h hose Tightening torque N m kgf m ft lb 2 Bracket A 8 Washer T1 8 0 8 5 8 3 Master cylinder ASSY 9 Operating cylinder T2 15 1 5 10 8 4 Clutch pipe T3 18 1 8 13 0 5 Clamp T4 25 2 5 18 1 6 Bracket B T5...

Page 2561: ...Clip 7 Clutch hose Tightening torque N m kgf m ft lb 2 Bracket A 8 Washer T1 8 0 8 5 8 3 Master cylinder ASSY 9 Operating cylinder T2 15 1 5 10 8 4 Clutch pipe T3 18 1 8 13 0 5 Clamp T4 25 2 5 18 1 6...

Page 2562: ...YLINDER NON TURBO MODEL 1 Reservoir cap 6 Return spring Tightening torque N m kgf m ft lb 2 Reservoir tank 7 Piston T 10 1 0 7 3 Oil seal 8 Push rod 4 Straight pin 9 Piston stop ring 5 Master cylinder...

Page 2563: ...rvoir cap 7 Gasket Tightening torque N m kgf m ft lb 2 Reservoir tank 8 Return spring T1 10 1 0 7 3 Oil seal 9 Piston T2 46 6 4 75 34 4 4 Straight pin 10 Push rod 5 Master cylinder 11 Piston stop ring...

Page 2564: ...16 Assist bushing 27 Clutch switch With cruise control 6 Brake pedal 17 Assist rod B 7 Clevis pin 18 Spring A If equipped Tightening torque N m kgf m ft lb 8 Brake pedal spring 19 Rod If equipped T1...

Page 2565: ...ing A If equipped 19 Adjusting bolt 4 Bushing C 12 Rod If equipped 5 Clutch clevis pin 13 Bushing B If equipped Tightening torque N m kgf m ft lb 6 Assist rod A 14 Clip If equipped T1 8 0 8 5 8 7 Clip...

Page 2566: ...s hot after running Use SUBARU genuine fluid grease etc or the equivalent Do not mix fluid grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolt...

Page 2567: ...tion of flywheel when loos ening tightening bolt etc 499747100 CLUTCH DISC GUIDE Used when removing and installing clutch disc to flywheel 499057000 TORX PLUS Used for removing and installing flywheel...

Page 2568: ...ving clutch cover 2 EXCEPT EUROPE AND AUSTRALIA NON TURBO MODELS AND TURBO MOD EL 1 Remove transmission assembly from vehicle body Ref to MT 32 REMOVAL Manual Trans mission Assembly 2 Install ST on fl...

Page 2569: ...ST end into the pilot bearing NOTE When installing clutch disc be careful its direction ST 499747100 CLUTCH DISC GUIDE 2 Install clutch cover on flywheel and tighten bolts to the specified torque NOT...

Page 2570: ...cleaning fluid Europe and Australia Non Turbo models Except Europe and Australia Non Turbo models and Turbo model 2 Hardened facing Correct by using emery paper or replace 3 Oil soakage on facing Rep...

Page 2571: ...d torsion spring fail ure Replace defective parts Europe and Australia Non Turbo models Except Europe and Australia Non Turbo models and Turbo model 2 CLUTCH COVER NOTE Visually check for the followin...

Page 2572: ...face of pres sure plate 4 Loose strap plate setting bolt 5 Worn diaphragm sliding surface Europe and Australia Non Turbo models Except Europe and Australia Non Turbo models and Turbo model A Pressure...

Page 2573: ...utch Disc and Cover 3 Using ST remove flywheel ST 498497100 CRANKSHAFT STOPPER B INSTALLATION 1 EUROPE AND AUSTRALIA NON TURBO MODELS 1 Install flywheel and ST ST 498497100 CRANKSHAFT STOPPER 2 Tighte...

Page 2574: ...ND TURBO MODEL INSTALLATION Clutch Disc and Cover 4 Install transmission assembly Ref to MT 35 INSTALLATION Manual Transmission Assem bly C INSPECTION CAUTION Since this bearing is grease sealed and i...

Page 2575: ...ing a flat type screwdriver B INSTALLATION 1 NON TURBO MODEL NOTE Before or during assembling lubricate the following points with a light coat of grease Contact surface of lever and pivot Contact surf...

Page 2576: ...release bearing tab 3 Apply grease to the specified points Spline FX2200 Part No 000040901 Shaft SUNLIGHT 2 Part No 003602010 4 Insert the release fork shaft into release fork NOTE Make sure the cutou...

Page 2577: ...ent when servicing the clutch 1 Check the bearing for smooth movement by ap plying force in the radial direction Radial direction stroke 1 4 mm 0 055 in 2 Check the bearing for smooth rotation by appl...

Page 2578: ...Turbo model Turbo model 4 Remove operating cylinder from transmission Non Turbo model Turbo model B INSTALLATION 1 Install in the reverse order of removal NOTE Before installing operating cylinder ap...

Page 2579: ...cylinder en sure that clutch operates properly Ref to CL 31 Clutch Fluid Air Bleeding C INSPECTION 1 Check operating cylinder for damage If operat ing cylinder is damaged replace it 2 Check operating...

Page 2580: ...ilt B INSTALLATION 1 Install master cylinder to body and install clutch pipe to master cylinder CAUTION Check that pipe is routed properly Tightening torque T1 15 N m 1 5 kgf m 10 8 ft lb T2 18 N m 1...

Page 2581: ...40M Part No 004404003 2 To assemble the master cylinder reverse the se quence of disassembly procedure Tightening torque T 10 N m 1 0 kgf m 7 ft lb E INSPECTION If any damage deformation wear swelling...

Page 2582: ...TALLATION Install in the reverse order of removal NOTE Bleed clutch fluid Ref to CL 31 Clutch Fluid Air Bleeding Tightening torque T1 15 N m 1 5 kgf m 10 8 ft lb T2 18 N m 1 8 kgf m 13 0 ft lb C INSPE...

Page 2583: ...clutch reser voir tank filled with brake fluid to eliminate entry of air Clutch pedal operating must be very slow For convenience and safety it is advisable to have two men working The amount of brake...

Page 2584: ...te cloth when loosening it to prevent brake fluid from being splashed over surrounding parts NOTE During bleeding operation keep the clutch reser voir tank filled with brake fluid to eliminate entry o...

Page 2585: ...operating cylinder when performing this procedure 6 Repeat these steps until there are no more air bubbles in the vinyl tube CAUTION Cover the bleeder with waste cloth when loos ening it to prevent b...

Page 2586: ...ble from PHV NOTE Carefully protect boot and inner cable from damage when disconnecting PHV cable 7 Remove nut which secures clutch master cylin der 8 Remove bolts and nuts which secure brake and clu...

Page 2587: ...it with a new one Never fail to cover outer cable end with boot Be careful not to kink accelerator cable Always use new clevis pins 2 Adjust clutch pedal Ref to CL 37 ADJUST MENT Clutch Pedal 3 Adjus...

Page 2588: ...4 Remove clutch pedal from clutch pedal bracket 5 Remove following parts B to G from clutch ped al bracket A as shown in figure A Pin B Lever A Clutch pedal B Bushing A Clip If equipped B Bushing S I...

Page 2589: ...Install pad stopper bushing C spacer and bushing to clutch pedal 3 Install rod S spring S bushing S clip bushing clutch switch and bushing C to clutch pedal brack et 4 Install clutch pedal to pedal b...

Page 2590: ...st 1 Ensure that the clutch pedal contacts stop per bolt when releasing the clutch pedal 2 Ensure that the clutch pedal contacts clutch pedal bracket stopper when fully depressing the clutch pedal 5 T...

Page 2591: ...Ref to CL 40 IN STALLATION Clutch Switch 2 RHD MODEL 1 Measure the full stroke amount of clutch pedal NOTE Measure the length between seat cushion front end and center portion of clutch pedal Slide t...

Page 2592: ...lengthen arrow direction as shown in the figure 8 Move the clevis pin in lateral direction to ensure it moves smoothly 9 Tighten the push rod lock nut Tightening torque Clutch stopper nut 10 N m 1 0 k...

Page 2593: ...l 4 Connect clutch switch connector C INSPECTION 1 Check the clutch switch continuity If continuity is not as specified replace the switch 1 Disconnect the clutch switch connector 2 Measure the resist...

Page 2594: ...n shifting into the first gear However because much trou ble of this sort is due to defective synchronization mecha nism carry out the test as described after Method of testing Ref to CL 42 DIAGNOSTIC...

Page 2595: ...e Step Value Yes No 1 CHECK GEAR NOISE 1 Start the engine 2 Disengage the clutch and shift quickly from neutral to reverse in idling condition Is an abnormal noise heard from the transmission gears Go...

Page 2596: ...Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is ne...

Page 2597: ......

Page 2598: ...FS Page 1 General Description 2 2 Wheel Alignment 6 3 Front Transverse Link 14 4 Front Ball Joint 16 5 Front Strut 17 6 Front Stabilizer 21 7 Front Crossmember 22 8 Front Support Arm 23 9 General Dia...

Page 2599: ...lerance 0 30 0 05 0 05 0 25 0 15 Caster 3 05 2 50 2 40 3 10 Toe in 0 3 mm 0 0 12 in Each toe angle 0 15 Kingpin angle 14 15 14 15 13 30 14 30 Wheel arch height Tolerance 12 24 mm 0 47 0 94 in 388 mm 1...

Page 2600: ...ont 22 Dust cover T6 50 5 1 37 8 Ball joint 23 Helper T7 55 5 6 41 9 Transverse link 24 Coil spring T8 70 7 1 51 10 Cotter pin 25 Damper strut T9 100 10 2 74 11 Front bushing 26 Adjusting bolt T10 125...

Page 2601: ...nstallation disassembly and replacement Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners inclu...

Page 2602: ...000 PLATE 2 28199AC010 BOLT 927680000 INSTALLER REMOVER SET Used for replacing transverse link bushing 927760000 STRUT MOUNT SOCKET Used for disassembling and assembling strut and shock mount TOOL NAM...

Page 2603: ...tire run out ball joint excessive play wear tie rod end excessive play wear wheel bearing excessive play right and left wheel base imbalance steering link part deformed excessive play suspension part...

Page 2604: ...l 5 Measure distance between measuring point A and center of wheel Model for Australia 431 12 24 mm 16 97 0 47 0 94 in 1 Front fender 4 Front wheel arch height 7 Measuring point 2 Outer rar quarter 5...

Page 2605: ...cription Rear Ref to RS 2 SPECIFICATIONS General Description Front Camber Adjustment 1 Loosen two self locking nuts located at lower front portion of strut CAUTION When adjusting bolt needs to be loos...

Page 2606: ...f the wheel and then in stall the wheel alignment gauge ST 927380002 ADAPTER 3 Follow the wheel alignment gauge operation manual to measure the caster angle NOTE Refer to the SPECIFICATIONS for the ca...

Page 2607: ...s line up with front sides at height corresponding to center of spindles 4 Measure distance B between left and right marks Toe in can then be obtained by the follow ing equation A B Toe in Adjustment...

Page 2608: ...cking nut on inner side of link rear CAUTION When loosening or tightening adjusting bolt hold bolt head and turn self locking nut Discard loosened self locking nut and re place with a new one 2 Turn a...

Page 2609: ...lly in toe out direction in order to make thrust angle adjust ment 3 When left and right adjusting bolts are turned in crementally by one graduation in the same direc tion the thrust angle will change...

Page 2610: ...EEL ALIGNMENT Thrust angle r 2 Right rear wheel toe in angle Left rear wheel toe in angle NOTE Here use only positive toe in values from each wheel to substitute for and in the equation 1 Front 2 Body...

Page 2611: ...dy NOTE These bolts should be tightened to such an extent that they can still move back and forth in the oblong shaped hole in the bracket which holds the bush ing 2 Install bolts used to connect tran...

Page 2612: ...Install front bushing in correct direction as shown in figure 2 REAR BUSHING 1 Install rear bushing to transverse link and align aligning marks scribed on the two 2 Tighten self locking nut CAUTION D...

Page 2613: ...ud end then insert new cotter pin and bend it around castle nut 4 Install front wheel C INSPECTION 1 Measure free play of ball joint by the following procedures Replace with a new one when the free pl...

Page 2614: ...curing strut mount to body B INSTALLATION 1 Install strut mount at upper side of strut to body and tighten with nuts Tightening torque 20 N m 2 0 kgf m 14 5 ft lb 2 Position aligning mark on camber ad...

Page 2615: ...While holding the piston rod end with finger tips move the rod up and down 4 If the piston rod moves at least 10 mm 0 39 in in the former step purge air from the strut 3 Air purging procedure 1 Place...

Page 2616: ...iston rod Measure the play as follows Fix outer shell and fully extend the rod Set a dial gauge at the end of the rod L 10 mm 0 39 in then apply a force of W 20 N 2 kgf 4 lb to threaded portion With t...

Page 2617: ...fore disposal of strut Before handling gas filled struts be sure to wear goggles to protect eyes from gas oil and or filings 1 Place the gas filled strut A on a flat and level surface with piston rod...

Page 2618: ...ligning it with paint mark on stabilizer Ensure that bushing and stabilizer have the same identification colors when installing 2 Always tighten rubber bushing location when wheels are in full contact...

Page 2619: ...r along with steering gearbox CAUTION When removing crossmember downward be careful that tie rod end does not interfere with SFJ boot B INSTALLATION 1 Install in the reverse order of removal CAUTION A...

Page 2620: ...up plate 5 Remove the two nuts at both ends of the arm re spectively B INSTALLATION Install in the reverse order of removal Tightening torque Front support arm to crossmember 30 N m 3 1 kgf m 22 1 ft...

Page 2621: ...r replace coil springs with new ones 4 Fault in operation of damper strut and or shock absorber Replace 5 Damage or deformation of strut mount and or shock absorber mount Replace 6 Unsuitability of ma...

Page 2622: ...Description 2 2 Wheel Alignment 8 3 Rear Stabilizer 9 4 Rear Arm 10 5 Link Upper 14 6 Rear Shock Absorber 16 7 Link Front 18 8 Link Rear 19 9 Support Sub Frame Front 21 10 Rear Sub Frame 22 11 Helper...

Page 2623: ...sion parts and connections for deformities replace with new ones as required Model Sedan Wagon OUTBACK TURBO 2 0 L 2 0 L 2 5 L Except Australia Australia Australia Rear Camber Tolerance 0 45 0 30 0 20...

Page 2624: ...k front T5 65 6 6 48 7 Link rear 21 Rear sub frame T6 80 8 2 59 8 Adjusting bolt 22 Support sub frame RH T7 120 12 2 88 9 Link rear bushing 23 Support sub frame LH T8 150 15 3 111 10 Adjusting washer...

Page 2625: ...ESCRIPTION 2 SHOCK ABSORBER 1 Mount 4 Coil spring Tightening torque N m kgf m ft lb 2 Rubber seat upper 5 Shock absorber T1 30 3 1 22 4 3 Dust cover 6 Self locking nut T2 35 3 6 26 T3 160 16 3 118 RS...

Page 2626: ...g bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces before installation Before installing O rings or sna...

Page 2627: ...g 20099AE020 INSTALLER REMOVER SET Used for replacing rear arm front bushing 20099AE040 INSTALLER REMOVER SET Used for replacing rear arm rear bushing 20099AE030 HELPER SOCKET WRENCH Used for replacin...

Page 2628: ...shock mount TOOL NAME REMARKS Alignment gauge Used for wheel alignment measurement Turning radius gauge Used for wheel alignment measurement Toe in gauge Used for toe in measurement Transmission jack...

Page 2629: ...rear wheel alignment must be mea sured and or adjusted at once to obtain accuracy Measure and or adjust the rear wheel alignment to gether with the front Follow the procedure in FS section Wheel Align...

Page 2630: ...se order of removal NOTE Ensure that bushing and stabilizer have the same identification colors when installing CAUTION Discard old self locking nut and replace with a new one Tightening torque Stabil...

Page 2631: ...t Bearing 4 Remove bolt securing parking brake cable clamp to rear arm 5 Remove bolt securing brake hose to rear arm 6 Remove bolt securing ABS sensor to rear arm 7 Suspend the back plate from sub fra...

Page 2632: ...ar ing 4 Install bolt securing ABS sensor to rear arm 5 Install bolt securing brake hose to rear arm 6 Install bolt securing parking brake cable clamp to rear arm 7 Place jack furnished with vehicle u...

Page 2633: ...f bushing then press bushing out of position 2 REAR BUSHING Using ST C and bearing puller press rear bushing out of place ST C 20099AE040INSTALLER REMOVER SET D ASSEMBLY 1 FRONT BUSHING 1 Using ST A B...

Page 2634: ...ress bushing into rear arm ST C D 20099AE040INSTALLER REMOVER SET 1 Insert bushing into bore in ST D 2 Set ST C ST D and bearing puller in posi tion as shown in the figure and press bushing into posit...

Page 2635: ...of removal observing the following instructions CAUTION Using transmission jack support rear arm horizontally install link upper and tighten nuts to specified torque Tighten nut when installing adjust...

Page 2636: ...press bushing into place ST 20099AE010 INSTALLER REMOVER CAUTION Outer bushing has a directional design Be sure to install bushing with longer inner hous ing side facing vehicle rear E INSPECTION Vis...

Page 2637: ...loor mat Wagon mod el 3 Detach trunk mat Sedan model 4 Roll up the trunk side trim Sedan model 5 Remove bolt securing shock absorber to rear arm 6 Use a jack to support the shock absorber 7 Remove nut...

Page 2638: ...n model 7 Install trunk mat Sedan model NOTE Check wheel alignment and adjust if necessary C DISASSEMBLY For disassembly of shock absorber refer to proce dures outlined under front strut as a guide Re...

Page 2639: ...single unit B INSTALLATION Install in the reverse order of removal observing the following instructions CAUTION Using transmission jack support rear arm horizontally install link front and tighten nut...

Page 2640: ...stabilizer link 5 Use transmission jack to support rear arm hori zontally 6 Remove bolt securing link rear to rear arm 7 Scribe an alignment mark on link rear adjusting bolt and sub frame 8 Remove bol...

Page 2641: ...Tighten nut when installing adjusting bolt Replace self locking nut NOTE Check wheel alignment and adjust if necessary C DISASSEMBLY Using ST A B press bushing out of place ST A B 20099AE000INSTALLER...

Page 2642: ...ar sub frame 2 Remove support sub frame front B INSTALLATION 1 Install in reverse order of removal Tightening torque Support sub frame front to rear arm bracket 80 N m 8 2 kgf m 59 ft lb Support sub f...

Page 2643: ...rame 8 Remove support sub frame front 9 After removing bolts remove sub frame and support sub frame from vehicle body B INSTALLATION 1 Install in reverse order of removal 2 For installation and tighte...

Page 2644: ...e vehicle support it with safety stands rigid racks 2 Using ST remove helper ST 20099AE030 HELPER SOCKET WRENCH B INSTALLATION Install in the reverse order of removal Tightening torque 32 N m 3 3 kgf...

Page 2645: ...r replace coil springs with new ones 4 Fault in operation of damper strut and or shock absorber Replace 5 Damage or deformation of strut mount and or shock absorber mount Replace 6 Unsuitability of ma...

Page 2646: ...WHEEL AND TIRE SYSTEM WT Page 1 General Description 2 2 Tire 4 3 Steel Wheel 5 4 Aluminum Wheel 6 5 Wheel Balancing 7 6 T type Tire 8 7 Full Wheel Cap 9 8 General Diagnostic Table 10...

Page 2647: ...70 D16 16 4T 50 mm 1 97 in Tire size Tire inflation pressure kPa kg cm2 psi Light load Full load Trailler towing 2 0 L model Front and Rear 195 60R15 88V Ft 220 2 2 32 Rr 210 2 1 30 Ft 220 2 2 32 Rr...

Page 2648: ...71 oz 28101AA041 25 g 0 88 oz 28101AA051 30 g 1 06 oz 28101AA061 35 g 1 23 oz 28101AA071 40 g 1 41 oz 28101AA081 45 g 1 59 oz 28101AA091 50 g 1 76 oz 55 g 1 94 oz 28101AA111 60 g 2 12 oz Balance weigh...

Page 2649: ...read is found 2 When the tread wear indicator appears as a solid band across the tread 3 When extremely biased wear on tire tread can been seen after replacing tire check wheel align ment Ref to FS 6...

Page 2650: ...tightening torque 88 N m 9 kgf m 65 ft lb CAUTION Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally until the specified torque is reached For drum...

Page 2651: ...heir appearance and safety do the following 1 Do not damage aluminum wheels during remov al disassembly installation wheel balancing etc After removing aluminum wheels place them on a rubber mat etc 2...

Page 2652: ...justing the wheel balance 4 Use genuine balance weights CAUTION Balance weights are available for use with any of 14 to 17 inch wheels Service limit A Weight for steel wheel 2 16 mm 0 085 in Weight fo...

Page 2653: ...eater than 80 km h 50 MPH Drive as slowly as possible and avoid pass ing over bumps B REPLACEMENT Refer to Removal and Installation of Steel Wheel for removal installation of T type tires Ref to WT 5...

Page 2654: ...over inserted between openings in the cap B INSTALLATION Align the valve hole in the wheel cap with the valve on the wheel and secure the wheel cap by tapping four points by hand C INSPECTION 1 Check...

Page 2655: ...mptom Possible cause Remedy Front wheel shimmy Worn or improperly inflated of tire Replace Wheel is out of balance Adjustment Abnormal tire wear Improperly inflated of tire Replace Sways pitches Worn...

Page 2656: ...cription 2 2 Differential Gear Oil 22 3 Front Differential 23 4 Rear Differential for T type 24 5 Rear Differential for VA type 41 6 Rear Differential Front Oil Seal 58 7 Rear Differential Front Membe...

Page 2657: ...ralia Except Australia Rear differential type VA type T type XJ T1 JP With LSD T2 VB Gear ratio Number of gear teeth 4 111 37 9 3 900 39 10 4 111 37 9 3 700 37 10 Oil capacity 0 8 2 0 8 US qt 0 7 lmp...

Page 2658: ...85W 80W 75W 90 25 30 5 0 22 15 23 32 86 59 77 5 Front and rear bearing preload at companion flange bolt hole N kgf lb New bearing T type 19 6 28 4 2 0 2 9 4 4 6 4 VA type 12 7 32 4 1 3 3 3 2 9 7 3 Us...

Page 2659: ...in 38336AA160 1 613 mm 0 0635 in 38336AA050 1 625 mm 0 0640 in 38336AA170 1 638 mm 0 0645 in 38336AA060 1 650 mm 0 0650 in 38336AA180 1 663 mm 0 0655 in 38336AA070 1 675 mm 0 0659 in 38336AA190 1 688...

Page 2660: ...Pinion height adjusting shim 383495200 3 09 mm 0 1217 in 383505200 3 12 mm 0 1228 in 383515200 3 15 mm 0 1240 in 383525200 3 18 mm 0 1252 in 383535200 3 21 mm 0 1264 in 383545200 3 24 mm 0 1276 in 383...

Page 2661: ...eload adjusting washer 19 Side gear Tightening torque N m kgf m ft lb 6 Differential carrier 20 Pinion mate gear T1 10 3 1 05 7 6 7 Front bearing 21 Pinion mate gear washer T2 29 4 3 00 21 7 8 Collar...

Page 2662: ...sting spacer 15 Side bearing retainer shim Tightening torque N m kgf m ft lb 5 Bearing preload adjusting washer 16 Side bearing retainer T1 10 3 1 05 7 6 6 Differential carrier 17 Side oil seal T2 29...

Page 2663: ...r 18 Side gear thrust washer 6 Differential carrier 19 Side gear Tightening torque N m kgf m ft lb 7 Front bearing 20 Pinion mate gear T1 25 2 5 18 1 8 Collar 21 Pinion shaft lock pin T2 34 3 5 25 3 9...

Page 2664: ...FFERENTIAL MOUNTING SYSTEM 1 Rear differential front member 5 Sub frame Tightening torque N m kgf m ft lb 2 Protector T1 65 6 6 48 3 Rear differential member plate T2 70 7 1 51 4 Rear differential ASS...

Page 2665: ...ause each part on the vehicle is hot after running Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers Be sur...

Page 2666: ...HANDLE Used for installing front and rear bearing cone 398477702 DRIFT Used press fitting the bearing cone of differential carrier front 398217700 ATTACHMENT SET Stand for rear differential carrier di...

Page 2667: ...k nut 398467700 DRIFT Used for removing pinion pilot bearing and front bearing cone 399780104 WEIGHT Used for installing front bearing cone pilot bear ing companion flange 899580100 INSTALLER Used for...

Page 2668: ...ing backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used measuring backlash between side gear and pinion hypoid gear Used with MAGNET BASE 498...

Page 2669: ...Used for installing rear bearing cone For T type 398457700 ATTACHMENT Used for removing side bearing retainer For T type 398477703 DRIFT 2 Used for press fitting the bearing race rear of differential...

Page 2670: ...DUMMY SHAFT Used for adjusting pinion height and preload For T type 398507703 DUMMY COLLAR Used for adjusting pinion height and preload For T type 398517700 REPLACER Used for removing rear bearing co...

Page 2671: ...usting pinion height For T type 398527700 PULLEY ASSY Used for removing oil seal and side bearing cup For T type 399527700 PULLER SET Used for extracting side bearing cone 1 BOLT 2 PULLER 3 HOLDER 4 A...

Page 2672: ...oil seal For T type 398237700 GAUGE Used for installing side bearing For T type 28099PA100 DRIVE SHAFT REMOVER Used for removing rear drive shaft from rear differential For T type 498175500 INSTALLER...

Page 2673: ...type 498447100 INSTALLER Used for installing oil seal For VA type 399520105 SEAT Used for removing side bearing cone Used with PULLER SET 899524100 For VA type 498485400 DRIFT Used for installing side...

Page 2674: ...ed for press fitting the bearing race front of differential carrier For VA type 498447150 DUMMY SHAFT Used for adjusting pinion height and pre load For VA type 32285AA000 DUMMY COLLAR Used for adjusti...

Page 2675: ...for removing side bearing race Used with SEAT 499705404 For VA type 899874100 INSTALLER Used for installing companion flange For VA type 899524100 DIFFERENTIAL BEARING PULLER SET Used for removing si...

Page 2676: ...OSE TOOLS TOOL NAME REMARKS Transmission Jack Used for assembly disassembly of rear differential Puller Used for removal of side bearing retainer T type Thickness Gauge Used for measuring clearance Ti...

Page 2677: ...NOTE Apply fluid packing to drain plug in T type VA type uses a new aluminum gasket Fluid packing THREE BOND 1105 Part No 004403010 or equivalent Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft lb...

Page 2678: ...ferential A NOTE 1 AT MODEL For front differential of automatic transmission re fer to AT section Ref to AT 124 Front Differen tial 2 MT MODEL For front differential of manual transmission refer to MT...

Page 2679: ...r If equipped 9 Remove propeller shaft Ref to DS 14 REMOVAL Propeller Shaft 10 Prepare a transmission jack and a band 11 Loosen self locking nuts connecting rear differ ential to rear crossmember 12 R...

Page 2680: ...ut axle shaft from rear differential NOTE If axle shaft is difficult to remove from rear differen tial use ST to remove it ST 28099PA100 DRIVE SHAFT REMOVER 21 Take down transmission jack 22 Secure re...

Page 2681: ...rear dif ferential stud bolt is properly inserted into rear crossmember bushing 8 After rear differential stud bolt has been inserted into rear crossmember bushing raise transmission jack to make jac...

Page 2682: ...19 Tighten filler plug NOTE Apply fluid packing to plug Fluid packing THREE BOND 1105 Part No 04403010 or equivalent Tightening torque 49 0 N m 5 0 kgf m 36 2 ft lb C DISASSEMBLY To detect real cause...

Page 2683: ...TION Be careful not to hit the teeth against the case 7 Remove O ring from side bearing retainer 8 Remove oil seal from side bearing retainer 9 When replacing side bearing pull bearing cup from side b...

Page 2684: ...E The gears as well as thrust washers should be marked or kept separated left and right and front and rear 14 Hold companion flange with ST and remove drive pinion nut ST 498427200 FLANGE WRENCH 15 Ex...

Page 2685: ...Y NOTE Assemble in the reverse order of disassembling Check and adjust each part during assembly Keep the shims and washers in order so that they are not misinstalled Thoroughly clean the surfaces on...

Page 2686: ...justing spacer and washer front bearing cone ST2 companion flange and washer and drive pinion nut ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR 5 Turn ST1 with hand to make it seated and tighte...

Page 2687: ...tween the case and ST2 ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE Preload adjusting washer Part No Thickness mm in 383705200 2 59 0 1020 383715200 2 57 0 1012 383725200 2 55 0...

Page 2688: ...ng cone into case with ST1 ST2 and ST3 ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER T Thickness of pinion height adjusting shim mm in To Thickness of shim temporarily insert...

Page 2689: ...ge bearing ST1 899874100 INSTALLER ST2 399780104 WEIGHT 9 Install new self locking nut fix companion flange with ST and then tighten ST 498427200 FLANGE WRENCH Tightening torque 181 N m 18 5 kgf m 134...

Page 2690: ...7700 DRIFT NOTE When replacing bearing cone replace it with bear ing cap as a set 13 Install bearing cup to side bearing retainer NOTE Press in while be careful not to scratch bearing cup and side bea...

Page 2691: ...nge adjust side retainer shim with the following procedure When backlash is more than 0 20 mm 0 0079 in Reduce shim thickness on crown gear back in crease shim thickness on crown gear side When backla...

Page 2692: ...2 When the contact pattern is incorrect read just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be sure to wipe off red lead completely after adjust ment is completed Correct toot...

Page 2693: ...ing item Contact area is small Contact pattern Corrective action Increase thickness of drive pin ion height adjusting shim in order to bring drive pin ion close to crown gear 19 If proper tooth contac...

Page 2694: ...mate gear Replace if crack score or other defects are evi dent on tooth surface Replace if thrust washer contacting surface is worn or seized Slight damage of the surface can be corrected by oil ston...

Page 2695: ...ef to DI 30 ASSEMBLY Rear Differ ential for T type 5 TOTAL PRELOAD Using a gauge check the turning resistance in crease Turning resistance increase 2 9 10 8 N 0 3 1 1 kgf 0 7 2 4 lb If the increase of...

Page 2696: ...eld cover 9 Remove propeller shaft Ref to DS 14 REMOVAL Propeller Shaft 10 Prepare a transmission jack and a band 11 Loosen self locking nuts connecting rear differ ential to rear crossmember 12 Remov...

Page 2697: ...lateral link bolt 21 Pull out axle shaft from rear differential NOTE If axle shaft is difficult to remove from rear differen tial use a tire lever to remove it 22 Take down transmission jack 23 Secure...

Page 2698: ...rear dif ferential stud bolt is properly inserted into rear crossmember bushing 8 After rear differential stud bolt has been inserted into rear crossmember bushing raise transmission jack to make jack...

Page 2699: ...l cause of trouble inspect the follow ing items before disassembling Tooth contact of crown gear and pinion and backlash Runout of crown gear at its back surface Turning resistance of drive pinion 1 S...

Page 2700: ...SSY ST2 499705404 OUTER RACE PULLER SEAT 9 Remove oil seal from right and left holders with screwdriver 10 Extract bearing cone with ST1 and ST2 NOTE Do not attempt to disassemble the parts unless nec...

Page 2701: ...ust washers should be marked or kept separated left and right and front and rear 14 Hold companion flange with ST and remove self locking nut ST 498427200 FLANGE WRENCH 15 Extract the companion flange...

Page 2702: ...e reverse order of disassembling Check and adjust each part during assembly Keep the shims and washers in order so that they are not misinstalled Thoroughly clean the surfaces on which the shims washe...

Page 2703: ...d and re use the used washer 5 Then install preload adjusting spacer and washer front bearing cone ST2 companion flange and washer and self locking nut ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY C...

Page 2704: ...00 1 500 0 0591 38336AA120 1 513 0 0596 38336AA010 1 525 0 0600 38336AA130 1 538 0 0606 38336AA020 1 550 0 0610 38336AA140 1 563 0 0615 38336AA030 1 575 0 0620 38336AA150 1 588 0 0625 38336AA040 1 600...

Page 2705: ...ion and press the rear bearing cone into position with ST ST 498175500 INSTALLER 4 Insert drive pinion into differential carrier install the previously selected bearing preload adjusting spacer and wa...

Page 2706: ...and pinion mate shaft into differen tial case NOTE Apply gear oil on both sides of the washer and on the side gear shaft before installing Insert the pinion mate shaft into the differential case by al...

Page 2707: ...00 DRIFT 12 Assemble holders 1 Install oil seal into right and left holders ST 498447100 AXLE SHAFT OIL SEAL IN STALLER 2 Install bearing race into right and left hold ers ST 398477702 BEARING OUTER R...

Page 2708: ...carri er Align contact point of dial gauge with tooth face of crown gear and move crown gear while holding drive pinion still Read value indicated on dial gauge NOTE If measured backlash is not withi...

Page 2709: ...correct read just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be sure to wipe off red lead completely after adjust ment is completed Correct tooth contact Checking item Tooth con...

Page 2710: ...cking item Contact area is small Contact pattern Corrective action Increase thickness of drive pin ion height adjusting shim in order to bring drive pin ion close to crown gear NOTE Be sure to wipe of...

Page 2711: ...ling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washers of side gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5...

Page 2712: ...t tooth contact between crown gear and drive pinion Ref to DI 47 ASSEMBLY Rear Differential for VA type F ADJUSTMENT 1 SIDE GEAR BACKLASH Adjust side gear backlash Ref to DI 47 ASSEMBLY Rear Different...

Page 2713: ...es a new aluminum gasket Fluid packing THREE BOND 1105 Part No 004403010 or equivalent Tightening torque T type 49 N m 5 0 kgf m 36 2 ft lb VA type 34 N m 3 5 kgf m 25 3 ft lb 6 Jack up rear wheels an...

Page 2714: ...nion flange 15 Tighten self locking nut within the specified torque range so that the turning resistance of com panion flange becomes the same as that before re placing oil seal ST 498427200 FLANGE WR...

Page 2715: ...rential front member Tightening torque T1 65 N m 6 6 kgf m 48 ft lb T2 110 N m 11 2 kgf m 81 ft lb C INSPECTION 1 Check rear differential front member for dam age bend or corrosion If damage bend or c...

Page 2716: ...r Loose bolts and nuts such as crown gear bolt Retighten Damage due to overloading Replace 4 Noises when starting or shifting gears NOTE Noises may be caused by differential as sembly universal joint...

Page 2717: ...DI 62 DIFFERENTIALS GENERAL DIAGNOSTIC TABLE MEMO...

Page 2718: ...4 4 Oil Seal 5 5 Transfer Drive Gear MT 6 6 Transfer Driven Gear MT 7 7 Reduction Drive Gear without VTD 8 8 Reduction Drive Gear with VTD 9 9 Reduction Driven Gear without VTD 10 10 Reduction Driven...

Page 2719: ...TRANSFER CASE GENERAL DESCRIPTION 1 General Description A NOTE For general description refer to AT section or MT section AT model Ref to AT 2 General Description MT model Ref to MT 2 General Descript...

Page 2720: ...SFER CASE TRANSFER CASE AND EXTENSION FOR MT 2 Transfer Case and Extension for MT A NOTE For removal installation and inspection work refer to MT section Ref to MT 47 Transfer Case and Extension Case...

Page 2721: ...TC 4 TRANSFER CASE TRANSFER CLUTCH AND EXTENSION FOR AT 3 Transfer Clutch and Exten sion for AT A NOTE For removal installation and inspection work refer to AT section Ref to AT 90 Transfer Clutch...

Page 2722: ...C 5 TRANSFER CASE OIL SEAL 4 Oil Seal A NOTE For removal installation and inspection work refer to AT section or MT section AT model Ref to AT 48 Extension Case Oil Seal MT model Ref to MT 41 Oil Seal...

Page 2723: ...TC 6 TRANSFER CASE TRANSFER DRIVE GEAR MT 5 Transfer Drive Gear MT A NOTE For removal installation and inspection work refer to MT section Ref to MT 51 Transfer Drive Gear...

Page 2724: ...TC 7 TRANSFER CASE TRANSFER DRIVEN GEAR MT 6 Transfer Driven Gear MT A NOTE For removal installation and inspection work refer to MT section Ref to MT 53 Transfer Driven Gear...

Page 2725: ...TC 8 TRANSFER CASE REDUCTION DRIVE GEAR WITHOUT VTD 7 Reduction Drive Gear without VTD A NOTE For removal installation and inspection work refer to AT section Ref to AT 104 Reduction Drive Gear...

Page 2726: ...TC 9 TRANSFER CASE REDUCTION DRIVE GEAR WITH VTD 8 Reduction Drive Gear with VTD A NOTE For removal installation and inspection work refer to AT section Ref to AT 104 Reduction Drive Gear...

Page 2727: ...TC 10 TRANSFER CASE REDUCTION DRIVEN GEAR WITHOUT VTD 9 Reduction Driven Gear with out VTD A NOTE For removal installation and inspection work refer to AT section Ref to AT 101 Reduction Driven Gear...

Page 2728: ...TC 11 TRANSFER CASE REDUCTION DRIVEN GEAR WITH VTD 10 Reduction Driven Gear with VTD A NOTE For removal installation and inspection work refer to AT section Ref to AT 101 Reduction Driven Gear...

Page 2729: ...SE CENTER DIFFERENTIAL 11 Center Differential A NOTE For removal installation and inspection work refer to AT or MT section AT model Ref to AT 106 Center Differential Carrier MT model Ref to MT 55 Cen...

Page 2730: ...TC 13 TRANSFER CASE TRANSFER CLUTCH PRESSURE TEST 12 Transfer Clutch Pressure Test A NOTE For transfer clutch pressure work refer to AT sec tion Ref to AT 38 Transfer Clutch Pressure Test...

Page 2731: ...FER CASE TRANSFER DUTY SOLENOID AND VALVE BODY 13 Transfer Duty Solenoid and Valve Body A NOTE For removal installation and inspection work refer to AT section Ref to AT 70 Transfer Duty So lenoid and...

Page 2732: ...DRIVE SHAFT SYSTEM DS Page 1 General Description 2 2 Propeller Shaft 14 3 Front Axle 17 4 Hub Unit Bearing 23 5 Front Drive Shaft 28 6 Rear Drive Shaft 34 7 General Diagnostic Table 38...

Page 2733: ...ATIONS 1 PROPELLER SHAFT Propeller shaft type DOJ type Front propeller shaft Joint to joint length L1 mm in AT 629 24 76 MT 688 27 09 Rear propeller shaft Joint to joint length L2 mm in 773 30 43 Outs...

Page 2734: ...FT ASSEMBLY Model Type of drive shaft assembly SHAFT Boot band identification Shaft diameter Color 2 5 L MT BJ87 SFJ82 28 mm 1 10 in Pink Except 2 5 L MT BJ87 SFJ82 26 mm 1 02 in TURBO BJ87 SFJ82 26 m...

Page 2735: ...2 5 L 3 0 L TURBO AT MT MT AT Without VDC AT With VDC Shaft 79AC 79AC RH 79AC LH 82AC RH 82AC LH No of identifica tion protrusion on shaft None 1 One 2 Two A 82AC RH D 79AC LH G Identification protru...

Page 2736: ...DRIVE SHAFT SYSTEM GENERAL DESCRIPTION B COMPONENT 1 PROPELLER SHAFT 1 Propeller shaft Tightening torque N m kgf m ft lb 2 Rear differential T1 31 3 2 23 1 3 Bushing T2 52 5 3 38 3 DS 00137 1 2 3 3 T...

Page 2737: ...Hub 3 Outer race SFJ 12 Tone wheel 21 Axle nut Olive color 4 Snap ring 13 Baffle plate 5 Trunnion 14 Oil seal IN Tightening torque N m kgf m ft lb 6 Free ring 15 Snap ring T 216 22 159 7 Circlip 16 B...

Page 2738: ...b 2 Outer race DOJ 9 Boot DOJ 16 Axle nut Olive color 3 Snap ring 10 Boot BJ 4 Inner race 11 BJ ASSY Tightening torque N m kgf m ft lb 5 Ball 12 Tone wheel T1 66 6 7 48 5 6 Cage 13 Hub unit bearing T2...

Page 2739: ...careful not to burn your hands because each part on the vehicle is hot after running Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other man...

Page 2740: ...sed for installing axle shaft into housing Used with ADAPTER 927390000 925091000 BAND TIGHTEN ING TOOL Used for tightening boot band A Jig for band B Ratchet wrench 926470000 AXLE SHAFT PULLER Used fo...

Page 2741: ...for disassembling and assembling front housing bearing Used with HOUSING STAND 927400000 927140000 AXLE SHAFT PULLER PLATE Same as plate 2 included in AXLE SHAFT PULLER 926470000 927390000 ADAPTER Us...

Page 2742: ...PULLER 927100000 927410000 OIL SEAL INSTALLER Used for installing oil seal into front housing Used with HOUSING STAND 927400000 398507703 DUMMY COLLAR Used for removing hub ASSY from hub unit 39952010...

Page 2743: ...alling hub 927450000 HUB INSTALLER Used for installing hub unit into hub ASSY Used with BEARING SPACER 28499AE000 and HUB STAND 927080000 28099PA090 OIL SEAL PRO TECTOR Used for installing rear drive...

Page 2744: ...ar differ ential 28099AC000 BOOT BAND PLI ERS Used for tightening front BJ boot band TOOL NAME REMARKS Puller Used for removing ball joint from knuckle arm Dial Gauge Used for inspecting propeller sha...

Page 2745: ...ake 4 Jack up vehicle and support it with sturdy racks 5 Remove center exhaust pipes 6 Remove rear exhaust pipe and muffler 7 Remove heat shield cover 8 Put matching marks on propeller shaft and rear...

Page 2746: ...Tube surfaces for dents or cracks 2 Splines for deformation or abnormal wear 3 Joints for non smooth operation or abnormal noise 4 Center bearing for free play noise or non smooth operation 5 Oil sea...

Page 2747: ...runout with a dial gauge at the center of front and rear propeller shaft tubes Runout Limit 0 6 mm 0 024 in 4 CENTER BEARING FREE PLAY 1 Remove front and center exhaust pipes 2 Remove rear exhaust pip...

Page 2748: ...heel bearings 5 Remove stabilizer link 6 Remove disc brake caliper from housing and suspend it from strut using a wire 7 Remove disc rotor from hub If disc rotor seizes up within hub drive disc rotor...

Page 2749: ...ing bolt head remove bolts which connect housing and strut and disconnect housing from strut B INSTALLATION 1 While aligning alignment mark on camber ad justing bolt head connect housing and strut CAU...

Page 2750: ...ged Be sure to tighten axle nut to specified torque Do not overtighten it as this may dam age wheel bearing 11 After tightening axle nut lock it securely 12 Install wheel and tighten wheel nuts to spe...

Page 2751: ...Using ST2 press inner race to drive out outer bearing ST1 927400000 HOUSING STAND ST2 927100000 BEARING REMOVER CAUTION Do not remove outer race unless it is faulty Discard outer race after removal Do...

Page 2752: ...s outer race when installing bear ing Be careful not to remove plastic lock from in ner race when installing bearing Charge bearing with new grease when outer race is not removed Specified grease SHEL...

Page 2753: ...ening torque 18 N m 1 8 kgf m 13 0 ft lb 11 Attach hub to ST1 securely 12 Clean dust or foreign particles from the pol ished surface of hub 13 Using ST2 press bearing into hub by driving in ner race S...

Page 2754: ...ABS sensor 7 Remove brake caliper from back plate and sus pend it from stabilizer using a piece of wire 8 Remove disc rotor from hub NOTE Before removing disc rotor mark the matching surface of hub an...

Page 2755: ...3 Remove axle nut 4 Using ST1 and ST2 pull axle shaft into place ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER 5 Temporarily tighten axle nuts 6 Install disc rotor on hub 7 Install disc br...

Page 2756: ...ore installing wheel on vehicle If wheel is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged Be sure to tighten axle nut to specified torque Do not overt...

Page 2757: ...hammer hub bolts This may deform hub D ASSEMBLY 1 Using ST press new hub bolt into place CAUTION Ensure hub bolt closely contacts hub Use a 12 mm 0 47 in hole in the ST to pre vent hub bolt from tilt...

Page 2758: ...DS 27 DRIVE SHAFT SYSTEM HUB UNIT BEARING E INSPECTION Check the removed parts for wear and damage If defective replace with new ones CAUTION If a bearing is faulty replace it as a hub unit bearing...

Page 2759: ...d to remove use ST1 and ST2 ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE CAUTION Be careful not to damage oil seal lip and tone wheel when removing front drive shaft When front drive shaft is t...

Page 2760: ...hten it as this may dam age wheel bearing 8 After tightening axle nut lock it securely C DISASSEMBLY 1 Place alignment marks on shaft and outer race 2 Remove SFJ boot band and boot CAUTION Be careful...

Page 2761: ...t in a vise between wooden blocks CAUTION Do not place drive shaft directly in the vise use wooden block 12 Raise boot band claws by means of screwdriv er and hammer 13 Cut and remove the boot CAUTION...

Page 2762: ...rease to shaft NOTE The inside of the larger end of BJ boot and the boot groove shall be cleaned so as to be free from grease and other substances 5 Install boot projecting portion to BJ groove 6 Set...

Page 2763: ...40 g 1 06 to 1 41 oz to the entire inner surface of boot 18 Install SFJ boot taking care not to twist it CAUTION The inside of the larger end of SFJ boot and the boot groove shall be cleaned so as to...

Page 2764: ...equal grease coating E INSPECTION Check the removed parts for damage wear corro sion etc If faulty repair or replace 1 DOJ Double Offset Joint Check seizure corrosion damage wear and ex cessive play...

Page 2765: ...sert BJ into rear hub splines CAUTION Be careful not to damage tone wheel 2 Using ST1 and ST2 pull drive shaft into place ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER CAUTION Do not hammer...

Page 2766: ...ase is a special grease grease for con stant velocity joint Do not confuse with other greases NOTE Disassemble exercising care not to lose balls 6 pcs 8 To remove the cage from the inner race turn the...

Page 2767: ...nd fit snap ring with pliers NOTE Confirm that the snap ring is completely fitted in the shaft groove 5 Install cage which was previously fitted to inner race fixed upon shaft NOTE Fit the cage with t...

Page 2768: ...ening boot exercise care so that the air within the boot is appropriate 15 Tighten band by using ST ST 925091000 BAND TIGHTENING TOOL NOTE Tighten band until it cannot be moved by hand 16 Tap on the c...

Page 2769: ...ration increases in proportion to vehicle speed 1 Worn or damaged universal joint Replace 2 Unbalanced propeller shaft due to bend or dent Replace 3 Loose installation of propeller shaft Retighten 4 W...

Page 2770: ...e 1 General Description 2 2 ABS Control Module and Hydraulic Control Unit ABSCM H U 6 3 ABS Sequence Control 9 4 Front ABS Sensor 12 5 Rear ABS Sensor 15 6 Front Tone Wheel 19 7 Rear Tone Wheel 20 8 G...

Page 2771: ...mm 0 0173 0 0370 in ABS sensor resistance 1 25 0 25 k Marks of the harness Front LH Except OUTBACK Yellow OUTBACK Brown Front RH Except OUTBACK White OUTBACK Light blue Rear LH Yellow Rear RH White G...

Page 2772: ...ENT 1 SENSOR 1 G sensor 5 Tone wheel Rear Tightening torque N m kgf m ft lb 2 Clip 6 Housing T1 7 5 0 75 5 4 3 Rear ABS sensor LH 7 Front ABS sensor LH T2 33 3 3 24 4 ABS spacer 8 Tone wheel Front ABS...

Page 2773: ...t 6 Front RH outlet Tightening torque N m kgf m ft lb 2 Damper 7 Primary inlet T1 18 1 8 13 06 3 ABS control module and hydrau lic control unit 8 Rear LH outlet T2 33 3 3 24 9 Rear RH outlet T3 38 3 8...

Page 2774: ...bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect ground ca ble from...

Page 2775: ...id on vehicle body 8 Remove ABSCM H U ground terminal from bracket 9 Remove ABSCM H U from engine compart ment CAUTION ABSCM H U cannot be disassembled Do not attempt to loosen bolts and nuts Do not d...

Page 2776: ...ng and compression and then the FR side performs de compression holding and compression 7 Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression a...

Page 2777: ...nit begins to work and check the fol lowing working sequence 1 The FL wheel performs decompression holding and compression in sequence and subsequently the FR wheel repeats the cycle 2 The RR wheel pe...

Page 2778: ...MONITOR NOTE In the event of any trouble the sequence control may not be operative In such a case activate the sequence control referring to ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR Ref to ABS 9...

Page 2779: ...ve FR outlet valve RR inlet valve RR outlet valve RL inlet valve Pump motor Pressure of master cylinder Operational pressure of sequence control Operational pattern of sequence control Operational gui...

Page 2780: ...s terminals When select monitor is not used 3 When the brake pedal is released during se quence control and the braking lamp switch is set to off 4 When brake pedal is depressed after ignition key is...

Page 2781: ...CAUTION Be careful not to damage pole piece located at tip of the sensor and teeth faces during re moval Do not pull sensor harness during removal B INSTALLATION 1 Temporarily install front ABS senso...

Page 2782: ...tions adjust the gap using spacer Part No 26755AA000 4 After confirmation of the ABS sensor clearance connect connector to ABS sensor 5 Connect connector to battery ground cable C INSPECTION 1 ABS SEN...

Page 2783: ...sensor clearance B A ABS sensor standard clearance 0 3 0 8 mm 0 012 0 031 in NOTE If the clearance is outside specifications adjust the gap using spacer Part No 26755AA000 3 OUTPUT VOLTAGE Output volt...

Page 2784: ...ift up the vehicle 3 Remove fuel tank cover 4 Disconnect rear ABS sensor connector 5 Remove rear sensor harness from clip on body side 6 Remove bolts which hold rear sensor harness brackets 7 Remove r...

Page 2785: ...during removal B INSTALLATION 1 Install rear drive shaft to the vehicle Ref to DS 34 INSTALLATION Rear Drive Shaft 2 Temporarily install rear ABS sensor on rear arm CAUTION Be careful not to strike AB...

Page 2786: ...cations adjust the gap using spacer Part No 26755AA000 5 After confirmation of the ABS sensor clearance connect connector to ABS sensor and install fuel tank cover 6 Connect connector to battery groun...

Page 2787: ...sensor clearance B A ABS sensor standard clearance 0 44 0 94 mm 0 0173 0 0370 in NOTE If the clearance is outside specifications adjust the gap using spacer Part No 26755AA000 3 OUTPUT VOLTAGE Output...

Page 2788: ...Refer to Front Drive Shaft because front tone wheel is integrated with front drive shaft Ref to DS 28 INSTALLATION Front Drive Shaft C INSPECTION Visually check tone wheels teeth 44 pieces for cracks...

Page 2789: ...efer to Rear Drive Shaft because rear tone wheel is integrated with rear drive shaft Ref to DS 34 INSTALLATION Rear Drive Shaft C INSPECTION Visually check tone wheels teeth 44 pieces for cracks or de...

Page 2790: ...Box 3 Disconnect connector from G sensor 4 Remove G sensor from body CAUTION Do not drop or bump G sensor B INSTALLATION 1 Install in the reverse order of removal NOTE Do not install G sensor in the w...

Page 2791: ...terminal R70 No 2 No 3 Is the voltage within the specified value when G sensor is inclined backwards to 90 0 5 0 9 V G sensor is nor mal Replace G sensor 5 CHECK G SENSOR 1 Turn ignition switch to OF...

Page 2792: ...l Module I O Signal 12 6 Subaru Select Monitor 16 7 Read Diagnostic Trouble Code DTC 19 8 Inspection Mode 21 9 Clear Memory Mode 22 10 ABS Warning Light Illumination Pattern 23 11 List of Diagnostics...

Page 2793: ...which might influence the ABS problem Ref to ABS 8 INSPECTION General Description Is the component part that might influence the ABS problem normal Component part is normal Go to step 2 Repair or repl...

Page 2794: ...nector Ref to ABS 28 Diag nostics Chart with Diagnosis Connector NOTE For diagnostic trouble code DTC list refer to List of Diagnostics Trouble Code DTC Ref to ABS 24 WITHOUT SUBARU SELECT MONITOR LIS...

Page 2795: ...nostic trouble code DTC Ref to ABS 16 READ DIAGNOS TIC TROUBLE CODE DTC OPERA TION Subaru Select Monitor Confirm that no DTC is displayed Does ABS warning light remain off ABS warning light remains of...

Page 2796: ...K ACC ON before starting engine START On after starting Engine is running On after starting Engine is stop Timing Immediately after ignition is ON Immediately after ignition starts When advancing km h...

Page 2797: ...ity cannot be obtained or steering arm refuses to work when applying brakes Yes No When Vehicle turns to right Vehicle turns to left Spins Others b Directional stability cannot be obtained or steering...

Page 2798: ...slope Others Condition a Brakes Deceleration g Continuous Intermittent b Accelerator Acceleration g Continuous Intermittent c Vehicle speed km h MPH Advancing Accelerating Reducing speed Low speed Tur...

Page 2799: ...andard voltage 12 V or more Specific gravity Above 1 260 2 BRAKE FLUID 1 Check brake fluid level 2 Check brake fluid leakage 3 HYDRAULIC UNIT Check the hydraulic unit With brake tester Ref to ABS 8 CH...

Page 2800: ...ng for electrical systems 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without printer Sp...

Page 2801: ...c control unit ABSCM H U 5 Data link connector for Subaru select monitor 8 ABS sensor 9 Wheel cylinder 2 Proportioning valve 6 Transmission control module only AT vehicle 10 G sensor 3 Diagnosis conne...

Page 2802: ...ABS 11 ABS DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION ABS00302 1 ABS00305 4 10 ABS00303 ABS00306 7 8 ABS00304 3 5 ABS00307...

Page 2803: ...d hydraulic control unit connector are as shown in the figure When the connector is removed from the ABSCM H U the connector switch closes the circuit between terminal No 22 and No 23 The ABS warning...

Page 2804: ...1 2 23 Less than 1 5 V when the stop light is OFF and 10 15 V when the stop light is ON ABS warning light 2 22 23 Less than 1 5 V during 1 5 seconds when ignition switch is ON and 10 15 V after 1 5 se...

Page 2805: ...ight outlet solenoid valve 21 Front left ABS sensor 4 Motor relay 14 Transmission control module only AT model 22 Front right ABS sensor 5 Motor 23 Rear left ABS sensor 6 Front left inlet solenoid val...

Page 2806: ...ABS 15 ABS DIAGNOSTICS CONTROL MODULE I O SIGNAL C WAVEFORM ABS00110 ABS sensor Standard output voltage at 20 Hz 0 12 1 V Terminal No 9 10 11 12 7 8 14 15 0 V 20 Hz...

Page 2807: ...the YES key 10 On the Diagnostic Code s Display display screen select the Current Diagnostic Code s or History Diagnostic Code s and press the YES key NOTE For detailed operation procedure refer to t...

Page 2808: ...RU SELECT MONITOR OPERATION MANUAL 4 ABS SEQUENCE CONROL Display screen Contents to be monitored Unit of measure FR Wheel Speed Wheel speed detected by the Front Right ABS sensor is displayed km h or...

Page 2809: ...It appears on the select monitor display in volts 5 V Motor relay monitor Motor relay operation monitor signal ON Stop light switch Stop light switch signal OFF ABS signal to TCM ABS operation signal...

Page 2810: ...rst These repeat for a maximum of 3 minutes NOTE When there are no diagnostic trouble codes DTC in memory only the start code 11 is shown When on board diagnosis of the ABS control module detects a pr...

Page 2811: ...OSTICS READ DIAGNOSTIC TROUBLE CODE DTC 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for information about how to obtain and understand diagnostic trouble codes DTC Ref to ABS 16 Subaru...

Page 2812: ...GNOSTICS INSPECTION MODE 8 Inspection Mode A OPERATION Reproduce the condition under which the problem has occurred as much as possible Drive the vehicle at a speed more than 40 km h 25 MPH for at lea...

Page 2813: ...e NOTE After diagnostics is completed make sure to clear memory Make sure only start code 11 is shown after memory is cleared 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for informatio...

Page 2814: ...FF repair the ABS warning light circuit or diagnosis cir cuit Ref to ABS 28 Diagnostics Chart with Diagnosis Connector NOTE Even though the ABS warning light does not go out 1 5 seconds after it illum...

Page 2815: ...nector 28 Rear left ABS sensor Ref to ABS 46 DTC 28 ABNORMAL ABS SENSOR REAR LH Diagnostics Chart with Diagnosis Connector 29 Any one of four Ref to ABS 50 DTC 29 ABNORMAL ABS SENSOR SIGNAL ANY ONE OF...

Page 2816: ...T RIGHT ABNORMAL ABS SENSOR SIGNAL Diagnostics Chart with Subaru Select Moni tor 23 Open or short circuit in front left ABS sensor circuit Open or short circuit in front left ABS sensor circuit Ref to...

Page 2817: ...8 DTC 44 ABS AT CONTROL NON CON TROLLED Diagnostics Chart with Subaru Select Monitor 44 ABS AT control Con trolled ABS AT control Con trolled Ref to ABS 120 DTC 44 ABS AT CONTROL CON TROLLED Diagnosti...

Page 2818: ...ABS 27 ABS DIAGNOSTICS LIST OF DIAGNOSTICS TROUBLE CODE DTC MEMO...

Page 2819: ...M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 2820: ...chassis ground Connector terminal LHD B62 No 5 Chassis ground RHD B100 No 18 Chassis ground Is the measured value less than the speci fied value 3 V Go to step 4 Repair warning light harness 4 CHECK...

Page 2821: ...the speci fied value 3 V Go to step 8 Repair wiring har ness 8 CHECK GROUND CIRCUIT OF ABSCM H U Measure resistance between ABSCM H U and chassis ground Connector terminal F49 No 23 GND Is the measure...

Page 2822: ...ABS 31 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2823: ...4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27...

Page 2824: ...than the speci fied value 0 5 Go to step 4 Repair harness connector between ABSCM H U and diagnosis connec tor 4 CHECK GENERATOR 1 Start the engine 2 Idle the engine 3 Measure voltage between generato...

Page 2825: ...U 10 CHECK WIRING HARNESS Measure resistance between connector F45 or F2 and chassis ground Connector terminal LHD F45 No 5 Chassis ground RHD F2 No 18 Chassis ground Is the measured value less than...

Page 2826: ...ABS 35 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2827: ...N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 2828: ...OSIS LINE 1 Turn ignition switch to OFF 2 Connect diagnosis terminal B81 to diag nosis connector B82 No 8 3 Disconnect connector from ABSCM H U 4 Measure resistance between ABSCM H U connector and cha...

Page 2829: ...ctor E DTC 23 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT LH NOTE For the diagnostic procedure refer to DTC 27 Ref to ABS 40 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTA...

Page 2830: ...ABS 39 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2831: ...RONT ABS SENSOR LH FRONT ABS SENSOR RH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 9 10 11 12 1 2 1 2 1 4...

Page 2832: ...n the speci fied value 1 V Go to step 3 Replace ABS sen sor Front Ref to ABS 12 Front ABS Sensor Rear Ref to ABS 15 Rear ABS Sensor 3 CHECK BATTERY SHORT OF ABS SEN SOR 1 Turn ignition switch to ON 2...

Page 2833: ...ci fied value 1 V Go to step 7 Repair harness between ABSCM H U and ABS sensor 7 CHECK INSTALLATION OF ABS SENSOR Turn ignition switch to OFF Are the ABS sensor installation bolts tightened with the s...

Page 2834: ...d DTC 23 F49 No 9 Chassis ground DTC 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 12 Repair harness between ABSCM H U a...

Page 2835: ...Diagnostics Chart with Diagnosis Connector I DTC 24 ABNORMAL ABS SENSOR FRONT LH NOTE For the diagnostic procedure refer to DTC 28 Ref to ABS 46 DTC 28 ABNORMAL ABS SENSOR REAR LH Diagnostics Chart w...

Page 2836: ...ABS 45 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2837: ...RONT ABS SENSOR RH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 9 10 11 12 1 2 1 2 1 4 7 8 1 2 5 6 14 15 1...

Page 2838: ...itch ON 5 Rotate wheels and measure voltage at specified frequency Ref to ABS 15 WAVEFORM Control Module I O Signal NOTE When this inspection is completed the ABS control module sometimes stores the t...

Page 2839: ...assis ground Rear RH No 1 Chassis ground Rear LH No 1 Chassis ground Does the measured value exceed the specified value 1 M Go to step 10 Replace ABS sen sor Front Ref to ABS 12 Front ABS Sensor Rear...

Page 2840: ...is not installed near the sensor harness Go to step 16 Install the noise sources apart from the sensor har ness 16 CHECK SHIELD CIRCUIT 1 Connect all connectors 2 Measure resistance between shield co...

Page 2841: ...9 FRONT ABS SENSOR LH FRONT ABS SENSOR RH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 9 10 11 12 1 2 1 2 1...

Page 2842: ...eplace tire 3 CHECK WEAR OF TIRE Is the tire worn excessively Not worn excessively Go to step 4 Replace tire 4 CHECK TIRE PRESSURE Is the tire pressure correct Correct tire pressure Go to step 5 Adjus...

Page 2843: ...other foreign matter ABS sensor piece or the tone wheel is not contaminated Go to step 10 Thoroughly remove dirt or other foreign mat ter 10 CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL Are there broken...

Page 2844: ...AGNOSTICS CHART WITH DIAGNOSIS CONNECTOR 13 CHECK ANY OTHER DTC APPEARANCE Are other DTC being output Other DTC is not indicated A temporary poor contact Proceed with the diagnosis corre sponding to t...

Page 2845: ...Connector N DTC 33 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM H U FRONT LH NOTE For the diagnostic procedure refer to DTC 37 Ref to ABS 56 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSC...

Page 2846: ...ABS 55 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2847: ...NOSIS Faulty harness connector Faulty inlet solenoid valve in ABSCM H U TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6...

Page 2848: ...is ground Connector terminal F49 No 23 Chassis ground Is the measured value less than the speci fied value 0 5 Go to step 3 Repair ABSCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTORS Is there...

Page 2849: ...Connector R DTC 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM H U FRONT LH NOTE For the diagnostic procedure refer to DTC 38 Ref to ABS 60 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABS...

Page 2850: ...ABS 59 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2851: ...NOSIS Faulty harness connector Faulty outlet solenoid valve in ABSCM H U TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6...

Page 2852: ...is ground Connector terminal F49 No 23 Chassis ground Is the measured value less than the speci fied value 0 5 Go to step 3 Repair ABSCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTORS Is there...

Page 2853: ...CM H U 1 Turn ignition switch to OFF 2 Disconnect connector from ABSCM H U 3 Measure resistance between ABSCM H U and chassis ground Connector terminal F49 No 23 Chassis ground Is the measured value l...

Page 2854: ...oise sources such as an antenna installed near the sensor harness Noise source is not installed near the sensor harness Go to step 5 Install the noise sources apart from the sensor har ness 5 CHECK AB...

Page 2855: ...source voltage of the ABSCM H U is low or high TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 2856: ...F49 No 1 Chassis ground Is the measured value within the specified range 10 17 V Go to step 4 Repair harness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H...

Page 2857: ...YMPTOM ABS does not operate WIRING DIAGRAM ABS00310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 31 3 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 TCM B...

Page 2858: ...he specified value 1 V Go to step 4 Repair harness between TCM and ABSCM H U 4 CHECK BATTERY SHORT OF HARNESS 1 Turn ignition switch to ON 2 Measure voltage between ABSCM H U connector and chassis gro...

Page 2859: ...ion mode 5 Read out the DTC Is the same DTC still being output Same DTC is not indicated Go to step 10 Replace ABSCM H U Ref to ABS 6 ABS Control Mod ule and Hydraulic Control Unit ABSCM H U 10 CHECK...

Page 2860: ...ABS 69 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 2861: ...NG DIAGRAM ABS00297 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 24 1 23 VALVE RELAY F49 MOTOR RELAY FR OUTLET...

Page 2862: ...o to step 3 Repair ABSCM H U ground harness 3 CHECK VALVE RELAY IN ABSCM H U Measure resistance between ABSCM H U and terminals Terminals No 23 No 24 Does the measured value exceed the specified value...

Page 2863: ...ABS does not operate WIRING DIAGRAM ABS00298 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 25 1 23 26 VALVE REL...

Page 2864: ...ECK GROUND CIRCUIT OF ABSCM H U 1 Turn ignition switch to OFF 2 Measure resistance between ABSCM H U connector and chassis ground Connector terminal F49 No 23 Chassis ground Is the measured value less...

Page 2865: ...ABS00311 2 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 B64 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 2 3 1 2 STOP LIGHT SWITCH B64 B65 WITHOUT C...

Page 2866: ...ified range 10 15 V Go to step 3 Repair harness between stop light switch and ABSCM H U 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in connector between stop light switch and ABSCM H U Th...

Page 2867: ...SIS Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00312 F55 R70 F62 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABS G SENSOR F49 2 1 3 F49 1 2 3 4 5 6 7 8 9 1...

Page 2868: ...tween G sensor con nector terminals Connector terminal R70 No 1 No 3 Is the measured value within the specified range 4 75 5 25 V Go to step 4 Repair harness connector between G sensor and ABSCM H U 4...

Page 2869: ...or terminal R70 No 2 No 3 Is the measured value within the specified range when G sensor is horizontal 2 1 2 5 V Go to step 10 Replace G sen sor Ref to ABS 21 G Sensor 10 CHECK G SENSOR Measure voltag...

Page 2870: ...AGNOSTICS CHART WITH DIAGNOSIS CONNECTOR 14 CHECK ANY OTHER DTC APPEARANCE Are other DTC being output Other DTC is not indicated A temporary poor contact Proceed with the diagnosis corre sponding to t...

Page 2871: ...S00313 BATTERY 1 23 20 5 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 NO 18 15A SBF 4 50A SBF 1 100A DATA LINK CONNECTOR 5 4 B40 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27...

Page 2872: ...urn ignition switch to OFF 2 Disconnect ABSCM H U connector 3 Check whether communication to other systems can be executed normally Are the name and year of the system dis played on the select monitor...

Page 2873: ...ltage between ABSCM H U connector and chassis ground Connector terminal F49 No 1 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 11 Repair open circuit in harness be...

Page 2874: ...BLE CODE DIAGNOSIS ABS warning light circuit is shorted TROUBLE SYMPTOM ABS warning light remains on NO TROUBLE CODE displayed on the select monitor NOTE When the ABS warning light is OFF and NO TROUB...

Page 2875: ...J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4...

Page 2876: ...and Hydraulic Control Unit ABSCM H U 4 CHECK WIRING HARNESS Measure resistance between connector F45 or F2 and chassis ground Connector terminal LHD F45 No 5 Chassis ground RHD F2 No 18 Chassis ground...

Page 2877: ...ru Select Monitor D DTC 23 OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT NOTE For the diagnostic procedure refer to DTC 27 Ref to ABS 88 DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR C...

Page 2878: ...ABS 87 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR MEMO...

Page 2879: ...ABS SENSOR LH FRONT ABS SENSOR RH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 9 10 11 12 1 2 1 2 1 4 7 8 1...

Page 2880: ...Rear wheel 0 44 0 94 mm 0 0173 0 0370 in Go to step 4 Adjust the gap NOTE Adjust the gap us ing spacers Part No 26755AA000 If spacers cannot correct the gap re place worn sensor or worn tone wheel 4 C...

Page 2881: ...lue 1 V Go to step 10 Replace ABS sen sor Front Ref to ABS 12 Front ABS Sensor Rear Ref to ABS 15 Rear ABS Sensor 10 CHECK BATTERY SHORT OF ABS SEN SOR 1 Turn ignition switch to ON 2 Measure voltage b...

Page 2882: ...an the speci fied value 1 V Go to step 14 Repair harness between ABSCM H U and ABS sensor 14 CHECK INSTALLATION OF ABS SENSOR Are the ABS sensor installation bolts tightened with the specified torque...

Page 2883: ...nal DTC 21 F49 No 11 Chassis ground DTC 23 F49 No 9 Chassis ground DTC 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground Does the measured value exceed the spec ified value 1 M Go to step 19...

Page 2884: ...s Chart with Subaru Select Monitor H DTC 24 FRONT LEFT ABNORMAL ABS SENSOR SIGNAL NOTE For the diagnostic procedure refer to DTC 28 Ref to ABS 94 DTC 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL Diagnostic...

Page 2885: ...R LH FRONT ABS SENSOR RH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 9 10 11 12 1 2 1 2 1 4 7 8 1 2 5 6 14...

Page 2886: ...ess Noise source is not installed near the sensor harness Go to step 5 Install the noise sources apart from the sensor har ness 5 CHECK SHIELD CIRCUIT 1 Turn ignition switch to OFF 2 Connect all conne...

Page 2887: ...nspection is completed the AB SCM H U sometimes stores the trouble code 29 Connector terminal DTC 22 LHD F45 No 11 No 12 RHD F2 No 12 No 13 DTC 24 LHD F45 No 8 No 9 RHD F2 No 15 No 16 DTC 26 F55 No 5...

Page 2888: ...1 Chassis ground Rear RH No 1 Chassis ground Rear LH No 1 Chassis ground Does the measured value exceed the specified value 1 M Go to step 17 Replace ABS sen sor Front Ref to ABS 12 Front ABS Sensor...

Page 2889: ...is not installed near the sensor harness Go to step 23 Install the noise sources apart from the sensor har ness 23 CHECK SHIELD CIRCUIT 1 Connect all connectors 2 Measure resistance between shield co...

Page 2890: ...ABS 99 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR MEMO...

Page 2891: ...R72 F49 FRONT ABS SENSOR LH FRONT ABS SENSOR RH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 9 10 11 12 1...

Page 2892: ...p 3 Replace tire 3 CHECK WEAR OF TIRE Is the tire worn excessively Not worn excessively Go to step 4 Replace tire 4 CHECK TIRE PRESSURE Is the tire pressure correct Correct tire pressure Go to step 5...

Page 2893: ...on taminated by mud or other foreign matter ABS sensor piece or the tone wheel is not contaminated Go to step 10 Thoroughly remove mud or other foreign mat ter 10 CHECK DAMAGE OF ABS SENSOR OR TONE WH...

Page 2894: ...AGNOSTICS CHART WITH SUBARU SELECT MONITOR 13 CHECK ANY OTHER DTC APPEARANCE Are other DTC being output Other DTC is not indicated A temporary poor contact Proceed with the diagnosis corre sponding to...

Page 2895: ...ics Chart with Subaru Select Monitor M DTC 33 FRONT LEFT INLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 37 Ref to ABS 106 DTC 37 REAR LEFT INLET VALVE MAL FUNCTION Diagnostics...

Page 2896: ...ABS 105 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR MEMO...

Page 2897: ...Faulty harness connector Faulty inlet solenoid valve TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6 7 8 9 10 11 12 13 1...

Page 2898: ...nector and chassis ground Connector terminal F49 No 23 Chassis ground Is the measured value less than the speci fied value 0 5 Go to step 3 Repair ABSCM H U ground harness 3 CHECK POOR CONTACT IN CONN...

Page 2899: ...ics Chart with Subaru Select Monitor Q DTC 34 FRONT LEFT OUTLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 38 Ref to ABS 110 DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION Diagnostics...

Page 2900: ...ABS 109 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR MEMO...

Page 2901: ...Faulty harness connector Faulty outlet solenoid valve TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 2902: ...ssis ground Connector terminal F49 No 23 Chassis ground Is the measured value less than the speci fied value 0 5 Go to step 3 Repair ABSCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTORS Is ther...

Page 2903: ...ABSCM H U 1 Turn ignition switch to OFF 2 Disconnect connector from ABSCM H U 3 Measure resistance between ABSCM H U and chassis ground Connector terminal F49 No 23 Chassis ground Is the measured valu...

Page 2904: ...such as an antenna installed near the sensor harness Noise source is not installed near the sensor harness Go to step 5 Install the noise sources apart from the sensor har ness 5 CHECK ABSCM H U 1 Tur...

Page 2905: ...S Power source voltage of the ABSCM H U is low TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1...

Page 2906: ...ssis ground Is the measured value within the specified range 10 15 V Go to step 4 Repair harness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn igni...

Page 2907: ...S Power source voltage of the ABSCM H U is high TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00294 1 23 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 2908: ...ssis ground Is the measured value within the specified range 10 17 V Go to step 4 Repair harness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn igni...

Page 2909: ...PTOM ABS does not operate WIRING DIAGRAM ABS00310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 31 3 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 TCM B55...

Page 2910: ...ctor terminal and chassis ground Connector terminal B55 No 21 Chassis ground Is the measured value within the specified range 10 15 V Go to step 5 Go to step 4 4 CHECK AT Is the AT functioning normall...

Page 2911: ...OM ABS does not operate WIRING DIAGRAM ABS00310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 31 3 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 TCM B55 2...

Page 2912: ...Turn ignition switch to OFF 2 Connect all connectors to TCM 3 Turn ignition switch to ON 4 Measure voltage between ABSCM H U connector and chassis ground Connector terminal F49 No 3 Chassis ground F4...

Page 2913: ...IRING DIAGRAM ABS00297 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 24 1 23 VALVE RELAY F49 MOTOR RELAY FR OUTL...

Page 2914: ...U connector and chassis ground Connector terminal F49 No 23 Chassis ground Is the measured value less than the speci fied value 0 5 Go to step 3 Repair ABSCM H U ground harness 3 CHECK POOR CONTACT IN...

Page 2915: ...IRING DIAGRAM ABS00297 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 24 1 23 VALVE RELAY F49 MOTOR RELAY FR OUTL...

Page 2916: ...NECTORS Is there poor contact in connectors between generator battery and ABSCM H U There is no poor contact Go to step 3 Repair connector 3 CHECK ABSCM H U 1 Connect all connectors 2 Erase the memory...

Page 2917: ...TOM ABS does not operate WIRING DIAGRAM ABS00298 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 25 1 23 26 VALVE...

Page 2918: ...ERATION Operate the sequence control Ref to ABS 9 ABS Sequence Control NOTE Use the diagnosis connector to operate the se quence control Can motor revolution noise buzz be heard when carrying out the...

Page 2919: ...S does not operate WIRING DIAGRAM ABS00298 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 25 1 23 26 VALVE RELAY...

Page 2920: ...nce control There is no poor contact Go to step 3 Replace ABSCM H U Ref to ABS 6 ABS Control Mod ule and Hydraulic Control Unit ABSCM H U 3 CHECK POOR CONTACT IN CONNECTORS Turn ignition switch to OFF...

Page 2921: ...oes not operate WIRING DIAGRAM ABS00298 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 25 1 23 26 VALVE RELAY F49...

Page 2922: ...CK GROUND CIRCUIT OF ABSCM H U 1 Turn ignition switch to OFF 2 Measure resistance between ABSCM H U connector and chassis ground Connector terminal F49 No 23 Chassis ground Is the measured value less...

Page 2923: ...NG DIAGRAM ABS00311 2 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT F49 B64 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F49 2 3 1 2 STOP LIGHT SWITCH B64 B6...

Page 2924: ...op lights circuit 4 CHECK OPEN CIRCUIT IN HARNESS 1 Turn ignition switch to OFF 2 Disconnect connector from ABSCM H U 3 Depress brake pedal 4 Measure voltage between ABSCM H U connector and chassis gr...

Page 2925: ...DIAGNOSIS Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00312 F55 R70 F62 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABS G SENSOR F49 2 1 3 F49 1 2 3 4 5 6 7...

Page 2926: ...poor contact Proceed with the diagnosis corre sponding to the DTC 5 CHECK INPUT VOLTAGE OF G SENSOR 1 Turn ignition switch to OFF 2 Remove console box 3 Disconnect G sensor from body Do not disconnec...

Page 2927: ...R Measure voltage between G sensor connector terminals Connector terminal R70 No 2 No 3 Is the voltage between within the specified range when G sensor is inclined backwards to 90 0 5 0 9 V Go to step...

Page 2928: ...ABS 137 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR MEMO...

Page 2929: ...NOSIS Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00312 F55 R70 F62 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABS G SENSOR F49 2 1 3 F49 1 2 3 4 5 6 7 8 9...

Page 2930: ...cated A temporary poor contact Proceed with the diagnosis corre sponding to the DTC 5 CHECK FREEZE FRAME DATA 1 Select Freeze frame data on the select monitor 2 Read front right wheel speed on the sel...

Page 2931: ...minal F49 No 6 Chassis ground Is the measured value less than the speci fied value 1 V Go to step 13 Repair harness between G sensor and ABSCM H U 13 CHECK POOR CONTACT IN CONNECTORS Is there poor con...

Page 2932: ...R70 No 2 No 3 Is the voltage within the specified range when G sensor is inclined forwards to 90 3 7 4 1 V Go to step 20 Replace G sen sor Ref to ABS 21 G Sensor 20 CHECK G SENSOR Measure voltage betw...

Page 2933: ...SIS Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00312 F55 R70 F62 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABS G SENSOR F49 2 1 3 F49 1 2 3 4 5 6 7 8 9 1...

Page 2934: ...or contact Proceed with the diagnosis corre sponding to the DTC 5 CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn ignition switch to OFF 2 Disconnect connector from ABSCM H U...

Page 2935: ...voltage within the specified range when G sensor is inclined backwards to 90 0 5 0 9 V Go to step 10 Replace G sen sor Ref to ABS 21 G Sensor 10 CHECK ABSCM H U 1 Turn ignition switch to OFF 2 Connec...

Page 2936: ...ABS 145 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR MEMO...

Page 2937: ...IS Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00312 F55 R70 F62 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABS G SENSOR F49 2 1 3 F49 1 2 3 4 5 6 7 8 9 10...

Page 2938: ...1 G Sensor 4 CHECK OUTPUT OF G SENSOR USING SE LECT MONITOR Read the select monitor display Is the G sensor output on the monitor display within the specified range when G sensor is inclined backwards...

Page 2939: ...ined forwards to 90 3 7 4 1 V Go to step 11 Replace G sen sor Ref to ABS 21 G Sensor 11 CHECK G SENSOR Measure voltage between G sensor connector terminals Connector terminal R70 No 2 No 3 Is the volt...

Page 2940: ...ake dragging ABSCM H U solenoid valve ABS sensor Master cylinder Brake caliper piston Parking brake Axle wheels Brake pedal play Long brake pedal stroke Air in brake line Brake pedal play Vehicle pitc...

Page 2941: ...ABS 150 ABS DIAGNOSTICS GENERAL DIAGNOSTICS TABLE MEMO...

Page 2942: ...CCM 8 3 Hydraulic Control Unit H U 10 4 ABS Sequence Control 16 5 VDC Sequence Control 19 6 Yaw Rate and Lateral G Sensor 22 7 Steering Angle Sensor 26 8 Front ABS Sensor 27 9 Rear ABS Sensor 28 10 Fr...

Page 2943: ...ness Front LH Except OUTBACK Yellow OUTBACK Brown Front RH Except OUTBACK White OUTBACK Light blue Rear LH Except OUTBACK Yellow OUTBACK Yellow Rear RH Except OUTBACK White OUTBACK White Yaw rate and...

Page 2944: ...SCRIPTION B COMPONENT 1 ABS SENSOR 1 Clip 5 Housing Tightening torque N m kgf m ft lb 2 Rear ABS sensor 6 Front ABS sensor T 33 3 3 24 3 ABS spacer 7 Tone wheel Front 4 Tone wheel Rear VDC00069 7 6 3...

Page 2945: ...YAW RATE AND LATERAL G SENSOR 3 STEERING ANGLE SENSOR 1 Yaw rate and lateral G sensor Tightening torque N m kgf m ft lb T 7 5 0 76 5 5 VDC00070 1 T T 1 Steering angle sensor 2 Roll connector 3 Combina...

Page 2946: ...TION 4 VDC CONTROL MODULE VDCCM LHD model RHD model 1 VDC control module Tightening torque N m kgf m ft lb T 7 5 0 76 5 5 1 VDC control module Tightening torque N m kgf m ft lb T 7 5 0 76 5 5 VDC00072...

Page 2947: ...ay 10 Ground terminal T1 13 1 3 9 4 3 Valve relay 11 Front LH outlet T2 18 1 8 13 0 4 Cap 12 Secondary inlet T3 33 3 3 24 5 Bracket 13 Front RH outlet T4 38 3 9 28 6 Hydraulic control unit 14 Primary...

Page 2948: ...olts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect ground ca ble from...

Page 2949: ...s on the back side of the cov er 3 Remove three bolts which secure the fuse box onto body side then move the fuse box aside LHD model RHD model 4 Remove two bolts which install VDCCM onto body side br...

Page 2950: ...being driven Also make sure there are no abnormalities of the VDC function or steering operation NOTE If it is not possible to drive the vehicle use SUBA RU SELECT MONITOR Ref to VDC 9 WITH SUBARU SE...

Page 2951: ...ne compartment CAUTION Hydraulic unit cannot be disassembled Do not attempt to loosen bolts and nuts Do not drop or bump hydraulic unit Do not turn the hydraulic unit upside down or place it on its si...

Page 2952: ...h mating receptacle 5 Connect connector to hydraulic unit 6 Install air intake duct 7 Connect ground cable to battery 8 Bleed air from the brake system 2 RELAY BOX 1 Install relay box and connector br...

Page 2953: ...NOTE Wrap sealing tape around the pressure gauge 4 Bleed air from the pressure gauges 5 Perform ABS sequence control Ref to VDC 16 ABS Sequence Control 6 When the hydraulic unit begins to work and fir...

Page 2954: ...ing remove the pressure gauges from caliper bodies 17 Connect the air bleeder screws to RL and RR caliper bodies 18 Bleed air from brake line 2 CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TES...

Page 2955: ...d compression meets the stan dard values Also check if any irregular brake pedal tightness is felt 8 Remove pressure gauges from FL and FR cali per bodies 9 Remove air bleeder screws from the RL and R...

Page 2956: ...performs decompression holding and compression in sequence and subsequently the FR wheel repeats the cycle 2 The RR wheel performs decompression holding and compression in sequence and subsequently th...

Page 2957: ...ECT MONITOR NOTE In the event of any trouble the sequence control may not be operative In such a case activate the sequence control referring to ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR Ref to VD...

Page 2958: ...ry suction valve FL outlet valve FL inlet valve FR outlet valve FR inlet valve RR outlet valve RR inlet valve RL outlet valve RL inlet valve Pump motor Pressure of master cylinder Pressure of RR wheel...

Page 2959: ...s terminals When select monitor is not used 3 When the brake pedal is released during se quence control and the braking lamp switch is set to off 4 When brake pedal is depressed after ignition key is...

Page 2960: ...n the brake pedal must not be depressed Engine must operate If the VDC sequence control does not start do the procedure over again 5 After completion of VDC sequence control turn ignition switch OFF 2...

Page 2961: ...valve FL inlet valve FR outlet valve FR inlet valve RR outlet valve RR inlet valve RL outlet valve RL inlet valve Pump motor Pressure of master cylinder Pressure of RL wheel cylinder Pressure of FL w...

Page 2962: ...is terminals When select monitor is not used 3 When the brake pedal is pressed during se quence control and the braking lamp switch is set to on 4 When brake pedal is depressed after ignition key is t...

Page 2963: ...verse order of removal NOTE Do not install yaw rate and lateral G sensor in the wrong direction There is an arrow on the sensor showing which side faces the front of the vehicle CAUTION After completi...

Page 2964: ...LATERAL G SEN SOR 1 Remove yaw rate and lateral G sensor from vehicle 2 Measure voltage between yaw rate and lat eral G sensor connector terminals Connector terminal R100 No 5 No 6 NOTE If the yaw rat...

Page 2965: ...HECK YAW RATE AND LATERAL G SEN SOR 1 Remove console box 2 Remove yaw rate and lateral G sensor from vehicle Do not disconnect connector 3 Read the select monitor display NOTE If the yaw rate and late...

Page 2966: ...MENT Control Module I O Sig nal Is the voltage within the specified range 2 1 V 2 9 V Go to step 2 Replace yaw rate and lateral G sen sor is normal 2 CHECK YAW USING OSCILLOSCOPE 1 Turn ignition switc...

Page 2967: ...CAUTION After completion of installation procedure the following two position settings must be made Steering angle sensor center positioning Yaw rate and lateral G sensor 0 positioning These procedur...

Page 2968: ...8 Front ABS Sensor A NOTE The ABS sensor installed on VDC equipped vehi cles is the same as the one on ABS equipped vehi cles Therefore for removal inspection and installation refer to ABS section Ref...

Page 2969: ...9 Rear ABS Sensor A NOTE The ABS sensor installed on VDC equipped vehi cles is the same as the one on ABS equipped vehi cles Therefore for removal inspection and installation refer to ABS section Ref...

Page 2970: ...VDC FRONT TONE WHEEL 10 Front Tone Wheel A NOTE As front tone wheel is integrated with front drive shaft refer to DS section for removal installation and inspection procedures Ref to DS 28 Front Drive...

Page 2971: ...30 VDC REAR TONE WHEEL 11 Rear Tone Wheel A NOTE As rear tone wheel is integrated with rear drive shaft refer to DS section for removal installation and inspection procedures Ref to DS 34 Rear Drive S...

Page 2972: ...tch assembly out from center console 5 Disconnect electric connectors and antenna feeder cord and then disconnect heater control unit 6 Remove screw and detach the bracket and then remove switch panel...

Page 2973: ...C INSPECTION Check continuity between VDC off switch termi nals If NG replace VDC off switch Switch position Tester connection Specified condition OFF 6 5 More than 1 M ON 6 5 Less than 1 VDC00103 1...

Page 2974: ...I O Signal 13 6 VDCCM Connector Cover 19 7 Subaru Select Monitor 20 8 Read Diagnostic Trouble Code DTC 23 9 Inspection Mode 24 10 Clear Memory Mode 25 11 Warning Light Illumination Pattern 26 12 List...

Page 2975: ...TC Calling up diagnostic trouble code DTC Ref to VDC 23 WITHOUT SUBARU SELECT MONITOR OPERATION Read Diagnostic Trouble Code DTC Is diagnostic trouble code DTC readable Can be read Go to step 3 Inspec...

Page 2976: ...tic Trouble Code DTC Is only the start code issued Only start code indicated Complete the diagnosis Go to step 5 5 PERFORM THE DIAGNOSIS 1 Inspect using Diagnostics Chart with Diag nostic Connector Re...

Page 2977: ...s diagnostic trouble code DTC is dis played DTC is indicated Go to step 3 Go to step 5 3 CHECK WARNING LIGHT Check lighting pattern of the warning light Ref to VDC 26 INSPECTION Warning Light Illumina...

Page 2978: ...Code DTC Ref to VDC 29 WITH SUBARU SELECT MONI TOR LIST List of Diagnostic Trouble Code DTC 2 Repair trouble cause 3 Perform the clear memory mode Ref to VDC 25 WITH SUBARU SELECT MONI TOR OPERATION C...

Page 2979: ...o MPH When turning to right Steering angle deg Steering time sec When turning to left Steering angle deg Steering time sec When moving other electrical parts Parts name Operating condition VDC OFF ind...

Page 2980: ...to km h MPH to MPH While traveling at a constant speed km h MPH When decelerating km h to km h MPH to MPH When turning to right Steering angle deg Steering time sec When turning to left Steering angle...

Page 2981: ...re kPa Front LH tire kPa Rear RH tire kPa Rear LH tire kPa e Degree of wear Front RH tire Front LH tire Rear RH tire Rear LH tire f Steering wheel Sharp turn Slow turn Straight ahead operation Returne...

Page 2982: ...cific gravity of electrolyte Standard voltage 12 V or more Specific gravity Above 1 260 2 BRAKE FLUID 1 Check brake fluid level 2 Check brake fluid leakage 3 HYDRAULIC UNIT Check the hydraulic unit VD...

Page 2983: ...ng for electrical systems 22771AA030 SELECT MONI TOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without printer S...

Page 2984: ...portioning valve 9 VDC OFF indicator light 15 Yaw rate lateral G sensor 3 Engine control module 10 Steering angle sensor 16 Transmission control module 4 Master cylinder 11 Data link connector for SUB...

Page 2985: ...VDC 12 VDC DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION VDC00156 6 7 8 9 VDC00169 11 VDC00166 5 VDC00157 17 VDC00167 1 18 VDC00170 12 13 VDC00168 15 VDC00171 10...

Page 2986: ...ICAL SPECIFICATION NOTE The terminal numbers in the VDC control module connector are as shown in the figure When the connector is removed from the VDCCM the connector switch closes the circuit between...

Page 2987: ...5 V pulse signal EAC 45 1 3 5 1 5 V pulse signal Revolution 9 1 10 1 5 V pulse signal Relay box Valve relay power supply 27 1 10 15 V when ignition switch is ON Valve relay coil 47 1 Less than 1 5 V w...

Page 2988: ...4 1 Less than 1 5 V during 1 5 seconds when ignition switch is ON and 10 15 V after 1 5 seconds Diagnosis connector Terminal No 8 13 Terminal No 5 74 Select moni tor Data is received 11 1 Less than 1...

Page 2989: ...noid valve 19 Primary pressure sensor 32 Yaw rate and lateral G sensor 7 Front left outlet solenoid valve 20 Secondary pressure sensor 33 Engine control module 8 Front right inlet solenoid valve 21 VD...

Page 2990: ...easure input output signal voltage NOTE Measure with the VDCCM connector cover removed Ref to VDC 19 VDCCM Connector Cover 1 WAVEFORM VDC00184 65 64 20 ms V 3 2 1 0 5 0 V 2 1 2 9 V 0 5 10 1 2 67 64 2...

Page 2991: ...VDC 18 VDC DIAGNOSTICS CONTROL MODULE I O SIGNAL VDC00185 V 4 0 4 0 2 5 V 83 1 81 1 1 5 V 5 ms 3 5 V 2 5 V 1 2 2 1 Can communication line 2 Terminal No...

Page 2992: ...p cover 5 Remove screws securing connector cover CAUTION Do not allow harness to catch on adjacent parts during installation 6 Remove connector cover B INSTALLATION Install in the reverse order of rem...

Page 2993: ...lection Menu display screen select the Brake Control System and press the YES key 8 Press the YES key after displayed the informa tion of engine type 9 On the Brake Diagnosis display screen select the...

Page 2994: ...d Wheel speed detected by the Rear Left ABS sensor is displayed km h or MPH Steering angle sensor Steering wheel angle detected by the steering angle sensor is dis played deg Yaw rate sensor Vehicle s...

Page 2995: ...urn the Subaru Se lect Monitor and ignition switch to OFF NOTE For detailed operation procedure refer to the SUB ARU SELECT MONITOR OPERATION MANUAL 4 FUNCTION CHECK Display screen Contents to be moni...

Page 2996: ...s DTCs in memory only the start code 11 is shown When on board diagnosis of the VDC control module detects a problem the information up to a maximum of three will be stored in the EEP ROM as a diagnos...

Page 2997: ...ION MODE 9 Inspection Mode A OPERATION Reproduce the condition under which the problem has occurred as much as possible Drive the vehicle at least ten minutes NOTE Make sure vehicle does not pull to o...

Page 2998: ...e NOTE After diagnostics is completed make sure to clear memory Make sure only start code 11 is shown after memory is cleared 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for informa ti...

Page 2999: ...cle wheel is stuck or free spinning for ap proximately 1 minute power transfer fluctuation to the remaining wheels will occur Power transfer conditions will differ from those occurring during normal v...

Page 3000: ...Diagnostics Chart with Diagnosis Connector 27 Rear left ABS sensor Ref to VDC 50 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR LH Diagnostics Chart with Diagnosis Connector 22...

Page 3001: ...OLENOID VALVE CIRCUIT S SECONDARY CUT Diagnostics Chart with Diagno sis Connector 63 Primary suction valve Ref to VDC 68 DTC 63 ABNORMAL OUTLET AND SUCTION SOLE NOID VALVE CIRCUIT S PRIMARY SUCTION Di...

Page 3002: ...DC 114 DTC 71 ABNORMAL STEERING ANGLE SENSOR Diagnostics Chart with Diagnosis Connector 71 51 44 F87 No 27 lead circuit is open Ref to VDC 114 DTC 71 ABNORMAL STEERING ANGLE SENSOR Diagnostics Chart w...

Page 3003: ...tor 34 FL pressure reducing valve malfunction Front left outlet sole noid valve Ref to VDC 154 DTC 34 FL PRESSURE REDUCING VALVE MALFUNCTION FRONT LEFT OUTLET VALVE MAL FUNCTION Diagnostics Chart with...

Page 3004: ...UNCTION Diagnostics Chart with Select Monitor 62 Normal opening valve 1 malfunction Secondary cut valve malfunction Ref to VDC 150 DTC 62 NORMAL OPENING VALVE 1 MALFUNCTION SECONDARY CUT VALVE MALFUNC...

Page 3005: ...CEEDS SPECIFICATION SECOND ARY PRESSURE SENSOR Diagnostics Chart with Select Monitor 74 Pressure sensor 1 off set is too big Primary pressure sen sor offset is too big Ref to VDC 269 DTC 74 PRESSURE S...

Page 3006: ...orted VDC operating indicator light circuit is open or shorted VDC OFF indicator light circuit is open or shorted TROUBLE SYMPTOM When ignition switch is turned ON engine OFF ABS warning light VDC war...

Page 3007: ...79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H...

Page 3008: ...47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6...

Page 3009: ...r terminal ABS warning light F87 No 54 Chassis ground VDC warning light F87 No 53 Chassis ground VDC operating indicator light F87 No 32 Chassis ground VDC OFF indicator light F87 No 52 Chassis ground...

Page 3010: ...INDICATOR LIGHTS 1 Connect connector to VDCCM 2 Turn ignition switch to ON Do ABS warning light VDC warning light VDC operating indicator light and VDC OFF indicator light turn on Turn s on A temporar...

Page 3011: ...3 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33...

Page 3012: ...value less than the speci fied value 0 5 Go to step 4 Repair harness connector between VDCCM and diagnosis con nector 4 CHECK WIRING HARNESS 1 Place a sheet of thick paper thickness 1 5 mm 0 059 in in...

Page 3013: ...3 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B36...

Page 3014: ...5 6 7 8 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39...

Page 3015: ...or shorted VDC OFF switch is shorted TROUBLE SYMPTOM When starting the engine and while VDC OFF indicator light is kept ON NOTE When pushing the VDC OFF switch for 10 seconds or more while revving th...

Page 3016: ...79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H...

Page 3017: ...7 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32...

Page 3018: ...f Switch Is VDC OFF switch OK OK Go to step 4 Replace VDC OFF switch 4 CHECK WIRING HARNESS 1 Turn ignition switch to OFF 2 Disconnect VDCCM connector from VDCCM 3 Turn ignition switch to ON Does the...

Page 3019: ...3 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B36...

Page 3020: ...47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6...

Page 3021: ...CHECK DIAGNOSIS LINE 1 Turn ignition switch to OFF 2 Connect diagnosis terminal B81 to diag nosis connector B82 No 8 3 Disconnect connector from VDCCM 4 Measure resistance between VDCCM con nector an...

Page 3022: ...nector G DTC 23 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT LH NOTE For diagnostic procedure refer to DTC 27 Ref to VDC 50 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE...

Page 3023: ...2 B100 F55 R49 B15 R73 49 19 17 16 14 15 1 55 46 18 1 2 B6 2 1 R72 8 9 11 12 13 VDC CONTROL MODULE FRONT ABS SENSOR LH FRONT ABS SENSOR RH LHD RHD REAR ABS SENSOR LH REAR ABS SENSOR RH F87 56 57 59 60...

Page 3024: ...han the speci fied value 1 V Go to step 3 Replace ABS sen sor Front Ref to VDC 27 Front ABS Sensor Rear Ref to VDC 28 Rear ABS Sensor 3 CHECK BATTERY SHORT OF ABS SEN SOR 1 Turn ignition switch to ON...

Page 3025: ...LATION OF ABS SENSOR Tightening torque 33 10 N m 3 3 1 0 kgf m 24 7 ft lb Are the ABS sensor installation bolts tightened securely Tightened securely Go to step 8 Tighten ABS sen sor installation bolt...

Page 3026: ...the current diagnosis still being output Same DTC indicated Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM Go to step 12 12 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagno...

Page 3027: ...agnosis Connector K DTC 24 ABNORMAL ABS SENSOR ABNORMAL ABS SENSOR SIGNAL FRONT LH NOTE For diagnostic procedure refer to DTC 28 Ref to VDC 56 DTC 28 ABNORMAL ABS SENSOR ABNOR MAL ABS SENSOR SIGNAL RE...

Page 3028: ...VDC 55 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3029: ...F55 R49 B15 R73 49 19 17 16 14 15 1 55 46 18 1 2 B6 2 1 R72 8 9 11 12 13 VDC CONTROL MODULE FRONT ABS SENSOR LH FRONT ABS SENSOR RH LHD RHD REAR ABS SENSOR LH REAR ABS SENSOR RH F87 56 57 59 60 62 63...

Page 3030: ...VDCCM Connector Cover 4 Connect the oscilloscope to the connector 5 Turn ignition switch ON 6 Rotate wheels and measure voltage at specified frequency Ref to ABS 15 WAVEFORM Control Module I O Signal...

Page 3031: ...H No 1 Chassis ground Rear RH No 1 Chassis ground Rear LH No 1 Chassis ground Does the measured value exceed the specified value 1 M Go to step 10 Replace ABS sen sor Front Ref to VDC 27 Front ABS Sen...

Page 3032: ...sources apart from the sensor har ness Go to step 16 16 CHECK SHIELD CIRCUIT 1 Connect all connectors 2 Measure resistance between shield con nector and chassis ground Connector terminal RHD model DTC...

Page 3033: ...2 F2 B100 F55 R49 B15 R73 49 19 17 16 14 15 1 55 46 18 1 2 B6 2 1 R72 8 9 11 12 13 VDC CONTROL MODULE FRONT ABS SENSOR LH FRONT ABS SENSOR RH LHD RHD REAR ABS SENSOR LH REAR ABS SENSOR RH F87 56 57 59...

Page 3034: ...sensor installation bolts tightened securely Tightened securely Go to step 6 Tighten ABS sen sor installation bolts securely 6 CHECK ABS SENSOR GAP Measure tone wheel to pole piece gap over entire per...

Page 3035: ...30 Rear Tone Wheel Go to step 11 11 CHECK TONE WHEEL RUNOUT Measure tone wheel runout Is the measured value less than the specified value 0 05 mm 0 0020 in Go to step 12 Repair tone wheel Front Ref t...

Page 3036: ...is Connector Q DTC 35 ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT S REAR RH INLET NOTE For diagnostic procedure refer to DTC 62 Ref to VDC 64 DTC 62 ABNORMAL INLET AND CUT SOLE NOID VALVE CIRCUIT S...

Page 3037: ...UNIT VDC5 F91 VDC CONTROL MODULE F87 FR OUTLET FR INLET RL OUTLET RL INLET RR OUTLET RR INLET PRIMARY CUT PRIMARY SECTION SECONDARY CUT PRIMARY PRESSURE SENSOR SECONDARY PRESSURE SENSOR SECONDARY SECT...

Page 3038: ...connec tor and chassis ground Connector terminal DTC 31 VDC5 No 5 Chassis ground DTC 33 VDC5 No 8 Chassis ground DTC 35 VDC5 No 7 Chassis ground DTC 37 VDC5 No 6 Chassis ground DTC 61 VDC5 No 9 Chass...

Page 3039: ...n VDCCM connec tor and chassis ground Connector terminal DTC 31 F87 No 30 Chassis ground DTC 33 F87 No 24 Chassis ground DTC 35 F87 No 23 Chassis ground DTC 37 F87 No 31 Chassis ground DTC 61 F87 No 2...

Page 3040: ...No 24 VDC2 No 2 DTC 35 F87 No 23 VDC2 No 2 DTC 37 F87 No 31 VDC2 No 2 DTC 61 F87 No 25 VDC2 No 2 DTC 62 F87 No 26 VDC2 No 2 Is the measured value within the specified range 7 10 Go to step 9 Repair ha...

Page 3041: ...ctor W DTC 36 ABNORMAL OUTLET AND SUCTION SOLENOID VALVE CIRCUIT S REAR RH OUTLET NOTE For diagnostic procedure refer to DTC 64 Ref to VDC 70 DTC 64 ABNORMAL OUTLET AND SUCTION SOLENOID VALVE CIRCUIT...

Page 3042: ...VDC 69 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3043: ...LIC UNIT VDC5 F91 VDC CONTROL MODULE F87 FR OUTLET FR INLET RL OUTLET RL INLET RR OUTLET RR INLET PRIMARY CUT PRIMARY SECTION SECONDARY CUT PRIMARY PRESSURE SENSOR SECONDARY PRESSURE SENSOR SECONDARY...

Page 3044: ...onnec tor and chassis ground Connector terminal DTC 32 VDC5 No 1 Chassis ground DTC 34 VDC5 No 4 Chassis ground DTC 36 VDC5 No 3 Chassis ground DTC 38 VDC5 No 2 Chassis ground DTC 63 VDC5 No 10 Chassi...

Page 3045: ...ween VDCCM connec tor and chassis ground Connector terminal DTC 32 F87 No 3 Chassis ground DTC 34 F87 No 51 Chassis ground DTC 36 F87 No 50 Chassis ground DTC 38 F87 No 4 Chassis ground DTC 63 F87 No...

Page 3046: ...o 51 VDC2 No 1 DTC 36 F87 No 50 VDC2 No 1 DTC 38 F87 No 4 VDC2 No 1 DTC 63 F87 No 29 VDC2 No 1 DTC 64 F87 No 2 VDC2 No 1 Is the measured value within the specified range 3 6 Go to step 9 Repair harnes...

Page 3047: ...OM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00143 VDC CONTROL MODULE 1 55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1...

Page 3048: ...transmitter properly installed Tightened securely Go to step 4 Properly install the car telephone or the wireless trans mitter 4 CHECK SOURCES OF SIGNAL NOISE Are noise sources such as an antenna ins...

Page 3049: ...operate VDC does not operate WIRING DIAGRAM VDC00144 VDC CONTROL MODULE 1 55 28 F87 SBF 1 GENERATOR SBF 4 IGNITION SWITCH F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13...

Page 3050: ...between battery ignition switch and VDCCM 4 CHECK GROUND CIRCUIT OF VDCCM 1 Turn ignition switch to OFF 2 Measure resistance between VDCCM con nector and chassis ground Connector terminal F87 No 1 Cha...

Page 3051: ...11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B135 ENGINE CONTROL MODULE B134 B135 A...

Page 3052: ...nd ECM 2 CHECK GROUND SHORT OF HARNESS Measure resistance between VDCCM connec tor and chassis ground Connector terminal F87 No 21 Chassis ground F87 No 43 Chassis ground F87 No 8 Chassis ground Does...

Page 3053: ...VDC 8 VDC Control Mod ule VDCCM Go to step 8 8 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being out put Other DTC indicated Proceed with the diagnosis corr...

Page 3054: ...C DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR 11 CHECK ENGINE Is the engine functioning normally Operates properly Replace ECM Ref to FU H6DO 46 Engine Control Module Repair engine Step Val...

Page 3055: ...231 VDC CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17...

Page 3056: ...contact in TCM connectors There is poor contact Repair connector Go to step 3 3 CHECK TCM 1 Turn ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform inspection mode 5 Read out...

Page 3057: ...BACK Y Does the VDCCM identification mark agree with the vehicle specifications Agree Go to step 3 Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 3 CHECK TCM SPECIFICATIONS Check the TCM identi...

Page 3058: ...trouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same DTC indicated Go to step 6 The original VDCCM has been faulty 6 CHECK VDCCM Is the same diagnostic...

Page 3059: ...6 36 14 5 3 6 10 12 9 F87 YAW RATE AND LATERAL G SENSOR F55 R49 R100 VDC HYDRAULIC UNIT F91 VDC5 PRIMARY PRESSURE SENSOR SECONDARY PRESSURE SENSOR F55 1 2 3 4 5 6 7 8 9 10 11 12 F91 1 2 3 4 5 6 7 8 9...

Page 3060: ...ERY SHORT OF SENSOR AND HARNESS Measure voltage between VDCCM and chas sis ground Connector terminal F87 No 63 Chassis ground Lateral G sensor F87 No 78 Chassis ground Pressure sensor Is the measured...

Page 3061: ...ON 2 Measure voltage between VDCCM and chassis ground Connector terminal F87 No 63 Chassis ground Lateral G sensor F87 No 78 Chassis ground Pressure sensor Is the measured value less than the speci f...

Page 3062: ...VDC 89 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3063: ...2 5 9 L 6 B231 VDC CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21...

Page 3064: ...und Connector terminal F87 No 83 Chassis ground F87 No 81 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair or replace harness connec tor between VDCCM TCM and...

Page 3065: ...een steering angle sensor terminals Connector terminal B231 No 1 No 2 Does the measured value exceed the spec ified value 1 M Go to step 12 Go to step 11 11 CHECK POOR CONTACT IN CONNECTORS Is there p...

Page 3066: ...VDC 93 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3067: ...77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 H6 RH4 A24 A24 C11 A33 A25 A25 WO OO LH4 ENGINE CONTROL MODULE B134 B136 A C H4 H6 4 CYLINDER ENGINE RHD MODEL 4...

Page 3068: ...ue exceed the specified value 1 M Go to step 3 Repair or replace ground short cir cuit between VDCCM and ECM 3 CHECK BATTERY SHORT OF HARNESS 1 Turn ignition switch to ON 2 Measure voltage between VDC...

Page 3069: ...RASE MEMORY 1 Connect all connectors 2 Erase the memory Can the memory be erased Can be erased Go to step 7 Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 7 CHECK DIAGNOSTIC TROUBLE CODE 1 Perfo...

Page 3070: ...VDC 97 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3071: ...6 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 H6 RH4 A10 A10 WO OO LH4 ENGINE CONTROL MODULE B...

Page 3072: ...Is the measured value less than the speci fied value 0 5 Go to step 3 Repair harness connector between VDCCM and ECM 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in connectors between VDC...

Page 3073: ...19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 SBF 3 50A VDC7...

Page 3074: ...OF VALVE RE LAY Measure resistance between valve relay termi nals Terminals No 30 No 87a Does the measured value exceed the specified value 1 M Go to step 4 Replace valve relay 4 CHECK CONTACT POINT...

Page 3075: ...IN CONTROL CIR CUIT OF RELAY BOX 1 Turn ignition switch to OFF 2 Disconnect connector F90 from relay box 3 Measure resistance between relay box connector and valve relay installing point Connector ter...

Page 3076: ...F87 No 47 Chassis ground F87 No 27 Chassis ground Does the measured value exceed the specified value 1 M Go to step 15 Repair harness between VDCCM and relay box and check all fuses 15 CHECK BATTERY...

Page 3077: ...ground Connector terminal VDC1 No 2 Chassis ground Is the measured value less than the speci fied value 1 V Go to step 21 Replace relay box Check fuse No 8 21 CHECK RESISTANCE OF INLET AND CUT SOLENO...

Page 3078: ...nition switch to ON 2 Measure voltage between VDCH U con nector and chassis ground Connector terminal VDC2 No 2 Chassis ground Is the measured value less than the speci fied value 1 V Go to step 26 Re...

Page 3079: ...resistance between VDCCM con nector and chassis ground Connector terminal F87 No 30 Chassis ground F87 No 24 Chassis ground F87 No 23 Chassis ground F87 No 31 Chassis ground F87 No 26 Chassis ground F...

Page 3080: ...IN CONNECTORS Is there poor contact in connector between VDCCM and VDCH U There is poor contact Repair connector Go to step 32 32 CHECK VDCCM 1 Connect all connectors 2 Erase the memory 3 Perform ins...

Page 3081: ...VDC2 VDC1 4 6 86 1 85 30 30 86 85 87 5 VDC4 F90 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78...

Page 3082: ...erminals No 30 No 87 Does the measured value exceed the spec ified value 1 M Go to step 4 Replace motor relay 4 CHECK SHORT OF MOTOR RELAY Measure resistance between motor relay ter minals Terminals N...

Page 3083: ...box connector Connector terminal VDC4 No 4 VDC7 No 86 Is the measured value less than the specified value 0 5 Go to step 10 Replace relay box 10 CHECK OPEN CIRCUIT IN CONTROL CIR CUIT OF RELAY BOX 1 R...

Page 3084: ...d F87 No 10 Chassis ground Does the measured value exceed the specified value 1 M Go to step 16 Repair harness between VDCCM and relay box Check fuse SBF holder 16 CHECK BATTERY SHORT IN HARNESS BE TW...

Page 3085: ...OTOR OPERATION Operate the check sequence Ref to VDC 19 VDC Sequence Control Can motor revolution noise buzz be heard when carrying out the check sequence Noise heard Go to step 21 Replace VDCH U Ref...

Page 3086: ...VDC 113 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3087: ...B231 VDC CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 1...

Page 3088: ...g angle sensor and chassis ground Connector terminal B231 No 4 Chassis ground Is the measured value within the specified range 10 15 V Go to step 6 Go to step 4 4 CHECK OUTPUT VOLTAGE OF VDCCM 1 Turn...

Page 3089: ...DTC indicated Go to step 10 Go to step 9 9 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being out put Other DTC indicated Proceed with the diagnosis corre sp...

Page 3090: ...VDC 117 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3091: ...67 66 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51...

Page 3092: ...nd lateral G sen sor securely 4 CHECK POWER SUPPLY OF YAW RATE AND LATERAL G SENSOR 1 Turn ignition switch OFF 2 Disconnect connector from yaw rate and lateral G sensor 3 Turn ignition switch to ON 4...

Page 3093: ...lace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 10 CHECK HARNESS OF YAW RATE AND LAT ERAL G SENSOR 1 Disconnect connector from VDCCM 2 Measure resistance between VDCCM and yaw rate and lateral G sen...

Page 3094: ...fied range 2 1 2 9 V Go to step 15 Replace yaw rate and lateral G sen sor Ref to VDC 22 Yaw Rate and Lateral G Sensor 15 CHECK YAW RATE AND LATERAL G SEN SOR 1 Turn ignition switch to ON 2 Check oscil...

Page 3095: ...67 66 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51...

Page 3096: ...Ref to VDC 22 Yaw Rate and Lateral G Sensor 4 CHECK OPEN CIRCUIT IN YAW RATE AND LATERAL G SENSOR OUTPUT HARNESS AND GROUND HARNESS 1 Connect connector to yaw rate and lateral G sensor 2 Disconnect c...

Page 3097: ...No 5 No 6 Is the measured value within the specified range when yaw rate and lateral G sensor is inclined 90 to left 3 3 3 7 V Go to step 10 Replace yaw rate and lateral G sen sor Ref to VDC 22 Yaw R...

Page 3098: ...VDC 125 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR MEMO...

Page 3099: ...76 F91 VDC5 F88 2 3 F88 F91 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40...

Page 3100: ...r replace VDCCM connec tor Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 4 CHECK POWER SUPPLY OF PRESSURE SENSOR NOTE When this inspection is carried out DTC 51 AB NORMAL VALVE RELAY is memoriz...

Page 3101: ...o 14 Chassis ground Is the measured value less than the speci fied value 0 5 V Go to step 10 Repair harness between VDCH U and VDCCM 10 CHECK OUTPUT VOLTAGE OF PRESSURE SENSOR 1 Turn ignition switch t...

Page 3102: ...V Go to step 15 Replace VDCH U Ref to VDC 8 VDC Control Mod ule VDCCM 15 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in connector between VDCCM and pressure sensor There is poor contact Re...

Page 3103: ...3 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64...

Page 3104: ...sconnect VDCCM connector 3 Check whether communication to other systems can be executed normally Are the name and year of the system dis played on the select monitor Displayed Go to step 10 Go to step...

Page 3105: ...11 Insert VDCCM connector into VDCCM until the clamp locks onto it 11 CHECK POWER SUPPLY CIRCUIT 1 Turn ignition switch to ON engine OFF 2 Measure ignition power supply voltage between VDCCM connecto...

Page 3106: ...with Select Monitor C DTC 23 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORTED BAT TERY NOTE For diagnostic procedure refer to DTC 27 Ref to VDC 134 DTC 27 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORTED BAT...

Page 3107: ...5 R49 B15 R73 49 19 17 16 14 15 1 55 46 18 1 2 B6 2 1 R72 8 9 11 12 13 VDC CONTROL MODULE FRONT ABS SENSOR LH FRONT ABS SENSOR RH LHD RHD REAR ABS SENSOR LH REAR ABS SENSOR RH F87 56 57 59 60 62 63 65...

Page 3108: ...0 0370 in Go to step 4 Adjust the gap NOTE Adjust the gap us ing spacers Part No 26755AA000 If spacers cannot correct the gap re place worn sensor or worn tone wheel 4 CHECK TONE WHEEL RUNOUT Measure...

Page 3109: ...ue 1 V Go to step 10 Replace ABS sen sor Front Ref to VDC 27 Front ABS Sensor Rear Ref to VDC 28 Rear ABS Sensor 10 CHECK BATTERY SHORT OF ABS SEN SOR 1 Turn ignition switch to ON 2 Measure voltage be...

Page 3110: ...ATION OF ABS SENSOR Are the ABS sensor installation bolts tightened securely Tightening torque 33 10 N m 3 3 1 0 kgf m 24 7 ft lb Tightened securely Go to step 15 Tighten ABS sen sor installation bolt...

Page 3111: ...n the current diagnosis still being output Same pattern Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM Go to step 19 19 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic...

Page 3112: ...SIGNAL Diagnostics Chart with Select Monitor G DTC 24 FRONT LEFT ABS SENSOR SIGNAL NOTE For diagnostic procedure refer to DTC 28 Ref to VDC 140 DTC 28 REAR LEFT ABS SENSOR SIGNAL Diagnostics Chart wi...

Page 3113: ...9 19 17 16 14 15 1 55 46 18 1 2 B6 2 1 R72 8 9 11 12 13 VDC CONTROL MODULE FRONT ABS SENSOR LH FRONT ABS SENSOR RH LHD RHD REAR ABS SENSOR LH REAR ABS SENSOR RH F87 56 57 59 60 62 63 65 82 83 80 27 28...

Page 3114: ...urces apart from the sensor har ness Go to step 5 5 CHECK SHIELD CIRCUIT 1 Turn ignition switch to OFF 2 Connect all connectors 3 Measure resistance between shield con nector and chassis ground Connec...

Page 3115: ...DTC 29 Connector terminal DTC 22 F87 No 14 No 15 DTC 24 F87 No 49 No 19 DTC 26 F87 No 18 No 46 DTC 28 F87 No 16 No 17 Is oscilloscope pattern smooth as shown in figure Smooth pattern Go to step 15 Go...

Page 3116: ...17 CHECK HARNESS CONNECTOR BETWEEN VDCCM AND ABS SENSOR 1 Connect connector to ABS sensor 2 Disconnect connector from VDCCM 3 Measure resistance at VDCCM connector terminals Connector terminal DTC 22...

Page 3117: ...ance between shield con nector and chassis ground Connector terminal DTC 22 F45 No 10 Chassis ground DTC 22 F2 No 17 Chassis ground DTC 24 F45 No 10 Chassis ground DTC 24 F2 No 17 Chassis ground Is th...

Page 3118: ...VDC 145 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3119: ...100 F55 R49 B15 R73 49 19 17 16 14 15 1 55 46 18 1 2 B6 2 1 R72 8 9 11 12 13 VDC CONTROL MODULE FRONT ABS SENSOR LH FRONT ABS SENSOR RH LHD RHD REAR ABS SENSOR LH REAR ABS SENSOR RH F87 56 57 59 60 62...

Page 3120: ...tallation bolts tightened securely Tightened securely Go to step 6 Tighten ABS sen sor installation bolts securely 6 CHECK ABS SENSOR GAP Measure tone wheel to pole piece gap over entire perimeter of...

Page 3121: ...C 30 Rear Tone Wheel Go to step 11 11 CHECK TONE WHEEL RUNOUT Measure tone wheel runout Is the measured value less than the specified value 0 05 mm 0 0020 in Go to step 12 Repair tone wheel Front Ref...

Page 3122: ...Monitor M DTC 35 RR HOLD VALVE MALFUNCTION REAR RIGHT INLET VALVE MAL FUNCTION NOTE For diagnostic procedure refer to DTC 62 Ref to VDC 150 DTC 62 NORMAL OPENING VALVE 1 MAL FUNCTION SECONDARY CUT VAL...

Page 3123: ...UNIT VDC5 F91 VDC CONTROL MODULE F87 FR OUTLET FR INLET RL OUTLET RL INLET RR OUTLET RR INLET PRIMARY CUT PRIMARY SECTION SECONDARY CUT PRIMARY PRESSURE SENSOR SECONDARY PRESSURE SENSOR SECONDARY SECT...

Page 3124: ...onnec tor and chassis ground Connector terminal DTC 31 VDC5 No 5 Chassis ground DTC 33 VDC5 No 8 Chassis ground DTC 35 VDC5 No 7 Chassis ground DTC 37 VDC5 No 6 Chassis ground DTC 61 VDC5 No 9 Chassis...

Page 3125: ...VDCCM connec tor and chassis ground Connector terminal DTC 31 F87 No 30 Chassis ground DTC 33 F87 No 24 Chassis ground DTC 35 F87 No 23 Chassis ground DTC 37 F87 No 31 Chassis ground DTC 61 F87 No 25...

Page 3126: ...24 VDC2 No 2 DTC 35 F87 No 23 VDC2 No 2 DTC 37 F87 No 31 VDC2 No 2 DTC 61 F87 No 25 VDC2 No 2 DTC 62 F87 No 26 VDC2 No 2 Is the measured value within the specified range 7 10 Go to step 9 Repair harn...

Page 3127: ...tor S DTC 36 RR PRESSURE REDUCING VALVE MALFUNCTION REAR RIGHT OUTLET VALVE MALFUNCTION NOTE For diagnostic procedure refer to DTC 64 Ref to VDC 156 DTC 64 NORMAL CLOSING VALVE 1 MAL FUNCTION SECONDAR...

Page 3128: ...VDC 155 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3129: ...IC UNIT VDC5 F91 VDC CONTROL MODULE F87 FR OUTLET FR INLET RL OUTLET RL INLET RR OUTLET RR INLET PRIMARY CUT PRIMARY SECTION SECONDARY CUT PRIMARY PRESSURE SENSOR SECONDARY PRESSURE SENSOR SECONDARY S...

Page 3130: ...nec tor and chassis ground Connector terminal DTC 32 VDC5 No 1 Chassis ground DTC 34 VDC5 No 4 Chassis ground DTC 36 VDC5 No 3 Chassis ground DTC 38 VDC5 No 2 Chassis ground DTC 63 VDC5 No 10 Chassis...

Page 3131: ...en VDCCM connec tor and chassis ground Connector terminal DTC 32 F87 No 3 Chassis ground DTC 34 F87 No 51 Chassis ground DTC 36 F87 No 50 Chassis ground DTC 38 F87 No 4 Chassis ground DTC 63 F87 No 29...

Page 3132: ...51 VDC2 No 1 DTC 36 F87 No 50 VDC2 No 1 DTC 38 F87 No 4 VDC2 No 1 DTC 63 F87 No 29 VDC2 No 1 DTC 64 F87 No 2 VDC2 No 1 Is the measured value within the specified range 3 6 Go to step 9 Repair harness...

Page 3133: ...ROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00143 VDC CONTROL MODULE 1 55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7...

Page 3134: ...ransmitter properly installed Tightened securely Go to step 4 Properly install the car telephone or the wireless trans mitter 4 CHECK SOURCES OF SIGNAL NOISE Are noise sources such as an antenna insta...

Page 3135: ...ate VDC does not operate WIRING DIAGRAM VDC00144 VDC CONTROL MODULE 1 55 28 F87 SBF 1 GENERATOR SBF 4 IGNITION SWITCH F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14...

Page 3136: ...tor between battery ignition switch and VDCCM 4 CHECK GROUND CIRCUIT OF VDCCM 1 Turn ignition switch to OFF 2 Measure resistance between VDCCM and chassis ground Connector terminal F87 No 1 Chassis gr...

Page 3137: ...6 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B135 ENGINE CONTROL MODULE B134 B135 A B H6 RH4 WO B136 C LH4 OO RH4 B RH4 WO LH4 RH4 OO B134...

Page 3138: ...onnector between VDCCM and ECM 3 CHECK BATTERY SHORT OF HARNESS Measure voltage between VDCCM connector and chassis ground Terminal F87 No 21 Chassis ground Is the measured value less than the specifi...

Page 3139: ...c trouble code A temporary poor contact 9 CHECK ECM 1 Turn ignition switch to ON 2 Measure voltage between ECM connector terminal and chassis ground Connector terminal H4 engine RHD without OBD model...

Page 3140: ...VDC 167 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3141: ...6 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B135 ENGINE CONTROL MODULE B134 B135 A B H6 RH4 WO B136 C LH4 OO RH4 B RH4 WO LH4 RH4 OO B134...

Page 3142: ...ween VDCCM and ECM 3 CHECK BATTERY SHORT OF HARNESS Measure voltage between VDCCM connector and chassis ground Connector terminal F87 No 43 Chassis ground Is the measured value less than the specified...

Page 3143: ...ic trouble code A temporary poor contact 9 CHECK ECM 1 Turn ignition switch to ON 2 Measure voltage between ECM connector terminal and chassis ground Connector terminal H4 engine RHD without OBD model...

Page 3144: ...VDC 171 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3145: ...6 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 B135 ENGINE CONTROL MODULE B134 B135 A B H6 RH4 WO B136 C LH4 OO RH4 B RH4 WO LH4 RH4 OO B134...

Page 3146: ...ween VDCCM and ECM 3 CHECK BATTERY SHORT OF HARNESS Measure voltage between VDCCM connector and chassis ground Connector terminal F87 No 8 Chassis ground Is the measured value less than the specified...

Page 3147: ...c trouble code A temporary poor contact 9 CHECK ECM 1 Turn ignition switch to ON 2 Measure voltage between ECM connector terminal and chassis ground Connector terminal H4 engine RHD without OBD model...

Page 3148: ...VDC 175 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3149: ...NTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 1...

Page 3150: ...ntact in TCM connectors There is poor contact Repair connector Go to step 3 3 CHECK TCM 1 Turn ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform inspection mode 5 Read out t...

Page 3151: ...entification mark TCM identification mark LHD H4 engine model YZ RHD H4 engine model ZG LHD OUTBACK H4 enigne model ZB RHD OUTBACK H4 enigne model ZJ LHD OUTBACK H6 enigne model ZD RHD OUTBACK H6 enig...

Page 3152: ...ouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same DTC indicated Go to step 6 The original VDCCM has been faulty 6 CHECK VDCCM Is the same diagnostic tr...

Page 3153: ...out of specification TROUBLE SYMPTOM ABS does not operate VDC does not operate Step Value Yes No 1 CHECK AT SYSTEM 1 Start the engine 2 Check AT system diagnostic trouble code Is the AT system diagnos...

Page 3154: ...VDC 181 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3155: ...36 14 5 3 6 10 12 9 F87 YAW RATE AND LATERAL G SENSOR F55 R49 R100 VDC HYDRAULIC UNIT F91 VDC5 PRIMARY PRESSURE SENSOR SECONDARY PRESSURE SENSOR F55 1 2 3 4 5 6 7 8 9 10 11 12 F91 1 2 3 4 5 6 7 8 9 10...

Page 3156: ...Y SHORT OF SENSOR AND HARNESS Measure voltage between VDCCM and chas sis ground Connector terminal F87 No 63 Chassis ground Lateral G sensor F87 No 78 Chassis ground Pressure sensor Is the measured va...

Page 3157: ...N 2 Measure voltage between VDCCM and chassis ground Connector terminal F87 No 63 Chassis ground Lateral G sensor F87 No 78 Chassis ground Pressure sensor Is the measured value less than the speci fie...

Page 3158: ...VDC 185 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3159: ...5 9 L 6 B231 VDC CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22...

Page 3160: ...d Connector terminal F87 No 83 Chassis ground F87 No 81 Chassis ground Does the measured value exceed the specified value 1 M Go to step 4 Repair or replace harness connec tor between VDCCM TCM and st...

Page 3161: ...steering angle sensor terminals Connector terminal B231 No 1 No 2 Does the measured value exceed the spec ified value 1 M Go to step 12 Go to step 11 11 CHECK POOR CONTACT IN CONNECTORS Is there poor...

Page 3162: ...VDC 189 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3163: ...39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 H6 RH4 A24 A24 C11 A33 A25 A25 WO OO LH4 ENGINE CONTROL MODULE B134 B136 A C H4 H6 4 CYLINDER ENGINE RHD MODEL 4 CYLINDER ENGINE LHD MODEL RH4 LH4...

Page 3164: ...h to ON 2 Measure voltage between VDCCM and chassis ground Connector terminal F87 No 45 Chassis ground Is the measured value less than the speci fied value 0 5 V Go to step 4 Repair or replace battery...

Page 3165: ...IC TROUBLE CODE 1 Perform inspection mode 2 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same DTC indicated Replace ECM Ref t...

Page 3166: ...VDC 193 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3167: ...1 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 H6 RH4 A24 A24 C11 A33 A25 A25 WO OO LH4 ENGINE CONTROL MODULE B134 B136 A C H4 H6 4 CYLINDER ENGINE RHD MODEL 4 CYLINDER ENGINE LHD MODEL RH4 L...

Page 3168: ...th OBD model B134 No 33 Chassis ground H4 engine LHD model B134 No 25 Chassis ground H6 engine model B136 No 11 Chassis ground Is the measured value within the specified range 10 15 V Go to step 4 Go...

Page 3169: ...77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 H6 RH4 A24 A24 C11 A33 A25 A25 WO OO LH4 ENGINE CONTROL MODULE B134 B136 A C H4 H6 4 CYLINDER ENGINE RHD MODEL 4...

Page 3170: ...ctor terminal F87 No 75 Chassis ground F87 No 45 Chassis ground Is the measured value less than the speci fied value 0 5 V Go to step 3 Repair or replace battery short cir cuit between VDCCM and ECM 3...

Page 3171: ...Go to step 6 Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 6 CHECK DIAGNOSTIC TROUBLE CODE 1 Perform inspection mode 2 Read out the diagnostic trouble code Is the same diagnostic trouble code a...

Page 3172: ...VDC 199 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3173: ...77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 H6 RH4 A10 A10 WO OO LH4 ENGINE CONTROL MODULE B13...

Page 3174: ...s the measured value less than the speci fied value 0 5 Go to step 3 Repair harness connector between VDCCM and ECM 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in connectors between VDCCM...

Page 3175: ...14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 SBF 3 50A VDC7 VDC6 MOTOR RELAY VA...

Page 3176: ...VALVE RE LAY Measure resistance between valve relay termi nals Terminals No 30 No 87a Does the measured value exceed the specified value 1 M Go to step 4 Replace valve relay 4 CHECK CONTACT POINT OF...

Page 3177: ...CIR CUIT OF RELAY BOX 1 Turn ignition switch to OFF 2 Disconnect connector F90 from relay box 3 Measure resistance between relay box con nector and valve relay installing point Connector terminal VDC...

Page 3178: ...ound Connector terminal VDC1 No 2 Chassis ground Does the measured value exceed the specified value 1 M Go to step 15 Replace relay box and check fuse No 8 15 CHECK RESISTANCE OF INLET AND CUT SOLENOI...

Page 3179: ...exceed the spec ified value 1 M Go to step 19 Repair harness between VDCH U and VDCCM 19 CHECK HARNESS CONNECTOR BETWEEN VDCCM AND VDCH U 1 Connect connector F91 to VDCH U 2 Measure resistance betwee...

Page 3180: ...diagnostic trouble code as in the current diagnosis still being output Same DTC indicated Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM Go to step 23 23 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODE...

Page 3181: ...16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 SBF 3 50A VDC7 VDC6 MOTOR REL...

Page 3182: ...esistance between valve relay terminals Terminals No 30 No 87 Does the measured value exceed the spec ified value 1 M Go to step 4 Replace valve relay 4 CHECK CONTACT POINT OF VALVE RE LAY Measure res...

Page 3183: ...relay box and check all fuses 9 CHECK BATTERY SHORT IN CONTROL SYSTEM HARNESS OF VALVE RELAY 1 Turn ignition switch to ON 2 Measure voltage between VDCCM connec tor and chassis ground Connector termi...

Page 3184: ...nnector terminal F87 No 30 Chassis ground F87 No 24 Chassis ground F87 No 23 Chassis ground F87 No 31 Chassis ground F87 No 26 Chassis ground F87 No 25 Chassis ground F87 No 3 Chassis ground F87 No 51...

Page 3185: ...the memory 3 Perform inspection mode 4 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same DTC indicated Replace VDCCM Ref to...

Page 3186: ...VDC 213 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3187: ...1 4 6 86 1 85 30 30 86 85 87 5 VDC4 F90 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77...

Page 3188: ...measured value exceed the spec ified value 1 M Go to step 4 Replace relay box 4 CHECK BATTERY SHORT IN CIRCUIT OF RELAY BOX Measure voltage between relay box connector and chassis ground Connector te...

Page 3189: ...alue 1 V Go to step 9 Repair harness between VDCCM and relay box 9 CHECK POOR CONTACT IN CONNECTORS Turn ignition switch to OFF Is there poor contact in connector between VDCH U relay box and VDCCM Th...

Page 3190: ...VDC 217 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3191: ...4 6 86 1 85 30 30 86 85 87 5 VDC4 F90 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 7...

Page 3192: ...relay ter minals Terminals No 85 No 30 No 85 No 87 Does the measured value exceed the specified value 1 M Go to step 4 Replace motor relay 4 CHECK INPUT VOLTAGE OF RELAY BOX 1 Disconnect connector F8...

Page 3193: ...nt and relay box connector Connector terminal VDC4 No 4 VDC7 No 86 Is the measured value less than the specified value 0 5 Go to step 9 Replace relay box 9 CHECK OPEN CIRCUIT IN CONTROL CIR CUIT OF RE...

Page 3194: ...k fuse SBF holder 15 CHECK BATTERY SHORT IN HARNESS BE TWEEN RELAY BOX AND VDCCM Measure voltage between VDCCM connector and chassis ground Connector terminal F87 No 10 Chassis ground Is the measured...

Page 3195: ...CT MONITOR 19 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being out put Other DTC indicated Proceed with the diagnosis corre sponding to the diagnostic trou...

Page 3196: ...VDC 223 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3197: ...4 6 86 1 85 30 30 86 85 87 5 VDC4 F90 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75...

Page 3198: ...Disconnect connector F89 from relay box 2 Disconnect connector from VDCCM 3 Turn ignition switch to ON 4 Measure voltage between relay box con nector and chassis ground Connector terminal F89 No 2 Ch...

Page 3199: ...perate the check sequence Ref to VDC 19 VDC Sequence Control Can motor revolution noise buzz be heard when carrying out the check sequence Noise heard Go to step 8 Replace VDCH U Ref to VDC 8 VDC Cont...

Page 3200: ...VDC 227 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3201: ...CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 1...

Page 3202: ...K VDCCM 1 Turn ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform inspection mode 5 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current...

Page 3203: ...1 VDC CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18...

Page 3204: ...agnostic trouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same DTC indicated Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM Go to step 2 2 CHECK AN...

Page 3205: ...NTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 1...

Page 3206: ...HECK RUNNING FIELD Check if the vehicle was driven on banked road surfaces or sandy surfaces not dirt road surfaces Was the vehicle driven on banked road sur faces or sandy surfaces not dirt road sur...

Page 3207: ...B231 VDC CONTROL MODULE F96 B225 F87 B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B231 1 2 3 4 B234 1 2 3 4 5 6 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 1...

Page 3208: ...NTACT IN CONNECTORS Is there poor contact in yaw rate sensor con nector There is poor contact Repair or replace VDCCM connec tor Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 4 CHECK GROUND CIR...

Page 3209: ...teering angle sensor 3 Erase the memory 4 Perform inspection mode 5 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same DTC ind...

Page 3210: ...VDC 237 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3211: ...64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49...

Page 3212: ...T OF STEERING ANGLE SENSOR USING SELECT MONITOR 1 Drive the vehicle on a flat road 2 Stop the vehicle in a straight line 3 Select Current data display Save on the select monitor 4 Read steering angle...

Page 3213: ...K ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being out put Other DTC indicated Proceed with the diagnosis corre sponding to the diagnostic trouble code The origi...

Page 3214: ...VDC 241 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3215: ...63 67 66 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50...

Page 3216: ...to step 3 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in yaw rate and lateral G sensor connector There is poor contact Repair or replace VDCCM connec tor Replace VDCCM Ref to VDC 8 VDC Co...

Page 3217: ...ON 2 Measure voltage between VDCCM and chassis ground Connector terminal F87 No 65 Chassis ground Is the measured value less than the speci fied value 0 5 V Replace yaw rate and lateral G sen sor Ref...

Page 3218: ...VDC 245 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3219: ...6 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 4...

Page 3220: ...3 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in yaw rate and lateral G sensor connector There is poor contact Repair or replace VDCCM connec tor Replace VDCCM Ref to VDC 8 VDC Control M...

Page 3221: ...d VDCCM 8 CHECK YAW RATE AND LATERAL G SEN SOR 1 Turn ignition switch to OFF 2 Install yaw rate and lateral G sensor to body 3 Remove VDCCM connector cover Ref to VDC 19 VDCCM Connector Cover 4 Connec...

Page 3222: ...VDC 249 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3223: ...67 66 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51...

Page 3224: ...ound Is the measured value within the specified range 10 15 V Go to step 6 Go to step 4 4 CHECK OUTPUT VOLTAGE OF VDCCM 1 Turn ignition switch to OFF 2 Disconnect connector from VDCCM 3 Remove cover f...

Page 3225: ...less than the speci fied value 0 5 Go to step 10 Repair harness between yaw rate and lateral G sen sor and VDCCM 10 CHECK GROUND SHORT OF HARNESS Measure resistance between VDCCM and chassis ground Co...

Page 3226: ...3 Connect all connectors 4 Turn ignition switch to ON 5 Measure voltage between yaw rate and lat eral G sensor connector terminals Connector terminal F87 No 66 No 64 Is the measured value within the...

Page 3227: ...nostics Chart with Select Monitor AY DTC 73 ABNORMAL LATERAL G SENSOR OUTPUT NOTE For diagnostic procedure refer to DTC 73 Ref to VDC 256 DTC 73 EXCESSIVE LATERAL G SENSOR SIGNAL Diagnostics Chart wit...

Page 3228: ...VDC 255 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3229: ...63 67 66 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50...

Page 3230: ...step 3 Replace yaw rate and lateral G sen sor Ref to VDC 22 Yaw Rate and Lateral G Sensor 3 CHECK POOR CONTACT IN CONNECTORS Turn ignition switch to OFF Is there poor contact in connector between VDCC...

Page 3231: ...VDC00182 65 63 67 66 70 64 10 11 9 F88 F55 R49 4 3 12 2 4 5 8 1 5 6 R100 6 F88 R100 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54...

Page 3232: ...M Ref to VDC 8 VDC Control Mod ule VDCCM Go to step 4 4 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being out put Other DTC indicated Proceed with the diagn...

Page 3233: ...ensor from vehicle 3 Connect connector to yaw rate and lateral G sensor 4 Connect connector to VDCCM 5 Turn ignition switch to ON 6 Measure voltage between yaw rate and lat eral G sensor connector ter...

Page 3234: ...the memory 3 Perform inspection mode 4 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagnosis still being output Same pattern Replace VDCCM Ref to VDC 8...

Page 3235: ...RING DIAGRAM VDC00181 78 36 77 76 F91 VDC5 F88 2 3 F88 F91 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47...

Page 3236: ...ace VDCCM connec tor Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 4 CHECK POWER SUPPLY OF PRESSURE SENSOR NOTE When this inspection is carried out DTC 51 AB NORMAL VALVE RELAY is memorized but...

Page 3237: ...Turn ignition switch to OFF 2 Disconnect connector from VDCCM 3 Remove cover from VDCCM Ref to VDC 19 REMOVE VDCCM Connector Cover 4 Connect connector to VDCCM 5 Connect all connectors 6 Turn ignition...

Page 3238: ...VDC 265 VDC DIAGNOSTICS DIAGNOSTICS CHART WITH SELECT MONITOR MEMO...

Page 3239: ...WIRING DIAGRAM VDC00181 78 36 77 76 F91 VDC5 F88 2 3 F88 F91 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46...

Page 3240: ...or replace VDCCM connec tor Replace VDCCM Ref to VDC 8 VDC Control Mod ule VDCCM 4 CHECK POWER SUPPLY OF PRESSURE SENSOR NOTE When this inspection is carried out DTC 51 AB NORMAL VALVE RELAY is memori...

Page 3241: ...RE SENSOR 1 Turn ignition switch to OFF 2 Disconnect connector from VDCCM 3 Remove cover from VDCCM Ref to VDC 19 REMOVE VDCCM Connector Cover 4 Connect connector to VDCCM 5 Connect all connectors 6 T...

Page 3242: ...ECT MONITOR BE DTC 74 PRESSURE SENSOR 1 OFFSET IS TOO BIG PRIMARY PRESSURE SENSOR NOTE For diagnostic procedure refer to DTC 74 Ref to VDC 270 DTC 74 PRESSURE SENSOR 2 OFFSET IS TOO BIG SECONDARY PRES...

Page 3243: ...C00181 78 36 77 76 F91 VDC5 F88 2 3 F88 F91 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76...

Page 3244: ...Read pressure sensor output on the select monitor display Is the measured value within the specified range when brake pedal is depressed 0 48 0 72 V Go to step 3 Replace VDCH U Ref to VDC 8 VDC Contr...

Page 3245: ...1 78 36 77 76 F91 VDC5 F88 2 3 F88 F91 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 7...

Page 3246: ...terminal F91 No 13 Chassis ground F91 No 14 Chassis ground Is the measured value less than the speci fied value 0 5 V Go to step 4 Repair harness between VDCH U and VDCCM 4 CHECK INPUT VOLTAGE OF PRES...

Page 3247: ...0 2 V Go to step 9 Replace VDCH U Ref to VDC 8 VDC Control Mod ule VDCCM 9 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in connector between VDCCM and pressure sensor There is poor contact...

Page 3248: ...r Brake caliper Parking brake Axle wheels Brake pedal play Faulty steering angle sensor or improper neutral position Faulty yaw rate and lateral G sensor or improper installation Brake pads Brake pipe...

Page 3249: ...uspension play or fatigue reduced damping Axle wheels Tire specifications wear and pressures Noise inside passenger compartment VDCCM Faulty steering angle sensor or improper neutral position Faulty y...

Page 3250: ...ring angle sensor or improper neutral position Faulty yaw rate and lateral G sensor or improper installation Incorrect wiring or piping connections Power steering system Brake caliper Brake pads Disc...

Page 3251: ...VDC 278 VDC DIAGNOSTICS GENERAL DIAGNOSTIC TABLE MEMO...

Page 3252: ...embly 23 5 Rear Brake Pad 26 6 Rear Disc Rotor 27 7 Rear Disc Brake Assembly 29 8 Master Cylinder 32 9 Brake Booster 34 10 Proportioning Valve 39 11 Brake Fluid 40 12 Air Bleeding 42 13 Brake Hose 44...

Page 3253: ...dimensions length width thickness 82 4 33 7 9 0 mm 3 244 1 327 0 354 in Clearance adjustment Automatic adjustment Master cyl inder Type Tandem Effective diameter 26 99 mm 1 1 16 in RHD without VDC 25...

Page 3254: ...with VDC LHD Non turbo model Turbo model Brake pedal force Fluid pressure Fluid pressure Brake fluid pres sure without engine running 147 N 15 kgf 33 lb 686 kPa 7 kg cm2 100 psi 588 kPa 6 kg cm2 85 p...

Page 3255: ...body 11 Pad clip 19 Adhesive shim Option code EC EK KA B4 MT 2 Air bleeder screw 12 Outer shim Option code KO K1 K4 KA Except B4 MT KS 3 Guide pin Green 4 Pin boot 13 Inner shim Option code KO K1 K4 K...

Page 3256: ...Piston 19 Spring washer 32 Disc rotor 7 Piston boot 20 Parking brake lever 33 Bushing 8 Boot ring 21 Parking brake shoe Secondary 9 Lock pin Yellow 22 Parking brake shoe Primary Tightening torque N m...

Page 3257: ...ER LHD models without VDC 1 Cap 6 Secondary piston Tightening torque N m kgf m ft lb 2 Filter 7 Cylinder body T 14 1 4 10 1 3 Reservoir tank 8 Cylinder pin With ABS 4 Piston retainer 9 Seal 5 Primary...

Page 3258: ...TION LHD model with VDC 1 Cap 6 Secondary piston Tightening torque N m kgf m ft lb 2 Filter 7 Cylinder body T 14 1 4 10 1 3 Reservoir tank 8 Cylinder pin 4 C ring 9 Seal 5 Primary piston 10 Pin BR 002...

Page 3259: ...del 1 Cap 6 Primary piston 11 Pin 2 Filter 7 Secondary piston 3 Reservoir tank 8 Cylinder body Tightening torque N m kgf m ft lb 4 Bracket 9 Cylinder pin With ABS T 14 1 4 10 1 5 Piston retainer 10 Se...

Page 3260: ...RAL DESCRIPTION 4 HILL HOLDER 1 Clamp 4 Adjusting nut Tightening torque N m kgf m ft lb 2 PHV cable 5 Lock nut T1 3 5 0 35 2 5 3 PHV Pressure hold valve 6 To clutch pedal T2 18 1 8 13 0 BR 00121 1 1 2...

Page 3261: ...AL DESCRIPTION 5 BRAKE PIPES AND HOSE LHD model BR 00209 AT MODEL MT MODEL 1 1 2 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 T2 T1 T1 T2 T1 T1 T1 T1 T1 T1 T2 T1 T1 T1 T1 T1 T2 T1 T1 T1 T1 T1 T2 T2 T1 T1 T1 T1...

Page 3262: ...lb 2 Proportioning valve 9 Rear brake pipe LH T1 15 1 5 10 8 3 Front brake hose RH 10 Rear brake hose rear LH T2 18 1 8 13 0 4 Front brake hose LH 11 Rear brake hose RH 5 Center brake pipe assembly 1...

Page 3263: ...BRAKE GENERAL DESCRIPTION RHD model BR 00210 AT MODEL MT MODEL 1 1 2 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T1 T2 T2 T2 T2 T2 T2...

Page 3264: ...2 Proportioning valve 9 Rear brake pipe LH T1 15 1 5 10 8 3 Front brake hose RH 10 Rear brake hose rear LH T2 18 1 8 13 0 4 Front brake hose LH 11 Rear brake hose RH 5 Center brake pipe assembly 12 Re...

Page 3265: ...ION 6 BRAKE BOOSTER 1 Push rod 5 Filter 9 Valve body 2 Return spring 6 Silencer 10 Plunger valve 3 Reaction disc 7 Operating rod 11 Diaphragm plate 4 Key 8 Poppet valve 12 Valve return spring 8 7 9 6...

Page 3266: ...Assist spring 26 Lever 5 Brake pedal pad 16 Assist bushing 6 Brake pedal 17 Assist rod B Tightening torque N m kgf m ft lb 7 Clevis pin 18 Spring S T1 8 0 8 5 8 8 Brake pedal spring 19 Rod S T2 18 1 8...

Page 3267: ...switch 6 Stopper Tightening torque N m kgf m ft lb 2 Pedal bracket 7 Snap pin T1 8 0 8 5 8 3 Spacer 8 Brake pedal spring T2 18 1 8 13 0 4 Bushing 9 Brake pedal pad T3 29 3 0 21 7 5 Clevis pin 10 Brak...

Page 3268: ...1 Stopper 7 Brake pedal pad Tightening torque N m kgf m ft lb 2 Bushing 8 Brake pedal T1 8 0 8 5 8 3 Pedal bracket 9 Clevis pin T2 18 1 8 13 0 4 Stop light switch 10 Brake pedal spring T3 30 3 1 22 4...

Page 3269: ...ket 7 Brake pedal pad Tightening torque N m kgf m ft lb 2 Stop light switch 8 Brake pedal T1 8 0 8 5 8 3 Spacer 9 Snap pin T2 18 1 8 13 0 4 Bushing 10 Brake pedal spring T3 30 3 1 22 4 5 Clevis pin 6...

Page 3270: ...ine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop...

Page 3271: ...ote AS880N Part No 26298AC000 to the frictional portion between pad and pad clip 2 Apply thin coat of Molykote AS880N Part No 26298AC000 between pad and pad inner shim Option code KO K1 K4 KA Except B...

Page 3272: ...n A wear indicator is provided on the inner disc brake pad If the pad wears down to such an ex tent that the end of the wear indicator contacts the disc rotor a squeaking sound is produced as the whee...

Page 3273: ...el nuts 2 Set a dial gauge on the disc rotor Turn disc rotor to check runout NOTE Make sure that dial gauge is set 5 mm 0 20 in inward of rotor outer perimeter If disc rotor runout is above standard v...

Page 3274: ...mud and foreign particles from caliper body assembly and support B INSTALLATION 1 Install disc rotor on hub 2 Install support on housing Tightening torque 78 N m 8 kgf m 58 ft lb CAUTION Replace pad c...

Page 3275: ...orce piston out 5 Remove the piston seal from caliper body cylin der CAUTION Be careful not to scratch the inner surface of cylinder and piston seal groove 6 Remove the lock pin boot and guide pin boo...

Page 3276: ...t 8 Apply a coat of specified grease to the lock pin and guide pin outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No K0779GA102 9 Install the lock pin boot and guide pi...

Page 3277: ...Rear Disc Rotor 3 Install pad on support 4 Install caliper body on support Tightening torque 39 N m 4 0 kgf m 28 9 ft lb NOTE If it is difficult to push piston during pad replace ment loosen air bleed...

Page 3278: ...installing an 8 mm bolt in holes B on the rotor B INSTALLATION 1 Install in the reverse order of removal 2 Adjust parking brake Ref to PB 11 ADJUST MENT Parking Brake Assembly C INSPECTION 1 Secure di...

Page 3279: ...SC ROTOR 3 Measure disc rotor thickness NOTE Make sure that micrometer is set 5 mm 0 20 in in ward of rotor outer perimeter Disc rotor thickness A Standard value 10 mm 0 39 in Service limit 8 5 mm 0 3...

Page 3280: ...tening torque 78 N m 8 0 kgf m 58 ft lb CAUTION Always replace the pads for both the left and right wheels at the same time Also replace pad clips if they are twisted or worn A wear indicator is provi...

Page 3281: ...erior using brake fluid 2 Apply a coat of brake fluid to piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surf...

Page 3282: ...LUBE RX 2 Part No 003606000 8 Install guide pin boot on caliper body 9 Install lock pin boot on caliper body and insert lock pin sleeve into place E INSPECTION 1 Repair or replace faulty parts 2 Check...

Page 3283: ...1 Remove pin with drift pin which secures reserve tank to master cylinder 2 Remove cylinder pin with magnetic pick up tool while pushing in primary piston 3 Pry up the pawl and remove the piston retai...

Page 3284: ...cylinder E INSPECTION If any damage deformation wear swelling rust and other faults are found on the primary piston as sembly secondary piston assembly supply valve stopper or gasket replace the fault...

Page 3285: ...ake booster installing nuts 5 Remove brake booster while shunning brake pipes NOTE Be careful not to drop brake booster Brake booster should be discarded if it has been dropped Use special care when h...

Page 3286: ...s do not drag C INSPECTION 1 OPERATION CHECK WITHOUT GAUG ES CAUTION When checking operation be sure to securely apply the hand brake Checking without gauges This method cannot determine the exact por...

Page 3287: ...gauges 2 OPERATION CHECK WITH GAUGES CAUTION When checking operation be sure to securely apply the hand brake Checking with gauges Connect gauges as shown in Figure After bleeding air from pressure g...

Page 3288: ...eep engine running until a vacuum of 66 7 kPa 500 mmHg 19 69 in Hg point B is indicated on vacuum gauge while the pedal is still depressed 2 Stop engine and watch vacuum gauge If the vacuum drop range...

Page 3289: ...standard value listed Model OUTBACK Except OUTBACK RHD without VDC RHD with VDC LHD Brake pedal force Fluid pressure Fluid pressure 147 N 15 kgf 33 lb 686 kPa 7 kg cm2 100 psi 588 kPa 6 kg cm2 85 psi...

Page 3290: ...rtioning valve to brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft lb Proportioning valve to bracket 18 N m 1 8 kgf m 13 0 ft lb C INSPECTION 1 Install oil pressure gauges to measure the mas ter cylinder...

Page 3291: ...ately 500 m2 16 9 US fl oz 17 6 Imp fl oz for to tal brake system 1 Either jack up vehicle and place a safety stand under it or lift up vehicle 2 Remove both front and rear wheels 3 Draw out the brake...

Page 3292: ...proximately 20 seconds At this time check pedal to see if it shows any unusual movement Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install whe...

Page 3293: ...eration keep the brake reser voir tank filled with brake fluid to eliminate entry of air Brake pedal operation must be very slow For convenience and safety two people should do the work 1 Loosen wheel...

Page 3294: ...ake pedal with a 490 N 50 kgf 110 lb load and measure the distance between the brake pedal and steering wheel With the brake pedal released measure the distance between the pedal and steering wheel ag...

Page 3295: ...eform flare nut 2 Pull out clamp to remove brake hose 3 Remove bolt at strut and union bolt 2 REAR BRAKE HOSE 1 Separate brake pipe from brake hose NOTE Always use flare nut wrench and be careful not...

Page 3296: ...hile holding hexagonal part of brake hose fit ting with a wrench tighten flare nut to the specified torque Tightening torque Brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft lb 8 Bleed air from the brake...

Page 3297: ...m wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits Be careful not to damage airbag system wir ing harness when servicing the center brake pipe...

Page 3298: ...ention not to damage hexagonal head of flare nut by using pipe wrench without fail 5 Detach PHV along with support from side frame CAUTION Exercise utmost care to prevent foreign matter from entering...

Page 3299: ...n of lever Grease SUNLIGHT 2 Part No 003602010 6 Be sure to bleed air from the brake system 7 Adjust PHV cable Ref to BR 49 Adjustment CAUTION After replacing PHV cable with new one oper ate clutch pe...

Page 3300: ...higher inclination 1 If vehicle does not stop Tighten adjusting nut of PHV cable 2 If vehicle does not start properly Case A When hill holder is released later than engagement of clutch pedal Engine...

Page 3301: ...ove clevis pins which secure lever to push rod and operating rod 7 Remove PHV adjusting nut and lock nut 8 Remove cable clamp and disconnect PHV ca ble from PHV CAUTION Carefully protect boot and inne...

Page 3302: ...h secures brake pedal to brake booster operating rod Also disconnect stop light switch connector 5 Remove AT unit from brake panel 2 nuts 6 Remove two bolts and four nuts which secure brake pedal to p...

Page 3303: ...topper 5 Remove the brake pedal pad RHD model NOTE For disassembly procedures refer to AT MODEL Ref to BR 52 AT MODEL DISASSEMBLY Brake Pedal 2 AT MODEL 1 Remove the brake switch 2 Unbolt and then rem...

Page 3304: ...ling spacer Tightening torque T 29 N m 3 0 kgf m 21 7 ft lb 4 Set brake pedal position by adjusting position of stop light switch Pedal position L LHD 126 4 mm 4 98 in RHD 154 9 mm 6 10 in Tightening...

Page 3305: ...02 in Brake pedal free play A 1 3 mm 0 04 0 12 in Depress brake pedal pad with a force of less than 10 N 1 kgf 2 lb 3 If it is not in specified value adjust it by adjusting brake booster operating ro...

Page 3306: ...m 5 8 ft lb C INSPECTION 1 If stop light switch does not operate properly or if it does not stop at the specified position replace with a new one Specified position L 2 1 5 0 mm 0 079 0 059 0 in 2 Me...

Page 3307: ...n the lock nut and adjust stop light switch po sition until the clearance A between threaded end of the stop light switch and the stopper becomes 0 3 mm 0 012 in Then tighten the lock nut 1 Stop light...

Page 3308: ...ce the rear brake and cable system 3 Excessive pedal stroke 1 Entry of air into the hydraulic mechanism Bleed the air 2 Excessive play in the master cylinder push rod Adjust 3 Fluid leakage from the h...

Page 3309: ...djust 5 Sealing of PHV is poor Replace entire PHV assembly 3 Shock is felt when starting 1 Poor adjustment of starting performance Adjust 2 When depressing the brake pedal strongly The stronger brake...

Page 3310: ...PARKING BRAKE PB Page 1 General Description 2 2 Parking Brake Lever 6 3 Parking Brake Cable 7 4 Parking Brake Assembly 9 5 General Diagnostic Table 12...

Page 3311: ...SPECIFICATIONS Type Mechanical on rear brakes drum in disc Effective drum diameter mm in 170 6 69 Lining dimensions length width thickness mm in 162 6 30 0 3 2 6 40 1 181 0 126 Clearance adjustment Ma...

Page 3312: ...rut 14 Shoe hold down cup 3 Spring washer 9 Shoe guide plate 15 Shoe hold down spring 4 Lever 10 Primary return spring 16 Shoe hold down pin 5 Parking brake shoe Primary 11 Secondary return spring 17...

Page 3313: ...mp Tightening torque N m kgf m ft lb 2 Parking brake switch 8 Parking brake cable RH T1 5 9 0 60 4 3 3 Lock nut 9 Clamp Rear disc brake model only T2 18 1 8 13 0 4 Adjusting nut T3 32 3 3 24 5 Equaliz...

Page 3314: ...hands because each part on the vehicle is hot after running Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tig...

Page 3315: ...USTMENT Parking Brake Lever C INSPECTION While pulling parking brake lever upward count the notches Lever stroke 7 to 8 notches when pulled with a force of 196 N 20 kgf 44 lb Incorrect adjust the park...

Page 3316: ...able from rear brake Ref to PB 9 REMOVAL Parking Brake Assem bly 12 Pull out clamp from rear brake 13 Remove bolt and bracket from trailing link bracket 14 Remove bolt and clamp from rear floor 15 Det...

Page 3317: ...the removed cable and replace if damaged rusty or malfunctioning 1 Check for smooth operation of the cable 2 Check the inner cable for damage and rust 3 Check the outer cable for damage bends and cra...

Page 3318: ...hub drive disc rotor out by installing an 8 mm bolt in holes B on the rotor 5 Remove shoe return spring from parking brake assembly 6 Using a standard screwdriver remove front shoe hold down spring an...

Page 3319: ...with right one NOTE Ensure that adjuster assembly is securely installed with screw in the left side facing vehicle front NOTE Ensure that shoe return spring is installed as shown in Figure 3 Adjust pa...

Page 3320: ...using a slot type screw driver until brake shoe is in close contact with disc rotor 3 Turn back downward adjusting screw 3 or 4 notches 4 Install adjusting hole cover to back plate 2 LEVER STROKE 1 Re...

Page 3321: ...e cause Remedy Brake drag Parking brake lever is maladjusted Adjustment Parking brake cable does not move Repair or replace Parking brake shoe clearance is maladjusted Adjustment Return spring is faul...

Page 3322: ...Page 1 General Description 2 2 Steering Wheel 24 3 Universal Joint 25 4 Tilt Steering Column 28 5 Steering Gearbox LHD MODEL 31 7 Pipe Assembly 70 8 Oil Pump 79 9 Reservoir Tank 90 10 Power Steering...

Page 3323: ...e Valve Power steering system Rotary valve Pump Power steering system Type Vane pump Oil tank Installed on body Output cm3 cu in rev 7 2 0 439 9 6 0 65 0 586 0 040 Relief pressure kPa kg cm2 psi 9 807...

Page 3324: ...4 or less Turning resistance N kgf lb Within 30 mm 1 18 in from rack center in straight ahead position Less than 11 18 1 14 2 51 Maximum allowable value 12 7 1 3 2 9 Oil pump Power steering system Pul...

Page 3325: ...Turbo model 1 Crossmember Pipe 5 mm 0 20 in 2 DOJ Shaft or joint 14 mm 0 55 in 3 DOJ Valve housing 11 mm 0 43 in 4 Pipe Pipe 2 mm 0 08 in 5 Stabilizer Pipe 5 mm 0 20 in 6 Exhaust pipe Pipe 15 mm 0 59...

Page 3326: ...PS 5 POWER ASSISTED SYSTEM POWER STEERING GENERAL DESCRIPTION A Except 3 0 L and Turbo model B 3 0 L and Turbo model PS 00197 A B 9 8 1 6 4 3 2 7 5 11 12 10 A A A...

Page 3327: ...STEERING WHEEL AND COLUMN 1 Bushing 6 Steering wheel Tightening torque N m kgf m ft lb 2 Seal 7 Airbag module T1 1 2 0 12 0 9 3 Steering shaft 8 Lower steering wheel cover T2 25 2 5 18 1 4 Steering ro...

Page 3328: ...PS 7 POWER ASSISTED SYSTEM POWER STEERING GENERAL DESCRIPTION MEMO...

Page 3329: ...9 10 10 58 59 57 57 61 62 12 12 13 13 14 15 16 17 18 60 19 19 19 19 51 50 34 32 20 21 23 25 22 24 26 27 36 29 30 36 37 38 39 40 41 42 43 44 45 46 47 56 55 54 53 52 43 44 45 46 47 48 49 31 28 35 33 37...

Page 3330: ...Pulley 39 Castle nut T3 8 0 8 5 8 12 Oil pump 40 Dust seal T4 13 1 3 9 4 13 Bracket 41 Clip T5 15 1 5 10 8 14 Belt tension nut 42 Tie rod end T6 15 1 5 10 8 15 Bushing 43 Clip T7 15 7 1 6 11 6 16 Belt...

Page 3331: ...2 3 4 4 4 4 4 4 5 6 7 7 8 8 10 11 10 11 12 12 13 14 15 16 17 18 19 20 21 22 23 39 40 27 26 34 28 29 30 31 32 33 36 37 38 35 41 42 43 24 44 24 25 46 25 47 48 49 50 51 34 35 45 52 52 55 56 53 54 T3 T12...

Page 3332: ...k bracket 35 Lock washer T3 13 1 3 9 4 10 Pulley 36 Holder T4 15 7 1 6 11 6 11 Oil pump 37 Bushing T5 20 2 0 14 5 12 Bracket 38 Oil seal T6 22 2 2 15 9 13 Belt tension nut 39 Seal ring T7 24 2 4 17 4...

Page 3333: ...0 L and Turbo model be cause it cannot be disassembled 1 Pulley 7 Cam ring 13 Rear body 2 Oil seal 8 Circlip 14 Pressure swtich 3 Front casing 9 Straight pin 15 Connector 4 O ring 10 Rotor 5 Socket 11...

Page 3334: ...fy the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running Use SUBARU genuine steering f...

Page 3335: ...700000 WRENCH Used for removing and installing tie rod Apply this tool to rack 925711000 PRESSURE GAUGE Used for measuring oil pump pressure 926200000 STAND Used when inspecting characteristic of gear...

Page 3336: ...000 SPANNER For the lock nut when adjusting backlash of gearbox Measurement of rotating resistance of gear box assembly 34199AE020 MOUNT Used for disassembling oil pump 34199AE030 INSTALLER Used for i...

Page 3337: ...0 INSTALLER B Used for installing ball bearing into housing 926370000 INSTALLER A Used for installing valve assembly into valve housing assembly Used with STAND BASE 927630000 926390001 COVER REMOVER...

Page 3338: ...leaking points 926400000 GUIDE Right side of rack when installing rack bush ing Used with GUIDE 927660000 927660000 GUIDE Right side of rack when installing rack bush ing Used with GUIDE 926400000 927...

Page 3339: ...h INSTALLER B 927620000 34199AE060 INSTALLER Used for installing oil seal 34099FA120 INSTALLER REMOVER SEAL Used for installing valve housing oil seal Used with INSTALLER SEAL 34099FA130 Used for inst...

Page 3340: ...30 INSTALLER SEAL Used for installing valve housing oil seal Used with INSTALLER AND REMOVER SEAL 34099FA120 926250000 GUIDE Used for installing holder ASSY into rack hous ing 927490000 INSTALLER A B...

Page 3341: ...ving back up ring and oil seal 927520000 INSTALLER D Used for installing pinion bearing 927530000 INSTALLER E Used for installing pinion bearing 927570000 SPACER Used for installing pinion oil seal IL...

Page 3342: ...ack and seal into housing assembly 34099FA030 INSTALLER REMOVER Used for removing and installing rack oil seal outer inner 34199AE010 INSTALLER Used for installing rack oil seal outer 34099FA060 PUNCH...

Page 3343: ...for supporting housing assembly 34099FA080 PUNCH Used for removing caulking 34199AE090 PLUG WRENCH Used for removing plug 34199AE100 PLUG OIL SEAL REMOVER Used for removing plug oil seal ILLUSTRATION...

Page 3344: ...EAL REMOVER Used for removing gearbox oil seal 34199AE130 GEARBOX OIL SEAL INSTALLER Used for installing gearbox oil seal TOOL NAME REMARKS Spring scale Used for measuring tightening torque Snap ring...

Page 3345: ...2 Install in the reverse order of removal NOTE Align matching marks on steering wheel and steer ing column Tightening torque 4 5 N m 4 5 kgf m 32 5 ft lb Column cover to steering wheel clearance 2 4...

Page 3346: ...he short yoke side Raise universal joint to make sure the bolt is properly passing through the cutout at the ser rated section 4 Tighten bolt on the long yoke then that on the short yoke side Tighteni...

Page 3347: ...ice limit Maximum load 5 49 N 0 56 kgf 1 23 lb or less Service limit Maximum load 5 49 N 0 56 kgf 1 23 lb or less Service limit Maximum load 8 43 N 0 86 kgf 1 90 lb or less Inspection Corrective actio...

Page 3348: ...PS 27 POWER ASSISTED SYSTEM POWER STEERING UNIVERSAL JOINT Service limit Maximum load 8 43 N 0 86 kgf 1 90 lb or less 1 Short yoke PS 00037 1...

Page 3349: ...R ASSISTED SYSTEM POWER STEERING TILT STEERING COLUMN 4 Tilt Steering Column A REMOVAL 1 Tilt steering column Tightening torque N m kgf m ft lb 2 Universal joint T1 24 2 4 17 4 T2 25 2 5 18 1 PS 00201...

Page 3350: ...ON 1 Set grommet to toe board 2 Insert end of steering shaft into toe board grom met 3 Tighten steering shaft mounting bolts under in strument panel Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 4 Con...

Page 3351: ...on switch harness be tween column cover mounting bosses Tightening torque 1 2 N m 0 12 kgf m 0 9 ft lb CAUTION Don t overtorque screw E INSPECTION 1 BASIC INSPECTION Measure overall length of steering...

Page 3352: ...stle nut 6 Remove jack up plate and front stabilizer Ref to FS 21 REMOVAL Front Stabilizer 7 Remove one pipe joint at the center of gearbox and connect vinyl hose to pipe and joint Discharge fluid by...

Page 3353: ...Be careful not to damage these pipes 4 Install universal joint Ref to PS 25 INSTAL LATION Universal Joint 5 Connect tie rod end and knuckle arm and tight en with castle nut Fit cotter pin into the nu...

Page 3354: ...HD MODEL 13 Install jack up plate 14 Lower vehicle 15 Check fluid level in oil tank 16 After adjusting toe in and steering angle tight en lock nut on tie rod end Tightening torque 83 N m 8 5 kgf m 61...

Page 3355: ...a wrench 32 mm 1 26 in width across flats or adjustable wrench remove tie rod CAUTION Check ball joint for free play and tie rod for bends Replace if necessary Check dust seals used with tie rod end b...

Page 3356: ...N Do not reuse removed rack bushing and circlip 16 Insert ST from pinion housing side and remove oil seal using a press ST 34199AE050 OIL SEAL REMOVER NOTE Discard removed oil seal 2 CONTROL VALVE ASS...

Page 3357: ...ly from valve housing using pipe of I D 44 to 46 mm 1 73 to 1 81 in and a press 7 Using ST and press remove oil seal and special bearing from valve housing ST 34099FA120 INSTALLER REMOVER SEAL CAUTION...

Page 3358: ...ON Use only SUBARU genuine grease for gearbox Grease VALIANT GREASE M2 Part No 003608001 net 0 5 kg 1 1 lb 1 Force fit oil seal using ST ST 34199AE050 INSTALLER CAUTION Be careful not to damage or scr...

Page 3359: ...on ring to prevent seal from being damaged 5 Insert rack assembly into rack housing from cyl inder side and remove ST after it has passed com pletely through oil seal NOTE Before inserting rack assemb...

Page 3360: ...y a thin film of grease to sliding portion of rack shaft CAUTION When moving rack to stroke end without tie rod attached prevent shocks from being ap plied at the end Do not apply grease to threaded p...

Page 3361: ...ahead direction 3 Apply grease to sleeve 4 Tighten adjusting screw by approx two threads 5 Apply liquid packing to at least 1 3 of entire perimeter of adjusting screw thread Liquid packing THREE BOND...

Page 3362: ...tions of boots to the following portions in both sides of assembled steering gear box The groove on gearbox The groove on the rod Make sure that boot is installed without unusual inflation or deflatio...

Page 3363: ...upper pipe D second Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 2 CONTROL VALVE ASSEMBLY Specified steering grease VALIANT GREASE M2 Part No 003608001 1 Clean all parts and tools before reassembling...

Page 3364: ...27620000 INSTALLER B NOTE Apply specified power steering fluid to oil seal and ST3 being careful not to damage oil seal lip Push oil seal until ST3 contacts housing end face 8 Remove ST3 and fit backi...

Page 3365: ...oil seal at the inside might be damaged 18 Apply grease to sliding surface of sleeve and spring seat then insert sleeve into pinion housing Fit spring into sleeve screw pack grease inside of screw the...

Page 3366: ...ue Lock nut 39 N m 4 0 kgf m 29 ft lb NOTE Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut Make adjustment so that steering wheel can be rotated fully from lock...

Page 3367: ...and pinion engage uniformly and smoothly with each other Refer to Service limit 2 Keeping rack pulled out all the way so that all teeth emerge check teeth for damage Even if abnormality is found in e...

Page 3368: ...aluminum plates etc between vise and gearbox ST 926200000 STAND Sliding resistance of rack shaft Service limit 304 N 31 kgf 68 lb or less 3 RACK SHAFT PLAY IN RADIAL DIREC TION Right turn steering Ser...

Page 3369: ...axial direction Service limit 0 5 mm 0 020 in or less On condition P 20 49 N 2 5 kgf 4 11 lb 5 TURNING RESISTANCE OF GEARBOX Using ST measure gearbox turning resistance ST 926230000 SPANNER Service li...

Page 3370: ...to clean the gearbox hoses pipes and surrounding parts After completing repair work clean these ar eas again Oil leak check procedure and replacement parts NOTE Parts requiring replacement are describ...

Page 3371: ...fter this op eration CAUTION If leakage from f is noted again The oil seal of pinion and valve assembly is damaged Replace pinion and valve assembly with a new one Or replace the oil seal and the part...

Page 3372: ...er 10 Disconnect one pipe joint A from center of gearbox assembly and connect a vinyl hose to it While turning steering wheel to the left and right drain fluid through the hose Similarly drain fluid f...

Page 3373: ...roll connector Ref to AB 19 ADJUSTMENT Roll Connector CAUTION Ensure that front wheels are set in straight for ward direction 10 Install steering wheel Ref to PS 24 INSTAL LATION Steering Wheel 11 Ins...

Page 3374: ...ot to scratch rack surface as oil leaks may result 5 Using ST loosen lock nut ST 926230000 SPANNER 6 Tighten adjusting screw until it no longer tight ens 7 Using a wrench 32 mm width across flats or a...

Page 3375: ...ce pipes and or flare nuts if damaged 10 Slide dust cover out CAUTION Be careful not to scratch housing or input shaft during dust cover removal Also do not al low foreign matter to enter housing inte...

Page 3376: ...seal out ST 34099FA030 INSTALLER REMOVER CAUTION Block pipe connection of steering body to prevent fluid from flowing out Do not allow rack to come in contact with in ner wall of cylinder Otherwise c...

Page 3377: ...out CAUTION Discard back up ring and oil seal after removal and replace with new ones ST 927580000 REMOVER 16 Using ST1 and ST2 repair cylinder s clinched sections ST1 34099FA080 PUNCH ST2 34099FA070...

Page 3378: ...face Replace plug circumference O rings with new ones 19 Set ST on drawing dimension ST 34199AE120 GEARBOX OIL SEAL RE MOVER 20 Insert ST into gearbox while setting stopper in advance 21 By fixing 2 s...

Page 3379: ...s shown Apply a coat of grease to needle bearing ST 926200000 STAND CAUTION Use a ST to support steering body Ensure that needle bearing is free from de fects If it is faulty replace steering body wit...

Page 3380: ...r side ST 34199AE000 GUIDE Oil seal CAUTION Be sure to apply grease so that it covers the entire surface of rack gear teeth Do not allow grease to block air vent hole on rack 7 Slowly press inner side...

Page 3381: ...9 Install holder from cylinder side of steering body Tightening torque 64 5 N m 6 5 0 5 kgf m 47 0 3 6 ft lb 10 Attach ST to rack cylinder Using a press in stall back up ring and oil seal NOTE Press S...

Page 3382: ...eth of valve assembly and attach valve assembly CAUTION Be careful not to scratch oil seal on valve gear teeth Be careful not to scratch seal ring of valve circumference 14 Apply grease on oil seal ci...

Page 3383: ...n sert sleeve into steering body Charge the adjusting screw with grease and then insert the spring into adjusting screw and install on steering body 18 Tighten the adjusting screw to specified torque...

Page 3384: ...adjusting screw with a wrench to prevent it from turning while tightening lock nut 24 Extend the rack approx 40 mm 1 57 in be yond side of steering body 25 Install the tie rod and a new lock washer in...

Page 3385: ...with clip small 30 After installing check the boot end is posi tioned into groove on tie rod 31 If the tie rod end was removed screw in the lock nut and tie rod end to screwed portion of tie rod and...

Page 3386: ...and pinion engage uniformly and smoothly with each other Refer to Service limit 2 Keeping rack pulled out all the way so that all teeth emerge check teeth for damage Even if abnormality is found in ei...

Page 3387: ...less Difference between left and right sliding resis tance Less than 20 3 RACK SHAFT PLAY IN RADIAL DIREC TION Right turn steering Service limit Less than 0 4 mm 0 016 in direction Less than 0 6 mm 0...

Page 3388: ...0106 in or less On condition P 20 49 N 2 5 kgf 4 11 lb 5 TURNING RESISTANCE OF GEARBOX Using ST measure gearbox turning resistance ST 926230000 SPANNER Service limit Straight ahead position within 30...

Page 3389: ...parts including damaged parts and spare parts damaged In actual disas sembly work accidental damage as well as inevita ble damage to some related parts must be taken into account and spare parts for...

Page 3390: ...g from f The oil seal of rack housing is damaged Re place the oil seal and the parts that are dam aged during disassembly with new ones F ADJUSTMENT 1 Adjust front toe Standard of front toe IN 3 OUT 3...

Page 3391: ...d counterclockwise Discharge fluid similarly from the other pipe CAUTION Improper removal and installation of parts often causes fluid leak trouble To prevent this clean the surrounding portions befor...

Page 3392: ...ting pipes use two wrench es to prevent deformities Be careful to keep pipe connections free from foreign matter 7 Lower the vehicle 8 Remove intake duct 9 Remove bolt A Except 3 0 L and Turbo model D...

Page 3393: ...th B INSTALLATION 1 Tighten bolt A CAUTION Visually check that hose between tank and pipe D is free from bending or twisting Except 3 0 L and Turbo model 3 0 L and Turbo model 1 Connect pipe D or retu...

Page 3394: ...ue 7 4 N m 0 75 kgf m 5 4 ft lb 4 Tighten joint nut Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 5 Connect pipe A and B Connect pipes A and B to four pipe joints of gear box Connect upper pipe B firs...

Page 3395: ...f m 14 5 ft lb T2 24 N m 2 4 kgf m 17 4 ft lb 6 Install jack up plate 7 Connect battery ground cable 8 Feed the specified fluid NOTE Never start the engine before feeding the fluid oth erwise vane pum...

Page 3396: ...lose to crossmember Pipe to crossmember clearance 10 mm 0 39 in min 2 Check that clearance between cruise con trol pump and power steering hose is at least 10 mm 0 39 in If it is not bend section B do...

Page 3397: ...oil pump the fluid etc due to over heat So avoid to keep this kind of condition when servicing as well as driving Part name Inspection Remedy Pipe O ring fitting surface for damage Nut for damage Pip...

Page 3398: ...ly no leakage This is because the flu id spilt during the last maintenance was not completely wiped off Be sure to wipe off spilt fluid thor oughly after maintenance A Except 3 0 L and Turbo model B 3...

Page 3399: ...are nut or eye bolt Loosen and retighten if ineffective replace Poor insertion of hose poor clamping Retighten or replace clamp Damaged O ring or gasket Replace O ring or gasket pipe or hose with new...

Page 3400: ...ow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from entering the hose and pipe cover the open ends of them with a clean cloth 6 Remove bolts which install p...

Page 3401: ...CAUTION Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from entering the hose cover the open ends of them with a clean cloth 7 Remove bolts which...

Page 3402: ...directly in the vise use soft pads and hold oil pump lightly to protect the pump 2 Tighten bolt which installs oil pump and switch bracket to bracket Tightening torque 37 3 N m 3 8 kgf m 27 5 ft lb Ti...

Page 3403: ...l pulley belt cover bracket 11 Connect ground terminal of battery 12 Feed the specified power steering fluid Ref to PS 92 Power Steering Fluid CAUTION Never start the engine before feeding the fluid o...

Page 3404: ...all pulley belt cover 8 Connect ground terminal of battery 9 Feed the specified power steering fluid Ref to PS 92 Power Steering Fluid CAUTION Never start the engine before feeding the fluid otherwise...

Page 3405: ...inside the front casing Remove it completely by blowing com pressed air 5 Ensure that parts are free from rust Use specified hydraulic oil for rust prevention after cleaning and drying 6 Reverse the...

Page 3406: ...eassembly procedures have been com pleted turn shaft by hand to ensure it turns smooth ly If it binds or other unusual conditions are evident disassemble again and check for foreign matter trapped on...

Page 3407: ...s and side sur faces 7 Rotor 1 Wear and damage on sliding surfaces 2 Ridge wear on vane sliding grooves If light leaks with vane in slit against light source 3 Damage resulting from snap ring removal...

Page 3408: ...ay of pulley shaft On condition P 9 8 N 1 0 kgf 2 2 lb Service limit Radial play Direction 0 4 mm 0 016 in or less Axial play Direction 0 6 mm 0 024 in or less 2 Ditch deflection of pulley Service lim...

Page 3409: ...ing the measurement 1 REGULAR PRESSURE MEASUREMENT 1 Connect ST1 ST2 and ST3 ST1 92511000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A 2 Disconnect pressure hose from the...

Page 3410: ...psi 4 If it is not within the specified value replace the oil pump 3 Measure working pressure 1 Using STs measure working pressure 2 Open valve 3 Measure working pressure of control valve by turning w...

Page 3411: ...n fluid from the reservoir tank 2 Disconnect return hose and suction hose from reservoir tank CAUTION Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matt...

Page 3412: ...acket 2 Connect return hose and suction hose to reser voir tank 3 Feed the specified power steering fluid Ref to PS 92 Power Steering Fluid C INSPECTION Check reservoir tank for cracks breakage or dam...

Page 3413: ...voir surface of oil pump read the fluid level on the COLD side 2 Check at temperature 80 C 176 F on res ervoir surface of oil pump read the fluid level on the HOT side C REPLACEMENT 1 Set the vehicle...

Page 3414: ...n the tank leave it about half an hour and then do the step 5 all over again 8 Stop the engine and take out safety stands after jacking up vehicle again Then lower the vehicle and idle the engine 9 Co...

Page 3415: ...iformity of pulley belt cross section Pulley belt touches to pulley bottom Poor revolution of pulleys except oil pump pulley Poor revolution of oil pump pulley Adjust or replace 2 Tire and rim Imprope...

Page 3416: ...d power steering can be operated easily due to its light steering effort If doing so the disk rotates slightly and makes creaking noise The noise is generated by creaking between the disk and pads If...

Page 3417: ...squeak intermittent or continuous While engine is running Maladjustment of pulley belt Damaged or charged pulley belt Unequal length of pulley belts Adjust or replace Replace two belts as a set Run o...

Page 3418: ...than the specified value 2 26 N 0 23 kgf 0 51 lb Go to step 4 Check adjust and replace if neces sary 4 CHECK STEERING WHEEL EFFORT Measure steering wheel effort Is the fluctuation width less than the...

Page 3419: ...1 61 kgf 3 55 lb or less in all positions within 20 difference between clock wise and counterclockwise Go to step 11 Readjust back lash and if ineffec tive replace bad parts 11 CHECK GEARBOX Measure...

Page 3420: ...by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations contained in...

Page 3421: ...2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION G2300GE7 CRUISE CONTROL SYSTEM CC CRUISE CONTROL SYSTEM DIAGNOSTICS CC IMMOBILIZER DIAGNOSTICS IM...

Page 3422: ...7 Heater Unit 30 8 Blower Motor Assembly 31 9 Heater Blower Resistor 32 10 Heater Core 33 11 Control Unit 34 12 Compressor 35 13 Condenser 37 14 Receiver Drier 39 15 Intake Unit 40 16 Flexible Hose 42...

Page 3423: ...Air flow rate LHD model 300 m3 10 593 cu ft h Heat mode FRESH FULL HOT at 12 5 V RHD model 300 m3 10 593 cu ft h Max air flow rate LHD model 500 m3 17 655 cu ft h Temperature control switch FULL COLD...

Page 3424: ...u in Expansion valve Type External equalizing Evaporator Type Single tank Dimensions W H T 235 224 60 mm 9 25 8 82 2 36 in Blower fan Fan type Sirocco fan Outer diameter width 150 75 mm 5 91 2 95 in P...

Page 3425: ...xternally equalizing Evaporator Type Multi tank Dimensions W H T 214 4 195 58 mm 8 44 7 68 2 28 in Blower fan Fan type Sirocco fan Outer diameter width 150 75 mm 5 91 2 95 in Power consumption 220 W a...

Page 3426: ...in Expansion valve Type Internal equalizing Evaporator Type Single tank Dimensions W H T 235 224 60 mm 9 25 8 82 2 36 in Blower fan Fan type Sirocco fan Outer diameter width 150 75 mm 5 91 2 95 in Po...

Page 3427: ...ternally equalizing Evaporator Type Multi tank Dimensions W H T 214 4 195 58 mm 8 44 7 68 2 28 in Blower fan Fan type Sirocco fan Outer diameter width 150 75 mm 5 91 2 95 in Power consumption 220 W at...

Page 3428: ...ator With AUTO A C model 16 Aspirator inlet With AUTO A C model 2 Side link 3 Vent lever 10 Mix lever 17 Foot door 4 Case A 11 Case D 5 DEF door 12 Mix door Tightening torque N m kgf m ft lb 6 Vent do...

Page 3429: ...nt door lever A 12 Heater core 20 Aspirator inlet With AUTO A C model 4 Vent door lever B 13 Mix door 5 DEF door lever 14 Foot door 6 Side link A 15 Foot duct Tightening torque N m kgf m ft lb 7 Foot...

Page 3430: ...C 17 Blower motor 3 Door A 10 Blower plate 18 Fan 4 Intake unit case upper 11 Resistor 5 Thermistor With A C model 12 Evaporator With A C model Tightening torque N m kgf m ft lb 6 Block expansion valv...

Page 3431: ...ower 2 Door lever 9 Block expansion valve With A C model 15 Drain hose 3 Intake unit case upper 4 Resistor 10 Evaporator With A C model Tightening torque N m kgf m ft lb 5 Door A 11 Thermistor With A...

Page 3432: ...NERAL DESCRIPTION 3 CONTROL UNIT MANUAL A C A LHD model B RHD model 1 Switch 4 Base unit 7 Fan switch ASSY 2 Dial knob 5 Cover 8 Circuit ASSY 3 Control unit panel ASSY 6 Temperature control cable 9 Bu...

Page 3433: ...ND A C GENERAL DESCRIPTION 4 CONTROL UNIT AUTO A C A LHD model B RHD model 1 Control unit panel 4 Control unit case 7 Bulb 2 Circuit ASSY 5 Incar sensor 3 Electronic control unit 6 Aspirator hose AC 0...

Page 3434: ...ITIONING UNIT LHD Model 1 Condenser 5 Hose Low pressure Tightening torque N m kgf m ft lb 2 Pipe Condenser Receiver drier 6 Compressor T1 7 4 0 75 5 4 7 Hose High pressure T2 15 1 5 10 8 3 Receiver dr...

Page 3435: ...CRIPTION RHD Model 1 Compressor 5 Pipe B Condenser C unit Tightening torque N m kgf m ft lb 2 Hose High pressure 6 Condenser T1 5 5 0 56 4 1 3 Hose Low pressure T2 7 4 0 75 5 4 4 Pipe A Condenser C un...

Page 3436: ...t 7 V belt Tightening torque N m kgf m ft lb 2 Idler pulley adjuster 8 Compressor belt cover T1 7 4 0 75 5 4 3 Idler pulley T2 23 2 3 17 4 Compressor bracket main T3 23 0 2 35 17 0 5 Compressor T4 28...

Page 3437: ...FC 12 refrigerant cannot be used in the HFC 134a A C system The HFC 134a refrigerant also cannot be used in the HFC 12 A C system If an incorrect or no refrigerant is used poor lu brication will resul...

Page 3438: ...ll them Use a torque wrench to tighten the O ring fittings Over tightening will damage the O ring and tube end distortion If the operation is interrupted before completing a pipe connection recap the...

Page 3439: ...ith a torque wrench If only one wrench is used to tighten the tightening torque will be excessive or insufficient This may cause a pipe distortion or gas leak resulting in damage to hoses and pipes Af...

Page 3440: ...must also not be interchanged HFC 134a CFC 12 Tool screw type Millimeter size Inch size Valve type Quick joint type Screw in type Tools and Equipment Description Wrench Various WRENCHES will be requir...

Page 3441: ...ringe A graduated plastic SYRINGE will be needed to add oil back into the system The syringe can be found at a pharmacy or drug store Vacuum pump A VACUUM PUMP in good working condition is necessary a...

Page 3442: ...upply houses Electronic leak detector An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A C equipment supplier Weight scale A WEIGHT SCALE such as an electronic cha...

Page 3443: ...pair order High pressure side is unusually high Defective condenser fan motor Clogged condenser fan Too much refrigerant Air inside the system Defective receiver dryer Replace the fan motor Clean the...

Page 3444: ...the operation manual attached to the refrigerant recovery system 1 Perform the compressor oil return operation Ref to AC 29 OPERATION Compressor Oil 2 Stop the engine 3 Make sure the valves on low hi...

Page 3445: ...rmal tem perature if the system is evacuated using vacuum pump 1 Close all valves of manifold gauge 2 Install the low high pressure hoses to corre sponding service ports on vehicle CAUTION Be sure tha...

Page 3446: ...applicable press a purge valve on mani fold gauge only for a couple of seconds to allow the air in the center hose to escape by the refriger ant 14 Make sure that the high pressure valve of man ifold...

Page 3447: ...Engine running at 1 500 rpm Blower speed setting to Hi Temperature setting to MAX COOL Air inlet setting to RECIRC Window open 23 Open the low pressure valve and charge the specified amount of refrig...

Page 3448: ...ned area of compressor and other joints on the compressor 7 Check the thermal limiter if equipped on the compressor housing 8 Check the compressor shaft seal at the area near the center of compressor...

Page 3449: ...1 minute Stop the blower to check the ventilation grille on the instru ment panel While moving the tester closer to the grille run the blower for 1 or 2 seconds then stop it Check the grille at that p...

Page 3450: ...control switch to HI 6 Leave in this condition for 10 minutes B REPLACEMENT NOTE If a component is replaced add an appropriate amount of compressor oil When replacing the compressor the new com press...

Page 3451: ...the hoses 5 Remove A C unit Ref to AC 40 Intake Unit 6 Using a Torx wrench remove airbag control unit 7 Disconnect connector of airbag main harness near steering support beam 8 Loosen bolts and nuts...

Page 3452: ...t stay and CRU unit stay 5 Disconnect connector of sunroof 6 Disconnect servo connector 7 Disconnect motor connector 8 Remove 3 screws 9 Disconnect aspirator pipe A and remove blow er motor B INSTALLA...

Page 3453: ...ect power transistor connector 3 Loosen 2 screws to remove power transistor B INSTALLATION Install in the reverse order of removal C INSPECTION 1 MANUAL A C Measure switch resistance If NG replace the...

Page 3454: ...OR AND A C HEATER CORE 10 Heater Core A REMOVAL 1 Remove heater unit Ref to AC 30 REMOV AL Heater Unit 2 Remove screws to separate heater unit case 3 Remove heater core B INSTALLATION Install in the r...

Page 3455: ...m battery 2 Remove front cover A 3 Loosen 2 screws B to remove center panel C 4 Set temperature control switch to FULL HOT and disconnect temperature control cable from heater unit 5 Loosen screws to...

Page 3456: ...p the engine 3 Using refrigerant recovery system discharge re frigerant Ref to AC 23 OPERATION Refriger ant Recovery Procedure 4 Disconnect ground cable from battery 5 Remove duct A 6 Disconnect low p...

Page 3457: ...INSTALLATION 1 Install in the reverse order of removal 2 Replace O rings on low high pressure hoses with new ones then apply compressor oil 3 When replacing compressor adjust amount of compressor oil...

Page 3458: ...the radiator panel CAUTION Be careful not to damage condenser fins If a damaged fin is found repair it using a thin screwdriver If condenser is replaced add appropriate amount of compressor oil to th...

Page 3459: ...ND A C CONDENSER C INSPECTION 1 Confirm that no dust or insects are found on the condenser fins Air blow or flush fins with water as needed 2 Confirm that no oil leaks from condenser If a failure is f...

Page 3460: ...Loosen mounting bolts C to remove receiver dryer CAUTION The receiver drier contains a desiccant After disconnecting receiver drier plug it to avoid moisture If receiver drier is replaced add appropri...

Page 3461: ...5 Remove keyless unit and CRU unit 6 Disconnect sunroof connector 7 Disconnect servo motor connector 8 Disconnect heater blower power transistor con nector 9 Disconnect heater blower motor connector...

Page 3462: ...ome screws and clips then separate intake unit case 2 Remove thermostat A and then detach evapo rator B 3 Remove the block expansion valve A from evaporator CAUTION If evaporator is replaced add appro...

Page 3463: ...nnect hose from compressor 7 Remove low pressure hose A from the vehicle 8 Remove hose attaching bolts D 9 Disconnect hose from compressor 10 Disconnect hose from condenser 11 Disconnect high pressure...

Page 3464: ...oint box 2 Main fuse box AC 00303 C H G B D E F A 1 2 4 cylinder engine model 6 cylinder engine model Main fan relay F Sub fan relay B A C relay A A Main fan relay 1 F Sub fan relay 1 G Main fan relay...

Page 3465: ...RELAY AND FUSE B INSPECTION 3 4 Continuity exists 1 2 No continuity While applying battery voltage to the cable be tween 3 and 4 check continuity between 1 and 2 If no continuity exists replace the re...

Page 3466: ...the pressure switch A LHD model B RHD model AC 00470 2 1 2 1 A B Tester con nection Operation Specified condition kPa kg cm2 psi High and low pressure switch 1 2 Turns OFF Increasing to 2 942 196 30...

Page 3467: ...g to 2 940 196 29 98 2 00 426 28 Decreasing to 177 20 1 8 0 2 26 3 Turns ON Increasing to 216 or less 2 2 31 Decreasing to 2 350 196 23 97 2 00 341 28 Middle pressure switch 3 4 Turns OFF 1 370 120 13...

Page 3468: ...nect ambient sensor connector 4 Remove ambient sensor from radiator lower panel B INSTALLATION Install in the reverse order of removal C INSPECTION Ref to AC 50 DTC 21 OR 21 AMBIENT SEN SOR Diagnostic...

Page 3469: ...nect sunload sensor connector NOTE Be careful not to damage sensors and interior trims when removing them B INSTALLATION Install in the reverse order of removal C INSPECTION Ref to AC 56 DTC 25 OR 25...

Page 3470: ...B 4 Loosen screw C to remove center panel D 5 Remove meter visor E 6 Loosen screws to remove grille 2 AIR VENT GRILLE PASSENGER SIDE 1 Remove grille using sharp edged screwdriver NOTE Wrap screwdrive...

Page 3471: ...ter Duct A REMOVAL 1 Remove heater unit Ref to AC 30 REMOV AL Heater Unit 2 Remove front seat Ref to SE 7 REMOVAL Front Seat 3 Remove front side sill cover 4 Pull off floor mat to remove heater duct B...

Page 3472: ...D A C HEATER VENT DUCT 24 Heater Vent Duct A REMOVAL 1 Remove instrument panel Ref to EI 35 RE MOVAL Instrument Panel Assembly 2 Remove nine screws 3 Remove heater vent duct B INSTALLATION Install in...

Page 3473: ...ure switch A C switch Blower switch Wire harness Strange noise V Belt Magnet clutch Compressor Cold air not emitted Refrigerant V Belt Magnet clutch Compressor Pressure switch A C switch Blower switch...

Page 3474: ...is Procedure LHD Model 14 6 Self Diagnosis Procedure RHD Model 18 7 Diagnostics for A C System Failure LHD Model 20 8 Diagnostics for A C System Failure RHD Model 32 9 List of Diagnostic Trouble Code...

Page 3475: ...DIAGNOSIS SYS TEMS DO NOT OPERATE Diag nostics for A C System Failure RHD Model 2 CHECK DTC Check DTC Is DTC indicated DTC indicated LHD Ref to AC 50 Diagnostic Procedure with Diagnostic Trou ble Code...

Page 3476: ...CHECK COMPARTMENT TEMPERATURE 1 Turn A C switch ON 2 Set temperature at 18 C 65 F FULL COOL 3 Check compartment temperature changes Is the compartment temperature changed Compartment temperature chang...

Page 3477: ...nds quickly A C system is OK LHD Ref to AC 24 COMPART MENT TEMPERA TURE DOES NOT CHANGE FROM SET TEMPERA TURE OR AIR CONDITIONING SYSTEM DOES NOT RESPOND QUICKLY Diag nostics for A C System Failure LH...

Page 3478: ...ness when servicing the A C control panel A C control module and junction box B INSPECTION Before performing diagnosis check the following items which might affect engine problems 1 BATTERY 1 Measure...

Page 3479: ...IGERANT LINE Check contact for refrigerant line A 4 CONTROL LINKAGE 1 Check state of mode door control rod and link age 2 Check state of air mix door control rod and link age 3 Check state of intake d...

Page 3480: ...85 F a DEF switch display illuminates b Outlet air temperature AUTO control Air flow AUTO control Outlet DEF Inlet FRESH Compressor ON 4 FRESH RECIRC switch FRESH RECIRC switch ON Changes from RECIRC...

Page 3481: ...module 10 A C fuse 3 In vehicle sensor 7 Air mix door actuator 11 Mode door actuator 4 Sunload sensor 8 Intake door actuator 1 Ambient sensor 5 Evaporator sensor 9 Intake door actuator 2 Heater module...

Page 3482: ...AC 9 HVAC SYSTEM AUTO A C DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION MEMO...

Page 3483: ...ONTROL MODULE I O SIGNAL 4 A C Control Module I O Signal A ELECTRICAL SPECIFICATION 1 LHD MODEL 1 A C control module 2 To i49 b 3 To i48 a AC 00361 10 20 9 19 8 18 7 17 6 16 5 15 4 14 3 13 2 12 1 11 8...

Page 3484: ...uator a4 a3 BATT voltage AUTO mode positive at terminal a4 and negative at a3 temperature set at 18 C 65 F negative at terminal a4 and posi tive at a3 temperature set at 32 C 90 F Air mix door actuato...

Page 3485: ...GNOSTICS A C CONTROL MODULE I O SIGNAL 2 RHD MODEL 1 A C control module 2 To i49 b 3 To i48 a AC 00316 10 20 9 19 8 18 7 17 6 16 5 15 4 14 3 13 2 12 1 11 8 16 7 15 6 14 5 13 4 12 3 11 2 10 1 9 i49 To...

Page 3486: ...BATT voltage AUTO mode positive at terminal b1 and negative at b11 temperature set at 18 C 65 F negative at terminal b1 and pos itive at b11 temperature set at 32 C 90 F Air mix door actuator P B R a...

Page 3487: ...DIAGNOSIS PROCEDURE LHD MODEL 5 Self Diagnosis Procedure LHD Model A OPERATION 1 Temperature control dial 3 FRESH RECIRC switch 5 MODE switch 2 AUTO switch 4 DEF switch AC 00317 OUT TEMP OUT TEMP BRIG...

Page 3488: ...the sunload sensor in a place where it senses direct sunlight Is the DTC 20 indicated on indicator DTC 20 indicated Go to step 4 Perform diagnosis procedure accord ing to the dis played DTC Ref to AC...

Page 3489: ...sured temperature Is a proper input signal value displayed in each sensor Proper input signal value dis played End Go to step 7 7 CHECK POOR CONTACT Check poor contact in A C control module con nector...

Page 3490: ...AC 17 HVAC SYSTEM AUTO A C DIAGNOSTICS SELF DIAGNOSIS PROCEDURE LHD MODEL MEMO...

Page 3491: ...AG NOSIS MODE 1 Turn ignition switch to OFF 2 While pushing AUTO and FRESH RECIRC switches turn ignition switch to ON 3 Make sure that all characters on the display blinks four times Can it be moved t...

Page 3492: ...ERATION OF EACH ACTUATOR BLOWER FAN AND COMPRESSOR CLUTCH 1 After finishing sensor and potentiometer check modes display goes to actuator check mode when DEF switch is pushed 2 Operate the actuator di...

Page 3493: ...OUBLE SYMPTOM Set temperature is not indicated on display switch LEDs are faulty and switches do not operate Self diagnosis system does not operate WIRING DIAGRAM AC 00318 A8 B2 B1 B12 i48 A i49 B AUT...

Page 3494: ...TROL MODULE POWER CIRCUIT Measure voltage between A C control module connector terminal and chassis ground when turning ignition switch to ACC Connector terminal i49 No 2 Chassis ground Does the measu...

Page 3495: ...1 SBF 4 i48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 i49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A B 2 1 4 2 1 3 4 1 2 BLOWER MOTOR RESISTOR BLOWER MOTOR BLOWER MOTOR RELAY IGNITION SWITCH 2...

Page 3496: ...terminals as follows Positive terminal of battery to terminal No 1 of blower fan motor relay Negative terminal of battery to terminal No 3 of blower fan motor relay 4 Measure resistance between No 2...

Page 3497: ...6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 4 F17 F16 2 1 i49 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 3498: ...NTROL MODULE i48 A i49 B AUTO A C CONTROL MODULE B36 i1 1 F46 B108 REF TO EG LH6 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L...

Page 3499: ...sured value exceed the spec ified value 10 V Go to step 3 Repair harness for power supply line of the A C com pressor 3 CHECK SIGNAL VOLTAGE FROM A C RE LAY 1 Turn ignition switch to ON 2 Turn A C swi...

Page 3500: ...chassis ground Connector terminal 4 CYLINDER MODEL F17 No 1 Chassis ground 6 CYLINDER MODEL F17 No 4 Chassis ground Is the measured value less than the speci fied value 1 Go to step 8 Repair harness b...

Page 3501: ...No 4 Chassis ground Does the measured value exceed the spec ified value 1 Go to step 13 Repair harness between sub fan motor connector and chassis ground 13 CHECK POOR CONTACT Check poor contact in s...

Page 3502: ...pirator duct connection 17 CHECK EACH ACTUATOR Check the actuators for proper operation using the self diagnostic function Ref to AC 14 OPERATION Self Diagnosis Procedure LHD Model Is the operation of...

Page 3503: ...L D FRESH RECIRC DOES NOT CHANGE TROUBLE SYMPTOM FRESH RECIRC mode door does not change WIRING DIAGRAM AC 00365 A7 A15 B91 B201 i40 i49 B i48 A AUTO A C CONTROL MODULE 2 1 INTAKE DOOR ACTUATOR 7 8 B91...

Page 3504: ...i48 No 7 Chassis ground Is the measured value less than the speci fied value 1 V Go to step 5 Repair short circuit in harness between A C con trol module and intake door actua tor 5 CHECK HARNESS CONN...

Page 3505: ...SIS SYSTEMS DO NOT OPERATE TROUBLE SYMPTOM Set temperature is not indicated on display switch LEDs are faulty and switches do not operate Self diagnosis system does not operate WIRING DIAGRAM AC 00366...

Page 3506: ...T Measure voltage between A C control module connector terminal and chassis ground when turning ignition switch to ACC Connector terminal i48 No 3 Chassis ground Does the measured value exceed the spe...

Page 3507: ...B1 3 2 1 BPC 7 3 2 12 B2 1 2 i52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B i49 3 4 1 2 i28 B80 B50 i20 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G...

Page 3508: ...the measured value less than the specified value 1 Go to step 4 Repair harness between BPC and chassis ground 4 CHECK BPC Measure voltage between BPC connector and chassis ground Connector terminal B...

Page 3509: ...pecified value 1 Go to step 9 Replace blower fan motor relay 9 CHECK BLOWER FAN MOTOR 1 Disconnect connector from blower fan motor 2 Connect battery positive terminal to ter minal No 1 negative termin...

Page 3510: ...AC 37 HVAC SYSTEM AUTO A C DIAGNOSTICS DIAGNOSTICS FOR A C SYSTEM FAILURE RHD MODEL MEMO...

Page 3511: ...3 2 12 B2 1 2 i52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B i49 3 4 1 2 i28 B80 B50 i20 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K...

Page 3512: ...ed of blower fan Connector terminal B1 No 2 Chassis ground Is the measured value same as the speci fied value LO Approx 0 5 V OFF Aprrox 5 V HI Approx 0 V Replace BPC Go to step 4 4 CHECK HARNESS BETW...

Page 3513: ...to step 8 Repair harness between blower fan motor relay and A C control module 8 CHECK UNDER AUTO MODE 1 Connect all of removed relays and discon nected connectors 2 Start the engine and turn the A C...

Page 3514: ...AC 41 HVAC SYSTEM AUTO A C DIAGNOSTICS DIAGNOSTICS FOR A C SYSTEM FAILURE RHD MODEL D FRESH RECIRC DOES NOT CHANGE TROUBLE SYMPTOM FRESH RECIRC mode door does not change...

Page 3515: ...is changed when pushing the FRESH RECIRC switch Does the mode selection change Mode selection changes Go to step 8 Go to step 2 AC 00368 BATTERY NO 17 SBF 1 SBF 4 IGNITION SWITCH B12 B2 i48 AUTO A C...

Page 3516: ...ch 2 Measure voltage between A C control mod ule and chassis ground Connector terminal i49 No 2 Chassis ground Is the measured value less than the speci fied value 1 V Go to step 6 Repair harness for...

Page 3517: ...O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 4 F17 F16 2 1 i49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 i48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 3518: ...1 F44 B61 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5...

Page 3519: ...value exceed the spec ified value 10 V Go to step 4 Repair harness for power supply line 4 CHECK A C RELAY 1 Remove A C relay in main fuse box 2 Check A C relay Ref to AC 44 INSPEC TION Relay and Fus...

Page 3520: ...or 6 CYLINDER MODEL Connect battery positive terminal to termi nal No 1 2 3 and negative terminal to ter minal No 4 of main fan motor connector Does the main fan rotate Main fan motor rotates Go to st...

Page 3521: ...4 of sub fan motor connector Does the sub fan motor rotate Sub fan motor rotates Go to step 15 Replace sub fan motor with a new one 15 CHECK EACH SENSOR AND POTENTIOME TER Check the sensors and poten...

Page 3522: ...mbient sensor Open 21 Short 22 In vehicle sensor Open 22 Short 24 Evaporator sensor Open 24 Short 25 Sunload sensor Open 25 Short 26 Mode door actuator Open 26 Short DTC 30 31 32 33 34 35 Faulty Door...

Page 3523: ...TO or ECON switch is ON WIRING DIAGRAM AC 00371 B17 B6 F78 F2 B100 B36 i1 2 1 AMBIENT SENSOR 9 8 E6 D6 F78 1 2 i49 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D...

Page 3524: ...between connector termi nals of A C control module Connector terminal i49 No 6 No 17 Is the measured value the same as speci fied value Approx 4 5 V Go to step 4 Go to step 6 4 CHECK HARNESS CONNECTO...

Page 3525: ...DTC 22 OR 22 IN VEHICLE SENSOR TROUBLE SYMPTOM When turning AUTO switch to ON blower fan speed outlet port and inlet port is not changed If DTC 22 or 22 appears on the display replace the A C control...

Page 3526: ...AC 53 HVAC SYSTEM AUTO A C DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC LHD MODEL MEMO...

Page 3527: ...23 B17 B7 B88 B36 i1 3 1 EVAPORATION THRMO SWITCH J6 i49 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2...

Page 3528: ...sure voltage between A C control mod ule connector terminals Connector terminal i49 No 7 No 17 Is the measured value the same as speci fied value Approx 4 5 V Go to step 4 Go to step 6 4 CHECK HARNESS...

Page 3529: ...sor identified that sunlight is at minimum Then A C system is controlled to HOT side NOTE When the sunload sensor is checked inside the passenger compartment or in the shade DTC 25 may ap pear on the...

Page 3530: ...e less than the speci fied value 1 Go to step 3 Repair harness between A C con trol module and sunload sensor 3 CHECK HARNESS CONNECTOR BETWEEN A C CONTROL MODULE AND SUNLOAD SENSOR Measure resistance...

Page 3531: ...32 33 34 OR 35 MODE DOOR ACTUATOR TROUBLE SYMPTOM Air flow outlet is not changed WIRING DIAGRAM AC 00372 B77 A i48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B77 i40 B201 4 7 1 2 10 8 9 5 6 A6 A5 A1 A2 A1...

Page 3532: ...Press the mode switch to VENT position and measure the voltage between auto A C control module and chassis ground when DEF is changed to VENT position Connector terminal i48 No 5 Chassis ground Is th...

Page 3533: ...5 Chassis ground Is the measured value within specified value 5 V Go to step 9 Go to step 8 8 CHECK HARNESS BETWEEN AUTO A C CONTROL MODULE AND MODE DOOR AC TUATOR 1 Turn the ignition switch to OFF 2...

Page 3534: ...Connector terminal i48 No 10 B77 No 6 9 Is the measured value less than specified value 1 Replace the auto A C control mod ule Repair the har ness between auto A C control mod ule and mode door actuat...

Page 3535: ...l i48 No 9 Chassis ground Is the measured value within specified value VENT BI LEVEL HEAT 5V D H DEF 0 V Go to step 19 Go to step 16 16 CHECK AUTO A C CONTROL MODULE SIG NAL POWER SUPPLY 1 Turn the ig...

Page 3536: ...ode door actuator and chassis ground Connector terminal B77 No 10 Chassis ground Is the measured value less than specified value 1 Replace the mode door actuator Repair the har ness between auto A C c...

Page 3537: ...AC 64 HVAC SYSTEM AUTO A C DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC LHD MODEL MEMO...

Page 3538: ...c Trouble Code DTC RHD Model A DTC 21 OR 21 IN VEHICLE SENSOR TROUBLE SYMPTOM When turning AUTO switch to ON blower fan speed outlet port and inlet port is not changed NOTE If DTC 21 or 21 appears on...

Page 3539: ...NG DIAGRAM AC 00373 A11 A10 F78 F2 B100 B36 i1 1 2 AMBIENT SENSOR 4 3 D6 E6 F78 1 2 i48 A B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4...

Page 3540: ...een connector termi nals of A C control module Connector terminal i48 No 11 No 10 Is the measured value same as the speci fied value Approx 4 5 V Go to step 4 Go to step 6 4 CHECK HARNESS CONNECTOR BE...

Page 3541: ...L C DTC 23 OR 23 EVAPORATOR SENSOR WIRING DIAGRAM AC 00374 A12 A10 A i52 2 1 EVAPORATION THRMO SWITCH BLOWER MODULE 9 10 i49 B i48 A AUTO A C CONTROL MODULE A i52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i49...

Page 3542: ...asure voltage between A C control mod ule connector terminals Connector terminal i48 No 12 No 10 Is the measured value same as the speci fied value Approx 3 3 V Go to step 4 Go to step 6 4 CHECK HARNE...

Page 3543: ...ide Sensor identified that sunlight is at minimum Then A C system is controlled to HOT side NOTE When the sunload sensor is checked inside the passenger compartment or in the shade DTC 25 may ap pear...

Page 3544: ...s than the speci fied value 1 Go to step 3 Repair harness between A C con trol module and sunload sensor 3 CHECK HARNESS CONNECTOR BETWEEN A C CONTROL MODULE AND SUNLOAD SENSOR Measure resistance of h...

Page 3545: ...IX MOTOR POTENTIOMETER LINE WIRING DIAGRAM AC 00376 1 3 5 6 7 D i45 AIR MIX DOOR ACTUATOR 9 11 10 8 7 A10 A5 A6 B1 B11 HEATER MODULE AUTO A C CONTROL MODULE A i48 B i49 D 3 2 1 4 5 6 7 i49 1 2 3 4 5 6...

Page 3546: ...the measured value same as the specified value Approx 1 2 k Go to step 4 Replace air mix door actuator 4 CHECK POTENTIOMETER Measure resistance for the signal line of the potentiometer when the lever...

Page 3547: ...ween A C control module and air mix door actuator Connector terminal i49 No 1 D No 6 Is the measured value less than the specified value 1 Go to step 9 Repair harness between A C con trol module and a...

Page 3548: ...AC 75 HVAC SYSTEM AUTO A C DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC RHD MODEL MEMO...

Page 3549: ...MODEL F DTC 28 OR 29 MODE DOOR ACTUATOR POTENTIOMETER LINE WIRING DIAGRAM 1 3 5 6 7 E i45 MODE DOOR ACTUATOR 3 11 4 1 2 A10 A5 A14 A16 A8 HEATER MODULE AUTO A C CONTROL MODULE A i48 B i49 E 1 2 3 4 5...

Page 3550: ...measured value same as the specified value Approx 1 2 k Go to step 4 Replace mode door actuator 4 CHECK POTENTIOMETER Measure resistance for the signal line of the potentiometer when the lever is in t...

Page 3551: ...etween A C control module and mode door actuator Connector terminal i48 No 8 E No 7 Is the measured value less than the specified value 1 Go to step 9 Repair harness between A C con trol module and mo...

Page 3552: ...s In vehicle ambient water temperature evaporator sunload etc Component parts Symptom Previous mode immediately before resetting operation is not retained in memory A C system fails to operate when IG...

Page 3553: ...AC 80 HVAC SYSTEM AUTO A C DIAGNOSTICS SYMPTOM RELATED DIAGNOSTIC MEMO...

Page 3554: ...s Airbag Module 13 6 Side Airbag Module 14 7 Main Harness 15 8 Side Airbag Harness 16 9 Airbag Control Module 17 10 Side Airbag Sensor 18 11 Roll Connector 19 12 Front Sub Sensor 20 13 Front Sub Senso...

Page 3555: ...que N m kgf m ft lb 8 Side airbag harness T1 7 4 0 75 5 4 2 TORX bolt T30 9 Side airbag module T2 10 1 0 7 2 3 Airbag module ASSY Driver 10 Airbag main harness T3 20 2 0 14 5 4 Airbag module ASSY Pass...

Page 3556: ...t may inflate If sensors airbag module airbag control module pretensioner and harness are deformed or dam aged replace them with new genuine parts When checking the system be sure to use a dig ital ci...

Page 3557: ...the airbag system wire harness do not attempt to re pair using soldering equipment Be sure to replace the faulty harness with a new genuine part Install the wire harness securely with the speci fied...

Page 3558: ...e vehicle including the front wheel apron front fender and front side frame re move parts and take utmost care not to apply paint or the flame of the welding burner directly to the front sub sensors a...

Page 3559: ...module do not place any objects on it or pile airbag modules on top of each other If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object a seri...

Page 3560: ...TOOL 98299PA030 98299SA010 TEST HARNESS ADAPTER D Used for deplaying the driver s airbag module Used with DEPLOYMENT TOOL 98299PA030 Can not reuse 98299PA030 DEPLOYMENT TOOL Used for deploying the ai...

Page 3561: ...locked 2 DRIVER S AIRBAG PASSENGER S AIR BAG SIDE AIRBAG FRONT SUB SENSOR HARNESS TO AIRBAG MAIN HARNESS AND PRETENSIONER 1 How to disconnect 1 Push lock arm A 2 With lock arm A pushed in move slide...

Page 3562: ...UTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked 4 FRONT SUB SENSOR SIDE AIRBAG SENSOR 1 How to disconnect Holding outer part A pull it in...

Page 3563: ...ollowing and replace damaged parts with new parts Airbag module is cracked or deformed Harness and or connector is cracked deformed or open Lead wire is exposed Mounting bracket is cracked or deformed...

Page 3564: ...r is scratched or cracked 9 MAIN HARNESS Check for the following and replace damaged parts with new parts Harness is open lead wire is exposed and cor rugated tube is noticeably cracked Connector is s...

Page 3565: ...4 Using TORX BIT T30 remove two TORX bolts on side of steering wheel 5 Disconnect airbag connector on back of airbag module and then remove airbag module 6 Refer to CAUTION for handling of a removed...

Page 3566: ...ch airbag connector from support beam bracket 5 Remove three bolts and then carefully remove airbag module 6 Refer to CAUTION for handling of a removed airbag module Ref to AB 3 CAUTION GENERAL DESCRI...

Page 3567: ...e airbag module Ref to SE 9 DISASSEMBLY Front Seat B INSTALLATION Ref to SE 8 INSTALLATION Front Seat C INSPECTION CAUTION Refer to CAUTION in General Description before handling the airbag module Ref...

Page 3568: ...E MOVAL Instrument Panel Assembly 4 Disconnect connector from airbag control mod ule 5 Disconnect front sub sensor connector blue from airbag main harness 6 Detach clips from steering support beam and...

Page 3569: ...console box Ref to EI 34 REMOV AL Console Box 5 Roll up floor mat and then disconnect two 12 pin yellow connectors from airbag control module 6 Disconnect connector from side airbag sensor Ref to AB...

Page 3570: ...witch OFF 2 Disconnect the ground cable from the battery and wait for at least 20 seconds before starting work 3 Remove console box Ref to EI 34 REMOV AL Console Box 4 Disconnect connector from airbag...

Page 3571: ...Inner Trim 4 Remove Outer Belt FRONT Ref to SB 7 OUTER BELT FRONT REMOVAL Front Seat Belt 5 Remove bracket A and then remove cap B 6 Using E12 TORX remove two TORX nuts and then detach side airbag sen...

Page 3572: ...eel Ref to PS 24 RE MOVAL Steering Wheel 7 Remove steering column cover 8 Remove screws and then remove roll connec tor B INSTALLATION Install in the reverse order of removal C INSPECTION Check for th...

Page 3573: ...onds before starting work 3 Remove front bumper Ref to EI 14 REMOV AL Front Bumper 4 Disconnect connector from front sub sensor 5 Remove front sub sensor A B INSTALLATION Install in the reverse order...

Page 3574: ...ment Panel Assembly 4 Disconnect front sub sensor connector blue from airbag main harness 5 Remove front bumper Ref to EI 14 REMOV AL Front Bumper 6 Disconnect connector from front sub sensor 7 Remove...

Page 3575: ...Leave it unattended for 40 min utes and then discard it Do not let water get on the deployed airbag module Wrap the deployed airbag module in an air tight vinyl bag and discard it If circumstances do...

Page 3576: ...conds before starting work 3 Pull out the two stopper pins and lower the glove box 4 Disconnect airbag connectors AB9 and AB10 5 Short terminal to alligator clip furnished as de ployment tool 6 Connec...

Page 3577: ...the front seat cushion 4 Adjust both the front seat and front seat backrest to center positions 5 Short terminal to alligator clip furnished as de ployment tool 6 Connect the deployment tool and adapt...

Page 3578: ...nal Then de ploy the airbag module CAUTION After deployment the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let water get on the deployed airbag...

Page 3579: ...ration Wash your hands afterwards After deployment the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let water get on the deployed airbag module W...

Page 3580: ...en de ploy the airbag module CAUTION After deployment the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let water get on the deployed airbag modul...

Page 3581: ...n additional tire with the wheel on top and then fasten them tight with rope 10 Move the battery at least 5 m 16 ft from vehi cle and secure the nearby area Connect the de ployment tool alligator clip...

Page 3582: ...he deployment tool and adapter A de ployment CAUTION The deployment tool should be kept shorted until just before deployment of the airbag mod ule 9 Connect adapter A deployment connector 2D to airbag...

Page 3583: ...ool to the battery positive terminal Then de ploy the airbag module CAUTION After deployment the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let...

Page 3584: ...Electrical Components Location 15 5 Airbag Connector 17 6 Airbag Warning Light Illumination Pattern 19 7 Read Diagnostic Trouble Code DTC 20 8 Inspection Mode 21 9 Clear Memory Mode 22 10 Airbag Warn...

Page 3585: ...o to Airbag Warning Light Fail ure Ref to AB 24 Airbag Warn ing Light Failure 3 Perform the diagnosis 1 Judge the possible cause from List of Diagnostic Trouble Code DTC Ref to AB 28 List of Diagnosti...

Page 3586: ...Miles Vin No Date Problem Occurred Registration Year Weather Fine Cloudy Rainy Snowy Other Temperature C F Road Condition Level road Uphil Downhill Rough road Others Vehicle Operation Starting Idling...

Page 3587: ...hicle immediately Airbag or pretensioner may in flate incorrectly or not inflate in collision If sensors airbag module airbag control module pretensioner and harness are deformed or dam aged replace t...

Page 3588: ...ness do not attempt to re pair using soldering equipment Be sure to replace the faulty harness with a new genuine part Install the wire harness securely with the speci fied clips to avoid interference...

Page 3589: ...r performing sheet metal work on the front part of the vehicle including the front wheel apron front fender and front side frame re move the front sub sensors and wire harness of the airbag system Whe...

Page 3590: ...airbag module do not place any objects on it or pile airbag modules on top of each other If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object...

Page 3591: ...AL DESCRIPTION B INSPECTION Before diagnosing check the following items that might be related to the engine problem 1 BATTERY Measure battery voltage and specific gravity of electrolyte Standard volta...

Page 3592: ...C PREPARATION TOOL CAUTION Be sure to use specified test harness F G H K and I or I2 when measuring voltage resistance etc of AIRBAG system component parts 1 TEST HARNESS F AB 00058 3F 5 6 1 2 3 4 5...

Page 3593: ...AB 10 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 2 TEST HARNESS G AB 00059 3G 3G 1 2 3 6 5 4 7 8 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 1 2 3 4 5 6 7 8 1G 1G 2G PN 98299FC020 2G...

Page 3594: ...AB 11 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 3 TEST HARNESS H AB 00060 PN 98299FA030 1H 2H 3H 1H 2H 3H 1 3 3 1 2 1 2 1 2 1 2 4 5 6 4 5 6 2...

Page 3595: ...AB 12 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 4 TEST HARNESS N AB 00064 2Q 2Q 1Q 1Q 1B 2B 1A 2A 1B 2B 1A 2A PN 98299SA000...

Page 3596: ...35 36 37 27 28 29 30 31 32 38 39 40 5l 4l 3l 6l 2l 1l 1l 3l 1l 6l 2l 5l 4l 1 1 1 2 3 4 5 6 9 10 7 8 2 3 4 2 3 4 5 1 1 2 3 4 5 6 7 8 9 101112 2 3 4 5 6 7 8 9 10111213141516171819 32 27 21 38 41 45 42 4...

Page 3597: ...esistor is used during diagnostics The airbag resistor has the same resistance as the airbag module and thus provides safety when used instead of the airbag module It also makes it possible to finish...

Page 3598: ...belt pretensioner RH 6 Inflator Passenger Connec tor No AB1 AB2 AB3 AB6 AB7 AB8 AB9 AB10 AB11 AB12 AB13 AB14 Pole 12 2 2 28 2 2 2 2 2 2 2 2 Color Yellow Yellow Yellow Yellow Black Yellow Yellow Yello...

Page 3599: ...6 Inflator Passenger Connec tor No AB1 AB2 AB3 AB6 AB7 AB8 AB9 AB10 AB11 AB12 AB13 AB14 Pole 12 2 2 28 2 2 2 2 2 2 2 2 Color Yellow Yellow Yellow Yellow Black Yellow Yellow Yellow Blue Blue Yellow Blu...

Page 3600: ...it is locked 2 DRIVER S AIRBAG PASSENGER S AIR BAG SIDE AIRBAG FRONT SUB SENSOR HARNESS TO AIRBAG MAIN HARNESS AND PRETENSIONER 1 How to disconnect 1 Push lock arm A 2 With lock arm A pushed in move s...

Page 3601: ...ard CAUTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked 4 FRONT SUB SENSOR SIDE AIRBAG SENSOR 1 How to disconnect 1 Holding outer part A pul...

Page 3602: ...N 6 Airbag Warning Light Illumi nation Pattern A INSPECTION Keep the ignition switch ON and confirm that the airbag warning light remains off approximately 6 seconds after being turned on 1 Airbag war...

Page 3603: ...3 sec on indicates a one NOTE List of Diagnostic Trouble Code DTC Ref to AB 28 List of Diagnostic Trouble Code DTC Airbag Warning Light Failure Ref to AB 24 Airbag Warning Light Failure 4 Turn the ign...

Page 3604: ...AB 21 AIRBAG SYSTEM DIAGNOSTICS INSPECTION MODE 8 Inspection Mode A OPERATION Recreate the circumstance by referring to the con ditions described in the checklist...

Page 3605: ...Once the memory is erased the warning light re turns to the normal flash rate 0 6 sec on The fail ure to recover the normal flash rate indicates that trouble parts still remain Having repaired such pa...

Page 3606: ...AB 23 AIRBAG SYSTEM DIAGNOSTICS CLEAR MEMORY MODE MEMO...

Page 3607: ...part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons WIRING DIA...

Page 3608: ...8 4 Pull out the two stopper pins and lower the glove box and disconnect connectors AB10 and AB9 5 Disconnect the connector AB6 from the airbag control module and connect the connector 1I in test harn...

Page 3609: ...cting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons WIRING DIAGRAM IGNITION RELAY AB 00356 3 BATTERY AIRBAG INDICATOR LIGHT AIRBAG...

Page 3610: ...e battery ground cable and wait more than 20 seconds 2 Disconnect the connector AB1 from B31 3 Connect the battery ground cable and turn the ignition switch ON Is the airbag warning light turned on Ai...

Page 3611: ...ostic Chart with Diagnostic Trouble Code DTC 21 Provided Airbag control module is faulty Ref to AB 40 DTC 21 Diagnostic Chart with Diagnostic Trouble Code DTC 22 Provided Front airbag module and seat...

Page 3612: ...rouble Code DTC 54 Provided Side airbag sensor LH is faulty Ref to AB 68 DTC 54 Diagnostic Chart with Diagnostic Trouble Code DTC 55 Provided Side airbag module is inflated Ref to AB 68 DTC 55 Diagnos...

Page 3613: ...ag system be sure to turn the ignition switch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll controller...

Page 3614: ...nd con nect the connector 1F in test harness F to connector AB8 4 Connect the airbag resistor to connector 3F in test harness F 5 Connect the battery ground cable and turn the ignition switch ON Does...

Page 3615: ...esistance of the connector 2I in test harness I2 Connector terminal 2I No 1 No 4 2I No 4 Chassis ground 2I No 1 Chassis ground Does the measured value exceed the specified value 1 M Replace the airbag...

Page 3616: ...AB 33 AIRBAG SYSTEM DIAGNOSTICS DIAGNOSTIC CHART WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 3617: ...nition switch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconne...

Page 3618: ...battery ground cable and wait more than 20 seconds 2 Disconnect two airbag resistors from the connectors 3K and 4K in test harness K 3 Remove lower cover and disconnect the connector AB3 from AB8 4 Di...

Page 3619: ...witch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect each...

Page 3620: ...nnector AB8 5 Connect the airbag resistor to connector 3F in test harness F 6 Connect the battery ground cable and turn the ignition switch ON Does the airbag warning light operate prop erly Operates...

Page 3621: ...n switch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect ea...

Page 3622: ...airbag module Ref to AB 13 Passen ger s Airbag Mod ule Go to step 2 2 CHECK AIRBAG MAIN HARNESS 1 Turn the ignition switch OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disc...

Page 3623: ...e starting to work Before replacing the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly Step Value Yes No 1 CHECK IF DTC...

Page 3624: ...ger s airbag module Ref to AB 13 REMOVAL Passenger s Airbag Module Front sub sensor of both sides Ref to AB 20 REMOVAL Front Sub Sensor Front seat belt outer with pretensioner of both sides Ref to SB...

Page 3625: ...B18 from the airbag control module Ref to AB 17 Airbag Control Module Check if rust or damage appear on the har ness connector and the control module connector Rust or damage on the har ness connector...

Page 3626: ...AB 43 AIRBAG SYSTEM DIAGNOSTICS DIAGNOSTIC CHART WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 3627: ...d wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly...

Page 3628: ...s I2 to connector AB6 4 Connect the battery ground cable and turn the ignition switch ON 5 Measure the voltage between connector 2I in test harness I2 and chassis ground Connector terminal 2I No 3 Cha...

Page 3629: ...d wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly...

Page 3630: ...nector AB6 4 Connect the battery ground cable and turn the ignition switch ON 5 Measure the voltage between the connec tor 2I in test harness I2 and the chassis ground Connector terminal 2I No 6 Chass...

Page 3631: ...cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect each part and confirm that the warni...

Page 3632: ...onnector terminal 3I No 2 Chassis ground 3I No 4 Chassis ground Does the measured value exceed the specified value 1 M Replace the airbag control module Ref to AB 17 Airbag Control Module Go to step 3...

Page 3633: ...ONT SUB SENSOR HARNESS RH 1 Connect connector 1F in test harness F to the connector AB15 2 Measure the resistance between connector 3H in test harness H and connector 3F in the test harness F Connecto...

Page 3634: ...H Measure the resistance between connector 3H in test harness H and the chassis ground Connector terminal 3H No 3 Chassis ground 3H No 4 Chassis ground Does the measured value exceed the specified val...

Page 3635: ...cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect each part and confirm that the warnin...

Page 3636: ...ound Connector terminal 3I No 1 Chassis ground 3I No 3 Chassis ground Does the measured value exceed the specified value 1 M Replace the air bag control mod ule Ref to AB 17 Airbag Control Module Go t...

Page 3637: ...rness 7 CHECK FRONT SUB SENSOR HARNESS LH 1 Connect connector 1F in test harness F to connector AB12 2 Measure the resistance between connector 3H in test harness H and connector 3F in test harness F...

Page 3638: ...H Measure the resistance between connector 3H in test harness H and the chassis ground Connector terminal 3H No 3 Chassis ground 3H No 4 Chassis ground Does the measured value exceed the specified val...

Page 3639: ...the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airb...

Page 3640: ...ness 3 Disconnect the connector AB18 from air bag control module Ref to AB 17 REMOVAL Airbag Control Module 4 Connect connector 1I in test harness I2 to connector AB18 5 Measure the resistance betwee...

Page 3641: ...the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airb...

Page 3642: ...s 3 Disconnect the connector AB17 from the airbag control module Ref to AB 17 REMOVAL Airbag Control Module 4 Connect connector 1I in test harness I2 to connector AB17 5 Measure the resistance between...

Page 3643: ...ag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airbag modul...

Page 3644: ...seat with side airbag module RH Ref to SE 7 Front Seat Go to step 2 2 CHECK SIDE AIRBAG HARNESS RH 1 Turn the ignition switch OFF disconnect the battery ground cable and wait more than 20 seconds 2 Di...

Page 3645: ...ag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airbag modul...

Page 3646: ...ith side airbag module LH Ref to SE 7 Front Seat Go to step 2 2 CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disconne...

Page 3647: ...the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airb...

Page 3648: ...7 Measure the resistance between connector 3I in test harness I2 and connector 3G in test harness G Connector terminal 3I No 17 3G No 2 3I No 18 3G No 4 3I No 19 3G No 1 3I No 20 3G No 5 Is the measu...

Page 3649: ...the airbag module roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airb...

Page 3650: ...3 7 Measure the resistance between connector 3I in test harness I2 and connector 3G in test harness G Connector terminal 3I No 5 3G No 5 3I No 14 3G No 1 3I No 15 3G No 4 3I No 16 3G No 2 Is the measu...

Page 3651: ...sensor LH is faulty When Code 53 is displayed the circuit within the side airbag sensor LH is faulty Replace the side airbag sensor LH Ref to AB 18 Side Airbag Sensor T DTC 55 This code is displayed w...

Page 3652: ...AB 69 AIRBAG SYSTEM DIAGNOSTICS DIAGNOSTIC CHART WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 3653: ...ion switch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect...

Page 3654: ...isconnect the connectors AB17 and AB18 from the airbag control module Ref to AB 17 Airbag Control Module 5 Connect the connector 1I in test harness I2 to connector AB18 6 Measure the resistance betwee...

Page 3655: ...ion switch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect...

Page 3656: ...t the connectors AB17 and AB18 from the airbag control module Ref to AB 17 Airbag Control Module 5 Connect the connector 1I in test harness I2 to the connector AB17 6 Measure the resistance between co...

Page 3657: ...switch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and sensor reconnect eac...

Page 3658: ...at Belt Go to step 2 2 CHECK SIDE AIRBAG HARNESS RH 1 Turn the ignition switch OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disconnect the airbag resistor from the test harn...

Page 3659: ...witch OFF disconnect the ground cable from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module roll connector control module and the sensor reconnect e...

Page 3660: ...Seat Belt Go to step 2 2 CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disconnect the airbag resistor from the test ha...

Page 3661: ...AB 78 AIRBAG SYSTEM DIAGNOSTICS DIAGNOSTIC CHART WITH DIAGNOSTIC TROUBLE CODE DTC MEMO...

Page 3662: ...SEAT BELT SYSTEM SB Page 1 General Description 2 2 Inspection Locations After a Collision 6 3 Front Seat Belt 7 4 Rear Seat Belt 9 5 Disposal of Pretensioner 12...

Page 3663: ...eral Description A COMPONENT 1 FRONT SEAT BELT 1 Adjuster anchor ASSY 5 Outer belt ASSY Tightening torque N m kgf m ft lb 2 Anchor cover T1 7 5 0 76 5 5 3 Webbing guide T2 30 3 1 22 4 Inner belt ASSY...

Page 3664: ...SEAT BELT SEDAN BODY 1 Outer seat belt RH 5 Inner seat belt CENTER Tightening torque N m kgf m ft lb 2 Outer seat belt CENTER 6 Inner seat belt LH T 30 3 1 22 3 Outer seat belt LH 7 Case center ELR 4...

Page 3665: ...ON 3 REAR SEAT BELT WAGON BODY 1 Outer seat belt RH 4 Inner seat belt RH Tightening torque N m kgf m ft lb 2 Outer seat belt CENTER 5 Inner seat belt LH T1 30 3 1 22 3 Outer seat belt LH T2 53 5 4 39...

Page 3666: ...the pre tensioner If it is dented cracked or deformed re place it with a new one Do not use the airbag or pretensioner parts from other vehicles Always replace parts with new parts When handling a se...

Page 3667: ...ONS AFTER A COLLISION 2 Inspection Locations After a Collision A INSPECTION Check for the following and then replace with new parts if necessary Center pillar lower garnish is discolored or cracked Wi...

Page 3668: ...4 Remove bracket 5 Remove webbing guide 6 Remove anchor cover Loosen shoulder anchor bolt and then detach shoulder anchor from center pillar 7 Turn over the floor mat to remove bolt 8 Disconnect yell...

Page 3669: ...reverse order of removal Tightening torque Refer to COMPONENT in General Descrip tion Ref to SB 2 FRONT SEAT BELT COMPONENT General Description C INSPECTION 1 OUTER BELT FRONT Check for the following...

Page 3670: ...SEDAN BODY 1 Remove the rear seat cushion Ref to SE 17 SEDAN REMOVAL Rear Seat 2 Remove bolts and then detach inner belt 4 OUTER BELT SIDE WAGON BODY 1 Remove rear quarter trim Ref to EI 40 WAG ON REM...

Page 3671: ...ound 2 OUTER BELT CENTER SEDAN BODY Install in the reverse order of removal CAUTION During installation make sure that seat belts are not twisted After installation make sure that seat belts can be sm...

Page 3672: ...he following and replace with new parts if necessary Seat belt is slackened bent or frayed Seat belt is abnormally wound or extended 3 INNER BELT SEDAN BODY Check for the following and replace with ne...

Page 3673: ...the deployed the pretensioner in an airtight vinyl bag and then discard it B OPERATION 1 DEPLOYING WHILE INSTALLED IN VE HICLE 1 Fold backrest all the way forward and then move front seat all the way...

Page 3674: ...and wait for more than 20 seconds before starting work 3 Remove outer belt front Ref to SB 7 RE MOVAL Front Seat Belt 4 Cut off seat belt as close to retractor as possible 5 Short terminal to alligat...

Page 3675: ...cle and secure the nearby area Connect the deployment tool alligator clip to the battery minus terminal 11 Connect the other terminal of deployment tool to the battery plus terminal Then deploy preten...

Page 3676: ...Headlight Assembly 15 13 Headlight Bulb 17 14 Front Turn Signal Light Bulb 18 15 Parking Light Bulb 19 16 Front Fog Light Assembly 20 17 Front Fog Light Bulb 21 18 Rear Combination Light Assembly 22 1...

Page 3677: ...parts and switches All airbag system wiring harnesses and connectors are yellow Do not use electric test equipment on these circuits Be careful not to damage the airbag system wiring harness when ser...

Page 3678: ...LINDER NON TURBO ENGINE MODEL SCHEMATIC Clearance Light and Illumination Light System Ref to WI 257 RHD 6 CYLINDER ENGINE AND TURBO ENGINE MODEL SCHEMATIC Clear ance Light and Illumination Light Syste...

Page 3679: ...INE MODEL Ref to WI 262 RHD 6 CYLINDER ENGINE MODEL SCHEMATIC Front Fog Light System B INSPECTION 1 FRONT FOG LIGHT SWITCH Measure front fog light switch resistance 2 FRONT FOG LIGHT RELAY Measure fro...

Page 3680: ...h ON 2 Turn on the headlight or front fog light 3 Push the rear fog light switch and check if the rear fog light turns on 2 REAR FOG LIGHT RELAY Measure rear fog light relay resistance between termina...

Page 3681: ...Signal Light and Hazard Light System B INSPECTION 1 TURN SIGNAL SWITCH Ref to LI 11 INSPECTION Combination Switch Light 2 HAZARD SWITCH Measure hazard switch resistance 3 TURN SIGNAL HAZARD MODULE Co...

Page 3682: ...up light switch resistance 2 INHIBITOR SWITCH A T Measure inhibitor switch resistance Switch position Terminal No Standard When shift lever is set in reverse position 1 and 2 Less than 1 Other positio...

Page 3683: ...ef to WI 273 WAGON MODEL SCHEMATIC Stop Light System B INSPECTION 1 STOP LIGHT SWITCH Measure stop light switch resistance A Without cruise control B With cruise control Switch position Terminal No St...

Page 3684: ...2 REAR GATE LATCH SWITCH Measure rear gate latch switch 3 TRUNK ROOM LIGHT SWITCH Measure trunk room light switch A Front door switch B Rear door switch Switch position Terminal No Standard When door...

Page 3685: ...TOR 1 Turn on the headlights 2 Confirm the headlight beam level is lowered by changing the switch position to 0 1 2 3 4 5 2 HEADLIGHT BEAM LEVELER SWITCH Connect battery headlight beam leveler switch...

Page 3686: ...ight 2 DIMMER AND PASSING SWITCH LHD model and RHD model with rear fog light RHD model without rear fog light LI 00009 LI 00010 A LHD model and RHD model with rear fog light B RHD model without rear f...

Page 3687: ...RHD model with rear fog light RHD model without rear fog light Switch position Terminal No Standard Left 1 and 2 Less than 1 Neutral More than 1 M Right 2 and 3 Less than 1 Switch position Terminal No...

Page 3688: ...teering Wheel 3 Remove steering column cover 4 Remove combination switch Ref to LI 11 RE MOVAL Combination Switch Light Ref to WW 8 REMOVAL Combination Switch Wiper 5 Loosen 3 screws 6 Disconnect conn...

Page 3689: ...14 LIGHTING SYSTEM COMBINATION BASE SWITCH ASSEMBLY 2 PARKING SWITCH Measure parking switch resistance Switch position Terminal No Standard OFF 2 and 4 Less than 1 ON 1 and 4 Less than 1 1 2 3 4 LI 00...

Page 3690: ...ground cable from battery 2 Remove duct A when right side headlight is re moved 3 Disconnect headlight bulb connector 4 Remove three bolts and disconnect connectors and then detach headlight assembly...

Page 3691: ...is fully charged Bounce the vehicle several times to normalize the suspension Make certain that someone is seated in the driv er s seat Turn the headlights on and then adjust the low beam pattern to t...

Page 3692: ...Dust moisture etc entering the headlight may affect its the performance 1 Disconnect ground cable from battery 2 Remove duct A when right side headlight is re moved 3 Remove back cover A 4 Disconnect...

Page 3693: ...bly Ref to LI 15 RE MOVAL Headlight Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check th...

Page 3694: ...LI 15 RE MOVAL Headlight Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb spe...

Page 3695: ...move mounting bolts and then detach fog light assembly 2 OUTBACK 1 Disconnect ground cable from battery 2 Turn stone guard counterclockwise and then re move it 3 Remove mounting bolts 4 Remove two cli...

Page 3696: ...fog light bulb 2 OUTBACK 1 Remove fog light assembly Ref to LI 20 OUTBACK REMOVAL Front Fog Light Assem bly 2 Disconnect harness connector 3 Loosen screws and turn the bulb assembly counterclockwise...

Page 3697: ...ove three nuts and then detach rear combi nation light while disconnecting connector 2 WAGON 1 Disconnect ground cable from battery 2 Remove two rear quarter trim covers 3 Remove two nuts and then rem...

Page 3698: ...rear finisher light 5 Remove ten nuts and then detach rear finisher light from trunk lid 2 WAGON 1 Disconnect ground cable from battery 2 Remove rear gate trim A Ref to EI 44 RE MOVAL Rear Gate Trim 3...

Page 3699: ...e rear combination light assembly Ref to LI 22 WAGON REMOVAL Rear Combination Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1...

Page 3700: ...emove the bulb 2 WAGON 1 Open rear gate lower trim cover 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow ou...

Page 3701: ...assembly Ref to LI 22 WAGON REMOVAL Rear Combination Light Assembly 2 Remove the light cover mounting screws then detach the cover 3 Turn the socket and remove the bulb B INSTALLATION Install in the r...

Page 3702: ...ocket and remove the bulb 2 WAGON 1 Open rear gate lower trim cover 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb...

Page 3703: ...crew A and then remove the lens B SEDAN WAGON 2 Remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specificatio...

Page 3704: ...connect ground cable from battery 2 Remove cap a by prying on the edge with a screwdriver 3 Remove screws b and then detach cover c 4 Remove screws d and then detach high mounted stop light while disc...

Page 3705: ...2 Pull out the light from body while pushing it in di rection of vehicle front 3 Disconnect harness connector and remove the light B INSTALLATION Install in the reverse order of removal C INSPECTION 1...

Page 3706: ...pot light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 SPOT LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General...

Page 3707: ...Install in the reverse order of removal C INSPECTION 1 ROOM LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG repl...

Page 3708: ...STALLATION Install in the reverse order of removal C INSPECTION 1 LUGGAGE ROOM LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Descr...

Page 3709: ...attery 2 Disconnect harness connectors and remove trunk room light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specifica...

Page 3710: ...x Ref to EI 32 REMOVAL Glove Box 3 Disconnect harness connector 4 Remove glove box light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Ch...

Page 3711: ...move the lens then detach the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS...

Page 3712: ...and Washer System 7 3 Combination Switch Wiper 8 4 Wiper Blade 10 5 Washer Tank and Motor 11 6 Front Wiper Arm 12 7 Front Wiper Motor and Link 13 8 Front Washer Nozzle 14 9 Rear Wiper Arm 15 10 Rear W...

Page 3713: ...1 General Description A SPECIFICATIONS Front wiper motor Input 12 V 72 W or less Rear wiper motor Input 12 V 36 W or less Front washer motor Pump type Centrifugal Input 12 V 36 W or less Rear washer m...

Page 3714: ...S GENERAL DESCRIPTION B COMPONENT 1 FRONT WIPER 1 Wiper rubber 4 Wiper link Tightening torque N m kgf m ft lb 2 Wiper blade ASSY 5 Wiper motor T1 6 0 0 61 4 4 3 Wiper arm T2 20 2 0 14 5 WW 00057 1 1 2...

Page 3715: ...AR WIPER 1 Wiper rubber 6 Cushion Tightening torque N m kgf m ft lb 2 Wiper blade ASSY 7 Spacer B T1 5 9 0 6 4 3 3 Wiper arm 8 Nut T2 7 4 0 75 5 4 4 Wiper motor 9 Cap T3 7 8 0 8 5 8 5 Spacer A 10 Wipe...

Page 3716: ...S GENERAL DESCRIPTION 3 WASHER TANK 1 Washer nozzle 5 Front washer motor Tightening torque N m kgf m ft lb 2 Washer hose 6 Rear washer motor T 6 0 0 61 4 4 3 Washer tank 7 Grommet 4 Washer tank cap WW...

Page 3717: ...al parts and switches Wire harnesses and connectors of all airbag sys tem are yellow color Do not use a tester on these circuits Care must be taken when installing the piping hose so that no bending j...

Page 3718: ...R RHD MODEL Ref to WI 327 RHD MODEL SCHEMATIC Wiper and Washer System Rear B INSPECTION Symptom Repair order Wiper and washers do not operate 1 Wiper fuse F B No 14 15 2 Combination switch 3 Wiper mot...

Page 3719: ...onnector terminal LHD model and RHD model with rear fog light If continuity is not as specified replace the switch WW 00004 WW 00045 Switch position Terminal No Standard FRONT OFF 7 and 16 Less than 1...

Page 3720: ...voltage from after the second time the wiper stops If operation is not as specified replace the switch Switch position Terminal No Standard FRONT OFF 3 and 12 Less than 1 INT 3 and 12 Less than 1 LO...

Page 3721: ...er from the blade assembly D ASSEMBLY 1 Insert the wiper rubber onto the blade so that the stopper is in the position shown at the bottom of the wiper arm 2 Make sure the wiper rubber is securely fast...

Page 3722: ...INSTALLATION Install in the reverse order of removal C DISASSEMBLY Remove washer motor from tank D ASSEMBLY 1 Assemble in the reverse order of disassembly 2 Confirm that water does not leak from inst...

Page 3723: ...op posite 1 Install in the reverse order of removal 2 Operate wiper once 3 Align wiper blade to ceramic print point mark A of front window pane Tightening torque Refer to COMPONENT in General Descrip...

Page 3724: ...Descrip tion Ref to WW 3 FRONT WIPER COM PONENT General Description C INSPECTION 1 When battery is connected to terminal of con nectors confirm that motor operates at low speed 2 When battery is conn...

Page 3725: ...liquid sprayer Ref to WW 14 ADJUSTMENT Front Washer Nozzle C INSPECTION Make sure the nozzle and hose are not clogged Make sure the hose is not bent D ADJUSTMENT NOTE Adjustment positions for left ha...

Page 3726: ...ON 1 Install in the reverse order of removal 2 Operate rear wiper once 3 Align blade to rear defogger heat wire A Tightening torque Refer to COMPONENT in General Descrip tion Ref to WW 4 REAR WIPER CO...

Page 3727: ...wiper cushion with the arrow mark facing up as shown in the figure Tightening torque Refer to COMPONENT in General Descrip tion Ref to WW 4 REAR WIPER COM PONENT General Description C INSPECTION 1 Con...

Page 3728: ...ver or other tool and re move the washer nozzle B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the position of the washer liquid sprayer Ref to WW 17 ADJUSTMENT Rear Washer Nozzle C...

Page 3729: ...LLATION 1 WAGON Install in the reverse order of removal C INSPECTION 1 WAGON 1 Turn the rear wiper switch to ON 2 Apply battery voltage to the rear terminals 8 and 2 and then inspect the voltage of 6...

Page 3730: ...ral Description 2 2 Radio System 3 3 Cigarette Lighter System 4 4 Radio Body 5 5 Front Speaker 6 6 Front Tweeter 7 7 Rear Speaker 8 8 Woofer 9 9 Speaker Amplifier 10 10 Antenna 11 11 Antenna Amplifier...

Page 3731: ...ttery ground cable Otherwise the memory will be erased Reassemble in reverse order of disassembly un less otherwise indicated Adjust parts to the given specifications Connect connectors and hoses secu...

Page 3732: ...wer supply for radio 2 Check radio ground 3 Remove radio for repair A specific speaker does not operate 1 Check speaker 2 Check output circuit between radio and speaker Radio generates noise with engi...

Page 3733: ...ET 4 ENTERTAINMENT CIGARETTE LIGHTER SYSTEM 3 Cigarette Lighter System A SCHEMATIC 1 CIGARETTE LIGHTER Ref to WI 233 SCHEMATIC Front Accessory Power Supply System...

Page 3734: ...Remove two screws B and hook D then re move center panel C while disconnecting connec tor 4 Remove fitting screws and slightly pull radio out from center console 5 Disconnect electric connectors and a...

Page 3735: ...Disconnect ground cable from battery 2 Remove front door trim Ref to EI 30 REMOV AL Front Door Trim 3 Remove front speaker mounting screws 4 Disconnect harness connector and remove front speaker B IN...

Page 3736: ...T FRONT TWEETER 6 Front Tweeter A REMOVAL 1 Disconnect ground cable from battery 2 Remove gusset cover 3 Disconnect harness connector and remove tweeter B INSTALLATION Install in the reverse order of...

Page 3737: ...1 Disconnect ground cable from battery 2 Remove rear door trim Ref to EI 31 REMOV AL Rear Door Trim 3 Remove rear speaker mounting screws 4 Disconnect harness connector and remove rear speaker B INSTA...

Page 3738: ...1 Disconnect ground cable from battery 2 Remove rear shelf trim Ref to EI 45 Remov al Rear Shelf Trim 3 Remove woofer mounting screws 4 Disconnect harness connector and then re move woofer B INSTALLA...

Page 3739: ...REMOVAL 1 Disconnect ground cable from battery 2 Remove passenger s seat Ref to SE 7 RE MOVAL Front Seat 3 Disconnect harness connector 4 Remove mounting nuts and then detach speak er amplifier B INS...

Page 3740: ...be A and press the foil B against the wire C with your finger To locate the broken point move the probe along the antenna wire B REPAIR 1 Clean antenna wire and the surrounding area with a cloth dampe...

Page 3741: ...to EI 40 WAGON REMOVAL Rear Quarter Trim 3 Disconnect harness connector and terminal 4 Remove mounting screw and detach antenna amplifier B INSTALLATION Install in the reverse order of removal C INSPE...

Page 3742: ...o Standard 1 a and Amplifier Less than 1 1 b and Amplifier More than 100 k 1 c and Amplifier Less than 1 1 d and Amplifier More than 100 k 2 and Amplifier More than 100 k 3 and Amplifier More than 100...

Page 3743: ...arette Lighter A REMOVAL 1 Disconnect ground cable from battery 2 Remove center panel Ref to ET 5 REMOV AL Radio Body 3 Disconnect harness connectors and remove cig arette lighter B INSTALLATION Insta...

Page 3744: ...COMMUNICATION SYSTEM COM Page 1 General Description 2 2 Horn System 3 3 Horn 4 4 Horn Switch 5...

Page 3745: ...COM 2 COMMUNICATION SYSTEM GENERAL DESCRIPTION 1 General Description A PREPARATION TOOL 1 GENERAL TOOLS TOOL NAME REMARKS Circuit Tester Used for measuring resistance and voltage...

Page 3746: ...m B INSPECTION 1 HORN RELAY Measure horn relay resistance between terminals indicated in table below while connecting terminal No 4 to battery positive terminal and terminal No 3 to battery ground ter...

Page 3747: ...emove horn bracket mounting bolt A 3 Disconnect harness connector and remove horn assembly B B INSTALLATION Install in the reverse order of removal C INSPECTION With 12 V direct current supply between...

Page 3748: ...Disconnect ground cable from battery 2 Remove the driver s airbag module Ref to AB 12 Driver s Airbag Module 3 Remove horn switch from steering wheel as shown B INSTALLATION Install in the reverse ord...

Page 3749: ...COM 6 COMMUNICATION SYSTEM HORN SWITCH MEMO...

Page 3750: ...bly 16 8 Rear Door Glass 17 9 Rear Regulator and Motor Assembly 18 10 Windshield Glass 19 11 Rear Gate Glass 22 12 Rear Quarter Glass 24 13 Rear Window Glass 26 14 Roof Window Glass 27 15 Inner Rearvi...

Page 3751: ...GENERAL DESCRIPTION 1 General Description A COMPONENT 1 FIXED GLASS SEDAN 1 Windshield glass 4 Rearview mirror mount 7 6 light glass 2 Dam rubber 5 Locate pin 3 Molding 6 Rear window glass GW 00080 2...

Page 3752: ...RRORS GENERAL DESCRIPTION 2 FIXED GLASS WAGON 1 Windshield glass 4 Rearview mirror mount 7 Rear quarter glass 2 Dam rubber 5 Locate pin 8 Locate pin 3 Molding 6 Fastener 9 Rear gate glass GW 00081 1 2...

Page 3753: ...MIRRORS GENERAL DESCRIPTION 3 FRONT DOOR GLASS 1 Glass 4 Regulator ASSY Tightening torque N m kgf m ft lb 2 Door sash Front 5 Motor ASSY T1 7 35 0 75 5 4 3 Door sash Rear T2 14 1 4 10 1 GW 00082 1 2...

Page 3754: ...S MIRRORS GENERAL DESCRIPTION 4 REAR DOOR GLASS 1 Glass 4 Regulator ASSY Tightening torque N m kgf m ft lb 2 Door sash Front 5 Motor ASSY T1 7 35 0 75 5 4 3 Door sash Rear T2 14 1 4 10 1 GW 00083 1 2...

Page 3755: ...GW 6 GLASS WINDOWS MIRRORS GENERAL DESCRIPTION 5 MIRRORS 1 Outer mirror 3 Mount 5 Mirror 2 Rearview mirror 4 Spring GW 00084 1 2 3 4 5...

Page 3756: ...connected always conduct an operational check after connecting them again Avoid impact and damage to the glass C PREPARATION TOOL TOOL NAME REMARKS Circuit Tester Used for checking voltage and continu...

Page 3757: ...Ref to WI 286 RHD MODEL SCHEMATIC Power Window System B INSPECTION Symptom Repair order All power windows does not operate 1 Fuse SBF 6 F B No 18 2 Power window circuit breaker 3 Power window relay 4...

Page 3758: ...w Defogger System A SCHEMATIC Ref to WI 296 SCHEMATIC Rear Window Defogger System B INSPECTION Symptom Repair order Rear window defogger does not operate 1 Fuse M B No 1 2 Rear defogger relay 3 Defogg...

Page 3759: ...DEICER SYSTEM 4 Windshield Wiper Deicer System A SCHEMATIC Ref to WI 328 SCHEMATIC Wiper Deicer System B INSPECTION Symptom Repair order Wiper deicer does not operate 1 Fuse F B No 18 19 2 Wiper deice...

Page 3760: ...or System 2 REMOTE CONTROL MIRROR RHD MODEL Ref to WI 299 RHD MODEL SCHEMATIC Remote Controlled Rearview Mirror System B INSPECTION Symptom Repair order All function does not operate 1 Fuse F B No 4 2...

Page 3761: ...33 REMOV AL Outer Mirror Assembly 7 Remove gusset 8 Operate the power window switch to move glass to the position shown in the figure and then re move the two nuts from service holes 9 Take out door g...

Page 3762: ...mm 0 39 to 0 59 in from fully closed position While applying outward pressure of 45 5 N 4 59 0 51 kgf 10 1 1 1 lb F to upper edge of glass above midpoint of two outer stabilizers press inner stabilize...

Page 3763: ...ts alternately step by step to obtain dimensions shown below cross sec tion A NOTE If two nuts are loosened at the same time sash moves back and forth Therefore when one nut is adjusted secure the oth...

Page 3764: ...f one sash to the maximum amount and the other to the minimum amount is not permitted Such adjustment may result in application of exces sive load to regulator 11 After adjustments tighten nuts 12 Aft...

Page 3765: ...L Front Door Glass 5 Disconnect motor connector 6 Loosen four bolts and two nuts to pull out regu lator assembly 7 Loosen screws to remove motor assembly B INSTALLATION 1 Install in the reverse order...

Page 3766: ...e different in dimension Special notes for rear glass are given below 1 Adjust glass position using the following dimen sions as a guide line NOTE If dimensions are smaller than the given dimen sions...

Page 3767: ...ing nut 5 Remove front sash 6 Disconnect motor connector 7 Loosen four bolts and two nuts to remove regu lator assembly 8 Loosen screws to remove motor assembly B INSTALLATION 1 Install in the reverse...

Page 3768: ...ng face and edge of windshield glass to cut the adhesive layer NOTE Because matching pins are bonded to the corners of glass use piano wire to cut the pin 2 USING PIANO WIRE 1 Remove cowl panel Ref to...

Page 3769: ...to make uniform clearance between body and glass in four corners 6 Place locating pins A and body on glass 7 Remove glass from body 8 Fit molding mark B to notch A of ceramic print 9 Apply primer to a...

Page 3770: ...stand for about 24 hours NOTE For minimum drying time and time the vehicle must be left standing before driving after bonding follow instructions or instruction manual from the adhe sive manufacturer...

Page 3771: ...glass is not allowed B INSTALLATION 1 Apply adhesive evenly to the glass attachment area 2 Insert the glass clip pin into the rear gate hole and after pushing on the area around the clip pin to secur...

Page 3772: ...cle must be left standing before driving after bonding follow in structions or instruction manual from the adhesive manufacturer When a vehicle is returned to the user tell him or her that the vehicle...

Page 3773: ...ove glass in the same procedure as for windshield glass Ref to GW 19 REMOVAL Windshield Glass 2 WAGON Remove glass in the same procedure as for windshield glass Ref to GW 19 REMOVAL Windshield Glass 1...

Page 3774: ...imum drying time and time the vehicle must be left standing before driving after bonding follow instructions or instruction manual from the adhe sive manufacturer 4 After curing of adhesive pour water...

Page 3775: ...t rear defogger terminals 4 After completion of all work allow vehicle to stand for about 24 hours NOTE For minimum drying time and time the vehicle must be left standing before driving after bonding...

Page 3776: ...7 GLASS WINDOWS MIRRORS ROOF WINDOW GLASS 14 Roof Window Glass A REMOVAL Ref to SR 6 REMOVAL Sunroof Lid B INSTALLATION Ref to SR 6 INSTALLATION Sunroof Lid C ADJUSTMENT Ref to SR 6 ADJUSTMENT Sunroof...

Page 3777: ...rror base 90 degrees clockwise or coun terclockwise to remove it 2 Remove spring from mirror base CAUTION Be careful not to damage the mirror surface B INSTALLATION Install in the reverse order of rem...

Page 3778: ...power window main switch 2 Disconnect connectors from power window main switch and mirror switch 2 SUB SWITCH Remove two hooks A of switch panel to remove power window sub switch and disconnect conne...

Page 3779: ...OFF 3 and 7 and 1 Less than 1 DOWN 7 and 9 3 and 1 Less than 1 AUTO DOWN 7 and 9 3 and 1 Less than 1 Switch position Terminal No Standard UP 9 and 5 1 and 4 Less than 1 OFF 1 and 5 and 4 Less than 1...

Page 3780: ...ors at the back of heater control unit 1 AUTO A C LHD RHD 2 MANUAL A C LHD RHD Switch position Terminal No Standard OFF More than 1 M ON i48 13 and i49 12 Less than 1 Switch position Terminal No Stand...

Page 3781: ...e lead of voltmeter to positive termi nal of voltmeter and then move negative lead along the wire up to the negative terminal end If voltage changes from zero to several volts during movement of lead...

Page 3782: ...ter Mirror Assembly A REMOVAL 1 Remove door trim Ref to EI 30 REMOVAL Front Door Trim 2 Remove sealing cover to disconnect mirror con nector 3 Loosen screws to remove mirror assembly B INSTALLATION In...

Page 3783: ...battery voltage is applied to terminals Mirror heater not equipped model If NG replace the mirror Mirror heater equipped model If NG replace the mirror Switch position Terminal No OFF UP 1 and 3 DOWN...

Page 3784: ...bladed screwdriver without sharp edg es to lift the mirror out of the mirror holder A Also remove the connector from the back of mirrors with heaters 4 Warm the area around the mirror holder A with a...

Page 3785: ...ONTROL MIRROR SWITCH 21 Remote Control Mirror Switch A REMOVAL 1 Remove power window main switch panel 2 Remove four hook to remove remote control mir ror switch B INSTALLATION Install in the reverse...

Page 3786: ...If NG replace the switch GW 00134 4 3 2 6 9 8 7 1 Switch position Terminal No Standard OFF More than 1 M UP 7 and 4 2 and 1 Less than 1 DOWN 7 and 2 4 and 1 Less than 1 LEFT 9 and 4 2 and 1 Less than...

Page 3787: ...WIPER DEICER 22 Wiper Deicer A INSPECTION Refer to INSPECTION under Rear Window Defog ger Ref to GW 32 INSPECTION Rear Window Defogger B REPAIR Refer to REPAIR under Rear Window Defogger Ref to GW 32...

Page 3788: ...MODEL Remove radio bracket and then remove wiper de icer switch Ref to ET 5 REMOVAL Radio Body B INSTALLATION Install in the reverse order of removal C INSPECTION Move wiper deicer switch to each pos...

Page 3789: ...GW 40 GLASS WINDOWS MIRRORS WIPER DEICER SWITCH MEMO...

Page 3790: ...BODY STRUCTURE BS Page 1 General Description 2 2 Datum Points 3 3 Datum Dimensions 10...

Page 3791: ...BS 2 BODY STRUCTURE GENERAL DESCRIPTION 1 General Description A PREPARATION TOOL TOOL NAME REMARKS Tram tracking gauge Used for measuring dimen sion Tape measure Used for measuring dimen sion...

Page 3792: ...hole at front pillar lower portion M6 88 Retainer attaching square hole at side rail outer 8 8 mm 0 31 0 31 in 64 Center pillar LWR gauge hole 16 mm 0 63 in dia 19 Retainer attaching hole at side rai...

Page 3793: ...floor side attaching hole 13 mm 0 51 in dia 99 Rear combination light mounting hole 8 mm 0 31 in dia 83 Rear skirt outer burring hole 20 mm 0 79 in dia 93 Rear panel inner trim attaching hole UPR 8 m...

Page 3794: ...LH 12 mm 0 47 in dia 51 Front side frame Ft gauge hole 20 mm 0 79 in dia 55 Crossmember front floor gauge hole M10 59 Frame rear floor side gauge hole 30 mm 1 18 in dia 52 Front side frame Ft gauge h...

Page 3795: ...BS 6 BODY STRUCTURE DATUM POINTS BS 00486 51 52 50 BS 00490 9 BS 00487 53 56 55 54 BS 00491 57 58 BS 00488 46 59 BS 00492 BS 00489 1 BS 00493 8 9 10...

Page 3796: ...BS 7 BODY STRUCTURE DATUM POINTS BS 00494 6 7 BS 00498 13 14 BS 00495 11 BS 00499 47 49 72 34 BS 00496 3 4 5 60 BS 00500 48 BS 00497 43 BS 00501 11 10...

Page 3797: ...BS 8 BODY STRUCTURE DATUM POINTS BS 00502 70 BS 00506 67 BS 00503 65 41 46 BS 00507 40 38 39 BS 00504 45 BS 00508 42 24 BS 00505 12 17 BS 00509 25...

Page 3798: ...BS 9 BODY STRUCTURE DATUM POINTS BS 00510 18 19 16 BS 00513 41 BS 00511 64 20 15 22 BS 00514 70 26 BS 00512 44 36 23 BS 00515 21...

Page 3799: ...all the di mensions When using a tape measure carefully measure dimensions without letting the tape measure sag or twist Measure the linear dimensions between cores of holes Suffixes RH and LH indica...

Page 3800: ...H to 3 RH 897 35 31 10 RH to 3 LH 1 679 66 10 10 RH to 8 RH 504 19 84 10 LH to 3 RH 1 679 66 10 10 LH to 8 LH 504 19 84 8 RH to 8 LH 1 398 55 04 9 RH to 9 LH 1 020 40 16 8 RH to 10 LH 1 519 59 80 6 RH...

Page 3801: ...1 1170 46 06 47 1 85 545 21 46 1180 46 46 1813 71 38 159 6 26 253 9 96 68 2 68 623 24 53 51 52 9 54 53 55 23 0 91 150 5 91 56 57 50 50 51 51 52 52 53 54 56 57 58 59 59 58 57 56 54 53 51 52 9 53 53 9 5...

Page 3802: ...BS 13 BODY STRUCTURE DATUM DIMENSIONS MEMO...

Page 3803: ...BS 14 BODY STRUCTURE DATUM DIMENSIONS 3 WINDSHIELD AND DOORS BS 00101 21 81 19 88 89 87 23 85 82 20 64 12 17 67 10 11 67 16 18 19 24 42 44 36 23 22 20 64 14 13 82...

Page 3804: ...60 33 86 81 to 23 RH 812 31 97 20 LH to 24 LH 860 33 86 81 to 23 LH 812 31 97 19 RH to 23 RH 899 35 39 82 LH to 21 LH 1 019 40 12 19 LH to 23 LH 899 35 39 82 RH to 21 LH 1 606 63 23 20 RH to 36 RH 1 5...

Page 3805: ...53 41 to 25 1 290 50 79 40 RH to 40 LH 1 392 54 80 41 to 12 1 228 48 35 41 to 38 1 639 64 53 41 to 21 RH 940 37 01 41 to 39 RH 1 642 64 65 41 to 21 LH 940 37 01 41 to 39 LH 1 642 64 65 41 to 17 RH 1 2...

Page 3806: ...BS 17 BODY STRUCTURE DATUM DIMENSIONS MEMO...

Page 3807: ...BS 18 BODY STRUCTURE DATUM DIMENSIONS 5 TRUNK LID AND REAR GATE BS 00103 72 34 48 70 47 46 41 49 43 45 46 99 97 84 94 81 90 91 94 99 84 22 83 93 86 91 92 81 38 82 46 97 95 21 100 100...

Page 3808: ...2 RH to 94 LH 1 710 67 32 48 to 46 LH 1 191 46 89 22 LH to 94 RH 1 710 67 32 70 RH to 70 LH 1 215 47 83 38 to 97 RH 3 100 122 05 72 RH to 72 LH 1 320 51 97 38 to 97 LH 3 227 127 05 81 to 38 2 351 92 5...

Page 3809: ...BS 20 BODY STRUCTURE DATUM DIMENSIONS MEMO...

Page 3810: ...ATION DRIVER INFO IDI Page 1 General Description 2 2 Combination Meter System 4 3 Combination Meter Assembly 14 4 Speedometer 18 5 Tachometer 19 6 Fuel Gauge 20 7 Water Temperature Gauge 21 8 Ambient...

Page 3811: ...light 12 V 1 4 W HI beam indicator light 12 V 1 4 W Door open warning light LED Seat belt warning light LED Brake fluid and parking brake warning light 12 V 1 4 W FWD indicator light 12 V 1 4 W AIRBA...

Page 3812: ...ight 12 V 1 4 W ABS warning light 12 V 1 4 W Check engine warning light Malfunc tion indicator light 12 V 1 4 W HI beam indicator light 12 V 1 4 W Door open warning light 12 V 2 0 W LCD back light Sea...

Page 3813: ...ssion control module 2 Harness 3 Speedometer MT Ref to IDI 6 CHECK VEHICLE SPEED SENSOR INSPECTION Combi nation Meter System AT Ref to IDI 7 CHECK TRANSMIS SION CONTROL MODULE INSPEC TION Combination...

Page 3814: ...ssis ground Connector terminal Standard meter i12 No 7 Chassis ground Luminiscent meter i10 No 9 Chassis ground i12 No 1 Chassis ground Does the measured value exceed the specified value 10 V Go to st...

Page 3815: ...switch to ON 4 Measure voltage between vehicle speed sensor connector and engine ground Connector terminal B17 No 3 Engine ground Does the measured value exceed the spec ified value 10 V Go to step 3...

Page 3816: ...red value same as the speci fied value 0 V 5 V Go to step 2 Check transmis sion control mod ule Ref to AT 2 Basic Diagnostic Procedure 2 CHECK HARNESS BETWEEN TRANSMIS SION CONTROL MODULE AND COMBINA...

Page 3817: ...Ref to EN H4SOw oOBD 2 Basic Diagnostic Proce dure or Ref to EN H4DOSTC 2 Basic Diagnostic Proce dure or Ref to EN H6DO 2 Basic Diagnostic Procedure or Ref to EN H6DO 2 Basic Diagnostic Procedure 2 CH...

Page 3818: ...vel Sensor or Ref to FU H4SOw oOBD 62 REMOVAL Fuel Sub Level Sensor or Ref to FU H4DOSTC 62 REMOVAL Fuel Sub Level Sensor or Ref to FU H6DO 68 REMOVAL Fuel Sub Level Sensor 2 Measure the resistance be...

Page 3819: ...Connector terminal R58 No 6 R59 No 2 Is the measured value less than the specified value 10 Go to step 5 Repair wiring har ness 5 CHECK FUEL LEVEL SENSOR GROUND CIRCUIT Measure the resistance between...

Page 3820: ...connector from engine coolant temperature sensor and combination meter 3 Measure resistance between engine cool ant temperature sensor harness connector and combination meter harness connector Connect...

Page 3821: ...Sensor Is the ambient sensor OK Ambient sensor is OK Go to step 3 Replace the ambi ent sensor 3 CHECK HARNESS BETWEEN AMBIENT SENSOR AND COMBINATION METER 1 Disconnect connector from combination meter...

Page 3822: ...ctor B and combination meter con nector A Connector terminal Printed circuit connector B No 1 Combination meter connector A No 7 Printed circuit connector B No 2 Combination meter connector A No 7 Is...

Page 3823: ...Loosen screws C to remove center panel D 5 Remove meter visor E NOTE The following illustration is for LHD model The lay out for RHD model is symmetrically opposite 6 Remove screws of combination met...

Page 3824: ...ger prints on the glass surface and meter surfaces 1 STANDARD METER 1 Disengage claw F to remove case B from back cover A 2 Disengage claw G to remove meter glass E reflector D and window plate C from...

Page 3825: ...and window plate E from case C 4 Remove connector cover and release connector lock by pulling both end of it disconnect FPC Flex ible Printed Circuit connector P 5 Pull up claw N on back cover A with...

Page 3826: ...23 HOLD 24 LCD IDI00031 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 Water temperature gauge ring 2 Tachometer and water temperature gauge ring 3 ABS 4 VDC 5 Oil pressure 6 Check e...

Page 3827: ...Ref to IDI 15 DISASSEMBLY Combination Meter As sembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure speedometer resistance If NG replace speedometer and fuel gauge assem...

Page 3828: ...Ref to IDI 15 DISASSEMBLY Combination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure tachometer resistance If NG replace tachometer and water temperature g...

Page 3829: ...ISASSEMBLY Combination Meter As sembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure fuel gauge resistance If NG replace speedometer and fuel gauge assem bly If OK replac...

Page 3830: ...IDI 15 DISASSEMBLY Combination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure water temperature gauge resistance If NG replace tachometer and water temperat...

Page 3831: ...d cable from battery 3 Disconnect ambient sensor connector 4 Remove ambient sensor from radiator lower panel B INSTALLATION Install in the reverse order of removal C INSPECTION Measure ambient sensor...

Page 3832: ...SEATS SE Page 1 General Description 2 2 Front Seat 7 3 Rear Seat 17...

Page 3833: ...SE 2 SEATS GENERAL DESCRIPTION 1 General Description A COMPONENT 1 FRONT SEAT SE 00197 b a 1 2 3 4 5 6 7 8 9 9 10 10 10 10 9 10 10 11 12 13 13 14 T2 T1 T2 T1 T1 T3 T1 T2 T2 T2 T1 T1 A B...

Page 3834: ...lide rail inner ASSY T1 30 3 1 22 a 8 way power seat 8 Slide rail outer ASSY T2 53 5 4 39 b 6 way power seat 9 Hinge ASSY T3 10 1 0 7 1 Seat back pad 10 Hinge cover 2 Headrest 11 Rod 3 Seat back board...

Page 3835: ...SE 4 SEATS GENERAL DESCRIPTION 2 REAR SEAT SEDAN 1 Backrest 3 Cushion Tightening troque N m kgf m ft lb 2 Head restraint T 24 5 2 50 18 1 SE 00251 1 2 2 2 3 T...

Page 3836: ...ON 3 REAR SEAT WAGON 1 Cover 5 Backrest RH Tightening troque N m kgf m ft lb 2 Cushion RH 6 Backrest LH T1 10 1 0 7 2 3 Cushion LH 7 Head restraint T2 24 5 2 50 18 1 4 Hook T3 33 3 40 24 1 SE 00198 1...

Page 3837: ...ON B CAUTION When removing front seat from a side airbag load ed vehicle follow cautions given in the airbag sec tion C PREPARATION TOOL 1 GENERAL TOOL TOOL NAME REMARKS Long Nose Pliers Used for remo...

Page 3838: ...nnect connectors of seat heater and seat belt warning Seat heater equipped seat 8 Remove two bolts at rear side of seat rail 9 Move seat to full rear end 10 Remove two bolts at front side of seat rail...

Page 3839: ...11 Remove front seat from vehicle B INSTALLATION 1 STANDARD SEAT 1 Install in the reverse order of removal 2 Place slide rail rear inner on location bolts A 3 Tighten the four bolts of slide rail NOT...

Page 3840: ...nd remove hog rings using a plier 5 Remove clamp of side airbag wire harness Side airbag equipped seat 6 Remove clamp of seat heater wire harness Seat heater equipped seat 7 Turn cover and cushion and...

Page 3841: ...t pad 14 Remove clamp of airbag wire harness on back side of seat Side airbag equipped seat 15 Remove the two cap nuts and then remove side airbag module assembly Side airbag equipped seat 16 Remove r...

Page 3842: ...r wire harness Seat heater equipped seat 20 Remove hog rings A Tilt type seat Non tilt type seat Leather type seat 21 Remove cushion cover 22 Remove cushion pad 23 Remove clip pins and remove seat lif...

Page 3843: ...slide rail 28 Remove 4 screws and then remove hinge Non tilt type seat 29 Remove 2 bolts and then remove slide rail Non tilt type seat 30 Remove connecting wire 2 POWER SEAT 1 Remove seats from vehicl...

Page 3844: ...ag equipped seat 6 Remove clamp of seat heater wire harness Seat heater equipped seat 7 Turn cover and cushion and remove the two bolts from hinge 8 Remove hinge screw cover and screws and re move sea...

Page 3845: ...irbag equipped seat 15 Remove the two cap nuts and then remove side airbag module assembly Side airbag equipped seat 16 Remove the 4 bolts of seat hinge assembly and then remove seat cushion 17 Remove...

Page 3846: ...seat switch connector on the underside of the cover and remove the hinge cover 6 way power seat Remove the reclining lever cover and screw dis connect the power seat switch connector on the un dersid...

Page 3847: ...type standard seat 2 POWER SEAT 1 Assemble in the reverse order of disassembly NOTE Do not contaminate or damage cover While installing hog rings prevent seat from get ting wrinkled Make sure the conn...

Page 3848: ...and then remove rear floor front mat 5 Remove bolts and nuts of bracket hinge 6 Remove rear seat backrest 2 SEDAN 1 Slightly raise front of cushion while pushing down on cushion in the direction of A...

Page 3849: ...per back side of the rear seat backrest to the body hook 2 Tighten the bolt and install the backrest 3 Hook and fasten the seat cushion to the hook on the lower part of the rear seat backrest Tighteni...

Page 3850: ...ings 6 Remove backrest hook 7 Remove hook at bottom 8 Remove 4 pawls 9 Remove 8 hog rings A 10 Remove the hog rings A on front side of cush ion pad Armrest equipped seat 11 Remove cover When disassemb...

Page 3851: ...cushion mat 15 Remove hook and then remove frame 16 Remove hog rings A and then remove cover Separated type seat 2 SEDAN 1 Remove the rear seat from the vehicle Ref to SE 17 REMOVAL Rear Seat 2 Remove...

Page 3852: ...and then remove the seat cover D ASSEMBLY 1 WAGON 1 Assemble in the reverse order of disassembly NOTE Do not contaminate or damage cover While installing wire rings prevent seat from get ting wrinkle...

Page 3853: ...SE 22 SEATS REAR SEAT MEMO...

Page 3854: ...23 9 Rear Outer Handle 24 10 Rear Door Latch Assembly 25 11 Rear Door Lock Actuator 26 12 Rear Gate Outer Handle 27 13 Rear Gate Latch Assembly 28 14 Rear Gate Latch Lock Actuator 29 15 Trunk Lid Loc...

Page 3855: ...OCK ASSEMBLY 1 Inner remote ASSY 6 Striker Tightening torque N m kgf m ft lb 2 Inner remote cover 7 Door outer handle T1 6 4 0 65 4 7 3 Bell crank 8 Key cylinder T2 7 35 0 75 5 4 4 Auto door lock actu...

Page 3856: ...ey cylinder 6 Rear gate outer handle Tightening torque N m kgf m ft lb 2 Cable 7 Rear gate actuator T1 7 5 0 76 5 5 3 Striker 8 Rear gate latch T2 25 2 5 18 1 4 Trunk lid lock ASSY T3 18 1 8 13 0 5 Tr...

Page 3857: ...CRIPTION 3 HOOD LOCK AND REMOTE OPENERS 1 Hood lock ASSY 4 Cover Tightening torque N m kgf m ft lb 2 Lever ASSY 5 Pull handle ASSY T1 6 4 0 65 4 7 3 Cable 6 Striker T2 32 3 3 23 9 SL 00116 HOOD SEDAN...

Page 3858: ...S GENERAL DESCRIPTION 4 IMMOBILIZER SYSTEM NOTE IMM ECM location for RHD model is symmetrically opposite 1 Antenna 3 Immobilizer control module IMM ECM 2 Immobilizer indicator light LED bulb 4 Transpo...

Page 3859: ...SL 6 SECURITY AND LOCKS GENERAL DESCRIPTION 5 KEYLESS ENTRY SYSTEM 1 Keyless entry control module 2 Rear gate latch switch Wagon 3 Door switch SL 00117 1 2 3...

Page 3860: ...if so designated Connect connectors and hoses securely during reassembly After reassembly ensure all functional parts operate smoothly Airbag system wiring harness is routed near the electrical parts...

Page 3861: ...System 4 Check the door lock actuator and the circuit Ref to SL 10 CHECK DOOR LOCK ACTUA TOR AND CIRCUIT INSPECTION Door Lock Control System Door lock switch knob does not operate Check the door lock...

Page 3862: ...epair harness Step Value Yes No 1 CHECK DOOR LOCK SWITCH CIRCUIT 1 Disconnect the keyless entry control mod ule harness connector 2 Measure the resistance between the har ness connector terminal and c...

Page 3863: ...lue exceed the specified value 10 V Go to step 2 Replace the key less entry control module 2 CHECK OUTPUT SIGNAL Measure the voltage between the harness con nector terminal of keyless entry control mo...

Page 3864: ...is unlocked Empty 8 Empty 9 Empty 10 Room light Ignition switch illumina tion 11 OUTPUT 0 V is detected when pressing the transmitter OPEN button 0 V is detected when any door is open Turn signal lig...

Page 3865: ...TE If the door lock control system does not operate when using the door lock switch check the door lock control system Ref to SL 8 INSPECTION Door Lock Control System 1 Check the transmitter battery R...

Page 3866: ...6 in the main fuse box Is the fuse blown The fuse is not blown Check power sup ply and ground cir cuit Ref to SL 13 CHECK POWER SUPPLY AND GROUND CIRCUIT INSPECTION Keyless Entry Sys tem Replace the...

Page 3867: ...ground Connector terminal B176 No 2 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 2 Repair harness and or connec tor 2 REGISTRATION CONNECTOR INPUT VOLT AGE INSPE...

Page 3868: ...und Rear gate B176 No 4 chassis ground Is the measured value less than the specified value when all doors and rear gate are closed 10 V The door switch is OK Go to step 3 3 CHECK DOOR SWITCH 1 Disconn...

Page 3869: ...nnector terminal and chassis ground Connector terminal B176 No 1 chassis ground Is the measured value same as the speci fied value 0 V The key warning switch is OK Go to step 4 4 CHECK KEY WARNING SWI...

Page 3870: ...n or short between keyless entry control mod ule and turn signal lights Replace the key less entry control module Step Value Yes No 1 CHECK ROOM LIGHT OPERATION Make sure the room light illuminates wh...

Page 3871: ...c ified value 10 V Go to step 2 Check harness for open circuit or shorts between the ignition switch illumination and fuse 2 CHECK HARNESS BETWEEN IGNITION SWITCH ILLUMINATION AND KEYLESS EN TRY CONTR...

Page 3872: ...g cover Ref to EB 13 RE MOVAL Front Sealing Cover 3 Remove the two rod joints 4 Remove the screw and detach the front inner remote B INSTALLATION Install in the reverse order of removal NOTE Make sure...

Page 3873: ...2 Remove the two bolts Remove the front outer handle A CAUTION Do not use excessive force to remove the door panel This will deform it B INSTALLATION Install in the reverse order of removal NOTE Make...

Page 3874: ...r remote Ref to SL 19 REMOVAL Front Inner Remote 5 Remove the front door glass Ref to GW 12 REMOVAL Front Door Glass 6 Remove three nuts and detach the front door sash Rear 7 Remove the three screws a...

Page 3875: ...ck ac tuator B INSTALLATION Install in the reverse order of removal NOTE Make sure the lock works properly after installation C INSPECTION 1 Disconnect the door lock actuator harness con nector 2 Conn...

Page 3876: ...Sealing Cover 3 Remove the two rod joints 4 Remove the screw and detach the inner remote B INSTALLATION Install in the reverse order of removal NOTE Make sure the inner remote works properly after in...

Page 3877: ...Inner Remote 4 Remove the rear door latch assembly Ref to SL 25 REMOVAL Rear Door Latch Assembly 5 Remove the two bolts and nut Remove the rear outer handle CAUTION Do not use excessive force to remo...

Page 3878: ...f to EB 16 RE MOVAL Rear Sealing Cover 4 Remove the rear inner remote Ref to SL 23 REMOVAL Rear Inner Remote 5 Remove the three screws and bolt 6 Disconnect the connector Remove the rear door latch as...

Page 3879: ...ac tuator B INSTALLATION Install in the reverse order of removal NOTE Make sure the lock works properly after installation C INSPECTION 1 Disconnect the door lock actuator harness con nector 2 Connec...

Page 3880: ...m 2 Remove the rear gate latch rod 3 Remove the nut holding the rear gate outer han dle and then remove the rear gate outer handle B INSTALLATION Install in the reverse order of removal NOTE Make sure...

Page 3881: ...e the rear gate key cylinder rod 4 Remove the rear gate outer handle Ref to SL 27 REMOVAL Rear Gate Outer Handle 5 Remove the three bolts 6 Remove the two connectors and pull out the latch B INSTALLAT...

Page 3882: ...tor B INSTALLATION Install in the reverse order of removal NOTE Make sure the lock works properly after installation C INSPECTION 1 Disconnect the door lock actuator harness con nector 2 Connect the b...

Page 3883: ...the lock assembly Remove the lock assembly B B INSTALLATION Install in the reverse order of removal NOTE Apply grease to parts that rub Make sure the lock works properly after installa tion C INSPECT...

Page 3884: ...tall in the reverse order of removal NOTE Apply grease to parts that rub Make sure the release cable works properly after installation C ADJUSTMENT Loosen the bolt Adjust the lock assembly while movin...

Page 3885: ...opener pull handle 5 Remove the striker from the trunk lid 6 Remove the cable from the striker 3 FUEL FLAP OPENER 1 Remove the rear seat Ref to SE 17 REMOV AL Rear Seat 2 Remove the center pillar lowe...

Page 3886: ...anel to left and remove B INSTALLATION 1 HOOD OPENER Install in the reverse order of removal 2 TRUNK LID OPENER Install in the reverse order of removal 3 FUEL FLAP OPENER Install in the reverse order...

Page 3887: ...ON 1 Remove the instrument panel lower cover 2 Remove the lower column cover 3 Unfasten the hold down clip which secures the harness and disconnect the connector of the igni tion switch from the body...

Page 3888: ...2 Remove the rod clamp Replace the key cylin der 2 TRUNK LID 1 Remove the trunk trim Ref to EI 47 REMOV AL Trunk Lid Trim 2 Remove the rod clamp Remove the lock plate Replace the key cylinder 3 REAR G...

Page 3889: ...e for LHD models The positions for RHD models are symmetrically opposite 1 Disconnect ground cable from battery 2 Remove instrument panel lower cover Ref to EI 35 REMOVAL Instrument Panel Assembly 3 D...

Page 3890: ...nstrument panel lower cover Ref to EI 35 REMOVAL Instrument Panel Assembly 3 Remove screws separate upper column cover and lower column cover 4 Disconnect immobilizer antenna connector A from immobili...

Page 3891: ...ery 2 Remove glove box Ref to EI 32 REMOVAL Glove Box 3 Remove nut then remove keyless entry control module B and the other electrical control module A while disconnecting connector 4 Disconnect keyle...

Page 3892: ...equiva lent D REPLACEMENT 1 TRANSMITTER REGISTRATION NOTE A maximum of 3 transmitters can be registered for each individual vehicle 1 Remove the side sill cover at the driver s side then connect the...

Page 3893: ...SL 40 SECURITY AND LOCKS KEYLESS TRANSMITTER MEMO...

Page 3894: ...SUNROOF T TOP CONVERTIBLE TOP SUNROOF SR Page 1 General Description 2 2 Sunroof Control System 5 3 Sunroof Lid 6 4 Sunroof Assembly 7 5 Sunroof Motor 11 6 Sunroof Switch 14...

Page 3895: ...escription A COMPONENT 1 SEDAN 1 Glass lid 6 Sunroof bracket Front Tightening torque N m kgf m ft lb 2 Guide rail cover 7 Motor cover T 7 4 0 75 5 4 3 Sunshade 8 Motor ASSY 4 Drain tube 9 Frame ASSY 5...

Page 3896: ...SCRIPTION 2 WAGON 1 Glass lid Front 5 Frame ASSY Front Tightening torque N m kgf m ft lb 2 Glass lid Rear 6 Drain tube T1 7 4 0 75 5 4 3 Sunshade 7 Cover T2 1 5 0 15 1 1 4 Frame ASSY Rear 8 Frame brac...

Page 3897: ...rd memory contents before disconnecting the battery ground cable Otherwise the memory will be erased Reassemble in reverse order of disassembly un less otherwise indicated Adjust parts to the given sp...

Page 3898: ...heck gears and bearings for wear 3 Check cables for wear 4 Check cable pipe for deformities Failure of sunroof Motor operates properly 1 Check guide rail for foreign particles 2 Check guide rail for i...

Page 3899: ...sun shade 2 Remove covers A then remove nuts B 3 Remove the sunroof lid carefully B INSTALLATION Install in the reverse order of removal CAUTION When installing sunroof lid be careful not to pinch the...

Page 3900: ...ove room lamp harness clip A 6 Disconnect sunroof harness connector 7 Remove motor cover 8 Remove sunroof brackets front A and rear B 9 Remove nuts then detach the sunroof frame 2 WAGON FRONT 1 Discon...

Page 3901: ...m Ref to EI 42 WAGON REMOVAL Roof Trim 3 Remove rear sunroof lid Ref to SR 6 SEDAN AND WAGON REAR REMOVAL Sunroof Lid 4 Disconnect drain tubes A from rear sunroof frame 5 Disconnect sunroof harness co...

Page 3902: ...or more C DISASSEMBLY 1 SEDAN AND WAGON FRONT 1 Remove sunroof frame 2 Remove rail stoppers A 3 Pull out the sunshade A from sunroof frame 2 WAGON REAR 1 Remove rear sunroof frame 2 Remove sunroof mo...

Page 3903: ...scale to measure force required to move the sunshade Force required to move rear sunshade Less than 24 5 4 9 N 2 5 0 5 kgf 5 5 1 1 lb NOTE Considerable force is required to start sunshade moving so t...

Page 3904: ...g screw 2 WAGON 1 Completely close the front and rear sunroof then tilt up the front sunroof to the most upper po sition 2 Disconnect ground cable from battery 3 Remove rear sunroof lid Ref to SR 6 SE...

Page 3905: ...when installing sunroof motor 1 Check the matching mark A of sunroof motor 2 Confirm the matching mark A of sunroof brack et link 3 Install sunroof motor 4 After installing the motor reconfirm the ma...

Page 3906: ...of Open 6 Close sunroof 150 mm 5 91 in away from completely closed position Closed 7 Completely close sunroof Closed Operation Switch position 1 Completely close front and rear sunroof Closed 2 Tilt u...

Page 3907: ...INSTALLATION Install in the reverse order of removal C INSPECTION 1 SEDAN Measure sunroof switch resistance 2 WAGON Measure sunroof switch resistance SR 00039 A B Switch position Terminal No Standard...

Page 3908: ...0 Side Sill Spoiler 29 11 Front Door Trim 30 12 Rear Door Trim 31 13 Glove Box 32 14 Roof Rail 33 15 Console Box 34 16 Instrument Panel Assembly 35 17 Upper Inner Trim 38 18 Lower Inner Trim 39 19 Rea...

Page 3909: ...Bumper face Except OUTBACK 6 Cover Tightening torque N m kgf m ft lb 2 Bumper face OUTBACK 7 Toeing hook cover Except OUT BACK T1 30 3 1 22 3 Bumper beam T2 17 7 1 8 13 0 4 Side stay 8 Toeing hook co...

Page 3910: ...GENERAL DESCRIPTION 2 REAR BUMPER SEDAN 1 Bumper beam 4 Side stay Tightening torque N m kgf m ft lb 2 Side bracket 5 Hook T1 93 9 5 69 3 Bumper face 6 Bracket T2 7 4 0 75 5 4 T3 2 0 2 1 4 EI 00403 1...

Page 3911: ...IPTION 3 REAR BUMPER WAGON 1 Bumper beam 4 Bumper face OUTBACK Tightening torque N m kgf m ft lb 2 Side bracket 5 Side stay T1 93 9 5 96 3 Bumper face Except OUTBACK 6 Hook T2 7 4 0 75 5 4 T3 2 0 2 1...

Page 3912: ...CK 3 Side protector Front fender 7 Side protector Side sill B OUTBACK 4 Side protector Front door 1 Front side protector 5 Side protector Rear door Tightening torque N m kgf m ft lb 2 Rear side protec...

Page 3913: ...A Front door 3 Weatherstrip upper 8 Weatherstrip lower B Rear door 4 Clip 9 Upper trim C Rear gate 5 Pad 10 Side trim 1 Gusset cover 6 Trim panel 11 Lower trim 2 Bracket 7 Power window switch cover E...

Page 3914: ...1 Side sill rear lower cover 2 Center pillar upper trim 7 Trunk side trim 12 Front pillar lower trim 3 Rear pillar upper trim 8 Rear pillar lower trim 13 Side sill front lower cover 4 Rear shelf trim...

Page 3915: ...lower trim 11 Center pillar lower trim 2 Center pillar upper trim 7 Lid 12 Side sill rear lower cover 3 Rear pillar upper trim 8 Rear skirt trim 13 Front pillar lower trim 4 Rear rail trim 9 Hook 14 S...

Page 3916: ...itch panel 3 Hook 13 Console box 23 Meter visor 4 Grille side P 14 Rear ash tray 24 Grille vent D 5 Grille vent P 15 Console lid 25 Grille center 6 Glove box panel 16 Console cover 7 Glove box lid 17...

Page 3917: ...EI 10 EXTERIOR INTERIOR TRIM GENERAL DESCRIPTION 9 INNER ACCESSORIES 1 Hook 2 Sun visor 3 Assist grip EI 00293 1 2 3...

Page 3918: ...ver Used for removal of trim Adhesive remover Used for removal of side protector Primer Used for installation of side protector Infrared lamp Used for disassembly assembly of side protector Tow sided...

Page 3919: ...lle A REMOVAL 1 Open hood 2 Loosen bolts and nuts to remove front grill B INSTALLATION Install in the reverse order of removal Tightening torque A Nut 4 4 1 5 N m 0 45 0 15 kgf m 3 3 1 1 ft lb B Bolt...

Page 3920: ...FRONT UNDER COVER 3 Front Under Cover A REMOVAL 1 Lift up the vehicle 2 Loosen bolts and clips to remove under cover B INSTALLATION Install in the reverse order of removal Tightening torque 18 4 N m 1...

Page 3921: ...he mud gruand 4 Remove clip at bottom of bumper 5 Remove clip A and pull out bumper slightly 6 Disconnect electrical connector of fog light to re move bumper 7 Remove bumper beam B INSTALLATION Instal...

Page 3922: ...r Solid paint Hardener PB Thinner T 301 Mixing ratio Main agent vs hardener 4 1 Viscosity 10 13 sec 20 C 68 F Film thickness 35 45 Spraying pressure 245 343 kPa 2 5 3 5 kg cm2 36 50 psi Use section bl...

Page 3923: ...Kit NRM Pro cess No Process name Job contents 1 Cleaning Clean the area to be repaired using water 2 Sanding Grind the repairing area with 500 sand paper in a feathering motion 3 Finish Resin section...

Page 3924: ...nd the side just opposite the beveled area with sand paper 40 to 60 and clean using a sol vent Temporarily spot weld the side using a PP welding rod and heater gun 1 Welded spot Use heater gun and PP...

Page 3925: ...ating Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min utes Recommended surfacer UPS 300 Flex Primer No 303 UPS 300 Exclusive hardener NPS 725 Exclu...

Page 3926: ...ng pressure 245 343 kPa 2 5 3 5 kg cm2 36 50 psi 22 Drying Allow the coated surface to dry at 20 C 68 F for two hours or 60 C 140 F for 30 minutes NOTE Do not allow the temperature to exceed 80 C 176...

Page 3927: ...trunk rear trim 4 Remove hook A to pull off rear side of trunk side trim 5 Remove two nuts from each side to remove rear bumper 6 Loosen clips to remove upper beam A from bumper face 2 WAGON 1 Lift u...

Page 3928: ...guide pin B securely Tightening torque Refer to COMPONENT in General Descrip tion Ref to EI 3 REAR BUMPER SE DAN COMPONENT General Description 2 WAGON 1 Install in the reverse order of removal 2 Fit s...

Page 3929: ...IOR TRIM MUD GUARD 6 Mud Guard A REMOVAL 1 Jack up the vehicle 2 Remove screws and clips to remove mud guard B INSTALLATION Insert hook into body and tighten it with screw and clip A Except OUTBACK B...

Page 3930: ...23 EXTERIOR INTERIOR TRIM PROTECTOR 7 Protector A REMOVAL 1 Except OUTBACK NOTE Pay attention to the position of clips a c A Section A B Section B C Section C EI 00297 A B B A A C A A A A A a b c A B...

Page 3931: ...move clip a and bolt b NOTE Pay attention to the position of clip C A Section A C Section C E Section E B Section B D Section D EI 00298 A A A A A A A A A A A A A A A A A A A D A A A A A A A A A A A B...

Page 3932: ...tape is hard to remove heat to ap proximately 40 C 104 F 4 Apply an even coat of adhesive remover to the two sided tape Recommended adhesive remover SUMITOMO 3M4000 or equivalent CAUTION Do not apply...

Page 3933: ...to 40 to 60 C 104 to 140 F and rear surface of side pro tector to 20 to 30 C 68 to 86 F 3 Remove tack paper from two sided paper While aligning clips with holes in body panel attach two sided tape to...

Page 3934: ...ood 2 Remove wiper arm Ref to WW 12 REMOV AL Front Wiper Arm 3 Remove front panel seal 4 Remove clips A and cowl side panel C Loos en clips D on six positions and remove cowl side panel B INSTALLATION...

Page 3935: ...connector a of high mounted stop light 3 Remove mounting nut of rear spoiler to remove rear spoiler B INSTALLATION 1 Install in the reverse order of removal 2 Clean mounting surfaces of trunk lid and...

Page 3936: ...9 EXTERIOR INTERIOR TRIM SIDE SILL SPOILER 10 Side Sill Spoiler A REMOVAL Remove clips 1 on front 6 on lower 1 on side re move side spoiler B INSTALLATION Install in the reverse order of removal EI 00...

Page 3937: ...tch panel to remove power window main switch 3 Disconnect electrical connectors from power window main switch and mirror switch 4 Remove three screws and clips 5 Remove gusset cover Disconnect electri...

Page 3938: ...o remove upper hook Pull down it to remove lower claw Re move inner remote cover 2 Remove two hook A of switch panel to remove power window sub switch and disconnect electrical connector 3 Remove thre...

Page 3939: ...EI 32 EXTERIOR INTERIOR TRIM GLOVE BOX 13 Glove Box A REMOVAL 1 Remove stoppers 2 Loosen screws to remove glove box B INSTALLATION Install in the reverse order of removal EI 00177 EI 00178...

Page 3940: ...of Rail A REMOVAL 1 Remove roof trim Ref to EI 42 REMOVAL Roof Trim 2 Remove five mounting nuts and then detach roof rail carefully B INSTALLATION Install in the reverse order of removal Tightening to...

Page 3941: ...OX 15 Console Box A REMOVAL 1 Remove shift knob A MT model and front cov er B 2 Remove tray A and console cover B 3 Remove console box A B INSTALLATION Install in the reverse order of removal 1 Hook p...

Page 3942: ...ons for RHD model are symmetrically op posite 1 Disconnect ground cable from battery 2 Remove lower cover 3 Remove lower column cover and disconnect harness connectors to steering column 4 Remove stee...

Page 3943: ...er side 11 Set temperature control switch A to FULL HOT and then disconnect temperature control ca ble from bottom of heater unit Manual A C equipped model NOTE Do not move the switch and link when in...

Page 3944: ...re assembly When storing the removed instrument panel place it standing up on the floor B INSTALLATION Install in the reverse order of removal CAUTION Be careful not to snag the harness NOTE When set...

Page 3945: ...e center pillar upper trim C B INSTALLATION Install in the reverse order of removal CAUTION Be sure to securely hook pawls of inner trim panel to body flange NOTE When installing center pillar upper t...

Page 3946: ...on Ref to SE 17 REMOVAL Rear Seat then remove side sill rear upper cover C For wagon Rise rear seat cushion then remove side sill rear upper cover C 4 Remove side sill rear lower cover D 5 Remove cent...

Page 3947: ...Ref to EI 49 RE MOVAL Luggage Floor Mat 3 Remove rear skirt trim A 4 Remove rear quarter lower trim mounting volts screws and clips then remove the trim B 5 Remove rear mole C 6 Remove rear quarter up...

Page 3948: ...EI 41 EXTERIOR INTERIOR TRIM SUN VISOR 20 Sun Visor A REMOVAL Remove mounting screws then detach sun visor A and hook B B INSTALLATION Install in the reverse order of removal EI 00200 A B...

Page 3949: ...RE MOVAL Upper Inner Trim 8 Remove rear window mole A of both sides 9 Remove screw B of rear quarter lower trim shown in the figure 10 Remove rear quarter upper trim C of both sides 11 Remove clips an...

Page 3950: ...ower trim shown in the figure 10 Remove rear quarter upper trim D of both sides 11 Remove rear rail trim E 12 Remove cover B while detaching snap lock carefully Put the rear center seat belt tongue A...

Page 3951: ...not to damage clips or their holes 1 Remove clips and detach rear gate lower trim A 2 Remove caps and screws and then detach high mounted stop light cover A 3 Remove rear gate upper trim A B INSTALLAT...

Page 3952: ...Ref to SE 17 SE DAN REMOVAL Rear Seat 3 Remove inner seat belt RH then disconnect in ner seat belt RH A and outer seat belt center B 4 Detach rear shelf trim through each rear outer seat belt from sli...

Page 3953: ...TRIM TRUNK TRIM 24 Trunk Trim A REMOVAL 1 Remove clips and then detach trunk rear trim A 2 Remove luggage hook B and clips then detach trunk side trim C B INSTALLATION Install in the reverse order of...

Page 3954: ...EI 47 EXTERIOR INTERIOR TRIM TRUNK LID TRIM 25 Trunk Lid Trim A REMOVAL Remove clips and detach trunk lid trim A B INSTALLATION Install in the reverse order of removal EI 00300...

Page 3955: ...ower Inner Trim 5 Remove clips from floor mat NOTE When pulling out edge do not pull mat alone pull mat together with edge Ply off two steel clips on side sill front cover and one on side sill rear co...

Page 3956: ...49 EXTERIOR INTERIOR TRIM LUGGAGE FLOOR MAT 27 Luggage Floor Mat A REMOVAL Remove clips then detach rear floor mats and box es B INSTALLATION Install in the reverse order of removal 1 Clips EI 00218...

Page 3957: ...EI 50 EXTERIOR INTERIOR TRIM TRUNK ROOM MAT 28 Trunk Room Mat A REMOVAL Draw out trunk room mat B INSTALLATION Install in the reverse order of removal EI 00219...

Page 3958: ...ODY PANELS EB Page 1 General Description 2 2 Front Hood 9 3 Fender Panel 10 4 Front Door Panel 11 5 Front Sealing Cover 13 6 Rear Door Panel 14 7 Rear Sealing Cover 16 8 Trunk Lid Panel 17 9 Rear Gate...

Page 3959: ...cification A A 1 Front fender and 2 front door 4 6 1 0 mm 0 181 0 039 in B B 2 Front door and 3 rear door 5 1 1 0 mm 0 201 0 039 in C C 3 Rear door and 4 rear quarter 4 6 1 0 mm 0 181 0 039 in D D 5 D...

Page 3960: ...GENERAL DESCRIPTION B COMPONENT 1 FRONT HOOD 1 Front hood 5 Buffer A Tightening torque N m kgf m ft lb 2 Seal Front hood 6 Buffer B T1 24 5 2 5 18 1 3 Hinge 7 Plug 4 Buffer C 8 Seal ASSY EB 00039 1 2...

Page 3961: ...ghtening torque N m kgf m ft lb 2 Weatherstrip Outer 8 Door checker T1 7 35 0 75 5 4 3 Clip Weatherstrip outer 9 Lower hinge T2 18 1 8 13 4 Stabilizer Lifter 10 Upper hinge T3 30 3 1 22 5 Stabilizer O...

Page 3962: ...Outer 6 Bracket Tightening torque N m kgf m ft lb 2 Clip Weatherstrip outer 7 Sealing cover T1 7 35 0 75 5 4 3 Stabilizer Outer 8 Door checker T2 18 1 8 13 4 Stabilizer Inner 9 Lower hinge T3 30 3 1...

Page 3963: ...EXTERIOR BODY PANELS GENERAL DESCRIPTION 4 TRUNK LID PANEL 1 Torsion bar 4 Hinge ASSY Tightening torque N m kgf m ft lb 2 Trunk lid 5 Cover T1 18 1 8 13 3 Weatherstrip T2 14 1 4 10 EB 00042 1 2 3 4 5...

Page 3964: ...L DESCRIPTION 5 REAR GATE PANEL 1 Gas stay 4 Buffer Rear gate Tightening torque N m kgf m ft lb 2 Hinge 5 Buffer cover T1 7 5 0 76 5 5 3 Rear gate 6 Buffer Back door T2 14 1 4 10 1 T3 25 2 5 18 1 1 2...

Page 3965: ...S 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge 927780000 REMOVER Used for removing and installing trunk torsion bar TOOL NAM...

Page 3966: ...the reverse order of removal 2 Adjust clearance between hood and fender Clearance must be equal at both sides Tightening torque 24 5 N m 2 5 kgf m 18 ft lb C ADJUSTMENT 1 Use hinge mounting holes to...

Page 3967: ...4 Remove front bumper face Ref to EI 14 RE MOVAL Front Bumper 5 Remove headlights Ref to LI 15 REMOVAL Headlight Assembly 6 Remove mud guard Ref to EI 22 REMOVAL Mud Guard 7 Remove bolts and clips to...

Page 3968: ...to protect it from damage 9 Remove checker bolts 10 Remove door side bolts for upper and lower hinges to remove door 11 Using special tool remove body side bolts for upper and lower hinges and remove...

Page 3969: ...TERIOR BODY PANELS FRONT DOOR PANEL 3 Loosen screw A and tap striker B using plas tic hammer to adjust striker CAUTION Do not use impact wrench Welding area on striker nut plate is easily broken EB 00...

Page 3970: ...over gets broken replace it with a new one B INSTALLATION 1 Install in the reverse order of removal 2 When replacing sealing cover use butyl tape 3 Press sealer applied area firmly to prevent any floa...

Page 3971: ...Support the door with the jack to protect it 8 Remove checker bolts 9 Remove door side bolts for upper and lower hinges to remove door 10 Using special tool remove body side bolts for upper and lower...

Page 3972: ...R BODY PANELS REAR DOOR PANEL 3 Loosen screw A and tap striker B using plas tic hammer to adjust striker CAUTION Do not use an impact wrench The welding area on the striker nut plate is easily broken...

Page 3973: ...gets broken replace it with a new one B INSTALLATION 1 Install in the reverse order of removal 2 When replacing sealing cover use butyl tape 3 Press sealer applied area firmly to prevent any floating...

Page 3974: ...inge link ST 927780000 REMOVER CAUTION During removal and installation carefully han dle torsion bar It will generate reactive force 3 Remove right left torsion bars B INSTALLATION 1 TRUNK LID 1 Insta...

Page 3975: ...washer hose from rear gate 11 Using a support support the rear gate while re moving gas stay mounting bolts NOTE When the rear gate is released it may hit and dam age the body To prevent this place a...

Page 3976: ...fully ex tended and secure body side on vise stand Drill a hole in 2 to 3 mm 0 08 to 0 12 in diameter at a point 10 to 200 mm 0 39 to 7 87 in from door side and bleed gas stay completely CAUTION Gas...

Page 3977: ...EB 20 EXTERIOR BODY PANELS REAR GATE PANEL MEMO...

Page 3978: ...OL SYSTEM CC Page 1 General Description 2 2 Actuator 4 3 Cruise Control Module 6 4 Cruise Control Main Switch 7 5 Cruise Control Command Switch 8 6 Stop and Brake Switch 9 7 Clutch Switch 10 8 Inhibit...

Page 3979: ...ion are for LHD vehicles Cruise control actuator and cruise contorol module loca tion for RHD vehicles are symmetically opposite 1 Actuator 4 Cruise control main switch 7 Cruise control module 2 Inhib...

Page 3980: ...ontents before disconnecting the battery ground cable Otherwise the memory will be erased Reassemble parts in the reverse order of disas sembly unless otherwise indicated Adjust parts to specification...

Page 3981: ...cable end to throttle cam and then remove cable from throttle cam 4 Remove actuator attaching bolts 5 Remove actuator while disconnecting connec tor LHD RHD B INSTALLATION Install in the reverse orde...

Page 3982: ...SYSTEM ACTUATOR C INSPECTION Measure cruise control actuator resistance If NG replace cruise control actuator Terminal No Standard 4 and 1 Approx 5 4 and 2 Approx 5 4 and 5 Approx 5 3 and 6 Approx 39...

Page 3983: ...ery 2 Remove glove box Ref to EI 32 REMOVAL Glove Box 3 Remove nut then remove cruise control module A and the other electrical control module B while disconnecting connector 4 Disconnect cruise contr...

Page 3984: ...fting screws and slightly pull radio and switch assembly out from center console 6 Disconnect electric connectors and antenna feeder cord and then disconnect heater controlunit 7 Remove screw and deta...

Page 3985: ...odule 5 Disconnect airbag module connector on back of airbag module 6 Remove horn switch from steering wheel as shown 7 Disconnect horn and cruise control command switch connector then remove cruise c...

Page 3986: ...to BR 55 REMOVAL Stop Light Switch B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the brake switch A and stop light switch B resistance If NG replace stop and brake switch...

Page 3987: ...r from the clutch switch and then remove the switch Ref to CL 40 RE MOVAL Clutch Switch B INSTALLATION Install in the reverse order of removal C INSPECTION Measure clutch switch resistance If NG repla...

Page 3988: ...and then remove the switch Ref to AT 50 REMOV AL Inhibitor Switch B INSTALLATION Installation is in the reverse order of removal C INSPECTION Measure inhibitor switch resistance If NG replace inhibit...

Page 3989: ...CC 12 CRUISE CONTROL SYSTEM INHIBITOR SWITCH...

Page 3990: ...stic Procedure 2 2 General Description 4 3 Electrical Components Location 7 4 Cruise Control Module I O Signal 8 5 Subaru Select Monitor 10 6 Diagnostics Chart with Symptom 12 7 List of Diagnostic Tro...

Page 3991: ...ECK VEHICLE SPEED IS HELD WITHIN SET SPEED Make sure vehicle speed is held within set speed Is vehicle speed held within set speed 3 km h 2 MPH Vehicle speed is held within set speed Go to step 6 Go t...

Page 3992: ...E CONTROL RELEASE OP ERATION Check cruise control release operation Is cruise control released after clutch pedal has been depressed MT Cruise control is released Finish the diag nostics Go to symptom...

Page 3993: ...ng harness is routed near the cruise control module and cruise control command switch CAUTION All airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment...

Page 3994: ...d tool CARTRIDGE Troubleshooting for electrical systems 22771AA030 SUBARU SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer...

Page 3995: ...ator cable A when the cruise control throttle is moved by hand If NG check throttle cam 4 THROTTLE CAM Check that the throttle cam moves smoothly If NG repair throttle cam 5 CABLE FREE PLAY Check that...

Page 3996: ...cles Cruise control actuator and cruise control module locations for RHD vehicles are symmetrically opposite Cruise control main switch location is different depending on destination CC 00095 1 2 3 4...

Page 3997: ...present when command switch is released Main power supply 11 Battery voltage is present when main switch is turned ON 0 volt is present when main switch is turned OFF Ignition switch 12 Battery voltag...

Page 3998: ...ly Approx 5 and 0 volt pulse signals are alternately input to cruise control mod ule Stop light switch 20 Turn ignition switch to OFF Then check that Battery voltage is present when brake pedal is dep...

Page 3999: ...ed by the driver but also the cancel condition input by the driver The content of memory is cleared when igni tion switch or cruise main switch is turned OFF 2 Real time diagnosis The real time diagno...

Page 4000: ...to OFF 3 REAL TIME DIAGNOSIS 1 Connect select monitor 2 Turn ignition switch and cruise control main switch to ON 3 Turn Subaru Select Monitor switch to ON 4 On the Main Menu display screen select the...

Page 4001: ...ACTUATOR MOTOR CLUTCH Diagnostics Chart with Trouble Code 4 Vehicle speed does not increase or does not return to set speed after RESUME ACCEL switch has been pressed 1 Check RESUME ACCEL switch Ref t...

Page 4002: ...MT 1 Check clutch switch Ref to CC 22 CHECK CLUTCH SWITCH MT Diag nostics Chart with Symptom 2 Check motor drive sys tem Ref to CC 32 DTC 35 AND 36 ACTUATOR MOTOR Diagnostics Chart with Trouble Code...

Page 4003: ...3 NO 18 SBF 4 i19 SMJ CRUISE CONTROL MAIN SWITCH i19 1 3 4 5 6 2 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A...

Page 4004: ...terminal B94 No 12 Chassis ground Does the measured value exceed the spec ified value 10 V Go to step 2 Check fuse No 18 in fuse relay box Check harness for open or short between cruise control module...

Page 4005: ...and cruise control main switch is turned to ON WIRING DIAGRAM M2 B2 A2 1 11 15 12 6 i1 B36 CRUISE CONTROL MODULE B94 BATTERY IGNITION SWITCH 6 1 5 3 NO 18 SBF 4 i19 SMJ CRUISE CONTROL MAIN SWITCH i19...

Page 4006: ...se control main switch and fuse relay box 2 CHECK CRUISE CONTROL MAIN SWITCH CIRCUIT 1 Turn ignition switch OFF 2 Disconnect cruise control module harness connector 3 Measure resistance between cruise...

Page 4007: ...F2 CRUISE CONTROL MODULE B94 BATTERY 5 M B NO 6 S1 B100 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F2 RESUME ACCEL SWITCH CANCEL SWITCH SET COAST SWITCH HORN SWITCH 4 B68 HORN RELAY STEERI...

Page 4008: ...en RESUME ACCEL switch is not pressed 0 V and when RESUME ACCEL switch is pressed 10 V Go to step 3 Go to step 4 3 CHECK CANCEL SWITCH CIRCUIT Measure voltage between harness connector terminal and ch...

Page 4009: ...E SYMPTOM Cruise control cannot be set WIRING DIAGRAM CC 00080 CRUISE CONTROL MODULE B65 BRAKE SWITCH STOP LIGHT SWITCH STOP LIGHT SWITCH AND BRAKE SWITCH CLUTCH SWITCH MT 2 1 4 3 BATTERY F B NO 16 SB...

Page 4010: ...ound Does the measured value exceed the specified value 10 V Go to step 3 Check harness for open or short between stop light brake switch and cruise control module AT Check clutch switch and the cir c...

Page 4011: ...Cruise control cannot be set WIRING DIAGRAM CC 00080 CRUISE CONTROL MODULE B65 BRAKE SWITCH STOP LIGHT SWITCH STOP LIGHT SWITCH AND BRAKE SWITCH CLUTCH SWITCH MT 2 1 4 3 BATTERY F B NO 16 SBF 1 SBF 2...

Page 4012: ...ess for open or short between clutch switch and cruise control module 2 CHECK CLUTCH SWITCH CIRCUIT 1 Turn cruise control main switch and ignition switch OFF 2 Disconnect stop light switch and brake s...

Page 4013: ...TOR SWITCH AT TROUBLE SYMPTOM Cruise control cannot be set WIRING DIAGRAM CC 00098 4 12 11 B94 12 7 T3 B14 T7 B12 STARTER MOTOR INHIBITOR SWITCH AT CRUISE CONTROL MODULE B12 1 2 3 4 5 6 7 8 9 10 11 12...

Page 4014: ...o to step 2 Check harness for open or short between inhibitor switch and cruise control module 2 CHECK INHIBITOR SWITCH CIRCUIT 1 Turn cruise control main switch and ignition switch OFF 2 Disconnect s...

Page 4015: ...d via control module relay when main switch is ON Ref to CC 31 DTC 28 WIRING HARNESS OPENED Diagnostics Chart with Trouble Code 35 Motor drive system is abnormal Motor output circuit is open or shorte...

Page 4016: ...f cruise control module TROUBLE SYMPTOM Cruise control is canceled and memorized cruise speed is also canceled Once cruise control is canceled cruise control cannot be set until the ignition switch an...

Page 4017: ...control cannot be set Cancelled immediately WIRING DIAGRAM CRUISE CONTROL MODULE B17 B94 GE 3 1 2 BATTERY M B NO 5 C17 AT 19 6 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 IGNITION RELAY VE...

Page 4018: ...vehicle speed sensor harness connector terminal and cruise control module harness connector terminal Connector terminal B17 No 1 B94 No 19 Is the measured value less than the speci fied value 10 Go t...

Page 4019: ...ss than the speci fied value 10 Go to step 7 Repair harness 7 CHECK TRANSMISSION CONTROL MOD ULE 1 Connect harness connector to transmission control module 2 Lift up the vehicle and support with safet...

Page 4020: ...the specified value 1 250 Go to step 2 Charge or replace battery Go to step 2 2 CHECK FUSES CONNECTORS AND HAR NESSES Check the condition of the main and other fuses and harnesses and connectors Also...

Page 4021: ...DIAGNOSIS Open or poor contact of cruise control actuator motor TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM CC 00083 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 4022: ...value 10 Go to step 3 Repair harness 3 MEASURE RESISTANCE OF ACTUATOR Measure resistance of cruise control actuator motor Terminals No 4 No 1 No 4 No 2 No 4 No 5 Is the measured value same as the spe...

Page 4023: ...AGNOSIS Open or poor contact of cruise control actuator motor clutch TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM CC 00083 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 4024: ...fied value 10 Go to step 3 Repair harness 3 MEASURE RESISTANCE OF ACTUATOR CLUTCH Measure resistance of cruise control actuator clutch Terminals No 3 No 6 Is the measured value same as the specified...

Page 4025: ...ge and disengage improperly Cable and inner gear are OK Replace cruise control actuator Ref to CC 4 Actuator Check the cruise control cable adjustment Ref to CC 6 CABLE FREE PLAY INSPECTION General De...

Page 4026: ...l Components Location 5 4 Immobilizer Control Module I O Signal 6 5 Subaru Select Monitor 7 6 Read Diagnostic Trouble Code DTC 8 7 Clear Memory Mode 9 8 Diagnostic Procedure for Immobilizer Indicator...

Page 4027: ...MINATION OF IMMOBILIZER INDICATOR LIGHT Turn ignition switch ON Does immobilizer indicator light illuminate Immobilizer indicator light illu minates Check immobi lizer indicator light circuit Ref to I...

Page 4028: ...ng turned ON or OFF while diagnostic items are being checked do not allow keys with different ID codes close to the ignition switch If ignition key is in a key holder remove it from holder before carr...

Page 4029: ...tool CARTRIDGE Troubleshooting for electrical systems 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French...

Page 4030: ...OMPONENTS LOCATION 3 Electrical Components Location A LOCATION NOTE IMM ECM location for RHD model is symmetrically opposite 1 Antenna 3 Immobilizer control module IMM ECM 2 Immobilizer indicator ligh...

Page 4031: ...IM 6 IMMOBILIZER DIAGNOSTICS IMMOBILIZER CONTROL MODULE I O SIGNAL 4 Immobilizer Control Module I O Signal A SCHEMATIC Ref to WI 236 SCHEMATIC Immobilizer System...

Page 4032: ...cord them 2 READ DIAGNOSTIC TROUBLE CODE DTC FOR ENGINE Refer to Read Diagnostic Trouble Code for infor mation about how to indicate DTC Ref to IM 8 Read Diagnostic Trouble Code DTC 3 INTERFACE CHECK...

Page 4033: ...ter displayed information of engine type 4 On the Engine Diagnosis display screen se lect the Diagnostic Code s Display and then press the YES key 5 On the Diagnostic Code s Display display screen sel...

Page 4034: ...layed information of engine type 4 On the Engine Diagnosis display screen se lect the Clear Memory and then press the YES key 5 When the Done and Turn Ignition Switch OFF are shown on the display scre...

Page 4035: ...4 B141 1 2 3 4 5 6 7 8 9 10 11 12 5 4 6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 24 25 26 27 16 17 18 28 29 19 20 21 30 B136 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21...

Page 4036: ...3 4 5 6 7 8 9 10 11 12 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 B36 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L...

Page 4037: ...d the spec ified value 10 V Go to step 4 Check harness for open or short between IMM ECM and ignition switch 4 CHECK IMM ECM POWER SUPPLY CIR CUIT 1 Turn ignition switch OFF 2 Measure voltage between...

Page 4038: ...ation meter harness connector terminal Connector terminal H4 non TURBO model B141 No 9 i12 No 1 LHD H6 model B141 No 9 i10 No 13 RHD H6 and H4 TURBO models B141 No 9 i10 No 7 Is the measured value les...

Page 4039: ...2 CHECK KEY SWITCH CIRCUIT WIRING DIAGRAM IM 00051 4 B141 B74 F2 B100 IMMOBILIZER CONTROL MODULE KEY WARNING SWITCH BATTERY 2 1 M B No 6 L L R R 16 LHD MODEL RHD MODEL L R B74 1 2 1 2 B141 1 2 3 4 5...

Page 4040: ...ep 3 Replace key warn ing switch 3 CHECK KEY SWITCH 1 Remove the ignition key from the ignition switch 2 Measure the resistance between key warn ing switch connector terminals Terminal No 1 No 2 Does...

Page 4041: ...Circuit Failure Except Antenna Circuit Communication failure between IMM ECM and ECM Ref to IM 18 DTC P1572 IMM CIR CUIT FAILURE EXCEPT ANTENNA CIRCUIT Diagnostic Procedure with Trouble Code DTC P157...

Page 4042: ...the vehicle Refer to teaching operation manual Is teaching operation for all keys completed Teaching operation for all keys is completed END Replace ECM Ref to FU H4SO 45 Engine Control Module or Ref...

Page 4043: ...DEL 6 CYLINDER ENGINE MODEL H4 H6 B141 1 2 3 4 5 6 7 8 9 10 11 12 SBF 1 SBF 5 SBF 4 IGNITION SWITCH C16 B23 B22 B19 D17 OO WO D18 B135 B B136 C B137 D ENGINE CONTROL MODULE B135 ENGINE CONTROL MODULE...

Page 4044: ...URBO model IM 00061 12 2 3 10 6 1 11 B141 IMMOBILIZER CONTROL MODULE BATTERY F B No 11 B141 1 2 3 4 5 6 7 8 9 10 11 12 SBF 1 SBF 5 SBF 4 IGNITION SWITCH B135 ENGINE CONTROL MODULE B19 B14 B5 B135 5 6...

Page 4045: ...the spec ified value 10 V Go to step 3 Check harness for open or short between IMM ECM and ignition switch 3 CHECK GROUND CIRCUIT OF IMM ECM 1 Turn ignition switch OFF 2 Measure resistance between IM...

Page 4046: ...CM har ness connector terminal and chassis ground Connector terminal B141 No 1 No 6 Chassis ground Is the measured value same as the speci fied value 0 V Go to step 7 Repair harness between IMM ECM an...

Page 4047: ...TERFACE CHECK Perform interface check Does Commun Line Shorted to Battery appear on screen Commun Line Shorted to Bat tery appears on screen Replace ECM Ref to FU H4SO 45 Engine Control Module or Ref...

Page 4048: ...2 ReplaceIMMECM Ref to SL 36 Immobilizer Con trol Module and then replace all ignition keys including the tran sponder Then perform teaching operation Refer to teaching opera tion manual Pub No S0820G...

Page 4049: ...all keys completed Teaching operation for all keys is completed END Replace all ignition keys including the transponder Go to step 2 2 PERFORM TEACHING OPERATION ON IG NITION KEY Perform teaching oper...

Page 4050: ...ef to FU H6DO 46 Engine Control Module Ref to FU H4DOSTC 40 Engine Control Module Then perform teaching operation Refer to teaching operation manual Pub No S0820GZ F DTC P1577 IMM CONTROL MODULE EEPRO...

Page 4051: ...IM 26 IMMOBILIZER DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH TROUBLE CODE DTC G DTC P1570 ANTENNA DIAGNOSIS Faulty antenna WIRING DIAGRAM IM 00066 2 1 B142 IMMOBILIZER CONTROL MODULE ANTENNA B142 1 2...

Page 4052: ...A CIRCUIT 1 Turn ignition switch ON Engine OFF 2 Measure voltage between antenna harness connector and chassis ground Connector terminal B142 No 1 Chassis ground Is the measured value same as the spec...

Page 4053: ...tion fur nished with vehicle Does engine start Engine starts Replace ignition key including the transponder Then perform teaching opera tion Refer to teaching opera tion manual Pub No S0820GZ ReplaceI...

Page 4054: ...mbling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satis...

Page 4055: ......

Page 4056: ...235 21 Immobilizer System 236 22 Keyless Entry System 240 23 Muffler Actuator Control System 246 24 Back up Light System 247 25 Clearance Light and Illumination Light System 248 26 Front Fog Light Sys...

Page 4057: ...9 Harness components location 330 50 Front Wiring Harness 334 51 Bulkhead Wiring Harness In Engine Room 338 52 Bulkhead Wiring Harness In Compartment 346 53 Engine Wiring Harness and Transmission Cord...

Page 4058: ...d ground point or negative battery terminal and the positive lead to the connector or component ter minal 2 Contact the positive probe of the voltmeter on connector A The voltmeter will indicate a vol...

Page 4059: ...infinite the wiring is open 4 HOW TO DETERMINE A SHORT CIR CUIT 1 Test lamp method Connect a test lamp rated at approximately 3 watts in place of the blown fuse and allow current to flow through the...

Page 4060: ...presence of a lock and pin number of each terminal are indicated in the sketch of each connector In the sketch the highest pole number refers to the number of poles which the con nector has For examp...

Page 4061: ...nector is described in figure NOTE A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that ter minal In...

Page 4062: ...is used Each unit is directly grounded to the body or indi rectly grounds through a harness ground terminal Different symbols are used in the wiring diagram to identify the two grounding systems The...

Page 4063: ...ally closed relay has one or more contacts The wiring diagram shows the relay mode when the energizing circuit is OFF WI 00114 Relay type 4 pole 6 pole 4 pole 6 pole Normally open type Normally closed...

Page 4064: ...s to the area or system of the vehicle Symbol Wiring harness and cord F Front wiring harness B Bulkhead wiring harness E Engine wiring harness T Transmission cord Rear oxygen sensor cord D Door cord L...

Page 4065: ...B FUSE NO 9 FB 16 F B FUSE NO 11 IG MB 5 HEADLIGHT RELAY TO POWER SUPPLY ROUTING LW 4 R 3 YL LW R YL 2 YB 1 RY 2 LW 2 R 1 YL 3 P LW B1 R A1 F44 F45 F23 F7 B61 B62 B REF TO GND 02 RL 2 R 1 YL 3 B71 B1...

Page 4066: ...roughout the text correspond with those shown in the POWER SUPPLY ROUT ING in the wiring diagram Accordingly using the POWER SUPPLY ROUT ING and wiring diagrams permits service personnel to understand...

Page 4067: ...s or edges and bolts or screws 3 When installing parts be careful not to catch them on the wiring harness 4 When disconnecting a connector do not pull the wires but pull while holding the connector bo...

Page 4068: ...B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2 I1 J1 H6 M4M5M6 L4 L5 L6 N5 N6 O4 O5 O6 N4 P4 P5 N2 O1 O2 P1 P2 N3 O3 P3 P6 A3 B3 C3 E4 E5 E6 E1 E2 B4 B5 B6...

Page 4069: ...ATION OF SMJ SHOWN IN THE WIRING DIAGRAM WI 01089 T BW BW Y Y B36 i1 Y N3 BW Y BW J1 i1 B36 SMJ WI 01079 B4 B5 B6 A4 A5 A6 C5 C6 F6 D4 D5 D6 F1 H1 C4 G6 G1 C2 K1 M1M2 K6 L1 D1 D2 A1 A2 B1 B2 I6 J6 L2...

Page 4070: ...WI 15 WIRING SYSTEM SUPER MULTIPLE JUNCTION SMJ MEMO...

Page 4071: ...LAY F FOG RELAY A C RELAY SBF 2 SBF 7 SBF 8 SBF 5 SBF 6 SBF 3 SBF 4 SBF 1 H L relay LH MAIN FUSE BOX M B 6 CYLINDER ENGINE MODEL FUSE RELAY BOX F B No 2 No 7 No 9 No 6 No 1 No 13 No 14 No 15 No 16 No...

Page 4072: ...INAL SBF 7 ALT MB 12 MB 11 MB 10 F39 BLACK BLACK BLACK F35 GREEN F26 F34 F39 F26 F34 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 OTHER CURRENTS BATTERY CURRENT F25 F35 W W W REF TO ENGINE ELECTRICAL SYSTEM E G...

Page 4073: ...MB 6 MB 1 MB 3 MB 2 MB 4 MB 8 MB 7 HORN RELAY MAIN FUSE BOX M B BL 4 W 2 YR 6 LB 5 BR 1 W 4 WL 1 LR 2 R 3 RG 4 L 1 R 3 BW 2 W F36 F68 BLACK 1 2 3 3 4 1 2 1 2 3 4 5 6 7 8 F37 BLACK F39 BLACK 4 1 2 3 6...

Page 4074: ...8 9 1 2 3 4 5 6 7 8 9 10 B158 E i5 B B152 D 1 2 3 4 5 6 7 8 9 10 11 12 G LgB Or TAIL ILLUMI NATION RELAY FUSE RELAY BOX F B No 18 15A i5 B B51 A B152 D B52 C B158 E F41 G F40 F FB 36 A3 BG G7 No 5 10...

Page 4075: ...7 Y E9 YG E4 FB 38 FB 31 FB 30 FB 29 FB 12 F1 YB E2 YG B9 YR C3 YR B6 B8 LB C2 LB E10 LY E3 RY G5 RG D9 RW D6 WR D8 F7 BL E6 A8 GW B11 FB 11 FB 10 FB 8 FB 7 FB 9 FB 39 ST FB 6 FB 13 FB 28 IG 2 REF TO...

Page 4076: ...elay FB 13 Keyless entry control module FB 14 Airbag control module FB 15 Airbag control module FB 16 Engine control module Fuel pump relay Ignition coil 6 cylinder engine model Ignition coil and igni...

Page 4077: ...Step light RH FB 33 Auto A C control module Combination meter Radio FB 34 License plate light LH License plate light RH Tail light LH Tail light RH Trailer connector FB 35 Front clearance light LH Fr...

Page 4078: ...C RELAY SBF 2 SBF 7 SBF 8 SBF 5 SBF 6 SBF 3 SBF 4 SBF 1 H L relay LH MAIN FUSE BOX M B 6 CYLINDER ENGINE MODEL FUSE RELAY BOX F B No 2 No 7 No 9 No 6 No 1 No 4 No 5 No 3 No 8 H L relay RH MAIN FAN 30...

Page 4079: ...MB 12 MB 11 MB 10 F39 BLACK BLACK BLACK F35 GREEN F26 F34 F39 F26 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 OTHER CURRENTS BATTERY CURRENT F25 F35 W W W REF TO ENGINE ELECTRICAL SYSTEM E G RH6 09 E G RTB 06 E...

Page 4080: ...ILER CONNECTOR BL 4 W 2 YR 6 LB 5 BR 1 W 4 WL 1 LR LR 7 10 LR 2 R 3 RG 4 L 1 R 3 BW 2 W B143 B186 BLACK 1 2 3 3 4 1 2 1 2 3 4 5 6 7 8 B144 BLACK F39 BLACK 4 1 2 3 6 5 SBF 5 30A SBF 2 50A SBF 3 50A SBF...

Page 4081: ...B 20 GB B1 FB 21 FB 1 GB G3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 B158 E i5 B B152 D 1 2 3 4 5 6 7 8 9 10 11 12 G LgB Or TAIL ILLUMI NATION RELAY FUSE RELAY BOX F B No 1...

Page 4082: ...3 E1 BW F6 F3 F2 E7 Y E9 YG E4 FB 38 FB 31 FB 30 FB 29 FB 12 F1 YB E2 YG B9 YR C3 YR B6 B8 LB C2 LB E10 LY E3 RY G5 RG D9 RW D6 WR D8 F7 BL E6 A8 GW B11 FB 11 FB 10 FB 8 FB 7 FB 9 FB 39 ST FB 6 FB 13...

Page 4083: ...signal light RH Trailer connector Turn signal switch FB 6 Blower motor relay FB 7 Front fog light relay FB 8 ABS control module VDC hydraulic module FB 9 Fuel pump relay FB 10 Stop light switch FB 11...

Page 4084: ...ation light LH Vanity mirror illumination light RH FB 30 Radio Radio amplifier FB 31 Front washer motor Front wiper motor Front wiper washer switch FB 33 Auto A C control module Combination meter Radi...

Page 4085: ...RH GND L 01 GND L 01 4 CYLINDER ENGINE MODEL H4 H6 H4 H4 F21 F19 F6 F3 1 2 1 F17 B 4 MAIN FAN MOTOR 6 CYLINDER ENGINE MODEL GB 1 B B B GB 2 B B ABS VDC VDC F73 B B GB 1 B REF TO ANTI LOCK BRAKE SYSTE...

Page 4086: ...W RELAY SEAT BELT TIMER B70 B 2 COMBINATION SWITCH WIPER COMBINATION SWITCH LIGHTING GND L 02 GND L 02 B184 B GRAY BLACK F23 F7 1 2 3 B192 D72 3 4 1 2 B B 3 D1 B30 13 B157 B IGNITION RELAY GND L 01 A...

Page 4087: ...ITCH 6 CYLINDER ENGINE MODEL R52 B 3 ROOM LIGHT R54 B 2 VANITY MIRROR ILLUMINATION LIGHT LH GND L 04 C GND L 04 D B 6 KEYLESS ENTRY CONTROL MODULE B86 B 4 BLOWER MOTOR RESISTOR AUTO A C B94 B 6 CRUISE...

Page 4088: ...2 REAR COMBINATION LIGHT LH R44 B 1 SEAT HEATER LH R32 B 1 REAR ACCESSORY POWER SUPPLY SOCKET 4 CYLINDER ENGINE MODEL 6 CYLINDER ENGINE MODEL H4 H6 SEDAN MODEL WAGON MODEL SD WG A i11 B B16 COMBINATIO...

Page 4089: ...R130 B REAR DEFOGGER SEDAN 2 B GB 11 WG SD SEDAN MODEL WAGON MODEL SD WG B GB 4 B GB 6 i29 AIRBAG CONTROL MODULE 28 27 B GR 11 REAR FINISHER LIGHT LH 7 D33 REAR FINISHER LIGHT RH REAR FINISHER LIGHT...

Page 4090: ...R 1 AWD VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR AT CONTROL TRANSMISSION B54 A B55 B B56 C 16 BrW W 20 Or Y 19 W W 18 L Y 17 G W 15 B Y 14 W B11 BLACK 1 2 5 6 7 8 13 14 15 16 9 10...

Page 4091: ...21 13 14 15 16 17 18 22 23 24 B B55 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 GRAY TRANSMISSION CONTROL MODULE 6 CYLINDER ENGINE MODEL BL W B9 B8 LgB A10 Sb A19 BrW A21 G B24 Lg B...

Page 4092: ...ION COIL AND IGNITOR REF TO ENGINE ELECTRICAL SYSTEM E G LH4 07 E3 B22 OXYGEN SENSOR 1 B17 1 2 3 B25 1 2 E12 1 2 3 4 B18 1 2 3 4 GRAY B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 1 2 3 4 5 6 7 8 9 1...

Page 4093: ...12 13 14 15 16 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B134 A 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 1...

Page 4094: ...18 22 B83 C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 DARK GRAY GRAY B79 B20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 9 21 30 31 D B137 1 2 7...

Page 4095: ...ULE GND R 01 GND R 01 4 CYLINDER ENGINE MODEL H4 H6 H4 H4 F21 F19 F6 F3 1 2 F88 B 3 SHIELD JOINT CONNECTOR VDC GB 1 B B B GB 2 B B ABS VDC VDC F73 B B GB 1 B REF TO ANTI LOCK BRAKE SYSTEM ABS RTB 03 A...

Page 4096: ...OF 16 9 COMBINATION SWITCH WIPER COMBINATION SWITCH LIGHTING GND R 02 GND R 02 B184 B GRAY BLACK GREEN F23 F7 1 2 3 B192 D72 3 4 1 2 B B 3 D1 B30 36 B157 B IGNITION RELAY GND R 01 A B129 1 2 BLACK BRO...

Page 4097: ...TURN SIGNAL LIGHT LH R52 B 3 ROOM LIGHT R54 B 2 VANITY MIRROR ILLUMINATION LIGHT LH GND R 04 C B 6 KEYLESS ENTRY CONTROL MODULE MAIN RELAY B77 B 7 MODE ACTUATOR MANUAL A C B88 B 3 EVAPORATION THERMO S...

Page 4098: ...DEFOGGER CONDENSER R26 B 2 REAR COMBINATION LIGHT RH R28 B 2 REAR COMBINATION LIGHT LH R110 B B 10 11 POWER AMPLIFIER MCINTOSH AUDIO MODEL R44 B 1 SEAT HEATER LH R32 B 1 REAR ACCESSORY POWER SUPPLY SO...

Page 4099: ...WAGON MODEL SD WG B GB 4 B GB 6 i29 AIRBAG CONTROL MODULE 28 27 B GR 11 REAR FINISHER LIGHT LH R126 B 5 MUFFLER ACTUATOR CONTROL MODULE TURBO ENGINE MODEL 7 D33 REAR FINISHER LIGHT RH REAR FINISHER L...

Page 4100: ...SENSOR 1 AWD VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR AT CONTROL TRANSMISSION B54 A B55 B B56 C 16 BrW W 20 Or Y 19 W W 18 L Y 17 G W 15 B Y 14 W B11 BLACK 1 2 5 6 7 8 13 14 15 16...

Page 4101: ...B55 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 GRAY TRANSMISSION CONTROL MODULE 4 CYLINDER TURBO ENGINE MODEL BL W B9 B8 GB A10 Sb A19 BrW A21 W B24 OrL B18 B53 B330 BL 4 SHIELD JO...

Page 4102: ...OR 1 AWD VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR AT CONTROL TRANSMISSION B54 A B55 B B56 C 16 BrW W 20 L Y 19 G W 18 BY Y 17 Lg W 15 B Y 14 W B11 BLACK 1 2 5 6 7 8 13 14 15 16 9 1...

Page 4103: ...AND IGNITOR REF TO ENGINE ELECTRICAL SYSTEM E G RH4 07 E3 B22 OXYGEN SENSOR 1 B17 1 2 3 B25 1 2 E12 1 2 3 4 B18 1 2 3 4 BLACK B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 1 2 3 4 5 6 7 8 9 10 11 12...

Page 4104: ...11 12 13 14 15 16 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3...

Page 4105: ...LE AIR CONTROL SOLENOID VALVE BW E7 3 B COMBINATION METER BL i11 B16 BY 2 E31 IGNITION COIL NO 1 BY 2 E34 IGNITION COIL NO 4 BY 2 E32 IGNITION COIL NO 2 B76 1 2 GREEN BLACK A E BLACK E7 B17 1 2 3 BLAC...

Page 4106: ...17 18 22 B83 C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 DARK GRAY GRAY B79 B20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 9 21 30 31 D B137 1 2...

Page 4107: ...E G RH4 04 REF TO GROUND DISTRIBUTION GND L 04 GND R 04 REF TO GROUND DISTRIBUTION GND L 03 GND R 03 CHECK CONNECTOR DIAGNOSIS CONNECTOR DIAGNOSIS TERMINAL i1 B36 B31 AB1 i11 i10 YELLOW GRAY GREEN C B...

Page 4108: ...ONT SUB SENSOR RH INFLATOR PASSENGER SIDE YELLOW YELLOW YELLOW BLUE AB13 AB16 AB7 AB8 AB6 AB3 AB12 AB11 AB15 AB16 AB13 AB14 AB9 AB10 AB9 AB15 W 1 W W W Y Y Y Y 2 W 1 W 2 15 26 W W 9 20 13 14 11 10 Y 1...

Page 4109: ...G 3 AB17 AB21 AB20 AB23 AB28 AB19 AB26 AB21 AB28 AB23 AB18 AB17 AB24 AB19 AB25 AB26 AB24 AB18 AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH INFLATOR SIDE LH INFLATOR SIDE RH ELR W...

Page 4110: ...i10 GRAY YELLOW AB6 B82 B79 GREEN A i10 GREEN B i11 i12 AIRBAG CONTROL MODULE AB6 i28 B81 B82 B79 TO POWER SUPPLY ROUTING B GB 6 B GB 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8...

Page 4111: ...ONT SUB SENSOR RH INFLATOR PASSENGER SIDE YELLOW YELLOW YELLOW BLUE AB13 AB16 AB7 AB8 AB6 AB3 AB12 AB11 AB15 AB16 AB13 AB14 AB9 AB10 AB9 AB15 W 1 W W W Y Y Y Y 2 W 1 W 2 15 26 W W 9 20 13 14 11 10 Y 1...

Page 4112: ...G 3 AB17 AB21 AB20 AB23 AB28 AB19 AB21 AB28 AB23 AB18 AB17 AB24 AB19 AB25 AB26 AB24 AB18 AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH INFLATOR SIDE LH INFLATOR SIDE RH ELR WITH P...

Page 4113: ...i10 GRAY YELLOW AB6 B82 B79 GREEN A i10 GREEN B i11 i12 AIRBAG CONTROL MODULE AB6 i28 B81 B82 B79 TO POWER SUPPLY ROUTING B GB 6 B GB 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8...

Page 4114: ...NT SUB SENSOR RH INFLATOR PASSENGER SIDE YELLOW YELLOW YELLOW BLUE AB13 AB16 AB7 AB8 AB6 AB3 AB12 AB11 AB15 AB16 AB13 AB14 AB9 AB10 AB9 AB15 W 1 W W W Y Y Y Y 2 W 1 W 2 15 26 W W 9 20 13 14 11 10 Y 1...

Page 4115: ...B 3 AB17 AB21 AB20 AB23 AB28 AB19 AB21 AB28 AB23 AB18 AB17 AB24 AB19 AB25 AB26 AB24 AB18 AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH INFLATOR SIDE LH INFLATOR SIDE RH ELR WITH PR...

Page 4116: ...WI 61 WIRING SYSTEM AIRBAG SYSTEM MEMO...

Page 4117: ...9 20 21 22 23 34 35 32 33 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 B136 GL A C ML 01 A C ML 01 LOr A9 VY D13 LgR C11 B134 A B C B135 B136 D B137 A17 WO OO C30 B2...

Page 4118: ...16 VR 3 L 12 YR 2 W 13 WOr Y RB VR L YR W WOr 11 REF TO CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM ILM LH4 03 Y R 6 10 RB 5 VR 4 L 3 YR 2 W 9 WOr 1 VG 14 R 1 i28 SMJ i20 i15 BLACK BLACK BLACK BLAC...

Page 4119: ...A A C MR 02 B A C MR 02 C A C MR 02 D A C MR 02 E RW F83 1 2 F79 1 2 LgR 5 4 6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 24 25 26 27 16 17 18 28 29 19 20 21 30 A C MR 01 A C MR 01 PRESSURE SWITCH THERMAL P...

Page 4120: ...B88 7 1 3 B80 i15 A C MR 01 A GL B RB VR LY YR WOr BY RY LY BG LgR PG B GL BL LgW RB VR LY YR WOr BY RY LY BG PG VY Y BL LgW RB VR LY YR WOr BY RY LY BG i20 PG VY Y BL LgW RB VR LY YR VG V BW GL WOr...

Page 4121: ...12 13 14 15 16 A i49 B D Y VY BR BY SMJ 11 1 2 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5 4 6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 24 25 2...

Page 4122: ...B 33 M B FUSE NO 2 B GL FB 19 F B FUSE NO 17 IG YR FB 28 F B FUSE NO 4 ACC GW VG GB B5 IG 2 IGNITION RELAY IG GB GB E4 GE B36 SMJ i1 GREEN C B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 2...

Page 4123: ...I6 F6 10 Sb Sb 9 WG 3 E8 Sb 2 Or 1 F78 AMBIENT SENSOR THERMOMETER EVAPORATION THERMOSWITCH AIR MIX ACTUATOR Sb 3 1 B88 GY 2 YL 1 WR 4 WG 3 Sb 5 B235 B36 i1 SMJ A C AL4 04 A F2 B100 E2 B21 1 2 1 2 3 B...

Page 4124: ...TUATOR FRESH RECIRC ACTUATOR A i48 B i49 B201 i40 i28 8 7 BL LgW Y RB VR L Y RB BL LgW Sb GR Sb R VR L L YR YR WOr B Y RB VR L WOr WOr YR BL LgW YR i55 i51 1 2 B A i49 BLACK YR A10 B Sb BLACK BLACK B9...

Page 4125: ...10 2 3 1 4 1 2 3 4 5 6 7 8 i20 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 i48 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A i49 B B135 B B134 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8...

Page 4126: ...5 6 7 8 9 10 11 12 13 14 15 16 A i49 B TO POWER SUPPLY ROUTING LR FB 33 M B FUSE NO 2 B GL FB 19 F B FUSE NO 17 IG YR FB 28 F B FUSE NO 4 ACC VG GB B5 FB 22 REAR DEFOGGER RELAY GB GB GB E4 B36 SMJ i1...

Page 4127: ...G6 H6 I6 F6 16 Sb Sb 9 PW 3 E8 Sb 2 Or 1 F78 AMBIENT SENSOR THERMOMETER EVAPORATION THERMOSWITCH AIR MIX ACTUATOR Sb 3 1 B88 GY 2 YL 1 WR 4 WG 3 Sb 5 B235 B36 i1 SMJ A C AL6 04 A F2 B100 E2 B21 1 2 1...

Page 4128: ...TUATOR FRESH RECIRC ACTUATOR A i48 B i49 B201 i40 i28 8 7 BL LgW Y RB VR L Y RB BL LgW Sb Sb R VR L L YR YR WOr B Y RB VR L WOr WOr YR BL LgW YR i55 i51 1 2 B A i49 BLACK YR A10 B Sb BLACK BLACK B91 1...

Page 4129: ...3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 TB B134 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 A TB A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2...

Page 4130: ...R H6 B7 LOr GW LgR LOr LOr F6 GE B36 SMJ i1 GREEN C B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 FB 22 REAR DEFOGGER RELAY DATA LINK CONNECTOR CHECK CONNECTOR BL BR 16 AT MT B22...

Page 4131: ...0 1 2 LIGHT GRAY i48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A BLACK 1 2 3 F78 E8 BLACK WG 10 E2 B21 PW PW Sb BrW BL A9 B A15 B B2 LgW 3 B5 RY Or Or D6 A C AR4 02 B i28 B BLACK i52 1 2 3 4 5 6 7 8 9 10...

Page 4132: ...9 20 i48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A i49 B i48 A B i49 AUTO A C CONTROL MODULE GR A4 A5 A8 A14 WR 1 GR 2 SUNLOAD SENSOR RB 1 LW 2 WOr 4 GY 8 WG 10 YL 7 WR 11 Sb 9 Sb 3 HEATER MODULE i45 i...

Page 4133: ...CK 1 2 3 4 5 6 7 8 i20 i48 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 i49 B B134 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22...

Page 4134: ...ILLUMINATION LIGHT SYSTEM ILM RH6 03 GB BL GB E4 B8 GW G6 B17 LgR LgR H6 B7 LOr GW LgR LOr F6 GE B36 SMJ i1 GREEN C B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 FB 22 REAR DEFOG...

Page 4135: ...W 5 Sb 9 GL 1 BR 7 BLOWER MODULE i52 B36 i1 SMJ A C AR6 04 C A C AR6 01 A F2 B100 1 2 BLACK LIGHT GRAY BLACK 1 2 3 F78 E8 BLACK PW 16 E2 B21 PW PW Sb BrW BL A9 B A15 B B2 LgW 3 B5 RY Or Or D6 A C AR6...

Page 4136: ...8 9 10 11 12 13 14 15 16 A i49 B i48 A B i49 AUTO A C CONTROL MODULE GR A4 A5 A8 A14 WR 1 GR 2 i51 SUNLOAD SENSOR RB 1 LW 2 WOr 4 GY 8 WG 10 YL 7 WR 11 Sb 9 Sb 3 HEATER MODULE i45 1 2 BLACK BLACK i51...

Page 4137: ...3 4 5 6 7 8 9 10 11 12 13 14 ABS LHD 01 ABS LHD 01 LY 2 WB 3 1 WC OC 2 B64 B65 LgY G1 WB 2 WB LY 7 B62 F45 i1 B36 STOP LIGHT SWITCH WITHOUT CRUISE CONTROL MODEL WITH CRUISE CONTROL MODEL BLACK F49 1...

Page 4138: ...E3 DATA LINK CONNECTOR BLACK BLACK F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 WL 3 RY WL RY 4 5 8 BR 6 GW BR B B B21 F44 B61 BL 16 BR GE DIAGNOSIS CONNECT...

Page 4139: ...20 21 22 27 28 29 30 31 23 24 25 26 8 9 9 10 13 11 12 10 11 12 8 3 7 6 28 1 2 1 2 1 4 7 8 1 2 5 6 14 15 1 2 W R Lg LgB SB L G SB SB RB RW P Y Lg LgB L G W 2 30 B B R 23 B RB RW P Y SB L P SB W B RB RW...

Page 4140: ...HD 01 ABS RHD 01 LY 2 WB 3 1 WC OC 2 B64 B65 LgY G1 WB 2 WB LY 6 B62 F45 B100 F2 i1 B36 STOP LIGHT SWITCH WITHOUT CRUISE CONTROL MODEL WITH CRUISE CONTROL MODEL B 26 ABS MOTOR GROUND B B F73 MOTOR REL...

Page 4141: ...R BLACK F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 WL 19 RY WL RY 20 5 8 GW BR B B B21 BL 16 BR GE DIAGNOSIS CONNECTOR DIAGNOSIS TERMINAL TRANSMISSION CONT...

Page 4142: ...8 29 30 31 23 24 25 26 15 9 16 17 14 12 13 10 11 12 8 3 7 6 28 1 2 1 2 1 4 7 8 1 2 5 6 14 15 1 2 W R Lg LgB SB L G SB SB RB RW P Y Lg LgB L G W 2 30 B B R 23 B RB RW P Y SB L P SB W B RB RW P YB W B L...

Page 4143: ...20 21 22 23 24 25 26 27 28 29 30 LY WB 1 2 B64 LgY G1 WB 2 WB LY 6 B100 F2 B62 F45 i1 B36 STOP LIGHT SWITCH BLACK F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 2...

Page 4144: ...OR BLACK F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 WL 19 RY WL RY 20 5 8 GW BR REF TO GROUND DISTRIBUTION GND R 03 B B BL 16 BR GE DIAGNOSIS CONNECTOR DIA...

Page 4145: ...14 12 13 10 11 12 8 3 7 6 28 1 2 1 2 1 4 7 8 1 2 5 6 14 15 1 2 W R Lg LgB SB L G SB SB RB RW P Y Lg LgB L G W 2 30 B B R 23 B RB RW P Y SB L P SB W B RB RW P YB W B L P RB RW P YB 2 3 W R W 1 B B SB...

Page 4146: ...WI 91 WIRING SYSTEM ANTI LOCK BRAKE SYSTEM MEMO...

Page 4147: ...6 7 8 9 13 14 15 10 11 12 FB 39 IGNITION RELAY IG P FB 27 F B FUSE NO 12 TO POWER SUPPLY ROUTING TRANSMISSION CONTROL MODULE DIMMER AND STABILIZING POWER CIRCUIT CUSTOM CPU I F R N D 3 2 POWER HOLD 1...

Page 4148: ...MODULE BL GE B22 E3 LY 1 WB 2 2 3 B64 B65 WITHOUT CRUISE CONTROL MODEL WITH CRUISE CONTROL MODEL STOP LIGHT SWITCH 1 2 1 2 1 9 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 5 6 7 8 3 4 2 3 9 1 8 10...

Page 4149: ...16 17 18 22 23 24 A B54 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 RG B23 BrR REF TO GROUND DISTRIBUTION GND L 02 B129 B133 KICK...

Page 4150: ...7 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 GREEN B56 C 1 2 7 8 9...

Page 4151: ...EMPERATURE SENSOR VEHICLE SPEED SENSOR 1 AWD AT5 VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR B53 B11 T4 BY SHIELD JOINT CONNECTOR 7 SB 6 BL 1 B 2 SB 3 A16 BW A5 RW A22 LR A20 YW W W Y...

Page 4152: ...N4 LB M4 GB E4 Br B4 BrG P5 WG N5 B1 B3 B14 B4 B5 B6 B7 C17 C10 L RL LgB G RG YL LB GB Br C11 BrG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 4153: ...RANSMISSION CONTROL MODULE BrR WG WG B16 B23 B11 B129 B133 KICK DOWN SWITCH WG 2 B 1 WG 5 BrR 3 B 4 V 2 BW 1 POWER MODE AND SNOW HOLD MODE SWITCH POWER SNOW HOLD OFF AT LH6 01 A REF TO CLEARANCE LIGHT...

Page 4154: ...23 24 GRAY B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 W 16 WB 17 BL 13 WG 15 SHIELD AND SENSOR GROUND JOINT CONNECTOR B83 WG 1 2 3 4 5 6 7 8 3 4 1 2 A23 A24 C15 C24 B12 C1 B5...

Page 4155: ...2 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 E13 1 2 3 BLACK DARK GRAY B20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 W 5 W 4 W 6 STEERING ANGLE...

Page 4156: ...SOR VEHICLE SPEED SENSOR 1 AWD AT5 VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR B11 T4 Sb SHIELD JOINT CONNECTOR 7 L 8 SB 9 LgB 4 BY 5 A16 BW A5 RW A22 LR A11 Lg W W Y W Y W Lg G YW Br...

Page 4157: ...2 3 4 5 6 7 8 9 13 14 15 10 11 12 FB 39 IGNITION RELAY IG P FB 27 F B FUSE NO 12 TO POWER SUPPLY ROUTING TRANSMISSION CONTROL MODULE ILLUMINATION CONTROL CIRCUIT CUSTOM CPU I F R N D 3 2 POWER HOLD 1...

Page 4158: ...B40 B22 B55 C B56 TRANSMISSION CONTROL MODULE BL GE B22 E3 LY 1 WB 2 2 3 B64 B65 WITHOUT CRUISE CONTROL MODEL WITH CRUISE CONTROL MODEL STOP LIGHT SWITCH 1 2 1 2 1 9 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11...

Page 4159: ...22 23 24 GRAY B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 A B54 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19...

Page 4160: ...0 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43 40 41 74 72 73 70 71 39 37 38 35 36 69 67 68 66 33 34 61 64 31 32 29 30 58 GREEN B56 C 1 2 7...

Page 4161: ...TEMPERATURE SENSOR VEHICLE SPEED SENSOR 1 AWD AT5 VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR B53 B11 T4 BY SHIELD JOINT CONNECTOR 7 SB 6 BL 1 B 2 SB 3 A16 BW A5 RW A22 LR A20 YW W W...

Page 4162: ...GB 5 LgB 14 R N D 3 2 1 V B GW FB 39 IGNITION RELAY IG FB 27 F B FUSE NO 12 TO POWER SUPPLY ROUTING 3 L 2 RL 1 LgB 8 G 7 RG 6 YL 5 LB 4 B REF TO GROUND DISTRIBUTION GND R 03 SMJ B36 L P4 RL M5 LgB L4...

Page 4163: ...3 14 15 16 17 18 19 20 21 22 23 24 TRANSMISSION CONTROL MODULE BrR WG WG B16 B23 B11 B129 B133 KICK DOWN SWITCH WG 2 B 1 WG 5 BrR 3 B 4 V 2 BW 1 POWER MODE AND SNOW HOLD MODE SWITCH POWER SNOW HOLD OF...

Page 4164: ...4 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 GRAY B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 W 16 WB 17 BL 13 WG 15 SHIELD AND SENSOR GROUND JOINT CONNECT...

Page 4165: ...0 21 13 14 15 16 17 18 22 23 24 E13 1 2 3 BLACK DARK GRAY B20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 W 5 W 4 W 6 STEERING ANGLE SENSOR JOINT CONNECTOR B234 STEERING ANGLE SENSOR B231 B 2 B 1 B 3 B 81...

Page 4166: ...SOR VEHICLE SPEED SENSOR 1 AWD AT5 VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR B11 T4 A16 BW A5 RW A22 LR A11 Lg W W Y W Y W Lg G YW BrY RY WL YG BrW Br BW RW LR Lg B55 TRANSMISSION C...

Page 4167: ...5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 GREEN i10 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 TRANSMISSION CONTROL MODULE B55 B B56 C GREEN C B56...

Page 4168: ...LD MODE SWITCH POWER SNOW HOLD OFF AT RH6 01 A REF TO CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM ILM RH6T 01 B B VW OrB Sb B15 B13 B2 REF TO GROUND DISTRIBUTION GND R 03 4 5 6 2 3 1 B OrB B VW B Sb...

Page 4169: ...1 2 B64 STOP LIGHT SWITCH A B54 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 GRAY B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 BL BR A23 A24 C15 C24 B12 C1 B5...

Page 4170: ...5 7 8 9 16 17 18 22 23 24 A B54 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B134 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 2...

Page 4171: ...ID AT9 B L B L 2 4 B TIMING SOLENOID SPORTS SHIFT SOLENOID AT8 AT10 Y Y Y SHIFT SOLENOID 2 AT6 G G 15 B BW 17 16 WL 19 20 Or 12 11 1 2 4 3 5 13 9 6 16 BL A10 GB A19 Sb B8 W B18 OrL B24 W A20 L A9 G A7...

Page 4172: ...WI 117 WIRING SYSTEM A T CONTROL SYSTEM MEMO...

Page 4173: ...RY D14 1 2 D2 D12 1 2 i26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 BLACK BLACK D4 BLACK LR YG FB 33 M B FUSE NO 2 B FB 30 F B FUSE NO 9 ACC TO POWER SUPPLY ROUTING SMJ WB RY LR YG 10 6 3 9 8 2 TWISTED WIRE W...

Page 4174: ...IRE RW 14 LY 6 RB 13 WR RW LY RW LY RW LY RB WR 5 RW 12 LY 4 RB 13 WR 5 B 11 B D23 BLACK D29 BLACK R11 R14 RADIO i26 R14 D27 R11 D21 i53 R98 D29 D23 i29 GR REAR DOOR SPEAKER RH 2 1 REAR DOOR SPEAKER L...

Page 4175: ...rW 2 1 D4 D2 D12 D14 B30 i1 B36 D1 WB BrW D14 1 2 D2 D12 1 2 i26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 BLACK D4 BLACK LR YG FB 33 M B FUSE NO 2 B FB 30 F B FUSE NO 9 ACC TO POWER SUPPLY ROUTING SMJ WB RY L...

Page 4176: ...RW 16 LY 7 RB 15 WR RW LY RW LY RW LY RB WR 6 RW 12 LY 4 RB 13 WR 5 B 11 B D23 BLACK D29 BLACK R11 R14 RADIO i26 R14 D27 R11 D21 i53 R98 D29 D23 i29 GR REAR DOOR SPEAKER RH 2 1 REAR DOOR SPEAKER LH 2...

Page 4177: ...12 G BrW 3 9 WB RY 2 8 G BrW 6 5 WB RY G BrW WB RY 6 15 7 16 RB WR RW LY REF TO CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM ILM RH6T 03 24 25 G BrW 24 25 WB RY i29 B GR i20 B80 i1 B36 B101 B30 SMJ i...

Page 4178: ...A WB 2 RB 1 WB 1 2 W V 1 2 2 1 FRONT DOOR SPEAKER RH V 2 1 FRONT DOOR SPEAKER LH W 2 1 FRONT DOOR TWEETER LH W P 2 1 R117 D4 D2 D12 D14 D69 R101 R99 D68 POWER AMPLIFIER R110 B225 B97 B212 F86 R1 W P 1...

Page 4179: ...5 Lg 6 W 1 Lg 2 W 12 Lg 4 REAR DOOR SPEAKER RH W 5 Or 6 W 1 Lg 2 REAR DOOR SPEAKER LH TWISTED WIRE R14 D27 D29 D23 D21 R11 R110 POWER AMPLIFIER R110 BLACK D29 BLACK GREEN D23 1 2 1 2 3 4 5 6 7 8 9 10...

Page 4180: ...EEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 CHARGE WARNING LIGHT i12 C COMBINATION METER 4 CYLINDER NON TURBO ENGINE MODEL CHARGE WARNING LIGHT i12 C C8...

Page 4181: ...METER 12 Combination Meter A SCHEMATIC 1 4 CYLINDER NON TURBO ENGINE MODEL M H4 01 M H4 01 WI 00841 GREEN i10 To A GREEN i11 To B GREEN i12 To C A1 A7 A8 A15 A16 A29 A30 A14 B1 B4 B8 B9 B5 B7 B15 B16...

Page 4182: ...RAKE SWITCH VDC CONTROL MODULE VDC WARNING LIGHT FWD INDICATOR LIGHT MALFUNCTION INDICATOR LIGHT OIL PRESSURE WARNING LIGHT ABS WARNING LIGHT CHARGE WARNING LIGHT PARKING BRAKE BRAKE FLUID LEVEL WARNI...

Page 4183: ...LIGHT RELAY RH TURN SIGNAL SWITCH HI BEAM INDICATOR LIGHT P M H4 04 E M H4 02 A M H4 04 B AIRBAG WARNING LIGHT ODO TRIP LCD BACK LIGHT AIRBAG CONTROL MODULE IGN IGN IGN B B B15 B14 B8 B13 AIRBAG CIRC...

Page 4184: ...ERATURE GAUGE FUEL GAUGE ODO METER TRIP METER OUT TEMP SPEEDOMETER TACHOMETER I F F A6 A18 BUZZER I F I F BUZZER CIRCUIT AT MODELS MT MODELS AT MT B CLOCK TRANSMISSION CONTROL MODULE VEHICLE SPEED SEN...

Page 4185: ...MOBILIZER CONTROL MODULE C7 FRONT DOOR WARNING LIGHT LH REAR DOOR WARNING LIGHT LH REAR DOOR WARNING LIGHT RH FRONT DOOR WARNING LIGHT RH A23 A28 C1 A7 A28 A10 A29 VEHICLE OUTLINE A30 IMMOBILIZER INDI...

Page 4186: ...STEM COMBINATION METER 2 LHD 6 CYLINDER ENGINE MODEL M LH6 01 M LH6 01 WI 00846 GREEN i10 To A A8 A7 A1 A30 A14 A29 A16 A15 GREEN i12 To C C5 C8 C4 C1 C9 C18 C17 GREEN i11 To B B8 B9 B15 B16 PP PP SAE...

Page 4187: ...BEAM INDICATOR LIGHT SEAT BELT WARNING LIGHT VDC OFF INDICATOR LIGHT MALFUNCTION INDICATOR LIGHT OIL PRESSURE WARNING LIGHT VDC OPERATION INDICATOR LIGHT CHARGE WARNING LIGHT PARKING BRAKE BRAKE FLUID...

Page 4188: ...LH6 04 E M LH6 02 A M LH6 04 C IGN IGN B B A7 B12 M LH6 04 D A19 A16 A20 A15 A21 A14 A22 A12 DIMMER CIRCUIT M LH6 02 B STABILIZING POWER CIRCUIT CFL LED FOR POINTER INVERTER CIRCUIT LED DRIVER DRIVER...

Page 4189: ...F A9 C1 B M LH6 03 C C5 B7 B15 A13 E M LH6 03 E C6 IMMOBILIZER CONTROL MODULE FUEL GAUGE MODULE DRIVER POWER CIRCUIT DRIVER DRIVER DRIVER DOOR WARNING BACK LIGHT FUEL RING WARNING TACHO RING SPEEDO RI...

Page 4190: ...B ROOM LIGHT B SPEEDOMETER TACHOMETER I F I F I F A28 A28 B6 A28 A11 TRANSMISSION CONTROL MODULE ENGINE CONTROL MODULE VEHICLE SPEED SENSOR MT AT FRONT DOOR SWITCH RH FRONT DOOR SWITCH LH REAR DOOR S...

Page 4191: ...NATION METER 3 RHD 6 CYLINDER ENGINE AND TURBO ENGINE MODEL M RH6T 01 M RH6T 01 WI 00851 GREEN i10 To A A8 A7 A1 A30 A14 A29 A16 A15 GREEN i12 To C C5 C8 C4 C1 C9 C18 C17 GREEN i11 To B C10 B9 B8 B16...

Page 4192: ...INDICATOR LIGHT VDC OFF INDICATOR LIGHT MALFUNCTION INDICATOR LIGHT OIL PRESSURE WARNING LIGHT VDC OPERATION INDICATOR LIGHT CHARGE WARNING LIGHT PARKING BRAKE BRAKE FLUID LEVEL WARNING LIGHT ABS WAR...

Page 4193: ...R6T 04 E M R6T 02 A M R6T 04 C IGN IGN B B B3 A13 M R6T 04 D A19 A16 A20 A15 A21 A14 A22 DRIVER A12 DIMMER CIRCUIT M R6T 02 B STABILIZING POWER CIRCUIT CFL LED FOR POINTER INVERTER CIRCUIT LED DRIVER...

Page 4194: ...B15 B7 A17 A7 E M R6T 03 E B16 M R6T 03 D IMMOBILIZER CONTROL MODULE TRANSMISSION CONTROL MODULE SPORTS SHIFT FUEL GAUGE MODULE DRIVER POWER CIRCUIT DRIVER DRIVER DRIVER DOOR WARNING BACK LIGHT FUEL...

Page 4195: ...T B SPEEDOMETER TACHOMETER I F I F I F A28 A28 B6 A28 A11 TRANSMISSION CONTROL MODULE TRANSMISSION CONTROL MODULE ENGINE CONTROL MODULE VEHICLE SPEED SENSOR MT AT FRONT DOOR SWITCH RH FRONT DOOR SWITC...

Page 4196: ...WI 141 WIRING SYSTEM COMBINATION METER MEMO...

Page 4197: ...10 2 OrB YB OrB YB LR LR V BW i60 i61 B36 I1 A2 OrB B2 M2 YB LR MT C C L4C 02 A B107 BLUE 1 2 B65 BLACK 1 2 3 4 BLACK B68 1 2 3 4 5 BROWN i19 1 2 3 4 5 6 B94 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 4198: ...R B GB 3 BOr YB 4 BL 16 B B 6 OrL 3 RL 2 BG 5 BY 1 E3 B22 VEHICLE SPEED SENSOR MT BR GW GB BL 3 1 2 6 B17 F44 B61 BR TRANSMISSION CONTROL MODULE AT GB BOr C17 B22 B56 C B55 B 18 GW 17 LgR 14 OrL 13 RL...

Page 4199: ...0858 T7 T3 B12 CRUISE CONTROL MODULE WB 4 B94 AT 12 INHIBITOR SWITCH A T BY 7 BW P R N D 3 2 1 12 WB 11 WG WG TO BATTERY TERMINAL B14 STARTER MOTOR T7 1 2 3 4 5 6 7 8 9 10 11 12 B12 1 2 3 4 5 6 7 8 9...

Page 4200: ...LR V BW ON i19 OFF OrB YB LR B36 I1 A2 OrB B2 M2 YB LR MT C C L4S 02 A B107 BLUE 1 2 B65 BLACK 1 2 3 4 BLACK B68 1 2 3 4 5 BROWN i19 1 2 3 4 5 6 B94 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 4201: ...R B GB 3 BOr YB 4 BL 16 B B 6 OrL 3 RL 2 BG 5 BY 1 E3 B22 VEHICLE SPEED SENSOR MT BR GW GB BL 3 1 2 6 B17 F44 B61 BR TRANSMISSION CONTROL MODULE AT GB BOr C17 B22 B56 C B55 B 18 GW 17 LgR 14 OrL 13 RL...

Page 4202: ...0861 T7 T3 B12 CRUISE CONTROL MODULE WB 4 B94 AT 12 INHIBITOR SWITCH A T BY 7 BW P R N D 3 2 1 12 WB 11 WG WG TO BATTERY TERMINAL B14 STARTER MOTOR T7 1 2 3 4 5 6 7 8 9 10 11 12 B12 1 2 3 4 5 6 7 8 9...

Page 4203: ...2 A B65 BLACK 1 2 3 4 BLACK B68 1 2 3 4 5 BROWN i19 1 2 3 4 5 6 B94 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CRUISE CONTROL MODULE B94 YW F87 58 VDC CONTROL MODULE YW YW 8 F96 B255 i60...

Page 4204: ...9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GW BR B GB 3 BOr YB 4 WG 2 B B 6 OrL 3 RL 2 BG 5 BY 1 E49 B252 6 F44 B61 BR GB BOr C17 B22 18 GW 17 LgR 14 OrL 13 RL 5 BG 7 BY A C C LH6 01 B7...

Page 4205: ...00864 T7 T3 B12 CRUISE CONTROL MODULE WB 4 B94 12 INHIBITOR SWITCH A T BY 7 BW P R N D 3 2 1 12 WB 11 WG WG TO BATTERY TERMINAL B14 STARTER MOTOR T7 1 2 3 4 5 6 7 8 9 10 11 12 B12 1 2 3 4 5 6 7 8 9 10...

Page 4206: ...N i19 OFF OrB YB LR B36 I1 A2 OrB B2 M2 YB LR MT C C RH4 02 A B107 BLUE 1 2 B65 BLACK 1 2 3 4 BLACK B68 1 2 3 4 5 BROWN i19 1 2 3 4 5 6 B94 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 AT...

Page 4207: ...B GB 3 BOr YB 4 BL 16 B 6 OrL 3 RL 2 BG 5 BY 1 E3 B22 VEHICLE SPEED SENSOR MT BR GW GB BL 3 1 2 B17 TRANSMISSION CONTROL MODULE AT GB BOr C17 B22 B56 C B55 B 18 GW 17 LgR 14 OrL 13 RL 5 BG 7 BY AT A C...

Page 4208: ...0867 T7 T3 B12 CRUISE CONTROL MODULE WB 4 B94 12 INHIBITOR SWITCH A T BY 7 BW P R N D 3 2 1 12 WB 11 WG WG TO BATTERY TERMINAL B14 STARTER MOTOR T7 1 2 3 4 5 6 7 8 9 10 11 12 B12 1 2 3 4 5 6 7 8 9 10...

Page 4209: ...rB B2 M2 YB LR C C RH6 02 A B65 BLACK 1 2 3 4 BLACK B68 1 2 3 4 5 BROWN i19 1 2 3 4 5 6 B94 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CRUISE CONTROL MODULE B94 YW F87 58 VDC CONTROL MOD...

Page 4210: ...AND SENSOR GROUND JOINT CONNECTOR W WG BL WB 13 17 16 15 B83 B79 B40 B94 GRAY GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B7 BLACK 4 1 2 3 6 5 GRAY B B55 1 2 3 4 10 11...

Page 4211: ...00870 T7 T3 B12 CRUISE CONTROL MODULE WB 4 B94 12 INHIBITOR SWITCH A T BY 7 BW P R N D 3 2 1 12 WB 11 WG WG TO BATTERY TERMINAL B14 STARTER MOTOR T7 1 2 3 4 5 6 7 8 9 10 11 12 B12 1 2 3 4 5 6 7 8 9 10...

Page 4212: ...WI 157 WIRING SYSTEM CRUISE CONTROL SYSTEM MEMO...

Page 4213: ...E COMBINATION METER 4 CYLINDER ENGINE MODEL C i12 H C ENGINE COOLANT TEMPERATURE GAUGE COMBINATION METER 6 CYLINDER ENGINE MODEL A B i10 i11 C i12 PW C8 BL C9 PW C5 B15 LHD RHD BL C6 B16 PW A5 D4 PW B...

Page 4214: ...16 5 6 7 BROWN B GREEN B21 BLACK 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GW FB 39 IGNITION RELAY...

Page 4215: ...1 RB 3 BW 5 FUEL PUMP RELAY GR Lg 3 RB 4 FUEL PUMP FUEL PUMP ASSEMBLY 3 RB RB B RB 2 1 B REF TO GROUND DISTRIBUTION GND L 04 ENGINE CONTROL MODULE Lg GR A16 B7 E G LH4 07 A R57 B97 B46 3 4 1 2 GREEN R...

Page 4216: ...4 C E G LH4 04 B B21 E2 GOr 5 GW PW 10 WG E11 GW B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

Page 4217: ...LH4 04 E E G LH4 05 F WB 12 INHIBITOR SWITCH BY 7 BW P T3 B12 T7 R N D 3 2 1 12 WB 11 WG 6 BR B47 BROWN B12 F44 3 1 2 4 5 6 5 6 3 4 1 2 7 8 T7 5 6 3 4 1 2 11 12 9 10 7 8 B134 B135 B136 1 2 3 4 5 6 7 8...

Page 4218: ...READ MEMORY CONNECTOR C E G LH4 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 2 B26 VG B15 PG B20 V Or GW 7 B40 B125 VG PG 10 Or 1 BL BL 13 BL 12 BR 1 VW 6 Or 4 BL...

Page 4219: ...BW BL RW RB YR 2 4 1 W C23 SB 3 2 1 B155 CO RESISTOR BR YR WR 2 4 3 E13 THROTTLE POSITION SENSOR B21 E2 RY 9 RB 12 LgY BR YR WR 11 LW 8 SHIELD AND SENSOR GROUND JOINT CONNECTOR 6 4 5 BL B83 B155 3 2...

Page 4220: ...BY PL Y Or 1 2 E15 CAMSHAFT POSITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 3 E14 E10 E15 1 2 1 3 4 5 6 2 E7 LIGHT GRAY LIGHT GRAY BLACK PL 17 R Y 19 G 18 20 W B Or G...

Page 4221: ...2 13 14 15 16 17 18 19 20 RG YR WR R 5 14 B YG GW RG 4 6 Sb GR L YW BP BL BW B BR B PB BL BL BL B6 BL BW A27 A25 YG A26 Sb B RG POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 1 4...

Page 4222: ...A4 P 9 YL Br Y 1 E G LH4 03 G LIGHT GRAY LIGHT GRAY FUEL INJECTOR NO 1 Y 2 Br 1 FUEL INJECTOR NO 4 Y 2 GB 1 FUEL INJECTOR NO 3 Y 2 GOr 1 PL A13 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 E6 LIGHT GRAY B...

Page 4223: ...29 RB BW BrB R59 L 2 BrB 1 FUEL SUB LEVEL SENSOR RB BW FUEL PUMP FUEL PUMP ASSEMBLY 2 1 R58 B 3 L 6 FUEL LEVEL SENSOR 1 2 3 4 5 6 7 8 B97 R58 GRAY B46 3 4 1 2 GREEN R57 1 2 3 4 5 6 1 2 3 4 5 6 BLACK A...

Page 4224: ...D E G L4O 08 E E G L4O 05 C B21 E2 GOr 5 GW PW 10 WG E11 GW B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 4225: ...P T3 B12 T7 R N D 3 2 1 12 WB 11 WG 6 BR B47 BROWN BLACK B12 F44 3 1 2 4 5 6 5 6 3 4 1 2 7 8 T7 5 6 3 4 1 2 11 12 9 10 7 8 B135 B136 1 2 3 4 5 6 7 8 9 10 11 12 B REF TO GROUND DISTRIBUTION GND L 03 Lg...

Page 4226: ...DIATOR FAN SYSTEM R F H4 01 RL A14 GR A13 REF TO VEHICLE DYNAMIC CONTROL SYSTEM VDC LH4 03 YB C8 L A25 R A24 OrB C2 C7 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28...

Page 4227: ...DULE E G L4O 08 K B79 B76 GREEN B126 GREEN GRAY GRAY B40 B75 GREEN B125 GREEN BROWN D B137 C B136 A B134 CHECK CONNECTOR LINE END CONNECTOR B79 B126 1 A21 C3 DATA LINK CONNECTOR TEST MODE CONNECTOR G...

Page 4228: ...E2 RB 12 LgY 11 RY YR WR BR 9 SHIELD AND SENSOR GROUND JOINT CONNECTOR 3 2 BW BW RY BW 1 BW BW RG B83 F26 3 2 1 B19 B18 T6 1 2 3 4 REAR OXYGEN SENSOR 2 1 4 3 WR YR 3 BR 2 4 B19 T5 B100 F2 BW WL 2 1 4...

Page 4229: ...6 W OrG BrW BY 14 15 W WL R Br 2 BR WG Br BR YR R BY PL Y Or 1 2 E15 CAMSHAFT POSITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 3 BR 1 E15 E14 E20 1 2 1 3 4 5 6 2 E7 LI...

Page 4230: ...B BL BL BL D14 C19 BL BL BW C26 A33 A32 B RG POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 2 1 4 3 E12 GW YW RG L PURGE CONTROL SOLENOID VALVE 2 1 E4 WR Y 6 BP E12 1 2 3 4 5 6 7...

Page 4231: ...CTOR NO 1 Y 2 Br 1 FUEL INJECTOR NO 4 Y 2 GB 1 FUEL INJECTOR NO 3 Y 2 GOr 1 PL A23 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 E6 BROWN E16 E17 1 2 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B134 1 2 3...

Page 4232: ...Y FUEL PUMP RELAY FUEL PUMP FUEL LEVEL SENSOR FUEL SUB LEVEL SENSOR GREEN B46 BLACK R57 GRAY R58 B97 R59 6 2 3 1 4 5 1 2 3 5 6 7 4 8 1 2 2 1 3 4 2 1 4 3 6 5 B135 B A B134 1 2 3 4 10 11 12 19 20 21 13...

Page 4233: ...4 GB E4 SMJ B36 E G LH6 08 D E G LH6 09 C GB 5 B21 E2 GOr 15 G PW 16 PW E11 G B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 B21 LIGHT GRAY GREEN GREEN B i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 C B56 1 2...

Page 4234: ...BR 6 F46 B108 BL 2 WB B134 A B B135 C B136 D B137 B REF TO GROUND DISTRIBUTION GND L 03 TO BATTERY TERMINAL OrB A11 YB A4 GY B16 BrR A12 L C11 R C12 REF TO VEHICLE DYNAMIC CONTROL SYSTEM VDC LH6 03 R...

Page 4235: ...34 CHECK CONNECTOR TEST MODE CONNECTOR A20 B75 A10 B76 1 A5 A21 DATA LINK CONNECTOR LINE END CHECK CONNECTOR E E G LH6 03 B75 GREEN 1 2 B76 GREEN 1 2 GW VW V Or VG GW 7 W 13 WB 12 Or 1 WR BR 1 VG 6 VG...

Page 4236: ...07 E G LH6 07 L E G LH6 03 F BLACK BLACK BLACK E20 E13 E21 4 1 2 3 6 5 B83 1 2 3 5 BW SB BW SB SB RG BW SB 8 7 6 BL BW RY SB B26 RG B19 W B17 WL C13 2 1 4 3 T6 B19 DARK GRAY B20 1 2 3 B83 PRESSURE SE...

Page 4237: ...L SOLENOID VALVE EXHAUST GAS RECIRCRATION SOLENOID PURGE CONTROL SOLENOID VALVE C B136 D B137 E1 B20 9 3 2 RG BOr BL YR Y Or BL YR Y Or BL YR Y LgR BW 7 4 YL BrG RG RG LgR BW LgR BW YL BrG YL BrG YL Y...

Page 4238: ...10 11 12 13 14 15 16 E49 B252 E3 B22 FRONT OXYGEN A F SENSOR LH 3 4 2 1 2 E48 KNOCK SENSOR 2 2 E14 KNOCK SENSOR 1 E47 E24 3 4 1 2 1 2 B252 B21 LIGHT GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 4239: ...D P B24 P 17 E19 POWER STEERING OIL PRESSURE SWITCH WR B18 WR 5 RY G R P G YL R P WL RY WL RY PW 12 E8 ENGINE COOLANT TEMPERATURE SENSOR AND THERMOMETER E G LH6 05 O 3 2 1 3 2 1 E G LH6 11 R E15 1 2 3...

Page 4240: ...E G LH6 04 J E G LH6 01 B E G LH6 02 C SHIELD AND SENSOR GROUND JOINT CONNECTOR A C COMPRESSOR A B134 D B137 C B136 E G LH6 10 T E G LH6 10 S 2 3 1 F26 F82 B252 DARK GRAY GREEN BLACK C B136 1 2 7 8 9...

Page 4241: ...Y L C22 R GR R G L Y Y W B BW R W BW WG B BW WG R BW BW G BW WG Y BW BW L BW WG 1 1 1 E31 IGNITION COIL NO 1 IGNITION COIL NO 2 IGNITION COIL NO 3 IGNITION COIL NO 4 IGNITION COIL NO 5 IGNITION COIL N...

Page 4242: ...YL P 1 2 E43 C3 12 FUEL INJECTOR NO 5 2 1 V V C1 9 VW E44 FUEL INJECTOR NO 6 2 1 VW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 C6 15 PL E16 FUEL INJECTOR NO 2 2 1 PL E6 C5 14 FUEL INJECTOR NO 3 2 1 PB PB...

Page 4243: ...MBLY 1 RB RB B RB 2 1 B REF TO GROUND DISTRIBUTION GND R 04 ENGINE CONTROL MODULE Lg Lg GR A29 A16 B7 OI WI WITHOUT IMMOBILIZER MODEL WITH IMMOBILIZER MODEL WI OI E G RH4 07 A R57 R58 GRAY B46 3 4 1 2...

Page 4244: ...4 GB E4 SMJ B36 E G RH4 06 D E G RH4 04 C E G RH4 04 B B21 E2 GOr 5 GW PW 10 WG E11 GW B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 A B134 1 2 3 4...

Page 4245: ...11 WG B47 BROWN B12 T7 3 1 2 4 5 6 5 6 3 4 1 2 11 12 9 10 7 8 B134 B135 B136 1 2 3 4 5 6 7 8 9 10 11 12 B REF TO GROUND DISTRIBUTION GND R 03 RL A3 GR A12 OV WV MT MT AT AT AT AT B28 MT 1 A B134 1 2 3...

Page 4246: ...R READ MEMORY CONNECTOR C E G RH4 02 E E G RH4 03 B E G RH4 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 2 B26 VG B15 PG B20 V Or GW 7 B40 B125 VG PG 10 Or 1 BL BL...

Page 4247: ...BL RW RB 2 4 1 W C23 SB 3 2 1 B155 CO RESISTOR BR YR WR 2 4 3 E13 THROTTLE POSITION SENSOR B21 E2 RY 9 RB 12 LgY BR YR WR 11 SHIELD AND SENSOR GROUND JOINT CONNECTOR 6 4 5 BW SB RG RY BL B83 B155 3 2...

Page 4248: ...IR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 3 E10 E14 E15 1 2 1 3 4 5 6 2 E7 LIGHT GRAY BLACK PL 17 R Y 19 B 18 W Or GL 4 GY LB B W 1 Br L 3 LW RY SHIELD AND SENSOR GROUND JOINT CONNECTOR 3 2 BW...

Page 4249: ...10 11 12 13 14 15 16 17 18 19 20 RG YR WR R 5 14 B YG GW RG 4 6 Sb GR L YW BP BL BW B BR B PB BL BL BL BW A27 A25 YG A26 Sb B RG POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 1...

Page 4250: ...A4 P 9 YL Br Y 1 E G RH4 03 G LIGHT GRAY LIGHT GRAY FUEL INJECTOR NO 1 Y 2 Br 1 FUEL INJECTOR NO 4 Y 2 GB 1 FUEL INJECTOR NO 3 Y 2 GOr 1 PL A13 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 E6 LIGHT GRAY B...

Page 4251: ...rB Lg GR B25 A2 C10 B135 A B134 B B136 C E G R4O 08 A E G R4O 02 B R57 R58 GRAY B46 3 4 1 2 GREEN R57 1 2 3 4 5 6 1 2 3 4 5 6 BLACK A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2...

Page 4252: ...D E G R4O 08 E E G R4O 05 C B21 E2 GOr 5 GW PW 10 WG E11 GW B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 4253: ...B 12 INHIBITOR SWITCH AT BY 7 BW P T3 B12 T7 R N D 3 2 1 12 WB 11 WG B47 BROWN B12 3 1 2 4 5 6 T7 5 6 3 4 1 2 11 12 9 10 7 8 B135 B136 1 2 3 4 5 6 7 8 9 10 11 12 B REF TO GROUND DISTRIBUTION GND R 03...

Page 4254: ...7 REF TO RADIATOR FAN SYSTEM R F H4 01 RL A14 GR A13 REF TO VEHICLE DYNAMIC CONTROL SYSTEM VDC RH4 03 YB C8 L A25 R A24 OrB C2 C7 B137 D A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 4255: ...5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 2 Or C21 BG D16 VG V B40 BL 13 OrW BL 12 VG 10 BR 1 VW 6 Or 1 BL 8 Or 4 VG 12 GW 7 BG BW 1 2 T2 B25 OrW BL 1 B76 B75 NEUTRAL POSI...

Page 4256: ...R 9 SHIELD AND SENSOR GROUND JOINT CONNECTOR 2 3 BW BW RY BW 4 BW BW RG B83 REAR OXYGEN SENSOR 2 1 4 3 WR YR 3 BR 2 4 B19 T5 BW WL 2 1 4 3 YR W T6 B100 F2 24 BR BR GENERATOR BR 3 F26 C25 BR B B135 B18...

Page 4257: ...ITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y PL 17 R Y 19 G 18 W Or GL 4 GY LB B W 1 Br L 3 LW RY 20 B E14 E10 E15 1 3 4 5 6 2 E7 LIGHT GRAY LIGHT GRAY GRAY LIGHT GRA...

Page 4258: ...YW 6 5 RY RB RG L BP BW B 8 BL BR 16 BL BR B PB BL BL BL D14 BL C19 BW C26 A33 RY A32 RB B RG POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 2 1 4 3 E12 GW YW RG L PURGE CONTROL S...

Page 4259: ...CTOR NO 1 Y 2 Br 1 FUEL INJECTOR NO 4 Y 2 GB 1 FUEL INJECTOR NO 3 Y 2 GOr 1 PL A23 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 E6 BROWN E16 E17 1 2 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B134 1 2 3...

Page 4260: ...PUMP ASSEMBLY FUEL PUMP RELAY FUEL PUMP FUEL LEVEL SENSOR FUEL SUB LEVEL SENSOR GREEN B46 BLACK R57 GRAY R58 R59 6 2 3 1 4 5 1 2 2 1 3 4 2 1 4 3 6 5 B135 B A B134 1 2 3 4 10 11 12 19 20 21 13 5 6 14 1...

Page 4261: ...ND R 04 I F I F GOr B5 PW A5 BW D4 RW A4 OrW C4 GB E4 SMJ B36 E G RH6 08 D E G RH6 09 C GB 5 B21 E2 GOr 15 G PW 16 PW E11 G B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 B21 LIGHT GRAY GREEN GREEN B D C A...

Page 4262: ...6 04 E E G RH6 05 F WB 12 INHIBITOR SWITCH BY 7 BW P T3 B12 T7 R N D 3 2 1 12 WB 11 WG B134 A B B135 C B136 D B137 B REF TO GROUND DISTRIBUTION GND R 03 OrB A11 YB A4 GY B3 BrR A12 L C11 R C12 REF TO...

Page 4263: ...34 CHECK CONNECTOR TEST MODE CONNECTOR A20 B75 A10 B76 1 A5 A21 DATA LINK CONNECTOR LINE END CHECK CONNECTOR E E G RH6 03 B75 GREEN 1 2 B76 GREEN 1 2 GW VW V Or VG GW 7 W 13 WB 12 Or 1 WR BR 1 VG 6 VG...

Page 4264: ...K E20 E13 E21 4 1 2 3 6 5 B83 1 2 3 5 BW SB BW SB SB RG BW SB 8 7 6 BL BW RY SB B26 RG B19 B17 WL C13 2 1 4 3 T6 B19 GRAY B20 1 2 3 B83 E21 3 1 2 E20 2 1 RB B9 C B136 B135 B 1 2 7 8 9 5 6 3 4 10 11 12...

Page 4265: ...L SOLENOID VALVE EXHAUST GAS RECIRCRATION SOLENOID PURGE CONTROL SOLENOID VALVE C B136 D B137 E1 B20 9 3 2 RG BOr BL YR Y Or BL YR Y Or BL YR Y LgR BW 7 4 YL BrG RG RG LgR BW LgR BW YL BrG YL BrG YL Y...

Page 4266: ...10 11 12 13 14 15 16 E49 B252 E3 B22 FRONT OXYGEN A F SENSOR LH 3 4 2 1 2 E48 KNOCK SENSOR 2 2 E14 KNOCK SENSOR 1 E47 E24 3 4 1 2 1 2 B252 B21 LIGHT GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 4267: ...D P B24 P 17 E19 POWER STEERING OIL PRESSURE SWITCH WR B18 WR 5 RY G R G YL R P P WL RY WL RY PW 12 E8 ENGINE COOLANT TEMPERATURE SENSOR AND THERMOMETER E G RH6 05 O 3 2 1 3 2 1 E G RH6 11 R E15 1 2 3...

Page 4268: ...ELD AND SENSOR GROUND JOINT CONNECTOR A C COMPRESSOR A B134 D B137 C B136 E G RH6 10 T E G RH6 10 S 2 3 1 F26 B252 DARK GRAY GREEN GRAY C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22...

Page 4269: ...C22 R GR R G R W BW W BW WG R BW BW G BW WG Y BW BW L BW WG B BW WG 1 1 1 E31 IGNITION COIL NO 1 IGNITION COIL NO 2 IGNITION COIL NO 3 IGNITION COIL NO 4 IGNITION COIL NO 5 IGNITION COIL NO 6 3 1 2 E3...

Page 4270: ...YL P YL BR 1 2 E43 C3 12 FUEL INJECTOR NO 5 2 1 V V C1 9 VW E44 FUEL INJECTOR NO 6 2 1 VW GR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 C6 15 PL E16 FUEL INJECTOR NO 2 2 1 PL Lg YL BR Lg YL LR YL LB YL Br...

Page 4271: ...1 2 GREEN R57 1 2 3 4 5 6 BLACK 7 8 9 10 W B LgB 14 B98 R2 R3 B99 LgB Lg 16 Lg W B FUEL PUMP FUEL PUMP ASSEMBLY 2 1 R58 Lg B FUEL PUMP CONTROLLER 8 6 RB LgB 10 9 R122 W 7 B 5 RB RB 1 R122 1 2 3 4 5 6...

Page 4272: ...G RTB 09 E G RTB 10 D E E G RTB 05 C E G RTB 05 B GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 2 1 3 VEHICLE SPEED SENSOR B17 C B136 A 1 2 7 8 9 5 6 3...

Page 4273: ...6 B134 B137 B REF TO GROUND DISTRIBUTION GND R 03 Lg B A D TO BATTERY TERMINAL B14 STARTER MOTOR A16 A B134 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 D B137 1 2 7 8 9 5 6 3 4 10 11 12...

Page 4274: ...2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 D B137 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15...

Page 4275: ...7 8 9 10 11 12 13 14 15 16 1 2 1 2 Or A8 A21 VG B40 BL 13 BL BL 12 VG 10 BR 1 Lg 8 VG 6 1 Or BL 8 Or 4 VG 12 GW 7 B79 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 BG BL 1 3 T9 B128 NEUTRAL POSITION SWITCH MT...

Page 4276: ...R 2 1 Lg BY 3 4 B18 WB YR REAR OXYGEN SENSOR 1 2 L W 4 3 T6 T5 1 2 3 4 1 2 C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15...

Page 4277: ...2 23 24 25 26 E14 E10 GRAY GRAY ENGINE CONTROL MODULE C B136 B B135 D B137 B21 SB C12 GY B10 B B1 W B4 W B22 SB C3 BrL D22 LB D11 WOr B2 R C11 L M E G RTB 06 C1 OrL YL OrL 7 8 LB WOr 10 12 B220 SOLENO...

Page 4278: ...VALVE 1 2 E7 3 E7 1 2 3 Q R F 14 E2 B21 GOr 11 12 PB Br PB Br G RY W G RY W BW R POWER STEERING OIL PRESSURE SWITCH E19 B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 2...

Page 4279: ...ION SENSOR E13 ENGINE COOLANT TEMPERATURE SENSOR AND THERMOMETER E8 B8 16 YW B9 20 RB B7 19 LgY 18 B18 17 BrW 15 Or R YG BG H WG Or R BG R YG BG BG H WG YW RB LgY RG BrW PW B135 B 5 6 7 8 2 1 9 4 3 10...

Page 4280: ...YV RB BOr R D8 R BW C17 BW BP B BL A15 E1 BL C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B84 E 5 6 7 8 2 1 9 4 3 10 11 12 13 14 15 16 17 D B137 1 2 7 8 9 5 6 3 4 10 11 12 19...

Page 4281: ...NO 3 2 1 PL C6 PL 10 FUEL INJECTOR NO 2 2 1 E4 RG D16 RG YW W GW R LW LgY YW R W R GW R LW R LgY R 2 PURGE CONTROL SOLENOID VALVE 1 2 C B136 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23...

Page 4282: ...WI 227 WIRING SYSTEM ENGINE ELECTRICAL SYSTEM MEMO...

Page 4283: ...0 A i11 B i12 C 16 BR R59 1 2 BLACK BROWN R57 1 2 3 4 5 6 R58 GRAY 1 2 3 4 5 6 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN B i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 1 2 3 4 5 6 7 8 9 10...

Page 4284: ...9 10 11 12 13 14 15 16 GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 B252 1 2 3 4 5 6 7 8 B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28...

Page 4285: ...UB LEVEL SENSOR R58 L 6 B 3 BrB BrB BW BW 2 B 6 BL BL BR 17 E3 GE B22 B99 R3 R15 R57 i10 A i11 B 16 BR BLACK BROWN R57 1 2 3 4 5 6 R58 GRAY 1 2 3 4 5 6 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GREEN...

Page 4286: ...WI 231 WIRING SYSTEM FUEL GAUGE SYSTEM MEMO...

Page 4287: ...POWER SUPPLY ROUTING FB 39 IGNITION RELAY IG GW GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 BP A5 i10 A COMBINATION METER BP BP C2 i1 B36 i12 C B BP 1 B 2 SMJ B29 T8 LO AWD INDICATOR LIGHT SWITCH B29...

Page 4288: ...C WI 00944 FAPS 01 FAPS 01 YR FB 28 F B FUSE NO 4 ACC TO POWER SUPPLY ROUTING i28 B V 2 BW 3 YR 2 B 1 i24 i25 i24 i25 1 2 3 1 2 FRONT ACCESSORY POWER SUPPLY SOCKET REF TO CLEARANCE LIGHT AND ILLUMINAT...

Page 4289: ...GHT LEVELING SWITCH LHD SMJ HEADLIGHT LEVELER LH HEADLIGHT LEVELER RH WG 3 GY 2 B 1 WG 12 GY 13 RG WG GY RG B B 14 B36 i1 i28 i39 B100 F2 RHD WG 7 GY 9 RG WG GY RG 8 B100 F2 F58 F59 i39 GRAY F58 GRAY...

Page 4290: ...MATIC WI 00946 HORN 01 HORN 01 BL RG MB 9 HORN RELAY MB 6 HORN RELAY TO POWER SUPPLY ROUTING HORN RG RG 5 B100 F2 RG 1 B68 F5 BL HORN F47 BL HORN SWITCH B68 1 3 2 4 5 LHD LHD RHD RHD F2 BLACK 3 4 1 2...

Page 4291: ...KEY WARNING SWITCH IMMOBILIZER CONTROL MODULE B141 BrR 1 2 1 2 1 2 3 4 5 6 7 8 F44 BLACK GREEN B74 C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B141 1 2 3 4 5 6 7 8 9 10 11 12 IMB L 01 IMB L 01 H6 H4 H4 6...

Page 4292: ...H4 H6 H4 H6 B135 B ENGINE CONTROL MODULE YB RY RG D18 D17 B19 H4 B135 B B137 D B141 1 2 3 4 5 6 7 8 9 10 11 12 H4 R9 1 2 3 B142 1 2 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 1...

Page 4293: ...NING SWITCH IMMOBILIZER CONTROL MODULE B141 BrR IMB R 01 IMB R 01 H6T H4N H4N IMMOBILIZER INDICATOR LIGHT LR A9 LR C1 H6T BrR A7 1 2 1 2 BLACK GREEN B74 C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B141 1 2...

Page 4294: ...6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 24 25 26 27 16 17 18 28 29 19 20 21 30 B136 C B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 R3 1 2 3 4 5 6 7 8 11 13 14 12 15...

Page 4295: ...B MB 8 M B FUSE NO 6 B TO POWER SUPPLY ROUTING WR LR WG 12 16 5 1 W 15 KEYLESS ENTRY CONTROL MODULE B176 W 16 F2 B100 W WG 2 1 KEY WARNING SWITCH B74 13 K L L 02 B74 1 2 BLACK B176 2 3 4 5 6 7 1 8 9 1...

Page 4296: ...T MODEL WITH VANITY MIRROR ILLUMINATION LIGHT MODEL WVM OVM B176 GREEN A i10 1 2 3 8 9 10 4 11 12 13 14 22 23 5 6 7 15 16 17 24 25 26 18 27 28 29 30 19 20 21 2 3 4 5 6 7 1 8 9 10 11 12 13 14 15 16 17...

Page 4297: ...7 D32 R14 D47 R39 D35 RG 4 LgY 2 RG 7 LgY 6 FRONT DOOR LOCK ACTUATOR RH REAR GATE LOCK ACTUATOR REAR DOOR LOCK ACTUATOR LH REAR DOOR LOCK ACTUATOR RH B 1 2 3 4 5 6 7 8 BLACK D35 D18 D32 D72 D26 D47 GR...

Page 4298: ...O 3 B MB 3 M B FUSE NO 2 B MB 8 M B FUSE NO 6 B TO POWER SUPPLY ROUTING WR LR WG 12 16 5 1 W 15 KEYLESS ENTRY CONTROL MODULE B176 W WG 2 1 KEY WARNING SWITCH B74 13 K L R 02 B74 1 2 BLACK B176 2 3 4 5...

Page 4299: ...2 23 5 6 7 15 16 17 24 25 26 18 27 28 29 30 19 20 21 2 3 4 5 6 7 1 8 9 10 11 12 13 14 15 16 17 18 BLACK BLACK D46 R37 1 2 1 2 R16 BLACK R22 R9 R12 1 2 3 1 2 3 D34 R52 B90 1 2 3 1 3 4 5 6 2 WVM OVM B90...

Page 4300: ...G LgY RG 1 4 D27 D32 R14 D47 R39 D35 RG 4 LgY 2 RG 7 LgY 6 FRONT DOOR LOCK ACTUATOR LH REAR GATE LOCK ACTUATOR REAR DOOR LOCK ACTUATOR LH REAR DOOR LOCK ACTUATOR RH B 1 2 3 4 5 6 7 8 BLACK D35 D18 D32...

Page 4301: ...SE NO 18 IG GB GB GB 15 B98 R2 B R127 1 2 R2 BLUE 2 3 4 5 6 7 8 9 11 12 13 14 17 18 19 20 10 1 15 16 GB 2 BrL 3 R126 BrL C7 ENGINE CONTROL MODULE C B136 L 1 R127 MUFFLER ACTUATOR R 2 L 1 R 4 MUFFLER A...

Page 4302: ...7 B B WAGON MODEL SEDAN MODEL WG SD R37 1 2 1 2 B24 B12 1 2 D42 D49 3 4 1 2 R62 R64 3 4 1 2 R60 T7 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 BrY B...

Page 4303: ...3 WO OO WO OO B136 C B137 D ENGINE CONTROL MODULE V 4 BW 10 OP CONNECTOR B228 B71 TO POWER SUPPLY ROUTING R43 R42 1 3 4 5 6 2 B69 3 4 1 2 BLACK B43 B116 B133 1 2 3 4 5 6 D7 1 2 3 8 9 10 4 11 12 13 14...

Page 4304: ...TE LIGHT SEDAN SEDAN WAGON SD WG TO POWER SUPPLY ROUTING FB 34 F B FUSE NO 5 BL BR FB 35 F B FUSE NO 5 BL 15 B B B WG 3 2 SD BL B 4 2 R26 REAR COMBINATION LIGHT RH WG 3 2 SD BL B R3 B99 BL B 2 BL 1 7...

Page 4305: ...SWITCH ILLUMI LIGHT V 1 BW 6 i39 HEADLIGHT LEVELER SWITCH ILLUMI LIGHT V BW 1 7 i26 RADIO ILLUMI LIGHT V 2 BW 3 i25 FRONT ACCESSORY POWER SUPPLY SOCKET ILLUMI LIGHT V 4 BW 2 i7 FRONT FOG LIGHT SWITCH...

Page 4306: ...IL ILLUMINA TION RELAY BW BW 11 V V 10 B69 V 4 BW 10 OP CONNECTOR B228 B71 TO POWER SUPPLY ROUTING R43 R42 1 3 4 5 6 2 B69 3 4 1 2 B116 B133 1 2 3 4 5 6 B134 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7...

Page 4307: ...TE LIGHT SEDAN SEDAN WAGON SD WG TO POWER SUPPLY ROUTING FB 34 F B FUSE NO 5 BL BR FB 35 F B FUSE NO 5 BL 15 B B B WG 3 2 SD BL B 4 2 R26 REAR COMBINATION LIGHT RH WG 3 2 SD BL B R3 B99 BL B 2 BL 1 7...

Page 4308: ...i7 FRONT FOG LIGHT SWITCH ILLUMI LIGHT V B10 B B20 i49 AUTO A C CONTROL MODULE V 2 B 1 i21 ASH TRAY ILLUMI LIGHT GLOVE BOX ILLUMI LIGHT V B 2 1 i23 B i28 ILM LH6 01 A BW 1 BW B V A7 COMBI NATION METE...

Page 4309: ...R B228 B71 TO POWER SUPPLY ROUTING R43 R42 1 3 4 5 6 2 B69 3 4 1 2 BLACK B43 B116 B133 1 2 3 4 5 6 D7 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 5 4 6 7 8 2 1 9 3...

Page 4310: ...B 1 2 LICENSE PLATE LIGHT SEDAN SEDAN WAGON SD WG TO POWER SUPPLY ROUTING FB 34 F B FUSE NO 5 BL BR FB 35 F B FUSE NO 5 B B B WG 3 2 SD BL B 4 2 R26 REAR COMBINATION LIGHT RH WG 3 2 SD BL B BL B 2 BL...

Page 4311: ...i39 HEADLIGHT LEVELER SWITCH ILLUMI LIGHT V BW 1 7 i26 RADIO ILLUMI LIGHT V 4 BW 2 i43 WIPER DEICER SWITCH ILLUMI LIGHT V 4 BW 2 i7 FRONT FOG LIGHT SWITCH ILLUMI LIGHT SWITCH IS IN STEERING SIDE PANE...

Page 4312: ...RELAY BW BW 7 V V 6 REF TO GROUND DISTRIBUTION GND R 02 B69 V 4 BW 10 OP CONNECTOR B228 B71 TO POWER SUPPLY ROUTING R43 R42 1 3 4 5 6 2 B69 3 4 1 2 BROWN B116 B133 1 2 3 4 5 6 D7 1 2 3 8 9 10 4 11 12...

Page 4313: ...1 2 LICENSE PLATE LIGHT SEDAN SEDAN WAGON SD WG TO POWER SUPPLY ROUTING FB 34 F B FUSE NO 5 BL BR FB 35 F B FUSE NO 5 BL 5 B B B WG 3 2 SD BL B 4 2 R26 REAR COMBINATION LIGHT RH WG 3 2 SD BL B R2 B98...

Page 4314: ...TCH ILLUMI LIGHT SWITCH IS IN STEERING SIDE PANEL V B10 BW B20 i49 AUTO A C CONTROL MODULE V 2 B 1 i21 ASH TRAY ILLUMI LIGHT GLOVE BOX ILLUMI LIGHT V B 2 1 i23 B i28 ILM RH6 01 A BW 1 BW B V B3 COMBI...

Page 4315: ...GHT RH RG RL 4 SWITCH IS IN STEERING SIDE PANEL SWITCH IS IN CENTER PANEL SS SC LHD RHD LHD RHD BW BP 19 LHD F2 B100 V V 18 YB 1 GB 3 LR 5 W 4 Lg 2 i7 FRONT FOG LIGHT SWITCH SWITCH IS IN CENTER PANEL...

Page 4316: ...L 04 REF TO GROUND DISTRIBUTION GND L 01 REF TO CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM ILM LH6 03 FRONT FOG LIGHT RELAY WB 1 B 2 B B SMJ B36 i1 RG 30 V 33 BP 31 WB 29 B48 B61 F44 i28 i7 F21 F6...

Page 4317: ...N STEERING SIDE PANEL ON OFF FRONT FOG LIGHT LH WB 1 B 2 F6 FRONT FOG LIGHT RH BLACK i7 1 3 4 5 6 2 1 2 RELAY BLOCK BLACK B48 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34...

Page 4318: ...WI 263 WIRING SYSTEM FRONT FOG LIGHT SYSTEM MEMO...

Page 4319: ...ECTOR LB 8 B 16 R 7 13 B71 F44 B61 LB 9 B REF TO GROUND DISTRIBUTION GND L 02 WITH REAR FOG LIGHT MODEL WITHOUT REAR FOG LIGHT MODEL WF OF WITH REAR FOG LIGHT MODEL LW LB WITHOUT REAR FOG LIGHT MODEL...

Page 4320: ...CTOR LB 1 OF B 9 R 2 14 8 WF 16 7 13 B71 F44 B61 LB 9 B REF TO GROUND DISTRIBUTION GND R 02 1 WF WF OF OF F44 F7 F23 1 2 3 B196 1 2 B71 B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 BLACK GRAY GRAY GREEN B...

Page 4321: ...2 B B 3 ROOM LIGHT DOOR OFF ON B B REF TO GROUND DISTRIBUTION GND L 03 YL WAGON WG 1 2 R56 1 2 3 B228 B176 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 SMJ WITH VANITY MIRROR ILLUMINATION LIGHT MODEL WITHOUT...

Page 4322: ...17 18 19 20 21 22 23 24 25 26 27 28 29 30 C L L 03 F B BrR 3 1 R12 FRONT DOOR SWITCH RH R16 REAR DOOR SWITCH RH B WG 3 1 B LW 3 1 R9 FRONT DOOR SWITCH LH i10 A i12 i53 R98 C COMBINATION METER 4 CYLIND...

Page 4323: ...H SEDAN B REF TO GROUND DISTRIBUTION GND L 05 LR 2 YL 1 R27 YL 1 B 2 D37 D38 REAR GATE LATCH SWITCH WAGON LR YL D46 YL 1 B 2 C L L 01 E C L L 02 F C L L 01 D D46 BLACK BLUE R20 R37 R27 WG SD WG SD WAG...

Page 4324: ...L R 02 B C L R 02 C WR PB YR YR 5 LR LR 1 WR WR 2 B B 3 ROOM LIGHT DOOR OFF ON B B REF TO GROUND DISTRIBUTION GND R 03 YL WAGON WG 1 2 R56 1 2 3 B228 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 SMJ WITH VANIT...

Page 4325: ...B LW 3 1 R12 FRONT DOOR SWITCH RH R16 REAR DOOR SWITCH RH B WG 3 1 B BrR 3 1 R9 FRONT DOOR SWITCH LH i10 A i12 i53 R98 C COMBINATION METER 4 CYLINDER NON TURBO ENGINE MODEL i10 A i12 C COMBINATION MET...

Page 4326: ...H SEDAN B REF TO GROUND DISTRIBUTION GND R 05 LR 2 YL 1 R27 YL 1 B 2 D37 D38 REAR GATE LATCH SWITCH WAGON LR YL D46 YL 1 B 2 C L R 01 D C L R 02 F C L R 01 E D46 BLACK BLUE R20 R37 R27 WG SD WG SD WAG...

Page 4327: ...D STOP LIGHT LY 1 WB 2 2 OC WC 3 WB 1 B 2 WB 1 B 2 WB 2 B 1 B REF TO GROUND DISTRIBUTION GND L 04 05 GND R 04 05 R24 R60 R28 B97 R1 B64 B65 R26 R66 R19 1 2 WB B WB 6 WB B97 R1 WB 2 WB 5 B WB B 7 OC WC...

Page 4328: ...WB 2 2 OC WC 3 WB 3 B 2 WB 1 B 2 WB 3 B 7 B 8 B R37 D33 R28 B64 B65 R26 D39 R38 D34 R79 3 2 WB B WB 7 B WB B 1 OC WC WITHOUT CRUISE CONTROL MODEL WITH CRUISE CONTROL MODEL OC WC R37 1 2 B64 1 2 BLACK...

Page 4329: ...03 COMBINATION METER 4 CYLINDER ENGINE MODEL TURN SIGNAL INDICATOR LIGHT A B i10 i11 LH RH B TURN SIGNAL SWITCH L N R B i28 W 16 B100 F2 SMJ TURN L 02 B TURN L 02 A i22 1 2 3 4 5 6 7 8 BLACK B32 1 2...

Page 4330: ...TURN SIGNAL LIGHT LH BG 2 B 1 F54 SIDE TURN SIGNAL LIGHT LH BG 2 B 1 R79 TRAILER CONNECTOR REAR TURN SIGNAL LIGHT RH B LgB 5 BG 4 B 7 B 8 R26 LgB 4 B 2 1 SD WG 2 4 2 1 SD WG 2 R28 REAR TURN SIGNAL LI...

Page 4331: ...20 21 22 23 24 25 26 27 28 29 30 GREEN B 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 B WITH REAR FOG LIGHT MODEL WITHOUT REAR FOG LIGHT MODEL B BG 1 B 2 SIDE TURN SIGNAL LIGHT LH B148 WR OR B B7 BG A23 LgB...

Page 4332: ...9 FRONT TURN SIGNAL LIGHT LH BG 2 B 1 R79 TRAILER CONNECTOR REAR TURN SIGNAL LIGHT RH B LgB 5 BG 4 B 8 B 7 R26 LgB 4 B 2 1 SD WG 2 4 2 1 SD WG 2 R28 REAR TURN SIGNAL LIGHT LH BG B TURN R 01 A BG BG 20...

Page 4333: ...H4N H6T GW C3 BL C14 GW A8 H6T H4N H6T H4N GOr 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 OIL PRESSURE WARNING...

Page 4334: ...b B36 B36 Or Sb 2 1 F78 SMJ F78 1 2 GREEN BLACK C GREEN B i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i11 COMBINATION METER i10 A i11 B i12 C 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 i1 I F REF TO GROUND DISTR...

Page 4335: ...1 12 GREEN GRAY C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 BRAKE FLUID LEVEL SWITCH R2 BLUE 2 3 4 5 6 7 8 9 11...

Page 4336: ...CH REAR TILT LIMIT SWITCH WG WG 10 R3 B99 WG WG 8 R1 B97 FRONT TILT MOTOR SLIDE MOTOR REAR TILT MOTOR WG 2 B 1 R109 B61 F44 RECLINING SWITCH POWER WINDOW CIRCUIT BREAKER SLIDE SWITCH FRONT TILT SWITCH...

Page 4337: ...WINDOW MAIN SWITCH OFF UP DOWN B FL U FL D E ILLUMI FRONT LH LOCK AUTO UP AUTO DOWN LR 2 L 1 FRONT POWER WINDOW MOTOR LH P W L 04 C P W L 03 B P W L 02 A GREEN D3 1 2 B41 1 2 B REF TO GROUND DISTRIBUT...

Page 4338: ...6 RB 4 L 2 LR 1 D17 B REF TO GROUND DISTRIBUTION GND L 02 LR 2 L 1 D11 B101 B30 D1 D7 P W L 01 A GB 9 RB 5 RY 4 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B FR U FR D E FRONT RH 1 2 1 2 D17 D13 1 2 3 4...

Page 4339: ...B30 D1 D7 P W L 01 B GB 9 GR 13 YR 8 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B RL U RL D E REAR LH 1 2 1 2 D25 D24 1 2 3 4 5 6 D7 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 REAR POWER WINDOW MOTOR LH GRE...

Page 4340: ...30 D1 D7 P W L 01 C GB 9 LG 16 LY 14 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B RR U RR D E REAR RH REAR POWER WINDOW MOTOR RH D30 2 GB 21 LG 20 LY LG LY R3 B99 R1 B97 1 2 1 2 D31 D30 1 2 3 4 5 6 D7 1...

Page 4341: ...H OFF UP DOWN B FR U FR D E ILLUMI FRONT RH LOCK AUTO UP AUTO DOWN LR 2 L 1 FRONT POWER WINDOW MOTOR RH P W R 04 C P W R 03 B P W R 02 A GREEN D3 1 2 B41 1 2 B REF TO GROUND DISTRIBUTION GND R 02 REF...

Page 4342: ...RB 4 L 2 LR 1 D17 B REF TO GROUND DISTRIBUTION GND R 02 LR 2 L 1 D11 B101 B30 D1 D7 P W R 01 A GB 9 RB 5 RY 4 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B FL U FL D E FRONT LH 1 2 1 2 D17 D13 1 2 3 4 5...

Page 4343: ...1 GB 3 GB D21 R11 B30 D1 D7 P W R 01 B GB 9 GR 13 YR 8 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B RL U RL D E REAR LH 1 2 1 2 D25 D24 1 2 3 4 5 6 REAR POWER WINDOW MOTOR LH GREEN D24 2 GB GR 14 13 YR...

Page 4344: ...GB 3 GB D27 R14 B30 D1 D7 P W R 01 C GB 9 LG 16 LY 14 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B RR U RR D E REAR RH REAR POWER WINDOW MOTOR RH D30 2 GB 11 LG 12 LY LG LY R3 B99 R1 B97 1 2 1 2 D31 D3...

Page 4345: ...CONTROL MODULE F17 2 1 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 BLACK F16 BLACK SUB FAN MOTOR MAIN FAN MOTOR OO WO NON TURBO ENGINE WITH...

Page 4346: ...ELAY 1 3 4 B253 RW B 5 1 LB GL AIR CONDITIONING RELAY HOLDER W L GL L RL LW 3 4 34 31 32 30 3 4 2 1 F16 F27 F29 30A SUB FAN RELAY 2 GL L GR LR 25 28 27 29 F28 SUB FAN RELAY 1 LB B LW LR RL RW GR D17 D...

Page 4347: ...4 B253 RW B 5 1 LB GL AIR CONDITIONING RELAY HOLDER W L GL L RL LW 3 4 34 31 32 30 3 4 2 1 F16 F27 F29 30A SUB FAN RELAY 2 GL L GR LR 25 28 27 29 F28 SUB FAN RELAY 1 LB B LW LR RL RW GR D17 D24 D28 B...

Page 4348: ...ATER REAR ACCESSORY POWER SUPPLY RELAY 1 2 3 4 5 6 7 8 B97 R1 1 3 4 5 6 2 RELAY BLOCK BLACK B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 2 9 3 4 5 6 7...

Page 4349: ...B 3 BW 6 i33 REAR FOG LIGHT SWITCH ON OFF G 5 B REF TO GROUND DISTRIBUTION GND L 05 B 1 LW 2 B196 LR 1 B 2 R64 LB LB 4 F2 B100 LR 1 B 2 D42 REAR FOG LIGHT RH WAGON REAR FOG LIGHT LH WAGON LR 1 B 2 D49...

Page 4350: ...3 B 6 i33 REAR FOG LIGHT SWITCH ON OFF BW 5 B REF TO GROUND DISTRIBUTION GND R 05 B 1 LW 2 B196 LR 1 B 2 R64 LR 1 B 2 D42 REAR FOG LIGHT RH WAGON REAR FOG LIGHT LH WAGON LR 1 B 2 D49 B 1 B BLACK i7 1...

Page 4351: ...D48 SD OC WC B R65 RL R17 B GD B REAR DEFOGGER WAGON EUROPE MODELS D74 REAR DEFOGGER WAGON OTHER MODELS REAR DEFOGGER SEDAN WITH CHOKE COIL REAR DEFOGGER SEDAN WITHOUT CHOKE COIL CHOKE COIL 1 2 3 4 5...

Page 4352: ...WI 297 WIRING SYSTEM REAR WINDOW DEFOGGER SYSTEM MEMO...

Page 4353: ...1 D61 B30 D1 D15 D11 B101 L R DOWN UP L N R ON OFF LH RH UP DOWN REARVIEW MIRROR LH MIRROR HEATER LH RH UP DOWN B REF TO GROUND DISTRIBUTION GND L 02 YR YG LW 3 LG 2 1 1 OH WH 5 4 3 2 RL YR 8 YG 18 LW...

Page 4354: ...R DOWN UP L N R ON OFF LH RH UP DOWN REARVIEW MIRROR RH MIRROR HEATER LH RH UP DOWN B REF TO GROUND DISTRIBUTION GND R 02 YR YG LW 3 LG 2 1 1 OH WH 5 4 3 2 RL YR 8 YG 18 LW 7 LG 6 5 RL YR YG LW LG RL...

Page 4355: ...GREEN C i12 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 R8 1 2 3 4 B44 1 2 3 4 5 6 7 8 9 10 21 9 32 B99 1 2 3 4...

Page 4356: ...BL B11 BrR H6 H4 BL E5 GB BL G 7 BrR 6 BW 8 B 3 2 9 F26 F2 B100 GENERATOR BW 24 REF TO GROUND DISTRIBUTION GND L 02 B REF TO GROUND DISTRIBUTION GND L 04 BrR B 4 2 R8 AT MT B17 F26 GREEN 1 2 3 R8 1 2...

Page 4357: ...2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 GREEN A i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GW B5 TO POWER SUPPLY ROUTING FB 39 IGNITION RELAY IG GW BL A5 i10 A...

Page 4358: ...E5 GB BL G 7 BrR 6 BW 8 B 3 2 9 VDC ABS B62 F26 F45 F2 B100 VDC ABS GENERATOR BW 7 BW BW BW 20 REF TO GROUND DISTRIBUTION GND R 03 B REF TO GROUND DISTRIBUTION GND R 04 BL B 4 2 R8 AT MT B17 BLACK F26...

Page 4359: ...YR L L FB 29 F B FUSE NO 4 ACC TO POWER SUPPLY ROUTING B104 R41 R44 3 4 1 2 1 2 3 4 BLUE BLUE RELAY BLOCK BLACK B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37...

Page 4360: ...MATIC ST 01 ST 01 WI 01085 ST IGNITION SWITCH ST TO POWER SUPPLY ROUTING WB BATTERY 1 1 B14 STARTER MOTOR AT WG MT WB AT MT MT 12 INHIBITOR SWITCH BY 7 BW P R N D 3 2 1 12 WB 11 WG AT T7 T3 B12 T7 B12...

Page 4361: ...1 L 3 OPEN CLOSE SUNROOF SWITCH TILT UP TILT DOWN SUNROOF SWITCH OPEN CLOSE SUNROOF SWITCH SUNROOF CONTROL MODULE MOTOR SEDAN Br 4 G 1 B 3 W 4 L 1 B 3 WG 1 2 3 4 5 6 7 8 F44 B41 1 2 R128 S1 BLACK S2 1...

Page 4362: ...WI 307 WIRING SYSTEM SUNROOF SYSTEM MEMO...

Page 4363: ...OUTLET SOLENOID VALVE PUMP MOTOR HYDRAULIC MODULE FL INLET SOLENOID VALVE FR OUTLET SOLENOID VALVE FR INLET SOLENOID VALVE RL OUTLET SOLENOID VALVE RL INLET SOLENOID VALVE RR OUTLET SOLENOID VALVE RR...

Page 4364: ...DC LH4 04 B VDC LH4 03 C B255 F96 B62 F45 7 13 14 53 28 32 52 9 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 YW 8 16 14 13 15 YW 58 YW VDC LH4 01 A W R G B W R G B SECONDLY PRESSURE SENSOR...

Page 4365: ...OL MODULE F87 B255 TRANSMISSION CONTROL MODULE B56 C ENGINE CONTROL MODULE B134 A B136 C B79 B40 E3 GE B22 B61 BROWN B231 1 2 3 4 B234 1 2 3 4 5 6 1 2 3 4 5 6 7 8 F44 B82 1 2 3 4 5 6 7 8 GRAY GREEN BL...

Page 4366: ...RH 1 2 L P BLACK R73 R72 B6 B15 2 1 1 GRAY 1 GRAY F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 4...

Page 4367: ...PUMP MOTOR HYDRAULIC MODULE FL INLET SOLENOID VALVE FR OUTLET SOLENOID VALVE FR INLET SOLENOID VALVE RL OUTLET SOLENOID VALVE RL INLET SOLENOID VALVE RR OUTLET SOLENOID VALVE RR INLET SOLENOID VALVE...

Page 4368: ...2 52 9 GREEN A i10 YW 8 16 14 13 15 YW 58 YW VDC LH6 01 A W R G B W R G B SECONDARY PRESSURE SENSOR BLACK F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7...

Page 4369: ...LE B134 A B136 C B79 B40 B83 E49 GE B252 B61 BLACK B231 1 2 3 4 B234 1 2 3 4 5 6 1 2 3 4 5 6 7 8 F44 B82 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 DARK GRAY B252 GRAY GREEN BLACK B79 2 3 4 5 6 7 9 1 8 10 11 12...

Page 4370: ...1 BROWN GRAY BROWN GRAY F88 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76 77 75 42 43...

Page 4371: ...PUMP MOTOR HYDRAULIC MODULE FL INLET SOLENOID VALVE FR OUTLET SOLENOID VALVE FR INLET SOLENOID VALVE RL OUTLET SOLENOID VALVE RL INLET SOLENOID VALVE RR OUTLET SOLENOID VALVE RR INLET SOLENOID VALVE...

Page 4372: ...11 53 28 32 52 15 GREEN C i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN A i10 YW 14 16 14 13 15 YW 58 YW VDC RH4 01 A W R G B W R G B SECONDLY PRESSURE SENSOR BLACK F91 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1...

Page 4373: ...19 20 21 B135 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B REF TO GROUND DISTRIBUTION GND R 02 03 B136 C OO C8 A25 C2 A10 C7 A24 WO WITH OB...

Page 4374: ...RW FRONT ABS SENSOR RH 1 2 L P BLACK R73 R72 B6 B15 2 1 1 GRAY 1 GRAY F88 F55 F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53...

Page 4375: ...PUMP MOTOR HYDRAULIC MODULE FL INLET SOLENOID VALVE FR OUTLET SOLENOID VALVE FR INLET SOLENOID VALVE RL OUTLET SOLENOID VALVE RL INLET SOLENOID VALVE RR OUTLET SOLENOID VALVE RR INLET SOLENOID VALVE...

Page 4376: ...W 14 16 14 13 15 YW 58 YW VDC RH6 01 A W R G B SECONDLY PRESSURE SENSOR BLACK F91 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BLACK F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15...

Page 4377: ...RIBUTION GND R 02 03 SHIELD AND SENSOR GROUND JOINT CONNECTOR W 16 WB 17 BL 13 WG 15 WG BL 2 B83 E49 GE B252 19 20 7 10 6 5 4 3 1 2 21 22 F96 B255 F2 B100 BLACK B231 1 2 3 4 B234 1 2 3 4 5 6 B82 1 2 3...

Page 4378: ...K R73 R72 B6 B15 2 1 BROWN GRAY BROWN GRAY F87 56 57 59 60 62 63 65 82 83 80 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 54 55 52 53 50 51 81 48 49 46 47 44 45 78 79 76...

Page 4379: ...2 3 RL B 5 YB 17 LgR 11 GY 16 BL RL 8 B 2 7 B70 B8 F32 YB 17 LgR YB LgR 2 B100 F2 F32 1 2 B70 2 3 6 4 5 7 1 8 9 11 12 15 13 14 16 10 17 18 FRONT WIPER SWITCH INTER MITTENT WIPER MODULE INT VOLUME WAS...

Page 4380: ...B 17 LgR 11 GY 16 BL RL 8 B 2 7 11 17 WF OF 12 2 8 3 B70 B8 F146 B146 1 2 B70 2 3 6 4 5 7 1 8 9 11 12 15 13 14 16 10 17 18 FRONT WIPER SWITCH INTER MITTENT WIPER MODULE INT VOLUME WASHER SWITCH COMBIN...

Page 4381: ...EAR WIPER MOTOR B 2 YG 8 Lg 7 LW YG 3 Br 6 BrW 5 REAR WIPER WASHER SWITCH OFF ON WASH WASH BrW 12 GR 10 B 2 YG 1 BrW 2 YG YG Lg LW 1 Lg 4 LW 2 B 3 B B B B 1 YG 3 Lg 5 LW 4 D35 D33 D43 R37 R39 R116 R3...

Page 4382: ...B YG 1 BrW 2 YG YG Lg LW 1 Lg 4 LW 2 B 3 B B B B 1 YG 3 Lg 5 LW 4 D35 D33 D43 R37 R39 R116 B70 B147 D43 3 4 1 2 B147 R37 1 2 1 2 1 2 3 4 5 6 7 8 R116 D35 1 2 3 4 5 6 7 8 BLACK B70 2 3 6 4 5 7 1 8 9 1...

Page 4383: ...B B36 i1 B177 ON OFF P3 RY OrG O1 GB 4 YG 3 B 1 OrG 2 RY 2 B 1 20 19 21 23 RY 1 B 6 OrG 3 BW 5 LgB 4 WB 2 B SMJ B192 B191 B177 i43 i28 LB 27 LHD RHD 28 GB 24 YG 26 WIPER DEICER TIMER B192 3 4 1 2 i43...

Page 4384: ...WI 329 WIRING SYSTEM WIPER DEICER SYSTEM MEMO...

Page 4385: ...ss 6 Rear door cord RH 11 Rear door cord LH 2 Engine wiring harness 7 Rear wiring harness 12 Front door cord LH 3 Bulkhead wiring harness 8 Roof cord 13 Transmission cord 4 Instrument panel wiring har...

Page 4386: ...H 11 Rear door cord LH 2 Engine wiring harness 7 Rear wiring harness 12 Front door cord LH 3 Bulkhead wiring harness 8 Roof cord 13 Transmission cord 4 Instrument panel wiring harness 9 Fuel tank cord...

Page 4387: ...11 Rear door cord LH 2 Engine wiring harness 7 Rear wiring harness 12 Front door cord LH 3 Bulkhead wiring harness 8 Roof cord 13 Transmission cord 4 Instrument panel wiring harness 9 Fuel tank cord...

Page 4388: ...11 Rear door cord LH 2 Engine wiring harness 7 Rear wiring harness 12 Front door cord LH 3 Bulkhead wiring harness 8 Roof cord 13 Transmission cord 4 Instrument panel wiring harness 9 Fuel tank cord...

Page 4389: ...A 3 A C relay Relay holder F32 2 Green C 3 Front washer motor F33 2 B 3 Rear washer motor F34 4 C 3 SBF holder F35 2 Black B 4 Main fuse box M B F36 3 C 4 F37 6 Black C 4 F38 1 C 4 F39 8 Black B 3 F40...

Page 4390: ...F31 F30 F29 F67 A C relay holder 4 Cylinder engine model A C relay holder 6 Cylinder engine model F6 F16 F17 F47 F26 F91 F49 F82 F24 F25 F23 F58 F32 F33 F88 F19 F34 F38 F68 F55 F54 F87 F78 F21 F73 GB...

Page 4391: ...C relay Relay holder F34 4 C 3 SBF holder F35 2 Black B 4 Main fuse box M B F39 8 Black B 3 F41 7 Gray B 2 Fuse relay box F B F44 8 B 3 B61 Bulkhead wiring harness F45 8 B 3 B62 Bulkhead wiring harne...

Page 4392: ...66 F28 F27 F31 F30 F29 F67 A C relay holder 4 Cylinder engine model A C relay holder 6 Cylinder engine model F6 F16 F47 F25 F26 F91 F49 F24 F55 F41 F86 F83 F23 F79 F81 F58 F19 F34 F35 F17 F5 F21 F73 G...

Page 4393: ...3 B14 1 Black B 3 Starter Magnet B15 2 Brown B 3 Front ABS sensor LH Outback model 2 B 3 Front ABS sensor LH Other models B16 2 Gray B 3 Brake fluid level switch B17 3 B 2 Vehicle speed sensor MT B18...

Page 4394: ...WI 339 WIRING SYSTEM BULKHEAD WIRING HARNESS IN ENGINE ROOM WI 01032 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B155 B17 B18 B19 B10 B25 B22 B328 B21 B11 B29 B12 B14 B16 B17 B6 B7 B8 GB 4 B15 GB 3 B24...

Page 4395: ...ol actuator B8 5 B 3 Front wiper motor B10 4 B 2 A C pressure switch B11 20 Black B 3 T4 Transmission AT B12 12 B 3 T3 B14 1 Black B 3 Starter Magnet B15 2 Brown B 3 Front ABS sensor LH B16 2 Gray B 3...

Page 4396: ...WI 341 WIRING SYSTEM BULKHEAD WIRING HARNESS IN ENGINE ROOM WI 01033 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B10 B22 B252 B21 B19 B11 B12 B14 B16 B6 B20 B7 B8 B15 B253 GB 4 GB 10 GB 3...

Page 4397: ...e speed sensor MT B18 4 B 2 Oxygen sensor B19 4 B 2 T5 Rear oxygen sensor cord With OBD model B20 16 B 2 E1 Engine wiring harness Turbo engine model B21 20 B 2 E2 Engine wiring harness B22 16 Brown B...

Page 4398: ...3 4 5 1 2 3 4 5 A B C D A B C D B155 B20 B6 B18 B16 B19 B128 B220 B3 B17 B22 B21 B328 B18 B146 B147 B22 B21 B212 B15 B144 B186 B143 B145 B7 B148 B14 1 B25 1 B24 2 B11 4 B12 5 B29 3 2 3 4 5 B221 GB 4 G...

Page 4399: ...agnet B15 2 Brown B 3 Front ABS sensor LH B16 2 Gray B 2 Brake fluid level switch B19 6 B 2 T5 Rear oxygen sensor cord B20 16 Dark gray B 2 E1 Engine wiring harness B21 20 B 2 E2 B22 16 Brown B 2 E3 B...

Page 4400: ...IRING SYSTEM BULKHEAD WIRING HARNESS IN ENGINE ROOM WI 01035 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B6 B19 B16 B20 B22 B252 B21 B146 B147 B15 B11 B12 B144 B186 B143 B145 B7 B148 B14 GB 4 GB 3 B8 B253 GB...

Page 4401: ...2 Transmission control module AT B55 24 Gray C 2 B56 24 Green C 2 B61 8 B 2 F44 Front wiring harness B62 16 B 2 F45 Front wiring harness B64 2 Black B 2 Stop light switch B65 4 Black B 2 Stop brake sw...

Page 4402: ...3 B116 B125 B126 B30 B31 B41 B192 B228 B224 B74 B68 B72 GB 6 B43 B82 B79 B137 B135 B83 B101 B90 B176 B91 B35 B88 B86 With OBD model Without OBD model WO WO OO OO WO WO OO B125 B100 B141 B231 B126 B76...

Page 4403: ...connector Without OBD model 2 Green C 1 B125 Line end connector With OBD model B129 2 B 2 Kick down switch AT B131 5 A 2 Rear fog light relay Relay block B133 6 C 3 AT power mode hold mode switch B134...

Page 4404: ...3 B116 B125 B126 B30 B31 B41 B192 B228 B224 B74 B68 B72 GB 6 B43 B82 B79 B137 B135 B83 B101 B90 B176 B91 B35 B88 B86 With OBD model Without OBD model WO WO OO OO WO WO OO B125 B100 B141 B231 B126 B76...

Page 4405: ...odule B55 24 Gray C 2 B56 24 Green C 2 B61 8 B 2 F44 Front wiring harness B62 16 B 2 F45 Front wiring harness B65 4 Black B 2 Stop brake switch B68 5 C 2 Cruise control sub switch B69 4 D 2 Parking sw...

Page 4406: ...4 B157 B191 B48 B225 B42 B131 B133 B116 B30 B31 B41 B192 B228 B231 B224 B74 B68 B72 GB 6 B82 B79 B134 B136 B137 B135 B297 B83 B101 B47 B94 B90 B176 B91 B88 B86 B300 B182 B76 B77 B80 B201 B61 B100 B181...

Page 4407: ...158 10 Gray C 1 Fuse relay box F B B176 18 B 4 Keyless entry control module B177 2 B 1 Wiper deicer B181 1 B 2 B182 Fan ground joint connector B182 1 B 2 B18 Fan ground joint connector B183 1 C 1 B184...

Page 4408: ...4 B157 B191 B48 B225 B42 B131 B133 B116 B30 B31 B41 B192 B228 B231 B224 B74 B68 B72 GB 6 B82 B79 B134 B136 B137 B135 B297 B83 B101 B47 B94 B90 B176 B91 B88 B86 B300 B182 B76 B77 B80 B201 B61 B100 B181...

Page 4409: ...ule B55 24 Gray C 3 B56 24 Green C 3 B61 8 B 3 F44 Front wiring harness B62 8 B 3 F45 Front wiring harness B64 2 Black B 3 Stop light switch B65 4 Black B 3 Stop brake switch With cruise control B68 5...

Page 4410: ...B31 B97 6 B98 7 B99 8 B122 1 B53 2 B54 3 B55 4 B56 5 B86 B88 B91 B75 B76 B136 B135 B137 B84 B134 B77 B237 B133 B116 B82 B79 B80 B43 GB 5 B70 B35 B68 B72 B228 B41 B192 B74 B224 B196 B231 B87 B122 B94 B...

Page 4411: ...Engine control module Turbo engine model 35 Engine control module Non turbo engine model B135 28 C 2 Engine control module B136 24 C 2 Engine control module Turbo engine model 26 Engine control module...

Page 4412: ...B31 B97 6 B98 7 B99 8 B122 1 B53 2 B54 3 B55 4 B56 5 B86 B88 B91 B75 B76 B136 B135 B137 B84 B134 B77 B237 B133 B116 B82 B79 B80 B43 GB 5 B70 B35 B68 B72 B228 B41 B192 B74 B224 B196 B231 B87 B122 B94 B...

Page 4413: ...agnosis connector B83 22 C 1 Shield sensor ground joint connec tor E G B90 6 B 4 R50 Roof cord B94 20 Black C 1 Cruise control module B97 6 B 3 R1 Rear wiring harness B98 20 Blue B 3 R2 B99 20 B 3 R3...

Page 4414: ...57 1 2 3 4 5 6 7 B30 B31 B98 5 B99 6 B100 7 B53 1 B54 2 B55 3 B56 4 B176 B75 B76 B300 B32 B136 B135 B137 B134 B133 B116 B82 B79 B80 B35 B182 GB 5 B69 B71 B68 B72 B228 B41 B192 B74 B224 B196 B231 B101...

Page 4415: ...osition sensor Without OBD model Gray Camshaft position sensor With OBD model E16 2 Light gray B 3 Injector 2 E17 2 Light gray B 4 Injector 4 E18 6 Dark gray B 3 Exhaust gas recircration solenoid E19...

Page 4416: ...SYSTEM ENGINE WIRING HARNESS AND TRANSMISSION CORD WI 01040 1 2 3 4 5 1 2 3 4 5 A B C D A B C D T6 T5 T3 T4 T7 GE E3 E2 E58 E21 E20 E7 E13 E12 E6 E5 E4 E8 E53 E19 E11 E10 T5 T2 T1 T8 T6 E14 E18 E16 E...

Page 4417: ...3 Throttle position sensor E14 2 Gray B 3 Knock sensor E15 2 Light gray B 3 Camshaft position sensor E16 2 Dark gray B 3 Injector 2 E17 2 Dark gray B 4 Injector 4 E19 1 B 2 Power steering oil pressure...

Page 4418: ...NG SYSTEM ENGINE WIRING HARNESS AND TRANSMISSION CORD WI 01041 1 2 3 4 5 1 2 3 4 5 A B C D A B C D T6 T5 T3 T4 T7 GE E21 E7 E1 E13 E14 E32 E34 E31 E6 E33 E5 E8 E4 E19 E11 E10 T5 T9 T6 E39 E16 E15 E3 E...

Page 4419: ...4 E18 6 Dark gray A 3 Exhaust gas recircration solenoid valve E19 1 C 2 Power steering oil pressure switch E20 2 Black A 3 Intake air temperature sensor E21 3 Black A 2 Pressure sensor E24 4 Dark gra...

Page 4420: ...INE WIRING HARNESS AND TRANSMISSION CORD WI 01042 1 2 3 4 5 1 2 3 4 5 A B C D A B C D E1 E7 T6 T5 E47 E5 E6 E43 E49 E3 E2 E14 E10 E16 E17 E44 E46 E34 E32 E24 E8 E48 E19 E45 E15 E33 E11 E31 E30 E21 E13...

Page 4421: ...ch i20 8 Black C 2 B80 Bulkhead wiring harness i21 2 C 3 Ash tray illumination light i22 8 B 3 Hazard switch i23 2 B 4 Glove box illumination light i24 2 C 3 Front accessory power supply socket i25 2...

Page 4422: ...5 A B C D A B C D i5 i1 i39 i7 i33 i19 i20 i26 i60 i61 i53 i23 i62 i19 i43 i40 i55 i17 i22 i49 i48 i51 i15 i21 i28 i25 i24 GR GB 7 i29 Switch is in sterring side panel Switch is in center panel 4 Cyli...

Page 4423: ...g harness i21 2 C 2 Ash tray illumination light i22 8 B 2 Hazard switch i23 2 B 1 Glove box illumination light i24 2 C 2 Front accessory power supply socket i25 2 C 2 Front accessory power supply sock...

Page 4424: ...1 2 3 4 5 A B C D A B C D 4 Cylinder engine model 6 Cylinder engine model H4 H4 H6 i51 i23 i52 i22 i48 i45 i26 i21 i28 GB 7 i24 i25 i20 i62 i39 i60 i61 i33 i7 i7 i1 i5 i19 i43 i10 i12 i12 i11 GR i29 i...

Page 4425: ...Blue B 3 Seat heater RH R42 6 C 3 Seat heater switch RH R43 6 Blue C 3 Seat heater switch LH R44 4 Blue C 3 Seat heater LH R49 8 C 3 F55 Front wiring harness R50 4 B 2 B90 Bulkhead wiring harness With...

Page 4426: ...WI 371 WIRING SYSTEM REAR WIRING HARNESS WI 01045 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R50 R98 R3 R1 GB 8 R12 R14 R51 R55 R52 R56 R54 R73 R72 R9 R11 R16 R41 R43 R42 R8 R44 R109 R4 R70 R49...

Page 4427: ...eater switch LH R44 4 Blue C 3 Seat heater LH R49 8 B 1 F55 Front wiring harness R50 4 B 2 B90 Bulkhead wiring harness Without vanity mirror illumi 6 B 2 B90 Bulkhead wiring harness With vanity mirror...

Page 4428: ...373 WIRING SYSTEM REAR WIRING HARNESS WI 01046 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R50 GB 8 R12 R51 R14 R55 R52 R56 R54 R73 R72 R9 R11 R16 R43 R42 R109 R44 R4 R70 R98 R101 R49 R2 R3 R1 R99 R41 R110 R...

Page 4429: ...switch RH R43 6 Blue B 3 Seat heater switch LH R44 4 Blue C 3 Seat heater LH R49 8 C 3 F55 Front wiring harness without VDC model 12 C 3 Front wiring harness with VDC model R50 6 B 2 B90 Bulkhead wiri...

Page 4430: ...WI 375 WIRING SYSTEM REAR WIRING HARNESS WI 01047 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R50 GB 8 R12 R14 R51 R55 R52 R56 R54 R128 R73 R72 R9 R11 R16 R43 R109 R44 R42 R41 R8 R4 R70 R100 R49 R98 R1 R3...

Page 4431: ...R42 6 C 3 Seat heater switch RH R43 6 Blue C 3 Seat heater switch LH R44 4 Blue C 3 Seat heater LH R49 8 B 2 F55 Front wiring harness without VDC model 12 B 2 Front wiring harness with VDC model R50 6...

Page 4432: ...WI 377 WIRING SYSTEM REAR WIRING HARNESS WI 01048 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R50 GB 8 R12 R14 R52 R55 R54 R73 R72 R9 R11 R16 R56 R51 R16 R43 R42 R109 R44 R4 R70 R100 R98 R49 R2 R3 R1 R8 R41...

Page 4433: ...RH D14 2 Black B 2 Front door tweeter RH D15 6 B 2 Remote control rearview mirror RH Without mirror heater 8 B 2 Remote control rearview mirror RH With mirror heater D17 6 B 2 Front power window sub...

Page 4434: ...WI 379 WIRING SYSTEM DOOR CORD WI 01049 1 2 3 4 5 1 2 3 4 5 A B C D A B C D D14 D15 D17 D11 D12 D13 D18 D27 D20 D29 D1 D4 D5 D61 D7 D72 D2 D3 D10 D21 D23 D24 D25 D26 D30 D31 D32...

Page 4435: ...15 6 C 3 Remote control rearview mirror LH Without mirror heater 8 C 3 Remote control rearview mirror LH With mirror heater D17 6 B 3 Front power window sub switch LH D18 4 B 3 Front door lock actuato...

Page 4436: ...WI 381 WIRING SYSTEM DOOR CORD WI 01050 1 2 3 4 5 1 2 3 4 5 A B C D A B C D D4 D5 D61 D7 D1 D2 D68 D3 D72 D27 D10 D29 D11 D69 D14 D15 D17 D18 D12 D13 D20 D21 D23 D24 D25 D26 D30 D31 D32...

Page 4437: ...15 Rear wiring harness R58 6 C 2 Fuel gauge module fuel pump assembly R59 2 C 2 Fuel gauge sub module R60 8 B 4 R24 Rear wiring harness R62 4 C 4 Rear finisher light RH R63 2 C 3 License plate light R...

Page 4438: ...SYSTEM REAR WIRING HARNESS AND TRUNK LID CORD WI 01051 1 2 3 4 5 1 2 3 4 5 A B C D A B C D GB 11 R22 R97 R122 R124 R125 R15 R57 R59 R58 R126 R127 R19 R20 R117 R130 R24 R60 R28 R64 R79 R26 R62 R27 R63...

Page 4439: ...tenna amplifier R116 8 C 3 Rear wiper intermittent module R122 10 C 1 Fuel pump control module R124 1 C 1 R125 Fuel pump control module shield joint connector R125 1 C 1 R124 Fuel pump control module...

Page 4440: ...WIRING HARNESS AND REAR GATE CORD 1 2 3 4 5 1 2 3 4 5 A B C D A B C D D49 D47 D48 D43 D45 D40 D39 GB 11 D37 D38 D34 D35 R39 R38 R26 R22 R97 R124 R125 R32 R28 R25 R59 R15 R57 R58 R79 R116 R122 D46 D47...

Page 4441: ...WI 386 WIRING SYSTEM REAR WIRING HARNESS AND REAR GATE CORD MEMO...

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Subaru 2003 Legacy, Service Manual

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Summary of Contents for 2003 Legacy

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