Subaru 2009 IMPREZA Service Manual Download Page 2113 | Manualshive

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5MT-41

Transfer Drive Gear

MANUAL TRANSMISSION AND DIFFERENTIAL

E: INSPECTION

1) Bearing
Replace the bearings in the following cases.
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
2) Drive gear
If the drive gear tooth surface and shaft are exces-
sively broken or damaged, replace the drive gear.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.

Clearance:

0.01 — 0.15 mm (0.0004 — 0.0059 in)

If the measurement is not within specification, se-
lect a suitable snap ring and replace it.

Snap ring (Outer-30)

Part number

Thickness mm (in)

805030041

1.53 (0.0602)

805030042

1.65 (0.0650)

805030043

1.77 (0.0697)

MT-00138

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Summary of Contents for 2009 IMPREZA

Page 1: ...anuals are used when performing mainte nance repair or diagnosis of Subaru IMPREZA Applicable model 2009MY GE GH The manuals contain the latest information at the time of publication Changes in the sp...

Page 2: ...URE 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 and...

Page 3: ...parts refer to parts catalogue Example HU 00017 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 T...

Page 4: ...are included in one service procedure appropriate reference is provided for each parts Example A Component D Cautions G Tightening torque B Process E Tool number of special tool H Illustration C Refe...

Page 5: ...AGNOSIS 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 inclu...

Page 6: ...ration CD Compact Disc OP Option Parts COMPL Complete OBD On Board Diagnosis CPU Central Processing Unit P S Power Steering DOHC Double Overhead Camshaft P W Power Window DTC Diagnosis Trouble Code PC...

Page 7: ...155 6 1 160 6 3 Model 2 5 L Turbo 2 5 L turbo WRX SS model 2 5 L Engine type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement DOHC SOHC Bore stroke mm in 99 5 7...

Page 8: ...id Gear ratio 3 900 3 900 3 900 4 111 Reduction gear Rear Transfer reduction Type of gear Helical Helical Gear ratio 1 000 1 000 Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid Gear ratio 3 9...

Page 9: ...eplacing engine oil only 2 US qt Imp qt 4 0 4 2 3 5 Transmission gear oil 2 US qt Imp qt 3 5 3 7 3 1 3 5 3 7 3 1 ATF 2 US qt Imp qt 9 3 9 6 9 8 10 1 8 2 8 4 9 3 9 6 9 8 10 1 8 2 8 4 Front differential...

Page 10: ...6 610 1 345 620 1 367 Gross vehicle weight G V W kg lb 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 Gross axle weight G A W F...

Page 11: ...1 366 620 1 366 625 1 377 Gross vehicle weight G V W kg lb 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 990 4 387 1 990 4 387 1 990 4 387 Gross axle weight G A W Front kg...

Page 12: ...30 1 389 635 1 400 Gross vehicle weight G V W kg lb 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 Gross axle weight G A W Front kg lb 1 02...

Page 13: ...0 1 345 620 1 367 Gross vehicle weight G V W kg lb 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 Gross axle weight G A W Front...

Page 14: ...20 1 367 620 1 367 620 1 366 620 1 366 Gross vehicle weight G V W kg lb 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 950 4 299 1 990 4 387 1 990 4 387 Gross ax...

Page 15: ...389 630 1 389 635 1 400 Gross vehicle weight G V W kg lb 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 1 990 4 387 Gross axle weight G A...

Page 16: ...id bodily injury and interrupting traffic 6 AIRBAG To prevent bodily injury from unexpected deploy ment of airbags and unnecessary maintenance fol low the instructions in this manual when performing m...

Page 17: ...y to prevent from penetrating into floor or flowing out for environmental protection Follow all government and local regulations con cerning disposal of refuse when disposing 14 ENGINE COOLANT When ha...

Page 18: ...PC 4 Precaution PRECAUTION...

Page 19: ...6 ENSURING SECURITY DURING WORK When working in a group of two or more perform the work with calling each other to ensure mutual safety 7 LIFT AND JACK When using a lift or shop jack to raise a vehicl...

Page 20: ...reach the supporting locations The figure of vehicle indicates the supporting locations supporting procedures etc for 5 door model and they are same for 4 door model Supporting locations Pantograph j...

Page 21: ...NT 4 Note NOTE Lift Rigid rack A Attachment NT 00241 A A Attachment NT 00242 A...

Page 22: ...ign the center of attachment with the center of cutout portions Front Rear Model with side sill spoiler For the models with side sill spoiler align the center of attachment with the center of vehicle...

Page 23: ...NT 6 Note NOTE A Front B Rear 1 Front crossmember 2 Rear differential 1 2 A B NT 00210...

Page 24: ...TIE DOWNS The tie down hooks are used when transporting vehicles and when using the chassis dynamo Attach tie down only to the specified locations on the vehicle TIE DOWN LOCATION 1 Hook for tie down...

Page 25: ...NT 8 Note NOTE TIE DOWN HOOK EYE BOLT A Front tie down hook B Rear tie down hook C Eye bolt NT 00213 A B C...

Page 26: ...NT 9 Note NOTE TIE DOWN DIRECTION CAUTION Pull the tie down chains LH and RH in the same direction but front and rear side in the counter di rection Recommended NG Tie down direction NT 00214 NT 00215...

Page 27: ...he rear tie down hooks from vehicle inside When the vehicle is tied down from vehicle outside hook the hooks of tie down chain on the rear tie down hooks from vehicle outside A Front tie down hook B R...

Page 28: ...y used for towing and sea transportation tie down and do not use them for ground and freight transportation A Front tie down hook C Chain pulling range at tie down condition D 400 mm 15 7 in B Eye bol...

Page 29: ...at tie down condition are appropriate in the following procedures 1 Measure the distance A between the center of wheel and highest arch point 2 Compare the measured dimensions of before and after tie...

Page 30: ...use the holes at the front side When the vehicle is tied down from vehicle inside hook the hooks of tie down chain from vehicle inside and when the vehicle is tied down from vehicle outside hook the...

Page 31: ...carrier truck instead of towing When towing other vehicles pay attention to the following to prevent hook or vehicle damage resulting from excessive weight Do not tow other vehicles with a front tie...

Page 32: ...NT 15 Note NOTE REAR CAUTION When tightening the eye bolt using a wheel wrench be careful not to scratch the bumper 1 Eye bolt 2 Jack handle 2 NT 00192 1 1 A Eye bolt B Wheel wrench B A NT 00224...

Page 33: ...vehicle lower side because of little clearance under the front bumper Use a supporting board rubber where the clearance is too small Perform the operation being careful with the position shown in the...

Page 34: ...HOOD COMPONENT General Description CAUTION Always perform works such as inspections and maintenance with both damper stays attached Do not leave one side of damper stay removed The hood cannot be clo...

Page 35: ...ing contact a dealer or agent 13 GENERAL SCAN TOOL Using general scan tools will greatly improve the ef ficiency of repairing engine electronic controls Subaru Select Monitor can be used to diagnose t...

Page 36: ...LOCATIONS The V I N Vehicle Identification Numbers is used to classify the vehicle POSITIONING OF THE LABEL FOR IDENTIFICATION 1 Vehicle identification number V I N 2 Emission control label 4 MVSS la...

Page 37: ...ISSION 5MT REAR DIFFERENTIAL MODEL NUMBER LABEL 1 Engine serial number 2 Engine type Crankcase upper side 1 AT type and transmission serial number label 1 MT type and transmission serial number ID 000...

Page 38: ...2 5 L AWD 7 2 5 L AWD turbo 7 3 Grade 0 2 5 i Limited 1 2 5 i 2 2 5 i S 3 OUTBACK SPORTS 4 2 5 GT 5 WRX S MT 2 5 GT S AT 6 WRX SS 8 6 Restraint 6 Manual belts dual airbag side airbag 9 X Check digit 0...

Page 39: ...ifferential 3 and 4 75 Classification 75 5MT 5 8 Series 8 5MT 6 V Transmission specifications V Full time AWD single range 5MT with viscous coupling center differential 7 C Mounted engine C 925 SOHC W...

Page 40: ...mber F I K N T U V Y Z Aluminum wheel Cruise control Leather package Genuine leather seat High grade audio Navigation system Satellite tuner Rear disc brake package Audio satellite switch F G J O W Z...

Page 41: ...aded gasoline In order to reduce air pollution use unleaded gas oline for the vehicle equipped with catalytic con verter Using leaded gasoline may damage the catalytic converter 3 LUBRICANTS Use the l...

Page 42: ...erature Engine oil 1 10W 30 10W 40 2 5W 30 5W 40 Recommended Manual transmission oil front differential gear oil and rear differential gear oil F 22 4 14 50 68 86 104 C 30 20 10 0 10 20 30 40 32 2 1 R...

Page 43: ...aterials Alternative Remarks Automatic transmission fluid SUBARU ATF IDEMITSU ATF HP Power steering fluid SUBARU ATF HP DEXRON III Brake fluid SUBARU genuine brake fluid FMVSS No 116 DOT3 Clutch fluid...

Page 44: ...GTIGHT LYW No 2 grease KOPR KOTE Clutch release lever Steering shaft bearing MT main shaft oil seal lip Select lever shift lock KOPR KOTE 003603001 Steering gearbox VALIANT GREASE M 2 003608001 ONE LU...

Page 45: ...mission oil pan AT model THREE BOND 1217B K0877YA020 Rear differential Oil pressure switch Engine THREE BOND 1324 004403042 Rear differential Service hole plug THREE BOND 1105 004403010 DOW CORNING No...

Page 46: ...the vehicle is about to be delivered to customer attach the room lamp fuse 4 Door lock unlock and open close operations 1 Using the key check the door can be locked or unlocked normally 2 Open and clo...

Page 47: ...hat are equipped on vehicle 2 60 seconds after turning ignition switch from ON to ACC or OFF or imme diately after removing the key check that the security indicator light is blinking 29 Starting cond...

Page 48: ...ND OPEN CLOSE OPERATIONS 1 Using the key lock and unlock the door several times to check for normal operation Open and close the door several times for smooth movement 2 Close the door of driver seat...

Page 49: ...de 5 CHILD SAFETY LOCK 1 Set the child safety lock lever on both rear doors to the lock position 2 Close the rear doors completely 3 Check that the lock levers of the rear doors are in the unlock posi...

Page 50: ...e the rear gate 2 Operate the lever using a tool such as a screwdriver to check that the rear gate is un locked normally 8 OPERATION CHECK OF TRUNK LID RELEASE HANDLE 1 Use a flat tip screwdriver Slid...

Page 51: ...l lid is unlocked normally Check that the fill er cap is securely closed 10 ACCESSORY Check that the following accessories are provided Owner s manual Warranty booklet Maintenance note Spare key Key N...

Page 52: ...t or corrosions due to fluid leaks Check that the battery caps are securely tightened 13 BRAKE FLUID Check the brake fluid amount If the amount is in sufficient carry out a brake line test to identify...

Page 53: ...ck the AT front differential oil amount If the amount of oil is insufficient check for leaks Then add the necessary amount of the specified AT front differential oil CAUTION If gear oil is spilt over...

Page 54: ...all the door windows Remove the key from the ignition switch and close all the doors including rear gate Press the LOCK ARM button momentarily on the keyless transmitter Check that all the doors be c...

Page 55: ...door lock switch Next close all the doors including rear gate Check if all doors are locked and buzzer sounds once and the hazard light flashes once Driver s side Passenger s side Alarm sound operatio...

Page 56: ...lock buzzer sounds once the hazard light flashes once and the security display light flashes as indicated below the alarm system is in the monitoring condition Alarm system monitoring prepared conditi...

Page 57: ...r with one of the doors including the rear gate opened 9 Check that the buzzer sounds 5 times to give the door not fully closed warning 10 Close all the doors including rear gate 11 Check that the sys...

Page 58: ...zard light flashes security indicator illuminates 20 Check that the condition in 19 continues for 30 seconds or more or until the UNLOCK DISARM button of the keyless transmitter is pressed 21 Check th...

Page 59: ...nger get out of the passenger s seat and check whether the OFF light of the pas senger side airbag ON OFF indicator illuminates 24 SEAT BELT 1 Pull out the seat belt and then release it Check that the...

Page 60: ...ormal condition 3 System failure Normal condition System failure IG ON During tire pressure decrease warning or ID has not registered 1 Light OFF 1 Illuminates after 25 blinks ON OFF 1 PI 00375 ON OFF...

Page 61: ...7 Go to step 6 6 DIAGNOSIS 1 Check the trouble history using the Subaru Select Monitor Is DTC displayed on the Subaru Select Monitor Repair the trouble cause Ref to TPM diag 2 PROCEDURE Basic Diagnost...

Page 62: ...30 EXHAUST Listen to the exhaust noise to see if no noises are observed Check that no leaks are found 31 INDICATOR AND WARNING LIGHTS Check that all indicator lights and warning lights are operating...

Page 63: ...control mirror operates nor mally 44 BRAKE TEST Check the foot brake for normal operations 45 PARKING BRAKE Check the parking brake for normal operations When pulling the parking brake lever with a fo...

Page 64: ...n or which must be kept dry Close all the windows and doors securely Close the front hood trunk lid and rear gate before start ing the test Connect a hose to a tap and spray water on the vehicle The r...

Page 65: ...Check the whole vehicle body for flaking paint damage by transportation corrosion dirt cracks or blisters NOTE It is better to determine an inspection pattern in order to avoid missing an area since t...

Page 66: ...PI 22 Pre delivery Inspection PRE DELIVERY INSPECTION...

Page 67: ...eral Description PERIODIC MAINTENANCE SERVICES 1 General Description A GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before the...

Page 68: ...urbo model R R Turbo model 4 Drive belt s I I I R 5 Camshaft drive belt I I I R 6 Fuel line I I I I Note 1 7 Fuel filter R R 8 Air cleaner element R R R R Note 2 9 Cooling system I I I I 10 Engine coo...

Page 69: ...gram 2 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 3 A tire should be replaced when the tread wear indicator appears as a solid band ac...

Page 70: ...81 4 96 108 120 132 144 156 168 180 192 1 000 miles 3 7 5 15 22 5 30 37 5 45 52 5 60 67 5 75 82 5 90 97 5 105 112 5 120 1 Engine oil R R R R R R R R R R R R R R R R R 2 Engine oil filter R R R R R R R...

Page 71: ...uel line 7 5 months I 12 000 km 7 500 miles Transmission oil 15 months R 24 000 km 15 000 miles ATF 15 months R 24 000 km 15 000 miles Front and rear differential oil 15 months R 24 000 km 15 000 mile...

Page 72: ...level Recommended oil Refer to RM section for the engine oil vis cosity Ref to RM 2 LUBRICANTS RECOM MENDED MATERIALS Recommended Materials Engine oil capacity Refer to SPC section for the engine oil...

Page 73: ...the engine and warm it up for a time 6 After turning off the engine wait a few minutes for the oil to return to the oil pan before checking the level NOTE Just after driving or while the engine is wa...

Page 74: ...by pulling the boot Do not pull the cord itself 4 Remove the spark plug with a spark plug socket 5 Install in the reverse order of removal Tightening torque 21 N m 2 1 kgf m 15 5 ft lb 2 SOHC MODEL LH...

Page 75: ...que Ignition coil 16 N m 1 6 kgf m 11 8 ft lb 4 DOHC MODEL LH 1 Remove the battery and battery carrier 2 Disconnect the air duct from the secondary air pump 3 Remove the bolts attaching the air duct t...

Page 76: ...V belt tension and adjust it if neces sary by changing the generator installing position or idler pulley installing position Ref to PM 13 REPLACEMENT V belt Belt tension A When replacing 7 9 mm 0 276...

Page 77: ...he V belt With using tension gauge 8 Stop the engine and then check the belt tension and adjust it With using tension gauge 9 Idle the engine for approx 1 min to normalize the V belt With using tensio...

Page 78: ...ers 4 Remove the V belts Ref to ME H4SO 39 REMOVAL V belt 5 Remove the crank pulley Ref to ME H4SO 46 REMOVAL Crank Pulley 6 Remove the timing belt cover Ref to ME H4SO 48 REMOVAL Timing Belt Cover 7...

Page 79: ...Ref to CO H4DOTC 25 REMOVAL Radiator Main Fan and Fan Motor Ref to CO H4DOTC 27 REMOVAL Radiator Sub Fan and Fan Motor 2 Protect the radiator with cardboard and blanket 3 Remove the V belts Ref to ME...

Page 80: ...ing the timing belt be sure to align all alignment marks on the belt with corre sponding marks on the sprockets If incorrectly installed interference between pistons and valves may occur B INSPECTION...

Page 81: ...s C on intake and exhaust camshaft pulley RH side are aligned 2 Make sure single line D on exhaust cam shaft pulley RH side is aligned to timing belt cover notch E 3 Make sure single line A on intake...

Page 82: ...internally so check pipes areas near pipes and engine compartment piping for rust hose damage loose band etc If faulty parts are found repair or replace them Non turbo model Ref to FU H4SO 76 Fuel Del...

Page 83: ...r A REPLACEMENT For fuel filter replacement procedure refer to FU section Non turbo model Ref to FU H4SO 70 Fuel Filter Turbo model Ref to FU H4DOTC 78 Fuel Filter B INSPECTION If the filter is clogge...

Page 84: ...r cleaner case rear and air cleaner element 6 Install in the reverse order of removal CAUTION Be sure to use SUBARU genuine air cleaner el ement depending on the engine type when re placing the air cl...

Page 85: ...re sensor 4 Remove the clip B from the air cleaner case 5 Open the air cleaner case and remove the air cleaner element 6 Install in the reverse order of removal CAUTION Be sure to use SUBARU genuine a...

Page 86: ...r with coolant Wipe off check points before applying pressure Use care not to spill coolant when detaching tester from radiator Do not remove the radiator side cap Turbo model 2 Check the radiator cap...

Page 87: ...rmostat Ref to CO H4SO 19 Radiator Ref to CO H4SO 22 Radiator Cap Turbo model Ref to CO H4DOTC 16 Water Pump Ref to CO H4DOTC 18 Thermostat Ref to CO H4DOTC 20 Radiator Ref to CO H4DOTC 24 Radiator Ca...

Page 88: ...ce other engine coolant may cause corrosion 11 Close the radiator cap or the coolant filler tank cap on turbo models and start the engine Race 5 to 6 times at 3 000 rpm or less then stop the en gine C...

Page 89: ...e find the proper SUBARU Super Coolant concentration in the table and add dilution water to the SUBARU Super Coolant concentrat ed type until it reaches the proper dilution Recommended engine coolant...

Page 90: ...for fluid leaks If fluid leaks are found repair or replace If fluid leaks are not found add clutch fluid to bring it up to MAX C of clutch reservoir tank Recommended clutch fluid Refer to RM section R...

Page 91: ...then tight en the drain plug to specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft lb Aluminum gas ket silver 70 N m 7 1 kgf m 51 6 ft lb Copper gasket brown 70 N m 7 1 kgf m 51 6 ft lb Metal...

Page 92: ...pilt over exhaust pipe wipe it off with cloth to avoid emitting smoke or caus ing a fire 6 Check ATF level after raising ATF temperature to 70 80 C 158 176 F by driving the vehicle for 5 10 km 3 6 mil...

Page 93: ...heck the level and leaks of the ATF Ref to PM 28 INSPECTION Automatic Transmission Fluid A Level gauge B Inspection position when HOT 70 80 C 158 176 F C Upper level D Lower level E Inspection positio...

Page 94: ...plug hole If the level is low refill up to the bottom of filler plug B REPLACEMENT 1 FRONT DIFFERENTIAL MT MODEL For MT model differential oil is used as manual transmission oil for lubricating the di...

Page 95: ...plug after draining oil NOTE Apply liquid gasket to the drain plug threads Liquid gasket THREE BOND 1105 Part No 004403010 Tightening torque 49 N m 5 0 kgf m 36 2 ft lb 4 After installing the drain p...

Page 96: ...etc on master cylinder and wheel cylinder NOTE When the brake fluid level in the reservoir tank is lower than specified limit the brake warning light on the combination meter will illuminate Visually...

Page 97: ...tch thread end against the stopper 8 Check that the clearance C between stop per and brake switch thread end is within the specification 9 Pull the pedal pad and check the play Check that the stop lig...

Page 98: ...onnect the vacuum hose to inspect function of check valve Blow compressed air into vacuum hose from the end of brake booster side Check that the air flows from the air hose on engine side Next blow ai...

Page 99: ...brake fluid Recommended brake fluid Refer to RM section Ref to RM 4 FLUID RECOMMENDED MATERIALS Recommend ed Materials Perform the same procedure as for bleeding the brake line until new brake fluid...

Page 100: ...r and correct or replace if it is damaged or worn Front Rear 4 Remove the caliper body Ref to BR 16 Front Disc Brake Assembly Ref to BR 23 Rear Disc Brake Assembly 5 Tighten the wheel nuts to secure d...

Page 101: ...dents or other damage If the inside surface of the brake drum is streaked correct the surface with emery cloth 200 or more If it is unevenly worn or tapered or the outer surface of the brake drum is d...

Page 102: ...adjusting screw in the direction of the arrow shoe extension direction as shown in the figure until it is locked slightly until the disc no longer rotates with both hands 5 Loosen the adjusting screw...

Page 103: ...nt If the free play exceeds the standard replace the ball joint Ref to FS 17 Front Ball Joint 5 Damage of dust boots Visually inspect the ball joint dust boots If it is dam aged remove the front arm R...

Page 104: ...within tolerance Toe in Camber Thrust angle Ref to RS 8 Wheel Alignment 2 When the camber angle does not conform to tol erance value visually inspect the following compo nents If the deformation is ob...

Page 105: ...le 7 While supporting the front drive shaft horizontal ly with one hand turn the hub with the other hand to check for noise or binding If the hub is noisy or binds replace the front hub unit 2 REAR HU...

Page 106: ...e front axle boots A and rear axle boots B for deformation damage or failure If faulty re place with a new part Ref to DS 26 Front Drive Shaft Ref to DS 30 Rear Drive Shaft 2 PROPELLER SHAFT Inspect t...

Page 107: ...2 If the tire appears to be worn unevenly adjust the wheel alignment 3 Next make a tire rotation between front and rear as shown in the figure make sure tires are worn evenly When the direction of tir...

Page 108: ...icle and check the following items during operation 1 Steering force The effort required for steering should be smooth and even at all points and should not vary 2 Pulled to one side Steering wheel sh...

Page 109: ...3 of entire perimeter of adjusting screw thread 4 Install the lock nut While holding the adjust ing screw with a wrench tighten the lock nut us ing ST ST 926230000 SPANNER Tightening torque lock nut...

Page 110: ...ts and or replace their parts NOTE Wipe the leaked fluid off after correcting fluid leaks Also pay attention to clearances between hoses or piping and other parts when inspecting fluid leaks 7 HOSES O...

Page 111: ...A C Filter A REPLACEMENT 1 Remove the glove box damper 2 Disengage the stopper section and pull the glove box lid to remove it 3 Pinch the claw to unlock and remove the A C fil ter 4 Install in the re...

Page 112: ...PM 48 A C Filter PERIODIC MAINTENANCE SERVICES...

Page 113: ...CATION Fuel tank Capacity 64 2 16 9 US gal 14 1 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 550 850 kPa 5 6 8 7 kg cm2 79 7 123 2 psi Discharge rate 125 2 33 US...

Page 114: ...l Description FUEL INJECTION FUEL SYSTEMS B COMPONENT 1 INTAKE MANIFOLD T1 T1 5 12 T3 T1 16 2 T3 6 14 17 18 T1 T1 1 T1 T3 T3 T3 10 11 10 11 10 11 8 T3 7 13 10 11 4 4 2 T3 T3 13 T3 FU 04391 9 T3 T3 T4...

Page 115: ...12 Purge control solenoid valve Tightening torque N m kgf m ft lb 5 Plug cord stay 13 Plug cord holder T1 6 4 0 7 4 7 6 EGR valve 14 Fuel pipe ASSY T2 17 1 7 12 5 7 Fuel pipe protector RH 15 Nipple T...

Page 116: ...3 CRANKSHAFT POSITION CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 3 Camshaft position sensor Tightening torque N m kgf m ft lb 2 Knock sensor 4 Camshaft position sensor support T...

Page 117: ...FU H4SO 6 General Description FUEL INJECTION FUEL SYSTEMS 4 FUEL TANK T4 T1 T4 T3 T3 T3 T2 T3 T3 T4 5 17 4 3 18 19 20 2 15 16 10 13 12 7 6 9 8 1 T2 T3 17 T1 14 11 FU 04412 21 21...

Page 118: ...3 Fuel tank band LH 12 Fuel sub level sensor gasket 21 Self locking nut 4 Delivery tube 13 Fuel sub level sensor filter 5 Jet pump tube 14 Fuel sub level sensor protector Tightening torque N m kgf m f...

Page 119: ...SYSTEMS 5 FUEL LINE FU 03433 D C 13 T2 D 2 4 T1 3 5 T1 T1 1 7 8 11 12 1 1 10 T3 T2 B A 2 E T2 A B 6 E 17 19 C T4 T4 T4 33 31 32 F F T2 T3 T2 1 1 1 1 40 40 T2 30 29 1 15 14 16 1 1 1 T2 21 1 1 22 1 1 23...

Page 120: ...nsor bracket A 7 Evaporation hose A 23 Pressure control solenoid valve bracket A 37 Fuel tank pressure sensor bracket B 8 Evaporation hose B 38 Pressure hose 9 Clamp 24 Pressure control solenoid valve...

Page 121: ...ion pipe A 8 Evaporation hose A 14 Evaporation hose C 3 Fuel filler cap 9 Grommet 4 Filler ring 10 Evaporation pipe B Tightening torque N m kgf m ft lb 5 Filler pipe gasket 11 Quick connector T1 4 4 0...

Page 122: ...7 FUEL PUMP 1 Sub tank bracket ASSY 6 Fuel filter 10 Sub tank 2 O ring 7 Clip 11 Cushion 3 O ring 8 Spacer 12 Fuel level sensor 4 Fuel pump harness 9 Pump ASSY 13 Fuel temperature sensor 5 Spring 1 4...

Page 123: ...ents are extremely hot after driv ing Be wary of receiving burns from heated parts Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the...

Page 124: ...ICK CONNECTOR RELEASE Used for removing the quick connector 18471AA000 FUEL PIPE ADAPTER Used for draining fuel 1B022XU0 SUBARU SELECT MONITOR III KIT Used for draining fuel and each inspection TOOL N...

Page 125: ...re sensor con nector B 8 Disconnect the engine coolant hoses A from throttle body 9 Remove the bolts B which secure the throttle body to the intake manifold and remove the throttle body B INSTALLATION...

Page 126: ...NGINE NORMAL MODE OPERA TION Subaru Select Monitor A To ECM connector Throttle sensor Accelerator pedal Terminal No Standard Main Not depressed Full closed 18 and 29 Approx 0 6 V Depressed Full opened...

Page 127: ...intake duct air intake chamber and intake boot Ref to IN H4SO 8 REMOVAL Air Intake Duct Ref to IN H4SO 7 REMOVAL Air Intake Chamber 9 Remove the generator Ref to SC H4SO 16 REMOVAL Generator 10 Disco...

Page 128: ...ng pump switch A 20 Disconnect the connector from the oil pressure switch B 21 Disconnect the connector from camshaft posi tion sensor 22 Disconnect the front oxygen A F sensor con nector A and rear o...

Page 129: ...AUTION Be careful not to spill fuel Catch the fuel from hoses using a container or cloth 28 Remove the intake manifold from cylinder head B INSTALLATION 1 Install the intake manifold onto cylinder hea...

Page 130: ...ng solenoid valve 7 Connect the front oxygen A F sensor connec tor A and rear oxygen sensor connector B 8 Connect the connectors to camshaft position sensor 9 Connect the connector to the power steeri...

Page 131: ...e generator Ref to SC H4SO 16 INSTALLATION Generator 20 Install the air intake duct air intake chamber and intake boot Ref to IN H4SO 8 INSTALLA TION Air Intake Duct Ref to IN H4SO 7 IN STALLATION Air...

Page 132: ...e the harness band B which holds the engine harness to the fuel injector pipe 10 Remove the purge control solenoid valve Ref to EC H4SO 9 REMOVAL Purge Control Solenoid Valve 11 Remove the bolts which...

Page 133: ...el pipe from intake manifold D ASSEMBLY NOTE When assembling the nipple apply liquid gasket Liquid gasket THREE BOND 1105 Part No 004403010 or equivalent Tightening torque 17 N m 1 7 kgf m 12 5 ft lb...

Page 134: ...harness to the intake manifold 7 Secure the engine harness to intake manifold with bolts Tightening torque 19 N m 1 9 kgf m 14 0 ft lb 8 Install the purge control solenoid valve Ref to EC H4SO 9 INST...

Page 135: ...TION EGR Valve 15 Install the throttle body to the intake manifold Ref to FU H4SO 14 INSTALLATION Throttle Body 16 Install the ignition coil and ignitor assembly Ref to IG H4SO 6 INSTALLATION Ignition...

Page 136: ...Tightening torque 18 N m 1 8 kgf m 13 3 ft lb C INSPECTION 1 Immerse the engine coolant temperature sensor and a thermometer in water CAUTION Take care not to allow water to get into the en gine cool...

Page 137: ...METHOD WITH CIRCUIT TESTER 1 Disconnect the ground cable from battery 2 Remove the crankshaft position sensor Ref to FU H4SO 26 REMOVAL Crankshaft Position Sensor 3 Measure the resistance between cra...

Page 138: ...the probe to ECM connector 8 Start the engine and let it idle 9 Check the pattern is as same as the waveform and voltage shown below A To ECM connector Terminal No Probe 13 14 A One crankshaft rotati...

Page 139: ...haft position sensor support as a unit 6 Remove the camshaft position sensor from the camshaft position sensor support B INSTALLATION Install in the reverse order of removal Tightening torque Camshaft...

Page 140: ...7 Start the engine and let it idle 8 Check the pattern is as same as the waveform and voltage shown below A To ECM connector Terminal No Probe 12 22 A One camshaft rotation FU 04346 A 5 6 7 2 1 4 3 2...

Page 141: ...ylinder block B INSTALLATION 1 Install the knock sensor to the cylinder block NOTE Extraction area of knock sensor cord must be posi tioned at a 60 angle relative to the engine rear Tightening torque...

Page 142: ...FU H4SO 31 Knock Sensor FUEL INJECTION FUEL SYSTEMS C INSPECTION Measure the resistance between knock sensor ter minals Terminal No Standard 1 and 2 560r28 k 2 1 EC 02428...

Page 143: ...ion Sensor A SPECIFICATION Throttle body is a non disassembled part so do not remove the throttle position sensor from throttle body Refer to Throttle Body for removal and installation procedure Ref t...

Page 144: ...manifold ab solute pressure sensor and remove the manifold absolute pressure sensor from throttle body B INSTALLATION Install in the reverse order of removal NOTE Use new O rings Tightening torque 2 N...

Page 145: ...Ref to FU H4SO 34 REMOVAL Mass Air Flow and Intake Air Temperature Sen sor 3 Connect terminal No 3 to the battery positive terminal and terminal No 4 to the battery ground terminal terminal No 5 to t...

Page 146: ...3 Remove the EGR valve from intake manifold B INSTALLATION Install in the reverse order of removal NOTE Use a new gasket Tightening torque 19 N m 1 9 kgf m 14 0 ft lb C INSPECTION 1 Measure the resis...

Page 147: ...s the engine harness to the fuel injector pipe 9 Remove the bolts which hold fuel injector pipe onto intake manifold 10 Remove the fuel injector while lifting up the fuel injector pipe 2 LH SIDE 1 Rel...

Page 148: ...d 9 Remove the fuel injector while lifting up the fuel injector pipe B INSTALLATION 1 RH SIDE Install in the reverse order of removal NOTE Use new O rings Tightening torque 19 N m 1 9 kgf m 14 0 ft lb...

Page 149: ...ng torque 6 4 N m 0 7 kgf m 4 7 ft lb Tightening torque 19 N m 1 9 kgf m 14 0 ft lb Tightening torque 19 N m 1 9 kgf m 14 0 ft lb C INSPECTION Measure the resistance between fuel injector termi nals A...

Page 150: ...lift diagnosis oil pressure switch 4 Remove the variable valve lift diagnosis oil pres sure switch LH side RH side B INSTALLATION Install in the reverse order of removal NOTE Apply liquid gasket to th...

Page 151: ...nnect the connector from oil temperature sensor 5 Remove the oil temperature sensor B INSTALLATION Install in the reverse order of removal NOTE Apply liquid gasket to the oil temperature sensor thread...

Page 152: ...pe cools otherwise it will damage the exhaust pipe B INSTALLATION CAUTION If lubricant is spilt onto the exhaust pipe wipe it off completely with cloth to avoid emission of smoke or causing a fire 1 B...

Page 153: ...xygen A F sensor connector and fasten the harness with clips 6 Connect the ground cable to battery C INSPECTION Measure the resistance between front oxygen A F sensor terminal A Front oxygen A F senso...

Page 154: ...s otherwise it will dam age the exhaust pipe B INSTALLATION CAUTION If lubricant is spilt onto the exhaust pipe wipe it off completely with cloth to avoid emission of smoke or causing a fire 1 Before...

Page 155: ...ensor connector and fasten the harness with clips 6 Connect the ground cable to battery C INSPECTION Measure the resistance between rear oxygen sen sor terminal A Front oxygen A F sensor connector B R...

Page 156: ...ts and nuts which hold the ECM to the bracket 6 Disconnect the ECM connectors and take out the ECM B INSTALLATION Install in the reverse order of removal CAUTION When the ECM of model with immobilizer...

Page 157: ...ve the main relay from the relay block on the back side of the glove box B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Measure the resistance between main relay ter minals IN 0...

Page 158: ...STEMS 2 Connect terminal No 3 to battery positive termi nal and terminal No 4 to the battery ground termi nal and measure the resistance between the main relay terminals Terminal No Standard 1 and 2 L...

Page 159: ...ove the fuel pump relay from the relay block on the back side of the glove box B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Measure the resistance between fuel pump relay term...

Page 160: ...STEMS 2 Connect terminal No 3 to battery positive termi nal and terminal No 4 to the battery ground termi nal and measure the resistance between the fuel pump relay terminals Terminal No Standard 1 an...

Page 161: ...ove the electronic throttle control relay from the relay block on the back side of the glove box B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Measure the resistance between el...

Page 162: ...STEMS 2 Connect terminal No 3 to battery positive termi nal and terminal No 4 to the battery ground termi nal and measure the resistance between the electronic throttle control relay terminals Termina...

Page 163: ...to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION Be careful not to spill fuel Catch the fuel fro...

Page 164: ...the working area CAUTION Be careful not to spill fuel Fuel may remain in the fuel filler pipe Drain ing the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and th...

Page 165: ...cushion Ref to SE 11 REMOVAL Rear Seat 6 Remove the service hole cover of fuel pump 1 Disconnect fuel pump connector A and re move clip B 2 Remove the screw C 3 Push the grommet D down and remove the...

Page 166: ...L Propeller Shaft 17 Remove the heat shield cover and fuel tank protector 18 Disconnect the connector from the rear ABS wheel speed sensor 19 Remove the parking brake cable clamp from the body 20 Disc...

Page 167: ...the fig ure 24 Disconnect the fuel filler hose A and evapora tion hose B 25 Support the fuel tank with a transmission jack remove the bolts from the fuel tank band and re move the fuel tank from the...

Page 168: ...ightening torque 2 5 N m 0 3 kgf m 1 8 ft lb 3 Connect the quick connector of the evaporation hose to the evaporation pipe CAUTION Check that there is no damage or dust on the quick connector If neces...

Page 169: ...ar suspension assembly and tighten the bolts which secure the rear suspen sion assembly to the body Tightening torque T1 70 N m 7 1 kgf m 51 6 ft lb T2 145 N m 14 8 kgf m 106 9 ft lb 3 Install the rea...

Page 170: ...uffler 14 Lower the vehicle 15 Connect the parking brake cable to the parking brake assembly Ref to PB 7 INSTALLATION Parking Brake Assembly Rear Disc Brake 16 Install the rear disc brake assembly Tig...

Page 171: ...seat cushion Ref to SE 12 INSTALLATION Rear Seat 24 Connect the ground cable to battery 25 Inspect the wheel alignment and adjust if nec essary C INSPECTION 1 Check that the fuel tank does not have ho...

Page 172: ...PROCEDURE Fuel 4 Disconnect the ground cable from battery 5 Open the fuel filler lid and remove the filler cap 6 Remove the screws which secure gasket 7 Remove the rear wheel RH 8 Lift up the vehicle...

Page 173: ...el filler pipe neck and set the cup B and tighten the screws NOTE If the edges of rubber gasket are folded toward in side straighten it with a flat tip screwdriver 4 Securely insert the fuel filler ho...

Page 174: ...me 7 Install the rear mud guard RH Ref to EI 28 IN STALLATION Mud Guard 8 Lower the vehicle 9 Install the rear wheel RH Tightening torque 100 N m 10 2 kgf m 73 8 ft lb 10 Connect the ground cable to b...

Page 175: ...ening torque 7 5 N m 0 8 kgf m 5 5 ft lb 2 Install the shut valve to the fuel filler pipe Ref to EC H4SO 18 INSTALLATION Shut Valve E INSPECTION 1 Check that the fuel filler pipe does not have holes c...

Page 176: ...DURE Fuel 2 Drain fuel Ref to FU H4SO 52 DRAINING FUEL WITH SUBARU SELECT MONITOR PROCEDURE Fuel 3 Disconnect the ground cable from battery 4 Remove the rear seat cushion Ref to SE 11 REMOVAL Rear Sea...

Page 177: ...plate Tighten the nuts to the specified torque in the or der as shown in the figure NOTE Use a new gasket and retainer Tightening torque 4 4 N m 0 4 kgf m 3 2 ft lb C INSPECTION 1 Disconnect the grou...

Page 178: ...om sub tank 4 Slide the fuel level sensor in the direction of the arrow and remove the fuel level sensor by pressing the claw A of the fuel level sensor B INSTALLATION Install in the reverse order of...

Page 179: ...ain fuel Ref to FU H4SO 52 DRAINING FUEL WITH SUBARU SELECT MONITOR PROCEDURE Fuel 3 Disconnect the ground cable from battery 4 Remove the rear seat cushion Ref to SE 11 REMOVAL Rear Seat 5 Remove the...

Page 180: ...fied torque in the order as shown in the figure After tightening install the rubber cap C shown in the figure NOTE Use a new gasket and retainer Do not forget to install rubber cap C Tightening torque...

Page 181: ...to FU H4SO 67 REMOVAL Fuel Level Sensor 3 Disconnect the pump assembly connector from the sub tank bracket assembly 4 Cut off the tab holders connecting the sub tank bracket assembly and the sub tank...

Page 182: ...flat tip screwdriver A etc with tape B Be careful not to drop or apply any impact to the pump assembly NOTE If the spacer and O ring is remaining on the pump assembly remove these B INSTALLATION 1 Ass...

Page 183: ...new O rings Apply gasoline to the O ring The O rings of the black and white connectors are identified by a difference in diameter Be careful not to confuse the two during assembly O ring inner diamet...

Page 184: ...b tank with a new cushion 8 Connect the pump assembly connector to the sub tank bracket assembly 9 Install the fuel level sensor and fuel temperature sensor Ref to FU H4SO 67 INSTALLATION Fuel Level S...

Page 185: ...1 Release the fuel pressure Ref to FU H4SO 52 RELEASING OF FUEL PRESSURE PROCE DURE Fuel 2 Remove the fuel damper from the fuel delivery line B INSTALLATION CAUTION If fuel hoses or clamps are damaged...

Page 186: ...rge damper stay 2 Disconnect the evaporation hose from the purge damper B INSTALLATION CAUTION If the evaporation hose is damaged replace with a new hose Install in the reverse order of removal Tighte...

Page 187: ...r Mat 5 In the engine compartment disconnect the fuel delivery hoses and evaporation hose CAUTION Be careful not to spill fuel Catch the fuel from hoses using a container or cloth 1 Set the ST to the...

Page 188: ...Remove the rear mud guard RH Ref to EI 28 REMOVAL Mud Guard 2 Remove the evaporation hose 3 Remove the right side trunk side trim 4 door model Ref to EI 61 REMOVAL Trunk Room Trim 4 Remove the right s...

Page 189: ...QUICK CONNECTOR CAUTION Make sure there are no damage or dust on con nections If necessary clean seal surface of pipe 1 Set the retainer to quick connector NOTE Use a new retainer 2 Connect the quick...

Page 190: ...059 in L2 22 5r2 5 mm 0 886r0 098 in CAUTION Be sure to inspect hoses and their connections for any leakage of fuel 4 EVAPORATION HOSE CONNECTION Connect the evaporation hose to the pipe with an overl...

Page 191: ...ump function Replace the fuel pump 3 Clogged fuel filter Replace the fuel filter Clean or replace the fuel tank if necessary 4 Clogged or bent fuel pipe or hose Clean correct or replace fuel pipe or h...

Page 192: ...placement Vehicle components are extremely hot after driving Be wary of receiving burns from heated parts Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks...

Page 193: ...ore refer to Front Ex haust Pipe for the removal procedure Ref to EX H4SO 6 REMOVAL Front Exhaust Pipe B INSTALLATION The front catalytic converter is integrated into the front exhaust pipe therefore...

Page 194: ...refer to Center Ex haust Pipe for the removal procedure Ref to EX H4SO 9 REMOVAL Center Exhaust Pipe B INSTALLATION The rear catalytic converter is integrated into the center exhaust pipe therefore r...

Page 195: ...l 4 Tilt the rear seat backrest forward 5 Remove the sub trunk box and spacers 4 door model 6 Remove the luggage floor box and spacers 5 door model 7 Remove the center canister cover 8 Remove the cani...

Page 196: ...B B NOTE Disconnect the quick connector as shown in the fig ure 13 Disconnect connector C from the drain valve and remove the drain valve 14 Disconnect purge tube A and vent tube B NOTE Disconnect th...

Page 197: ...If necessary clean the seal surface of the pipe When connecting the quick connector se curely insert the pipe all the way before locking the retainer If it is not possible to perform the push lock op...

Page 198: ...8 Canister EMISSION CONTROL AUX EMISSION CONTROL DEVICES Tightening torque 18 N m 1 8 kgf m 13 3 ft lb C INSPECTION Make sure that the canister drain valve and tube are not cracked or loose EC 02363 E...

Page 199: ...the connector and evaporation hos es of purge control solenoid valve and then re move the purge control solenoid valve B INSTALLATION Install in the reverse order of removal Tightening torque 19 N m...

Page 200: ...terminals 2 Check that air does not come out of B when blowing in A 3 Connect the terminal No 1 to the battery positive terminal and the terminal No 2 to the battery neg ative terminal Check that air...

Page 201: ...oval procedures refer to the FU H4SO section Ref to FU H4SO 35 REMOVAL EGR Valve B INSTALLATION For installation procedure refer to FU H4SO section Ref to FU H4SO 35 INSTALLATION EGR Valve C INSPECTIO...

Page 202: ...procedures refer to the FU H4SO section Ref to FU H4SO 67 REMOVAL Fuel Level Sensor B INSTALLATION For installation procedure refer to FU H4SO section Ref to FU H4SO 67 INSTALLATION Fuel Level Sensor...

Page 203: ...Sensor for installation procedure Ref to FU H4SO 67 INSTALLATION Fuel Level Sen sor C INSPECTION Measure the resistance between fuel temperature sensor terminals CAUTION When measuring the resistance...

Page 204: ...rocedures refer to the FU H4SO section Ref to FU H4SO 68 REMOVAL Fuel Sub Level Sensor B INSTALLATION For installation procedure refer to FU H4SO section Ref to FU H4SO 69 INSTALLATION Fuel Sub Level...

Page 205: ...ank pressure sensor B 7 Remove the fuel tank pressure sensor along with the bracket 8 Remove the fuel tank pressure sensor from the bracket cover B INSTALLATION Install in the reverse order of removal...

Page 206: ...ve 6 Remove the nuts C which secure the bracket to the fuel tank 7 Remove the pressure control solenoid valve and bracket as a unit 8 Remove the pressure control solenoid valve from the bracket B INST...

Page 207: ...EVICES 12 Drain Filter A SPECIFICATION The drain valve is a non disassembled part so do not remove the drain filter from drain valve Refer to Canister for removal and installation procedures Ref to EC...

Page 208: ...spill fuel 1 Remove the fuel filler pipe Ref to FU H4SO 61 REMOVAL Fuel Filler Pipe 2 Disconnect the evaporation hose from the shut valve 3 Remove the shut valve from the fuel filler pipe B INSTALLAT...

Page 209: ...L Refer to Canister for removal procedures Ref to EC H4SO 5 REMOVAL Canister B INSTALLATION Refer to Canister for installation procedures Ref to EC H4SO 7 INSTALLATION Canister C INSPECTION Measure th...

Page 210: ...o unlock 3 Remove the PCV hose assembly ST 18353AA000 CLAMP PLIERS B INSTALLATION NOTE Replace the clamp with a new part 1 Install the PCV hose assembly then lock by fit ting the ST on the clamp protr...

Page 211: ...IN H4SO 2 General Description INTAKE INDUCTION 1 General Description A COMPONENT 15 10 12 10 18 T3 6 5 13 14 17 T6 T6 T6 T4 7 4 3 2 1 6 5 6 T4 5 T2 T2 T2 T5 16 9 8 T1 9 11 IN 02543...

Page 212: ...driv ing Be wary of receiving burns from heated parts Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Before disco...

Page 213: ...STALLATION Install in the reverse order of removal CAUTION Be sure to use SUBARU genuine air cleaner el ement depending on the engine type when re placing the air cleaner elements Using other air clea...

Page 214: ...s air flow and intake air temperature sensor and re move the clip B 4 Loosen the clamp A which connects the air cleaner case to intake boot 5 Remove the clips B from the air cleaner case front 6 Remov...

Page 215: ...ear to the hole on the air cleaner case front to install 3 Install the clips B to the air cleaner case front then tighten the clamp A that connects the air cleaner case rear to the intake boot Tighten...

Page 216: ...es air intake chamber to the air intake chamber stay 4 Disconnect the connector D 5 Disconnect the blow by hoses and then remove air intake chamber B INSTALLATION Install in the reverse order of remov...

Page 217: ...EMOVAL Remove the clip which secures the air intake duct and remove the air intake duct B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Check for cracks or loose connections 2 Ch...

Page 218: ...refore refer to Air Clean er Case for the removal procedure Ref to IN H4SO 5 REMOVAL Air Cleaner Case B INSTALLATION The resonator chamber and air cleaner case are in tegrated into one unit therefore...

Page 219: ...IN H4SO 10 Resonator Chamber INTAKE INDUCTION...

Page 220: ...300 rpm kPa kg cm2 psi 1 020 1 275 10 4 13 0 148 185 Number of piston rings Pressure ring 2 Oil ring 1 Intake valve timing Constant Open BTDC 0 Close ABDC 58 Low speed Open BTDC 0 Close ABDC 10 High s...

Page 221: ...e seat 90 Contacting width between valve and valve seat mm in Standard Intake 0 8 1 4 0 03 0 055 Exhaust 1 2 1 8 0 047 0 071 Valve guide Clearance between the valve guide and valve stem mm in Standard...

Page 222: ...0 25 0 0098 US 1 620 1 623 0 0638 0 0639 Bushing of small end Clearance between piston pin and bushing mm in Standard 0 0 022 0 0 0009 Crankshaft and crankshaft bearing Bending limit mm in 0 035 0 00...

Page 223: ...t T2 9 75 1 0 7 2 4 Timing belt cover No 2 LH 13 Front timing belt cover T3 24 5 2 5 18 1 5 Cam sprocket No 1 14 Timing belt cover LH T4 39 4 0 28 8 6 Belt idler A 15 Crank pulley MT model T5 78 8 0 5...

Page 224: ...ion MECHANICAL 2 CYLINDER HEAD AND CAMSHAFT ME 03997 17 21 10 11 30 19 28 27 29 12 13 14 15 16 18 3 31 8 5 1 2 3 4 8 8 6 7 26 24 23 22 7 10 19 T6 T8 5 9 20 T4 T8 T7 2 T9 T8 T3 T9 T6 T5 T7 T7 T2 T1 T4...

Page 225: ...9 7 Plug T4 9 75 1 0 7 2 8 Spark plug pipe gasket 24 Gasket T5 10 1 0 7 4 9 Cylinder head RH 25 Oil temperature sensor T6 17 1 7 12 5 10 Cylinder head gasket 26 Variable valve lift diagnosis oil pres...

Page 226: ...ASSEMBLY 1 Intake valve rocker ASSY 4 Exhaust rocker shaft Tightening torque N m kgf m ft lb 2 Valve rocker nut 5 Exhaust valve rocker arm T1 6 0 6 4 4 3 Valve rocker adjusting screw T2 9 75 1 0 7 2 T...

Page 227: ...ICAL 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 03...

Page 228: ...n MECHANICAL 5 CYLINDER BLOCK ME 03982 1 29 28 2 3 3 3 4 4 4 5 31 6 7 32 8 32 9 10 10 11 10 28 12 29 15 25 23 22 T9 T10 T2 T2 T5 T6 T2 T2 T2 T4 T10 T2 T4 T4 T2 T10 T4 T5 T7 13 24 26 T1 T8 17 18 19 20...

Page 229: ...ter by pass pipe 22 Water pump sealing T3 10 1 0 7 4 7 Oil pump 23 Oil filter T4 25 2 5 18 4 8 Front oil seal 24 Gasket T5 Ref to ME H4SO 76 INSTAL LATION Cylinder Block 9 Rear oil seal 25 Water pump...

Page 230: ...eel MT model 11 Connecting rod nut 19 Crankshaft bearing 5 4 Ball bearing MT model 12 Connecting rod 5 Top ring 13 Connecting rod bearing Tightening torque N m kgf m ft lb 6 Second ring 14 Connecting...

Page 231: ...eral Description MECHANICAL 7 ENGINE MOUNTING 1 Front cushion rubber 2 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 62 7 ME 00413 T2 T1 T1 T3...

Page 232: ...g special attention to engine oil passages pistons 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 g...

Page 233: ...ing cam sprocket LH side CAM SPROCKET WRENCH 499207100 can also be used 1B022XU0 SUBARU SELECT MONITOR III KIT Used for various inspections 498267800 CYLINDER HEAD TABLE Used for replacing valve guide...

Page 234: ...STAND 499817100 498497100 CRANKSHAFT STOPPER Used for removing and installing the flywheel and drive plate 498747300 PISTON GUIDE Used for installing piston in cylinder 498857100 VALVE OIL SEAL GUIDE...

Page 235: ...499587200 CRANKSHAFT OIL SEAL INSTALLER Used for installing crankshaft oil seal Used together with CRANKSHAFT OIL SEAL GUIDE 499597100 499587500 OIL SEAL INSTALLER Used for installing the camshaft oil...

Page 236: ...et RH side 499497000 TORX PLUS Used for removing and installing camshaft cap 499587100 OIL SEAL INSTALLER Used for installing oil pump oil seal 499597000 OIL SEAL GUIDE Used for installing the camshaf...

Page 237: ...718000 VALVE SPRING REMOVER Used for removing and installing valve spring 499767200 VALVE GUIDE REMOVER Used for removing valve guides 499767400 VALVE GUIDE REAMER Used for reaming valve guides 499767...

Page 238: ...0 LH 498457100 499977400 CRANK PULLEY WRENCH Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts AT model 499977100 CRANK PULLEY WRENCH Used to stop rotation of t...

Page 239: ...or removing the quick connector 18354AA000 VALVE ROCKER HOLDER Used for installing the valve rocker assembly intake 2 piece set 18258AA000 SPRING INSTALLER Used for installing the valve rocker assembl...

Page 240: ...open the throttle valve 9 Check the starter motor for satisfactory perfor mance and operation 10 Secure the compression gauge tightly against the spark plug hole NOTE When using a screw in type compre...

Page 241: ...e speed when no loaded Head light heater fan rear defroster radiator fan A C and etc are OFF Idle speed No load and at P or N position on AT model or neutral position on MT model 700r100 rpm AT model...

Page 242: ...onnected properly 2 Check the malfunction indicator light does not illuminate 2 Warm up the engine 3 Stop the engine and turn the ignition switch to OFF 4 Connect the timing light to 1 cylinder spark...

Page 243: ...urement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1 Needle is steady but lower than normal position This tendency becomes more evident as engine temperature rises Air...

Page 244: ...kPa 3 0 kg cm2 43 psi or more at 5 000 rpm If the oil pressure is out of specification check oil pump oil filter and lubrication line Ref to LU H4SO 22 INSPECTION Engine Lubrication System Trouble in...

Page 245: ...Release the fuel pressure Ref to FU H4SO 52 RELEASING OF FUEL PRESSURE PROCE DURE Fuel 2 Open the fuel filler lid and remove the fuel filler cap 3 Disconnect the fuel delivery hose from the fuel dampe...

Page 246: ...s then remove the rocker cover RH 9 When inspecting 2 and 4 cylinders 1 Disconnect the spark plug cords from spark plugs on LH side Ref to IG H4SO 4 LH SIDE REMOVAL Spark Plug 2 Place a suitable conta...

Page 247: ...dead center of the compression stroke 2 Adjust the 1 cylinder valve clearance 1 Loosen the valve rocker nut and screw 2 Set a suitable thickness gauge 3 While noting the valve clearance tighten the v...

Page 248: ...r Ref to IN H4SO 8 REMOV AL Air Intake Duct Ref to IN H4SO 5 RE MOVAL Air Cleaner Case Ref to IN H4SO 7 REMOVAL Air Intake Chamber 8 Remove the under cover 9 Remove the radiator from vehicle Ref to CO...

Page 249: ...BELT REMOV AL V belt 2 Remove the bolts which secure the power steering pump to the bracket 3 Place the power steering pump on the right side wheel apron 15 Lift up the vehicle 16 Remove the front and...

Page 250: ...on hose B 1 Disconnect the quick connector of the fuel delivery hose by pushing the ST in the direction of the arrow ST 42099AE000 QUICK CONNECTOR RELEASE 2 Remove the clip and disconnect the evapo ra...

Page 251: ...ch cover MT mod el 4 Slowly move the engine away from engine compartment NOTE Be careful not to damage adjacent parts or body panels with crank pulley oil level gauge etc 27 Remove the engine mounting...

Page 252: ...AT model 1 Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate NOTE Be careful not to drop bolts into the t...

Page 253: ...Install the front and center exhaust pipe Ref to EX H4SO 7 INSTALLATION Front Exhaust Pipe 17 Lower the vehicle 18 Connect the following hoses 1 Fuel delivery hose and evaporation hose 2 Heater inlet...

Page 254: ...to CO H4SO 13 FILLING OF ENGINE COOLANT REPLACE MENT Engine Coolant 27 Check the ATF level and replenish it if neces sary AT model Ref to 4AT 27 INSPECTION Automatic Transmission Fluid 28 Charge the...

Page 255: ...ssembly Ref to ME H4SO 30 REMOVAL Engine Assembly 2 Remove the engine mounting from the engine assembly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 35 N m...

Page 256: ...499817100 ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order The procedure for overhauling of the engine will be completed when you go throu...

Page 257: ...t and water with cloth Do not use the front side belt if there is any oil grease or coolant on the belt Be careful not to rub the belt end surface with bare hands exposed core may cause injury 1 Wipe...

Page 258: ...the groove of each pulley with cloth 2 Wipe off any oil water dirt and rust on the front of the crank pulley with cloth 3 Slowly turn the crank pulley clockwise so that the service hole of the crank...

Page 259: ...holder CAUTION When it is difficult to place the rear side belt to the crank pulley groove pull out the belt guide holder half way then place the rear side belt into the groove so that it comes in be...

Page 260: ...e belt guide is not off from the crank pulley groove 1 The rib of the rear side belt is securely placed on the groove of the A C compressor pulley 2 The rib of the rear side belt is securely placed on...

Page 261: ...t twisted 2 The rib of the rear side belt is securely placed on the groove of the A C compressor pulley 3 The rib of the rear side belt is securely placed on the groove of the crank pulley 4 The surfa...

Page 262: ...ve the belt stopper from the compressor bracket CAUTION Always remove the belt stopper failure to do so may cause smoke fire or belt cutting 16 Make sure that the belt rib is securely installed on the...

Page 263: ...fraying or wear is found 2 Check the front side belt tension and adjust it if necessary by changing the generator installing po sition Front side belt tension with belt tension gauge When installing...

Page 264: ...han 45 CAUTION If the tightening angle of crank pulley bolt is less than 45 the bolt is damaged In this case the bolt must be replaced 1 Replace the crank pulley bolts and clean them Crank pulley bolt...

Page 265: ...crankshaft thread using com pressed air 3 Apply engine oil to the crank pulley bolt seat and thread 4 Tighten the bolts temporarily with tightening torque of 44 N m 4 5 kgf m 32 5 ft lb 5 Tighten the...

Page 266: ...ve the front timing belt cover B INSTALLATION 1 Install the front timing belt cover Tightening torque 5 N m 0 5 kgf m 3 7 ft lb 2 Install the timing belt cover LH Tightening torque 5 N m 0 5 kgf m 3 7...

Page 267: ...e alignment mark or arrow mark which indi cates the direction of rotation on timing belt fade away put new marks before removing the timing belt as shown in procedures below 1 Use the ST to turn crank...

Page 268: ...tak ing three minutes or more Do not allow press pressure to exceed 9 807 N 1 000 kgf 2 205 lb Push in the adjuster rod to the end face of the cylinder However do not push in the adjuster rod below th...

Page 269: ...ith the mark A on crank sprocket 3 Turn the camshaft sprocket No 2 using ST1 and turn the camshaft sprocket No 1 using ST2 so that their alignment marks A come to top posi tions ST1 18231AA010 CAM SPR...

Page 270: ...b 9 Install the timing belt cover Ref to ME H4SO 48 INSTALLATION Timing Belt Cover 10 Install the crank pulley Ref to ME H4SO 46 INSTALLATION Crank Pulley 11 Install the V belts Ref to ME H4SO 39 IN S...

Page 271: ...pe vise Push the adjuster rod vertically Press the adjuster rod gradually taking three minutes or more Do not allow press pressure to exceed 9 807 N 1 000 kgf 2 205 lb Push in the adjuster rod to the...

Page 272: ...M SPROCKET WRENCH B INSTALLATION 1 Fasten the cam sprocket and install to the cam shaft using ST NOTE Do not confuse cam sprockets LH and RH dur ing installation They should be distinguished by the L...

Page 273: ...INSPECTION 1 Check the cam sprocket teeth for abnormal wear and scratches 2 Make sure there is no free play between cam sprocket and key 3 Check the cam sprocket protrusion used for sen sor for damage...

Page 274: ...move the crank sprocket B INSTALLATION 1 Install the crank sprocket 2 Install the timing belt Ref to ME H4SO 50 INSTALLATION Timing Belt 3 Install the timing belt cover Ref to ME H4SO 48 INSTALLATION...

Page 275: ...y 1 Use the ST to rotate the spring stopper in the direction of the arrow to remove it from ad juster pin ST 18258AA000 SPRING INSTALLER 2 Remove the bolts a through j in alphabet ical sequence NOTE L...

Page 276: ...e 25 N m 2 5 kgf m 18 4 ft lb 3 Tighten the bolts i through j to specified torque Tightening torque 6 N m 0 6 kgf m 4 4 ft lb 4 Use the ST to rotate the spring stopper in the direction of the arrow to...

Page 277: ...s with same mark ings are properly assembled E INSPECTION 1 INTAKE VALVE ROCKER ASSEMBLY 1 If the roller or valve contact surface of valve rocker arm is worn or dented excessively replace the valve ro...

Page 278: ...RH NOTE Do not damage or lose the seal rubber when re moving the timing belt covers 8 Remove the tensioner bracket 9 Remove the camshaft position sensor support LH side only 10 Remove the valve rocker...

Page 279: ...ghten the bolts a through d in alphabetical sequence 3 Install the valve rocker assembly Ref to ME H4SO 58 INSTALLATION Valve Rocker Assembly 4 Tighten the TORX bolts e through j in al phabetical sequ...

Page 280: ...the timing belt cover No 2 RH Tightening torque 5 N m 0 5 kgf m 3 7 ft lb 9 Install the timing belt cover No 2 LH Tightening torque 5 N m 0 5 kgf m 3 7 ft lb 10 Install the cam sprocket Ref to ME H4S...

Page 281: ...Base circle step of adjacent intake cams low speed and high speed Standard 0 03 mm 0 001 in or less 5 Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal and ch...

Page 282: ...Remove the cylinder head bolts in alphabetical sequence as shown in the figure NOTE Leave bolts a and c engaged by three or four threads to prevent the cylinder head from falling 12 While tapping the...

Page 283: ...ME H4SO 50 INSTALLATION Timing Belt 9 Adjust the valve clearance Ref to ME H4SO 29 ADJUSTMENT Valve Clearance 10 Install the rocker cover 1 Install the rocker cover gasket to the rocker cover NOTE Use...

Page 284: ...ntion not to damage the lips of in take valve oil seals and exhaust valve oil seals For removal and installation procedures of the valve guide intake valve oil seal and exhaust valve oil seal refer to...

Page 285: ...er seating E INSPECTION 1 CYLINDER HEAD 1 Check for cracks or damage Use liquid penetrant tester on the important sections to check for fissures Check that there are no marks of gas leaking or wa ter...

Page 286: ...f valve guide with a caliper gauge Clearance between the valve guide and valve stem Standard Intake 0 035 0 062 mm 0 0014 0 0024 in Exhaust 0 040 0 067 mm 0 0016 0 0026 in 2 If the clearance between t...

Page 287: ...hes nor damages exist on the inner surface of valve guide holes in cyl inder head 5 Put a new valve guide coated with sufficient oil in the cylinder head and insert the ST1 into valve guide Press in u...

Page 288: ...eck the contact condition between valve and valve seat after replacing the valve guide 4 INTAKE AND EXHAUST VALVE 1 Inspect the flange of valve and valve stem and replace the valve with a new part if...

Page 289: ...the spring is out of the specified position When readjusting the surfaces of valve and valve seat When replacing the valve guide 2 Place the cylinder head on ST1 and use ST2 to press fit the oil seal...

Page 290: ...er 11 Remove the flywheel MT model Ref to CL 13 REMOVAL Flywheel 12 Remove the oil separator cover 13 Remove the water by pass pipe for heater 14 Remove the water pump Ref to CO H4SO 15 REMOVAL Water...

Page 291: ...ly 23 Remove the service hole plugs using a hexa gon wrench 14 mm 24 Remove the service hole cover ME 00300 1 Service hole plug 4 Piston pin 7 Seal washer 2 Gasket 5 Service hole cover 8 Washer 3 Snap...

Page 292: ...ST 499097700 PISTON PIN REMOVER NOTE Be careful not to confuse the original combination of piston piston pin and cylinder 27 Similarly draw out the piston pins from 3 and 4 pistons 28 Remove the cylin...

Page 293: ...nkshaft bearings from cylinder block using a hammer handle NOTE Press the crankshaft bearing at the end opposite to locking lip to remove Be careful not to confuse the crankshaft bearing combination 3...

Page 294: ...new O rings 3 Apply liquid gasket to the mating surfaces of cyl inder block RH and position cylinder block LH NOTE Install within 5 min after applying liquid gasket Do not allow liquid gasket to jut i...

Page 295: ...ing bolts A D further in alphabetical order Tightening torque 18 N m 1 8 kgf m 13 3 ft lb 8 Tighten the RH side cylinder block connecting bolts E J further in alphabetical order Tightening torque 18 N...

Page 296: ...14 Position the second ring gap at 180 on the re verse side the top ring gap 15 Position the upper rail gap at C in the figure 16 Align the upper rail spin stopper E to the side hole D on the piston 1...

Page 297: ...NOTE Use new snap rings 20 Install the piston 1 Set the parts so that the 1 and 2 cylinders are on the upper side 2 Using the ST1 turn the crankshaft so that 1 and 2 connecting rods are set at bottom...

Page 298: ...ert ST3 into the service hole to align pis ton pin hole with connecting rod small end ST3 499017100 PISTON PIN GUIDE 3 Apply a coat of engine oil to piston pin and insert the piston pin into piston an...

Page 299: ...asket NOTE Use a new gasket Tightening torque 70 N m 7 1 kgf m 51 6 ft lb ME 00140 1 Piston 5 Service hole plug Tightening torque N m kgf m ft lb 2 Piston pin 6 Service hole cover T1 6 4 0 7 4 7 3 Sna...

Page 300: ...baffle plate Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb 26 Apply liquid gasket to the mating surfaces of oil pan and install the oil pan NOTE Install within 5 min after applying liquid gasket Liqui...

Page 301: ...00 OIL SEAL INSTALLER NOTE Use a new front oil seal 2 Apply liquid gasket to the mating surfaces of oil pump NOTE Install within 5 min after applying liquid gasket Liquid gasket THREE BOND 1217G Part...

Page 302: ...ightening torque 36 N m 3 7 kgf m 26 6 ft lb 37 Install the crank sprocket Ref to ME H4SO 56 INSTALLATION Crank Sprocket 38 Install the timing belt Ref to ME H4SO 50 INSTALLATION Timing Belt 39 Adjust...

Page 303: ...o that they are kept in their original combinations groups and not mixed together 3 Remove the piston rings using piston ring ex pander 4 Remove the oil ring by hand NOTE Arrange the removed piston ri...

Page 304: ...ail expander and lower rail by hand 5 Install the second ring and top ring using piston ring expander NOTE Assemble so that the piston ring mark R faces the top side of the piston E INSPECTION 1 CYLIN...

Page 305: ...ylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure using a cylinder bore gauge NOTE Measurement should be performed...

Page 306: ...sured value of taper out of roundness or cylinder to piston clearance is out of standard or if there is any damage on the cyl inder wall rebore it to replace with an oversize piston CAUTION When any o...

Page 307: ...When installing oil ring on piston be careful of the direction of each rail 2 Using the piston insert the piston ring and oil ring into the cylinder so that they are perpendicular to the cylinder wall...

Page 308: ...tigauge If any oil clearance is not within the standard replace the defective bearing with a new part of standard size or under size as necessary Connecting rod oil clearance Standard 0 016 0 044 mm 0...

Page 309: ...of the crankshaft If it exceeds the limit correct or replace it NOTE If a suitable V block is not available using just the 1 and 5 crankshaft bearings on cylinder block position the crankshaft on cyli...

Page 310: ...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 Bearing size Thickness at center 1 998 2 011 0 0787 0 0792 2 000 2 013 0 0787 0 0793 1 492 1 50...

Page 311: ...Oil Temperature Sen sor 9 Remove the oil switching solenoid valve holder from the cylinder head 2 LH SIDE 1 Disconnect the ground cable from battery 2 Remove the V belts Ref to ME H4SO 39 REMOVAL V be...

Page 312: ...removal NOTE Use a new gasket Apply liquid gasket to variable valve lift diagnosis oil pressure switch threads Install the oil switching solenoid valve to the holder then install it to the cylinder h...

Page 313: ...MECHANICAL 23 Intake and Exhaust Valve A SPECIFICATION Refer to Cylinder Head for removal and installa tion procedures of the intake and exhaust valves Ref to ME H4SO 64 REMOVAL Cylinder Head Ref to M...

Page 314: ...6 Piston MECHANICAL 24 Piston A SPECIFICATION Refer to Cylinder Block for removal and installa tion procedures of pistons Ref to ME H4SO 72 REMOVAL Cylinder Block Ref to ME H4SO 76 INSTALLATION Cylind...

Page 315: ...g Rod MECHANICAL 25 Connecting Rod A SPECIFICATION Refer to Cylinder Block for removal and installa tion procedures of connecting rod Ref to ME H4SO 72 REMOVAL Cylinder Block Ref to ME H4SO 76 INSTALL...

Page 316: ...shaft MECHANICAL 26 Crankshaft A SPECIFICATION Refer to Cylinder Block for removal and installa tion procedures of the crankshaft Ref to ME H4SO 72 REMOVAL Cylinder Block Ref to ME H4SO 76 INSTALLATIO...

Page 317: ...tem B Friction Seizure of crankshaft and connecting rod bearing C Seized camshaft C Seized or stuck piston and cylinder C 2 Initial combustion does not occur Starter Defective starter C Engine control...

Page 318: ...ve timing B Improper engine oil low viscosity B 4 Engine stalls after initial combustion Engine control system Ref to EN H4SO diag 2 Basic Diagnostic Procedure A Intake system Loosened or cracked inta...

Page 319: ...d fuel line C Lack of fuel or insufficient fuel B Timing belt Defective timing C Compression Incorrect valve clearance B Loosened spark plug or defective gasket B Loosened cylinder head bolt or defect...

Page 320: ...tive fuel pump and relay B Clogged fuel line B Lack of fuel or insufficient fuel C Timing belt Defective timing B Compression Incorrect valve clearance B Loosened spark plug or defective gasket B Loos...

Page 321: ...gine does not return to idle Engine control system Ref to EN H4SO diag 2 Basic Diagnostic Procedure A Intake system Loosened or cracked vacuum hose A Others Stuck or damaged throttle valve A 6 Dieseli...

Page 322: ...Defective oil filter gasket B Defective crankshaft oil seal B Defective rocker cover gasket B Loosened oil drain plug or defective gasket B Loosened oil pan fitting bolts or defective oil pan B 10 Exc...

Page 323: ...nge of spark plug Improper octane value gasoline Clank when engine speed is 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft mai...

Page 324: ...ME H4SO 106 Engine Noise MECHANICAL...

Page 325: ...XHAUST 1 General Description A COMPONENT 4 DOOR MODEL 27 26 21 17 15 14 10 11 13 12 22 28 25 24 23 16 18 20 20 31 30 19 EX 02481 T2 T10 T9 T2 T2 T2 T2 T2 T2 T2 T3 T4 T5 T5 T5 T7 T6 T2 T8 T8 5 9 5 5 4...

Page 326: ...RH T5 30 3 1 22 1 9 Muffler LH 24 Front catalytic converter upper cover T6 35 3 6 25 8 10 Center exhaust pipe front upper cover 25 Front catalytic converter lower cover T7 40 4 1 29 5 26 Front exhaust...

Page 327: ...4SO 4 General Description EXHAUST 5 DOOR MODEL 27 26 21 17 15 14 10 11 13 12 22 28 25 24 23 16 18 20 20 30 29 19 EX 02482 1 2 5 3 5 8 7 T8 4 6 5 9 T2 T10 T9 T2 T2 T2 T2 T2 T2 T2 T3 T4 T5 T5 T5 T1 T7 T...

Page 328: ...fire may happen 1 Gasket 15 Center exhaust pipe front lower cover 30 Hanger bracket AT model 2 Spring 3 Chamber 16 Front oxygen A F sensor Tightening torque N m kgf m ft lb 4 Rear exhaust pipe 17 Fro...

Page 329: ...pipe onto cylinder heads CAUTION Be careful not to drop the front and center ex haust pipe assembly 9 Remove the bolt which holds center exhaust pipe to hanger bracket 10 Remove the front exhaust pip...

Page 330: ...b 3 Install the front and center exhaust pipe to the vehicle as a unit NOTE Use a new gasket 4 Temporarily tighten the nuts which hold front ex haust pipe to cylinder heads 5 Install the center exhaus...

Page 331: ...tor A and rear oxygen sensor connector B and fasten the harness with the clip C 11 Install the air intake duct Ref to IN H4SO 8 INSTALLATION Air Intake Duct 12 Connect the ground cable to battery C I...

Page 332: ...ront Oxygen A F Sensor Ref to FU H4SO 43 REMOVAL Rear Oxygen Sensor B INSTALLATION 1 Install the front oxygen A F sensor and rear ox ygen sensor Ref to FU H4SO 41 INSTALLA TION Front Oxygen A F Sensor...

Page 333: ...e muffler CAUTION Be careful not to drop the rear exhaust pipe 4 DOOR MODEL 5 DOOR MODEL 5 Apply a coat of spray type lubricant to the mating area of cushion rubber 6 Remove the rear exhaust pipe from...

Page 334: ...m 35 4 ft lb 4 DOOR MODEL 5 DOOR MODEL 4 Install the rear exhaust pipe to center exhaust pipe NOTE Use a new gasket Tightening torque 18 N m 1 8 kgf m 13 3 ft lb 5 Lower the vehicle C INSPECTION 1 Che...

Page 335: ...shion rubber CAUTION Be careful not to drop the muffler during remov al 4 DOOR MODEL 5 DOOR MODEL B INSTALLATION Install in the reverse order of removal NOTE Use a new gasket and self locking nut Afte...

Page 336: ...m in 76 2 99 Number of impeller vanes 8 Pump pulley diameter mm in 60 2 36 Clearance between impeller and case Standard mm in 0 5 1 5 0 020 0 060 Thermostat Type Wax pellet type Starting temperature t...

Page 337: ...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 9 3 Heater by pass hose 7 Clip Second 12 1 2 8 9 4 Thermostat T2 12 1...

Page 338: ...odel 6 Radiator inlet hose 16 ATF hose B AT model Tightening torque N m kgf m ft lb 7 Engine coolant reservoir tank cap 17 ATF pipe AT model T1 5 0 5 3 7 8 Over flow hose 18 ATF hose C AT model T2 7 5...

Page 339: ...ponents are extremely hot after driv ing Be wary of receiving burns from heated parts Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at t...

Page 340: ...d to stop rotation of the crank pulley when loosening or tightening crank pulley bolts AT model 18231AA010 CAM SPROCKET WRENCH Used for removing and installing cam sprocket CAM SPROCKET WRENCH 4992071...

Page 341: ...12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 3 1 2 7 4 5 6 16 7 1 2 22 19 18 11 12 20 21 10 13 E E M 2 1 M F109 B360 10 1 SBF 6 MAIN SBF No 3 No 22 No 26 18 29 B C E ECM No 2 5 6 7 8 2 1 9 4...

Page 342: ...peed During acceleration 70 134 km h 43 83 MPH During deceleration 65 129 km h 40 80 MPH OFF OFF Low Speed High Speed Low OFF Low Speed High Speed High Low Speed High Speed High Speed During accelerat...

Page 343: ...round Is the voltage 10 V or more Go to step 4 Go to step 5 4 CHECK POWER SUPPLY TO SUB FAN RE LAY 1 Turn the ignition switch to ON 2 Measure the voltage between the sub fan relay terminal and chassis...

Page 344: ...inal No 2 of the sub fan motor assembly and the ground terminal to terminal No 1 Does the radiator sub fan rotate Go to step 13 Replace the sub fan motor assem bly Ref to CO H4SO 25 Radiator Sub Fan a...

Page 345: ...he battery 2 Measure the resistance between terminals at main fan relay 1 switch side Is the resistance less than 1 Go to step 22 Replace the main fan relay 1 Ref to AC 39 Relay and Fuse 22 CHECK HARN...

Page 346: ...tep 29 Repair the open circuit of harness between main fan relay 2 and chassis ground 29 CHECK POWER SUPPLY TO MAIN FAN RE LAY 2 1 Turn the ignition switch to ON 2 Measure the voltage between main fan...

Page 347: ...ylinder block Always use SUBARU Super Coolant since other coolant may cause corrosion 3 Fill engine coolant into the reservoir tank up to FULL level 4 Close the radiator cap and start the engine Race...

Page 348: ...rature find the proper SUBARU Super Coolant concentration in the table and add dilution water to the SUBARU Super Coolant concentrat ed type until it reaches the proper dilution Engine coolant and dil...

Page 349: ...MOVAL Camshaft Position Sensor 8 Remove the cam sprocket LH Ref to ME H4SO 54 REMOVAL Cam Sprocket 9 Remove the belt cover LH No 2 10 Remove the tensioner bracket 11 Disconnect the hose from water pum...

Page 350: ...Install the timing belt cover Ref to ME H4SO 48 INSTALLATION Timing Belt Cover 10 Install the crank pulley Ref to ME H4SO 46 INSTALLATION Crank Pulley 11 Install the V belts Ref to ME H4SO 39 IN STAL...

Page 351: ...mostat B INSTALLATION 1 Install a gasket to thermostat NOTE Use a new gasket 2 Install the thermostat and thermostat cover NOTE Install with the jiggle pin facing upward Tightening torque 12 N m 1 2 k...

Page 352: ...lift when the valve begins to open and when the valve is fully opened During the test agitate the water for even temper ature distribution The measured value should meet the specification NOTE Leave...

Page 353: ...ove the under cover 5 Remove the heat shield cover from radiator AT model 6 Drain the engine coolant Ref to CO H4SO 13 DRAINING OF ENGINE COOLANT REPLACEMENT Engine Coolant 7 Disconnect the main fan m...

Page 354: ...wer cushion to the hole on the radiator lower bracket 2 Install the radiator to vehicle NOTE Make pins on the lower side of radiator be fitted into the radiator lower cushions 3 Install the radiator u...

Page 355: ...NSPECTION Automatic Transmission Fluid C INSPECTION 1 Remove the radiator cap fill the radiator with en gine coolant and then install the tester to the instal lation position of cap 2 Apply a pressure...

Page 356: ...ap is functioning properly if it holds the service limit pressure for 5 6 seconds Replace the cap if it is opened under a pressure less than the service limit value Standard 93 123 kPa 0 95 1 25 kg cm...

Page 357: ...ATF hose from the clip of the radia tor main fan shroud AT model 8 Lower the vehicle 9 Drain approximately 2 0 2 of coolant Ref to CO H4SO 13 DRAINING OF ENGINE COOL ANT REPLACEMENT Engine Coolant 10...

Page 358: ...the bolts which hold the radiator sub fan shroud to the radiator Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb Tightening torque 3 N m 0 3 kgf m 2 2 ft lb C DISASSEMBLY 1 Remove the clip which holds...

Page 359: ...7 Remove the ATF hose from the clip of the radia tor sub fan shroud AT model 8 Lower the vehicle 9 Remove the air intake duct Ref to IN H4SO 8 REMOVAL Air Intake Duct 10 Drain approximately 2 0 2 of c...

Page 360: ...gf m 5 5 ft lb Tightening torque 3 N m 0 3 kgf m 2 2 ft lb C DISASSEMBLY 1 Remove the clip which holds the sub fan motor assembly connector onto the radiator sub fan shroud 2 Remove the bolts which ho...

Page 361: ...over flow hose connected to the radiator filler neck 2 Push in the hook A and pull the reserve tank in the direction of the arrow to remove B INSTALLATION Install in the reverse order of removal C IN...

Page 362: ...EN H4SO diag 2 Basic Diagnostic Procedure l Excessive back pressure in exhaust system Clean or replace m Insufficient clearance between piston and cylinder Adjust or replace n Slipping clutch Repair o...

Page 363: ...0 43 Discharge rate 2 US qt Imp qt min 47 0 49 7 41 4 or more Relief valve working pressure kPa kg cm2 psi 588 6 0 85 Oil filter Filter type Full flow filter type Filtration area cm2 sq in Outer diam...

Page 364: ...h an API standard and SAE viscosity number specified by Subaru NOTE The proper viscosity oil helps the engine main tain its ideal temperature and cranking speed in creased by reducing viscosity fricti...

Page 365: ...kgf m ft lb 7 Inner rotor 21 Oil level gauge guide T1 5 0 5 3 7 8 Outer rotor 22 O ring T2 6 4 0 7 4 7 9 Oil pump cover 23 Oil pan T3 10 1 0 7 4 10 Oil filter 24 Oil level gauge T4 25 2 5 18 4 11 O ri...

Page 366: ...Inner rotor 21 Oil level gauge guide T1 5 0 5 3 7 8 Outer rotor 22 Oil pan T2 5 4 0 6 4 0 9 Oil pump cover 23 Oil level gauge T3 6 4 0 7 4 7 10 Oil filter 24 Drain plug gasket T4 10 1 0 7 0 11 O ring...

Page 367: ...he ground cable from battery If the engine oil is spilt over exhaust pipe or the under cover wipe it off with cloth to avoid emitting smoke or causing a fire Prepare a container and cloth to prevent s...

Page 368: ...0 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 i1 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 369: ...arness between oil pressure switch connector and chassis ground Connector terminal E11 No 1 Chassis ground Is the voltage 10 V or more Replace the oil pressure switch Go to step 3 3 CHECK COMBINATION...

Page 370: ...ore checking the level NOTE Just after driving or while the engine is warm en gine oil level shows in the range between the F line and the notch mark This is caused by thermal ex pansion of engine oil...

Page 371: ...e when checking oil level Recommended oil Refer to SPECIFICATION for recommended oil Ref to LU H4SO 2 SPECIFICATION General Description Engine oil capacity Refer to SPECIFICATION for engine oil ca pac...

Page 372: ...E H4DOTC 60 REMOVAL Crank Sprocket 7 Remove the bolts which secure oil pump to cyl inder block NOTE When disassembling and checking the oil pump loos en the relief valve plug before removing the oil p...

Page 373: ...ck et 7 Install the water pump Ref to CO H4SO 15 INSTALLATION Water Pump Ref to CO H4DOTC 16 INSTALLATION Water Pump 8 Install the crankshaft position sensor Ref to FU H4SO 26 INSTALLATION Crankshaft...

Page 374: ...ll the inner and outer rotors 4 Assemble the oil relief valve and install relief valve spring and plug NOTE Use a new gasket 5 Install the oil pump cover Tightening torque T1 5 4 N m 0 6 kgf m 4 0 ft...

Page 375: ...ump inner rotor and the oil pump cover as shown in the figure If clearance is out of standard replace the rotor or the oil pump case Side clearance Specification 0 02 0 07 mm 0 0008 0 0028 in 4 OIL RE...

Page 376: ...9 Remove the radiator upper brackets 10 Support the engine with a lifting device and wire ropes 11 Lift up the vehicle CAUTION When lifting up the vehicle raise up wire ropes at the same time 12 Remo...

Page 377: ...torque 6 4 N m 0 7 kgf m 4 7 ft lb 3 Install the oil strainer to cylinder block NOTE Use new O rings Tightening torque 10 N m 1 0 kgf m 7 4 ft lb 4 Tighten the oil strainer stay together with the baf...

Page 378: ...hat the engine mounting nuts A and locator B are securely installed Turbo model Tightening torque 85 N m 8 7 kgf m 62 7 ft lb Non turbo model Turbo model 9 Install the front exhaust pipe Ref to EX H4S...

Page 379: ...ake boot Turbo model 17 Install the air intake chamber Non turbo mod el Ref to IN H4SO 7 INSTALLATION Air In take Chamber 18 Install the air intake duct Ref to IN H4SO 8 INSTALLATION Air Intake Duct R...

Page 380: ...the terminal from oil pressure switch 4 Remove the oil pressure switch B INSTALLATION 1 Apply liquid gasket to the oil pressure switch threads Liquid gasket THREE BOND 1324 Part No 004403042 or equiva...

Page 381: ...BRICATION 4 Install the generator to the bracket Ref to SC H4SO 16 INSTALLATION Generator 5 Connect the ground cable to battery C INSPECTION Check the oil pressure switch installation portion for oil...

Page 382: ...ll the oil filter turning it by hand being care ful not to damage the seal rubber of the oil filter Tighten the oil filter Black with an outer diame ter of 68 mm 2 68 in approx 1 rotation after the se...

Page 383: ...valve in oil filter Replace Malfunction of oil relief valve in oil pump Clean or replace Clogged oil passage Clean Excessive tip clearance and side clearance of oil pump rotor Replace Clogged oil stra...

Page 384: ...necessary removal installation dis assembly and replacement Vehicle components are extremely hot after driving Be wary of receiving burns from heated parts Be sure to tighten fasteners including bolts...

Page 385: ...MS D PREPARATION TOOL 1 SPECIAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for inspecting the accelerator pedal TOOL NAME REMARKS Circ...

Page 386: ...disassembled D INSPECTION 1 Check for smooth operation when the accelera tor pedal is depressed 2 Check if the accelerator pedal returns to its orig inal position smoothly when the pedal is released 1...

Page 387: ...TC diag 35 READ CURRENT DATA FOR ENGINE NORMAL MODE OPERA TION Subaru Select Monitor A To ECM connector A To ECM connector Accelerator pedal sensor Accelerator pedal Terminal No Standard Main Not depr...

Page 388: ...SP H4SO 6 Accelerator Pedal SPEED CONTROL SYSTEMS...

Page 389: ...ectric Secondary coil resistance 11 2 k r15 Spark plug Manufacturer and type NGK FR5AP 11 Thread size diameter pitch length mm 14 1 25 19 Spark plug gap mm in 1 0 1 1 0 039 0 043 Electrode Platinum 1...

Page 390: ...on or disassembly be sure to clarify the failure Avoid unnecessary removal in stallation disassembly and replacement Vehicle components are extremely hot after driving Be wary of receiving burns from...

Page 391: ...he boot Do not pull the cord itself 4 Remove the spark plug with a spark plug socket 2 LH SIDE 1 Remove the battery Ref to SC H4SO 22 REMOVAL Battery 2 Remove the spark plug cords by pulling the boot...

Page 392: ...pistons or excessive clearance between valve guides and stems 4 Overheating White or light gray insulator with black or brown spots and bluish burnt electrodes indicate engine overheating incorrect i...

Page 393: ...Install in the reverse order of removal Tightening torque 8 N m 0 8 kgf m 5 9 ft lb CAUTION Connect the spark plug cords to correct posi tions Failure to do so will damage the unit C INSPECTION Check...

Page 394: ...Plug Cord A INSPECTION Check the following items Damage to cords deformation burning or rust formation of terminals Resistance value of cords Specified resistance 1 cord 5 0 12 1 k 2 cord 8 5 19 9 k 3...

Page 395: ...IG H4SO 8 Spark Plug Cord IGNITION...

Page 396: ...0 9 kgf m 6 5 ft lb or more 16 7 N m 1 7 kgf m 12 3 ft lb or more Rotating speed 870 rpm or more 710 rpm or more Lock characteristics Voltage 4 V 3 5 V Current 680 A or less 960 A or less Torque 17 N...

Page 397: ...b or more 16 7 N m 1 7 kgf m 12 3 ft lb or more Rotating speed 870 rpm or more 710 rpm or more Lock characteristics Voltage 4 V 3 5 V Current 680 A or less 960 A or less Torque 17 N m 1 7 kgf m 12 5 f...

Page 398: ...ernal gear ASSY 18 Starter cover ASSY 3 Shift lever 11 Shaft 4 Plate 12 Pinion gear Tightening torque N m kgf m ft lb 5 Seal rubber 13 Seal rubber T1 1 4 0 1 1 0 6 Magnet switch ASSY 14 Yoke ASSY T2 6...

Page 399: ...t 7 Bearing 13 Terminals 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 5 3 5 5 Bearing retainer 11 Rectifier T2 108...

Page 400: ...or disassembly be sure to clarify the failure Avoid unnecessary removal in stallation disassembly and replacement Vehicle components are extremely hot after driving Be wary of receiving burns from he...

Page 401: ...TC 13 REMOVAL Intercooler 4 Remove the air intake chamber stay LH Non turbo model MT MODEL AT MODEL 5 Disconnect the connector B and terminal A from starter 6 Remove the starter from transmission NOTE...

Page 402: ...brush holder assem bly and through bolts B on both sides and re move the starter cover assembly 4 Remove the brush holder assembly from the ar mature assembly NOTE Hold the brush with your fingers so...

Page 403: ...shaft and shift lever together as one unit 10 Use the following procedures to remove the overrunning clutch from the shaft 1 Use an appropriate tool such as a fit socket wrench and remove the stopper...

Page 404: ...grease to the sliding surfaces of the inter nal gear assembly shaft Grease Multemp 6129 or equivalent 2 Assemble the shaft to the internal gear assem bly 3 Assemble the overrunning clutch as follows 1...

Page 405: ...NOTE Apply grease to the moving parts of the shift lever Grease Multemp 6129 or equivalent 5 Apply grease to the inside of the internal gear assembly and pinion gear and attach the pinion gear to the...

Page 406: ...he armature assembly NOTE Be careful not to damage the brushes 10 Secure starter cover assembly to the brush holder assembly with screws A Tightening torque 1 4 N m 0 1 kgf m 1 0 ft lb 11 Install thro...

Page 407: ...ausing it to move towards the core When the steel sheet has moved or vibrated re place or repair the armature with the shorted circuit 5 Armature ground test Use a circuit tester to touch the probe of...

Page 408: ...nd Also check to be sure there is no continuity be tween M terminal and B Terminal Resistance S M 1 or less S Ground 1 or less M B 1 M or more 6 SWITCH ASSEMBLY OPERATION 1 Using a lead wire connect t...

Page 409: ...model Max 11 V 95 A AT model Max 11 V 90 A Rotating speed MT model 2 500 rpm or more AT model 2 000 rpm or more 2 Load test Apply the specified braking torque to starter The condition is normal if th...

Page 410: ...Ref to ME H4DOTC 40 FRONT SIDE BELT REMOVAL V belt 5 Remove the bolts which secure the generator to the bracket B INSTALLATION Install in the reverse order of removal CAUTION Check and adjust the fro...

Page 411: ...them apart to disassemble 4 Using a vise support the rotor and remove the pulley nut CAUTION When holding the rotor with a vise place alumi num plates or wooden pieces on the vise jaws to prevent rot...

Page 412: ...tator coil CAUTION The rectifier is easily damaged by heat Do not allow a 180 270 W soldering iron to contact the terminals for 5 seconds or more at a time 8 Use the following procedures to remove the...

Page 413: ...TION After re assembling remove the wire 2 Install the ball bearings 1 Set the ball bearings in the front cover then securely install an appropriate tool such as a socket wrench of proper size to the...

Page 414: ...for contamination or any roughness on 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 Replace the rotor ass...

Page 415: ...is a ser vice limit mark A on each brush Brush length Standard 18 5 mm 0 728 in Service limit 5 0 mm 0 197 in 2 Check that there is appropriate pressure on the brush spring Using a spring pressure ind...

Page 416: ...ny fire For safety in case an explosion does occur wear eye protection or shield your eyes when working near any battery In addition never lean over the battery Ventilate sufficiently when using or ch...

Page 417: ...e battery at the current value specified by manufacturer or at approximately 1 10 of battery s ampere hour rating 4 QUICK CHARGING Quick charging is a method that the battery is charged in a short per...

Page 418: ...SC H4SO 24 Battery STARTING CHARGING SYSTEMS...

Page 419: ...al scan tool communicate with vehicle normally Go to step 4 Inspection using Diagnostics Pro cedure for Subaru Select Monitor Communication Ref to EN H4SO diag 84 Diagnostic Pro cedure for Subaru Sele...

Page 420: ...ient air 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 speed r...

Page 421: ...TEERING warning light Glow indicator Sedimentor indicator Others b Fuel level Lack of fuel Yes No Indicator position of fuel gauge Experienced running out of fuel Yes No c Intentional connecting or di...

Page 422: ...g spec ECM to avoid any damage on the fuel injection system NOTE When replacing the ECM of the models with Immo bilizer immobilizer system must be registered To do so all ignition keys and ID cards ne...

Page 423: ...or trouble Further against such a failure of sensors as may disable the drive the fail safe function is provided to ensure the minimal drivability The OBD system incorporated with the vehicles within...

Page 424: ...DIAGNOSTICS D PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system 499987500 CRANKSHAFT SOCKET Used for r...

Page 425: ...AGNOSTICS 4 Electrical Component Location A LOCATION 1 CONTROL MODULE 1 Engine control module ECM 3 Delivery test mode connector 4 Data link connector 2 Malfunction indicator light EN 06236 1 3 4 2 EN...

Page 426: ...1 Mass air flow and intake air temperature sensor 3 Engine coolant temperature sensor 6 Camshaft position sensor 4 Electronic throttle control 7 Crankshaft position sensor 2 Manifold absolute pressure...

Page 427: ...EN H4SO diag 10 Electrical Component Location ENGINE DIAGNOSTICS EN 06225 1 EN 01971 2 3 EN 02179 EN 01972 4 5 EN 00010 6 EN 00011 7 EN 00012 EN 04089 8...

Page 428: ...INE DIAGNOSTICS 1 Front oxygen A F sensor 3 Front catalytic converter 4 Rear catalytic converter 2 Rear oxygen sensor 1 Fuel level sensor 3 Fuel tank pressure sensor 4 Fuel sub level sensor 2 Fuel tem...

Page 429: ...EN H4SO diag 12 Electrical Component Location ENGINE DIAGNOSTICS EN 05725 2 1 EN 06168 3 EN 03132 4...

Page 430: ...OID VALVE ACTUATOR EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 Purge control solenoid valve 4 Fuel injector 6 Variable valve lift diagnosis oil pressure switch 2 EGR valve 5 Oil switchin...

Page 431: ...EN H4SO diag 14 Electrical Component Location ENGINE DIAGNOSTICS 1 EN 05732 EN 01976 2 EN 03105 3 EN 03106 4 EN 04985 5 6...

Page 432: ...EN H4SO diag 15 Electrical Component Location ENGINE DIAGNOSTICS 1 Pressure control solenoid valve 3 Drain valve 4 Drain filter 2 Canister EN 06228 3 1 2 4 EN 06167 1 EN 06157 2 EN 06158 4 3 3...

Page 433: ...IAGNOSTICS 1 Starter 5 Electronic throttle control relay 8 Radiator main fan relay 2 2 Fuel pump 6 Radiator main fan relay 1 9 A F oxygen sensor relay 3 Main relay 7 Radiator sub fan relay 10 Starter...

Page 434: ...EN H4SO diag 17 Electrical Component Location ENGINE DIAGNOSTICS EN 05616 1 2 EN 05726 EN 06378 9 3 4 5 EN 04465 6 8 7 EN 06328 10...

Page 435: ...lly opened 4 17 Power supply B134 19 5 5 Ground sensor B134 29 0 0 Electronic throttle control motor B137 5 Duty waveform Duty waveform Drive frequency 500 Hz Electronic throttle control motor B137 4...

Page 436: ...ng 8 14 MT model Cranking with the clutch pedal pressed 8 14 Starter relay control B136 20 ON 0 5 or less OFF 10 13 ON 0 5 or less OFF 12 14 A C switch B136 24 ON 10 13 OFF 0 ON 12 14 OFF 0 Ignition s...

Page 437: ...4 B134 20 0 or 10 13 0 or 12 14 Waveform Power steering oil pressure switch B134 33 ON 1 or less OFF 10 13 ON 1 or less OFF 12 14 Blower fan switch B135 11 ON 0 OFF 10 13 ON 0 OFF 12 14 Manual A C mo...

Page 438: ...d 0 When brake pedal is depressed 12 14 When brake pedal is released 0 Cruise control main switch B135 12 ON 0 OFF 5 ON 0 OFF 5 Cruise control command switch B135 24 When operating nothing 3 5 4 5 Whe...

Page 439: ...ule ECM I O Signal ENGINE DIAGNOSTICS Input output name Measuring condition Waveform 1 Crankshaft position sensor At idling 2 Camshaft position sensor At idling EN 05322 ONE CRANK ROTATION 5V 10ms 0 E...

Page 440: ...PEDAL POSITION SENSOR CLUTCH SWITCH STARTER RELAY IGNITION SWITCH STARTER MOTOR FUEL PUMP RELAY FUEL PUMP C25 C16 C6 B21 B29 B22 B32 B30 B31 B27 B23 M B FUSE No 13 M B FUSE No 11 F B FUSE No 4 F B FUS...

Page 441: ...20 A7 4 5 FUSE RELAY BLOCK A F OXYGEN SENSOR RELAY MAIN RELAY IG RELAY ELECTRONIC THROTTLE CONTROL RELAY PURGE CONTROL SOLENOID VALVE EGR VALVE IGNITION COIL IGNITOR ASSY COMBINATION METER MALFUNCTION...

Page 442: ...9 A6 A28 D4 D5 A19 5 6 10 14 5 3 B17 C28 C17 7 FUEL INJECTOR No 1 FUEL INJECTOR No 2 FUEL INJECTOR No 3 FUEL INJECTOR No 4 DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE ELECTRONIC THROTTLE CONTROL MANIF...

Page 443: ...24 D31 D30 A32 A31 7 2 11 8 12 13 A30 15 MASS AIR FLOW INTAKE AIR TEMPERATURE SENSOR FRONT OXYGEN A F SENSOR RH REAR OXYGEN SENSOR LH VVL DIAGNOSIS OIL PRESSURE SWITCH LH VVL DIAGNOSIS OIL PRESSURE SW...

Page 444: ...5 C18 C29 C27 B20 A5 C33 C24 C34 C26 C9 13 12 6 C15 MT B11 11 15 2 8 STOP LIGHT SWITCH BRAKE SWITCH SUB FAN RELAY MAIN FAN RELAY CRUISE CONTROL SWITCH BODY INTEGRATED UNIT IMMOBILIZER BODY INTEGRATED...

Page 445: ...ELECTRICAL SPECIFICATION Measuring condition After engine is warmed up Set the select lever in P range or N range or the shift lever in neutral Turn the A C to OFF Turn all the accessory switches to...

Page 446: ...aru Select Monitor or general scan tool because the circuit for Subaru Select Monitor may be damaged 1 2 3 4 5 7 6 8 9 10 11 12 13 15 14 16 EN 04893 Terminal No Contents Terminal No Contents 1 Blank 9...

Page 447: ...nostic data 2 MODE 02 Powertrain freeze frame data 3 MODE 03 Emission related powertrain DTC 4 MODE 04 Clear Reset emission related diagnostic information 5 MODE 06 Request on board monitoring test re...

Page 448: ...pening angle 13 Check whether oxygen sensor is installed 15 Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor Bank 1 Sensor 2 V and 1C Supporting OBD system 1F Elapse...

Page 449: ...MODE 04 PID Data Unit of measure 02 DTC that caused the freeze frame data storage required by CARB 03 Fuel system control status 04 Calculated engine load value 05 Engine coolant temperature C 06 Shor...

Page 450: ...l Bank 1 Sensor 2 88 0B 07 0B Oxygen sensor drop abnormal Bank 1 Sensor 2 08 0B A5 0B 05 10 Oxygen sensor response abnormal Bank 1 Sensor 2 06 10 21 89 20 Catalyst deterioration diagnosis Bank 1 31 8A...

Page 451: ...NOTE The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor 4 Connect the diagnosis cable to the SDI 5 Connect the SDI to data link co...

Page 452: ...low g s or lb m 2 5 g s or 0 33 lb m Throttle opening angle signal Throttle Opening Angle 2 0 Rear oxygen sensor voltage Rear O2 Sensor V 0 1 0 7 V Battery voltage Battery Voltage V 12 14 V Mass air f...

Page 453: ...ter switch signal Starter Switch OFF Rear oxygen monitor Rear O2 Rich Signal ON OFF Knocking signal Knocking Signal OFF Crankshaft position sensor signal Crankshaft Position Sig ON Camshaft position s...

Page 454: ...tch OFF when OFF SET COAST switch signal SET COAST Switch OFF when OFF RES ACC switch signal RESUME ACCEL Switch OFF when OFF Brake switch signal Brake Switch OFF when OFF Main switch signal Main Swit...

Page 455: ...of evaporative emission purge control system Evaporative purge system Supp YES Test of evaporative emission purge control system Evaporative purge system Rdy NO Secondary air system test Secondary air...

Page 456: ...S Monitoring test of fuel system Fuel system monitoring Comp NO Monitoring test of comprehensive component Component monitoring Enable YES Monitoring test of comprehensive component Component monitori...

Page 457: ...2 Absolute Throttle Pos 2 32 Absolute accelerator opening angle 1 Accelerator Pedal Pos 1 13 Absolute accelerator opening angle 2 Accelerator Pedal Pos 2 13 Target throttle opening angle Target Throt...

Page 458: ...peed signal Vehicle Speed km h or MPH Ignition timing advance for 1 cylinder Ignition timing adv 1 Intake air temperature signal Intake Air Temp C or F Intake air amount Mass Air Flow g s or lb m Thro...

Page 459: ...System Selection Menu display select Engine Control System 3 Click the OK button after the information of engine type has been displayed 4 On Engine Diagnosis display select Entry VIN 5 Perform the pr...

Page 460: ...ic Trouble Code DTC 2 SUBARU SELECT MONITOR OBD MODE 1 On Main Menu display select Each System Check 2 On System Selection Menu display select Engine Control System 3 Click the OK button after the inf...

Page 461: ...sor 1 P0132 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 P0137 O2 Sensor Circuit Low Voltage Bank 1 Sensor 2 P0138 O2 Sensor Circuit High Voltage Bank 1 Sensor 2 P0140 O2 Sensor Circuit No Activity...

Page 462: ...P1570 Antenna P1571 Reference Code Incompatibility P1572 IMM Circuit Failure Except Antenna Circuit P1574 Key Communication Failure P1576 EGI Control Module EEPROM P1577 IMM Control Module EEPROM P157...

Page 463: ...While servicing do not depress or release the clutch pedal or accelerator pedal quickly re gardless of the engine speed Quick operation may cause the vehicle to drop off the free roller To prevent the...

Page 464: ...nostic Trouble Code DTC Ref to EN H4SO diag 86 List of Diagnostic Trouble Code DTC Release the parking brake The speed difference between front and rear wheels may light the ABS warning light but this...

Page 465: ...e ABS warning light but this in dicates no malfunctions When engine control diag nosis is finished perform the ABS memory clearance procedure of self diagnosis system Ref to ABS diag 21 Clear Memory M...

Page 466: ...PREPARATION FOR DRIVE CYCLE 1 Check that the battery voltage is 12 V or more and fuel remains approx half 20 40 2 5 3 10 6 US gal 4 4 8 8 Imp gal 2 After performing the diagnostics and clearing the me...

Page 467: ...r C as well P0303 Cylinder 3 Misfire Detected Complete diagnosis with drive cycle B or C as well P0304 Cylinder 4 Misfire Detected Complete diagnosis with drive cycle B or C as well P0420 Catalyst Sys...

Page 468: ...th drive cycle A or C as well P0302 Cylinder 2 Misfire Detected Complete diagnosis with drive cycle A or C as well P0303 Cylinder 3 Misfire Detected Complete diagnosis with drive cycle A or C as well...

Page 469: ...is with drive cycle A or B as well P0172 System Too Rich Bank 1 Complete diagnosis with drive cycle A or B as well P0301 Cylinder 1 Misfire Detected Complete diagnosis with drive cycle A or B as well...

Page 470: ...by disconnecting the bat tery terminals 6 DRIVE CYCLE E 1 Make sure that the battery voltage is 10 9 V or more 2 Perform the Clear Memory Mode Ref to EN H4SO diag 55 Clear Memory Mode 3 Drive for app...

Page 471: ...lect Monitor 3 If the values from step 2 satisfy the following two conditions start the engine Condition Engine coolant temperature Intake air temperature d 5 C 41 F Engine coolant temperature Fuel te...

Page 472: ...or 2 SUBARU SELECT MONITOR OBD MODE 1 On Main Menu display select Each System Check 2 On System Selection Menu display select Engine Control System 3 Click the OK button after the information of en gi...

Page 473: ...ype has been displayed 12 On Engine Diagnosis display select Sys tem Operation Check Mode 13 On System Operation Check Mode display select Actuator ON OFF Operation 14 Select the desired compulsory ac...

Page 474: ...on the moni tor 1 FUEL PUMP CONTROL OFF DRIVE CAUTION After executing the operation check mode exe cute the Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memo ry Mode 1 On System Operation...

Page 475: ...urn to the System Op eration Check Mode screen NOTE For detailed operation procedures refer to PC ap plication help for Subaru Select Monitor 5 INJECTOR CONTROL INJECTION STOP MODE CAUTION After execu...

Page 476: ...k the OK button 3 In the EGR Valve Control display click the button or the button to change the setting values then click the OK button Setting is possible in increments of 1 STEP How ever the STEP nu...

Page 477: ...iag 62 MALFUNCTION INDICATOR LIGHT DOES NOT COME ON Malfunction Indicator Light p 3 Malfunction indicator light does not go off Ref to EN H4SO diag 64 MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF Malfu...

Page 478: ...f the diagnostic system detects a misfire which could damage the catalyst the malfunction indica tor light will blink at a cycle of 1 Hz 4 Turn the ignition switch to OFF and connect the delivery test...

Page 479: ...or light does not illuminate WIRING DIAGRAM EN 06660 3 B72 i1 B36 B136 i10 SBF 6 1 11 2 B72 16 MAIN SBF No 5 38 E 1 3 4 5 6 2 B136 i10 ECM COMBINATION METER IGNITION SWITCH BATTERY 16 10 11 12 13 14 1...

Page 480: ...poor contact of combination meter connector Is there poor contact of combi nation meter connector Repair the poor contact of combi nation meter con nector Go to step 4 4 CHECK HARNESS BETWEEN COMBINA...

Page 481: ...tors from ECM 3 Turn the ignition switch to ON Does the malfunction indicator light illuminate Repair the short circuit of harness between ECM and combination meter connector Replace the ECM Ref to FU...

Page 482: ...MAIN SBF No 5 IGNITION SWITCH BATTERY B135 B363 B136 B C B72 B75 2 1 3 4 6 2 1 2 3 4 5 6 8 B122 7 1 5 C11 C6 B122 B27 TERMINAL No OPTIONAL ARRANGEMENT 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20...

Page 483: ...lfunction indicator light illuminate Repair the ground short circuit of har ness between ECM and combi nation meter con nector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND DE LIVERY TEST MODE CONNECTO...

Page 484: ...NITION SWITCH BATTERY B135 B363 B136 B C B72 B75 2 1 3 4 6 2 1 2 3 4 5 6 8 B122 7 1 5 C11 C6 B122 B27 TERMINAL No OPTIONAL ARRANGEMENT 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32...

Page 485: ...indica tor light blinks when delivery test mode con nector is connect ed 2 CHECK HARNESS BETWEEN ECM AND DE LIVERY TEST MODE CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors fro...

Page 486: ...and ground line Ref to EN H4SO diag 74 CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE ECM Diagnostics for Engine Starting Failure p 4 Inspection of ignition control system Ref to EN H4SO...

Page 487: ...13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B225 B225 B106 E 12 10 ECM B136 B106 B72 B136 20 32 B14 1 2 M 1 3 4 5 6 2 BATTERY STARTER RELAY STARTER MOTOR MAGNE...

Page 488: ...ck the starter motor Ref to SC H4SO 7 Starter Go to step 5 5 CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR 1 Disconnect the connector from ignition switch 2 Measure the power supply volt...

Page 489: ...ition switch to OFF 2 Disconnect the connector from inhibitor switch 3 Measure the resistance of harness between starter relay connector and inhibitor relay con nector Connector terminal B225 No 10 T7...

Page 490: ...ess than 1 Go to step 17 Replace the clutch start switch Ref to CL 27 Clutch Switch 17 CHECK HARNESS BETWEEN ECM AND CLUTCH START SWITCH Measure the resistance of harness between ECM and clutch start...

Page 491: ...2 30 31 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 29 30 31 32 33 34 35 B21 B72 1 3 4 5 6 2 A B B137 5 6 7 8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19...

Page 492: ...ep 4 Repair the open or groundshortcircuit of power supply circuit 4 CHECK INPUT VOLTAGE OF MAIN RELAY Measure the voltage between main relay con nector and chassis ground Connector terminal B220 No 3...

Page 493: ...8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19 20 21 27 28 29 30 31 19 B21 E2 E12 SBF 7 32 49 33 47 1 2 3 4 B137 18 26 6 3 4 1 2 E ECM 5 6 B220 B21 1 2 3 4 E12 9 10 1 2 3 4 5 6 7 8 11 12 14...

Page 494: ...lown out of fuse 3 CHECK HARNESS BETWEEN ECM AND IG NITION COIL AND IGNITOR ASSEMBLY 1 Turn the ignition switch to OFF 2 Measure the resistance between ECM and the ignition coil and ignitor assembly c...

Page 495: ...4 Is the resistance less than 1 Go to step 7 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM and ignition coil and ignitor as sembly c...

Page 496: ...Inspection Mode WIRING DIAGRAM EN 07185 1 5 MAIN SBF No 12 SBF 6 E 3 1 B72 B220 B136 No 11 FUEL PUMP RELAY FUEL PUMP ECM BATTERY IGNITION SWITCH B136 B72 1 3 4 5 6 2 R58 B220 R58 M 6 5 E B97 R1 4 R57...

Page 497: ...itch to ON 2 Measure the voltage of power supply circuit between fuel pump connector and chassis ground Connector terminal R58 No 5 Chassis ground Is the voltage 10 V or more Replace the fuel pump Ref...

Page 498: ...Is the resistance less than 1 Go to step 8 Repair the open circuit of harness between ECM and fuel pump relay connector 8 CHECK POWER SUPPLY OF FUEL PUMP RELAY 1 Turn the ignition switch to ON 2 Meas...

Page 499: ...1 2 1 2 1 2 10 9 8 11 42 48 43 44 45 B137 E5 E16 E6 E17 B21 E2 SBF 7 B220 40 39 38 37 B220 E B137 B21 ECM FUEL INJECTOR No 1 MAIN RELAY BATTERY FUEL INJECTOR No 2 FUEL INJECTOR No 3 FUEL INJECTOR No 4...

Page 500: ...Disconnect the connectors from ECM 2 Measure the resistance of harness between ECM and fuel injector connector Connector terminal 1 B137 No 8 E5 No 1 2 B137 No 9 E16 No 1 3 B137 No 10 E6 No 1 4 B137 N...

Page 501: ...14 15 16 B21 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 42 43 36 37 38 39 48 49 50 51 52 53 54 40 41 44 45 46 47 B40 DATA LINK CONNECTOR 4 5 7 16 B...

Page 502: ...harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and data link connector Open circuit of harness between ECM and engine ground Poor contact of ECM...

Page 503: ...ION Diagnostic Procedure with Diagnostic Trouble Code DTC P0076 Intake Valve Control Solenoid Circuit Low Bank 1 Ref to EN H4SO diag 109 DTC P0076 INTAKE VALVE CONTROL SOLE NOID CIRCUIT LOW BANK 1 Dia...

Page 504: ...with Diagnostic Trouble Code DTC P0128 Coolant Thermostat Engine Coolant Temperature Below Thermostat Regulating Temperature Ref to EN H4SO diag 144 DTC P0128 COOLANT THERMOSTAT ENGINE COOLANT TEMPERA...

Page 505: ...DTC P0302 Cylinder 2 Misfire Detected Ref to EN H4SO diag 179 DTC P0302 CYLINDER 2 MISFIRE DETECTED Diagnostic Procedure with Diagnostic Trouble Code DTC P0303 Cylinder 3 Misfire Detected Ref to EN H4...

Page 506: ...M PURGE CONTROL VALVE CIRCUIT LOW Diagnostic Procedure with Diagnostic Trouble Code DTC P0459 Evaporative Emission System Purge Control Valve Circuit High Ref to EN H4SO diag 225 DTC P0459 EVAPORATIVE...

Page 507: ...or Circuit Range Performance High Bank1 Sensor1 Ref to EN H4SO diag 249 DTC P1153 O2 SENSOR CIRCUIT RANGE PERFORMANCE HIGH BANK1 SENSOR1 Diagnostic Procedure with Diagnostic Trouble Code DTC P1160 Ret...

Page 508: ...rol Module EEPROM Ref to IM diag 23 DTC P1577 IMM CONTROL MODULE EEPROM Diag nostic Procedure with Diagnostic Trouble Code DTC P1578 Meter Failure Ref to IM diag 23 DTC P1578 METER FAILURE Diagnostic...

Page 509: ...ITCH A B VOLTAGE CORRELATION Diagnostic Procedure with Diagnostic Trouble Code DTC P2138 Throttle Pedal Position Sensor Switch D E Voltage Correlation Ref to EN H4SO diag 302 DTC P2138 THROTTLE PEDAL...

Page 510: ...ble Code DTC Detecting Criteria TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspe...

Page 511: ...inal E71 No 1 Engine ground Is the resistance 1 M or more Go to step 3 Repair the ground short circuit of har ness between ECM and variable valve lift diagnosis oil pressure switch connector 3 CHECK H...

Page 512: ...ria TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO di...

Page 513: ...inal E72 No 1 Engine ground Is the resistance 1 M or more Go to step 3 Repair the ground short circuit of har ness between ECM and variable valve lift diagnosis oil pressure switch connector 3 CHECK H...

Page 514: ...6 C B137 D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN A F...

Page 515: ...F SENSOR CONNEC TOR Measure the resistance of harness between ECM and front oxygen A F sensor connector Connector terminal B135 No 9 E22 No 1 B135 No 8 E22 No 3 Is the resistance less than 1 Go to st...

Page 516: ...B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN A F SENSOR A F...

Page 517: ...easure the resistance between ECM and front oxygen A F sensor connector Connector terminal B136 No 2 E22 No 4 B136 No 3 E22 No 4 Is the resistance less than 1 Go to step 3 Repair the harness and conne...

Page 518: ...D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN A F SENSOR A...

Page 519: ...in the harness between ECM and front oxygen A F sensor connector Go to step 2 2 CHECK GROUND CIRCUIT FOR ECM 1 Disconnect the connectors from ECM 2 Measure the resistance between ECM and chassis groun...

Page 520: ...1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 B136 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 33 34 29 32 30 31 35 B135 5 6 7 8 2 1...

Page 521: ...from ECM 3 Measure the resistance between ECM and oxygen sensor connector Connector terminal B136 No 4 E23 No 1 Is the resistance less than 1 Go to step 3 Repair the harness and connector NOTE In thi...

Page 522: ...1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 B136 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 33 34 29 32 30 31 35 B135 5 6 7 8 2...

Page 523: ...ss between ECM and rearoxygensensor connector Go to step 2 2 CHECK GROUND CIRCUIT FOR ECM 1 Disconnect the connectors from ECM 2 Measure the resistance between ECM and chassis ground Connector termina...

Page 524: ...CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRI...

Page 525: ...General Scan Tool Instruction Manual Is the measured value 73 3 106 6 kPa 550 800 mmHg 21 65 31 50 inHg when the ignitionisturnedON and20 0 46 7 kPa 150 350 mmHg 5 91 13 78 inHg during idling Go to s...

Page 526: ...PTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE...

Page 527: ...cuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND OIL SWITCHING SOLENOID VALVE Measure the resistance between EC...

Page 528: ...MPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDUR...

Page 529: ...HECK HARNESS BETWEEN ECM AND OIL SWITCHING SOLENOID VALVE Measure the resistance of harness between ECM and oil switching solenoid valve connec tor Connector terminal B137 No 25 E67 No 1 B137 No 24 E6...

Page 530: ...PTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE...

Page 531: ...f harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND OIL SWITCHING SOLENOID VALVE Measure the resistance between ECM and...

Page 532: ...MPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDUR...

Page 533: ...or 2 CHECK HARNESS BETWEEN ECM AND OIL SWITCHING SOLENOID VALVE Measure the resistance between ECM and oil switching solenoid valve connector Connector terminal B137 No 31 E68 No 1 B137 No 30 E68 No 2...

Page 534: ...UTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING...

Page 535: ...FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appro priate DTC using the List of Diag nostic Trouble Code DTC Ref to EN H4SO diag 86 List of Diagnos tic Trouble Code DTC Replace th...

Page 536: ...or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06636 E B8...

Page 537: ...he following item Open circuit in harness between main relay and mass air flow and intake air tempera ture sensor con nector Poor contact of main relay connec tor 3 CHECK HARNESS BETWEEN ECM AND MASS...

Page 538: ...or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06636 E B...

Page 539: ...ation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4SO diag 34 Subaru Select Moni tor General scan tool For detailed operation procedures refer to the general scan tool operation manual...

Page 540: ...ng Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspecti...

Page 541: ...tor NOTE In this case repair the following item Open circuit of harness between ECM and manifold absolute pressure sensor connector Poor contact of ECM connector Poor contact of coupling connector 3 C...

Page 542: ...ing Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspect...

Page 543: ...n tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4SO diag 34 Subaru Select Moni tor General scan tool For detailed operation procedu...

Page 544: ...AUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRIN...

Page 545: ...tailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4SO diag 34 Subaru Select Moni tor General scan tool For detailed operation procedures refer to the general scan tool opera...

Page 546: ...placing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06636 E B83 3 B...

Page 547: ...cir cuit has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case tem porary poor con tact of connector may be the cause 2 CHECK H...

Page 548: ...eplacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06636 E B83 3...

Page 549: ...ow and intake air tempera ture sensor con nector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEM PERATURE SENSOR CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect...

Page 550: ...g Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PRO...

Page 551: ...her Go to step 2 Even if DTC is detected the cir cuit has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case tem porary poor con...

Page 552: ...ng Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PR...

Page 553: ...or connector Repair the poor contact of ECM or engine coolant temperature sen sor connector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND EN GINE COOLANT TEMPERATURE SENSOR CONNECTOR 1 Turn the ignitio...

Page 554: ...C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11 12...

Page 555: ...the resistance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and elec tronic throttle con trol connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the connect...

Page 556: ...C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11 1...

Page 557: ...less than 5 Go to step 3 Repair the harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact...

Page 558: ...mory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode Step Check Yes No 1 CHECK TIRE SIZE Is the tire size as specified and...

Page 559: ...YMPTOM Hard to start Improper idling Poor driving performance CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspe...

Page 560: ...gine cool ant temperature sensor terminals when the engine coolant is cold and after warmed up Terminals No 1 No 2 Is the resistance of engine cool ant temperature sensor differ ent between when engin...

Page 561: ...replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode Step Check Yes No 1 CHECK ENGIN...

Page 562: ...21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN A F SENSOR A F O...

Page 563: ...CM and front oxygen A F sensor connector 3 Measure the resistance between ECM and chassis ground Connector terminal B135 No 9 Chassis ground B135 No 8 Chassis ground Is the resistance 1 M or more Go t...

Page 564: ...B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN A F SENSOR A F...

Page 565: ...FRONT OXYGEN A F SENSOR CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from front oxy gen A F sensor 3 Turn the ignition switch to ON 4 Measure the voltage between ECM and c...

Page 566: ...B B136 C B137 D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN...

Page 567: ...following items Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a...

Page 568: ...C B137 D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN A F SE...

Page 569: ...terminal B135 No 9 E22 No 1 B135 No 8 E22 No 3 Is the resistance less than 1 Go to step 2 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between...

Page 570: ...9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 B136 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 33 34 29 32 30 31 35 B135 5 6 7 8 2 1...

Page 571: ...135 No 4 E23 No 3 B134 No 29 E23 No 4 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM and re...

Page 572: ...1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 B136 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 33 34 29 32 30 31 35 B135 5 6 7 8 2 1...

Page 573: ...No 4 E23 No 3 B134 No 29 E23 No 4 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM and rear...

Page 574: ...1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 B136 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 33 34 29 32 30 31 35 B135 5 6 7 8 2...

Page 575: ...or contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR Measure the resistance between rear oxygen sensor connector and chassis ground Connector terminal E23 No 3...

Page 576: ...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 33 34 29 32 30 31 B136 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 33 34 29 32 30 31 35 B135 5 6 7...

Page 577: ...data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4SO di...

Page 578: ...o 3 Chassis ground Is the voltage 0 2 0 5 V Replace the rear oxygen sensor Ref to FU H4SO 43 Rear Oxygen Sen sor Repair the harness and connector NOTE In this case repair the following item Open circu...

Page 579: ...RESSURE WARNING Place NO OPEN FLAMES signs near the working area CAUTION Be careful not to spill fuel Measure the fuel pressure Ref to ME H4SO 27 INSPECTION Fuel Pressure CAUTION Release fuel pressure...

Page 580: ...nsor Ref to FU H4SO 34 Mass Air Flow and Intake Air Temper ature Sensor 6 CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR 1 Start the engine and warm up engine until coolant temperature is highe...

Page 581: ...etecting Criteria CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE...

Page 582: ...ep Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appro priate DTC using the List of Diag nostic Trouble Code DTC Ref to EN H4SO diag 86 List of Diagnos tic Tro...

Page 583: ...TION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING...

Page 584: ...t has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case tem porary poor con tact of connector may be the cause 2 CHECK HARNESS B...

Page 585: ...UTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING...

Page 586: ...re sen sor connectors Go to step 3 3 CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and fuel temperature sensor...

Page 587: ...YMPTOM Hard to start Improper idling Poor driving performance CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspe...

Page 588: ...ep Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appro priate DTC using the List of Diag nostic Trouble Code DTC Ref to EN H4SO diag 86 List of Diagnos tic Tro...

Page 589: ...g Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PRO...

Page 590: ...re 215 C 419 F or more Go to step 2 Even if DTC is detected the cir cuit has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case t...

Page 591: ...ng Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PR...

Page 592: ...M or oil temperature sensor connec tor Repair the poor contact of ECM or the oil temperature sensor connector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND OIL TEMPERATURE SENSOR CONNECTOR 1 Turn the i...

Page 593: ...C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11 12...

Page 594: ...tance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and elec tronic throttle con trol connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the connector to ECM...

Page 595: ...C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11 1...

Page 596: ...d electron ic throttle control connector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL 1 Connect the connector to ECM 2 Measure the resistance between...

Page 597: ...y Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06633 E6 E17 E5 E16 1 2 1 2 1 2 1 2 1 2 10 9 8 11 42 48...

Page 598: ...ween ECM and fuel injector on faulty cylinders Connector terminal 1 B137 No 8 E5 No 1 2 B137 No 9 E16 No 1 3 B137 No 10 E6 No 1 4 B137 No 11 E17 No 1 Is the resistance less than 1 Go to step 4 Repair...

Page 599: ...ft position sensor Go to step 9 9 CHECK CRANK SPROCKET Remove the timing belt cover Ref to ME H4SO 48 REMOVAL Timing Belt Cover Is the crank sprocket rusted or does it have broken teeth Replace the cr...

Page 600: ...o step 15 15 CHECK MISFIRE SYMPTOM 1 Turn the ignition switch to ON 2 Read the DTC NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4SO dia...

Page 601: ...re not found check the IGNITION CONTROL SYS TEM of 1 and 2 cylinders side Ref to EN H4SO diag 76 IGNITION CONTROL SYS TEM Diagnostics for Engine Starting Failure Go to DTC P0171 Ref to EN H4SO diag 16...

Page 602: ...OUP OF 2 AND 4 CYLINDERS Are there any faults in 2 and 4 cylinders Repair or replace faulty parts NOTE Check the follow ing items Spark plug Fuel injector Compression ra tio Skipping timing belt teeth...

Page 603: ...or driving performance Knocking occurs CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO...

Page 604: ...sistance 600 k or more Go to step 2 Repair the poor contact of ECM connector 2 CHECK KNOCK SENSOR 1 Disconnect the connector from knock sen sor 2 Measure the resistance between knock sensor terminals...

Page 605: ...oor driving performance Knocking occurs CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4S...

Page 606: ...an 500 k Replace the knock sensor Ref to FU H4SO 30 Knock Sensor Repair the short circuit to ground in harness between ECM and knock sensor connector NOTE The harness be tween both con nectors are shi...

Page 607: ...f engine to start CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE In...

Page 608: ...ensor Terminals No 1 No 2 Is the resistance between 1 and 4 k Go to step 3 Replace the crank shaft position sen sor Ref to FU H4SO 26 Crankshaft Posi tion Sensor 3 CHECK HARNESS BETWEEN ECM AND CRANKS...

Page 609: ...SYMPTOM Engine stalls Failure of engine to start CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref...

Page 610: ...y 2 CHECK CRANK SPROCKET Remove the timing belt cover Are crank sprocket teeth cracked or damaged Replace the crank sprocket Ref to ME H4SO 56 Crank Sprocket Go to step 3 3 CHECK INSTALLATION CONDITIO...

Page 611: ...Engine stalls Failure of engine to start CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4...

Page 612: ...the resistance between camshaft position sensor connector and engine ground Connector terminal E15 No 1 Engine ground Is the resistance 1 M or more Go to step 3 Repair the short circuit to ground in h...

Page 613: ...tecting Criteria TROUBLE SYMPTOM Engine stalls Failure of engine to start CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode...

Page 614: ...tors are shielded Remove the shield and re pair the ground short circuit of the harness circuit 3 CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR Is the camshaft position sensor installation...

Page 615: ...arts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06658 E E18 2 5 6 4 3 1 B21 E2...

Page 616: ...CURRENT DATA FOR ENGINE Ref to EN H4SO diag 34 Subaru Select Moni tor General scan tool For detailed operation procedures refer to the general scan tool operation manual Is the measured value 53 3 kPa...

Page 617: ...137 C B136 E E A B134 B134 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 33 34 29 32 30 31 B136 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 618: ...H4SO 2 Gen eral Description Go to step 2 2 CHECK WAVEFORM DATA ON THE SUBA RU SELECT MONITOR WHILE DRIVING 1 Drive at a constant speed between 80 112 km h 50 70 MPH 2 After 5 minutes have elapsed in...

Page 619: ...ep 4 The waveform is displayed at abnor mal condition 1 Go to step 4 The waveform is displayed at abnor mal condition 2 Go to step 5 4 CHECK CATALYTIC CONVERTER Is the catalytic converter dam aged Rep...

Page 620: ...WEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch to ON 2 Measure the voltage between rear oxygen sensor connector and chassis ground Connector terminal E23 No 3 Chassis ground Is t...

Page 621: ...RE Inspection Mode WIRING DIAGRAM EN 07194 SBF 7 E4 1 2 E2 B21 41 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VAL...

Page 622: ...ain valve Ref to EC H4SO 19 Drain Valve 5 CHECK PURGE CONTROL SOLENOID VALVE Operate the purge control solenoid valve using the Subaru Select Monitor NOTE Purge control solenoid valve operation can be...

Page 623: ...SO 54 Fuel Tank Is the fuel tank damaged or is there any hole of more than 1 0 mm 0 04 in dia in it Repair or replace the fuel tank Ref to FU H4SO 54 Fuel Tank Go to step 10 10 CHECK ANY OTHER MECHANI...

Page 624: ...8 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BATTERY E4 1 2 R68 1 2 16 10 11...

Page 625: ...he resistance of harness between ECM and drain valve connector Connector terminal B136 No 17 R86 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repa...

Page 626: ...1 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BATTERY E4 1 2 R68 1 2 16 10...

Page 627: ...Measure the voltage between ECM and chassis ground Connector terminal B136 No 17 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between ECM and drain valve...

Page 628: ...g Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspectio...

Page 629: ...cap securely 2 CHECK PRESSURE VACUUM LINE NOTE Check the following items Disconnection leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank Disconnection...

Page 630: ...iteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mo...

Page 631: ...air the harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact of ECM connector Poor contact of coup...

Page 632: ...riteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection M...

Page 633: ...Subaru Select Monitor or gen eral scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4SO diag 34 Subaru Select Moni tor General sc...

Page 634: ...ROCEDURE Inspection Mode WIRING DIAGRAM EN 07194 SBF 7 E4 1 2 E2 B21 41 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRA...

Page 635: ...in valve Ref to EC H4SO 19 Drain Valve 5 CHECK PURGE CONTROL SOLENOID VALVE Operate the purge control solenoid valve using the Subaru Select Monitor NOTE Purge control solenoid valve operation can be...

Page 636: ...SO 54 Fuel Tank Is the fuel tank damaged or is there any hole of more than 0 5 mm 0 020 in dia in it Repair or replace the fuel tank Ref to FU H4SO 54 Fuel Tank Go to step 10 10 CHECK ANY OTHER MECHAN...

Page 637: ...WIRING DIAGRAM EN 07194 SBF 7 E4 1 2 E2 B21 41 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTRO...

Page 638: ...ain valve Ref to EC H4SO 19 Drain Valve 5 CHECK PURGE CONTROL SOLENOID VALVE Operate the purge control solenoid valve using the Subaru Select Monitor NOTE Purge control solenoid valve operation can be...

Page 639: ...el tank Ref to FU H4SO 54 Fuel Tank Is the fuel tank damaged Repair or replace the fuel tank Ref to FU H4SO 54 Fuel Tank Go to step 10 10 CHECK ANY OTHER MECHANICAL TROU BLE IN EVAPORATIVE EMISSION CO...

Page 640: ...194 SBF 7 E4 1 2 E2 B21 41 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BATT...

Page 641: ...lenoid valve Connector terminal B137 No 29 E4 No 1 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness betwe...

Page 642: ...7194 SBF 7 E4 1 2 E2 B21 41 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BAT...

Page 643: ...ECM and chassis ground Connector terminal B137 No 29 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between ECM and purge control sole noid valve connec to...

Page 644: ...t occur GENERAL DESCRIPTION Ref to GD H4SO 133 DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH Diagnostic Trouble Code DTC Detecting Criteria CAUTION After servicing or replacing faulty parts perform Clear...

Page 645: ...rouble Code DTC Detecting Criteria CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO d...

Page 646: ...B137 B136 D B220 C E C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1...

Page 647: ...Check the air cleaner element Is there excessive clogging on air cleaner element Replace the air cleaner element Ref to IN H4SO 4 Air Cleaner Ele ment Go to step 3 3 CHECK ELECTRONIC THROTTLE CON TROL...

Page 648: ...B136 D B220 C E C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9...

Page 649: ...nd throttle body Cracks of intake manifold gasket and throttle body gasket Disconnection of vacuum hoses Is there any fault in air intake system Repair air suction and leaks Go to step 3 3 CHECK ELECT...

Page 650: ...55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06629 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4...

Page 651: ...e DTC using the List of Diag nostic Trouble Code DTC Ref to EN H4SO diag 86 List of Diagnos tic Trouble Code DTC Go to step 2 2 CHECK HARNESS BETWEEN ECM AND IG NITION SWITCH 1 Turn the ignition switc...

Page 652: ...2 E2 B21 E 3 1 B134 B135 A D B137 C B136 B No 13 B134 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 33 34 29 32 30 31 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15...

Page 653: ...E Diagnostic Procedure with Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appro priate DTC using the List of Diag nostic Troub...

Page 654: ...1 34 B134 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 33 34 29 32 30 31 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 29 30 31 32 33 34...

Page 655: ...between ECM and chassis ground Connector terminal B134 No 7 Chassis ground B135 No 2 Chassis ground Is the voltage 13 15 V Go to step 3 Repair the open or groundshortcircuit of power supply circuit 3...

Page 656: ...ng CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode W...

Page 657: ...HARNESS CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and transmission harness connector T3 3 Measure the resistance between ECM and chassis ground Connector termina...

Page 658: ...TION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING...

Page 659: ...he poor contact of ECM connector Go to step 2 2 CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and neutral posi...

Page 660: ...ing CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode...

Page 661: ...e the resistance of harness between ECM and inhibitor switch connector Connector terminal B136 No 31 T7 No 6 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this ca...

Page 662: ...UTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING...

Page 663: ...e less than 1 Go to step 3 Repair the open circuit in harness between ECM and transmission har ness connector 3 CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNEC TOR Measure the resistance...

Page 664: ...A B135 B B136 C B137 D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT...

Page 665: ...stance of harness between ECM and front oxygen A F sensor connector Connector terminal B135 No 9 E22 No 1 B135 No 8 E22 No 3 Is the resistance less than 1 Go to step 3 Repair the harness and connector...

Page 666: ...A B135 B B136 C B137 D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRON...

Page 667: ...to step 3 Repair the ground short circuit of har ness between ECM and front oxy gen A F sensor connector 3 CHECK OUTPUT SIGNAL FOR ECM 1 Connect the connector to ECM 2 Turn the ignition switch to ON 3...

Page 668: ...1 41 48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BATTERY E4 1 2 R68 1 2 16...

Page 669: ...l solenoid valve con nector Connector terminal B136 No 28 R68 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit...

Page 670: ...48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BATTERY E4 1 2 R68 1 2 16 10 1...

Page 671: ...and chassis ground Connector terminal B136 No 28 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between ECM and pressure control solenoid valve con nector...

Page 672: ...48 D29 R68 1 2 R57 R15 11 10 R2 B98 R3 B99 R1 B97 R81 R82 8 C17 C28 R86 1 2 B136 C B137 D E PURGE CONTROL SOLENOID VALVE ECM DRAIN VALVE PRESSURE CONTROL SOLENOID VALVE BATTERY E4 1 2 R68 1 2 16 10 11...

Page 673: ...he drain hose Replace the drain hose Go to step 3 3 CHECK DRAIN VALVE OPERATION 1 Turn the ignition switch to OFF 2 Connect the delivery test mode connector at the lower portion of instrument panel on...

Page 674: ...ROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44...

Page 675: ...hose assembly connector Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND PCV HOSE ASSEMBLY Measure the resistance between PCV hose assembly connector and chassis ground Connector ter...

Page 676: ...to EN H4SO diag 260 DTC P1498 EGR SOLE NOID VALVE SIGNAL 4 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC CR DTC P1495 EGR SOLENOID VALVE SIGNAL 2 CIRCUIT MALFUNC...

Page 677: ...NAL 2 CIRCUIT MALFUNCTION LOW IN PUT Diagnostic Trouble Code DTC Detecting Criteria Ref to GD H4SO 174 DTC P1496 EGR SO LENOID VALVE SIGNAL 3 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Trouble Code DTC...

Page 678: ...20 40 39 38 37 MAIN RELAY B220 4 3 FUSE RELAY BLOCK B134 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 32 31 26 27 33 34 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

Page 679: ...tor terminal DTC P1492 B134 No 8 E18 No 3 DTC P1494 B134 No 9 E18 No 1 DTC P1496 B134 No 10 E18 No 4 DTC P1498 B134 No 20 E18 No 6 Is the resistance less than 1 Go to step 3 Repair the harness and con...

Page 680: ...NAL 2 CIRCUIT MALFUNCTION HIGH IN PUT Diagnostic Trouble Code DTC Detecting Criteria Ref to GD H4SO 174 DTC P1497 EGR SO LENOID VALVE SIGNAL 3 CIRCUIT MALFUNCTION HIGH INPUT Diagnostic Trouble Code DT...

Page 681: ...Is the voltage 10 V or more Repair the short circuit to power supply in harness between ECM and EGR valve con nector Repair the poor contact of ECM connector EN 06658 E E18 2 5 6 4 3 1 B21 E2 E2 B21 4...

Page 682: ...13 B134 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 33 34 29 32 30 31 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 29 30 31 32 33 34...

Page 683: ...ESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR 1 Disconnect the connectors from ECM 2 Measure the resistance between ECM and chassis ground Connector terminal B135 No 5 Chassis ground Is the resistance 1...

Page 684: ...rform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection Mode WIRING DIAGRAM EN 06633 E6 E17 E5 E16 1 2 1 2 1 2 1 2 1...

Page 685: ...A B136 C B137 D BATTERY ELECTRONIC THROTTLE CONTROL RELAY 1 2 3 4 5 6 E2 B21 B122 E E E 39 20 E57 4 6 1 2 3 5 37 36 52 35 34 ELECTRONIC THROTTLE CONTROL TERMINAL No OPTIONAL ARRANGEMENT 18 17 38 19 8...

Page 686: ...not to spill fuel Measure the fuel pressure Ref to ME H4SO 27 INSPECTION Fuel Pressure CAUTION Release fuel pressure before removing the fuel pressure gauge Is the measured value 339 5 360 5 kPa 3 5...

Page 687: ...and warm up engine until coolant temperature is higher than 75 C 167 F 2 For AT models set the select lever to P range or N range and for MT models place the shift lever in the neutral position 3 Tur...

Page 688: ...njector terminals on faulty cylinder Terminals No 1 No 2 Is the resistance 5 20 Go to step 13 Replace the faulty fuel injector Ref to FU H4SO 36 Fuel Injector 13 CHECK POWER SUPPLY LINE 1 Turn the ign...

Page 689: ...he timing belt dislocated from its proper position Repair the installa tion condition of timing belt Ref to ME H4SO 49 Timing Belt Go to step 19 19 CHECK ELECTRONIC THROTTLE CON TROL RELAY 1 Turn the...

Page 690: ...tween ECM and chassis ground Connector terminal B134 No 19 Chassis ground B134 No 18 Chassis ground B134 No 18 B136 No 6 B134 No 28 Chassis ground Is the resistance 1 M or more Go to step 25 Repair th...

Page 691: ...tronic throttle con trol connector 30 CHECK SENSOR OUTPUT 1 Connect all connectors 2 Turn the ignition switch to ON 3 Read the data of main throttle sensor signal using Subaru Select Monitor NOTE For...

Page 692: ...THROTTLE CON TROL MOTOR HARNESS Measure the resistance between electronic throttle control connectors Connector terminal E57 No 2 E57 No 1 Is the resistance 1 M or more Go to step 36 Repair the short...

Page 693: ...B136 C B137 D B21 E2 ECM B21 E2 50 51 3 4 E2 B21 E B21 E22 B138 B134 B135 A B B136 C 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 33 34 29 32 30 31 BATTERY FRONT OXYGEN...

Page 694: ...7 18 19 20 21 29 30 31 32 33 34 35 A B C TERMINAL No OPTIONAL ARRANGEMENT AMONG 1 2 5 AND 6 E23 1 53 1 19 E2 B21 E B21 E23 REAR OXYGEN SENSOR 1 3 4 2 2 3 4 B1 B4 A29 C4 B138 3 4 5 6 1 2 7 8 1 2 3 4 5...

Page 695: ...resistance between ECM and chassis ground Connector terminal B135 No 9 Chassis ground B135 No 8 Chassis ground Is the resistance 1 M or more Go to step 5 Repair the ground short circuit of har ness be...

Page 696: ...DATA FOR ENGINE Ref to EN H4SO diag 34 Subaru Select Moni tor General scan tool For detailed operation procedures refer to the general scan tool operation manual Is the engine coolant tempera ture 75...

Page 697: ...Flow and Intake Air Temper ature Sensor 14 CHECK REAR OXYGEN SENSOR DATA 1 Warm up the engine until engine coolant temperature is higher than 75 C 167 F and keep the engine speed at 3 000 rpm 2 minute...

Page 698: ...o to step 18 18 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and rear oxygen sensor 3 Measure the resistance of harn...

Page 699: ...0 C E C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10...

Page 700: ...pair the short circuit to power in the harness between ECM and electronic throttle control relay con nector Go to step 4 4 CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RE LAY 1 Turn the i...

Page 701: ...S BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL 1 Connect the connector to ECM 2 Measure the resistance between electronic throttle control connector and engine ground Connector terminal E57 No 3 Engine...

Page 702: ...terminal B137 No 5 E57 No 2 B137 No 4 E57 No 1 Is the resistance less than 1 Go to step 15 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between...

Page 703: ...d Poor contact of coupling connector 19 CHECK ELECTRONIC THROTTLE CON TROL Measure the resistance between electronic throttle control terminals Terminals No 2 No 1 Is the resistance 50 or less Go to s...

Page 704: ...4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11 12 19 20 2...

Page 705: ...e connectors from ECM 2 Turn the ignition switch to ON 3 Measure the voltage between electronic throttle control relay connector and chassis ground Connector terminal B220 No 32 Chassis ground Is the...

Page 706: ...8 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18...

Page 707: ...on trol relay Ref to FU H4SO 50 Electronic Throttle Control Relay 2 CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUP PLY 1 Turn the ignition switch to ON 2 Measure the voltage betwee...

Page 708: ...n Mode WIRING DIAGRAM EN 06643 B315 E C ECM B136 B137 D B83 B315 4 6 5 1 3 2 D3 A5 1 2 3 4 5 6 B21 E2 D2 B122 1 2 3 4 5 6 7 8 B21 B137 5 6 7 8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19 20...

Page 709: ...s the resistance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and accelera tor pedal position sensor connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the...

Page 710: ...on Mode WIRING DIAGRAM EN 06643 B315 E C ECM B136 B137 D B83 B315 4 6 5 1 3 2 D3 A5 1 2 3 4 5 6 B21 E2 D2 B122 1 2 3 4 5 6 7 8 B21 B137 5 6 7 8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19 2...

Page 711: ...OTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND AC CEL...

Page 712: ...n Mode WIRING DIAGRAM EN 06643 B315 E C ECM B136 B137 D B83 B315 4 6 5 1 3 2 D3 A5 1 2 3 4 5 6 B21 E2 D2 B122 1 2 3 4 5 6 7 8 B21 B137 5 6 7 8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19 20...

Page 713: ...tance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and accelera tor pedal position sensor connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the connector t...

Page 714: ...on Mode WIRING DIAGRAM EN 06643 B315 E C ECM B136 B137 D B83 B315 4 6 5 1 3 2 D3 A5 1 2 3 4 5 6 B21 E2 D2 B122 1 2 3 4 5 6 7 8 B21 B137 5 6 7 8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19 2...

Page 715: ...the harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact of coupling connector 3 CHECK HA...

Page 716: ...E C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11...

Page 717: ...1 Disconnect the connectors from ECM 2 Measure the resistance of harness between ECM and electronic throttle control connector Connector terminal B134 No 18 E57 No 6 B134 No 28 E57 No 4 B134 No 29 E5...

Page 718: ...CM 3 Measure the resistance between ECM con nectors Connector terminal B134 No 19 B134 No 18 B134 No 19 B134 No 28 Is the resistance 1 M or more Repair the poor contact of elec tronic throttle con tro...

Page 719: ...E C1 C21 D4 D5 A29 A19 D2 D1 D3 A5 D7 A28 A18 C6 ECM 31 29 30 32 B21 E57 B122 1 2 3 4 5 6 7 8 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 1 2 8 9 5 6 3 4 10 11...

Page 720: ...or pedal position sensor signal and the sub accelerator pedal position sensor signal 0 V Replace the accel erator pedal Ref to SP H4SO 4 Accelerator Pedal Repair the harness and connector NOTE In this...

Page 721: ...00 DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW Diagnostic Trouble Code DTC Detecting Criteria CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATI...

Page 722: ...teria CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4SO diag 55 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO diag 44 PROCEDURE Inspection M...

Page 723: ...sor 11 Fuel pump and fuel pump relay 12 EGR valve 3 Engine does not return to idle 1 Engine coolant temperature sensor 2 Electronic throttle control 3 Manifold absolute pressure sensor 4 Mass air flow...

Page 724: ...rature sensor 2 4 Crankshaft position sensor 3 5 Camshaft position sensor 3 6 Fuel injection parts 4 7 Electronic throttle control 8 Fuel pump and fuel pump relay 9 EGR valve 7 Spark knock 1 Mass air...

Page 725: ...EN H4SO diag 308 General Diagnostic Table ENGINE DIAGNOSTICS...

Page 726: ...ENOID CIRCUIT HIGH BANK 1 Diagnostic Trouble Code DTC Detecting Criteria P0082 Intake Valve Control Solenoid Circuit Low Bank 2 Ref to GD H4SO 24 DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW BA...

Page 727: ...UIT NO ACTIVITY DETECTED BANK 1 SENSOR 1 Diagnostic Trouble Code DTC Detecting Criteria P0137 O2 Sensor Circuit Low Voltage Bank 1 Sensor 2 Ref to GD H4SO 54 DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE BA...

Page 728: ...1 or Single Sensor Ref to GD H4SO 90 DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT BANK 1 OR SINGLE SENSOR Diagnostic Trouble Code DTC Detecting Criteria P0341 Camshaft Position Sensor A Circuit Range...

Page 729: ...rite ria P0507 Idle Air Control System RPM Higher Than Expected Ref to GD H4SO 140 DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED Diagnostic Trouble Code DTC Detecting Crite ria P0512 Star...

Page 730: ...SIGNAL 1 CIRCUIT MALFUNCTION HIGH INPUT Diagnostic Trouble Code DTC Detecting Criteria P1494 EGR Solenoid Valve Signal 2 Circuit Malfunction Low Input Ref to GD H4SO 174 DTC P1494 EGR SOLENOID VALVE S...

Page 731: ...L POSITION SEN SOR A MINIMUM STOP PERFORMANCE Diagnostic Trouble Code DTC Detecting Criteria P2122 Throttle Pedal Position Sensor Switch D Circuit Low Input Ref to GD H4SO 187 DTC P2122 THROTTLE PEDAL...

Page 732: ...sure switch remains OFF even though the intake valve tried to enter high mode oil switching solenoid valve duty is large this is judged as a Low NG High NG When the variable valve lift diagnosis oil p...

Page 733: ...s OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Low side 208 ms High side 3000 ms Secondary Pa...

Page 734: ...C P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE PERFORMANCE BANK 2 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0026 Ref to GD H4SO 8 DTC P0026 INTAKE VALVE CON TROL SOLENO...

Page 735: ...g at en gine status such as deceleration fuel cut 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after 42000 ms seconds or more have passed sinc...

Page 736: ...ion Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditi...

Page 737: ...uty control and the output terminal voltage at ON is 0 V and the output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains Low 2 COMPONENT DESCRIPTION 3 ENABL...

Page 738: ...n Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is mor...

Page 739: ...uty control and the output terminal voltage at ON is 0 V and the output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains High 2 COMPONENT DESCRIPTION 3 ENAB...

Page 740: ...Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more...

Page 741: ...e output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains Low 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE After starting the engine...

Page 742: ...tor Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are es...

Page 743: ...output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains High 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE After starting the engine...

Page 744: ...or Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are est...

Page 745: ...air pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition or when it is High whereas it seemed to be Low from the engine condition 2 COMPONENT DESCRIPTION 3 ENAB...

Page 746: ...OK If the duration of time while the following conditions are met is longer than the time indicated judge as OK Time Needed for Diagnosis Low side Less than 1 second High side Less than 1 second Judge...

Page 747: ...is longer than the time indicated judge as NG Time Needed for Diagnosis 2000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and...

Page 748: ...e following conditions are established is more than the predetermined time Time Needed for Diagnosis 2000 ms K DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW BANK 2 1 OUTLINE OF DIAGNOSIS NOTE Fo...

Page 749: ...oltage increases Judge as a high side NG when the air flow voltage indicates a large val ue regardless of running in a state where the air flow voltage decreases Judge air flow sensor property NG when...

Page 750: ...n 1 second High Less than 1 second Judgement Value Malfunction Criteria Threshold Value Low Output voltage 1 49 V Engine speed t 2000 rpm Throttle opening angle t 12 Intake manifold pressure t 66 7 kP...

Page 751: ...than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the...

Page 752: ...the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if...

Page 753: ...ing conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Jud...

Page 754: ...conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgeme...

Page 755: ...of engine condition 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition A Air 1 Ai...

Page 756: ...uminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1 seco...

Page 757: ...han the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the N...

Page 758: ...onger than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clea...

Page 759: ...are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as...

Page 760: ...tions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Ju...

Page 761: ...d judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous ti...

Page 762: ...ed judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous t...

Page 763: ...DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis only once after engine start A Resistance value k B Temperature C F 1 Connector 2 Thermistor element Secondary Parameters...

Page 764: ...ntinuous driving cy cles Normality Judgement Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria...

Page 765: ...e them to judge as NG when the engine coolant temperature does not decrease when it should 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis only once after sta...

Page 766: ...s time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value Engine coola...

Page 767: ...is lower than the estimated engine coolant temperature and the difference between them is large Judge as OK when the engine coolant temperature becomes to 75 C 167 F and the difference is small befor...

Page 768: ...eeded for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value Battery voltage t 10 9 V Estimate ambient temperature t 7 C 19 4 F Thermostat malfunction diagnosis Incomple...

Page 769: ...rcuit of sensor Judge as NG when the element voltage is out of the specified range 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Elect...

Page 770: ...ndicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more t...

Page 771: ...ircuit of sensor Judge as NG when the element voltage is out of the specified range 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Elec...

Page 772: ...000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are e...

Page 773: ...s Clogged ventilation holes are diagnosed When the holes are clogged the A F output variation becomes slow comparing with the actual A F variation because oxygen which reaches the zirconia layer is in...

Page 774: ...ZrO2 4 Ceramic heater 2 Exhaust gas Secondary Parameters Enable Condition Time needed for all secondary parame ters to be in enable conditions t 1024 ms Battery voltage t 10 9 V Barometric pressure 75...

Page 775: ...gnosis 32 ms 4 1640 time s Judgement Value Malfunction Criteria Threshold Value parafca td2faf td2lmd 0 45 where td2faf N td2faf n 1 d2faf n td2lmd N td2lmd n 1 d2lmd n add up to 32 ms 4 1640 time s d...

Page 776: ...tect open circuits of the sensor Judge as NG when the impedance of the element is large 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A...

Page 777: ...s soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed fo...

Page 778: ...ct continuity NG of the oxygen sensor If the oxygen sensor voltage reading is not within the probable range considering the operating conditions judge as NG 2 COMPONENT DESCRIPTION A Electromotive for...

Page 779: ...Not in operation Closed loop control at the oxygen sensor In operation Misfire detection every 200 rotations 5 time s Front oxygen A F sensor compensation coefficient Not in limit value Battery voltag...

Page 780: ...predetermined time Time Needed for Diagnosis High Less than 1 second Low 1 Less than 1 second Low 2 Less than 1 second Low 3 Less than 1 second AG DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE BANK 1 SENS...

Page 781: ...sor voltage is large rich when recovering from a deceleration fuel cut Lean o rich diagnosis response 1 Measure the response time for oxygen sensor output changes when the A F ratio changes from lean...

Page 782: ...sensor voltage for the timing of the deceleration Secondary Parameters Enable Condition Battery voltage t 10 9 V A F main feedback control condition Completed Deceleration fuel cut time is 6000 ms or...

Page 783: ...ate the minimum response time for output change between 0 5 V and 0 2 V for the judgement criteria A 0 55 V E 0 V H Execute the malfunction judge ment in 2000 ms from the recov ery of fuel cut on dece...

Page 784: ...es Normality Judgement 1 Regardless of a deceleration fuel cut if the response time diagnosis value when the oxygen sensor volt age has changed from rich to lean is shorter than the threshold value ju...

Page 785: ...calculate the minimum response time for output change between 0 3 V and 0 5 V for the judgement criteria A 0 55 V G More than 120000 ms J Judge NG when the voltage of rear oxygen sensor is 0 25 V or l...

Page 786: ...ion fuel cut if the response time diagnosis value when the oxygen sensor volt age has changed from rich to lean is shorter than the threshold value judgement value judge as a normal condition Response...

Page 787: ...EMENT 4 GENERAL DRIVING CYCLE Perform the diagnosis once after starting the engine A Electromotive force B Air fuel ratio C Rich D Lean E Theoretical air fuel ratio F Comparative voltage 1 Atmosphere...

Page 788: ...Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1...

Page 789: ...riving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 10 s...

Page 790: ...when the malfunction criteria below continues for 10 seconds Time Needed for Diagnosis 10 s Secondary Parameters Enable Condition A F main learning system In operation Engine coolant temperature t 75...

Page 791: ...lly fuel temperature is lower than engine coolant temperature When the fuel temperature becomes higher than the engine coolant temperature the range is considered to be shifted and judged as NG Stuck...

Page 792: ...ys perform diagnosis after 20 seconds have passed since the engine started Judgement Value Malfunction Criteria Threshold Value Fuel level t 9 6 2 2 54 US gal 2 11 Imp gal Elapsed time after starting...

Page 793: ...when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1 second Judgem...

Page 794: ...nger than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clea...

Page 795: ...is longer than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK an...

Page 796: ...bnormality Judgement Judge as NG when the following conditions are established Secondary Parameters Enable Condition Battery voltage t 10 9 V Engine speed t Value from Map Map Engine coolant temperatu...

Page 797: ...engine Time Needed for Diagnosis Less than 1 second Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and cl...

Page 798: ...time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunctio...

Page 799: ...time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunctio...

Page 800: ...judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time...

Page 801: ...ed judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous t...

Page 802: ...fire 180 Interval Difference Method MT 1 800 rpm or less AT None 360 Interval Difference Method whole range 720 Interval Difference Method 3 000 rpm or more 2 Misfire every time FTP 1 5 times misfire...

Page 803: ...100 3 9 13 3 100 3 9 13 3 100 3 9 13 3 100 3 9 13 3 100 3 9 13 3 100 3 9 13 3 100 3 9 13 3 100 3 9 rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300 kPa mmHg inHg 26 195 0 7 7 23 9...

Page 804: ...the following figure pick a cylinder as the standard and name it omg 0 And the former crank shaft position speed is named omg 1 the second former crankshaft position speed is named omg 2 the third is...

Page 805: ...the following cases domg 180 judgement value of positive side domg 180 d judgement value of negative side Judgement value before 180 CA Diagnostic value domg 360 omg 1 omg 0 omg 3 omg 2 Misfire judgem...

Page 806: ...iving cy cles Normality Judgement Time Needed for Diagnosis 1000 engine revs Diagnostic value domg 720 omg 1 omg 0 omg 5 omg 4 Misfire judgement domg 720 Judgement value o Judge as mis fire Judgement...

Page 807: ...e Code DTC Detecting Criteria AW DTC P0304 CYLINDER 4 MISFIRE DETECTED 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0301 Ref to GD H4SO 78 DTC P0301 CYLINDER 1 MISFIRE DETECTED...

Page 808: ...longer than the time indicated judge as NG Time Needed for Diagnosis 1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and c...

Page 809: ...s longer than the time indicated judge as NG Time Needed for Diagnosis 1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and...

Page 810: ...G when the crank signal is not input even though the starter was rotated 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Cam signal B Cra...

Page 811: ...lluminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Ti...

Page 812: ...en there is a problem in the number of crankshaft signals for every revolution 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION A Cam signal B Crankshaft signal 1 Crankshaft position sensor 2 Crank sprocket...

Page 813: ...luminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than th...

Page 814: ...position sensor Judge as NG when the number of camshaft signals remains abnormal 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Camsha...

Page 815: ...ight Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the pr...

Page 816: ...or output property Judge as NG when the camshaft line signal input timing is shifted from the crankshaft signal because of tim ing belt tooth chip etc 2 COMPONENT DESCRIPTION A Camshaft signal B Crank...

Page 817: ...Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Engine two revolutions Second...

Page 818: ...re negative pressure is constant because the throttle valve is fully closed during de celeration fuel cut At this time when the EGR valve is opened closed the intake manifold pressure will change EGR...

Page 819: ...et the EGR target step to 0 3 Label the intake manifold pressure as PMOF2 which is observed after one second has passed since EGR target step was set to 0 after two seconds have passed since the enabl...

Page 820: ...f the following conditions are established Time Needed for Diagnosis 1 time Judgement Value Malfunction Criteria Threshold Value PMON PMOF1 PMOF2 2 2 5 kPa 18 63 mmHg 0 7 inHg A 3000 ms C 1000 ms D 45...

Page 821: ...en Sensor B Deterioration 1 Front oxygen A F sensor 2 Front oxygen sensor 3 Catalytic converter Secondary Parameters Enable Condition Battery voltage t 10 9 V Barometric pressure t 75 kPa 563 mmHg 22...

Page 822: ...omes the predetermined value or more calculate the diag nostic value Abnormality Judgement If the duration of time while the following conditions are met is within the time indicated judge as NG Time...

Page 823: ...ssure change using the fuel tank pressure sensor When in 0 04 inch diagnosis perform in the order of mode Z o mode A o mode B o mode C and mode D When in 0 02 inch diagnosis perform in the order of mo...

Page 824: ...tank pressure returns to the target start level of P2 cal culation If the tank pressure does not become the value make advanced OK judgement 0 18600 ms Mode D Negative pressure variation measure ment...

Page 825: ...shifting pressure If the tank pressure does not change to the Mode E shifting pressure make advanced OK judgement 0 0 ms 200000 ms Mode E Evaporation generated amount calculation Calculate the amount...

Page 826: ...atmospheric air pressure Normally the solenoid is set to OFF The valve opens and closes mechanically in accordance with the pressure difference between tank and atmospheric air or tank and canister Th...

Page 827: ...pressure and the part below Y is charged with canister pressure If the atmospheric air pressure port is A tank pressure port is B and canister pressure port is C the air flows according to pressure di...

Page 828: ...Code DTC Detecting Criteria GENERAL DESCRIPTION When B C solenoid OFF When Solenoid is ON a Barometric pressure b Fuel tank c Canister 1 Valve a Barometric pressure b Fuel tank c Canister EN 01718 A B...

Page 829: ...ed 1050 rpm 6000 rpm Fuel tank pressure t 4 kPa 30 mmHg 1 2 inHg Intake manifold relative vacuum relative pres sure t 26 7 kPa 200 mmHg 7 9 inHg Vehicle speed t 32 km h 19 9 MPH Fuel level 9 6 2 2 54...

Page 830: ...after starting the engine t 120 s Fuel temperature 10 C 14 F 55 C 131 F Fuel level 9 6 2 2 54 US gal 2 11 Imp gal 54 4 2 14 37 US gal 11 97 Imp gal Intake manifold relative vacuum relative pres sure...

Page 831: ...Z and Judge as NG when the following conditions are es tablished after predetermined amount of time Time Needed for Diagnosis 0 ms 3000 ms 13000 ms Malfunction Indicator Light Illumination Illuminates...

Page 832: ...NERAL DESCRIPTION Normal Normal when evptez evptezha d 0 4 kPa 3 mmHg 0 1 inHg is established Time Needed for Diagnosis 0 ms 3000 ms 1 Mode Z 3 Fuel tank pressure 5 OK judgement 2 3000 ms 4 0 4 kPa 3...

Page 833: ...ha 0 9 kPa 6 5 mmHg 0 3 inHg No fuel sloshing of over 2 2 0 53 US gal 0 44 Imp gal lasts for more than 40000 ms Judge as abnormal when all are established 1 Mode Z 4 Fuel tank pressure 7 40000 ms no f...

Page 834: ...s not reach the target negative pressure judge that there is a large leak age in the system and terminate the evaporative emission control system diagnosis Abnormality Judgement Judge as NG large leak...

Page 835: ...riving cy cles Judgement Value Malfunction Criteria Threshold Value DTC P2 1 5 P1 Value of Map 5 P0442 P2 Tank pressure that changes every 10000 ms in mode D P1 Tank pressure that changes every 10000...

Page 836: ...en the tank pressure returns to the start level of P2 calculation or when the pre determined amount of time has passed Mode D Calculate the amount of negative pressure change Monitor the tank pressure...

Page 837: ...1 inHg 0 4 kPa 2 7 mmHg 0 1 inHg 0 4 kPa 2 7 mmHg 0 1 inHg 10 2 2 64 US gal 2 2 Imp gal 0 kPa 0 mmHg 0 inHg 0 1 kPa 0 5 mmHg 0 inHg 0 2 kPa 1 7 mmHg 0 1 inHg 0 4 kPa 2 7 mmHg 0 1 inHg 0 4 kPa 2 7 mmH...

Page 838: ...4 2 mmHg 0 2 inHg 0 6 kPa 4 2 mmHg 0 2 inHg 0 6 kPa 4 2 mmHg 0 2 inHg 20 2 5 28 US gal 4 4 Imp gal 0 1 kPa 1 mmHg 0 inHg 0 4 kPa 3 25 mmHg 0 1 inHg 0 5 kPa 4 1 mmHg 0 2 inHg 0 5 kPa 4 1 mmHg 0 2 inHg...

Page 839: ...level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Bobbin 8 Magnetic plate 14 Retainer 2 Coil...

Page 840: ...udgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement V...

Page 841: ...ut level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Bobbin 8 Magnetic plate 14 Retainer 2 Coi...

Page 842: ...Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement...

Page 843: ...e sta tus 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after 60 s have passed since the engine started Pay attention to the fuel level and tem...

Page 844: ...ter counts up Time Needed for Diagnosis 60 s 16 time s or more Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as...

Page 845: ...E OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform...

Page 846: ...ation Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined...

Page 847: ...L DRIVING CYCLE Perform the diagnosis when purging enable conditions are met without idling A Output voltage B Input voltage C To fuel tank 1 Connector 2 Terminals Secondary Parameters Enable Conditio...

Page 848: ...DETECTED VERY SMALL LEAK 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0442 Ref to GD H4SO 99 DTC P0442 EVAPORATIVE EMIS SION CONTROL SYSTEM LEAK DETECTED SMALL LEAK Diagnostic...

Page 849: ...uit of the purge control solenoid valve Judge as NG when the ECM output level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform t...

Page 850: ...icator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are...

Page 851: ...uit of the purge control solenoid valve Judge as NG when the ECM output level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform t...

Page 852: ...cator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are...

Page 853: ...tect malfunctions of the fuel level sensor output property If the fuel level does not vary in a particular driving condition engine condition where it should judge as NG 2 COMPONENT DESCRIPTION 3 ENAB...

Page 854: ...s are established Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value Accumulated amount of intake air t 330957 g 11672 85 oz Max Min values of fuel level...

Page 855: ...n or short circuit of fuel level sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine contro...

Page 856: ...urs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Need...

Page 857: ...n or short circuit of fuel level sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine contro...

Page 858: ...urs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Need...

Page 859: ...output voltage variation of the fuel level sensor is larger than the threshold value 2 ENABLE CONDITIONS 3 GENERAL DRIVING CYCLE Always perform the diagnosis continuously at idle speed Pay attention t...

Page 860: ...ulative values are not over the thresh old value Otherwise when either of them is over the threshold value the diagnosis counter counts up Judge as NG if the counter indicated 4 time s A 12288 ms C Ma...

Page 861: ...t Value Malfunction Criteria Threshold Value Integrated times of the condition reaching follows t 4 time s DELFLMAX t Value from Map or SUMFL t 25 92 V At this time DELFLMAX Maximum difference of sen...

Page 862: ...uration of time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a...

Page 863: ...ormality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 10 s Secondary Param...

Page 864: ...riving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 10 s...

Page 865: ...dicated judge as NG Time Needed for Diagnosis 180000 ms Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and...

Page 866: ...mmobilizer key Use of unregistered key in body integrated unit P1570 Antenna Faulty antenna P1571 Reference Code Incompatibility Reference code incompatibility between body integrated unit and ECM P15...

Page 867: ...0 kbps 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine 5 DIAGNOSTIC METHOD Abnormality Judgement Judge as NG when the following conditions are...

Page 868: ...ined time Time Needed for Diagnosis 1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Judgement Value Malfunction Criteria Threshold Value Battery voltage 10...

Page 869: ...alfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG when the malfunction criteria below are met Secondary Parameters En...

Page 870: ...2 ENABLE CONDITIONS 3 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 4 DIAGNOSTIC METHOD Abnormality Judgement Judge as NG if the criteria below are met Time Needed for Diagnosis Unde...

Page 871: ...tes abnormally 4 When the communication between main CPU mo sub CPU is abnormal 5 When the input amplifier circuit of throttle position sensor 1 is abnormal 6 When the cruise control cannot be cancele...

Page 872: ...lliseconds 7 200 milliseconds Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Secondary Parameters Enable Condition 1 Ignition switch ON 2 Ignition switch ON 3 Non...

Page 873: ...hrottle control is operating 5 DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis Target opening angle and actual opening angle 250 mi...

Page 874: ...icator Light Illumination Illuminates as soon as a malfunction occurs 1 Difference between target opening angle and actual opening angle 2 Target throttle opening angle 3 NG area 1 Judgement time mill...

Page 875: ...ditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement...

Page 876: ...ted judge as NG Time Needed for Diagnosis 100 time s Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and cl...

Page 877: ...tion Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear NG when there is change in the neutral SW Time Needed fo...

Page 878: ...ated judge as NG Time Needed for Diagnosis 100 time s Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and c...

Page 879: ...tion Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear NG when there is change in the neutral SW Time Needed fo...

Page 880: ...da value is abnormal in accordance with O value of front oxygen A F sensor and running conditions such as vehicle speed amount of intake air engine coolant temperature sub feedback control etc 2 COMPO...

Page 881: ...Parameters Enable Condition Time needed for all secondary parameters to be in enable conditions t 4096 ms Battery voltage t 10 9 V Barometric pressure t 75 kPa 563 mmHg 22 2 inHg Rear oxygen sensor su...

Page 882: ...bda value is abnormal in accordance with O value of front oxygen A F sensor and running conditions such as vehicle speed amount of intake air engine coolant temperature sub feedback control etc 2 COMP...

Page 883: ...Parameters Enable Condition Time needed for all secondary parameters to be in enable conditions t 4096 ms Battery voltage t 10 9 V Barometric pressure t 75 kPa 563 mmHg 22 2 inHg Rear oxygen sensor su...

Page 884: ...n with the motor power stopped 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Ignition switch ON o OFF Ignition switch OFF o ON Only after clearing memory 1 Opener spring 4 Full c...

Page 885: ...nction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis 3...

Page 886: ...ssure control solenoid valve Judge as NG when ECM output level is different from actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis...

Page 887: ...Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second...

Page 888: ...ure control solenoid valve Judge as NG when ECM output level is different from actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis af...

Page 889: ...s Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 secon...

Page 890: ...CLE Always perform the diagnosis continuously 1 Bobbin 8 Magnetic plate 14 Retainer 2 Coil 9 Shaft 15 Diaphragm 3 Diode 10 Plate 16 Movable core 4 Stator core 11 Valve 17 Spring 5 End plate 12 Housing...

Page 891: ...OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction C...

Page 892: ...GNOSIS Detect the blow by hose disconnection abnormality Judge as NG when the diagnosis terminal voltage is high 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the d...

Page 893: ...urs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 sec...

Page 894: ...el differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform diagnosis continuously during EGR operation 1 Engine control module ECM 3 Detectin...

Page 895: ...curs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 128 ms Judgeme...

Page 896: ...ut level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3 Detecting ci...

Page 897: ...curs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 128 ms Judgeme...

Page 898: ...492 Ref to GD H4SO 170 DTC P1492 EGR SOLENOID VALVE SIGNAL 1 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Trouble Code DTC Detecting Cri teria CU DTC P1497 EGR SOLENOID VALVE SIGNAL 3 CIRCUIT MALFUNCTION...

Page 899: ...ed judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous...

Page 900: ...tic Trouble Code DTC Detecting Criteria DB DTC P1574 KEY COMMUNICATION FAILURE 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0513 Ref to GD H4SO 142 DTC P0513 INCORRECT IMMO BIL...

Page 901: ...after engine starting within the predetermined time Time Needed for Diagnosis 14 seconds Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cycles Nor...

Page 902: ...continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criter...

Page 903: ...zone 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km h 50 MPH or more A Electr...

Page 904: ...Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following...

Page 905: ...e as NG 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km h 50 MPH or more A Ele...

Page 906: ...lfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following c...

Page 907: ...n the malfunction criteria below are met Time Needed for Diagnosis 500 milliseconds For NG 2000 milliseconds For OK Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs...

Page 908: ...diagnosis continuously 5 DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis 400 milliseconds For NG 2000 milliseconds For OK Malfuncti...

Page 909: ...switch OFF o ON Only after clearing memory 5 DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis 600 milliseconds For NG 400 millisecon...

Page 910: ...the NG when the malfunction criteria below are met Time Needed for Diagnosis 8 80 milliseconds Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs 1 Engine control mo...

Page 911: ...pedal position sensor 1 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 912: ...is 100 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions ar...

Page 913: ...pedal position sensor 1 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 914: ...sis 32 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions ar...

Page 915: ...pedal position sensor 2 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 916: ...is 100 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions ar...

Page 917: ...pedal position sensor 2 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 918: ...is 100 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions ar...

Page 919: ...f throttle position sensor 1 is different from the throttle position sensor 2 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Throttle p...

Page 920: ...ity Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 24 ms Judgement Value Mal...

Page 921: ...sition sensor 1 is different from the throttle position sensor 2 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module EC...

Page 922: ...ormality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 116 ms Judgement Val...

Page 923: ...ons are met is longer than the time indicated judge as NG Time Needed for Diagnosis 328 ms Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles...

Page 924: ...dgement If the duration of time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminat...

Page 925: ...udgement If the duration of time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illumina...

Page 926: ...GD H4SO 202 Diagnostic Trouble Code DTC Detecting Criteria GENERAL DESCRIPTION...

Page 927: ...TION Fuel tank Capacity 64 2 16 9 US gal 14 1 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 550 850 kPa 5 61 8 67 kgf cm2 79 8 123 3 psi Discharge rate 155 2 40 9...

Page 928: ...INJECTION FUEL SYSTEMS B COMPONENT 1 INTAKE MANIFOLD 8 9 9 T2 T2 T5 T5 T2 7 7 8 T3 17 18 16 15 11 11 21 10 10 22 11 T3 23 23 24 4 5 12 25 26 6 T2 T2 B B A A 19 20 27 14 10 3 2 3 1 13 T4 T4 T4 T4 T2 T...

Page 929: ...27 Air control hose 5 Vacuum hose D 17 Filter 6 Vacuum hose C 18 Intake manifold Tightening torque N m kgf m ft lb 7 Intake manifold gasket 19 Wastegate control solenoid valve ASSY T1 1 25 0 1 0 9 8...

Page 930: ...MS 3 CRANKSHAFT POSITION CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 3 Camshaft position sensor LH Tightening torque N m kgf m ft lb 2 Knock sensor 4 Camshaft position sensor RH T...

Page 931: ...FU H4DOTC 6 General Description FUEL INJECTION FUEL SYSTEMS 4 FUEL TANK T1 14 12 T4 T4 T3 T3 T3 T2 T3 T3 T4 3 19 20 21 2 17 18 7 10 9 1 11 15 13 T2 T3 6 16 5 4 16 FU 04297 22 23 23 T1 8 T1...

Page 932: ...sub level sensor gasket 23 Self locking nut 4 Delivery tube 14 Fuel sub level sensor protector 5 Return tube 15 Fuel sub level sensor filter Tightening torque N m kgf m ft lb 6 Jet pump tube 16 Retain...

Page 933: ...FU 04298 T3 D 14 7 T1 6 13 T1 T1 1 4 5 9 1 1 10 B A T3 1 1 1 1 22 22 23 16 17 18 19 20 21 T3 G 14 H 37 35 C F F T3 T4 39 24 1 1 1 1 30 27 1 1 1 25 26 28 29 32 1 33 31 1 36 34 38 T3 T3 1 T5 T5 T5 42 4...

Page 934: ...24 PCV drain tube 39 Canister 8 Fuel damper holder 25 Evaporation hose D 40 Canister cover LH 9 Clamp 26 Evaporation hose E 41 Center canister cover 10 Purge damper 27 Pressure control solenoid valve...

Page 935: ...tion pipe A 8 Evaporation hose A 14 Evaporation hose C 3 Fuel filler cap 9 Grommet 4 Filler ring 10 Evaporation pipe B Tightening torque N m kgf m ft lb 5 Filler pipe gasket 11 Quick connector T1 4 4...

Page 936: ...S 7 FUEL PUMP 1 Sub tank bracket ASSY 6 Fuel filter 10 Sub tank 2 O ring 7 Clip 11 Cushion 3 O ring 8 Spacer 12 Fuel level sensor 4 Fuel pump harness 9 Pump ASSY 13 Fuel temperature sensor 5 Spring 2...

Page 937: ...of sensors or units be sure to disconnect the ground cable from the bat tery Place NO OPEN FLAMES signs near the working area Prepare a container and cloth to prevent scattering of fuels when perform...

Page 938: ...or on the fuel delivery hose side of the engine compart ment 1B022XU0 SUBARU SELECT MONITOR III KIT Used for draining fuel and each inspection TOOL NAME REMARKS Circuit tester Used for measuring resis...

Page 939: ...nt 6 Remove the intercooler Ref to IN H4DOTC 13 REMOVAL Intercooler 7 Disconnect the connectors from the throttle posi tion sensor 8 Remove the bolts which secure the air by pass pipe and PCV pipe to...

Page 940: ...THROTTLE SENSOR METHOD WITH SUBARU SELECT MONITOR 1 Turn the ignition switch to ON engine OFF 2 Read the throttle opening angle signal and volt age of throttle sensor using Subaru Select Monitor Ref...

Page 941: ...ne Coolant 10 Remove the air intake duct Ref to IN H4DOTC 11 REMOVAL Air Intake Duct 11 Remove the air intake boot 12 Remove the intercooler Ref to IN H4DOTC 13 REMOVAL Intercooler 13 Remove the gener...

Page 942: ...rusion of the clamp as shown in the figure below unlock the clamp and disconnect ST 18353AA000 CLAMP PLIERS 23 Disconnect the air control hose A from the wastegate actuator and loosen the clamp that h...

Page 943: ...l pressure switch B and crankshaft position sensor C 27 Disconnect the connector from power steering pump switch 28 Disconnect the knock sensor connector 29 Disconnect the connector from the secondary...

Page 944: ...the air duct from the secondary air pump and remove the bolts securing the air duct on the rocker cover LH 33 Disconnect the connector from ignition coil 34 Disconnect the connector from the front oxy...

Page 945: ...ION Be careful not to spill fuel Catch the fuel from hoses using a container or cloth 1 Attach ST to the fuel return pipe as shown in the figure 2 Insert the front side of ST into the quick con nector...

Page 946: ...d replace them with new parts 3 Connect the front oxygen A F sensor connec tor and secure the engine harness to the rocker cover RH with clip A and stay B Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb...

Page 947: ...ect the connector to the engine coolant temperature sensor A oil pressure switch B and crankshaft position sensor C 8 Connect the connector to the knock sensor 9 Connect the connector to the power ste...

Page 948: ...actuator and install the turbocharger to the in take duct Tightening torque 3 N m 0 3 kgf m 2 2 ft lb Except for WRX SS model WRX SS model 14 Connect the brake booster vacuum hose 15 Connect the PCV h...

Page 949: ...LLATION Coolant Filler Tank 23 Install the generator Ref to SC H4SO 16 INSTALLATION Generator 24 Install the intercooler Ref to IN H4DOTC 13 INSTALLATION Intercooler 25 Install the air intake boot Tig...

Page 950: ...ol solenoid valve 1 from the intake manifold 4 Disconnect the filter assembly 5 Remove the solenoid valve bracket assembly from the intake manifold and disconnect the con nector from the wastegate con...

Page 951: ...ove the bolt which secures the fuel injector pipe LH onto the intake manifold and disconnect the pressure regulator vacuum hose from the in take manifold 12 Remove the bolts which hold fuel injector p...

Page 952: ...erator valve assembly from the intake manifold D ASSEMBLY 1 Install the tumble generator valve assembly onto intake manifold NOTE Use new O rings Tightening torque 8 3 N m 0 8 kgf m 6 1 ft lb 2 Instal...

Page 953: ...gf m 14 0 ft lb RH side LH side 8 Secure the fuel injector pipe LH to intake mani fold with bolt and connect the pressure regulator vacuum hose to the intake manifold Tightening torque 6 4 N m 0 7 kgf...

Page 954: ...t the evaporation hose as shown in the fig ure 14 Connect the connectors to the wastegate con trol solenoid valve manifold absolute pressure sensor and purge control solenoid valve 2 and in stall the...

Page 955: ...all the fuel pipe protector RH to the intake manifold Tightening torque 19 N m 1 9 kgf m 14 0 ft lb 18 Install the fuel pipe protector LH to the intake manifold and install the engine ground terminal...

Page 956: ...et Tightening torque 18 N m 1 8 kgf m 13 3 ft lb C INSPECTION 1 Immerse the engine coolant temperature sensor and a thermometer in water CAUTION Take care not to allow water to get into the en gine co...

Page 957: ...N 1 CRANKSHAFT POSITION SENSOR METHOD WITH CIRCUIT TESTER 1 Disconnect the ground cable from battery 2 Remove the crankshaft position sensor Ref to FU H4DOTC 32 REMOVAL Crankshaft Position Sensor 3 Me...

Page 958: ...t the probe to ECM connector 7 Start the engine and let it idle 8 Check the pattern is as same as the waveform and voltage shown below A To ECM connector Terminal No Probe 13 14 A One crankshaft rotat...

Page 959: ...the ground cable from battery 2 Remove the intake manifold Ref to FU H4DOTC 16 REMOVAL Intake Manifold 3 Remove the camshaft position sensor LH B INSTALLATION Install in the reverse order of removal T...

Page 960: ...et it idle 8 Check the pattern is as same as the waveform and voltage shown below A To ECM connector Camshaft position sensor Terminal No Probe RH 11 LH 21 RH and LH 22 A One camshaft rotation FU 0405...

Page 961: ...block B INSTALLATION 1 Install the knock sensor to the cylinder block NOTE The portion of the knock sensor cord that is pulled out must be positioned at a 60 angle relative to the engine rear Tighteni...

Page 962: ...FU H4DOTC 37 Knock Sensor FUEL INJECTION FUEL SYSTEMS C INSPECTION Measure the resistance between knock sensor ter minals Terminal No Standard 1 and 2 560 r28 k 2 1 EC 02428...

Page 963: ...on Sensor A SPECIFICATION Throttle body is a non disassembled part so do not remove the throttle position sensor from throttle body Refer to Throttle Body for removal and installation procedure Ref to...

Page 964: ...sor Ref to FU H4DOTC 39 REMOV AL Mass Air Flow and Intake Air Temperature Sensor 3 Connect terminal No 3 to the battery positive terminal and terminal No 4 to the battery ground terminal terminal No 5...

Page 965: ...rom intake manifold 3 Remove the manifold absolute pressure sensor from the solenoid valve bracket B INSTALLATION Install in the reverse order of removal Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb...

Page 966: ...e connector from fuel injector 7 Remove the bolts which hold fuel injector pipe onto intake manifold 8 Remove the fuel injector 2 LH SIDE 1 Release the fuel pressure Ref to FU H4DOTC 60 RELEASING OF F...

Page 967: ...r B INSTALLATION 1 RH SIDE Install in the reverse order of removal NOTE Use new O rings Tightening torque 19 N m 1 9 kgf m 14 0 ft lb Tightening torque 19 N m 1 9 kgf m 14 0 ft lb 2 LH SIDE Install in...

Page 968: ...EMS Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb Tightening torque 19 N m 1 9 kgf m 14 0 ft lb C INSPECTION Measure the resistance between fuel injector termi nals Terminal No Standard 1 and 2 Approx...

Page 969: ...Remove the intake manifold Ref to FU H4DOTC 16 REMOVAL Intake Manifold 5 Disconnect the connector from the tumble gen erator valve assembly 6 Remove the fuel injector Ref to FU H4DOTC 41 REMOVAL Fuel...

Page 970: ...lve Actuator A SPECIFICATION The tumble generator valve assembly cannot be disassembled Refer to Tumble Generator Valve Assembly for removal and installation procedures Ref to FU H4DOTC 44 REMOVAL Tum...

Page 971: ...lve and remove the oil flow control solenoid valve D ASSEMBLY 1 Install the oil flow control solenoid valve Tightening torque 8 N m 0 8 kgf m 5 9 ft lb 2 Apply liquid gasket to the two bolts securing...

Page 972: ...from the bracket B INSTALLATION Install in the reverse order of removal Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb C INSPECTION 1 Measure the resistance between the boost con trol solenoid valve te...

Page 973: ...will damage the exhaust pipe B INSTALLATION CAUTION If lubricant is spilt onto the exhaust pipe wipe it off completely with cloth to avoid emission of smoke or causing a fire 1 Before installing fron...

Page 974: ...F Sensor FUEL INJECTION FUEL SYSTEMS 7 Connect the ground cable to battery C INSPECTION Measure the resistance between front oxygen A F sensor terminal Terminal No Standard 1 and 2 2 4 r0 24 20 C 68...

Page 975: ...removing the rear oxygen sensor wait until exhaust pipe cools otherwise it will dam age the exhaust pipe B INSTALLATION CAUTION If lubricant is spilt onto the exhaust pipe wipe it off completely with...

Page 976: ...and hold the rear oxygen sensor harness with the clip A AT MODEL MT MODEL 4 Lower the vehicle 5 Connect the ground cable to battery C INSPECTION Measure the resistance between rear oxygen sen sor ter...

Page 977: ...ts and bolts which hold the ECM to the bracket 6 Disconnect the ECM connectors and take out the ECM B INSTALLATION Install in the reverse order of removal CAUTION When the ECM of model with immobilize...

Page 978: ...ove the main relay from the relay block on the back side of the glove box B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Measure the resistance between main relay ter minals IN...

Page 979: ...EMS 2 Connect terminal No 3 to the battery positive terminal and the No 4 terminal to the battery ground terminal and measure the resistance be tween the main relay terminals Terminal No Standard 1 an...

Page 980: ...move the fuel pump relay from the relay block on the back side of the glove box B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Measure the resistance between fuel pump relay ter...

Page 981: ...EMS 2 Connect terminal No 3 to the battery positive terminal and the No 4 terminal to the battery ground terminal and measure the resistance be tween the fuel pump relay terminals Terminal No Standard...

Page 982: ...move the electronic throttle control relay from the relay block on the back side of the glove box B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Measure the resistance between e...

Page 983: ...EMS 2 Connect terminal No 3 to the battery positive terminal and the No 4 terminal to the battery ground terminal and measure the resistance be tween the electronic throttle control relay terminals Te...

Page 984: ...door model Ref to EI 61 REMOVAL Trunk Room Trim 3 Remove the right side rear quarter trim 5 door model Ref to EI 58 REMOVAL Rear Quarter Trim 4 Remove the fuel pump control unit 4 DOOR MODEL 5 DOOR MO...

Page 985: ...ILLER HOSE PROCE DURE Fuel Be careful not to let the battery run out 1 Release the fuel pressure Ref to FU H4DOTC 60 RELEASING OF FUEL PRES SURE PROCEDURE Fuel 2 Attach ST to the fuel delivery pipe an...

Page 986: ...Be careful not to spill fuel 9 Install the related parts in the reverse order after draining the fuel Tightening torque 2 5 N m 0 3 kgf m 1 8 ft lb 5 DOOR MODEL WARNING Place NO OPEN FLAMES signs nea...

Page 987: ...f to SE 11 REMOVAL Rear Seat 6 Remove the service hole cover of fuel pump 1 Disconnect fuel pump connector A and re move clip B 2 Remove the screw C 3 Push the grommet D down and remove the service ho...

Page 988: ...MOVAL Propeller Shaft 17 Remove the heat shield cover and fuel tank protector 18 Disconnect the connector from the rear ABS wheel speed sensor 19 Remove the parking brake cable clamp from the body 20...

Page 989: ...n the fig ure 24 Disconnect the fuel filler hose A and evapora tion hose B 25 Support the fuel tank with a transmission jack remove the bolts from the fuel tank band and re move the fuel tank from the...

Page 990: ...Tightening torque 2 5 N m 0 3 kgf m 1 8 ft lb 3 Connect the quick connector of the evaporation hose to the evaporation pipe CAUTION Check that there is no damage or dust on the quick connector If nece...

Page 991: ...upport the rear suspension assembly and install the rear suspension assembly to the body Tightening torque T1 70 N m 7 1 kgf m 51 6 ft lb T2 145 N m 14 8 kgf m 106 9 ft lb 3 Install the rear shock abs...

Page 992: ...rake cable to the parking brake assembly Ref to PB 7 INSTALLATION Parking Brake Assembly Rear Disc Brake 16 Install the rear disc brake assembly Tightening torque 66 N m 6 7 kgf m 48 7 ft lb 17 Instal...

Page 993: ...seat cushion Ref to SE 12 INSTALLATION Rear Seat 24 Connect the ground cable to battery 25 Inspect the wheel alignment and adjust if nec essary C INSPECTION 1 Check that the fuel tank does not have h...

Page 994: ...ONITOR PROCEDURE Fuel 4 Disconnect the ground cable from battery 5 Open the fuel filler lid and remove the filler cap 6 Remove the screws which secure gasket 7 Remove the rear wheel RH 8 Lift up the v...

Page 995: ...uel filler pipe neck and set the cup B and tighten the screws NOTE If the edges of rubber gasket are folded toward in side straighten it with a flat tip screwdriver 4 Securely insert the fuel filler h...

Page 996: ...rear mud guard RH Ref to EI 28 IN STALLATION Mud Guard 8 Lower the vehicle 9 Install the rear wheel RH Tightening torque 100 N m 10 2 kgf m 73 8 ft lb 10 Connect the ground cable to battery 11 Inspect...

Page 997: ...ening torque 7 5 N m 0 8 kgf m 5 5 ft lb 2 Install the shut valve to the fuel filler pipe Ref to EC H4DOTC 21 INSTALLATION Shut Valve E INSPECTION 1 Check that the fuel filler pipe does not have holes...

Page 998: ...in fuel Ref to FU H4DOTC 60 DRAIN ING FUEL WITH SUBARU SELECT MONITOR PROCEDURE Fuel 3 Disconnect the ground cable from battery 4 Remove the rear seat cushion Ref to SE 11 REMOVAL Rear Seat 5 Remove t...

Page 999: ...ate Tighten the nuts to the specified torque in the or der as shown in the figure NOTE Use a new gasket and retainer Tightening torque 4 4 N m 0 4 kgf m 3 2 ft lb C INSPECTION 1 Disconnect the ground...

Page 1000: ...from sub tank 4 Slide the fuel level sensor in the direction of the arrow and remove the fuel level sensor by pressing the claw A of the fuel level sensor B INSTALLATION Install in the reverse order o...

Page 1001: ...FU H4DOTC 60 DRAIN ING FUEL WITH SUBARU SELECT MONITOR PROCEDURE Fuel 3 Disconnect the ground cable from battery 4 Remove the rear seat cushion Ref to SE 11 REMOVAL Rear Seat 5 Remove the service hol...

Page 1002: ...ified torque in the order as shown in the figure After tightening install the rubber cap C shown in the figure NOTE Use a new gasket and retainer Do not forget to install rubber cap C Tightening torqu...

Page 1003: ...to FU H4DOTC 75 REMOVAL Fuel Level Sensor 3 Disconnect the pump assembly connector from the sub tank bracket assembly 4 Cut off the tab holders connecting the sub tank bracket assembly and the sub ta...

Page 1004: ...flat tip screwdriver A etc with tape B Be careful not to drop or apply any impact to the pump assembly NOTE If the spacer and O ring is remaining on the pump assembly remove these B INSTALLATION 1 Ass...

Page 1005: ...e new O rings Apply gasoline to the O ring The O rings of the black and white connectors are identified by a difference in diameter Be careful not to confuse the two during assembly O ring inner diame...

Page 1006: ...p assembly connector to the sub tank bracket assembly 9 Install the fuel level sensor and fuel temperature sensor Ref to FU H4DOTC 75 INSTALLA TION Fuel Level Sensor 10 Inspect the fuel level sensor R...

Page 1007: ...uel pressure Ref to FU H4DOTC 60 RELEASING OF FUEL PRES SURE PROCEDURE Fuel 2 Remove the fuel damper from fuel delivery hose A and fuel return hose B B INSTALLATION CAUTION If fuel hoses or clamps are...

Page 1008: ...ay 2 Disconnect the evaporation hose from the purge damper and remove the purge damper B INSTALLATION CAUTION If the evaporation hose is damaged replace with a new hose Install in the reverse order of...

Page 1009: ...ompartment disconnect the fuel delivery hoses fuel return hoses and evaporation hoses CAUTION Be careful not to spill fuel Catch the fuel from hoses using a container or cloth 1 Set the ST to the fuel...

Page 1010: ...ration pipe 1 Remove the rear mud guard RH Ref to EI 28 REMOVAL Mud Guard 2 Remove the evaporation hose 3 Remove the right side trunk side trim 4 door model Ref to EI 61 REMOVAL Trunk Room Trim 4 Remo...

Page 1011: ...LINE QUICK CONNECTOR CAUTION Make sure there are no damage or dust on con nections If necessary clean seal surface of pipe 1 Set the retainer to quick connector NOTE Use a new retainer 2 Connect the...

Page 1012: ...L1 2 5r1 5 mm 0 098r0 059 in L2 22 5r2 5 mm 0 886r0 098 in CAUTION Be sure to inspect hoses and their connections for any leakage of fuel 4 EVAPORATION HOSE CONNECTION Connect the evaporation hose to...

Page 1013: ...pump function Replace the fuel pump 3 Clogged fuel filter Replace the fuel filter Clean or replace the fuel tank if necessary 4 Clogged or bent fuel pipe or hose Clean correct or replace fuel pipe or...

Page 1014: ...Description A COMPONENT 1 SECONDARY AIR PUMP 1 Secondary air pump 4 Secondary air pump cover Tightening torque N m kgf m ft lb 2 Clip 5 Harness stay T1 6 4 0 7 4 7 3 Secondary air pump bracket 6 Seco...

Page 1015: ...7 Air duct A Tightening torque N m kgf m ft lb 2 Gasket 8 Air duct B T1 6 4 0 7 4 7 3 Gasket 9 Secondary air combination valve LH T2 9 0 9 6 6 4 Clip 10 Secondary air pipe LH T3 19 1 9 14 0 5 Secondar...

Page 1016: ...hicle components are extremely hot after driving Be wary of receiving burns from heated parts Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid ra...

Page 1017: ...to Center Ex haust Pipe for removal procedures Ref to EX H4DOTC 8 REMOVAL Center Exhaust Pipe B INSTALLATION The front catalytic converter is integrated into the center exhaust pipe front Refer to Cen...

Page 1018: ...o Center Ex haust Pipe for removal procedures Ref to EX H4DOTC 8 REMOVAL Center Exhaust Pipe B INSTALLATION The rear catalytic converter is integrated into the center exhaust pipe rear Refer to Center...

Page 1019: ...el 4 Tilt the rear seat backrest forward 5 Remove the sub trunk box and spacers 4 door model 6 Remove the luggage floor box and spacers 5 door model 7 Remove the center canister cover 8 Remove the can...

Page 1020: ...e B B NOTE Disconnect the quick connector as shown in the fig ure 13 Disconnect connector C from the drain valve and remove the drain valve 14 Disconnect purge tube A and vent tube B NOTE Disconnect t...

Page 1021: ...r If necessary clean the seal surface of the pipe When connecting the quick connector se curely insert the pipe all the way before locking the retainer If it is not possible to perform the push lock o...

Page 1022: ...10 Canister EMISSION CONTROL AUX EMISSION CONTROL DEVICES Tightening torque 18 N m 1 8 kgf m 13 3 ft lb C INSPECTION Make sure that the canister drain valve and tube are not cracked or loose EC 02363...

Page 1023: ...purge control solenoid valve 1 3 Disconnect the evaporation hose from the intake manifold and fuel pipe assembly 2 PURGE CONTROL SOLENOID VALVE 2 1 Disconnect the ground cable from battery 2 Remove th...

Page 1024: ...lb 2 PURGE CONTROL SOLENOID VALVE 2 Install in the reverse order of removal NOTE Connect the evaporation hose as shown in the fig ure Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb A Purge control sole...

Page 1025: ...TROL SOLENOID VALVE 1 Measure the resistance between the purge con trol solenoid valve terminals 2 Check that air does not come out of B when blowing in A Purge control solenoid valve 1 Purge control...

Page 1026: ...1 to the battery positive terminal and the terminal No 2 to the battery neg ative terminal When supplying air to A check that air is discharged from B Purge control solenoid valve 1 Purge control sol...

Page 1027: ...res refer to the FU H4DOTC section Ref to FU H4DOTC 75 REMOVAL Fuel Level Sensor B INSTALLATION For installation procedures refer to the FU H4DOTC section Ref to FU H4DOTC 75 IN STALLATION Fuel Level...

Page 1028: ...vel Sensor for installation procedure Ref to FU H4DOTC 75 INSTALLATION Fuel Level Sensor C INSPECTION Measure the resistance between fuel temperature sensor terminals CAUTION When measuring the resist...

Page 1029: ...es refer to the FU H4DOTC section Ref to FU H4DOTC 76 REMOVAL Fuel Sub Level Sensor B INSTALLATION For installation procedures refer to the FU H4DOTC section Ref to FU H4DOTC 77 INSTALLATION Fuel Sub...

Page 1030: ...fuel tank pressure sensor B 7 Remove the fuel tank pressure sensor along with the bracket 8 Remove the fuel pressure sensor from the bracket B INSTALLATION Install in the reverse order of removal Tigh...

Page 1031: ...lve 6 Remove the nuts C which secure the bracket to the fuel tank 7 Remove the pressure control solenoid valve and bracket as a unit 8 Remove the pressure control solenoid valve from the bracket B INS...

Page 1032: ...ICES 11 Drain Filter A SPECIFICATION The drain valve is a non disassembled part so do not remove the drain filter from drain valve Refer to Canister for removal and installation procedures Ref to EC H...

Page 1033: ...spill fuel 1 Remove the fuel filler pipe Ref to FU H4DOTC 69 REMOVAL Fuel Filler Pipe 2 Disconnect the evaporation hose from the shut valve 3 Remove the shut valve from the fuel filler pipe B INSTALL...

Page 1034: ...Refer to Canister for removal procedures Ref to EC H4DOTC 7 REMOVAL Canister B INSTALLATION Refer to Canister for installation procedures Ref to EC H4DOTC 9 INSTALLATION Canis ter C INSPECTION Measur...

Page 1035: ...PCV hose assembly to un lock 4 Remove the PCV hose assembly ST 18353AA000 CLAMP PLIERS B INSTALLATION 1 Install the PCV hose assembly then lock by fit ting the ST on the clamp protrusion NOTE Use a n...

Page 1036: ...se order of removal Tightening torque 19 N m 1 9 kgf m 14 0 ft lb C INSPECTION 1 SECONDARY AIR PUMP 1 Disconnect the ground cable from battery 2 Remove the secondary air pump Ref to EC H4DOTC 24 REMOV...

Page 1037: ...ir combination valve LH 2 SECONDARY AIR COMBINATION VALVE RH 1 Disconnect the ground cable from battery 2 Remove the intercooler Ref to IN H4DOTC 13 REMOVAL Intercooler 3 Remove the intake manifold Re...

Page 1038: ...14 0 ft lb 2 SECONDARY AIR COMBINATION VALVE RH Install in the reverse order of removal NOTE Use a new gasket Tightening torque T1 6 4 N m 0 7 kgf m 4 7 ft lb T2 9 N m 0 9 kgf m 6 6 ft lb A Secondary...

Page 1039: ...he terminals of secondary air combination valve LH 2 Check that air does not come out of B when blowing in A 3 Connect the terminal No 2 to the battery positive terminal and the terminal No 1 to the b...

Page 1040: ...does not come out of B when blowing in A 3 Connect the terminal No 6 to the battery positive terminal and the terminal No 4 to the battery neg ative terminal When supplying air to A check that air is...

Page 1041: ...r temperature sensor 7 Air cleaner case Front Tightening torque N m kgf m ft lb 8 Air intake duct T1 1 0 1 0 7 2 Air cleaner case Rear 9 Clip T2 2 5 0 3 1 8 3 Clip 10 Cushion T3 6 0 6 4 4 4 Air intake...

Page 1042: ...lenoid valve bracket 3 Solenoid valve bracket ASSY 10 Air by pass pipe 4 Intake duct 11 Clip Tightening torque N m kgf m ft lb 5 Engine harness ASSY 12 Vacuum hose T1 6 4 0 7 4 7 6 Vacuum hose 13 Brak...

Page 1043: ...n INTAKE INDUCTION 3 INTERCOOLER 1 Intercooler 5 Spacer Tightening torque N m kgf m ft lb 2 O ring 6 Cushion T1 6 5 0 7 4 8 3 Air by pass valve 7 Intercooler stay T2 16 1 6 11 8 4 O ring 8 Clip IN 025...

Page 1044: ...rque N m kgf m ft lb 2 Gasket 9 Clip T1 5 0 5 3 7 3 Turbocharger 10 Oil outlet hose T2 8 8 0 9 6 5 4 Water pipe 11 Turbocharger stay RH T3 16 1 6 11 8 5 Clip 12 Turbocharger stay LH T4 20 2 0 14 8 6 E...

Page 1045: ...m ft lb 2 Gasket 9 Clip T1 4 9 0 5 3 6 3 Turbocharger 10 Oil outlet hose T2 6 5 0 7 4 8 4 Water pipe 11 Turbocharger stay RH T3 16 1 6 11 8 5 Clip 12 Turbocharger stay LH T4 20 2 0 14 8 6 Engine cool...

Page 1046: ...tion or disassembly be sure to clarify the failure Avoid unnecessary removal in stallation disassembly and replacement Vehicle components are extremely hot after driving Be wary of receiving burns fro...

Page 1047: ...clip B from the air cleaner case front 5 Open the air cleaner case and remove the air cleaner element B INSTALLATION Install in the reverse order of removal CAUTION Be sure to use SUBARU genuine air...

Page 1048: ...olt A and nut B which secure the air cleaner case front to the body 9 Remove the air cleaner case front B INSTALLATION 1 Install the bolt A and nut B which secure the air cleaner case front to the bod...

Page 1049: ...connector A to the mass air flow and intake air temperature sensor 6 Install the air intake duct Ref to IN H4DOTC 11 INSTALLATION Air Intake Duct 7 Connect the ground cable to battery C INSPECTION Ch...

Page 1050: ...A REMOVAL Remove the clip which secures the air intake duct and remove the air intake duct B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Check for cracks or loose connections 2...

Page 1051: ...o FU H4DOTC 16 REMOVAL Intake Manifold 3 Remove the sensor engine harness and fuel pipe attached to the intake manifold Ref to FU H4DOTC 25 DISASSEMBLY Intake Mani fold 4 Remove the intake duct from i...

Page 1052: ...ocharger 4 Remove the bolts which secure the intercooler to the intercooler stay and remove the intercooler 5 Remove the brake booster vacuum hose from the clip A and remove the intercooler stay B INS...

Page 1053: ...the air by pass valve from intercooler D ASSEMBLY Assemble in the reverse order of disassembly NOTE Use new O rings Be careful not to pinch the O ring Tightening torque 6 5 N m 0 7 kgf m 4 8 ft lb E I...

Page 1054: ...f to IN H4DOTC 13 REMOVAL Intercooler 7 Remove the center exhaust pipe Ref to EX H4DOTC 8 REMOVAL Center Exhaust Pipe 8 Lower the vehicle 9 Remove the joint pipe from the turbocharger 10 Disconnect th...

Page 1055: ...harger stay B INSTALLATION 1 Install the turbocharger stay Tightening torque T1 33 N m 3 4 kgf m 24 3 ft lb T2 42 5 N m 4 3 kgf m 31 3 ft lb 2 Connect the oil outlet hose to the oil outlet pipe 3 Conn...

Page 1056: ...rger to the intake duct Tightening torque 3 N m 0 3 kgf m 2 2 ft lb Except for WRX SS model WRX SS model 6 Connect the engine coolant hoses to the coolant filler tank 7 Install the joint pipe to turbo...

Page 1057: ...d mea sure the pressure when the control rod stroke D becomes 1 mm 0 04 in If it is not within the stan dard replace the turbocharger assembly CAUTION Do not pressurize over 56 0 kPa 0 57 kgf cm2 8 12...

Page 1058: ...not pressurize over 89 9 kPa 0 92 kgf cm2 13 0 psi to prevent damaging the waste gate actuator Operating pressure Control rod stroke 2 mm 0 08 in Standard 74 7 80 8 kPa 0 76 0 82 kgf cm2 10 8 11 7 ps...

Page 1059: ...e C from the air by pass valve A 2 Remove the air by pass valve A from the inter cooler B INSTALLATION Install in the reverse order of removal NOTE Use new O rings Be careful not to pinch the O ring T...

Page 1060: ...umber of piston rings Pressure ring 2 Oil ring 1 Intake valve timing Open Max retard ATDC 5 Min advance BTDC 35 Close Max retard ABDC 65 Min advance ABDC 25 Exhaust valve timing Open BBDC 55 Close ATD...

Page 1061: ...16 0 0026 Inside diameter mm in 6 000 6 012 0 2362 0 2367 Valve stem outer diameters mm in Intake 5 955 5 970 0 2344 0 2350 Exhaust 5 945 5 960 0 2341 0 2346 Valve guide protrusion mm in 15 8 16 2 0 6...

Page 1062: ...0 25 0 0098 US 1 614 1 622 0 0635 0 0639 Bushing of small end Clearance between piston pin and bush ing mm in Standard 0 0 022 0 0 0009 Crankshaft and crankshaft bearing Bending limit mm in 0 035 0 0...

Page 1063: ...t tension adjuster ASSY 17 Timing belt cover RH T5 24 5 2 5 18 1 18 Crank pulley MT model T6 25 2 5 18 4 7 Belt idler 19 Timing belt guide MT model T7 39 4 0 28 8 8 Exhaust cam sprocket RH 20 O ring T...

Page 1064: ...ECHANICAL 2 CYLINDER HEAD AND CAMSHAFT T7 1 T5 T5 T6 T6 T6 T6 T4 3 7 6 9 8 10 12 28 31 13 25 21 20 6 16 17 18 9 8 19 15 14 29 11 5 4 22 T7 T7 14 29 12 27 27 26 27 31 30 T2 T2 T2 T3 T4 11 2 T3 T2 T2 T3...

Page 1065: ...cap T3 29 3 0 21 4 7 Exhaust camshaft cap RH 24 Oil filler duct T4 Ref to ME H4DOTC 68 INSTALLATION Cylinder Head 8 Gasket 25 O ring 9 Oil return cover 26 Oil pipe LH T5 Ref to ME H4DOTC 62 INSTALLAT...

Page 1066: ...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 1067: ...MECHANICAL 4 CYLINDER BLOCK ME 04087 T4 T2 T2 T10 T6 T10 T6 T2 T9 T9 T6 9 10 10 11 13 25 26 4 4 4 3 3 3 2 1 5 10 T6 24 17 27 T9 T2 14 28 T3 18 10 T2 29 T2 23 31 T1 T7 19 20 21 22 T5 32 30 29 30 12 16...

Page 1068: ...er by pass pipe 22 Drain plug gasket T3 10 1 0 7 2 7 Oil pump 23 Oil level gauge guide T4 First 12 1 2 8 9 Second 12 1 2 8 9 8 Front oil seal 24 Oil filter 9 Rear oil seal 25 Gasket T5 16 1 6 11 8 10...

Page 1069: ...eel MT model 11 Connecting rod bolt 19 Crankshaft bearing 5 4 Ball bearing MT model 12 Connecting rod 5 Top ring 13 Connecting rod bearing Tightening torque N m kgf m ft lb 6 Second ring 14 Connecting...

Page 1070: ...ME H4DOTC 12 General Description MECHANICAL 6 ENGINE MOUNTING 1 Front cushion rubber Tightening torque N m kgf m ft lb T1 35 3 6 25 8 T2 85 8 7 62 7 ME 03547 1 T2 T1 T1 T2...

Page 1071: ...oil prior to assem bly Be careful not to let oil grease or engine coolant contact the timing belt clutch disc and flywheel All removed parts if to be reused should be reinstalled in the original posit...

Page 1072: ...ND 499817100 498497100 CRANKSHAFT STOPPER Used for removing and installing the flywheel and drive plate 498747300 PISTON GUIDE Used for installing the piston into the cylinder 498857100 VALVE OIL SEAL...

Page 1073: ...R Used for removing and installing connecting rod bushing 499097700 PISTON PIN REMOVER ASSY Used for removing piston pin 499207400 CAM SPROCKET WRENCH Used for removing and installing exhaust cam spro...

Page 1074: ...l seal 499597100 CRANKSHAFT OIL SEAL GUIDE Used for installing crankshaft oil seal Used together with CRANKSHAFT OIL SEAL INSTALLER 499587200 499597200 OIL SEAL GUIDE Used for installing the camshaft...

Page 1075: ...sed together with ENGINE STAND ADAPTER RH 498457000 LH 498457100 499977100 CRANK PULLEY WRENCH Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts MT model 499977...

Page 1076: ...st valve guides 18353AA000 CLAMP PLIERS Used for removing and installing the PCV hose This tool is made by the French company CAILLAU code 54 0 000 205 To make it easier to obtain it has been provided...

Page 1077: ...99AE000 QUICK CONNECTOR RELEASE Used for disconnecting quick connector of the engine compartment 1B022XU0 SUBARU SELECT MONITOR III KIT Used for various inspections TOOL NAME REMARKS Compression gauge...

Page 1078: ...ully open the throttle valve 9 Check the starter motor for satisfactory perfor mance and operation 10 Secure the compression gauge tightly against the spark plug hole NOTE When using a screw in type c...

Page 1079: ...e speed when no loaded Head light heater fan rear defroster radiator fan A C and etc are OFF Idle speed No load and at P or N position on AT model or neutral position on MT model 700r100 rpm 5 Check t...

Page 1080: ...ing check the following item 1 Check the air cleaner element is free from clogging spark plugs are in good condition and hoses are connected properly 2 Check the malfunction indicator light does not i...

Page 1081: ...model 70 6 kPa 530 mmHg 20 85 inHg or more MT model ME 03897 Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1 Needle is steady...

Page 1082: ...kPa 3 0 kgf cm2 43 psi or more at 5 000 rpm If the oil pressure is out of specification check oil pump oil filter and lubrication line Ref to LU H4SO 22 INSPECTION Engine Lubrication System Trouble i...

Page 1083: ...Disconnect the fuel delivery hose from fuel damper and connect fuel pressure gauge 4 Start the engine 5 Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake mani fo...

Page 1084: ...G H4DOTC 7 REMOVAL Ignition Coil 3 Place a suitable container under the vehicle 4 Disconnect the PCV hose from the rocker cover RH NOTE For the PCV hose affixed with the clamp fit the de pression in t...

Page 1085: ...rt a thickness gauge in a direction as hori zontal as possible with respect to the valve lifter Lift up the vehicle and then measure the ex haust valve clearances If the measured value is not within t...

Page 1086: ...0 1846 13228 AB122 4 70 0 1850 13228 AB132 4 71 0 1854 13228 AB142 4 72 0 1858 13228 AB152 4 73 0 1862 13228 AB162 4 74 0 1866 13228 AB172 4 75 0 1870 13228 AB182 4 76 0 1874 13228 AB192 4 77 0 1878 1...

Page 1087: ...8 AB612 5 19 0 2043 13228 AB622 5 20 0 2047 13228 AB632 5 21 0 2051 13228 AB642 5 22 0 2055 13228 AB652 5 23 0 2059 13228 AB662 5 24 0 2063 13228 AB672 5 25 0 2067 13228 AB682 5 26 0 2071 13228 AB692...

Page 1088: ...he air intake duct and air cleaner case Ref to IN H4DOTC 11 REMOVAL Air Intake Duct Ref to IN H4DOTC 9 REMOVAL Air Cleaner Case 9 Remove the intercooler Ref to IN H4DOTC 13 REMOVAL Intercooler 10 Remo...

Page 1089: ...p switch connector 3 Remove the power steering pump from the engine 4 Place the power steering pump on the right side wheel apron 18 Remove the center exhaust pipe Ref to EX H4DOTC 8 REMOVAL Center Ex...

Page 1090: ...Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate 26 Remove the pitching stopper 27 Attach ST to the fuel...

Page 1091: ...nector 3 Insert the back side of ST into the quick con nector and push ST in the direction of arrow mark to disconnect the fuel return hose 29 Remove the clip and disconnect the evapora tion hose from...

Page 1092: ...om clutch cover MT mod el 4 Slowly move the engine away from engine compartment NOTE Be careful not to damage adjacent parts or body panels with crank pulley oil level gauge etc 34 Remove the engine m...

Page 1093: ...he torque converter clutch to drive plate AT model 1 Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate NOT...

Page 1094: ...he center exhaust pipe Ref to EX H4DOTC 10 INSTALLATION Center Ex haust Pipe 18 Connect the ground cable Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 19 Lower the vehicle 20 Connect the following hos...

Page 1095: ...o AC 22 PROCEDURE Refrigerant Charging Procedure 31 Check the ATF level and replenish it if neces sary AT model Ref to 4AT 27 INSPECTION Automatic Transmission Fluid 32 Install the V belt cover Tighte...

Page 1096: ...engine assembly Ref to ME H4DOTC 30 REMOVAL Engine Assembly 2 Remove the engine mounting from the engine assembly B INSTALLATION Install in the reverse order of removal Tightening torque 35 N m 3 6 kg...

Page 1097: ...499817100 ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order The procedure for overhauling of the engine will be completed when you go thro...

Page 1098: ...ust and water with cloth Do not use the front side belt if there is any oil grease or coolant on the belt Be careful not to rub the belt end surface with bare hands exposed core may cause injury 1 Wip...

Page 1099: ...n the groove of each pulley with cloth 2 Wipe off any oil water dirt and rust on the front of the crank pulley with cloth 3 Slowly turn the crank pulley clockwise so that the service hole of the crank...

Page 1100: ...e holder CAUTION When it is difficult to place the rear side belt to the crank pulley groove pull out the belt guide holder half way then place the rear side belt into the groove so that it comes in b...

Page 1101: ...he belt guide is not off from the crank pulley groove 1 The rib of the rear side belt is securely placed on the groove of the A C compressor pulley 2 The rib of the rear side belt is securely placed o...

Page 1102: ...ot twisted 2 The rib of the rear side belt is securely placed on the groove of the A C compressor pulley 3 The rib of the rear side belt is securely placed on the groove of the crank pulley 4 The surf...

Page 1103: ...e the belt stopper from the compressor bracket CAUTION Always remove the belt stopper failure to do so may cause smoke fire or belt cutting 16 Make sure that the belt rib is securely installed on the...

Page 1104: ...k fraying or wear is found 2 Check the front side belt tension and adjust it if necessary by changing the generator installing po sition Front side belt tension with belt tension gauge When installing...

Page 1105: ...N m 4 5 kgf m 32 5 ft lb 4 Tighten the crank pulley bolts Tightening torque 130 N m 13 3 kgf m 95 9 ft lb 3 Check that the tightening angle of the crank pul ley bolt is 45 or more Perform the followin...

Page 1106: ...ening angle of crank pulley bolt is less than 65 the bolt is damaged In this case the bolt must be replaced 1 Replace the crank pulley bolts and clean them Crank pulley bolt Part No 12369AA011 2 Clean...

Page 1107: ...elt cover RH B 6 Remove the front timing belt cover C B INSTALLATION 1 Install the front timing belt cover C Tightening torque 5 N m 0 5 kgf m 3 7 ft lb 2 Install the timing belt cover RH B Tightening...

Page 1108: ...belt cover Ref to ME H4DOTC 49 REMOVAL Timing Belt Cover 4 Remove the timing belt guide MT model 5 If the alignment mark or arrow mark which indi cates the direction of rotation on timing belt fade a...

Page 1109: ...AUTION After the timing belt has been removed never rotate the intake and exhaust sprocket If the cam sprocket is rotated the intake and exhaust valve heads strike together and valve stems are bent 2...

Page 1110: ...cylinder Do not release the press pressure until stop per pin is completely inserted 1 Attach the automatic belt tension adjuster assembly to vertical pressing tool 2 Slowly push in the adjuster rod...

Page 1111: ...intake cam sprocket RH with notch A on the timing belt cover Make sure that the double line marks C on intake and exhaust cam sprockets are aligned 5 Align the single line mark B on exhaust cam sprock...

Page 1112: ...hafts are rotated to install the timing belts 2 intake and 4 exhaust cam of camshaft LH are held pushing their corre sponding valves down Under this condition these valves are held lifted Camshaft RH...

Page 1113: ...he timing belt slips by 1 or more teeth the valve and piston may hit each other Make sure that the direction of belt rotation is correct 9 Install the belt idlers Tightening torque 39 N m 4 0 kgf m 28...

Page 1114: ...ting the timing belt guide NOTE Before attaching the bolts clean the bolt holes of the timing belt cover Apply liquid gasket to the bolt thread of cam sprocket section when reusing bolts Liquid gasket...

Page 1115: ...ant contact the timing belt Remove quickly and thoroughly if this happens Do not bend the timing belt sharply In radial diameter h 60 mm 2 36 in or more 2 AUTOMATIC BELT TENSION ADJUSTER 1 Visually ch...

Page 1116: ...end surface of the body If it is not within spec ifications replace the automatic belt tension adjust er assembly with a new part Amount of rod protrusion H 5 2 6 2 mm 0 205 0 244 in 3 BELT TENSION PU...

Page 1117: ...sprockets LH and RH dur ing installation ST 499207400 CAM SPROCKET WRENCH Tightening torque Tighten to 30 N m 3 1 kgf m 22 1 ft lb of torque and then tighten further by 45 ST 499977500 CAM SPROCKET WR...

Page 1118: ...emove the crank sprocket B INSTALLATION 1 Install the crank sprocket 2 Install the timing belt Ref to ME H4DOTC 52 INSTALLATION Timing Belt 3 Install the timing belt cover Ref to ME H4DOTC 49 INSTALLA...

Page 1119: ...move the cam sprocket Ref to ME H4DOTC 59 REMOVAL Cam Sprocket 6 Disconnect the oil flow control solenoid valve connector 7 Remove the timing belt cover No 2 LH 8 Remove the timing belt cover No 2 RH...

Page 1120: ...ch the journal surface when remov ing the oil seal 20 Similarly remove the camshaft RH and related parts B INSTALLATION 1 Install the camshaft Apply engine oil to the cylinder head at camshaft bearing...

Page 1121: ...kgf m 7 2 ft lb T2 20 N m 2 0 kgf m 14 8 ft lb 4 After tightening the camshaft cap ensure the camshaft rotates only slightly while holding it at base circle 3 Apply a thin coat of engine oil to the pe...

Page 1122: ...ker cover gasket to the rocker cover Outer section and ignition coil section NOTE Use a new rocker cover gasket 2 Apply liquid gasket to the specified point of the cylinder head NOTE Install within 5...

Page 1123: ...ec essary Camshaft bend limit 0 020 mm 0 00079 in 2 Check the journal for damage and wear Re place if faulty 3 Check the cutout portion used for camshaft sen sor for damage Replace if faulty 4 Check t...

Page 1124: ...0 kgf m 14 8 ft lb 5 Remove the camshaft cap 6 Measure the widest point of the plastigauge on each journal If oil clearance exceeds the standard replace the camshaft If necessary replace the camshaft...

Page 1125: ...E H4DOTC 40 REMOVAL V belt 2 Remove the intake manifold Ref to FU H4DOTC 16 REMOVAL Intake Manifold 3 Remove the crank pulley Ref to ME H4DOTC 47 REMOVAL Crank Pulley 4 Remove the timing belt cover Re...

Page 1126: ...everse order of installing and loosen them further by 180 5 Tighten all bolts to 49 N m 5 0 kgf m 36 1 ft lb in alphabetical order 6 Tighten all bolts by 80 to 90 in alphabetical order 7 Tighten all b...

Page 1127: ...y liquid gasket to the specified point of the cylinder head NOTE Install within 5 min after applying liquid gasket Liquid gasket THREE BOND 1217G Part No K0877Y0100 or equivalent 3 Install the rocker...

Page 1128: ...ark each valve to prevent confusion Pay careful attention not to damage the lips of in take valve oil seals and exhaust valve oil seals Keep all the removed parts in order for re install ing in their...

Page 1129: ...der head on ST1 ST1 498267600 CYLINDER HEAD TABLE 3 Install the valve spring and retainer NOTE Be sure to install the valve spring with its close coiled end facing the cylinder head side 1 Exhaust val...

Page 1130: ...rinder Warping limit 0 035 mm 0 0014 in Grinding limit 0 3 mm 0 012 in Standard height of cylinder head 127 5 mm 5 02 in NOTE Uneven torque for the cylinder head bolts can cause warpage When reinstall...

Page 1131: ...exist on the inner surface of valve guide holes in cyl inder head 5 Put a new valve guide coated with sufficient oil in the cylinder head and insert the ST1 into valve guide Press in until the valve g...

Page 1132: ...ble to differentiate between the intake valve and the exhaust valve by their overall length Valve overall length Intake 104 4 mm 4 110 in Exhaust 104 65 mm 4 1201 in 5 VALVE SPRING 1 Check the valve s...

Page 1133: ...eals and exhaust valve oil seals are distinguished by their colors Color of rubber part Intake Gray Exhaust Green 7 VALVE LIFTER 1 Check the valve lifter visually 2 Measure the outer diameter of valve...

Page 1134: ...7 Remove the crank sprocket Ref to ME H4DOTC 60 REMOVAL Crank Sprocket 8 Remove the generator and A C compressor with their brackets 9 Remove the camshaft Ref to ME H4DOTC 61 REMOVAL Camshaft 10 Remo...

Page 1135: ...g surface of cylinder block and oil pump 20 Remove the front oil seal from the oil pump 21 Remove the oil pan 1 Set the part so that the cylinder block LH is on the upper side 2 Remove the bolts which...

Page 1136: ...bly 26 Remove the service hole plugs using a hexa gon wrench 14 mm 27 Remove the service hole cover ME 00300 1 Service hole plug 4 Piston pin 7 Seal washer 2 Gasket 5 Service hole cover 8 Washer 3 Sna...

Page 1137: ...499097700 PISTON PIN REMOVER ASSY NOTE Be careful not to confuse the original combination of piston piston pin and cylinder 30 Similarly draw out the piston pins from 3 and 4 pistons 31 Remove the cy...

Page 1138: ...nkshaft bearings from cylinder block using a hammer handle NOTE Press the crankshaft bearing at the end opposite to locking lip to remove Be careful not to confuse the crankshaft bearing combination 3...

Page 1139: ...new O rings 3 Apply liquid gasket to the mating surfaces of cyl inder block RH and position cylinder block LH NOTE Install within 5 min after applying liquid gasket Do not allow liquid gasket to jut...

Page 1140: ...ting bolts A D further in alphabetical order Tightening torque 18 N m 1 8 kgf m 13 3 ft lb 8 Tighten the RH side cylinder block connecting bolts E J further in alphabetical order Tightening torque 18...

Page 1141: ...gap at A or B in the fig ure 14 Position the second ring gap at 180 on the re verse side the top ring gap 15 Position the upper rail gap at C in the figure 16 Align the upper rail spin stopper E to th...

Page 1142: ...block attach the snap ring in the service hole of the cylin der block and the piston hole on the opposite side NOTE Use new snap rings A Front side ME 00306 4 3 2 1 A 1 Piston 4 Gasket Tightening tor...

Page 1143: ...n front mark towards the front of the engine 21 Install the piston pin 1 Apply a coat of engine oil to ST3 2 Insert ST3 into the service hole to align the piston pin hole and the connecting rod small...

Page 1144: ...pper side Following the same pro cedures as used for 1 and 2 cylinders install the pistons and piston pins 8 Install the service hole cover NOTE Use new O rings Tightening torque 6 4 N m 0 7 kgf m 4 7...

Page 1145: ...asket THREE BOND 1217G Part No K0877Y0100 or equivalent Tightening torque 5 N m 0 5 kgf m 3 7 ft lb 28 Apply liquid gasket to the mating surface of oil separator cover and the threaded portion of bolt...

Page 1146: ...lded Align the flat surface of oil pump s inner rotor with crankshaft before installation Use new O rings and oil seals Do not forget to assemble O rings 5 Apply liquid gasket to the three bolts threa...

Page 1147: ...nition coil section NOTE Use a new rocker cover gasket 2 Apply liquid gasket to the specified point of the cylinder head NOTE Install within 5 min after applying liquid gasket Liquid gasket THREE BOND...

Page 1148: ...so that they are kept in their original combinations groups and not mixed together 3 Remove the piston rings using piston ring ex pander 4 Remove the oil ring by hand NOTE Arrange the removed piston r...

Page 1149: ...er rail expander and lower rail by hand 5 Install the second ring and top ring using piston ring expander NOTE Assemble so that the piston ring mark R faces the top side of the piston E INSPECTION 1 C...

Page 1150: ...rust and piston pin directions at the heights as shown in the figure using a cylinder bore gauge NOTE Measurement should be performed at a tempera ture of 20 C 68 F Taper Standard 0 015 mm 0 0006 in O...

Page 1151: ...is out of standard or if there is any damage on the cyl inder wall rebore it to replace with an oversize piston CAUTION When any of the cylinders needs reboring all other cylinders must be bored at th...

Page 1152: ...l When installing oil ring on piston be careful of the direction of each rail 2 Using the piston insert the piston ring and oil ring into the cylinder so that they are perpendicular to the cylinder wa...

Page 1153: ...stigauge If any oil clearance is not within the standard replace the defective bearing with a new part of standard size or under size as necessary Connecting rod oil clearance Standard 0 017 0 045 mm...

Page 1154: ...of the crankshaft If it exceeds the limit correct or replace it NOTE If a suitable V block is not available using just the 1 and 5 crankshaft bearings on cylinder block position the crankshaft on cyl...

Page 1155: ...andard 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 Bearing size Thickness at center 1 998 2 011 0 0787 0 0792 2 000 2 013 0 0787 0 0793 1 490 1 502...

Page 1156: ...CHANICAL 21 Intake and Exhaust Valve A SPECIFICATION Refer to Cylinder Head for removal and installa tion procedures of the intake and exhaust valves Ref to ME H4DOTC 67 REMOVAL Cylinder Head Ref to M...

Page 1157: ...Piston MECHANICAL 22 Piston A SPECIFICATION Refer to Cylinder Block for removal and installa tion procedures of pistons Ref to ME H4DOTC 76 REMOVAL Cylinder Block Ref to ME H4DOTC 81 INSTALLATION Cyl...

Page 1158: ...Rod MECHANICAL 23 Connecting Rod A SPECIFICATION Refer to Cylinder Block for removal and installa tion procedures of connecting rod Ref to ME H4DOTC 76 REMOVAL Cylinder Block Ref to ME H4DOTC 81 INST...

Page 1159: ...haft MECHANICAL 24 Crankshaft A SPECIFICATION Refer to Cylinder Block for removal and installa tion procedures of the crankshaft Ref to ME H4DOTC 76 REMOVAL Cylinder Block Ref to ME H4DOTC 81 INSTALLA...

Page 1160: ...stem B Friction Seizure of crankshaft and connecting rod bearing C Seized camshaft C Seized or stuck piston and cylinder C 2 Initial combustion does not occur Starter Defective starter C Engine contro...

Page 1161: ...lve timing B Improper engine oil low viscosity B 4 Engine stalls after initial combustion Engine control system Ref to EN H4DOTC diag 2 Basic Diagnostic Procedure A Intake system Loosened or cracked i...

Page 1162: ...ged fuel line C Lack of fuel or insufficient fuel B Timing belt Defective timing C Compression Incorrect valve clearance B Loosened spark plug or defective gasket B Loosened cylinder head bolt or defe...

Page 1163: ...ective fuel pump and relay B Clogged fuel line B Lack of fuel or insufficient fuel C Timing belt Defective timing B Compression Incorrect valve clearance B Loosened spark plug or defective gasket B Lo...

Page 1164: ...ine does not return to idle Engine control system Ref to EN H4DOTC diag 2 Basic Diagnostic Procedure A Intake system Loosened or cracked vacuum hose A Others Stuck or damaged throttle valve A 6 Diesel...

Page 1165: ...Defective oil filter gasket B Defective crankshaft oil seal B Defective rocker cover gasket B Loosened oil drain plug or defective gasket B Loosened oil pan fitting bolts or defective oil pan B 10 Ex...

Page 1166: ...ane value gasoline Clank when engine speed is between 1 000 and 2 000 rpms Noise is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft main bearing Worn conne...

Page 1167: ...Exhaust manifold RH lower cover 14 Gasket T3 40 4 1 29 5 5 Front exhaust pipe upper cover 15 Joint pipe T4 42 5 4 3 31 3 6 Front exhaust pipe insulator RH 16 Gasket T5 Ref to FU H4DOTC 48 INSTALLATIO...

Page 1168: ...upper cover Rear 18 Self locking nut T5 30 3 1 22 1 7 Clamp 19 Muffler LH T6 35 3 6 25 8 8 Rear catalytic converter lower cover 20 Muffler RH T7 42 5 4 3 31 3 21 Muffler cutter Models with muffler cu...

Page 1169: ...0 6 Center pipe upper cover Rear 17 Gasket T5 30 3 1 22 1 7 Clamp 18 Self locking nut T6 35 3 6 25 8 8 Rear catalytic converter lower cover 19 Muffler T7 42 5 4 3 31 3 20 Muffler cutter Models with m...

Page 1170: ...installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Vehicle components are extremely hot after driv ing Be wary of receiving...

Page 1171: ...Oxygen A F Sensor 6 Remove the exhaust manifold RH lower cover and exhaust manifold LH cover 7 Remove the bolts and nuts which hold front ex haust pipe assembly onto joint pipe 8 While holding the fr...

Page 1172: ...g torque 40 N m 4 1 kgf m 29 5 ft lb 5 Install the joint pipe to the front exhaust pipe as sembly NOTE Use a new gasket Tightening torque 42 5 N m 4 3 kgf m 31 3 ft lb 6 Install the exhaust manifold R...

Page 1173: ...hicle 5 Remove the bolts which secure the lower side of the turbocharger lower cover 6 Lower the vehicle 7 Remove the turbocharger upper cover 8 Remove the bolts which hold the upper side of the turbo...

Page 1174: ...ex haust pipe 14 Remove the bolt which holds center exhaust pipe bracket to transmission 15 Remove the bolt which holds center exhaust pipe to hanger bracket and remove the center ex haust pipe CAUTIO...

Page 1175: ...ds center exhaust pipe to hanger bracket 4 Temporarily tighten the bolt which holds the cen ter exhaust pipe to the transmission 5 Install the center exhaust pipe along with the tur bocharger cover st...

Page 1176: ...er Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 12 Attach the turbocharger upper cover Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 13 Lift up the vehicle 14 Tighten the bolts that secure the lower...

Page 1177: ...er 7 Remove the bolts and nuts which hold front ex haust pipe assembly onto joint pipe 8 Remove the center exhaust pipe Ref to EX H4DOTC 8 REMOVAL Center Exhaust Pipe 9 Remove the turbocharger Ref to...

Page 1178: ...ust pipe CAUTION Be careful not to drop the rear exhaust pipe 4 DOOR MODEL 5 DOOR MODEL 5 Apply a coat of spray type lubricant to the mating area of cushion rubber 6 Remove the rear exhaust pipe from...

Page 1179: ...m 35 4 ft lb 4 DOOR MODEL 5 DOOR MODEL 4 Install the center exhaust pipe to rear exhaust pipe NOTE Use a new gasket Tightening torque 18 N m 1 8 kgf m 13 3 ft lb 5 Lower the vehicle C INSPECTION 1 Ch...

Page 1180: ...cushion rubber CAUTION Be careful not to drop the muffler during remov al 4 DOOR MODEL 5 DOOR MODEL B INSTALLATION Install in the reverse order of removal NOTE Use a new gasket and self locking nut A...

Page 1181: ...EX H4DOTC 16 Muffler EXHAUST...

Page 1182: ...Pump pulley diameter mm in 60 2 36 Clearance between impeller and case Standard mm in 0 5 1 5 0 020 0 059 Thermostat Type Wax pellet type Starting temperature to open 76 80 C 169 176 F Fully opens 91...

Page 1183: ...ER 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 9 3 Heater by pass hose 7 Coolant filler by pass hose Second 12 1 2 8 9 4 Thermostat...

Page 1184: ...eneral Description COOLING 2 RADIATOR AND RADIATOR FAN 30 T1 T4 T4 9 7 10 8 29 32 27 26 5 5 25 24 CO 02542 31 12 11 14 T2 T3 13 T2 T3 5 6 5 T4 T5 1 2 3 4 28 22 23 21 5 5 C B 15 15 18 19 20 B C T4 T4 1...

Page 1185: ...ant can be spilled If the oil spills wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection Follow all government and local regulations con cerning...

Page 1186: ...cket 499977100 CRANK PULLEY WRENCH Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts MT model 499977400 CRANK PULLEY WRENCH Used to stop rotation of the crank p...

Page 1187: ...RU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester Used for measuring resistance and voltage Radiator cap tester Used for checking radiator and r...

Page 1188: ...14 15 16 17 18 19 20 21 22 23 24 5 6 7 F27 RELAY HOLDER 1 2 3 4 5 6 7 8 9 1011121314151617181920 1 2 3 4 5 6 7 8 9 101112 3 1 2 7 4 5 6 16 7 2 1 22 19 18 11 12 E6 E5 C10 B7 20 21 10 13 E E M 1 2 M TH...

Page 1189: ...leration 70 105 km h 43 65 MPH During deceleration 65 103 km h 40 64 MPH OFF OFF Low Speed High Speed Low High Speed High Speed High Speed High High Speed High Speed High Speed During acceleration 106...

Page 1190: ...nector terminal F27 No 10 Chassis ground Is the voltage 10 V or more Go to step 4 Go to step 5 4 CHECK POWER SUPPLY TO SUB FAN RE LAY 1 Turn the ignition switch to ON 2 Measure the voltage between the...

Page 1191: ...No 2 Does the radiator sub fan rotate Go to step 13 Replace the sub fan motor 13 CHECK MAIN FAN RELAY 2 Measure the resistance of main fan relay 2 Terminals No 21 No 18 Is the resistance less than 1...

Page 1192: ...n main fan relay 1 terminal and main fan motor connector Connector terminal F17 No 1 F36 No 6 Is the resistance less than 1 Go to step 23 Repair the open circuit of the har ness between main fan relay...

Page 1193: ...e between main fan relay 2 terminal and chassis ground Connector terminal F27 No 20 Chassis ground Is the voltage 10 V or more Go to step 30 Repair the power supply line 30 CHECK MAIN FAN RELAY 2 1 Tu...

Page 1194: ...ly made for Subaru engines with an aluminum cylinder block Always use SUBARU Super Coolant since other coolant may cause corrosion 3 Fill engine coolant into the reservoir tank up to FULL level 4 Clos...

Page 1195: ...rature find the proper SUBARU Super Coolant concentration in the table and add dilution water to the SUBARU Super Coolant concentrat ed type until it reaches the proper dilution Engine coolant and dil...

Page 1196: ...ler No 2 C 9 Remove the cam sprocket LH Ref to ME H4DOTC 59 REMOVAL Cam Sprocket 10 Remove the belt cover No 2 LH 11 Remove the tensioner bracket 12 Disconnect the hose from water pump 13 Remove the w...

Page 1197: ...N Timing Belt 10 Install the timing belt cover Ref to ME H4DOTC 49 INSTALLATION Timing Belt Cover 11 Install the crank pulley Ref to ME H4DOTC 47 INSTALLATION Crank Pulley 12 Install the V belts Ref t...

Page 1198: ...ostat B INSTALLATION 1 Install a gasket to thermostat NOTE Use a new gasket 2 Install the thermostat and thermostat cover NOTE Install the parts with the jiggle pin facing upward Tightening torque 12...

Page 1199: ...lift when the valve begins to open and when the valve is fully opened During the test agitate the water for even temper ature distribution The measured value should meet the specification NOTE Leave t...

Page 1200: ...emove the under cover 5 Remove the heat shield cover from radiator AT model 6 Drain the engine coolant Ref to CO H4DOTC 14 DRAINING OF ENGINE COOL ANT REPLACEMENT Engine Coolant 7 Disconnect the conne...

Page 1201: ...s 16 Move the radiator to the left while lifting it up ward 17 Lift the radiator up and remove the radiator from vehicle B INSTALLATION 1 Attach the radiator lower cushion to the hole on the radiator...

Page 1202: ...the vehicle 9 Connect the ATF cooler hoses AT model 10 Connect the radiator outlet hose 11 Connect the connectors of main fan motor con nector A and sub fan motor connector B 12 Install the heat shiel...

Page 1203: ...sition of the cap 2 Apply a pressure of 122 kPa 1 2 kg cm2 18 psi to the radiator and check the following points Leakage from the radiator or its vicinity Leakage from the hose or its connections CAUT...

Page 1204: ...it is opened under a pressure less than the service limit value Coolant filler tank side Specification 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Service limit 83 kPa 0 85 kg cm2 12 psi Radiator side Spec...

Page 1205: ...radiator AT model 7 Remove the ATF hose from the hose clip of the radiator main fan motor assembly AT model 8 Lower the vehicle 9 Remove the air intake duct Ref to IN H4DOTC 11 REMOVAL Air Intake Duct...

Page 1206: ...ft lb C DISASSEMBLY 1 Remove the clip which holds the main fan motor connector onto the radiator main fan shroud 2 Remove the nut which holds the radiator main fan to the main fan motor 3 Remove the b...

Page 1207: ...Remove the bolts which secure the radiator sub fan motor assembly and the over flow pipe 10 Raise the radiator sub fan motor assembly slightly remove the pin at the lower part of the ra diator sub fa...

Page 1208: ...n shroud 2 Remove the nut which holds the radiator sub fan to the sub fan motor 3 Remove the bolts which hold the sub fan motor onto the radiator sub fan shroud D ASSEMBLY Assemble in the reverse orde...

Page 1209: ...EMOVAL 1 Pull out the over flow hose A 2 Pull out the reservoir tank to the arrow direction while pushing the claw B B INSTALLATION Install in the reverse order of removal C INSPECTION Make sure the e...

Page 1210: ...3 2 US qt 2 6 Imp qt of coolant Ref to CO H4DOTC 14 DRAIN ING OF ENGINE COOLANT REPLACEMENT Engine Coolant 2 Disconnect the engine coolant hoses from cool ant filler tank 3 Remove the bolts which secu...

Page 1211: ...ef to EN H4DOTC diag 2 PROCEDURE Basic Diagnostic Procedure l Excessive back pressure in exhaust system Clean or replace m Insufficient clearance between piston and cylinder Adjust or replace n Slippi...

Page 1212: ...CO H4DOTC 32 Engine Cooling System Trouble in General COOLING...

Page 1213: ...LU H4DOTC 2 General Description LUBRICATION 1 General Description A SPECIFICATION Specifications for the turbo model are included in the LU H4SO section Ref to LU H4SO 2 Gen eral Description...

Page 1214: ...SP H4DOTC 2 General Description SPEED CONTROL SYSTEMS 1 General Description A SPECIFICATION Specifications for the turbo model are the same as the SOHC model Ref to SP H4SO 2 General Description...

Page 1215: ...ion system Independent ignition coil Manufacturer Diamond Electric Spark plug Manufacturer and type NGK SILFR6A Thread size diameter pitch length mm 14 1 25 26 5 Spark plug gap mm in 0 7 0 8 0 028 0 0...

Page 1216: ...t them from dust and dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Vehicle components are extremely...

Page 1217: ...e the ignition coil NOTE Turn 3 ignition coil by 180 degrees to remove it 5 Remove the spark plug with a spark plug socket 2 LH SIDE 1 Remove the battery Ref to SC H4SO 22 REMOVAL Battery 2 Disconnect...

Page 1218: ...rode erosion 1 Normal Brown to grayish tan deposits and slight electrode wear indicate correct spark plug heat range 2 Carbon fouled Dry fluffy carbon deposits on insulator and elec trode are mostly c...

Page 1219: ...e the carbon or oxide deposits If depos its are too stubborn replace the spark plugs After cleaning the spark plugs measure the spark plug gap using a gap gauge NOTE Never use a plug cleaner Never use...

Page 1220: ...rocedure Ref to IG H4DOTC 4 REMOVAL Spark Plug B INSTALLATION Install in the reverse order of removal Tightening torque 16 N m 1 6 kgf m 11 8 ft lb C INSPECTION For inspection procedure refer to Diagn...

Page 1221: ...IG H4DOTC 8 Ignition Coil IGNITION...

Page 1222: ...H4DOTC 2 General Description STARTING CHARGING SYSTEMS 1 General Description A SPECIFICATION Specifications for the turbo model are included in the SC H4SO section Ref to SC H4SO 2 General Descriptio...

Page 1223: ...tool communicate with vehicle normally Go to step 4 Inspection using Diagnostics Proce dure for Subaru Select Monitor Communication Ref to EN H4DOTC diag 81 Diagnostic Pro cedure for Subaru Select Mo...

Page 1224: ...bient air 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 speed...

Page 1225: ...EERING warning light Glow indicator Sedimentor warning light Others b Fuel level Lack of fuel Yes No Indicator position of fuel gauge Experienced running out of fuel Yes No c Intentional connecting or...

Page 1226: ...rong spec ECM to avoid any damage on the fuel injection system NOTE When replacing the ECM of the models with Immo bilizer immobilizer system must be registered To do so all ignition keys and ID cards...

Page 1227: ...lt or trouble Further against such a failure of sensors as may disable the drive the fail safe function is provided to ensure the minimal drivability The OBD system incorporated with the vehicles with...

Page 1228: ...DIAGNOSTICS D PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system 499987500 CRANKSHAFT SOCKET Used for...

Page 1229: ...GINE DIAGNOSTICS 4 Electrical Component Location A LOCATION 1 CONTROL MODULE 1 Engine control module ECM 3 Delivery test mode connector 4 Data link connector 2 Malfunction indicator light EN 06153 1 3...

Page 1230: ...old absolute pressure sensor 4 Knock sensor 7 Mass air flow and intake air temperature sensor 2 Engine coolant temperature sensor 5 Intake camshaft position sensor 3 Electronic throttle control 6 Cran...

Page 1231: ...EN H4DOTC diag 10 Electrical Component Location ENGINE DIAGNOSTICS EN 01927 1 EN 00295 2 EN 01928 3 EN 02169 4 EN 01798 5 EN 02919 6 EN 06149 7 EN 05373 8...

Page 1232: ...diag 11 Electrical Component Location ENGINE DIAGNOSTICS 1 Front oxygen A F sensor 3 Rear oxygen sensor 4 Rear catalytic converter 2 Front catalytic converter 1 2 3 4 EN 06854 1 EN 00303 EN 01800 2 EN...

Page 1233: ...C diag 12 Electrical Component Location ENGINE DIAGNOSTICS 1 Fuel level sensor 3 Fuel tank pressure sensor 4 Fuel sub level sensor 2 Fuel temperature sensor EN 06154 2 1 3 4 EN 03147 2 1 EN 06168 3 EN...

Page 1234: ...ION SYSTEM PARTS 1 Wastegate control solenoid valve 4 Ignition coil 7 Secondary air combination valve RH 2 Purge control solenoid valve 2 5 Intake oil flow control solenoid valve 8 Secondary air combi...

Page 1235: ...EN H4DOTC diag 14 Electrical Component Location ENGINE DIAGNOSTICS EN 01935 1 2 EN 05069 3 EN 05070 4 EN 05071 5 EN 04936 6 EN 04990 7 EN 04991 8 EN 04992 9...

Page 1236: ...EN H4DOTC diag 15 Electrical Component Location ENGINE DIAGNOSTICS 1 Pressure control solenoid valve 3 Drain valve 4 Drain filter 2 Canister EN 06155 3 1 2 4 EN 06167 1 EN 06157 2 EN 06158 4 3 3...

Page 1237: ...e relay 2 2 Fuel pump 7 Radiator sub fan relay 3 Main relay 8 Radiator main fan relay 2 11 Secondary air pump relay 4 Fuel pump relay 9 Secondary air combination valve relay 1 12 A F oxygen sensor rel...

Page 1238: ...l B135 26 0 3 4 5 Shield B135 35 0 0 Ground B135 34 0 0 Intake air temperature sensor signal B135 18 0 3 4 6 0 3 4 6 Wastegate control solenoid valve B137 27 0 or 10 13 0 or 12 14 Waveform Starter swi...

Page 1239: ...ss OFF 12 14 Model with A C only Malfunction indicator light B136 11 Light ON 1 or less Light OFF 10 14 Engine speed output B136 22 0 13 or more Waveform Purge control solenoid valve 1 B137 29 ON 1 or...

Page 1240: ...137 17 ON 10 13 OFF 0 ON 12 14 OFF 0 Signal B137 16 0 0 Acceleratorpedal position sensor Main sensor signal B135 23 Fully closed 1 Fully opened 3 3 Fully closed 1 Fully opened 3 3 Main power supply B1...

Page 1241: ...position sensor signal RH B134 26 Fully closed 0 4 1 2 Fully opened 2 8 4 6 Fully closed 0 4 1 2 Fully opened 2 8 4 6 Tumble generator valve position sensor signal LH B134 16 Fully closed 0 4 1 2 Ful...

Page 1242: ...137 3 0 0 Ground body B136 6 0 0 Input output name Measuring condition Waveform 1 Crankshaft position sensor At idling 2 Camshaft position sensor At idling Contents Connector No Terminal No Signal V N...

Page 1243: ...FUEL TEMPER ATURE SENSOR 12 AT 1 MT MT AT AT C31 P N IGNITION SWITCH STARTER MOTOR M B FUSE No 13 M B FUSE No 11 F B FUSE No 21 F B FUSE No 12 FUEL PUMP RELAY FUEL PUMP JOINT CONNECTOR TEST MODE SUB...

Page 1244: ...N COIL No 4 PCV HOSE ASSY ELECTRONIC THROTTLE CONTROL RELAY MAIN RELAY A F OXYGEN SENSOR RELAY PURGE CONTROL SOLENOID VALVE 1 PURGE CONTROL SOLENOID VALVE 2 INTAKE CAMSHAFT POSITION SENSOR LH INTAKE C...

Page 1245: ...34 A29 A6 A19 D4 A28 D5 B34 B26 B35 7 4 8 7 3 10 9 EN 06126 FUEL INJECTOR No 1 FUEL INJECTOR No 2 FUEL INJECTOR No 3 FUEL INJECTOR No 4 WASTEGATE SOLENOID VALVE MASS AIR FLOW INTAKE AIR TEMPERATURE SE...

Page 1246: ...RY AIR COMBINATION VALVE RELAY 2 RELAY HOLDER FUSE 60A RELAY HOLDER FUSE 10A A13 A14 A25 A24 CRANKSHAFT POSITION SENSOR D17 D16 D15 D14 OIL FLOW CONTROL SOLENOID VALVE LH D22 D23 A26 D12 D13 A16 TUMBL...

Page 1247: ...27 C34 B20 B32 C28 C17 10 MT 13 11 7 EN 05718 FUEL TANK PRESSURE SENSOR PRESSURE CONTROL SOLENOID VALVE DRAIN VALVE STOP LIGHT SWITCH BRAKE SWITCH CRUISE CONTROL SWITCH SUB FAN RELAY MAIN FAN RELAY A...

Page 1248: ...ELECTRICAL SPECIFICATION Measuring condition After engine is warmed up Set the select lever in P range or N range or the shift lever in neutral Turn the A C to OFF Turn all the accessory switches to...

Page 1249: ...Select Monitor or general scan tool because the circuit for Subaru Select Monitor may be damaged 1 2 3 4 5 7 6 8 9 10 11 12 13 15 14 16 EN 04893 Terminal No Contents Terminal No Contents 1 Power supp...

Page 1250: ...rain diagnostic data 2 MODE 02 Powertrain freeze frame data 3 MODE 03 Emission related powertrain DTC 4 MODE 04 Clear Reset emission related diagnostic information 5 MODE 06 Request on board monitorin...

Page 1251: ...ass air flow sensor gm s 11 Throttle valve absolute opening angle 12 Secondary air control status 13 Check whether oxygen sensor is installed 15 Oxygen sensor output voltage and short term fuel trim a...

Page 1252: ...o clear the emission related diagnostic infor mation MODE 04 PID Data Unit of measure 02 DTC that caused the freeze frame data storage required by CARB 03 Fuel system control status 04 Calculated engi...

Page 1253: ...orative emission control system leak detected Fuel filler cap off 3B 94 FE Evaporative emission control system 0 04 inch leak 95 FE 3C 96 FE Evaporative emission control system 0 02 inch leak 97 FE 3D...

Page 1254: ...neral Scan Tool ENGINE DIAGNOSTICS 7 MODE 07 Refer to the data of DTC pending code for troubleshooting result about emission in the first time 8 MODE 09 Refer to the data of vehicle specification V I...

Page 1255: ...r NOTE The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor 4 Connect the diagnosis cable to the SDI 5 Connect the SDI to data link c...

Page 1256: ...s or 0 35 0 40 lb m Throttle opening angle signal Throttle Opening Angle 2 0 2 4 Rear oxygen sensor voltage Rear O2 Sensor V 0 1 0 V Battery voltage Battery Voltage V 12 15 V Mass air flow voltage Ai...

Page 1257: ...ON OFF Delivery test mode terminal Test Mode Signal OFF D check Require Flag D check Require Flag OFF Delivery test mode terminal Delivery Mode Connector Test Mode Connector OFF Neutral position switc...

Page 1258: ...switch signal Clutch Switch OFF when OFF Stop light switch signal Stop Light Switch OFF when OFF SET COAST switch signal SET COAST Switch OFF when OFF RES ACC switch signal RESUME ACCEL Switch OFF whe...

Page 1259: ...heating type catalyst Heated catalyst Rdy N A Test of evaporative emission purge control system Evaporative purge system Supp YES Test of evaporative emission purge control system Evaporative purge s...

Page 1260: ...test of misfire Misfire monitoring Comp YES Monitoring test of fuel system Fuel system monitoring Enable YES Monitoring test of fuel system Fuel system monitoring Comp NO Monitoring test of comprehen...

Page 1261: ...erature C Absolute throttle opening angle 2 Absolute Throttle Pos 2 31 Absolute accelerator opening angle 1 Accelerator Pedal Pos 1 13 Absolute accelerator opening angle 2 Accelerator Pedal Pos 2 13 T...

Page 1262: ...front oxygen A F sensor Bank 1 Short term fuel trim B1 Long term fuel trim by front oxygen A F sensor Bank 1 Long term fuel trim B1 Intake manifold absolute pressure signal Mani Absolute Pressure mmH...

Page 1263: ...ic Trouble Code DTC 2 SUBARU SELECT MONITOR OBD MODE 1 On Main Menu display select Each System Check 2 On System Selection Menu display select Engine Control System 3 Click the OK button after the inf...

Page 1264: ...edal Position Sensor Switch A Circuit High P0131 O2 Sensor Circuit Low Voltage Bank 1 Sensor 1 P0132 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 P0137 O2 Sensor Circuit Low Voltage Bank 1 Sensor 2...

Page 1265: ...d Runner Control Stuck Closed Bank 1 P2007 Intake Manifold Runner Control Stuck Closed Bank 2 P2008 Intake Manifold Runner Control Circuit Open Bank 1 P2009 Intake Manifold Runner Control Circuit Low...

Page 1266: ...it Low P2420 Evaporative Emission System Switching Valve Control Circuit High P2431 Secondary Air Injection System Air Flow Pressure Sensor Circuit Range Performance P2432 Secondary Air Injection Syst...

Page 1267: ...hile servicing do not depress or release the clutch pedal or accelerator pedal quickly re gardless of the engine speed Quick operation may cause the vehicle to drop off the free roller To prevent the...

Page 1268: ...of Di agnostic Trouble Code DTC Ref to EN H4DOTC diag 83 List of Diagnos tic Trouble Code DTC Release the parking brake The speed difference between front and rear wheels may light the ABS warning lig...

Page 1269: ...e ABS warning light but this in dicates no malfunctions When engine control diag nosis is finished perform the ABS memory clearance procedure of self diagnosis system Ref to ABS diag 21 Clear Memory M...

Page 1270: ...PREPARATION FOR DRIVE CYCLE 1 Check that the battery voltage is 12 V or more and fuel remains approx half 20 40 2 5 3 10 6 US gal 4 4 8 8 Imp gal 2 After performing the diagnostics and clearing the me...

Page 1271: ...l System Leak Detected Small Leak Engine coolant temperature at engine start is less than 25 C 77 F P0451 Evaporative Emission Control System Pressure Sensor P0456 Evaporative Emission Control System...

Page 1272: ...System Too Lean Bank 1 Complete diagnosis with drive cycle A or B as well P0172 System Too Rich Bank 1 Complete diagnosis with drive cycle A or B as well P0244 Turbo Super Charger Wastegate Solenoid...

Page 1273: ...d by disconnecting the bat tery terminals 6 DRIVE CYCLE E 1 Make sure that the battery voltage is 10 9 V or more 2 Perform the Clear Memory Mode Ref to EN H4DOTC diag 54 Clear Memory Mode 3 Drive for...

Page 1274: ...ru Select Monitor 3 If the values from step 2 satisfy the following two conditions start the engine Condition Engine coolant temperature Intake air temperature d 5 C 41 F Engine coolant temperature Fu...

Page 1275: ...display select Each System Check 2 On System Selection Menu display select Engine Control System 3 Click the OK button after the information of en gine type has been displayed 4 On Engine Diagnosis di...

Page 1276: ...A located under the glove box 6 Connect SDI to data link connector located in the lower portion of the instrument panel on the driv er s side CAUTION Do not connect the scan tools except for Suba ru S...

Page 1277: ...d 2 Compulsory radiator fan relay operation check Radiator Fan Relay Compulsory air conditioning relay operation check A C Compressor Relay Compulsory wastegate control solenoid valve operation check...

Page 1278: ...eck mode execute the Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode 1 On System Operation Check Mode display select Fuel Pump Control 2 On Fuel Pump Control display select OFF...

Page 1279: ...C ap plication help for Subaru Select Monitor 5 INJECTOR CONTROL INJECTION STOP MODE CAUTION After executing the system operation check mode execute the Clear Memory Mode Ref to EN H4DOTC diag 54 OPER...

Page 1280: ...iag 61 MALFUNCTION INDICATOR LIGHT DOES NOT COME ON Malfunction Indicator Light p 3 Malfunction indicator light does not go off Ref to EN H4DOTC diag 63 MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF Mal...

Page 1281: ...the malfunction indica tor light goes out If it does not go off either the en gine or emission control system has malfunction 3 Turn the ignition switch to OFF and connect the delivery test mode conne...

Page 1282: ...tor light does not illuminate WIRING DIAGRAM EN 06128 SBF 6 MAIN SBF No 5 B72 B36 B136 ECM i1 i1 E 3 11 i10 2 38 16 B72 i10 B136 1 3 4 5 6 2 1 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22...

Page 1283: ...contact of combination meter connector Is there poor contact of combi nation meter connector Repair the poor contact of combi nation meter con nector Go to step 4 4 CHECK HARNESS BETWEEN COMBINA TION...

Page 1284: ...from ECM 3 Turn the ignition switch to ON Does the malfunction indicator light illuminate Repair the ground short circuit of har ness between ECM and combi nation meter con nector Replace the ECM Ref...

Page 1285: ...6 33 34 35 SBF 6 MAIN SBF No 5 B72 B36 B135 B136 ECM i1 1 E 1 1 C11 16 B27 i10 B C B72 B75 i10 B136 1 2 1 2 1 2 1 2 C B135 B363 B363 B364 B364 i1 B 2 38 C6 B122 1 3 4 5 6 2 1 2 3 4 5 6 7 8 B122 B76 B7...

Page 1286: ...alfunction indicator light illuminate Repair the ground short circuit of har ness between ECM and combi nation meter con nector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND DE LIVERY TEST MODE CONNECT...

Page 1287: ...MAIN SBF No 5 B72 B36 B135 B136 ECM i1 1 E 1 1 C11 16 B27 i10 B C B72 B75 i10 B136 1 2 1 2 1 2 1 2 C B135 B363 B363 B364 B364 i1 B 2 38 C6 B122 1 3 4 5 6 2 1 2 3 4 5 6 7 8 B122 B76 B75 B76 3 1 5 6 7 2...

Page 1288: ...on indica tor light blinks when delivery test mode con nector is connect ed 2 CHECK HARNESS BETWEEN ECM AND CHASSIS GROUND TERMINAL 1 Turn the ignition switch to OFF 2 Disconnect the connectors from E...

Page 1289: ...d ground line Ref to EN H4DOTC diag 73 CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE ECM Diagnostics for Engine Starting Failure p 4 Inspection of ignition control system Ref to EN H4DOT...

Page 1290: ...2 20 B225 MAIN SBF SBF 6 E 11 9 12 10 B136 B72 B14 M 2 6 3 AT CLUTCH START SWITCH 2 1 B106 ECM BATTERY IGNITION SWITCH STARTER RELAY STARTER MOTOR AT MT MT EN 07196 AT MT B12 T3 T7 INHIBITOR SWITCH P...

Page 1291: ...or more Check the starter motor Ref to SC H4SO 7 Starter Go to step 5 5 CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ig...

Page 1292: ...or more Go to step 12 Repair open circuit or short circuit to ground in harness between ignition switch connector and clutch start switch connector 12 CHECK CLUTCH START SWITCH Measure the resistance...

Page 1293: ...easure the resistance between inhibitor switch terminals Connector terminal No 6 No 9 Is the resistance less than 1 Go to step 17 Replace the inhibi tor switch Ref to 4AT 48 Inhibitor Switch 17 CHECK...

Page 1294: ...1 24 23 22 21 ECM E E B134 B135 A C B136 D B137 B 35 34 40 No 13 D7 36 B134 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 33 34 29 32 30 31 B135 5 6 7 8 2 1 9 4 3 10 24 22...

Page 1295: ...sis ground Is the voltage 10 V or more Go to step 4 Repair the open or groundshortcircuit of power supply circuit 4 CHECK INPUT VOLTAGE OF MAIN RELAY Measure the voltage between main relay con nector...

Page 1296: ...AM EN 06132 5 6 7 8 2 1 9 4 3 10 22 23 11 12 13 14 15 24 25 26 16 17 18 19 20 21 27 28 29 30 31 SBF 6 MAIN SBF B72 B137 18 19 20 21 ECM No 12 E 1 3 26 E2 B21 E31 E31 E32 E33 E34 E32 E33 E34 6 1 2 3 B2...

Page 1297: ...ngine ground E34 No 3 Engine ground Is the voltage 10 V or more Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ignition coil...

Page 1298: ...ine ground B137 No 19 Engine ground B137 No 20 Engine ground B137 No 21 Engine ground Is the resistance 1 M or more Go to step 7 Repair the ground short circuit of har ness between ECM and ignition co...

Page 1299: ...alve Op eration Check Mode Does the fuel pump emit oper ating sound Check the fuel injector circuit Ref to EN H4DOTC diag 79 FUEL INJEC TOR CIRCUIT Diagnostics for Engine Starting Failure Display the...

Page 1300: ...05898 E 4 1 2 SBF 7 3 1 2 2 1 2 B21 1 1 2 48 54 53 52 51 8 9 10 11 1 2 B21 B137 E5 E5 E2 E6 E6 E16 E16 E17 E17 ECM B137 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 3...

Page 1301: ...ECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM 3 Measure the resistance of harness between ECM and fuel injector connector Connector terminal B137 No 8 E5 No 1 B137 No 9...

Page 1302: ...13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 42 43 36 37 38 39 48 49 50 51 52 53 54 40 41 44 45 46 47 B40 4 5 7 16 B122 1 2 3 4 5 6 7 8 B122 16 10 11 12 13 14 15 25 24 30 9 8...

Page 1303: ...he harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and data link connector Open circuit of harness between ECM and engine ground Poor contact of E...

Page 1304: ...01 DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW BANK 1 SENSOR 2 Diagnostic Procedure with Diagnostic Trouble Code DTC P0038 HO2S Heater Control Circuit High Bank 1 Sensor 2 Ref to EN H4DOTC diag 103 DTC...

Page 1305: ...C diag 135 DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE BANK 1 SENSOR 1 Diagnostic Procedure with Diagnostic Trou ble Code DTC P0132 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 Ref to EN H4DOTC diag 137...

Page 1306: ...f to EN H4DOTC diag 172 DTC P0302 CYLINDER 2 MISFIRE DETECTED Diagnostic Procedure with Diagnostic Trouble Code DTC P0303 Cylinder 3 Misfire Detected Ref to EN H4DOTC diag 172 DTC P0303 CYLINDER 3 MIS...

Page 1307: ...dure with Diagnostic Trouble Code DTC P0448 Evaporative Emission Control System Vent Control Circuit Shorted Ref to EN H4DOTC diag 223 DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUI...

Page 1308: ...cedure with Diagnostic Trouble Code DTC P0700 Transmission Control System Mil Request Ref to EN H4DOTC diag 248 DTC P0700 TRANSMISSION CONTROL SYSTEM MIL REQUEST Diagnostic Procedure with Diagnostic T...

Page 1309: ...ULE EEPROM Diag nostic Procedure with Diagnostic Trouble Code DTC P1577 IMM Control Module EEPROM Ref to IM diag 23 DTC P1577 IMM CONTROL MODULE EEPROM Diagnostic Procedure with Diagnostic Trouble Cod...

Page 1310: ...HAFT POSI TION ACTUATOR CONTROL CIRCUIT HIGH BANK 2 Diagnostic Proce dure with Diagnostic Trouble Code DTC P2096 Post Catalyst Fuel Trim System Too Lean Bank 1 Ref to EN H4DOTC diag 311 DTC P2096 POST...

Page 1311: ...to EN H4DOTC diag 348 DTC P2432 SECONDARY AIR INJEC TION SYSTEM AIR FLOW PRESSURE SENSOR CIRCUIT LOW Diagnos tic Procedure with Diagnostic Trouble Code DTC P2433 Secondary Air Injection System Air Fl...

Page 1312: ...VCS system operating angle approximately 0 Go to step 2 Check the follow ing item and repair or replace if neces sary Oil pipe clog Oil flow control solenoid valve clog or dirt of oil routing setting...

Page 1313: ...system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRE...

Page 1314: ...system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRE...

Page 1315: ...proximately 0 Go to step 2 Check the follow ing item and repair or replace if neces sary Oil pipe clog Oil flow control solenoid valve clog or dirt of oil routing setting of spring Intake camshaft dir...

Page 1316: ...15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47...

Page 1317: ...epair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM and front oxy gen A F sensor connector Poor contact of coupling connector 2 CHECK FRONT...

Page 1318: ...8 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47 46 49 48 5...

Page 1319: ...ECM 3 Measure the resistance between ECM and front oxygen A F sensor connector Connector terminal B136 No 3 E22 No 2 B136 No 2 E22 No 2 Is the resistance less than 1 Go to step 3 Repair the harness an...

Page 1320: ...28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47 46 49 48...

Page 1321: ...in the harness between ECM and front oxygen A F sensor connector Go to step 2 2 CHECK GROUND CIRCUIT FOR ECM 1 Disconnect the connectors from ECM 2 Measure the resistance between ECM and chassis grou...

Page 1322: ...23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 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 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3 10 22 23...

Page 1323: ...easure the resistance between the ECM and rear oxygen sensor connector Connector terminal B136 No 4 T6 No 1 Is the resistance less than 1 Go to step 3 Repair the harness and connector NOTE In this cas...

Page 1324: ...2 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 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 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3 10 22 23...

Page 1325: ...ess between ECM and rearoxygensensor connector Go to step 2 2 CHECK GROUND CIRCUIT FOR ECM 1 Disconnect the connectors from ECM 2 Measure the resistance between ECM and chassis ground Connector termin...

Page 1326: ...AUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode...

Page 1327: ...e General Scan Tool Instruction Manual Is the measured value 73 3 106 6 kPa 550 800 mmHg 21 65 31 50 inHg when the ignitionisturnedON and20 0 46 7 kPa 150 350 mmHg 5 91 13 78 inHg during idling Go to...

Page 1328: ...ON After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WI...

Page 1329: ...OR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appropri ate DTC using the List of Diagnostic Trouble Code DTC Ref to EN H4DOTC diag 83 List of Diagnos tic Trouble Code DTC Replace th...

Page 1330: ...replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 06135 B...

Page 1331: ...ollowing item Open circuit in harness between main relay connec tor and mass air flow and intake air temperature sen sor connector Poor contact of main relay connec tor 3 CHECK HARNESS BETWEEN ECM AND...

Page 1332: ...r replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 06135...

Page 1333: ...ation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operation procedures refer to the general scan tool operation manu...

Page 1334: ...g Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Insp...

Page 1335: ...tor NOTE In this case repair the following item Open circuit of harness between ECM and manifold absolute pressure sensor connector Poor contact of ECM connector Poor contact of coupling connector 3 C...

Page 1336: ...ng Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Ins...

Page 1337: ...tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operation proced...

Page 1338: ...TION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WI...

Page 1339: ...ailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operation procedures refer to the general scan tool oper...

Page 1340: ...acing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 06135 B135 5...

Page 1341: ...e cir cuit has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case tem porary poor con tact of connector may be the cause 2 CHECK...

Page 1342: ...lacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 06135 B135...

Page 1343: ...or Repair the poor contact of ECM or mass air flow and intake air tempera ture sensor con nector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEM PERATURE SENSOR CONNECTOR...

Page 1344: ...Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43...

Page 1345: ...gher Go to step 2 Even if DTC is detected the cir cuit has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case tem porary poor con...

Page 1346: ...g Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43...

Page 1347: ...sor connector Repair the poor contact of ECM or engine coolant temperature sen sor connector Go to step 3 3 CHECK HARNESS BETWEEN ECM AND EN GINE COOLANT TEMPERATURE SENSOR CONNECTOR 1 Turn the igniti...

Page 1348: ...25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4 10 11...

Page 1349: ...6 Is the resistance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and elec tronic throttle con trol connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the c...

Page 1350: ...3 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4 10 11...

Page 1351: ...less than 5 Go to step 3 Repair the harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact...

Page 1352: ...Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode Step Check Yes No 1 CHECK TIRE SIZE Is the tire size as specified and...

Page 1353: ...YMPTOM Hard to start Improper idling Poor driving performance CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Ins...

Page 1354: ...gine cool ant temperature sensor terminals when the engine coolant is cold and after warmed up Terminals No 1 No 2 Is the resistance of engine cool ant temperature sensor differ ent between when engin...

Page 1355: ...lacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode Step Check Yes No 1 CHECK ENG...

Page 1356: ...16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47 46 49 48 51...

Page 1357: ...CM and front oxygen A F sensor connector 3 Measure the resistance between ECM and chassis ground Connector terminal B135 No 9 Chassis ground B135 No 8 Chassis ground Is the resistance 1 M or more Go t...

Page 1358: ...28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47 46 49 48...

Page 1359: ...D FRONT OXYGEN A F SENSOR CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from front oxygen A F sensor 3 Turn the ignition switch to ON 4 Measure the voltage between ECM and ch...

Page 1360: ...13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44...

Page 1361: ...following items Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a...

Page 1362: ...26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47 46...

Page 1363: ...terminal B135 No 9 E22 No 1 B135 No 8 E22 No 3 Is the resistance less than 1 Go to step 2 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between E...

Page 1364: ...23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 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 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3 10 22 23 1...

Page 1365: ...inal B135 No 4 T6 No 3 B135 No 30 T6 No 4 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM an...

Page 1366: ...23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 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 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3 10 22 23...

Page 1367: ...l B135 No 4 T6 No 3 B135 No 30 T6 No 4 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM and r...

Page 1368: ...2 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 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 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3 10 22 23...

Page 1369: ...or contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR Measure the resistance between rear oxygen sensor connector and chassis ground Connector terminal T6 No 3...

Page 1370: ...24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 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 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3 10...

Page 1371: ...he data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOT...

Page 1372: ...5 V Replace the rear oxygen sensor Ref to FU H4DOTC 50 Rear Oxygen Sen sor Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between ECM and rear oxy...

Page 1373: ...r vacuum hose from intake manifold Ref to ME H4DOTC 25 INSPEC TION Fuel Pressure CAUTION Release fuel pressure before removing the fuel pressure gauge NOTE If fuel pressure does not increase squeeze t...

Page 1374: ...s refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Monitor General scan tool For detailed operation procedures refer to the general scan tool operation manual Is the measur...

Page 1375: ...ing Criteria CAUTION After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE...

Page 1376: ...p Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appro priate DTC using the List of Diag nostic Trouble Code DTC Ref to EN H4DOTC diag 83 List of Diag nostic Tr...

Page 1377: ...fter servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING D...

Page 1378: ...it has returned to a normal condition at this time Repro duce the failure and then perform the diagnosis again NOTE In this case tem porary poor con tact of connector may be the cause 2 CHECK HARNESS...

Page 1379: ...After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING...

Page 1380: ...nd fuel temperature sen sor connectors Go to step 3 3 CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and fuel t...

Page 1381: ...25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4 10 11...

Page 1382: ...esistance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and elec tronic throttle con trol connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the connector to...

Page 1383: ...3 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4 10 11...

Page 1384: ...less than 5 Go to step 3 Repair the harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact...

Page 1385: ...Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05897 E E M 10 7 6 5 6 No 11 B220 R122 B135 B B136 C R58 B97 7 B33 C12 13 14 9 8 5 6 5 R1 4 R1 B97 5 1 R1...

Page 1386: ...l R122 No 5 Chassis ground Is the resistance less than 5 Go to step 3 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness between fuel pump control uni...

Page 1387: ...TOR Measure the resistance between fuel pump control unit connector and chassis ground Connector terminal R122 No 9 Chassis ground R122 No 8 Chassis ground Is the resistance 1 M or more Go to step 7 R...

Page 1388: ...rm Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05903 1 2 7 8 9 5 6 3 4 10 11 12 19...

Page 1389: ...es No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appropri ate DTC using the List of Diagnostic Trouble Code DTC Ref to EN H4DOTC diag 83 List of Diagnos tic Trouble Code...

Page 1390: ...Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05903 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31...

Page 1391: ...nector Connector terminal B137 No 27 E64 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit of harness between EC...

Page 1392: ...y Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05903 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31...

Page 1393: ...Diagnostic Procedure with Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK HARNESS BETWEEN ECM AND WASTEGATE CONTROL SOLENOID VALVE CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the co...

Page 1394: ...arts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05898 E 4 1 2 SBF 7 3 1 2...

Page 1395: ...ween ECM and fuel injector connector on faulty cylin ders Connector terminal 1 B137 No 8 E5 No 1 2 B137 No 9 E16 No 1 3 B137 No 10 E6 No 1 4 B137 No 11 E17 No 1 Is the resistance less than 1 Go to ste...

Page 1396: ...r crankshaft position sensor loosely installed Tighten the cam shaft position sen sor or crankshaft position sensor Go to step 9 9 CHECK CRANK SPROCKET Remove the timing belt cover Is the crank sprock...

Page 1397: ...o step 15 15 CHECK MISFIRE SYMPTOM 1 Turn the ignition switch to ON 2 Read the DTC NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC d...

Page 1398: ...ot found check the IGNITION CON TROL SYSTEM of 1 and 2 cylin ders side Ref to EN H4DOTC di ag 75 IGNITION CONTROL SYS TEM Diagnostics for Engine Starting Failure Go to DTC P0171 Ref to EN H4DOTC diag...

Page 1399: ...OUP OF 2 AND 4 CYLINDERS Are there any faults in 2 and 4 cylinders Repair or replace faulty parts NOTE Check the follow ing items Spark plug Fuel injector Compression ra tio Skipping timing belt teeth...

Page 1400: ...oor driving performance Knocking occurs CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H...

Page 1401: ...he resistance 600 k or more Go to step 2 Repair the poor contact of ECM connector 2 CHECK KNOCK SENSOR 1 Disconnect the connector from knock sen sor 2 Measure the resistance between knock sensor termi...

Page 1402: ...Poor driving performance Knocking occurs CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN...

Page 1403: ...han 500 k Replace the knock sensor Ref to FU H4DOTC 36 Knock Sensor Repair the short circuit to ground in harness between ECM and knock sensor connector NOTE The harness be tween both con nectors are...

Page 1404: ...f engine to start CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DU...

Page 1405: ...Terminals No 1 No 2 Is the resistance between 1 and 4 k Go to step 3 Replace the crank shaft position sen sor Ref to FU H4DOTC 32 Crankshaft Posi tion Sensor 3 CHECK HARNESS BETWEEN ECM AND CRANKSHAFT...

Page 1406: ...E SYMPTOM Engine stalls Failure of engine to start CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode...

Page 1407: ...ROCKET Remove the timing belt cover Are crank sprocket teeth cracked or damaged Replace the crank sprocket Ref to ME H4DOTC 60 Crank Sprocket Go to step 3 3 CHECK INSTALLATION CONDITION OF TIMING BELT...

Page 1408: ...4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05904 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17...

Page 1409: ...osition sensor connector Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNEC TOR Measure the resistance between camshaft position sensor connector and en...

Page 1410: ...RATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05904 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 33 3...

Page 1411: ...ft posi tion sensor con nector Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNEC TOR Measure the resistance between camshaft position sensor connector...

Page 1412: ...o consecutive driving cycles with fault occur GENERAL DESCRIPTION Ref to GD H4DOTC 98 DTC P0410 SECONDARY AIR INJECTION SYS TEM Diagnostic Trouble Code DTC Detecting Criteria CAUTION After servicing o...

Page 1413: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1414: ...operation procedure refer to Clear Memory Mode Ref to EN H4DOTC diag 54 Clear Memory Mode and Compulsory Valve Operation Check Mode Ref to EN H4DOTC diag 55 Com pulsory Valve Operation Check Mode The...

Page 1415: ...12 and No 13 of the secondary air pump relay 2 Measure the resistance between secondary air pump relay terminals Terminals No 14 No 11 Is the resistance less than 1 Go to step 9 Replace the sec ondar...

Page 1416: ...o consecutive driving cycles with fault occur GENERAL DESCRIPTION Ref to GD H4DOTC 107 DTC P0411 SECONDARY AIR INJECTION SYS TEM INCORRECT FLOW DETECTED Diagnostic Trouble Code DTC Detecting Criteria...

Page 1417: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1418: ...d cylinder head Is there damage or disconnec tion of the pipe Replace the pipe between second ary air combination valve and cylinder head Go to step 2 2 CHECK SECONDARY AIR COMBINATION VALVE Race the...

Page 1419: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 108 DTC P0413 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE A CIRCUIT OPEN Diagnostic Trouble Code DTC Detecting Criteria CAUTION...

Page 1420: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1421: ...tor NOTE In this case repair the following item Open circuit in harness between ECM and second ary air combination valve relay 1 con nector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN E...

Page 1422: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 109 DTC P0414 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE A CIRCUIT SHORTED Diagnostic Trouble Code DTC Detecting Criteria CAUTI...

Page 1423: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1424: ...Turn the ignition switch to OFF 2 Disconnect the connector from ECM and secondary air combination valve relay 1 3 Measure the voltage between ECM and chassis ground Connector terminal B135 No 15 Chas...

Page 1425: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 109 DTC P0416 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE B CIRCUIT OPEN Diagnostic Trouble Code DTC Detecting Criteria CAUTION...

Page 1426: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1427: ...tor NOTE In this case repair the following item Open circuit in harness between ECM and second ary air combination valve relay 2 con nector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN E...

Page 1428: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 109 DTC P0417 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE B CIRCUIT SHORTED Diagnostic Trouble Code DTC Detecting Criteria CAUTI...

Page 1429: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1430: ...Turn the ignition switch to OFF 2 Disconnect the connector from ECM and secondary air combination valve relay 2 3 Measure the voltage between ECM and chassis ground Connector terminal B135 No 14 Chas...

Page 1431: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 110 DTC P0418 SECONDARY AIR INJECTION SYS TEM CONTROL A CIRCUIT OPEN Diagnostic Trouble Code DTC Detecting Criteria CAUTION After se...

Page 1432: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1433: ...nnector NOTE In this case repair the following item Open circuit in harness between ECM and second ary air pump relay connector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND SECON...

Page 1434: ...7 D B136 C 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 33 34 29 32 30 31 35 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 29 30 31 32...

Page 1435: ...H4DOTC 2 General Descrip tion Go to step 2 2 CHECK WAVEFORM DATA ON THE SUBA RU SELECT MONITOR WHILE DRIVING 1 Drive at a constant speed between 80 112 km h 50 70 MPH 2 After 5 minutes have elapsed i...

Page 1436: ...ep 4 The waveform is displayed at abnor mal condition 1 Go to step 4 The waveform is displayed at abnor mal condition 2 Go to step 5 4 CHECK CATALYTIC CONVERTER Is the catalytic converter dam aged Rep...

Page 1437: ...WEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch to ON 2 Measure the voltage between rear oxygen sensor connector and chassis ground Connector terminal T6 No 3 Chassis ground Is th...

Page 1438: ...ostic Trouble Code DTC Ref to EN H4DOTC diag 83 List of Diagnos tic Trouble Code DTC Go to step 2 2 CHECK PURGE LINE OF THE PURGE CON TROL SOLENOID VALVE 2 Is there any clogging flattened part or bent...

Page 1439: ...WIRING DIAGRAM SBF 7 E4 E 21 22 23 24 ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 1440: ...e Ref to EC H4DOTC 22 Drain Valve 5 CHECK PURGE CONTROL SOLENOID VALVE Operate the purge control solenoid valve using the Subaru Select Monitor NOTE Purge control solenoid valve operation can be execu...

Page 1441: ...DOTC 62 Fuel Tank Is the fuel tank damaged or is there any hole of more than 1 0 mm 0 04 in dia in it Repair or replace the fuel tank Ref to FU H4DOTC 62 Fuel Tank Go to step 10 10 CHECK ANY OTHER MEC...

Page 1442: ...7 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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...

Page 1443: ...Measure the resistance of harness between ECM and drain valve connector Connector terminal B136 No 17 R86 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this...

Page 1444: ...5 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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...

Page 1445: ...ON 4 Measure the voltage between ECM and chassis ground Connector terminal B136 No 17 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between ECM and drain...

Page 1446: ...g Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Insp...

Page 1447: ...cap securely 2 CHECK PRESSURE VACUUM LINE NOTE Check the following items Disconnection leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank Disconnection...

Page 1448: ...iteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspecti...

Page 1449: ...Repair the harness and connector NOTE In this case repair the following item Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact of ECM connector Poor contact of c...

Page 1450: ...riteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspect...

Page 1451: ...Subaru Select Monitor or gen eral scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General...

Page 1452: ...n Mode WIRING DIAGRAM SBF 7 E4 E 21 22 23 24 ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 1 2 3 4 5 6 7 8 9 10 1...

Page 1453: ...Ref to EC H4DOTC 22 Drain Valve 5 CHECK PURGE CONTROL SOLENOID VALVE Operate the purge control solenoid valve using the Subaru Select Monitor NOTE Purge control solenoid valve operation can be execut...

Page 1454: ...OTC 62 Fuel Tank Is the fuel tank damaged or is there any hole of more than 0 5 mm 0 020 in dia in it Repair or replace the fuel tank Ref to FU H4DOTC 62 Fuel Tank Go to step 10 10 CHECK ANY OTHER MEC...

Page 1455: ...F 7 E4 E 21 22 23 24 ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

Page 1456: ...e Ref to EC H4DOTC 22 Drain Valve 5 CHECK PURGE CONTROL SOLENOID VALVE Operate the purge control solenoid valve using the Subaru Select Monitor NOTE Purge control solenoid valve operation can be execu...

Page 1457: ...l tank Ref to FU H4DOTC 62 Fuel Tank Is the fuel tank damaged Repair or replace the fuel tank Ref to FU H4DOTC 62 Fuel Tank Go to step 10 10 CHECK ANY OTHER MECHANICAL TROU BLE IN EVAPORATIVE EMISSION...

Page 1458: ...ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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 2...

Page 1459: ...olenoid valve Connector terminal B137 No 29 E4 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness betw...

Page 1460: ...ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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 1461: ...ween ECM and chassis ground Connector terminal B137 No 29 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between ECM and purge control sole noid valve conn...

Page 1462: ...t occur GENERAL DESCRIPTION Ref to GD H4DOTC 148 DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH Diagnostic Trouble Code DTC Detecting Criteria CAUTION After servicing or replacing faulty parts perform Cle...

Page 1463: ...ic Trouble Code DTC Detecting Criteria CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4...

Page 1464: ...ef to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM 32 20 B225 MAIN SBF SBF 6 E 11 9 12 10 B136 B72 B14 M 2 6 3 A...

Page 1465: ...using the List of Diagnostic Trouble Code DTC Ref to EN H4DOTC diag 83 List of Diagnos tic Trouble Code DTC Go to step 2 2 CHECK HARNESS BETWEEN ECM AND IG NITION SWITCH CONNECTOR 1 Turn the ignition...

Page 1466: ...30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 C SBF 6 MAIN SBF SBF 7 B72 A7 B2 C23 D2 A5 D3 B5 B19 No 12 E2 B21 24 23 22 21 ECM E E B134 B135 A C B136 D B137 B 35 34 40 No...

Page 1467: ...CE Diagnostic Procedure with Diagnostic Trou ble Code DTC Step Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appropri ate DTC using the List of Diagnostic Trou...

Page 1468: ...37 B136 D C E 38 39 28 6 24 25 E2 B21 E57 4 6 1 2 3 5 D4 D5 A29 A19 D7 A5 D2 D1 D3 35 34 37 40 36 A28 C6 A18 ECM B21 B72 E57 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 34 35 36 3...

Page 1469: ...l B134 No 7 Chassis ground B135 No 2 Chassis ground Is the voltage 13 15 V Go to step 3 Repair the open or groundshortcircuit of power supply circuit 3 CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTL...

Page 1470: ...Diagnostic Trouble Code DTC Detecting Criteria TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Mem...

Page 1471: ...HARNESS CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and transmission harness connector T3 3 Measure the resistance between ECM and chassis ground Connector termin...

Page 1472: ...ic Trouble Code DTC Detecting Criteria TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode...

Page 1473: ...ltage 10 V or more Repair the poor contact of ECM connector Go to step 2 2 CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connector...

Page 1474: ...L Diagnostic Trouble Code DTC Detecting Criteria TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Me...

Page 1475: ...Measure the resistance of harness between ECM and inhibitor switch connector Connector terminal B136 No 31 T7 No 6 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In...

Page 1476: ...tic Trouble Code DTC Detecting Criteria TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode...

Page 1477: ...ors from ECM and neutral position switch 3 Measure the resistance of harness between ECM and neutral position switch connector Connector terminal B136 No 31 T12 No 1 B136 No 6 T12 No 2 Is the resistan...

Page 1478: ...11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43...

Page 1479: ...stance of harness between ECM and front oxygen A F sensor connector Connector terminal B135 No 9 E22 No 1 B135 No 8 E22 No 3 Is the resistance less than 1 Go to step 3 Repair the harness and connector...

Page 1480: ...11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43...

Page 1481: ...to step 3 Repair the ground short circuit of har ness between ECM and front oxy gen A F sensor connector 3 CHECK OUTPUT SIGNAL FOR ECM 1 Connect the connector to ECM 2 Turn the ignition switch to ON 3...

Page 1482: ...R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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...

Page 1483: ...ontrol solenoid valve con nector Connector terminal B136 No 28 R68 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open cir...

Page 1484: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 177 DTC P1410 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE STUCK OPEN Diagnostic Trouble Code DTC Detecting Criteria CAUTION Afte...

Page 1485: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1486: ...ir combina tion valve air inlet and check whether there are leaks at the pipe connections Are there air leaks from the pipe connections Replace the sec ondary air combi nation valve on the side with t...

Page 1487: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 178 DTC P1418 SECONDARY AIR INJECTION SYS TEM CONTROL A CIRCUIT SHORTED Diagnostic Trouble Code DTC Detecting Criteria CAUTION After...

Page 1488: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1489: ...ary air pump relay 3 Measure the voltage between ECM and chassis ground Connector terminal B136 No 8 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between...

Page 1490: ...R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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 1491: ...ECM and chassis ground Connector terminal B136 No 28 Chassis ground Is the voltage 10 V or more Repair the short circuit to power in the harness between ECM and pressure control solenoid valve con ne...

Page 1492: ...57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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...

Page 1493: ...he drain hose Replace the drain hose Go to step 3 3 CHECK DRAIN VALVE OPERATION 1 Turn the ignition switch to OFF 2 Connect the delivery test mode connector at the lower portion of instrument panel on...

Page 1494: ...ing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 0...

Page 1495: ...Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND PCV HOSE ASSEMBLY CONNECTOR Measure the resistance between PCV hose assembly connector and chassis ground Connector terminal B134 No...

Page 1496: ...2 3 4 5 6 27 26 33 34 35 B136 C SBF 6 MAIN SBF SBF 7 B72 A7 B2 C23 D2 A5 D3 B5 B19 No 12 E2 B21 24 23 22 21 ECM E E B134 B135 A C B136 D B137 B 35 34 40 No 13 D7 36 B134 5 6 7 8 2 1 9 4 3 10 24 22 23...

Page 1497: ...ECK HARNESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR 1 Disconnect the connectors from ECM 2 Measure the resistance between ECM and chassis ground Connector terminal B135 No 5 Chassis ground Is the resi...

Page 1498: ...replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRING DIAGRAM EN 05898 E...

Page 1499: ...7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 34 35 36 37 38 39 40 41 48 49 50 51 52 53 54 42 43 44 45 46 47 26 27 28 29 30 3132 33 B21 1 2 3 4 5 6 7 8 B122 B136 C B134 A 36 40 34 35 37 C21 C1...

Page 1500: ...Release fuel pressure before removing the fuel pressure gauge NOTE If fuel pressure does not increase squeeze the fuel return hose 2 to 3 times then measure fuel pressure again Is the measured value...

Page 1501: ...tion procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Monitor General scan tool For detailed operation procedures refer to the general scan tool operation manual...

Page 1502: ...fuel injector connector on faulty cylin ders Connector terminal 1 B137 No 8 E5 No 1 2 B137 No 9 E16 No 1 3 B137 No 10 E6 No 1 4 B137 No 11 E17 No 1 Is the resistance less than 1 Go to step 13 Repair...

Page 1503: ...CHECK INSTALLATION CONDITION OF TIMING BELT Turn the crankshaft using ST and align the alignment mark on crank sprocket with align ment mark on cylinder block ST 499987500 CRANKSHAFT SOCKET Is the tim...

Page 1504: ...istance between ECM and chassis ground Connector terminal B134 No 19 Chassis ground B134 No 18 Chassis ground B134 No 18 B136 No 6 B134 No 28 Chassis ground Is the resistance 1 M or more Go to step 26...

Page 1505: ...gnition switch to OFF 2 Disconnect the connectors from ECM 3 Measure the resistance between ECM con nectors Connector terminal B134 No 19 B134 No 18 B134 No 19 B134 No 28 Is the resistance 1 M or more...

Page 1506: ...nce 1 M or more Go to step 36 Repair the short circuit to ground in harness between ECM and elec tronic throttle con trol connector 36 CHECK ELECTRONIC THROTTLE CON TROL MOTOR HARNESS Measure the resi...

Page 1507: ...o EN H4DOTC diag 43 PROCE DURE Inspection Mode Step Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appropri ate DTC using the List of Diagnostic Trouble Code DT...

Page 1508: ...ef to EN H4DOTC diag 43 PROCE DURE Inspection Mode Step Check Yes No 1 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the appropri ate DTC using the List of Diagnostic Trouble Cod...

Page 1509: ...ION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIR...

Page 1510: ...between ECM and tumble generator valve assembly RH con nector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR Measure the resistance be...

Page 1511: ...N After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIR...

Page 1512: ...tch to OFF 2 Disconnect the connectors from the ECM 3 Measure the voltage between ECM and chassis ground Connector terminal B137 No 22 Chassis ground B137 No 23 Chassis ground Is the voltage 5 V or mo...

Page 1513: ...ON After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRI...

Page 1514: ...etween ECM and tumble generator valve assembly LH con nector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR Measure the resistance betw...

Page 1515: ...After repair or replacement of faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag 43 PROCE DURE Inspection Mode WIRI...

Page 1516: ...tch to OFF 2 Disconnect the connectors from the ECM 3 Measure the voltage between ECM and chassis ground Connector terminal B137 No 12 Chassis ground B137 No 13 Chassis ground Is the voltage 5 V or mo...

Page 1517: ...lls Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag...

Page 1518: ...E In this case repair the following item Open circuit in harness between ECM and tumble generator valve assembly RH con nector Poor contact of ECM connector Poor contact of coupling connector 3 CHECK...

Page 1519: ...alls Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag...

Page 1520: ...scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operation p...

Page 1521: ...lls Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag...

Page 1522: ...E In this case repair the following item Open circuit in harness between ECM and tumble generator valve assembly LH con nector Poor contact of ECM connector Poor contact of coupling connector 3 CHECK...

Page 1523: ...alls Poor driving performance CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC diag...

Page 1524: ...scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operation p...

Page 1525: ...TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC d...

Page 1526: ...cuit of harness between ECM and oil flow control solenoid valve connector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND OIL FLOW CONTROL SOLENOID VALVE CON NECTOR Measure the resi...

Page 1527: ...a TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC...

Page 1528: ...CK HARNESS BETWEEN ECM AND OIL FLOW CONTROL SOLENOID VALVE CON NECTOR Measure the resistance of harness between ECM and oil flow control solenoid valve connec tor Connector terminal B137 No 17 E38 No...

Page 1529: ...TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC d...

Page 1530: ...cuit of harness between ECM and oil flow control solenoid valve connector Poor contact of coupling connector 2 CHECK HARNESS BETWEEN ECM AND OIL FLOW CONTROL SOLENOID VALVE CON NECTOR Measure the resi...

Page 1531: ...a TROUBLE SYMPTOM Improper idling CAUTION After servicing or replacing faulty parts perform Clear Memory Mode Ref to EN H4DOTC diag 54 OPERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC...

Page 1532: ...Go to step 2 Repair the short circuit to power in harness between ECM and oil flow control solenoid valve connector 2 CHECK HARNESS BETWEEN ECM AND OIL FLOW CONTROL SOLENOID VALVE CON NECTOR Measure t...

Page 1533: ...13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 A B135 B B136 C B137 D 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44...

Page 1534: ...31 B19 T5 2 2 T5 B19 3 1 4 3 1 4 B21 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 37 36 39 38 41 40 43 42 44 45 47 46 49 48 51 50 53 52 54 BATTERY S...

Page 1535: ...resistance between ECM and chassis ground Connector terminal B135 No 9 Chassis ground B135 No 8 Chassis ground Is the resistance 1 M or more Go to step 5 Repair the ground short circuit of har ness b...

Page 1536: ...ME H4DOTC 25 INSPECTION Fuel Pres sure CAUTION Release fuel pressure before removing the fuel pressure gauge NOTE If fuel pressure does not increase squeeze fuel return hose 2 to 3 times then measure...

Page 1537: ...emperature sensor Ref to FU H4DOTC 39 Mass Air Flow and Intake Air Temper ature Sensor 14 CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR 1 Start the engine and warm up engine until coolant temp...

Page 1538: ...lutch pedal MT model Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operat...

Page 1539: ...llowing item Open circuit in harness between ECM and rear oxy gen sensor con nector Poor contact of coupling connector 20 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Connect the conne...

Page 1540: ...22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4...

Page 1541: ...short circuit to power in the harness between ECM and electronic throttle control relay con nector Go to step 4 4 CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RE LAY CONNECTOR 1 Turn the...

Page 1542: ...ECM AND ELECTRONIC THROTTLE CONTROL CON NECTOR 1 Connect the connector to ECM 2 Measure the resistance between electronic throttle control connector and engine ground Connector terminal E57 No 3 Engi...

Page 1543: ...ector terminal B137 No 5 E57 No 2 B137 No 4 E57 No 1 Is the resistance less than 1 Go to step 15 Repair the harness and connector NOTE In this case repair the following item Open circuit in harness be...

Page 1544: ...Poor contact of coupling connector 19 CHECK ELECTRONIC THROTTLE CON TROL Measure the resistance between electronic throttle control terminals Terminals No 2 No 1 Is the resistance 50 or less Go to st...

Page 1545: ...2 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4 10 11 12 19 20...

Page 1546: ...onnectors from ECM 2 Turn the ignition switch to ON 3 Measure the voltage between electronic throttle control relay connector and chassis ground Connector terminal B220 No 32 Chassis ground Is the vol...

Page 1547: ...21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 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...

Page 1548: ...trol relay Ref to FU H4DOTC 57 Electronic Throttle Control Relay 2 CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUP PLY 1 Turn the ignition switch to ON 2 Measure the voltage between...

Page 1549: ...ection Mode WIRING DIAGRAM EN 05690 B315 C B136 B137 D B83 B315 4 6 5 1 3 2 B21 B23 B29 B22 B31 B30 D2 B21 E2 D1 1 2 3 4 5 6 7 8 B21 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 2...

Page 1550: ...o 6 Is the resistance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and accelera tor pedal position sensor connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect...

Page 1551: ...pection Mode WIRING DIAGRAM EN 05690 B315 C B136 B137 D B83 B315 4 6 5 1 3 2 B21 B23 B29 B22 B31 B30 D2 B21 E2 D1 1 2 3 4 5 6 7 8 B21 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25...

Page 1552: ...NOTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND AC CE...

Page 1553: ...ection Mode WIRING DIAGRAM EN 05690 B315 C B136 B137 D B83 B315 4 6 5 1 3 2 B21 B23 B29 B22 B31 B30 D2 B21 E2 D1 1 2 3 4 5 6 7 8 B21 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25 2...

Page 1554: ...resistance 1 M or more Go to step 2 Repair the short circuit to ground in harness between ECM and accelera tor pedal position sensor connector 2 CHECK SHORT CIRCUIT INSIDE THE ECM 1 Connect the connec...

Page 1555: ...pection Mode WIRING DIAGRAM EN 05690 B315 C B136 B137 D B83 B315 4 6 5 1 3 2 B21 B23 B29 B22 B31 B30 D2 B21 E2 D1 1 2 3 4 5 6 7 8 B21 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24 25...

Page 1556: ...NOTE In this case repair the following item Open circuit of harness between ECM and engine ground Poor contact of ECM connector Poor contact of coupling connector 3 CHECK HARNESS BETWEEN ECM AND AC CE...

Page 1557: ...23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 1 2 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 7 32 33 34 35 1 2 3 4 5 6 E57 1 2 7 8 9 5 6 3 4 10...

Page 1558: ...OR 1 Disconnect the connectors from ECM 2 Measure the resistance of harness between ECM and electronic throttle control connector Connector terminal B134 No 18 E57 No 6 B134 No 28 E57 No 4 B134 No 29...

Page 1559: ...from ECM 3 Measure the resistance between ECM con nectors Connector terminal B134 No 19 B134 No 18 B134 No 19 B134 No 28 Is the resistance 1 M or more Repair the poor contact of elec tronic throttle c...

Page 1560: ...Inspection Mode WIRING DIAGRAM EN 05690 B315 C B136 B137 D B83 B315 4 6 5 1 3 2 B21 B23 B29 B22 B31 B30 D2 B21 E2 D1 1 2 3 4 5 6 7 8 B21 1 2 3 4 12 13 14 15 5 6 7 8 16 17 18 19 9 10 11 20 21 22 23 24...

Page 1561: ...tor pedal position sensor signal and the sub accelerator pedal position sensor signal 0 V Replace the accel erator pedal Ref to SP H4SO 4 Accelerator Pedal Repair the harness and connector NOTE In thi...

Page 1562: ...24 ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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 1563: ...enoid valve 2 Connector terminal B136 No 7 E52 No 2 Is the resistance less than 1 Go to step 4 Repair the harness and connector NOTE In this case repair the following item Open circuit of harness betw...

Page 1564: ...3 24 ECM 2 1 C17 C28 D29 C7 R15 R57 R57 R82 R81 R81 R68 R86 R86 R2 B98 R3 B99 B99 R1 B97 B97 2 2 1 1 11 10 E52 2 1 E52 E4 B98 R68 1 2 B21 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 1565: ...etween ECM and chassis ground Connector terminal B136 No 7 Chassis ground Is the voltage 10 V or more Repair the short to power in the har ness between ECM and purge control solenoid valve 2 connector...

Page 1566: ...o consecutive driving cycles with fault occur GENERAL DESCRIPTION Ref to GD H4DOTC 225 DTC P2431 SECONDARY AIR INJECTION SYS TEM AIR FLOW PRESSURE SENSOR CIRCUIT RANGE PERFORMANCE Diagnostic Trouble C...

Page 1567: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1568: ...pressure intake pipe absolute pressure and atmospheric pressure and com pare with the actual atmospheric pressure NOTE For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN...

Page 1569: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 226 DTC P2432 SECONDARY AIR INJECTION SYS TEM AIR FLOW PRESSURE SENSOR CIRCUIT LOW Diagnostic Trouble Code DTC Detecting Crite ria C...

Page 1570: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1571: ...ctor NOTE In this case repair the following item Open circuit in harness between ECM and second ary air combination valve RH connec tor Poor contact of ECM connector Poor contact of coupling connector...

Page 1572: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 227 DTC P2433 SECONDARY AIR INJECTION SYS TEM AIR FLOW PRESSURE SENSOR CIRCUIT HIGH Diagnostic Trouble Code DTC Detecting Crite ria...

Page 1573: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1574: ...scan tool NOTE Subaru Select Monitor For detailed operation procedures refer to READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC diag 34 Subaru Select Moni tor General scan tool For detailed operation p...

Page 1575: ...o consecutive driving cycles with fault occur GENERAL DESCRIPTION Ref to GD H4DOTC 228 DTC P2440 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE STUCK OPEN BANK1 Diagnostic Trouble Code DTC Detecting...

Page 1576: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1577: ...sory Valve Operation Check Mode for more operation procedures Ref to EN H4DOTC diag 55 Compulsory Valve Op eration Check Mode Does the secondary air combi nation valve RH repeatedly switch to ON and O...

Page 1578: ...sistance between the sec ondary air combination valve relay 1 terminals Terminals No 3 No 4 Is the resistance less than 1 Go to step 10 Replace the sec ondary air combina tion valve relay 1 Ref to EN...

Page 1579: ...VE STUCK OPEN BANK1 Diagnostic Procedure with Diagnostic Trouble Code DTC 13 CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 1 CONNECTOR Measure the resistance between the secondar...

Page 1580: ...o consecutive driving cycles with fault occur GENERAL DESCRIPTION Ref to GD H4DOTC 228 DTC P2442 SECONDARY AIR INJECTION SYS TEM SWITCHING VALVE STUCK OPEN BANK2 Diagnostic Trouble Code DTC Detecting...

Page 1581: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1582: ...sory Valve Operation Check Mode for more operation procedures Ref to EN H4DOTC diag 55 Compulsory Valve Op eration Check Mode Does the secondary air combi nation valve LH repeatedly switch to ON and O...

Page 1583: ...esistance between the sec ondary air combination valve relay 2 terminals Terminals No 7 No 8 Is the resistance less than 1 Go to step 10 Replace the sec ondary air combina tion valve relay 2 Ref to EN...

Page 1584: ...VE STUCK OPEN BANK2 Diagnostic Procedure with Diagnostic Trouble Code DTC 13 CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 2 CONNECTOR Measure the resistance between the secondar...

Page 1585: ...mediately at fault recognition GENERAL DESCRIPTION Ref to GD H4DOTC 229 DTC P2444 SECONDARY AIR INJECTION SYS TEM PUMP STUCK ON Diagnostic Trouble Code DTC Detecting Criteria CAUTION After servicing o...

Page 1586: ...9 20 21 33 34 29 32 30 31 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B136 1 5 7 6 2 8 3 4 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2...

Page 1587: ...ature is higher than 75 C 167 F 2 Check whether the secondary air pump is operating Is the secondary air pump oper ating Go to step 3 Replace the sec ondary air combi nation valve LH Ref to EC H4DOTC...

Page 1588: ...e 1 Electronic throttle control 2 Engine coolant temperature sensor 3 Manifold absolute pressure sensor 4 Mass air flow sensor 4 Poor acceleration 1 Manifold absolute pressure sensor 2 Mass air flow a...

Page 1589: ...eak in air intake system 7 Spark knock 1 Manifold absolute pressure sensor 2 Mass air flow and intake air temperature sensor 3 Engine coolant temperature sensor 4 Knock sensor 5 Fuel injection parts 4...

Page 1590: ...Diagnostic Trouble Code DTC Detecting Crite ria P0068 MAP MAF Throttle Position Correlation Ref to GD H4DOTC 24 DTC P0068 MAP MAF THROTTLE POSITION CORRELATION Diagnostic Trouble Code DTC Detecting Cr...

Page 1591: ...TED BANK 1 SENSOR 1 Diagnostic Trouble Code DTC Detecting Criteria P0137 O2 Sensor Circuit Low Voltage Bank 1 Sensor 2 Ref to GD H4DOTC 55 DTC P0137 O2 SENSOR CIRCUIT LOW VOLT AGE BANK 1 SENSOR 2 Diag...

Page 1592: ...gnostic Trouble Code DTC Detecting Criteria P0336 Crankshaft Position Sensor A Circuit Range Performance Ref to GD H4DOTC 94 DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE PERFORMANCE Diagnostic...

Page 1593: ...c Trou ble Code DTC Detecting Criteria P0457 Evaporative Emission Control System Leak Detected Fuel Cap Loose Off Ref to GD H4DOTC 139 DTC P0457 EVAPORATIVE EMISSION CON TROL SYSTEM LEAK DETECTED FUEL...

Page 1594: ...153 O2 Sensor Circuit Range Performance High Bank1 Sensor1 Ref to GD H4DOTC 171 DTC P1153 O2 SENSOR CIRCUIT RANGE PERFORMANCE HIGH BANK1 SENSOR1 Diagnostic Trouble Code DTC Detecting Criteria P1160 Re...

Page 1595: ...E MANIFOLD RUNNER CONTROL CIRCUIT OPEN BANK 1 Diagnostic Trouble Code DTC Detecting Criteria P2009 Intake Manifold Runner Control Circuit Low Bank 1 Ref to GD H4DOTC 194 DTC P2009 INTAKE MANIFOLD RUNN...

Page 1596: ...13 DTC P2123 THROTTLE PEDAL POSITION SENSOR SWITCH D CIRCUIT HIGH INPUT Diagnostic Trouble Code DTC Detecting Criteria P2127 Throttle Pedal Position Sensor Switch E Circuit Low Input Ref to GD H4DOTC...

Page 1597: ...c Trou ble Code DTC Detecting Criteria P2442 Secondary Air Injection System Switching Valve Stuck Open Bank2 Ref to GD H4DOTC 228 DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN BA...

Page 1598: ...ing advance 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates 1 AVCS timing cont...

Page 1599: ...ination Illuminates when malfunction occurs in 2 continuous driving cycles Normality Judgement Judge as OK and clear the NG if the following conditions are established within the predetermined time Ti...

Page 1600: ...2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting engine and while AVCS is not operating 1 AVCS timing controller 3 Engine control...

Page 1601: ...OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0016 Ref to GD H4DOTC 12 DTC P0016 CRANKSHAFT PO SITION CAMSHAFT POSITION CORRELATION BANK1 Diagnostic Trouble Code DTC Detecting Cr...

Page 1602: ...ng at en gine status such as deceleration fuel cut 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after 42000 ms seconds or more have passed sin...

Page 1603: ...tion Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following condit...

Page 1604: ...duty control and the output terminal voltage at ON is 0 V and the output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains Low 2 COMPONENT DESCRIPTION 3 ENAB...

Page 1605: ...on Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is mo...

Page 1606: ...duty control and the output terminal voltage at ON is 0 V and the output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains High 2 COMPONENT DESCRIPTION 3 ENA...

Page 1607: ...n Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is mor...

Page 1608: ...he output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains Low 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE After starting the engine...

Page 1609: ...ator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are e...

Page 1610: ...e output terminal voltage at OFF is the battery voltage Judge as NG when the terminal voltage remains High 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE After starting the engine...

Page 1611: ...tor Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are es...

Page 1612: ...air pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition or when it is High whereas it seemed to be Low from the engine condition 2 COMPONENT DESCRIPTION 3 ENA...

Page 1613: ...OK If the duration of time while the following conditions are met is longer than the time indicated judge as OK Time Needed for Diagnosis Low side Less than 1 second High side Less than 1 second Judg...

Page 1614: ...voltage increases Judge as a high side NG when the air flow voltage indicates a large val ue regardless of running in a state where the air flow voltage decreases Judge air flow sensor property NG whe...

Page 1615: ...n 1 second High Less than 1 second Judgement Value Malfunction Criteria Threshold Value Low Output voltage 1 5 V Engine speed t 2500 rpm Throttle opening angle t 15 Intake manifold pressure t 53 3 kPa...

Page 1616: ...r than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear th...

Page 1617: ...er than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear t...

Page 1618: ...owing conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality J...

Page 1619: ...conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgeme...

Page 1620: ...nt of engine condition 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition A Air 1...

Page 1621: ...luminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1 sec...

Page 1622: ...than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the...

Page 1623: ...longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and cle...

Page 1624: ...are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge a...

Page 1625: ...itions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement J...

Page 1626: ...ed judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous t...

Page 1627: ...ted judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous...

Page 1628: ...DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis only once after engine start A Resistance value k B Temperature C F 1 Connector 2 Thermistor element Secondary Parameters...

Page 1629: ...continuous driving cy cles Normality Judgement Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criter...

Page 1630: ...se them to judge as NG when the engine coolant temperature does not decrease when it should 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Perform the diagnosis only once after sta...

Page 1631: ...us time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value Engine cool...

Page 1632: ...e is lower than the estimated engine coolant temperature and the difference between them is large Judge as OK when the engine coolant temperature becomes to 75 C 167 F and the difference is small befo...

Page 1633: ...t Value Malfunction Criteria Threshold Value Battery voltage t 10 9 V Estimate ambient temperature t 7 C 19 4 F Thermostat malfunction diagnosis Incomplete Engine coolant temperature at engine startin...

Page 1634: ...ircuit of sensor Judge as NG when the element voltage is out of the specified range 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Elec...

Page 1635: ...Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more...

Page 1636: ...circuit of sensor Judge as NG when the element voltage is out of the specified range 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Ele...

Page 1637: ...1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are...

Page 1638: ...as Clogged ventilation holes are diagnosed When the holes are clogged the A F output variation becomes slow comparing with the actual A F variation because oxygen which reaches the zirconia layer is i...

Page 1639: ...n Time needed for all secondary parame ters to be in enable conditions t 1024 ms Battery voltage t 10 9 V Barometric pressure 75 kPa 563 mmHg 22 2 inHg Closed loop control with main feedback Operation...

Page 1640: ...ed time Time Needed for Diagnosis 32 ms 4 820 time s Judgement Value Malfunction Criteria Threshold Value parafca td2faf td2lmd 0 22 AT model 0 28 WRX S model 0 267 WRX SS model where td2faf N td2faf...

Page 1641: ...etect open circuits of the sensor Judge as NG when the impedance of the element is large 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A...

Page 1642: ...as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed f...

Page 1643: ...ect continuity NG of the oxygen sensor If the oxygen sensor voltage reading is not within the probable range considering the operating conditions judge as NG 2 COMPONENT DESCRIPTION A Electromotive fo...

Page 1644: ...Not in operation Closed loop control at the oxygen sensor In operation Misfire detection every 200 rotations 5 time s Front oxygen A F sensor compensation coefficient Not in limit value Battery volta...

Page 1645: ...predetermined time Time Needed for Diagnosis High Less than 1 second Low 1 Less than 1 second Low 2 Less than 1 second Low 3 Less than 1 second AE DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE BANK 1 SENSO...

Page 1646: ...sensor voltage is large rich when recovering from a deceleration fuel cut Lean o rich diagnosis response 1 Measure the response time for oxygen sensor output changes when the A F ratio changes to lea...

Page 1647: ...n sensor voltage for the timing of the deceleration Secondary Parameters Enable Condition Battery voltage t 10 9 V A F main feedback control condition Completed Deceleration fuel cut time is 5000 ms o...

Page 1648: ...late the minimum response time for output change between 0 5 V and 0 2 V for the judgement criteria A 0 55 V B 0 5 V C 0 2 V D 0 15 V E 0 V F More than 5000 ms G Measure the response time H Execute th...

Page 1649: ...cy cles Normality Judgement 1 Regardless of a deceleration fuel cut if the response time diagnosis value when the oxygen sensor volt age has changed from rich to lean is shorter than the threshold va...

Page 1650: ...calculate the minimum response time for output change between 0 3 V and 0 5 V for the judgement criteria A 0 55 V B 0 5 V C 0 3 V D 0 25 V E 0 V F More than 5 seconds G More than 120000 ms H Measure...

Page 1651: ...tion fuel cut if the response time diagnosis value when the oxygen sensor volt age has changed from rich to lean is shorter than the threshold value judgement value judge as a normal condition Respons...

Page 1652: ...GEMENT 4 GENERAL DRIVING CYCLE Perform the diagnosis once after starting the engine A Electromotive force B Air fuel ratio C Rich D Lean E Theoretical air fuel ratio F Comparative voltage 1 Atmosphere...

Page 1653: ...n Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1...

Page 1654: ...mality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 10 s Secondary Paramet...

Page 1655: ...ion criteria below continues for 10 seconds Time Needed for Diagnosis 10 s Secondary Parameters Enable Condition A F main learning system In operation Engine coolant temperature t 70 C 158 F Engine lo...

Page 1656: ...ally fuel temperature is lower than engine coolant temperature When the fuel temperature becomes higher than the engine coolant temperature the range is considered to be shifted and judged as NG STUCK...

Page 1657: ...ays perform diagnosis after 20 seconds have passed since the engine started Judgement Value Malfunction Criteria Threshold Value Fuel level t 9 6 2 2 54 US gal 2 11 Imp gal Elapsed time after starting...

Page 1658: ...when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis Less than 1 second Judge...

Page 1659: ...onger than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and cle...

Page 1660: ...et is longer than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK...

Page 1661: ...judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous tim...

Page 1662: ...ted judge as NG Time Needed for Diagnosis 24 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous...

Page 1663: ...ic line coming from the fuel pump control unit Fuel pump control unit detects the open or short circuit malfunction for each line and then sends NG signals if one of them is found NG 2 COMPONENT DESCR...

Page 1664: ...he continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value...

Page 1665: ...A RANGE PERFORMANCE 1 OUTLINE OF DIAGNOSIS Detect the malfunction of wastegate control solenoid valve function Judge as NG when becoming high wastegate pressure 2 COMPONENT DESCRIPTION 3 ENABLE CONDIT...

Page 1666: ...206 6 1550 61 206 6 1550 61 206 6 1550 61 206 6 1550 61 4000 159 8 1199 47 2 188 6 1415 55 7 206 6 1550 61 206 6 1550 61 206 6 1550 61 206 6 1550 61 5000 133 4 1001 39 4 160 1 1201 47 3 179 7 1348 53...

Page 1667: ...following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 640 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normal...

Page 1668: ...the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 640 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs No...

Page 1669: ...fire 180 Interval Difference Method MT 1 800 rpm or less AT None 360 Interval Difference Method whole range 720 Interval Difference Method 3 000 rpm or more 2 Misfire every time FTP 1 5 times misfire...

Page 1670: ...100 3 9 13 3 100 3 9 13 3 100 3 9 13 3 100 3 9 rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700 kPa mmHg inHg 29 3 220 8 7 26 7 200 7 9 26 7 200 7 9 26 7 200 7 9 27 3 205 8 1 2...

Page 1671: ...16 1 54 7 410 16 1 Vehicle speed 64 km h 39 8 MPH rpm 750 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700 kPa mmHg inHg 27 3 205 8 1 23 3 175 6 9 23 6 177 7 23 3 175 6 9 24 180 7 1 2...

Page 1672: ...the following figure pick a cylinder as the standard and name it omg 0 And the former crank shaft position speed is named omg 1 the second former crankshaft position speed is named omg 2 the third is...

Page 1673: ...the following cases domg 180 judgement value of positive side domg 180 d judgement value of negative side Judgement value before 180 CA Diagnostic value domg 360 omg 1 omg 0 omg 3 omg 2 Misfire judge...

Page 1674: ...00 engine revs Diagnostic value domg 720 omg 1 omg 0 omg 5 omg 4 Misfire judgement domg 720 Judgement value o Judge as misfire Judgement Value Judge that malfunction occurs when the misfire ratio is h...

Page 1675: ...DETECTED 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0301 Ref to GD H4DOTC 81 DTC P0301 CYLINDER 1 MIS FIRE DETECTED Diagnostic Trouble Code DTC Detecting Criteria Judgement...

Page 1676: ...F DIAGNOSIS Detect the open or short circuit of knock sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis contin...

Page 1677: ...osis 1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions...

Page 1678: ...F DIAGNOSIS Detect the open or short circuit of knock sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis contin...

Page 1679: ...osis 1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions...

Page 1680: ...ot input even though the starter was rotated 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Camshaft signal RH B Camshaft signal LH C C...

Page 1681: ...Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time T...

Page 1682: ...the number of crankshaft signals for every revolution 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS A Camshaft signal RH B Camshaft signal LH C Crankshaft signal D Number of crankshaft signals 30 1 Cran...

Page 1683: ...lluminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than t...

Page 1684: ...gnals remains abnormal 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously A Camshaft signal RH B Camshaft signal LH C Crankshaft signal D Num...

Page 1685: ...or Diagnosis 3000 ms Normality Judgement 2 Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagno...

Page 1686: ...nation valve one side closed pulse diagnosis Estimate ambient temperature t 4 4 C Battery voltage t 10 9 V Barometric pressure t 75 kPa 563 mmHg 22 2 inHg Engine In operation Feasible area for diagnos...

Page 1687: ...ressure P0R measurement 2 Ne 8 Pump supply pressure check judgement 3 Secondary air pump operating status 12 Both banks all closed pressure P0RL measurement 9 Flow amount check judgement 4 E COMB valv...

Page 1688: ...Time Needed for Diagnosis 2000 ms 2800 ms Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG...

Page 1689: ...lve is closed Calculate the voltage pulse of the pump delivery pipe pressure when the LH combination valve is closed and the RH combination valve is open The calculation of delivery pipe pressure shou...

Page 1690: ...stuck valve Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 4000 ms 992 ms 992 ms 992 ms Ma...

Page 1691: ...lve turns open o closed Delivery pipe pressure should vary when the LH combination valve turns open o closed When the variation is small determine that the LH combination valve is stuck closed Abnorma...

Page 1692: ...Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time P0RL Both banks all closed pressure P0R Right bank all...

Page 1693: ...3 640 25 2 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 90 6 680 26 8 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 96 720 28 3 1000 800 600 400 200 0...

Page 1694: ...1000 1200 1400 1600 1800 2000 101 3 760 29 9 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 106 6 800 31 5 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1...

Page 1695: ...H comb valve switches V 10 0 35 15 0 53 20 0 71 25 0 88 26 0 92 11 0 025 0 025 0 025 0 005 0 12 0 035 0 035 0 035 0 015 0 13 0 05 0 05 0 05 0 025 0 14 0 05 0 05 0 05 0 025 0 V Map 8 Amount of intake a...

Page 1696: ...cated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continu...

Page 1697: ...e Time Needed for Diagnosis Less than 1 second BG DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0413 Ref...

Page 1698: ...d judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous...

Page 1699: ...the sensor output with a de teriorated catalyst becomes high and the inversion time is shortened For this reason the catalyst diagnosis is carried out by monitoring the front oxygen sensor output and...

Page 1700: ...g conditions are established is within the predetermined time Time Needed for Diagnosis 30 55 seconds Secondary Parameters Enable Conditions Battery voltage t 10 9 V Atmospheric pressure t 75 kPa 563...

Page 1701: ...ON BK DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0442 Ref to GD H4DOTC 114 DTC P0442 EVAPORATIVE EMISSION CONTROL S...

Page 1702: ...e fuel tank pressure sensor When in 0 04 inch diagnosis perform in the order of mode Z o mode A o mode B o mode C and mode D When in 0 02 inch diagnosis perform in the order of mode A o mode B o mode...

Page 1703: ...he target start level of P2 cal culation If the tank pressure does not become the value make advanced OK judgement 0 18600 ms Mode D Negative pressure variation measure ment evaporation leakage diagno...

Page 1704: ...E shifting pressure If the tank pressure does not change to the Mode E shifting pressure make advanced OK judgement 0 0 ms 200000 ms Mode E Evaporation generated amount calculation Calculate the amoun...

Page 1705: ...atmospheric air pressure Normally the solenoid is set to OFF The valve opens and closes mechanically in accordance with the pressure difference between tank and atmospheric air or tank and canister T...

Page 1706: ...pressure and the part below Y is charged with canister pressure If the atmospheric air pressure port is A tank pressure port is B and canister pressure port is C the air flows according to pressure d...

Page 1707: ...Code DTC Detecting Criteria GENERAL DESCRIPTION When B C solenoid OFF When Solenoid is ON a Barometric pressure b Fuel tank c Canister 1 Valve a Barometric pressure b Fuel tank c Canister EN 01718 A...

Page 1708: ...peed 1050 rpm 6500 rpm Fuel tank pressure t 4 kPa 30 mmHg 1 2 inHg Intake manifold relative vacuum relative pressure t 13 3 kPa 100 mmHg 3 9 inHg Vehicle speed t 32 km h 19 9 MPH Fuel level 9 6 2 2 54...

Page 1709: ...after starting the engine t 120 s Fuel temperature 10 C 14 F 55 C 131 F Fuel level 9 6 2 2 54 US gal 2 11 Imp gal 54 4 2 14 37 US gal 11 97 Imp gal Intake manifold relative vacuum relative pres sure...

Page 1710: ...Z and Judge as NG when the following conditions are es tablished after predetermined amount of time Time Needed for Diagnosis 0 ms 3000 ms 13000 ms Malfunction Indicator Light Illumination Illuminate...

Page 1711: ...RAL DESCRIPTION Normal evptez evptezha d 0 4 kPa 3 mmHg 0 1 inHg Normal when above is established Time Needed for Diagnosis 0 ms 3000 ms 1 Mode Z 3 Fuel tank pressure 5 OK judgement 2 3000 ms 4 0 4 kP...

Page 1712: ...zha 0 9 kPa 6 5 mmHg 0 3 inHg No fuel sloshing of over 2 2 0 53 US gal 0 44 Imp gal lasts for more than 40000 ms Judge as abnormal when all are established 1 Mode Z 4 Fuel tank pressure 7 40000 ms no...

Page 1713: ...se if the tank pressure does not reach the target negative pressure judge that there is a large leak age in the system and terminate the evaporative emission control system diagnosis Abnormality Judge...

Page 1714: ...s driving cycles Judgement Value Malfunction Criteria Threshold Value DTC P2 1 5 P1 Value of Map 5 P0442 P2 Tank pressure that changes every 10000 ms in mode D P1 Tank pressure that changes every 1000...

Page 1715: ...when the tank pressure returns to the start level of P2 calculation or when the pre determined amount of time has passed Mode D Calculate the amount of negative pressure change Monitor the tank pressu...

Page 1716: ...inHg 0 4 kPa 2 7 mmHg 0 1 inHg 0 4 kPa 2 7 mmHg 0 1 inHg 10 2 2 64 US gal 2 2 Imp gal 0 kPa 0 mmHg 0 inHg 0 1 kPa 0 5 mmHg 0 inHg 0 2 kPa 1 7 mmHg 0 1 inHg 0 4 kPa 2 7 mmHg 0 1 inHg 0 4 kPa 2 7 mmHg...

Page 1717: ...4 2 mmHg 0 2 inHg 0 6 kPa 4 2 mmHg 0 2 inHg 0 6 kPa 4 2 mmHg 0 2 inHg 20 2 5 28 US gal 4 4 Imp gal 0 1 kPa 1 mmHg 0 inHg 0 4 kPa 3 25 mmHg 0 1 inHg 0 5 kPa 4 1 mmHg 0 2 inHg 0 5 kPa 4 1 mmHg 0 2 inHg...

Page 1718: ...t level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Bobbin 8 Magnetic plate 14 Retainer 2 Coi...

Page 1719: ...Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement...

Page 1720: ...ut level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Bobbin 8 Magnetic plate 14 Retainer 2 Co...

Page 1721: ...Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement...

Page 1722: ...ne sta tus 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after 60 s have passed since the engine started Pay attention to the fuel level and te...

Page 1723: ...nter counts up Time Needed for Diagnosis 60 s 16 time s or more Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge a...

Page 1724: ...INE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perfor...

Page 1725: ...nation Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined...

Page 1726: ...AL DRIVING CYCLE Perform the diagnosis when purging enable conditions are met without idling A Output voltage B Input voltage C To fuel tank 1 Connector 2 Terminals Secondary Parameters Enable Conditi...

Page 1727: ...TECTED VERY SMALL LEAK 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0442 Ref to GD H4DOTC 114 DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED SMALL LEAK Diagnostic...

Page 1728: ...cuit of the purge control solenoid valve Judge as NG when the ECM output level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform...

Page 1729: ...dicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions ar...

Page 1730: ...cuit of the purge control solenoid valve Judge as NG when the ECM output level differs from the actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform...

Page 1731: ...icator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are...

Page 1732: ...etect malfunctions of the fuel level sensor output property If the fuel level does not vary in a particular driving condition engine condition where it should judge as NG 2 COMPONENT DESCRIPTION 3 ENA...

Page 1733: ...ns are established Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value Accumulated amount of intake air t 330957 g 11672 85 oz Max min values of fuel leve...

Page 1734: ...n or short circuit of fuel level sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine contro...

Page 1735: ...curs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Nee...

Page 1736: ...en or short circuit of fuel level sensor Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine contr...

Page 1737: ...curs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Nee...

Page 1738: ...f output voltage variation of the fuel level sensor is larger than the threshold value 2 ENABLE CONDITION 3 GENERAL DRIVING CYCLE Always perform the diagnosis continuously at idle speed Pay attention...

Page 1739: ...cumulative values are not over the thresh old value Otherwise when either of them is over the threshold value the diagnosis counter counts up Judge as NG if the counter indicated 4 time s A 12288 ms...

Page 1740: ...t Value Malfunction Criteria Threshold Value Integrated times of the condition reaching follows t 4 time s DELFLMAX t Value from Map or SUMFL t 25 92 V At this time DELFLMAX Maximum difference of sen...

Page 1741: ...duration of time while the following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 512 ms Malfunction Indicator Light Illumination Illuminates as soon as...

Page 1742: ...dicated judge as NG Time Needed for Diagnosis 180000 ms Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and...

Page 1743: ...mmobilizer key Use of unregistered key in body integrated unit P1570 Antenna Faulty antenna P1571 Reference Code Incompatibility Reference code incompatibility between body integrated unit and ECM P15...

Page 1744: ...500 kbps 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine 5 DIAGNOSTIC METHOD Abnormality Judgement Judge as NG when the following conditions ar...

Page 1745: ...mined time Time Needed for Diagnosis 1000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Judgement Value Malfunction Criteria Threshold Value Battery voltage 1...

Page 1746: ...alfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG when the malfunction criteria below are met Secondary Parameters En...

Page 1747: ...2 ENABLE CONDITION 3 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 4 DIAGNOSTIC METHOD Abnormality Judgement Judge as NG if the criteria below are met Time Needed for Diagnosis Unde...

Page 1748: ...ates abnormally 4 When the communication between main CPU mo sub CPU is abnormal 5 When the input amplifier circuit of throttle position sensor 1 is abnormal 6 When the cruise control cannot be cancel...

Page 1749: ...lliseconds 7 200 milliseconds Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Secondary Parameters Enable Conditions 1 Ignition switch ON 2 Ignition switch ON 3 No...

Page 1750: ...throttle control is operating 5 DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis Target opening angle and actual opening angle 250 m...

Page 1751: ...ndicator Light Illumination Illuminates as soon as a malfunction occurs 1 Difference between target opening angle and actual opening angle 2 Target throttle opening angle 3 NG area 1 Judgement time mi...

Page 1752: ...ditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement...

Page 1753: ...e indicated judge as NG Time Needed for Diagnosis 100 time s Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as O...

Page 1754: ...unction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear NG when there is change in the neutral SW Time Needed...

Page 1755: ...cated judge as NG Time Needed for Diagnosis 100 time s Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and...

Page 1756: ...unction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear NG when there is change in the neutral SW Time Needed...

Page 1757: ...bda value is abnormal in accordance with O value of front oxygen A F sensor and running conditions such as vehicle speed amount of intake air engine coolant temperature sub feedback control etc 2 COMP...

Page 1758: ...dary Parameters Enable Condition Time needed for all secondary parameters to be in enable conditions t 4096 ms Battery voltage t 10 9 V Barometric pressure t 75 kPa 563 mmHg 22 2 inHg Rear oxygen sens...

Page 1759: ...mbda value is abnormal in accordance with O value of front oxygen A F sensor and running conditions such as vehicle speed amount of intake air engine coolant temperature sub feedback control etc 2 COM...

Page 1760: ...dary Parameters Enable Condition Time needed for all secondary parameters to be in enable conditions t 4096 ms Battery voltage t 10 9 V Barometric pressure t 75 kPa 563 mmHg 22 2 inHg Rear oxygen sens...

Page 1761: ...on with the motor power stopped 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Ignition switch ON o OFF Ignition switch OFF o ON Only after clearing memory 1 Opener spring 4 Full...

Page 1762: ...unction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the following conditions are established Time Needed for Diagnosis...

Page 1763: ...essure control solenoid valve Judge as NG when ECM output level is different from actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis...

Page 1764: ...s Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 secon...

Page 1765: ...voltage deviation for the given time Compare the difference between Max and Min values with threshold value and also compare the sum value with the threshold value If both values exceed the threshold...

Page 1766: ...ated judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuo...

Page 1767: ...sure control solenoid valve Judge as NG when ECM output level is different from actual terminal level 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the diagnosis a...

Page 1768: ...es Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 seco...

Page 1769: ...CYCLE Always perform the diagnosis continuously 1 Bobbin 8 Magnetic plate 14 Retainer 2 Coil 9 Shaft 15 Diaphragm 3 Diode 10 Plate 16 Movable core 4 Stator core 11 Valve 17 Spring 5 End plate 12 Housi...

Page 1770: ...OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction...

Page 1771: ...DIAGNOSIS Detect the blow by hose release abnormality Judge as NG when the diagnosis terminal voltage is high 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Always perform the dia...

Page 1772: ...curs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis Less than 1 se...

Page 1773: ...ted judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuou...

Page 1774: ...tic Trouble Code DTC Detecting Criteria CZ DTC P1574 KEY COMMUNICATION FAILURE 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P0513 Ref to GD H4DOTC 155 DTC P0513 INCORRECT IM MOB...

Page 1775: ...Diagnosis 14 seconds Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cycles Normality Judgement Judge as OK and clear the NG if the following condi...

Page 1776: ...s are established Time Needed for Diagnosis Less than 1 second Judgement Value Malfunction Criteria Threshold Value Continuous time of Target engine speed Actual engine speed 100 rpm except for WRX SS...

Page 1777: ...ime indicated judge as NG Time Needed for Diagnosis 3000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the...

Page 1778: ...ime indicated judge as NG Time Needed for Diagnosis 3000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the...

Page 1779: ...time indicated judge as NG Time Needed for Diagnosis 3000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if th...

Page 1780: ...time indicated judge as NG Time Needed for Diagnosis 3000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if th...

Page 1781: ...each timing which occurs immediately after the tumble generator valve output is set to OFF o ON and judge open NG when the open NG signal is sent 96 ms 20 time s in a row Time Needed for Diagnosis 96...

Page 1782: ...g which occurs immediately after the tumble generator valve output is set to OFF o ON and judge overcurrent NG when the overcurrent NG signal is sent 96 ms 10 time s in a row Time Needed for Diagnosis...

Page 1783: ...each timing which occurs immediately after the tumble generator valve output is set to OFF o ON and judge open NG when the open NG signal is sent 96 ms 20 time s in a row Time Needed for Diagnosis 96...

Page 1784: ...g which occurs immediately after the tumble generator valve output is set to OFF o ON and judge overcurrent NG when the overcurrent NG signal is sent 96 ms 10 time s in a row Time Needed for Diagnosis...

Page 1785: ...following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normali...

Page 1786: ...following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normali...

Page 1787: ...following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normali...

Page 1788: ...following conditions are met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normali...

Page 1789: ...2000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are...

Page 1790: ...ed for Diagnosis 2000 ms DS DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW BANK 2 1 OUTLINE OF DIAGNOSIS NOTE For the detection standard refer to DTC P2088 Ref to GD H4DOTC 201 DTC P2...

Page 1791: ...n zone 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km h 50 MPH or more A Elec...

Page 1792: ...when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predete...

Page 1793: ...ge as NG 2 COMPONENT DESCRIPTION 3 ENABLE CONDITIONS 4 GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km h 50 MPH or more A El...

Page 1794: ...when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predete...

Page 1795: ...en the malfunction criteria below are met Time Needed for Diagnosis 500 milliseconds For NG 2000 milliseconds For OK Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occur...

Page 1796: ...diagnosis continuously 5 DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis 400 milliseconds For NG 2000 milliseconds For OK Malfunct...

Page 1797: ...switch OFF o ON Only after clearing memory 5 DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met Time Needed for Diagnosis 600 milliseconds For NG 400 millisecon...

Page 1798: ...r the NG when the malfunction criteria below are met Time Needed for Diagnosis 8 80 milliseconds Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs 1 Engine control m...

Page 1799: ...r pedal position sensor 1 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 1800: ...sis 100 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions a...

Page 1801: ...r pedal position sensor 1 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 1802: ...osis 32 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions a...

Page 1803: ...r pedal position sensor 2 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 1804: ...sis 100 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions a...

Page 1805: ...r pedal position sensor 2 Judge as NG if out of specification 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module ECM 3...

Page 1806: ...sis 100 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions a...

Page 1807: ...of throttle position sensor 1 is different from the throttle position sensor 2 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Throttle...

Page 1808: ...lity Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 24 ms Judgement Value Ma...

Page 1809: ...osition sensor 1 is different from the throttle position sensor 2 2 COMPONENT DESCRIPTION 3 ENABLE CONDITION 4 GENERAL DRIVING CYCLE Always perform the diagnosis continuously 1 Engine control module E...

Page 1810: ...Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time Time Needed for Diagnosis 116 ms Judgement Va...

Page 1811: ...ed judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous...

Page 1812: ...ted judge as NG Time Needed for Diagnosis 2500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuou...

Page 1813: ...dge as NG Time Needed for Diagnosis 328 ms Malfunction Indicator Light Illumination Illuminates when malfunction occurs in 2 continuous driving cy cles Normality Judgement Judge as OK and clear the NG...

Page 1814: ...re met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as...

Page 1815: ...re met is longer than the time indicated judge as NG Time Needed for Diagnosis 500 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as...

Page 1816: ...tion standard refer to DTC P0410 Ref to GD H4DOTC 98 DTC P0410 SECONDARY AIR INJECTION SYSTEM Diagnostic Trouble Code DTC Detecting Criteria EN DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE...

Page 1817: ...ed for Diagnosis 8000 ms Malfunction Indicator Light Illumination Illuminates as soon as a malfunction occurs Normality Judgement Judge as OK and clear the NG if the continuous time while the followin...

Page 1818: ...GD H4DOTC 230 Diagnostic Trouble Code DTC Detecting Criteria GENERAL DESCRIPTION...

Page 1819: ...CS 2 General Description CONTROL SYSTEMS 1 General Description A SPECIFICATION Item Specifications Swing torque of rod against lever N kgf lb 3 7 0 38 0 83 or less...

Page 1820: ...on 30 Clamp 6 Selector lever COMPL 19 Select lever rod 31 Shift lock clamp 7 Bushing 20 Spring A 8 Rod detent 21 Bracket Tightening torque N m kgf m ft lb 9 Spring detent 22 Gasket T1 2 2 0 2 1 6 10 B...

Page 1821: ...t and insulator ASSY 14 O ring 24 Boss 5 Plate ASSY 15 Boot 25 Bushing 6 Lever 16 Spring pin 26 Self locking nut 7 Bushing 17 Joint 8 Lock wire 18 Rod Tightening torque N m kgf m ft lb 9 Snap ring 19...

Page 1822: ...c of different grades or manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Apply grease onto sliding o...

Page 1823: ...SYSTEMS 2 AT Shift Lock Control System A LOCATION 1 TCM P range 4 Key cylinder with built in key warning switch 6 P range switch 2 Body integrated unit 7 Key lock solenoid 3 Stop light switch 5 Shift...

Page 1824: ...CS 7 AT Shift Lock Control System CONTROL SYSTEMS CS 00874 1 2 CS 00945 CS 00876 3 CS 00359 7 4 CS 00877 5 6...

Page 1825: ...ange Shift lock solenoid signal B279 12 8 5 16 V when shift lock is released 0 V when shift lock is operating Key warning switch signal B279 2 9 16 V when key is inserted 0 V when key is removed Key l...

Page 1826: ...GRAM 1 Ignition switch 5 TCM shift range information 9 Battery 2 Stop light switch 6 Key lock solenoid 10 VDC ABS vehicle speed information 3 Key warning switch 7 Shift lock solenoid 4 Body integrated...

Page 1827: ...ver from the P range to other ranges Perform the inspection of SELECT LEVER CANNOT BE LOCKED OR RELEASED Ref to CS 14 SELECT LEVER CANNOT BE LOCKED OR RELEASED INSPECTION AT Shift Lock Control System...

Page 1828: ...6 CHECK KEY INTERLOCK 1 Turn the ignition switch to OFF 2 Shift the select lever to other than P range Can the ignition key be removed Perform the inspection of KEY INTERLOCK CAN NOT BE LOCKED OR REL...

Page 1829: ...29 30 31 32 33 34 35 B281 C i84 A OFF ACC ACC ON B IG MAIN SBF SBF 6 IGNITION SWITCH SBF 8 No 12 No 7 BATTERY JOINT GROUND CONNECTOR i97 B281 C B280 B i84 A B279 D B1 D22 C20 D27 A28 B17 E E BODY INTE...

Page 1830: ...ground B280 No 7 Chassis ground B279 No 22 Chassis ground Is the voltage 9 16 V Go to step 3 Check harness for open circuit between the body integrated unit and the battery or a blown fuse 3 CHECK HA...

Page 1831: ...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 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 D B279 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 1...

Page 1832: ...h condition for 5 seconds or more Is there a DTC of a current mal function Follow the DTC to perform inspection and repair Go to step 5 5 CHECK CURRENT DATA Select the current data display and display...

Page 1833: ...and chassis ground 10 CHECK P RANGE SWITCH Measure the resistance between P range switch connector terminals Terminals No 2 No 1 Is it less than 10 in the P range and 1 M or more in ranges other than...

Page 1834: ...9 10 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 B281 B280 C B SBF 8 No 7 B6 D22 CS 01028 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 5 4 6 7 8...

Page 1835: ...display and display Key locking output Ref to LAN diag 15 OPERATION Subaru Select Monitor Is the display ON in the P range and OFF in ranges other than P Go to step 12 Go to step 6 6 CHECK DTC OF BODY...

Page 1836: ...ck sole noid 3 Check for open circuit of harness short cir cuit to battery or short circuit to ground between the body integrated unit and key lock solenoid Connector terminal B279 No 11 B350 No 2 Is...

Page 1837: ...OVAL Rear Ex haust Pipe Ref to EX H4DOTC 15 REMOV AL Muffler 6 Remove the heat shield cover 7 Remove the cable from arm assembly 8 Raise the claw of clamp and remove the cable 9 Lower the vehicle 10 R...

Page 1838: ...he vehicle 12 Shift the range select lever to N range 13 Secure the cable to the bracket Ref to CS 26 INSTALLATION Select Cable 14 Adjust the select cable position Ref to CS 27 ADJUSTMENT Select Cable...

Page 1839: ...ate COMPL 3 Remove the spacer bolt and remove the plate guide COMPL 4 Remove the shift lock clamp spring A select le ver rod lock plate cushion and bushing 5 Remove the bracket 6 Remove the detent spr...

Page 1840: ...n 12 Pull out the arm assembly remove select lever COMPL and remove bracket arm detent and bush ing 13 Remove the rod detent and spring detent from the bracket arm detent A P range switch terminal B S...

Page 1841: ...oid terminals to the connector 4 After completing installation shift the select le ver from P range to D range then check wheth er the indicator and select lever matches whether the pointer and positi...

Page 1842: ...er and rear exhaust pipes and the muffler Turbo model Ref to EX H4DOTC 8 REMOVAL Center Exhaust Pipe Ref to EX H4DOTC 13 REMOVAL Rear Exhaust Pipe Ref to EX H4DOTC 15 REMOVAL Muf fler 7 Remove the hea...

Page 1843: ...ect cable position Ref to CS 27 ADJUSTMENT Select Cable 8 Install the heat shield cover 9 Install the front center and rear exhaust pipes and the muffler Non turbo model Ref to EX H4SO 7 INSTALLATION...

Page 1844: ...he vehicle on a lift 2 Shift the select lever to N range 3 Lift up the vehicle 4 Remove the rear exhaust pipe and muffler Non turbo model Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe Ref to EX H4SO 12...

Page 1845: ...indicator assembly 6 While pressing the shift lock release button shift the select lever to the N range 7 Remove the spacer bolt and remove the plate guide COMPL 8 Using a flat tip screwdriver with a...

Page 1846: ...the D range normal mode posi tion and be careful for the following points Insert the protrusion B of the plate guide COMPL into the hole on shift lock solenoid unit A Insert link D of the shift lock...

Page 1847: ...d then operate the solenoid Terminals No 3 No 4 Does the shift lock solenoid operate normally Go to step 3 Replace the shift lock solenoid 3 CHECK P RANGE SWITCH 1 Shift the select lever to P range 2...

Page 1848: ...CS 31 Body Integrated Unit CONTROL SYSTEMS 6 Body Integrated Unit A NOTE Refer to Body Integrated Unit for removal and in stallation procedure Ref to SL 50 Body Integrat ed Unit...

Page 1849: ...the clamp 7 Remove the bushing and insulator assembly 8 Remove the harness clamp from the plate as sembly 9 Remove the plate assembly from the vehicle body 10 Lift up the vehicle 11 Remove the rear ex...

Page 1850: ...om joint 15 Remove the cushion rubber from the vehicle body 16 Extract the spring pin and remove the joint 17 Lower the vehicle 18 Remove the gear shift lever A Stay B Transmission bracket A Stay B Ro...

Page 1851: ...e cushion rubber on the vehicle body Tightening torque 18 N m 1 8 kgf m 13 3 ft lb 5 Using new self locking nuts connect the rod to the joint Tightening torque 12 N m 1 2 kgf m 8 9 ft lb 6 Using new s...

Page 1852: ...3 Tighten the bolt B 4 Tighten the bolt A 5 Tighten the bolts C and D 10 Install the harness clamp to the plate 11 Install the boot and insulator assembly and se cure with a clamp 12 Install the cons...

Page 1853: ...pin and then remove the bushing and snap ring 8 Remove the boss from the joint 9 Remove the bushing and spacer from the boss 10 Remove the bushing and cushion rubber from the stay A O ring B Bushing...

Page 1854: ...cking nuts install the boss to the joint Tightening torque 12 N m 1 2 kgf m 8 9 ft lb 4 Install the snap ring to gear shift lever and install the bushing NOTE Apply grease to the bushing 5 Apply greas...

Page 1855: ...all the rod Tightening torque 12 N m 1 2 kgf m 8 9 ft lb 10 Install a new lock wire NOTE Install the lock wire to the stay groove Bend the extra wire to the same direction of lock wire winding A Snap...

Page 1856: ...y parts Compare the removed parts with new parts to judge if there are damages or not 2 Check the swing torque of rod linked with the gear shift lever If the torque exceeds the specifications replace...

Page 1857: ...s not illuminate Adjust the select cable and inhibitor switch or inspect the circuit AT shift lock system does not operate normally Adjust the select cable and inhibitor switch or inspect the circuit...

Page 1858: ...0 694 Rev 2 272 Model Non turbo Turbo Number of front sun gear teeth 33 Number of front pinion teeth 21 Number of front internal gear teeth 75 Number of rear sun gear teeth 42 Number of rear pinion te...

Page 1859: ...Using material except rec ommended one or substi tute would cause trouble Fluid capacity 2 US qt Imp qt 9 3 9 6 9 8 10 1 8 2 8 4 Lubrication system Forced feed lubrication with oil pump Oil Automatic...

Page 1860: ...final reduction gear ratio 4 111 37 9 3 900 39 10 Lubrication oil 1 Item 3 API standard 2 Front differential gear oil 4 SAE viscosity No and applicable temperature Front differential oil capacity 2 U...

Page 1861: ...ASSY T2 41 4 2 30 2 3 Differential oil level gauge 13 Differential gear oil drain plug T3 44 4 5 32 5 Aluminum gasket silver 4 Stay 14 Gasket 5 Seal pipe 15 Oil seal 70 7 1 51 6 Copper gasket brown 6...

Page 1862: ...g 14 Stud bolt T1 7 0 7 5 2 5 Drive pinion shaft 15 O ring T2 13 1 3 9 6 6 Roller bearing 16 O ring T3 18 1 8 13 3 7 Drive pinion shim 17 Oil seal retainer T4 25 2 5 18 4 8 Oil pump housing 18 Oil sea...

Page 1863: ...ion AUTOMATIC TRANSMISSION 3 TRANSMISSION CASE AND CONTROL DEVICE T2 T1 T2 T5 T5 T8 T1 1 36 AT 04874 2 3 31 37 39 23 22 33 32 29 34 4 7 6 5 8 38 9 10 11 14 15 16 18 19 20 21 17 T3 35 28 24 25 27 26 T6...

Page 1864: ...t 6 Shaft 23 Detent spring 7 Parking pawl 24 Ball Tightening torque N m kgf m ft lb 8 Parking support 25 Spring T1 5 0 5 3 7 9 Gasket 26 Gasket T2 6 0 6 4 4 10 ATF inlet pipe 27 ATF outlet pipe T3 12...

Page 1865: ...ng torque N m kgf m ft lb 2 Transmission harness 7 Front vehicle speed sensor T1 7 0 7 5 2 3 O ring 8 O ring T2 8 0 8 5 9 4 O ring 9 Rear vehicle speed sensor T3 10 1 0 7 4 5 Torque converter turbine...

Page 1866: ...h cover 16 Driven plate reverse clutch 3 D ring 10 Snap ring 17 Drive plate reverse clutch 4 Reverse clutch piston 11 Driven plate high clutch 18 Retaining plate reverse clutch 5 D ring 12 Drive plate...

Page 1867: ...ng 12 Rear internal gear 20 Spring retainer 4 Snap ring 13 Washer 21 2 4 brake piston 5 Front planetary carrier 14 Snap ring 22 D ring 6 Thrust needle bearing 15 Retaining plate 23 D ring 7 Rear sun g...

Page 1868: ...26 Leaf spring 5 Dish plate 16 Snap ring 27 Drive plate 6 Snap ring 17 Thrust needle bearing 28 Driven plate 7 Cover 18 Seal ring 29 Dish plate 8 Spring retainer 19 Needle bearing 30 Low reverse brake...

Page 1869: ...ring 6 Snap ring 11 Lock nut 2 Ball bearing 7 Ball bearing 12 Gasket 3 Reduction drive gear 8 Snap ring 4 Reduction drive shaft 9 Reduction driven gear Tightening torque N m kgf m ft lb 5 Drive pinio...

Page 1870: ...ear 2 Pinion shaft 8 O ring 3 Differential case RH 9 Differential side retainer Tightening torque N m kgf m ft lb 4 Straight pin 10 Lock plate T1 25 2 5 18 4 5 Differential case LH 11 Washer T2 62 6 3...

Page 1871: ...12 Rear drive shaft 21 Test plug 4 Driven plate thick 13 Ball bearing 22 O ring 5 Drive plate 14 Seal ring 6 Driven plate thin 15 Gasket Tightening torque N m kgf m ft lb 7 Retaining plate 16 Transfer...

Page 1872: ...TRANSMISSION MOUNTING 1 Pitching stopper 3 Transmission rear crossmember Tightening torque N m kgf m ft lb 2 Rear cushion rubber 4 Stopper T1 35 3 6 25 8 T2 40 4 1 29 5 T3 50 5 1 36 9 T4 58 5 9 42 8...

Page 1873: ...burns from heated parts Use SUBARU genuine gear oil SUBARU genu ine ATF and specified grease or equivalent Do not mix gear oil grease etc of different grades or manufacturers Be sure to tighten bolts...

Page 1874: ...easuring oil pressure 498897200 OIL PRESSURE GAUGE ADAPTER Used at the oil pump housing when measuring reverse clutch pressure and line pressure 498897700 OIL PRESSURE ADAPTER SET Used for measuring t...

Page 1875: ...he front differential side retainer oil seal 498057300 INSTALLER Used for installing the extension oil seal 41099AC000 ENGINE SUPPORT ASSY Used for supporting the engine 498077000 REMOVER Used for rem...

Page 1876: ...and installing the differen tial side retainer WRENCH ASSEMBLY 499787000 can also be used 398437700 DRIFT Used for installing the converter case oil seal 398487700 INSTALLER Used for installing the f...

Page 1877: ...ring 498247001 MAGNET BASE Used for measuring the gear backlash Used together with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring the gear backlash Used together with MAGNET BASE 4982470...

Page 1878: ...nhibitor switch 499787700 WRENCH Used for removing and installing the drive pinion lock nut 499787500 ADAPTER Used for removing and installing the drive pinion lock nut 398643600 GAUGE Used for measur...

Page 1879: ...he mating surface of the transmission to the end face of the reduction gear 499737000 PULLER Used for removing the reduction driven gear assembly 499737100 PULLER SET Used for removing the reduction d...

Page 1880: ...e 2 4 brake snap ring 498437000 HIGH CLUTCH PISTON GUIDE Used for installing the high clutch piston 498437100 LOW CLUTCH PISTON GUIDE Used for installing the low clutch piston 899580100 INSTALLER Used...

Page 1881: ...side retainer oil seal 398497701 INSTALLER Used for installing the needle bearing 899524100 PULLER SET Use only the bolt Used together with PULLER SET 499737100 Used together with PULLER 499737000 1 P...

Page 1882: ...play Thickness gauge Used for measuring clearance of the clutch brake and oil pump Micrometer Used for measuring thickness of the drive pinion Spring scale Used for measuring the starting torque of th...

Page 1883: ...ld be careful not to add ATF to the upper level Overfilling of ATF may cause oil splashing 6 Check ATF level after raising ATF temperature to 70 80 C 158 176 F by running the vehicle again or by idlin...

Page 1884: ...e and possible cause Corrective action Large amount of metallic pieces are found Excessive wear of the internal of the trans mission body Replace ATF and check if AT operates correctly Thick and varni...

Page 1885: ...differential gear oil will be hot Be careful not to receive burns Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire If differential...

Page 1886: ...slip lock up check 1 The check is to be performed on a flat and straight road or on a free roller NOTE Slip lock up will not operate when the vehicle is lifted up off of its wheels since there is no...

Page 1887: ...l level is cor rect 6 Increase the ATF temperature to 70 to 80 C 158 to 176 F by idling the engine for approximate ly 30 minutes with select lever set to N or P 7 Place the wheel chocks at the front a...

Page 1888: ...pm or less If the stall speed is higher than the specified range attempt to finish the stall test in as short a time as possible in order to prevent the automatic transmission from sustaining damage S...

Page 1889: ...ree measurements and take the average value 1 Fully apply the parking brake 2 Start the engine Check the idle speed A C OFF 3 Shift the select lever from N to D range Using a stop watch measure the ti...

Page 1890: ...t lever is in R or 2nd of manual mode with en gine under stall conditions 3 Measure the line pressure within 5 seconds after shifting the select lever to each position If the line pressure needs to be...

Page 1891: ...re fuse on the FWD mode switch If no oil pressure is produced or if it does not change in AWD mode there may be a problem in the transfer duty solenoid or control valve body If oil pressure is produce...

Page 1892: ...REMOVAL Intercool er 6 Remove the air intake chamber stay Non turbo model 7 Disconnect the following connectors and termi nals Non turbo model Turbo model 8 Remove the starter Ref to SC H4SO 7 RE MOVA...

Page 1893: ...o prevent entry of foreign parti cles into the transmission fluid 14 Remove the pitching stopper bracket 15 Disconnect the engine harness then remove the harness connector from the engine harness brac...

Page 1894: ...bolts which secure the front arm ball joint to the front housing and separate the front arm and housing 31 Pull out the front drive shaft from the transmis sion 1 Using a tire lever or a crow bar etc...

Page 1895: ...tes of transmission jack do not touch the oil pan 35 Remove the transmission rear crossmember from the vehicle 36 While lowering the transmission jack gradually fully retract the engine support and th...

Page 1896: ...n jack gradual ly turn the screw of engine support then tilt the engine forward and connect 5 Install the transmission rear crossmember Tightening torque T1 35 N m 3 6 kgf m 25 8 ft lb T2 70 N m 7 1 k...

Page 1897: ...er 12 Remove the ST 13 Install the engine harness bracket Non turbo model Tightening torque T 16 N m 1 6 kgf m 11 8 ft lb 14 Install the harness connector to engine harness bracket then connect the ha...

Page 1898: ...Attach the stabilizer link to the front arm Tightening torque 45 N m 4 6 kgf m 33 2 ft lb 28 Install the shift select cable onto the select le ver Ref to CS 26 INSTALLATION Select Ca ble 29 Install t...

Page 1899: ...round cable to battery 43 Fill transmission with ATF through the oil charge pipe until the fluid level is between the up per and lower level on the COLD side of the level gauge Ref to 4AT 27 Automatic...

Page 1900: ...REMOV AL Rear Exhaust Pipe Ref to EX H4SO 12 REMOVAL Muffler 4 Remove the center and rear exhaust pipes and the muffler Turbo model Ref to EX H4DOTC 8 REMOVAL Center Exhaust Pipe Ref to EX H4DOTC 13...

Page 1901: ...STALLATION Rear Exhaust Pipe Ref to EX H4SO 12 INSTALLATION Muffler 6 Install the center rear exhaust pipes and the muffler Turbo model Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe Ref to EX H...

Page 1902: ...MOVAL Muf fler Turbo model Ref to EX H4DOTC 13 REMOVAL Rear Ex haust Pipe Ref to EX H4DOTC 15 REMOV AL Muffler 6 Remove the heat shield cover 7 Remove the propeller shaft Ref to DS 10 RE MOVAL Propell...

Page 1903: ...drain plug Tightening torque Aluminum gasket silver 44 N m 4 5 kgf m 32 5 ft lb Copper gasket brown 70 N m 7 1 kgf m 51 6 ft lb Metal gasket black 70 N m 7 1 kgf m 51 6 ft lb 5 Separate the front dri...

Page 1904: ...ere is continuity in only one direction or in other points adjust the inhibitor switch Ref to 4AT 48 ADJUSTMENT Inhibitor Switch 4 Repeat the above inspection in other gear rang es If there are abnorm...

Page 1905: ...6 Remove the snap pin and washer from the shifter arm 7 Remove the plate assembly from the transmis sion case 8 Using the ST remove the spring pin and remove the shifter arm ST 398791600 REMOVER 9 Rem...

Page 1906: ...o the transmission Tightening torque T 25 N m 2 5 kgf m 18 4 ft lb 8 Install the washer and snap pin to the shifter arm 9 Install the front and center exhaust pipes Non turbo model Ref to EX H4SO 7 IN...

Page 1907: ...the front center and rear exhaust pipes and the muffler Non turbo model Ref to EX H4SO 6 REMOVAL Front Exhaust Pipe Ref to EX H4SO 9 REMOVAL Center Exhaust Pipe Ref to EX H4SO 10 REMOV AL Rear Exhaus...

Page 1908: ...bly B INSTALLATION 1 Pass the transmission harness assembly through the hole of the transmission case 2 Connect the control valve connector and trans mission ground Tightening torque 8 N m 0 8 kgf m 5...

Page 1909: ...el Ref to EX H4SO 7 INSTALLATION Front Ex haust Pipe Ref to EX H4SO 9 INSTALLA TION Center Exhaust Pipe Ref to EX H4SO 10 INSTALLATION Rear Exhaust Pipe Ref to EX H4SO 12 INSTALLATION Muffler 13 Insta...

Page 1910: ...e ground cable from the battery 3 Lift up the vehicle 4 Disconnect the connector from the rear vehicle speed sensor 5 Remove the rear vehicle speed sensor B INSTALLATION Install in the reverse order o...

Page 1911: ...REMOVAL When removing the torque converter turbine speed sensor refer to Front Vehicle Speed Sensor Ref to 4AT 51 REMOVAL Front Vehicle Speed Sensor B INSTALLATION When installing the torque converter...

Page 1912: ...net 10 Completely remove the remaining liquid gasket on the transmission case and oil pan 11 Remove the control valve strainer tightening bolt and remove control valve strainer from the control valve...

Page 1913: ...Liquid gasket THREE BOND 1217B Part No K0877YA020 or equivalent 6 Install the oil pan by equally tightening the bolts Tightening torque 5 N m 0 5 kgf m 3 7 ft lb 7 Fill ATF from the oil charge pipe Re...

Page 1914: ...form replacement with a new gasket and tighten the drain plug ATF Tightening torque 25 N m 2 5 kgf m 18 4 ft lb 7 Remove the oil pan CAUTION Be careful not to allow foreign matter such as dust or dirt...

Page 1915: ...rface Liquid gasket THREE BOND 1217B Part No K0877YA020 or equivalent 8 Fill the 3 holes aside from the bolt holes in the transmission case with liquid gasket Liquid gasket THREE BOND 1217B Part No K0...

Page 1916: ...ATIC TRANSMISSION 13 Perform learning control promotion Ref to 4AT diag 17 FACILITATION OF LEARNING CONTROL OPERATION Subaru Select Moni tor C INSPECTION Check parts for holes damages or adhesion of d...

Page 1917: ...ect the Subaru Select Monitor to data link connector 6 Turn the ignition switch to ON 7 Turn off all switches causing an electrical load such as headlights A C seat heater and rear de fogger etc 2 AIR...

Page 1918: ...abnormal ly is displayed start the AT air bleeding over from the beginning When communication error occurs during air bleeding select lever does not shift occasionally If select lever does not shift...

Page 1919: ...the connector from TCM 4 Remove the TCM B INSTALLATION 1 Install the TCM Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 2 Connect the connector to TCM 3 Install in the reverse order of removal 4 Perfo...

Page 1920: ...ing it and while turning with pliers pull straight out by hand 7 Disconnect the ATF cooler hoses from the pipes NOTE Do not use a screwdriver or other pointed tools If it is hard to remove the hose wr...

Page 1921: ...lded over exces sively bent or twisted Insert the hose to the specified position 4 Connect the ATF cooler hose to the pipe on the radiator side NOTE Install so that the hose is not folded over exces s...

Page 1922: ...en the trans mission radiator pipes and hoses 2 Check the clamp for deformation 3 Lightly bend the hose and check for cracks in the surface or other damages 4 Pinch the hose with your fingers and chec...

Page 1923: ...model 2 Install the air intake chamber Non turbo model Ref to IN H4SO 7 INSTALLATION Air Intake Chamber 3 Install the intercooler Turbo model Ref to IN H4DOTC 13 INSTALLATION Inter cooler C INSPECTION...

Page 1924: ...nge side B INSTALLATION 1 Apply ATF on a new O ring and install together with the oil charge pipe NOTE Use a new bolt Tightening torque 38 N m 3 9 kgf m 28 0 ft lb 2 Install the air intake chamber Non...

Page 1925: ...convert er clutch assembly as necessary B INSTALLATION 1 When the oil pump shaft is removed install the shaft to converter case 2 Install the oil pump shaft to the torque converter clutch assembly and...

Page 1926: ...e Dimension A Non turbo model 1 1 1 3 mm 0 043 0 051 in Turbo model 2 7 2 9 mm 0 106 0 114 in 6 Install the transmission assembly to the vehicle Ref to 4AT 40 INSTALLATION Automatic Transmission Assem...

Page 1927: ...aring to the end sur face of the reduction drive gear NOTE Install the thrust needle bearing in the correct direc tion 2 Install a new gasket 3 Install the extension case to transmission case 4 Tighte...

Page 1928: ...fer clutch pipe to the extension case while being careful not to deform the pipe 4 Install the transfer clutch assembly to the case NOTE Be careful not to damage the seal ring Insert the transfer clut...

Page 1929: ...tall the transfer clutch assembly to the case 3 Tighten the bolts to secure the case Tightening torque 25 N m 2 5 kgf m 18 4 ft lb 4 Install the transmission assembly to the vehicle Ref to 4AT 40 INST...

Page 1930: ...ft to remove the transfer clutch piston D ASSEMBLY 1 Install the transfer clutch piston 2 Install the return spring to transfer clutch piston 3 Apply ATF to the lip of transfer clutch piston seal then...

Page 1931: ...INSTALLER 7 Install the driven plate drive plate retaining plate and snap ring 8 Apply compressed air to see if the assembled parts move smoothly 9 Check the clearance between the snap ring and retain...

Page 1932: ...rance exceeds the service limits re place the plate set drive plate and driven plate and select and adjust a retaining plate to be within the initial standard value Initial standard 0 7 1 1 mm 0 028 0...

Page 1933: ...GAUGE 3 Calculation formula T A B 35 4 mm T A B 1 3937 in T Thrust needle bearing thickness A Distance from the end of the ST to end of rear drive shaft B Distance from the mating surface of the trans...

Page 1934: ...ET B INSTALLATION 1 Set the range select lever to the P range 2 Using a plastic hammer install the reduction driven gear assembly and the new washer and tighten the new drive pinion lock nut Tightenin...

Page 1935: ...ve snap ring from the reduction driven gear D ASSEMBLY 1 Install the snap ring to the gear inner grove on the reduction driven gear 2 Install the new ball bearing to reduction driven gear using press...

Page 1936: ...s fit it to the bottom of bearing shoulder com pletely 2 Install the reduction driven gear Ref to 4AT 78 INSTALLATION Reduction Driven Gear 3 Join the transmission case and the extension case and then...

Page 1937: ...eal ring outer surface and shaft grooves 4 Apply ATF to new seal rings then install E INSPECTION Rotate the bearing by hand and check that it ro tates smoothly Check parts for holes damage or adhesion...

Page 1938: ...ove the parking pawl return spring and shaft B INSTALLATION 1 Install the parking pawl return spring and shaft 2 Install the reduction drive gear Ref to 4AT 80 INSTALLATION Reduction Drive Gear 3 Inst...

Page 1939: ...Breather Hose 7 Remove the oil charge pipe Ref to 4AT 68 REMOVAL Oil Charge Pipe 8 Remove the ATF inlet and outlet pipes Ref to 4AT 64 REMOVAL ATF Cooler Pipe and Hose 9 Remove the converter case ali...

Page 1940: ...se Liquid gasket THREE BOND 1215 Part No 004403007 or equivalent 8 Install the converter case being careful not to damage the bushing and oil seal NOTE Use new bolts for the oil charge pipe Tightening...

Page 1941: ...14 Install the torque converter clutch assembly Ref to 4AT 69 INSTALLATION Torque Convert er Clutch Assembly 15 Install the transmission assembly to the vehi cle Ref to 4AT 40 INSTALLATION Automatic...

Page 1942: ...ate the converter case and transmission case Ref to 4AT 83 REMOVAL Converter Case 9 Separate the transmission case and extension case section Ref to 4AT 71 REMOVAL Exten sion Case 10 Remove the reduct...

Page 1943: ...Case 6 Insert the inhibitor switch connector and trans mission harness connector onto the stay 7 Install the ATF cooler pipe Ref to 4AT 65 IN STALLATION ATF Cooler Pipe and Hose 8 Install the oil cha...

Page 1944: ...haft 3 Remove the oil pump inner rotor and outer rotor 2 OIL SEAL RETAINER 1 Remove the oil seal retainer 2 Remove the O ring 3 Remove the oil seal from the oil seal retainer A Seal ring A Oil pump co...

Page 1945: ...he oil seal retainer and new seal rings and install them After installing adjust the tooth contact with the drive pinion backlash Ref to 4AT 91 ADJUSTMENT Oil Pump Hous ing NOTE There are two types of...

Page 1946: ...or dents or faults 3 Oil pump rotor assembly selection 1 Tip clearance Install the inner rotor and outer rotor to the oil pump With rotor gears facing each other mea sure the crest to crest clearance...

Page 1947: ...install the thrust needle bearing to the oil pump cover 5 After correctly installing the new gasket to the case mating surface carefully install the oil pump housing assembly Be careful to avoid hitt...

Page 1948: ...MOVAL Reduction Drive Gear 12 Remove the reduction driven gear Ref to 4AT 78 REMOVAL Reduction Driven Gear 13 Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil p...

Page 1949: ...ransmission Assembly C DISASSEMBLY 1 Flatten the lock nut tab and then remove the lock nut while holding the rear spline part of the drive pinion shaft using ST1 and ST2 Pull out the drive pinion coll...

Page 1950: ...2 L1 L2 T1 T1 116 N m 11 8 kgf m 85 6 ft lb Required torque setting T2 Tightening torque L1 ST2 length 0 072 m 2 83 in L2 Torque wrench length Example ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499...

Page 1951: ...etely 2 Install the oil pump housing assembly to the con verter case and secure them by tightening the four bolts evenly NOTE Use an old gasket or aluminum washer to prevent damaging the mating surfac...

Page 1952: ...Check item Tooth contact surface is slightly shifted toward the toe side under a no load con dition When driving it moves towards the heel side Face contact Check item Backlash is too large Contact pa...

Page 1953: ...contact area is too small Contact pattern Corrective action Increase the thickness of the pin ion height adjusting washer according to the proce dures for moving the drive pinion closer to the hypoid...

Page 1954: ...8630AA010 WRENCH COMPL RETAINER NOTE ST WRENCH ASSEMBLY 499787000 can also be used Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case 11 Rem...

Page 1955: ...rmal protrusion A 50 55 mm 1 97 2 17 in 12 Install the torque converter clutch assembly Ref to 4AT 69 INSTALLATION Torque Convert er Clutch Assembly 13 Install the transmission assembly to the vehi cl...

Page 1956: ...remove and install the oil seal and O ring 1 Remove the O ring 2 Remove the oil seal 3 Remove the split pin and then remove the claw ST 398527700 PULLER ASSY 4 Attach two claws to the outer race and...

Page 1957: ...he hypoid driven gear and secure by tightening the bolt Tightening torque 62 N m 6 3 kgf m 45 7 ft lb 5 Measurement of backlash Selection of washer 1 Install the SUBARU genuine axle shaft to different...

Page 1958: ...AT 102 ADJUST MENT Front Differential Assembly F ADJUSTMENT 1 Using the ST screw in the differential side re tainer until resistance is felt ST 18630AA010 WRENCH COMPL RETAINER NOTE Screw in the RH si...

Page 1959: ...ches and secure it with the lock plate Then after returning the RH dif ferential side retainer retighten until it stops Ro tate the drive pinion 2 or 3 times Tighten the RH differential side retainer...

Page 1960: ...spec ification using ST2 ST3 ST4 and ST5 ST1 499787700 WRENCH ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE ST4 499787500 ADAPTER ST5 498255400 PLATE Backlash 0 13 0 18 mm 0 0051 0 0071 in 10 Adj...

Page 1961: ...L Oil Charge Pipe 8 Remove the ATF inlet and outlet pipes Ref to 4AT 64 REMOVAL ATF Cooler Pipe and Hose 9 Separate the converter case from the transmis sion case Ref to 4AT 83 REMOVAL Converter Case...

Page 1962: ...rake seal 18 Remove the snap ring 19 Take out the 2 4 brake spring retainer 20 Remove the 2 4 brake piston and 2 4 brake piston retainer while taking care not to damage them 21 Pull out the leaf sprin...

Page 1963: ...ow reverse brake 24 Turn the transmission case upside down and then take out the socket bolts while holding the one way clutch inner race by hand 25 Remove the spring retainer 26 Take out the return s...

Page 1964: ...d retaining plate neatly in this order on surface table 9 Set the dial gauge to retaining plate and read its scale NOTE The value which is read in the gauge at this time is zero point 10 Scale and rec...

Page 1965: ...ll the dish plate driven plate drive plate and retaining plate and then secure them with a snap ring NOTE Pay attention to the orientation of the dish plate 15 Apply compressed air intermittently to c...

Page 1966: ...it thickness 3 90 mm 0 154 in 18 Install the leaf spring of the low reverse brake 19 Install the 2 4 brake piston and 2 4 brake re tainer by aligning the hole of the 2 4 brake retainer with the hole o...

Page 1967: ...which does not bend against load as a flat board to be put on retaining plate Use a flat board weighing less than 10 2 kg 22 5 lb 4 Put the flat board on retaining plate 5 Using the following formula...

Page 1968: ...lculation Calculate with A and B dimensions recorded before If the calculated value exceeds the ser vice limits replace the drive plate and select and adjust the retaining plate to be within stan dard...

Page 1969: ...bearing 31 Apply vaseline and attach the thrust needle bearing to the high clutch hub then engage the splines of the front planetary carrier correctly to in stall the high clutch hub 32 Install the th...

Page 1970: ...ose 40 Install the ATF cooler pipe Ref to 4AT 65 IN STALLATION ATF Cooler Pipe and Hose 41 Install the oil charge pipe together with an O ring Ref to 4AT 68 INSTALLATION Oil Charge Pipe 42 Insert the...

Page 1971: ...COMPRESSOR ST2 498627100 SEAT 4 Take out the clutch cover spring retainer high clutch piston and reverse clutch piston 5 Remove the seal ring and lip seal from the high clutch piston and reverse clutc...

Page 1972: ...re verse brake and remove the snap ring from the low clutch drum using ST1 and ST2 ST1 498627100 SEAT ST2 398673600 COMPRESSOR 8 Remove the one way clutch Ref to 4AT 105 REMOVAL AT Main Case A Front p...

Page 1973: ...le bearing after taking out the snap ring 3 2 4 BRAKE Separate the 2 4 brake piston and piston retainer 4 ONE WAY CLUTCH INNER RACE 1 Remove the seal ring 2 Remove the needle bearing using ST ST 39852...

Page 1974: ...verse clutch piston 2 Install the high clutch piston to the reverse clutch piston NOTE Be careful not to damage the seal ring and lip seal 3 Install the reverse clutch piston to the high clutch drum A...

Page 1975: ...ining plate neatly in this order on sur face table 2 Set the dial gauge to the clutch and read its scale NOTE The value which is read in the gauge at this time is zero point 3 Scale and record the wei...

Page 1976: ...tall the thickest driven plate to piston side and then install the driven plate drive plate retain ing plate to high clutch drum 10 Install the snap ring to high clutch drum 11 Apply compressed air in...

Page 1977: ...in default stan dard values 14 Selection of the reverse clutch retaining plate 1 Place the dish plate driven plate drive plate and retaining plate neatly in this order on sur face table 2 Set the dial...

Page 1978: ...at three or more locations spaced by equal distances and take the average value NOTE If measuring in three locations measure every 120 If measuring in four locations measure every 90 7 Install the dr...

Page 1979: ...m 0 063 in 2 PLANETARY GEAR AND LOW CLUTCH 1 Apply ATF to a new D ring and install it to the low clutch piston 2 Install the low clutch piston to low clutch drum NOTE Be careful not to damage the D ri...

Page 1980: ...ss shims on both sides to prevent plate from tilting 2 Check the clearance between retaining plate and low clutch operation Initial standard 0 7 1 1 mm 0 028 0 043 in Limit thickness 1 6 mm 0 063 in I...

Page 1981: ...ch drum 14 Install the thrust needle bearing in the correct direction 15 Install the rear sun gear in the correct direction A Rear internal gear B Low clutch drum A Thrust needle bearing B Low clutch...

Page 1982: ...in the clockwise direction and rotates freely in the counterclockwise direction 3 2 4 BRAKE 1 Apply ATF to the new D ring then install to the 2 4 brake piston 2 Install 2 4 brake piston to 2 4 brake...

Page 1983: ...h inner race 5 ONE WAY CLUTCH OUTER RACE 1 Install the needle bearing and then secure with the snap ring 2 Install the one way clutch and one way clutch in ner race then secure with the snap ring 3 Se...

Page 1984: ...it to be within specifications Ref to 4AT 91 ADJUSTMENT Oil Pump Housing 3 2 4 BRAKE Check the following items Drive plate facing for wear or damage Driven plate for discoloration burned color Snap ri...

Page 1985: ...MOVAL Air Breather Hose 7 Wrap vinyl tape around the nipple attached to the air breather hose 8 Remove the pitching stopper bracket 9 Remove the inhibitor switch Ref to 4AT 49 REMOVAL Inhibitor Switch...

Page 1986: ...connector and trans mission harness connector onto the stay 10 Install the air breather hose Ref to 4AT 67 INSTALLATION Air Breather Hose 11 Insert the input shaft while rotating it lightly by hand an...

Page 1987: ...ATURE WARNING LIGHT Turn the ignition switch to ON and wait for at least 2 seconds Does the ATF temperature warning light illuminate Go to step 3 Check the ATF temperature warn ing light 3 CHECK ATF T...

Page 1988: ...iagnostic Trouble Code DTC for DTC Ref to 4AT diag 29 List of Diagnostic Trouble Code DTC 2 Repair the trouble cause 3 Perform the Clear Memory Mode 4 Perform the Inspection Mode Ref to 4AT diag 20 In...

Page 1989: ...hers Place Highland Suburbs Inner city Uphill Rough road Others Ambient air temperature Hot Warm Cool Cold Vehicle speed km h MPH AT warning light ATF temperature warning light Blinks continuously Doe...

Page 1990: ...ttery voltage and specific gravity of the electrolyte Standard voltage 12 V or more Specific gravity 1 260 or more 2 TRANSMISSION GROUND Make sure that the ground terminal bolt is tightened securely C...

Page 1991: ...IAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester Used for mea...

Page 1992: ...SMISSION DIAGNOSTICS 4 Electrical Component Location A LOCATION 1 CONTROL MODULE 1 Engine control module ECM 3 Transmission control module TCM 4 Data link connector 2 ATF temperature warning light AT...

Page 1993: ...4AT diag 8 Electrical Component Location AUTOMATIC TRANSMISSION DIAGNOSTICS 1 AT 01874 AT 04561 2 AT 04854 3 AT 01877 4 AT 01876 5...

Page 1994: ...AUTOMATIC TRANSMISSION DIAGNOSTICS 2 SENSOR 1 Accelerator pedal position sensor 4 Rear vehicle speed sensor 6 ATF temperature sensor 2 Front vehicle speed sensor 5 Torque converter turbine speed senso...

Page 1995: ...4AT diag 10 Electrical Component Location AUTOMATIC TRANSMISSION DIAGNOSTICS AT 00375 1 AT 01474 2 4 AT 04909 3 5 AT 00331 6 AT 04842...

Page 1996: ...ON DIAGNOSTICS 3 SOLENOID 1 Line pressure linear solenoid 4 Low reverse duty solenoid 6 Transfer duty solenoid 2 High clutch duty solenoid 5 Low clutch duty solenoid 7 Lock up duty solenoid 3 2 4 brak...

Page 1997: ...round Select lever P range Less than 1 Select lever Except P range 8 or more N range switch B55 No 11 Chassis ground Select lever N range Less than 1 Select lever Except N range 8 or more R range swit...

Page 1998: ...d B55 No 4 B55 No 3 Ignition switch ON throttle fully closed in R range after warm up 3 7 7 7 4 0 6 0 Ignition switch ON throttle fully open in R range after warm up 1 1 5 1 Line pressure linear solen...

Page 1999: ...Less than 1 Power GND1 B54 No 21 Chassis ground 0 Less than 1 Control GND2 B54 No 22 Chassis ground 0 Less than 1 Control GND1 B54 No 23 Chassis ground 0 Less than 1 SPORT shift switch B54 No 17 Chass...

Page 2000: ...nstrument panel on the driv er s side CAUTION Do not connect the scan tools other than the Subaru Select Monitor 6 Start the PC 7 Turn the ignition switch to ON 8 Run the PC application for Subaru Sel...

Page 2001: ...nal ATF Temp C or F Gear position Gear Position Line pressure control duty ratio Line Pressure Duty Ratio Lock up clutch control duty ratio Lock Up Duty Ratio Transfer clutch control duty ratio Transf...

Page 2002: ...ry 2 1 Warm up or cool down until the ATF temperature displayed on the Subaru Select Monitor is 60 80 C 140 176 F 2 Shift the select lever to P range 3 Fully apply the parking brake 4 Lift up the vehi...

Page 2003: ...the List of Diagnos tics Trouble Code After repairing the locations in dicated by the DTC start the AT learning mode over from the beginning If the message AT learning ended abnormally is displayed s...

Page 2004: ...agnostic Trouble Code DTC A OPERATION Refer to Subaru Select Monitor for information on how to display a DTC Ref to 4AT diag 15 OP ERATION Subaru Select Monitor For details concerning DTCs refer to Li...

Page 2005: ...ON DIAGNOSTICS 8 Inspection Mode A PROCEDURE WARNING Observe the traffic law when driving on public roads 1 Shift the select lever to D range and then drive the vehicle at 60 km h 37 MPH for at least...

Page 2006: ...emory Mode AUTOMATIC TRANSMISSION DIAGNOSTICS 9 Clear Memory Mode A OPERATION Refer to Subaru Select Monitor for information about how to clear a DTC Ref to 4AT diag 17 CLEAR MEMORY MODE OPERATION Sub...

Page 2007: ...ch occurred previously can also be identified through the memory function If the ATF temperature warning light does not blink when a problem actually occurs the problem can be determined by checking t...

Page 2008: ...80 B A1 A9 B3 B9 TCM B55 AT OIL TEMP i10 8 7 6 5 4 3 2 1 22 23 21 20 19 16 15 14 13 12 11 10 9 34 35 33 32 17 30 18 31 29 28 27 26 25 24 i84 A B280 B 18 17 B55 16 10 11 12 13 14 15 25 24 30 9 8 7 17 1...

Page 2009: ...TCM 1 Display the current data of TCM using Sub aru Select Monitor Ref to 4AT diag 15 OPERATION Subaru Select Monitor 2 Read the data of Diagnosis Light Is ON displayed Go to step 6 Replace the TCM R...

Page 2010: ...3 22 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B54 5 6 7 2 1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 E C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18...

Page 2011: ...nce 1 M or more Go to step 5 Repair the short circuit of harness between data link connector and ground terminals 5 CHECK ENGINE GROUND CIRCUIT Check the engine ground circuit Is the engine ground cir...

Page 2012: ...tor 12 CHECK INSTALLATION OF TRANSMISSION HARNESS CONNECTOR Is the transmission harness connector connected to bulk head harness connector Go to step 13 Connect the bulk head harness con nector to tra...

Page 2013: ...nnector terminal B54 No 20 B11 No 20 B54 No 21 B11 No 20 B54 No 22 B11 No 19 B54 No 23 B11 No 19 Is the resistance less than 1 Go to step 19 Repair the open circuit of harness between TCM and transmis...

Page 2014: ...cle sensor torque converter tur bine speed sensor or control valve malfunction Ref to 4AT diag 51 DTC P0731 GEAR 1 INCORRECT RATIO Diagnostic Procedure with Diagnostic Trouble Code DTC P0732 Gear 2 In...

Page 2015: ...AT diag 68 DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT Diagnostic Proce dure with Diagnostic Trouble Code DTC P1706 AT Vehicle Speed Sensor Circuit Mal function Rear wheel Rear vehicle speed sensor is f...

Page 2016: ...Diagnostic Trouble Code DTC A DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT PRNDL INPUT DTC DETECTING CONDITION Inhibitor switch is faulty Multiple range signals are input at a time No range signal is...

Page 2017: ...18 17 13 10 14 11 2 8 3 1 T7 B55 B12 T3 T3 B12 5 4 2 3 1 4 P R N D E TCM B55 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 33 34 29 32 30 31 35 i10 B280 B FB 36 F B FUSE...

Page 2018: ...t lever to N range Does the combination meter N range indicator light illumi nate Go to step 11 Go to step 10 10 CHECK N RANGE SWITCH Read the data of N range using Subaru Select Monitor Is ON display...

Page 2019: ...to IDI 4 INSPECTION Combination Meter System Is the P range indicator light bulb OK Go to step 42 Replace the com bination meter assembly Ref to IDI 16 Combina tion Meter 20 CHECK HARNESS CONNECTOR B...

Page 2020: ...o step 42 Repair ground short circuit in R range circuit 28 CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and inhibitor...

Page 2021: ...switch connector and poor contact of the connector 36 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON...

Page 2022: ...hassis ground Connector terminal B55 No 10 Chassis ground Is the resistance 1 M or more Go to step 42 Repair ground short circuit in D range circuit 42 CHECK POOR CONTACT Is there poor contact of the...

Page 2023: ...ION Input signal circuit to ATF temperature sensor is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 04753 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 23 12 15 11 9...

Page 2024: ...e decreases Go to step 4 Go to step 6 4 CHECK INPUT SIGNAL FOR TCM 1 Connect the connector to transmission 2 Connect the Subaru Select Monitor to data link connector 3 Turn the ignition switch to ON 4...

Page 2025: ...ONDITION Input signal circuit to ATF temperature sensor is shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 04753 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 23 12 15 11 9 4...

Page 2026: ...ance of harness between TCM connector and chassis ground Connector terminal B55 No 12 Chassis ground B55 No 23 Chassis ground Is the resistance 1 M or more Go to step 5 Repair the short circuit of har...

Page 2027: ...ted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 04497 10 5 B11 T4 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 TCM B55 B53 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B53...

Page 2028: ...t of the con nector 3 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and chassis ground Connector terminal B55 No 1 Chassis ground B55 No...

Page 2029: ...2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 1...

Page 2030: ...ubaru Select Monitor Ref to LAN diag 15 OPERATION Subaru Select Monitor Is ON displayed Go to step 5 Go to step 6 5 CHECK TCM Read the data of Stop Light Switch using Sub aru Select Monitor Ref to 4AT...

Page 2031: ...esistance of harness between body integrated unit and stop light switch Connector terminal B280 No 2 Chassis ground Is the resistance 1 M or more Go to step 9 Repair the short circuit of harness betwe...

Page 2032: ...hicle speed sensor is shorted or open TROUBLE SYMPTOM Driving performance is poor WIRING DIAGRAM AT 04499 18 14 B11 T4 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 TCM B55 B53 1 2 3 4 5 6 7...

Page 2033: ...ector terminal T4 No 14 No 18 Is the resistance 450 650 Go to step 4 Replace the front vehicle speed sen sor Ref to 4AT 51 Front Vehicle Speed Sensor 4 CHECK INPUT SIGNAL FOR TCM 1 Connect all connect...

Page 2034: ...2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 33 34 29 32 30 31 35 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 1...

Page 2035: ...GRATED UNIT INPUT SIGNAL 1 Disconnect the harness connector of body integrated unit 2 Measure the voltage of harness between body integrated unit and stop light switch Connector terminal B280 No 2 Cha...

Page 2036: ...ow Excessive shift shock Tight corner braking phenomenon occurs Gear is not shifted to reverse Gear position is held by fail safe function Step Check Yes No 1 CHECK THROTTLE OPENING ANGLE SEN SOR Read...

Page 2037: ...nal cir cuit 2 CHECK AT TURBINE REVOLUTION SPEED SENSOR CIRCUIT Perform the diagnosis according to DTC P0715 Ref to 4AT diag 42 DTC P0715 INPUT TURBINE SPEED SENSOR CIRCUIT Diag nostic Procedure with...

Page 2038: ...ignal circuit of lock up duty solenoid is open or shorted TROUBLE SYMPTOM No lock up occurs After engine is warmed up WIRING DIAGRAM AT 04755 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 6 B...

Page 2039: ...nd transmission con nector 4 CHECK LOCK UP DUTY SOLENOID Measure the resistance between transmission connector receptacle s terminals Connector terminal T4 No 12 No 20 Is the resistance 2 0 6 0 Go to...

Page 2040: ...rain the automatic transmission fluid CAUTION Do not drain ATF until it cools down 3 Remove the oil pan 4 Disconnect the connector from the control valve body 5 Measure the resistance between lock up...

Page 2041: ...nal circuit of line pressure linear solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 04756 3 B11 AT2 T4 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 4 B55...

Page 2042: ...IN TRANSMISSION 1 Remove the transmission connector from bracket 2 Drain the automatic transmission fluid CAUTION Do not drain ATF until it cools down 3 Remove the oil pan 4 Disconnect the connector f...

Page 2043: ...ir the open circuit of harness between TCM and transmission con nector 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and transmission g...

Page 2044: ...LOW CLUTCH DUTY SOLENOID IN TRANSMISSION 1 Remove the transmission connector from bracket 2 Drain the automatic transmission fluid CAUTION Do not drain ATF until it cools down 3 Remove the oil pan 4 D...

Page 2045: ...2 Repair the open circuit of harness between TCM and transmission con nector 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND Measure the resistance of harness between TCM connector and chass...

Page 2046: ...SSION 1 Remove the transmission connector from bracket 2 Drain the automatic transmission fluid CAUTION Do not drain ATF until it cools down 3 Remove the oil pan 4 Disconnect the connector from the 2...

Page 2047: ...ignal circuit of high clutch duty solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 04759 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 6 B54 B11 AT2 T4 7 3...

Page 2048: ...he vehicle 3 Connect the Subaru Select Monitor to data link connector 4 Start the engine 5 Run the Subaru Select Monitor 6 Warm up the engine until the ATF tempera ture exceeds 80 C 176 F 7 Shift the...

Page 2049: ...0 Go to step 8 Replace the con trol valve body Ref to 4AT 58 Control Valve Body 8 CHECK HARNESS CONNECTOR BETWEEN HIGH CLUTCH DUTY SOLENOID AND TRANSMISSION Measure the resistance of harness between h...

Page 2050: ...t signal circuit of low reverse duty solenoid is open or shorted TROUBLE SYMPTOM Gear is not changed WIRING DIAGRAM AT 04760 B11 1 2 3 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 5 B54 B11 AT2 T4 6 1...

Page 2051: ...ubaru Select Monitor to data link connector 3 Start the engine 4 Run the Subaru Select Monitor 5 Warm up the transmission until the ATF temperature exceeds approximately 80 C 176 F 6 Stop the engine 7...

Page 2052: ...NESS CONNECTOR BETWEEN TRANSMISSION AND LOW REVERSE DUTY SOLENOID Measure the resistance of harness between low reverse duty solenoid and transmission con nector Connector terminal T4 No 6 AT2 No 1 Is...

Page 2053: ...tep 2 Go to step 3 2 CHECK OUTPUT SIGNAL OF INTEGRATED UNIT 1 Display the following items using Subaru Select Monitor Ref to LAN diag 33 Read Current Data Key warning SW Shift position P SW Stop light...

Page 2054: ...inal B279 No 12 Chassis ground Is the voltage 10 5 V or more Go to step 7 Go to step 8 7 CHECK OUTPUT SIGNAL OF BODY INTE GRATED UNIT 1 Lift up the vehicle 2 Start the engine 3 Shift the select lever...

Page 2055: ...rcuit of TCM is open or shorted TROUBLE SYMPTOM No lock up or tight corner braking phenomenon is occurred WIRING DIAGRAM IGNITION SWITCH BATTERY REAR VEHICLE SPEED SENSOR AT 04571 AT4 T4 9 3 1 2 E SBF...

Page 2056: ...peed sensor connector 3 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and chassis ground Connector terminal B55 No 15 Chassis ground B55...

Page 2057: ...tance less than 1 Go to step 2 Repair the open circuit of harness between TCM and transmission con nector 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness conne...

Page 2058: ...K TRANSFER DUTY SOLENOID IN TRANSMISSION 1 Lift up the vehicle 2 Drain the automatic transmission fluid CAUTION Do not drain ATF until it cools down 3 Remove the extension case 4 Disconnect the connec...

Page 2059: ...gnal circuit of SPORT manual mode switch is shorted TROUBLE SYMPTOM Manual mode can not be set The SPORT indicator light does not illuminate No SPORT mode occurs WIRING DIAGRAM AT 04572 A B117 TCM B54...

Page 2060: ...ONNECTOR BETWEEN TCM AND SPORT SHIFT SWITCH 1 Disconnect the connector from TCM 2 Measure the resistance of harness between TCM connector and SPORT shift switch con nector Connector terminal B117 No 7...

Page 2061: ...g light go off Go to step 4 Go to step 11 4 CHECK SPARE FUSE Is the spare fuse OK Go to step 5 Replace the fuse AT 04975 i10 i84 8 7 6 5 4 3 2 1 22 23 21 20 19 16 15 14 13 12 11 10 9 34 35 33 32 17 30...

Page 2062: ...ARNESS CONNECTOR BETWEEN FUSE BOX AND CHASSIS GROUND Measure the resistance of the harness between fuse box and chassis ground Connector terminal i5 No 13 Chassis ground Is the resistance less than 1...

Page 2063: ...iag nosis according to DTC Go to step 4 4 CHECK TCM Read the Tiptronic Mode Switch data using the Subaru Select Monitor Is ON displayed Go to step 9 Go to step 5 5 CHECK HARNESS CONNECTOR BETWEEN TCM...

Page 2064: ...sistance between switch terminals Connector terminal B117 No 5 No 6 Is the resistance less than 1 Go to step 12 Replace the guide plate assembly 12 CHECK HARNESS CONNECTOR BETWEEN SWITCH AND CHASSIS G...

Page 2065: ...ARNESS CONNECTOR BETWEEN SWITCH AND CHASSIS GROUND Measure the resistance of harness between switch and chassis ground Connector terminal B117 No 10 Chassis ground Is the resistance less than 1 Go to...

Page 2066: ...2 27 26 A B A1 A9 B3 B9 8 7 6 5 4 3 2 1 22 23 21 20 19 16 15 14 13 12 11 10 9 34 35 33 32 17 30 18 31 29 28 27 26 25 24 A B B55 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1...

Page 2067: ...Subaru Select Monitor Is 2 displayed Go to step 3 Replace the TCM Ref to 4AT 63 Transmission Con trol Module TCM 3 CHECK TCM 1 Shift down the selector lever 2 Read the Gear Position data of TCM using...

Page 2068: ...Go to step 2 2 CHECK COMBINATION METER Ref to IDI 4 INSPECTION Combination Meter System Is the buzzer OK Refer to Diagnos tics with Phenome non Ref to 4AT diag 84 Diagnostics with Phenomenon Replace t...

Page 2069: ...w Noise occurs while driving in D4 Final gear Low reverse brake Planetary gear Reduction gear Differential gear oil level too high or too low Vehicle moves when select lever is in N range Select cable...

Page 2070: ...w clutch One way clutch Vehicle does not start in D range Engine stalls Reverse clutch Vehicle does not start in R range only Engine operates Control valve Acceleration during standing start is poor H...

Page 2071: ...ol valve Lock up facing Engine speed signal Parking brake does not function Select cable AT select lever Parking mechanism Shift lever cannot be moved or is hard to move from P range ATF spurts out AT...

Page 2072: ...tion sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Control valve Low clutch duty solenoid 2 4 brake ATF deterioration Engine performance Slippage occurs when shif...

Page 2073: ...speed sensor Accelerator pedal position sensor ATF temperature sensor Control valve Transfer clutch Transfer valve Transfer pipe Transfer duty solenoid It is not set in FWD mode TCM Transfer clutch T...

Page 2074: ...2nd 2 062 1 882 3rd 1 448 1 296 4th 1 088 0 972 5th 0 780 0 738 Reverse 3 333 Front reduction gear Final Type of gear Hypoid Gear ratio 3 900 Rear reduction gear Transfer Type of gear Helical Gear ra...

Page 2075: ...ft lb 2 Gasket 7 Pitching stopper bracket T1 44 4 5 32 5 Aluminum gasket silver 3 Drain plug 8 Oil level gauge non turbo model 4 Harness bracket non turbo model 9 Oil level gauge turbo model 70 7 1 51...

Page 2076: ...n MANUAL TRANSMISSION AND DIFFERENTIAL Transmission case tightening torque Bolt No Bolt size mm Tightening torque N m kgf m ft lb 5 15 8 25 2 5 18 4 1 4 16 17 10 39 4 0 28 8 MT 00003 9 5 7 16 17 3 4 1...

Page 2077: ...g 34 Lock nut 7 Key 21 2nd driven gear 35 Inner baulk ring 8 Woodruff key 22 2nd driven gear bushing 36 Synchro cone 9 Drive pinion collar 23 3rd 4th driven gear 37 Outer baulk ring 10 Needle bearing...

Page 2078: ...29 Lock nut 6 Inner baulk ring 30 Straight pin 7 3rd synchro cone 20 5th gear thrust washer non turbo model 31 Reverse idler gear shaft 8 Outer baulk ring 32 Washer 9 3rd 4th coupling sleeve 21 5th ne...

Page 2079: ...g Outer 3 Straight pin 10 Interlock plunger 17 Reverse fork rod arm 4 Reverse fork rod 11 1st 2nd fork rod 18 Reverse shifter lever 5 Checking ball plug 12 3rd 4th shifter fork 6 Gasket 13 1st 2nd shi...

Page 2080: ...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 7 4 7 11 Reverse check spring 26 R...

Page 2081: ...n 13 Retainer lock plate 2 Hypoid driven gear 8 Roller bearing 3 Pinion shaft 9 Differential case Tightening torque N m kgf m ft lb 4 Straight pin 10 Oil seal T1 25 2 5 18 4 5 Washer 11 Differential s...

Page 2082: ...ng torque N m kgf m ft lb 2 Spacer 8 Center crossmember T1 35 3 6 25 8 3 Lower cushion rubber 9 Rear plate T2 50 5 1 36 9 4 Front plate 10 Front crossmember T3 58 5 9 42 8 5 Transmission cushion rubbe...

Page 2083: ...driv ing Be wary of receiving burns from heated parts Use SUBARU genuine gear oil grease or equiv alent Do not mix gear oil grease etc of different grades or manufacturers Be sure to tighten fasteners...

Page 2084: ...ALL INSTALLER Used for installing reverse shifter rail arm 899524100 PULLER SET Used for removing and installing the roller bear ing differential 1 Puller 2 Cap 399780104 WEIGHT Used for measuring pre...

Page 2085: ...the side gear and pinion and the hypoid gear Used together with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring backlash between the side gear and pinion and the hypoid gear Used together...

Page 2086: ...tial case 499277200 INSTALLER Used for press fitting the 2nd driven gear roller bearings and the 5th driven gear onto the driven shaft 499757002 INSTALLER Used for installing the snap ring OUT 25 and...

Page 2087: ...ball bearing onto the transmission main shaft Used together with REMOVER 899714110 499917500 DRIVE PINION GAUGE ASSY Used for adjusting the drive pinion shim 499927100 HANDLE Used for fitting the tran...

Page 2088: ...removing and installing the driven gear assembly lock nut 899714110 REMOVER Used for fixing the transmission main shaft drive pinion and rear drive shaft 899864100 REMOVER Used for removing transmiss...

Page 2089: ...ling the drive pinion lock nut 398497701 ADAPTER Used for installing roller bearing onto the differ ential case Used together with INSTALLER 499277100 499587000 INSTALLER Used for installing the drive...

Page 2090: ...ing the extension case roller bearing 398643600 GAUGE Used for measuring total end play extension end play and drive pinion height 398177700 INSTALLER Used for installing the bearing cone of transfer...

Page 2091: ...IDE OIL SEAL INSTALLER Used for installing the differential side retainer oil seal 398791700 STRAIGHT PIN REMOVER 2 Used for installing and removing the straight pin TOOL NAME REMARKS Circuit tester U...

Page 2092: ...not to burn yourself Be careful not to spill the transmission gear oil on the exhaust pipe to prevent emission of smoke or causing a fire If gear oil is spilled wipe it off completely 4 Using the TOR...

Page 2093: ...er and intake boot Non turbo model Ref to IN H4SO 7 REMOV AL Air Intake Chamber 6 Remove the air intake chamber stay Non turbo model 7 Remove the intercooler Turbo model Ref to IN H4DOTC 13 REMOVAL In...

Page 2094: ...ORT ASSY 17 Lift up the vehicle 18 Remove the front and center exhaust pipes Non turbo model Ref to EX H4SO 6 REMOV AL Front Exhaust Pipe Ref to EX H4SO 9 REMOVAL Center Exhaust Pipe 19 Remove the cen...

Page 2095: ...10 REMOVAL Propeller Shaft 25 Remove the gear shift rod and the stay from the transmission 1 Disconnect the stay from the transmission 2 Disconnect the gear shift rod from the trans mission 26 Discon...

Page 2096: ...Always support the transmission case with a transmission jack 31 Remove the front crossmember and rear cross member from the vehicle 32 While lowering the transmission jack tighten the turnbuckle of...

Page 2097: ...the transmission gradually using a transmission jack 2 Engage at the spline section NOTE Be careful not to hit the main shaft against the clutch cover 5 While raising the transmission jack loosen the...

Page 2098: ...14 INSTALLATION Throttle Body 13 Lift up the vehicle 14 Install the front drive shaft into the transmis sion ST 28399SA010 OIL SEAL PROTECTOR 15 Insert the front arm ball joint into the housing lower...

Page 2099: ...Ref to EX H4SO 10 INSTALLATION Rear Ex haust Pipe Ref to EX H4SO 12 INSTALLA TION Muffler Turbo model Ref to EX H4DOTC 13 INSTALLATION Rear Exhaust Pipe Ref to EX H4DOTC 15 IN STALLATION Muffler 22 In...

Page 2100: ...stall the air intake chamber stay Non turbo model Tightening torque 16 N m 1 6 kgf m 11 8 ft lb 31 Install the air intake chamber and intake boot Non turbo model Ref to IN H4SO 7 INSTALLATION Air Inta...

Page 2101: ...Pipe 5 Remove the rear exhaust pipe and muffler Non turbo model Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe Ref to EX H4SO 12 REMOVAL Muf fler Turbo model Ref to EX H4DOTC 13 REMOVAL Rear Ex haust Pip...

Page 2102: ...Ref to EX H4SO 9 INSTALLATION Center Exhaust Pipe 7 Install the center exhaust pipe Turbo model Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe 8 Install the rear exhaust pipe and muffler Non tur...

Page 2103: ...H4SO 10 REMOVAL Rear Exhaust Pipe Ref to EX H4SO 12 REMOVAL Muf fler Turbo model Ref to EX H4DOTC 13 REMOVAL Rear Ex haust Pipe Ref to EX H4DOTC 15 REMOV AL Muffler 5 Remove the heat shield cover 6 Re...

Page 2104: ...transmis sion Ref to DS 26 REMOVAL Front Drive Shaft 7 Remove the differential side retainer oil seal NOTE Be sure to replace the differential side retainer oil seal whenever the front drive shaft is...

Page 2105: ...ATION 1 BACK UP LIGHT SWITCH NEUTRAL POSITION SWITCH 1 Install the back up light switch neutral position switch with the harness Tightening torque 32 3 N m 3 3 kgf m 23 8 ft lb 2 Connect the connector...

Page 2106: ...Disconnect the connector of neutral position switch 3 Measure the resistance between neutral posi tion switch terminals Non turbo model Turbo model 4 Replace faulty parts Gear shift position Terminal...

Page 2107: ...Use a new gasket Tightening torque 44 N m 4 5 kgf m 32 5 ft lb Aluminum gasket silver 70 N m 7 1 kgf m 51 6 ft lb Copper gasket brown 70 N m 7 1 kgf m 51 6 ft lb Metal gasket black 4 Attach the trans...

Page 2108: ...ansfer case together with the ex tension case assembly 4 Remove the shifter arm 5 Remove the extension case assembly B INSTALLATION 1 Install the center differential and transfer driven gear into the...

Page 2109: ...sfer case and center differential ST 398643600 GAUGE 11 Measure the height T between the extension case and transfer drive gear ST 398643600 GAUGE NOTE Thickness of ST 15 mm 0 59 in 12 Calculate the t...

Page 2110: ...ansfer case Tightening torque 40 N m 4 1 kgf m 29 5 ft lb 17 Attach the shifter arm to transfer case 18 Hang the shifter arm on 3rd 4th fork rod 19 Install the extension case assembly along with the t...

Page 2111: ...al D ASSEMBLY 1 EXTENSION CASE 1 Using the ST install the oil seal to the extension case Ref to 5MT 31 Oil Seal NOTE Use a new oil seal 2 Install the shift bracket to extension case Tightening torque...

Page 2112: ...ven gear 3 Install the extension case assembly 4 Install the transfer case and the extension case assembly Ref to 5MT 36 INSTALLATION Transfer Case and Extension Case Assembly 5 Install the back up li...

Page 2113: ...oil lubrication 2 Drive gear If the drive gear tooth surface and shaft are exces sively broken or damaged replace the drive gear 3 Measure the clearance between snap ring and inner race of ball beari...

Page 2114: ...uter races from the extension case and transfer case B INSTALLATION 1 Install the bearing outer races to extension case and transfer case 2 Install the transfer driven gear 3 Install the transfer case...

Page 2115: ...n 1 0 Imp ton 2 Using ST install the roller bearing transfer case side ST 499757002 INSTALLER CAUTION Do not apply a load in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton E INSPECTION 1 Bearing Replace...

Page 2116: ...Install the transfer case together with the exten sion case assembly Ref to 5MT 36 INSTALLA TION Transfer Case and Extension Case Assembly 5 Install the back up light switch and the neutral position s...

Page 2117: ...check ball 5 Remove the reverse check sleeve B INSTALLATION 1 Install the reverse check sleeve Tightening torque 6 4 N m 0 7 kgf m 4 7 ft lb 2 Install the reverse check ball reverse accent spring gas...

Page 2118: ...ev and reverse check spring to the reverse check sleeve NOTE Be sure to position the bent section of reverse check spring to fit in the groove of the check cam 2 Hook the curved section of the reverse...

Page 2119: ...ier towards the reverse gear 3 Make adjustment so that the heavy stroke re verse side is a little heavier than the lighter stroke 1st 2nd side 4 To adjust remove the bolts holding the reverse check sl...

Page 2120: ...the arm returns to neutral when released from the reverse position If the arm does not return properly replace the reverse check plate Reverse check plate Part number A No AngleT Remarks 32189AA001 0...

Page 2121: ...ring mounting bolt 5 Remove the main shaft rear plate 6 Remove the coupling bolts and nuts and sepa rate the transmission case into the right and left case 7 Remove the drive pinion shaft assembly fro...

Page 2122: ...are not caught between the cases Tightening torque 8 mm bolt 25 N m 2 5 kgf m 18 4 ft lb 10 mm bolt 39 N m 4 0 kgf m 28 8 ft lb 7 Tighten the ball bearing mounting bolts Tightening torque 30 N m 3 1...

Page 2123: ...r 16 Inspect and adjust backlash and tooth contact of the hypoid gear Ref to 5MT 70 INSPECTION Front Differential Assembly 17 After checking the tooth contact of the hypoid gears remove the lock plate...

Page 2124: ...ase knock pin into the knock pin hole of the needle bearing outer race NOTE Align the end face of the seal with surface A when installing the oil seal 3 Install the drive pinion shaft assembly Ref to...

Page 2125: ...ASSEMBLY 1 When the sleeve and hub assemblies have been disassembled reassemble by aligning the align ment marks NOTE Position the open ends of the spring 120 apart 2 Install the 3rd drive gear outer...

Page 2126: ...l or double row tapered roller bearing turbo model into the rear section of transmission main shaft CAUTION Do not apply a load in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST...

Page 2127: ...owing cases When the bearing balls outer races and inner races are broken or rusty When the bearing is worn When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication...

Page 2128: ...s deformed hard ened worn or defective in any way 7 O ring Replace the O ring if the sealing face is deformed hardened damaged worn or defective in any way 8 Gearshift mechanism Repair or replace the...

Page 2129: ...mbly on trans mission main case RH without shim and tighten the bearing mounting bolts 4 Perform inspection and adjustment of ST NOTE Loosen the two bolts and adjust so that the scale indicates 0 5 co...

Page 2130: ...Extension Case Assembly 13 Install the manual transmission assembly to the vehicle Ref to 5MT 25 INSTALLATION Manual Transmission Assembly C DISASSEMBLY NOTE Attach a cloth to the end of driven shaft...

Page 2131: ...CH 50 ST2 899884100 HOLDER 5 Remove the 5th driven gear using ST ST 499857000 5TH DRIVEN GEAR REMOVER 6 Remove the woodruff key 7 Remove the roller bearing and 3rd 4th driven gear using ST1 and ST2 ST...

Page 2132: ...ear washer and snap ring outer of the 1st driven gear Non turbo model D ASSEMBLY 1 Install the sleeve and the gear and hub assem bly by matching the alignment marks NOTE Make sure that there is no lar...

Page 2133: ...ushing ST1 499277200 INSTALLER ST2 499587000 INSTALLER 5 Install the 2nd driven gear inner baulk ring syn chro cone and outer baulk ring and insert them onto driven shaft 6 After installing key on dri...

Page 2134: ...ocknut in 2 locations Using a spring scale check that starting torque of the roller bearing is 0 1 to 1 5 N 0 01 to 0 15 kgf 0 02 to 0 34 lbf 10 Install the roller bearing onto the drive pinion shaft...

Page 2135: ...of the drive pin ion shaft should be checked for smooth rotation be fore the drive pinion shaft assembly is disassembled In this case because a preload is working on the bearing its rotation feels lik...

Page 2136: ...ce the ball detent if deformed excessively worn or defective in any way 6 Oil seal Replace the oil seal if the lip is deformed hard ened worn or defective in any way 7 O ring Replace the O ring if the...

Page 2137: ...peat steps 1 through 4 to adjust starting torque 6 Recheck that the starting torque is within the specified range then crimp the lock nut at four po sitions A Adjusting washer No 1 B Adjusting washer...

Page 2138: ...the differential side retainers using ST ST 18630AA010 WRENCH COMPL RETAINER 8 Remove the bearing outer race from the trans mission case ST 398527700 PULLER ASSY B INSTALLATION 1 Install the different...

Page 2139: ...rential assem bly toward hypoid driven gear side ST 899904100 STRAIGHT PIN REMOVER 3 Pull out the pinion shaft and remove the differ ential bevel pinion differential bevel gear and washer 4 Using the...

Page 2140: ...NOTE Face the chamfered side of washer toward gear 2 Measure the backlash between differential bevel gear and differential pinion If backlash is not within specified value install a suitable washer t...

Page 2141: ...earing outer races are used as a set ST1 499277100 BUSHING 1 2 INSTALLER ST2 398497701 ADAPTER 5 Install the hypoid driven gear to the differential case using twelve bolts Tightening torque T 62 N m 6...

Page 2142: ...contacts adjacent gear teeth during measurement ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18 mm 0 0051 0 0071 in 2 HYPOID GEAR BACKLASH 1 Set the ST1 ST2 and ST3 Ins...

Page 2143: ...correct F ADJUSTMENT 1 BEVEL PINION GEAR BACKLASH 1 Disassemble the front differential assembly Ref to 5MT 67 DISASSEMBLY Front Differen tial Assembly 2 Select a different washer from the table and in...

Page 2144: ...ighten the side retainer to move the driven gear closer to the drive pinion shaft Flank contact Check item Backlash is too small Contact pattern Corrective action Loosen the side retainer to move the...

Page 2145: ...t Check item Teeth contact area is too small Contact pattern Corrective action Reduce the thickness of drive pinion shim and loosen the side retainer to move the driven gear away from the drive pinion...

Page 2146: ...the straight pin NOTE Be sure to install the reverse idler gear shaft from rear side 2 Check and adjust clearance between the re verse idler gear and the timing case wall surface Ref to 5MT 74 INSTALL...

Page 2147: ...gear and shaft for dam age Replace if it is damaged D ADJUSTMENT 1 Select the appropriate reverse shifter lever from the table below and adjust until the clearance be tween the reverse idler gear and...

Page 2148: ...the straight pin by tapping with the ST and pull out the 5th shifter fork ST 398791700 STRAIGHT PIN REMOVER 2 9 Remove the plugs springs and check balls 10 Drive out the straight pin by tapping with t...

Page 2149: ...E Set the reverse fork rod to neutral Make sure the interlock plunger before installa tion is on the reverse fork rod side ST 398791700 STRAIGHT PIN REMOVER 2 8 Install the 5th shifter fork onto the r...

Page 2150: ...h drive gear and the coupling sleeve If any clearance is not within specifications replace the shifter fork as required Clearance a and b 9 3 mm 0 366 in a b Measured value A 1st driven gear B Reverse...

Page 2151: ...ces A and B If any clearance is not within specifications replace the rod or fork as required Clearance A 3rd 4th 5th 0 5 1 3 mm 0 020 0 051 in Clearance B 1st 2nd 3rd 4th 0 4 1 4 mm 0 016 0 055 in a...

Page 2152: ...cceleration a Defective pitching stopper adjustment Adjust b Loose engine mounting bolts Tighten or replace c Worn fork shifter broken shifter fork rail spring Replace d Worn or damaged ball bearing R...

Page 2153: ...id gear noises Troubles of the differential and hypoid gear always appear as noise problems Therefore noise is the first indication of trouble However noises from the engine muffler tire exhaust gas b...

Page 2154: ...5MT 82 General Diagnostic Table MANUAL TRANSMISSION AND DIFFERENTIAL...

Page 2155: ...2 25 0 065 0 089 Flywheel side 1 35 1 95 0 053 0 077 Limit of sinking 0 3 0 012 Deflection limit mm in 0 7 0 028 at R 110 4 33 Clutch release lever ratio 1 6 Release bearing Grease packed self alignin...

Page 2156: ...ASSY Tightening torque N m kgf m ft lb 8 Clevis pin T1 7 8 0 8 5 8 2 Washer 9 Snap pin T2 15 1 5 11 1 3 Clutch hose 10 Lever T3 18 1 8 13 3 4 Bracket 11 Pedal T4 25 2 5 18 4 5 Clip 12 Operating cylind...

Page 2157: ...eservoir cap 6 Return spring 11 Bleeder screw 2 Reservoir tank 7 Piston 3 Oil seal 8 Push rod ASSY Tightening torque N m kgf m ft lb 4 Straight pin 9 Piston stop ring T1 7 8 0 8 5 8 5 Master cylinder...

Page 2158: ...Description CLUTCH SYSTEM 4 OPERATING CYLINDER Non turbo model 1 Push rod 4 Piston spring Tightening torque N m kgf m ft lb 2 Boot 5 Operating cylinder T 7 8 0 8 5 8 3 Piston 6 Bleeder screw T 5 4 3 2...

Page 2159: ...L 6 General Description CLUTCH SYSTEM Turbo model 1 Push rod 4 Piston spring Tightening torque N m kgf m ft lb 2 Boot 5 Operating cylinder T 7 8 0 8 5 8 3 Piston 6 Bleeder screw CL 00504 T 5 4 3 2 1 6...

Page 2160: ...nap pin 13 Assist rod A 22 Lever 5 Brake pedal pad 14 Clip 23 Clutch switch clutch start 6 Brake pedal 15 Assist spring 7 Clevis pin 16 Assist bushing Tightening torque N m kgf m ft lb 8 Brake pedal s...

Page 2161: ...ng Be wary of receiving burns from heated parts Use SUBARU genuine fluid grease etc or equivalent Do not mix fluid grease etc of different grades or manufacturers Be sure to tighten fasteners includin...

Page 2162: ...ed for stopping rotation of the flywheel when loosening tightening bolts etc 499747100 CLUTCH DISC GUIDE Used when installing the clutch disc to the fly wheel TOOL NAME REMARKS Circuit tester Used for...

Page 2163: ...499747100 CLUTCH DISC GUIDE 2 Install the clutch cover to the flywheel and tight en the bolts to the specified torque NOTE When installing the clutch cover to the flywheel position the clutch cover so...

Page 2164: ...c 3 Oil soakage on facing Replace the clutch disc and inspect the transmis sion front oil seal transmission case mating sur face engine rear oil seal and other locations for oil leakage 4 Deflection o...

Page 2165: ...repair if defective 1 Loose thrust rivet 2 Damaged or worn bearing contact area at the center of diaphragm spring 3 Damaged or worn disc contact surface of the pressure plate 4 Loose strap plate inst...

Page 2166: ...que in crisscross order Tightening torque 72 N m 7 3 kgf m 53 1 ft lb 3 Install the clutch disc and cover Ref to CL 10 INSTALLATION Clutch Disc and Cover 4 Install the transmission assembly Ref to 5MT...

Page 2167: ...ion main shaft spline Use grease con taining molybdenum disulfide 1 Apply grease KOPR KOTE Part No 003603001 to the contact point of the release lever and operating cylinder 2 While pushing the releas...

Page 2168: ...servicing the clutch 1 Check the bearing for smooth movement by ap plying force to the bearing in the radial direction Radial direction stroke 1 6 mm 0 063 in 2 While applying force to the bearing in...

Page 2169: ...STALLATION NOTE The illustration below is suitable for every model Perform the same procedures for the other models 1 Install in the reverse order of removal NOTE Before installing the operating cylin...

Page 2170: ...suitable for every model Perform the same procedures for the other models During assembly apply hydraulic oil to all parts Recommended clutch fluid New FMVSS No 116 DOT3 or DOT4 brake flu id 1 Instal...

Page 2171: ...y if spilled B INSTALLATION 1 Install the master cylinder to the vehicle body and connect the clutch pipe to the master cylinder NOTE Check that the pipe is routed properly Tightening torque T1 15 N m...

Page 2172: ...e installation Grease SILICONE GREASE G 40M Part No 004404003 2 Assemble in the reverse order of disassembly Tightening torque 10 N m 1 0 kgf m 7 4 ft lb E INSPECTION If any damage deformation wear sw...

Page 2173: ...ing cylinder 7 Remove the bracket B INSTALLATION Install in the reverse order of removal NOTE The illustration below is suitable for every model Perform the same procedures for the other models Bleed...

Page 2174: ...NOTE During bleeding operation keep the clutch reser voir tank filled with brake fluid to prevent entry of air Clutch pedal must be operated very slowly Bleed air from the oil line with help of a co w...

Page 2175: ...fluid Release the air bleeder for 1 or 2 seconds Next with the bleeder closed slowly release the clutch pedal CAUTION Cover the bleeder with cloth to prevent brake fluid from being splashed on surroun...

Page 2176: ...rcool er 8 Remove the nut which secures the clutch master cylinder 9 Remove the bolts and nuts which secure the brake pedal and clutch pedal and remove the ped al assembly B INSTALLATION 1 Install in...

Page 2177: ...imately 10 N 1 kgf 2 lbf to check that the clutch pedal deflection is within the service limit If it exceeds the service limit replace with new bushings Deflection of the clutch pedal Service limit 4...

Page 2178: ...on the clutch switch side 6 Turn the push rod to lengthen until clutch pedal contacts the clutch switch 7 Turn further in the direction that will shorten the push rod arrow direction shown in figure b...

Page 2179: ...ases If the clutch fluid level increases the hydraulic clutch is properly adjusted If the fluid level does not increase or the push rod does not retract replace the master cylin der with a new part Re...

Page 2180: ...on adjust the stroke Ref to CL 24 ADJUSTMENT Clutch Pedal 3 Connect the clutch switch connector 2 CLUTCH SWITCH CLUTCH START 1 Fully depress the clutch and hold it 2 Install the clutch pedal plate and...

Page 2181: ...and check the clutch start circuit D ADJUSTMENT 1 Loosen the lock nut of clutch switch clutch start 2 Fully depress the clutch pedal and hold it 3 Adjust the gap of the clutch pedal plate and the clut...

Page 2182: ...drags As a symptom of this trouble a harsh scratching noise occurs and control becomes difficult when shifting gears The symptom becomes more apparent when shifting into the 1st gear However because m...

Page 2183: ...rrective action Insufficient pedal play Adjust the free play of the pedal Insufficient clutch pedal free play Adjust the free play of the pedal Excessively worn and damaged pedal shaft and or bushing...

Page 2184: ...Tolerance 12 mm 24 mm 0 47 in 0 94 in mm in 392 15 4 387 15 2 Camber Tolerance r0 45c Differences between RH and LH 45c or less 0 05c 0 10c Caster Referential Value 5 50c 5 55c Steering angle Toleranc...

Page 2185: ...neral Description FRONT SUSPENSION B COMPONENT 18 FS 00303 T1 T11 T6 T8 T8 T5 T9 T10 T9 T4 T2 T7 T4 16 26 17 19 20 1 21 22 23 24 26 9 10 11 12 13 15 26 26 26 T2 T7 26 14 29 T7 T7 T7 5 8 7 T3 3 4 25 27...

Page 2186: ...ncluding bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points 1 Front crossmember 15 Jack up plate 29 Flange nut 2 Housing 16 Dust seal 3 Ball joint 17 Strut...

Page 2187: ...ont arm front bushing 20299AG000 REMOVER Used for replacing front arm rear bushing Used together with BASE 20999AG010 20299AG010 BASE Used for replacing front arm rear bushing Used together with REMOV...

Page 2188: ...ring wheel alignment Alignment gauge adapter Used for measuring wheel alignment Turning radius gauge Used for measuring wheel alignment Toe in gauge Used for toe in measurement Dial gauge Used for dam...

Page 2189: ...suspension parts Check adjust and measure the wheel alignment in accordance with the procedures indicated in the figure Wheel arch height front and rear wheels Ref to FS 8 WHEEL ARCH HEIGHT INSPECTIO...

Page 2190: ...ine for 5 m 16 ft or more 4 Suspend a thread from the wheel arch point A in the figure below and affix at a position directly above the center of wheel 5 Measure the distance between the point A and t...

Page 2191: ...front lower section of the strut NOTE When the adjusting bolt needs to be loosened or tightened hold its head with a wrench and turn the flange nut 3 Turn the camber adjusting bolt so that the cam ber...

Page 2192: ...ts Tightening torque 155 N m 15 8 kgf m 114 3 ft lb To increase camber Rotate the left side counterclockwise Rotate the right side clockwise To decrease camber Rotate the left side clockwise Rotate th...

Page 2193: ...d to adjust the steering angle of both inner and outer wheels 2 Check the toe in NOTE Correct the boot if it is twisted 5 FRONT WHEEL TOE IN Inspection Toe in 0r3 mm 0r0 12 in 1 Set the toe in gauge i...

Page 2194: ...62 7 ft lb NOTE Check and correct the tie rod boot if twisted 6 REAR WHEEL TOE IN Inspection Toe in 0r3 mm 0r0 12 in Refer to FRONT WHEEL TOE IN for rear toe in in spection procedures Ref to FS 11 FR...

Page 2195: ...ocking nut Tightening torque 100 N m 10 2 kgf m 73 8 ft lb To increase toe in Rotate the left side clockwise Rotate the right side counterclockwise To decrease toe in Rotate the left side counterclock...

Page 2196: ...tion adjust the other rear wheel equally in toe out direction in order to make the thrust angle ad justment 3 When the left and right adjusting bolts are turned by one graduation the thrust angle will...

Page 2197: ...n the reverse order of removal NOTE Tighten the small type crossmember support plate together with stabilizer bracket After installing the stabilizer bracket to the cross member tighten the crossmembe...

Page 2198: ...N Be sure to use a new self locking nut Ensure the stabilizer bushing and stabilizer have the same identification colors Install the stabilizer bushing front cross member side while aligning it with t...

Page 2199: ...N m 5 1 kgf m 36 9 ft lb CAUTION Do not apply grease to the tapered portion of ball stud 2 Install the ball joint into front arm Tightening torque Castle nut 39 N m 4 0 kgf m 28 8 ft lb 3 Retighten th...

Page 2200: ...c tion shown in the figure measure the length 22 3 Determine free play using the following for mula S 22 21 4 Replace with a new part if the play exceeds specification Front ball joint Specification f...

Page 2201: ...ll the stud bolt ST 20299AG020 STUD BOLT SOCKET Tightening torque 110 N m 11 2 kgf m 81 1 ft lb 2 Using new bolts and self locking nuts temporari ly tighten the front arm to crossmember 3 Secure the f...

Page 2202: ...he ST and a press remove the rear bush ing ST1 20299AG000 REMOVER ST2 20299AG010 BASE D ASSEMBLY 1 FRONT BUSHING Assemble in the reverse order of disassembly 2 REAR BUSHING 1 Install the rear bushing...

Page 2203: ...ST and a press install the rear bush ing ST1 20299AG000 REMOVER ST2 20299AG010 BASE E INSPECTION 1 Check the front arm for damage or cracks and correct or replace if defective 2 Check the bushing for...

Page 2204: ...nstall the strut mount at the upper side of strut to body and tighten it with new self locking nuts Tightening torque 20 N m 2 0 kgf m 14 8 ft lb 2 Align alignment marks on the camber adjusting bolt a...

Page 2205: ...hat its end face seats well in the spring seat as shown in the figure 3 Install the helper and dust cover to the piston rod 4 Pull the piston rod fully upward and install the spring seat NOTE Position...

Page 2206: ...P2 0 8 mm 0 031 in If the play exceeds limit replace the strut 2 STRUT MOUNT Check the rubber part for deformation cracks or deterioration and then replace it with a new part if defective 3 DUST COVE...

Page 2207: ...l CAUTION Use a new bolt and self locking nut For parts which are not reusable refer to COMPONENT Ref to FS 3 COMPONENT General Descrip tion Always tighten the bushing in the state where the vehicle i...

Page 2208: ...h height Adjust or replace the coil springs with new parts 4 Fault in operation of strut or shock absorber Replace 5 Damage or deformation of strut mount or shock absorber mount Replace 6 Unsuitable l...

Page 2209: ...rear toe in and front camber can be adjusted Adjust if the toe in or camber tolerance exceeds specifications Other items indicated in the specifications table cannot be adjusted If other items exceed...

Page 2210: ...abilizer link 18 Adjusting bolt T5 70 7 1 51 6 7 Rear lateral link 19 Adjusting washer T6 80 8 2 59 8 Rear housing 20 Rear lateral link bushing T7 90 9 2 66 4 9 Upper arm 21 Flange nut T8 100 10 2 73...

Page 2211: ...Do not mix grease etc of different grades or manufac turers Before securing a part on a vise place cushioning material such as wood blocks aluminum plate or cloth between the part and the vise Be sure...

Page 2212: ...INSTALLER REMOVER Used for replacing the front lateral link bushing 499755602 PRESS Used for replacing the rear trailing link bushing 20099AE010 INSTALLER REMOVER Used for replacing the rear lateral...

Page 2213: ...OTECTOR Used for installing the rear drive shaft to the rear differential For oil seal protection 20099PA010 INSTALLER REMOVER Used for replacing the bushing of the rear housing Used together with BUS...

Page 2214: ...EMARKS Alignment tester Used for measuring wheel alignment Toe in gauge Used for toe in measurement Jack Used for removing and installing suspension Bearing puller Used for removing bushings Coil spri...

Page 2215: ...R SUSPENSION 2 Wheel Alignment A INSPECTION NOTE Measure and adjust the front and rear wheel align ment at a time Refer to FS section for measure ment and adjustment of wheel alignment Ref to FS 7 INS...

Page 2216: ...tate where the vehicle is at curb weight and the wheels are in full contact with the ground Align the paint mark end of stabilizer to the end of bushing when installing Install in the reverse order of...

Page 2217: ...nut Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground Install in the reverse order of removal Tightening torque 90 N m 9 2...

Page 2218: ...SHING REMOVER ST2 20099PA010 INSTALLER REMOVER BASE D ASSEMBLY 1 REAR TRAILING LINK BUSHING Using the ST A and ST B press fit the bushing ST A 8998741000 INSTALLER ST B 20299AG010 BASE CAUTION Make su...

Page 2219: ...hydraulic press ST1 20099FG000 BUSHING REMOVER ST2 20099PA010 INSTALLER REMOVER BASE CAUTION Make sure to press the bushing straight in E INSPECTION Visually check the trailing link for damage and de...

Page 2220: ...state where the vehicle is at curb weight and the wheels are in full contact with the ground 1 Install in the reverse order of removal 2 Inspect the wheel alignment and adjust if neces sary Tightenin...

Page 2221: ...scrip tion for the tightening torque Ref to RS 3 COMPONENT General Description 2 Check the wheel alignment and adjust it if nec essary C DISASSEMBLY Refer to Front Strut for disassembly procedure Ref...

Page 2222: ...e bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground 1 Install in the reverse order of removal Tightening torque Front lateral link Sub frame 1...

Page 2223: ...the ground 1 Install in the reverse order of removal Tightening torque Rear lateral link 120 N m 12 2 kgf m 88 5 ft lb Shock absorber 120 N m 12 2 kgf m 88 5 ft lb Stabilizer link 45 N m 4 6 kgf m 33...

Page 2224: ...6 Remove the rear parking brake cable from the parking brake assembly Ref to PB 6 REMOV AL Parking Brake Assembly Rear Disc Brake 7 Remove the rear hub unit bearing and suspend the rear brake from the...

Page 2225: ...b weight and the wheels are in full contact with the ground 1 Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion for the tightening torque Ref to RS 3...

Page 2226: ...ch height Adjust or replace the coil springs with new parts 4 Fault in operation of strut or shock absorber Replace 5 Damage or deformation of strut mount or shock absorber mount Replace 6 Unsuitable...

Page 2227: ...RS 20 General Diagnostic Table REAR SUSPENSION...

Page 2228: ...e Wheel size Offset mm in P C D mm in Tire inflation pressure kPa kgf cm2 psi Front wheel Rear wheel 2 5 i 2 5 i S P205 55R16 89V 16 61 2JJ 55 2 17 100 3 94 230 2 3 33 220 2 2 32 2 5 GT 2 5 GT S WRX S...

Page 2229: ...35 oz 28101AG032 12 5 g 0 44 oz 28101AG042 15 g 0 53 oz 28101AG052 17 5 g 0 62 oz 28101AG062 20 g 0 71 oz 28101AG072 22 5 g 0 79 oz 28101AG082 25 g 0 88 oz 28101AG092 27 5 g 0 97 oz 28101AG102 30 g 1...

Page 2230: ...ring control module 3 Transmitter Snap in type Tightening torque N m kgf m ft lb 4 Valve T1 1 4 0 14 1 2 Screw T2 7 5 0 76 5 5 WT 00131 1 T2 3 4 T1 2 TOOL NAME REMARKS Air pressure gauge Used for meas...

Page 2231: ...prevent damaging the transmitter set the tire changer boom in the position as shown in the figure 1 If large cracks on side wall damage or cracks on the tread is found 2 When the tread wear indicator...

Page 2232: ...e WHEEL AND TIRE SYSTEM NOTE Vehicles equipped with tire pressure monitoring systems will require re registration of transmitter ID Ref to TPM diag 10 REGISTER TRANS MITTER ID OPERATION Subaru Select...

Page 2233: ...10 2 kgf m 73 8 ft lb CAUTION Tighten the wheel nuts in two or three steps by gradually increasing the torque on opposing nuts until they reach the specified torque Do not push the wrench by foot Alwa...

Page 2234: ...7 REMOVAL Alumi num Wheel B INSTALLATION Refer to Aluminum Wheel for installation proce dure of steel wheels Ref to WT 7 INSTALLA TION Aluminum Wheel C INSPECTION Refer to Aluminum Wheel for inspecti...

Page 2235: ...59 oz 28101SA140 50 g 1 76 oz 55 g 1 94 oz 28101SA150 60 g 2 12 oz Balance weight part number Adhesive type weight for aluminum wheel Weight 28101AG002 5 g 0 18 oz 28101AG012 7 5 g 0 26 oz 28101AG022...

Page 2236: ...re is replaced or worn proper wheel balance may be lost Check the tire dynamic bal ance and repair if necessary 2 When checking the dynamic balance use the wheel balancer Insert the balance weights in...

Page 2237: ...ive the vehicle as slowly as possible and avoid bumps on the road B REPLACEMENT Refer to Removal Installation of Aluminum Wheel for removal and installation procedures of the T type tire Ref to WT 7 A...

Page 2238: ...hole and remove the cap by prying the remover to the tire side B INSTALLATION 1 Align the valve with the valve hole in the hubcap 2 Install the hubcap by tapping it in the order from 1 to 3 described...

Page 2239: ...ON 1 TRANSMITTER SNAP IN TYPE CAUTION Use the new transmitter assembly or replace the new valve and screw when installing 1 Replace the valve and screw with a new part when reusing transmitter Tighten...

Page 2240: ...monitoring control module Ref to TPM diag 10 REGISTER TRANSMITTER ID OPERATION Subaru Select Monitor 2 TIRE PRESSURE MONITORING CONTROL MODULE Install in the reverse order of removal Tightening torque...

Page 2241: ...nit bearing Ref to DS 25 INSPECTION Rear Hub Unit Bearing Vehicle is abnormally out of balance Improperly inflated tire Adjust the tire pressure Uneven wear Check the tire referring to Abnormal tire w...

Page 2242: ...ure Improper wheel balancing Check the wheel balance Ref to WT 9 ADJUSTMENT Wheel Bal ancing Front wheel alignment Check the front wheel alignment Ref to FS 7 INSPECTION Wheel Alignment Rear wheel ali...

Page 2243: ...IBLE INSPECTION Sub aru Select Monitor 4 Read the DTC Ref to TPM diag 16 OPERATION Read Diagnostic Trouble Code DTC Is DTC displayed Go to step 4 Go to step 3 3 PERFORM GENERAL DIAGNOSTICS 1 Perform t...

Page 2244: ...lower the air pressure in the tires will drop causing the tire pressure warning light to illuminate even if the pressure in the tires was adjusted to standard values indoors To avoid this it is necess...

Page 2245: ...TRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester Used for measuring resistance voltage and...

Page 2246: ...on TIRE PRESSURE MONITORING SYSTEM DIAGNOSTICS 3 Electrical Component Location A LOCATION 1 Tire pressure monitoring control module 2 Tire pressure warning light 3 Snap in type transmitter TPM00046 1...

Page 2247: ...Tire pressure warning light output Illuminate when malfunction occurs or tire pressure decreases System failure blinks 25 times o illuminates Tire pressure decreases turns on 4 Speed sensor signal Whi...

Page 2248: ...AGRAM 1 Battery power supply 4 Antenna 8 Vehicle speed signal 2 Ignition power supply 5 GND 9 Subaru Select Monitor 3 Tire pressure monitoring control module 6 Transmitter 10 Body integrated unit 7 Co...

Page 2249: ...gnosis display select Diagnostic Code s Display NOTE For details concerning the operation procedure refer to PC application help for Subaru Select Monitor For details concerning DTCs refer to List of...

Page 2250: ...fer to PC application help for Subaru Select Moni tor 1 Data monitor Analog Display Contents to be monitored Unit of measure Tire 1 FN code LEARN LOW BAT OFF WAKE RE ME NORMAL LEARN Transmitted trans...

Page 2251: ...s displayed select OK 7 Touch the transmitter registration tool to the side wall area near the air valve on the front left tire and press the switch The transmitter ID is sent to the tire pressure mon...

Page 2252: ...SYMPTOM Communication is impossible between the tire pressure monitoring control module and the Subaru Select Monitor WIRING DIAGRAM B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SBF 1 SBF 8 No 4 B40 R21...

Page 2253: ...A LINK CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the tire pressure monitoring control module 3 Measure the resistance between data link connector and chassis ground Connector terminal B...

Page 2254: ...GROUND 1 Turn the ignition switch to OFF 2 Disconnect the connector from the tire pres sure monitoring control module 3 Measure the resistance of harness between tire pressure monitoring control modu...

Page 2255: ...d No diagnostic Code Present is displayed on Subaru Select Monitor the system is operating properly WIRING DIAGRAM FB 36 F B FUSE NO 5 IG 2 6 i10 2 34 FB 17 F B FUSE NO 7 B i53 R98 R211 FB 48 F B FUSE...

Page 2256: ...Monitoring Sys tem Go to step 2 2 CHECK WIRING HARNESS Measure the resistance between tire pressure monitoring control module and combination meter connector Connector terminal i10 No 34 R211 No 2 Is...

Page 2257: ...c Trouble Code DTC TIRE PRESSURE MONITORING SYSTEM DIAGNOSTICS 6 Read Diagnostic Trouble Code DTC A OPERATION For details concerning DTC reading procedure re fer to Subaru Select Monitor Ref to TPM di...

Page 2258: ...on Mode TIRE PRESSURE MONITORING SYSTEM DIAGNOSTICS 7 Inspection Mode A PROCEDURE Reproduce the malfunction occurrence condition as much as possible Drive the vehicle at 40 km h 25 MPH or faster for a...

Page 2259: ...8 Clear Memory Mode TIRE PRESSURE MONITORING SYSTEM DIAGNOSTICS 8 Clear Memory Mode A OPERATION For details concerning DTC clear operation refer to Subaru Select Monitor Ref to TPM diag 8 Subaru Selec...

Page 2260: ...attern A INSPECTION 1 Ignition switch 8 Tire pressure warning light 14 Tire pressure warning light 2 OFF 9 Light OFF 15 Light OFF 3 ON 10 Light ON 16 Blink 4 Start 11 System status 17 1 second 5 Tire...

Page 2261: ...sure monitoring control module warning light circuit and the combination meter cir cuit Ref to TPM diag 22 TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF Tire Pressure Warning Light Trouble Indicator L...

Page 2262: ...to TPM diag 8 READ DIAGNOSTIC TROUBLE CODE DTC OPERATION Subaru Select Monitor Is diagnostics code DTC dis played Perform the diag nosis according to the DTC Ref to TPM diag 26 List of Diagnostic Trou...

Page 2263: ...ure warning light remains illuminating after engine starts WIRING DIAGRAM FB 36 F B FUSE NO 5 IG 2 6 i10 2 34 FB 17 F B FUSE NO 7 B i53 R98 R211 FB 48 F B FUSE NO 4 IG 16 5 9 R211 1 2 3 4 5 6 7 8 9 10...

Page 2264: ...2 2 CHECK TRANSMITTER ID Display the transmitter ID of the tire pressure monitor system Is the transmitter ID registered Go to step 3 Register the trans mitter ID Ref to TPM diag 10 REGISTER TRANSMITT...

Page 2265: ...e the engine starts tire pressure warning light blinks 25 times and then illuminates WIRING DIAGRAM FB 36 F B FUSE NO 5 IG 2 6 i10 2 34 FB 17 F B FUSE NO 7 B i53 R98 R211 FB 48 F B FUSE NO 4 IG 16 5 9...

Page 2266: ...form displayed in the oscilloscope of Subaru Select Monitor Is the pattern the same output waveform as shown in the fig ure 1 400r20 ms Duty 50 High Battery voltage Low 1 5 V or less Check the combi n...

Page 2267: ...iagnos tic Procedure with Diagnostic Trouble Code DTC 23 Transmitter 3 No Data Data cannot be received from transmit ter 3 Ref to TPM diag 29 DTC 23 TRANSMITTER 3 NO DATA Diagnos tic Procedure with Di...

Page 2268: ...BATTERY VOLT AGE DECREASE Diagnostic Proce dure with Diagnostic Trouble Code DTC 52 Transmitter 2 Battery Voltage Decrease Transmitter battery voltage is low Ref to TPM diag 35 DTC 52 TRANSMITTER 2 BA...

Page 2269: ...14 TIRE 4 AIR PRESSURE DE CREASE Diagnostic Procedure with Diagnostic Trouble Code DTC B DTC 12 TIRE 2 AIR PRESSURE DECREASE NOTE Refer to DTC 14 for diagnostic procedure Ref to TPM diag 29 DTC 14 TIR...

Page 2270: ...SMITTER 4 NO DATA Di agnostic Procedure with Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK TIRES Lift up the vehicle and check for damage in the tires Are there cracks or damage Replace the ti...

Page 2271: ...e the front right transmitter 4 CHECK FR TRANSMITTER ID Check the ID displayed in the updated ID dis play and the tire 2 registered ID Are the two IDs same Go to step 5 Record the received ID update a...

Page 2272: ...gnostic Procedure with Diagnostic Trouble Code DTC J DTC 32 TRANSMITTER 2 PRESSURE DATA ABNORMAL NOTE Refer to DTC 34 for diagnostic procedure Ref to TPM diag 32 DTC 34 TRANSMITTER 4 PRESSURE DATA ABN...

Page 2273: ...ace the front right transmitter 4 CHECK FR TRANSMITTER ID Check the ID displayed in the updated ID dis play and the tire 2 registered ID Are the two IDs same Go to step 5 Record the received ID update...

Page 2274: ...gnostic Procedure with Diagnostic Trouble Code DTC N DTC 42 TRANSMITTER 2 FUNCTION CODE ABNORMAL NOTE Refer to DTC 44 for diagnostic procedure Ref to TPM diag 34 DTC 44 TRANSMITTER 4 FUNCTION CODE ABN...

Page 2275: ...Check the ID displayed in the updated ID dis play and the tire 2 registered ID Are the two IDs same Go to step 5 Record the received ID update as the FR transmit ter Go to step 5 5 START RR TRANSMITT...

Page 2276: ...54 for diagnostic procedure Ref to TPM diag 35 DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE Diagnostic Procedure with Diagnostic Trouble Code DTC T DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE DTC D...

Page 2277: ...i10 2 31 R211 I F 9 R211 B301 B310 FB 36 F B FUSE NO 5 IG B301 4 5 6 7 8 9 16 17 18 19 20 2 3 1 21 22 23 24 25 26 10 11 13 14 12 15 B310 23 33 1 2 3 4 5 6 7 8 9 10 11 12 ABS VDC ABS VDC 12 14 15 16 1...

Page 2278: ...t that time Is the vehicle speed being input Replace the tire pressure monitor ing control module Ref to WT 13 TIRE PRESSURE MONITORING CONTROL MOD ULE REMOVAL Tire Pressure Monitoring Sys tem Go to s...

Page 2279: ...ht blinks 25 times and then illuminates Tire pressure monitoring system has malfunction Air pressure sensor malfunction Air pressure sensor is out of battery Tire pressure monitoring control module is...

Page 2280: ...turer has its base oil and addi tives Thus do not mix two or more brands Model 2 5 L Non turbo 4AT 5MT Rear differential type T type Identification T2 T1 Type of gear Hypoid gear Gear ratio Number of...

Page 2281: ...in 0 10 0 20 0 004 0 008 Hypoid driven gear runout on its back surface mm in 0 05 0 002 Preload adjusting spacer Part No Length mm in 383695201 56 2 2 213 383695202 56 4 2 220 383695203 56 6 2 228 383...

Page 2282: ...323 383595200 3 39 0 1335 383605200 3 42 0 1346 383615200 3 45 0 1358 383625200 3 48 0 1370 383635200 3 51 0 1382 383645200 3 54 0 1394 383655200 3 57 0 1406 383665200 3 60 0 1417 383675200 3 63 0 142...

Page 2283: ...oad adjusting washer 18 Side gear thrust washer 31 Gasket 6 Differential carrier 19 Side gear 7 Front bearing 20 Pinion mate gear Tightening torque N m kgf m ft lb 8 Spacer 21 Pinion mate gear washer...

Page 2284: ...1 Rear differential front member 5 Dynamic damper ASSY 5 door AT model Tightening torque N m kgf m ft lb 2 Rear differential member plate T1 50 5 1 36 9 3 Rear differential ASSY 6 Self locking nut T2...

Page 2285: ...onents are extremely hot after driv ing Be wary of receiving burns from heated parts Use SUBARU genuine gear oil grease Do not mix gear oil grease etc of different grades or manufacturers Be sure to t...

Page 2286: ...ed for installing the front and rear bearing cones 398477702 DRIFT Used for press fitting the bearing race front of the differential carrier 398217700 ATTACHMENT SET Stand for rear differential carrie...

Page 2287: ...ing and front bearing cone 399780104 WEIGHT Used for installing the front bearing cone and the pilot bearing companion flange 899580100 INSTALLER Used for press fitting the front bearing cone and pilo...

Page 2288: ...measuring backlash between side gear and pinion and hypoid gear Used together with the MAGNET BASE 498247001 398507704 BLOCK Used for adjusting pinion height and preload 398177700 INSTALLER Used for...

Page 2289: ...Used for installing the side oil seal 398507702 DUMMY SHAFT Used for adjusting pinion height and preload 398507703 DUMMY COLLAR Used for adjusting pinion height and preload 398517700 REPLACER Used fo...

Page 2290: ...sed for removing front oil seal Used for removing side bearing cup 28099PA090 OIL SEAL PROTECTOR Used for installing the rear drive shaft to the rear differential For oil seal protection 28099PA100 DR...

Page 2291: ...SY Used for removing the differential side bearing cone 398417700 DRIFT Used for installing side bearing race TOOL NAME REMARKS Transmission jack Used for assembly disassembly of the rear differential...

Page 2292: ...wary of receiving burns 3 Tighten the oil drain plug NOTE Apply liquid gasket to the drain plug Liquid gasket THREE BOND 1105 Part No 004403010 or equivalent Tightening torque 49 N m 5 0 kgf m 36 1 ft...

Page 2293: ...ssembly A NOTE 1 AT MODEL For front differential of automatic transmissions re fer to the 4AT section Ref to 4AT 98 Front Dif ferential Assembly 2 MT MODEL For front differential of the manual transmi...

Page 2294: ...uf fler Turbo model Ref to EX H4DOTC 14 REMOVAL Rear Ex haust Pipe Ref to EX H4DOTC 16 REMOV AL Muffler 10 Remove the heat shield cover 11 Remove the propeller shaft Ref to DS 10 REMOVAL Propeller Sha...

Page 2295: ...shaft to the rear cross member using wire 14 Remove the rear differential front member 15 Support the rear differential with the transmis sion jack 16 Remove the self lock nuts which hold the rear di...

Page 2296: ...g the rear differential stud bolt into the rear crossmember bushing lift up the transmis sion jack and align the rear differential to its attach ment position 5 Install the dynamic damper assembly 5 d...

Page 2297: ...fferential Gear Oil 16 Inspect the wheel alignment and adjust if nec essary C DISASSEMBLY To detect the real cause of trouble inspect the fol lowing items before disassembling Tooth contact and backla...

Page 2298: ...side bearing remove the bearing cup from the side retainer using ST ST 398527700 PULLER ASSY 8 Remove the bearing cone with ST NOTE Do not attempt to disassemble the parts unless necessary Set the pul...

Page 2299: ...together with rear bearing cone pinion height ad justing washer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT 15 Remove the rear bearing cone from drive pin ion by sup...

Page 2300: ...eplace the oil seal with a new part at every dis assembly Be careful not to mix up the oil seal RH and LH Apply differential gear oil to the lips when install ing the oil seal 1 Adjusting preload for...

Page 2301: ...ar ing and tighten the self locking nut while mea suring the initial load or initial torque with a spring scale or torque wrench Select the pre load adjusting washer and spacer so that the specified p...

Page 2302: ...ge NOTE Make sure there is no clearance between 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 10...

Page 2303: ...r and washer 5 Press fit the front bearing cone into case with ST1 ST2 and ST3 ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER T Thickness of pinion height adjusting washer mm...

Page 2304: ...careful not to damage the bearing ST1 899874100 INSTALLER ST2 399780104 WEIGHT 9 Apply seal material on the drive pinion shaft thread and new self locking nut seat Seal material THREE BOND 1324 Part N...

Page 2305: ...gear tooth surfaces and thrust washer surfaces 4 After inserting the pinion shaft lock pin into differential case stake the both sides of the hole to prevent pin from falling off 13 Install the driven...

Page 2306: ...ng torque 10 5 N m 1 1 kgf m 7 7 ft lb 6 Measure the hypoid driven gear to drive pin ion backlash Set the magnet base on differen tial carrier Align the contact point of dial gauge with tooth face of...

Page 2307: ...eds the specification check for any for eign material between the hypoid driven gear and differential case and for any deformation of the case or gear Hypoid driven gear back surface runout 0 05 mm 0...

Page 2308: ...bringing drive pinion away from hypoid driven gear Toe contact inside contact Check item Teeth contact area is too small Contact pattern Corrective action Reduce the thickness of pin ion height adjus...

Page 2309: ...the RH and LH side retainers 22 Install new O rings to the side retainers on both sides 23 Install the oil seal to the side retainer of both sides Ref to DI 37 REPLACEMENT Rear Dif ferential Side Oil...

Page 2310: ...Replace if seizure peeling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washer of the side gear and pinion mate gear Replace if seized flawed abnormally worn...

Page 2311: ...adjust the side retainer shim 6 COMPANION FLANGE 1 If rust or dirt is attached to the companion flange remove them 2 Set a dial gauge at a companion flange surface mating surface of propeller shaft a...

Page 2312: ...VEN GEAR BACKLASH Adjust hypoid driven gear backlash Ref to DI 22 ASSEMBLY Rear Differential 3 TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION Adjust the tooth contact between hypoid driven...

Page 2313: ...1105 Part No 004403010 or equivalent Tightening torque 49 N m 5 0 kgf m 36 1 ft lb 7 Remove the rear exhaust pipe and muffler Non turbo model Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe Ref to EX H4S...

Page 2314: ...ue as that before re placing the oil seal ST 498427200 FLANGE WRENCH NOTE Use a new self locking nut Before installing the self locking nut apply seal material to self locking nut threads Seal materia...

Page 2315: ...oil seal B REPLACEMENT 1 Remove the rear differential Ref to DI 16 RE MOVAL Rear Differential 2 Remove the rear differential side oil seal using ST ST 398527700 PULLER ASSY 3 Using the ST install the...

Page 2316: ...ll the rear differ ential front member Tightening torque T1 50 N m 5 1 kgf m 36 9 ft lb T2 110 N m 11 2 kgf m 81 1 ft lb C INSPECTION 1 Check the rear differential front member for damage bend and cor...

Page 2317: ...the specified level 3 Damage NOTE Damaged parts should be replaced and also other parts should be thoroughly checked for any defect and should be re paired or replaced as required 1 Improper backlash...

Page 2318: ...ble When listening to noises shift the gear into four wheel drive and fourth speed po sition trying to pick up only differential noise 1 Improper tooth contact of hypoid gear Readjust or replace hypoi...

Page 2319: ...2 General Description TRANSFER CASE 1 General Description A NOTE For general description refer to 4AT or 5MT section 4AT model Ref to 4AT 2 General Description 5MT model Ref to 5MT 2 General Descripti...

Page 2320: ...se and Extension Case Assembly TRANSFER CASE 2 Transfer Case and Extension Case Assembly A NOTE For removal installation and inspection refer to the 5MT section Ref to 5MT 36 Transfer Case and Extensi...

Page 2321: ...TC 4 Transfer Clutch TRANSFER CASE 3 Transfer Clutch A NOTE For removal installation and inspection refer to the 4AT section Ref to 4AT 73 Transfer Clutch...

Page 2322: ...TC 5 Extension Case TRANSFER CASE 4 Extension Case A NOTE For removal installation and inspection refer to the 4AT section Ref to 4AT 71 Extension Case...

Page 2323: ...removal installation and inspection refer to the 4AT or 5MT section 4AT model Ref to 4AT 46 Extension Case Oil Seal Ref to 4AT 47 Differential Side Retainer Oil Seal 5MT model Ref to 5MT 31 Oil Seal R...

Page 2324: ...TC 7 Transfer Drive Gear TRANSFER CASE 6 Transfer Drive Gear A NOTE For removal installation and inspection refer to the 5MT section Ref to 5MT 40 Transfer Drive Gear...

Page 2325: ...TC 8 Transfer Driven Gear TRANSFER CASE 7 Transfer Driven Gear A NOTE For removal installation and inspection refer to the 5MT section Ref to 5MT 42 Transfer Driven Gear...

Page 2326: ...TC 9 Reduction Drive Gear TRANSFER CASE 8 Reduction Drive Gear A NOTE For removal installation and inspection refer to the 4AT section Ref to 4AT 80 Reduction Drive Gear...

Page 2327: ...TC 10 Reduction Driven Gear TRANSFER CASE 9 Reduction Driven Gear A NOTE For removal installation and inspection refer to the 4AT section Ref to 4AT 78 Reduction Driven Gear...

Page 2328: ...TC 11 Center Differential TRANSFER CASE 10 Center Differential A NOTE For removal installation and inspection refer to the 5MT section Ref to 5MT 44 Center Differen tial...

Page 2329: ...TC 12 Transfer Clutch Pressure Test TRANSFER CASE 11 Transfer Clutch Pressure Test A NOTE For inspection refer to the 4AT section Ref to 4AT 35 Transfer Clutch Pressure Test...

Page 2330: ...PROPELLER SHAFT Model All models Propeller shaft type EDJ Front propeller shaft Joint to joint length L1 mm in AT 735 5 28 96 MT 675 5 26 59 Rear propeller shaft Joint to Joint length L2 mm in 698 27...

Page 2331: ...Model Type of drive shaft Axle diameterI D mm in Axle length L mm in All models AC AAR 26 1 02 335 2 13 20 A Axle diameter B Axle length Model Type of drive shaft Axle diameterI D mm in Axle length L...

Page 2332: ...General Description DRIVE SHAFT SYSTEM B COMPONENT 1 PROPELLER SHAFT 1 Propeller shaft 3 Bushing Tightening torque N m kgf m ft lb 2 Rear differential T1 31 3 2 22 9 T2 52 5 3 38 4 DS 00368 3 3 T2 1...

Page 2333: ...t AAR 13 Axle nut 2 Baffle plate 8 Boot AC 3 Outer race AAR 9 AC shaft ASSY Tightening torque N m kgf m ft lb 4 Snap ring 10 Housing T1 220 22 4 162 3 5 Trunnion 11 Hub bolt T2 65 6 6 47 9 6 Boot band...

Page 2334: ...using 2 Outer race DOJ 9 Boot DOJ 16 Bushing 3 Snap ring 10 Boot BJ 4 Inner race 11 EBJ shaft ASSY Tightening torque N m kgf m ft lb 5 Ball 12 Rear hub unit bearing T1 65 6 6 47 9 6 Cage 13 Hub bolt T...

Page 2335: ...y and replacement Vehicle components are extremely hot after driv ing Be wary of receiving burns from heated parts Use SUBARU genuine grease etc or equivalent Do not mix grease etc of different grades...

Page 2336: ...ot band A Jig for the band B Ratchet wrench 926470000 AXLE SHAFT PULLER Used for removing the axle shaft Used together with AXLE SHAFT PULLER PLATE 28099PA110 18675AA000 DIFFERENTIAL SIDE OIL SEAL INS...

Page 2337: ...010 OIL SEAL PROTECTOR Used for installing front drive shaft into front differential For protecting the oil seal 28399AG000 HUB STAND Used for extracting hub bolt TOOL NAME REMARKS Puller Used for rem...

Page 2338: ...hicle 5 Remove the center exhaust pipe 6 Remove the rear exhaust pipe and muffler 7 Remove the heat shield cover 8 Make alignment marks on the flange yoke and rear differential before removal 9 Remove...

Page 2339: ...and replace if necessary Dents or cracks on the tube surface Splines for deformation or abnormal wear Unsmooth joint operation or abnormal noise Center bearing for free play noise or non smooth opera...

Page 2340: ...haft tube 5 Turn the propeller shaft slowly by hands to check for runout of the propeller shaft Runout Limit 0 6 mm 0 024 in 4 CENTER BEARING FREE PLAY 1 Remove the front and center exhaust pipes 2 Re...

Page 2341: ...brake caliper from the housing and suspend it from strut using a wire 7 Remove the disc rotor from the hub NOTE If it is difficult to remove the disc rotor from the hub drive the 8 mm bolt into the t...

Page 2342: ...6 IN STALLATION Front Drive Shaft 3 Install the front arm ball joint to the housing Tightening torque 50 N m 5 1 kgf m 36 9 ft lb 4 Install the ABS sensor harness to the strut 5 Install the ABS wheel...

Page 2343: ...tening the axle nut lock it securely 13 Install the wheel Tightening torque 100 N m 10 2 kgf m 73 8 ft lb 14 Connect the ground cable to battery 15 Inspect the wheel alignment and adjust if nec essary...

Page 2344: ...er the tool which charged magnetism to magnetic encoder Be careful not to damage the magnetic en coder E INSPECTION 1 Moving the front tire up and down by hand check there is no play in bearing and ch...

Page 2345: ...he housing and suspend it from strut using a wire 6 Remove the disc rotor from the hub NOTE If it is difficult to remove the disc rotor from the hub drive the 8 mm bolt into the threaded end of rotor...

Page 2346: ...nuts as this may dam age the axle bearing 7 After tightening the axle nut lock it securely 8 Install the wheel Tightening torque 100 N m 10 2 kgf m 73 8 ft lb C DISASSEMBLY Using the ST and a hydrauli...

Page 2347: ...rake hose bracket and the rear ABS wheel speed sensor Disc brake model Drum brake model 6 Remove the disc brake caliper from the rear housing and suspend it from the vehicle using a string Disc brake...

Page 2348: ...ear brake from the shock absorb er Drum brake model 12 Remove the snap pin and nut from the front lat eral link 13 Using a puller separate the rear housing and ball joint 14 Separate the upper arm tra...

Page 2349: ...lb 7 Install the rear disc rotor Disc brake model 8 Install the brake drum Drum brake model 9 Install the rear disc brake caliper on the rear housing Disc brake model Tightening torque 66 N m 6 7 kgf...

Page 2350: ...LY Rear Trailing Link D ASSEMBLY 1 REAR HUB UNIT BEARING Assemble in the reverse order of disassembly Tightening torque Rear hub unit bearing 65 N m 6 6 kgf m 47 9 ft lb 2 BUSHING For the installation...

Page 2351: ...he disc brake caliper from the rear housing and suspend it from the vehicle using a string Disc brake model 6 Remove the rear disc rotor Disc brake model 7 Remove the brake drum Drum brake model 8 Rem...

Page 2352: ...m 48 7 ft lb 7 While pressing the brake pedal tighten the new axle nuts to the specified torque Tightening torque 190 N m 19 4 kgf m 140 1 ft lb CAUTION Do not install wheel and let it touch the grou...

Page 2353: ...12 mm 0 47 in dia holes in the HUB STAND to prevent bolts from tilting E INSPECTION 1 Moving the rear tire up and down by hand check there is no backlash in bearing and check the wheel rotates smooth...

Page 2354: ...a bar remove the front drive shaft from transmission CAUTION Be careful not to allow the bar to damage holder area B INSTALLATION 1 Replace the differential side retainer oil seal with a new part NOTE...

Page 2355: ...and adjust if nec essary C DISASSEMBLY 1 Place alignment marks on the shaft and outer race 2 Remove the AAR boot band and boot CAUTION Be careful not to damage the boot 3 Place the drive shaft between...

Page 2356: ...nt marks and install the trunnion on the shaft Install the snap ring into the shaft groove securely 3 Fill 50 to 60 g 1 76 to 2 12 oz of specified grease into the interior of AAR outer race 4 Apply a...

Page 2357: ...rimped section of the boot band Large boot band 1 mm 0 04 in or less Small boot band 1 mm 0 04 in or less 12 Extend and retract the AAR repeatedly to pro vide an equal coating of grease E INSPECTION C...

Page 2358: ...5 Drain the differential gear oil 6 Remove the rear trailing link Ref to RS 10 REMOVAL Rear Trailing Link 7 Remove the rear lateral link Ref to RS 16 RE MOVAL Rear Lateral Link 8 Remove the rear drive...

Page 2359: ...d tighten them to the specified torque Tightening torque Stabilizer link 45 N m 4 6 kgf m 33 2 ft lb Shock absorber 120 N m 12 2 kgf m 88 5 ft lb Rear lateral link 120 N m 12 2 kgf m 88 5 ft lb Traili...

Page 2360: ...The grease is a special grease grease for con stant velocity joints Do not mix with other greases NOTE Disassemble exercising care not to lose balls 6 pcs 7 To remove the cage from inner race turn th...

Page 2361: ...ith pliers NOTE Confirm that the snap ring is completely fitted in the shaft groove 5 Install the cage to inner race fixed upon shaft NOTE Fit the cage with the protruding section aligned with the tra...

Page 2362: ...g boot use care so that the air with in the boot is appropriate 15 Tighten the band using the ST ST 925091000 BAND TIGHTENING TOOL NOTE Tighten the band until it cannot be moved by hand 16 Tap the cli...

Page 2363: ...o FS 7 INSPECTION Wheel Alignment Rear wheel alignment Check the rear wheel alignment Ref to RS 8 INSPECTION Wheel Alignment Front strut Check the front strut Ref to FS 24 INSPEC TION Front Strut Rear...

Page 2364: ...DS 36 General Diagnostic Table DRIVE SHAFT SYSTEM...

Page 2365: ...ABS wheel speed sensor ABS wheel speed sensor gap for reference Front 0 77 1 43 mm 0 030 0 056 in Rear 0 64 1 56 mm 0 025 0 061 in Identifications of harness marks color Front RH K1 White LH K2 Yello...

Page 2366: ...SPEED SENSOR G SENSOR 1 G sensor 4 Rear ABS wheel speed sensor LH Tightening torque N m kgf m ft lb 2 Front ABS wheel speed sensor LH 5 Hub unit bearing T1 7 5 0 76 5 5 3 Front housing 6 Magnetic enco...

Page 2367: ...d unnecessary re moval installation disassembly and replacement Vehicle components are extremely hot after driv ing Be wary of receiving burns from heated parts Be sure to tighten fasteners including...

Page 2368: ...1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester Used for measuring resistance voltage and current Pressure gauge Used for measuri...

Page 2369: ...ash it off immediately with water and wipe clean 7 Loosen the nuts and remove the ABSCM H U CAUTION Do not drop or bump the ABSCM H U Do not turn the ABSCM H U upside down or place it sideways for sto...

Page 2370: ...d on the pressure gauge and check if the fluctuation of the values between decompression and compression meets the stan dard values Depress the brake pedal and check that the kick back is normal and t...

Page 2371: ...he inspection depress the brake pedal and check that it is not abnormally hard and tight ness is normal D REPLACEMENT CAUTION Because the seal of the ABSCM cannot be re placed do not pull or peel it b...

Page 2372: ...l do not attempt repair by filing or with a metal scraper To remove the seal residue always use a plastic scraper Do not use chemical such as paint thinner etc to clean 7 Position the coil of the new...

Page 2373: ...r under the driver s side instrument panel lower cover 2 Turn the ignition switch to ON 3 Run the PC application for Subaru Select Mon itor 4 Set the Subaru Select Monitor to Brake Control mode 5 When...

Page 2374: ...SEQUENCE CONTROL ABS00943 1 2 3 4 5 6 7 8 9 10 11 12 13 14 24 25 28 27 26 V max 4 km h 2 5 MPH OFF 16 17 OFF ON OFF ON OFF ON 21 18 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON 15 19 18...

Page 2375: ...After completion of ABS sequence control 4 When a malfunction is detected 1 All wheel speed 11 RR compression valve 20 0 6 seconds 2 Ignition key 12 RL decompression valve 21 0 4 seconds 3 ABS warnin...

Page 2376: ...careful not to damage the sensor NOTE Check the identification mark on the harness to make sure there is no warpage RH K1 White LH K2 Yellow Check if the harness is not pulled and does not come in co...

Page 2377: ...er supply to No 2 terminal of sensor connector as shown in the figure then at tach resistance to the No 1 terminal Rotate the wheel at about 2 75 km h 2 MPH and measure the voltage using an oscillosco...

Page 2378: ...ar axle CAUTION Be careful not to damage the sensor Do not apply excessive force to the sensor harness B INSTALLATION Install in the reverse order of removal CAUTION Be careful not to damage the senso...

Page 2379: ...Front Hub Bearing for installation be cause the front magnetic encoder is integrated with front hub bearing Ref to DS 18 INSTALLATION Front Hub Unit Bearing C INSPECTION Visually check the magnetic en...

Page 2380: ...ar Hub Unit Bearing for installation because the rear magnetic encoder is integrated with rear hub unit bearing Ref to DS 24 INSTALLATION Rear Hub Unit Bearing C INSPECTION Visually check the magnetic...

Page 2381: ...to data link connector 3 Set the Subaru Select Monitor to the Brake Control System mode 4 Set the display in the Current Data Display Save mode 5 Read the G sensor output value Is the value 1 2 1 2 m...

Page 2382: ...aru Select Monitor 4 Read the DTC using Subaru Select Monitor Ref to ABS diag 19 OPERATION Read Diagnostic Trouble Code DTC Is DTC displayed on the Subaru Select Monitor Record the DTCs and Informatio...

Page 2383: ...C ON before starting engine START ON after starting engine engine is running ON after starting engine engine is at a standstill Timing Immediately after turning the ignition ON Immediately after turni...

Page 2384: ...ore starting engine START ON after starting engine engine is running ON after starting engine engine is at a standstill Timing Immediately after turning the ignition ON Immediately after turning the i...

Page 2385: ...cannot be obtained or the steering does not respond when applying brakes Yes No When When turning to the right When turning to the left When spinning out Others b Directional stability cannot be obta...

Page 2386: ...rs Condition a Brakes Deceleration G Intermittent Temporary b Accelerator Acceleration G Intermittent Temporary c Vehicle speed km h MPH Advancing While accelerating While decelerating At low speed Wh...

Page 2387: ...ck the hydraulic unit When using the brake tester Ref to ABS 8 CHECKING THE HYDRAULIC UNIT ABS OPERA TION WITH THE BRAKE TESTER INSPECTION ABS Control Module and Hydraulic Control Unit ABSCM H U When...

Page 2388: ...trol unit ABSCM H U 4 ABS warning light 9 G sensor 5 Brake and EBD warning light 10 Transmission control module TCM AT model 2 Two way connector 6 Caliper body 3 Data link connector For Subaru Select...

Page 2389: ...ABS diag 9 Electrical Component Location ABS DIAGNOSTICS ABS00405 1 ABS01036 4 5 ABS01037 3 ABS00408 8 7 7 FRONT 8 7 7 ABS00407 REAR 9 ABS00599...

Page 2390: ...ATION NOTE Terminal numbers in ABSCM H U connector are shown in the figure ABS warning light illuminates when the connector is removed from ABSCM H U 1 ABS control module and hydraulic control unit AB...

Page 2391: ...veform Rear RH wheel Power supply 3 15 4 5 16 5 V Signal 4 5 9 16 8 mA Rectangle waveform CAN communication line 26 2 5 1 5 V pulse signal CAN communication line 11 3 5 2 5 V pulse signal Valve relay...

Page 2392: ...ission control module TCM 27 Front ABS wheel speed sensor LH 5 Valve relay 28 Front ABS wheel speed sensor RH 6 Motor relay 17 Engine control module ECM 7 Motor 18 Body integrated unit 29 Rear ABS whe...

Page 2393: ...was used to install the Subaru Select Monitor 4 Connect the diagnosis cable to SDI 5 Connect SDI to data link connector located in the lower portion of the instrument panel on the driv er s side CAUTI...

Page 2394: ...r LH is displayed km h or MPH RR Wheel Speed Wheel speed detected by rear ABS wheel speed sensor RH is displayed km h or MPH RL Wheel Speed Wheel speed detected by rear ABS wheel speed sensor LH is di...

Page 2395: ...eed sensor RH is displayed in km h or MPH FL Wheel Speed Wheel speed detected by front ABS wheel speed sensor LH is displayed in km h or MPH RR Wheel Speed Wheel speed detected by rear ABS wheel speed...

Page 2396: ...LE SYMPTOM Communication is impossible between ABS and Subaru Select Monitor WIRING DIAGRAM MAIN SBF SBF 6 No 33 B40 B301 E E 16 7 7 15 18 ABS01039 B301 B40 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 2...

Page 2397: ...n switch to OFF 2 Disconnect the ABSCM H U ECM and TCM 3 Measure the resistance between data link connector and chassis ground Connector terminal B40 No 7 Chassis ground Is the resistance 1 M or more...

Page 2398: ...ground Connector terminal B301 No 15 Chassis ground Is the resistance less than 0 5 Go to step 12 Repair the open circuit and poor contact of the har ness between ABSCM H U and connector 12 CHECK POO...

Page 2399: ...op in ABSCM H U power supply etc the DTC suffixed with a question mark is displayed on Subaru Se lect Monitor display screen This shows it may be an unreliable reading If No diagnostic Code Present is...

Page 2400: ...0 Inspection Mode ABS DIAGNOSTICS 8 Inspection Mode A PROCEDURE Reproduce the malfunction occurrence condition as much as possible Drive the vehicle at a speed of 40 km h 25 MPH or more for at least o...

Page 2401: ...tem 3 Click the OK button after the ABS is dis played 4 On Brake Control Diagnosis display select Clearing Memory 5 When the Clear Memory is shown on the screen click the YES button 6 When Done and Tu...

Page 2402: ...arning Light Brake Warning Light Il lumination Pattern 3 When ABS warning light does not go off check the combination meter circuit Ref to ABS diag 23 ABS WARNING LIGHT DOES NOT GO OFF ABS Warning Lig...

Page 2403: ...d Diagnostic Trouble Code DTC Is DTC displayed Perform the diag nosis according to DTC Go to step 3 3 CHECK LAN SYSTEM Perform the diagnosis for LAN system Ref to LAN diag 31 OPERATION Read Diagnostic...

Page 2404: ...13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 1 2 B99 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 i84 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 2405: ...r terminal i10 No 8 Chassis ground Is the resistance 1 M or more Go to step 6 Repair the harness between combina tion meter and brake fluid level switch 6 CHECK PARKING BRAKE SWITCH 1 Disconnect the c...

Page 2406: ...0105 ABS wheel speed sensor malfunction ABS wheel speed sensor abnormal signal Abnormal signal of rear ABS wheel speed sensor RH Rear Right ABS Sen sor Signal Ref to ABS diag 32 DTC C0105 REAR ABS WHE...

Page 2407: ...n in hydraulic unit Front inlet valve LH FL Hold Valve mal function Ref to ABS diag 38 DTC C0120 FRONT INLET SOLENOID VALVE LH MALFUNC TION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U D...

Page 2408: ...126 REAR INLET SOLENOID VALVE RH MALFUNC TION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U Diagnostic Procedure with Diagnostic Trouble Code DTC C0127 Outlet valve malfunction in hydraul...

Page 2409: ...Trouble Code DTC B DTC C0102 ABS WHEEL SPEED SENSOR MALFUNCTION RL SENSOR BROKEN WIRE INPUT VOLTAGE TOO HIGH NOTE Refer to DTC C0104 for diagnostic procedure Ref to ABS diag 30 DTC C0104 ABS WHEEL SPE...

Page 2410: ...WIRING DIAGRAM ABS01041 4 3 1 16 17 2 15 R72 E R73 B6 B15 1 2 6 5 B301 2 1 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 2 1 2 1 B98 R2 B99 R3 2 4 1 3 R73 R72 B15 B6 B98 B...

Page 2411: ...o 2 B301 No 1 B15 No 1 Is the resistance less than 0 5 Go to step 3 Repair the harness connectorbetween ABSCM H U and ABS wheel speed sensor 3 CHECK GROUND SHORT OF HARNESS Measure the resistance betw...

Page 2412: ...SCM H U POWER SUPPLY CIRCUIT 1 Turn the ignition switch to OFF 2 Disconnect the ABSCM H U connectors 3 Turn the ignition switch to ON 4 Measure the voltage between ABSCM H U connector and chassis grou...

Page 2413: ...WIRING DIAGRAM ABS01041 4 3 1 16 17 2 15 R72 E R73 B6 B15 1 2 6 5 B301 2 1 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 2 1 2 1 B98 R2 B99 R3 2 4 1 3 R73 R72 B15 B6 B98 B...

Page 2414: ...ACEMENT ABS Control Mod ule and Hydraulic Control Unit ABSCM H U Go to step 6 6 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check DTC using List of Diagnostic Trouble Code DTC Ref to...

Page 2415: ...0 Inspection Mode 4 Read the DTC Is the same DTC displayed Replace the ABSCMonly Ref to ABS 8 REPLACEMENT ABS Control Mod ule and Hydraulic Control Unit ABSCM H U Go to step 13 13 CHECK FOR ANY OTHER...

Page 2416: ...ke warning light comes on as well as the ABS warning light WIRING DIAGRAM ABS01041 4 3 1 16 17 2 15 R72 E R73 B6 B15 1 2 6 5 B301 2 1 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 1...

Page 2417: ...m 5 5 ft lb For four wheels Go to step 6 Tighten the ABS wheel speed sen sor installation bolts 6 CHECK ABS WHEEL SPEED SENSOR SIG NAL 1 Install the ABS wheel speed sensor 2 Prepare an oscilloscope 3...

Page 2418: ...ULIC CONTROL UNIT ABSCM H U Diagnostic Procedure with Diagnostic Trouble Code DTC L DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U NOTE R...

Page 2419: ...TC DETECTING CONDITION Faulty harness connectors Defective inlet solenoid valve in ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE Brake warning light comes on as well as the...

Page 2420: ...th Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK INPUT VOLTAGE OF ABSCM H U 1 Turn the ignition switch to OFF 2 Disconnect the ABSCM H U connectors 3 Run the engine at idle 4 Measure the volta...

Page 2421: ...TC DETECTING CONDITION Faulty harness connectors Defective outlet solenoid valve in ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE Brake warning light comes on as well as the...

Page 2422: ...terminal B301 No 15 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the ABSCM H U ground harness 3 CHECK POOR CONTACT OF CONNECTOR Is there poor contact of connec tor between gener...

Page 2423: ...MODULE MALFUNCTION DTC DETECTING CONDITION Defective ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE Brake warning light comes on as well as the ABS warning light WIRING DIAGR...

Page 2424: ...electronic components installed correctly Go to step 4 Install the radio wave devices and electronic compo nents properly 4 CHECK CAUSE OF SIGNAL NOISE Is there a noise source such as an antenna inst...

Page 2425: ...or too high TROUBLE SYMPTOM ABS does not operate EBD may not operate NOTE If EBD does not operate the brake warning light illuminates in addition to ABS warning light Both warning lights go off if vo...

Page 2426: ...ound Is the voltage 10 15 V Go to step 4 Repair the ABSCM H U power circuit 4 CHECK THE ABSCM H U GROUND CIR CUIT 1 Turn the ignition switch to OFF 2 Measure the resistance between the ABSCM H U conne...

Page 2427: ...OUBLE SYMPTOM Possibly the vehicle speed cannot output on CAN Step Check Yes No 1 CHECK LAN SYSTEM Perform the diagnosis for LAN system Ref to LAN diag 31 OPERATION Read Diagnostic Trouble Code DTC Is...

Page 2428: ...pending on the trouble contents NOTE Brake warning light comes on as well as ABS warning light when EBD does not operate WIRING DIAGRAM B301 B301 E 14 15 ABSCM H U 18 M FL INLET MAIN SBF SBF 6 No 1 No...

Page 2429: ...arness 3 CHECK VALVE RELAY IN ABSCM H U Measure the resistance between the ABSCM H U terminals Terminals No 14 No 15 Is the resistance 1 M or more Go to step 4 Replace the ABSCMonly Ref to ABS 8 REPLA...

Page 2430: ...relay Faulty harness connectors TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM B301 E E 13 15 12 ABSCM H U 18 M MAIN SBF SBF 6 No 33 E SBF 1 FL INLET FR INLET RL INLET RR INLET FL OUTLET FR OUTL...

Page 2431: ...tage 10 15 V Go to step 5 Repair the harness connectorbetween battery ignition switch and ABSCM H U 5 CHECK THE ABSCM H U GROUND CIR CUIT 1 Turn the ignition switch to OFF 2 Measure the resistance bet...

Page 2432: ...1 5 3 8 B159 B301 B65 7 5A B225 2 1 B225 B434 B159 R168 R168 B99 B99 R3 B99 R3 B435 2 2 1 2 3 4 1 2 3 4 5 B434 B435 3 1 1 2 2 5Dr 5Dr 5Dr 5Dr 4Dr 4 DOOR MODEL B65 4Dr 9 15 7 4Dr 4Dr 6 7 1 2 3 4 1 2 3...

Page 2433: ...PEN CIRCUIT IN HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the ABSCM H U connectors 3 Depress the brake pedal 4 Measure the voltage between ABSCM H U connector and chassis ground Connector...

Page 2434: ...C C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION DTC DETECTING CONDITION Defective G sensor TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00808 ABSCM H U B301 B301 10 24 21 15 B292 ABS G SENSOR E...

Page 2435: ...e the console box 3 Remove the G sensor from vehicle Do not disconnect the connector 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor connector terminals Connector terminal B292...

Page 2436: ...8 G Sensor 11 CHECK POOR CONTACT OF CONNECTOR Turn the ignition switch to OFF Is there poor contact of connec tors between ABSCM H U and G sensor Repair the connec tor Go to step 12 12 CHECK ABSCM H U...

Page 2437: ...TC C0119 G SENSOR OUTPUT SIGNAL MALFUNCTION DTC DETECTING CONDITION Defective G sensor TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00808 ABSCM H U B301 B301 10 24 21 15 B292 ABS G SENSOR E...

Page 2438: ...ackward to 90 Go to step 5 Replace G sensor Ref to ABS 18 G Sensor 5 CHECK POOR CONTACT OF CONNECTOR Turn the ignition switch to OFF Is there poor contact of connec tors between ABSCM H U and G sensor...

Page 2439: ...Go to step 12 Replace G sensor Ref to ABS 18 G Sensor 12 CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector terminal B292 No 2 No 3 Is the voltage 0 5 1 0 V when G sen...

Page 2440: ...ABS wheel speed sensor Master cylinder Brake caliper and piston Parking brake Axle and wheels Brake pedal play Long brake pedal stroke Air in brake line Brake pedal play Vehicle vertical pitching Sus...

Page 2441: ...identification ABS wheel speed sensor ABS wheel speed sensor gap for reference Front 0 77 1 43 mm 0 030 0 056 in Rear 0 64 1 56 mm 0 025 0 061 in Identifications of harness marks color Front RH K1 Wh...

Page 2442: ...VDC B COMPONENT 1 ABS WHEEL SPEED SENSOR 1 Front ABS wheel speed sensor 4 Hub unit bearing Tightening torque N m kgf m ft lb 2 Front housing 5 Magnetic encoder T1 7 5 0 76 5 5 3 Rear ABS wheel speed s...

Page 2443: ...escription VEHICLE DYNAMICS CONTROL VDC 2 YAW RATE G SENSOR 3 STEERING ANGLE SENSOR 1 Yaw rate G sensor 2 Bracket Tightening torque N m kgf m ft lb T 7 5 0 76 5 5 VDC00447 1 2 T T 1 Steering angle sen...

Page 2444: ...m the battery Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Vehicle components are extremely hot after d...

Page 2445: ...IPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester Used for measuring resistance voltage and current Pressure gauge U...

Page 2446: ...and remove the VDCCM H U CAUTION Do not drop or bump the VDCCM H U Do not turn the VDCCM H U upside down or place it sideways during storage Be careful not to let foreign matter enter the VDCCM H U Be...

Page 2447: ...UNIT ABS OPERATION WITH THE BRAKE TESTER INSPECTION ABS Control Module and Hydraulic Control Unit ABSCM H U 3 CHECKING THE HYDRAULIC UNIT VDC OPERATION USING A PRESSURE GAUGE 1 Lift up the vehicle an...

Page 2448: ...ssion in sequence and subse quently the RL wheel repeats the cycle 7 Read values indicated on the brake tester and check if the fluctuation of the values between de compression and compression meets s...

Page 2449: ...lb 10 Check that there is no foreign matter in mating surface between the VDCCM H U 11 Using a TORX bit E5 tighten the screws in the order of 1 through 4 again Tightening torque 3 N m 0 3 kgf m 2 2 ft...

Page 2450: ...oned at the center When the center position is not correct ad just the wheel alignment 3 Set the Subaru Select Monitor to the vehicle and select the Set up mode for Neutral of Steering Angle Sensor La...

Page 2451: ...R Ref to ABS 10 ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR OPERA TION ABS Sequence Control 2 CONDITIONS FOR ABS SEQUENCE CONTROL Ref to ABS 11 CONDITIONS FOR ABS SE QUENCE CONTROL OPERATION ABS S...

Page 2452: ...DC SEQUENCE CONTROL WITH SUBARU SELECT MONITOR NOTE In the event of any trouble sequence control will not operate 1 Connect the Subaru Select Monitor to data link connector under the driver s side ins...

Page 2453: ...SEQUENCE CONTROL 20 ON ON 23 23 23 4 37 5 19 32 3 2 1 22 22 23 22 22 22 22 V max 4 km h 2 5 MPH V max 10 km h 6 MPH OFF OFF OFF OFF OFF ON VDC 21 27 28 25 26 24 29 30 31 25 24 8 7 9 10 OFF 11 OFF 12...

Page 2454: ...compression valve 26 1 6 seconds 2 Ignition key 15 RR decompression valve 27 Point A 3 ABS warning light 16 RR compression valve 28 Reset 4 VDC warning light 17 RL decompression valve 29 0 8 seconds 5...

Page 2455: ...in the reverse order of removal Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb CAUTION After completion of installation set the follow ing two positions Positioning to the center of steering angle sen...

Page 2456: ...ness connectorbetween yaw rate G sen sor and VDCCM H U Or replace yaw rate G sensor 4 CHECK G SENSOR Read the display of Subaru Select Monitor NOTE When the yaw rate G sensor is moved with its power s...

Page 2457: ...screws securing the steering column upper cover 7 Disconnect the connector of roll connector and steering angle sensor 8 Remove the screws which secure the roll con nector to steering column 9 Remove...

Page 2458: ...er to Airbag System before per forming the service operation Ref to AB 5 CAUTION General Description 17 Connect the ground cable to battery CAUTION After completion of installation adjust the fol lowi...

Page 2459: ...ABS Wheel Speed Sensor A NOTE Vehicles equipped with VDC have the same ABS wheel speed sensor as installed on vehicles equipped with ABS Refer to Front ABS Wheel Speed Sensor for removal installation...

Page 2460: ...ABS Wheel Speed Sensor A NOTE Vehicles equipped with VDC have the same ABS wheel speed sensor as installed on vehicles equipped with ABS Refer to Rear ABS Wheel Speed Sensor for removal installation...

Page 2461: ...C 9 Front Magnetic Encoder A NOTE Vehicles equipped with VDC have the same mag netic encoder as installed on vehicles equipped with ABS Refer to Front Magnetic Encoder for re moval installation and in...

Page 2462: ...DC 10 Rear Magnetic Encoder A NOTE Vehicles equipped with VDC have the same mag netic encoder as installed on vehicles equipped with ABS Refer to Rear Magnetic Encoder for re moval installation and in...

Page 2463: ...e the screws and then remove the VDC OFF switch B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the resistance between the VDC OFF switch terminals If it is not within the...

Page 2464: ...the DTC using the Subaru Select Monitor Ref to VDC diag 22 OPERATION Read Diagnostic Trouble Code DTC NOTE If the communication function of the Subaru Se lect Monitor cannot be executed properly chec...

Page 2465: ...ef to VDC diag 33 LIST List of Diagnostic Trouble Code DTC 2 Correct the cause of trouble 3 Perform the Clear Memory Mode Ref to VDC diag 24 OPERATION Clear Memory Mode 4 Perform the Inspection Mode R...

Page 2466: ...before starting engine START ON after starting engine engine is running ON after starting engine engine is at a standstill Timing Immediately after turning the ignition switch to ON Immediately after...

Page 2467: ...rning to the right Steering angle deg Steering time Sec When turning to the left Steering angle deg Steering time Sec When other electrical parts are operating Part name Operating condition VDC operat...

Page 2468: ...e Cloudy Rainy Snowy Others b Ambient temperature C F c Road Inner city Suburbs Highway Local street Uphill Downhill Paved road Gravel road Muddy road Sandy place Straight road Sharp curve Gentle curv...

Page 2469: ...pressure Front RH tire 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 turning Gentle turning Stra...

Page 2470: ...ULIC UNIT Check the hydraulic unit When using the brake tester Ref to VDC 8 CHECKING THE HYDRAULIC UNIT ABS OPERA TION WITH THE BRAKE TESTER INSPECTION VDC Control Module and Hydraulic Control Unit VD...

Page 2471: ...sensor 6 VDC indicator light 12 Yaw rate G sensor 2 Connector 7 VDC warning light and VDC OFF indicator light 13 Data link connector 3 Transmission control module TCM 14 Engine control module ECM 8 S...

Page 2472: ...VDC diag 10 Electrical Component Location VEHICLE DYNAMICS CONTROL VDC DIAGNOSTICS VDC00455 1 VDC00543 5 6 7 16 4 8 VDC00544 VDC00234 11 10 10 VDC00456 12 VDC00545 13...

Page 2473: ...ctor are shown in the figure When the connector is removed from the VDCCM H U the brake warning light EBD warning light ABS warning light VDC warning light VDC OFF indicator light and the hill start a...

Page 2474: ...eel Power supply 2 25 4 5 16 5 V Signal 27 5 9 16 8 mA Rectangle waveform Rear RH wheel Power supply 3 25 4 5 16 5 V Signal 4 5 9 16 8 mA Rectangle waveform CAN communication line 35 2 5 1 5 V pulse s...

Page 2475: ...ontrol Module I O Signal VEHICLE DYNAMICS CONTROL VDC DIAGNOSTICS B WIRING DIAGRAM 3 7 6 5 11 M 12 13 20 2 24 23 22 4 28 1 29 37 14 8 9 10 15 16 17 18 21 33 32 31 42 27 43 30 34 35 38 39 40 41 26 25 1...

Page 2476: ...sensor LH 7 Motor 24 VDC warning light and VDC OFF indicator light 38 Front ABS wheel speed sensor RH 8 Front inlet solenoid valve LH 9 Front outlet solenoid valve LH 25 ABS warning light 39 Rear ABS...

Page 2477: ...means the USB port which was used to install the Subaru Select Monitor 4 Connect the diagnosis cable to SDI 5 Connect SDI to data link connector located in the lower portion of the instrument panel on...

Page 2478: ...nd signal is displayed 1 or 0 ABS Control Flag ABS operation condition is displayed ON or OFF EBD Control Flag EBD operation condition is displayed ON or OFF TCS Control Flag TCS operation condition i...

Page 2479: ...R Wheel Speed Wheel speed detected by rear ABS wheel speed sensor RH is displayed in km h or MPH RL Wheel Speed Wheel speed detected by rear ABS wheel speed sensor LH is displayed in km h or MPH Accel...

Page 2480: ...Identification 7 Enter the applied model of 7 digit alphanumeric characters and press the Enter key 8 When the confirmation screen indicating the ve hicle information appears check that the correct ap...

Page 2481: ...on is impossible between VDC and Subaru Select Monitor WIRING DIAGRAM 7 28 MAIN SBF SBF 6 F B No 33 M B No 13 B310 VDCCM H U E 25 B40 7 16 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10...

Page 2482: ...Mod ule and Hydraulic Control Unit VDCCM H U Go to step 6 6 CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the VDCCM H U ECM...

Page 2483: ...AND CHASSIS GROUND 1 Turn the ignition switch to OFF 2 Disconnect the connector from the VDCCM H U 3 Measure the resistance of harness between VDCCM H U connector and chassis ground Connector termina...

Page 2484: ...uble Code DTC Up to 3 DTCs are displayed in the order of detec tion If a particular DTC is not stored in memory prop erly at the occurrence of problem due to a drop in VDCCM H U power supply etc the D...

Page 2485: ...CONTROL VDC DIAGNOSTICS 8 Inspection Mode A PROCEDURE Reproduce the malfunction occurrence condition as much as possible Drive the vehicle at least ten minutes NOTE Make sure the vehicle is not dragg...

Page 2486: ...ake Control System 3 Click the OK button after VDC is displayed 4 On Brake Control Diagnosis display select Clearing Memory 5 When the Clear Memory is shown on the screen click the YES button 6 When D...

Page 2487: ...e warning light EBD warning light 2 OFF 9 VDC indicator light 3 ON 10 VDC warning light and VDC OFF indicator light 13 Parking brake 4 Engine start 14 Released 5 ABS warning light 11 Several seconds d...

Page 2488: ...ht do not go off check the combination meter circuit or CAN communica tion circuit Ref to VDC diag 29 VDC INDICA TOR LIGHT DOES NOT GO OFF Warning Light Illumination Pattern Ref to VDC diag 30 VDC WAR...

Page 2489: ...ion switch to ON Does other indicator light illumi nate soon after ON Go to step 2 Perform the self diagnosis of com bination meter 2 CHECK VDCCM When the engine does not start display the cur rent da...

Page 2490: ...n the ignition switch to ON engine OFF Do other warning lights illumi nate Go to step 2 Check the combi nation meter 2 READ DTC Read the DTC Ref to VDC diag 22 Read Diagnostic Trouble Code DTC Is DTC...

Page 2491: ...diagnosis for LAN system Ref to LAN diag 31 OPERATION Read Diagnostic Trouble Code DTC Is there any fault in LAN sys tem Perform the diag nosis according to DTC for LAN sys tem Go to step 3 3 CHECK C...

Page 2492: ...on indicator light illuminate Repair the engine Go to step 3 3 CHECK ENGINE COOLANT TEMPERA TURE Warm up the engine and check if VDC warning light and VDC OFF indicator light illumination condition ch...

Page 2493: ...44 45 46 23 22 25 24 i10 E MAIN SBF SBF 6 E No 5 35 10 B310 B38 B16 i3 i10 VDCCM H U B3 B9 A1 A9 C15 2 27 26 8 24 1 2 i84 A B280 B B281 C 1 2 B99 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22...

Page 2494: ...ector and chassis ground Connector terminal i10 No 8 Chassis ground Is the resistance 1 M or more Go to step 6 Repair the harness between combina tion meter and brake fluid level switch 6 CHECK PARKIN...

Page 2495: ...LEFT ABS SENSOR SIGNAL Diagnostic Procedure with Diagnostic Trouble Code DTC C0025 09B1H 09B2H 09C0H Rear Righ ABS Sensor Circuit Open or Shorted Battery Open high input of rear ABS wheel speed sen so...

Page 2496: ...in VDCCM H U Ref to VDC diag 49 DTC C0037 RL HOLD VALVE MALFUNCTION Diagnostic Procedure with Diagnostic Trouble Code DTC C0038 10B8H 10C0H 10C1H 10D0H RL Pressure Reducing Valve malfunction Rear outl...

Page 2497: ...n BLS open circuit Ref to VDC diag 68 DTC C0054 BLS CIR CUIT OPEN Diagnostic Procedure with Diagnos tic Trouble Code DTC 043CH BLS ON malfunction BLS ON malfunction Ref to VDC diag 70 DTC C0054 BLS ON...

Page 2498: ...30H Steering Angle Sensor Offset is too big Excessive steering angle sensor output off set Ref to VDC diag 78 DTC C0071 STEERING ANGLE SENSOR OFFSET IS TOO BIG Diag nostic Procedure with Diagnostic Tr...

Page 2499: ...Sensor Type Abnormal Different yaw rate sen sor specification Ref to VDC diag 94 DTC C0072 SENSOR TYPE ABNORMAL Diagnostic Procedure with Diagnostic Trouble Code DTC C0073 1D46H 1D47H Lateral G Sensor...

Page 2500: ...CLE DYNAMICS CONTROL VDC DIAGNOSTICS C0081 2201H 2202H System Failure System malfunction Ref to VDC diag 102 DTC C0081 SYSTEM FAILURE Diagnostic Procedure with Diagnostic Trouble Code DTC DTC Detailed...

Page 2501: ...ocedure with Diagnostic Trouble Code DTC B DTC C0023 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT NOTE For the diagnostic procedure refer to DTC C0027 RL WHEEL SPEED SENSOR CIRCUIT OPEN HIGH IN PUT Ref...

Page 2502: ...3 1 26 27 2 25 B98 R72 R2 B99 R3 E 2 4 1 3 R73 B6 B15 R73 R72 1 2 6 5 B310 2 1 2 1 2 1 B15 B6 B98 B99 VDCCM H U 2 1 B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37...

Page 2503: ...10 No 27 R73 No 1 B310 No 2 R73 No 2 Is the resistance less than 0 5 Go to step 3 Repair the harness connectorbetween VDCCM H U and ABS wheel speed sensor 3 CHECK GROUND SHORT OF HARNESS Measure the r...

Page 2504: ...H U connector 3 Turn the ignition switch to ON 4 Measure the voltage between VDCCM H U connector terminals Connector terminal B310 No 28 B310 No 25 Is the voltage 10 15 V Go to step 6 Check the gener...

Page 2505: ...27 2 25 B98 R72 R2 B99 R3 E 2 4 1 3 R73 B6 B15 R73 R72 1 2 6 5 B310 2 1 2 1 2 1 B15 B6 B98 B99 VDCCM H U 2 1 B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40...

Page 2506: ...nly Ref to VDC 9 REPLACEMENT VDC Control Mod ule and Hydraulic Control Unit VDCCM H U Go to step 6 6 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Ref to...

Page 2507: ...Mode Ref to VDC diag 23 Inspection Mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM only Ref to VDC 9 REPLACEMENT VDC Control Mod ule and Hydraulic Control Unit VDCCM H U Go to step 13...

Page 2508: ...ABS warning light when EBD does not operate WIRING DIAGRAM VDC00529 4 3 1 26 27 2 25 B98 R72 R2 B99 R3 E 2 4 1 3 R73 B6 B15 R73 R72 1 2 6 5 B310 2 1 2 1 2 1 B15 B6 B98 B99 VDCCM H U 2 1 B310 4 5 6 7...

Page 2509: ...m 0 76 kgf m 5 5 ft lb For four wheels Go to step 6 Tighten the ABS wheel speed sen sor installation bolts 6 CHECK ABS WHEEL SPEED SENSOR SIG NAL 1 Install the ABS wheel speed sensor 2 Prepare an osc...

Page 2510: ...procedure refer to DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION Ref to VDC diag 50 DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION Diagnostic Procedure with Di agnostic Trouble Code DTC N DTC C0035 RR H...

Page 2511: ...AL CLOSING VALVE 2 MALFUNCTION Ref to VDC diag 50 DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION Diagnostic Procedure with Di agnostic Trouble Code DTC S DTC C0061 NORMAL OPENING VALVE 1 MALFUNCTION NOT...

Page 2512: ...N Faulty harness connectors Defective VDCH U solenoid valve TROUBLE SYMPTOM ABS does not operate EBD does not operate VDC does not operate WIRING DIAGRAM MAIN SBF SBF 6 No 33 B310 E E 25 28 VDCCM H U...

Page 2513: ...is ground Connector terminal B310 No 25 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the VDCCM H U ground harness 3 CHECK POOR CONTACT OF CONNEC TORS Is there poor contact of con...

Page 2514: ...C0041 ECM DTC DETECTING CONDITION Defective VDCCM H U TROUBLE SYMPTOM ABS does not operate EBD does not operate VDC does not operate WIRING DIAGRAM VDCCM H U 25 B310 E B310 4 5 6 7 8 9 26 27 28 29 30...

Page 2515: ...radio wave devices and electronic components installed correctly Go to step 4 Install the radio wave devices and electronic compo nents properly 4 CHECK CAUSE OF SIGNAL NOISE Is there a noise source...

Page 2516: ...e identification symbol cor rect Go to step 4 Replace the VDCCM only Ref to VDC 9 REPLACEMENT VDC Control Mod ule and Hydraulic Control Unit VDCCM H U 3 CHECK VDCCM H U IDENTIFICATION SYMBOL Check the...

Page 2517: ...H U power supply voltage TROUBLE SYMPTOM ABS does not operate EBD may not operate VDC does not operate NOTE Warning lights go off if voltage returns WIRING DIAGRAM MAIN SBF SBF 6 No 33 B310 E E 25 28...

Page 2518: ...erminal B310 No 28 Chassis ground Is the voltage 10 15 V Go to step 4 Repair the power supply circuit 4 CHECK VDCCM H U GROUND CIRCUIT 1 Turn the ignition switch to OFF 2 Measure the resistance betwee...

Page 2519: ...CONNEC TORS Is there poor contact of TCM connector Repair the connec tor Go to step 3 3 CHECK TCM Is the TCM normal Go to step 4 Replace the TCM Ref to 4AT 63 Transmission Con trol Module TCM 4 CHECK...

Page 2520: ...ped on the upper part of the H U AT S1 MT S5 WRX SS S2 except for WRX SS Is the identification symbol cor rect Go to step 4 Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule and Hydraulic Control...

Page 2521: ...e diag nosis according to DTC Ref to VDC diag 33 List of Diagnostic Trou ble Code DTC It results from a temporary noise interference Step Check Yes No 1 CHECK AT SYSTEM 1 Start the engine 2 Check the...

Page 2522: ...PTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31...

Page 2523: ...o to step 4 Check output of the steering angle sensor Ref to VDC diag 82 DTC C0071 STEER ANGLE SENSOR OP Diagnostic Proce dure with Diagnos tic Trouble Code DTC 4 CHECK OUTPUT OF YAW RATE G SEN SOR Co...

Page 2524: ...does not operate WIRING DIAGRAM B310 E 24 25 VDCCM H U 28 PUMP MOTOR M FL INLET MAIN SBF SBF 6 No 1 No 33 E BATTERY IGNITION SWITCH SOLENOID VALVE FR INLET RL INLET RR INLET FL OUTLET FR OUTLET RL OUT...

Page 2525: ...d Connector terminal B310 No 25 Chassis ground Is the resistance less than 0 5 Go to step 4 Repair the VDCCM H U ground harness 4 CHECK VDCCM H U VALVE RELAY Measure the resistance between VDCCM H U c...

Page 2526: ...VDC does not operate EBD may not operate WIRING DIAGRAM B310 E 23 25 VDCCM H U 28 PUMP MOTOR M FL INLET MAIN SBF SBF 6 No 33 E BATTERY IGNITION SWITCH SOLENOID VALVE MOTOR RELAY VALVE RELAY FR INLET...

Page 2527: ...harness 4 CHECK VDCCM H U MOTOR RELAY Measure the resistance between VDCCM H U connector terminals Terminals No 23 No 22 Is the resistance 1 M or more Go to step 5 Replace the VDCCM H U Ref to VDC 7...

Page 2528: ...does not operate EBD may not operate WIRING DIAGRAM B310 E 23 25 VDCCM H U 28 PUMP MOTOR M FL INLET MAIN SBF SBF 6 No 33 E BATTERY IGNITION SWITCH SOLENOID VALVE MOTOR RELAY VALVE RELAY FR INLET RL IN...

Page 2529: ...nals Terminals No 23 No 22 Is the resistance 1 M or more Go to step 2 Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule and Hydraulic Control Unit VDCCM H U 2 CHECK VDCCM H U 1 Connect all connec...

Page 2530: ...42 43 44 45 46 20 21 23 24 22 25 MAIN SBF SBF 2 No 8 E 7 5A B225 2 1 B434 B159 R168 B99 R3 B99 R3 B435 2 2 1 2 5Dr 5Dr 5Dr 4Dr 9 15 7 4Dr 4Dr 6 7 1 2 9 4 7 6 2 1 5 3 8 B159 B65 B225 R168 B99 1 2 3 4 1...

Page 2531: ...Replace the fuse 5 CHECK OPEN CIRCUIT OF HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from the VDCCM H U 3 Depress the brake pedal 4 Measure the voltage between VDCCM H U conne...

Page 2532: ...42 43 44 45 46 20 21 23 24 22 25 MAIN SBF SBF 2 No 8 E 7 5A B225 2 1 B434 B159 R168 B99 R3 B99 R3 B435 2 2 1 2 5Dr 5Dr 5Dr 4Dr 9 15 7 4Dr 4Dr 6 7 1 2 9 4 7 6 2 1 5 3 8 B159 B65 B225 R168 B99 1 2 3 4...

Page 2533: ...ressed simultaneously with depressing brake pedal with left foot Were the acceleration pedal and brake pedal depressed simultaneously System is normal DTC may be recorded while brake is applied during...

Page 2534: ...1 42 43 44 45 46 20 21 23 24 22 25 MAIN SBF SBF 2 No 8 E 7 5A B225 2 1 B434 B159 R168 B99 R3 B99 R3 B435 2 2 1 2 5Dr 5Dr 5Dr 4Dr 9 15 7 4Dr 4Dr 6 7 1 2 9 4 7 6 2 1 5 3 8 B159 B65 B225 R168 B99 1 2 3 4...

Page 2535: ...onnect the connector from the VDCCM H U 2 Measure the resistance between VDCCM H U and stop light switch Connector terminal 4 DOOR MODEL B65 No 4 B310 No 30 5 DOOR MODEL B65 No 2 B310 No 30 Is the res...

Page 2536: ...PTOM Hill start assist does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 3...

Page 2537: ...Select Monitor 4 Read the indication of longitudinal G sensor output When the yaw rate G sensor is inclined 90 to the front is the indicated value 6 8 12 8 m s2 Go to step 4 Replace the yaw rate G se...

Page 2538: ...2 2 CHECK POOR CONTACT OF CONNEC TORS Is there poor contact of ECM connector Repair the connec tor Go to step 3 3 CHECK ECM Is ECM normal Go to step 4 Replace the ECM 4 CHECK VDCCM H U 1 Connect all c...

Page 2539: ...Memory Mode NOTE DTC may be re corded If cranking is performed dur ing driving 2 CHECK POOR CONTACT OF CONNEC TORS Is there poor contact of ECM connector Repair the connec tor Go to step 3 3 CHECK EC...

Page 2540: ...TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34...

Page 2541: ...ering wheel 2 CHECK VDCCM H U 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Clear the memory Ref to VDC diag 24 Clear Memory Mode 4 Perform the Inspection Mode Ref to VDC diag 23 Inspec...

Page 2542: ...ensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 3...

Page 2543: ...diag 24 Clear Memory Mode 4 Perform the Inspection Mode Ref to VDC diag 23 Inspection Mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM only Ref to VDC 9 REPLACEMENT VDC Control Mod ule...

Page 2544: ...sensor 3 Turn the ignition switch to ON 4 Measure the voltage between the steering angle sensor and chassis ground Connector terminal B231 No 4 Chassis ground Is the voltage 10 15 V Go to step 2 Repai...

Page 2545: ...Repair the harness between the steer ing angle sensor and VDCCM H U 5 CHECK STEERING ANGLE SENSOR 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Clear the memory Ref to VDC diag 24 Clear...

Page 2546: ...light does not illuminate though problem is detected The ABS and VDC operate normally if voltage returns WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6...

Page 2547: ...ion switch to OFF 2 Connect all connectors 3 Clear the memory Ref to VDC diag 24 Clear Memory Mode 4 Perform the Inspection Mode Ref to VDC diag 23 Inspection Mode 5 Read the DTC Is the same DTC displ...

Page 2548: ...E SYMPTOM VDC does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 1...

Page 2549: ...Park the vehicle straight 3 Select Current Data Display Save in Subaru Select Monitor 4 Read the steering angle sensor output dis played on display Is the reading indicated on monitor display 5 5 Go...

Page 2550: ...sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32...

Page 2551: ...IRCUIT Measure the resistance between yaw rate G sensor and chassis ground Connector terminal B230 No 4 Chassis ground Is the resistance less than 0 5 Go to step 3 Repairthe yaw rate G sensor ground c...

Page 2552: ...dirt road VDCCM H U may record DTC when the vehicle ran the road with banks or sandy surface which does not mean a dirt road Go to step 2 2 CHECK YAW RATE G SENSOR INSTAL LATION Is the yaw rate G sens...

Page 2553: ...r display 4 4 deg s Go to step 6 Replace the yaw rate G sensor Ref to VDC 16 Yaw Rate and G Sensor 6 CHECK YAW RATE G SENSOR 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Clear the memo...

Page 2554: ...ector from yaw rate G sensor 3 Turn the ignition switch to ON 4 Measure the voltage between yaw rate G sensor and chassis ground Connector terminal B230 No 1 Chassis ground Is the voltage 10 15 V Go t...

Page 2555: ...een yaw rate G sensor and VDCCM H U 5 CHECK YAW RATE G SENSOR 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Clear the memory Ref to VDC diag 24 Clear Memory Mode 4 Perform the Inspectio...

Page 2556: ...ESSIVE LATERAL G SENSOR SIGNAL Ref to VDC diag 95 DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL Diagnostic Procedure with Diag nostic Trouble Code DTC Step Check Yes No 1 CHECK YAW RATE G SENSOR IDENTIF...

Page 2557: ...BLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00690 1 2 3 4 B310 VDCCM H U 25 10 35 B231 B230 2 4 1 3 1 4 2 3 E B231 SBF 6 MAIN SBF No 33 E B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36...

Page 2558: ...When the yaw rate G sensor is inclined 90 to the right is the indicated value 6 8 12 8 m s2 Go to step 4 Replace the yaw rate G sensor Ref to VDC 16 Yaw Rate and G Sensor 4 CHECK LATERAL G SENSOR Read...

Page 2559: ...H U Ref to VDC 7 VDC Control Mod ule and Hydraulic Control Unit VDCCM H U 3 CHECK OUTPUT OF PRESSURE SENSOR WITH SUBARU SELECT MONITOR 1 Select Current Data Display Save in Subaru Select Monitor 2 Rea...

Page 2560: ...E B18 B3 B9 BODY INTEGRATED UNIT 1 2 3 4 5 B434 B436 B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 IG2 RELAY B3...

Page 2561: ...NESS BETWEEN BODY INTE GRATED UNIT AND BACK UP LIGHT SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from body inte grated unit and back up light switch 3 Measure the resistance o...

Page 2562: ...ot operate WIRING DIAGRAM VDC00561 MAIN SBF SBF 8 No 4 C136 ECM C E C25 C27 C35 B107 1 2 3 4 5 B440 B441 B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12...

Page 2563: ...ot depressed and is ON displayed when depressed Go to step 5 Go to step 4 4 CHECK HARNESS BETWEEN ECM AND CLUTCH SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and clutc...

Page 2564: ...oor contact of the VDCCM H U and yaw rate G sensor connector Repair the connec tor Go to step 2 2 CHECK VDCCM H U 1 Replace the yaw rate G sensor Ref to VDC 16 Yaw Rate and G Sensor 2 Connect all conn...

Page 2565: ...brake Axle and wheels Brake pedal play Defective steering angle sensor or improper neutral position Defective yaw rate G sensor or improper installation Brake pad Brake pipe Long brake pedal stroke Ae...

Page 2566: ...sor gap Master cylinder Brake caliper Brake pad Disc rotor Brake pipe Brake booster Suspension play or fatigue reduced damping Axle and wheels Tire specifications tire wear and air pressures Noise fro...

Page 2567: ...ear and air pressures Incorrect wiring or piping connections Brake caliper Brake pipe Steering wheel drag while driving VDCCM H U Defective ABS wheel speed sensor or sensor gap Defective steering angl...

Page 2568: ...hen the VDC OFF switch is depressed NOTE When pressing VDC OFF switch for 10 seconds or more VDC OFF indicator light goes off and cannot operate any more When turning the ignition switch from OFF to O...

Page 2569: ...ness mm in 92 0 33 0 9 0 3 622 1 299 0 354 Clearance adjustment Automatic adjustment Rear drum brake Type Drum Leading Trailing type Effective drum inner diameter mm in 254 10 Effective cylinder diame...

Page 2570: ...10 256 10 08 Lining thickness mm in 4 5 0 177 1 5 0 059 Rear brake disc type Inside diameter mm in 190 7 48 191 7 52 Lining thickness mm in 2 8 0 11 1 5 0 059 Parking brake Lever stroke 7 8 notches 2...

Page 2571: ...screw 10 Pad clip 17 Bushing 3 Guide pin 11 Outer shim 4 Pin boot 12 Inner shim Tightening torque N m kgf m ft lb 5 Piston seal 13 Pad Outside T1 8 0 8 5 9 6 Piston 14 Pad Inside T2 27 2 8 19 9 7 Pis...

Page 2572: ...Piston 20 Lever 32 Disc rotor 7 Piston boot 21 Parking brake shoe Secondary 33 Outer shim SUS 8 Support 22 Parking brake shoe Primary 34 Inner shim 9 Lock pin silver 23 Strut 10 Bushing 24 Strut spri...

Page 2573: ...n 9 Adjusting lever 3 Back plate 10 Adjusting spring Tightening torque N m kgf m ft lb 4 Upper shoe return spring 11 Shoe hold down spring T1 8 0 8 5 9 5 Retainer 12 Adjuster T2 9 0 9 6 6 6 Parking br...

Page 2574: ...4 MASTER CYLINDER 1 Cap 6 Secondary piston 11 O ring 2 Filter 7 Cylinder body 3 Reservoir tank 8 Cylinder pin Tightening torque N m kgf m ft lb 4 C ring 9 Seal T 13 1 3 9 6 5 Primary piston 10 Pin BR...

Page 2575: ...rol unit ABSCM H U Tightening torque N m kgf m ft lb 2 Two way connector T1 15 1 5 11 1 3 Front brake hose RH 8 Bracket T2 18 1 8 13 3 4 Front brake hose LH 9 Master cylinder T3 19 1 9 14 5 Clamp 10 V...

Page 2576: ...2 Two way connector 3 Rear brake pipe ASSY 7 Rear brake hose LH Drum brake model Tightening torque N m kgf m ft lb 4 Rear brake hose RH Disc brake model T1 15 1 5 11 1 8 Clamp T2 18 1 8 13 3 5 Rear b...

Page 2577: ...BR 10 General Description BRAKE 7 BRAKE BOOSTER 1 Brake booster Tightening torque N m kgf m ft lb T 18 1 8 13 3 BR 00465 1 T...

Page 2578: ...Brake pedal ASSY 5 Clutch pedal pad Tightening torque N m kgf m ft lb 2 Stop light switch 6 Clutch switch cruise control T1 8 0 8 5 8 3 Brake pedal pad 7 Clutch switch clutch start T2 18 1 8 13 3 4 C...

Page 2579: ...BR 12 General Description BRAKE AT model 1 Brake pedal ASSY 3 Brake pedal pad Tightening torque N m kgf m ft lb 2 Stop light switch T 18 1 8 13 3 T T 1 2 3 BR 00659...

Page 2580: ...cement Use SUBARU genuine grease etc or equivalent Do not mix grease etc of different grades or man ufacturers Before securing a part in a vise place cushioning material such as wood blocks aluminum p...

Page 2581: ...es of the pad inner shim 3 Install the pad to support 4 Install the caliper body to the support Tightening torque 27 N m 2 8 kgf m 19 9 ft lb C INSPECTION Check the pad thickness A NOTE Always replace...

Page 2582: ...ay and axle hub runout before the inspection of disc rotor runout limit Ref to DS 16 INSPECTION Front Axle 2 Secure the disc rotor by tightening the five wheel nuts 3 Set a dial gauge 10 mm 0 39 in in...

Page 2583: ...body assembly 6 Remove mud and foreign matter from the caliper body assembly and the support B INSTALLATION 1 Apply a thin coat of Molykote M7439 Part No K0770YA000 or grease contained in the pad kit...

Page 2584: ...ing brake fluid 2 Apply a coat of brake fluid to piston seal and in stall piston seal in the groove on caliper body 3 Apply a coat of brake fluid to the inner surface of cylinder and the entire outer...

Page 2585: ...n and guide pin into position and make sure that they slide and seat proper ly E INSPECTION 1 Repair or replace the faulty parts 2 Check the caliper body and piston for uneven wear damage or rust 3 Ch...

Page 2586: ...ontained in the pad kit to the pad clip 2 Apply a thin coat of Molykote AS880N Part No K0777YA010 or the grease contained in the pad kit to the contact surface between the pad and shim 3 Apply a thin...

Page 2587: ...e twisted or worn A wear indicator is installed on the inner disc brake pad If the pad is worn to the limit the end of wear indicator contacts disc rotor and a squeaking sound is heard as the wheel ro...

Page 2588: ...threads B of the rotor then remove the rotor B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the parking brake Ref to PB 8 AD JUSTMENT Parking Brake Assembly Rear Disc Brake C INSPE...

Page 2589: ...om the disc rotor outer perimeter and then measure the disc rotor thickness If the thickness of the disc rotor exceeds the service limit replace with a new disc rotor A B BR 00036 Specification Limit...

Page 2590: ...cessary to remove it when servicing the caliper body assembly 6 Remove mud and foreign matter from the caliper body assembly and the support CAUTION Be careful not to allow foreign matter to enter the...

Page 2591: ...h the piston out 4 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove 5 Remove the pin boot D ASSEMBLY 1 Clean the inside of the caliper body...

Page 2592: ...ort 9 Install the pin boot to the support and then insert the pin into the specified position CAUTION Insert pin into position and make sure that it slides and seats properly E INSPECTION 1 Repair or...

Page 2593: ...cult to remove drive it out by installing an 8 mm bolt into bolt hole in brake drum B INSTALLATION Install in the reverse order of removal C INSPECTION 1 If the inside surface of the brake drum has sc...

Page 2594: ...e and the wheel cylinder Contact surface of the brake shoe and the ad juster Contact surface of lever and brake shoe 2 Connect the parking brake cable to the parking brake lever 3 Check that the parki...

Page 2595: ...ar Drum Brake Shoe BRAKE C INSPECTION Measure the lining thickness If it exceeds the ser vice limit replace the brake shoe with a new part Lining thickness Standard value 4 5 mm 0 177 in Limit 1 5 mm...

Page 2596: ...the rear hub unit bearing Ref to DS 24 INSTALLATION Rear Hub Unit Bearing 4 Install the brake hose Ref to BR 40 REAR BRAKE HOSE INSTALLATION Brake Hose CAUTION When connecting brake hoses do not twis...

Page 2597: ...lb CAUTION Be sure to use recommended brake fluid 3 Bleed air from brake system Ref to BR 37 PROCEDURE Air Bleeding C REPLACEMENT 1 Remove mud and dirt from the surface of brake master cylinder 2 Sec...

Page 2598: ...on install the cylinder pin 11 While pushing in the primary piston install the C ring to the groove using pliers CAUTION Make sure the C ring is installed to the groove securely 12 Install the seal to...

Page 2599: ...re that the booster shell and vacuum pipe are not subject to strong impacts Be careful not to drop the brake booster If the booster is dropped replace it Use special care when handling the operating r...

Page 2600: ...bleeder screw 8 N m 0 8 kgf m 5 9 ft lb 10 Perform a road test to make sure the brakes do not drag C INSPECTION NOTE If the vehicle is equipped with a brake assist mech anism the following may result...

Page 2601: ...en gine 3 As the engine starts the brake pedal should move slowly toward the floor If the pedal height does not change the brake booster is faulty NOTE If faulty check precisely with gauges LOADED AI...

Page 2602: ...acuum gauge 2 Stop the engine and check the vacuum gauge If the vacuum pressure drop within 15 seconds after stopping the engine is 3 3 kPa 25 mmHg 0 98 inHg or less the function of brake booster is n...

Page 2603: ...ul not to allow dirt or dust to enter the reservoir tank NOTE During the operation keep the reservoir tank filled with brake fluid to eliminate entry of air Operate the brake pedal slowly For convenie...

Page 2604: ...e phenomena that occur when the brake assist mechanism functions properly Brake feel is soft when brake pedal is depressed hard or quicker than usual A light crack is heard when brake pedal is de pres...

Page 2605: ...ing wheel again Specification of pedal stroke When depressing the pedal with a force of 500 N 51 kgf 112 lbf 95 mm 3 74 in or less 11 If the distance is more than specification there is a possibility...

Page 2606: ...N m 3 4 kgf m 24 3 ft lb 2 Install the brake hose to the caliper using a new gasket Tightening torque union bolt 18 N m 1 8 kgf m 13 3 ft lb 3 Position the disc in straight position and route the bra...

Page 2607: ...using a new gasket Tightening torque union bolt 18 N m 1 8 kgf m 13 3 ft lb Disc brake Drum brake 5 Tighten the flare nut to the specified torque Tightening torque brake pipe flare nut 15 N m 1 5 kgf...

Page 2608: ...its Be careful not to damage the airbag system wiring harness when servicing the center brake pipe When installing the brake pipe do not bend After installing the brake pipe and hose per form air blee...

Page 2609: ...which secures the clutch master cylinder 7 Remove the bolt and nut which secures the ped al bracket 2 AT MODEL 1 Remove the steering column Ref to PS 15 REMOVAL Tilt Steering Column 2 Disconnect the c...

Page 2610: ...the brake pedal NOTE Replace with a new clevis pin Apply a thin coat of KOPR KOTE Part No 003603001 to the clevis pin 3 Make sure that the switch clip gray is securely installed to the brake pedal br...

Page 2611: ...2 mm 0 020 0 079 in When pulling the brake pedal upward with a force of less than 10 N 1 kgf 2 lbf 3 If out of specification perform the procedures below to adjust 4 Remove the stop light switch Ref t...

Page 2612: ...e stop light switch to the stopper brown at the brake ped al side until it stops Turn the stop light switch clock wise and install the switch 3 Pull up the brake pedal and make sure that play is 0 5 2...

Page 2613: ...4 door model 2 If the stop light switch does not operate properly replace with a new part Switch Pedal Terminal No Standard Stop light Released 1 and 2 1 M or more Depressed Less than 1 Switch Pedal...

Page 2614: ...k adjust or replace the rear brake and cable system 3 Excessive pedal stroke 1 Entry of air into the hydraulic mechanism Bleed air 2 Excessive play in the master cylinder push rod Adjust 3 Fluid leaka...

Page 2615: ...BR 48 General Diagnostic Table BRAKE...

Page 2616: ...0 0 4 5 9 6 1 575 0 177 165 8 30 0 2 8 6 53 1 181 0 11 Clearance adjustment Automatic adjusting Manual adjustment Lever stroke Notches N kgf lbf 7 8 200 20 4 45 1 Back plate 7 Strut 12 Adjusting sprin...

Page 2617: ...ceiving burns from heated parts Use SUBARU genuine grease etc or equivalent Do not mix grease etc of different grades or man ufacturers Be sure to tighten fasteners including bolts and nuts to the spe...

Page 2618: ...adjusting nut self locking nut 3 Be sure to adjust the lever stroke Ref to PB 4 ADJUSTMENT Parking Brake Lever C INSPECTION 1 Operate the parking brake lever 3 to 4 times and fully return the lever 2...

Page 2619: ...Brake Shoe 9 Remove the clamp from the rear brake 10 Remove the cable clamp from the rear arm bracket 11 Remove the cable clamp from rear floor 12 Remove the grommet from the rear floor and remove th...

Page 2620: ...ing two methods in order 1 Turn the adjusting screw using a flat tip screwdriver until the brake shoe moves ade quately away from the disc rotor 2 If disc rotor is seized on the hub drive the disc rot...

Page 2621: ...E Install the adjuster with screw section in the ar rowed direction shown in the figure below 5 Check that the parking brake cable does not fall from the cable guide 6 Install the brake shoes to the b...

Page 2622: ...ontact with the disc rotor 5 Loosen the adjusting screw by 5 notches to op posite direction of arrow CAUTION Check there is no brake drag If the amount that the adjusting screw is turned back is littl...

Page 2623: ...se Corrective action Brake drag Parking brake lever not adjusted correctly Adjust Parking brake cable does not move Correct or replace Parking brake shoe clearance is maladjusted Adjust Return spring...

Page 2624: ...PB 10 General Diagnostic Table PARKING BRAKE...

Page 2625: ...n Clockwise Hydraulic oil Power steering system Capacity 2 US qt Imp qt Oil tank 0 2 0 2 0 2 Whole system 0 7 0 7 0 6 Steering wheel Free play mm in 17 0 67 Steering shaft Clearance between the steeri...

Page 2626: ...T 1 STEERING WHEEL AND COLUMN 1 Bushing 5 Steering wheel Tightening torque N m kgf m ft lb 2 Steering shaft 6 Airbag module T1 1 2 0 12 0 9 3 Steering roll connector 7 Steering wheel lower cover T2 25...

Page 2627: ...ft lb 2 Hose turbo model 10 Suction hose T1 7 5 0 76 5 5 3 Eye bolt gasket 11 Hose bracket T2 10 1 0 7 4 4 Clip 12 Clip T3 13 1 3 9 6 5 Clamp E 13 Clip T4 18 1 8 13 3 6 Cap 14 Return hose T5 40 4 1 2...

Page 2628: ...12 5 11 Pinion valve ASSY 31 Pipe B T5 20 2 0 14 8 12 Oil seal 32 Pipe A T6 24 2 4 17 7 13 Back up washer 33 Steering body T7 25 2 5 18 4 14 Ball bearing 34 Oil seal T8 27 2 8 19 9 15 Snap ring 35 Pi...

Page 2629: ...se SUBARU genuine power steering fluid grease etc or the equivalent Do not mix fluid grease etc of different grades or manufacturers Be sure to tighten fasteners including bolts and nuts to the specif...

Page 2630: ...GAUGE Used for measuring oil pressure 926200000 STAND Used when inspecting characteristic of gear box assembly and disassembling it Used together with BOSS D 34199AG000 34099AC010 ADAPTER HOSE A Used...

Page 2631: ...n fluid leaks from pinion side of gearbox assembly remove pipe B from valve housing attach this tool and check fluid leaking points 34099FA060 PUNCH HOLDER Used for crimping 34199FE040 INSTALLER A B C...

Page 2632: ...en inspecting characteristic of gear box assembly and disassembling it Used together with STAND 926200000 34199AG040 GUIDE Used for installing seal ring of rack 34199AG070 FORMER Used for forming seal...

Page 2633: ...oil seal of valve housing Used together with SEAL INSTALLER 34099FA130 Used for installing ball bearing of valve hous ing Used for removing oil seal and ball bearing from valve housing 34199AG080 FORM...

Page 2634: ...PS 11 General Description POWER ASSISTED SYSTEM POWER STEERING 34199FE020 BASE Used for crimping ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199FE020...

Page 2635: ...tem before per forming service on the airbag modules Ref to AB 5 CAUTION General Description 1 Align the center position of the roll connector Ref to AB 26 ADJUSTMENT Roll Connector 2 Install in the r...

Page 2636: ...stall the universal joint to the serrations of gearbox assembly by matching alignment marks 3 Tighten the bolts Tightening torque 24 N m 2 4 kgf m 17 7 ft lb CAUTION Excessively large tightening torqu...

Page 2637: ...the swing torque of universal joint Service limit Maximum load 3 8 N 0 39 kgf 0 86 lbf or less Service limit Maximum load 3 8 N 0 39 kgf 0 86 lbf or less Service limit Maximum load 7 3 N 0 74 kgf 1 64...

Page 2638: ...5 Remove all connectors from the steering col umn 6 Remove the two bolts under instrument panel securing the steering column 7 Pull out the steering shaft assembly from the hole on toe board CAUTION B...

Page 2639: ...ON Insert the roll connector guide pin into the guide hole on lower end of steering wheel sur face to prevent damage C DISASSEMBLY Remove the two screws securing the upper steer ing column covers and...

Page 2640: ...emoving the castle nut use a puller to remove the tie rod end from the knuckle arm 8 Remove the front crossmember support plate jack up plate and front stabilizer Ref to FS 16 REMOVAL Front Stabilizer...

Page 2641: ...ATION 1 Insert the gearbox into crossmember being careful not to damage gearbox boot 2 Install the gearbox and bracket Temporarily tighten the bolts 3 Insert bolts through the clamp to temporarily tig...

Page 2642: ...ON Front Stabilizer 10 Install the front crossmember support plate and jack up plate 11 Install the front exhaust pipe assembly Non turbo model Ref to EX H4SO 7 INSTALLA TION Front Exhaust Pipe 12 Ins...

Page 2643: ...p plate as a unit 2 Secure the gearbox removed from vehicle in a vise using ST ST1 926200000 STAND ST2 34199AG000 BOSS D CAUTION Secure the gearbox in a vise using ST as shown in the figure Do not sec...

Page 2644: ...e the valve assembly 12 Using a drill release the crimping of holder CAUTION Make a hole of 2 mm 0 08 in depth using a drill with 3 mm 0 12 in diameter 13 Remove the holder 14 Attach the ST to the pin...

Page 2645: ...e gearbox removed from vehicle in a vise using ST ST1 926200000 STAND ST2 34199AG000 BOSS D CAUTION Secure the gearbox in a vise using ST as shown in the figure Do not secure the gearbox without this...

Page 2646: ...press remove the bushing and oil seal from the valve housing ST 34199AG090 INSTALLER REMOVER CAUTION Do not apply a force to the end surface of valve housing Do not reuse the oil seal after removal 11...

Page 2647: ...0 GUIDE G 26 5 Using the ST A and ST B attach the oil seal to ST C ST 34199FE040 INSTALLER A B C INSTALLER A 34199FE070 INSTALLER B 34199FE080 INSTALLER C 34199FE090 NOTE Face the oil seal in the dire...

Page 2648: ...ST 34199FE000 INSTALLER REMOVER 12 Set the ST to the end of rack ST 34199FE000 INSTALLER REMOVER 13 Using a press press fit until the mark on the ST is aligned with the end surface of the holder 14 Re...

Page 2649: ...alve assembly 22 Install a new gasket on valve assembly Insert the valve assembly into place while facing the rack teeth toward pinion 23 Tighten the bolts alternately to secure the valve assembly Tig...

Page 2650: ...specification using adjusting screw Ref to PS 34 TURNING RESISTANCE OF GEARBOX INSPECTION Steering Gearbox 31 Apply liquid gasket to lock nut and install it into adjusting screw While holding the adju...

Page 2651: ...ure that the boot is installed without unusual inflation or deflation 36 Install a new boot band Using band clamp pli ers crimp it so that the clearance of crimping por tion becomes 2 mm 0 079 in or l...

Page 2652: ...d end turn it slowly at a radius several times as large as possible Finally make sure that the boot is installed in the specified position without inflating 41 Remove the gearbox from ST ST1 926200000...

Page 2653: ...INSTALLER REMOVER 6 Apply vinyl tape to the groove of pinion 7 Install the back up ring and oil seal to pinion and then remove the vinyl tape 8 Attach the ST to pinion and install the seal ring ST 341...

Page 2654: ...nd bearing of valve assembly 17 Install new O ring to valve assembly 18 Insert the valve assembly into place while fac ing the rack teeth toward pinion 19 Tighten the bolts alternately to secure the v...

Page 2655: ...URNING RESISTANCE OF GEARBOX INSPECTION Steering Gearbox 25 Apply liquid gasket to lock nut and install it into adjusting screw While holding the adjusting screw with wrench tighten the lock nut using...

Page 2656: ...nion engage uniformly and smoothly with each other Refer to Service limit 2 Pull out the entire rack to allow viewing of the teeth and check for damage Even if abnormality is found in either 1 or 2 re...

Page 2657: ...Right turn steering Service limit 0 12 mm 0 005 in or less Condition Weighting point L1 10 mm 0 39 in P 98 N 10 kgf 22 lb Measuring point L2 25 mm 0 98 in 4 INPUT SHAFT PLAY In radial direction Servi...

Page 2658: ...side respectively with the gearbox mounted to the vehicle and remove fluid from surrounding portions Then turn the steering wheel from lock to lock about 30 to 40 times with the engine running then re...

Page 2659: ...ls are set in the straight ahead position or error is more than 5 on the periphery of the steering wheel correctly re install the steering wheel 4 If the steering wheel spokes are not horizontal with...

Page 2660: ...ischarge the fluid by turning the steering wheel fully clockwise and counterclockwise Dis charge the fluid similarly from other pipes 4 Remove the clamp E from return hose and pres sure hose 5 Disconn...

Page 2661: ...bo model 8 Disconnect the suction hose and return hose from the reservoir tank 9 Remove the hose bracket and take out the hose assembly from vehicle 1 Suction hose 2 Pressure hose 1 Suction hose 2 Pre...

Page 2662: ...AUTION Firmly insert the plastic clip of return hose to the bracket 4 Connect the suction hose and pressure hose to the oil pump Tighten the eye bolt of pressure hose Tightening torque 40 N m 4 1 kgf...

Page 2663: ...l Description 9 Install the front crossmember support plate and jack up plate 10 Lower the vehicle 11 Tighten the bolts which hold the hose bracket Tightening torque 10 N m 1 0 kgf m 7 4 ft lb 12 Inst...

Page 2664: ...actually leaking This is because the fluid spilt during the last maintenance was not completely wiped off Be sure to wipe off spilt fluid thoroughly after maintenance Part Maintenance parts Corrective...

Page 2665: ...lace with a new part Crack or damage in hose hardware Replace with a new part Leakage from surrounding of cast iron portion of oil pump 14 and 15 in the figure Damaged O ring Replace the oil pump Dama...

Page 2666: ...tter from entering the hose and pipe cover the open ends with clean cloth Non turbo model Turbo model 5 Remove the installation bolt of the power steer ing pump bracket 6 Place the oil pump bracket in...

Page 2667: ...d seizure of the oil pump 4 Connect the pressure hose and suction hose Tightening torque Eye bolt 40 N m 4 1 kgf m 29 5 ft lb CAUTION Be careful when installing If the hose is twisted it may come into...

Page 2668: ...ge Replace with a new part 2 Bend Measure the V groove deflection If it exceeds the service limit replace the pulley with a new part 3 Oil pump Interior 1 Faulty or seized of vane pump Check the rotat...

Page 2669: ...P When applying the force of 9 8 N 1 0 kgf 2 2 lbf Service limit Play in the radial direction Direction 0 4 mm 0 016 in or less Axial play Direction 0 9 mm 0 035 in or less 2 Deflection of the pulley...

Page 2670: ...Non turbo model Turbo model 5 Attach the ST3 to the end of pressure hose which is removed from pump 6 Replenish power steering fluid up to the specified level 7 Open the valve and start the engine 8...

Page 2671: ...9AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A Service limit Non turbo model 7 350 8 050 kPa 75 82 kgf cm2 1 066 1 167 psi Turbo model 8 100 8 800 kPa 83 90 kgf cm2 1 174 1 276 psi 4 If it is out...

Page 2672: ...k from the body B INSTALLATION 1 Install the reservoir tank to the body Tightening torque 13 N m 1 3 kgf m 9 6 ft lb 2 Connect the hose to the reservoir tank 3 Replenish power steering fluid up to the...

Page 2673: ...lowly from lock to lock until the bubbles stop appearing on oil surface while keeping the fluid at the level in the Step 4 6 If the steering wheel is turned in a low fluid level condition air will be...

Page 2674: ...to pulley bottom Poor revolution of pulleys except oil pump pulley Poor revolution of oil pump pulley Adjust or replace 2 Tire and wheel Improper tire out of specifications 1 Improper wheel out of spe...

Page 2675: ...w to rapid step by step Trouble Possible cause Corrective action Hiss noise continuous While engine is running Relief valve emits operating sound when steering wheel is completely turned in either dir...

Page 2676: ...r hose Replace the oil pump or hose if the noise can be heard when vehicle is running as well as being stopped Torque converter growl air conditioner compression growl Remove the power steering pul le...

Page 2677: ...teering effort less than 2 26 N 0 23 kgf 0 51 lbf Go to step 4 Check adjust and replace if neces sary 4 CHECK STEERING WHEEL EFFORT Measure the steering wheel effort Is the difference of steering effo...

Page 2678: ...f to PS 34 TURNING RESISTANCE OF GEARBOX INSPECTION Steering Gearbox Is the rotating resistance of steeringgearboxlessthan11 3N 1 15 kgf 2 54 lbf Is the differ ence between right and left sides less t...

Page 2679: ...l with ABS 10 0 39 14 Front suspension bracket to Return hose 5 0 20 15 Front wheel apron to Return hose 5 0 20 16 VDC H U bracket to Suction hose Model with vehicle dynamics control VDC 5 0 20 17 Air...

Page 2680: ...PS 57 General Diagnostic Table POWER ASSISTED SYSTEM POWER STEERING PS 00772 4 1 6 15 20 21 22 23 29 30 32 33 24 25 26 27 5 8 9 13 14 28 31 10 11 16 3 12 19 18 17 7 2...

Page 2681: ...PS 58 General Diagnostic Table POWER ASSISTED SYSTEM POWER STEERING...

Page 2682: ...motor Type Magnet motor 250 W or less 12 V Fan type and size diameter width Sirocco fan type 150 75 mm 5 91 2 95 in Item Specifications Type of air conditioner Reheat air mix type Cooling capacity 5 0...

Page 2683: ...r100 rpm Turbo MT model no load 750r100 rpm Turbo MT model A C ON 800r100 rpm Triple switch Pressure switch Low pressure switch operating pressure ON o OFF 177r25 kPa 1 80r0 25 kgf cm2 25 7r3 6 psi OF...

Page 2684: ...mm 11 42 6 77 1 54 in Blower fan Fan type Sirocco fan Outer diameter width 150 75 mm 5 91 2 95 in Power consumption 250 W Condenser fan Sub fan Motor type Magnet Power consumption 90 W Fan outer diam...

Page 2685: ...5 General Description HVAC SYSTEM HEATER VENTILATOR AND A C Thermo control amplifier operating temperature 1 ON 2 OFF 3 1 5r0 3 C 34 7r0 5 F 4 1 0r0 5 C 33 8r0 9 F Item Specifications AC 00601 1 2 3...

Page 2686: ...O ring 17 Heater core cover 29 Vent door link 6 Evaporator pipe 18 O ring 30 Defroster door link 7 Evaporator 19 Clamp 31 Mode link 8 Lining 20 Heater core 9 Evaporator sensor 21 Pipe clamp Tightening...

Page 2687: ...oster door link 5 O ring 17 O ring 29 Mode link 6 Evaporator pipe 18 Clamp 7 Evaporator 19 Heater core Tightening torque N m kgf m ft lb 8 Lining 20 Pipe clamp T1 5 0 0 5 3 7 9 Thermostat 21 Foot duct...

Page 2688: ...OWER MOTOR UNIT 1 Lining 6 Hose 11 Relay holder bracket 2 Upper case 7 Lower case 3 Intake door actuator 8 Lining Tightening torque N m kgf m ft lb 4 Filter 9 Intake door link T 7 5 0 76 5 5 5 Blower...

Page 2689: ...C 3 CONTROL MODULE Auto A C model 1 FRESH RECIRC switch 5 Air flow control dial Tightening torque N m kgf m ft lb 2 Rear window defogger switch 6 Temperature control dial T 2 0 2 1 48 3 A C switch 7 C...

Page 2690: ...window defogger switch 11 Valve 2 Air flow control dial 7 FRESH RECIRC switch 3 Fan speed control dial 8 Switch board Tightening torque N m kgf m ft lb 4 Temperature control dial 9 Air flow control c...

Page 2691: ...ENTILATOR AND A C 4 AIR CONDITIONING UNIT 1 Condenser 5 O ring Tightening torque N m kgf m ft lb 2 Hose High pressure 6 Clamp T1 7 5 0 76 5 5 3 Hose Low pressure 7 Pipe T2 10 1 0 7 4 4 Compressor T2 5...

Page 2692: ...ILATOR AND A C 5 COMPRESSOR 1 Compressor bracket 4 Compressor bracket non turbo model Tightening torque N m kgf m ft lb 2 Compressor T1 26 5 2 7 19 5 3 V belt 5 Compressor bracket turbo model T2 36 3...

Page 2693: ...OR AND A C 6 HEATER DUCT 1 Front defroster nozzle 4 Side vent duct RH 7 Rear heater duct LH 2 Side defroster duct 5 Center vent duct 8 Rear heater duct RH 3 Side vent duct LH 6 Center vent duct front...

Page 2694: ...ere using a plug or tape In order to avoid moisture store the oil in a container with its cap tightly closed 3 REFRIGERANT CFC 12 refrigerant cannot be used in a HFC 134a A C system HFC 134a refrigera...

Page 2695: ...ings to avoid sticking before installation Use a torque wrench to tighten the O ring fittings Over tightening will result in damage of the O ring and deformation of the pipe end If the work is interru...

Page 2696: ...n stallation Apply compressor oil to the pipe grooves After tightening use a clean cloth to remove ex cess compressor oil from the connections and any oil which may have run on the vehicle body or oth...

Page 2697: ...and CFC 12 systems must also not be interchanged HFC 134a CFC 12 Tool screw type Millimeter size Inch size Valve type Quick joint type Screw in type ILLUSTRATION Tools and Equipment Wrench Various WRE...

Page 2698: ...il into the system again A syringe can be available at a pharmacy or drug store Vacuum pump A VACUUM PUMP is necessary for a good working condition and may be available at either a refrigerant supplie...

Page 2699: ...ECTOR can be available at either a spe cialty tool supplier or an A C equipment supplier Weight scale A WEIGHT SCALE such as an electronic charging scale or a bath room scale with digital display will...

Page 2700: ...efective condenser fan motor Clogged condenser fin Too much refrigerant Air inside the system Defective receiver dryer Replace the fan motor Clean the condenser fin Discharge refrigerant Replace the r...

Page 2701: ...peration manual attached to the refrigerant recovery system 1 Perform compressor oil return operation Ref to AC 26 PROCEDURE Compressor Oil 2 Stop the engine 3 Make sure the valves on low high pressur...

Page 2702: ...d 1 Close all valves of the manifold gauge 2 Attach the low pressure side and high pressure side hoses to the vehicle service port CAUTION Confirm that the connections are secure 3 Connect the center...

Page 2703: ...4a source 13 Loosen the center manifold hose connection on the manifold gauge for a few seconds if there is a purge valve on the manifold gauge push this in stead to allow the air in the center manifo...

Page 2704: ...do not open the high pressure side valve Always fill from the low pressure side valve A C switch ON Engine running at 1 500 rpm Blower speed setting to HI Temperature setting to MAX COOL Air inlet se...

Page 2705: ...leak age about 3 g 0 1 oz per year This is not a prob lem 3 Starting from the connection between low pres sure pipe and evaporator check the system for leakage along the low pressure side through the...

Page 2706: ...position 5 Turn the blower control switch to HI 6 Leave in this condition for 10 minutes B REPLACEMENT NOTE If a component has been replaced add an ap propriate amount of compressor oil same as the a...

Page 2707: ...ve the engine ECM protect cover 4 Disconnect the intake door actuator and blower motor harness connectors 5 Remove the relay holder 6 Remove the bolts and nuts to remove blower motor unit assembly B I...

Page 2708: ...the floor mat near the blower motor 4 Remove the screws and detach the blower mo tor B INSTALLATION Install in the reverse order of removal C INSPECTION Connect the battery positive terminal to termin...

Page 2709: ...istor Auto A C Model A REMOVAL 1 Remove the instrument panel lower Ref to EI 51 INSTRUMENT PANEL LOWER REMOVAL Center Console 2 Disconnect the power transistor connector 3 Remove the two screws and re...

Page 2710: ...T PANEL LOWER REMOVAL Center Console 2 Disconnect the blower resistor connector 3 Remove the two screws and remove the blower resistor B INSTALLATION Install in the reverse order of removal C INSPECTI...

Page 2711: ...ch the pipe 5 Remove the heater core cover 6 Remove the heater core B INSTALLATION CAUTION Replace O rings and pipe clamps with new parts and install securely 1 Install in the reverse order of removal...

Page 2712: ...ent panel Ref to EI 49 ORNAMENT PANEL REMOVAL Center Con sole 3 Remove the control wires from both sides of the heater and cooling unit 4 Remove the screws and claws and remove the control module from...

Page 2713: ...tery 2 Remove the ornament panel Ref to EI 49 ORNAMENT PANEL REMOVAL Center Con sole 3 Remove the screws and claws and remove the control module from the ornament panel B INSTALLATION Install in the r...

Page 2714: ...ll in the reverse order of removal 2 Replace the O rings on low high pressure hos es with new parts then apply compressor oil 3 After replacing the compressor adjust the amount of compressor oil Ref t...

Page 2715: ...compressor Ref to AC 26 REPLACEMENT Compressor Oil B INSTALLATION CAUTION Replace the O rings on hoses or pipes with new parts and then apply compressor oil Confirm that lower guide A of condenser fit...

Page 2716: ...nel Assembly 6 Remove the blower motor unit assembly Ref to AC 27 REMOVAL Blower Motor Unit Assem bly 7 Disconnect the harness connectors of the actu ator thermo sensor power transistor and blower res...

Page 2717: ...the evaporator is replaced add an appropriate amount of compressor oil to evaporator Ref to AC 26 REPLACEMENT Compressor Oil B INSTALLATION CAUTION Install the sensor in the location shown in the figu...

Page 2718: ...C 21 PROCEDURE Refrigerant Recovery Procedure 3 Remove the bolt and detach the hoses and pipes B INSTALLATION CAUTION Replace the O rings with new parts When connecting hoses do not apply an ex cessiv...

Page 2719: ...attery voltage to the terminal between 3 and 4 check for continuity between 1 and 2 2 Replace the relay if faulty 1 Joint box 2 Main fuse box Main fan relay 1 A Main fan relay 2 B Sub fan relay C A C...

Page 2720: ...h effectively controls the radiator fan output by judging high load low load in normal range If the refrigerant pressure is abnormally low the low pressure switch determines that there is insufficient...

Page 2721: ...ground cable from the battery 2 Disconnect the ambient sensor connector 3 Remove the ambient sensor from the radiator lower panel B INSTALLATION Install in the reverse order of removal C INSPECTION Re...

Page 2722: ...out the sunload sensor from the back side of the instrument panel 4 Disconnect the harness connector and remove the sunload sensor CAUTION Be careful not to damage the interior trims when removing the...

Page 2723: ...m battery 2 Remove the instrument panel lower cover Ref to EI 46 REMOVAL Instrument Panel Lower Cov er 3 Disconnect the connector and aspirator hose remove the screw and remove the in vehicle sen sor...

Page 2724: ...er panel 3 Remove the claws and remove the air vent cen ter grille from the center panel 2 SIDE GRILLE 1 Remove the ornament panel Ref to EI 49 ORNAMENT PANEL REMOVAL Center Con sole 2 Remove the claw...

Page 2725: ...ter cooling unit Ref to AC 36 REMOVAL Heater and Cooling Unit 2 Remove the front seats Ref to SE 6 REMOV AL Front Seat 3 Remove the front side sill cover 4 Pull off the floor mat to remove the rear he...

Page 2726: ...NTILATOR AND A C 26 Heater Vent Duct A REMOVAL 1 Remove the instrument panel Ref to EI 52 REMOVAL Instrument Panel Assembly 2 Remove the screws and then remove the heater vent duct B INSTALLATION Inst...

Page 2727: ...C Filter A REPLACEMENT 1 Remove the glove box damper 2 Remove the stoppers and pull the glove box lid assembly forward to remove 3 Pinch the tabs to release the lock and remove the A C filter 4 Instal...

Page 2728: ...clutch Compressor Pressure switch A C switch Blower switch Wiring harness Noise V belt Magnet clutch Compressor Cold air not emitted Refrigerant V belt Magnet clutch Compressor Pressure switch Aspira...

Page 2729: ...A C Temperature control cable Manual A C Temperature control switch Wiring harness Auto A C Unable to switch blow vents Mode actuator Auto A C Mode switch cable Manual A C Mode switch Auto A C Wiring...

Page 2730: ...AC 50 General Diagnostic Table HVAC SYSTEM HEATER VENTILATOR AND A C...

Page 2731: ...ction part be confirmed Repair the mal functioning part in accordance with each diagnostic chart Go to step 3 3 CHECK COMPARTMENT TEMPERATURE 1 Turn on the A C switch 2 Turn the temperature control di...

Page 2732: ...ure the battery voltage and specific gravity of the electrolyte Standard voltage 12 V Specific gravity 1 260 or more 2 Check the condition of the fuses for A C system power supply and other fuses 3 Ch...

Page 2733: ...Auto function Operate in order from 1 1 Set the following dial and switch to AUTO Air flow control dial Fan speed control dial FRESH RECIRC switch A C switch 2 Turn the temperature control dial comple...

Page 2734: ...Location HVAC SYSTEM AUTO A C DIAGNOSTICS 3 Electrical Component Location A LOCATION 1 ENGINE COMPARTMENT 1 A C compressor 3 Pressure switch 4 Ambient sensor 2 A C relay AC 01879 2 1 3 AC 01973 1 2 A...

Page 2735: ...HVAC SYSTEM AUTO A C DIAGNOSTICS 2 COMPARTMENT 1 Evaporator sensor 4 Blower motor 7 Mode door actuator 2 Air mix door actuator 5 Sunload sensor 8 In vehicle sensor 3 Auto A C control module 6 Intake...

Page 2736: ...V 17 RECIRC sensor Ignition switch ON 25 C 2 5 V 18 Post evaporator sensor Depends on temperature after the evaporator 1 4 5 V 19 CAN Lo Unable to measure the voltage for digital signal 20 CAN Hi Unab...

Page 2737: ...AC diag 8 Auto A C Control Module I O Signal HVAC SYSTEM AUTO A C DIAGNOSTICS B WIRING DIAGRAM 1 AIR CONDITIONER AUTO A C MODEL Ref to WI 85 WIRING DIAGRAM Air Conditioning System...

Page 2738: ...all switch LEDs on the control panel illuminate Do all LEDs blink eight times Go to step 3 Replace the con trol panel 3 CHECK SENSOR MALFUNCTION 1 Set the air flow control dial and the fan speed contr...

Page 2739: ...ocedure for Actuators 7 CHECK MODE DOOR POSITION DRIVE SIG NAL 1 Press the A C switch 2 Place the fan speed control dial in each position and then check each LED illumination conditions Ref to AC diag...

Page 2740: ...switch LED blinks Illuminates for 1 sec turns off for 1 sec Rear window defogger switch LED is turned off Rear window defogger switch LED illuminates 1st Ambient sensor FRESH RECIRC switch LED blinks...

Page 2741: ...d in the past FACE AUTO MIX 1 Blinking Illumi nates for 0 2 sec turns off for 0 2 sec FRESH RECIRC switch LED is turned off FRESH RECIRC switch LED blinks Illuminates for 0 2 sec turns off for 0 2 sec...

Page 2742: ...t temperature is not indicated on the display switch LEDs are faulty and switches do not operate Self diagnosis system does not operate WIRING DIAGRAM F B No 7 F B No 22 F B No 31 MAIN SBF SBF 6 ACC i...

Page 2743: ...een A C control panel and fuse 3 CHECK A C CONTROL MODULE POWER CIRCUIT Measure the voltage between A C control panel harness connector terminal and chassis ground after turning the ignition switch to...

Page 2744: ...ove the blower motor relay 3 Turn the ignition switch to ON 4 Use a tester to measure the voltage between the terminals Connector terminal B386 No 2 Chassis ground Is the voltage 10 V or more Go to st...

Page 2745: ...onnect the connector from blower motor 3 Connect the battery positive terminal to the blower motor connector terminal No 2 and the negative terminal to No 1 4 Make sure the blower motor runs Does the...

Page 2746: ...ate at high speed Not adjustable WIRING DIAGRAM i88 40 FB 46 F B FUSE NO 22 IG i88 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 36 37 38 39 40 FB 8 F...

Page 2747: ...POWER TRANSISTOR Measure the resistance between power transis tor terminals using a tester Connector terminal B57 No 3 No 1 Is the resistance less than 10 Replace the power transistor Ref to AC 29 RE...

Page 2748: ...10 2 3 1 4 36 A B F37 B143 C F35 M B A4 B13 C3 C7 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B361 F108 14 9 B360 F109 1 9 2 3 1 4 ECM B136 C...

Page 2749: ...sure switch harness connector terminal and chassis ground Connector terminal B10 No 2 Chassis ground Is the voltage 10 V or more Go to step 4 Check for open or short circuit in the harness between fus...

Page 2750: ...switch to ON 3 Measure the voltage between ECM connec tor terminal and chassis ground Connector terminal B136 No 9 Chassis ground Is the voltage 10 V or more Go to step 10 Check for open or short cir...

Page 2751: ...R TROUBLE SYMPTOM FRESH RECIRC mode is not changed WIRING DIAGRAM AC 01758 i88 7 6 FB 46 F B FUSE NO 22 IG B163 5 4 1 8 6 i88 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 2752: ...r terminal i88 No 8 B163 No 6 i88 No 7 B163 No 5 i88 No 6 B163 No 4 Is the resistance less than 1 Go to step 3 Repair the harness between auto A C controlmoduleand intake door actua tor 3 CHECK OPERAT...

Page 2753: ...r flow outlet is not changed WIRING DIAGRAM AC 01963 i88 AUTO A C CONTROL MODULE 1 2 3 4 B77 6 1 5 2 3 TO POWER SUPPLY CIRCUIT FB 18 F B FUSE NO 7 B B77 i88 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1...

Page 2754: ...ator terminals using a tester Connector terminal B77 No 3 No 1 B77 No 3 No 2 B77 No 3 No 5 B77 No 3 No 6 Is the resistance between 80 100 Go to step 3 Replace the mode door actuator 3 CHECK HARNESS BE...

Page 2755: ...r temperature does not change WIRING DIAGRAM AUTO A C CONTROL MODULE AIR MIX DOOR ACTUATOR AC 01812 i88 25 26 27 28 B239 6 1 5 2 3 FB 18 F B FUSE NO 7 B B239 i88 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 2756: ...Connector terminal B239 No 3 No 1 B239 No 3 No 2 B239 No 3 No 5 B239 No 3 No 6 Is the resistance between 80 100 Go to step 3 Replace the air mix door actuator 3 CHECK HARNESS BETWEEN AUTO A C CONTROL...

Page 2757: ...No 2 No 1 Is the resistance approximately 3 k at 25 C 77 F Go to step 2 Replace the ambi ent sensor Ref to AC 41 REMOVAL Ambi ent Sensor Auto A C Model 2 CHECK INPUT SIGNAL FOR AMBIENT SEN SOR 1 Turn...

Page 2758: ...meter Ref to IDI 16 REMOVAL Com bination Meter Repair the open circuit of the har ness between the combination meter and ambient sen sor 6 CHECK HARNESS CONNECTOR BETWEEN COMBINATION METER AND AUTO A...

Page 2759: ...and FRESH RECIRC do not change after turning the AUTO switch to ON Failure related to the in vehicle sensor is indicated in self diagnosis WIRING DIAGRAM AC 01700 i88 17 14 i55 1 2 i55 1 2 i88 1 2 3 4...

Page 2760: ...between connector terminals of auto A C control module Connector terminal i88 No 17 i88 No 14 Is the voltage approx 5 V Go to step 4 Go to step 6 4 CHECK HARNESS BETWEEN AUTO A C CONTROL MODULE AND IN...

Page 2761: ...TO A C DIAGNOSTICS C EVAPORATOR SENSOR WIRING DIAGRAM EVAPORATOR SENSOR AUTO A C CONTROL MODULE AC 01760 i88 18 14 B88 1 2 B88 i88 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...

Page 2762: ...ntrol module Connector terminal i88 No 18 i88 No 14 Is the voltage approx 5 V Go to step 4 Go to step 6 4 CHECK HARNESS CONNECTOR BETWEEN AUTO A C CONTROL MODULE AND EVAP ORATOR SENSOR 1 Turn the igni...

Page 2763: ...t minimum Then A C system is controlled to HOT side NOTE When the sunload sensor check is performed indoors or in the shade it could be diagnosed as having an open circuit Always check the sunload sen...

Page 2764: ...C controlmoduleand sunload sensor 3 CHECK HARNESS CONNECTOR BETWEEN AUTO A C CONTROL MODULE AND SUN LOAD SENSOR Measure the resistance of the harness between the auto A C control module and sunload s...

Page 2765: ...temperature does not increase hot air does not come out Connector Poor contact Auto A C control module Air mix door actuator In vehicle sensor ambient sensor evaporator sensor and sunload sensor In v...

Page 2766: ...de airbag module LH 12 Airbag module ASSY Passenger 20 Curtain airbag sensor RH 5 Airbag rear harness LH 13 Side airbag module RH 21 Satellite safing sensor 6 Airbag module ASSY Driver 14 Occupant det...

Page 2767: ...kgf m 5 5 ft lb 3 SIDE AIRBAG MODULE Tightening torque 6 N m 0 61 kgf m 4 4 ft lb 4 CURTAIN AIRBAG MODULE 5 DOOR MODEL 4 DOOR MODEL Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb 5 AIRBAG CONTROL MOD...

Page 2768: ...tening torque 7 5 N m 0 76 kgf m 5 5 ft lb 8 CURTAIN AIRBAG SENSOR CAUTION Do not reuse mounting bolts and nuts Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb 9 SATELLITE SAFING SENSOR CAUTION Do not...

Page 2769: ...a minimal current inside tester When checking use a test harness 1 Damage to connector terminal cause malfunction Do not di rectly apply the tester probe to connector terminal of airbag Do not allow...

Page 2770: ...defective parts with new parts Never reuse a deployed airbag module and pre tensioner Do not discard the uninflated airbag or preten sioner When airbag control module front sub sensor side airbag sens...

Page 2771: ...wn Do not place any objects on the airbag module Do not pile up the airbag module If the airbag inflates for some reason when an airbag module pad is touching oth er objects it may cause serious accid...

Page 2772: ...G CONTROL MODULE 1 How to disconnect CAUTION When disconnecting connector be sure to hold the connector not the harness Press the lock lever plate A and pull out the lock lever 2 How to connect CAUTIO...

Page 2773: ...connect from the driver s airbag module assembly or the retractor assembly 2 How to connect CAUTION Be sure to insert the connector in until it is locked Press in the push lock securely Then pull it g...

Page 2774: ...lock A in the direction of ar row and hold it 2 While holding the slide lock A pull the con nector B in the direction of arrow 2 How to connect CAUTION Be sure to insert the connector in until it is l...

Page 2775: ...rection of arrow 3 Push the lock arm again 4 Holding outer part pull it in the direction of arrow to disconnect the connector 2 How to connect CAUTION Be sure to insert the connector in until it is lo...

Page 2776: ...ndition and play 4 For the passenger s seat replace the seat cush ion pad frame assembly with a new part if the seat cushion frame assembly is deformed or cracked 5 If there are tears or loosening in...

Page 2777: ...rbag is deployed 6 FRONT SUB SENSOR If the section of vehicle as shown in the figure is damaged check the following items and replace the damaged parts with new parts Front sub sensor is cracked or de...

Page 2778: ...bly Do not disas semble Cracks or deformation found in the seat cushion frame or seat cushion pad Scratches cracks or deformation found on the passenger detection system pressure sen sor hoses or pass...

Page 2779: ...ag mod ule Ref to AB 8 PROCEDURE Airbag Connec tor 7 Refer to CAUTION for handling of a removed airbag module Ref to AB 5 CAUTION General Description B INSTALLATION CAUTION Refer to CAUTION of General...

Page 2780: ...irbag module 5 Refer to CAUTION for handling of a removed airbag module Ref to AB 5 CAUTION General Description B INSTALLATION CAUTION Do not allow harness and connectors to inter fere or get tangled...

Page 2781: ...stener at the bottom back side of backrest 7 Open the fastener at the rear side of backrest 8 Remove the hog rings of backrest cover CAUTION When removing the hog rings be careful not to tear the viny...

Page 2782: ...neral Description before handling the airbag module Ref to AB 5 CAUTION General Description Check for the following and replace damaged parts with new parts Ref to AB 13 SIDE AIR BAG MODULE INSPECTION...

Page 2783: ...urtain airbag module CAUTION Be careful not to damage the curtain airbag module during removal Never open the curtain airbag module before deploying it Never reuse the deployed curtain airbag module 5...

Page 2784: ...sensor Roof trim Front pillar upper trim Center pillar upper trim Rear quarter pillar trim Airbag guide 2 When damage is found by visual check Assist grip Assist grip bracket Curtain airbag harness an...

Page 2785: ...the center panel Ref to EI 49 CEN TER PANEL REMOVAL Center Console 5 Remove the console front panel Ref to EI 49 CONSOLE FRONT PANEL REMOVAL Center Console 6 Remove the audio 7 Remove the heater duct...

Page 2786: ...sub sensor 6 Disconnect the connector from front sub sensor B INSTALLATION CAUTION Do not reuse the bolt and nut Always use new bolts and nuts for them When installing the sensor insert the set pin o...

Page 2787: ...Do not separate the side airbag sensor and bracket Doing so will cause the airbag system malfunction If the sensor is removed from the bracket be sure to replace with a new part 5 Disconnect the airb...

Page 2788: ...tain airbag sensor 5 Disconnect the airbag connector B INSTALLATION CAUTION Do not reuse the bolt and nut Always use new bolts and nuts for them When installing the sensor securely insert the arrest p...

Page 2789: ...LLATION CAUTION Do not reuse the bolt and nut Always use new bolts and nuts for them When installing the satellite safing sensor cover push the cover securely until it contacts the floor panel If the...

Page 2790: ...nector B INSTALLATION 1 Install in the reverse order of removal 2 Before installing steering wheel be sure to ad just the direction of roll connector with steering Ref to AB 26 ADJUSTMENT Roll Connect...

Page 2791: ...of the Subaru Se lect Monitor cannot be executed properly check the communication circuit Ref to AB diag 26 COMMUNICATION FOR INI TIALIZING IMPOSSIBLE INSPECTION Sub aru Select Monitor 5 Record all D...

Page 2792: ...egistration Year Weather Fine Cloudy Rainy Snowy Others Temperature C F Road Condition Flat road Uphill Downhill Gravel road Others Vehicle Operation Starting Idling Driving Constant speed Acceleratin...

Page 2793: ...l circuit tester Use of an analog circuit tester may cause the airbag to activate erroneously due to a minimal current inside tester When checking use a test harness 1 Damage to connector terminal cau...

Page 2794: ...enger s side and curtain or the pretensioner The removed front seat with airbag module must be kept at least 200 mm 8 in away from walls and other objects When painting or performing sheet metal work...

Page 2795: ...ear doors rear crossmember and rear floorpan remove the side airbag sensors cur tain airbag sensor satellite safing sensor and wir ing harness of the airbag system Do not discard undeployed airbag mod...

Page 2796: ...the airbag module Do not pile up the airbag module If the airbag inflates for some reason when an airbag module pad is touching other objects it may cause serious accident B INSPECTION Measure the bat...

Page 2797: ...TEST HARNESS H ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FA0...

Page 2798: ...GNOSTICS TEST HARNESS N ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA000 TEST HARNESS N Used when measuring voltage and resistance of driver s airbag module and seat belt preten sioner 2N 1N ST...

Page 2799: ...IAGNOSTICS TEST HARNESS P ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA020 TEST HARNESS P Used when measuring voltage and resistance of driver s airbag module harness ST98299SA020 1P 2P 3P AB 0...

Page 2800: ...BAG SYSTEM DIAGNOSTICS TEST HARNESS Q ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA040 TEST HARNESS Q Used when measuring voltage and resistance of driver s airbag module 2Q 1Q ST98299SA040 AB...

Page 2801: ...neral Description AIRBAG SYSTEM DIAGNOSTICS TEST HARNESS AG ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299AG070 TEST HARNESS AG Used when measuring voltage and resistance of airbag control module...

Page 2802: ...11 12 78 22 73 71 24 63 16 13 14 65 62 60 61 34 43 33 40 74 75 20 18 21 17 64 15 72 23 57 66 58 2AG 9 8 7 6 5 4 3 2 1 10 45 46 49 50 35 48 42 47 41 20 18 14 13 12 17 16 15 19 11 10 9 8 7 6 5 4 3 2 1...

Page 2803: ...21 22 23 24 25 26 27 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 68 67 66 65 64 63 69 70 71 72 73 74 55 56 61 62 75 76 77 78 3 4 5 6 7 8 10 11 12 13 28 29 30 31 32 60 59 58 57 1...

Page 2804: ...LLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299AG010 TEST HARNESS V Used when measuring voltage and resistance of side airbag sensor and curtain airbag sensor ST98299AG010 1V 3V 2V AB 00677 3V 2V 1V...

Page 2805: ...AGNOSTICS TEST HARNESS AB ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA000 TEST HARNESS AB Used when measuring voltage and resistance of occupant detection system ST98299XA000 OD 00029 1AB 2AB...

Page 2806: ...ATION TOOL NUMBER DESCRIPTION REMARKS 98299PA040 AIRBAG RESISTOR Used in replacement of airbag module for which resistance value is same as airbag module Two ST are required for diagnosis of two stage...

Page 2807: ...KS 98299AG090 TEST HARNESS AI Used when diagnosing the side airbag sensor and curtain airbag sensor Used together with test harness V TOOL NAME REMARKS Circuit tester Used for measuring resistance vol...

Page 2808: ...4 Airbag main harness 12 Seat belt pretensioner LH 20 Buckle switch RH 5 Roll connector 13 Curtain airbag sensor RH 21 Belt tension sensor 6 Passenger s airbag inflator 14 Curtain airbag sensor LH 22...

Page 2809: ...emale Female Female Female Female Male Connector No AB21 AB23 AB24 AB25 AB26 AB28 AB31 AB32 AB33 AB34 AB37 AB38 Pin 2 4 4 4 2 4 2 4 2 4 2 2 Color Black Yellow Yellow Yellow Black Yellow Black Yellow B...

Page 2810: ...diag 21 Airbag Connector AIRBAG SYSTEM DIAGNOSTICS 5 Airbag Connector A PROCEDURE For detailed operation procedure refer to the Air bag Connector in airbag section Ref to AB 8 PROCEDURE Airbag Connect...

Page 2811: ...s in airbag control module connector are shown in the figure The airbag warning light illuminates when the connector is removed from the airbag control module AB 02006 18 19 20 21 22 23 24 25 26 27 28...

Page 2812: ...g module level two 1 8 1 7 Front sub sensor LH 1 30 1 28 Front sub sensor RH 1 29 1 27 Ground line GND 1 25 1 26 Passenger s airbag OFF indicator 1 17 Passenger s airbag ON indicator 1 23 Passenger s...

Page 2813: ...on of instrument panel on the driver s side 2 Connect the diagnosis cable to data link connector CAUTION Do not connect the scan tools other than the Subaru Select Monitor 4 Turn the ignition switch t...

Page 2814: ...enger s airbag operating state 11 Passenger s airbag non operating state NOTE For details concerning the operation procedure refer to PC application help for Subaru Select Monitor 3 CLEAR MEMORY MODE...

Page 2815: ...ation is impossible between the airbag control module and the Subaru Select Monitor WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 MAIN SBF SBF 6 No 25 B40 B31 AB1 E 16 7 No 13 3 AB6 E E 16 26...

Page 2816: ...CONTROL MODULE CON NECTOR 1 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Confirm that the connectors of the airbag control modules AB6 AB...

Page 2817: ...rolmoduleand the data link con nector Or replace the airbag main harness along with the bulkhead har ness 11 CHECK POWER SUPPLY CIRCUIT 1 Turn the ignition switch to ON 2 Measure the voltage between c...

Page 2818: ...YMPTOM Airbag warning light remains on NO TROUBLE CODE will be displayed on the Subaru Select Monitor NOTE For detailed operation procedures refer to Airbag Warning Light Failure Ref to AB diag 34 Air...

Page 2819: ...Read Diagnostic Trouble Code DTC AIRBAG SYSTEM DIAGNOSTICS 8 Read Diagnostic Trouble Code DTC A OPERATION For details about reading of DTCs refer to Subaru Select Monitor Ref to AB diag 24 Subaru Se l...

Page 2820: ...AB diag 31 Inspection Mode AIRBAG SYSTEM DIAGNOSTICS 9 Inspection Mode A PROCEDURE Recreate the circumstance by referring to the con ditions described in the checklist...

Page 2821: ...STEM DIAGNOSTICS 10 Clear Memory Mode A OPERATION Clear the memory in the following steps after the malfunction is repaired For details concerning DTC clear operation refer to Subaru Select Monitor Re...

Page 2822: ...ICS 11 Airbag Warning Light Illumination Pattern A INSPECTION Turn the ignition switch to ON and confirm that the airbag warning light remains on for approx 6 sec onds then turns off afterwards 1 Airb...

Page 2823: ...ly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the airbag rear harness disconnect the side airbag m...

Page 2824: ...t go off Go to step 4 Go to step 5 4 CHECK GROUND CIRCUIT Measure the resistance between connector 2AG in the test harness AG and chassis ground Connector terminal 2AG No 4 Chassis ground 2AG No 3 Cha...

Page 2825: ...rning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the airbag rear harness d...

Page 2826: ...to step 4 Go to step 4 4 CHECK AIRBAG WARNING LIGHT CIRCUIT IN COMBINATION METER 1 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnec...

Page 2827: ...DRIVER S AIR BAG FAILURE Diag nostic Chart with Trouble Code 16 Passenger s Airbag failure Airbag main harness circuit Passenger s side is shorted to power supply Airbag module harness circuit Passen...

Page 2828: ...tem is faulty Airbag rear harness circuit is open shorted shorted to ground or shorted to power supply Occupant detection harness is faulty Refer to Occupant Detection System for details on DTC 2C Ref...

Page 2829: ...Side airbag sensor LH is faulty Ref to AB diag 72 DTC 54 SIDE AIRBAG SENSOR LH FAILURE Diagnostic Chart with Trouble Code 55 Side Curtain Airbag Firing output Side airbag module and curtain airbag mod...

Page 2830: ...y Airbag module harness circuit Driver s side is shorted to power supply Roll connector is shorted to power supply Airbag control module is faulty Driver s airbag module is faulty Ref to AB diag 86 DT...

Page 2831: ...Ref to AB diag 102 DTC E6 FRONT SEN SOR BUS LH COMMU NICATION ERROR Diagnostic Chart with Trouble Code Ref to AB diag 102 DTC E7 FRONT SENSOR BUS LH COMMUNICATION ERROR Diagnostic Chart with Trouble...

Page 2832: ...bag control module is faulty Ref to AB diag 113 DTC F1 SIDE SENSOR BUS LH COMMUNICA TION ERROR Diagnos tic Chart with Trouble Code Ref to AB diag 113 DTC F2 SIDE SENSOR BUS LH COMMUNICATION ERROR Diag...

Page 2833: ...3B FRONT SUB SENSOR LH FALSE INSTALLATION Diag nostic Chart with Trouble Code 3C Satellite Sensor Bus failure Satellite safing sensor is faulty Ref to AB diag 123 DTC 3C SATELLITE SENSOR BUS FAIL URE...

Page 2834: ...OSTICS 5D Curtain Airbag Sensor LH false installation Curtain A B sensor is misinstalled Airbag control module is faulty Ref to AB diag 124 DTC 5D CURTAIN AIR BAG SENSOR LH FALSE INSTALLATION Diagnost...

Page 2835: ...arting to work When replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting...

Page 2836: ...it for 20 seconds or more 2 Disconnect the test harness N from connec tor AB38 3 Disconnect the test harness Q from connec tor AB37 4 Remove the instrument panel lower cover and disconnect the connect...

Page 2837: ...3AG No 4 3AG No 2 3AG No 3 3AG No 3 3AG No 4 Is the resistance 1 M or more Go to step 6 Replace the airbag main harness along with body harness 6 CHECK AIRBAG CONTROL MODULE 1 Connect all connectors 2...

Page 2838: ...r and seat belt pretensioner connector for safety reasons NOTE Prior to starting work prepare two airbag resistors 98299PA040 WIRING DIAGRAM Step Check Yes No 1 CHECK POOR CONTACT OF CONNEC TORS Check...

Page 2839: ...rness along with body harness 4 CHECK AIRBAG MAIN HARNESS PASSEN GER S AIRBAG HARNESS Measure the resistance between connectors 3AG in the test harness AG and between con nector 3AG and chassis ground...

Page 2840: ...he airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconn...

Page 2841: ...nnect the test harness N from connec tor AB38 3 Disconnect the test harness Q from connec tor AB37 4 Remove the instrument panel lower cover and disconnect the connector AB7 from AB2 5 Connect the con...

Page 2842: ...the Inspection Mode 4 Read the DTC Is the same DTC displayed Replace the airbag control module Ref to AB 21 Airbag Control Module Go to step 6 6 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC di...

Page 2843: ...n replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main ha...

Page 2844: ...IRBAG HARNESS 1 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the airbag resistor from the con nectors 2P and 3P of test harness...

Page 2845: ...work When replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly Step Check Yes No 1 CHECK...

Page 2846: ...or Front outer seat belt with pretensioner of both sides Ref to SB 17 Front Seat Belt Steering roll connector Ref to AB 26 Roll Connector Occupant detection system passenger s seat cushion frame assem...

Page 2847: ...ontrol module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and pas...

Page 2848: ...terminal 2AG No 9 2AG No 8 2AG No 9 Chassis ground 2AG No 8 Chassis ground Is the resistance 1 M or more Replace the clock Ref to IDI 21 REMOVAL Clock Repair the bulk head harness Or replace the airba...

Page 2849: ...test harness AG connector 1AG to the connectors AB6 AB17 AB18 5 Connect the connector 1AB in the test har ness AB to the connector AB53 6 Measure the resistance between connector 6AG in the test harn...

Page 2850: ...TENSION SENSOR FAILURE NOTE Refer to Occupant Detection System for details on DTC 2C Ref to OD diag 24 DTC 2C BELT TENSION SENSOR FAILURE Diagnostic Procedure with Diagnostic Trouble Code DTC M DTC 3...

Page 2851: ...and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the...

Page 2852: ...place the body integrated unit Repair the bulk head harness Or replace the airbag main harness along with body harness 3 CHECK AIRBAG HARNESS 1 Turn the ignition switch to OFF 2 Connect the connectors...

Page 2853: ...disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the airbag rear harness disconnect the side airbag module connector curtain airbag module conn...

Page 2854: ...B17 AB18 7 Measure the resistance between the test harness AG connector 5AG and the test har ness AJ connector 3AJ Connector terminal 5AG No 5 3AJ No 1 5AG No 7 3AJ No 2 Is the resistance less than 10...

Page 2855: ...disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the airbag rear harness disconnect the side airbag module connector curtain airbag module conn...

Page 2856: ...B17 AB18 7 Measure the resistance between the test harness AG connector 5AG and the test har ness AJ connector 3AJ Connector terminal 5AG No 1 3AJ No 2 5AG No 3 3AJ No 1 Is the resistance less than 10...

Page 2857: ...odule and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and passenger s...

Page 2858: ...n switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the connector AB26 from seat belt pretensioner RH 3 Disconnect the connector AB33 from cur tain ai...

Page 2859: ...odule and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and passenger s...

Page 2860: ...ion switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the connector AB21 from seat belt pretensioner LH 3 Disconnect the connector AB31 from cur tain...

Page 2861: ...eared Replace the following parts Airbag control module Ref to AB 21 Airbag Control Module Side airbag module operating side Ref to AB 17 Side Airbag Module Side airbag sensor operating side Ref to AB...

Page 2862: ...urtain airbag module connector and seat belt pretensioner connector for safety reasons WIRING DIAGRAM Step Check Yes No 1 CHECK POOR CONTACT OF CONNEC TORS Check for poor contact of the connectors bet...

Page 2863: ...CHECK AIRBAG REAR HARNESS PRE TENSIONER HARNESS RH Measure the resistance between connector 3AG terminals in the test harness AG Connector terminal 3AG No 18 3AG No 20 Is the resistance 1 M or more G...

Page 2864: ...urtain airbag module connector and seat belt pretensioner connector for safety reasons WIRING DIAGRAM Step Check Yes No 1 CHECK POOR CONTACT OF CONNEC TORS Check for poor contact of the connectors bet...

Page 2865: ...CHECK AIRBAG REAR HARNESS PRE TENSIONER HARNESS LH Measure the resistance between connector 3AG terminals in the test harness AG Connector terminal 3AG No 10 3AG No 12 Is the resistance 1 M or more G...

Page 2866: ...e starting to work When replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspect...

Page 2867: ...tion switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the airbag resistor from test har ness 3 Disconnect connector AB24 from side air bag module RH...

Page 2868: ...e starting to work When replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspect...

Page 2869: ...tion switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the airbag resistor from test har ness 3 Disconnect connector AB19 from side air bag module LH...

Page 2870: ...replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main har...

Page 2871: ...battery and wait for 20 seconds or more 2 Disconnect the test harness N from connec tor AB38 3 Disconnect the test harness Q from connec tor AB37 4 Remove the instrument panel lower cover and disconne...

Page 2872: ...3AG No 2 3AG No 1 3AG No 4 3AG No 2 3AG No 3 3AG No 3 3AG No 4 Is the resistance 1 M or more Go to step 6 Replace the airbag main harness along with body harness 6 CHECK AIRBAG CONTROL MODULE 1 Connec...

Page 2873: ...t pretensioner connector for safety reasons NOTE Prior to starting work prepare two airbag resistors 98299PA040 WIRING DIAGRAM Step Check Yes No 1 CHECK POOR CONTACT OF CONNEC TORS Check for poor cont...

Page 2874: ...rness along with body harness 4 CHECK AIRBAG MAIN HARNESS PASSEN GER S AIRBAG HARNESS Measure the resistance between connectors 3AG in the test harness AG and between con nector 3AG and chassis ground...

Page 2875: ...he airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconn...

Page 2876: ...or more 2 Disconnect the test harness N from connec tor AB38 3 Disconnect the test harness Q from connec tor AB37 4 Remove the instrument panel lower cover and disconnect the connector AB7 from AB2 5...

Page 2877: ...the Inspection Mode 4 Read the DTC Is the same DTC displayed Replace the airbag control module Ref to AB 21 Airbag Control Module Go to step 6 6 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other DTC di...

Page 2878: ...n replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main ha...

Page 2879: ...3 CHECK AIRBAG MAIN HARNESS PASSEN GER S AIRBAG HARNESS 1 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the airbag resistor fro...

Page 2880: ...harness disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the airbag rear harness disconnect the side airbag module connector curtain airbag mod...

Page 2881: ...Measure the resistance between connector 6AG in the test harness AG and connector 2N in the test harness N Connector terminal 6AG No 6 2N No 1 6AG No 8 2N No 2 Is the resistance less than 10 Go to ste...

Page 2882: ...harness disconnect the airbag module connectors of the driver s and passenger s seats for safety When inspecting the airbag rear harness disconnect the side airbag module connector curtain airbag mod...

Page 2883: ...Measure the resistance between connector 6AG in the test harness AG and connector 2N in the test harness N Connector terminal 6AG No 1 2N No 2 6AG No 3 2N No 1 Is the resistance less than 10 Go to ste...

Page 2884: ...control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and p...

Page 2885: ...ition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the connector AB26 from seat belt pretensioner RH 3 Disconnect connector AB24 from side air ba...

Page 2886: ...control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors of the driver s and p...

Page 2887: ...ition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Disconnect the connector AB21 from seat belt pretensioner LH 3 Disconnect connector AB19 from side air ba...

Page 2888: ...r to DTC E4 for details on DTC E2 Ref to AB diag 100 DTC E4 FRONT SENSOR BUS RH COM MUNICATION ERROR Diagnostic Chart with Trouble Code AM DTC E3 FRONT SENSOR BUS RH COMMUNICATION ERROR NOTE Refer to...

Page 2889: ...from battery and wait 20 seconds or more before starting to work When replacing the airbag module seat belt pretensioner roll connector control module and sen sor reconnect each part and check that t...

Page 2890: ...AG and connector 3H in the test harness H Connector terminal 4AG No 14 3H No 5 4AG No 12 3H No 6 Is the resistance less than 10 Go to step 3 Replace the airbag main harness along with body harness 3 C...

Page 2891: ...er to DTC E8 for details on DTC E6 Ref to AB diag 103 DTC E8 FRONT SENSOR BUS LH COM MUNICATION ERROR Diagnostic Chart with Trouble Code AP DTC E7 FRONT SENSOR BUS LH COMMUNICATION ERROR NOTE Refer to...

Page 2892: ...onnector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors and seat belt...

Page 2893: ...p 3 Replace the airbag main harness along with body harness 3 CHECK AIRBAG MAIN HARNESS FRONT SENSOR BUS LH Measure the resistance between connector 4AG in the test harness AG and chassis ground and t...

Page 2894: ...RROR Diagnostic Chart with Trouble Code AS DTC EA SIDE SENSOR BUS RH COMMUNICATION ERROR NOTE Refer to DTC EC for details on DTC EA Ref to AB diag 106 DTC EC SIDE SENSOR BUS RH COMMU NICATION ERROR Di...

Page 2895: ...oll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors and seat...

Page 2896: ...rs AB17 AB6 AB18 from airbag control module 6 Connect the connector 1AG in the test har ness AG to the connectors AB17 AB6 AB18 7 Disconnect the connector AB28 from side airbag sensor RH and connect t...

Page 2897: ...een connector 3V in test harness V Connector terminal 3V No 2 Chassis ground 3V No 1 Chassis ground 3V No 2 3V No 1 Is the resistance 1 M or more Go to step 6 Replace the airbag rear harness along wit...

Page 2898: ...Trouble Code AIRBAG SYSTEM DIAGNOSTICS AV DTC ED SIDE SENSOR BUS RH COMMUNICATION ERROR NOTE Refer to DTC EE for details on DTC ED Ref to AB diag 110 DTC EE SIDE SENSOR BUS RH COMMU NICATION ERROR Di...

Page 2899: ...oll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors and seat...

Page 2900: ...g sensor RH 6 Connect the connector AB28 of side air bag sensor RH and the connector 1AI in the test harness AI 7 Connect the connector 2AI in the test har ness AI and the connector 1V in the test har...

Page 2901: ...sis ground and the resistance between connector 5AG terminals in the test harness AG Connector terminal 5AG No 16 Chassis ground 5AG No 14 Chassis ground 5AG No 16 5AG No 14 Is the resistance 1 M or m...

Page 2902: ...RROR Diagnostic Chart with Trouble Code AY DTC F2 SIDE SENSOR BUS LH COMMUNICATION ERROR NOTE Refer to DTC F4 for details on DTC F2 Ref to AB diag 114 DTC F4 SIDE SENSOR BUS LH COMMU NICATION ERROR Di...

Page 2903: ...rbag main harness disconnect the airbag module connectors and seat belt pretensioners of the driver s and passenger s seats for safety reasons When inspecting the airbag rear harness disconnect the si...

Page 2904: ...s 3 CHECK AIRBAG REAR HARNESS BE TWEEN AIRBAG CONTROL MODULE AND SIDE AIRBAG SENSOR LH Measure the resistance between connector 5AG in the test harness AG and chassis ground and the resistance between...

Page 2905: ...lear the memory 3 Perform the Inspection Mode 4 Read the DTC Is the same DTC displayed Go to step 7 Go to step 8 7 REPLACE SIDE AIRBAG SENSOR LH AND CHECK AIRBAG CONTROL MODULE AF TER REPLACEMENT 1 Tu...

Page 2906: ...oll connector control module and sen sor reconnect each part and check that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connectors and seat...

Page 2907: ...rbag sensor LH 6 Connect the connector AB23 of side air bag sensor LH and the connector 1AI in the test harness AI 7 Connect the connector 2AI in the test har ness AI and the connector 1V in the test...

Page 2908: ...istance between connector 5AG termi nals in test harness AG Connector terminal 3V No 2 Chassis ground 3V No 1 Chassis ground 5AG No 10 5AG No 8 Is the resistance 1 M or more Go to step 6 Replace the a...

Page 2909: ...r to DTC FA for details on DTC F8 Ref to AB diag 121 DTC FA SATELLITE SENSOR BUS COM MUNICATION ERROR Diagnostic Chart with Trouble Code BE DTC F9 SATELLITE SENSOR BUS COMMUNICATION ERROR NOTE Refer t...

Page 2910: ...ing light operates properly When inspecting the airbag main harness disconnect the airbag module connectors and seat belt pretensioners of the driver s and passenger s seats for safety reasons When in...

Page 2911: ...o 6 Is the resistance less than 10 Go to step 3 Replace the airbag rear harness along with body harness 3 CHECK AIRBAG REAR HARNESS BE TWEEN AIRBAG CONTROL MODULE AND SATELLITE SAFING SENSOR Measure t...

Page 2912: ...1 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Replace the front sub sensor LH with a genuine sensor Ref to AB 22 REMOVAL Front Sub Senso...

Page 2913: ...REPLACE SIDE AIRBAG SENSOR LH 1 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Replace the side A B sensor LH with a genuine sensor Ref to...

Page 2914: ...nction of the Subaru Se lect Monitor cannot be executed properly check the communication circuit Ref to AB diag 26 COMMUNICATION FOR INI TIALIZING IMPOSSIBLE INSPECTION Sub aru Select Monitor 5 Record...

Page 2915: ...ll Downhill Gravel road Others Vehicle operation Starting Idling Driving Constant speed Accelerating Decelerating Turning Others Details of problem Airbag warning light operation Normal After turning...

Page 2916: ...he seat cushion cover is removed make sure to replace the hang wire on the seat cushion side with a new wire 5 Never connect the battery in reverse polarity Occupant detection system may be destroyed...

Page 2917: ...test harness 1 SPECIAL TOOL TEST HARNESS D ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system ILLUSTRATION TOOL NUMBER D...

Page 2918: ...OCCUPANT DETECTION SYSTEM DIAGNOSTICS TEST HARNESS Y ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299AG040 TEST HARNESS Y Used for troubleshooting seat belt buckle switch ST98299AG040 2Y 1Y 1Y 1Y 2...

Page 2919: ...EM DIAGNOSTICS TEST HARNESS AB ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA000 TEST HARNESS AB Used when measuring voltage and resistance of occupant detection system ST98299XA000 OD 00029 1AB...

Page 2920: ...TECTION SYSTEM DIAGNOSTICS TEST HARNESS AE ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA030 TEST HARNESS AE TEST HARNESS Y adapter harness Used for troubleshooting seat belt buckle switch ST982...

Page 2921: ...ription OCCUPANT DETECTION SYSTEM DIAGNOSTICS TEST HARNESS AC ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA010 TEST HARNESS AC Used for troubleshooting seat belt tension sen sor ST98299XA010 OD...

Page 2922: ...AL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA020 TEST HARNESS AD Used when measuring voltage and resistance of the seat belt tension sensor TOOL NAME REMARKS Circuit tester Used for mea...

Page 2923: ...AGNOSTICS 4 Electrical Component Location A LOCATION 1 Occupant detection control module 3 Airbag ON OFF indicator light 5 Seat belt tension sensor 2 Occupant detection sensor 4 Buckle switch Passenge...

Page 2924: ...1 How to disconnect Press the lock arm A and disconnect the connec tor CAUTION When pulling the slide lock or disconnecting connector be sure to hold the connector not the harness 2 How to connect Hol...

Page 2925: ...name Terminal No Input Output value Remarks IG power supply 9 9 16 V When ignition switch ON Airbag control module communication COM 10 Open collector terminal Communication line Airbag control module...

Page 2926: ...other than before and behind the seat such as the breakdown etc is input 4 Displayed when it is initial 5 Seat position sensor not supported 6 Seat belt fastened 7 Seat belt not fastened 8 Displayed w...

Page 2927: ...djusted to all the way up and select the OK 7 When the Re zeroing Unbelt the Passenger seatbelt Continue OK Quit NO is displayed make sure the passenger s seatbelt is disconnect ed from the buckle and...

Page 2928: ...m diagnosis Ref to AB diag 26 COMMUNICATION FOR INITIALIZ ING IMPOSSIBLE INSPECTION Subaru Select Monitor 2 WITHOUT DTC DETECTING CONDITION Defective combination meter Open circuit of harness TROUBLE...

Page 2929: ...Trouble Code DTC OCCUPANT DETECTION SYSTEM DIAGNOSTICS 8 Read Diagnostic Trouble Code DTC A OPERATION For details on reading DTCs refer to Airbag Sys tem Diagnosis Subaru Select Monitor Ref to AB dia...

Page 2930: ...OD diag 18 Inspection Mode OCCUPANT DETECTION SYSTEM DIAGNOSTICS 9 Inspection Mode A PROCEDURE Recreate the circumstance by referring to the con ditions described in the checklist...

Page 2931: ...YSTEM DIAGNOSTICS 10 Clear Memory Mode A OPERATION Clear the memory in the following steps after the malfunction is repaired For details to clear the DTC refer to Airbag Sys tem Diagnosis Subaru Selec...

Page 2932: ...GNOSTICS 11 Airbag Warning Light Illumination Pattern A INSPECTION Turn the ignition switch to ON and confirm that the airbag warning light remains on for approx 6 sec onds and then goes off afterward...

Page 2933: ...ag ON OFF Indicator Light Illumination Pattern A INSPECTION 1 Passenger s airbag ON indicator light 4 Ignition switch 9 Adult 5 Light OFF 10 OFF 2 Passenger s airbag OFF indicator light 6 Light ON 11...

Page 2934: ...2C BELT TENSION SENSOR FAILURE Diagnostic Procedure with Diagnostic Trouble Code DTC 27 ODS Failure Occupant detection control module and airbag con trol module communication is faulty Airbag rear har...

Page 2935: ...to OFF disconnect the ground cable from battery and wait for 20 seconds or more 2 Replace the passenger s seat cushion pad frame assembly Ref to SE 6 REMOVAL Front Seat Ref to SE 8 PASSENGER S SEAT DI...

Page 2936: ...seat belt tension sensor is faulty Airbag main harness circuit is open or shorted Occupant detection control module is faulty WIRING DIAGRAM 3 5 6 4 1 2 3 AB53 AB59 AB56 1 2 3 4 5 6 AB53 AB56 1 2 3 O...

Page 2937: ...und cable from battery and wait for 20 seconds or more 2 Disconnect the test harness AC from the belt tension sensor connector AB56 3 Connect the test harness AD 1AD to the connector AB56 4 Disconnect...

Page 2938: ...of the connectors between the occupant detection control module and airbag control module Is there poor contact Reconnect the connector If the fault is not fixed replace the airbag harness Go to step...

Page 2939: ...airbag harness Go to step 2 2 CHECK BUCKLE SWITCH 1 Turn the ignition switch to OFF disconnect the battery ground terminal and wait for 20 sec onds 2 Disconnect the buckle switch connector AB60 3 Con...

Page 2940: ...OD diag 28 Diagnostic Procedure with Diagnostic Trouble Code DTC OCCUPANT DETECTION SYSTEM DIAGNOSTICS...

Page 2941: ...NT SEAT BELT 1 Adjustable anchor ASSY 4 Inner seat belt ASSY Tightening torque N m kgf m ft lb 2 Anchor cover 5 Belt tension sensor Passenger s side only T1 7 5 0 76 5 5 3 Outer seat belt ASSY T2 30 3...

Page 2942: ...ter seat belt ASSY LH 3 point type Tightening torque N m kgf m ft lb 2 Shoulder seat belt center ASSY 5 door model T1 30 3 1 22 1 6 Shoulder seat belt center ASSY 4 door model T2 53 5 4 39 1 3 Outer s...

Page 2943: ...nsioner wipe it off immediately with a dry cloth Do not expose the pretensioner to high temperature or flame Do not allow current to flow through or voltage to reach the pretensioner Do not use a circ...

Page 2944: ...ARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for setting of each function and trouble shooting for electrical system ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA000 TEST HARNESS AB Used wh...

Page 2945: ...AT BELT SYSTEM TEST HARNESS AE ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299XA030 TEST HARNESS AE Used for diagnosing seat belt tension sensor Used together with test harness Y ST98299XA030 OD 00...

Page 2946: ...1AG 1 2 9 14 15 16 17 18 19 20 21 22 23 24 25 26 27 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 68 67 66 65 64 63 69 70 71 72 73 74 55 56 61 62 75 76 77 78 3 4 5 6 7 8 10 11 12 1...

Page 2947: ...78 22 73 71 24 63 16 13 14 65 62 60 61 34 43 33 40 74 75 20 18 21 17 64 15 72 23 57 66 58 2AG 9 8 7 6 5 4 3 2 1 10 45 46 49 50 35 48 42 47 41 20 18 14 13 12 17 16 15 19 11 10 9 8 7 6 5 4 3 2 1 4AG 1 2...

Page 2948: ...cription SEAT BELT SYSTEM TEST HARNESS Y ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299AG040 TEST HARNESS Y Used for troubleshooting seat belt buckle switch ST98299AG040 2Y 1Y 1Y 1Y 2Y 2Y AB 01069...

Page 2949: ...replacement of airbag module for which resistance value is same as airbag module Two ST are required for diagnosis of two stage inflator type airbag module TOOL NAME REMARKS TORX T50 Used for removing...

Page 2950: ...Connector SEAT BELT SYSTEM 2 Pretensioner Connector A PROCEDURE Refer to Airbag Connector of Airbag section for the connectors of the seat belt pretensioners and buckle switch RH Ref to AB 8 PROCEDUR...

Page 2951: ...Locations After a Collision SEAT BELT SYSTEM 3 Inspection Locations After a Collision A INSPECTION Refer to Inspection Locations After a Collision of Airbag section Ref to AB 12 Inspection Loca tions...

Page 2952: ...Select Current Data Display and read the data of IG power supply voltage 2 Turn the ignition switch ON mo OFF Does the voltage change between 10 V or higher mo less than 1 5 V matching the ignition sw...

Page 2953: ...ce the harness 9 CHECK SEAT BELT BUCKLE SWITCH LH Measure the resistance between the connector terminals of the driver s seat belt switch when the driver s seat belt is fastened and detached Connector...

Page 2954: ...integrated unit Ref to SL 50 REMOVAL Body Integrated Unit Replace with new parts according to DTC 39 16 CHECK HARNESS 1 Disconnect the clock connector 2 Turn the ignition switch to ON 3 Measure the vo...

Page 2955: ...LAN diag 33 OPERA TION Read Current Data Does the data indicate the nor mal vehicle speed Go to step 11 Check the follow ing items LAN system Ref to LAN diag 69 DTC U1223 CAN HS VDC ABS NO RECEIVE DA...

Page 2956: ...belt 8 Remove the center pillar upper trim Ref to EI 57 REMOVAL Upper Inner Trim 9 Remove the bolts and then remove adjustable anchor assembly 2 INNER SEAT BELT ASSEMBLY 1 Turn the ignition switch to...

Page 2957: ...the following and replace with new parts if necessary Pretensioner is cracked or deformed Seat belt is slackened bent or worn Seat belt is abnormally wound or extended Inner seat belt assembly is def...

Page 2958: ...ot remove the bolt and nut securing the re tractor and bracket 4 DOOR MODEL Remove the bolt 2 SHOULDER SEAT BELT CENTER ASSEMBLY 5 DOOR MODEL 1 Remove the shoulder anchor bolt cover A 2 Remove the sho...

Page 2959: ...ER SEAT BELT ASSEMBLY 1 Remove the rear seat cushion 2 Remove the bolts then remove the center seat belt assembly B INSTALLATION CAUTION During installation make sure that the seat belts are not twist...

Page 2960: ...er seat belt assembly 5 DOOR MODEL 4 DOOR MODEL C INSPECTION Check for the following and replace with new parts if necessary Seat belt is slackened bent or worn Seat belt is abnormally wound or extend...

Page 2961: ...SB 22 Rear Seat Belt SEAT BELT SYSTEM...

Page 2962: ...wiring harnesses or connector circuits Be careful not to damage the airbag system wiring harness when servicing electrical parts and switches Headlight Halogen type low beam 12 V 55 W HID type low be...

Page 2963: ...N TOOL 1 SPECIAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester...

Page 2964: ...LIGHTING SWITCH IN SPECTION Combination Switch Light 2 DIMMER PASSING SWITCH Measure the resistance between dimmer passing switch terminals Ref to LI 12 DIMMER PASS ING SWITCH INSPECTION Combination...

Page 2965: ...ect the Subaru Select Monitor 2 Read the DTC of the integrated unit Is DTC displayed Perform the diag nosis according to DTC Go to step 2 2 CHECK INPUT SIGNAL 1 Display the current data of the integra...

Page 2966: ...Measure the resistance between front fog light switch terminals Ref to LI 12 FRONT FOG LIGHT SWITCH INSPECTION Combination Switch Light 2 FRONT FOG LIGHT RELAY Connect terminal No 4 to battery positi...

Page 2967: ...switch terminals Ref to LI 12 TURN SIGNAL SWITCH INSPECTION Combination Switch Light 2 HAZARD SWITCH Measure the resistance between hazard switch ter minals Replace the hazard switch if faulty 3 TURN...

Page 2968: ...erminals Replace the back up light switch if faulty 2 INHIBITOR SWITCH AT MODEL Measure the resistance between the inhibitor switch terminals Replace the inhibitor switch if faulty Switch position Ter...

Page 2969: ...stem B INSPECTION 1 STOP LIGHT SWITCH Measure the resistance between stop light switch terminals 5 door model 4 door model Replace the stop light switch if faulty Switch position Terminal No Standard...

Page 2970: ...e the rear gate latch and actuator assembly if faulty 3 TRUNK LID SWITCH Measure the resistance between trunk lid switch terminals Replace the trunk lid latch and actuator assembly if faulty Switch po...

Page 2971: ...er lower 3 Remove the three mounting screws of steering column cover upper 4 Disconnect the connector from combination switch 5 Remove the three screws and pull out the com bination base switch assemb...

Page 2972: ...ty 4 FRONT FOG LIGHT SWITCH Replace the combination switch light if faulty Switch position Terminal No Standard OFF 1 M or more Tail 14 and 16 Less than 1 Head 13 14 and 16 Less than 1 Switch position...

Page 2973: ...er 4 Remove the four screws and remove the roll connector 5 Remove the three screws 6 Disconnect the harness connector and remove the combination base switch assembly B INSTALLATION 1 Install in the r...

Page 2974: ...B INSTALLATION Install in the reverse order of removal Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb C DISASSEMBLY 1 HID HEADLIGHT BALLAST CAUTION Do not perform work with wet hands The HID headligh...

Page 2975: ...wo min utes or more 1 Before checking the headlight beam level be sure of the following The area around the headlight has not sustained any accident damage or other type of deformation Vehicle is park...

Page 2976: ...moving the headlight bulb LH 5 Disconnect the harness connector 6 Remove the bulb assembly A then remove the high beam To remove the low beam remove the back cover B and then go to step 7 7 Disconnect...

Page 2977: ...eneral Description 2 Install the factory HID bulb to check whether it lights properly 3 If it does not light properly replace with a new bulb 4 Inspect the HID ballast Inspect the ballast in the follo...

Page 2978: ...light bulb to remove 2 Disconnect the ground cable from battery 3 Turn the mud guard inward 4 Turn socket A from the wheel arch and re move the front turn signal light bulb B INSTALLATION Install in...

Page 2979: ...nal light bulb to remove 2 Disconnect the ground cable from battery 3 Turn the mud guard inward 4 Turn socket A from the wheel arch and re move the clearance parking light bulb B INSTALLATION Install...

Page 2980: ...Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb C ADJUSTMENT 1 FOG LIGHT AIMING 1 Before checking the fog light beam level be sure of the following The area around the fog light has not sustained any a...

Page 2981: ...just the front fog light pattern by inserting a Philips screwdriver to the adjusting hole 1 Adjusting hole A Vehicle center B Bulb center marking C 3 m 10 ft D Height of fog light center h mm in at 3...

Page 2982: ...n turn over the mud guard 3 Disconnect the harness connector 4 Rotate the bulb then detach the fog light bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the b...

Page 2983: ...nect the harness connector and rear combination light B INSTALLATION Install in the reverse order of removal Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb C INSPECTION 1 4 DOOR MODEL 1 Visually check...

Page 2984: ...TION Install in the reverse order of removal C INSPECTION 1 4 DOOR MODEL 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATION General Description 3 If NG rep...

Page 2985: ...e socket and remove the bulb 2 5 DOOR MODEL 1 Remove the rear combination light assembly Ref to LI 23 5 DOOR MODEL REMOVAL Rear Combination Light Assembly 2 Turn the socket and remove the bulb B INSTA...

Page 2986: ...ground cable from battery 2 Remove the rear gate trim Ref to EI 66 RE MOVAL Rear Gate Trim 3 Disconnect the harness connector 4 Remove the attachment nuts and remove the rear finisher light assembly B...

Page 2987: ...or models with a rear fog light the back up light is installed on the passenger s side 1 Disconnect the ground cable from battery 2 Remove the bulb inspection cover of the rear gate trim 3 Turn the so...

Page 2988: ...move the bulb 2 5 DOOR MODEL 1 Disconnect the ground cable from battery 2 Remove the license plate light while pushing it to the left and pulling it 3 Remove the bulb B INSTALLATION Install in the rev...

Page 2989: ...nuts then detach the high mounted stop light 4 5 DOOR MODEL WITH BUILT IN LARGE TYPE ROOF SPOILER 1 Disconnect the ground cable from battery 2 Remove the roof spoiler Ref to EI 39 RE MOVAL Roof Spoil...

Page 2990: ...STALLATION Install in the reverse order of removal C INSPECTION 1 SPOT MAP LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATION General Descriptio...

Page 2991: ...ication Ref to LI 2 SPECIFICATION General Description 3 If NG replace the bulb with a new part 2 ROOM LIGHT SWITCH 1 Measure the resistance between room light switch terminals 2 Connect terminal No 3...

Page 2992: ...INSTALLATION 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 SPECIFICATION General Desc...

Page 2993: ...erclockwise 60 to remove it and disconnect the harness connector 3 Remove bulb A B INSTALLATION Install in the reverse order of removal C INSPECTION 1 TRUNK ROOM LIGHT BULB 1 Visually check the bulb f...

Page 2994: ...48 A Ignition switch illumination connector B Ignition switch illumination C Immobilizer antenna connector LI 00343 C B A Step Check Yes No 1 CHECK THE IGNITION SWITCH ILLUMINA TION Make sure the igni...

Page 2995: ...ctor LIGHTING SYSTEM 29 Reflex Reflector A REMOVAL 1 Remove the reflex reflector by pressing the claw of the reflex reflector from the backside of bumper B INSTALLATION Install in the reverse order of...

Page 2996: ...om the battery 2 Remove the screw and pull out the door switch 3 Disconnect the harness connector B INSTALLATION Install in the reverse order of removal C INSPECTION Refer to the door switch inspectio...

Page 2997: ...ess Rear wiper motor Input 12 V 42 W or less Front washer motor Pump type Centrifugal Input 12 V 36 W or less Rear washer motor Pump type Centrifugal Input 12 V 36 W or less 1 Wiper rubber 4 Wiper lin...

Page 2998: ...n WIPER AND WASHER SYSTEMS 2 REAR WIPER 1 Wiper rubber 4 Wiper arm cover Tightening torque N m kgf m ft lb 2 Wiper blade ASSY 5 Pivot cap T1 6 0 0 61 4 4 3 Wiper arm 6 Wiper motor T2 8 0 0 82 5 9 WW 0...

Page 2999: ...hese circuits Care must be taken when connecting the hose to the pipe so that no bending jamming etc are caused If even a small amount of silicon oil or grease enters tank and washer fluid passages an...

Page 3000: ...PECIAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for setting of each function and trouble shooting for electrical system TOOL NAME RE...

Page 3001: ...Ref to WW 18 Rear Wiper Arm Rear wiper motor Ref to WW 19 Rear Wiper Motor Washer tank motor Ref to WW 13 Washer Tank and Motor Front washer nozzle Ref to WW 17 Front Washer Nozzle Rear washer nozzle...

Page 3002: ...INSTALLATION Install in the reverse order of removal C INSPECTION Inspect the continuity between each connector terminal If continuity is not at the standard value replace the switch WW 00547 WW 00548...

Page 3003: ...ground 3 Replace the body integrated unit Ref to SL 50 Body Integrated Unit 2 Check the intermittent operation inspection of the wiper switch alone 1 Set the voltage meter between terminal No 7 and N...

Page 3004: ...B281 No 18 B70 No 10 B281 No 27 B70 No 13 B281 No 28 B70 No 12 Is the resistance less than 10 Go to step 3 Repair the harness between the body integrated unit and wiper switch 3 CHECK INPUT VOLTAGE OF...

Page 3005: ...4 Measure the resistance between the har ness connector terminals of the body integrated unit and rear wiper motor Connector terminal B279 No 8 D43 No 1 B279 No 9 D43 No 2 Is the resistance less than...

Page 3006: ...he direction of arrow A and re move it from arm B INSTALLATION 1 Install in the reverse order of removal 2 Confirm that the clip is locked securely C DISASSEMBLY 1 FRONT Pull side A of the wiper rubbe...

Page 3007: ...into claw B 2 Insert the wiper rubber until its top end protrudes approx 20 mm 0 79 in from stopper D 3 Insert the wiper rubber into claw A E INSPECTION 1 When the wiper does not operate properly in s...

Page 3008: ...Remove the bolts and nuts and remove the washer tank B INSTALLATION Install in the reverse order of removal Tightening torque 6 0 N m 0 61 kgf m 4 4 ft lb C DISASSEMBLY Pull out the washer motor from...

Page 3009: ...reverse order of removal 2 Operate the wiper once 3 Align the wiper blade to ceramic print point mark A of front window panel Tightening torque Refer to COMPONENT of General Descrip tion Ref to WW 2 F...

Page 3010: ...Tighten the nut where rod A and link plate B is aligned in a straight line 5 Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to WW 2 FRONT WIP...

Page 3011: ...16 Front Wiper Motor and Link WIPER AND WASHER SYSTEMS 4 Connect the battery and confirm that the motor stops at the automatic stop position after the motor operates at low speed again 3 2 5 4 1 WW 00...

Page 3012: ...N 1 VISUAL CHECK Check the following items if a failure is found re place the parts Make sure the nozzle and hose are not clogged Make sure the hose is not bent 2 SPRAY POSITION CHECK 1 Turn the wiper...

Page 3013: ...tall in the reverse order of removal 2 Operate the rear wiper once 3 Align the blade with the marking A of the glass Tightening torque Refer to COMPONENT of General Descrip tion Ref to WW 3 REAR WIPER...

Page 3014: ...sure that the pivot cap with the round mark facing up as shown in the figure Tightening torque Refer to COMPONENT of General Descrip tion Ref to WW 3 REAR WIPER COMPO NENT General Description C INSPEC...

Page 3015: ...Install in the reverse order of removal C INSPECTION 1 VISUAL CHECK Check the following items if a failure is found re place the parts Make sure the nozzle and hose are not clogged Make sure the hose...

Page 3016: ...cord the memory contents before disconnecting the bat tery ground cable Otherwise the memory is cleared Reassemble the parts in the reverse order of dis assembly procedure unless otherwise indicated A...

Page 3017: ...tenna Symptom Repair order No power coming in No display and no sound from speakers 1 Check the fuse and power supply for audio 2 Check the audio ground 3 Remove the audio for repair A specific speake...

Page 3018: ...played then it switches to the map screen by pressing the Agree key When a screen other than the opening screen is displayed press the MAP key Standard value The map screen should be dis played OK Nor...

Page 3019: ...item and then the screen fades out ON Normal OFF Abnormal Check the signal line connection If there are no problems the unit could be faulty CHECK SPEED SENSOR NOTE Before starting inspections check...

Page 3020: ...49 CEN TER PANEL REMOVAL Center Console 3 Remove the screws and partially pull the audio out from center console 4 Disconnect the harness connectors and antenna feeder cord 5 Remove the audio 6 Remove...

Page 3021: ...ct the ground cable from the battery 2 Remove the front door trim Ref to EI 43 RE MOVAL Door Trim 3 Remove the front speaker mounting screws 4 Disconnect the harness connector and remove the front spe...

Page 3022: ...isconnect the ground cable from battery 2 Remove the front door gusset cover Ref to EI 43 REMOVAL Door Trim 3 Disconnect the harness connector 4 Remove the screws and detach the tweeter B INSTALLATION...

Page 3023: ...ect the ground cable from the battery 2 Remove the rear door trim Ref to EI 43 RE MOVAL Door Trim 3 Remove the rear speaker mounting screws 4 Disconnect the harness connector and remove the rear speak...

Page 3024: ...AL Roof Trim 2 Disconnect the harness connectors and termi nals and remove the fitting nut A 3 Pull off the antenna from the roof B INSTALLATION Install in the reverse order of removal C INSPECTION Ch...

Page 3025: ...CE DURE Airbag Connector 6 Remove the steering wheel Ref to PS 12 RE MOVAL Steering Wheel 7 Remove the screws to remove the lower cover from steering wheel 8 Loosen the screws on the backside of the s...

Page 3026: ...ion Body ENTERTAINMENT 10 Navigation Body A PROCEDURE For the removal and installation operation proce dures of navigation unit refer to the removal and in stallation procedures of the audio unit Ref...

Page 3027: ...r green of GPS anten na NOTE Attach a string of about 50 cm in length etc to the GPS antenna for easy installation work 5 Remove the combination meter assembly Ref to IDI 16 REMOVAL Combination Meter...

Page 3028: ...ront Acces sory Power Supply Socket System B REMOVAL 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower Ref to EI 51 INSTRUMENT PANEL LOWER REMOVAL Center Console 3 Disconn...

Page 3029: ...y Power Supply Socket System B REMOVAL 1 Disconnect the ground cable from battery 2 Remove the console box Ref to EI 48 RE MOVAL Console Box 3 Disconnect the harness connector and remove the claws two...

Page 3030: ...ground cable from battery 2 Remove the console box Ref to EI 48 RE MOVAL Console Box 3 Disconnect the harness connector 4 Disengage four claws and remove the AUX in put terminal by pushing it into th...

Page 3031: ...e disconnecting the bat tery ground cable Otherwise the memory is cleared Reassemble the parts in the reverse order of dis assembly procedure unless otherwise indicated Adjust parts to the given speci...

Page 3032: ...esistance between termi nals when connecting terminal No 4 to the battery positive terminal and terminal No 3 to the battery ground terminal C NOTE For procedure of each component in the horn sys tem...

Page 3033: ...emove the horn bracket mounting bolt and re move the horn assembly B INSTALLATION Install in the reverse order of removal Tightening torque Lo side 18 N m 1 8 kgf m 13 3 ft lb Hi side 13 N m 1 3 kgf m...

Page 3034: ...2 Remove the driver s airbag module Ref to AB 15 REMOVAL Driver s Airbag Module B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the resistance between horn switch termi nal...

Page 3035: ...COM 6 Horn Switch COMMUNICATION SYSTEM...

Page 3036: ...PONENT 1 FIXED GLASS 5 DOOR MODEL 1 Windshield glass 5 Spring 9 Fastener 2 Dam rubber 6 Locating pin 10 Locating pin 3 Molding 7 Seal 11 Spacer 4 Rearview mirror mount 8 Rear quarter glass 12 Rear gat...

Page 3037: ...LASS 4 DOOR MODEL 1 Windshield glass 5 Spring 9 Fastener 2 Dam rubber 6 Locating pin 10 Locating pin 3 Molding 7 Seal 11 Rear window glass 4 Rearview mirror mount 8 Rear quarter glass 12 Spacer 9 10 2...

Page 3038: ...Description GLASS WINDOWS MIRRORS 3 FRONT DOOR GLASS 1 Glass run rubber 4 Door sash Tightening torque N m kgf m ft lb 2 Glass 5 Regulator motor ASSY T 7 5 0 76 5 5 3 Weather strip outer GW 00745 1 2 3...

Page 3039: ...SS WINDOWS MIRRORS 4 REAR DOOR GLASS 1 Glass run rubber 4 Rear outer gusset cover Tightening torque N m kgf m ft lb 2 Glass 5 Regulator motor ASSY T 7 5 0 76 5 5 3 Weather strip outer 6 Door sash GW 0...

Page 3040: ...are disconnected always conduct an operational check after connecting them again Avoid impact and damage to the glass 1 Outer mirror case ASSY 5 Mount Tightening torque N m kgf m ft lb 2 Mirror 6 Spr...

Page 3041: ...U0 SUBARU SELECT MONITOR III KIT Used for setting of each function and trouble shooting for electrical system TOOL NAME REMARKS Circuit tester Used for checking voltage and continuity Piano wire Used...

Page 3042: ...nt door glass Ref to GW 11 Front Door Glass Front regulator motor assembly Ref to GW 12 Front Regulator and Motor Assembly Rear door glass Ref to GW 18 Rear Door Glass Rear regulator motor assembly Re...

Page 3043: ...5 Remove the screws to remove the power win dow main switch assembly 2 SUB SWITCH 1 Open the screw cover by using a flat tip screw driver 2 Remove the screw to remove the power window main switch pane...

Page 3044: ...sen ger s side UP 14 and 8 12 and 19 Less than 1 OFF 14 and 12 14 and 8 1 M or more 8 and 12 8 and 19 12 and 19 Less than 1 DOWN 14 and 12 8 and 19 Less than 1 Rear LH UP 14 and 7 5 and 19 Less than 1...

Page 3045: ...move the two bolts 4 Tilt the door glass forward and remove the door glass from the glass run rubber 5 Remove the door glass while tilting CAUTION Avoid impact and damage to the glass B INSTALLATION C...

Page 3046: ...r and motor assembly B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to GW 4 FRONT DOOR GLASS COMPONENT General Description C IN...

Page 3047: ...fer to the respective section Scalp cap Ref to GW 14 Scalp Cap Outer mirror assembly Ref to GW 15 Outer Mirror Assembly Outer mirror Ref to GW 16 Outer Mirror Remote control mirror switch Ref to GW 17...

Page 3048: ...the clips A from inside of outer mirror 3 Pull the scalp cap towards the front of the outer mirror then remove the scalp cap 4 Align clips A on the reverse side of the scalp cap and the clip attachme...

Page 3049: ...que 4 5 N m 0 46 kgf m 3 3 ft lb C INSPECTION Check to ensure that the outer mirror moves prop erly when the battery voltage is applied to termi nals Model without mirror heater Replace the outer mirr...

Page 3050: ...flat tip screwdriver When installing the mirror insert the fitting area securely 1 Face the mirror upward 2 Use a flat tip screwdriver to remove clips A 3 Lift the lower mirror up to remove hooks B 4...

Page 3051: ...sition and check continuity between terminals Switch the change over switch to the right side Switch the change over switch to the left side If NG replace the remote control mirror switch Switch posit...

Page 3052: ...the glass by itself to the lowest position within the door panel The glass may come off of the sash and be come damaged 5 Lower the glass slowly to the bottom most posi tion in the door panel 6 Remov...

Page 3053: ...r and motor assembly B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to GW 5 REAR DOOR GLASS COMPONENT General Description C INS...

Page 3054: ...mount of soapy water to the ad hesive part 8 Make a slit using a cutter knife to make it easier to insert the windshield glass knife 9 Insert the windshield glass knife into the adhe sive 10 While hol...

Page 3055: ...ive part using drill or cutter knife 8 Pass the piano wire through the hole and attach both the wire ends securely to pieces of wood 9 Pull the wire ends alternately to cut off the adhe sive part B IN...

Page 3056: ...ld glass C 2 Install the molding from both corners of the upper edge toward the center 3 Install the molding from both corners of the upper edge toward the lower side 4 Apply the double sided tapes B...

Page 3057: ...and internal trim is hard to wipe off Mask the circumference of such area Let primer dry for about ten minutes before in stalling the glass Do not touch the surface coated with primer 10 Apply adhesi...

Page 3058: ...anual from the adhesive man ufacturer 15 After curing of adhesive pour the water on ex ternal surface of vehicle to check that there are no water leaks NOTE When a vehicle is returned to the user tell...

Page 3059: ...ef to GW 20 REMOVAL Windshield Glass B INSTALLATION 1 Apply the primer to the glass and body sides in the same procedure as for windshield glass Ref to GW 21 INSTALLATION Windshield Glass 2 Fabricate...

Page 3060: ...ing follow instruc tions or instruction manual from the adhesive man ufacturer 7 After curing of adhesive pour the water on exter nal surface of vehicle to check that there are no wa ter leaks NOTE Wh...

Page 3061: ...ATION 1 Apply the primer to the glass and body sides in the same procedure as for windshield glass Ref to GW 21 INSTALLATION Windshield Glass 2 Fabricate the cartridge nozzle tip as shown and set the...

Page 3062: ...ction manual from the adhesive man ufacturer 6 After curing of adhesive pour the water on exter nal surface of vehicle to check that there are no wa ter leaks NOTE When a vehicle is returned to the us...

Page 3063: ...body integrated unit 3 HEAT WIRE INSPECTION CAUTION When wiping off the stain on glass with cloth use a dry and soft cloth and move it in the direc tion of the heat wire extension to avoid damage to t...

Page 3064: ...e heat wire is open at the voltage change point 9 Repair the heat wire that determines the place of the open circuit Ref to GW 30 REPAIR Rear Window Defogger System C REPAIR 1 Clean the broken portion...

Page 3065: ...body 2 Apply the primer to the glass and body sides in the same procedure as for windshield glass Ref to GW 21 INSTALLATION Windshield Glass 3 Fabricate the cartridge nozzle tip as shown and set the...

Page 3066: ...e to check that there are no wa ter leaks NOTE When a vehicle is returned to the user tell him or her that the vehicle should not be subjected to heavy impact for at least three days 2 4 DOOR MODEL 1...

Page 3067: ...or minimum drying time and vehicle standing time before driving after bonding follow instruc tions or instruction manual from the adhesive man ufacturer 7 After curing of adhesive pour the water on ex...

Page 3068: ...2 Remove the spring from the mirror base 3 When the mirror base is damaged use a piano wire spatula etc to remove B INSTALLATION Install in the reverse order of removal NOTE If the mirror base is remo...

Page 3069: ...of Rear Win dow Defogger System Ref to GW 29 HEAT WIRE INSPECTION INSPECTION Rear Window Defogger System NOTE Heat wire inspection needs removing installing pro cedure of instrument panel assembly C R...

Page 3070: ...GW 36 Wiper Deicer System GLASS WINDOWS MIRRORS...

Page 3071: ...BS 2 General Description BODY STRUCTURE 1 General Description A SPECIFICATION Refer to Body Repair Manual for general descrip tion of body structure reference points and refer ence dimensions...

Page 3072: ...g light AWD warning light AT model Hill start assist warning light MT model with VDC Tire pressure warning light Vehicle dynamics control VDC warning light Vehicle dynamics control VDC indicator light...

Page 3073: ...rints on the glass surface and meter surfaces Do not apply an excessive force on the printed circuit Do not drop or otherwise apply impact When the combination meter of model with immobilizer has been...

Page 3074: ...1 DTC DISPLAY MODE INSPECTION Combination Meter System Warning light indicator and LCD display checks are performed when self diagnosis is performed After this every time the odo trip meter knob is pr...

Page 3075: ...gauge Engine coolant temperature gauge Fuel level warning light Warning light indicator light 0 0 Lowest point Lowest point Light ON Light OFF Engine coolant temper ature indicator light color is blue...

Page 3076: ...gauge does not operate Turbo model 1 Communication circuit 2 Engine coolant temperature sen sor 3 Harness 4 Combination meter Ref to IDI 9 CHECK ENGINE COOLANT TEM PERATURE SENSOR INSPECTION Combinati...

Page 3077: ...rminal Model without VDC B301 No 23 i10 No 31 Model with VDC B310 No 33 i10 No 31 Is the resistance less than 10 Model without VDC Check the ABS control mod ule Ref to ABS diag 2 Basic Diagnostic Proc...

Page 3078: ...5 CHECK COMMUNICATION BETWEEN BODY INTEGRATED UNIT AND METERS 1 Remove the fuel sub level sensor Ref to FU H4SO 67 REMOVAL Fuel Sub Level Sen sor Ref to FU H4DOTC 76 REMOVAL Fuel Sub Level Sensor 2 Sh...

Page 3079: ...at may have a temporary poor contact Replace the fuel level sensor 11 CHECK COMBINATION METER OPERA TION 1 Remove the combination meter 2 Attach the combination meter to another vehicle on which the f...

Page 3080: ...Go to step 4 Check the door switch circuit Ref to SL 10 CHECK DOOR LOCK SWITCH INSPECTION Door Lock Control System 4 CHECK COMMUNICATION STATUS 1 Turn the ignition switch to ON engine OFF and run the...

Page 3081: ...t cancelled however once igni tion switch is turned OFF or the vehicle is driven the DTC display mode is cancelled automatically for safety When the DTC of individual control modules changes in status...

Page 3082: ...ay is not displayed 1 Setting 2 Communication circuit 3 Clock body Ref to IDI 15 CHECK COMMUNICATION CIRCUIT OF FUEL ECONOMY SYSTEM INSPECTION Clock System Step Check Yes No 1 CHECK POWER SUPPLY 1 Dis...

Page 3083: ...sis ground Connector terminal i59 No 6 Chassis ground Is the resistance less than 10 Go to step 3 Repair or replace the harness 3 CHECK HARNESS BETWEEN CLOCK AND COMBINATION METER 1 Disconnect the com...

Page 3084: ...SENSOR Diagnostic Procedure for Sensors Is the ambient sensor operating properly Go to step 4 Replace the ambi ent sensor 4 CHECK AMBIENT TEMPERATURE DIS PLAY 1 Connect the combination meter connecto...

Page 3085: ...splayed Clock is normal Go to step 3 3 CHECK DIAGNOSTIC TROUBLE CODE DTC 1 Prepare the Subaru Select Monitor kit 2 Turn the ignition switch to ON engine OFF and run the PC application for Subaru Selec...

Page 3086: ...connector is con nected securely Make sure that each meter operates normal ly When the combination meter of model with immobilizer has been replaced be sure to per form the registration of immobilizer...

Page 3087: ...dometer INSTRUMENTATION DRIVER INFO 5 Speedometer A SPECIFICATION Since the meter case assembly cannot be disas sembled do not remove or inspect the speedome ter alone Do not remove the cover on the b...

Page 3088: ...hometer INSTRUMENTATION DRIVER INFO 6 Tachometer A SPECIFICATION Since the meter case assembly cannot be disas sembled do not remove or inspect the tachometer alone Do not remove the cover on the back...

Page 3089: ...l Gauge INSTRUMENTATION DRIVER INFO 7 Fuel Gauge A SPECIFICATION Since the meter case assembly cannot be disas sembled do not remove or inspect the fuel gauge alone Do not remove the cover on the back...

Page 3090: ...TRUMENTATION DRIVER INFO 8 Engine Coolant Temperature Gauge A SPECIFICATION Since the meter case assembly cannot be disas sembled do not remove or inspect the engine cool ant temperature gauge alone D...

Page 3091: ...able from battery 2 Remove the audio Ref to ET 6 REMOVAL Audio 3 Reach through the audio space to release the four tabs from the bracket behind the instrument panel 4 Disconnect the harness connector...

Page 3092: ...IDI 22 Clock INSTRUMENTATION DRIVER INFO...

Page 3093: ...er 14 Connecting cable Tightening torque N m kgf m ft lb 5 Backrest pad 15 Outer slide rail T1 6 0 61 4 4 6 Seat side cover inside 16 Seat hinge inner cover LH T2 9 8 1 0 7 2 7 Seat hinge inner cover...

Page 3094: ...le 4 Backrest frame ASSY 12 Inner slide rail Tightening torque N m kgf m ft lb 5 Backrest cover 13 Outer slide rail T1 6 0 61 4 4 6 Backrest pad 14 Seat heater unit T2 52 5 3 38 4 7 Seat side cover in...

Page 3095: ...LH 3 Backrest knob 5 door model only 12 Seat cushion pad 4 Headrest bushing 13 Hinge ASSY center Tightening torque N m kgf m ft lb 5 Backrest cover RH 14 Striker T1 17 6 1 79 13 0 6 Backrest pad RH 1...

Page 3096: ...itself Always replace the seat cushion pad and frame assembly as a set The seat cushion pad and cushion frame are adjusted as a set at the time of manufacture If cushion pads and cushion frames are co...

Page 3097: ...to CAUTION of General Description before starting the work Ref to SE 5 CAU TION General Description 1 Disconnect the ground cable from battery and wait for 20 seconds or more before starting work 2 R...

Page 3098: ...he screws to detach the seat side cover inside 7 Remove the bolts on the side of seat cushion as sembly and then remove the slide rail 8 Remove the bolts from reclining hinge of both sides 9 Remove th...

Page 3099: ...headrest cover from the headrest 2 PASSENGER S SEAT CAUTION If the seat cushion cover is removed or re placed make sure to perform passenger detec tion system adjustment after installing the seat to t...

Page 3100: ...tion Ref to SE 2 FRONT SEAT LH COM PONENT General Description 1 DRIVER S SEAT NOTE When installing the inner seat belt assembly fol low the procedure described in the seat belt sec tion Ref to SB 17...

Page 3101: ...emble the backrest in the reverse order of disassembly 3 When installing the backrest assembly to the seat cushion assembly fill the gap in the front side of slide rail LH and in the rear side of slid...

Page 3102: ...ting the ser vice of airbag system 1 Disconnect the ground cable from battery and wait for 20 seconds or more before starting work 2 Remove the hooks three locations while lifting up the rear seat cus...

Page 3103: ...h new hooks Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to SE 4 REAR SEAT COMPO NENT General Description C DISASSEMBLY 1 Remove the rear se...

Page 3104: ...separate the seat cushion cover and seat cushion pad 11 Open the plastic fastener and then remove the headrest cover from the headrest 12 Remove the plastic fastener and hog rings and then remove the...

Page 3105: ...c tor Connector terminal No 1 No 3 No 1 No 4 No 3 No 4 If no continuity exists replace the seat heater unit with a new part 3 SEAT HEATER SWITCH CHECK THERMISTOR OUTPUT VOLTAGE 1 Connect the battery t...

Page 3106: ...orque N m kgf m ft lb 2 Front door latch and door lock actuator ASSY T1 6 5 0 66 4 8 8 Striker T2 7 5 0 76 5 5 3 Door outer handle 9 Rear door latch and door lock actuator ASSY T3 18 1 8 13 3 4 Door o...

Page 3107: ...CKS 2 REAR GATE LOCK AND TRUNK LID 1 Rear gate latch and actuator ASSY 3 Trunk lid latch and actuator ASSY Tightening torque N m kgf m ft lb 4 Trunk lid striker T1 7 5 0 76 5 5 2 Rear gate striker T2...

Page 3108: ...OPENERS A Fuel lock release B Fuel and trunk lock release C Hood lock release 1 Cover 5 Lever ASSY bracket Tightening torque N m kgf m ft lb 2 Pull handle ASSY 6 Lever ASSY T 33 3 36 24 2 3 Cable 7 Fr...

Page 3109: ...CKS 4 KEYLESS ENTRY SYSTEM 1 Body integrated unit 4 Keyless entry control module 7 Trunk lid latch switch 4 door model 2 Power window main switch 5 Door switch 3 Rear gate latch switch 5 door model 6...

Page 3110: ...embly unless otherwise indicated Adjust the parts to the specifications described in this manual if so designated Connect the connectors securely during reassembly After reassembly make sure all the f...

Page 3111: ...REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit tester Used for measuring resistance and voltage Drill Used for replacing ignit...

Page 3112: ...defective with the fuse check the power supply and ground circuit Ref to SL 9 CHECK POWER SUPPLY AND GROUND CIRCUIT INSPECTION Door Lock Control System 2 Check the power supply and ground circuit for...

Page 3113: ...und B280 No 6 Chassis ground B281 No 2 Chassis ground Is the voltage 10 V or more Go to step 2 Check the harness for open or short circuit between body integrated unit and fuse 2 CHECK GROUND CIRCUIT...

Page 3114: ...rom No continuity 1 M or more to Continuity exists less than 10 Go to step 4 Replace the power window main switch or door lock switch 4 CHECK DOOR LOCK SWITCH Check the continuity when the door lock s...

Page 3115: ...y inte grated unit and rear gate opener button Connector terminal B281 No 24 D47 No 2 Is the resistance less than 10 Go to step 3 Repair or replace the harness 3 CHECK HARNESS Measure the resistance b...

Page 3116: ...D46 No 1 5 door model Is the resistance less than 10 Go to step 4 Repair or replace the harness 4 CHECK HARNESS TRUNK OR REAR GATE UNLOCK Measure the resistance between the trunk lid lock actuator or...

Page 3117: ...h and Door Lock Actuator Assembly Rear door lock actuator Ref to SL 37 INSPECTION Rear Door Latch and Door Lock Actuator Assembly Is the door lock actuator OK Go to step 9 Replace the door latch and d...

Page 3118: ...DULE 2 BODY INTEGRATED UNIT Refer to the Control Module I O Signal of the LAN SYSTEM DIAGNOSTICS Ref to LAN diag 10 ELEC TRICAL SPECIFICATION Control Module I O Signal Content Terminal No Measuring co...

Page 3119: ...s Entry Sys tem 4 Check the power supply and ground circuit for body integrated unit Ref to SL 18 CHECK BODY INTE GRATED UNIT POWER SUPPLY AND GROUND CIRCUIT INSPEC TION Keyless Entry System 5 Check t...

Page 3120: ...ule Ref to SL 18 CHECK KEYLESS ENTRY CONTROL MODULE INSPECTION Keyless Entry Sys tem 3 Check the key warning switch Ref to SL 21 CHECK KEY WARN ING SWITCH INSPECTION Keyless Entry System 4 Check the t...

Page 3121: ...nd unlock the doors and rear gate of vehicle For the 4 door model unlock the trunk lid Can lock unlock of doors and unlock of the trunk lid be per formed properly on the inspec tion target vehicle Go...

Page 3122: ...ry con trol module is nor mal 2 CHECK POWER SUPPLY 1 Disconnect the keyless entry control mod ule harness connector 2 Measure the voltage between harness con nector terminal and chassis ground Connect...

Page 3123: ...ss con nector that the display does not change 3 Check the harness for open or short circuits between the body integrated unit terminal and the faulty door switch terminal Connector terminal Front doo...

Page 3124: ...parts Door switch Trunk lid latch and actuator ASSY Rear gate latch and actuator ASSY 5 CHECK DOOR SWITCH Measure the resistance between faulty door switch terminals Connector terminal Front RH door s...

Page 3125: ...ltage 10 V or more Go to step 4 Go to step 5 4 CHECK KEY WARNING SWITCH CIRCUIT 1 Remove the key from ignition switch 2 Measure the voltage between harness con nector terminal and chassis ground Conne...

Page 3126: ...ground Connector terminal R52 No 3 Chassis ground Is the voltage 10 V or more Replace the body integrated unit Ref to SL 50 Body Integrated Unit Repair or replace the harness Step Check Yes No 1 CHEC...

Page 3127: ...o confirm as there may be no change of OFF o ON at first Does display change from OFF o ON Go to step 3 Replace the body integrated unit Ref to SL 50 Body Integrated Unit 3 CHECK KEYLESS BUZZER 1 Remo...

Page 3128: ...es UNLOCK occur Check body inte grated unit Ref to SL 50 Body Integrated Unit Check the follow ing Keyless entry control module Transmitter 3 CHECK HARNESS 1 Disconnect the harness connector of body i...

Page 3129: ...to step 5 Check the harness for open or short circuits between the ignition switch illumination and fuse 5 CHECK IGNITION SWITCH ILLUMINATION CIRCUIT 1 Disconnect the harness connector of body integra...

Page 3130: ...the security indicator light blink at 3 second intervals Go to step 3 Check the security indicator light cir cuit Ref to SL 30 CHECK SECURITY INDI CATOR LIGHT CIRCUIT INSPECTION Security System 3 CHEC...

Page 3131: ...ess Entry Sys tem 8 CHECK SECURITY ALARM OPERATION Check the security alarm operation Do all security alarms operate Horn sound Hazard lights flash Security indicator light illuminates Go to step 9 Ch...

Page 3132: ...s the LOCK button of the keyless transmitter NOTE Wait until the security indicator light blinks twice within 0 5 seconds at 2 second intervals If the 30 second monitoring lag has been set wait 30 sec...

Page 3133: ...o to step 3 Repair or replace the harness 3 CHECK GROUND CIRCUIT OF TRUNK LID SWITCH OR REAR GATE LATCH SWITCH 1 Disconnect the harness connector of the trunk lid switch or the rear gate latch switch...

Page 3134: ...CATOR LIGHT CIR CUIT Measure the resistance between the combina tion meter harness connector terminal and the security control unit harness connector termi nal Connector terminal i10 No 39 i84 No 10 I...

Page 3135: ...er supply Is the IG power supply voltage within r1 V against BATT volt age The ignition switch input circuit is OK Go to step 2 2 CHECK IGNITION SWITCH CIRCUIT 1 Turn the ignition switch to OFF 2 Disc...

Page 3136: ...and remove the inner re mote handle B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Check the cable of the door opener and door lock for deformation When it is deformed straight...

Page 3137: ...Move the front outer handle towards the rear and remove the front outer handle CAUTION Do not apply excessive force to remove the handle from the door panel The door panel may become deformed 8 Remove...

Page 3138: ...or assembly B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to SL 2 DOOR LOCK ASSEM BLY COMPONENT General Description C INSPECTI...

Page 3139: ...Install in the reverse order of removal C INSPECTION 1 Check the cable of the door opener and door lock for deformation When it is deformed straight en it because failure operations may occur When it...

Page 3140: ...e rear outer handle towards the rear and remove the rear outer handle 8 Remove the outer spacer and remove the frame assembly from the inner side 9 Remove the TORX bolt 10 Remove the frame assembly fr...

Page 3141: ...r lock actuator assembly B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to SL 2 DOOR LOCK ASSEM BLY COMPONENT General Descripti...

Page 3142: ...utton hook and remove the rear gate opener button B INSTALLATION CAUTION Make sure that the harness grommet is secure ly installed If not properly installed this may cause water immersion Install in t...

Page 3143: ...tening torque Refer to COMPONENT of General Descrip tion Ref to SL 3 REAR GATE LOCK AND TRUNK LID COMPONENT General Descrip tion C INSPECTION 1 REAR GATE LATCH 1 Check the latch for deformation or abn...

Page 3144: ...GATE LOCK AND TRUNK LID COMPONENT General Descrip tion NOTE Apply grease to the movable part C INSPECTION 1 TRUNK LID LATCH 1 Check the latch for deformation or abnormal wear 2 Check the safety lever...

Page 3145: ...ALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to SL 4 FRONT HOOD LOCK AND REMOTE OPENERS COMPONENT General Description NOTE Apply gr...

Page 3146: ...on the driver s side Remove the clip holding the cable 3 Remove the opener lever 1 4 Remove the pin 2 and remove front cover 3 5 Remove the bolt and nut and remove the pull handle assembly 4 6 Remove...

Page 3147: ...e driver s side Remove the clip holding the cable 3 Remove the opener lever and detach the cover 1 4 Remove the bolt and nut and remove the pull handle assembly 2 5 Remove the cable 3 from the pull ha...

Page 3148: ...ed off B INSPECTION 1 Remove the instrument panel lower cover 2 Remove the lower column cover 3 Unfasten the fixing clip which secures harness and then disconnect the connector of the ignition switch...

Page 3149: ...3 Remove the sealing cover Ref to EB 22 RE MOVAL Front Sealing Cover 4 Remove the rod clamp 5 Remove the plug to the rear of the door panel 6 Remove the TORX bolt 1 7 Remove the key cylinder along wi...

Page 3150: ...Module A NOTE The control of security system is carried out in body integrated unit Refer to the section on the body in tegrated unit for the work procedures Removal Ref to SL 50 REMOVAL Body Inte gra...

Page 3151: ...ft up the front hood approx 12 cm 4 7 in or more and then drop it off to check the operation of security alarm 7 If NG adjust the impact sensitivity 2 IMPACT SENSITIVITY ADJUSTMENT 1 Connect the Subar...

Page 3152: ...ect the harness connector 4 Remove the bolt and then remove the keyless entry control module 2 4 DOOR MODEL 1 Disconnect the ground cable from battery 2 Remove the rear shelf trim Ref to EI 60 RE MOVA...

Page 3153: ...t and then remove the keyless buzzer B INSTALLATION Install in the reverse order of removal Tightening torque 13 N m 1 33 kgf m 9 6 ft lb C INSPECTION Using the Subaru Select Monitor perform forced op...

Page 3154: ...MOBILIZER Set the current settings as recorded 1 Disconnect the ground cable from battery 2 Remove the driver s side instrument panel lower cover Ref to EI 46 REMOVAL Instrument Pan el Lower Cover 3 R...

Page 3155: ...nput the 8 digit ID number attached to the plas tic bag of the keyless transmitter or inside the trans mitter from left to right then press the Enter key NOTE Press the key on the Subaru Select Monito...

Page 3156: ...l Module A NOTE The control of immobilizer system is carried out in body integrated unit Refer to the section on the body integrated unit for the work procedures Removal Ref to SL 50 REMOVAL Body Inte...

Page 3157: ...AL Instrument Panel Lower Cov er 5 Disconnect the immobilizer antenna connector A and ignition switch lighting connector B 6 Loosen the screw and release the lock D at op posite side using flat tip sc...

Page 3158: ...SL 54 Immobilizer Antenna SECURITY AND LOCKS...

Page 3159: ...OMPONENT 1 Glass lid 7 Frame ASSY Tightening torque N m kgf m ft lb 2 Weather strip 8 Deflector T1 4 5 0 46 3 3 3 Guide rail cover 9 Shade stopper T2 6 0 0 61 4 3 4 Sunshade 10 Motor ASSY 5 Drain tube...

Page 3160: ...ttery ground cable in order to prevent memory deletion Reassemble the parts in the reverse order of disassembly unless otherwise indicated Adjust parts to the given specifications Connect the connecto...

Page 3161: ...cedure of each component in the sunroof control system refer to the respective section Glass lid Ref to SR 5 Glass Lid Sunroof assembly Ref to SR 6 Sunroof Assembly Sunroof motor Ref to SR 7 Sunroof M...

Page 3162: ...olts A and then adjust the height with moving the lid side Difference in height between glass lid and roof panel L 0 75 mm 0 03 in D FORCED DRIVE CAUTION After a forced operation make sure to perform...

Page 3163: ...and as sist rail bracket rear B 7 Remove the curtain airbag module model with curtain airbag module Ref to AB 19 REMOVAL Curtain Airbag Module 8 Remove the bolts and nuts and remove the frame assembly...

Page 3164: ...n the reverse order of removal 2 Perform the initialize operation of motor 1 Tilt up the glass lid 2 Release the switch once and press the tilt up switch again for 15 seconds 3 When the glass lid is r...

Page 3165: ...nstall in the reverse order of removal C INSPECTION Measure the sunroof switch resistance Replace the sunroof switch if defective NOTE If the glass lid does not operate or is not supplied with power m...

Page 3166: ...ly B INSTALLATION Install in the reverse order of removal C INSPECTION 1 CHECK FOR MOVING LOAD OF SUNSHADE 1 Attach a spring scale to sunshade edge using a cloth 2 Pull the spring scale to measure mov...

Page 3167: ...SR 10 Sunshade SUNROOF T TOP CONVERTIBLE TOP SUNROOF...

Page 3168: ...Description EXTERIOR INTERIOR TRIM 1 General Description A COMPONENT 1 FRONT GRILLE 2 UNDER COVER 1 Front grille ASSY 2 Front grille emblem Tightening torque N m kgf m ft lb T 14 1 43 10 3 1 2 EI 0176...

Page 3169: ...I 3 General Description EXTERIOR INTERIOR TRIM 3 UNDER PROTECTOR 1 Fuel tank protector RH 2 Fuel tank protector LH Tightening torque N m kgf m ft lb T1 9 0 92 6 6 T2 18 1 84 13 3 2 1 EI 02041 T2 T1 T2...

Page 3170: ...IOR TRIM 4 FRONT HOOD GRILLE 1 Front hood grille 6 Grommet Tightening torque N m kgf m ft lb 2 Clip anchor 7 Hood duct T1 1 0 0 1 0 7 3 Bolt 8 Hood duct inner T2 4 5 0 46 3 3 4 Protector 9 Clip 5 Gask...

Page 3171: ...BUMPER 1 Front grille ASSY 5 Front side bracket Tightening torque N m kgf m ft lb 2 Front hook cover 6 Front bracket center lower T1 14 1 43 10 3 3 Bumper face 7 Bumper beam reinforcement T2 32 3 26...

Page 3172: ...NTERIOR TRIM 6 REAR BUMPER 5 DOOR MODEL 1 Bumper face 4 Rear side cover lower Tightening torque N m kgf m ft lb 2 Rear bracket corner 5 Lower bracket T 45 4 59 33 2 3 Rear side bracket 6 Bumper beam r...

Page 3173: ...NTERIOR TRIM 7 REAR BUMPER 4 DOOR MODEL 1 Bumper face 4 Rear side cover lower Tightening torque N m kgf m ft lb 2 Rear bracket corner 5 Lower bracket T 45 4 59 33 2 3 Rear side bracket 6 Bumper beam r...

Page 3174: ...8 General Description EXTERIOR INTERIOR TRIM 8 MUD GUARD 9 COWL PANEL 1 Front mud guard 2 Rear mud guard LH 3 Rear mud guard RH 1 Cowl panel 2 Cowl panel side 3 Gasket EI 02024 2 1 3 1 2 2 3 EI 01951...

Page 3175: ...POILER 1 Roof spoiler 3 Washer nozzle Tightening torque N m kgf m ft lb 2 High mounted stop light T 7 5 0 76 5 5 1 Rear spoiler 3 High mounted stop light Tightening torque N m kgf m ft lb 2 High mount...

Page 3176: ...INTERIOR TRIM 12 SIDE SILL SPOILER 13 ROOF MOLDING 1 Side sill spoiler 2 Gasket 1 Roof molding 3 Roof carrier attachment bracket Tightening torque N m kgf m ft lb 2 Rivet 4 Clip T 7 5 0 76 5 5 1 2 EI...

Page 3177: ...NK LID GARNISH 1 Rear gate garnish 3 Rear gate opener button harness Tightening torque N m kgf m ft lb 2 Ornament T 4 5 0 46 3 3 1 Rear gate garnish 3 License light bracket Tightening torque N m kgf m...

Page 3178: ...Door lock switch 2 Gusset cover front 10 Power window main switch ASSY 3 Upper weather strip 7 Power window switch panel front RH 11 Gusset cover rear 4 Inner remote 12 Power window switch panel rear...

Page 3179: ...Rear cup holder 2 Console front panel MT model 7 Console box outer 12 Console box end cap 3 Shift boot 8 Console box end cover 13 AUX input terminal 4 Parking brake lever boot 9 Console pocket 14 Cap...

Page 3180: ...RIOR INTERIOR TRIM 18 INSTRUMENT PANEL 1 Instrument panel side cover 4 Console side panel LH 7 Switch panel ASSY 2 Instrument panel ASSY 5 Instrument panel lower cover 3 Console side panel RH 6 Fuse b...

Page 3181: ...lle RH 2 Sunload sensor 8 Air vent side grille LH 14 Ornament panel RH 3 Cushion 9 Combination meter ASSY 15 Control module 4 Instrument panel ASSY 10 Audio 16 Center panel 5 Defroster side grille 11...

Page 3182: ...iption EXTERIOR INTERIOR TRIM 1 Instrument panel pad and frame ASSY 3 Glove box pad Tightening torque N m kgf m ft lb 4 Glove box damper T 7 5 0 76 5 5 2 Glove box lid ASSY 5 Instrument panel lower EI...

Page 3183: ...IM 1 Steering support beam bracket 4 Knee guard panel Tightening torque N m kgf m ft lb 2 Passenger s airbag module ASSY 5 Instrument panel ASSY T1 7 5 0 76 5 5 3 Steering support beam ASSY T2 25 2 55...

Page 3184: ...cription EXTERIOR INTERIOR TRIM 1 Center vent duct 4 Defroster nozzle ASSY 6 Instrument panel pad and frame ASSY 2 Side vent duct LH 5 Side defroster 3 Side vent duct RH 7 Center vent duct front EI 01...

Page 3185: ...2 Center pillar upper trim 8 Rear outside scuff plate 13 Luggage room end cover 3 Rear quarter upper trim 9 Rear inside scuff plate 4 Front pillar lower trim 10 Side seat belt cover Tightening torque...

Page 3186: ...side scuff plate 15 Sub trunk box 3 Quarter upper trim front 10 Quarter upper trim rear 16 Rear shelf trim 4 Front pillar lower trim 11 Quarter lower trim 5 Front outside scuff plate 12 Trunk lid trim...

Page 3187: ...RIM 22 ROOF TRIM 1 Rear gate pillar trim 2 Rear gate upper trim 3 Rear gate lower trim 1 Model without sunroof 5 door model 3 Model without sunroof 4 door model 4 Model with sunroof 4 door model 2 Mod...

Page 3188: ...lb 2 Sun visor T 7 5 0 76 5 5 1 Front heat shield cover 4 Rear heat shield cover 5 door model Tightening torque N m kgf m ft lb 2 Center heat shield cover turbo model T1 7 5 0 76 5 5 5 Rear heat shiel...

Page 3189: ...RIOR TRIM B PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removing trim KTC AP201 10A KTC AP201 N KTC AP203 10A KTC AP20L 10B Or equivalent Clip clamp pliers Used for removal of various cli...

Page 3190: ...A REMOVAL 1 Remove the front bumper face Ref to EI 29 FRONT BUMPER FACE REMOVAL Front Bumper 2 Remove the screws from the reverse side of the bumper face and remove the front grille assembly B INSTAL...

Page 3191: ...the hood duct assembly 4 Remove the nuts A and clips B and remove the front hood grille B INSTALLATION Install in the reverse order of removal NOTE Insert the hooks B of the front hood duct into holes...

Page 3192: ...ver A REMOVAL 1 Lift up the vehicle 2 Remove clips A and C and bolts B in the front fender then remove the front under cover B INSTALLATION Install in the reverse order of removal Tightening torque 14...

Page 3193: ...nuts B and then re move the fuel tank protector B INSTALLATION CAUTION Do not reuse the nut self locking nut Always replace with a new part Install in the reverse order of removal Tightening torque Re...

Page 3194: ...e the front wheels 3 Remove the screws and clips to remove the mud guard 2 REAR MUD GUARD 1 Jack up the vehicle 2 Remove the rear wheels 3 Remove the screws and clips to remove the mud guard B INSTALL...

Page 3195: ...easier to detach them from the fender side in the order from 1 to 3 while pulling up the bumper face to the direction of arrow B upward 7 Remove the bumper from the vehicle body 8 Remove the front gr...

Page 3196: ...Install in the reverse order of removal NOTE Fit the bumper face to the gap B between the guide bracket A and fender securely Tightening torque Refer to COMPONENT of General Descrip tion Ref to EI 5...

Page 3197: ...Solid paint Hardener PB Thinner T 301 Mixture ratio Main agent Hardener 4 1 Viscosity 10 13 sec 20 C 68 F Film thickness 35 45 Spraying pressure 245 343 kPa 2 5 3 5 kgf cm2 36 50 psi Use section bloc...

Page 3198: ...r swelled part can be removed Process 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...

Page 3199: ...le solvent NRM No 900 Precleno white gasoline or alcohol etc 5 Cutting If the damage is a crack or a hole cut a guide slit of 20 to 30 mm 0 79 to 1 18 in in length along the crack or hole up to the bu...

Page 3200: ...ompletely clean the entire coated area using solvent similar to that used in process No 4 13 Primer coating Apply a coat of primer to the repaired surface and its surrounding areas Mask these areas if...

Page 3201: ...ended at 20 C 68 F for at least 10 minutes until the topcoated area is half dry NOTE Be careful to keep dust or dirt from coming in contact with the affected area 21 Top coat II Not required Apply a c...

Page 3202: ...ehicle body CAUTION Do not pull with an excessive force Otherwise the bracket installation area may be damaged 5 DOOR MODEL 4 DOOR MODEL 1 Lifting the whole bumper face upward and twist it forward the...

Page 3203: ...ear bumper face from vehicle body and remove each bumper bracket Corner bracket Lower bracket B INSTALLATION Install in the reverse order of removal NOTE If the bumper face comes off easily from the b...

Page 3204: ...Detach tabs D and E 4 Remove the clips A and B and remove the cowl panel CAUTION When removing clip B push the claws of the clips from both the left and right to remove If pulled with excessive force...

Page 3205: ...he bolts and nuts 5 Remove the clips and remove the roof spoiler B INSTALLATION CAUTION Improper installing may cause the water leak age make sure the harness grommet is in stalled securely Check that...

Page 3206: ...UTION When removing the nut be careful not to drop the nut inside the trunk lid panel Be careful not to cause damage during re moval and installation B INSTALLATION CAUTION Improper installing may cau...

Page 3207: ...the clips and detach the side spoiler B INSTALLATION Install in the reverse order of removal NOTE For the rearmost clip securing the side sill spoiler install through the air flap 1 Side sill spoiler...

Page 3208: ...f Trim 4 Remove the nut and remove the roof carrier bracket B INSTALLATION CAUTION Always replace clips that were damaged during removal of the roof molding 1 Install the roof carrier bracket Tighteni...

Page 3209: ...ition in step 1 and lift up the gusset cover 3 Remove the gusset cover in the direction of the arrow to detach the clip section B and dis connect the connector 3 Open the cover of the inner remote sec...

Page 3210: ...trim 2 REAR DOOR 1 Disconnect the ground cable from battery 2 Remove the gusset cover 1 Push gusset cover in direction of vehicle front to detach the claws A on the backside of the gusset cover 2 Inse...

Page 3211: ...witch panel 5 Remove the door trim screws 6 Remove the door trim 1 Remove the clips then lift the door trim NOTE Insert a plastic clip remover into the slit at the bot tom of the door trim to lift the...

Page 3212: ...onnect the ground cable from battery 2 Remove the plastic hook A and remove the in strument panel side cover LH 3 Remove the screws 4 Remove plastic hook A disconnect connectors and remove the instrum...

Page 3213: ...battery 2 Remove the glove box damper 3 Remove the stopper section and pull out the glove box lid assembly towards yourself 4 Remove the instrument panel lower cover Ref to EI 51 INSTRUMENT PANEL LOW...

Page 3214: ...MOVAL 1 Disconnect the ground cable from the battery 2 Remove the parking brake lever boot 3 Remove bolt A screw B and clip C 4 Disconnect connectors and remove the console box B INSTALLATION Install...

Page 3215: ...l 3 Detach plastic hook A and remove the console front panel NOTE When removing the console front panel pull it in the direction of the rear vehicle 4 Remove the clips and screws and remove the consol...

Page 3216: ...or by pulling it 3 Insert the plastic clip remover into the slit on the bottom of the center panel to lift the panel 4 Remove the claws and resin hook and then re move the center panel 5 Detach the pl...

Page 3217: ...rnament panel RH Ref to EI 49 ORNAMENT PANEL REMOVAL Center Con sole 5 Remove the instrument panel lower cover Ref to EI 46 REMOVAL Instrument Panel Lower Cov er 6 Remove the glove box lid Ref to EI 4...

Page 3218: ...le box Ref to EI 48 REMOV AL Console Box 5 Remove the console box Ref to EI 48 RE MOVAL Console Box 6 Remove the console front panel Ref to EI 49 CONSOLE FRONT PANEL REMOVAL Center Console 7 Remove th...

Page 3219: ...n route the harness 3 Install in the reverse order of removal Tightening torque Steering support beam steering support beam bracket 25 N m 2 55 kgf m 18 4 ft lb Steering shaft Ref to PS 3 STEERING WHE...

Page 3220: ...isassem bly until the instrument panel assembly is formed NOTE Method of installing insulator Adhesive Use polyurethane adhesive When assembling the instrument panel assembly wait until the adhesive h...

Page 3221: ...plate 3 Remove clip A and remove the front pillar low er trim 4 Remove the rear seat cushion Ref to SE 11 REMOVAL Rear Seat 5 Remove clip A and remove the inside scuff plate CAUTION Do not pull with...

Page 3222: ...INTERIOR TRIM 7 Remove the clips of the center pillar lower trim 8 Spread the lower trim outwards to remove the claw and pull on the upper trim to remove B INSTALLATION Install in the reverse order o...

Page 3223: ...de of the pil lar trim and remove the bolt NOTE Remove the molding A and remove the cap from the backside of pillar trim not to damage the trim 7 Pull and remove the upper trim clip section of the cen...

Page 3224: ...nt trim and remove the bolt inside NOTE Remove the molding A and remove the cap from the backside of pillar trim not to damage the trim 4 Remove the side belt cover C 5 Remove center belt cover D and...

Page 3225: ...the cap from the backside of pillar trim not to damage the trim 6 Remove side belt cover A 7 Remove the bolts and clips and remove the quarter upper trim front 8 Remove the rear seat Ref to SE 11 REMO...

Page 3226: ...t the ground cable from battery 2 Remove the rear quarter trim Ref to EI 59 4 DOOR MODEL REMOVAL Rear Quarter Trim 3 Remove the seat belt center anchor lower bolt 4 Remove the clips and remove the rea...

Page 3227: ...1 Remove the rear seat backrest Ref to SE 11 REMOVAL Rear Seat 2 Remove the trunk room mat 3 Remove the clips and then remove the trunk room rear trim 4 Remove the clips and remove the trunk side trim...

Page 3228: ...e screws and detach the sun visor 2 Disconnect the connector Model with vanity mirror light 3 While pressing the A on the both side using flat tip screwdriver pull the sun visor hook to remove it B IN...

Page 3229: ...Pull the left side of assist grip and rotate the right side of it counterclockwise to remove 3 Remove the roof trim Ref to EI 64 REMOV AL Roof Trim 4 Remove the bolts and remove the assist grip bracke...

Page 3230: ...trim out of the vehicle be careful not to damage the room inner trim Per form this work with 3 persons 1 Disconnect the ground cable from battery 2 Apply protective tape etc to prevent damage to the...

Page 3231: ...he passenger s side door all the way and maintain at that position 18 Take out the roof trim from the passenger s side opening NOTE Rotate the roof trim to go through the gap between the front accesso...

Page 3232: ...follow the procedures below Applying excessive force when removing can damage the trim Use flat tip screwdrivers 1 or clip removers 2 to de tach the claws of the trim 1 Use a flat tip screwdriver 1 t...

Page 3233: ...wdriver 1 as shown in the figure to detach the claws of the trim 2 Insert a flat tip screwdriver 2 as shown in the figure to detach the claws of the trim Tools used Flat tip screwdriver 1 Axle length...

Page 3234: ...e the lower inner trim Ref to EI 55 RE MOVAL Lower Inner Trim 6 Remove the footrest MT model 7 Remove the clips from the floor mat 8 Remove the mat hook on both sides 9 Remove the mat from toe board a...

Page 3235: ...ar Finisher Light Assembly 4 Disconnect the connector Rear gate opener button harness connector Rear request switch harness connector Smart keyless models 5 Remove the nuts 6 Remove the clips and remo...

Page 3236: ...the upper corner of the trunk lid garnish 2 Place your hands between the trunk lid garnish and the trunk lid panel and remove the trunk lid garnish starting from the edge in order B INSTALLATION Insta...

Page 3237: ...ts to remove the front heat shield cover 2 CENTER HEAT SHIELD COVER 1 Remove the rear exhaust pipe Turbo model Ref to EX H4DOTC 13 RE MOVAL Rear Exhaust Pipe Non turbo model Ref to EX H4SO 10 RE MOVAL...

Page 3238: ...hield Cover EXTERIOR INTERIOR TRIM B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion Ref to EI 22 HEAT SHIELD COVER COMPONENT General...

Page 3239: ...pplication tape to the end of the rear gate panel 2 Application tape 2 A A EI 02395 A A 1 1 1 1 Match the end of the application tape to the end of the rear gate panel 3 Application tape 4 Fold the sl...

Page 3240: ...EI 74 Ornament EXTERIOR INTERIOR TRIM...

Page 3241: ...EB 2 General Description EXTERIOR BODY PANELS 1 General Description A SPECIFICATION 1 FRONT EB 00520 A C A E B F J K H 2 1 I D G C E 2 4 4 5 B 2 3 D 2 4 F 4 6 F1 F 2...

Page 3242: ...anel Rear end only 4 8 0 7 1 0 mm 0 14 0 03 0 04 in E Front fender panel to Front pillar panel 3 0r1 0 mm 0 12r0 04 in F Front fender panel to Front door panel F1 4 0r1 0 mm 0 16r0 04 in F2 0 1 0 0 5...

Page 3243: ...EB 4 General Description EXTERIOR BODY PANELS 2 REAR 5 DOOR MODEL EB 00483 B 4 E D H M B A K L G F 2 7 E D 4 G 4 8 F 3 6 5 B1 B 2 C J C 2 4 C1 C2 4 8 G2 G1 A 1 2 A1 A2 I...

Page 3244: ...0 20r0 04 in E Rear gate panel to Rear bumper 8 0r1 0 mm 0 31r0 04 in F Rear quarter panel to Fuel filler lid 3 5r0 5 mm 0 14r0 02 in G Rear quarter panel to Fuel filler lid G1 3 5r0 5 mm 0 14r0 06 i...

Page 3245: ...EB 6 General Description EXTERIOR BODY PANELS 3 REAR 4 DOOR MODEL B 1 3 A 1 2 D 1 4 A D B G L J K F EB 00485 C I E 4 E 4 5 F 4 5 E2 E1 C 1 4 H B1 B2 C2 C1...

Page 3246: ...nel to Fuel filler lid E1 3 5r0 5 mm 0 14r0 06 in E2 4 0r0 5 mm 0 18r0 06 in F Rear quarter panel to Fuel filler lid 3 5r0 5 mm 0 14r0 02 in G Roof panel to Rear door sash G1 5 0r1 0 mm 0 20r0 04 in G...

Page 3247: ...B COMPONENT 1 FRONT HOOD 1 Insulator 4 Seal front panel Tightening torque N m kgf m ft lb 2 Front hood panel 5 Damper stay T1 7 5 0 76 5 5 3 Seal intake duct 6 Hinge T2 20 2 04 14 5 T3 25 2 55 18 4 T4...

Page 3248: ...EB 9 General Description EXTERIOR BODY PANELS 2 FRONT FENDER Tightening torque N m kgf m ft lb T 7 4 0 75 5 5 EB 00372 T T T T T T T T...

Page 3249: ...t door panel 5 Upper hinge Tightening torque N m kgf m ft lb 2 Front door weather strip 6 Lower hinge T1 7 5 0 76 5 5 3 Sealing cover 7 Front door weather strip outer T2 25 2 55 18 4 4 Checker T3 30 3...

Page 3250: ...r door panel 5 Upper hinge Tightening torque N m kgf m ft lb 2 Rear door weather strip 6 Lower hinge T1 7 5 0 76 5 5 3 Sealing cover 7 Rear door weather strip outer T2 25 2 55 18 4 4 Checker T3 30 3 0...

Page 3251: ...neral Description EXTERIOR BODY PANELS 5 REAR GATE 1 Rear gate damper stay 3 Rear gate panel Tightening torque N m kgf m ft lb 2 Hinge T1 10 1 02 7 4 T2 20 2 04 14 8 T3 25 2 55 18 4 EB 00378 3 T3 T3 T...

Page 3252: ...re heavy When removing or installing do not drop and damage the panels Do not damage the panel painting surface 1 Trunk lid panel 4 Trunk lid lock ASSY Tightening torque N m kgf m ft lb 2 Torsion bar...

Page 3253: ...TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge 927780000 REMOVER Used for removing and installing the trunk tor sion bar TOOL NAME REMARKS Support jack Us...

Page 3254: ...ps 2 FRONT HOOD SEAL Remove the seal 3 FRONT HOOD DAMPER CAUTION Do not damage piston rods and oil seals Never disassemble cylinders They contain gas The front hood panel is heavy When remov ing or in...

Page 3255: ...oup of two or more 1 Remove the front hood insulator 2 Remove the front hood seal 3 Remove the window washer hose and nozzle Ref to WW 17 REMOVAL Front Washer Noz zle 4 Remove the front hood damper 5...

Page 3256: ...CATION General Description 2 Use the hinge mounting bolts to align the front hood longitudinal and lateral position 3 Adjust the height at the front end of hood Ref to SL 41 ADJUSTMENT Front Hood Lock...

Page 3257: ...B and C from the vehi cle exterior 2 Detach tabs D and E 7 Remove the bolt and remove the front fender panel 2 COWL SIDE STAY For operation procedures refer to performance stay items Ref to EB 19 REM...

Page 3258: ...ance Stay A REMOVAL 1 Remove the front fender Ref to EB 18 RE MOVAL Front Fender 2 Remove the bolts and harness clip and remove the front performance stay B INSTALLATION Install in the reverse order o...

Page 3259: ...SL 34 REMOVAL Front Door Latch and Door Lock Actuator Assembly 9 Remove the front outer handle Ref to SL 33 REMOVAL Front Outer Handle 10 Remove the front door weather strip NOTE If the weather strip...

Page 3260: ...OR COMPO NENT General Description 7 Install while paying attention to make a uniform clearance around the front door panel For the di mension of clearance refer to SPECIFICATION in General Description...

Page 3261: ...s broken replace it with a new part B INSTALLATION 1 Install in the reverse order of removal 2 When replacing the sealing cover use the butyl tape 3 Press the butyl tape applied area firmly to pre ven...

Page 3262: ...ear Door Latch and Door Lock Actuator Assembly 8 Remove the rear outer handle Ref to SL 36 REMOVAL Rear Outer Handle 9 Remove the rear door weather strip NOTE If the weather strip clip is removed with...

Page 3263: ...le paying attention to make a uniform clearance around the rear door panel For the di mension of clearance refer to SPECIFICATION in General Description Ref to EB 2 SPECIFI CATION General Description...

Page 3264: ...he cover If cover gets broken replace it with a new part B INSTALLATION 1 Install in the reverse order of removal 2 When replacing the sealing cover use the butyl tape 3 Press the butyl tape applied a...

Page 3265: ...el the door sash tape from the door sash NOTE If the tape is difficult to remove warm the tape with a hairdryer etc to make the removal easier Use a household hairdryer Do not use industrial dryers If...

Page 3266: ...s are formed If air bubbles are formed reapply the tape If the tape is wrinkled etc during application replace the tape Turning points and ends of the tape will be a cause for peeling if the pressure...

Page 3267: ...r end of the tape is to be aligned so that a space of approximately 3 7 mm 0 15 in remains so that the attachment holes of the weather strip outer are not blocked Position of the arrow 6 Apply tape fr...

Page 3268: ...ont sash line 2 Apply tape from the top of the vehicle towards the bottom 3 Match the rear door upper sash corner and the cut area of the tape as shown in the figure Posi tion of the arrow NOTE Apply...

Page 3269: ...holes of the weather strip outer are not blocked Position of the arrow 9 Apply tape from the top of the vehicle towards the bottom 10 Fold the corners at the door upper end area in the order of 1 2 1...

Page 3270: ...REMOVAL Rear Gate Latch and Actuator Assembly 8 Remove the roof spoiler Ref to EI 39 RE MOVAL Roof Spoiler 9 Remove the rubber duct A connection 10 Remove harness clip of each connector from the rear...

Page 3271: ...PANEL 1 Install in the reverse order of removal Tightening torque 25 N m 2 55 kgf m 18 4 ft lb 2 Install while paying attention to make a uniform clearance around the rear gate panel For the di mensi...

Page 3272: ...DISPOSAL 1 REAR GATE DAMPER STAY CAUTION Gas is colorless odorless and harmless How ever gas pressure may spray cutting powder or oil Be sure to wear dust resistant goggles 1 Cover with a vinyl sack a...

Page 3273: ...EMOVAL Trunk Lid 7 Remove the rear shelf trim Ref to EI 60 RE MOVAL Rear Shelf Trim 8 Remove the bolts then remove the trunk lid arm 3 TRUNK LID PANEL 1 Disconnect the ground cable from battery 2 Disc...

Page 3274: ...o EB 2 SPECIFICATION Gener al Description 1 Adjust the trunk lid panel lateral position 1 Loosen the mounting bolt 2 Align the trunk lid panel lateral panel dimen sion 2 Adjust the gap between trunk l...

Page 3275: ...ape to the position shown in the following figure 4 Peel away the film of a 5 Peel away the backing paper of b and adhere the protector tape to the vehicle body 6 Get rid of water and air bubbles in t...

Page 3276: ...ontrol module ECM 5 Transmission control module TCM AT model 7 Neutral position switch MT model 2 Cruise control command switch 3 Stop light and brake switch 6 Inhibitor switch AT model 8 Clutch switc...

Page 3277: ...cting the ground cable from battery Otherwise the memory will be cleared Reassemble the parts in the reverse order of disassembly unless otherwise indicated Adjust the parts to specifications specifie...

Page 3278: ...ion procedures of the control module refer to Engine section B REMOVAL 2 5 L turbo model Ref to FU H4DOTC 52 RE MOVAL Engine Control Module ECM 2 5 L non turbo model Ref to FU H4SO 2 SPECIFICATION Gen...

Page 3279: ...ctor on back of the airbag module Ref to AB 8 PROCE DURE Airbag Connector 7 Remove the steering wheel Ref to PS 12 RE MOVAL Steering Wheel 8 Remove the screws to remove the lower cover from steering w...

Page 3280: ...CC 6 Combination Meter CRUISE CONTROL SYSTEM 4 Combination Meter A NOTE For the combination meter refer to the IDI sec tion Ref to IDI 16 Combination Meter...

Page 3281: ...CC 7 Stop Light Brake Switch CRUISE CONTROL SYSTEM 5 Stop Light Brake Switch A NOTE For stop light brake switch refer to BR Ref to BR 45 Stop Light Switch...

Page 3282: ...CC 8 Clutch Switch CRUISE CONTROL SYSTEM 6 Clutch Switch A NOTE For clutch switch refer to CL Ref to CL 27 Clutch Switch...

Page 3283: ...ission Control Module TCM CRUISE CONTROL SYSTEM 7 Transmission Control Module TCM A NOTE For transmission control module TCM refer to Automatic Transmission section Ref to 4AT 63 Transmission Control...

Page 3284: ...CC 10 Inhibitor Switch CRUISE CONTROL SYSTEM 8 Inhibitor Switch A NOTE For inhibitor switch refer to Automatic Transmis sion section Ref to 4AT 48 INSPECTION Inhib itor Switch...

Page 3285: ...CC 11 Neutral Position Switch CRUISE CONTROL SYSTEM 9 Neutral Position Switch A NOTE For neutral position switch refer to Manual Trans mission Differential section Ref to 5MT 33 Switches and Harness...

Page 3286: ...CC 12 Neutral Position Switch CRUISE CONTROL SYSTEM...

Page 3287: ...ABS VDC related DTC displayed Perform the diag nosis according to the engine or ABS VDC related DTC Go to phenome non 2 Ref to CC diag 9 DIAG NOSTIC PROCE DURE WITH PHENOMENON Diagnostics with Phenom...

Page 3288: ...p 12 Go to phenome non 7 Ref to CC diag 9 DIAG NOSTIC PROCE DURE WITH PHENOMENON Diagnostics with Phenomenon 12 CHECK CRUISE CONTROL RELEASE OP ERATION Check the cruise control release operation Is th...

Page 3289: ...rness when servicing the cruise control com mand switch Airbag system wiring harness is routed near the cruise control command switch B PREPARATION TOOL 1 SPECIAL TOOL 2 GENERAL TOOL C INSPECTION Meas...

Page 3290: ...OCATION 1 Engine control module ECM 5 Transmission control module TCM AT model 7 Neutral position switch MT model 2 Cruise control command switch 3 Stop light and brake switch 6 Inhibitor switch AT mo...

Page 3291: ...al is released Main switch B12 0 V is detected while the main switch is pressed or turned on Approx 5 V is detected when the main switch is OFF Ground GND CONTROL 1 GND CONTROL 2 A5 Ignition switch B1...

Page 3292: ...to OFF 2 Real time Diagnosis Real time diagnosis function is used to determine whether or not the input signal system is in good or der according to signal emitted from switches sen sors etc 1 Vehicl...

Page 3293: ...e deleted by clearing memory on the engine side NOTE The latest code will be cleared by turning ignition switch to OFF 3 REAL TIME DIAGNOSIS 1 Connect the Subaru Select Monitor 2 Turn the ignition swi...

Page 3294: ...t Ref to CC diag 10 CHECK CRUISE INDICATOR LIGHT AND CRUISE SET INDICATOR LIGHT Diag nostics with Phenomenon 4 Vehicle speed is not held within set speed r3 km h r2 MPH Check the vehicle speed sensor...

Page 3295: ...stem 2 Check the cruise indicator light and cruise set indicator light if they illuminate Do the cruise indicator light and cruise set indicator light illumi nate Go to step 2 Replace the meter case a...

Page 3296: ...s code is displayed without depressing the brake pedal Ref to CC diag 16 12 Diagnos tic Procedure with Cancel Code 13 Clutch Switch Clutch switch is turned to ON and then the cruise control is release...

Page 3297: ...24 32 Diagnos tic Procedure with Cancel Code 34 Prohibition of cruise con trol at continuing big Accel angle The vehicle has been driven at higher speed than set vehicle speed for an abnormally long t...

Page 3298: ...to CC diag 25 62 Diagnostic Procedure with Cancel Code 63 Abnormality of change in vehicle speed Malfunction of vehicle speed signal variation is detected Ref to CC diag 25 63 Diagnostic Procedure wit...

Page 3299: ...WIRING DIAGRAM CC 00601 B136 9 30 29 2 3 8 2 31 20 19 18 22 21 10 12 11 14 24 34 33 27 26 16 1 2 3 4 5 6 13 23 15 25 8 7 17 35 ST3 SET COAST SWITCH RESUME ACCEL SWITCH CANCEL SWITCH B136 C ECM B24 C6...

Page 3300: ...resistance between switch termi nals when the cruise control command switch is not depressed Terminals No 6 No 7 Is the resistance approx 4 k Go to step 4 Replace the cruise control command switch Ref...

Page 3301: ...30 29 32 28 31 20 19 18 22 21 10 12 11 14 24 34 33 27 26 16 1 2 3 4 5 6 13 23 15 25 8 7 17 35 C 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 29 30 31 32 33 34 35 B B...

Page 3302: ...door model B65 No 3 Chassis ground 4 door model B65 No 1 Chassis ground Is the voltage 10 V or more Go to step 3 Check fuse No 4 in fuse relay box Check for open or short in the har ness between stop...

Page 3303: ...9 32 28 31 20 19 18 22 21 10 12 11 14 24 34 33 27 26 16 1 2 3 4 5 6 13 23 15 25 8 7 17 35 C 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 29 30 31 32 33 34 35 B B225...

Page 3304: ...open or shorted circuit of harness between clutch switch and fuse relay box 2 CHECK CLUTCH SWITCH CIRCUIT 1 Turn the ignition switch to OFF 2 Disconnect the harness connector of ECM 3 Measure the res...

Page 3305: ...or more Go to step 3 Check for open or short in the har ness between inhibitor switch and ECM 3 CHECK INHIBITOR SWITCH CIRCUIT 1 Turn the ignition switch to OFF 2 Disconnect the starter motor harness...

Page 3306: ...ch to ON 4 Measure the voltage between harness con nector terminal and chassis ground Connector terminal Non turbo model B25 No 2 Chassis ground Turbo model T12 No 1 Chassis ground Is the voltage 10 V...

Page 3307: ...1 Diagnostic Procedure with Cancel Code Step Check Yes No 1 CHECK IGNITION SWITCH CIRCUIT 1 Turn the ignition switch to OFF 2 Disconnect the ECM harness connector 3 Turn the ignition switch to ON 4 Me...

Page 3308: ...initial operation of combination meter is completed check if ABS or VDC warn ing light continues to illuminate Does the warning light continue to illuminate Check ABSCM or VDCCM Ref to ABS diag 2 Basi...

Page 3309: ...iagnosis for DTC 22 Refer to DTC 22 for diagnostic procedure Ref to CC diag 23 22 Diagnostic Procedure with Cancel Code M 34 The vehicle has been driven at a speed higher than set speed for a long tim...

Page 3310: ...led immediately Refer to DTC 22 for diagnostic procedure Ref to CC diag 23 22 Diagnostic Procedure with Cancel Code V 64 Malfunction related to engine is detected Refer to the Engine Diagnostic Proced...

Page 3311: ...CC diag 26 Diagnostic Procedure with Cancel Code CRUISE CONTROL SYSTEM DIAGNOSTICS...

Page 3312: ...2 Basic Diagnostic Proce dure Inspect the DTC display body inte grated unit Go to step 7 5 CHECK ENGINE START Turn the ignition switch to START Does the starter operate Go to step 6 Check the LAN comm...

Page 3313: ...key is on a key holder remove it from the key holder be fore performing diagnoses When repeatedly turning the ignition switch to ON or OFF while diagnostic items are being checked it should be switch...

Page 3314: ...ION TOOL 1 SPECIAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit test...

Page 3315: ...diag 5 Electrical Component Location IMMOBILIZER DIAGNOSTICS 3 Electrical Component Location A LOCATION 1 Antenna 3 Body integrated unit 4 Transponder 2 Security indicator light LED bulb IM 00276 3 2...

Page 3316: ...IM diag 6 Immobilizer Control Module I O Signal IMMOBILIZER DIAGNOSTICS 4 Immobilizer Control Module I O Signal A WIRING DIAGRAM 1 IMMOBILIZER Ref to WI 157 WIRING DIAGRAM Immobilizer System...

Page 3317: ...w to display a DTC Ref to IM di ag 8 Read Diagnostic Trouble Code DTC 3 COMMUNICATION LINE CHECK NOTE The communication line between ECM and body integrated unit can be checked in System Opera tion Ch...

Page 3318: ...refer to PC application help for Subaru Select Monitor For detailed concerning DTC refer to the List of Diagnostic Trouble Codes DTC Ref to IM di ag 14 LIST List of Diagnostic Trouble Code DTC 2 BODY...

Page 3319: ...l diagnosis of the electronic throttle control is performed Wait for 10 seconds or more after turning the ignition switch to ON and then start the engine For detailed operation procedures refer to PC...

Page 3320: ...12 A10 C2 C20 B17 39 E 1 B1 M B No 8 SBF 8 D27 i84 A B280 B B281 C 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 B281 i84 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2...

Page 3321: ...CHECK BODY INTEGRATED UNIT POWER SUPPLY CIRCUIT 1 Turn the ignition switch to OFF 2 Measure the voltage between the body inte grated unit harness connector terminal and chassis ground Connector termin...

Page 3322: ...ht IMMOBILIZER DIAGNOSTICS 2 CHECK KEY SWITCH CIRCUIT WIRING DIAGRAM IM 00278 B350 M B No 14 D2 3 4 B350 1 2 3 4 5 4 6 7 2 9 3 10 22 23 11 12 13 14 15 24 25 26 27 16 17 18 28 29 19 20 21 30 B279 D B27...

Page 3323: ...key warning switch 3 CHECK KEY WARNING SWITCH 1 Remove the ignition key from ignition switch 2 Measure the resistance between key warn ing switch connector terminals Connector terminal No 3 No 4 Is th...

Page 3324: ...d Ref to IM diag 19 DTC P1572 IMM CIRCUIT FAILURE EXCEPT ANTENNA CIRCUIT Diagnostic Procedure with Diagnostic Trouble Code DTC P1574 Key Communication Failure Communication failure between key and bod...

Page 3325: ...er to the PC application help for Subaru Select Monitor Is registration for all keys com plete End Replace ignition keys including transponder which cannot be registered Go to step 2 2 PERFORM REGISTR...

Page 3326: ...ntegrated unit 2 Measure the resistance between harness connector and chassis ground Connector terminal B280 No 26 Chassis ground Is the resistance less than 10 Repair the har ness Go to step 3 3 CHEC...

Page 3327: ...0 30 V Approx 0 1 second after inserting the key Is the voltage 0 V Approx 1 second after inserting the key Go to step 7 Replace the body integrated unit Ref to SL 50 Body Integrated Unit Replace all...

Page 3328: ...l keys com plete End Go to step 2 2 CHECK FOR ANY OTHER DTC ON DISPLAY Is any other immobilizer DTC displayed Check the appro priate DTC using the List of Diag nostic Trouble Code DTC Ref to IM diag 1...

Page 3329: ...280 B B281 C D27 ECM B136 C 1 2 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 7 32 33 34 35 BODY INTEGRATED UNIT IM 00322 E A28 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 1...

Page 3330: ...stance less than 10 Go to step 4 Repair the open circuit of the body integrated unit ground circuit 4 CHECK GROUND CIRCUIT FOR ECM Measure the resistance between the ECM ground terminal and engine gro...

Page 3331: ...d repair the harness between the body integrated unit and ECM 9 CHECK ECM BY COMMUNICATION LINE CHECK 1 Connect the harness connector to ECM 2 Disconnect the harness connector from body integrated uni...

Page 3332: ...ponder Execute the regis tration procedure next Refer to the PC application help for Subaru Select Monitor Replace the body integrated unit Ref to SL 50 Body Integrated Unit Replace all ignition keys...

Page 3333: ...k Go to step 3 3 PERFORM REGISTRATION ON IGNITION KEY Perform registration on all keys of the vehicle Refer to the PC application help for Subaru Select Monitor Is registration for all keys com plete...

Page 3334: ...Y Ref to IM diag 15 DTC P0513 INCORRECT IMMO BILIZER KEY Diagnostic Procedure with Diagnostic Trouble Code DTC DTC P1570 ANTENNA Ref to IM diag 16 DTC P1570 ANTENNA Diagnostic Procedure with Diag nost...

Page 3335: ...ody control Ref to LAN diag 6 INSPECTION General Description Is the component that might influence the body control prob lem normal Go to step 3 Repair or replace each component 3 CHECK DTC 1 Read the...

Page 3336: ...display OK NG Fuel gauge display OK NG Display of other indicators Malfunction indicator light ON OFF SPORT indicator light AT warning light ON Blink OFF Engine coolant temperature warning light ON Bl...

Page 3337: ...Yes No Rear wiper does not operate Yes No Doors can not be locked unlocked with central door lock switch Yes No Doors can not be locked unlocked with keyless entry system Yes No Rear gate can not be...

Page 3338: ...eed km h MPH While accelerating Acceleration km h MPH to km h MPH Decelerating With braking Deceleration km h MPH to km h MPH Decelerating Without braking Deceleration km h MPH to km h MPH Flat road U...

Page 3339: ...d protect it with insulating tape etc B INSPECTION Before performing diagnostics check the following item which might affect body integrated unit mal functions 1 Measure the battery voltage and check...

Page 3340: ...ION TOOL 1 SPECIAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1B022XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system TOOL NAME REMARKS Circuit test...

Page 3341: ...it 6 A C control panel 9 Combination meter 2 Engine control module ECM 7 Center display 10 Steering angle sensor 3 Auto A C control module 8 Transmission control module TCM 11 ABS CM H U or VDCCM H U...

Page 3342: ...LAN diag 9 Electrical Component Location LAN SYSTEM DIAGNOSTICS 1 LAN00303 LAN00425 2 LAN00299 7 8 LAN00297 LAN00008 11...

Page 3343: ...Ground B17 mo chassis ground Less than 1 5 V Always Ground C20 mo chassis ground Less than 1 5 V Always Ground D27 mo chassis ground Less than 1 5 V Always Key warning switch D2 mo chassis ground Less...

Page 3344: ...ned Rear gate opener button C24 mo chassis ground 8 V or more o less than 1 5 V Switch OFF o ON Manual switch LOCK A15 mo chassis ground 8 V or more o less than 1 5 V Switch OFF o ON Manual switch UNL...

Page 3345: ...clearance light illuminates Illumination Vi3 A26 mo chassis ground Less than 1 5 V Always Fuel level sensor C7 mo chassis ground Approx 2 96 Ignition ON Wiper deicer rear defogger switch A16 mo chassi...

Page 3346: ...round 8 V or more o less than 1 5 V Lo beam ON Hi beam OFF front fog light switch ON DRL cancel output D18 mo chassis ground 8 V or more o less than 1 5 V When Hi beam 100 illuminates Room light outpu...

Page 3347: ...ine Keyless entry control module communication A24 Can not be measured because of digital communication Serial communication line SSM communication K line B20 Can not be measured because of digital co...

Page 3348: ...s used to install the Subaru Select Monitor 4 Connect the diagnosis cable to SDI 5 Connect the SDI to data link connector located in the lower portion of the instrument panel on the driver s side 6 St...

Page 3349: ...umber of transmitter registered is dis played Front Wheel Speed km h CAN data input value Reception from VDC module VDC ABS latest f code DTC display Tempo rarily CAN data input value It is normal whe...

Page 3350: ...tegrated unit input value ON when bright switch is ON P SW ON OFF Body integrated unit input value ON when shift range is in parking Shift lever P switch signal MT Reverse Switch ON OFF Body integrate...

Page 3351: ...e ON when ignition switch is turned to ON and buckle switch is turned off P belt warning light O P ON OFF Body integrated unit output value ON when ignition switch is turned to ON occupant is seated a...

Page 3352: ...n from vehicle dynamic control VDC to high speed control module Small Light SW ON OFF CAN data output value ON when small light is illuminated Headlamp ON OFF CAN data output value When headlight LO i...

Page 3353: ...nated Lighting Hi Lamp Output ON OFF Body integrated unit output value ON when Hi beam is illuminated Front Fog Lamp Output ON OFF Body integrated unit output value ON when Front fog light is ON DRL C...

Page 3354: ...ted unit setting items Customize setting Map Light Setting ON OFF Body integrated unit setting items Customize setting Belt Warning Switch ON OFF Body integrated unit setting items Customize setting A...

Page 3355: ...ting for lighting off time Rr defogger op mode Normal Continuous Security Alarm Setup ON OFF Impact Sensor Setup ON OFF Option setting Alarm delay setup ON OFF Lockout prevention ON OFF Impact sensor...

Page 3356: ...to Factory key illumi nation blinks when ignition key is turned ON to notify that the settings are unconfirmed Key illumination does not blink with ignition switch turned to ON and go off with door cl...

Page 3357: ...tion operation Market mode Each settings have been set It can be recognized by key ring illumination coming on in concocting with room light and going off with ignition switch turned to ON Data Initia...

Page 3358: ...o PC application help for Subaru Select Moni tor 7 CLEAR MEMORY MODE 1 On Main Menu display select Each System Check 2 On System Selection Menu display select In teg unit mode 3 Press the OK key after...

Page 3359: ...ay time is 0 second Lockout prevention ON ON Lockout prevention in active condition The function does not operate if safety knob is locked by hand OFF Lockout prevention in inactive condition Impact s...

Page 3360: ...ext starts End cancels the opera tion and OK returns to the System Operation Check Mode display screen NOTE If not equipped based on area or condition pro cess will not go on Initial button setting Ex...

Page 3361: ...9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 B281 C 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 0 3 1 2 B279 D B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 3362: ...ted unit connec tor 3 Measure the resistance between data link connector and chassis ground Connector terminal B40 No 7 Chassis ground Is the resistance 1 M or more Go to step 7 Repair the harness and...

Page 3363: ...2 Disconnect the connector from body inte grated unit 3 Measure the resistance of harness between the body integrated unit and chassis ground Connector terminal B280 No 20 Chassis ground Is the resis...

Page 3364: ...de DTC LAN SYSTEM DIAGNOSTICS 7 Read Diagnostic Trouble Code DTC A OPERATION For details concerning DTC reading procedure re fer to Subaru Select Monitor Ref to LAN diag 15 READ DIAGNOSTIC TROUBLE COD...

Page 3365: ...ear Memory Mode LAN SYSTEM DIAGNOSTICS 8 Clear Memory Mode A OPERATION For details concerning DTC clear operation refer to Subaru Select Monitor Ref to LAN diag 25 CLEAR MEMORY MODE OPERATION Subaru S...

Page 3366: ...ode 3 On the Integ Unit mode failure diag display screen select the Current Data Display Save 4 Using the scroll key scroll the display screen up or down until the desired data is shown Ref to LAN dia...

Page 3367: ...er Customizing LAN SYSTEM DIAGNOSTICS 10 User Customizing A OPERATION For detailed procedures of User Customizing refer to SUBARU SELECT MONITOR Ref to LAN diag 26 USER CUSTOMIZING OPERA TION Subaru S...

Page 3368: ...put short GND output short in shift lock circuit Ref to LAN diag 49 DTC B1106 SHIFT LOCK CIRCUIT FAILURE Diagnostic Proce dure with Diagnostic Trouble Code DTC U1201 CAN HS counter abnormal Communicat...

Page 3369: ...t data abnormal Received error data from meter Ref to LAN diag 80 DTC U1311 CAN LS METER UNIT DATA ABNORMAL Diagnostic Procedure with Diagnostic Trouble Code DTC U1321 CAN LS meter no receive data Not...

Page 3370: ...221 P1718 C0057 It is possible that the ECM is faulty U1222 Ref to LAN diag 67 DTC U1222 CAN HS TCM NO RECEIVE DATA Diagnostic Procedure with Diagnostic Trouble Code DTC U1222 P0600 C0057 It is possib...

Page 3371: ...TC indicated by body integrated unit Ref to LAN diag 15 READ DIAGNOSTIC TROUBLE CODE DTC OPERATION Subaru Select Monitor Is the DTC B1100 displayed current malfunction Go to step 2 Temporary EEPROM ac...

Page 3372: ...battery run out occurs WIRING DIAGRAM LAN00406 B6 C2 A28 D27 B17 C20 i84 B280 B A E MAIN SBF FB 18 No 7 B281 C E E BATTERY BODY INTEGRATED UNIT BACK UP POWER SUPPLY SYSTEM CONTROL POWER SUPPLY MB 29...

Page 3373: ...lfunction Go to step 3 Go to step 5 3 CHECK FUSE 1 Turn the ignition switch to OFF 2 Inspect the fuse Is the fuse OK Go to step 4 Replace the defec tive fuse 4 CHECK HARNESS 1 Disconnect the body inte...

Page 3374: ...occurs WIRING DIAGRAM LAN00406 B6 C2 A28 D27 B17 C20 i84 B280 B A E MAIN SBF FB 18 No 7 B281 C E E BATTERY BODY INTEGRATED UNIT BACK UP POWER SUPPLY SYSTEM CONTROL POWER SUPPLY MB 29 No 8 FUSE RELAY B...

Page 3375: ...lfunction Go to step 3 Go to step 5 3 CHECK FUSE 1 Turn the ignition switch to OFF 2 Inspect the fuse Is the fuse OK Go to step 4 Replace the defec tive fuse 4 CHECK HARNESS 1 Disconnect the body inte...

Page 3376: ...C OFF IG ON E MAIN SBF FB 29 No 31 B280 B i84 A B281 C BATTERY BODY INTEGRATED UNIT ACC POWER SUPPLY IG POWER SUPPLY IGNITION SWITCH A28 D27 B17 C20 E E FB 38 No 12 1 3 4 5 6 2 B72 SBF 6 FUSE RELAY BO...

Page 3377: ...tep 3 Go to step 5 3 CHECK FUSE 1 Turn the ignition switch to OFF 2 Inspect the fuse Is the fuse OK Go to step 4 Replace the defec tive fuse 4 CHECK HARNESS 1 Disconnect the body integrated unit conne...

Page 3378: ...SBF FB 29 No 31 B280 B i84 A B281 C BATTERY BODY INTEGRATED UNIT ACC POWER SUPPLY IG POWER SUPPLY IGNITION SWITCH A28 D27 B17 C20 E E FB 38 No 12 1 3 4 5 6 2 B72 SBF 6 FUSE RELAY BOX i97 JOINT GROUND...

Page 3379: ...lfunction Go to step 3 Go to step 5 3 CHECK FUSE 1 Turn the ignition switch to OFF 2 Inspect the fuse Is the fuse OK Go to step 4 Replace the defec tive fuse 4 CHECK HARNESS 1 Disconnect the body inte...

Page 3380: ...terlock does not keep lock condition WIRING DIAGRAM LAN00286 D11 FB 38 F B FUSE NO 12 IG MB 28 M B FUSE NO 14 B E 3 4 2 1 D2 D22 B1 B279 D B280 B B350 B350 B350 1 2 3 4 B279 D 5 4 6 7 8 2 1 9 3 10 22...

Page 3381: ...No 1 ground terminal Is the solenoid activated and then key locked Go to step 5 Replace the key lock solenoid 5 CHECK HARNESS 1 Disconnect the body integrated unit connec tor B279 2 Measure the resis...

Page 3382: ...nnec tor B279 and shift lock solenoid connector B117 3 Connect the disconnected connectors 4 Turn the ignition switch to ON then keep the Parking range for approx 5 seconds 5 Read the DTC of body inte...

Page 3383: ...hassis ground Connector terminal B279 No 12 Chassis ground Is the resistance 1 M or more Replace the body integrated unit Ref to SL 50 REMOVAL Body Integrated Unit Repair the short circuit of harness...

Page 3384: ...55 B B3 B9 B280 B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 2...

Page 3385: ...grated unit using Subaru Select Monitor Is U1201 a current malfunc tion Go to step 5 Go to step 16 5 CHECK STEERING ANGLE SENSOR NOTE For model without VDC Go to step 7 1 Turn the ignition switch to O...

Page 3386: ...e resistance 60 Go to step 11 Repair or replace the open circuit of harness 11 CHECK DTC 1 Turn the ignition switch to ON 2 Read the DTC of body integrated unit using Subaru Select Monitor Is U1201 a...

Page 3387: ...r terminal B40 No 14 B55 No 17 B40 No 6 B55 No 18 Is harness normal Go to step 17 Repair or replace the harness 17 CHECK HARNESS Using the tester inspect the open circuit of har ness and short power s...

Page 3388: ...6 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 TCM B55 B B3 B9 B280 B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30...

Page 3389: ...rent malfunc tion Go to step 4 Go to step 10 4 CHECK HARNESS 1 Turn the ignition switch to OFF 2 Disconnect all connectors B280 B310 or B301 B55 B136 B230 B231 that are con nected to high speed CAN co...

Page 3390: ...the ignition switch to ON 2 Using the tester measure the voltage between terminals of data link connector and chassis ground Connector terminal B40 No 6 Chassis ground B40 No 14 Chassis ground Is the...

Page 3391: ...B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 6 14 B40...

Page 3392: ...ignition switch to ON 5 Read the DTC of body integrated unit using Subaru Select Monitor Is U1211 a current malfunc tion Replace the ECM Ref to FU H4SO 45 REMOVAL Engine Control Module ECM Ref to FU H...

Page 3393: ...280 B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 6 14...

Page 3394: ...onnected connectors 4 Turn the ignition switch to ON 5 Read the DTC of body integrated unit using Subaru Select Monitor Is U1212 a current malfunc tion Replace the TCM Ref to 4AT 63 Transmission Con t...

Page 3395: ...B280 B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 6 1...

Page 3396: ...the ignition switch to ON 5 Read the DTC of body integrated unit using Subaru Select Monitor Is U1213 a current malfunc tion Replace the VDC ABS CM Ref to VDC 7 VDC Con trol Module and Hydraulic Contr...

Page 3397: ...5 6 27 26 33 34 35 TCM B55 B B3 B9 B280 B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 4...

Page 3398: ...CK HARNESS 1 Turn the ignition switch to OFF 2 Disconnect all connectors B280 B310 or B301 B55 B136 B230 B231 that are con nected to high speed CAN communication line 3 Using the tester inspect the op...

Page 3399: ...H4DOTC 52 REMOVAL Engine Control Module ECM Replace the body integrated unit Ref to SL 50 REMOVAL Body Integrated Unit 8 CHECK HARNESS 1 Turn the ignition switch to OFF 2 Shake the harness used for C...

Page 3400: ...10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 6 14 B40 1 2 3...

Page 3401: ...cted to high speed CAN communication line 3 Using the tester inspect the open circuit of harness and short power supply output short GND output short Connector terminal B55 No 17 B40 No 14 B55 No 18 B...

Page 3402: ...B280 B 35 10 B310 2 1 B231 2 3 B230 B230 1 2 3 4 B231 1 2 3 4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 6 1...

Page 3403: ...short power supply output short GND output short Connector terminal Models with VDC B40 No 6 B310 No 35 B40 No 14 B310 No 10 Models without VDC B40 No 6 B301 No 26 B40 No 14 B301 No 11 Is harness nor...

Page 3404: ...ON A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 i50 1 2 3 8 9 10 4 13 14 15 16 5 6 7 11 12 17 18 19 20 21 22 23 24 i85 1 2 3 4 5 6 7 8 9 10 11...

Page 3405: ...ation i84 No 9 i50 No 6 navigation Is harness normal Go to step 4 Repair or replace the harness 4 CHECK AUDIO OR NAVIGATION 1 Connect the disconnected connectors 2 Disconnect the connector of navigati...

Page 3406: ...ch to ON 4 Read the DTC of body integrated unit using Subaru Select Monitor Is U1300 a current malfunc tion Repair or replace the harness Go to step 8 8 CHECK CONNECTOR 1 Turn the ignition switch to O...

Page 3407: ...AGRAM A9 A1 i84 A 26 i10 27 19 i88 i85 i50 20 ON WN 12 11 6 18 WN ON A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 i50 1 2 3 8 9 10 4 13 14 15 1...

Page 3408: ...84 No 1 i10 No 27 combination meter i84 No 9 i10 No 26 combination meter i84 No 1 i88 No 20 auto A C i84 No 9 i88 No 19 auto A C i84 No 1 i85 No 12 audio i84 No 9 i85 No 11 audio i84 No 1 i50 No 18 na...

Page 3409: ...ated unit Ref to SL 50 REMOVAL Body Integrated Unit Go to step 9 9 CHECK HARNESS 1 Turn the ignition switch to OFF 2 Shake the harness used for low speed CAN communication circuit 3 Turn the ignition...

Page 3410: ...tion is not transmitted sending receiv ing normally WIRING DIAGRAM A9 A1 i84 A 26 i10 27 19 i88 i85 i50 20 ON WN 12 11 6 18 WN ON A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 2...

Page 3411: ...A C i84 No 9 i88 No 19 auto A C i84 No 1 i85 No 12 audio i84 No 9 i85 No 11 audio i84 No 1 i50 No 18 navigation i84 No 9 i50 No 6 navigation Is harness normal Go to step 4 Repair or replace the harne...

Page 3412: ...u Select Monitor Is U1302 a current malfunc tion Repair or replace the open short cir cuit of the harness Go to step 9 9 CHECK CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect all connectors i...

Page 3413: ...Read the DTC of body integrated unit using Subaru Select Monitor Is U1311 a current malfunc tion Replace the com bination meter Ref to IDI 16 REMOVAL Com bination Meter Go to step 4 4 CHECK HARNESS 1...

Page 3414: ...s U1321 a current malfunc tion Go to step 3 Go to step 7 3 CHECK DTC 1 Turn the ignition switch to OFF 2 Disconnect all connectors i84 i10 i88 i85 or i50 that are connected to low speed CAN communicat...

Page 3415: ...to step 6 Replace the com bination meter Ref to IDI 16 REMOVAL Com bination Meter 6 CHECK DTC 1 Turn the ignition switch to OFF 2 Disconnect all connectors i84 i10 i88 i85 or i50 that are connected t...

Page 3416: ...r short circuit in keyless UART circuit TROUBLE SYMPTOM Door lock does not operate with keyless WIRING DIAGRAM LAN00294 FB 11 M B FUSE NO 8 B 4 3 7 A24 i84 R80 E R80 1 2 3 4 5 6 7 8 A A i84 1 2 3 4 5...

Page 3417: ...circuit of harness and short power supply output short GND output short Connector terminal i84 No 24 R80 No 3 Is harness normal Go to step 4 Repair or replace the harness 4 CHECK HARNESS Using the tes...

Page 3418: ...free from illuminating blinking System is normal Refer to the follow ing to check Automatic trans mission Shift lock control system LAN system Warning light also blinks when DTC B1106 occurs EBD warni...

Page 3419: ...m is normal Refer to the follow ing to check Seat belt warn ing system Combination meter system LAN system Rear window defogger Rear window defogger operates by operating the switch Indicator in the s...

Page 3420: ...and ignition System is normal Refer to the follow ing to check Spot map light Security and locks LAN system Key illumination ON OFF according to the operation of the driver s side door open close and...

Page 3421: ...LAN diag 88 General Diagnostic Table LAN SYSTEM DIAGNOSTICS...

Page 3422: ...or negative battery terminal and the positive lead to the connector or component ter minal 2 Touch connector A with the positive probe of the volt meter The voltmeter will indicate a voltage 3 Touch c...

Page 3423: ...the wiring between adjacent connectors When the ohmmeter indicates infinite the wiring is open 4 HOW TO DETERMINE A SHORT CIRCUIT 1 WITH TEST LIGHT Connect a test light rated at approx 3 watts in plac...

Page 3424: ...of poles or pins presence of a lock are indicated in the sketch of each connector In the sketch the highest pole number refers to the number of poles which the connector has For example the sketch of...

Page 3425: ...is described in the 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 the...

Page 3426: ...ch unit is either directly grounded to the body or indirectly grounds through a harness ground ter minal Different symbols are used in the wiring dia gram to identify the two grounding systems The gro...

Page 3427: ...lly closed relay has one or more contacts The wiring diagram shows the relay mode when the en ergizing circuit is OFF WI 16724 Relay type 4 pole 6 pole 4 pole 6 pole Normally open type Normally closed...

Page 3428: ...r system of the vehicle Symbol Wiring harness and cord F Front wiring harness B Bulkhead wiring harness E Engine wiring harness T Transmission cord D Door cord LH RH Rear gate cord Rear door cord LH R...

Page 3429: ...C EL HEADLIGHT LH LOW HIGH HEADLIGHT RH LOW HIGH REF TO FOG H4 01 REF TO FOG H6 01 REF TO ST MT 01 REF TO ST AT 01 B51 A B52 C F41 G FB 37 D4 D7 BG D11 A2 WR G4 BL G1 BR D10 FB 35 FB 34 1 2 3 4 5 6 7...

Page 3430: ...Each grounding point can be located easily by re ferring to the corresponding wiring harness 8 DIODE A symbol is used to indicate a diode 9 WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagra...

Page 3431: ...nnector symbols are used in each wiring diagram to easily identify the wiring harness con nectors WI 02756 Standard type Female Standard type Male Water proof type Female Water proof type Male Pole Fr...

Page 3432: ...xhaust Gas Recirculation F B Fuse Relay Box FL Front Left FR Front Right FWD Front Wheel Drive G Gravity G sensor H L Headlight HI High I F Interface IG Ignition Illumi Illumination INT Intermittent L...

Page 3433: ...s not interfere with the body end parts edges 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...

Page 3434: ...1 No 32 No 33 No 20 No 21 No 22 No 23 No 24 No 25 No 26 No 13 No 14 No 15 No 16 No 17 No 18 No 19 No 6 No 7 No 8 No 9 No 10 No 11 No 12 No 1 No 2 No 3 No 4 No 5 No 9 No 10 No 3 No 4 No 1 No 2 No 5 No...

Page 3435: ...B BATTERY MB 2 MB 10 F26 F25 MB 4 MB 29 MB 1 MB 9 MB 8 MB 7 MB 6 P SUP 05 B P SUP 05 A P SUP 03 C No 2 25A P SUP 04 I P SUP 04 H P SUP 03 D No 8 20A No 3 25A No 5 10A No 1 30A No 16 7 5A No 10 25A A7...

Page 3436: ...8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B B143 No 7 15A No 9 15A B143 B F35 C F36 E B145 G B186 H R H1 B6 BL C9 RL C8 B16 GW E1 BG B8 GY E4 B18 W G2 C11 P SUP 02 C P SUP 02 D M...

Page 3437: ...FB 4 FB 5 FB 6 FB 8 FB 9 FB 11 FB 10 LB E3 WL E1 C23 P SUP 02 E P SUP 02 H P SUP 03 J P SUP 02 I FUSE RELAY BOX F B i5 A R168 B B52 C B152 D B158 E B159 F GY BG C4 BY REF TO AT CONTROL SYSTEM AT 01 R...

Page 3438: ...72 IGNITION SWITCH FB 20 D6 FB 23 FB 24 FB 25 FB 49 FB 27 FB 28 FB 29 FB 32 FB 34 FB 35 FB 36 FB 38 YL YG B1 YG C3 YG A17 YR C7 F4 YB A1 GrR D7 YR FB 30 GY A5 B18 YW B14 YL GY C8 A6 GB D9 C16 GL BrW A...

Page 3439: ...3 Secondary air pump relay MB 34 Secondary air combination valve relay 1 Secondary air combination valve relay 2 ALT 1 Combination meter ST 1 Starter relay ST 2 Starter relay ECM Clutch switch FB 3 St...

Page 3440: ...ion coil No 4 Rear vehicle speed sensor FB 41 Airbag control module FB 42 Power window relay FB 44 ABS control module VDC control module Steering angle sensor Yaw rate G sensor FB 45 A C control panel...

Page 3441: ...6 1 2 F17 2 1 NA 2 1 1 2 3 4 1 3 2 4 5 1 2 3 4 5 6 7 8 B220 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 F27 19 20 18 21 22 7 4 5 6 3...

Page 3442: ...BY 10 B180 BY 24 D B279 BY D27 B367 BY 7 B230 BY 4 B75 BY 2 VDC B230 1 2 3 4 1 2 3 8 9 10 4 13 14 15 16 5 6 7 11 12 17 18 19 20 21 22 23 24 BY GAB 1 B GAB 2 BW B BW AB6 25 26 B75 1 2 1 2 3 4 5 6 7 8 9...

Page 3443: ...B C20 B B17 1 2 2 3 1 4 1 2 2 1 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 B71 13 4 5 6 11 12 14 15 10 17 16 9 1 2 3 7 8 1 9 10 18...

Page 3444: ...1 2 1 2 D58 D59 1 2 1 2 3 4 3 2 1 8 7 6 5 4 4 5 6 7 8 9 16 17 18 19 20 2 3 1 21 22 23 24 25 26 10 11 13 14 12 15 1 2 3 D43 1 2 3 4 R55 R52 1 2 3 R139 B 2 D47 1 2 OR WR R56 A 1 2 3 4 6 7 8 9 5 10 WR 5D...

Page 3445: ...R42 4Dr 4Dr 1 2 3 4 5 6 R28 R26 3 2 1 8 7 6 5 4 R60 1 2 3 4 5 6 7 8 9 10 11 12 R211 4Dr R44 R41 1 2 3 4 R80 B 7 R41 B 1 1 2 3 4 R43 4 DOOR MODEL 4 DOOR MODEL 2 5 DOOR MODEL 5 DOOR MODEL 1 FUEL PUMP AS...

Page 3446: ...i88 BY 34 i16 BY 8 i84 BY A28 BY 21 i10 A A BY 22 i22 BY 3 i87 C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 ON WN WA ON WN WA 1 1 2 3 4 6 7 8 9 5 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 3 4 5...

Page 3447: ...10 D102 B B B3 5 D125 B i6 B 7 i23 B 1 AD2 B B 1 D84 i101 3 B D83 i76 B 3 B AD1 i24 B 2 i15 B B B 1 i6 1 2 3 4 5 6 7 8 9 10 D15 D5 4 1 2 3 6 5 1 1 2 3 4 5 B D102 1 2 3 i24 1 2 3 4 AD2 1 2 2 3 4 5 1 6...

Page 3448: ...1 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 E22 E23 BL 52 BY 35 BY 34 BY BW 37 R BW 36 BL 1 BL BR BW B21 E2 BY BY BW BW BL BL B B BW BR BY MT 3 1 6 5 4 2 B...

Page 3449: ...B GE BW D1 BW 34 B BR D2 BR 35 B BL C15 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 1 3 4 5 6 2 E41 BR B B B B B B BR D B137 8 5 6 10 11 12 1...

Page 3450: ...1 2 2 1 2 3 4 GND 10 GND 10 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 A B54 B B55 5 6 7 2 1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20...

Page 3451: ...E SENSOR FRONT OXYGEN A F SENSOR C4 B1 B4 REAR OXYGEN SENSOR FUEL INJECTOR No 1 D29 PURGE CONTROL SOLENOID VALVE D9 D10 D11 SUB FAN RELAY JOINT CONNECTOR PRESSURE SWITCH A C RELAY BODY INTEGRATED UNIT...

Page 3452: ...ESSURE SWITCH ENGINE COOLANT TEMPERATURE SENSOR A23 OIL TEMPERATURE SENSOR A31 VVL DIAGNOSIS OIL PRESSURE SWITCH RH A32 A19 VVL DIAGNOSIS OIL PRESSURE SWITCH LH CRANKSHAFT POSITION SENSOR KNOCK SENSOR...

Page 3453: ...GND 05 Lg W B12 B28 B20 B24 YL Y C26 C34 BR WL B17 WB B98 R57 B97 R58 R15 R57 FUEL PUMP ASSY 2 3 6 5 WB YG GR GY FUEL PUMP FUEL TEMPERATURE SENSOR WB WB 3 YG YG 6 RB RB 4 E G NA 08 A 5 WB 4 YG 8 1 B R...

Page 3454: ...34 35 21 22 BY BY JOINT GROUND CONNECTOR i97 BY 1 BY 1 REF TO GND GND 06 BY 1 BY 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1...

Page 3455: ...MT MODEL AT MODEL 3 WB WR 1 LW WB TO POWER SUPPLY CIRCUIT ST 2 IG SW ST ST 1 F B FUSE NO 21 ST MB 22 SBF 5 B MB 24 SBF 7 B MB 23 SBF 7 B C32 C20 C31 A7 B2 C21 C1 WB WL WR WR 3 4 WL WR 2 WY 1 WY B220 F...

Page 3456: ...1 2 BLUE C25 5 6 7 2 1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 B B135 CLUTCH SWITCH MULTI JOINT CONNECTOR MULTI JOINT CONNECTOR B107 GY RY 2 P L 1 1 AT AT...

Page 3457: ...B18 E G NA 09 Q E G NA 08 K E G NA 08 M E G NA 06 L E G NA 06 N E G NA 09 P E G NA 09 O BLACK E22 3 1 6 5 4 2 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 2...

Page 3458: ...T GRAY E10 BLACK E15 1 2 GRAY E14 1 2 BLACK E57 1 2 3 4 5 6 WL B22 E G NA 05 L E G NA 05 N BR BW BR BW GE 2 E G NA 08 T E G NA 08 U Lg LgB RL YG G P LW E G NA 10 S D B137 8 5 6 10 11 12 13 14 15 7 2 1...

Page 3459: ...YG 2 PG 45 Or Or 1 E17 FUEL INJECTOR No 4 DARK GRAY DARK GRAY E5 E16 DARK GRAY DARK GRAY E6 E17 1 2 YG YB 48 E2 B21 E G NA 05 J YG 2 YG 5 YB 6 BrG 4 GY 3 RY 1 E18 EGR VALVE BLACK E4 1 2 DARK GRAY E18...

Page 3460: ...E68 BLACK E75 1 2 YG B30 B83 JOINT CONNECTOR E21 E19 E61 E68 E67 E75 3 2 P 1 LY LW 9 PB A33 PB POWER STEERING OIL PRESSURE SWITCH LOr E G NA 06 U E G NA 06 T K E G NA 05 M E G NA 05 V E G NA 10 W E G...

Page 3461: ...NA 03 C BY 52 BL DARK GRAY E12 1 2 3 4 BL A5 BL C15 BL D26 B122 3 4 5 6 1 2 7 8 A B134 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 32 31 26 27 33 34 MT 1 BL 1 1 1 1 1 1...

Page 3462: ...LgB 2 8 YL YB R1 B97 10 E G NA 03 E E G NA 08 V E G NA 06 S B B135 C B136 ECM C17 LgB LgB LgB R3 B99 1 YW YW 12 C28 R B32 Br R68 R86 C B136 B B135 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21...

Page 3463: ...NG OIL PRESSURE SWITCH C12 PURGE CONTROL SOLENOID VALVE 1 WASTEGATE CONTROL SOLENOID VALVE A22 C17 C28 B32 B22 FUEL INJECTOR No 1 D8 D9 D10 SUB FAN RELAY JOINT CONNECTOR A C CONTROL PANEL PRESSURE SWI...

Page 3464: ...TLE CONTROL A16 A26 D23 D22 A25 A15 MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR A13 A14 D13 D12 D1 D7 D3 A5 D2 OIL FLOW CONTROL SOLENOID VALVE LH OIL FLOW CONTROL SOLENOID VALV...

Page 3465: ...WB 3 R 7 Br 4 RB 4 G 5 LgR 6 YL 10 WL 5 YL R YW Br WL YL R YW Br WL LgB YL LgB G LgR YB RB 5 11 WB R Br WL YW YG WB R Br WL REF TO GND GND 01 REF TO GND GND 05 1 REF TO FUEL GAUGE SYSTEM F G 01 GR GY...

Page 3466: ...TO AIR CONDITIONING SYSTEM A A C 01 02 P C24 YB C33 LOr C9 REF TO RADIATOR FAN SYSTEM R F 01 RL C18 BR C29 WL C26 BR C34 REF TO IMMOBILIZER SYSTEM IMB 01 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17...

Page 3467: ...26 33 34 35 BY 19 38 32 21 22 1 2 OIL PRESSURE WARNING LIGHT MALFUNCTION INDICATOR LIGHT MICRO COMPUTER ENGINE COOLANT TEMPER ATURE GAUGE TACHO METER LgR P REF TO CAN COMMUNICATION SYSTEM CAN 01 26 2...

Page 3468: ...1 12 MT MODEL AT MODEL 2 GB WR MT MODEL AT MODEL 3 WB WR MT MODEL AT MODEL 1 LW WB TO POWER SUPPLY CIRCUIT ST 2 IG SW ST ST 1 F B FUSE NO 21 ST MB 22 SBF 5 B MB 24 SBF 7 B MB 23 SBF 7 B C32 C20 C31 A7...

Page 3469: ...SE NO 4 IG MB 27 M B FUSE NO 13 B B440 B438 B442 B441 B363 B75 1 2 B76 B107 BLUE GRAY BLACK BLACK ORANGE GREEN GREEN GREEN 1 2 3 4 5 C B136 B B135 P 4 BL 7 VR 5 BL 8 GY 16 W B27 1 1 L BL B75 B76 B363...

Page 3470: ...4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B315 1 2 3 4...

Page 3471: ...IGHT GRAY LIGHT GRAY E36 1 R 2 GW 3 Y CAMSHAFT POSITION SENSOR RH R YB 48 E2 B21 LIGHT GRAY E10 1 2 E36 E35 1 2 3 E G TB 06 L E G TB 08 S E G TB 08 T E G TB 12 U E G TB 10 R E G TB 07 E G TB 07 A B134...

Page 3472: ...THROTTLE CONTROL E G TB 14 V E G TB 09 X E G TB 14 Y E G TB 09 W A18 W G W 25 A28 L L L 24 P E G TB 06 O E G TB 06 D B137 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 31...

Page 3473: ...RL D22 RB E40 1 2 46 GW L GW BR SECONDARY AIR COMBINATION VALVE LH D23 RL A B134 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 32 31 26 27 33 34 27 WL YR 16 WR WR A16 WL A...

Page 3474: ...B15 RB B14 R C8 RG W 2 F11 F9 1 3 4 2 9 7 8 10 12 13 14 5 6 15 16 11 SECONDARY AIR RELAY HOLDER BUS BAR D BROWN B144 1 5 7 6 2 8 3 4 9 B B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3...

Page 3475: ...ROL SOLENOID VALVE LH D15 GL GR GW E38 1 2 22 WB 21 GB WB GB D16 GR OIL FLOW CONTROL SOLENOID VALVE RH D17 GW D B137 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 31 26 27...

Page 3476: ...BY 1 E6 FUEL INJECTOR No 3 PB D10 R 2 PB 52 BR BR 1 E17 FUEL INJECTOR No 4 PG D11 R 2 PG 51 BL BL 1 E G TB 07 U DARK GRAY DARK GRAY E5 E16 DARK GRAY DARK GRAY E6 E17 1 2 E52 BLUE E64 BLACK BLACK E4 D...

Page 3477: ...No 4 E80 LEAK DIAGNOSIS CONNECTOR BL D26 E G TB 01 A A B134 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 32 31 26 27 33 34 BLACK E33 E31 BLACK E34 E32 1 2 3 YR A30 YR 45...

Page 3478: ...29 9 17 18 25 21 23 24 32 31 26 27 33 34 BL SB SB BL BL B122 JOINT CONNECTOR B122 3 4 5 6 1 2 7 8 1 1 BL 1 1 1 1 E G TB 05 J E G TB 04 H BL 1 LgY B128 1 2 3 4 BL C15 MT REF TO CRUISE CONTROL SYSTEM C...

Page 3479: ...11 12 13 14 15 16 F108 2 3 8 10 1 9 4 11 12 13 14 15 16 5 6 7 17 18 F17 YG 1 B 2 F17 MAIN FAN MOTOR B361 1 7 2 3 4 5 6 8 9 10 11 12 13 14 F16 F109 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 3480: ...B143 A B CHARGE WARNING LIGHT F37 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CHG 01 CHG 01 F26 REF TO POWER SUPPLY CIRCUIT P SUP 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B143 B...

Page 3481: ...BY 6 B12 T3 B12 1 2 3 4 5 6 7 8 9 10 11 12 2 MT AT MT AT 1 B225 MT MODEL AT MODEL 1 MT MODEL AT MODEL 2 3 LW WB WB WR MT MODEL AT MODEL GB WR C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28...

Page 3482: ...27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 B B135 5 6 7 2 1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 W...

Page 3483: ...1 3 R9 11 LOr LOr 4Dr 5Dr R60 3 2 1 8 7 6 5 4 B REF TO GND GND 05 i1 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 B99 1 2 3 4 5 6 7 8 9 10 11 12 D46 2 3 4 5 6 7 8 9 11 12...

Page 3484: ...GND GND 07 B 2 4 Lg LB 5 B Lg LB B B D102 A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 D72 D84 D83 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14...

Page 3485: ...10 11 12 13 14 15 16 4Dr 5Dr REF TO GND GND 05 B REF TO GND GND 04 B RE GS 01 I RE GS 02 M RE GS 02 L RE GS 02 N RE GS 04 RE GS 04 D46 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23...

Page 3486: ...WI 67 Remote Engine Start System WIRING SYSTEM...

Page 3487: ...VDC BATTERY IGNITION SWITCH DATA LINK CONNECTOR JOINT CONNECTOR MULTI JOINT CONNECTOR JOINT CONNECTOR MULTI JOINT CONNECTOR INHIBITOR SWITCH COMBINATION METER BODY INTEGRATED UNIT ABS CONTROL MODULE...

Page 3488: ...F B JOINT GROUND CONNECTOR CONTROL VALVE BODY ATF TEMPERATURE SENSOR LINE PRESSURE LINEAR SOLENOID LOW CLUTCH DUTY SOLENOID HIGH CLUTCH DUTY SOLENOID LOW REVERSE DUTY SOLENOID 2 4 BRAKE DUTY SOLENOID...

Page 3489: ...2 23 32 31 26 27 33 34 35 A B54 B158 E 1 2 3 4 7 8 5 6 i5 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A10 i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31...

Page 3490: ...5 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B438 B442 B436 B440 B53 1 2 3 4 5...

Page 3491: ...3 4 B301 ABS VDC 11 L 26 R B230 3 L 2 R R B3 B280 B L B9 B231 R 2 L 1 R B18 B55 B TCM L B17 R C27 B136 C ECM L C35 4 5 6 7 8 9 16 17 18 19 20 2 3 1 21 22 23 24 25 26 10 11 13 14 12 15 4 5 6 7 8 9 26 2...

Page 3492: ...EM ST 01 AT 04 AT 04 B12 1 2 3 4 5 6 7 8 9 10 11 12 12 11 9 GL 10 BrY 3 2 RG WG WR WB 1 BG 8 LG B 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B B55...

Page 3493: ...1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 A B54 B B55 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 1 2...

Page 3494: ...17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 RELAY BLOCK 7 5A B76 GREEN 1 2 1 B75 GREEN 1 2 B123 B434 B436 1 2 3 4 5 6 7 8 9 10 B117 1 2 3 4 5 6...

Page 3495: ...r B65 1 2 3 4 4Dr B435 1 2 3 4 5 B99 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 7 5A BrR 1 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 3...

Page 3496: ...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 36 37 38 39 40 i1 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 23 20 BrW BrW 2 I F 22 B...

Page 3497: ...3 1 21 22 23 24 25 26 10 11 13 14 12 15 B40 W GY W BL 16 GY 8 5 BL 4 L 14 REF TO ENGINE ELECTRICAL SYSTEM E G NA 04 R 6 VR 7 MB 27 M B FUSE NO 13 B FB 32 F B FUSE NO 4 IG B440 B438 5 1 GY GY B40 1 2 3...

Page 3498: ...2 B W 1 2 GOr GB 2 1 Lg BY 2 1 L P ABS 02 B ABS 02 C 16 2 1 24 25 26 10 11 13 14 12 15 B301 4 5 6 7 8 9 17 18 19 20 3 21 22 23 B B98 2 3 4 5 6 7 8 9 11 12 13 14 17 18 19 20 1 10 15 16 1 2 3 4 5 6 7 8...

Page 3499: ...UT SECONDARY SUCTION VDC 04 C FB 44 F B FUSE NO 33 IG FB 3 F B FUSE NO 8 B VDC 04 B VDC 04 A 7 5A 2 1 B225 R168 B B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38...

Page 3500: ...EM E G NA 04 E G TB 05 MB 27 M B FUSE NO 13 B GY FB 32 F B FUSE NO 4 IG REF TO GND GND 06 BY JOINT GROUND CONNECTOR i97 REF TO PARKING BRAKE BRAKE FLUID LEVEL WARNING LIGHT SYSTEM BR W 01 VDC 04 E VDC...

Page 3501: ...3 R72 REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH 4 3 1 Lg LgB L G 2 Lg BY L P B98 R2 2 1 B W 2 1 GB GOr 1 2 1 2 Lg BY L P B99 R3 B99 1 2 3 4 5 6 7 8 9 10 11 12 B310 B98 2 3 4 5 6 7...

Page 3502: ...GY L BY 2 3 1 4 B231 STEERING ANGLE SENSOR R L GY 2 1 BY 3 4 B318 B231 1 2 3 4 VDC CONTROL MODULE VDC 01 C REF TO GND GND 03 B REF TO GND GND 02 BY VDC 02 E VDC 02 D B310 4 5 6 7 8 9 26 27 28 29 30 2...

Page 3503: ...DC WITHOUT VDC VDC ABS R211 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 B FB 32 F B FUSE NO 4 IG B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B310 4 5 6 7 8 9 26 27 28 29 3...

Page 3504: ...16 A F37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F109 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 PL PL 5 B36 i1...

Page 3505: ...7 3 GY 2 1 4 9 GOr M A C 01 A LgW LgW 7 BL BL 8 GY GY 27 LY BY 28 BOr BOr 23 BrY BrY 24 B36 i1 B36 i1 5 6 3 2 4 i15 1 2 OFF 3 4 M A C 02 M A C 02 B89 B163 B386 i16 B27 i1 5 6 7 8 2 1 9 4 3 10 24 22 23...

Page 3506: ...OINT GROUND CONNECTOR BW BY 2 GY V 1 7 8 REF TO CLEARANCE LIGHT ILLUMINATION LIGHT SYSTEM ILLUMI 04 REF TO GND GND 06 BY i16 1 2 3 4 5 6 7 8 9 10 11 12 TERMINAL No OPTIONAL ARRANGEMENT 1 i97 2 3 4 5 1...

Page 3507: ...C3 C7 LOr 14 LOr 9 THROUGH JOINT CONNECTOR B361 F108 GOr 1 GOr 9 THROUGH JOINT CONNECTOR B360 F109 GRAY B360 F108 1 9 2 3 8 10 4 11 12 13 14 15 16 5 6 7 17 18 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 3508: ...9 32 31 1 2 3 4 5 6 27 26 33 34 35 REF TO GND GND 01 B INTAKE DOOR ACTUATOR i1 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 B163 1 2 3 4 5 6 B386 7 6 2 3 4 5 1 i88 1 2 3...

Page 3509: ...R i10 I F I F B38 i3 Or Or 1 Sb Sb 2 A A C 04 B A A C 04 C A A C 04 D A A C 04 E POWER SUPPLY CIRCUIT MICRO COMPUTER CAN TRANSCEIVER RECEIVER WL WL 2 R167 i102 i3 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 2...

Page 3510: ...34 BY BY BY JOINT GROUND CONNECTOR i97 i98 1 1 BY 1 BY 1 REF TO GND GND 06 BY i88 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 36 37 38 39 40 TERMIN...

Page 3511: ...O 7 B WL IN VEHICLE SENSOR GrB OrG i55 1 2 EVAPORATOR SENSOR GrB BrW GrB BrW GrB BrW GrB BrW B88 1 2 B88 i51 i55 B77 B239 1 2 BROWN i88 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2...

Page 3512: ...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 36 37 38 39 40 B438 B440 MULTI JOINT CONNECTOR GY GY 1 5 B443 B440 MULTI JOINT CONNECTOR VR VR 2 2 BODY INTEGRATED...

Page 3513: ...4 7 8 BW B 26 YB YL 6 5 Br L 27 29 FRONT SUB SENSOR LH FRONT SUB SENSOR RH DRIVER S AIRBAG MODULE AB2 AB7 YW YG YB YL PASSENGER S AIRBAG MODULE AB38 AB37 YL 2 YR 1 Y 2 YB 1 AB9 YG 2 YW 1 YL 4 YB 3 GAB...

Page 3514: ...N AIRBAG SENSOR LH AB32 SIDE AIRBAG SENSOR LH SIDE AIRBAG MODULE LH L 23 YL 6 YR 5 AIRBAG CONTROL MODULE AB17 RB 21 WR 20 RB 1 WR 2 AB41 SATELLITE SAFETY SENSOR AB32 YELLOW YELLOW YELLOW AB23 AB17 3 4...

Page 3515: ...URTAIN AIRBAG MODULE RH CURTAIN AIRBAG SENSOR RH Y YB AB34 AB24 SIDE AIRBAG MODULE RH SIDE AIRBAG SENSOR RH Y YB L W 18 17 YR 4 YL 3 8 7 AB18 B 16 Lg 24 REF TO OCCUPANT DETECTION SYSTEM ODS 01 3 4 3 2...

Page 3516: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B280 B 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 i59 1 2 3 4 6 7 8 9 5 10 R B 3 1 2 3 4 5 1 6 7 8 i97 i77 1 2 3 4 5 6 7 8 9 10 A i84...

Page 3517: ...13 14 15 16 17 18 10 B31 R82 GRAY AB53 1 3 4 5 6 2 AB61 AB58 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 i3 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 1...

Page 3518: ...1 LR LR R1 REF TO GND GND 03 RW 4 W 3 B 1 Lg 3 RL 4 SEAT HEATER RH R41 R44 R41 R42 R44 1 2 3 4 SEAT HEATER LH SEAT HEATER SWITCH RH LR RW W B B 1 R42 RELAY BLOCK B225 1 2 9 10 11 12 13 14 15 16 17 18...

Page 3519: ...8 THROUGH JOINT CONNECTOR LY LY 15 9 LY D18 F103 DAYTIME RUNNING LIGHT RESISTOR G W 2 1 W 6 G 4 LY 5 F27 DAYTIME RUNNING LIGHT RELAY 1 7 2 3 4 5 6 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1...

Page 3520: ...D UNIT B281 C B280 B B279 D LY Br B12 LB C8 LB D6 C1 D2 C3 Br D7 LY Br B22 F27 FUSE GY 1 2 BL BG 9 GY 8 15A 15A LY D1 H L 03 B B280 B 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 3521: ...C15 LY C4 A28 MB 29 M B FUSE NO 8 B FB 18 F B FUSE NO 7 B WL WL B6 FB 38 F B FUSE NO 12 IG GR GR B1 FB 29 F B FUSE NO 31 ACC YR YR B7 B225 FUSE RELAY BLOCK 4 3 10A LG C2 B280 B 1 2 3 4 5 6 7 8 9 10 11...

Page 3522: ...CAN JOINT CONNECTOR i77 GREEN i77 1 2 3 4 5 6 7 8 9 10 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 31 32 33 34 35 36 37 38 39 40 B280 B 1 2 3 4 5 6 7 8 9 10 1...

Page 3523: ...4 TB B REF TO GND GND 05 B D34 3 2 1 8 7 6 5 4 R26 R28 1 2 3 4 5 6 NA 2 T1 T13 GL BrY B24 T1 BACK UP LIGHT SWITCH 1 T1 B24 NA TB MT T3 B12 BrY 10 LW 9 B12 T3 2 GL AT MT MT AT MULTI JOINT CONNECTOR BrY...

Page 3524: ...11 12 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 3...

Page 3525: ...21 22 23 24 25 26 B301 4 5 6 7 8 9 16 17 18 19 20 2 3 1 21 22 23 24 25 26 10 11 13 14 12 15 B435 B434 B437 B436 1 2 3 4 5 B99 R82 1 2 3 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33...

Page 3526: ...UMI LIGHT B358 1 BW VDC OFF SWITCH ILLUMI LIGHT B318 2 BW 1 8 Gr B V BW ST1 B68 WITH VDC VDC B71 B68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ST3 SATELLITE SWITCH ILLUMI LIGHT 1 2 B280 B 1 2 3 4 5 6 7 8 9 10...

Page 3527: ...ONT CLEARANCE LIGHT RH F125 7 BG B BL 7 BG BL 2 1 THROUGH JOINT CONNECTOR B360 F109 F126 7 BL B REF TO GND GND 01 B REF TO GND GND 01 B 4 4 D34 R38 B B 1 R60 R24 B B LICENSE PLATE LIGHT RH D44 1 BW B...

Page 3528: ...5 16 17 18 19 20 21 22 23 24 25 26 i22 1 2 3 4 B350 1 2 3 4 i24 AD3 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 RELAY BLOCK MB 2...

Page 3529: ...BW 2 NAVIGATION UNIT i87 C C1 V BW C7 1 1 i99 i100 JOINT GROUND CONNECTOR ILLUMI 05 H 1 2 3 4 5 6 7 8 9 10 11 12 i88 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 3530: ...CATOR LIGHT BY 21 BY 22 P 27 LgR 26 COMBINATION METER i10 FB 17 F B FUSE NO 7 B WL BY B B BY REF TO GND GND 06 REF TO GND GND 03 REF TO GND GND 02 BY JOINT GROUND CONNECTOR i97 3 BY 3 3 BY 3 BY P P Lg...

Page 3531: ...IG TO POWER SUPPLY CIRCUIT B 7 RB 6 LB 5 3 2 1 4 TURN SIGNAL SWITCH RB LB B 3 1 2 B71 TURN 02 A TURN 02 B REF TO GND GND 01 REF TO GND GND 03 TURN SIGNAL HAZARD MODULE B32 TURN 01 TURN 01 RH OFF LH TR...

Page 3532: ...G C22 BODY INTEGRATED UNIT B281 C HAZARD SWITCH JOINT GROUND CONNECTOR i22 COMBINATION METER i10 i5 A C B52 FUSE RELAY BOX F B ON OFF TURN 03 C TURN 03 D REF TO GND GND 06 TURN SIGNAL HAZARD MODULE B...

Page 3533: ...COMBINATION LIGHT LH TURN 03 TURN 03 REF TO GND GND 05 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B REF TO GND GND 05 B R82 1 2 3 4 5 6 7 8 9 10 11 12 Gr Gr 2 R81 R82 4Dr 4Dr Gr 4 B 2 R26 WR...

Page 3534: ...27 16 17 18 28 29 19 20 21 30 B279 D C L 01 C L 01 REF TO GND GND 06 2 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 i84 A 5 6 7 8 2 1 9 4 3 10 24 22...

Page 3535: ...RELAY BLOCK LG 4 3 LR 10A LG LG 1 R50 B90 RELAY BLOCK B225 R60 R50 3 2 1 8 7 6 5 4 B281 C i102 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 R52 1 2 3 R81 R82 LR LR 6 4Dr...

Page 3536: ...5 26 27 16 17 18 28 29 19 20 21 30 B279 D C L 03 C L 03 REF TO GND GND 05 REF TO GND GND 03 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 B281 C 1 2 3 4 5 6 7 8 9 10 11 12...

Page 3537: ...REF TO GND GND 01 03 F W 01 F W 01 B B B8 FRONT WIPER MOTOR 2 GY YB 1 BL 3 RL 5 B70 COMBINATION SWITCH B 4 BODY INTEGRATED UNIT GY C5 B281 C ON OFF EW MIST ON OFF EW W HI LO INT OFF ACC S1 S2 S3 INT1...

Page 3538: ...13 i84 A D 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 B279 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 B281 C R W 02 A R W 02 B RE...

Page 3539: ...IRCUIT D43 REAR WIPER MOTOR 3 Lg 1 4 B97 R1 Lg 8 LW Lg LW 7 B B 1 D43 1 2 3 4 R W 02 R W 02 LW 2 R W 01 B R W 01 A REF TO GND GND 04 B D34 3 2 1 8 7 6 5 4 R39 D35 YG Lg 4 6 LW 5 R82 1 2 3 4 5 6 7 8 9...

Page 3540: ...PANEL WIPER DEICER REAR DEFOGGER SWITCH GY 7 GY 39 LgR LgR P i77 2 1 2 P 1 CAN JOINT CONNECTOR GR B1 WL B6 AA AA MANUAL A C AUTO A C AA MA i88 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 3541: ...6 YR A3 D12 D2 D84 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 16 17 18 19 20 21 D83 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 WB LOr WB LOr A7 A8 i76 WB LOr 2 1...

Page 3542: ...A AUDIO B2 B5 B1 B6 i86 AUDIO B68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 i54 1 2 3 4 6 7 8 9 5 10 i86 1 2 3 4 5 6 7 8 i3 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 REF TO CLE...

Page 3543: ...M WI 22959 FB 22 F B FUSE NO 20 ACC TO POWER SUPPLY CIRCUIT YG YG YG YG 1 i24 AD1 AD2 B B B B 2 B 1 1 JOINT GROUND CONNECTOR i99 i100 i24 AD1 REF TO GND GND 07 FAPS 01 FAPS 01 B i24 1 2 3 4 TERMINAL N...

Page 3544: ...32 Rear Accessory Power Supply Socket System A WIRING DIAGRAM WI 16959 TO POWER SUPPLY CIRCUIT YW YW 2 B 1 REAR ACCESSORY POWER SUPPLY SOCKET R32 RAPS 01 RAPS 01 REF TO GND GND 05 R32 1 2 B 11 YW YW R...

Page 3545: ...01 Gr A4 Gr Gr Gr 9 B38 i3 PARKING BRAKE SWITCH R4 R3 B99 Gr Gr Gr 5 B437 B439 MULTI JOINT CONNECTOR Gr Gr 3 3 NAVI 02 A NAVI 02 B A17 PG PG PG B36 i1 i3 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 1...

Page 3546: ...WI 21450 NAVI 01 B NAVI 01 A SATELLITE SWITCH ST3 B68 ST1 1 V 9 Y Gr Sb 8 BW B 3 Br R VOL MUTE VOL MODE SEEK SEEK 5 4 ST3 1 2 3 4 5 6 7 8 ROLL CONNECTOR 1 2 B68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 REF T...

Page 3547: ...G BrY G BrY C8 C2 i101 WB LOr 2 1 D83 6 5 RB WR RB WR C13 C5 R10 D28 RW GrG REAR DOOR SPEAKER RH GrG 1 2 D29 RW i102 BR WR R167 7 6 YB YB 14 i76 D84 G BrY WB LOr 2 1 FRONT DOOR SPEAKER LH WB 1 2 D2 L...

Page 3548: ...5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 i84 A HORN 01 HORN 01 B68 ST1 ST3 Br 2 3 R BY B BY ST3 B68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B225 10A LR 3 4 FUS...

Page 3549: ...9 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 UNLOCK LOCK LB B1 Lg B2 B B181 1 2 B 1 2 GR B GR GR B181 B182 D7 A D102 B 1 3 4 5 6 2 2 3 4 5 1 6 7 8 i99 1 2 3 1 2 3 8 9 10 4 11...

Page 3550: ...15 16 17 18 19 20 21 D7 D13 D84 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 16 17 18 19 20 21 5 L 6 1 4 R D17 D13 D17 OFF DOWN UP P W 02 P W 02 FRONT RH UP DOWN OFF P W 01 D P W 01 E P W 01 A P W...

Page 3551: ...2 A5 i76 D83 R167 i102 BY A7 10 9 GR 10 9 BY GR BY GR BY GR 7 8 4 D22 R10 3 2 1 BY GR GB GB OFF DOWN UP P W 03 P W 03 D7 REAR LH UP DOWN OFF L R i102 D7 A R10 7 4 8 5 6 1 2 3 1 2 3 4 5 6 7 8 9 10 11...

Page 3552: ...2 13 14 15 16 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 D30 1 3 4 5 6 2 D31 1 2 4 5 6 7 8 3 B97 1 2 3 4 5 6 7 8 9 10 11 12 GB R98 i53 LY L LY L LY L 7 8 4 P W 01 C 5 G 6 R D31 10 9 G R 1 4 D30 D28 R13 3...

Page 3553: ...14 15 16 17 18 19 20 21 D84 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 D83 i3 R M 01 R M 01 i6 B WH OH WH OH OH WH D15 D5 i6 OH OH 3 5 8 7 6 2 1 4 D15 D5 WH WH 4 3 6 9...

Page 3554: ...i88 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 36 37 38 39 40 i77 i53 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 i3 5 6 7 8 2 1 9...

Page 3555: ...WI 136 Combination Meter System WIRING SYSTEM 38 Combination Meter System A WIRING DIAGRAM 1 NORMAL METER WI 16969 C M NM 01 C M NM 01 i10 CONNECT 22 21 20 19 2 1 40 39...

Page 3556: ...C M NM 03 A C M NM 05 B IGNITION SWITCH IG TURN SIGNAL HAZARD MODULE PARKING BRAKE BRAKE FLUID LEVEL WARNING LIGHT CHARGE WARNING LIGHT OIL PRESSURE WARNING LIGHT MALFUNCTION INDICATOR LIGHT TURN SIG...

Page 3557: ...C C M NM 04 D 29 DRIVE CIRCUIT CLOCK FUEL ECONOMY INDICATOR UNIT AMBIENT SENSOR BODY INTEGRATED UNIT OP CONNECTOR DRIVE CIRCUIT DIMMER DRIVE CIRCUIT DIMMER DRIVE CIRCUIT DIMMER MICRO COMPUTER POWER S...

Page 3558: ...WN ABS WN VDC ECM OP CONNECTOR NAVIGATION UNIT VDC CONTROL MODULE ABS CONTROL MODULE OP CONNECTOR BODY INTEGRATED UNIT TPM CONTROL MODULE LCD SHIFT INDICATOR SPORT SHIFT ODO TRIP METER CAN TRANSCEIVE...

Page 3559: ...E INDICATOR LIGHT ENGINE COOLANT TEMPERATURE WARNING LIGHT ABS WARNING LIGHT SEAT BELT WARNING LIGHT TIRE INFLATION PRESSURE WARNING LIGHT CRUISE INDICATOR LIGHT CRUISE SET INDICATOR LIGHT WI 22139 AW...

Page 3560: ...WI 141 Combination Meter System WIRING SYSTEM 2 LUMINESCENT METER WI 16973 C M LM 01 C M LM 01 i10 CONNECT 22 21 20 19 2 1 40 39...

Page 3561: ...03 A C M LM 05 B BATTERY IGNITION SWITCH IG TURN SIGNAL HAZARD MODULE PARKING BRAKE BRAKE FLUID LEVEL WARNING LIGHT CHARGE WARNING LIGHT OIL PRESSURE WARNING LIGHT MALFUNCTION INDICATOR LIGHT TURN SIG...

Page 3562: ...C C M LM 04 D 29 DRIVE CIRCUIT DIMMER DRIVE CIRCUIT DIMMER DRIVE CIRCUIT DIMMER PLATE ILLUMI LIGHT INDICATOR NEEDLE ILLUMI LIGHT LCD ILLUMI LIGHT MICRO COMPUTER DRIVE CIRCUIT SECURITY IMMOBILIZER IND...

Page 3563: ...OUT VDC WITH VDC WITH NAVIGATION BUZZER ENGINE COOLANT TEMPERATURE GAUGE TACHOMETER SPEEDOMETER FUEL GAUGE MICRO COMPUTER DRIVE CIRCUIT TRIP RESET SWITCH LCD SHIFT INDICATOR SPORT SHIFT ODO TRIP METER...

Page 3564: ...LIGHT AT AT HI BEAM INDICATOR LIGHT DOOR WARNING LIGHT LOW FUEL WARNING LIGHT LIGHTING INDICATOR LIGHT ABS WARNING LIGHT SEAT BELT WARNING LIGHT TIRE INFLATION PRESSURE WARNING LIGHT AWD HILL START AS...

Page 3565: ...28 11 12 13 14 15 16 17 18 19 20 21 B301 PG 23 B310 PG 33 ABS VDC I F B310 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 2...

Page 3566: ...1 9 2 3 8 10 4 11 12 13 14 15 16 5 6 7 17 18 Or Sb 1 i97 2 3 4 5 1 6 7 8 i98 1 2 4 5 6 7 8 3 I F EU U4 EU U4 TO POWER SUPPLY CIRCUIT AMBIENT SENSOR THROUGH JOINT CONNECTOR COMBINATION METER MICRO COMP...

Page 3567: ...10 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 36 37 38 39 40 B98 2 3 4 5 6 7 8 9 11 12 13 14 17 18 19 20 1 10 15 16 R57 i102 1 2 3 4 5 6 7 8 9 10 1...

Page 3568: ...29 30 31 32 33 34 35 13 i84 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 BrW LM NM NM LM C TEMP 02 A C TEMP 02 B LgR A9 P A1 R B3 L B9 i84 A B280 B i77 P P LgR 3 2 3 LgR 2 BY BY BY i97 1 1 1 2 3 4 5 1...

Page 3569: ...9 17 18 25 21 23 24 32 31 26 27 33 34 NA TB B136 C 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 C TEMP 01 A C TEMP 01 B 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 3570: ...2 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 39 40 i1 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 3571: ...2 24 L L L B 2 1 B16 i3 5 6 7 8 2 1 9 4 3 10 24 22 23 25 27 26 28 11 12 13 14 15 16 17 18 19 20 21 B16 BR W 01 BR W 01 i102 B i10 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BrW WL FB 36 F B FUSE NO 5...

Page 3572: ...R50 R55 B90 R50 4 BrY 1 W 4 GY 3 BrY 2 1 BrY 5 4 GY 3 L R W L B R R128 R187 B41 R128 R187 R55 1 2 1 CLOSE OPEN DOWN UP S R 01 S R 01 B B 2 B B444 B440 1 2 3 4 5 GY GY 1 1 R50 3 2 1 8 7 6 5 4 1 2 3 4...

Page 3573: ...1 D B279 COMBINATION METER i10 YG R BL RL R80 1 2 3 4 5 6 7 8 SEC 01 SEC 01 MB 21 HORN RELAY BrR BrR 5 B38 i3 2 A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3...

Page 3574: ...02 SEC 02 REF TO ENGINE ELECTRICAL SYSTEM E G NA 04 E G TB 05 DATA LINK CONNECTOR W VR 16 GY 8 7 BL 5 BL 4 BY REF TO GND GND 03 B BY A28 REF TO GND GND 06 BY B279 D B280 B 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 3575: ...H R9 B 3 YW 1 REAR DOOR SWITCH LH R22 WR 9 WR LW 8 LW YL 10 R39 R99 i54 D35 B B YL LW LOr LOr WR LOr R167 i102 3 YW YW YW 4 BODY INTEGRATED UNIT i84 A A19 A6 A32 A20 YL A33 B 4 YL YL 3 YL 3 R38 D34 B...

Page 3576: ...1 B281 C i10 IMB 01 IMB 01 REF TO GND GND 06 REF TO GND GND 03 WL 1 BrR SECURITY IMMOBILIZER INDICATOR LIGHT 39 B415 1 2 BLACK A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 2...

Page 3577: ...35 13 LOCK OFF UNLOCK 2 1 B GY 3 LG R52 ON DOOR OFF D72 R52 D102 i102 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 REF TO GND GN...

Page 3578: ...FUSE NO 9 MB 21 HORN RELAY D47 GR 2 B 1 GR GR 12 R39 D35 GR GR 8 MB 28 M B FUSE NO 14 B B164 1 YB 2 B LOCK OFF UNLOCK REF TO GND GND 07 B REF TO GND GND 03 B i99 1 B 1 K L 03 D 1 7 2 3 4 5 6 8 9 10 11...

Page 3579: ...26 2 1 RG LgY D32 1 2 D46 R24 R60 A i84 LgY 17 RG LgY RG 18 i101 D84 RG RG K L 03 K L 03 A22 BL i102 i53 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4Dr 5Dr A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18...

Page 3580: ...4 K L 04 K L 04 R22 R16 1 2 3 R12 R9 4Dr 5Dr A i84 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 REF TO GND GND 04 05 B B REF TO GND GND 05 B 8 9 K L...

Page 3581: ...4 15 16 17 18 19 20 6 7 5A BrR 1 2 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 B225 TO POWER SUPPLY CIRCUIT MULTI JOINT CONNECTO...

Page 3582: ...T AT C25 MT MT 1 2 GY 1 B107 RY 2 C B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B B135 5 6 7 2 1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18...

Page 3583: ...0 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 BY BY 1 1 1 BY WR 3 4 WL 15A B220 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 31 32 33 34 35 36 37 38 39 40...

Page 3584: ...B137 D 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 31 26 27 A B134 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 32 31 26 27 33 34 1 MT T3...

Page 3585: ...B441 B445 B442 1 2 3 4 5 B225 13 14 15 16 17 27 24 25 26 20 21 22 23 29 30 31 28 32 35 33 34 37 38 39 36 40 8 9 10 11 12 1 2 5 3 4 7 6 19 18 B99 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 3586: ...B136 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21 22 23 29 32 31 1 2 3 4 5 6 27 26 33 34 35 B B135 5 6 7 2 1 3 4 29 10 11 12 13 14 15 25 24 16 30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 3...

Page 3587: ...30 9 8 17 18 19 20 28 21 22 23 32 31 26 27 33 34 35 BY BY 1 1 1 BY WR 3 4 WL 15A 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 31 32 33 34 35 36 37 38 39 40 B220...

Page 3588: ...24 W 25 G L L 4 G 6 L A28 W A18 B12 1 2 3 4 5 6 7 8 9 10 11 12 1 1 B12 T3 WB BW 11 BL 1 C6 BL A B134 8 5 6 10 11 12 13 14 15 7 2 1 3 4 16 30 19 20 22 28 29 9 17 18 25 21 23 24 32 31 26 27 33 34 B122...

Page 3589: ...3 4 5 6 7 8 9 10 B280 B 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 B225 i50 1 2 3 8 9 10 4 13 14 15 16 5 6 7 11 12 17 18 19 20 21 22 23 24 A i85 A 1 2 3 4 5 6 7 8 9 10 11 12...

Page 3590: ...16 17 18 19 20 2 3 1 21 22 23 24 25 26 10 11 13 14 12 15 B280 B 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 C B136 B B55 16 10 11 12 13 14 15 25 24 30 9 8 7 17 18 19 20 28 21...

Page 3591: ...4 4 5 6 7 8 9 26 27 28 29 30 2 3 1 31 32 33 34 35 36 10 11 14 15 16 17 18 19 37 38 39 40 12 13 41 42 43 44 45 46 20 21 23 24 22 25 B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B40 B280 B 1 2 3 4 5 6 7...

Page 3592: ...NO 6 ACC YL GL BrY 2 1 B24 R139 1 2 B128 3 4 1 2 R50 B12 1 2 3 4 5 6 7 8 9 10 11 12 2 4 BrY B128 T9 2 1 GW GL G T13 T1 T1 P R N D INHIBITOR SWITCH BACK UP LIGHT SWITCH BACK UP LIGHT SWITCH COMPASS MIR...

Page 3593: ...H 12 Front door cord LH 2 Engine wiring harness 8 Rear wiring harness LH 13 Transmission cord 3 Bulkhead wiring harness 9 Roof cord 14 Rear oxygen sensor cord 4 Instrument panel wiring harness 10 Trun...

Page 3594: ...H 2 Engine wiring harness 8 Rear wiring harness LH 13 Transmission cord 3 Bulkhead wiring harness 9 Roof cord 14 Rear oxygen sensor cord 4 Instrument panel wiring harness 10 Rear gate cord 15 Generato...

Page 3595: ...fan motor turbo model Black C 2 Main fan motor non turbo model F21 2 Brown D 3 Front fog light LH F24 1 C 2 Magnet clutch F25 1 C 2 Generator terminal B F26 3 C 2 Generator F27 22 Black B 4 Relay hold...

Page 3596: ...g Harness WIRING SYSTEM WI 21478 1 2 3 4 5 1 2 3 4 5 A B C D A B C D F6 F26 F25 F5 F24 F125 F21 F17 GB 2 GB 1 F126 F108 F27 F109 F37 F36 1 NON TURBO MODEL 2 TURBO MODEL F11 2 F35 F70 F9 F16 F47 F78 1...

Page 3597: ...sensor LH B16 2 Gray B 4 Brake fluid level switch B21 54 Black B 3 E2 Engine wiring harness B24 2 Gray B 3 T1 Back up light switch MT model B25 2 Brown B 3 T2 Neutral position switch B143 20 B 4 Main...

Page 3598: ...Wiring Harness In Engine Compartment WIRING SYSTEM WI 21479 1 2 3 4 5 1 2 3 4 5 A B C D A B C D AB13 B146 B164 B147 B8 B3 B21 GA GV B12 B14 B10 B361 B301 B321 B6 B16 AB16 B145 B143 B186 B144 B15 B25 B...

Page 3599: ...Brake fluid level switch B19 4 B 3 T5 Rear oxygen sensor cord B21 54 Black B 3 E2 Engine wiring harness B128 4 B 3 T9 Transmission cord MT model B143 20 B 4 Main fuse box M B B144 9 Brown B 4 B145 7...

Page 3600: ...n Engine Compartment WIRING SYSTEM WI 21480 1 2 3 4 5 1 2 3 4 5 A B C D A B C D AB13 B146 B164 B147 B8 B3 B21 GA GV B14 B128 B19 B10 B361 B301 B321 B6 B16 AB16 B145 B143 B186 B144 B15 B360 B310 B19 B1...

Page 3601: ...14 C 2 Roll connector B70 18 C 2 Combination switch B71 17 C 2 B72 6 C 2 Ignition switch B75 2 Green B 4 B76 Delivery test mode connector B76 2 Green B 4 B75 B77 6 B 3 Mode door actuator Auto A C B83...

Page 3602: ...239 6 B 3 Air mix door actuator Auto A C B279 30 C 3 Body integrated unit B280 26 C 3 B281 28 C 3 B292 3 D 4 ABS G sensor without VDC B315 6 C 3 Accelerator pedal position sensor B318 4 B 1 VDC OFF sw...

Page 3603: ...White or natural color WI 21481 1 2 3 4 5 1 2 3 4 5 A B C D A B C D GB 6 GB 3 GAB 2 B36 B57 B239 B88 GB 4 B279 GB 5 B280 B281 B41 B318 B38 B177 B87 B90 B27 B415 B220 B76 B75 B98 B97 B89 B134 B40 B32 B...

Page 3604: ...E18 6 Dark gray A 4 EGR valve E19 1 B 2 Power steering oil pressure switch E21 3 Black A 4 Manifold absolute pressure sensor E22 6 Black A 1 Front oxygen A F sensor E23 4 Dark gray A 1 Rear oxygen se...

Page 3605: ...ng Harness and Transmission Cord WIRING SYSTEM WI 21482 1 2 3 4 5 1 2 3 4 5 A B C D A B C D E21 T4 E18 E2 E61 E4 E8 E75 E71 E5 E19 E11 E10 E16 E15 E17 MT AT T3 E22 E23 E72 E68 T2 T1 E67 E14 E57 E6 GE...

Page 3606: ...3 E34 3 Black B 4 Ignition coil No 4 E35 3 Light gray A 4 Camshaft position sensor LH E36 3 Light gray A 2 Camshaft position sensor RH E37 2 Blue B 4 Oil flow control solenoid valve LH E38 2 Blue B 1...

Page 3607: ...Connector Connecting to No Pole Color Area No Description T3 12 Black D 4 B12 Bulkhead wiring harness T4 20 Gray D 4 B11 T5 4 Dark gray C 3 B19 T6 4 Dark gray D 5 Rear oxygen sensor T7 9 Black C 5 In...

Page 3608: ...nsmission Cord WIRING SYSTEM WI 21483 1 2 3 4 5 1 2 3 4 5 A B C D A B C D GE E2 E57 E52 E21 E14 E38 E5 E22 E64 E16 E40 E51 E32 E37 E34 E31 E33 E19 E4 E8 E11 E41 E80 E10 E35 AT E55 E36 E17 E6 T5 MT T13...

Page 3609: ...socket pocket light i29 1 Black B 3 Audio bracket ground i50 24 B 4 Navigation module i51 2 B 3 Sunload sensor i53 16 C 5 R98 Rear wiring harness RH i54 10 C 5 R99 Rear wiring harness RH i55 2 B 3 In...

Page 3610: ...t Panel Wiring Harness WIRING SYSTEM i101 WI 21484 1 2 3 4 5 1 2 3 4 5 A B C D A B C D GB 12 i3 i5 i54 i53 i76 i102 i100 i99 i1 i50 i51 i59 i29 i22 i23 i85 i86 i15 i16 i24 i88 i55 i77 i84 i98 i97 i10...

Page 3611: ...iring harness R52 3 A 3 Room light R55 10 Gray B 3 Sunroof motor assembly R56 2 B 2 Spot map light R57 12 B 4 R15 Rear wiring harness RH R58 6 B 4 Fuel pump assembly R59 2 B 5 Fuel sub level sensor R6...

Page 3612: ...LH AB21 2 Black C 4 Pretensioner LH AB23 4 Yellow C 4 Side airbag sensor LH AB24 4 Yellow B 2 Side airbag module RH AB26 2 Black B 2 Pretensioner RH AB28 4 Yellow B 2 Side airbag sensor RH AB34 4 Yell...

Page 3613: ...3 4 5 A B C D A B C D R50 R64 R99 R52 AB34 R16 GB 8 GB 7 GB 9 AB56 R56 R62 R128 R187 AB19 R1 AB18 AB17 R168 R3 R167 R9 R10 R211 R4 AB23 AB21 R2 R98 R12 R13 AB28 AB26 AB53 R44 R42 R43 R72 R15 R57 R58 R...

Page 3614: ...rror heater 10 B 2 Outer mirror assembly RH with mirror heater D17 8 B 2 Front power window sub switch D18 2 B 3 Front door lock actuator RH D22 8 C 4 R10 Rear wiring harness LH D23 2 C 4 Rear door sp...

Page 3615: ...IRING SYSTEM WI 21486 1 2 3 4 5 1 2 3 4 5 A B C D A B C D D15 D14 D17 D15 D125 D28 D18 D13 D29 D83 D84 D5 D5 D4 D102 D7 D72 D22 D3 D2 D23 D24 D25 D26 D30 D31 D32 D12 1 WITHOUT MIRROR HEATER 2 WITH MIR...

Page 3616: ...ion light LH R60 8 B 4 R24 Rear wiring harness RH R65 1 B 2 Rear defogger R66 2 B 4 High mounted stop light Rear spoiler R76 2 B 4 License plate light R80 8 B 2 Keyless entry control module R86 2 Blac...

Page 3617: ...WI 198 Rear Wiring Harness and Trunk Lid Cord WIRING SYSTEM WI 21487 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R22 AB32 R24 R60 R122 R26 R186 R76 R66 R97 AB31 R65 AB33 R19 R174 R20 R28 R80 R86 GB 10...

Page 3618: ...Gray C 2 Luggage room light White or natural color Connector Connecting to No Pole Color Area No Description D34 8 B 4 R38 Rear wiring harness RH D35 14 B 4 R39 D39 2 B 3 High mounted stop light D43...

Page 3619: ...ear Wiring Harness and Rear Gate Cord WIRING SYSTEM WI 21488 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R141 R80 AB31 R86 R38 D34 D89 R28 R26 D137 D47 D43 D44 D48 D39 GB 10 AB32 R22 R97 D58 D46 D59 R122 AB33...

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