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Subaru Impreza 2003, Service Manual

The Subaru Impreza 2003 Service Manual is a comprehensive manual that provides detailed instructions on maintenance, repair, and troubleshooting for your vehicle. Download this manual for free from manualshive.com to ensure your Subaru Impreza is running smoothly and efficiently. Stay informed and keep your car in top condition.

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DI-59

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

(3) Install the front bearing race to differential
carrier using ST1 and ST2.

ST1

398477701

HANDLE

ST2

398447110

DRIFT

(4) Insert the front bearing cone.

NOTE:
Use a new front bearing cone.

(5) Insert the ST1 into case with pinion height
adjusting shim and rear bearing cone fitted onto
it.

NOTE:
• Re-use the used washer if not deformed.
• Use a new rear bearing cone.

(6) Then install the preload adjusting spacer
and washer, front bearing cone, ST2, compan-
ion flange, and washer and self-locking nut.

ST1

498447150

DUMMY SHAFT

ST2

32285AA000 DUMMY COLLAR

(7) Turn the ST1 with hand to make it seated,
and tighten the self locking nut while measuring
the preload with spring balance. Select the pre-
load adjusting washer and spacer so that the
specified preload is obtained when nut is tight-
ened to the specified torque.

NOTE:
• Use a new self-locking nut.
• Measure the preload in direction of tangent to
flange.
• Be careful not to give excessive preload.
• When tightening the self locking nut, lock ST1
with ST2 as shown in the figure.
ST1

398507150

DUMMY SHAFT

ST2

498447704

BLOCK

Tightening torque:

191 N·m (19.5 kgf-m, 141 ft-lb)

(A) Pinion height adjusting shim

(B) Preload adjusting spacer

(C) Preload adjusting washer

(B)

(A)

(C)

ST2

ST1

DI-00080

DI-00152

Front and rear bearing preload

For new bearing:
12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
at companion flange bolt hole

Preload adjusting 
washer

Part No.

Thickness mm (in)

38336AA000

1.500 (0.0591)

38336AA120

1.513 (0.0596)

38336AA010

1.525 (0.0600)

38336AA130

1.538 (0.0606)

38336AA020

1.550 (0.0610)

38336AA140

1.563 (0.0615)

38336AA030

1.575 (0.0620)

38336AA150

1.588 (0.0625)

38336AA040

1.600 (0.0630)

38336AA160

1.613 (0.0635)

38336AA050

1.625 (0.0640)

38336AA170

1.638 (0.0645)

38336AA060

1.650 (0.0650)

38336AA180

1.663 (0.0655)

38336AA070

1.675 (0.0659)

38336AA190

1.688 (0.0665)

38336AA080

1.700 (0.0669)

38336AA200

1.713 (0.0674)

38336AA090

1.725 (0.0679)

38336AA210

1.738 (0.0684)

38336AA100

1.750 (0.0689)

38336AA220

1.763 (0.0694)

38336AA110

1.775 (0.0699)

ST1

ST2

DI-00081

Summary of Contents for Impreza 2003

Page 1: ...AL INFORMATION SECTION Pub No G1860GE1 ENGINE SECTION 1 Pub No G1860GE2 ENGINE SECTION 2 Pub No G1860GE3 TRANSMISSION SECTION Pub No G1860GE4 CHASSIS SECTION Pub No G1860GE5 BODY SECTION Pub No G1860G...

Page 2: ......

Page 3: ...guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replaceme...

Page 4: ......

Page 5: ...FOREWORD FW Page 1 Foreword 2...

Page 6: ...nuals are used when performing mainte nance repair or diagnosis of the Subaru IMPRE ZA Applied model GD GG from 2003MY The manuals contain the latest information at the time of publication Changes in...

Page 7: ...HOW TO USE THIS MANUAL HU Page 1 How to Use This Manual 2...

Page 8: ...CTURE 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 a...

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

Page 10: ...ed in one service procedure appropriate reference are provided for each part Example A Component D Caution G Tightening torque B Process E Tool number of special tool H Illustration C Reference F Name...

Page 11: ...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 12: ...HU 6 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL...

Page 13: ...SPECIFICATIONS SPC Page 1 Impreza 2...

Page 14: ...earance Without catalytic converter mm in 150 5 9 155 6 1 2 150 5 9 155 6 1 2 160 6 3 With catalytic converter mm in 150 5 9 155 6 1 3 150 5 9 155 6 1 3 160 6 3 155 6 1 Model 1 6 L Non turbo 2 0 L Tur...

Page 15: ...lyst NGK BKR6E without catalyst CHAMPION RC10YC4 with catalyst NGK BKR5E 11 with catalyst CHAMPION RC10YC4 NGK BKR5E 11 With OBD CHAMPION RC8YC4 CHAMPION RC10YC4 NGK PFR6G NGK PFR6G Alternate NGK BKR6...

Page 16: ...33 2 272 3 333 2 272 3 333 2 272 3 545 Dual range 1 447 1 447 Reduction gear Front drive 1st reduction Type of gear Helical Helical Helical Helical Gear ratio 1 000 1 000 1 000 1 000 Final reduction T...

Page 17: ...tank 2 US gal Imp gal 50 13 2 11 0 60 15 9 13 2 Engine oil Total capacity 2 US qt Imp qt 4 0 4 2 3 5 4 5 4 8 4 0 4 0 4 2 3 5 4 5 4 8 4 0 Engine oil amount for refill 2 US qt Imp qt Approx 4 0 4 2 3 5...

Page 18: ...Total kgf lb 1 190 2 624 1 235 2 723 1 240 2 734 1 250 2 755 1 255 2 756 1 275 2 810 1 270 2 800 1 270 2 800 Maximum permissible axle weight M P A W Front kgf lb 890 1 962 890 1 962 890 1 962 890 1 96...

Page 19: ...b 1 275 2 810 1 270 2 800 1 275 2 810 1 295 2 855 1 290 2 844 1 290 2 844 1 295 2 855 1 285 2 833 Maximum permissible axle weight M P A W Front kgf lb 890 1 962 890 1 962 890 1 962 890 1 962 890 1 962...

Page 20: ...877 1 300 2 866 1 305 2 877 1 300 2 866 1 305 2 877 1 295 2 855 1 285 2 833 1 325 2 921 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 950 2 094 950 2 094 950 2 094 950 2 094 950 2 094...

Page 21: ...77 1 325 2 921 1 320 2 910 1 325 2 921 1 320 2 910 1 325 2 921 1 315 2 899 1 325 2 921 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 950 2 094 950 2 094 950 2 094 950 2 094 950 2 094...

Page 22: ...325 2 921 1 395 3 075 1 370 3 020 1 390 3 065 1 395 3 075 1 410 3 109 1 400 3 087 1 410 3 109 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 990 2 185 990 2 185 990 2 185 990 2 185 990...

Page 23: ...3 109 1 415 3 120 1 395 3 075 1 415 3 120 1 415 3 120 1 470 3 241 1 450 3 197 1 470 3 241 Maximum permissible axle weight M P A W Front kgf lb 990 2 183 990 2 183 990 2 183 990 2 183 990 2 183 990 2 1...

Page 24: ...otal kgf lb 1 280 2 822 1 285 2 833 1 290 2 844 1 305 2 877 1 300 2 866 1 300 2 866 1 305 2 877 1 295 2 855 Maximum permissible axle weight M P A W Front kgf lb 900 1 984 900 1 984 900 1 984 900 1 984...

Page 25: ...Total kgf lb 1 300 2 866 1 305 2 877 1 320 2 910 1 315 2 899 1 315 2 899 1 320 2 910 1 330 2 932 1 370 3 020 Maximum permissible axle weight M P A W Front kgf lb 900 1 984 900 1 984 900 1 984 900 1 98...

Page 26: ...l kgf lb 1 350 2 977 1 345 2 965 1 350 2 977 1 350 2 977 1 340 2 955 1 360 2 999 1 340 2 955 1 380 3 042 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 950 2 094 950 2 094 950 2 094 95...

Page 27: ...0 Total kgf lb 1 360 2 999 1 355 2 987 1 360 2 999 1 360 2 999 1 350 2 977 1 370 3 020 1 390 3 065 1 410 3 109 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 950 2 094 950 2 094 950 2...

Page 28: ...00 1 322 600 1 322 600 1 322 595 1 311 Total kgf lb 1 430 3 153 1 430 3 153 1 430 3 153 1 425 3 142 Maximum permissible axle weight M P A W Front kgf lb 990 2 183 990 2 183 990 2 183 990 2 183 Rear kg...

Page 29: ...260 2 778 1 280 2 822 1 280 2 822 1 270 2 800 1 290 2 844 1 285 2 833 1 300 2 866 1 305 2 877 Maximum permissible axle weight M P A W Front kgf lb 890 1 962 890 1 962 890 1 962 890 1 962 890 1 962 95...

Page 30: ...f lb 1 320 2 910 1 305 2 877 1 325 2 921 1 305 2 877 1 325 2 921 1 320 2 910 1 340 2 955 1 400 3 086 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 950 2 094 950 2 094 950 2 094 950 2...

Page 31: ...109 1 415 3 120 1 415 3 120 1 395 3 075 1 410 3 109 1 415 3 120 1 430 3 153 Maximum permissible axle weight M P A W Front kgf lb 990 2 183 990 2 183 990 2 183 990 2 183 990 2 183 990 2 183 990 2 183 9...

Page 32: ...0 1 257 585 1 290 585 1 290 Total kgf lb 1 435 3 164 1 470 3 241 1 470 3 241 Maximum permissible axle weight M P A W Front kgf lb 990 2 183 1 030 2 271 1 030 2 271 Rear kgf lb 920 2 028 920 2 028 920...

Page 33: ...246 Total kgf lb 1 290 2 844 1 310 2 888 1 305 2 877 1 300 2 866 1 315 2 899 1 330 2 932 1 345 2 965 1 340 2 955 Maximum permissible axle weight M P A W Front kgf lb 900 1 984 900 1 984 900 1 984 900...

Page 34: ...585 1 830 Total kgf lb 1 355 2 987 1 350 2 977 1 360 2 999 1 350 2 977 1 360 2 999 1 340 2 955 1 355 2 987 1 410 3 109 Maximum permissible axle weight M P A W Front kgf lb 950 2 094 950 2 094 950 2 0...

Page 35: ...85 1 830 585 1 830 Total kgf lb 1 415 3 120 1 430 3 153 1 430 3 153 1 410 3 109 1 435 3 164 Maximum permissible axle weight M P A W Front kgf lb 990 2 183 990 2 183 990 2 183 990 2 183 990 2 183 Rear...

Page 36: ...SPC 24 SPECIFICATIONS IMPREZA...

Page 37: ...PRECAUTION PC Page 1 Precaution 2...

Page 38: ...performing maintenance on airbag components or nearby and airbag wiring harnesses or nearby To prevent unexpected deployment perform one of the steps below and then wait at least 20 seconds to dischar...

Page 39: ...NOTE NT Page 1 Note 2...

Page 40: ...uch parts when there is a risk of static electricity Always use a static electricity pre vention cord or touch grounded metal before con ducting work 3 BATTERY When removing the battery cables always...

Page 41: ...revent the vehicle from falling which could result in injury Be especially careful to make sure the vehicle is balanced before raising it Be sure to set the wheel stoppers when jacking up only the fro...

Page 42: ...NT 4 NOTE NOTE A Front B Rear 1 Front crossmember 2 Rear differential NT 00062 1 2 A B...

Page 43: ...tie downs only to the specified points on the vehicle Tie down point Chain direction at tie down condition Chain pulling range at tie down condition 1 Hook for tie down 2 Hook for towing and tie down...

Page 44: ...wn condition Measure the distance L between tire highest point to arch highest point before tie down and after tie down Difference of measurement value drop height shall be within 50 8 mm 1 97 in Make...

Page 45: ...s with AWD AT or VTD use a loader instead of towing When towing other vehicles to prevent excessive weight from damaging the hook or vehicle Do not tow other vehicles with a front hook for tie down Ma...

Page 46: ...he hood in this position remove the windshield washer hose attaching clip from the hood 11 TRAINING For information about training contact a dealer or agent 12 GENERAL SCAN TOOL Using general scan too...

Page 47: ...IDENTIFICATION ID Page 1 Identification 2...

Page 48: ...R compliance plate Australia model 4 Tire inflation pressure label Driver side Australia model Tire inflation pressure label Driver side Except Australia model 6 Model number plate 7 Vehicle identific...

Page 49: ...FICATION MANUAL TRANSMISSION REAR DIFFERENTIAL MODEL NUMBER PLATE 1 Transmission serial number ID 00055 1 1 Type white paint ID 00056 1 ID 00057 Option CODE Applied model TRIM CODE COLOR CODE Transmis...

Page 50: ...MPI 5 speed MT R SOHC MPI 4 speed AT J SOHC MPI Full time AWD 5 speed MT K SOHC MPI Full time AWD 5 speed MT Dual range D DOHC Turbo Full time AWD 5 speed MT H DOHC Turbo Full time AWD 6 speed MT T DO...

Page 51: ...del year C 2003MY 5 L Destination K Right hand drive model market L Left hand drive model market 6 5 Grade 3 BASE 4 TS 5 GX 6 RS 7 OUTBACK 8 WRX E STi 7 R Transmission fuel feed system K SOHC MPI Dual...

Page 52: ...le Range 5 speed MT V Full time AWD 5 speed MT with viscous coupling center dif ferential single range W Full time AWD 6 speed MT with viscous coupling center dif ferential single range X Full time AW...

Page 53: ...ID 7 IDENTIFICATION IDENTIFICATION Option code ECPS Digits Code Meaning Details 1 and 2 EC Destination EC EC KO KO K4 K4 KS KS EK EK KA KA K1 K1 E2 E2 3 and 4 PS Main option of vehicle...

Page 54: ...ID 8 IDENTIFICATION IDENTIFICATION...

Page 55: ...RECOMMENDED MATERIALS RM Page 1 Recommended Materials 2...

Page 56: ...w will result in damage or poor operation of the engine and fuel injection sys tem Use the specified gasoline to correct perfor mance Unleaded gasoline Use unleaded gasoline and not leaded gasoline on...

Page 57: ...PI Spec CCMC Spec ACEA Spec API Spec Engine oil SL SJ Grade Energy conserving or SH G4 or G5 A1 A2 or A3 SG SF Manual transmission oil GL 5 AT front differential gear oil GL 5 Rear differential gear o...

Page 58: ...No and applicable temperature Engine oil SOHC model DOHC turbo model RM 00007 F 22 4 14 50 68 86 104 C 30 20 10 0 10 20 30 40 5W 30 32 10W 30 or 10W 40 0W 20 Recommend RM 00003 F 22 4 14 50 68 86 104...

Page 59: ...n oil and rear differential gear oil AT front differential gear oil SAE viscosity No and applicable temperature RM 00004 F 22 4 14 50 68 86 104 C 30 20 10 0 10 20 30 40 85W 75W 90 80W 90 32 RM 00005 F...

Page 60: ...h other refrigerants Also do not use any compressor oil except for DH PR Fluid Recommended Alternative Remarks Automatic transmission fluid DEXRON III Power steering fluid DEXRON III Brake fluid FMVSS...

Page 61: ...ke Drum brake wheel cylinder Niglube RX 2 K0779GA102 Drum brake Brake shoe Molykote No 7439 003602001 Brake pad Molykote AS 880N K0777YA010 Front axle SFJ SSG 6003 28093TA000 Front axle EBJ Front axle...

Page 62: ...ue converter clutch case Transmission oil pan 6MT model Three Bond 1215 004403007 Dow Corning s No 7038 Transmission oil pan AT model Three Bond 1217B K0877YA020 Rear differential Three Bond 1324 0044...

Page 63: ...PRE DELIVERY INSPECTION PI Page 1 Pre delivery Inspection 2...

Page 64: ...heck that the vehicle before delivery is in a nor mal state Check for any damage or missing parts that may have taken place during transportation or storage Make sure to provide a complete vehicle to...

Page 65: ...heck that the trunk opens nor mally 2 Using the key check that the trunk lid can be unlocked normally 3 Open and close the trunk lid to see that there are no abnormal conditions 9 Check the rear gate...

Page 66: ...ms operate normally 34 Window washer Check that the window washer system operates normally 35 Wiper Check that the wiper system operates normally 36 Power window operation check Check the power window...

Page 67: ...3 FUSE INSTALLATION A vehicle just delivered has no fuse for the room lamp circuit to prevent battery discharge Attach a 15 A fuse A as shown in the figure 4 CONNECTION OF AIR CONDITIONER HARNESS A ve...

Page 68: ...Verify that all the doors including rear gate are not unlocked when pressing power door lock switch to unlock side 5 Verify that the door is not opened when operat ing door lock knob to unlock positio...

Page 69: ...the rear gate several times for smooth movement 2 Operate the rear gate lever to check that the rear gate is locked and unlocked normally 1 Remove the blind cover inside the rear gate 2 Check that the...

Page 70: ...are securely tightened 14 BRAKE FLUID Check the brake fluid amount If the amount is in sufficient carry out a brake line test to identify brake fluid leaks and check the brake operation Af ter that re...

Page 71: ...n sufficient check that no leaks are found Then add the necessary amount of the specified fluid 20 WINDOW WASHER FLUID Check the window washer fluid amount If the amount is insufficient check that no...

Page 72: ...ck that the malfunction indicator light starts blinking If the light blinks return the ignition key to LOCK and discon nect the test mode connector Then turn the igni tion key to ON again If the malfu...

Page 73: ...ow switches one by one to check that each of the power windows goes up and down with no abnormal noises 37 BRAKE TEST Check the foot brake for normal operations 38 PARKING BRAKE Check the parking brak...

Page 74: ...the hood and trunk lid before starting the test Connect a hose to a tap and spray water on the vehicle The rate of water discharge must be ap prox 20 25 2 5 3 6 6 US gal 4 4 5 5 Imp gal per minute Whe...

Page 75: ...ehicles left for a long time or during low temperature period sprinkle some water heated to 50 60 C 122 140 F over the vehicle to raise its surface temperature be fore peeling off the wrap guard Do no...

Page 76: ...PI 14 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION...

Page 77: ...Air Cleaner Element 22 11 Cooling System 23 12 Coolant 25 13 Idle Mixture 27 14 Clutch System 28 15 Transmission Gear Oil 30 16 Hill holder System 31 17 ATF 32 18 Front Rear Differential Gear Oil 34 1...

Page 78: ...ERIODIC MAINTENANCE SERVICES GENERAL DESCRIPTION 1 General Description A GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become s...

Page 79: ...ths or km miles whichever occurs first Month 12 24 36 48 60 72 84 96 Remarks 1 000 km 1 6 5 15 30 45 60 75 90 105 120 1 000 miles 1 3 9 19 28 38 47 56 66 75 1 Engine oil R R R R R R R R 2 Engine oil f...

Page 80: ...0 miles 3 7 5 15 22 5 30 1 Engine oil R R R R 2 Engine oil filter R R R R Maintenance Interval Number of months or km miles whichever occurs first Months 12 24 36 48 Remarks 1 000 km 1 6 25 50 75 100...

Page 81: ...ended service for safe vehicle operation NOTE 1 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is a maintenance free part ATF...

Page 82: ...ly Replace more fre quently Fuel line 12 months I 15 000 km 9 000 miles Transmission oil Replace more fre quently ATF Replace more fre quently Front rear dif ferential oil Replace more fre quently Bra...

Page 83: ...eplace more fre quently Fuel line 6 months I 12 500 km 7 500 miles Transmission oil Replace more fre quently ATF Replace more fre quently Front rear dif ferential oil Replace more fre quently Brake li...

Page 84: ...e hole cover Turbo model 3 Drain the engine oil by loosening engine oil drain plug DOHC TURBO MODEL SOHC MODEL 4 Replace the drain plug gasket 5 Tighten the engine oil drain plug after draining engine...

Page 85: ...1 Imp qt SOHC MODEL EXCEPT FOR SOHC MODEL The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed NOTE When replenishing oil i...

Page 86: ...to bring the level up to the F line 5 After turning off the engine wait a few minutes for the oil to drain back into oil pan before checking the level 6 Just after driving or while the engine is warm...

Page 87: ...filter by turning it by hand being careful not to damage the seal rubber 5 Tighten more approx 2 3 to 3 4 turn after the seal rubber contacts the cylinder block Do not tighten excessively or oil may l...

Page 88: ...r head and spark plug If a torque wrench is not available tighten the spark plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns 2 DOHC MODEL 1 Disconnect the battery cables...

Page 89: ...belts if cracks fraying or wear is found 2 Remove the V belt cover and radiator reservoir tank 3 Check the belt tension using belt tension gauge And adjust it if necessary by changing the genera tor...

Page 90: ...ghten the lock bolt A 6 Tighten the slider bolt B Tightening torque Lock bolt 25 N m 2 5 kgf m 18 ft lb Slider bolt 8 N m 0 8 kgf m 5 8 ft lb 7 Idle the engine for approx 5 min to normalize the V belt...

Page 91: ...4 FRONT SIDE BELT IN STALLATION V belt DOHC Turbo model Ref to ME H4DOTC 55 FRONT SIDE BELT INSTALLATION V belt Tightening torque 23 N m 2 3 kgf m 17 0 ft lb 8 Idle the engine for approx 5 min to norm...

Page 92: ...o lock the crankshaft use ST Remove the pul ley bolt 2 5 L model ST 499977100 CRANKSHAFT PULLEY WRENCH Except for 2 5 L model ST 499977400 CRANKSHAFT PULLEY WRENCH 7 Remove the crankshaft pulley 8 Rem...

Page 93: ...diator with cardboard and blanket 3 Remove the V belts Ref to ME H4DOTC 55 V belt 4 Remove the air conditioning compressor drive belt tensioner 5 Remove the pulley bolt To lock the crankshaft use ST E...

Page 94: ...nt marks on the belt with corre sponding marks on the sprockets If incorrectly installed interference between pistons and valves may occur B INSPECTION 1 SOHC MODEL 1 Remove the front timing belt cove...

Page 95: ...ions check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the timing belt width W If it is less than 30 mm 1 18 in check idlers tensioner water pu...

Page 96: ...rnally so check pipes areas near pipes and engine compartment piping for rust hose damage loose bands etc If faulty parts are found repair or replace them SOHC model Ref to FU H4SO 65 Fuel Delivery Re...

Page 97: ...r replacement procedures refer to FU section SOHC model Ref to FU H4SO 62 Fuel Filter DOHC Turbo model Ref to FU H4DOTC 66 Fuel Filter B INSPECTION 1 If it is clogged or if replacement interval has be...

Page 98: ...leaner case 4 Remove the air cleaner 5 Install in the reverse order of removal NOTE Fasten with a clip after inserting the lower tab of the case 2 TURBO MODEL 1 Remove the clip B above the air cleaner...

Page 99: ...not to spill coolant when detaching the tester from radiator Do not remove the radiator side cap Turbo model 2 Check the radiator cap valve open pressure us ing radiator cap tester NOTE Rust or dirt o...

Page 100: ...4 Radiator Cap DOHC Turbo model Ref to CO H4DOTC 19 Water Pump Ref to CO H4DOTC 21 Thermostat Ref to CO H4DOTC 23 Radiator Ref to CO H4DOTC 27 Radiator Cap 4 Check the electric fan operates using Suba...

Page 101: ...Imp qt 1 6 L MT model Approx 7 4 2 7 8 US qt 6 5 Imp qt 2 0 L Non turbo AT model Approx 6 9 2 7 3 US qt 6 1 Imp qt 2 0 L Non turbo MT model Approx 7 0 2 7 1 US qt 6 2 Imp qt 2 0 L Turbo AT model Appro...

Page 102: ...that the coolant concentration must be in creased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read t...

Page 103: ...mixture using CO meter 4 If out of specification adjust the idle mixture us ing CO adjusting screw of mass air flow sensor 5 After adjusting the CO value check and adjust the increment coefficient of...

Page 104: ...e mov ing shift lever into reverse 3 Stop depressing the clutch pedal when gearshifting is complete With the clutch pedal in this position measure the distance between the upper side of pedal pad and...

Page 105: ...and hydraulic line 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 FM...

Page 106: ...lb 6MT Oil pan side 44 N m 4 5 kgf m 32 5ft lb 6MT Clutch housing side 70 N m 7 1 kgf m 51 6 ft lb 3 Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge N...

Page 107: ...clutch engine tends to stall Loos en the adjusting nut gradually until smooth starting is enabled B When the hill holder is released earlier than engagement to clutch vehicle slips down slight ly Tig...

Page 108: ...er be tween upper and lower marks CAUTION Use care not to exceed the upper limit level Remember that the addition of ATF to the up per limit mark when the transmission is cold will result in overfilli...

Page 109: ...TER NOTE ATF filter is a maintenance free part ATF filter needs replacement when it has physically dam aged or ATF leaked For the replacement procedures of the ATF filter Ref to 4AT 69 ATF Filter A Le...

Page 110: ...e drain plug to specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft lb 3 Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge NOTE Each oil manufact...

Page 111: ...t 0 8 1 0 lmp qt NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands 5 Install the filler plug onto rear differential gear case firmly NOTE Apply fluid packin...

Page 112: ...lly check the brake hose using a mirror where it is difficult to see for any damage B CHECKING 1 SERVICE BRAKE 1 Check the free play of brake pedal with a force of less than 10 N 1 kgf 2 lb Brake peda...

Page 113: ...pplying the same pedal force Make sure the travel distance should not change 2 With the brake pedal depressed start the en gine Make sure the pedal should move slightly to ward the floor 3 With the br...

Page 114: ...17 6 Imp fl oz for total brake system 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it de pressed 7 Loosen the bleeder screw approx 1 4 turn until a sma...

Page 115: ...eel nuts to secure disk rotor 6 Set a dial gauge at a point less than 10 mm 0 39 in from outer periphery of rotor and then measure the disk rotor runout Disc rotor runout limit Front 0 075 mm 0 0030 i...

Page 116: ...rface with emery cloth 200 or more If it is unevenly worn tapered or the outside surface of brake drum is damaged correct or replace it Brake drum inner diameter Standard value 228 6 mm 9 000 in Servi...

Page 117: ...noticeable replace them 4 When the shoe return spring tension is exces sively weakened replace it B ADJUSTMENT 1 REAR DRUM BRAKE The main brake is adjusted automatically and so there is no need to ad...

Page 118: ...the ball joint 2 If the dust seal is damaged replace with the new ball joint NOTE When the transverse link ball joint has been re moved or replaced check the toe in of front wheel If the front wheel...

Page 119: ...ink UPR arm R sub frame etc Body parts to which suspensions are installed 3 When the toe in and thrust angle are out of stan dard value adjust them so that they conform to re spective service standard...

Page 120: ...nd out to check bearing free play 3 Loosen the wheel nuts and remove rear wheel 4 If the bearing free play exists in step 2 above attach a dial gauge to the hub COMPL and mea sure axial displacement i...

Page 121: ...e hub unit COMPL with hand to check for noise or binding If the hub unit COMPL is noisy or binds replace the hub unit COMPL A Rear housing B Tone wheel C Hub bolt D Hub unit COMPL E Socket bolt F Wash...

Page 122: ...front axle boots A and rear axle boots B for deformation damage or failure If faulty re place them with new ones Ref to DS 33 Front Drive Shaft Ref to DS 38 Rear Drive Shaft 2 PROPELLER SHAFT Inspect...

Page 123: ...should return to its original posi tion after it has been turned and then released 2 STEERING SHAFT JOINT 1 When the steering wheel free play is excessive disconnect the universal joint of steering sh...

Page 124: ...m 61 5 ft lb 5 POWER STEERING FLUID LEVEL NOTE Check at power steering fluid temperature 20 C 68 F read the fluid level on the COLD side Check at power steering fluid temperature 80 C 176 F read the f...

Page 125: ...e if necessary 9 GEARBOX BOOTS Inspect both sides of gearbox boots as follows and correct the defects if necessary 1 A and B positions of gearbox boot are fitted correspondingly in A and B grooves of...

Page 126: ...PM 50 PERIODIC MAINTENANCE SERVICES STEERING SYSTEM POWER STEERING...

Page 127: ...le in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations contained in this manual are based o...

Page 128: ...ICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 G1860GE2 LUBRICATION LU H4SOw oOBD SPEED CONTROL SYSTEMS SP H4SOw oOBD IGNITION IG H4SOw oOBD STARTING CHARGING SYSTEMS SC H4SOw oOBD ENGINE DIAGNOSTI...

Page 129: ...ir Temperature Sensor 34 11 Idle Air Control Solenoid Valve 35 12 EGR Valve 36 13 Air Assist Injector Solenoid Valve 37 14 Fuel Injector 38 15 Front Oxygen A F Sensor 44 16 Rear Oxygen Sensor 46 17 En...

Page 130: ...Specification Fuel tank Capacity 50 2 13 2 US gal 11 0 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 370 677 kPa 3 77 6 9 kg cm2 53 6 98 psi Discharge flow More...

Page 131: ...ENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD 1 6 L MODEL FU 00953 21 22 19 5 6 7 8 9 3 2 4 15 21 18 17 16 14 13 12 1 20 18 18 17 17 11 23 T2 T1 T1 T2 T6 T5 T5 T5 T2 T3 T6 T5 T5 T5 2 19 4 3 5 6 T2...

Page 132: ...l injector 15 Fuel pipe protector RH T2 5 0 0 51 3 7 4 O ring 16 Fuel pipe ASSY T3 6 4 0 65 4 7 5 O ring 17 Fuel hose T4 17 1 7 12 5 6 O ring 18 Clip T5 19 1 9 14 0 7 Plug 19 Clip T6 25 2 5 18 4 8 PCV...

Page 133: ...ON FUEL SYSTEMS GENERAL DESCRIPTION 2 0 L MODEL FU 00954 20 21 5 6 7 8 9 10 3 2 4 17 17 17 20 22 18 18 14 16 18 13 12 1 19 15 11 4 3 5 6 T2 T2 T1 T1 T1 T1 T1 T1 T5 T4 T4 T4 T2 T5 T4 T4 T3 T3 T5 T5 T5...

Page 134: ...elerator cable bracket 3 Fuel injector 13 Fuel pipe protector LH 23 EGR valve 4 O ring 14 Plug cord holder LH 5 O ring 15 Fuel pipe protector RH Tightening torque N m kgf m ft lb 6 O ring 16 Fuel pipe...

Page 135: ...sket 5 Throttle body Tightening torque N m kgf m ft lb 2 Throttle position sensor 6 Intake air temperature sensor T1 1 6 0 16 1 2 3 Idle air control solenoid valve 7 Grommet T2 22 2 2 15 9 4 Manifold...

Page 136: ...3 CRANKSHAFT POSITION CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 4 Camshaft position sensor support Tightening torque N m kgf m ft lb 2 Knock sensor T1 6 4 0 65 4 7 3 Camshaft po...

Page 137: ...EL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 4 FUEL TANK FU 00908 T1 T1 T3 T2 T2 T2 T3 6 5 7 8 9 9 8 17 20 11 11 21 11 11 22 23 19 18 1 2 3 2 4 A B 24 15 A B T1 D C D C 18 11 11 11 11 11 24 12 13 10...

Page 138: ...on hose E 4 Fuel tank 14 Evaporation hose C 24 Evaporation hose F 5 Fuel pump gasket 15 Evaporation pipe ASSY 25 Evaporation hose G 6 Fuel pump ASSY 16 Evaporation pipe 7 Fuel level sensor 17 Fuel ret...

Page 139: ...FU H4SO 11 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 5 FUEL LINE FU 00516 12 11 1 1 1 7 1 1 9 10 10 1 6 5 4 3 2 1 1 8 24 24 18 23 13 14 1 1 21 20 25 22 19 17 16 15 C B B A C A T...

Page 140: ...hose A 23 Two way valve drain hose B 4 Fuel filter holder 14 Canister 24 Clamp 5 Fuel filter cup 15 Canister bracket plate 25 Front canister bracket 6 Fuel filter 16 Cushion 7 Evaporation hose 17 Cani...

Page 141: ...e ASSY 6 Air vent pipe 11 Filler cap tether 2 Evaporation hose holder 7 Air vent pipe holder 12 Filler pipe protector 3 Clip 8 Filler pipe packing 4 Clamp 9 Filler ring Tightening torque N m kgf m ft...

Page 142: ...the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical...

Page 143: ...Disconnect the air by pass hose from throttle body 1 6 L model 7 Disconnect the engine coolant hoses A from throttle body 8 Remove the bolts B which install the throttle body to intake manifold B INS...

Page 144: ...connect the cruise control cable B With cruise control model 7 Remove the power steering pump and reservoir tank from bracket 1 Remove the resonator chamber Ref to IN H4SO 7 REMOVAL Resonator Chamber...

Page 145: ...throttle body 11 Disconnect the brake booster hose 12 Remove the air cleaner case stay RH and en gine harness bracket and then disconnect the en gine harness connectors from the bulkhead harness conn...

Page 146: ...m fuel pipes WARNING Do not spill fuel Catch fuel from hoses in a container or cloth 20 Remove the bolts which hold the intake mani fold onto cylinder heads 21 Remove the intake manifold B INSTALLATIO...

Page 147: ...o the oil pressure switch 6 Connect the connector to the crankshaft position sensor 7 Connect the knock sensor connector 8 Connect the connectors to the engine coolant temperature sensor 9 Install the...

Page 148: ...e connector to the power steering pump switch 3 Tighten the bolts which install the power steering pump bracket Tightening torque 22 N m 2 2 kgf m 15 9 ft lb 4 Install the power steering pipes onto th...

Page 149: ...1 Disconnect the engine ground terminal from in take manifold 2 Disconnect the ignition coil and ignitor assembly Ref to IG H4SO 8 REMOVAL Ignition Coil Ig nitor ASSY 3 Remove the throttle body Ref to...

Page 150: ...noid Valve 11 Remove the harness bands A and bolts B which hold the engine harness onto intake mani fold 12 Remove the engine harness from the intake manifold 13 Remove the bolt which installs the fue...

Page 151: ...Loosen the clamp which holds the fuel injector pipe LH to fuel hose and then remove the pipe from fuel hose 18 Loosen the clamp which holds the fuel injector pipe RH to fuel hose and then remove the p...

Page 152: ...3 7 ft lb 3 Connect the fuel injector pipe RH to fuel hose and then tighten the clamp screw 4 Connect the fuel injector pipe LH to fuel hose and then tighten the clamp screw 5 Connect the air by pass...

Page 153: ...9 kgf m 13 7 ft lb RH SIDE LH SIDE 8 Tighten the two bolts which install the fuel pipes on intake manifold Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb 1 6 L MODEL 2 0 L MODEL 9 Install the engine...

Page 154: ...injector solenoid valve 1 6 L model Ref to FU H4SO 37 INSTALLATION Air Assist Injector Solenoid Valve 17 Install the EGR valve Ref to FU H4SO 36 INSTALLATION EGR Valve 18 Install the throttle body to...

Page 155: ...he air intake duct and air cleaner case Ref to IN H4SO 6 REMOVAL Air Intake Duct and Ref to IN H4SO 5 REMOVAL Air Cleaner Case 3 Disconnect the connector from the engine cool ant temperature sensor 4...

Page 156: ...ery 2 Remove the bolt which installs the crankshaft position sensor to cylinder block 3 Remove the crankshaft position sensor and then disconnect the connector from it B INSTALLATION Install in the re...

Page 157: ...nsor to the camshaft position sensor sup port 4 Remove the bolt which installs the camshaft po sition sensor support to the camshaft cap LH 5 Remove the camshaft position sensor and cam shaft position...

Page 158: ...he knock sensor to cylinder block Tightening torque 24 N m 2 4 kgf m 17 4 ft lb NOTE For tightening torque refer to COMPONENT Ref to FU H4SO 3 COMPONENT General De scription The extraction area of the...

Page 159: ...T General De scription CAUTION When installing the throttle position sensor ad just to specified data C ADJUSTMENT 1 Turn the ignition switch to OFF 2 Loosen the throttle position sensor holding screw...

Page 160: ...the data link connector 5 Turn the ignition switch to ON and the Subaru Select Monitor switch to ON 6 Select the 2 Each System Check in Main Menu 7 Select the Engine Control System in Selec tion Menu...

Page 161: ...e from battery 2 Disconnect the connector from manifold abso lute pressure sensor 3 Remove the manifold absolute pressure sensor B INSTALLATION Install in the reverse order of removal NOTE For tighten...

Page 162: ...Temperature Sen sor A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the connector from the intake air temperature sensor 3 Remove the intake air temperature sensor from the air clea...

Page 163: ...battery 2 Disconnect the connector from the idle air con trol solenoid valve 3 Remove the idle air control solenoid valve from throttle body B INSTALLATION Install in the reverse order of removal NOTE...

Page 164: ...ground cable from battery 2 Disconnect the connector from EGR valve 3 Remove the EGR valve from intake manifold B INSTALLATION Install in the reverse order of removal NOTE For tightening torque refer...

Page 165: ...nect the ground cable from battery 2 Disconnect the connector A from the air assist injector solenoid valve and then disconnect the air by pass hoses B 3 Remove the air assist injector solenoid valve...

Page 166: ...hamber Ref to IN H4SO 7 REMOVAL Resonator Chamber 5 Remove the spark plug cords from spark plugs 1 and 3 cylinders 6 Remove the power steering pump and tank from brackets 1 Remove the front side V bel...

Page 167: ...apron 7 Remove the fuel pipe protector RH 8 Disconnect the connector from fuel injector 9 Remove the bolts which hold the fuel injector pipe to intake manifold 10 Remove the fuel injector from intake...

Page 168: ...y 5 Disconnect the connector from the front window washer motor 6 Disconnect the connector from the rear gate glass washer motor 7 Disconnect the rear window glass washer hose from washer motor and th...

Page 169: ...MODEL 14 Remove the fuel injector from intake manifold 1 Remove the fuel injector securing clip 2 Remove the fuel injector while lifting up the fuel injector pipe B INSTALLATION 1 RH SIDE Install in...

Page 170: ...19 N m 1 9 kgf m 13 7 ft lb Tightening torque 33 N m 3 4 kgf m 24 3 ft lb 2 LH SIDE Install in the reverse order of removal NOTE Replace O rings with new ones Tightening torque 5 0 N m 0 51 kgf m 3 7...

Page 171: ...FU H4SO 43 FUEL INJECTION FUEL SYSTEMS FUEL INJECTOR Tightening torque 19 N m 1 9 kgf m 13 7 ft lb Tightening torque 19 N m 1 9 kgf m 13 7 ft lb FU 00309 FU 00266...

Page 172: ...ON When removing the oxygen A F sensor wait until the exhaust pipe cools otherwise it will damage the exhaust pipe B INSTALLATION 1 Before installing the front oxygen A F sensor apply anti seize compo...

Page 173: ...FU H4SO 45 FUEL INJECTION FUEL SYSTEMS FRONT OXYGEN A F SENSOR 5 Connect the battery ground cable to battery FU 00009...

Page 174: ...en removing the oxygen sensor wait until the exhaust pipe cools otherwise it will dam age the exhaust pipe B INSTALLATION 1 Before installing the rear oxygen sensor apply the anti seize compound only...

Page 175: ...FU H4SO 47 FUEL INJECTION FUEL SYSTEMS REAR OXYGEN SENSOR 5 Connect the battery ground cable to battery FU 00009...

Page 176: ...e floor mat of front passenger seat 4 Remove the protect cover 5 Remove the nuts A which hold ECM to bracket 6 Remove the clip B from bracket 7 Disconnect the ECM connectors and take out the ECM B INS...

Page 177: ...AL 1 Disconnect the ground cable from battery 2 Remove the passenger s side front side sill cov er 3 Remove the bolt which holds the main bracket on body 4 Disconnect the connectors from main relay B...

Page 178: ...d cable from battery 2 Remove the passenger s side front side sill cov er 3 Remove the bolt which holds the fuel pump relay bracket on body 4 Disconnect the connector from fuel pump 5 Remove the fuel...

Page 179: ...c onds 4 Turn the ignition switch to OFF 2 DRAINING FUEL WARNING Place NO FIRE signs near working area Be careful not to spill fuel 1 Set the vehicle on a lift 2 Disconnect the ground cable from batte...

Page 180: ...l into under the body 7 Remove the rear crossmember Ref to RS 21 REMOVAL Rear Crossmember 8 Disconnect the two way valve hose A from two way valve and then disconnect the canister hose B from canister...

Page 181: ...canister hose B to canister 4 Connect the fuel filler hose and air vent hose 5 Connect the fuel hoses and then secure them with clips and quick connector Ref to FU H4SO 66 INSTALLATION Fuel Delivery...

Page 182: ...UEL TANK 10 Connect the connector to fuel pump relay C INSPECTION 1 Make sure there are no cracks holes or other damage on fuel tank 2 Make sure the fuel hoses and fuel pipes are not cracked and the c...

Page 183: ...t the ground cable from battery 5 Remove the screws holding packing in place 6 Loosen the rear wheel nuts RH 7 Lift up the vehicle 8 Remove the rear wheel RH 9 Drain fuel from the fuel tank Set a cont...

Page 184: ...pipe to the under side of vehicle 18 Remove the air vent pipe together with clip from body B INSTALLATION 1 Hold the fuel filler flap open 2 Set the fuel saucer A with rubber packing C and then inser...

Page 185: ...the air vent hose approx 25 to 30 mm 0 98 to 1 18 in into the lower end of air vent pipe and then hold the clip L 27 5 2 5 mm 1 083 0 098 in 8 Tighten the bolt which holds the fuel filler pipe bracket...

Page 186: ...O 58 FUEL INJECTION FUEL SYSTEMS FUEL FILLER PIPE 12 Lower the vehicle 13 Tighten the wheel nuts 14 Connect the connector to fuel pump relay 15 Connect the battery ground cable to battery FU 00262 FU...

Page 187: ...Set a container un der the vehicle and then remove the drain plug from fuel tank 6 Tighten the fuel drain plug Tightening torque 26 N m 2 7 kgf m 19 2 ft lb 7 Raise the rear seat and then turn the flo...

Page 188: ...ical sequence as shown in the figure Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb C INSPECTION Connect the lead harness to connector terminal of fuel pump and then apply the battery power supply to...

Page 189: ...not to spill fuel NOTE Fuel level sensor is built in the fuel pump assembly 1 Remove the fuel pump assembly Ref to FU H4SO 59 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et 3 Re...

Page 190: ...rom holder B INSTALLATION CAUTION If the fuel hoses are damaged at connecting portion replace them with new ones If clamps are badly damaged replace them with new ones 1 Install in the reverse order o...

Page 191: ...ll fuel 1 Remove the fuel tank Ref to FU H4SO 52 REMOVAL Fuel Tank 2 Move the clip and disconnect the evaporation hose from fuel cut valve 3 Remove the bolts which install the fuel cut valve B INSTALL...

Page 192: ...R VALVE 27 Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H4SO 51 RELEASING OF FUEL PRESSURE OPERA TION Fuel 2 Remove the fuel damper valve from the fuel re turn line B INSTALLATION...

Page 193: ...filler flap lid and then remove the fuel filler cap 4 Remove the floor mat Ref to EI 55 REMOVAL Floor Mat 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation pipes and...

Page 194: ...retainer B B INSTALLATION 1 Connect the quick connector on fuel delivery line NOTE Replace the retainer with a new one Make sure that the connected portion is not dam aged or has dust If necessary cl...

Page 195: ...ecified Type B When the fitting length is not specified 2 2 5 1 5 mm 0 098 0 059 in L 22 5 2 5 mm 0 886 0 098 in 3 Connect the evaporation hose to pipe by approx 15 to 20 mm 0 59 to 0 79 in from the h...

Page 196: ...ible cause Corrective action 1 Insufficient fuel supply to the injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Trouble in el...

Page 197: ...ONTROL AUX EMISSION CONTROL DEVICES EC H4SO Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 4 4 EGR Valve 5 5 Canister 6 6 Purge Control Solenoid Valve 7 7 Two wa...

Page 198: ...in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful n...

Page 199: ...he same as those for center exhaust pipe Ref to EX H4SO 9 REMOVAL Center Exhaust Pipe B INSTALLATION The front and rear catalytic converter and center exhaust pipe are integrated into one unit There f...

Page 200: ...e same as those for center exhaust pipe Ref to EX H4SO 9 REMOVAL Center Exhaust Pipe B INSTALLATION The front and rear catalytic converter and center exhaust pipe are integrated into one unit There fo...

Page 201: ...EC H4SO 5 EMISSION CONTROL AUX EMISSION CONTROL DEVICES EGR VALVE 4 EGR Valve A PROCEDURE For EGR valve removal and installation proce dures refer to FU section Ref to FU H4SO 36 EGR Valve...

Page 202: ...ich hold the two can ister hoses and then disconnect the three evapo ration hoses from canister 3 Remove the canister from body B INSTALLATION Install in the reverse order of removal Tightening torque...

Page 203: ...tor and hoses from the purge control solenoid valve and then remove the purge control solenoid valve B INSTALLATION 1 Install in the reverse order of removal Tightening torque 19 N m 1 9 kgf m 13 7 ft...

Page 204: ...vehicle 2 Remove the canister from body Ref to EC H4SO 6 REMOVAL Canister 3 Remove the two way valve with bracket as a sin gle unit from body 4 Remove the two way valve from bracket B INSTALLATION In...

Page 205: ...INTAKE INDUCTION IN H4SO Page 1 General Description 2 2 Air Cleaner Element 4 3 Air Cleaner Case 5 4 Air Intake Duct 6 5 Resonator Chamber 7...

Page 206: ...IN H4SO 2 INTAKE INDUCTION GENERAL DESCRIPTION 1 General Description A COMPONENT IN 00178 T2 T2 T4 T4 T4 T5 19 19 20 20 18 15 11 11 11 17 16 9 12 10 13 14 3 4 T1 T1 2 1 2 1 T3 5 6 21 T3 8 7 21...

Page 207: ...hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of...

Page 208: ...an er case to stay 3 Remove the clip B above the air cleaner case 4 Remove the air cleaner element B INSTALLATION Install in the reverse order of removal NOTE Fasten with a clip after inserting the lo...

Page 209: ...aner case to the stay 4 Disconnect the hoses and intake duct from the air cleaner case 5 Loosen the clamp which connects the air cleaner case to throttle body 6 Remove the air cleaner case B INSTALLAT...

Page 210: ...the resonator chamber and air cleaner case 1 6 L and 2 0 L 2 5 L B INSTALLATION Install in the reverse order of removal NOTE Refer to COMPONENT for tightening torque Ref to IN H4SO 2 COMPONENT Genera...

Page 211: ...take duct Ref to IN H4SO 6 REMOVAL Air Intake Duct 2 Remove the resonator chamber B INSTALLATION Install in the reverse order of removal NOTE Refer to COMPONENT for tightening torque Ref to IN H4SO 2...

Page 212: ...IN H4SO 8 INTAKE INDUCTION RESONATOR CHAMBER...

Page 213: ...Valve Clearance 32 9 Engine Assembly 35 10 Engine Mounting 42 11 Preparation for Overhaul 43 12 V belt 44 13 Crankshaft Pulley 47 14 Timing Belt Cover 49 15 Timing Belt Assembly 50 16 Camshaft Sprock...

Page 214: ...42 BBDC 48 BBDC 50 BBDC Closing 10 ATDC 4 ATDC 6 ATDC Valve clearance Intake mm in 0 20 0 02 0 0079 0 0008 Exhaust mm in 0 25 0 02 0 0098 0 0008 Idling speed At neutral position on MT or P or N positi...

Page 215: ...ead Surface warpage limit 0 05 mm 0 0020 in Surface grinding limit 0 1 mm 0 004 in Standard height 97 5 mm 3 84 in Valve seat Refacing angle 90 Contacting width Intake STD 1 0 mm 0 039 in Limit 1 7 mm...

Page 216: ...mm 3 6214 3 6218 in B 91 975 91 985 mm 3 6211 3 6214 in 0 25 mm 0 0098 in OS 92 225 92 235 mm 3 6309 3 6313 in 0 50 mm 0 0197 in OS 92 475 92 485 mm 3 6407 3 6411 in 2 5 L STD A 99 485 99 495 mm 3 916...

Page 217: ...0020 in Thickness at center portion 1 6 L 2 0 L STD 1 492 1 501 mm 0 0587 0 0591 in 0 03 mm 0 0012 in US 1 510 1 513 mm 0 0594 0 0596 in 0 05 mm 0 0020 in US 1 520 1 523 mm 0 0598 0 0600 in 0 25 mm 0...

Page 218: ...ournal outer diameter 1 3 STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 3607 2 3613 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 74...

Page 219: ...in US 2 017 2 020 mm 0 0794 0 0795 in 0 05 mm 0 0020 in US 2 027 2 030 mm 0 0798 0 0799 in 0 25 mm 0 0098 in US 2 127 2 130 mm 0 0837 0 0839 in 2 4 5 STD 2 000 2 013 mm 0 0787 0 0793 in 0 03 mm 0 0012...

Page 220: ...7 2 4 Timing belt cover No 2 LH 13 Front timing belt cover T3 25 2 5 18 1 5 Camshaft sprocket No 1 14 Timing belt cover LH T4 39 4 0 28 9 6 Belt idler No 1 15 Crankshaft pulley 1 6 L and 2 0 L model T...

Page 221: ...xhaust valve rocker ASSY 13 Camshaft cap LH 4 Camshaft cap RH 14 Oil filler cap 5 Oil seal 15 Gasket T2 5 0 5 3 6 6 Camshaft RH 16 Oil filler duct T3 10 1 0 7 2 7 Plug 17 O ring T4 18 1 8 13 0 8 Spark...

Page 222: ...shaft support Tightening torque N m kgf m ft lb 2 Valve rocker nut 6 Intake rocker shaft T1 5 0 5 3 6 3 Valve rocker adjust screw 7 Exhaust rocker shaft T2 10 1 0 7 2 4 Spring 8 Exhaust valve rocker a...

Page 223: ...PTION 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 0...

Page 224: ...T5 Ref to ME H4SO 76 INSTALLATION Cylinder Block 7 Oil pump 20 Metal gasket 8 Front oil seal 21 Oil level gauge guide 9 Rear oil seal 22 Water pump sealing T6 70 7 1 50 6 10 O ring 23 Oil filter T7 Fi...

Page 225: ...ME H4SO 13 MECHANICAL GENERAL DESCRIPTION 6 CRANKSHAFT AND PISTON ME 00190 T1 T1 9 1 16 17 16 17 6 5 4 3 2 12 11 10 7 9 9 8 6 5 4 15 18 9 8 10 12 11 7 13 12 14 T2 T2...

Page 226: ...odel 10 Connecting rod bolt 18 Crankshaft bearing 5 3 Drive plate AT model 11 Connecting rod 4 Top ring 12 Connecting rod bearing Tightening torque N m kgf m ft lb 5 Second ring 13 Connecting rod cap...

Page 227: ...CHANICAL GENERAL DESCRIPTION 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 63 ME 00413 T2 T1 T1 T3...

Page 228: ...r to assembly Be careful not to let oil grease or coolant contact the timing belt clutch disc and flywheel All removed parts if to be reused should be re installed in the original positions and direct...

Page 229: ...ithout printer Spanish 22771AA090 Without printer 498267800 CYLINDER HEAD TABLE Used for replacing valve guides Used for removing and installing valve springs 498277200 STOPPER SET Used for installing...

Page 230: ...sed for stopping rotation of flywheel when loos ening and tightening crankshaft pulley bolt etc 498547000 OIL FILTER WRENCH Used for removing and installing oil filter 498747000 PISTON GUIDE Used for...

Page 231: ...IDE Used for installing piston in cylinder 2 5 L model 498857100 VALVE OIL SEAL GUIDE Used for press fitting of intake and exhaust valve guide oil seals 499017100 PISTON PIN GUIDE Used for installing...

Page 232: ...sed for removing flywheel Dual mass flywheel 499587200 CRANKSHAFT OIL SEAL INSTALLER Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL GUIDE 499597100 499587500 OIL SEAL INSTALLER...

Page 233: ...499097700 PISTON PIN REMOVER ASSY Used for removing piston pin 499207400 CAMSHAFT SPROCKET WRENCH Used for removing and installing camshaft sprocket RH side 499497000 TORX PLUS Used for removing and i...

Page 234: ...ft oil seal Used with CAMSHAFT OIL SEAL INSTALLER 499587500 499597100 CRANKSHAFT OIL SEAL GUIDE Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL INSTALLER 499587200 499718000 VALV...

Page 235: ...9767400 VALVE GUIDE REAMER Used for reaming valve guides 499767700 VALVE GUIDE ADJUSTER Used for installing valve guide Intake side 499767800 VALVE GUIDE ADJUSTER Used for installing valve guide Exhau...

Page 236: ...opping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts 1 6 L and 2 0 L model 499977100 CRANKSHAFT PULLEY WRENCH Used for stopping rotation of crankshaft pulley when...

Page 237: ...ition that the engine is removed from the vehi cle V belt Timing Belt Valve Rocker Assembly Camshaft Cylinder Head 499897200 PISTON CIR CLIP PLIERS Used for removing and installing piston pin circlip...

Page 238: ...ully open the throttle valve 6 Check the starter motor for satisfactory perfor mance and operation 7 Hold the compression gauge tight against spark plug hole NOTE When using a screw in type compressio...

Page 239: ...peed 5 When using the tachometer Secondary pick up type 1 Attach the pick up clip to No 1 cylinder spark plug cord 2 Start the engine and then read the engine idle speed NOTE When using the OBD II gen...

Page 240: ...t to 1 cylinder spark plug cord and illuminate the timing mark with timing light 3 Start the engine at idle speed and check the ig nition timing Ignition timing BTDC rpm 1 6 L model With OBD 5 10 650...

Page 241: ...ut lower than normal position This ten dency becomes more evident as engine temperature rises Leakage around intake manifold gasket or disconnection or damaged vacuum hose 2 When engine speed is reduc...

Page 242: ...at 5 000 rpm CAUTION If the oil pressure is out of specification check the oil pump oil filter and lubrication line Ref to LU H4SO 20 INSPECTION En gine Lubrication System Trouble in General If the o...

Page 243: ...e fuel delivery hoses from fuel damper and then connect the fuel pressure gauge 4 Connect the connector of fuel pump relay 5 Start the engine 6 Measure the fuel pressure while disconnecting the pressu...

Page 244: ...H4SO 5 LH SIDE REMOVAL Spark Plug 2 Disconnect the PCV hose from rocker cover LH 3 Remove the bolts and then remove the rocker cover LH 9 Set the 1 cylinder piston to top dead center of compression st...

Page 245: ...r formed while engine is cold 1 Set the 1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise using socket wrench NOTE When arrow mark A on the camshaft sp...

Page 246: ...valve clearanc es 6 Similar to adjustment procedures used for 1 cylinder adjust the 2 3 and 4 cylinder valve clearances NOTE Be sure to set the cylinder pistons to their re spective top dead centers...

Page 247: ...the fuel filler cap 6 Disconnect the ground cable from battery 7 Remove the air intake duct and air cleaner case Ref to IN H4SO 6 REMOVAL Air Intake Duct and Ref to IN H4SO 5 REMOVAL Air Cleaner Case...

Page 248: ...nnector 6 Accelerator cable A and cruise control ca ble B Model with cruise control 7 Power steering switch connector 13 Disconnect the following hoses 1 Brake booster vacuum hose 2 Heater inlet outle...

Page 249: ...move the bolts which install the power steering pump bracket 5 Remove the power steering tank from bracket by pulling it upward 6 Place the power steering pump on right side wheel apron 15 Remove the...

Page 250: ...prevent fuel from splashing Catch fuel from the hose into container 21 Support the engine with a lifting device and wire ropes 22 Support the transmission with a garage jack CAUTION Before moving the...

Page 251: ...etc 26 Remove the front cushion rubbers B INSTALLATION 1 Install the front cushion rubbers Tightening torque 34 N m 3 5 kgf m 25 3 ft lb 2 Install the engine onto transmission 1 Position the engine in...

Page 252: ...on verter clutch to drive plate 2 Tighten other bolts while rotating the engine by using a socket wrench NOTE Be careful not to drop the bolts into torque convert er clutch housing Tightening torque 2...

Page 253: ...ctors 16 Connect the following cables 1 Accelerator cable 2 Cruise control cable Model with cruise con trol 17 Adjust each connected cable 18 Install the air cleaner case stay Tightening torque 16 N m...

Page 254: ...gine assembly Ref to ME H4SO 35 REMOVAL Engine Assembly 2 Remove the engine mounting from engine as sembly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 35 N...

Page 255: ...ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order It will be the complete procedure for overhauling of the engine itself when you go throug...

Page 256: ...tain the specified belt tension Ref to ME H4SO 45 INSPECTION V belt 2 Tighten the lock bolt A 3 Tighten the slider bolt B Tightening torque Lock bolt A 25 N m 2 5 kgf m 18 1 ft lb Slider bolt B 8 N m...

Page 257: ...nd then check the belt tension is within specified value With using tension gauge 8 Adjust the belt tension until the value within specification With using tension gauge C INSPECTION 1 PROCEDURES WITH...

Page 258: ...using belt tension gauge and adjust it if necessary by changing the generator installing position and or idler pulley in stalling position Belt tension A 490 640 N 50 0 65 3 kgf 110 2 143 9 lb B 350 4...

Page 259: ...kshaft pulley bolts Tightening torque 127 N m 13 0 kgf m 94 0 ft lb 3 Confirm that the tightening angle of crankshaft pulley bolt is 45 degrees or more If the tightening angle of crankshaft pulley bol...

Page 260: ...grees conduct the following procedures 1 Replace the crankshaft pulley bolts and clean them Crankshaft pulley bolt 12369AA011 2 Clean the crankshaft thread using an air gun 3 Apply engine oil to the c...

Page 261: ...ATION 1 Install the front timing belt cover Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 2 Install the timing belt cover LH Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 3 Install the crankshaft pulley R...

Page 262: ...ew marks before removing the tim ing belt as shown in procedures below 1 Turn the crankshaft using ST Align the mark a of sprocket to cylinder block notch b and ensure the right side cam sprocket mark...

Page 263: ...ually tak ing more than 3 minutes Do not allow press pressure to exceed 9 807 N 1 000 kgf 2 205 lb Press the adjuster rod as far as the end sur face of cylinder Do not press the adjuster rod into the...

Page 264: ...LER INSTALLATION Timing Belt Assembly 2 Installation of timing belt 1 Turn the camshaft sprocket No 2 using ST1 and then turn the camshaft sprocket No 1 using ST2 so that their alignment marks A come...

Page 265: ...ming belt guide mounting bolts 2 Check and adjust the clearance between timing belt and timing belt guide by using thick ness gauge Clearance 1 0 0 5 mm 0 039 0 020 in 3 Tighten the timing belt guide...

Page 266: ...3 If the adjuster rod is not stiff and moves down replace the automatic belt tension adjust er assembly with a new one CAUTION Always use a vertical type pressing tool to move the adjuster rod down Do...

Page 267: ...N 1 Install the camshaft sprocket No 1 To lock the camshaft use ST ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque 78 N m 8 0 kgf m 57 9 ft lb NOTE Do not confuse the right and left side camsh...

Page 268: ...f to ME H4SO 44 IN STALLATION V belt C INSPECTION 1 Check the sprocket teeth for abnormal wear and scratches 2 Make sure there is no free play between sprock et and key 3 Check the camshaft sprocket n...

Page 269: ...ATION 1 Install the crankshaft sprocket 2 Install the camshaft sprocket Ref to ME H4SO 55 INSTALLATION Camshaft Sprocket 3 Install the timing belt assembly Ref to ME H4SO 51 INSTALLATION Timing Belt A...

Page 270: ...er assembly to gouge knock pins 2 Tighten the bolts e through h to specified torque 3 Tighten the bolts a through d to specified torque Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 2 Adjust the valve...

Page 271: ...CKER SHAFT 1 Measure the inside diameter of valve rocker arm and outside diameter of valve rocker shaft and de termine the difference between the two oil clear ance Clearance between arm and shaft Sta...

Page 272: ...e the timing belt cover No 2 RH NOTE Do not damage or lose the seal rubber when re moving the timing belt covers 9 Remove the tensioner bracket 10 Remove the camshaft position sensor support LH side o...

Page 273: ...REE BOND 1280B Part No K0877YA018 NOTE Apply a coat of 3 mm 0 12 in dia A liquid gasket along edge B of the camshaft cap C mating sur face 2 Temporarily tighten the bolts g through j in alphabetical s...

Page 274: ...8 Install the camshaft position sensor support LH side only 9 Install the tensioner bracket Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 10 Install the timing belt cover No 2 RH Tightening torque 5...

Page 275: ...34 00 mm 1 3386 in 2 CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial gauge If the clearance exceeds the limit replace the camshaft support Standard 0 030 0 090 mm 0 0012 0 0035 in...

Page 276: ...head from falling 11 While tapping the cylinder head with a plastic hammer separate it from cylinder block 12 Remove the bolts a and c to remove cylinder head 13 Remove the cylinder head gasket CAUTIO...

Page 277: ...rocket Ref to ME H4SO 55 INSTALLATION Camshaft Sprocket 8 Install the timing belt assembly Ref to ME H4SO 51 INSTALLATION Timing Belt As sembly 9 Install the timing belt cover Ref to ME H4SO 49 INSTAL...

Page 278: ...se spe cial care not to damage the oil seal lip 3 Install the valve spring and retainer NOTE Be sure to install the valve springs with their close coiled end facing the seat on the cylinder head 4 Set...

Page 279: ...in take valve and valve seat are reconditioned or in take valve guide is replaced Use pliers to pinch and remove oil seal from valve 1 Place the cylinder head on ST1 2 Press fit oil seal using ST2 CA...

Page 280: ...0 05 mm 0 0020 in re grind the surface with a surface grinder Warping limit 0 05 mm 0 0020 in Grinding limit 0 1 mm 0 004 in Standard height of cylinder head 97 5 mm 3 839 in NOTE Uneven torque for th...

Page 281: ...placement Valve guide inner diameter 6 000 6 012 mm 0 2362 0 2367 in Valve stem outer diameters Intake 5 950 5 965 mm 0 2343 0 2348 in Exhaust 5 945 5 960 mm 0 2341 0 2346 in 1 Place the cylinder head...

Page 282: ...669 in 7 Ream the inside of valve guide with ST Gently rotate the reamer clockwise while press ing it lightly into valve guide and return it also ro tating clockwise After reaming clean the valve guid...

Page 283: ...ke Standard 1 0 mm 0 039 in Limit 0 6 mm 0 024 in Exhaust Standard 1 2 mm 0 047 in Limit 0 6 mm 0 024 in Valve overall length Intake 120 6 mm 4 75 in Exhaust 121 7 mm 4 79 in 2 Put a small amount of g...

Page 284: ...to ME H4SO 47 REMOVAL Crankshaft Pulley 8 Remove the generator and A C compressor with their brackets 9 Remove the rocker cover 10 Remove the cylinder head bolts in alphabetical sequence shown in the...

Page 285: ...l not to scratch the mating surface of cylinder block and oil pump 21 Removal of oil pan 1 Turn the cylinder block to face the 2 and 4 piston sides upward 2 Remove the bolts which secure the oil pan t...

Page 286: ...Rotate the crankshaft to bring 1 and 2 pis tons to bottom dead center position and then re move the piston circlip through service hole of 1 and 2 cylinders ST 499897200 PISTON CIRCLIP PLIER 1 Service...

Page 287: ...upper side and then remove the cylinder block connecting bolts 34 Separate the cylinder blocks RH and LH NOTE When separating the cylinder block do not allow the connecting rod to fall and damage the...

Page 288: ...the crankshaft on 2 and 4 cylinder block 2 Apply fluid packing to the mating surface of 1 and 3 cylinder block and position it on 2 and 4 cylinder block Fluid packing Part No 004403007 THREE BOND 1215...

Page 289: ...olts A D to 90 in alphabetical sequence 6 Further tighten the RH side bolts E J to 90 in alphabetical sequence 7 Tighten the 8 mm and 6 mm cylinder block con necting bolts in alphabetical sequence sho...

Page 290: ...3 Position the upper rail gap at G in the figure CAUTION Ensure ring gaps do not face the same direc tion Ensure ring gaps are not within the piston skirt area 14 Install the circlip Install circlips...

Page 291: ...odel ST2 498747300 PISTON GUIDE 2 5 L model 16 Installing piston pin 1 Apply a coat of engine oil to the ST3 before insertion 2 Insert the ST3 into service hole to align pis ton pin hole with connecti...

Page 292: ...t NOTE Use a new gasket 7 Turn the cylinder block to face the 3 and 4 piston side upward Using the same procedures as used for 1 and 2 cylinders install the pis tons and piston pins ME 00160 ME 00140...

Page 293: ...THREE BOND 1215 or equivalent 22 Apply fluid packing to the matching surfaces and then install the oil separator cover Fluid packing Part No 004403007 THREE BOND 1215 or equivalent 23 Install the fly...

Page 294: ...que First 12 N m 1 2 kgf m 8 7 ft lb Second 12 N m 1 2 kgf m 8 7 ft lb CAUTION Be sure to use a new gasket When installing the water pump tighten the bolts in two stages in alphabetical sequence as sh...

Page 295: ...Install the crankshaft pulley Ref to ME H4SO 47 INSTALLATION Crankshaft Pul ley 37 Install the generator and A C compressor brackets on cylinder head 38 Install the V belt Ref to ME H4SO 44 IN STALLAT...

Page 296: ...ply oil on the threads 5 Install the expander lower rail and upper rail in this order by hand Then install the second ring and top ring using piston ring expander E INSPECTION 1 CYLINDER BLOCK 1 Visua...

Page 297: ...cyl inder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure using a cylinder bore gauge NOTE Measurement should be performed a...

Page 298: ...tempera ture of 20 C 68 F Cylinder to piston clearance at 20 C 68 F Standard 0 010 0 030 mm 0 0004 0 0012 in Limit 0 050 mm 0 0020 in 6 Boring and honing 1 If the value of taper out of roundness or c...

Page 299: ...ton pin circlip for distortion cracks and wear 4 PISTON RING 1 If the piston ring is broken damaged or worn or if its tension is insufficient or when the piston is re placed replace the piston ring wi...

Page 300: ...n 3 Install the connecting rod fitted with bearing to crankshaft and then measure the side clearance thrust clearance Replace the connecting rod if the side clearance exceeds the specified limit Conne...

Page 301: ...Thickness at cen ter Outer diameter of crank pin Standard 1 492 1 501 0 0587 0 0591 47 984 48 000 1 8891 1 8898 0 03 0 0012 undersize 1 510 1 513 0 0594 0 0596 47 954 47 970 1 8879 1 8868 0 05 0 0020...

Page 302: ...and correct or re place if it exceeds the limit NOTE If a suitable V block is not available install the 1 and 5 crankshaft bearing on cylinder block posi tion the crankshaft on these bearings and mea...

Page 303: ...62 59 978 2 3607 2 3613 47 954 47 970 1 8879 1 8886 51 954 51 970 2 0454 2 0461 51 954 51 970 2 0454 2 0461 Bearing size Thickness at center 2 017 2 020 0 0794 0 0795 2 019 2 022 0 0795 0 0796 1 510 1...

Page 304: ...and relay A Lack of or insufficient fuel B Belt Defective B Defective timing B Compression Incorrect valve clearance C Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defect...

Page 305: ...ystem Ref to EN H4SO 2 Basic Diagnostic Procedure or Ref to EN H4SOw oOBD 2 Basic Diagnostic Procedure A Intake system Loosened or cracked intake duct A Loosened or cracked PCV hose A Loosened or crac...

Page 306: ...Lubrication system Incorrect oil pressure B Cooling system Overheating C Over cooling C Others Malfunction of evaporative emission control system A 4 Surging Engine control system Ref to EN H4SO 2 Ba...

Page 307: ...tive gasket C Loosened cylinder head bolts or defective gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn or stuck piston rings cylinder and piston C Incorrec...

Page 308: ...iming B Compression Incorrect valve clearance B Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defective gasket C Improper valve seating B Defective valve stem C Worn or br...

Page 309: ...ombustion chamber Wrong spark plug Improper gasoline Clank when engine speed is medium 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn cra...

Page 310: ...ME H4SO 98 MECHANICAL ENGINE NOISE...

Page 311: ...EXHAUST EX H4SO Page 1 General Description 2 2 Front Exhaust Pipe 6 3 Center Exhaust Pipe 9 4 Rear Exhaust Pipe 10 5 Muffler 12...

Page 312: ...T GENERAL DESCRIPTION 1 General Description A COMPONENT 1 1 6 L EX 00123 T7 T1 T6 T2 T2 T3 T6 T5 T5 T1 T2 T2 16 16 16 27 17 18 28 29 30 20 21 19 26 22 25 23 1 2 3 3 4 5 6 7 8 24 11 12 10 9 15 13 14 31...

Page 313: ...lower cover 30 Rear catalytic converter 6 Front exhaust pipe 20 Protector 31 Gasket 7 Front exhaust pipe lower cover RH 21 Gasket 8 Front exhaust pipe upper cover RH 22 Front oxygen A F sensor Tighten...

Page 314: ...EX H4SO 4 EXHAUST GENERAL DESCRIPTION 2 2 0 L EX 00124 T7 T1 T6 T2 T2 T3 T6 T5 T5 T1 T2 T2 16 16 16 28 18 19 29 30 31 21 22 20 27 23 26 24 1 2 3 3 4 5 6 7 8 25 11 17 10 9 15 13 14 T5 T2 12 12 T4 T4...

Page 315: ...sure to disconnect the ground cable from battery 1 Front exhaust pipe upper cover 16 Cushion rubber 29 Rear catalytic converter upper cover 2 Front exhaust pipe lower cover 17 Rear exhaust pipe 3 Cla...

Page 316: ...or connector 4 Lift up the vehicle 5 Separate the front and center exhaust pipe as sembly and rear exhaust pipe CAUTION Be careful the exhaust pipe is hot 1 6 L 2 0 L 6 Remove the under cover 7 Remove...

Page 317: ...to FU H4SO 44 RE MOVAL Front Oxygen A F Sensor and Ref to FU H4SO 46 REMOVAL Rear Oxygen Sen sor B INSTALLATION 1 Install the front oxygen A F sensor and the rear oxygen sensor Ref to FU H4SO 44 INST...

Page 318: ...lds the front and center exhaust pipe assembly to hanger bracket Tightening torque 35 N m 3 6 kgf m 26 0 ft lb 9 Lower the vehicle 10 Connect the rear oxygen sensor connector 11 Connect the front oxyg...

Page 319: ...the front exhaust pipe Ref to EX H4SO 6 REMOVAL Front Exhaust Pipe B INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit Refer to the procedure for install ing the front ex...

Page 320: ...ARU CRC to the mating area of cushion rubbers in advance SUBARU CRC Part No 004301003 4 Remove the rear exhaust pipe bracket from cushion rubber B INSTALLATION 1 Apply a coat of SUBARU CRC to the mati...

Page 321: ...center exhaust pipe Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 1 6 L 2 0 L C INSPECTION 1 Make sure there are no exhaust leaks from con nections and welds 2 Make sure there are no holes or rusting...

Page 322: ...04301003 3 Remove the front right and left cushion rubber and detach the muffler assembly B INSTALLATION 1 Install in the reverse order of removal NOTE Replace the gasket with a new one Tightening tor...

Page 323: ...System 7 3 Radiator Sub Fan System 10 4 Engine Coolant 14 5 Water Pump 16 6 Thermostat 19 7 Radiator 21 8 Radiator Cap 24 9 Radiator Main Fan and Fan Motor 25 10 Radiator Sub Fan and Fan Motor 26 11...

Page 324: ...charge pressure 6 000 rpm 225 4 kPa 23 0 mAq Engine coolant temperature 85 C 185 F Impeller diameter 76 mm 2 99 in Number of impeller vanes 8 Pump pulley diameter 60 mm 2 36 in Clearance between impel...

Page 325: ...ON B COMPONENT 1 WATER PUMP 1 Water pump ASSY 5 Gasket Tightening torque N m kgf m ft lb 2 Gasket 6 Thermostat cover T1 First 12 1 2 8 7 Second 12 1 2 8 7 3 Heater by pass hose 4 Thermostat T2 6 5 0 6...

Page 326: ...p 16 ATF hose clamp AT model T1 4 4 0 45 3 3 6 Radiator inlet hose 17 ATF inlet hose A AT model T2 12 1 2 8 7 7 Engine coolant reservoir tank cap 18 ATF outlet hose A AT model T3 18 1 8 13 0 8 Overflo...

Page 327: ...om dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because...

Page 328: ...ening and tightening crankshaft pulley bolts 1 6 L and 2 0 L model 499977100 CRANK PULLEY WRENCH Used for stopping rotation of crankshaft pul ley when loosening and tightening crank shaft pulley bolt...

Page 329: ...AN MOTOR 1 2 26 28 27 25 F17 2 1 B134 ECM F17 2 1 F16 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 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 330: ...ircuit in harness between main fan motor connector and chassis ground 3 CHECK POOR CONTACT Check poor contact in main fan motor connec tor Is there poor contact in main fan motor connector Repair the...

Page 331: ...tance of main fan relay Terminal No 26 No 25 Is the resistance less than 1 Go to step 12 Replace the main fan relay 12 CHECK HARNESS BETWEEN MAIN FAN RELAY TERMINAL AND MAIN FAN MOTOR CONNECTOR Measur...

Page 332: ...AN MOTOR 1 2 26 28 27 25 F17 2 1 B134 ECM F17 2 1 F16 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 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 333: ...d Is the voltage more than 10 V Go to step 2 Go to step 5 2 CHECK GROUND CIRCUIT OF SUB FAN MOTOR 1 Turn the ignition switch to OFF 2 Measure the resistance between sub fan motor connector and chassis...

Page 334: ...ness between sub fan relay and ignition switch 10 CHECK SUB FAN RELAY 1 Turn the ignition switch to OFF 2 Measure the resistance of sub fan relay Terminals No 17 No 18 Is the resistance more than 1 M...

Page 335: ...or between sub fan and ECM Is there poor contact in con nector between sub fan motor and ECM Repair the poor contact connector Verify the DTC Repair the trouble cause Ref to EN H4SO 38 Read Diagnostic...

Page 336: ...T model Approx 6 9 2 7 29 US qt 6 07 Imp qt 2 0 L and 2 5 L MT model Approx 7 0 2 7 4 US qt 6 2 Imp qt NOTE The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially made fo...

Page 337: ...entration must be in creased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read the scale on the vertic...

Page 338: ...L Timing Belt Assembly 4 Remove the automatic belt tension adjuster 5 Remove the belt idler No 2 6 Remove the camshaft sprocket LH by using ST ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE Also the CAMS...

Page 339: ...he camshaft sprockets LH by using ST ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE Also the CAMSHAFT SPROCKET WRENCH 499207100 can be used Tightening torque 78 N m 8 0 kgf m 57 9 ft lb 6 Install the bel...

Page 340: ...nout in thrust direction while rotating the pulley Thrust runout limit 0 5 mm 0 020 in 4 Check the clearance between impeller and pump case Clearance between impeller and pump case Standard 0 5 0 7 mm...

Page 341: ...6 Remove the thermostat cover and gasket and then pull out the thermostat B INSTALLATION 1 Install the thermostat in water pump and then in stall the thermostat cover together with a gasket NOTE When...

Page 342: ...ter temperature gradually and measure the temperature and valve lift when the valve be gins to open and when the valve is fully opened During the test agitate the water for even temper ature distribut...

Page 343: ...tor main fan motor A and sub fan motor B 7 Disconnect the radiator outlet hose from water pump 8 Disconnect the ATF cooler hoses from ATF pipe AT model Plug the openings in the hose and radiator with...

Page 344: ...e NOTE Fit the pins on lower side of radiator into the cush ions on the body side 3 Install the radiator upper brackets and then tighten the bolts Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 4 Attac...

Page 345: ...n Fluid C INSPECTION 1 Remove the radiator cap top off radiator and then attach the tester to radiator in place of cap 2 Apply a pressure of 157 kPa 1 6 kg cm2 23 psi to the radiator to check if 1 Eng...

Page 346: ...r stops Radiator cap is functioning properly if it holds the service limit pressure for 5 to 6 seconds Standard pressure 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Service limit pressure 83 kPa 0 85 kg cm2...

Page 347: ...ator main fan shroud to radiator 11 Remove the radiator fan motor assembly B INSTALLATION Install in the reverse order of removal NOTE If it is difficult to install the radiator main fan motor assembl...

Page 348: ...fan shroud to radiator 10 Remove the radiator sub fan motor assembly through the under side of vehicle B INSTALLATION Install in the reverse order of removal NOTE Refer to COMPONENT for tightening tor...

Page 349: ...low hose from the radiator filler neck position 2 Pressing the pawl A remove the reservoir tank by pulling in the direction indicated by the arrow B INSTALLATION Install in the reverse order of remova...

Page 350: ...Basic Diagnostic Proce dure k Excessive back pressure in exhaust system Clean or replace l Insufficient clearance between piston and cylinder Adjust or replace m Slipping clutch Repair or replace n Dr...

Page 351: ...U H4SO Page 1 General Description 2 2 Oil Pressure System 6 3 Engine Oil 8 4 Oil Pump 10 5 Oil Pan and Strainer 14 6 Oil Pressure Switch 18 7 Engine Oil Filter 19 8 Engine Lubrication System Trouble i...

Page 352: ...in Capacity at 80 C 176 F 600 rpm Discharge pressure 98 kPa 1 0 kg cm2 14 psi Discharge quantity 3 2 2 3 4 US qt 2 8 Imp qt min 5 000 rpm Discharge pressure 294 kPa 3 0 kg cm2 43 psi Discharge quantit...

Page 353: ...ng Tightening torque N m kgf m ft lb 6 Oil pump case 18 Baffle plate T1 5 0 5 3 6 7 Inner rotor 19 O ring T2 6 4 0 65 4 7 8 Outer rotor 20 Oil strainer T3 10 1 0 7 2 9 Oil pump cover 21 Oil level gaug...

Page 354: ...from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands becaus...

Page 355: ...ening and tightening crankshaft pulley bolt For 1 6 L and 2 0 L models 499977100 CRANKSHAFT PULLEY WRENCH Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulle...

Page 356: ...7 16 23 30 19 20 22 26 27 28 29 8 17 24 31 18 25 i2 B21 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 14 31 No 13 SBF 4 SBF 1 B72 1 4 B72 3 4 1 2 RHD LHD BATTERY IGNITION SWITCH COMBINATION METE...

Page 357: ...or from oil pressure switch 3 Turn the ignition switch to ON 4 Measure the voltage of harness between the oil pressure switch connector and chassis ground Connector terminal E11 No 1 Chassis ground Is...

Page 358: ...e engine oil 2 Lift up the vehicle 3 Drain the engine oil by loosening the engine oil drain plug NOTE Prepare the container for draining of engine oil 4 Tighten the engine oil drain plug after drainin...

Page 359: ...the vehicle is used in areas with very high temper atures or for other heavy duty applications the fol lowing viscosity oils may be used API classification SL or SJ or SH SAE Viscosity No 30 40 10W 50...

Page 360: ...position sensor 7 Remove the V belts Ref to ME H4SO 44 REMOVAL V belt 8 Remove the belt tensioner 9 Remove the crankshaft pulley by using ST ST 499977400 CRANKSHAFT PULLEY WRENCH 1 6 L and 2 0 L mode...

Page 361: ...f removal Do the following 1 Apply fluid packing to the matching surfaces of oil pump Fluid packing THREE BOND 1215 Part No 004403007 or equivalent 2 Replace the O ring A with a new one 3 Apply a coat...

Page 362: ...using ST ST 499587100 OIL SEAL INSTALLER NOTE Use a new oil seal 2 Apply a coat of engine oil to the inner and outer rotors 3 Install the inner and outer rotors in their original positions 4 Install...

Page 363: ...e oil pump inner rotor and pump cover If clearance exceeds the lim it replace the rotor or pump body Side clearance Standard 0 02 0 07 mm 0 0008 0 0028 in Limit 0 12 mm 0 0047 in 4 OIL RELIEF VALVE Ch...

Page 364: ...t the engine with a lifting device and wire ropes 9 Lift up the vehicle CAUTION When lifting up the vehicle rise up the wire rope together 10 Remove the under cover 11 Drain the engine oil Set a conta...

Page 365: ...TION Before installing the oil pan clean the sealant from oil pan and engine block 1 Install the baffle plate Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 2 Install the oil strainer onto baffle plat...

Page 366: ...NOTE Always use new gaskets 8 Install the under cover 9 Lower the vehicle CAUTION When lowering the vehicle lower the lifting de vice and wire rope together 10 Remove the lifting device and steel cab...

Page 367: ...RAINER 16 Connect the battery ground cable to battery 17 Fill engine oil Ref to LU H4SO 8 INSPEC TION Engine Oil C INSPECTION By visual check make sure the oil pan oil strainer oil strainer stay and b...

Page 368: ...king to the oil pressure switch threads Fluid packing THREE BOND 1324 Part No 004403007 or equivalent 2 Install the oil pressure switch onto engine block Tightening torque 25 N m 2 5 kgf m 18 1 ft lb...

Page 369: ...ter by turning it by hand being careful not to damage seal rubber 3 Tighten more approx 2 3 to 3 4 turn after the seal rubber contacts the oil pump case Do not tighten excessively or oil may leak C IN...

Page 370: ...of oil filter Clean or replace Malfunction of oil relief valve of oil pump Clean or replace Clogged oil passage Clean Excessive tip clearance and side clearance of oil pump rotor and gear Replace Clo...

Page 371: ...SPEED CONTROL SYSTEMS SP H4SO Page 1 General Description 2 2 Accelerator Pedal 4 3 Accelerator Control Cable 9...

Page 372: ...At pedal pad 52 57 mm 2 05 2 24 in 1 Accelerator bracket 7 Accelerator pedal lever 13 Kick down switch AT model 2 Stopper 8 Spring pin 3 Bushing 9 Accelerator pedal Tightening torque N m kgf m ft lb 4...

Page 373: ...d replacement Be careful not to burn your hands because each part in the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or...

Page 374: ...engine compartment LHD SOHC MODEL RHD SOHC MODEL LHD DOHC TURBO MODEL RHD DOHC TURBO MODEL 6 Remove the instrument panel lower cover from instrument panel 7 Disconnect the connector from kick down swi...

Page 375: ...ver 12 Disconnect the accelerator cable stopper A from bracket 13 Separate the accelerator cable and bracket B INSTALLATION 1 Install in the reverse order of removal NOTE If the cable clamp is damaged...

Page 376: ...apply grease to the portions indicated in the figure Grease SUNLIGHT No 2 Part No 003602010 A Accelerator bracket B Stopper C Bushing D Clip E Accelerator spring F Accelerator pedal spring G Accelera...

Page 377: ...erate properly or if it does not stop at the specified position re place with a new one Specified position A 2 0 3 5 mm 0 079 0 098 in F ADJUSTMENT 1 Check the pedal stroke and free play by operat ing...

Page 378: ...the stroke of accelera tor pedal If it is not within specified value adjust it by adjust ing the position of kick down switch CAUTION Be careful not to rotate the kick down switch Kick down switch str...

Page 379: ...the cable clamp is damaged replace it with a new one Never fail to cover the outer cable end with boot Be careful not to kink the accelerator cable Do not apply grease to except specified part 2 Apply...

Page 380: ...SP H4SO 10 SPEED CONTROL SYSTEMS ACCELERATOR CONTROL CABLE...

Page 381: ...IGNITION IG H4SO Page 1 General Description 2 2 Spark Plug 5 3 Ignition Coil Ignitor ASSY 8 4 Spark Plug Cord 10...

Page 382: ...2 0 L DIAMOND 2 5 L Primary coil resistance 1 6 L 0 7 10 2 0 L 0 73 10 2 5 L Secondary coil resistance 1 6 L 13 0 k 20 2 0 L 12 8 k 15 2 5 L Insulation resistance between primary terminal and case Mor...

Page 383: ...RAL DESCRIPTION B COMPONENT 1 1 6 L MODEL 1 Spark plug 4 Spark plug cord 2 4 Tightening torque N m kgf m ft lb 2 Spark plug cord 1 3 T1 6 4 0 65 4 7 3 Ignition coil ignitor ASSY T2 21 2 1 15 5 IG 0001...

Page 384: ...he failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running Be sure to tighten fasteners incl...

Page 385: ...the boot not cord itself 4 Remove the spark plugs using spark plug sock ets 2 LH SIDE 1 Disconnect the ground cable from battery 2 Disconnect the washer motor connector 3 Disconnect the rear window gl...

Page 386: ...e scription The above torque should be only applied to new spark plugs without oil on their threads In case their threads are lubricated the torque should be reduced by approx 1 3 of the specified tor...

Page 387: ...iming loose spark plugs wrong selection of fuel hotter range plug etc It is advisable to replace with plugs having colder heat range D CLEANING Clean the spark plugs in a sand blast type cleaner Avoid...

Page 388: ...MODEL 3 Disconnect the connector from ignition coil and ignitor ASSY 4 Remove the ignition coil and ignitor ASSY 1 6 L MODEL 2 0 L and 2 5 L MODEL B INSTALLATION Install in the reverse order of remova...

Page 389: ...ce 1 6 L model Primary side Between terminal No 1 and No 4 0 7 10 Between terminal No 1 and No 2 0 7 10 Secondary side Between A and B 13 0 k 20 Between C and D 13 0 k 20 Specified resistance 2 0 L an...

Page 390: ...4 Spark Plug Cord A INSPECTION Check for 1 Damage to cords deformation burning or rust formation of terminals 2 Resistance values of cords Resistance value 1 cord 5 6 10 6 k 2 cord 7 3 13 7 k 3 cord 5...

Page 391: ...STARTING CHARGING SYSTEMS SC H4SO Page 1 General Description 2 2 Starter 7 3 Generator 14 4 Battery 20...

Page 392: ...6 7 N m 1 70 kgf m 12 3 ft lb or more Rotating speed 870 rpm or more 710 rpm or more Lock character istics Voltage 4 V 3 5 V Current 680 A or less 960 A or less Torque 17 N m 1 73 kgf m 12 5 ft lb or...

Page 393: ...70 kgf m 12 3 ft lb or more Rotating speed 860 rpm or more 710 rpm or more Lock character istics Voltage 5 V 3 5 V Current 515 A or less 960 A or less Torque 16 N m 1 63 kgf m 11 8 ft lb or more 31 N...

Page 394: ...L 1 Front bracket 7 Internal gear ASSY 13 Brush holder ASSY 2 Sleeve bearing 8 Shaft ASSY 14 Sleeve bearing 3 Lever set 9 Gear ASSY 15 Rear cover 4 Magnet switch ASSY 10 Packing 16 Rear cover set 5 St...

Page 395: ...gear assembly 13 Armature 2 Front bracket 8 Shaft assembly 14 Brush holder assembly 3 Lever set 9 Gear assembly 15 Brush 4 Magnet switch assembly 10 Ball 16 Sleeve bearing 5 Stopper set 11 Packing 17...

Page 396: ...ilure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running Be sure to tighten fasteners including...

Page 397: ...he intercooler Turbo model Ref to IN H4DOTC 10 REMOVAL Intercool er 4 Remove the air cleaner case stay Non turbo model MT MODEL AT MODEL 5 Disconnect the connector and terminal from starter 6 Remove t...

Page 398: ...mounting surface of switch assembly 3 Remove both through bolts and brush holder screws and then detach the rear cover and brush holder 4 Remove the armature and yoke from front brack et The ball use...

Page 399: ...metal fitting while holding the in sulating plate against the brush holder Remove the insulating plate The brush and spring can be easily removed from the brush holder at this time D ASSEMBLY 1 Assem...

Page 400: ...se the iron sheet to vibrate and to be attracted to core If the iron sheet is attracted or vibrates the armature which is short circuited must be replaced or repaired 5 Armature ground test Using a ci...

Page 401: ...hm check that there is continuity between terminals S and M and between terminal S and ground Also check to be sure there is no continuity be tween terminals M and B Terminal Specified resistance S M...

Page 402: ...e its satisfactory performance when installed on the engine Three performance tests no load test load test and lock test are presented here however if the load test and lock test cannot be performed c...

Page 403: ...than 300 A 870 rpm 2 0L Non turbo AT 2 5L AT More than 400 A 710 rpm 2 0L Turbo MT More than 280 A 860 rpm 2 0L Turbo AT More than 400 A 710 rpm 3 Lock test With the starter stalled or not rotating me...

Page 404: ...side V belt Ref to ME H4SO 44 FRONT SIDE BELT RE MOVAL V belt or Ref to ME H4DOTC 55 FRONT SIDE BELT REMOVAL V belt 5 Remove the bolts which install generator onto bracket B INSTALLATION Install in t...

Page 405: ...d remove pulley nut CAUTION When holding the rotor with a vise place alumi num plates or wooden pieces on the vise jaws to prevent rotor from damage 5 Remove the ball bearing as follows 1 Remove the b...

Page 406: ...re than 5 seconds at once because the rectifier cannot withstand so much heat 8 Remove the IC regulator as follows 1 Remove the screws which secure IC regula tor to rear cover 2 Unsolder the connectio...

Page 407: ...move the wire after reassembly 2 Install the ball bearing 1 Set the ball bearing on the front cover and then securely install an appropriate tool such as a fit socket wrench to the bearing outer race...

Page 408: ...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 If the slip ring is...

Page 409: ...the brush Each brush has the service limit mark A on it Brush length Standard 18 5 mm 0 728 in Service limit 5 0 mm 0 197 in 2 Checking brush spring for proper pressure Using a spring pressure indicat...

Page 410: ...connected to it while you are at the same time in contact with any other metallic portion of the vehicle This may cause a short circuit 1 EXTERNAL PARTS Check for the existence of dirt or cracks on ba...

Page 411: ...ed by manufacturer or at approx 1 10 of the battery s am pere hour rating 4 QUICK CHARGING Quick charging is a method in which the battery is charged in a short period of time with a relatively large...

Page 412: ...SC H4SO 22 STARTING CHARGING SYSTEMS BATTERY...

Page 413: ...O Signal 27 8 Data Link Connector 28 9 OBD II General Scan Tool 29 10 Subaru Select Monitor 31 11 Read Diagnostic Trouble Code DTC 38 12 Inspection Mode 39 13 Drive Cycle 44 14 Clear Memory Mode 46 15...

Page 414: ...ink connec tor 3 Turn the ignition switch to ON and the Sub aru Select Monitor or OBD II general scan tool switch to ON 4 Read the DTC on the Subaru Select Monitor or OBD II general scan tool Does the...

Page 415: ...gear oil level check Ref to 4AT 32 Differential Gear Oil 3 ATF leak check Ref to 4AT 31 Automatic Transmission Fluid 4 Differential gear oil leak check Ref to 4AT 32 Differential Gear Oil 5 Stall tes...

Page 416: ...rs Outdoor temperature C F Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine speed...

Page 417: ...tion of fuel gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of parts...

Page 418: ...dules at the harness side connector use a tapered pin with a diameter of less than 0 64 mm 0 025 in Do not insert the pin more than 5 mm 0 20 in into the part 6 Before removing the ECM from the locate...

Page 419: ...f diagnosis system B INSPECTION Before performing diagnostics check the following items which might affect engine problems 1 BATTERY 1 Measure battery voltage and specific gravity of electrolyte Stand...

Page 420: ...ition of compen sating element etc The MFI system also has the following features Reduced emission of harmful exhaust gases Reduction in fuel consumption Increased engine output Superior acceleration...

Page 421: ...CTRICAL COMPONENTS LOCATION 4 Electrical Components Location A LOCATION 1 ENGINE MODULE 1 Engine control module ECM 3 Test mode connector 4 Data link connector 2 Malfunction indicator light EN 01397 L...

Page 422: ...EN H4SO 10 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00156 EN 01399 2 EN 01149 3 EN 01150 4...

Page 423: ...ENTS LOCATION SENSOR 1 Intake air temperature sensor 3 Engine coolant temperature sen sor 5 Knock sensor 2 Manifold absolute pressure sen sor 6 Camshaft position sensor 4 Throttle position sensor 7 Cr...

Page 424: ...EN H4SO 12 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00006 2 EN 00160 EN 00008 3 EN 00161 EN 00010 5 EN 00011 6 EN 00012 7...

Page 425: ...O 13 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Front oxygen A F sensor 3 Front catalytic converter 4 Rear catalytic converter 2 Rear oxygen sensor EN 00162 EN 00014 1 EN 00163 EN 00016 3 EN...

Page 426: ...EN H4SO 14 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Fuel level sensor EN 01401 LHD 1 EN 01402 RHD 1 EN 01403 1...

Page 427: ...CATION SOLENOID VALVE EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 Idle air control solenoid valve 4 Air assisted injector solenoid valve 1 6 L model 5 EGR valve 2 Purge control solenoid...

Page 428: ...EN H4SO 16 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00249 EN 00250 2 EN 00251 3 EN 01595 4 EN 01590 5...

Page 429: ...IAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Inhibitor switch 4 Fuel pump relay 7 Starter 2 Fuel pump 5 Radiator main fan relay 3 Main relay 6 Radiator sub fan relay EN 01405 3 5 6 7 4 1 2 LHD EN 01406...

Page 430: ...EN H4SO 18 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00178 EN 01407 2 EN 01408 4 3 LHD EN 01409 4 3 RHD 6 5 EN 00180 EN 00181...

Page 431: ...EN H4SO 19 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 2 TRANSMISSION MODULE 1 Transmission control module TCM AT model 2 AT diagnostic indicator light AT model EN 01410 2 1 LHD EN 01411 1 2 RHD...

Page 432: ...EN H4SO 20 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 01412 1 LHD EN 01413 RHD 1 EN 01414 2...

Page 433: ...SENSOR 1 Rear vehicle speed sensor AT model 3 Front vehicle speed sensor AT model 5 ATF temperature sensor AT model 2 Front vehicle speed sensor MT model 4 Torque converter turbine speed sensor 6 Brak...

Page 434: ...MT MODELS 1 Shift solenoid valve 1 4 Low clutch timing solenoid 7 2 4 brake timing solenoid 2 Shift solenoid valve 2 5 Lock up duty solenoid 8 Transfer duty solenoid 3 Line pressure duty solenoid 6 2...

Page 435: ...ensor output waveform Signal B135 17 0 0 Shield B135 28 0 0 Camshaft position sensor Signal B135 7 6 0 7 to 7 Sensor output waveform Signal B135 18 0 0 Shield B135 28 0 0 Throttle position sensor Sign...

Page 436: ...13 Waveform Power supply B135 2 10 13 13 14 Fuel pump relay control B134 2 ON 0 5 or less OFF 10 13 0 5 or less A C relay control B134 9 ON 0 5 or less OFF 10 13 ON 0 5 or less OFF 13 14 Radiator fan...

Page 437: ...13 ON 1 or less OFF 13 14 Immobilizer input output B137 17 Less than 1 More than 4 Less than 1 More than 4 Immobilizer input output B137 18 Less than 1 More than 4 Less than 1 More than 4 Power steer...

Page 438: ...e Condition Data A ELECTRICAL SPECIFICATION Measuring condition After the engine is warmed up Gear position is in N or P range A C is turned OFF All accessory switches are turned OFF Content Specified...

Page 439: ...OL MODULE TCM I O SIGNAL 7 Transmission Control Mod ule TCM I O Signal A ELECTRICAL SPECIFICATION For electrical specification of TCM I O signal refer to 4AT section Ref to 4AT 13 ELECTRICAL SPECIFICA...

Page 440: ...e OBD II general scan tools and the Subaru Se lect Monitor because the circuit for the Subaru Select Monitor may be damaged EN 00037 1 2 3 4 5 7 6 8 9 10 11 12 13 15 14 16 Terminal No Contents Termina...

Page 441: ...agnostic Trouble Code DTC 2 MODE 01 CURRENT POWERTRAIN DIAGNOSTIC DATA Refers to data denoting the current operating condition of analog input output digital input output or the pow ertrain system A l...

Page 442: ...data denoting emission related power train DTC Ref to EN H4SO 38 Read Diagnostic Trouble Code DTC 5 MODE 04 CLEAR RESET EMISSION RELATED DIAGNOSTIC INFORMATION Refers to mode used to clear or reset em...

Page 443: ...the diagnosis cable to data link connector CAUTION Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 5 Turn the ignition switch to ON engine OFF and Subaru Select...

Page 444: ...1 Knock sensor signal Knocking Correction deg Atmospheric absolute pressure signal Atmosphere Pressure mmHg kPa inHg or psi Intake manifold relative pressure signal Mani Relative Pressure mmHg kPa in...

Page 445: ...Crankshaft position sensor signal Crankshaft Position Sig ON or OFF Camshaft position sensor signal Camshaft Position Sig ON or OFF Rear defogger switch signal Rear Defogger Switch ON or OFF Blower f...

Page 446: ...st Diagnosis Complete or incomplete Test of heated catalytic converter Heated catalyst No support Test of evaporative emission purge control system Evaporative purge system No support Test of secondar...

Page 447: ...the YES key A list of support data is shown in the following table NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MANUAL Contents Display Unit of measure DTC for fr...

Page 448: ...ing Signal ON or OFF When knocking signal is entered Radiator sub fan relay signal Radiator Fan Relay 2 ON or OFF When radiator sub fan relay is in function Engine torque control signal 1 Torque Contr...

Page 449: ...control duty ratio Lock Up Duty Ratio Transfer clutch control duty ratio Transfer Duty Ratio Power supply for throttle position sensor Throttle Sensor Power V Torque converter turbine speed signal AT...

Page 450: ...U SELECT MONITOR OBD MODE 1 On Main Menu display screen select the 2 Each System Check and press the YES key 2 On System Selection Menu display screen select the Engine Control System and press the YE...

Page 451: ...No Activity Detected Bank 1 Sensor 1 P0137 O2 Sensor Circuit Low Voltage Bank 1 Sensor 2 P0138 O2 Sensor Circuit High Voltage Bank 1 Sensor 2 P0327 Knock Sensor 1 Circuit Low Input Bank 1 or Single S...

Page 452: ...Valve Signal 1 Circuit Malfunction Low Input P1511 ISC Solenoid Valve Signal 1 Circuit Malfunction High Input P1512 ISC Solenoid Valve Signal 2 Circuit Malfunction Low Input P1513 ISC Solenoid Valve S...

Page 453: ...may cause vehicle to jump off free rollers In order to prevent the vehicle from slipping due to vibration do not place any wooden blocks or similar items between the safety stands and the vehicle Sin...

Page 454: ...ed on display screen If trouble still remains in memory the corre sponding DTC appears on display screen NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL For...

Page 455: ...posi tion AT models or 1st gear MT models and drive the vehicle at 5 to 10 km h 3 to 6 MPH NOTE On AWD vehicles release the parking brake The speed difference between front and rear wheels may light A...

Page 456: ...ut the diagnosis which is marked on DTC twice then after finishing first diagnosis stop the engine and do second time at the same condition 2 AFTER RUNNING 20 MINUTES AT 80 KM H 50 MPH IDLE ENGINE FOR...

Page 457: ...gnosis frequency is different from misfire ratio P0303 Cylinder 3 Misfire Detected Diagnosis frequency is different from misfire ratio P0304 Cylinder 4 Misfire Detected Diagnosis frequency is differen...

Page 458: ...een select the 2 Each System Check and press the YES key 2 On System Selection Menu display screen select the Engine Control System and press the YES key 3 Press the YES key after the information of e...

Page 459: ...cable to data link connector CAUTION Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 6 Turn the ignition switch to ON engine OFF and Subaru Select Monitor swit...

Page 460: ...re refer to SUBA RU SELECT MONITOR OPERATION MANUAL Contents Display Compulsory fuel pump relay oper ation check Fuel Pump Relay Compulsory radiator fan relay operation check Radiator Fan Relay Compul...

Page 461: ...OES NOT COME ON Malfunction indicator light 3 Malfunction indicator light does not go off Ref to EN H4SO 53 MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF Malfunction indicator light 4 Malfunction indica...

Page 462: ...tor light 2 After starting the engine the malfunction indica tor light goes out If it does not either the engine or the emission control system is malfunctioning 3 If the diagnosis system senses a mis...

Page 463: ...POOR CONTACT Check poor contact by shaking or pulling ECM connector and harness Does the malfunction indicator light illuminate Repair poor con tact in ECM con nector Go to step 3 EN 01417 1 B72 B134...

Page 464: ...this case repair the following Open circuit in harness between ECM and combi nation meter con nector Poor contact in coupling connector 5 CHECK POOR CONTACT Check poor contact in combination meter con...

Page 465: ...tion indicator light illuminate Repair short circuit in harness between combina tion meter and ECM connector Replace the ECM Ref to FU H4SO 48 Engine Control Module ECM EN 01417 1 B72 B134 SBF 4 4 28...

Page 466: ...6 IGNITION SWITCH B134 A B136 C SBF 4 4 A28 C3 ECM i12 1 2 3 4 5 6 8 7 9 10 11 12 13 14 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B72 3 4 1 2...

Page 467: ...e ignition switch to OFF 2 Disconnect the connector from ECM 3 Measure the resistance of harness between test mode connector and chassis ground Connector terminal B76 No 1 Chassis ground Is the resist...

Page 468: ...B136 C SBF 4 4 A28 C3 ECM i12 1 2 3 4 5 6 8 7 9 10 11 12 13 14 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B72 3 4 1 2 SBF 1 No 13 1 B22 E3 16...

Page 469: ...t blinks at a cycle of 3 Hz when test mode connec tor is connected 2 CHECK HARNESS BETWEEN ECM CON NECTOR AND ENGINE GROUNDING TER MINAL 1 Turn the ignition switch to OFF 2 Disconnect the connector fr...

Page 470: ...ply and ground line Ref to EN H4SO 62 CONTROL MODULE POWER SUPPLY AND GROUND LINE Diagnostics for Engine Starting Failure 3 Inspection of ignition control system Ref to EN H4SO 65 IGNITION CONTROL SYS...

Page 471: ...ory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01440 12 INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 B72 12 11 T7 T3 B12 1 3 IGNITION SWI...

Page 472: ...Disconnect the connector from ignition switch 2 Measure the power supply voltage between ignition switch connector and chassis ground Connector terminal B72 No 1 Chassis ground Is the voltage more th...

Page 473: ...er in the P or N range 2 Measure the resistance between inhibitor switch terminals Connector terminal T3 No 11 No 12 Is the resistance less than 1 Repair open or ground short cir cuit in harness betwe...

Page 474: ...Terminals No 3 No 5 No 4 No 6 Is the resistance less than 10 Go to step 2 Replace the main relay EN 01444 B72 3 4 1 2 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 B2 B1 C12 C16 B21 C5 A35...

Page 475: ...e the resistance between ECM and chassis ground Connector terminal B136 No 12 Chassis ground Is the resistance more than 1 M Go to step 6 Repair ground short circuit in har ness between ECM connector...

Page 476: ...tween ECM connec tor and chassis ground Connector terminal B135 No 1 Chassis ground B135 No 2 Chassis ground B136 No 23 Chassis ground Is the voltage more than 10 V Check ignition control system Ref t...

Page 477: ...hread portion on engine 4 While opening the throttle valve fully crank the engine to check that spark occurs at each cylinder Does spark occur at each cyl inder Check fuel pump system Ref to EN H4SO 6...

Page 478: ...Engine ground Is the resistance less than 5 Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit in harness between ignition coil igni tor ASSY connec tor and...

Page 479: ...tor NOTE In this case repair the following Open circuit in harness between ECM and ignition coil ignitor ASSY connector Poor contact in coupling connector 7 CHECK HARNESS BETWEEN ECM AND IG NITION COI...

Page 480: ...Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01420 B72 R15 F44 R58 3 4 1 2 SBF 1 No 11 SBF 4 E E 1 10 4 B72 F44 B61 B46 R58 R57 R15 SBF 5 2 1 3 4 4 M 1 4 1 B136 ECM 3...

Page 481: ...circuit in harness between fuel pump connec tor and chassis grounding terminal Poor contact in coupling connector 3 CHECK POWER SUPPLY TO FUEL PUMP 1 Turn the ignition switch to ON 2 Measure the volta...

Page 482: ...uel pump relay Ref to FU H4SO 50 Fuel Pump Relay 7 CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNECTOR 1 Disconnect the connectors from ECM 2 Measure the resistance of harness between ECM and fuel...

Page 483: ...injector emits operating sound Use a sound scope or attach a screwdriver to the injector for this check Dose the fuel injector operate Check the fuel pressure Ref to ME H4SO 31 INSPECTION Fuel Pressu...

Page 484: ...o 34 E5 No 1 2 B134 No 23 E16 No 1 3 B134 No 22 E6 No 1 4 B134 No 8 E17 No 1 Is the resistance less than 1 Go to step 4 Repair harness and connector NOTE In this case repair the following Open circuit...

Page 485: ...h Input Ref to EN H4SO 98 DTC P0108 MANIFOLD ABSOLUTE PRES SURE BAROMETRIC PRESSURE CIRCUIT HIGH INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC P0111 Intake Air Temperature Circuit Range...

Page 486: ...gnostic Procedure with Diagnostic Trouble Code DTC P0172 System too Rich Bank 1 Ref to EN H4SO 141 DTC P0172 SYSTEM TOO RICH BANK 1 Diagnostic Procedure with Diagnostic Trouble Code DTC P0301 Cylinder...

Page 487: ...7 DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED Diagnostic Procedure with Diagnostic Trou ble Code DTC P0507 Idle Control System RPM Higher Than Expected Ref to EN H4SO 189 DTC P0507 IDLE CONT...

Page 488: ...stic Proce dure with Diagnostic Trouble Code DTC P0748 Pressure Control Solenoid A Elec trical Ref to 4AT 76 DTC 75 LINE PRESSURE DUTY SOLENOID Diagnostic Procedure with Diagnostic Trouble Code DTC P0...

Page 489: ...d Valve Signal 4 Cir cuit Malfunction Low Input Ref to EN H4SO 240 DTC P1498 EGR SOLENOID VALVE SIGNAL 4 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC P1499 EGR S...

Page 490: ...Ref to IM 23 DTC P1576 EGI CONTROL MODULE EEPROM Diagnos tics Chart with Diagnostic Trouble Code DTC P1577 IMM Control Module EEPROM Ref to IM 23 DTC P1577 IMM CONTROL MODULE EEPROM Diagnos tics Chart...

Page 491: ...Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 Inspection Mode WIRING DIAGRAM EN 01421 B18 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B135 1 2 3 4 B22 1 2 3 4...

Page 492: ...tance less than 1 Go to step 3 Repair the open circuit in harness between ECM and front oxygen A F sensor connector 3 CHECK HARNESS BETWEEN MAIN RELAY AND FRONT OXYGEN A F SENSOR CON NECTOR Measure th...

Page 493: ...GRAM Step Check Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Does the Subaru Select Moni tor or OBD II general scan tool display DTC P0031 and P0037 at the same time Go to step 2 Go to step 5 EN 01421 B18...

Page 494: ...or contact in ECM connector Poor contact in coupling connector 4 CHECK CURRENT DATA 1 Start the engine 2 Read the data of front oxygen A F sensor heater current using Subaru Select Monitor or OBD II g...

Page 495: ...F sensor connector terminals Terminals No 3 No 4 Is the resistance less than 10 Repair harness and connector NOTE In this case repair the following Open or ground short circuit in har ness between fr...

Page 496: ...FROM ECM 1 Turn the ignition switch to ON 2 Measure the voltage between ECM connec tor and chassis ground Connector terminal B136 No 6 Chassis ground B136 No 17 Chassis ground Is the voltage more tha...

Page 497: ...peration procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4SO 31 Subaru Select Moni tor OBD II general scan tool For detailed operation procedure refer to the OBD II General Scan Tool In...

Page 498: ...O 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01422 BATTERY B61 F44 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 1 4 3 2 8 B22 B83 B19 E3 B47 B22 1...

Page 499: ...uction Manual Is the current more than 0 2 A Repair the con nector NOTE In this case repair the following Poor contact in rear oxygen sen sor connector Poor contact in rear oxygen sen sor connecting h...

Page 500: ...lowing Open circuit in harness between main relay and rear oxygen sen sor connector Poor contact in rear oxygen sen sor connector Poor contact in coupling connector 7 CHECK REAR OXYGEN SENSOR 1 Turn t...

Page 501: ...he voltage between ECM connector and chassis ground Connector terminal B136 No 4 Chassis ground Is the voltage more than 8 V Go to step 2 Go to step 3 EN 01422 BATTERY B61 F44 2 B47 MAIN RELAY 1 2 3 5...

Page 502: ...or or the OBD II general scan tool NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4SO 31 Subaru Select Moni tor OBD II general scan to...

Page 503: ...f faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01423 1 2 3 4 5 6 7 8 9 10 11...

Page 504: ...SOLENOID VALVE CON NECTOR 1 Turn ignition switch to OFF 2 Disconnect connector from ECM 3 Measure resistance of harness between ECM and air assist injector solenoid valve con nector Connector terminal...

Page 505: ...lty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01423 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 506: ...short circuit in har ness between ECM and air assist injector solenoid valve connector After repair replace ECM Ref to FU H4SO 48 Engine Control Module ECM Replace air assist injector solenoid valve...

Page 507: ...of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM 19 3 15 MANIFOLD ABSOLUTE PRES...

Page 508: ...IGNAL FOR ECM Measure the voltage between ECM connector and chassis ground Connector terminal B135 No 3 Chassis ground Is the voltage more than 4 5 V Go to step 5 Go to step 4 4 CHECK OUTPUT SIGNAL FO...

Page 509: ...r 8 CHECK HARNESS BETWEEN MANIFOLD ABSOLUTE PRESSURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM 3 Measure the resistance of harness between ECM and...

Page 510: ...t of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM 19 3 15 MANIFOLD ABSOLUTE PRE...

Page 511: ...tact with SUB ARU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple parts 4 CHECK INPUT SIGNAL FOR ECM Measure the voltage between ECM connec...

Page 512: ...connector Repair poor con tact in manifold absolute pressure sensor connector Replace the mani fold absolute pres sure sensor Ref to FU H4SO 33 Manifold Absolute Pressure Sensor 10 CHECK HARNESS BETWE...

Page 513: ...of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM B19 D6 INTAKE AIR TEMPERATURE...

Page 514: ...ly 2 Measure the engine coolant temperature using Subaru Select Monitor or OBD II general scan tool NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGIN...

Page 515: ...y parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM B19 D6 INTAKE AIR TEMPERATURE SENSOR 9...

Page 516: ...ontact in ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE SENSOR AND ECM CON NECTOR 1 Turn the ignition switch to OFF 2 Disconnect...

Page 517: ...y parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM B19 D6 INTAKE AIR TEMPERATURE SENSOR 9...

Page 518: ...take air tem perature and manifold absolute pressure sen sor connector and engine ground Connector terminal E20 No 1 Engine ground Is the voltage more than 10 V Repair battery short circuit in har nes...

Page 519: ...engine ground Connector terminal E20 No 2 Engine ground Is the resistance less than 5 Replace the intake air temperature sensor Ref to FU H4SO 34 Intake Air Temper ature Sensor Repair harness and con...

Page 520: ...ION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM...

Page 521: ...ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the c...

Page 522: ...ION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM...

Page 523: ...ine coolant temperature sensor connector and engine ground Connector terminal E8 No 1 Engine ground Is the voltage more than 10 V Repair battery short circuit in har ness between ECM and engine coolan...

Page 524: ...Connector terminal E8 No 2 Engine ground Is the resistance less than 5 Replace the engine coolant temperature sen sor Ref to FU H4SO 27 Engine Coolant Temperature Sen sor Repair harness and connector...

Page 525: ...rformance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode...

Page 526: ...Y OTHER DTC ON DISPLAY Is any other DTC displayed Inspect DTC P0122 or P0123 using List of Diag nostic Trouble Code DTC Ref to EN H4SO 73 List of Diagnostic Trouble Code DTC NOTE In this case it is no...

Page 527: ...e CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING D...

Page 528: ...2 CHECK OUTPUT SIGNAL FOR ECM Measure the voltage between ECM connector and chassis ground while throttle valve is fully closed Connector terminal B135 No 3 Chassis ground Is the voltage more than 4...

Page 529: ...istance of harness between ECM connector and throttle position sensor connector Connector terminal B135 No 13 E13 No 3 Is the resistance less than 1 Go to step 8 Repair harness and connector NOTE In t...

Page 530: ...e CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING D...

Page 531: ...connector 2 CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from throttle posi tion sensor 3 Measure the resistance of h...

Page 532: ...UTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGR...

Page 533: ...using List of Diagnostic Trouble Code DTC Ref to EN H4SO 73 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0125 Go to step 2 2 CHECK THERMOSTAT Does the ther...

Page 534: ...ment of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode Step Check Yes No 1 CHECK ANY OTHER DTC O...

Page 535: ...k Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 73 List of Diagnostic Trouble Code DTC Go to step 2 EN 01421 B18...

Page 536: ...he data of front oxygen A F sensor signal during racing using Subaru Select Moni tor or OBD II general scan tool NOTE Air fuel ratio is rich at normal condition or dur ing racing To increase engine sp...

Page 537: ...items Loose installation of portions Damage crack hole etc of parts Looseness of front oxygen A F sensor Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is t...

Page 538: ...ear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01421 B18 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B135 1 2 3 4 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 539: ...e connectors from ECM and front oxygen A F sensor connector 3 Measure the resistance of harness between ECM and front oxygen A F sensor connector Connector terminal B136 No 13 Chassis ground B136 No 2...

Page 540: ...ear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01421 B18 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B135 1 2 3 4 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 541: ...2 Disconnect the connectors from front oxygen A F sensor 3 Measure the voltage of harness between ECM connector and chassis ground Connector terminal B136 No 13 Chassis ground B136 No 22 Chassis grou...

Page 542: ...ON Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01421 B18 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B135 1 2 3 4 B22 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 543: ...Code DTC NOTE In this case it is not necessary to inspect DTC P0133 Go to step 2 2 CHECK EXHAUST SYSTEM NOTE Check the following items Loose installation of front portion of exhaust pipe onto cylinder...

Page 544: ...ON Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01421 B18 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B135 1 2 3 4 B22 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 545: ...B136 No 13 B18 No 1 B136 No 22 B18 No 2 Is the resistance less than 1 Go to step 2 Repair harness and connector NOTE In this case repair the following Open circuit in harness between ECM and front ox...

Page 546: ...39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01422 BATTERY B61 F44 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 1 4 3 2 8 B22 B83 B19 E3 B47 B22 1...

Page 547: ...age 490 mV Go to step 5 Go to step 3 3 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and rear oxygen sensor 3 Measur...

Page 548: ...E Check the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fault in...

Page 549: ...O 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01422 BATTERY B61 F44 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 1 4 3 2 8 B22 B83 B19 E3 B47 B22 1...

Page 550: ...ltage 250 mV Go to step 5 Go to step 3 3 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and rear oxygen sensor 3 Meas...

Page 551: ...E Check the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fault in...

Page 552: ...SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01422 BATTERY B61 F44 2 B47 MAIN RELAY 1 2 3 5 4 6 F44 1 2 3 4 5 6 7 8 C4 B14 B19 D15 C16 C5 REAR OXYGEN SENSOR ECM 1 4 3 2 8 B22 B83 B19 E3 B47 B22...

Page 553: ...SYSTEM TOO RICH BANK 1 Diagnostic Procedure with Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check DTC using List of Diagnostic Trouble C...

Page 554: ...K PCV VALVE Is PCV valve operated Go to step 6 Replace the PCV valve 6 CHECK FUEL PRESSURE Warning Place NO FIRE signs near the working area Be careful not to spill fuel on the floor 1 Release fuel pr...

Page 555: ...H4SO 31 Subaru Select Moni tor OBD II general scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual Is the engine coolant tempera ture 70 100 C 158 212 F...

Page 556: ...cedure with Diagnostic Trouble Code DTC AE DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE For the diagnostic procedure refer to DTC P0304 Ref to EN H4SO 144 DTC P0304 CYLINDER 4 MISFIRE DETECTED Diagnosti...

Page 557: ...rts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01428 B22 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 558: ...faulty cylinders 3 Measure the resistance between ECM con nector and engine ground on faulty cylinders Connector terminal 1 E5 No 1 Engine ground 2 E16 No 1 Engine ground 3 E6 No 1 Engine ground 4 E17...

Page 559: ...Chassis ground Is the voltage more than 10 V Repair battery short circuit in har ness between ECM and fuel injector After repair replace the ECM Ref to FU H4SO 48 Engine Control Module ECM Go to step...

Page 560: ...or blink Go to step 15 Go to step 14 14 CHECK CAUSE OF MISFIRE DIAGNOSED Was the cause of misfire iden tified when the engine is run ning Ex Disconnection of spark plug cord Finish diagnostics operati...

Page 561: ...r DTC displayed Does the Subaru Select Moni tor or OBD II general scan tool indicate DTC P0301 and P0302 Go to step 22 Go to step 18 18 CHECK DIAGNOSTIC TROUBLE CODE DTC ON DISPLAY Is any other DTC di...

Page 562: ...AND 4 CYLINDERS Are there faults in 3 and 4 cylinders Repair or replace faulty parts NOTE Check the fol lowing items Spark plugs Fuel injectors Ignition coil If no abnormal is discovered check for 16...

Page 563: ...ratio Skipping timing belt teeth Go to DTC P0171 Ref to EN H4SO 140 DTC P0171 SYSTEM TOO LEAN BANK 1 Diagnostic Pro cedure with Diag nostic Trouble Code DTC 26 CYLINDER AT RANDOM Is the engine idle r...

Page 564: ...ving performance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPER...

Page 565: ...ector Poor contact in knock sensor con nector Poor contact in coupling connector 2 CHECK KNOCK SENSOR 1 Disconnect the connector from knock sen sor 2 Measure the resistance between knock sen sor conne...

Page 566: ...iving performance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPE...

Page 567: ...Knock Sensor Repair ground short circuit in har ness between knock sensor con nector and ECM connector NOTE The harness be tween both con nectors is shielded Repair short circuit of har ness together...

Page 568: ...acement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01430 1 2 17 28 B21...

Page 569: ...tion sensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair ground short circuit in harness togeth er with shield Go to step 3 3 CHECK HARNESS BETWEEN CRANK SHAFT POSI...

Page 570: ...r or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01430 1 2 1...

Page 571: ...nk shaft position sen sor installation bolt securely 3 CHECK CRANKSHAFT SPROCKET Remove the front belt cover Are crankshaft sprocket teeth cracked or damaged Replace the crank shaft sprocket Ref to ME...

Page 572: ...pair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01431 B2...

Page 573: ...t position sensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair ground short circuit in harness togeth er with shield Go to step 3 3 CHECK HARNESS BETWEEN CAMSHAFT P...

Page 574: ...N After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM E...

Page 575: ...nal E15 No 1 Engine ground Is the resistance less than 10 Repair ground short circuit in har ness between camshaft position sensor and ECM connector NOTE The harness be tween both con nectors are shie...

Page 576: ...ng Belt Cover Are camshaft sprocket teeth cracked or damaged Replace the cam shaft sprocket Ref to ME H4SO 55 Camshaft Sprocket Go to step 9 9 CHECK INSTALLATION CONDITION OF TIMING BELT Turn the cams...

Page 577: ...PERATION Inspec tion Mode WIRING DIAGRAM EN 01432 B137 B135 B134 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E18 2 5 1 4 3 6 B22 B61 F44 E3 B328 E58 B22 E3 6 4 5 3 2 1 1 5 A17 A16 A15 A18 B21 D...

Page 578: ...O EGR SOLE NOID VALVE 1 Disconnect the connector from EGR sole noid valve 2 Turn the ignition switch to ON 3 Measure the voltage between EGR solenoid valve and engine ground Connector terminal E18 No...

Page 579: ...tor 7 CHECK HARNESS BETWEEN EGR SOLE NOID VALVE AND ECM CONNECTOR Measure the resistance of harness between EGR solenoid valve and chassis ground Connector terminal B134 No 15 Chassis ground B134 No 1...

Page 580: ...ode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01433 B18 B19 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B137 B135 BATTERY REAR OXYGEN SENSOR FRONT OXYGEN A F SENS...

Page 581: ...ter Between front catalytic converter and rear cat alytic converter Is there a fault in exhaust sys tem Repair or replace the exhaust sys tem Ref to EX H4SO 2 Gen eral Description Go to step 3 3 CHECK...

Page 582: ...ment of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01434 PURGE CONTROL SOL...

Page 583: ...purge control solenoid valve connector 3 CHECK HARNESS BETWEEN PURGE CON TROL SOLENOID VALVE AND ECM CON NECTOR Measure the resistance of harness between ECM and purge control solenoid valve of har n...

Page 584: ...in purge control solenoid valve connector Is there poor contact in purge control solenoid valve connec tor Repair poor con tact in purge con trol solenoid valve connector Contact with SUB ARU distribu...

Page 585: ...ment of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01434 PURGE CONTROL SOL...

Page 586: ...ep 3 3 CHECK POOR CONTACT Check poor contact in ECM connector Is there poor contact in ECM connector Repair poor con tact in ECM con nector Replace the ECM Ref to FU H4SO 48 Engine Control Module ECM...

Page 587: ...H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01435 BATTERY SBF 1 SBF 4 B135 ECM i12 A i11 i1 B36 i2 B37 B99 R3 C COMBINATION METER B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 B72 IGNITION SW...

Page 588: ...B135 No 25 Chassis ground Is the voltage less than 0 12 V Go to step 4 Go to step 3 EN 01436 BATTERY SBF 1 SBF 4 B135 ECM i12 A i11 i2 B37 C COMBINATION METER B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1...

Page 589: ...nector and chassis ground Connector terminal B135 No 25 Chassis ground Is the voltage more than 0 12 V Go to step 5 Go to step 6 5 CHECK HARNESS BETWEEN ECM AND COMBINATION METER 1 Turn the ignition s...

Page 590: ...fuel pump assembly Ref to FU H4SO 59 Fuel Pump 2 Measure the resistance between fuel level sensor and terminals with its float set to the full position Terminals No 3 No 5 Is the resistance 0 5 2 5 R...

Page 591: ...H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01435 BATTERY SBF 1 SBF 4 B135 ECM i12 A i11 i1 B36 i2 B37 B99 R3 C COMBINATION METER B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 B72 IGNITION SW...

Page 592: ...M i12 A i11 i2 B37 C COMBINATION METER B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 B72 IGNITION SWITCH 4 B37 i2 No 13 31 C7 A2 C6 2 21 25 B72 3 4 1 2 3 4 1 2 R58 4 1 2 3 6 5 R15 B99 i3 B99 i2 1 2 3 4...

Page 593: ...TANK CORD 1 Turn the ignition switch to OFF 2 Separate fuel tank cord connector R57 and rear wiring harness connector R15 3 Measure the resistance between ECM and fuel tank cord Connector terminal B1...

Page 594: ...f to FU H4SO 59 Fuel Pump 2 While moving the fuel level sensor float up and down measure resistance between fuel level sensor terminals Terminals No 3 No 5 Is the resistance more than 54 5 Replace the...

Page 595: ...LE SYMPTOM Occurrence of noise Overheating CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4...

Page 596: ...CONDITIONING RELAY HOLDER MAIN FAN RELAY MAIN FAN MOTOR 1 2 26 28 27 25 F17 12 2 B134 ECM F45 B62 4 3 F96 B225 13 14 F17 2 1 F16 F27 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 597: ...PEED SENSOR INTERMITTENT ERRATIC HIGH Diagnostic Procedure with Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Inspect the rele vant DTC usin...

Page 598: ...CK TRANSMISSION TYPE Is the target AT model Go to step 2 Go to step 3 EN 01438 BATTERY 4 1 2 10 ECM COMBINATION METER VEHICLE SPEED SENSOR 3 1 2 B17 B137 17 TCM B56 IGNITION SWITCH B72 No 18 B22 E3 16...

Page 599: ...ter and Ref to 4AT 52 Front Vehicle Speed Sensor and Ref to 4AT 56 Rear Vehicle Speed Sensor and Ref to 4AT 57 Torque Con verter Turbine Speed Sensor 4 CHECK HARNESS BETWEEN ECM AND COMBINATION METER...

Page 600: ...DIAGRAM EN 01439 B137 B135 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E7 2 5 1 4 3 6 B22 E3 B21 E2 B22 E3 6 4 5 3 2 1 1 2 A6 A20 A19 A5 B21 D14 A7 4 1 3 15 16 SBF 5 BATTERY MAIN RELAY IDLE AI...

Page 601: ...n switch to OFF 2 Remove the idle air control solenoid valve from throttle body Ref to FU H4SO 35 REMOVAL Idle Air Control Solenoid Valve 3 Remove the throttle body from intake mani fold Ref to FU H4S...

Page 602: ...AGRAM EN 01439 B137 B135 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E7 2 5 1 4 3 6 B22 E3 B21 E2 B22 E3 6 4 5 3 2 1 1 2 A6 A20 A19 A5 B21 D14 A7 4 1 3 15 16 SBF 5 BATTERY MAIN RELAY IDLE AIR C...

Page 603: ...sket idle air con trol solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses Is there a fault in air intake sys tem Repair air suction and leaks Go to step 3 3 CHECK THROTTLE C...

Page 604: ...EST CIRCUIT DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode R...

Page 605: ...INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 B72 12 11 T7 T3 B12 1 3 IGNITION SWITCH 1 2 1 2 T7 1 2 3 4 5 6 7 8 9 10 11 12 B72 20 B136 ECM AT VEHICLES MT VEHICLES 1 2 BATTERY B12 1...

Page 606: ...TOR Turn the ignition switch to ON NOTE Place the inhibitor switch in each position AT model Depress or release the clutch pedal MT model Dose the starter motor oper ate Repair battery short circuit i...

Page 607: ...EN 01439 B137 B135 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E7 2 5 1 4 3 6 B22 E3 B21 E2 B22 E3 6 4 5 3 2 1 1 2 A6 A20 A19 A5 B21 D14 A7 4 1 3 15 16 SBF 5 BATTERY MAIN RELAY IDLE AIR CONTROL...

Page 608: ...anifold gasket idle air con trol solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses Is there a fault in air intake sys tem Repair air suction and leaks Go to step 3 3 CHECK...

Page 609: ...CEDURE WITH DIAGNOSTIC TROUBLE CODE DTC BA DTC P0558 GENERATOR CIRCUIT LOW INPUT CAUTION For diagnostic procedure refer to DTC P0559 Ref to EN H4SO 197 DTC P0559 GENERATOR CIRCUIT HIGH INPUT Diagnosti...

Page 610: ...faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 Inspection Mode WIRING DIAGRAM EN 01441 B62 B136 F45 F26 F26 ECM GENERATOR...

Page 611: ...stance more than 1 M Go to step 2 Repair the ground short circuit in har ness between ECM and purge control solenoid valve connector 2 CHECK HARNESS BETWEEN GENERATOR AND ECM CONNECTOR Measure the res...

Page 612: ...n CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 Inspection Mode WIRING DIAGRAM EN 0...

Page 613: ...ly clamped Go to step 4 Tighten the clamp of terminal 4 CHECK INPUT VOLTAGE OF ECM 1 Run the engine at idle 2 Measure the voltage between ECM connec tor and chassis ground Connector terminal B135 No 1...

Page 614: ...n CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 Inspection Mode WIRING DIAGRAM EN 0...

Page 615: ...htly clamped Go to step 4 Tighten the clamp of terminal 4 CHECK INPUT VOLTAGE OF ECM 1 Run the engine at idle 2 Measure the voltage between ECM connec tor and chassis ground Connector terminal B135 No...

Page 616: ...39 OPERATION Inspec tion Mode WIRING DIAGRAM Step Check Yes No 1 CHECK HARNESS BETWEEN TCM AND CCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and CCM 3 Measure t...

Page 617: ...WD models raise all wheels off ground 3 Start the engine 4 Turn the cruise control main switch to ON 5 Move select lever to D range and slowly increase vehicle speed to 50 km h 31 MPH 6 Turn the cruis...

Page 618: ...e WIRING DIAGRAM EN 01444 B72 3 4 1 2 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 B2 B1 C12 C16 B21 C5 A35 A7 C26 D14 B9 C10 C23 B47 E3 B22 1 2 3 5 6 4 ECM E E 1 4 B134 B135 B136 A C D B1...

Page 619: ...AGNOSTIC TROUBLE CODE DTC Step Check Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check the relevant DTC using the List of Diagnostic Trouble Code DTC Ref to EN H4SO 73 List of D...

Page 620: ...LOW DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct Cl...

Page 621: ...CONDITIONING RELAY HOLDER MAIN FAN RELAY MAIN FAN MOTOR 1 2 26 28 27 25 F17 12 2 B134 ECM F45 B62 4 3 F96 B225 13 14 F17 2 1 F16 F27 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 622: ...n fan relay control circuit Go to step 3 3 CHECK POWER SUPPLY FOR RELAY 1 Remove the main fan relay from A C relay holder 2 Turn the ignition switch to ON 3 Measure the voltage between fuse and relay...

Page 623: ...HIGH DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct Cl...

Page 624: ...CONDITIONING RELAY HOLDER MAIN FAN RELAY MAIN FAN MOTOR 1 2 26 28 27 25 F17 12 2 B134 ECM F45 B62 4 3 F96 B225 13 14 F17 2 1 F16 F27 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 625: ...in fan relay and sub fan relay with A C models 3 Disconnect the test mode connector 4 Turn the ignition switch to ON 5 Measure the voltage between ECM and chassis ground Connector terminal B134 No 14...

Page 626: ...th fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode W...

Page 627: ...luminate when depressing the brake pedal Go to step 2 Repair or replace the brake light cir cuit EN 01446 BATTERY B65 3 4 1 2 TO STOP LIGHTS SBF 1 SBF 2 No 16 B65 BRAKE LIGHT SWITCH 2 3 B64 BRAKE LIGH...

Page 628: ...l B55 No 12 Chassis ground Is the resistance more than 1 M Go to step 4 Repair ground short circuit in har ness between TCM and brake light switch con nector 4 CHECK INPUT SIGNAL FOR TCM 1 Connect the...

Page 629: ...c Procedure with Diagnostic Trouble Code DTC BK DTC P0732 GEAR 2 INCORRECT RATIO NOTE For the diagnostic procedure refer to DTC P0734 Ref to EN H4SO 217 DTC P0734 GEAR 4 INCOR RECT RATIO Diagnostic Pr...

Page 630: ...place the throttle posi tion sensor circuit Go to step 3 3 CHECK FRONT VEHICLE SPEED SENSOR CIRCUIT Check front vehicle speed sensor circuit Ref to 4AT 53 DTC 33 FRONT VEHICLE SPEED SENSOR Diagnostic...

Page 631: ...ure with Diagnostic Trouble Code DTC Is there any trouble in throttle position sensor circuit Repair or replace the throttle posi tion sensor circuit Go to step 4 4 CHECK TORQUE CONVERTER TURBINE SPEE...

Page 632: ...Repair or replace the ATF tempera ture sensor circuit Go to step 9 9 CHECK POOR CONTACT Check poor contact in TCM connector Is there poor contact in TCM connector Repair poor con tact in TCM con necto...

Page 633: ...ct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01447 B12 T3 B14 T7 INHIBITOR SWITCH STARTER MOTO...

Page 634: ...l B136 No 21 Chassis ground Is the resistance more than 1 M Go to step 4 Repair ground short circuit in har ness between ECM and trans mission harness connector 4 CHECK TRANSMISSION HARNESS CON NECTOR...

Page 635: ...conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01447 B12 T3 B14 T7 INHIBITOR SWITCH STARTE...

Page 636: ...ion except for neutral 2 Measure the resistance between transmis sion harness connector terminals Is the resistance less than 1 Go to step 6 Repair short circuit in transmission harness or replace neu...

Page 637: ...s conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM EN 01447 B12 T3 B14 T7 INHIBITOR SWITCH START...

Page 638: ...oor contact in ECM connector Repair poor con tact in ECM con nector Contact with SUB ARU distributor service NOTE Inspection by DTM is required be cause probable cause is deteriora tion of multiple pa...

Page 639: ...motor ground line Poor contact in starter motor con nector Poor contact in starter motor ground Starter motor 8 CHECK INHIBITOR SWITCH Measure the resistance between inhibitor switch connector recept...

Page 640: ...ar Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM Step Check Yes No 1 CHECK DRIVING CONDITION 1 Start and warm up the engine until the radia tor fan makes...

Page 641: ...TIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC 2 CHECK ACCESSORY Are car phone and or CB installed on vehicle Repair grounding line of car phone or CB system Replace the TCM Ref to 4AT 70 Transmission...

Page 642: ...ycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tio...

Page 643: ...TCM 3 Measure the resistance of harness between ECM and chassis ground Connector terminal B137 No 19 Chassis ground Is the resistance more than 1 M Go to step 3 Repair ground short circuit in har ness...

Page 644: ...on Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode WIRING DIAGRAM Step Check Yes No 1 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to ON 2 Measure the voltage between ECM a...

Page 645: ...No 19 Chassis ground Is the voltage 1 4 V Even if malfunc tion indicator light lights up the cir cuit has returned to a normal condi tion at this time NOTE In this case repair the following Poor cont...

Page 646: ...of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode Step Check Yes No 1 CHECK ANY OTHER DTC ON DI...

Page 647: ...of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec tion Mode Step Check Yes No 1 CHECK ANY OTHER DTC ON DI...

Page 648: ...ear Memory Mode and Inspection Mode Ref to EN H4SO 39 Inspection Mode WIRING DIAGRAM EN 01421 B18 3 4 1 2 5 6 B47 F44 1 2 3 4 5 6 7 8 B136 B135 1 2 3 4 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SBF 5...

Page 649: ...Check Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Check DTC using the List of Diag nostic Trouble Code DTC Ref to EN H4SO 73 List of Diagnostic Trouble Code DTC NOTE It is not n...

Page 650: ...heck Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Inspect DTC using List of Diagnostic Trouble Code DTC Ref to EN H4SO 73 List of Diagnostic Trouble Code DTC Go to step 2 EN 0142...

Page 651: ...oximately 5 seconds and quickly release accelerator pedal to decrease engine speed Is the voltage more than 1 1 V Go to step 6 Go to step 4 4 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR 1 Tu...

Page 652: ...Ref to EN H4SO 240 DTC P1498 EGR SOLENOID VALVE SIGNAL 4 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trou ble Code DTC CB DTC P1495 EGR SOLENOID VALVE SIGNAL 2 CIRCUIT MALFUNCTI...

Page 653: ...ION Inspec tion Mode WIRING DIAGRAM EN 01432 B137 B135 B134 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E18 2 5 1 4 3 6 B22 B61 F44 E3 B328 E58 B22 E3 6 4 5 3 2 1 1 5 A17 A16 A15 A18 B21 D14 A7...

Page 654: ...o 17 E18 No 1 DTC P1496 B134 No 16 E18 No 4 DTC P1498 B134 No 15 E18 No 3 Is the resistance less than 1 Go to step 3 Repair harness and connector NOTE In this case repair the following Open circuit in...

Page 655: ...ION Inspec tion Mode WIRING DIAGRAM EN 01432 B137 B135 B134 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E18 2 5 1 4 3 6 B22 B61 F44 E3 B328 E58 B22 E3 6 4 5 3 2 1 1 5 A17 A16 A15 A18 B21 D14 A7...

Page 656: ...air the following Open circuit in harness between ECM connector and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector 3 CHECK HARNESS BETWEEN ECM AND EGR SOLENOID...

Page 657: ...Ref to EN H4SO 245 DTC P1516 ISC SOLENOID VALVE SIGNAL 4 CIRCUIT MALFUNCTION LOW INPUT Diagnostic Procedure with Diagnostic Trou ble Code DTC CJ DTC P1513 ISC SOLENOID VALVE SIGNAL 2 CIRCUIT MALFUNCTI...

Page 658: ...439 B137 B135 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E7 2 5 1 4 3 6 B22 E3 B21 E2 B22 E3 6 4 5 3 2 1 1 2 A6 A20 A19 A5 B21 D14 A7 4 1 3 15 16 SBF 5 BATTERY MAIN RELAY IDLE AIR CONTROL SOLE...

Page 659: ...E7 No 1 DTC P1514 B134 No 5 E7 No 6 DTC P1516 B134 No 19 E7 No 3 Is the resistance less than 1 Go to step 3 Repair harness and connector NOTE In this case repair the following Open circuit in harness...

Page 660: ...439 B137 B135 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E E B47 E7 2 5 1 4 3 6 B22 E3 B21 E2 B22 E3 6 4 5 3 2 1 1 2 A6 A20 A19 A5 B21 D14 A7 4 1 3 15 16 SBF 5 BATTERY MAIN RELAY IDLE AIR CONTROL SOLE...

Page 661: ...Open circuit in harness between ECM connector and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector 3 CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALV...

Page 662: ...RCUIT LOW INPUT DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mo...

Page 663: ...INHIBITOR SWITCH STARTER MOTOR 7 P R N D 3 2 1 SBF 4 SBF 1 B14 B72 12 11 T7 T3 B12 1 3 IGNITION SWITCH 1 2 1 2 T7 1 2 3 4 5 6 7 8 9 10 11 12 B72 20 B136 ECM AT VEHICLES MT VEHICLES 1 2 BATTERY B12 1...

Page 664: ...Depress the clutch pedal MT model Does the starter motor oper ate when ignition switch is turned to ST Repair harness and connector NOTE In this case repair the following Open or ground short circuit...

Page 665: ...inal B134 No 9 Chassis ground Is the voltage more than 10 V Repair poor con tact in ECM con nector Go to step 2 EN 01444 B72 3 4 1 2 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 B2 B1 C12...

Page 666: ...s ground Connector terminal B135 No 9 Chassis ground Is the resistance less than 10 Repair ground short circuit in har ness between ECM connector and battery termi nal Go to step 3 3 CHECK FUSE SBF 5...

Page 667: ...cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec t...

Page 668: ...HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and TCM 3 Measure the resistance of harness between ECM and chassis ground Connector termin...

Page 669: ...g cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39 OPERATION Inspec...

Page 670: ...in har ness between ECM and TCM connector After repair replace the ECM Ref to FU H4SO 48 Engine Control Module ECM 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Me...

Page 671: ...TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 3...

Page 672: ...ECM con nector Replace the ECM Ref to FU H4SO 48 Engine Control Module ECM 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and TCM...

Page 673: ...TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4SO 46 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4SO 39...

Page 674: ...ECM con nector Replace the ECM Ref to FU H4SO 48 Engine Control Module ECM 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and TCM...

Page 675: ...amshaft position sensor 3 11 Oxygen sensor 12 Fuel pump and fuel pump relay 3 Engine does not return to idle 1 Idle air control solenoid valve 2 Engine coolant temperature sensor 3 Accelerator cable 6...

Page 676: ...2 Intake air temperature sensor 3 Manifold absolute pressure sensor 4 Engine coolant temperature sensor 2 5 Crankshaft position sensor 3 6 Camshaft position sensor 3 7 Fuel injection parts 4 8 Throttl...

Page 677: ...r Temperature and Manifold Absolute Pressure Sensor 34 10 Idle Air Control Solenoid Valve 35 11 Fuel Injector 36 12 Oxygen Sensor 41 13 Engine Control Module ECM 43 14 Main Relay 44 15 Fuel Pump Relay...

Page 678: ...L 2 5 L Fuel tank Capacity 50 2 13 2 US gal 11 0 Imp gal 60 2 15 9 US gal 13 2 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 370 677 kPa 3 77 6 9 kg cm2 53 6 98 p...

Page 679: ...EL SYSTEMS GENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD FU 00906 21 21 22 20 5 6 7 8 2 9 20 13 3 2 4 16 19 17 15 12 11 1 19 19 18 18 18 14 10 23 4 3 5 T3 T3 T6 T5 T5 T5 T3 T6 T2 T5 T5 T3 T5 T5 T5...

Page 680: ...ensor 23 Accelerator cable bracket 3 Fuel injector 4 O ring 14 O ring Tightening torque N m kgf m ft lb 5 O ring 15 Plug cord holder LH T1 1 5 0 15 1 1 6 Plug 16 Fuel pipe protector RH T2 3 4 0 35 2 5...

Page 681: ...FUEL SYSTEMS GENERAL DESCRIPTION 2 AIR INTAKE SYSTEM 1 Gasket 4 Throttle body Tightening torque N m kgf m ft lb 2 Throttle position sensor T1 1 6 0 16 1 2 3 Idle air control solenoid valve T2 22 2 2...

Page 682: ...ON 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...

Page 683: ...TION FUEL SYSTEMS GENERAL DESCRIPTION 4 FUEL TANK 1 6 L and 2 0 L MODEL FU 00908 T1 T1 T3 T2 T2 T2 T3 6 5 7 8 9 9 8 17 20 11 11 21 11 11 22 23 19 18 1 2 3 2 4 A B 24 15 A B T1 D C D C 18 11 11 11 11 1...

Page 684: ...tion hose E 4 Fuel tank 14 Evaporation hose C 24 Evaporation hose F 5 Fuel pump gasket 15 Evaporation pipe ASSY 25 Evaporation hose G 6 Fuel pump ASSY 16 Evaporation pipe 7 Fuel level sensor 17 Fuel r...

Page 685: ...FUEL SYSTEMS GENERAL DESCRIPTION 2 5 L MODEL FU 00909 T1 T1 T3 T2 T2 T2 T2 T3 7 6 8 9 10 10 9 19 18 22 12 12 12 23 12 12 24 25 12 21 20 1 2 3 4 2 5 A B 28 29 16 F F A E T1 T1 D C D C 20 12 12 12 12 12...

Page 686: ...Evaporation pipe ASSY 28 Fuel sub level sensor 5 Fuel tank 17 Evaporation pipe 29 Evaporation hose F 6 Fuel pump gasket 18 Fuel return hose A 30 Evaporation hose G 7 Fuel pump ASSY 19 Jet pump hose 8...

Page 687: ...FU H4SOw oOBD 11 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 5 FUEL LINE FU 00910 12 11 1 1 1 7 1 1 9 10 10 1 6 5 4 3 2 1 1 8 24 24 18 23 13 14 1 1 21 20 25 22 19 17 16 15 C B B A C A T...

Page 688: ...er hose A 23 Two way valve drain hose B 4 Fuel filter holder 14 Canister 24 Clamp 5 Fuel filter cup 15 Canister bracket plate 25 Front canister bracket 6 Fuel filter 16 Cushion 7 Evaporation hose 17 C...

Page 689: ...pipe ASSY 7 Air vent pipe holder Tightening torque N m kgf m ft lb 2 Evaporation hose holder 8 Filler pipe packing T 7 5 0 76 5 5 3 Clip 9 Filler ring 4 Clamp 10 Filler cap 5 Air vent hose 11 Filler c...

Page 690: ...on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electri...

Page 691: ...e and throttle position sensor 6 Disconnect the air by pass hose from purge con trol solenoid valve 7 Disconnect the engine coolant hoses from throt tle body 8 Remove the bolts which install the throt...

Page 692: ...cable A 6 Disconnect the cruise control cable B Model with cruise control 7 Remove the power steering pump and tank from brackets 1 Remove the resonator chamber Ref to IN H4SO 7 REMOVAL Resonator Cham...

Page 693: ...t hose from throt tle body 11 Disconnect the brake booster hose 12 Remove the air cleaner case stay RH and en gine harness bracket and then disconnect the en gine harness connectors from bulkhead harn...

Page 694: ...es in a container or cloth 19 Remove the bolts which hold the intake mani fold onto cylinder heads 20 Remove the intake manifold B INSTALLATION 1 Install the intake manifold onto cylinder heads NOTE A...

Page 695: ...ion sensor 6 Connect the knock sensor connector 7 Connect the connectors to engine coolant tem perature sensor 8 Install the air cleaner case stay RH and engine harness bracket and then connect the en...

Page 696: ...et Tightening torque 22 N m 2 2 kgf m 16 2 ft lb 4 Install the power steering pipes onto intake manifold protector RH 5 Install the front side V belt Ref to ME H4SO 44 INSTALLATION V belt 6 Install th...

Page 697: ...cable to battery C DISASSEMBLY 1 Disconnect the engine ground cable from intake manifold 2 Disconnect the connector from ignition coil ig nitor ASSY 3 Remove the ignition coil ignitor ASSY 4 Disconne...

Page 698: ...uum hose from intake manifold 9 Remove the fuel pipe protector LH 10 Remove the fuel pipe protector RH 11 Disconnect the connectors from fuel injectors 12 Disconnect the connector from purge control s...

Page 699: ...ove the two bolts which hold the fuel pipes on intake manifold 20 Remove the fuel injectors 1 Remove the fuel injector securing clip 2 Remove the fuel injector while lifting up the fuel injector pipe...

Page 700: ...tor A from intake manifold D ASSEMBLY 1 Install the fuel pipe assembly B and pressure regulator A etc to intake manifold 2 Tighten the bolt which installs the fuel pipes on intake manifold Tightening...

Page 701: ...ing clip 7 Tighten the bolt which installs the fuel injector pipe on intake manifold Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb 8 Tighten the two bolts which install the fuel pipes on intake manif...

Page 702: ...jectors and purge control solenoid valve 14 Hold the engine harness by harness band A and harness bracket B NOTE Do not use harness bands on the harnesses which are supposed to be protected by fuel pi...

Page 703: ...gf m 2 5 ft lb NOTE Replace the O ring with a new one 21 Connect the connector to intake air tempera ture and manifold absolute pressure sensor 22 Connect the connectors to throttle position sen sor a...

Page 704: ...ove the air intake duct and air cleaner case Ref to IN H4SO 6 REMOVAL Air Intake Duct and Ref to IN H4SO 5 REMOVAL Air Cleaner Case 3 Disconnect the connector from engine coolant temperature sensor 4...

Page 705: ...tery 2 Remove the bolt which installs the crankshaft position sensor to cylinder block 3 Remove the crankshaft position sensor and then disconnect the connector from it B INSTALLATION Install in the r...

Page 706: ...sensor to camshaft position sensor support 4 Remove the bolt which installs the camshaft po sition sensor support to camshaft cap LH 5 Remove the camshaft position sensor and cam shaft position senso...

Page 707: ...INSTALLATION 1 Install the knock sensor to cylinder block NOTE For tightening torque refer to COMPONENT Ref to FU H4SOw oOBD 3 COMPONENT General Description Extraction area of knock sensor cord must...

Page 708: ...connector from throttle position sensor 3 Remove the throttle position sensor holding screws and remove it B INSTALLATION Install in the reverse order of removal NOTE For tightening torque refer to CO...

Page 709: ...peration procedures refer to Subaru Select Monitor Operation Manual 3 Insert the cartridge to Subaru Select Moni tor 4 Connect the Subaru Select Monitor to data link connector 5 Turn the ignition swit...

Page 710: ...lug cord from ignition coil and ignitor ASSY 3 Disconnect the connector from intake air tem perature and manifold absolute pressure sensor 4 Remove the intake air temperature and manifold absolute pre...

Page 711: ...le from battery 2 Disconnect the connector from idle air control solenoid valve 3 Remove the idle air control solenoid valve from throttle body B INSTALLATION Install in the reverse order of removal N...

Page 712: ...k plug cords from spark plugs 1 and 3 cylinders 6 Remove the power steering pump and tank from brackets 1 Remove the front side V belt Ref to ME H4SO 44 REMOVAL V belt 2 Remove the bolts which hold th...

Page 713: ...connector from fuel injector 9 Remove the bolts which hold the fuel injector pipe to intake manifold 10 Remove the fuel injector from intake manifold 1 Remove the fuel injector securing clip 2 Remove...

Page 714: ...tank on body 5 Disconnect the connector from front window washer motor 6 Disconnect the connector from rear gate glass washer motor 7 Disconnect the rear window glass washer hose from washer motor and...

Page 715: ...4 Remove the fuel injector from intake manifold 1 Remove the fuel injector securing clip 2 Remove the fuel injector while lifting up the fuel injector pipe B INSTALLATION 1 RH SIDE Install in the reve...

Page 716: ...Install in the reverse order of removal NOTE Replace the O rings with new ones Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb Tightening torque 5 0 N m 0 51 kgf m 3 7 ft lb Tightening torque 19 N m 1...

Page 717: ...ION When removing the oxygen sensor wait until the exhaust pipe cools otherwise it will dam age exhaust pipe B INSTALLATION 1 Before installing the oxygen sensor apply anti seize compound only to the...

Page 718: ...FU H4SOw oOBD 42 FUEL INJECTION FUEL SYSTEMS OXYGEN SENSOR 5 Connect the battery ground cable to battery FU 00009...

Page 719: ...he floor mat of front passenger seat 4 Remove the protect cover 5 Remove the nuts A which hold the ECM to bracket 6 Remove the clip B from bracket 7 Disconnect the ECM connectors and take out the ECM...

Page 720: ...AL 1 Disconnect the ground cable from battery 2 Remove the front side sill cover of passenger side 3 Remove the bolt which holds the main relay bracket on body 4 Disconnect the connectors from main re...

Page 721: ...d cable from battery 2 Remove the front side sill cover of passenger side 3 Remove the bolt which holds the fuel pump relay bracket on body 4 Disconnect the connector from fuel pump relay 5 Remove the...

Page 722: ...n the ignition switch to OFF 2 DRAINING FUEL WARNING Place NO FIRE signs near working area Be careful not to spill fuel on floor 1 Set the vehicle on a lift 2 Disconnect the ground cable from battery...

Page 723: ...k cord on floor panel down under body 7 Remove the rear crossmember Ref to RS 21 REMOVAL Rear Crossmember 8 Disconnect the two way valve hose A from two way valve and disconnect the canister hose B fr...

Page 724: ...anister hose B to canister 4 Connect the fuel filler hose and air vent hose 5 Connect the fuel hoses and then secure them with clips and quick connector Ref to FU H4SOw oOBD 64 INSTALLATION Fuel De li...

Page 725: ...FUEL TANK 10 Connect the connector to the fuel pump relay C INSPECTION 1 Make sure there are no cracks holes or other damage on fuel tank 2 Make sure the fuel hoses and fuel pipes are not cracked and...

Page 726: ...l filler cap 4 Disconnect the ground cable from battery 5 Remove the screws holding packing in place 6 Remove the nuts of rear wheel RH 7 Lift up the vehicle 8 Remove the rear wheel RH 9 Drain fuel fr...

Page 727: ...iller pipe 14 Remove the bolt which holds the fuel filler pipe bracket on body 15 Loosen the clamp and separate the fuel filler hose A from fuel filler pipe 16 Move the clip and separate the air vent...

Page 728: ...pipe 5 Connect the air vent hose to the fuel filler pipe 6 Insert the fuel filler hose A approx 35 to 40 mm 1 38 to 1 57 in over the lower end of fuel filler pipe and tighten the clamp CAUTION Do not...

Page 729: ...oration hoses onto clip of fuel filler pipe 10 Install the fuel filler pipe protector 11 Install the rear wheel RH 12 Lower the vehicle 13 Tighten the wheel nuts 14 Connect the connector to the fuel p...

Page 730: ...ft up the vehicle 5 Drain fuel from fuel tank Set a container under vehicle and remove the drain plug from fuel tank 6 Tighten the fuel drain plug Tightening torque 26 N m 2 7 kgf m 19 2 ft lb 7 Raise...

Page 731: ...from fuel tank 6 Tighten the fuel drain plug Tightening torque 26 N m 2 7 kgf m 19 2 ft lb 7 Raise the rear seat and turn the floor mat up 8 Remove the access hole lid 9 Disconnect the connector from...

Page 732: ...figure Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb 1 6 L and 2 0 L MODEL 2 5 L MODEL C INSPECTION Connect the lead harness to connector terminal of fuel pump and apply battery power supply to chec...

Page 733: ...or is built in the fuel pump assembly 1 Remove the fuel pump assembly Ref to FU H4SOw oOBD 54 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et 1 6 L and 2 0 L MODEL 2 5 L MODEL 3 R...

Page 734: ...up the vehicle 3 Drain fuel from fuel tank Set a container under vehicle and remove the drain plug from fuel tank 4 Tighten the fuel drain plug Tightening torque 26 N m 2 7 kgf m 19 2 ft lb 5 Remove t...

Page 735: ...FU H4SOw oOBD 59 FUEL INJECTION FUEL SYSTEMS FUEL SUB LEVEL SENSOR B INSTALLATION Install in the reverse order of removal Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb FU 00115...

Page 736: ...he filter from holder B INSTALLATION CAUTION If fuel hoses are damaged at connecting por tion replace them with new ones If clamps are badly damaged replace them with new ones 1 Install in the reverse...

Page 737: ...on floor 1 Remove the fuel tank Ref to FU H4SOw oOBD 47 REMOVAL Fuel Tank 2 Move the clip and disconnect the evaporation hose from fuel cut valve 3 Remove the bolts which install the fuel cut valve B...

Page 738: ...MPER VALVE 24 Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H4SOw oOBD 46 RELEASING OF FUEL PRESSURE OPERATION Fuel 2 Remove the fuel damper valve from fuel return line B INSTALLAT...

Page 739: ...and remove the fuel filler cap 4 Remove the floor mat Ref to EI 55 REMOV AL Floor Mat 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation pipes and hos es 6 In the engin...

Page 740: ...ake sure the connected portion is not damaged or not covered with dust If necessary clean the seal surface of pipe 1 Set the new retainer B to connector A 2 Push the pipe into connector completely NOT...

Page 741: ...0 098 0 059 in L 22 5 2 5 mm 0 886 0 098 in 3 Connect the evaporation hose to pipe by approx 15 mm 0 59 in from hose end L 17 5 2 5 mm 0 689 0 098 in CAUTION Be sure to inspect the hoses and their co...

Page 742: ...e and possible cause Corrective action 1 Insufficient fuel supply to injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Trouble...

Page 743: ...ON CONTROL AUX EMISSION CONTROL DEVICES EC H4SOw oOBD Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 4 4 Canister 5 5 Purge Control Solenoid Valve 6 6 Two way Va...

Page 744: ...rts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be carefu...

Page 745: ...same as those for center exhaust pipe Ref to EX H4SOw oOBD 9 RE MOVAL Center Exhaust Pipe B INSTALLATION The front catalytic converter and center exhaust pipe are integrated into one unit Therefore th...

Page 746: ...ame as those for center exhaust pipe Ref to EX H4SOw oOBD 9 RE MOVAL Center Exhaust Pipe B INSTALLATION The rear catalytic converter and center exhaust pipe are integrated into one unit Therefore the...

Page 747: ...which hold the two can ister hoses and then disconnect the three evapo ration hoses from canister 3 Remove the canister from body B INSTALLATION Install in the reverse order of removal Tightening tor...

Page 748: ...e connector and hose of purge control solenoid valve and then remove the purge control solenoid valve B INSTALLATION Install in the reverse order of removal Tightening torque 19 N m 1 9 kgf m 13 7 ft...

Page 749: ...vehicle 2 Remove the canister from body Ref to EC H4SOw oOBD 5 REMOVAL Canister 3 Remove the two way valve with bracket as a sin gle unit from body 4 Remove the two way valve from bracket B INSTALLAT...

Page 750: ...EC H4SOw oOBD 8 EMISSION CONTROL AUX EMISSION CONTROL DEVICES TWO WAY VALVE...

Page 751: ...INTAKE INDUCTION IN H4SOw oOBD Page 1 General Description 2...

Page 752: ...IN H4SOw oOBD 2 INTAKE INDUCTION GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is included in IN H4SO section Ref to IN H4SO 2 General Description...

Page 753: ...MECHANICAL ME H4SOw oOBD Page 1 General Description 2...

Page 754: ...ME H4SOw oOBD 2 MECHANICAL GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to ME H4SO 2 General Description...

Page 755: ...EXHAUST EX H4SOw oOBD Page 1 General Description 2 2 Front Exhaust Pipe 6 3 Center Exhaust Pipe 9 4 Rear Exhaust Pipe 10 5 Muffler 11...

Page 756: ...ENERAL DESCRIPTION 1 General Description A COMPONENT 1 WITH CATALYTIC CONVERTER EX 00150 T7 T1 T6 T2 T2 T3 T6 T5 T5 T1 T2 T2 16 16 16 18 19 28 29 30 21 22 20 27 23 26 24 1 2 3 3 4 5 6 7 8 25 11 17 10...

Page 757: ...pipe upper cover 30 Rear catalytic converter 6 Front exhaust pipe 20 Center exhaust pipe lower cover 7 Front exhaust pipe lower cover RH 21 Protector Tightening torque N m kgf m ft lb 22 Gasket T1 8 0...

Page 758: ...EX H4SOw oOBD 4 EXHAUST GENERAL DESCRIPTION 2 WITHOUT CATALYTIC CONVERTER EX 00151 T6 T5 T3 T4 T4 T1 T2 T2 T2 16 16 16 18 17 19 20 23 22 21 1 2 3 3 4 5 6 7 8 11 24 12 10 9 15 13 14 T5 T4 25 25 T1 T2...

Page 759: ...Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect the ground cable from battery 1 Front exhaust pipe upper...

Page 760: ...n the front and center exhaust pipe assembly 7 Remove the bolt which installs the front and cen ter exhaust pipe assembly to hanger bracket 8 Remove the front and center exhaust pipe as sembly from ve...

Page 761: ...ront and center exhaust pipe assembly to hanger bracket 5 Tighten the nuts which hold the front exhaust pipe onto cylinder heads Tightening torque 30 N m 3 1 kgf m 22 1 ft lb 6 Install the under cover...

Page 762: ...OBD 8 EXHAUST FRONT EXHAUST PIPE 11 Connect the battery ground cable to battery C INSPECTION 1 Make sure there are no exhaust leaks from con nections and welds 2 Make sure there are no holes or rustin...

Page 763: ...front exhaust pipe Ref to EX H4SOw oOBD 6 REMOVAL Front Exhaust Pipe B INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit Refer to the procedure for install ing the front...

Page 764: ...er B INSTALLATION 1 Apply a coat of SUBARU CRC to mating area of cushion rubbers in advance SUBARU CRC Part No 004301003 2 Install the rear exhaust pipe bracket to cushion rubber NOTE Replace the gask...

Page 765: ...004301003 3 Remove the front right and left cushion rubber and detach the muffler assembly B INSTALLATION 1 Install in the reverse order of removal NOTE Replace the gasket with a new one Tightening to...

Page 766: ...EX H4SOw oOBD 12 EXHAUST MUFFLER...

Page 767: ...COOLING CO H4SOw oOBD Page 1 General Description 2...

Page 768: ...CO H4SOw oOBD 2 COOLING GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to CO H4SO 2 General Description...

Page 769: ...LUBRICATION LU H4SOw oOBD Page 1 General Description 2...

Page 770: ...LU H4SOw oOBD 2 LUBRICATION GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is the same as that of model with OBD Ref to LU H4SO 2 General Description...

Page 771: ...SPEED CONTROL SYSTEMS SP H4SOw oOBD Page 1 General Description 2...

Page 772: ...H4SOw oOBD 2 SPEED CONTROL SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATION Specification of model without OBD is the same as that of model with OBD Ref to SP H4SO 2 General Descripti...

Page 773: ...IGNITION IG H4SOw oOBD Page 1 General Description 2...

Page 774: ...IG H4SOw oOBD 2 IGNITION GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specifications for model without OBD is included in IG H4SO section Ref to IG H4SO 2 General Description...

Page 775: ...STARTING CHARGING SYSTEMS SC H4SOw oOBD Page 1 General Description 2...

Page 776: ...H4SOw oOBD 2 STARTING CHARGING SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Specification of model without OBD is included in SC H4SO section Ref to SC H4SO 2 General Descriptio...

Page 777: ...CM I O Signal 18 6 Subaru Select Monitor 21 7 Read Diagnostic Trouble Code DTC 24 8 Inspection Mode 26 9 Clear Memory Mode 28 10 Compulsory Valve Operation Check Mode 29 11 Malfunction Indicator Light...

Page 778: ...or 3 Turn the ignition switch to ON and the SUB ARU Select Monitor switch to ON 4 Read any DTC on SUBARU Select Monitor Ref to EN H4SOw oOBD 24 WITH SUB ARU SELECT MONITOR OPERATION Read Diagnostic Tr...

Page 779: ...Table Ref to EN H4SOw oOBD 97 INSPECTION General Diagnos tic Table 3 CHECK INDICATION OF DTC ON MALFUNC TION INDICATOR LIGHT 1 Perform the read DTC read memory mode Ref to EN H4SOw oOBD 24 WITH OUT SU...

Page 780: ...Others Outdoor temperature C F Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine s...

Page 781: ...position of fuel gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of p...

Page 782: ...nsors or all electrical control modules at the harness side connector use a tapered pin with a diameter of less than 0 64 mm 0 025 in Do not insert the pin more than 5 mm 0 20 in into the part 6 Befor...

Page 783: ...and rear wheels After di agnosis of engine control system perform the ABS memory clearance procedure of self diagnosis sys tem B INSPECTION Before performing diagnostics check the following items whi...

Page 784: ...N REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical systems 22771AA030 SUBARU SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 W...

Page 785: ...PONENTS LOCATION 4 Electrical Components Location A LOCATION 1 MODULE A LHD B RHD 1 Engine control module ECM 3 Read memory connector 5 Data link connector 2 Malfunction indicator light 4 Test mode co...

Page 786: ...EN H4SOw oOBD 10 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00156 EN 01517 2 EN 01518 4 3 EN 01519 5...

Page 787: ...CATION 2 SENSOR 1 Engine coolant temperature sen sor 3 Throttle position sensor 7 Vehicle speed sensor 4 Knock sensor 2 Intake air temperature and Mani fold absolute pressure sensor 5 Crankshaft posit...

Page 788: ...EN H4SOw oOBD 12 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 01521 1 EN 01522 2 EN 01523 3 EN 01524 4 EN 01525 5 EN 01526 6 EN 01527 7...

Page 789: ...EN H4SOw oOBD 13 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 8 Oxygen sensor With catalyst con verter model EN 01528 8 EN 01529 8...

Page 790: ...ONENTS LOCATION 3 SOLENOID VALVE EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS 1 Purge control solenoid valve 3 Ignition coil and ignitor ASSY 4 CO resistor Without catalyst con verter model...

Page 791: ...EN H4SOw oOBD 15 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 01531 1 EN 01532 2 EN 01533 3 EN 01534 4...

Page 792: ...EN H4SOw oOBD 16 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION A LHD B RHD 1 Fuel pump 2 Main relay 3 Fuel pump relay EN 01535 A 2 3 1 EN 01536 B 2 3 1...

Page 793: ...EN H4SOw oOBD 17 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 01537 1 EN 01538 3 2 A EN 01539 3 2 B...

Page 794: ...Signal B136 7 0 Rich mixture 0 7 Lean mixture 0 Shield B136 23 0 0 Engine cool ant temper ature sensor Signal B136 14 0 6 1 0 0 6 1 0 After warm up GND B136 16 0 0 Vehicle speed sensor B135 24 0 or 5...

Page 795: ...ted 0 Back up power supply B136 9 10 13 13 14 Control unit power sup ply B136 1 10 13 13 14 2 Ignition con trol 1 2 B134 25 0 3 4 max 3 4 B134 26 0 3 4 max Fuel injector 1 B134 4 10 13 13 14 Waveform...

Page 796: ...relay 2 con trol B134 12 ON 0 OFF 10 13 ON 0 OFF 13 14 Self shutoff control B135 19 10 13 13 14 Malfunction indicator light B134 11 Light ON 1 max Light OFF 10 14 Engine speed output B134 30 0 13 min...

Page 797: ...d in lower portion of instrument panel on driver s side 2 Connect the diagnosis cable to data link connector CAUTION Do not connect the scan tools except for SUB ARU Select Monitor 5 Turn the ignition...

Page 798: ...e sensor signal mmHg or kPa or inHg or psi Intake air temperature signal C or F Throttle position signal V Injection pulse width ms ISC valve step STEP Oxygen sensor output signal 1 V Knock correction...

Page 799: ...relay is in function Knocking signal ON or OFF When knocking signal is entered Radiator fan relay signal 2 ON or OFF When radiator fan relay 2 is in function Engine torque control signal 1 ON or OFF...

Page 800: ...AL For detailed concerning DTCs refer to the List of DTC Ref to EN H4SOw oOBD 55 LIST List of Di agnostic Trouble Code DTC 2 WITHOUT SUBARU SELECT MONITOR Step Check Yes No 1 CHECK STATUS OF CHECK MAL...

Page 801: ...gment 0 2 seconds ON signifies one And middle segment 0 5 sec onds ON means OK code NOTE For detailed concerning DTCs refer to the List of DTC Ref to EN H4SOw oOBD 55 LIST List of Di agnostic Trouble...

Page 802: ...LECT MONITOR After performing diagnostics and clearing memory check for any remaining unresolved trouble data 1 Connect the test mode connector green at the lower portion of instrument panel on the dr...

Page 803: ...s side 5 Turn the ignition switch to ON Does the malfunction indicator light come on Go to step 2 Check the follow ing and repair if necessary NOTE Open or short circuit in engine control module powe...

Page 804: ...CATOR LIGHT 1 Turn the ignition switch to OFF 2 Set the shift lever to neutral position MT model or set selector lever to P position AT model 3 Connect the test mode connector and read memory connect...

Page 805: ...el on the driver s side 2 Each valve functions when the ignition switch is turned to ON engine OFF A list of the support portion is shown in the follow ing table A Test mode connector Contents Compuls...

Page 806: ...OES NOT COME ON Malfunction Indicator Light 3 Malfunction indicator light does not go off Ref to EN H4SOw oOBD 34 MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF Malfunction Indicator Light 4 Malfunction...

Page 807: ...g the engine the malfunction indica tor light goes out If it does not either the engine or the emission control system is malfunctioning Ref to EN H4SOw oOBD 2 PROCEDURE Ba sic Diagnostic Procedure 3...

Page 808: ...than 1 V Go to step 4 Go to step 2 2 CHECK POOR CONTACT Does the malfunction indicator light come on when shaking or pulling ECM connector and harness Repair poor con tact in the ECM connector Go to...

Page 809: ...ion meter connector Repair the poor contact in combi nation meter con nector Go to step 6 6 CHECK HARNESS BETWEEN COMBINA TION METER AND IGNITION SWITCH CON NECTOR 1 Turn the ignition switch to ON 2 M...

Page 810: ...switch to ON Does the malfunction indicator light come on Repair the short circuit in harness between combina tion meter and ECM connector Replace the ECM Ref to FU H4SOw oOBD 43 Engine Control Modul...

Page 811: ...1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 i12 1 2 3 4 5 6 8 7 9 10 11 12 13 14 21 9 32 i2 1 2 3 4 5 6 10 11 12 13 14 15 7 16 23 30 19 20 22 26 27 28 29 8 17 24 31 18 25 B134 1 2 3 4 5...

Page 812: ...tor Connector terminal B135 No 14 B75 No 1 Is the resistance less than 1 Go to step 4 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between ECM and...

Page 813: ...onnec tor Replace the ECM Ref to FU H4SOw oOBD 43 Engine Control Module ECM EN 01547 BATTERY 1 B72 i2 B75 B76 B37 IGNITION SWITCH i11 COMBINATION METER C i12 A B134 A B135 B SBF 4 4 A11 B14 ECM LHD 14...

Page 814: ...nd line Ref to EN H4SOw oOBD 42 ENGINE CONTROL MODULE ECM POWER SUPPLY AND GROUND LINE Diagnostics for Engine Starting Failure 3 Inspection of ignition control system Ref to EN H4SOw oOBD 45 IGNITION...

Page 815: ...step 2 Go to step 3 2 CHECK DTC Ref to EN H4SOw oOBD 24 OPERATION Read Diagnostic Trouble Code DTC Is the DTC stored in memory Ref to EN H4SOw oOBD 55 LIST List of Diagnostic Trouble Code DTC Record...

Page 816: ...4 No 1 Engine ground Is the resistance less than 1 Repair the ground short circuit Go to step 6 6 CHECK HARNESS BETWEEN ECM AND STARTER MOTOR CIRCUIT 1 Turn the ignition switch to START 2 Measure the...

Page 817: ...otor and ignition switch connector Go to step 11 11 CHECK TRANSMISSION HARNESS 1 Disconnect the connector from inhibitor switch 2 Measure the resistance of harness between transmission harness and inh...

Page 818: ...135 B136 B22 E3 MAIN RELAY 1 B19 C1 13 15 14 16 C2 C9 B7 A7 A8 A27 C22 C21 ECM 2 3 5 4 6 SBF 1 SBF 4 SBF 5 No 11 F44 B61 2 RHD RHD LHD LHD 1 B72 IGNITION SWITCH 4 BATTERY 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 819: ...tep 4 Repair the open or ground short cir cuit of power sup ply circuit 4 CHECK INPUT VOLTAGE OF ECM 1 Turn the ignition switch to ON 2 Measure the voltage between ECM connec tor and chassis ground Co...

Page 820: ...r terminal B47 No 5 Chassis ground B47 No 6 Chassis ground Is the voltage more than 10 V Go to step 10 Repair the open or ground short cir cuit in harness of power supply cir cuit 10 CHECK INPUT VOLTA...

Page 821: ...and Ref to EN H4SOw oOBD 26 OPERATION Inspection Mode WIRING DIAGRAM EN 01550 B134 B72 B22 E3 ECM 26 25 27 SBF 4 SBF 1 BATTERY NO 11 E12 4 1 IGNITION SWITCH 6 14 4 5 3 3 4 1 2 IGNITION COIL IGNITOR AS...

Page 822: ...epair the har ness and connec tor NOTE In this case repair the following Open circuit or ground short in harness between ignition coil igni tor ASSY and ignition switch connector Poor contact in coupl...

Page 823: ...coil ignitor ASSY 8 CHECK HARNESS BETWEEN ECM AND IG NITION COIL IGNITOR ASSY CONNEC TOR 1 Disconnect the connector from ECM 2 Measure the resistance of harness between ECM and ignition coil ignitor A...

Page 824: ...ween ECM and chassis ground Connector terminal B134 No 26 Chassis ground Is the resistance more than 1 M Go to step 12 Repair the ground short circuit in har ness between ECM and ignition coil ignitor...

Page 825: ...D 26 OPER ATION Inspection Mode WIRING DIAGRAM EN 01551 BATTERY 1 B72 B97 R1 B134 IGNITION SWITCH B46 R58 R57 R15 FUEL PUMP RELAY FUEL PUMP 4 ECM 1 4 B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 826: ...c tor NOTE In this case repair the following Open circuit in harness between fuel pump connec tor and chassis grounding terminal Poor contact in couplingconnector R15 and B97 3 CHECK POWER SUPPLY TO F...

Page 827: ...ETWEEN ECM AND FUEL PUMP RELAY CONNECTOR 1 Disconnect the connectors from ECM 2 Measure the resistance of harness between ECM and fuel pump relay connector Connector terminal With Immobilizer B134 No...

Page 828: ...cope or attach a screwdriver to injector for this check Does the fuel injector emit operating sound Check the fuel pressure Ref to ME H4SO 31 INSPECTION Fuel Pressure Go to step 2 EN 01552 BATTERY E5...

Page 829: ...EEN ECM AND FUEL INJECTOR CONNECTOR 1 Disconnect the connector from ECM 2 Connect the connector to 1 fuel injector 3 Measure the resistance of harness between ECM and fuel injector connector Connector...

Page 830: ...minal B134 No 14 Chassis ground Is the resistance less than 1 Repair the ground short circuit in har ness between ECM and fuel injector connector Go to step 10 10 CHECK HARNESS BETWEEN ECM AND FUEL IN...

Page 831: ...c Procedure with Diagnostic Trouble Code DTC 24 Idle air control solenoid valve Idle air control solenoid valve is not in function Harness connector between ECM and idle air control solenoid valve is...

Page 832: ...o specifi cation Ref to EN H4SOw oOBD 89 DTC 46 CO RESISTOR GENERAL SPEC VEHICLES Diagnostic Procedure with Diagnostic Trouble Code DTC 51 Neutral position switch MT Neutral position switch signal is...

Page 833: ...e stalls Restarting impossible CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOB...

Page 834: ...Poor contact in couplingconnector B21 4 CHECK HARNESS BETWEEN ECM AND CRANKSHAFT POSITION SENSOR CON NECTOR Measure the resistance of harness between ECM connector and chassis ground Connector termina...

Page 835: ...DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC 8 CHECK ANY OTHER DTCs APPEARANCE Is any other DTC displayed Proceed with the diagnosis corre sponding to the DTC A temporary poor co...

Page 836: ...SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspection Mode WIRING DIAGRAM Step Check Yes No 1 CHECK OPERATION OF STARTER MOTOR Does the starter motor oper ate when...

Page 837: ...tor from ECM 3 Set the selector lever to P or N position AT model 4 Turn the ignition switch to START 5 Measure the power supply voltage between ECM connector and chassis ground Connector terminal B13...

Page 838: ...to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspection Mode WIRING DIAGRAM Step Check Yes No 1 CHECK CONDITION OF CAMSHAFT POSI TION SENSOR INSTALLATION Are...

Page 839: ...ound Is the resistance less than 5 Repair the ground short circuit in har ness between camshaft position sensor and ECM connector Go to step 5 5 CHECK INPUT SIGNAL FOR ECM 1 Turn the ignition switch t...

Page 840: ...ous idling Poor driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SO...

Page 841: ...NECTOR 1 Turn the ignition switch to ON 2 Measure the voltage between engine coolant temperature sensor connector and engine ground Connector terminal E8 No 1 Engine ground Is the voltage more than 10...

Page 842: ...nnector Poor contact in couplingconnector B21 Poor contact in sensor ground joint connector B83 5 CHECK ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between engine cool ant temperature sen...

Page 843: ...Poor driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 O...

Page 844: ...ss and connec tor NOTE In this case repair the following Open circuit in harness between knock sensor and ECM connector Poor contact in knock sensor con nector Poor contact in couplingconnector B21 4...

Page 845: ...faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspection Mode WIRING DIAGRAM EN 01557 BATTERY E2 E2...

Page 846: ...ECM and idle air control solenoid valve connector Poor contact in couplingconnector B21 3 CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR 1 Disconnect the connector from ECM 2...

Page 847: ...ol Solenoid Valve 8 CHECK AIR BY PASS LINE 1 Turn the ignition switch to OFF 2 Remove the idle air control solenoid valve from throttle body Ref to FU H4SOw oOBD 35 Idle Air Control Solenoid Valve 3 R...

Page 848: ...rmance CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspecti...

Page 849: ...136 No 15 E20 No 3 Is the resistance less than 1 Go to step 4 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between ECM and intake air temperature a...

Page 850: ...ACT Check poor contact in ECM connector Is there poor contact in ECM connector Repair the poor contact in ECM connector Contact with your SUBARU distribu tor service NOTE Inspection by your SUBARU dis...

Page 851: ...ous idling Engine stalls Poor driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and...

Page 852: ...tween ECM and chassis ground 3 CHECK INPUT SIGNAL FOR ECM 1 Connect the connector to ECM and throttle position sensor 2 Ignition the switch to ON 3 Measure the voltage between ECM termi nals while thr...

Page 853: ...e stalls Idle mixture is out of specifications CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref...

Page 854: ...ircuit between main relay and oxygen sensor 4 CHECK HARNESS CONNECTOR BETWEEN OXYGEN SENSOR AND ENGINE GROUND CABLE Measure the resistance between oxygen sen sor and chassis ground Connector terminal...

Page 855: ...obe at ECM connec tor terminal positive and its ground lead at negative 4 Start the engine Do 0 1 and 1 V waveform pat terns alternately appear on the oscilloscope screen Go to step 9 Replace the oxy...

Page 856: ...No 1 CHECK SPEEDOMETER OPERATION IN COMBINATION METER Does the speedometer operate normally Go to step 2 Check the speed ometer and vehi cle speed sensor EN 01561 SBF 1 SBF 4 BATTERY IGNITION SWITCH...

Page 857: ...EEN ECM AND COMBINATION METER CONNECTOR Measure the voltage between ECM and chas sis ground Connector terminal B135 No 24 Chassis ground Is the voltage more than 2 V Repair the har ness and connec tor...

Page 858: ...epair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspection Mode WIRING DIAGRAM...

Page 859: ...nector from purge control solenoid valve 4 Turn the ignition switch to ON 5 Measure the voltage between ECM and chassis ground Connector terminal B134 No 2 Chassis ground Is the voltage more than 10 V...

Page 860: ...connec tor NOTE In this case repair the following Open circuit in harness between main relay and purge control sole noid valve connec tor Poor contact in main relay con nector Poor contact in couplin...

Page 861: ...shorted CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspec...

Page 862: ...terminal B135 No 17 Chassis ground Is the resistance less than 10 Repair the ground short circuit in har ness between ECM and TCM connector Go to step 2 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR M...

Page 863: ...nce CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspection...

Page 864: ...al B136 No 5 Chassis ground B136 No 16 Chassis ground Is the resistance more than 1 M Go to step 4 Repair the ground short circuit in har ness between ECM and mani fold absolute pres sure sensor conne...

Page 865: ...o specifications TROUBLE SYMPTOM Erroneous idling Mixture ratio is too rich or too lean CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oO...

Page 866: ...55 No 1 B136 No 12 B155 No 2 B136 No 16 B155 No 3 Is the resistance less than 1 Go to step 4 Repair the open circuit in harness between ECM and CO resistor con nector 4 CHECK HARNESS BETWEEN CO RESIS...

Page 867: ...shorted TROUBLE SYMPTOM Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN...

Page 868: ...step 5 Repair the short circuit in transmis sion harness or replace neutral position switch 5 CHECK NEUTRAL POSITION SWITCH Measure the resistance between transmission harness connector terminals Con...

Page 869: ...open or shorted TROUBLE SYMPTOM Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and...

Page 870: ...he har ness and connec tor NOTE In this case repair the following Open circuit in harness between ECM and inhibitor switch connector Poor contact in couplingconnector B12 Poor contact in inhibitor swi...

Page 871: ...repair or replacement of faulty parts conduct Clear Memory and inspection modes Ref to EN H4SOw oOBD 28 OPERATION Clear Memory Mode and Ref to EN H4SOw oOBD 26 OPER ATION Inspection Mode WIRING DIAGRA...

Page 872: ...of terminal 4 CHECK INPUT VOLTAGE OF ECM 1 Run the engine at idle 2 Measure the voltage between ECM connec tor and chassis ground Connector terminal B136 No 1 Chassis ground B136 No 2 Chassis ground...

Page 873: ...rs 1 ECM power supply 2 Spark plug 3 Engine coolant temperature sensor 4 Pressure regulator 5 Manifold absolute pressure sensor 6 Fuel pump 7 Fuel injector 8 Camshaft position sensor 9 Crankshaft posi...

Page 874: ...ration 1 Spark plug 2 Throttle position sensor 3 Ignition coil 4 Fuel pump 5 Pressure regulator 6 Fuel injector 7 Manifold absolute pressure sensor 8 Engine coolant temperature sensor 9 Idle air contr...

Page 875: ...1 Pressure regulator 2 Manifold absolute pressure sensor 3 Engine coolant temperature sensor 4 Throttle sensor 5 Fuel pump A B B B B 14 Remarks 1 ECM power supply 2 Manifold absolute pressure sensor...

Page 876: ...EN H4SOw oOBD 100 ENGINE DIAGNOSTICS GENERAL DIAGNOSTIC TABLE...

Page 877: ...l fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine p...

Page 878: ......

Page 879: ...olenoid Valve 36 13 Fuel Injector 37 14 Tumble Generator Valve Assembly 41 15 Tumble Generator Valve Actuator 42 16 Wastegate Control Solenoid Valve 43 17 Front Oxygen A F Sensor 44 18 Rear Oxygen Sen...

Page 880: ...IONS Fuel tank Capacity 60 2 15 9 US gal 13 2 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 450 677 kPa 4 59 6 9 kg cm2 65 27 98 2 psi Discharge flow More than 13...

Page 881: ...UEL SYSTEMS GENERAL DESCRIPTION B COMPONENT 1 INTAKE MANIFOLD FU 00966 16 15 11 T6 T1 T6 T1 T1 24 24 23 6 2 2 3 3 T7 1 5 2 3 4 14 12 13 21 22 T1 T6 T5 T3 T6 T6 T3 T6 T7 T6 T6 T4 8 7 18 20 17 19 7 10 1...

Page 882: ...cuum hose 17 Fuel pipe protector RH 6 Vacuum control hose 18 Blow by hose stay Tightening torque N m kgf m ft lb 7 Intake manifold gasket 19 Intake manifold T1 5 0 0 5 3 6 8 Guide pin 20 Wastegate con...

Page 883: ...TAKE SYSTEM 1 Gasket 5 Manifold absolute pressure sensor Tightening torque N m kgf m ft lb 2 Throttle position sensor 6 Gasket T1 1 6 0 16 1 2 3 Idle air control solenoid valve 7 O ring T2 2 8 0 29 2...

Page 884: ...SITION CAMSHAFT POSITION AND KNOCK SENSORS 1 Crankshaft position sensor 4 AVCS camshaft position sensor STi model and Australia model Tightening torque N m kgf m ft lb 2 Knock sensor T1 6 4 0 65 4 7 3...

Page 885: ...EL SYSTEMS GENERAL DESCRIPTION 4 FUEL TANK FU 00909 T1 T1 T3 T2 T2 T2 T2 T3 7 6 8 9 10 10 9 19 18 22 12 12 12 23 12 12 24 25 12 21 20 1 2 3 4 2 5 A B 28 29 16 F F A E T1 T1 D C D C 20 12 12 12 12 12 2...

Page 886: ...vaporation pipe ASSY 28 Fuel sub level sensor 5 Fuel tank 17 Evaporation pipe 29 Evaporation hose F 6 Fuel pump gasket 18 Fuel return hose A 30 Evaporation hose G 7 Fuel pump ASSY 19 Jet pump hose 8 F...

Page 887: ...FU H4DOTC 9 FUEL INJECTION FUEL SYSTEMS GENERAL DESCRIPTION 5 FUEL LINE FU 00516 12 11 1 1 1 7 1 1 9 10 10 1 6 5 4 3 2 1 1 8 24 24 18 23 13 14 1 1 21 20 25 22 19 17 16 15 C B B A C A T...

Page 888: ...hose A 23 Two way valve drain hose B 4 Fuel filter holder 14 Canister 24 Clamp 5 Fuel filter cup 15 Canister bracket plate 25 Front canister bracket 6 Fuel filter 16 Cushion 7 Evaporation hose 17 Can...

Page 889: ...pe ASSY 6 Air vent pipe 11 Filler cap tether 2 Evaporation hose holder 7 Air vent pipe holder 12 Filler pipe protector 3 Clip 8 Filler pipe packing 4 Clamp 9 Filler ring Tightening torque N m kgf m ft...

Page 890: ...nd replacement Be careful not to burn your hands because each part on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or...

Page 891: ...alve B and manifold absolute pressure sensor C 4 Disconnect the accelerator cable 5 Disconnect the engine coolant hoses from throt tle body 6 Remove the bolts which secure the throttle body to intake...

Page 892: ...IN H4DOTC 7 REMOVAL Air Cleaner 8 Remove the air cleaner element 9 Remove the intercooler Ref to IN H4DOTC 10 REMOVAL Intercooler 10 Disconnect the accelerator cable 11 Remove the coolant filler tank...

Page 893: ...right side wheel apron 13 Disconnect the emission hose from PCV valve 14 Disconnect the engine coolant hoses from throttle body 15 Disconnect the brake booster hose 16 Disconnect the pressure hose fro...

Page 894: ...ion sensor 21 Disconnect the connector from camshaft posi tion sensor 22 Disconnect the connector from ignition coil 23 Disconnect the engine harness fixed by clip A from bracket 24 Disconnect the fue...

Page 895: ...the fuel delivery hose return hose and evaporation hose 3 Connect the connector to the oil pressure switch B crankshaft position sensor C and engine coolant temperature sensor A 4 Connect the connect...

Page 896: ...head harness connectors 10 Connect the brake booster vacuum hose 11 Connect the engine coolant hoses to throttle body 12 Connect the emission hose to PCV valve 13 Connect the pressure hose to intake...

Page 897: ...TALLATION Coolant Filler Tank 16 Connect the accelerator cable Ref to SP H4SO 9 INSTALLATION Accelerator Control Cable 17 Install the intercooler Ref to IN H4DOTC 11 INSTALLATION Intercooler 18 Instal...

Page 898: ...he throttle posi tion sensor A idle air control solenoid valve B and manifold absolute pressure sensor C 5 Disconnect the engine harness fixed by clip D from intake manifold 6 Remove the throttle body...

Page 899: ...e the purge control solenoid valve 12 Disconnect the evaporation hose from intake manifold 13 Disconnect the evaporation hose from purge valve Except Australia model 14 Remove the two bolts which hold...

Page 900: ...sen the clamp which holds the front left side fuel hose to injector pipe and remove the pipe from clamp 20 Remove the fuel injector pipe LH 21 Remove the bolts which install the fuel pipe on intake ma...

Page 901: ...l the fuel pipe assembly and pressure reg ulator to intake manifold Tightening torque 4 9 N m 0 5 kgf m 3 6 ft lb 4 Install the fuel injector pipe LH 5 Connect the left side fuel hose to injector pipe...

Page 902: ...e two bolts which install the fuel pipes on the left side of intake manifold Tightening torque 4 9 N m 0 5 kgf m 3 6 ft lb 11 Connect the evaporation hoses to the purge valve Except Australia model NO...

Page 903: ...nect the evaporation hose as shown in the fig ure 15 Connect the connector to the purge control so lenoid valve 16 Connect the connector to the tumble generator valve sensor Except STi model 17 Connec...

Page 904: ...ontrol solenoid valve B and manifold absolute pressure sensor C 21 Connect the engine harness with clip D to in take manifold 22 Install the engine ground cable to intake mani fold Tightening torque 1...

Page 905: ...FU H4DOTC 27 FUEL INJECTION FUEL SYSTEMS INTAKE MANIFOLD E INSPECTION Make sure the fuel pipe and fuel hoses are not cracked and the connections are tightened firmly...

Page 906: ...enerator Ref to SC H4SO 14 REMOVAL Generator 3 Drain the engine coolant Ref to CO H4DOTC 17 DRAINING OF ENGINE COOL ANT REPLACEMENT Engine Coolant 4 Disconnect the connector from engine coolant temper...

Page 907: ...ound cable from battery 2 Remove the bolt which installs the crankshaft position sensor to cylinder block 3 Remove the crankshaft position sensor and dis connect the connector from it B INSTALLATION I...

Page 908: ...Disconnect the ground cable from battery 2 Disconnect the connector from camshaft posi tion sensor 3 Remove the camshaft position sensor from cam shaft support LH B INSTALLATION Install in the revers...

Page 909: ...stralia model 1 Disconnect the ground cable from battery 2 Remove the intercooler Ref to IN H4DOTC 10 REMOVAL Intercooler 3 Remove the intake manifold Ref to FU H4DOTC 14 REMOVAL Intake Manifold 4 Dis...

Page 910: ...from cylinder block B INSTALLATION 1 Install the knock sensor to cylinder block Tightening torque 24 N m 2 4 kgf m 17 4 ft lb NOTE Extraction area of knock sensor cord must be posi tioned at a 60 ang...

Page 911: ...m battery 2 Remove the intercooler Ref to IN H4DOTC 10 REMOVAL Intercooler 3 Disconnect the connector from throttle position sensor 4 Remove the throttle position sensor holding screws and remove it B...

Page 912: ...ature Sensor A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the connector from mass air flow and intake air temperature sensor 3 Remove the mass air flow and intake air temper ature...

Page 913: ...oid valve Ref to FU H4DOTC 36 REMOVAL Idle Air Control Solenoid Valve 3 Disconnect the connectors from manifold abso lute pressure sensor 4 Remove the manifold absolute pressure sensor from throttle b...

Page 914: ...ery 2 Disconnect the connector from idle air control solenoid valve 3 Remove the idle air control solenoid valve from throttle body 4 Remove the gasket from throttle body B INSTALLATION Install in the...

Page 915: ...nd remove the fuel filler cap 3 Disconnect the ground cable from battery 4 Remove the intake manifold Ref to FU H4DOTC 14 REMOVAL Intake Manifold 5 Remove the fuel pipe protector RH 6 Disconnect the c...

Page 916: ...filler cap 3 Disconnect the ground cable from battery 4 Remove the intake manifold Ref to FU H4DOTC 14 REMOVAL Intake Manifold 5 Remove the fuel pipe protector LH 6 Disconnect the connector from fuel...

Page 917: ...kgf m 14 0 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 2 LH SIDE Install in the reverse order of removal NOTE Replace the O ring and insulators wi...

Page 918: ...40 FUEL INJECTION FUEL SYSTEMS FUEL INJECTOR 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 Tightening torque 19 N m 1 9 kgf m 14 0 ft lb FU 00044 FU 00618...

Page 919: ...ect the ground cable from battery 4 Remove the intake manifold Ref to FU H4DOTC 14 REMOVAL Intake Manifold 5 Disconnect the connector from tumble generator valve sensor 6 Disconnect the connector from...

Page 920: ...p 3 Disconnect the ground cable from battery 4 Remove the intake manifold Ref to FU H4DOTC 14 REMOVAL Intake Manifold 5 Disconnect the connector from tumble generator valve actuator RH 6 Remove the tu...

Page 921: ...tor A from bracket 3 Disconnect the connector B from wastegate control solenoid valve 4 Remove the bracket from body 5 Disconnect the pressure hoses C from waste gate control solenoid valve 6 Remove t...

Page 922: ...racket B 4 Remove the front right side wheel 5 Lift up the vehicle 6 Remove the service hole cover 7 Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen A F sensor and leave it...

Page 923: ...JET LUBE CAUTION Never apply anti seize compound to the protec tor of front oxygen A F sensor 2 Install the front oxygen A F sensor Tightening torque 30 N m 3 1 kgf m 22 1 ft lb 3 Install the service...

Page 924: ...04301003 6 Remove the rear oxygen sensor CAUTION When removing the oxygen sensor wait until the exhaust pipe cools otherwise it will dam age the exhaust pipe B INSTALLATION 1 Before installing the rea...

Page 925: ...FU H4DOTC 47 FUEL INJECTION FUEL SYSTEMS REAR OXYGEN SENSOR 4 Connect the clip to crossmember 5 Lower the vehicle 6 Connect the battery ground cable to battery FU 00082 FU 00009...

Page 926: ...t until the exhaust pipe cools otherwise it will damage the exhaust pipe B INSTALLATION 1 Before installing the exhaust temperature sen sor apply anti seize compound only to the thread ed portion of r...

Page 927: ...r Trim 3 Detach the floor mat of front passenger seat side 4 Remove the protect cover 5 Remove the nuts A which hold the ECM to bracket 6 Remove the clip B from bracket 7 Disconnect the ECM connectors...

Page 928: ...1 Disconnect the ground cable from battery 2 Remove the glove box Ref to EI 39 REMOV AL Glove Box 3 Remove the bolt which holds the main relay bracket on body 4 Disconnect the connectors from main rel...

Page 929: ...able from battery 2 Remove the glove box Ref to EI 39 REMOV AL Glove Box 3 Remove the bolt which holds the fuel pump relay bracket on body 4 Disconnect the connector from fuel pump relay 5 Remove the...

Page 930: ...EMOVAL 1 Disconnect the ground cable from battery 2 Remove the rear quarter trim Ref to EI 48 REMOVAL Rear Quarter Trim 3 Disconnect the connector from fuel pump control unit 4 Remove the fuel pump co...

Page 931: ...sec onds 4 Turn the ignition switch to OFF 2 DRAINING FUEL WARNING Place NO FIRE signs near working area Be careful not to spill fuel on floor 1 Set the vehicle on a lift 2 Disconnect the ground cabl...

Page 932: ...k cord on floor panel down under body 7 Remove the rear crossmember Ref to RS 21 REMOVAL Rear Crossmember 8 Disconnect the two way valve hose A from two way valve and disconnect the canister hose B fr...

Page 933: ...canister hose B to canister 4 Connect the fuel filler hose and air vent hose 5 Connect the fuel hoses and secure them with clips and quick connector Ref to FU H4DOTC 70 INSTALLATION Fuel Delivery Ret...

Page 934: ...EL TANK 10 Connect the connector to the fuel pump relay C INSPECTION 1 Make sure there are no cracks holes or other damage on fuel tank 2 Make sure the fuel hoses and fuel pipes are not cracked and th...

Page 935: ...t the ground cable from battery 5 Remove the screws holding the packing in place 6 Loosen the rear right side wheel nuts 7 Lift up the vehicle 8 Remove the rear right side wheel 9 Drain fuel from fuel...

Page 936: ...ller pipe to under side of ve hicle 18 Remove the air vent pipe together with clip from body B INSTALLATION 1 Hold the fuel filler flap open 2 Set the fuel saucer A with rubber packing C and insert th...

Page 937: ...ert the air vent hose approx 25 to 30 mm 0 98 to 1 18 in into the lower end of air vent pipe and hold clip L 27 5 2 5 mm 1 083 0 098 in 8 Tighten the bolt which holds the fuel filler pipe bracket on b...

Page 938: ...FU H4DOTC 60 FUEL INJECTION FUEL SYSTEMS FUEL FILLER PIPE 14 Connect the connector to the fuel pump relay 15 Connect the battery ground cable to battery FU 00871 FU 00009...

Page 939: ...Set a container under vehicle and remove the drain plug from fuel tank 6 Tighten the fuel drain plug Tightening torque 26 N m 2 7 kgf m 19 2 ft lb 7 Raise the rear seat and turn the floor mat up 8 Re...

Page 940: ...tical sequence as shown in the figure Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb C INSPECTION Connect the lead harness to connector terminal of fuel pump and then apply battery power supply to che...

Page 941: ...t to spill fuel on floor NOTE Fuel level sensor is built in fuel pump assembly 1 Remove the fuel pump assembly Ref to FU H4DOTC 61 REMOVAL Fuel Pump 2 Disconnect the connector from fuel pump brack et...

Page 942: ...tank Set a container under vehicle and remove the drain plug from fuel tank 4 Tighten the fuel drain plug Tightening torque 26 N m 2 7 kgf m 19 2 ft lb 5 Remove the rear seat 6 Remove the service hol...

Page 943: ...FU H4DOTC 65 FUEL INJECTION FUEL SYSTEMS FUEL SUB LEVEL SENSOR B INSTALLATION Install in the reverse order of removal Tightening torque 4 4 N m 0 45 kgf m 3 3 ft lb FU 00115...

Page 944: ...r from holder B INSTALLATION CAUTION If fuel hoses are damaged at connecting por tions replace them with new ones If clamps are badly damaged replace them with new ones 1 Install in the reverse order...

Page 945: ...eful not to spill fuel on floor 1 Remove the fuel tank Ref to FU H4DOTC 54 REMOVAL Fuel Tank 2 Move the clip and disconnect the evaporation hose from fuel cut valve 3 Remove the bolts which install th...

Page 946: ...PER VALVE 32 Fuel Damper Valve A REMOVAL 1 Release the fuel pressure Ref to FU H4DOTC 53 RELEASING OF FUEL PRES SURE OPERATION Fuel 2 Remove the fuel damper valve from fuel return line B INSTALLATION...

Page 947: ...uel filler flap lid and remove the fuel filler cap 4 Remove the floor mat Ref to EI 55 REMOVAL Floor Mat 5 Remove the fuel delivery pipes and hoses fuel return pipes and hoses evaporation pipes and ho...

Page 948: ...e connected portion is not damaged or has dust If necessary clean the seal surface of pipe 1 Set the new retainer B to connector A 2 Push the pipe into connector completely NOTE At this time two click...

Page 949: ...098 0 059 in L 22 5 2 5 mm 0 886 0 098 in 3 Connect the evaporation hose to pipe by approx 15 mm 0 59 in from hose end L 17 5 2 5 mm 0 689 0 098 in CAUTION Be sure to inspect the hoses and their conn...

Page 950: ...rouble and possible cause Corrective action 1 Insufficient fuel supply to injector 1 Fuel pump will not operate Defective terminal contact Inspect connections especially ground and tighten securely Tr...

Page 951: ...AUX EMISSION CONTROL DEVICES EC H4DOTC Page 1 General Description 2 2 Front Catalytic Converter 3 3 Rear Catalytic Converter 4 4 Precatalytic Converter 5 5 Canister 6 6 Purge Control Solenoid Valve 7...

Page 952: ...s in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful...

Page 953: ...s a unit Ref to EX H4DOTC 9 REMOVAL Center Exhaust Pipe 2 Separate the front catalytic converter A from rear catalytic converter B Except for Australia model B INSTALLATION NOTE Replace the gaskets wi...

Page 954: ...a unit Ref to EX H4DOTC 9 REMOVAL Center Exhaust Pipe 2 Separate the rear catalytic converter B from front catalytic converter A Except for Australia model B INSTALLATION NOTE Replace the gaskets with...

Page 955: ...cept for STi and Australia model Precatalytic converter A is built in the joint pipe Refer to the removal of joint pipe for removal procedure Ref to EX H4DOTC 13 REMOVAL Joint Pipe B INSTALLATION Inst...

Page 956: ...ich hold the two can ister hoses and then disconnect the three evapo ration hoses from canister 3 Remove the canister from body B INSTALLATION 1 Install in the reverse order of removal Tightening torq...

Page 957: ...e 3 Remove the bolt which installs the purge control solenoid valve onto intake manifold B INSTALLATION Install in the reverse order of removal Tightening torque 19 N m 1 9 kgf m 13 7 ft lb NOTE Conne...

Page 958: ...the vehicle 2 Remove the canister from body Ref to EC H4DOTC 6 REMOVAL Canister 3 Remove the two way valve with bracket as a unit from body 4 Remove the two way valve from bracket B INSTALLATION Inst...

Page 959: ...INTAKE INDUCTION IN H4DOTC Page 1 General Description 2 2 Air Cleaner 7 3 Air Intake Duct 8 4 Intake Duct 9 5 Intercooler 10 6 Turbocharger 12 7 Air By pass Valve 14 8 Resonator Chamber 15...

Page 960: ...ightening torque N m kgf m ft lb 9 Air intake duct T1 7 5 0 76 5 5 2 Air cleaner upper cover 10 Resonator chamber ASSY T2 33 3 4 24 6 3 Air cleaner element 11 Cushion rubber T3 2 5 0 25 1 8 4 Spacer 1...

Page 961: ...NERAL DESCRIPTION 2 INTAKE DUCT 1 Clamp 5 Air by pass hose C Tightening torque N m kgf m ft lb 2 PCV hose ASSY 6 Intake duct T1 19 1 9 13 7 3 Air by pass hose A 7 Clamp T2 3 0 3 2 2 4 Air by pass hose...

Page 962: ...6 Air by pass valve 11 Clamp 2 Intercooler bracket RH 7 Gasket 3 Intercooler bracket LH 8 Clamp Tightening torque N m kgf m ft lb 4 Clamp 9 Air by pass hose A T1 3 0 3 2 2 5 Air intake duct 10 Interco...

Page 963: ...ft lb 2 Metal gasket 9 Clip T1 4 4 0 45 3 3 3 Turbocharger 10 Oil outlet hose T2 4 9 0 50 3 6 4 Water pipe 11 Turbocharger bracket RH T3 29 3 0 21 7 5 Clamp 12 Turbocharger bracket LH T4 35 3 6 25 8 6...

Page 964: ...hem from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands be...

Page 965: ...Remove the air cleaner upper cover 6 Remove the air cleaner element 7 Remove the air cleaner lower case B INSTALLATION Install in the reverse order of removal Tightening torque 33 N m 3 4 kgf m 24 6...

Page 966: ...hich install the air intake duct on front side of body B INSTALLATION Install in the reverse order of removal Tightening torque 7 5 N m 0 76 kgf m 55 ft lb C INSPECTION 1 Inspect for cracks and loose...

Page 967: ...to FU H4DOTC 14 REMOVAL Intake Manifold 3 Remove the sensor engine harness and fuel pipe attached to intake manifold Ref to FU H4DOTC 20 DISASSEMBLY Intake Mani fold 4 Remove the intake duct from int...

Page 968: ...by pass hoses from intercool er 2 Separate the air by pass valve from intercooler 3 Remove the bolts which secure the intercooler to bracket 4 Separate the intercooler air duct from turbo charger 5 Se...

Page 969: ...rse order of removal Tightening torque 16 N m 1 6 kgf m 11 6 ft lb C DISASSEMBLY 1 Remove the intercooler ducts from intercooler D ASSEMBLY Assemble in the reverse order of disassembly Tightening torq...

Page 970: ...er 6 Disconnect the engine coolant hose which is connected to coolant filler tank 7 Loosen the clamp which secures the turbocharg er to intake duct 8 Remove the bolt which secures the bracket of oil p...

Page 971: ...stall the joint pipe to turbocharger NOTE Replace the gasket with a new one Tightening torque 35 N m 3 6 kgf m 25 8 ft lb 5 Connect the engine coolant hose 6 Install the turbocharger bracket Tightenin...

Page 972: ...ir By pass Valve A REMOVAL 1 Remove the air by pass valve from intercooler 2 Disconnect the air by pass hoses from air by pass valve B INSTALLATION Install in the reverse order of removal Tightening t...

Page 973: ...resonator chamber mounting bolt on right side of engine compartment 5 Remove the front right tire and lift up the vehi cle 6 Remove the front mudguard RH 7 Remove the resonator chamber from the inside...

Page 974: ...IN H4DOTC 16 INTAKE INDUCTION RESONATOR CHAMBER...

Page 975: ...Assembly 44 10 Engine Mounting 53 11 Preparation for Overhaul 54 12 V belt 55 13 Crankshaft Pulley 58 14 Timing Belt Cover 59 15 Timing Belt Assembly 60 16 Camshaft Sprocket 69 17 Crankshaft Sprocket...

Page 976: ...Stroke mm in 92 75 3 62 2 95 Piston displacement cm3 cu in 1 994 121 67 Compression ratio 8 0 Compression pres sure at 200 300 rpm kPa kgf cm2 psi 981 1 177 10 12 142 171 Number of piston rings Press...

Page 977: ...it 0 10 mm 0 0039 in Cylinder head Surface warpage limit 0 05 mm 0 0020 in Surface grinding limit 0 3 mm 0 012 in Standard height 127 5 mm 5 02 in Valve seat Refacing angle 90 Contacting width Intake...

Page 978: ...t be fitted into position with thumb at 20 C 68 F Piston ring Piston ring gap Top ring STD 0 20 0 25 mm 0 0079 0 0098 in Limit 1 0 mm 0 039 in Second ring STD 0 40 0 50 mm 0 016 0 020 in Limit 1 0 mm...

Page 979: ...13 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 742 59 758 mm 2 3520 2 3527 in 2 4 STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 36...

Page 980: ...9 in Engine Type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement Belt driven double overhead camshaft 4 valve cylinder Bore Stroke mm in 92 75 3 62 2 95 Piston...

Page 981: ...it 0 10 mm 0 0039 in Cylinder head Surface warpage limit 0 05 mm 0 0020 in Surface grinding limit 0 3 mm 0 012 in Standard height 127 5 mm 5 02 in Valve seat Refacing angle 90 Contacting width Intake...

Page 982: ...be fitted into position with thumb at 20 C 68 F Piston ring Piston ring gap Top ring STD 0 20 0 25 mm 0 0079 0 0098 in Limit 1 0 mm 0 039 in Second ring STD 0 40 0 50 mm 0 016 0 020 in Limit 1 0 mm 0...

Page 983: ...13 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 742 59 758 mm 2 3520 2 3527 in 2 4 STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 36...

Page 984: ...Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement Belt driven double overhead camshaft 4 valve cylinder Bore Stroke mm in 92 75 3 62 2 95 Piston displacement cm3...

Page 985: ...it 0 10 mm 0 0039 in Cylinder head Surface warpage limit 0 05 mm 0 0020 in Surface grinding limit 0 3 mm 0 012 in Standard height 127 5 mm 5 02 in Valve seat Refacing angle 90 Contacting width Intake...

Page 986: ...t be fitted into position with thumb at 20 C 68 F Piston ring Piston ring gap Top ring STD 0 20 0 25 mm 0 0079 0 0098 in Limit 1 0 mm 0 039 in Second ring STD 0 40 0 50 mm 0 016 0 020 in Limit 1 0 mm...

Page 987: ...613 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 742 59 758 mm 2 3520 2 3527 in 2 4 STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 3...

Page 988: ...2 in US 2 017 2 020 mm 0 0794 0 0795 in 0 05 mm 0 0020 in US 2 027 2 030 mm 0 0798 0 0799 in 0 25 mm 0 0098 in US 2 127 2 130 mm 0 0837 0 0839 in 2 4 5 STD 2 000 2 013 mm 0 0787 0 0793 in 0 03 mm 0 00...

Page 989: ...65 4 7 4 Timing belt cover No 2 LH 13 Belt idler No 2 T3 25 2 5 18 1 5 Tensioner bracket 14 Belt idler T4 39 4 0 28 9 6 Automatic belt tension adjuster ASSY 15 Timing belt cover LH T5 98 10 72 4 16 Fr...

Page 990: ...cover No 2 LH 13 Belt idler No 2 T3 25 2 5 18 1 5 Tensioner bracket 14 Belt idler T4 39 4 0 28 9 6 Automatic belt tension adjuster ASSY 15 Timing belt cover LH T5 98 10 72 4 16 Front belt cover T6 Ref...

Page 991: ...SCRIPTION 2 CYLINDER HEAD AND CAMSHAFT EXCEPT FOR STi AND AUSTRALIA MODEL ME 00756 T2 T4 T3 T5 T4 T2 T2 T1 7 6 14 9 8 10 15 16 13 12 32 29 30 31 3 4 27 23 24 21 32 18 19 14 26 28 25 20 22 17 16 11 5 4...

Page 992: ...ning torque N m kgf m ft lb 7 Intake camshaft cap Rear RH 21 Intake camshaft cap Center LH T1 Ref to ME H4DOTC 81 INSTALLATION Cylinder Head Assembly 8 Intake camshaft cap RH 22 Intake camshaft cap Re...

Page 993: ...E H4DOTC 19 MECHANICAL GENERAL DESCRIPTION STi AND AUSTRALIA MODEL ME 00705 T2 T3 T4 T2 T2 T1 1 3 7 6 9 8 10 12 13 28 24 25 26 23 19 20 28 15 16 11 17 22 27 21 18 10 14 13 11 5 4 T3 T3 T5 2 T3 T5 T5 T...

Page 994: ...assembly LH 5 Intake camshaft RH Tightening torque N m kgf m ft lb 6 Exhaust camshaft cap Front RH 18 Intake camshaft cap LH T1 Ref to ME H4DOTC 81 INSTALLATION Cylinder Head Assembly 7 Exhaust camsh...

Page 995: ...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 996: ...o ME H4DOTC 93 INSTALLATION Cylinder Block 7 Oil pump 22 Metal gasket 8 Front oil seal 23 Oil level gauge guide 9 Rear oil seal 24 Oil filter T6 69 7 0 50 9 10 O ring 25 Gasket T7 First 12 1 2 8 7 Sec...

Page 997: ...ement AT model 11 Connecting rod bolt 19 Crankshaft bearing 5 4 Drive plate AT model 12 Connecting rod 5 Top ring 13 Connecting rod bearing Tightening torque N m kgf m ft lb 6 Second ring 14 Connectin...

Page 998: ...NERAL DESCRIPTION 6 ENGINE MOUNTING 1 Heat shield cover 3 Front engine mounting bracket Tightening torque N m kgf m ft lb 2 Front cushion rubber T1 35 3 6 25 8 T2 42 4 3 30 9 T3 85 8 7 62 7 ME 00706 3...

Page 999: ...ial attention to the engine oil passages pis tons and bearings Rotating parts and sliding parts such as piston bearing and gear should be coated with oil prior to assembly Be careful not to let oil gr...

Page 1000: ...valve guides Used for removing and installing valve springs 498457000 ENGINE STAND ADAPTER RH Used with ENGINE STAND 499817000 498457100 ENGINE STAND ADAPTER LH Used with ENGINE STAND 499817000 49849...

Page 1001: ...sed for press fitting of intake and exhaust valve guide oil seals 499017100 PISTON PIN GUIDE Used for installing piston pin piston and connect ing rod 499037100 CONNECTING ROD BUSHING REMOVER INSTALLE...

Page 1002: ...except for STi model 499207400 CAMSHAFT SPROCKET WRENCH Used for removing and installing exhaust cam shaft sprocket and intake camshaft sprocket RH Except for STi and Australia model 18231AA010 CAMSH...

Page 1003: ...STALLER Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL GUIDE 499597100 499597100 CRANKSHAFT OIL SEAL GUIDE Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL...

Page 1004: ...0 VALVE GUIDE REMOVER Used for removing valve guides 499767400 VALVE GUIDE REAMER Used for reaming valve guides 499817000 ENGINE STAND Stand used for engine disassembly and assem bly Used with ENGINE...

Page 1005: ...ng and tightening crankshaft pulley bolts 499987500 CRANKSHAFT SOCKET Used for rotating crankshaft 498547000 OIL FILTER WRENCH Used for removing and installing the oil filter 499587100 OIL SEAL INSTAL...

Page 1006: ...SEAL GUIDE Used for installing camshaft oil seal for DOHC engine Used with OIL SEAL GUIDE 499587600 498277200 STOPPER SET Used for installing automatic transmission assem bly to engine 24082AA210 CART...

Page 1007: ...ondition that the engine is removed from the vehi cle V belt Timing Belt Camshaft Cylinder Head 22771AA030 SUBARU SELECT MONI TOR KIT Troubleshooting for electrical systems English 22771AA030 Without...

Page 1008: ...spark plug hole NOTE When using a screw in type compression gauge the screw put into cylinder head spark plug hole should be less than 18 mm 0 71 in long 8 Crank the engine by means of starter motor...

Page 1009: ...Control System Diagnosis 10 Select the 1 12 Data Display in Data Display Menu 11 Start the engine and then read the engine idle speed 12 Check the idle speed when unloaded With headlights heater fan r...

Page 1010: ...t the SUBARU SELECT MONITOR to data link connector 6 Turn the ignition switch to ON and SUBARU SELECT MONITOR switch to ON 7 Select the 2 Each System Check in Main Menu 8 Select the Engine Control Sys...

Page 1011: ...ormal position This ten dency becomes more evident as engine temperature rises Leakage around intake manifold gasket or disconnection or damaged vacuum hose 2 When engine speed is reduced slowly from...

Page 1012: ...t 5 000 rpm If the oil pressure is out of specification check oil pump oil filter and lubrication line Ref to LU H4DOTC 21 INSPECTION Engine Lubrica tion System Trouble in General If the oil pressure...

Page 1013: ...elivery hoses from fuel fil ter and then connect the fuel pressure gauge 4 Connect the connector of fuel pump relay 5 Start the engine 6 Measure the fuel pressure while disconnecting the pressure regu...

Page 1014: ...9 When inspecting the 1 and 3 cylinders 1 Pull out the engine harness connector with bracket from air cleaner upper cover 2 Remove the air cleaner case Ref to IN H4DOTC 7 REMOVAL Air Cleaner 3 Disconn...

Page 1015: ...exhaust valve clearances while lift ing up the vehicle Valve clearance Intake 0 20 0 02 mm 0 0079 0 0008 in Exhaust 0 25 0 02 mm 0 0098 0 0008 in NOTE If the measured value is not within specificatio...

Page 1016: ...med while engine is cold 1 Measure all valve clearances Ref to ME H4DOTC 40 INSPECTION Valve Clear ance NOTE Record each valve clearance after it has been measured 2 Remove the camshaft Ref to ME H4DO...

Page 1017: ...71 5 05 0 1988 13228 AB481 5 06 0 1992 13228 AB491 5 07 0 1996 13228 AB501 5 08 0 2000 13228 AB511 5 09 0 2004 13228 AB521 5 10 0 2008 13228 AB531 5 11 0 2012 13228 AB541 5 12 0 2016 13228 AB551 5 13...

Page 1018: ...connect the ground cable from battery 7 Remove the radiator from vehicle Ref to CO H4DOTC 23 REMOVAL Radiator 8 Remove the coolant filler tank Ref to CO H4DOTC 33 REMOVAL Coolant Filler Tank 9 Disconn...

Page 1019: ...om brack et 1 Loosen the lock bolt and slider bolt and then remove the front side V belt Ref to ME H4DOTC 55 FRONT SIDE BELT RE MOVAL V belt 2 Disconnect the power steering switch con nector 3 Remove...

Page 1020: ...se fork from release bearing MT model 1 Remove the clutch operating cylinder from transmission 2 Remove the plug using a 10 mm hexagon wrench 3 Screw the 6 mm dia bolt into release fork shaft and remo...

Page 1021: ...t 25 Support the engine with a lifting device and wire ropes 26 Support the transmission with a garage jack NOTE Before moving the engine away from transmission check to be sure no work has been overl...

Page 1022: ...ly move the engine away from engine compartment NOTE Be careful not to damage adjacent parts or body panels with crank pulley oil pressure gauge etc 29 Remove the front cushion rubbers B INSTALLATION...

Page 1023: ...engine onto transmission 1 Position the engine in engine compartment and then align it with the transmission NOTE Be careful not to damage the adjacent parts or body panels with crank pulley oil press...

Page 1024: ...bolts which hold the torque con verter clutch to drive plate 2 Tighten other bolts while rotating the engine by using ST CAUTION Be careful not to drop bolts into the torque con verter clutch housing...

Page 1025: ...ermi nals 1 Engine ground terminal 2 Engine harness connectors 3 Generator connector and terminal 4 A C compressor connectors 21 Connect the following cables 1 Accelerator cable 2 Clutch release sprin...

Page 1026: ...ME H4DOTC 52 MECHANICAL ENGINE ASSEMBLY 31 Remove the front hood stay and close the front hood 32 Take off the vehicle from lift arms...

Page 1027: ...gine assembly Ref to ME H4DOTC 44 REMOVAL Engine Assembly 2 Remove the engine mounting from engine as sembly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 35...

Page 1028: ...ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order It will be the complete procedure for overhauling of the engine itself when you go throu...

Page 1029: ...DOTC 56 INSPECTION V belt 2 Tighten the lock bolt A 3 Tighten the slider bolt B Tightening torque Lock bolt through bolt 25 N m 2 5 kgf m 18 1 ft lb Slider bolt 8 N m 0 8 kgf m 5 5 ft lb 4 Idle the en...

Page 1030: ...belt tension is within specified value With using tension gauge 7 Adjust the belt tension until the value within specification With using tension gauge C INSPECTION 1 WITHOUT USING BELT TENSION GAUGE...

Page 1031: ...sing belt tension gauge And adjust it if necessary by changing the genera tor installing position and or idler pulley installing position Belt tension A 490 640 N 50 65 kgf 110 144 lb B 350 450 N 36 4...

Page 1032: ...htening angle of crankshaft pulley bolt is less than 45 de grees conduct the following procedures CAUTION If the tightening angle of crankshaft pulley bolt is less than 45 degrees the bolt should be d...

Page 1033: ...ng belt cover C B INSTALLATION 1 Install the front timing belt cover C Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 2 Install the timing belt cover RH B Tightening torque 5 N m 0 5 kgf m 3 6 ft lb 3 In...

Page 1034: ...ing belt guides MT model 5 If the alignment mark and or arrow mark which indicates rotation direction on timing belt fade away put new marks before removing the timing belt as follows 1 Turn the crank...

Page 1035: ...fter the timing belt has been removed never rotate the intake and exhaust camshaft sprock et If the camshaft sprocket is rotated the in take and exhaust valve heads strike together and valve stems are...

Page 1036: ...the adjuster rod into the cylinder Doing so may damage the cylinder Do not release the press pressure until stopper pin is completely inserted 1 Attach the automatic belt tension adjuster assembly to...

Page 1037: ...over 3 Align single line mark A on the intake cam shaft sprocket RH with notch B on timing belt cover Make sure double lines C on intake camshaft and exhaust camshaft sprockets are aligned 4 Align sin...

Page 1038: ...re rotated to install the timing belts 2 intake and 4 exhaust cam of camshafts LH are held to push their corre sponding valves down Under this condition these valves are held lifted Camshafts RH are h...

Page 1039: ...iston Ensure the belt s rotating direction is correct 4 Install the belt idlers Tightening torque 39 N m 4 0 kgf m 28 9 ft lb NOTE Make sure that the marks on the timing belt and sprockets are aligned...

Page 1040: ...etween timing belt and timing belt guide Clearance 1 0 0 5 mm 0 039 0 020 in 3 Tighten the bolts Tightening torque 10 N m 1 0 kgf m 7 2 ft lb Tightening torque 6 4 N m 0 7 kgf m 5 1 ft lb Tightening t...

Page 1041: ...rod ends for abnormal wear or scratches If necessary replace the automatic belt tension adjuster assem bly NOTE Slight traces of oil at rod s oil seal does not indicate a problem 2 Check that the adju...

Page 1042: ...ith a new one Rod extension H 5 7 0 5 mm 0 224 0 020 in 3 BELT TENSION PULLEY 1 Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches Replace the be...

Page 1043: ...prockets To lock the camshaft use ST ST 18231AA010 CAMSHAFT SPROCKET WRENCH INTAKE LH ST 499207400 CAMSHAFT SPROCKET WRENCH Except INTAKE LH 2 STi AND AUSTRALIA MODEL 1 Remove the V belt Ref to ME H4D...

Page 1044: ...TALLATION V belt 2 STi AND AUSTRALIA MODEL 1 Install the camshaft sprocket No 1 and No 2 To lock the camshaft use ST ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque 98 N m 10 kgf m 72 4 ft lb...

Page 1045: ...ATION 1 Install the crankshaft sprocket 2 Install the camshaft sprocket Ref to ME H4DOTC 70 INSTALLATION Camshaft Sprocket 3 Install the timing belt assembly Ref to ME H4DOTC 62 INSTALLATION Timing Be...

Page 1046: ...the tensioner bracket 8 Remove the timing belt cover No 2 LH 9 Remove the timing belt cover No 2 RH 10 Disconnect the ignition coil connector 11 Remove the ignition coil 12 Remove the rocker cover and...

Page 1047: ...H4DOTC 71 REMOVAL Crankshaft Sprock et 7 Disconnect the variable valve timing solenoid valve assembly connector 8 Remove the tensioner bracket 9 Remove the timing belt cover No 2 LH 10 Remove the timi...

Page 1048: ...ne oil to the cylinder head at camshaft bearing location before installing the camshaft In stall the camshaft so that each valves is close to or in contact with base circle of cam lobe NOTE When the c...

Page 1049: ...in alphabetical sequence shown in the figure and then tighten to specified torque Tightening torque T1 10 N m 1 0 kgf m 7 2 ft lb T2 20 N m 2 0 kgf m 14 5 ft lb 4 Similarly tighten the cap on exhaust...

Page 1050: ...ghtening torque 5 N m 0 5 kgf m 3 6 ft lb 9 Install the tensioner bracket Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 10 Install the timing belt cover No 2 LH Tightening torque 5 N m 0 5 kgf m 3 6 f...

Page 1051: ...noid valve assembly installation 1 Apply fluid packing sparingly to cap mating surface NOTE Do not apply fluid packing excessively Failure to do so may cause excess packing to come out and flow toward...

Page 1052: ...600 OIL SEAL GUIDE ST2 499597200 OIL SEAL GUIDE 4 Rocker cover installation 1 Install the gasket on rocker cover Install the peripheral gasket and ignition coil gasket 2 Apply fluid packing to four fr...

Page 1053: ...ulley Ref to ME H4DOTC 58 INSTALLATION Crankshaft Pulley 17 Install the V belt Ref to ME H4DOTC 55 INSTALLATION V belt C INSPECTION 1 Measure the bend and repair or replace if nec essary Limit 0 020 m...

Page 1054: ...ht H replace if the limit has been exceeded Cam height H Standard Except for STi model Intake 46 25 46 35 mm 1 821 1 825 in Exhaust 46 15 46 25 mm 1 817 1 821 in STi model Intake 45 25 45 35 mm 1 781...

Page 1055: ...LATION 1 Install the cylinder head and gaskets on cylinder block NOTE Use new cylinder head gaskets Be careful not to scratch the mating surface of cylinder head and cylinder block 2 Tighten the cylin...

Page 1056: ...ATION V belt C DISASSEMBLY 1 Remove the valve lifters 2 Compress the valve spring and remove the valve spring retainer key Remove each valve and valve spring ST1 498267600 CYLINDER HEAD TABLE ST2 4997...

Page 1057: ...Intake valve oil seal 9 Valve lifter 2 Intake valve 6 Valve spring 10 Exhaust valve oil seal 3 Cylinder head 7 Retainer 11 Intake valve guide 4 Valve spring seat 8 Retainer key 12 Exhaust valve guide...

Page 1058: ...tap the valve spring retainers lightly with wooden hammer for better seating 2 Apply oil to the surface of the valve lifter 3 Install the valve lifter E INSPECTION 1 CYLINDER HEAD 1 Make sure that no...

Page 1059: ...If the clearance between valve guide and stem exceeds the limit replace the valve guide or valve itself whichever shows greater amount of wear See the following procedure for valve guide re placement...

Page 1060: ...en reaming If the inner surface of the valve guide is torn the edge of the reamer should be slightly ground with an oil stone If the inner surface of the valve guide becomes lustrous and the reamer do...

Page 1061: ...il seal to the specified dimension indicated in the figure by using ST2 ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE NOTE Apply engine oil to oil seal before press fit Differen...

Page 1062: ...emove the valve and neutralize it by immersing it in water and dispose of it in the same way that general steel materials are disposed of The disposal method is described in the following 1 Wearing ru...

Page 1063: ...H4DOTC 81 REMOVAL Cylinder Head As sembly 10 Remove the clutch disc and cover MT model Ref to CL 20 REMOVAL Clutch Disc and Cov er 11 Remove the flywheel MT model Ref to CL 24 REMOVAL Flywheel 12 Rem...

Page 1064: ...flat bladed screwdriver as shown in the fig ure when removing the oil pump NOTE Be careful not to scratch the mating surface of cyl inder block and oil pump ME 00138 1 Service hole plug 3 Circlip 5 Se...

Page 1065: ...odel except for STi model ST 499097600 PISTON PIN REMOVER Ex cept for Australia model NOTE Be careful not to confuse the original combination of piston piston pin and cylinder 27 Similarly remove the...

Page 1066: ...34 Remove the crankshaft bearings from cylinder block using a hammer handle NOTE Do not confuse the combination of crankshaft bear ings Press the bearing at the end opposite to locking lip 35 Draw ou...

Page 1067: ...1 and 3 cylinder block and position it on 2 and 4 cylinder block Fluid packing Part No 004403007 THREE BOND 1215 or equivalent NOTE Do not allow fluid packing to jut into O ring grooves oil passages...

Page 1068: ...con necting bolts in alphabetical sequence shown in the figure Tightening torque A G 25 N m 2 5 kgf m 18 1 ft lb H 6 4 N m 0 65 kgf m 4 7 ft lb 9 Install the rear oil seal using ST1 and ST2 ST1 499597...

Page 1069: ...osition the upper rail gap at G in the figure NOTE Ensure ring gaps do not face the same direction Ensure ring gaps are not within the piston skirt area 16 Install the circlip Install the circlips in...

Page 1070: ...insert pistons in their cylinders us ing ST2 ST2 398744300 PISTON GUIDE NOTE Piston front mark faces towards the front of the en gine 18 Installing piston pin 1 Apply a coat of engine oil to ST3 and t...

Page 1071: ...ecting rod through service hole 3 Using the ST install the circlip ST 499897200 PISTON CIRCLIP PLIERS NOTE Use new circlips 4 Apply fluid packing around the service hole plug Fluid packing Part No 004...

Page 1072: ...0 65 kgf m 4 7 ft lb 21 Install the oil strainer and O ring Tightening torque 10 N m 1 0 kgf m 7 ft lb 22 Install the oil strainer stay 23 Apply fluid packing to the matching surfaces and then instal...

Page 1073: ...ver 28 Installation of oil pump 1 Discard the front oil seal after removal Re place with a new one using the ST ST 499587100 OIL SEAL INSTALLER 2 Apply fluid packing to the matching surface of oil pum...

Page 1074: ...Ref to ME H4DOTC 81 INSTALLATION Cylinder Head Assembly 36 Install the oil level gauge guide and tighten the attaching bolt LH side 37 Install the rocker cover 38 Install the crankshaft sprocket Ref...

Page 1075: ...connecting rod cap and bearing in order to prevent confusion 3 Remove the piston rings using the piston ring ex pander 4 Remove the oil ring by hand NOTE Arrange the removed piston rings in proper or...

Page 1076: ...uts apply oil on the threads 4 Install the oil ring spacer upper rail and lower rail in this order by hand Then install the second ring and top ring with a piston ring expander E INSPECTION 1 CYLINDER...

Page 1077: ...n directions at the heights 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 Limit 0 050 mm 0 0020...

Page 1078: ...ders needs reboring all other cylinders must be bored at the same time and use oversize pistons Do not perform bor ing on one cylinder only nor use an oversize piston for one cylinder only 2 If the cy...

Page 1079: ...er rail When installing on piston be careful of each rail s direction 2 Squarely place the piston ring and oil ring in cyl inder and then measure the piston ring gap with a thickness gauge 3 Measure...

Page 1080: ...oil clearance on individual connect ing rod bearings by means of plastigauge If any oil clearance is not within specification replace the defective bearing with a new one of standard size or undersiz...

Page 1081: ...if defective 2 Measure the crankshaft bend and correct or re place if it exceeds the limit NOTE If a suitable V block is not available install the 1 and 5 crankshaft bearing on cylinder block posi tio...

Page 1082: ...13 0 0787 0 0793 1 486 1 498 0 0585 0 0590 0 03 0 0012 undersize Journal O D 59 962 59 978 2 3607 2 3613 59 962 59 978 2 3607 2 3613 51 954 51 970 2 0454 2 0461 Bearing size Thickness at cen ter 2 017...

Page 1083: ...VE 21 Intake and Exhaust Valve A REMOVAL AND INSTALLATION For operations related to intake and exhaust valve refer to 19 Cylinder Head Ref to ME H4DOTC 81 REMOVAL Cylinder Head As sembly and Ref to ME...

Page 1084: ...0 MECHANICAL PISTON 22 Piston A REMOVAL AND INSTALLATION For operations related to piston refer to 20 Cylin der Block Ref to ME H4DOTC 89 REMOVAL Cylinder Block and Ref to ME H4DOTC 93 INSTALLATION Cy...

Page 1085: ...CONNECTING ROD 23 Connecting Rod A REMOVAL AND INSTALLATION For operations related to connecting rod refer to 20 Cylinder Block Ref to ME H4DOTC 89 REMOVAL Cylinder Block and Ref to ME H4DOTC 93 INST...

Page 1086: ...ANICAL CRANKSHAFT 24 Crankshaft A REMOVAL AND INSTALLATION For operations related to crankshaft refer to 20 Cylinder Block Ref to ME H4DOTC 89 RE MOVAL Cylinder Block and Ref to ME H4DOTC 93 INSTALLAT...

Page 1087: ...p and relay A Lack of or insufficient fuel B Belt Defective B Defective timing B Compression Incorrect valve clearance C Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defe...

Page 1088: ...system Ref to EN H4DOTC 2 Basic Diagnostic Procedure A Intake system Loosened or cracked intake duct A Loosened or cracked PCV hose A Loosened or cracked vacuum hose A Defective intake manifold gaske...

Page 1089: ...B Lubrication system Incorrect oil pressure B Cooling system Overheating C Over cooling C Others Malfunction of evaporative emission control system A 4 Surging Engine control system Ref to EN H4DOTC 2...

Page 1090: ...ive gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn or stuck piston rings cylinder and piston C Incorrect valve timing A Lubrication system Incorrect oil pr...

Page 1091: ...rrect valve clearance B Loosened spark plugs or defective gasket C Loosened cylinder head bolts or defective gasket C Improper valve seating B Defective valve stem C Worn or broken valve spring C Worn...

Page 1092: ...line Clank when engine speed is medium 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft main bearing Worn bearing at crankshaft...

Page 1093: ...EXHAUST EX H4DOTC Page 1 General Description 2 2 Front Exhaust Pipe 7 3 Center Exhaust Pipe 9 4 Joint Pipe 13 5 Rear Exhaust Pipe 14 6 Muffler 15...

Page 1094: ...2 EXHAUST GENERAL DESCRIPTION 1 General Description A COMPONENT 1 FRONT EXHAUST PIPE EX 00128 T1 T1 T3 T3 T4 T3 T3 T4 T1 T2 T1 1 3 7 9 11 13 12 8 5 15 19 18 17 16 20 21 24 22 14 4 2 25 A A 23 6 10 T5...

Page 1095: ...gen A F Sensor 5 Front exhaust pipe upper clamp 18 Exhaust manifold LH 6 Front exhaust pipe upper cover 19 Exhaust manifold lower cover LH 7 Front exhaust pipe upper insulator RH 20 Gasket T6 Ref to F...

Page 1096: ...ver Front 16 Clamp Tightening torque N m kgf m ft lb 6 Bracket 17 Chamber T1 13 1 3 9 6 7 Gasket 18 Cushion rubber T2 18 1 8 13 0 8 Center pipe upper cover Rear 19 Spring T3 30 3 1 22 4 9 Center pipe...

Page 1097: ...1 13 1 3 9 6 5 Center pipe lower cover 14 Chamber T2 18 1 8 13 0 6 Bracket MT vehicles only 15 Cushion rubber T3 30 3 1 22 4 7 Bracket AT vehicles only 16 Spring T4 35 3 6 26 0 8 Rear catalytic conver...

Page 1098: ...rom dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because...

Page 1099: ...which hold the front exhaust pipe assembly to cylinder head exhaust port 8 Remove the front exhaust pipe assembly 9 Remove the covers from exhaust manifold and front exhaust pipe 10 Separate the front...

Page 1100: ...nd lower exhaust manifold covers LH Tightening torque 19 N m 1 9 kgf m 13 7 ft lb 7 Install the lower exhaust manifold cover RH Tightening torque 19 N m 1 9 kgf m 13 7 ft lb 8 Install the front oxygen...

Page 1101: ...e alignment marks on the universal joint so that it can be reassembled at the original serration 8 Remove the bolts which install the lower side of turbocharger upper cover CAUTION Be careful the turb...

Page 1102: ...n the center exhaust pipe 20 Remove the center exhaust pipe B INSTALLATION NOTE Replace the gaskets with new ones 1 Install the center exhaust pipe and temporarily tighten the bolt which holds the cen...

Page 1103: ...f m 26 0 ft lb 9 Lower the vehicle 10 Place the turbocharger lower cover and tighten the bolts which install the upper side of lower cover Tightening torque 7 4 N m 0 75 kgf m 5 4 ft lb 11 Place the t...

Page 1104: ...e cutout at serrated section 4 Tighten the bolt on long yoke side then that on the short yoke side Tightening torque 24 N m 2 4 kgf m 17 4 ft lb CAUTION Make sure that the universal joint bolts are ti...

Page 1105: ...e under cover 6 Remove the lower exhaust manifold cover RH 7 Remove the nuts which hold the front exhaust manifold to joint pipe 8 Remove the center exhaust pipe Ref to EX H4DOTC 9 REMOVAL Center Exha...

Page 1106: ...ar exhaust pipe B INSTALLATION NOTE Replace the gaskets with new ones 1 Install the rear exhaust pipe to muffler Tightening torque 48 N m 4 9 kgf m 35 4 ft lb 2 Install the rear exhaust pipe to center...

Page 1107: ...tate removal apply a coat of SUBARU CRC to the mating area of rubber cushions in ad vance SUBARU CRC Part No 004301003 B INSTALLATION 1 Install in the reverse order of removal NOTE Replace the gasket...

Page 1108: ...EX H4DOTC 16 EXHAUST MUFFLER...

Page 1109: ...Radiator Sub Fan System 12 4 Engine Coolant 17 5 Water Pump 19 6 Thermostat 21 7 Radiator 23 8 Radiator Cap 27 9 Radiator Main Fan and Fan Motor 28 10 Radiator Sub Fan and Fan Motor 30 11 Reservoir Ta...

Page 1110: ...5 C 185 F Impeller diameter 76 mm 2 99 in Number of impeller vanes 8 Pump pulley diameter 60 mm 2 36 in Clearance between impeller and case Standard 0 5 0 7 mm 0 020 0 028 in Limit 1 0 mm 0 039 in Thr...

Page 1111: ...ermostat cover 5 Gasket Tightening torque N m kgf m ft lb 2 Gasket 6 Heater by pass hose T1 First 12 1 2 8 7 Second 12 1 2 8 7 3 Thermostat 7 Coolant filler tank by pass hose 4 Water pump ASSY 8 Water...

Page 1112: ...IPTION 2 RADIATOR AND RADIATOR FAN CO 00206 22 21 B C T2 18 20 19 17 17 17 17 T3 T2 T3 33 32 B C 17 34 29 30 34 35 35 36 36 31 17 17 T2 13 16 38 7 26 25 5 5 28 9 T2 T2 T4 T4 T1 T1 12 15 11 14 T3 5 5 5...

Page 1113: ...iator 20 ATF pipe AT model 3 Radiator upper cushion 21 ATF inlet hose B AT model 33 Oil cooler outlet hose B MT model with oil cooler 4 Radiator upper bracket 22 ATF outlet hose B AT model 5 Clamp 23...

Page 1114: ...haft pulley bolts 18231AA010 CAMSHAFT SPROCKET WRENCH Used for removing and installing intake cam shaft sprocket Except for STi and Australia model 499207400 CAMSHAFT SPROCKET WRENCH Used for removing...

Page 1115: ...27 25 E B84 5 RHD LHD LHD RHD LHD RHD 23 21 22 24 F27 F16 F17 30A AIR CONDITIONING RELAY HOLDER SUB FAN RELAY 1 SUB FAN RELAY 2 3 4 7 5 6 8 18 20 19 17 E SUB FAN MOTOR 2 1 3 4 ECM E17 E28 5 3 4 1 2 F1...

Page 1116: ...ch to OFF 2 Disconnect the connector from main fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 96 C 205 F 4 Stop the engine and turn ignition switch to ON 5...

Page 1117: ...ch to OFF 2 Remove the fuse No 18 from joint box 3 Check the condition of fuse Is the fuse blown out Replace the fuse Repair the open circuit in harness between main fan relay and ignition switch 12 C...

Page 1118: ...l No 2 and ground terminal to termi nal No 1 of main fan motor connector Does the main fan rotate Repair the poor contact in main fan motor connector Replace the main fan motor with a new one 20 CHECK...

Page 1119: ...FAN RELAY TERMINAL AND MAIN FAN MOTOR CONNECTOR Measure the resistance of harness between main fan motor connector and main fan relay terminal Connector terminal F17 No 2 F27 No 24 Is the resistance...

Page 1120: ...7 25 E B84 5 RHD LHD LHD RHD LHD RHD 23 21 22 24 F27 F16 F17 30A AIR CONDITIONING RELAY HOLDER SUB FAN RELAY 1 SUB FAN RELAY 2 3 4 7 5 6 8 18 20 19 17 E SUB FAN MOTOR 2 1 3 4 ECM E17 E28 5 3 4 1 2 F16...

Page 1121: ...witch to OFF 2 Disconnect the connector from sub fan motor 3 Start the engine and warm it up until engine coolant temperature increases over 96 C 205 F 4 Stop the engine and turn ignition switch to ON...

Page 1122: ...on switch to OFF 2 Remove the fuse No 17 from joint box 3 Check the condition of fuse Is the fuse blown out Replace the fuse Repair the open circuit in harness between sub fan relay and ignition switc...

Page 1123: ...2 and ground terminal to termi nal No 3 or No 4 of sub fan motor connector Does the main fan rotate Repair the poor contact in sub fan motor connector Replace the sub fan motor with a new one 20 CHEC...

Page 1124: ...FAN RE LAY TERMINAL AND SUB FAN MOTOR CONNECTOR Measure the resistance of harness between sub fan motor connector and sub fan relay2 terminal Connector terminal F16 No 2 F27 No 17 Is the resistance le...

Page 1125: ...filler tank side cap with radiator side cap NOTE Do not remove the radiator side cap when filling engine coolant The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially m...

Page 1126: ...centration must be in creased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read the scale on the verti...

Page 1127: ...s LH by using ST Ref to ME H4DOTC 69 REMOVAL Cam shaft Sprocket 9 Remove the belt cover No 2 LH 10 Remove the tensioner bracket 11 Disconnect the hose from water pump 12 Remove the water pump B INSTAL...

Page 1128: ...9 ft lb 10 Install the timing belt Ref to ME H4DOTC 63 TIMING BELT INSTALLATION Timing Belt Assembly 11 Install the V belts Ref to ME H4DOTC 55 INSTALLATION V belt 12 Install the radiator Ref to CO H4...

Page 1129: ...e thermostat cover and gasket and then pull out the thermostat B INSTALLATION 1 Install the thermostat in water pump and then in stall the thermostat cover together with a gasket NOTE When reinstallin...

Page 1130: ...the thermostat and thermometer in water Raise water temperature gradually and measure the temperature and valve lift when the valve be gins to open and when the valve is fully opened During the test...

Page 1131: ...OL ANT REPLACEMENT Engine Coolant 6 Disconnect the connectors of radiator main fan motor A and sub fan motor B 7 Disconnect the radiator outlet hose from thermo stat cover 8 Disconnect the ATF cooler...

Page 1132: ...ackets 17 While lifting the radiator up slide it to the left 18 Lift up the radiator and then remove it from ve hicle B INSTALLATION 1 Attach the radiator mounting cushions to the holes on vehicle 2 I...

Page 1133: ...stall the air intake duct Ref to IN H4DOTC 8 INSTALLATION Air In take Duct 9 Lift up the vehicle 10 Connect the ATF cooler hoses AT model 11 Connect the oil cooler hose MT model with oil cooler 12 Con...

Page 1134: ...tank in place of cap 2 Apply a pressure of 122 kPa 1 2 kg cm2 18 psi to the radiator to check if 1 Engine coolant leaks at around radiator 2 Engine coolant leaks at around hoses or connections CAUTIO...

Page 1135: ...lant filler tank side Standard pressure 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Service limit pressure 83 kPa 0 85 kg cm2 12 psi Radiator side Standard pressure 122 152 kPa 1 24 1 55 kg cm2 18 22 psi Se...

Page 1136: ...p the vehicle 3 Remove the under cover 4 Disconnect the connector of main fan motor A 5 Lower the vehicle 6 Remove the air intake duct 7 Disconnect the overflow hose 8 Remove the overflow pipe 9 Remov...

Page 1137: ...bolts to install it Tightening torque 4 9 N m 0 50 kgf m 3 6 ft lb C DISASSEMBLY 1 Remove the nut which holds the fan itself onto fan motor and shroud assembly 2 Remove the bolts which install the fa...

Page 1138: ...nect the connector of sub fan motor B 5 Lower the vehicle 6 Remove the air intake duct 7 Remove the bolts which hold the sub fan shroud to radiator 8 Remove the overflow pipe 9 Remove the radiator sub...

Page 1139: ...emove the nut which holds the fan itself onto fan motor and shroud assembly 3 Remove the bolts which install the fan motor onto shroud D ASSEMBLY Assemble in the reverse order of disassembly Tightenin...

Page 1140: ...ck position 2 Pull out the reservoir tank to direction of arrow while pushing the pawl A B INSTALLATION Install in the reverse order of removal NOTE Refer to COMPONENT for tightening torque Ref to CO...

Page 1141: ...C 7 REMOVAL Air Cleaner 3 Remove the air cleaner element 4 Disconnect the engine coolant hoses from cool ant filler tank 5 Remove the bolts and nut which install the cool ant filler tank 6 Disconnect...

Page 1142: ...back pressure in exhaust system Clean or replace l Insufficient clearance between piston and cylinder Adjust or replace m Slipping clutch Repair or replace n Dragging brake Adjust o Defective thermost...

Page 1143: ...e 1 General Description 2 2 Oil Pressure System 6 3 Engine Oil 8 4 Oil Pump 10 5 Oil Pan and Strainer 14 6 Oil Pressure Switch 18 7 Engine Oil Cooler 19 8 Engine Oil Filter 20 9 Engine Lubrication Sys...

Page 1144: ...79 in Capacity at 80 C 176 F 600 rpm Discharge pressure 98 kPa 1 0 kg cm2 14 psi Discharge quantity 4 6 2 4 9 US qt 4 0 Imp qt min 5 000 rpm Discharge pressure 294 kPa 3 0 kg cm2 43 psi Discharge quan...

Page 1145: ...ue N m kgf m ft lb 7 Inner rotor 19 Rocker cover T1 5 0 5 3 6 8 Outer rotor 20 Baffle plate T2 6 4 0 65 4 7 9 Oil pump cover 21 O ring T3 10 1 0 7 0 10 Oil filter 22 Oil strainer T4 44 4 5 32 5 11 Oil...

Page 1146: ...from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands becau...

Page 1147: ...ARKS 499977400 CRANKSHAFT PULLEY WRENCH Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolt 498547000 OIL FILTER WRENCH Used for removing and installin...

Page 1148: ...18 19 20 21 22 23 24 25 26 27 28 29 30 21 9 32 1 2 3 4 5 6 10 11 12 13 14 15 7 16 23 30 19 20 22 26 27 28 29 8 17 24 31 18 25 i2 B21 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 No 14 SBF 4 SBF...

Page 1149: ...to OFF 2 Disconnect the connector from oil pressure switch 3 Turn the ignition switch ON 4 Measure the voltage of harness between the combination meter connector and chassis ground Connector terminal...

Page 1150: ...ine is warm en gine oil level may show in the range between the F line and notch mark This is caused by thermal expansion of engine oil NOTE To prevent overfilling the engine oil do not add oil above...

Page 1151: ...scous friction and thus increasing cranking speed CAUTION When replenishing oil it does not matter if the oil to be added is a different brand from that in the engine however use oil having the API cl...

Page 1152: ...ler and water pump 6 Remove the radiator Ref to CO H4SO 21 REMOVAL Radiator 7 Remove the crankshaft position sensor 8 Remove the V belts Ref to ME H4DOTC 55 REMOVAL V belt 9 Remove the rear side V bel...

Page 1153: ...cking to the matching surfaces of oil pump Fluid packing THREE BOND 1215 Part No 004403007 or equivalent 2 Replace the O ring A with a new one 3 Apply a coat of engine oil to the inside of oil seal 4...

Page 1154: ...seal by using ST ST 499587100 OIL SEAL INSTALLER NOTE Use a new oil seal 2 Apply a coat of engine oil to the inner and outer rotors 3 Install the inner and outer rotors in their original positions 4 I...

Page 1155: ...oil pump inner rotor and pump cover If clearance exceeds the lim it replace the rotor or pump body Side clearance Standard 0 02 0 07 mm 0 0008 0 0028 in Limit 0 12 mm 0 0047 in 4 OIL RELIEF VALVE Che...

Page 1156: ...ve the air intake boot and air cleaner upper cover 6 Remove the intercooler Ref to IN H4DOTC 10 REMOVAL Intercooler 7 Remove the pitching stopper 8 Remove the radiator upper brackets 9 Support the eng...

Page 1157: ...n cutter 16 Remove the oil strainer 17 Remove the baffle plate B INSTALLATION CAUTION Before installing the oil pan clean sealant from oil pan and engine block 1 Install the baffle plate Tightening to...

Page 1158: ...8 Lower the vehicle CAUTION When lowering the vehicle lower the lifting de vice and wire rope together 9 Remove the lifting device and steel cables 10 Install the pitching stopper Tightening torque T1...

Page 1159: ...all the front wheels 16 Connect the battery ground cable to battery 17 Fill engine oil Ref to LU H4DOTC 8 IN SPECTION Engine Oil C INSPECTION By visual check make sure the oil pan oil strainer oil str...

Page 1160: ...cking to the oil pressure switch threads Fluid packing THREE BOND 1324 Part No 004403007 or equivalent 2 Install the oil pressure switch onto engine block Tightening torque 25 N m 2 5 kgf m 18 1 ft lb...

Page 1161: ...ngine Oil Filter 7 Remove the connector and then remove the oil cooler B INSTALLATION 1 Install in the reverse order of removal Tightening torque T1 54 N m 5 5 kgf m 40 ft lb T2 69 N m 7 0 kgf m 50 6...

Page 1162: ...t by hand being careful not to damage seal rubber 3 Tighten more approx 2 3 to 3 4 turn after the seal rubber contacts the oil pump case Do not tighten excessively or oil may leak C INSPECTION 1 After...

Page 1163: ...tion of oil by pass valve of oil filter Clean or replace Malfunction of oil relief valve of oil pump Clean or replace Clogged oil passage Clean Excessive tip clearance and side clearance of oil pump r...

Page 1164: ...LU H4DOTC 22 LUBRICATION ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL...

Page 1165: ...SPEED CONTROL SYSTEMS SP H4DOTC Page 1 General Description 2...

Page 1166: ...SP H4DOTC 2 SPEED CONTROL SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATION Specifications for Turbo model is included in SP H4SO section Ref to SP H4SO 2 General Description...

Page 1167: ...IGNITION IG H4DOTC Page 1 General Description 2 2 Spark Plug 4 3 Ignition Coil Ignitor ASSY 7...

Page 1168: ...on A SPECIFICATIONS Item Designation Ignition coil ignitor assembly Model FK0186 Ignition type Direct ignition Manufacturer DIAMOND Spark plug Type and manufacturer NGK PFR6G Thread size mm 14 P 1 25...

Page 1169: ...e sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running Be sure to tig...

Page 1170: ...IN H4DOTC 7 REMOVAL Air Cleaner 3 Disconnect the connector from ignition coil 4 Remove the ignition coil 5 Remove the spark plugs with the spark plug sockets 2 LH SIDE 1 Disconnect the battery cables...

Page 1171: ...rque should be reduced by approx 1 3 of the specified torque in order to avoid over stressing 2 LH SIDE 1 Install in the reverse order of removal Tightening torque Spark plug 21 N m 2 1 kgf m 15 2 ft...

Page 1172: ...ting White or light gray insulator with black or brown spots and bluish burnt electrodes indicates engine overheating Moreover the appearance results from incorrect ignition timing loose spark plugs w...

Page 1173: ...fer to the Spark Plug Removal for removal pro cedure 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 7 ft lb C INSPEC...

Page 1174: ...IG H4DOTC 8 IGNITION IGNITION COIL IGNITOR ASSY...

Page 1175: ...STARTING CHARGING SYSTEMS SC H4DOTC Page 1 General Description 2...

Page 1176: ...SC H4DOTC 2 STARTING CHARGING SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATION Specifications for Turbo model is included in SC H4SO section Ref to SC H4SO 2 General Description...

Page 1177: ...O Signal 28 8 Data Link Connector 29 9 OBD II General Scan Tool 30 10 Subaru Select Monitor 32 11 Read Diagnostic Trouble Code DTC 39 12 Inspection Mode 40 13 Drive Cycle 46 14 Clear Memory Mode 48 1...

Page 1178: ...tor 3 Turn the ignition switch to ON and the Sub aru Select Monitor or OBD II general scan tool switch to ON 4 Read the DTC on Subaru Select Monitor or OBD II general scan tool Does the Subaru Select...

Page 1179: ...gear oil level check Ref to 4AT 32 Differential Gear Oil 3 ATF leak check Ref to 4AT 31 Automatic Transmission Fluid 4 Differential gear oil leak check Ref to 4AT 32 Differential Gear Oil 5 Stall test...

Page 1180: ...rs Outdoor temperature C F Hot Warm Cool Cold Place Highway Suburbs Inner city Uphill Downhill Rough road Others Engine temperature Cold Warming up After warming up Any temperature Others Engine speed...

Page 1181: ...ition of fuel gauge c Intentional connecting or disconnecting of harness connectors or spark plug cords Yes No What d Intentional connecting or disconnecting of hoses Yes No What e Installing of parts...

Page 1182: ...ensors or all electrical control modules at the harness side connector use a tapered pin with a diameter of less than 0 64 mm 0 025 in Do not insert the pin more than 5 mm 0 20 in into the part 6 Befo...

Page 1183: ...a mal function of the system The reason for this is the speed difference between front and rear wheels After diagnosis of engine control system perform the ABS memory clearance procedure of self diag...

Page 1184: ...ty of fuel is controlled by an intermittent injection system where the electro magnetic injection valve fuel in jector opens only for a short period of time de pending on the quantity of air required...

Page 1185: ...S ELECTRICAL COMPONENTS LOCATION 4 Electrical Components Location A LOCATION 1 ENGINE Module 1 Engine control module ECM 3 Test mode connector 4 Data link connector 2 Malfunction indicator light EN 01...

Page 1186: ...EN H4DOTC 10 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00156 EN 01271 2 EN 01272 3 4 EN 01273...

Page 1187: ...absolute pressure sen sor 5 Camshaft position sensor 8 Tumble generator valve position sensor 2 Engine coolant temperature sensor 6 Crankshaft position sensor 3 Throttle position sensor 7 Mass air fl...

Page 1188: ...EN H4DOTC 12 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00294 2 EN 00295 3 EN 00296 EN 00297 4 EN 00298 5 EN 00299 6 7 EN 00300 8 EN 00301...

Page 1189: ...nt oxygen A F sensor 3 Exhaust temperature sensor Except for Australia DOHC Turbo model and STi model 5 Rear oxygen sensor Except for Australia model 2 Precatalytic converter Except for Australia DOHC...

Page 1190: ...EN H4DOTC 14 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00303 EN 00304 3 2 4 EN 00305 5 EN 00306 6 EN 00307 EN 01568 5...

Page 1191: ...EN H4DOTC 15 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 Fuel level sensor 2 Fuel sub level sensor EN 01276 1 2 EN 01277 1 2 EN 00310 1 EN 00311 2...

Page 1192: ...ATION Solenoid Valve Actuator Emission Control System Parts and Ignition System Parts 1 Wastegate control solenoid valve 3 Purge control solenoid valve 5 Tumble generator valve actuator 2 Idle air con...

Page 1193: ...EN H4DOTC 17 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION EN 00313 1 EN 00314 2 EN 00315 3 EN 00316 4 5 EN 00317...

Page 1194: ...Fuel pump 5 Fuel pump control unit 9 Radiator sub fan relay 2 2 Inhibitor switch 6 Radiator main fan relay 1 10 Starter 3 Main relay 7 Radiator main fan relay 2 4 Fuel pump relay 8 Radiator sub fan re...

Page 1195: ...EN H4DOTC 19 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 1 EN 00320 2 EN 00321 4 3 EN 01281 5 EN 01282 EN 01596 7 8 6 9 EN 01328 10...

Page 1196: ...OTC 20 ENGINE DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 2 TRANSMISSION Module 1 Transmission control module TCM for AT model 2 AT diagnostic indicator light for AT model EN 01284 1 2 1 EN 00327 EN 01...

Page 1197: ...vehicle speed sensor for AT model 3 Front vehicle speed sensor for AT model 5 ATF temperature sensor for AT model 2 Front vehicle speed sensor for MT model 4 Torque converter turbine speed sensor for...

Page 1198: ...odel 1 Inhibitor switch 4 Line pressure duty solenoid 7 2 4 brake duty solenoid 2 Shift solenoid valve 1 5 Lock up duty solenoid 8 Low clutch timing solenoid valve 3 Shift solenoid valve 2 6 Transfer...

Page 1199: ...5 17 0 0 0 9 Shield B135 26 0 0 GND sen sor B135 19 0 0 Front oxy gen A F sensor heater Signal 1 B84 5 0 1 0 0 1 0 Signal 2 B84 4 0 1 0 0 1 0 Rear oxygen sensor heater signal B137 13 0 1 0 0 1 0 Engin...

Page 1200: ...lose B136 5 0 or 5 0 or 5 Tumble generator valve LH open B136 10 0 or 5 0 or 5 Tumble generator valve LH close B136 11 0 or 5 0 or 5 Wastegate control sole noid valve B84 24 10 13 13 14 Starter switch...

Page 1201: ...l B135 8 1 7 2 4 1 1 1 6 Power supply B135 9 5 5 GND sen sor B135 19 0 0 Fuel level sensor B135 25 0 12 4 75 0 12 4 75 Small light switch B134 17 ON 0 OFF 10 13 ON 0 OFF 13 14 Blower fan switch B134 9...

Page 1202: ...8 0 0 GND ignition system B137 18 0 0 GND power supply B137 17 0 0 B134 22 0 0 GND control systems B134 7 0 0 B134 15 0 0 GND oxygen sensor heater 1 B84 9 0 0 GND oxygen sensor heater 2 B84 8 0 0 Cont...

Page 1203: ...Condition Data A ELECTRICAL SPECIFICATION Measuring condition After warm up the engine Gear position is in neutral position A C is turned to OFF All accessory switches are turned to OFF Content Speci...

Page 1204: ...H4DOTC 28 ENGINE DIAGNOSTICS TRANSMISSION CONTROL MODULE TCM I O SIGNAL 7 Transmission Control Module TCM I O Signal A ELECTRICAL SPECIFICATION Ref to 4AT 13 Transmission Control Module TCM I O Signa...

Page 1205: ...han the OBD II general scan tools and Subaru Select Monitor because the circuit for Subaru Select Monitor may be damaged EN 00037 1 2 3 4 5 7 6 8 9 10 11 12 13 15 14 16 Terminal No Contents Terminal N...

Page 1206: ...E 01 CURRENT POWERTRAIN DI AGNOSTIC DATA Refers to data denoting the current operating con dition of analog input output digital input output and or the powertrain system A list of the support data an...

Page 1207: ...t data denoting emission related power train DTC Ref to EN H4DOTC 39 Read Diagnostic Trouble Code DTC 5 MODE 04 CLEAR RESET EMISSION RELATED DIAGNOSTIC INFORMATION Refers to the mode used to clear or...

Page 1208: ...diagnosis cable to data link connector CAUTION Do not connect the scan tools except for Suba ru Select Monitor and OBD II general scan tool 5 Turn the ignition switch to ON engine OFF and Subaru Sele...

Page 1209: ...1 Resistance Front oxygen A F sensor output signal A F Sensor 1 Rear oxygen sensor output signal Rear O2 Sensor V Short term fuel trim A F Correction 1 Knock sensor signal Knocking Correction deg Atmo...

Page 1210: ...n fan relay signal Radiator Fan Relay 1 ON or OFF Fuel pump relay signal Fuel Pump Relay ON or OFF Knocking signal Knocking Signal ON or OFF Radiator sub fan relay signal Radiator Fan Relay 2 ON or OF...

Page 1211: ...atalyst Diagnosis Complete or incomplete Test of heated catalyst Heated catalyst No support Test of evaporative emission purge control system Evaporative purge system No support Test of secondary air...

Page 1212: ...pport data is shown in the following table NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MANUAL Contents Display Unit of measure DTC for freeze frame data Freeze f...

Page 1213: ...OFF When knocking signal is entered Radiator sub fan relay signal Radiator Fan Relay 2 ON or OFF When radiator sub fan relay is in function Engine torque control signal 1 Torque Control Signal 1 ON o...

Page 1214: ...nsor Voltage V 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 Transfer Du...

Page 1215: ...DE 1 On the Main Menu display screen select the 2 Each System Check and press the YES key 2 On the System Selection Menu display screen select the Engine Control System and press the YES key 3 Press t...

Page 1216: ...gh Input P0117 Engine Coolant Temperature Circuit Low Input P0118 Engine Coolant Temperature Circuit High Input P0122 Throttle Pedal Position Sensor Switch A Circuit Low Input P0123 Throttle Pedal Pos...

Page 1217: ...53 Shift Solenoid A Electrical P0758 Shift Solenoid B Electrical P0771 Low Clutch Timing Solenoid P0778 Pressure Control Solenoid B Electrical P0785 Shift Timing Solenoid P0851 Neutral Switch Input Ci...

Page 1218: ...noid Valve Signal 2 Circuit Malfunction Short P1518 Starter Switch Circuit Low Input P1560 Back up Voltage Circuit Malfunction P1570 Antenna P1571 Reference Code Incompatibility P1572 IMM Circuit Fail...

Page 1219: ...ers In order to prevent the vehicle from slipping due to vibration do not place any wooden blocks or similar items between the safety stands and the vehicle Since the rear wheels will also rotate do n...

Page 1220: ...isplay screen NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL For detailed concerning the DTC refer to the List of Diagnostic Trouble Code DTC Ref to EN H4DO...

Page 1221: ...o 6 MPH NOTE On AWD model release the parking brake The speed difference between front and rear wheels may light ABS warning light but this indi cates no malfunctions When the engine control di agnosi...

Page 1222: ...ne coolant temperature specified items at starting the diagnosis is carried out after en gine warm up Carry out the diagnosis which is marked on DTC twice then after finishing first diagnosis stop the...

Page 1223: ...20 seconds F Accelerate to 97 km h 60 MPH within 10 seconds DTC Item Condition P0121 Throttle Pedal Position Sensor Switch A Circuit Range Performance P0139 O2 Sensor Circuit Slow Response Bank 1 Sen...

Page 1224: ...TOR OPERATION MANUAL 2 SUBARU SELECT MONITOR OBD MODE 1 On the Main Menu display screen select the 2 Each System Check and press the YES key 2 On the System Selection Menu display screen select the En...

Page 1225: ...he diagnosis cable to data link connector CAUTION Do not connect scan tools except for the Suba ru Select Monitor and OBD II general scan tool 6 Turn the ignition switch to ON engine OFF and Subaru Se...

Page 1226: ...detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL Contents Display Compulsory fuel pump relay oper ation check Fuel Pump Relay Compulsory radiator fan relay operation c...

Page 1227: ...ON Malfunction Indicator Light 3 Check that the malfunction indicator light does not go off Ref to EN H4DOTC 55 MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF Malfunction Indicator Light 4 Check that the...

Page 1228: ...er starting the engine the malfunction indica tor light goes out If it does not either the engine or the emission control system is malfunctioning 3 If the diagnosis system senses a misfire which coul...

Page 1229: ...Is the voltage less than 1 V Go to step 4 Go to step 2 2 CHECK POOR CONTACT Does the malfunction indicator light come on when shaking or pulling ECM connector and harness Repair the poor contact in E...

Page 1230: ...air the following Open circuit in harness between ECM and combi nation meter con nector Poor contact in couplingconnector 5 CHECK POOR CONTACT Check poor contact in combination meter con nector Is the...

Page 1231: ...m ECM 3 Turn the ignition switch to ON Does the malfunction indicator light come on Repair the short circuit in harness between combina tion meter and ECM connector Replace the ECM Ref to FU H4DOTC 49...

Page 1232: ...5 A5 i12 A i11 C B125 B100 B126 A LHD 14 RHD 13 E RHD LHD LHD RHD 1 C7 A6 5 LHD RHD COMBINATION METER B72 B22 B75 B125 B134 B76 B126 i11 i11 B84 i1 RHD F60 LHD 3 4 1 2 1 2 3 4 5 6 7 8 9 12 13 10 11 14...

Page 1233: ...tion switch to OFF 2 Disconnect the connector from ECM 3 Measure the resistance of harness between test mode connector and chassis ground Connector terminal B76 No 1 Chassis ground Is the resistance l...

Page 1234: ...00 B126 A LHD 14 RHD 13 E RHD LHD LHD RHD 1 C7 A6 5 LHD RHD COMBINATION METER B72 B22 B75 B125 B134 B76 B126 i11 i11 B84 i1 RHD F60 LHD 3 4 1 2 1 2 3 4 5 6 7 8 9 12 13 10 11 14 1 2 3 4 5 6 7 8 9 10 1...

Page 1235: ...blinks at a cycle of 3 Hz when test mode connec tor is connected 2 CHECK HARNESS BETWEEN ECM CON NECTOR AND ENGINE GROUNDING TER MINAL 1 Turn the ignition switch to OFF 2 Disconnect the connector from...

Page 1236: ...y and ground line Ref to EN H4DOTC 63 CONTROL MODULE POWER SUPPLY AND GROUND LINE Diagnostics for Engine Starting Failure 3 Inspection of ignition control system Ref to EN H4DOTC 67 IGNITION CONTROL S...

Page 1237: ...motor oper ate Go to step 2 Go to step 3 2 CHECK DTC Is the DTC displayed Ref to EN H4DOTC 39 OPERA TION Read Diagnostic Trou ble Code DTC Using the List of Diagnostic Trou ble Code DTC check the app...

Page 1238: ...R 1 Ignition the switch to OFF 2 Disconnect the connector from ignition switch 3 Measure the power supply voltage between ignition switch connector and chassis ground Connector terminal B72 No 1 Chass...

Page 1239: ...14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 TO FRONT OXYGEN A F SENSOR A2 E8 E9 A22 D17 D8 D18 A7 A15 C1 E2 E3 E10 A14 No 11 B61 F44 B47 B100 F2 E3 F6...

Page 1240: ...e the main relay B72 B84 3 4 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 DATA LINK CONNECTOR A2 E8...

Page 1241: ...the ground short circuit in har ness between ECM connector and main relay connector and then replace ECM 5 CHECK OUTPUT VOLTAGE FROM ECM 1 Connect the connector to ECM 2 Turn the ignition switch to ON...

Page 1242: ...voltage between ECM connec tor and chassis ground Connector terminal B84 No 2 Chassis ground B84 No 3 Chassis ground Is the voltage more than 10 V Check the ignition control system Ref to EN H4DOTC 67...

Page 1243: ...de WIRING DIAGRAM LHD model EN 01294 IGNITION SWITCH SBF 4 SBF 1 B72 B137 B100 F2 F2 24 23 22 21 8 7 9 10 11 ECM No 11 E E 1 4 E3 F60 E31 E31 E32 E33 E34 IGNITION COIL No 1 IGNITION COIL No 2 IGNITION...

Page 1244: ...ESSURE OPERATION Fuel 3 Contact the spark plug s thread portion on engine 4 While opening the throttle valve fully crank engine to check that spark occurs at each cyl inder Does spark occur at each cy...

Page 1245: ...Open circuit in harness between ignition coil igni tor assembly con nector and engine grounding terminal 5 CHECK HARNESS BETWEEN ECM AND IG NITION COIL IGNITOR ASSEMBLY CON NECTOR 1 Turn the ignition...

Page 1246: ...R122 E E M RHD RHD 10 7 6 FUEL PUMP RELAY FUEL PUMP CONTROLLER FUEL PUMP SBF 5 B61 B46 R122 B134 A B137 D R15 R57 R58 R3 ECM B99 B99 R58 B97 R1 F44 8 LHD LHD BATTERY LHD 20 RHD 27 LHD 19 RHD 26 LHD 7...

Page 1247: ...mp operation check can also be execut ed using the Subaru Select Monitor For the procedure refer to Compulsory Valve Operation Check Mode Ref to EN H4DOTC 49 Compulsory Valve Opera tion Check Mode Doe...

Page 1248: ...model EN 01297 BATTERY FUEL INJECTORS MAIN RELAY E 4 1 2 SBF 5 3 1 2 2 1 2 F60 E 1 1 2 1 9 10 11 12 2 13 I4 3 E1 D6 D5 D4 1 8 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 2...

Page 1249: ...l injector emit operating sound Check the fuel pressure Ref to ME H4DOTC 39 INSPECTION Fuel Pressure Go to step 2 EN 01298 BATTERY FUEL INJECTORS MAIN RELAY E 4 1 2 SBF 5 3 1 2 2 1 2 1 1 2 1 9 10 11 1...

Page 1250: ...No 1 E5 No 1 B137 No 6 E16 No 1 B137 No 5 E6 No 1 B137 No 4 E6 No 1 Is the resistance less than 1 Go to step 4 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in...

Page 1251: ...with Diagnostic Trouble Code DTC P0101 Mass or Volume Air Flow Circuit Range Performance Ref to EN H4DOTC 99 DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE PERFORMANCE Diagnostic Procedure with Diag...

Page 1252: ...139 DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE BANK 1 SENSOR 2 Diagnostic Procedure with Diagnostic Trouble Code DTC P0138 O2 Sensor Circuit High Voltage Bank 1 Sensor 2 Ref to EN H4DOTC 142 DTC P0138 O...

Page 1253: ...EN SOR B CIRCUIT BANK 2 Diagnostic Procedure with Diagnostic Trou ble Code DTC P0420 Catalyst System Efficiency Below Threshold Bank 1 Ref to EN H4DOTC 183 DTC P0420 CATALYST SYSTEM EFFI CIENCY BELOW...

Page 1254: ...ure with Diagnostic Trouble Code DTC P0565 Cruise Control On Signal Ref to EN H4DOTC 225 DTC P0565 CRUISE CONTROL ON SIGNAL Diagnostic Procedure with Diagnostic Trouble Code DTC P0604 Internal Control...

Page 1255: ...ure with Diagnostic Trouble Code DTC or Ref to EN H4DOTC 250 DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH MT MODEL Diagnostic Procedure with Diagnostic Trouble Code DTC P0864 TCM Communication Circuit...

Page 1256: ...CIRCUIT RANGE PERFORMANCE LOW BANK1 SENSOR1 Diagnostic Procedure with Diagnostic Trouble Code DTC P1153 O2 Sensor Circuit Range Perfor mance High Bank1 Sensor1 Ref to EN H4DOTC 284 DTC P1153 O2 SENSO...

Page 1257: ...NTROL MODULE EEPROM Diagnos tics Chart with Diagnostic Trouble Code DTC P1698 Engine Torque Control Cut Signal Circuit Low Input Ref to EN H4DOTC 305 DTC P1698 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT...

Page 1258: ...the AVCS operating angle and vari able valve timing solenoid valve duty output using Subaru Select Monitor and OBD II gen eral scan tool NOTE Subaru Select Monitor For detailed operation procedure re...

Page 1259: ...d vari able valve timing solenoid valve duty output using Subaru Select Monitor and OBD II gen eral scan tool NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA...

Page 1260: ...ory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01299 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD RHD 8 9 4 5 19 2...

Page 1261: ...tance less than 1 Go to step 3 Repair the open circuit in harness between ECM and front oxygen A F sensor connector 3 CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN A F SENSOR CONNEC TOR Measure the resis...

Page 1262: ...y Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01299 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD RHD 8 9 4 5 19 29...

Page 1263: ...CURRENT DATA 1 Start the engine 2 Read the data of front oxygen A F sensor heater current using Subaru Select Monitor or OBD II general scan tool NOTE Subaru Select Monitor For detailed operation pro...

Page 1264: ...ctor Go to step 8 8 CHECK FRONT OXYGEN A F SENSOR 1 Turn the ignition switch to OFF 2 Measure the resistance between front oxy gen A F sensor connector terminals Terminals No 2 No 1 Is the resistance...

Page 1265: ...the ignition switch to ON 2 Measure the voltage between ECM connec tor and chassis ground Connector terminal B84 No 4 Chassis ground B84 No 5 Chassis ground Is the voltage more than 8 V Go to step 3 G...

Page 1266: ...refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC 32 Subaru Select Mon itor OBD II general scan tool For detailed operation procedure refer to the OBD II General Scan Tool Instruction Manual...

Page 1267: ...3 RHD LHD RHD B260 1 2 B259 1 LHD LHD LHD LHD RHD LHD B22 B83 RHD RHD 3 4 1 2 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B137 F60 F44 B83 B47 B19 B84 1 2 7 8 9 5 6 3 4 10 11 1...

Page 1268: ...0 2 A Repair the con nector NOTE In this case repair the following Poor contact in rear oxygen sen sor connector Poor contact in rear oxygen sen sor connecting harness connector Poor contact in ECM co...

Page 1269: ...case repair the following Open circuit in harness between main relay and rear oxygen sen sor connector Poor contact in rear oxygen sen sor connector Poor contact in coupling connector 7 CHECK REAR OX...

Page 1270: ...8 V Go to step 2 Go to step 3 EN 01300 BATTERY MAIN RELAY B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD LHD RHD B260 1 2 B259 1 LHD LHD LHD LHD RHD LHD B22 B83 RHD RHD 3 4 1 2...

Page 1271: ...neral scan tool NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC 32 Subaru Select Mon itor OBD II general scan tool For detailed o...

Page 1272: ...faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01301 B83 MANIFOLD ABSOLUTE...

Page 1273: ...DTC RHD model EN 01302 B83 MANIFOLD ABSOLUTE PRESSURE SENSOR THROTTLE BODY 3 2 1 19 9 8 ECM B135 E21 E2 B21 3 1 20 18 16 1 2 3 B83 B21 E21 1 2 3 4 5 6 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 2...

Page 1274: ...ag nostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0106 2 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Inspect the rele vant DTC List of Diagnostic Trou ble...

Page 1275: ...emory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01303 B83 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15...

Page 1276: ...Is any other DTC displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect...

Page 1277: ...ing performance WIRING DIAGRAM EN 01303 B83 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 BATTERY E B61 F44 8 LHD RHD LHD RHD B83 1 B3 MASS AIR FLOW AND INTAKE AIR...

Page 1278: ...ensor NOTE In this case repair the following Open or ground short circuit in har ness between mass air flow sen sor and ECM con nector Poor contact in mass air flow sen sor or ECM con nector Go to ste...

Page 1279: ...tor 6 CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR Measure the resistance of harness between ECM and chassis ground Connector terminal B136 No 13 Chassis ground B136 No 7 Chassis groun...

Page 1280: ...de Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01303 B83 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28...

Page 1281: ...nc tion indicator light lights up the cir cuit has returned to a normal condi tion at this time Go to step 2 2 CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR 1 Turn the ignition switch t...

Page 1282: ...mory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01301 B83 MANIFOLD ABSOLUTE PRESSURE SENSOR THROTTLE BODY...

Page 1283: ...nd Connector terminal B135 No 9 Chassis ground Shake the ECM harness and connector while monitoring value of voltage meter Does the voltage change Repair the poor contact in ECM connector Contact your...

Page 1284: ...NIFOLD ABSOLUTE PRESSURE SEN SOR CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM 3 Measure the resistance of harness between ECM and manifold absolute pressure sensor c...

Page 1285: ...mory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01301 B83 MANIFOLD ABSOLUTE PRESSURE SENSOR THROTTLE BODY...

Page 1286: ...nd Connector terminal B135 No 9 Chassis ground Shake the ECM harness and connector while monitoring value of voltage meter Does the voltage change Repair the poor contact in ECM connector Contact your...

Page 1287: ...BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SEN SOR CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM 3 Measure the resistance of harness between ECM and manifold absolute...

Page 1288: ...ode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01303 B83 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 2...

Page 1289: ...he engine coolant temperature using Subaru Select Monitor or OBD II general scan tool NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4...

Page 1290: ...o EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01303 B83 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 1...

Page 1291: ...ontact in joint connector 2 CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from mass air flow and...

Page 1292: ...to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01303 B83 B3 B135 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17...

Page 1293: ...ine ground Connector terminal B3 No 4 Engine ground Is the voltage more than 10 V Repair the battery short circuit in har ness between mass air flow and intake air tempera ture sensor and ECM connecto...

Page 1294: ...ground Connector terminal B3 No 5 Engine ground Is the resistance less than 5 Replace the mass air flow and intake air temperature sensor Ref to FU H4DOTC 34 Mass Air Flow and Intake Air Temper ature...

Page 1295: ...Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01304 B83 B135 ECM 19 18 E8 ENGINE COOLANT TEMPERATURE SENSOR 2 1 1 2 17 18...

Page 1296: ...ECM Poor contact in coupling connector Poor contact in joint connector 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the c...

Page 1297: ...Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01304 B83 B135 ECM 19 18 E8 ENGINE COOLANT TEMPERATURE SENSOR 2 1 1 2 17 18...

Page 1298: ...temperature sensor connector and engine ground Connector terminal E8 No 2 Engine ground Is the voltage more than 10 V Repair the battery short circuit in har ness between ECM and engine coolant temper...

Page 1299: ...nector terminal E8 No 1 Engine ground Is the resistance less than 5 Replace the engine coolant temperature sen sor Ref to FU H4DOTC 28 Engine Coolant Temperature Sen sor Repair the har ness and connec...

Page 1300: ...fter repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model E...

Page 1301: ...Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0121 Replace the throt tle position sensor Ref to FU H4DOTC 33 Throttle Position Sensor EN...

Page 1302: ...replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01305 E2 E13...

Page 1303: ...ROUBLE CODE DTC RHD model EN 01306 E2 E13 B21 B83 THROTTLE POSITION SENSOR 1 3 2 20 19 18 1 3 B135 ECM 9 19 7 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 E13 1 2 3...

Page 1304: ...IGNAL FOR ECM Measure the voltage between ECM connector and chassis ground while throttle valve is fully closed Connector terminal B135 No 9 Chassis ground Is the voltage more than 4 5 V Go to step 4...

Page 1305: ...tance of harness between ECM connector and throttle position sensor connector Connector terminal B135 No 7 E13 No 3 Is the resistance less than 1 Go to step 8 Repair the har ness and connec tor NOTE I...

Page 1306: ...replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01305 E2 E13...

Page 1307: ...ROUBLE CODE DTC RHD model EN 01306 E2 E13 B21 B83 THROTTLE POSITION SENSOR 1 3 2 20 19 18 1 3 B135 ECM 9 19 7 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 E13 1 2 3...

Page 1308: ...ector 2 CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNEC TOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from throttle posi tion sensor 3 Measure the resistance of harnes...

Page 1309: ...e Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01304 B83 B135 ECM 19 18 E8 ENGINE COOLANT TEMPERATURE SENSOR 2 1 1 2 17 18...

Page 1310: ...nostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0125 Go to step 2 2 CHECK ENGINE COOLING SYSTEM NOTE Check the following items Thermostat open stuck Coolant level Coolant...

Page 1311: ...and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01299 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD RHD 8 9 4 5 19 29 18 ECM...

Page 1312: ...sured value 0 85 1 15 in idling Go to step 3 Go to step 4 3 CHECK REAR OXYGEN SENSOR SIGNAL 1 Race the engine at speeds from idling to 5 000 rpm for a total of 5 cycles NOTE To increase the engine spe...

Page 1313: ...Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01299 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD RHD 8 9 4 5 1...

Page 1314: ...displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC P0133 Go to...

Page 1315: ...3 12 3 RHD LHD RHD B260 1 2 B259 1 LHD LHD LHD LHD RHD LHD B22 B83 RHD RHD 3 4 1 2 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B137 F60 F44 B83 B47 B19 B84 1 2 7 8 9 5 6 3 4 10...

Page 1316: ...l Is the voltage 0 2 0 4 V Go to step 4 Replace the rear oxygen sensor Ref to FU H4DOTC 46 Rear Oxygen Sen sor 4 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch t...

Page 1317: ...OTE Check the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fault i...

Page 1318: ...3 12 3 RHD LHD RHD B260 1 2 B259 1 LHD LHD LHD LHD RHD LHD B22 B83 RHD RHD 3 4 1 2 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B137 F60 F44 B83 B47 B19 B84 1 2 7 8 9 5 6 3 4 10...

Page 1319: ...l Is the voltage 0 2 0 4 V Go to step 4 Replace the rear oxygen sensor Ref to FU H4DOTC 46 Rear Oxygen Sen sor 4 CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR 1 Turn the ignition switch t...

Page 1320: ...OTE Check the following items Loose installation of portions Damage crack hole etc of parts Looseness and ill fitting of parts between front oxygen A F sensor and rear oxygen sensor Is there a fault i...

Page 1321: ...E3 12 3 RHD LHD RHD B260 1 2 B259 1 LHD LHD LHD LHD RHD LHD B22 B83 RHD RHD 3 4 1 2 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B135 B137 F60 F44 B83 B47 B19 B84 1 2 7 8 9 5 6 3 4 1...

Page 1322: ...YSTEM TOO RICH BANK 1 Diagnostic Procedure with Diagnostic Trouble Code DTC Step Check Yes No 1 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Inspect the rele vant DTC using List of Diagno...

Page 1323: ...careful not to spill fuel on the floor 1 Release the fuel pressure 1 Disconnect the connector from fuel pump relay 2 Start the engine and run it until it stalls 3 After the engine stalls crank it for...

Page 1324: ...FOR ENGINE Ref to EN H4DOTC 32 Subaru Select Mon itor OBD II general scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual Is the temperature more than 6...

Page 1325: ...Select Monitor or OBD II general scan tool NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE Ref to EN H4DOTC 32 Subaru Select Mon itor OBD II gene...

Page 1326: ...Mode WIRING DIAGRAM EN 01296 F44 B97 B134 B137 B46 R122 E E M RHD RHD 10 7 6 FUEL PUMP RELAY FUEL PUMP CONTROLLER FUEL PUMP SBF 5 B61 B46 R122 B134 A B137 D R15 R57 R58 R3 ECM B99 B99 R58 B97 R1 F44...

Page 1327: ...mp control unit and chassis ground Connector terminal R122 No 5 Chassis ground Is the resistance less than 5 Go to step 3 Repair the har ness and connec tor NOTE In this case repair the following Open...

Page 1328: ...ontrol unit and ECM Poor contact in fuel pump control unit and ECM con nector 6 CHECK HARNESS BETWEEN FUEL PUMP CONTROL UNIT AND ECM CONNECTOR Measure the resistance of harness between fuel pump contr...

Page 1329: ...performance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRI...

Page 1330: ...DTC ON DISPLAY Is any other DTC displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC NOTE In this case it is not necess...

Page 1331: ...repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01307 MAIN R...

Page 1332: ...No 1 Is the resistance less than 1 Go to step 4 Repair the open circuit in harness between ECM and wastegate control solenoid valve connector NOTE In this case repair the following Open circuit in har...

Page 1333: ...repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01307 MAIN R...

Page 1334: ...nition switch to ON 4 Measure the voltage between ECM and chassis ground Connector terminal B84 No 24 Chassis ground Is the voltage more than 10 V Repair the battery short circuit in har ness between...

Page 1335: ...cedure with Diagnostic Trouble Code DTC AK DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE For the diagnostic procedure refer to DTC P0304 Ref to EN H4DOTC 160 DTC P0304 CYLINDER 4 MISFIRE DETECTED Diagnos...

Page 1336: ...ve driving cycles with fault Immediately at fault recognition A misfire which could damage catalyst occurs TROUBLE SYMPTOM Engine stalls Erroneous idling Rough driving CAUTION After repair or replacem...

Page 1337: ...D5 D4 1 8 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 1338: ...EN H4DOTC 75 List of Diagnostic Trouble Code DTC Go to step 2 EN 01298 BATTERY FUEL INJECTORS MAIN RELAY E 4 1 2 SBF 5 3 1 2 2 1 2 1 1 2 1 9 10 11 12 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31...

Page 1339: ...ine ground 2 E16 No 1 Engine ground 3 E6 No 1 Engine ground 4 E17 No 1 Engine ground Is the resistance more than 1 M Go to step 4 Repair the ground short circuit in har ness between fuel injector and...

Page 1340: ...en ECM connec tor and chassis ground on faulty cylinders Connector terminal 1 B84 No 1 Chassis ground 2 B137 No 6 Chassis ground 3 B137 No 5 Chassis ground 4 B137 No 4 Chassis ground Is the voltage mo...

Page 1341: ...coming on or blinking Go to step 15 Go to step 14 14 CHECK CAUSE OF MISFIRE DIAGNOSED Was the cause of misfire diag nosed when the engine is run ning Finish the diag nostics operation if the engine h...

Page 1342: ...UBLE SYMPTOM Poor driving performance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode...

Page 1343: ...en knock sensor and ECM connector Poor contact in knock sensor con nector Poor contact in coupling connector 2 CHECK KNOCK SENSOR 1 Disconnect the connector from knock sen sor 2 Measure the resistance...

Page 1344: ...OUBLE SYMPTOM Poor driving performance Knocking occurs CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mod...

Page 1345: ...ock Sensor Repair the ground short circuit in har ness between knock sensor con nector and ECM connector NOTE The harness be tween both con nectors is shielded Repair the short circuit of harness toge...

Page 1346: ...talls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40...

Page 1347: ...shaft posi tion sensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair ground short circuit in harness togeth er with shield 3 CHECK HARNESS BETWEEN CRANK SHAFT POSITI...

Page 1348: ...MPTOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to...

Page 1349: ...ep 3 Tighten the crank shaft position sen sor installation bolt securely 3 CHECK CRANKSHAFT SPROCKET Remove the front belt cover Are the crankshaft sprocket teeth cracked or damaged Replace the crank...

Page 1350: ...TOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to E...

Page 1351: ...ition sensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair the ground short circuit in harness together with shield Go to step 3 3 CHECK HARNESS BETWEEN CAMSHAFT POS...

Page 1352: ...t TROUBLE SYMPTOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection...

Page 1353: ...HAFT POSITION SENSOR AND ECM CONNEC TOR Measure the resistance of harness between camshaft position sensor connector and engine ground Connector terminal E15 No 1 Engine ground Is the resistance less...

Page 1354: ...d securely Go to step 8 Tighten the cam shaft position sen sor installation bolt securely 8 CHECK CAMSHAFT SPROCKET Remove the front belt cover Ref to ME H4DOTC 59 Timing Belt Cover Are the camshaft s...

Page 1355: ...SYMPTOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref...

Page 1356: ...Is the resistance less than 1 Go to step 3 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between AVCS camshaft position sensor and ECM connec tor P...

Page 1357: ...SYMPTOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref...

Page 1358: ...5 Is the resistance less than 1 Go to step 3 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between AVCS camshaft position sensor and ECM connec tor...

Page 1359: ...RAM EN 01310 BATTERY MAIN RELAY E 2 6 4 5 3 2 1 1 4 3 2 RHD RHD LHD LHD FRONT OXYGEN A F SENSOR 6 4 B19 D13 B17 B26 E4 E5 E19 E29 E18 5 3 REAR OXYGEN SENSOR 1 RHD RHD LHD LHD 1 2 B19 B19 1 2 B47 B47 3...

Page 1360: ...nt catalytic converter and rear cat alytic converter Is there a fault in exhaust sys tem Repair or replace the exhaust sys tem Ref to EX H4DOTC 2 General Descrip tion Go to step 3 3 CHECK REAR CATALYT...

Page 1361: ...OTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01311 MAIN RELAY B47 1 2 3 5 4 6 BATTERY E B61 F44 F60 LHD E3 F44 B47 B84 B84 E4 PURGE CON...

Page 1362: ...No 2 Is the resistance less than 1 Go to step 4 Repair the open circuit in harness between ECM and purge control sole noid valve connec tor NOTE In this case repair the following Open circuit in harn...

Page 1363: ...OTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01311 MAIN RELAY B47 1 2 3 5 4 6 BATTERY E B61 F44 F60 LHD E3 F44 B47 B84 B84 E4 PURGE CON...

Page 1364: ...3 3 CHECK POOR CONTACT Check the poor contact in ECM connector Is there poor contact in ECM connector Repair the poor contact in ECM connector Replace the ECM Ref to FU H4DOTC 49 Engine Control Module...

Page 1365: ...4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R15 B135 ECM No 13 B36 i12 i1 B36 B100 F2 F60 E3 E3 B99 R3 i1 B36 i1 E E E E RHD RHD RHD LHD FUEL GAUGE 4 A i11 C IGNITION SWITCH COMBINATION METER SBF...

Page 1366: ...ny other DTC displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC NOTE In this case it is not necessary to inspect DTC...

Page 1367: ...6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R15 B135 ECM No 13 B36 i12 i1 B36 B100 F2 F60 E3 E3 B99 R3 i1 B36 i1 E E E E RHD RHD RHD LHD FUEL GAUGE 4 A i11 C IGNITION SWITCH COMBINATION METER SBF 4 SB...

Page 1368: ...he voltage change Repair the poor contact in ECM connector Even if malfunc tion indicator light lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the...

Page 1369: ...hort circuit in fuel tank cord 8 CHECK FUEL TANK CORD 1 Disconnect the connector from fuel pump assembly 2 Measure the resistance between fuel pump assembly and chassis ground Connector terminal R59 N...

Page 1370: ...6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R15 B135 ECM No 13 B36 i12 i1 B36 B100 F2 F60 E3 E3 B99 R3 i1 B36 i1 E E E E RHD RHD RHD LHD FUEL GAUGE 4 A i11 C IGNITION SWITCH COMBINATION METER SBF 4 SB...

Page 1371: ...harness between ECM and chassis ground Connector terminal B135 No 25 Chassis ground Is the voltage more than 4 75 V Go to step 4 Repair the battery short circuit between ECM and combination meter conn...

Page 1372: ...connector and fuel sub level sensor 9 CHECK FUEL LEVEL SENSOR 1 Remove the fuel pump assembly Ref to FU H4DOTC 61 Fuel Pump 2 While moving the fuel level sensor float up and down measure the resistanc...

Page 1373: ...6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R15 B135 ECM No 13 B36 i12 i1 B36 B100 F2 F60 E3 E3 B99 R3 i1 B36 i1 E E E E RHD RHD RHD LHD FUEL GAUGE 4 A i11 C IGNITION SWITCH COMBINATION METER SBF 4 S...

Page 1374: ...between fuel level sensor terminals changes smoothly Terminals No 3 No 5 Does the resistance change smoothly approx 0 5 52 Go to step 3 Replace the fuel level sensor Ref to FU H4DOTC 63 Fuel Level Se...

Page 1375: ...ROUBLE SYMPTOM Occurrence of noise Overheating CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to...

Page 1376: ...2 26 28 27 25 E B84 5 RHD LHD LHD RHD LHD RHD 23 21 22 24 F27 F16 F17 30A AIR CONDITIONING RELAY HOLDER SUB FAN RELAY 1 SUB FAN RELAY 2 3 4 7 5 6 8 18 20 19 17 E SUB FAN MOTOR 2 1 3 4 ECM E17 E28 5 3...

Page 1377: ...any other DTC displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC Check the radiator fan fan motor and thermostat Ref...

Page 1378: ...istance of harness between TCM connector and chassis ground Connector terminal B56 No 17 Chassis ground Is the resistance more than 1 M Go to step 3 Repair the ground short circuit in har ness between...

Page 1379: ...m vehicle speed sensor and ECM 3 Measure the resistance of harness between vehicle speed sensor connector and chassis ground Connector terminal B17 No 1 Chassis ground Is the resistance more than 1 M...

Page 1380: ...ansmission type AT Go to step 2 Go to step 3 EN 01313 E E F2 i11 i11 i1 B36 i2 B37 B100 B17 B22 E3 F60 1 LHD LHD BATTERY IGNITION SWICTH COMBINATION METER VEHICLE SPEED SENSOR B134 B134 B72 B72 ECM 4...

Page 1381: ...ly Go to step 4 Check the speed ometer Ref to IDI 18 Speedom eter 4 CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from combinat...

Page 1382: ...Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01314 BATTERY MAIN RELAY E E 8 6 4 5 3 2 1 RHD RHD LHD LHD 10 IDLE AIR CONTROL SOLENOID VALVE 1 3 E7 B47 B47...

Page 1383: ...Turn the ignition switch to ON 2 Start the engine and warm up the engine 3 Turn all accessory switches to OFF 4 Read the data of idle air control solenoid valve duty ratio using Subaru Select Monitor...

Page 1384: ...ar Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01314 BATTERY MAIN RELAY E E 8 6 4 5 3 2 1 RHD RHD LHD LHD 10 IDLE AIR CONTROL SOLENOID VALVE 1 3 E7 B47 B47 3...

Page 1385: ...y for adjustment Go to step 3 Adjust the throttle cable Ref to SP H4SO 9 INSTALLATION Accelerator Con trol Cable 3 CHECK AIR INTAKE SYSTEM 1 Turn the ignition switch to ON 2 Start the engine and idle...

Page 1386: ...ction Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01314 BATTERY MAIN RELAY E E 8 6 4 5 3 2 1 RHD RHD LHD LHD 10 IDLE AIR CONTROL SOLENOID VALVE 1 3 E7 B47 B47 3 4 1 2 5 6 F44 1 2 3 4 5...

Page 1387: ...oid valve con nector Connector terminal B137 No 10 E7 No 1 Is the resistance less than 1 Go to step 4 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness...

Page 1388: ...ction Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01314 BATTERY MAIN RELAY E E 8 6 4 5 3 2 1 RHD RHD LHD LHD 10 IDLE AIR CONTROL SOLENOID VALVE 1 3 E7 B47 B47 3 4 1 2 5 6 F44 1 2 3 4 5...

Page 1389: ...B137 No 10 Chassis ground Is the voltage more than 10 V Repair the battery short circuit in har ness between ECM and idle air control solenoid valve connector After repair replace the ECM Ref to FU H4...

Page 1390: ...or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 00338 BATTERY IGNITI...

Page 1391: ...RTER MOTOR Does the starter motor oper ate when ignition switch is turned to ON Repair the battery short circuit in starter motor cir cuit After repair replace the ECM Ref to FU H4DOTC 49 Engine Contr...

Page 1392: ...8 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01314 BATTERY MAIN RELAY E E 8 6 4 5 3 2 1 RHD RHD LHD LHD 10 IDLE AIR CONTROL SOLENOID VALVE 1...

Page 1393: ...ld gasket idle air con trol solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses Is there a fault in air intake sys tem Repair the air suc tion and leaks Go to step 3 3 CHECK...

Page 1394: ...eous idling Poor driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC...

Page 1395: ...ure sensor Poor contact in ECM Poor contact in joint connector 2 CHECK HARNESS BETWEEN EXHAUST GAS TEMPERATURE SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector fro...

Page 1396: ...neous idling Poor driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOT...

Page 1397: ...gas temperature sensor connector and engine ground Connector terminal B279 No 1 Engine ground Is the voltage more than 10 V Repair the battery short circuit in har ness between ECM and exhaust gas te...

Page 1398: ...ition switch to OFF 2 Measure the resistance of harness between exhaust gas temperature sensor connector and engine ground Connector terminal B279 No 2 Engine ground Is the resistance less than 5 Repl...

Page 1399: ...ir or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01316 B62 B84 F45...

Page 1400: ...istance more than 1 M Go to step 2 Repair the ground short circuit in har ness between ECM and purge control solenoid valve connector 2 CHECK HARNESS BETWEEN GENERATOR AND ECM CONNECTOR Measure the re...

Page 1401: ...ng cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection M...

Page 1402: ...short circuit in harness between TCM and CCM connector 3 CHECK INPUT SIGNAL FOR TCM 1 Connect the connector to TCM and CCM 2 Lift up the vehicle or set the vehicle on free rollers CAUTION Raise all wh...

Page 1403: ...model EN 01292 B72 B84 3 4 1 2 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 TO FRONT OXYGEN A F SENSOR A...

Page 1404: ...7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 DATA LINK CONNECTOR A2 E8 E9 A22 D17 D8 D18 A7 A15 C1 E2 E3 E10...

Page 1405: ...LOW DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty parts conduct Cle...

Page 1406: ...2 26 28 27 25 E B84 5 RHD LHD LHD RHD LHD RHD 23 21 22 24 F27 F16 F17 30A AIR CONDITIONING RELAY HOLDER SUB FAN RELAY 1 SUB FAN RELAY 2 3 4 7 5 6 8 18 20 19 17 E SUB FAN MOTOR 2 1 3 4 ECM E17 E28 5 3...

Page 1407: ...radi ator fan relay con trol circuit 3 CHECK POWER SUPPLY FOR RELAY 1 Remove the fan relay 1 and fan relay 2 from A C relay holder 2 Turn the ignition switch to ON 3 Measure the voltage between fuse...

Page 1408: ...IAGNOSTIC TROUBLE CODE DTC 7 CHECK POOR CONTACT Check poor contact in ECM or fan relay con nector Is there poor contact in ECM or fan relay connector Repair poor con tact in ECM or fan relay connector...

Page 1409: ...NTROL CIRCUIT HIGH DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Radiator fan does not operate properly Overheating CAUTION After repair or replacement of faulty pa...

Page 1410: ...2 26 28 27 25 E B84 5 RHD LHD LHD RHD LHD RHD 23 21 22 24 F27 F16 F17 30A AIR CONDITIONING RELAY HOLDER SUB FAN RELAY 1 SUB FAN RELAY 2 3 4 7 5 6 8 18 20 19 17 E SUB FAN MOTOR 2 1 3 4 ECM E17 E28 5 3...

Page 1411: ...n relay 2 and fan mode relay 3 Disconnect the test mode connector 4 Turn the ignition switch to ON 5 Measure the voltage between ECM and chassis ground Connector terminal B84 No 17 Chassis ground B84...

Page 1412: ...Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM Step Check Yes No 1 CHECK OPERATION OF BRAKE LIGHT Does the brake light come on...

Page 1413: ...2 Chassis ground Is the resistance more than 1 M Go to step 4 Repair the ground short circuit in har ness between TCM and brake light switch con nector 4 CHECK INPUT SIGNAL FOR TCM 1 Connect the conne...

Page 1414: ...c Procedure with Diagnostic Trouble Code DTC BV DTC P0732 GEAR 2 INCORRECT RATIO NOTE For the diagnostic procedure refer to DTC P0734 Ref to EN H4DOTC 239 DTC P0734 GEAR 4 IN CORRECT RATIO Diagnostic...

Page 1415: ...ir or replace the throttle posi tion sensor circuit Go to step 3 3 CHECK FRONT VEHICLE SPEED SENSOR CIRCUIT Check the front vehicle speed sensor circuit Ref to 4AT 53 DTC 33 FRONT VEHICLE SPEED SENSOR...

Page 1416: ...h Diagnos tic Trouble Code DTC Is there any trouble in throttle position sensor circuit Repair or replace the throttle posi tion sensor circuit Go to step 4 4 CHECK TORQUE CONVERTER TURBINE SPEED SENS...

Page 1417: ...t Repair or replace the ATF tempera ture sensor circuit Go to step 9 9 CHECK POOR CONTACT Check poor contact in TCM connector Is there poor contact in TCM connector Repair the poor contact in TCM conn...

Page 1418: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 OPERATION In spection Mode WIRING DIAGRAM EN 01318 B12 T3 B14 T7 INHIBITOR SWITCH STARTER MOTOR P R N D 3 2 1 12 7 12 11 B12 T7 1 2 3 4 5...

Page 1419: ...B134 No 8 Chassis ground Is the resistance more than 1 M Go to step 4 Repair ground short circuit in har ness between ECM and trans mission harness connector 4 CHECK TRANSMISSION HARNESS CON NECTOR 1...

Page 1420: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 OPERATION In spection Mode WIRING DIAGRAM EN 01318 B12 T3 B14 T7 INHIBITOR SWITCH STARTER MOTOR P R N D 3 2 1 12 7 12 11 B12 T7 1 2 3 4 5...

Page 1421: ...ss or replace neutral position switch 5 CHECK NEUTRAL POSITION SWITCH 1 Place the shift lever in a position except for neutral 2 Measure the resistance between transmis sion harness connector terminal...

Page 1422: ...IC TROUBLE CODE DTC 9 CHECK POOR CONTACT Check poor contact in transmission harness connector Is there poor contact in trans mission harness connector Repair poor con tact in transmis sion harness con...

Page 1423: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 OPERATION In spection Mode WIRING DIAGRAM EN 01318 B12 T3 B14 T7 INHIBITOR SWITCH STARTER MOTOR P R N D 3 2 1 12 7 12 11 B12 T7 1 2 3 4 5...

Page 1424: ...there poor contact in ECM connector Repair poor con tact in ECM con nector Contact your Sub aru distributor ser vice NOTE Inspection by DTM is required be cause probable cause is deteriora tion of mul...

Page 1425: ...otor ground line Poor contact in starter motor con nector Poor contact in starter motor ground Starter motor 8 CHECK INHIBITOR SWITCH Measure the resistance between inhibitor switch connector receptac...

Page 1426: ...TION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 OPERATION In spection Mode WIRING DIAGRAM EN 01318 B12 T3 B14 T7 INHIBITOR SWITCH STARTER MOTOR P R N D 3 2 1 12 7 12 11 B12 T7 1 2 3 4 5...

Page 1427: ...N HARNESS CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and transmission harness connector T9 3 Measure the resistance of harness between ECM and neutral switch conn...

Page 1428: ...Check Yes No 1 CHECK DRIVING CONDITION 1 Start and warm up the engine until the radia tor fan makes one complete rotation 2 Drive the vehicle Is the AT shift control function ing properly Go to step...

Page 1429: ...cles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode W...

Page 1430: ...3 Measure the resistance of harness between ECM and chassis ground Connector terminal B137 No 19 Chassis ground Is the resistance less than 10 Repair the ground short circuit in har ness between ECM a...

Page 1431: ...cles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode W...

Page 1432: ...1 V Repair the poor contact in ECM connector Go to step 4 4 CHECK OUTPUT SIGNAL FROM ECM Measure the voltage between ECM and chas sis ground Connector terminal B137 No 19 Chassis ground Does the volt...

Page 1433: ...Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01320 E2 E50 F61 F74 B200 F2 B100 B83 TUMBLE GEN...

Page 1434: ...CODE DTC RHD model EN 01321 E2 E50 B21 B83 1 3 2 20 10 18 1 3 B135 ECM 9 19 13 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 E50 1 2 3 B21 1 2 5 6 7 8 13 14 15 16 9 1...

Page 1435: ...L FOR ECM Measure the voltage between ECM connector and chassis ground while tumble generator valve is fully closed Connector terminal B135 No 9 Chassis ground Is the voltage more than 4 5 V Go to ste...

Page 1436: ...nnector and tumble generator valve position sensor connector Connector terminal B135 No 13 E50 No 3 Is the resistance less than 1 Go to step 8 Repair the har ness and connec tor NOTE In this case repa...

Page 1437: ...Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01320 E2 E50 F61 F74 B200 F2 B100 B83 TUMBLE GEN...

Page 1438: ...CODE DTC RHD model EN 01321 E2 E50 B21 B83 1 3 2 20 10 18 1 3 B135 ECM 9 19 13 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 E50 1 2 3 B21 1 2 5 6 7 8 13 14 15 16 9 1...

Page 1439: ...BETWEEN TUMBLE GENERATOR VALVE POSITION SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from throttle posi tion sensor 3 Measure the resistance of harness between...

Page 1440: ...Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01322 E2 E54 F61 F74 B200 F2 B100 B83 TUMBLE GEN...

Page 1441: ...CODE DTC RHD model EN 01591 E2 E54 B21 B83 TUMBLE GENERATOR VALVE POSITION SENSOR 1 3 2 20 9 18 1 3 B135 ECM 9 19 23 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 E54...

Page 1442: ...CHECK INPUT SIGNAL FOR ECM Measure the voltage between ECM connector and chassis ground while throttle valve is fully closed Connector terminal B135 No 9 Chassis ground Is the voltage more than 4 5 V...

Page 1443: ...and throttle position sensor connector Connector terminal B135 No 23 E54 No 3 Is the resistance less than 1 Go to step 8 Repair the har ness and connec tor NOTE In this case repair the following Open...

Page 1444: ...t Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM LHD model EN 01322 E2 E54 F61 F74 B200 F2 B100 B83 TUMBLE GE...

Page 1445: ...CODE DTC RHD model EN 01591 E2 E54 B21 B83 TUMBLE GENERATOR VALVE POSITION SENSOR 1 3 2 20 9 18 1 3 B135 ECM 9 19 23 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 E54...

Page 1446: ...TUMBLE GENERATOR VALVE POSITION SENSOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from throttle posi tion sensor 3 Measure the resistance of harness between tumble...

Page 1447: ...g List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC Go to step 2 2 CHECK TUMBLE GENERATOR VALVE RH 1 Remove the tumble generator valve assem bly 2 Check the t...

Page 1448: ...g List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC Go to step 2 2 CHECK TUMBLE GENERATOR VALVE RH 1 Remove the tumble generator valve assem bly 2 Check the t...

Page 1449: ...ulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01323 E55 F61 LHD F74 1 2 1 2 5 6 7 8 13...

Page 1450: ...5 No 2 B136 No 5 Is the resistance less than 1 Go to step 2 Repair the open circuit between ECM and tumble generator valve connector NOTE In this case repair the following Open circuit in harness betw...

Page 1451: ...aulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01323 E55 F61 LHD F74 1 2 1 2 5 6 7 8 1...

Page 1452: ...sconnect the connector from tumble gen erator valve connector 3 Measure the voltage between tumble gener ator valve actuator and chassis ground Connector terminal E55 No 1 Chassis ground E55 No 2 Chas...

Page 1453: ...lty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01324 E51 F61 LHD F74 1 2 1 2 5 6 7 8 13...

Page 1454: ...1 No 2 B136 No 11 Is the resistance less than 1 Go to step 2 Repair the open circuit between ECM and tumble generator valve connector NOTE In this case repair the following Open circuit in harness bet...

Page 1455: ...ulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01324 E51 F61 LHD F74 1 2 1 2 5 6 7 8 13...

Page 1456: ...CTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from tumble gen erator valve connector 3 Measure the voltage between tumble gener ator valve actuator and chassis ground Connector ter...

Page 1457: ...TC ON DISPLAY Does the Subaru Select Moni tor or OBD II general scan tool indicate DTC P1134 Replace the ECM Ref to FU H4DOTC 49 Engine Control Module ECM A temporary poor contact EN 01299 BATTERY MAI...

Page 1458: ...ar Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01299 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD RHD 8 9 4...

Page 1459: ...4 No 29 B18 No 3 B84 No 19 B18 No 4 Is the resistance less than 1 Go to step 2 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between ECM and front o...

Page 1460: ...ear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01299 BATTERY MAIN RELAY SBF 5 B47 1 2 3 5 4 6 E E B61 F44 2 LHD RHD LHD RHD B100 F2 F60 E3 12 3 RHD RHD 8 9 4...

Page 1461: ...3 Measure the voltage between ECM connec tor and chassis ground Connector terminal B84 No 19 Chassis ground Is the voltage more than 4 5 V Go to step 4 Go to step 5 4 CHECK OUTPUT SIGNAL FOR ECM Measu...

Page 1462: ...ne stalls Poor driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 4...

Page 1463: ...ting for all DTC P0301 P0302 P0303 and P0304 Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC Does failure for repair or replacement exist Repair or replace the failure then replace precata lyt...

Page 1464: ...replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01325 F61 LHD E2 B136 B...

Page 1465: ...rness between ECM and variable valve timing sole noid valve connec tor Poor contact in coupling connec tor 2 CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE Measure the resistance b...

Page 1466: ...replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01325 F61 LHD E2 B136 B...

Page 1467: ...lve connec tor Poor contact in coupling connec tor 2 CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variab...

Page 1468: ...eplacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01326 F61 LHD E2 B84 B13...

Page 1469: ...rness between ECM and variable valve timing sole noid valve connec tor Poor contact in coupling connec tor 2 CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE Measure the resistance b...

Page 1470: ...replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 01326 F61 LHD E2 B84 B1...

Page 1471: ...lve connec tor Poor contact in coupling connec tor 2 CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variab...

Page 1472: ...UTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 0...

Page 1473: ...ER DTC ON DISPLAY Is any other DTC displayed Inspect the rele vant DTC using List of Diagnostic Trouble Code DTC Ref to EN H4DOTC 75 List of Diagnostic Trouble Code DTC NOTE In this case it is not nec...

Page 1474: ...r repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection Mode WIRING DIAGRAM EN 00338 BATTE...

Page 1475: ...motor oper ate when ignition switch is turned to START Repair the har ness and connec tor NOTE In this case repair the following Open or ground short circuit in har ness between ECM and starter motor...

Page 1476: ...r driving performance CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspection...

Page 1477: ...ase it is not necessary to inspect DTC P1544 Go to step 2 2 CHECK EXHAUST SYSTEM Check the exhaust system parts NOTE Check the following items Loose installation of exhaust manifold Cracks or hole of...

Page 1478: ...7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31 13 14 15 16 17 27 28 18 22 23 24 25 26 BATTERY IGNITION SWITCH MAIN RELAY SBF 4 SBF 1 SBF 5 B72 TO FRONT OXYGEN A F SENSOR A2 E8 E9 A22 D17 D8 D18 A7 A15 C1 E2...

Page 1479: ...tor terminal B137 No 10 Chassis ground Is the resistance less than 10 Repair the ground short circuit in har ness between ECM connector and battery termi nal Go to step 3 B72 B84 3 4 1 2 1 2 7 8 9 5 6...

Page 1480: ...OUBLE CODE DTC 3 CHECK FUSE SBF 5 Is the fuse blown Replace the fuse Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between ECM and battery Poor cont...

Page 1481: ...driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspec...

Page 1482: ...SS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and TCM 3 Measure the resistance of harness between ECM and chassis ground Connector terminal B1...

Page 1483: ...driving cycles with fault CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN H4DOTC 40 Inspec...

Page 1484: ...ECM and TCM connector After repair replace the ECM Ref to FU H4DOTC 49 Engine Control Module ECM 2 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Measure the voltage...

Page 1485: ...with fault TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref...

Page 1486: ...ECM connector Replace the ECM Ref to FU H4DOTC 49 Engine Control Module ECM 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and TCM...

Page 1487: ...with fault TROUBLE SYMPTOM Excessive shift shock CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN H4DOTC 48 OP ERATION Clear Memory Mode and Inspection Mode Ref...

Page 1488: ...ECM connector Replace the ECM Ref to FU H4DOTC 49 Engine Control Module ECM 4 CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connectors from ECM and TCM...

Page 1489: ...3 10 Camshaft position sensor 3 11 Oxygen sensor 12 Fuel pump and fuel pump relay 3 Engine does not return to idle 1 Idle air control solenoid valve 2 Engine coolant temperature sensor 3 Accelerator c...

Page 1490: ...r 3 Engine coolant temperature sensor 2 4 Crankshaft position sensor 3 5 Camshaft position sensor 3 6 Fuel injection parts 4 7 Throttle position sensor 8 Fuel pump and fuel pump relay 7 Spark knock 1...

Page 1491: ...d ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement o...

Page 1492: ......

Page 1493: ...e 1 General Description 2 2 Select Lever 9 3 Select Cable 13 4 AT Steering Shift Switch 16 5 MT Gear Shift Lever 18 6 Reverse Check Cable 31 7 MT Drive Select Lever 36 8 Drive Select Cable 38 9 Genera...

Page 1494: ...CS 2 CONTROL SYSTEMS GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Item Specification Swing torque of rod against lever N kgf lb 3 7 0 38 0 84 or less...

Page 1495: ...13 Indicator cover 23 Cover 4 Select lever ASSY 14 Blind 5 Spring pin 15 Cushion plate Tightening torque N m kgf m ft lb 6 Arm ASSY 16 Guide plate T1 7 5 0 76 5 5 7 Bushing 17 Snap pin T2 13 1 3 9 4...

Page 1496: ...5 Bulb 17 Spring 29 Nut A 6 Guide plate 18 Rod 7 Lever 19 Clip Tightening torque N m kgf m ft lb 8 Spacer 20 Base plate T1 2 0 0 2 1 4 9 Bracket guide 21 Arm T2 7 5 0 76 5 5 10 Spring pin 22 Bushing...

Page 1497: ...Plate ASSY 12 Spring pin 21 Front cover 4 Lever 13 Cushion rubber 5 Bushing 14 Bushing B Tightening torque N m kgf m ft lb 6 Bushing 15 Joint T1 7 5 0 76 5 5 7 Lock wire 16 Rod T2 12 1 2 8 7 8 Boot 1...

Page 1498: ...Spring 20 Bush 7 Holder 21 Reverse check cable Tightening torque N m kgf m ft lb 8 Seat cushion 22 Washer T1 1 3 0 13 0 96 9 Lever 23 Snap pin T2 7 5 0 76 5 5 10 Bush 24 Bracket T3 11 8 1 2 8 7 11 Spa...

Page 1499: ...IPTION 4 DRIVE SELECT LEVER 1 Knob 6 Spring Tightening torque N m kgf m ft lb 2 Cushion 7 Lever ASSY T1 1 6 0 16 1 2 3 Plate ASSY 8 Clip T2 18 1 8 13 0 4 Bushing 9 Clevis pin 5 Cable 10 Snap pin CS 00...

Page 1500: ...RU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Plac...

Page 1501: ...s then remove the four bolts to take out the select lever assembly from the body B INSTALLATION 1 Mount the select lever onto the vehicle body 2 Tighten the four bolts to install the select lever to t...

Page 1502: ...to 4AT 49 AD JUSTMENT Inhibitor Switch 1 The engine starts operating when select le ver is in range P and N but not in other posi tions 2 The back up light is lit when the select lever is in range R b...

Page 1503: ...eak the bulb during removal 4 Remove the blind 5 Remove the clips and then remove the guide plate 6 Remove the screw 7 Remove the bushing 8 Remove the clip and then remove the rod and the spring 9 Rem...

Page 1504: ...Gener al Description 3 Assembly is in the reverse order of disassembly 4 After completion of fitting transfer the select le ver to range P 1 then check whether the in dicator and select lever agree w...

Page 1505: ...to EX H4SOw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SOw oOBD 11 RE MOVAL Muffler 6 Remove the center and rear exhaust pipes and muffler DOHC turbo model Ref to EX H4DOTC 9 REMOVAL Center Ex...

Page 1506: ...d Ref to EX H4SO 12 INSTALLATION Muffler SOHC without OBD model Ref to EX H4SOw oOBD 7 INSTALLATION Front Exhaust Pipe Ref to EX H4SOw oOBD 9 INSTALLATION Center Exhaust Pipe Ref to EX H4SOw oOBD 10 I...

Page 1507: ...t shield cover If equipped 4 Loosen the adjusting nut on each side 5 Turn the adjusting nut B until it lightly touches the connector 6 While preventing the adjusting nut B from mov ing with a wrench t...

Page 1508: ...the airbag module should be repaired by referring to Airbag Sys tem Ref to AB 12 REMOVAL Driver s Air bag Module 4 Remove the RH and LH screws retaining the AT steering shift switch 5 Remove the AT st...

Page 1509: ...DOWN SWITCH 1 Press DOWNSHIFT of shift switch 2 Measure the resistance between terminals of shift switch connector B236 Connector terminal B236 No 3 No 5 Is the resistance less than 10 Go to step 3 Re...

Page 1510: ...t pipe and muffler SOHC model Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 12 REMOVAL Muffler SOHC without OBD model Ref to EX H4SOw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX H...

Page 1511: ...Rear Ex haust Pipe Ref to EX H4DOTC 15 REMOV AL Muffler 9 Remove the crossmember Ref to 6MT 35 REMOVAL Transmission Mounting System 10 Remove the snap pin and washer and then re move the reverse check...

Page 1512: ...y put them onto transmission mount 3 Lift up the vehicle 4 Mount the cushion rubber on body Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 5 Connect the rod to the joint Tightening torque 18 N m 1 8 kg...

Page 1513: ...Ref to CS 38 INSTALLATION Drive Select Cable 11 Install console box Ref to EI 42 INSTALLA TION Console Box 2 6MT 1 Insert the gear shift lever from room side NOTE After inserting the rod and stay temp...

Page 1514: ...ithout any twist Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb 9 Install the console box Ref to EI 42 INSTAL LATION Console Box 10 Check that the gear shift is correctly shifted to each gear C DISASS...

Page 1515: ...ring pin and then remove the bushing A from gear shift lever 2 6MT 1 Remove the spring pin from slider 2 Remove the slider and spring 3 Cut the band clip A Bushing B Stay C Cushion rubber A O ring B O...

Page 1516: ...6 Remove the holder and spring seat 7 Disassemble the lock wire NOTE Do not reuse the lock wire 8 Remove the boss from rod 9 Remove the rod from lever 10 Separate the rod and inner boot A Cable plate...

Page 1517: ...from gear shift le ver 14 Remove the spring pin and then remove the bush and snap ring 15 Remove the bush and spacer from boss 16 Remove the bush and cushion rubber from stay A Snap ring A O ring B Bu...

Page 1518: ...installing the spacer 4 Insert the gear shift lever into the boot hole 5 Install the snap ring and stay to bushing B 6 Tighten with lock wire to the extent that the boot will not come off NOTE Always...

Page 1519: ...he bush and cushion rubber on the stay 2 Install the bush and spacer to boss 3 Install the snap ring to gear shift lever and then install the bush NOTE Apply grease to the bush 4 Apply grease to the b...

Page 1520: ...8 7 ft lb 9 Install the boss to rod Tightening torque 11 8 N m 1 2 kgf m 8 7 ft lb 10 Install a new lock wire NOTE Install the lock wire to the stay groove Bend the extra wire to same direction of lo...

Page 1521: ...Install the seat cushion and spring 15 Adjust the length between end of cable plate and reverse check cable to 84 mm 3 31 in and then tighten the lock nut Tightening torque 6 N m 0 6 kgf m 4 4 ft lb 1...

Page 1522: ...elation of the gear shift lever If the torque exceeds the specification replace the bushing or retighten the nuts Swing torque 3 7 N 0 38 kgf 0 84 lb or less 2 6MT 1 Check each part bushing cushion ru...

Page 1523: ...ck cable from gear shift lever 7 Lift up the vehicle 8 Remove the under cover 9 Remove the rear exhaust pipe and muffler Ref to EX H4DOTC 14 REMOVAL Rear Ex haust Pipe Ref to EX H4DOTC 15 REMOV AL Muf...

Page 1524: ...e lock nut then remove the reverse check cable from cable plate B INSTALLATION 1 Adjust the length between end of cable plate and reverse check cable to 84 mm 3 31 in and then tighten the lock nut Tig...

Page 1525: ...Install the reverse check cable end washer and snap pin to reverse check lever NOTE Take care to install the snap pin in proper direction 9 Fix the reverse check cable to clip of stay NOTE Install th...

Page 1526: ...TC 14 REMOVAL Rear Ex haust Pipe Ref to EX H4DOTC 15 REMOV AL Muffler 4 Remove the crossmember Ref to 6MT 35 REMOVAL Transmission Mounting System 5 Remove the snap pin and washer and then sep arate th...

Page 1527: ...TALLATION Rear Ex haust Pipe Ref to EX H4DOTC 15 INSTAL LATION Muffler 11 Install the reverse check cable end washer and snap pin to reverse check lever NOTE Take care to install the snap pin in prope...

Page 1528: ...he cable from lever assembly B INSTALLATION 1 Attach the drive select cable to the lever assem bly and secure with the clamp 2 Install the drive select lever Tightening torque 18 N m 1 8 kgf m 13 0 ft...

Page 1529: ...bushing D ASSEMBLY 1 Assemble in the reverse order of disassembly Tightening torque 1 6 N m 0 16 kgf m 1 2 ft lb 2 Make sure the select lever moves smoothly E INSPECTION 1 Make sure the select lever...

Page 1530: ...re to move the transmission to HI or LO position by moving the drive select lever If it doesn t adjust the cable Ref to CS 38 ADJUST MENT Drive Select Cable 2 Make sure the cable operates smoothly If...

Page 1531: ...k up light does not light up Adjust select cable and inhibitor switch or inspect circuit 2 MT gear shift lever 6MT Shift into reverse is impossible Adjust reverse check cable Shift into reverse is pos...

Page 1532: ...CS 40 CONTROL SYSTEMS GENERAL DIAGNOSTIC TABLE...

Page 1533: ...17 Shift Solenoids Duty Solenoids and ATF Temperature Sensor 64 18 Transfer Duty Solenoid and Valve Body 66 19 ATF Filter 69 20 Transmission Control Module TCM 70 21 ATF Cooler Pipe and Hose 71 22 Ai...

Page 1534: ...ent pump Driving method Driven by engine Number of teeth Inner rotor 9 Outer rotor 10 Type 4 forward 1 reverse double row planetary gears Multi plate clutch 3 sets Multi plate brake 2 sets One way clu...

Page 1535: ...of vehicle speed and accel erator throttle opening Fluid Dexron III type Fluid capac ity 1 6 L FWD model 8 0 8 3 2 8 5 8 8 US qt 7 0 7 3 Imp qt 1 6 L AWD and 2 0 L Non turbo model 8 4 8 7 2 8 9 9 2 U...

Page 1536: ...ratio 4 111 37 9 4 444 40 9 Lubrication oil 1 Item 3 API classification 2 Front differential gear oil 4 SAE viscosity No and appli cable temperature Front differential oil capacity 1 1 1 3 2 1 2 1 4...

Page 1537: ...del 2 O ring 9 Input shaft 16 Torque converter clutch case 3 Differential oil level gauge 10 O ring 4 Stay 11 Torque converter clutch ASSY Tightening torque N m kgf m ft lb 5 Seal pipe 12 Drain plug T...

Page 1538: ...7 0 7 5 1 3 Seal ring 14 Stud bolt T2 13 1 3 9 4 4 Thrust needle bearing 15 O ring T3 18 1 8 13 0 5 Drive pinion shaft 16 O ring T4 25 2 5 18 1 6 Roller bearing 17 Oil seal retainer T5 40 4 1 30 7 Shi...

Page 1539: ...AL DESCRIPTION 3 TRANSMISSION CASE AND CONTROL DEVICE AT 00854 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 23 25 26 27 28 29 30 32 34 33 31 36 37 35 39 40 42 41 38 43 T4 T9 T5 T1 T10 T...

Page 1540: ...d 26 Stud bolt Long Tightening torque N m kgf m ft lb 8 Straight pin 27 Parking rod T1 3 5 0 36 2 6 9 Return spring 28 Manual plate T2 5 0 5 3 6 10 Shaft 29 Spring pin T3 6 0 6 4 11 Parking pawl 30 De...

Page 1541: ...erter turbine speed sensor 16 Separate plate 28 SPORT shift solenoid if equipped 17 Fluid filter 6 O ring 18 Fluid filter 7 Front vehicle speed sensor 19 Lower valve body Tightening torque N m kgf m f...

Page 1542: ...ng retainer 15 Dish plate 2 Lip seal 9 Cover 16 Driven plate 3 D ring 10 Snap ring 17 Drive plate 4 Reverse clutch piston 11 Driven plate 18 Retaining plate 5 D ring 12 Drive plate 19 Snap ring 6 D ri...

Page 1543: ...ternal gear 21 2 4 brake piston 4 Snap ring 13 Washer 22 D ring 5 Front planetary carrier 14 Snap ring 23 D ring 6 Thrust needle bearing 15 Retaining plate 24 2 4 brake piston retainer 7 Rear sun gear...

Page 1544: ...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 and reverse bra...

Page 1545: ...ap ring 11 Reduction drive shaft 2 Ball bearing 7 Ball bearing 12 Ball bearing 3 Reduction drive gear 8 Reduction driven gear 4 Reduction drive shaft 9 Washer Tightening torque N m kgf m ft lb 5 Drive...

Page 1546: ...Pinion gear 17 Revolution gear 29 Lock nut 6 Carrier 18 Driven plate Thick 30 Gasket 7 Planetary pinion shaft 19 Driven plate 31 Extension case 8 Snap ring 20 Driven plate Thin 9 Seal ring 21 Driven...

Page 1547: ...ferential side retainer 3 Differential case RH 10 Circlip Tightening torque N m kgf m ft lb 4 Straight pin 11 Lock plate T1 25 2 5 18 1 5 Differential case LH 12 Axle shaft T2 62 6 3 45 6 6 Taper roll...

Page 1548: ...p ring 12 Rear drive shaft 21 Test plug 4 Pressure plate 13 Ball bearing 22 O ring 5 Drive plate 14 Seal ring 23 Clip 6 Driven plate 15 Gasket 7 Retaining plate 16 Transfer clutch pipe Tightening torq...

Page 1549: ...0 Rear wheel sensor 3 Driven plate Thin 12 Gasket 4 Driven plate Thick 13 Multi plate clutch LSD pipe Tightening torque N m kgf m ft lb 5 Retaining plate 14 Extension case T1 7 0 7 5 1 6 Snap ring 15...

Page 1550: ...g stopper 4 Rear cushion rubber AWD model Tightening torque N m kgf m ft lb 2 Rear bracket FWD model 5 Crossmember T1 35 3 6 26 3 Rear cushion rubber FWD model 6 Stopper T2 39 4 0 29 T3 50 5 1 37 T4 5...

Page 1551: ...e careful not to burn your hands because each part on the vehicle is hot after running Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grad...

Page 1552: ...OIL PRESSURE GAUGE ASSY Used for measuring oil pressure 498897200 ADAPTER Used oil pump housing when measuring reverse clutch pressure and line pressure 498897700 ADAPTER SET Used for measuring trans...

Page 1553: ...2 ENGINE SUPPORT 41099AA020 398527700 PULLER ASSY Used for removing extension case roller bear ing Used for removing extension oil seal Used for removing front differential side retainer bearing outer...

Page 1554: ...installing transfer outer snap ring Used with GUIDE 499257300 499257300 SNAP RING OUTER GUIDE Used for installing transfer outer snap ring Used with INSTALLER 499247400 499787000 WRENCH ASSY Used for...

Page 1555: ...398487700 INSTALLER Used for installing taper roller bearing of front dif ferential 398673600 COMPRESSOR Used for removing and installing clutch spring 498255400 PLATE Used for measuring backlash of...

Page 1556: ...001 MAGNET BASE Used for measuring gear backlash Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring gear backlash Used with MAGNET BASE 498247001 498517000 REPLACER Used for removi...

Page 1557: ...pis ton 499267300 STOPPER PIN Used for installing inhibitor switch 499787700 WRENCH Used for removing and installing drive pinion lock nut 499787500 ADAPTER Used for removing and installing drive pini...

Page 1558: ...utch piston retainer spring when installing snap ring 499577000 GAUGE Used for measuring the transmission case mating surface to the reduction gear end sur face For MPT model 398744300 GAUGE Use for m...

Page 1559: ...gear assem bly 499737100 PULLER SET Used for removing reduction drive gear assem bly 498077600 REMOVER Used for removing ball bearing 498937110 HOLDER Used for removing and installing drive pinion loc...

Page 1560: ...00 HIGH CLUTCH PIS TON GUIDE Used for installing high clutch piston 498437100 LOW CLUTCH PIS TON GUIDE Used for installing low clutch piston 899580100 INSTALLER Used for press fitting the ball bearing...

Page 1561: ...398497701 SEAT Used for installing needle bearing 899524100 PULLER SET Using the bolt only 1 Bolt Used with PULLER SET 499737100 Used with PULLER 499737000 1 Puller 2 Cap 24082AA210 Newly adapted tool...

Page 1562: ...mission end play Thickness gauge Used for measuring clearances of clutch brake and oil pump Micro meter Used for measuring thickness of drive pinion Spring balance Used for measuring starting torque o...

Page 1563: ...on of ATF to the up per limit mark when the transmission is cold will result in overfilling of ATF causing a trans mission failure 6 Check ATF level after raising ATF temperature to 70 80 C 158 176 F...

Page 1564: ...gear oil completely CAUTION Directly after the engine has been running the differential gear oil is hot Be careful not to burn yourself Be careful not to spill the differential gear oil on exhaust pip...

Page 1565: ...to 50 km h 25 to 31 MPH Check the 1st gear engine brake when shifting between 2 1 range while driving in the 2 range 2nd gear 20 to 30 km h 12 to 19 MPH 6 LOCK UP FUNCTION Check that engine speed doe...

Page 1566: ...throttle 10 When the engine speed is stabilized record that speed quickly and release the accelerator ped al 11 Shift the select lever to N range and cool down the engine by idling it for more than on...

Page 1567: ...t fully open Erroneous engine operation Torque converter clutch s one way clutch slipping Greater than specifications D Line pressure too low Low clutch slipping One way clutch malfunction R Line pres...

Page 1568: ...interval between tests Make three measurements and take the average value 1 Fully apply the parking brake 2 Start the engine Check the idling speed A C OFF 3 Shift the select lever from N to D range U...

Page 1569: ...3 Measure the line pressure within 5 seconds after shifting the select lever to each position If line pressure needs to be measured again allow the engine to idle and then stop it to cool down for at...

Page 1570: ...If oil pressure is produced in the FWD mode the problem is similar to that in the AWD mode NOTE Before setting in FWD mode install the spare fuse on FWD mode switch VTD MODEL Check transfer clutch pr...

Page 1571: ...aner case stay Non turbo model 8 Disconnect the following connectors 1 Transmission harness connector 2 Transmission ground terminal 9 Remove the starter 2 0 L Non turbo and 2 5 L models Ref to SC H4S...

Page 1572: ...st Pipe and Ref to EX H4SO 12 RE MOVAL Muffler 19 Remove the center and rear exhaust pipes and muffler Turbo model Ref to EX H4DOTC 9 REMOVAL Center Ex haust Pipe Ref to EX H4DOTC 14 REMOV AL Rear Exh...

Page 1573: ...s which hold the lower side of transmission to engine 29 Place the transmission jack under transmis sion NOTE Make sure that the support plates of transmission jack don t touch the oil pan 30 Remove t...

Page 1574: ...6 ft lb T2 70 N m 7 1 kgf m 51 ft lb 5 Take off the transmission jack 6 Tighten the nuts and bolts which hold the lower side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 ft lb 7 L...

Page 1575: ...m 43 ft lb 12 Lift up the vehicle 13 Install the front drive shafts into transmission 1 Lift up the vehicle 2 Install the front drive shaft into transmission 3 Drive a new drive spring pin into chamfe...

Page 1576: ...to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe 25 Install the under cover 26 Lower the vehicle 27 Install the ATF level gauge 28 Connect the following connectors 1 Transmission harness connectors 2...

Page 1577: ...VAL Rear Exhaust Pipe and Ref to EX H4SO 12 RE MOVAL Muffler 4 Remove the center and rear exhaust pipes and muffler Turbo model Ref to EX H4DOTC 9 REMOVAL Center Ex haust Pipe Ref to EX H4DOTC 14 REMO...

Page 1578: ...ION Rear Exhaust Pipe and Ref to EX H4SOw oOBD 11 INSTALLATION Muffler 6 Install center and rear exhaust pipes and muf fler Turbo model Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe Ref to EX H...

Page 1579: ...haust Pipe and Ref to EX H4DOTC 15 RE MOVAL Muffler 4 Remove the heat shield cover If equipped 5 Remove the propeller shaft Ref to DS 15 RE MOVAL Propeller Shaft 6 Using the ST remove the oil seal ST...

Page 1580: ...de 3 Check if there is continuity at equal points when the select lever is turned 1 5 in both directions from N range If there is continuity in one direction and the conti nuity in the other or if the...

Page 1581: ...the air cleaner case Non turbo model Ref to IN H4SO 5 REMOVAL Air Cleaner Case 4 Remove the intercooler Turbo model Ref to IN H4DOTC 10 REMOVAL Intercool er 5 Disconnect the inhibitor switch connector...

Page 1582: ...eutral position 4 Using the ST tighten the bolts of inhibitor switch ST 499267300 STOPPER PIN Tightening torque 3 5 N m 0 36 kgf m 2 6 ft lb 5 Install the select cable to range select lever 6 Install...

Page 1583: ...odel Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe 10 Lower the vehicle 11 Install the inhibitor switch connector from stay 12 Connect the inhibitor switch connector 13 Install the air cleaner...

Page 1584: ...move the front center exhaust pipes and muffler Non turbo model Ref to EX H4SOw oOBD 6 REMOVAL Front Exhaust Pipe Ref to EX H4SOw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SOw oOBD 11 REMOVAL...

Page 1585: ...n 21 Remove the duty solenoid connectors and ATF temperature sensor Remove the connectors from clip and disconnect the connectors 22 Remove the harness assembly B INSTALLATION 1 Pass the harness assem...

Page 1586: ...lso the torque converter turbine speed sen sor and then fasten the harness Tightening torque 7 N m 0 7 kgf m 5 1 ft lb 7 Install the oil cooler pipes NOTE Be sure to use a new copper washer Tightening...

Page 1587: ...d Ref to EX H4SO 12 INSTALLATION Muffler 12 Install the center rear exhaust pipes and muf fler Turbo model Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe Ref to EX H4DOTC 14 IN STALLATION Rear E...

Page 1588: ...EMOVAL When removing the rear vehicle speed sensor re fer to Front Vehicle Speed Sensor Ref to 4AT 52 REMOVAL Front Vehicle Speed Sensor B INSTALLATION When installing the rear vehicle speed sensor re...

Page 1589: ...REMOVAL When removing the torque converter turbine speed sensor refer to Front Vehicle Speed Sensor Ref to 4AT 52 REMOVAL Front Vehicle Speed Sensor B INSTALLATION When installing the torque converter...

Page 1590: ...ect each solenoid connector and re move ATF temperature sensor from control valve 9 Remove the control valve NOTE When removing the control valve body be careful not to interfere with transfer duty so...

Page 1591: ...Apply proper amount of liquid gasket to the en tire oil pan mating surface Liquid gasket THREE BOND 1217B Part No K0877YA020 Bolt length mm in A 30 1 18 B 55 2 17 A Lock up duty solenoid Blue B Low c...

Page 1592: ...ngth are different 2 Remove the duty solenoids solenoids and sen sor from the lower valve body NOTE Arrange the removed bolts in good order to assem ble in the same place as disassembly because the bo...

Page 1593: ...alve body 10 Place a shop cloth to the piston removal hole 11 Using an air compressor apply air slowly to each piston hole and remove the pistons 12 Remove the seal ring from piston D ASSEMBLY 1 Insta...

Page 1594: ...er positions to middle valve body 7 Install three filters to lower valve body NOTE Pay attention to the location of filters 8 Install lower separate plate to lower valve body 9 Temporarily assemble va...

Page 1595: ...e that each component is free of harmful gouges cuts or dust Bolt length mm in A 40 1 57 B 62 2 44 C 73 2 87 D 79 3 11 A Lock up duty solenoid Blue B Low clutch timing solenoid Gray C Line pressure du...

Page 1596: ...specified position A Oil pan B Drain plug A Lock up duty solenoid Blue B Low clutch timing solenoid Gray C Line pressure duty solenoid Red D Shift solenoid 2 Yellow E Shift solenoid 1 Green F 2 4 brak...

Page 1597: ...b 7 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Ref to 4AT 31 Automatic Transmission Fluid 8 Check the ATF level Ref to 4AT 31 Automat ic Transmission Fluid 2 ATF...

Page 1598: ...bo model Ref to EX H4DOTC 9 REMOVAL Center Ex haust Pipe 8 Remove the rear exhaust pipe and muffler Non turbo model Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 12 REMOVAL Muffler Tu...

Page 1599: ...nstall the transfer duty solenoid and trans fer valve body Tightening torque T 8 N m 0 8 kgf m 5 8 ft lb 2 Connect the transfer duty solenoid connec tor 2 Install a new gasket and the extension case t...

Page 1600: ...pipes and muf fler Turbo model Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe Ref to EX H4DOTC 14 IN STALLATION Rear Exhaust Pipe and Ref to EX H4DOTC 15 INSTALLATION Muffler 8 Connect the trans...

Page 1601: ...ng the following formula T2 L2 L1 L2 T1 T1 14 N m 1 4 kgf m 10 1 ft lb Required torque setting T2 Tightening torque L1 ST length 0 078 m 3 07 in L2 Torque wrench length Example NOTE Align ST with torq...

Page 1602: ...e TCM B INSTALLATION 1 Install the TCM LHD model Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb RHD model Tightening torque 18 N m 1 8 kgf m 13 ft lb 2 Connect the connectors to TCM 3 Install in the r...

Page 1603: ...e to protect it Turn it with pli ers and then pull directly out with your hand 6 Disconnect ATF cooler hoses from pipes NOTE Do not remove with a screwdriver or other point ed tools When the hose is d...

Page 1604: ...o the specified po sition 5 Install the under cover 6 Install battery and washer tank 7 Fill ATF Ref to 4AT 31 Automatic Transmis sion Fluid NOTE Make sure there are no ATF leaks in joints between the...

Page 1605: ...ODEL 2 Install the air cleaner case 2 0 L Non turbo and 2 5 L models Ref to IN H4SO 5 INSTALLATION Air Cleaner Case 3 Install intercooler Turbo model Ref to IN H4DOTC 11 INSTALLATION Inter cooler C IN...

Page 1606: ...ing from the flange face B INSTALLATION 1 Install the oil charger pipe with new O ring Tightening torque 41 N m 4 2 kgf m 30 4 ft lb 2 Install the air cleaner case 2 0 L Non turbo and 2 5 L models Ref...

Page 1607: ...y in its groove 3 Insert the input shaft while turning lightly by hand Normal protrusion A 50 55 mm 1 97 2 17 in 4 Holding the torque converter clutch assembly by hand carefully install it to the torq...

Page 1608: ...n equation T A B 0 40 mm 0 015 in T Shim clearance A Distance from end of extension case to end of rear drive shaft B Height from end of transmission case to end of reduction drive gear 4 Attach the s...

Page 1609: ...ear with vaseline NOTE Install thrust needle bearing in the correct direction 2 Install new gasket 3 Install the extension case to the transmission case 4 Tighten bolts to secure the case Tightening t...

Page 1610: ...not to damage the oil seal in the exten sion 2 Remove the transmission clutch pipe without bending pipe 2 VTD MODEL 1 Remove snap ring using ST1 ST2 ST3 and a press ST1 398673600 COMPRESSOR ST2 498627...

Page 1611: ...pe 4 Install the transfer clutch assembly to the case NOTE Be careful not to damage the seal rings Insert the clutch assembly fully into position until the bearing shoulder bottoms 2 VTD MODEL 1 Press...

Page 1612: ...ST3 398663600 PLIERS E INSPECTION Use forced air to make sure the transfer pipe and extension case routes are not clogged and do not leak Measure the extension end play and adjust it to within specifi...

Page 1613: ...ENT Transfer Clutch 2 Install the transfer clutch assembly to the case 3 Tighten bolts to secure the case Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 4 Install the transmission assembly to vehicle R...

Page 1614: ...the piston D ASSEMBLY 1 Install the transfer clutch piston 2 Install return spring to transfer piston 3 Install transfer clutch piston seal 4 Install ST to rear drive shaft ST 499257300 SNAP RING OUTE...

Page 1615: ...led parts move smoothly 9 Check clearance between snap ring and pres sure plate Ref to 4AT 84 INSPECTION Trans fer Clutch 10 Press fit a new ball bearing with ST ST 899580100 INSTALLER 11 Coat a new s...

Page 1616: ...lue 0 7 1 1 mm 0 028 0 043 in Allowable limit 1 6 mm 0 063 in 4 Check if the tight corner braking does not occur when the vehicle is started with steering wheel held at fully turned position If tight...

Page 1617: ...77000 GUAGE When not using ST apply T A 0 45 mm B H T A 0 0177 in B H T Thrust needle bearing thickness A Distance from end of extension case to end of reduction drive shaft B Distance from end of tra...

Page 1618: ...culation for 0 05 mm 0 0020 in of clearance T 90 50 90 35 0 4 0 55 T 3 5630 3 5571 0 0157 0 0216 Calculation when clearance is 0 25 mm 0 0098 in T 90 50 90 35 0 2 0 35 T 3 5630 3 5571 0 0079 0 0138 Ca...

Page 1619: ...sion case joining edge to center differential clutch drum edge ST 398744300 GAUGE 4 Calculation formula T A B 0 45 mm T A B 0 0177 in NOTE Calculation formula for T is applied when mea suring using ST...

Page 1620: ...4AT 85 VTD MODEL ADJUSTMENT Transfer Clutch 2 Install drive plate and driven plate 3 Insert rear driveshaft into the center differential assembly 4 Join transmission case and extension case In stall...

Page 1621: ...s Make sure the clutch hub is oriented in the cor rect direction E INSPECTION Inspect parts to make sure there are no holes cuts and that they are not dusty Inspect extension end play and adjust it to...

Page 1622: ...mission assembly from the ve hicle Ref to 4AT 39 REMOVAL Automatic Transmission Assembly 2 Remove rear vehicle speed sensor and sepa rate the transmission case and extension case Ref to 4AT 77 REMOVAL...

Page 1623: ...3 Using a plastic hammer install the center differ ential assembly 4 Install a new self lock nut and a washer Tightening torque 100 N m 10 2 kgf m 73 8 ft lb 5 After tightening stake the lock nut secu...

Page 1624: ...nstall snap ring to reduction driven gear 2 Using a press install a new ball bearing to re duction driven gear 3 Install snap ring to reduction driven gear E INSPECTION Check ball bearing and gear for...

Page 1625: ...nsert it fully into position until the bearing shoulder bottoms 2 Install the reduction driven gear Ref to 4AT 91 INSTALLATION Reduction Driven Gear 3 Combine the transmission case with the exten sion...

Page 1626: ...ly vaseline to outer surface of seal ring and shaft groove 4 Attach new seal rings E INSPECTION Rotate bearing by hand make sure it rotates smoothly Make sure that each component is free of harm ful g...

Page 1627: ...STALLATION 1 Install the center differential assembly with the shim s NOTE Insert the center differential assembly and shim s completely into the bearing shoulder bottom 2 Insert the rear driveshaft R...

Page 1628: ...n gears and washers 4 Insert the shaft into the center differential as sembly 5 Install the snap ring 6 Using a press install a new ball bearing into the center differential assembly ST 498077000 REMO...

Page 1629: ...e parking pawl return spring and shaft B INSTALLATION 1 Install the parking pawl shaft and return spring 2 Install the reduction drive gear Ref to 4AT 93 INSTALLATION Reduction Drive Gear 3 Install th...

Page 1630: ...ic hammer separate the transmission case and torque converter clutch case NOTE Be careful not to damage the oil seal and bush ing inside the torque converter clutch case by the oil pump cover Be caref...

Page 1631: ...Ref to 4AT 73 IN STALLATION Air Breather Hose 11 Install the oil cooler pipes Ref to 4AT 72 IN STALLATION ATF Cooler Pipe and Hose 12 Install the oil charger pipe with O ring Ref to 4AT 74 INSTALLATIO...

Page 1632: ...ase sections Ref to 4AT 98 RE MOVAL Torque Converter Clutch Case 9 Separate transmission case and extension case sections Ref to 4AT 77 REMOVAL Extension Case 10 Remove the reduction drive gear MPT mo...

Page 1633: ...tension case with the transmis sion case and install vehicle speed sensor 1 rear Ref to 4AT 77 INSTALLATION Extension Case 7 Insert inhibitor switch and transmission connec tor into stay 8 Install the...

Page 1634: ...the inner and outer rotor 2 OIL SEAL RETAINER 1 Remove the oil seal retainer 2 Remove the O ring 3 Remove the oil seal from oil seal retainer A Seal rings A Oil pump cover B Oil pump housing A Inner...

Page 1635: ...or smooth rotation of the rotor 4 Install the oil seal retainer and new seal rings After adjusting the drive pinion backlash and tooth contact Ref to 4AT 105 ADJUSTMENT Oil Pump Housing 2 OIL SEAL RET...

Page 1636: ...oil pump housing to rotor clearances Side clearance 0 02 0 04 mm 0 0008 0 0016 in 3 If depth and or side clearances are outside specifications replace rotor assembly Non turbo model Turbo model Measur...

Page 1637: ...lutch Attach the thrust needle bearing to the oil pump cover with vaseline 5 After correctly installing the new gasket to the case mating surface carefully install the oil pump housing assembly Be car...

Page 1638: ...REMOVAL Reduction Drive Gear 12 Remove the center differential carrier VTD model Ref to 4AT 95 REMOVAL Center Differ ential Carrier 13 Remove the reduction driven gear Ref to 4AT 90 REMOVAL Reduction...

Page 1639: ...ll the transmission assembly to vehicle Ref to 4AT 42 INSTALLATION Automatic Transmission Assembly C DISASSEMBLY 1 Straighten the staked portion of the lock nut and remove the lock nut while locking t...

Page 1640: ...length 0 072 m 2 83 in L2 Torque wrench length Example ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE Install ST2 to torque wrench as straight as possi ble 6 Measure the startin...

Page 1641: ...ust the backlash between drive pinion and crown gear Ref to 4AT 116 ADJUSTMENT Front Differential 5 Apply red lead evenly to the surfaces of three or four teeth of the crown gear Rotate the drive pini...

Page 1642: ...n Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear Toe contact Inside end contact Checking item Contact areas is small Contact pattern Correcti...

Page 1643: ...er to move drive pin ion close to crown gear 6 If tooth contact is correct mark the retainer posi tion and loosen it After fitting a new O ring and oil seal screw in the retainer to the marked positio...

Page 1644: ...onverter Clutch Case 9 Remove the seal pipe 10 Remove the differential side retainer with ST NOTE Hold the differential case assembly by hand to avoid damaging retainer mounting hole of the torque con...

Page 1645: ...y hand and verify the protrusion amount Normal protrusion A 50 55 mm 1 97 2 17 in 12 Install the torque converter clutch assembly Ref to 4AT 75 INSTALLATION Torque Convert er Clutch Assembly 13 Instal...

Page 1646: ...ooth contact remove and install the oil seal and O ring 1 Remove O ring 2 Remove oil seal 3 Take out either split pin remove claw ST 398527700 PULLER ASSY 4 Securely attach two claws to outer race set...

Page 1647: ...ar and secure by tightening the bolt Standard tightening torque 62 N m 6 3 kgf m 45 6 ft lb 5 Measurement of backlash Selection of washer 1 Measure the gear backlash with ST1 and ST2 and insert ST2 th...

Page 1648: ...etainer until light contact is felt NOTE Screw in the RH side slightly deeper than the LH side ST 499787000 WRENCH ASSY 2 Remove the oil pump housing 3 Thoroughly remove the liquid gasket from the cas...

Page 1649: ...retainer 1 3 4 notches further This sets the preload Finally secure the retainer with its lock plate NOTE Turning the retainer by one tooth changes the backlash about 0 05 mm 0 0020 in 8 Turn the dri...

Page 1650: ...oler inlet and outlet pipes Ref to 4AT 71 REMOVAL ATF Cooler Pipe and Hose 9 Separation of torque converter clutch case and transmission case Ref to 4AT 98 REMOVAL Torque Converter Clutch Case 10 Remo...

Page 1651: ...e bearing planetary gear assembly and the low clutch assembly 18 Remove 2 4 brake seal 19 Remove snap ring 20 Take out 2 4 brake return spring 21 Remove the 2 4 brake piston and piston retain er witho...

Page 1652: ...te and dish plate 25 Turn the transmission case upside down and then take out the socket bolts while holding the one way clutch inner race with hand 26 Take out the spring retainer 27 Take out the ret...

Page 1653: ...head bolts evenly from the rear side of the transmission case Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 6 Place the front side of transmission body up 7 Install thrust needle bearing 8 Installati...

Page 1654: ...d 2 4 brake re tainer by aligning hole of 2 4 brake retainer and hole of transmission case 13 Install 2 4 brake piston return spring to trans mission case 14 Position snap ring in transmission Using S...

Page 1655: ...8 After all 2 4 brake component parts have been installed blow in air intermittently and confirm the operation of the brake 19 Check the clearance between the retaining plate and the snap ring NOTE Se...

Page 1656: ...nstall the thrust needle bearing in proper direc tion 25 Install the high clutch assembly 26 Adjust total end play Ref to 4AT 105 AD JUSTMENT Oil Pump Housing 27 Install the thrust needle bearing in p...

Page 1657: ...aft while turning lightly by hand At this time not to damage the bushing Normal protrusion A 50 55 mm 1 97 2 17 in 35 Install the torque converter clutch assembly Ref to 4AT 75 INSTALLATION Torque Con...

Page 1658: ...the low clutch drum 2 Take out front planetary carrier 3 Take out rear sun gear 4 Take out rear planetary carrier washer and thrust needle bearing A Reverse clutch piston B Cover C Return spring A Hig...

Page 1659: ...one way clutch inner race to the low clutch drum and apply compressed air to remove the low clutch piston 10 Remove the one way clutch inner race 11 Remove the one way clutch after taking out the snap...

Page 1660: ...e bearing ST 398527700 PULLER ASSY 5 ONE WAY CLUTCH OUTER RACE 1 Remove the one way clutch after taking out the snap ring 2 Remove the needle bearing after taking out the snap ring A 2 4 brake piston...

Page 1661: ...high clutch piston ST 498437000 HIGH CLUTCH PISTON GAUGE 6 Avoid folding the high clutch piston seal when installing the cover to high clutch piston 7 Using ST1 and ST2 install snap ring ST1 39867360...

Page 1662: ...ven plate drive plate retaining plate and snap ring 13 Apply compressed air intermittently to check for operation 14 Measure the clearance between the retaining plate and snap ring Reverse clutch At t...

Page 1663: ...time be careful not to fold cover seal during installation ST1 498627100 SEAT ST2 398673600 COMPRESSOR ST3 498437100 LOW CLUTCH PISTON GUIDE 6 Install the dish plate driven plates drive plates and re...

Page 1664: ...e limit 1 6 mm 0 063 in If the clearance is out of the specified range se lect a proper retaining plate so that the standard clearance can be obtained 9 Install washer to rear internal gear 10 Install...

Page 1665: ...n gear in proper direction 16 Install the thrust needle bearing in proper direc tion 17 Install front planetary carrier to low clutch drum A Washer B Rear planetary carrier A Rear planetary carrier B...

Page 1666: ...ewed from the front of the vehicle 3 2 4 BRAKE 1 Install 2 4 brake piston to 2 4 brake piston re tainer 4 ONE WAY CLUTCH INNER RACE 1 Using a press and ST install the needle bearing to the inner race...

Page 1667: ...llowing items Drive plate facing for wear and damage Snap ring for wear return spring for breakage or setting and spring retainer for deformation Lip seal and lathe cut seal ring for damage Piston che...

Page 1668: ...inhibitor switch connector from stay 7 Wrap vinyl tape around the nipple attached to the air breather hose 8 Remove pitching stopper bracket 9 Remove the inhibitor switch 10 Remove control valve body...

Page 1669: ...h 9 Insert inhibitor switch and transmission connec tor into stay 10 Install air breather hose Ref to 4AT 73 IN STALLATION Air Breather Hose 11 Insert the input shaft while turning lightly by hand and...

Page 1670: ...4AT 138 AUTOMATIC TRANSMISSION TRANSMISSION CONTROL DEVICE...

Page 1671: ...21 7 Read Diagnostic Trouble Code DTC 24 8 Inspection Mode 26 9 Clear Memory Mode 27 10 POWER Indicator Light Display 28 11 List of Diagnostic Trouble Code DTC 29 12 Diagnostic Procedure for POWER In...

Page 1672: ...replace each item 2 CHECK POWER INDICATOR LIGHT Turn the ignition switch to ON Does the POWER indicator light illuminate Go to step 4 Go to step 3 3 CHECK POWER INDICATOR LIGHT 1 Turn the ignition swi...

Page 1673: ...yed Complete the diagnosis Go to step 6 6 PERFORM THE DIAGNOSIS 1 Inspect using Diagnostics Chart with DTC Ref to 4AT 41 Diagnostic Procedure with Diagnostic Trouble Code DTC NOTE For DTC table refer...

Page 1674: ...rs Place High Suburbs Inner city Uphill Rough road Others Outdoor temperature Hot Warm Cool Cold Vehicle speed km h MPH AT diagnostic indicator light POWER indicator light Continuously lit Not lit Sel...

Page 1675: ...in in order to avoid poor contact Do not insert the pin more than 0 65 mm 0 256 in B INSPECTION 1 BATTERY Measure the battery voltage and specific gravity of electrolyte Standard voltage 12 V or more...

Page 1676: ...the engine while checking operation of se lector lever Without SPORT shift With SPORT shift 6 POWER SWITCH Make sure that the POWER indicator light in com bination meter comes ON when turning the POW...

Page 1677: ...ubleshooting for electrical systems 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without...

Page 1678: ...OMPONENTS LOCATION 4 Electrical Components Location A LOCATION 1 CONTROL MODULE 1 Engine control module ECM 3 Transmission control module TCM 4 Data link connector 2 POWER indicator light AT diag nost...

Page 1679: ...4AT 9 AUTOMATIC TRANSMISSION DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION LHD RHD AT 00323 1 AT 01103 2 3 AT 00416 3 AT 00372 4 AT 00417...

Page 1680: ...OSTICS ELECTRICAL COMPONENTS LOCATION 2 SENSOR 1 Throttle position sensor 4 Rear vehicle speed sensor 6 ATF temperature sensor 2 Front vehicle speed sensor 5 Torque converter turbine speed sensor 3 In...

Page 1681: ...4AT 11 AUTOMATIC TRANSMISSION DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION SOHC model DOHC turbo model AT 00328 1 2 4 AT 00329 AT 01133 2 4 3 AT 00330 5 AT 00331 6 AT 00332...

Page 1682: ...olenoid 1 5 Lock up duty solenoid 8 Transfer duty solenoid 2 Solenoid 2 6 2 4 brake duty solenoid 9 Sport shift solenoid with SPORT shift 3 Line pressure duty solenoid 7 2 4 brake timing solenoid 4 Lo...

Page 1683: ...han P range except N range More than 8 N range switch B55 14 Select lever in N range Less than 1 Select lever in any other than N range except P range More than 8 R range switch B55 3 Select lever in...

Page 1684: ...e Front vehicle speed sensor B55 18 Vehicle stopped 0 450 650 Vehicle speed at least 20 km h 12 MPH More than 1 AC range Torque converter turbine speed sensor B55 8 Engine idling after warm up D range...

Page 1685: ...Throttle fully open with engine OFF after warm up Less than 0 5 2 4 brake timing solenoid B54 16 1st gear Less than 1 10 16 3rd gear More than 9 Low clutch timing solenoid B54 15 2nd gear Less than 1...

Page 1686: ...wn switch ON Less than 1 Shift down switch OFF More than 8 Buzzer with SPORT shift B56 2 ON Less than 1 OFF More than 8 SPORT shift indicator with SPORT shift B56 12 SPORT shift mode OFF More than 4 S...

Page 1687: ...STICS TRANSMISSION CONTROL MODULE TCM I O SIGNAL B SCHEMATIC 1 WITHOUT SPORT SHIFT AT 01134 33 34 35 36 37 38 32 39 40 41 42 43 44 45 46 47 48 49 50 51 4 5 6 7 8 9 10 11 12 13 14 15 17 19 21 23 25 27...

Page 1688: ...mbination meter Speedome ter circuit 25 3 range indicator light 42 Rear vehicle speed sensor 26 3 range switch 43 Front vehicle speed sensor 9 AT OIL TEMP light 27 2 range indicator light 44 Shift sol...

Page 1689: ...NOSTICS TRANSMISSION CONTROL MODULE TCM I O SIGNAL 2 WITH SPORT SHIFT AT 01135 1 2 3 4 5 7 6 8 9 31 30 29 28 27 26 25 24 23 22 21 20 19 18 11 13 12 14 17 16 15 10 32 33 40 34 35 36 37 38 39 41 42 43 4...

Page 1690: ...D switch 9 Cruise control module 28 D range switch 46 ATF temperature sensor 10 ABS control module 29 3 range switch 47 Shift solenoid 1 11 AT OIL TEMP warning light 30 2 range switch 48 Shift solenoi...

Page 1691: ...he YES key after the information of transmission type is displayed 9 On the Transmission Diagnosis display screen select the DTC Display and press the YES key 10 On the DTC Display display screen sele...

Page 1692: ...OFF Shift up signal with SPORT shift Up Switch ON or OFF Shift down signal with SPORT shift Down Switch ON or OFF SPORT shift mode signal with SPORT shift Tip Mode Switch ON or OFF Anti lock brake sy...

Page 1693: ...ssion Control System and press the YES key 3 Press the YES key after the information of transmission type is displayed 4 On the Transmission Diagnosis display screen select the Clear Memory and press...

Page 1694: ...indicator light blink at 4 Hz intervals NOTE Blinks every 0 125 1 8 seconds until the ignition switch is turned OFF Repair the power supply and ground circuit Ref to 4AT 36 CHECK POWER SUPPLY AND GROU...

Page 1695: ...indicates a ten and the short segment 0 2 sec on signifies a one 2 WITH SUBARU SELECT MONITOR Refer to Subaru Select Monitor for information about how to obtain and understand DTC Ref to 4AT 21 OPERAT...

Page 1696: ...ATIC TRANSMISSION DIAGNOSTICS INSPECTION MODE 8 Inspection Mode A OPERATION Shift the select lever to D range and drive continu ously for 10 seconds or more at 60 km h 37 MPH WARNING Observe the road...

Page 1697: ...DTC can be cleared by removing the specified TCM connector for at least two minutes CLEAR MEMORY Remove the TCM connector B56 for at least two minutes TCM connector B56 is located in the line to memo...

Page 1698: ...termined by a DTC during on board diagnostics operation Problems which occurred previously can also be identified through the memory function If the POWER indicator does not show a prob lem although a...

Page 1699: ...e Code DTC 45 Intake manifold pres sure signal SOHC model Detects open or shorted input signal circuit Ref to 4AT 62 DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL NON TURBO MODEL Diagnostic Procedure with Di...

Page 1700: ...t put signal circuit Ref to 4AT 90 DTC 79 TRANSFER DUTY SOLENOID Diagnostic Procedure with Diagnostic Trouble Code DTC 93 Rear vehicle speed sensor Detects open or shorted input signal circuit Ref to...

Page 1701: ...ndicator Light A POWER INDICATOR LIGHT DOES NOT COME ON OR GO OFF DIAGNOSIS The POWER Indicator light circuit is open or shorted TROUBLE SYMPTOM When the ignition switch is turned to ON engine OFF POW...

Page 1702: ...2 B55 B55 i1 B56 T3 B12 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1112 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 1415 1617 1819 20 2122 23 24 i2 1 2 3...

Page 1703: ...7 8 9 10 1112 1 2 3 4 5 6 1 2 3 4 5 6 5 6 1 2 3 4 5 7 8 9 7 1 2 3 4 5 6 7 8 9 10 8 9 7 6 8 7 9 8 10 1112 10 11 9 10 12 13 10 1112 13 11 12 14 14 15 1314 16 15 17 18 16 19 20 21 17 18 19 22 23 24 20 21...

Page 1704: ...combination meter connector and chassis ground Connector terminal i11 No 7 Chassis ground Is the voltage more than 9 V Go to step 6 Repair the open circuit in harness between combina tion meter and ba...

Page 1705: ...ircuit Ref to 4AT 109 CHECK INHIBI TOR SWITCH Diagnostic Proce dure without Diag nostic Trouble Code DTC 10 CHECK SHORT CIRCUIT OF HARNESS 1 Disconnect the connector from TCM 2 Remove the combination...

Page 1706: ...F45 B62 NO 4 NO 11 SBF 4 SBF 1 LHD LHD IGNITION SWITCH C1 A23 A24 C15 C24 18 1 2 3 4 5 6 7 8 9 10 12 131415 16 1718 19 20 21 22 23 11 24 B54 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 19 20 21 22 23...

Page 1707: ...to step 5 5 CHECK FUSE NO 11 Remove the fuse No 11 Is the fuse No 11 blown out Replace the fuse No 11 If replaced fuse No 11 has blown out easily repair short circuit in harness between fuse No 11 an...

Page 1708: ...5 5 6 6 7 7 8 8 9 9 13 14 15 20 19 17 16 10 10 11 11 12 1314 1516 12 BATTERY E E F45 B62 NO 4 NO 11 SBF 4 SBF 1 LHD LHD IGNITION SWITCH C1 A23 A24 C15 C24 18 1 2 3 4 5 6 7 8 9 10 12 131415 16 1718 19...

Page 1709: ...ar of sys tem displayed on Subaru Select Monitor Go to step 6 Go to step 5 5 CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Connect the TCM connector 3 Disconnect the ECM co...

Page 1710: ...nce more than 1 M Go to step 10 Repair the har ness and connec tor between TCM and data link con nector 10 CHECK INSTALLATION OF TCM CONNEC TOR Turn the ignition switch to OFF Is the TCM connector ins...

Page 1711: ...up after engine warm up The POWER indicator light remains on when vehicle speed is 0 WIRING DIAGRAM AT 01139 30 17 B55 B134 ECM B134 B55 TCM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 9 1...

Page 1712: ...55 No 17 Chassis ground Is the voltage more than 10 5 V Even if the POWER indicator lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector o...

Page 1713: ...F 2 Disconnect the connectors from TCM and ECM 3 Measure the resistance of harness between TCM and ECM connector Connector terminal B54 No 1 B135 No 28 Is the resistance less than 1 Go to step 3 Repai...

Page 1714: ...ECM Go to step 7 6 CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and ECM 2 Connect the Subaru Select Monitor to data link connector 3 Start the engine and tur...

Page 1715: ...TEMPERATURE SENSOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from transmission and TCM 3 Measure the resistance of harness between TCM and transmission connector Connector terminal...

Page 1716: ...between TCM and transmission con nector 5 CHECK ATF TEMPERATURE SENSOR 1 Turn the ignition switch to OFF 2 Connect the connectors to transmission and TCM 3 Turn the ignition switch to ON and start en...

Page 1717: ...of the con nector or harness may be the cause Repair the har ness or contact in ATF temperature sensor and trans mission connector Go to step 10 9 CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITO...

Page 1718: ...22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 18 13 14 15 25 26 11 12 23 24 6 7 19 20 29 30 4 5 16 17 27 28 B21 1 2 1 2 3 3 4 4 5 6 7 8 9 13 14 15 20 19 17 16 10 11 12 18 B22 E13 B...

Page 1719: ...NNECTOR B137 D A7 B22 E3 13 15 3 14 16 B21 E2 20 19 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B22 B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 B84 1 2 7 8 9 5 6 3 4 10 11 12 19 2...

Page 1720: ...ine ground B84 No 8 Engine ground B84 No 9 Engine ground B136 No 1 Engine ground Is the resistance less than 5 Go to step 3 Repair the open circuit in harness between ECM connector and engine groundin...

Page 1721: ...tion sensor connector 9 CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM Measure the resistance of harness between TCM and ECM connector Connector terminal SOHC MODEL B54 No 3 B136 No 17 DOHC TURBO MODEL B...

Page 1722: ...Measure the voltage between TCM connector and chassis ground Connector terminal B54 No 2 Chassis ground Is the voltage 4 8 5 3 V Even if the POWER indicator lights up the cir cuit has returned to a n...

Page 1723: ...CODE DTC E DTC 33 FRONT VEHICLE SPEED SENSOR DIAGNOSIS The vehicle speed signal is abnormal The circuit in combination meter is faulty The harness connector between TCM and vehicle speed sensor is in...

Page 1724: ...9 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 i11 i1 1 2 3 4 5 6 7 8 9 10 11 23 24 12 13 14 15 16 17 18 19 20 21 22 B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 i11 17 18 B11 B36 B37 i1...

Page 1725: ...ssis ground Is the resistance more than 1 M Go to step 5 Repair the short circuit in harness between TCM and transmission con nector and poor contact in cou pling connector 5 CHECK FRONT VEHICLE SPEED...

Page 1726: ...onnect all connectors 2 Connect the Subaru Select Monitor to data link connector 3 Lift up or raise the vehicle and place safety stands NOTE On AWD models raise all wheels off floor 4 Turn the ignitio...

Page 1727: ...t of TCM is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM AT 01145 14 15 B11 B53 3 T4 TCM B55 8 9 1 2 RH SENSOR LH RH LHD MODEL RHD MODEL TORQUE CONVERTER TURBINE SPEED B55 1 2...

Page 1728: ...in cou pling connector 4 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and chassis ground Connector terminal B55 No 9 Chassis ground Is the resist...

Page 1729: ...is time A temporary poor contact of the con nector or harness may be the cause Repair the har ness or connector in TCM and trans mission Go to step 11 10 CHECK INPUT SIGNAL FOR TCM USING OSCILLOSCOPE...

Page 1730: ...the resistance less than 1 Go to step 2 Repair the open circuit in harness between TCM and ECM connector 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM Measure the resistance of harness between TCM con...

Page 1731: ...t and rust Go to step 6 6 CHECK GROUND LINE BETWEEN TRANS MISSION AND BODY Check installing condition of the ground line in transmission and body Tightening torque 10 16 N m 1 0 1 6 kgf m 7 2 11 6 ft...

Page 1732: ...TCM and ECM 3 Measure the resistance of harness between TCM and ECM connector Connector terminal SOHC WITHOUT OBD MODEL B54 No 1 B136 No 11 SOHC WITH OBD MODEL B54 No 1 B137 No 2 Is the resistance le...

Page 1733: ...e Repair the har ness or connector in TCM and ECM Go to step 7 6 CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and ECM 2 Connect the Subaru Select Monitor to d...

Page 1734: ...SION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and shift solenoid 1 connector Connector terminal B54 No 22...

Page 1735: ...OLD mode switch to ON 2 Measure the voltage between TCM connec tor and chassis ground Connector terminal B54 No 22 Chassis ground Is the voltage less than 1 V Even if the POWER indicator lights up the...

Page 1736: ...ssion connector 9 CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 1 AND TRANSMISSION Measure the resistance of harness between shift solenoid 1 connector and transmission ground Connector terminal T4 N...

Page 1737: ...SSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and shift solenoid 2 connector Connector terminal B54 No 5...

Page 1738: ...een front and rear wheels may light the ABS warning light but this indicates no malfunction When AT control di agnosis is finished perform the ABS memory clearance procedure of on board diagnostics sy...

Page 1739: ...ssion connector 8 CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 2 AND TRANSMISSION Measure the resistance of harness between shift solenoid 2 connector and transmission ground Connector terminal T4 N...

Page 1740: ...D TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector terminal B54...

Page 1741: ...re the voltage between TCM connec tor and chassis ground Connector terminal B54 No 15 Chassis ground Is the voltage less than 1 V Even if the POWER indicator lights up the cir cuit has returned to a n...

Page 1742: ...connector 9 CHECK HARNESS CONNECTOR BETWEEN LOW CLUTCH TIMING SOLENOID AND TRANSMISSION Measure the resistance of harness between low clutch timing solenoid connector and trans mission ground Connect...

Page 1743: ...D TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector terminal B54...

Page 1744: ...icle speed to 10 km h 6 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When AT control di agnosis is finished perform the...

Page 1745: ...Shift Sole noids Duty Sole noids and ATF Temperature Sen sor 8 CHECK HARNESS CONNECTOR BETWEEN 2 4 BRAKE TIMING SOLENOID AND TRANSMISSION Measure the resistance of harness between 2 4 brake timing sol...

Page 1746: ...ss between TCM and transmission con nector 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND Measure the resistance of harness between TCM and chassis ground Connector terminal B54 No 9 Chassis...

Page 1747: ...is ground Is the voltage less than 1 V Even if the POWER indicator lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be...

Page 1748: ...transmission ground Terminals No 1 Transmission ground Is the resistance 2 0 4 5 Go to step 11 Replace the line pressure duty solenoid Ref to 4AT 64 Shift Solenoids Duty Solenoids and ATF Temperature...

Page 1749: ...harness between TCM and transmission con nector 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND Measure the resistance of harness between TCM and chassis ground Connector terminal B54 No 18 C...

Page 1750: ...4 No 18 Chassis ground Is the voltage less than 1 V Even if the POWER indicator lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or ha...

Page 1751: ...r and transmission ground Terminals No 1 Transmission ground Is the resistance 2 0 4 5 Go to step 11 Replace the 2 4 brake duty sole noid Ref to 4AT 64 Shift Sole noids Duty Sole noids and ATF Tempera...

Page 1752: ...open or shorted TROUBLE SYMPTOM No lock up after engine warm up WIRING DIAGRAM Step Check Yes No 1 CHECK DTC Do multiple DTCs appear in the on board diagnostics test mode Go to another DTC Go to step...

Page 1753: ...13 No 16 Is the resistance 10 17 Go to step 5 Go to step 11 5 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select Monitor Go to step 8 Go to step 6 6 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Conn...

Page 1754: ...he vehicle until ATF reaches its operating temperature 6 Read the data of lock up duty solenoid using Subaru Select Monitor Lock up duty solenoid is indicated in 7 Move the selector lever to D range a...

Page 1755: ...mper ature Sensor 12 CHECK HARNESS CONNECTOR BETWEEN LOCK UP DUTY SOLENOID AND TRANS MISSION Measure the resistance of harness between lock up duty solenoid and transmission con nector Connector termi...

Page 1756: ...SIS Output signal circuit of SPORT shift solenoid is open or shorted TROUBLE SYMPTOM Engine brake is effective at D 3 2 ranges WIRING DIAGRAM AT 00663 14 TRANSMISSION B54 TCM AT10 SPORT SHIFT SOLENOID...

Page 1757: ...M AND TRANSMISSION Measure the resistance of harness between TCM connector and chassis ground Connector terminal B54 No 14 Chassis ground Is the resistance more than 1 M Go to step 3 Repair the short...

Page 1758: ...d when engine brake is effective Connector terminal B54 No 14 Chassis ground Is the voltage less than 1 V Even if POWER indicator lights up the circuit has returned to a nor mal condition at this time...

Page 1759: ...on con nector 9 CHECK HARNESS CONNECTOR BETWEEN SPORT SHIFT SOLENOID AND TRANSMIS SION Measure the resistance of harness between SPORT shift solenoid connector and transmis sion ground Connector termi...

Page 1760: ...TCM AND TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector termina...

Page 1761: ...ector terminal B54 No 6 Chassis ground Is the voltage less than 1 V Go to step 6 Go to step 12 6 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Move the select lever to D range 2 Measure the voltage between T...

Page 1762: ...ON engine OFF and turn Subaru Select Monitor switch to ON 4 Move the select lever to D range with throt tle fully open vehicle speed 0 km h or 0 MPH 5 Read the data of transfer duty solenoid using Sub...

Page 1763: ...LENOID AND TRANS MISSION Measure the resistance of harness between transfer duty solenoid and transmission con nector Connector terminal T4 No 6 AT4 No 1 Is the resistance less than 1 Go to step 15 Re...

Page 1764: ...cessive tight corner braking WIRING DIAGRAM AT 01148 19 20 B11 B53 9 T4 TCM B54 A B55 B B24 A19 7 8 RH SHIELD AND SENSOR GROUND JOINT CONNECTOR LH RH LHD MODEL RHD MODEL REAR VEHICLE B55 1 2 3 4 5 6 7...

Page 1765: ...Chassis ground Is the resistance more than 1 M Go to step 5 Repair the short circuit in harness between TCM and transmission con nector 5 CHECK REAR VEHICLE SPEED SENSOR Measure the resistance between...

Page 1766: ...t this time A temporary poor contact of the con nector or harness may be the cause Repair the har ness or connector in TCM and trans mission Go to step 11 10 CHECK INPUT SIGNAL FOR TCM USING OSCILLOSC...

Page 1767: ...8 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 i10 1 2 29 30 3 4 5 6 11 12 9 10 7 8...

Page 1768: ...19 20 21 22 23 24 25 26 27 28 29 30 i10 SBF 4 SBF 1 No 13 IGNITION SWITCH FWD i11 i2 B37 i3 B38 C B55 B B56 TCM C B i10 F45 B62 F27 B4 C7 30 15 29 C2 B20 COMBINATION METER E E FWD SWITCH i3 1 2 3 4 5...

Page 1769: ...pair the open circuit in harness between TCM and FWD switch con nector 5 CHECK HARNESS CONNECTOR BETWEEN FWD SWITCH AND CHASSIS GROUND Measure the resistance of harness between FWD switch and chassis...

Page 1770: ...sis ground Is the resistance more than 1 M Go to step 11 Repair the short circuit in harness between TCM and combination meter connector 11 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Turn the ignition swi...

Page 1771: ...SWITCH Diag nostic Procedure without Diagnostic Trouble Code DTC Check the brake switch circuit Ref to EN H4SO 213 DTC P0703 TORQUE CON VERTER BRAKE SWITCH B CIR CUIT Diagnos tic Procedure with Diagno...

Page 1772: ...F when the throttle is partially open or fully closed but it is not ON when the throttle is fully opened The kick down switch circuit is open or shorted TROUBLE SYMPTOM No kick down occurs when the th...

Page 1773: ...ick down switch 5 CHECK HARNESS CONNECTOR BETWEEN TCM AND KICK DOWN SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from kick down switch 3 Measure the resistance of harness conne...

Page 1774: ...ISSION DIAGNOSTICS DIAGNOSTIC PROCEDURE WITHOUT DIAGNOSTIC TROUBLE CODE DTC 9 CHECK POOR CONTACT Is there poor contact Repair the poor contact Replace the TCM Ref to 4AT 70 Transmission Con trol Modul...

Page 1775: ...i2 B37 i1 B36 C B55 TCM B B56 B133 C B i10 B16 C7 C11 B23 COMBINATION METER E B55 B133 B56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

Page 1776: ...6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 4 5 6 1 2 3 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 1777: ...round Connector terminal B133 No 4 Chassis ground Is the resistance less than 1 Go to step 5 Repair the open circuit in harness between POWER switch and chassis ground 5 CHECK POWER SWITCH 1 Turn the...

Page 1778: ...d Is the voltage more than 10 V Go to step 10 Replace the TCM Ref to 4AT 70 Transmission Con trol Module TCM 10 CHECK INPUT SIGNAL FOR TCM Measure the signal voltage for TCM while turn ing POWER switc...

Page 1779: ...ITCH DIAGNOSIS The input signal circuit of inhibitor switch is open or shorted TROUBLE SYMPTOM Shift characteristics are erroneous Engine brake is not effected when selector lever is in 3 range Engine...

Page 1780: ...5 4 3 P R N D 3 2 1 9 8 10 3 11 4 6 5 3 2 1 8 7 6 5 4 T7 T7 B12 B55 B55 i1 T3 B12 1 2 3 4 1 2 3 4 5 6 5 6 1 2 3 4 5 6 7 8 9 1 2 3 1 2 3 7 8 9 4 5 6 4 5 6 7 8 9 10 7 7 8 8 9 9 10 11 12 10 11 10 11 12 1...

Page 1781: ...7 10 9 8 7 6 5 4 P R N D 3 2 1 9 8 10 3 11 4 6 5 3 2 1 8 7 6 5 4 T7 T7 B12 B55 B55 T3 B12 1 2 3 4 1 2 3 4 5 6 5 6 7 8 9 1 2 3 1 2 3 7 8 9 4 5 6 4 5 6 7 8 9 10 7 8 9 10 11 12 10 11 12 13 14 15 12 13 1...

Page 1782: ...D light up Go to step 11 Go to step 41 11 CHECK INDICATOR LIGHT Does the combination meter D range indicator illuminate Go to step 12 Go to step 44 12 CHECK D RANGE SWITCH When the 3 range is selected...

Page 1783: ...ssis ground Is the voltage less than 1 V Go to step 25 Go to step 65 25 CHECK INPUT SIGNAL FOR TCM 1 Position the select lever to any other than P range 2 Measure the voltage between TCM and chassis g...

Page 1784: ...the combination meter 3 Remove the R range indicator light bulb from combination meter Is R range indicator light bulb OK Go to step 33 Replace the R range indicator light bulb Ref to IDI 14 Combina...

Page 1785: ...ween TCM and combination meter Connector terminal B55 No 14 i12 No 12 Is the resistance less than 1 Go to step 65 Repair the open circuit in harness between TCM connector and combination meter and poo...

Page 1786: ...Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis ground Connector terminal B55 No 4 Chassis ground Is the resistan...

Page 1787: ...CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and...

Page 1788: ...etween TCM and inhibitor switch connector and poor contact in coupling connec tor 60 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3...

Page 1789: ...mbination meter 3 Measure the resistance of harness between TCM and chassis ground Connector terminal B55 No 7 Chassis ground Is the resistance more than 1 M Go to step 65 Repair the ground short circ...

Page 1790: ...2nd gear at 2 3 D ranges WIRING DIAGRAM LHD MODEL AT 01156 SBF 4 SBF 1 No 13 IGNITION SWITCH i11 i2 B37 i1 B36 BATTERY C B55 TCM B133 B i10 B15 C7 COMBINATION METER E E B55 B133 1 2 3 4 5 6 7 8 9 10 1...

Page 1791: ...H i11 i2 B37 i3 B38 C B55 TCM B133 B i10 B15 C7 1 31 COMBINATION METER E B55 B133 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 4 5 6 1 2 3 7 8 9 10 11 12 13 14 15 16 17 1...

Page 1792: ...resistance less than 1 Go to step 6 Repair the HOLD switch 6 CHECK HOLD SWITCH 1 Turn the HOLD switch to OFF 2 Measure the resistance between terminals of HOLD switch Terminals No 4 No 2 Is the resist...

Page 1793: ...nd Is the voltage more than 8 V Go to step 11 Replace the TCM Ref to 4AT 70 Transmission Con trol Module TCM 11 CHECK INPUT SIGNAL FOR TCM Measure the signal voltage for TCM while turn ing HOLD switch...

Page 1794: ...switch input signal circuit is open or shorted TROUBLE SYMPTOM No SPORT shift mode occurs Does not shift gears in SPORT shift mode WIRING DIAGRAM AT 001158 15 4 B55 TCM B237 SPORT SHIFT SWITCH B237 1...

Page 1795: ...T shift switch 3 Measure the resistance of harness between SPORT shift switch connector and chassis ground Connector terminal B237 No 4 Chassis ground Is the resistance less than 1 Go to step 6 Repair...

Page 1796: ...onnector terminal B55 No 15 Chassis ground Is the voltage less than 1 V Even if the POWER indicator lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of...

Page 1797: ...ep 18 Replace the TCM Ref to 4AT 70 Transmission Con trol Module TCM 18 CHECK INPUT SIGNAL FOR TCM 1 Move the select lever to shift up side 2 Measure the signal voltage for TCM Connector terminal B55...

Page 1798: ...air the short circuit in harness between SPORT shift switch con nector and TCM connector 24 CHECK INPUT SIGNAL FOR TCM 1 Connect the all connectors 2 Turn the ignition switch to ON Engine is stopped 3...

Page 1799: ...oes not change WIRING DIAGRAM AT 01159 No 13 BATTERY IGNITION SWITCH SBF 1 SBF 4 i10 i11 i3 B38 B37 i2 B56 COMBINATION METER TCM B25 C7 B22 B23 B24 15 12 13 14 12 4 3 13 SPORT SHIFT INDICATOR B56 1 2...

Page 1800: ...step 4 Repair the open circuit in harness between TCM and combination meter connector and poor contact in coupling connec tor 4 CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER Measure the r...

Page 1801: ...DIAGRAM AT 01160 No 13 BATTERY IGNITION SWITCH SBF 1 SBF 4 B37 i2 E 31 i10 i3 B38 B56 COMBINATION METER TCM 26 27 2 11 BUZZER B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 i10 1 2...

Page 1802: ...ssis ground Connector terminal B56 No 21 Chassis ground Is the resistance more than1 M Go to step 2 Repair the short circuit in harness between TCM and combination meter connector 2 CHECK COMBINATION...

Page 1803: ...level too high or too low Noise occurs while driving in D4 Final gear Low reverse brake Planetary gear Reduction gear Differential gear oil level too high or too low Engine stalls while shifting from...

Page 1804: ...does not start in D 3 or 2 range only engine stalls Reverse clutch Vehicle starts in R range only engine revving up Control valve Acceleration during standing starts is poor high stall rpm Control va...

Page 1805: ...lve Lock up facing Engine speed signal Parking brake is not effected Select cable Select lever Parking mechanism Shift lever cannot be moved or is hard to move from P range ATF spurts out ATF level to...

Page 1806: ...re duty solenoid Control valve 2 4 brake timing solenoid 2 4 brake ATF deterioration Engine performance Low clutch timing solenoid Low clutch Slippage occurs from 3rd to 4th gear TCM Throttle position...

Page 1807: ...Vibration occurs during straight forward operation TCM Lock up duty solenoid Lock up facing Lock up damper HOLD switch Vibration occurs during turns tight corner braking phenome non TCM Front vehicle...

Page 1808: ...IAGNOSTIC Select lever is too high to move unreasonable resistance Detente spring Manual plate Select lever slips out of operation during acceleration or while driving on rough terrain Select cable Se...

Page 1809: ...d Extension Case Assembly 53 10 Rear Case 57 11 Transfer Drive Gear 58 12 Transfer Driven Gear 60 13 Center Differential 62 14 Reverse Check Sleeve 63 15 Transmission Case 66 16 Main Shaft Assembly fo...

Page 1810: ...ar ratio High 1 000 Low 1 447 Front reduction gear Final Type of gear Hypoid Gear ratio 4 111 3 900 3 900 4 444 4 111 Rear reduction gear Transfer Type of gear Helical Gear ratio 1 000 1 100 1 000 Fin...

Page 1811: ...95AA101 0 500 0 0197 Main shaft rear plate Dimension A mm in Part No Mark 4 00 4 13 0 1575 0 1626 32294AA041 1 3 87 3 99 0 1524 0 1571 32294AA051 2 Snap ring Outer 19 Part No Thickness mm in 031319000...

Page 1812: ...52 0 0992 805025057 2 72 0 1071 805025054 2 57 0 1012 805025058 2 37 0 0933 Reverse shifter lever Part No Mark Remarks 32820AA070 7 Further from case wall 32820AA080 8 Standard 32820AA090 9 Closer to...

Page 1813: ...oser to 5th gear 32189AA010 1 31 Arm stops closer to 5th gear 33189AA020 2 34 Arm stops in the cen ter 32189AA030 3 37 Arm stops closer to reverse gear 32189AA040 4 40 Arm stops closer to reverse gear...

Page 1814: ...to ball bearing clearance 0 01 0 15 mm 0 0004 0 0059 in Washer 38 1 50 t Part No Thickness mm in Part No Thickness mm in 803038021 0 925 0 950 0 0364 0 0374 803038023 1 025 1 050 0 0404 0 0413 803038...

Page 1815: ...5MT 7 MANUAL TRANSMISSION AND DIFFERENTIAL GENERAL DESCRIPTION B COMPONENT 1 TRANSMISSION CASE MT 00002 T 3 1 2 4 5 12 10 11 18 13 9 8 7 6 16 14 15 17...

Page 1816: ...t 17 High low cable bracket B Dual range 4 Snap ring Outer 12 Clip 5 Speedometer driven gear 13 Oil level gauge Non turbo model 18 Oil level gauge Turbo model 6 Washer 14 Oil seal Dual range 7 Speedom...

Page 1817: ...AL TRANSMISSION AND DIFFERENTIAL GENERAL DESCRIPTION 2 DRIVE PINION ASSEMBLY AWD MODEL MT 00954 5 4 1 25 26 27 28 29 21 22 22 23 31 30 32 33 34 24 20 18 19 6 3 2 12 11 10 9 8 7 13 16 17 14 15 T1 T3 35...

Page 1818: ...bevel gear sleeve 6 Driven shaft 20 Synchro cone Except 1 6 L model 33 Washer 7 Key 34 Lock washer 8 Woodruff key 21 Inner baulk ring Except 1 6 L model 35 Lock nut 9 Drive pinion collar 36 2nd baulk...

Page 1819: ...Lock nut 4 Roller bearing 14 Reverse driven gear 5 1st gear trust plate 15 2nd baulk ring Tightening torque N m kgf m ft lb 6 Outer snap ring 16 2nd driven gear T1 29 4 3 0 21 7 7 Washer 17 2nd gear b...

Page 1820: ...RANSMISSION AND DIFFERENTIAL GENERAL DESCRIPTION 3 MAIN SHAFT ASSEMBLY SINGLE RANGE AWD MODEL MT 00800 1 4 4 19 20 21 22 23 24 26 36 35 37 38 27 28 29 30 31 32 33 34 5 18 9 5 6 7 8 9 10 11 12 13 14 15...

Page 1821: ...L model 18 Baulk ring Except turbo and 2 5 L model 32 Snap ring 33 Lock washer 7 3rd synchro cone Turbo and 2 5 L model 19 5th gear thrust washer 34 Lock nut 20 5th needle bearing race 35 Reverse idl...

Page 1822: ...dle bearing race 29 Reverse idler gear shaft 6 3rd baulk ring 18 Needle bearing 30 Reverse idler gear 7 Coupling sleeve 19 Main shaft rear plate 31 Washer 8 Synchronizer hub 20 5th drive gear 9 Shifti...

Page 1823: ...L RANGE AWD MODEL MT 00006 3 4 4 T2 T3 T1 T4 5 2 1 6 6 7 8 9 10 11 17 18 19 20 21 22 23 30 31 32 33 34 35 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 63 66 67 68 69 70 71 72 73 74 75 76 77 62 6...

Page 1824: ...shaft 13 Snap ring Outer 28 41 4th needle bearing race 69 Low switch 14 Oil squeeze 42 Needle bearing 70 Gasket 15 Straight pin 43 4th gear thrust washer 71 Straight pin 16 Snap ring Outer 28 44 Ball...

Page 1825: ...nterlock plunger 18 Reverse shifter lever 3 Straight pin 11 1st 2nd fork rod 4 Reverse fork rod 12 3rd 4th shifter fork Tightening torque N m kgf m ft lb 5 Checking ball plug 13 1st 2nd shifter fork T...

Page 1826: ...7 Snap ring 8 Oil seal 23 Back up light switch 9 Snap ring Inner 24 Roller bearing Tightening torque N m kgf m ft lb 10 Reverse check plate 25 Transfer driven gear T1 6 4 0 65 4 7 11 Reverse check spr...

Page 1827: ...k up light switch 4 Oil seal 14 Reverse return spring 5 Ball 15 Reverse check cam Tightening torque N m kgf m ft lb 6 Reverse accent spring 16 Reverse accent shaft T1 6 4 0 65 4 7 7 Washer 17 Return s...

Page 1828: ...driven gear 9 Roller bearing 3 Pinion shaft 10 Differential case Tightening torque N m kgf m ft lb 4 Straight pin 11 Oil seal T1 25 2 5 18 1 5 Washer 12 Differential side retainer T2 62 6 3 45 6 6 Di...

Page 1829: ...r Tightening torque N m kgf m ft lb 2 Spacer 8 Cushion D T1 7 5 0 76 5 5 3 Cushion C 9 Center crossmember T2 35 3 6 26 4 Front plate 10 Rear plate T3 50 5 1 37 5 Dynamic damper Except 1 6 L model 11 F...

Page 1830: ...NERAL DESCRIPTION 1 6 L FWD MODEL 1 Pitching stopper 3 Rear crossmember Tightening torque N m kgf m ft lb 2 Rear cushion rubber 4 Rubber cushion T1 35 3 57 25 8 T2 50 5 1 36 9 T3 58 5 9 42 8 T4 70 7 1...

Page 1831: ...at of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply gear oil o...

Page 1832: ...703 4 ADAPTER 398497701 5 BOLT 899520107 6 NUT 021008000 399780104 WEIGHT Used for measuring preload on roller bearing 498077000 REMOVER Used for removing roller bearing of drive pinion shaft 49807730...

Page 1833: ...hypoid gear Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring backlash between side gear and pinion and hypoid gear Used with MAGNET BASE 498247001 498427100 STOPPER Used for secu...

Page 1834: ...nstalling transmission main shaft lock nut 498937000 TRANSMISSION HOLDER Used for removing and installing transmission main shaft lock nut 499277100 BUSH 1 2 INSTALLER Used for installing 1st driven g...

Page 1835: ...nstalling snap ring OUT 25 and ball bearing 25 26 17 Used for installing bearing cone of transfer driven gear extension core side 499787000 WRENCH ASSY Used for removing and installing differential si...

Page 1836: ...NSTALLER Used for installing 4th needle bearing race and ball bearing onto transmission main shaft Used with REMOVER 899714110 499917500 DRIVE PINION GAUGE ASSY Used for adjusting drive pinion shim 49...

Page 1837: ...RENCH 35 Used for removing and installing driven pinion lock nut and main shaft lock nut 499987300 SOCKET WRENCH 50 Used for removing and installing driven gear assembly lock nut 899714110 REMOVER Use...

Page 1838: ...in shaft and drive pinion 899884100 HOLDER Used for tightening lock nut on sleeve 899904100 REMOVER Used for removing and installing straight pin 899988608 SOCKET WRENCH 27 Used for removing and insta...

Page 1839: ...Used with INSTALLER 499277100 499587000 INSTALLER Used for installing driven gears to driven shaft 899824100 PRESS Used for installing speedometer shaft oil seal 499987100 SOCKET WRENCH 35 Used for re...

Page 1840: ...t 498057300 INSTALLER Used for installing extension oil seal 498255400 PLATE Used for measuring backlash 498077400 SYNCHRONIZER CONE REMOVER Used for removing synchronizer cone of main shaft Used for...

Page 1841: ...ngine 41099AA020 ENGINE SUPPORT Used for supporting engine 398527700 PULLER ASSY Used for removing extension case roller bearing 398643600 GAUGE Used for measuring total end play extension end play an...

Page 1842: ...g of transfer drive gear 398507703 DUMMY COLLAR Used for installing input shaft holder oil seal For dual range model 398663600 PLIERS Used for removing and installing input shaft snap ring For dual ra...

Page 1843: ...ANDER Used for removing and installing snap ring For dual range model 899580100 INSTALLER Used when pressing ball bearings into input shaft For dual range model 399513600 INSTALLER Used when pressing...

Page 1844: ...DESCRIPTION 2 GENERAL PURPOSE TOOLS 499797000 INSTALLER Used for installing differential side retainer oil seal TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage and ampere ILLUST...

Page 1845: ...irectly after the engine has been running the transmission gear oil is hot Be careful not to burn yourself NOTE Tighten the transmission gear oil drain plug after draining the transmission gear oil Ti...

Page 1846: ...r Turbo model Ref to IN H4DOTC 10 REMOVAL Intercooler 6 Disconnect the following connectors 1 Neutral position switch connector 2 Back up light switch connector 3 High low switch connector Dual range...

Page 1847: ...tch release fork from release bearing Turbo model 1 Remove the clutch operating cylinder from transmission 2 Remove the plug using 10 mm hexagon wrench 3 Screw the 6 mm dia bolt into release fork shaf...

Page 1848: ...N When removing the exhaust pipes be careful each exhaust pipe does not drop out 19 Remove the heat shield cover If equipped 20 Remove the hanger bracket from right side of transmission 21 Remove the...

Page 1849: ...shaft is withdrawn from clutch cover 30 Separate the transmission assembly and rear cushion rubber B INSTALLATION 1 Install the rear cushion rubber to transmission assembly Tightening torque 35 N m 3...

Page 1850: ...ng torque 50 N m 5 1 kgf m 36 9 ft lb 8 Remove the ST 9 Install the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft lb T2 58 N m 5 9 kgf m 43 ft lb 10 Lift up the vehicle 11 Install the f...

Page 1851: ...opeller Shaft 17 Install the heat shield cover If equipped 18 Install the hanger bracket on right side of trans mission 19 Install the rear exhaust pipe and muffler 20 Install the front exhaust pipe a...

Page 1852: ...tening torque 13 N m 1 3 kgf m 9 4 ft lb 2 Vehicle speed sensor connector 3 Neutral position switch connector 4 Back up light switch connector 5 High low switch connector Dual range model 27 Install t...

Page 1853: ...CUSHION RUB BER 1 Disconnect the ground cable from battery 2 Jack up the vehicle and support it with sturdy racks 3 Remove the front and center exhaust pipes Non turbo model Without OBD Ref to EX H4S...

Page 1854: ...m 7 1 kgf m 51 ft lb T2 140 N m 14 3 kgf m 103 ft lb 3 Remove the transmission jack 4 Install the heat shield cover If equipped 5 Install the front and center exhaust pipes Non turbo model Without OBD...

Page 1855: ...Remove the rear exhaust pipe and muffler 4 Remove the heat shield cover If equipped 5 Remove the propeller shaft Ref to DS 15 RE MOVAL Propeller Shaft 6 Using the ST remove the oil seal ST 398527700 P...

Page 1856: ...Turbo MODEL 5 Lift up the vehicle 6 Remove the back up light switch and neutral po sition switch with harness 2 HIGH LOW SWITCH 1 Disconnect the ground cable from battery 2 Remove the air intake duct...

Page 1857: ...cable to clamp 3 Connect the connector of high low switch 4 Install the air intake duct and cleaner case Ref to IN H4SO 5 INSTALLATION Air Cleaner Case and Ref to IN H4SO 6 INSTALLATION Air Intake Du...

Page 1858: ...H 1 Turn ignition switch to OFF 2 Disconnect connector high low switch 3 Measure the resistance between high low switch terminals 4 Replace defective parts Gear shift position Terminal No Specified re...

Page 1859: ...3 ft lb 3 Connect the connector to vehicle speed sensor 4 Install the front center exhaust pipes and muf fler 5 Lower the vehicle 6 Connect the battery ground cable to battery C INSPECTION Inspect th...

Page 1860: ...gasket with a new one Tightening torque 69 N m 7 0 kgf m 50 6 ft lb 3 Attach the transmission to ST ST 499937100 TRANSMISSION STAND 4 Rotating parts should be coated with oil prior to assembly 5 All d...

Page 1861: ...move the transfer case with extension 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 transfe...

Page 1862: ...T 30 mm 1 18 in Thickness of ST 13 Select the suitable washer in the following ta ble Standard clearance 0 15 0 35 mm 0 0059 0 0138 in 14 Fit the thrust washer on center differential Thrust washer 50...

Page 1863: ...6 Install the extension assembly into transfer case Tightening torque 40 N m 4 1 kgf m 29 7 ft lb 17 Install the shifter arm to transfer case 18 Hang the shifter arm on 3rd 4th fork rod 19 Install the...

Page 1864: ...f to 5MT 47 Oil Seal D ASSEMBLY 1 EXTENSION CASE 1 Using the ST install the oil seal to extension case Ref to 5MT 47 Oil Seal NOTE Use a new oil seal 2 Install the shift bracket to extension case Tigh...

Page 1865: ...5 kgf m 18 1 ft lb 2 Install back up light switch and neutral position switch Ref to 5MT 49 INSTALLATION Switch es and Harness 3 Install the manual transmission assembly to ve hicle Ref to 5MT 41 INST...

Page 1866: ...er driven gear 3 Install the extension case assembly 4 Install the transfer case and extension case as sembly Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly 5 Install the back u...

Page 1867: ...ication 2 Drive gear Replace the drive gear in the following cases If their tooth surfaces and shaft are excessively broken or damaged 3 Measure the clearance between snap ring and inner race of ball...

Page 1868: ...aring outer race from extension case and transfer case B INSTALLATION 1 Install the bearing outer race to extension case and transfer case 2 Install the transfer driven gear 3 Install the transfer cas...

Page 1869: ...1 US ton 1 0 Imp ton 2 Using the ST install the roller bearing transfer case side ST 499757002 INSTALLER NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton E INSPECTION 1 Beari...

Page 1870: ...case as sembly Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly 5 Install the back up light switch and neutral posi tion switch Ref to 5MT 48 REMOVAL Switches and Harness 6 Install the...

Page 1871: ...d reverse check ball 5 Remove the reverse check sleeve B INSTALLATION 1 Install the reverse check sleeve Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 2 Install the ball spring washer and plug to tra...

Page 1872: ...accent shaft check cam return spring and check spring onto reverse check sleeve NOTE Be sure the bent section of reverse check spring is positioned in the groove in check cam 2 Hook the bent section o...

Page 1873: ...to 1 ea between sleeve assembly and case to adjust the clearance CAUTION Be careful not to break the O ring when placing shim s NOTE When the shim is removed the neutral position will move closer to...

Page 1874: ...ension Case Assembly 4 Remove the bearing mounting bolts 5 Remove the main shaft rear plate 6 Put vinyl tape around the splines of right and left axle drive shafts to prevent damage to oil seal 7 Sepa...

Page 1875: ...REMOVAL Transfer Case and Extension Case Assembly 4 Remove the input shaft holder 5 Remove the high low switch Ref to 5MT 48 REMOVAL Switches and Harness 6 Using the ST drive out the straight pin and...

Page 1876: ...w shifter fork together with high low shifter shaft and washer NOTE Be careful not to drop the two high low shifter piec es 12 Remove the main shaft assembly and input shaft assembly CAUTION Be carefu...

Page 1877: ...tween Confirm that the speedometer gear is meshed Tightening torque 8 mm bolt 25 N m 2 5 kgf m 18 1 ft lb 10 mm bolt 39 N m 4 0 kgf m 28 9 ft lb 7 Tighten the ball bearing attachment bolts Tightening...

Page 1878: ...n Tighten the lock plate NOTE Carry out this job on both upper and lower retain ers Tightening torque T 25 N m 2 5 kgf m 18 1 ft lb 18 Selecting of main shaft rear plate Ref to 5MT 82 ADJUSTMENT Main...

Page 1879: ...10 Place the transmission with case left side fac ing downward and put ST1 on bearing cup 11 Screw the retainer assembly into left case from the bottom using ST2 Fit the ST3 on transmission main shaf...

Page 1880: ...he retainer lightly with plastic hammer 17 Inspect and adjust the backlash and tooth con tact of hypoid gear Ref to 5MT 107 INSPEC TION Front Differential Assembly 18 After checking the tooth contact...

Page 1881: ...earing outer race knock pin hole into transmission case knock pin NOTE Align the end face of seal with surface A when in stalling oil seal 3 Install the drive pinion assembly Ref to 5MT 93 INSTALLATIO...

Page 1882: ...NE REMOV ER 6 Using the ST1 and ST2 remove rest of the parts NOTE Replace the sleeve and hub with new ones Do not attempt to disassemble because they must engage at a specified point If they should be...

Page 1883: ...DEL 1 Assemble when each sleeve and hub assembly are disassembled NOTE Position the open ends of spring 120 apart 2 Install the 3rd drive gear baulk ring sleeve and hub assembly for 3rd needle bearing...

Page 1884: ...5th needle bearing race onto the rear section of transmission main shaft NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton Face the thrust washer in correct direction ST1 899...

Page 1885: ...ing ST1 and ST2 NOTE Secure the lock nuts in two places after tightening ST1 499987003 SOCKET WRENCH ST2 498937000 TRANSMISSION HOLDER Tightening torque 120 N m 12 2 kgf m 88 5 ft lb 2 AWD TURBO MODE...

Page 1886: ...MOVER ST2 499877000 RACE 4 5 INSTALLER 4 Install the baulk ring needle bearing 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Align the baulk ring and gear hub assembly with...

Page 1887: ...earing After press fitting make sure the synchro cone rotates freely ST 499757002 INSTALLER 9 Install the synchro cone stopper and snap ring to 5th Rev sleeve and hub assembly 10 Install the rest part...

Page 1888: ...dle bearing 32 30 25 7 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Face thrust washer in the correct direction 5 Drive ball bearing onto the rear section of trans mission...

Page 1889: ...ses When the sliding surface is damaged or abnor mally worn When the inner wall is abnormally worn 3 Gears Replace the gears with new ones if their tooth surfaces are broken damaged or excessively wor...

Page 1890: ...ansmission main case surface and select the proper plate in the following table NOTE Before measuring tap the end of main shaft with a plastic hammer lightly in order to make the clear ance zero betwe...

Page 1891: ...rive pinion assembly Ref to 5MT 93 INSTALLATION Drive Pinion Shaft Assem bly 5 Install the transmission case Ref to 5MT 69 INSTALLATION Transmission Case 6 Install the transfer case with extension cas...

Page 1892: ...and Do not reuse the ball bearing ST1 499757002 INSTALLER ST2 498077400 SYNCHRO CONE REMOV ER 6 Using the ST1 and ST2 remove rest of the parts NOTE Replace the sleeve and hub with new ones Do not atte...

Page 1893: ...77000 RACE 4 5 INSTALLER 4 Install the baulk ring needle bearing 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Face the thrust washer in correct direction A Sleeve and hub...

Page 1894: ...ll the baulk ring and synchro cone onto 5th Rev sleeve and hub assembly using ST and a press NOTE Use a new ball bearing After press fitting make sure the synchro cone rotates freely ST 499757002 INST...

Page 1895: ...arings having other defects 2 Bushing each gear Replace the bushing in the following cases When the sliding surface is damaged or abnor mally worn When the inner wall is abnormally worn 3 Gears Replac...

Page 1896: ...5MT 88 MANUAL TRANSMISSION AND DIFFERENTIAL MAIN SHAFT ASSEMBLY FOR DUAL RANGE F ADJUSTMENT Choose the main shaft rear plate Ref to 5MT 82 ADJUSTMENT Main Shaft Assembly for Single Range...

Page 1897: ...to 5MT 93 INSTALLATION Drive Pinion Shaft Assem bly 5 Install the transmission case Ref to 5MT 69 INSTALLATION Transmission Case 6 Install the transfer case with extension case as sembly Ref to 5MT 53...

Page 1898: ...s a guide in selecting a suitable snap ring ST1 899580100 INSTALLER ST2 399513600 INSTALLER 2 Install the snap ring on input shaft 3 Inspect the clearance between ball bearing and snap ring Ref to 5MT...

Page 1899: ...es if their tooth surfaces are broken damaged or excessively worn Correct or replace if the cone that contacts the baulk ring is rough or damaged Correct or replace if the inner surface or end face is...

Page 1900: ...T SHAFT ASSEMBLY Clearance 0 0 12 mm 0 0 0047 in If the measurement is not within specification se lect a suitable snap ring A Snap ring Snap ring Part No Thickness mm in 805028050 2 48 0 0976 8050280...

Page 1901: ...shim and tighten the bearing mounting bolts 4 Inspection and adjustment of ST NOTE Loosen the two bolts and adjust so that the scale indicates 0 5 correctly when the plate end and the scale end are on...

Page 1902: ...d of driven shaft on the fric tional side of thrust needle bearing to prevent damage during disassembly or reassembly 1 Straighten the lock nut at staked portion Re move the lock nut using ST1 ST2 and...

Page 1903: ...Except 1 6 L model 10 Remove the 2nd driven gear assembly 1 6 L model 11 Remove the 1st driven gear 2nd gear bushing gear and hub using ST1 and ST2 NOTE Replace the gear and hub if necessary Do not a...

Page 1904: ...o disassemble if at all possible because they must engage at a specified point If they have to be dis assembled mark the engaging point beforehand ST1 499757002 SNAP RING GUIDE ST2 899714110 REMOVER 8...

Page 1905: ...outer baulk ring and insert onto driven shaft Except 1 6 L model 6 Install the 2nd driven gear 1st 2nd bulk ring and insert onto driven shaft 1 6 L model 7 After installing the key on driven shaft ins...

Page 1906: ...en installing the roller bearing note its direc tions front and rear because the knock pin hole in outer race is offset 12 Install the washer using ST1 ST2 and press NOTE Discard the old lock nuts rep...

Page 1907: ...placed Be sure the insert keys are correctly located in the insert key grooves inside the reverse driven gear A Driven shaft B Drive shaft C Drive pinion collar D Needle bearing 25 30 20 E Washer No 2...

Page 1908: ...revious step to drive pinion shaft by hand NOTE Align ring groove with insert 6 Install 1st 2nd driven gear bushing to drive pin ion shaft using ST1 and ST2 ST1 499877000 RACE 4 5 INSTALLER ST2 499277...

Page 1909: ...ace with new ones Secure lock nut in four places Tightening torque 120 N m 12 2 kgf m 88 5 ft lb E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Re...

Page 1910: ...essed against the cone Clearance A 0 5 1 0 mm 0 020 0 040 in When the contact surface of the synchronizer ring insert is scored or abnormally worn down 5 Shifting insert key Replace the insert if defo...

Page 1911: ...the following table Repeat steps 1 through 4 to adjust starting torque 6 Recheck that the starting torque is within speci fied range then clinch the lock nut at four positions A Adjusting washer No 1...

Page 1912: ...seal 7 Remove the differential side retainers using ST ST 499787000 WRENCH ASSY B INSTALLATION 1 Install the differential side retainers using ST ST 499787000WRENCH ASSY 2 Install the bearing outer ra...

Page 1913: ...en the twelve bolts and remove the hypoid driven gear 3 Drive out the straight pin from differential assem bly toward hypoid driven gear ST 899904100 REMOVER 4 Pull out the pinion shaft and remove the...

Page 1914: ...jacent gear teeth during measurement ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18 mm 0 0051 0 0071 in 3 Align the pinion shaft and differential case at their holes an...

Page 1915: ...pinion shaft tooth surface are damaged excessively worn or seized The roller bearing on the drive pinion shaft has a worn or damaged roller path There is damage wear or seizure of the differ ential be...

Page 1916: ...check the backlash ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400 PLATE Backlash 0 13 0 18 mm 0 0051 0 0071 in NOTE If the backlash is outside specified range adjust it by turning t...

Page 1917: ...ges by 0 05 mm 0 020 in 3 TOOTH CONTACT OF HYPOID GEAR 1 Adjust until the tooth contact is correct 2 Check and adjust the tooth contact with follow ing Tooth contact Checking item Tooth contact patter...

Page 1918: ...ar Toe contact Inside end contact Checking item Contact areas is small Contact pattern Corrective action Increase thickness of drive pin ion shim in order to bring drive pinion close to driv en gear H...

Page 1919: ...shaft and press fit the oil seal with ST NOTE Use a new oil seal if it has been removed ST 899824100 or 499827000PRESS 2 Install the vehicle speed sensor Ref to 5MT 51 INSTALLATION Vehicle Speed Senso...

Page 1920: ...ear shaft and secure with straight pin NOTE Be sure to install the reverse idler shaft from rear side 2 Inspect and adjust the clearance between re verse idler gear and transmission case wall Ref to 5...

Page 1921: ...reverse idler gear and shaft for dam age Replace if damaged D ADJUSTMENT 1 Select the appropriate reverse shifter lever from the table below and adjust until the gap between the reverse idler gear and...

Page 1922: ...Dual Range 7 Remove the differential assembly Ref to 5MT 104 REMOVAL Front Differential Assembly 8 Drive out the straight pin with ST and 5th shifter fork ST 398791700 STRAIGHT PIN REMOVER 9 Remove t...

Page 1923: ...e sure the interlock plunger installing be fore is on the reverse fork rod side ST 398791700 STRAIGHT PIN REMOVER 8 Install the 5th shifter fork onto the rear of reverse fork rod Align holes in the tw...

Page 1924: ...ifter fork as re quired Clearance a and b 7 3 mm 0 287 in 5 Inspect the clearance between 5th drive gear and coupling sleeve If any clearance is not within specifications replace the shifter fork as r...

Page 1925: ...0 055 in Clearance B 3rd 4th to 5th 0 5 1 3 mm 0 020 0 051 in 5th shifter fork Non turbo Part No Mark Remarks 32812AA201 4 Approach to 5th gear by 0 2 mm 0 008 in 32812AA211 5 Standard 32812AA221 6 Be...

Page 1926: ...t side Be careful not to drop the two needle bearings and collar contained in counter gear B INSTALLATION 1 Install the O ring and straight pin onto counter gear shaft 2 Install the following parts in...

Page 1927: ...0 05 0 35 mm 0 0020 0 0138 in 2 If the clearance is out of measured value select a snap ring and install to put clearance within mea sured value Ref to 5MT 119 ADJUSTMENT Counter Gear D ADJUSTMENT Se...

Page 1928: ...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 Replace e Exc...

Page 1929: ...of the differential and hypoid gear always appear as noise problems Therefore noise is the first indication of the trouble However noises from the engine muffler tire exhaust gas bear ing body etc are...

Page 1930: ...5MT 122 MANUAL TRANSMISSION AND DIFFERENTIAL GENERAL DIAGNOSTIC...

Page 1931: ...up Light Switch 45 11 Neutral Position Switch 47 12 Extension Case 49 13 Reverse Checking System 55 14 Transfer Drive Gear 58 15 Transfer Driven Gear 60 16 Center Differential 62 17 Oil Pump 63 18 Tra...

Page 1932: ...o 3 900 Rear reduc tion gear Transfer Type of gear Helical Gear ratio 1 100 1 000 Final Type of gear Hypoid Gear ratio 3 545 3 900 Front differ ential Type and number of gear Straight bevel gear Bevel...

Page 1933: ...ightening torque N m kgf m ft lb 2 Oil seal 9 Speedometer driven gear T1 6 4 0 65 4 7 3 Snap ring 10 Snap ring T2 41 4 2 30 2 4 Washer 11 Gasket T3 50 5 1 36 9 5 Speedometer gear shaft 12 Oil seal T4...

Page 1934: ...hose 7 Plug 13 Oil chamber 2 Transmission harness stay 8 Gasket 3 Plug 9 Spring Tightening torque N m kgf m ft lb 4 Gasket 10 Ball T1 6 4 0 65 4 7 5 Spring 11 Lubrication pipe T2 37 3 8 27 3 6 Plunger...

Page 1935: ...ch 10 Pressure relief valve T1 13 1 3 9 6 3 Back up light switch 11 Return spring T2 16 1 6 11 8 4 O ring 12 Ball T3 32 3 3 23 6 5 Adapter plate 13 Plunger T4 34 3 5 25 1 6 Transmission case 14 Spring...

Page 1936: ...n Tightening torque N m kgf m ft lb 2 Oil pump cover 9 Plate T1 6 4 0 65 4 7 3 Oil guide 10 Gasket T2 10 1 0 7 4 4 Oil pump driven gear ASSY 11 Oil guide T3 25 2 5 18 1 5 Oil pump rotor ASSY 12 Oil pi...

Page 1937: ...l 30 Spring 5 Oil plate 18 Oil seal 31 Gasket 6 Snap ring 19 Dust cover 32 Plug 7 Oil pump drive gear 20 Snap ring 33 Plunger 8 Center differential 21 Washer 9 Shim 22 Bush Tightening torque N m kgf m...

Page 1938: ...19 3rd 4th fork rod 4 Reverse interlock block 12 Reverse shifter arm 20 3rd 4th shifter arm 5 Interlock arm 13 Reverse fork rod 21 1st 2nd shifter arm 6 Striking rod 14 Selector arm COMPL 22 3rd 4th f...

Page 1939: ...ing 15 Needle bearing 26 Snap ring 5 Synchro cone 16 5th drive gear 27 Washer 6 Outer baulk ring 17 5th baulk ring 28 Washer 7 3rd 4th sleeve 18 5th 6th sleeve 29 Lock nut 8 3rd 4th hub 19 5th 6th hub...

Page 1940: ...o cone Tightening torque N m kgf m ft lb 6 Thrust bearing 18 Inner baulk ring T1 285 29 1 210 265 27 0 195 7 Needle bearing 19 2nd driven gear 8 Driven shaft 20 Needle bearing T2 570 58 1 420 530 54 0...

Page 1941: ...Reverse idler gear 18 Spring pin 3 Reverse idler gear No 2 11 Spring 19 Knock pin 4 Needle bearing 12 Sub gear 5 Reverse idler synchro set 13 Friction plate Tightening torque N m kgf m ft lb 6 Revers...

Page 1942: ...erential case 16 Speedometer drive gear 3 Pinion shaft 10 Oil seal 4 Straight pin 11 Differential side retainer Tightening torque N m kgf m ft lb 5 Washer 12 O ring T1 25 2 5 18 1 6 Differential bevel...

Page 1943: ...ft 6 Differential side retainer 11 Speedometer drive gear 2 Hypoid driven gear 7 O ring 3 Roller bearing 8 Axle drive shaft Tightening torque N m kgf m ft lb 4 Differential case ASSY 9 Retainer lock p...

Page 1944: ...N m kgf m ft lb 2 Spacer T1 7 5 0 76 5 5 3 Cushion C 9 Rear plate T2 35 3 6 25 8 4 Front plate 10 Front crossmember T3 50 5 1 36 9 5 Rear cushion rubber 11 Center crossmember EUROPE model T4 58 5 9 4...

Page 1945: ...o tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply gear oil onto sliding or revolution surfaces before installation Re...

Page 1946: ...g main shaft axial end play 498247001 MAGNET BASE Used for measuring backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring backla...

Page 1947: ...aper roller bear ing 899858600 REMOVER Used for removing roller bearing 399513600 INSTALLER Used for installing oil seal 499757002 INSTALLER Used for installing bearing cone of transfer driven gear ex...

Page 1948: ...RESS Used for installing speedometer oil seal when installing speedometer cable to transmission 499877000 RACE 4 5 INSTALLER Used for disassembling driven shaft and transfer driven gear 899864100 REMO...

Page 1949: ...ving and installing straight pin 899824100 PRESS Used for installing speedometer shaft oil seal 498057300 INSTALLER Used for installing extension oil seal 498255400 PLATE Used for measuring backlash I...

Page 1950: ...AA020 ENGINE SUPPORT Used for supporting engine 398527700 PULLER ASSY Used for removing extension case oil seal and clutch housing oil seal 398643600 GAUGE Used for measuring total end play extension...

Page 1951: ...d for removing and installing neutral set spring Used with CLAW 18756AA000 499247300 INSTALLER Used for removing axle shaft Used with REMOVER ASSY 499095500 499095500 REMOVER ASSY Used for removing ax...

Page 1952: ...ball bear ing 499797000 OIL SEAL INSTALLER Used for installing differential side retainer oil seal 498077610 REMOVER Used for removing speedometer drive gear 398497701 SEAT Used for installing transfe...

Page 1953: ...498745600 INSTALLER Used for installing oil pump drive gear 18632AA000 STAND ASSY Used for disassembling and assembling trans mission 18671AA000 OIL SEAL GUIDE Used for installing oil seal to reverse...

Page 1954: ...with OIL SEAL GUIDE 18671AA000 18657AA000 INSTALLER Used for installing oil seal to shift rod 18758AA000 PULLER Used for removing extension taper roller bearing outer race 18831AA000 GAUGE Used for me...

Page 1955: ...18756AA000 CLAW Used for installing and removing neutral set spring Used with INSTALLER 399893600 18754AA000 REMOVER Used for removing each parts of driven gear 18757AA000 STRAIGHT PIN REMOVER Used fo...

Page 1956: ...t lock nut Used with BASE 18664AA000 18667AA000 HOLDER Used for installing and removing drive pinion shaft lock nut Used with BASE 18664AA000 18664AA000 BASE Used for installing and removing main shaf...

Page 1957: ...sed for disassembling main shaft TY856WN model 18651AA000 INSTALLER Used for assembling main shaft 18852AA000 TORQUE WRENCH Used for tightening main shaft lock nut Used for tightening drive pinion sha...

Page 1958: ...ock nut 18669AA000 PUNCH Used for caulking driven shaft lock nut 18670AA000 PUNCH Used for caulking drive pinion shaft lock nut 18620AA000 ADAPTER WRENCH Used for installing and removing driven gear s...

Page 1959: ...shaft lock nut 18723AA000 REMOVER Used for disassembling the driven shaft 18630AA000 WRENCH ASSY Used for removing and installing differential side retainer left side 18672AA000 GUIDE CLIP Used for i...

Page 1960: ...isassembling main shaft 18654AA000 INSTALLER Used for assembling driven shaft 18663AA000 SOCKET Used for installing and removing oil pump cover 18853AA000 HEIGHT GAUGE Used for selecting shift rod ILL...

Page 1961: ...NERAL PURPOSE TOOLS 18760AA000 CLAW Used for removing front side retainer bearing outer race Used with PULLER ASSEMBLY 398527705 TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage...

Page 1962: ...CAUTION Directly after the engine has been running the transmission gear oil is hot Be careful not to burn yourself NOTE Tighten the transmission gear oil drain plug after draining transmission gear o...

Page 1963: ...kgf m 32 5 ft lb Clutch housing side 70 N m 7 1 kgf m 51 6 ft lb 3 Remove the rear exhaust pipe and muffler 4 Remove the propeller shaft Ref to DS 15 RE MOVAL Propeller Shaft 5 Using the ST remove the...

Page 1964: ...t and then install it Tightening torque 5 9 N m 0 6 kgf m 4 4 ft lb NOTE Ensure the sensor mounting hole is clean and free of foreign matter Discard the vehicle speed sensor and after re moval replace...

Page 1965: ...ways support the transmission case with a transmission jack 7 Remove the rear crossmember 8 Remove the rear cushion rubber B INSTALLATION 1 PITCHING STOPPER 1 Install the pitching stopper Tightening t...

Page 1966: ...ion below are not satisfactory 1 PITCHING STOPPER Make sure that the pitching stopper is not bent or damaged Make sure that the rubber is not stiff cracked or otherwise damaged 2 CROSSMEMBER AND CUSHI...

Page 1967: ...isconnect the connector located on upper side of transmission 8 Disconnect the ground cable at upper side of transmission case and body 9 Remove the starter assembly Ref to SC H4SO 7 REMOVAL Starter 1...

Page 1968: ...nk from housing 18 Using the ST remove the spring pin of front drive shaft ST 398791700 REMOVER NOTE Do not reuse the spring pin 19 Remove the front drive shaft 20 Set the transmission jack under the...

Page 1969: ...is inserted completely Make sure the rear side of engine is lowered Tightening torque 50 N m 5 1 kgf m 36 9 ft lb 3 Move the transmission to the right side then in stall the joint COMPL bolt stay bolt...

Page 1970: ...the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 36 9 ft lb T2 58 N m 5 9 kgf m 42 8 ft lb 8 Install the clutch operating cylinder Tightening torque 41 N m 4 2 kgf m 30 2 ft lb NOTE Check th...

Page 1971: ...kgf m 33 2 ft lb NOTE Discard the loosened self locking nut and replace with a new one 16 Install the propeller shaft Ref to DS 16 IN STALLATION Propeller Shaft 17 Install the center exhaust pipe Ref...

Page 1972: ...4 5 kgf m 32 5 ft lb Clutch housing 70 N m 7 1 kgf m 51 6 ft lb 3 Attach the transmission to ST ST 18632AA000 STAND ASSY 4 Rotating parts should be coated with oil prior to assembly 5 All disassemble...

Page 1973: ...ION AND DIFFERENTIAL AIR BREATHER HOSE 8 Air Breather Hose A REMOVAL Disconnect the air breather hose B INSTALLATION Install the air breather hose C INSPECTION Make sure the hose is not cracked or clo...

Page 1974: ...INSTALLATION Install in the reverse order of removal NOTE Always use a new gasket Tightening torque 32 N m 3 3 kgf m 23 6 ft lb C INSPECTION 1 Make sure there is no damage on pipe If there is damage r...

Page 1975: ...Tightening torque 32 N m 3 3 kgf m 23 6 ft lb 2 Connect the back up light switch connector 3 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assemb...

Page 1976: ...ntercooler 3 Disconnect the transmission harness and chas sis harness 4 Measure the resistance between back up light switch terminals If it is not within specifications re place the back up light swit...

Page 1977: ...switch Tightening torque 32 N m 3 3 kgf m 23 6 ft lb 2 Connect the neutral position switch connector and clip 3 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual T...

Page 1978: ...ercooler 3 Disconnect the transmission harness and chas sis harness 4 Measure the resistance between neutral posi tion switch terminals If it is not within specifica tions replace the neutral position...

Page 1979: ...case Ref to 6MT 51 ADJUSTMENT Extension Case 2 Apply oil lightly to the outer periphery of bearing cone and then install it to extension case 3 Select the thrust washer of transfer drive gear and the...

Page 1980: ...g Sys tem 2 Install the extension case oil seal Ref to 6MT 33 REPLACEMENT Oil Seal 3 Using the ST install the shifter arm oil seal ST1 18657AA000 INSTALLER ST2 18671AA000 OIL SEAL GUIDE 4 Install the...

Page 1981: ...1 TRANSFER DRIVEN GEAR BEARING THRUST WASHER ADJUSTMENT 1 Using the ST remove the bearing cone from ex tension case ST 18758AA000 PULLER 2 Remove the thrust washer 3 Measure the depth Z between end o...

Page 1982: ...between end of ST and bearing cone ST 18831AA000 GAUGE 14 Calculate the value t of transfer driven gear bearing thrust washer using the following equation t Z 100 Y 0 04 to 0 11 mm 0 0016 to 0 0043 i...

Page 1983: ...set spring and support ST1 18756AA000 CLAW ST2 398663600 PLIERS 20 Install the snap ring 21 Install the center differential 2 SELECTING THE TRANSFER DRIVE GEAR THRUST WASHER 1 Measure the height Z bet...

Page 1984: ...d transfer drive gear 0 45 0 65 mm 0 018 0 026 in 5 Install the selected thrust washer t mm in Thickness of transfer drive gear thrust washer Y mm in Depth from end of ST to transfer drive gear Z mm i...

Page 1985: ...ring and washer from reverse check shaft 5 Remove the reverse check shaft and spring from extension case 6 Remove the spring pin and then remove the re verse check lever and oil seal from reverse chec...

Page 1986: ...se check shaft to ex tension case NOTE Be sure the spring end aligns with the hole of re verse check shaft and cutout portion of extension case 4 Install the washer and snap ring 5 Set the ST1 to reve...

Page 1987: ...Transmission Assembly C INSPECTION 1 Make sure there is no damage on each parts 2 Make sure the reverse check lever operates smoothly 3 Make sure there is no oil leakage on oil seal part of reverse ch...

Page 1988: ...1 ft lb 2 If the ball bearing transfer drive gear or snap ring is replaced select the transfer drive gear thrust washer Ref to 6MT 50 ASSEMBLY Extension Case 3 Install the extension case Ref to 6MT 49...

Page 1989: ...ive gear Replace the drive gear in the following cases If their tooth surface and shaft are excessively broken or damaged 3 Measure the clearance between snap ring and inner race of ball bearing with...

Page 1990: ...sher Ref to 6MT 51 ADJUSTMENT Extension Case 3 Install the extension case Ref to 6MT 49 IN STALLATION Extension Case 4 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION M...

Page 1991: ...of 10 kN 1 ton 1 1 US ton 1 0 Imp ton E INSPECTION 1 Bearings Replace the bearing in following cases Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make ab normal nois...

Page 1992: ...NSTALLATION 1 Install the needle bearing 2 Install the thrust washer and center differential 3 If replacing the center differential select the transfer drive gear and thrust washer and install Ref to...

Page 1993: ...driven gear Ref to 6MT 60 REMOVAL Transfer Driven Gear 5 Remove the center differential Ref to 6MT 62 REMOVAL Center Differential 6 Remove the oil guide 7 Remove the snap ring 8 Using the ST remove th...

Page 1994: ...Remove the oil pump rotor B INSTALLATION 1 Apply oil to the outer periphery of outer rotor then install to transmission case 2 Install the thrust washer to main shaft part 3 Install the oil pump cove...

Page 1995: ...erential 13 Install the transfer driven gear Ref to 6MT 60 INSTALLATION Transfer Driven Gear 14 Install the extension case Ref to 6MT 49 IN STALLATION Extension Case 15 Install the manual transmission...

Page 1996: ...ERENTIAL OIL PUMP 3 Side clearance Measure to the transmission case and rotor Re place the inner rotor and outer rotor as a set if clear ance exceeds specification Specification of side clearance 0 03...

Page 1997: ...tension Case 5 Remove the transfer driven gear Ref to 6MT 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6MT 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6MT 63...

Page 1998: ...ng through the pilot bolt installation hole If not aligned remove the transmission case then shift each shifter fork and interlock block to neutral posi tion 5 Using a new gasket install the pilot bol...

Page 1999: ...ack up light switch and harness Ref to 6MT 44 INSTALLATION Oil Pipe Ref to 6MT 47 IN STALLATION Neutral Position Switch Ref to 6MT 45 INSTALLATION Back up Light Switch 15 Install the manual transmissi...

Page 2000: ...the oil strainer D ASSEMBLY 1 Install the oil strainer and magnet Tightening torque 10 N m 1 0 kgf m 7 4 ft lb 2 Apply liquid gasket to the oil pan Liquid gasket THREE BOND 1215 3 Install the oil pan...

Page 2001: ...INSPECTION 1 Completely remove with shop cloth if sludge is adhered to the oil pan magnet 2 Make sure there is no clog on the oil strainer If clogged remove clog or replace the oil strainer 3 Make sur...

Page 2002: ...e the center differential Ref to 6MT 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6MT 63 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 67 REMOVAL Transmission Case 9 Remov...

Page 2003: ...the driven gear assembly to 1st 2nd shifter fork assembly 4 Install the main shaft assembly to 3rd 4th shifter fork and then assemble to driven gear assembly 5 Install the 5th 6th shifter fork assemb...

Page 2004: ...ly driven gear assembly and reverse idler gear as sembly then install to the adapter plate at once NOTE Two people should do the work 10 Install the plunger checking spring new gasket and checking plu...

Page 2005: ...f to 6MT 60 INSTALLATION Transfer Driven Gear 21 Install the extension case Ref to 6MT 49 IN STALLATION Extension Case 22 Install the oil pipe neutral position switch back up light switch and harness...

Page 2006: ...899864100 REMOVER 6 Remove the 5th 6th sleeve 6th needle bearing and 6th baulk ring 7 Set the ST on 3rd drive gear then remove each part using press ST 18720AA000 REMOVER D ASSEMBLY NOTE Replace the f...

Page 2007: ...h hub and 4th bush 1 Set to the main shaft taking care of 3rd 4th hub installing direction 2 Set to the main shaft taking care not to overlap the main shaft oil hole and 4th bush oil hole 3 Using the...

Page 2008: ...key in proper place of 3rd 4th sleeve NOTE Angle of each shifting insert key is 120 apart 7 Install the 3rd 4th sleeve to 3rd 4th hub NOTE 3rd 4th sleeve has a groove for identification Install the 3r...

Page 2009: ...bush oil hole 2 Using the ST press in the 5th bush ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 kN 4 0 ton 4 4 US ton 3 9 Imp ton 12 Make sure the 4th...

Page 2010: ...not apply pressure in excess of 40 kN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE When pressing in 5th 6th hub align the protrusion portion of outer baulk ring and cutout portion of 5th 6th bush by moving the...

Page 2011: ...two grooves for identification Install the 5th 6th sleeve with the groove facing to 5th drive gear side 20 Install the 6th baulk ring 21 Sufficiently apply gear oil to the main shaft 6th needle beari...

Page 2012: ...y pressure in excess of 40 kN 4 0 ton 4 4 US ton 3 9 lmp ton 28 Using the ST install the retainer and outer bearing inner race ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pre...

Page 2013: ...n the sliding surface is damaged or abnor mally worn 3 Gears Replace the gears in the following cases Gear teeth surfaces are broken or excessively worn Parts that contact the baulk ring is damaged Th...

Page 2014: ...area in the figure during measurement 3 Measure the height to edge surface of ball bear ing height A1 NOTE Set the indicator of height gauge near measuring object then lock the dial 1 as shown in the...

Page 2015: ...270 83 271 40 10 66 10 69 805072010 1 65 0 065 271 41 271 98 10 69 10 71 805072011 1 95 0 077 271 99 272 56 10 71 10 73 805072012 2 25 0 089 A1 mm in Part No Thickness mm in 270 83 271 40 10 66 10 69...

Page 2016: ...6MT 119 ADJUSTMENT Shifter Fork and Rod 3 Install the thrust needle bearing NOTE Make sure to install the thrust needle bearing in proper direction 4 Install the 1st needle bearing 5 Install the drive...

Page 2017: ...g 5th 6th driven gear and 3rd 4th driven gear ST1 18723AA000 REMOVER ST2 499877000 REMOVER 5 Remove the driven gear key 6 Remove the 2nd gear 7 Remove the needle bearing and 1st 2nd sleeve 8 Remove th...

Page 2018: ...of 1st driven gear 2 Install the 1st needle bearing 3 Install the 1st driven gear to driven shaft 4 Install the inner baulk ring 5 Align protrusion portions of the 1st synchro cone to the holes of 1s...

Page 2019: ...f not reassemble 10 Install the shifting insert key in proper place of 1st 2nd sleeve NOTE Angle of each shifting insert key is 120 apart 11 Install the 1st 2nd sleeve to 1st 2nd hub NOTE Make sure to...

Page 2020: ...n portion of 2nd synchro cone with 2nd driven gear hole then install 17 Install the key 18 Using the ST install the 3rd 4th driven gear ST 18654AA000 INSTALLER CAUTION Do not apply pressure in excess...

Page 2021: ...the ST install the ball bearing ST 18654AA000INSTALLER CAUTION Do not apply pressure in excess of 40 kN 4 0 ton 4 4 US ton 3 9 lmp ton NOTE Make sure to install the ball bearing in proper direc tion...

Page 2022: ...se when turned Bearings having other defects 2 Bushing each gear Replace the bushings in the following case When the sliding surface is damaged or abnor mally worn 3 Gears Replace the gears in the fol...

Page 2023: ...djust backlash closest to specification Backlash specification at axial direction of driv en gear assembly 0 1 0 3 mm 0 0039 0 0118 in A Transmission case B Ball bearing C Driven gear assembly t Thick...

Page 2024: ...d Rod 2 Install the reverse idler gear assembly Ref to 6MT 73 INSTALLATION Main Shaft Assembly 3 Install the transmission case Ref to 6MT 68 INSTALLATION Transmission Case 4 Install the oil pump Ref t...

Page 2025: ...ing from reverse sleeve 8 Remove the reverse idler gear No 2 9 Remove the washer and needle bearing 10 Remove the knock pin 11 Remove the snap ring and friction plate from reverse gear A Reverse sleev...

Page 2026: ...e friction plate and snap ring NOTE Make sure to install the friction plate in proper di rection 3 Sufficiently apply gear oil to the shaft needle bearing and inner periphery of reverse drive gear 4 I...

Page 2027: ...e to install the reverse sleeve in proper di rection 9 Sufficiently apply gear oil to the collar needle bearing and inner periphery of reverse drive gear 10 Install the outer baulk ring reverse synchr...

Page 2028: ...ushings in the following case When the sliding surface is damaged or abnor mally worn 3 Gears Replace the gears in the following cases The gear teeth surfaces are broken or excessive ly worn The parts...

Page 2029: ...t on drive plate and clutch housing 2 Apply liquid gasket to the clutch housing Liquid gasket THREE BOND 1215 3 Install each gear assembly Ref to 6MT 73 IN STALLATION Main Shaft Assembly 4 Install the...

Page 2030: ...pin ion NOTE Note dimension A for selection of drive pinion shim ST 398643600 GAUGE 2 Install the inner bearing inner race to drive pinion shaft using ST and press ST 18723AA000 REMOVER CAUTION Do not...

Page 2031: ...ock nut to obtain dimension A 37 0 5 mm 1 46 0 02 in ST 18670AA000 PUNCH NOTE Do not crack the caulking part of lock nut 8 Using the ST measure dimension B of the drive pinion ST 398643600 GAUGE 9 Cal...

Page 2032: ...smoothly or make ab normal noise when turned 4 Adapter plate Replace the adapter plate in the following cases Worn rusted and damaged bearing Damaged adapter plate 5 Make sure the pipe and pipe chambe...

Page 2033: ...toward heel Face contact Checking item Backlash is too large Contact pattern Corrective action Verify the backlash again and then adjust it Flank contact Checking item Backlash is too small Contact pa...

Page 2034: ...L DRIVE PINION SHAFT ASSEMBLY Heel contact Outside end contact Checking item Contact areas is small Contact pattern Corrective action Increase thickness of drive pin ion shim in order to bring drive p...

Page 2035: ...e the transfer driven gear Ref to 6MT 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6MT 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6MT 63 RE MOVAL Oil Pump 8...

Page 2036: ...side retainer to both side ST1 499787000 WRENCH ASSY RIGHT SIDE ST2 18630AA000 WRENCH ASSY LEFT SIDE NOTE Be careful not to damage the oil seal 5 Install the axle shaft NOTE Replace the circlip with a...

Page 2037: ...LLATION Main Shaft Assembly 17 Install the transmission case Ref to 6MT 68 INSTALLATION Transmission Case 18 Install the oil pump Ref to 6MT 64 INSTAL LATION Oil Pump 19 Install the center differentia...

Page 2038: ...etween the speedometer drive gear and roller bearing NOTE Be careful not to damage the differential case 6 Using the ST remove the roller bearing ST 498077000 REMOVER 2 SIDE RETAINER 1 Remove the O ri...

Page 2039: ...EVEL PINION GEAR BACKLASH IN SPECTION Front Differential Assembly 4 Using the ST align the pinion shaft and differen tial case at their holes and then drive the straight pin into holes ST 899904100 RE...

Page 2040: ...ail to turn smoothly or make ab normal noise when turned 1 BEVEL PINION GEAR BACKLASH Measure the bevel pinion gear backlash If it is not within specifications install a suitable washer to adjust it R...

Page 2041: ...pinion gear backlash Ref to 6MT 110 BEVEL PINION GEAR BACKLASH INSPECTION Front Differential Assembly 2 Disassemble the differential case Ref to 6MT 107 DIFFERENTIAL CASE DISASSEMBLY Front Differenti...

Page 2042: ...on is 0 backlash 6 Mark an engagement point on the right and left side retainer and clutch housing 7 Return the left side retainer for three teeth and screw in the right side retainer for three teeth...

Page 2043: ...9 Remove each gear assembly Ref to 6MT 72 REMOVAL Main Shaft Assembly 10 Remove the drive pinion shaft assembly Ref to 6MT 99 REMOVAL Drive Pinion Shaft Assem bly 11 Remove the front differential ass...

Page 2044: ...6MT 68 INSTALLATION Transmission Case 9 Install the oil pump Ref to 6MT 64 INSTAL LATION Oil Pump 10 Install the center differential Ref to 6MT 62 INSTALLATION Center Differential 11 Install the trans...

Page 2045: ...ar assembly at once Ref to 6MT 73 INSTALLATION Main Shaft Assembly 2 Install the transmission case Ref to 6MT 68 INSTALLATION Transmission Case 3 Install the oil pump Ref to 6MT 64 INSTAL LATION Oil P...

Page 2046: ...the ST remove the 5th 6th shifter fork ST 398791700 REMOVER 2 Using the ST remove the 5th 6th shifter arm ST 398791700 REMOVER 4 SHIFT ARM SHAFT Using the ST remove the selector arm ST 398791700 REMOV...

Page 2047: ...he ST install the reverse arm ST 398791700 REMOVER NOTE Make sure to install the reverse arm and rod in proper direction 2 1st 2nd 3rd 4th SHIFTER FORK 1 Using the ST install the 1st 2nd shifter fork...

Page 2048: ...t 2nd shifter arm 5 Using the ST install the 3rd 4th shifter fork ST 398791700 REMOVER NOTE Make sure to install the 3rd 4th shifter fork in proper direction 3 5th 6th SHIFTER FORK 1 Using ST install...

Page 2049: ...rse interlock block and interlock block to striking rod NOTE Make sure to install the reverse interlock block and interlock block in proper direction E INSPECTION 1 Check the shift shaft and shift rod...

Page 2050: ...n shaft snap ring Ref to 6MT 83 ADJUSTMENT Main Shaft Assembly 4 Shift the 1st 2nd sleeve to 1st driven gear side then press down to the stopper and measure B1 NOTE Set the indicator of height gauge n...

Page 2051: ...n NOTE The indicator is installed upside down compared to the setting procedure of zero point Add d1 fixing value 55 mm 2 17 in from the following figure to B2 to obtain measurement value of B2 2 SELE...

Page 2052: ...he sleeve lifted up straight Measure five points of the sleeve turning every approx 72 Round off each two upper and lower measurement value Use the remaining center val ue as measurement value 2 Set t...

Page 2053: ...OF 5th 6th FORK ROD NOTE Perform the following procedures when Replacing the main shaft Replacing the 3rd to 6th drive gear and bush Replacing the 3rd to 6th synchro ring assembly Replacing the 3rd 4t...

Page 2054: ...asuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve 6th side Perform the measuring procedure with two peo ple and measure the sleeve l...

Page 2055: ...gear measurement value 55 mm 2 17 in D2 Length from main shaft rear bearing snap ring groove to sleeve groove edge when shift ed to 6th gear NOTE The indicator is installed upside down compared to th...

Page 2056: ...easurement Do not place the height gauge on shaded area in the figure during measurement 4 Press the reverse sleeve to reverse side idler gear No 2 then measure T NOTE Set the indicator of height gaug...

Page 2057: ...e verse sleeve neutral position Select the fork rod which applies to the calculated value from following equation Equation T 4 8 mm 0 189 in T 4 8 mm 0 189 in mm in Lot No Mark 33 50 33 80 1 3189 1 33...

Page 2058: ...meter Gear B INSTALLATION 1 Install the pitching stopper bracket Tightening torque 41 N m 4 2 kgf m 30 2 ft lb 2 Install the speedometer gear Ref to 6MT 113 INSTALLATION Speedometer Gear 3 Install the...

Page 2059: ...tall the clutch release bearing guide Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb E INSPECTION 1 Make sure there is no damage or crack on the clutch housing Replace the clutch housing with a new on...

Page 2060: ...nt 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 Replace e Excessive clearance between splines of s...

Page 2061: ...the differential and hypoid gear always appear as noise problems Therefore noise is the first indication of the trouble However noises from the engine muffler tire exhaust gas bear ing body etc are e...

Page 2062: ...6MT 132 MANUAL TRANSMISSION AND DIFFERENTIAL GENERAL DIAGNOSTIC TABLE...

Page 2063: ...Cover 20 3 Flywheel 24 4 Release Bearing and Lever 26 5 Operating Cylinder 29 6 Master Cylinder 31 7 Clutch Pipe and Hose 35 8 Clutch Fluid 37 9 Clutch Fluid Air Bleeding 38 10 Clutch Pedal 40 11 Clu...

Page 2064: ...mm in 3 4 0 12 0 16 3 4 0 12 0 16 Clutch disc Depth of rivet head mm in Standard 1 3 1 9 0 051 0 075 Limit of sinking 0 3 0 012 Limit for deflection mm in 0 8 0 031 at R 107 4 21 0 8 0 031 at R 110 4...

Page 2065: ...se lever sealing 7 Clip Tightening torque N m kgf m ft lb 2 Clutch cable bracket 8 Clutch release bearing T 16 1 6 11 8 3 Retainer spring 9 Clutch cover 4 Pivot 10 Clutch disk 5 Clutch release lever 1...

Page 2066: ...0 L SOHC MODEL 1 Clutch release lever sealing 6 Clutch release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 16 1 6 11 8 3 Pivot 8 Clutch disc T2 72 7 3 52 8 4 Clutch...

Page 2067: ...DEL 1 Clutch release lever seal 6 Release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 16 1 6 11 8 3 Pivot 8 Clutch disc T2 72 7 3 52 8 4 Release lever 9 Double mass f...

Page 2068: ...MODEL 1 Clutch release lever sealing 5 Clutch release bearing Tightening torque N m kgf m ft lb 2 Clutch release lever 6 Clutch cover T1 16 1 6 11 8 3 Clutch release lever shaft 7 Clutch disc T2 44 4...

Page 2069: ...MODEL 1 Operating cylinder 6 Pipe Tightening torque N m kgf m ft lb 2 Washer 7 Master cylinder ASSY T1 8 0 8 5 8 3 Clutch hose 8 Clevis pin T2 15 1 5 10 8 4 Bracket 9 Snap pin T3 18 1 8 13 0 5 Clip 1...

Page 2070: ...linder ASSY Tightening torque N m kgf m ft lb 2 Washer 8 Clevis pin T1 8 0 8 5 8 3 Clutch hose 9 Snap pin T2 15 1 5 10 8 4 Bracket 10 Pedal T3 18 1 8 13 0 5 Clip 11 Clamp T4 25 2 5 18 1 6 Clutch pipe...

Page 2071: ...6 Pipe Tightening torque N m kgf m ft lb 7 Master cylinder ASSY T1 8 0 8 5 8 2 Washer 8 Clevis pin T2 15 1 5 10 8 3 Clutch hose 9 Snap pin T3 18 1 8 13 0 4 Bracket 10 Lever T4 37 3 8 27 5 5 Clip 11 O...

Page 2072: ...al T1 7 5 0 76 5 53 2 Washer 10 Clamp T2 8 0 8 5 8 3 Clutch hose 11 Clutch pipe T3 15 1 5 10 8 4 Bracket 12 Bracket T4 18 1 8 13 0 5 Clip 13 Operating cylinder STi model T5 25 2 5 18 1 6 Master cylind...

Page 2073: ...rvoir cap 7 Gasket Tightening torque N m kgf m ft lb 2 Reservoir tank 8 Return spring T1 10 1 0 7 3 Oil seal 9 Piston T2 46 6 4 75 34 4 4 Straight pin 10 Push rod 5 Master cylinder 11 Piston stop ring...

Page 2074: ...r cap 7 Gasket Tightening torque N m kgf m ft lb 2 Reservoir tank 8 Return spring T1 10 1 0 7 3 Oil seal 9 Piston T2 46 6 4 75 34 4 4 Straight pin 10 Push rod 5 Master cylinder 11 Piston stop ring 6 C...

Page 2075: ...3 Cylinder boot 2 Reservoir tank 8 Master cylinder 3 Washer 9 Return spring Tightening torque N m kgf m ft lb 4 Clip 10 Piston T1 8 0 8 5 8 5 Hose 11 Push rod T2 10 1 0 7 6 Reservoir tank bracket 12 P...

Page 2076: ...just bolt 5 Brake pedal pad 16 Assist bushing 27 Clutch switch With cruise control 6 Brake pedal 17 Assist rod B 7 Clevis pin 18 Spring A Tightening torque N m kgf m ft lb 8 Brake pedal spring 19 Rod...

Page 2077: ...ch pedal T1 5 9 0 60 4 3 3 Clutch pedal bracket 11 Clutch cable T2 8 0 8 5 8 4 Snap pin 12 Clutch cable clamp T3 18 1 8 13 0 5 Brake pedal pad 13 Clip T4 29 3 0 21 7 6 Brake pedal 14 Spring assist 7 C...

Page 2078: ...3 Clutch pedal 11 Spring A 19 Clutch pedal bracket 4 Bushing 12 Rod S 5 Clutch clevis pin 13 Bushing B Tightening torque N m kgf m ft lb 6 Assist rod A 14 O ring T1 8 0 8 5 8 7 Clip 15 Clip T2 18 1 8...

Page 2079: ...clamp Tightening torque N m kgf m ft lb 2 Bushing 8 Spacer T1 5 9 0 6 4 3 3 Clutch pedal bracket 9 Bracket T2 8 0 8 5 8 4 Clutch pedal pad 10 Adjust bolt T3 18 1 8 13 0 5 Clutch pedal 11 Spring T4 29...

Page 2080: ...r manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces...

Page 2081: ...00 TORX PLUS Used for removing flywheel Dual mass fly wheel type For 2 5 L model TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage and ampere Dial Gauge Used for measuring clutch...

Page 2082: ...2 EXCEPT 2 5 L MODEL 1 Remove the transmission assembly from vehicle body Ref to 5MT 38 REMOVAL Manual Trans mission Assembly 2 Install the ST on flywheel ST 499747100 CRANKSHAFT STOPPER 3 Remove the...

Page 2083: ...bolts to specified torque NOTE When installing the clutch cover on flywheel po sition the clutch cover so that there is a gap of 120 or more between 0 marks on the flywheel and clutch cover 0 marks in...

Page 2084: ...eakage 2 5 L MODEL Except 2 5 L MODEL 4 Deflection on facing If deflection exceeds the specified value at the out er circumference of facing repair or replace ST 499747100 CLUTCH DISC GUIDE Limit for...

Page 2085: ...he following items without disas sembling and replace or repair if defective 1 Loose thrust rivet 2 Damaged or worn bearing contact area at center of diaphragm spring 2 5 L MODEL Except 2 5 L MODEL A...

Page 2086: ...and Cover 3 Using the ST remove the flywheel ST 498497100 CRANKSHAFT STOPPER B INSTALLATION 1 2 5 L MODEL 1 Install the flywheel and ST ST 498497100 CRANKSHAFT STOPPER 2 Tighten the flywheel attachin...

Page 2087: ...DEL INSTALLATION Clutch Disc and Cover 4 Install the transmission assembly Ref to 5MT 41 INSTALLATION Manual Transmission Assem bly C INSPECTION CAUTION Since this bearing is grease sealed and is of a...

Page 2088: ...in engine side 4 Remove the clutch release bearing from the clutch cover using flat type screwdriver B INSTALLATION 1 EXCEPT DOHC TURBO MODEL NOTE Before or during assembling lubricate the following...

Page 2089: ...rk into release bearing tab 3 Apply grease to the specified points SplineFX2200 Part No 000040901 ShaftSUNLIGHT 2 Part No 003602010 4 Insert the release fork shaft into release fork NOTE Make sure the...

Page 2090: ...when servicing the clutch 1 Check the bearing for smooth movement by ap plying force in the radial direction Radial direction stroke 1 4 mm 0 055 in 2 Check the bearing for smooth rotation by apply i...

Page 2091: ...TC 10 REMOVAL Intercooler 3 Remove the clutch hose from operating cylinder CAUTION Cover the hose joint to prevent clutch fluid from flowing out NON TURBO MODEL DOHC TURBO MODEL 5MT DOHC TURBO MODEL 6...

Page 2092: ...orque T1 18 N m 1 8 kgf m 13 0 ft lb T2 41 N m 4 2 kgf m 30 2 ft lb NOTE Be sure to install the clutch hose with the mark side facing upward Be careful not to twist the clutch hose during in stallatio...

Page 2093: ...uickly if spilt B INSTALLATION 1 Install the master cylinder to body and install the clutch pipe to master cylinder CAUTION Check that the pipe is routed properly Tightening torque T1 15 N m 1 5 kgf m...

Page 2094: ...ap ring to pre vent the rod washer piston and return spring from flying out 5 Remove the clutch damper 2 RHD DOHC TURBO MODEL 1 Remove the hose 2 Remove the reservoir tank and bracket 3 Remove the str...

Page 2095: ...4 ft lb 2 Apply a coat of grease to the contacting surfaces of the push rod and piston before installation Grease SILICONE GREASE G40M Part No 004404003 3 To assemble the master cylinder reverse the s...

Page 2096: ...rust or other faults are found on the cylinder piston push rod fluid reservoir return spring gasket clutch damper cylinder boot and hose replace the faulty part A Master cylinder body B Return spring...

Page 2097: ...et 5 Remove the hose from operating cylinder 6 Remove the bracket 2 RHD DOHC TURBO MODEL 1 Remove the intercooler Ref to IN H4DOTC 10 REMOVAL Intercooler 2 Drain the clutch fluid Ref to CL 37 Clutch F...

Page 2098: ...to CL 38 Clutch Fluid Air Bleeding Tightening torque T1 7 5 N m 0 76 kgf m 5 53 ft lb T2 8 N m 0 8 kgf m 5 8 ft lb T3 15 N m 1 5 kgf m 10 8 ft lb T4 18 N m 1 8 kgf m 13 0 ft lb T5 25 N m 2 5 kgf m 18...

Page 2099: ...ser voir tank filled with brake fluid to eliminate entry of air Clutch pedal operating must be very slow For convenience and safety it is advisable to have two men working The amount of brake fluid re...

Page 2100: ...rque T 8 N m 0 8 kgf m 5 8 ft lb 6 After depressing the clutch pedal make sure that there are no leaks evident in the entire system 7 After bleeding air from the system ensure that clutch operates pro...

Page 2101: ...e clutch pedal NOTE Set the air breather screw part higher than tip of op erating cylinder when performing this procedure 10 Repeat these steps until there are no more air bubbles in the vinyl tube CA...

Page 2102: ...from PHV Model with hill holder CAUTION Carefully protect the boot and inner cable from damage when disconnecting the PHV cable 8 Remove the nut which secures clutch master cylinder 9 Remove the bolts...

Page 2103: ...tch pedal Except 1 6 L model 5 Remove the master cylinder mounting nuts Ex cept 1 6 L model 6 Remove the PHV adjusting nut and lock nut Model with hill holder 7 Remove the cable clamp and disconnect t...

Page 2104: ...tion Ref to CL 45 ADJUSTMENT Clutch Pedal C DISASSEMBLY 1 LHD MODEL Except 1 6 L MODEL 1 Remove the clips assist spring rod and bush ing 2 Remove the spring pin and lever 3 Remove the clutch pedal and...

Page 2105: ...e the clip then pull out the clevis pin 3 Remove the assist rod spring and bushing 4 Remove the clutch pedal from clutch pedal bracket 5 Remove the following parts B to H from clutch pedal bracket A a...

Page 2106: ...s of pedal bracket clutch pedal and brake pedal then attach the brake pedal bushings spring and clutch cable 1 6 L model 5 Install the hill holder cable to clutch pedal Mod el with hill holder 2 RHD M...

Page 2107: ...PEDAL Except 1 6 L MODEL 1 Turn the lock nuts until clutch pedal full stroke length is within specifications CAUTION Do not attempt to turn the clutch switch to ad just clutch pedal full stroke length...

Page 2108: ...tracts Ensure that clutch fluid level in reservoir tank increases If the clutch fluid level in creases hydraulic the clutch is properly adjusted if fluid level does not increase or push rod does not r...

Page 2109: ...to twist the cable during adjust ment Play 3 4 mm 0 12 0 16 in Full stroke 24 26 mm 0 94 1 02 in 6 Upon completion of adjustment securely lock the spherical nut with lock nut Tightening torque 5 9 N m...

Page 2110: ...ch pedal to pedal bolt and connect the clutch cable to bracket with clamp 3 Connect the clutch cable end to pedal end 4 Connect the clutch cable to release lever 5 Install the grommet to toe board 6 A...

Page 2111: ...n adjust the stroke Ref to CL 45 ADJUSTMENT Clutch Pedal 3 Connect clutch switch connector C INSPECTION 1 If the clutch switch does not operate properly or if it does not stop at the specified positio...

Page 2112: ...lace 2 Clutch drags As a symptom of this trouble a harsh scratching noise develops and control becomes quite difficult when shifting gears The symptom becomes more apparent when shifting into the firs...

Page 2113: ...ragm spring Replace Trouble Corrective action Insufficient pedal play Adjust pedal play Clutch pedal free play insufficient Adjust pedal free play Excessively worn and damaged pedal shaft and or bushi...

Page 2114: ...CL 52 CLUTCH SYSTEM GENERAL DIAGNOSTIC TABLE...

Page 2115: ...nced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during re...

Page 2116: ......

Page 2117: ...1 General Description 2 2 Wheel Alignment 7 3 Front Transverse Link 16 4 Front Ball Joint 19 5 Front Strut 20 6 Front Stabilizer 24 7 Front Crossmember 25 8 Sub Frame 26 9 Front Support Arm 28 10 Gen...

Page 2118: ...0 0 20 0 05 Caster common difference 0 45 3 25 3 35 3 25 3 35 3 25 Toe in 0 3 mm 0 0 12 in Each toe angle 0 07 30 Kingpin angle tolerance 0 45 14 20 14 35 13 30 13 45 13 20 Wheel arch height tolerance...

Page 2119: ...B COMPONENT FS 00093 T8 T9 T3 16 33 34 15 11 28 28 26 25 24 23 22 21 20 19 18 17 28 1 2 28 5 4 3 6 28 7 8 9 27 10 28 28 28 4 11 8 31 9 27 28 10 12 15 30 32 29 28 14 13 12 T7 T11 T10 T15 T14 T5 T12 T6...

Page 2120: ...lper T5 40 4 1 30 7 Stopper rubber Front 24 Coil spring T6 45 4 6 33 8 Ball joint 25 Damper strut T7 50 5 1 37 9 Transverse link 26 Adjusting bolt T8 55 5 6 41 10 Cotter pin 27 Castle nut T9 70 7 1 52...

Page 2121: ...val installation disassembly and replacement Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Before securing a part on a v...

Page 2122: ...7680000 INSTALLER REMOVER SET Used for replacing transverse link bushing 927760000 STRUT MOUNT SOCKET Used for disassembling and assembling strut and shock mount TOOL NAME REMARKS Alignment gauge Used...

Page 2123: ...spension part deformed excessive play Check adjust and or measure the wheel alignment in accordance with procedures indicated in the figure Wheel arch height Front and rear Ref to FS 8 WHEEL ARCH HEIG...

Page 2124: ...t directly above center of wheel 5 Measure the distance between measuring point A and center of wheel 1 Wheel arch height 4 Front wheel arch height 7 Measuring point 2 Front fender 5 Rear wheel arch h...

Page 2125: ...S 2 SPECIFICATIONS General Description Rear Ref to RS 2 SPECIFICATIONS General Description Front Camber Adjustment 1 Loosen the two self locking nuts located at lower front portion of strut NOTE When...

Page 2126: ...he wheel alignment gauge ST 927380002 ADAPTER 3 Follow the wheel alignment gauge operation manual to measure caster angle NOTE Refer to the SPECIFICATIONS for caster values Ref to FS 2 SPECIFICATIONS...

Page 2127: ...e the dis tance A between marks 3 Move the vehicle forward to rotate wheels 180 NOTE Whenever rotating the wheels drive the vehicle for ward 4 Measure the distance B between right and left marks Toe i...

Page 2128: ...Adjustment 1 Loosen the self locking nut on inner side of link rear NOTE When loosening or tightening the adjusting bolt hold the bolt head and turn self locking nut 2 Turn the adjusting bolt head unt...

Page 2129: ...e 100 N m 10 2 kgf m 74 ft lb Toe in is increased Rotate camber adjusting bolt LH clockwise Rotate camber adjusting bolt RH counterclockwise Toe in is decreased Rotate camber adjusting bolt LH counter...

Page 2130: ...heel equally in toe out direction in order to make thrust angle adjust ment 3 When the right and left adjusting bolts are turned incrementally by one graduation in the same direc tion the thrust angle...

Page 2131: ...WHEEL ALIGNMENT Thrust angle r 2 Right rear wheel toe in angle Left rear wheel toe in angle Here use only positive toe in values from each wheel to substitute for and in the equation 1 Front 2 Body ce...

Page 2132: ...uring transverse link to crossmember and then extract the transverse link from crossmember B INSTALLATION 1 Temporarily tighten the two bolts used to secure rear bushing of transverse link to body NOT...

Page 2133: ...ar bushing and body Tightening torque 250 N m 25 5 kgf m 184 ft lb NOTE Move the rear bushing back and forth until trans verse link to rear bushing clearance is established as indicated in the figure...

Page 2134: ...rks scribed on the two 2 Tighten the new self locking nut NOTE While holding the rear bushing so as not to change position of aligning marks tighten the self locking nut Tightening torque 190 N m 19 4...

Page 2135: ...d end then insert a new cotter pin and bend it around castle nut 4 Install the front wheel C INSPECTION 1 Measure the play of ball joint by the following procedures Replace with a new one when the pla...

Page 2136: ...unt at upper side of strut to body and then tighten with the nuts Tightening torque 20 N m 2 0 kgf m 14 5 ft lb 2 Position the aligning mark on camber adjust ment bolt with aligning mark on lower side...

Page 2137: ...4 If the piston rod moves at least 10 mm 0 39 in in the former step purge air from the strut 3 Air purging procedure 1 Place the strut vertically with piston rod fac ing up 2 Fully extend the piston r...

Page 2138: ...y extend the rod Set a dial gauge at the end of rod L 10 mm 0 39 in then apply a force of W 20 N 2 kgf 4 lb to threaded portion With the force of 20 N 2 kgf 4 lb applied read dial gauge indication P1...

Page 2139: ...to 3 mm 0 08 to 0 12 in dia drill make holes in areas shown in the figure 2 STi MODEL CAUTION Before handling gas filled struts be sure to wear goggles to protect eyes from gas oil and filings Do not...

Page 2140: ...ation colors when installing 2 Always tighten the bushing location when tires are in full contact with the ground and vehicle is curb weight Tightening torque Jack up plate to crossmember Except STi m...

Page 2141: ...adually along with steering gear box CAUTION When removing the crossmember downward be careful that tie rod end does not interfere with SFJ boot B INSTALLATION 1 Install in the reverse order of remova...

Page 2142: ...e bolts in the order of 2 3 4 5 and 6 B INSTALLATION Install in the reverse order of removal NOTE Replace the M12 bolt with a new one Tightening torque T1 34 N m 3 5 kgf m 25 ft lb T2 55 N m 5 6 kgf m...

Page 2143: ...rque NOTE The tightening torque differs by the color for bolt 3 Always verify the bolt color before checking tightening torque Tightening torque T1 34 N m 3 5 kgf m 25 ft lb T2 55 N m 5 6 kgf m 41 ft...

Page 2144: ...ck up plate 5 Remove the two nuts at both ends of arm re spectively B INSTALLATION Install in the reverse order of removal Tightening torque Front support arm to crossmember 30 N m 3 1 kgf m 22 ft lb...

Page 2145: ...or replace the coil springs with new ones 4 Fault in operation of damper strut and or shock absorber Replace 5 Damage or deformation of strut mount and or shock absorber mount Replace 6 Unsuitability...

Page 2146: ...FS 30 FRONT SUSPENSION GENERAL DIAGNOSTIC TABLE...

Page 2147: ...REAR SUSPENSION RS Page 1 General Description 2 2 Wheel Alignment 10 3 Rear Stabilizer 11 4 Rear Trailing Link 12 5 Rear Strut 16 6 Lateral link 17 7 Rear Crossmember 21 8 General Diagnostic Table 23...

Page 2148: ...tems exceeds specifications check suspension parts and con nections for deformities replace with new ones as required Model Sedan Wagon OUTBACK Non turbo Turbo Non turbo Turbo Camber tolerance 0 45 1...

Page 2149: ...CRIPTION B COMPONENT 1 REAR SUSPENSION AWD MODEL RS 00098 29 22 22 22 28 22 22 22 22 22 11 T3 22 30 31 9 10 T1 T4 22 20 21 23 T11 27 26 25 T7 16 24 T8 15 14 T10 T6 9 10 T2 3 4 7 T2 9 T3 12 T7 17 T7 18...

Page 2150: ...20 Strut mount cap T2 25 2 5 18 1 7 Stabilizer link except STi model 21 Strut mount T3 45 4 6 33 2 8 Rear lateral link with stabilizer except STi model 22 Self locking nut T4 55 5 6 41 23 Dust cover T...

Page 2151: ...1 4 Bushing D 15 Strut mount cap T3 90 9 2 66 5 Bushing A 16 Strut mount T4 100 10 2 74 6 Front lateral link 17 Dust cover T5 115 11 7 85 7 Self locking nut 18 Coil spring T6 130 13 3 96 8 Washer 19 H...

Page 2152: ...e to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from o...

Page 2153: ...ster gauge when measuring camber and caster 1 28199AC000 PLATE 2 28199AC010 BOLT 927720000 INSTALLER REMOVER Used for replacing front bushing 927730000 INSTALLER REMOVER Used for replacing rear bushin...

Page 2154: ...INSTALLER REMOVER Used for replacing lateral link bushing 927700000 INSTALLER REMOVER Used for replacing lateral link bushing 927690000 INSTALLER REMOVER Used for replacing lateral link bushing ILLUS...

Page 2155: ...e Used for wheel alignment measurement Turning radius gauge Used for wheel alignment measurement Toe in gauge Used for toe in measurement Transmission jack Used for suspension assembly disassembly Bea...

Page 2156: ...nment A INSPECTION NOTE Front and rear wheel alignment must be simulta neously measured and or adjusted Follow the pro cedure in FS section Wheel Alignment for measurement and or adjustment of wheel a...

Page 2157: ...have the same identification colors when installing 2 Always tighten the stabilizer bushing location when tires are in full contact with the ground and the vehicle is curb weight Tightening torque St...

Page 2158: ...nsor harness 4 Remove the bolt which secures the trailing link to trailing link bracket 5 Remove the bolt which secures the trailing link to rear housing B INSTALLATION 1 Install in the reverse order...

Page 2159: ...s the front bushing out of place ST 927720000 INSTALLER REMOVER SET 2 REAR BUSHING 1 Remove the housing Ref to DS 24 REMOV AL Rear Axle 2 Using the ST press the rear bushing out of place ST 927730000...

Page 2160: ...rface CAUTION Install the front bushing in the proper direction as shown in the figure 2 REAR BUSHING 1 Using the ST press the bushing into trailing link ST 927730000 INSTALLER REMOVER SET NOTE If it...

Page 2161: ...link upside down Press the ST plunger in the opposite direction that outlines in the former procedure until bushing is correctly posi tioned in trailing link ST 927730000 INSTALLER REMOVER SET 4 Insta...

Page 2162: ...UTION Check the hose clip is positioned properly Check the brake hose for twisting or exces sive tension Do not subject the ABS wheel speed sensor harness to excessive tension 4 Lower the vehicle and...

Page 2163: ...re tainer Always use bolt shown in the figure as supporting point for ST during removal 7 Remove the DOJ from rear differential using tire lever VA type NOTE The side spline shaft circlip comes out t...

Page 2164: ...are in full contact with the ground and ve hicle is curb weight Secure the bolt head and tighten the nut when installing the adjusting bolt NOTE Check the wheel alignment and adjust if necessary C DIS...

Page 2165: ...nto trailing link apply water diluted TIRE LUBE to the inner surface of ST as a lubricant Specified lubricant TIRE LUBE water 1 3 3 Using the ST press the bushing into place 4 Press the ST plunger unt...

Page 2166: ...upside down Press the ST plunger in opposite direction that outlined in the former procedure until bushing is correctly posi tioned in trailing link E INSPECTION Visually check the lateral links for...

Page 2167: ...53 REMOVAL Rear Differential for VA type 4 Place the transmission jack under rear cross member 5 Remove the bolts securing crossmember to ve hicle body and then remove the crossmember 6 Scribe an ali...

Page 2168: ...or VA type 3 Always tighten the rubber bushing when tires are in full contact with the ground and vehicle is curb weight 4 Check the wheel alignment and adjust if neces sary 2 FWD MODEL NOTE Discard t...

Page 2169: ...eight Adjust or replace the coil springs with new ones 4 Fault in operation of damper strut or shock absorber Replace 5 Damage or deformation of strut mount or shock absorber mount Replace 6 Unsuitabi...

Page 2170: ...RS 24 REAR SUSPENSION GENERAL DIAGNOSTIC TABLE...

Page 2171: ...WHEEL AND TIRE SYSTEM WT Page 1 General Description 2 2 Tire 4 3 Steel Wheel 5 4 Aluminum Wheel 6 5 Wheel Balancing 7 6 T type Tire 8 7 Full Wheel Cap 9 8 General Diagnostics Table 10...

Page 2172: ...5 6JJ RS 205 50R16 87V 16 6 1 2JJ WRX 215 45R17 87W 17 7JJ STi 225 45R17 90W 17 7 1 2JJ 53 2 09 T type tire T125 70D15 95M 15 4T 53 2 09 T135 70D16 100M 16 4T 50 1 97 T135 70D17 102M 17 4T 40 1 57 Spe...

Page 2173: ...oz 28101SA090 25 g 0 88 oz 723141340 30 g 1 06 oz 723141350 35 g 1 23 oz 723141360 40 g 1 41 oz 723141370 45 g 1 59 oz 723241380 50 g 1 76 oz 723241580 55 g 1 94 oz 723241590 60 g 2 12 oz Balance weig...

Page 2174: ...riginally installed 1 When a large crack on the side wall dam age or a crack on tread are found 2 When the tread wear indicator appears as a solid band across the tread 3 When a crack on tire valve is...

Page 2175: ...wrench Wheel nut tightening torque 90 N m 9 1 kgf m 65 7 ft lb CAUTION Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally until the specified torqu...

Page 2176: ...appearance and safety do the following 1 Do not damage the aluminum wheels during re moval installation wheel balancing etc After re moving the aluminum wheels place them on a rubber mat etc 2 While t...

Page 2177: ...e aluminum wheel is not available Balance weights are available for use with any of 14 to 16 inch wheels Service limit A Weight for steel wheel 5 g 0 18 oz 25 g 0 88 oz 2 0 mm 0 08 in 30 g 1 06 oz or...

Page 2178: ...rive as slowly as possible and avoid pass ing over bumps B REPLACEMENT Refer to Removal and Installation of Steel Wheel for removal installation of T type tires Ref to WT 5 Steel Wheel CAUTION Replace...

Page 2179: ...over inserted between openings on cap B INSTALLATION Align the valve hole in wheel cap with the valve on wheel and secure the wheel cap by tapping four points by hand C INSPECTION 1 Check the wheels f...

Page 2180: ...tire adjust the tire air pressure properly Wheel is out of balance Adjustment Abnormal tire wear Improperly inflated tire Replace Sways pitches Worn or improperly inflated tire In case of worn tire re...

Page 2181: ...fferential Gear Oil 25 3 Front Differential 26 4 Rear Differential for T type 27 5 Rear Differential for VA type 53 6 Rear Differential Front Oil Seal 69 7 Rear Differential Side Oil Seal 71 8 Rear Di...

Page 2182: ...0 8 US qt 0 7 Imp qt Rear differential gear oil GL 5 MODEL 2 5 L 2 0 L Turbo AT MT AT MT Except Australia Australia Except Australia Australia Rear differential type T type model with LSD LSD type Vis...

Page 2183: ...8 1 8 4 0 4 1 8 7 STi model 25 9 41 5 2 6 4 2 5 8 9 3 VA type 12 7 32 4 1 3 3 3 2 9 7 3 Side gear backlash mm in T type 0 10 0 20 0 0039 0 0079 VA type 0 05 0 15 0 0020 0 0059 Side bearing standard wi...

Page 2184: ...713 0 0674 38336AA090 1 725 0 0679 38336AA210 1 738 0 0684 38336AA100 1 750 0 0689 38336AA220 1 763 0 0694 38336AA110 1 775 0 0699 Pinion height adjusting shim Part No Thickness mm in 32295AA200 0 150...

Page 2185: ...39 0 0941 383815200 2 37 0 0933 383825200 2 35 0 0925 383835200 2 33 0 0917 383845200 2 31 0 0909 Pinion height adjusting shim Part No Thickness mm in 383495200 3 09 0 1217 383505200 3 12 0 1228 38351...

Page 2186: ...com panion flange bolt hole N kgf lb 25 9 41 5 2 6 4 2 5 8 9 3 Preload adjusting spacer Part No Length mm in 31454AA130 52 2 2 055 31454AA140 52 4 2 063 31454AA150 52 6 2 071 31454AA160 52 8 2 079 31...

Page 2187: ...38336AA340 3 42 0 1346 38336AA350 3 45 0 1358 38336AA360 3 48 0 1370 38336AA370 3 51 0 1382 38336AA380 3 54 0 1394 38336AA390 3 57 0 1406 38336AA400 3 60 0 1417 38336AA410 3 63 0 1429 38336AA420 3 66...

Page 2188: ...case 5 Bearing preload 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 Pinio...

Page 2189: ...r 17 Side oil seal T1 10 3 1 05 7 6 5 Bearing preload adjusting washer 18 Gasket T2 29 3 0 21 7 Except for STi model 6 Differential carrier 19 Differential case Viscous cou pling type 7 Front bearing...

Page 2190: ...ng preload adjusting washer 18 Side gear thrust washer 6 Differential carrier 19 Side gear Tightening torque N m kgf m ft lb 7 Front bearing 20 Pinion mate gear T1 25 2 5 18 1 8 Collar 21 Pinion shaft...

Page 2191: ...htening torque N m kgf m ft lb 2 Plate 9 Differential mount front cover T1 20 2 0 14 5 3 Crossmember T2 33 3 4 24 3 4 Differential rear member T3 65 6 6 47 9 5 Differential mount lower bracket T4 70 7...

Page 2192: ...ause each part on the vehicle is hot after running Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers Be sur...

Page 2193: ...HANDLE Used for installing front and rear bearing cone 398477702 DRIFT Used press fitting the bearing cone of differential carrier rear 398217700 ATTACHMENT SET Stand for rear differential carrier di...

Page 2194: ...k nut 398467700 DRIFT Used for removing pinion pilot bearing and front bearing cone 399780104 WEIGHT Used for installing front bearing cone pilot bear ing companion flange 899580100 INSTALLER Used for...

Page 2195: ...ing backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used measuring backlash between side gear and pinion hypoid gear Used with MAGNET BASE 498...

Page 2196: ...ATTACHMENT Used for removing side bearing retainer For T type 398477703 DRIFT2 Used for press fitting the bearing race rear of differential carrier For T type 398437700 DRIFT Used for installing side...

Page 2197: ...e 398507703 DUMMY COLLAR Used for adjusting pinion height and preload For T type 398517700 REPLACER Used for removing rear bearing cone For T type 398487700 DRIFT Used for press fitting the side beari...

Page 2198: ...for removing front oil seal Used for removing side bearing cup For T type 398227700 WEIGHT Used for installing side bearing For T type 28099PA090 OIL SEAL PROTEC TOR Used for installing rear drive sha...

Page 2199: ...VER Used for removing rear drive shaft from rear differential For T type 498175500 INSTALLER Used for installing rear bearing cone For VA type 499785500 WRENCH ASSY Used for removing and installing si...

Page 2200: ...105 SEAT Used for removing side bearing cone Used with PULLER SET 899524100 For VA type 399703600 PULLER ASSY Used for removing companion flange 498485400 DRIFT Used for installing side bearing cone F...

Page 2201: ...DRIFT Used for press fitting the bearing race front of differential carrier For VA type 498447150 DUMMY SHAFT Used for adjusting pinion height and Pre load For VA type 498515500 REPLACER Used for remo...

Page 2202: ...EAT Used for removing side bearing race Used with PULLER ASSY 499705401 For VA type 499705401 PULLER ASSY Used for removing side bearing race Used with SEAT 499705404 For VA type 899874100 INSTALLER U...

Page 2203: ...bearing cone of differ ential For T type STi model 498937110 HOLDER DRIVE PINION This special tool is used for current automatic transmis sion Used for installing pilot bearing For T type STi model 18...

Page 2204: ...e Used for installing side bearing race STi model TOOL NAME REMARKS Transmission jack Used for assembly disassembly of rear differential Puller Used for removal of side bearing retainer Thickness gaug...

Page 2205: ...plug for T type Use a new aluminum gasket for VA type Fluid packing THREE BOND 1105 Part No 004403010 or equivalent Tightening torque T type 49 N m 5 0 kgf m 36 2 ft lb VA type 34 N m 3 5 kgf m 25 3 f...

Page 2206: ...For front differential of AUTOMATIC TRANSMIS SION refer to AT section Ref to 4AT 112 Front Differential 2 MT MODEL For front differential of manual transmission refer to 5MT or 6MT section Ref to 5MT...

Page 2207: ...ef to EX H4SO 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 12 REMOVAL Muffler Turbo model Ref to EX H4DOTC 14 REMOVAL Rear Ex haust Pipe and Ref to EX H4DOTC 15 RE MOVAL Muffler 9 Remove the heat s...

Page 2208: ...er to body Loosen the bolt A first then remove the bolts B NOTE Support the front member with use of a helper to prevent it from dropping 19 Remove the bolt A 20 While slowly lowering the transmission...

Page 2209: ...talling procedure hereafter is in the reverse order of removal 5 After installation fill the differential carrier with gear oil to the filler plug level Ref to DI 25 Differ ential Gear Oil C DISASSEMB...

Page 2210: ...retainer ST 398457700 ATTACHMENT 6 Pull out the differential case assembly from dif ferential carrier NOTE Be careful not to hit the teeth against the case 7 When replacing the side bearing pull the...

Page 2211: ...ithout LSD NOTE The gears as well as thrust washers should be marked or kept separated right and left front and rear 12 Hold the companion flange with ST and remove the drive pinion nut ST 498427200 F...

Page 2212: ...ut the front bearing cup and rear bearing cup in this order out of case by using a brass bar 2 STi MODEL To detect the real cause of trouble inspect the fol lowing items before disassembling Tooth con...

Page 2213: ...h a puller NOTE Each shim which is installed to adjust the side bearing preload should be kept together with its mating retainer ST 398457700 ATTACHMENT 6 Pull out the differential case assembly from...

Page 2214: ...E WRENCH 11 Extract the companion flange with a puller 12 Press the end of drive pinion shaft and extract it together with the rear bearing cone preload adjust ing spacer and washer NOTE Hold the driv...

Page 2215: ...s when installing the oil seal 1 Adjusting preload for front and rear bearings Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height ad justing washer are not...

Page 2216: ...98507702 DUMMY SHAFT ST2 398507704 BLOCK Tightening torque 181 N m 18 5 kgf m 134 ft lb A Pinion height adjusting shim B Preload adjusting spacer C Preload adjusting washer B A C ST2 ST1 DI 00080 DI 0...

Page 2217: ...0 20 mm 0 0079 in NOTE Use copies of this page Example of calculation To 2 20 1 20 3 40 mm N 0 23 mm H 1 T 3 40 0 23 0 01 0 20 3 42 Result Thickness 3 42 mm Therefore use the shim 383605200 Front and...

Page 2218: ...4 WEIGHT ST3 899580100 INSTALLER 6 Insert the spacer then press fit the pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER 7 Fit a new oil seal with ST NOTE Press fit until th...

Page 2219: ...20 mm 0 0039 0 0079 in 2 Adjust the backlash as specified by select ing the side gear thrust washer 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur face...

Page 2220: ...ring with new one Replace the broken or corroded side retainer shim with a new one of same thickness 4 Align the arrow mark on differential carrier with the mark on side retainer during installation N...

Page 2221: ...n backlash Backlash 0 10 0 20 mm 0 0039 0 0079 in 15 Check the crown gear runout on its back sur face and make sure that pinion and crown gear ro tate smoothly Limit of runout Less than 0 05 mm 0 0020...

Page 2222: ...k contact Checking item Backlash is too small Contact pattern Corrective action Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear Toe contact In...

Page 2223: ...18 Install the oil seals to the right and left side bearing retainers 19 Align the arrow mark on differential carrier with the mark on side retainer during installation 20 Tighten the side bearing re...

Page 2224: ...Apply chassis grease between the lips when installing the oil seal Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height adjusting shim are not affected by th...

Page 2225: ...MY COLLER ST4 498937110 HOLDER DRIVE PINION T mm Thickness of selected pinion height adjusting shim T1 mm Thickness of inserted pinion height adjusting shim T2 mm Punch mark number on installed drive...

Page 2226: ...ad adjusting washer and spacer from the following table 12 Hold the companion flange with ST and remove the self lock nut ST 498427200 FRANGE WRENCH 13 Extract the companion flange with a puller DI 00...

Page 2227: ...he ST ST 498427200 FRANGE WRENCH 17 Install the crown gear on differential case NOTE Before installing the bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1324 Part No 004403042 or equivale...

Page 2228: ...ler 5 Tighten the side bearing retainer bolts Tightening torque 10 3 N m 1 05 kgf m 7 6 ft lb 6 Measure the crown gear to drive pinion backlash Set the magnet base on differential carrier Align the co...

Page 2229: ...utions back and forth until a definite contact pattern appears on the crown gear 2 When the contact pattern is incorrect read just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be...

Page 2230: ...r to move drive pinion away from crown gear Heel contact Outside end contact Checking item Contact area is small Contact pattern Corrective action Increase thickness of drive pin ion height adjusting...

Page 2231: ...s evident replace as a set Slight damage of tooth can be corrected by oil stone or the like 2 Side gear and pinion mate gear Replace if crack score or other defects are evi dent on tooth surface Repla...

Page 2232: ...Differential for T type 5 TOTAL PRELOAD Using a gauge check the turning resistance in crease Total preload Except for STi model 20 7 54 4 N 2 1 5 5 kgf 4 7 12 2 lb STi model 28 5 57 0 N 2 9 5 8 kgf 6...

Page 2233: ...Ref to EX H4SOw oOBD 11 REMOVAL Muffler Non turbo model with OBD Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 12 REMOVAL Muffler 9 Remove the heat shield cover 10 Remove the front c...

Page 2234: ...to bolts B NOTE Support the front member with use of a helper to prevent it from dropping 19 Remove the bolt A 20 While slowly lowering the transmission jack move the rear differential forward and th...

Page 2235: ...r installation fill the differential carrier with gear oil to the upper plug level Ref to DI 26 Front Differential C DISASSEMBLY To detect the real cause of trouble inspect the fol lowing items before...

Page 2236: ...the oil seal from right and left holders using screwdriver NOTE Perform this operation only when changing oil seal 10 Extract the bearing cone with ST1 and ST2 NOTE Do not attempt to disassemble the...

Page 2237: ...nion flange with ST and remove the self locking nut ST 498427200 FLANGE WRENCH 15 Extract the companion flange with a puller 16 Press the end of drive pinion shaft and extract it together with the rea...

Page 2238: ...s Be careful not to mix up the right and left hand races of the bearings Replace the oil seal with a new one at every dis assembly Apply chassis grease between the lips when installing the oil seal 1...

Page 2239: ...d in direction of tangent to flange Be careful not to give excessive preload When tightening the self locking nut lock ST1 with ST2 as shown in the figure ST1 398507150 DUMMY SHAFT ST2 498447704 BLOCK...

Page 2240: ...this one NOTE Use 1 to 3 shims as required for adjustment T To N 0 05 mm where T Thickness of pinion height adjusting shim mm To Thickness of shim originally installed mm N Reading of thickness gauge...

Page 2241: ...9580100 INSTALLER 6 Insert the spacer then press fit the pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER 7 Fit a new oil seal with ST NOTE Press fit until the end of oil se...

Page 2242: ...gear backlash as specified by selecting the side gear thrust washer 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 4 After driving in the pinion...

Page 2243: ...disas sembly 4 Temporally tighten the side holder RH and LH in differential carrier to install 14 Perform the backlash adjustment of pinion crown gear set and preload adjustment of differen tial side...

Page 2244: ...within specified range repeat the procedures for pinion crown gear set backlash adjustment and differential side bearing preload adjustment Backlash 0 10 0 15 mm 0 0039 0 0059 in 15 Draw a matching m...

Page 2245: ...2 When the contact pattern is incorrect read just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be sure to wipe off red lead completely after adjust ment is completed Correct toot...

Page 2246: ...gear Heel contact Outside end contact Checking item Contact area is small Contact pattern Corrective action Increase thickness of drive pin ion height adjusting shim in order to bring drive pin ion cl...

Page 2247: ...ent 5 Oil seal Replace if deformed or damaged and at every dis assembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces ar...

Page 2248: ...DI 58 ASSEMBLY Rear Differential for VA type 2 CROWN GEAR BACKLASH Adjust the crown gear backlash Ref to DI 58 ASSEMBLY Rear Differential for VA type 3 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINI...

Page 2249: ...Tightening torque T type 49 N m 5 0 kgf m 36 2 ft lb VA type 34 N m 3 5 kgf m 25 3 ft lb 6 Jack up the vehicle and support with sturdy racks 7 Remove the rear exhaust pipe and muffler 8 Remove the pr...

Page 2250: ...f locking nut within the specified torque range so that the preload of companion flange becomes the same as that before replacing oil seal ST 498427200 FLANGE WRENCH NOTE Use a new self locking nut Ti...

Page 2251: ...Muffler Non turbo model with OBD Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SO 12 REMOVAL Muffler Turbo model Ref to EX H4DOTC 14 REMOVAL Rear Ex haust Pipe and Ref to EX H4DOTC 15 RE...

Page 2252: ...ferential fit ST to the bolts as shown in the figure so as not to damage the side bearing retainer ST 208099PA100 DRIVE SHAFT REMOVER 9 Suspend the rear drive shaft to the rear cross member using wire...

Page 2253: ...rigid racks 6 Remove the wheels 7 Remove the rear exhaust pipe and muffler Non turbo model without OBD Ref to EX H4SOw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX H4SOw oOBD 11 REMOVAL Muffler Non...

Page 2254: ...ferential using tire lever NOTE When removing the DOJ from rear differential fit tire lever to the bolt as shown in the figure so as not to damage the axle shaft holder The side spline shaft circlip c...

Page 2255: ...shaft with a new one 1 Install the ST to rear differential ST 28099PA090 SIDE OIL SEAL PROTEC TOR 2 Install the spline shaft until the spline portion is inside the side oil seal 3 Remove the ST ST 28...

Page 2256: ...ef to DI 27 REMOVAL Rear Differential for T type VA type Ref to DI 53 REMOVAL Rear Differential for VA type 10 Remove the differential rear member B INSTALLATION Install in the reverse order of remova...

Page 2257: ...or replace 3 Insufficient or improper oil used Replace the seized part and fill with spec ified oil to specified level 3 Damage NOTE Damaged parts should be replaced and also other parts should be tho...

Page 2258: ...When listening to noises shift gears into four wheel drive and fourth speed position try ing to pick up only differential noise 1 Improper tooth contact of hypoid gear Readjust or replace the hypoid g...

Page 2259: ...l 5 5 Transfer Drive Gear MT 6 6 Transfer Driven Gear MT 7 7 Reduction Drive Gear 4AT without VTD 8 8 Reduction Drive Gear 4AT with VTD 9 9 Reduction Driven Gear 4AT without VTD 10 10 Reduction Driven...

Page 2260: ...DESCRIPTION 1 General Description A NOTE For general description refer to 4AT 5MT or 6MT section 4AT model Ref to 4AT 2 General Description 5MT model Ref to 5MT 2 General Description 6MT model Ref to...

Page 2261: ...ND EXTENSION MT 2 Transfer Case and Extension MT A NOTE For removal installation and inspection work refer to 5MT or 6MT section 5MT model Ref to 5MT 53 Transfer Case and Extension Case Assembly 6MT m...

Page 2262: ...ER CASE TRANSFER CLUTCH AND EXTENSION 4AT 3 Transfer Clutch and Exten sion 4AT A NOTE For removal installation and inspection work refer to 4AT section Ref to 4AT 81 Transfer Clutch Ref to 4AT 77 Exte...

Page 2263: ...OIL SEAL 4 Oil Seal A NOTE For removal installation and inspection work refer to 4AT 5MT or 6MT section 4AT model Ref to 4AT 47 Extension Case Oil Seal 5MT model Ref to 5MT 47 Oil Seal 6MT model Ref...

Page 2264: ...E TRANSFER DRIVE GEAR MT 5 Transfer Drive Gear MT A NOTE For removal installation and inspection work refer to 5MT or 6MT section 5MT model Ref to 5MT 58 Transfer Drive Gear 6MT model Ref to 6MT 58 Tr...

Page 2265: ...TRANSFER DRIVEN GEAR MT 6 Transfer Driven Gear MT A NOTE For removal installation and inspection work refer to 5MT or 6MT section 5MT model Ref to 5MT 60 Transfer Driven Gear 6MT model Ref to 6MT 60 T...

Page 2266: ...C 8 TRANSFER CASE REDUCTION DRIVE GEAR 4AT WITHOUT VTD 7 Reduction Drive Gear 4AT without VTD A NOTE For removal installation and inspection work refer to 4AT section Ref to 4AT 93 Reduction Drive Gea...

Page 2267: ...TC 9 TRANSFER CASE REDUCTION DRIVE GEAR 4AT WITH VTD 8 Reduction Drive Gear 4AT with VTD A NOTE For removal installation and inspection work refer to 4AT section Ref to 4AT 93 Reduction Drive Gear...

Page 2268: ...0 TRANSFER CASE REDUCTION DRIVEN GEAR 4AT WITHOUT VTD 9 Reduction Driven Gear 4AT without VTD A NOTE For removal installation and inspection work refer to 4AT section Ref to 4AT 90 Reduction Driv en G...

Page 2269: ...C 11 TRANSFER CASE REDUCTION DRIVEN GEAR 4AT WITH VTD 10 Reduction Driven Gear 4AT with VTD A NOTE For removal installation and inspection work refer to 4AT section Ref to 4AT 90 Reduction Driv en Gea...

Page 2270: ...CASE CENTER DIFFERENTIAL 11 Center Differential A NOTE For removal installation and inspection work refer to 5MT or 6MT section 5MT model Ref to 5MT 62 Center Differential 6MT model Ref to 6MT 62 Cent...

Page 2271: ...TC 13 TRANSFER CASE TRANSFER CLUTCH PRESSURE TEST 12 Transfer Clutch Pressure Test A NOTE For inspection work refer to 4AT section Ref to 4AT 38 Transfer Clutch Pressure Test...

Page 2272: ...ANSFER DUTY SOLENOID AND VALVE BODY 13 Transfer Duty Solenoid and Valve Body A NOTE For removal installation and inspection work refer to 4AT section Ref to 4AT 64 Shift Solenoids Duty Solenoids and A...

Page 2273: ...DRIVE SHAFT SYSTEM DS Page 1 General Description 2 2 Propeller Shaft 15 3 Front Axle 18 4 Rear Axle 24 5 Front Drive Shaft 33 6 Rear Drive Shaft 38 7 General Diagnostic Table 44...

Page 2274: ...Propeller shaft type UJ DOJ UJ Front propeller shaft Joint to joint length L1 mm in AT 584 22 99 579 22 79 MT 643 25 32 638 25 12 584 22 99 Rear propeller shaft Joint to joint length L2 mm in 708 27...

Page 2275: ...D mm Axle length L mm Sedan Non turbo Turbo AT EBJ87 SFJ82 26 1 02 325 Turbo MT except STi EBJ87 SFJ82 28 1 10 325 Turbo MT STi BJ92 DOJ87 28 1 10 250 Wagon Non turbo Turbo AT EBJ87 SFJ82 26 1 02 314...

Page 2276: ...J79 DOJ79 Sedan 2 0 L Non turbo MT 2 368 23 D BJ79 DOJ79 1 358 23 E BJ79 DOJ79 Sedan 1 6 L 2 0 L Non turbo AT 3 363 24 F BJ79 DOJ79 Wagon 1 6 L 2 0 L Non turbo AT None 355 24 G EBJ82 DOJ82 Wagon turbo...

Page 2277: ...DOJ79 sedan R152R L I BJ79 DOJ79 wagon R160RH B EBJ82 DOJ82 sedan LH F BJ79 DOJ79 wagon R152R L J BJ79 DOJ79 wagon R160LH C BJ79 DOJ79 sedan R160RH G EBJ82 DOJ82 wagon RH K Identification protrusion...

Page 2278: ...PTION B COMPONENT 1 PROPELLER SHAFT 1 Propeller shaft DOJ type 4 Rear differential T type Tightening torque N m kgf m ft lb 2 Propeller shaft 3UJ type T1 38 3 9 28 3 3 Rear differential VA type T2 52...

Page 2279: ...Oil seal OUT 3 Outer race SFJ 11 EBJ ASSY 19 Hub bolt 4 Snap ring 12 Tone wheel with ABS 20 Hub 5 Trunnion 13 Baffle plate 21 Axle nut 6 Free ring 14 Oil seal IN 7 Circlip 15 Snap ring Tightening torq...

Page 2280: ...OJ Turbo EBJ ASSY 22 Hub 4 Snap ring 13 Baffle plate 23 Axle nut 5 Inner race 14 Oil seal IN No 2 6 Ball 15 Oil seal IN Tightening torque N m kgf m ft lb 7 Cage 16 Housing T1 13 1 3 9 4 8 Circlip 17 B...

Page 2281: ...grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified poin...

Page 2282: ...REMOVER Used for removing front hub Used with HUB STAND 927080000 927420000 HUB REMOVER Used for removing rear hub Used with HUB STAND 927080000 927080000 HUB STAND Used for disassembling and assembli...

Page 2283: ...00 AXLE SHAFT PULLER PLATE Same as plate 2 included in AXLE SHAFT PULLER 926470000 927390000 ADAPTER Used as an adapter for AXLE SHAFT INSTALLER 922431000 927400000 HOUSING STAND Used for disassemblin...

Page 2284: ...USING STAND Used for disassembling and assembling rear housing bearing Used with BEARING PULLER 927440000 927120000 HUB INSTALLER Used for installing hub 927440000 BEARING REMOVER Used for disassembli...

Page 2285: ...ed for pressing hub bearing into hub Used with HUB STAND 927080000 28099PA090 OIL SEAL PROTEC TOR Used for installing rear drive shaft into rear dif ferential For protecting oil seal 28099PA100 DRIVE...

Page 2286: ...PLI ERS Used for tightening front BJ boot band TOOL NAME REMERKS Puller Used for removing ball joint from knuckle arm Dial gauge Used for inspecting propeller shaft run out Snap ring pliers Used for i...

Page 2287: ...the parking brake 4 Jack up the vehicle and support it with sturdy racks 5 Remove the center exhaust pipes 6 Remove the rear exhaust pipe and muffler 7 Remove the differential mount front cover 8 Mak...

Page 2288: ...Tighten the remaining bolts to specified torque Tightening torque 90 N m 9 2 kgf m 66 ft lb 4 Install the center exhaust pipes 5 Install the rear exhaust pipe and muffler C INSPECTION NOTE Do not dis...

Page 2289: ...Remove the rear exhaust pipe and muffler 3 Remove the heat shield cover 4 Set the dial gauge with its indicator stem at cen ter of propeller shaft tube 5 Turn the propeller shaft slowly by hands to c...

Page 2290: ...arings 4 Remove the stabilizer link SEDAN WAGON 5 Remove the disc brake caliper from housing and suspend it from strut using a wire 6 Remove the disc rotor from hub NOTE If the disc rotor seizes up wi...

Page 2291: ...mporarily tighten the front axle to front strut 2 Insert the front drive shaft into front axle 3 Temporarily tighten the axle nut 4 Install the transverse link ball joint to housing Tightening torque...

Page 2292: ...torque Do not overtighten it as this may dam age the wheel bearing 13 After tightening the axle nut lock it securely 14 Install the ABS wheel speed sensor on hous ing Tightening torque 32 N m 3 3 kgf...

Page 2293: ...0 HOUSING STAND ST2 927100000 BEARING PULLER 8 Using the ST and a hydraulic press drive the hub bolts out ST 927080000 HUB STAND D ASSEMBLY NOTE When the hub is to be removed from housing re place the...

Page 2294: ...contacts the circlip ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND 8 Invert the ST and housing ST 927400000 HOUSING STAND 9 Apply sufficient grease to the oil seal lip Specified grease...

Page 2295: ...ire up and down by hand check there is no backlash in bearing and check the wheel rotates smoothly 2 Inspect the lean of axis direction using a dial gauge Replace the hub bearing if the load range exc...

Page 2296: ...loosen the adjusting nut 6 Remove the disc brake caliper from back plate and suspend it from strut using a piece of wire 7 Remove the disc rotor from hub NOTE If the disc rotor seizes up within hub dr...

Page 2297: ...p the vehicle and remove the rear wheel cap and wheels 3 Unlock the axle nut 4 Remove the axle nut using a socket wrench CAUTION Be sure to loosen and retighten the axle nut af ter removing the wheel...

Page 2298: ...lent to prevent brake fluid from spill ing 10 Disconnect the parking brake cable end 11 Disconnect the rear stabilizer from rear lateral link Remove the bolts which secure the trailing link assembly t...

Page 2299: ...trut 2 Insert the rear drive shaft into rear axle NOTE Be careful not to damage the inner oil seal lip 3 Temporarily tighten the axle nut 4 Using a new self locking nut temporarily tighten the rear ho...

Page 2300: ...14 kgf m 101 ft lb 17 Tighten the installation bolt of rear housing as sembly and trailing link assembly Tightening torque 90 N m 9 2 kgf m 66 ft lb 2 DRUM BRAKE 1 Temporarily tighten the rear axle to...

Page 2301: ...cle be in curb weight whenever carrying out the tightening of bush portions 18 Tighten the installation bolt of rear housing as sembly and lateral link assembly Tightening torque 137 N m 14 kgf m 101...

Page 2302: ...000 HUB STAND 2 Remove foreign particles dust rust etc from mating surfaces of the hub tone wheel and then in stall the tone wheel to hub Model with ABS NOTE Ensure the tone wheel closely contacts the...

Page 2303: ...press the sub seal into place ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER 9 Apply sufficient grease to oil seal lip Specified grease SHELL 6459N NOTE If specified grease is not availa...

Page 2304: ...ire up and down by hand check there is no backlash in bearing and check the wheel rotates smoothly 2 Inspect the lean of axis direction using a dial gauge Replace the hub bearing if the load range exc...

Page 2305: ...e front drive shaft is to be replaced also replace the inner oil seal B INSTALLATION 1 Insert the BJ into hub splines CAUTION Be careful not to damage the inner oil seal lip and tone wheel 2 Using the...

Page 2306: ...bly 5 Wipe off the grease CAUTION The grease is a special grease Do not confuse with other greases 6 Place alignment marks on free ring and trunnion 7 Remove the free ring from trunnion CAUTION Be ca...

Page 2307: ...Place the BJ boot and small boot band on BJ side of shaft CAUTION Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches 2 Place the drive shaft in a vise CAUTION Do not...

Page 2308: ...53 to 3 88 oz of specified grease into the interior of SFJ outer race 13 Apply a coat of specified grease to free ring and trunnion 14 Align the alignment marks on free ring and trun nion and then in...

Page 2309: ...to an extent that the boot underneath is not damaged 22 Cut off the band with an allowance of about 10 mm 0 39 in left from clip and bend this allowance over clip CAUTION Be careful so that the end o...

Page 2310: ...e bolt which secures the trailing link to housing 7 Remove the bolts which secure the front lateral link and rear lateral link to housing 8 Remove the rear ABS wheel speed sensor from back plate 9 Rem...

Page 2311: ...rive shaft into rear axle 2 Temporarily tighten the axle nut 3 Install the rear drive shaft to rear differential us ing the ST ST 28099PA090 OIL SEAL PROTECTOR 4 Temporarily tighten the front lateral...

Page 2312: ...g out the tightening of bush portions 13 Tighten the installation bolt of rear housing as sembly and lateral link assembly Tightening torque 137 N m 14 kgf m 101 ft lb 14 Tighten the installation bolt...

Page 2313: ...SEMBLY NOTE Use specified grease BJ side Except STi model Molylex No 2 Part No 723223010 STi model NTG2218 M Part No 28395FE010 DOJ side VU 3A702 Yellow Part No 23223GA050 1 Install the BJ boot in spe...

Page 2314: ...l the DOJ boot taking care not to twist it NOTE Inside of the larger end of DOJ boot and boot groove shall be cleaned so as to be free from grease and other substances When installing the DOJ boot pos...

Page 2315: ...repair or replace 1 DOJ Double Offset Joint Check seizure corrosion damage wear and ex cessive play 2 Shaft Check excessive bending twisting damage and wear 3 BJ Bell Joint Check seizure corrosion dam...

Page 2316: ...ation increase in pro portion to vehicle speed 1 Worn or damaged universal joint Replace 2 Unbalanced propeller shaft due to bend or dent Replace 3 Loose installation of propeller shaft Retighten 4 Wo...

Page 2317: ...2 2 ABS Control Module and Hydraulic Control Unit ABSCM H U 7 3 ABS Sequence Control 10 4 Front ABS Wheel Speed Sensor 13 5 Rear ABS Wheel Speed Sensor 16 6 Front Tone Wheel 19 7 Rear Tone Wheel 20 8...

Page 2318: ...7 1 2 mm 0 028 0 047 in ABS wheel speed sensor resis tance Front 1 25 0 25 k Rear 1 15 0 115 k Marks of harness Front RH White LH Yellow Rear RH Light blue LH Brown G sensor G sensor voltage 2 3 0 2...

Page 2319: ...ensor LH Tightening torque N m kgf m ft lb 2 Rear ABS wheel speed sensor RH 6 Front ABS wheel speed sensor RH T1 18 1 8 13 0 T2 33 3 3 24 3 Adjusting spacer 7 Lateral G sensor STi model 4 Rear ABS whe...

Page 2320: ...ont RH outlet Tightening torque N m kgf m ft lb 2 Damper 7 Primary inlet T1 18 1 8 13 0 3 ABS control module and hydrau lic control unit ABSCM H U 8 Rear LH outlet T2 33 3 3 24 9 Rear RH outlet T3 38...

Page 2321: ...les and protective shoes during opera tion Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not...

Page 2322: ...030 SUBARU SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without printer Spanish 22771AA090 Without p...

Page 2323: ...ed Do not attempt to loosen bolts and nuts Do not drop or bump the ABSCM H U Do not turn the ABSCM H U upside down or place it on its side Be careful to prevent foreign particles from getting into ABS...

Page 2324: ...an dard values Also check if any irregular brake pedal tightness is felt 8 Remove the pressure gauges from the FL and FR caliper bodies 9 Remove the air bleeder screws from the RL and RR caliper bodie...

Page 2325: ...6 Hydraulic unit begins to work and check the fol lowing working sequence 1 The FL wheel performs decompression holding and compression in sequence and subsequently the FR wheel repeats the cycle 2 T...

Page 2326: ...WITH SUB ARU SELECT MONITOR NOTE In the event of any trouble the sequence control may not be operative In such a case activate the sequence control referring to ABS SEQUENCE CONTROL WITH DIAGNOSIS CON...

Page 2327: ...E CONTROL ABS00014 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 23 26 25 27 24 V max 4 km h 2 5 MPH 17 OFF 19 20 OFF ON OFF ON OFF ON 32 30 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON 18 29 3...

Page 2328: ...the Subaru Select Monitor is not used 5 When the brake pedal is not depressed after ignition key is turned to ON and within 0 5 seconds after ABS warning light goes out When the Subaru Select Monitor...

Page 2329: ...and remove the front ABS wheel speed sensor CAUTION Be careful not to damage the pole piece locat ed at tip of the sensor and teeth faces during re moval Do not pull the sensor harness during remov al...

Page 2330: ...ion or body when steering wheel is turned 4 After confirmation of the ABS wheel speed sen sor clearance connect the connector to ABS wheel speed sensor 5 Connect the battery ground cable to battery C...

Page 2331: ...0 3 0 8 mm 0 012 0 031 in NOTE If the clearance is out of specification readjust us ing spacer Part No 26755AA000 3 OUTPUT VOLTAGE Output voltage can be checked by the following method Install the re...

Page 2332: ...6 Remove the rear tone wheel while removing the hub from housing and hub assembly Ref to DS 24 REMOVAL Rear Axle B INSTALLATION 1 Install the rear tone wheel on hub then rear housing on hub Ref to DS...

Page 2333: ...HEEL SPEED SENSOR 1 Check the pole piece of ABS wheel speed sen sor for foreign particles or damage If necessary clean the pole piece or replace ABS wheel speed sensor 2 Measure the ABS wheel speed se...

Page 2334: ...75 km h 2 MPH or equiva lent Output voltage specification 0 12 1 V at 20 Hz NOTE Regarding terminal No please refer to item 1 ABS WHEEL SPEED SENSOR Ref to ABS 17 ABS WHEEL SPEED SENSOR INSPECTION Re...

Page 2335: ...Front Drive Shaft because front tone wheel is integrated with front drive shaft Ref to DS 33 INSTALLATION Front Drive Shaft C INSPECTION Visually check the tone wheel s teeth 44 pieces for cracks or...

Page 2336: ...nstalled to rear hub Ref to DS 24 REMOVAL Rear Axle B INSTALLATION Refer to Rear Axle because the rear tone wheel is installed to rear hub Ref to DS 27 INSTALLATION Rear Axle C INSPECTION Visually che...

Page 2337: ...sconnect the connector from G sensor 4 Remove the G sensor from body CAUTION Do not drop or bump the G sensor G sensor and the bracket are integrated into one unit Therefore do not disassemble it B IN...

Page 2338: ...erminals Connector terminal B292 No 2 No 3 Is the voltage 0 7 0 2 V when G sensor is inclined backwards to 90 G sensor is nor mal Replace the G sensor 5 CHECK G SENSOR 1 Turn the ignition switch to OF...

Page 2339: ...I 42 REMOVAL Console Box 3 Disconnect the connector from lateral G sensor 4 Remove the lateral G sensor from vehicle CAUTION Do not drop or bump the lateral G sensor B INSTALLATION 1 Install in the re...

Page 2340: ...als Connector terminal B257 No 2 No 3 Is the voltage 1 5 0 2 V when lateral G sensor is inclined backwards to 90 Lateral G sensor is normal Replace the lateral G sensor 5 CHECK LATERAL G SENSOR 1 Turn...

Page 2341: ...6 Subaru Select Monitor 17 7 Read Diagnostic Trouble Code DTC 20 8 Inspection Mode 21 9 Clear Memory Mode 22 10 ABS Warning Light Brake Warning Light Illumination Pattern 23 11 List of Diagnostic Tro...

Page 2342: ...DTC Ref to ABS 20 Read Diagnostic Trouble Code DTC Record all DTCs Is only the start code issued Go to step 3 Go to step 4 3 PERFORM THE GENERAL DIAGNOSTICS 1 Inspect using General Diagnostics Table R...

Page 2343: ...o data link connector 3 Turn the ignition switch to ON and SUBARU SELECT MONITOR to ON NOTE If the communication function of Subaru Select Monitor cannot be executed normally check communication circu...

Page 2344: ...ry mode Ref to ABS 18 CLEAR MEMORY MODE OPERA TION Subaru Select Monitor 4 Perform the inspection mode Ref to ABS 21 Inspection Mode 5 Calling up the DTC Ref to ABS 17 READ DIAGNOSTIC TROUBLE CODE DTC...

Page 2345: ...on is ON Immediately after ignition starts When advancing km h to km h MPH to MPH While traveling at a constant speed km h MPH When decelerating km h to km h MPH to MPH When turning to right Steering...

Page 2346: ...ering time sec When turning to left Steering angle deg Steering time sec When operating other electrical parts Parts name Operating condition ABS operating condi tion Does not operate Operates only wh...

Page 2347: ...ained or steering refuses to work when accelerating Yes No When Vehicle turns to right Vehicle turns to left Spins Others c Brakes out of order Yes No What Braking distance is long Brakes lock or drag...

Page 2348: ...slope Others Condition a Brakes Deceleration g Continuous Intermittent b Accelerator Acceleration g Continuous Intermittent c Vehicle speed km h MPH Advancing Accelerating Reducing speed Low speed Tur...

Page 2349: ...y Above 1 260 2 BRAKE FLUID 1 Check the brake fluid level 2 Check the brake fluid leakage 3 HYDRAULIC UNIT Check the hydraulic unit With brake tester Ref to ABS 9 CHECKING THE HYDRAULIC UNIT ABS OPERA...

Page 2350: ...OOL NUMBER DESCRIPTION REMARKS 24082AA210 CARTRIDGE Troubleshooting for electrical systems 22771AA030 SUBARU SELECT MONITOR KIT Troubleshooting for electrical systems TOOL NAME REMARKS Circuit tester...

Page 2351: ...smission control module TCM AT model 12 Master cylinder 13 Brake EBD warning light 2 Connector 7 Tone wheel 14 Lateral G sensor STi model 3 Diagnosis connector 8 ABS wheel speed sensor 4 ABS warning l...

Page 2352: ...ABS 12 ABS DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION ABS00101 1 ABS00337 13 ABS00102 10 ABS00106 3 ABS00344 5 ABS00107 7 8 FRONT 7 8 ABS00104 REAR ABS00345 14...

Page 2353: ...ctor are as shown in the fig ure When the connector is removed from ABSCM H U the connector switch closes the circuit between ter minal No 22 and No 23 The ABS warning light illuminates 1 ABS control...

Page 2354: ...is OFF and 10 15 V when the stop light is ON ABS warning light 2 22 23 Less than 1 5 V within 1 5 seconds immediately after ignition switch has been turned to ON and 10 15 V after 1 5 sec onds has ela...

Page 2355: ...H 4 ABS control module area 15 Rear outlet solenoid valve RH 25 Front ABS wheel speed sensor RH 5 Valve relay 16 Transmission control module TCM AT model 26 Rear ABS wheel speed sensor LH 6 Motor rela...

Page 2356: ...ABS 16 ABS DIAGNOSTICS CONTROL MODULE I O SIGNAL C WAVEFORM 1 ABS wheel speed sensor 2 Terminal No 3 Standard output voltage ABS00034 V 1 2 3 9 10 7 8 0 20 Hz 1V 20 Hz 0 12 12 11 15 14...

Page 2357: ...ter the information of en gine type is displayed 9 On the ABS Diagnosis display screen select the DTC Display and press YES key 10 On the DTC Display display screen select the Current DTC or History D...

Page 2358: ...itored Unit of measure FR Wheel Speed Wheel speed detected by Front ABS wheel speed sensor RH is displayed km h or MPH FL Wheel Speed Wheel speed detected by Front ABS wheel speed sensor LH is display...

Page 2359: ...ay operation monitor signal Stop light switch Stop light switch signal ABS signal to TCM ABS operation signal from ABS control module to TCM ABS AT control ABS operation signal from ABS control module...

Page 2360: ...no DTCs in memory only the start code 11 is shown When on board diagnosis of the ABS control module detects a problem the information up to a maximum of three will be stored in EEP ROM as a DTC When...

Page 2361: ...AGNOSTICS INSPECTION MODE 8 Inspection Mode A OPERATION Reproduce the condition under which the problem has occurred as much as possible Drive the vehicle at a speed more than 40 km h 25 MPH for at le...

Page 2362: ...diagnostics is completed make sure to clear memory Make sure only start code 11 is shown after memory is cleared 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for information about how t...

Page 2363: ...he ABS warning light circuit or diagnosis cir cuit Ref to ABS 29 Diagnostics Procedure without Diagnostic Trouble Code DTC NOTE Even though the ABS warning light does not go out 1 5 seconds after it i...

Page 2364: ...tic Trouble Code DTC 25 Rear ABS wheel speed sensor RH Ref to ABS 43 DTC 25 ABNORMAL ABS WHEEL SPEED SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR RH Diagnostics Procedure without Diagnostic Trou...

Page 2365: ...gnostics Procedure without Diagnostic Trouble Code DTC 38 Rear outlet valve LH Ref to ABS 70 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM H U REAR LH Diagnostics Procedure without Diagnost...

Page 2366: ...o ABS 104 DTC 25 OPEN OR SHORT CIR CUIT IN REAR RIGHT ABS WHEEL SPEED SENSOR CIRCUIT Diagnostics Procedure with Diagnostic Trouble Code DTC 26 44C5 4545 44E5 4445 4505 4485 Rear ABS wheel speed sensor...

Page 2367: ...138 DTC 42 POWER SUPPLY VOLT AGE TOO HIGH Diagnostics Procedure with Diag nostic Trouble Code DTC 44 1600 ABS AT control Non Controlled ABS AT control Non Controlled Ref to ABS 141 DTC 44 ABS AT CONTR...

Page 2368: ...nostics Procedure with Diagnostic Trouble Code DTC 73 7A00 Open or short circuit in Lateral G sensor circuit Open or short circuit in Lateral G sensor circuit Ref to ABS 175 DTC 73 OPEN OR SHORT CIR C...

Page 2369: ...7 6 B3 1 24 TB TURBO ENGINE MODEL NA NON TURBO ENGINE MODEL 4 23 22 B22 B82 E3 TB TB NA NA 16 F60 E3 16 B100 F2 F46 B301 B22 B82 B36 B264 i11 C i10 B i2 B225 RELAY HOLDER 1 1 2 1 2 3 4 1 2 1 2 3 4 5 6...

Page 2370: ...B37 B200 F74 COMBINATION METER E E E C7 1 6 B3 1 9 20 19 4 23 22 B82 31 F49 B82 B264 i11 C i10 B i2 F74 B225 3 4 1 2 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 17 18 19 20 21 22 23 2...

Page 2371: ...No 1 Chassis ground Is the voltage less than 3 V Go to step 5 Repair battery short in the warn ing light harness 5 CHECK WIRING HARNESS 1 Turn the ignition switch to OFF 2 Install the combination mete...

Page 2372: ...pair open circuit in the ABSCM H U ground harness 9 CHECK WIRING HARNESS Measure the resistance between connector B37 and chassis ground Connector terminal LHD B37 No 15 Chassis ground RHD B37 No 1 Ch...

Page 2373: ...RBO ENGINE MODEL 4 23 22 B22 B82 E3 TB TB NA NA 16 F60 E3 16 B100 F2 F46 B301 B22 B82 B36 B264 i11 C i10 B i2 B225 RELAY HOLDER 1 1 2 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 3 4 1 2 8 9 10 11 12 13 14 15 16...

Page 2374: ...o 8 i2 i11 C B i10 i2 B37 B200 F74 COMBINATION METER E E E C7 1 6 B3 1 9 20 19 4 23 22 B82 31 F49 B82 B264 i11 C i10 B i2 F74 B225 3 4 1 2 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 1...

Page 2375: ...n switch to OFF Is there poor contact at battery terminal Repair or tighten the battery termi nal Go to step 6 6 CHECK POWER SUPPLY OF ABSCM 1 Start the engine 2 Idle the engine 3 Measure the voltage...

Page 2376: ...har ness 11 CHECK WIRING HARNESS 1 Connect the connector to ABSCM H U 2 Measure the resistance between connector B37 and chassis ground Connector terminal LHD B37 No 15 Chassis ground RHD B37 No 1 Ch...

Page 2377: ...00350 E SBF 1 SBF 4 BATTERY E NO 13 21 B301 B301 B37 i2 B36 i1 B16 B16 i1 B99 R3 R4 i11 C i10 B i10 B ABSCM H U IGNITION SWITCH BRAKE FLUID LEVEL SWITCH BRAKE WARNING LIGHT 14 C7 2 B19 15 1 2 1 2 3 4...

Page 2378: ...NO 13 21 B49 F49 B37 i2 B37 B36 B16 B16 i2 B99 R3 R4 i11 C i10 B i10 B IGNITION SWITCH BRAKE FLUID LEVEL SWITCH BRAKE WARNING LIGHT 31 C7 29 B19 3 1 2 1 2 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20...

Page 2379: ...arking brake switch 3 Measure the resistance between parking brake switch terminal and chassis ground Is the resistance more than 1 M Go to step 4 Replace the park ing brake switch 4 CHECK GROUND SHOR...

Page 2380: ...N TURBO ENGINE MODEL 4 23 22 B22 B82 E3 TB TB NA NA 16 F60 E3 16 B100 F2 F46 B301 B22 B82 B36 B264 i11 C i10 B i2 B225 RELAY HOLDER 1 1 2 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 3 4 1 2 8 9 10 11 12 13 14 15...

Page 2381: ...B225 B37 No 13 No 18 No 8 i2 i11 C B i10 i2 B37 B200 F74 COMBINATION METER E E E C7 1 6 B3 1 9 20 19 4 23 22 B82 31 F49 B82 B264 i11 C i10 B i2 F74 B225 3 4 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9...

Page 2382: ...M H U connector and chassis ground Connector terminal LHD B301 No 4 Chassis ground RHD F49 No 4 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the har ness connector between ABSCM...

Page 2383: ...ABNORMAL ABS WHEEL SPEED SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT LH NOTE For the diagnostic procedure refer to DTC 27 Ref to ABS 44 DTC 27 ABNORMAL ABS WHEEL SPEED SENSOR OPEN CIRCUIT OR...

Page 2384: ...DIAGNOSTIC TROUBLE CODE DTC H DTC 27 ABNORMAL ABS WHEEL SPEED SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR LH DIAGNOSIS Faulty ABS wheel speed sensor Broken wire input voltage too high Faulty ha...

Page 2385: ...5 9 4 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH B15 B15 2 1 FRONT ABS SENSOR LH F94 F94 B303 R73 R72 2 1 1 2 2 1 1 3 5 6 7 2 B301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 2...

Page 2386: ...NT ABS SENSOR RH F95 F95 2 1 FRONT ABS SENSOR LH F94 F94 F62 F74 R73 R72 2 1 1 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 19 20 21 13 14 15 16 17 18 22 F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21...

Page 2387: ...e the ABS wheel speed sen sor Front Ref to ABS 13 Front ABS Wheel Speed Sensor Rear Ref to ABS 16 Rear ABS Wheel Speed Sensor 3 CHECK BATTERY SHORT OF ABS WHEEL SPEED SENSOR 1 Turn the ignition switch...

Page 2388: ...BATTERY SHORT OF HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM H U connector and chassis ground Connector terminal DTC 21 LHD B301 No 11 Chassis ground RHD F49 No 11 Ch...

Page 2389: ...No 1 Chassis ground Is the resistance more than 1 M Go to step 11 Replace the ABS wheel speed sen sor and ABSCM H U Front Ref to ABS 13 Front ABS Wheel Speed Sensor Rear Ref to ABS 16 Rear ABS Wheel S...

Page 2390: ...same DTC as in current diagnosis still being output Replace the ABSCM H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM H U Go to step 14 14 CHECK ANY OTHER DTC APPEARANCE Are othe...

Page 2391: ...ABNORMAL ABS WHEEL SPEED SENSOR ABNORMAL ABS WHEEL SPEED SENSOR SIGNAL FRONT LH NOTE For the diagnostic procedure refer to DTC 28 Ref to ABS 52 DTC 28 ABNORMAL ABS WHEEL SPEED SENSOR ABNORMAL ABS WHE...

Page 2392: ...DIAGNOSTIC TROUBLE CODE DTC L DTC 28 ABNORMAL ABS WHEEL SPEED SENSOR ABNORMAL ABS WHEEL SPEED SENSOR SIGNAL REAR LH DIAGNOSIS Faulty ABS wheel speed sensor signal noise irregular signal etc Faulty ha...

Page 2393: ...5 9 4 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH B15 B15 2 1 FRONT ABS SENSOR LH F94 F94 B303 R73 R72 2 1 1 2 2 1 1 3 5 6 7 2 B301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 2...

Page 2394: ...urely ABS00354 15 14 10 9 8 7 23 F74 B200 REAR ABS SENSOR RH B99 R72 R3 E 3 2 2 1 12 13 32 31 21 20 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH F95 F95 2 1 FRONT ABS SENSOR LH F94 F94 F62 F74 R73 R...

Page 2395: ...When this inspection is completed the ABS control module sometimes stores DTC 29 or DTC 56 Connector terminal DTC 22 LHD B15 No 1 No 2 RHD F95 No 1 No 2 DTC 24 LHD F45 No 20 No 24 RHD F94 No 1 No 2 D...

Page 2396: ...or 9 CHECK GROUND SHORT OF ABS WHEEL SPEED SENSOR Measure the resistance between ABS wheel speed sensor and chassis ground Terminals Front RH No 1 Chassis ground Front LH No 1 Chassis ground Rear RH N...

Page 2397: ...ors between ABSCM H U and ABS wheel speed sensor Go to step 14 Repair the con nector 14 CHECK SOURCES OF SIGNAL NOISE Is the car telephone or wireless transmitter properly installed Go to step 15 Prop...

Page 2398: ...with the diagnosis corre sponding to DTC A temporary noise interference NOTE Although the ABS warning light re mains illuminating at this point this is a normal condition Vehicle must be driven at ap...

Page 2399: ...OR ABNORMAL ABS WHEEL SPEED SENSOR SIGNAL ANY ONE OF FOUR DIAGNOSIS Faulty ABS wheel speed sensor signal noise irregular signal etc Faulty tone wheel Wheels turning freely for a long time TROUBLE SYMP...

Page 2400: ...5 9 4 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH B15 B15 2 1 FRONT ABS SENSOR LH F94 F94 B303 R73 R72 2 1 1 2 2 1 1 3 5 6 7 2 B301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 2...

Page 2401: ...NT ABS SENSOR RH F95 F95 2 1 FRONT ABS SENSOR LH F94 F94 F62 F74 R73 R72 2 1 1 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 19 20 21 13 14 15 16 17 18 22 F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21...

Page 2402: ...ons cor rect Go to step 3 Replace the tire 3 CHECK WEAR OF TIRE Is the tire worn excessively Replace tire Go to step 4 4 CHECK TIRE PRESSURE Is the tire pressure correct Go to step 5 Adjust tire pres...

Page 2403: ...el speed sen sor piece or the tone wheel contaminated by dirt or other foreign matter Thoroughly remove dirt or other foreign mat ter Go to step 10 10 CHECK DAMAGE OF ABS WHEEL SPEED SENSOR OR TONE WH...

Page 2404: ...STICS DIAGNOSTICS PROCEDURE WITHOUT DIAGNOSTIC TROUBLE CODE DTC 13 CHECK ANY OTHER DTC APPEARANCE Are other DTCs being output Proceed with the diagnosis corre sponding to DTC A temporary poor contact...

Page 2405: ...e Code DTC O DTC 33 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM H U FRONT LH NOTE For the diagnostic procedure refer to DTC 37 Ref to ABS 66 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSC...

Page 2406: ...C Q DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM H U REAR LH DIAGNOSIS Faulty harness connector Faulty inlet solenoid valve in ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not op...

Page 2407: ...B225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2408: ...n ABSCM H U connector and chassis ground Connector terminal LHD B301 No 23 Chassis ground RHD F49 No 23 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the ABSCM H U ground harness...

Page 2409: ...Code DTC S DTC 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM H U FRONT LH NOTE For the diagnostic procedure refer to DTC 38 Ref to ABS 70 DTC 38 ABNORMAL OUTLET SOLE NOID VALVE CIRCUIT S IN ABS...

Page 2410: ...U DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM H U REAR LH DIAGNOSIS Faulty harness connector Faulty outlet solenoid valve in ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not o...

Page 2411: ...B225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2412: ...n ABSCM H U connector and chassis ground Connector terminal LHD B301 No 23 Chassis ground RHD F49 No 23 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the ABSCM H U ground harness...

Page 2413: ...lty ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In addition to the ABS warning light brake warning light illuminates WIRING DIAGRAM ABS00234 E ABSCM H U 23 1 2 3 4 5 6 7 8...

Page 2414: ...r Go to step 3 3 CHECK SOURCES OF SIGNAL NOISE Is the car telephone or the wireless transmitter properly installed Go to step 4 Properly install the car telephone or wireless transmit ter 4 CHECK SOUR...

Page 2415: ...SOURCE VOLTAGE IS ABNORMAL DIAGNOSIS Power source voltage of the ABSCM H U is low or high TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In addition to the ABS warning light brake war...

Page 2416: ...B225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2417: ...LHD B301 No 1 Chassis ground RHD F49 No 1 Chassis ground Is the voltage 10 17 V Go to step 4 Repair the power supply circuit and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the ignition switc...

Page 2418: ...ol faults TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00360 3 31 LHD LHD RHD RHD 1 B55 F74 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 21 21 B55 TCM...

Page 2419: ...9 No 3 Chassis ground Is the voltage less than 1 V Go to step 4 Repair the har ness between TCM and ABSCM H U 4 CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage be...

Page 2420: ...y 4 Perform the inspection mode 5 Read out the DTC Is the same DTC as in the cur rent diagnosis still being out put Replace the ABSCM H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit AB...

Page 2421: ...TIC TROUBLE CODE DTC Y DTC 51 ABNORMAL VALVE RELAY DIAGNOSIS Faulty valve relay TROUBLE SYMPTOM ABS does not operate EBD does not operate in some malfunctions NOTE In addition to the ABS warning light...

Page 2422: ...S RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 1...

Page 2423: ...und RHD F49 No 23 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the ABSCM H U ground harness 3 CHECK VALVE RELAY IN ABSCM H U Measure the resistance between ABSCM H U and terminal...

Page 2424: ...RR OUTLET BATTERY SBF 1 SBF 4 SBF HOLDER No 18 E IGNITION SWITCH ABS RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD B61 F44 F44 F96 B255 B61 4 4 LHD R...

Page 2425: ...Is the voltage 10 15 V Go to step 4 Repair the har ness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the ignition switch to OFF 2 Measure the res...

Page 2426: ...eed with the diagnosis corre sponding to DTC A temporary poor contact NOTE Although the ABS warning light re mains illuminating at this point this is a normal condition Vehicle must be driven at appro...

Page 2427: ...OME ON Depress the brake pedal Do the stop lights come on Go to step 2 Repair the stop lights circuit ABS00366 BATTERY 2 1 SBF 1 SBF 2 No 16 B64 1 F44 B61 B64 1 2 2 3 OC OC E RHD LHD LHD RHD 7 2 STOP...

Page 2428: ...tween stop light switch and ABSCM H U 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between stop light switch and ABSCM H U Repair the con nector Go to step 4 4 CHECK ABSCM H...

Page 2429: ...ING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3 4 5...

Page 2430: ...nor mal Erase the DTC Go to step 2 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1 2 3 F49 F49 F62 F74 B200 B261 B257 B292 AB...

Page 2431: ...ector from ABSCM H U 3 Measure the resistance between ABSCM H U connector terminals Connector terminal LHD B301 No 6 No 28 RHD F49 No 6 No 28 Is the resistance 5 0 5 6 k Go to step 5 Repair the har ne...

Page 2432: ...r 10 CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector terminal B292 No 2 No 3 Is the voltage 3 7 4 1 V when G sensor is inclined for wards to 90 Go to step 11 Replace...

Page 2433: ...rate WIRING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1...

Page 2434: ...nor mal Erase the DTC Go to step 2 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1 2 3 F49 F49 F62 F74 B200 B261 B257 B292 AB...

Page 2435: ...ABSCM H U 3 Measure the resistance between ABSCM H U connector terminals Connector terminal LHD B301 No 29 No 28 RHD F49 No 29 No 28 Is the resistance 5 0 5 6 k Go to step 5 Repair the har ness conne...

Page 2436: ...LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector terminal B257 No 2 No 3 Is the voltage between 3 7 4 1 V when lateral G sensor is inclined right to 90 Go t...

Page 2437: ...3 E E 4 5 LHD LHD DATA LINK CONNECTOR RHD LHD LHD RHD 5 20 23 1 IGNITION SWITCH ABS RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 7 6 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 B40...

Page 2438: ...ABSCM 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 ABSCM H U ECM and TCM connectors 3 Measure the...

Page 2439: ...GROUND 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM H U and transmission 3 Measure the resistance of harness between ABSCM H U and chassis ground Connector terminal LHD B30...

Page 2440: ...DTC B NO DTC DIAGNOSIS ABS warning light circuit is shorted TROUBLE SYMPTOM ABS warning light remains on NO DTC displayed on the Subaru Select Monitor NOTE When the ABS warning light is OFF and NO DT...

Page 2441: ...B36 B264 i11 C i10 B i2 B225 RELAY HOLDER 1 1 2 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9...

Page 2442: ...B i10 i2 B37 B200 F74 COMBINATION METER E E E C7 1 6 B3 1 9 20 19 4 23 22 B82 31 F49 B82 B264 i11 C i10 B i2 F74 B225 3 4 1 2 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 17 18 19 20 21...

Page 2443: ...step 4 Replace the ABSCM H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM H U 4 CHECK WIRING HARNESS Measure the resistance between connector and chassis ground Connector terminal...

Page 2444: ...DTC D DTC 23 OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS WHEEL SPEED SEN SOR CIRCUIT NOTE For the diagnostic procedure refer to DTC 27 Ref to ABS 105 DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS WHEEL S...

Page 2445: ...WITH DIAGNOSTIC TROUBLE CODE DTC F DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS WHEEL SPEED SENSOR CIRCUIT DIAGNOSIS Faulty ABS wheel speed sensor Broken wire input voltage too high Faulty harness c...

Page 2446: ...5 9 4 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH B15 B15 2 1 FRONT ABS SENSOR LH F94 F94 B303 R73 R72 2 1 1 2 2 1 1 3 5 6 7 2 B301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29...

Page 2447: ...T ABS SENSOR RH F95 F95 2 1 FRONT ABS SENSOR LH F94 F94 F62 F74 R73 R72 2 1 1 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 19 20 21 13 14 15 16 17 18 22 F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2...

Page 2448: ...wheel 0 3 0 8 mm 0 012 0 031 in Rear wheel 0 7 1 2 mm 0 028 0 047 in Go to step 4 Adjust the gap NOTE Adjust the gap us ing spacers Part No 26755AA000 If the spacers can not correct gap re place worn...

Page 2449: ...sen sor Front Ref to ABS 13 Front ABS Wheel Speed Sensor Rear Ref to ABS 16 Rear ABS Wheel Speed Sensor 10 CHECK BATTERY SHORT OF ABS WHEEL SPEED SENSOR 1 Turn the ignition switch to ON 2 Measure the...

Page 2450: ...sensor 13 CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM H U connector and chassis ground Connector terminal DTC 21 LHD B301 No 11 Chassis ground R...

Page 2451: ...No 1 Chassis ground Is the resistance more than 1 M Go to step 18 Replace the ABS wheel speed sen sor and ABSCM H U Front Ref to ABS 13 Front ABS Wheel Speed Sensor Rear Ref to ABS 16 Rear ABS Wheel S...

Page 2452: ...tion mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM H U Go to step 21 21 CHECK ANY OTHER DTC APPEARANCE Are other DTCs being output Proceed with t...

Page 2453: ...ostic Trouble Code DTC H DTC 24 FRONT LEFT ABNORMAL ABS WHEEL SPEED SENSOR SIGNAL NOTE For the diagnostic procedure refer to DTC 28 Ref to ABS 114 DTC 28 REAR LEFT ABNORMAL ABS WHEEL SPEED SENSOR SIGN...

Page 2454: ...DIAGRAM LHD MODEL ABS00353 15 14 10 9 8 7 23 B303 REAR ABS SENSOR RH B99 R72 R3 E 2 1 2 1 10 16 5 9 4 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH B15 B15 2 1 FRONT ABS SENSOR LH F94 F94 B303 R73 R...

Page 2455: ...T ABS SENSOR RH F95 F95 2 1 FRONT ABS SENSOR LH F94 F94 F62 F74 R73 R72 2 1 1 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 19 20 21 13 14 15 16 17 18 22 F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2...

Page 2456: ...con nector and chassis ground Connector terminal DTC 22 LHD B303 No 2 Chassis ground RHD F62 No 2 Chassis ground DTC 24 LHD B303 No 1 Chassis ground RHD F62 No 1 Chassis ground NOTE If the DTC is 26 2...

Page 2457: ...g ure Go to step 15 Go to step 12 12 CHECK CONTAMINATION OF ABS WHEEL SPEED SENSOR OR TONE WHEEL Remove the disc rotor or drum from hub in accordance with DTC Is the ABS wheel speed sen sor piece or t...

Page 2458: ...ABS Wheel Speed Sensor Rear Ref to ABS 16 Rear ABS Wheel Speed Sensor 17 CHECK HARNESS CONNECTOR BETWEEN ABSCM H U AND ABS WHEEL SPEED SENSOR 1 Connect the connector to ABS wheel speed sensor 2 Disco...

Page 2459: ...UIT 1 Connect all connectors 2 Measure the resistance between shield con nector and chassis ground Connector terminal DTC 22 LHD B303 No 2 Chassis ground RHD F62 No 2 Chassis ground DTC 24 LHD B303 No...

Page 2460: ...SPEED SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR DIAGNOSIS Faulty ABS wheel speed sensor signal noise irregular signal etc Faulty tone wheel Wheels turning freely for a long time TROUBLE SYMPTOM ABS does...

Page 2461: ...5 9 4 REAR ABS SENSOR LH R73 2 1 FRONT ABS SENSOR RH B15 B15 2 1 FRONT ABS SENSOR LH F94 F94 B303 R73 R72 2 1 1 2 2 1 1 3 5 6 7 2 B301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29...

Page 2462: ...T ABS SENSOR RH F95 F95 2 1 FRONT ABS SENSOR LH F94 F94 F62 F74 R73 R72 2 1 1 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 19 20 21 13 14 15 16 17 18 22 F49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2...

Page 2463: ...hten the ABS wheel speed sen sor installation bolts securely 6 CHECK ABS WHEEL SPEED SENSOR GAP Measure the tone wheel to ABS wheel speed sensor piece gap over entire perimeter of the wheel Is the gap...

Page 2464: ...Rear ABS Wheel Speed Sensor and Front Ref to ABS 19 Front Tone Wheel Rear Ref to ABS 20 Rear Tone Wheel Go to step 11 11 CHECK TONE WHEEL RUNOUT Measure the tone wheel runout Is the runout less than 0...

Page 2465: ...dure with Diagnostic Trouble Code DTC M DTC 33 FRONT LEFT INLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 37 Ref to ABS 126 DTC 37 REAR LEFT INLET VALVE MALFUNCTION Diagnostics...

Page 2466: ...TIC TROUBLE CODE DTC O DTC 37 REAR LEFT INLET VALVE MALFUNCTION DIAGNOSIS Faulty harness connector Faulty inlet solenoid valve TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In additio...

Page 2467: ...225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2468: ...istance between ABSCM H U connector and chassis ground Connector terminal LHD B301 No 23 Chassis ground RHD F49 No 23 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the ABSCM H U g...

Page 2469: ...ure with Diagnostic Trouble Code DTC Q DTC 34 FRONT LEFT OUTLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 38 Ref to ABS 130 DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION Diagnostics...

Page 2470: ...IC TROUBLE CODE DTC S DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION DIAGNOSIS Faulty harness connector Faulty outlet solenoid valve TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In additi...

Page 2471: ...225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2472: ...istance between ABSCM H U connector and chassis ground Connector terminal LHD B301 No 23 Chassis ground RHD F49 No 23 Chassis ground Is the resistance less than 0 5 Go to step 3 Repair the ABSCM H U g...

Page 2473: ...ulty ABSCM H U TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In addition to the ABS warning light brake warning light illuminates WIRING DIAGRAM ABS00234 E ABSCM H U 23 1 2 3 4 5 6 7...

Page 2474: ...3 3 CHECK SOURCES OF SIGNAL NOISE Is the car telephone or wireless transmitter properly installed Go to step 4 Properly install the car telephone or wireless transmit ter 4 CHECK SOURCES OF SIGNAL NOI...

Page 2475: ...42 POWER SUPPLY VOLTAGE TOO LOW DIAGNOSIS Power source voltage of the ABSCM H U is low TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In addition to the ABS warning light brake warning...

Page 2476: ...225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2477: ...is ground RHD F49 No 1 Chassis ground Is the voltage 10 17 V Go to step 4 Repair the har ness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the ign...

Page 2478: ...2 POWER SUPPLY VOLTAGE TOO HIGH DIAGNOSIS Power source voltage of the ABSCM H U is high TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In addition to the ABS warning light brake warnin...

Page 2479: ...225 1 2 2 1 3 4 B264 LHD 2 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 2480: ...ground RHD F49 No 1 Chassis ground Is the voltage 10 and 17 V Go to step 4 Repair the har ness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the i...

Page 2481: ...T CX AWD MT STi model CY AWD MT STi with Driver s control center differential model Does the vehicle specification and ABSCM H U specifica tion match Go to step 2 Replace the ABSCM H U Ref to ABS 7 AB...

Page 2482: ...nctioning normally Replace the TCM Repair the AT 5 CHECK OPEN CIRCUIT OF HARNESS Measure the voltage between ABSCM H U connector and chassis ground Connector terminal LHD B301 No 3 Chassis ground B301...

Page 2483: ...lts TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00360 3 31 LHD LHD RHD RHD 1 B55 F74 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 21 21 B55 TCM 1 F74...

Page 2484: ...PEN CIRCUIT OF HARNESS 1 Turn the ignition switch to OFF 2 Connect all connectors to TCM 3 Turn the ignition switch to ON 4 Measure the voltage between ABSCM H U connector and chassis ground Connector...

Page 2485: ...PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC Y DTC 51 VALVE RELAY MALFUNCTION DIAGNOSIS Faulty valve relay TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE In addition to the ABS warning l...

Page 2486: ...RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B225 10...

Page 2487: ...OFF 2 Measure the resistance between ABSCM H U connector and chassis ground Connector terminal LHD B301 No 23 Chassis ground RHD F49 No 23 Chassis ground Is the resistance less than 0 5 Go to step 3 R...

Page 2488: ...BF 1 SBF 3 SBF 4 No 18 No 8 E IGNITION SWITCH ABS RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD 3 F46 B264 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 2489: ...nit ABSCM H U 2 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nectors between generator battery and ABSCM H U Repair the con nector Go to step 3 3 CHECK ABSCM H U 1 Connect all connect...

Page 2490: ...RR OUTLET BATTERY SBF 1 SBF 4 SBF HOLDER No 18 E IGNITION SWITCH ABS RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD B61 F44 F44 F96 B255 B61 4 4 LHD R...

Page 2491: ...p 3 Repair the ABSCM H U ground harness 3 CHECK MOTOR OPERATION Operate the sequence control Ref to ABS 10 ABS Sequence Control NOTE Use the diagnosis connector to operate se quence control Can motor...

Page 2492: ...LET BATTERY SBF 1 SBF 4 SBF HOLDER No 18 E IGNITION SWITCH ABS RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD B61 F44 F44 F96 B255 B61 4 4 LHD RHD LHD...

Page 2493: ...nd Hydraulic Control Unit ABSCM H U 3 CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF Is there poor contact in con nector between generator bat tery and ABSCM H U Repair the con necto...

Page 2494: ...BATTERY SBF 1 SBF 4 SBF HOLDER No 18 E IGNITION SWITCH ABS RELAY RELAY HOLDER E 9 F46 B108 B225 1 2 2 1 3 4 B264 LHD 2 B200 F74 RHD RHD LHD RHD LHD LHD RHD B61 F44 F44 F96 B255 B61 4 4 LHD RHD LHD RH...

Page 2495: ...between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM H U connector and chassis ground Connector t...

Page 2496: ...aru Select Monitor 2 Release the brake pedal 3 Read the stop light switch output in Subaru Select Monitor data display Is the reading indicated on monitor display less than 1 5 V Go to step 2 Go to st...

Page 2497: ...between ABSCM H U connector and chassis ground Connector terminal LHD B301 No 2 Chassis ground RHD F49 No 2 Chassis ground Is the voltage 10 15 V Go to step 5 Repair the har ness between stop light sw...

Page 2498: ...WIRING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3 4...

Page 2499: ...isplay 2 1 2 5 V when G sensor is in horizontal posi tion Go to step 2 Go to step 5 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25...

Page 2500: ...e resistance between ABSCM H U connector terminals Connector terminal LHD B301 No 6 No 28 RHD F49 No 6 No 28 Is the resistance 5 0 5 6 k Go to step 7 Repair the har ness connector between G sensor and...

Page 2501: ...o step 12 12 CHECK ABSCM H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM H...

Page 2502: ...NG DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3 4 5 6...

Page 2503: ...5 V when G sensor is in horizontal position Go to step 2 Go to step 5 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1 2 3 F49...

Page 2504: ...heel speed on the Subaru Select Monitor display Is the rear right wheel speed on monitor display 0 km h 0 MPH Go to step 8 Go to step 16 8 CHECK FREEZE FRAME DATA Read rear left wheel speed on the Sub...

Page 2505: ...G sensor from vehicle Do not disconnect connector 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor con nector terminals Connector terminal B292 No 1 No 3 Is the voltage 4 75 5 2...

Page 2506: ...e ignition switch to OFF Is there poor contact in con nector between ABSCM H U and G sensor Repair the con nector Go to step 22 22 CHECK ABSCM H U 1 Connect all connectors 2 Erase the memory 3 Perform...

Page 2507: ...DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3 4 5 6 7...

Page 2508: ...when G sensor is in horizontal position Go to step 2 Go to step 6 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1 2 3 F49 F49...

Page 2509: ...SHORT OF HARNESS Measure the resistance between ABSCM H U connector and chassis ground Connector terminal LHD B301 No 28 Chassis ground RHD F49 No 28 Chassis ground Is the resistance more than 1 M Go...

Page 2510: ...ory 4 Perform the inspection mode 5 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM...

Page 2511: ...DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3 4 5 6 7...

Page 2512: ...rase the DTC Go to step 2 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1 2 3 F49 F49 F62 F74 B200 B261 B257 B292 ABS G SENSOR...

Page 2513: ...Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM H U Ref to ABS 7 ABS Control Mo...

Page 2514: ...Ref to ABS 21 G Sen sor 12 CHECK ABSCM H U 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform the inspection mode 5 Read out the DTC Is the same DTC as in current...

Page 2515: ...operate WIRING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257...

Page 2516: ...onitor display 2 3 2 7 V when lateral G sensor is in hor izontal position Go to step 2 Go to step 5 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 2...

Page 2517: ...the ignition switch to OFF 2 Disconnect the connector from ABSCM H U 3 Measure the resistance between ABSCM H U connector terminals Connector terminal LHD B301 No 28 No 30 RHD F49 No 28 No 30 Is the...

Page 2518: ...TORS Turn the ignition switch to OFF Is there poor contact in con nector between ABSCM H U and lateral G sensor Repair the con nector Go to step 12 12 CHECK ABSCM H U 1 Connect all connectors 2 Erase...

Page 2519: ...ate WIRING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2...

Page 2520: ...2 7 V when lateral G sensor is in hor izontal position Go to step 2 Go to step 5 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 2...

Page 2521: ...ru Select Monitor display Is the rear right wheel speed on monitor display 0 km h 0 MPH Go to step 8 Go to step 16 8 CHECK FREEZE FRAME DATA Read rear left wheel speed on the Subaru Select Monitor dis...

Page 2522: ...connector 4 Turn the ignition switch to ON 5 Measure the voltage between lateral G sen sor connector terminals Connector terminal B257 No 1 No 3 Is the voltage 4 75 5 25 V Go to step 17 Repair the har...

Page 2523: ...TORS Turn the ignition switch to OFF Is there poor contact in con nector between ABSCM H U and lateral G sensor Repair the con nector Go to step 22 22 CHECK ABSCM H U 1 Connect all connectors 2 Erase...

Page 2524: ...e WIRING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3...

Page 2525: ...7 V when Lateral G sensor is in horizontal position Go to step 2 Go to step 6 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1...

Page 2526: ...H U connector and chassis ground Connector terminal LHD B301 No 28 Chassis ground RHD F49 No 28 Chassis ground Is the resistance more than 1 M Go to step 7 Repair the har ness between lat eral G sens...

Page 2527: ...ory 4 Perform the inspection mode 5 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM...

Page 2528: ...WIRING DIAGRAM LHD MODEL ABS00368 B301 B303 B293 B292 B257 B261 ABS G SENSOR EXCEPT STi MODEL E 3 2 1 ABS G SENSOR STi MODEL 3 2 1 ABS LATERAL G SENSOR STi MODEL 3 2 1 B292 B261 B303 B301 B257 1 2 3...

Page 2529: ...rase the DTC Go to step 2 ABS00369 B292 B261 F62 F74 F49 B257 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 1 2 3 F49 F49 F62 F74 B200 B261 B257 B292 ABS G SENSOR...

Page 2530: ...connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM H U Ref to ABS 7 ABS Control Mod ule and Hy...

Page 2531: ...l G sensor Ref to ABS 23 Lateral G Sensor 12 CHECK ABSCM H U 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform the inspection mode 5 Read out the DTC Is the same...

Page 2532: ...ABSCM H U solenoid valve ABS wheel speed sensor Master cylinder Brake caliper piston Parking brake Axle wheels Brake pedal play Long brake pedal stroke Air in brake line Brake pedal play Vehicle pitc...

Page 2533: ...otor 40 7 Rear Disc Brake Assembly 42 8 Rear Drum Brake Shoe 47 9 Rear Drum Brake Drum 49 10 Rear Drum Brake Assembly 50 11 Master Cylinder 53 12 Brake Booster 55 13 Proportioning Valve 60 14 Brake Fl...

Page 2534: ...inch type 17 inch type Type Disc Floating type Disc Fixed type ventilated Effective disc diameter 230 mm 9 06 in 261 mm 10 28 in 268 mm 10 55 in Disc thickness Outer diameter 10 266 mm 0 39 10 47 in 1...

Page 2535: ...in 1 5 mm 0 059 in 16 10 mm 0 39 in 1 5 mm 0 059 in 17 9 2 mm 0 362 in 1 2 mm 0 047 in Disc thickness Except 17 24 mm 0 94 in 22 mm 0 87 in 17 30 mm 1 18 in 28 mm 1 10 in Disc runout 0 075 mm 0 0030 i...

Page 2536: ...242 psi 1 471 kPa 15 kg cm2 213 psi Brake fluid pressure with engine running and vacuum at 66 7 kPa 500 mmHg 19 69 inHg 147 N 15 kgf 33 lb 5 982 kPa 61 kg cm2 868 psi 5 982 kPa 61 kg cm2 868 psi 5 29...

Page 2537: ...d clip 3 Guide pin Green 11 Outer shim Tightening torque N m kgf m ft lb 4 Pin boot 12 Inner shim T1 8 0 8 5 8 5 Piston seal 13 Pad Outside T2 18 1 8 13 0 6 Piston 14 Pad Inside T3 37 3 8 27 5 7 Pisto...

Page 2538: ...in Green 11 Outer shim Tightening torque N m kgf m ft lb 4 Pin boot 12 Inner shim T1 8 0 8 5 8 5 Piston seal 13 Pad Outside T2 27 2 8 19 9 6 Piston 14 Pad Inside T3 37 3 8 27 5 7 Piston boot 15 Disc r...

Page 2539: ...3 Caliper body 11 Outer shim Tightening torque N m kgf m ft lb 4 M clip 12 Inner shim T1 8 0 8 5 8 5 Cross spring 13 Pad Outside T2 18 1 8 13 0 6 Pad pin 14 Pad Inside T3 80 8 2 59 7 Piston seal 15 D...

Page 2540: ...dy 9 Piston 3 Air bleeder screw 10 Piston seal Tightening torque N m kgf m ft lb 4 Guide plate 11 Pad shim T1 18 1 8 13 0 5 Cross spring 12 Pad Outside T2 20 2 0 14 5 6 Clip 13 Pad Inside T3 155 15 8...

Page 2541: ...ing 6 Piston 19 Spring washer 32 Disc rotor 7 Piston boot 20 Parking brake lever 33 Bushing 8 Boot ring 21 Parking brake shoe Secondary 9 Lock pin Yellow 22 Parking brake shoe Primary Tightening torqu...

Page 2542: ...cup 6 Piston boot 19 Retainer 32 Shoe hold down spring 7 Boot ring 20 Spring washer 33 Disc rotor 8 Pad clip 21 Parking brake lever 9 Inner pad 22 Parking brake shoe Secondary Tightening torque N m kg...

Page 2543: ...her 29 Shoe hold down spring 6 Piston 18 Parking brake lever 30 Disc rotor 7 Piston seal 19 Parking brake shoe Secondary 8 Clip 20 Parking brake shoe Primary Tightening torque N m kgf m ft lb 9 Pad pi...

Page 2544: ...her 23 Drum 4 Piston 14 Parking brake lever 24 Plug 5 Cup 15 Brake shoe Trailing 6 Spring 16 Brake shoe Leading Tightening torque N m kgf m ft lb 7 Wheel cylinder body 17 Shoe hold down spring T1 8 0...

Page 2545: ...STER CYLINDER LHD MODEL 1 Cap 6 Secondary piston Tightening torque N m kgf m ft lb 2 Filter 7 Cylinder body T1 15 1 5 10 8 3 Reservoir tank 8 Cylinder pin 4 Piston retainer 9 Seal 5 Primary piston 10...

Page 2546: ...TION RHD MODEL 1 Cap 6 Secondary piston Tightening torque N m kgf m ft lb 2 Filter 7 Cylinder body T1 15 1 5 10 8 3 Reservoir tank 8 Cylinder pin 4 Piston retainer 9 Seal 5 Primary piston 10 Pin BR 00...

Page 2547: ...ABSCM H U Tightening torque N m kgf m ft lb 2 Proportioning valve T1 15 1 5 10 8 3 Front brake hose RH 8 Bracket T2 18 1 8 13 0 4 Front brake hose LH 9 Master cylinder T3 32 3 3 23 6 5 Clamp 10 Hill h...

Page 2548: ...ning torque N m kgf m ft lb 2 Proportioning valve T1 15 1 5 10 8 3 Front brake hose RH 8 Bracket T2 18 1 8 13 0 4 Front brake hose LH 9 Master cylinder T3 32 3 3 23 6 5 Clamp 10 Hill holder 6 Gasket 1...

Page 2549: ...rake hose LH Disc brake model Tightening torque N m kgf m ft lb 2 Two way connector T1 15 1 5 10 8 3 Rear brake pipe assembly 7 Rear brake hose LH Drum brake model T2 18 1 8 13 0 4 Rear brake hose RH...

Page 2550: ...ger valve 3 Reaction disc 7 Operating rod 11 Diaphragm plate 4 Key 8 Poppet valve 12 Valve return spring 1 Push rod 5 Plunger valve 9 Operating rod 2 Return spring 6 Key 10 Silencer 3 Diaphragm plate...

Page 2551: ...ket 12 Clutch cable clamp T2 8 0 8 5 8 4 Snap pin 13 Clip T3 18 1 8 13 0 5 Brake pedal pad 14 Spring assist T4 30 3 1 22 4 6 Brake pedal 15 Stop light switch T5 33 3 3 24 3 7 Clevis pin 16 Brake pedal...

Page 2552: ...od B 27 Protector 6 Brake pedal 18 Spring S 7 Clevis pin 19 Rod S Tightening torque N m kgf m ft lb 8 Brake pedal spring 20 Bushing S T1 8 0 8 5 8 9 Clutch pedal pad 21 O ring T2 18 1 8 13 0 10 Clutch...

Page 2553: ...LHD AT MODEL 1 Stopper 6 Brake pedal pad Tightening torque N m kgf m ft lb 2 Bushing 7 Brake pedal T1 8 0 8 5 8 3 Pedal bracket 8 Clevis pin T2 18 1 8 13 0 4 Stop light switch 9 Brake pedal spring T3...

Page 2554: ...pper 6 Brake pedal pad Tightening torque N m kgf m ft lb 2 Snap pin 7 Brake pedal bracket ASSY T1 8 0 8 5 8 3 Clevis pin 8 Cover T2 18 1 8 13 0 4 Stop light switch 9 Protector T3 33 3 3 24 3 5 Brake p...

Page 2555: ...ent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the...

Page 2556: ...LS 2 GENERAL PURPOSE TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925460000 WHEEL CYLINDER 11 16 ADAPTER Used for installing cup onto wheel cylinder piston Size 11 16 TOOL NAME REMARKS SNAP RING...

Page 2557: ...ove proceed as follows 1 Remove the caliper body from support 2 Remove the support 3 Place a support in a vise between wooden blocks 4 Attach a rod of less than 12 mm 0 47 in dia to the shaded area of...

Page 2558: ...the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the clip 5 Remove the pad pins and cross spring 6 Use a wrench to expand the pads and then...

Page 2559: ...pad pins on caliper body 4 Install the M clip 5 Install the cross spring 3 17 INCH TYPE 1 Apply thin coat of Molykote AS880N Part No K0779YA010 to the frictional portion between pad and pad shim 2 Ins...

Page 2560: ...if there is oil or grease on it 3 17 INCH TYPE Check the pad thickness A NOTE Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or...

Page 2561: ...2 16 INCH AND 17 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nut 3 Lift up the vehicle and then remove the front wheel 4 Remove the caliper body from housing and sus pend from strut usin...

Page 2562: ...specified value re place the disc rotor Disc rotor runout limit 0 075 mm 0 0030 in 4 Set a micrometer 10 mm 0 39 in inward of the rotor outer perimeter and then measure the disc rotor thickness If the...

Page 2563: ...not be removed when servicing the caliper body assembly 8 Clean mud and foreign particles from the caliper body assembly and support 2 16 INCH TYPE CAUTION Do not allow brake fluid to come in contact...

Page 2564: ...ew ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 7 Bleed air from the brake system 2 16 INCH TYPE 1 Install the caliper body on housing Tightening torque 80 N m 8...

Page 2565: ...move the piston boot 5 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove 6 Remove the guide pin and boot from caliper body 2 16 INCH TYPE 1 C...

Page 2566: ...out 5 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove D ASSEMBLY 1 14 INCH AND 15 INCH TYPE 1 Clean the caliper body interior using brake f...

Page 2567: ...nd piston Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 6 Position the boot in grooves on cylinder and pis ton 7 Install the bo...

Page 2568: ...n into cylinder 6 Position the boot in grooves on cylinder and pis ton E INSPECTION 1 Repair or replace the faulty parts 2 Check the caliper body and piston for uneven wear damage or rust 3 Check the...

Page 2569: ...move the pad NOTE If the brake pad is difficult to remove use the same procedure as for front disc brake pad Ref to BR 25 REMOVAL Front Brake Pad 2 15 INCH TYPE 1 Set the vehicle on a lift 2 Loosen th...

Page 2570: ...37 N m 3 8 kgf m 27 5 ft lb NOTE If it is difficult to push the piston during pad replace ment loosen air bleeder to facilitate work 2 15 INCH TYPE 1 Apply a thin coat of Molykote AS880N Part No K0777...

Page 2571: ...pad wears down to such an extent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there...

Page 2572: ...rotor seizes up within hub drive the disc rotor out by installing an 8 mm bolt in holes B on rotor B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the parking brake Ref to PB 10 AD J...

Page 2573: ...rotor thickness If the thickness of disc rotor is out side the service limit replace the disc rotor Standard value Service limit Disc outer dia Disc rotor thickness A 14 10 mm 0 39 in 8 5 mm 0 335 in...

Page 2574: ...e in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Remove the...

Page 2575: ...n between pad and pad clip 3 Install the pads on caliper body 4 Replace the brake hose gaskets with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 5 Bleed air f...

Page 2576: ...vent the piston from jumping out and avoid being damaged 4 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out 5 Remove the piston seal from caliper body c...

Page 2577: ...the piston boot to caliper body and then attach boot ring 7 Apply a coat of specified grease to the guide pin outer surface sleeve outer surface cylinder inner surface and boot grooves Grease NIGLUBE...

Page 2578: ...ner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and install it in the groove on piston Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston in...

Page 2579: ...alling an 8 mm bolt into bolt hole in brake drum 6 Hold the hold down pin by securing rear of back plate with your hand 7 Disconnect the hold down cup from hold down pin by rotating hold down cup 8 Di...

Page 2580: ...secure the shoes 7 Fix the shoes by connecting hold down cup to hold down pin 8 Connect the lower shoe return spring 9 Set the outside diameter of brake shoes less than 0 5 to 0 8 mm 0 020 to 0 031 in...

Page 2581: ...mm bolt into bolt hole in the brake drum B INSTALLATION Set the outside diameter of brake shoes less than 0 5 to 0 8 mm 0 020 to 0 031 in in comparison with inside diameter of brake drum C INSPECTION...

Page 2582: ...KE REMOV AL Brake Hose 8 Remove the hub Ref to DS 24 REMOVAL Rear Axle 9 Disconnect the ABS wheel speed sensor from back plate 10 Remove the brake assembly 11 Remove the bolts installing wheel cylinde...

Page 2583: ...Corning Molykote No 7439 Part No 003602001 9 Install the brake shoe Ref to BR 48 INSTAL LATION Rear Drum Brake Shoe 10 Install the brake drum Ref to BR 49 IN STALLATION Rear Drum Brake Drum 11 After i...

Page 2584: ...n 2 STs are available in different sizes CAUTION When replacing the repair kit make sure that the sizes of cylinder and cup are same as those which were replaced CAUTION While assembling be careful to...

Page 2585: ...Remove the cylinder pin with magnetic pick up tool while pushing in primary piston by screwdriver which wrapped with tape Model with ABS 5 Pry up the pawl and then remove the piston re tainer Hold pis...

Page 2586: ...n wear swelling rust and other faults are found on the primary piston as sembly secondary piston assembly supply the valve stopper or gasket replace the faulty part NOTE The primary and secondary pist...

Page 2587: ...brake booster The brake booster should be discarded if it has been dropped Use special care when handling the operating rod If excessive force is applied to the operating rod sufficient to cause a ch...

Page 2588: ...ance between threaded end of stop light switch and stopper If it is not within spec ified value adjust it by adjusting the position of stop light switch Ref to BR 74 ADJUSTMENT Stop Light Switch If it...

Page 2589: ...the condition of check valve and vacuum hose Replace them if faulty and conduct the test again If no improvement is observed check precisely with gauges Operation check 1 With the engine off depress...

Page 2590: ...Damaged diaphragm Leak from valve body seal and bearing portion Leak from plate and seal assembly portion Leak from poppet valve assembly portion Loaded air tightness check 1 Start the engine and dep...

Page 2591: ...ure must be greater than the standard value listed Model with ABS Brake pedal force 147 N 15 kgf 33 lb 294 N 30 kgf 66 lb Fluid pressure 14 686 kPa 7 kg cm2 100 psi 588 kPa 6 kg cm2 85 psi 1 961 kPa 2...

Page 2592: ...tioning valve to brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft lb Proportioning valve to bracket 18 N m 1 8 kgf m 13 0 ft lb C INSPECTION 1 Install the oil pressure gauges to measure the master cylind...

Page 2593: ...ding operation keep the brake reser voir tank filled with brake fluid to eliminate entry of air The brake pedal operating must be very slow For convenience and safety two people should do the work The...

Page 2594: ...ning torque Bleeder screw Except for 17 inch type 8 N m 0 8 kgf m 5 8 ft lb 17 inch type 20 N m 2 0 kgf m 14 5 ft lb 10 Bleed air from each wheel cylinder using the same procedures as described in ste...

Page 2595: ...k 1 Loosen the wheel nuts jack up the vehicle sup port it with safety stands and remove the wheel 2 Disconnect the brake line at primary and sec ondary sides 3 Put a plastic bag cover on master cylind...

Page 2596: ...the entire system 6 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 N 50 kgf 110 lb load and measure the distance between brake pedal and steering wheel With the b...

Page 2597: ...the brake hose to strut Tightening torque 32 N m 3 3 kgf m 23 6 ft lb 2 Install the brake hose to caliper using a new gas ket Tightening torque Union bolt 18 N m 1 8 kgf m 13 0 ft lb 3 Position the d...

Page 2598: ...1 5 kgf m 10 8 ft lb 5 Bleed air from the brake system 3 REAR BRAKE HOSE DRUM BRAKE 1 Install the brake hose to wheel cylinder Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 2 Secure the brake hose to...

Page 2599: ...ring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits Be careful not to damage the airbag system wiring harness when servicing the center brake pipe W...

Page 2600: ...re removing the clutch cable from toe board remove the grommet Slowly remove the clutch cable being careful not to scratch it 7 Depress the clutch pedal and then disconnect the clutch cable from clutc...

Page 2601: ...ODEL 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower cover from instrument panel 3 Disconnect the connectors for stop light switch etc from pedal bracket 4 Remove the sn...

Page 2602: ...Switch 2 Remove the nut and pull out the bolt until brake pedal is able to remove then remove brake pedal 3 Remove the bushing spring and stopper 4 Remove the brake pad 2 LHD 2 0 L MT MODEL 1 Remove t...

Page 2603: ...racket temporarily 2 Clean the inside of bores of clutch pedal and brake pedal apply grease and set the bushings into bores 3 Align bores of the pedal bracket clutch pedal and brake pedal attach the b...

Page 2604: ...and clutch pedal Service limit 5 0 mm 0 197 in or less 2 Check the position of pedal pad Pedal height L 148 mm 5 83 in Brake pedal free play A 1 3 mm 0 04 0 12 in Depress brake pedal pad with a force...

Page 2605: ...0 8 kgf m 5 8 ft lb C INSPECTION 1 If the stop light switch does not operate properly or if it does not stop at the specified position re place with a new one Specified position L 2 mm 0 079 in 2 Mea...

Page 2606: ...tighten the lock nut Tightening torque 8 N m 0 8 kgf m 5 8 ft lb NOTE Tighten the lock nut B until the clearance between threaded end of stop light switch and stopper be comes 0 mm 0 in Hold the stop...

Page 2607: ...may dissolve paint Pay attention not to damage hexagonal head of the flare nut by using pipe wrench without fail 5 Detach the PHV along with support from side frame CAUTION Exercise utmost care to pre...

Page 2608: ...s is damaged re place it with a new one Avoid sharp bending of PHV cable as it may cause breakage 4 Connect the PHV cable with clips 5 Apply grease to the following points Hook portion of return sprin...

Page 2609: ...gine tends to stall Loosen adjusting nut gradually until smooth start ing is enabled Case B When the hill holder is released earlier than engagement of clutch pedal Vehicle slips down slightly Tighten...

Page 2610: ...r hose 11 Uneven effect of the parking brake Check adjust or replace the rear brake and cable system 3 Excessive pedal stroke 1 Entry of air into the hydraulic mechanism Bleed the air 2 Excessive play...

Page 2611: ...e disc brake 1 Excessively worn pad or the support Replace the pad or the support In the case of the drum brake 1 Excessively worn shoe ridge Replace the back plate 2 Lack of oil on the shoe ridge sur...

Page 2612: ...BR 80 BRAKE GENERAL DIAGNOSTICS...

Page 2613: ...PARKING BRAKE PB Page 1 General Description 2 2 Parking Brake Lever 6 3 Parking Brake Cable 7 4 Parking Brake Assembly Rear Disc Brake 8 5 General Diagnostic Table 11...

Page 2614: ...n rear brakes Mechanical on rear brakes drum in disc Effective drum diameter mm in 228 6 9 170 6 69 190 7 48 Lining dimensions length width thickness mm in 218 8 35 0 4 1 8 61 1 378 0 161 162 6 30 0 3...

Page 2615: ...tainer 9 Shoe guide plate 16 Shoe hold down pin 3 Spring washer 10 Primary return spring 17 Adjusting hole cover 4 Lever 11 Secondary return spring 5 Parking brake shoe Primary 12 Adjusting spring Tig...

Page 2616: ...ake lever 7 Clamp Tightening torque N m kgf m ft lb 2 Parking brake switch 8 Parking brake cable RH T1 5 9 0 6 4 3 3 Lock nut 9 Cable guide T2 18 1 8 13 0 4 Adjusting nut 10 Clamp Rear disc brake mode...

Page 2617: ...your hands because each part on the vehicle is hot after running Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure t...

Page 2618: ...g Brake Lever C INSPECTION While pulling the parking brake lever upward count the notches Lever stroke 7 to 8 notches when pulled with a force of 196 N 20 kgf 44 lb If not as specified adjust the park...

Page 2619: ...trailing link bracket 13 Remove the bolt and clamp from rear floor 14 Detach the grommet from rear floor 15 Remove the cable assembly from cabin by forcibly pulling it backward 16 Detach the parking...

Page 2620: ...rive the disc rotor out by installing two 8 mm bolts in holes B on rotor 5 Remove the shoe return spring from parking brake assembly 6 Remove the front shoe hold down spring and pin with pliers 7 Remo...

Page 2621: ...n se cure the secondary side brake shoe with shoe hold down pin cup NOTE Install the strut spring of both right and left wheels facing vehicle front Install the adjuster assembly with screw on left si...

Page 2622: ...om back plate 2 Turn the adjusting screw using a flat tip screw driver until brake shoe is in close contact with disc rotor 3 Turn back downward the adjusting screw 3 or 4 notches 4 Install the adjust...

Page 2623: ...e cause Remedy Brake drag Parking brake lever is maladjusted Adjustment Parking brake cable does not move Repair or replace Parking brake shoe clearance is maladjusted Adjustment Return spring is faul...

Page 2624: ...PB 12 PARKING BRAKE GENERAL DIAGNOSTIC TABLE...

Page 2625: ...ring Wheel 23 3 Universal Joint 24 4 Tilt Steering Column 26 5 Steering Gearbox LHD MODEL 29 6 Steering Gearbox RHD MODEL 47 7 Pipe Assembly LHD MODEL 65 8 Pipe Assembly RHD MODEL 72 9 Oil Pump 80 10...

Page 2626: ...Rotary valve Pump Power steering system Type Vane pump Oil tank Installed on body Output cm3 cu in rev 7 2 0 439 7 8 0 476 7 2 0 439 7 8 0 476 Relief pressure kPa kg cm2 psi 6 174 6 860 63 70 896 994...

Page 2627: ...0 012 or less 0 19 0 0075 or less Input shaft play In radial direction mm in 0 18 0 0071 or less In axial direction mm in 0 5 0 020 or less Turning resistance N kgf lb Maximum allowable value Less tha...

Page 2628: ...on Minimum allowance 1 Crossmember Pipe 5 mm 0 20 in 2 DOJ Shaft or joint 14 mm 0 55 in 3 DOJ Valve housing 11 mm 0 43 in 4 Pipe Pipe 2 mm 0 08 in 5 Stabilizer Pipe 5 mm 0 20 in 6 Exhaust pipe Pipe 11...

Page 2629: ...PS 5 POWER ASSISTED SYSTEM POWER STEERING GENERAL DESCRIPTION RHD MODEL PS 00428 1 8 5 7 4 6 3 2 9...

Page 2630: ...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 2631: ...58 18 19 19 19 T5 T9 T9 T8 T8 T1 T4 T2 T2 T3 T6 T7 T9 T9 T2 T12 10 9 4 4 4 1 6 58 57 8 12 15 13 14 16 6 2 57 16 4 4 9 8 10 5 4 58 T2 T5 T4 T2 T3 T7 T6 T9 T11 14 13 4 12 3 T12 1 5 2 3 T4 B A 11 11 38 3...

Page 2632: ...ng Tightening torque N m kgf m ft lb 9 Reservoir tank 35 Sleeve T1 6 0 6 4 3 10 Reservoir tank bracket 36 Adapter T2 7 4 0 75 5 4 11 Pulley 37 Clamp T3 8 0 8 5 8 12 Oil pump 38 Cotter pin T4 13 1 3 9...

Page 2633: ...8 T14 T15 T16 T10 T13 53 52 7 6 2 15 16 52 16 4 4 9 8 10 5 4 40 41 42 43 44 47 28 27 29 30 31 32 33 34 35 48 50 49 51 46 39 38 37 36 35 34 33 32 31 30 29 28 27 26 26 25 53 T9 T11 T9 T8 T14 17 18 19 20...

Page 2634: ...Clip T2 8 0 8 5 8 8 Cap 33 Boot T3 13 1 3 9 4 9 Reservoir tank 34 Wire T4 15 1 5 10 8 10 Reservoir tank bracket 35 Tie rod T5 15 7 1 6 11 6 11 Pulley 36 Holder T6 20 2 0 14 5 12 Oil pump 37 Bush T7 2...

Page 2635: ...PS 11 POWER ASSISTED SYSTEM POWER STEERING GENERAL DESCRIPTION 3 OIL PUMP EXCEPT DOHC TURBO MODEL 1 Oil pump ASSY PS 00024 1...

Page 2636: ...PS 12 POWER ASSISTED SYSTEM POWER STEERING GENERAL DESCRIPTION DOHC TURBO MODEL 1 Oil pump ASSY PS 00005 1...

Page 2637: ...eful not to burn your hands because each part on the vehicle is hot after running Use SUBARU genuine power steering fluid grease etc or the equivalent Do not mix steering fluid grease etc with that of...

Page 2638: ...700000 WRENCH Used for removing and installing tie rod Apply this tool to rack 925711000 PRESSURE GAUGE Used for measuring oil pump pressure 926200000 STAND Used when inspecting characteristic of gear...

Page 2639: ...000 926230000 SPANNER For the lock nut when adjusting backlash of gearbox 34099PA100 SPANNER Used for measuring the rotating resistance of gear box assembly 34199AE040 OIL CHARGE GUIDE Used for chargi...

Page 2640: ...aking points 926370000 INSTALLER A Used for installing valve assembly into valve housing assembly Used with STAND BASE 34099FA100 For LHD model 34099FA100 STAND BASE Used for assembling power steering...

Page 2641: ...of rack when installing rack bush Used with GUIDE 926400000 For LHD model 927620000 INSTALLER B Used for installing oil seal of valve housing Used with INSTALLER A 926360000 For LHD model 926360000 I...

Page 2642: ...FA130 Used for installing valve housing ball bearing Used for removing oil seal and ball bearing from valve housing For LHD model 34099FA130 INSTALLER SEAL Used for installing valve housing oil seal U...

Page 2643: ...0000 REMOVER Used for removing back up ring and oil seal For RHD model 34199AE000 GUIDE Used for installing rack and seal into housing assembly For RHD model 34099FA030 INSTALLER REMOVER Used for remo...

Page 2644: ...oil seal outer For RHD model 34099FA060 PUNCH HOLDER Used for caulking For RHD model 34099FA070 BASE Used for supporting housing assembly For RHD model 34099FA080 PUNCH Used for removing caulking For...

Page 2645: ...PLUG OIL SEAL REMOVER Used for removing plug oil seal For RHD model 34199AE110 PLUG OIL SEAL INSTALLER Used for installing plug oil seal For RHD model 34199AE120 GEARBOX OIL SEAL REMOVER Used for rem...

Page 2646: ...POWER ASSISTED SYSTEM POWER STEERING GENERAL DESCRIPTION 34199AE130 GEARBOX OIL SEAL INSTALLER Used for installing gearbox oil seal For RHD model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199A...

Page 2647: ...ys refer to Airbag System before per forming airbag module service Ref to AB 3 CAUTION General Description 1 Align the center of roll connector Ref to AB 18 ADJUSTMENT Roll Connector 2 Install in the...

Page 2648: ...l joint to serrated section of gear box as sembly 3 Tighten the bolt Tightening torque 24 N m 2 4 kgf m 17 4 ft lb CAUTION Excessively large tightening torque of the uni versal joint bolts may lead to...

Page 2649: ...rque of universal joint is as shown in the figures Service limit Maximum load 3 8 N 0 39 kgf 0 86 lb or less Service limit Maximum load 3 8 N 0 39 kgf 0 86 lb or less Service limit Maximum load 7 3 N...

Page 2650: ...POWER ASSISTED SYSTEM POWER STEERING TILT STEERING COLUMN 4 Tilt Steering Column A REMOVAL 1 Tilt steering column 2 Universal joint Tightening torque N m kgf m ft lb T1 24 2 4 17 4 T2 25 2 5 18 1 PS...

Page 2651: ...the tilt lever secured tighten the steering shaft mounting bolts under instrument panel Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 4 Connect all connectors under instrument panel 5 Connect the air...

Page 2652: ...ength of the steering column If not as specified replace Standard value Overall length L Except STi model 825 7 1 5 mm 32 51 0 059 in STi model 818 7 1 5 mm 32 23 0 059 in 2 AIRBAG MODEL INSPECTION WA...

Page 2653: ...from knuckle arm after pulling off cotter pin and remov ing castle nut 9 Remove the jack up plate and front stabilizer 10 Remove the one pipe joint at center of gearbox and connect vinyl hose to pipe...

Page 2654: ...0 until cotter pin hole is aligned with the slot in nut and then bend the cotter pin to lock 7 Install the front stabilizer to vehicle Ref to FS 24 INSTALLATION Front Stabilizer 8 Install the front ex...

Page 2655: ...ure the gearbox removed from vehicle in vice using ST ST 926200000 STAND CAUTION Secure the gearbox in a vise using ST as shown Do not attempt to secure it without this ST 3 Remove the tie rod end and...

Page 2656: ...arp pointed pliers rotate the rack stopper in direction of the arrow until end of the cir clip comes out of stopper Rotate the circlip in op posite direction and pull it out 14 Pull the rack assembly...

Page 2657: ...from the vehicle in vise using ST ST 926200000 STAND CAUTION Secure the gearbox in a vise using ST as shown Do not attempt to secure it without this ST 3 Using the ST loosen the lock nut ST 926230000...

Page 2658: ...e to the end surface of valve housing Do not reuse the oil seal after removal 11 Remove the snap ring using snap ring pliers CAUTION Be careful not to scratch the pinion and valve assembly 12 Press ou...

Page 2659: ...formation is noted on flats at the end of rack shape by using file and wash with cleaning fluid ST 926390001 COVER REMOVER 5 Apply genuine grease to the teeth of thoroughly washed rack assembly and th...

Page 2660: ...lace while facing rack teeth toward pinion 14 Tighten the bolts alternately to secure valve as sembly Tightening torque 25 N m 2 5 kgf m 18 1 ft lb CAUTION Be sure to alternately tighten the bolts 15...

Page 2661: ...loosen it by 25 24 Install the lock nut While holding the adjusting screw with a wrench tighten lock nut using ST ST 926230000 SPANNER Tightening torque Lock nut 39 N m 4 0 kgf m 28 9 ft lb NOTE Hold...

Page 2662: ...oove on tie rod 32 If the tie rod end was removed screw in the lock nut and tie rod end to screwed portion of tie rod and then tighten the lock nut temporarily in a position as shown in the figure Ins...

Page 2663: ...ER SEAL ST2 34099FA130 INSTALLER SEAL 4 To avoid scratching the oil seal apply a coat of grease to the contact surface of installer and oil seal 5 Verify the oil seal direction Attach the oil seal to...

Page 2664: ...la tion 15 Install the snap ring using snap ring pliers NOTE Rotate the snap ring to check for proper installa tion 16 Apply the specified grease to dust cover 17 Install the dust cover on valve assem...

Page 2665: ...r of adjusting screw thread Liquid gasket THREE BOND 1141 26 Tighten the adjusting screw to specified torque Tightening torque 7 4 N m 0 75 kgf m 5 4 ft lb 27 After tightening to the specified tighten...

Page 2666: ...and pinion engage uni formly and smoothly with each other Refer to Service limit 2 Keeping the rack pulled out all the way so that all teeth emerge check teeth for damage Even if abnormality is found...

Page 2667: ...ng alu minum plates etc between vise and gearbox ST 926200000 STAND Sliding resistance of rack shaft Service limit 400 N 41 kgf 90 lb or less 3 RACK SHAFT PLAY IN RADIAL DIREC TION Right turn steering...

Page 2668: ...lb In axial direction Service limit 0 5 mm 0 020 in or less On condition P 20 49 N 2 5 kgf 4 11 lb 5 TURNING RESISTANCE OF GEARBOX Using the ST measure the gearbox turning resis tance ST 34099PA100 S...

Page 2669: ...e respectively with the gearbox mounted to the vehicle and remove fluid from the surrounding portions Then turn the steer ing wheel from lock to lock thirty to forty times with the engine running then...

Page 2670: ...re not horizontal when wheels are set in the straight ahead position and error is more than 5 on the periphery of steer ing wheel correctly re install the steering wheel 4 If the steering wheel spokes...

Page 2671: ...le arm after pulling off cotter pin and remov ing castle nut 9 Remove the jack up plate and front stabilizer 10 Remove the one pipe joint at center of gearbox and connect vinyl hose to pipe and joint...

Page 2672: ...ut to the specified tightening torque tighten it further within 60 until cotter pin hole is aligned with slot in the nut Fit the cotter pin into nut and then bend the pin to lock 7 Install the front s...

Page 2673: ...vise using the ST ST 926200000 STAND CAUTION Secure the gearbox assembly in a vise using the ST as shown Do not attempt to secure it without this ST 2 Remove the tie rod end and lock nut from gear box...

Page 2674: ...e spring and sleeve 9 Disconnect the pipes A and B from steering body and control valve housing 10 Clean the dirt of input shaft Remove the dust cover taking care not to scratch the housing or in put...

Page 2675: ...nch 32 mm 1 26 in width across flats or adjustable wrench 14 Install the ST on valve side of rack and press outer side oil seal out taking care not to contact rack with steering body inner surface ST...

Page 2676: ...s ST1 34099FA080 PUNCH ST2 34099FA070 BASE 17 If the cylinder edge is deformed in a convex shape repair using an oil stone 18 Remove the oil seal using ST and press from plug ST 34199AE100 PLUG OIL SE...

Page 2677: ...to gear box 21 By fixing the 2 surface width press in by rotat ing the rod and attach to oil seal 22 While fixing the 2 surface width pull out the oil seal by rotating nut CAUTION Take care not to sc...

Page 2678: ...le bearing ST 926200000 STAND CAUTION Ensure the needle bearing is free from defects If it is faulty replace the steering body with a new one 4 Using the ST B and ST C attach the oil seal to ST A ST 9...

Page 2679: ...y from cylin der side ST 34199AE000 GUIDE Oil seal CAUTION Do not allow grease to block the air vent hole on rack 9 Make the ST2 pass through rack and then push in the rack and ST2 using a press until...

Page 2680: ...Apply a coat of grease on the gear teeth of valve assembly and then attach the valve assem bly taking care not to scratch oil seal and seal ring 14 Apply grease on the oil seal circumference and then...

Page 2681: ...eering body Charge the adjusting screw with grease and then insert the spring into adjusting screw and install on steering body 19 Tighten the adjusting screw to specified torque Tightening torque 7 4...

Page 2682: ...ck Tightening torque 90 N m 9 0 kgf m 65 1 ft lb NOTE Check the mating face of rack and tie rod for for eign material dirt dust and etc If required clean the mating face 28 Apply a coat of grease to t...

Page 2683: ...igure Installed tie rod length L Sedan 25 mm 0 98 in Wagon 15 mm 0 59 in 33 Inspect the gearbox as follows A Holding the tie rod end repeat lock to lock two or three times as quickly as possible B Hol...

Page 2684: ...er Refer to Service limit 2 Keeping the rack pulled out all the way so that all teeth emerge check teeth for damage Even if abnormality is found in either 1 or 2 replace the entire gearbox 4 Gearbox u...

Page 2685: ...ting alumi num plates etc between vise and gearbox ST 926200000 STAND Sliding resistance of rack shaft Service limit 400 N 41 kgf 90 lb or less 3 RACK SHAFT PLAY IN RADIAL DIREC TION Left turn steerin...

Page 2686: ...22 lb In axial direction Service limit 0 5 mm 0 020 in or less On condition P 20 49 N 2 5 kgf 4 11 lb 5 TURNING RESISTANCE OF GEARBOX Using the ST measure gearbox turning resistance ST 34099PA100 SPA...

Page 2687: ...the suspected portion between immediately after and several hours after this operation 3 Inspect leakage from a The oil seal is damaged Replace the valve assem bly with a new one 4 Inspect leakage fr...

Page 2688: ...ing wheel spokes are not horizontal when wheels are set in the straight ahead position and error is more than 5 on the periphery of steer ing wheel correctly re install the steering wheel 4 If the ste...

Page 2689: ...nter of gear box and then connect the vinyl hose to pipe and joint Discharge fluid by turning steering wheel fully clockwise and counterclockwise Discharge fluid similarly from the other pipe 4 Remove...

Page 2690: ...H4DOTC 7 REMOVAL Air Clean er 2 Remove the coolant filler tank 3 Remove the two bolts fixing pipe C and D 4 Disconnect the pipe C from oil pump Dis connect the pipe D from return hose CAUTION Do not a...

Page 2691: ...ening torque T1 19 N m 1 9 kgf m 13 7 ft lb T2 21 N m 2 1 kgf m 15 2 ft lb 3 Temporarily connect the pipe C and D to gear box 4 Temporarily install the clamp E on pipes C and D NOTE Ensure the letter...

Page 2692: ...Ref to IN H4DOTC 7 INSTALLATION Air Cleaner and Ref to IN H4SO 6 INSTALLA TION Air Intake Duct 11 Connect the battery ground cable to battery 12 Feed the specified fluid CAUTION Never start the engine...

Page 2693: ...rvice lives of the hos es the oil pump the fluid etc due to over heat Part name Inspection Remedy Pipe O ring fitting surface for damage Nut for damage Pipe for damage Replace with a new one Clamp Cla...

Page 2694: ...hat although one judges fluid leakage there is actually no leakage This is because the fluid spilt during the last maintenance was not completely wiped off Be sure to wipe off spilt fluid thoroughly a...

Page 2695: ...13 in figure Crack or damage in hose Replace with a new one Crack or damage in hose hardware Replace with a new one Leakage from surrounding of cast iron portion of oil pump 14 and 15 in figure Damage...

Page 2696: ...pe joint at the center of gear box and then connect the vinyl hose to pipe and joint Discharge fluid by turning steering wheel fully clockwise and counterclockwise Discharge fluid similarly from the o...

Page 2697: ...er the open ends of them with a clean cloth 7 Turbo model 1 Remove the air cleaner Ref to IN H4DOTC 7 REMOVAL Air Clean er 2 Remove the coolant filler tank 3 Remove the two bolts fixing pipe C and D 4...

Page 2698: ...MODEL 1 Connect the pipe D to oil tank 2 Using a new gasket connect the pipe C to oil pump Tightening torque 39 N m 4 0 kgf m 28 9 ft lb 3 Tighten the two bolts fixing pipe C and D bolt A for Non tur...

Page 2699: ...A and B to four pipe joints of gearbox Connect the upper pipe B first and lower pipe A second Tightening torque 24 N m 2 4 kgf m 17 4 ft lb 8 Install the jack up plate 9 Install the air intake duct ai...

Page 2700: ...es and or hoses as shown in the figure 1 Clearance between blow by hose and pipe 3 5 mm 0 12 0 20 in 3 Clearance between side frame and hose 15 mm 0 59 in or more 5 Steering gearbox 2 No interference...

Page 2701: ...rvice lives of the hos es the oil pump the fluid etc due to over heat Part name Inspection Remedy Pipe O ring fitting surface for damage Nut for damage Pipe for damage Replace with a new one Clamp Cla...

Page 2702: ...hat although one judges fluid leakage there is actually no leakage This is because the fluid spilt during the last maintenance was not completely wiped off Be sure to wipe off spilt fluid thoroughly a...

Page 2703: ...l cooler 22 in figure Crack or damage in hose Replace with a new one Crack or damage in hose hardware Replace with a new one Leakage from surrounding of cast iron portion of oil pump 14 and 15 in figu...

Page 2704: ...ome into contact with pulley belt To prevent foreign matter from entering the hose cover the open ends of them with a clean cloth 6 Remove the bolts which install the power steer ing pump bracket 7 Pl...

Page 2705: ...l pump to bracket Tightening torque 15 7 1 6 kgf m 11 6 ft lb Tightening torque 37 3 3 8 kgf m 27 5 ft lb 2 Tighten the bolts which install the power steering pump bracket 3 Interconnect the pipe C an...

Page 2706: ...tening torque 25 N m 2 5 kgf m 18 1 ft lb 8 Install the pulley belt cover 9 Connect the battery ground cable to battery 10 Feed the specified power steering fluid Ref to PS 88 Power Steering Fluid CAU...

Page 2707: ...ley 1 Damage Replace it with a new one 2 Bend Measure the V ditch deflection If it exceeds the service limit replace the pulley with a new one 3 Oil pump Interior 1 Defect or burning of vane pump Chec...

Page 2708: ...pulley shaft Condition P When applying the force of 9 8 N 1 0 kgf 2 2 lb Service limit Radial play Direction 0 4 mm 0 016 in or less Axial play Direction 0 9 mm 0 035 in or less 2 Ditch deflection of...

Page 2709: ...install the ST2 to the pump instead of pipe C 5 Install the ST3 to end of pipe C removed from pump 6 Replenish power steering fluid up to the specified level 7 Open the valve and start the engine 8 M...

Page 2710: ...DAPTER HOSE A Service limit 1 6 L model 6 174 6 860 kPa 63 70 kg cm2 896 994 psi 2 0 L Non turbo model 2 5 L model 6 767 7 453 kPa 69 76 kg cm2 981 1 081 psi 2 0 L Turbo model 7 350 8 036 kPa 75 82 kg...

Page 2711: ...ing the hose and pipe cover the open ends of them with a clean cloth 4 Remove the reservoir tank from bracket by pull ing it upwards B INSTALLATION 1 Install the reservoir tank to bracket 2 Connect th...

Page 2712: ...steering wheel slowly from lock to lock until bubbles stop appearing on oil sur face while keeping the fluid at that level 6 If turning the steering wheel in low fluid level condition air will be suck...

Page 2713: ...pulley belt cross section Pulley belt touches to pulley bottom Poor revolution of pulleys except oil pump pulley Poor revolution of oil pump pulley Adjust or replace 2 Tire and wheel Improper tires o...

Page 2714: ...ncrete road and in D range for automatic trans mission vehicle Trouble Possible cause Corrective action Hiss noise continuous While engine is running Relief valve emits operating sound when steering w...

Page 2715: ...inside of oil pump hose Replace the oil pump hose if the noise can be heard when running as well as stand still Torque converter growl air conditioner compression growl Remove the power steering pul l...

Page 2716: ...Ref to PS 25 INSPECTION Universal Joint Is the folding torque less than 7 3 N 0 74 kgf 1 64 lb Go to step 6 Replace with new one 6 CHECK UNIVERSAL JOINT Measure the folding torque of the joint yoke of...

Page 2717: ...customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations cont...

Page 2718: ...2003 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION G1860GE6 CRUISE CONTROL SYSTEM CC CRUISE CONTROL SYSTEM DIAGNOSTICS CC IMMOBILIZER DIAGNOSTICS IM...

Page 2719: ...embly 26 8 Power Transistor Auto A C Model 27 9 Blower Resistor Without A C Model and Manual A C Model 28 10 Heater Core 29 11 Control Unit 30 12 Compressor 31 13 Condenser 33 14 Heater and Cooling Un...

Page 2720: ...Type Magnet motor 200 W or less at 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 1 k...

Page 2721: ...00 200 kPa 6 12 2 kg cm2 87 29 psi Thermo control amplifier working temperature Evaporator outlet air 1 ON 2 OFF 3 2 5 0 5 C 36 5 0 9 F 4 1 5 0 5 C 35 0 9 F AC 00601 1 2 3 4 Item Specifications Type o...

Page 2722: ...fan Motor type Magnet Power consumption 120 W Turbo model 70 W Non turbo model Fan outer diameter 320 mm 12 6 in Idling speed A C ON MPFI model 850 100 rpm Dual switch Pressure switch Low pressure swi...

Page 2723: ...se 23 Expansion valve 4 Mode actuator lever 14 Mix actuator 24 Evaporator 5 Foot lever 15 Mix actuator lever 25 Evaporator cover 6 Spring 16 Unit assembly 26 Thermistor 7 Mode actuator link 17 Aspirat...

Page 2724: ...alve 3 Mode lever 12 Mix lever 20 Evaporator 4 Foot lever 13 Unit assembly 21 Evaporator cover 5 Spring 14 Foot duct 22 Thermistor 6 Mode link 15 Clip 7 Defroster lever 16 Packing Tightening torque N...

Page 2725: ...1 Upper case 6 Blower link lever C 11 Power transistor 2 Servo motor 7 Filter cover 12 Power transistor cover 3 Blower link 8 Filter 4 Blower link lever A 9 Blower motor assembly Tightening torque N m...

Page 2726: ...UT A C MODEL AND MANUAL A C MODEL 1 Upper case 6 Filter cover Tightening torque N m kgf m ft lb 2 Blower link 7 Filter T 7 4 0 75 5 4 3 Blower link lever A 8 Blower motor assembly 4 Blower link lever...

Page 2727: ...GENERAL DESCRIPTION 3 CONTROL UNIT AUTO A C MODEL 1 Switch 5 Aspirator hose 9 Bulb 2 Control lever 6 Switch assembly 10 Control case 3 Control panel 7 Control base 4 In vehicle sensor 8 Electronic co...

Page 2728: ...l panel 11 Mode cable 2 Fan control plate 7 A C switch with A C model 12 Temperature cable 3 Temperature control plate 8 Rear window defogger switch 13 Bulb 4 Mode control plate 9 Heater control base...

Page 2729: ...D MODEL 1 Condenser 6 O ring Tightening torque N m kgf m ft lb 2 Hose High pressure 7 Clamp A T1 7 4 0 75 5 4 3 Hose Low pressure 8 Clamp B T2 15 1 5 10 8 4 Bracket 9 Tube To condenser 5 Compressor 10...

Page 2730: ...AND A C GENERAL DESCRIPTION RHD MODEL 1 Condenser 4 Tube Tightening torque N m kgf m ft lb 2 Hose High pressure 5 Compressor T1 7 4 0 75 5 4 3 Hose Low pressure 6 O ring T2 15 1 5 10 8 AC 00610 T2 T2...

Page 2731: ...torque N m kgf m ft lb 2 Idler pulley adjuster 8 Compressor belt cover T1 7 4 0 75 5 4 3 Idler pulley 9 Compressor belt cover bracket T2 22 6 2 3 16 6 4 Compressor upper bracket T3 23 0 2 35 17 0 5 C...

Page 2732: ...ND A C GENERAL DESCRIPTION 6 HEATER DUCT 1 Front defroster nozzle 4 Side ventilation duct LH 7 Rear heater duct RH 2 Side defroster duct LH 5 Side ventilation duct RH 3 Side defroster duct RH 6 Rear h...

Page 2733: ...not be used in the HFC 134a A C system The HFC 134a refrigerant also cannot be used in the CFC 12 A C system If an incorrect or no refrigerant is used poor lu brication will result and the compressor...

Page 2734: ...be fore installation Apply the oil to the area including the O rings and tube beads After tightening use a clean shop cloth to re move excess oil from the connections and any oil which may have run on...

Page 2735: ...ply refrigerant oil to the various parts They can be obtained at a hardware or drug store Manifold gauge set A MANIFOLD GAUGE SET with hoses can be obtained from either a commercial refrigeration supp...

Page 2736: ...ore Thermometer Pocket THERMOMETERS are available from either industrial hard ware store or commercial refrigeration supply houses Electronic leak detector An ELECTRONIC LEAK DETECTOR can be obtained...

Page 2737: ...e 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 receiver...

Page 2738: ...n the operation manual attached to the refrigerant recovery system 1 Perform the compressor oil return operation Ref to AC 25 OPERATION Compressor Oil 2 Stop the engine 3 Make sure the valves on low h...

Page 2739: ...manifold gauge set with the vacuum pump 4 Carefully open the valves on the low high pres sure sides to activate the vacuum pump 5 After the low pressure gauge reaches 100 0 kPa 750 mmHg 29 5 inHg or h...

Page 2740: ...source 14 Loosen the center hose connection on the manifold gauge set if applicable press a purge valve on the manifold gauge set only for a couple of seconds to allow the air in the center hose to es...

Page 2741: ...pressor damage 22 Set up the vehicle to the following status A C switch ON Engine running at 1 500 rpm Blower speed setting to HI Temperature setting to MAX COOL Air inlet setting to RECIRC Windows op...

Page 2742: ...of leakage about 3 g 0 1 oz per year This is not a problem 8 Starting from the connection between the low pressure pipe and evaporator check the system for leakage along the low pressure side through...

Page 2743: ...n 5 Turn the blower control switch to HI 6 Leave in this condition for 10 minutes B REPLACEMENT NOTE If a component is replaced add an appropriate amount of compressor oil When replacing the compresso...

Page 2744: ...wer resis tor connector 6 Loosen the bolt and nut to remove the blower motor unit assembly B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT in General Descri...

Page 2745: ...MODEL 8 Power Transistor Auto A C Model A REMOVAL 1 Remove the glove box Ref to EI 39 REMOV AL Glove Box 2 Disconnect the power transistor connector 3 Loosen the two screws to remove the power transi...

Page 2746: ...e box Ref to EI 39 REMOV AL Glove Box 2 Disconnect the blower resistor connector 3 Loosen the two screws to remove the blower re sistor B INSTALLATION Install in the reverse order of removal C INSPECT...

Page 2747: ...10 Heater Core A REMOVAL 1 Remove the heater and cooling unit Ref to AC 34 REMOVAL Heater and Cooling Unit 2 Loosen the screws to remove the heater core cover 3 Remove the heater core B INSTALLATION I...

Page 2748: ...ND A C CONTROL UNIT 11 Control Unit A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the center console panel 3 Disconnect the connector and aspirator hose A B INSTALLATION Install in the...

Page 2749: ...oil return operation Ref to AC 25 OPERATION Compressor Oil 2 Turn the A C switch OFF and stop the engine 3 Using the refrigerant recovery system dis charge refrigerant Ref to AC 20 OPERATION Refriger...

Page 2750: ...apply compressor oil 3 When replacing compressor adjust amount of compressor oil Ref to AC 25 OPERATION Compressor Oil 4 Charge refrigerant Ref to AC 21 OPERA TION Refrigerant Charging Procedure Tigh...

Page 2751: ...e compressor Ref to AC 25 REPLACEMENT Compressor Oil B INSTALLATION 1 Install in the reverse order of removal CAUTION Replace the O rings on hoses or pipes with new ones and then apply compressor oil...

Page 2752: ...to remove the hoses LHD MODEL RHD MODEL 5 Remove the instrument panel Ref to EI 43 REMOVAL Instrument Panel Assembly 6 Remove the support beam 7 Remove the blower motor unit assembly Ref to AC 26 REM...

Page 2753: ...nit 2 Loosen the screws and clip to remove the evap orator cover 3 Remove the evaporator 4 Loosen the two bolts to remove the expansion valve CAUTION If the evaporator is replaced add appropriate amou...

Page 2754: ...vehicle 8 Remove the high pressure hose attaching bolts C 9 Disconnect the high pressure hose from com pressor 10 Disconnect the high pressure hose from con denser 11 Remove the high pressure hose fr...

Page 2755: ...ing battery voltage to the terminal be tween 3 and 4 check continuity between 1 and 2 If no continuity exists replace the relay with a new one 1 Joint box 2 Main fuse box Main Fan Relay 1 A Main Fan R...

Page 2756: ...emove the pressure switch harness connector Using a circuit tester inspect the ON OFF opera tion of pressure switch 2 1 AC 00642 Terminal No Operation Standard kPa kg cm2 psi High and low pressure swi...

Page 2757: ...REMOVAL 1 Open the front hood 2 Disconnect the ground cable from battery 3 Disconnect the ambient sensor connector 4 Remove the ambient sensor from radiator lower panel B INSTALLATION Install in the...

Page 2758: ...e ground cable from battery 2 Remove the front defroster grille 3 Disconnect the sunload sensor connector A CAUTION Be careful not to damage the sensors and inte rior trims when removing them B INSTAL...

Page 2759: ...emove the center air vent grille B 2 SIDE GRILLE 1 Disconnect the ground cable from battery 2 Remove the heater vent duct Ref to AC 43 REMOVAL Heater Vent Duct 3 Loosen the screws to remove the side a...

Page 2760: ...HEATER DUCT 22 Heater Duct A REMOVAL 1 Remove the front seat Ref to SE 6 REMOV AL Front Seat 2 Remove the front side sill cover 3 Pull off the floor mat to remove the heater duct B INSTALLATION Insta...

Page 2761: ...C HEATER VENT DUCT 23 Heater Vent Duct A REMOVAL 1 Remove the instrument panel Ref to EI 43 REMOVAL Instrument Panel Assembly 2 Remove the screws 3 Remove the heater vent duct B INSTALLATION Install...

Page 2762: ...Pressure switch A C switch Blower switch Wire harness Strange noise V Belt Magnet clutch Compressor Cold air not emitted Refrigerant V Belt Magnet clutch Compressor Pressure switch A C switch Blower s...

Page 2763: ...l Description 3 3 Electrical Components Location 5 4 A C Control Module I O Signal 7 5 Diagnostics Chart for Self diagnosis 9 6 Diagnostics for A C System Malfunction 12 7 Diagnostic Procedure for Act...

Page 2764: ...Can the malfunction part be confirmed Repair the mal function part according to each diagnostics chart Go to step 3 3 CHECK COMPARTMENT TEMPERATURE 1 Turn the A C switch ON 2 Set the temperature at m...

Page 2765: ...fect A C system problems 1 BATTERY 1 Measure the battery voltage and specific gravity of electrolyte Standard voltage 12 V Specific gravity Above 1 260 2 Check the condition of the fuses for A C syste...

Page 2766: ...si tion Outlet air Cool Fan speed 4th Compressor ON C Turn the temperature control dial from maxi mum cold position to maximum hot position grad ually Outlet air Cool Hot Fan speed AUTO Compressor ON...

Page 2767: ...SYSTEM AUTO A C DIAGNOSTICS ELECTRICAL COMPONENTS LOCATION 3 Electrical Components Location A LOCATION 1 ENGINE COMPARTMENT 1 A C compressor 3 Pressure switch 4 Ambient sensor 2 A C relay 2 1 3 2 4 1...

Page 2768: ...TION 2 PASSENGER COMPARTMENT 1 Evaporator sensor 4 Intake door actuator 7 Sunload sensor 2 Blower motor 5 Air mix door actuator 8 In vehicle sensor built in Auto A C control module 3 Blower motor resi...

Page 2769: ...aporator sensor B7 B17 Thermometer B15 B12 Sunload sensor B16 B17 Approx 5 disconnect connector and ignition switch ON Air mix door actuator B5 B1 Battery voltage ignition switch ON Air mix door actua...

Page 2770: ...NTROL MODULE I O SIGNAL B SCHEMATIC 1 AIR CONDITIONER AUTO A C LHD MODEL Ref to WI 54 AUTO A C LHD MODEL SCHE MATIC Air Conditioning System 2 AIR CONDITIONER AUTO A C RHD MODEL Ref to WI 58 AUTO A C R...

Page 2771: ...ll switch LED illuminates RHD model or blink LHD model on control panel Do all LED illuminate or blink Go to step 3 Check the switch LED 3 CHECK SENSORS MALFUNCTION 1 Turn the fan speed control dial t...

Page 2772: ...that blower fan speed changes depending on set temperature Does the blower fan speed change Go to step 7 Check the blower motor circuit Ref to AC 14 BLOWER MOTOR IS NOT ROTATED Diag nostics for A C S...

Page 2773: ...illumi nate A C switch LED illu minate FRESH RECIRC switch LED illuminate HEAT Evaporator sensor A C switch LED and FRESH RECIRC switch LED illumi nate A C switch LED illu minate FRESH RECIRC switch L...

Page 2774: ...et temperature is not indicated on the display switch LEDs are faulty and switches do not operate Self diagnosis system does not operate WIRING DIAGRAM A8 B2 B1 B12 B282 A B283 B AUTO A C CONTROL MODU...

Page 2775: ...ODULE POWER CIRCUIT Measure the voltage between A C control module connector terminal and chassis ground when turning the ignition switch to ACC Connector terminal B283 No 2 Chassis ground Is the volt...

Page 2776: ...ated in HI WIRING DIAGRAM A16 B11 B14 B50 B87 B275 BATTERY F B NO 1 F B NO 2 F B NO 17 SBF 3 SBF 1 SBF 4 B282 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B283 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

Page 2777: ...e ignition switch to OFF 2 Remove the blower fan motor relay 3 Connect the battery positive terminal to No 1 terminal and negative terminal to No 3 terminal of blower fan motor connector 4 Measure the...

Page 2778: ...Y 1 SUBFAN RELAY 2 AIR CONDITIONING RELAY 1 26 28 27 25 23 21 22 24 7 5 6 8 18 20 19 17 10 9 2 3 4 A6 A9 E28 E17 E27 ECM B134 A B84 E B14 B3 B4 AUTO A C CONTROL MODULE B282 A B283 B 3 4 1 2 8 9 10 11...

Page 2779: ...RELAY 1 26 28 27 25 23 21 22 24 7 5 6 8 18 20 19 17 10 11 12 9 2 3 4 A6 A9 E28 E17 E27 ECM B134 A B84 E B14 B3 B4 AUTO A C CONTROL MODULE B282 A B283 B 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6...

Page 2780: ...F79 F17 1 2 F16 2 1 F45 B134 A 21 9 3 4 5 6 10 11 12 13 14 15 7 16 23 30 19 20 22 26 27 28 29 8 17 24 31 18 25 1 2 32 33 34 35 B137 D 14 5 2 3 4 6 7 8 9 10 11 12 16 15 19 13 18 1 17 20 B136 C 19 8 3...

Page 2781: ...A C CONTROL MODULE B282 A B283 B F24 F79 F27 F96 B255 F45 B60 2 1 2 1 F79 F17 1 2 F16 2 1 B134 A 21 9 3 4 5 6 10 11 12 13 14 15 7 16 23 30 19 20 22 26 27 28 29 8 17 24 31 18 25 1 2 32 33 34 35 B136 C...

Page 2782: ...AC 37 INSPECTION Relay and Fuse Is the operation of the relay OK Go to step 5 Replace the A C relay 5 CHECK OPERATION OF MAIN FAN MOTOR 1 Start the engine 2 Turn the A C switch to ON 3 Check the opera...

Page 2783: ...s ground SOHC model F16 No 2 Chassis ground Is the voltage more than 10 V Go to step 12 Repair the open circuit in harness for power supply circuit 12 CHECK GROUND CIRCUIT OF SUB FAN MOTOR 1 Turn the...

Page 2784: ...17 CHECK EACH ACTUATOR Check the actuators for proper operation using the self diagnostic function Ref to AC 9 Diagnostics Chart for Self diagnosis Is the operation of each actua tor normal Go to ste...

Page 2785: ...RS 7 Diagnostic Procedure for Actuators A INTAKE DOOR ACTUATOR TROUBLE SYMPTOM FRESH RECIRC mode is not changed WIRING DIAGRAM A7 A15 B91 B283 B B282 A AUTO A C CONTROL MODULE 2 1 INTAKE DOOR ACTUATOR...

Page 2786: ...t circuit in harness for power supply line 4 CHECK HARNESS CONNECTOR BETWEEN A C CONTROL MODULE AND FRESH RE CIRC ACTUATOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from A C control...

Page 2787: ...DOOR ACTUATOR TROUBLE SYMPTOM Air flow outlet is not changed WIRING DIAGRAM AC 00676 B283 B282 B77 B6 AUTO A C CONTROL MODULE MODE DOOR ACTUATOR 2 3 1 B12 A12 B A 3 4 1 2 8 9 10 11 12 13 14 15 16 17...

Page 2788: ...C control module harness connector terminal and chas sis ground with oscilloscope Connector terminal B282 No 12 Chassis ground Is the voltage approx 5 5 V Go to step 4 Replace the auto A C control mo...

Page 2789: ...R ACTUATOR TROUBLE SYMPTOM Outlet air temperature is not changed WIRING DIAGRAM AC 00677 B283 B282 B293 B5 AUTO A C CONTROL MODULE AIR MIX DOOR ACTUATOR 2 3 1 B12 A4 B A 3 4 1 2 8 9 10 11 12 13 14 15...

Page 2790: ...odule harness connector terminal and chas sis ground with oscilloscope Connector terminal B282 No 4 Chassis ground Is the voltage approx 5 5 V Go to step 4 Replace the auto A C control mod ule 4 CHECK...

Page 2791: ...position WIRING DIAGRAM AC 00678 B283 B282 F78 F45 B62 AUTO A C CONTROL MODULE AMBIENT SENSOR B17 B9 B A 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 B283 B 1 2 3 4 F78 1 2 LHD MODEL 2 RHD MODEL...

Page 2792: ...control module Connector terminal B283 No 9 No 17 Is the voltage approx 5 V Go to step 4 Go to step 6 4 CHECK HARNESS CONNECTOR BETWEEN A C CONTROL MODULE AND AMBIENT SENSOR 1 Turn the ignition switch...

Page 2793: ...LE SYMPTOM When turning the AUTO switch to ON blower fan speed outlet port and inlet port is not changed If the switch LED indicates that the sensor is malfunctioning replace the A C control module Th...

Page 2794: ...NOSTICS DIAGNOSTIC PROCEDURE FOR SENSORS C EVAPORATOR SENSOR WIRING DIAGRAM AC 00679 B17 B7 B256 1 2 EVAPORATION THERMO SWITCH B283 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B256 B283 B B28...

Page 2795: ...A C control module connector terminals Connector terminal B283 No 7 No 17 Is the voltage approx 5 V Go to step 4 Go to step 6 4 CHECK HARNESS CONNECTOR BETWEEN A C CONTROL MODULE AND EVAPORA TOR SENS...

Page 2796: ...sunload sensor at a place where sun shines directly on it WIRING DIAGRAM AC 00680 B B283 A B282 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3 4 1 2 8 9 1...

Page 2797: ...ir the har ness between A C control module and sunload sen sor 3 CHECK HARNESS CONNECTOR BETWEEN A C CONTROL MODULE AND SUNLOAD SENSOR Measure the resistance of harness between A C control module and...

Page 2798: ...s Main and sub Sensors In vehicle ambient water temperature evaporator sunload etc In vehicle sensor aspirator duct Symptom A C system fails to operate Burned out fuse Illumination does not dim at nig...

Page 2799: ...Driver s Airbag Module 12 5 Passenger s Airbag Module 13 6 Side Airbag Module 14 7 Airbag Control Module 16 8 Side Airbag Sensor 17 9 Roll Connector 18 10 Front Sub Sensor 19 11 Disposal of Airbag Mod...

Page 2800: ...g sensor T1 5 9 0 59 4 4 2 TORX bolt T30 8 Side airbag harness T2 7 4 0 75 5 4 3 Airbag module ASSY Driver s side 9 Side airbag module T3 10 1 0 7 2 10 Airbag main harness T4 20 2 0 14 5 4 Airbag modu...

Page 2801: ...ectly or not inflate in collision If sensors airbag module airbag control module pretensioner and harness are deformed or dam aged replace them with new genuine parts When checking the airbag system b...

Page 2802: ...em wire harness do not attempt to re pair using soldering equipment Be sure to replace the faulty harness with a new genuine part Install the wire harness securely with the speci fied clips to avoid i...

Page 2803: ...d airbag or pretensioner When painting or performing sheet metal work on the front part of the vehicle including the front wheel apron front fender and front side frame re move the front sub sensors a...

Page 2804: ...not place any objects on it or pile airbag modules on top of each other If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object a serious acciden...

Page 2805: ...OOL 98299PA030 98299SA010 TEST HARNESS ADAPTER D Used for deploying the driver s airbag module Used for deploying the seat belt pretensioner Used with DEPLOYMENT TOOL 98299PA030 Can not reuse 98299PA0...

Page 2806: ...is locked 2 DRIVER S AIRBAG BETWEEN AIRBAG HARNESS AND ROLL CONNECTOR PAS SENGER S AIRBAG AND SIDE AIRBAG 1 How to disconnect 1 Push the lock arm A 2 With the lock arm A pushed in move the slide lock...

Page 2807: ...in until it locks Then pull on it gently to make sure that it is locked At this time be sure to insert the push lock in 4 FRONT SUB SENSOR AND SIDE AIR BAG SENSOR 1 How to disconnect Holding outer pa...

Page 2808: ...em parts 1 DRIVER S AIRBAG MODULE 1 Check for the following and replace damaged parts with new parts Airbag module is cracked or deformed Harness and or connector is cracked deformed or open Lead wire...

Page 2809: ...maged parts with new parts Side airbag sensor is cracked or deformed Mounting bracket is cracked or deformed Connector is scratched or cracked Side airbag is deployed operating side 7 ROLL CONNECTOR C...

Page 2810: ...eering wheel 5 Disconnect the airbag connector on the back of airbag module and then remove the airbag mod ule 6 Refer to CAUTION for handling of a removed airbag module Ref to AB 3 CAUTION General De...

Page 2811: ...the three bolts and then carefully re move the airbag module 6 Refer to CAUTION for handling of a removed airbag module Ref to AB 3 CAUTION General Description B INSTALLATION Install in the reverse or...

Page 2812: ...nect the ground cable from battery and wait for at least 20 seconds before starting work 3 Remove the front seat from the vehicle Ref to SE 6 REMOVAL Front Seat 4 Remove the clip and then remove the s...

Page 2813: ...UTION General Description Perform the inspection of following items and re place the damaged parts with new ones Ref to AB 10 SIDE AIRBAG MODULE INSPECTION Inspection Locations After a Collision 1 Wit...

Page 2814: ...tarting work 3 Remove the console cover Ref to EI 42 RE MOVAL Console Box 4 Remove the center console panel Ref to EI 43 REMOVAL Instrument Panel Assembly 5 Disconnect the connector from airbag contro...

Page 2815: ...ont Seat Belt 4 Detach the side airbag sensor and then discon nect the airbag connector B INSTALLATION CAUTION Use new TORX bolts T30 when reassembling Install in the reverse order of removal Tighteni...

Page 2816: ...ll connector B INSTALLATION 1 Install in the reverse order of removal 2 Before installing the steering wheel be sure the direction of roll connector is adjusted with steering Ref to AB 18 ADJUSTMENT R...

Page 2817: ...s to remove the sensor cov er 5 Remove the bolt and then detach the front sub sensor 6 Disconnect the connector from front sub sensor B INSTALLATION Install in the reverse order of removal Tightening...

Page 2818: ...the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let water get on the deployed airbag module Wrap the deployed airbag module in an air tight viny...

Page 2819: ...an airtight vinyl bag and discard it 2 PASSENGER S AIRBAG MODULE 1 Turn the ignition switch to OFF 2 Disconnect the ground cable from battery and wait for at least 20 seconds before starting work 3 Re...

Page 2820: ...gnition switch to OFF 2 Disconnect the ground cable from battery and wait for at least 20 seconds before starting work 3 Disconnect the side airbag module connector yellow under the front seat cushion...

Page 2821: ...ect the other cable of the deployment tool to the battery positive terminal Then deploy the airbag module CAUTION After deployment the airbag module will be especially hot Leave it unattended for 40 m...

Page 2822: ...deployment the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let water get on the deployed airbag module Wrap the deployed airbag module in an ai...

Page 2823: ...irbag module 13 Wrap the deployed airbag module in an airtight vinyl bag and discard it 2 PASSENGER S AIRBAG MODULE 1 Turn the ignition switch to OFF 2 Disconnect the ground cable from battery and wai...

Page 2824: ...a rope 10 Move the battery at least 5 m 16 ft from vehi cle and secure the nearby area Connect the de ployment tool alligator clip to the battery negative terminal 11 Connect the other cable of the de...

Page 2825: ...ment B CAUTION The deployment tool should be kept shorted terminals until just before deployment of the airbag module 8 Connect the adapter A connector to airbag mod ule 9 Install the side airbag modu...

Page 2826: ...ol to the battery positive terminal Then deploy the airbag module CAUTION After deployment the airbag module will be especially hot Leave it unattended for 40 min utes and then discard it Do not let w...

Page 2827: ...s Location 17 5 Airbag Control Module I O Signal 19 6 Airbag Connector 25 7 Airbag Warning Light Illumination Pattern 27 8 Read Diagnostic Trouble Code DTC 28 9 Inspection Mode 29 10 Clear Memory Mode...

Page 2828: ...irbag Warning Light Fail ure Ref to AB 31 Airbag Warn ing Light Failure 3 PERFORM THE DIAGNOSIS 1 Judge the possible cause from List of Diad nostic Trouble Code DTC Ref to AB 38 List of Diagnostic Tro...

Page 2829: ...km Miles Vin No Date Problem Occurred Registration Year Weather Fine Cloudy Rainy Snowy Other Temperature C F Road Condition Level road Uphill Downhill Rough road Others Vehicle Operation Starting Id...

Page 2830: ...ged replace them with new genuine parts Do not use the airbag system and pretensioners on other vehicles When replacing parts be sure to replace them with new parts When checking the airbag system be...

Page 2831: ...water or oil to come in contact with the connector terminals Do not touch the connec tor terminals Either of the airbag modules for driver passen ger or side or pretensioner must not be disassem bled...

Page 2832: ...l apron front fender and front side frame re move the front sub sensors and wire harness of the airbag system When painting or performing sheet metal work on the side of the vehicle including the side...

Page 2833: ...do not place any objects on it or pile airbag modules on top of each other If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object a serious acci...

Page 2834: ...ove 1 260 C PREPARATION TOOL CAUTION Be sure to use specified test harness when measuring the voltage resistance etc of AIRBAG sys tem component parts 1 TEST HARNESS M AB 00304 5M 1 2 3 4 5 6 1 2 1 Lg...

Page 2835: ...AB 9 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 2 TEST HARNESS F AB 00305 3F 5 6 1 2 3 4 5 6 PN 98299FC010 2 1 2F 1F 2F 3F 2 1 2 1 1F 4 3 1 2...

Page 2836: ...AB 10 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 3 TEST HARNESS G AB 00306 3G 3G 1 2 3 6 5 4 7 8 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 1 2 3 4 5 6 7 8 1G 1G 2G PN 98299FC020 2G...

Page 2837: ...AB 11 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 4 TEST HARNESS H AB 00307 PN 98299FA030 1H 2H 3H 1H 2H 3H 1 3 3 1 2 1 2 1 2 1 2 4 5 6 4 5 6 2...

Page 2838: ...AB 12 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 5 TEST HARNESS L AB 00308 3L 3L 1 2 5 6 3 4 1L 1L 2L 2L 1 2 2 1 3 1 2 6 4 5 PN 98299FE000 1 2...

Page 2839: ...5 34 36 30 24 43 4 44 3 37 27 21 38 32 46 42 45 41 33 14 31 5 1 6 2 19 13 29 39 40 20 28 15 17 23 25 22 26 18 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 3 4 5 6 7 8 9 11 12 13 14 17 18 19 20 1 10 15 16 1...

Page 2840: ...AB 14 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 7 TEST HARNESS N AB 00309 2N 2N 1N 1N 1B 2B 1A 2A 1B 2B 1A 2A PN 98299SA000...

Page 2841: ...AB 15 AIRBAG SYSTEM DIAGNOSTICS GENERAL DESCRIPTION 8 TEST HARNESS T AB 00336 1 2 2 3 4 5 6 1 5 1 3 4 2 6 3 4 5 6 1 2 3 4 5 6 2T 2T 1T 1T PN 98299SA060...

Page 2842: ...esistor is used during diagnostics The airbag resistor has the same resistance as the airbag module and thus provides safety when used instead of the airbag module It also makes it possible to finish...

Page 2843: ...ner RH 12 Side airbag sensor LH 6 Passenger s airbag inflator 13 Side airbag sensor RH Connector No AB1 AB2 AB3 AB4 AB7 AB8 AB9 AB10 AB11 AB12 AB13 AB14 Pole 6 2 28 4 12 12 2 4 2 4 2 2 Color Yellow Bl...

Page 2844: ...ensor LH 6 Passenger s airbag inflator 13 Side airbag sensor RH Connector No AB1 AB2 AB3 AB4 AB7 AB8 AB9 AB10 AB11 AB12 AB13 AB14 Pole 6 2 28 4 12 12 2 4 2 4 2 2 Color Yellow Black Yellow Yellow Yello...

Page 2845: ...R 2 RW GR GY 3 5 4 5 3 19 2 L W W W L GB 7 2 GR 1 2 W L BR BR GR GR GR 9 B B B B18 1 BR 16 BR 6 E B AIRBAG CIRCUIT AIRBAG INDICATOR LIGHT COMBINATION METER B i10 C i11 C B i11 GREEN i10 GRAY B79 BROWN...

Page 2846: ...11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 FRONT SUB SENSOR LH AB18 AIRBAG CONTROL MODULE INFLATOR PASSENGER SIDE INFLATOR DRIVER SIDE STEERING ROLL CONNECTOR AB3 E W 1 2 26 15 FRONT SUB S...

Page 2847: ...WITH PRETENSIONER RH ELR WITH PRETENSIONER LH SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH INFLATOR SIDE RH INFLATOR SIDE LH AB8 AB7 AB20 6 YR YL 1 2 YR YL 5 AB11 AB28 Y 2 Y Y 1 2 Y 1 2 1 6 5 AB12 AB10...

Page 2848: ...C6 C7 21 LgR LgR GW GW GW R FB 17 IG F B FUSE NO 18 GB 6 R 5 GW LgR Or Or 1 4 3 5 3 19 2 L V Y Lg LR RY V L GB 7 2 LgR 1 2 V L B B GR 10 B B B B18 6 E B AIRBAG CIRCUIT AIRBAG INDICATOR LIGHT COMBINATI...

Page 2849: ...3 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 FRONT SUB SENSOR LH AB18 AIRBAG CONTROL MODULE INFLATOR PASSENGER SIDE INFLATOR DRIVER SIDE STEERING ROLL CONNECTOR AB3 E B B 1 2 L Br L Br 26 15 FRONT S...

Page 2850: ...ITH PRETENSIONER RH ELR WITH PRETENSIONER LH SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH INFLATOR SIDE RH INFLATOR SIDE LH AB8 AB7 AB20 6 YR YL 1 2 YR YL 5 AB11 AB28 YG 2 YB YG 1 2 YB 1 2 1 6 5 AB12 A...

Page 2851: ...it is locked 2 DRIVER S AIRBAG BETWEEN AIRBAG MAIN HARNESS AND ROLL CONNECTOR PASSENGER S AIRBAG AND SIDE AIR BAG 1 How to disconnect 1 Push the lock arm A 2 With the lock arm A pushed in move the sl...

Page 2852: ...insert the connector in until it locks Then pull on it gently to make sure that it is locked Be sure to push the push lock in securely 4 FRONT SUB SENSOR AND SIDE AIR BAG SENSOR 1 How to disconnect Ho...

Page 2853: ...N 7 Airbag Warning Light Illumi nation Pattern A INSPECTION Keep the ignition switch to ON and confirm that the airbag warning light remains off after being turned on for approx 6 seconds 1 Airbag war...

Page 2854: ...ent 0 3 sec on indicates a one NOTE List of Diagnostic Trouble Code DTC Ref to AB 38 List of Diagnostic Trouble Code DTC Airbag Warning Light Failure Ref to AB 31 Airbag Warning Light Failure 4 Turn t...

Page 2855: ...AB 29 AIRBAG SYSTEM DIAGNOSTICS INSPECTION MODE 9 Inspection Mode A OPERATION Recreate the circumstance by referring to the con ditions described in the checklist...

Page 2856: ...minal No 2 4 Once the memory is erased the warning light re turns to the normal flash rate 0 6 sec on The fail ure to recover the normal flash rate indicates that trouble parts still remain Having rep...

Page 2857: ...AB3 is not connected properly to the airbag control module CAUTION Before diagnosing the airbag system be sure to turn the ignition switch to OFF disconnect the ground cable from battery and wait mor...

Page 2858: ...d B31 Is the poor contact in connec tors AB1 and B31 Repair the body harness or replace the body harness with airbag main harness Go to step 2 BATTERY AB3 B31 AB1 No 13 IGNITION SWITCH AIRBAG CIRCUIT...

Page 2859: ...trol Module Go to step 5 5 CHECK AIRBAG MAIN HARNESS 1 Turn the ignition switch to OFF disconnect the battery ground cable and wait more than 20 seconds 2 Connect the connector AB1 to B31 3 Disconnect...

Page 2860: ...poor contact in connec tors AB1 and B31 Repair the body harness or replace the body harness with airbag main harness Go to step 2 BATTERY AB3 B31 AB1 No 13 IGNITION SWITCH AIRBAG CIRCUIT AIRBAG INDIC...

Page 2861: ...AIN HARNESS 1 Turn the ignition switch to OFF disconnect the battery ground cable and wait more than 20 seconds 2 Connect the connector AB1 to B31 3 Disconnect the connectors AB26 and AB21 4 Remove th...

Page 2862: ...rning light operates properly When inspecting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons WIRING DIAGRAM BATTERY AB3 B31 AB1 No...

Page 2863: ...switch to OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disconnect the connector AB1 from B31 3 Connect the battery ground cable and turn the ignition switch to ON Is the ai...

Page 2864: ...ess circuit passenger is shorted to power supply Airbag module harness passenger is shorted to power supply Airbag control module is faulty Passenger s airbag module is faulty Ref to AB 47 DTC 16 Diag...

Page 2865: ...sensor RH is faulty Side airbag harness RH is faulty Airbag control module is faulty Ref to AB 69 DTC 51 Diagnostic Procedure with Diagnostic Trouble Code DTC 52 Provided Side airbag sensor LH is fau...

Page 2866: ...y Airbag control module is faulty Ref to AB 78 DTC 65 Diagnostic Procedure with Diagnostic Trouble Code DTC 66 Provided Seat belt pretensioner LH circuit is shorted to power supply Pretensioner is fau...

Page 2867: ...re to turn the ignition switch to OFF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll conn...

Page 2868: ...t harness F 5 Connect the battery ground cable and turn the ignition switch to ON Does the airbag warning light operate properly Replace the roll connector Ref to AB 18 Roll Connector Go to step 3 3 C...

Page 2869: ...to OFF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and senso...

Page 2870: ...ground cable and wait more than 20 seconds 2 Disconnect the airbag resistor from the con nector 3F in test harness F 3 Remove the instrument panel lower cover and disconnect the connector AB26 from A...

Page 2871: ...onnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect...

Page 2872: ...4 Connect the connector 1F in test harness F to connector AB21 5 Connect the airbag resistor to connector 3F in test harness F 6 Connect the battery ground cable and turn the ignition switch to ON Do...

Page 2873: ...FF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor rec...

Page 2874: ...ing light operate properly Replace the pas senger airbag module Ref to AB 13 Passen ger s Airbag Mod ule Go to step 2 2 CHECK AIRBAG MAIN HARNESS 1 Turn the ignition switch to OFF disconnect the batte...

Page 2875: ...Passenger s airbag module Ref to AB 13 Passenger s Airbag Module Front sub sensor of both sides Ref to AB 19 Front Sub Sensor Front seat belt outer with pretensioner of both sides Ref to SB 12 Front S...

Page 2876: ...than 20 seconds 2 Disconnect the connectors AB3 AB7 and AB8 from the airbag control module Ref to AB 16 Airbag Control Module Check if rust or damage appear on the harness connec tor and the control...

Page 2877: ...han 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operate...

Page 2878: ...than 20 seconds before operation 2 Disconnect the airbag connector AB1 from the body harness B31 3 Connect the connector 2M in test harness M to connector AB1 4 Measure the resistance between connecto...

Page 2879: ...han 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operate...

Page 2880: ...20 seconds before operation 2 Disconnect the airbag connector AB1 from the body harness B31 3 Connect the connector 2M in test harness M to the airbag connector AB1 4 Measure the resistance between th...

Page 2881: ...d wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning...

Page 2882: ...onnector 1H in test harness H to connector AB15 3 Measure the resistance between connector 3R in test harness R and connector 3H in test harness H Connector terminal 3R No 7 3H No 5 3R No 9 3H No 6 Is...

Page 2883: ...tor terminal 3F No 5 Chassis ground 3F No 6 Chassis ground Is the resistance more than 1 M Go to step 9 Replace the body harness with front sub sensor har ness RH 9 CHECK FRONT SUB SENSOR RH 1 Connect...

Page 2884: ...wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning l...

Page 2885: ...Connect the connector 1H in test harness H to connector AB18 3 Measure the resistance between connector 3R in test harness R and connector 3H in test harness H Connector terminal 3R No 6 3H No 6 3R N...

Page 2886: ...terminal 3F No 5 Chassis ground 3F No 6 Chassis ground Is the resistance more than 1 M Go to step 9 Replace the body harness with front sub sensor har ness LH 9 CHECK FRONT SUB SENSOR LH 1 Connect the...

Page 2887: ...g module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the...

Page 2888: ...onnector 3R in test harness R and connector 3F in test harness F Connector terminal 3R No 20 3F No 4 3R No 18 3F No 3 Is the resistance less than 10 Go to step 3 Replace the body harness with side air...

Page 2889: ...ag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect th...

Page 2890: ...nnector 3R in test harness R and connector 3F in test harness F Connector terminal 3R No 12 3F No 4 3R No 10 3F No 3 Is the resistance less than 10 Go to step 3 Replace the body harness with side airb...

Page 2891: ...seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver...

Page 2892: ...y Replace the front seat with side air bag module RH Ref to SE 6 Front Seat Go to step 2 2 CHECK SIDE AIRBAG HARNESS RH 1 Turn the ignition switch to OFF disconnect the battery ground cable and wait m...

Page 2893: ...e seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver...

Page 2894: ...Replace the front seat with side air bag module LH Ref to SE 6 Front Seat Go to step 2 2 CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch to OFF disconnect the battery ground cable and wait mo...

Page 2895: ...g module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the...

Page 2896: ...t the con nector 1G in test harness G to connector AB12 7 Measure the resistance between connector 4R in test harness R and connector 3G in test harness G Connector terminal 4R No 5 3G No 2 4R No 7 3G...

Page 2897: ...ag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect th...

Page 2898: ...e air bag control module Ref to AB 16 Airbag Control Module 5 Connect the connector 1R in test harness R to connector AB7 6 Disconnect the connector AB10 from the side airbag sensor LH and connect the...

Page 2899: ...ed when the side airbag is deployed When this code is displayed the memory cannot be erased Replace the following parts Airbag control module Ref to AB 16 Airbag Control Module Front seat with side ai...

Page 2900: ...ch to OFF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sen...

Page 2901: ...harness 3 Disconnect the connector AB28 from AB11 4 Disconnect the connectors AB7 and AB8 from the airbag control module Ref to AB 16 Airbag Control Module 5 Connect the connector 1R in test harness...

Page 2902: ...ch to OFF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sen...

Page 2903: ...ness 3 Disconnect the connector AB29 from AB9 4 Disconnect the connectors AB7 and AB8 from the airbag control module Ref to AB 16 Airbag Control Module 5 Connect the connector 1R in test harness R to...

Page 2904: ...to OFF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor...

Page 2905: ...to SB 12 Front Seat Belt Go to step 2 2 CHECK SIDE AIRBAG HARNESS RH 1 Turn the ignition switch to OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disconnect the airbag resisto...

Page 2906: ...OFF disconnect the ground cable from battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and the sens...

Page 2907: ...ef to SB 12 Front Seat Belt Go to step 2 2 CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch to OFF disconnect the battery ground cable and wait more than 20 seconds 2 Disconnect the airbag resi...

Page 2908: ...AB 82 AIRBAG SYSTEM DIAGNOSTICS DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC...

Page 2909: ...SYSTEM SB Page 1 General Description 2 2 Pretensioner Connector 7 3 Seat Belt Warning System 8 4 Inspection Locations After a Collision 11 5 Front Seat Belt 12 6 Rear Seat Belt 14 7 Disposal of Preten...

Page 2910: ...ION 1 General Description A COMPONENT 1 FRONT SEAT BELT 1 Adjuster anchor ASSY 3 Outer belt ASSY Tightening torque N m kgf m ft lb 2 Anchor cover 4 Inner belt ASSY T1 7 5 0 76 5 5 T2 30 3 1 22 T3 53 5...

Page 2911: ...PTION 2 REAR SEAT BELT SEDAN MODEL 1 Outer seat belt RH ASSY 4 Center seat belt LH ASSY Tightening torque N m kgf m ft lb 2 Shoulder seat belt CTR ASSY 5 Case center ELR T 30 3 1 22 3 Outer seat belt...

Page 2912: ...REAR SEAT BELT WAGON MODEL 1 Outer seat belt RH ASSY 4 Center seat belt RH ASSY Tightening torque N m kgf m ft lb 2 Shoulder seat belt CTR ASSY 5 Center seat belt LH ASSY T 30 3 1 22 3 Outer seat bel...

Page 2913: ...t to flow through or voltage to reach the pretensioner Do not use a circuit tester to check resistance of the pretensioner Do not disassemble or attempt to repair the pre tensioner If it is dented cra...

Page 2914: ...SCRIPTION REMARKS 98299SA010 ADAPTER D DEPLOYMENT Used for deploying the pretensioner Used with DEPLOYMENT TOOL 98299PA030 98299PA030 DEPLOYMENT TOOL Used for deploying the pretensioner Used with ADAP...

Page 2915: ...ctor to disconnect from retrac tor assembly 2 How to connect Connect the connector in reverse order of discon necting At this time be sure to insert the connector in until connecting sound is heard CA...

Page 2916: ...r the open harness short cir cuit and poor con tact of connector between seat belt timer module and battery 3 CHECK HARNESS AND SEAT BELT SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the conn...

Page 2917: ...CHECK VEHICLE MODEL Check the model of vehicle Is the vehicle MT model Go to step 11 Go to step 13 11 CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND SEAT BELT TIMER MODULE 1 Turn the ignition switch...

Page 2918: ...Start the engine and set the vehicle speed less than 19 km h 12 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When diagn...

Page 2919: ...IONS AFTER A COLLISION 4 Inspection Locations After a Collision A INSPECTION Check for the following and then replace with new parts if necessary Center pillar lower garnish is discolored or cracked W...

Page 2920: ...and then loosen the three bolts to remove the front outer belt 6 Remove the center pillar upper trim Ref to EI 46 REMOVAL Upper Inner Trim 7 Remove the two bolts and adjustable anchor as sembly CAUTI...

Page 2921: ...NENT General Description 2 FRONT INNER BELT Install in the reverse order of removal Tightening torque Ref to SB 2 FRONT SEAT BELT COMPO NENT General Description C INSPECTION 1 FRONT OUTER BELT Check...

Page 2922: ...3 Remove the quarter pillar trim Ref to EI 48 REMOVAL Rear Quarter Trim 4 Remove the rear shelf trim Ref to EI 53 RE MOVAL Rear Shelf Trim 5 Remove the bolts and then detach the seat belt 3 CENTER BEL...

Page 2923: ...oulder anchor bolt and then de tach the shoulder anchor from quarter pillar 2 Remove the quarter trim Ref to EI 48 RE MOVAL Rear Quarter Trim 3 Remove the three bolts and then detach the outer belt ce...

Page 2924: ...n make sure that the seat belts are smoothly extended and wound 6 CENTER BELT WAGON MODEL Install in the reverse order of removal CAUTION During installation make sure that the seat belts are not twis...

Page 2925: ...t vi nyl bag and then discard it If circumstances do not permit pretensioner de ployment contact a SUBARU dealer B OPERATION 1 DEPLOYING OF PRETENSIONER WHILE INSTALLED IN VEHICLE 1 Fold backrest all...

Page 2926: ...LE 1 Fold the backrest all the way forward and then move the front seat all the way forward 2 Turn the ignition switch to OFF disconnect the ground cable from battery and wait for more than 20 seconds...

Page 2927: ...n fasten them tight with a rope 10 Move the battery at least 5 m 16 ft from the vehicle and secure the nearby area Connect the deployment tool alligator clip to the battery negative terminal 11 Connec...

Page 2928: ...SB 20 SEAT BELT SYSTEM DISPOSAL OF PRETENSIONER...

Page 2929: ...Switch Assembly 13 12 Headlight Assembly 14 13 Headlight Bulb 16 14 Front Turn Signal Light Bulb 17 15 Clearance Parking Light Bulb 18 16 Front Fog Light Assembly 19 17 Front Fog Light Bulb 20 18 Rear...

Page 2930: ...g harnesses and connectors are yellow Do not use electric test equipment on these cir cuits Be careful not to damage the airbag system wiring harness when servicing electrical parts and switches C PRE...

Page 2931: ...LLUMINATION CON TROL EXCEPT FOR AUSTRALIA STi MODEL SCHEMATIC Clearance Light and Illumination Light System 6 CLEARANCE LIGHT AND ILLUMINA TION LIGHT STi MODEL FOR AUSTRALIA Ref to WI 205 RHD FOR AUST...

Page 2932: ...210 RHD EXCEPT FOR EUROPE MODEL SCHEMATIC Front Fog Light System B INSPECTION 1 FRONT FOG LIGHT SWITCH Measure the front fog light switch resistance 2 FRONT FOG LIGHT RELAY Measure the front fog light...

Page 2933: ...XCEPT FOR EUROPE MODEL SCHEMATIC Rear Fog Light System B INSPECTION 1 REAR FOG LIGHT SWITCH 1 Turn the ignition switch to ON 2 Turn on the headlight or front fog light 3 Push the rear fog light switch...

Page 2934: ...Signal Light and Hazard Light System B INSPECTION 1 TURN SIGNAL SWITCH Ref to LI 11 INSPECTION Combination Switch Light 2 HAZARD SWITCH Measure the hazard switch resistance 3 TURN SIGNAL AND HAZARD MO...

Page 2935: ...SWITCH A T Measure the inhibitor switch resistance A Non turbo model B Turbo model Switch position Terminal No Standard When shift lever is set in reverse position Turbo model 2 and 4 Non turbo model...

Page 2936: ...B INSPECTION 1 STOP LIGHT SWITCH Measure the stop light switch resistance A Without cruise control B With cruise control Switch position Terminal No Standard When brake pedal is depressed 1 and 2 With...

Page 2937: ...nce 2 REAR GATE LATCH SWITCH Measure the rear gate latch switch resistance 3 TRUNK ROOM LIGHT SWITCH Measure the trunk room light switch resistance Switch position Terminal No Standard When door is op...

Page 2938: ...firm the headlight beam level is lowered by changing the switch position to 0 1 2 3 2 HEADLIGHT BEAM LEVELER SWITCH Connect the battery headlight beam leveler switch connector and circuit tester as sh...

Page 2939: ...model RHD except for Europe model 2 DIMMER AND PASSING SWITCH LHD model and RHD for Europe model RHD except for Europe model LI 00009 LI 00068 A LHD model RHD model for Europe B RHD model Except for...

Page 2940: ...el and RHD for Europe model RHD except for Europe model Switch position Terminal No Standard Left 1 and 2 Less than 1 Neutral More than 1 M Right 2 and 3 Less than 1 Switch position Terminal No Standa...

Page 2941: ...screws 7 Disconnect the connector and remove the com bination base switch assembly B INSTALLATION 1 Install in the reverse order of removal 2 Align the attaching direction of roll connector with the...

Page 2942: ...ming If the light is necessary to check aim ing do not turn on for more than 2 minutes NOTE Before checking the headlight aiming be sure of the following The area around the headlight has not sustaine...

Page 2943: ...ern for RHD model is symmetrically opposite A Vehicle center B Bulb center making W mm in H mm in h mm in at 3 m 10 ft Sedan Wagon TS GX RS WRX STi TS GX WRX OUTBACK 1 279 50 35 644 25 35 639 25 16 64...

Page 2944: ...ttery 2 Remove the air intake duct A when right side headlight bulb is removed 3 Disconnect the harness connector 4 Remove the bulb ASSY A high beam To re move the low beam remove the back cover B and...

Page 2945: ...he harness connector A and then turn the socket B and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specif...

Page 2946: ...mbly Ref to LI 14 REMOVAL Headlight Assembly 2 Turn the socket A and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check...

Page 2947: ...isconnect the ground cable from battery 2 Disengage the hooks six places and then re move the fog light cover 3 Remove the mounting bolts and then detach the fog light assembly by disconnecting the ha...

Page 2948: ...bly 2 Remove the two screws and then remove the back cover 3 Remove the spring retainer and then detach the fog light bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visuall...

Page 2949: ...im of rear portion 4 Remove the four nuts and then detach the rear combination light while disconnecting connector 2 WAGON 1 Disconnect the ground cable from battery 2 Remove the clips and then detach...

Page 2950: ...on Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to...

Page 2951: ...e the rear combination light assembly Ref to LI 21 WAGON REMOVAL Rear Combi nation Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECT...

Page 2952: ...N 1 Remove the rear combination light assembly Ref to LI 21 WAGON REMOVAL Rear Combi nation Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal...

Page 2953: ...ve the rear combination light assembly Ref to LI 21 WAGON REMOVAL Rear Combi nation Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPEC...

Page 2954: ...ght mounting screw A and then remove the lens B 2 Remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specificat...

Page 2955: ...unt ed stop light assembly 3 Disconnect the connector of high mounted stop light from body harness 3 WAGON 1 Disconnect the ground cable from battery 2 Remove the cap a by prying on the edge with scre...

Page 2956: ...2 Pull out the light from body while pushing it in di rection of vehicle front 3 Disconnect the harness connector and remove the light B INSTALLATION Install in the reverse order of removal C INSPECTI...

Page 2957: ...pot map light B INSTALLATION 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 SPECIFICATIONS...

Page 2958: ...LATION Install in the reverse order of removal C INSPECTION 1 ROOM LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If...

Page 2959: ...B 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 SPECIFICATIONS General...

Page 2960: ...tery 2 Disconnect the harness connectors and remove the trunk room light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb spe...

Page 2961: ...x Ref to EI 39 REMOV AL Glove Box 3 Disconnect the harness connector 4 Remove the glove box light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow...

Page 2962: ...LI 34 LIGHTING SYSTEM GLOVE BOX LIGHT...

Page 2963: ...d Washer System 5 3 Combination Switch Wiper 6 4 Wiper Blade 9 5 Washer Tank and Motor 11 6 Front Wiper Arm 12 7 Front Wiper Motor and Link 13 8 Front Washer Nozzle 15 9 Rear Wiper Arm 16 10 Rear Wipe...

Page 2964: ...ss 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 link...

Page 2965: ...R WIPER 1 Wiper rubber 7 Spacer B Tightening torque N m kgf m ft lb 2 Wiper blade ASSY 8 Nut T1 6 0 0 61 4 4 3 Wiper arm 9 Cap T2 7 5 0 76 5 5 4 Wiper motor 10 Wiper arm cover T3 8 0 0 82 5 9 5 Spacer...

Page 2966: ...r Do not use a tester on these cir cuits Care must be taken when installing the piping hose so that no bending jamming etc are caused If even a little oil or grease such as silicon oil gets in the tan...

Page 2967: ...MODEL Ref to WI 258 RHD MODEL SCHEMATIC Wiper and Washer System Rear B INSPECTION Symptom Repair order Wiper and washers do not operate 1 Wiper fuse F B No 14 15 2 Combination switch 3 Wiper motor 4...

Page 2968: ...continuity between each connector terminal LHD model and RHD model Europe model If continuity is not as specified replace the switch WW 00004 WW 00045 Switch position Terminal No Standard FRONT OFF 7...

Page 2969: ...he switch Switch position Terminal No Standard FRONT OFF 3 and 12 Less than 1 INT 3 and 12 Less than 1 LO 3 and 11 Less than 1 HI 2 and 11 Less than 1 Washer ON 8 and 17 Less than 1 REAR Washer ON 8 a...

Page 2970: ...tage to switch terminals 16 and 2 4 Inspect the voltage of combination switch terminals Terminals LHD model and RHD model Europe model No 7 No 2 RHD model Except for Europe model No 3 No 8 If operatio...

Page 2971: ...ly C DISASSEMBLY 1 METAL TYPE Pull on the side A of wiper rubber stopper and then remove the rubber from blade assembly 2 RESIN TYPE Pull the wiper rubber top slightly from the stopper A and pull it o...

Page 2972: ...9 in from the stopper D 3 Insert the wiper rubber into the claw A E INSPECTION 1 When the wiper does not perform well inspect the following Make sure the movable part of the blade assem bly moves smoo...

Page 2973: ...NSTALLATION 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 tank D ASSEMBLY 1 Assemble in the reverse order of disas...

Page 2974: ...site 1 Install in the reverse order of removal 2 Operate the wiper once 3 Align the wiper blade to the ceramic print point mark A of front window pane Tightening torque Refer to COMPONENT in General D...

Page 2975: ...3 Disconnect the ground cable from battery 4 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 i...

Page 2976: ...14 WIPER AND WASHER SYSTEMS FRONT WIPER MOTOR AND LINK 4 Connect the battery and confirm that the motor stops at automatic stop position after the motor op erates at low speed again 3 2 5 4 1 WW 0002...

Page 2977: ...yer Ref to WW 15 ADJUSTMENT Front Washer Nozzle C INSPECTION Make sure the nozzle and hose are not clogged Make sure the hose is not bent D ADJUSTMENT NOTE This adjustment position is for left handed...

Page 2978: ...1 Install in the reverse order of removal 2 Operate the rear wiper once 3 Align the blade to rear defogger heat wire A Tightening torque Refer to COMPONENT in General Descrip tion Ref to WW 3 REAR WI...

Page 2979: ...oval 2 Install the rear wiper cushion with the arrow mark facing up as shown in the figure Tightening torque Refer to COMPONENT in General Descrip tion Ref to WW 3 REAR WIPER COMPONENT General Descrip...

Page 2980: ...then remove the washer nozzle B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the position of the washer liquid sprayer Ref to WW 18 ADJUSTMENT Rear Washer C INSPECTION Make sure the...

Page 2981: ...in the reverse order of removal C INSPECTION 1 Disconnect the connector from wiper control re lay 2 Connect the positive lead from the battery to terminal 8 and the negative lead to terminal 6 Connect...

Page 2982: ...WW 20 WIPER AND WASHER SYSTEMS WIPER CONTROL RELAY WAGON MODEL...

Page 2983: ...ription 2 2 Radio System 3 3 Front Accessory Power Supply Socket System 4 4 Radio Body 5 5 Front Speaker 6 6 Tweeter 7 7 Rear Speaker 8 8 Antenna 9 9 Antenna Amplifier 10 10 Noise Suppressor 11 11 Fro...

Page 2984: ...tery ground cable Otherwise the memory will be erased Reassemble in reverse order of disassembly un less otherwise indicated Adjust parts to the given specifications Connect the connectors and hoses s...

Page 2985: ...power supply for radio 2 Check the radio ground 3 Remove the radio for repair A specific speaker does not operate 1 Check the speaker 2 Check the output circuit between radio and speaker Radio generat...

Page 2986: ...RTAINMENT FRONT ACCESSORY POWER SUPPLY SOCKET SYSTEM 3 Front Accessory Power Sup ply Socket System A SCHEMATIC 1 FRONT ACCESSORY POWER SUPPLY SOCKET Ref to WI 179 SCHEMATIC Front Accessory Power Suppl...

Page 2987: ...battery 2 Remove the center panel while disconnecting connector 3 Remove the fitting screws and slightly pull out the radio from center console 4 Disconnect the harness connectors and antenna feeder...

Page 2988: ...ect the ground cable from battery 2 Remove the front door trim Ref to EI 37 RE MOVAL Front Door Trim 3 Remove the front speaker mounting screws 4 Disconnect the harness connector and remove front spea...

Page 2989: ...ect the ground cable from battery 2 Remove the front door trim Ref to EI 37 RE MOVAL Front Door Trim 3 Remove the tweeter mounting screws 4 Disconnect the harness connector and remove tweeter B INSTAL...

Page 2990: ...nect the ground cable from battery 2 Remove the rear door trim Ref to EI 38 RE MOVAL Rear Door Trim 3 Remove the rear speaker mounting screws 4 Disconnect the harness connector and remove rear speaker...

Page 2991: ...re with your fin ger To locate the broken point move the probe along antenna wire B REPAIR 1 Clean the antenna wire and surrounding area with a cloth dampened by alcohol 2 Paste a thin masking film on...

Page 2992: ...Roof Trim 3 Disconnect the harness connector and terminal 4 Remove the mounting screws and detach the antenna amplifier B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the...

Page 2993: ...connector from an tenna amplifier 5 Disconnect the harness connector of noise sup pressor from terminal on glass antenna 6 Remove the harness clip 7 Remove the mounting nut and detach the noise suppre...

Page 2994: ...wer Sup ply Socket A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the center panel Ref to ET 5 RE MOVAL Radio Body 3 Disconnect the harness connectors and remove front accessory power s...

Page 2995: ...COMMUNICATION SYSTEM COM Page 1 General Description 2 2 Horn System 3 3 Horn 4 4 Horn Switch 5...

Page 2996: ...record memory contents before disconnecting the battery ground cable Otherwise the memory will be erased Reassemble in reverse order of disassembly un less otherwise indicated Adjust parts to the give...

Page 2997: ...INSPECTION 1 HORN RELAY Measure the horn relay resistance between termi nals indicated in table below when connecting the terminal No 4 to battery positive terminal and ter minal No 3 to battery grou...

Page 2998: ...the horn bracket mounting bolt A 3 Disconnect the harness connector and remove the horn assembly B B INSTALLATION Install in the reverse order of removal C INSPECTION With 12 V direct current supplie...

Page 2999: ...und cable from battery 2 Remove the driver s airbag module Ref to AB 12 Driver s Airbag Module 3 Remove the horn switch from steering wheel as shown in the figure B INSTALLATION Install in the reverse...

Page 3000: ...COM 6 COMMUNICATION SYSTEM HORN SWITCH...

Page 3001: ...rol Mirror System 15 7 Scalp Cap 16 8 Outer Mirror Assembly 17 9 Outer Mirror 19 10 Remote Control Mirror Switch 20 11 Rear Door Glass 22 12 Rear Regulator and Motor Assembly 24 13 Windshield Glass 25...

Page 3002: ...GENERAL DESCRIPTION 1 General Description A COMPONENT 1 FIXED GLASS SEDAN 1 Windshield glass 4 Rearview mirror mount 7 Spring 2 Dam rubber 5 Locate pin 8 Fastener 3 Molding 6 Rear window glass GW 002...

Page 3003: ...S GENERAL DESCRIPTION 2 FIXED GLASS WAGON 1 Windshield glass 5 Locate pin 9 Glass 2 Dam rubber 6 Fastener 10 Spring 3 Molding 7 Rear quarter glass 4 Rearview mirror mount 8 Locate pin GW 00203 1 2 6 3...

Page 3004: ...MIRRORS GENERAL DESCRIPTION 3 FRONT DOOR GLASS 1 Glass 4 Regulator ASSY Tightening torque N m kgf m ft lb 2 Door sash Front 5 Motor ASSY T1 7 4 0 75 5 5 3 Door sash Rear T2 13 7 1 4 10 1 GW 00250 1 2...

Page 3005: ...MIRRORS GENERAL DESCRIPTION 4 REAR DOOR GLASS 1 Glass 4 Regulator ASSY Tightening torque N m kgf m ft lb 2 Door sash Front 5 Motor ASSY T1 7 4 0 75 5 5 3 Door sash Rear T2 13 7 1 4 10 1 GW 00251 1 2...

Page 3006: ...check after connecting them again Avoid impact and damage to glass C PREPARATION TOOL 1 Outer mirror 3 Mount 5 Mirror 2 Inner rearview mirror 4 Spring 6 Scalp cap TOOL NAME REMARKS Circuit Tester Used...

Page 3007: ...WI 232 RHD MODEL SCHEMATIC Power Window System B INSPECTION Symptom Repair order All power windows do not operate 1 Fuse SBF 6 F B No 18 RHD model 2 Power window circuit breaker 3 Power window relay...

Page 3008: ...MAIN SWITCH Install in the reverse order of removal 2 SUB SWITCH Install in the reverse order of removal C INSPECTION 1 MAIN SWITCH LHD MODEL Measure the switch resistance GW 00202 GW 00207 GW 00209...

Page 3009: ...side AUTO UP 12 and 6 7 and 1 Less than 1 UP 12 and 6 7 and 1 Less than 1 OFF 1 and 6 1 and 7 6 and 7 Less than 1 DOWN 12 and 7 6 and 1 Less than 1 AUTO DOWN 12 and 7 6 and 1 Less than 1 Front passeng...

Page 3010: ...Remove the gusset 5 Remove the stabilizers and trim hooks 6 Remove the rear end of door weather strip and weather strip outer 7 Operate the power window switch to move the glass to position shown in t...

Page 3011: ...e inner panel 2 Temporarily tighten the regulator B channel in a position at the top of slotted hole 3 Lower the door glass 10 to 15 mm 0 39 to 0 59 in from fully closed position While applying out wa...

Page 3012: ...visually ensure positional relationship between retainer molding and glass of the roof side and then begin with rear sash ad justment Adjust two adjusting bolts alternately step by step to obtain dime...

Page 3013: ...f one sash to the maximum amount and the other to the minimum amount is not permitted Such adjustment may re sult in application of excessive load to regulator 11 After adjustments tighten the nuts 12...

Page 3014: ...o remove motor assembly B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the front door glass Ref to GW 11 AD JUSTMENT Front Door Glass Tightening torque Refer to COMPONENT in General...

Page 3015: ...REMOTE CONTROL MIRROR RHD MODEL Ref to WI 244 RHD MODEL SCHEMATIC Remote Controlled Rearview Mirror System B INSPECTION Symptom Repair order All functions do not operate 1 Fuse F B No 1 F B No 4 F B N...

Page 3016: ...A REPLACEMENT 1 Turn the rearview mirror downward 2 Insert a thin screw driver push the clip part of scalp cap and remove the scalp cap 3 Insert the claw at the bottom of scalp cap into door mirror 4...

Page 3017: ...cap Ref to GW 16 RE PLACEMENT Scalp Cap 2 Remove the door trim Ref to EI 37 REMOV AL Front Door Trim 3 Remove the mirror gusset cover 4 Disconnect the mirror connector 5 Loosen the screws to remove t...

Page 3018: ...en battery voltage is applied to terminals Mirror heater not equipped model If NG replace the mirror Mirror heater equipped model If NG replace the mirror Switch position Terminal No OFF UP 4 and 6 DO...

Page 3019: ...wdriver without sharp edges to lift the mirror out of the mirror holder A 4 Disconnect the mirror heater connector from back of mirror model with mirror heater 5 Warm the area around the mirror holder...

Page 3020: ...ROL MIRROR SWITCH 10 Remote Control Mirror Switch A REMOVAL 1 Remove the console cover 2 Disconnect the connector 3 Remove the remote control mirror switch from console cover B INSTALLATION Install in...

Page 3021: ...n If NG replace the switch GW 00134 4 3 2 6 9 8 7 1 Switch position Terminal No Standard OFF More than 1 M UP 4 and 6 2 and 1 Less than 1 DOWN 6 and 2 4 and 1 Less than 1 LEFT 4 and 8 2 and 1 Less tha...

Page 3022: ...rim hook 4 Remove the front end and rear end of door weather strip 5 Loosen the two screws to remove the weather strip outer 6 Operate the power window switch to move the glass to position shown in th...

Page 3023: ...ng the following di mensions as a guide line NOTE If the dimensions are smaller than the given di mensions glass may get caught in weather strip during lifting lowering operation In the worst case it...

Page 3024: ...ve motor assembly B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the rear door glass Ref to GW 23 AD JUSTMENT Rear Door Glass Tightening torque Refer to COMPONENT in General Descrip...

Page 3025: ...hing pins are bonded to cor ners of glass use piano wire to cut the pin 2 USING PIANO WIRE 1 Remove the cowl panel Ref to EI 32 RE MOVAL Cowl Panel 2 Remove the roof molding and upper front mold ing 3...

Page 3026: ...the body with alcohol or white gasoline to remove thoroughly chips dusts and dirt from body face 4 Place the glass on body 5 Adjust the glass position to make uniform clear ance between body and glas...

Page 3027: ...ghtly press the windshield glass for tight fit 15 Make flush the adhesive surface jutted out us ing spatula 16 After completion of all work allow the vehicle to stand for about 24 hours NOTE When the...

Page 3028: ...t one hour after installation conduct a wa ter leak test 4 After completion of all work allow the vehicle to stand for about 24 hours NOTE When the door is opened closed after glass is bonded always l...

Page 3029: ...tand for about 24 hours NOTE When the door is opened closed after glass is bonded always lower the door glass and then open close door carefully Move the vehicle slowly For minimum drying time and tim...

Page 3030: ...L SCHEMATIC Rear Window Defogger System 2 REAR WINDOW DEFOGGER RHD MODEL Ref to WI 242 RHD MODEL SCHEMATIC Rear Window Defogger System B INSPECTION Symptom Repair order Rear window defogger does not o...

Page 3031: ...olt heat wire is open between wire cen ter and ground 5 Apply positive lead of voltmeter to positive termi nal of voltmeter and then move the negative lead along the wire up to negative terminal end I...

Page 3032: ...se it carefully Move the vehicle slowly For minimum drying time and time the vehicle must be left standing before driving after bonding follow the instructions or instruction manual from adhesive manu...

Page 3033: ...3 GLASS WINDOWS MIRRORS ROOF WINDOW GLASS 19 Roof Window Glass A REMOVAL Ref to SR 5 REMOVAL Sunroof Lid B INSTALLATION Ref to SR 5 INSTALLATION Sunroof Lid C ADJUSTMENT Ref to SR 5 ADJUSTMENT Sunroof...

Page 3034: ...ove the mirror base using piano wire or spatula etc CAUTION Be careful not to damage the windshield glass B INSTALLATION 1 If removing the mirror base remove the remain ing adhesive thoroughly and the...

Page 3035: ...BODY STRUCTURE BS Page 1 General Description 2 2 Datum Points 3 3 Datum Dimensions 11...

Page 3036: ...BS 2 BODY STRUCTURE GENERAL DESCRIPTION 1 General Description A PREPARATION TOOL TOOL NAME REMARKS Tram tracking gauge Used for measuring dimen sion Tape measure Used for measuring dimen sion...

Page 3037: ...ia Symmetrical 18 Fender attaching hole 12 mm 0 47 in dia Symmetrical 71 Harness clip attaching hole 7 mm 0 28 in dia Symmetrical 4 Hood hinge attaching hole 12 mm 0 47 in dia Symmetrical 19 Fender at...

Page 3038: ...31 Washer hose attaching hole LH 7 mm 0 28 in dia 58 Rear bumper plate nut attaching hole 11 mm 0 43 in dia Sym metrical 72 Trim upper clip attaching hole 8 5 mm 0 335 in dia Symmetrical 32 Rear combi...

Page 3039: ...dia 68 Rear skirt inner side gauge hole 10 mm 0 39 in dia Symmetri cal 63 Feeder line fixing hole 7 mm 0 28 in dia Symmetrical 55 Rear combination light mounting hole 8 mm 0 31 in dia Symmet rical 65...

Page 3040: ...0 63 in dia Symmetrical 87 Rear differential attaching hole 16 mm 0 63 in dia Symmetrical 82 Front crossmember attaching hole 12 4 mm 0 488 in dia Symmet rical 88 Rear suspension attaching hole 16 mm...

Page 3041: ...BS 7 BODY STRUCTURE DATUM POINTS WAGON MODEL BS 00521 1 7 5 2 BS 00525 18 19 BS 00522 4 90 3 10 BS 00526 21 20 BS 00523 8 9 BS 00556 22 BS 00524 12 24 BS 00527 30...

Page 3042: ...E DATUM POINTS WAGON MODEL SEDAN MODEL WAGON MODEL SEDAN MODEL WAGON MODEL SEDAN MODEL SEDAN MODEL BS 00528 31 77 91 72 BS 00532 50 51 BS 00529 32 58 BS 00533 55 56 58 BS 00530 33 BS 00534 60 BS 00531...

Page 3043: ...BS 9 BODY STRUCTURE DATUM POINTS SEDAN MODEL SEDAN MODEL BS 00536 67 BS 00540 70 74 BS 00537 76 68 BS 00541 75 BS 00538 69 BS 00542 81 80 BS 00539 62 73 71 BS 00543 82 92...

Page 3044: ...BS 10 BODY STRUCTURE DATUM POINTS BS 00544 86 85 84 83 94 BS 00546 88 89 93 BS 00545 87...

Page 3045: ...all the di mensions When using a tape measure carefully measure dimensions without letting the tape measure sag or twist Measure the linear dimensions between cores of holes Suffixes RH and LH indicat...

Page 3046: ...NTER STRUCTURE 1 Standard line 2 Side sill 3 Upper surface BS 00633 81 82 83 84 85 87 89 90 91 81 82 87 92 88 2 80 80 81 82 90 90 83 84 86 86 84 83 85 85 87 87 88 88 91 91 89 89 81 92 82 81 83 84 86 8...

Page 3047: ...tandard line 206 8 11 88 RH to 88 LH 920 36 22 91 from standard line 674 26 54 91 RH to 91 LH 1 205 47 44 89 from standard line 205 8 07 89 RH to 89 LH 1 110 43 70 81 to 82 317 12 48 93 RH to 93 LH 1...

Page 3048: ...37 32 4 RH to 2 LH 1 583 62 32 10 to 2 LH 948 37 32 4 LH to 2 RH 1 583 62 32 4 RH to 2 RH 779 30 67 3 RH to 3 LH 1 396 54 96 4 LH to 2 LH 779 30 67 3 RH to 4 LH 1 470 57 87 4 RH to 3 RH 430 16 93 3 L...

Page 3049: ...2 44 17 Wagon model 21 LH to 22 LH 985 38 78 10 to 12 RH 1 106 43 54 Sedan model 24 to 65 1 232 48 50 Wagon model 10 to 12 LH 1 122 44 17 Wagon model 24 to 65 1 237 48 70 Sedan model 10 to 12 LH 1 106...

Page 3050: ...60 71 62 RH to 74 RH 592 23 31 Wagon model 70 RH to 75 RH 1 443 56 81 62 LH to 74 LH 603 23 74 Sedan model 70 LH to 75 LH 1 443 56 81 65 to 67 RH 1 501 59 09 70 RH to 91 LH 1 532 60 32 65 to 67 LH 1...

Page 3051: ...1 534 60 39 65 to 77 LH 1 538 60 55 33 RH to 72 LH 1 344 52 91 71 RH to 72 RH 1 223 48 15 33 LH to 72 RH 1 344 52 91 71 LH to 72 LH 1 223 48 15 62 RH to 72 RH 732 28 82 72 RH to 72 LH 1 226 48 27 62...

Page 3052: ...6 32 RH to 58 LH 1 139 44 84 30 to 32 LH 850 33 46 32 LH to 58 RH 1 139 44 84 30 to 33 RH 904 35 59 33 RH to 91 LH 993 39 09 30 to 33 LH 904 35 59 33 LH to 91 LH 993 39 09 30 to 65 1 292 50 87 77 RH t...

Page 3053: ...44 02 50 to 71 LH 1 562 61 50 63 LH to 65 1 118 44 02 60 to 62 RH 1 338 52 68 63 RH to 71 RH 1 283 50 51 60 to 62 LH 1 338 52 68 63 LH to 71 LH 1 283 50 51 62 RH to 63 RH 773 30 43 65 to 66 RH 956 37...

Page 3054: ...to 60 734 28 90 67 RH to 69 784 30 87 55 RH to 55 LH 1 406 55 35 67 LH to 69 784 30 87 55 RH to 58 LH 1 297 51 06 68 RH to 68 LH 1 020 40 16 55 LH to 58 RH 1 297 51 06 68 RH to 69 681 26 81 56 RH to...

Page 3055: ...T Horizontal and vertical dimensions are values measured from datum points 0 Unit mm in BS 00602 61 3 2 41 314 12 36 133 3 5 25 429 16 89 740 29 13 924 36 38 20 3 0 80 838 32 99 860 33 86 906 35 67 86...

Page 3056: ...BS 22 BODY STRUCTURE DATUM DIMENSIONS...

Page 3057: ...ATION DRIVER INFO IDI Page 1 General Description 2 2 Combination Meter System 3 3 Combination Meter Assembly 14 4 Speedometer 18 5 Tachometer 19 6 Fuel Gauge 20 7 Water Temperature Gauge 21 8 Ambient...

Page 3058: ...ge Cross coil type Tachometer Electric pulse type Turn signal indicator light 14 V 1 4 W LED Charge indicator light 14 V 1 4 W LED Oil pressure indicator light LED ABS warning light LED Malfunction in...

Page 3059: ...VER INFO COMBINATION METER SYSTEM 2 Combination Meter System A SCHEMATIC 1 COMBINATION METER Ref to WI 86 SCHEMATIC Combination Meter 2 OUTSIDE TEMPERATURE INDICATOR Ref to WI 224 SCHEMATIC Outside Te...

Page 3060: ...SENSOR INSPECTION Combi nation Meter System AT model Ref to IDI 7 CHECK TRANSMIS SION CONTROL MOD ULE TCM INSPECTION Combi nation Meter System Tachometer does not operate 1 ECM 2 Harness 3 Tachometer...

Page 3061: ...step 2 Check the harness for open or short between ignition switch and combi nation meter 2 CHECK POWER SUPPLY FOR COMBINA TION METER Measure the voltage between combination meter connector and chassi...

Page 3062: ...Turn the ignition switch to ON 4 Measure the voltage between vehicle speed sensor connector and engine ground Connector terminal B17 No 3 Chassis ground Is the voltage more than 10 V Go to step 3 Chec...

Page 3063: ...s ground Connector terminal B56 No 17 Chassis ground Is the voltage less than 1 V more than 5 V Go to step 2 Check the TCM Ref to 4AT 2 Basic Diagnostic Procedure 2 CHECK HARNESS BETWEEN TCM AND COMBI...

Page 3064: ...EN H4SO 2 Basic Diagnostic Procedure or Ref to EN H4SOw oOBD 2 Basic Diagnostic Proce dure or Ref to EN H4DOTC 2 Basic Diagnostic Procedure 2 CHECK HARNESS BETWEEN COMBINA TION METER AND ECM 1 Turn t...

Page 3065: ...ter 2 Measure the resistance between fuel sub level sensor harness connector terminal and combination meter harness connector termi nal Connector terminal R59 No 1 i12 No 2 Is the resistance less than...

Page 3066: ...nd combi nation meter harness connector terminal Connector terminal R58 No 3 i12 No 2 Is the resistance less than 10 Go to step 9 Repair the wiring harness 9 CHECK FUEL LEVEL SENSOR GROUND CIRCUIT Mea...

Page 3067: ...era ture sensor OK Go to step 2 Replace the engine coolant temperature sen sor 2 CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND COMBINATION METER 1 Turn the ignition switch to OFF 2 Disco...

Page 3068: ...No 8 RHD model F78 No 2 i10 No 11 F78 No 1 i10 No 8 Is the resistance less than 10 Go to step 4 Repair the wiring harness 4 CHECK AMBIENT SENSOR 1 Remove the ambient sensor 2 Check the ambient sensor...

Page 3069: ...bient sen sor 3 Measure the resistance between ambient sensor harness connector terminal combina tion meter harness connector terminal and auto A C control module harness connector terminal Connector...

Page 3070: ...f combination meter and pull out the meter toward you 5 Disconnect the connector in the upper area of combination meter to remove the meter CAUTION Be careful not to damage the meter or instru ment pa...

Page 3071: ...2 Disengage the claw G to remove the meter glass E reflector D and window plate C from inner case 3 Pull up the claw A in portion B of combination meter printed circuit C with combination pliers Push...

Page 3072: ...ASSEMBLY 2 STi MODEL FOR AUSTRALIA CAUTION Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces Disengage the claw E to remove the meter glass D reflector C and...

Page 3073: ...n turbo model or speedometer Turbo model 2 Speedometer and tachometer 3 Turn signal indicator light RH 4 HI beam indicator light 5 Speedometer Non turbo model or tachometer Turbo model 6 POWER indicat...

Page 3074: ...Ref to IDI 15 DISASSEMBLY Combination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the speedometer resistance If NG replace the speedometer and tachometer...

Page 3075: ...ef to IDI 15 DISASSEMBLY Combination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the tachometer resistance If NG replace the speedometer and tachometer a...

Page 3076: ...SASSEMBLY Com bination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the fuel gauge resistance If NG replace the water temperature gauge and fuel gauge ass...

Page 3077: ...ef to IDI 15 DISASSEMBLY Combination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the water temperature gauge resistance If NG replace the water temperatu...

Page 3078: ...attery 2 Disconnect the ambient sensor connector 3 Remove the ambient sensor A from radiator lower panel B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the ambient sensor...

Page 3079: ...SEATS SE Page 1 General Description 2 2 Front Seat 6 3 Rear Seat 17...

Page 3080: ...35 5 Headrest lock bush 16 Reclining lever T2 10 1 02 7 38 6 Side airbag module 17 Seat hinge outer cover T3 17 7 1 81 13 1 7 Support pad B 18 Lifter lever T4 20 2 04 14 8 8 Support pad A 19 Seat hin...

Page 3081: ...t 6 Hook Tightening torque N m kgf m ft lb 2 Headrest 7 Backrest pad ASSY T1 10 1 02 7 38 3 Cushion 8 Backrest cover ASSY T2 24 5 2 5 18 1 4 Arm rest 9 Rear pad cushion frame ASSY 5 Center through fra...

Page 3082: ...ge ASSY LH 4 Backrest cover RH 12 Backrest pad LH Tightening torque N m kgf m ft lb 5 Backrest pad RH 13 Backrest cover LH T1 17 3 1 76 12 8 6 Backrest frame RH 14 Backrest frame LH T2 24 5 2 5 18 1 7...

Page 3083: ...rom a side airbag loaded vehicle follow cautions given in the airbag section C PREPARATION TOOL 1 GENERAL TOOL TOOL NAME REMARKS Long Nose Pliers Used for removing hog ring Hog Ring Pliers Used for in...

Page 3084: ...to full rear end 8 Remove the two bolts at front side of seat rail 9 Disconnect the connector under seat Seat belt warning light connector Driver s seat Side airbag connector with side airbag 10 Remo...

Page 3085: ...5 Remove two bolts from reclining hinge on each side 6 Remove the hook at bottom of backrest 7 Open the zipper behind of backrest 8 Remove the hog rings A of backrest cover 9 Remove the hog rings A wh...

Page 3086: ...o outside of seat from inside and then remove them 12 Pull out the backrest frame 13 Remove the hog rings A at bottom of seat back Side airbag equipped seat 14 Remove the hog rings A at front of seat...

Page 3087: ...and then remove the headrest cover from headrest Bucket type seat 1 Remove the seat from vehicle Ref to SE 6 REMOVAL Front Seat 2 Remove the seat lifter cover using a flat tip screwdriver or equivale...

Page 3088: ...t 8 Open the zipper behind of backrest Side airbag equipped seat 9 Remove the hog rings A of backrest cover Side airbag equipped seat 10 Open the zipper behind of backrest cover and then remove the ho...

Page 3089: ...ck cover from seat back Side airbag equipped seat 14 Remove the connection wire A and then loosen the bolts and nuts to remove slide rail 15 Remove the inner belt 16 Remove the hook A and then remove...

Page 3090: ...cover outer 3 Remove the seat hinge cover inner 4 Remove the bolts from reclining hinge on each side 5 Remove the hook at bottom of backrest 6 Open the zipper behind of backrest 7 Remove the hog rings...

Page 3091: ...at from inside and then remove them 11 Pull out the backrest frame 12 Remove the hog rings A at bottom of seat back Side airbag equipped seat 13 Remove the hog rings A at front of seat back and then r...

Page 3092: ...Open the zipper at bottom of headrest and then remove the headrest cover from headrest Bucket type seat 1 Remove the seat from vehicle Ref to SE 6 REMOVAL Front Seat 2 Remove the reclining lever and...

Page 3093: ...ide airbag equipped seat 9 Remove the hog rings A at side of inside back rest from backrest frame Side airbag equipped model 10 Pull out the backrest frame Side airbag equipped seat 11 Remove the hog...

Page 3094: ...S SIDE Assemble in the reverse order of disassembly CAUTION Because it may cause the side airbag to acti vate incorrectly observe the following steps to install the side airbag correctly Be careful n...

Page 3095: ...detach the rear seat cushion 2 Remove the bolts securing lower portion of backrest and then open the center trunk through lid 3 Lift the rear seat backrest and then remove it B INSTALLATION 1 WAGON M...

Page 3096: ...move the rear seat Ref to SE 17 WAGON MODEL REMOVAL Rear Seat 2 Remove the hog rings A behind of seat back rest 3 Remove the hog rings A on front side of cush ion pad and remove the cover 4 Remove the...

Page 3097: ...seat cover 7 Remove the nuts and screws and then disas semble the armrest assembly D ASSEMBLY 1 WAGON MODEL Assemble in the reverse order of disassembly NOTE Do not contaminate or damage the cover Whi...

Page 3098: ...SE 20 SEATS REAR SEAT...

Page 3099: ...ter Handle 27 10 Rear Door Latch Assembly 28 11 Rear Door Lock Actuator 29 12 Rear Gate Outer Handle 30 13 Rear Gate Latch Assembly 31 14 Rear Gate Latch Lock Actuator 32 15 Trunk Lid Lock Assembly 33...

Page 3100: ...ouble lock A Front B Rear Tightening torque N m kgf m ft lb T1 6 4 0 65 4 7 1 Inner remote ASSY 5 Door latch T2 7 4 0 75 5 5 2 Inner remote cover 6 Striker T3 17 6 1 8 13 0 3 Bell crank 7 Door outer h...

Page 3101: ...m kgf m ft lb T1 6 4 0 65 4 7 1 Inner remote ASSY 6 Striker T2 7 4 0 75 5 5 2 Inner remote cover 7 Door outer handle T3 17 6 1 8 13 0 3 Bell crank 8 Outer handle cover 4 Auto door lock actuator 9 Key...

Page 3102: ...k B Rear gate Tightening torque N m kgf m ft lb T1 4 5 0 45 3 3 1 Key cylinder 5 Rear gate outer handle T2 25 2 5 18 4 2 Cable 6 Rear gate actuator 3 Striker 7 Rear gate latch 4 Trunk lid lock ASSY 8...

Page 3103: ...ESCRIPTION 3 HOOD LOCK AND REMOTE OPENERS A Sedan B Wagon Tightening torque N m kgf m ft lb T1 6 4 0 65 4 7 1 Hood lock ASSY 4 Cover T2 32 3 3 23 9 2 Lever ASSY 5 Pull handle ASSY 3 Cable SL 00174 HOO...

Page 3104: ...S GENERAL DESCRIPTION 4 IMMOBILIZER SYSTEM NOTE IMM ECM location for RHD model is symmetrically opposite 1 Antenna 3 Immobilizer control module IMM ECM 4 Transponder 2 Immobilizer indicator light LED...

Page 3105: ...icated Adjust parts to specifications contained in this manual if so designated Connect the connectors and hoses securely during reassembly After reassembly ensure all functional parts operate smoothl...

Page 3106: ...TOOL 1 SPECIAL TOOLS 2 GENERAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925580000 PULLER Used for removing trim clip TOOL NAME REMARKS Circuit Tester Used for measuring resistance and voltag...

Page 3107: ...m 4 Check the door lock actuator and the circuit Ref to SL 12 CHECK DOOR LOCK ACTUATOR AND CIRCUIT INSPECTION Door Lock Control System The door lock switch does not oper ate Check the door lock switch...

Page 3108: ...double lock module harness connector 2 Measure the voltage between the harness connector terminal and chassis ground Connector terminal Without double lock B176 No 5 16 Chassis ground With double loc...

Page 3109: ...or terminal Without double lock B176 No 8 Chassis ground With double lock B325 No 4 Chassis ground Is the resistance less than 10 The door lock switch is OK Go to step 3 3 CHECK DOOR LOCK SWITCH 1 Dis...

Page 3110: ...ntrol module or double lock module 3 CHECK DOOR LOCK ACTUATOR Check the door lock actuator Front door lock actuator Ref to SL 25 Front Door Lock Actuator Rear door lock actuator Ref to SL 29 Rear Door...

Page 3111: ...tep Check Yes No 1 CHECK OUTPUT SIGNAL Measure the resistance between double lock module harness connector terminal and chas sis ground when turning the key cylinder lock switch to lock position Conne...

Page 3112: ...Room light Ignition switch illumina tion 11 OUTPUT 0 V is present when pressing the transmitter OPEN button 0 V is present when any door is open Turn signal light Left 12 OUTPUT Battery voltage is pre...

Page 3113: ...NSPECTION INSPECTION Door Lock Control System 1 Check the transmitter battery Ref to SL 16 CHECK TRANSMIT TER BATTERY INSPECTION Key less Entry System 2 Check the key warning switch Ref to SL 19 CHECK...

Page 3114: ...x and SBF 6 in the main fuse box Is the fuse blown out Replace the fuse with a new one Check the power supply and ground circuit Ref to SL 16 CHECK POWER SUPPLY AND GROUND CIRCUIT INSPECTION Keyless E...

Page 3115: ...r and chassis ground Connector terminal B176 No 2 Chassis ground Is the voltage more than 10 V Go to step 2 Repair the har ness and or con nector 2 REGISTRATION CONNECTOR INPUT VOLT AGE INSPECTION 1 C...

Page 3116: ...0 V when all doors and rear gate are closed The door switch is OK Go to step 3 3 CHECK DOOR SWITCH 1 Disconnect the door switch harness connec tor 2 Measure the resistance between door switch terminal...

Page 3117: ...etween harness con nector terminal and chassis ground Connector terminal B176 No 1 Chassis ground Is the voltage 0 V The key warning switch is OK Go to step 4 4 CHECK KEY WARNING SWITCH 1 Disconnect t...

Page 3118: ...sure the room light illuminates when the room light switch is turned to ON Does the room light illuminate Go to step 2 Check the room light circuit 2 CHECK HARNESS BETWEEN ROOM LIGHT AND KEYLESS ENTR...

Page 3119: ...k B325 No 1 R224 No 2 B79 No 13 R224 No 2 Is the resistance less than 10 Check the ignition switch illumina tion If NG replace the ignition switch illumination Check the follow ing Without double lock...

Page 3120: ...sealing cover Ref to EB 17 RE MOVAL Front Sealing Cover 3 Remove a screw and two rod joints 4 Remove the front inner remote B INSTALLATION Install in the reverse order of removal NOTE Make sure the i...

Page 3121: ...Front Door Trim 2 Remove the sealing cover Ref to EB 17 RE MOVAL Front Sealing Cover 3 Remove the front door glass Ref to GW 10 REMOVAL Front Door Glass 4 Remove the key cylinder Ref to SL 38 FRONT DO...

Page 3122: ...to EB 17 RE MOVAL Front Sealing Cover 4 Remove the front inner remote Ref to SL 22 REMOVAL Front Inner Remote 5 Remove three screws and a bolt 6 Remove the front door latch assembly and then disconnec...

Page 3123: ...ator termi nals If NG replace the door lock actuator 1 Without double lock 2 With double lock DOOR ACTUATOR RH DOOR ACTUATOR LH Terminal No Actuator operation No 3 and No 1 Unlocked Locked No 1 and No...

Page 3124: ...o EB 20 RE MOVAL Rear Sealing Cover 3 Remove a screw and two rod joints 4 Remove the inner remote B INSTALLATION Install in the reverse order of removal NOTE Make sure the inner remote works properly...

Page 3125: ...Remote 4 Remove the rear door latch assembly Ref to SL 28 REMOVAL Rear Door Latch Assembly 5 Loosen two bolts and a nut to remove the rear outer handle CAUTION Do not use excessive force to remove the...

Page 3126: ...to EB 20 RE MOVAL Rear Sealing Cover 4 Remove the rear inner remote Ref to SL 26 REMOVAL Rear Inner Remote 5 Remove three screws and a bolt 6 Disconnect the connector and then remove the rear door lat...

Page 3127: ...r termi nals If NG replace the door lock actuator 1 Without double lock 2 With double lock DOOR ACTUATOR RH DOOR ACTUATOR LH Terminal No Actuator operation No 3 and No 1 Unlocked Locked No 1 and No 3...

Page 3128: ...ve the rear gate latch assembly Ref to SL 31 REMOVAL Rear Gate Latch Assembly 3 Loosen two nuts to remove the rear gate outer handle B INSTALLATION Install in the reverse order of removal NOTE Make su...

Page 3129: ...e trim Ref to EI 52 RE MOVAL Rear Gate Trim 3 Remove three bolts 4 Disconnect the connectors and then remove the rear gate latch assembly B INSTALLATION Install in the reverse order of removal NOTE Ma...

Page 3130: ...gate lock actuator B INSTALLATION Install in the reverse order of removal NOTE Make sure the lock works properly after installation C INSPECTION 1 Disconnect the door lock actuator harness con nector...

Page 3131: ...trunk lid lock as sembly B INSTALLATION Install in the reverse order of removal NOTE Apply grease to parts that rub Make sure the lock works properly after installa tion C INSPECTION 1 Check the strik...

Page 3132: ...ll in the reverse order of removal NOTE Apply grease to parts that rub Make sure the release cable works properly after installation C ADJUSTMENT Loosen the bolt Adjust the lock assembly while moving...

Page 3133: ...m opener pull handle 5 Remove the striker from trunk lid 6 Remove the cable from striker 3 FUEL FLAP OPENER 1 Remove the rear seat Ref to SE 17 REMOV AL Rear Seat 2 Remove the center pillar lower trim...

Page 3134: ...anel to left and remove B INSTALLATION 1 HOOD OPENER Install in the reverse order of removal 2 TRUNK LID OPENER Install in the reverse order of removal 3 FUEL FLAP OPENER Install in the reverse order...

Page 3135: ...SPECTION 1 Remove the instrument panel lower cover 2 Remove the lower column cover 3 Unfasten the hold down clip which secures har ness and disconnect the connector of ignition switch from body harnes...

Page 3136: ...ve the door trim Ref to EI 37 REMOV AL Front Door Trim 2 Remove the sealing cover Ref to EB 17 RE MOVAL Front Sealing Cover 3 Remove the front door glass Ref to GW 10 REMOVAL Front Door Glass 4 Remove...

Page 3137: ...D models The positions for RHD models are symmetrically opposite 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower cover Ref to EI 43 REMOVAL Instrument Panel Assembly 3 D...

Page 3138: ...nel lower cover Ref to EI 43 REMOVAL Instrument Panel Assembly 3 Remove the screws separate upper column cover and lower column cover 4 Disconnect the immobilizer antenna connector A from immobilizer...

Page 3139: ...ery 2 Remove the instrument panel lower cover Ref to EI 43 REMOVAL Instrument Panel Assembly 3 Remove the nut and then remove the keyless entry control module while disconnecting connec tor 4 Disconne...

Page 3140: ...isconnect the ground cable from battery 2 Remove the instrument panel lower cover Ref to EI 43 REMOVAL Instrument Panel Assembly 3 Remove the nut then remove the double lock module while disconnecting...

Page 3141: ...mitters can be regis tered for each individual vehicle When replacing the transmitter key registration to immobilizer system is also necessary 1 Remove the side sill cover at driver s side then connec...

Page 3142: ...SL 44 SECURITY AND LOCKS KEYLESS TRANSMITTER...

Page 3143: ...SUNROOF T TOP CONVERTIBLE TOP SUNROOF SR Page 1 General Description 2 2 Sunroof Control System 4 3 Sunroof Lid 5 4 Sunroof Assembly 6 5 Sunroof Motor 8 6 Sunroof Switch 9...

Page 3144: ...ERAL DESCRIPTION 1 General Description A COMPONENT 1 Glass lid 5 Sunroof bracket Tightening torque N m kgf m ft lb 2 Guide rail cover 6 Motor cover T 7 4 0 75 5 4 3 Sunshade 7 Motor ASSY 4 Drain tube...

Page 3145: ...d memory contents before disconnecting the battery ground cable Otherwise the memory will be erased Reassemble in reverse order of disassembly un less otherwise indicated Adjust parts to the given spe...

Page 3146: ...heck gears and bearings for wear 3 Check cables for wear 4 Check cable pipe for deformities Failure of sunroof Motor operates properly 1 Check guide rail for foreign particles 2 Check guide rail for i...

Page 3147: ...ly B INSTALLATION Install in the reverse order of removal C ADJUSTMENT 1 ALIGNMENT OF HEIGHT BETWEEN SUNROOF LID AND ROOF PANEL Loosen the sunroof lid installation nuts and then adjust the height by a...

Page 3148: ...AL Roof Trim 3 Remove the sunroof lid Ref to SR 5 REMOV AL Sunroof Lid 4 Disconnect the drain tubes from sunroof frame 5 Remove the room lamp harness clip A 6 Disconnect the sunroof harness connector...

Page 3149: ...sunroof frame D ASSEMBLY Assemble in the reverse order of disassembly E INSPECTION 1 CHECK FOR MOVING LOAD OF SUN SHADE 1 Attach a spring scale to sunshade edge using a cloth 2 Pull the spring scale b...

Page 3150: ...nroof cable when installing sunroof motor 1 Check the alignment mark A of sunroof motor 2 Confirm the alignment mark A of sunroof bracket link 3 Install the sunroof motor 4 After installing the motor...

Page 3151: ...mounting screw B 3 Disconnect the harness connectors and remove the sunroof switch B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the sunroof switch resistance Switch Term...

Page 3152: ...SR 10 SUNROOF T TOP CONVERTIBLE TOP SUNROOF SUNROOF SWITCH...

Page 3153: ...11 Side Sill Spoiler 36 12 Front Door Trim 37 13 Rear Door Trim 38 14 Glove Box 39 15 Roof Rail 40 16 Roof Molding 41 17 Console Box 42 18 Instrument Panel Assembly 43 19 Upper Inner Trim 46 20 Lower...

Page 3154: ...NERAL DESCRIPTION 1 General Description A COMPONENT 1 FRONT GRILLE 2 UNDER COVER 1 Front grille 2 Front grille emblem 3 Clip 1 Under cover 2 Clip side Tightening torque N m kgf m ft lb T 14 1 42 10 3...

Page 3155: ...3 EXTERIOR INTERIOR TRIM GENERAL DESCRIPTION 3 HOOD GRILLE 1 Hood grille 4 Packing Tightening torque N m kgf m ft lb 2 Bolt 5 Clip T 4 5 0 46 3 32 3 Grille duct 6 Side plate EI 00442 1 6 2 T 4 6 5 4...

Page 3156: ...UMPER 1 Bumper face 5 Bumper energy absorber Tightening torque N m kgf m ft lb 2 Fog light cover 6 Bumper beam T1 32 3 3 24 3 Bumper corner bracket 7 Bumper extension wagon turbo model T2 69 7 0 51 4...

Page 3157: ...er face 5 Bumper side cover Tightening torque N m kgf m ft lb 2 Bumper upper beam 6 License plate base T1 33 3 4 24 3 Bumper upper bracket 7 Bumper energy absorber T2 34 3 5 25 4 Bumper side bracket 8...

Page 3158: ...ERAL DESCRIPTION 6 MUD GUARD 7 COWL PANEL 1 Mud guard 3 Sub frame cover 5 Mud guard plate 2 Clip 4 Front air flap plate 6 Rear air flap plate 1 Cowl panel 3 Protector 4 Seal 2 Cowl side panel EI 00419...

Page 3159: ...R 9 REAR SPOILER 1 Roof spoiler 3 Clip Tightening torque N m kgf m ft lb 2 Cap T 7 4 0 75 5 46 1 Rear spoiler 4 Grommet Tightening torque N m kgf m ft lb 2 Protector 5 Seal RH T 7 4 0 75 5 46 3 Clip 6...

Page 3160: ...DESCRIPTION 10 SIDE SILL SPOILER 11 ROOF RAIL 1 Side sill spoiler 3 Protector 5 Clip Side sill spoiler 2 End cover 4 Rivet clip 6 Clip 1 Roof rail Tightening torque N m kgf m ft lb T 7 4 0 75 5 46 EI...

Page 3161: ...OR INTERIOR TRIM GENERAL DESCRIPTION 12 ROOF MOLDING A For sedan model B For wagon model C For wagon model with roof rail 1 Roof molding 3 Clip B 5 Clip D 2 Clip A 4 Clip C EI 00443 1 A 3 4 2 5 B 1 1...

Page 3162: ...ENERAL DESCRIPTION 13 DOOR TRIM A Front door trim B Rear door trim C Rear gate trim 1 Gusset cover 4 Clip 6 Power window switch cover 2 Bracket 5 Trim panel 7 Lower trim 3 Weather strip upper EI 00425...

Page 3163: ...BOX 1 Console cover 6 Lid hinge 11 Lower bracket 2 Cup holder 7 Rear lid 12 Lock 3 Bracket 8 Console box 13 Front cover AT model 4 Strip 9 Console pocket 14 Front cover MT model 5 Upper lid 10 Upper b...

Page 3164: ...cover 17 Glove box panel 3 Air vent grille defroster 11 Console cover 18 Console reinforcement 4 Grille cover 12 Center panel 19 Coin box 5 Meter visor 13 Center pocket 6 Defroster grille 14 Ash tray...

Page 3165: ...im 6 Trunk rear trim 10 Center pillar lower trim 2 Center pillar upper trim 7 Trunk side trim 11 Side sill front cover 3 Rear pillar upper trim 8 Rear pillar lower trim 12 Front garnish 4 Rear shelf t...

Page 3166: ...er lower trim 11 Side sill front cover 2 Center pillar upper trim 7 Hook 10 Front garnish 3 Rear pillar upper trim 8 Rear skirt trim 11 Rear garnish 4 Rear rail trim 9 Side sill rear cover 12 Front ga...

Page 3167: ...EI 15 EXTERIOR INTERIOR TRIM GENERAL DESCRIPTION 18 ROOF TRIM SEDAN MODEL 19 ROOF TRIM WAGON MODEL 1 Roof trim 1 Roof trim 2 Roof trim Model with sun roof 3 Sun roof garnish EI 00431 1 EI 00432 1 2 3...

Page 3168: ...ON 20 LUGGAGE FLOOR MAT 21 HEAT SHIELD COVER 1 Front floor mat 3 Side floor mat RH 5 Side floor mat LH 2 Floor box 4 Center floor mat 1 Front heat shield cover 2 Center heat shield cover 3 Rear heat s...

Page 3169: ...DESCRIPTION 22 INNER ACCESSORIES B PREPARATION TOOL 1 Hook 3 Assist grip 4 Center visor 2 Sun visor TOOL NAME REMARKS Clip remover Used for removal of trim Clip clamp pliers Used for removal of vario...

Page 3170: ...OR TRIM FRONT GRILLE 2 Front Grille A REMOVAL 1 Open the front hood 2 Remove the four clips A 3 Remove the right and left hooks on the lower side B INSTALLATION Install in the reverse order of removal...

Page 3171: ...B remove the four clips A and then remove the hood grille B INSTALLATION 1 Replace the four clips with new ones 2 Engage the four clips of hood grille to front hood panel CAUTION Make sure that the a...

Page 3172: ...Install the hood duct with clip A and seven bolts 6 Install the hood insulator with new clips C INSPECTION Make sure that the clip is firmly engaged Make sure that there is no abnormal gap at whole pe...

Page 3173: ...NT UNDER COVER 4 Front Under Cover A REMOVAL 1 Lift up the vehicle 2 Loosen the bolts and clips to remove the under cover B INSTALLATION Install in the reverse order of removal Tightening torque 14 N...

Page 3174: ...the mud guard and then remove the clips A and B which secure the front bumper to fender 5 Remove the two clips A turn over the mud guard and then remove the clip B Same proce dure on the right side 6...

Page 3175: ...then remove the bumper beam from body B INSTALLATION 1 Install in the reverse order of removal 2 Secure the slider A to guide plate B Tightening torque Refer to COMPONENT in General Descrip tion Ref...

Page 3176: ...for each color Solid paint Hardener PB Thinner T 301 Mixing ratio Main agent vs hardener 4 1 Viscosity 10 13 sec 20 C 68 F Film thickness 35 45 Spraying pressure 245 343 kPa 2 5 3 5 kg cm2 36 50 psi U...

Page 3177: ...e removed Pro cess No Process name Job contents 1 Cleaning Clean the area to be repaired using water 2 Sanding Grind the repairing area with 500 sand paper in a feathering motion 3 Finish Resin sectio...

Page 3178: ...le solvent NRM No 900 Precleno white gasoline or alcohol 5 Cutting If nature of damage are cracks or holes 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 b...

Page 3179: ...3 Primer coating Apply a coat of primer to the repaired surface and its surrounding areas Mask these areas if nec essary Recommended primer Mp 364 PP Primer NOTE Be sure to apply one coat of primer at...

Page 3180: ...s 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 clear coat three times at an interval of 3 to 5 minutes Recommended pa...

Page 3181: ...ly Ref to LI 21 REMOVAL Rear Combination Light Assembly 5 Remove the screw and two clips both sides 6 Remove the floor box 7 Remove the rear skirt trim 8 Turn over the rear quarter lower trims on both...

Page 3182: ...2 SEDAN MODEL Refer to description about removal of rear bumper of wagon model Ref to EI 29 WAGON MODEL REMOVAL Rear Bumper B INSTALLATION 1 WAGON MODEL 1 Install in the reverse order of removal Tight...

Page 3183: ...GUARD 7 Mud Guard A REMOVAL 1 Jack up the vehicle 2 Remove the screws and clips to remove mud guard B INSTALLATION Insert the hook into body and tighten it with screw and clip Tightening torque 14 N...

Page 3184: ...el A REMOVAL 1 Open the front hood 2 Remove the wiper arm Ref to WW 12 RE MOVAL Front Wiper Arm 3 Remove the front panel seal 4 Disengage the clips A to remove the cowl pan el B INSTALLATION Install i...

Page 3185: ...0 C 104 F If the double sided tape remains thick on surface due to interfacial peeling apply the solvent after slicing off the double sided tape using a cutter 2 Adhere the masking tape around the dou...

Page 3186: ...SIZED ROOF SPOILER 1 Apply the primer to spoiler surface where the double sided tape is adhered and then adhere the double sided tape as shown in the figure Primer 3M K 500 or equivalent Double sided...

Page 3187: ...ve rear spoiler CAUTION When removing the nut do not drop it into trunk lid Pay attention to avoid damage during remov al or installation Small sized rear spoiler Four tightening positions Large sized...

Page 3188: ...ips one on front fender arch six on bottom of side sill spoiler then remove the side spoiler NOTE Some vehicle have a clip to retain the splash board together with side sill spoiler forward of rear ti...

Page 3189: ...pper hook Pull down it to remove the lower hook Remove the inner remote cover 3 Remove the screw 4 Remove the power window switch assembly and disconnect the harness connector for models with power wi...

Page 3190: ...l the inner remote cover toward you to re move upper hook Pull down it to remove the lower hook Remove the inner remote cover 3 Remove the screw and clip 4 Remove the clips A of trim panel using clip...

Page 3191: ...EI 39 EXTERIOR INTERIOR TRIM GLOVE BOX 14 Glove Box A REMOVAL 1 Open the glove box 2 Loosen the screws to remove the glove box B INSTALLATION Install in the reverse order of removal EI 00465...

Page 3192: ...Roof Trim 2 Remove the four mounting nuts and then detach the roof rail carefully B INSTALLATION Install in the reverse order of removal CAUTION Be careful not to scratch the body panels with roof ra...

Page 3193: ...oof molding and glass and then remove the claw of internal clip B INSTALLATION 1 Remove the clip of roof and rear pillar sedan model from roof molding and then install it to body side CAUTION Make sur...

Page 3194: ...ect the ground cable from battery 2 Remove the console cover 3 Remove the shift knob MT model and front cover 4 Loosen the screws to remove the console box B INSTALLATION Install in the reverse order...

Page 3195: ...rews remove the clip A discon nect the connectors and then remove the instru ment panel lower cover 3 Remove the clip A and then remove the center console panel 4 Remove the glove box Ref to EI 39 REM...

Page 3196: ...EI 44 EXTERIOR INTERIOR TRIM INSTRUMENT PANEL ASSEMBLY 11 Remove the instrument panel installation bolts EI 00493...

Page 3197: ...panel place it standing up on the floor B INSTALLATION CAUTION Be careful not to snag the harness Carry out installation checking that the har ness is connected correctly When setting the instrument...

Page 3198: ...belt shoulder anchor and then remove the center pillar upper trim C B INSTALLATION Install in the reverse order of removal CAUTION Be sure to securely hook pawls of inner trim panel to body flange NO...

Page 3199: ...t cover A 2 Remove the rear seat cushion Ref to SE 17 REMOVAL Rear Seat and then remove side sill rear cover B 3 Remove the center pillar lower trim C B INSTALLATION Install in the reverse order of re...

Page 3200: ...ear Seat 2 Remove the side sill rear cover 3 Remove the rear rail trim A 4 Loosen the screws and clips to remove the rear quarter upper trim B 5 Remove the rear skirt trim C 6 Loosen the bolts and cli...

Page 3201: ...TERIOR INTERIOR TRIM SUN VISOR 22 Sun Visor A REMOVAL Remove the mounting screws and then detach the sun visor A hook B and center visor C B INSTALLATION Install in the reverse order of removal EI 004...

Page 3202: ...emove the upper inner trim Ref to EI 46 RE MOVAL Upper Inner Trim 9 Remove the quarter upper trim Ref to EI 48 SEDAN MODEL REMOVAL Rear Quarter Trim 10 Remove the clips and then remove the roof trim 2...

Page 3203: ...NTERIOR TRIM ROOF TRIM 10 Remove the rear quarter upper trim B of both sides 11 Remove the clips and then remove the roof trim B INSTALLATION Install in the reverse order of removal E Clip E A C D B E...

Page 3204: ...TRIM REAR GATE TRIM 24 Rear Gate Trim A REMOVAL CAUTION Be careful not to damage the clips or their holes 1 Remove the clips and then detach the rear gate trim B INSTALLATION Install in the reverse or...

Page 3205: ...ound cable from battery 2 Remove the high mount stop light 3 Remove the rear quarter upper trim Ref to EI 48 REMOVAL Rear Quarter Trim 4 Remove the seat belt center anchor lower bolt 5 Remove the rear...

Page 3206: ...the rear seat backrest Ref to SE 17 SEDAN MODEL REMOVAL Rear Seat 2 Remove the clip A 3 Loosen the clips and then detach the trunk rear trim B 4 Loosen the clips to remove the trunk side trim C B INST...

Page 3207: ...er and center pillar lower trim Ref to EI 47 REMOVAL Lower Inner Trim 5 Remove the foot rest 6 Remove the clips from floor mat 7 Remove the mat hook 8 Remove the mat from toe board area 9 Remove the m...

Page 3208: ...56 EXTERIOR INTERIOR TRIM LUGGAGE FLOOR MAT 28 Luggage Floor Mat A REMOVAL Remove the clips and then detach the rear floor mats and boxes B INSTALLATION Install in the reverse order of removal EI 005...

Page 3209: ...EI 57 EXTERIOR INTERIOR TRIM TRUNK ROOM MAT 29 Trunk Room Mat A REMOVAL Draw out the trunk room mat B INSTALLATION Install in the reverse order of removal EI 00507...

Page 3210: ...VER 1 Loosen the four bolts to remove the center heat shield cover 3 REAR HEAT SHIELD COVER 1 Remove the muffler Ref to EX H4SO 12 RE MOVAL Muffler Ref to EX H4SOw oOBD 11 REMOVAL Muffler Ref to EX H4...

Page 3211: ...NELS EB Page 1 General Description 2 2 Front Hood Panel 13 3 Front Fender Panel 14 4 Front Door Panel 15 5 Front Sealing Cover 17 6 Rear Door Panel 18 7 Rear Sealing Cover 20 8 Trunk Lid Panel 21 9 Re...

Page 3212: ...ion Part Standard A Front hood panel to Front fender panel NON TURBO 4 0 1 0 mm 0 16 0 04 in TURBO 3 7 1 0 mm 0 15 0 04 in B Front fender panel to Front door panel 4 7 1 0 mm 0 19 0 04 in C Front door...

Page 3213: ...04 0 02 in B Front bumber to Front grille Longitudinal direction 1 0 1 0 mm 0 04 0 04 in C Front hood panel to Front grille Steel 6 8 1 0 mm 0 27 0 04 in Aluminum 6 5 1 0 mm 0 26 0 04 in D Front hood...

Page 3214: ...eral direction 5 0 1 0 mm 0 20 0 04 in B Trunk lid panel to Rear bumper 7 0 1 5 mm 0 28 0 06 in C Trunk lid panel to Rear combination light Longitudi nal direction 7 0 1 0 mm 0 28 0 04 in D Trunk lid...

Page 3215: ...in B Rear gate panel to Rear combination light Lateral direction 5 0 1 0 mm 0 20 0 04 in C Rear gate panel to Rear combiantion light Longitudi nal direction 6 0 1 0 mm 0 24 0 04 in D Roof panel to Rea...

Page 3216: ...BODY PANELS GENERAL DESCRIPTION B COMPONENT 1 FRONT HOOD 1 Front hood 4 Seal Intake duct Turbo model Tightening torque N m kgf m ft lb 2 Seal Front panel T 24 5 2 5 18 1 3 Hinge 5 Seal Hood 4 1 3 2 5...

Page 3217: ...EB 7 EXTERIOR BODY PANELS GENERAL DESCRIPTION 2 FRONT FENDER PANEL 1 Front fender panel Tightening torque N m kgf m ft lb T 7 4 0 75 5 5 EB 00120 T T T 1...

Page 3218: ...ing torque N m kgf m ft lb 2 Weatherstrip Outer 7 Checker T1 7 4 0 75 5 5 3 Clip Weatherstrip outer 8 Lower hinge T2 24 5 2 5 18 1 4 Stabilizer Outer 9 Upper hinge T3 29 4 3 0 21 7 5 Stabilizer Inner...

Page 3219: ...bracket Tightening torque N m kgf m ft lb 2 Clip Weatherstrip outer 7 Sealing cover T1 7 4 0 75 5 5 3 Stabilizer Outer 8 Checker T2 24 5 2 5 18 1 4 Stabilizer Inner 9 Lower hinge T3 29 4 3 0 21 7 5 Re...

Page 3220: ...XTERIOR BODY PANELS GENERAL DESCRIPTION 5 TRUNK LID PANEL 1 Torsion bar 4 Hinge ASSY Tightening torque N m kgf m ft lb 2 Trunk lid panel T1 7 5 0 76 5 5 3 Weatherstrip T2 14 1 43 10 3 EB 00123 1 2 T1...

Page 3221: ...l and installa tion do not damage the panel painting surface While removing the mounting bolts using assis tance devices such as a support jack will help sup port the panel Be careful not to lose smal...

Page 3222: ...S 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge 927780000 REMOVER Used for removing and installing trunk torsion bar TOOL NAM...

Page 3223: ...everse order of removal 2 Adjust the clearance between front hood panel and front fender panel Clearance must be equal at both sides Tightening torque 24 5 N m 2 5 kgf m 18 1 ft lb C ADJUSTMENT 1 Use...

Page 3224: ...spoiler 3 Remove the front bumper face Ref to EI 22 REMOVAL Front Bumper 4 Remove the mud guard Ref to EI 31 RE MOVAL Mud Guard 5 Loosen the bolts to remove front fender panel B INSTALLATION 1 Install...

Page 3225: ...nt Door Latch Assembly 7 Remove the front outer handle Ref to SL 23 REMOVAL Front Outer Handle 8 Remove the front pillar lower trim to disconnect the connector from body harness 9 Put a wooden block o...

Page 3226: ...n of front door panel longitudinally and vertically ST 925610000 DOOR HINGE WRENCH 2 Loosen the screw A and tap striker B using a plastic hammer to adjust striker to align the position of front door p...

Page 3227: ...orce will easily break the cover If the cover gets broken replace it with a new one B INSTALLATION 1 Install in the reverse order of removal 2 When replacing the sealing cover use the butyl tape 3 Pre...

Page 3228: ...dle Ref to SL 27 REMOVAL Rear Outer Handle 7 Remove the center pillar lower trim Ref to EI 47 REMOVAL Lower Inner Trim 8 Disconnect the connector of door harness 9 Put a wooden block on the jack and p...

Page 3229: ...to align the po sition of rear door panel longitudinally and vertical ly 2 Loosen the screw A and then tap striker B using plastic hammer to adjust striker to align the position of rear door panel lat...

Page 3230: ...rce will easily break the cover If the cover gets broken replace it with a new one B INSTALLATION 1 Install in the reverse order of removal 2 When replacing the sealing cover use butyl tape 3 Press th...

Page 3231: ...tion carefully han dle the torsion bar because it will generate re active force 3 Remove the right left torsion bars CAUTION Be careful not to get hit by the trunk lid be cause the trunk lid will slam...

Page 3232: ...A connection and then pull out the harness and washer hose from rear gate 9 Using a support support the rear gate while re moving the rear gate damper stay mounting bolts CAUTION When the rear gate i...

Page 3233: ...olt A NOTE After supporting the rear gate with a jack start op eration C DISPOSAL 1 REAR GATE DAMPER STAY CAUTION Gas is colorless odorless and harmless How ever gas pressure may spray the cutting pow...

Page 3234: ...EB 24 EXTERIOR BODY PANELS REAR GATE PANEL...

Page 3235: ...OL SYSTEM CC Page 1 General Description 2 2 Actuator 3 3 Cruise Control Module 4 4 Cruise Control Main Switch 5 5 Cruise Control Command Switch 6 6 Stop and Brake Switch 8 7 Clutch Switch 9 8 Inhibito...

Page 3236: ...d Reassemble parts in the reverse order of disas sembly unless otherwise indicated Adjust parts to specifications specified in this manual Connect the connectors and hoses securely dur ing reassembly...

Page 3237: ...hing bolts 5 Remove the actuator while disconnecting the connector B INSTALLATION Install in the reverse order of removal Tightening torque 7 4 N m 0 75 kgf m 5 4 ft lb Cable end nut 12 N m 1 2 kgf m...

Page 3238: ...VAL 1 Disconnect the ground cable from battery 2 Remove the side sill front cover 3 Disconnect the connector from cruise control module 4 Remove the bolt then detach the cruise control module A B INST...

Page 3239: ...nel lower cover 4 Disconnect the connector from cruise control main switch 5 Remove the main switch by pushing it outward B INSTALLATION Install in the reverse order of removal C INSPECTION Measure th...

Page 3240: ...of airbag module 6 Remove the horn switch from steering wheel as shown 7 Disconnect the horn and cruise control com mand switch connector then remove the cruise control command switch 2 THREE SPOKES S...

Page 3241: ...ODEL If NG replace the cruise control command switch Switch Position Terminal No Standard value CANCEL ON 1 and 2 Less than 1 ON 1 and 3 Less than 1 SET COAST OFF 1 and 2 More than 1 M ON 1 and 2 Less...

Page 3242: ...o BR 73 REMOVAL Stop Light Switch B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the brake switch A and stop light switch B resistance If NG replace the stop and brake swi...

Page 3243: ...rom clutch switch and then remove the switch Ref to CL 42 DIS ASSEMBLY Clutch Pedal B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the clutch switch resistance If NG repla...

Page 3244: ...h and then remove the switch Ref to 4AT 49 RE MOVAL Inhibitor Switch B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the inhibitor switch resistance If NG replace the inhib...

Page 3245: ...Basic Diagnostic Procedure 2 2 General Description 3 3 Electrical Components Location 5 4 Cruise Control Module I O Signal 6 5 Subaru Select Monitor 8 6 Diagnostic Procedure with Symptom 10 7 List of...

Page 3246: ...to step 6 Go to symptom 3 Ref to CC 10 SYMPTOM CHART Diagnos tic Procedure with Symptom 6 CHECK RESUME ACCEL OPERATION Check the RESUME ACCEL operation Does the vehicle speed increase or return to set...

Page 3247: ...the airbag system wiring harness when servicing the cruise control mod ule and cruise control command switch B PREPARATION TOOL 1 SPECIAL TOOLS 2 GENERAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION RE...

Page 3248: ...when the cruise control throttle is moved by hand If NG check the throttle cam 4 THROTTLE CAM Check that the throttle cam moves smoothly If NG repair the throttle cam 5 CABLE FREE PLAY Check that the...

Page 3249: ...NENTS LOCATION 3 Electrical Components Location A LOCATION 1 Actuator 4 Cruise control main switch 7 Cruise control module 2 Inhibitor switch AT model 5 Clutch switch MT model 3 Cruise control command...

Page 3250: ...voltage is present when command switch is turned to RESUME ACCEL position 0 volt is present when command switch is released SET COAST switch 10 Battery voltage is present when command switch is turne...

Page 3251: ...l is released 0 volt is present when clutch pedal is depressed Data link connector 17 Data link connector 18 Vehicle speed sensor MT model TCM AT model 19 Lift up the vehicle until all four wheels are...

Page 3252: ...gnosis The real time diagnosis function is used to deter mine whether or not the input signal system is in good order according to signal emitted from switches sensors etc 1 Vehicle cannot be driven a...

Page 3253: ...onitor switch to ON 4 On the Main Menu display screen select the Each System Check and press YES key 5 On the System Selection Menu display screen select the Cruise Control and press YES key 6 Press t...

Page 3254: ...e system Ref to CC 32 DTC 37 ACTUATOR MOTOR CLUTCH Diagnostic Procedure with DTC 4 Vehicle speed does not increase or does not return to set speed after RESUME ACCEL switch has been pressed 1 Check th...

Page 3255: ...odel 1 Check the clutch switch Ref to CC 20 CHECK CLUTCH SWITCH MT MODEL Diagnostic Procedure with Symptom 2 Check the motor drive system Ref to CC 30 DTC 35 AND 36 ACTUATOR MOTOR Diagnostic Procedure...

Page 3256: ...SYMPTOM Cruise control can be set but indicator does not come on When main switch is pressed WIRING DIAGRAM CC 00173 B161 SBF 4 BATTERY CRUISE CONTROL MAIN SWITCH B94 CRUISE CONTROL MODULE F B No 18...

Page 3257: ...and chassis ground Connector terminal B94 No 12 Chassis ground Is the voltage more than 10 V Go to step 2 Check the fuse No 18 in fuse relay box Check the har ness for open or short between cruise con...

Page 3258: ...module operates the main switch circuit is in normal condition The main relay operation can be checked by hearing the operation sound This operation sound will be heard when the ignition switch and c...

Page 3259: ...t between cruise control main switch and fuse relay box 2 CHECK CRUISE CONTROL MAIN SWITCH CIRCUIT 1 Turn the ignition switch OFF 2 Disconnect the cruise control module har ness connector 3 Measure th...

Page 3260: ...00185 S1 BATTERY HORN SWITCH CRUISE CONTROL COMMAND SWITCH HORN RELAY HORN SET COAST SWITCH RESUME ACCEL SWITCH CANCEL SWITCH B94 CRUISE CONTROL MODULE M B No 6 10 9 1 2 3 B68 1 2 3 4 STEERING ROLL CO...

Page 3261: ...E ACCEL switch is pressed Go to step 3 Go to step 4 3 CHECK CANCEL SWITCH CIRCUIT Measure the voltage between harness connec tor terminal and chassis ground when CAN CEL switch is pressed and not pres...

Page 3262: ...Cruise control cannot be set WIRING DIAGRAM CC 00033 B107 B94 B65 AT AT MODEL MT MT MODEL 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 BATTERY CRUISE CONTROL MODULE SBF 1 SBF 2 F B No 16 CLU...

Page 3263: ...r terminal B65 No 4 Chassis ground Is the voltage more than 10 V Go to step 3 Check the har ness for open or short between stop light brake switch and cruise control module AT model Check the clutch s...

Page 3264: ...control cannot be set WIRING DIAGRAM CC 00033 B107 B94 B65 AT AT MODEL MT MT MODEL 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 BATTERY CRUISE CONTROL MODULE SBF 1 SBF 2 F B No 16 CLUTCH SW...

Page 3265: ...eck the harness for open or short between clutch switch and cruise control module 2 CHECK CLUTCH SWITCH CIRCUIT 1 Turn the cruise control main switch and igni tion switch OFF 2 Disconnect the stop lig...

Page 3266: ...R SWITCH AT MODEL TROUBLE SYMPTOM Cruise control cannot be set WIRING DIAGRAM CC 00175 B12 B94 T3 T7 B14 3 4 1 2 8 9 10 11 12 5 6 7 3 4 1 2 8 9 10 11 12 5 6 7 T7 B12 CRUISE CONTROL MODULE 4 12 11 12 7...

Page 3267: ...10 V Go to step 2 Check the harness for open or short between inhibitor switch and cruise control module 2 CHECK INHIBITOR SWITCH CIRCUIT 1 Turn the cruise control main switch and igni tion switch to...

Page 3268: ...od ule relay when main switch is ON Ref to CC 29 DTC 28 WIRING HARNESS OPENED Diagnostic Pro cedure with DTC 35 Motor drive system is abnormal Motor output circuit is open or shorted Motor drive circu...

Page 3269: ...control module TROUBLE SYMPTOM Cruise control is canceled and memorized cruise speed is also canceled Once cruise control is canceled cruise control cannot be set until the ignition switch and cruise...

Page 3270: ...mediately WIRING DIAGRAM CC 00176 BATTERY CRUISE CONTROL MODULE SBF 4 F B No 18 IGNITION SWITCH B17 TCM E C17 B17 B22 B94 E3 B56 B56 C GE VEHICLE SPEED SENSOR MT 1 2 3 6 19 B94 B22 E 16 MT AT 1 2 3 1...

Page 3271: ...NSOR AND ENGINE GROUND 1 Turn the ignition switch to OFF 2 Measure the resistance between vehicle speed sensor harness connector terminal and engine ground Connector terminal B17 No 2 Engine ground Is...

Page 3272: ...ter than 10 km h 6 MPH Warning Be careful not to be caught by the running wheels 4 Measure the voltage between transmission control module harness connector terminal and chassis ground Connector termi...

Page 3273: ...battery specific gravity more than 1 260 Go to step 2 Charge or replace the battery Go to step 2 2 CHECK FUSES CONNECTORS AND HAR NESSES Check the condition of the main and other fuses and harnesses a...

Page 3274: ...GNOSIS Open or poor contact of cruise control actuator motor TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM CC 00177 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 3275: ...he resistance less than 10 Go to step 3 Repair the har ness 3 MEASURE RESISTANCE OF ACTUATOR Measure the resistance of cruise control actua tor motor Terminals No 4 No 1 No 4 No 2 No 4 No 5 Is the res...

Page 3276: ...SIS Open or poor contact of cruise control actuator motor clutch TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM CC 00177 B94 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 3277: ...the resistance less than 10 Go to step 3 Repair the har ness 3 MEASURE RESISTANCE OF ACTUATOR CLUTCH Measure the resistance of cruise control actua tor clutch Terminals No 3 No 6 Is the resistance app...

Page 3278: ...ner gear engage and disengage improperly Replace the cruise control actuator Ref to CC 3 Actuator Check the cruise control cable adjustment Ref to CC 4 CABLE FREE PLAY Gen eral Description Step Check...

Page 3279: ...omponents Location 5 4 Immobilizer Control Module I O Signal 6 5 Subaru Select Monitor 7 6 Read Diagnostic Trouble Code DTC 8 7 Clear Memory Mode 9 8 Diagnostics Chart for Immobilizer Indicator Light...

Page 3280: ...start Go to step 4 Go to step 5 4 CHECK ILLUMINATION OF IMMOBILIZER INDICATOR LIGHT Turn the ignition switch to ON Does the immobilizer indicator light illuminate Check the immobi lizer indicator lig...

Page 3281: ...ned ON or OFF while diagnostic items are being checked do not allow keys with different ID codes close to the ignition switch If the ignition key is in a key holder remove it from the holder before ca...

Page 3282: ...RIDGE Troubleshooting for electrical systems 22771AA030 SELECT MONITOR KIT Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080...

Page 3283: ...OMPONENTS LOCATION 3 Electrical Components Location A LOCATION NOTE IMM ECM location for RHD model is symmetrically opposite 1 Antenna 3 Immobilizer control module IMM ECM 4 Transponder 2 Immobilizer...

Page 3284: ...IM 6 IMMOBILIZER DIAGNOSTICS IMMOBILIZER CONTROL MODULE I O SIGNAL 4 Immobilizer Control Module I O Signal A SCHEMATIC 1 IMMOBILIZER Ref to WI 182 SCHEMATIC Immobilizer Sys tem...

Page 3285: ...then record them 2 READ DIAGNOSTIC TROUBLE CODE DTC FOR ENGINE Refer to Read DTC for information about how to in dicate DTC Ref to IM 8 Read Diagnostic Trou ble Code DTC 3 INTERFACE CHECK NOTE The co...

Page 3286: ...en press the YES key 3 Press the YES key after the information of en gine type is displayed 4 On the Engine Diagnosis display screen se lect the DTC Display and then press the YES key 5 On the DTC Dis...

Page 3287: ...after the information of en gine type is displayed 4 On the Engine Diagnosis display screen se lect the Clear Memory and then press the YES key 5 When the Done are shown on the display screen turn the...

Page 3288: ...EL 22 B141 3 4 1 2 8 9 10 11 12 5 6 7 21 9 32 i2 1 2 3 4 5 6 10 11 12 13 14 15 7 16 23 30 19 20 22 26 27 28 29 8 17 24 31 18 25 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...

Page 3289: ...T 1 Turn the ignition switch to OFF 2 Measure the voltage between IMM ECM har ness connector terminal and chassis ground Connector terminal B141 No 10 No 11 Chassis ground Is the voltage more than 10...

Page 3290: ...CK KEY SWITCH CIRCUIT WIRING DIAGRAM IM 00074 B74 B62 F45 KEY WARNING SWITCH B141 IMMOBILIZER CONTROL MODULE LHD RHD LHD RHD BATTERY M B No 6 4 1 2 23 B74 1 2 B141 3 4 1 2 8 9 10 11 12 5 6 7 F45 3 4 1...

Page 3291: ...ce less than 1 Go to step 3 Replace the key warning switch 3 CHECK KEY SWITCH 1 Remove the ignition key from the ignition switch 2 Measure the resistance between key warn ing switch connector terminal...

Page 3292: ...Diagnostic Trou ble Code DTC P1571 Reference Code Incompati bility Reference code incompatibility between IMM ECM and ECM Ref to IM 18 DTC P1571 REFER ENCE CODE INCOMPATIBILITY Diag nostics Chart with...

Page 3293: ...operation man ual Pub No S0820GZ Is teaching operation for all keys completed END Replace all ignition keys including the transponder Go to step 2 2 PERFORM TEACHING OPERATION ON IG NITION KEY Perform...

Page 3294: ...M 16 IMMOBILIZER DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE DTC B DTC P1570 ANTENNA DIAGNOSIS Faulty antenna WIRING DIAGRAM IM 00008 2 1 B142 IMMOBILIZER CONTROL MODULE ANTENNA B142 1...

Page 3295: ...re the voltage between antenna har ness connector and chassis ground Connector terminal B142 No 2 Chassis ground Is the voltage 0 V Go to step 6 Repair the har ness between IMM ECM and antenna because...

Page 3296: ...ion on all keys of the vehicle Refer to the teaching operation man ual Is teaching operation for all keys completed END Replace the ECM Ref to FU H4SO 48 Engine Control Module ECM Ref to FU H4SOw oOBD...

Page 3297: ...0 11 12 13 14 15 7 16 23 19 20 22 26 27 28 8 17 24 18 25 1 2 B141 3 4 1 2 8 9 10 11 12 5 6 7 B135 B 21 9 3 4 5 6 10 11 12 13 14 15 7 16 19 20 22 8 17 18 1 2 24 23 25 27 26 28 TB NA RHD RHD MODEL LHD L...

Page 3298: ...ground Connector terminal B141 No 2 No 3 Chassis ground Is the resistance less than 10 Go to step 4 Repair the open circuit of IMM ECM ground circuit 4 CHECK HARNESS BETWEEN IMM ECM AND ECM 1 Disconne...

Page 3299: ...OBD B137 No 17 No 18 Engine ground RHD SOHC model without OBD B135 No 22 No 23 Engine ground Turbo model B135 No 5 No 14 Engine ground Is the voltage 0 V Go to step 8 Repair the har ness between IMM E...

Page 3300: ...Con trol Module ECM Then per form teaching operation Refer to the teaching oper ation manual Pub No S0820GZ Go to step 10 10 CHECK ECM BY INTERFACE CHECK Perform interface check Does Communication Lin...

Page 3301: ...FUNCTION Insert the key to ignition switch LOCK posi tion measure changes in voltage between Antenna connector Connector terminal B142 No 1 No 2 Is the voltage 30 to 30 V Approx 0 1 second after inse...

Page 3302: ...IM 24 IMMOBILIZER DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE DTC...

Page 3303: ...mbling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satis...

Page 3304: ......

Page 3305: ...182 21 Keyless Entry System 186 22 Back up Light System 195 23 Clearance Light and Illumination Light System 196 24 Front Fog Light System 208 25 Headlight System 211 26 In Compartment Light System 21...

Page 3306: ...s In Engine Room 267 48 Bulkhead Wiring Harness In Compartment 275 49 Engine Wiring Harness and Transmission Cord 281 50 Instrument Panel Wiring Harness 287 51 Rear Wiring Harness Bulkhead Wiring Harn...

Page 3307: ...oor connectors etc If no problems are encountered check the component parts 5 CONFIRMATION OF SYSTEM OPERA TION After repairing ensure that the system operates properly B BASIC INSPECTION 1 VOLTAGE ME...

Page 3308: ...inals 1 3 and 6 as shown in table be low 3 HOW TO DETERMINE AN OPEN CIR CUIT 1 Voltmeter Method An open circuit is determined by measuring the voltage between respective connectors and ground using a...

Page 3309: ...rom power supply If the test lamp goes out when a connector is disconnected the wiring between that connection and next connector far ther from the power supply is shorted 2 Ohmmeter method Disconnect...

Page 3310: ...ence of a lock and pin number of each terminal are indicated in the sketch of each connector In the sketch the highest pole number refers to the number of poles which con nector has For example the sk...

Page 3311: ...s described in figure NOTE A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that ter minal In wiring d...

Page 3312: ...wires is used Each unit is directly grounded to the body or indi rectly grounds through a harness ground terminal Different symbols are used in the wiring diagram to identify the two grounding systems...

Page 3313: ...rmally closed relay has one or more contacts The wiring diagram shows the relay mode when energizing circuit is OFF WI 00114 Relay type 4 pole 6 pole 4 pole 6 pole Normally open type Normally closed t...

Page 3314: ...f the vehicle Symbol Wiring harness and cord F Front wiring harness B Bulkhead wiring harness E Engine wiring harness T Transmission cord Rear oxygen sensor cord D Door cord LH RH Rear door cord LH RH...

Page 3315: ...HEAD LIGHT RELAY LH G P SUP 04 D H L 2L 01 RL LW GR LB MB 10 M B FUSE NO 8 MB 11 M B FUSE NO 9 FB 16 F B FUSE NO 11 IG MB 5 HEADLIGHT RELAY TO POWER SUPPLY ROUTING LW 4 R 3 YL LW R YL 2 YB 1 RY 2 LW...

Page 3316: ...ame characters with arrows facilitates wire tracing from one page to the next A A B B 10 SYMBOLS OF WIRE CONNECTION AND CROSSING 11 POWER SUPPLY ROUTING A symbol is used to indicate the power supply i...

Page 3317: ...YMBOL IN WIRING HARNESS Main symbols of connector in wiring harness are indicated in below Female Male Water proof type Standard type WI 02445 Female Male Pole From 1 to 8 Pole From 9 to 20 Pole More...

Page 3318: ...A C Air Conditioning AD Auto Down AT Automatic Transmission AU Auto Up B Battery DN Down E Ground F B Fuse Joint Box FL1 5 Fusible link 1 5 mm2 IG Ignition Illumi Illumination LH Left Hand Lo Low M Mo...

Page 3319: ...and bolts or screws 3 When installing the parts be careful not to catch them on the wiring harness 4 When disconnecting a connector do not pull the wires but pull while holding the connector body 5 So...

Page 3320: ...F B No 2 No 7 No 9 No 6 No 1 No 13 No 14 No 15 No 16 No 17 No 18 No 19 No 7 No 8 No 9 No 10 No 11 No 12 No 1 No 2 No 3 No 4 No 5 No 6 No 4 No 5 No 3 No 8 H L relay RH FWD SWITCH MAIN FAN 20A SUB FAN...

Page 3321: ...CK BLACK BLACK F35 GREEN F26 F34 F39 F26 F34 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 F25 F35 W W W SBF HOLDER 30A W 2 WR 4 1 2 P SUP L 03 B P SUP L 03 A P SUP L 03 C No 3 10A No 9 15A No 8 15A SBF 1 80A HEA...

Page 3322: ...0A MB 5 MB 11 MB 10 MB 12 MB 9 MB 6 MB 7 HORN RELAY MAIN FUSE BOX M B BL 4 W 2 YR 6 G 5 BR 1 WR 4 WL 1 LR 2 R 3 RG 4 L 1 R 3 BW 2 W F36 F68 BLACK 1 2 3 3 4 1 2 1 2 3 4 5 6 7 8 F37 BLACK F39 BLACK 4 1...

Page 3323: ...58 R79 E B271 B B152 D 1 2 3 4 5 6 7 8 9 10 11 12 G LgB Or TAIL ILLUMI NATION RELAY FUSE RELAY BOX F B No 18 15A B271 B B51 A B152 D B52 C B158 E F41 R3 R79 B99 G F40 F FB 5 D7 BG G7 No 5 10A No 12 10...

Page 3324: ...No 7 15A No 8 20A No 16 20A No 19 20A No 10 10A No 4 20A No 9 15A No 15 30A No 14 10A B11 G E1 BW F6 R F3 L F2 Y E7 Y E9 WR E4 FB 25 WG FB 24 FB 26 FB 27 FB 29 F1 YB E2 YG B9 C3 YR B6 B8 LR C2 RW E10...

Page 3325: ...ight Trunk room light Sedan FB 10 Bright switch Combination meter Front fog light relay Front fog light switch Headlight leveling switch Illumination light Rear fog light relay Rear fog light switch F...

Page 3326: ...WI 22 WIRING SYSTEM POWER SUPPLY ROUTING FB 32 ABS control module FB 33 Front fog light relay FB 34 Blower motor relay FB 35 Keyless entry control module FB 36 Combination meter No Load...

Page 3327: ...9 No 6 No 1 No 13 No 14 No 15 No 16 No 17 No 18 No 19 No 7 No 8 No 9 No 10 No 11 No 12 No 1 No 2 No 3 No 4 No 5 No 6 No 4 No 5 No 3 No 8 H L relay RH FWD SWITCH MAIN FAN 20A SUB FAN 20A Horn relay SUB...

Page 3328: ...F26 F34 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 CURRENT FROM IGNITION SWITCH IG TERMINAL CURRENT FROM IGNITION SWITCH ACC TERMINAL OTHER CURRENTS BATTERY CURRENT F25 F35 W W W SBF HOLDER 30A W 2 WR 4 1 2 P...

Page 3329: ...BR 1 W 4 WL 1 LR 2 R 3 RG 4 L 1 R 3 BW 2 W B143 B186 BLACK 1 2 3 3 4 1 2 1 2 3 4 5 6 7 8 B144 BLACK F39 BLACK 4 1 2 3 6 5 SBF 5 30A SBF 2 50A SBF 3 50A SBF 4 50A P SUP R 02 C P SUP R 02 B F39 B144 B14...

Page 3330: ...FB 17 B1 FB 18 GB G3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 B158 E B271 B B152 D 1 2 3 4 5 6 7 8 9 10 11 12 G LgB Or TAIL ILLUMI NATION RELAY FUSE RELAY BOX F B No 18 15...

Page 3331: ...T No 3 15A No 1 15A No 2 15A No 7 15A No 8 20A No 16 20A No 19 20A No 10 10A No 4 20A No 9 15A No 15 30A No 14 10A B11 G E1 BW F6 R F3 L F2 Y E7 Y E9 YL E4 FB 25 FB 26 FB 27 FB 29 F1 YB E2 YG B9 C3 YR...

Page 3332: ...ight RH FB 5 Front turn signal light LH FB 6 Front clearance light LH Front clearance light RH FB 7 License plate light Tail light LH Tail light RH Trailer connector FB 10 Bright switch Combination me...

Page 3333: ...tercooler water spray switch Intercooler water spray timer Seat heater relay FB 29 Rear fog light relay FB 30 Mirror heater relay FB 31 Stop light switch FB 32 ABS control module FB 33 Front fog light...

Page 3334: ...LIGHT SWITCH REAR FOG LIGHT SWITCH B B F17 GRAY 3 4 1 2 D7 1 2 3 8 9 10 4 11 12 13 14 15 16 5 6 7 B 1 B F17 F7 GRAY 1 2 RELAY BLOCK B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 3335: ...16 2 3 B GB 4 B B16 1 2 B12 1 2 3 4 5 6 7 8 9 10 11 12 B284 1 3 4 5 6 2 7 8 9 10 B47 BROWN 3 4 1 2 5 6 1 2 B129 1 2 B70 2 3 6 4 5 7 1 8 9 11 12 15 13 14 16 10 17 18 GND 01 A B71 2 3 4 5 6 7 1 8 9 10...

Page 3336: ...1 2 3 4 5 6 7 8 9 10 B97 1 2 3 4 5 6 7 8 D11 24 23 22 21 20 6 5 2 1 4 3 7 8 9 25 14 13 12 11 10 15 18 17 16 19 D15 3 2 1 8 7 6 5 4 6 B304 B 2 ABS CONDENSER BY 3 BW 4 B 1 B 2 GB 9 B198 B306 BY 1 FRONT...

Page 3337: ...6 B 2 B 4 TRUNK ROOM LIGHT SWITCH SEDAN REAR COMBINATION LIGHT LH SEDAN R28 B 4 2 R116 B REAR WIPER INTERMITTENT MODULE WAGON GND 03 D B120 1 2 3 4 5 6 7 8 9 10 11 12 13 14 11 GB 4 B 27 W GB 5 W 28 RA...

Page 3338: ...B HIGH MOUNTED STOP LIGHT D74 B B D43 B 3 REAR WIPER MOTOR D46 B 2 1 1 REAR GATE LATCH SWITCH R66 B 2 HIGH MOUNTED STOP LIGHT REAR SPOILER GND 04 E R60 R24 B B 1 D35 R39 B B 3 D43 D35 3 4 1 2 R66 2 1...

Page 3339: ...4 B 1 B 13 BR RELAY BLOCK B225 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 2 9 3 4 5 6 7 8 RELAY HOLDER F27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19...

Page 3340: ...9 10 11 12 B7 1 3 4 5 6 2 B284 1 3 4 5 6 2 7 8 9 10 B47 BROWN 3 4 1 2 5 6 1 2 B129 1 2 B70 2 3 6 4 5 7 1 8 9 11 12 15 13 14 16 10 17 18 GND 06 A B71 2 3 4 5 6 7 1 8 9 10 11 12 13 14 15 16 17 6 B7 CRU...

Page 3341: ...R22 1 2 3 R57 R15 BW B 4 R1 B97 B B B B D11 B101 B B 1 R8 1 2 R58 1 3 4 5 6 2 R122 1 2 3 4 5 6 7 8 9 10 B97 1 2 3 4 5 6 7 8 D11 24 23 22 21 20 6 5 2 1 4 3 7 8 9 25 14 13 12 11 10 15 18 17 16 19 D15 3...

Page 3342: ...NK ROOM LIGHT SWITCH SEDAN REAR COMBINATION LIGHT LH SEDAN R28 B 4 2 R116 B REAR WIPER INTERMITTENT MODULE WAGON GND 08 D B120 1 2 3 4 5 6 7 8 9 10 11 12 13 14 11 GB 4 B 27 B BY GB 5 B BY 28 RADIO SRS...

Page 3343: ...GH MOUNTED STOP LIGHT D48 B D39 B D43 B 3 REAR WIPER MOTOR D46 B 2 1 REAR GATE LATCH SWITCH R66 B 2 HIGH MOUNTED STOP LIGHT REAR SPOILER GND 09 E R60 R24 B B 1 D35 R39 B B 3 D43 D35 3 4 1 2 R66 2 1 1...

Page 3344: ...33 34 35 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 B135 B 5 4 6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 24 25 26 27 16 17 18 28 29 19 20 21 30 B136 C BROWN GREEN GRAY BROW...

Page 3345: ...11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5 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 B135 B 5 4 6 7 8 2 1 9 3 10 22 23 11 12 13 14 15 2...

Page 3346: ...4 35 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 B135 B GREEN BROWN R3 B99 B22 E3 B76 GB BR 3 BR R57 GE R15 3 GB BR i2 B37 6 BW BR 1 TEST MODE CONNECTOR DATA LINK CONNEC...

Page 3347: ...6 27 28 29 30 31 32 33 34 35 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 B135 B BROWN GREEN BROWN R3 B99 E3 B22 B76 BW BW 6 GW R57 GE R15 3 BW BR i2 B37 11 BW GW 1 TEST...

Page 3348: ...W 3 B128 BR 3 i12 A BW A8 BW D17 ENGINE CONTROL MODULE B134 A B136 C B137 D B84 E VEHICLE SPEED SENSOR MT NEUTRAL POSITION SWITCH COMBINATION METER IGNITION COIL No 4 IGNITION COIL No 2 IGNITION COIL...

Page 3349: ...MODULE B134 A B136 C B137 D B84 E VEHICLE SPEED SENSOR MT NEUTRAL POSITION SWITCH COMBINATION METER IGNITION COIL No 4 IGNITION COIL No 2 IGNITION COIL No 3 IGNITION COIL No 1 FUEL PUMP ASSEMBLY IDLE...

Page 3350: ...TRANSMISSION VEHICLE SPEED SENSOR 1 AWD VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR GRAY BLACK B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 A B54 1 2 7 8 9 5...

Page 3351: ...NTROL TRANSMISSION VEHICLE SPEED SENSOR 1 AWD VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR GRAY BLACK B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 A B54 1 2 7 8...

Page 3352: ...G CONTROL MODULE AB3 B81 B82 B79 B37 i2 TO POWER SUPPLY ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 BR BR GREEN i11 YELLOW...

Page 3353: ...R LH FRONT SUB SENSOR RH INFLATOR PASSENGER SIDE YELLOW YELLOW YELLOW AB15 AB3 AB18 AB2 AB21 AB3 AB26 AB15 AB18 AB4 GB 5 AB27 AB21 W W Y Y Y Y AB14 AB13 W 1 W 2 15 26 W W 9 20 13 14 11 10 Y 1 Y YL YB...

Page 3354: ...3 B 4 Gr 1 Y 2 Lg 3 Br 4 AB7 AB19 AB29 AB10 AB12 AB9 AB20 AB19 AB12 AB10 AB8 AB7 AB11 AB9 AB28 AB20 AB11 AB8 AIRBAG CONTROL MODULE SIDE AIR BAG SENSOR RH SIDE AIR BAG SENSOR LH INFLATOR SIDE LH INFLAT...

Page 3355: ...L V REF TO GND 07 CHECK CONNECTOR DIAGNOSIS CONNECTOR DIAGNOSIS TERMINAL B31 AB1 i11 i10 GRAY YELLOW AB3 B79 GREEN B C i10 AIRBAG CONTROL MODULE AB3 B81 B82 B79 B37 i2 TO POWER SUPPLY ROUTING 1 2 3 4...

Page 3356: ...ATOR PASSENGER SIDE YELLOW YELLOW YELLOW AB15 AB3 AB18 AB2 AB21 AIRBAG CONTROL MODULE AB3 AB26 AB14 AB15 AB18 AB13 AB4 GB 5 AB27 AB21 AB13 L Br YL YB YG YR G 2 W G W 1 15 26 G W 9 20 13 14 11 10 YL 1...

Page 3357: ...2 G 3 B 4 W 1 L 2 G 3 B 4 AB7 AB19 AB29 AB10 AB12 AB9 AB20 AB19 AB12 AB10 AB8 AB7 AB11 AB9 AB28 AB20 AB11 AB8 AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH INFLATOR SIDE LH INFLAT...

Page 3358: ...4 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 RELAY HOLDER F27 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 E B84 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21...

Page 3359: ...FB 27 F B FUSE NO 9 ACC GB GY B19 REF TO R DEF L 01 B10 B20 B V REF TO ILM L 01 GE GREEN BROWN BROWN C B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 GY C17 B56 C TRANSMISSION CONT...

Page 3360: ...BP 1 F78 AMBIENT SENSOR SUNLOAD SENSOR i10 B COMBINATION METER BL 1 2 i51 YB B12 BP B11 BL B8 F45 B62 i1 B36 i2 B37 1 2 B256 F78 i51 BLACK BP 10 BP BL 23 BL YB 21 YB GR 7 GR GR EVAPORATION THERMO SWI...

Page 3361: ...G 19 B100 F2 TB NA TB TB TURBO ENGINE MODEL NA NON TURBO ENGINE MODEL NA B77 MODE ACTUATOR LW 1 3 RY 2 B B293 AIR MIX ACTUATOR 1 GY L 3 B 2 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B282...

Page 3362: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B137 D B B135 B B134 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 RELAY HOLDER F27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2...

Page 3363: ...FUSE NO 18 IG YG LR B1 FB 27 F B FUSE NO 9 ACC GB GY B19 REF TO R DEF R 01 B10 B20 V REF TO ILM ROI 01 ILM RWI 01 GE GREEN BROWN C B56 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 GY...

Page 3364: ...Or 2 F78 AMBIENT SENSOR SUNLOAD SENSOR YB 1 2 i51 F45 B62 i2 B37 1 2 F78 B256 i51 BLACK W 23 W Or 24 Or YB 26 YB GR 25 GR GR EVAPORATION THERMO SWITCH YB 1 2 B256 R YB W 13 GREEN B i10 1 2 3 4 5 6 7...

Page 3365: ...WG 3 E8 THERMOMETER WG WG 10 B21 E2 WG WG 15 B21 E2 TB NA TB NA B77 MODE ACTUATOR LW 1 3 RY 2 B B293 AIR MIX ACTUATOR 1 GY L 3 B 2 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B282 GRAY 1...

Page 3366: ...30 31 23 24 25 26 B 26 ABS MOTOR GROUND B B302 MOTOR RELAY FR OUTLET FR INLET RL OUTLET RL INLET RR OUTLET RR INLET FL OUTLET FL INLET SOLENOID VALVE LgY B3 RY B19 C7 RW RW COMBINATION METER PARKING B...

Page 3367: ...21 22 27 28 29 30 31 23 24 25 26 YG WR 3 6 BR 2 BR BR BR F44 B61 BR 16 F60 E3 E3 BR 16 B100 F2 BR 1 BR GE DIAGNOSIS CONNECTOR DIAGNOSIS TERMINAL B 1 3 2 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2...

Page 3368: ...W L G 2 3 W B 1 R B99 R3 F94 B15 R73 R72 B292 REAR ABS SENSOR LH REAR ABS SENSOR RH ABS G SENSOR EXCEPT STi MODEL 2 3 W VW 1 RW B292 ABS G SENSOR STi MODEL 2 3 W BrY 1 LR B257 ABS LATERAL G SENSOR STi...

Page 3369: ...11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 B 26 1 B MOTOR RELAY FL INLET FL OUTLET FR INLET FR OUTLET RL INLET RL OUTLET RR INLET SOLENOID VALVE GW 31 B3 C7 WR COMBI NATION METER B...

Page 3370: ...8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 YR 18 WL YR WL 19 3 6 BR REF TO GND 07 B B B21 GW 16 BR GE DIAGNOSIS CONNECTOR DIAGNOSIS CONNECTOR TRANSMISSION CONTROL MODULE B55...

Page 3371: ...31 32 YG YL LG LR YG YL LG LR B99 R3 1 2 R73 R72 F62 F74 2 3 4 5 6 7 8 12 14 15 13 16 17 18 19 20 9 21 10 11 1 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25 26 F4...

Page 3372: ...0 C17 B23 B11 B20 VEHICLE SPEED SENSOR 1 AWD VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR B24 A19 B18 A10 B8 B9 SHIELD JOINT CONNECTOR LINE END CHECK CONNECTOR TRANSMISSION CONTROL MOD...

Page 3373: ...LY ROUTING TRANSMISSION CONTROL MODULE DIMMER CIRCUIT R N D 3 2 1 B PL A3 3 GR 2 RL 1 Lg 8 W 7 RB 6 YB 5 LB 4 B REF TO GND 02 B36 GR 9 RL 8 Lg 7 W 6 RB 5 YB 4 LB 3 B1 B3 B14 B4 B5 B6 B7 GR RL Lg W RB...

Page 3374: ...B 4 V 3 B 6 POWER MODE AND SNOW HOLD MODE SWITCH POWER SNOW HOLD OFF REF TO ILM L 01 B11 GW B23 BrB REF TO GND 02 1 2 3 4 5 6 7 8 9 10 GREEN i11 C GREEN B i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 3375: ...DULE LY WB 2 1 B64 STOP LIGHT SWITCH 1 2 1 9 2 3 4 1 2 7 8 9 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 5 6 7 8 5 6 3 4 2 3 9 1 8 10 4 5 11 12 6 7 13 14 10 11 10 11 12 19 20 21 13 3 4 10 11 12 19 20 2...

Page 3376: ...2 13 14 15 26 27 28 16 17 18 19 20 21 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 23 24 25...

Page 3377: ...URE SENSOR VEHICLE SPEED SENSOR 1 AWD AT5 VEHICLE SPEED SENSOR 2 TORQUE CONVERTER TURBINE SPEED SENSOR B53 B11 T4 BY SHIELD JOINT CONNECTOR 6 LgB 4 SB 5 BL 3 L 1 SB 2 BW 9 B 7 SB 8 A16 LgR A5 RW A22 L...

Page 3378: ...8 F B FUSE NO 11 F B FUSE NO 13 F B FUSE NO 16 M B FUSE NO 4 SBF 4 SBF 2 STOP LIGHT SWITCH SBF 5 SBF 1 BATTERY P R N D 3 2 1 COMBINATION METER DIMMER CIRCUIT HOLD FWD AT OIL TEMP POWER TO BRIGHT SWITC...

Page 3379: ...gB 11 RL 9 P GrL 8 7 RB 6 YL 5 LB 4 C2 B3 B14 B4 B5 B6 B7 LgB B1 Or RL P RB GrL YL LB B55 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 B56 C B55 B REF To CLEARANCE LIGHT AND ILLUMI...

Page 3380: ...8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GRAY B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 GREEN C B56 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 1...

Page 3381: ...DULE 1 2 1 2 7 8 9 1 2 5 6 3 4 10 11 12 19 20 21 13 3 4 10 11 12 19 20 21 13 14 15 5 6 14 15 16 17 18 22 23 24 7 8 9 16 17 18 22 23 24 GRAY B79 2 3 9 1 8 10 4 5 11 12 6 7 13 14 BROWN B22 1 2 3 4 5 6 7...

Page 3382: ...29 30 GRAY B B55 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 23 24 A B54 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20...

Page 3383: ...SB 5 Gr 3 1 SB 2 A16 GB A14 YL A5 RW A22 GL A20 WR Gr W Y W Y W W G RY YG WG BW WB GB W 8 YL RW GL WR Gr B56 TRANSMISSION CONTROL MODULE C B55 B B54 A SPORTS SHIFT SOLENOID AT4 BROWN B54 A 1 2 21 22 2...

Page 3384: ...H FRONT DOOR TWEETER LH D4 B101 D11 D14 1 2 D2 D12 1 2 B120 1 2 3 4 5 6 7 8 9 10 11 12 13 14 D4 LR YG FB 9 M B FUSE NO 2 B FB 27 F B FUSE NO 9 ACC TO POWER SUPPLY ROUTING WB RY LR YG 10 6 3 9 8 2 WB R...

Page 3385: ...W 12 LY 4 13 WR 5 B 11 B D23 D29 D21 D27 RADIO B120 B265 D27 B269 D21 D29 D23 B GR REAR DOOR SPEAKER RH ANTENNA AMP 2 1 1 REAR DOOR SPEAKER LH 2 1 4 3 W W B97 R1 3 RW LY 4 3 B120 1 2 3 4 5 6 7 8 9 10...

Page 3386: ...O ILM R 01 D1 D11 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 1 1 WITH ILLUMINATION CONTROL MODEL YL WITHOUT ILLUMINATION CONTROL MODEL B FRONT DOOR TWEETER RH WB RY WB RY 25 24...

Page 3387: ...3 B GR REAR DOOR SPEAKER RH 2 1 REAR DOOR SPEAKER LH 2 1 4 3 RW LY 4 3 B120 1 2 3 4 5 6 7 8 9 10 11 12 13 14 NON TURBO ENGINE MODEL TURBO ENGINE MODEL NA TB NA NA TB TB NA NA TB TB 1 2 1 2 3 4 1 2 B12...

Page 3388: ...W 1 TO POWER SUPPLY ROUTING FB 36 F B FUSE NO 13 IG RW REF TO P SUP REF TO P SUP BW B1 BW BW 8 BW BW 13 i10 i11 B C COMBINATION METER i2 B37 B62 F45 F26 F25 GREEN GREEN B i10 1 2 3 4 5 6 7 8 9 10 11...

Page 3389: ...LY ROUTING FB 36 F B FUSE NO 13 IG GW REF TO P SUP REF TO P SUP BW B1 BW BW BW BW 18 i10 i11 B C COMBINATION METER i2 B37 B62 F45 F26 F25 GREEN GREEN B i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 3390: ...NATION METER 11 Combination Meter A SCHEMATIC 1 EXCEPT FOR AUSTRALIA STi MODEL CM EA 01 CM EA 01 WI 02301 GREEN i12 To A GREEN i10 To B GREEN i11 To C B16 B29 B15 B14 B7 B8 B1 B30 A7 A14 A3 A4 A8 A13...

Page 3391: ...TOR LIGHT MALFUNCTION INDICATOR LIGHT OIL PRESSURE WARNING LIGHT ABS WARNING LIGHT CHARGE WARNING LIGHT PARKING BRAKE BRAKE FLUID LEVEL WARNING LIGHT AT OIL TEMP WARNING LIGHT PARKING BRAKE SWITCH MET...

Page 3392: ...ATOR LIGHT LH HEAD LIGHT RELAY RH TURN SIGNAL SWITCH HI BEAM P METER 04 E METER 02 A METER 04 C AIRBAG WARNING LIGHT AIRBAG CONTROL MODULE IGN IGN IGN B B SNOW HOLD PILOT LIGHT AWD LO INDICATOR LIGHT...

Page 3393: ...RCUIT I F AT MODEL MT MODEL AT MT WITH AUTO A C MODEL AC B TRANSMISSION CONTROL MODULE VEHICLE SPEED SENSOR AUTO A C CONTROL MODULE TRANSMISSION CONTROL MDDULE WITH SPORTS SHIFT MODEL ENGINE CONTROL M...

Page 3394: ...WIRING SYSTEM COMBINATION METER 2 FOR AUSTRALIA STi MODEL CM FA 01 CM FA 01 WI 02547 GREEN i12 To A GREEN i10 To B GREEN i11 To C B16 B29 B15 B14 B7 B8 B1 B30 A7 A14 A3 A4 A8 A13 A6 C1 C2 C6 C5 C9 C1...

Page 3395: ...WARNING LIGHT PARKING BRAKE SWITCH CM FA 03 A B19 B1 B2 B3 A6 B9 B5 HI BEAM INDICATOR LIGHT B29 DIMMER SWITCH B30 B INTERCOOLER WATER SPRAY TANK LEVEL WARNING LIGHT INTERCOOLER WATER SPRAY TANK LEVEL...

Page 3396: ...NDICATOR LIGHT DIMMER CIRCUIT LIQUID CRYSTAL DISPLAY BACK LIGHT LETTER PLATE ILLUMINATION LIGHT POINTER ILLUMINATION LIGHT DIMMER CIRCUIT DIMMER CIRCUIT CM FA 04 B CM FA 04 C MICROCOMPUTER DRIVER CLOC...

Page 3397: ...ANCE LIGHT INDICATOR LIGHT I F I F 5V B12 B11 B8 C2 C2 ELECTRICALLY ERASABLE PROGRAMMABLE ROM LIQUID CRYSTAL DISPLAY OUT TEMP LIQUID CRYSTAL DISPLAY ODO TRIP METER TRIP RESET SWITCH VEHICLE SPEED SENS...

Page 3398: ...H SET RESUME CANCEL LY LY 2 WB 3 RY 1 4 B65 YR 1 YG 2 B107 B68 RG 1 RW LgB 2 3 MT AT AT GB 12 GB RG 3 CRUISE CONTROL MAIN SWITCH STOP LIGHT AND BRAKE SWITCH CLUTCH SWITCH MT GB 5 1 6 4 2 GL YG LR V YL...

Page 3399: ...BR GY 3 GOr GW 16 E3 B22 VEHICLE SPEED SENSOR MT B REF TO GND 07 BR GB GY GW 3 1 2 B17 TRANSMISSION CONTROL MODULE AT GY GOr C17 B22 B56 C B55 B 18 BrW 17 LgR AT MT 1 2 3 GREEN C B56 1 2 3 4 10 11 12...

Page 3400: ...MOTOR BY 12 BW WB WR WR 7 B94 T3 B12 12 11 CRUISE CONTROL MODULE B94 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 T7 B12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 WB B7 CRUISE...

Page 3401: ...E2 F61 WG WG 19 F2 B100 WG WG THERMOMETER WG 3 E8 BW BL 15 BW 15 B22 E3 TB NA TB NA NA TB E8 1 2 3 B21 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GRE...

Page 3402: ...E8 GE BW 15 B22 E3 E8 1 2 3 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GREEN BROWN A i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 H C GREEN C i11 1 2 3 4 5 6 7 8 9 10 TB NA TB NA LIGHT GRAY B21 1 2 5 6 7 8 13...

Page 3403: ...WI 99 WIRING SYSTEM ENGINE COOLANT TEMPERATURE GAUGE SYSTEM...

Page 3404: ...EL PUMP RELAY MAIN RELAY PURGE CONTROL SOLENOID VALVE FUEL INJECTOR NO 1 FUEL INJECTOR NO 2 FUEL INJECTOR NO 3 FUEL INJECTOR NO 4 IDLE AIR CONTROL SOLENOID VALVE TRANSMISSION CONTROL MODULE AT TO AIR...

Page 3405: ...E CONNECTOR THERMOMETER OIL PRESSURE SWITCH LINE END CONNECTOR NEUTRAL POSITION SWITCH MT MT MT CRANKSHAFT POSITION SENSOR KNOCK SENSOR POWER STEERING OIL PRESSURE SWITCH ENGINE GROUND THROTTLE POSITI...

Page 3406: ...R VW 3 BY 4 BY B B REF TO GND 03 ENGINE CONTROL MODULE VW GR B7 A16 B135 A B134 B E G LOO 08 B A BY B BY 7 BY BY B FUEL PUMP FUEL PUMP ASSEMBLY 1 4 1 2 3 4 5 6 7 8 B97 R58 R15 3 4 1 2 B46 GREEN A B134...

Page 3407: ...2 B37 i2 GW 5 GW WG 10 WG E11 GW GREEN LIGHT GRAY A i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GREEN B i10 GREEN C i11 A B134 BROWN GREEN 14 2 1 3 VEHICLE SPEED SENSOR MT B17 B17 1 2 3 5 6 7 8 2 1 9 4 3 10...

Page 3408: ...TCH AT BY 7 BW P T3 B12 T7 R N D 3 2 1 12 WB 11 WR 2 BR B47 BROWN BLACK B12 F44 3 1 2 4 5 6 5 6 3 4 1 2 7 8 T7 5 6 3 4 1 2 11 12 9 10 7 8 B135 B136 1 2 3 4 5 6 7 8 9 10 11 12 B REF TO GND 02 LgW B MT...

Page 3409: ...B135 C B136 REF TO A C ALH 01 REF TO R F NA 01 RL A3 GR A12 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 B135 B A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20...

Page 3410: ...OR G E G LOO 03 D E G LOO 02 C E G LOO 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 LB B26 GB B3 LgB B40 BR 13 BR BR 12 LgB 10 BR 1 BW 6 LB B 8 Or 4 LgB 12 GB 7 B14 O...

Page 3411: ...OSITION SENSOR B21 E2 Sb 12 Lg 11 BY YR WR BR 9 B28 3 2 1 E13 DARK BROWN 1 2 3 4 B136 C WR YR 3 BR 2 4 C12 Y A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31...

Page 3412: ...1 BR WG Br BR YR R BY Y PL Or 1 2 E15 CAMSHAFT POSITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 3 E14 E10 E15 1 2 1 3 4 5 6 2 1 3 4 5 6 2 E7 LIGHT GRAY LIGHT GRAY BLA...

Page 3413: ...A25 YL A26 GW B POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 3 E12 GW B B GW GW BR YW RG L PURGE CONTROL SOLENOID VALVE 3 R YR A2 2 WR WL WL 2 1 E4 WR R 3 1 2 4 1 2 4 BG E12 1 2...

Page 3414: ...A4 P 9 YL Br Y 1 E G LOO 03 I FUEL INJECTOR NO 1 Y 2 Br 1 FUEL INJECTOR NO 4 Y 2 GB 1 FUEL INJECTOR NO 3 Y 2 GOr 1 PL A13 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 LIGHT GRAY BROWN LIGHT GRAY LIGHT GRA...

Page 3415: ...WI 111 WIRING SYSTEM ENGINE ELECTRICAL SYSTEM...

Page 3416: ...ENOID VALVE PURGE CONTROL DOLENOID VALVE TRANSMISSION CONTROL MODULE AT EXHAUST GAS RECIRCRATION SOLENID VALVE TO AIR CONDITIONING RELAY TO FRONT WIPER SWITCH TO AUTO A C CONTROL MODULE TO MAIN FAN RE...

Page 3417: ...RMOMETER OIL PRESSURE SWITCH LINE AND CONNECTOR NEUTRAL POSITION SWITCH MT MT CRANKSHAFT POSITION SENSOR KNOCK SENSOR B17 B18 B28 B16 B27 A7 A35 C26 POWER STEERING OIL PRESSURE SWITCH C25 C9 C16 C5 B2...

Page 3418: ...4 1 2 GREEN B99 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5 6 7 8 2 1 9 4 3...

Page 3419: ...2 GW 5 GW WG 10 WG E11 GW 14 2 1 3 VEHICLE SPEED SENSOR MT B17 B17 1 2 3 GREEN B 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 BROWN i1 1 2 3 4 5 6 7 8 9 10 11 1...

Page 3420: ...WB 12 INHIBITOR SWITCH AT BY 7 BW P T3 B12 T7 R N D 3 2 1 12 WB 11 WR 2 BR B47 BROWN B12 F44 3 1 2 4 5 6 5 6 3 4 1 2 7 8 T7 5 6 3 4 1 2 11 12 9 10 7 8 B135 B136 1 2 3 4 5 6 7 8 9 10 11 12 B REF TO GND...

Page 3421: ...A C B136 D B137 REF TO IMB L 02 YB D17 RY D18 REF TO R F NA 01 RL A14 GR A13 B137 D A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B136 C REF T...

Page 3422: ...B40 BR 13 BR 12 LgB 10 BR 1 BW 6 B 8 Or 4 LgB 12 GB 7 GB BR 1 2 T2 B25 B76 B75 NEUTRAL POSITION SWITCH MT B25 1 2 B137 D MT Or B125 B126 RL B REF TO GND 02 B300 1 3 4 5 6 2 A21 RW RW 1 BW 4 B300 LINE...

Page 3423: ...W RG B83 F26 3 2 1 E13 1 2 3 4 B19 1 2 3 4 REAR OXYGEN SENSOR 2 1 4 3 WR YR 3 BR 2 4 C25 L B19 B83 3 2 1 4 5 6 F45 B136 C DARK BROWN 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 17 18 19 20 B21 LIGHT GRAY W...

Page 3424: ...Or 1 2 E15 CAMSHAFT POSITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 1 E14 E10 E15 1 2 BLACK LIGHT GRAY LIGHT GRAY 1 3 4 5 6 2 E7 BLACK 17 Y 19 18 Or GL 4 LB B W 1 L 3...

Page 3425: ...32 GW B WL POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 2 1 4 3 E12 GW BW GW GW BR BR B 1 4 2 2 0L 1 6L 3 PURGE CONTROL SOLENOID VALVE 2 1 E4 WR Y A12 7 G YG YG AIR ASSIST INJEC...

Page 3426: ...EL INJECTOR NO 3 Y 2 GOr 1 PL A23 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 E6 E16 E17 1 2 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2...

Page 3427: ...WI 123 WIRING SYSTEM ENGINE ELECTRICAL SYSTEM...

Page 3428: ...L INJECTOR NO 4 AIR FLOW SENSOR E27 A6 TO AIR CONDITIONING RELAY B12 TO FRONT WIPER SWITCH TO AUTO A C CONTROL MODULE A9 E17 TO MAIN SUB FAN RELAY 1 TO MAIN SUB FAN RELAY 2 E28 A3 TO REAR WINDOW DEFOG...

Page 3429: ...E GENERATOR VALVE ANGLE SENSOR LH B13 B23 CRANKSHAFT POSITION SENSOR KNOCK SENSOR 5 B2 B11 B1 B10 B21 B4 B22 A22 D17 D8 ENGINE GROUND 1 ENGINE CONTROL MODULE FUEL LEVEL SENSOR 6 IGNITION COIL NO 1 IGN...

Page 3430: ...GREEN 7 8 9 10 BY B BR BrW LgR 20 B99 R3 B97 R1 BR 3 BrW 11 LgR VW 19 VW GB BrW R59 L 2 BrW 1 FUEL SUB LEVEL SENSOR R59 1 2 BY B FUEL PUMP FUEL PUMP ASSEMBLY 1 4 R58 BR 5 L 3 FUEL LEVEL SENSOR VW BW...

Page 3431: ...LTB 05 D B37 i2 GREEN A i12 GREEN BROWN B i10 GREEN C i11 14 2 1 3 VEHICLE SPEED SENSOR B17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 1 2 3...

Page 3432: ...R E10 BR YR 6 4 LR YL 5 3 2 1 B61 F44 B47 E G LTB 06 K E G LTB 05 I E G LTB 06 J WB 2 BR BR 8 LR BR B47 BROWN 3 1 2 4 5 6 B134 B84 B REF TO GND 02 LgW B A E TO BATTERY TERMINAL B14 STARTER MOTOR WB A1...

Page 3433: ...L A3 B134 A B B135 E B84 REF TO IMB L 02 YB B14 RY B5 REF TO R F TB 01 RL E17 GR E28 A B134 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 E B84 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 29 30 31...

Page 3434: ...NECTOR TEST MODE CONNECTOR I E G LTB 03 E E G LTB 02 D E G LTB 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 Or A8 GB A21 LgB B40 BR 13 RL BR 12 LgB 10 BR 1 YB 8 BW 6...

Page 3435: ...Lg WB EXHAUST GAS TEMPERATURE SENSOR 1 2 B279 W YR FRONT OXYGEN A F SENSOR 2 1 W B 3 4 B18 RW YR REAR OXYGEN SENSOR 2 1 LR W 3 4 B19 1 2 B19 1 2 3 4 1 2 1 2 3 4 D B137 B135 B 1 2 7 8 9 5 6 3 4 10 11...

Page 3436: ...0 B B21 SB B22 SB B4 W W G OrL WL OrL WL Or W RL W R B Or W W RL 1 2 E10 CRANKSHAFT POSITION SENSOR 1 2 E15 E14 E1 1 2 3 4 6 CAMSHAFT POSITION SENSOR 2 GE 2 KNOCK SENSOR C15 Or C9 Y C3 W C2 R C14 SB O...

Page 3437: ...Y L LG GY R OrB LY L LG YG R OrB C12 GrG C6 G LY L LG YG R 18 GW G 2 G GrG 3 GrG 20 5 14 6 15 21 POWER STEERING OIL PRESSURE SWITCH E19 1 2 1 G 2 GrG GB GB WB WB C16 OrL C17 RW RW 9 RW OrL 10 OrL 1 2...

Page 3438: ...E SENSOR 3 2 E21 1 3 2 1 3 2 1 THROTTLE POSITION SENSOR E13 ENGINE COOLANT TEMPERATURE SENSOR AND THERMOMETER E8 B23 9 BrR 4 10 BrY 13 16 YB 16 20 Sb 4 19 Lg BrR BrY YB Sb Lg 5 18 L 17 17 BY BY 15 15...

Page 3439: ...WY RY BY LY RY BY GY RY BL BL BY BR Y YB YR YG GR BL BW BY B BR Y YB YR YG GR BL BW BY B BR D23 D22 D21 E9 A22 D8 D18 A7 Y YB YR YG BL E8 BL BW D17 BW BY B BR A15 C1 BR BR 1 2 3 F60 1 2 3 4 5 6 7 8 9...

Page 3440: ...E16 WL GW R LgY LgY R GW R LW R W R YW R 2 B100 F2 B61 F44 PG 3 PB 14 P 2 YL YL 1 PL 13 WL PG PB P PL WL 23 PURGE CONTROL SOLENOID VALVE 1 2 E5 DARK GRAY BLACK BROWN DARK GRAY DARK GRAY DARK GRAY E6...

Page 3441: ...WI 137 WIRING SYSTEM ENGINE ELECTRICAL SYSTEM...

Page 3442: ...CTOR NO 1 FUEL INJECTOR NO 2 FUEL INJECTOR NO 3 FUEL INJECTOR NO 4 IDLE AIR CONTROL SOLENOID VALVE TRANSMISSION CONTROL MODULE AT TO AIR CONDITIONING RELAY TO EVAPORATION THERMO SWITCH TO AIR CONDITIO...

Page 3443: ...NECTOR THERMOMETER OIL PRESSURE SWITCH NEUTRAL POSITION SWITCH MT SHIELD AND SENSOR GROUND JOIN CONNECTOR CRANKSHAFT POSITION SENSOR KNOCK SENSOR 5 POWER STEERING OIL PRESSURE SWITCH ENGINE GROUND PRE...

Page 3444: ...7 B135 A B134 B GR FB 21 F B FUSE NO 11 IG E G ROO 08 B E G ROO 03 A 1 2 3 4 5 6 7 8 B97 R58 R15 3 4 1 2 B46 GREEN A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29...

Page 3445: ...B21 E2 B37 i2 WR 5 GW WG 10 WG E11 GW GREEN LIGHT GRAY A i12 GREEN B i10 GREEN C i11 A B134 GREEN 31 2 1 3 VEHICLE SPEED SENSOR MT B17 1 2 3 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 1...

Page 3446: ...AT BY 7 BW P T3 B12 T7 R N D 3 2 1 12 WB 11 WR B47 BROWN B12 3 1 2 4 5 6 T7 5 6 3 4 1 2 11 12 9 10 7 8 B135 B136 1 2 3 4 5 6 7 8 9 10 11 12 B REF TO GND 07 Lg B MT AT AT MT 5 4 6 7 8 2 1 9 3 10 22 23...

Page 3447: ...136 REF TO IMB R 02 REF TO A C ARH 01 RY B22 YG B23 REF TO R F NA 01 WL A3 GR A12 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 B135 B A B134 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 3448: ...NNECTOR TEST MODE CONNECTOR G E G ROO 03 D E G ROO 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 RB B26 GR B3 LgB B40 GW 13 GW GW 12 LgB 10 BR 1 RW 6 RW 4 RG 1 RB B 8...

Page 3449: ...12 3 4 17 18 19 20 B136 C DARK BROWN OXYGEN SENSOR WITH IMMOBILIZER MODEL 2 4 1 WR YR 3 BR 2 4 B28 BR YR 3 Sb 1 2 B8 LgW B18 CO ADJUSTING RESISTOR WITHOUT IMMOBILIZER MODEL B21 5 4 6 7 8 2 1 9 3 10 2...

Page 3450: ...Y Y PL Or 1 2 E15 CAMSHAFT POSITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 3 E14 E10 E15 1 2 1 3 4 5 6 2 E7 LIGHT GRAY LIGHT GRAY BLACK BLACK BLACK 17 W Y PL 19 B 18...

Page 3451: ...POWER STEERING OIL PRESSURE SWITCH E19 GR IGNITION COIL AND IGNITOR 3 3 1 2 4 1 2 4 E12 GW B B GW GW BR YW RG L PURGE CONTROL SOLENOID VALVE 3 YR A2 2 WR R WL WL 2 1 E4 WR R BY E12 1 2 3 4 5 6 7 8 2 1...

Page 3452: ...A4 P 9 YL Br Y 1 E G ROO 03 J FUEL INJECTOR NO 1 Y 2 Br 1 FUEL INJECTOR NO 4 Y 2 GB 1 FUEL INJECTOR NO 3 Y 2 GOr 1 PL A13 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 LIGHT GRAY BROWN LIGHT GRAY LIGHT GRA...

Page 3453: ...WI 149 WIRING SYSTEM ENGINE ELECTRICAL SYSTEM...

Page 3454: ...ER TO LIGHTING SWITCH 3 4 1 2 FUEL PUMP WS OS WS OS FRONT OXYGEN A F SENSOR REAR OXYGEN SENSOR AIR ASSIST INJECTOR SOLENOID VALVE PURGE CONTROL SOLENOID VALVE TRANSMISSION CONTROL MODULE AT IMMOBILIZE...

Page 3455: ...ST MODE CONNECTOR THERMOMETER OIL PRESSURE SWITCH LINE END CONNECTOR NEUTRAL POSITION SWITCH MT MT CRANKSHAFT POSITION SENSOR KNOCK SENSOR POWER STEERING OIL PRESSURE SWITCH ENGINE GROUND THROTTLE POS...

Page 3456: ...134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5 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 B135 B BY B BR BW 5 B99 R...

Page 3457: ...E G RWO 05 D B21 E2 WR 5 GW WG 10 WG E11 GW 2 1 3 VEHICLE SPEED SENSOR MT B17 B17 1 2 3 B137 D GREEN B 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 A B134 1 2...

Page 3458: ...12 13 14 15 26 27 28 16 17 18 19 20 21 B135 B B C TO BATTERY TERMINAL B14 STARTER MOTOR MT 4 C20 C21 C20 AT E G RWO 01 AT WS WS OS OS 2 WB 4 WL W W YR C23 2 2 3 2 3 WITH SECURITY EXCEPT FOR AUSTRALIA...

Page 3459: ...D4 B134 A C B136 D B137 REF TO IMB R 01 RY D17 YG D18 REF TO R F NA 01 WL A14 GR A13 B137 D A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B136...

Page 3460: ...4 5 6 7 8 9 10 11 12 13 14 1 2 Or C21 GR D16 LgB RL B40 GW 13 GW 12 LgB 10 BR 1 RG 6 RG 4 RL 1 B 8 Or 4 LgB 12 GB 7 GR GW 1 2 T2 B25 RB GW 1 B76 B75 NEUTRAL POSITION SWITCH MT B25 1 2 MT B126 RB Or B1...

Page 3461: ...CONNECTOR 4 2 BW BW RL GY 1 BW BW RG B83 B2 3 2 1 E13 B83 1 2 3 4 B19 1 2 3 4 REAR OXYGEN SENSOR 2 1 4 3 WR YR 3 BR 2 4 Gr YR LW W B BW YR L B19 B B135 B136 C 1 2 5 6 7 8 13 14 15 16 9 10 11 12 3 4 1...

Page 3462: ...PL 14 15 LB Br R Br BR WG Br BR YR R BY PL Y Or 1 2 E15 CAMSHAFT POSITION SENSOR B W 1 3 E7 IDLE AIR CONTROL SOLENOID VALVE GL LB 4 6 L RY 2 5 Y Y 3 E14 E15 E20 1 2 LIGHT GRAY BLACK 1 3 4 5 6 2 E7 BL...

Page 3463: ...GW D14 GW GW BW C26 A33 YL A32 LgW BL WL POWER STEERING OIL PRESSURE SWITCH E19 GR PURGE CONTROL SOLENOID VALVE 2 1 E4 WR Y A12 7 G PL PL AIR ASSIST INJECTOR SOLENOID VALVE 2 1 E42 Y G BY 5 6 7 8 2 1...

Page 3464: ...EL INJECTOR NO 3 Y 2 GOr 1 PL A23 PL Lg 10 FUEL INJECTOR NO 2 Y 2 Lg 1 E5 E6 E16 E17 1 2 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2...

Page 3465: ...WI 161 WIRING SYSTEM ENGINE ELECTRICAL SYSTEM...

Page 3466: ...NG SWITCH REAR OXYGEN SENSOR IDLE AIR CONTROL SOLENOID VALVE EXHAUST GAS TEMPERATURE SENSOR IMMOBILIZER CONTROL MODULE TRANSMISSION CONTROL MODULE AT PURGE CONTROL SOLENOID VALVE 1 2 3 4 FUEL PUMP 6 5...

Page 3467: ...UEL LEVEL SENSOR 6 IGNITION COIL NO 1 IGNITION COIL NO 2 IGNITION COIL NO 3 IGNITION COIL NO 4 ACTIVE VALVE CONTROL SOLENOID LH ACTIVE VALVE CONTROL SOLENOID RH TUMBLE GENERATOR VALVE LH TUMBLE GENERA...

Page 3468: ...8 9 10 BY BW BR BrB LgR 27 B99 R3 B97 R1 GW 6 BrW 18 LgR LgB 26 LgB GW BrW R59 L 2 BrB 1 FUEL SUB LEVEL SENSOR R59 1 2 BY BW FUEL PUMP FUEL PUMP ASSEMBLY 1 4 R58 BR 5 L 3 FUEL LEVEL SENSOR LgB BW FUEL...

Page 3469: ...EHICLE SPEED SENSOR MT B17 GW GW B56 C GY AT C17 TRANSMISSION CONTROL MODULE AT B37 i2 31 MT STi MODEL EXCEPT STi MODEL STi EST GREEN A i12 GREEN B i10 GREEN i11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 3470: ...STARTER MOTOR A B134 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 E B84 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 E G RTB 01 12 INHIBITOR SWITCH A...

Page 3471: ...REF TO AT R 04 B134 A B B135 D B137 E B84 REF TO IMB R 02 RY B14 YG B5 REF TO R F TB 01 WL E17 GR E28 A B134 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 E B84 1 2 7 8 9 5 6 3 4 10 11 12 1...

Page 3472: ...GW 12 LgB 10 BR 1 BR 8 RW 6 6 Or B 8 Or 4 LgB 12 GB 7 B79 GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GR GW 1 3 T9 B128 GW 1 B76 B75 NEUTRAL POSITION SWITCH A20 RG A10 RL B125 RG 1 RL B300 B REF TO GND 07 4...

Page 3473: ...S TEMPERATURE SENSOR 1 2 B279 BR YR FRONT OXYGEN A F SENSOR 2 1 B W 3 4 B18 RW YR REAR OXYGEN SENSOR 1 2 RW W 4 3 B19 1 2 B18 1 2 3 4 1 2 D B137 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 2...

Page 3474: ...Y 1 2 E10 B20 E1 CRANKSHAFT POSITION SENSOR 1 2 E15 E14 1 2 3 4 6 CAMSHAFT POSITION SENSOR LIGHT GRAY LIGHT GRAY LIGHT GRAY 2 GE 2 KNOCK SENSOR OrL WL Or W RL W C15 B C9 R C3 G C2 W C14 SB WL OrL B R...

Page 3475: ...RY L YL WL GL W G RY L YL WL GL W BW R POWER STEERING OIL PRESSURE SWITCH E19 B135 B 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 B136 C 5 6 7 8 2 1 9 4 3 10 11 12 13 14...

Page 3476: ...3 2 E21 1 3 2 1 3 2 1 THROTTLE POSITION SENSOR E13 ENGINE COOLANT TEMPERATURE SENSOR AND THERMOMETER E8 B23 9 R B13 10 L B8 16 YB B9 20 Sb B7 19 Lg 18 B18 17 BY 15 YR WR Or R YG BG H WG YR BG R WR BG...

Page 3477: ...Y RY BY Y RY BY RY BR BL BL BY BR D23 D22 D21 E9 A22 D8 D18 A7 Y YB YR YG BW E8 BW BW D17 BW BY B GW A15 C1 GW GW D B137 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 13 14 15 16 17 18 22 23 24 B136 C 5 6 7 8 2...

Page 3478: ...O 4 2 1 FUEL INJECTOR NO 3 2 1 PL D6 PL 10 FUEL INJECTOR NO 2 2 1 E4 WL E16 WL YW W GW R LW LgY YW R W R GW R LW R LgY R 2 PURGE CONTROL SOLENOID VALVE 1 2 D B137 1 2 7 8 9 5 6 3 4 10 11 12 19 20 21 1...

Page 3479: ...ULE NON TURBO ENGINE MODEL FOR EUROPE B25 B135 B 16 BR F2 B100 1 BR BR E3 F60 16 BR R59 1 2 BROWN BROWN R15 R58 GREEN A i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B99 i2 BROWN i1 F60 B22 1 2 3 4 5 6 7 8 9 1...

Page 3480: ...CONTROL MODULE NON TURBO ENGINE MODEL FOR EUROPE B25 B135 B 16 BR R59 1 2 R15 R58 GREEN A i12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GREEN BROWN C i11 B135 B TB NA...

Page 3481: ...OWER SUPPLY ROUTING RW RW 14 RW C7 WB B10 B37 i2 WB WB 1 i2 B37 B REF TO GND 02 AWD LO INDICATOR LIGHT WB B 2 1 B29 T8 AWD LO SWITCH B29 1 2 GREEN i11 1 2 3 4 5 6 7 8 9 10 GREEN B i10 1 2 3 4 5 6 7 8...

Page 3482: ...WB 3 AWD LO INDICATOR LIGHT WB B 2 1 B29 T8 AWD LO SWITCH i10 i11 B C B29 1 2 GREEN i11 1 2 3 4 5 6 7 8 9 10 GREEN B 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...

Page 3483: ...PS 01 FAPS 01 WI 02529 YR FB 28 F B FUSE NO 4 ACC TO POWER SUPPLY ROUTING B REF TO ILM L 01 ILM ROI 01 ILM RWI 01 V 2 1 4 YR 1 B 3 B119 B119 FRONT ACCESSORY POWER SUPPLY SOCKET 3 4 1 2 WITH ILLUMINATI...

Page 3484: ...RG LY RB WR RG LY RB WR B REF TO GROUND DISTRIBUTION LHD GND 02 RHD GND 07 5 GB 4 RG 3 LY 2 RB 1 WR 6 B F59 5 GB 4 RG 3 LY 2 RB 1 WR 6 B F58 B REF TO GROUND DISTRIBUTION LHD GND 01 RHD GND 06 HEADLIG...

Page 3485: ...ORN 01 WI 02370 BL RG MB 4 HORN RELAY MB 5 HORN RELAY TO POWER SUPPLY ROUTING HORN RG RG 10 B62 F45 RG 1 B68 F5 BL HORN F47 BL HORN SWITCH LHD LHD RHD RHD F45 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19...

Page 3486: ...IZER CONTROL MODULE B141 BrR LR i2 B37 20 LR W B62 F45 23 W 1 2 1 2 1 2 3 4 5 6 7 8 F44 BLACK B74 B141 1 2 3 4 5 6 7 8 9 10 11 12 GREEN B i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2...

Page 3487: ...EAR DOOR SWITCH RH R16 1 3 Y B REAR DOOR SWITCH LH R22 DIODE WAGON R30 R38 D34 3 B B R39 D35 REF TO GND 03 B B D46 REAR GATE LATCH SWITCH WAGON REF TO GND 02 B99 R3 Y Y 24 WG WAGON WG TURBO ENGINE MOD...

Page 3488: ...8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GREEN C i11 1 2 3 4 5 6 7 8 9 10 i2 25 26 27 28 29 30 31 32 24 23 22 11 12 13 14 15 16 17 18 19 20 21 7 8 9 10 1 2 3 4 5 6 1 6 TB NA...

Page 3489: ...12 13 14 15 16 BROWN 4 YR YR Y 1 YR 2 1 3 Y B FRONT DOOR SWITCH LH B268 1 3 Y B REAR DOOR SWITCH RH R16 1 3 Y B REAR DOOR SWITCH LH R22 DIODE WAGON R30 R38 D34 3 B B R39 D35 REF TO GND 08 B B D46 REAR...

Page 3490: ...B 35 F B FUSE NO 3 B MB 6 M B FUSE NO 6 B TO POWER SUPPLY ROUTING BG WB W WR 12 LgB 13 16 15 1 KEYLESS ENTRY CONTROL MODULE B176 W 23 W F45 B62 W WR 2 1 KEY WARNING SWITCH B74 B74 1 2 BLACK REF TO TUR...

Page 3491: ...6 1 2 3 B176 GREEN B i10 1 2 3 8 9 10 4 11 12 13 14 22 23 5 6 7 15 16 17 24 25 26 18 27 28 29 30 19 20 21 B176 KEYLESS ENTRY CONTROL MODULE 1 2 3 LR L B DOOR OFF ON 4 2 3 LR YR B R52 B224 R50 B90 ROOM...

Page 3492: ...17 Or 18 D34 D47 R38 D33 R37 R3 B99 KEYLESS ENTRY CONTROL MODULE B176 D72 B101 D11 B30 D1 RW 1 LgB 3 RG 19 Or 10 YR 16 B 1 D18 RG 1 Or 3 RG 15 Or 10 Or 6 RG 7 2 1 4 2 LgB RG WG D26 B269 D21 RG 1 Or 3...

Page 3493: ...RODK 01 K L RODK 01 WI 02378 WB W FB 35 F B FUSE NO 3 B MB 6 M B FUSE NO 6 B TO POWER SUPPLY ROUTING WB W WR 16 15 1 KEYLESS ENTRY CONTROL MODULE B176 W WR 2 1 KEY WARNING SWITCH B74 B74 1 2 BLACK B1...

Page 3494: ...7 15 16 17 24 25 26 18 27 28 29 30 19 20 21 B176 KEYLESS ENTRY CONTROL MODULE 1 2 3 LR L B DOOR OFF ON 4 2 3 LR YR B R52 D46 R50 B90 ROOM LIGHT REAR GATE LATCH SWITCH WAGON TO POWER SUPPLY ROUTING MB...

Page 3495: ...gB 13 RG 14 2 1 4 2 WG D26 B269 D21 RG LgB RG 2 LgB 1 WAGON WG FRONT DOOR LOCK ACTUATOR DRIVER SIDE FRONT DOOR LOCK ACTUATOR PASSENGER SIDE REAR DOOR LOCK ACTUATOR LH REAR GATE LOCK ACTUATOR WAGON B B...

Page 3496: ...WB ST IGNITION SWITCH ST FB 20 F B FUSE NO 17 IG GOr W 15 B11 KEY WARNING SWITCH B B324 A 4 B324 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A BLUE INHIBITOR SWITCH AT P R N D 3 2 1 7 BY 12 BW 11 12 T7 B14...

Page 3497: ...18 25 D35 3 4 1 2 GREEN C i11 1 2 3 4 5 6 7 8 9 10 LR COMBI NATION METER CODE ENTRY CONNECTOR i10 B i11 C i2 B37 i2 B37 Y 17 Y B14 YR 2 Y 1 LR C10 16 DOOR DIODE WAGON B99 R3 Y 17 3 4 1 2 B90 LR LOr B...

Page 3498: ...NGER SIDE B101 D11 D18 D32 RG LgB LgB 3 6 1 WR 4 REAR DOOR LOCK ACTUATOR LH B269 D21 LgB 1 Br 2 B270 D22 RG 4 D26 RG 15 LgB Br 14 10 REF TO GND 06 WG KEY CYLINDER SWITCH GL 1 Br 2 W 3 D82 W 18 W B3 Or...

Page 3499: ...LIGHT LH WAGON BACK UP LIGHT RH WAGON BrY B 3 4 R26 BrY 1 B 2 BrY 1 B 2 R26 R28 B24 BACK UP LIGHT SWITCH MT GB BrY 2 4 B128 B99 R3 T9 MT WG SD WG SD AT MT NA TB NA TB INHIBITOR SWITCH AT P R N D 3 2...

Page 3500: ...SSORY POWER SUPPLY SOCKET ILLUMI LIGHT OFF B T P ON V B 1 3 B116 V 2 B 4 B119 FRONT FOG LIGHT SWITCH ILLUMI LIGHT MODE CONTROL PANEL ILLUMI LIGHT MANUAL A C V B 4 2 B160 V 5 B 6 B168 REAR FOG LIGHT SW...

Page 3501: ...3 RW PL RW C7 WR C8 WB B10 P B16 G B15 B C6 GR A14 RL Lg W RB YB LB OrW OrW B B B C9 P DIMMER CIRCUIT DIMMER CIRCUIT R N D 3 2 1 AWD LO INDICATOR LIGHT POWER MODE INDICATOR LIGHT OUT TEMP LCD BACK LIG...

Page 3502: ...LIGHT LH WAGON REAR COMBINATION LIGHT RH WAGON LICENSE PLATE LIGHT RY B 1 2 F22 WR B 1 WR 2 B 7 8 R79 WR 6 B 2 R28 FRONT CLEARANCE LIGHT RH RY B 1 2 F4 REAR COMBINATION LIGHT LH SEDAN WR B 1 4 R28 REA...

Page 3503: ...IGHT SWITCH ILLUMI LIGHT MODE CONTROL PANEL ILLUMI LIGHT MANUAL A C V B 4 2 B160 V 6 B 8 B168 REAR FOG LIGHT SWITCH ILLUMI LIGHT AUTO A C CONTROL MODULE V B 2 6 B195 V B10 B B20 HEADLIGHT BEAM LEVELER...

Page 3504: ...LB YL YL B B B C9 P DIMMER CIRCUIT DIMMER CIRCUIT R N D 3 2 1 AWD LO INDICATOR LIGHT POWER MODE INDICATOR LIGHT OUT TEMP LCD BACK LIGHT ODO TRIP LCD BACK LIGHT ILLUMINATION LIGHT HOLD MODE INDICATOR...

Page 3505: ...EAR COMBINATION LIGHT RH WAGON LICENSE PLATE LIGHT WR B 1 2 F22 WR B 1 WR 2 B 7 8 R79 WR 6 B 2 R28 FRONT CLEARANCE LIGHT RH WR B 1 2 F4 REAR COMBINATION LIGHT LH SEDAN WR B 1 4 R28 REAR COMBINATION LI...

Page 3506: ...RKING SWITCH AT SELECT LEVER ILLUMI LIGHT FRONT ACCESSORY POWER SUPPLY SOCKET ILLUMI LIGHT OFF B T P ON V YL 1 3 B116 V 2 YL 4 B119 FRONT FOG LIGHT SWITCH ILLUMI LIGHT MODE CONTROL PANEL ILLUMI LIGHT...

Page 3507: ...10 YL A4 LB A5 YL YL B YL B C9 P DIMMER CIRCUIT DIMMER CIRCUIT R N D 3 2 1 AWD LO INDICATOR LIGHT POWER MODE INDICATOR LIGHT OUT TEMP LCD BACK LIGHT ODO TRIP LCD BACK LIGHT ILLUMINATION LIGHT HOLD MOD...

Page 3508: ...EAR COMBINATION LIGHT RH WAGON LICENSE PLATE LIGHT WR B 1 2 F22 WR B 1 WR 2 B 7 8 R79 WR 6 B 2 R28 FRONT CLEARANCE LIGHT RH WR B 1 2 F4 REAR COMBINATION LIGHT LH SEDAN WR B 1 4 R28 REAR COMBINATION LI...

Page 3509: ...V3 PARKING SWITCH INTERCOOLER WATER SPRAY SWITCH FRONT ACCESSORY POWER SUPPLY SOCKET ILLUMI LIGHT OFF B T P ON V YL 4 2 B294 V 2 YL 4 B119 FRONT FOG LIGHT SWITCH ILLUMI LIGHT V YL 4 2 B160 REAR FOG LI...

Page 3510: ...11 1 2 3 4 5 6 7 8 9 10 i3 2 3 6 7 4 5 8 9 19 18 17 16 15 14 13 12 1 11 10 20 21 22 GW i2 1 2 3 8 9 10 4 11 12 13 14 22 23 5 6 7 15 16 17 24 25 26 18 27 28 29 30 31 32 19 20 21 ILM FA 01 F ILM FA 01 B...

Page 3511: ...LATE LIGHT WR B 1 2 F22 WR B 1 WR 2 B 7 8 R79 FRONT CLEARANCE LIGHT RH WR B 1 2 F4 REAR COMBINATION LIGHT LH WR B 1 4 R28 REAR COMBINATION LIGHT RH WR B 1 4 R26 R63 R63 WR B 2 1 B99 WR 11 WR 2 1 F4 BL...

Page 3512: ...B 1 FRONT FOG LIGHT LH B306 WB 2 BY 1 FRONT FOG LIGHT RH WB WB 9 B REF TO GND 01 B REF TO GND 01 V 1 3 B 5 V 4 B 2 FRONT FOG LIGHT SWITCH ON OFF WITH REAR FOG LIGHT MODEL WITHOUT REAR FOG LIGHT MODEL...

Page 3513: ...T FOG LIGHT RELAY RL 27 WR 28 V 24 BY 26 B196 DIODE REAR FOG LIGHT BY 1 YW 2 F21 WR 1 B 2 FRONT FOG LIGHT LH F6 WR 1 B 2 FRONT FOG LIGHT RH WR WR 6 B REF TO GND 06 B REF TO GND 06 V 1 3 B 5 V 4 2 FRON...

Page 3514: ...W 2 F21 WR 1 B 2 FRONT FOG LIGHT LH F6 WR 1 B 2 FRONT FOG LIGHT RH WR WR 6 B REF TO GND 06 B REF TO GND 06 V 1 3 B 5 V BY 4 2 FRONT FOG LIGHT SWITCH ON OFF REF TO RFOG OE 01 WITH REAR FOG LIGHT MODEL...

Page 3515: ...10 21 22 11 23 24 HEADLIGHT RH LW 2 1 R F99 F45 B62 LW 3 G LW G 22 LW B30 R B29 10 LW R 11 B i10 G 3 RW 4 B85 i2 B37 G 8 R 7 B 16 17 13 B71 DIMMER PASSING SWITCH UP LOW PASS HF HU HL E LIGHTING SWITC...

Page 3516: ...37 G 1 R 2 B 9 10 14 8 OE FE 7 16 17 13 B71 DIMMER PASSING SWITCH UP LOW PASS HF HU HL E LIGHTING SWITCH OFF HC TC EL WF OF WF OF B85 1 2 1 2 3 4 5 6 7 8 F44 B71 2 3 4 5 6 7 1 8 9 10 11 12 13 14 15 16...

Page 3517: ...Y B B268 FRONT DOOR SWITCH RH 1 3 Y LW Y LOr i1 R22 B36 R3 B99 i2 B37 13 2 LOr B B267 FRONT DOOR SWITCH LH 1 3 REAR DOOR SWITCH LH DOOR WARNING LIGHT LR C10 Y B14 LW B13 LR LR 20 COMBINATION METER B C...

Page 3518: ...SEDAN B REF TO GND 04 05 LR 1 YR 2 R27 YR 1 B 2 R141 R30 R37 D33 REAR GATE LATCH SWITCH WAGON LR D46 YR 1 YR 1 B 2 Y 1 YR 2 1 YR 2 C L L 01 B C L L 01 A D46 BLACK BLACK BLACK R20 R141 WG SD WG SD WAGO...

Page 3519: ...SECURITY MODEL OS WS Y B B268 FRONT DOOR SWITCH LH 1 3 Y LOr Y LOr i2 R22 B37 R3 B99 i2 B37 17 5 LOr B B267 FRONT DOOR SWITCH RH 1 3 REAR DOOR SWITCH LH DOOR WARNING LIGHT LR C10 Y B14 LOr B13 LR LR 1...

Page 3520: ...EDAN B REF TO GND 09 10 LR 1 YL 2 R27 YL 1 B 2 R141 R30 R38 D34 REAR GATE LATCH SWITCH WAGON LR D46 YR 1 YR YR 4 B 2 Y 1 YR 2 1 YR 2 C L R 01 B C L R 01 A D46 BLACK BLACK BLACK R20 R141 R27 SD SD WAGO...

Page 3521: ...AGON R28 WB 5 B 2 STOP LIGHT RH WAGON R26 WB 5 B 2 LY 2 WB 1 TRAILER CONNECTOR WB 3 B 7 B 8 R79 B64 R19 HIGH MOUNTED STOP LIGHT SEDAN WB 2 B 1 R66 HIGH MOUNTED STOP LIGHT SEDAN REAR SPOILER HIGH MOUNT...

Page 3522: ...B176 F45 B62 GW 22 W 12 BrR BrR BY B 2 BY 3 LgB 5 BG GB W BrR BY LgB BG 4 W LH RH 23 1 3 2 BY LgB BG 2 3 1 TURN SIGNAL HAZARD MODULE B32 B71 TURN SIGNAL SWITCH L N R B REF TO GND 02 COMBINATION METER...

Page 3523: ...RH SEDAN R26 LgB 2 B 4 REAR TURN SIGNAL LIGHT RH WAGON R26 LgB 3 B 2 F22 FRONT TURN SIGNAL LIGHT LH BG 3 B 2 R28 REAR TURN SIGNAL LIGHT LH SEDAN BG 2 B 4 R28 REAR TURN SIGNAL LIGHT LH WAGON BG 3 B 2 B...

Page 3524: ...71 TURN SIGNAL SWITCH L N R B REF TO GND 07 COMBINATION METER TURN SIGNAL INDICATOR LIGHT A C i12 i11 i2 B37 BG A7 LgB C3 C6 1 2 3 i22 1 2 3 4 5 6 7 8 GREEN i11 C 1 2 3 4 5 6 7 8 9 10 GREEN A i12 1 2...

Page 3525: ...LgB 2 B 4 REAR TURN SIGNAL LIGHT RH WAGON R26 LgB 3 B 2 F22 FRONT TURN SIGNAL LIGHT LH BG 3 B 2 R28 REAR TURN SIGNAL LIGHT LH SEDAN BG 2 B 4 R28 REAR TURN SIGNAL LIGHT LH WAGON BG 3 B 2 B REF TO GND...

Page 3526: ...3 4 17 18 19 20 BLACK LIGHT GRAY OIL PRESSURE SWITCH E11 GREEN B 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 RW 14 B37 i2 B100 F2 18 GW GW NA TB NON TURBO ENG...

Page 3527: ...9 10 11 12 3 4 17 18 19 20 OIL PRESSURE SWITCH E11 GREEN B i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GW GW 31 B37 i2 AT MODEL MT MODEL AT MT NON TURBO ENGINE...

Page 3528: ...B i11 C I F I F I F REF TO GND 02 POWER CIRCUIT BL YB B17 BP B9 A11 AUTO A C CONTROL MODULE B282 A B283 B BP BL BP BL BP BL 5 4 F78 1 2 GREEN BLACK BROWN C i11 1 2 3 4 5 6 7 8 9 10 B283 GRAY 1 2 3 4...

Page 3529: ...F I F REF TO GND 07 POWER CIRCUIT GW LR 16 31 GW i2 B37 LR Or W B9 YB B17 A11 AUTO A C CONTROL MODULE B282 A B283 B Or YB Or YB 13 14 F78 1 2 GREEN BLACK C i11 1 2 3 4 5 6 7 8 9 10 B283 GRAY 1 2 3 4 5...

Page 3530: ...1 C PARKING BRAKE BRAKE FLUID LEVEL WARNING LIGHT 2 P Lg PARKING BRAKE SWITCH R4 B99 P Lg 15 BW 8 B62 13 BW BW F45 B16 B REF TO GND 02 GENERATOR 1 BW F26 Lg 1 B 2 F26 1 2 3 B16 1 2 GRAY BRAKE FLUID LE...

Page 3531: ...P P PARKING BRAKE SWITCH R4 B99 P P 3 BW 4 18 BW BW B62 B16 F45 B REF TO GND 07 GENERATOR 1 BW F26 P 1 AS FOR AUSTRALIA STi MODEL OTHER MODELS OM B 2 F26 1 2 3 B16 1 2 GRAY GREEN GREEN BRAKE FLUID LEV...

Page 3532: ...4 B GB B 1 D7 13 GB B 5 L 1 LR 2 B30 D1 POWER WINDOW MAIN SWITCH OFF UP DOWN B FL U FL D E FRONT LH LOCK AUTO UP AUTO DOWN LR 2 L 1 FRONT POWER WINDOW MOTOR LH P W L 04 C P W L 03 B P W L 02 A 1 2 3 4...

Page 3533: ...9 GB GB 3 8 RL 6 BL 4 L 7 LR 5 D17 B REF TO GND 01 LR 2 L 1 D11 B101 B30 D1 D7 P W L 01 A GB 13 BL 7 RL 6 B 5 POWER WINDOW MAIN SWITCH OFF UP DOWN B FR U FR D E FRONT RH 1 2 1 2 D17 D13 1 2 3 4 5 6 D7...

Page 3534: ...B 3 8 LW 6 GW 4 RW 7 RL 5 D25 B REF TO GND 01 RL 2 RW 1 D22 B270 B30 D1 D7 P W L 01 B GB 13 LY 10 GY 11 B 5 POWER WINDOW MAIN SWITCH OFF UP DOWN B RL U RL D E REAR LH 1 2 1 2 D24 D25 1 2 3 4 5 6 8 7 D...

Page 3535: ...B 3 8 LW 6 GW 4 RW 7 RL 5 D31 B REF TO GND 01 RL 2 RW 1 D28 B266 B30 D1 D7 P W L 01 C GB 13 GW 15 LW 16 B 5 POWER WINDOW MAIN SWITCH OFF UP DOWN B RR U RR D E REAR RH 1 2 1 2 D30 D31 1 2 3 4 5 6 8 7 D...

Page 3536: ...7 12 GB B 1 L 7 LR 6 B30 D1 POWER WINDOW MAIN SWITCH OFF UP DOWN B FR U FR D E FRONT RH LOCK AUTO UP AUTO DOWN LR 2 L 1 FRONT POWER WINDOW MOTOR RH P W R 04 C P W R 03 B P W R 02 A GREEN D3 1 2 B41 1...

Page 3537: ...9 GB GB 3 8 RL 6 BL 4 L 7 LR 5 D17 B REF TO GND 06 LR 2 L 1 D11 B101 B30 D1 D7 P W R 01 A GB 12 BL 3 RL 2 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B FL U FL D E FRONT LH 1 2 1 2 D17 D13 1 2 3 4 5 6 D7...

Page 3538: ...B 3 8 LW 6 GW 4 RW 7 RL 5 D25 B REF TO GND 06 RL 2 RW 1 D22 B270 B30 D1 D7 P W R 01 B GB 12 LY 10 GOr 9 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B RL U RL D E REAR LH 1 2 1 2 D25 D24 1 2 3 4 5 6 D7 1...

Page 3539: ...GW LW 2 GB GB 3 8 LW 6 GW 4 RW 7 RL 5 D31 B REF TO GND 06 RL 2 RW 1 D28 B266 B30 D1 D7 P W R 01 C GB 12 GW 14 LW 13 B 1 POWER WINDOW MAIN SWITCH OFF UP DOWN B RR U RR D E REAR RH REAR POWER WINDOW MO...

Page 3540: ...16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 F16 BLACK SUB FAN MOTOR MAIN FAN MOTOR RELAY HOLDER F27 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 LH...

Page 3541: ...CONTROL MODULE MAIN FAN MOTOR 1 3 4 2 WL B B YR B84 E E B84 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 1 1 2 2 3 F45 2 3 4 5 6 7 8 13 15 16 14 17 18 19 20 2...

Page 3542: ...1 G 3 LY 4 LY 6 B 7 B 8 WG SD B85 DIODE REAR FOG AND LIGHTING BW 1 YW G RW 2 3 4 G G 22 B REF TO GND 04 B REF TO GND 01 V 2 1 RW YW 4 G B 5 3 B 6 REAR FOG LIGHT SWITCH ON OFF B85 B131 F45 B99 2 3 6 7...

Page 3543: ...B 8 WG SD B85 DIODE LIGHTING G 1 RW 2 B196 DIODE REAR FOG BY 1 YW 2 B REF TO GND 09 B REF TO GND 06 V 2 1 RW YW 4 G B 5 3 B 6 REAR FOG LIGHT SWITCH ON OFF B85 B196 1 2 B131 BLACK BLACK MB 8 HEADLIGHT...

Page 3544: ...TOR LR 2 V 1 G 3 LY 4 LY 6 B 7 B 8 WG SD B85 DIODE LIGHTING G 1 RW 2 B196 DIODE RW 1 BY 3 YW 2 B REF TO GND 09 B REF TO GND 07 B85 1 2 B131 BLACK BLACK R26 2 6 5 4 3 1 MB 8 HEADLIGHT RELAY B99 R3 LY L...

Page 3545: ...ODULE REAR DEFOGGER WAGON WITHOUT CHOKE COIL REAR DEFOGGER SEDAN REAR DEFOGGER WAGON WITH CHOKE COIL L B21 D4 OO WO RL A14 R A13 CHOKE COIL RL 2 B 1 CHOKE COIL D74 D48 D40 TB NA SD WG R130 OC WC OC WC...

Page 3546: ...3 OS NA SD WG R39 D35 WAGON SEDAN WG SD TURBO ENGINE MODEL NON TURBO ENGINE MODEL TB NA D35 3 4 1 2 1 2 3 4 5 6 7 8 B97 B296 3 4 1 2 5 6 7 8 2 1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 1...

Page 3547: ...EATER LH RH UP DOWN REF TO GND 03 B REF TO GND 01 02 L B RL 6 LG 4 5 1 OH WH 4 8 6 7 R BY 23 B 1 RB 22 LR 21 20 R D11 B101 BY 23 B 1 RL 22 Lg 21 20 R L B RB 6 LR 4 5 1 WH OH 4 8 6 7 R YR 4 Lg 8 RL 6 R...

Page 3548: ...TO GND 06 07 B REF TO GND 08 L B RB 6 LR 4 5 1 OH WH 4 8 6 7 R BY 23 B 1 RB 22 LR 21 20 R D1 B30 BY 23 B 1 RL 22 Lg 21 20 R L B RB 6 Lg 4 5 1 WH OH 4 8 6 7 R YR 4 Lg 8 RL 6 R 1 LR 9 RB 7 B 2 B284 D5 D...

Page 3549: ...TING COMBINATION METER SEAT BELT WARNING LIGHT SEAT BELT SWITCH BL B 1 2 B REF TO GND 08 R8 B99 R3 i10 B i11 C i2 B37 B37 i2 BL BL BL B9 GW 31 GW GW GW C7 BL 30 19 R8 1 2 GREEN B i10 1 2 3 4 5 6 7 8 9...

Page 3550: ...3 KEY WARNING SWITCH W WR 2 1 B74 F45 B62 B37 i2 i1 B36 W W 23 BL 22 BL B9 RW C7 14 B44 SEAT BELT TIMER WR LOr B BrW 7 GB BL 9 2 3 8 6 B74 1 2 R8 1 2 B267 1 2 3 BLACK GREEN B i10 1 2 3 4 5 6 7 8 9 10...

Page 3551: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 RW GB FB 36 F B FUSE NO 13 IG FB 17 F B FUSE NO 18 IG TO POWER SUPPLY ROUTING COMBINATION METER i10 B i11 C B37 i2 i1 B36 BL 22 BL B9 RW...

Page 3552: ...GB FB 36 F B FUSE NO 13 IG FB 17 F B FUSE NO 18 IG TO POWER SUPPLY ROUTING COMBINATION METER i10 B i11 C B37 i2 i2 B37 BL 19 BL B9 GW C7 31 B44 SEAT BELT TIMER GY B BR 7 GB BL 9 2 3 6 SEAT BELT WARNIN...

Page 3553: ...5 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 2 9 3 4 5 6 7 8 L 7 RB 8 9 10 11 13 RHD 37 YR L 1 RHD RHD LHD LHD OFF LO L 2 GB 4 G 1 B 3 R43 HI SEAT HEATER...

Page 3554: ...U AT MT B323 W W 2 1 3 WB LR RB 4 WL SECURITY RELAY AU INHIBITOR SWITCH AT P R N D 3 2 1 T7 7 BW 12 BY B12 T3 11 12 1 3 2 MT AT EXCEPT FOR AUSTRALIA MODEL FOR AUSTRALIA MODEL AU EA 1 FOR AUSTRALIA MOD...

Page 3555: ...Y YR Y R3 B99 4 17 Y YR 1 2 YR B D46 REAR GATE LATCH SWITCH WAGON 1 2 YR B R27 1 2 YR 1 R37 D33 B 3 R39 D35 WG SD R30 DIODE REAR GATE WG WG SD TRUNK ROOM LIGHT SWITCH SEDAN Y B R16 1 3 REAR DOOR SWIT...

Page 3556: ...1 9 4 3 10 24 22 23 25 11 12 13 14 15 26 27 28 16 17 18 19 20 21 B135 B WB WB B134 A 1 2 3 4 10 11 12 19 20 21 13 5 6 14 15 7 8 9 16 17 18 22 C20 OO WO B135 B WITH SECURITY FOR AUSTRALIA MODEL AND WIT...

Page 3557: ...28 16 17 18 19 20 21 B135 B WITH SECURITY FOR AUSTRALIA MODEL AND WITHOUT SECURITY MODEL WITH SECURITY EXCEPT FOR AUSTRALIA MODEL OS WS OO WO EXCEPT OBD MODEL OBD MODEL WS OS 2 WB W 4 WL W B323 SECUR...

Page 3558: ...CUIT BREAKER R GB OPEN CLOSE SUNROOF SWITCH TILT UP TILT DOWN SUNROOF SWITCH SUNROOF CONTROL MODULE MOTOR Br 4 G 1 B 3 W 4 L 1 B 3 LHD LHD RHD LHD RHD RHD 1 2 3 4 5 6 7 8 F44 B41 1 2 S1 BLACK S2 1 2 3...

Page 3559: ...11 12 15 13 14 16 10 17 18 FRONT WIPER SWITCH INTER MITTENT WIPER MODULE INT VOLUME WASHER SWITCH COMBINATION SWITCH ON OFF EW W OFF OFF INT LO HI OFF ACC S1 S2 S3 MIST MIST OFF MIST MIST OFF INT1 IN...

Page 3560: ...14 16 10 17 18 FRONT WIPER SWITCH INTER MITTENT WIPER MODULE INT VOLUME WASHER SWITCH COMBINATION SWITCH ON OFF EW W OFF OFF INT LO HI OFF ACC S1 S2 S3 MIST MIST OFF MIST MIST OFF INT1 INT2 B REF TO...

Page 3561: ...WASH WASH LB 12 GR 10 B 2 WG 1 LB 2 WG WR LB 7 YB LG LW 1 LG 4 LW 2 B 3 B REF TO GND 04 05 B REF TO GND 02 B B 3 YB YB 4 LG 1 LW 2 D34 D35 D43 R39 R38 R116 R3 B99 R1 B97 B70 F33 F45 B62 YB LB GR 1 LB...

Page 3562: ...LW 1 LG 4 LW 2 B 3 B REF TO GND 09 10 B REF TO GND 07 B B 3 LG 1 LW 2 D34 D35 D43 R39 R38 R116 R3 B99 B70 B147 YL YL LB GR 24 LB 7 GR 16 D43 3 4 1 2 B147 1 2 1 2 3 4 5 6 7 8 R116 D35 B70 2 3 6 4 5 7...

Page 3563: ...ACC TO POWER SUPPLY ROUTING COMBINATION METER i10 B i11 C B37 i2 i1 B36 YG 17 YG B5 RW C7 14 INTERCOOLER WATER SPRAY TANK LEVEL WARNING LIGHT YR 3 RW 5 V 4 B REF TO GROUND DISTRIBUTION GND 02 B294 IN...

Page 3564: ...TERCOOLER WATER SPRAY TIMER B286 RW YR L B FB 10 F B FUSE NO 12 YG 8 V B REF TO GROUND DISTRIBUTION GND 08 L 2 B 1 YG 3 B 4 REF TO GROUND DISTRIBUTION GND 08 INTERCOOLER WATER SPRAY MOTOR AND LEVEL WA...

Page 3565: ...ss 6 Rear door cord RH 11 Rear door cord LH 2 Engine wiring harness 7 Rear wiring harness 12 Front door cord LH 3 Bulkhead wiring harness 8 Roof cord 13 Transmission cord 4 Instrument panel wiring har...

Page 3566: ...H 11 Rear door cord LH 2 Engine wiring harness 7 Rear wiring harness 12 Front door cord LH 3 Bulkhead wiring harness 8 Roof cord 13 Transmission cord 4 Instrument panel wiring harness 9 Fuel tank cord...

Page 3567: ...F25 1 B 2 Generator F26 3 Green B 2 F27 30 Black B 4 A C relay holder F32 2 Green B 4 Front washer motor F33 2 B 4 Rear washer motor F34 4 Black B 4 SBF holder F35 2 Black B 4 M B F36 3 B 4 F37 6 Blac...

Page 3568: ...ea No Name AB14 2 Yellow B 4 AB13 Airbag wiring harness AB18 2 Yellow D 3 Front sub sensor WI 02215 1 2 3 4 5 1 2 3 4 5 A B C D A B C D F4 F99 F59 F23 F98 F46 AB14 F27 F60 F61 F94 F33 F32 F44 F74 F45...

Page 3569: ...pressor F25 1 B 2 Generator F26 3 Green B 2 F27 30 Black B 4 A C relay holder F34 4 Black B 4 SBF holder F35 2 Black B 4 M B F39 8 Black B 4 F41 7 Gray A 2 F B F44 8 Black A 3 B61 Bulkhead wiring harn...

Page 3570: ...e Color Area No Name AB14 2 Yellow B 2 AB13 Airbag wiring harness AB15 2 Yellow C 1 Front sub sensor RH F44 WI 02216 1 2 3 4 5 1 2 3 4 5 A B C D A B C D F23 F98 F79 F22 F27 F94 F45 F74 F58 GB 1 F49 F7...

Page 3571: ...d level switch B17 3 B 3 Vehicle speed sensor MT B18 4 B 2 Front oxygen A F sensor With OBD B19 4 B 2 Rear oxygen sensor With OBD B21 20 Light gray B 2 E2 Engine wiring harness B22 16 Brown B 2 E3 B24...

Page 3572: ...ROOM Airbag Wiring Harness Connector Connecting to No Pole Color Area No Name AB15 2 Yellow C 1 Front sub sensor RH WI 02217 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B302 B303 B301 B15 B29 B328 AB15 B22 B2...

Page 3573: ...uid level switch B17 4 B 3 Vehicle speed sensor Except STi model 3 B 3 Vehicle speed sensor STi model B18 4 B 2 Front oxygen A F sensor B19 4 B 3 Rear oxygen sensor B20 10 B 2 E1 Engine wiring harness...

Page 3574: ...ENGINE ROOM Airbag Wiring Harness Connector Connecting to No Pole Color Area No Name AB15 2 Yellow C 1 Front sub sensor RH WI 02218 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B305 B20 B15 B18 B127 B301 B279...

Page 3575: ...tic converter equipped vehicle without OBD 4 B 3 Front oxygen A F sensor With OBD B19 4 B 3 Rear oxygen sensor With OBD B21 20 Light gray B 3 E2 Engine wiring harness B22 16 Brown B 3 E3 B24 2 Gray B...

Page 3576: ...onnector Connecting to No Pole Color Area No Name AB18 2 Yellow D 4 Front sub sensor LH WI 02219 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B8 B28 B255 AB18 B14 B147 B146 B7 B148 B12 B17 B11 B186 B145 B144 B...

Page 3577: ...B 3 Vehicle speed sensor MT STi model 4 Black B 3 Vehicle speed sensor Except for MT STi model B18 4 A 2 Front oxygen A F sensor B19 4 B 3 Rear oxygen sensor B20 10 B 2 E1 Engine wiring harness B21 20...

Page 3578: ...rbag Wiring Harness Connector Connecting to No Pole Color Area No Name AB18 2 Yellow D 4 Front sub sensor LH AB18 WI 02220 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B8 B16 B3 B127 B255 B14 B147 B146 B148 B1...

Page 3579: ...joint connec tor E G With OBD 8 C 4 Shield sensor ground joint connec tor E G Without OBD B84 31 B 4 Engine control module B85 2 B 3 Diode Rear fog light B87 2 B 5 Blower fan motor B90 4 A 5 R50 Roof...

Page 3580: ...lay block 5 Black C 2 Mirror heater relay Relay block 5 Black C 2 Seat heater relay Relay block B256 2 B 3 Evaporator sensor B257 3 D 5 ABS lateral G sensor STi model B261 6 D 5 Joint connector ABS ST...

Page 3581: ...221 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B158 B44 B30 WO B125 B83 B36 B85 B51 B271 B195 B160 B40 B79 B132 B300 B52 B119 B120 B31 AB1 B133 GB 6 B116 AB3 B292 GR B72 B68 B81 B61 B200 WO B224 B286 B198 OO...

Page 3582: ...B76 2 Green C 4 B75 B77 3 B 2 Mode actuator B79 14 Gray C 4 Check connector B81 1 2 C 4 Diagnosis terminal Ground B82 6 Black C 4 Diagnosis connector B83 4 C 2 Shield sensor ground joint connec tor E...

Page 3583: ...ion light B225 8 Black C 4 Fuse Relay block 5 Black C 4 Power window relay Relay block 5 Black C 4 Front fog light relay Relay block 5 Black C 4 Ignition relay Relay block 5 Black C 4 Mirror heater re...

Page 3584: ...D A B C D OBD model Except OBD model WO OO B94 GB 3 AB3 B196 B32 B208 B46 B47 B87 B286 B101 B91 B77 B275 GB 4 GB 5 B199 B198 B107 B54 B55 B56 B53 WO B125 B134 B283 GB 6 B282 GR B43 B116 B237 B292 B133...

Page 3585: ...Black A 2 Idle air control solenoid valve E8 3 Light gray A 3 Engine coolant temperature sensor and thermometer E10 2 Light gray B 3 Crankshaft position sensor E11 1 B 2 Oil pressure switch E12 4 Gray...

Page 3586: ...head wiring harness MT T2 2 Brown D 2 B25 Bulkhead wiring harness MT T3 12 D 4 B12 Bulkhead wiring harness AT T4 20 Black D 4 B11 Bulkhead wiring harness AT T8 2 D 2 B29 Bulkhead wiring harness MT Non...

Page 3587: ...ay B 3 Crankshaft position sensor E11 1 B 2 Oil pressure switch E12 4 Gray A 2 Ignition coil and ignitor 1 6 L model Dark gray A 2 Ignition coil and ignitor Except 1 6 L model E13 4 Dark brown A 2 Thr...

Page 3588: ...ing harness MT T2 2 Brown D 2 B25 Bulkhead wiring harness MT T3 12 D 4 B12 Bulkhead wiring harness AT T4 20 Black D 4 B11 Bulkhead wiring harness AT T8 2 D 2 B29 Bulkhead wiring harness MT Non colored...

Page 3589: ...or E14 2 Brown A 4 Knock sensor STi model and except for Australia STi model 2 Light gray A 4 Knock sensor Except for STi model except for Australia E15 2 Light gray B 4 Camshaft position sensor E16 2...

Page 3590: ...3 12 D 4 B12 Bulkhead wiring harness AT T4 20 Black D 4 B11 Bulkhead wiring harness AT T9 4 D 2 B128 Bulkhead wiring harness MT Non colored WI 02225 1 2 3 4 5 1 2 3 4 5 A B C D A B C D MT AT T9 T3 T4...

Page 3591: ...ness A LOCATION 1 LHD MODEL Connector Connecting to No Pole Color Area No Name i1 24 Brown C 3 B36 Bulkhead wiring harness i2 24 C 3 B37 i10 30 Green B 2 Combination meter i11 10 Green B 3 i12 14 Gree...

Page 3592: ...WI 288 WIRING SYSTEM INSTRUMENT PANEL WIRING HARNESS WI 02226 1 2 3 4 5 1 2 3 4 5 A B C D A B C D i12 i10 i11 i59 i51 i22 i2 i1...

Page 3593: ...rness i3 10 Black C 3 B38 Bulkhead wiring harness MT STi model except for Australia and New Zealand model 22 Black C 3 B38 Bulkhead wiring harness AT and MT STi model for Australia and New Zealand mod...

Page 3594: ...WI 290 WIRING SYSTEM INSTRUMENT PANEL WIRING HARNESS WI 02227 1 2 3 4 5 1 2 3 4 5 A B C D A B C D i51 i59 i12 i2 i3 i22 i11 i10...

Page 3595: ...Seat heater RH R42 4 B 3 Seat heater switch RH R43 4 Blue B 3 Seat heater switch LH R44 4 Blue C 4 Seat heater LH R72 2 A 3 Rear ABS sensor RH R73 2 B 5 Rear ABS sensor LH R97 2 B 5 Antenna amp Sedan...

Page 3596: ...A 4 Fuel pump assembly R59 2 B 4 Fuel sub level sensor Turbo model Non colored Connector Connecting to No Pole Color Area No Name AB7 12 Yellow C 2 Airbag control module AB8 12 Yellow B 2 Airbag contr...

Page 3597: ...AD WIRING HARNESS ROOF CORD AND FUEL TANK CORD WI 02228 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B97 AB8 AB7 R55 R56 R52 R72 R58 R59 B269 B265 AB20 AB12 B266 B268 B99 R3 R1 R50 GB 7 R41 R15 R57 R42 R43 AB1...

Page 3598: ...ABS sensor RH R73 2 B 5 Rear ABS sensor LH R97 2 B 5 Antenna amp Sedan model Non colored Connector Connecting to No Pole Color Area No Name B97 8 Black B 2 R1 Rear wiring harness B99 32 B 2 R3 Rear wi...

Page 3599: ...ecting to No Pole Color Area No Name AB7 12 Yellow C 2 Airbag control module AB8 12 Yellow C 2 Airbag control module AB9 2 Yellow C 4 Seat airbag module LH AB10 4 Yellow C 5 Side sensor LH AB11 2 Yell...

Page 3600: ...AD WIRING HARNESS ROOF CORD AND FUEL TANK CORD AB8 WI 02229 1 2 3 4 5 1 2 3 4 5 A B C D A B C D B99 R3 GB 7 R55 R56 R52 R72 R58 R59 B269 R73 R15 R8 R41 R57 B265 B266 B267 B97 R1 R4 R43 R42 R50 R44 B27...

Page 3601: ...Green B 2 Front power window motor RH D14 2 B 1 Front door tweeter RH D15 6 B 1 Remote control rearview mirror RH Without mirror heater 8 Black B 1 Remote control rearview mirror RH With mirror heate...

Page 3602: ...WI 298 WIRING SYSTEM DOOR CORD WI 02532 1 2 3 4 5 1 2 3 4 5 A B C D A B C D D29 D27 D11 D12 D18 D28 D17 D13 D15 D14 D30 D31 D32 D72 D24 D22 D26 D25 D7 D21 D23 D3 D8 D4 D2 D1 D5...

Page 3603: ...h mirror heater D17 8 C 4 Front power window sub switch LH D18 4 C 4 Front door lock actuator LH Without double lock 6 Black C 4 Front door lock actuator LH With double lock D21 4 C 4 B269 Bulkhead wi...

Page 3604: ...WI 300 WIRING SYSTEM DOOR CORD WI 02230 1 2 3 4 5 1 2 3 4 5 A B C D A B C D D29 D27 D1 D2 D3 D72 D28 D5 D11 D15 D4 D8 D82 D7 D30 D31 D32 D18 D24 D22 D26 D25 D14 D13 D17 D21 D23 D12...

Page 3605: ...Trunk room light R24 2 B 4 R60 Trunk lid cord R26 6 C 3 Rear combination light RH R27 2 C 2 Trunk room light switch R28 6 B 1 Rear combination light LH R60 2 B 4 R24 Rear wiring harness R63 2 Black C...

Page 3606: ...WI 302 WIRING SYSTEM REAR WIRING HARNESS AND TRUNK LID CORD WI 02231 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R28 R66 R122 R17 R60 R24 R130 R27 R79 R63 GB 8 R19 R65 R20 R145 R26 R16...

Page 3607: ...combination light RH R28 6 C 1 Rear combination light LH R30 2 D 4 Diode Luggage room light R37 2 D 4 D33 Rear gate cord R38 4 D 4 D34 Rear gate cord R39 4 Blue D 4 D35 Rear gate cord R63 2 Black D 2...

Page 3608: ...No Name D33 2 D 4 R37 Rear wiring harness D34 4 D 4 R38 Rear wiring harness D35 4 Blue D 4 R39 Rear wiring harness D39 2 B 3 High mounted stop light D43 4 A 2 Rear wiper motor D46 2 Black A 2 Rear ga...

Page 3609: ...WI 305 WIRING SYSTEM REAR WIRING HARNESS AND REAR GATE CORD WI 02232 1 2 3 4 5 1 2 3 4 5 A B C D A B C D R122 R79 GB 8 R63 D33 D34 D35 R37 R38 R39 R30 R16 R116 R26 R141 R97 R28 D46 D47 D43 D39 D74...

Page 3610: ...WI 306 WIRING SYSTEM REAR WIRING HARNESS AND REAR GATE CORD...

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