Subaru SVX 1992 Manual Download Page 570

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Summary of Contents for SVX 1992

Page 1: ...SPECIFICATIONS SUBARU SVX 1992 1 1 Page S SPECIFICATIONS 2 A 2 DOOR COUPE 2...

Page 2: ...oom Rear mm in 1 385 54 5 Wheelbase mm in 2 610 102 8 T d Front mm in 1 500 59 1 rea Rear mm in 1 480 58 3 Minimum road clearance at C W 135 5 3 mm in 2 WEIGHT Front kg lb 944 2 080 955 2 105 965 2 12...

Page 3: ...aximum torque N m kg m tl m fp 309 31 5 228 at 4 400 4 ELECTRICAL Ignition timing at BTDC rpm 20 at 610 idling speed Spark NGK PFR6G 11 PFR 6B 11 plug Type and manufacturer NIPPONDENSO PK20PR 11 Gener...

Page 4: ...ion Turns lock to lock 3 1 Minimum turning circle m ft Wall to wall 11 8 38 7 Curb to curb 10 8 35 4 7 SUSPENSION Front Macpherson strut type Independent Coil spring Rear Dual link strut type Independ...

Page 5: ...trans e US qt Imp qt 9 5 9 8 10 0 10 4 8 4 8 6 mission fluid AT differential C US qt Imp qt 1 1 1 3 1 2 1 4 1 0 1 1 gear oil _ 4WD rear differ C US qt Imp qt T 0 8 0 9 0 7 ential gear oil Power steeri...

Page 6: ...YSTEM AIRBAG 4 3 VEHICLE IDENTIFICATION NUMBER V I N 5 4 IDENTIFICATION NUMBER AND LABEL LOCATIONS 6 1 5 THEFT PREVENTION 7 6 RECOMMENDED FUEL LUBRICANTS SEALANTS AND ADHESIVES 9 7 TIGHTENING TORQUE O...

Page 7: ...ON if the engine is hot the cooling fan may start to operate 6 While the engine is in operation properly ventilate the workshop 7 While the engine is in operation be aware of any moving parts such as...

Page 8: ...ering will not work when the engine is OFF You will have to use greater effort for the brake pedal and steering wheel g Before towing check transmission oil and differen tial oil levels and top up to...

Page 9: ...n of harness connectors or neglect of tight ening sensor mounting bolts can lead to failure of deployment in an accident Recheck each check point after maintenance work and use the on board self diagn...

Page 10: ...er Vehicle attributes Check digit Vehicle identification J F 1 C X 3 4 3 X P H 1 0 0 0 0 1 i L L Stop Mark Sequential number 100001 and after 2 Door Coupe Transmission type H Full time AWD 4AT K 4AT M...

Page 11: ...ications such as Technical information Service bulletins and other information Vacuum hose piping label Emission control label Vehicle identification number plate 1 1 r r r i r r Bar cord label Califo...

Page 12: ...lled parts shown below Additionally the R DOT label is stuck or R DOT is stamped on the main spare parts shown below 1 T P label and R DOT label A T P label O CAC A x A AA lnAlm U L7 424 B R DOT label...

Page 13: ...1 3 105021 GENERAL INFORMATION OFront hood 2 Fender 0 Door Rear quarter OTrt Fig 12 6 Front bumper Rear bumper 1 Engine C1 011 Automatic transmission...

Page 14: ...it does not exceed 5 of the fuel mixture AND it is accompanied by sufficient quantities of the proper cosolvents and corrosion inhibitors re quired to prevent fuel system damage Otherwise fuel contai...

Page 15: ...n Contacting surfaces of drum Grease Grease P N 003602000 brake shoes and shoe clearance adjuster P N 623029980 BJ and DOJ joints of axle shafts for AT Control cables and carburetor Slicolube G 30M li...

Page 16: ...d a Avoid using any coolant or only water other than this designated type to prevent corrosion b SUBARU s engine is aluminum alloy and so special care is necessary 3 SEALANTS Recommended Application E...

Page 17: ...2 8 6 52 62 9 0 10 8 65 78 14 2 16 8 103 122 15 0 17 8 108 129 2 BODY Unit N m kg m ft Ib Dia mm 4T 7T 9T 4 1 7 2 6 0 17 0 27 1 2 2 0 t JtJ J 5 2 9 5 9 0 30 0 60 2 2 4 3 r 6 5 4 9 3 0 55 0 95 4 0 6 9...

Page 18: ...sitions 1 GARAGE JACK g 74 13 f19 7 5 a Never get under the vehicle while it is supported by a jack b When jacking up the vehicle place chocks to hold wheels c After jacking up the vehicle with garage...

Page 19: ...e front and rear of the car then lift the vehicle up Lift 11 l11 J J d Safety stand n n c Cl 015 Fig 16 a Never get under the vehicle while it is supported only by the jack Always use safety stands to...

Page 20: ...vehicle which is heavier than towing vehicle c Do not apply excessive lateral load to towing hook d Wrap the towing rope with cloth to prevent dam aging bumper etc e Keep the vehicle level during tow...

Page 21: ...11 GENERAL INFORMATION 9 Front Hood Stay Installation Points 1 FRONT HOOD STAY Fig 21 Fig 22 a If front hood must be opened fully for ease of operation change the mounting position of the front hood s...

Page 22: ...WIPER 6 N WHEEL NUTS FOR LOOSENESS AND TIRE INFLATION PRESSURE 7 O SEAT ADJUSTER AND SEAT BELTS 7 P FUSES 8 Q DIAGNOSIS CONNECTOR 8 R PREPARATION FOR UNDERSIDE INSPECTION Refer to 1 3 0602 S AIRBAG I...

Page 23: ...or proper fitting 4 Leakage in any of the above Check fluid leveller operation while pushing it down with a screwdriver Fig 1 Recommended brake fluid FMVSS No 116 fresh DOTS or DOT4 brake fluid a The...

Page 24: ...y of electrolyte can be measured with a hydrometer Holding the glass tube vertically slowly draw the liquid into the tube Take the reading on the float scale at the highest point of the liquid When re...

Page 25: ...ehicle on a level surface 2 Remove oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted with the symbol on the top appearing as s...

Page 26: ...e specified range marked on the gauge Insert a finger into the filler port to determine whether the oil is level with the port opening Filler hole Drain hole B1 075 Fig 8 A WD rear differential Recomm...

Page 27: ...er ratio Freezing point C F 30 12 10 50 20 4 100 undiluted 45 49 a Before raising wiper arm up set wiper mode switch under lower cover to WINTER b Before checking the windshield wiper remove the blade...

Page 28: ...ADJUSTER AND SEAT BELTS CHECK POINTS 1 Front and rear seats and their facing materials 2 Front seat operation 3 Rear seat folding operation 4 Seat belts and their fit 3 Installing procedure for child...

Page 29: ...CONNECTOR CHECK POINTS 1 Check engine light flashing 2 Jumper connector removal Check the check engine light flashing a With the jumper connector connected set the igni tion switch to ON with engine O...

Page 30: ...nd boots for damage 3 Tie rod and tie rod end for proper installation or damage 1 Check the universal joint for looseness When checking turn ignition switch to ACC posi tion Tightening torque 21 26 Na...

Page 31: ...ling with your fingers from the underside Retighten the clamps if necessary a When retightening the clamps do not tighten them excessively b When checking the fuel system use extreme care to prevent a...

Page 32: ...ssed Make sure that the brake can be kept that way for at least five seconds Also check for air in the brake system or brake fluid leakage 3 Perform the adjustment of operating rod ASSY as follows 1 B...

Page 33: ...free play Free play 0 17 mm 0 0 67 in T C1 033 Fig 26 2 With the car moving straight ahead check for hard steering shimmy or other abnormalities 3 Make a turn and check for hard or heavy steering whe...

Page 34: ...l at the COLD position of the level gauge a The available power steering fluid is the automatic transmission fluid Be sure to use the recommended fluid b When power steering fluid is added be careful...

Page 35: ...ired to remove scratches or rust the area to be corrected must be limited as much as possible Re painting and spray painting must be avoided whenever possible 2 Carefully check each window glass for s...

Page 36: ...ND INSPECT FUEL SYSTEM LINES AND CONNECTIONS 7 AIR FILTER ELEMENTS 8 SPARK PLUG 9 DIFFERENTIAL FRONT AND REAR LUBRICANTS GEAR OIL 10 AUTOMATIC TRANSMISSION FLUID 11 BRAKE FLUID 12 DISC BRAKE PADS AND...

Page 37: ...ial Front Rear Lubricants Gear oil I See NOTE 3 10 Automatic transmission fluid 1 See NOTE 4 11 Brake fluid R R See NOTE 5 12 Disc brake pad and disc Front and rear axle boots and axle shaft joints I...

Page 38: ...gram Examples of severe driving conditions 1 Repeated short distance driving item 3 12 and 13 only 2 Driving on rough and or muddy roads Item 12 13 and 15 only 3 Driving in dusty conditions 4 Driving...

Page 39: ...i tioner drive belt remove the alternator in advance Pulley arrangement Belt tension A Belt tension Gauge with 98 N 10 kg 22 lb force ALT A C g A B A B New belt 637 785 N 80 65 637 736 N 65 75 4 0 5 0...

Page 40: ...Alternator 1 Loosen the lock nut 2 Loosen the slider bolt I ly 3 Remove the front side belt 4 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension shown in the ab...

Page 41: ...e two bolts MAINTENANCE INTERVAL Number of months or km miles whichever occurs first Months 3 7 5 15 22 5 30 37 5 45 52 5 60 x1 000 4 8 12 24 36 48 60 72 84 96 km x1 000 3 7 5 15 22 5 30 37 5 45 52 5...

Page 42: ...ove the drive belt Refer to Drive Belt s I 11 Remove the alternator 1 Disconnect the alternator connector and B termi nal 2 Remove the alternator mounting bolts and drive belt cover bracket q1 Rcrnnxi...

Page 43: ...racket ASSY riy 1 B INSTALLATION To install reverse order of removal procedures For installation of tensioner adjuster and timing belt refer to 2 3 ENGINE W2C2 CW2C3 14 Remove the crankshaft pulley 15...

Page 44: ...our rotations check cam sprocket to determine idler alignment timing belt back surface for cracks or damage If a fault ness Replace worn timing belt is found replace the belt with a new one 4 Install...

Page 45: ...3 5 7 15 22 5 30 37 5 45 52 5 60 miles R R R R R l R I R R R 1 3 Tighten engine oil drain plug after draining engine oil Tightening torque 44 N m 4 5 kg m 33 ft Ib 4 Fill engine oil through filler pi...

Page 46: ...ce 2 Remove oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted with the symbol on the top appearing as shown in the figure 4 Re...

Page 47: ...turn after the seal rubber contacts the cylinder block Do not tighten excessively or oil may leak 5 After installing oil filter run engine and make sure that no oil is leaking around seal rubber The...

Page 48: ...center 9 Install reserve tank to original position 10 Slowly pour prepared coolant from radiator filler port to neck of filler then pour into reserve tank up to FULL level Coolant capacity Pour up to...

Page 49: ...E TO ADJUST THE CONCENTRA TION OF THE COOLANT To adjust the concentration of the coolant replace the all amount of coolant with an undiluted solution of SUBARU genuine coolant concentration 50 B INSPE...

Page 50: ...careful not to spill fuel on the floor 1 Removal 1 Before removing the hose filter pump etc be sure to release the fuel pressure as follows Disconnect the wiring connector of the fuel pump Crank the e...

Page 51: ...clamp is too deformed replace with a new one c Correct the hose position by removing any twist so that it will not interfere with the filter body or washer tank before tightening the screw of the hos...

Page 52: ...air cleaner element The filter paper of the element is wetted with a special non inflammable slow evaporating viscous liquid It is resistant to cold weather and has a long service life Dirt adhering t...

Page 53: ...22 5 30 37 5 45 52 5 60 x1 000 4 8 12 24 36 48 60 72 84 96 km x1 000 3 7 5 15 22 5 30 37 5 45 52 5 60 miles 1 i I I I IR Spark plug gap 1 0 1 1 mm 0 039 0 043 in When installing spark plugs on cylind...

Page 54: ...d between two points on the level gauge If the oil level is at lower point or below add some oil up to upper point F g 35 Oil capacity 1 1 1 3e 1 2 1 4USqt 1 0 1 1Impqt MAINTENANCE INTERVAL Number of...

Page 55: ...capacity 0 8 e 0 8 US qt 0 7 Imp qt Fluid packing Three Bond 1105 or equivalent Drain plug tightening torque 44 N m 4 5 kg m 33 ft Ib SAE Viscosity No and Applicable Temperature F1 30 0 30 60 90 CI 3...

Page 56: ...le also serves as fluid filler NOTE Do not fill the fluid above upper point of level gauge Recommended automatic transmission fluid ATF Dexron II Upper level Lower level Upper level J Lower level J 0...

Page 57: ...ths or km miles whichever occurs first Months 3 7 5 15 22 5 30 37 5 45 52 5 60 x1 000 4 8 12 24 36 48 60 72 84 96 km x1 000 3 7 5 15 22 5 30 37 5 45 52 5 60 miles R T l R Recommended brake fluid FMVSS...

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Page 60: ...hs or km miles whichever occurs first Months 3 7 5 15 22 5 30 37 5 45 52 5 60 x1 000 4 8 12 24 36 48 60 72 84 96 km x1 000 3 7 5 15 22 5 30 37 5 45 52 5 60 miles l I l I II Brake drum inside diameter...

Page 61: ...2 Turn adjuster toward arrow mark upward until it is locked slightly by using slot type screw driver as shown in illustration below Adjuster Cover rubber Slot type screwdriver Back Plate B1 090 I Fig...

Page 62: ...ervoir tank is lower than the specified limit the brake fluid warning light on the instrument panel will come on 1 SERVICE BRAKE 1 Check the free play of brake pedal with a force of less than 10 N 1 k...

Page 63: ...M 1 With the engine off depress the brake pedal several times applying the same pedal force Make sure the travel distance should not change 2 With the brake pedal depressed start the engine Make sure...

Page 64: ...s or km miles whichever occurs first Months 3 7 5 15 22 5 30 37 5 45 52 5 60 x1 000 4 8 12 24 36 48 60 72 84 96 km x1 000 3 7 5 15 22 5 30 37 5 45 52 5 60 miles 1 I I I 1 Steering force The effort req...

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Page 71: ...fer to 4 2 WHEELS AND AXELS W2AOI MAINTENANCE INTERVAL Number of months or km miles whichever occurs first Months 3 15 22 5 30 37 5 45 52 5 60 x1 000 4 8 24 36 48 60 72 84 96 km r x1 000 3 7 15 22 5 3...

Page 72: ...ES Ioi6A21 1 5 6 While supporting rear drive shaft horizontally with If hub is noisy or binds disassemble rear axle and check one hand turn hub with the other to check for noise or condition of oil se...

Page 73: ...AINTENANCE INTERVAL Number of months or km miles whichever occurs first Months 3 7 5 15 22 5 30 37 5 45 52 5 60 x1 000 4 8 12 24 36 48 60 72 84 96 km x1 000 3 7 5 15 22 5 30 37 5 45 52 5 60 miles Insp...

Page 74: ...TRANSMISSION AND DIFFERENTIAL TOOLS 3 AUTOMATIC TRANSMISSION AND DIFFERENTIAL TOOLS 5 4 REAR FINAL DRIVE SYSTEM AWD MODELS TOOLS 8 5 SUSPENSION TOOLS 10 6 WHEELS AND AXLES TOOLS 11 7 STEERING SYSTEM T...

Page 75: ...GUIDE VALVE OIL SEAL GUIDE CP PISTON PIN GUIDE CONNECTING ROD BUSHING REMOVER INSTALLER Used to install piston in cylinder For press fitting of intake and Used to install piston pin piston Used to rem...

Page 76: ...06 499767200 499767400 499817300 499817400 VALVE GUIDE REMOVER VALVE GUIDE REAMER ENGINE STAND COMPL RH ENGINE STAND COMPL LH For removing valve guides For reaming valve guides Stand used for engine d...

Page 77: ...to draw out crankshaft shaft pulley when loosening and ton circlip sprocket tightening crankshaft pulley bolts o moo 0 0 0 0 o o oho oho B1 142 C1 111 B1 136 CI 151 499525500 498307500 498348500 BOLT...

Page 78: ...00 498677010 REMOVER TABLE OIL PRESSURE GAUGE ASSY COMPRESSOR For removing differential taper Used to remove transfer piston Used when measuring oil pres Used to remove band piston roller bearing seal...

Page 79: ...03600 399893600 SOCKET COMPRESSOR PULLER PLIERS Used to remove and install brake Used to remove and install Used to install band servo Used to remove and install band clutch spring clutch spring c 131...

Page 80: ...ER 499095500 O f Bl 347 B1 348 Bl 349 B1 350 499787100 499827000 899524100 498307500 WRENCH ASSY PRESS PULLER SET SELECT MONITOR KIT Used to remove and install drive Used to install speedometer Used t...

Page 81: ...01 O O 0 2 DRFr 398477102 3 DRIFT 2 3984771031 B1 216 B1 217 B1 218 B1 219 398237700 398417700 498427200 398437700 GAUGE DRIFT FLANGE WRENCH DRIFT Side bearing Oil seal Companion flange Oil seal B1 22...

Page 82: ...ment B1 228 131 229 B1 230 B1 231 398527700 399527700 399780104 899580100 PULLEY ASSY PULLER SET WEIGHT INSTALLER Oil seal Side bearing cup Side bearing cone Front bearing cone Pilot bear Front bearin...

Page 83: ...OVER INSTALLER REMOVER Used as an adapter for Camber Used to disassemble and assem Used to install and remove lat Used to replace lateral link bush Caster Gauge when measuring ble strut mount eral lin...

Page 84: ...as an adapter for AXLE semble hub bolt in front and semble rear housing bearing AXLE SHAFT PULLER I SHAFT INSTALLER 922431000 rear hub CP 0 Used with HOUSING STAND 926470000 Used to assemble front and...

Page 85: ...g bearing into housing ASSY rear housing into housing ASSY Used with HOUSING STAND a Used with HOUSING STAND Used with HOUSING STAND Used with HOUSING STAND FRONT 28099PA010 FRONT 28099PA010 REAR 2809...

Page 86: ...To Gauge Ole B1 251 B1 252 B1 254 B1 263 34099PAl00 926450000 926280000 34099PA090 LOCK NUT WRENCH COVER FORMER PINION GUIDE For the lock nut when adjust Used to install oil seal Seal ring Used to in...

Page 87: ...99PA060 34099PA030 34099PA040 34099PA050 BEARING INSTALLER INSTALLER A INSTALLER B INSTALLER D Used to remove oil seal and bearing oil valve housing Used to install oil seal into rack ASSY Used to ins...

Page 88: ...WRENCH ENGINE SUPPORT ASSY PLIERS Trim clip Door hinge For supporting engine Used to remove and install the power antenna 267 268 v e C1 142 499897100 ENGI 9989 NGINE TOOL 86399PA000 C1 143 42199PA00...

Page 89: ...MENT TOOL Used to check the supplemental restraint system Used to check the supplemental restraint system Used to check the supplemental restraint system Used to operate the supplemental restraint sys...

Page 90: ...fying our customers by keeping their vehicle in optimum condition When replacement of parts during re pair work is needed be sure to use SUBARU genuine parts All information illustration and specifica...

Page 91: ...atic Drawing 3 3 General Precautions 4 4 Crankcase Emission Control System 4 5 Three way Catalyst 5 6 A F Control System 5 7 Ignition Control System 6 8 EGR Exhaust Gas Recirculation System 7 9 Evapor...

Page 92: ...s a signal for optimal control of ignition timing Crank angle sensor 1 2 Detects engine speed Revolution Exhaust emission control system Ignition control system Cam angle sensor Detects reference sign...

Page 93: ...l filter TCM PURGE DUTY CONTROL 21 Fuel um EGR CONTROL p p RADIATOR FAN CONTROL 22 Induction valve diaphragm A C DUTY CONTROL 23 Induction control valve FUEL PUMP DISCHARGE FLOW CONTROL I SYSTEM DIAGN...

Page 94: ...inals from bending 6 Use SUBARU genuine parts 7 Record how hoses are connected before discon necting 1 When disconnecting vacuum hoses use tags to identify how they should be reconnected 2 After compl...

Page 95: ...urification efficiency on all components HC CO and NOx a balance should be kept among the concentrations of the components These concentrations vary with the air fuel ratio The air fuel ratio needs to...

Page 96: ...iters The ECU has a learning control function which pro vides superb transient characteristics for responsive ignition timing control Refer to 2 7 FUEL INJECTION SYSTEM IG switch t F_ r j Cam angle r...

Page 97: ...pressure is transmitted to the EGR valve diaphragm when the EGR solenoid valve is A DESCRIPTION I opened by the signal from ECU and the EGR valve is opened As a result the exhaust gas is sent into th...

Page 98: ...OUT C2 054 Fig 6 3 EGR SOLENOID VALVE The EGR solenoid valve is situated between the throttle body and EGR valve EGR solenoid valve is opened by a signal emitted from the ECU Therefore throttle port p...

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Page 100: ...into the collector chamber after being mixed with fresh external air To purge solenoid valve From fuel tank o Filter O U _u0 h Charcoal el Filter Air B2 386 Fig 11 Refer to 2 8 Fuel System as for rem...

Page 101: ...thereby reducing the generation of evaporation gas at higher engine speeds Fuel pump modulator Resistor 1 ECU Fuel pump Fuel tank C2 062 Fig 12 B FUNCTION 1 At low engine speeds the source current fl...

Page 102: ...a 5 If voltage did not change check for following 1 Measure voltage between ECU and body Specified voltage B61 No 14 Body 5V min 2 Remove fuel pump modulator and measure re sistance of harness connect...

Page 103: ...1 11 Vacuum Fitting EGR valve EGR vacuum control Hose Throttle body o Pipe Pressure regulator EGR solenoid vlave Purge control solenoid valve uc Induction tank solenoid valve Check valve Canister To F...

Page 104: ...G SYSTEM 2 11 SUBARU SVX 1992 T 74 Page C COMPONENT PARTS 2 1 Engine Mounting 2 2 Transmission Mounting 3 W SERVICE PROCEDURE 4 1 General Precautions 4 2 Engine 5 3 Front Cushion Rubber 15 4 Transmiss...

Page 105: ...1 I I I I 1 I 1 I 1 I 1 T3 T2 T1 1 a 1 1 1 I 1 1 l 1 II 11 11 11 i l 1 1 1 T2 T3 Tightening torque Nm kg m ft Ib 1 Front engine mounting bracket RH T1 49 69 5 7 36 51 2 Front cushion rubber RH T2 20...

Page 106: ...pper 2 Rear cushion rubber AWD 3 Rear crossmember 4 Rear cushion rubber FWD Tightening torque N rn kg m ft Ib T1 44 54 4 5 5 5 33 40 T2 47 67 4 8 6 8 35 49 T3 18 31 1 8 3 2 13 23 T4 54 83 5 5 8 5 40 6...

Page 107: ...to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil Place a cover over fenders as required for protection 3 Prior to starting work prepare the following...

Page 108: ...2 Remove canister and bracket 13 Remove exhaust system 14 Disconnect power steering hoses from gear box 15 Disconnect ATF cooler hoses 16 Remove nuts which hold lower side of engine to transmission an...

Page 109: ...move under cover and drain coolant 1 Raise the vehicle 71 RPmnvp under rnvar 6 Remove cooling system 1 Disconnect radiator outlet hose from thermostat 21 Disconnect ATF cooler hoses from nines y y 6 D...

Page 110: ...cle system 1 Remove collector cover 2 Collect refrigerant from A C system 2 Remove air intake boot 3 Disconnect high pressure hose and low pressure hose from A C compressor a Be careful not to lose O...

Page 111: ...le speed sensor 2 connector 1 Disconnect the following harness connectors Power steering harness connector Engine harness connector Engine ground terminal Ignition coil harness connector Alternator co...

Page 112: ...eering hose to reservoir tank Heater hose Inlet and outlet 0 Power steering hose to cooling pipe Heater Heater Brake booster outlet z inlet o vacuum hose Power steering 10 from gear L CID I Illl IIIII...

Page 113: ...xhaust pipes and rear catalyst 17 Remove nuts which install front cushion rubber to converter sub frame Refer to C 2 9 14 Disconnect power steerinq hose from gear box dill s Sub frame j r C2 105 Fig 1...

Page 114: ...Fig 23 Protect throttle body with cloth etc so as not to damage it by wire rope 24 Remove engine itself 1 Slightly raise engine 2 Raise transmission with garage jack 3 Move engine horizontally 4 Slowl...

Page 115: ...transmission and install lower side of starter 11 Tighten nuts which install front cushion rubber to sub frame 12 Connect power steering hoses to gear box 13 Connect ATF cooler hoses 14 Install exhaus...

Page 116: ...n hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose Power steering oil hose to cooler hose Power steering oil hose to gear box pipe Power steering oil hose to reservoir...

Page 117: ...onnector Engine ground terminal Alternator connector and terminal A C compressor connector Fig 31 19 Connect pressure hose onto A C compressor and charge with refrigerant 1 Connect high pressure and l...

Page 118: ...intake boot 4 Remove grille ASSY 5 Remove radiator bracket and A C condenser install ing bolts riy 33 rig 34 8 Support engine with a lifting device and wire ropes i _ 7771 7 C2 108 Fig 35 I iy ov 9 Re...

Page 119: ...ove bolts which install power steering fluid cooling hose onto body rig s 13 Remove stabilizer ASSY 1 Remove right side brake hose and ABS harness from strut 2 Remove stabilizer link 3 After marking w...

Page 120: ...install stabilizer clump onto sub frame 2 Install stabilizer lever to stabilizer CP Align the point mark between stabilizer CP and lever Stabilizer lever Marking y Lower arm C4 109 Fig 43 Tightening...

Page 121: ...wire ropes 7 Connect Oz sensor 1 t 2 connectors 8 Remove wire ropes and lifting device 9 Install pitching stopper 10 Install air intake system 1 Install air intake boot 2 Install throttle body cover 1...

Page 122: ...r side of transmission to engine 13 Remove ATF level gauge and front differential oil level gauge 14 Remove under cover 15 Remove exhaust system 16 Remove propeller shaft i nemove selector caDie rrom...

Page 123: ...em 1 Remove throttle body cover 2 Remove air intake boot Fig 46 I iy i 6 Remove pitching stopper and bracket 1 Remove pitching stopper 2 After disconnecting transmission air vent hoses from bracket re...

Page 124: ...2 connector Transmission harness connectors 02 sensor 1 r 2 RH ft LH connectors Transmission ground terminal connector Engine ground terminal j Oz sensor I r Transmission connector _ 1 11 I 1 1 Transm...

Page 125: ...which install upper side of starter and remove starter ASSY I iy re_ riy uv 10 Separate torque converter from drive plate 1 Remove service hole plug 2 Remove bolts which hold torque converter to drive...

Page 126: ...aft 17 Remove selector cable from selector lever ASSY 18 Remove selector cable bracket from body 1 11 l 77 Adjusting nut J __J7 Bolt C3 109 Fig 55 19 Remove performance rod rig 70 20 Remove front axle...

Page 127: ...ING SYSTEM 23 Place transmission jack under transmission L I JJJ1 C2 121 Fig 60 24 Remove bolts which are installing rear crossmem ber to bodv 24 25 Remove transmission Move torque converter and trans...

Page 128: ...tall torque converter to drive plate 9 stopper a 11 Install starter ASSY 12 Install front axle shaft into transmission 13 Install selector cable to selector lever ASSY 14 Install selector cable bracke...

Page 129: ...el gauge 8 Install torque converter to drive plate 1 Tighten bolts which hold torque converter to drive plate 2 While cranking the engine tighten other bolts Be careful not to drop bolts into torque c...

Page 130: ...2 119 Fig 65 Tightening torque N m kg m ft Ib 46 54 4 7 5 5 34 40 4 Lift up the vehicle 5 Tighten nut which install lower side of starter to transmission Tightening torque N m kg m ft Ib 46 54 4 7 5 5...

Page 131: ...ose 9 Blow by hose Tightening torque N m kg m ft Ib 20 Install engine hook 24 39 2 4 4 0 17 29 21 Install air intake system 1 Install air intake boot 2 Install throttle body cover 3 Install center bea...

Page 132: ...in the reverse order of removal proce dures 1 Install rear cushion rubber Tightening torque N m kg m ft Ib 18 31 1 8 3 2 13 23 2 Install transmission rear crossmember T1 T2 T3 T1 D L 000 T1 T3 T1 C2...

Page 133: ...X 1992 T 2 2 Page 1 Foreword 2 2 Ignition Timing 2 3 Engine Idle Speed 2 4 Engine Compression 2 5 Intake Manifold Vacuum 3 6 Cylinder Head Cover 4 7 Fuel Injector 5 8 Collector and Intake Manifold ASS...

Page 134: ...light is off 2 Warm up the engine 3 Connect Select Monitor and measure engine rpm Function model 04 4 Check idle speed when unloaded with headlights heater fan rear defroster radiator fan air conditi...

Page 135: ...Needle is steady but lower than normal position This tendency Leakage around air intake system becomes more evident as engine temperature rises 2 When engine speed is reduced slowly from higher speed...

Page 136: ...ubsequent removal operation follow the same procedures steps 5 through 10 that are outlined under the CYLINDER HEAD COVER LH B INSTALLATION Installation is in the reverse order of removal proce dures...

Page 137: ...r 2 Start engine 3 Run engine until it stalls 4 After it stalls crank starter for approximately 5 seconds and turn ignition switch to OFF 2 Remove corrector cover 3 Disconnect throttle cable and cruis...

Page 138: ...moving the compressor and bracket take care not to over stretch the pipes and hoses Fig 9 B INSTALLATION Fig 10 Installation is in the reverse order of removal procedure Observe the following 1 Remove...

Page 139: ...BARU CRC 004301003 to threaded por tion of oxygen OZ sensor again and leave it for one minute or more 5 Remove oxygen OZ sensor by using socket and wrench When removing do not force oxygen OZ sensor e...

Page 140: ...Piston 9 S SPECIFICATIONS AND SERVICE DATA 10 A SPECIFICATIONS 10 B SERVICE DATA 11 C COMPONENT PARTS 15 1 Timing Belt 15 2 Cylinder Head and Camshaft 16 3 Cylinder Head and Valve ASSY 17 4 Cylinder...

Page 141: ...ake valves and two exhaust valves per cylinder The intake and exhaust ports are arranged in a cross flow design The exhaust camshafts on the left and right banks are driven by a single timing belt and...

Page 142: ...A hydraulic belt tension adjuster constantly maintains specified belt tension to properly drive the camshafts as well as to provide a maintenance free advantage Alignment mark V Alignment mark belt c...

Page 143: ...between the arm and rod is balanced Since the thrust F works to the arm the pulley is rotated counterclock Fig 3 wise giving tension PB to the belt 2 Action for balancing the belt tension When tension...

Page 144: ...mshaft The intake cam shaft also has a sub gear for eliminating gear backlash thereby reducing gear noise The cam nose part is finished with chill treatment to increase wear resistance and anti scuffi...

Page 145: ...the oil quantity inside the high pressure chamber Accordingly the bucket plunger and adjuster body work as an integral unit to push down the valve stem to open the valve The passage for supplying oil...

Page 146: ...two intake and two exhaust which are arranged in a cross flow design are used per cylinder The cylinder head gasket is made from carbon material not asbestos Its core is metal provided with metal hoo...

Page 147: ...lly cast with aluminum cylinder block Seven main journal block designs are employed to increase stiffness and quiet operation The oil pump is located in the front center of the cylinder block and the...

Page 148: ...in is located in an offset position The Nos 1 3 and 5 pistons are offset in the lower direction while the Nos 2 4 and 6 pistons are offset in the upper direction The piston head is recessed for both t...

Page 149: ...815 x 2 95 Piston displacement cm3 cu in 3 318 202 46 Compression ratio 10 0 Compression pressure kPa kg cm2 psi at 200 300 rpm 1 177 1 422 12 14 5 171 206 Number of piston rings Pressure ring 2 Oil...

Page 150: ...rust clearance STD 0 02 0 08 0 0008 0 0031 Exhaust Limit 0 12 0 0047 STD 0 037 0 072 0 0015 0 0028 Oil clearance Limit 0 10 0 0039 STD 0 029 0 175 0 0011 0 0069 Camshaft gear Backlash Limit 0 30 0 011...

Page 151: ...32 975 1 2978 1 2982 Hydraulic lash Bush I D 33 009 33 031 1 2996 1 3004 adjuster Oil l STD 0 028 0 078 0 0011 0 0031 c earance Limit 0 110 0 0043 Surface warpage limit mating with cylinder head 0 05...

Page 152: ...0 05 0 0020 Connecting STD 1 486 1 498 0 0585 0 0590 rod bearing 0 03 mm 0 0012 in U S 1 496 1 509 0 0589 0 0594 Thickness at center portion 0 05 mm 0 0020 in U S 1 506 1 519 0 0593 0 0598 0 25 mm 0 0...

Page 153: ...3 7 0 05 mm 2 027 2 030 0 0798 0 0799 0 0020 in U S 0 25 mm 2 127 2 130 0 0837 0 0839 0 0098 in U S STD 2 000 2 013 0 0787 0 0793 h C k ft 0 03 mm 0 0012 in U S 2 019 2 022 0 0795 0 0796 ran s a beari...

Page 154: ...tensioner bracket Belt tensioner Belt idler No 2 Belt tension adjuster Left hand camshaft sprocket Timing belt Right hand belt cover Front belt cover Left hand belt cover Crank shaft pulley v l Tight...

Page 155: ...aft R H 7 Camshaft gear spring 8 Sub gear 9 Wave washer 10 Snap ring 11 Camshaft plug 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Exhaust camshaft RH Camshaft oil seal Cylinder head bolt short...

Page 156: ...d and Valve ASSY p 1 Exhaust valve 2 Intake valve 3 Valve spring seat 4 Intake valve oil seal 5 Inner valve spring 6 Outer valve spring 7 Retainer 8 Retainer key 9 Hydraulic lash adjuster 10 Exhaust v...

Page 157: ...pump Front oil seal ear oil seal ring Service hole cover Cylinder block LH 13 Water pump uffle plate Oil strainer Gasket Oil pan Oil drain plug Gasket Oil level gauge guide Oil level gauge Water by pa...

Page 158: ...ng 6 Piston 7 Piston pin 8 Circlip 9 Connecting rod bolt 10 Connecting rod 11 Connecting rod bearing 12 Connecting rod cap 13 Crank shaft 14 Woodruff key 15 Crank shaft bearing 1 3 7 16 Crank shaft be...

Page 159: ...ngs 4 Rotating parts and sliding parts such as piston bearing and gear should be coated with oil prior to assembly 5 Be careful not to let oil grease or coolant contact the timing belt 6 All removed p...

Page 160: ...ELT COVER 4 Remove power steering pump bracket 5 Remove A C belt tensioner bracket 6 Remove A C compressor 7 Remove A C compressor bracket h I 2 OO C2 200 Fig 16 1 Remove pulley bolt To lock crankshaf...

Page 161: ...n on timing belt fade away put new marks before removing timing belt as follows 1 Turn crankshaft and align alignment marks on crankshaft sprocket and left and right camshaft sprockets with marks of b...

Page 162: ...on timing belts in relation to the sprockets 3 4 5 Fig 27 4 BELT TENSIONER AND IDLER Loosen tensioner adjuster mounting bolts Remove belt idler Remove belt idler No 2 Remove timing belt J 10 0 0 0 c2...

Page 163: ...OLT But this PULLER has no holes to fit crank shaft sprocket holes Therefore drill two holes in PULLER to fit crankshaft sprocket holes to following dimensions Hole center to hole center Pitch 41 mm 1...

Page 164: ...ly check oil seals for leaks and rod ends for abnormal wear or scratches If necessary replace faulty parts Slight traces of oil at rod oil seal does not indicate a problem 2 While holding tensioner wi...

Page 165: ...ner bracket 2 Install right hand belt cover No 2 3 Install left hand belt cover No 2 4 Install crankshaft sprocket 5 Install right hand camshaft sprocket To lock camshaft use CAMSHAFT SPROCKET WRENCH...

Page 166: ...to place while pushing tension adjuster rod into body using a press a Do not allow press pressure to exceed 9 807 N 1 000 kg 2 205 lb b Do not release press pressure until stopper pin is completely in...

Page 167: ...NE 3 TIMING BELT T 35 43 V T N m kg m ft Ib 3 6 4 4 26 32 C2 217 Fig 32 1 Installation of timing belt 1 Using SPROCKET WRENCH turn sprockets and align their alignment marks with marks of belt covers a...

Page 168: ...ly 53 tooth length 53 tooth length c OO Alignment mark Alignment mark Alignment mark _ o ICI C C2 223 Fig 34 2 Install belt idler No 2 5 After ensuring that the marks on timing belt and 3 Install belt...

Page 169: ...3 Install left hand belt cover 4 Install crankshaft pulley 5 Install pulley bolt To lock crankshaft use CRANK SHAFT PULLEY WRENCH 5 RELATED PARTS 1 Install A C compressor bracket 2 Install A C compres...

Page 170: ...ting bolts and pull the bolt head using pliers Be careful not to pull any harness by mistake 3 Disconnect blow by hose and remove cylinder head cover and gasket 4 Remove front camshaft cap 5 Remove ca...

Page 171: ...39 2 See the rear side of the camshaft gears and make sure that the match marks of the intake camshaft gear driven gear and exhaust camshaft gear drive gear are aligned Match 0 mark C I C e Match mar...

Page 172: ...camshaft cap while holding the in take camshaft with one hand and then remove the camshaft If it is hard to remove the camshaft rotate W3A2 2 3 the exhaust camshaft clockwise Arrange the camshaft cap...

Page 173: ...for aligning the cam shaft gear match marks before removing camshafts 1 Remove ignition coils 2 Disconnect blow by hose and remove cylinder head cover and gasket 3 Remove front camshaft cover 4 Remov...

Page 174: ...repeat step 4 above 5 Remove the camshaft cap while holding the in take camshaft with one hand and then remove the camshaft If it is hard to remove the camshaft rotate the exhaust camshaft countercloc...

Page 175: ...of the camshaft in a vice using a rag a Never attempt to hold the cam lobe or journal in the vice b Pay attention not to damage the cam lobe and journal Fig 53 3 Remove snap ring using CAMSHAFT GEAR...

Page 176: ...meter 1 2 3 4 Standard 31 943 31 963 mm 27 946 27 963 mm 1 2576 1 2584 in 1 1002 1 1009 in 4 Measure the cam height H If it exceeds the limit replace camshaft Unit mm in H 28 mm 1 10 in B2 098 Fig 56...

Page 177: ...n each journal If the oil clearance exceeds the limit replace the camshaft If necessary replace the camshaft caps and cylinder head as a set Standard oil clearance 0 037 0 072 mm 0 0015 0 0028 in Limi...

Page 178: ...cure the shaft portion of the camshaft in a vice using a rag a Never attempt to hold the cam lobe or journal in the vice b Pay attention not to damage the cam lobe and journal Fig 63 2 Turn the sub ge...

Page 179: ...ydraulic lash adjusters 2 Apply a coat of engine oil to the camshaft jour nals 3 Set the exhaust camshaft on the cylinder head with the front end notch of the camshaft facing directly downward Then at...

Page 180: ...o the camshaft jour nals 3 Align the intake camshaft match mark with the match mark of the exhaust camshaft which is already installed In this case make sure that the notch on the front end of the int...

Page 181: ...d journal decreases evenly at three places If not loosen the bolts by reversing the illustrated numerical sequence and then repeat step 5 above Fig 71 6 Tighten each bolts to the specified torque in t...

Page 182: ...tion precautions are the same as those for the LH camshafts except the method of aligning the camshaft gear match marks 1 Installation of exhaust camshaft 1 Apply a coat of engine oil to the hydraulic...

Page 183: ...ine oil to the hydraulic lash adjuster surface and insert hydraulic lash adjusters 2 Apply a coat of engine oil to the camshaft jour nals 3 Align the intake camshaft match mark with the match mark of...

Page 184: ...ront camshaft cover 4 Apply a coat of grease to oil seal lips and install oil seal Use a new oil seal 5 Install camshaft plug 6 Installation of cylinder head cover 1 Completely remove excess fluid pac...

Page 185: ...2 3 w4A1 ENGINE 46 Fig 82 9 Remove exhaust manifold and gasket 10 Remove cylinder head covers camshafts and re lated parts Refer to 3 Camshafts W3A0 j...

Page 186: ...umerical sequence shown in Figure Leave bolts 5 or engaged by three or four threads to prevent cylinder head from falling 4 While tapping cylinder head with a plastic hammer separate it from cylinder...

Page 187: ...Arrange the hydraulic lash adjusters in order so that b Use extreme care not to damage the lips of the they can be installed in their original positions intake valve oil seals and exhaust valve oil se...

Page 188: ...LINDER HEAD TABLE 49826 7500 Thickness gauge o CD o 0 o B U pl J J U 1 C2 27o Fig 88 2 VALVE SEAT Inspect intake and exhaust valve seats and correct the contact surfaces with valve seat cutter if they...

Page 189: ...5 Coat a new valve guide with oil and insert it into the bore Place the VALVE GUIDE REMOVER into the valve guide and press the guide into the cylinder head until the upper end of the guide is flush w...

Page 190: ...imit 0 8 mm 0 031 in Valve overall length Intake 90 00 mm 3 5433 in Exhaust 90 85 mm 3 5768 in H 4 go 1 90 1 H o 9 0 1 B2 106 Fig 94 2 Put a small amount of grinding compound on the seat surface and l...

Page 191: ...SEAL INSTALLER a Apply engine oil to oil seal before force fitting b Be sure to press by hand never hammer on the special tool c Differentiate between intake valve oil seal and ex haust valve oil sea...

Page 192: ...Coat stem of each valve with engine oil and insert valve into valve guide When inserting valve into valve guide use special care not to damage the oil seal lip 2 Install valve spring and retainer Be...

Page 193: ...7 0 kg m 51 ft Ib in the numerical order shown in Figure 4 Back off all bolts by 180 5 Further back off all bolts by 180 6 Tighten all bolts to 27 N m 2 8 kg m 20 ft Ib in the numerical order shown in...

Page 194: ...d ASSY and gas kets T 23 26 N m Collector and intake manifold 2 3 2 7 kg m ASSY 17 20 ft Ib I r 1 r I e Gasket j jam 0 1 F n J f Pi I r J C2 282 Fig 104 4 Connect two water hoses to thotttle body 5 Co...

Page 195: ...lated parts Refer to 2 Timing belt MAO 2 Remove cylinder head covers and camshafts and related parts Refer to 3 Camshafts CW3A0 3 Remove intake manifold cylinder head and related parts Refer to 4 Cyli...

Page 196: ...when removing oil 7 Removal of oil pan 1 Turn cylinder block with 2 4 and 6 piston sides facing upward 2 Remove bolts which secure oil pan to cylinder block 3 Insert a oil pan cutter blade between cy...

Page 197: ...using hexagon wrench 14 mm 2 Rotate crankshaft to bring 1 and 2 pistons to BDC position then remove piston circlip through service hole of 1 and 2 cvlinders ly n r f C I l IL PISTON PIN REMOVER 49909...

Page 198: ...and 4 pistons through service hole of 1 and 2 cylinders 6 Rotate crankshaft to bring 5 and 6 pistons BDC position then remove piston circlip through service hole of 5 and 6 cylinders 7 Draw out pisto...

Page 199: ...ft hand and right hand cylinder blocks When separating cylinder block do not allow the connecting rod to fall and damage the cylinder block 3 Remove rear oil seal 4 Remove crankshaft together with con...

Page 200: ...a straight edge and correct by grinding if necessary Warping limit 0 05 mm 0 0020 in Grinding limit 0 4 mm 0 016 in 2 CYLINDER AND PISTON 1 The cylinder bore size is stamped on the cylinder block s f...

Page 201: ...C 68 F Standard 0 010 0 030 mm 0 0004 0 0012 in Limit 0 060 mm 0 0024 in Standard diameter A 96 905 96 915 mm 3 8151 3 8155 in B 96 895 96 905 mm 3 8148 3 8151 in C 96 885 96 895 mm 3 8144 3 8148 in...

Page 202: ...rail Oil ring Spacer 3 Lower rail B2 115 Fig 120 2 Squarely place piston ring and oil ring in cylinder using piston and measure the piston ring gap with a thickness gauge Unit mm in Standard Limit 0...

Page 203: ...the large or small end thrust surface is damaged 2 Check for bend or twist using a connecting rod aligner Replace connecting rod if the bend or twist exceeds the limit Limit of bend or twist per 100...

Page 204: ...clearance at the connecting rod small end If not within specifications replace connecting rod and connecting rod cap as a set Clearance between piston pin and bushing Standard 0 0 018 mm 0 0 0007 in L...

Page 205: ...1 734 51 750 0 25 0 0098 2 3520 2 3527 2 0368 2 0374 I undersize Bearing size 2 127 2 130 2 129 2 132 2 129 2 132 1 620 1 623 Illl I Thickness at center 0 0837 0 0839 0 0838m 0 0839 0 0838 0 0839 0 06...

Page 206: ...they are assembled correctly by checking their matching number b When tightening the connecting rod nuts apply oil on the threads 4 Installation of piston rings and oil ring 1 Install oil ring spacer...

Page 207: ...ankshaft on the 1 3 t 5 cylinder block 3 Apply fluid packing to the mating surface of 1 3 It 5 cylinder block and put 0 rings on the grooves of 1 3 ft 5 cylinder block and then position 2 4 r 6 cylind...

Page 208: ...15 N m 1 5 cylinder block side connecting bolts re tighten connect kg m 11 ft Ib on the 1 3 and 5 cylinder block side ing bolts to 15 N m 1 5 kg m 11 ft Ib in the numerical in the numerical sequence s...

Page 209: ...l se quence shown in figure 5 Tighten other cylinder block connecting bolts to specified torque 6 Install rear oil seal Flywheel attaching bolt Re aoilseal OIL SEAL INSTALLE tS 499587200 o o OIL SEAL...

Page 210: ...their cylinders CRANKSHAFT SOCKET 49998 7500 PISTON GUIDE 49874 7100 C2 308 Fig 140 2 Installing piston pin 1 Insert the PISTON PIN GUIDE into service hole to align piston pin hole with connecting rod...

Page 211: ...stons in their cylinders 2 Installing piston pin 1 Insert the PISTON PIN GUIDE into service hole to align piston pin hole with connecting rod small end Apply a coat of engine oil to PISTON PIN GUIDE b...

Page 212: ...nd 6 T 62 76 6 3 7 7 46 56 4 e T 6 7 0 6 0 7 4 3 5 1 4 41 10 1 T N m kg m ft Ib C2 312 Fig 146 Turn cylinder block so that 5 and 6 cylinders face upward Using the same procedures as used for 1 and 2 c...

Page 213: ...0 9 1 1 6 5 an T 6 7 0 6 0 7 4 3 5 1 T 69 75 7 0 7 6 51 55 o o ooh o o T 6 7 0 6 0 7 4 3 5 1 T 4 4 5 4 0 45 0 55 3 3 4 0 T N m kg m ft Ib T 4 4 5 4 0 45 0 55 3 3 4 0 C2 313 Fig 147 1 Install baffle p...

Page 214: ...ng installation Referto2 4 ENGINE LUBRICATION SYSTEM W1E0 a Do not forget to install O ring and seal when install ing oil pump b Align flat surface of oil pump s inner rotor with crankshaft before ins...

Page 215: ...r burning in exhaust system 11 Knocking 12 Excessive engine oil consumption 13 Excessive fuel consumption TROUBLE No POSSIBLE CAUSE 1 2 3 4 5 6 7 8 9 10 11 12 13 STARTER 0 a Defective battery to start...

Page 216: ...0 0 e Defective fuel pump O D d 0 0 e Clogged fuel line 0 0 0 0 L e Lack of or insufficient fuel BELT 0 0 0 e Defective 0 0 0 L 0 0 0 0 0 0 Defective timing FRICTION d Seizure of crankshaft and connec...

Page 217: ...tive crankshaft oil seal d 0 0 Defective rocker cover gasket 0 0 Loosened oil drain plug or defective gasket 0 Loosened oil pan fitting bolts or defective oil pan COOLING SYSTEM D d 0 0 O e Overheatin...

Page 218: ...ng with an overload a Wrong spark plug Improper gasoline Metallic knock when engine Sound is reduced when spark e Worn crankshaft main bearing speed is medium 1 000 to 2 000 plug in noisy cylinder is...

Page 219: ...FUNCTION 2 1 General 2 2 Lubrication Lines 3 3 Oil Pump 4 4 Oil Filter 5 5 Oil Pan r Oil Strainer 5 6 Oil Pressure Switch 5 S SPECIFICATIONS AND SERVICE DATA 6 C COMPONENT PARTS 7 1 Oil Pump 7 2 Oil...

Page 220: ...il filter via the oil passage on the lower right side of cylinder block After filtered the oil filter engine oil delivered to the crank journal bearings via the oil gallery on the cylinder block and t...

Page 221: ...l pool t t Oil strainer No 2 Ex camshaft journal No 3 4 Ex camshaft journal Ex cam shaft Thrust support J of cam shaft Fr cam journal Oil pan N 0 r OD 1 Connecting rod 4 Connecting rod 5 Connecting ro...

Page 222: ...e crankshaft the outer rotor is rotated changing the size of the space between the two rotors because of the different number of teeth used on the rotors Oil pump cover o Outer rotor i o Inner rotor o...

Page 223: ...n the oil pan B FUNCTION T D 31 4 1 I 000 0 1 Contacts 4 Molded portion 2 Diaphragm 5 Terminal 3 Spring 132 146 6 Oil Pressure Switch A CONSTRUCTION The oil pressure switch is located on the front rig...

Page 224: ...79 pressure 98 kPa 1 0 kg cmz 14 psi Capacity 80 C 600 rpm Discharge quantity 5 5 f 5 8 US qt 4 8 Imp qt min 176 F pressure 294 We 3 0 kg cm2 43 psi 5 000 rpm Discharge quantity 56 f 14 8 US gal 12 3...

Page 225: ...Tightening torque N m kg rn ft 1b T1 6 7 0 6 0 7 4 3 5 1 T2 4 7 0 4 0 7 2 9 5 1 T3 40 48 4 1 4 9 30 35 T4 12 16 1 2 1 6 9 12 Fig 6 1 Oil pump case 2 Inner rotor 3 Outer rotor 4 Oil pump cover 5 Front...

Page 226: ...I r _ _ 1 Oil pan 2 Gasket 3 Drain plug 4 Gasket O 5 Oil strainer 6 O ring 7 Baffle plate T4 8 Oil level gauge 9 Oil level gauge guide lop 10 O ring Tightening torque N m kg m ft 1b T1 4 4 5 4 0 45 0...

Page 227: ...cover and drive belts Refer to 1 5 Drive Belts 01A0 8 Remove A C belt idler pulley ASSY 9 Remove power steering pump bracket Do not remove power steering pump 10 Remove crank angle sensors 11 Remove c...

Page 228: ...nt the relief valve from under going pressure variations Replace the original number of washers during reassembly 1 TIP CLEARANCE Measure the tip clearance of rotors If the clearance exceeds the limit...

Page 229: ...Free length 73 7 mm 2 902 in Installed length 54 7 mm 2 154 in Load when installed 93 2N 9 5kg 20 9lb 5 OIL PUMP CASE Check the oil pump case for worn shaft hole clogged oil passage worn rotor chambe...

Page 230: ...pply fluid packing to oil pressure switch threads before installation Fluid packing Three bond 1324 or equivalent 2 Oil Pan A REMOVAL 1 Open the front hood 2 Disconnect ground cable from the negative...

Page 231: ...r similar tool in place of oil 0 T 9 11 0 9 1 1 6 5 8 0 _ T 4 4 5 4 0 45 0 55 3 3 4 0 T 4 4 5 4 T Nm kg m ft 1b 0 45 0 55 3 3 4 0 C2 143 14 Remove baffle plate Fig 21 Installation is in the reverse or...

Page 232: ...Clean or replace 1 Warning light remains 2 Low oil pressure Clogged oil passage Clean on Excessive tip clearance and side clearance of oil pump rotor and gear Replace Clogged oil strainer or broken pi...

Page 233: ...Mechanical Seal 3 5 Thermostat 4 S SPECIFICATIONS AND SERVICE DATA 5 A SPECIFICATIONS 5 B SERVICE DATA 5 C COMPONENT PARTS 6 1 Water Pump 6 2 Radiator and Radiator Fan 7 3 Water Pipe 8 W SERVICE PROCE...

Page 234: ...d step With thermostat opened This cooling system operates in three steps depending When the coolant temperature is above 76 80 C 169 on the temperature of the coolant flowing through the 176 F the th...

Page 235: ...hich is connected to the radiator hose via the thermostat It then flows along the perim eter of the impeller and is delivered to the engine s water passage Pulley Mechanical seal O Pulley 0 0 CC 0 I J...

Page 236: ...y a totally enclosed wax pellet which expands with in creased temperature It provides the sure open close operation of the valve and features high durability 1 Valve O 2 Spring 2 Stopper 4 Piston 5 Gu...

Page 237: ...0 Imp gal min Pump speed total 6 000 rpm 23 0 mAq 75 5 ft Aq Discharge performance III water head Engine coolant tempera 85 C 185 F ture Impeller diameter 76 mm 2 99 in Number of impeller vanes 8 Pump...

Page 238: ...Pump 1 C r Al L r J T2 1 Gasket 2 Water pump CP 3 Heater hose Inlet 4 Heater hose Outlet 5 Thermostat Tightening torque N m kg m ft Ib 6 Gasket T1 First 10 14 1 0 1 4 7 10 7 Thermostat cover Second 1...

Page 239: ...Fig 1 70 i 1 T2 T2 Tz 10 11 T3 i C I I Radiator Upper cushion Upper bracket Radiator inlet hose Clamp Fan control main shroud Fan control main and motor Fan control sub shroud Fan control sub and mot...

Page 240: ...Pipe Fig 7 1 Water pipe CP 2 Water temperature gauge 3 Water temperature sensor 4 O ring 5 O ring 6 Auxiliary air control valve ENGINE COOLING SYSTEM y tc n y t yuo n1 ny n t lul T R_71Y1R f17 AZ_F 11...

Page 241: ...Fig 8 6 Remove radiator bracket 7 Remove radiator sub fan motor ASSY Radiator sub fan Radiator ator main fan I 1 C2 015 Fig 9 8 Remove V belt s Refer to Chapter 1 5 section 1 9 Remove timing belt Refe...

Page 242: ...8 in Limit 1 0 mm 0 039 in 0 0 0 C2 010 Fig 14 5 After water pump installation check pulley shaft for water leaks If leaks are noted replace water pump ASSY FC INSTALLATION Installation is in the reve...

Page 243: ...d when the valve is fully opened During the test agitate the water for even temperature distribution The measurement should be to the specification Starts to open 76 0 80 0 C 169 176 F Fully opens 91...

Page 244: ...ain ATF into container h_ Clan the nine holes so as not to snill ATF_ 1f11 flicrnnnPrt inlat hn P from watar ninp_ _ 11 C2 014 Fig 23 12 y 111 RPmnvp rarfiatnr unner hracket 1 6 Lower the vehicle 71 n...

Page 245: ...ompletely For more than 5 minutes at 2 000 to 3 000 rpm 5 Stop engine and wait until temperature drops to a safe level 6 Remove radiator cap 7 If coolant level drops in radiator add coolant to filler...

Page 246: ...an r Radiator main fan C2 015 Fig 26 6 Remove fan motor from shroud B INSTALLATION Installation is in the reverse order of removal proce dures Observe the following 1 Before installing radiator fan mo...

Page 247: ...ging brake Adjust o Improper transmission oil Replace p Defective thermostat Replace q Malfunction of radiator fan Inspect radiator fan relay water temperature sensor or motor and replace there O li a...

Page 248: ...and installation of the Airbag system can lead to personal injury caused by uninten tional activation of the Airbag system All Airbag system electrical wiring harnesses and connectors are covered with...

Page 249: ...the quantity of air required for one cycle of operation In actual operation the injection quantity is determined by the duration of an electric pulse applied to the fuel injector and this permits sim...

Page 250: ...ontrol cable 19 Air flow sensor 20 Fuel filter 21 Fuel pump 22 Induction valve diaphragm 23 Induction control valve 24 PCV valve 25 One way valve 26 Vacuum tank 27 Induction control solenoid valve 28...

Page 251: ...y is sent to the by pass air control solenoid valve which regulates engine idle speed Air cleaner Air flow sensor J Throttle body f Collector chamber J Intake manifold By pass air con trol solenoid J...

Page 252: ...converts the opening of the throttle valve into an electric signal and sends it to the ECU Using this signal the ECU precisely controls the air fuel ratio during acceleration and deceleration as well...

Page 253: ...he fuel pipe and delivered to the respective cylinders fuel filter Fuel is regulated to the optimum pressure Fuel injection timing and the amount of fuel injected is regulated by the ECU F Fuel tank F...

Page 254: ...intake Diaphragm manifold I From Valve fuel injector a To fuel tank B2 284 Fig 6 3 FUEL INJECTOR The MPFI system employs a gallery type side feed type fuel injector The gallery type fuel injector is i...

Page 255: ...e induction control system opens and closes the as the high charging efficiency induction control valve to change the intake air flowrate Pressure vibration in collector 00 1 A A Close en 0 o Op 90 a...

Page 256: ...pressure transmitted to the diaphragm The intake manifold pressure is controlled by opening closing the induction solenoid valve which is deter mined by the ECU according to the engine speed and fuel...

Page 257: ...entration between the inside and outside and the electromotive force generated is large When a lean air fuel mixture is burnt in the cylinder oxygen remains in the exhaust gases even after the catalyt...

Page 258: ...he crank angle position It is designed so that the ECU accurately reads the number of pulses which occur when protrusions provided at the perimeter of the crank sprocket rotating together with the cra...

Page 259: ...ocket is provided with one protrusion As the cam shaft sprocket rotates a half crank sprocket speed cam angle sensor emits a signal to the ECU whenever engine rotates two revolutions The ECU detects t...

Page 260: ...I t i l Water temperature sensor Detects coolant temperature npu s gna Knock sensor 1 Knock sensor 2 Detects engine knocking for all cylinders Vehicle speed sensor Detects vehicle speed Atmospheric pr...

Page 261: ...ensor 2 I I 1 I t I I am angle I I I I I I I I I sensor I I I I I I 5 Air intake timing Intake valve I Open timing I Fuel 1 1 5 injection Ti C2 175 Fig 21 The amount of fuel injected by the injector v...

Page 262: ...of fuel injection so that the air fuel ratio meets the requirements of varying engine operations These correction coefficients are classified as follows 1 Air fuel ratio coefficient Allotted to provi...

Page 263: ...t is judged as a rich mixture In other words when the air fuel ratio is richer than the theoretical air fuel ratio t nt c t c E d t of c U C Variation in throttle valve position Acceleration increment...

Page 264: ...r flow sensor In Subaru engines however an air fuel ratio learning control system constantly memorizes the amount of correction required in relation to the basic amount of fuel to be injected the basi...

Page 265: ...ils are directly and another on the right cylinder block thus ensuring mounted to the spark plugs of the respective cylinders accurate digital engine knock control IG switch _ ECU I I r Crank angle I...

Page 266: ...h is judged at BTDC 100 40 i I t 6 I 700 i 10 130 I i i j 3 2 5 lin n AIA AMAAWnnn I I I I I Zone 1 I I I I I I I I I I I I I I Zone 2 I I I I I I I I I Zone 3 I I I Zone 4 I I I I I I I I I I I I 4 C...

Page 267: ...hibitor switch etc When coolant temperature is cold the amount of by pass air is controlled by auxiliary air control valve and by pass air control solenoid valve When coolant tem perature is hot it is...

Page 268: ...d valve based on the signals sent from the water temperature sensor OZ sensors 1 and 2 crank angle sensor 1 etc Refer to C 2 1 Section 8 Intake manifold pressure line Exhaust gas line C2 053 Fig 32 7...

Page 269: ...0 HI HI 0 X HI HI 0 HI HI X OFF OFF X X 0 LO LO 0 X OFF OFF 0 11 MD MD 0 Signal ON X signal OFF 9 ENGINE TORQUE CONTROL In order to reduce gear shift shocks and protect trans mission gears engine torq...

Page 270: ...belt 9 Diagnosis of SRS 10 Ground C2 180 Fig 33 Mode Engine Read memory Test mode terminal terminal U check Ignition ON DISCONNECT DISCONNECT Read memory Ignition ON CONNECT DISCONNECT D check Ignitio...

Page 271: ...h ON ON Read memory 0 X Ignition switch ON Engine OFF Trouble code memory Engine ON ON D check X 0 Engine ON Trouble code Clear memory 0 0 Engine ON Trouble code When the engine operates at a speed gr...

Page 272: ...el cut in relation engine speed vehicle speed and throt noid valve Abnormal signal produced in monitor circuit tle sensor position 28 Knock sensor 2 LH Abnormal voltage produced in knock sensor mon Se...

Page 273: ...er 2 EGR pipe cover 3 EGR valve 4 Gasket 5 Recirulation gas temperature sensor 6 Collector 7 Gasket A RH 8 Intake manifold R H 9 Gasket A LH 10 Fuel injector 11 O ring A 12 O ring B 13 Fuel pipe 14 Wa...

Page 274: ...FUEL INJECTION SYSTEM C2001 2 7 2 Air Intake Boot and Throttle Body iu cm ssion nose nn 11 Auxiliary air control valve Fig 35 C2 182 27...

Page 275: ...2 7 C300 FUEL INJECTION SYSTEM 3 Air Cleaner 1 Air flow sensor 2 Air cleaner upper cover 3 Air cleaner element 4 Air cleaner under cover 5 Clip 6 Bracket 7 Resonator CP Fig 36 C2 183 28...

Page 276: ...MPFI related part is a precision part Do not drop them 6 Observe the following cautions when installing a radio in MPFI equipped models a The antenna must be kept as far apart as possible from the co...

Page 277: ...2 7 IT400 FUEL INJECTION SYSTEM 4 Electric Unit Location 1 SENSOR AND SOLENOID VALVE Fig 37 C2 392 30 solenoid valve solenoid valve...

Page 278: ...Is r I Engine ground l Power steering switch O2 sensor 2 I OJ Knock sensor 1 71 Knock sensor 2 r OO I I I Cam angle sensor I t _ i II 1 1 I h 1 Air flow sensor i d I 1 I _ I I I s1 1 I _ Crank angle I...

Page 279: ...upplemental Restraint System Airbag Airbag system wiring harness is routed near the MPFI control unit ECU main relay and fuel pump relay C2 397 a All Airbag system wiring harness and connectors are co...

Page 280: ...de designated CLEAR MEMORY MODE When more than one trouble code is outputted begin troubleshooting with the smallest trouble code number and proceed to the next higher code After correcting each probl...

Page 281: ...28 Knock sensor 2 LH Abnormal voltage in knock sensor monitor circuit 29 Crank angle sensor 2 No signal from crank angle sensor 2 but two signals from crank angle sensor 1 31 Throttle sensor Abnormal...

Page 282: ...ong segment 1 2 sec on indicates a ten and the short segment 0 2 sec on signifies one Example When only one part has failed Flashing code 12 unit second 0 7 0 11 IN 240 2 1 2 1 1 2 81 0 3 0 3 me When...

Page 283: ...heck if CHECK ENGINE light lights up NO Inspect control unit power supply and ground line and CHECK ENGINE nlight line YES Trouble code is indicated Confirm trouble code Disconnect read memory termina...

Page 284: ...n code NO YES Check if specification code coincides with vehicle specifi NO Inspect vehicle identification line cations Repair harness or connector YES Drive at speed greater than 11 km h 7 mph for at...

Page 285: ...sec onds Release accelerator pedal completely Start engine CHECK ENGINE light blinks to indicate vehicle specifica tion code O YES Drive at speed greater than 11 km h 7 mph for at least one minutes W...

Page 286: ...12 By pass air control ISC Duty ratio on by pass air control system F13 OZ sensor 1 RH signal 02R V Voltage from OZ sensor 1 RH F14 02 sensor 2 LH signal 02L V Voltage from OZ sensor 2 LH F15 Oz Max R...

Page 287: ...ion UD 4 Read memory position RM FA1 5 6 7 Engine torque control TR 8 Parking position switch PK 9 49 states and Canada California discrimination FC 10 1 2 3 Radiator sub fan R2 4 Radiator main fan R1...

Page 288: ...8 1 2 GND B60 6 0 0 Vcc B60 3 5 5 Throttle sensor Signal B60 2 GND B60 1 0 0 1 0 Signal B59 6 0 6 1 2 sensor Sealed B59 17 0 0 Signal B59 5 0 6 1 Oz sensor 2 Sealed B59 17 0 0 Signal B61 5 2 4 2 4 Kno...

Page 289: ...ge control B62 6 ON 0 OFF 10 13 ON 0 OFF 10 13 EGR control B62 22 ON 0 OFF 10 13 ON 0 OFF 10 13 Recirculation gas tempera ture sensor B59 4 Engine torque control B59 20 ON 0 OFF 5 Inertia Resonance su...

Page 290: ...ot OK Inspection of ECU power supply and ground line 11 Repair power supply or ground line OK Not OK Inspection of ignition control system Repair ignition control system OK Not OK Inspection of fuel p...

Page 291: ...OK 3 I Check power supply circuit of ECU 1 Repair or replace harness connector OK 4 Check ground circuit of ECU Not OK Repair or replace harness connector OK Check ignition control system Not OK a 35...

Page 292: ...1352 No 4 Body 10 V min 1352 No 5 Body 10 V min 1352 1 2 5 6 V 0 p00 0 C2 326 Fig 43 4 Turn ignition switch to OFF and connect connec tor 1333 3 CHECK POWER SUPPLY CIRCUIT OF ECU 1 Disconnect ECU conn...

Page 293: ...lace harness connector and ignitor OK Not OK 3 Check ignitor output signal Replace ignitor OK 4 Check harness connector between ignitor Not OK ir or replace between connector Repair ignition coil OK N...

Page 294: ...FUEL INJECTION SYSTEM ITSCol 2 7 a 859 ECU Va Main relay 0 0 d 862 II I I N Diode a IG SW 5 6 YYV Y c r 3 4 i uxr i I 2 t II Iqnition coil II C2 329 Fig 46 47...

Page 295: ...V min 2 1311 No 2 Body 5 V min 3 1311 No 3 Body 5 V min 4 1311 No 4 Body 5 V min 5 1311 No 5 Body 5 V min 6 1311 No 6 Body 5 V min 4 CHECK HARNESS CONNECTOR BETWEEN IG NITOR AND EACH IGNITION COIL 1...

Page 296: ...eplace harness connector Not OK Repair or replace harness connector 5 I Check harness connector between ECU Not OK and fuel pump relay OK Not OK Check contact of ECU connector terminal OK Replace ECU...

Page 297: ...T8D0j FUEL INJECTION SYSTEM C B61 d B62 ECU Fuel pump relay Fuel pump o M V R23 I B51 No 16 15A 58F 4 o IG SW SBF 2 R19 R2 WO O R33 R34 H H 1 1 D vv E _ Ilus E Fuel pump modulator Resistor C2 333 Fig...

Page 298: ...CU 1 Turn ignition switch to ON 2 Measure voltage between ECU connector 1347 and body Connector r Terminal Specified voltage 1362 No 23 Body 10 V min 3 Measure voltage at same terminal while cranking...

Page 299: ...ss connector OK Not OK 3 Check fuel injector Replace fuel injector OK 4 Check signal on ECU Not OK Repair or replace harness connector between ECU and fuel injector OK Not OK 5 Check ground circuit of...

Page 300: ...y 10 V min 5 E7 No 2 Body 10 V min 6 E10 No 2 Body 10 V min Fig 53 3 CHECK FUEL INJECTOR Measure resistance between connector terminals of each fuel injector Specified resistance 11 12 f2 4 CHECK SIGN...

Page 301: ...ignition 0 Failure of engine start switch is turned ON OK Not OK 1 1 Check input signal for ECU Check contact of ECU connector terminal OK Replace ECU Repair ECU connector and terminal Not OK 2 I Chec...

Page 302: ...ENSOR 1 1 Turn ignition switch to OFF 2 Remove alternator 3 Disconnect connector from ECU and crank angle sensor 1 4 Measure resistance of harness connector between ECU and crank angle sensor 1 Connec...

Page 303: ...ck inhibitor switch OK Not OK 3 Check starter ASSY OK Repair or replace harness connector of starter power supply Repair security system except Canada model Refer to C 6 2 Replace starter ASSY OK Repa...

Page 304: ...FUEL INJECTION SYSTEM T9Bo 2 7 InhibItor switch P N 0 B61 T1 ECU B73 ST SBF 4 O I G O o O OFF ACC Starter ASSY U U C2 342 Fig 58 57...

Page 305: ...ig oy 3 CHECK STARTER ASSY 1 Remove starter ASSY 1 Turn ignition switch to OFF 2 Remove battery ground terminal 3 Lift up the vehicle and remove nut which installs lower side of starter 4 Lower the ve...

Page 306: ...act of ECLI connector terminal r OK Replace ECU Repair ECU connector and terminal 1111 Not OK Not OK 2 Check harness connector between ECU Repair or replace harness connector and cam angle sensor OK N...

Page 307: ...y 1 Mfg min 1359 No 9 Body 1 Mfg min Fig 63 C2 409 Fig 62 Using voltage meter Check if voltage varies synchronously with engine revolution when cranking while monitoring voltage between ECU connector...

Page 308: ...of each fuel injector 01 Check fuel pressure Not OK Not OK 2 Check voltage of power supply for injector 11 Repair or replace harness connector OK Not OK 3 Check fuel injector Replace fuel injector OK...

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Page 310: ...2 No 12 Body 10 V min 3 E62 No 11 Body 10 V min 4 E62 No 26 Body 10 V min 5 E59 No 1 Body 10 V min 6 E59 No 12 Body 10 V min Connector fr Terminal Specified voltage 1 E5 No 2 Body 10 V min 2 E8 No 2 B...

Page 311: ...eous idling Poor driving performance Not OK 1 Check water temperature sensor 1 Replace water temperature sensor I I F OK Not OK 2l Check harness connector between ECU and wa ter temperature sensor 00...

Page 312: ...tor terminals Terminal Specified resistance No 1 No 2 20 30 kit 20 C 68 F No 1 No 2 0 3 0 4 kit 80 C 176 F E24 U I U U l i Water temperature sensor I 1 I C2 351 Fig 68 2 CHECK HARNESS CONNECTOR BETWEE...

Page 313: ...ROUBLE SYMPTOM Poor driving performance I Check contact of ECU connector terminal OK Replace ECU Repair ECU connector and terminal Not OK Replace knock sensor 1 2 Check knock sensor 1 I OK Repair or r...

Page 314: ...d body Connector Terminal Specified voltage 1356 No 5 Body 2 3 V 2 CHECK KNOCK SENSOR 1 1 Remove collector 2 Disconnect connector from knock sensor 1 3 Measure resistance between knock sensor 1 con ne...

Page 315: ...UBLE SYMPTOM Engine stall Erroneous idling Poor driving performance Check contact of ECU connector terminal OK Replace ECU Repair ECU connector and terminal Not OK Not OK 2 Check harness connector bet...

Page 316: ...ine idling Connector r Terminal Specified voltage 1360 No 11 Body 13 14 V 1360 No 5 Body 0 8 1 2 V 1360 No 6 Body 0 0 V 2 CHECK HARNESS CONNECTOR BETWEEN ECU AND AIR FLOW SENSOR 1 Turn ignition switch...

Page 317: ...ge of power supply for ECU OK Not OK 4 Check input signal from by pass air con trol solenoid valve 2 Check harness connector between ECU and main relay OK 3 1 Check power supply circuit of main relay...

Page 318: ...FUEL INJECTION SYSTEM TSHo 2 7 Main relay O 0 r__0 0 1 862 E _ v w o SBF 2 ECU CLOSE OPEN y U 31z E15 B5 fl By pass air control solenoid va I ve C2 357 Fig 73 71...

Page 319: ...ntrol solenoid valve 4 Measure resistance of harness connector between ECU and solenoid valve Connector fr Terminal Specified resistance 1362 No 2 E15 No 3 0 f2 1362 No 1 E15 No 1 0 f2 Connector Termi...

Page 320: ...al signal is entered from knock sensor 2 a Poor driving performance OK Not OK Check contact of ECU connector terminal OK Replace ECU Repair ECU connector and terminal Not OK Replace knock sensor 2 2 C...

Page 321: ...Connector r Terminal Specified voltage B61 No 6 Body 3 4 V 2 CHECK KNOCK SENSOR 2 1 Remove collector 2 Disconnect connector from knock sensor 2 3 Measure resistance between knock sensor 2 con nector t...

Page 322: ...nputs to ECU more than 12 times OK 11 Not OK 10 1 Check connector of ECU connector OK Replace ECU Repair ECU connector Not OK 2 Check harness connector between ECU Repair or replace harness connector...

Page 323: ...2 Remove alternator 3 Disconnect connector from ECU and crank angle sensor 2 4 Measure resistance of harness connector between ECU and crank angle sensor 2 Connector r Terminal Specified resistance 13...

Page 324: ...ngine stall Poor driving performance Not OK 1 Check throttle sensor b Replace throttle body OK 2 I Check harness connector between ECU and Not OK Repair or replace harness connector throttle sensor OK...

Page 325: ...1 r C3 087 Fig 83 Connector r Term inaUSpecified resistance 1360 No 3 E11 No 2 0 f2 1360 No 2 E11 No 1 0 f2 1360 No 1 E11 No 3 0 i2 2 Measure resistance of harness connector between throttle sensor c...

Page 326: ...or Not OK Not OK Replace 0 sensor 1 2 Check Oz sensor 1 OK 3 Check harness connector between ECU Not OK Repair or replace harness connector and OZ sensor 1 OK 4 Check harness connector between main No...

Page 327: ...CU connectors 3 Measure resistance of harness connector between ECU and OZ sensor 1 Connector r Terminal Specified resistance 1359 No 6 E8 No 4 0 S2 3 Measure resistance between OZ sensor 1 connector...

Page 328: ...round line for vehicle speed sensor 2 TROUBLE SYMPTOM Poor driving performance Repair or replace power supply and or ground circuit OK 2 Check power supply and ground line of I ECU It OK Check contact...

Page 329: ...2 7 TWO FUEL INJECTION SYSTEM 860 No 15 SBF 4 ECU ICA IG SW 45A 89 vla J1 1 L 77 Vehicle speed sensor2 C2 365 Fig 86 82...

Page 330: ...gnition switch to OFF 2 Disconnect 139 connector from vehicle speed sen sor 2 3 Measure resistance of harness connector between ECU and vehicle speed sensor 2 Connector r Terminal Specified resistance...

Page 331: ...onnector between ECU and main relay OK Not OK 3 1 Check power supply circuit of main relay OK Replace main relay Repair or replace harness connector of main relay power supply circuit 5 Check harness...

Page 332: ...FUEL INJECTION SYSTEM TSrvoj 2 7 Main relay 0 0 B62 E MN N 4 7 1 BS2 SBF 2 ECU T 22 U E16 _ ALAr kf i EGR solenoid valve C2 367 Fig 89 85...

Page 333: ...ch to ON 2 Measure voltage between main relay connector and body Connector Terminal Specified voltage 1352 No 1 Body 10 V min 1352 No 2 Body 10 V min 4 CHECK INPUT SIGNAL FROM EGR SOLENOID VALVE 1 Tur...

Page 334: ...r between ECU and main relay 3 1 Check power supply circuit of main relay OK OK Replace main relay Repair or replace harness connector of main relay power supply circuit 5 I Check harness connector be...

Page 335: ...2 7 TSOO1 FUEL INJECTION SYSTEM Main relay 0 r O 0 7 B62 4 E N B52 SBF 2 ECU 0 E14 Rurge control eolenoid valve C2 369 Fig 91 88...

Page 336: ...in relay connector and body Connector Fr Terminal Specified voltage 1352 No 1 Body 10 V min 1352 No 2 Body 10 V min 4 CHECK INPUT SIGNAL FROM PURGE CON TROL SOLENOID VALVE 1 Turn ignition switch to ON...

Page 337: ...minal Not OK Not OK Replace 02 sensor 2 2 Check Oz sensor 2 OK 3 Check harness connector between ECU Not OK Repair or replace harness connector and OZ sensor 2 OK 4 Check harness connector between mai...

Page 338: ...onnectors 3 Measure resistance of harness connector between ECU and Oz sensor 2 Connector r Terminal Specified resistance 1361 No 5 1316 No 4 0 C1 3 Measure resistance between 02 sensor 2 connector an...

Page 339: ...r ECU from TCU I Check contact of ECU connector terminal OK Replace ECU Repair ECU connector Not OK Not OK 2 Check harness connector between ECU Repair or replace harness connector and TCU r OK Not OK...

Page 340: ...erminal and body Connector r Terminal Specified voltage 1359 No 50 Body 5 V min 2 CHECK HARNESS CONNECTOR BETWEEN ECU AND TCU 1 Turn ignition switch to OFF 2 Disconnect connectors from ECU and TCU 3 M...

Page 341: ...sensor Not OK Check harness connector I Replace air flow sensor OK Not OK 3 Check water temperature sensor 0 Replace water temperature sensor OK Not OK 4 Check throttle sensor 0 Replace throttle body...

Page 342: ...so 2 7 S TROUBLE CODE 45 ATMOSPHERIC PRESSURE SENSOR DIAGNOSIS Faulty atmospheric pressure sensor inside ECU When trouble code 45 appears on display replace ECU TROUBLE SYMPTOM Erroneous idling Failur...

Page 343: ...input signal for ECU OK TROUBLE SYMPTOM Erroneous idling Check contact of ECU connector terminal r OK Replace ECU Repair ECU connector Not OK Not OK 2 Check inhibitor switch 0 Replace inhibitor switch...

Page 344: ...pecified voltage 1360 No 10 Body 0 V N Range 1360 No 10 Body 8 V min Other range 2 CHECK INHIBITOR SWITCH 1 Turn ignition switch to OFF 2 Disconnect bulkhead harness connector 1313 3 Measure resistanc...

Page 345: ...eous idling Poor warm up performance with select lever in P position OK Not OK 10 1 Check contact of ECU connector terminal OK Replace ECU Repair ECU connector Not OK Replace inhibitor switch 2 I Chec...

Page 346: ...d voltage 1359 No 9 Body 0 V P Range 1359 No 9 Body 8 V min Other range 2 CHECK INHIBITOR SWITCH 1 Turn ignition switch to OFF 2 Disconnect bulkhead harness connector 1313 3 Measure resistance between...

Page 347: ...nnector terminal OK Replace ECU Repair ECU connector Not OK Not OK 2 I Check harness connector between ECU Replace or replace harness connector and recirculation gas temperature sensor F OK Replace re...

Page 348: ...SENSOR 1 Turn ignition switch to OFF 2 Disconnect recirculation gas temperature sensor connector 3 Measure resistance of harness connector between gas temperature sensor and ECU Connector r Terminal...

Page 349: ...OUBLE CODE 56 EGR SYSTEM DIAGNOSIS Mechanical trouble for EGR valve EGR vacuum control ler and or EGR line EGR valve may be stuck OPEN or CLOSE Refer to C 2 1 EGR system TROUBLE SYMPTOM Poor driving p...

Page 350: ...e of select monitor No 498347500 Problem occurs No trouble codes appear in Read Memory U Check or D check mode Measure each item in I mode select monitor function 1 Refer to General Troubleshooting Ta...

Page 351: ...1Battery 2 ICharging system SPECIFIED DATA 1 10 to 12V 2 12 to 14V Check battery voltage and electrolyte s specific grav ity Check regulating voltage On no load Check alternator D MODE F02 F03 Vehicle...

Page 352: ...194 degF F06 80 to 90 degC Probable cause Item outside specified data 1 Water temperature sensor Check water temperature sensor Refer to T7F0 a F05 Water temperature is indicated in degF b F06 Water t...

Page 353: ...ter warm up 15 to 25 e Probable cause Item outside specified data 1 Air flow sensor Check MODE F08 2 I Engine speed Check MODE F04 r 3 Crank angle sensor 1 Check crank angle sensor 1 Refer to T7A0 J M...

Page 354: ...E F14 OK 5 Vehicle speed signal Check MODE F02 or MODE F03 OK 6 Air flow signal Check MODE F08 OK 7 By pass air control Check MODE F12 1 8 1 Battery voltage L MODE F12 By pass air control ISC CONDITIO...

Page 355: ...17 02 Max 02 Rmax 02 Lmax CONDITION Idling after warm up Probable cause Item outside specified data 1 I Injector pulse width SPECIFIED DATA 0 8 to 0 9 V I Check MODE F11 I OK 2 102 sensor 1 or 2 OK Ch...

Page 356: ...arm up 10 to 10 deg Engine speed low to high Probable cause Item outside specified data 1 Knock sensor 1 and or 2 Check knock sensor 1 and or 2 Refer to T7F0 T710 CONDITION SPECIFIED DATA Idling after...

Page 357: ...9 Power steering switch PS 10 IG AC ID AP NT PS C2 377 Fig 102 U MODE FA1 ON H OFF SIGNAL Description Requirement for LED ON LED No Signal name Presentation 3 DIAG terminal is connected into the test...

Page 358: ...e IH 10 R2 R1 FP ER IH C2 379 Requirement for LED ON 3 Radiator sub fan is in operation 4 Radiator main fan is in operation 6 Fuel pump is in normal operation 7 EGR solenoid valve is in operation 9 In...

Page 359: ...6 7 8 9 10 II C2 381 Requirement for LED ON 4 Fuel pump relay is in operation Y MODE FA5 ON H OFF SIGNAL Description LED No Signal name Presentation 1 2 3 4 5 Oz monitor RH OR 6 7 8 9 10 Oz monitor L...

Page 360: ...SPECIFICATIONS AND SERVICE DATA 8 C COMPONENT PARTS 9 1 Fuel Tank 9 2 Fuel Lines 10 W SERVICE PROCEDURE 11 1 Precautions 11 2 On Car Service 11 3 Fuel Tank 12 4 Fuel Filler Pipe 14 5 Fuel Filter 15 6...

Page 361: ...el cut valve roll over tank to the intake manifold and consists of a pump filter valve which is equipped with a two way valve canister and fuel pump and fuel filter And the jet pump is used to pre pur...

Page 362: ...one made of metal and in addition will never become rusty The fuel tank has two chambers and is provided with a suction jet pump which transfers fuel from one chamber to another M2001 2 8 The fuel tan...

Page 363: ...groove by centrifugal force During the time fuel flows from one groove to the next a pressure differential is produced by friction of the flow 3 Thus fuel pressure increases while the action is descr...

Page 364: ...sure allows fuel to be sucked up The jet pump utilizes the velocity of fuel returning from the engine to produce negative pressure inside the jet pump Fuel return Engine Fuel return I Jet pump Pump o...

Page 365: ...The fuel filter utilizes a pressure withstanding cartridge design It has a filter element built into the metal case With this design fuel flows from the perimeter of the element to the interior of the...

Page 366: ...FUEL SYSTEM nnsool 2 8 6 Roll Over Valve The roll over valve is for prevention of fuel leakage in the event of the vehicle rolling over Fig 6 7...

Page 367: ...apacity 70 C 18 5 US gal 15 4 Imp gal Fuel tank Location Under rear seat Type Impeller Fuel pump Discharge pressure 250 1 kPa 2 55 kg cm2 36 3 psi Discharge flow More than 140 2 37 0 US gal 30 8 Imp g...

Page 368: ...Evaporation hose 4 Fuel hose ASSY 5 Fuel tank cap holder 6 Fuel tank cap 7 Fuel cut valve 8 Cap rubber 9 Fuel tank harnness 10 Fuel filler duct 11 Fuel tank 12 Fuel pump ASSY 13 Bracket holder 14 Fuel...

Page 369: ...ap king king I filler pipe 5 Air vent hose A 6 Air vent pipe Protector 8 Air vent hose B Check valve _ Canister 11 Canister bracket 12 Fuel delivery pipe 13 Fuel return pipe 14 Evaporation pipe 15 Fue...

Page 370: ...Car Service A MEASUREMENT OF FUEL PRESSURE 1 Release fuel pressure Refer to Section 1 W1A0 2 Connect fuel pump connector 3 Install fuel pressure gauge 1 Disconnect fuel hose from fuel filter 2 Connec...

Page 371: ...ool Special tool REPLACER 42911PA000 3 Drain fuel from tank 4 Install fuel tank cap 5 Disconnect fuel tank connector r C2 032 Fig 12 6 Lift up the vehicle 7 Remove rear exhaust pipe and muffler ASSY a...

Page 372: ...L12 L Fuel return line L 20 25 mm 0 79 0 98 in Evaporation line L 15 20 mm 0 59 0 79 in B2 259 Fig 18 Fitting Clamp Hose 1 4 0 04 0 16 When fitting length is specified 20 25 0 79 0 98 1 4 0 04 0 16 I...

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Page 376: ...e from fuel or foreign particles before installation Wipe mounting holes packing etc with a cloth 3 When installing fuel tank cap use special tool Special tool REPLACER 42911 PA000 7 Fuel Meter Unit A...

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Page 380: ...ked fuel separator Replace separator 4 Inoperated fuel pump modulator or this circuit Replace Refer to C 2 1 M10C0 4 Defective fuel meter indicator 1 Defective operation of fuel meter unit Replace 2 D...

Page 381: ...UBARU SVX 1992 2 9 Page C COMPONENT PARTS 2 1 Exhaust System 2 W SERVICE PROCEDURE 3 1 Exhaust System 3 2 Exhaust Manifold 4 3 Front Exhaust Pipe 5 4 Rear Catalytic Converter 7 5 Rear Exhaust Pipe 8 6...

Page 382: ...Gasket Oxygen sensor Front exhaust pipe ASSY LH Front exhaust pipe ASSY RH Hanger bracket 14 Nut 15 Gasket 16 Spring 17 Bolt 18 Rear catalytic converter 19 Protector 20 Gasket 21 Rear exhaust pipe han...

Page 383: ...e sure clearances between parts and car body are larger than specified values 2 If any clearance is not loosen all connections 3 Adjust where necessary to obtain proper clearance 4 Tighten all connect...

Page 384: ...ss 2 Remove front under cover 3 Remove exhaust manifold covers 4 Remove front exhaust pipes Ref to 3 Front Exhaust Pipe W3A0 5 Disconnect EGR pipe from exhaust manifold RH i EGR pipe c o D 1 j I o I n...

Page 385: ...e 1 Disconnect oxygen sensor harness 2 Remove front under cover 3 Remove exhaust manifold covers 4 Remove rear catalytic converter protector 5 Remove nuts which connect front exhaust pipe to exhaust m...

Page 386: ...aust Pipe I B INSTALLATION 1 Insert rear exhaust pipe bracket into rubber cushion To facilitate insertion apply a coat of SUBARU CRC5 56 004301003 to the mating area of rubber cushion in advance 2 Loo...

Page 387: ...m front ex haust pipes 3 Disconnect rear catalytic converter from rear ex haust pipe 4 Remove rear catalytic converter B INSTALLATION Installation is in the reverse order of removal proce dures Observ...

Page 388: ...ng bband and C2 406 Fig 11 4 Remove rear exhaust pipe from rubber cushion To facilitate its removal apply a coat of SUBARU CRC5 56 004301003 in advance B INSTALLATION 1 Insert rear exhaust pipe bracke...

Page 389: ...e Muffler C2 134 Fig 12 4 Connect rear exhaust pipe to rear catalytic converter Be sure to install bolts springs and self locking nuts in the order Ref to 4 Rear Catalytic Converter W4B0 Always instal...

Page 390: ...e muffler ASSY from rubber cushions To facilitate their removal apply a coat of SUBARU CRC5 56 004301003 to them in advance 4 Remove tail pipe cutters from muffler ASSY FB INSTALLATION 1 Instsll tail...

Page 391: ...EXHAUST SYSTEM w6Boj 2 9 Seal bearing band Rear exhaust Seal bearing pipe Muffler C2 134 Fig 15 11...

Page 392: ...Torque Converter 4 3 Lock up Control System 5 4 Oil Pump 7 5 Planetary Gear 9 6 Reverse Clutch 10 7 High Clutch 11 8 Band Brake 12 9 One way Clutch 13 10 Low r Reverse Brake 14 11 Forward Clutch Over...

Page 393: ...lic pres sure controlling duty solenoid Features 1 Two one way clutches and four accumulators are used to reduce gear shift shock and gear select shock and a fully electronic control from 1st to 4th s...

Page 394: ...n section section High clutch Front planetary gear Rear planetary gear Forward clutch r One way clutch 3 4 E7 F 1 00 0 00 00 00 1 Oil pan Control valve Automatic transmission section Overrunning clutc...

Page 395: ...changed by the stator so that the oil will assist impeller rotation b in Fig 2 With this action the torque is multiplied The stator is subject to reverse torque when it changes the direction of oil fl...

Page 396: ...ine rpm reaches a certain level This direct coupling elimi nates torque converter slip and thus leads to a reduc tion in engine rpm which in turn results in less fuel consumption and less noise The si...

Page 397: ...hen forced against the impeller cover and turned as an integral unit with the cover Thus power from the engine is directly transmitted to the transmission input shaft That is the transmission is direc...

Page 398: ...in the Figure 2 The ATF sucked into section A rotates in the direc tion of the arrow driven directly by engine and is compressed at the delivery side of section B It is then discharged 3 The discharg...

Page 399: ...e Line pressure Rev clutch pressure j Feedback pressure X Pressure Vane ring regulator valve I To torque counverter t k rag valve Pressure Fulcrum modifier pressure Drain O Return spring C O v O O Ret...

Page 400: ...ier 101 B3 454 Fig 9 The automatic transmission uses a planetary gear sys tem instead of the parallel shaft two shafts gear sys tem adopted in the manual transmission The advantage of the planetary ge...

Page 401: ...ng 11 Drive plate 5 Spring 12 Retaining plate 6 Spring 13 Snap ring 7 Spring retainer 14 High clutch drum B3 455 Fig 10 B FUNCTION DURING OPERATION Hydraulic pressure is applied to the reverse clutch...

Page 402: ...ch piston while the drum rotates idle It thus avoids build up of residual pressure in the clutch drum and a resultant half engaged clutch which may otherwise be caused by centrifugal oil pressure C3 0...

Page 403: ...nd band servo piston O D are forced down ward by the return spring as shown in A of the Figure When hydraulic pressure 2A is applied to the servo chamber II it causes the band servo piston to come int...

Page 404: ...9 One way Clutch A CONSTRUCTION The one way clutch O W C is a Sprague type Two clutches are used One is mounted between the one way clutch outer race and the rear internal gear ASSY The other is loca...

Page 405: ...er race of the transmis sion case engagement surface Snap ring Retaining plate Transmission case Lip seal Dish plate Piston Bolt Lathe cut seal ring Clutch spring retainer Forward clutch drum Driven p...

Page 406: ...ed to the pressure chamber I from the hydraulic pressure controller dur ing forward operation in the D 3 2 range and 1st range the forward clutch piston forces the overrun ning clutch piston This caus...

Page 407: ...nd is spline fitted to the torque fitted inside the shaft by a roll pin The torque converter converter turbine hub The rear end is spline fitted to side of the shaft becomes the drain circuit for the...

Page 408: ...shaft propeller shaft rear differential rear wheel Shim Oil pump housing Lock washer rTransmission case Bolt Reduction driven rr Oil seal retainer gear Collar Drive pinion Lock nut shaft O ring Lock...

Page 409: ...a Converter case Speedometer shaft Oil seal Snap ring Washer Speedometer driven gear Speedometer drive gear 83 471 Fig 24 Fig 26 The differential bevel gear is locked to the axle shaft by The speedom...

Page 410: ...l shaft The manual plate is fan shaped and is provided with seven grooves on its edge corresponding to shift ranges from P to 1 A detent spring roller fits into the groove corresponding to the range s...

Page 411: ...actuator The parking pawl turns in the direction of the parking gear using the parking pawl shaft as a pivot It then engages with the parking gear groove If the end of the parking pawl rides over the...

Page 412: ...or a variety of driving conditions When actual driving conditions vehicle speed throttle opening gear range wheel slip etc are detected by various sensors the control unit selects a duty ratio most su...

Page 413: ...to the drive plates and driven plates is controlled by applying oil pressure to the transfer piston from the transfer oil pressure control device including the duty solenoid Also the transfer clutch d...

Page 414: ...f the transmission case to the rear of the case It is then delivered to the oil pressure circuit provided in the plane on which the transfer valve body is mounted This line pressure is reduced to a fi...

Page 415: ...2 9 CNN rnnmm nwnnn a nnnnnl mm nnn Il 1 Pressure regulator valve 2 Pressure regulator plug 3 Pressure regulator sleeve plug 1 4 Pressure modifier valve 5 Manual valve 6 Pilot valve 0 n 7 Accumulator...

Page 416: ...O O O O O 42 sequence valve Shift valve B 42 relay valve Shift valve A O v 0 0 O O O Overrunning clutch control valve O O O O Overrunning clutch j O reducing valve 00 OO OO O O 0 O Shuttle shift valve...

Page 417: ...ine pressure Duty solenoid B lock up and an ATF temperature sensor ATF temperetur solenoid a lock up B3 480 Fig 35 4 RELATED PARTS 2 Solenoid ASSY Solenoid 2 shift Duty solenoid A Solenoid 1 shift lin...

Page 418: ...c circuit 1 Oil cooler outlet pipe Cooling line from control valve to oil cooler inside radiator 2 Transfer control pipe Line pressure supply line to transfer control valve 3 Reverse clutch pressure p...

Page 419: ...0 N D 0 3 0 2 0 0 1 0 0 0 Line pressure P RN D321 T _ 1 t L J J 1 B3 484 Fig 39 When the valve is set in the line pressure no delivery position the pressure is relieved Simultaneously changes three d...

Page 420: ...e retards 3 2 timing valve the release of band servo pressure and creates a temporary neutral condition so that vehi cle speed can be changed smoothly 1st Reducing valve Reduces the low reverse brake...

Page 421: ...B High C FWD C ow OVR C RoV B OWC 1 2 O O O O I 1ST O O O 2ND O O O O D 3RD O O O 4TH O O O 1ST O O O 2NDD O O O 3D o 0 0 O _at 4TH O O O K r 1ST O O O O O 2 2ND O O O O t1 3 D O O O O 4TH 1 O O O 1S...

Page 422: ...Front planetary carrier Rear planetary carrier FI RI Front internal gear Rear internal gear B3 486 Fig 41 1st 2nd 3rd 4th Rev Input member RS RS RS FC RI RS FC RS FS member FI RC FI RC FI RC FI RC FI...

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Page 425: ...I I Low reverse brake I r Low one way clutch 1 2 From engine 1l i 1 To propeller shaft Front differential Rear drive shaft To front axles L Transfer clutch Drive pinion Front sun gear Parking gear Fro...

Page 426: ...e the one way clutch 1 2 is released and is idling reverse power is not transmit ted and engine braking is not performed Operating condition of parts Power flow in acceleration Forward clutch Applied...

Page 427: ...raking is not provided During deceleration at 2 range the overrunning clutch operates to check idling of the one way clutch 3 4 Reverse power is transmitted to the engine providing engine braking acti...

Page 428: ...ange the overrunning clutch is applied and checks the reverse rotation of the one way clutch 3 4 Thus reverse power is transmitted to the engine and engine brak ing is performed Operating condition of...

Page 429: ...ay clutch reverse power is transmitted to the engine and engine braking is per formed Operating condition of parts Power flow in acceleration High clutch Applied a Input shaft Brake band Contracted l...

Page 430: ...coasting and deceleration low r reverse brake and overrunning clutch are operating so that reverse power is transmitted to the engine and engine brak ing action is provided Operating condition of par...

Page 431: ...ng everse c utc i Front sun gear V Front pinion gear i Front internal gear V Reduction drive shaft i Reduction gear Drive pinion o Transfer clutch 1 l Front differential o Rear differential Front plan...

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Page 445: ...lectronic control 1 O functions Solenoid output ON OFF I INPUT I Shift solenoid 1 I Throttle opening sensor I I I ON OFF I Two solenoid are combined I for 1st to 4th speeds Shift solenoid 2 I Transmis...

Page 446: ...ntrol transfer clutch torque is controlled to ABS signal eliminate the influence of engine braking and reduce the degree of coupling between front and rear wheels Atmospheric pressure sensor Detects a...

Page 447: ...e is regulated according to throttle opening vehicle speed and range signals Line pressure con Shifting control Line pressure is reduced when shifting to lessen shifting trol shock Starting control Li...

Page 448: ...ed are detected by this throttle sensor output 2 VEHICLE SPEED SENSOR 1 MOUNTED IN SIDE THE TRANSMISSION AWD The vehicle speed sensor output shaft rotation sensor is mounted to the extension case from...

Page 449: ...lever is set to P or N the electrical circuit is connected in the inhibitor switch and the starter circuit is energized for cracking the engine When the selector lever is set to R D 3 2 or 1 range the...

Page 450: ...LINE PRESSURE This solenoid is mounted to the control valve and its duty ratio is controlled by the signal sent from TCU This solenoid then controls the pressure modifier valve and pressure regulator...

Page 451: ...sensor tions ature switch switch switch signal signal pressure Control item switch 1 2 rpm sensor signal 1 Shift control 0 0 O 0 0 1 Ordinary shift control 2 ABS operation con 0 trol 3 Cruise control...

Page 452: ...tch switch switch signal signal pressure Control item switch 1 2 rpm sor signal 6 Shift timing control 0 0 0 1 Shift range control 2 Lock up con 0 0 O trol 3 Overrunning 0 0 0 clutch control 4 Line pr...

Page 453: ...ontrol unit O r I I Ti7 wz 7 m m mg7om I I I H I Duty Shift Shift Solenoid 3 Duty I I I solenoid B solenoid solenoid Over solenoid A I I I Lock uP 1 2 running line I Duty I d C I I L I I clutch pressu...

Page 454: ...noid 1 Solenoid 2 1St 0 0 2nd X 0 3rd X X 4th 0 X 100 1 2 I 2 3 1 3 4 J 3 4 _ i 1 2 i I 2 3 i d I 0 50 y t o I r I i f I I I I 1 I I I I I I I I I I I 1 I I I 0 Low High Vehicle speed C3 038 Fig 58 Wh...

Page 455: ...y w y i r 1 C 1 I i I Solenoid 1 Solenoid 2 I Clutch fluid Sensors Throttle opening Vehicle speed I Vehicle speed I sensor I i Throttle sensor i Shift command Determination of optimum signals gear pos...

Page 456: ...r words high clutch release and brake band application are properly timed by electronic control This eliminates engine rev up under no load or hesitation Servo piston 3rd release chamber High clutch o...

Page 457: ...pressure torque converter reg ulator pressure acts on the lock up clutch disengaging circuit while the engaging circuit communicates with the oil cooler circuit Accordingly the lock up clutch is disen...

Page 458: ...al pressure pressure modifier pressure for regulating the line pressure to an optimum pressure corresponding to the driving conditions 4 This pressure modifier pressure is applied to the pressure regu...

Page 459: ...alve I Drain Line pressure optimally r 1 regulated for clutch operation I Duty solenoid A I __j Line pressure I Pressure regulator valve Throttle pressure also I I serves as a signal to optimally c I...

Page 460: ...rn 100 i 1 I 1 1 100 1 I I I I I _ I I 1 J J 2 3 3 4 75 1 2 2 33 4 75 1 2 j 2 3 3 4 1 2 2 3 3 4 I o j c 50 50 fl d I I o d I i o I I t i F 25 I j I 25 I I I I j I i 0 20 40 60 80 100 120 140 160 180 2...

Page 461: ...is engaged by the shift range and cruise control signals to automatically action of shift solenoid 3 control the operation of the overrunning clutch and for 2 In range 2 the overrunning clutch is enga...

Page 462: ...same as in 1st range immediately after reverse At more than set vehicle speed and fully slip detection closed throttle 4 Control in turns Decreases transfer oil pressure upon 1st thru 4th and detecti...

Page 463: ...eg ulated to a constant pilot pressure by the transfer pilot valve 2 The pilot pressure is regulated to the transfer duty pressure by the duty solenoid C whose duty ratio is controlled by the TCU corr...

Page 464: ...heric pressure sensor The results of self diagnosis are displayed by flashing power indicator lamp 1 Repeated flashing at 4 Hz Error such as battery trouble 2 Repeated flashing at 2 Hz Normal 3 Output...

Page 465: ...or switch or any of the solenoids 1 Vehicle speed sensor A dual speed sensing system is used The speed signal is taken from the transmission output shaft revolution sensor and also from a sensor built...

Page 466: ...2 750 rpm One way clutch Sprague type one way clutch Type 4 forward 1 reverse double row planetary gears Multi plate clutch 4 sets C l l Mufti plate brake 1 set ontro e ement Band brake 1 set One way...

Page 467: ...d and Hydraulic accelerator throttle opening control Fluid Automatic transmission fluid ATF DEXRON II Fluid capacity AWD 9 5 C 10 0 US qt 8 4 Imp qt Lubrication system Forced feed lubrication with oil...

Page 468: ...3 2 SOBO1 AUTOMATIC TRANSMISSION AND DIFFERENTIAL B ADJUSTING PARTS Fig 71 C3 042 94...

Page 469: ...5 0 063 0 071 0 079 play 7 RETAINING PLATE 31567AA000 020 050 4 6 4 8 5 0 5 2 5 4 0 181 0 189 0 197 0 205 0 213 Adjusting clearance of reverse clutch 8 RETAINING PLATE 31567AA190 260 3 6 3 8 4 0 4 2 4...

Page 470: ...3 2 Soco AUT OMATIC TRANSMISSION AND DIFFERENTIAL C LOCATION AND INSTALLING DIRECTION OF THRUST NEEDLE BEARING AND WASHER O Fig 72 C3 043 96 O...

Page 471: ...J Ii Bond esur L Q o JR pressure Band s Bend rrvo 4A pressure Band servoJR pressure J Reverses Clutch pretsun Lines pressure send servo 2A Pr u Drain Band servo I O o 2A pressure Band servo3R pr Forw...

Page 472: ...Overrunning clutch pressure pipe o 0 pressure o Forward lll o O o o 0 o o o 0 0 o clutch pressure 0 O o o p 0 0 o O O D O o O o J Q 0 O o 0 0 0 Rear view Extension case Transmission case Transfer clu...

Page 473: ...sher 7 Speedometer shaft 8 Clip 9 Bushing 10 Oil pump shaft 11 Bushing 13 Seal pipe 14 Speedometer driven gear 15 Snap ring 17 Drain plug 18 Oil seal 19 Air breather hose clip T1 20 Bushing 21 Torque...

Page 474: ...I 0 0 r I u 0 0 i Ti 5 T2 1 I I 1 1 I 1 i 1 Fig 76 1 Crown gear 2 Straight pin 3 Pinion shaft 4 Differential case RH 5 Differential case lH 6 Taper roller bearing 7 Oil seal LH 8 O ring 9 Differential...

Page 475: ...Thrust washer 17 Air breather hose 18 Drive pinion shaft 19 Roller bearing tit 20 Shim 21 Test plug 22 Oil pump housing 23 Pin 24 Side seal 25 Control piston 26 Plane seal 27 Gasket 28 O ring 29 Oil s...

Page 476: ...9 Snap ring 10 Plug 11 O ring 12 Oil seal 13 Releaf valve 14 Pipe 15 Roller bearing 16 Flange bolt 17 Parking support 18 Parking rod 19 Return spring 20 Shaft 21 Parking pawl 22 Inlet pipe 23 Outlet...

Page 477: ...ainer 3 Transmission harness 4 O ring 5 Duty sol A Line pressure 6 Sol ASSY 7 Upper valve body 8 Ball 9 Upper separator plate 10 Lower separator plate 11 Lower valve body 12 Duty sol B Lock up 13 Pipe...

Page 478: ...late 12 Drive plate 13 Retaining plate 14 Snap ring 15 Lock nut 16 Brake band adjusting screw 17 Strut 18 Band servo piston stem 19 Spring 20 Lathe cut seal ring 21 Band servo piston 1 2 22 O ring 23...

Page 479: ...Thicker 10 Retaining plate 11 Snap ring 12 Thrust needle bearing 13 High clutch hub 14 Thrust needle bearing 15 Front sun gear 16 Thrust needle bearing Fig 81 17 Front planetary carrier 18 Thrust need...

Page 480: ...Dish plate 11 Snap ring 12 Spring retainer 13 Spring 14 Lathe cut seal ring 15 Overrunning piston 16 Lip seal 17 Forward piston 18 Lip seal 19 Lathe cut seal ring 20 Forward clutch drum e 21 Needle b...

Page 481: ...Reduction Gear Tightening torque N m kg m ft Ib T 98 5 10 0 5 72 3 3 6 Fig 83 3 Reduction drive shaft 4 Plug 5 Ball bearing 6 Reduction drive gear 7 Snap ring 8 Drive pinion shaft 9 Washer 10 Reductio...

Page 482: ...cut seal ring Transfer clutch piston 1 o 10 L h t e l i O e cu s r ng at a T3 11 12 Needle bearing Rear drive shaft 13 Ball bearing O O v 14 Seal ring 0 p 15 Revolution sensor 4WD 16 Pilot valve pipe...

Page 483: ...ful not to scratch or dent any part while checking for proper operation with an air gun 4 Complete the job from cleaning to completion of assembly as continuously and speedily as possible in order to...

Page 484: ...n an incorrect reading of the oil level 2 Check whether the oil level is between the upper F and lower L marks If it is below the lower limit mark add oil until the level reaches the upper mark 3 OIL...

Page 485: ...Using a socket wrench immobilize the end of the 10 mm screw projecting on the left side of the transmission case and loosen the nut with a double end wrench In the case of occurrence of problems 1 and...

Page 486: ..._ 0 R N D 3 2 1 Signal sent to AT control unit Ignition circuit Back up light circuit Also check that continuity in ignition circuit does not exist when selector lever is in R 3 2 and 1 ranges C3 051...

Page 487: ...C Transfer clutch solenoid Approx 12 If part is faulty its resistance valve will be different from the standard value indicated above 11 to n 16 135 14 g I Vehicle speed 1 H I sensor 1 j vc Y 2 pole...

Page 488: ...hten ATF drain plug after draining ATF Tightening torque 23 26 Nom 2 3 2 7 kg m 17 20 ft Ib 3 Remove oil pan and gasket Drain oil into a container 4 Disconnect solenoid valve connectors Remove connect...

Page 489: ...connections c Tighten duty solenoid B lock up bracket and two bolts also used to tighten valve body o o 0 o l e _ O G o 1 C o 0 o r h f o Vaseline B3 231 y g Fig 98 ened later Duty sol B lock up 4 In...

Page 490: ...ust cover 6 Remove propeller shaft For removal of propeller shaft refer to 3 4 AWD SYSTEM W1B0 Before removing propeller shaft scribe alignment marks on propeller shaft and rear differential coupling...

Page 491: ...a container to catch oil flowing from extension 0 Install duty solenoid C Et transfer valve body b Do not force extension back before disconnecting 0 Install pipe and clamp solenoid connector Otherwi...

Page 492: ...ial 18 27 1 8 2 8 13 20 At center bearing 34 44 3 5 4 5 25 33 Align marks on propeller shaft and rear differential coupling 6 Install front exhaust pipe Tightening torque N m kg m ft Ib At engine 25 3...

Page 493: ...achometer scale 2 Place the wheel chocks at the front and rear of all wheels and engage the parking brake P 108 3 Move the manual linkage to ensure it operates prop erly and shift the selector lever t...

Page 494: ...lag is longer than specified Line pressure too low Reverse clutch worn Low Et Rev brake worn Forward one way clutch not operating properly D LINE PRESSURE TEST 1 GENERAL If the clutch or the brake ban...

Page 495: ...5 12 8 164 182 441 569 1 128 1 255 2 4 5 5 8 64 82 164 182 441 569 1 128 1 255 1 4 5 5 8 64 82 11 5 12 8 164 182 Accelerator pedal I Full closed Fully open E TRANSFER CLUTCH PRESSURE TEST Check trans...

Page 496: ...ht corner braking occurs when the steering wheel is fully turned at low speed 1 Determine the applicable trouble code and check the corresponding duty solenoid C transfer for improper operation 2 If t...

Page 497: ...3 2 D range Power pattern 100 I I I I I I 1 I r 75 1 2 1 2 2 3 2 3 3 4 3 4 50 I lo I I o I 25 I I r I I I I I I I I I 1 I I I I I I I 0 20 40 60 80 100 120 140 160 180 200 12 25 37 50 62 75 87 99 112...

Page 498: ...3 2 woo AUTOMATIC TRANSMISSION AND DIFFERENTIAL 4 Overall Transmission SECTIONS THAT CAN BE DETACHED ASSEMBLED Section D YES Section E YES Section F YES C3 062 Fig 117 124...

Page 499: ...emnorarilv after drainina y 4 Extract the torque converter a Extract the torque converter horizontally Be careful not to scratch the bushing inside the oil pump shaft b Note that oil pump shaft also c...

Page 500: ...rom the flange face Attach the O ring to the pipe sections IL a Separate these cases while tapping lightly on the housing b Be careful not to damage the oil seal and bushing inside the converter case...

Page 501: ...ill two holes in the puller Reduction o c driven gear 1 c c 62 2 44 1 0 0 j C PULLER SET I Y 899524100 0 35 die mm in B3 267 Fig 130 3 Separate both sections 3 TRANSMISSION CASE SECTION 1 Remove the r...

Page 502: ...ace of the transmission case b Note that the parking rod and drive pinion protrude from the matina surface _ For Duty sol A For Sol 2 shift 7 For Sol 1 shift Grounding O e Sol 3 shift I o f For Duty s...

Page 503: ...12 Loosen the reverse clutch drum lightly by turning Fig 145 the adjusting screw Then remove the oil pump hous ing 15 Take out the high clutch Be careful not to lose the total end play adjusting thru...

Page 504: ...igh clutch hub High clutch hub J l I U J 1 I I B3 281 Fig 147 17 Take out the front sun gear Front sun gear J I I I I I L B3 282 Fig 148 18 Take out the front planetary carrier Front planetary carrier...

Page 505: ...After removing the snap ring inner take out the unit servo piston by applying compressed air from the release pressure side Hold the servo piston with a rag so that it will not be ejected with the ai...

Page 506: ...Q Accumulator 3 4 c Accumulator 1 2 oo eAccumulator 2 3 Accumulator ND 7 B3 293 Fig 159 y I ly I vv 29 Remove the parking rod together with the manual lever Then remove the manual shaft by pulling of...

Page 507: ...is not allowed b Be careful not to damage the retainer mounting hole of the converter case and the speedometer gears 5 Remove the vehicle speed sensor 2 a Pay attention so as not to forget to remove t...

Page 508: ...valve body B3 304 Fig 171 4 Take out the roller bearing r 1g 7 Z B ASSEMBLY OF OVERALL TRANSMIS SION 1 CONVERTER CASE SECTION 1 Check the appearance of each component and clean Make sure each part is...

Page 509: ...ted If shaft insertion is correct replace the axle shaft b Be sure to use a new circlip 8 Wrap vinyl tape around the splined portion of the axle shaft 9 Install the oil seal and outer race taper rolle...

Page 510: ...er 3 notches and secure it with the locking tab Then back off the RH retainer and retighten until it stops Repeat this procedure several times Tighten the RH retainer 1 3 4 notches further This sets t...

Page 511: ...ped wear Reduce thickness of drive pinion height on surfaces adjusting shim in order to move drive pinion away from crown gear Toe contact d I id Adjust as for flank contact contact ns e en gpz Contac...

Page 512: ...are not to damage the oil seal lips Then secure with three bolts Make sure the O ring is fitted correctly in position Tightening torque 6 8 N m 0 6 0 8 kg m 4 3 5 8 ft Ib Fig 183 16 Apply vaseline to...

Page 513: ...to tilt the piston when installing b Be careful not to damage the lip seal r ri n Long bar o o 0 nLlfiil 1 COMPRESSOR 398673600 0 Q SEAT _ _ r o 498627000 B3 322 Fig 189 7 Install the one way clutch...

Page 514: ......

Page 515: ...cial attention not to damage the seal ring 2 Installation is complete when the drum recedes 2 5 mm 0 098 in from the inner race surface Fig 195 13 Assemble the overrunning clutch hub a Join the thrust...

Page 516: ...0 Install the high clutch hub Attach the thrust needle bearing to the hub with vase line and install the hub by correctly engaging the splines of the front planetary carrier 0 v Thrust needle 0 1 bear...

Page 517: ...careful not to damage the brake band when installing b Install the strut to the band servo piston stem Then tighten it temporarily to avoid tilting the band Hg 206 24 Adjustment of total end play and...

Page 518: ...22 1 0 0 039 803031023 1 2 0 047 803031024 1 4 0 055 803031025 1 6 0 063 803031026 1 8 0 071 803031027 2 0 0 079 Reverse clutch end play Unit mm C M 0 4 m C Clearance between oil pump housing hose and...

Page 519: ...reful not to damage the con verter case bushing and oil seal Tightening torque 38 44 Nom 3 9 4 5 kg m 28 33 ft Ib 4 CONTROL VALVE AND OIL PAN 1 Install four accumulators with oil pans facing up ward B...

Page 520: ...t or break the O ring Then tighten bolts Tightening torque 7 9 N m 0 7 0 9 kg m 5 1 6 5 ft Ib _ Oil strainer a U G B3 347 Fig 214 5 Secure five connectors o For Duty sol A For Sol 2 shift For Sol 1 sh...

Page 521: ...use a new gasket 3 Install the pipe and clamp securely 4 Install the transfer clutch assembly to the case a Be careful not to damage the seal rings b Insert the clutch assembly fully into position unt...

Page 522: ...the transfer clutch hub Be sure to engage the spline teeth correctly 4 With gasket inserted between them install the extension case to the transmission case Be sure to use a new gasket a After inserti...

Page 523: ...18 21 ft Ib When tightening the lock nut be careful not to turn the adjusting screw 8 Install the pitching stopper bracket Tightening torque 36 42 Nam 3 7 4 3 kg m 27 31 ft Ib Tightening torque Nam kg...

Page 524: ...14 4 Using a press remove the ball bearing 1 1y ZZU B INSPECTION Make sure that each component is free of harmful gouges cuts or dust C ASSEMBLY 1 Press fit the ball bearing and reduction drive gear t...

Page 525: ...e body a Do not lose the nine 9 steel balls contained in the upper valve body b Do not lose an orifice and a strainer contained in the lower valve body c Remove the upper lower valve body tightening b...

Page 526: ...o o o o o o 010 05 U O 0 O O O O O QJ o po r L O O D o p o O O rt o o oU o Q o o 15 O a Strainer location o O O O O O 0 o vGlo o Nine steel ball location O oip ti Cr Jo 7 o o i I B3 364 Fig 229 b Tigh...

Page 527: ...ng and control piston Also remove the O ring friction ring two side seals and plain seal fig 233 5 Remove two seal rings R and two seal rings H B INSPECTION 1 Make sure that each component is free of...

Page 528: ...0012 0 0017 in Cam ring 0 034 mm 0 010 0 024 mm 0 0013 in 0 0004 0 0009 in Select vanes which are the same height as the rotor Friction ring C 0 ring 0 Cam ring B3 371 Fig 236 2 Install the vane ring...

Page 529: ...m 17 20 ft Ib a Align both pivots with the pivot holes of the cover and install the cover being careful not to apply undue force to the pivots b After assembling turn the oil pump shaft to check for...

Page 530: ...CH 499787100 HOLDER 498937100 133 3761 Fig 241 2 Using a press separate the rear roller bearing and outer race from the shaft Fig 242 3 Using a press separate the front roller bearing from the shaft B...

Page 531: ...Z4u 5 Measure the starting torque of the bearing Make sure the starting torque is within the specified range If out of the allowable range replace the roller bearing Starting torque 0 3 2 0 Nom 3 20...

Page 532: ...o the oil hole and check the reverse clutch for smooth operation 4 Measuring clearance Retaining plate selection Standard value 0 5 0 8 mm 0 020 0 031 in Allowable limit 1 2 mm 0 047 in B INSPECTION 1...

Page 533: ...1 Using the same special tools as those used in disas sembling assemble the piston spring retainer CP and snap ring 2 Install the driven plate thin drive plates driven plates and retaining plate in th...

Page 534: ...er and remove the snap ring from the forward clutch by using SEAT 498627100 and COMPRESSOR 398673600 6 Install the one way clutch inner race to the forward clutch drum and apply compressed air to remo...

Page 535: ...plate Outer race Drive plate Driven plate Driven plate C3 080 Fig 254 1 Fit the forward piston and overrunning piston to the forward clutch drum Align the forward piston cut out portion with the soli...

Page 536: ...ning clutch 1 0 1 4 0 039 0 055 2 0 0 079 Before measuring clearance place the same thickness of shim on both sides to prevent retaining plate from tilting If the clearance is out of the specified ran...

Page 537: ...uts damage or other faults C ASSEMBLY Assemble the one way clutch 3 4 and secure with the snap ring Pay attention to the orientation of the one way clutch 3 4 Confirm Assemble the rear internal gear a...

Page 538: ...ut seal ring 4 Band servo piston 5 Lathe cut seal ring 6 O ring 7 Band servo retainer 8 O ring 9 Spring 10 Retainer 11 Snap ring 12 Lathe cut seal ring 13 Band servo piston O D 14 O ring 15 O D servo...

Page 539: ...ther faults C ASSEMBLY 1 Install the washer differential bevel gear and differ ential bevel pinion in the differential case RN Insert the pinion shaft and fit the straight pin Make sure that the case...

Page 540: ...01 II 1 1 p DIAL GAUGE 498247100 B3 401 Fig 266 5 Install the speedometer drive gear Then force fit the taper roller bearing with a press Be sure to position correctly the locking end of the speedomet...

Page 541: ...remove the piston B3 407 Fig 272 B INSPECTION 1 Check the drive plate facing for wear and damage 2 Check the snap ring for wear return spring for permanent set and breakage and spring retainer for def...

Page 542: ...E Seal piston I B3 411 Fig 274 If the clearance is not within the specified range select a proper pressure plate Before measuring clearance place the same thickness of shim on both sides to prevent pr...

Page 543: ...1 Remove the plate Then remove the spring and pilot valve together 2 Remove the straight pin and pry out the plug with a screwdriver Then extract the spring and transfer clutch valve together Be caref...

Page 544: ...conducted by rotating with simple easy operations and proceeding to complicated difficult operations The most important thing in troubleshooting is to understand the customer s complaint and distingu...

Page 545: ...is operation Problems which occurred previously can also be identified through the memory function If the power indicator does not show a problem al though a problem is occurring the problem can be de...

Page 546: ...mp blinks at 4 Hz intervals Ensure indicator lamp blinks Indicator lamp blinks at 2 Hz intervals Faulty battery Normal No Faulty indicator lamp circuit or TCU I Previous problem history check procedur...

Page 547: ...Select monitor 11 Duty solenoid A Detects open or shorted drive circuit as well as valve seizure 12 Duty solenoid B Detects open or shorted drive UU circuit as well as valve seizure 13 Shift solenoid...

Page 548: ...e cleared by turning the ignition switch OFF after conducting self diagnosis operation Previous trouble codes how ever cannot be cleared since they are stored in the ECU memory which is operating on t...

Page 549: ...Fill range Selector lever in N range Less than 1 range Si l switch gna B66 8 Selector lever in any other 9 13 than N range I hibi D Selector lever in D range Less than 1 n tor range switch switch Sign...

Page 550: ...4 Selector lever in 2nd or 3rd Less than 1 20 30 gear Selector lever in 1st or 2nd 10 14 gear Shift solenoid 2 B68 13 Selector lever in 3rd or 4th Less than 1 20 30 gear Selector lever in N range Less...

Page 551: ...and duty sole Not OK Repair harness connector noid A and TCU and resistor OK Not OK 3 Check duty solenoid A s ground line 1 Repair ground line r OK Not OK 4 Check resistor 0 Check and replace resisto...

Page 552: ......

Page 553: ...l poor contact Replace TCU TCU OK 2 Check harness between TCU and duty solenoid Not OK Repair harness j OK Not OK 3 Check duty solenoid B s ground line Repair ground line OK Not OK 4 Check duty soleno...

Page 554: ...CTION MODE Mode 12 Condition Start the engine and increase vehicle speed to 60 krn h 37 MPH When wheels are locked up Specified data LUDTY F12 95 5 wheel locked up release 1 Disconnect connector from...

Page 555: ...CU terminal poor contact TCU OK 2 Check harness between TCU and shift solenoid Not OK Repair harness 3 OK Not OK 3 Check shift solenoid 3 s ground line Repair ground line r OK Not OK 4 Check shift sol...

Page 556: ...TCU and shift sole noid 3 1 Disconnect connector from TCU 2 Disconnect connector from transmission 3 Measure resistance between TCU connector and transmission connector and between TCU connector and...

Page 557: ...e TCU TCU r OK f 2 Check harness between TCU and shift solenoid Not OK b Repair harness Il 2 j OK Not OK 3 Check shift solenoid 2 s grounding line 1110 Repair grounding line OK Not OK 4 Check shift so...

Page 558: ...from transmission 3 Measure resistance between TCU connector and transmission connector and between TCU connector and body Connector terminal Specified resistance B68 No 13 B14 No 2 0 i2 B68 No 13 Bod...

Page 559: ...nal poor contact Replace TCU TCU j OK 2 Check harness between TCU and shift solenoid Not OK 0 Repair harness 1 OK Not OK 3 Check shift solenoid 1 s ground line 1111 Repair ground line OK Not OK 4 Chec...

Page 560: ...ransmission 3 Measure resistance between TCU connector and transmission connector and between TCU connector and body Connector Fr terminal Specified resistance 1368 No 14 1314 No 3 0 i2 1368 No 14 Bod...

Page 561: ...CU OK Repair TCU terminal poor contact Replace TCU r Not OK 2 Check harness between TCU and ATF tempera Not OK Repair harness ture sensor r OK 3 Check ATF temperature sensor Not OK Replace ATF tempera...

Page 562: ...2 Disconnect connector from transmission 3 Measure resistance between TCU connector and transmission connector and between TCU connector and body Connector fr terminal Specked voltage 1367 No 10 1314...

Page 563: ...engine warm up Power indicator remains on when vehicle speed 1 Measure signal voltage input of TCU OK Repair TCU terminal poor contact Replace TCU Not OK Not OK 2 Check harness between TCU and ECU MP...

Page 564: ...No 5 Body 10 V min SELECT MONITOR FUNCTION MODE Mode 06 Condition After warming up the engine Specified data EREV F06 Engine speed is shown in rpm 2 CHECK HARNESS BETWEEN TCU AND ECU MPFQ 1 Disconnec...

Page 565: ...ot OK 2 Check harness between TCU and duty solenoid 0 Repair harness j OK Not OK 3 Check duty solenoid C s ground line 11 Repair ground line OK Not OK 4 Check duty solenoid C b Replace duty solenoid C...

Page 566: ...tion Ignition switch ON Engine OFF Specified data 4WDTY F13 95 FWD mode 25 max AWD mode D range Full throttle 2 CHECK HARNESS BETWEEN TCU AND DUTY SOLENOID C 1 Disconnect connector from TCU 2 Disconne...

Page 567: ...sive shift shock Not OK I Repair ECU MPFI terminal poor contact Replace 1 Measure signal voltage output of ECU MPFI ECU OK 2 Measure signal voltage input of TCU Not OK Repair or replace harness connec...

Page 568: ...OFF 2 Measure signal voltage output of ECU MPFI OF 2 MEASURE SIGNAL VOLTAGE INPUT OF TCU 1 Disconnect connector from TCU 2 Turn ignition switch ON with engine OFF 3 Measure signal voltage input of TC...

Page 569: ...ock excessive tight corner braking t Measure signal voltage input of TCU OK b Repair TCU terminal poor contact Replace TCU r Not OK 2 Check harness connector between TCU and I Not OK Repair harness co...

Page 570: ......

Page 571: ...pair TCU terminal poor contact Replace TCU Not OK 2 Check harness between TCU and vehicle speed Not OK Repair harness connector sensor 1 OK Not OK 3 Check vehicle speed sensor 1 b Replace vehicle spee...

Page 572: ...F02 Vehicle speed miles h Mode 03 km h indication 2 CHECK HARNESS CONNECTOR BETWEEN TCU AND VEHICLE SPEED SENSOR 1 1 Disconnect connector from TCU 2 Disconnect connector from transmission 3 Measure re...

Page 573: ...K Repair harness connector hicle speed sensor 2 I OK Not OK 3 Check voltage of power supply line III Repair or replace power supply circuit OK Not OK 4 Check vehicle speed sensor 2 1 Replace vehicle s...

Page 574: ...stance between TCU connector and vehicle speed sensor 2 connector and vehicle speed sensor 2 connector and body Connector r terminal Specified resistance 866 No 11 B9 No 1 0 0 1366 No 11 Body 1 Mfg mi...

Page 575: ...rring measure performance characteristics of sensors actu ators etc in the F mode select monitor function and compare with the basic data to determine the cause of problems Trouble occurs No trouble c...

Page 576: ...nt from vehicle speed sensor 2 Vehicle speed km h sent 05 Vehicle speed sensor 2 VSP2 km h from vehicle speed sen sor 2 06 Engine RPM EREV rpm Engine speed sent from EGI unit ATF temperature F sent 07...

Page 577: ...When 2 range is selected A1 4 3 range switch R3 When 3 range is selected 5 D range switch RD When D range is selected B 1 range switch R1 When 1 range is selected 7 Manual switch MS When manual switch...

Page 578: ...data should be indicated Indications EAT F00 4r DT 1 Check loose or poor connectors or shortcircuit 2 Check type of cartridge Check improper cartridge Replace with proper one D MODE 01 BATTERY VOLTAG...

Page 579: ...2 I 18 m h Check performance characteristics of vehicle speed sensor 1 Ref to T4K0 OK Check TCU and replace if necessary F MODE 04 SPEED SENSOR 2 VSP 2 CONDITION Raise vehicle off ground and operate a...

Page 580: ...F06 1 500 rpm V OK Check TCU and replace if necessary H MODE 08 ATF TEMPERATURE ATFT SPECIFIED DATA CONDITION 1 Ambient temperature 10 C 1 Low ATF temperature before engine vehicle 2 ATF temperature...

Page 581: ......

Page 582: ......

Page 583: ...e cause if outside specified data r 1 IThrottle sensor 2 Vehicle speed sensor 1 3 Vehicle speed sensor 2 41Engine speed SPECIFIED DATA 1 Lock up system released 5 2 Lock up system applied 95 Indicatio...

Page 584: ...sensor 1 Check in F02 mode Ref to T5E0 1 3 Vehicle speed sensor 2 Check in F04 mode Ref to T5F0 4 ATF temperature sensor Check in F08 mode Ref to T5H0j 1 5 Inhibitor switch Check for operation Ref to...

Page 585: ...I F97 F o I Reference values 1 Lights up when the ABS signal is entered No 5 2 Lights up when the cruise control is set No 6 3 Lights up when the fuse is installed in FWD switch No 8 FWD switch ECU E...

Page 586: ...ected No 1 2 Lights up when the R range is selected No 2 3 Lights up when the 2 range is selected No 3 4 Lights up when the 3 range is selected No 4 5 Lights up when the D range is selected No 5 6 Lig...

Page 587: ...ontact j Not OK 2 Check harness connector between TCU and man Not OK Repair harness connector ual switch OK Not OK 3 Check manual switch ground line 00 Repair ground line OK Not OK 4 Check manual swit...

Page 588: ...nnection Fig 302 3 Measure resistance between TCU connector and manual switch connector and between TCU and body Connector ft terminal Specked resistance 1366 No 6 1151 No 1 0 0 B66 No 6 Body 1 Mfg mi...

Page 589: ...l signal is entered No 2 2 Lights up when the brake switch is turned ON No 3 Stop brake switch FI O B44 Stop light switch SBF 3 rr 8 R B R rim W j W FL 1 5 45A No 12 20A 5 Stop lights WR ECU TCU MPFI...

Page 590: ...to personal injury or death in the event of a severe frontal collision all maintenance must be performed by an authorized SVX dealer Improper maintenance including incorrect re moval and installation...

Page 591: ...a shift lock sys lock tem is utilized to prevent shifting of the selector lever from P to any other position unless the brake pedal is depressed This system is also provided with a key interlock whic...

Page 592: ...is set at P e Shift lock is designed to properly release even when shift lever is hard to shift due to current flow interruption run down battery etc n r lever be moved by pressing the button Lock pl...

Page 593: ...te Key push interlock position Key push stroke 3 mm 0 12 ii _ Stopper spring Stopper Interlock in operation Selector lever set at View B any other than P position Rotator Section A A View B C3 103 Fig...

Page 594: ...switch 11 Bulb 12 Socket 13 Plate 14 Packing 15 Washer 16 Snap pin 17 Outer cable 18 Rod 19 Spring pin 20 Spring 21 Ball 22 Seat 23 Spring 24 Selector lever 25 Boot 26 Nut 1 27 Inner cable 28 Nut 2 29...

Page 595: ...A t 4 Front exhaust cover C3 107 3 Disconnect the cable from the selector lever 1 o I1 Adjusting nut 1 i 1 l 1 1 _ I_ I Bolt C3 109 Fig 9 4 Remove the console box For removal of the console box refer...

Page 596: ...emove the following parts from the grip Grip button Spring 7027 1 Grip button 2 Spring 3 Grip V C3 115 C3 112 Fig 12 7 Remove the selector fever ASSY B DISASSEMBLY 1 Remove the grip from the selector...

Page 597: ...ace if defective 2 Confirm the following parts for operating condition before ASSY 1 Sliding condition of the grip button in the grip it should move smoothly 2 Insertion of the grip on the selector le...

Page 598: ...lease button to the indica shown in Fig 26 for cover 9 Assemble the indicator cover to the plate Tightening torque 1 3 2 6 N m 0 13 0 27 kg m 0 9 2 0 ft Ib J CM C P C3 123 Fig 23 U Green 2 pole for bu...

Page 599: ...et 8 Adjust the inner cable length 1 Put connector into contact with nut 2 Return nut to rotate 1 2 3 Tighten nut 10 i i 2 O C3 124 Fig 29 9 After completion of fitting make sure that the selec tor le...

Page 600: ...P Also check that the ignition key can be removed from the LOCK position only 2 Ensure the selector lever moves from P to any other position when the brake pedal is depressed with ignition key set at...

Page 601: ...g shaft ASSY 2 Wiring Diagram To Power Supply Routing FB 1 FB 11 FB 8 FB 25 B75 Key lock solenoid s Key warning switch 0 5 Stop brake C swl tch stop light switch 0 w wR B98 B47 B65 _ wR wR wR I nh i b...

Page 602: ...oves from P to any other po sition while depressing brake pedal t Yes Move shift lever to N and turn ignition switch OFF Check if ignition key can be removed from slot prop erly No Check if ignition k...

Page 603: ...p light system No Disconnect connector from shift lock unit Check if shift lock occurs when shift lever is moved to T Yes Replace shift lock unit No Disconnect connector from shift lock solenoid Check...

Page 604: ...Repair harness or faulty connector contact between main fuse and unit Repair harness or faulty connector contact between stop light switch and unit Check fuse Repair harness or faulty connector contac...

Page 605: ...No Repair harness or faulty connector contact between ignition switch and unit Yes Disconnect harness from unit Check if resistance between terminal No 9 of con nector R47 and terminal No 11 is at lea...

Page 606: ...sconnect harness from unit Check if resistance be tween terminal No 9 of harness connector R47 and terminal No 11 is at least 8 ohms A Yes Key lock solenoid circuit open Repair harness or faulty conne...

Page 607: ...ferential LSD 5 S SPECIFICATIONS AND SERVICE DATA 7 C COMPONENT PARTS 9 1 Rear Differential Mounting System 9 2 Propeller Shaft and Drive Shaft 10 3 Rear Differential Assembly 11 W SERVICE PROCEDURE 1...

Page 608: ...3 4 M l ool AWD SYSTEM M MECHANISM AND FUNCTION 1 AWD System C3 125 Fig 1...

Page 609: ...YSTEM M MECHANISM AND FUNCTION 2 Propeller Shaft The propeller shaft utilizes a 2 piece design that is provided with three joints fikA l V T F Transmission side Rear differential side Center mounting...

Page 610: ...limited slip differential LSD incorporating outer plates inner plates and viscous coupling with silicon oil The spindle which is an inte gral part of the rear drive shaft is coupled with the differen...

Page 611: ...is fitted and set in position On the inner plate no positioning ring is used The plate can be moved a certain amount on the hub spline in the axial direction Sealed inside the housing is a mixture of...

Page 612: ...urns idle due to a difference in the road resis tance a speed difference occurs between the right and left wheel Since the VC is installed between the right and left wheels a differential torque is ge...

Page 613: ......

Page 614: ...0 1240 in 383525200 3 18 mm 0 1252 in 383535200 3 21 mm 0 1264 in 383545200 3 24 mm 0 1276 in 383555200 3 27 mm 0 1287 in 383565200 3 30 mm 0 1299 in 383575200 3 33 mm 0 1311 in Pinion height adjust i...

Page 615: ...System Rear sub frame Rear differential member Stopper Upper Front bushing Stopper Under Rear differential Bracket Tightening torque N m kg m ft Ib T1 53 65 5 4 6 6 39 48 T2 61 76 6 2 7 8 45 56 T3 12...

Page 616: ...differential 6 Circlip 7 Baffle plate DOJ 8 Outer race DOJ 9 Snap ring 10 Inner race DOJ 11 Ball 12 Cage 13 Circlip 14 Boot band DOJ 15 Boot DOJ 16 Boot band DOJ 17 Boot band BJ 18 Boot BJ 19 Boot ba...

Page 617: ...11 Companion flange 3 Pinion height adjusting washer 12 Self locking nut 4 Rear bearing 13 Side bearing 5 Bearing preload adjusting spacer 14 Side bearing retainer 6 Bearing preload adjusting washer 1...

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Page 620: ......

Page 621: ......

Page 622: ...urning resistance of companion flange Measure turning resistance after making sure that the companion flange turns smoothly o Companion flange I Spring balance C3 144 Fig 24 8 Remove self locking nut...

Page 623: ...xhaust pipe refer to 2 EXHAUST SYSTEM W5A0 8 Remove the DOJ of rear drive shaft from the rea differential 1 Remove the ABS sensor cable clamp and parkinc brake cable guide from the trailing link Parki...

Page 624: ...t need not be removed Special tool 10 Remove the side oil seal DRIVE SHAFT REMOVER 28099PA100 PULLER ASSY 398527700 t3 c i 83 153 Fig 35 Fig 37 11 Drive in a new side oil seal with DRIFT Apply chassis...

Page 625: ...ing Check that oil seal lip is not folded over inward Fig 38 2 Insert the spline shaft until the spline portion is inside the side oil seal t Iy F 1y 4V V y wI 13 Reassembling procedure hereafter is t...

Page 626: ...545 27011 AA242 GEAR RATIO 3 545 O FUJI HEAVY INDUSTRIES LTD C3 153 Fig 42 Fig 43 C REMOVAL 1 Disconnect the ground cable from battery 2 Move the selector lever to N 3 Release the parking brake 4 Loo...

Page 627: ...Secure rear drive shaft to rear sub frame using wire 12 Remove the rear differential ASSY from body 1 Remove the four bolts which secure the bracket to the rear differential member rig 4o 2 Support t...

Page 628: ...ly Remove side bearing re tainer attaching bolts set ATTACHMENT to differential case and extract right and left side bearing retainers with a puller Each shim which is installed to adjust the side bea...

Page 629: ...ap front bearing cup and 10 Extract the companion flange with a puller rear bearing cup in this order out of case by using a 11 Press the end of drive pinion shaft and extract it brass bar together wi...

Page 630: ...ch part during assembly 2 Keep the shims and washers in order so that they are not misinstalled 3 Thoroughly clean the surfaces on which the shims washers and bearings are to be installed 4 Apply gear...

Page 631: ...8 34 16 67 N 0 85 1 7 kg 1 87 3 75 lb at companion flange bolt hole Preload adjusting washers Part No Length mm in 383705200 2 59 0 1020 383715200 2 57 0 1012 383725200 2 55 0 1004 383735200 2 53 0 09...

Page 632: ...5200 3 18 0 1252 383535200 3 21 0 1264 383545200 3 24 0 1276 383555200 3 27 0 1287 383565200 3 30 0 1299 383575200 3 33 0 1311 383585200 3 36 0 1323 383595200 3 39 0 1335 383605200 3 42 0 1346 3836152...

Page 633: ...the bolt heads 10 Install self locking nut with washer B3 182 Fig 72 Torque Drive pinion nut 167 196 N m 17 0 20 0 kg m 123 145 ft lb 11 Assembling differential case Install side gears and pinion mate...

Page 634: ...r example if the bearing measured width is 19 89 mm value of E or F is as follows 20 00 19 89 0 11 E or F G r GZ Number marked on side bearing re tainer Differential carrier __ Differential case eaeo...

Page 635: ...e correct by decreasing the shim thickness on one side and increasing the shim thickness on the other side the same amount Total shim thickness must be the same to maintain proper preload Backlash 0 1...

Page 636: ...bolt 19 25 N m 1 9 2 6 kg m 14 19 ft Ib F G INSTALLATION To install reverse the removal sequence 1 Install the rear differential ASSY to body 2 Insert the DOJ of rear drive shaft into the rear differ...

Page 637: ...s of drive pinion height adjusting washer in order to bring drive pin ends ion closer to drive gear center Flank contact Backlash is too small This may cause noise and stepped wear on Reduce thickness...

Page 638: ...ver r1g a 7 Remove the propeller shaft from body Refer to Propeller Shaft Wrap metal parts installed at the rubber boot center DOJ with a cloth or rubbered material to prevent it from damage by interf...

Page 639: ...ential to rear differential member Fig 90 B INSTALLATION To install reverse the removal sequence 1 Install the rear differential member When installing the rear differential member pay at tention not...

Page 640: ...3 4 W3B0 AWD SYSTEM Lower stopper O Upper stopper C3 163 Fig 91 2 Installing procedure hereafter is the reverse of the removal 34...

Page 641: ...ar Readjust or replace Excessive preload for side rear or front bearing Readjust or replace Insufficient or improper oil used Replace seized part and fill with specified oil to specified level Damage...

Page 642: ...ear Replace hypoid gear set Improper preload for front or rear bearings Readjust Seized scored or chipped front or rear bearing Replace Seized scored or chipped side bearing Replace Vibrating differen...

Page 643: ...ternal combu N stion does not 1 11 12 5 6 7 2 3 4 8 9 10 0 occur a c Internal combu 1 11 2 3 4 5 6 7 8 9 10 12 13 stion occur 0 Engine stalls after initial 1 2 8 9 5 6 7 13 14 15 10 11 12 3 4 combusti...

Page 644: ...n N X Shock occurs when select lever is moved from N to D X X X X Excessive time lag occurs when select lever is moved from N to D x x Shock occurs when select lever is moved from N to R X X X X Exces...

Page 645: ...er is hard to move x x x x Select lever is too light to move unreasonable resistance X X ATF spurts out X Differential oil spurts out X Differential oil level changes excessively X X Odor is produced...

Page 646: ...o ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during re pair work is needed be sure to use SUBARU genuine parts All...

Page 647: ...rformed by an authorized SUBARU dealer Improper maintenance including incorrect re moval and installation of the Airbag system can lead to personal injury caused by uninten tional activation of the Ai...

Page 648: ...the cushion rubber which has resulted in elimination of any vibration by combined use of other rubbers to improve passenger comfort This type also maintains a wide distance between the upper and lowe...

Page 649: ...are optimally designed to act in response to vertical lateral and longitudinal loads transmitted from the tires Thus riding comfort and steering stability are substantially enhanced Longitudinal loads...

Page 650: ...sion 343 35 77 Stabilizer Bar diameter mm in 17 0 67 Coil diameter mm in UPR 135 5 31 LWR 155 6 10 Coil spring Coefficient of spring N mm kg mm Ib in 19 2 1 96 109 8 20 3 2 07 115 9 Rear Outer cylinde...

Page 651: ...t stabilizer 17 Stabilizer lever 18 Stabilizer link 19 Stabillzer bush 20 Clamp 21 Stopper 22 Front support 23 Rear support 24 Peformance rod Fig 3 Tightening torque N m kg m ft Ib T1 132 172 13 5 17...

Page 652: ...25 1 4 2 6 10 19 T10 16 24 1 6 2 4 12 17 T11 12 24 1 2 2 4 9 17 Fig 4 1 Strut mount 2 Upper rubber seat 3 Guide 4 Dust cover 5 Coil spring 6 Helper 7 Lower rubber seat 8 Strut COMPL 9 Sub frame 10 Fr...

Page 653: ...el forward position 1 Inflate tire pressure to specifications 4 Suspend thread from wheel arch to determine a 2 Set vehicle under curb weight conditions Empty point directly above center of spindle lu...

Page 654: ...rd old self locking nut and replace with a new one 2 While aligning scale for adjustment bolt located at rear of vehicle with mark on strut bracket set camber angle within proper specifications Inner...

Page 655: ...hin specifications b Correct tie rod boot if twisted Rear toe in adjustment 1 Loosen self locking nut on rear lateral link a When loosening or tightening adjustment bolt hold bolt head and turn self l...

Page 656: ...sition measure both the inner and outer wheel steering angle Inner wheel 36 2 1 5 Steering angle Outer wheel 31 6 1 5 Adjustment Turn tie rod to adjust steering angle of both inner and outer wheels a...

Page 657: ...orque N m kg m ft Ib T1 127 167 13 0 17 0 93 7 123 2 T2 76 100 7 8 10 2 56 1 73 8 T3 45 59 4 6 6 0 33 2 43 5 I T2 I 1 T1 T1 3 0 T3 o i J C4 467 Fig 14 1 Lift up vehicle and remove front wheels 2 Separ...

Page 658: ...ont sub frame and lower arm and tighten bolts with vehicle weight on suspension Self lock nut must be replaced with a new one when ever it is removed B INSPECTION 1 Check lower arm for wear damage and...

Page 659: ...ig 18 1 Lift up vehicle and remove front wheels 2 Remove four bolts then ball joint C4 104 Fig 19 3 To install reverse above removal procedures F B INSPECTION 1 Check ball joint free play in three dir...

Page 660: ...r 8 Coil spring 9 Helper 10 Lower rubber seat 11 Strut COMPL 12 Adjusting bolt Tightening torque N m kg m ft Ib T1 34 48 3 5 4 9 25 1 35 4 T2 49 59 5 0 6 0 36 1 43 5 T3 132 172 13 5 17 5 97 4 126 9 p...

Page 661: ...ing bolt head remove nuts which connect housing and 9 Remove bolts from housing and remove strut strut Be careful not to damage ABS sensor harness and Do not remove upper bolt brake piping 10 To insta...

Page 662: ...of the rod and apply a weight of 20 N 2 kg 4 lb to the threaded portion Read the dial gauge indication The amplitude of the gauge needle pointer is the deflection of the rod Limit of deflection Less...

Page 663: ...od as shown in Figure 32 Upper spring seat Align helper and dust Dust cover cover with graded portion Helper of piston rod Rod C4 5981 Fig 32 5 Pull the piston rod fully upward and install rubber seat...

Page 664: ...abilizer 2 Stabilizer lever 3 Stabilizer link 4 Stabilizer bush 5 Clamp Tightening torque N m kg m ft lb T1 21 28 2 1 2 9 15 5 21 0 T2 45 59 4 6 6 0 33 2 43 5 T3 32 42 3 3 4 3 23 6 31 0 C4 470 Fig 34...

Page 665: ...C4 109 Fig 38 v r f dr 3i t A F a Front C4 111 Fig 41 c Be sure to align alignment mark when installing stabilizer lever and stabilizer B INSPECTION 1 Check bushing for cracks fatigue or damage 2 Che...

Page 666: ...nd connectors are colored yellow Do not use electrical test equipment on these circuit b Be careful not to damage Airbag system wiring harness when servicing the steering ASSY SUSPENSION 1 2 3 4 5 Sub...

Page 667: ...Place alignment mark before removing Fig 43 hag 44 3 Remove OZ sensor connector 4 Remove power steering connector 5 Remove throttle cover 6 Remove air intake duct 7 Attach lifting wire to engine rig...

Page 668: ...nine inint from steering gear hox nine I C4 121 13 Place alignment mark on stabilizer and stabilizer Fig 51 lever before removing Stabilizer lever Marking I r I Lower arm C4 109 18 Plug steering hose...

Page 669: ...C4 125 Fig 57 25 Remove sub frame Be careful not to damage power steering solenoid harness 26 Remove stabilizer from sub frame 27 Remove gear box assembly from sub frame 28 To install reverse above re...

Page 670: ...alling universal joint refer to instructions under 4 3 STEERING SYSTEM as a guide d Center roll connector as instructed under 5 5 WlEl e Purge air from power steering system refer to 4 3 W5G0 f When t...

Page 671: ...11 14 80 101 C4 485 Fig 61 1 Lift up vehicle and remove rear wheels 2 Disconnect ABS sensor clamp and parking brake cable bracket Parking brake cable guide 1 Trailing link ABS sensor cable clamp C3 14...

Page 672: ...use 1 Front lateral link T1 8 2 Rear lateral link O 3 Pillow ball bush 4 Bush E 5 Bush C 6 Adjusting bolt 7 Adjusting washer 8 Washer 9 Cap 10 Rear sub frame o 4 3 T2 C4473 Fig 64 1 Lift up vehicle an...

Page 673: ...ential using DRIVE SHAFT REMOVER 28099PA100 Use bolt shown in Fig 71 as a supporting point for REMOVER to prevent side bearing retainer from sus taininn damane 1 27 61 nisrnnnprt trailinn link at hnus...

Page 674: ...of body C4 474 Fig 74 a When tightening bushing make sure vehicle weight is on suspension b Align alignment mark when installing adjustment bolt B INSPECTION Check bushing for cracks fatigue or damag...

Page 675: ...F 55 C4 483 Fig 76 a Using the following figure as a guide verify the type of bushings b Select INSTALLER Fr REMOVER according to the type of bushings used Bush C Bush E Rear lateral link Brown Front...

Page 676: ...TALLER r REMOVER press bushing C and bushing E into place l Press a4asa Fig 78 2 Using an INSTALLER r REMOVER press pillow ball bushing into place Press cam 2 iR C i Lateral link C4 484 Fig 79 a Disca...

Page 677: ...bber seat 8 Strut COMPL Tightening torque N rn kg rn ft Ib T1 49 69 5 7 36 51 T2 12 24 1 2 2 4 9 17 T3 132 172 13 5 17 5 98 127 C4 475 Fig 80 1 Lift up vehicle and remove rear wheels 2 Disconnect batt...

Page 678: ...to Front Strut ASSY as a guide for inspection procedures Paint Notch i Outside of body 04 460 Fig 85 ny ov D ASSEMBLY Refer to Front Strut ASSY as a guide for assembly procedures a Install rear strut...

Page 679: ...tening torque N m kg m ft Ib T1 14 25 1 4 2 6 10 19 T2 16 24 1 6 2 4 12 17 3 T1 4 Tt i 2 T2 1 Rear stabilizer 2 Stabilizer link 3 Stabilizer bush 4 Clamp 5 Stabilizer bracket C4 477 Fig 87 1 Lift up v...

Page 680: ...ilizers during installation b Right stabilizer has one more bend section than left stabilizer f ig 90 c Do not confuse upper and lower sides of clamp during installation to C4 214 Fig 91 B INSPECTION...

Page 681: ...e A REMOVAL AND INSTALLATION a m 1 Rear sub frame 2 Front support 3 Rear support 4 Stopper 5 Stabilizer bracket Tightening torque N m kg m ft Ib T1 127 157 13 16 94 116 T2 44 74 4 5 7 5 33 54 0 LI 00...

Page 682: ...nge 3 Release parking brakes 41 Remove rear exhaust t iae and muffler Fig 93 7 Remove differential member 9 Remove stabilizer brackets l I I i i Stabilizer bracket 04 157 Fig 96 10 Remove trailing lin...

Page 683: ...links a For installation and tightening torque of rear differ ential refer to 3 4 W2A0 b For installation and tightening torque of brake parts refer to 4 4 W2A1 c When tightening trailing and lateral...

Page 684: ...operation of damper strut Replace 5 Damage or deformation of damper strut lower end bushing Replace 6 Unsuitability of maximum and or minimum length of damper strut Replace with proper parts 7 Deforma...

Page 685: ...NENT PARTS 9 1 Front Axle 9 2 Rear Axle 10 W SERVICE PROCEDURE 11 1 Front Axle 11 2 Front Drive Shaft 17 3 Replacement of Front Drive Shaft Boot 22 4 Rear Axle 27 5 Rear Drive Shaft 34 6 Replacement o...

Page 686: ...angle Since the drive shaft employs constant velocity joints it provides smooth even rotation of the drive wheels without any vibration The bearing utilizes a preloaded non adjustable ta pered roller...

Page 687: ...BJ which provides a maximum operating angle of 46 FTJ g n HE 1 T 13 Transmission side Tire side C4 313 Fig 2 1 CONSTRUCTION OF FREE RING TRIPOD JOINT FTJ The FTJ is an improved version of the TJ trip...

Page 688: ...ploys constant velocity joints it provides smooth even rotation of the drive wheels without any vibration The bearing is a preloaded non adjustable tapered roller unit type The hub is fitted to the ta...

Page 689: ...mbined in order to improve resistance to corrosion The constant velocity joint on the tire side is a bell type BJ which provides a maximum operating angle of 46 C4 314 Fig 5 3 Aluminum Wheel A GENERAL...

Page 690: ...CD mm in P225 50R16 91V 16 x 7 1 2JJ 55 2 17 114 3 4 50 T type Spare tire Tire size Rim size Rim offset mm in PCD mm in T135 80D16 16 x 4T 45 1 77 114 3 4 50 Offset 1 P C D C4 312 Fig 7 2 TIRE INFLATI...

Page 691: ...5AC 25 286 5 11 28 24 0 0 945 FTJ BJ 95AC 25 L U O 13 Transmission side Tire side L C4 357 Fig 8 4 REAR DRIVE SHAFT ASSEMBLY Type of axle shaft ASSY Distance between inner and outer boots L Diameter D...

Page 692: ...18 oz Balance weight part number For aluminum wheel Weight g oz 23141 GA462 5 0 18 23141 GA472 10 0 35 23141 GA481 15 0 53 23141 GA491 20 0 71 Wheel balancing 23141GA501 25 0 88 _ 23141GA511 30 1 06 2...

Page 693: ...WHEELS AND AXLES Clool 4 2 C COMPONENT PARTS 1 Front Axle 1 H h ran Fig 10 Il JI 3 SSG 6003 C4 315 9...

Page 694: ...1 11 Buffle plate BJ 12 BJ ASSY 13 Boot band protector 14 Boot band 15 Boot BJ 16 Boot DOJ 17 Circlip 18 Cage 19 Ball 20 Inner race DOJ 21 Span ring 22 Outer race DOJ 23 Buffle plate DOA 24 O ring 25...

Page 695: ...0 1 6 7 12 1 SHELL 6459N 2 Molylex N02 P N723223017 3 SSG 6003 C4 315 1 Hub cap 2 O ring 3 Axle nut 4 Hub 5 Tone wheel 6 Oil seal OUT 7 Housing 8 Bearing 9 Snap ring 10 Oil seal IN 11 Baffle plate BJ...

Page 696: ...per bolt Be sure to loose and retighten axle nut after removing wheel from vehicle Failure to follow this rule may damage wheel bearings 5 Remove bolts which secure ball joint to housing C4 101 Fig 14...

Page 697: ...14 Using a puller remove tie rod ball joint from knuckle arm Fig 21 15 Remove housing assembly 16 Install in reverse order of removal For installation and tightening torque of suspension parts refer...

Page 698: ...atch polished area of hub b Be sure to install inner race on the side of outer race from which it was removed Fig 24 3 Remove disc cover from housing Fig 25 4 Using a standard screwdriver remove outer...

Page 699: ...ge If defective replace with a new one a If a bearing is faulty replace it as the bearing set b Be sure to replace oil seal at every overhaul JJ IJJJJ Replace as a set B4 596 Fig 30 D ASSEMBLY 1 Attac...

Page 700: ...nap ring in its groove Make sure to install it firmly to groove 7 Using OIL SEAL INSTALLER FRONT 28099PA030 press inner oil seal until it contacts circlip OIL SEAL INSTALLER FRONT 28099 PA030 7 HOUSIN...

Page 701: ...R FRONT 28099 PA020 a O o I HUB STAND 28099 PA080 C4 333 Fig 37 2 Front Drive Shaft A REMOVAL AND INSTALLATION 1 Move select lever to Neutral 2 Release parking brake lever 3 Lift up vehicle and remove...

Page 702: ...Twrench Brake 1 hose C4 113 Fig 41 10 Place alignment marks on stabilizer lever and stabi lizer and remove stabilizer lever Stabilizer lever Marking Lower arm C4 109 Fig 42 11 Loosen stabilizer clamp...

Page 703: ...lip 1 Using AXLE SHAFT INSTALLER 922431000 and ADAPTER 927390000 pull drive shaft into place a Make sure O ring is properly installed on transmis sion spindle b Apply a sufficient coat of grease to t...

Page 704: ...snap ring and trunnion Fig 52 Be sure to wrap shaft splines with vinyl tapeto prevent boot from scratches 10 Remove FTJ boot 11 Remove BJ boot band and boot C INSPECTION Check the removed parts for d...

Page 705: ...on shaft C4 342 Fig 53 4 Install snap ring to shaft Confirm that the snap ring is completely fitted in the shaft groove 5 Fill 100 to 110 g 3 53 to 3 88 oz of specified grease into the interior of FT...

Page 706: ...d remove front wheel Do not remove axle nut 4 Disconnect front exhaust pipe 5 Remove stabilizer link 6 Disconnect ABS harness clamp from strut 7 Disconnect brake hose clamp from strut 8 Disconnect low...

Page 707: ...Remove FTJ outer race The grease is a special grease Do not confuse with other greases 14 Place alignment marks on free ring and trunnion y V y Be sure to wrap shaft splines with vinyl tape to prevent...

Page 708: ...ed grease The inside of the larger end of BJ boot and the boot groove must be cleaned so as to be free from grease and other substances 2 Place FTJ boot at the center of shaft 3 Align alignment marks...

Page 709: ...installing FTJ boot position outer race of FTJ at center of its travel 12 Put a band through the clip and wind twice in alignment with band groove of boot Use a new band 13 Pinch the end of band with...

Page 710: ...ose contact with clip 17 Fix boot on BJ in the same manner Extend and retract FTJ to provide equal grease coat ing 18 Install remaining parts in reverse order of removal For installation and tightenin...

Page 711: ...Ball 7 Snap ring 20 Inner race DOJ 8 Bearing 21 Span ring 18 13 9 Housing 22 Outer race DOJ 14 10 Oil seal IN No 1 23 Buffle plate DOJ w2 a i16 11 Buffle plate BJ 24 O ring G C14 12 BJ ASSY 25 Circli...

Page 712: ..._ C4 306 I ly 6 Remove axle nut using a socket wrench Be sure to loosen and retighten axle nut after removing wheel from vehicle Failure to follow this rule may damage wheel bearings 7 Return parking...

Page 713: ...r assembly securing bolts rig I 15 Disconnect trailing link from housing rig ou 1 1g d I 17 Remove two nuts securing strut to housing Do not remove upper bolts rig rsz 18 Remove caliper assembly and f...

Page 714: ...curing bolts and housing 24 Install in reverse order of removal For installation and tightening torque of suspension parts refer to 4 1 C200 For installation and tightening torque of brake parts refer...

Page 715: ...ARING PULLER REAR 927100000 remove bear ing by pressing inner race a Do not remove bearing unless damaged b Do not re use bearing after removal BEARING INSTALLER REAR 92710 0000 O Fig 86 If inner bear...

Page 716: ...osely contacts hub b Use a 12 mm 0 42 in hole in the HUB STAND 28099PA080 to prevent hub bolt from tilting during installation HUB STAND 28099 PA080 i C4 349 Fig 92 2 Remove foreign particles dust rus...

Page 717: ...il seal into housing until it touches bottom OIL SEAL INSTALLER REAR 170 HOUSING STAND REAR 28099 PA060 C4 340 Fig 97 8 Apply sufficient grease to oil seal lip Specified grease SHELL 6459N a If specif...

Page 718: ...nut 5 Loosen axle nut using socket wrench a Do not remove axle nut b Be sure to loosen and retighten axle nut after removing wheel from vehicle Failure to follow this rule may damage wheel bearings 6...

Page 719: ...ul not to damage oil seal lip when removing drive shafts b Left DOJ spline end is removed together with cir clip Do not remove circlip from right DOJ installed inside of rear differential c Wrap groun...

Page 720: ...ing torque of suspension parts refer to 4 1 C200 For installation and tightening torque of brake parts refer to 4 4 C200 a Use a new self lock nut b Always tighten axle nut before installing wheel on...

Page 721: ...nt Check seizure corrosion damage wear and excessive play 2 Shaft Check excessive bending twisting damage and wear 3 Boot Check for wear warping breakage or scratches 4 Grease Check for discoloration...

Page 722: ...lace the matched position of circlip in the ball groove of outer race c Pull the shaft lightly and assure that the circlip is completely fitted in the groove u 84 615 Fig 119 11 Apply an even coat of...

Page 723: ...from housing 11 Remove DOJ from rear differential using DRIVE SHAFT REMOVER 28099PA100 Be careful not to damage side bearing retainer Always use bolt shown in Figure 123 as supporting point for REMOVE...

Page 724: ...d excessive play 2 Shaft Check excessive bending twisting damage and wear 3 Boot Check for wear warping breakage or scratches 4 Grease Check for discoloration or fluidity C INSTALLATION Use specified...

Page 725: ...ig 133 10 Install circlip in the groove on DOJ outer race a Assure that the balls cage and inner race are com pletely fitted in the outer race of DOJ b Exercise care not to place the matched position...

Page 726: ...lowance over the clip Be careful so that the end of the band is in close contact with clip 18 Fix up boot on BJ in the same manner 19 Place protector onto BJ boot band Extend and retract DOJ to provid...

Page 727: ...appears as a solid band across the tread Tire tread Al 6 045 Fig 140 a When replacing a tire make sure to use only the same size construction and load range as originally installed Avoid mixing radia...

Page 728: ...install it prop erly not to have a slack otherwise it may hit wheel while driving 4 When washing aluminum wheel use neutral syn thetic detergent and water Avoid using the cleanser including abrasive h...

Page 729: ...This lengthens service life of tires a When rotating tires replace unevenly worn or dam aged tires with new ones b Since T type tire for temporary use is prepared as a spare tire tire rotation is as...

Page 730: ...the smaller tire size a tire chain will not fit properly and will result in damage to the vehicle and the tire d When using a T type tire Do not drive at a speed greater than 80 km h 50 MPH Drive as s...

Page 731: ...All Airbag system electrical wiring harnesses and connectors are covered with yellow outer insulation Do not use electrical test equipment on any circuit related to the Supplemental Restraint System...

Page 732: ...1 Steering Column UNLOCK position 1 Universal joint 2 Telescopic shaft 3 Coating plate 4 Capsule 5 Curling plate 6 Lifting spring 7 Steering shaft 8 Telescopic lever 9 Tilt up lever 10 Tilt select le...

Page 733: ...detachable capsule set 4 RUBBER COUPLING A rubber coupling is used between the two universal joints in the engine compartment to reduce flutter kickbacks and the noise from the steering gearbox Fig 2...

Page 734: ...acket and the support bracket In a collision the curling plate deforms to effectively absorb the energy of the impact Bracket Curling plate Support bracket Before energy absorption Force After energy...

Page 735: ...heel Oil will then be delivered to chamber A or B via pipe A 5 or B 4 Oil in chamber A or B acts on rack piston to produce the force required to move rack shaft 8l to the left or the right This helps...

Page 736: ...inder 3 Rack shaft 6 Power cylinder 04 007 Fig 9 The gearbox is integrated with a built in control valve The control valve and power cylinder are connected to and power cylinder The rack shaft is used...

Page 737: ...g Cross section view A Cross section view B of oil passage of fail safe function switch circuit C4 008 Fig 10 The control valve consists of a rotor which rotates together with the steering shaft a pin...

Page 738: ...elivered from the oil pump returns to the oil reservoir so that neither oil pressure builds up nor does the power cylinder activate Chamber A Chamber B Va From oil pump ti From oil pump _j U 3 To B b...

Page 739: ...relief valves 1 Vane pump The vane pump consists of a rotor cam rings and ten vanes When the rotor rotates the vane located in each groove of the rotor is radially swung out by centrifugal force and p...

Page 740: ...en the front and rear of orifice 2 in response to increases in discharge flow the valve spool moves against the tension of the flow control spring so that the oil flow is controlled by the open and cl...

Page 741: ...his permits the driver to use less steering effort during low speed driving and to have a firm rigid response during high speed driving A FEATURE 1 Less steering effort is required even when the steer...

Page 742: ...the system to maintain the same steering characteristic as a conventional steering system even when a problem occurs in such electrical units as ECU vehicle speed signal engine speed signal solenoid...

Page 743: ...STEERING SYSTEM M3B1 4 3 B OPERATION 1 HYDRAULIC SYSTEM Fig 18 04 012 13 sptmu Power steering warning lamp...

Page 744: ...eeve Rotary type control valve composed of sleeve and that forms a passage It drives the solenoid by current pinion shaft torsion bar and reaction chamber reaction from the ECU to control reaction pre...

Page 745: ...1 Construction The input shaft has 3 reaction arms each with a V groove cut lengthwise to convert thrust from the reac tion piston into turning torque The reaction piston moves back and forth in the...

Page 746: ...flow control char The construction is basically the same as the engine acteristic speed sensing type but flow control valve design is Oil reservoir tank Spool valve Return port Flow control spring To...

Page 747: ...eaction control valve and engine speed sensors sends current correspond ECU Vehicle speed sensor 2 I MPFI ECU I engine speed I Diagnosis connector Battery Ignition switch I I CPU Memory Trouble detect...

Page 748: ...voir tank are connected by a path making the reaction pressure 0 kPa 0 kg cm 0 psi In this condition the reaction pressure does not work on the reaction piston nor does the reaction piston operate So...

Page 749: ...ol valve in the same direction the pump pressure divided at the valve spot is led into the power steering reaction chamber to act on the reaction piston As a result a rigid steering response is felt b...

Page 750: ...2 system o 0 3 0 30 3 0 3 1 2 R 4 Backup power supply system 30 0 3 0 3 0 30 3 0 30 3 0 3 1 2 5 Engine speed signal system incl EGI ECU T i r 0 3 0 3 _ k3 _ a 0 3 0 3 0 3 0 3 1 2 pm lf s 1i Normal 0 s...

Page 751: ...ystem Rotary valve Overall gear ratio 16 2 Type Vane pump Oil reservoir tank Installed on pump Output cm3 cu in rev 9 6 0 586 Relief pressure kPa kg cm2 psi 7 846 80 1 138 Oil pump Power steering syst...

Page 752: ...ck center in straight N kg lb ahead position Less than 11 18 1 14 2 51 Maximum allowable value 12 7 1 3 2 9 Pulley shaft mm in Radial play 0 4 0 016 or less Axial play 0 9 0 035 or less Oil pump Power...

Page 753: ...ontrol sub switch 4 Steering wheel ASSY 5 Combination switch ASSY 6 Cap LH 7 Column cover telescopic 8 Grommet 9 Column cover fixed 10 Column ASSY 11 Column guide 12 Dust seal ASSY 13 Protector 14 Ste...

Page 754: ...8 Hose A 9 Hose B 10 Return pipe ASSY 11 Return hose ASS 12 Gearbox clamp 13 Universal joint c 14 Clamp hose k I T6 I Steering gearbox j T6 Tightening torque N m kg m ft b T5 T1 10 20 1 0 2 0 7 14 T2...

Page 755: ...T 18 Plate T6 2 ly I l 19 Pressure pad 32 Ball bearing 20 Seat 33 Y pa king 21 Pipe C 34 Back up ring 22 Pipe D 35 Dust seal yyll 23 Lock washer 36 Valve housing ASSY V n 24 Tie rod CP LH 37 Dust cov...

Page 756: ...Connector O ring O ring Connector ASSY Oil pump switch Front body valve ASSY Flow control valve Front body Spring O ring O ring Shaft Oil seal Ball bearing Pulley Rear body Gasket Cartridge ASSY Strai...

Page 757: ...1 Disconnect battery earth terminal 2 Remove airbag module ASSY Ref to 5 5 No W1 B2 a Turn ignition switch OFF and wait 10 minutes before starting work b After removal store airbag module with pad sid...

Page 758: ...rration I C4 034 Fig 34 4 Disconnect connectors for ignition switch steering ECU and combination switch wiring harness under instrument panel 5 Remove two nuts and a bolt under instrument panel securi...

Page 759: ...Column guide I 5 Combination switch ASSY 12 Dust seal ASSY I 6 I Cap LH 13 Protector 7 Column cover telescopic C4273 Fig 36 1 Remove steering wheel nut then draw out wheel from shaft using steering pu...

Page 760: ...ce if faulty 1 H Looseness C4269 Fig 38 Standard value of universal joint free play 0 mm 0 in Max value of universal joint swinging torque 0 3 N m 0 03 kg m 0 2 ft Ib 0 Overall length of steering colu...

Page 761: ...el to neutral and install it onto steering shaft Insert roll connector guide pin into guide hole on lower end of surface of steering wheel to prevent damage Draw out airbag system connector horn conne...

Page 762: ...ng 18 Plate 19 Pressure pad 20 Seat 21 Pipe C 22 Pipe D 23 Lock washer 24 Tie rod CP LH 25 Tie rod end ASSY RH 26 Retaining ring 27 Shim 28 Ball bearing 29 Spacer 30 Oil seal 31 Pinion valve ASSY Fig...

Page 763: ...hicle with a jack and remove front wheels 4 Remove front under cover 69 C4 281 Fig 43 6 Installation is in the reverse order of removal Apply sealant to large end of boot and silicon grease to small e...

Page 764: ...e a drain fluid rotating steering wheel to the right and 1e Similarly loosen flare nut securing other pipe a disconnect the pipe and drain fluid from the pipe a After removal cover with a waste cloth...

Page 765: ...ASSY so 2 To ease removal of gearbox turn gearbox ASSY that it can be reassembled at the original serration around so that control valve faces rear b Do not turn steering wheel as this will cause the...

Page 766: ...ox after removal of pipe clamp 3 Disconnect pipes A and B from steering body and control valve housing Replace pipes and or flare nuts if damaged Fig 57 4 Remove tie rod end and lock nut 5 Pry off cli...

Page 767: ...hten adjusting screw until it no longer tightens WRENCH ock nut J Adjusting screw 34099PA100 04 046 Fig 63 10 Using WRENCH 32 mm 1 26 in width across flats P N 34099PA100 or adjustable wrench remove t...

Page 768: ...high pressure seal Insert REMOVER from valve side and lightly tap it using a hammer to drive out back up ring and oil seal Discard back up ring and oil seal after removal replace with new ones REMOVER...

Page 769: ...iston Be careful not to scratch outer surface of rack piston and seal ring groove A scratch may reduce the sealing effect resulting in faulty piston operation Sharp edged long rod Seal ring O ring 84...

Page 770: ...g 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 entire gearbox ASSY 1 Bend of rack shaft 2 Bend of cylinder portion...

Page 771: ...etween left and right sliding resistance Less than 20 Unit mm in 98 N 10 kg 22 1b Lower side Left turn 1 Measuring I point 5 0 20 5 0 20 04 243 Fig 76 Right turn steering Service limit Less than 0 4 m...

Page 772: ...gearbox Specified grease for gearbox VALIANT GREASE M2 Parts No 003608001 net 0 5 kg 1 1 Ib 1 Reassembly of rack ASSY 1 Attach steering body ASSY to STAND as shown Apply a coat of grease to needle be...

Page 773: ...e of steering body ASSY Rack ASSY e uy Back up ring I C4 080 5 Installation of holder ASSY Attach GUIDE to rack ASSY to prevent scratching cylinder and apply a thin coat of grease to rack ASSY and GUI...

Page 774: ...ousing or pinion fr valve ASSY is replaced with a new one add two or three shims install valve ASSY on pinion housing and tighten with two bolts to 20 29 Nom 2 0 3 0 kg m 14 22 ft Ib Then measure clea...

Page 775: ...this surface 2 Charge hole with grease 3 Charge adjusting screw with grease C4 296 Fig 91 The left and right tie rod CP differ as indicated in the table below Left tie rod pinion No air vent hole pro...

Page 776: ...olding adjusting plug using a closed wrench tighten lock nut using LOCK NUT WRENCH Tightening torque 59 74 N m 6 0 7 5 kg m 43 54 ft Ib i i LOCK NUT WRENCH 34099PA100 04 052 Fig 97 a Do not allow liqu...

Page 777: ...ig I u l 5 If tie rod end was removed screw in lock nut and tie rod end to screwed portion of tie rod and tighten lock nut temporarily in a position as shown in the illustration Fig 102 Pay attention...

Page 778: ...OUT 3 mm IN 0 12 OUT 0 12 in 2 Adjust steering angle of wheels Inner wheel 34 42 37042 Outer wheel 30006 33006 3 If steering wheel spokes are not horizontal when wheels are set in the straight ahead p...

Page 779: ...ed portion and turn the steering wheel from lock to lock about 30 to 40 times with engine running then make compari son of the suspected portion between immediately after and several hours after this...

Page 780: ...sing is damaged Replace the oil seal and the parts that are damaged during disassembly with new ones B DISASSEMBLY 1 ENGINE SPEED SENSING TYPE 1 Remove dust cover a Be careful not to scratch housing o...

Page 781: ...ousing ASSY rig I i4 2 Remove valve housing ASSY together with pin ion fr valve ASSY as a unit When extracting valve ASSY remove input shaft and valve ASSY as a unit 2 Disassembly of control valve ASS...

Page 782: ...t to drop valve ASSY REMOVER 34099PA070 lol lol I I C4 067 1 1g 1 19 2 Remove spacer and take off the sleeve smoothly a Scratching input shaft can cause oil to leak b Do not deform spacer as it is reu...

Page 783: ...R 926450000 04 291 Fig 123 5 Apply a coat of grease to inner wall of FORMER and secure seal ring assembled in step 9 as shown Leave seal ring unattended for approximately 10 minutes until it settles d...

Page 784: ...nstall Y packing and back up washer in valve housing a Face Y packing in the direction shown in Figure 127 when installing b To avoid scratching Y packing apply a coat of grease to contact surface of...

Page 785: ...r until it contacts staged portion of input shaft 2 ELECTRONICALLY CONTROLLED TYPE Before assembly clean parts and tools in kerosene and dry with compressed air Do not use organic solvent 1 Apply grea...

Page 786: ...135 6 Install spacer and retaining ring a Fit retaining ring properly in groove b Be careful not to scratch input shaft as it can cause oil to leak c Do not expand retaining ring excessively Fig 136 7...

Page 787: ...m bracket and leave as it is 8 Raise vehicle 9 Remove under cover 10 Remove bolts securing oil cooler with condenser from both sides 11 Slightly lift and move radiator ASSY and draw out oil cooler 04...

Page 788: ...e order of removal 6 Oil Pump Reservoir Tank A REMOVAL 1 Disconnect battery earth terminal 2 Remove belt cover 3 Loosen nuts which secure idler pulley 4 Loosen slider bolt and remove V belt rig 14z 5...

Page 789: ...enough to be rotated with your hand press pump against tank while removing bolts Failure to do so causes fluid to spill out Remove tank as quickly as possible and wipe clean fluid spilled on parts Exc...

Page 790: ...ice limit replace oil pump ASSY with a new one Refer to Service limit 5 Oil pump Interior Oil pump emits a noise that is markedly 2 Bend in the shaft or damage to bear different in tone and loudness f...

Page 791: ...sistance to rotation of pulley Service limit Maximum load 9 22 N 0 94 kg 2 07 lb or less Ditch deflection of pulley Service limit 1 0 mm 0 039 in or less Fig 149 A rather higher value may be indicated...

Page 792: ...ASSY 7 Flow control valve 8 Front body 9 Spring 10 O ring 11 O ring 12 Shaft 13 Oil seal 14 Ball bearing 15 Pulley 16 Rear body 17 Gasket 18 Cartridge ASSY 19 Straight pin 20 Pressure plate 21 Cam ri...

Page 793: ...et 3 Remove pump bracket from vise 4 Place pump in a vise Use soft jaws 5 Remove bolts which have already been loosened in step 1 above Fig 153 6 Remove gasket 4 Removal of cartridge ASSY pressure pla...

Page 794: ...es 4 Bearing damage 4 Side plate Wear and damage on sliding surfaces Replace with a new one 5 Cam ring Ridge wear on sliding surfaces 6 Vane Excessive wear on nose radius and side surfaces replace wit...

Page 795: ...Insert pin into holes in cam and pressure plate a Ensure that vane is installed with R side facing the cam b Check that vane moves smoothly c Apply a coat of automatic transmission fluid DEXRON II to...

Page 796: ...ering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm 0 12 in In case the following happens leave it about half an hour and then do step 6 again a The...

Page 797: ...cification 2 Improper or unbal 2 Improper rims out ance toe in of specification 3 Loose connection of 3 Tires not properly suspension inflated O K O K Fluid NOT O K Refill bleed air replace Others K R...

Page 798: ...hoses Replace bad parts Measure regular pressure at Leakage of fluid line Replace idling with valve opened O K Obstacle in fluid line Replace fluid or component of I I fluid line Poor work of relief...

Page 799: ...2 26 N 0 23 kg 0 51 lb or less in both direction Fluctuation width is 1 08 N 0 11 kg 0 24 lb or less f O K Measure folding torque of the joint ASSY Result 5 49 N 0 56 kg 1 23 lb or less for long yoke...

Page 800: ...positions 11 8 1 2 2 6 or less resistance Difference be tween left 20 or less and right turns 265 27 60 or less Sliding re sistance Difference be tween left 20 or less and right turns V1y I U Measure...

Page 801: ...sistance Straight ahead position within 30 mm 1 18 in from rack center Less than 10 49 N 1 07 kg 2 36 lb Maximum allowable torque 11 8N 1 2kg 2 6lb C4 247 Fig 169 Sliding resistance Left turn steering...

Page 802: ...or damaged hose end fit ting Damaged gasket Damaged oil seal Leaks at oil tank Location I Leaks at filler neck Location s Cracked oil tank Damaged O ring Damaged cap packing Cracked filler neck Fluid...

Page 803: ...STEERING SYSTEM T2041 4 3 Fig 172 73...

Page 804: ...Gearbox ASSY or Subframe Loosened installation of Oil pump pulley or other pulleys Retighten Loosened linkage or play of steering sys or suspension Retighten or replace Loosened tightening of joint A...

Page 805: ...or pipe Abnormal inside of oil tank Removed oil tank cap Whistle continuous Abnormal pipe of Gearbox ASSY While engine is running or abnormal inside of Hose Inspect and retighten fluid line connection...

Page 806: ...Oil pump makes whine or growl noise slightly due to its mechanism Even if the noise can be heard when steering wheel is turned at standstill there is no abnormal function in the system provided that...

Page 807: ...n 11D Pipe to sub frame 5 0 20 2 Cylinder pipe to ATF pipe 15 0 59 FTJ Free ring Tripod Joint to Shaft and Universal joint 13 0 51 Hydraulic reaction harness 20 0 79 ASSY to FTJ Hydraulic pressure rea...

Page 808: ...I Instruct customers X10 Although surface layer materials of rubber hoses have excellent weathering resistance heat resistance and resistance for low temperature brittleness they are likely to be dam...

Page 809: ...al from diagnosis connector terminal Power steering mode terminals No 5 TEST No 6 READ MEMORY No 7 DIAGNOSIS No trouble code appears D check Trouble code appears Check as per trouble code D check Trou...

Page 810: ...No 6 3 D CHECK 1 Turn ignition switch OFF 2 Connect male terminal to diagnosis connector mode terminal No 5 3 Start engine 4 Drive vehicle at least 10 meters 33 ft 5 Disconnect male terminal from diag...

Page 811: ...back up power supply f 1 1 f r 0 3 0 3 0 30 3 0 30 3 0 3 1 2 5 Engine speed signal system including EGI ECU P R PR P 0 3 0 3 0 30 30 3 0 3 0 3 0 3 0 3 1 2 Normal EM M os 0 s C4 616 Fig 175 2 HOW TO R...

Page 812: ...Computes and sends Control unit ECU control output signal in 0 0 0 0 relation to input signal received Regulates reaction cham ber oil pressure Maxi Output signal Solenoid mum reaction force heavy st...

Page 813: ...gular pulse at 11 YG 0V 10V min 10V min vehicle speed of 0 km h 0 Solenoids side MPH Solenoid 2 9 BrW 0V 0 to 1V 0 to 1 V Return side Warning lamp 9 WL 0V 10V min 10V min Read memory 6 Br 0V 5V 5V mod...

Page 814: ...FAULTY Diagnosis Faulty lamp wiring Faulty power supply system Faulty ECU 1 Check warning lamp wiring D side wiring OK 2 Check ECU power supply OK Check ECU connector terminals for poor contact OK Re...

Page 815: ...ce Battery I m CPU F5 B44 wL Fuse OD a Ln a box o 0 O z z E GBI il B 0 L W W STEERING il Combination meter B40 i6 CD B53 1234 5678 u u 1 91191111121131141151161171181 P1 2 4 5 6 7 8 C 8 16 1 9 1101111...

Page 816: ...nition switch OFF 2 Disconnect ECU from connector 3 Turn ignition switch ON 4 Measure voltage between ECU connector terminal and GND Connector Terminal Specified voltage 1353 No 16 Body 10V min Connec...

Page 817: ...87...

Page 818: ...arness Faulty ECU 1 Check D check and read memory harnesses OK Check ECU power supply Refer to T4A0 OK 2 Check warning lamp system OK Check ECU connector terminals for poor contact OK Replace ECU Symp...

Page 819: ...ib i3 ED RW RW i1 B40 16 W 840 B 1 i6 1 234 5678 1 2345 678910 9 1011 1213141516 17 l8 11111211311411511611711811912012122 8 1 7 1 6 14 5 1 4 1 i1 i3 3 11 2 10 1 9 87 5 4 21 98876 5 321 18171615141312...

Page 820: ...NOT O K Open circuit between connector 1340 and ECU terminals 3 Turn ignition switch OFF 4 Remove steering warning lamp including combina tion meter 5 Apply a voltage of 12 volts across warning lamp...

Page 821: ...olenoid unit Replace power steering assembly or valve it OK Not OK 2 Check harness between ECU and solenoid 61 Repair or replace harness OK 3 Check harness between power supply and sole Not OK noid Re...

Page 822: ...tinuity between connector B53 terminals indicated below 3 CHECK HARNESS 1 Turn ignition switch OFF 2 Disconnect ECU from connector 1317 3 Measure voltage across connector 1317 and GND Connector Fr Ter...

Page 823: ...illuminates Not OK 1 Check solenoid unit Replace power steering or valve OK Not OK 2 Check harness between ECU and solenoid Repair or replace harness OK Not OK Check ECU connector terminals for poor...

Page 824: ...connector 1317 dicated below 3 Measure resistance between connector 1353 termi nals and check continuity between connector 1353 Connector Terminal Specified resistance terminal and GND indicated below...

Page 825: ...y ECU Not OK Check speedometer operation 11101 Check speedometer cable OK Not OK 1 Check vehicle speed sensor 2 input signal at 2 Check vehicle speed sensor 2 and harness ECU OK Not OK Check ECU conne...

Page 826: ...ls and connector B7 termi nal and GND indicated below Connector fr Terminal Specified resistance 139 No 2 137 No 22 1 Q max 137 No 11 Body 1 Mfg min 5a C4 582 Fig 196 2 CHECK VEHICLE SPEED SENSOR 2 AN...

Page 827: ...PPLY Diagnosis Faulty back up power supply harness Faulty ECU Nnt OK Symptom Trouble contents are not retained in memory FL 1 5 F16 B53 F17 1234 12345678 123 S678 910111213141516 C4586 I Fig 200 f17 S...

Page 828: ...CK UP POWER SUP PLY HARNESS 1 Measure voltage across connector F16 terminal and GND Connector fr Terminal Specified voltage F16 No 2 Body 10V min If fuse No 25 is blown it can be identified by shorted...

Page 829: ...MPFI ECU or harness Faulty ECU Not OK Symptom Engine operation is controlled only by vehicle speed sensor 2 5V MPF1 B61 83 ECU Y Y Combination meter B61 12345678 9 1011 1213141516 CPU ECU Electronical...

Page 830: ...onnect ECU from connectors 2 Turn ignition switch ON 3 Disconnect MPFI ECU from connectors 3 Start engine 4 Measure resistance between ECU connector and 4 Observe waveform pattern shown on oscilloscop...

Page 831: ...tional activation of the Airbag system All Airbag system electrical wiring harnesses and connectors are covered with yellow outer insulation Do not use electrical test equipment on any circuit related...

Page 832: ...ich feature heat dissipa tion and superb braking stability In addition the disc brake quickly restores the original braking performance even when wet The brake disc which is externally mounted is secu...

Page 833: ...he tip of the wear indicator comes into contact with the disc rotor and makes a squeaking sound as the wheel rotates This indicates that the pad needs to be replaced O O 0 Wear indicator Disc rotor Ne...

Page 834: ...magnet 1 84 351 Fig 5 Under normal conditions the float remains above the reed switch and the magnetic force from the perma nent magnet in the float is unable to activate it There fore the circuit is...

Page 835: ...able pressure chamber i 101 v 13 1 0 1 Push rod 2 3 Return spring Reaction disc 0 0 0 0 4 Key 0 5 Filter i i 6 O Silencer 7 Operating rod D6 0 8 Poppet valve OD o 0 0 9 Valve body I 10 Plunger valve I...

Page 836: ...pet valve 0 00 0 0 0 q o 0 0 o r Filter L Valve return spring Passage B key Diaphragm plate i Constant pressure chamber Return spring C4 501 Fig 7 2 BRAKE BOOSTER ON When the brake pedal is depressed...

Page 837: ...disc due to the reaction force of oil pressure delivered from the master cylinder As a result pressure differential is maintained between the constant pressure chamber and variable pressure chamber u...

Page 838: ...nd moves the master cylinder piston via the push rod At this point a boosting force does not occur but oil atmospheric air and at the same time moves the pressure is produced by movement of the master...

Page 839: ...Stop plate Circlip Balance spring Spring Retainer Master cylinder Primary Valve Rear wheel 7 cylinder O ring Outer cup Inner cup I I I Rear wheel cylinder C4 507 Fig 13 In case of failure in one circu...

Page 840: ...ear wheel valve is opened cylinder This is the split point fluid pressure As the valve opens the rear wheel cylinder fluid pres Th th I t h r Valve Cylinder body Rear wheel cylinder Master 0 cylinder...

Page 841: ...r wheel cylinder C4 512 Fig 18 2 As the master cylinder fluid pressure increases it overcomes spring tension This causes the secondary valve piston and inner piston to move toward the primary circuit...

Page 842: ...ressure control for the two rear wheels if either wheel starts to lock 2 COMPONENTS The ABS consists of four tone wheels 5t four ABS sensors an electronic control unit 70 a hydraulic control unit and...

Page 843: ...When the slip is 100 the wheel locks and does not rotate wheel speed 0 although vehicle speed exists The relationship between the frictional force of a wheel in the fore and aft direction and the slip...

Page 844: ...ECTRONIC CONTROL UNIT E C U The electronic control unit is a digital type that utilizes LSI elements to achieve compact structure and improve circuit reliability It consists of an arithmetic circuit c...

Page 845: ...al Current control I I I ch 4 circuit circuit F i ch 4 ch 2 Ich 2 I Monitor circuit I l 1 I I I 1 I I J Fail memory I _ Driving relay in hydraulic l control unit H U Battery I I I Stabilized power I s...

Page 846: ...l to decrease brake fluid pressure Set point of slip ratio Dummy vehicle speed Wheel speed Vehicle speed Wheel speed b20 Wheel acceleration 1310 0 b0 Control Decrease signal Hold Increase A B C D E F...

Page 847: ...DRAULIC CONTROL UNIT The hydraulic control unit is a fluid pressure control assembly which consists of an electric motor plunger pump damper housing magnet valve and relay The magnet valve moves to th...

Page 848: ...01 has its spring set to act by high fluid pressure and not by normal fluid pressure When cur rent does not flow through the magnet valve the outlet port is sealed so that the oil passage to reservoi...

Page 849: ...This closes the inlet port of the magnet valve and pressure is sealed by the ball of valve F to shut out opens the outlet port so that wheel cylinder pressure the fluid pressure in master cylinder 1T...

Page 850: ...p is held in reservoir 6 Ffg 31 4 Pressure increase action with ABS in operation When current flowing through magnet valve is inter rupted OFF by an instruction emitted from the E C U the fluid pressu...

Page 851: ...B RAKES MSAO 4 4 6 Parking Brake A OUTLINE The rear disc brake has its parking brake drum housed in the disc rotor for improved performance Fig 33 21...

Page 852: ...force applied to brake shoe and the reaction force of A applied to brake shoe 5V via point P provide brake application when the shoes are pressed against the brake drum 6 77 O P point C r u T l O Z O...

Page 853: ...i ameter 42 8 x 2 1 685 x 0 08 mm in Pad dimensions length x width x thickness 146 6 x 47 0 x 11 0 5 77 x 1 850 x 0 433 mm in Clearance adjustment Automatic adjustment Type Disc Floating type Effectiv...

Page 854: ...2 7 18 x 1 18 x 0 126 mm in Clearance adjust Manual adjustment ment Type Tandem Effective diameter 26 99 1 1 16 Master mm in cyl Reservoir type Sealed type inder Brake fluid reservoir capacity 180 10...

Page 855: ...kPa 5 kg cm2 71 psi without engine run ning 294N 30kg 66 lb 1 569 kPa 16 kg cm2 228 psi Brake booster Brake fluid pressure with engine running 147N 15 kg 33 lb 4 511 kPa 46 kg cm 654 psi and vacuum a...

Page 856: ...8 Piston 9 Piston boot 10 Guide pin 11 Pad clip 12 Support 13 Housing 14 Shim 15 Inner shim 16 Innerpad 17 Outer pad 18 Outer shim 19 Disc cover 20 Disc rotor Tightening torque N m kg m ft Ib T1 34 44...

Page 857: ...5 T4 22 31 2 2 3 2 16 23 Grease EeR RUBBER GREASE or NIGLUBE RX 2 GREASE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Guide pin Lock pin Lock pin boot Lock pin sleeve Air bleeder screw Guide pin bo...

Page 858: ...6 Primary piston 7 C ring I 8 Level indicator 3 ASSY Secondary piston n stopper Ilj Yc JS1 10 0 Gasket I 11 Reservoir stopper bolt I 12 Connector bracket i 07 Tightening torque N m kg m ft lb T1 10 18...

Page 859: ...Reaction disc 0 0 0 0 4 Key v uo 5 Filter I O 6 Silencer o0 7 Operating rod 8 Poppet valve O O o 9 Valve body 10 Plunger valve I 0 11 Push rod retainer 7 15 14 O5 C 12 Diaphragm plate 13 Valve return...

Page 860: ...Body COMPLbracket LH 18 Front ABS sensor RH 19 Front ABS sensor LH 20 Grommet 21 Bracket 22 Control spacer 23 Front harness clamp 24 Electronic control unit ASSY 25 Rear sensor sub ASSY RH 26 Rear se...

Page 861: ...hoe Secondary Parking brake shoe Primary Strut spring Strut T3 Shoe guide plate Primary return spring Secondary return spring Adjusting spring Adjusting ASSY Shoe hold down cup Shoe hold down spring T...

Page 862: ...8 Piston 9 Piston boot 10 Guide pin 11 Pad clip 12 Support 13 Housing 14 Shim 15 Innershim 16 Innerpad 17 Outer pad 18 Outer shim 19 Disc cover 20 Disc rotor Tightening torque N m kg m ft 1b T1 34 44...

Page 863: ...rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad c Replace pad if there is oil or grease on it 6 Apply thin coat of PBC GREASE 725191330 or 003607000 to...

Page 864: ...y ASSY Do not allow brake fluid to come in contact with vehicle body wipe off completely if spilled Brake hose 7 C4 524 Fig 49 3 Remove lock pin I ly 4 Raise caliper body and move it toward vehicle ce...

Page 865: ...rom caliper body 5 Remove guide pin boot 5D71NSPECTION 1 Repair or replace faulty parts 2 Check caliper body and piston for uneven wear damage or rust 3 Check rubber parts for damage or deterioration...

Page 866: ...tes If this sound is heard replace the pad c When replacing the pad replace pads of the right and left wheels at the same time 3 Apply thin coat of PBC GREASE 725191330 or 003607000 to the frictional...

Page 867: ...8 Piston seal g Tightening torque N m kg m ft Ib 9 Piston Ti 16 24 1 6 2 4 12 17 10 Piston boot T2 46 58 4 7 5 9 34 43 11 Boot ring T3 7 9 0 7 0 9 5 1 6 5 12 Pad clip T4 22 31 2 2 3 2 16 23 13 Shim 14...

Page 868: ...is oil or grease on it 6 Apply thin coat of PBC GREASE 725191330 or 003607000 to the frictional portion between pad and pad clip 7 Install pad on support Guide pin Outer pad Shim JRubber costing Shim...

Page 869: ...t with vehicle body wipe off completely if spilled fig 6 3 Remove lock pin f 1g 68 4 Raise caliper body and move it toward vehicle center to separate it from support 5 Remove support from back plate R...

Page 870: ...iper body 3 Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston 4 Insert piston into cylinder Do not force piston into cylinder 5 Apply a coat of specified...

Page 871: ...coating Inner pad Ppad must be installed with the clip of pad facing lower side of vehicle 84 371 Fig 76 F INSTALLATION 5 Install caliper body on support 1 Install disc rotor on hub 6 Connect brake ho...

Page 872: ...old down spring 7 Strut spring 16 Shoe hold down pin i T 2 8 Strut 17 Adjusting hole cover 3 9 Shoe guide plate 4 1 7 III 9 Tightening torque N m kg m ft Ib T 46 58 4 7 5 9 34 43 1 Brake grease 1 Dow...

Page 873: ...dard 190 mm 7 48 in Service limit 191 mm 7 52 in 2 Measure the lining thickness If it exceeds the limit replace shoe ASSY Lining thickness Standard 3 2 mm 0 126 in Service limit 1 5 mm 0 059 in Replac...

Page 874: ...ice hole in hub C4 543 Fig 84 f Ensure that shoe return spring is installed as shown in Fig 85 Back plate Shoe guide plate Retainer Soring washer Lever Primary LSecondary shoe L shoe return return spr...

Page 875: ...Slot type screw driver ng screw Back plate Fig 88 4 Install adjusting hole cover to back plate W3D2 4 4 04 141 I Fig 89 2 Forcibly pull parking brake lever 3 to 5 times 3 Adjust parking brake lever b...

Page 876: ...ake cable RH 7 T2 I 11 Cable guide LH 12 Cable guide RH 13 Clamp r y 1 I S m T2 T3 T3 11 T7 4 6 CA Tightening torque N tn kg m ft Ib V t I T1 4 4 7 4 0 45 r 0 75 3 3 5 4 T2 13 23 1 3 2 3 9 17 i 5 T2 T...

Page 877: ...aliz er er C4 204 Fig 95 Fig 96 9 Remove two bolts securing front of tank cover I l 4 Propeller shaft I J Brake cable _ Tank cover 04 207 ig 98 0 While pushing brake cable remove brake cable Fig 99 47...

Page 878: ...rake Lever I A REPLACEMENT I 1 Remove console box from front floor 2 Disconnect electric connector for parking brake switch 3 Disconnect shift lock unit for parking brake lever 4 Remove adjuster and l...

Page 879: ...n stopper 10 Gasket 11 Reservoir stopper bolt 12 Connector bracket Tightening torque N m kg m ft Ib T1 10 18 1 0 1 8 7 13 T2 13 18 1 3 1 8 9 13 T3 1 5 2 9 0 15 0 3 1 1 2 2 C4 5a5 I Fig 105 1 Disconnec...

Page 880: ...er pistons and piston cups Be careful not to damage parts when washing If methanol is used for washing do not dip rubber parts such as piston cups in it for more than 30 seconds otherwise they may bec...

Page 881: ...2 ft Ib If the gasket and secondary piston stopper are assem bled without pushing in the primary piston scratches may be caused on the secondary piston and no pres sure may be built up in the secondar...

Page 882: ...4 Valve body seal 15 Bearing 16 Plate and seal Con chamber 04 500 Fig 111 1 Disconnect battery ground cable 2 Raise vehicle using a jack 3 Disconnect performance rod from sub frame rig 1 1 3 rig I Iz...

Page 883: ...t Fig 114 9 Disconnect low pressure air conditioner pipe Refer to 4 7 W2A0 10 Disconnect vacuum hose from brake booster l I O i1 p er I Brake booster i Brake pedal I II I o I C4 231 Fig 117 14 Remove...

Page 884: ...times applying the same pedal force as that used in ordinary braking operations The pedal stroke should be greatest on the 1st depression and it should become smaller with each successive depression I...

Page 885: ...e greater than the standard value listed below Brake pedal force All model 147N 15 kg 33 lb 490 kPa 5 kg cMZ 71 psi 294N 30kg 66 lb 1 569 kPa 16 kg cmz 228 psi 9 BOOSTING ACTION CHECK Set the vacuum g...

Page 886: ...ng and installing the brake pipe make sure that it is not bent b After installing the brake pipe and hose bleed the air c After installing the brake hose make sure that it does not touch the tire or s...

Page 887: ...ake pedal Repeat these steps until there are no more air bubbles in the vinyl tube Allow 3 to 4 seconds between two brake pedal opera tions 4 Tighten air bleeder securely when no air bubbles are visib...

Page 888: ...ir bleeder of and insert the other end of the tube into a container to collect the brake fluid Fig 127 Brake fluid replacement sequence C C 0 Front right C Master Rear right cylinder Hydraulic unit 20...

Page 889: ...e gauges 3 Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure The standard values are shown in figure In case of failure in one circuit o Split point a _ When both circuit...

Page 890: ...d surface wipe it off quickly if spilt 6 Remove proportioning valve Fig 134 Do not disassemble or adjust the proportioning valve The proportioning valve must be replaced as an as sembly I C INSTALLATI...

Page 891: ...53 Fig 135 Be careful not to damage pole piece located at tip of A REMOVAL the sensor during removal 4 Remove ABS sensor bracket and brake pipe bracket 1 FRONT 1 Disconnect battery ground cable 2 Disc...

Page 892: ...eed sensor termi nals ABS sensor Terminal No Standard Front LH 22 and 4 Front RH 11 and 21 1 kf2 Rear LH 7 and 9 0 0 2 Rear RH 24 and 26 Front LH 22 and 10 20 34 Front RH 11 and 10 20 34 More than 1 0...

Page 893: ...Front hub 84 78 Fig 143 3 OUTPUT VOLTAGE 1 Output voltage can be checked by the following method Install resistor and condenser as follows then rotate wheel about 2 75 km h 1 7 MPH or equivalent Osill...

Page 894: ...5 0 9 1 1 T2 13 18 1 3 1 8 9 13 T3 23 42 2 3 4 3 17 31 T4 7 9 0 7 0 9 5 1 6 5 T5 15 20 1 5 2 0 11 14 T6 2 3 0 2 0 3 1 4 2 2 T5 I II c7 m n i a l i c l i f13 14 I T3 1 10 Front RH outlet 11 Front LH ou...

Page 895: ...lic unit upside down or place n its side 3e careful to prevent foreign particles from getting hydraulic unit Vhen a new hydraulic unit is installed apply a coat ust preventive wax Nippeco LT or GB to...

Page 896: ...d Diagram Terminal location 85 86 93 113 0 Turning off electricity 30 87a 0 0 87 30 87 00 a a I a5 87 Valve relay Turning on electricity 30 87a Oft j es 8s between 85 and 86 30 87 00 DC 12 V o 85 86 7...

Page 897: ...heck that connector is connected correctly and that 1 Remove right front seat connector terminal sliding resistance is correct 2 Remove floor mat located under lower right side of front seat 3 Remove...

Page 898: ...oster or check valve Correct or replace 2 Unstable or uneven braking 1 Fluid on the lining rotor Eliminate cause of fluid leakage clean or replace 2 Rotor eccentricity Correct or replace the rotor 3 I...

Page 899: ...proper disc caliper operation Correct or replace 8 Improper adjusted wheel bearing Adjust or replace 5 Brake noise 1 creak sound 1 Hardened or deteriorated pad Replace the pad 2 Worn pad Replace the p...

Page 900: ...trouble code designated SELF DIAGNOSIS Trouble code designated Troubleshoot in accor dance with trouble code I Inspection using General Troubleshooting Chart T7A0 T6A0 Repair Trouble code designated I...

Page 901: ...E CODES c If the LED does not activate though the warning light is ON the power supply may be inoperative Fig 155 Trouble code Contents of diagnosis 0 LED OFF Improper power line voltage or faulty har...

Page 902: ...LED The LED in the ABS control unit flashes the code blinks corresponding to the faulty part Example 5 2 13 5 2 13 sec a sec a T Trouble code 1 0 4 1 0 sec 0 4 1 0 sec 5 2 13 5 2 13 0 0 0 sec 0 0 a s...

Page 903: ...km h 1 7 MPH Right rear wheel 24 200 300 mV No 24 No 26 GND 26 0V AC range Vehicle speed 2 75 km h 1 7 Stop light switch 25 0V 13 14V When brake pedal is depressed Motor monitoring 14 0V 13 14V When...

Page 904: ...diagnosis zi RRH circuit LED FRH Current RLH QUO 111 I control Current control Stop light SW circuit Fail memory I G SW I Alternator ABS control circuit FRH RLH and Safety circuit Monitor circuit Warn...

Page 905: ...Z Zl 098 R3 Hydraulic unit 19 F LH F RN R LH R RH 43 D I I NI I NI R36 R18 Rear ABS Rear ABS sensor LH sensor RH Rl8 Gray F43 Gray R36 Gray B65 B I ack B98 Wh I te Rl B I ack R7 4 3 2 1 1 2 1 M56 8 7...

Page 906: ...18 sensor LH 3101 B3 Gray B 8 Gray 21 B39 B I ac k 112 3 4 5 6 7 8 9 10 11 121314 ID Wh I te B40 B I ac k 12 3 f 6 78 911 6111 112131415161718 83 B I ac k 1 2 F 3 2 4 5 a 6 6 7j8 9 19 boll l 13 14 iI1...

Page 907: ...resumes although ignition switch remains ON Repair harness connector OK 2 I Check input voltage of ABS control unit to alter nator Not OK Repair harness connector or alternator OK 3 1 Check ABS contr...

Page 908: ...easure voltage between ABS control unit connec tor and ground 2 CHECK INPUT VOLTAGE OF ABS CONTROL UNIT TO ALTERNATOR 1 Start the engine 2 Measure voltage between ABS control unit connec tor and groun...

Page 909: ...lenoid OK 2 Check signal emitted from solenoid on ABS con trol unit side OK Replace ABS control unit Not OK TROUBLE SYMPTOM ABS does not operate Replace hydraulic unit Not OK Repair harness connector...

Page 910: ...2 Body 2 B34 No 11 Body 3 B34 No 12 Body 4 B34 No 3 Body Fig 163 2 CHECK SOLENOID ON ABS CONTROL UNIT SIDE 1 Turn ignition switch ON 2 Attach circuit tester s positive probe to terminal cor responding...

Page 911: ...K I 2 I Check sensor I Not OK after tone wheel check Replace sensor TROUBLE SYMPTOM 0 ABS does not operate OK Replace ABS C U terminal poor contact Replace ABS C U OK Repair harness connector F B 84S...

Page 912: ...ODE Connector Terminal 5 Sensor LH No 1 No 2 6 Sensor RH No 1 No 2 Specified Resistance 0 8 1 3 ks2 TROUBLE CODE Connector fr Terminal 5 R7 No 4 No 22 6 117 No 11 No 21 Specified Voltage 200 300 mV at...

Page 913: ...Check sensor Not OK Faulty sensor OK TROUBLE SYMPTOMS ASS does not operate Rear wheels only are occasionally controlled by ABS Replace ABS C U terminal poor contact Replace ABS C U Repair harness conn...

Page 914: ...AT model 4 Disconnect ABS control unit connector and measure resistance between sensor and ground Connector r Terminal Specified Resistance R7 No 26 Body 1 Mfg min R7 No 9 Body 1 Mfg min 2 CHECK SENSO...

Page 915: ...k motor relay contacts on hydraulic unit side Not OK 3 Check motor relay OK Replace hydraulic unit Not OK 4 Check relay coil on hydraulic unit side OK Not OK 5 1 Check and repair motor power line harn...

Page 916: ...istance between hydraulic unit termi nals Terminal Specified Resistance No 5 No 6 45 55 0 When resistance checks out Not OK check relay as a single unit If resistance checks out OK replace hydraulic u...

Page 917: ...ty hydraulic unit valve relay Interference with other system 1 Check valve relay on ABS control unit side OK 2 Check hydraulic unit valve relay Not OK 3 1 Check valve relay it OK Check trouble code 1...

Page 918: ...R7 R 0101 R1 BrR r T7r Gw GIW ABS FL 1000 741 Contro I unit r as TT FR r RL RR E Y R7 8101 f 3 R1 ao 123451617181911011111211311411 1 1 1234 8910 2 Hydraulic unit 19 02122 324 2 2 29 031 23 343 1 1 1...

Page 919: ...applied No 87 30 1 MCI when no voltage is applied No 87a 30 1 Mil when 12 volts applied No 87a 30 0 f2 when no voltage is applied 4 CHECK HYDRAULIC UNIT VALVE RELAY COIL 1 Disconnect connector from hy...

Page 920: ...nit or faulty ground system Faulty ABS sensor 1 CHECK POWER SUPPLY TO ABS CONTROL UNIT 1 Refer to trouble code 0 T5A0 2 CHECK ABS SENSOR 1 Refer to trouble code 5 and 6 T5C0 and trouble code 7 and 8 T...

Page 921: ...During shifts Band brake locks wheels b When riding over an obstacle c During rough road driving d During U turns Slip signal often is emitted e When wheels are stuck Except for those outlined above...

Page 922: ...ng or maintained to less than 35 mm pitch Check that harnesses are not routed too closely to other electrical units which could serve as a source of noise Check if vehicle I Check ground clearance and...

Page 923: ...troke Check if Yes brakes oper ate properly No Stopping distance may sometimes be longer than for models not equipped with ABS Check wheels and asso ciated parts for loose ness Check tires for imprope...

Page 924: ...ept for those outlined above E FREQUENT ABS OPERATION ABS oper Check if Yes ates fre brake force quently is properly distributed to wheels Check using self diagnosis system Normal Go to A Faulty wheel...

Page 925: ...a new one 4 Check tone wheel for looseness 84 543 Fig 173 Tightening torque 10 16 N m 1 1 6 kg m 7 12 ft Ib 5 Measure tone wheel to pole piece gap over entire perimeter of the wheel 84 542 Fig 172 Fro...

Page 926: ...amaged 2 Check bracket for looseness or improper installation damper for damage and attaching nuts for looseness Specifications Parts must be tightly in place and I I free from damage 3 Check connecto...

Page 927: ...G To avoid rendering the Airbag system inoper ative which could lead to personal injury or death in the event of a severe frontal collision all maintenance must be performed by an authorized SUBARU de...

Page 928: ...IONS AND SERVICE DATA A SERVICE DATA 1 3 mm 0 04 0 12 in Brake pedal Free play Depress brake pedal pad with a force of less than 10 N 1 kg 2 lb l A d l Free play At pedal pad 1 4 mm 0 04 0 16 in cce e...

Page 929: ...Clip 5 Bushing 6 Spring 7 Accelerator pedal 8 Accelerator pedal stopper 9 Stop lamp switch 10 Bushing 11 Spacer 12 Spring 13 Stop lamp switch stopper 14 Clevis pin 15 Snap pin 16 Pedal pad 17 Brake p...

Page 930: ...it by turning nut connecting accelerator cable to throttle body Free play at pedal pad 1 4 mm 0 04 0 16 in Stroke at pedal pad 53 57 mm 2 09 2 24 in 1 BRAKE PEDAL 1 Check position of pedal pad If it i...

Page 931: ...secure pedal bracket i i I i m 7S 1 I I I C4 094 Fig 5 6 Disconnect grommet from toe board and remove accelerator pedal and bracket together with accelerator cable 7 Remove bushing and cable stopper f...

Page 932: ...these parts for wear or damage 2 Lightly move pedal pad in the lateral direction to ensure pedal deflection is in specified range Deflection of brake and accelerator pedal Service limit 5 0 mm 0 197 i...

Page 933: ...eflection 1 ACCELERATOR AND BRAKE PEDAL ASSY TO 1 g mm 0 04 0 31 in GETHER WITH ACCELERATOR CABLE Installation is in the reverse order of removal 1 After installing accelerator cable bracket on toe bo...

Page 934: ...amp switch does not light up Adjust position of stop lamp switch Stop lamp switch is not smooth and or stroke is not correct Replace Insufficient pedal play Adjust pedal play Brake pedal freeplay insu...

Page 935: ...55 9 Compressor Oil 57 10 Cooling Unit 58 11 Heater Unit 60 12 Blower Motor Assembly 60 13 Control Unit 61 14 Compressor 62 15 Condenser 66 16 Receiver Drier 68 17 Trinary Switch 69 18 Pipe I r Hose...

Page 936: ...n is added which corrects for external temperature depending on the temperature requirements of the passengers 8 An electric cooling fan is used with three settings LOW MEDIUM HIGH which reduces noise...

Page 937: ...switch ON o o OFF AUTO I EON 0 0 O C1 T G97DEF VENT CIRC TEMP O o A OUTTEMP Loo it HHI C4 363 Fig 3 4 DEF SWITCH When the DEF switch is pressed the set temperature display and DEF switch LED umber wi...

Page 938: ...367 Fig 7 8 LO LOW SWITCH When the LO switch is pressed when any of the AUTO ECON DEF and VENT switches are ON the LO switch LED umber will illuminate and the fan speed fixed in the LOW approx 4 V po...

Page 939: ...switch will increase the temper ature 1 C 1 F Each press of the 0 switch will decrease the temper ature 1 C 1 F When the set temperature is 18 C 65 F the air mix door is fixed at the max cold position...

Page 940: ...me status as MED 0 0 0 MED tic m No starting with pressing n control the AUTO switch will Auto be established HI 0 0 0 Set at matic No HIGH control Auto Air flow is automati Set at matic Auto Set at c...

Page 941: ...AUTO switch is ON and ambient temperature is high and the set temperature is MAX COLD 18 C 65 F o r Heater core Blower motor Evaporator l F I I l r C4 375 cig 14 4 DEF DEF position can be selected by...

Page 942: ...IR FLOW AND OPERATION OF EACH DOOR Fresh air 1 7 _ Defroster door r CIRC Air mix door Vent door at door Airmix Heater Blower motor Heater door core Evaporator er V 1 7 l t 1 4 Driver side Center outle...

Page 943: ...operation only and cannot be operated manually The DEF HEAT mode is set only in the heater start control mode A cut off is provided in the heat door so that small amounts of air can flow out heat out...

Page 944: ...Five cylinders and pistons are axially arranged around the drive shaft with equal separation of 72 These pistons per form the suction compression and discharge strokes The piston operating in the cyl...

Page 945: ...determined by the opening of the solenoid valve in the cylinder valve stroke Valve stroke ry P Ps u Pd C41014 Fig 3 3 Control of solenoid valve Fig 4 The valve opening force is created by the suction...

Page 946: ......

Page 947: ...through the expansion valve varies in quantity temperature and pressure resulting in insufficient cooling 2 It removes moisture from the refrigerant 3 It removes foreign substance from the refrigeran...

Page 948: ...quiet condenser fan oper ation during intermediate pressure operation 118 20 1 2 0 2 17 1 2 8 2 648 196 27 2 0 384 28 ON Diaphragm Spring Contact point OFF 127 29 1 3 0 3 1 471 196 15 2 0 213 28 18 4...

Page 949: ...275 kPa 13 kg cm2 185 psi When the refrigerant pressure is below 1 275 kPa 13 kg cm2 185 psi the tension of spring 48 exceeds the refrigerant pressure and pushes the shaft down to open the contact tur...

Page 950: ...high pressure liquid refrigerant which comes from the liquid tank to misty low pressure refrigerant and delivers to the evaporator Being at low pressure and low temperature the liquid refrigerant evap...

Page 951: ...hese pressures and the pressures are in the following condition P PZ P P2 F That means the valve is closed with the ball pushed upward B Operation of the valve with the sensing bulb at low temperature...

Page 952: ...tch sensor and engine con trol unit It compares the computed results and P B R signal and issues signals to the door motor fan control amplifier and compressor solenoid actuator This method automatica...

Page 953: ...to a resistance value which is sent to the auto amplifier s V Ambinient sensor I C4 403 Fig 42 f 1g 43 11 SUNLOAD SENSOR The sunload sensor detects the amount of solar radia tion and is installed on t...

Page 954: ...or is installed on the evaporator assembly case heater unit side It converts the temper ature of air flowing to the heater unit into a resistance value after passing through the evaporator and sends i...

Page 955: ...fan motor generates maximum air flow Normally the air flow is controlled by the fan control amplifier Because the fan control amplifier itself causes a small amount of voltage drop the MAX HI relay is...

Page 956: ......

Page 957: ...the position of terminal plate or MAX HOT or MAX COLD position the current is cut off and the motor stops rotating If the auto amplifier output signal turns OFF the motor operation stops irrespective...

Page 958: ...terminal plate or DEF or VENT position the current is cut off and the motor stops rotating If the auto amplifier output signal turns OFF the motor operation stops irrespective of the position of the...

Page 959: ...rolled to change from DEF to AUTO through DEF HEAT in the AUTO mode 5 COOLER START CONTROL The cooler start control function controls the outlet air quantity between OFF and AUTO levels until the evap...

Page 960: ...Evaporator Air mix door motor Water temp sensor tltl Iltnttl II Receiver drier Compressor Outlet air Outlet air Compressor delivery Mode door temp flow control control control control control MPFI o...

Page 961: ......

Page 962: ...4 7 M5D2 AUTOMATIC AIR CONDITIONING SYSTEM 2 PASSENGER COMPARTMENT unit Fig 65 C4 426 28...

Page 963: ...ke Evaporator sensor Driver circuit Fresh door I I 20 Fresh motor Refrigerant temp sensor I AUTO switch Hot side ECON switch CPU Driver circuit I Cold side Air mix door VENT switch Feed back signal mo...

Page 964: ...perature setting I L J C4 428 Fig 67 When the temperature adjustment switch on the control panel is pressed to set a specific temperature the auto amplifier performs computation based on various input...

Page 965: ...AUTOMATIC AIR CONDITIONING SYSTEM M5F1 4 7 Max hot Air mix door opening Max cold Cooling side f Overall signal T Heating side C4 429 Fig 68 31...

Page 966: ...w y Air outlet position Air flow LO voltage VENT BI LEVEL 4 5V HEAT DEF HEAT 5 5V DEF 8 0V 2 Heater start control 1 The heater start control is performed correspond ing to the air outlet position This...

Page 967: ...ake sensor is greater than 20 C 68 F when starting the air condi tioner the auto amplifier performs cooler start control The air flow is set at AUTO LO level when the intake sensor detected temperatur...

Page 968: ...Fig 73 When the AUTO switch on the control panel is pressed the switch signal is sent into the auto amplifier The auto amplifier microcomputer computes the outlet air tem perature based on the evapora...

Page 969: ...sw 1 I 1 I V hi l a 20 Fresh I I n e c e sensor I 5 Circ I 1 A bi t I m en sensor I J _ I I Intake Sunload sensor I door 1 motor Evaporator sensor I 1 1 I Temp adjust switch Temperature setting I I C4...

Page 970: ...ING SYSTEM Intake Conditions Sunload None In vehicle sensor 25 C 77 F Set temperature 24 C 75 F AUTO switch ON RECIRC L 20 FRESH 1 I 1 I 1 I I I I FRESH _ I I I I I 1 18 23 35 40 C 64 73 95 104 F Ambi...

Page 971: ...I 1 I I I Evaporator sensor I Solenoid I I actuator Temp adjust switch I Temperature setting Compressor L C4 438 Fig 77 1 Automatic control of compressor The compressor operation mode is controlled a...

Page 972: ...zone A I rig 1 f Evaporator protection against freezing The compressor magnet clutch is turned OFF depend ing on the air temperature detected by the evaporator intake sensor Compressor ______ Compres...

Page 973: ...3 37 5 temp 41 1 5 29 1 Compressor ON OFF oC F C4 445 Fig 84 CIRC switch OFF Refrigerant temp sensor temp Compressor OFF ON 3 37 I I 1 34 I I 5 33 _ _ _ I Ambient 0 3 37 5 temp 5 23 1 5 29 0 32 1 i 41...

Page 974: ...rant temperature sensor Compressor ON Compressor OFF 15 0 C 5 32 F 6 AUTOMATIC CONTROL OF AMBIENT TEM PERATURE CORRECTION The temperature data obtained by the ambient sensor is sent to the auto amplif...

Page 975: ...Middle pressure M M Cooling fan Cooling fan RH LH 04 450 Fig 89 Input signal Output signal Compressor Vehicle speed Engine water Air conditioner Cooling fan signal temperature intermediate MPFI unit s...

Page 976: ...ch o When ambient temperature is high compartment temperature is decreased below the standard level 05 Standard No correction is made 0 When ambient temperature is low compartment temperature is decre...

Page 977: ...diameter x width 150 x 65 mm 5 91 x 2 56 in Power consumption 250W at 12 5V Motor type Magnet Fan control Main fan Power consumption 175W at 12V Fan outer diameter x blade 320 mm 12 60 in x 4 Motor ty...

Page 978: ...4 7 cioo AUTOMATIC AIR CONDITIONING SYSTEM C COMPONENT PARTS 1 Air Conditioning System Control unit Sunload sensor Fig 16 I 0 Ambient sensor Condenser C4 1018 10...

Page 979: ...ed Because R134a compressor oil is very hygroscopic easily absorbs moisture when parts of the air conditioning sys tem are being removed quickly install a blind plug to pre vent contact with the outsi...

Page 980: ......

Page 981: ...ly use R134a specified tools and parts Do not mix with R12 tools and parts If R134a and R12 refrigerant or compres sor oil is mixed poor lubrication will result and the com pressor itself may be destr...

Page 982: ...r equivalent is recommended U C4 617 Fig 22 SYRINGE A graduated plastic SYRINGE will be needed to add oil back into the system The syringe can be found at a pharmacy or drug store _ lili I lilil B4 66...

Page 983: ...An ELECTRONIC LEAK DETECTOR can be obtained from either a m specialty tool supply or an air conditioning equipment supplier o Must be capable of detecting R 134a Refrigerant O B4 670 4 Fig 27 WEIGHT S...

Page 984: ...connection remove the pro tective seals If for any reason you have to stop before making a connection recap the tube component or fitting B4 671 Fig 104 Visually inspect the O ring surface the O ring...

Page 985: ...Using a back up wrench in conjunction with a calibrated torque wrench torque the connection to the midrange of the specification After completion of torquing use a clean shop towel to remove any exce...

Page 986: ...k Discharge Pres sure 1 Replace parts 2 Check the O ring 3 Other Evacuating for approx 30 minutes for an in service system Airtight check Manifold gauge pointer does not move to cor rect atmospheric p...

Page 987: ......

Page 988: ......

Page 989: ...Connect the center hose from the manifold to the valve Place the 13 6 kg 30 lb container on the scale valve end down Fig 34 3 PURGE THE CENTER HOSE 1 Verify that all three hose connections are tight a...

Page 990: ...ed should have already been closed Low pressure gauge Compound pressure gauge High pressure gauge Close J Close IL 11 IIl 1I IL I 134 697 Fig 38 3 With the OFF switch on and the windows rolled down st...

Page 991: ...t have an adequate refrigerant charge to begin with 2 The area where the leak test is conducted must be free of wind and drafts with still air being the ideal condition 3 The atmosphere where the leak...

Page 992: ......

Page 993: ......

Page 994: ...arts that have been removed for cracks or scratches and if 1 Remove refrigerant temperature and evaporator necessary repair or replace them sensors 2 Unfasten clamps and separate upper and lower cases...

Page 995: ...t temperature sensor C4 627 Fig 135 7 Install evaporator sensor t1g I Jti 11 Heater Unit A REMOVAL 1 Remove heater hoses inlet outlet in engine com partment Drain as much coolant from heater unit as p...

Page 996: ...ille O V C4 s2s Fig 137 3 Remove control unit attaching screws 4 Remove aspirator duct 5 Disconnect control unit harness connector 6 Remove control unit F B DISASSEMBLY AND ASSEMBLY 1 Remove screws 2...

Page 997: ...d high pressure hoses and compressor connections immediately after disconnecting piping tc prevent entry of dirt dust water etc Lower pressure hose 1 y Y n High pressure hose C4 634 Fig 142 6 Disconne...

Page 998: ...AUTOMATIC AIR CONDITIONING SYSTEM Iw14AO 4 7 Sub bracket E C 637 4 Fig 145 12 Remove compressor bracket attaching bolts Fig 146 13 Remove compressor from bracket c4 63s j Fig 147 63...

Page 999: ...installing Low pressure hose High pressure hose C4 641 Fig 149 Tightening torque N m kg m ft Ib Hose attaching bolts 10 20 1 0 2 0 7 14 3 After adjusting compressor belt tension tighten lock bolt and...

Page 1000: ...5 80 637 736 N 65 75 4 0 5 0 mm 0 157 6 0 7 0 mm 0 236 kg 143 kg 143 176 lb 165 lb 0 197 in 0 276 in 392 588 343 441 5 0 6 0 0 8 0 7 Existing belt N 40 60 8 kg N 35 45 kg 77 99 mm 0 197 mm 0 276 Cl 03...

Page 1001: ...iping to prevent dirt dust water etc 1 _ I 11 O 1 i High pressure hose 0 C4 645 Fig 154 6 Remove main and sub radiator fans Remove water hose located under radiator fan shroud rig I 55 7 Move canister...

Page 1002: ...and apply a coat of compressor oil to it before install ing C INSPECTION 1 Make sure the condenser fins are free from dust and insects If the fins are clogged clean by blowing air or water through the...

Page 1003: ...ent en try of dirt dust water etc rig I 4 Separate bracket from receiver dryer T v Receiver drier Bracket 0 o v 04 651 Fig 161 5 To install reverse removal procedures Replace old O ring used with pipi...

Page 1004: ...1 4 8 10 Pipe attaching bolt 5 4 9 3 0 55 0 95 4 0 6 9 B INSPECTION 1 Remove cap from high pressure line service valve and connect gauge manifold to service valve 2 Disconnect pressure switch harness...

Page 1005: ...tall reverse removal procedures Replace old O ring used with piping with new one and apply a coat of compressor oil to it before install ing 2 LOW PRESSURE HOSE 1 Recover refrigerant 2 Remove throttle...

Page 1006: ...sed with piping with new one and apply a coat of compressor oil to it before installing 2 LOW PRESSURE HOSE 1 Recover refrigerant 2 Remove throttle body cover 3 Remove air intake duct 4 Remove ignitio...

Page 1007: ...ck conduction with a circuit tester ohm range I _ COO Fan fuse I I D I O A fuse C4 656 according to the following table 3 1 4 Fig 166 6 OFF relay and Hi relay iek l o 0 U l I L FF F relay 1 O al HI re...

Page 1008: ...the Auto amp may be damaged 4 Every Auto A C related part is a precision part Do not drop them 2 Pre inspection Before troubleshooting check the following items 1 POWER SUPPLY 1 Measure battery volta...

Page 1009: ...0 2 Check using sight glass 3 Check using manifold gauge Self diagnosis T400 Step 1 Check switch LEDs and seg ments Step 2 Check sensors and door motors Step 3 Check output equipment Step 4 Correct se...

Page 1010: ...P 4 Self diagnosis does not start Self diagnosis starts STEP 1 Check switch LEDs and segments on set temperature display pelf diagnosis automatically starts after an elapse of 9 seconds I DEF switch t...

Page 1011: ...With ON with OFF and AUTO switches pressed turn ignition switch ON Self diagnosis does not start Hg 769 STEP 1 o O OFF A O 1 o EF v rT C TEMP 1717 11 OUTOEW STEP 1 Check whether all switch LEDs turn O...

Page 1012: ...orted 14 24 Evaporator sensor Open or shorted 15 25 Refrigerant tem Open or shorted perature sensor 16 26 Water tempera Open or shorted ture sensor 31 Air mix door Faulty PBR 32 Mode door PBR Faulty M...

Page 1013: ...ber illuminates o 0 0 OFF AUTO ECON e o 1 WDEF VENT CI RC o e d I pU LTENp Loo K HI Oo 0 Blinks three times C4 664 Fig 174 Set system to STEP 2 in self diagnosis mode Turn ignition switch OFF Turn ign...

Page 1014: ...ht received Monitors refrigerant temperature determined by auto F08 Tref Refrigerant temperature deg C F amplifier in relation to signal sent from refrigerant temperature sensor Monitors water tempera...

Page 1015: ...itch is pressed the corresponding display and LED flash 3 INPUT OUTPUT FAULT DATA Mode Display Cord Display Content 00 Normal 11 ROM S O OPEN 21 ROM S S IN VEHICLE SENSOR SHORT 12 AMB S O OPEN 22 AMB...

Page 1016: ...AUTOMATIC AIR CONDITIONING SYSTEM T6001 4 7 6 Schematic Fig 175 C4 665 81...

Page 1017: ...i16 b12 b11 Sunload sensor i16 b13 b11 BATT voltage AUTO mode positive at terminal Air mix door motor i17 a5 a6 a5 and negative 0 at a6 temperature set at 18 C 65 F negative 0 at terminal a5 and posi...

Page 1018: ...o amplifier Faulty harness connector Faulty connector TROUBLE SYMPTOM Set temperature is not indicated on display switch LEDs are faulty and switches do not operate Self diagnosis system does not oper...

Page 1019: ...Connector r Terminal Specified voltage Ignition switch OFF i17 No 1 0 Body Approx 12 V ACC i17 No 18 0 Body Approx 12 V ON i16 No 2 Body Approx 12 V Fig 178 2 CHECK GROUNDING CIRCUIT 1 Disconnect Auto...

Page 1020: ...ircuit OK Not OK Not OK 2 Check OFF relay control circuit 3 Check auto amplifier control circuit OK OK Not OK 4 I Check blower motor power circuit I Faulty harness Faulty auto amplifier Install new on...

Page 1021: ...89b 879 ill a X17 B9b BM2 2 1 ILL o 3 I GN 2 BM6 9 is Z Auto amp 11 Il el 1 an Blower 1 an motor control BM7 BD i 2 4 z 1 3 L BM1 HI velay 895 BM8 B9b B95 BM7 BM5 BMb ill i17 12345678 12 1234 5678 12...

Page 1022: ...M8 No 3 Body Approx 12 V AUTO switch ON FAN switch HI BM8 No 3 Body Approx 1 V max fig 182 3 CHECK AUTO AMPLIFIER CONTROL CIRCUIT 1 Turn the ignition switch to ON 2 Measure voltage between AUTO amp co...

Page 1023: ...voltage between HI relay connector termi nal and body Connector Terminal Specified voltage BM5 No 1 Body Approx 12 V Fig 186 7 CHECK HI RELAY GROUND CIRCUIT 1 Disconnect HI relay connector 2 Measure...

Page 1024: ...lower motor rotates in HI but not in LO and MED 895 BM1 BM8 OFF relay L J 896 BM2 2 4 Iu 1 3 o T IGN BM6 1 Blower M motor Fan control 4 amp BM7 ED 2 4 1 HI relay BM8 B96 895 BM7 BM5 BM6 12345678 12 7...

Page 1025: ...2 V Fig 190 2 CHECK FAN CONTROL AMPLIFIER CONTROL VOLTAGE 1 Connect fan control amp connector 2 Turn the ignition switch to ON 3 Measure voltage between fan control amp connec tor terminal and body Co...

Page 1026: ...y TROUBLE SYMPTOM Blower motor speed does not change but is constant Not OK Faulty auto amplifier or harness Not OK Not OK 3 Check HI relay control circuit OK Faulty auto amplifier or harness 895 k1 O...

Page 1027: ...RCUIT 1 Disconnect fan control amp connector 2 Turn the ignition switch to ON 3 Measure voltage between HI relay connector termi nal and body Connector r Terminal Specified voltage AUTO switch ON FAN...

Page 1028: ...r sensor Refrigerant temperature sensor Air mix door motor P B R Mode door motor P B R OK Check aspirator and duct OK Check air mix door motor OK Check heater OK Check compressor operation OK Check co...

Page 1029: ...el OK 6 Check air conditioner relay magnet clutch circuit OK Faulty air conditioner relay 7 Check sensor OK Faulty auto amplifier TROUBLE SYMPTOM Magnet clutch does not engage Magnet clutch does not d...

Page 1030: ...4 P compressor relay i71 i16 i17 43 r 1 234 5678 12345678910 l 2345678 9101112131415161718 11121314151617181920 910111213141516 b8 MPFI C9 unit d18 F8 870 Com pressor F38 F7 B71 Ambient I sensor I Bn...

Page 1031: ...A C relay connector ter minal and body Connector ft Terminal Specified voltage F23 No 1 Body Approx 12 V rig r yy 3 CHECK PRESSURE SWITCH CONTINUITY 1 Disconnect pressure switch connector 2 Measure r...

Page 1032: ...dy Approx 12 V C 0 a m C4 692 6 CHECK AIR CONDITIONER RELAY MAGNET CLUTCH 1 Remove A C relay 2 Measure resistance between A C relay connector terminal and body Connector Terminal Specified resistance...

Page 1033: ...y air mix door system or auto amplifier OK Check pressure using manifold gauge 3 Check solenoid actuator resistance Not OK Faulty solenoid actuator OK Faulty auto amplifier or harness F8 B70 B79 ill l...

Page 1034: ...2 Body harness No 2 0 Solenoid Display 41 0 A Display 42 0 65 A Fig 205 2 CHECK AIR MIX DOOR 1 Set to self diagnosis function STEP 3 2 Visually inspect link movement to check air mix door position Sp...

Page 1035: ...pproxi mately 10 C 50 F This indicates that freeze protec tion function is operating and is not a problem 1 1 Check solenoid actuator control current OK 2 I Check sensor Not OK Not OK TROUBLE SYMPTOM...

Page 1036: ...noid actuator Display 41 0 A Display 42 0 65 A Fig 207 2 CHECK SENSORS Use self diagnosis function STEP 2 Sensors to check Standard value Ambient sensor Evaporator sensor Ensure sensors and their cir...

Page 1037: ...AUTO 1 ECON switch LED illuminates 0 Outlet air temperature 3 ECON switch 1 ECON switch ON 8 0 Air flow AUTO control Temp control switch 18 32 C 65 85 F 0 Outlet Inlet FRESH Compressor OFF 1 DEF swit...

Page 1038: ...sometimes Air bubbles always ap Frost like appears NO air bubbles appear appear when engine pear speed is increased or de creased State in sight glass u High pressure side is hot High pressure side i...

Page 1039: ...erheat B4 713 Fig 210 High pressure side is too high and low pressure side is too low Fig 211 B4 714 Area near low pressure pipe connection and service valves are considerably cold as compared with ar...

Page 1040: ...mely low between receiver drier and tioning parts LO HI as compared with areas near receiver drier expansion valve is clogged o Check compressor oil for contamination Expansion valve inlet may be fros...

Page 1041: ...d and restarted cycle LO HI 84 718 Fig 215 Low pressure side becomes negative Receiver drier or front rear High pressure side is closed After the system is left at rest side of expansion valve s pipe...

Page 1042: ...rcuit Not OK 1 Check in vehicle sensor OK Not OK 2 Check input signals for in vehicle sensor OK Repair Auto amplifier terminal poor contact Replace auto amplifier Replace and recheck TROUBLE SYMPTOM F...

Page 1043: ...U C CIS 10 9 93 6 00 5 3 75 3 002 42 1 06 0 20 10 0 10 20 25 30 40 C 4 14 32 50 68 77 86 104 OF 04 401 Fig 219 2 CHECK INPUT SIGNALS FOR IN VEHICLE SENSOR 1 Remove auto amplifier 2 Turn ignition switc...

Page 1044: ...mbient sensor Not OK b 1 Replace ambient sensor OK OK Repair auto amplifier terminal poor contact Replace 2 Check input signals for ambient sensor auto amplifier Not OK T 0 Replace and recheck Not O I...

Page 1045: ...8 77 86 104 OF C4 404 Fig 223 2 CHECK INPUT SIGNALS FOR AUTO AMPLI FIER 1 Turn ignition ON 2 Measure voltage between ambient sensor connector and body Connector fr Terminal Specified voltage F38 No 2...

Page 1046: ...inal poor contact Replace 1 Check output signals for auto amplifier auto amplifier OK Not OK 0 Replace and recheck 2 Check input signals for auto amplifier Repair harness or replace sunload sensor Sun...

Page 1047: ...16 13 11 Approx 5 V 1 1g lli 2 CHECK INPUT SIGNALS FOR AUTO AMPLI FIER 1 Remove cover from sunload sensor allowing sun light to hit sunload sensor 2 Measure voltage between auto amplifier connector If...

Page 1048: ...arness or replace intake sensor OK OK Repair auto amplifier terminal poor contact Replace 2 Check input signals for intake sensor auto amplifier Not OK T Not O 0 Replace and recheck OK 3 Check output...

Page 1049: ...CK INPUT SIGNALS FOR INTAKE SEN SOR 1 Turn ignition switch to ON 2 Measure voltage between connector 1396 and bo Connector fr Terminal Specified voltage 1396 No 12 Body Approx 5 V 3 Measure voltage be...

Page 1050: ...emperature sensor Not OK Not OK 3 Check input signals for auto amplifier OK Repair harness Repair harness or replace refrigerant temperature sensor Repair auto amplifier terminal poor contact Replace...

Page 1051: ...y 20 16 43 15 Y 010 9 C c0 N 6 19 d 5 4 01 2 67 2 201 83 1 28 0 20 10 0 10 20 25 30 40 C 4 14 32 50 68 77 86 104 F C4 408 Fig 237 2 CHECK INPUT SIGNALS FOR EVAPORATOR SENSOR 1 Turn ignition switch to...

Page 1052: ...ature sensor OK OK 2 Check input signals for water temperature sensor Not OK Not OK 3 Check output signals for auto amplifier OK Repair harness Repair auto amplifier terminal poor contact Replace auto...

Page 1053: ...S FOR WATER TEM PERATURE SENSOR 1 Turn ignition switch to ON 2 Measure voltage between connector HU3 and body Connector Terminal Specified voltage HU3 No 2 Body Approx 5 V 3 Measure voltage between wa...

Page 1054: ...E SYMPTOM Outlet air temperature does not change Compart ment temperature cannot be controlled to set value Check trouble cord 33 Repair auto amplifier terminal poor contact Replace auto amplifier Rep...

Page 1055: ...sure voltage between auto amplifier connector Connector Terminal Specified voltage i16 No 1 No 11 Approx 5 V O t o III s o C4 728 Fig 247 3 CHECK HARNESS CONNECTOR BETWEEN AUTO AMPLIFIER AND AIR MIX D...

Page 1056: ...OUBLE SYMPTOM Outlet air temperature does not change Compart ment temperature cannot be controlled to set value Not OK Repair auto amplifier connector poor contact Re place auto amplifier Replace and...

Page 1057: ...Since auto amplifier cyclically produces an output of approximately 10 volts analog circuit tester pointer deflects between 0 and 5 volts tlg zbu 2 CHECK HARNESS CONNECTOR BETWEEN AUTO AMPLIFIER AND...

Page 1058: ...fier Repair auto amplifier terminal poor contact Replace auto amplifier OK a Replace and recheck 3 Check harness connector between auto amplifier Not OK Repair harness and mode door motor OK Replace m...

Page 1059: ...ltage between auto amplifier connector Connector Fr Terminal Specified voltage i16 No 1 No 11 Approx 5 V rig Z54 3 CHECK HARNESS CONNECTOR BETWEEN AUTO AMPLIFIER AND MODE DOOR MOTOR 1 Disconnect auto...

Page 1060: ...fier terminal poor contact Replace auto amplifier OK 0 Replace and recheck 2 Check harness connector between auto amplifier Not OK and mode door motor Repair harness OK Replace mode door motor Mode do...

Page 1061: ...onnect auto amplifier and mode door motor connector 2 Measure resistance between auto amplifier and mode door motor connector Connector fr Terminal Specified resistance i17 No 3 HU2 No 5 0 0 i17 No 4...

Page 1062: ...r motor TROUBLE SYMPTOM Inlet is not switched among FRESH 20 FRESH and RECIRC Not OK Replace fuse or repair harness Not OK Not OK Repair auto amplifier terminal poor contact Replace auto amplifier Rep...

Page 1063: ...pprox 5 V EXCEPT 45 Approx 0 V i16 No 6 Body Display shows 41 20 FRESH Approx 5 V EXCEPT 41 Approx 0 V i16 No 7 Body Display shows 42 43 44 FRESH Approx 5 V EXCEPT 42 43 44 Approx 0 V Measure voltage...

Page 1064: ...ct monitor power to ON ERs 0 A C 1 Pressing 1 and ENT will convert display to reed I I YEAR F00 1991 Pressing T will convert display to reed T set F01 75 deg F A MODE 00 AUTO AIR CONDITIONER Probable...

Page 1065: ...ON Engine warming up completely after starting A C system operating in AUTO mode SPECIFICATION DATA Check displayed values to ensure air flow inlet and outlet are controlled as indicated on To control...

Page 1066: ...7 4 5 4 g 48 20 10 0 10 20 Overall signal T C4 744 Fig 263 REC FRE 19 2 17 5 19 5 14 16 22 10 13 2 1 1 2 g 9 4 111 4 I 12 4 10 I 4 7 6V I 7 7 7 8 __ 9 8 VI I 6 V _ 9 0 7 0 5 SV HEAT 5 r T 4 5V VENT B...

Page 1067: ...en circuit 20 deg F Shorted circuit 117 deg F Check duct between aspirator and in vehicle sensor OK Check as per trouble codes 11 and 21 CONDITION SPECIFICATION DATA Engine warmed up completely Temper...

Page 1068: ...ted Indication 20 deg F open circuit 117 deg F shorted circui Not OK Check magnet clutch circuit Not OK Repair leaks and replenish refrigerant G MODE 06 Sunload sensor Q sun CONDITION Engine warmed up...

Page 1069: ...eg F open circuit 13 77 deg F short circuit Check as per trouble codes 13 and 23 I MODE 08 Refrigerant temperature sensor T ref CONDITION Engine warmed up completely after starting After operating A C...

Page 1070: ...emperature from 18 to 32 C 65 to temperature setting from 18 C 65 F 0 to 32 C 85 F 85 F 100 Reference Air mix door target position is apparent value deter Probable cause item outside specified date mi...

Page 1071: ...cause item outside specified date I 1 I Check as per trouble codes 32 and 34 I OK I Check and repair mode door motor linkage I SPECIFICATION DATA MODE pot 100 mode door in VENT MODE pot 0 mode door i...

Page 1072: ...set to check output equipment Control panel display Select monitor display Temperature set to 41 45 on control panel display 41 43 44 45 0 00 A using DEF switch 42 0 65 A Probable cause item outside...

Page 1073: ...y C 6 C C U d C m Y M M a co W N a N a E m i C E 3 0 C o U o O U V U o U 0 O t Fuse 0 0 0 0 0 0 Harness and connector 0 0 0 0 0 0 0 0 0 0 GND ground 0 0 0 0 Auto amplifier 0 0 0 0 0 0 0 0 0 0 Air mix...

Page 1074: ...the Supplemental Restraint System Airbag 5 1 Page M MECHANISM AND FUNCTION 2 1 Body Construction 2 2 Cross sectional Structure of Body 3 3 Steering Support Beam 5 4 Quietness 6 5 Plastic and Resin mol...

Page 1075: ...5 1 Inn1oo1 BODY AND EXTERIOR M MECHANISM AND FUNCTION 1 Body Construction The vehicle body is of monocoque construction with high rigidity Fig 1 05 495 2...

Page 1076: ...BODY AND EXTERIOR M2ool 5 1 2 Cross sectional Structure of Body C C D D B B A A r E E F F G G I J J Fig 2 N N K K L P P R R H H M M C5 496 3...

Page 1077: ...5 1 M200 BODY AND EXTERIOR o r l Fig 3 p t 44 High tensile strength steel sheet V r J I C5 497 4...

Page 1078: ...5 1 3 Steering Support Beam A steering support beam is provided between the left and right front pillars to reinforce the steering column It also minimizes vibration and steering column extension in a...

Page 1079: ...surface with steel panels This increases the dampening effect 2 Silencers over the floor area Silencers minimize the transmission of noise vibration into the passenger compartment An asphalt sheet co...

Page 1080: ...AND EXTERIOR IMaoo1 5 1 3 Sound absorbing materials roof lower front pillers rear bulkhead etc to increase Insulators are installed in the engine hood toe board the sound absorbing effect Fig 6 C5 49...

Page 1081: ...astic and Resin molded Outer Parts Trunk Lid SMC Rear Bumper Polypropylene Rear Quarter Garnish Y ABSresin J o _ r y C Side Garnish j Polypropylene Under Cover Polypropylene with glass fiber Front Bum...

Page 1082: ...01 2 Metallic finish silver and peacock blue color Clear Color base Intermediate o paint O o O O O tea o e o o Colored mica Pigment C5 503 Fig 10 3 Mica finish black and dark red color Fig 8 De endin...

Page 1083: ...ed by the color during the body servicing an area is provided color of the base layer For convenience in checking the where the mica base and clear layers are not applied yr f v Ye jy B r s l Body sid...

Page 1084: ...ody against corrosion 1 Panel Arrangement C5 507 Fig 14 2 Galvanized Sheet Metal Application rig a 3 Cation Electrocoating C5 509 Fig 16 rig I 5 Polyvinyl Chloride PVC Application Uses new material C5...

Page 1085: ......

Page 1086: ...XTERIOR M MECHANISM AND FUNCTION 7 Rust Prevention 8 Rustproof Parts Fig 1 No Applied section Anti rust material Remarks 1 Rubber arch protector Polyethylene mud guard i F d p 8 en er r Mud guard Arch...

Page 1087: ...tion Anti rust material Remarks 2 Rubber arch protector Polyethylene mud guard Rear quarter panel Rear arch inner panel M M ud guard av Arch protector C5 526 2 3 Polyethylene with glass fiber j V L I...

Page 1088: ...5 1 M7001 BODY AND EXTERIOR No Applied section Anti rust material Remarks 5 Polypropylene I d J d I V J d d C5 526 9 6 Multi layer plastic I I I rte C5 526 6...

Page 1089: ...BODY AND EXTERIOR M7ooi 5 1 No Applied section Anti rust material Remarks 7 Nylon Plug Polypropylene Hot melting plug c M C I1 o U C5 526 7 Fig 2...

Page 1090: ......

Page 1091: ...senger compartment side of the floor panels to prevent rust formation on the lapped portions SEC A Transmission cross member locating portion j 7 SEC B Muffler hanger locating portion Fig 23 J SEC C C...

Page 1092: ...5 1 M7021 BODY AND EXTERIOR 2 Galvanized Sheet Metal Application Galvanized sheet metal is used for all body sheet metal parts gay o lkko 40 P 4 Fig 24 Galvanized both side 14 C5 517...

Page 1093: ...Adhesive Application 2O Front hood Hood hinge t Fuel flap 1 i y O Engine compartment 127 Under floor Door ODoor hinge C5 518 Pa_ 25 No Applied section Anti rust material Remarks 1 Sealer o f Qo 0 I e...

Page 1094: ...pplied section Anti rust material Remarks 2 Sealer A lA J l l 11 O j 00 o 0 0 O Anti rust type adhesive 40 Adhesive Sec A C5 519 2 3 i Sealer O o O OD o I B Adhesive Anti rust type adhesive Sec B C5 5...

Page 1095: ...BODY AND EXTERIOR IM7oa1 5 1 No Applied section Anti rust material Remarks 5 Sealer o dPP C5 519 5 6 Sealer C 0 Anti rust type adhesive Adhesive Sec C C5 519 6 7 Sealer o O o o 0 o C5 519 7 17...

Page 1096: ...5 1 IM7o51 BODY AND EXTERIOR 5 Polyvinyl Chloride PVC Application Uses new material Thickness 400 microns 300 microns 100 microns Fig 26 C5 520 18...

Page 1097: ...view Applied section Thickness Remarks 1 Front wheel house Over 400 microns Front wheel apron Sec A Sec B C5 521 1 2 I J J r 1 Rear wheel house Over 400 microns L Sec C C5 521 2 3 Toe board 00ver 300...

Page 1098: ...300 microns Over 400 microns Sec D C5 521 4 5 Rear floor pan Carer 100 microns front _ V C5 521 5 6 Rear floor pan rear Over 300 microns Over 400 microns Sec E Sec F C5 521 6 7 Side rear floor Carer 3...

Page 1099: ...ACC Application Uses new material Fig 27 Unit mm in No Cross sectional view Applied section Thickness Remarks 1 Front section of 10 microns front hood Front section of FFront hood ront hood IN front...

Page 1100: ...5 1 IM7071 BODY AND EXTERIOR 7 Hot Wax Application Fig 29 C5 523 22...

Page 1101: ...ront hood r T_ T F 1 Sec A C5 524 1 2 Front hood Over 20 microns hinge Dry condition I I I I I I C5 524 2 3 Front panel Bulkhead Over 20 microns inside of duct Dry condition Lower section of pitching...

Page 1102: ...Dry condition Sec B C5 524 5 6 Front side frame Cnrer 20 microns front Dry condition Sec C C5 524 6 7 Front side frame Over 20 microns Apply wax to front Dry condition the flanged end Side frame UPR...

Page 1103: ...ame Over 20 microns front Dry condition Sec E C5 524 8 9 Sec V C5 524 9 U V a M O C Front side frame Over 20 microns rear Dry condition Over 50 microns Dry condition M O c o Applied wax thickness in t...

Page 1104: ...front fender Dry condition U1 Lower section of front pillar Frontfender Front pillar Outer Sec F C5 524 10 11 Side sill Over 20 microns Dry condition Side sill inner Reinforcement Side sill Outer Sec...

Page 1105: ...dition Over 50 microns Dry condition View K Rear floor pan front n a 0 c Sec W Crossmember A C5 524 13 I 14 Inside of gusset Over 20 microns Dry condition Over 50 microns Dry condition 0 39 11 Side Se...

Page 1106: ...Rear arch inner I Min 80 3 15 Rear quarter panel outer C5 524 17 9 l Sec L 18 Inside of rear Over 20 microns j quarter panel Dry condition Rear arch inner Area adjoining side bumper Min 80 3 15 Rear q...

Page 1107: ...lied section Anti rust material Remarks 1 Rubber arch protector Polyethylene mud guard Fender L Mud guard Arch protector C5 526 1 2 Rubber arch protector Polyethylene F1 mud guard i I i 0 Rear quarter...

Page 1108: ...5 1 M7081 BODY AND EXTERIOR 30...

Page 1109: ...BODY AND EXTERIOR nmos1 5 1 No Applied section Anti rust material Remarks 6 Mufti layer plastic n l j j C5 526 6 7 Nylon Plug Polypropylene Hot melting plug _ 1 I I c i C II to g C5 526 7 Fig 32 31...

Page 1110: ...and tires Label affixed to the rear side of rear differential A slight spray of wax mist is allowable OZ sensor Exhaust pipe and muffler A slight spray of wax mist is allowable Axle shaft and propell...

Page 1111: ...over 50 microns Rear floor pan front in this section Rear floor pan rear L Fuel tank SEC G Muffler C5 529 1 2 Over 300 microns Wax mist may settle Propeller shaft Dry condition onto exhaust pipe Wax...

Page 1112: ...0 microns Do not apply wax to I I f I I i t Li I i I I I 1 r I Dry condition crossmember above exhaust pipes I 1 I I L U i L Not applied here C5 529 4 5 Rear floor pan front Over 300 microns Dry condi...

Page 1113: ...n the components in side the tires because Over 300 microns Dry condition there is the possibility that wax mist may contaminate brake rotors and wheels rl Parking brake Not applied here cable holder...

Page 1114: ...ry condition Over 50 microns Dry condition Mud guard SEC H C5 529 9 10 Over 300 microns Apply masking to the Dry condition entire filler and drain holes d a d U U U O Q9 C5 529 10 11 Over 300 microns...

Page 1115: ...ND EXTERIOR IM7091 5 1 No Applied section Thickness Remarks 12 Over 300 microns Dry condition b y V O V O 4 U Y9 C5 529 12 13 Tape must be re moved at pre delivery inspection Masking D I C5 529 13 Fig...

Page 1116: ...is used for roof components thus reducing weight Sheet metal components are copper plated for rust proofing When opened Fully closed tilted up Pause after tilt up Slides to rear in tilted up mode Full...

Page 1117: ...e slider is pulled back by the motor The slider guide pin moves along the guide hole to tilt the rear of the lifter up When the OPEN switch is pressed again the slider is pulled back further Since the...

Page 1118: ...tor consists essentially of a motor timing gear and limit switch The timing gear is provided with a pinion gear cam mechanism and the limit switch turns the relay on or off according to the tilt up po...

Page 1119: ...ch closes or opens according to the tilt up position of the slide panel It also activates when the RELAY Close switch Open switch M _ Motor a 7 r 0 m T Limit switch TJ7I C NO I I NC P U T Programable...

Page 1120: ...ed again the slide panel continues to move to the fully closed position Open operation When the OPEN switch is pressed current flows to activate the transistor and relay so that the motor rotates in t...

Page 1121: ...tate in the direction that opens the slide panel fully rig 4b 43 f g 44 Closed operation When the CLOSE switch is pressed current flows to turn the transistor and relay ON the P U T is held OFF the mo...

Page 1122: ...ing the circuit in a stand by mode for ready operation Mg 4d 44 rig 4i When the CLOSE switch is pressed again the transistor and relay turn ON The motor will then rotate in the direction that closes t...

Page 1123: ...gh The front drain tube is routed to the inner side of the the side rail and rear pillar front wheel arch through the front pillar The rear drain 1 1 j1 I Sunroof unit Front drain tube Rear drain tube...

Page 1124: ...5 1 MSOO BODY AND EXTERIOR 9 Ventilation Fresh air flows through the cowl panel into the passen ger compartment via the air conditioning system Fig 50 46...

Page 1125: ...BODY AND EXTERIOR IMSOO 5 1 Air outlet ports are located on the rear quarter panels pressure develops while driving near the back of the rear bumper where high vacuum Cs s47 Fig 51 47...

Page 1126: ...atum points used during body repairs In addition guide holes locators and indents are provided to facilitate panel replacement and achieve alignment accuracy Left and right datum points are all symmet...

Page 1127: ...BODY AND EXTERIOR stool 5 1 Fig 53 49...

Page 1128: ...ing harness attaching clip hole 7 mm 0 28 in dia Symmetrical Rear strut mounting hole 10 mm 0 39 in dia Symmetrical Frame radiator panel LWR gauge hole 20 mm 0 79 in dia Symmetrical Front side frame g...

Page 1129: ...mm 0 39 in dia Symmetrical Rear quarter panel outer flange graded portion Symmetrical Rear bumper mounting hole 45 mm 1 77 in dia Symmetrical Rear skirt frame gauge hole 15 mm 0 59 in dia Symmetrical...

Page 1130: ...5 1 stool BODY AND EXTERIOR c O o I1 c o L I 1 4 4 o i C5 305 Fig 55 C5 306 Fig 56 0 o C5 307 Fig 57 C5 308 Fig 58 O r 7r o C C5 309 Fig 59 C5 310 Fig 60 11 1 C5 311 Fig 61 C5 312 Fig 62 52...

Page 1131: ...1 i mo o _ J n I D r Q I C l c io C5 313 Fig 63 C5 314 Fig 64 J J o o r C o I l o C5 315 Fig 65 I I C5 316 Fig 66 0 0 0__ _ _ O U o 0 I o C5 317 Fig 67 C5 318 Fig 68 c 1 J o O O O _J O 1 n QQ C5 319...

Page 1132: ...ODY AND EXTERIOR o C U C5 321 Fig 71 C5 322 Fig 72 o 7Y 1 G v U C5 323 Fig 73 C5 324 Fig 74 t s 9 O I J 1 C5 325 Fig 75 C5 326 Fig 76 3 o 0 Z 5 Z5 o o O O o _ o J O Q o 0 0 I U O e C5 327 Fig 77 C5 32...

Page 1133: ...7 Fig 80 I C5 338 Fig 81 C5 339 Fig 82 2 Datum Dimensions Use a tram tracking gauge to measure all dimensions If a measuring tape is used be extremely careful because it tends to deflect or twist whic...

Page 1134: ...40 0R 4 L L DL R 352 13 86 O R 490 19 29 R L 1 354 53 31 R R R L 946 37 24 L L 295 11 61 R L 1 338 52 68 1 048 41 26 R R L OL 968 38 11 L O R 1 109 43 66 1 120 44 09 A suffix character R or L refers t...

Page 1135: ...ODY AND EXTERIOR s202 5 1 2 CENTER STRUCTURE a Each dimension indicates a projected dimension between hole centers b All dimensions refer to the distance between the center of holes a C5 3ai Fig 85 57...

Page 1136: ...e Unit mm in Y 000 Fr a o 0 0 000 0 f 8 O o I i o n R 1 O I I X49 1 00 O o o p 1 _ oe oo o 0 00 C O O a o _ FJ C5 342 Fig 86 3 DOORS 05 343 Fig 87 Unit mm in 1 228 48 35 981 38 62 1 079 42 48 913 35 9...

Page 1137: ...mm in Front Windshield Rear Window o 896 35 28 t 745 29 33 L O 1 004 39 53 OR 866 34 09 R R 1 1 134 44 65 R 1 002 39 45 a All dimensions refer to the distance between the centers of holes when measure...

Page 1138: ...RUNK LID Fig 89 Unit mm in R R L 606 23 86 668 26 30 L R L R L R 1 172 46 14 572 22 52 L R L 900 35 43 494 19 45 R L L R 786 30 94 All dimensions refer to the distance between the centers of holes whe...

Page 1139: ...ig 90 Unit mm in R L 1 464 57 64 OR R L 1 138 44 80 945 L 37 20 R 1 056 41 57 856 33 70 a All distance refer to the distance between the centers of holes when measured in a straight line b A suffix ch...

Page 1140: ...aiming is misaligned due to damaged body panel repair headlamp mating surface using body and headlamp datum points as a guide 10 o 10 0 J J Fig 91 a A suffix character R or L refers to the right or t...

Page 1141: ...panel and rear skirt extension by using brace weld method make sure both _a o Fig 92 2 spot welds or plug welds parts are new If either of the parts is old they cannot be properly jointed by brace we...

Page 1142: ...el Front bulkhead Steering support beam Bracket Rear crossmember Front floor frame Front side sill INNER Front floor Front floor reinforcement Reinforcement parking brake Crossmember front floor Front...

Page 1143: ...3 9 17 T2 5 4 9 3 0 55 0 95 4 0 6 9 T3 23 42 2 3 4 3 17 31 T4 10 18 1 0 1 8 7 13 T1 T2 c 1 Lever ASSY 2 Front hood 3 Seal front grille head light 4 Seal radiator panel 5 Seal cowl panel 6 Gas stay 7...

Page 1144: ...5 1 C300 BODY AND EXTERIOR 3 Trunk Lid Trunk Lid Opener Fuel Flap and Fuel Flap Opener Til Fig 95 05 129 66...

Page 1145: ...T T a Fig 96 Tightening torque N m kg m ft 1b T 69 118 7 0 12 0 51 87 1 Front beam 2 Energy absorbing foam 3 Bumper face 4 Front skirt LWR 5 Holder UPR 6 Side bracket 7 Holder LWR 8 Side stay bracket...

Page 1146: ...5 Rear Bumper 1 Rear beam 2 Energy absorbing foam 3 Bumper face 4 Holder UPR 5 Joint holder UPR 6 Holder LWR 7 Bracket LWR 8 Side bracket 9 Bracket side LWR 10 Cap 11 J net Tightening torque N m kg m...

Page 1147: ...BODY AND EXTERIOR csooi 5 1 6 Body Parts UC 1 MIL h Fig 4 O V C5 660 7...

Page 1148: ...5 1 C600 BODY AND EXTERIOR 1 Cowl panel 2 Protector 3 Side cowl panel 4 Cowl panel net passenger s side 5 Cowl panel net driver s side 6 Cover net 3 6 4 L Ib 2 I 1 V v 6 C5 133 Fig 99 70...

Page 1149: ......

Page 1150: ...5 1 C700 BODY AND EXTERIOR 1 Rear quarter garnish 2 Door side garnish 8 Front side garnish 12 Rear side garnish 05 137 Fig 103 72...

Page 1151: ......

Page 1152: ...de ASSY 4 Lower panel 5 Lower panel 6 Rear guide ASSY 7 Drive unit 8 Relay 9 Harness 10 Harness 11 Sunroof trim 12 Guide rail 13 Set bracket 14 Set bracket RH 15 Guide rail 16 Motor ASSY 17 Set bracke...

Page 1153: ...remove washer hose 2 Remove studs which hold gas stays to hood Be careful because hood drops under its own weight when gas stays are removed f 1g 7 06 3 Remove hood attaching bolts from hinge and de t...

Page 1154: ...l out Release cable Be careful not to bend or break cable _ e e o o a o_ Washer hose C5 145 Fig 113 C5 146 Fig 114 2 Remove insulator from front hood 5 GAS STAYS 1 Open front hood 2 Remove studs which...

Page 1155: ...ty lever is properly caught by striker under the hood s own weight b Route hood lock release cable and hold with clips c After installing release cable ensure it operates smoothly d Apply grease to sl...

Page 1156: ...areful because trunk lid drops under its own weight when gas stays are removed C5 165 Fig 120 3 Remove hinge from trunk lid Fig 122 2 GAS STAYS 1 Open trunk lid Remove gas stays mounting bolts Be care...

Page 1157: ...ylinder from trunk lid _ Rod Clip _ U U I a _ T C5 171 Fig 126 4 TRUNK LID OPENER 1 Remove trunk trims Trunk trim UPR Trunk trim Side Trim panel trunk rear C5 172 3 Remove cable from clips 4 Remove dr...

Page 1158: ...ion is in the reverse order of removal a When installing cover to pull handle assembly ob serve the following Engage pull handle assembly pawls firmly b After installing opener cable ensure it moves s...

Page 1159: ...r resin and hardener only by amount needed 7 Be sure to store acetone and other solvents in sealed containers 8 Pay attention to keep resin or hardener from getting on working clothes Wipe thoroughly...

Page 1160: ...FRP body rig I b Necessary A To be performed if necessary Unnecessary Process No fob contents A B C D E 1 Cutting A 0 De greasing Sanding 1 Washing 1 Masking a Modeling of trunk lid edge 0 Preparation...

Page 1161: ...ve usage instructions for repair materials given in manual 2 If small cracks are found on painted surface remove paint layer and check if FRP body is cracked Process No Process name Job contents D Cut...

Page 1162: ...led surface using coarse No 24 to 80 sand paper then finish with fine 240 sand paper Y 50 mm 1 97 in i C5 279 Fig 140 Broken edge Sand area about 50 mm 1 97 in from broken edge Inside surface only I p...

Page 1163: ...ove patch plate later attach gummed cloth tape to plate mat impreg Put glass mat on patch plate Mix resin and hardener thoroughly in cup and apply mixture to glass mat by nated with pressing with roll...

Page 1164: ...nd pull out wire to front side and fix Wire Adhesive tape Adhesive tape Glass mat Plastic pad Plastic pad C5 285 Fig 146 Broken edge Place patch plate and glass mat prepared in 2 by giving a little ov...

Page 1165: ...epaired surface with coarse No 24 to 120 sand paper Excessively thick resin at body overlapping portion may impair normal closing of trunk Reduce resin thick ness as necessary using sand paper I C5 28...

Page 1166: ...s with roller or spatula for complete adhesion while preventing air bubbles mat impreg from forming nated with If hollow can be repaired by simply filling with putty apply putty to hollowed portion wi...

Page 1167: ...d lamp Keep temperature below 80 C 176 F when using lamp mat impreg Resin will harden in 30 to 45 minutes at 60 C 140 F nated with resin mixture and putty fill ing j 1 C5 291 Fig 152 Hollow dent minut...

Page 1168: ...Undercoating Perform coating in the same manner as iron plate coating Drying 2 Bake paint in the same manner as iron plate coating f Sanding 4 After complete hardening of paint finish surface with No...

Page 1169: ...lts which hold hinge to car body and detach Driver s seat fuel flap and hinge as a unit Cal C5 180 Fig 154 2 FUEL FLAP OPENER 1 Remove trims Trunk trim UPR i Trunk I I trim Side Trim panel trunk rear...

Page 1170: ...installing cover to pull handle assembly ob serve the following Engage pull handle assembly pawls firmly b Make sure the clearance between fuel flap and car body is equal at all points c After install...

Page 1171: ...irbag system wiring harness when servicing the front bumper A REMOVAL 1 Lift up the car 2 Remove under cover 3 Detach front side of mud guard rig ices rig 104 r1g 100 6 Remove bolts securing lower sid...

Page 1172: ...ATION To install the front bumper reverse the above removal procedures a Be extremely careful to prevent scratches on bumper face as it is made of resin b Be careful not to scratch the body when remov...

Page 1173: ...only 7 Remove nut from side of bumper 6 Rear Bumper 5 Remove trim panel trunk rear and detach rear side of trunk trim side A REMOVAL 1 Lift up the car Please balance weights etc in the trunk compartm...

Page 1174: ...y and take out bumper B INSTALLATION To install the rear bumper reverse the above removal procedures a Be extremely careful to prevent scratches on bumper face as it is made of resin b Be careful not...

Page 1175: ...ews and bolts A REMOVAL 1 DOOR SIDE GARNISH 1 Remove door trim 2 Remove three nuts 1 1g f b C5 201 Fig 9 2 Remove retainer Clip Retainer Garnish Body panel C5 202 rig u Fig 10 3 Remove clips I J 1 Fen...

Page 1176: ...detach gar nish Fender Garnish Clips Clip u C5 205 2 Remove rear quarter trim 3 Remove motor ASSY for automatic shoulder belt 4 Remove nuts Fig 13 3 REAR SIDE GARNISH 1 Remove screws and bolts o f 1...

Page 1177: ......

Page 1178: ...ock paint for top coat Paint in use for each color 9 Paint in use for each color Solid paint Metallic paint Hardener PB Hardener PB 6 Top coat paint Thinner T 301 Thinner T 306 Mixing ratio Main agent...

Page 1179: ...BODY AND EXTERIOR w801 5 1 r masking mica r silver metallic 05 273 Fig 195 101...

Page 1180: ...the repairing area with 500 sandpaper in a feathering motion Resin section Coated section Repeatedly apply wax to the affected area using a soft cloth such as flannel Perform either the same operatio...

Page 1181: ...suitable solvent NRM No 900 Precleno white gasoline or alcohol If nature of damage is cracks or holes cut a Unit mm in 79 1 20 30 0 18 guide slit of 20 to 30 mm 0 79 to 1 18 in in length along the cra...

Page 1182: ...II 135 307 Fig 200 Sand the welded spot smooth with 240 sandpaper Mask the black substrate section as indicated in the figure using masking tape 11 Masking Recommended masking tape Nichiban No 533 or...

Page 1183: ...hickness 40 5011 Spraying thickness 245 343 kPa Coated film thickness 20 3011 2 5 3 5 kg cm2 36 50 psi Leave unattended at 20 C 68 F for at least 10 minutes until the topcoated area is half 20 Leave u...

Page 1184: ...e carefull not to damage Airbag system wiring harness when servicing the front fender A REMOVAL 1 Lift up the car 2 Remove under cover 3 Remove mud guard 4 Remove front combination light 5 Remove bolt...

Page 1185: ...uted near the mud guard and front arch protector a All Airbag system wiring harness and connectors are colored yellow Do not use electrical test equip ment on these circuit b Be carefull not to damage...

Page 1186: ...per side then remove clip r1g z73 6 Peel rear end of rear side garnish refer to removal of rear side garnish and then remove clip r1g L14 7 Detach arch protector B INSTALLATION Installation is in the...

Page 1187: ...of opal nff usinn a flathprl screwririver c 5 22s Fig 220 B INSTALLATION Installation is in the reverse order of removal 109 V 61 Remove clios 3 Remove wiper arms 4 Remove side cowl panel to pry it o...

Page 1188: ...ATION F B_ INSTALLATION 1 Insert pawls of grill lower side into holes of body 2 Push clip into clip hole in body 15 Under Cover Installation is in the reverse order of removal 17 Ornament A REMOVAL A...

Page 1189: ...x 1 3 2 Remove clips attached to front side of sunroof trim L by Dullina trim from inside of compartment y 3 Move trim forward and detach trim end from holder C5 2461 Fig 229 B INSTALLATION Fig 230 In...

Page 1190: ...6 Remove sunroof panel 3 SUNROOF FRAME 2 SUNROOF MOTOR AND RELAY 1 Remove rear quarter trim pillar trim roof trim etc 1 Remove rear quarter trim pillar trim roof trim etc Refer to chapter 5 3 Refer to...

Page 1191: ...olts 1 SUNROOF PANEL MOTOR AND RELAY Installation is in the reverse order of removal Sun roof trim reference pin must be fitted in holder notch 2 SUNROOF FRAME 1 Insert frame rear end slit to two bolt...

Page 1192: ...0 232 0 020 in Difference in height between roof panel and sunroof panel 0 1 0 mm 0 0 039 in 114 R1 Tinhfinn cnfi tir n4nf mn nfiinn nl c 4 Install sunroof panel 5 Adjust height by turning adjusting...

Page 1193: ...parts Garnish must be free from waves When sun roof is fully closed must be no clearance between garnish and sun roof trim Sun roof must be free from slack and noise when it is fully opened and closed...

Page 1194: ...e for deformities 1 Check guide rail for foreign particles Check guide rail for improper installation Failure of sunroof to operate Check parts for mutual interference Motor operates properly Check ca...

Page 1195: ...er Remote Assembly 19 7 Link t Safety Knob 20 8 Door Latch and Striker 20 9 Key Lock 21 10 Outer Handle 21 11 Stopper 22 0 12 Door Sash and Door Window Lower Glass 22 13 Door Window Regulator 24 14 Do...

Page 1196: ...l and reaches a point just before the fully closed position it encounters resistance caused by weather strips and stabilizer mechanism This resistance pre vents the window from closing completely To a...

Page 1197: ...nd outer handle ADJUSTMENT The operating resistance of the outer handle can be adjusted by changing the length of the rod installed ie height can be adjusted four positions by rotating this Ijusting s...

Page 1198: ...THERSTRIP A multi seal weatherstrip is used on each mating sur face of the door and body This weatherstrip effectively reduces the road and wind noises and prevents water and air leaks 4 STABILIZER A...

Page 1199: ...ined at the connection between windshield and door glass and between roof and door glass Aweath erstrip is used at the portion between the door glass and quarter glass so as to obtain a flush glass su...

Page 1200: ...109 The curvature of the quarter window glass at the rear pillar portion is reduced so that the rear pillar is covered with glass for a smooth surface at the joint between roof and quarter glass and...

Page 1201: ...eristics The rear window glass angle is also reduced and the roof panel and rear quarter window are made flush to provide a smooth outline with improved aerodynamic characteristics Rear window glass 0...

Page 1202: ...5 2 S1001 DOORS AND WINDOWS S SERVICE DATA 1 Door Alignment Unit mm in Door panel S f O 0 o to ci Fender Fig 12 Front pillar F 4 5 1 0 0 177 0 039 uarter panel Gap 1 0 10 039 C5 114 8...

Page 1203: ...DOORS AND WINDOWS Ciol 5 2 C COMPONENT PARTS 1 Door 1 DOOR PANEL TRIM Fig 13 C5 116 9...

Page 1204: ...y knob cover 3 Safety knob ASSY 4 Link 5 Rod holder 6 Inner remote ASSY 7 Latch actuator 8 Striker 9 Sealing cover O Ilea 40 Tightening torque N m kg m ft Ib T1 4 4 7 4 0 45 0 75 3 3 5 4 T2 4 4 8 3 0...

Page 1205: ...or window upper glass ASSY 2 Fastener 3 Hole plug 4 Stopper 5 Protector 6 Checker 7 Checker pin 8 Outer weatherstrip 9 Outer stabilizer 10 Inner stabilizer 11 Door window lower glass ASSY 12 Lower sas...

Page 1206: ...1 Rear quarter window upper glass ASSY 2 Cover mat 3 Cover tape 4 Sealing cover 5 Outer weatherstrip 6 Outer stabilizer 7 Inner stabilizer ASSY A 8 Inner stabilizer ASSY B 9 Regulator rail ASSY 10 Ad...

Page 1207: ...DOORS AND WINDOWS 03011 5 2 3 Window Glass 1 WINDSHIELD 20 03 3 O 1 Glass ASSY 2 Dam rubber 3 Locating pin C5 120 Fig 17...

Page 1208: ...5 2 C3021 DOORS AND WINDOWS 2 REAR WINDOW GLASS 2 1 Glass ASSY 2 Dam rubber 3 Locating pin C5 121 Fig 18 14...

Page 1209: ...s Z 1 1 Door sash weatherstrip 2 Tapping screw 3 Canoe clip 4 Grommet 5 Clip 6 Door weatherstrip ASSY 7 Door weatherstrip lower ASSY 8 Clip 9 Grommet 10 Retainer ASSY 11 Tapping screw 12 Drip weathers...

Page 1210: ...chart shows the main procedures for removing and installing the door and its related parts For details refer to the text I Remove inner stabilizer I Disconnect joints be Separate door window tween lat...

Page 1211: ...es by loosening mounting bolts M8 off of door and remove door from body Fig 22 a Work carefully to avoid damaging door b Disconnect harness first f B INSTALLATION 1 Install door itself to hinges with...

Page 1212: ...MOVAL 1 Remove trim panel 2 Remove harness cover tape adhering sealing cover and remove trim bracket Speaker Trim connector bracket e U O O JJ C5 056 Fig 27 3 Remove sealing cover and sealer with a sp...

Page 1213: ...plied in a continuous line 5 Checker REMOVAL 1 Remove trim panel 2 Remove sealing cover 3 Apply a cloth to door and body to prevent damaging them and remove checker pin by driving it upward Be careful...

Page 1214: ...close door window glass 4 Remove remote ASSY from latch 5 Turn rod holder to disconnect joint between key lock ASSY and rod 6 Turn rod holder to disconnect joint between outer handle and rod 7 Loosen...

Page 1215: ...C5 297 Fig 35 3 Apply seal lock agent to screw thread area Seal lock agent OxOxOxO A REMOVAL 1 Remove trim panel 2 Remove sealing cover 3 Completely close door glass 4 Turn rod holder to disconnect j...

Page 1216: ...Sash t Door Window Lower Glass A REMOVAL 1 Remove trim panel 2 Remove sealing cover 3 Remove inner remote ASSY 4 Completely close door window glass 5 Disconnect door mirror harness connector and re mo...

Page 1217: ...section 8 Remove inner stabilizer and outer weatherstrip to center working hole of door panel 0 Door window lower glass 1 _ Lower sash _ mounting i IIII bolts 5 068 Fig 44 10 Remove speaker and then...

Page 1218: ...tor wire from clip and then loosen nuts and remove regulator rail ASSY with regulator motor and wire Motor connector Clip Wire Fig 45 B INSTALLATION Installation is in the reverse order of removal Low...

Page 1219: ...door panel B INSTALLATION Installation is in the reverse order of removal B INSTALLATION Install weatherstrip into door panel ditch firmly Installation is in the reverse order of removal Regulator tig...

Page 1220: ...rter window lower glass 5 Remove inner stabilizers 6 Move rear quarter window glass connecting section to center of the working hole 7 Remove two bolts and remove rear quarter lower window glass from...

Page 1221: ...B INSTALLATION 1 Remove rear seat 2 Remove rear quarter trim panel 3 Remove sealing cover 4 Remove rear quarter window lower glass 5 Remove regulator rail ASSY with regulator motor and wire Installati...

Page 1222: ...of Adhesion Type Window Glass 1 PROCEDURES OF REMOVAL AND INSTALLATION Finishing and cleaning adhe sion surface Application primer Application of adhesive Installation of glass Installation of moldin...

Page 1223: ...r window glass 1 Remove wiper arm 2 Remove front fender rubber seal cowl panel and front pillar cover 3 Remove molding 4 Remove glass 1 Put protective tape on body to prevent damage 2 Apply soapy wate...

Page 1224: ...let 1st primer dry spontaneously for about 10 minutes c Do not touch primer coated surface under any cir cumstances 6 Application of adhesive 1 Cut nozzle tip of cartridge as shown in figure below 2...

Page 1225: ...ip located between rear quarter window and rear window and remove glass in same manner as in windshield Fig 61 B INSTALLATION 1 Install glass and weatherstrip in same manner as in windshield t JI C5 4...

Page 1226: ...o surface of door to be adhered a If primer has dropped on door finish it is hard to wipe it off So protect with masking b Primer must not project from black frame of glass c After applying primer let...

Page 1227: ...and the other on inside Plastic panel on outside panel Upper door glass L_3_r Plastic panel on compartment side 2 Move glass in direction of arrow so that middle weatherstrip is 8 mm 0 31 in wide ove...

Page 1228: ...e 3 Cleaning glass 1 Remove dirt and dust from surface of glass to be adhered 2 Clean surface of glass to be adhered with alcohol or white gasoline 4 Application of primer 1 Using a sponge apply prime...

Page 1229: ...484 Ensure that weatherstrip is approximately 8 mm 0 31 in wide over its entire length as in upper door glass installation 2 Install screws and clips to secure rear quarter upper glass assembly Fig 76...

Page 1230: ...r of window install inner stabilizer and tighten bolt Adjust glass in fore aft direction just before window is completely closed OK Raise and lower window to ensure that glass is properly adjusted I N...

Page 1231: ...abilizer outer inner 2 4 0 094 Stabilizer 3 6 outer inner I In out 4 t2 0 08 direction I Q a o oZJ a o II U dJ I Regulator rail 0 In out adjustment I G6 0 24 2 0 08 screw 4 0 16 In out direction In ou...

Page 1232: ...Stabilizer outer inner _ 3 0 0 118 4 5 0 177 In out direction 2 0 08 Regulator rail o 0 In out adjustment screw 4110 16 2 10 08 6 0 24 Motor can be 0 08 2 10 08 In out direction adjusted 2 0 08 from...

Page 1233: ...ass Half open position C5 383 Fig 79 2 Move inner stabilizer in either direction until glass free play is eliminated and secure it at that position 1 1g 80 2 FORE AFT GLASS ADJUSTMENT 1 Temporarily ti...

Page 1234: ...djust Door glass Rear quarter glass c Adjust rear quarter glass using both adjustment nut and regulator motor attaching bolts i C5 387 Fig 83 4 After properly adjusting glass tighten regulator at tach...

Page 1235: ...e amount after glass adjust ment o Protrusion caused by bolt adjustment l C5 391 Fig 87 3 Tighten adjustment nuts 4 Raise and lower window to re check that glass is properly adjusted If glass is out o...

Page 1236: ...ot I OK I Tighten attaching bolt while pressing inner j bilizer against glass to eliminate free play FFF I Not OK I _ _ _ Move glass so that upper edge is approxi I mately 5 mm 0 20 in away from midfr...

Page 1237: ...Inner handle stops halfway Contact of upper rod with inner handle Eliminate contact by bending upper rod mounting case properly 6 Door cannot be locked or unlocked by key Joint of key lock rod is dis...

Page 1238: ...activation of the Airbag system All Airbag system electrical wiring harnesses and connectors are covered with yellow outer insulation Do not use electrical test equipment on any circuit related to th...

Page 1239: ...RECLINING When the reclining lever is moved up the reclining hinge lock is released The seat backrest can be ad justed every 2 and also folded fully forward D WALK IN SYSTEM When getting in or out of...

Page 1240: ...D 000 D co o C A A B B Mg 4 G HEADREST FORE AND AFT ADJUST MENT 1 CONSTRUCTION To adjust the headrest hold it with both hands Move it in the fore and aft direction and release it at the desired posit...

Page 1241: ...5 3 nnlH3 SEATS SEAT BELTS AND INTERIOR 3 MECHANISM Fore aft adjustment Rear lifter adjustment O C5 369 Fig 8 Front lifter adjustment Fig 10 Reclining adjustment Fig 11 Fig 9...

Page 1242: ...rest can be folded forward to gain access to trunk compartment providing good use of space Backrest is equipped with an interlock When interlock is activated backrest fold down is disabled from pas se...

Page 1243: ...tch 2 Guide rail 3 Warning switch 4 Knee panel passenger 5 Shoulder belt 6 Door latch switch 7 Knee panel driver 8 Lap belt 9 Inner belt ASSY 10 Buckle switch 11 Belt guide 12 ELR ASSY 13 Motor ASSY 1...

Page 1244: ...body of the driver and passenger in a front end collision 2 Submarine preventing material incorporated in pas senger seat cushion Unlike the drivers seat the position of the passenger seat can be opt...

Page 1245: ...urrent flow from relay L1 to relay L2 The shoulder anchor then moves in the direction corre sponding with current flow It takes approximately two seconds for the shoulder anchor to travel from the fro...

Page 1246: ...Backrest ASSY 3 Back garnish 4 Lumbar lever 5 Knob 6 Cushion ASSY 7 Slide tilt unit 8 Cover 9 Power switch ASSY 10 Slide tilt knob 11 Belt holder 12 Outer hinge ASSY 13 Inner hinge ASSY 14 Connecting...

Page 1247: ...ning torque N m kg m ft 1b T 42 62 4 3 6 3 31 46 Fig 18 15 1 Headrest 2 Backrest ASSY 3 Back garnish 4 Lumber lever 5 Knob 6 Hinge cover IN 7 Cushion ASSY 8 Hinge cover OUT 9 Belt holder 10 Hinge knob...

Page 1248: ...Rear Seat Fig 19 Replacement parts 8 1 Headrest 2 Striker 3 Headrest bush 4 Knob 5 Backrest ASSY Tightening torque N rn kg m ft 1b 6 Hinge T1 18 31 1 8 3 2 13 23 7 Cushion ASSY T2 7 13 0 7 1 5 1 9 3...

Page 1249: ...R 4 Front Seat Belt Fig 20 9 10 Limit switch Rail ASSY Clip Shoulder anchor ER13 Lock device Motor ASSY Inner belt ASSY ELR ASSY RH Outer belt ASSY C5 377 12 Tightening torque N rn kg rn ft 1b T1 10 1...

Page 1250: ...D INTERIOR IC5001 5 3 5 Rear Seat Belts C Tightening torque N m kg m ft b T1 23 49 2 3 5 0 17 36 T2 5 4 9 3 0 55 0 95 4 0 6 9 Fig 21 1 Outer belt ASSY RH 2 Outer belt ASSY LH 3 Inner belt ASSY RH 4 In...

Page 1251: ...yul 5 6 10 11 I 13 Fig 22 1 Rearview mirror ASSY 2 Rearview mirror cap 3 Hook 4 Hook cap 5 Sunvisor cap 6 Sunvisor ASSY 7 Vanity mirror Vanity mirror flap 9 Bulb 10 Lens 11 Assist rail BRKT 12 Assist...

Page 1252: ...RIP V n O c n n u 11 1 Front pillar upper trim 2 Rear pillar upper trim 3 Rear quarter trim 4 Side sill lower cover 5 Front pillar lower trim 6 Side sill upper cover 7 Rear quarter BRKT 8 Pockt 9 Armr...

Page 1253: ...TS AND INTERIOR 8 Trunk Trim Fig 24 1 Rear shelf trim 2 Cap 3 Speaker agrille 4 Trunk upper trim 5 Bulk side trim 6 Trunk side trim 7 Trunk rear panel trim 8 Garnish trunk 9 Trunk edge 10 R combi cove...

Page 1254: ...SEATS SEAT BELTS AND INTERIOR IC9oo1 5 3 9 Roof Trim Floor Mat Sun roof vehicle 1 Roof trim 2 Center trim 3 Floor mat Fig 25 Without sun roof vehicle C5 382 17...

Page 1255: ...olt cover at rear end of slide rail 7 Remove bolts securing seat rear Fig 29 10 Remove front seat from vehicle Be careful not to scratch seat when removing it from vehicle B INSTALLATION 1 Remove head...

Page 1256: ...nk r 0 yI C5 406 Fig 32 5 Roll up left and right edges of floor mat at backrest remove four bolts two on each side and remove backrest A REMOVAL 1 Push left and right hooks A down C5 407 Fig 30 2 Whil...

Page 1257: ...en the connector is reconnected making the automatic shoulder belt inop erative A REMOVAL 1 Disconnect battery ground cable 2 Push emergency release button on the shoulder anchor and remove belt PuSn...

Page 1258: ...houlder anchor Emergency r release buckle Ills Wire C5 413 Fig 39 a Do not remove grease from wire b Do not bend or twist wire too sharply D INSTALLATION Installation is in the reverse order of remova...

Page 1259: ...r cover Refer to W9A0 8 Roll up floor mat and remove the two bolts Fig 42 B INSTALLATION Installation is in the reverse order of removal 5 Front Seat Belt ELR Assembly Supplemental Restraint System Ai...

Page 1260: ...disassembly procedures D OPERATION CHECK f A REMOVAL 1 INNER BELT ASSY 1 Remove rear seat cushion Refer to MAO 2 Remove bolts fig 4 Perform operation checks before installing new parts 1 Align point...

Page 1261: ...after instal lation of ELR a Be extremely careful not to confuse center seat anchor plate with outer seat anchor plate during in stallation b Ensure that seat belts are free from twisting after instal...

Page 1262: ...rs are colored yellow Do not use electical test equipment on these circuit b Be careful not to damage Airbag system wiring harness when servicing the side sill lower cover A REMOVAL 1 Disconnect batte...

Page 1263: ...Fig 56 4 Remove screw from each side of rear shelf trim C5 430 Fig 57 5 Carefully remove the three clips one at a time from front edge of rear shelf trim move it forward Clip r C5 431 Fig 58 rig o I...

Page 1264: ...emove front pillar upper trim Refer to W1 1A0 3 Remove rear shelf trim Refer to W10A0 3 Remove rear pillar upper trim Refer to W12A0 4 Remove coat hanger hook 4 Remove assist rail bracket C5 435 Fig 6...

Page 1265: ...tors Remove two screws and con nectors remove spotlight assembly II T Fig 67 8 Remove spotlight base without sunroof vehicle J i J C5 441 Fig 70 11 Remove four clips and roof trim a o Clip C5 444 Fig...

Page 1266: ...ful not to damage Airbag system wiring harness when servicing the floor mat A REMOVAL 1 Disconnect battery ground cable 2 Remove front seat Refer to W1A0 3 Remove rear seat cushion Refer to W2A0 4 Rem...

Page 1267: ...tting floor mat in position pass power seat harness and connector through hole C5 448 Fig 78 2 Align edge of floor mat with side sill lower cover I I II Clip Inl C5 450 Fig 80 16 Trunk Trim A REMOVAL...

Page 1268: ...trim Weatherstrip Clip C5 453J Fig 83 4 Remove eight clips then upper trunk trim B INSTALLATION Install in reverse order of above removal procedures Make sure edge of side trunk trim and upper thank...

Page 1269: ...ails rail deformities or scratches etc Check if seat belt warning light remains off when au Not OK tomatic shoulder belt system is operated over its en tire range OK SELF DIAGNOSIS I Troubleshooting i...

Page 1270: ...ion switch is turned ON the warning light will remain on after it blinks for 6 2 seconds If any shoulder belt or lap belt for the driver or front passenger is unfastened after the ignition switch is t...

Page 1271: ...h are ON 22 Open and closed ends of passenger s door latch switch are OFF 23 Front limit switch on passenger s side remains ON 24 Rear limit switch on passenger s side remains ON 25 Front and rear lim...

Page 1272: ...ted only the initial trouble code which is detected by the system is memorized After any repairs the automatic shoulder belt system must be operated over its entire range with the follow ing fuse remo...

Page 1273: ...13 Warning light 5 10 13 Ignition switch 6 0 0 13 14 Battery 8 13 14 GND Ground R32 9 Door latch switch on passenger s side 10 10 13 0 Door latch switch on passenger s side 11 10 13 0 Door latch switc...

Page 1274: ...on SwitCh j C7 C7 3 N 61 L T3 44 1D2 a C CB ia 3 a seat belt Combination meter I 12 Di R15 W co D3 R37 1 13 112 I 2I B90 36 ri _ 134567 8 9101t1213141516 CD 34 12 1 5678 10 CB41 1 6 TI 11121345 161711...

Page 1275: ...5 3 Shoulder belt Front door Front limit buckle switch RH latch switch RH switch RH rear limit switch Motor RH Fig 91 C5 559 39 Front door Front limit Shoulder belt M r F L latch switch LH switch LH...

Page 1276: ...unit and door latch switch OK Repair control unit terminal poor contact Replace control unit TROUBLE SYMPTOM Driver s shoulder anchor is inoperative OK Repair control unit terminal poor contact Replac...

Page 1277: ...connect connector from door latch switch 2 Disconnect connector from control unit 3 Measure resistance between control unit connector and body 2 CHECK DOOR LATCH SWITCH 1 Disconnect connector from doo...

Page 1278: ...shoulder anchor is inoperative Key warning chime operates with driver s door closed and with ignition switch OFF OK Repair control unit terminal poor contact Replace control unit Replace door latch sw...

Page 1279: ...isconnect connector from door latch switch 2 Disconnect connector from control unit 3 Measure resistance between control unit connector and door latch switch connector Connector r terminal Specified r...

Page 1280: ...anchor reaches front end Anchor stops midway on rail Not OK koj Replace motor Not OK Repair motor harness SBF 4 F17 F9 No 15 8100 R32 FL 1 5 45A 1 G_ SW BAY e_ w l0A GR GR T 7 V W No 22 15A SBF 1 30A...

Page 1281: ...d body Connector r terminal Specified resistance 1337 No 2 Body 1 MQ min Terminal fr polarity diagnosis R39 No 1 No 2 Shoulder anchor moves to rear end 1139 No 1 No 2 Shoulder anchor moves to front en...

Page 1282: ...ar limit switch OK 2 Check rear limit switch wire harness OK 3 Check motor OK 4 Check motor harness OK Repair control unit terminal poor contact Replace control unit Replace rear limit switch Not OK R...

Page 1283: ...No 2 Body 1 MQ min 3 CHECK MOTOR 1 Disconnect motor connector and apply 12 volts DC to motor terminals Terminal ft polarity diagnosis 1139 No 1 No 2 Shoulder anchor moves to rear end 1139 No 1 No 2 S...

Page 1284: ...r control unit terminal poor contact Replace control unit TROUBLE SYMPTOM Shoulder anchor does not move in direction of faulty limit switch Not OK Not OK Connect connectors firmly and recheck Replace...

Page 1285: ...switch connector C5 555 Fig 103 Connector t terminal Specified resistance 1338 No 1 No 2 1 MQ min Switch side F12f 19 4 3 Ili C5 557 Fig 104 3 CHECK FRONT AND REAR LIMIT SWITCH WIRE HARNESS 1 Disconn...

Page 1286: ...re harness OK Repair control unit terminal poor contact Replace control unit Not OK TROUBLE SYMPTOM Warning light remains off when shoulder belt is fas tened Shoulder anchor operates properly Connect...

Page 1287: ...tch connec tor s terminals 3 CHECK BUCKLE SWITCH WIRE HARNESS 1 Disconnect two connectors from control unit 2 Disconnect buckle switch connector 3 Measure resistance between buckle switch connec tor a...

Page 1288: ...n control unit and door latch switch OK Repair control unit terminal poor contact Replace control unit F9 I G SW TROUBLE SYMPTOM Passenger s shoulder anchor does not operate OK Repair control unit ter...

Page 1289: ...tch switch 2 Measure resistance between door latch switch ter minals Connector Fr terminal Specified resistance D23 No 2 No 3 1 MQ min Door open D23 No 2 No 1 1 Mfg min Door closed Twitch side 3 2 1 o...

Page 1290: ...t and door latch switch OK Repair control unit terminal poor contact Replace control unit TROUBLE SYMPTOM Passenger s shoulder anchor does not operate OK Repair control unit terminal poor contact Repl...

Page 1291: ...h switch ter minals Connector r terminal Specified resistance D23 No 2 No 3 1 Q max Door closed D23 No 2 No 1 1 Q max Door open Twitch side a or latch switch B5 127 Fig 110 3 CHECK HARNESS CONNECTOR B...

Page 1292: ...particles are noted proceed to 3 Motor Inspection 1 Check front limit switch Not OK Replace front limit switch OK 2 Check front limit switch wire harness Not OK 00 Replace wire harness OK Not OK 3 1...

Page 1293: ...otor terminals Terminal polarity diagnosis 1313 No 1 No 2 Shoulder anchor moves to rear end 1313 No 1 No 2 Shoulder anchor moves to front end i Motor side i Motor connector 1i C5 460 Fig 113 4 CHECK M...

Page 1294: ...Motor Inspection 1 Check rear limit switch Not OK Replace rear limit switch OK Not OK 2 Check rear limit switch wire harness Repair wire harness OK Not OK 3 Check motor Replace motor OK Not OK 4 Chec...

Page 1295: ...ITCH WIRE HARNESS 1 Disconnect two connectors from control unit 2 Disconnect connector from rear limit switch 3 Measure resistance between rear limit switch con nector and body Connector terminal Spec...

Page 1296: ...es OK Repair control unit terminal poor contact Replace control unit TROUBLE SYMPTOM Shoulder anchor does not move in direction of faulty limit switch Not OK Reconnect firmly and recheck Not OK Replac...

Page 1297: ...s Connector terminal Specified resistance R14 No 1 No 2 1 MQ min Switch side 4 3 Rear limit switch buckle switch connector C5 462 Fig 118 Fig 119 3 CHECK FRONT AND REAR LIMIT SWITCH WIRE HARNESS 1 Dis...

Page 1298: ...ntrol unit terminal poor contact Replace control unit Not OK Not OK Not OK TROUBLE SYMPTOM Warning light remains off when shoulder belt is unfas tened Shoulder anchor operates properly Reconnect firml...

Page 1299: ...ckle switch connec tor terminals 3 CHECK BUCKLE SWITCH WIRE HARNESS 1 Disconnect two connectors from control unit 2 Disconnect buckle switch connector 3 Measure resistance between buckle switch connec...

Page 1300: ...to shorted key warning switch circuit 1 1 Check battery harness OK Repair control unit terminal poor contact Replace control unit Not OK TROUBLE SYMPTOM Automatic shoulder belt system does not operate...

Page 1301: ...SEATS SEAT BELTS AND INTERIOR T4M1 5 3 1 CHECK BATTERY HARNESS Check battery harness for shortcircuits or discontinuity Refer to T5B1 65...

Page 1302: ...s ON Yes Troubleshoot according to symptoms Check power supply and ground circuits B POWER SUPPLY AND GROUND CIRCUITS 1 1 Check power supply circuit Not OK Repair wiring If shorted replace fuse after...

Page 1303: ...max 3 CHECKIF SPECIFIED VOLTAGE IS APPLIED TO EACH SYSTEM CIRCUIT 1 Check that control unit connector is properly con nected 2 Measure voltage between control unit connector and body Connector termin...

Page 1304: ...resistance between buckle switch s termi nals Terminal Specified resistance 1314 No 3 No 4 1 Mfg min 1338 No 3 No 4 1 Mfg min 1 Switch sdie 0 z J I t 4 3 i I r Rear limit switch buckle switch connect...

Page 1305: ...tion meter connector and control unit connector Connector terminal Specified resistance i8 No 15 1432 No 5 1 Q max 3 CHECK WIRE HARNESS BETWEEN IGNITION SWITCH AND WARNING LIGHT 1 Disconnect combinati...

Page 1306: ...ntrol unit 2 Apply 12 volts DC to terminals to check that buzzer sounds Terminal polarity 1390 No 1 12 V 1390 No 12 12 V 1 1 Check wire harness for shortcircuits Not OK Repair wire harness OK Repair c...

Page 1307: ...der the seat C5 494 Fig 124 J WARNING IS NOT EMITTED WHEN LAP BELT IS UNLATCHED FROM BUCKLE 1 1 Check lap belt switch OK 2 I Check lap belt harness OK Repair control unit terminal poor contact Replace...

Page 1308: ...g the Airbag system inoper ative which could lead to personal injury or death in the event of a severe frontal collision all maintenance must be performed by an authorized SUBARU dealer Improper maint...

Page 1309: ...5 4 IC1001 INSTRUMENT PANEL C COMPONENT PARTS 1 Console Box 1 A T cover 2 Tray 3 Mat 4 Ashtray ASSY 5 Console box ASSY 6 Lid 7 Bracket console C5 101 Fig 1 2...

Page 1310: ...console comp 3 Pad frame B 4 Visor 5 Clock 6 Grille vent D CTR 7 Panel lower cover 8 Cover lower 9 Ashtray ASSY 10 Grille vent P CTR 11 Base D 3 12 Base P 13 Base CTR 14 Cover audio 15 Panel radio 16...

Page 1311: ...inf instrument panel 3 Cap 4 Cover instrument side 5 Grille speaker ASSY 6 Pin front panel 7 Grommet 8 Reinf pocket D 9 Reinf pocket C 10 Pocket 11 Pad frame P 12 Striker compl 13 Bracket striker 14 H...

Page 1312: ...arness when servicing the combination meter 2 Console Box rig a A REMOVAL 5 Remove three screws from console box 1 Disconnect ground cable from battery 2 Remove console panel by taking off three clips...

Page 1313: ...to 5 3 W1 W 41 Remove radio qroundinca wire Bolt I 1 4 1 Screw rivet C5 563 Fig 10 riy I i 7 Remove panel lower cover by removing four bolts C5 033 Fig 12 ly 6 6 Remove lower cover by removing six cl...

Page 1314: ...and right 11 Remove caps from both ends of instrument panel sides and remove bolts C5 4 Fig 14 101 I Mniar ctaarinn rnliimn Fig 15 r C5 040 13 Remove visor by removing seven screws and dis Fig 18 7 Fi...

Page 1315: ...transmission select lever and sur rounding portion with cloth to avoid damaging 19 Remove instrument panel by pulling it forward B INSTALLATION 1 Installation is in the reverse order of removal Obser...

Page 1316: ...INSTRUMENT PANEL w3ao1 5 4 3 Set clips located at both inside ends of instrument panel onto body side Fig 24 9...

Page 1317: ...sed on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD All rights reserved This book may not be reproduced or copied in whole or in part without...

Page 1318: ...5 5 M100 SUPPLEMENTAL RESTRAINT SYSTEM M MECHANISM AND FUNCTION 1 SRS Airbag C5 710 Fig 1 Orange Yellow...

Page 1319: ...ting the steering The SRS airbag is provided as an auxiliary driver restraint wheel system to be used in combination with the seat belt When an impact greater than a set level is applied to the front...

Page 1320: ...afety sensor sense an impact at the same time Fig 3 1 AIRBAG CONTROL MODULE The airbag control module is installed ahead of the front floor tunnel It detects the vehicle s deceleration by receiv ing e...

Page 1321: ...02 Fig 4 3 SAFETY SENSOR Two safety sensors are built into the airbag control module The construction is similar to that of the front sensors 4 AIRBAG MODULE The airbag module is located at the center...

Page 1322: ...module To disconnect the connector press wire 1 of the control module as illustrated below until the green lever 1 2 tilts up This unlocks the double lock then you can pull off the connector while pr...

Page 1323: ...ection occurs or if the airbag control module detects an abnormality When the airbag system is normal this light goes out approximately eight seconds after turning the ignition switch ON The wire harn...

Page 1324: ...MANUFACTURE AS NOTED ON THE CERTIFICATION PLATE THE SRS AIRBAG SYSTEM MUST BE INSPECTED BY A SUBARU DEALER See your owner s manual for more information about the SRS AIRBAG SYSTEM PRECAUTION TOUJOURS...

Page 1325: ...HOULD ONLY BE INSTALLED IN VEHI CLES EQUIPPED WITH AIRBAG SYSTEM AND IS TO BE INSTALLED AND OR DISASSEMBLED ONLY BY TRAINED PER SONNEL CONTENTS ARE POISONOUS AND EXTREMELY FLAMMABLE DO O NOT DISMANTLE...

Page 1326: ...ot the designated trouble code is output during on board diagnostics Refer to Diagnostics Section Replacement standard Bracket is deformed Housing is cracked or deformed The label that identifies the...

Page 1327: ...on of col umn bracket L Less than 0 5 mm 0 020 in B5 12381 Fig 14 Check to ensure that new airbag module is properly installed in steering wheel After installing airbag module check to ensure that it...

Page 1328: ...bolt 7 Airbag control module 8 Airbag module ASSY 9 Airbag control module BRKT 10 Front sensor ASSY RH 11 Grommet 12 Front sensor ASSY LH 13 Airbag main harness 14 Protector LH 15 Protector H RH 16 Pr...

Page 1329: ...he ignition switch off disconnect the negative battery terminal then the posi tive terminal in advance and wait for more than 20 seconds before starting work O O nOn n D 03 C5 031 Fig 19 3 When checki...

Page 1330: ...parts may be damaged and its reliability greatly lowered r1g z4 7 Before connecting the airbag system to ground make sure that the grounding terminal is free from paint and contamination 8 Do not allo...

Page 1331: ...6 2 When removing and installing the airbag module the operator should stand as much as possible on the side of the airbag module GOOD NO GOOD C5 015 Fig 27 Fig 28 4 Do not check airbag module continu...

Page 1332: ...ved airbag module be sure to otherwise a dangerous condition may be created if the place it in parallel with floor with the pad facing up Do not module malfunctions place it against a wall or place an...

Page 1333: ...m both sides of steering wheel Using TORXO BIT T30 Tamper resistant type remove four TORXO bolts Fig 34 Fig 35 6 Refer to 5 5 W1 B1 for handling of a removed airbag module 3 INSTALLATION First make su...

Page 1334: ...eat painting mist or the flame of the welding burner directly to the front sensors and wire harness of the airbag system 1 1g ti 2 REMOVAL 1 Turn ignition switch off 2 Disconnect ground cable from bat...

Page 1335: ...to 5 1 W12A1 8 Remove wiring harness bracket 1 C5 153 Fig 41 9 Pry off four clips securing front sensor harness with standard screwdriver 10 Remove grommet Sunroof drain hose C With sunroof model C5...

Page 1336: ...arness spool Do not reconnect airbag connector at spool until front sensors are securely re installed Remove 1 Base _ r r Console panel Section Cl C5 151 B58 i 7 AB I 11 C5 355 Fig 47 6 Roll up floor...

Page 1337: ...heat and light sources and mois ture and dust Fig 51 2 REMOVAL 1 Turn ignition switch off 2 Disconnect ground cable from battery and wait for at least 20 seconds before starting work 3 Remove lower co...

Page 1338: ...nd steering gearbox make sure to center roll connector built into com bination switch assembly 1 Make sure that front wheels are positioned straight ahead 2 Install gearbox steering shaft and combinat...

Page 1339: ...ad position Failure to do this might damage roll connector 2 Install column cover and center roll connector 1g 67 3 Install steering wheel in neutral position Carefully insert roll connector pin into...

Page 1340: ...s indicates a cur Check the memory for intermittent problems by performing the procedure out rent problem lined in 5 5 T1B0 ON BOARD DIAGNOSTICS I I Confirm flashing trouble code Confirm flashing norm...

Page 1341: ...ble code clear mem ory as follows Make sure ignition switch is ON and engine OFF Connect one DIAG terminal on diagnosis connector terminal No 9 While warning light is flashing connect the other DIAL t...

Page 1342: ...con trol module 21 Provided Airbag control module is faulty 1 Airbag main harness is shorted to power supply 2 Front sensor harness is shorted to power supply 23 Provided 3 Airbag module harness is d...

Page 1343: ...SUPPLEMENTAL RESTRAINT SYSTEM T1 D2 5 5 2 HOW TO READ TROUBLE CODE Example Flashing ON Code 12 OFF Flashing ON Code 21 OFF Flashing ON Normal I I Code OF u LL JJF 0 6 0 6 Second 135 1321 Fig 64 27...

Page 1344: ...arness C con I C nector 1 C to AB8 Refer to 5 4 W3A0 with airbag resistor attached to test harness C connector 3C Turn ignition switch ON Does airbag warning light go OFF after 8 seconds and remain of...

Page 1345: ...for more than 30 seconds See notes 1 and 2 16 If YES disconnect battery Turn ignition switch OFF and wait 20 seconds Install airbag module Refer to 5 5 W1B5 and pro ceed to step 18 17 If NO replace c...

Page 1346: ...WarnIn9 sensor L I ght AN Dimmer cIrcu t a16 c 4 a 9 a15 a14 12 1 1 0 1 AB I AB4 RH IG F B 5w R No 15 10A _ I N0 16 15A II T 0 No 8 15A Diagnosis connector 12 84 5678910 36 Time control unit 58 Booste...

Page 1347: ...STEM Taoo 5 5 3 Wiring Location Fig 70 Connector No AB AB AB3 AB4 AB5 AB AB7 AB8 Pole 7 3 3 2 2 12 3 3 Color Yellow Yellow Yellow Blue Orange Yellow Yellow Yellow j male female female female female fe...

Page 1348: ...o use specified test harness A B or C when measuring voltage resistance etc of AIRBAG system component parts A TEST HARNESS A PN 98299PA000 4A 5A 3 2 1 21 12 7654 3A 4A CD 1234 5679 110111112113114115...

Page 1349: ...NT SYSTEM r48OI 5 5 B TEST HARNESS B PN 98299PA010 7B 5B 8B 16I 5l413 4 1312 1 1 1 12111098765 21 12 3B 12345 6789 1011121314151617181920 12 12 loon 4B 38 12 34 123 4 5678910 1 56789101112 9 9 11 Fig...

Page 1350: ...5 5 R4CO SUPPLEMENTAL RESTRAINT SYSTEM IC TEST HARNESS C PN 98299PA020 2C 3C 1C 2C Brl A 1 23 2 L Gwr R L w tato j It cli LL I I B5 1249 Fig 73 34...

Page 1351: ...istor is used during diagnostics The airbag ule It also makes it possible to finish diagnostics in less resistor has the same resistance as the airbag module and time thus provides safety when used in...

Page 1352: ...ont sensor and harness inspection OK 2 Airbag main harness inspection OK Replace airbag control module e Airbag control module is faulty Not OK I Replace front sensor Not OK I Replace airbag main harn...

Page 1353: ...17 No 18 1 4 1 6 kQ LH AB5 No 15 No 16 1 4 1 6 kf2 2 AIRBAG MAIN HARNESS INSPECTION 1 Disconnect connector AB6 from airbag control module and connect AB6 to test harness B connector 8B 5B Terminals S...

Page 1354: ...tion switch OFF disconnect battery ground terminal and then wait at least 20 seconds 1 FRONT SENSOR LH AND RH INSPECTION 1 Disconnect connectors AB4 and AB5 from airbag control module 2 Connect connec...

Page 1355: ...t OK I Replace fuse No 8 CAUTION Before performing diagnostics on airbag system turn ignition switch OFF disconnect battery ground cable and then wait at least 20 seconds After 20 seconds elapse remov...

Page 1356: ...r pillar and connect connector AB1 to test harness A connector 2A B58 AB1 2A n 5A rr f 112 1 3 4 5 6 7 8 9110 111 112 1 131 14 1 15 116 117 18 C5 347 Fig 79 4 Measure resistance between test harness A...

Page 1357: ...switch OFF disconnect battery ground cable and then wait at least 20 seconds 1 AIRBAG MAIN HARNESS INSPECTION 1 Remove lower cover and panel Refer to 5 4 W3A0 and connect connector AB8 at harness spo...

Page 1358: ...AUTION Before performing diagnostics on airbag system turn ignition switch OFF disconnect battery ground cable and then wait at least 20 seconds After 20 seconds elapse remove instrument panel lower c...

Page 1359: ...8 at harness spool OK 3 Roll connector double lock inspection at connectors AB2 and AB7 CAUTION Before performing diagnostics on airbag system turn ignition switch OFF disconnect battery ground cable...

Page 1360: ...RESTRAINT SYSTEM T6F3 5 5 3 ROLL CONNECTOR DOUBLE LOCK INSPEC TION AT CONNECTORS AB2 AND AB7 1 Remove airbag module Refer to 5 5 W1 B2 and check double lock at connectors AB2 and AB7 at roll connecto...

Page 1361: ...1 CONTENTS OF DIAGNOSIS 9 Airbag control module is faulty Replace airbag control module CAUTION Before performing diagnostics on airbag system turn ignition switch OFF disconnect battery ground cable...

Page 1362: ...seconds elapse remove instrument panel lower cover and disconnect AB3 and AB8 1 FRONT SENSOR INSPECTION 1 Disconnect connectors AB4 and AB5 from airbag control module Refer to 5 5 W1 E2 2 Connect con...

Page 1363: ...No 16 OK Repair body harness CAUTION Before performing diagnostics on airbag system turn ignition switch OFF disconnect battery ground cable and then wait at least 20 seconds After 20 seconds elapse...

Page 1364: ...8 at front lower pillar and connect connector AB1 to test harness A connector 2A 3 FUSE No 16 INSPECTION Make sure ignition switch is turned OFF then remove and visually check fuse No 16 Fig 92 Fig 91...

Page 1365: ...ics on allrbag system turn ignition switch OFF disconnect battery ground cable and then wait at least 20 seconds 1 INSPECTION OF BODY HARNESS CONNECTOR AND AIRBAG WARNING LIGHT 1 Turn ignition switch...

Page 1366: ...t connectors 613 and 713 If resistance is greater than 10 ohms body grounding cir cuit is faulty and should be repaired If resistance is less than 10 ohms go to step 2 below 2 Connect connectors AB1 a...

Page 1367: ...turn ignition switch OFF disconnect battery ground cable and then wait at least 20 seconds 1 FUSE No 15 INSPECTION 1 Remove and visually check fuse No 15 2 BODY HARNESS INSPECTION Turn ignition switc...

Page 1368: ...to make sure airbag warning light illumi nates If it does not replace airbag warning light unit Fig 102 4 AIRBAG MAIN HARNESS INSPECTION 1 Turn ignition switch OFF disconnect battery ground cable and...

Page 1369: ...eck parts 2 Airbag component parts appearance inspection Not O K Replace faulty parts O K 3 I Airbag component parts vibration inspection Not O K Replace faulty parts O K 4 Showering inspection to bod...

Page 1370: ...ness W1D1 Airbag control module WIE1 21 o Airbag control module W1E1 Airbag main harness W1D1 Roll connector W1F1 23 9 Airbag module W1B1 e Front sensor RH LH Wici Airbag control module WlE1 2 AIRBAG...

Page 1371: ...light illumination check I Not O K Go to TlE0 basic diagnostics procedure O K Clear memory CAUTION Before performing diagnostics on airbag system turn ignition switch OFF disconnect battery ground cab...

Page 1372: ...uct vibration inspection on fuse No 16 airbag main harness airbag control module and body harness Gently shake each part 4 SHOWERING INSPECTION TO BODY 1 Spray water on vehicle body CAUTION Do not dir...

Page 1373: ...manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during re pair work is needed be sure to use SUBARU ge...

Page 1374: ...CTION 2 1 Alternator 2 2 Ignition Coil 3 3 Spark Plug 3 S SPECIFICATIONS AND SERVICE DATA 4 C COMPONENT PARTS 6 1 Starter 6 2 Alternator 7 W SERVICE PROCEDURE 8 1 Starter 8 2 Alternator 12 3 Ignition...

Page 1375: ...vel of output voltage In this case voltage is slightly greater than specified 2 Diagnosis warning regulated voltage however voltage regulation is still When any of the following problems occur the cha...

Page 1376: ...rk plug cable is not used secondary voltage drop leaks etc do not occur The result is high perfor mance reliability Secondary terminal Secondary terminal Primary coil Core i Ignition coil Case lJUUaLU...

Page 1377: ...ft Ib Rotating speed 1 000 rpm or more Voltage 4 V Lock characteristics Current 980 A or less Torque 23 N m 2 3 kg m 17 ft Ib or more 2 ALTERNATOR Type Rotating field three phase type Voltage regulat...

Page 1378: ...ure DIAMOND Primary coil resistance 0 68 0 830 Secondary coil resistance Insulation resistance between primary terminal and case More than 10 Mfg 4 SPARK PLUG Type and Manufacture PFR68 11 PFR6G 11 NG...

Page 1379: ...tarter O J 1 Sleeve bearing 2 Front bracket 3 lever set 4 Magnet switch ASSY 5 Yoke 6 Gear ASSY 7 Shaft ASSY 8 Internal gear ASSY 9 Over running clutch 10 Stopper set 11 Packing 12 Ball 13 Armature 14...

Page 1380: ...ENGINE ELECTRICAL SYSTEM C2ool 6 1 2 Alternator Fig 5 06 042 7...

Page 1381: ...tor from terminal M of switch ASSY and connect terminal M to ground termi nal of battery with a lead wire Next gently push pinion back with your fingertips and measure pinion gap 2 If pinion gap is ou...

Page 1382: ...current draw when the voltage is ad justed to the specified voltage Lock test Standard Voltage Current 4 V 980 A max Torque 23 Nom 2 3 kg m 17 ft Ib min B DISASSEMBLY 1 Loosen nut which holds termina...

Page 1383: ...r and clutch from shaft J19 Stopper _ Ring Shaft 136 450 Fig 14 C INSPECTION 1 ARMATURE 1 Check commutator for any sign of burns of rough surfaces or stepped wear If wear is of a minor nature correct...

Page 1384: ...if it exceeds the service limit Replace if abnormal wear or cracks are noticed Brush length Standard 17 0 mm 0 669 in Service limit 11 5 mm 0 453 in Wear limit line I i 1 Brush 86 455 Fig 19 2 Brush...

Page 1385: ...sleeve bearing Armature shaft gear Outer periphery of plunger Mating surface of plunger and lever Gear shaft splines Mating surface of lever and clutch Ball at the armature shaft end Internal and plan...

Page 1386: ...nal B coil to remove stator coil Remove rectifier Finish the work rapidly less than three seconds be cause the rectifier cannot withstand heat very well Nut Rectifier O O 0 Rear cover ft 06 018 Fig 29...

Page 1387: ...od condition if continuity exists only in the direction from the heat sink to the diode lead Fig 31 3 Checking trio diode Check the trio diode using a circuit tester It is in good condition if continu...

Page 1388: ...1 Continuity test Inspect stator coil for continuity between each end of the lead wires If there is no continuity between individ ual lead wires the lead wire is broken and so replace stator ASSY Fig...

Page 1389: ...039 Fig 41 4 Install front bearing retainer Fig 39 C ASSEMBLY 5 BEARING front side 1 Check front ball bearing If resistance is felt while rotating or if abnormal noise is heard replace the ball beari...

Page 1390: ...Using accurate tester measure the primary coil re sistance If the resistance is extremely low this indicates the presence of a short circuit Specified resistance Primary side 0 68 0 83 II Fig 43 3 He...

Page 1391: ...Coil W3A0 2 Remove spark plug using spark plug wrench 3 When installing spark plugs on cylinder head use spark plug wrench Spark NGK PFR6B 11 PFR6G 11 NIPPONDENSO PK20PR 11 Ignition coil C6 032 Fig 4...

Page 1392: ...t is advisable to replace with plugs having hotter heat range Bfr130 3 Oil fouled Wet black deposits show excessive oil entrance into combustion chamber through worn rings and pistons or excessive cle...

Page 1393: ...his may damage platinum tip of electrode However if carbon accumulates excessively on electrodes due to poor sparks use plug cleaner under the following condi tions Plug cleaner usage condition Air pr...

Page 1394: ...ding of yoke field coil Insufficient carbon brush length Insufficient brush spring pressure Starter starts but does not crank Failure of pinion gear to engage Worn pinion teeth engine ring gear Improp...

Page 1395: ...at 1 500 rpm VB 12 5V 12 5V VBS_15 5V Check IC regulator as a Turn light switch ON single unit while engine idles Terminal voltage Check if charge bulb comes on when terminal NO I Replace charge bulb...

Page 1396: ...dealer Improper maintenance including incorrect re moval and installation of the Airbag system can lead to personal injury caused by uninten tional activation of the Airbag system All Airbag system e...

Page 1397: ...cator light 12 V 1 4 W Oil pressure indicator light 12 V 1 4 W A B S warning light 12 V 1 4 W AT oil temp warning light 12 V 1 4 W d E Malfunction indicator lamp 12 V 1 4 W c O High beam indicator lig...

Page 1398: ...gh mount stop light 12 V 5 W LED Room light 12 V 8 W Spot light 12 V 8 W Trunk room light 12 V 5 W Courtesy light 12 V 1 4 W Glove box light 12 V 3 4 W Ash tray illumination light 12 V 1 4 W Vanity mi...

Page 1399: ...After reassembly ensure functional parts operate smoothly 1 Audio A REMOVAL AND INSTALLATION 1 RADIO BODY 1 Lower steering wheel Tilt adjustment and move it back Telescopic adjustment 2 Remove lower c...

Page 1400: ...rd screw driver Be careful not to damage instrument panel 4 DOOR SPEAKER 1 Remove door trim 2 Remove screws which secure door speaker 3 Disconnect connector 5 REAR SPEAKER 1 Remove rear backrest 2 Rem...

Page 1401: ...6 2 w2B1 BODY ELECTRICAL SYSTEM 5 Remove screws which secure combination meter and pull combination meter out Fig 9 B INSTALLATION Fig 10 6 1 COMBINATION METER...

Page 1402: ...meter in position Force exceed ing 118 N 12 kg 26 lb may damage it Fuel gauge illumination F Door open right r Seat belt Door open left rSpeedometer F I illumination 0 Turn signal right Hi beam Turn s...

Page 1403: ...switch to OFF position Fuel gauge F Fusible link 15A E Fuel gauge unit Ignition q switch B J Fuel tank 86 103 Fig 13 It is normal if the readings of fuel gauge are within the tolerances of all length...

Page 1404: ...BODY ELECTRICAL SYSTEM W3A0 6 2 3 Cruise Control A SCHEMATIC Battery S7 SN Throttle valve DAST EL AE ACCE L Fig 14 06 081 9...

Page 1405: ...p light switch ON signal Brake pedal depressed cancel 2 Brake switch OFF signal Brake pedal depressed control 3 Cancel switch ON signal Control lever set to CANCEL 4 Inhibitor switch ON signal Selecto...

Page 1406: ...roups Cancels erroneous B Brake switch OFF are simultaneously entered cruise control switch operation Stop light switch ON and memory speed will be or are cancelled Brake pedal depressed System resume...

Page 1407: ...emitted from control unit energizes solenoid to open valve A This causes section E to open to the atmosphere so that actuator moves control cable so that throttle valve closes The above operation of t...

Page 1408: ...te no diaphragm operation occurs as the atmospheric pressure is kept inside the actuator To accelerator pedal Throttle valve lll i i S O y y 0 Actuator Throttle cam B6 215 Fig 16 6 ENGINE THROTTLE The...

Page 1409: ...in Ib t Make sure cover is securely positioned Keep inner cable deflection within 1 in either direction Apply an even coat of grease ii to joint of dam Install cruise control cable on R H side of and...

Page 1410: ...ly when routing maintaining a bend radius of greater than 30 mm 1 18 in e Firmly connect rubber hoses and actuator main taining a clearance of less than 2 mm 0 08 in between them 2 ACTUATOR 1 Remove c...

Page 1411: ...40 km h 25 MPH 2 Ensure that vehicle continues to decelerate while holding sub switch in SET COAST mode and that it maintains that optional speed when subswitch is re leased When vehicle speed reaches...

Page 1412: ...BODY ELECTRICAL SYSTEM w4001 6 2 4 Front Wiper and Washer 1 Wiper motor ASSY 2 Wiper link ASSY 3 Wiper arm 4 Rubber ASSY 5 Wiper blade 6 Cover Fig 20 17...

Page 1413: ...in hole on body Tightening torque 4 4 7 4 Nom 45 75 kg cm 39 65 in Ib 4 NOZZLE 1 Disconnect washer hose from nozzle 2 Push nozzle clip in direction A See Figure below 3 Remove nozzle from hood Fig 23...

Page 1414: ...fuel warning sensor thermistor Connect fuel gauge unit and test lamp 12V 3 OW to battery and connect terminal 2 to battery and terminal 5 to test lamp respectively Ensure that test lamp remains off w...

Page 1415: ...nd main electrical units devices is as shown in the following illustration Also refer to the wiring diagram FAN RH FAN LH F L 1 5 26 25 24 23 _ 22 FWD A C C6 12s Fig 27 Relay side CHHHH9 H H HHH HE X1...

Page 1416: ...of the gauge enter of the gauge Black mark Front C6 11 2 Fig 32 A INSPECTION 1 HEAT WIRES 1 Start the engine so that battery is being charged 2 Turn defogger switch ON 3 Check each heat wire at its c...

Page 1417: ...rinted heat wire characteristics 0 12 Midpoint Approx 6 V 0 Terminal Terminal Heat wire length Abnormal heat wire characteristics 12 1 Broken or open circuit i 6 1 I 1 1 0 1 f Terminal y Terminal Heat...

Page 1418: ...BODY ELECTRICAL SYST EM w1ooo 6 2 10 Rear Wiper and Washer 3 Wiper blade Rubber ASSY Head cover Wiper arm Cap Wash nozzle ASSY Cushion Special washer Cover shaft Motor ASSY Fig 37 23...

Page 1419: ...Fig 39 B REMOVAL AND INSTALLATION 1 WIPER ARM 1 Remove head cover 2 Remove nut and wiper arm 2 Remove rear gate trim Ref to 5 3J 3 Disconnect connector Motor Er relay 4 Separate washer hoses at joint...

Page 1420: ...OR 5 COCK LO Main Box U LO A A LOCK 8 UNLOC C TIMER 4 R V LO DRIVER S DOOR LOCK UU 6LL DOOR LOCK PASSENGER S DOOR LOCK SWITCH U L PARKING LIGHT SWITCH PARKING LIGHT RELAY N101 TO PARKING LIGHT CIRCUIT...

Page 1421: ......

Page 1422: ...rol unit The sensor sensitivity can be fine tuned changing the level of impact required to set off the alarm To reduce sensitivity turn the screw counter clockwise Increase sensitivity by turning the...

Page 1423: ...l unit near the shock sensor adjustment screw The fuse protects the circuit board from power serges or shorts To replace the fuse place a screwdriver in the end of the fuse holder and turn counter clo...

Page 1424: ...ly and brace 3 Remove the two attaching bolts from the electronic control module bracket 4 Gently pull the electronic control unit away from inside the dash Disconnect the connector from the back of t...

Page 1425: ...parking lights flash as a signal the transmitter codes need to be reprogrammed Press the button on each remote transmitter twice and one more time on one of the transmitters a total of five 5 times T...

Page 1426: ...OFF The alarm should sound immediately when the main switch is pressed OFF 12 Disarm the system and stop the alarm by pressing the remote transmitter button 3 SHOCK SENSOR 1 Unlatch the hood 2 Arm th...

Page 1427: ...M G COMPONENT LOCATIONS Fuse box Horn relay Parking light relay Driver s door lock actuator and latch switch Ignition switch Passive belt controller Trunk lid switch Dome light timer Door lock timer F...

Page 1428: ...B74 45 amp OFF i 1 10 amp o No 15 ST Starter circuit Starter interrupt relay Ba Starter 873 motor Key plate sw itch 65 Drivers door handle sw i t 1 2 Drivers door lock actuator 02 C OL 3 Passenger doo...

Page 1429: ...WIRING DIAGRAM CONTINUED Rearwindow defogger Defogger 20 amp To parking light circuit 845 1 B46 843 B54 C I I Fl _ LY LJ LJ H Parking Parking Horn Parking light li ght Horn buttom security light switc...

Page 1430: ...2 W11Qo BODY ELECTRICAL SYSTEM H SECURITY SYSTEM WIRING DIAGRAM CONTINUED Dome light switch R10 oN b 4 rT1 OFF OOOR J C6 095 8 Continued on next page Driver door Passenger door latch switch latch swit...

Page 1431: ...1 121314M5 1617 191191111121131141151l6187 9 8910 1121 S 31 1110987 21 B73 01 022 875 B90 023 R28 12 1 2 12345678 12 3 34 3456 91011121314116 123 4567 i19 D4 OD 877 R10 R22 021 875 12 34 21 543 6 12 2...

Page 1432: ...7 ARM 0 83 C6 097 Fig 51 PIN ARM DIS ARM 85 12V 12V 86 EARTH OPEN 87a OPEN 30 87 OPEN 2 Security system electronic module r AN shift lock Dome light controller 06 M8 Fig 52 PIN KEY IN KEY OUT 1 12V 12...

Page 1433: ...06 100 Fig 54 PIN HORN ON HORN OFF ALARM ON 1 EARTH 12V EARTH 2 12V 12V 12V 3 12V OPEN 12V 4 N A N A N A 5 N A N A N A 5 SECURITY SWITCH a o 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 O 06 101 Fig 55 PIN SYS...

Page 1434: ...ig 56 PIN OFF ON DOOR 1 12V 12V 12V 2 EARTH EARTH EARTH 3 TIMER TIMER TIMER 4 OPEN EARTH TIMER 5 6 7 TRUNK LID SWITCH 1 2 Trunk 0 O lamp C6 103 Fig 57 O 2 i 4 3 Dome 40 12V light O O timer C6 104 Fig...

Page 1435: ...CTUATOR o 2 1 4 3 L U M C L U O 1 C6 105 Fig 59 PIN LOCK UNLOCK 1 OPEN EARTH 2 EARTH EARTH 3 EARTH 12V 4 12V EARTH 10 PASSENGERS DOOR LOCK ACTUATOR 0 0 2 1 4 3 L M O u J U C6 106A Fig 60 PIN LOCK UNLO...

Page 1436: ...ELECTRICAL SYSTEM 11 DOOR LATCH SWITCHES o 0 0 O o ZJ O 0 3 2 1 C6 107A Fig 61 DRIVERS PASSENGERS PIN LOCK UNLOCK PIN LOCK UNLOCK 1 EARTH OPEN 1 OPEN EARTH 2 EARTH EARTH 2 EARTH EARTH I 3 OPEN EARTH l...

Page 1437: ...T RELAYS Horn relay Parking light relay Parking lights ise box 0 VV J C6108 Fig 62 PIN HORN OFF HORN ON ALARM ON PIN LIGHT OFF LIGHT ON ALARM ON 1 OPEN EARTH EARTH 1 IGN IGN 12V 2 12V 12V 12V 2 OPEN 1...

Page 1438: ...e module Ref to 6 2 OK Is the 12 volt Not OK Replace the bat OK transmitter battery good tery OK Check the Elec tronic Control Not OK r Replace OK Module 1 Amp Replace the fuse r fuse it OK Check the...

Page 1439: ...CIRCUIT Open the drivers door Not OK Confirm that the door OK Check door monitor cir Does the alarm go off 10 monitor circuit will acti cult vate the interior light OK OK Is the horn sounding in Not O...

Page 1440: ...O INSPECTION OF TRUNK CIRCUIT Re arm the system then open the trunk Does the Not OK system go off immediately OK Disarm the system by pressing transmitter button once Not OK Check the door lock circui...

Page 1441: ...a door or trunk Go to section A OK Switch the ignition ON Does the ignition key turn off Not OK the alarm Check the ignition circuit Ref to 6 3 OK I Go to section 1 I R INSPECTION OF SECURITY SWITCH...

Page 1442: ...5 0 6 seconds 3 Rear defogger timer 15 4 minutes 4 Illumination control 12 100 duty ratio 5 Interior light timer 10 3 seconds 6 Ignition key hole illumination OFF delay 10 3 seconds 7 Door key hole i...

Page 1443: ...r wiper switch ACC IGN a5 Latch switch b3 RH b6 a6 Time b7 control unit b8 a7 b5 a19 Rear wiper relay a1 a3 a2 a9 0 Rear defogger relay 812 a13 a b 1898 6 4321 8 654321 201 I 1 1 1 d 131211 1 16 11 51...

Page 1444: ...c field When the multi pole ring magnet built into the sensor rotates along with the revolution of the transmission s driven gear the direction of the mag netic field applied to the MRE cyclically cha...

Page 1445: ...cle speed sensor clean dirt etc from surrounding areas Take care not to allow foreign matter to get into mounting hole 1 Remove collector cover 2 Disconnect vehicle speed sensor connector 3 Turn and r...

Page 1446: ...r memory c The content of memory is cleared when ignition switch or cruise main switch is turned OFF Real time diagnosis The real time diagnosis function is used to determine whether or not the input...

Page 1447: ...select monitor 2 Turn ignition switch and cruise main switch ON 3 Set select monitor in FAO mode 4 Ensure that normal indication is displayed when controls are operated as indicated below When SET COA...

Page 1448: ...code Abbreviation ontents o agnos s 10 OK Normal 31 MOTOR Open or shorted vacuum pump motor circuit harness 32 VENT VALVE Open or shorted vent circuit harness FB1 OUTPUT 33 C U RELAY Deposited safety...

Page 1449: ...h main switch ON Then check that Brake switch 15 0 volts are present when brake pedal is depressed Battery voltage is present when brake pedal is released or 0 volts are present when select lever is s...

Page 1450: ...OK Check if RESUME ACCEL switch functions properly OK Check if SET COAST switch functions properly OK Check if CANCEL switch functions properly Not OK Not OK Not OK Not OK Not OK Not OK Not OK OK Chec...

Page 1451: ...l unit or its associated circuits basic checks must first be con ducted at the power supply ground circuit various terminal voltages etc Cruise control unit is not easily accessible for removal In add...

Page 1452: ...signal approx 0 5 volts is present when all four wheels are raised off ground and one of them is rotated Turn main switch ON Move select lever to any position other than P or N Brake switch No 15 Unde...

Page 1453: ...ise control main switch light Check cruise control main Not OK and circuit switch circuit Repair OK Not OK Check cruise main relay circuit Repair OK Faulty cruise control unit Main relay 0 I B8 Combin...

Page 1454: ...ing repair If no output from the cruise control unit replace the cruise control unit 1 CHECKING THE INDICATOR LIGHT IN THE CRUISE CONTROL MAIN SWITCH 1 Remove cruise main switch 2 Measure resistance v...

Page 1455: ...air the shorted part of the circuit Fuse replace 9 If main relay operates this circuit operates normally When turning ON ignition switch and main switch a Whether main relay is normal or not can be ch...

Page 1456: ...easure the voltage between the main relay and the B45 No 9 Body 10 13 V body 2 Check ON OFF function of main switch Measure resistance between main switch and terminal Terminal Specified resistance No...

Page 1457: ...de with a select monitor 65 Check input of cruise control sub switch SET COAST SW RESUME ACCEL SW 66 Trouble code 11 Stop light switch brake switch and inhibitor switch 68 Trouble code 12 Failure of e...

Page 1458: ...harnesses and connec tors Not OK I Troubleshooting of each trouble code By checking the trouble codes it can be read through a self diagnosis but it is effective to use a select monitor 1 READING THE...

Page 1459: ...uise sub switch OK Failure of the Cruise control unit TROUBLE SYMPTOM The cruise control cannot be set or it is cancelled imme diately RESUME ACCEL cannot be operated Check for disconnection of the ha...

Page 1460: ...onnector Use together with horn power supply 2 Check voltage between sub switch connector and body Connector ft terminal Specified voltage 1354 No 1 Body 10 13 V 3 Check for harness short circuit betw...

Page 1461: ...d stop light switch OK Not OK 3 Check inhibitor relay and inhibitor switch OK TROUBLE SYMPTOM The cruise control cannot be set Check for proper contact in the harnesses and connectors Failure in wirin...

Page 1462: ...on sounds will be heard when relay contact points are separated 2 Check inhibitor relay When applying 12 V power to terminals No 1 to 2 of inhibitor relay Terminal Specked resistance No 3 No 4 1 MQ mi...

Page 1463: ...ise control cannot be set Cancelled immediately 1 Check rotation signal with select monitor OK Check for proper contact of harness Not OK After checking harnesses between cruise control unit and ECU M...

Page 1464: ...2 1 CHECK WITH SELECT MONITOR Measurement condition idling or 2 000 rpm E R E V F 0 3 2 000 rpm e Operation of function keys F o ENT Standard value 100 rpm Reference Indicated value for disconnection...

Page 1465: ...ncelled immediately OK 1 Check speed signal with select monitor Failure in cruise control unit Not OK 2 Perform a circuit test between B9 No 1 to B83 No 7 OK Perform a circuit test of the vehicle spee...

Page 1466: ...a failure in the speed sensor the indicated value of the meter will be incorrect When there is a disconnection or short circuit in the harness between vehicle speed sensor and the cruise control unit...

Page 1467: ...the sub switch I 1 I Check short circuit of cruise control sub switch I OK Check for short circuit in harness between switch and cruise control unit Not OK TROUBLE SYMPTOM Cruise control cannot be se...

Page 1468: ...tch 2 Perform a circuit test between each of terminals while pushing the sub switch Measure resistance between each terminal of cruise control sub switch 3 2 7 f2 J 06 052 Fig 83 Terminal Specified re...

Page 1469: ...monitor Check for poor contact in harness and connector Not OK 2 Measure resistance of vacuum pump and vent Not OK valve Malfunction in vacuum pump and vent valve OK 3 Perform a circuit test in harne...

Page 1470: ...VENT VALVE 1 Separate the connector 2 Measure the resistance value of the vacuum pump and vent valve Range 0 x 1 Connector fr terminal Specified resistance No 2 No 3 100 11100 No 2 No 1 Approx 53 i2...

Page 1471: ...UNIT CONTENT OF DIAGNOSIS Welding of built in relay of cruise control unit Fig 86 TROUBLE SYMPTOM Cruise canceling function does not operate but fuel safe function operates 78 Perform real time diagno...

Page 1472: ...ation of actuator while forcely operating vacuum pump A CHECK OPERATION OF VACUUM PUMP AND ACTUATOR ASSY CONTENT OF DIAGNOSIS Sticking of air leaves of vacuum pump and actuator or sticking of valve an...

Page 1473: ...uise vacuum pump connector No 2 and connect No 1 and No 4 to ground After connecting No 3 to ground throttle vehicle should be fully opened within 3 seconds In case it closes too late valve leakage 3...

Page 1474: ...ER AND WASHER SYSTEM 48 17 FUEL GAUGE SYSTEM 49 18 HORN AND CIGARETTE LIGHTER SYSTEM 51 19 LIGHTING HEADLIGHT t FOG LIGHT SYSTEM 52 20 LIGHTING TAIL LIGHT ILLUMINATION LIGHT etc SYSTEM 56 21 OIL PRESS...

Page 1475: ...ons front instrument panel etc the wiring diagram connector can be located WIRING DIAGRAM I ELECTRICAL WIRING HARNESS O 06 126 Fig 1 2 WIRING DIAGRAM The wiring diagram of each system is illustrated s...

Page 1476: ...a lock is included f4 3 2 1 Numbered in order from upper 9 8 7 6 5 right to lower left 4 Indicates the number of poles s Indicates a lock is included N 7 1 2 3 4 Numbered in order from upper left to...

Page 1477: ...diagram connectors which have no termi nal number refer to one pole types Sketches of these connectors are omitted intentionally 6 The following color codes are used to indicate the colors of the wire...

Page 1478: ...GB Body ground GE Engine ground GR Radio ground All wiring harnesses are provided with a ground point which should be securely connected a The allowable current in the above table indicates the tolera...

Page 1479: ...more contacts The wiring diagram shows the relay mode when the energizing circuit is OFF Relay type Energizing circuit ON 0 0 o _ 4 pole Normally open type 0 0 6 pole x It 0 Normally closed type 4 pol...

Page 1480: ...ickly to save time and labor 1 Identification of trouble symptom Determine what the problem is based on the symptom 2 Probable cause of trouble Look at the wiring diagram and check the system s circui...

Page 1481: ...e continuity When contacting the two leads in reverse there should be no continuity t g 72 3 Symbol o o indicates that continuity exists be tween two points or terminals For example when a switch posi...

Page 1482: ...r supply is shorted Test lamp Shorted wiring O O Fuse holder 86 247 Fig 15 2 Working Precautions 1 PRECAUTIONS WHEN WORKING WITH THE PARTS MOUNTED ON THE VEHICLE 1 When working under a vehicle which i...

Page 1483: ...htly connected Example LIFT I k kPUSH LIFT PUSH 1 r PUSH t 86 252 Fig 18 6 When checking continuity between connector termi nals or measuring voltage across the terminal and ground always contact test...

Page 1484: ...ion AU Auto Up B Battery DN Down DRL Daytime Running Light E Ground F B Fuse r Joint Box FL1 5 Fusible link 1 5 mm2 IG Ignition Illumi Illumination Abbr Full name LH Left Hand Lo Low M Motor M B Main...

Page 1485: ...are indicated where necessary by corresponding symbols as when two pages are needed for clear indication The FUSE NO t RATING corresponds with that used in the fuse box main fuse box fuse and joint b...

Page 1486: ...a symbol consisting of the same characters with arrows as shown below facilitates wire tracing from one page to the next AHA BHB Fj I SYMBOLS OF WIRE CONNECTION AND CROSSING Symbol Refers to wires wh...

Page 1487: ...5A W relay LH N o 23 20A 6 Br No 24 15A s 1 V No 26 15A 7 RY r 0 o 3 No 25 l0A BR LR Headlight relay RH 7 FUSE LOCATION M B E0 30F q SBF SBF Ulb FI L 0 a0F N a J O I 75r 1 5 FNT n 56F LJJ SBF SBF I 45...

Page 1488: ...o 6 20A F3 Gray 874 k LL U Z BT O u O RY 1 B r R 2 Acc BW 4 NIGIG I Ignition switch GW I FB 1 FB 2 FB 3 RY FB 4 W FB 5 LW FB 6 LOr FB 7 W FB 8 Empty RY F ___ FB 9 J Empty __ FE 10 GR_ ___ _ FB 11 Lg R...

Page 1489: ...D B m i3 Rad i o il5 7 B E Brake fluid level sensor Side marker F44 2 light RH r 841 y m B42 Front wiper Front turn E control module Side marker F2 2 e light LH B99 Head I i ght LH F2q 8 Lo beam R5 B...

Page 1490: ...Rear window D2 defogger switch Door handle switch D3 z B 3 850 Wiper select Key hole switch illumi 834 Check connector Power window D6 main switch 833 oC F Changing m i de v i LH r M3 connector D8 Wh...

Page 1491: ...switch R Rear side R29 marker LH Rear wiper R25 motor Automatic shoulder R32 belt control module Fuel pump R33 modu I ator PoVder R30 antenna Automatic shoulder R28 be I t control module Resistor R34...

Page 1492: ...BW O sensor 2 t Combination meter i 6 1 7 C Temp gauge i3 841 88 Gray B9 B I ac k BI6 Gra B1 Gra B69 Wh i te 21 123 123 43 12345 456 B13 B I ac k 812 Gray B35 Ye I I ow 836 B I ack 87 Gray 868 B I ac...

Page 1493: ...FS 1 SBF 6 FUSE N0 19 FUSE N0 12 Hydraulic unit I 1 L 7 F LH F RH R LH R RH U U R36 R18 Rear ABS Rear ABS sensor LH sensor RH RI8 Gray F43 Gray R36 Gray 865 B I ac k 098 White Rl B I ac k 4321 8765 1...

Page 1494: ...t B40 B I ac k 1234 S678 19 1101111121131141151161171181 B66 B I ac k 12345678910 111112113114115116117 18M1920 841 B I ue 8101 B I ue 1 2345 678910 111112113114151611718191201211221 a i6 b D 1 ff 16...

Page 1495: ...151 161171181191201 i p 84 l i2 B39 a 0 1 b 0 0 9 c E Stop braKe FWD swi tch switch Se I ect ChecK mon i tor connector connectcr CUL UL _jCD E I E g BleCK 12 314 M 151 g Eileck 9D Ye I I ow B7 Gray 12...

Page 1496: ...8101 R4 R7 ABS control l J unit Duty solenoid B Duty solenoid C Ell Brown B60 Ye I low B39 B I ack B9 B I ac k R5l B69 B67 B I ack F7 B I ac k B68 B I ac k 86l Ye I low Bl4 B I ac k White White 1 23...

Page 1497: ...12 FB 11 FUSE NQ 2 FB 25 FUSE N0 1 FB 8 FUSE N0 22 B98 B49 R3 R5 8100 Rb Inhibitor switch Bt3 p range 0 1 1 4 1 Transmission 4 Bl4 T2 Key warning s tch wi 5w Key lock e SS o ll 10 o enoid Wh i t e B65...

Page 1498: ...lack R24 Black f4 B I ac k D20 R31 B I ac K MIN2 D ED Eilack 1 2 34 56789 11121314F 697 1011121314 I I IIL21131141 L5116117 Fig 26 BBO i9 e 091 a Time control unit Front speaker LH LSJ G 841 i3 i4 Fro...

Page 1499: ...0 B93 r 840 D10 D16 6 il a i E c i8 B75 892 890 Ol D23 _ a Seat Belt 11 0 o Combination U o c O meter Key Security Time Front Front warning electronic control door latch door latch switch module unit...

Page 1500: ...lder belt Front limit Front limit Seat belt buckle switch LH buckle switch RH switch LH switch RH switch LH Rear limit switch Rear limit switch LH RH a i6 b 2 8 16 8 l 7 15 7 15 6 14 6 14 5 13 S 13 4...

Page 1501: ...SYSTEM To Power Supply Routing FB 24 FUSE NO 1 R T1 Bl3 Inhibitor iGR sw i tch B4 i Rbb Rbl Back up light LH Back up light RH Rbl B I ue R65 Rbb R63 Bl3 B I ac k 899 Wh 1 te 1 2 3 4 1 2 123 1112131 15...

Page 1502: ...8 ALT 1 FUSE N0 15 FUSE N0 15 B41 i3 F8 B70 B39 B I ac k F8 Wh i te B41 B I ue 123 456 1234 5678 123 5 678910 1 7 1 61 91101 111 121 13114 9 101112131415161718 11 1213141516171819202122 a b 8 16 8 t6...

Page 1503: ...BLESHOOTING oao1o 6 3 10 COMBINATION METER To c i To b i O O c16 c8 b8 at6 c15 c7 b7 a15 bIO b2 a10 c10 c2 c1 0oLI U b1 a9 O O O O O J t J O Q t 7 t 7 O Terminal position To a i6 O a8 a7 O all at 10 1...

Page 1504: ...ing warning light ATF temperature warning li Oil pressure warning light Stop light check light Charge warning light Low fuel warning light Parkin brake light Brake luid warninc7 Ilqht 4 1 Thermometer...

Page 1505: ...ed sensor Door RH 37 Door switch 12 O Door LH 3 Door switch 11 O Manu 2 Hold switch b5 Power 27 b6 A T control unit 1 Inhibitor switch Ill 31 b2 O 1 i1 P 14 4 Li 2 29 b4 0 2 u E U U B40 E L 3 3 o u b3...

Page 1506: ...5 J f8 B70 B31 D9 893 D16 B75 Key illumination light 9 9 04 P i nk D21 P i nk D3 B75 B I ac K 1 2 121 34 B I ec k 34 56789 12345678 1011 121314 NH 9 1011 12131415 l6 D4 Courtesy light LH 02l Courtesy...

Page 1507: ...2 Stop brake switch Stop ligh F__o 1 11 1111 r I t _61 i C L 0 a G b j C a A ff76 8 6 8 t6 7 15 7 15 7 5 6 14 6 14 T R4 5 13 5 13 5 13 4 12 4 12 1 2 3 11 3 11 3 L I LO 2 to 9 1 9 T M9 Horn relay E B I...

Page 1508: ...control unit unit B34 835 Check Select connector monitor r w Fw F W Z J U j WQ QQ F20 Gray 873 B I ac k White B85 B86 B I ac k 34 1234 1234 34 861 Ye I I ow B34 B I ec k 12345678 12345 6789 f910012131...

Page 1509: ...4 6 1 9 T3 5 13 Z T2 1 2 3 T I I I 2 10 21 ITO 1 W D B I ac K Vehicle speed sensor 2 Y 5 g W W L 0 c CD E 34 8 6 7 5 R 1 5 t3 T 2 2 1 1 9 Horn relay FMM E Gray 1 234 5161718 9110111112 Fig 34 Horn sw...

Page 1510: ...1 1 Cm B34 835 Check Select connector monitor w w w Z j LL J W QQ u Cruise pump 886 B I ac k B I ac k BB4 White B85 F20 Gray 12 FIT2 34 1234 1234 34 Bt4 B I ack B61 Y e I I ow 1234 5678 B35 Ye 12 34...

Page 1511: ...C L 0 r v B92 8 Or 5 0r 897 Security module U S A Door lock actuator RH Passen er Unlock Lock 22RG D16 893 e B 3 W M Dl5 B94 RG Door lock actuator LH Driver Unlock Lock Un I oc k D2 D10 830 LOCK 4 RG...

Page 1512: ...zo j a on m3 Bl3 Security B92 TI electronic module B73 873 Starter Adapter interrupt relay Inhibitor J switch 860 ye I I owl B59 Ye I low B67 B I ac k 1 12113141S 67891011 123456 11211311141151 16171...

Page 1513: ...WIRING DIAGRAM AND TROUBLESHO OTING 04013 6 3 CANADA model Door lock actuator RH Passenger Unlock Lock Door lock actuator LH Driver D15 DLO D22 Dl6 P34 R 4 56789 1011 121314 CC73 01 Fig 36 41...

Page 1514: ...F1r2T3 E Gray L L L L r 4 5126 7 3 8 B36 g36 9101112 Diagnosis Check connector connector B17 Bbl YeI low I B37 Power steering 12345678 D i agnos i s so I eno 1 d 9 1011 1213141516 terminal B60 wh i te...

Page 1515: ...98 Wh 1 te 872 123 1234 12 123 456 5678 Bl3 B I ac k F8 Wh i te B7 Gray B39 B I ack 840 Wh i te 1234 5678 123 4 6 1234 5678 9101112 7891 0lil21314 9101112131415161718 899 Whi t e B34 B I ac k B41 B I...

Page 1516: ...k mCrank I temperature I Utemperature Uangle Uangle angle Knock Knock sensor sensor sensor 2 sensor 1 sensor 1 sensor 2 E24 E23 E22 E21 E20 E19 Gray E27 E30 Gray E24 Brown E21 Gray Blt Gray Bt2 Gray B...

Page 1517: ...tt2 a1 1 1 J I I I I s 3c c m mm E2 r i 1 1 1 cca 12345678 gl I D 191101111121131141151161 Air flow 862 Yellow sensor Recircuration 1 Throttle Power temperature sensor steering sensor 1 11211314 S 6...

Page 1518: ...USE N0 15 B2 M Front washer motor B62 r Front wiper control unit I 3 I 4 I 9 I 17 C 850 B B I ack B10 B I eck B7 Gray 856 B2 Wh i te 1234 1 123 5678 1234567 II2 1 23 456 9101112 8910 111213 Fig 39 B V...

Page 1519: ...Black R23 MEM 12 345 45 B40 Wh i t e B39 B I eck 123 456 1 1 7 1 8 19 10111 12113114 B41 B I ue 899 Mb i te 1234 678 12345 678910 191101111121131141151161171181 11 1213141516171819 20 2122 B41 13 839...

Page 1520: ...ette lighter C 3 L R i9 i12 B F1 wR 3 Horn relay F3 Q w To Power Supply Routing FB 12 FB 2 FUSE N0 3 FUSE N0 12 Horn Switch Fi B I ac k i t2 B54 B I ac k B2 FS Wh i te i9 B I ue 213 345 9 0131 2131451...

Page 1521: ...ight il diode Fog light switch B40 OFF ON O F6 845 870 FB WL W ILLL L 7 W Lighting switch 855 Dimmer passing switch 857 B49 Dimmer diode B49 B I ac k F31 Gray f6 B I ec k 857 F60 Gray 1 12 2 1 2 B55 8...

Page 1522: ...3 F29 m f2B F22 Headlight Headlight LH LH Lo beam Hi beam I Relay 8 Head F7 B1 B I ac k F28 F41 Brown Brown F29 F42 B I ac k 12 F7 B I ac k 123 4 6 17 18 19 1101111121131141 B72 1234 5678 B40 Wh i te...

Page 1523: ...Fog light RH LH FO B70 Lighting switch B55 Dimmer passing switch LO UP PASS HF B57 HU HL RY E B49 B I ac k f6 B I ac k B57 12 2 863 B I ack 1 2 34 5 B55 12345678 910 1112 1314 F31 Gray F40 Gray F11M2...

Page 1524: ...Lo beam Hi beam 872 F9 Re I ay 8 Head 864 L DRL relay 2 Black f28 F41 Brown R48 Brown F29 F42 B I ac K E Bleck l 234 99 S 6 718L C 3 TO I 1 1718191101111121131141 D rP7 f 9 4_MiL I nh I b I tor swi tc...

Page 1525: ...ecurity module U S A 846 OFF ON B Perking T light switch P _ t B55 B a to t4 HEAD TAIL OFF EL TC i HC Illumi cancel VL V2 V3 I VR Lighting switch a 89t Time control module B45 I I B47 B46 B81 E B80 m...

Page 1526: ...5678910 li 12131415l617181920 6 16 1 8 l6 8 l6 Cl5 Wh i te 6 14 6 14 6 l4 1 2345 6789 5 l3 5 t3 5 73 11011 11121 13114IN1611 018119120 4 l2 4 12 4 l2 3 11 3 11 3 11 2 10 2 l0 2 0 i9 B l ue 84l B l ue...

Page 1527: ...y 839 B I ac k B6 Gray 1 23 1 5 9 2 6 0 3 7 4 8 12 123 456 7891011121314 4567 891011 121314 To Power Supply Routing FB 30 FB 28 FUSE NO 15 FUSE NG 15 B39 i2 v E4 E26 O Oil pressure switch B41 B I ue 1...

Page 1528: ...RG G 6 GY i2 B39 B39 B I ec k FB Wh i te 123 456 1234 5678 17 1 8 19 1101111 121131141 19 1 101 841 B I ue 899 Vdh i te 1 2345 678910 11111211311411511711811912012 1122 61 1 F8 870 a i6 b D 8 Ib 8 l6...

Page 1529: ...tor Lifter motor Front L Lifter motor Rear Fig 47 To Power Supply Routing R43 MB 2 P3 B I ue SBF 1 1 F9 B72 R45 White P6 Brown 898 2 213 R3 I P2 B I ac k P5 R45 12 123 PI I 34 456 B98 Wh i te 1 23 1 2...

Page 1530: ...Power window relay R44 Y Rear power O window motor RH Rl6 a M Rear power window sub switch RH R12 ON UP OFF B7 d b Rear power window sub switch LH R40 ON UP OFF Y 4 n L U U U Rear power O window motor...

Page 1531: ...UP OFF B93 D16 BY 4 K 2 Front power D7 window motor LH 830 Power window main switch LOCK NORMAL LOCK SW 0 LL 0 _ U_ o Position witch O O Front LH Front RH 0 10 01 01 01 0 O 1 01 4 Rear 0 1 10 RH O O R...

Page 1532: ...RELAY 7 A C COMP F23 Sub fan O motor F32 Main fan O motor f37 FAN RH 25A 25A o c O o FAN FG5 F10 Fll Flt LH Fl3 RELAY RELAY RELAY RELAY 4 3 2 1 FAN FAN FAN FAN RH 1 LH 2 LH 1 GND Air conditioner relay...

Page 1533: ...81920 i9 B I ue 12345 678910 11121314151617181920 122 854 Ye I i ow 12 34567891011 11211311141151INI 71181191201211122 B61 Ye I I ow 12345678 19 1011 12131141151161 B60 Ye I I ow 1 1314 S d6 12 F_11_...

Page 1534: ...E Changing connector F38 B I ac k 845 Wh i te i5 B lack B82 B I eok B96 F7 B I ack i l7 B I ac k 3141 1 121 21 11T 6 3 8 41511 617 56 4 4 1 2 2 56789 0 9 0 1 2 1314 789101112 3 9 011111211311 1 B9l B...

Page 1535: ...OFF relay c BM4 BM3 Evaporator Refrigerant sensor temperature sensor 2 3 T T 9 6 tRJI HU4 Heater unit cord L R gpl B I owe r BM5 v gMb motor uO Ou a Fan control HI relay amp HU3 M Hu Air mix door act...

Page 1536: ...L31141151161 ED 1 1121314 M516 91101111121131141151161171 9 Wh i te 891 B I ac k 1234 5678 12345678910 19 110111 1121 131141151 161171181 l 11213141516171819 20 B40 b i7 o Dimmer circuit Combination m...

Page 1537: ...b 1234567 1 819110 11 1213 Fig 51 R2 B97 L0r Fr L0r Rear wiper washer R5 B99 B56 sw itch GR GR WASH ON I NT OFF WASH E r BrR 1R L L L WR EW C1R B91 LB Time R control unit Rear wiper motor C R25 R2b B...

Page 1538: ...D16 B43 LH M RH 2 R R Rr 6 S U P M N 3 WY HEATER Side view mirror LH D8 D9 831 R R R a LH M RH i r r 4 W S U P M N z WG B HEATER 010 830 E B46 Mlh i te 12345 678910 Fig 52 B47 B I ac k 123 45 6789101...

Page 1539: ...ulder belt system Ref to Door lock system Re f to MPFI system B45 Wh i te 654 321 14131211 l0 9 8 7 Fig 53 gg2 Secur 1 ty modu I e U S A LR 9 GW rK 5 L Br Y n 0r ur LW 3 RW B Security switch B45 Ref t...

Page 1540: ...e speed sensor 2 BYV Bw B1 E2 E Combination meter 89 Black Bl Gray 1234 5678 1 2 3 1 9 1101 11 1 1 2 839 B I ec k 840 Wh I te a i6 b D c a 8 16 8 16 8 l6 L 7 15 7 15 7 15 6 14 6 14 6 l4 S 13 S 13 5 l3...

Page 1541: ...2l White 12 ED B90 B I ac k 2 1 12345678 6 5 4 3 9 1011 1213141516 Fig 55 R17 Vanity mirror light LH With sunroof R41 R42 R17 Vanity mirror LIRE B 1 1 i htLH J I thout sunroof R11 Vanity mirror light...

Page 1542: ...39 B I ac k 1023 12 34 1 456 23 4567 678910 171 51 91101111121131141 5 B40 Wh I te 1 1023 124 678 9 11131415161718 834 B I ac k 841 B I ue 12345 6789 12345 678910 11011 11121131141151IN171181191291 11...

Page 1543: ...WIRING DIAGRAM AND TROUBLESHOOTING 040331 6 3 33 STARTING SYSTEM Starter interrupt Bwr relay adapter U S A I nh i b i tor swi tch ff C E ED Black 12 S161718 3 4 1 9110111112 CU03 01 Fig 57 75...

Page 1544: ...2 12 u2 34 34 FB Nlh i te 1234 5678 191 101111121151141151161111181 841 B I ue 899 Wh i te 12345 6789L0 1111121131 4115116117 1181 191201211221 R72 WR Stop lamp checker R67 R66 R65 R64 Rbl Stop light...

Page 1545: ...BF 1 8100 F9 R6 B 2 r Power window B98 R3 R43 circuit breaker aw w Power window R44 re I ay O 1 s Sunroof relay R2I R43 R4l R44 SL S3 89B Wh ite S2 872 2 213 34 43 3 F1 2 1 2 3 11 12F 131 1 2L314 45 4...

Page 1546: ...o Lighting system Tail I I Iumi Ref to Auto A C system Radio clock system Combination meter 890 B I ac k 12345678 1 9 1 101 11 1121131141151 161 a 891 b B90 F8 Wh i te 1234 5678 9 101112131415161718 R...

Page 1547: ...B92 Security module U S A To Power Supply Routing MB 6 FUSE N0 25 Trunk room light R27 2 R75 21 892 1234 5678 9 1011 121314151617 F8 Wh i te 1234 5678 1 9 1 101111 21 131141 151161 71181 8100 B I ac k...

Page 1548: ...FTO 1 T 01 LMNR Turn signal switch v E Rear turn signal light RH F27 Gray F44 Gray B76 B I ac k 12 123 3 Bbl Mlh i t e 654 321 1413121110987 840 Wh 1 te F8 Wh i te 1234 5678 19 11011111211511411511611...

Page 1549: ...or D Fuel pump relay J Headlight relay LH K Headlight relay RH K Horn relay H Inhibitor relay A Main relay J Engine Control Module ECM H Power steering control module J Electrical control module Refer...

Page 1550: ...uit breaker belt control module C6 124 I H I C6 121 C6 123 DIAG terminal Data Y Q H _ N Fog light relay TCM Rear defogger relay Tail and illumination 0 relay link connector 6 f __ I j 11 II I Diagnosi...

Page 1551: ...6 3 10600 WIRING DIAGRAM AND TROUBLESHOOTING 6 Electrical Wiring Harness and Ground Point r L I A k A Front C6 001 06 001 Fig 65 84 meter cord...

Page 1552: ...Headlight LH Hi beam F29 2 Brown C2 Headlight LH Lo beam F30 1 x 2 Black B2 Horn F31 2 Gray B2 Front fog light LH F32 4 Gray B2 Radiator fan LH Sub fan F33 2 Black 82 A C compressor solenoid F34 1 Bl...

Page 1553: ...Front wiper motor 811 6 Gray A2 Igniter B12 7 Gray A3 111 B13 12 Black B3 T1 Transmission cord B14 16 Black B3 T2 B15 1 Black B3 Starter motor B16 4 Gray B3 02 sensor 2 B17 2 Black B3 Power steering...

Page 1554: ...Gray B1 Knock sensor 1 E21 2 Gray B1 Crank angle sensor 1 E22 2 Gray C2 Crank angle sensor 2 E23 2 Gray B2 Cam angle sensor E24 2 Brown B2 Water temperature sensor E25 1 Bt Thermometer E26 1 B2 Oil pr...

Page 1555: ...B2 Step light LH B78 20 Black B2 i10 B79 18 White B2 i11 Instrument panel center cord B80 22 Blue B2 i9 B81 14 White B2 Hazard switch 8 rear window de fogger switch B82 10 Black B2 HUi Heater unit cor...

Page 1556: ...18 White B2 B79 02 3 C2 Cigarette lighter 8 ash tray Illumination light B ground 03 1 C2 Cigarette lighter Power i14 2 White C2 CD illumination light 05 20 White B2 Radio 06 20 Black 82 Auto A C contr...

Page 1557: ...D9 10 83 B31 1 J Bulkhead wiring harness D10 14 B3 830 D15 4 D2 894 Bulkhead wiring harness D16 14 D2 B93 D17 8 White D2 Side view mirror RH D18 2 Green D2 Front power window motor RH D19 5 D3 Front p...

Page 1558: ...le Color Area No Name R29 2 Black B4 Rear side marker LH A30 3 B4 Power antenna R31 2 Black B4 Rear speaker LH R32 17 B4 Automatic shoulder bell control module R33 4 White B4 Fuel pump modulator R34 2...

Page 1559: ...wiring harness R67 4 B4 R66 Trunk lid hinge cord R68 2 Black B4 Rear side maker RH R69 4 Blue B4 Rear combination light RH R70 2 B4 Rear washer motor R71 1 84 Rear defogger Power R72 4 B4 Stop light...

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Subaru SVX 1992, Manual

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Summary of Contents for SVX 1992

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